Resin Panel Burr Cutting With Suction-Shaped Split Molds
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Solution Overview
Problem
Existing methods face challenges in reliably cutting burr portions, molding defects due to resin sheet peeling, and manufacturing thin hinges with high yield, particularly in resin panel production.
Innovation Solution
A method involving split molds with movable portions and pinch-off structures to securely cut burr portions, and using chamfered molds to prevent resin sheet peeling, combined with a hinge design featuring a slit for improved bendability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a movable portion is used to cut the burr portion, then the burr portion can be removed, but the burr portion may not be reliably engaged and cut if its configuration is unsuitable
Solution Approach 1:
A suction part is introduced as an intermediary mechanism between the movable portion and the burr portion. The suction part engages the burr portion by applying negative pressure, ensuring reliable engagement and cutting regardless of the burr portion's configuration. This mediator resolves the issue of unreliable direct mechanical engagement.
2Manufacturing precision
If the outer frame is retracted from the forward position, then the resin sheet can be shaped along the mold, but excessive retraction causes the resin sheet to peel off from the mold surface
Solution Approach 1:
The position of the outer frame is precisely controlled within a specific range during retraction. By optimizing the retraction distance parameter, the resin sheet is allowed to detach sufficiently from the forward position to be shaped along the mold cavity, while maintaining enough adhesion to prevent peeling off from the mold surface. This parameter optimization resolves the contradiction between shaping precision and adhesion strength.
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
Ensures reliable burr portion cutting, reduces molding defects, and enhances hinge flexibility in resin panels.
Implementation Method 1
the burr portion is shaped along the engaging portion by suctioning the burr portion to the engaging portion via the suction part
Implementation Method 2
by reducing the pressure in this space, the resin sheet can be shaped along the mold
Data Source
AI summary
A method of manufacturing a structure in which a burr portion can be more reliably cut. In a burr portion shaping step, the burr portion is sucked to an engaging portion by a suction part to shape the burr portion along the engaging portion, and in a cutting step, ae movable portion is moved relative to first and second split molds with the burr portion being shaped along the engaging portion, thereby the burr portion is cut from a molded main body along a cutting line.