Resin Molding Method Using Dual-Temperature Tablets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin molding techniques fail to sufficiently fill narrow spaces between a magnet hole and a magnet due to high viscosity of thermosetting resin at the later stages of filling, leading to incomplete filling.
Innovation Solution
A resin molding method and apparatus that injects thermosetting resin tablets at different temperatures, with a higher temperature tablet injected closer to the workpiece to maintain low viscosity and prevent early curing, allowing easier filling of narrow spaces by injecting a lower temperature tablet later.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermosetting resin is heated to even temperature in the pot and then pushed out by plunger to fill the magnet hole, then the resin can be injected into the magnet hole, but the viscosity of thermosetting resin becomes high during injection causing incomplete filling of narrow spaces
Solution Approach 1:
The resin pot is divided into multiple heating zones (first heating zone and second heating zone) with different temperature levels. The first heating zone maintains lower temperature to keep resin viscosity low for complete filling, while the second heating zone provides higher temperature to prevent premature curing. This segmentation allows simultaneous control of viscosity and curing prevention.
Solution Approach 2:
Different regions of the resin pot are assigned different thermal properties: the region near the plunger (second heating zone) is heated to higher temperature to prevent curing, while the region farther from the plunger (first heating zone) is heated to lower temperature to maintain low viscosity. This local quality differentiation resolves the contradiction between viscosity control and curing prevention.
2Reliability
If thermosetting resin is heated to high temperature to prevent curing, then curing is prevented, but viscosity increases making it difficult to fill narrow spaces
Solution Approach 1:
The heating system is segmented into two distinct zones with different temperature levels. The first heating zone operates at lower temperature to maintain low viscosity for narrow space filling, while the second heating zone operates at higher temperature to prevent curing. This segmentation allows both requirements to be met simultaneously in different regions.
Solution Approach 2:
The resin pot exhibits non-uniform thermal distribution with different heating intensities in different regions. The local quality of thermal environment is optimized: low temperature regions for viscosity control and high temperature regions for curing prevention, allowing the resin to satisfy both requirements during different phases of injection.
3Ease of manufacture
If uniform temperature heating is applied to the resin pot, then heating control is simple, but resin viscosity becomes non-uniform causing incomplete filling
Solution Approach 1:
The heating control system is segmented into multiple independent heating zones with separate temperature control. This allows different regions to be heated to different temperatures according to their specific requirements, achieving uniform filling while maintaining manageable control complexity through modular heating elements.
Solution Approach 2:
The temperature distribution in the resin pot is made non-uniform by design, with different heating intensities applied to different regions. This local quality optimization ensures that resin viscosity remains appropriate throughout the injection process, with cooler regions maintaining low viscosity and warmer regions preventing curing, thereby achieving complete and uniform filling.
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 ensures accurate and complete filling of insertion holes, including narrow spaces, by maintaining low viscosity of thermosetting resin during the injection process, thereby improving the filling accuracy and efficiency.
Implementation Method 1
a first tablet heating part that heats a first tablet formed of thermosetting resin to a first temperature; a second tablet heating part that heats a second tablet formed of thermosetting resin to a second temperature higher than the first temperature
Implementation Method 2
starting push-out by a plunger that slides in the pot and pouring the thermosetting resin into the insertion hole
Implementation Method 3
the magnet hole starts to be filled with thermosetting resin in a state in which thermosetting resin is heated to an even temperature in the pot. Further, thermosetting resin starts to be cured due to a heat in the magnet hole and the resin pot when it is injected into the magnet hole
Implementation Method 4
thermosetting resin that is melted in the resin pot is pushed out by a plunger, and the magnet hole is filled with thermosetting resin... the permanent magnet arranged inside can be fixed to the inside of the magnet hole
Data Source
AI summary
A resin molding method according to the present invention is a resin molding method that fills a space between an insertion hole provided in a workpiece and a member to be fixed inserted into the insertion hole with resin, the method comprising: injecting a first tablet formed of thermosetting resin having a first temperature into a position of a pot far from the workpiece, the pot pouring the resin into the workpiece and being provided in a molding die, injecting a second tablet formed of thermosetting resin having a second temperature higher than the first temperature into a position of the pot close to the workpiece; pouring the thermosetting resin into the insertion hole of the workpiece in an order of the second tablet and the first tablet by a plunger that slides in the pot.