Overmoulding Holding Element for Component Positioning
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Solution Overview
Problem
Existing overmoulding devices face challenges in effectively guiding and positioning components during the plastic injection process, particularly in ensuring precise control over the inflow of plastic and achieving efficient encapsulation without complex constructions or multiple steps.
Innovation Solution
A device with a single sleeve-shaped holding element and a tool part design that includes a feed area for the plastic, allowing radial flow around the component, and a controllable injection channel to manage the plastic inflow, ensuring good guidance and positioning of the component during overmoulding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single holding element is used to position the component, then the device complexity is reduced, but the guidance and positioning precision of the component deteriorates
Solution Approach 1:
The single holding element is designed to perform multiple functions: it serves as both a positioning element and a guide for the component, while also influencing the plastic inflow pattern. This multi-functional design allows one element to replace what would traditionally require multiple separate components, reducing device complexity while maintaining positioning precision through careful geometric design of the holding element's interaction surfaces
Solution Approach 2:
The holding element features locally optimized geometric characteristics at different positions: a first interaction surface for positioning the component in the closing direction, and a second interaction surface for guiding the component in the opening direction. These localized functional zones allow the single element to provide precise guidance throughout the molding cycle without requiring additional components
2Manufacturing precision
If the holding element is designed to influence plastic inflow, then the encapsulation quality is improved, but the load on the holding element increases
Solution Approach 1:
The holding element's interaction with the plastic material is designed to be dynamic rather than static. The geometric features of the holding element are optimized to naturally guide the plastic flow pattern during injection, allowing the element to influence encapsulation quality through its shape rather than requiring active force application. This reduces the mechanical load on the holding element while maintaining control over the plastic inflow and encapsulation quality
3Device complexity
If plastic flows directly around the component, then the injection process is simplified, but the load on the connection between holding element and component increases
Solution Approach 1:
The holding element incorporates locally optimized geometric features that intercept and redirect the plastic flow. By positioning these features at specific locations on the holding element, the design creates a controlled flow pattern where plastic is guided around the component in a predetermined path. This local flow control prevents direct high-velocity impact on the component-holding element connection, reducing the load on this critical interface while maintaining a relatively simple injection process
Data Source
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AI summary
The invention relates to a device (10; 10a) for encapsulating a component (1) with plastic material (2), comprising at least two tool parts (11, 12), which in a closed arrangement for encapsulating the component (1) form a receptacle (15) for the component (1), an injection channel (30) for supplying the liquefied plastic material (2) to the region of the receptacle (15), and a single retaining element (22) for positioning the component (1) in the receptacle (15), wherein the retaining element (22) can be moved in a first position for positioning the component (1) in the receptacle (15) and in a second position for preferably completely encapsulating the component (1) with the plastic material (2). According to the invention, the retaining element (22) holds the component (1) in the region of the receptacle (15) by means of form positive and/or clamping engagement.