Rotating Floating Core for Curved Branch Pipe Molding
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Solution Overview
Problem
Existing methods for integrally molding pipes with synthetic resin using floating cores are limited in producing pipes with branches, as they can only form straight branches and require additional machining to remove thin resin films, making them inefficient for producing curved or complex pipe configurations.
Innovation Solution
A method involving a mold with a main cavity and a branch cavity, where a floating core is used to form both the main pipe and branch pipe hollows by injecting molten resin and pressurized fluid, allowing for the formation of curved or complex pipe branches without the need for post-machining resin removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a sliding core is used for molding a branch, then a branch can be molded, but only a straight branch can be molded and machining is required to remove the thin resin film
Solution Approach 1:
Instead of using a sliding core that moves linearly to form straight branches, the invention inverts the approach by using a rotating core that can be positioned at different angles. The core rotates within the cavity to form branches in various directions, eliminating the need for sliding mechanisms and enabling curved branch configurations without post-machining.
Solution Approach 2:
The invention introduces dynamic capability to the molding process by enabling the core to rotate and change its angular position during the molding cycle. This dynamic adjustment allows the formation of branches in different configurations (straight, curved, angled) without requiring multiple fixed molds or post-manufacturing machining operations.
2Adaptability or versatility
If multiple floating cores are used to move in different directions, then a pipe with a branch can be integrally molded, but the mold structure becomes extremely difficult to implement
Solution Approach 1:
The invention merges multiple floating core functions into a single rotating core. Instead of implementing multiple independent floating cores that would require complex mold structures, one core is designed to rotate and assume different positions, thereby performing the function of multiple cores while simplifying the overall mold structure.
Solution Approach 2:
The rotating core serves multiple functions: it can form main pipes, branch pipes, and curved connections by rotating to different angular positions. This multi-functional core eliminates the need for specialized molds for each pipe configuration, significantly reducing device complexity while maintaining versatility.
3Manufacturing precision
If conventional pipe molding method using floating core is used, then high dimensional accuracy and good appearance can be achieved, but curved or complex pipe configurations cannot be molded
Solution Approach 1:
By making the floating core rotatable rather than fixed in a single position, the invention maintains the dimensional accuracy benefits of floating core molding while gaining the flexibility to form curved and complex pipe configurations. The core can be rotated to precise angular positions, ensuring accuracy is maintained even as configuration versatility increases.
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
Enables the efficient and cost-effective manufacturing of pipes with branches of various configurations, including curved designs, with high dimensional accuracy and improved surface finish, while minimizing waste and machining requirements.
Implementation Method 1
the pressurised fluid is pressure-injected, through the pressure port to move the floating core to the outlet side
Implementation Method 2
an excess resin is extruded from the outlet, whereby a hollow pipe is integrally molded
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention provides a method of manufacturing a pipe with a branch, which utilizes the conventional pipe molding method using a floating core, and while taking advantage of the pipe molding method, various types of pipes with a branch can be integrally molded with a synthetic resin with high efficiency. The method comprises injecting a molten resin into a main cavity 4, which has on its one end a pressure port 2 provided with a floating core 1 and on its other end a first outlet 3, and a branch cavity 5, which communicates with the main cavity 4 and has on its end a second outlet 6 allowed to open and close, pressure-injecting a pressurized fluid through the pressure port 2 after the injection of the molten resin, and moving the floating core 1 to the first outlet 3 side, and, at the same time, extruding the molten resin from the first outlet 3 to form a main pipe hollow, and opening the second outlet 6 after the main pipe hollow reaches a portion at which the branch cavity 5 communicates with the main cavity 4, and extruding the molten resin by the pressurized fluid from the second outlet 6 to form the branch pipe hollow.