Insert Molding with Ultrasonic Vibration for Resin-Powder Dispersion

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Solution Overview

Problem

Existing methods for manufacturing molded articles with insert-molded components in resin mixed with solid powder face challenges such as variability in mixing ratios, increased viscosity leading to manufacturing time extension, and reduced yield due to adherence and residue issues in the casting material cup.

Innovation Solution

A method involving direct injection of molding material and solid powder into a molding die, followed by agitation within the die to disperse the powder, and embedding the component while vibrating the die to ensure uniform dispersion and efficient embedding of the component into the resin-powder mixture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the molding material and solid powder are mixed in a casting material cup before injection, then the mixture can be injected into the casting die, but the solid powder precipitates in the cup causing die-to-die variation in mixing ratio

Engineering Contradiction:

Improveease of mixingVSAvoidmixing ratio consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-mixing the molding material and solid powder in a mixer before injection, ensuring uniform dispersion. The mixed material is then injected into the casting die in a single operation, preventing precipitation and maintaining consistent mixing ratio across all dies.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a mixer as an intermediary device between the material storage and injection system. This mixer ensures thorough and uniform mixing of the molding material and solid powder before injection, acting as a mediator that prevents precipitation and maintains consistent mixing ratios.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the mixing ratio of solid powder is increased to improve product properties, then the viscosity of the agitated mixture increases, making injection difficult and lengthening manufacturing time

Engineering Contradiction:

Improveproduct propertiesVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the conventional mechanical agitation system with an ultrasonic vibration system. The ultrasonic vibrations effectively disperse the solid powder in the molding material without significantly increasing viscosity, enabling easy injection even at high solid powder content while maintaining short manufacturing cycles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and dispersion characteristics of the solid powder through ultrasonic vibration. This parameter change prevents aggregation and maintains low viscosity even at high solid powder concentrations, allowing for rapid injection and short manufacturing time.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the viscosity of the agitated mixture is high, then the mixture adheres more to the surface of the casting material cup, increasing residue and decreasing yield ratio

Engineering Contradiction:

Improvemixing uniformityVSAvoidyield ratio

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces mechanical agitation with ultrasonic vibration, which prevents the molding material and solid powder from adhering to the cup surface. The ultrasonic energy keeps the mixture fluid and non-sticky, minimizing residue and maximizing yield ratio.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies mechanical vibration in the form of ultrasonic waves to the molding material and solid powder mixture. This vibration prevents adhesion to the cup surface by maintaining the mixture in a fluid state, thereby reducing residue and improving yield ratio.

Inventive Principle:

Principle #18Mechanical vibration

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 achieves consistent mixing ratios across articles, reduces manufacturing time, and enhances yield by minimizing residue and adherence, allowing for efficient production with reduced pressure and torque, thus improving the manufacturing efficiency and magnetic characteristics of the final product.

Implementation Method 1

an ultrasonic generator (103) for vibrating the injection mold (100) at ultrasonic frequencies

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS8840821B2Method of manufacturing molded article including component insert-molded in resin mixed with solid powder

Publication Date: 2014.09.23 DENSO CORP

AI summary

The exemplary embodiment provides a method of manufacturing a molded article including a component insert-molded in a molding material mixed with solid powder. The method includes an injecting step of injecting the molding material and the solid powder into a molding die, an agitating step of agitating the molding material and the solid powder within the molding die to disperse the solid powder in the molding material, and an embedding step of pressing and embedding the component into the agitated mixture of the molding material and the solid powder while vibrating at least one of the component and the molding die.