Virtual 3D Patterns in Injection Moldings
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Solution Overview
Problem
Current methods for producing three-dimensional patterns on moldings are complex, costly, and limited to polymeric plastics, failing to efficiently create glossy, three-dimensionally appearing patterns with fine line structures on variously composed moldings that are optically visible but not haptically perceptible, especially for composite materials including metals.
Innovation Solution
An injection molding process using a modified injection mold with a preform having a three-dimensional pattern and a thermoplastic film pigmented with platelet-shaped effect pigments, where the film forms an adhesive connection with the preform and replicates the pattern optically, creating a virtual three-dimensional effect on the surface without a corresponding three-dimensional structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional embossed structuring methods are used to create three-dimensional patterns on moldings, then the patterns are visible and provide depth effect, but the equipment outlay is high and the surfaces are susceptible to dirt and mechanical deformation
Solution Approach 1:
The patent uses a preform with a three-dimensional pattern that serves as a master model. This preform is placed in the injection mold cavity, and the thermoplastic material is injected to replicate the pattern. The preform is then removed, leaving a negative impression of the three-dimensional pattern in the molded article. This copying approach eliminates the need for complex embossing equipment while achieving the desired visual depth effect.
Solution Approach 2:
The patent replaces mechanical embossing systems with an injection molding process. Instead of using high-pressure embossing tools to physically deform the molding surface, the three-dimensional pattern is created by injecting thermoplastic material around a preform and allowing it to solidify. This substitution of mechanical deformation with a casting-like process reduces equipment complexity and protects the pattern from mechanical damage.
2Illumination intensity
If multiple layers with effect pigments are used to achieve optical effects, then the visual appearance is enhanced, but the production process requires many work steps and complex lamination
Solution Approach 1:
The patent combines the preform with the three-dimensional pattern, the thermoplastic material, and the effect pigments into a single integrated injection molding process. The preform is placed in the mold cavity, effect pigments are mixed with the thermoplastic material, and everything is formed in one injection step. This eliminates the need for separate lamination and assembly steps required by conventional multi-layer approaches.
Solution Approach 2:
The preform with the three-dimensional pattern is prepared in advance and placed in the injection mold cavity before the thermoplastic material is injected. This preliminary placement allows the pattern to be replicated during the injection process itself, rather than requiring post-processing or separate assembly steps. The effect pigments are also pre-mixed with the thermoplastic material to ensure uniform distribution.
3Shape
If transfer films with decorative elements are used to create patterns, then optically attractive moldings with non-haptic patterns are produced, but the process requires high equipment and material expenditure with two injection molding steps
Solution Approach 1:
The patent extracts the decorative function from a separate transfer film and integrates it directly into the injection mold cavity as a preform. Instead of using a carrier film with decorative elements that needs to be transferred and bonded, the three-dimensional pattern is created by the preform itself, which is simply placed in the cavity and removed after injection. This eliminates the need for transfer films, release layers, and complex bonding processes.
Solution Approach 2:
The preform with the three-dimensional pattern is prepared in advance and placed in the injection mold cavity before the thermoplastic material is injected. This preliminary placement allows the pattern to be replicated during the injection process itself, rather than requiring post-processing or separate assembly steps. The effect pigments are also pre-mixed with the thermoplastic material to ensure uniform distribution.
4Shape
If conventional methods are used to produce three-dimensional patterns, then the patterns are visible, but they are haptically perceptible and susceptible to mechanical deformation
Solution Approach 1:
The patent creates a negative impression of the three-dimensional pattern through injection molding rather than creating actual raised or recessed features. The preform with the positive three-dimensional pattern is placed in the cavity, and the injected thermoplastic material replicates the pattern as a surface relief. When the preform is removed, the molded article retains the pattern as a durable surface feature that is visible but not susceptible to the same mechanical deformation as embossed features.
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 allows for the production of moldings with glossy, three-dimensionally appearing patterns on various compositions, including non-polymeric materials, using conventional tools and fewer steps, achieving a visually attractive and durable result with high line sharpness and uniform color.
Implementation Method 1
the platelet-shaped effect pigments that on the outer surface of the preform Replicate and optically reinforce three-dimensional patterns on or in the thermoplastic film
Implementation Method 2
the thermoplastic film with at least the part of the outer surface of the preform, which has the three-dimensional pattern, and at the same time with the thermoplastic plastic melt forms an adhesive and form-fitting connection
Data Source
AI summary
The present invention relates to a method for creating virtual three-dimensional patterns in molded bodies, in particular an injection-molding method for producing molded bodies with a virtual three-dimensional pattern, said pattern being formed by platelet-shaped effect pigments. The invention also relates to the molded bodies produced by this method and to their use, in particular for decorative purposes.