Automated Rubber Molding Tab Extraction
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Solution Overview
Problem
Current methods for molding and de-molding rubber parts, particularly in shoe production, face inefficiencies due to the difficulty in removing rubber parts from molds without damaging them and the need for manual handling of excess flash material.
Innovation Solution
A system and method utilizing a mold with a cavity defining the desired rubber part shape and a tab extending from it, allowing for automated dispensing of rubber pellets, application of heat and pressure, and subsequent removal of the rubber part using a gripping device that engages the tab to peel it out, while also enabling easy removal of excess flash and tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If rubber parts are molded using traditional methods, then the rubber parts can be formed into desired shapes, but the rubber parts are difficult to remove from molds without damage and require manual handling of flash material
Solution Approach 1:
The invention introduces a tab feature that segments the rubber part into a main body and a removable tab portion. The tab extends beyond the mold cavity boundary and can be separated from the main rubber part after molding, allowing the main part to be removed from the mold without damage while the tab remains for subsequent removal
Solution Approach 2:
The tab is extracted as a separate removable element from the rubber part. After molding, the tab can be easily removed from the main rubber part body, enabling automated gripping and removal of the finished part from the mold without manually handling the flash material
2Productivity
If automated dispensing of rubber pellets is used, then production efficiency is improved, but precision in material placement and distribution must be maintained
Solution Approach 1:
The invention replaces manual mechanical handling of rubber material with an automated dispensing system that uses controlled mechanisms (such as gravimetric feeders or precision dosing devices) to dispense rubber pellets into the mold cavity, ensuring consistent and precise material placement while maintaining high production speed
Solution Approach 2:
The dispensing system controls the physical parameters of rubber material delivery, such as pellet flow rate, dispensing timing, and distribution pattern, to ensure precise material placement. The system may adjust parameters like dispensing pressure, duration, and position to achieve uniform rubber distribution throughout the mold cavity
3Extent of automation
If tabs are added to rubber parts for automated gripping, then de-molding becomes easier, but additional material is required and tabs must be removed afterward
Solution Approach 1:
The tab is designed as a temporary feature that is discarded after serving its purpose of enabling automated gripping and de-molding. The tab is easily removed from the rubber part body through cutting or breaking, and the discarded tab material can be collected and reused in the rubber compounding process, minimizing actual material waste
Solution Approach 2:
The tab is extracted as a separate removable element that can be easily separated from the main rubber part. This extraction allows the tab to serve its automated handling function while being minimal in size and material consumption, and its removal leaves the final rubber part ready for use without permanent modification
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 enables efficient, automated fabrication and de-molding of rubber parts with reduced material waste and improved precision, enhancing the production efficiency and quality of rubber components like shoe outsoles.
Implementation Method 1
a heating element positioned below the mold and operable for heating the mold to a temperature that causes the pellets to spread
Implementation Method 2
a press positioned below the mold and operable for applying pressure to the mold
Data Source
AI summary
Molded rubber objects may be molded and de-molded by defining both a desired final form for the molded rubber object and a tab extending from the final form of the molded rubber object using a cavity in a mold. Rubber pellets may be dispensed in predetermined amounts at desired location(s) within the cavity to provide the rubber needed to form the molded rubber object. Heat and pressure may be applied to the mold to cause the rubber pellets to fill the cavity defining both the desired final form of the molded rubber object and the tab. After the heat and pressure has been applied, a gripping device may grasp the tab and move the tab in a direction and with sufficient force to peel the rubber object from the mold cavity. If desired, the tab may be removed from the molded rubber object.