Seal Mold Layout for Close Flange-to-Seal Placement
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Solution Overview
Problem
Existing molding methods require a certain distance between a flange shape and a seal member on a base material, leading to an increase in the overall size of the product when the seal member is molded near the flange, which is undesirable.
Innovation Solution
A molding method involving a two-step process where a raw material is injected into a groove at a non-vulcanized state and then sandwiched between molds at a vulcanized state, using a cavity plate with grooves and connecting grooves to create gaps, allowing the seal member to be molded closer to the inclined portion of the base material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the seal member is molded close to the flange shape of the base material, then the area of the region inside the seal member is increased, but the distance between the flange shape and the seal member becomes too small causing molding defects
Solution Approach 1:
The mold is divided into multiple sections including a first mold, a second mold, and a third mold with different functions. The first mold has a shape that creates a gap, the second mold has a groove for sealing, and the third mold applies pressure. This segmentation allows each mold section to perform its specific function independently, enabling the seal member to be molded close to the flange shape while maintaining adequate spacing through the gap created by the first mold's shape.
Solution Approach 2:
The first mold's shape acts as an intermediary element that creates a gap between the inclined portion of the base material and the seal member. This intermediary structure allows the seal member to be positioned close to the flange shape while maintaining the necessary distance to prevent molding defects, thus resolving the contradiction between maximizing area and maintaining manufacturing precision.
2Manufacturing precision
If a certain distance is maintained between the flange shape and the seal member, then molding quality is ensured, but the overall area of the base material must be increased
Solution Approach 1:
The invention utilizes the vertical dimension by creating a gap through the three-dimensional shape of the first mold, rather than relying solely on horizontal spacing. This allows the seal member to be positioned closer to the flange shape in the horizontal plane while maintaining the necessary distance in the vertical direction through the mold's shaped gap, thereby reducing the overall base material area while preserving molding quality.
3Area of moving object
If the seal member is molded as close to the flange shape as possible, then area utilization is optimized, but the complexity of the molding process increases
Solution Approach 1:
The molding process is segmented into multiple independent mold sections, each with a specific function. This segmentation allows for optimized area utilization while managing complexity by dividing the overall process into manageable, specialized components rather than attempting to achieve close molding with a single complex mold design.
Solution Approach 2:
The first mold's shape is designed in advance to create the necessary gap before the sealing and pressing operations. This preliminary action of gap creation simplifies the subsequent molding steps by pre-establishing the proper spacing, thereby optimizing area utilization without proportionally increasing overall process 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
Reduces the distance between the inclined portion and the seal member without increasing the overall size of the base material, thereby optimizing the area utilization within the seal member region.
Implementation Method 1
a first step of injecting a raw material for the seal member into a groove at a temperature where the raw material is not vulcanized (crosslinked)... and a second step of sandwiching the base material between the first mold in which the raw material is injected into the groove and a second mold, and molding the raw material onto the base material as the seal member at a temperature where the raw material is vulcanized (crosslinked)
Data Source
AI summary
Disclosed herein are a molding method and a mold capable of further reducing the distance between a base material and a seal member. A molding method includes: a preforming step of injecting a rubber material into a groove at a temperature where the rubber material is not vulcanized, in a cavity plate including the groove into which the rubber material is injected; and a vulcanization molding step of sandwiching a base material between the cavity plate and a mold, and molding the rubber material onto the base material as a seal member at a temperature where the rubber material is vulcanized. The cavity plate includes a gap forming portion between such portion and an inclined portion of the base material when a flat surface and a flat surface of the base material are pressed in the vulcanization molding, and a connecting groove connecting the groove and the gap forming portion.