Magnetic Fixation for Resin Insert Members Without Residual Magnets
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Solution Overview
Problem
Existing methods for producing resin members with conductive paste layers and feed portions face challenges in fixing insert members within molds without leaving unrelated parts, particularly when using magnetic attraction, which can result in residual magnets in the final product, and in achieving low resistance and high stretchability for curved glass surfaces.
Innovation Solution
The method involves using a mold with a second magnetic attractor to fix an insert member with a first magnetic attractor, which becomes a feed portion, and injecting resin to integrate the insert member and the magnetic attractor into a resin panel, ensuring no unrelated parts remain, and connecting the resin member to an external feed member using a screw or two-solution-mixture paste for improved conductivity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnet is disposed in an insert member to fix it using magnetic attractive force, then the insert member can be adequately fixed in place within the mold, but a magnet having no relationship with the structural members of the window glass will remain in the insert member
Solution Approach 1:
The magnet is extracted from the insert member after serving its fixation purpose. The insert member is removed from the mold cavity before the magnet is released, allowing the magnet to be taken out separately and preventing it from remaining in the final window glass product.
Solution Approach 2:
The magnet is preliminarily attached to the insert member before molding to enable fixation during the molding process. This preliminary attachment allows the magnet to perform its fixation function temporarily, and then it can be removed in subsequent steps without being part of the final product.
2Reliability
If suction force is used to fix the insert member, then fixation during injection is achieved, but a hole may be generated in the resin panel due to suction force acting thereon
Solution Approach 1:
The suction-based mechanical fixation system is replaced with a magnetic attraction system. The magnet on the insert member attracts to the mold, providing fixation without requiring suction forces that would act on the resin panel and potentially create holes. This substitution eliminates the harmful effect while maintaining fixation stability.
3Reliability
If tape is used to fix the insert member in place, then fixation during injection is achieved, but the residue of the tape or the tape itself may remain in the product
Solution Approach 1:
The tape-based mechanical fixation system is replaced with a magnetic attraction system. The magnet provides fixation through magnetic force without leaving any residue or tape material in the final product, eliminating the contamination issue while maintaining adequate fixation stability during injection.
Solution Approach 2:
The magnetic fixation system uses invisible magnetic fields rather than visible tape materials, creating a more homogeneous final product without foreign residue. The magnetic force acts uniformly without leaving discrete material elements that would compromise product purity.
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 method effectively fixes the insert member within the mold without residual parts and enhances the conductivity and connection strength between the resin member and external feed member, improving workability and portability of the final product.
Implementation Method 1
positioning and fixing the insert member in place within the cavity using the magnetic attractive force of the first magnetic attractor and the second magnetic attractor
Implementation Method 2
a conductive paste layer, wherein a feed portion is provided at a predetermined position of the conductive paste layer
Data Source
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AI summary
A method for producing a resin member including a conductive paste layer and a feed portion that can suitably fix an insert member in place relative to a mold without leaving a part having no relationship with the structural members of the final product within the insert member, and a method for connecting the resin member produced with such a method to an external feed member. The method includes storing an insert member including an exterior resin film with a conductive paste layer, and a first magnetic attractor to become a feed portion into a cavity of a mold including a second magnetic attractor; positioning and fixing the insert member in the cavity using magnetic attractive force of the first and the second magnetic attractors; and injecting resin into the cavity to form a resin panel, thereby integrating the insert member with the resin panel to produce a resin member.