Resin Panel Foam Reinforcement Positioning
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Solution Overview
Problem
Existing resin hollow molded articles face challenges in precise positioning of reinforcing materials, rattling movement, and distortion due to molding shrinkage, particularly when multiple intermediate members are involved in the manufacturing process.
Innovation Solution
A resin panel with a hollow double-wall structure featuring a thermoplastic resin foam molded to match the internal shape, welded to the inner walls, and containing accommodation parts for reinforcing materials, which are arranged between molds to maintain precise positioning and prevent rattling and shrinkage-related distortions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple intermediate members (foam and reinforcing material) are inner packaged in a resin hollow molded article, then the reinforcing function is improved, but the positioning precision is lowered and rattling movement is caused
Solution Approach 1:
The foam is molded in advance before the blow molding process, allowing the reinforcing material to be positioned and fixed on the foam surface beforehand. This preliminary preparation ensures precise positioning of the reinforcing material while maintaining the strength benefits of having both foam and reinforcing material in the final product.
2Stability of the object's composition
If a metal reinforcing material is used which does not generate shrinkage, then the dimensional stability is improved, but the distortion due to molding shrinkage of resin hollow molded article is enlarged
Solution Approach 1:
The foam acts as an intermediary between the metal reinforcing material and the resin hollow molded article. During blow molding, the foam deforms along with the resin, absorbing the shrinkage and distortion, while the metal reinforcing material remains dimensionally stable. This mediator approach allows the metal reinforcing material to maintain its dimensional stability without causing or experiencing excessive distortion.
3Strength
If intermediate members are inserted during blow molding, then the reinforcing function is improved, but the configuration and positioning between molds becomes difficult
Solution Approach 1:
The foam is molded in advance as a separate component before the blow molding process. This allows the reinforcing material to be positioned on the foam surface in a simplified manner, and the entire assembly is then introduced into the mold as a pre-prepared unit, reducing the complexity of configuring and positioning multiple intermediate members during the blow molding process itself.
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 solution enables precise positioning of reinforcing materials, prevents rattling, and minimizes distortion by using a thermoplastic resin foam that is molded in advance to match the internal shape of the resin panel, facilitating easier molding and maintaining the reinforcing materials within the foam.
Implementation Method 1
the foam is welded on the inner wall faces of the front and back walls of the resin panel
Data Source
AI summary
Provided is a resin panel produced such that the positioning of a reinforcing material can be precisely done, rattling movement is prevented and distortion by molding shrinkage is not caused because the reinforcing materials are maintained in the foam.A resin panel is a hollow double-wall structure including a front wall, a back wall and a peripheral wall joining the front wall and back wall together. The peripheral wall of the resin panel has a welded part on its entire periphery. Within a hollow part is inner packed a foam made of a thermoplastic resin that is formed in advance in the substantially the same shape as the shape of the space within the hollow part. The foam is welded on the inner wall faces of the front wall and back wall of the resin panel. In the foam are formed accommodation parts for accommodating reinforcing materials. The reinforcing materials are lengthwise. The foam intervenes between the ends of both of the reinforcing materials and the peripheral wall.