Foamed Kneaded Material Cylinder Piston Gas Release Control
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Solution Overview
Problem
Existing methods for filling a mold's pattern forming space with foamed kneaded material often result in incomplete filling or leakage due to inadequate control over the piston's position and pressure, leading to suboptimal filling conditions.
Innovation Solution
A device and method that incorporate a position detection system, pressure detection system, and a controller to manage the piston's movement and gas release mechanism, ensuring the piston reaches the correct position and applies the necessary pressure to fill the mold effectively without leakage, by opening and closing the gas release hole based on detected positions and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the piston advances quickly to fill the mold cavity, then productivity is improved, but the foamed kneaded material may leak through the gas release hole or fail to maintain proper foaming condition
Solution Approach 1:
The gas release hole is dynamically opened during piston advancement to allow air escape, then closed before the piston completes its stroke. This dynamic control enables faster filling while preventing material leakage, resolving the contradiction between productivity and filling quality.
Solution Approach 2:
The gas release hole is opened in advance of piston contact with the material, and closed at the appropriate moment during compression. This preliminary action sequence ensures that air is evacuated before compression begins, maintaining proper foaming conditions while enabling efficient filling.
2Object-generated harmful factors
If the gas release hole remains open during piston advancement, then air can be discharged, but the foamed kneaded material may leak out from the gas release hole
Solution Approach 1:
The gas release hole undergoes periodic opening and closing during the piston stroke. It is opened during the advancement phase to discharge air, then closed during the compression phase to prevent material leakage. This periodic action resolves the contradiction between removing air and preventing loss of substance.
Solution Approach 2:
The gas release hole is opened in advance to allow air evacuation before compression begins, then closed at the appropriate moment. This preliminary opening followed by timely closure eliminates air entrapment while preventing material leakage through the hole.
3Manufacturing precision
If the piston compression force is increased to ensure complete filling, then manufacturing precision is improved, but the foamed structure may be damaged and burring may occur
Solution Approach 1:
Air is evacuated through the gas release hole before piston compression begins. This preliminary air removal allows subsequent compression to proceed with lower forces, ensuring complete filling while preserving the delicate foamed structure and preventing burring.
Solution Approach 2:
The gas release hole acts as an intermediary mechanism that removes air from the system before compression. By eliminating air as a compressible element, the piston can apply necessary compression force without excessive pressure that would damage the foam structure or cause burring.
4Device complexity
If the piston advancement position is not precisely controlled, then device complexity is reduced, but the filling condition becomes suboptimal leading to poor foaming quality
Solution Approach 1:
A position detection section monitors piston advancement position and provides feedback to the control section. The control section adjusts the gas release hole timing based on this feedback, ensuring optimal filling conditions while maintaining relatively simple device architecture through intelligent control.
Solution Approach 2:
Mechanical position sensing and control is replaced with a detection section that electronically monitors piston position. This substitution enables precise control of the gas release timing without requiring complex mechanical control mechanisms, resolving the contradiction between device simplicity and filling accuracy.
Data Source
AI summary
A device for forming foamed kneaded material and a method for forming foamed kneaded material are obtained capable of filling a pattern forming space of a mold with foamed kneaded material in a well foamed condition. First, a supply device supplies a foamed kneaded material (a) into a cylinder (20) (first process). Then, in a state in which an internal space (22) of the cylinder (20) is communicated with a pattern forming space (14) of a mold (12), the piston (26) disposed in the cylinder (20) is moved toward the foamed kneaded material (a) side while opening a gas release hole (40A) formed piercing through the piston (26) (second process). Then, at a timing when the piston (26) has reached an expected position (X) where the piston (26) is expected to be on contacting the foamed kneaded material (a) supplied into the cylinder (20), the gas release hole (40A) is closed by an open-close plug (40B) (third process). Then, the foamed kneaded material (a) supplied into the cylinder (20) is pressed toward the pattern forming space (14) side of the mold (12) by moving the piston (26) toward the foamed kneaded material (a) side (fourth process).