Structural Body Panel Molding With Suction-Assisted Burr Cutting
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Solution Overview
Problem
Existing methods face challenges in reliably cutting burr portions, shaping resin sheets without defects, and manufacturing thin hinges with high yield, particularly due to engagement issues with movable portions and pinch-off portions, and difficulties in conforming to mold surfaces.
Innovation Solution
A method involving split molds with movable portions and pinch-off portions that include suction parts and engaging portions to securely shape and cut burr portions, along with the use of chamfered molds to prevent resin sheet peeling, and a panel design with integrated hinges and slits 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 from the molded body, but the movable portion may not reliably engage the burr portion, causing cutting failures
Solution Approach 1:
The patent uses a suction part with negative pressure to engage the burr portion. The suction part creates a vacuum that reliably holds the burr portion during the cutting process, eliminating engagement failures that occur with mechanical contact alone.
Solution Approach 2:
The suction part acts as an intermediary between the movable portion and the burr portion. Instead of direct mechanical engagement, the suction part mediates the connection through atmospheric pressure differential, providing reliable engagement.
2Manufacturing precision
If the movable portion is butted against the pinch-off portion at the mold edge, then the cutting line is defined, but the cutting line may become distorted making it difficult to cut the burr portion
Solution Approach 1:
The mold is divided into a fixed portion and a movable portion, with the suction part positioned on the movable portion. This segmentation allows the suction part to engage the burr portion independently of the pinch-off portion's position, preventing cutting line distortion.
Solution Approach 2:
The suction part uses negative pressure to hold the burr portion, allowing the movable portion to move smoothly without being constrained by the pinch-off portion's exact position, thereby preventing cutting line distortion.
3Shape
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 patent controls the retraction amount of the outer frame as a critical parameter. By optimizing the retraction distance, the resin sheet is sufficiently shaped along the mold while maintaining adhesion to the mold surface, preventing peeling defects.
Solution Approach 2:
The molding process uses feedback control to adjust the outer frame retraction based on the resin sheet's shaping progress, ensuring the resin sheet remains adhered to the mold surface while achieving the desired shape.
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
Enhances the reliability of burr portion cutting, reduces molding defects, and improves hinge flexibility, ensuring secure engagement and smooth shaping of resin sheets without distortion or peeling, while allowing for thinner hinge structures.
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 is provided 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.