Curable Composition Mold-Making Kit for Complex Gap Shims
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Solution Overview
Problem
Current methods for preparing shims, especially for complex 3D shapes, are time-consuming due to resin preparation and curing processes, limiting workability and production rates.
Innovation Solution
A mold-making method involving a curable composition mixed with a curing agent, cooled to a predetermined temperature to prevent initial curing, then used to create a mold-making kit that is stored and brought to the worksite for application, allowing for improved workability and reduced preparation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If resin preparation work is performed at the worksite, then the mold-making process can be completed on-site, but the working time and place are greatly limited and workability is reduced
Solution Approach 1:
The curable composition is prepared and mixed in advance at a manufacturing location, then cooled to a predetermined temperature to prevent initial curing. This preliminary preparation allows the composition to be stored and transported to the worksite without initiating the curing process, enabling on-demand mold-making without time constraints at the worksite.
Solution Approach 2:
The process is divided into two independent stages: (1) resin preparation and cooling at a manufacturing location, and (2) application and curing at the worksite. This segmentation allows the time-consuming mixing and cooling processes to be performed in advance, decoupling the preparation time from the actual mold-making time at the worksite.
2Ease of manufacture
If resin materials are mixed at the worksite, then the mold can be made immediately, but the working place is greatly limited by the status of following steps
Solution Approach 1:
The curable composition is mixed and prepared in advance at a manufacturing location, then cooled to a predetermined temperature to prevent initial curing. This preliminary preparation allows the composition to be stored and transported to the worksite without initiating the curing process, enabling on-demand mold-making without time constraints at the worksite.
3Measurement precision
If a mold with complicated 3D shape is made using epoxy resin, then gap measurement accuracy is improved, but the process takes a very long time due to resin preparation and curing
Solution Approach 1:
The curable composition is prepared and mixed in advance at a manufacturing location, then cooled to a predetermined temperature to prevent initial curing. This preliminary preparation allows the composition to be stored and transported to the worksite without initiating the curing process, enabling on-demand mold-making without time constraints at the worksite.
Solution Approach 2:
The state of the curable composition is dynamically controlled through temperature management. By cooling the composition to a predetermined temperature, the curing process is suppressed during storage and transport, but can be initiated at the worksite by allowing the composition to return to room temperature or applying heat, thus enabling flexible timing of the mold-making process.
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 method enhances workability and reduces the time required for preparing shims by decoupling resin mixing from the worksite, preventing direct contact with components, and maintaining quality, while allowing for accurate molding of complex shapes.
Implementation Method 1
a step of cooling the curable composition to a predetermined temperature at which curing of the curable composition is not initiated
Implementation Method 2
mixing a resin material with a curing agent that promotes curing of the resin material
Data Source
AI summary
Provided is a method for making a mold of a gap between components, the method comprising: a step for preparing a curable composition by mixing a resin material with a curing agent that promotes curing of the resin material; a step for cooling the curable composition (M) to a predetermined temperature at which curing of the curable composition is not initiated, so as to manufacture a mold-making kit; a step for placing the mold-making kit in a gap between a first member and a second member so as to fill the gap; a step for curing the mold-making kit between the first member and the second member to mold the mold-making kit into the shape of the gap; and a step for removing the cured mold-making kit from the gap.