KR-20260067476-A - How to mold film inserts with biodegradable polycarbonate materials

Abstract

The present invention provides an insert molding method using a biodegradable polycarbonate film, characterized by comprising: a screen printing step of placing a biodegradable polycarbonate (PC) film on a screen equipment to print a design pattern; a film molding step of forming a shape on the printed film through high-pressure thermoforming; a trimming step of cutting the outer edge of the molded film; a laser etching step of forming a design pattern on the back surface of the trimmed film by laser etching processing; an insert injection step of placing the etched film on a mold and then back-injecting using biodegradable polycarbonate (PC) as an injection material; and an NC machining step of trimming the shape of the insert-injected film using NC machining equipment.

Inventors

• 구태환

Assignees

• 주식회사 세지솔로텍

Dates

Publication Date

20260513

Application Date

20241105

Claims (3)

1. Screen printing step of placing a biodegradable polycarbonate (PC) film onto a screen equipment to print a design pattern; A film forming step of forming a shape on the printed film through high-pressure thermoforming; A trimming step for cutting the outer edge of the molded film; A laser etching step of forming a design pattern on the back surface of the trimmed film by laser etching processing; An insert injection step of back-injecting using biodegradable polycarbonate (PC) as the injection material after placing the etched film into a mold; and A method for insert molding using a biodegradable polycarbonate film, characterized by including an NC machining step of trimming the shape of the insert-molded film using NC machining equipment.
2. In paragraph 1, The above screen printing step is, A film insert forming method characterized by placing the above film on the bottom, injecting ink into the screen, and printing a base color and a design pattern on the above film through a squeegee.
3. In paragraph 1, In the above film forming step, A film insert forming method characterized by placing the film on the core of the lower mold of a high-pressure thermoforming facility, preheating the upper part of the lower mold by heating it with a heating plate, and moving the lower mold upward to form the shape of the film with heat and high pressure.

Description

Method for molding film inserts using biodegradable polycarbonate materials The present invention relates to a method for molding film inserts using biodegradable polycarbonate material, and is a technology capable of producing automotive interior materials using biodegradable polycarbonate, which is an eco-friendly material. Polycarbonate (PC) is an engineering plastic that was first developed by Bayer of Germany. It is widely used in electronic devices and automotive interiors due to its excellent physical properties, such as heat resistance, impact resistance, processability, transparency, and flame retardancy. Polycarbonate (PC) is expensive to recycle, so it is sold or incinerated after use. However, toxic substances are generated during this process, and it does not decompose, causing environmental pollution. Samyang Corporation has developed a biodegradable polycarbonate (PC) material utilizing isosorbide, a bio-material derived from starch. There is a need for a method to produce automotive interior materials that replace conventional polycarbonate (PC) using such biodegradable polycarbonate (PC). FIG. 1 is a flowchart of a method for forming a film insert using a biodegradable polycarbonate material according to an embodiment of the present invention. FIG. 2 is an exemplary diagram of a screen printing step according to an embodiment of the present invention. FIG. 3 is an exemplary diagram of a film forming step according to an embodiment of the present invention. FIG. 4 is an exemplary diagram of a trimming step according to an embodiment of the present invention. FIG. 5 is an exemplary diagram of a laser etching step according to an embodiment of the present invention. FIG. 6 is an exemplary diagram of an insert injection step according to an embodiment of the present invention. FIG. 7 is an exemplary diagram of an NC machining step according to an embodiment of the present invention. Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings. The following description and the accompanying drawings are provided for the general understanding of the present invention and are not intended to limit the technical scope of the present invention. Furthermore, detailed descriptions of known configurations and functions that could unnecessarily obscure the essence of the present invention will be omitted. FIG. 1 is a flowchart of a method for forming a film insert using a biodegradable polycarbonate material according to an embodiment of the present invention. Referring to FIG. 1, the present invention performs film insert forming through a screen printing step (S 10), a film forming step (S 20), a trimming step (S 30), a laser etching step (S 40), an insert injection step (S 50), and an NC machining step (S 60). First, in the screen printing step (S 10), a sheet of biodegradable polycarbonate (PC) film is placed on a screen machine to print a design pattern. Figure 2 is an exemplary diagram of a screen printing step according to an embodiment of the present invention, illustrating the process. In detail, the screen printing step (S 10) involves placing the film (100) on the bottom, fixing the screen (11) to the plate (10), injecting ink (12) onto the screen (11), and using a squeegee (13) to print a base color and a design pattern on the film (100). Afterward, a binder is applied and a drying process is performed to print the desired pattern on the film. Next, in the film forming step (S 20), the printed film is subjected to high-pressure thermoforming. FIG. 3 is an exemplary diagram of a film forming step according to an embodiment of the present invention. The film forming step (S20) described in FIG. 3 represents a process of forming a printed film using high pressure and heat. In this step, the printed film (100) is placed in the lower mold (20) of a high-pressure thermoforming facility and secured using a mother tool (21). Then, the film (100) undergoes a preheating process by heating it with a heating plate (22) located on the upper part of the lower mold (20). Once preheating is complete, the lower mold moves to the upper part of the facility, and heat and high pressure are applied to form the shape of the film. In this embodiment, the film is formed into a dish shape. Next, the trimming step (S 30) is a step of cutting the outer edge of the molded film. FIG. 4 is an exemplary diagram of a trimming step according to an embodiment of the present invention. After placing the detailed molded film (100) onto the trimming mold (30), the upper die (31) of the trimming mold descends to cut the outer edge (110) of the film (100). Through this process, unnecessary parts are removed, leaving only the necessary parts. The next laser etching step (S 40) is a step of applying a design pattern to the back surface of the trimmed film by laser etching. FIG. 5 is an exemplary diagram of a laser etching step according to an embodiment of the present inventi