Bonded Part Resin Injection Deformation Control
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Solution Overview
Problem
In injection molding, forming hollow parts with multiple components using bonding resin can lead to deformation due to injection pressure, and current methods to address this, such as freezing with nitrogen gas or water, increase manufacturing costs and complexity.
Innovation Solution
A bonded part and manufacturing method where three parts are integrated using bonding resin injected from a single gate, with communication paths formed on the parts to distribute pressure and reduce deformation, eliminating the need for additional facilities or processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If three parts are integrally molded by providing a coating layer on the surfaces through insert molding, then the parts can be bonded together, but the outer wall surface of the hollow shape part has to be thoroughly molded with bonding resin which causes deformation of the hollow shape part
Solution Approach 1:
The invention divides the bonding resin injection process into two stages: first injecting bonding resin into bonding portions (grooves) on the surface of the hollow shape part, then injecting through a through-hole to fill the remaining space. This segmentation allows the hollow shape part to be molded without thorough coating, reducing deformation while maintaining bonding strength.
Solution Approach 2:
The invention performs preliminary bonding by first injecting bonding resin into grooves on the surface of the hollow shape part before filling the remaining space through a through-hole. This preliminary action establishes strong bonding at critical interfaces before the full molding process, preventing deformation.
2Strength
If bonding resin is filled into only necessary bonding portions by providing gates at two or more places, then bonding can be achieved, but the structure of the mold becomes complicated so that cost of the mold will be increased
Solution Approach 1:
The invention segments the bonding resin filling process into two stages: first filling bonding portions through surface grooves, then filling remaining spaces through a single through-hole. This allows a single gate to serve multiple purposes, simplifying the mold structure while maintaining bonding strength.
Solution Approach 2:
The through-hole serves multiple functions: it acts as a gate for injecting bonding resin, provides a path for air evacuation, and enables filling of the remaining space after surface bonding. This multi-functionality eliminates the need for multiple gates, simplifying the mold structure.
3Ease of manufacture
If the hollow shape part is formed by combining a container and a cover through injection molding, then the parts can be manufactured separately, but additional post-processing is required to bond them together which increases manufacturing cost
Solution Approach 1:
The invention merges the bonding process with the injection molding process by injecting bonding resin through a through-hole in the mold while the parts are assembled inside the mold. This integration eliminates separate post-processing bonding steps, improving manufacturing efficiency while maintaining ease of manufacture.
Solution Approach 2:
The bonding resin injection is performed preliminarily while the container and cover are assembled inside the mold, before the molding process completes. This preliminary bonding action integrates bonding with manufacturing, eliminating post-processing steps and improving productivity.
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 method effectively reduces deformation of hollow parts caused by injection pressure and prevents cost increases by simplifying the manufacturing process, allowing for the formation of complex shapes without additional processing or facilities.
Implementation Method 1
a bonded part formed by bonding a first part (10) having a hollow portion, a second part (20), and a third part (30) with injected bonding resin
Data Source
AI summary
In order to provide a bonded part capable of reducing deformation caused by injection pressure of bonding resin and preventing an increase in cost, the bonded part includes a first part, a second part, and a third part, wherein the first part includes a wall portion and a hollow portion surrounded by the wall portion, wherein a first shape portion formed of bonding resin is arranged at a position between the second part and the wall portion, wherein a second shape portion formed of the bonding resin is arranged at a position between the wall portion and the third part, and wherein a third shape portion formed of the bonding resin which connects the first shape portion and the second shape portion is arranged on the wall portion.