Sensor Integration in Injection Molded Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing injection molded components, such as pallets and receptacles, lack efficient methods to integrate sensors for quick identification of goods and origin, with current solutions being cumbersome and difficult to manufacture.
Innovation Solution
Incorporating sensors, like RFID tags, into the injection molded components by molding them into the component's structure using a specialized mold assembly with vacuum lines and pins to secure the sensors during the molding process, ensuring accurate placement and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensors are integrated into injection molded components using traditional methods, then sensor functionality is achieved, but manufacturing complexity and difficulty increase significantly
Solution Approach 1:
The patent merges the sensor integration process with the injection molding process itself. The sensor is positioned in the mold cavity before injection, and the molten material flows around and encapsulates the sensor in a single operation. This combining of operations eliminates separate sensor attachment steps, reducing manufacturing complexity while maintaining sensor integration capability.
Solution Approach 2:
The sensor is pre-positioned and secured in the mold cavity using vacuum lines and pins before the injection molding begins. This preliminary positioning ensures the sensor is correctly located and protected during the high-pressure injection process, eliminating the need for complex sensor mounting fixtures or post-molding sensor attachment operations.
2Ease of manufacture
If sensors are molded into injection molded components, then manufacturability improves, but sensor displacement during molding may occur
Solution Approach 1:
The patent introduces vacuum lines and extendable pins as intermediary mechanisms between the mold walls and the sensor. These intermediaries create a secure holding environment during injection by applying vacuum suction and mechanical restraint, preventing sensor displacement while allowing easy sensor removal after molding by retracting the pins.
Solution Approach 2:
The vacuum lines and pins provide protective support to the sensor before the high-pressure injection material arrives. This preliminary protection cushioning prevents the sensor from being displaced or damaged during the molding process, ensuring reliable position stability throughout the manufacturing operation.
3Manufacturing precision
If vacuum lines and pins are used to secure sensors during molding, then sensor placement accuracy improves, but device complexity increases
Solution Approach 1:
The mold assembly is designed so that the vacuum lines and extendable pins serve multiple functions: they position the sensor, secure it during injection, and can be retracted to release the sensor. This multi-functionality reduces the need for separate positioning fixtures and simplifies the overall mold design despite the added components.
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 allows for the seamless integration of sensors within injection molded components, enhancing their manufacturability and operability, enabling easy identification of goods and origin through radio wave communication, while preventing sensor displacement during the molding process.
Implementation Method 1
At least one vacuum line is in fluid communication with the suction surface
Data Source
AI summary
An injection molded component includes a wall that has an inner wall surface and an outer wall surface. A sensor is molded into one of the inner wall surface and the outer wall surface. A channel is at least partially surrounding the sensor.