Assembling Die for Smooth Cable Accessories
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Solution Overview
Problem
Existing rubber-type products molded from steel dies often have mold lines that affect appearance, functionality, and electrical performance, especially when exposed outdoors, as they attract pollution, undergo ultraviolet aging, and represent mechanical weak spots, and the polishing process can be flawed and non-uniform.
Innovation Solution
The assembling die design includes a cylindrical shield tube mold with a core rod assembly and an elastic mold sleeve, allowing for injection molding without mold lines, ensuring a smooth surface and eliminating the need for polishing, thereby enhancing product quality and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional steel dies are used for injection molding, then production efficiency is maintained, but mold lines are created on the product surface affecting appearance and quality
Solution Approach 1:
The mold is divided into multiple components including a fixed die, movable die, and removable core. The core can be extracted from the mold cavity after injection, allowing the product to be removed without traditional mold lines. This segmentation enables the core to be separated from the final product structure.
Solution Approach 2:
The core is designed as a removable component that is taken out of the mold cavity after injection molding. This extraction eliminates the need for the core to remain as part of the final mold structure, thereby preventing permanent mold lines on the product surface while maintaining production efficiency.
2Manufacturing precision
If polishing process is applied to remove mold lines, then appearance is improved, but product structure and performance are affected
Solution Approach 1:
The mold design incorporates a removable core that prevents mold line formation during the injection molding process itself. By addressing the surface quality issue at the molding stage rather than requiring post-processing, the product structure and performance are preserved without compromise.
3Manufacturing precision
If removable core is added to eliminate mold lines, then surface quality is improved, but mold complexity increases
Solution Approach 1:
The mold is divided into multiple components including a fixed die, movable die, and removable core. The core can be extracted from the mold cavity after injection, allowing the product to be removed without traditional mold lines. This segmentation enables the core to be separated from the final product structure.
Solution Approach 2:
The removable core serves multiple functions: it acts as a molding surface during injection, provides a release mechanism for the product, and eliminates the need for traditional mold line formation. This multi-functionality justifies the added complexity by delivering significant quality improvements.
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 results in products with no mold lines, improving appearance and functionality, reducing mechanical weaknesses, and ensuring consistent quality without additional polishing costs, thus enhancing the reliability and performance of cable accessories and high-voltage insulation products.
Implementation Method 1
injection molded from steel dies
Data Source
Figure 1
Figure 2
AI summary
An assembling die to produce a cable with entirely smooth molded accessories includes a shield tube mold and an elastic mold sleeve disposed in the shield tube mold. The shield tube mold includes an outer die and a core rod assembly. A first die cavity is defined in the outer die. The elastic mold sleeve is sleeved outside the core rod assembly and is received in the first die cavity. The core rod assembly passes through the outer die, and a space between the elastic mold sleeve and the core rod assembly forms a second die cavity.