Model Racing Track Perforated Contact Rail Injection Molding
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Solution Overview
Problem
Existing track sections for model vehicles are prone to mechanical instability, leading to detachment of the contact rail from the road element when frequently plugged and unplugged, requiring frequent repairs or replacement.
Innovation Solution
A track section design featuring a road element with perforations that integrate with a U-profile contact rail, ensuring a secure mechanical connection through partial penetration of the road element's material into the contact rail's perforations, preventing detachment and allowing for mass production using injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the contact rail is inserted into the road element and the protruding sections are bent over by hand to complete assembly, then the track section can be manufactured with simple means, but the contact rail may detach from the road element when sections are frequently connected and disconnected
Solution Approach 1:
The contact rail is pre-inserted into the road element during the injection molding process before the plastic material solidifies. The protruding sections are positioned in the recesses in advance, and the material flow penetrates through the perforations to secure the connection before final cooling and solidification occur.
Solution Approach 2:
The manual mechanical assembly process of inserting and bending the protruding sections by hand is replaced by an automated injection molding process. The plastic material itself performs the fastening function by flowing through the perforations and securing the contact rail, eliminating the need for subsequent manual bending operations.
2Ease of repair
If repairs are made by gluing or re-bending the U-shaped contact rail areas, then detachment can be temporarily fixed, but the repair measures are only of short duration and require repurchase
Solution Approach 1:
The invention creates a connection that is so durable and integrated that it eliminates the need for repairs altogether. The integral connection between road element and contact rail is designed to last the entire service life of the track section, making the product effectively non-disposable and eliminating the repair cycle.
3Reliability
If the contact rail is securely connected to the road element to prevent detachment, then mechanical stability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing of the road element and contact rail assembly is merged into a single injection molding operation. The contact rail is positioned within the mold cavity, and the plastic material is injected to form both the road element and the integral connection to the contact rail in one continuous process, eliminating separate assembly steps.
Solution Approach 2:
The injection molded plastic material serves multiple functions simultaneously: it forms the road surface structure, provides mechanical strength, and creates the securing connection to the contact rail through the perforations. This multi-functionality eliminates the need for separate fastening components or assembly operations.
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
The solution provides a stable and durable connection between the road element and contact rail, preventing detachment even with frequent use, and allows for efficient production of various track configurations, enhancing the mechanical stability and longevity of the track sections.
Implementation Method 1
This allows the material of the road element, particularly in an injection molding process, to flow into the perforation of the at least one contact rail
Data Source
Figure 1
AI summary
The invention relates to a roadway section (1) of a motor racing track for model vehicles, comprising a road element (2) which preferably forms a road for model vehicles and on which model vehicles can move, and comprising at least one contact rail (3a, 3b) for supplying power to said model vehicles, wherein the at least one contact rail (3a, 3b) has a perforation (4). The invention also relates to a method for producing a roadway section and to the use of an injection moulding tool for producing a roadway section (1) of a motor racing track for model vehicles.