Pneumatic Tool Ventilation Module Segmentation
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Solution Overview
Problem
The manufacturing of pneumatic tool housings using sand core molds often results in defects due to inappropriate sand burial or inadequate sand core strength, leading to non-uniform air control channels and reduced yield rates.
Innovation Solution
The introduction of a ventilation module within the housing, manufactured separately and integrated through injection molding with plastic steel, ensures precise sizing and communication with air channels, replacing traditional sand core methods and reducing human error and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sand core mold is used to manufacture air control channel, then housing can be manufactured with integrated air channels, but defects occur due to inappropriate sand burial or inadequate sand core strength
Solution Approach 1:
The air control channel is segmented from the housing structure. Instead of forming the air control channel directly in the housing through sand core mold, a separate ventilation module is manufactured and then integrated into the housing. This segmentation allows the ventilation module to be produced with higher precision using alternative methods while the housing can be manufactured independently, thereby resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The ventilation module serves as an intermediary component that replaces the problematic sand core mold process. By introducing this separate module with air inlet, air outlet, and ventilation space, the patent eliminates the need for sand burial and sand core strength issues while maintaining the functional air control channel. The module is connected to the housing through injection molding, providing a reliable connection without sand-related defects.
2Device complexity
If sand core mold is used for air control channel, then housing structure can be simplified, but yield rate decreases due to manufacturing defects
Solution Approach 1:
By dividing the air control function into a separate ventilation module, the patent eliminates the high-defect sand core molding process while maintaining structural simplicity. The module can be manufactured with higher yield using alternative methods and then integrated through injection molding, thus improving overall productivity without significantly increasing device complexity.
Solution Approach 2:
The patent changes the manufacturing parameters and methods for the air control channel from sand core molding to an alternative process for the ventilation module, followed by injection molding integration. This parameter change eliminates the root cause of defects (sand burial issues and sand core strength problems) while maintaining the functional requirements, thereby increasing the yield rate.
3Manufacturing precision
If ventilation module is manufactured separately and integrated through injection molding, then manufacturing precision of air channels is improved, but device complexity increases
Solution Approach 1:
The ventilation module acts as a pre-manufactured intermediary component that ensures high manufacturing precision for the air channels. By producing this module separately with controlled dimensions and then integrating it through injection molding, the patent achieves precise air channel formation while managing complexity through modular design. The injection molding process creates reliable connections without requiring complex assembly procedures.
Solution Approach 2:
The patent combines the ventilation module integration with the housing manufacturing process through injection molding. This merging of the module attachment step into the existing injection molding process minimizes additional complexity while ensuring precise positioning and secure connection of the ventilation module to the housing structure.
Data Source
AI summary
An air supply structure of a pneumatic tool includes a housing and a ventilation module. The housing includes an operating portion including an air chamber, a connecting portion including an accommodating space, and a holding portion including an air entering channel and an air exiting channel. The accommodating space is in communication with the air chamber, the air entering channel and the air exiting channel. The ventilation module, disposed in the connecting portion, includes an air inlet in communication with the air entering channel, an air outlet in communication with the air exiting channel, a first air opening in communication with the air chamber, a second air opening in communication with the air chamber, and a ventilation space. Thus, the size of the ventilation space of the ventilation module of individual pneumatic tools is ensured to be uniform to increase the manufacturing yield rate.