Resin Frame Corner Welding Mold for Uniform Surface Finish
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Solution Overview
Problem
Existing resin frame manufacturing methods result in a concave surface in the corner portion that is aesthetically inferior due to differences in surface roughness and color tone between the outer peripheral surface adjacent to the corner and the chamfered concave surface, requiring additional processes like chamfering and painting to match appearances.
Innovation Solution
A method involving molds with reference and blade portions to press and weld frame members, creating a concave corner surface without chamfering, ensuring the outer layers on both sides of the corner portion match the adjacent surfaces in appearance and surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If chamfering process is applied to create concave corner surface, then the corner portion can be formed, but the surface roughness and color tone differ from adjacent surfaces requiring additional painting process
Solution Approach 1:
The mold's reference surface and blade portion are designed in advance to automatically form the concave corner surface with uniform appearance during the welding process itself, eliminating the need for subsequent chamfering and painting operations. The mold structure pre-establishes the correct geometry and surface quality in one step.
Solution Approach 2:
The welding process itself serves multiple functions: it joins the frame members while simultaneously forming the concave corner surface with appropriate geometry and uniform appearance. The process is self-sufficient, requiring no additional finishing operations.
2Manufacturing precision
If additional chamfering and painting processes are used to match appearance, then surface uniformity is improved, but manufacturing complexity and process time increase
Solution Approach 1:
The mold integrates multiple functions into a single device: it holds the frame members during welding, forms the concave corner geometry, and ensures uniform surface appearance. This consolidation eliminates separate chamfering and painting processes, reducing overall manufacturing complexity.
Solution Approach 2:
The mold structure performs multiple operations simultaneously: welding the frame members, forming the concave corner shape, and creating uniform surface finish. This multi-functional approach replaces several specialized processes with one universal tool.
3Ease of manufacture
If welding margins are abutted and welded without mold pressure, then welding is simplified, but the corner portion geometry and surface finish become inconsistent
Solution Approach 1:
The mold acts as an intermediary between the welding margins, applying controlled pressure through its reference surface and blade portion. This mediation ensures consistent geometry and surface finish while maintaining the simplicity of the welding process itself.
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 method produces a resin frame with a concave corner surface that matches the adjacent surfaces in both color tone and surface finish, eliminating the need for additional processes like chamfering and painting, thereby enhancing the appearance and simplifying the manufacturing process.
Implementation Method 1
end surfaces of the pair of the frame members, which are adjacent to each other in the corner portion, are heated and melted as welding margins
Data Source
AI summary
A manufacturing method of a resin frame includes preparing a plurality of frame members, installing a pair of the frame members in the corner portion in a pair of molds, melting end surfaces of the pair of the frame members as welding margins, and welding the welding margins. The molds respectively includes a reference surface holding the frame members and a blade portion protruding to an inner side with respect to the reference surface. In the welding, in the corner portion, the pair of the frame members are pressed by the blade portions, so that the welding margin protrudes from between the blade portions, the outer peripheral surfaces of the pair of the frame members are bent inward, and the corner portion is made concave with respect to the portions adjacent to the corner portion.