Resin Impeller Gate Removal via Thin Connecting Portion
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Solution Overview
Problem
The existing manufacturing methods for impellers require complex and costly processes to remove unnecessary resin cladding portions formed during molding, leading to inefficiencies and increased costs due to the need for cutting or grinding.
Innovation Solution
A method involving the injection of resin through a die with a metallic bush, forming a thin connecting portion between the resin impeller main body and the unnecessary resin portion, and using pushing or withdrawing means to easily and quickly remove the unnecessary resin portion, eliminating the need for post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin molding is performed using a die with a gate, then the impeller main body is formed, but unnecessary resin cladding portions are formed that require complex removal processes
Solution Approach 1:
The patent applies preliminary action by forming a thin connecting portion between the unnecessary resin portion and the impeller main body during the molding process itself. This thin connecting portion is designed to be easily breakable, so that the unnecessary resin portion can be subsequently removed by simple pushing or withdrawing motions without requiring complex cutting or grinding operations.
2Productivity
If cutting or grinding is used to remove cladding portions, then the unnecessary resin can be removed, but manufacturing time increases and efficiency decreases
Solution Approach 1:
The patent applies the extraction principle by designing the unnecessary resin portion to be separable from the impeller main body through a thin connecting portion. This allows the unnecessary resin to be easily extracted or removed by simple pushing or withdrawing motions, eliminating the need for time-consuming cutting or grinding operations and significantly improving manufacturing efficiency.
3Ease of manufacture
If cladding portions are formed integrally with the molded product, then the structure is strong, but the removal operation becomes independent and increases cost
Solution Approach 1:
The patent applies local quality by creating a thin connecting portion with different properties than the main body structure. While the impeller main body maintains its integral strength, the connecting portion is specifically designed to be thin and easily breakable, allowing the removal operation to be integrated with the molding process and reducing manufacturing costs.
Data Source
AI summary
The present invention provides a manufacturing method for an impeller with which molding and high-quality finishing can be performed extremely easily and quickly through resin molding using a die, and an impeller manufactured by the impeller manufacturing method. A metallic bush is disposed in a die, whereupon a resin material is injected through a gate in the die. A connecting portion between an unnecessary resin portion formed from residual resin material in the gate and a resin impeller main body molded around the bush is formed to be thin, and the unnecessary resin portion is removed from the impeller main body using pushing or withdrawing means.