Plastic Composite Panel Structure for Easy Mold Release
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Solution Overview
Problem
The existing manufacturing methods for plastic composite material panels used in purpose-built vehicles often result in bent shape portions being caught in molds, leading to difficulties in removing the panels smoothly and potentially reducing the cross-section of the vehicle body frame.
Innovation Solution
A plastic composite material panel design featuring an outer plate portion and a material filling portion, where the material filling portion is thicker and integrally formed with the outer plate portion, along with bonding flanges, allows for improved moldability and secure bonding to the vehicle body frame, preventing cross-section reduction by using a gel-type plastic composite material and specific molding surfaces and grooves in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bent shape portion is formed in the plastic composite material panel, then the panel can be bonded to the vehicle body frame, but the bent shape portion is caught in the molding part of the mold, making it difficult to remove the panel smoothly
Solution Approach 1:
The plastic composite material panel is divided into a flat plate portion and a bent shape portion that is formed after molding. This segmentation allows the panel to be molded in a simple flat shape for easy removal, then subsequently bent into the final configuration for bonding, thus resolving the contradiction between bonding capability and mold removal ease.
Solution Approach 2:
The panel is first molded in a flat state before the bent shape is formed. This preliminary action of molding in a simple geometry allows easy removal from the mold, and the bent shape is created in a subsequent step to provide the bonding surface, thus separating the molding and bonding functions.
2Ease of manufacture
If the plastic composite material panel is molded with a bent shape, then it can bond to the vehicle body frame, but the cross-section of the vehicle body frame is reduced
Solution Approach 1:
The panel structure is segmented into a flat plate portion that contacts the vehicle body frame and a bent shape portion that provides bonding surface area. This segmentation allows the flat plate to maintain full frame cross-section contact while the bent portion provides bonding capability without reducing the effective structural cross-section.
Solution Approach 2:
The bonding function is moved from the primary structural dimension (frame cross-section) to a secondary dimension (bent shape extending from the plate). This dimensional transition allows bonding to occur on the bent portion while the flat plate maintains full contact with the frame cross-section, preventing strength reduction.
Data Source
AI summary
An embodiment includes a method of manufacturing a plastic composite material panel. A gel type plastic composite material is loaded onto a fixed die having a first molding surface of a flat shape for molding a material filling portion and a second molding surface for molding an outer plate portion. A first movable die having a third molding surface for molding the material filling portion and a fourth molding surface for molding the outer plate portion is combined with a second movable die having a molding groove for molding the material filling portion to the fixed die. The outer plate portion is formed by the second and fourth molding surfaces and the material filling portion is integrally formed with the outer plate portion by the first and third molding surfaces and the molding groove. The material filling portion is thicker than the outer plate portion.