Fiber-Resin Functional Layer for Integral Molded Projections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing resin battery cases have limited shaping freedom due to the need to embed retainers or shape electromagnetic wave-shielding sheets to conform to projections, restricting their design flexibility.
Innovation Solution
A resin formed article comprising a main body with a functional layer containing fibers and a second resin, and a projection formed by both first and second resins, where the second resin melts at a lower temperature than the first, allowing the first resin to permeate and fill concave portions, enabling integral formation of projections without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an electromagnetic wave-shielding sheet is disposed along a plate-like portion of a main body with a projection, then electromagnetic wave shielding is achieved, but the degree of freedom of shaping is limited due to the need to embed retainers or shape/trim the shielding sheet to conform to the projection
Solution Approach 1:
The electromagnetic wave-shielding sheet and the projection are merged into a single integral structure formed by co-molding the first resin (main body) and second resin (shielding sheet). This eliminates the need for separate attachment of retainers or trimming operations, allowing the shielding sheet to conform precisely to complex projection shapes while maintaining design freedom.
Solution Approach 2:
The functional layer containing the second resin is pre-placed in the mold before injecting the first resin. This preliminary positioning allows the second resin to be precisely located at the projection area, and the subsequent co-molding process automatically shapes it to match the projection geometry without requiring post-processing.
2Manufacturing precision
If retainers are embedded inside the projection or the electromagnetic wave-shielding sheet is shaped/trimmed to conform to the projection, then precise disposal of the shielding sheet is achieved, but additional processing steps and device complexity increase
Solution Approach 1:
The projection and electromagnetic wave-shielding sheet are combined into a single co-molded component. The first resin forms the main body projection while the second resin forms the shielding sheet that conforms to the projection shape, eliminating the need for separate retainers or post-molding trimming operations.
Solution Approach 2:
The invention utilizes the melting temperature difference between the first resin and second resin as a key parameter. The second resin has a lower melting temperature, allowing it to be melted by contact with the injected first resin, enabling the first resin to permeate and fill concave portions while the second resin forms the shielding layer.
3Ease of operation
If separate attachment methods are used for the electromagnetic wave-shielding sheet and projection, then assembly flexibility is maintained, but production time and productivity decrease
Solution Approach 1:
The main body, projection, and electromagnetic wave-shielding sheet are manufactured as a single integral piece through co-molding. The first resin and second resin are injected into the mold simultaneously or sequentially, and the lower-melting-point second resin is melted by contact with the first resin, allowing automatic permeation and filling without separate assembly steps.
Solution Approach 2:
The functional layer with the second resin is pre-positioned in the mold cavity before the first resin injection. This preliminary placement ensures correct positioning, and the subsequent injection process automatically completes the forming of both the projection and shielding sheet in one operation.
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 method provides a resin formed article with enhanced shaping freedom and integral projection strength, eliminating the need for separate attachment and enhancing design flexibility.
Implementation Method 1
a portion of the second resin included in the functional layer is melted by contact with the first resin supplied to the mold
Data Source
AI summary
A resin formed article, comprising a main body that includes a first resin; a functional layer that is disposed at at least a portion of a surface of the main body and includes a fiber and a second resin; and a projection that is disposed on the functional layer and includes the first resin and the second resin.