Mechanical Sequential Locking for Contamination-Free Injection Molds
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Solution Overview
Problem
Existing sequential locking devices for injection molding tools require external actuators or controllers, which increase manufacturing, installation, and operating costs, and are not suitable for producing contamination-free medical devices due to the use of hydraulic systems, and may lead to size and optimization issues with air pressurized or electromagnetic systems.
Innovation Solution
A self-sufficient mechanical sequential locking device that alternates securing and releasing connections between two sides of the injection molding tool without external control, using an elongate body with inner and outer engagement elements and locking elements to actuate the locking mechanism mechanically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic system is used to activate the sequential locking device, then the locking sequence can be achieved, but the risk of contamination increases making it unsuitable for medical devices
Solution Approach 1:
The patent replaces the hydraulic system with a purely mechanical sequential locking device. The locking mechanism uses mechanical engagement elements, cam mechanisms, and spring-loaded components to achieve the sequential locking sequence without any hydraulic fluid, thereby eliminating contamination risk while maintaining reliable operation.
2Force
If an air pressurized system is used to increase the power generated, then the locking force increases, but the size or height of the sequential molding tool has to be substantially increased
Solution Approach 1:
The mechanical sequential locking device utilizes the inherent mechanical advantage of its cam and lever mechanisms to generate sufficient locking force without requiring external pressurization systems. The spring-loaded components and mechanical leverage provide the necessary force within the existing tool footprint, avoiding the need to increase tool height.
3Reliability
If a double locking device is used to generate movement in perpendicular direction, then the sequential locking can be achieved, but the cooling input and output channels cannot be optimally arranged
Solution Approach 1:
The locking device is segmented into separate locking elements that can be independently positioned on the tool plates. This segmentation allows the cooling channels to be routed independently without being constrained by a unified double locking mechanism, enabling optimal thermal management design.
4Object-affected harmful factors
If an electro-magnetic latch is used to activate the sequential molding tool, then the need for hydraulic oil is removed, but the heat generated causes unexpected thermal expansion requiring insulators and extra cooling channels
Solution Approach 1:
The patent replaces the electro-magnetic latch with a purely mechanical activation system. The mechanical sequential locking device uses physical cam mechanisms and lever arms that are actuated by the molding tool's movement itself, eliminating electromagnetic components and their associated heat generation, thus avoiding thermal expansion issues entirely.
5Ease of operation
If external actuators or controllers are used for the locking device, then the locking sequence can be controlled, but the manufacturing, installation and operating costs significantly increase
Solution Approach 1:
The mechanical sequential locking device is self-actuating through the molding tool's own closing and opening movements. The cam mechanisms are positioned such that the natural movement of the tool plates during operation automatically triggers the sequential locking and unlocking sequence, eliminating the need for external actuators or controllers and significantly reducing system complexity and cost.
Data Source
AI summary
Embodiments of the invention provide a self-sufficient sequential locking device and an injection molding tool. The self-sufficient sequential locking device comprises an elongate body having two ends which are provided with first and second inner engagement elements respectively; first and second outer engagement elements selectably engageable with the first and second inner engagement elements respectively for alternatively establishing a first or a second connection by rotation of the elongate body between a first position in which the first connection is secured and the second connection is simultaneously releasable, and a second position in which the second connection is secured and the first connection is simultaneously releasable, and first and second locking element respectively cooperable with the first and second inner engagement element for securing the first connection when the elongate body is in the first position or the second connection when the elongate body is in the second position.