Metal-Resin Composite Molding with a Detachable Cavity Insert
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the production of metal-resin composites using a set of molds, the molding accuracy of the metal member is compromised due to the design of the mold cavity, which prevents the upper mold from accurately molding the metal member along the shape of the lower mold, leading to suboptimal integration with the resin material.
Innovation Solution
An apparatus and method that incorporates a molding auxiliary component detachably fixed to the upper mold, reducing the cavity space during metal member press molding and allowing for improved alignment with the lower mold, while the auxiliary component is removed during resin integration, ensuring precise shaping of the metal-resin composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cavity is formed in the upper mold for arranging resin material, then the metal-resin composite can be integrally molded, but the molding accuracy of the metal member is deteriorated
Solution Approach 1:
The upper mold is segmented into two functional parts: a molding auxiliary component that provides a pressing surface for accurate metal member molding, and a mold cavity portion that provides space for resin material arrangement. This segmentation allows each part to perform its specific function optimally without compromising the other.
Solution Approach 2:
The molding auxiliary component is attached to the upper mold before press molding the metal member to ensure accurate molding. After the metal member is molded, the auxiliary component is removed to form the cavity for resin material arrangement before integral molding.
2Productivity
If the upper mold is designed with a cavity for resin material, then the metal-resin composite can be produced, but the metal member cannot be molded along the shape of the lower mold
Solution Approach 1:
The upper mold configuration is made dynamic through the detachable molding auxiliary component. The component is attached during metal member molding to ensure shape accuracy, and removed during resin material arrangement to enable cavity formation. This dynamic reconfiguration allows the system to adapt to different molding requirements.
3Manufacturing precision
If the distance between the upper mold and lower mold is reduced for accurate metal member molding, then molding accuracy improves, but the cavity space for resin material is insufficient
Solution Approach 1:
The upper mold is divided into a pressing component and a cavity portion. The pressing component provides the necessary pressing surface for accurate metal member molding, while the cavity portion provides sufficient space for resin material arrangement. This segmentation resolves the conflict between reducing distance for accuracy and maintaining cavity volume.
Data Source
AI summary
An apparatus for manufacturing a metal-resin composite by press molding includes upper and lower molds sandwiching a metal member and a resin material, a molding auxiliary component detachably fixed to the upper mold to fill part of a cavity for the resin material between the upper and lower molds, and a drive unit that vertically moves at least one of the upper and lower molds. The molding auxiliary component has a first press surface for molding the metal member. The upper mold has a second press surface for integrally molding the metal member and the resin material when the molding auxiliary component is removed. The upper and lower molds are for pressing the resin material between the second press surface and the lower mold to cause the resin to flow to fill the cavity with the resin material when the molding auxiliary component is removed.