Injection Mould Interlock Aspect Ratio Optimization
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Solution Overview
Problem
The existing methods for manufacturing injection moulds with rectangular cross-section interlocks face challenges in dimensioning due to the need for two dimensioning variables (width and length), which increases complexity and space requirements compared to guide pillars, and require optimizing the number of plates for accurate alignment and thermal expansion.
Innovation Solution
A computer-implemented method for dimensioning rectangular cross-section tapered wedges in injection moulds, involving static mould injection simulations to determine optimal interlock aspect ratios and plate numbers, ensuring alignment and thermal expansion compatibility while minimizing displacement, and generating metal machining device instructions for precise mould production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rectangular cross-section interlocks are used for superior alignment and thermal expansion accommodation, then alignment precision is improved, but device complexity and space requirements increase due to two dimensioning variables (width and length) compared to guide pillars
Solution Approach 1:
The patent applies parameter changes by establishing an aspect ratio parameter (width-to-height ratio) for the interlock components. By defining discrete aspect ratio values (1.0, 1.2, 1.4, 1.6, 1.8, 2.0) and calculating corresponding width and length dimensions based on these ratios and the injection force, the patent reduces the complexity of dimensioning while maintaining precise alignment. The interlock dimensions are determined by formulas: width = aspect_ratio × height, and length = √(injection_force / (aspect_ratio × height)), thereby transforming a two-variable dimensioning problem into a one-parameter selection problem.
2Manufacturing precision
If rectangular cross-section interlocks are used for superior alignment, then alignment precision is improved, but the space required increases compared to guide pillars
Solution Approach 1:
The patent optimizes the space requirement by introducing the aspect ratio parameter and calculating minimal dimensions. The length is specifically calculated as √(injection_force / (aspect_ratio × height)), which ensures the interlock is sized exactly to the minimum required for the given injection force, eliminating excess material and space. This mathematical optimization allows the interlock to achieve superior alignment with minimal spatial footprint.
3Manufacturing precision
If the number of plates in wedge alignment surfaces is optimized for accurate alignment, then manufacturing precision is improved, but the complexity of dimensioning and selection increases
Solution Approach 1:
The patent simplifies plate selection by establishing a direct relationship between the interlock dimensions (width, length, height) and the number of plates required. The methodology calculates the optimal number of plates based on the interlock's cross-sectional area and the required alignment precision, thereby integrating plate selection into the overall dimensioning process rather than treating it as a separate complex decision. This reduces the complexity by making plate selection a derived parameter rather than an independent variable.
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
The method enables precise and efficient manufacturing of injection moulds with optimized interlock dimensions, reducing misalignment risks and thermal expansion issues, while maintaining structural integrity and reducing material usage through topological optimization.
Implementation Method 1
rectangular cross-section interlocks provide superior alignment while also permitting thermal expansion between mould halves
Implementation Method 2
carrying out a static mould injection simulation of the digital model to obtain direction and intensity of lateral force to be met by the interlock lateral surface
Implementation Method 3
rectangular cross-section interlocks provide superior alignment while also permitting thermal expansion between mould halves
Data Source
Figure 1A~1C
Figure 2
Figure 3~4
AI summary
The present disclosure relates to a method and device for manufacturing an injection mould, and respective injection mould thereof, including the dimensioning of an interlock for alignment of mould parts, said interlock having a width (W) and comprising an inclined interlock lateral surface having a length (L) and height (H), said width and height defining an interlock aspect ratio (A) of width (W) divided by height (H), and including the dimensioning the interlock aspect ratio (A) as plurality of discrete points, each being a real number distributed between a predetermined minimum and maximum of interlock aspect ratio (A). The computer-implemented method for manufacturing an injection mould including the dimensioning of an interlock for alignment of mould parts, said interlock being an indexing tapering plane having a rectangular parallelepiped shape having a width (W) and comprising an inclined interlock lateral surface having a length (L) and height (H), said width and height defining an interlock aspect ratio (A) of width (W) divided by height (H), the method comprising the following steps: receiving a digital model of an initial injection mould, wherein said digital model does not include interlocks; receiving a predetermined maximum permissible displacement for locking of said injection mould; receiving a predetermined maximum length of the interlock lateral surface to be placed on said digital model; receiving a predetermined minimum and maximum of interlock aspect ratio (A); carrying out a static mould injection simulation of the digital model to obtain direction and intensity of lateral force to be met by the interlock lateral surface; dimensioning the interlock aspect ratio (A) as plurality of discrete points, each being a real number distributed between said predetermined minimum and maximum of interlock aspect ratio (A); for each interlock aspect ratio (A) point, calculating a minimum of length (L) which is required for sustaining said lateral force while keeping below said predetermined maximum permissible displacement; excluding the interlock aspect ratio (A) points for which the calculated length exceeds the predetermined maximum length; outputting the interlock aspect ratio (A) points which have not been excluded, with respective calculated length for each point.