Panel Press Mold With Urethane Pad for Surface Defect Prevention
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Solution Overview
Problem
In press processing, surface defects due to mismatch between the panel and mold surfaces lead to quality issues and the need for manual post-processing, increasing production costs and time without ensuring uniformity.
Innovation Solution
A press mold with a urethane pad formed on the upper forming surface, bonded through a heat-resistant adhesive and elastically supported by gas springs, ensures a perfect match between the panel and mold surfaces, eliminating the need for manual post-processing by maintaining precise pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual post-processing is used to correct surface defects, then product quality can be improved, but production time and labor costs increase
Solution Approach 1:
The urethane pad is pre-formed on the upper forming surface with precise thickness (5-15mm) and surface properties before the pressing operation. This preliminary preparation ensures that the panel achieves perfect contact with the forming surface during pressing, preventing surface defects from occurring in the first place and eliminating the need for subsequent manual post-processing
Solution Approach 2:
The urethane pad acts as an intermediary layer between the rigid upper forming surface and the panel. It compensates for any mismatches or irregularities in the panel surface, ensuring uniform contact and pressure distribution during forming. This mediator prevents surface defects without requiring manual intervention afterward
2Manufacturing precision
If manual post-processing is used to correct surface defects, then product quality can be improved, but production cost increases
Solution Approach 1:
The urethane pad serves as a cost-effective intermediary solution that prevents surface defects during the forming process. By ensuring perfect contact between the panel and forming surface through the compliant urethane layer, the invention eliminates expensive manual post-processing operations while maintaining high surface quality
Solution Approach 2:
The invention changes the physical parameters of the forming surface by introducing a urethane pad with specific thickness (5-15mm) and material properties. This parameter change allows the surface to adapt to panel variations, preventing defects and reducing the need for costly manual corrections
3Strength
If a rigid forming surface is used, then structural strength is maintained, but surface defects occur due to mismatch with panel
Solution Approach 1:
The invention creates a composite structure combining the rigid upper die (providing structural strength) with the compliant urethane pad (providing surface adaptability). This composite approach maintains the overall mold strength while the urethane layer conforms to panel variations, preventing surface defects through perfect contact
Solution Approach 2:
The urethane pad is applied locally on the upper forming surface where direct contact with the panel occurs. This localized application provides the necessary compliance and adaptability at the contact interface while maintaining the rigid structure of the overall mold system
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 prevents surface defects and enables fully automated panel forming, improving quality and reducing labor costs by ensuring a precise and consistent forming process.
Implementation Method 1
an elastic unit mounted in the mounting recess, and configured to apply a pressure to the panel by being elastically supported in a vertical direction by an elastic unit
Implementation Method 2
The elastic unit may include a plurality of gas springs of which pressure is adjusted by a pressure control device
Implementation Method 3
The urethane pad may be bonded on the upper forming surface through a heat-resistant adhesive member that withstands a temperature range of 100° C. to 400° C.
Data Source
AI summary
A press mold for forming a panel, may include an upper die for vertically operating by an upper press, and having a mounting recess recessed upward at a lower surface central portion, a lower die disposed under the upper die, and configured to the vertically operate by a lower press, an upper pad disposed in a center portion of the mounting recess, and formed with an upper forming surface at a lower surface edge portion, a lower steel disposed under the upper pad, mounted on the lower die, and formed with a lower forming surface at an upper surface edge portion of the lower steel corresponding to the upper forming surface, and an upper steel mounted on the upper die at a position exterior to the lower forming surface.