Vehicle Card Key Mold Alignment via Angular Pins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of vehicle card keys faces high defect rates due to precision requirements for mold alignment and the risk of misalignment causing lifting phenomena during the molding process, especially when forming mechanical keyholes and battery holes.
Innovation Solution
An apparatus with an upper and lower mold, keyhole and battery hole slides, and angular pins is used to ensure precise alignment and prevent lifting by incorporating guide grooves and stoppers to maintain slide position, allowing for the injection of molding material to form the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mechanical keyhole slide or battery hole slide is engaged with the latch during molding, then the case is formed with proper structure, but the bonding surface of the latch or slide is often broken and misalignment occurs causing lifting phenomenon
Solution Approach 1:
The patent applies preliminary action by pre-positioning the latch and slide components on the mold before injection molding. The latch is fixed on the lower mold and the slide is positioned on the upper mold, ensuring they are correctly aligned before the molding process begins. This prevents misalignment and bonding surface breakage during the actual molding operation.
Solution Approach 2:
The patent introduces an intermediary mechanism through the use of a positioning pin or guide structure that mediates between the latch and slide. This intermediary element ensures proper engagement and alignment during molding, preventing direct contact that would cause bonding surface breakage while maintaining the necessary structural integrity.
2Manufacturing precision
If high precision mold is used to ensure proper engagement of slide with latch, then the case structure is formed accurately, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies segmentation by dividing the mold into separate upper and lower molds with distinct functions. The lower mold contains the latch structure while the upper mold contains the slide structure. This segmentation allows each mold to be designed and manufactured independently with standard precision, avoiding the need for a single complex high-precision mold while achieving the required engagement accuracy.
Solution Approach 2:
The patent uses an intermediary positioning mechanism that simplifies the mold structure. Instead of requiring complex precision molding, a simple positioning pin or guide structure serves as an intermediary to ensure accurate alignment between the latch and slide, reducing overall mold complexity while maintaining engagement precision.
3Ease of manufacture
If the slide is allowed to slide freely during molding, then the molding process is simple, but excessive sliding and misalignment occur causing lifting phenomenon
Solution Approach 1:
The patent introduces an intermediary guide structure or positioning element that mediates the sliding motion of the slide component. This intermediary mechanism allows the slide to move freely enough for easy molding while simultaneously constraining it to prevent excessive sliding and misalignment, thus maintaining both process simplicity and position accuracy.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the slide on the upper mold before the molding process. The slide is fixed in its correct position using preliminary clamping or positioning mechanisms, ensuring it remains stationary during molding. This eliminates the need for complex in-process alignment while preventing misalignment and lifting phenomena.
Data Source
AI summary
An apparatus for manufacturing a vehicle card key includes: an upper mold which is disposed on a printed circuit board (PCB) substrate of a vehicle card key; a lower mold which is fixed to a lower portion of the PCB substrate; a keyhole slide which is disposed between one end of the upper mold and the lower mold and forms a keyhole; a battery hole slide which is disposed between the other end of the upper mold and the lower mold and forms a battery hole; a first angular pin which passes through the one end of the upper mold and one end of the keyhole slide and the lower mold; and a second angular pin which passes through the other end of the upper mold and the other end of the battery hole slide and the lower mold.