Steam Distribution Member for Foamed Molded Article Bonding
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Solution Overview
Problem
Conventional methods for producing skin-covered foamed molded articles face challenges with insufficient fusion bonding between expanded beads and the skin, often requiring a long molding cycle due to issues with steam supply through a steam pin, where the resin adheres to or is stretched by the pin, hindering steam distribution.
Innovation Solution
A method and apparatus that form a recessed portion in the hollow molded body to create a steam hole, allowing efficient steam supply using a steam supply pipe with a protruding portion and outer pipe structure, enabling good fusion bonding between expanded beads and the skin without a long molding cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam is supplied through a steam pin inserted into the hollow molded body, then fusion bonding between expanded beads and skin can be achieved, but the resin adheres to or is stretched by the steam pin, hindering steam supply and requiring a long molding cycle
Solution Approach 1:
A steam distribution member is introduced as an intermediary component between the steam pin and the hollow molded body. This member has a steam supply hole that communicates with the interior of the hollow molded body, allowing steam to be supplied efficiently without the resin adhering to or stretching the steam pin itself. The steam distribution member acts as a mediator that enables steam supply while preventing the harmful effects of resin interaction with the steam pin.
Solution Approach 2:
The steam supply system is segmented into distinct components: the steam pin, the steam distribution member with steam supply hole, and the hollow molded body. This segmentation allows each component to perform its specific function independently, preventing the resin from affecting the entire steam supply system while enabling efficient steam distribution to the expanded beads.
2Reliability
If steam supply time is extended to ensure adequate heating and fusion bonding, then bonding quality improves, but production efficiency decreases due to longer molding cycle
Solution Approach 1:
The steam distribution member serves as an intermediary that enhances steam supply efficiency, allowing adequate heating and fusion bonding to be achieved in a shorter time period. This mediator enables better steam distribution throughout the hollow molded body, improving heat transfer efficiency and reducing the time required for complete fusion bonding.
Solution Approach 2:
The invention changes the parameter of steam supply efficiency by introducing the steam distribution member with steam supply hole. This structural modification improves the heat transfer parameters, allowing the fusion bonding process to occur more rapidly while maintaining or enhancing bonding quality, thus resolving the contradiction between bonding strength and production efficiency.
3Device complexity
If a simple steam pin structure is used, then device complexity is low, but steam supply efficiency is insufficient leading to poor fusion bonding
Solution Approach 1:
The steam distribution member is introduced as a relatively simple intermediary component that significantly enhances steam supply efficiency. While it does add a component to the system, the structure itself is straightforward - essentially a member with a steam supply hole that communicates with the hollow molded body interior. This minimal structural addition provides substantial improvement in steam distribution efficiency.
Solution Approach 2:
The steam distribution member with steam supply hole enables the system to self-distribute steam effectively throughout the hollow molded body. The structure allows steam to automatically reach the expanded beads through the communication hole, improving steam supply efficiency without requiring complex control mechanisms or additional active components.
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 allows for efficient steam supply, improving fusion bonding between expanded beads and the skin, reducing the molding cycle time, and enabling the production of complex shapes with enhanced productivity and bonding strength.
Implementation Method 1
heating and fusion bonding the expanded beads by supplying steam via a steam supply pipe inserted into the hollow molded body
Implementation Method 2
blow-molding a parison in a mold cavity to form a hollow molded body
Implementation Method 3
a parison in softened state as formed by extruding a molten thermoplastic resin using an extruder
Data Source
AI summary
A method for producing a skin-covered foamed molded article including blow-molding a parison in a mold cavity to form a skin consisting of a hollow molded body, in which the parison is in a softened state by extruding a molten thermoplastic resin, filling expanded beads in the hollow molded body, and heating and fusion bonding the beads by supplying steam via a steam supply pipe inserted into the hollow molded body. The parison is in contact with a protruding portion, formed by protrusion from an inner surface of the mold cavity to an inside of the cavity, forming a recessed portion having a shape corresponding to the protruding portion in the inward direction of the hollow molded body. A steam hole is formed in the recessed portion, a steam supply pipe is inserted into the body, and the expanded beads are heated and fusion bonded by supplying steam.