Sanitary Fitting Die Insert Stabilization via Injection Pressure
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Solution Overview
Problem
The existing production method for sanitary fittings limits design freedom due to the requirement for retractable die inserts to stabilize each other, which restricts the positioning of the spout relative to the base portion.
Innovation Solution
A production method that uses a moulding die with a die insert configured to be lost within the sanitary fitting, supported by at least one support insert, and stabilized by the pressure force of the injected mould, allowing for more flexible design options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If two retractable die inserts are used to stabilize each other, then the die inserts can maintain their position during injection, but the design freedom for positioning the spout relative to the base portion is limited
Solution Approach 1:
The invention extracts the stabilization function from the die inserts themselves and transfers it to the injected mould material. The die inserts are no longer required to stabilize each other mechanically, but are instead stabilized by the pressure force of the injected mould. This allows the die inserts to be positioned more freely, including at acute angles between the spout and base portion, without requiring mutual mechanical support structures.
Solution Approach 2:
The injected mould material acts as an intermediary that transfers stabilization force to the die inserts. Instead of the die inserts directly supporting each other, the mould material mediates this support by exerting pressure force on the die inserts during injection, thereby stabilizing them in their desired positions without requiring complex mechanical interlocking structures.
2Stability of the object's composition
If die inserts are directed towards each other under an acute angle to stabilize each other, then mutual stabilization is achieved, but the positioning flexibility of spout and base portion is restricted
Solution Approach 1:
The invention removes the requirement for acute-angle positioning of die inserts for stabilization purposes. By transferring the stabilization function to the injected mould material, the die inserts can be positioned at any angle, including the desired 90-degree angle between spout and base portion, without compromising their stability during injection.
Solution Approach 2:
The invention changes the stabilization mechanism from mechanical interlocking at acute angles to pressure-based stabilization by injected mould material. This parameter change allows the die inserts to be positioned at optimal geometric angles (such as 90 degrees) for the final product design, rather than being constrained to acute angles required for mutual mechanical support.
3Stability of the object's composition
If high injection pressure is applied to stabilize die inserts, then the die inserts maintain their position, but the requirement for precise die insert positioning and interlocking increases complexity
Solution Approach 1:
The invention extracts the stabilization function from the complex mechanical interlocking of die inserts and transfers it to the injected mould material. This simplifies the die insert arrangement, as they no longer require precise mutual positioning and interlocking structures, but can be independently positioned and stabilized by the mould material pressure.
Solution Approach 2:
The injected mould material serves itself to stabilize the die inserts. The same material that is being injected to form the product also automatically provides the stabilization force needed to maintain die insert positions, eliminating the need for separate mechanical stabilization structures and reducing overall system complexity.
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 method provides increased design freedom for sanitary fittings, allowing the spout and base portion to be positioned more freely without the need for acute angles, while maintaining a smooth surface for chrome-plating.
Implementation Method 1
stabilized by the pressure force of the injected mould
Data Source
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AI summary
A production method for a sanitary fitting (10) including the following steps: Providing a moulding die (50) for injection moulding of the sanitary fitting (10) which defines a mould cavity (54); Arranging a die insert (30), which is configured to be lost within the sanitary fitting (10), in the mould cavity (54); Arranging at least one support insert (56; 58) to support the die insert (30) within the mould cavity (54); Providing an injection channel (40, 60) which traverses the die insert (30) such that it reaches the mould cavity (54) on the other side of the die insert (30) with respect to the at least one support insert (56; 58) at an injection point (40) Injecting mould (70) through the injection channel (60) and out of the injection point (40) into the mould cavity (54) behind the die insert (30).