Resin Molding Device Segmented Mold Foaming Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin molding techniques face challenges in controlling the degree of foaming of base materials with foamed layers, leading to inconsistent rigidity, shock resistance, and adhesion between the skin and base materials due to factors like skin material insulation, foaming agent distribution, and mold opening dynamics.
Innovation Solution
A resin molding device with independently movable mold parts allows for differential movement and speed control during mold opening, enabling precise control of foaming on a portion-by-portion basis by using a separate mold part relative to the main mold part, considering factors like heat insulation and elastic forces of the skin material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base material is foamed using a base material-molding resin containing a foaming agent, then the resin product achieves desired lightweight properties and rigidity, but the degree of foaming becomes inconsistent due to skin material insulation affecting cooling uniformity
Solution Approach 1:
The mold is divided into a first mold that contacts the skin material and a second mold that does not contact the skin material. This segmentation allows independent temperature control and opening speed control for each mold, enabling uniform foaming despite the insulating effect of the skin material on certain portions of the base material.
Solution Approach 2:
The first mold and second mold are opened at different speeds during the foaming process. The mold that contacts the skin material is opened at a slower speed to compensate for the insulating effect, while the other mold opens at a faster speed. This dynamic adjustment ensures uniform foaming degree across the entire base material.
2Shape
If the skin material covers only a portion of the base material surface, then the resin product achieves desired structural properties, but heat insulation causes non-uniform cooling and affects skin layer formation
Solution Approach 1:
The mold is segmented into a first mold portion that contacts the skin material and a second mold portion that does not. This allows the first mold to be opened at a slower speed to maintain adequate cooling for skin layer formation, while the second mold opens faster, achieving uniform skin layer thickness despite the partial coverage configuration.
3Strength
If the entire base material is made solid without a foamed layer, then the resin product achieves sufficient strength, but the weight increases compared to foamed structures
Solution Approach 1:
The invention changes the physical state of the base material from solid to foamed by introducing a foaming agent. The controlled foaming process creates a cellular structure that reduces density and weight while maintaining adequate mechanical strength, achieving an optimal balance between weight reduction and strength retention.
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 optimizes the degree of foaming and thickness of the base material, ensuring consistent rigidity, shock resistance, and improved adhesion between the skin and base materials, addressing the limitations of previous methods.
Implementation Method 1
a base material-molding resin containing a foaming agent that forms the base material
Implementation Method 2
the base material-molding resin containing a foaming agent that forms the base material
Implementation Method 3
the skin material covering a portion of the base material-molding resin serves to insulate heat
Data Source
AI summary
A movable mold includes a main mold part, a separate mold part separate from the main mold part, and a relative movement mechanism moving the separate mold part relative to the main mold part in a driving direction of a mold driver.