Stacked Mold Insert Assembly for Complex Contour Cavities
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Solution Overview
Problem
Existing molding techniques face challenges in forming components with complex contour cavities, particularly those with negative draft angles, as traditional mold inserts can become trapped, limiting the fabrication of components with multiple cavities having complex surfaces.
Innovation Solution
A mold insert assembly comprising stacked mold inserts with baseplates and protruding mold boss segments, where each mold boss set forms a cavity-fill structure that can be removed from the component while retained with its baseplate, allowing for efficient molding of components with complex contour cavities, such as cascade grid panels for jet engine thrust reversers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mold inserts are used to form cavities with complex contours, then the cavities can be formed, but the mold inserts become trapped and cannot be removed due to negative draft angles
Solution Approach 1:
The mold insert is divided into multiple segments that can move independently relative to each other. The segments are connected through hinges or pivots, allowing the insert to change its configuration. During molding, the segments form the complete cavity contour. During ejection, the segments can pivot or hinge to create clearance, enabling the insert to be removed from the molded part even with negative draft angles.
Solution Approach 2:
The mold insert transitions from a static structure to a dynamic one with movable components. The insert includes elements that can rotate, slide, or pivot during the molding and ejection cycles. This dynamic capability allows the insert to adapt its shape and position, enabling it to form complex contours during molding and then be easily removed during ejection by changing its configuration.
2Manufacturing precision
If mold inserts are used to form multiple cavities, then cavity formation is achieved, but the complexity of the mold insert assembly increases
Solution Approach 1:
The mold insert is designed as a universal assembly that can form multiple different cavity configurations. The same insert, through its movable segments and reconfigurable structure, can create various cavity shapes and arrangements by changing the relative positions of its segments. This multi-functionality eliminates the need for multiple separate inserts for different cavity configurations, reducing overall assembly complexity.
Solution Approach 2:
The mold insert employs a nested structure where smaller functional elements are integrated within a larger modular framework. The baseplate contains integrated features that support multiple cavity formations, and segments can be nested or stacked to create different cavity arrangements. This nesting approach consolidates multiple cavity-forming capabilities into a single compact assembly, reducing the number of separate components needed.
3Manufacturing precision
If mold inserts with complex contours are used, then accurate cavity formation is achieved, but the handling and cleaning of the mold inserts becomes difficult
Solution Approach 1:
By dividing the complex contour insert into separate segments, each segment becomes smaller and easier to handle individually. The segments can be detached from each other through hinges or pivots, allowing them to be removed separately for cleaning. This segmentation reduces the overall handling difficulty compared to a single large complex insert, while still maintaining the ability to form accurate complex contours when assembled.
4Shape
If traditional molding techniques are used for components with negative draft angles, then the component shape is achieved, but the mold inserts cannot be ejected from the component
Solution Approach 1:
The mold insert incorporates dynamic elements that allow it to change its shape and position during the ejection process. The movable segments can pivot or slide to create clearance between the insert and the molded part, enabling ejection even when the part has negative draft angles that would normally trap a static insert. The insert effectively adapts its geometry during ejection to overcome the draft angle constraint.
Solution Approach 2:
Instead of trying to eject the insert in the traditional linear direction, the insert uses its movable segments to invert the ejection approach. The segments pivot or hinge to change the ejection path, allowing the insert to be withdrawn from the molded part at angles or in sequences that avoid interference from negative draft angles. This inverted approach to ejection geometry enables removal of inserts from parts that would normally trap them.
Data Source
AI summary
Methods of fabricating a component, such as a cascade grid panel for a jet engine thrust reverser, having a plurality of cavities extending through the component, with each cavity having at least one surface with a complex contour, and related devices. A plurality of two or more mold inserts are stacked to form a mold insert stack, with the mold insert stack having a plurality of mold bosses formed by mold boss sets. The mold boss sets are each formed by a mold boss segment from each of the mold inserts. Further, the mold boss segments are affixed to respective baseplates so that the mold boss segments can be handled as a group and remain properly positioned relative to their neighboring mold boss segments.