Toilet Blank Bonding With Partial Demolding Alignment
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Solution Overview
Problem
Traditional methods for manufacturing toilet blanks are inefficient, labor-intensive, and result in high scrap rates due to low structural strength, high mold usage, and difficulties in high-precision bonding, leading to high costs and low production efficiency.
Innovation Solution
A method involving a split structure manufacturing process where toilet blanks are formed from separate seat, inner container, and main body blanks using non-demolded mold parts for precise alignment and bonding, reducing operator contact and improving bonding accuracy through locating structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional integral mold grouting is used to manufacture toilet blanks, then the manufacturing process is simple, but the production efficiency is low, labor intensity is high, and the manufacturing cycle is long
Solution Approach 1:
The patent divides the traditional integral mold into multiple independent mold components (first mold component, second mold component, third mold component). Each component can be independently removed from its corresponding blank, enabling parallel processing and significantly improving production efficiency while reducing the overall manufacturing cycle time.
2Productivity
If split structure manufacturing with multiple blanks is used, then production efficiency improves, but the number of molds increases, processing cost increases, and bonding processes become cumbersome
Solution Approach 1:
The patent designs the mold components with universal functionality where each mold component serves multiple purposes: forming specific blank features, providing bonding surfaces, and acting as positioning references during assembly. This multi-functionality reduces the total number of molds needed and simplifies the manufacturing process.
Solution Approach 2:
The patent combines multiple functions into integrated mold components that simultaneously provide forming, bonding, and positioning capabilities. The mold components are designed to work together as a coordinated system, reducing the need for separate specialized molds and lowering overall manufacturing costs.
3Reliability
If complete demolding of blanks is performed before bonding, then operator contact with blanks increases, but full demolding is necessary for traditional bonding processes
Solution Approach 1:
The patent implements selective partial demolding where only specific mold components are removed from specific blanks based on bonding requirements. This segmented approach minimizes operator handling of fragile blanks while still enabling necessary bonding operations, thereby reducing scrap rate from operator contact.
Solution Approach 2:
The remaining mold components serve as intermediaries during the bonding process, providing stable support and precise positioning for the blanks. This eliminates the need for operators to directly handle and position fragile blanks, reducing contact-related damage and improving blank integrity.
4Ease of operation
If traditional bonding processes are used without positioning aids, then bonding operations are simple, but locating difficulties arise leading to low bonding precision
Solution Approach 1:
The mold components are designed with integrated positioning features that automatically align blanks during assembly. These features serve multiple functions: structural support, precise positioning, and bonding surface provision, enabling high-precision bonding without complex positioning operations.
Solution Approach 2:
The mold components are designed to self-align and self-position the blanks through built-in geometric features and locating structures. This self-positioning capability eliminates the need for complex external positioning aids or skilled operator intervention, achieving high bonding precision through the mold design itself.
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
The present invention relates to a method for manufacturing a toilet blank. The manufacturing method includes the following steps: a grouting step: producing a seat blank, an inner container blank and a main body blank; a first demolding step: demolding a part of a main body mold, a part of an inner container mold and a part of a seat mold; a first bonding step: bonding a first bonding surface of the inner container blank and a bonding surface of the main body blank to each other; a second demolding step: demolding another part of the inner container mold from the inner container blank; a second bonding step: bonding a bonding surface of the seat blank and a second bonding surface of the inner container blank to each other; and a third demolding step: demolding demolded parts of the seat mold, the inner container mold and the main body mold from a bonded toilet blank. By bonding the blanks to each other with parts of the molds not demolded, the contact of an operator with the blanks is reduced during bonding, and the blanks can be accurately located relative to each other using the parts of the molds.