Macroscopic Lost Part for Micro-Component Manipulation
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Solution Overview
Problem
In micro-injection molding, manipulating and positioning extremely small micro-components is time-consuming and prone to damage due to the difficulty in handling these components with existing manipulators, leading to long cycle times and reduced reproducibility.
Innovation Solution
A macroscopic lost part is used as an object holder within the injection mold to facilitate manipulation, allowing the manipulator to grasp the larger object holder instead of the micro-component, and a predetermined breaking point is incorporated to ensure safe detachment and reduce the risk of damage during the multi-component injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manipulator grasps the micro-component directly, then the micro-component can be manipulated, but the cycle time increases and the risk of damage increases due to fine positioning requirements
Solution Approach 1:
The patent introduces a macroscopic lost part as an intermediary object between the manipulator and the micro-component. The manipulator grasps the lost part instead of the micro-component directly, which serves as a mediator to transfer the manipulation action while protecting the micro-component from direct contact and fine positioning requirements.
Solution Approach 2:
The patent separates the manipulation function from the micro-component by using a distinct lost part. The lost part is designed as a separate macroscopic object with manipulation features, while the micro-component remains small and delicate. This segmentation allows the manipulator to interact with the lost part without needing to precisely position or grasp the micro-component.
2Ease of operation
If the lost part is made macroscopic to facilitate manipulation, then the ease of operation improves, but the volume of the semi-finished product increases
Solution Approach 1:
The lost part is designed as a disposable component that is removed after serving its manipulation purpose. It is made from inexpensive material (first material different from the micro-component's elastomer-based material) and is intentionally designed to be detachable or breakable, allowing the micro-component to be released without damage.
Solution Approach 2:
The lost part is pre-formed with predetermined breaking points or detachment features before the injection molding process. This preliminary design enables easy separation after the micro-component is formed, allowing the macroscopic manipulation aid to be removed without affecting the final micro-component.
3Measurement precision
If the lost part is used as an object holder, then the manipulation precision improves, but the device complexity increases due to the multi-component injection molding process
Solution Approach 1:
The patent combines the formation of the lost part and the micro-component into a single multi-component injection molding process. The lost part is formed in a first mold cavity and the micro-component in a second mold cavity, both using the same injection molding machine and process flow, thereby integrating multiple functions into one manufacturing step without requiring separate assembly operations.
Solution Approach 2:
The injection molding machine is designed to handle multiple mold cavities and different materials simultaneously. The same machine performs the function of forming both the macroscopic lost part and the microscopic micro-component, demonstrating multi-functionality that reduces overall device complexity despite the multi-component nature of the process.
Data Source
AI summary
A semi-finished product and a method for manufacturing a semi-finished product having at least one micro-component, which method uses a multi-component injection molding process, are disclosed, in which at least one mold chamber of an injection mold is provided with at least one lost part made of a first material, more particularly an injection-molded plastic material, and in another step for producing the micro-component, a second material, which is different from the first material and is elastomer-based, more particularly silicone-based, is injected, as a result of which a firm and form-fitting connection forms between the micro-component and the lost part. In order to be able to achieve advantageous cycle times in a risk-free way, it is proposed for the lost part to be embodied as a macroscopic object holder for the micro-component to permit manipulation of the semi-finished product and for the mold chamber to be provided with this lost part.