Magnet Unit Hole Venting Layout for Overflow-Free Injection Molding

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Solution Overview

Problem

Existing mold and magnet unit structures for injection-molding magnets lack efficiency in air venting, leading to potential overflow of magnetic material and suboptimal magnetic properties.

Innovation Solution

A method and structure for manufacturing a magnet unit involving a holding member with multiple holes and gas venting grooves that connect two or more holes, allowing for efficient air venting during injection molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional injection molding is used with simple air venting, then the manufacturing process is simple, but air venting efficiency is poor leading to magnetic material overflow

Engineering Contradiction:

Improveair venting efficiencyVSAvoidmold structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mold structure is segmented into multiple functional components: holding members with individual holes for each magnet, gas venting grooves positioned at specific locations, and multiple magnets arranged in a matrix. This segmentation allows air to be vented from multiple points simultaneously, improving air venting efficiency while maintaining manageable structural complexity through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Gas venting grooves are introduced as intermediary structures between the holding member holes and the external environment. These grooves serve as intermediate channels that efficiently conduct air away from the injection molding process, preventing air pockets and material overflow without requiring direct complex venting mechanisms in each hole

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If multiple holes are used in the holding member, then more magnets can be manufactured simultaneously, but air trapping increases leading to overflow

Engineering Contradiction:

Improvemagnet manufacturing throughputVSAvoidinjection molding quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Multiple individual hole venting requirements are merged into a unified gas venting groove system. The grooves are positioned to receive air from multiple holding member holes simultaneously, allowing high-throughput manufacturing of multiple magnets while maintaining injection molding quality through centralized air evacuation pathways

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The venting approach transitions from one-dimensional individual hole venting to a two-dimensional groove system that spans across multiple holes. The gas venting grooves are positioned to intersect with multiple hole openings, creating a multi-dimensional air escape network that handles high-volume production while preventing air trapping

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If injection molding pressure is increased to fill holes completely, then magnet filling is improved, but air entrapment and material overflow increase

Engineering Contradiction:

Improvemagnet filling completenessVSAvoidmagnetic material overflow

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

Gas venting grooves are pre-positioned and pre-configured in the mold structure before injection molding begins. This preliminary arrangement of venting pathways ensures that air can escape continuously during the injection process, allowing high injection pressure to achieve complete magnet filling without causing material overflow, as the air escape route is already established

Inventive Principle:

Principle #10Preliminary action

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 enhances the magnetic properties of the magnet unit by reducing overflow risks and allowing for improved design flexibility, resulting in a magnet unit with superior magnetic performance.

Implementation Method 1

the mold including one or more gas venting grooves, the process of placing the holding member in the mold causing the second surface to face the one or more gas venting grooves, and causing two or more of the multiple holes to be connected to each other via the one or more gas venting grooves

Methodology Applied

Scientific EffectGas venting:

Implementation Method 2

a process of injection-molding a magnetic material into the multiple holes of the holding member that is placed in the mold from a side of the first surface

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS20250132647A1Magnet unit and method for manufacturing the same

Publication Date: 2025.04.24 NICHIA CORP

AI summary

A method for manufacturing a magnet unit includes: a process of placing a holding member in a mold, the holding member including a first surface, a second surface, and multiple holes extending from the first surface to the second surface, the mold including one or more gas venting grooves, the process of placing in the mold causing the second surface to face the one or more gas venting grooves and causing two or more of the multiple holes to be connected to each other via the one or more gas venting grooves; a process of injection-molding a magnetic material into the multiple holes of the holding member that is placed in the mold from a side of the first surface; and a process of removing the holding member from the mold.