Molded Body Production Device with Multi-Directional Release Agent Injection
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Solution Overview
Problem
Conventional molded body production devices face quality defects and reduced productivity due to the inability to prevent molding material adhesion to the inner surfaces of the molding die, especially when using materials with high adhesive properties or high shrinkage ratios.
Innovation Solution
A molded body production device with a release agent injection system that applies release agent to both the upper and lower punch surfaces and the inner circumferential surface of the molding die, using separate nozzle holes capable of upward and downward injection, allowing for optimized release agent distribution and preventing material adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a release agent is applied only onto the lower and upper punch surfaces using a conventional nozzle, then the application process is simple, but the molding material adheres to the inner circumferential surface of the molding die causing quality defects
Solution Approach 1:
The release agent application system is segmented into multiple independent nozzle holes (first nozzle hole for upward injection, second nozzle hole for downward injection) that can be positioned at different locations. This segmentation allows the release agent to be applied to multiple surfaces (upper punch surface, lower punch surface, and inner circumferential surface) simultaneously, resolving the contradiction between application completeness and system simplicity.
Solution Approach 2:
The invention adds a vertical dimension to the release agent application by providing both upward-injecting and downward-injecting nozzle holes. This dimensional approach allows the release agent to reach surfaces that are otherwise inaccessible from a single injection direction, thereby preventing adhesion on the inner circumferential surface without significantly increasing system complexity.
2Manufacturing precision
If the upper punch is positioned above the upper end surface and the lower punch surface is aligned with the upper end surface during release agent application, then the nozzle can access both punch surfaces, but the inner circumferential surface remains uncovered
Solution Approach 1:
The nozzle is segmented into multiple injection openings with different orientations (upward and downward). This segmentation allows each opening to target specific surfaces independently, achieving complete coverage of all surfaces including the inner circumferential surface, without requiring complex punch positioning maneuvers.
Solution Approach 2:
The release agent is applied in advance to all surfaces (upper punch surface, lower punch surface, and inner circumferential surface) before the molding material is supplied. This preliminary application ensures that all surfaces are protected against adhesion before the molding process begins, eliminating the need for complex positioning adjustments during operation.
3Productivity
If a conventional single-direction nozzle is used for release agent application, then the device structure is simple, but productivity decreases due to quality defects requiring rework
Solution Approach 1:
The injection system is segmented into multiple nozzle holes with different injection directions (upward and downward). This segmentation enables simultaneous application of release agent to multiple surfaces in one operation, preventing adhesion defects and eliminating rework, thereby improving productivity without requiring complex external application mechanisms.
Solution Approach 2:
The multi-directional nozzle holes enable continuous and complete coverage of all surfaces that will contact the molding material. By ensuring the release agent is applied to the upper punch surface, lower punch surface, and inner circumferential surface in a single continuous action, the system prevents defects that would otherwise require stopping production for rework, thus maintaining continuous productive operation.
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 ensures high-quality molded bodies with improved productivity by effectively preventing material adhesion, reducing defects such as cords and cracks, and maintaining the integrity of the molded product.
Implementation Method 1
a release agent is applied onto each of the lower and upper punch surfaces by spraying the release agent upward and downward from the nozzle
Implementation Method 2
for the purpose of preventing adhesion or bonding of the molding material to the lower and upper punch surfaces
Data Source
AI summary
In a molded body production device, a release agent injection means applies a release agent onto an upper punch surface by injecting the release agent toward the upper punch surface in a state that an upper punch is located above an upper end surface of a molding die, and applies the release agent onto a lower punch surface and an inner circumferential surface exposing above the lower punch surface by injecting the release agent toward the lower punch surface in a state that the lower punch surface is located into the cavity and below the upper end surface of the molding die, before the molding material is filled into the cavity. This makes it possible to prevent the molding material from bonding to the upper punch surface, the lower punch surface and the inner circumferential surface defining the cavity.