Dip-Molded Medical Device Compression for Mold Removal
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Solution Overview
Problem
Dip-molded articles, such as inflatable medical devices, often have configurations that prevent the use of rigid molds due to the difficulty in removing the mold without damaging the article, especially when the mold orifice is small compared to the internal space, leading to challenges in extracting molding material without causing damage.
Innovation Solution
A dip-molded article processing machine and method that utilizes conveyor assemblies and compression sections to progressively compress and expel molding material from within the article, converting it into a flowable state for safe removal through a small orifice, while maintaining the integrity of the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid mold is used for dip molding, then the mold can provide structural support and precise shape definition, but the molded article cannot be stripped from the mold without damaging the article when the orifice is small compared to the internal space
Solution Approach 1:
The mold is divided into two parts: a rigid mold that provides structural support and shape definition, and a flexible mold that can be expanded and contracted. The flexible mold is removed from the article after curing, allowing the rigid mold to remain as the final shaping tool while eliminating the stripping problem.
Solution Approach 2:
The flexible mold transitions from a contracted state during molding to an expanded state for easy removal. This dynamic change in the mold's physical state allows it to adapt to the article's internal space and be removed without damaging the article, even when the orifice is small.
2Strength
If the mold orifice is small compared to the internal space, then the article can maintain its structural integrity, but removing the mold through the small orifice becomes difficult or impossible without tearing the article
Solution Approach 1:
The mold system is segmented into rigid and flexible components, where the flexible mold can be independently removed after curing. This allows the rigid mold to remain and define the final shape while the flexible portion is extracted through the small orifice without tearing the article.
Solution Approach 2:
The flexible mold's physical parameters (size, shape, stiffness) are changed by expanding and contracting it. When contracted, it can be easily removed through the small orifice; when expanded, it provides sufficient support during the molding process without compromising the article's structural integrity.
3Reliability
If manual mold removal is attempted, then the article can be processed, but the process is time-consuming and may cause damage to the article
Solution Approach 1:
The flexible mold is designed to dynamically expand and contract, allowing for rapid and easy removal after curing. This eliminates the need for time-consuming manual extraction processes and reduces the risk of article damage, as the mold can be quickly collapsed and pulled through the small orifice.
Solution Approach 2:
The flexible mold acts as an intermediary between the rigid mold and the final article. It provides temporary support during curing and then facilitates easy removal through its ability to contract, serving as a mediator that enables both structural integrity and efficient extraction without manual intervention.
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
Enables the removal of molding material from dip-molded articles in a damage-free, automated, clean, and cost-effective manner, ensuring the article's integrity and safety during processing.
Implementation Method 1
a first compression section comprising one or more rollers with an outer peripheral surface spaced apart from the first conveyor surface by a first gap distance, and a second compression section comprising a second conveyor assembly
Data Source
AI summary
Processes for the manufacturing of dip-molded articles can include the application of compression to remove molding materials from within the dip-molded articles. In some embodiments, inflatable implantable medical devices are dip-molded and can be manufactured using such compression processes.