Composite Foamed Injection Molding With 3D-Printed Reinforcement
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Solution Overview
Problem
Foamed injection-molded articles with three-dimensional structures suffer from low intermolecular bonding strength due to the lack of a compression process, resulting in inferior mechanical performance.
Innovation Solution
A method involving 3D printing of a reinforcing member, integrating it into a mold, and combining it with a foamed resin within a cavity to form a composite injection-molded article, where the resin is physically bonded to the reinforcing member through through-holes and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a foaming injection process is used to manufacture low-density products, then the product volume consistency is improved, but the intermolecular bonding strength deteriorates
Solution Approach 1:
The patent combines foamed resin with a reinforcing member (manufactured by 3D printing) to create a composite structure. The reinforcing member integrates into the foamed resin during injection molding, forming a composite material that maintains low density while significantly improving mechanical strength and intermolecular bonding.
2Ease of manufacture
If a foaming injection process without compression is used, then the manufacturing process simplicity is improved, but the mechanical performance deteriorates
Solution Approach 1:
By introducing a reinforcing member into the foamed resin composite, the patent achieves improved mechanical performance without adding complex compression processes. The reinforcing member provides structural integrity while the foaming process maintains simplicity.
Solution Approach 2:
The reinforcing member is strategically positioned within the foamed resin to provide localized strength enhancement. The 3D-printed reinforcing member can be designed with specific geometries and distributions to optimize mechanical performance in critical areas while maintaining overall process simplicity.
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 approach enables the production of a composite foamed injection-molded article with high strength and low density, suitable for applications requiring mechanical integrity, such as shoe soles, while maintaining shock absorption and comfort.
Implementation Method 1
a molten resin mixed with a foaming agent is injected into a mold and foamed to produce a desired product
Implementation Method 2
the foamed resin may be filled in one or more of the through-holes to physically bind with the reinforcing member
Data Source
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AI summary
A composite foamed injection-molded article and a method for manufacturing the same are provided. The manufacturing method for the composite foamed injection-molded article includes steps of: i) providing a reinforcement member manufactured through 3D printing; ii) providing the reinforcement member to at least one mold part selected from the group consisting of an upper mold part and a lower mold part; iii) forming a hollow space by coupling the upper mold part and the lower mold part; iv) providing a mixture in which a molten product is mixed with a foaming agent; v) injecting the mixture into the hollow space; vi) providing a combined-type foam injection molded product including the reinforcement member and a foam resin obtained by foaming the mixture in the hollow space; and vii) separating the upper mold part and the lower mold part so as to withdraw the composite foamed injection-molded article.