Molded Body Cell Size Control for Weight and Appearance

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Solution Overview

Problem

The challenge is to create a molded body for automobiles that achieves weight reduction while maintaining an improved external appearance, as increasing the proportion of cells in the molded body can lead to surface dimples.

Innovation Solution

A molded body comprising resin and cells with an average diameter of 0.03 mm to 0.13 mm and a number per unit area of at least 20 cells/mm², produced using a method involving a composition with a foaming agent and a movable molding apparatus to control cell formation, ensuring a favorable external appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the proportion of cells in the molded body is increased to achieve weight reduction, then the weight decreases, but surface dimples form and external appearance deteriorates

Engineering Contradiction:

Improveweight of molded bodyVSAvoidexternal appearance

Core Design Contradiction:

Weight of moving objectVSShape

Solution Approach 1:

The patent applies parameter changes by precisely controlling cell size (average diameter 0.03-0.13 mm) and cell density (≥20 cells/mm²) to resolve the contradiction. By changing these physical parameters within specific ranges, the invention achieves weight reduction through high cell proportion while preventing surface dimple formation, thus maintaining good external appearance.

Inventive Principle:

Principle #35Parameter changes

2Shape

If the cell size is increased to reduce the number of cells, then the external appearance improves, but the weight reduction effect decreases

Engineering Contradiction:

Improveexternal appearanceVSAvoidweight of molded body

Core Design Contradiction:

ShapeVSWeight of moving object

Solution Approach 1:

The patent resolves this contradiction by optimizing the cell size parameter within the specific range of 0.03-0.13 mm average diameter. This parameter change ensures that cells are small enough to prevent surface dimples (maintaining appearance) while being large enough to provide effective weight reduction, achieving both goals simultaneously.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent transitions from considering only cell size to controlling both cell size and cell density together. By adding the dimension of cell density control (≥20 cells/mm²), the invention achieves weight reduction through high cell proportion while maintaining appearance quality through appropriate size selection.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution effectively reduces weight and enhances the external appearance of the molded body by controlling cell size and distribution, preventing surface dimples and maintaining a favorable appearance even with a large number of cells.

Implementation Method 1

a molded body including air bubbles (cells), obtained by foaming a resin

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

supplying a composition including a resin and a foaming agent

Methodology Applied

Scientific EffectGas generation from foaming agent:

Data Source

PatentUS20220402445A1Molded body, and method for producing molded body

Publication Date: 2022.12.22 RESONAC CORP

AI summary

A molded body, comprising a resin and cells, the cells having an average diameter of from 0.03 mm to 0.13 mm, and a number per unit area of the cells at a cross-section of the molded body being no less than 20 cells/mm2.