CN116802039A - Two-shot molded transfer member with film decoration - Google Patents
Two-shot molded transfer member with film decoration Download PDFInfo
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- CN116802039A CN116802039A CN202280008383.XA CN202280008383A CN116802039A CN 116802039 A CN116802039 A CN 116802039A CN 202280008383 A CN202280008383 A CN 202280008383A CN 116802039 A CN116802039 A CN 116802039A
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- China
- Prior art keywords
- transfer member
- injection molding
- film layer
- component
- shot
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Links
- 238000005034 decoration Methods 0.000 title claims abstract description 18
- 238000001746 injection moulding Methods 0.000 claims abstract description 34
- 238000000034 method Methods 0.000 claims abstract description 33
- 238000002347 injection Methods 0.000 claims abstract description 20
- 239000007924 injection Substances 0.000 claims abstract description 20
- 229920003023 plastic Polymers 0.000 claims abstract description 16
- 230000001681 protective effect Effects 0.000 claims abstract description 11
- 239000002184 metal Substances 0.000 claims abstract description 8
- 239000004033 plastic Substances 0.000 claims abstract description 8
- 239000004417 polycarbonate Substances 0.000 claims description 10
- 229920000515 polycarbonate Polymers 0.000 claims description 10
- 238000002372 labelling Methods 0.000 description 2
- 239000002932 luster Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000012780 transparent material Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000010329 laser etching Methods 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002991 molded plastic Substances 0.000 description 1
- 238000007649 pad printing Methods 0.000 description 1
- 239000000088 plastic resin Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
Landscapes
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The present application provides a method for multi-shot injection molding of a transfer member having a film decoration, the method comprising: performing a first injection molding injection to form an opaque plastic portion and a protective film layer that together form a transfer member defining one or more apertures; and performing a second injection molding injection including the transfer member to form a transparent plastic portion on an a side of the transfer member and a metal film layer on a B side of the transfer member. There is provided a multi-shot injection molded transfer member having a film decoration, the member comprising an opaque plastic portion and a protective film layer that together form a transfer member defining one or more apertures, the transparent plastic portion on the a-side of the transfer member; and a metal film layer on the B side of the transfer member.
Description
Cross Reference to Related Applications
The application claims the benefit of spanish application P202130152 filed on month 2 of 2021 and U.S. application 17/677135 filed on month 22 of 2022. The disclosures of the above-identified applications are incorporated herein by reference in their entirety.
Technical Field
The application relates to a method for two-shot (2K) injection molding of transfer members with film decoration.
Background
Multi-shot injection molding (e.g., two shot or 2K injection molding) may be used to form decorative trim for automotive applications, and the like. To provide a bright or metal-like (e.g., chromium-like) luster, film decoration and other treatments may be used. One non-limiting example of such an automotive application is a light detection and ranging (LIDAR) device. Conventional methods involve forming plastic parts (e.g., polycarbonate or PC) and then applying a coating or other material in a subsequent step. These are relatively complex and expensive as they are not optimized. Accordingly, although conventional metallic luster LIDAR devices are used for their intended purpose, improvements are still needed in the relevant art.
Disclosure of Invention
According to one aspect of the present disclosure, a method for multi-shot injection molding of a transfer member having a film decoration is presented. In one exemplary embodiment, the method includes: performing a first injection molding injection to form an opaque plastic portion and a protective film layer that together form a transfer member defining one or more apertures; and performing a second injection molding injection including the transfer member to form a transparent plastic portion on an a side of the transfer member and a metal film layer on a B side of the transfer member.
In some embodiments, the second injection molding injection is laterally adjustable such that the one or more holes are disposed in a desired location. In some embodiments, lateral adjustability can be achieved using movable inserts within the mold cavity. In some embodiments, lateral adjustability can be achieved to compensate for shrinkage. In some embodiments, the opaque portion and the transparent portion are each formed from Polycarbonate (PC). In some embodiments, the protective film layer is a colored film layer. In some embodiments, the multi-shot injection molding includes only two shots. In some embodiments, the multi-shot injection molding includes three or more shots.
According to another aspect of the present disclosure, a multi-shot injection molded transfer member having a film decoration is presented. In one exemplary embodiment, the component includes an opaque plastic portion and a protective film layer that together form a transfer component defining one or more apertures, a transparent plastic portion on the a-side of the transfer component, and a metal film layer on the B-side of the transfer component.
In some embodiments, the transparent plastic portion and the metal film layer are formed via lateral adjustment such that the one or more holes are disposed in a desired location. In some embodiments, lateral adjustability can be achieved using movable inserts within the mold cavity. In some embodiments, lateral adjustability can be achieved to compensate for shrinkage. In some embodiments, the opaque portion and the transparent portion are each formed from Polycarbonate (PC). In some embodiments, the protective film layer is a colored film layer. In some embodiments, the multi-shot injection molding used to form the component includes only two shots. In some embodiments, the multi-shot injection molding to form the component includes three or more shots.
Further areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims and drawings provided hereinafter, wherein like reference numerals refer to like features throughout the several views of the drawings. It should be appreciated that the detailed description, including the disclosed embodiments and figures recited therein, is merely exemplary in nature and is intended for purposes of illustration only and is not intended to limit the scope of the disclosure, its application or uses. Accordingly, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure.
Drawings
FIGS. 1A-1C illustrate exemplary modified two shot (2K) injection molding and film transfer processes according to some embodiments of the present disclosure; and is also provided with
Fig. 2A-2B illustrate exemplary decorative components or designs that may be formed using modified 2K injection molding and film transfer processes according to some embodiments of the application.
Detailed Description
According to some embodiments of the present disclosure, improved two shot (2K) injection molding and film transfer processes are presented. Although 2K injection molding is specifically discussed herein, it should be understood that for more complex designs, there may be three or more injection molding shots. As previously mentioned, a problem with other decoration techniques is the accuracy of the methods that can be optimized by the process of the present disclosure. Alternative solutions for decoration are other combinations of methods with more steps to obtain the same appearance, such as (1) PC plus paint on the B-side and laser etching on the B-side to remove paint in the area to be transparent, (2) PC plus pad printing, and (3) PC plus in-mold labeling (IML) or in-mold decoration (IMD), which refers to a process of decorating or labeling molded plastic parts or components during a plastic injection molding cycle. When the mold is closed, a plastic resin is injected into the mold, permanently encapsulating the label within the finished part.
Referring now to fig. 1A-1B, an exemplary process or flow diagram of an improved injection molding and film transfer process is shown, according to some embodiments of the present disclosure. The improved method of the present disclosure provides for the complete decoration of injection molded parts completed from side B in an Injection Molding Machine (IMM). Process optimisation is performed to reduce the number of steps to obtain a fully decorated injection moulded part.
The 2K injection molding may include one or two shots formed of a transparent material, with a decorative film for the first and second stages. Prior to the solution, the part was a 2K injection molded part from side B without trim.
One key aspect is to use a film to decorate and/or protect the rinse in the first injection stage while injecting a transparent material onto the black top in the second stage. More specifically, the first film decoration and the protective film material and the second film decoration are transferred to the hole or hole on the first injection part of the second stage for decoration. In the second stage, the membrane is critical to the process working in conjunction with the part geometry. As shown, the process operates as a combination of transparent polycarbonate and other thermoplastic plus film to decorate on the B-side. As previously mentioned, conventional 2K injection molding processes already exist in many applications in industry, but do not include IML from the B side showing the film through only the first injection part transferred to the second stage. Thus, this process reduces the complexity of performing all decoration processes in the IMM during the injection cycle.
Fig. 1B-1C specifically illustrate an alternative process or flow chart in which an injection tool has a movable insert to adjust a first injection phase. Fig. 2A-2B also illustrate exemplary decorative components or designs that may be formed using the modified 2K injection molding and film transfer processes according to some embodiments of the application. It should be understood that these are merely examples for illustrative purposes and should not limit the applicability of the improved 2K injection molding process of the present disclosure.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed herein could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
It will also be appreciated that mixtures and matches of features, elements, methods and/or functions between the various examples are expressly contemplated herein such that one of ordinary skill in the art will recognize from the present teachings that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above.
Claims (16)
1. A method for multi-shot injection molding of a transfer member having a film decoration, the method comprising:
performing a first injection molding injection to form an opaque plastic portion and a protective film layer that together form a transfer member defining one or more apertures; and
a second injection molding injection including the transfer member is performed to form a transparent plastic portion on the a side of the transfer member and a metal film layer on the B side of the transfer member.
2. The method of claim 1, wherein the second injection molding injection is laterally adjustable such that the one or more holes are arranged in a desired location.
3. The method of claim 2, wherein the lateral adjustability is achieved using a movable insert within a mold cavity.
4. The method of claim 2, wherein the lateral adjustability is enabled to compensate for shrinkage.
5. The method of claim 1, wherein the opaque portion and the transparent portion are each formed from Polycarbonate (PC).
6. The method of claim 5, wherein the protective film is a colored film.
7. The method of claim 1, wherein the multi-shot injection molding comprises only two shots.
8. The method of claim 1, wherein the multi-shot injection molding comprises three or more shots.
9. A multi-shot injection molded transfer member having a film decoration, the member comprising:
an opaque plastic portion and a protective film layer that together form a transfer member defining one or more apertures;
a transparent plastic portion on the a side of the transfer member; and
a metal film layer on the B side of the transfer member.
10. The component of claim 9, the transparent plastic portion and the metal film layer being formed via lateral adjustment such that the one or more holes are arranged in a desired location.
11. The component of claim 10, wherein the lateral adjustability is achieved using a movable insert within a mold cavity.
12. The component of claim 10, wherein the lateral adjustability is enabled to compensate for shrinkage.
13. The component of claim 9, wherein the opaque portion and transparent portion are each formed from Polycarbonate (PC).
14. The component of claim 13, wherein the protective film layer is a colored film layer.
15. The component of claim 9, wherein the multi-shot injection molding to form the component comprises only a double shot.
16. The component of claim 9, wherein the multi-shot injection molding to form the component comprises three or more shots.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ESP202130152 | 2021-02-23 | ||
| US17/677,135 US20220266487A1 (en) | 2021-02-23 | 2022-02-22 | Two-shot molded transferred part with film decoration |
| US17/677,135 | 2022-02-22 | ||
| PCT/US2022/017427 WO2022182701A1 (en) | 2021-02-23 | 2022-02-23 | Two-shot molded transferred part with film decoration |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN116802039A true CN116802039A (en) | 2023-09-22 |
Family
ID=88038931
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202280008383.XA Pending CN116802039A (en) | 2021-02-23 | 2022-02-23 | Two-shot molded transfer member with film decoration |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN116802039A (en) |
-
2022
- 2022-02-23 CN CN202280008383.XA patent/CN116802039A/en active Pending
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