Composite Mold Press Surface Layout for Accurate Metal Forming
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Solution Overview
Problem
In the production of metal-resin composites using a set of molds, it is challenging to achieve accurate molding of the metal member due to the design of the mold cavity, which affects the integration of the metal and resin materials, leading to deteriorated molding accuracy.
Innovation Solution
The mold configuration includes an upper mold with a first press surface for forming the metal member and a second press surface for integrating the metal and resin, where the distance between the first press surface and the lower mold is shorter than the distance between the second press surface and the lower mold, allowing the metal member to closely follow the shape of the lower mold, thereby improving molding accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the mold cavity is designed according to the final shape of the metal-resin composite, then the integral molding of metal and resin is achieved, but the molding accuracy of the metal member is deteriorated
Solution Approach 1:
The upper mold is divided into two distinct press surfaces: a first press surface for metal member press-forming and a second press surface for integral molding. This segmentation allows each surface to be optimized for its specific function, resolving the contradiction between integral molding capability and metal member molding accuracy.
Solution Approach 2:
The invention introduces a vertical distance dimension between the first press surface and the lower mold, making it shorter than the distance between the second press surface and the lower mold. This dimensional differentiation enables the metal member to closely follow the lower mold shape during press-forming, improving molding accuracy while maintaining integral molding capability.
2Device complexity
If the distance between the press surface and lower mold is equal to the thickness of metal member and resin material, then the mold is fully closed, but the metal member cannot be pressed along the lower mold shape
Solution Approach 1:
The press surface is segmented into two distinct surfaces at different vertical positions. The first press surface is positioned closer to the lower mold, allowing the metal member to be pressed along the lower mold shape, while the second press surface is positioned higher to accommodate the resin material thickness for integral molding.
Solution Approach 2:
Different regions of the upper mold have different vertical positions relative to the lower mold. The first press surface region is designed with a shorter distance to the lower mold for accurate metal member forming, while the second press surface region has a longer distance to accommodate the final composite thickness.
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 configuration enhances the molding accuracy of the metal member by ensuring it follows the shape of the lower mold during press-forming, resulting in improved precision and quality of the metal-resin composite.
Implementation Method 1
a first press surface for press-forming the metal member
Implementation Method 2
an upper mold and a lower mold that sandwich the metal member and the resin material
Data Source
Figure 1~2
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Figure 5~6
AI summary
A mold 100 for producing a metal-resin composite by press-forming a metal member 10 and integrally molding the metal member 10 that is press-formed and a resin material includes an upper mold 110 and a lower mold 120 that sandwich the metal member 10 and the resin material. The upper mold 110 includes a first press surface 111a for press-forming the metal member 10 and a second press surface 111b for integrally molding the metal member 10 and the resin material. A distance d11 between the first press surface 111a and the lower mold 120 is shorter than a distance d12 between the second press surface 111b and the lower mold 120.