Outer shell for a dispenser
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Solution Overview
Problem
Conventional dispenser outer shells face issues with distortion and weak seams, leading to potential cracking under impact, and injection molding processes often result in overflow of plastic material, creating ridges on the inner surface which can obstruct product dispensing.
Innovation Solution
The outer shell is designed with recesses on the first component part that engage with protrusions in the mold to fix its position, preventing displacement and overflow during the injection of the second component part, ensuring a strong and smooth seam by using a two-component injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the first component part is retained in the mould during injection molding of the second component part, then the seam strength is improved, but the first component part may displace causing overflow of plastic material
Solution Approach 1:
The patent applies preliminary action by forming recesses in the first component part before the injection molding of the second component part. These recesses are specifically designed to engage with protrusions on the molding tool, pre-positioning the first component part to prevent displacement during subsequent injection processes. This preliminary positioning action ensures both strong seam formation and prevents plastic material overflow.
2Ease of manufacture
If the first component part is joined end-to-end with the second component part, then the outer shell can be formed, but the seam lacks sufficient strength to withstand impact forces
Solution Approach 1:
The patent applies local quality by creating recesses at specific locations on the first component part where it joins with the second component part. These locally modified regions with recesses engage with corresponding protrusions on the molding tool, creating localized strengthening zones. This allows the seam to withstand impact forces while maintaining the overall end-to-end joining approach for ease of manufacture.
3Manufacturing precision
If the first component part position changes during injection molding, then overflow of plastic material occurs, but fixing the position requires additional structural features
Solution Approach 1:
The patent applies segmentation by dividing the positioning function into multiple discrete recesses distributed on the first component part. Rather than using a single complex fixing structure, the positioning is achieved through several segmented recesses that collectively engage with protrusions on the molding tool. This segmented approach provides effective positioning while keeping the overall structure relatively simple.
Data Source
AI summary
An outer shell for a dispenser and a method for making same are provided, the outer shell including first and second injection molded plastic component parts. The first and second component parts each include an outer surface and an inner surface, with the first component part having a first mating surface directed to the outer surface of the first component part and the second component part having a second mating surface directed to an inner surface of the second component part. The first and second component parts are joined to each other along a seam by mating the first mating surface and the second mating surface during injection moulding. A plurality of recesses is formed in the inner surface of the first component part along the seam and/or on a gate protrusion extending away from a free end of the first mating surface of the first component part.