Two-Stage Mold Geometry for Accurate Metal-Resin Composite Forming
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Solution Overview
Problem
Molding accuracy of metal members in metal-resin composites is compromised due to the difficulty in pressing the metal member along the lower mold when using a set of molds designed for the final composite shape.
Innovation Solution
The mold configuration includes an upper mold with a first press surface closer to the lower mold than a second press surface, allowing the metal member to be pressed accurately along the lower mold's shape, and the use of movable portions to control resin flow and prevent strength loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the distance between the upper mold and lower mold is set to the thickness of metal member and resin material, then the mold structure is simplified, but the metal member cannot be properly pressed along the lower mold shape
Solution Approach 1:
The solution moves from a single-distance constraint to a two-distance configuration: the first press surface is positioned at a first distance from the lower mold for metal member press-forming, while the second press surface is positioned at a second distance for integral molding. This dimensional change in the mold structure allows both accuracy requirements to be met simultaneously
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
Improves molding accuracy of the metal member and ensures the metal-resin composite maintains structural integrity by preventing resin exclusion and enhancing corner precision.
Implementation Method 1
press-forming a metal member and integrally molding the metal member that is press-formed and a resin material
Data Source
AI summary
A mold for producing a metal-resin composite by press-forming a metal member and integrally molding the metal member that is press-formed and a resin material includes an upper mold and a lower mold that sandwich the metal member and the resin material. The upper mold includes a first press surface for press-forming the metal member and a second press surface for integrally molding the metal member and the resin material. A distance between the first press surface and the lower mold is shorter than a distance between the second press surface and the lower mold.