Magnetic Mold Fixation Air-Gap Mechanism for Injection Molding
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Solution Overview
Problem
In injection molding machines with magnetic mold fixation, strong residual magnetic flux makes it difficult and time-consuming to separate molds made from alloy steel with high coercive force, especially small molds, due to strong adhesion to clamp plates.
Innovation Solution
Incorporating an air-gap formation mechanism in at least one clamp plate that automatically forms an air-gap between the mold and the clamp plate as the movable platen moves, reducing the magnetic path and adhesion force by using first and second in-platen rollers with conveyance surfaces set at different heights, allowing the mold to separate easily.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If magnetic force generation mechanisms are used to fix molds to clamp plates, then mold fixation strength is improved, but mold separation difficulty increases due to strong residual magnetic flux
Solution Approach 1:
The patent extracts the harmful residual magnetic flux from the magnetic circuit by introducing a magnetic flux cutting member that creates an air gap, thereby separating the magnetic flux path from the mold and clamp plate contact interface. This allows the mold to be easily separated while maintaining strong fixation during molding operations.
Solution Approach 2:
The magnetic flux cutting member acts as an intermediary element between the mold and clamp plate. It mediates the magnetic interaction by providing a controlled air gap that prevents residual magnetic flux from causing strong adhesion during mold separation, while allowing the magnetic force generation mechanisms to maintain strong fixation when needed.
2Strength
If alloy steel molds with high coercive force are used, then mold strength and durability are improved, but magnetic adhesion to clamp plates increases making separation difficult
Solution Approach 1:
The patent extracts the harmful magnetic adhesion effect by introducing the magnetic flux cutting member that creates an air gap, removing the residual magnetic flux path that would otherwise cause strong adhesion between the alloy steel mold and clamp plate. This enables efficient mold exchange while maintaining the use of strong alloy steel molds.
Solution Approach 2:
The patent changes the magnetic circuit parameters by introducing an air gap through the magnetic flux cutting member. This parameter change disrupts the magnetic flux path and reduces the magnetic adhesion force, allowing alloy steel molds with high coercive force to be easily separated without compromising their strength and durability.
3Adaptability or versatility
If small molds are used, then product diversity and design flexibility are improved, but magnetic adhesion force becomes disproportionately strong making separation very difficult
Solution Approach 1:
The patent extracts the harmful residual magnetic flux that causes disproportionate adhesion in small molds by introducing the magnetic flux cutting member. This creates an air gap that prevents the magnetic flux from strongly adhering small molds to the clamp plates, enabling easy separation while maintaining the ability to produce diverse small products.
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
The air-gap formation mechanism significantly weakens the adhesion force, enabling easy separation of molds from the clamp plates, improving the efficiency of mold detachment and handling in injection molding machines.
Implementation Method 1
a magnetic flux cutting member for cutting a magnetic flux between the clamp plate and the mold
Implementation Method 2
magnetic force generation mechanisms for generating a magnetic force for fixing the molds to the fixation surfaces
Data Source
AI summary
The injection molding machine has a fixed platen and a movable platen for fixing a pair of molds; a pair of clamp plates mounted to the fixed platen and the movable platen, respectively, and having a fixation surface for mold fixation, respectively; and magnetic force generation mechanisms for generating a magnetic force for fixing the molds to the fixation surfaces. An air-gap formation mechanism is provided at least in one of the clamp plates for automatically forming air-gaps between the fixation surfaces and the molds in association with the movement start of the movable platen while the magnetic force generation mechanisms are inactivated for detaching the molds from the fixation surfaces.