Over-molded Component Assembly with Collapsible Core
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Solution Overview
Problem
The injection molding process struggles to create complex features like undercut portions efficiently, requiring costly secondary machining operations that increase processing time and labor.
Innovation Solution
An over-molding method where an insert member with a predetermined feature, such as an undercut portion, is molded into a component part using materials like glass-filled polypropylene, eliminating the need for secondary machining by integrating the feature directly during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If secondary machining operations are used to create complex features like undercut portions, then manufacturing precision and feature complexity are improved, but production cost and processing time increase
Solution Approach 1:
The patent merges the secondary machining operation with the primary injection molding process by integrating the undercut feature creation into the molding cavity design. The collapsible core mechanism allows the mold to dynamically change shape during ejection, combining what were previously separate operations into one integrated process, thereby eliminating additional machining steps and reducing production costs.
Solution Approach 2:
The patent applies dynamics by using a collapsible core that can change its geometric configuration during the molding process. The core transitions from a rigid structure during injection to a flexible, collapsible structure during ejection, enabling the removal of complex features like undercut portions without requiring secondary machining operations.
2Manufacturing precision
If secondary machining operations are used to create complex features, then manufacturing precision is improved, but processing time and labor costs increase
Solution Approach 1:
The patent combines the creation of complex features directly into the injection molding process through a specially designed collapsible core. This integration eliminates the need for separate secondary machining operations, thereby reducing total processing time while maintaining the required manufacturing precision for complex features like undercut portions.
Solution Approach 2:
The collapsible core is pre-configured within the mold cavity before injection begins. The core's ability to collapse during ejection is built into the mold design, allowing complex features to be formed during the initial molding process rather than requiring subsequent machining operations, thus saving time.
3Device complexity
If traditional molding processes are used without collapsible cores, then device complexity is reduced, but the ability to create complex features like undercut portions is limited
Solution Approach 1:
The patent introduces a collapsible core that transforms the static mold structure into a dynamic system. The core can change its geometric configuration during the ejection phase, enabling the creation of complex features like undercut portions that would be impossible with traditional rigid molds, while adding only moderate complexity to the overall device.
Solution Approach 2:
The mold cavity is segmented into multiple sections, including the collapsible core that can independently change shape. This segmentation allows the core to collapse during ejection while the rest of the mold remains stable, enabling complex feature creation without requiring complete redesign of the entire molding 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 approach reduces costs and processing time by allowing complex features to be integrally formed, enabling snap-fit joints with strong structural integrity and avoiding the need for secondary operations.
Implementation Method 1
injecting a material into the mold cavity to form an over-molded portion
Data Source
AI summary
A component part has an over-molded integrally formed insert member. The insert member has a predetermined feature. In addition, an end portion of the predetermined feature is exposed and free from over-molding.