Mold Base Plate Shaping for Injection Molding Precision
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Solution Overview
Problem
The existing methods for processing the mounting surface of a laminated body onto a mold in injection molding are cumbersome and require precise processing, making the production of molds with laminated bodies complex and time-consuming.
Innovation Solution
A mold manufacturing method involving shaping a laminated body on a base plate with a first member having a first opening, removing a second member, and performing cutting or nesting processes, followed by assembling the base plate into a mold base, eliminating the need for precise mounting surface processing and simplifying the mold production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mounting surface of the laminated body is precisely processed to improve quality, then the quality of the molded product is improved, but the manufacturing process becomes troublesome and complex
Solution Approach 1:
The base plate is integrated into the mold base as a single assembled unit, merging the mounting surface preparation into the base plate fabrication process itself. The laminated body is shaped directly on the base plate, eliminating the need for separate mounting surface processing steps while maintaining precision through the integrated design.
Solution Approach 2:
The base plate is pre-formed with the required mounting surface characteristics during its fabrication process. The laminated body is shaped directly on this pre-prepared base plate surface, eliminating the need for subsequent mounting surface processing. The preliminary preparation of the base plate ensures the required precision is achieved before the laminated body is attached.
2Manufacturing precision
If the laminated body is shaped directly on the base plate, then the adhesion and cutting accuracy are improved, but the second member must be removed requiring additional processing steps
Solution Approach 1:
The mold structure is divided into multiple members including the base plate with first opening and the second member. The second member is temporarily assembled to support the shaping process, then removed to enable cutting operations. This segmentation allows each component to serve its specific function optimally while maintaining overall manufacturing efficiency.
Solution Approach 2:
The second member is assembled in advance to provide support during the shaping process, ensuring cutting accuracy. After the shaping is complete, the second member is removed to allow for subsequent cutting operations. This preliminary support structure enables precise shaping without compromising later manufacturing steps.
3Ease of manufacture
If the base plate is assembled into the mold base, then the design freedom and ease of manufacture are improved, but the structural complexity of the mold increases
Solution Approach 1:
The mold is designed as an assembly of discrete components including the base plate, first member with opening, second member, and mold base. This segmentation allows each component to be manufactured independently using appropriate processes, improving ease of manufacture while the modular assembly manages overall structural complexity through standardized interfaces.
Solution Approach 2:
The base plate serves multiple functions: it provides the mounting surface for the laminated body, acts as a structural component of the mold, and integrates into the mold base assembly. This multi-functionality reduces the need for separate components, simplifying the overall structure while maintaining design freedom.
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 method allows for the easy and efficient manufacturing of molds with laminated bodies by directly shaping the laminated body on the base plate, reducing processing complexity and improving adhesion, cutting accuracy, and design freedom, while enhancing the quality of the molded products.
Implementation Method 1
shaping a laminated body that becomes a part of the mold by discharging molding material and stacking layers
Data Source
AI summary
A mold manufacturing method used in an injection molding apparatus has a first step of shaping a laminated body that becomes a part of the mold by discharging molding material and stacking layers on a base plate having a first member with a first opening and a second member assembled into the first opening, a second step of removing the second member from the base plate on which at least a part of the laminated body has been shaped, and performing at least one of a cutting process and an insertion of a nesting member on the laminated body, which is at least partially shaped, and a third step, performed after the second step, of assembling the base plate with the laminated body is shaped, or a base plate with the laminated body is shaped and all the second members are removed, into the second opening in a mold base.