Variable Volume Body for 3D Forming Film Molding
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Solution Overview
Problem
Conventional molding methods struggle with molding undercut portions, result in thermal corrugation, thickness deviation, distortion, and a whitening phenomenon due to elongation, and require additional cutting processes, limiting the quality and productivity of 3D-formed films.
Innovation Solution
A device with a mold and a press head unit featuring a variable volume body that adjusts its volume through gas introduction and discharge, allowing for uniform pressure molding of 3D shapes, including undercut portions, while reducing thickness deviation and preventing distortion and thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional molding methods are used, then the molding process is simple, but undercut portions cannot be molded and thermal corrugation occurs
Solution Approach 1:
The patent uses a variable volume body filled with gas (pneumatic system) to apply uniform pressure during molding. The gas pressure evenly distributes force across the forming film, preventing thermal corrugation and enabling precise molding of undercut portions without complex mechanical pressure systems
Solution Approach 2:
The variable volume body dynamically adjusts its volume to match the complex 3D geometry of the mold cavity. This dynamic adaptation allows uniform pressure distribution across irregular surfaces including undercut portions, resolving the contradiction between simple process and high molding quality
2Productivity
If hot press molding is used, then the forming film can be molded, but undercut portions cannot be molded and deformation or thickness deviation occurs
Solution Approach 1:
The pneumatic variable volume body provides uniform distributed pressure that conforms to the mold cavity shape, preventing localized over-pressure that causes thickness deviation and deformation while still enabling high productivity through efficient molding
3Shape
If ribbling molding is used, then the forming film can be elongated, but a whitening phenomenon occurs
Solution Approach 1:
The uniform gas pressure from the variable volume body elongates the forming film evenly without localized stress concentration, preventing the whitening phenomenon that occurs with ribbling molding while achieving the desired 3D shape
4Ease of operation
If conventional molding is used, then the process is straightforward, but spring back limits the molding range
Solution Approach 1:
The pneumatic system provides uniform sustained pressure that overcomes spring back effects, enabling molding of complex geometries including undercut portions while maintaining process simplicity through the straightforward operation of gas pressure control
Solution Approach 2:
The variable volume body dynamically conforms to different mold cavity shapes, providing adaptability for various molding ranges while the pneumatic system maintains process simplicity through universal pressure application
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
Enables precise molding of complex 3D shapes with reduced thickness deviation and distortion, eliminating the need for additional cutting processes and preventing whitening, thereby improving the quality and productivity of the forming film.
Implementation Method 1
a variable volume body which is coupled to the press head unit and has elasticity so that a volume thereof is variable due to gas introduction and discharge by the press head unit
Implementation Method 2
a variable volume body which is coupled to the press head unit and has elasticity so that a volume thereof is variable
Data Source
AI summary
A device for manufacturing a 3D forming film performs molding at a uniform pressure by using a variable volume body, and thus, enables undercut portion molding, prevents thermal corrugation on the curved portion, etc., of the forming film and the distortion of the forming film, reduces a thickness deviation of the forming film and excludes an additional cutting process after molding the forming film, thereby improving the quality of the 3D-molded forming film. The device for manufacturing the 3D forming film includes: a mold for molding a forming film; a press head unit which is positioned to correspond to the mold and has a variable spaced distance from the mold; and a variable volume body which is coupled to the press head unit and has elasticity so that a volume thereof is variable due to gas introduction and discharge by the press head unit.