Injection Compression Molding Apparatus for Stress-Free Precision Parts
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Solution Overview
Problem
Conventional injection molding technologies face challenges in manufacturing components with complicated structures and high dimensional precision, often resulting in stress residues and limited appearance decoration capabilities.
Innovation Solution
A modeling apparatus comprising a first set with a body, mold structure, and a second set with a movable portion, pushing mechanisms, and a valve, which forms an accommodating space for injecting and compressing plastic, allowing for low-pressure injection and in-mold decoration, thereby preventing stress residues and enabling the production of components with complex designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional injection molding technology uses high pressure to inject fluid plastic, then the molding speed is improved, but the fluid plastic distribution becomes non-uniform and stress residues occur
Solution Approach 1:
The patent employs hydraulic cylinder to provide compression force during the molding process, replacing pure high-pressure injection with a controlled compression mechanism that gradually reduces volume and eliminates air pockets without causing stress residues
Solution Approach 2:
The patent changes the physical state parameters by heating the plastic material to increase fluidity before injection, then uses controlled compression to achieve uniform distribution without high-pressure injection, thereby eliminating stress residues while maintaining molding speed
2Manufacturing precision
If conventional injection compression molding technology uses hydraulic cylinder to move the core, then dimensional precision is improved, but the ability to manufacture complicated structures is lost
Solution Approach 1:
The patent divides the molding system into separate functional modules: injection system for filling, compression system for densification, and decoration system for surface treatment. This segmentation allows each module to be optimized independently, enabling both complicated structure manufacturing and high dimensional precision
Solution Approach 2:
The patent creates a multi-functional molding apparatus that can perform injection, compression, and decoration operations in sequence within the same system, allowing it to manufacture complicated structures with high dimensional precision while maintaining the ability to handle various material types and structural complexities
3Ease of manufacture
If conventional molding technologies manufacture products according to mold structure shape, then manufacturing simplicity is maintained, but appearance decoration function is lost
Solution Approach 1:
The patent applies decoration treatments to the plastic material before injection by coating the mold cavity surface with decorative films or applying decorative layers to the mold structure. This preliminary action allows the base plastic to be injected in its natural state while the decoration is already in place, maintaining manufacturing simplicity while adding appearance decoration function
Solution Approach 2:
The patent merges the decoration function with the molding process by integrating decoration application into the mold structure itself, allowing both the structural forming and appearance decoration to occur in a single operation, thereby maintaining ease of manufacture while gaining decoration capabilities
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 apparatus achieves high dimensional precision and optical properties in manufactured components, reduces mold-locking force, and allows for rapid filling of the accommodating space, even with sticky plastics, effectively eliminating stress residues and enabling efficient production of complex structures like computer casings.
Implementation Method 1
the compression cylinder can compress the accommodating space to model the plastic
Implementation Method 2
the valve can be filled with the plastic and the plastic can be injected into the accommodating space through the valve
Data Source
AI summary
A modeling apparatus includes a first set and a second set. The first set includes a body and a first mold structure, the first mold structure is disposed on a surface of the body. The second mold includes a movable portion, a first pushing mechanism, a valve and a second pushing mechanism. A second mold structure of the movable portion is combined with the first mold structure to form an accommodating space. The first pushing mechanism is connected to the movable portion for moving the movable portion, so as to combine the second mold structure with the first mold structure. The valve is disposed on the second mold structure for injecting plastic into the accommodating space. The second pushing mechanism is connected to the pushing component. The second pushing mechanism drives the pushing component to pierce through the movable portion, to move the modeled plastic out of the accommodating space.