Modular Molding Assembly for Resin Fastener Arrays
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Solution Overview
Problem
Current roll-forming processes for molding resin into products with arrays of projections face limitations in achieving desired configurations and equipment efficiency, particularly in maintaining consistent product thickness and reducing pressure roll bending.
Innovation Solution
A modular molding apparatus with independently movable rotatable rollers and a common reaction surface allows for simultaneous molding of resin projections on multiple substrates, enabling efficient molding of continuous or interrupted layers with adjustable parameters like base layer thickness and nip pressure, and includes features like deflector shoes to prevent substrate creasing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single large pressure roll is used to apply pressure across the entire width of the substrate, then the molding process can be simplified, but the pressure roll bends under load which causes non-uniform gap and inconsistent product thickness
Solution Approach 1:
The patent divides the single large pressure roll into multiple smaller pressure rolls arranged side by side across the width of the substrate. Each pressure roll independently applies pressure to its designated zone without bending, eliminating the gap consistency problem while maintaining simplified molding process. The modular arrangement allows each roll to be supported independently at multiple points along its length.
Solution Approach 2:
The patent uses multiple identical pressure rolls that are replicas of a single design, each performing the same function in its own zone. This copying approach allows the system to achieve the performance of a large roll without the structural problems, as each smaller roll can be precisely manufactured and maintained with consistent dimensions.
2Productivity
If multiple molding zones are operated simultaneously on a single substrate, then productivity increases, but the equipment complexity and difficulty of maintaining uniform pressure across zones increases
Solution Approach 1:
The patent segments the molding apparatus into multiple independent molding modules, each with its own pressure roll, resin source, and control system. These modules operate simultaneously on different portions of the substrate or on separate substrates, multiplying productivity while keeping each module relatively simple and independently maintainable.
Solution Approach 2:
The patent designs the molding modules to be universal and interchangeable, with standardized interfaces and configurations. This allows the same module design to be replicated across multiple positions, simplifying equipment configuration while enabling simultaneous operation of multiple molding zones. The modules can be easily repositioned or reconfigured for different production requirements.
3Manufacturing precision
If the pressure roll and mold roll gap is reduced to achieve thinner base layers, then product specifications are met, but the risk of substrate creasing and defects increases
Solution Approach 1:
The patent divides the pressure application into multiple smaller pressure rolls, each with a shorter span. This segmentation reduces the bending moment and contact pressure concentration on any single point of the substrate, allowing the use of smaller gaps without causing creasing. The distributed pressure application across multiple rolls is gentler on the substrate than a single large roll.
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 solution enables efficient molding of resin projections on separate or connected substrates with quick reconfiguration of equipment, reducing pressure roll bending and allowing in-process adjustments, resulting in uniform fastener products with improved manufacturing efficiency.
Implementation Method 1
pressure-applying means to apply operating pressure to force the resin into the cavities at a pressure zone
Implementation Method 2
resin is drawn under shear force developed by rotation of the pressure roll
Implementation Method 3
molding cavities in the surface thereof and pressure-applying means to apply operating pressure to force the resin into the cavities
Implementation Method 4
knock-down roller arranged to level the fastener elements uniformly with respect to the layer of resin
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
A molding apparatus (10) defining a processing direction (25) includes multiple molding modules (100,100a,100b,100c) spaced apart in a lateral direction perpendicular to the processing direction (25) and a common reaction surface (12). Each molding module (100,100a,100b,100c) includes a frame (104,104a,104b,104c) and a mold roll (106,106a,106b,106c) that defines molding cavities (111a). Each mold roll (106,106a,106b,106c) defines a respective pressure zone (22) in cooperation with the reaction surface (12) and each mold roll (106,106a,106b,106c) is movable with respect to the reaction surface (12) by controlled operation of the frame (104,104a,104b,104c). Molten resin is introduced into the pressure zones (22) and forced into the molding cavities (111a) to form arrays of fastener elements (20) extending from base layers (19) of resin formed on the surfaces of the mold rolls (106,106a,106b,106c). The fastener elements (20) are withdrawn from the cavities (111a) while stripping the base layers (19) from the peripheral surfaces (111).