Injection molded component and method of injection molding
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Solution Overview
Problem
Existing injection molded components, such as pallets and receptacles, lack efficient methods for integrating sensors to provide quick and easy identification of goods and their origin, while also facing challenges in manufacturability and operability of these indicators.
Innovation Solution
Incorporating sensors, like RFID tags, into the injection molded components by molding them into the component's structure using a specialized mold assembly with vacuum lines and pins to secure the sensors in place during the molding process, ensuring proper orientation and integration with the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If sensors are integrated into injection molded components using conventional methods, then information transmission capability is improved, but manufacturability deteriorates
Solution Approach 1:
The patent merges the sensor integration process with the injection molding process itself. Sensors are positioned in the mold cavity before injection, and the plastic material is injected directly over and around the sensors, combining two separate operations (sensor installation and component manufacturing) into one integrated process. This eliminates post-molding sensor attachment steps and improves manufacturability while maintaining information transmission capability.
Solution Approach 2:
The patent performs preliminary positioning of sensors within the mold cavity before the injection molding process begins. Sensors are pre-placed in their final positions and secured with support structures, so that when the plastic material is injected, the sensors are already in their correct locations. This preliminary action eliminates the need for post-molding sensor installation and alignment, significantly improving manufacturability.
2Loss of time
If sensors are integrated into injection molded components, then identification efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the sensor integration with the injection molding process, merging the manufacturing of the component housing and the installation of sensors into a single operation. The mold cavity itself serves as the positioning fixture, and the injection process simultaneously forms the component and secures the sensors within it, reducing overall system complexity despite adding sensor functionality.
Solution Approach 2:
The injection molding process itself serves to position and secure the sensors. The plastic material, when injected, automatically surrounds and anchors the sensors in their designated locations within the component. The molding process provides its own positioning and fixation mechanisms through the mold cavity geometry and material flow patterns, eliminating the need for separate sensor mounting fixtures or complex assembly procedures.
3Reliability
If sensors are molded into the component structure, then integration reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses preliminary positioning features built into the mold cavity itself, such as ribs, recesses, or dedicated sensor mounting locations, that guide sensor placement before injection. These pre-formed mold features ensure sensors are positioned accurately and consistently, maintaining high integration reliability while managing manufacturing precision requirements through the mold's built-in guidance structures.
Solution Approach 2:
The patent controls the injection molding parameters (such as injection speed, pressure, and temperature) to ensure the plastic material flows in a controlled manner that properly positions and secures the sensors. By optimizing these process parameters, the system achieves reliable sensor integration without requiring excessively tight tolerances on sensor placement, balancing integration reliability with manufacturing precision.
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
This approach allows for the effective embedding of sensors within injection molded components, enhancing their ability to transmit information about the goods and their origin, while improving manufacturability and preventing sensor displacement during the molding process.
Implementation Method 1
At least one vacuum line is in fluid communication with the suction surface
Implementation Method 2
the injectable material travels over an inner surface of the sensor
Data Source
AI summary
An injection molded component includes a wall that has an inner wall surface and an outer wall surface. A sensor is molded into one of the inner wall surface and the outer wall surface. A channel is at least partially surrounding the sensor.