Replaceable Injection Mold Inner Block for Piezoelectric Ceramic Ejection
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Solution Overview
Problem
The existing injection mold technology faces challenges in efficiently producing piezoelectric ceramic products with complex shapes and small sizes, as it requires multiple plastic molds, leading to high manufacturing costs and difficulties in mass production, and the long, thin ejecting pins are prone to deformation or breakage under load.
Innovation Solution
The injection mold design incorporates a replaceable inner block with an ejector and a driving unit, allowing for a shorter ejecting pin and improved temperature control, enabling the efficient removal of molded products with reduced aspect ratio and facilitating continuous molding and replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a common injection mold with a long ejecting pin is used to mold small piezoelectric ceramic products, then the product can be removed from the mold, but the ejecting pin becomes thin and long, causing deformation or breakage under load
Solution Approach 1:
The mold is divided into an upper holder block and a lower holder block, with the ejecting pin located in the lower holder block. This segmentation allows the ejecting pin to be positioned optimally for strength while maintaining its removal function.
Solution Approach 2:
The ejecting pin is positioned horizontally rather than vertically, changing the dimensional orientation. This allows the pin to be shorter while still effectively removing the product from the mold cavity.
2Ease of operation
If the lower holder block is made thick to accommodate a long ejecting pin for micro-sized molding, then the product can be ejected, but the ejecting pin necessarily becomes longer and more prone to deformation
Solution Approach 1:
The ejecting pin is repositioned horizontally in the lower holder block rather than extending vertically through the entire block thickness. This dimensional change allows effective ejection while minimizing pin length and avoiding deformation.
3Reliability
If high-strength material is used to manufacture an accurately machined ejecting pin to prevent deformation, then the reliability improves, but the manufacturing cost considerably increases
Solution Approach 1:
By repositioning the ejecting pin horizontally and shortening its length, the design achieves adequate strength with standard materials, avoiding the need for expensive high-strength materials while maintaining reliability.
Solution Approach 2:
The geometry and positioning parameters of the ejecting pin are optimized to reduce length and improve structural efficiency, allowing the use of cost-effective materials while maintaining sufficient strength and durability.
4Manufacturing precision
If multiple plastic molds are manufactured to mold multiple piezoelectric ceramic products, then each product can be molded individually, but the manufacturing cost and manufacturing time increase, making mass production difficult
Solution Approach 1:
The injection mold is designed with replaceable inner blocks that can be quickly swapped to produce different piezoelectric ceramic products. This universal design allows a single mold structure to serve multiple product types, enabling mass production while maintaining precision.
Solution Approach 2:
The mold incorporates quick-change components including replaceable inner blocks, ejecting pins, and cooling channels that can be rapidly exchanged. This dynamic reconfigurability allows the mold to adapt to different product requirements without complete replacement, significantly improving productivity.
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 configuration reduces the risk of ejecting pin deformation, enhances productivity, and allows for rapid replacement of components, improving the efficiency and cost-effectiveness of producing piezoelectric ceramic products with complex shapes.
Implementation Method 1
elastic members that are disposed between the lower block and the ejecting plate and provide elastic force to the ejecting plate
Implementation Method 2
a driving unit that is disposed under the ejector, moved up/down by hydraulic pressure or pneumatic pressure supplied from the outside, and drives the ejector
Implementation Method 3
moved up/down by hydraulic pressure or pneumatic pressure supplied from the outside
Implementation Method 4
cooling water ports that are formed at the outer block and through which cold water or hot water supplied from the outside circulates inside the outer block and controls the temperature of the outer block
Data Source
AI summary
An injection mold (1) may include: an outer block (100) that is mounted and fixed to an injection molding machine and divided into an upper mold (110) and a lower mold (120), an inner block (200) composed of an upper block (230) and a lower block (220) that are replaceably mounted on the upper mold (110) and the lower mold (120), respectively; a metal core (300) mounted in the inner block (200) and has a cavity (310) for forming a molded product (10) with a molded portion having a size of tens to hundreds of micrometers; an ejector (400) coupled to the inner block (200) and removes the molded product (10) in the cavity (310) by moving straight; a driving unit (500) disposed inside the lower mold (120) is moved up/down by hydraulic pressure or pneumatic pressure supplied from the outside, and drives the ejector (400).