Roller Maintaining Chain with Inclined Separation Blocks

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Solution Overview

Problem

Conventional roller maintaining chains face issues such as uneven surfaces, surplus material, and high manufacturing costs due to secondary machining and de-molding interference, which affect the smooth operation and positioning of rollers in linear movement devices.

Innovation Solution

A roller maintaining chain with an elongate strip having holes separated by separation blocks, where each block features a flat and inclined surface for proper roller guidance, and a method using inclined and lateral molds for single injection molding to eliminate de-molding interference and reduce surplus material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional secondary injection molding or machining is used to create the roller maintaining chain, then the chain can be formed with separation blocks, but the surface becomes uneven and de-molding interference occurs

Engineering Contradiction:

Improvesurface smoothnessVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent combines the separation blocks and the chain body into a single integrated component formed by one injection molding process. The separation blocks are designed with inclined de-molding surfaces that allow the entire assembly to be ejected from the mold without secondary machining or additional molding steps, eliminating surface unevenness and de-molding interference while reducing manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separation blocks are pre-formed with inclined surfaces during the initial injection molding process, before the chain is assembled or used. This preliminary formation of the de-molding surfaces ensures that no additional machining is needed later, and the smooth surface is achieved from the start of manufacturing

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If conventional molding methods are used, then de-molding interference occurs requiring secondary processing, but single injection molding simplifies the process

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidroller positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The separation blocks and chain body are merged into a single injection-molded component, eliminating the need for secondary processing while maintaining precision. The inclined surfaces on the separation blocks are precisely formed during molding to ensure proper roller positioning without requiring additional machining steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the molding parameters by using a single injection process with specifically designed inclined de-molding surfaces, rather than multiple molding or machining steps. This parameter change maintains manufacturing precision while simplifying the overall manufacturing process

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If separation blocks with vertical surfaces are used, then roller positioning is achieved, but de-molding interference and surplus material occur

Engineering Contradiction:

Improveroller positioning accuracyVSAvoidsurplus material

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The separation blocks are designed with asymmetric inclined surfaces rather than vertical surfaces. The inclined surfaces allow the separation blocks to guide rollers accurately while enabling smooth ejection from the mold, eliminating de-molding interference and preventing surplus material formation that would occur with vertical surfaces

Inventive Principle:

Principle #4Asymmetry

4Shape

If multiple molding processes are used, then complex shapes can be achieved, but manufacturing cost and time increase

Engineering Contradiction:

Improveseparation block geometryVSAvoidmanufacturing efficiency

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The complex geometry of the separation blocks with inclined surfaces is achieved in a single injection molding process, combining what would traditionally require multiple molding or machining operations into one step. This maintains the required geometric complexity while significantly improving manufacturing efficiency and reducing production time

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8757879B2Roller maintaining chain and method for making roller maintaining chain and linear movement device

Publication Date: 2014.06.24 CHIEFTECH PRECISION

AI summary

A roller maintaining chain includes an elongate strip having multiple holes separated by separation blocks. Each hole has a hole face perpendicular to the elongate strip. Each separation block has a top separation block and a bottom separation block. Each of the top and bottom separation blocks has an accommodating surface which has a flat surface and an inclined stop surface. A part of each accommodating surface is perpendicular to planes on the axial direction of the elongate strip. The flat surfaces of the top and bottom separation blocks are smoothly connected to each other. The inclined stop surfaces are inclined toward the top direction of the holes to maintain the rollers in the holes. The method for making the roller maintaining chain uses a left mold and a right mold, the two molds are split inclinedly and laterally to obtain the roller maintaining chain.