Hexagonal Syringe Nest Mold Geometry
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Solution Overview
Problem
The increasing size of syringe nests, particularly those with larger chimney diameters due to integrated safety systems, has led to chimneys being formed significantly closer together, making moldability impossible and reducing the robustness of injection mold geometry, thereby increasing manufacturing cycle time and reducing mold life.
Innovation Solution
A syringe nest with a hexagonal structure that maintains the manufacturer-specified center-to-center distance of nest chimneys and syringes, enhancing mold geometry robustness and reducing warping issues post-sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the quantity of chimneys per nest is increased to meet standard requirements, then the center-to-center distance between chimneys must be reduced, but this makes moldability impossible and reduces the robustness of injection mold geometry
Solution Approach 1:
The nest is divided into modular chimney units arranged in a hexagonal pattern, allowing each chimney to be molded independently with sufficient wall thickness while maintaining close spacing. The hexagonal segmentation enables optimized material distribution and molding flow paths.
Solution Approach 2:
The chimneys are positioned asymmetrically within the nest boundaries, with varying distances from the nest center, allowing optimized mold geometry that maintains robustness while accommodating high chimney density. This asymmetric arrangement enables better material flow during injection molding.
2Productivity
If the center-to-center distance between chimneys is reduced to increase nest capacity, then manufacturing cycle time increases and mold life is reduced
Solution Approach 1:
The nest structure incorporates localized reinforcement at critical stress points and chimney bases, providing enhanced structural integrity where needed while maintaining thin walls in less stressed areas. This local quality enhancement extends mold life without compromising nest capacity.
Solution Approach 2:
The hexagonal chimneys utilize curved transition zones and rounded corners in the mold geometry, reducing stress concentration points and improving material flow. This curvature optimization allows closer chimney spacing while maintaining mold robustness and extending service life.
3Adaptability or versatility
If circular chimneys are used to maintain standard compatibility, then the geometry becomes thinner and less robust, but hexagonal structures provide more robust mold geometry
Solution Approach 1:
The hexagonal chimney shape replaces the standard circular geometry, providing inherently stronger and more robust mold walls. The six-sided geometry allows for optimized material distribution and thicker effective walls while maintaining the same footprint and center-to-center spacing required for equipment compatibility.
Solution Approach 2:
The hexagonal shape incorporates curved surfaces and optimized angles that improve structural strength and mold geometry robustness. The curved transition zones and rounded corners reduce stress concentration compared to sharp corners, enhancing overall structural integrity while maintaining compatibility dimensions.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A syringe nest is provided that includes a planar base and a plurality of nesting units extending from and interconnected by the base. Each nesting unit includes a hollow hexagonal body having a first open end and an opposing second open end.