Resin Molded Body Mount Base Rigidity Design
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Solution Overview
Problem
Resin molded articles with expanded layers for weight reduction often compromise on rigidity, leading to potential breakage or deformation under large fastening forces.
Innovation Solution
A resin molded article design featuring a hard skin layer with no pores on the surface and an expanded layer inside, incorporating a solid mount base structure with an inner and outer mount base portion joined by a joint mount base portion, and a solid layer with no expanded layer, which increases the rigidity and prevents deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If an expanded layer with a large number of pores is formed inside the resin molded article to promote weight reduction, then the weight is reduced, but the rigidity is lowered, causing the mount base to be broken or deformed under large fastening forces
Solution Approach 1:
The patent applies local quality by creating different structural zones within the resin molded article: an expanded layer with pores in the main body for weight reduction, and solid dense layers specifically at the mount base and its peripheral portion for maintaining high rigidity. This localized differentiation allows each region to have the properties needed for its specific function.
Solution Approach 2:
The patent segments the resin molded article into distinct functional regions: the expanded layer with large number of pores for the molded main body, and solid layers (mount base and peripheral solid layer) with no or few pores. This segmentation allows the weight reduction benefit in the main body while preserving structural integrity where needed.
2Weight of moving object
If the mount base is formed with the expanded layer structure to maintain weight reduction, then the weight is reduced, but the mount base may be broken or deformed upon receipt of large fastening force
Solution Approach 1:
The patent applies local quality by creating different structural zones within the resin molded article: an expanded layer with pores in the main body for weight reduction, and solid dense layers specifically at the mount base and its peripheral portion for maintaining high rigidity. This localized differentiation allows each region to have the properties needed for its specific function.
Solution Approach 2:
The peripheral solid layer acts as a cushioning zone that prevents stress concentration at the mount base boundaries. By providing this solid buffer region surrounding the mount base, the structure anticipates and mitigates the harmful effects of fastening forces before they can cause breakage or deformation.
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 design enhances the rigidity of the mount base, preventing deformation or breakage under large fastening forces while maintaining weight reduction benefits.
Implementation Method 1
the sliding die in the movable die is withdrawn in the direction in which the capacity of the cavity is increased to expand the fiber-containing thermoplastic resin by elastic restoring force (a springback phenomenon) of the fiber compressed by resin pressure
Data Source
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AI summary
An annular mount base 11 continuously protruded from one face of a panel main body 3 and surrounding a through hole 9 has a dual structure of an inner mount base portion 17 and an outer mount base portion 19 which are joined to each other by four parts of a joint mount base portion 21. A skin layer 23 is formed at the surface of a door inner panel 1. An expanded layer 25 with a large number of pores is formed inside the panel main body 3. The mount base 11 and a part of the panel main body 3 between the inner mount base portion 17 and the outer mount base portion 19 are formed of a solid layer 27 having no expanded layer 25. Whereby, a lightweight resin molded article including a high-rigidity mount base is provided.