Resin Sheet Slits for Deep Drawing Inflow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The resin sheet continuous pressing method faces limitations in the inflow property of resin material, leading to restricted maximum height and depth of molded products, and difficulty in achieving uniform thickness and deep drawing features.
Innovation Solution
The method involves forming slits on the strip-shape softened resin sheet before cutting it into units, which enhances the inflow property of the resin during press-molding, allowing for deeper and more complex shapes to be molded with consistent thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin sheet is heated to suitable temperature for press-molding, then the inflow property of resin material is improved, but the sheet shape cannot be maintained and molding precision deteriorates
Solution Approach 1:
The resin sheet is preliminarily heated before press-molding to improve inflow property, allowing the resin to flow properly into mold cavities while maintaining sheet integrity during the heating stage. This preliminary heating action enables subsequent deep drawing and complex shape formation without compromising initial sheet stability.
2Shape
If the maximum height and depth of molded products are increased, then more complex shapes can be achieved, but the thickness becomes non-uniform and molding precision deteriorates
Solution Approach 1:
Different regions of the resin sheet are subjected to different heating conditions and press-molding pressures. Areas requiring deep drawing receive targeted heating and pressure application, while other regions maintain appropriate thickness. This local quality approach enables complex shapes with vertical walls and embossment features while preserving overall thickness uniformity.
3Reliability
If the press-molding temperature is increased to improve inflow property, then deeper drawing is possible, but energy consumption increases
Solution Approach 1:
Instead of heating the entire resin sheet to high temperatures uniformly, the system applies partial heating only to specific areas and to the extent necessary for achieving the desired inflow property. This partial action approach enables deep drawing operations while minimizing overall energy consumption by avoiding excessive heating of the entire sheet.
Data Source
AI summary
A strip-shape softened resin sheet (S) which is continuously extruded from a molten resin extruder is cut to a unit resin sheet and a press molded product is manufactured by press-molding the unit resin sheet in a press-molding machine. Prior to cutting the continuously extruded strip-shape softened resin sheet (S) to the unit resin sheet (U) , the slits C1, C2, C3, C4 and C5 which promote the molding to the press molded part from the unit resin sheet (U) (improve an inflow property of the material) are formed by a cutter which is upwardly and downwardly driven by an air cylinder at a portion P3 in which the material therein is out of a range of the press molded products P1 and P2 obtained by press-molding the press molded product by using the press molding machine and becomes a scrap. The inflow property of the resin material for vertical walls and embossment portions when press-molding is improved and the defects of the product can be prevented.