Expansion-Molded Article Protrusion Geometry for Heat Fusion
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Solution Overview
Problem
The existing expanded article composites face issues with poor adhesion between the expansion-molded article and another member, often due to air pockets generated between the two components.
Innovation Solution
The expansion-molded article is designed with protrusions on its surface that are heat-fused with another member, where the protrusions have a shape with at least two surfaces and a boundary line that intersects the direction from the outside toward the center of the protrusion's apex, facilitating uniform heat fusion and strong adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional heat fusion method is used to bond another member to expansion-molded article, then bonding process is simple, but adhesion between expansion-molded article and another member is poor or ununiform
Solution Approach 1:
The invention applies local quality by creating protrusions with specific geometric features (boundary lines intersecting the direction from outside toward apex center) at specific locations on the expansion-molded article surface. These localized structural modifications enable uniform air pocket discharge during heat fusion, transforming the bonding interface from poor/ununiform adhesion to reliable, consistent adhesion while maintaining process simplicity.
2Ease of manufacture
If conventional heat fusion method is used to bond another member to expansion-molded article, then bonding process is simple, but air pockets are generated between the two components
Solution Approach 1:
The invention converts the harmful effect of air pockets into a beneficial process feature. The protrusions with specific boundary line configurations act as controlled air escape channels, guiding air pockets to discharge in predetermined directions during heat fusion. This transforms the harmful air entrapment into a controlled venting mechanism, eliminating air pockets while maintaining the simplicity of the heat fusion process.
3Reliability
If protrusions with specific boundary line configuration are formed on expansion-molded article, then uniform adhesion is achieved, but manufacturing complexity increases
Solution Approach 1:
The invention applies parameter changes by modifying the geometric parameters of surface protrusions - specifically the boundary line configuration relative to the apex center direction. This parameter modification creates an optimal structure for air pocket discharge during heat fusion, achieving uniform adhesion without requiring complex multi-component structures or additional manufacturing steps beyond standard molding capabilities.
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 configuration allows for a firm heat-fusion between the expansion-molded article and the another member, reducing the likelihood of air pockets and ensuring uniform adhesion, thereby enhancing the structural integrity of the laminated body.
Implementation Method 1
an expansion-molded article which is to be heat-fused with another member
Implementation Method 2
bonding the expansion-molded article and the another member together by heat fusion
Data Source
Figure 1(a)~1(i)
Figure 2(a)~2(g)
Figure 3(a)~3(h)
AI summary
In order that an expansion-molded article which can be firmly heat-fused with another member is realized, an expansion-molded article (10) is one that is to be heat-fused with another member (20), the expansion-molded article (10) includes at least one protrusion (120) which is formed on at least one surface of the expansion-molded article (10) which at least one surface is to be heat-fused with the another member (20), the at least one protrusion (120) has at least two surfaces as viewed from above, and as a boundary line between the at least two surfaces, at least one boundary line is present which intersects a direction from an outside of the at least one protrusion (120) toward a center of an apex of the at least one protrusion (120).