Molding unit and method of molding article

Abstract

The present disclosure relates to a molding unit having: a first molding station having a first mold with a first mold cavity; a second molding station having a second mold with a second mold cavity; a transfer unit having a support and at least a first core extending from the support, the transfer unit being arranged for moving the first core into a first molding position at the first molding station and into a second molding position at the second molding station, the first core extends into the first mold cavity when the first core is in the first molding position and extends into the second mold cavity when the first core is in the second molding position; and a core actuation unit arranged such that, at least at the first molding station, when the first core moves into the first molding position, the first core moves from a first core position into a second core position relative to the support.

Description

Technical Field

[0001] The present disclosure relates to a molding unit having at least two molding stations and a transfer station for transferring at least a first core between the at least two molding stations. Background Art

[0002] It is generally known that a molding unit may have at least two molding stations for sequentially injecting plastic material into a mold cavity to form at least a two-component article. A transfer unit such as a dividing plate may be used to transfer at least a first core between the at least two molding stations. Articles (e.g., a two-component toothbrush) may be made in such a molding unit. A molding unit having two molding stations may simultaneously inject different plastic materials at different molding stations.

[0003] There is generally a need to provide such moulding units with greater flexibility, thereby allowing a greater degree of product design options. Summary of the invention

[0004] According to at least one aspect, a molding unit is provided, the molding unit having: a first molding station, the first molding station including a first mold having a first mold cavity; a second molding station, the second molding station including a second mold having a second mold cavity; a conveying unit, the conveying unit including a support member and at least a first core extending from the support member, the conveying unit being arranged to move the first core to a first molding position at the first molding station and to a second molding position at the second molding station, the first core extending into the first mold cavity when the first core is in the first molding position and extending into the second mold cavity when the first core is in the second molding position; and a core actuating unit, the core actuating unit being arranged so that at least at the first molding station, when the first core is moved to the first molding position, the first core moves from the first core position to the second core position relative to the support member.

[0005] Preferred further features related to this aspect are in particular the presence of at least a third molding station; the presence of at least a second core extending from the support member, when the first core is in a first molding position in which the first core extends into the first mold cavity, the second core is in a first molding position in which the second core extends into the second mold cavity; a third core position, when the first core is in the second molding position, the first core will be in this third core position relative to the support member, and the core actuation unit is arranged to move the core into this third core position.

[0006] According to at least one aspect, there is provided a method of moulding an article, preferably by using a moulding unit as discussed herein, the method comprising the steps of:

[0007] - moving the first core into a first molding position in which the first core extends into a first mold cavity of a first mold,

[0008] - when moving the first core into the first molding position, moving the first core from a first core position relative to the support, where the first core is arranged, into a second core position relative to the support, wherein the first core is in the second core position when the first core is in the first molding position,

[0009] - injection moulding a first plastic component into the first mould cavity to form a first part of the article,

[0010] - moving the first core from the first molding position into a second molding position in which the first core extends into a second mold cavity of a second mold,

[0011] - moving the first core from the second core position relative to the support to a third core position relative to the support different from the second core position when moving the first core into the second molding position, wherein the first core is in the third core position when the first core is in the second molding position, and

[0012] - Injection moulding a second plastic component into the second mould cavity to form a second part of the article. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present disclosure will be further clarified by a detailed description of exemplary embodiments and with reference to the accompanying drawings. In the accompanying drawings,

[0014] Figure 1 is a diagram of a movable mold half, a transfer unit in a molding position relative to the movable mold half, and a fixed mold half of a molding unit according to the present disclosure, the molding unit having four molding stations;

[0015] Figure 2 Yes Figure 1 An illustration of the movable mold half shown, but with the transfer unit shown in an ejection position rather than a molding position;

[0016] Figure 3 yes Figure 2 An enlarged view of a portion of the movable mold half and a transfer unit is shown;

[0017] Figure 4A is a perspective view of a first core extending from a support and in a first core position relative to the support, and in particular, wherein a first core actuation subunit and a second core actuation subunit of a core actuation unit are positioned relative to each other such that they can be mechanically engaged when the support is moved toward the movable mold half;

[0018] Figure 4B yes Figure 4A a perspective view of the first core shown, but with the transfer unit moved towards the first molding station half of the movable mold half, so that the first core is now in a first molding position relative to the first mold cavity of the first molding station, and wherein the first core is moved by the mechanical interaction element of the core actuation unit into a second core position relative to the support;

[0019] Figure 4C is with Figure 4A a similar illustration with the first core in a fourth core position relative to the support and positioned for movement into a second molding position in a second mold cavity half of a second molding station half;

[0020] Figure 4D is with Figure 4B a similar illustration wherein the first core is moved into a third core position relative to the support and into a second molding position in which the first core extends into a second mold cavity half of a second mold station half; and

[0021] Figure 5 The semi-transparent illustration is of a portion of the support, showing elements of the first core actuation subunit which are otherwise hidden in the support, in particular the meshing rack and pinion. DETAILED DESCRIPTION

[0022] According to the present specification, the terms "first", "second", "third" and "fourth" etc. are not used to refer to the order of molding stations such that, for example, the first molding station will mean the molding process starts at the beginning thereof, if not otherwise indicated. These terms are only used to indicate different elements, objects or concepts (such as positions) of the same nature. For example, the use of the terms "first core position", "second core position", "third core position" and "fourth core position" does not necessarily mean that the core is subsequently moved into these positions as indicated by their numbering, but only means that the object can be brought into these four positions, and the order in which these positions are achieved is not constrained by the terms, but will become clear from the context provided by the description.

[0023] The molding unit as discussed herein comprises a fixed molding half and a movable molding half realizing at least two molding stations, each of which comprises at least one mold (or mold insert) defining at least one mold cavity, and the molding unit further comprises a transfer unit having at least a first core, the first core being arranged at a support of the transfer unit and extending from the support. The transfer unit is arranged to move the first core from one molding station (e.g. from the first molding station) to another molding station (e.g. to the second molding station) so that an intermediate product made at one molding station can be transferred to another molding station for adding another material component, wherein a final product or article can be produced, but this will exclude the case where the molding unit only produces intermediate products to be finished elsewhere. The transfer station may comprise a plate capable of rotation and axial movement, for example a dividing plate. Thus, the transfer unit may have four positions: a first transfer position in which the first core is positionally aligned with the first molding station; a second transfer position in which the first core extends into the first cavity of the first molding station, which can be said to be the first molding position of the first core; a third transfer position in which the first core is positionally aligned with the second molding station; and a fourth transfer position in which the first core extends into the second cavity of the second molding station, which can be said to be the second molding position of the first core. The transfer unit may include at least a second core, which may be moved simultaneously with the first core. When the first core extends into the first cavity of the first molding station, the second core may extend into the second cavity of the second molding station, and when the first core extends into the second cavity of the second molding station, the second core may extend into the first cavity of the first molding station. Instead of two molding stations, the molding unit may include three molding stations, or four molding stations, etc. Although the number of cores need not correspond to the number of molding stations, the transfer unit may include three cores in the case of three molding stations and four cores in the case of four molding stations. One of the molding stations may be replaced by a demoulding station, wherein, instead of a further molding step, the final or intermediate product or article is removed from the core. In addition, each molding station may include a plurality of cavities, and instead of a core, the transfer unit may include a corresponding plurality of cores, each of which extends into one of the plurality of cavities of the corresponding molding station, so that a plurality of articles or intermediate articles can be injection molded simultaneously at a given molding station. For example, the molds of different molding stations may each define two or three or four or eight or 16 or 32 or the like number of mold cavities for injection molding a corresponding number of intermediate or final products simultaneously. It should also be understood that the step of injection molding the plastic material into the mold cavity requires that the fixed molding half and the movable molding half are closed.

[0024] It is known that the molten plastic material of the component of the article or product to be manufactured in the mold cavity of the molding station is injected into the mold cavity through a nozzle arranged at the fixed molding half. Therefore, the injection side of the plastic material is predefined by the control device. If the other components of the product should now be overmolded only on the back side of the previously molded intermediate product, for example, where the back side should refer to the side of the product facing the movable molding half, the other components need to be guided from the front side of the product to the back side of the product, and corresponding channels must be provided because the injection side also remains as a fixed mold half. However, according to the present specification, at least the first core is arranged to be movable, specifically arranged to rotate around the axis of rotation, so that the previous back side of the intermediate product can face the fixed molding half. The axis of rotation can preferably coincide with or be parallel to the longitudinal axis of the first core, and further preferably wherein the longitudinal axis of the first core extends through the fixed end of the core and the free end opposite to the fixed end, the fixed end being the position where the core is attached to the support. Then, the other components do not need to be guided toward the back side and do not need to provide corresponding channels. This allows for greater design freedom in the final product appearance.

[0025] In brief, at least the first core is arranged to be rotatable, and a core actuation unit is provided to affect the selective rotation of the first core at least at one of the molding stations. The core actuation unit may have a first core actuation subunit and a second core actuation subunit, the first core actuation subunit being arranged at a support and connected to the first core, the second core actuation subunit being arranged at at least one of the first molding station or the second molding station to affect the rotation of the first core when the first core is moved into the corresponding molding position. The first core actuation subunit and the second core actuation subunit may be arranged for mechanical engagement when the first core is moved into at least one of the at least two molding positions.

[0026] Thus, the first core has a first core position relative to the support of the transfer unit before being moved into the first molding position. When the first core is in the first core position, it can be aligned in position with the first mold and thus with the first mold cavity. The first core has a second core position relative to the support that is different from the first core position and, in the case where the first core extends into the first cavity, when the first core is in the first molding position, the first core is in the second core position relative to the support. Furthermore, when the first core is in the second molding position, the first core can have a third core position relative to the support of the transfer station that is different from the second core position, in which second molding position the first core extends into the second cavity of the second mold. When the transfer unit moves the first core out of the first molding position, the first core can adopt a fourth core position relative to the support, which fourth core position can in particular be identical to the first core position relative to the support, i.e. the first core can move oppositely when the first core moves out of the first molding position compared to when the first core moves into the first molding position.

[0027] The core actuation unit is provided to influence the movement of the first core so that the first core is in a first core position or a second core position relative to the support depending on the position of the conveying unit. The core actuation unit may include a first core actuation subunit and a second core actuation subunit, the first core actuation subunit being arranged at the conveying unit, specifically at the support, and the second core actuation subunit being arranged at at least one of the two molding stations, for example at the first molding station. The first core actuation subunit and the second core actuation subunit may be arranged to be mechanically engaged when the conveying unit moves from its first conveying position to its second conveying position or when the conveying unit moves from its third conveying position to its fourth conveying position. As an example, the first core actuation subunit may include a first core actuation element, a second core actuation element and a first bending follower arranged at the first core actuation element. The second core actuation subunit may include a first guide bending element arranged at a fixed position relative to the first molding station. In operation, when the conveying unit (particularly the support) is moved, for example, from a first conveying position to a second conveying position, the first curve follower may form a mechanical engagement with the first guide curve element so that the first curve follower moves along the curve defined by the first guide curve element. The moved first curve follower may accordingly move the first core actuating element, and the first core actuating element may then move the second core actuating element to move the first core from a first core position relative to the support to a second core position relative to the support. To further give further details of this example, the first guide curve element may include a channel with an open end, and the first curve follower may be a protrusion, preferably a freely rotatable wheel, which engages with and is guided by the channel when the conveying unit is moved. The first core actuating element may be a linearly extended rack or gear rod that meshes with a gear or large gear that implements the second core actuating element. Therefore, the movement of the protrusion in the channel causes a linear movement of the gear rod, thereby causing the rotation of the gear. The rack may be arranged at a frame structure that is positively guided to move only in a linear manner. The gear may be fixedly connected at the first core, thereby causing the first core to rotate when the gear rotates; the first core may be arranged to rotate about a longitudinal axis, for example, the first core may be mounted on a longitudinally extending shaft.

[0028] The first guide bend element can be designed to rotate the first core in any desired angle in a clockwise or counterclockwise direction, for example, by 5 degrees or 10 degrees or 15 degrees or 20 degrees or 30 degrees or 45 degrees or 60 degrees or 75 degrees or 90 degrees or 120 degrees or 150 degrees or 180 degrees, or any other value between 0 degrees and 180 degrees (such as 18 degrees or 72 degrees, etc.). The core actuation unit may include a second guide bend element, which can then be arranged in a fixed position relative to the second molding station or any other molding station, and when the conveying unit moves from the third conveying position to the fourth conveying position, the first bend follower or the second bend follower arranged at the first core actuation element can then be engaged with the second guide bend element. The second guide bend element can be designed to rotate the first core by a rotation angle different from the rotation angle caused by the first guide bend element. For example, the first guiding bend element may be designed to rotate the first core by +90 degrees, and the second guiding bend element may be designed to rotate the first core by -90 degrees or +180 degrees, etc. When the first core is in the second molding position, the first core may then have a third core position relative to the support that is different from the second core position.

[0029] Although not essential, the core actuation unit may cause a movement of the first core when the conveying unit is moved out of the second conveying position in which the first core is in a second core position relative to the support, and the first core may thus be moved into a fourth core position when the conveying unit moves the first core out of the first molding position. The mentioned movement may preferably be a reverse movement of the first core as already explained, i.e. the fourth core position of the first core relative to the support may be identical to the first core position of the first core relative to the support. The resulting possibility of moving the first core relative to the support of the conveying unit into different rotational positions about the longitudinal axis of the first core allows the injection of additional plastic components at arbitrary circumferential positions around the intermediate product conveyed between the molding stations.

[0030] The first guide bend element (and all other guide bend elements, if such elements are present) may be replaceable (e.g. via a quick release mechanism) so that the angle of rotation caused by the first guide bend element may be varied and adapted to the product or article to be manufactured. This is particularly useful in cases where the mould unit is intended to mould small batches of various products.

[0031] An example method of molding an article or product according to the present disclosure may include the following steps:

[0032] (a) moving a first core into a first molding position in which the first core extends into a first mold cavity of a first mold,

[0033] (b) while moving the first core into the first molding position, moving the first core from a first core position relative to the support at which the first core is disposed to a second core position relative to the support, wherein the first core is in the second core position when the first core is in the first molding position,

[0034] (c) injection moulding a plastic component into a first mould cavity to form a part of the article, which may be a first plastic component forming a first intermediate article,

[0035] (d) moving the first core from the first molding position into a second molding position in which the first core extends into a second mold cavity of a second mold,

[0036] (e) moving the first core from a second core position relative to the support to a third core position relative to the support different from the second core position when moving the first core into the second molding position, wherein the first core is in the third core position when the first core is in the second molding position, and

[0037] (f) injection moulding a further plastic component into the second mould cavity to form a further part of the article, this may be a second component from the more than two components, or it may be the final component of a two-component article.

[0038] The steps of moving the first core from the first core position into the second core position and moving the first core from the second core position into the third core position may involve rotating the first core about a rotation axis, in particular about a longitudinal axis of the first core.

[0039] The method may further involve the step of moving the first core from the second core position back into the first core position when the first core is moved out of the first molding position.

[0040] The above description of the molding unit naturally translates into the corresponding method steps.

[0041] Figure 1 is a diagram of an example molding unit 1 comprising a movable molding half 2 and a fixed molding half 3, Figure 1 A view of the inside of the movable mould half 2 and the fixed mould half 3 is provided and it should be understood that Figure 1Therefore, no view of the molding unit 1 in its actual working arrangement is provided, in which the inner sides shown here will face each other and will usually be mounted on a common support. The molding unit 1 here comprises four molding stations 101, 102, 103 and 104, but it should be understood that in general a molding unit according to the present application has at least two molding stations, and thus may have two, three, four, five, etc. molding stations. Each molding station here comprises a mold 111, 112, 113, 114, and each mold defines a mold cavity 121, 122, 123 and 124. Likewise, it should be understood that each mold may define a plurality of mold cavities instead of a single mold cavity, so that a plurality of articles may be injection molded simultaneously (the term "article" may also include intermediate articles, since the final article may be made at only one of the molding stations, without excluding that the molding unit only allows the manufacture of intermediate articles to be completed elsewhere). The movable molding half 2 comprises a movable platen 4 carrying four mold halves 1110, 1120, 1130 and 1140. The transfer unit 20 has a support 21, which is realized here as a rotatable indexing plate carried on an axis to achieve axial and rotational movement, for example by a controllable drive unit, but it should be understood that the transfer unit according to the present application does not need to include a rotatable indexing plate, but may alternatively include, for example, a linear transfer plate, etc. The fixed molding half 3 comprises a fixed platen 4 carrying four complementary mold halves 1111, 1121, 1131 and 1141, which together with the mold halves 1110, 1120, 1130 and 1140 form the mentioned four molds 111, 112, 113 and 114, each of which defines at least one mold cavity 121, 122, 123, 124, respectively. In operation, the movable molding half 2 and the fixed molding half 3 will be clamped together to allow molten plastic material to be injection molded into the mold cavities 121, 122, 123, 124, specifically, wherein the molten plastic material can be injection molded into all mold cavities 121, 122, 123, 124 simultaneously. A first intermediate product can be made in the mold cavity 121, the first intermediate product can be overmolded with another plastic component in the mold cavity 122 to form a second intermediate product, which can then be overmolded in the mold cavity 123 to form a third intermediate product, and then the third intermediate product can be overmolded in the mold cavity 124 to form the final product. The final product will be a 4-component product. Accordingly, in the case of a two-component product, the molding unit will only need to include two molding stations, and for a 3-component product, three molding stations. The transfer unit can provide three preferably equidistant stops, and the molding unit can have only two molding stations. This allows the product to be demoulded from the core at the demoulding station. The three stops can then have an angular distance of 120 degrees from each other in the direction of rotation. Figure 1 In the embodiment shown, one of the molding stations can be replaced by a demolding station. The demolding station effectively allows the article to be removed from the transfer cycle without interrupting the injection cycle.

[0042] The molding unit 1 may be part of a plastic injection molding machine comprising an injection unit to provide heated molten plastic material to an inlet of a fixed molding half 3 (such an inlet is usually arranged on the back side of the fixed molding half 3, i.e., on the side opposite to the side where the mold halves are located). It is assumed here that the basic structure of a plastic injection molding machine is known to a person skilled in the art, and the focus of the present description is on the molding unit 1 and in particular on the novel features of the molding unit 1 discussed herein.

[0043] The support 21 of the transfer unit 20 is shown in a state in which it is in a molding position so that the movable mold half 2 and the fixed mold half 3 can now be clamped together. The support 21 carries four cores 201, 202, 203 and 204, which extend from the support 21 and are shown aligned one-to-one with the mold cavities 121, 122, 123 and 124. The support 21 is arranged so that it can be moved around the indexing plate axis A. I The support 21 is rotated so that in the example shown, a rotation of the support by plus or minus 90 degrees or multiples of plus or minus 90 degrees moves the cores 201, 202, 203, and 204 into a different one-to-one alignment with the mold cavities 121, 122, 123, and 124. As is known in the art, the support 21 can be motor driven. It is emphasized that the cores 201, 202, 203, and 204 and the mold cavities 121, 122, 123, and 124 shown here do not reflect the cores and cavities of any actual article to be manufactured, but rather the cores shown substantially completely fill the cavities and are therefore shown for explanation purposes only. Figure 1The cores shown show the cores in their respective mold positions. It should be understood that at molding station 101, the basic article structure 10 is molded, and at the other three molding stations 102, 103 and 104, the three overlapping molded portions 11, 12, 13 of the article 10 are molded, as indicated by the differently shaded oval areas on the article 10. As will be explained, when the core is moved into its molding position at molding station 102, the core is not rotated relative to the support in this example, but the mold is moved 180 degrees relative to the support at molding station 103 and 90 degrees relative to the support at molding station 104. Since the focus of the present disclosure is on the movement of the core relative to the support and therefore also relative to the mold, molding station 103 will be referred to as the first molding station and molding station 104 will be referred to as the second molding station, even though, as just explained, they are the third and fourth stations in the sequence of making the exemplary article 10.

[0044] Figure 2 It is an illustration of the movable molding half 2 together with the support 21 of the transfer unit 20 in an axially withdrawn position, in which the support is at a certain distance from the movable mold half 2 and the cores 201, 202, 203 and 204 do not extend into the corresponding parts of the cavities 121, 122, 123 and 124 formed by the mold halves 1110, 1120, 1130 and 1140.

[0045] Figure 3 yes Figure 2 A perspective view of a portion of the movable mold half 2 of the molding unit 1 together with the conveying unit 20 and the first core 203 and the second core 204 mounted at the support 21 of the conveying unit 20 together with the elements realizing the core actuation unit 300 is shown. The core actuation unit 300 comprises a first core actuation subunit 310 arranged at the conveying unit 20 (preferably arranged at the support 21) and a second core actuation subunit 320 arranged at the movable mold half 2. The first core actuation subunit 310 here comprises at least a first frame structure 311, which has a rack 3111 and a first bend follower 3112 and a second bend follower 3113. In addition, the first core actuation subunit 310 comprises a gear that forms a toothed engagement with the rack 3111, wherein the gear itself is not visible here and is referred to as Figure 5 The first core 203 is fixedly connected to the gear so that the rotation of the gear also rotates the first core 203. The second core actuating subunit 320 here comprises a first guiding bend element 321, which is here arranged at the first molding station 103 for ease of description. The first core 203 is shown in a first core position relative to the support 21. Figure 3, it is shown that the core actuation unit 300 may include: a further element of the first core actuation subunit 310, namely a second frame structure 312 including a rack and a first and a second bend follower arranged at the support 21 relative to the second core 204; and at least one further element, namely a second guide bend element 322 of the second core actuation subunit 320, which is arranged at the movable mold half 2, preferably at a second molding station 104 different from the first molding station 103 at which the first guide bend element 321 is arranged. The second core 204 may also be connected to a gear, which forms a gear engagement with the rack of the second frame structure 312.

[0046] The first core 203 in the first core position at the first molding station 103 carries the article 10 having the molded product formed in the previous molding station ( Figure 1 and Figure 2 The base structure molded at the molding station 101 in the molding station and the base structure molded at the previous molding station ( Figure 1 and Figure 2 A first overmolded structure 11 is overmolded onto the base structure at a molding station 102 in FIG. A second overmolded structure 12 (see FIG. Figure 1 ) can be added to the article 10 at the first molding station 103, and the third overmolding structure 13 can be added to the article 10 at the second molding station 104, as will be referred to in FIG. 4A to FIG. 4D Explained in more detail.

[0047] Reference Figure 4A and Figure 4B The present invention describes how the first core 203 moves from a first core position relative to the support 21 to a second core position relative to the support 21 due to the mechanical interaction between the first core actuating subunit 310 of the core actuating unit 300 and the second core actuating subunit 320 of the core actuating unit 300 when the conveying unit 20 (specifically the support 21) moves from the first conveying position shown to the second conveying position, in which the first core 203 is in its first molding position and extends into the first mold cavity 123 of the first mold 113, wherein the first mold half 1130 of the first mold 113 is shown here and the first mold half 1130 includes a first part 1230 of the first mold cavity 123.

[0048] Reference Figure 4C and Figure 4DIt is further described how the first core 203 is moved from the fourth core position relative to the support 21 to the third core position relative to the support 21 due to the mechanical interaction of the first core actuating subunit 310 of the core actuating unit 300 and the second core actuating subunit 320 of the core actuating unit 300 when the conveying unit 20 is moved from the third conveying position shown into the fourth conveying position in which the first core 203 is in its second molding position and extends into the second mold cavity 124 of the second mold 114, wherein here the first mold half 1140 of the second mold 114 is shown and the second mold half 1140 includes the first part 1240 of the second mold cavity 124. As already mentioned and as from Figure 1 As can be clearly seen in the drawings, the movable mould halves and the fixed mould halves are to be clamped together to form first and second moulds and first and second mould cavities in which moulding of the components of the article takes place.

[0049] exist Figure 4A , the transfer station 20 and the support 21 carrying the first core 203 are in a first transfer position in which the first core 203 is in its first core position relative to the support 21. The core actuation unit 300 includes elements of a first core actuation subunit 310 and a second core actuation subunit 320. Specifically, the first core actuation subunit 310 includes a first frame structure 311 disposed at the support 21, and the second core actuation subunit 320 includes a first guide bend element 321 disposed at the movable mold half (specifically disposed at the first molding station 103). The first frame structure 311 includes a first bend follower 3112 aligned with a groove 3211 of the first guide bend element, the groove 3211 defining a bend or channel into which the first bend follower 3112 will enter when the support 21 and the movable mold half 2 move toward each other. The first guiding bend element 321 is shown here as having a bend or channel on the inner side (i.e. the side facing the frame structure 311) and on the outer side. The situation here is that the first guiding bend element 321 is arranged to be replaceable in the first position and is arranged in the second position so that it can be positioned in a mirror-image manner on the other side of the frame structure 311. The guiding bend element 321 is configured here so that it will cause a -180 degree rotation of the first core 203 at the first molding station 103. If the guiding bend element is positioned at the other side of the frame structure 311, it will cause a +180 degree rotation of the first core 203, which will produce the same end result. If the first guiding bend element 321 is configured to cause a different rotation, for example -145 degrees, then when positioned on the other side of the frame structure 311, it will cause a +145 degree rotation. In Figure 4A, the first core 203 is shown in its first core position relative to the support 21. It can be seen that the first overmolded structure 11 molded at the previous molding station is positioned on top of the article 10, ie on the side facing the fixed mold half comprising the injection nozzle.

[0050] Figure 4B The first core 203 is shown at the first molding station 103 after the second overlapping molding structure 12 has been injection molded. The first core 203 is in its second core position relative to the support 21. The second core 203 is rotated by -180 degrees due to the mechanical interaction of the described mechanical interaction elements of the core actuation unit 300. Specifically, when the support 21 and the movable mold half 2 move toward each other, the first bend follower 3112 of the first frame structure 311 of the first core actuation subunit 310 enters into the bend or channel 3211. The first bend follower 3112 is thereby driven to perform a forced motion, which causes the rack 3111 of the first frame structure 311 to move linearly to the left (with reference to the plane of the paper), and the rack 3111 moves the gear fixedly connected to the first core 203 (see Figure 5 ), so that the first core 203 rotates relative to the support 21 by a predetermined angle (here -180 degrees), which is defined by the channel 3211 and the transmission of the rack 3111 and the pinion. The first core 203 is in the second core position relative to the support 21 and in the first molding position at the end of the movement, in which the first core extends into the first mold cavity 123 of the first mold 113. Due to the rotation of the first core 203, different parts of the article 10 face the fixed mold half, and thus the second overlapping molded structure 12 can be injection molded without any channels for guiding the injection molded material downwards. This allows greater freedom in designing the articles manufactured by the molding unit described here. In the embodiment shown here, when the support 21 and the movable mold half 2 are separated from each other again, the first core 203 rotates into the fourth core position relative to the support 21. Due to the reversal of the mechanical interaction just described, the fourth core position is then identical to the first core position. It may be considered to disengage the first frame structure 311 from the first guiding curve element 321 for a reverse movement so that a different rotation (if any) will occur and the fourth core position may then be different from the first core position.

[0051] exist Figure 4C2, the transfer station 20 and the support 21 carrying the first core 203 are in a third transfer position in which the first core 203 is in its fourth core position relative to the support 21, which here is identical to the first core position relative to the support 21. The core actuation unit 300 comprises elements of a first core actuation subunit 310 and a second core actuation subunit 320. Specifically, the first core actuation subunit 310 comprises a first frame structure 311 disposed at the support 21, and the second core actuation subunit 320 comprises a second guiding bend element 322 disposed at the second molding station 104. The first frame structure 311 comprises a first bend follower 3112 aligned with a groove 3221 of the second guiding bend element 322, the groove 3211 defining a bend or channel into which the first bend follower 3112 will enter when the support 21 and the movable mold half 2 move toward each other. The second guiding bend element 322 is shown here as having a bend or channel on the inner side (i.e. the side facing the first frame structure 311) and on the outer side. It is also the case here that the second guiding bend element 322 is arranged to be replaceable in the first position and is arranged in the second position so that it can be positioned in a mirror-image manner on the other side of the frame structure 311. The second guiding bend element 322 is configured here so that it will cause a -90 degree rotation of the first core at the second molding station 104. If the second guiding bend element is positioned at the other side of the frame structure, it will cause a +90 degree rotation of the first core. Figure 4C , the first core 203 is shown in its first core position relative to the support 21. It can be seen that the first overmolded structure 11 molded at the previous molding station is positioned on top of the article 10, as shown in FIG. Figure 4A The situation in.

[0052] Figure 4D The first core 203 is shown at the second molding station 104 after the third overlapping molding structure 13 has been injection molded. The first core 203 is in its third core position relative to the support 21. The second core 203 is rotated -90 degrees due to the mechanical interaction of the described mechanical interaction elements of the core actuation unit 300. Specifically, when the support 21 and the movable mold half 2 move toward each other, the first bend follower 3112 of the first frame structure 311 of the first core actuation subunit 310 enters the bend or channel 3221 of the second guide bend element 322. The first bend follower 3112 is thereby driven to perform a forced motion, which causes the rack 3111 of the first frame structure 311 to move to the left (with reference to the plane of the paper), and the rack 3111 moves the gear fixedly connected to the first core 203 (again, see Figure 5), so that the first core 203 is rotated relative to the support 21 by a predetermined angle (here -90 degrees), which is defined by the channel 3221 and the transmission of the rack 3111 and the pinion. The first core 203 is in the third core position relative to the support 21 and in the second molding position at the end of the movement, in which the first core extends into the second mold cavity 124 of the second mold 114. Due to the rotation of the first core 203, different parts of the article face the fixed mold half, and thus the third overmolded structure 13 can be injection molded without any channel for guiding the injection-molded material downwards.

[0053] Figure 5 3 is a diagram of a detail of a support 21 and a first core 203 connected to an element of a first core actuating subunit 310, wherein a first frame structure including a rack 3111 is shown. The support 21 is depicted so that the arrangement of the first core actuating subunit 310 extending within the support 21 can be seen. The first frame structure 311 is positively guided by the support 21 so that only linear reciprocating motion of the first frame structure is allowed. The rack 3111 is in a meshing arrangement with a gear 313 that is fixedly connected to the first core 203 so that the linear motion of the rack 3111 causes the rotation of the gear 313, which causes the rotation of the first core 203 around its longitudinal axis.

[0054] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​cited. Instead, unless otherwise indicated, each such dimension is intended to represent the stated value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

Claims

1. A molding unit, comprising: a first molding station having a first mold including a first mold cavity; a second molding station having a second mold including a second mold cavity; a conveying unit comprising a support and at least a first core extending from the support; the transfer unit being arranged for moving the first core into a first molding position at the first molding station and into a second molding position at the second molding station, the first core extending into the first mold cavity when the first core is in the first molding position and the first core extending into the second mold cavity when the first core is in the second molding position; as well as A core actuation unit is arranged such that, at least at the first molding station, the first core moves relative to the support from a first core position into a second core position when the first core moves into the first molding position. 2 . The molding unit according to claim 1 , wherein the first core is rotatable about a rotation axis, and the core actuation unit is arranged to move the first core from the first core position to the second core position by rotating about the rotation axis along a first rotation angle.

3. A moulding unit according to claim 1 or claim 2, wherein the core actuation unit is arranged to move the first core relative to the support into a third core position different from the second core position when the first core is moved into the second moulding position.

4. A molding unit according to one of claims 1 to 3, wherein the core actuation unit is arranged to move the first core from the second core position to a fourth core position when the first core is moved out of the first molding position and before moving the first core into the second mold position, preferably wherein the fourth core position is the same as the first core position.

5. A molding unit according to one of claims 1 to 4, wherein the core actuation unit comprises only mechanical interaction elements, preferably wherein the core actuation element comprises a first core actuation sub-unit arranged at the conveying unit and a second core actuation sub-unit arranged at the first molding station and / or the second molding station, further preferably wherein the first core actuation sub-unit comprises a first core actuation element capable of moving relative to the first core and a second core actuation element fixed relative to the first core, wherein the first core actuation element and the second core actuation element are arranged for mechanical interaction, so that movement of the first core actuation element causes movement of the second core actuation element and thereby causes movement of the first core. 6 . The molding unit according to claim 5 , wherein the first core actuating element and the second core actuating element are engaged with each other.

7. The molding unit according to claim 5 or claim 6, wherein the first core actuating element comprises a frame structure and a rack, and the second core actuating element comprises a gear.

8. A molding unit according to one of claims 5 to 7, wherein the second core actuating subunit includes at least a first guide bending element arranged at the first molding station and at least a first bending follower arranged at the first core actuating element, wherein the first bending follower is arranged to mechanically engage with the first guide bending element when the first core moves to the first molding position, and is arranged to move along the first guide bending element so that the first core actuating element and the mechanically interacting second core actuating element move, thereby moving the first core from the first core position to the second core position.

9. The molding unit according to claim 8, wherein the first guide curve element is replaceable.

10. A molding unit according to one of claims 5 to 9, wherein the second core actuating subunit includes a second guide bending element arranged at the second molding station, wherein a first bending follower is arranged to mechanically engage with the second guide bending element when the first core moves to the second molding position, and is arranged to move along the second guide bending element so that the first core actuating element and the mechanically interacting second core actuating element move, thereby moving the first core to a third core position.

11. The molding unit according to one of claims 1 to 10, comprising at least three molding stations, and wherein the transfer unit is arranged to move the first core from any one of the at least three molding stations to any other one of the at least three molding stations.

12. Moulding unit according to one of claims 1 to 11, wherein the transfer unit comprises an indexing plate realizing the support, the indexing plate being arranged for rotation about an indexing plate axis and for axial movement along the indexing plate axis.

13. A method of molding an article, preferably by using a molding unit according to any one of claims 1 to 12, comprising the following steps moving the first core into a first molding position in which the first core extends into a first mold cavity of a first mold; while moving the first core into the first molding position, moving the first core from a first core position relative to a support at which the first core is disposed to a second core position relative to the support, the second core position being different from the first core position, wherein the first core is in the second core position when the first core is in the first molding position; injection molding a first plastic component into the first mold cavity to form a first portion of the article; moving the first core from the first molding position to a second molding position in which the first core extends into a second mold cavity of a second mold; while moving the first core into the second molding position, moving the first core from the second core position relative to the support to a third core position relative to the support different from the second core position, wherein the first core is in the third core position when the first core is in the second molding position; as well as A second plastic component is injection molded into the second mold cavity to form a second portion of the article.

14. A method for molding an article according to claim 13, wherein moving the first core from the first core position to the second core position and moving the first core from the second core position to the third core position involves rotating the first core about a rotation axis, preferably wherein the rotation axis is coincident with or parallel to a longitudinal axis of the first core, further preferably wherein the longitudinal axis of the first core extends through a fixed end of the core and a free end opposite the fixed end, the fixed end being the position where the core is attached to the support.

15. A method of moulding an article according to claim 13 or claim 14, the method comprising the step of moving the first core from the second core position to a fourth core position as the first core moves from the first moulding position to the second moulding position, preferably wherein the fourth core position is the same as the first core position.

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