Spark Plug Insulator Mold Segmentation for Deformation Control
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Solution Overview
Problem
The existing methods for manufacturing spark plug insulators often result in deformation during the molding process due to frictional forces when releasing the molded body from the mold, leading to potential defects and inconsistencies in the final product.
Innovation Solution
A spark plug insulator production method that involves a mold disassembly technique where multiple mold pieces move at different timings to reduce frictional forces, ensuring minimal deformation by allowing the molded body to be released without significant distortion, and includes specific design features such as small surface inclinations and defined axial and circumferential ranges for the mold pieces to facilitate precise disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the molded body is released from the mold using conventional methods, then the molding process is simple, but the molded body deforms due to frictional force
Solution Approach 1:
The mold is divided into multiple mold pieces (first mold piece, second mold piece, third mold piece) that can move independently. This segmentation allows each piece to be released from the molded body at different timings, reducing the overall frictional force and preventing deformation of the molded body during release.
2Productivity
If all mold pieces are released simultaneously, then the release process is fast, but the molded body deforms due to concentrated frictional force
Solution Approach 1:
The release process is divided into sequential stages where mold pieces are released in a specific order. The first mold piece is released first, followed by the second and third mold pieces. This preliminary staged action distributes the frictional force over time, preventing sudden deformation while maintaining efficient production.
3Manufacturing precision
If the mold pieces are released sequentially at different timings, then the molded body deformation is reduced, but the release process becomes more complex
Solution Approach 1:
The mold pieces are designed with dynamic release mechanisms that allow them to move independently at different timings. The first mold piece can be released in the radial direction first, followed by the second and third pieces in subsequent stages. This dynamic approach achieves precise control over the release process while maintaining manageable system 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
This method effectively reduces deformation and ensures the production of insulators with precise dimensions and structures, enhancing the quality and reliability of spark plugs by minimizing defects caused by molding processes.
Implementation Method 1
the molded body has deformed as a result of frictional force causing the molded body to be pulled by the mold
Data Source
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AI summary
The present invention provides a technique for restraining deformation of a molded body in releasing the molded body from a mold. An employed rear mold is composed of a plurality of mold pieces. The plurality of mold pieces include a first mold piece which forms a first partial internal surface of the internal surface of the rear mold along the entire circumference of the internal surface, and a second mold piece which is located axially forward of the first mold piece and forms a second partial internal surface of the internal surface of the rear mold along the entire circumference of the internal surface. Releasing the molded body includes starting to move the first mold piece rearward in relation to a rear molded portion, and, subsequently to starting to move the first mold piece, starting to move the second mold piece rearward in relation to the rear molded portion, thereby disassembling the rear mold into the plurality of mold pieces. The rear mold may be composed of a plurality of mold pieces which form different portions of the internal surface of the rear mold.