Dual Flat-Screw Plasticizing for Compact Injection Molding
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Solution Overview
Problem
Existing injection molding devices face limitations in increasing plasticizing ability without increasing device size, as methods to enhance plasticization per unit time, such as increasing screw rotations or diameter, result in saturation or require larger motors.
Innovation Solution
A plasticizing device with two symmetrical flat screws and a shared barrel, featuring separate heating and drive mechanisms, along with a branch path and communication hole, to enhance plasticizing capacity while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of screw rotations is increased to increase plasticization amount, then plasticizing ability is improved, but the plasticization amount becomes constant (saturation) when rotations exceed a certain number
Solution Approach 1:
The invention divides the single flat screw into two separate flat screws (first flat screw and second flat screw) that rotate independently. Each screw has its own groove forming surface that processes material separately, then both contribute to the total plasticization capacity. This segmentation allows the system to overcome the saturation limit of a single screw by adding more processing elements without increasing the rotation speed of individual screws beyond the saturation point.
2Productivity
If the diameter of the flat screw is increased to increase plasticization capacity, then plasticizing ability is improved, but the size of the entire device is increased (requiring larger motor)
Solution Approach 1:
Instead of increasing the diameter of a single large screw, the invention uses two smaller flat screws with smaller diameters. Each screw maintains a compact size suitable for the existing motor and device envelope, while the combined capacity of both screws provides the required plasticization ability. This segmentation approach achieves higher productivity without proportionally increasing device volume.
Solution Approach 2:
The invention transitions from a single-screw system to a multi-screw system, adding the dimension of parallel processing. By introducing a second flat screw that operates simultaneously with the first, the system increases plasticization capacity not by expanding the diameter of individual screws, but by adding another processing dimension, thereby maintaining compact device size.
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
The solution achieves a high plasticizing ability with a compact device configuration, enabling efficient injection molding with optimized material supply and heating control.
Implementation Method 1
a heating section configured to heat the material supplied to the grooves of the first flat screw and of the second flat screw
Data Source
AI summary
A plasticizing device includes a first flat screw including a first groove forming surface in which a groove is formed and configured to rotate; a second flat screw including a second groove forming surface in which a groove is formed and configured to rotate; a barrel including a first facing surface facing the first groove forming surface and a second facing surface facing the second groove forming surface and formed with a communication hole through which a plasticized material is fed outside; and a heating section configured to heat the material supplied to the grooves of the first flat screw and of the second flat screw.