20240033981. RESIN MOLDED MEMBER AND MANUFACTURING METHOD THEREOF simplified abstract (KYB Corporation)
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RESIN MOLDED MEMBER AND MANUFACTURING METHOD THEREOF
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RESIN MOLDED MEMBER AND MANUFACTURING METHOD THEREOF - A simplified explanation of the abstract
This abstract first appeared for US patent application 20240033981 titled 'RESIN MOLDED MEMBER AND MANUFACTURING METHOD THEREOF
Simplified Explanation
The patent application describes a manufacturing method for a resin molded member. The method involves three steps:
1. Insert member molding step: This step involves building an insert member by stacking layers of a base resin that contains continuous fibers. A 3D printer is used to create the insert member.
2. Aligning step: The insert member is then aligned in a cavity of an injection molding mold.
3. Resin portion molding step: In this step, a resin portion is molded and integrated with the insert member by filling an injection molding resin into the cavity. The insert member is arranged on the surface of a weld portion during this step. The continuous fibers in the insert member are oriented in a direction that crosses over the weld portion, which is formed in the resin portion.
- The innovation of this patent lies in the use of a 3D printer to create the insert member, which is then integrated with a resin portion through injection molding. This allows for the formation of a resin molded member with continuous fibers oriented in a specific direction.
Potential applications of this technology:
- Automotive industry: The resin molded member with aligned continuous fibers can be used in various automotive components, such as structural parts, interior trim, or engine components. The improved strength and durability provided by the continuous fibers can enhance the performance and safety of these parts.
- Aerospace industry: The lightweight and strong resin molded member can find applications in the aerospace industry, such as in aircraft interiors, structural components, or engine parts. The ability to align the continuous fibers in specific directions can optimize the strength-to-weight ratio of these parts.
Problems solved by this technology:
- Enhanced strength and durability: By integrating continuous fibers into the resin molded member, the overall strength and durability of the component are improved. This can help prevent failures or damage under various operating conditions.
- Design flexibility: The use of a 3D printer allows for the creation of complex shapes and geometries for the insert member. This provides design flexibility and opens up possibilities for innovative product designs.
Benefits of this technology:
- Lightweight: The use of resin materials and continuous fibers allows for the creation of lightweight components. This can contribute to weight reduction in various industries, leading to improved fuel efficiency and cost savings.
- Improved performance: The aligned continuous fibers provide enhanced strength and stiffness to the resin molded member. This can result in improved performance characteristics, such as increased load-bearing capacity, reduced deformation, or improved resistance to impact or vibration.
- Cost-effective production: The combination of 3D printing and injection molding techniques can streamline the production process and reduce manufacturing costs. The ability to create complex shapes and integrate the insert member with the resin portion in a single step can lead to efficient and cost-effective production.
Original Abstract Submitted
a manufacturing method of a resin molded member includes: an insert member molding step of building an insert member by stacking layers of a base resin containing continuous fibers by using a 3d printer; an aligning step of aligning the insert member in a cavity of an injection molding mold; and a resin portion molding step of molding a resin portion integrated with the insert member by filling an injection molding resin into the cavity, wherein the insert member is arranged on a surface of a weld portion by the resin portion molding step, and the continuous fibers in the insert member are oriented in direction crossing over the weld portion, the weld portion being formed in the resin portion.
