Molding Apparatus with Suction Frame for Resin Adhesion
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Solution Overview
Problem
Existing molding methods for resin products, such as climate control ducts, face challenges in achieving uniform heat distribution and adequate adhesion between thermoplastic resin sheets, leading to poor traceability and inadequate bonding at parting lines, especially when using foamed resin sheets.
Innovation Solution
A molding apparatus with a movable frame equipped with a suction part that adsorbs and bonds thermoplastic resin sheets to the mold cavity surface, ensuring proper contact and shaping of the resin into a uniform thickness, thereby improving adhesion and preventing gaps between the sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sheets are reheated with infrared heaters during sheet blow molding, then the sheets are softened to enable molding, but the sheets fail to achieve uniform molten state and contain insufficient heat, causing poor traceability and inadequate adhesion
Solution Approach 1:
The patent changes the heating method from infrared radiant heating to contact heating with heated rolls. The rolls are heated to a specific temperature range (80-120°C) and directly contact the resin sheets, providing uniform heat distribution throughout the sheet material, achieving both sufficient temperature and uniform molten state
Solution Approach 2:
The patent replaces the radiant heat source system (infrared heaters) with a mechanical contact heating system (heated rolls). This mechanical system provides more controlled and uniform heat transfer through direct contact, resolving the issue of non-uniform heating while maintaining adequate temperature
2Temperature
If sheets are reheated with infrared heaters, then molding is enabled, but adhesion at pinched-off sections is inadequate
Solution Approach 1:
The patent changes the heating parameters by using contact heating with rolls at controlled temperatures (80-120°C) rather than radiant heating. This provides sufficient and uniform heat to the sheets, ensuring adequate adhesion strength at the pinched-off sections while maintaining the molding capability
Solution Approach 2:
The patent applies preliminary heating to the resin sheets using heated rolls before the molding process. This preliminary action ensures the sheets reach the appropriate temperature and uniform molten state in advance, which directly improves adhesion at the parting lines during subsequent molding
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 enhances the adhesion and uniformity of the resin product, ensuring a closed space and improved bonding at parting lines, even with foamed resin sheets, resulting in a more accurate and reliable molding process.
Implementation Method 1
a suction part for sucking the thermoplastic resin is provided in the frame
Implementation Method 2
the thermoplastic resin sheet is heated with an infrared heater and softened
Implementation Method 3
the sheet is attached firmly to the surface of the cavity by the blowing of a pressurized fluid between the sheets
Data Source
AI summary
A molding apparatus that adsorbs thermoplastic resin extruded in a sheet form from an extruding machine, onto a cavity of a mold, and shapes the thermoplastic resin into a shape according to the cavity is provided. The molding apparatus may include a frame that is positioned on a periphery of the mold and is movable relative to the mold, wherein a suction part for suctioning the thermoplastic resin is provided in a contact surface of the frame to contact the thermoplastic resin, and the suction part is provided in a linear shape along with a longitudinal direction of the frame positioned on the periphery of the mold.