Steering Wheel Mold Gate Layout for Hidden Resin Excision Marks
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Solution Overview
Problem
Existing molds for molding a resin layer with a core metal of a steering device, such as a steering wheel, result in gate residues that worsen the feel of the device when excised along the grip area, which is often visible and reduces design features.
Innovation Solution
A mold design with a gate positioned at the spoke molding part, allowing the gate residue to be excised at the less noticeable spoke area, and a vent positioned symmetrically to balance resin flow and minimize unevenness, with a runner configuration that facilitates easy removal of residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the gate is provided at the rim molding part (grip area), then the resin material can be injected effectively, but the gate residue becomes visible and worsens the feel of the steering device
Solution Approach 1:
The gate is positioned asymmetrically at the spoke molding part rather than at the rim molding part. This asymmetric placement moves the gate residue to a less visually prominent location (the spoke area) while maintaining effective resin injection into the rim grip area, thereby resolving the contradiction between manufacturing effectiveness and aesthetic quality.
2Ease of manufacture
If the gate residue is excised along the shape of the rim part, then the gate residue can be completely removed, but the excision mark worsens the feel of the steering device
Solution Approach 1:
By positioning the gate at the spoke molding part rather than the rim molding part, the excision of gate residue occurs at the spoke area which is less visible to passengers. This asymmetric positioning allows complete removal of gate residue while minimizing the aesthetic impact of excision marks.
3Productivity
If the vent is positioned to facilitate resin flow, then the molding process is efficient, but uneven resin flow may occur
Solution Approach 1:
The vent is positioned symmetrically with respect to the gate location, creating a balanced resin flow pattern. This symmetric arrangement ensures that resin flows evenly through the molding cavity while maintaining efficient molding process, resolving the contradiction between productivity and manufacturing precision.
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
Reduces the visibility of excision marks from gate and vent residues, maintaining the aesthetic appeal and design integrity of the steering device by positioning residues in less-touched areas and using decorative components to cover them.
Implementation Method 1
a gate for flowing a resin material into the mold
Data Source
AI summary
A mold for molding a resin layer integrally with a core metal of a steering device of a moving object is provided. The core metal includes a hub core metal part connecting to an axis of steering rotation, a spoke core metal part connecting to the hub core metal part, and a rim core metal part connecting to the spoke core metal part. The mold comprises: a spoke molding part for molding the resin layer integrally with the spoke core metal part; a rim molding part for molding the resin layer integrally with the rim core metal part; and a gate for flowing a resin material into the mold. Of the spoke molding part and the rim molding part, the gate is provided at the spoke molding part.