Movable Magnet Insert Retention in Injection Molding
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Solution Overview
Problem
Existing methods for retaining metal inserts during the molding of profiled beads in glazing are expensive and require complex electrical systems, making them costly and difficult to use, and often result in surface marks or deformation.
Innovation Solution
A process using movable magnets positioned within the molding cavity to attract and retain ferromagnetic inserts through the internal surface, eliminating the need for external seals and complex electrical equipment, allowing for simple and cost-effective retention and easy demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electromagnet is used to retain the metal insert during molding, then the insert can be reliably retained, but the manufacturing and operational costs increase due to complex electrical control systems
Solution Approach 1:
The patent replaces the electromagnet (electrical system) with a permanent magnet (mechanical/magnetic system). The permanent magnet is integrated into the mold cavity and retains the ferromagnetic insert through magnetic attraction without requiring electrical power supply or control systems, thereby eliminating the complexity associated with electromagnets while maintaining reliable insert retention.
2Device complexity
If a permanent magnet is used to retain the insert, then the system becomes simpler and cheaper, but the insert cannot be easily removed from the mold
Solution Approach 1:
The patent makes the magnet movable between two positions: an active position where it attracts and retains the insert during molding, and an inactive position where it is moved away from the mold cavity to allow easy removal of the insert with the molded profiled bead. This dynamic positioning resolves the contradiction between retention reliability and ease of removal.
3Reliability
If the magnet is positioned close to the insert for strong attraction, then retention is improved, but surface marks and deformation may occur on the insert
Solution Approach 1:
The patent introduces a non-ferromagnetic intermediary element (such as a plastic or metal barrier) between the magnet and the ferromagnetic insert. This intermediary transmits the magnetic attraction force while preventing direct contact between the magnet and the insert surface, thereby maintaining strong retention without causing surface marks or deformation.
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 provides reliable and inexpensive retention of ferromagnetic inserts during molding, preventing surface marks and deformation, and facilitates easy demolding through magnetic repulsion, reducing manufacturing and operational costs while avoiding complex equipment issues.
Implementation Method 1
a magnet which is movable between two positions, an active position A in which it exerts an attractive force on said insert through the internal surface of the molding cavity
Implementation Method 2
facilitates easy demolding through magnetic repulsion
Data Source
Figure 1
Figure 2(I)~3(A)
Figure 4(I)~5
AI summary
The invention relates to a method for moulding a profiled bead (3), in particular along the periphery of a window (4), or moulding a window made from plastic, in which a plastic material forming the profiled bead (3) or the plastic window is introduced into a mould cavity in which at lest one ferromagnetic insert (2), such as a trim, has been placed. The invention is characterised in that the insert (2) is held in place in the mould cavity (5) during the introduction of the plastic material by means of at least one magnet (40) which can move between two positions, namely: an active position, A, in which it exerts a force of attraction on the insert (2) through the inner surface of the mould cavity, and an inactive position, I, in which it does not exert a force of attraction on the insert (2).