Segmented Inner Mold for CFRP Spring Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing springs from Carbon Fiber Reinforced Plastic (CFRP) are limited in producing various shapes with different functions, such as conical and side load springs, and struggle with efficient separation from mandrels, restricting the versatility and performance of vehicle body components.
Innovation Solution
An injection molding apparatus featuring an axially extending support bar, an inner mold with axially divided parts, and an outer mold with a forming space, allowing for the creation of various spring shapes by ensuring the inner and outer mold surfaces are in close contact and the support bar can be smoothly removed, enabling the production of CFRP springs with diverse functionalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece inner mold is used, then the manufacturing process is simple, but the spring cannot be separated from the mandrel
Solution Approach 1:
The inner mold is divided into multiple axially segmented parts that can be separated from each other. This segmentation allows the mold to be disassembled into components that can be individually removed from the spring, enabling complete separation of the spring from the mandrel while maintaining the simplicity of the manufacturing process.
2Manufacturing precision
If the inner mold parts are tightly fitted, then the molding precision is high, but the support bar cannot be smoothly removed
Solution Approach 1:
Different regions of the inner mold parts have different fit characteristics. The portions contacting the support bar are designed with appropriate clearance for smooth removal, while the portions forming the spring geometry maintain tight fitting for high molding precision. This local differentiation of fit quality resolves the contradiction between precision and removability.
3Device complexity
If the inner mold has uniform width throughout, then the structure is simple, but various spring shapes cannot be produced
Solution Approach 1:
The inner mold is segmented axially into multiple parts, each capable of having different widths and geometries. This segmentation enables the production of various spring shapes (conical, side load, etc.) by configuring each segment appropriately, while the modular segmented structure itself remains relatively simple compared to a fully custom non-segmented mold.
Data Source
AI summary
Disclosed herein is an injection molding apparatus. That apparatus includes an axially extending bar shaped support bar and an inner mold that has a plurality of internal parts surrounding the support bar and is axially divided into a plurality of parts in which one or more corresponding parts in the inner parts have an inner circumferential surface width the same or larger than an outer circumferential surface width. The apparatus further includes an outer mold that has a plurality of axially divided external parts surrounding the inner mold and has a space between the inner circumferential surface of the outer mold and the outer circumferential surface of the inner mold.