Massage Roller Two-Shot Molding Drop Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional massage rollers face issues with accurate attachment of the leather layer due to the lack of a clear boundary between the tube and massage parts, leading to aesthetic concerns and potential detachment over time.
Innovation Solution
The use of a two-shot injection molding process forms a tube member and a coating member with distinct end parts and a drop area, allowing for precise attachment of a skin layer that covers the surface but leaves exposed areas on the lateral sides, ensuring accurate adhesion and preventing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one-shot injection molding is used to form the tube part and massage part, then the manufacturing process is simple, but the boundary between parts is unclear making it difficult to control the adherence area of the leather layer
Solution Approach 1:
The massage roller is divided into three distinct parts: tube part, massage part, and coating part. The coating part includes a drop portion that extends radially between the tube part and massage part, creating a clear boundary and attachment area for the leather layer. This segmentation allows precise control of the adherence area while maintaining manufacturing simplicity through sequential injection molding.
Solution Approach 2:
The drop portion is pre-formed as an integral part of the coating member during the injection molding process. This preliminary formation of the attachment structure ensures that the leather layer has a pre-defined, clear boundary area for adherence, eliminating the need for post-processing to create attachment boundaries.
2Ease of operation
If the leather layer is attached to the massage part without a clear boundary, then the attachment process is straightforward, but the adherence area distorts and the leather layer comes off after long usage
Solution Approach 1:
The drop portion serves as an intermediary structure between the tube part and massage part. It creates a dedicated attachment zone that mediates the connection between the leather layer and the underlying structure. This intermediary drop portion provides a stable, well-defined area for leather layer adherence, preventing distortion and detachment while maintaining ease of attachment.
3Device complexity
If no drop structure is formed between tube part and massage part, then the manufacturing process is simpler, but the aesthetic appearance is affected due to distortion of the adherence area
Solution Approach 1:
The drop portion is strategically positioned at the critical location where the leather layer attaches to the massage roller. This localized structural enhancement provides the necessary aesthetic appearance and functional performance only where needed, without complicating the overall device structure. The drop portion creates a visually appealing boundary that prevents distortion while maintaining simplicity elsewhere in the design.
Data Source
AI summary
A manufacturing method of a massage roller includes a first injection processing step, a second injection processing step, and a skin attaching step. In the first injection processing step, a tube member is injected to be formed in a mold. In the second injection processing step, a coating member is injected on the outer periphery of the tube member in the mold, wherein a drop exists between two ends of the coating member and the tube member. The skin attaching step is carried out after the second injection processing step, wherein a skin layer is attached to cover the surface of the coating member, finishing the massage roller. Accordingly, the tube member and coating member are formed through a two-shot injection molding operation, facilitating the attachment of the skin layer to the coating member, and providing an aesthetic appearance which is less distorted.