Embedded Ring Rotomolding Fixture for Hole-Free Tank Molding
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Solution Overview
Problem
Existing rotational molding methods struggle to securely embed metal rings or inserts, such as lock rings, in the center of a product without creating holes or requiring additional manufacturing steps like screwing them into threaded inserts, which increases time and cost.
Innovation Solution
A method and fixture system involving a rotational molding mold with an opening to fit a ring, a locking plate with slots for coupler teeth, and a fixture plate that securely holds the ring in place during molding, allowing for the ring to be embedded and later removed without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal ring or insert is placed in the center of a rotomolded part, then the part can be formed as a single piece, but support holes will appear in the resulting product
Solution Approach 1:
A support structure is introduced as an intermediary element that temporarily holds the metal ring or insert in place during the rotomolding process. This support structure is designed to be removable after molding, allowing the insert to be securely embedded without leaving permanent support holes in the final product surface.
2Reliability
If a lock ring is attached by screwing into threaded inserts, then secure attachment is achieved, but manufacturing time and expense increase
Solution Approach 1:
The metal ring or insert is merged with the rotomolded part by embedding it directly into the molded material during the forming process. This combines two separate operations (molding and attachment) into a single integrated process, eliminating the need for subsequent screwing or fastening steps while maintaining secure attachment.
Solution Approach 2:
The metal ring or insert is positioned and secured in place before the rotomolding process begins. This preliminary positioning ensures that the insert remains correctly located during molding, allowing direct embedding without requiring post-molding attachment operations.
3Manufacturing precision
If a fixture is used to hold the ring in place during molding, then secure placement is achieved, but the fixture must be removed after molding
Solution Approach 1:
The fixture used to hold the ring or insert during molding is designed as a temporary, disposable element that is discarded after serving its purpose. The fixture is removed after molding without damaging the final product, and its temporary nature simplifies the overall process by eliminating the need for complex, permanent positioning mechanisms.
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
Enables the cost-effective rotomolding of products with embedded lock rings by avoiding additional manufacturing steps, ensuring secure placement and easy removal of the fixture, thus reducing production time and expenses.
Implementation Method 1
The mold is then heated in an oven and rotated until the polymer material is melted
Implementation Method 2
The mold is then heated in an oven and rotated until the polymer material is melted. As the mold rotates, the polymer material coats the inside of the mold
Implementation Method 3
The mold is then cooled and the polymer material hardens
Data Source
AI summary
A method of and fixture for molding a product with an embedded ring. A system for molding a ring into a product including a rotational molding mold with an opening formed in the rotational molding mold sized to fit a ring. A fixture is removably couplable to the ring, wherein the ring and the fixture when coupled are removably couplable in the opening. The fixture is removed from the ring after the ring is molded into a product. A method of manufacturing a product with an embedded ring includes: coupling a ring to a fixture; clamping the fixture and the ring in an opening in a mold top; clamping the mold top to a mold bottom; rotomolding a product; unclamping the fixture from the mold top; uncoupling the fixture from the ring; unclamping the mold top and the mold bottom; and removing the product from the mold.