Elastic Polymer Insert Alignment for Micro-Injection Moulding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current injection moulding technologies face limitations in achieving precise shape and position tolerances, particularly in micro-injection moulded articles, due to alignment errors in moulds and inserts, which hinder high-accuracy production required by industries like information technology and laser technology.
Innovation Solution
A device and method for injection moulding that includes a mould with aligned inserts, where at least one insert has an elastic surface made of structured polymer, allowing for precise alignment and correction of alignment errors in the closed state, using materials like silicones and elastomers, and incorporating heating elements and alignment marks for enhanced precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection moulding methods are used, then production is simple and cost-effective, but manufacturing precision deteriorates with tolerances of around 10 micrometres
Solution Approach 1:
Alignment marks are pre-defined on the mould halves and inserts during mould fabrication. These marks serve as reference features that enable precise alignment to be performed later during mould closing, eliminating the need for complex real-time alignment procedures
Solution Approach 2:
The patent replaces complex mechanical alignment systems with an optical/electronic alignment system using alignment marks that can be detected by sensors or imaging systems. This substitution enables higher precision alignment while reducing mechanical complexity
2Manufacturing precision
If alignment is performed in the opened state of the mould, then inserts can be positioned, but alignment errors occur during or after mould closing
Solution Approach 1:
The patent implements a feedback mechanism where alignment marks on the mould halves and inserts are detected during the closing process. The detected positions are compared with target positions, and corrective actions are applied to ensure final alignment accuracy is achieved after closing
Solution Approach 2:
Alignment marks are pre-defined on the mould halves and inserts during mould fabrication. These marks serve as reference features that enable precise alignment to be performed later during mould closing, eliminating the need for complex real-time alignment procedures
3Manufacturing precision
If semiconductor industry methods are used for micro-replication, then manufacturing precision improves to micrometre or sub-micrometre range, but device complexity increases due to fundamental method differences
Solution Approach 1:
The patent uses inserts with structured surfaces that serve as masters or templates for replicating microstructures. These inserts are manufactured with high precision using semiconductor industry methods, then copied into the injection moulded articles through the moulding process, achieving micrometre precision without requiring the entire production system to be as complex
Solution Approach 2:
The patent divides the high-precision requirement into two segments: the inserts (which are manufactured with semiconductor-level precision) and the moulding process (which uses conventional injection moulding). This segmentation allows micrometre precision to be achieved in the inserts while keeping the overall production system relatively simple
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 enables the production of injection moulded articles with improved accuracy, allowing for the creation of microstructures and nanostructures with precise alignment, enabling high-quality, cost-effective, and rapid series production of components with stringent accuracy demands.
Implementation Method 1
at least one insert arranged in the injection moulding space, wherein the at least one insert comprises at least partially a polymer
Implementation Method 2
incorporating heating elements and alignment marks for enhanced precision
Data Source
AI summary
A method and device for injection moulding, in particular for micro-injection moulding, at least comprising a mould with a first mould half and a second mould half, wherein the first mould half and the second mould half define an injection moulding space in the closed state of the mould, and an insert arranged in the injection moulding space.