Dielectric Heating Injection Molding Device for Resin Solidification

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Solution Overview

Problem

Existing injection molding techniques require heating and cooling the entire molding die to solidify resin materials, leading to long tact times and low energy efficiency.

Innovation Solution

An injection molding device that incorporates a dielectric heat generating material mixed with the resin, combined with a high frequency oscillation unit applying alternate-current voltage between electrodes within the molding die, ensuring fluidity and controlled temperature distribution within the die.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire molding die is heated and cooled to solidify resin material, then the resin material can be properly solidified, but the tact time becomes long and energy efficiency decreases

Engineering Contradiction:

Improveresin solidificationVSAvoidtact time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention divides the heating function into two parts: the injection machine heats the resin material before injection, and the molding die with electrodes heats only the resin material locally after injection. This segmentation avoids heating the entire molding die, reducing energy consumption and tact time while ensuring proper resin solidification.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces the conventional thermal conduction heating system with a dielectric heating system using high-frequency electric fields. The electrodes apply alternating voltage to the resin material containing dielectric particles, generating heat internally through dielectric loss, which is more efficient and faster than conventional heating methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If the entire molding die is heated and cooled to solidify resin material, then the resin material can be properly solidified, but energy efficiency decreases

Engineering Contradiction:

Improveresin solidificationVSAvoidenergy efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The heating function is segmented between the injection machine (pre-heating resin) and the molding die with electrodes (local heating of resin). This avoids unnecessary heating of the entire molding die structure, reducing energy waste while ensuring complete resin solidification.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces inefficient thermal conduction heating with dielectric heating using high-frequency electric fields. The electrodes generate heat directly within the resin material through dielectric loss, significantly improving energy efficiency by heating only the resin and not the surrounding die structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If high frequency alternate-current voltage is applied to electrodes sandwiching resin material, then resin fluidity is maintained and processing time is shortened, but device complexity increases

Engineering Contradiction:

Improveprocessing timeVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The molding die with electrodes serves multiple functions: it acts as the traditional molding cavity and simultaneously functions as a dielectric heating device. The electrodes are integrated into the die structure, allowing the same component to perform both molding and rapid heating operations, thereby reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention changes the physical state of the resin material by applying high-frequency alternate-current voltage, which generates heat through dielectric loss. This parameter change (temperature increase via electric field) rapidly improves resin fluidity and shortens processing time without requiring complex additional heating mechanisms.

Inventive Principle:

Principle #35Parameter changes

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 maintains resin fluidity and reduces production costs by controlling temperature and pressure within the die, shortening processing time and enhancing product quality.

Implementation Method 1

a high frequency oscillation device which applies a high frequency alternate-current voltage to the pair of electrodes

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 2

a resin material in which a dielectric heat generating material is mixed

Methodology Applied

Scientific EffectElectromagnetic to thermal energy conversion: Electromagnetic Induction

Data Source

PatentUS11691324B2Injection molding device, injection molding method, and injection molding resin material

Publication Date: 2023.07.04 MAZDA MOTOR CORP

AI summary

An injection molding device includes an injection machine, a molding die, and a high frequency oscillation device. The injection machine injects a resin material containing a dielectric heat generating material while keeping fluidity by temperature control. The molding die includes a cavity being a channel of flow of the resin material, and a pair of electrodes, each of which faces the cavity, the pair of electrodes being disposed to sandwich the resin material therebetween in a direction crossing a direction of the flow. The high frequency oscillation device applies a high frequency alternate-current voltage to the pair of electrodes.