Two-color molded article convex joint interface
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Solution Overview
Problem
The appearance quality of two-color molded articles is compromised due to visible interfaces between primary and secondary molded articles, which can cause light reflection and lead to unsightly appearance issues, particularly in applications like vehicle headlamps.
Innovation Solution
A two-color molded article design featuring a first resin part with a bent portion and a second resin part with a convex joint portion that contacts the bent portion, reducing direct light reflection by scattering light and minimizing unfilled resin regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat interface is formed between the primary molded article and the secondary molded article, then the manufacturing process is simple, but the interface reflects external light directly to viewers, deteriorating appearance quality
Solution Approach 1:
The joint portion of the second resin part is formed with a convex curved surface (R = 1 to 3 mm) that contacts the bent portion of the first resin part. This curvature causes external light to scatter when it reaches the interface, preventing direct reflection to viewers and improving appearance quality while maintaining manufacturing simplicity through injection molding
2Object-affected harmful factors
If a convex joint portion with curved surface is formed to reduce light reflection, then appearance quality is improved, but the mold design becomes more complex
Solution Approach 1:
The convex joint portion is designed with a specific radius of curvature (R = 1 to 3 mm) that can be directly formed through injection molding processes. This curvature achieves light scattering to improve appearance while the radius range is selected to balance optical performance with manufacturability, avoiding excessive mold complexity
3Object-affected harmful factors
If the joint portion has a small radius of curvature, then light scattering is enhanced, but unfilled resin regions may occur in mold corners
Solution Approach 1:
The radius of curvature of the joint portion is optimized to a specific range (R = 1 to 3 mm). This parameter range is determined to provide sufficient light scattering effect while being large enough to allow complete resin filling during injection molding, preventing unfilled regions in mold corners
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 convex joint portion effectively reduces direct light reflection, enhancing the appearance quality of the two-color molded article by minimizing the visibility of light reflections and unfilled resin areas, thereby improving aesthetic appeal.
Implementation Method 1
the rate at which external light is directly reflected to a viewer when seeing the interface from one of the first resin part and the second resin part is reduced
Data Source
AI summary
A two-color molded article includes a first resin part, and a second resin part in contact with the first resin part so as to at least partially overlap the first resin part. The second resin part includes a single layer region provided between a first region and a second region and provided in a penetrating portion formed between a first portion and a second portion. The single layer region has a joint portion in contact with a bent portion. The joint portion is formed in a convex shape with respect to the bent portion.