Asymmetric Double-Sided Carpet Molded Article
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Solution Overview
Problem
The production of double-sided carpet type skin-equipped hollow molded articles often results in a degraded aesthetic appearance due to exposure of the resin cut surface along the parting line, as the existing methods of deburring lead to scraping of the skin on the back surface wall, increasing the plastic exposed surface.
Innovation Solution
A method involving a napped-type skin bonded to the front surface wall and a skin with a thickness smaller than the first skin bonded to the back surface wall, where the wall surface to which the first skin is bonded protrudes outward more than the wall surface to which the second skin is bonded in the parting line, allowing for inconspicuous deburring and masking of the cut portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If deburring is performed along the parting line after molding, then the molded article can be finished, but the skin on the back surface wall is scraped and the resin cut surface is exposed, degrading aesthetic appearance
Solution Approach 1:
The patent applies asymmetry by making the back surface wall protrude more than the front surface wall at the parting line position. This asymmetric design allows the deburring cut to occur on the protruding back surface wall, preventing the skin on the front surface wall from being scraped and exposed, thus resolving the contradiction between ease of manufacture and aesthetic appearance
Solution Approach 2:
The patent introduces a dimensional change by creating a protrusion in the back surface wall relative to the front surface wall at the parting line. This dimensional offset provides a buffer zone that absorbs the deburring cut, protecting the skin integrity and maintaining aesthetic appearance while still allowing effective deburring
2Manufacturing precision
If the wall surface of the back surface wall protrudes outward more than the wall surface of the front surface wall in the parting line, then deburring can be performed without scraping the skin, but the cut surface exposure still occurs
Solution Approach 1:
The patent applies local quality by using a napped-type skin specifically at the front surface wall where aesthetic appearance is critical. The nap structure locally masks the resin cut surface exposure, preventing the harmful effect of exposed plastic while maintaining skin integrity through the asymmetric protrusion design
Data Source
AI summary
An object of the present invention is to produce a double-sided carpet type skin-equipped hollow molded article so as to prevent degradation of aesthetic appearance of the hollow molded article. The double-sided carpet type skin-equipped hollow molded article includes: a hollow molded article main body made of a thermoplastic and having a front surface wall and a back surface wall; and skins integrally bonded to the respective front and back surface walls. A first skin bonded to the front surface wall is a napped-type skin. A second skin bonded to the back surface wall is a skin having a thickness smaller than a thickness of the first skin. A wall surface to which the first skin is bonded protrudes outward more than a wall surface to which the second skin is bonded in a parting line of the hollow molded article main body. The first skin has a large thickness and is a napped-type skin. Therefore, obtained is an effect that a nap raised after deburring and cutting masks a cut portion.