Transparent Gasket Mold Venting for Low Demolding Force
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Solution Overview
Problem
Existing gasket molding methods result in resin overflow and penetration between the workpiece and forming mold, leading to increased demolding force and dimensional inaccuracies due to resin deficiency or excess, affecting uniformity and accuracy.
Innovation Solution
A gasket forming method using an active energy ray curable liquid applied to a transparent forming mold with a cavity, bonded to a workpiece, cured by irradiation, and demolded with communication passages or clearance grooves to manage liquid overflow and ensure uniform dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molding resin is applied to the cavity and the forming mold and workpiece are bonded together, then the gasket can be formed, but the molding resin overflows from the cavity and penetrates between the workpiece and the molding/bonding surface of the forming mold, resulting in increased demolding force
Solution Approach 1:
The cavity is divided into a molding region and an overflow region by a partition wall. This segmentation allows the molding resin to be contained in separate zones, preventing it from penetrating between the workpiece and the forming mold surface, thereby reducing the demolding force while still enabling complete gasket formation.
2Ease of manufacture
If molding resin is applied to the cavity and the forming mold and workpiece are bonded together, then the gasket can be formed, but the molding resin overflows from the cavity, resulting in a decrease in overall dimensional accuracy
Solution Approach 1:
The cavity is segmented into a molding region with precise dimensional control and an overflow region that captures excess resin. The partition wall separates these regions, ensuring that the molding resin does not penetrate the bonding surface and compromise the dimensional accuracy of the formed gasket.
Solution Approach 2:
The overflow of molding resin, which was previously a harmful effect causing dimensional inaccuracies, is converted into a beneficial feature by providing an overflow region. This region safely captures the excess resin, allowing the molding process to proceed with ease while maintaining precise dimensional control in the gasket formation area.
3Ease of manufacture
If the cavity is completely sealed, then the molding resin is contained, but the trapped gas or excess resin cannot escape, increasing the demolding force and causing dimensional variations
Solution Approach 1:
The cavity is segmented into a sealed molding region for resin containment and a separate overflow region with an open end. This segmentation allows the molding resin to be contained during bonding while providing a designated escape path for excess resin and trapped gas, reducing the demolding force without compromising resin containment in the molding region.
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
Reduces demolding force and achieves uniform dimensional accuracy of gaskets by controlling resin overflow and penetration, stabilizing gasket dimensions and reducing variations.
Implementation Method 1
a curing step of curing the applied active energy ray curable liquid by irradiation with an active energy ray
Data Source
Figure 1~2A
Figure 2B
Figure 3A~3B
AI summary
The present invention is a gasket forming method for forming a gasket on a workpiece. The method comprises, in the following order, an application step for applying an activated energy beam-curing liquid on a cavity (41) of a transparent forming mold (40), an adhering step for adhering the forming mold (40), to which the activated energy beam-curing liquid has been applied, and a workpiece to each other, a curing step for curing the applied activated energy beam-curing liquid by radiating activated energy beams, and a mold release step for releasing the cured activated energy beam-curing liquid, together with the workpiece, from the forming mold (40). In the adhering step, when the workpiece and the forming mold (40) have been adhered to each other via the activated energy beam-curing liquid, some of the activated energy beam-curing liquid or gas is discharged, to the atmosphere, from a communication path (44) that is in communication with the cavity (41). As a result thereof, it is possible to reduce a releasing force for releasing the gasket from the forming mold and to uniform the dimensional precision of the gasket.