Screw Selection for Pulverized Resin Injection Molding
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Solution Overview
Problem
Conventional molding methods using pulverized material resin materials face issues with non-uniform particle shapes and sizes, leading to voids in molten resin, insufficient melting, and increased molding failures due to inappropriate screw configurations.
Innovation Solution
A method that measures the area of particle shapes of pulverized materials and determines a shape index to assess compatibility with the screw depth, displaying inappropriate conditions and adjusting molding parameters based on bulk density measurements to ensure proper mixing ratios and screw selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If pulverized material with random particle shapes and sizes is used for molding, then material utilization is improved by reusing molded products, but voids are generated in molten resin and plasticization becomes insufficient leading to molding failures
Solution Approach 1:
The patent changes the geometric parameters of the screw (groove depth, flight angle, diameter) to match the particle size characteristics of the pulverized material. By calculating the particle size distribution and selecting screw parameters that satisfy specific geometric relationships, the system optimizes plasticization efficiency while maintaining high material utilization of pulverized material.
2Ease of repair
If the particle size of pulverized material is large relative to screw groove depth, then material utilization is improved, but plasticization time increases and molding quality deteriorates
Solution Approach 1:
The patent establishes quantitative relationships between particle size parameters (area Ac, equivalent diameter) and screw parameters (groove depth Ds, flight angle). By changing these parameters to satisfy specific ratios and geometric conditions, the system achieves optimal plasticization speed and quality without compromising material utilization.
Solution Approach 2:
The patent performs preliminary measurement and calculation of particle size distribution before molding, and pre-selects the appropriate screw type based on these measurements. This preliminary action ensures that the screw parameters are optimized for the specific pulverized material being used, preventing plasticization problems before they occur.
3Device complexity
If conventional molding methods are used with pulverized material, then device complexity is reduced, but manufacturing precision deteriorates due to insufficient plasticization
Solution Approach 1:
The patent implements a feedback mechanism where particle size is measured, the screw type is selected based on measured parameters, and molding conditions are adjusted according to the selected screw characteristics. This closed-loop approach ensures consistent plasticization quality without requiring complex additional equipment.
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 allows for rapid and accurate determination of appropriate screw configurations, enhancing molding quality, reducing failures, and stabilizing production by ensuring proper plasticization and mixing ratios, even with randomly sized particles.
Implementation Method 1
the area Ac of a particle shape Qcg of the pulverized material Qc in one direction is measured
Implementation Method 2
a pulverized material resin material Q including a pulverized material Qc as at least a part is plasticized and injection-molded by rotating a screw 3 inserted in a heating tube 2
Implementation Method 3
a pulverized material resin material Q including a pulverized material Qc as at least a part is plasticized and injection-molded by rotating a screw 3 inserted in a heating tube 2
Data Source
AI summary
When a pulverized material resin material including a pulverized material as at least a part is plasticized and injection-molded by rotating a screw inserted in a heating tube, before use of the pulverized material, the area of a particle shape of the pulverized material in one direction is measured, a pulverized material shape index indicating the relative size of the area with respect to the depth of a screw groove is determined by computation processing, and when the size of the pulverized material shape index is equal to or greater than a preset setting value, the screw is determined to be inappropriate, and at least the result of the determination is displayed.