Resin Molding Load Control for High-Precision Cavity Filling
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Solution Overview
Problem
The increasing demand for precision in resin molded articles necessitates a technology capable of producing such articles with higher precision.
Innovation Solution
A resin molding device and method that includes a lower mold, an upper mold with a vertically movable cavity block, a clamp mechanism, a transfer mechanism, and a controller for adjusting clamp and plunger loads after cavity filling to achieve precise resin molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional resin molding is used, then production is simpler and faster, but manufacturing precision is insufficient
Solution Approach 1:
The controller performs first final adjustment control to set the clamp load to a final clamp load before the cavity is completely filled, and performs second final adjustment control to set the plunger load to a final plunger load after the first adjustment is completed. This preliminary adjustment of loads before and during cavity filling prevents excessive pressure and cavity depth variations, thereby improving dimensional accuracy of the resin molded article.
Solution Approach 2:
The system dynamically adjusts the clamp load and plunger load during the molding process based on real-time conditions. The controller modifies the clamp load during cavity filling and adjusts the plunger load in response to cavity pressure changes, enabling adaptive control that maintains optimal molding conditions throughout the process to achieve high precision.
2Manufacturing precision
If clamp load is increased to improve precision, then manufacturing precision improves, but the cavity depth changes due to mold deformation
Solution Approach 1:
The controller performs first final adjustment control to set the clamp load to a final clamp load before the cavity is completely filled with resin material. This preliminary adjustment prevents excessive mold deformation that would otherwise change the cavity depth, thereby maintaining dimensional accuracy without requiring excessive clamp load.
Solution Approach 2:
The system dynamically adjusts the clamp load during the cavity filling process. The controller increases the clamp load as the cavity fills with resin material to compensate for increasing internal pressure, maintaining constant cavity depth and preventing shape changes while achieving high precision molding.
3Manufacturing precision
If plunger load is increased to improve filling, then manufacturing precision improves, but clamp load must be increased which causes cavity depth change
Solution Approach 1:
The controller performs first final adjustment control to set the clamp load to a final clamp load before the cavity is completely filled, and performs second final adjustment control to set the plunger load to a final plunger load after the first adjustment is completed. This sequential adjustment ensures that when plunger load is increased to improve filling, the clamp load has already been optimized to prevent cavity depth changes.
Solution Approach 2:
The system coordinates dynamic adjustment of both clamp load and plunger load during the molding process. The controller adjusts the plunger load in response to cavity pressure changes while simultaneously adjusting the clamp load to maintain constant cavity depth, enabling improved filling without shape changes.
Data Source
AI summary
A resin molding device includes: a lower mold on which a substrate is placed; an upper mold in which a cavity is formed by a side block and a cavity block provided so as to be capable of ascending and descending vertically with respect to the side block; a clamp mechanism which clamps the lower mold and the upper mold; a transfer mechanism which supplies a resin material to the cavity by a plunger; and a controller which performs first final adjustment control for adjusting a clamp load of the clamp mechanism to a final clamp load after the cavity has been filled with the resin material supplied from the transfer mechanism and which performs second final adjustment control for driving the plunger after the first adjustment control has been completed and thereby adjusting a plunger load applied to the plunger to a final plunger load.