Injection Molded Substrate Dentil Profile Corner Cooling
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Solution Overview
Problem
Injection molded polymer substrates with thick sections, particularly at corners, face cooling defects and increased production cycle times due to uncontrolled cooling, and maintaining the location of grooves for soft wrap seams is challenging.
Innovation Solution
The implementation of a dentil profile edge or wall with alternating cavities and blocks along the edges of injection molded polymer substrates reduces the effective thickness of corners, preventing cooling defects and allowing for controlled cooling without extending production cycle times, while enabling secure attachment of a soft wrap cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the corner section is made thick to provide structural support, then the structural strength is improved, but the cooling time increases and production cycle time increases
Solution Approach 1:
The corner section is segmented into multiple regions with varying thicknesses through the dentil profile, creating alternating thick and thin sections along the edge. This segmentation allows different portions to serve different functions: thick portions provide structural support while thin portions enable faster cooling, resolving the contradiction between strength and cooling time.
Solution Approach 2:
The dentil profile creates local variations in thickness along the corner edge, with some areas having greater thickness for structural support and other areas having reduced thickness for accelerated cooling. This local differentiation of properties allows the single component to simultaneously achieve both structural integrity and efficient cooling without increasing overall production cycle time.
2Strength
If the corner section is made thick to provide structural support, then the structural strength is improved, but cooling defects occur
Solution Approach 1:
The corner is divided into alternating thick and thin sections through the dentil profile, preventing the formation of large continuous thick sections that are prone to cooling defects. The segmented structure ensures uniform heat distribution and eliminates the conditions that lead to sink marks and voids while maintaining adequate structural support.
Solution Approach 2:
By creating local thickness variations along the corner edge, the dentil profile ensures that no single area becomes excessively thick and prone to cooling defects. The alternating pattern of thick and thin sections distributes thermal stress uniformly and prevents the formation of defects while providing localized structural reinforcement where needed.
3Loss of time
If the groove location is changed to accommodate corner thickness reduction, then the production cycle time is reduced, but the soft wrap seam attachment is compromised
Solution Approach 1:
The dentil profile is designed in advance with the groove positioned at the optimal location along the corner edge, accounting for both the thickness reduction requirements and the soft wrap seam attachment needs. This preliminary positioning ensures that the groove remains at a location that facilitates rapid cooling while simultaneously providing a secure attachment point for the soft wrap seam, eliminating the need for design changes.
Solution Approach 2:
The groove in the dentil profile serves multiple functions: it facilitates the rapid cooling of the corner section by creating a thin section for heat dissipation, and simultaneously provides a secure attachment location for the soft wrap seam. This multi-functionality resolves the contradiction between production efficiency and attachment reliability without requiring separate features.
Data Source
AI summary
A molded component having a thickness reduction feature is provided. The molded component can include an injection molded polymer substrate having a front panel, a side panel, and a corner between and adjoining the front panel and the side panel. The substrate can also have a groove extending along the corner between the front panel and the side panel, the groove having a front panel edge and a side panel edge. The front panel edge and/or side panel edge have a dentil profile edge, the dentil profile edge reducing an effective thickness of the corner and thus providing increased or controlled cooling of the substrate.