Multi-Stage Helical Gear Molding with Rotating Core Release
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Solution Overview
Problem
Existing injection molding technologies are inadequate for manufacturing multi-stage helical gears with complex shapes such as first and second helical teeth, a central hole, and a spline, as they require mold structures that cannot accommodate these features.
Innovation Solution
A multi-stage helical gear manufacturing apparatus and method using a first mold member, a second mold member, a large gear rotation core, a sleeve pin, a small gear rotation insert, and an insert pin to form and remove a multi-stage helical gear through injection molding, allowing for the formation of first and second helical teeth and a center hole with a linear spline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional injection molding with simple mold members is used, then the manufacturing process is simple, but it cannot accommodate complex shapes such as multi-stage helical gears with different tooth inclinations
Solution Approach 1:
The mold is divided into multiple independent members: first mold member, second mold member, large gear rotation core, small gear rotation insert, sleeve pin, and insert pin. Each member can move and rotate independently to form different features of the complex gear, enabling the manufacturing of multi-stage helical gears with different tooth inclinations while maintaining manageable individual component complexity
Solution Approach 2:
The mold members are designed with dynamic capabilities including rotation (large gear rotation core, small gear rotation insert) and linear movement (sleeve pin, insert pin). These dynamic elements allow the mold to adapt its shape during the injection process to create complex geometries like helical teeth with varying inclinations and internal splines, resolving the contradiction between adaptability and structural complexity
2Manufacturing precision
If multiple rotating components are used to form complex geometries, then manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Multiple functions are merged into integrated components: the large gear rotation core both forms the large gear geometry and creates first helical teeth through its rotation; the small gear rotation insert similarly forms the small gear and second helical teeth. The sleeve pin and insert pin are combined to form both the center hole and internal splines, reducing the total number of components while achieving high manufacturing precision
Solution Approach 2:
Each mold member serves multiple purposes: the rotation cores and inserts form both external gear teeth and internal spline features; the pins serve both as cavity formers and as ejector mechanisms. This multi-functionality reduces device complexity while maintaining the ability to manufacture precise complex geometries
Data Source
AI summary
A multi-stage helical gear manufacturing apparatus includes a first mold member, a second mold member, a large gear rotation core, a sleeve pin, a small gear rotation insert, and an insert pin. The second mold member moves the insert pin and the small gear rotation insert after the insert pin is caused to retreat in relation to the small gear rotation insert at the time of mold opening. The first mold member prohibits rotation of the large gear rotation core at the time of mold clamping, permits rotation of the large gear rotation core when the insert pin and the small gear rotation insert of the second mold member are moved at the time of mold opening, and causes the sleeve pin to advance toward the second mold member in relation to the plastic after the insert pin and the small gear rotation insert are separated from the plastic.