Molded Laminated Structure with Negative Draft Angles
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Solution Overview
Problem
Conventional molding techniques are unable to efficiently produce molded laminated structures with negative draft angles, requiring multiple pieces and a time-consuming splicing process that can result in weak and uneven surfaces.
Innovation Solution
A method involving a preliminary structure with positive draft angles, a groove in one layer, and a folding process to create negative draft angles while maintaining the second layer continuous, filled with adhesive and optionally a filler material, to form a strong and aesthetically pleasing molded laminated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional molding techniques are used to produce structures with negative draft angles, then the structure cannot be removed from the mold, but using multiple-piece molds with splicing increases manufacturing complexity and time
Solution Approach 1:
The mold is divided into two separate members: a first mold member that forms the first outer layer with the groove, and a second mold member that forms the second outer layer. This segmentation allows each mold member to be simpler in design while collectively producing the complex negative draft angle structure. The first mold member creates a groove in the first outer layer, and the second mold member forms the second outer layer that bridges across this groove, enabling the final structure to have negative draft angles without requiring a complex multi-piece mold system.
2Ease of manufacture
If multiple separate pieces are molded and spliced together to form negative draft angles, then the structure can be manufactured, but the splicing process is time-consuming and reduces productivity
Solution Approach 1:
The first outer layer and second outer layer are molded together in a single integrated molding process to form a unified preliminary structure. The groove in the first outer layer and the continuous second outer layer that bridges across it are created simultaneously during molding, rather than as separate pieces requiring post-molding splicing. This merging of layers into a single molded structure eliminates the time-consuming manual splicing process and significantly improves manufacturing productivity.
3Ease of manufacture
If multiple pieces are spliced together to create negative draft angles, then the structure can be formed, but the bond lines create weak points and uneven surfaces
Solution Approach 1:
The first outer layer and second outer layer are molded together as a single integrated structure, eliminating the need for separate bonding operations. The groove in the first outer layer is filled with adhesive during the molding process itself, and the second outer layer is formed continuously across this groove, creating a unified structure without weak bond lines. This merging approach ensures uniform strength throughout the structure, particularly at what would otherwise be joint locations.
Solution Approach 2:
Adhesive is used as an intermediary material to fill the groove in the first outer layer and bond the first and second outer layers together. This adhesive intermediary creates a strong, continuous connection between the layers, eliminating weak points that would exist in mechanically spliced joints. The adhesive fills the groove completely and bonds the layers together, ensuring uniform strength distribution across the interface between layers.
4Ease of manufacture
If multiple pieces are spliced together, then negative draft angles can be achieved, but extensive post-molding processing is required to smooth surfaces
Solution Approach 1:
The first outer layer and second outer layer are molded together in a single integrated process, creating a unified preliminary structure with continuous surfaces. The groove in the first outer layer and the second outer layer that bridges across it are formed simultaneously during molding, eliminating the need for post-molding splicing and surface smoothing operations. This merged molding approach produces a structure that requires minimal post-molding processing, significantly reducing time loss.
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
Enables efficient manufacturing of molded laminated structures with negative draft angles, improving strength and surface quality by maintaining the second outer layer continuous and correctly oriented, reducing the need for extensive post-molding processing.
Implementation Method 1
an adhesive that fills the groove
Implementation Method 2
folding the preliminary structure at the bend to form a molded laminated structure
Data Source
AI summary
Disclosed herein is a molded laminated structure having negative draft angles and methods of manufacturing a molded laminated structure having negative draft angles. A preliminary structure having a first outer layer and a second outer layer is molded with a bend that divides the preliminary structure into two sections with an angle between the two sections of less than 180-degrees. Portions that extends from the sections are at positive draft angles. A groove is formed in the preliminary structure at the bend but not formed in a constant cross-section of the second outer layer. The preliminary structure is folding along the bend to at least partially close the groove and form a molded laminated structure with portions that extend at a negative draft configuration while retaining the second outer layer continuous throughout the molded laminated structure.