Net-Shape Plastic Pump Housing Mold Design
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Solution Overview
Problem
Conventional methods for manufacturing plastic pump housings for food applications require significant secondary machining, which exceeds the allowed glass fiber exposure limits and increases costs, making them unsuitable for high-temperature conditions.
Innovation Solution
A method using molds and cores configured to produce net-shape molded plastic pump housings with non-intersecting geometry fluid ports, eliminating the need for extensive secondary machining and maintaining glass fiber exposure within regulatory limits, involving a specific assembly and pulling process of molds and cores to form the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional molds and molding techniques are used to manufacture plastic pump housings, then manufacturing cost is reduced, but significant secondary machining is required which exceeds glass fiber exposure limits
Solution Approach 1:
The mold cavity and core are designed with pre-configured non-intersecting fluid ports that eliminate the need for secondary machining. The mold includes a first cavity with first and second fluid ports, and a first core with a fluid passage that defines a third fluid port, all configured to be non-intersecting to prevent glass fiber exposure during machining operations.
Solution Approach 2:
The mold is divided into separate components including a first mold half, a second mold half, and a first core, allowing each to be optimized independently. The first core is positioned within the first cavity and includes an interior surface that defines the pump housing interior, while the fluid ports are segmented into different locations to avoid intersection.
2Ease of manufacture
If plastic materials are used instead of conventional brass and stainless steel, then cost is reduced and lead is eliminated, but the materials must withstand high temperature conditions exceeding 300 degrees F
Solution Approach 1:
The patent utilizes plastic materials that can be formulated to withstand high temperature conditions exceeding 300 degrees F, replacing conventional brass and stainless steel materials. The plastic material is selected or engineered to provide both cost advantages and the necessary thermal resistance for food applications.
3Temperature
If glass filled plastics are used for high temperature resistance, then temperature capability is improved, but glass fiber exposure on wetted surfaces exceeds NSF International limits
Solution Approach 1:
The mold and core are designed to produce a net-shape molded housing where the fluid ports are non-intersecting, eliminating the need for secondary machining operations that would expose glass fibers on wetted surfaces. This preliminary design configuration ensures compliance with NSF International limits before the housing leaves the mold.
4Manufacturing precision
If secondary machining is performed on molded plastic housings, then dimensional accuracy is improved, but glass fiber exposure on interior surfaces increases beyond acceptable limits
Solution Approach 1:
The mold cavity and core are designed with precise dimensions and non-intersecting fluid port configurations that produce the final net-shape housing directly. This preliminary configuration achieves the required dimensional accuracy without requiring secondary machining operations that would expose glass fibers on the interior wetted surfaces.
Data Source
AI summary
A method of making a pump housing that is net-molded and immediately assumes its final shape and design specification without requiring more than de minimis secondary machining processes. The method utilizes molds and cores configured such that none of the fluid ports of the housing produced using the molds and cores have any intersecting geometry. The net-molded pump housing may also include a cross-tube insert providing flow communication between a fluid inlet port and a pressure relief port.