Variable-Thickness Transparent Resin for Deep-Look Molded Components
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Solution Overview
Problem
Existing resin molded components face issues such as increased cooling time, material usage, and sink marks due to constant thickness of secondary mold resin, which affects the visual sense of depth and quality of the molded product.
Innovation Solution
A molded component with a two-layer structure comprising a light-shielding resin member and an optically transparent resin member, where the transparent resin member has a constant peripheral thickness and a thinner interior portion, allowing for a visual sense of depth while reducing molding failures by using a primary and secondary molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the thickness of the transparent resin member is made constant to provide a visual sense of depth, then the aesthetic appearance is improved, but the cooling time during molding increases and sink marks occur
Solution Approach 1:
The transparent resin member is designed with different thickness regions: a peripheral portion with constant thickness to provide the visual sense of depth and aesthetic appearance, and an inner portion with reduced thickness to minimize cooling time and prevent sink marks. This local differentiation of thickness resolves the contradiction between aesthetic requirements and manufacturing efficiency.
2Shape
If the thickness of the transparent resin member is made constant to provide a visual sense of depth, then the aesthetic appearance is improved, but the amount of material used increases
Solution Approach 1:
The transparent resin member is designed with different thickness regions: a peripheral portion with constant thickness to provide the visual sense of depth and aesthetic appearance, and an inner portion with reduced thickness to minimize material usage. This local differentiation of thickness resolves the contradiction between aesthetic requirements and material efficiency.
3Shape
If the thickness of the transparent resin member is made constant to provide a visual sense of depth, then the aesthetic appearance is improved, but the incidence of sink marks increases
Solution Approach 1:
The transparent resin member is designed with different thickness regions: a peripheral portion with constant thickness to provide the visual sense of depth and aesthetic appearance, and an inner portion with reduced thickness to minimize material accumulation and prevent sink marks during molding. This local differentiation of thickness resolves the contradiction between aesthetic requirements and manufacturing quality.
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
The solution achieves a visual sense of depth while minimizing cooling time, material usage, and sink marks, enhancing the quality and appearance of the molded component by allowing for greater design freedom and reduced visibility of manufacturing defects.
Implementation Method 1
a molded component that displays an optical image that is visible from a front by allowing light that is emitted from a light source that is disposed at a back to pass therethrough
Data Source
AI summary
A molded component displays an optical image that is visible from a front by allowing light that is emitted from a light source that is disposed at a back to pass therethrough. The molded component includes a light-shielding resin member that has an optical transmission hole that has a shape depending on the optical image in a plan view, and a transparent resin member that is optically transparent and that is stacked on a surface of the light-shielding resin member that faces the front such that the transparent resin member covers at least the optical transmission hole. The transparent resin member includes a peripheral portion that has a constant thickness, and a thin portion that is disposed inside the peripheral portion and that is thinner than the peripheral portion.