Vacuum Mold Suction Hole Layout for Concave Surface Forming
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Solution Overview
Problem
The shaping property of resin sheets in vacuum molding is unsatisfactory due to the presence of reduced pressure suction holes in concave portions of the mold, leading to poor appearance of the molded body.
Innovation Solution
A mold with a concave portion reduced pressure suction hole index of 0.5 or lower is used, where reduced pressure suction holes in the concave portions are blocked, and the concave portions are regularly dispersed with controlled area ratios and depths, improving the shaping property and appearance of the molded body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reduced pressure suction holes are provided in concave portions of the mold, then the suction efficiency is improved, but the shaping property at the concave portions deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the treatment of reduced pressure suction holes based on their location. Holes in concave portions are blocked while holes in flat portions remain open, creating locally different properties to optimize both suction efficiency and shaping quality in different regions of the mold
Solution Approach 2:
The mold surface is segmented into concave portions and flat portions, with different suction hole configurations applied to each segment. This segmentation allows the patent to address the conflicting requirements of suction efficiency and shaping property in different areas independently
2Adaptability or versatility
If concave portions are formed on the mold to create convex portions on the resin sheet, then the design ability and functionality are improved, but the appearance of the molded body deteriorates due to poor shaping
Solution Approach 1:
The patent maintains concave portions for design functionality while locally modifying the suction hole distribution in and around these concave portions. This local modification ensures proper shaping and appearance quality without compromising the overall design ability provided by the concave portions
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 effectively improves the shaping property and appearance of the molded body by regulating the concave portion reduced pressure suction hole index, ensuring that reduced pressure suction holes do not interfere with the shaping process in concave areas, resulting in a superior finish.
Implementation Method 1
a mold which can be used in vacuum molding... capable of subjecting a resin sheet to reduced pressure suction via a plurality of reduced pressure suction holes thereby shaping the resin sheet to follow a shape of an inner surface of the cavity
Data Source
AI summary
A mold which can improve an appearance of a molded body is provided. A mold includes a cavity, the mold being capable of subjecting a resin sheet under reduced pressure suction via a plurality of reduced pressure suction holes thereby shaping the resin sheet to follow a shape of an inner surface of the cavity; wherein: the inner surface includes a base surface and a plurality of island-like concave portions provided in the base surface; and a concave portion reduced pressure suction hole index defined by an in-concave reduced pressure suction hole ratio divided by a concave portion area ratio is 0.5 or lower.