UV Curable Resin Molded Article for Curved Surfaces
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Solution Overview
Problem
Resin molded articles with inside decorative layers are difficult to affix to curved surfaces due to the hardness of liquid curable resin, which limits their flexibility and design quality on roundish or curved objects.
Innovation Solution
A resin molded article comprising a flexible ultraviolet curable resin base layer, a polymer membrane cover layer, and a decorative layer formed at recessed portions, where the decorative layer is visually recognizable and includes a metal layer with discontinuities for gloss and a shielding layer for contrast, allowing easy curvature and adherence to curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If liquid curable resin is used to form the resin base layer, then the resin molded article can be affixed to flat surfaces, but it cannot be easily curved or affixed to roundish curved surfaces due to its hardness
Solution Approach 1:
The patent changes the physical and chemical parameters of the resin by using ultraviolet curable resin with specific flexibility characteristics. The resin base layer is formed with controlled thickness (0.1-10mm) and curvature radius (10mm or more) to achieve the desired balance between flexibility and structural integrity, enabling affixation to curved surfaces while maintaining adequate strength
2Shape
If a decorative layer is formed on a flat surface, then it provides a two-dimensional appearance, but it cannot provide a three-dimensional visual effect
Solution Approach 1:
The patent transitions from a two-dimensional flat decorative layer to a three-dimensional structure by forming the decorative layer within a recessed portion of the resin base layer. This creates depth and volumetric appearance, allowing the decorative layer to be visually recognized in three dimensions while maintaining a relatively simple overall structure
3Shape
If the decorative layer includes a metal layer for gloss, then aesthetic quality is improved, but the metal layer may crack when the resin is curved
Solution Approach 1:
The patent applies different properties to different parts of the metal layer by forming it within the recessed portion rather than across the entire surface. The metal layer is discontinuous and localized to areas where curvature stress is reduced, providing gloss and aesthetic quality in the decorative areas while avoiding crack-prone regions
4Shape
If the shielding layer has high contrast (e.g., black) to improve design quality, then the ornamental portion emerges better, but the overall flexibility may be reduced
Solution Approach 1:
The patent controls the thickness and material composition of the shielding layer to balance optical contrast with mechanical flexibility. The shielding layer is formed with appropriate thickness to provide sufficient contrast for the ornamental portion to emerge, while maintaining overall flexibility of the resin molded article for curving and affixation
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 a three-dimensional decorative appearance and improved design quality on curved surfaces by providing flexibility and preventing peeling of the decorative layer, while maintaining high aesthetic quality and preventing cracks in the metal layer.
Implementation Method 1
a resin base layer formed of an ultraviolet curable resin
Data Source
AI summary
A resin molded article has a resin base layer formed of an ultraviolet curable resin. The resin base layer is provided on one end side with a cover layer made of a polymer membrane. Further, the resin base layer is provided on the other end side with recessed portions dented toward the cover layer. A decorative layer is formed at least at recessed portions. The decorative layer is visually recognizable through the resin base layer and the cover layer.