Flexible Mold Surface Pin Segments with Elastic Clamping
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Solution Overview
Problem
Existing mold technologies require high acquisition and machine costs, are space-intensive, and struggle to securely position pin segments under high process forces due to limited frictional forces and manufacturing tolerances, making them inefficient for processes like deep drawing.
Innovation Solution
A mold with pin segments that utilize a clamping element with resiliently flexible edges to generate radial clamping forces, allowing secure positioning and high process force absorption without hindering linear mobility, using a combination of guide and clamping elements that can be moved relative to each other to adjust and lock the pin segments in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If metallic molds are manufactured by milling or 3D printing, then the molds can be durable and long-lasting, but the acquisition costs and machine costs are high
Solution Approach 1:
The mold is divided into multiple pin segments that can be independently positioned and adjusted. This segmentation allows the mold to be reconfigured for different workpieces without manufacturing entirely new molds, reducing acquisition costs while maintaining durability through reusable pin segments and guide elements
Solution Approach 2:
The pin segments are made movable along the longitudinal axes within the guide element through-openings, allowing dynamic reconfiguration of the mold surface. This dynamic capability enables the same mold structure to adapt to different forming requirements, eliminating the need for multiple specialized molds and reducing overall acquisition costs
2Duration of action of stationary object
If metallic molds are manufactured by milling or 3D printing, then the molds can be durable and long-lasting, but the machine hours and operational costs are high
Solution Approach 1:
The pin segments are pre-positioned within the guide element structure with through-openings that guide their placement. This preliminary arrangement of components allows for rapid reconfiguration without requiring complex machining operations for each new workpiece, reducing machine hours and operational costs while maintaining the durability of the mold structure
Solution Approach 2:
The guide element structure with its through-openings automatically guides and positions the pin segments, eliminating the need for complex external positioning mechanisms or skilled operation. This self-positioning capability reduces operational complexity and machine costs while maintaining mold durability
3Device complexity
If pins are held in position by frictional forces, then the structure can be simple, but the positioning is not secure under high process forces
Solution Approach 1:
The pin segments are pre-positioned within the guide element structure during setup, and then the guide element is moved into a clamping position that secures them. This two-stage process (positioning then clamping) maintains simplicity while ensuring secure positioning under high process forces during deep drawing operations
Solution Approach 2:
The guide element acts as an intermediary between the pin segments and the clamping mechanism. It provides through-openings that guide the pins and simultaneously enables clamping action when moved into the clamping position, securing the pins reliably under high forces while maintaining structural simplicity
4Manufacturing precision
If molds are specifically manufactured for each workpiece, then the mold fits the workpiece precisely, but the acquisition costs and storage space requirements are high
Solution Approach 1:
The pin segments can be dynamically repositioned along their longitudinal axes within the guide element, allowing the mold surface to be reconfigured to match different workpiece geometries. This dynamic adaptability provides precise fit for various workpieces without requiring separate specialized molds for each, reducing acquisition costs and storage requirements
Solution Approach 2:
The mold is segmented into individually adjustable pin segments rather than a fixed monolithic structure. This segmentation enables precise configuration for different workpieces while using the same reusable mold components, eliminating the need to manufacture and store multiple specialized molds
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 secure, cost-effective, and space-efficient positioning of pin segments for forming processes, including deep drawing, by generating sufficient clamping forces to withstand high process forces while maintaining flexibility and reducing material and operational costs.
Implementation Method 1
the edges of the through-openings of the clamping element are designed to be resiliently flexible and are bent away from the plane of the clamping element in order to be pressed against the pin segments by the first guide element in a clamping manner
Data Source
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AI summary
The present invention relates to a mould (1) for flexibly forming a mould surface (10), having: a plurality of rod segments (11) each comprising a front face (11b), which together form the mould surface (10); a first guide element (12) having a plurality of through-openings (12a); and a clamping element (13) having a plurality of through-openings (13a), wherein the rod segments (11) run linearly movably and parallel to one another in the direction of their longitudinal extent through the through-openings (12a) in the first guide element (12) and through the through-openings (13a) in the clamping element (13), wherein the first guide element (12) and the clamping element (13) can move along the rod segments (11) with respect to each other, and wherein at least portions of the edges (13b) of the through-openings (13a) in the clamping element (13) are elastically bendable and are bent away from the plane of the clamping element (13) in order to be pressed against the rod segments (11) by the first guide element (12) in a clamping fashion.