Recirculating Manifold for Low-Viscosity Molding
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Solution Overview
Problem
Conventional injection molding systems face challenges in processing low-viscosity materials, particularly those with thermal sensitivity and multi-phase systems, especially when manufacturing smaller articles, as they are prone to thermal degradation and settling, which complicates the attachment of components like shaving aids to razors.
Innovation Solution
A method and apparatus that involve recirculating low-viscosity materials through a temperature-controlled manifold, using actuators to control injection valves for precise pressure injection into closed mold cavities, and incorporating a recirculation loop with a pump to maintain even distribution and prevent settling, allowing for the formation of small articles with minimized thermal degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding systems are used to process low-viscosity materials, then the materials can be injected into mold cavities, but the materials undergo thermal degradation and settling due to long residence times
Solution Approach 1:
The system continuously recirculates low-viscosity materials through the manifold and mold cavities, ensuring that materials are constantly moved and preventing settling or phase separation during the molding process. This continuous circulation maintains material homogeneity even for small injection volumes that would otherwise have long residence times.
2Volume of moving object
If the injection volume is reduced for smaller articles, then the articles can be manufactured with smaller dimensions, but the residence time increases causing thermal degradation and settling
Solution Approach 1:
By implementing continuous recirculation of the material through the manifold, the system ensures that even small injection volumes do not remain stationary for extended periods. The material is constantly refreshed and circulated, preventing thermal degradation and phase separation despite the small cavity sizes.
3Ease of manufacture
If low-viscosity materials are heated to reduce viscosity for injection, then the materials become easier to process, but thermal sensitivity of ingredients is exacerbated
Solution Approach 1:
The continuous recirculation system maintains material flow and prevents localized overheating or prolonged exposure to high temperatures. By constantly moving the material through the heated manifold, the system achieves adequate flow characteristics without subjecting thermally sensitive ingredients to excessive or prolonged thermal stress.
4Ease of manufacture
If multi-phase systems are heated and held for injection molding, then the materials can be processed, but settling of dispersed phase occurs
Solution Approach 1:
The continuous recirculation of multi-phase materials through the heated manifold prevents the dispersed phase from settling or separating. The constant motion and circulation maintain uniform phase distribution throughout the material, ensuring consistent product quality even for thermally sensitive multi-phase systems.
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 approach effectively reduces thermal degradation and settling of low-viscosity materials, enabling the efficient molding of small articles and their attachment to other components, such as shaving aids on razors, while maintaining material homogeneity and preventing product solidification issues.
Implementation Method 1
recirculating low-viscosity materials prior to injecting into one or more closed cavities
Implementation Method 2
moving a material through a temperature controlled manifold
Implementation Method 3
temperature controlled manifold
Implementation Method 4
moving a material through a temperature controlled manifold
Implementation Method 5
injecting the material at a controlled pressure into the one or more mold cavities
Implementation Method 6
injecting the material at a controlled pressure
Implementation Method 7
The plurality of mold cavities can be opened and the one or more molded articles can be removed from the plurality of mold cavities
Data Source
AI summary
A method of molding a personal care product, a manifold, and a cosmetic product molding apparatus are provided. In one embodiment, the method of molding a personal care product comprises: moving a material through a temperature controlled manifold, opening one or more injection valves between the temperature controlled manifold and one or more mold cavities, injecting the material at a controlled pressure into the one or mold cavities in a closed position to form one or more articles, closing the one or more injection valves between the temperature controlled manifold and one or more mold cavities after injecting the material into the one or more mold cavities, opening the one or more mold cavities, and removing the one or more articles from the one or more mold cavities.