Metallic Mold Groove Structure for Air Bubble Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional metallic mold structures for transfer molding do not effectively address the issue of air bubbles formed during the process, leading to defects such as voids and burning in the molded resin.
Innovation Solution
The metallic mold structure incorporates a recess with groove portions connected to it, allowing air bubbles to be discharged smoothly, and supplementary grooves for temporary accumulation, ensuring efficient transfer molding by rotating transfer rollers and positioning of metallic molds to remove air bubbles externally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metallic mold structure is used for transfer molding, then molding process can be performed, but air bubbles are formed in the recess causing defects such as voids and burning
Solution Approach 1:
The patent extracts the air bubbles from the recess by providing groove portions that extend from the recess to the surface of the transfer member. These grooves act as channels to remove the harmful air bubbles, preventing them from causing defects in the molded resin.
Solution Approach 2:
The groove portions serve as intermediary structures between the recess and the external environment. They facilitate the removal of air bubbles by providing a controlled path, acting as a mediator that enables air escape without compromising the molding process.
2Productivity
If resin is melted and supplied directly for transfer molding, then molding time is shortened, but air bubbles are more likely to be generated
Solution Approach 1:
The groove portions are pre-formed in the transfer member before the molding process. This preliminary structural preparation ensures that when air bubbles are generated during rapid molding, they can immediately be channeled outward through the pre-existing grooves, preventing defects without slowing down the molding process.
3Manufacturing precision
If recess is formed in transfer member, then resin pattern can be formed, but air bubbles accumulate in the recess
Solution Approach 1:
The patent segments the recess structure by dividing it into the recess cavity and the groove portions. This segmentation creates separate functional zones: the recess maintains the desired resin pattern while the groove portions provide dedicated air escape channels, preventing air bubble accumulation.
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 configuration enables effective removal of air bubbles, reducing defects and shortening molding time, while ensuring the resin is molded efficiently without voids or burning, and allows for the production of high-quality optical members.
Implementation Method 1
a transfer molding unit that performs transfer molding on front and rear surfaces of resin that has been melted and supplied
Implementation Method 2
air bubbles that are formed in the recess can be removed via the groove portions
Implementation Method 3
air bubbles discharged from the recess are temporarily accumulated in the supplementary groove portion and can be discharged even more smoothly via the groove portion
Implementation Method 4
the first transfer member is constituted by a first transfer roller that can be driven so as to rotate
Data Source
AI summary
A transfer molding method includes supplying melted resin to a first metallic mold, conveying the first metallic mold onto which the resin was supplied to a position opposing a second metallic mold, performing transfer molding by sandwiching the resin between the two metallic molds, and cooling the resin after performing transfer molding. The performing transfer molding includes discharging residual air that remains in a recess via a groove portion.