Rotor Resin Mold Structure for Easy Runner Removal
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Solution Overview
Problem
Conventional rotor manufacturing apparatuses face difficulties in efficiently removing the resin runner from the flow paths, leading to hindered productivity due to its solidification with the resin, making the removal process cumbersome.
Innovation Solution
The rotor manufacturing apparatus incorporates a first mold with a resin pot and a plunger, along with a runner plate that allows melted resin to flow and solidify around a reverse tapered portion, facilitating the separation and removal of the runner by moving the first mold body away from the runner plate, enabling easy extraction of the solidified runner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the resin pot and flow paths are integrated in a conventional rotor manufacturing apparatus, then the structure is simple, but the runner cannot be easily removed after solidification
Solution Approach 1:
The first mold body is divided into two separable parts: the resin pot portion and the flow path portion (runner plate). After resin injection and solidification, these parts can be separated to allow easy removal of the solidified runner from the flow path, while maintaining structural simplicity during the manufacturing process.
2Reliability
If the runner is solidified with the resin in the pot, then the resin filling is effective, but the runner removal becomes cumbersome and hinders productivity
Solution Approach 1:
By segmenting the mold body into separable resin pot and flow path portions, the runner can be easily removed after solidification without affecting the resin filling effectiveness. This resolves the contradiction between reliable resin filling and productive runner removal.
Solution Approach 2:
The mold structure transitions from a static integrated design to a dynamic separable design. The runner plate can be moved relative to the resin pot, enabling easy extraction of the solidified runner while maintaining effective resin filling during the process.
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 configuration allows for the easy removal of the resin runner, enhancing productivity by simplifying the process and improving the efficiency of rotor manufacturing.
Implementation Method 1
allows melted resin to flow and solidify around the portion
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Provided are a first mold (2) provided with a resin pot (5) having opposite ends with respective opening portions (5a, 5b), a plunger (6) that is located in the resin pot (5) and is movable from one of the opening portions (5a, 5b) of the resin pot (5) toward the other, and a second mold (16) on which the rotor body (100) is mounted and that is located facing the first mold (2). The first mold (2) includes a first mold body (3) having the resin pot (5), a runner plate (11) in a tabular shape located between the first mold body (3) and the second mold (16) while being allowed to separate from the first mold body (3) in a thickness direction, the runner plate (11) having a recess located on a side in contact with the first mold body (3), the recess constituting a part of a flow path (14) for allowing the resin melted to flow, and a resin accommodating space (X) surrounded by the resin pot (5), the plunger (6), and the recess to accommodate melted resin in a state where the first mold body (3) and the runner plate (11) are in contact with each other. The flow path (14) communicates with the resin accommodating space (X) in a state where the first mold body (3) and the runner plate (11) are in contact with each other.