Sintered Wire Mesh Bottom Member for Resin Gear Molding
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Solution Overview
Problem
Conventional methods for manufacturing resin gears face frequent replacement of wire mesh bottom members due to stress deformation, leading to increased drainage time and maintenance costs.
Innovation Solution
An apparatus with a bottom member composed of sintered layers of dutch-woven and plain-woven wire meshes, supported by a plate with higher opening rates than the drain passages, enhances mechanical strength without significantly affecting filtration performance, reducing the need for frequent replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single wire mesh is used as a bottom member, then the structure is simple and drainage is efficient, but the wire mesh deforms under stress and requires frequent replacement
Solution Approach 1:
The bottom member is constructed as a composite structure combining a wire mesh layer with a sintered plate layer. The wire mesh provides filtration function while the sintered plate provides mechanical strength and stress distribution, resolving the contradiction between simplicity and durability by integrating two materials with complementary properties.
Solution Approach 2:
The bottom member is divided into functional segments: a wire mesh portion for filtration and a sintered plate portion for structural support. This segmentation allows each component to optimize its specific function while working together as an integrated system, improving overall reliability without significantly complicating the structure.
2Reliability
If multiple wire meshes are stacked or sintered to enhance strength, then the bottom member durability improves, but the drainage time becomes longer
Solution Approach 1:
The composite bottom member uses a wire mesh layer for efficient filtration and drainage, combined with a sintered plate layer for mechanical strength. This allows achieving enhanced durability without adding multiple wire mesh layers that would impede drainage, as the sintered plate provides support without blocking fluid flow.
Solution Approach 2:
Different regions of the bottom member have different properties: the wire mesh portion is optimized for filtration and drainage with high porosity, while the sintered plate portion is optimized for mechanical strength. This local differentiation allows the system to achieve both strength and fast drainage simultaneously.
3Reliability
If the wire mesh is made stronger to reduce replacement frequency, then the bottom member durability improves, but the filtration performance decreases
Solution Approach 1:
The bottom member combines a wire mesh layer that maintains excellent filtration performance with a sintered plate layer that provides mechanical strength. The wire mesh retains its fine mesh structure for effective filtration while the sintered plate bears the mechanical loads, preventing the need to thicken or coarsen the wire mesh which would compromise filtration.
4Reliability
If a support plate is added to enhance bottom member strength, then the replacement frequency reduces, but the device complexity increases
Solution Approach 1:
The support function and filtration function are merged into a single integrated bottom member structure. The wire mesh and sintered plate are combined into one component that simultaneously provides filtration, drainage, and mechanical support, eliminating the need for separate support structures and minimizing overall device 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
The solution significantly reduces the frequency of bottom member replacement and maintenance costs while maintaining efficient drainage, ensuring continuous operation with improved mechanical strength and filtration efficiency.
Implementation Method 1
The two or more layers of wire meshes are secured to each other by sintering
Implementation Method 2
discharging the dispersion medium via the plurality of drain passages formed in the lower compression mold to form an aggregate
Data Source
AI summary
Provided herein is an apparatus of manufacturing a molding material that can significantly reduce the frequency of replacement of a bottom member without increasing the drainage time longer. A bottom member (39) is constituted of two layers of wire meshes including an annular dutch-woven wire mesh (39A) made of stainless steel and an annular plain-woven wire mesh made of stainless steel. The two layers of wire meshes are secured to each other by sintering. A support plate (40) made of stainless steel is disposed between the bottom member (39) and a lower hollow compression mold (2). The support plate (40) has a plurality of through holes (41) formed therein, and is configured to support the bottom member (39).