Tool Insert with Distortion Cushion for Curved Grinding Plates
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Solution Overview
Problem
Conventional injection molding methods for producing grinding plates with Velcro hooks face challenges such as limited surface availability for microstructuring, substructures being oriented in a non-optimal straight line, leading to unfavorable force transmission and three-dimensional distortion, which complicates the production process and results in a cost-intensive, labor-intensive, and complex adhesive connection.
Innovation Solution
A tool insert with a laminar structure and a distortion cushion is used, allowing for the introduction of curved surfaces and radially oriented Velcro hooks, enabling a robust and durable connection between the grinding plate and attachment, while minimizing distortion through iterative machining of the distortion cushion without altering the laminations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional injection molding methods are used to produce Velcro hooks on grinding plates, then the production process becomes complex and labor-intensive, but the connection strength between grinding plate and attachment is insufficient
Solution Approach 1:
The patent combines the Velcro hook production and attachment to the grinding plate surface into a single injection molding process. The tool insert with lamination assemblies allows Velcro hooks to be molded directly onto the grinding plate in one operation, eliminating the need for separate adhesive bonding steps and reducing production complexity while maintaining connection strength.
Solution Approach 2:
The tool insert serves multiple functions: it molds the grinding plate basic body, creates the Velcro hook microstructures, and ensures proper orientation and connection strength all in one device. The lamination assemblies provide both structural support and microstructuring capabilities, reducing the need for multiple specialized tools and processes.
2Reliability
If Velcro hooks are mounted using adhesive connection, then the connection can be formed, but the process requires complicated pretreatment and manual work steps
Solution Approach 1:
The injection molding process with the specialized tool insert performs the attachment function automatically. The molten material itself carries and positions the Velcro hooks, which are molded directly onto the grinding plate surface without requiring external adhesive applications or manual positioning steps. The process is self-contained and eliminates the need for separate pretreatment operations.
3Force
If substructures are arranged in straight lines, then the injection molding is simpler, but the force transmission is non-optimal
Solution Approach 1:
The patent uses radially oriented lamination assemblies arranged in arc segments rather than straight lines. This radial arrangement optimizes force transmission by aligning the Velcro hooks with the rotational direction of the grinding disk, improving mechanical efficiency. The curved configuration is achieved through the insert frame geometry and lamination assembly positioning.
4Productivity
If the grinding attachment is regularly exchanged due to wear, then the grinding function is maintained, but the connection method becomes a bottleneck for productivity
Solution Approach 1:
The radial arrangement of Velcro hooks in arc segments matches the rotational motion of the grinding disk, creating superior mechanical interlocking and force distribution. This optimized configuration increases the attachment's service life by distributing wear more evenly across the contact surface, while the strong Velcro connection allows for rapid attachment and detachment when exchange is needed.
Data Source
AI summary
A tool insert for the production of an object by an injection molding method, wherein the injection molding tool includes an insert frame and at least one lamination assembly having a plurality of individual laminations, wherein the at least one lamination assembly is inserted in the insert frame. In further aspects, the invention relates to a method and a system for producing an object having curved surfaces using the tool insert, and to an object which can be produced with the method. The system for producing an object comprises a tool insert and a sliding element. A basic idea of the invention is that curved surfaces can be introduced into the object in that the insert frame has curved surfaces and/or at least one distortion cushion is arranged between the insert frame and the at least one lamination assembly.