Molding Apparatus for Sheet Insert Placement
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Solution Overview
Problem
Conventional methods face difficulties in accurately placing sheet-like insert materials in molds, leading to issues like mold damage and reduced strength at the edges of resin molded products due to frayed fiber threads and inadequate incorporation of reinforcing materials.
Innovation Solution
A molding apparatus and method that involves a transfer device to deform the sheet-like insert material within the mold, allowing it to be precisely positioned, and an injection device to inject molding material, ensuring the insert material is securely integrated and glued during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sheet-like insert material is simply placed on the surface of the mold cavity, then the placement process is simple, but the insert material cannot be accurately positioned at desired locations
Solution Approach 1:
The insert material is deformed and positioned in advance before the molding process begins. The transfer device deforms the sheet-like insert material into a predetermined shape and places it at a predetermined position within the mold cavity before the molding material is injected, ensuring accurate positioning while maintaining operational simplicity.
2Shape
If textile sheets are cut into desired shapes before production, then the sheets can be shaped to fit the mold, but the edges fray and fiber threads come apart causing mold damage
Solution Approach 1:
The physical state of the insert material is changed by heating it to a temperature where it becomes pliable or melts. This parameter change allows the material to be deformed into the desired shape without causing fiber fraying or separation. The heated material can be shaped and then cooled to maintain its form, eliminating the harmful fraying effect while achieving the required shape conformity.
3Productivity
If the insert material is not deformed and placed carefully, then the placement process is fast, but the insert material cannot be positioned at desired locations leading to quality issues
Solution Approach 1:
The transfer device performs preliminary deformation and positioning of the insert material before the main molding process. By pre-shaping and pre-positioning the insert material according to the desired configuration, the system achieves both speed and precision - the material is rapidly placed while maintaining accurate positioning at the desired location within the mold cavity.
4Device complexity
If resin material is injected without the insert material being deformed, then the molding process is simple, but the insert material is not securely integrated into the molded product
Solution Approach 1:
The insert material is heated to change its physical parameters, making it pliable or melt it to a specific temperature range. This parameter change enables the material to be deformed and securely integrated into the molded product structure. When the molding material is injected, the heated insert material maintains its deformed shape and creates strong integration bonds, while the process remains relatively simple overall.
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 enables easy placement of sheet-like insert materials at predetermined positions within the mold, enhancing the strength and stability of the molded products by ensuring the reinforcing material is fully integrated and securely bonded, thus improving the overall quality and mechanical strength.
Implementation Method 1
by injection of the molding material into the mold during the molding step, the end of the insert material and the part of the insert material overlapped with each other are glued
Data Source
AI summary
A method for producing a molded product 70 involves the use of an insert material 80. The method for producing the molded product 70 includes a transfer step for transferring the insert material 80 into a mold 40 using a transfer device 87; a placement step for placing the insert material 80 in the mold 40 by deforming the insert material 80 in the mold 40; and a molding step for injecting a molding material into the mold 40, thereby producing the molded product 70 having the insert material 80.