Direct-Drive Intermediate Mold for Injection Molding
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Solution Overview
Problem
Conventional molding processes using rotating intermediate molds suffer from fluctuations in mold closure accuracy due to gear-driven rotary units, leading to misalignment and reduced durability.
Innovation Solution
The intermediate mold is directly mounted on a support member equipped with a direct drive motor, rotating coaxially with the mechanism, eliminating the need for gears and ensuring precise alignment and improved mold closure accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a gear-driven rotary unit is used to rotate the intermediate mold, then the mold can be rotated to perform multiple molding operations, but fluctuations in stopping position occur due to gear play, reducing mold closure accuracy
Solution Approach 1:
The patent replaces the gear-driven rotary mechanism with a direct-drive motor system. The intermediate mold is directly coupled to the motor shaft without intermediate mechanical transmission elements, eliminating gear play and achieving precise positioning. This substitution of mechanical transmission with direct electromagnetic drive resolves the contradiction between rotational capability and positioning accuracy.
2Manufacturing precision
If tapered guide pins are used to correct misalignment during mold closure, then mold closure accuracy can be improved, but stress is applied to the mold each time it closes, affecting durability
Solution Approach 1:
The direct-drive motor system performs preliminary positioning of the intermediate mold before mold closure occurs. By achieving precise alignment during the rotation and positioning phase, the mold components are already correctly aligned when closure happens, eliminating the need for tapered guide pins to force correction during closure. This prevents stress concentration and protects mold durability.
Data Source
AI summary
A molding apparatus is used, the apparatus including a mold made up of a first mold, a second mold opposite the first mold, and an intermediate mold disposed between the first mold and the second mold. The apparatus further includes a support member configured to support the intermediate mold, and an injection mechanism configured to inject molten resin. The support member includes a rotating mechanism. The intermediate mold is mounted on the rotating mechanism such as to rotate coaxially with the rotation axis of the rotating mechanism.