Mold for Insert Molding with Adjustable Gap and Movable Pin
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Solution Overview
Problem
Existing insert molding molds face issues with sliding failure of movable pins due to resin intrusion, leading to damage from solidified resin and inability to absorb workpiece thickness variations, resulting in potential damage to the workpiece.
Innovation Solution
A mold design with a movable pin that is initially placed in a non-contacting state during the first-mold-closing operation, allowing it to be fastened to the recess-side mold portion, and then contacts the workpiece during the second-mold-closing operation, with a resilient member absorbing any slide movement to prevent damage, and an adjustable gap between mold portions to manage resin intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the movable pin is configured to contact the workpiece during mold closing operation, then the workpiece can be properly clamped and positioned, but resin material may intrude into the slide gap causing sliding failure and fastening of the movable pin
Solution Approach 1:
The mold structure is designed to execute a first-mold-closing operation that places the movable pin in a non-contacting state before the actual molding process. This preliminary action prevents resin intrusion into the slide gap by ensuring the pin is not in contact with the workpiece when resin material is supplied, thereby preventing sliding failure while maintaining clamping reliability during the subsequent second-mold-closing operation
2Manufacturing precision
If the movable pin contacts the workpiece to clamp it, then positioning accuracy is improved, but the movable pin may become fastened due to resin solidification in the slide gap
Solution Approach 1:
The first-mold-closing operation serves as a preliminary action that positions the movable pin in a non-contacting state relative to the workpiece. This preliminary positioning prevents resin material from intruding into the slide gap between the movable pin and recess-side mold portion, thereby maintaining sliding reliability while allowing the pin to contact and clamp the workpiece accurately during the second-mold-closing operation
3Reliability
If the movable pin is held in a non-contacting state during first-mold-closing operation, then resin intrusion and sliding failure are prevented, but the workpiece cannot be clamped until the second operation
Solution Approach 1:
The mold closing operation is segmented into two distinct phases: a first-mold-closing operation that executes without movable pin contact to prevent resin intrusion, and a second-mold-closing operation that executes with movable pin contact to clamp the workpiece. This segmentation allows each phase to optimize its specific function, preventing sliding failure while maintaining efficient molding cycle progression
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
Prevents damage to the workpiece by maintaining the movable pin in a non-contacting state even after potential sliding failure, ensuring reliable clamping and reducing the formation of resin recesses in the molded product, facilitating easier defect detection.
Implementation Method 1
a resilient member that is configured to adjust an amount of slide movement of the movable pin relative to the second mold such that the resilient member absorbs a variation in a thickness of the workpiece
Data Source
AI summary
A second mold is divided into a recess-side mold portion, which includes a recess, and a remaining mold portion in a sliding direction of a movable pin, while a size of a gap between the recess-side mold portion and the remaining mold portion is adjustable. The second mold is configured to execute a first-mold-closing operation for contacting the recess-side mold portion to the first mold and thereafter a second-mold-closing operation for contacting the remaining mold portion to the recess-side mold portion. A distal end portion of the movable pin is configured to be placed into a non-contacting state, in which the distal end portion of the movable pin is not in contact with the workpiece, at a time of executing the first-mold-closing operation. The distal end portion of the movable pin is configured to contact the portion of the workpiece at a time of executing the second-mold-closing operation.