Embedded Eccentric Gear Assembly for Stable High-Quality Molding

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Solution Overview

Problem

The co-injection production process for eccentric gears is inefficient, labor-intensive, and prone to defects and mold damage due to manual placement of components, leading to low production efficiency and high defect rates.

Innovation Solution

An embedded eccentric gear structure comprising a gear block with an accommodating cavity and an eccentric block, where the eccentric block is fixed using rivets, allowing for stable eccentric rotation and movement through precise molding and embedding, improving installation convenience and quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If co-injection production process is used, then integration of gear block and eccentric block is achieved, but production efficiency is low and defect rate is high due to manual placement

Engineering Contradiction:

Improveintegration of componentsVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention divides the eccentric gear structure into two separately molded parts: a gear block and an eccentric block. These segments are produced independently through injection molding and then assembled together, eliminating the need for complex co-injection processes while maintaining integration benefits and improving production efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines the separately molded gear block and eccentric block into a unified eccentric gear structure through assembly. The eccentric block is positioned within the gear block using an accommodating cavity and fixed with rivets, achieving functional integration without requiring co-injection manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If manual placement of eccentric block is performed, then assembly is completed, but labor intensity increases and safety risks arise

Engineering Contradiction:

Improveassembly completionVSAvoidlabor intensity

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The eccentric block is pre-positioned within the accommodating cavity of the gear block during the assembly process. The cavity provides predetermined positioning features that guide the eccentric block into its correct location, eliminating the need for manual alignment and placement operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The accommodating cavity acts as an intermediary structure that facilitates the assembly of the eccentric block into the gear block. The cavity provides mechanical guidance and positioning, replacing manual placement operations and reducing labor intensity and safety risks.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If co-injection process is used, then single-step manufacturing is achieved, but mold damage risk increases due to placement operations

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidmold durability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The manufacturing process is segmented into separate injection molding operations for the gear block and eccentric block, followed by assembly. This avoids the complex co-injection process that requires specialized molds susceptible to damage from placement operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The eccentric block is extracted as a separate component from the co-injection process and manufactured independently. This removes the problematic manual placement step from the manufacturing flow, protecting molds from damage while achieving the same functional integration.

Inventive Principle:

Principle #2Taking out (Extraction)

4Stability of the object's composition

If embedded structure is used, then assembly stability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly stabilityVSAvoidembedding precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The accommodating cavity in the gear block is designed with specific local geometric features that match the eccentric block's outer contour. This localized precision fitting at the interface provides stable assembly without requiring high precision throughout the entire manufacturing process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Positioning features such as ribs and corresponding cavities are pre-formed during injection molding of the gear block and eccentric block. These preliminary positioning structures ensure accurate alignment during assembly, reducing the precision requirements for the final embedding operation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11441649B2Eccentric gear structure

Publication Date: 2022.09.13 GUANG ZHOU ANTU ELECTRIC

AI summary

An eccentric gear structure includes a gear block and an eccentric block embedded into the gear block; the gear block is provided with an accommodating cavity suitable for embedment of the eccentric block, the eccentric block is provided with a first through hole and a second through hole that deviates from the first through hole; an embedding hole is provided at an axis of the gear block, and an axis of the first through hole coincides with an axis of the embedding hole. The eccentric gear structure ensures the quality of the product through the embedded structure.