Metal-Resin Composite Mold Recess for Controlled Resin Leakage
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Solution Overview
Problem
In metal-resin composite production, it is challenging to prevent resin material leakage between molds, leading to issues like spot welding failure and non-filling due to insufficient filling pressure, which affects the quality and appearance of the composite.
Innovation Solution
A mold configuration with an upper and lower mold that includes a recess to collect leaking resin material, along with a recess shape and positioning that supports the resin material from below and includes a step to enhance filling pressure, preventing unintended leakage and maintaining surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a gap exists between upper mold and lower mold during press molding, then resin material can be injected into the mold cavity, but resin material leaks to unintended locations through the gap
Solution Approach 1:
The harmful function of the gap (resin leakage to unintended locations) is extracted and redirected to a specific recess area. The recess captures the leaking resin material and confines it to a controlled zone, separating the harmful leakage effect from the critical product areas.
Solution Approach 2:
The resin material that would normally be considered waste (leaking resin) is converted into a beneficial element by directing it into the recess. This prevents the resin from causing defects on the product surface while still utilizing the material that flows through the gap.
2Manufacturing precision
If resin material leaks to unintended locations, then filling pressure may be insufficient, but adding more resin increases leakage risk
Solution Approach 1:
The recess acts as an intermediary zone between the mold cavity and the exterior. It receives and contains the excess resin material, preventing it from reaching unintended locations while allowing the main cavity to maintain adequate filling pressure.
3Object-generated harmful factors
If recess is made longer in horizontal direction to collect more resin, then leakage collection capacity increases, but burr length increases affecting product appearance
Solution Approach 1:
Instead of extending the recess in the horizontal direction (which increases burr length), the recess is designed to extend in the vertical direction. This dimensional change allows adequate resin collection capacity while keeping the horizontal footprint compact, thus minimizing burr length on the product surface.
Data Source
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AI summary
A mold (100) is for press molding a metal plate (10) and a resin material (20) to produce a metal-resin composite (1). The mold (100) includes an upper mold (110) and a lower mold (120) that sandwich the metal plate (10) and the resin material (20). A cavity (C) for arranging the resin material (20) is provided by the upper mold (110) and the lower mold (120). The upper mold (110) has a recess into which the resin material (20) leaking from the cavity (C) is caused to flow.