Water Jacket Spacer Molding Bridge Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing production method of water jacket spacers for cylinder blocks faces issues with deformation during cooling due to thermal contraction, requiring costly and space-intensive jig setups to maintain shape, leading to increased production costs and reduced operational efficiency.
Innovation Solution
A production method involving the integral formation of a tubular spacer body with a connecting bridge via synthetic resin molding, which is cooled with the bridge fixed and then removed, preventing deformation and eliminating the need for jigs by cutting off the bridge after stabilization, thereby ensuring accurate shape retention and improved rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a spacer is made of synthetic resin formed by injection molding, then the spacer can be efficiently produced, but the spacer deforms during cooling due to thermal contraction
Solution Approach 1:
The connecting bridge is formed in advance during the injection molding process itself, before cooling occurs. This preliminary formation of the bridge structure prevents thermal contraction deformation during the subsequent cooling phase, as the bridge acts as an internal support framework that maintains the spacer's shape while the resin cools and contracts.
Solution Approach 2:
The connecting bridge serves as an intermediary structural element that mediates between the conflicting requirements of efficient injection molding and shape accuracy. The bridge is formed as part of the molding process but then removed after serving its temporary purpose of preventing deformation, thus acting as a mediator that enables both efficient production and precise shaping without requiring external jigs.
2Manufacturing precision
If a reforming tool (jig) is used to prevent deformation during cooling, then shape accuracy is maintained, but production cost and process complexity increase
Solution Approach 1:
The harmful element (deformation) is eliminated by extracting the support function from an external jig and integrating it into the spacer itself through the connecting bridge. The bridge is formed as part of the spacer during molding, performs the support function during cooling, and is then removed (taken out) after serving its purpose. This eliminates the need for separate reforming tools and complex jig setups.
Solution Approach 2:
The spacer becomes self-sufficient by incorporating the connecting bridge as an integral part of its structure during molding. The bridge automatically provides the necessary support to prevent thermal contraction deformation without requiring external intervention from jigs or reforming tools. The spacer essentially supports itself during the critical cooling phase through its own built-in bridge structure.
3Manufacturing precision
If the spacer is cooled and cured while set with a reforming tool, then dimensional stability is achieved, but setting space and jig preparation are required
Solution Approach 1:
The support function previously requiring separate jigs and reforming tools is merged directly into the spacer structure through the connecting bridge. The bridge is formed as an integral part of the spacer during injection molding, combining the spacer and support structure into a single component. This eliminates the need for separate setting spaces and jig preparation areas, as the support is built-in rather than external.
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 effectively prevents deformation, enhances productivity by simplifying the process, reduces costs, and improves material efficiency by eliminating the need for jigs and minimizing equipment requirements, while maintaining accurate shape and structural integrity.
Implementation Method 1
The long circular spacer is deformed because of the misalignment of thermal contraction caused by its figuration characteristic during the gradual cool down.
Data Source
AI summary
A production method of a water jacket spacer for use in a cylinder block with a water jacket formed around plural cylinder bores. The method comprises the fist step of integrally forming a tubular spacer body with a peripheral wall and a connecting bridge by way of synthetic resin molding so that corresponding regions of the peripheral wall are connected to each other via the connecting bridge, and the second step of cooling the tubular spacer body, with the connecting bridge fixed thereto, to prevent deformation of the tubular spacer body during the cooling process, and the third step of removing the connecting bridge from the tubular spacer body.