Extrusion Molded Article With Grooved Lid For Coating Adhesion
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Solution Overview
Problem
Extrusion molded articles with resin-coated core materials face issues with end part closure and temperature-induced exfoliation due to cut surfaces and thermal expansion differences between the core and coating materials.
Innovation Solution
An extrusion molded article design featuring a core material with a synthetic resin lid part that includes a groove and communication part to anchor the coating, allowing for tight closure and reducing delamination risks, along with a through hole for pressure relief and an exposed part for air discharge during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the core material is coated with resin using extrusion molding, then the coating part covers the external surface of the core material, but the cut surfaces at the ends remain exposed leading to exfoliation of the coating part
Solution Approach 1:
The end part is divided into a tube body and a separate lid part that closes the end. The lid part is then integrated with the coating part through the groove structure, creating a segmented solution that addresses the exposed cut surface problem while maintaining overall structural integrity.
Solution Approach 2:
The lid part is inserted into the tube body to close the end, forming a nested structure. The coating part then covers both the external surface and the lid part, creating a nested configuration where the lid is within the tube and both are covered by the coating.
2Reliability
If the core material is coated with resin using extrusion molding, then the coating part covers the external surface of the core material, but repeated temperature changes cause exfoliation due to thermal expansion differences
Solution Approach 1:
The groove part is formed only at the end part of the tube body, creating a localized stress relief structure. This local feature allows the coating part to be anchored at the end while maintaining flexibility elsewhere, addressing thermal expansion differences without compromising overall coating integrity.
Solution Approach 2:
The groove part is pre-formed in the tube body before coating, creating a cushioning structure that anticipates and accommodates future thermal expansion and contraction. This pre-prepared feature prevents coating exfoliation by providing a flexible anchor point that moves with temperature changes.
3Reliability
If a lid part is added to close the end, then the end part can be tightly closed, but the structure becomes more complex
Solution Approach 1:
The lid part, tube body, and coating part are merged into an integrated structure. The lid is inserted into the tube body and both are covered by the coating part, creating a combined structure that achieves tight closure while minimizing the number of separate components.
Solution Approach 2:
The coating part serves multiple functions: it covers the external surface for protection, covers the lid part for closure, and is anchored in the groove to prevent exfoliation. This multi-functionality reduces the need for additional specialized components, simplifying the overall structure.
4Manufacturing precision
If air is trapped in the groove part during molding, then defects like bubbles form, but releasing air requires additional structures
Solution Approach 1:
The groove part structure itself serves the dual function of anchoring the coating part and providing an air escape path. The communication part between the groove and internal space automatically allows air to escape during molding without requiring additional vents or channels, making the structure self-sufficient.
Solution Approach 2:
The groove part with its communication part serves multiple purposes: anchoring the coating part through the filling part, providing structural integration between lid and tube, and facilitating air escape during molding. This multi-functionality eliminates the need for separate air release structures.
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
The design effectively prevents exfoliation and delamination by anchoring the coating and allowing air release, ensuring a strong bond and reducing defects like bubble formation and rupture during temperature changes.
Implementation Method 1
The lid part includes a groove part formed in an external surface of the lid part intersecting with a longitudinal direction of the tube body. The groove part includes a communication part configured such that a longitudinal direction end part of the groove part communicates with an internal space of the tube body. The coating part includes a filling part configured to fill an inside of the groove part.
Implementation Method 2
the groove part includes a communication part configured such that a longitudinal direction end part of the groove part communicates with an internal space of the tube body
Implementation Method 3
the coating part may include a swelling part that expands into the internal space of the tube body through the communication part of the groove part
Implementation Method 4
the extrusion molding method is used. Since the core material has a predetermined length, the core materials are sequentially supplied to the extruder at a certain interval so as to cut, after coating, the coated core materials at positions of the respective intervals.
Data Source
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AI summary
An extrusion molded article is provided by coating a core material with a resin, in which longitudinal direction end parts are easily processed to be tightly closed. An extrusion molded article P includes: a core material 10; and a synthetic-resin-made coating part 20 coating an external surface of the core material 10. The core material 10 includes: a square tube body 30; and a synthetic-resin-made lid part 40 closing up a longitudinal direction end part of the square tube body 10. The lid part 40 includes a groove part 44 in an external surface thereof along the longitudinal direction of the square tube body 30. The groove part 44 includes a communication part 45 connecting a longitudinal direction end part thereof to an internal space 31 of the square tube body 30. The coating part 20 includes a filling part 21 filling an inside of the groove part 44.