Molding Tool Controllable Setting Elements for Micrometer Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional molding tools face challenges in achieving precise adjustments and maintaining micrometer-level tolerances, particularly when producing optical elements like lenses, due to gaps during mold core insertion and limited angle correction capabilities, leading to difficulties in producing workpieces with tight tolerances.
Innovation Solution
The introduction of controllable setting elements within the molding tool, which include adjustable elements that can be moved to engage or release the mold core, allowing for precise positioning and tilting without disassembly, and hydraulic expansion clamping for accurate adjustments, enabling precise alignment and angle correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding tools use simple spacer plates for mold core adjustment, then the device complexity is low, but the manufacturing precision cannot achieve micrometer-level tolerances
Solution Approach 1:
The adjustment mechanism is segmented into multiple independent adjusting elements distributed around the mold core, allowing localized and precise control of the mold core position without requiring complex overall structure
Solution Approach 2:
The patent replaces simple mechanical spacer plates with controllable adjusting elements that can provide precise positioning through controlled movement, achieving micrometer-level precision without proportionally increasing mechanical complexity
2Manufacturing precision
If the molding tool requires disassembly for mold core adjustment, then the device complexity is reduced, but the loss of time increases due to repeated assembly and disassembly
Solution Approach 1:
The adjusting elements are designed to be movable and controllable during operation, enabling dynamic adjustment of the mold core position without disassembly, thus saving time while maintaining precision
Solution Approach 2:
The mold core itself is equipped with engagement features that work with the adjusting elements, allowing the system to self-adjust without requiring external disassembly or complex intervention
3Manufacturing precision
If conventional molding tools lack angle correction capability, then the device complexity is low, but the manufacturing precision of optical elements deteriorates
Solution Approach 1:
The adjusting elements are positioned at different locations around the mold core, enabling localized adjustment that can correct angular deviations while keeping the overall structure relatively simple
Solution Approach 2:
The adjustment mechanism operates in multiple dimensions (radial and angular positions of different adjusting elements), allowing angle correction through positional adjustments rather than requiring complex rotational mechanisms
4Ease of operation
If the molding tool uses simple guide columns for alignment, then the device complexity is low, but the measurement precision of mold core position deteriorates
Solution Approach 1:
The adjusting elements act as intermediaries between the simple guide column alignment system and the mold core, providing fine-tuning capability that enhances position accuracy without complicating the overall alignment system
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 solution allows for reproducible positional accuracy of less than 10 μm, facilitating the production of optical elements with improved precision and reduced need for disassembly, enhancing the molding tool's capability to produce parts with tight tolerances.
Implementation Method 1
the receptacle for the mold core (3) being free of undercuts and/or being provided with controllable adjusting elements (11, 12, 13), in particular hydraulic expansion clamping elements
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to molding tools, in which a position of a molding tool (3) within a base tool (1) or a position of molding cores relative to each other can be set by adjusting a position of base tools (1A, 1B) by means of controllable adjustment elements (11, 2, 13, 15, 17).