Resin Molding Connection Part Design for Leakage Prevention
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Solution Overview
Problem
Resin moldings for vehicle interiors often suffer from aesthetic issues due to differences in thermal shrinkage and injection pressure, leading to resin leakage and wrinkles at the joined parts, which compromise their appearance and functionality.
Innovation Solution
A resin molding design featuring a connection part with a thin section between two substrates, where the density of one substrate is higher than the base part, and the other substrate is an injection-molded member connected along the plate face direction, with a gradual thinning section to reduce injection pressure and prevent resin leakage and wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin is injected against the end surface of a plate-like substrate to form an under shape structure, then the substrate can be connected to the injection-molded member, but resin leakage and wrinkles occur near the joined part due to injection pressure
Solution Approach 1:
The invention applies local quality by creating a thin part specifically at the connection part of the substrate, while maintaining normal thickness in other areas. This localized thinning concentrates the substrate material at the critical joining region, allowing the resin to penetrate and bond effectively without causing leakage or wrinkles on the aesthetic surface.
Solution Approach 2:
The invention changes the physical parameter of substrate thickness at the connection part by forming a thin part with reduced thickness. This parameter change allows controlled resin penetration into the substrate at the connection region while preventing resin from reaching the aesthetic surface, thereby solving the leakage and wrinkle problems.
2Manufacturing precision
If the substrate thickness is reduced at the connection part to prevent resin leakage, then aesthetic quality improves, but the overall structural strength may be compromised
Solution Approach 1:
The thin part is created only at the connection part where resin penetration is needed, while the rest of the substrate maintains its full thickness and structural integrity. This localized approach ensures that aesthetic quality is improved without compromising the overall structural strength of the substrate.
3Manufacturing precision
If a thin part is formed at the connection part with higher density, then resin leakage and wrinkles are suppressed, but the manufacturing process becomes more complex
Solution Approach 1:
The thin part is formed preliminarily during the substrate manufacturing process itself, rather than requiring separate post-processing steps. This preliminary formation of the thin part at the connection region integrates the solution into the existing manufacturing workflow, minimizing additional complexity.
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 design effectively suppresses differences in level, resin leakage, and wrinkle formation near the joined parts, enhancing the aesthetic quality and structural integrity of the resin molding.
Implementation Method 1
a connection part constituted of a thin part provided from one substrate to the other substrate near connected end surfaces
Implementation Method 2
a plate-like substrate including reinforcing fibers and a first thermoplastic resin binding the reinforcing fibers to each other
Data Source
AI summary
Provided is a resin molding in which two types of substrates have a connection part constituted of a thin part provided from the one substrate to the other substrate with a boundary defined by end surfaces of the respective substrates, wherein the density of the one substrate in the connection part is higher than the density of a base part excluding the connection part. The resin molding can have a configuration in which the one substrate is a plate-like substrate including reinforcing fibers and a first thermoplastic resin binding the reinforcing fibers to each other and the other substrate is an injection-molded member connected along the plate face direction of the one substrate from an end surface of the one substrate. Moreover, it is preferred that the connection part have, on the side thereof closer to the other substrate, a section gradually thinned from a position at which the connection part extends and the connection interface be located at an intermediate part of the part that is gradually thinned. It is preferred that the reinforcing fibers be plant fibers, such as kenaf.