Structural Element Fixing in Recesses for Precise Injection Molding
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Solution Overview
Problem
Existing methods for producing components with structural elements, such as those for electrical machines, face challenges in achieving high quality and dimensional accuracy while being simple, fast, and cost-effective, particularly due to difficulties in injection molding processes with complex geometries.
Innovation Solution
A method involving a carrier body with recesses, where a structural element is partially or fully arranged within a first recess portion and a filler means in a second recess portion, with a fixing material injected to secure the element, allowing for precise fixing and simplifying the injection molding process by isolating complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a structural element is fixed in a recess by injecting fixing material directly into the recess, then the fixing process is simple, but the dimensional accuracy and quality are poor due to complex geometries affecting the injection molding process
Solution Approach 1:
The recess is divided into two distinct portions: a first recess portion for receiving the structural element and a second recess portion for receiving the filler means. This segmentation isolates the complex geometry (second portion) from the injection molding process (first portion), allowing precise fixing of the structural element while simplifying the injection process by excluding problematic geometric regions.
Solution Approach 2:
The complex geometric regions (second recess portion) are extracted or excluded from the injection molding process. By placing filler means in these regions and defining them as separate from the first recess portion, the injection process only needs to fill the simpler first recess portion, thereby improving dimensional accuracy while reducing process complexity.
2Ease of manufacture
If filler means is arranged in complex geometry regions before injection, then the injection molding process is simplified, but the device complexity increases due to additional arrangement steps
Solution Approach 1:
The filler means is arranged in the second recess portion before the injection molding process begins. This preliminary action prepares the complex geometry regions in advance, ensuring they do not interfere with the subsequent injection process. The structural element is also positioned in the first recess portion beforehand, allowing the injection process to proceed smoothly with improved ease of manufacture.
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 enhances the quality and dimensional accuracy of components by ensuring reliable and reproducible fixing of structural elements within complex geometries, improving the efficiency and cost-effectiveness of the production process.
Implementation Method 1
a fixing material, in particular consisting of plastic, is injected into the first recess portion of the recess of the carrier body in the course of an injection moulding process, wherein the fixing material fixes the at least one structural element within the recess
Data Source
AI summary
A method for producing a component provided with at least one structural element, in particular a component for an electrical machine, wherein the structural element(s) is fixed in a recess of a carrier body by a fixing material introduced in an injection moulding process, wherein the following method steps are provided: providing a carrier body provided with at least one recess, arranging the structural element(s) at least partially, in particular completely, within a first recess portion arranged in the recess of the carrier body, arranging at least one filler means in a second recess portion of the recess of the carrier body, injecting a fixing material, in particular consisting of plastic, into the first recess portion of the recess of the carrier body in the course of an injection moulding process, wherein the fixing material fixes the at least one structural element(s) within the recess.