Flexible Mold Base with Protruding Resin Sheet
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Solution Overview
Problem
The existing flexible mold bases with glass sheets are prone to breaking, leading to contamination from glass fragments during manufacturing processes, as the end surfaces of the glass sheets are easily contacted, causing glass powder formation and environmental contamination.
Innovation Solution
A flexible mold base configuration featuring a glass sheet with a resin sheet and a bonding layer, where the resin sheet protrudes from the glass sheet, reducing contact with other members and minimizing glass breakage, and optionally bonded to both surfaces for enhanced protection and adhesive containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a glass sheet is used as the base for a flexible mold, then dimensional stability due to temperature change is improved, but the glass sheet is prone to breaking and causing contamination from glass fragments
Solution Approach 1:
The base is constructed as a composite structure combining a glass sheet with resin sheets and bonding layers. The glass sheet provides dimensional stability while the resin sheets and bonding layers protect the glass edges from contact and breakage, creating a material composite that achieves both dimensional stability and breakage resistance
Solution Approach 2:
Resin sheets are added to the glass sheet base to create a flexible protective structure. The resin sheets, particularly those protruding from the glass sheet, act as flexible protective shells that prevent direct contact with the fragile glass end surfaces while maintaining the overall flexibility needed for the mold application
2Ease of manufacture
If the end surfaces of the glass sheet are flush with other components, then manufacturing simplicity is improved, but contact with other members causes glass breakage and contamination
Solution Approach 1:
The resin sheets protrude from the glass sheet in the thickness dimension, creating a stepped structure where the resin extends beyond the glass edges. This dimensional change protects the glass end surfaces from contact with other members while maintaining manufacturing simplicity through a straightforward lamination process
Solution Approach 2:
Resin sheets are positioned to protrude from the glass sheet before the molding process begins, creating a protective cushion that prevents direct contact between other members and the vulnerable glass end surfaces, thereby preventing breakage before it can occur
3Reliability
If the resin sheet protrudes from the glass sheet, then glass breakage is reduced, but the base structure becomes more complex
Solution Approach 1:
The base is segmented into distinct functional layers: a glass sheet for dimensional stability, resin sheets for protection and flexibility, and bonding layers for attachment. This segmentation allows each component to perform its specific function while maintaining overall structural integrity without excessive complexity
Solution Approach 2:
The resin sheets serve multiple functions simultaneously: they protect the glass end surfaces from contact and breakage, provide flexibility to the base structure, and can contain bonding layers for attachment. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in overall structural complexity
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 significantly reduces glass fragment formation and scattering, maintaining dimensional stability and preventing adhesive contamination, while allowing for accurate uneven layer formation and cost-effective manufacturing.
Implementation Method 1
a bonding layer configured to bond the glass sheet and the resin sheet to each other
Data Source
AI summary
Provided is a base (1) for a flexible mold, including: a glass sheet (2); a resin sheet (3); and a bonding layer (4) configured to bond the glass sheet (2) and the resin sheet (3) to each other, wherein the resin sheet (3) protrudes from the glass sheet (2).