Resin Molding with Injection-Molded Extension Part
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Solution Overview
Problem
Conventional resin moldings for vehicle interiors, made entirely of thermoplastic resin without reinforcing fibers, are heavy and lack aesthetic under shape parts on their end surfaces, which are difficult to manufacture and attach without increasing weight or complexity.
Innovation Solution
A resin molding comprising a plate-like substrate with reinforcing fibers and an extension part formed by injection-molding thermoplastic resin along the substrate's end surface, allowing for aesthetic under shape parts and reduced weight through the use of plant fibers like kenaf, which also enhances strength with ribs if needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the entire resin molding is made of thermoplastic resin without reinforcing fibers, then the manufacturing process is simple, but the weight increases and strength decreases
Solution Approach 1:
The resin molding is divided into two distinct parts: a substrate made of thermoplastic resin containing reinforcing fibers for strength and weight reduction, and an extension part made of pure thermoplastic resin for aesthetic purposes. This segmentation allows each part to have optimized properties for its specific function.
Solution Approach 2:
Different regions of the molding have different material compositions tailored to their specific requirements. The substrate region uses fiber-reinforced resin for structural integrity, while the extension part uses pure resin for aesthetic appearance and ease of molding.
2Ease of manufacture
If the entire resin molding is made of thermoplastic resin without reinforcing fibers, then the molding process is simple, but the strength and structural integrity decrease
Solution Approach 1:
The molding is segmented into a substrate requiring high strength (fiber-reinforced) and an extension part requiring aesthetic appearance (pure resin), allowing each to be optimized independently.
Solution Approach 2:
The substrate uses composite materials combining thermoplastic resin with reinforcing fibers (such as plant fibers) to achieve high strength and stiffness, while the extension part uses pure thermoplastic resin for easier molding and aesthetic finish.
3Shape
If edge trimming is performed to remove burrs from the substrate, then the appearance improves, but the raw material yield decreases and additional processing time is required
Solution Approach 1:
The problematic edge region is extracted and formed as a separate extension part made of pure thermoplastic resin. This extension part is specifically designed to provide a clean, burr-free edge appearance without requiring trimming operations on the main substrate.
Solution Approach 2:
The extension part is molded simultaneously with the substrate in a single injection molding process, preliminarily forming the edge structure with clean surfaces before any finishing operations, thereby eliminating the need for subsequent edge trimming.
4Shape
If an aesthetic under shape part is added to the end surface of the substrate, then the appearance improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The substrate molding and extension part molding operations are merged into a single injection molding process. The mold is designed with cavities for both the substrate and the extension part, allowing simultaneous formation of both components in one cycle, thereby reducing manufacturing complexity despite the added aesthetic feature.
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 approach eliminates the need for edge trimming, improves raw material yield, reduces weight, and allows for the formation of aesthetic and strong resin moldings suitable for vehicle interiors with enhanced appearance and structural integrity.
Implementation Method 1
injecting a resin composed only of a thermoplastic resin containing no reinforcing fibers against a side surface that will become an end surface of the substrate
Implementation Method 2
press-molding the substrate and simultaneously injecting a resin
Data Source
AI summary
To provide a resin molding and a method for producing the same.A resin molding includes a plate-like substrate including reinforcing fibers and a first thermoplastic resin binding the reinforcing fibers to each other, and an extension part that is constituted of an injection-molded member and is extended from an end surface of the substrate along the plate face direction of the substrate. It is preferred that the reinforcing fibers be plant fibers, such as kenaf. It is preferred that the substrate and the extension part be connected flush to each other on, of the one surface and the other surface of the connection part of the substrate and the extension part, at least the side of one surface. Moreover, the extension part may further be provided with a plate-like part that constitutes an outer edge part of the resin molding and forms a shape involute toward the other surface. The method for producing a resin molding includes a shaping step of shaping the substrate and an extension part formation step of forming the extension part by injection-molding.