Mold Assembly Apparatus for Continuous Resin Forming and Joining

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Solution Overview

Problem

Conventional methods for assembling products from multiple parts using molds require alternating forming and assembly operations, leading to low production efficiency due to the need for frequent mold opening and clamping.

Innovation Solution

A method and apparatus where a mold with a first unit and a second unit are clamped, forming parts by injecting molten resin into cavities, and then the parts are held by the first unit while being opposed to corresponding assembling portions of the second unit, allowing for repetitive assembly without the need for frequent mold opening and clamping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If forming operation and assembly operation are alternately performed with mold opening and clamping at each operation, then parts can be formed and assembled separately, but production efficiency is low due to frequent mold opening and clamping

Engineering Contradiction:

Improveproduction efficiencyVSAvoidtime for mold opening and clamping

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent combines the forming operation and assembly operation into a single integrated process. The mold is opened only once after forming, and the formed parts are directly transferred to the assembly position within the same mold structure. This merging eliminates the need for repeated mold opening and clamping operations, thereby improving production efficiency and reducing time loss.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent maintains continuous useful action by keeping the mold in a clamped state during both forming and assembly operations. The transition from forming to assembly is seamless, with parts being transferred and assembled without interrupting the mold clamping state. This continuity eliminates idle time associated with repeated opening and closing of the mold, thereby enhancing productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Ease of manufacture

If mold is opened and clamped at each forming and assembly operation, then separate control of forming and assembly is possible, but device complexity increases due to multiple operation cycles

Engineering Contradiction:

Improveseparate control of forming and assemblyVSAvoidcomplexity of multiple operation cycles

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the forming and assembly operations into a single integrated mold structure that can perform both functions. The mold includes forming portions for creating parts and assembly portions for assembling them, all within one clamping cycle. This reduces the complexity of managing multiple separate operation cycles while maintaining the ability to control each function through the unified mold structure.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If forming portions are moved to assembly positions after forming, then parts can be transferred for assembly, but time is lost during the movement and repositioning process

Engineering Contradiction:

Improvetransfer of parts for assemblyVSAvoidtime for moving forming portions

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent maintains the mold in a continuously clamped state during the transfer of parts from forming portions to assembly portions. The movement of parts occurs without requiring the mold to open or re-clamp, thereby eliminating time loss associated with repositioning operations. The useful action of part transfer is performed seamlessly within the existing mold structure.

Inventive Principle:

Principle #20Continuity of useful 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 production efficiency by allowing continuous assembly of parts without the interruptions caused by mold opening and clamping, improving the overall efficiency of producing assembled products.

Implementation Method 1

forming the plurality of parts by injecting molten resin into each of a plurality of cavities defined in the mold clamped in the first step

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

opening the mold in a state in which the plurality of parts formed in the second step are held by the first unit

Methodology Applied

Scientific EffectMechanical retention:

Data Source

PatentUS11584052B2Method of producing assembled product and assembling apparatus

Publication Date: 2023.02.21 CANON KK

AI summary

An assembling apparatus that has a mold in which a second unit opposes a first unit and that is configured to assemble an assembled product from a plurality of parts. The first unit includes first, second, and third movable portions, which comprise, respectively, a plurality of first forming portions, a plurality of second forming portions, and a plurality of third forming. The second unit comprises a fourth movable portion, a fourth forming portion, a fifth forming portion, a sixth forming portion, and a plurality of assembling portions. The fourth movable portion is configured to move so as to switch at least one assembling portion opposed to at least one first forming portion, at least one other assembling portion opposed to the at least one second forming portion, and at least one remaining assembling portion opposed to at least one third forming portion.