Elastic Sheet Injection Molding for Central Positioning
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Solution Overview
Problem
Current injection molding methods for products with connection elastic sheets either limit the flexible arrangement of the sheet due to mold structure constraints or result in low assembling accuracy and unreliable connections when assembled separately.
Innovation Solution
An injection molding method that involves positioning a blank material with connection pieces and a material connection strip in a first mold, processing it to form a first injection product, and then using this product as an insert in a second mold to inject a second plastic part, allowing the elastic arm portions to be sealed and arranged centrally, enhancing positioning flexibility and connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connection elastic sheet is used as an insert in injection molding with a single mold, then the connection elastic sheet can be positioned and sealed, but it can only be arranged at an edge of the product due to mold structure limits, limiting electronic layout design flexibility
Solution Approach 1:
The injection molding process is divided into two separate stages using two different molds: the first mold positions and seals the connection elastic sheet, while the second mold forms the main product body. This segmentation allows the connection elastic sheet to be arranged at the middle of the product rather than being constrained to edge positions, thereby improving layout flexibility without overly complicating either individual mold structure.
Solution Approach 2:
The connection elastic sheet and its sealing are performed as a preliminary action in the first injection molding stage before the main product body is formed. By pre-positioning and sealing the elastic sheet in the first mold, the subsequent second molding stage can focus on forming the product body without worrying about the elastic sheet positioning, thus achieving flexible central arrangement while maintaining manageable mold structures.
2Adaptability or versatility
If the connection elastic sheet and injection-molded product are assembled together by plug-in structure, then the position where the connection elastic sheet is arranged can be selected flexibly, but the assembling accuracy is lower and the connection is not firm
Solution Approach 1:
The connection elastic sheet positioning, sealing, and product body formation are merged into an integrated two-stage injection molding process. The first mold simultaneously positions and seals the elastic sheet, while the second mold forms the product body that integrates with the sealed elastic sheet. This merging eliminates the need for separate plug-in assembly, achieving both flexible positioning and high manufacturing precision through seamless integration.
Solution Approach 2:
The first injection-molded product serves as an intermediary component that bridges the connection elastic sheet and the second injection-molded product body. The first product contains the sealed elastic sheet and acts as a mediator that is subsequently integrated into the second mold cavity, enabling flexible positioning while ensuring firm connection through the intermediary bonding structure.
3Adaptability or versatility
If the connection elastic sheet is arranged at the middle of the product, then the electronic layout design becomes more flexible, but the positioning and sealing in a single mold becomes structurally limited
Solution Approach 1:
The manufacturing process is segmented into two distinct injection molding operations with two different molds. The first mold is designed specifically for positioning and sealing the connection elastic sheet, while the second mold is designed for forming the main product body. This segmentation makes the central arrangement of the elastic sheet feasible by distributing the structural requirements across two specialized molds rather than attempting to accommodate everything in a single complex mold.
Solution Approach 2:
The connection elastic sheet positioning and sealing are performed as a preliminary action in the first molding stage before the main product body is formed. This preliminary action simplifies the second mold structure, as it only needs to form the product body without incorporating complex positioning and sealing mechanisms for the elastic sheet, thereby improving ease of manufacture while enabling flexible electronic layout design.
Data Source
AI summary
An injection molding method for a product with a connection elastic sheet, a loudspeaker and an electronic device are provided. The method comprises: providing a blank material comprising at least one connection piece and a material connection strip, and each connection piece comprising an elastic arm portion and a wire portion; positioning the blank material as an insert in a first injection mold by means of the material connection strip; injecting a first injection plastic part into the first injection cavity to obtain a first injection product; processing the first injection product for bending up the elastic arm portion toward an outer surface of the first injection plastic part; placing the processed first injection product into a second injection cavity of a second injection mold, and sealing the elastic arm portion; and injecting a second injection plastic part into the second injection cavity.