Encapsulation Device Volume Reduction for Cavity Prevention
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Solution Overview
Problem
Existing devices for encapsulating components with a casting compound often result in cavities or air inclusions due to thermal stress and material shrinkage, leading to potential damage and reduced assembly quality.
Innovation Solution
The device reduces the volume of the receiving space when tool parts are closed, using a movable element to apply pressure on the solidifying casting compound and employs a flexible web for tolerance compensation, which can be easily replaced, along with vacuum means for precise application and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a deformable film is used for tolerance compensation on the tool surface, then the film lies true to shape over the tool surface, but the film is subject to thermal stress and wear during operation
Solution Approach 1:
The tool is divided into multiple tool parts that can move relative to each other, with the deformable film applied only to specific tool part surfaces that require tolerance compensation. This segmentation allows the film to be localized to areas where it is most needed while reducing overall thermal stress exposure.
Solution Approach 2:
The tool parts are designed to be movable relative to one another, allowing dynamic adjustment of the receiving space volume. This dynamic capability enables the system to compensate for tolerances through controlled movement rather than relying solely on the deformable film's elastic properties, thereby reducing thermal stress on the film.
2Productivity
If high pressure and high temperature are used for injecting molding compound, then the molding compound fills the cavity effectively, but the deformable film is thermally stressed and worn
Solution Approach 1:
The deformable film serves as a cushioning element that compensates for volume changes and tolerances before the high-pressure injection occurs. By pre-positioning the film in a state ready to deform, the system absorbs some of the stress from subsequent high-pressure injection, protecting the film from excessive thermal and mechanical stress.
Solution Approach 2:
The system changes the volume parameter of the receiving space by moving tool parts during the injection process. This dynamic volume adjustment allows the molding compound to be injected at high pressure while the receiving space adapts to accommodate the material, distributing the stress and reducing thermal loading on the deformable film.
3Manufacturing precision
If the receiving space volume is reduced during solidification, then cavities and air inclusions are prevented, but the tool structure becomes more complex
Solution Approach 1:
The volume reduction function is merged with the existing movable tool part structure. The same tool parts that provide tolerance compensation through their deformable film coatings are also used to actively reduce the receiving space volume during solidification. This merging of functions avoids adding separate complex mechanisms for volume reduction.
Solution Approach 2:
The movable tool parts serve multiple functions: they provide tolerance compensation through their deformable film coatings, enable volume reduction during solidification to prevent cavities, and allow for the injection and solidification processes. This multi-functionality reduces the need for additional specialized components.
4Manufacturing precision
If the deformable film is permanently attached to the tool surface, then it provides continuous tolerance compensation, but it cannot be easily replaced when worn
Solution Approach 1:
The tool is segmented into removable tool parts, with the deformable film applied to specific surfaces of these modular components. This segmentation allows individual tool parts with worn films to be easily removed and replaced without affecting the entire tool assembly, significantly improving maintenance ease.
Solution Approach 2:
The system is designed to allow discarding of worn deformable films and recovery of the underlying tool part structure. When a film becomes worn, it can be removed and replaced while the tool part itself is retained and reused, optimizing resource utilization and reducing overall tool cost over time.
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 prevents cavities and ensures reliable, gap-free encapsulation of components, even with complex shapes, maintaining high assembly quality and extending tool life by minimizing wear on flexible components.
Implementation Method 1
the solidifying casting compound is subjected to pressure due to the reduction in volume of the receiving space, which pressure reliably prevents the formation of the cavities mentioned
Implementation Method 2
means are provided which are designed to reduce the volume of the receiving space when the at least two tool parts are in the closed position
Implementation Method 3
a tool surface can be coated with a PTFE film. A film of this type is highly deformable and lies true to shape over a tool surface
Data Source
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AI summary
The invention relates to a device (10; 10a) for producing components (3, 4) which are at least partially covered with a casting compound and (1) arranged on a carrier element (2), having at least two tool parts (11; 11a, 12) which are arranged so as to be movable relative to one another and which, in a closed position, form a receiving space (55) for receiving the carrier element (2) with the components (3. 4) and the casting compound (1), wherein at least one tool part (11, 11a) is operatively connected to an elastically formed element (30) on the side facing said tool part (11; 11a).