Protective Varnish Layer Region-Specific Stamping
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Solution Overview
Problem
Current methods for producing articles with surface structures in specific regions are inefficient and costly, as they require pre-structured transfer films that lack mechanical and chemical resistance, and the post-processing steps can result in inhomogeneous finishes and brittleness.
Innovation Solution
A method involving the use of transfer films with a protective varnish layer that is not fully cured or is thermoplastic, allowing for back-injection molding and subsequent stamping to create relief structures only in specific regions, while ensuring the varnish layer achieves full cure and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a post-structuring is applied to transfer films before production, then surface structures can be provided in specific regions, but the transfer films have insufficient resistance to mechanical or chemical strains
Solution Approach 1:
The protective varnish layer is applied to the transfer film in an uncured or thermoplastic state before the back-injection molding process, allowing the film to be shaped and structured. After molding, the varnish layer is cured to provide the desired surface structures in specific regions while achieving the required mechanical and chemical resistance.
Solution Approach 2:
The protective varnish layer transitions from an uncured or thermoplastic state during molding to a fully cured state afterward. This parameter change allows the material to be flexible and shapeable during processing, then becomes resistant and durable in the final product, simultaneously achieving surface structuring and strain resistance.
2Reliability
If the protective varnish layer is fully cured before stamping, then the surface is robust, but the molding process becomes complex and cost-intensive with inhomogeneous and blotchy results
Solution Approach 1:
The protective varnish layer is applied in an uncured or thermoplastic state before the back-injection molding process. This preliminary state allows easy shaping and stamping without requiring complex post-processing equipment or procedures, while still enabling the creation of robust surface structures after curing.
3Reliability
If the varnish layer is fully cured, then it provides high resistance, but it becomes brittle with low stretchability limiting shapeability
Solution Approach 1:
The protective varnish layer is maintained in an uncured or thermoplastic state during the back-injection molding and stamping processes, allowing high shapeability and stretchability. After the molding is complete, the varnish layer is cured to achieve high resistance and durability, thus obtaining both shapeability during processing and robustness in the final product.
4Shape
If transfer films are pre-structured before production, then surface structures are available, but subsequent production steps become challenging for registration with motifs and functional regions
Solution Approach 1:
The protective varnish layer is applied in an uncured or thermoplastic state that allows easy manipulation and positioning during the back-injection molding process. This enables simple registration with motifs and functional regions on the mold, while still allowing post-structuring to be created after molding without complex production steps.
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
This method enables the production of articles with region-specific surface structures that are both robust and flexible, allowing for the creation of three-dimensional or 2.5-dimensional shapes while maintaining high resistance to mechanical and chemical influences.
Implementation Method 1
This curing is effected for example by means of high-energy radiation, for example by means of UV radiation
Data Source
AI summary
A method of producing an article (1), wherein the method includes at least one of the steps A1) or A2) or A3): providing a base body (9), on which a transfer ply (3) and/or a print layer has been arranged, wherein the protective varnish layer (8) and/or the print layer has not yet been completely cured or is thermoplastic at least in regions; and wherein the method comprises the following steps in addition to at least one of the steps A1) or A2) or A3): e) forming at least one first region (5) and at least one second region (6) in the protective varnish layer (8) and/or print layer by means of stamping, wherein the at least one first region (5) has a relief structure; f) optionally curing the protective varnish layer (8) and/or print layer not yet completely cured at least in regions, wherein the protective varnish layer (8) and/or print layer cures completely at least in regions; g) obtaining an article (1).