UV Cured Convex Coating for Antidazzling Automotive Interiors
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Solution Overview
Problem
Synthetic resin molded articles used in automobile interiors lack sufficient visual variation and durability, with existing coatings failing to achieve uniformity and three-dimensional designs while maintaining antidazzling properties.
Innovation Solution
A decorative surface structure featuring a base coating region with convex portions formed by UV curing ink, allowing for varied three-dimensional patterns and improved wear resistance, achieved through a method involving ink jet application and controlled curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If base coating or clear coating is conducted on synthetic resin molded articles, then wear resistance and weather resistance are improved, but the coating surface becomes flat and even, resulting in insufficient visual variations and poor design representations
Solution Approach 1:
The patent applies local quality by creating convex portions with different surface properties on specific regions of the coating layer. These convex portions have different heights, curvatures, and densities in different areas, allowing local variations in light reflection and visual appearance while maintaining overall coating integrity and wear resistance.
Solution Approach 2:
The patent transitions from two-dimensional flat coatings to three-dimensional surface structures by forming convex portions with varying heights and depths. This dimensional change creates rich visual variations, shadows, and depth effects that enhance design representations while preserving the protective function of the coating.
2Adaptability or versatility
If emboss pattern with fine concavo-convex shapes is molded on synthetic resin molded articles, then design variations are improved, but coating thickness becomes non-uniform due to coating flow into concave regions, resulting in irregular coating and coloring
Solution Approach 1:
The patent applies preliminary action by first forming the convex portions on the coating layer before applying subsequent coatings. This ensures that the base structure with desired three-dimensional patterns is established first, and subsequent coatings conform to this structure, maintaining thickness uniformity and preventing irregular coloring.
Solution Approach 2:
Instead of forming concave patterns and hoping coatings fill them uniformly, the patent inverts the approach by forming convex portions. This inversion prevents coating material from pooling in low areas, as there are no concave regions to collect excess coating, thereby maintaining uniform coating thickness and consistent coloration.
3Ease of manufacture
If flat patterns are applied by coating and transcribing, then drawing patterns can be represented, but only flat patterns are obtained, limiting three-dimensional pattern representation and design quality
Solution Approach 1:
The patent merges two previously separate processes - the formation of three-dimensional patterns and the application of drawing patterns - into a single integrated process. By forming convex portions directly on the coating layer using inkjet technology, the patent combines structural three-dimensional patterning with decorative pattern application, achieving both in one step.
Solution Approach 2:
The patent replaces traditional mechanical embossing methods with inkjet-based deposition technology. Instead of using mechanical molds to create patterns, the patent uses digitally controlled inkjet deposition to form convex portions, enabling more flexible and precise three-dimensional pattern representation while maintaining ease of manufacture.
4Adaptability or versatility
If glossy finish is applied to create high-quality appearance, then aesthetic appeal is improved, but antidazzling function is impaired, causing safety issues for drivers
Solution Approach 1:
The patent applies local quality by creating areas with different surface characteristics - convex portions that provide antidazzling effects through diffuse reflection and flat areas that maintain gloss for aesthetic appeal. This local differentiation allows simultaneous achievement of both safety and aesthetic requirements in different regions of the same surface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables uniform coating, enhanced wear resistance, and high-quality three-dimensional designs with antidazzling properties, maintaining durability and aesthetic appeal over long-term use.
Implementation Method 1
applying an UV curing ink by ink jet method on the base coating region obtained in the step (a), wherein the UV curing ink is applied in amount of 20 to 100 g/m2 so that one droplet of the UV curing ink is 60 to 140 pg, (c) curing the UV curing ink applied in the step (b) with ultraviolet irradiation
Data Source
AI summary
Provided are a decorative surface structure of a synthetic resin molded article which has excellent wear resistance, design and texture, a method for producing the same, and a synthetic resin molded decorative article. Specifically provided are a decorative surface structure of an automobile interior part, which is capable of various design representations having an excellent three-dimensional appearance, while ensuring antidazzling property, and does not spoil glossy finish, a method for producing the same, and an automobile interior part. The decorative surface structure is comprised of a base coating region formed on a surface of a synthetic resin molded article by a coating layer and one or more convex portion formed on the base coating member.