Mesh Filter Gate Detachment and Rib Design for Injection Molding
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Solution Overview
Problem
Conventional mesh filters manufactured by injection molding face issues with resin flow distribution, leading to weakened mesh parts due to the gate placement, which affects the structural integrity and filter performance.
Innovation Solution
The design incorporates a ring-shaped frame body with a gate detachment part and outer ribs that accelerate resin flow away from the gate, ensuring the thick portion is the final filled portion, thereby reinforcing the mesh and preventing defects like short shot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the gate is positioned at the center of the mesh filter for injection molding, then the molding process is simplified, but the mesh portion becomes the final filled portion causing structural weakness
Solution Approach 1:
The gate detachment part is positioned asymmetrically at one specific location on the frame body rather than at the center, creating an asymmetric gate arrangement that directs resin flow away from the mesh portion and prevents it from being the final filled area
Solution Approach 2:
The frame body is designed with varying thickness, being thinner at the gate detachment part and thicker at the opposite side, creating local quality differences that control resin flow distribution and ensure the mesh portion is not the last area to be filled
2Manufacturing precision
If the mesh filter is manufactured by insert molding with a separate mesh member, then the mesh structure can be precisely controlled, but manufacturing time and complexity increase
Solution Approach 1:
The mesh portion and frame body are merged into a single integral structure formed by injection molding, eliminating the need for separate mesh members and insert molding operations, thereby reducing manufacturing steps and cycle time while maintaining structural precision
Solution Approach 2:
The frame body serves multiple functions: it provides structural support, acts as the mold cavity boundary, and includes the gate detachment part for process control, consolidating multiple functions into a single component that enables entire integral molding
Data Source
AI summary
A mesh filter includes a circular plate-shaped mesh portion having a plurality of openings allowing a fluid to pass, a ring-shaped frame body supporting an outer periphery of the mesh portion, and a button-shaped thick portion positioned on an inner peripheral side of the mesh portion. The frame body includes a gate detachment part at one place in a circumferential direction. The mesh portion includes a plurality of inner ribs and outer ribs symmetrical with respect to an imaginary straight line passing through a center of the gate detachment part and bisecting a planar shape of the frame body. The four inner ribs are formed at regular intervals in a peripheral area of a center axis of the thick portion. The outer ribs extend radially inward from an inner peripheral surface of the frame body and are separately formed on both sides of extended lines of the respective inner ribs.