Refrigerated Cabinet Tank Molding with Simultaneous Resin Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for molding tanks for refrigerated cabinets face issues such as excessive tolerances in thermoforming and rotational molding, poor adhesion between materials, separate equipment requirements, and lengthy enclosure preparation, as well as challenges in end-of-life disposal.
Innovation Solution
A method involving a mold coated with a high-density thermosetting resin, where both high-density and low-density thermosetting resins are injected and cured simultaneously to form a sandwich structure with perfect adhesion, eliminating the need for additional reinforcement and allowing for a single mold process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoforming or rotational molding is used to form the enclosure, then the manufacturing process is simplified, but the tolerances become excessive and adhesion between materials deteriorates
Solution Approach 1:
The invention merges the enclosure formation and filler injection steps into a single integrated molding process. The mold cavity itself forms the enclosure with precise tolerances, while the filler material is injected directly into the same mold, eliminating the need for separate thermoforming or rotational molding operations that produce excessive tolerances and poor adhesion.
Solution Approach 2:
The invention uses a composite structure consisting of an enclosure formed from mold material and a filler material injected into the enclosure. This composite approach allows each material to be optimized for its specific function while maintaining precise dimensional control and strong interfacial adhesion through the simultaneous curing process.
2Ease of manufacture
If separate equipment is used for forming the enclosure and filling it with foam, then each process can be optimized independently, but the overall preparation time increases significantly
Solution Approach 1:
The invention combines multiple manufacturing operations into a single integrated molding cycle. The mold cavity is prepared once, and both the enclosure formation and filler injection occur sequentially within the same equipment and time frame, eliminating the need for separate equipment and the associated transition and preparation times.
Solution Approach 2:
The mold cavity is pre-prepared with the enclosure geometry before the filler injection step. This preliminary formation of the enclosure within the mold allows the filler material to be injected directly into the predetermined space, eliminating the need for separate enclosure preparation operations.
3Strength
If the high-density resin is applied first and then the low-density resin is injected, then a sandwich structure is formed, but the adhesion between the two resins is poor
Solution Approach 1:
The invention controls the curing parameters of both resins to ensure they cure simultaneously or in a controlled sequence. By adjusting the cure time and temperature parameters, the high-density resin remains sufficiently reactive to bond with the low-density resin as it cures, creating strong interfacial adhesion while maintaining the desired sandwich structure and rigidity.
Solution Approach 2:
The invention uses a composite material system where the high-density and low-density resins are chemically compatible and designed to bond strongly to each other. The simultaneous or coordinated curing process ensures proper interfacial adhesion, creating a reliable composite structure with enhanced rigidity from the sandwich configuration.
4Ease of manufacture
If multiple separate steps are used for assembly (enclosure formation, drainage hole formation, pipe fitting), then each step can be controlled independently, but the overall assembly complexity increases
Solution Approach 1:
The invention merges multiple assembly operations into the single integrated molding process. The enclosure, drainage holes, and pipe fitting interfaces are all formed simultaneously during the molding cycle, eliminating the need for separate post-assembly steps and reducing overall assembly complexity while maintaining independent control over each feature through mold design.
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 results in a more rigid tank structure with improved adhesion and reduced assembly complexity, enabling a simpler and less expensive manufacturing process while facilitating easier disposal.
Implementation Method 1
A low-density thermosetting resin of a second polymer is injected into the mold. The resins are cured at least partially at the same time.
Data Source
Figure 1a~1c
Figure 2
Figure 3~4
AI summary
A method of molding a tank (1) for refrigerated cabinets comprises the steps of providing a mold (15) for manufacturing the tank (1); coating an inner face (15a) of the mold (15) with a layer of high-density thermosetting resin of a first polymer; closing the mold (15); injecting a low-density thermosetting resin of a second polymer into the mold (15); curing the high-density thermosetting resin to thereby define an enclosure (4); curing the low-density thermosetting resin to define a filler (4).