Molten Resin Sheet Molding with Pre-Mold Static Elimination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Resin sheets unintentionally coming too close to the mold can cause unintended wrinkles due to electrostatic attraction, leading to molding defects.
Innovation Solution
A molding device equipped with a resin sheet forming device, roller unit, mold, and static eliminator, where the static eliminator eliminates static from the resin sheet after it passes through the roller unit but before reaching the mold, preventing electrostatic attraction and ensuring the resin sheet remains aligned with the mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the resin sheet is hung down close to the mold to improve positioning accuracy, then the positioning precision is improved, but electrostatic attraction causes the resin sheet to unintentionally approach the mold, creating wrinkles and molding defects
Solution Approach 1:
The static eliminator is positioned to eliminate static charge from the resin sheet before it reaches the mold, preventing electrostatic attraction in advance. This preliminary action removes the harmful electrostatic effect that would otherwise cause the resin sheet to unintentionally approach the mold and create wrinkles
Solution Approach 2:
The invention converts the harmful electrostatic attraction into a beneficial controlled process by using the static eliminator to neutralize the static charge. The static eliminator transforms the problematic electrostatic field into a neutral state, allowing the resin sheet to be positioned close to the mold without unwanted attraction
2Object-affected harmful factors
If the resin sheet is hung down several dozens of millimeters from the mold to avoid electrostatic attraction, then electrostatic defects are reduced, but positioning accuracy and molding precision deteriorate
Solution Approach 1:
By eliminating static charge before the resin sheet reaches the mold area, the system allows the sheet to be positioned at the optimal distance for high molding precision without suffering from electrostatic attraction defects
3Productivity
If the resin sheet passes through the roller unit at high speed to improve productivity, then productivity is improved, but static charge accumulation increases, worsening electrostatic attraction problems
Solution Approach 1:
The static eliminator acts as an intermediary between the roller unit and the mold, neutralizing static charge that accumulates during high-speed passage through the rollers. This allows high productivity to be maintained without the harmful effects of static charge accumulation
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
Prevents resin sheets from unintentionally approaching the mold, reducing molding defects such as wrinkles and ensuring consistent shaping of the resin sheets into desired forms.
Implementation Method 1
the resin sheet is charged when the resin sheet passes through the first and second rollers, and is attracted to the mold by electrostatic action
Data Source
AI summary
A molding device incudes a resin sheet forming device, a roller unit, a mold, and a static eliminator. The resin sheet forming device is configured to extrude a resin sheet in a molten state; the roller unit includes first and second rollers; the first and second rollers are configured to rotate in opposite directions while sandwiching the resin sheet so as to feed the resin sheet below the first and second rollers; the mold has a shaping surface to shape the resin sheet; and the static eliminator is configured to eliminate static from the resin sheet at a point after the resin sheet pass through the roller unit but before a bottom edge of the resin sheet reaches a lower end of a molding area of the mold.