Synthetic Resin Molding Segmentation for Uniform Thickness
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Solution Overview
Problem
Conventional compression molding methods for synthetic resin moldings face challenges in achieving uniform quality and thickness, particularly in molding thick resin components like medical plug bodies, where inconsistent resin feeding and shaping lead to defects such as burrs or incomplete moldings.
Innovation Solution
The method involves cutting and extending melted synthetic resin raw materials, tearing off the extended portion, and molding the torn resin block, using a feeding path with a top force and bottom force to control temperature and phase states, ensuring precise metering and shaping to maintain uniform quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If compression molding is used to mold thick resin components, then the molding process can be simplified, but the resin feeding control becomes difficult leading to non-uniform quality and thickness
Solution Approach 1:
The molding process is segmented into two distinct phases: first injecting resin into the cavity to form a base layer, then adding additional resin blocks on top to achieve the desired thickness. This segmentation allows precise control over resin feeding at different stages, ensuring uniform quality throughout the thick component while maintaining relative process simplicity.
Solution Approach 2:
The cavity is first filled with resin to establish a controlled base structure before adding the remaining resin material. This preliminary action creates a foundation that guides subsequent resin placement, ensuring precise feeding control and uniform distribution throughout the thick molding, thereby improving manufacturing precision without significantly increasing overall process complexity.
2Volume of moving object
If the amount of resin raw materials is increased to obtain thick moldings, then the desired thickness is achieved, but burr formation occurs and quality uniformity deteriorates
Solution Approach 1:
The total resin volume is divided into multiple controlled portions: an initial resin injection that fills the cavity to a predetermined level, followed by additional resin blocks placed on top. This segmentation prevents overfilling and burr formation while ensuring the final component achieves the required thickness with uniform quality throughout, as each portion is precisely controlled.
Solution Approach 2:
The process uses partial filling in the first stage (injecting resin only to a specific level in the cavity) rather than attempting to fill the entire thick section at once. This partial action allows precise control over resin distribution, preventing excessive resin accumulation that would cause burrs, while still achieving the target thickness through controlled addition of subsequent resin portions.
3Object-generated harmful factors
If the amount of resin raw materials is decreased to avoid burr, then burr formation is reduced, but incomplete moldings occur and thickness requirement is not met
Solution Approach 1:
The resin feeding is segmented into a controlled initial injection that prevents overfilling and burr formation, followed by precise addition of additional resin blocks to achieve the required thickness. This segmentation allows the process to avoid the harmful effect of burr while simultaneously meeting the volume requirement for thick moldings, as each segment is precisely controlled.
Solution Approach 2:
The cavity is preliminarily filled with a controlled amount of resin to establish a base without exceeding the maximum safe level that would cause burrs. This preliminary action creates a foundation that prevents harmful overfilling, while subsequent controlled addition of resin blocks ensures the final thickness requirement is met without generating burr defects.
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 allows for continuous production of thick synthetic resin moldings with uniform quality and prescribed shapes, preventing resin content and shape changes during the molding process, thus addressing the limitations of conventional compression molding techniques.
Implementation Method 1
a process of feeding the melted synthetic resin raw material inside of a bottom force through a feeding path
Data Source
AI summary
The synthetic resin moldings are molded pressing the bottom force 210 to the top force for feeding 103, followed by feeding the melted synthetic resin raw material to the opening portion 2101 of the bottom force 210 through said feeding path 1023 of the top force for feeding 103, thereby filling said synthetic resin in the cavity in the mold CT1 made up by closing the mold with this top force for feeding 103 and the bottom force 210, followed by pushing down the bottom force 210, and extending said synthetic resin raw material contained in said feeding path 1023 and tearing off at the portion X where the raw material has prescribed amount of resin blocks RX for molding, pushing up this bottom force 210 in which these torn resin blocks RX are placed and remained to the top force for molding 104, thereby closing the mold and compressing.