Linear Slide Over-Molding Fabrication Method

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Solution Overview

Problem

The existing methods for producing linear slides with cylindrical rolling elements are complex, requiring separate injection molding of plastic guide structures and subsequent assembly, which complicates inventory control, increases labor costs, and affects the precision of the final product due to cumulative tolerances.

Innovation Solution

An over-molding technique is employed to directly mold guide structures onto the metal base of the linear slide within an injection mold, using a core with precise joint surfaces to control the flow of molten plastic and prevent overflow, thereby simplifying the manufacturing process and improving precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate injection molding of plastic guide structures is used, then manufacturing flexibility is improved, but device complexity and labor costs increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the metal base and plastic guide structures into a single integrated component through overmolding. The plastic guide structures are molded directly onto the metal base in one manufacturing process, eliminating the need for separate injection molding and assembly operations. This reduces device complexity and labor costs while maintaining manufacturing flexibility.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If separate assembly of guide structure components is used, then manufacturing flexibility is improved, but productivity decreases due to labor-intensive assembly

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The overmolding process combines the metal base and plastic guide structures into a single integrated component manufactured in one operation. This eliminates multiple assembly steps and labor-intensive operations, significantly improving productivity while maintaining the ability to manufacture different configurations.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If separate plastic guide structure components are assembled, then manufacturing flexibility is improved, but manufacturing precision deteriorates due to cumulative tolerances

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The overmolding process creates a single integrated component where the plastic guide structures are molded directly onto the metal base. This eliminates the interfaces between separate components, thereby eliminating cumulative tolerances and improving manufacturing precision while maintaining design flexibility.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If over-molding technique is used to integrate guide structures, then productivity is improved, but device complexity increases due to mold design

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmold complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The overmolding mold is segmented into two distinct parts: a cavity for forming the plastic guide structures and a core for forming the metal base. This segmentation allows the complex overmolding process to be managed through separate, manageable mold components that can be manufactured and maintained independently, reducing the practical complexity despite the integrated output.

Inventive Principle:

Principle #1Segmentation

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 enhances production efficiency, reduces costs, and improves the precision and quality of the linear slide by integrating the guide structures directly onto the metal base, avoiding the complexities of separate assembly and tolerances.

Implementation Method 1

filling a molten engineering plastic material into the cavity of the injection mold to form guide structures on the metal base

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

formation of a joint surface between the linear slide metal base and a core in the cavity of the mold to avoid an overflow of molten plastic

Methodology Applied

Scientific EffectSurface tension: Surface Tension

Data Source

PatentUS9435375B2Linear slide over-molding fabrication method, linear slide thus made

Publication Date: 2016.09.06 AMA TECH CORP

AI summary

A linear slide over-molding fabrication method for producing a linear slide by putting a metal base onto a core in an injection mold and filling a molten plastic in the injection mold to mold guide structures on the metal base for guiding cylindrical rolling elements. The metal base has a track groove for matching with a linear guideway, guide structure attachment portions at two opposite sides of the track groove, and first joint surfaces at two opposite sides relative to the guide structure attachment portions. The core has guide structure forming portions corresponding to the guide structure attachment portions, second joint surfaces respectively facing toward the first joint surfaces with a gap about 0.02 mm˜0.04 mm therebetween. Thus, the applied engineering plastic material can fill up the guide structure forming portions to form a plurality of guide structures on the two opposite sidewalls of the track groove.