Bypass Channel Formation in Injection Devices via Plastic Deformation
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Solution Overview
Problem
Existing methods for producing injection devices with bypass channels are costly and time-consuming due to the need for complex tools, additional equipment, and potential particle formation, leading to increased production costs and cycle times.
Innovation Solution
A method involving a preform placed in a tool where a cylindrical section is heated and a stamp is used to form the bypass channel through plastic deformation, eliminating the need for additional tools and reducing particle formation by forming the channel post-injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a die is used to form the bypass channel by pressing the preform, then the bypass channel is formed, but the production costs and cycle time increase due to additional tools and pressure application
Solution Approach 1:
The patent combines the bypass channel formation process with the existing injection molding process by using the injection molding machine's own components (injection unit and mold) to perform both operations. The preform is injection-molded and then immediately processed in the same machine without transferring to additional equipment, thereby eliminating the productivity loss from using separate tools and processes.
Solution Approach 2:
The injection molding machine is made multi-functional by enabling it to perform both injection molding and bypass channel formation. The mold includes a heating element and a pressing element that allow the same machine to first inject the preform and then form the bypass channel, eliminating the need for dedicated equipment for each operation.
2Ease of manufacture
If a die with pressure application is used to form the bypass channel, then the channel is created, but production costs increase due to additional tools
Solution Approach 1:
The patent merges the bypass channel formation function into the existing injection molding tool. The mold includes a pressing element and heating element integrated into the injection molding machine, eliminating the need for separate dies and pressure application equipment. This reduces tooling complexity while maintaining the ability to form the bypass channel.
Solution Approach 2:
The injection molding machine is designed to perform multiple functions: injection molding the preform and subsequently forming the bypass channel using integrated heating and pressing elements in the mold. This multi-functionality eliminates the need for additional specialized tools, reducing both device complexity and production costs.
3Ease of manufacture
If a folding core is used to form the bypass channel, then the channel is created, but particle formation and contamination occur during injection molding
Solution Approach 1:
The patent performs the bypass channel formation after the injection molding process is complete, rather than during injection molding. The preform is first injection-molded without any folding cores or complex tools, then heated and pressed to form the bypass channel. This preliminary separation of operations eliminates particle formation during the critical injection molding phase.
4Ease of manufacture
If inserts are used to form the bypass channel during injection molding, then the channel is created, but production cycles lengthen and costs increase due to the need for a second mold
Solution Approach 1:
The patent combines the bypass channel formation with the injection molding process by using the same injection molding machine and mold for both operations. The preform is injection-molded and then immediately processed in the same machine without requiring a second mold or separate equipment, thereby maintaining short production cycles while eliminating the need for insert handling.
Solution Approach 2:
The injection molding machine is made multi-functional, performing both injection molding and bypass channel formation in sequence using the same equipment. This eliminates the need for a second mold and insert handling operations, maintaining high productivity while achieving bypass channel formation.
5Ease of manufacture
If two-component injection molding is used to create the bypass channel, then the channel is formed, but tooling costs increase and tool utilization decreases due to complex tooling
Solution Approach 1:
The patent combines the bypass channel formation with the injection molding process by using the same injection molding machine and mold for both operations. The preform is injection-molded and then immediately processed in the same machine without requiring a second mold or separate equipment, thereby maintaining short production cycles while eliminating the need for insert handling.
Solution Approach 2:
The injection molding machine is made multi-functional, performing both injection molding and bypass channel formation in sequence using the same equipment. This eliminates the need for a second mold and insert handling operations, maintaining high productivity while achieving bypass channel formation.
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
This approach simplifies and cost-effectively forms bypass channels in injection devices, saving resources and preventing contamination, while reducing production costs and cycle times.
Implementation Method 1
The section of the cylindrical part is heated by a heat source. The heat source raises the material of this section to a temperature sufficient to allow the preform to be plastically deformed radially by the pressure of the die.
Implementation Method 2
The punch is then pressed into the heated portion of the cylindrical section, thereby forming the bypass channel through plastic deformation of the heated portion.
Data Source
Figure 1~4
AI summary
A tool (20) and a method for producing a bypass (2) in an injection device are disclosed. The preforms (5) of the injection device are placed in a tool (20). A partial region (9) of the cylindrical section (8) is heated with a heat source (24). The heated partial region (9) of the cylindrical section (8) is plastically deformed with a punch (21) of the tool (20) so that the bypass channel (2) is formed.