Tapered Flange Mold Assembly for Tape Reel Precision
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Solution Overview
Problem
Existing tape reel manufacturing methods do not provide a precise method for shaping the flanges, leading to suboptimal positioning error signals and tape winding issues due to lack of control over the taper angle and surface precision of the flanges.
Innovation Solution
A resin injection mold assembly with a convexly shaped mold surface is used to create flanges with tapered inside surfaces, featuring multiple sections with varying taper angles, ensuring precise molding and improved surface precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding methods are used to manufacture flanges, then the manufacturing process is simple, but the surface precision and taper angle accuracy of the flange inside surface are insufficient
Solution Approach 1:
The mold surface is divided into multiple sections (first, second, third surface sections) with different taper angles. Each section independently forms a corresponding region of the flange inside surface, allowing precise control of the tapered shape while maintaining a manageable mold structure.
Solution Approach 2:
Different sections of the mold surface have different taper angles tailored to specific regions of the flange. The first surface section has a larger taper angle for the inner region, the second surface section has a smaller taper angle for the outer region, and the third surface section has an intermediate taper angle for the transition region, optimizing each local area.
2Measurement precision
If the flange taper angle is not precisely controlled, then the molding process is simple, but the positioning error signal and tape winding accuracy deteriorate
Solution Approach 1:
The mold surface is pre-configured with the precise tapered geometry including multiple surface sections with specific taper angles before the molding process. This preliminary preparation of the mold surface ensures that the flange inside surface is formed with the correct taper angle and high surface precision during injection molding, eliminating the need for post-processing.
3Reliability
If a single taper angle is used for the entire flange inside surface, then the mold design is simple, but the tape winding stability and positioning accuracy are reduced
Solution Approach 1:
The mold surface is configured with different taper angles in different regions: the first surface section (inner region) has a larger taper angle, the second surface section (outer region) has a smaller taper angle, and the third surface section (transition region) has an intermediate taper angle. This local differentiation optimizes tape winding stability and positioning accuracy across the entire flange surface.
Solution Approach 2:
The flange inside surface is segmented into three regions corresponding to three mold surface sections. Each section is formed by a specific taper angle region of the mold, allowing the tape to be optimally positioned and wound across different radial positions of the flange.
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 method results in flanges with enhanced surface precision, facilitating stable and precise winding of recording tapes, reducing positional errors and maintaining the tape wound effectively.
Implementation Method 1
A resin material is injected into the mold assembly, and cooled or solidified and then removed as a molded flange from the mold assembly
Implementation Method 2
The resin injection mold assembly having a mold cavity for molding the flange has a mold surface which borders at least a part of the mold cavity configuring the tapered inside surface of the flange and is shaped convexly to the mold cavity
Data Source
AI summary
A tape reel assembly comprises a reel hub and flanges coaxially secured to, and extending radially outwardly from, opposite axial ends of the reel hub, respectively, each flange being molded by resin injection molding and having a tapered inside surface sloping down at a fixed taper angle from an inside periphery to an outside periphery thereof. The flange is molded by the use of an injection mold having a mold surface which borders at least a part of a mold cavity for configuration of the tapered inside surface of the flange and is convexly curved to the mold cavity.