Segmented Mold Sections for Thermoplastic Resin Molding
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Solution Overview
Problem
High-load press machines are expensive and lead to increased equipment costs, making it challenging to suppress insufficiently pressed areas in thermoplastic resin products during molding, especially when using low-load press machines.
Innovation Solution
Divide the molds into sections, allowing one section to protrude and press the thermoplastic resin material at different times to ensure even pressing, reducing the load required for molding, particularly in multi-layer products like battery frames or carbon fiber reinforced resin materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high-load press machine is used to suppress insufficiently pressed places, then the molding quality is improved, but the equipment cost increases
Solution Approach 1:
The mold is divided into multiple sections (first mold section and second mold section) that can be independently controlled. This segmentation allows each section to be pressed at different times and with different loads, enabling high molding quality in critical areas while using lower overall equipment load, thus reducing equipment costs.
Solution Approach 2:
The pressing process is performed in multiple stages: first pressing the first mold section, then pressing the second mold section after the first section is retracted. This preliminary action ensures that critical areas receive adequate pressing force while distributing the total load over time, allowing use of lower-load equipment.
2Ease of manufacture
If press molding is carried out by a low-load press machine, then the equipment cost is reduced, but insufficiently pressed places occur in the product
Solution Approach 1:
By dividing the mold into multiple independently controllable sections, the pressing operation can be distributed across different time stages. This allows a low-load press machine to achieve adequate pressing in each section sequentially, preventing insufficiently pressed places while using cost-effective equipment.
Solution Approach 2:
The pressing is performed periodically in two distinct stages: first pressing the first mold section, then retracting and pressing the second mold section. This periodic action allows the low-load machine to deliver sufficient pressing force to each section at different times, ensuring overall molding quality without requiring high peak loads.
3Force
If the mold is divided into sections and pressed at different times, then the load required for molding is reduced, but the molding process time increases
Solution Approach 1:
The mold is segmented into multiple sections that are pressed sequentially rather than simultaneously. This segmentation reduces the peak load required at any given moment, allowing the use of lower-load equipment while managing the extended process time through efficient sequential operations.
Solution Approach 2:
The first mold section is pressed and secured before the second section is pressed. This preliminary action allows each pressing operation to be optimized for lower load, and the retraction/repositioning time is minimized through efficient mold design, balancing reduced load requirements with acceptable process time.
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 method effectively suppresses the formation of insufficiently pressed areas in products even when using low-load press machines, reducing equipment costs and maintaining product quality.
Implementation Method 1
a heating step in which the thermoplastic resin material is heated
Implementation Method 2
press molding a thermoplastic resin material
Data Source
AI summary
A method of molding a thermoplastic resin material includes: a first molding step in which a second mold that, with a first mold, nips and presses the thermoplastic resin material and molds a product, is divided into plural sections, and one section at the divided second mold is structured so as to be able to enter into and exit from another section, and the one section is made to protrude-out with respect to the another section, and, at the one section, the thermoplastic resin material is pressed, and a portion of the product is molded; and a second molding step in which, after the first molding step, the one section is retracted into the another section, and, at the another section, the thermoplastic resin material is pressed, and a remaining portion of the product is molded.