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, with current solutions being cumbersome and difficult to manufacture.
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 during the molding process, ensuring proper orientation and integration with the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated into injection molded components using conventional methods, then sensor functionality is achieved, but manufacturability and operability are compromised
Solution Approach 1:
The sensor is positioned and secured in the mold cavity before injection molding begins. Vacuum lines and extendable pins are activated during the molding process to hold the sensor in place, ensuring proper integration before the material sets.
Solution Approach 2:
Vacuum lines are used to secure the sensor to the mold surface during the molding process. The vacuum pressure holds the sensor in the correct position and ensures proper contact with the mold surface for accurate information transfer.
2Loss of information
If sensors are molded into the component structure, then information transmission capability is enhanced, but device complexity increases
Solution Approach 1:
The sensor is merged with the injection molded component structure, creating an integrated unit where the sensor becomes part of the component itself. This combining of sensor and structural elements enhances information transmission while managing complexity through integration.
Solution Approach 2:
The injection molded component serves multiple functions: it provides structural support as a pallet or receptacle while simultaneously housing and protecting the sensor. This multi-functionality reduces the need for separate protective housings, managing complexity.
3Manufacturing precision
If vacuum lines and extendable pins are used to secure sensors, then sensor placement accuracy is improved, but manufacturing process complexity increases
Solution Approach 1:
Vacuum lines are integrated into the mold assembly to provide automatic sensor securing during the molding process. The pneumatic system activates vacuum pressure to hold the sensor in place, providing precise placement without requiring complex mechanical clamping mechanisms.
Solution Approach 2:
Extendable pins are used to dynamically adjust and secure the sensor position during molding. The pins can extend to engage with the sensor and retract after molding, providing adaptive positioning that accommodates sensor placement while maintaining process simplicity.
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 method allows for the seamless integration of sensors within injection molded components, enhancing their manufacturability and operability, enabling easy identification of goods and their origin through radio wave communication, while minimizing material disruption and preventing sensor movement during the molding process.
Implementation Method 1
At least one vacuum line is in fluid communication with the suction surface
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.