Insert Molding Guide Surface for Positioning Accuracy
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Solution Overview
Problem
Existing insert molding methods require expensive robots or significant manpower to accurately position insert members with process variations, leading to reduced profitability and productivity due to the need for complex and enlarged injection molding machines.
Innovation Solution
A method involving a mold with a guide surface that allows for the easy setting of an insert member with a projecting portion, which is guided by a tapered and straight surface to cancel positional variations, enabling the use of a simpler mold configuration and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a robot or manual operation is used to position the insert member with process variations, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The insert member itself serves as the guiding element. The projecting portion of the insert member is guided by the guide surface formed by the first and second molds, allowing the insert member to automatically correct its own positional variations without requiring external robots or additional guiding mechanisms
Solution Approach 2:
The guide surface acts as an intermediary between the insert member and the molds. This guide surface, formed by the first and second molds, mediates the positioning process by providing a tapered surface that guides the projecting portion of the insert member into the correct position
2Manufacturing precision
If a stiffening plate is incorporated into the injection molding machine to guide the insert member, then positioning accuracy is improved, but device complexity and machine size increase
Solution Approach 1:
The stiffening plate is completely removed from the system. Instead of adding a stiffening plate to the injection molding machine, the invention uses the guide surface formed by the molds themselves to guide the insert member, eliminating the need for additional components
Solution Approach 2:
The guiding function is merged with the mold structure. The guide surface is formed by the first and second molds themselves, combining the molding function and the guiding function into a single integrated system, eliminating the need for separate guiding mechanisms
Data Source
AI summary
A method of producing a molded product includes preparing a mold for insert molding, setting an insert member, forming a cavity in a condition in which the insert member is disposed by closing the mold and injecting a molten resin into the cavity. The mold for insert molding includes first and second molds, and the first mold has a guide surface provided at a part corresponding to a trunk portion of the molded product within a wall surface defining a groove portion which constitutes a part of the cavity. The insert member is set at the groove portion of the first mold while the projecting portion being guided by the guide surface.