Resin Block Production Device Using Melt and Layer Forming
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Solution Overview
Problem
Current methods for producing resin prototypes, such as carving resin blocks or using 3D printers, are limited in the types and colors of resin materials available, making it difficult to evaluate the characteristics of resin molded products for mass production, and often result in inaccurate dimensional accuracy and high costs.
Innovation Solution
A resin block production device and method that uses a slide unit, lifting unit, and heater unit with heat insulating members to melt and form resin blocks from pellets, allowing for the production of resin blocks with desired materials and colors, and enabling evaluation of characteristics for mass production prototypes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If resin blocks are produced by carving or 3D printing, then prototypes can be produced quickly, but the types and colors of resin materials are limited
Solution Approach 1:
The invention changes the physical state of resin from solid blocks to pellets, enabling melting and reforming. This parameter change allows any type of resin material to be used, resolving the material selection limitation while maintaining rapid prototype production capability
Solution Approach 2:
The invention utilizes phase transition of resin from solid to liquid state through melting, then back to solid upon cooling. This enables the production of resin blocks from pellets in various materials and colors, overcoming the limitation of pre-formed block materials
2Ease of manufacture
If resin blocks are produced by carving, then existing materials can be used, but dimensional accuracy and warpage control are poor
Solution Approach 1:
The invention replaces mechanical carving with a thermal processing system that melts and reforms resin pellets. This substitution enables precise dimensional control through controlled heating and cooling processes, eliminating warpage issues associated with mechanical carving
Solution Approach 2:
By controlling temperature parameters during melting and cooling processes, the invention achieves precise dimensional accuracy and prevents warpage, while still allowing ease of manufacture with various resin materials
3Reliability
If molds are made for mass production to evaluate resin characteristics, then accurate material evaluation is possible, but time and cost increase
Solution Approach 1:
The invention creates a copying system that produces resin blocks with identical material properties to mass production. By melting and reforming the same resin pellets, it creates accurate material copies for evaluation without requiring actual mass production molding, thus avoiding mold making time and costs
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 the production of resin blocks with desired materials and colors, allowing for accurate evaluation of resin molded product characteristics, improving dimensional accuracy and reducing costs by allowing for the use of any resin material and color, and producing high-quality resin blocks with minimal bubble formation.
Implementation Method 1
a heater unit (300) configured to heat and melt the resin material (7)
Implementation Method 2
a lifting unit (200) configured to compress the resin material (7) in a block shape at a predetermined pressure
Implementation Method 3
heat insulating members (124, 314)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided is a device capable of producing a resin block from any resin material. A resin pellet (7) supplied into a resin block forming space (150) is heated to be melted, and is cooled to be solidified, by means of a heater unit (300), so that a resin layer is formed. Each time the resin layer is formed, a lifting/lowering mechanism (230) of a lifting/lowering unit (200) lowers a bottom surface plate (215). Thus, the resin layers formed in the resin block forming space (150) are sequentially deposited forming a large-size resin block.