Technical Briefs

Assembly Molding of Tight Mechatronic System - A Model Approach

[+] Author and Article Information
Christoph Heinle

Institute of Polymer Technology, Universität Erlangen-Nürnberg, Am Weichselgarten 9, 91058 Erlangen-Tennenlohe, Germanyheinle@lkt.uni-erlangen.de

Martina Vetter, Gottfried W. Ehrenstein, Dietmar Drummer

Institute of Polymer Technology, Universität Erlangen-Nürnberg, Am Weichselgarten 9, 91058 Erlangen-Tennenlohe, Germany

J. Manuf. Sci. Eng 132(5), 054505 (Oct 05, 2010) (4 pages) doi:10.1115/1.4002547 History: Received February 02, 2010; Revised July 22, 2010; Published October 05, 2010; Online October 05, 2010

Offering a large variety of options, assembly injection molding represents an innovative and highly integrative technique of manufacturing mechatronic systems. This is due to the fact that it combines many technical functions such as casings and sealing of several elements made of different materials in one single manufacturing process. Particularly, the combination of various materials is a significant technological benefit and a big challenge at the same time. System tightness is a major target. This paper presents a model to improve the understanding of how leaking occurs and of the mechanisms underlying such as shrinkage and warpage behaviors related to material, process, and design. It shall also be the basis for investigations on the phenomena and development of strategies to improve the systems produced by assembly molding in terms of media tightness. Very important are the complex interaction and intereffects acting on thermal and structural shrinkages, the elements’ warpage entailed, and the adhesion between them.

Copyright © 2010 by American Society of Mechanical Engineers
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Figure 1

Mechanisms and influences on shrinkage and warpage with respect to system tightness (*v, specific volume; T, temperature)

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Figure 2

Sketch of 2D model approach for static-transient temperature field in mold, polymer, and insert. Left: geometry; right: factors influencing thermal masses.

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Figure 3

Static-transient 2D-cooling. Top: TMm/TMi∼1; bottom: TMm/TMi⪢1.

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Figure 4

Inhomogeneous shrinkage in a polymer in a cooled mold and with an uncooled metal insert because of the pressure and thermal conditions. Left: sketch TM:TMm/TMi⪢1; right: locally different pressure, spec. volume, temperature (pvT)-characteristic.

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Figure 6

Gaps between metal and polymer along the flow direction. Left: position of sections; right: photos of the sections.



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