Interdental Cleaner Mold Flow Path Ratio
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Solution Overview
Problem
The existing method for manufacturing interdental cleaners often results in insufficient filling of elastomer around the shaft portion due to pressure loss and leakage during the molding process, particularly at the coupling portion where the elastomer flow path area is smaller than the cleaning and slip resistance portions.
Innovation Solution
The method involves filling elastomer into a second mold from the distal end of the shaft portion, with a second mold design that ensures a flow path area ratio of at least 40% around the distal end handle portion to the proximal end shaft portion, reducing pressure loss and preventing elastomer leakage by smoothing the elastomer flow and using a composite material with glass fiber and titanium dioxide for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If elastomer is filled into the second mold from the distal end of the shaft portion, then insufficient filling around the shaft portion is suppressed, but pressure loss increases and elastomer may leak from the coupling portion
Solution Approach 1:
The invention divides the elastomer filling process into two separate steps: first filling the coupling portion through its dedicated gate, then filling the cleaning soft portion through gates at the distal end of the shaft. This segmentation allows each portion to be filled with appropriate pressure control, preventing both insufficient filling and leakage.
Solution Approach 2:
The coupling portion is filled with elastomer before the cleaning soft portion. By completing the filling of the coupling portion first, the invention ensures that this critical connection area is properly formed before subjecting it to the high pressures required for cleaning soft portion filling, thereby preventing leakage.
2Manufacturing precision
If very large injection pressure is applied to fill elastomer through the coupling portion, then filling completeness is improved, but elastomer leakage from the coupling portion occurs
Solution Approach 1:
The elastomer filling process is segmented into two sequential operations: first filling the coupling portion through its dedicated gate at lower pressure, then filling the cleaning soft portion through distal end gates. This prevents the coupling portion from being exposed to excessive pressure that would cause leakage.
Solution Approach 2:
The coupling portion is filled with elastomer in advance before the cleaning soft portion filling. This preliminary action ensures the coupling portion is properly formed and sealed before the high-pressure filling of the cleaning soft portion, preventing leakage during the process.
Data Source
AI summary
To provide method for manufacturing interdental cleaner for suppressing elastomer from insufficiently filling into space around shaft portion in filling the elastomer into mold. Method for manufacturing interdental cleaner includes first step of molding base portion having handle portion and shaft portion (40) by filling composite material into first mold, and second step of forming cleaning portion, slip resistance portion and coupling portion by filling elastomer into second mold (200) from distal end portion side of shaft portion (40) with base portion situated in second mold (200), second mold (200) having second space for forming cleaning portion, slip resistance portion and coupling portion. What is used as second mold (200) in second step has ratio no less than 40% of a flow path area in second space for elastomer around distal end portion of handle portion to flow path area in second space for elastomer around proximal end portion of shaft portion (40).