Flexible Packaging Structure for Vehicle Glass Encapsulation Sealing
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Solution Overview
Problem
Conventional encapsulation molds for vehicle glass injection molding face issues with glass breakage due to insufficient space and material overflow, leading to appearance defects and increased production costs.
Innovation Solution
A packaging structure made of flexible material with a lip and supporting edge is integrated into the encapsulation mold to provide a soft seal between the glass and the molding cavity, preventing breakage and overflow, and including a floating mechanism for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass thickness is increased, then glass strength is improved, but molding cavity space becomes insufficient leading to glass breakage
Solution Approach 1:
The packaging structure incorporates a floating mechanism that allows dynamic adjustment of the glass position within the molding cavity. The glass can move vertically on the packaging structure, enabling the system to adapt to different glass thicknesses and maintain optimal spacing during the injection molding process, thus preventing glass breakage while accommodating stronger, thicker glass.
2Volume of moving object
If glass thickness is decreased, then molding cavity space is increased, but gaps form between glass and molding cavity causing material overflow
Solution Approach 1:
The packaging structure serves as an intermediary element between the glass and the molding cavity. It includes a sealing portion that contacts the glass edge and provides a consistent seal, while the floating mechanism allows vertical movement to maintain proper spacing. This intermediary structure ensures reliable sealing regardless of glass thickness variations, preventing material overflow while accommodating thinner glass.
3Strength
If floating mechanism uses hard material, then structural strength is improved, but glass breakage risk increases due to direct contact
Solution Approach 1:
The packaging structure incorporates a buffer portion made of flexible or cushioning material that directly contacts the glass. This buffer layer absorbs mechanical stresses and prevents direct contact between the glass and hard components of the floating mechanism. The flexible material maintains structural integrity while protecting the glass from breakage during positioning and the injection molding process.
4Manufacturing precision
If manual removal of overflow is implemented, then appearance quality is improved, but production cycle time increases
Solution Approach 1:
The packaging structure with its sealing portion and floating mechanism automatically prevents material overflow by maintaining proper spacing and sealing between the glass and molding cavity. The system self-regulates the glass position and sealing contact during injection, eliminating the need for manual intervention to remove overflow. This automated prevention mechanism maintains high appearance quality while preserving production efficiency.
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
The flexible packaging structure reduces glass breakage and overflow, enhances sealing, and decreases production costs by improving the accuracy and efficiency of the injection molding process.
Implementation Method 1
at least a part of the packaging structure is made of flexible material
Data Source
AI summary
A packaging structure includes a main body adapted to be installed in an encapsulation mold and provided with an attachment surface to attach to at least part of a surface of a glass to be encapsulated, and a lip extending from the attachment surface of the main body to be suitable for sealing the surface of the glass, wherein at least a part of the packaging structure is made of flexible material.