Integrally Molded Passive Horn Using Thermoplastic Vulcanized Rubber
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Solution Overview
Problem
The traditional preparation process of passive horns involves multiple steps, resulting in low production efficiency, waste, environmental pollution, and uneven bonding lines due to manual assembly and the use of thermoformed materials.
Innovation Solution
A passive horn is integrally formed using thermoplastic vulcanized rubber, where the sealing ring, folding ring, and vibrating membrane are injection-molded into a single structure, with a T-shaped inner casing and inverted T-shaped iron piece, using injection-molding with thermoplastic vulcanized rubber and composite PP and glass fiber materials, to create a stable and seamless assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional multi-step processing method is used for passive horns, then various components can be separately processed, but production efficiency is low and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate components (hard rubber shell, folding ring, iron piece, vibrating membrane) into a single integrally molded structure. The injection molding process forms all these elements as one unified part, eliminating the need for separate processing steps, assembly operations, and multiple material applications. This directly resolves the contradiction by combining multiple components into one, thereby improving productivity while reducing processing complexity.
2Ease of manufacture
If thermoformed rubber material is used for folding ring, then the component can be formed, but scrap cannot be reused causing material loss
Solution Approach 1:
The patent changes the material parameter from thermosetting rubber to thermoplastic vulcanized rubber. This parameter change enables the material to be processed by injection molding, which allows for recycling of scrap material. The thermoplastic nature permits re-melting and re-processing of any scrap generated during manufacturing, thereby maintaining ease of manufacture while eliminating material loss.
3Reliability
If surface treatment and adhesive coating are applied, then components can be protected and bonded, but volatiles cause environmental pollution
Solution Approach 1:
The patent eliminates the need for separate surface treatment and adhesive coating steps by integrating all bonding functions into the integral molding process. The thermoplastic vulcanized rubber material inherently provides both structural integrity and bonding capability in a single piece, removing the harmful volatile emissions associated with traditional surface treatments and adhesives while maintaining reliable connections between components.
4Ease of manufacture
If manual bonding is used for assembly, then components can be joined, but boundary lines become uneven affecting appearance
Solution Approach 1:
The patent merges all components into a single integrally molded structure, eliminating manual bonding operations entirely. The injection molding process creates seamless transitions between what would have been separate components, ensuring perfectly uniform boundaries and surfaces without the irregularities introduced by manual assembly. This maintains ease of manufacture through automated molding while achieving superior manufacturing precision.
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 simplifies the structure, enhances sealing, reduces labor costs, improves production efficiency, and eliminates bonding lines, resulting in a high-quality, efficient, and environmentally friendly product.
Implementation Method 1
injecting a molten plastic raw material into the mold while injection-molding a first outer casing, a second outer casing and wrapping an inner casing with an iron piece
Implementation Method 2
the pressure of the injection molding is 40-200 MPa
Implementation Method 3
The temperature of the injection molding is 180-350 degrees Celsius
Implementation Method 4
after completing the injection-molding, adding water to cool to mold the product
Data Source
AI summary
A passive horn integrally formed using thermoplastic vulcanized rubber includes a first outer casing, a second outer casing, an inner casing and an iron piece. The first outer casing includes a sealing ring, a folding ring and a vibrating membrane, and the sealing ring, the folding ring and the vibrating membrane are integrally injection molded into the first outer casing. A groove is disposed in the second outer casing, and the first outer casing is disposed in the groove. The back surface of the vibrating membrane is provided with a casing groove sequentially embedded with the inner casing and the iron piece. Furthermore, a preparation method of a passive horn integrally formed using thermoplastic vulcanized rubber, which, under the condition of integrated injection molding, may improve the yield rate, ensure product quality, save assembly time and labor cost, and improve production efficiency.