Hollow Blow-Molded Foam Ventilation Path Cooling
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Solution Overview
Problem
Hollow blow-molded foams used in automotive ducts face issues with noise reduction and flow-rate efficiency due to non-foaming resin materials and inadequate cooling processes, leading to increased thickness and roughened inner surfaces which affect air flow resistance.
Innovation Solution
A method of forming hollow blow-molded foam with a ventilation path, where a foaming resin is sandwiched between molds and cooled by allowing a fluid to flow through the path, resulting in a surface with average roughness Rz of 100 μm or less, enhancing flow-rate efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling process is prolonged to sufficiently cool the inside of each wall, then the cooling effectiveness is improved, but the production time increases and the process becomes less efficient
Solution Approach 1:
The invention divides the cooling process into two independent stages: (1) cooling the outer surface of the hollow blow-molded foam through contact with the mold, and (2) cooling the inner surface through the ventilation path. This segmentation allows both surfaces to be cooled simultaneously through different mechanisms, improving overall cooling effectiveness without extending production time
Solution Approach 2:
The ventilation path acts as an intermediary channel that allows cooling fluid to reach the inner surface of the foam wall. This intermediary structure enables direct cooling of the previously inaccessible inner surface, significantly enhancing cooling efficiency without requiring prolonged external cooling
2Reliability
If the thickness of the hollow blow-molded foam is increased for better insulation, then the heat insulating property is improved, but the cooling process becomes less effective and the inner cells expand causing roughened inner surface
Solution Approach 1:
The cooling fluid is divided into two pathways: external cooling through the mold contact and internal cooling through the ventilation path. This segmentation enables effective cooling of thick-walled structures by addressing both the outer and inner surfaces simultaneously, preventing inner cell expansion and maintaining surface smoothness even with increased thickness
Solution Approach 2:
The invention introduces an internal cooling dimension by creating the ventilation path within the foam structure. This allows cooling to occur not only from the external dimension (mold contact) but also from the internal dimension (ventilation path), enabling effective cooling of thick walls without compromising surface quality
3Object-generated harmful factors
If a foaming resin is used to achieve noise reduction, then the sound absorbing property is improved, but the inner surface becomes rougher and air flow resistance increases
Solution Approach 1:
The foam wall structure is segmented into two functional zones: the outer surface that maintains smoothness for low air flow resistance, and the inner surface that contains the foamed structure for noise absorption. The ventilation path further segments the cooling function, allowing the foamed structure to be cooled effectively without compromising the outer surface smoothness
Solution Approach 2:
Different regions of the foam structure are given different qualities: the outer surface is maintained smooth for aerodynamic efficiency, while the inner surface develops the characteristic foamed texture for noise absorption. The ventilation path enables this differential quality distribution by providing targeted cooling to different regions
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 improves the flow-rate efficiency of fluids through the hollow blow-molded foam by reducing air resistance and preventing cell rupture, thus enhancing the cooling process and maintaining the shape of the foam.
Implementation Method 1
cooling the hollow blow-molded foam by allowing a fluid for use in cooling the hollow blow-molded foam to flow through the ventilation path
Implementation Method 2
allowing a fluid for use in cooling the hollow blow-molded foam to flow through the ventilation path
Data Source
AI summary
An object of the present invention is to provide a method of forming a hollow blow-molded foam and also provide such a hollow-molded foam, which are capable of improving a flow-rate efficiency of a fluid that flows through the inside of the hollow blow-molded foam. A foaming resin is sandwiched between molds so that a hollow blow-molded foam having a ventilation path is molded, and a fluid for use in cooling the hollow blow-molded foam is allowed to flow through the ventilation path so that the hollow blow-molded foam is cooled.