Resin Mold Air Permeable Interposing Layer Ventilation
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Solution Overview
Problem
Existing resin molding dies for vacuum molding face challenges with ventilation, as the grained resin layer can block exhaust holes, requiring extensive manual perforation and leading to clogging issues, which is labor-intensive and inefficient.
Innovation Solution
A mold with an air-permeable interposing layer between the mold surface and the design layer, allowing for easy formation and maintenance of ventilating throughholes without the need for precise initial placement, as these can be perforated to reach the interposing layer, reducing the effort required for ventilation and minimizing clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exhaust holes are formed in the die for vacuum molding, then ventilation characteristic is improved, but the grained resin layer blocks the exhaust holes causing clogging
Solution Approach 1:
A porous layer is introduced as an intermediary between the grained resin layer and the exhaust holes. This porous layer allows air and resin to pass through while preventing clogging of the exhaust holes by the grained resin layer, thus maintaining ventilation characteristic without the harmful clogging effect
Solution Approach 2:
The invention uses a porous layer with controlled porosity to enable air and resin permeation while preventing clogging. The porous structure allows necessary flow characteristics while the grained resin layer can be easily removed or cleaned without blocking the exhaust holes
2Reliability
If manual perforation is performed on all exhaust holes to ensure ventilation, then ventilation characteristic is improved, but the work required becomes enormous
Solution Approach 1:
The exhaust holes are pre-formed in the die before applying the grained resin layer. The porous layer is then applied over these pre-formed holes, ensuring ventilation pathways are established in advance without requiring extensive manual perforation work after resin application
Solution Approach 2:
The porous layer serves as a mediator that maintains ventilation through the grained resin layer without requiring manual perforation of each hole. It provides continuous air passage while allowing easy cleaning if clogging occurs
3Manufacturing precision
If the grained resin layer is made thick to improve grain inversion rate, then surface quality is improved, but exhaust holes become more difficult to maintain and clean
Solution Approach 1:
The porous layer acts as an intermediary that facilitates easy cleaning of exhaust holes even when the grained resin layer is thick. Air and resin can pass through the porous layer without clogging the deep exhaust holes, and maintenance becomes simpler due to the porous structure
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
This solution simplifies the process of creating and maintaining ventilation in resin molding dies, reducing the labor involved in initial hole formation and allowing for easy perforation of clogged areas, thereby ensuring consistent ventilation characteristics without extensive manual intervention.
Implementation Method 1
an air permeable interposing layer is interposed between the mold surface and the design layer
Data Source
Figure 1~2
Figure 3
Figure 4~7
AI summary
An object of the present invention is to provide a mold for resin molding which ensures ventilation characteristic without requiring an enormous amount of work. The mold for resin molding of the present invention includes: a mold 12; a design layer 16 formed inside the mold 12; and a air permeable interposing layer 22 for forming the design layer 16 on an inner surface of the mold 12. The mold 12 forms a ventilating throughhole 14. The design layer 16 is made of a resin having projections and depressions on the surface, and has a ventilating throughhole 18 formed so as to couple to the ventilating throughhole 14. The air permeable interposing layer 22 is arranged next to the inner surface of the mold 12 so that an inner surface of the design layer 16, the ventilating throughhole 18 of the design layer 16, and the ventilating throughhole 14 of the mold 12 couple to each other.