Molding Assembly With Breakable Core Bonds for Ring Sleeve Isolation
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Solution Overview
Problem
Existing molding assembly technologies face challenges in isolating connected parts of a component without causing damage, as the process of breaking bonds between integrated parts is cumbersome and unsatisfactory for users.
Innovation Solution
A method of manufacturing a component using a molding assembly that involves placing a core with recesses inside a mold to create separate cavities, allowing the molding material to set and form bonds between the main body and ring sleeve, and then removing the core to break these bonds, thus isolating the parts efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molding material is injected to form integrated parts with bonds, then manufacturing efficiency is improved, but user satisfaction deteriorates due to damage during isolation
Solution Approach 1:
The patent applies preliminary action by pre-defining fracture surfaces and separation planes during the molding process itself. The molding assembly includes predetermined separation planes that allow parts to be cleanly separated later without damage. This preliminary preparation eliminates the need for damaging post-manufacturing isolation while maintaining manufacturing efficiency.
2Ease of manufacture
If additional processes like grinding are used to break bonds, then part isolation is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the bond-breaking function from separate post-processing steps and integrates it into the molding process itself. The molding assembly directly creates predetermined separation planes that enable clean part isolation without requiring external grinding or breaking equipment, thereby reducing manufacturing process complexity.
3Productivity
If cores with openings are used to form bonds, then simultaneous casting is achieved, but bond breaking becomes necessary
Solution Approach 1:
The patent applies preliminary action by pre-defining fracture surfaces and separation planes during the molding process itself. The molding assembly includes predetermined separation planes that allow parts to be cleanly separated later without damage. This preliminary preparation eliminates the need for damaging post-manufacturing isolation while maintaining manufacturing efficiency.
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 enables the simultaneous and trouble-free manufacturing of multiple-piece components by hiding the fracture surfaces within the component, providing a simple, efficient, and user-friendly process.
Implementation Method 1
allowing the molding material to set inside the mold around the core within the first cavity and the second cavity to form a main body and at least one ring sleeve of the component
Data Source
AI summary
A method of manufacturing a component (124) having a main body (116) and at least one ring sleeve (118) through a molding assembly (100), the method comprising: providing a mold (102) having an inlet (115) and defining a hollow portion (H); placing at least one core to form a free-space (104, 106) within the component (124) inside the mold (102) to bifurcate the hollow portion (H) into a first cavity and a second cavity; pouring a molding material (117) inside the mold (102) through the inlet (115); allowing the molding material (117) to set inside the mold (102) around the core within the first cavity and the second cavity to form a main body (116) and at least one ring sleeve (118) of the component (124); connecting the first cavity and the second cavity and forming at least one first bond and one second bond (130, 132, 134, 136) between the main body (116) and the at least one ring sleeve (118); and removing the at least one core from at least part of the hollow portion (H) within the mold (102); characterized in that: providing the core with at least one recess allowing the molding material (117) to flow therethrough such that on withdrawing the core out of the mold (102), at least one first bond (130, 132) breaks and on withdrawing the core outside the mold (102), at least one second bond (134, 136) breaks.