Clamping Ring Molding with Top Injection and In-Melt Cutting
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Solution Overview
Problem
Current methods for manufacturing clamping rings, such as extrusion and injection molding, face inefficiencies due to the need for secondary processing, poor weld line quality, and difficulty in exhausting gas, leading to low production efficiency and quality issues.
Innovation Solution
A method and device that extrude plastic materials with memory properties, mold them in a plastic melt state, and use a molding die set to form a clamping ring within a molding cavity, optimizing production steps by cutting and shaping the ring in a single process, including core removal and die extrusion to create a limit end and annular stop edge, while synchronizing cooling and molding for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to manufacture clamping ring, then the clamping ring can be formed in one step, but weld lines are formed with poor quality and gas is difficult to exhaust
Solution Approach 1:
Instead of injecting from the conventional side walls, the patent injects plastic material from the central injection port on the top surface of the mold cavity. This inverted injection direction allows the material to flow downward along the pipe member, forming the clamping ring without creating problematic weld lines at 0-degree convergence points, thus resolving the weld line quality issue while maintaining one-step production
2Strength
If injection molding is performed from central injection port on top, then weld line strength is guaranteed, but secondary processing is required to punch and cut out top materials
Solution Approach 1:
The mold cavity is designed with a pre-formed top surface structure that matches the final product requirements. The injection molding process directly forms the clamping ring with the correct top surface geometry, eliminating the need for subsequent punching and cutting operations. This preliminary design action integrates what would have been secondary processing into the primary molding step
3Device complexity
If extrusion process is used to manufacture clamping ring, then the process is simple, but secondary thermal forming is required after cutting and cooling
Solution Approach 1:
The patent combines the extrusion process with the molding process into a single integrated operation. The extruded pipe member is immediately molded within the mold cavity while still in a plastic state, forming the clamping ring with its final shape including the top surface. This merging of extrusion and molding eliminates the separate thermal forming step that would otherwise be required after cooling
4Manufacturing precision
If annular stop edge is formed through thermal forming after extrusion, then positioning is ensured, but two-step processing is required
Solution Approach 1:
The mold cavity includes a molding die set with extrusion molds that are pre-configured to form the annular stop edge and other features directly during the molding process. This preliminary formation of positioning features within the mold eliminates the need for subsequent thermal forming operations, achieving both positioning accuracy and production efficiency
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 enhances production efficiency and quality by allowing for high-speed molding and processing of clamping rings with precise shaping and sealing, reducing the need for secondary processing and improving the strength and positioning of the clamping ring.
Implementation Method 1
an extruding step of extruding plastic materials having memory properties from an extruder
Implementation Method 2
a molding step of acting on plastic materials in a plastic melt state via a molding die set, thus to form a clamping ring from a pipe member
Implementation Method 3
a demolding step of taking out the clamping ring from the molding cavity to realize cutting-stock
Data Source
AI summary
Disclosed are a method, an extruder and an injection molding machine for manufacturing a clamping ring, solving problems that products produced by an extrusion method needs to be processed in two steps. The key point of technical solutions lie in a molding step of acting on a pipe member in a plastic melt state via a molding die set, to form a clamping ring from the pipe member; an injection mold injects plastic materials having memory properties through an injection gate to form a pipe member in the molding cavity, the pipe member comprises a clamping ring and a sealing film provided on one end of the clamping ring, the hydraulic mechanism drives a molding cutter to cut out a joint of the sealing film and the clamping ring in a plastic melt state, thereby a limit end is formed at one end of the clamping ring.