Hollow Molded Part Injection Molding for Uniform Thin Walls
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Solution Overview
Problem
Existing dip molding technologies face challenges with metal, ceramic, and glass formers due to oxidation, corrosion, brittleness, and high energy consumption, while plastic alternatives suffer from complex geometries, two-step manufacturing, and inadequate chemical resistance, leading to high costs and poor reproducibility.
Innovation Solution
A method using fluid assistance injection molding (FAIM) with a semi-aromatic polyamide resin composition to produce a one-piece hollow molded part, featuring a main conduit and branches, ensuring uniform wall thickness and surface quality, and incorporating a fluid inlet strategically positioned to facilitate complete filling of the mold cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal, ceramic or glass formers are used, then durability and service life are improved, but weight increases and energy consumption increases
Solution Approach 1:
The patent uses glass fiber reinforced polyamide 4T, which is a composite material combining glass fibers (providing strength and durability) with polyamide matrix (providing lightweight properties). This composite structure achieves both long service life and reduced weight compared to traditional metal, ceramic or glass formers.
2Reliability
If metal, ceramic or glass formers are used, then durability is improved, but manufacturing energy consumption increases
Solution Approach 1:
The glass fiber reinforced polyamide 4T material provides high durability while requiring lower manufacturing energy consumption compared to traditional metal, ceramic or glass formers. The composite material's inherent strength allows for reduced wall thickness and lighter construction, further reducing energy requirements.
3Weight of moving object
If plastic solutions are used to replace metal, ceramic or glass, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The former is divided into multiple sections that are separately molded and then welded together. This segmentation allows each section to be manufactured independently with optimized geometry, avoiding the complexity of molding the entire complex-shaped former as a single piece while still achieving the desired lightweight plastic construction.
4Adaptability or versatility
If two-step manufacturing methods are used, then manufacturing flexibility is improved, but manufacturing cost increases and reproducibility deteriorates
Solution Approach 1:
The former is manufactured in multiple sections through separate injection molding operations, with each section being welded together. This segmented approach provides manufacturing flexibility to optimize each section independently while maintaining cost-effectiveness through standardized welding processes and improved reproducibility through consistent multi-step manufacturing.
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
The method results in a lightweight, durable, and chemically resistant molded part with a smooth surface, suitable for high-temperature and mechanical operations, offering a long service life and reduced manufacturing costs.
Implementation Method 1
producing the hollow molded part by fluid assistance injection molding
Implementation Method 2
fluid is injected into the molten resin composition via a fluid inlet to obtain the molded part
Data Source
AI summary
The present invention concerns a method for injection moulding an ultra-thin walled article such as a glove (1), having in the thickness range 0.01 mm to 2.50 mm. The method entails injecting plasticised material into a mould and then stripping the moulded article from the mould, it being a feature of the invention that the valve gates adjacent to the surface of the mould are opened and closed independently of the injection stroke of the main injection barrel such that maximum or near maximum injection pressures may be built up within the plasticised material in the runner system before the valve gates are opened to allow material to flow into the mold cavity. In this respect, the present invention enables techniques associated with injection moulding, such as for example the production of engineered surface finishes or of localised variations in thickness, to be applied to thin-walled articles.