3D Injection Molding Apparatus Gas Evacuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional transfer in-mold injection molding methods fail to achieve high-quality textures and colors similar to real materials in injection molded products due to inadequate surface quality.
Innovation Solution
An injection molding apparatus and method that includes a gas-evaporating injection module with a cylindrical main body, guide grooves, and discharge members to remove gases from melted resin, combined with a suction system for high-speed air flow, ensuring complete gas discharge and surface layer transfer onto molded products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional transfer in-mold injection molding method is used, then injection molding process can be simplified, but surface quality of the products is not high
Solution Approach 1:
The patent applies preliminary action by evacuating gases from the melted resin before injection molding. The gas evacuation unit removes gases from the resin in advance, preventing defects during the molding process. This preliminary gas removal enables the use of conventional simplified injection molding processes while achieving high surface quality, as the gases that would cause surface defects are removed beforehand.
Solution Approach 2:
The patent extracts harmful gases from the melted resin using a gas evacuation unit equipped with discharge holes. By taking out the gases that cause surface defects before injection, the system maintains process simplicity while achieving high manufacturing precision. The extracted gases are removed from the resin flow path, preventing their negative impact on surface quality.
2Device complexity
If gases are not completely removed from melted resin, then injection molding process is simpler, but surface quality and texture realism are insufficient
Solution Approach 1:
The gas evacuation unit performs preliminary gas removal from the melted resin before injection molding. By evacuating gases in advance through discharge holes positioned in the resin flow path, the system achieves complete gas removal without complicating the overall injection molding process. This preliminary action ensures high surface quality, pattern fidelity, color accuracy, and texture realism.
Solution Approach 2:
The gas evacuation unit acts as an intermediary component between the resin supply and injection molding processes. It mediates by removing gases from the melted resin while maintaining compatibility with conventional injection molding equipment. This intermediary gas removal function enables complete gas elimination without significantly increasing device complexity, achieving high manufacturing precision.
3Reliability
If gas discharge holes are formed in the injection module, then gases can be evaporated and discharged, but the structure becomes more complex
Solution Approach 1:
The injection module is designed with multi-functionality by integrating gas discharge holes into the existing injection module structure. The same injection module performs both injection functions and gas evacuation functions. This universal design achieves reliable gas removal without significantly increasing device complexity, as the gas discharge capability is built into the existing component rather than adding separate dedicated equipment.
Solution Approach 2:
The gas evacuation function is merged with the injection module by forming discharge holes directly in the module structure. Instead of separating gas removal as a distinct complex subsystem, the patent combines gas evacuation capabilities with the existing injection mechanism. This merging achieves reliable gas discharge while minimizing additional structural complexity.
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 solution enables the production of injection molded products with high-quality patterns, colors, and textures by completely removing gases from the melted resin and transferring a surface layer, resulting in products that closely resemble real materials.
Implementation Method 1
a heating unit configured to heat the thermoplastic resin supplied from the supply unit to be melted as a melted resin
Implementation Method 2
a plurality of gas discharge holes are formed to discharge the gas evaporated from the melted resin passing through the inner space to the outside
Implementation Method 3
a suction member provided with a plurality of suction hoses radially connected to the hub box to suction air of the eject holes at a high speed using a vacuum suction force of a vacuum pump
Data Source
AI summary
Disclosed are a three dimensional injection molding apparatus and an injection molding method which are capable of manufacturing an injection molded product having patterns, colors, and textures which are high quality by injection molding after completely removing a gas included in a melted resin, and transferring a surface layer for expressing the patterns, colors, and textures to the injection molded product.