Rollable Cotter Block Alignment for Injection Mold Jamming
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Solution Overview
Problem
The existing injection molding processes for manufacturing liners for hydrogen tanks face challenges such as thickness deviations due to misalignment of molds and jamming of cotter blocks, leading to deformation and damage of the molded bodies.
Innovation Solution
An injection molding apparatus with a rollable second cotter block relative to a first cotter block, which aligns the second mold with the first mold, preventing jamming and ensuring precise alignment to minimize deformation and damage during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a first cotter block and a second cotter block are used to align the molds, then the alignment precision is improved, but the cotter blocks may jam during the molding process
Solution Approach 1:
The second cotter block is designed to rotate about its longitudinal axis during the molding process. This rotational movement transforms the static alignment function into a dynamic one, allowing the cotter block to adapt to dimensional variations and prevent jamming while maintaining alignment precision between the first and second molds
Solution Approach 2:
The alignment function is divided between two separate components: the first cotter block that remains fixed and the second cotter block that rotates. This segmentation allows each component to perform its specific function optimally - the first provides stable reference while the second accommodates variations through rotation
2Manufacturing precision
If the molds are accurately aligned to prevent thickness deviation, then the manufacturing precision is improved, but the alignment process becomes more complex
Solution Approach 1:
The rotating second cotter block automatically adjusts itself during the molding process to maintain proper alignment. The rotation mechanism enables the system to self-correct for dimensional variations without requiring external adjustment or complex control systems, thereby achieving precise liner thickness uniformity while keeping the alignment mechanism relatively simple
3Reliability
If the cotter blocks are made to prevent jamming, then the reliability is improved, but the alignment precision may be compromised
Solution Approach 1:
The rotation of the second cotter block during molding creates a dynamic alignment system that maintains contact between the cotter blocks and mold surfaces. This continuous rotational adjustment ensures smooth separation without jamming while preserving alignment accuracy through the geometric relationship between the rotating cotter block and the fixed first cotter block
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
The proposed solution reduces the defect rate of molded bodies, improves quality and productivity, and minimizes manufacturing costs by preventing cotter block jamming and ensuring accurate mold alignment.
Implementation Method 1
a second cotter block provided on the second mold, configured to be rollable relative to the first cotter block
Data Source
AI summary
The present disclosure provides an injection molding apparatus including a first mold, a second mold configured to be relatively movable toward or away from the first mold and define a cavity for forming a molded body collectively with the first mold, a stripper provided between the first mold and the second mold and configured to separate the molded body from the first mold, a first cotter block provided on the stripper, and a second cotter block provided on the second mold, configured to be rollable relative to the first cotter block, and configured to align the second mold with the first mold collectively with the first cotter block, thereby obtaining an advantageous effect of reducing a defect rate related to the molded body and improving quality and productivity.