Radio Wave Absorber Pellet Mixing for Stable Injection Molding
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Solution Overview
Problem
Existing radio wave absorbers face challenges in achieving stable radio wave absorbability during mass production, leading to variations in performance.
Innovation Solution
A pellet mixture comprising pellets with specific friction coefficient ratios and compositions, including magnetic and dielectric particles, is used to produce a radio wave absorber through injection molding, ensuring consistent supply and absorbability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a radio wave absorber is mass-produced by molding a composition containing radio wave absorbing material, then productivity is improved, but manufacturing precision deteriorates due to variations in radio wave absorbability
Solution Approach 1:
The composition is divided into two distinct types of pellets with different functions: Type A pellets provide flow control properties (friction coefficient) while Type B pellets provide radio wave absorbing properties. This segmentation allows each pellet type to be optimized independently for its specific function, ensuring consistent mixing and distribution during mass production while maintaining stable radio wave absorbability.
Solution Approach 2:
The invention controls the friction coefficient ratio (μA/μB) between the two pellet types within a specific range (0.70 ≤ μA/μB ≤ 0.95). By adjusting this friction parameter, the invention ensures proper mixing behavior during injection molding, preventing segregation and maintaining uniform distribution of radio wave absorbing material throughout the molded product, thus achieving both high productivity and manufacturing precision.
2Ease of manufacture
If the friction coefficient ratio between pellets is not controlled, then ease of manufacture is improved, but manufacturing precision deteriorates due to uneven material distribution
Solution Approach 1:
The invention introduces a specific friction coefficient ratio parameter (μA/μB between 0.70 and 0.95) as a controllable variable that governs the mixing and flow behavior of different pellets during injection molding. By setting this parameter within the optimal range, the process achieves automatic self-regulation of material distribution, maintaining manufacturing precision without complicating the molding process.
Solution Approach 2:
The friction coefficient ratio acts as an inherent feedback mechanism that automatically regulates material flow and distribution during molding. When the ratio is within the specified range, the system self-corrects for variations in melting behavior and flow characteristics, ensuring uniform material distribution without requiring complex process control systems.
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 mass production of radio wave absorbers with stable radio wave absorbability, reducing variations and enhancing the reliability of radar systems.
Implementation Method 1
a composition containing one or more kinds of particles selected from the group consisting of magnetic particles and dielectric particles, and a resin
Data Source
Figure 1~2
Figure 3
AI summary
There are provided a pellet mixture including: a pellet 0 which is a pellet of a composition containing at least a resin, and a pellet 1 which is a pellet of a composition containing one or more kinds of particles selected from the group consisting of magnetic particles and dielectric particles, and a resin, in which a volume content of the particles is higher than a volume content of the particles in the composition of the pellet 0, in which a friction coefficient of the composition of the pellet 0 with a metal is defined as µ0, a friction coefficient of the composition of the pellet 1 with the metal is defined as µ1, and a friction coefficient ratio (µ0/µ1) is 0.80 or less; a radio wave absorber which is a molded product obtained by molding the pellet mixture; a radio wave absorbing article which contains the radio wave absorber; and a method for producing a radio wave absorber, the method including molding the pellet mixture into a molded product.