Integrated forming die and forming method for composite special-shaped part

Abstract

A boss is arranged in the middle of a front mold core of a front mold, the boss is matched with a base plate of the composite special-shaped part, first strip-shaped grooves are formed in the boss, rapid cooling and rapid heating assemblies are assembled in the first strip-shaped grooves, positioning pins corresponding to annular inserts are arranged on the front mold core and distributed along the periphery of the boss, and the positioning pins are matched with the annular inserts. Three-stage stepped cavities are formed in a rear mold core of the rear mold, a second strip-shaped groove is formed in the first-stage stepped cavity, a groove extrusion assembly capable of stretching out or retracting back is arranged in each second strip-shaped groove, and the front mold and the rear mold are closed, so that the first-stage stepped cavity of the three-stage stepped cavities is communicated with a hot runner on the front mold, and the integrated forming mold is formed through combination. The machining device is small in occupied area and high in machining efficiency, assembly gaps of the machined composite special-shaped protection plate can be eliminated, and the structural strength is improved.

Description

Technical Field

[0001] This invention relates to the field of molds, and in particular to an integral molding mold and molding method for composite irregular parts. Background Technology

[0002] See Figure 1 This is a schematic diagram of a protective plate structure. The substrate of this protective plate is a fiberglass board with grooves. The fiberglass board is surrounded by a PP+GF 30% composite material frame. The frame has a two-stage stepped structure, with the first stage surrounding the substrate and multiple annular inserts on the surface of the second stage.

[0003] Currently, when manufacturing this type of protective panel, companies need to process the fiberglass board, outer frame, and ring insert separately, and then assemble them to obtain the product. This production method requires the assembly of multiple parts, which is costly, inefficient, and results in protective panel products with poor structural strength, making it difficult to meet the needs of customers.

[0004] Therefore, how to efficiently and cost-effectively process such high-strength protective plate products is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] One of the objectives of this invention is to address the shortcomings of existing technologies by providing an integral molding mold for composite irregular parts. This mold has a small footprint, high processing efficiency, and can eliminate assembly gaps in the processed composite irregular protective plates, thereby improving structural strength.

[0006] The second objective of this invention is to provide a method for preparing composite irregular parts by integral molding using the above-mentioned mold, which can efficiently and quickly process composite irregular protective plates with superior quality and strength.

[0007] One of the technical solutions to achieve the objective of this invention is: an integral molding mold for composite irregular parts, comprising a front mold and a rear mold. The front mold includes a panel, on which an A plate is mounted. A hot runner plate is disposed between the panel and the A plate, and a hot runner is disposed in the hot runner plate. A front mold core is disposed in the A plate, and a boss is disposed in the middle of the front mold core. The boss is a two-stage stepped boss, the first-stage surface of which is adapted to the substrate of the composite irregular part. A needle valve is installed on the second-stage surface and communicates with the hot runner. The boss is provided with a first strip groove adapted to the groove on the substrate of the composite irregular part. A rapid cooling and heating component is assembled in each of the first strip grooves. Positioning pins corresponding to the annular inserts are disposed on the front mold core and distributed along the periphery of the boss. The rear mold includes a base plate, on which a product ejector is mounted. The product ejection mechanism is provided with a B plate, and a rear mold core is provided in the B plate. The rear mold core is provided with three-level stepped cavities. The height of the first-level stepped cavity is lower than that of the second-level stepped cavity but higher than that of the third-level stepped cavity. The third-level stepped cavity is provided with a vent hole and an insert. The first-level stepped cavity is provided with a second strip groove that is adapted to the groove on the composite irregular part substrate. Each second strip groove is provided with a groove extrusion assembly that can extend or retract. The front mold and the rear mold are closed. The first-level stepped cavity corresponds to the boss, and the third-level stepped cavity corresponds to the front mold core. The space enclosed by the periphery of the composite irregular part substrate, the first-level stepped cavity, the second-level stepped cavity, the second-level stepped surface of the boss, the front mold core, and the insert forms the outer frame forming cavity of the composite irregular part, which is combined to form an integral forming mold.

[0008] The first-stage stepped cavity is provided with multiple positioning holes, and each positioning hole is equipped with a positioning suction cup.

[0009] The rapid cooling and heating assembly is fixedly installed in the first strip groove, and the inner cavity of the rapid cooling and heating assembly is connected to the cold medium inlet and outlet pipe and the hot medium inlet and outlet pipe.

[0010] The top surface of the rapid cooling and heating component is provided with a forming groove to accommodate the groove of the composite irregular part.

[0011] The top surface of the groove extrusion assembly is provided with forming ribs corresponding to the grooves of the composite irregular parts.

[0012] The extended end of the positioning pin passes through the second-stage stepped cavity of the rear mold core.

[0013] The second technical solution to achieve the objective of this invention is: a method for molding composite irregular parts using any of the above-mentioned integral molding molds, comprising the following steps: 1) Take the substrate of the composite irregular part, place it in the first-stage stepped cavity of the rear mold, and position it by positioning suction cup; 2) Take the corresponding number of ring inserts, place them around the boss of the front mold, and position them using positioning pins; 3) The front mold and the rear mold are joined together, so that the boss of the front mold contacts the substrate; 4) Introduce a heat transfer medium into the inner cavity of the rapid cooling and heating assembly to heat the corresponding position on the substrate to 100°C; 5) Inject 30% PP+GF molten material into the first-stage stepped cavity through the hot runner, wrap it around the substrate, and hold it under pressure; 6) The groove extrusion assembly moves toward the front mold and cooperates with the forming groove on the top surface of the rapid cooling and heating assembly to form a groove on the substrate. A cold medium is introduced into the inner cavity of the rapid cooling and heating assembly to complete the plasticization. 7) The front and rear molds open, and the ejector pins of the ejection mechanism push out the molded part.

[0014] The heat medium in step 4) is 100°C hot water, the molding time in step 6) is 30s, and the cold medium is room temperature water.

[0015] The above technical solution has the following beneficial effects: 1. The integrated molding die of this invention includes a front mold and a rear mold. The front mold includes a panel, on which an A-plate is mounted. A hot runner plate is disposed between the panel and the A-plate, and a hot runner is disposed in the hot runner plate to provide molten material. A front mold core is disposed in the A-plate, and a boss is disposed in the middle of the front mold core. The boss is a two-stage stepped boss, the first-stage surface of which is adapted to the composite irregular part substrate. A needle valve is installed on the second-stage surface and communicates with the hot runner. The boss is provided with a first strip groove adapted to the groove on the composite irregular part substrate. Each first strip groove is equipped with a rapid heating and cooling component for rapidly heating or cooling the corresponding position on the composite irregular part substrate. Positioning pins corresponding to the annular inserts are disposed on the front mold core, distributed along the periphery of the boss, for positioning the annular inserts. The rear mold includes a base plate, on which a product ejection mechanism is mounted for ejecting the molded product. The product ejection mechanism is provided with a B plate, in which a rear mold core is disposed. The rear mold core is provided with three-stage stepped cavities. The height of the first-stage stepped cavity is lower than that of the second-stage stepped cavity but higher than that of the third-stage stepped cavity. The third-stage stepped cavity is provided with vent holes and inserts to form a molding cavity for the outer frame of the composite irregular part, and to provide venting. The first-stage stepped cavity is provided with a second strip groove that corresponds to the groove on the substrate of the composite irregular part. Each second strip groove is provided with a groove extrusion assembly that can extend or retract to extrude grooves on the assembled substrate. The front mold and rear mold are joined together, with the first-level stepped cavity corresponding to the boss and the third-level stepped cavity corresponding to the front mold core. This allows the space enclosed by the periphery of the composite irregular part substrate, the first-level stepped cavity, the second-level stepped cavity, the second-level stepped surface of the boss, the front mold core, and the insert to form the outer frame forming cavity of the composite irregular part. This combination constitutes an integral molding mold. In the mold, the boss of the front mold core and the first-level stepped cavity on the rear mold core are used to clamp and position the substrate of the composite irregular part. The groove is formed by the groove extrusion component set on the rear mold core. The outer frame forming cavity of the composite irregular part is used for injection molding to obtain the outer frame, which wraps around the edge of the substrate. This can eliminate the assembly gap between the outer frame and the substrate and effectively ensure the connection strength between the outer frame and the substrate. Similarly, the annular insert is embedded in the outer frame, and the positioning pin maintains the hole shape of the annular insert during the embedding process, ensuring the normal function of the annular insert. This allows for the rapid and efficient production of high-quality, high-strength composite irregular part protective plates.

[0016] 2. The first-stage stepped cavity is provided with multiple positioning holes, and each positioning hole is equipped with a positioning suction cup for quickly positioning the substrate of the composite irregular part guard plate, so as to ensure the precision and quality of the injection molded product.

[0017] 3. The rapid cooling and heating assembly is fixedly installed in the first strip groove. The inner cavity of the rapid cooling and heating assembly is connected to the cold medium inlet and outlet pipe and the hot medium inlet and outlet pipe. The cold medium or the hot medium enters or flows out of the inner cavity of the rapid cooling and heating assembly through the cold medium inlet and outlet pipe and the hot medium inlet and outlet pipe, respectively, to rapidly heat or rapidly cool the area of ​​the composite irregular part corresponding to the first strip groove. Heating is used to soften the local area of ​​the substrate for extrusion molding, and cooling is used to plastically maintain the shape of the extruded substrate, thereby improving the molding efficiency of the composite irregular part and simplifying the molding process.

[0018] 4. The molding method of this invention involves first taking the substrate of the composite irregular-shaped protective plate and placing it in the first-stage stepped cavity of the rear mold. It is then quickly positioned using a positioning suction cup. A required number of annular inserts are then assembled onto the positioning pins of the front mold. After mold closing, the assembled substrate is located between the boss of the front mold core and the first-stage stepped cavity of the rear mold core. Simultaneously, the assembled annular inserts are positioned in the second-stage stepped cavity. By heating and softening the area of ​​the substrate to be processed into grooves, the groove extrusion assembly is activated, extruding the required grooves onto the substrate. The substrate is then rapidly cooled and plasticized. Simultaneously, 30% molten PP+GF material is injected into the first-stage stepped cavity, forming the outer frame of the composite irregular-shaped part within the surrounding cavity. This outer frame wraps around the perimeter of the substrate, simultaneously wrapping each annular insert. While the positioning pins occupy space, the inner holes of the wrapped annular inserts penetrate the entire outer frame. After mold opening and ejection, a high-quality composite irregular-shaped protective plate product with high connection strength is obtained. The entire processing is quick and convenient, with a short production cycle, eliminating assembly steps and reducing the use of connectors.

[0019] The following description, in conjunction with the accompanying drawings and specific embodiments, provides further details. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the protective plate in the background art of the present invention; Figure 2 This is a schematic diagram of the mold closing mechanism of the present invention; Figure 3 This is a schematic diagram of the structure of the panel of the present invention; Figure 4 This is a schematic diagram of the hot runner plate of the present invention (including hot runner and needle valve). Figure 5 This is a schematic diagram of the structure of plate A of the present invention; Figure 6 This is a schematic diagram of the front mold core of the present invention (including the rapid cooling and heating components). Figure 7 This is a schematic diagram of the structure of the rear mold core of the present invention (excluding the inserts); Figure 8 This is a schematic diagram of the structure of the rear mold core of the present invention (including inserts). Figure 9This is a schematic diagram showing the fit between the positioning suction cup and the rear mold core of the present invention; Figure 10 This is a schematic diagram of the structure of plate B of the present invention; Figure 11 This is a schematic diagram of the ejection mechanism of the product of the present invention (excluding the ejector pin, but including the cylinder with the groove extrusion assembly). Figure 12 This is a schematic diagram of the structure of the base plate of the present invention; Figure 13 This is a schematic diagram showing the cooperation between the rapid cooling and heating component and the groove extrusion component of the present invention; Figure 14 This is a schematic diagram showing the fit between the front mold core and the rear mold core of the present invention; Figure 15 for Figure 14 Enlarged view of point M in the middle.

[0021] In the attached diagram, 1 is the front mold, 101 is the panel, 102 is the A plate, 103 is the hot runner plate, 104 is the front mold core, 105 is the boss, 106 is the first strip groove, 107 is the rapid cooling and heating assembly, 108 is the positioning pin, 2 is the rear mold, 201 is the base plate, 202 is the product ejection mechanism, 203 is the B plate, 204 is the rear mold core, 205 is the three-stage stepped cavity, 205a is the first-stage stepped cavity, 205b is the second-stage stepped cavity, 205c is the third-stage stepped cavity, 206 is the second strip groove, 207 is the groove extrusion assembly, 208 is the positioning hole, 209 is the positioning suction cup, 210 is the vent hole, and 211 is the insert. Detailed Implementation

[0022] In this invention, structures or processes not described are conventional structures or processes in the mold industry. Example 1

[0023] See Figures 2 to 15The integral molding mold for the composite irregular part includes a front mold 1 and a rear mold 2. The front mold 1 includes a panel 101, on which an A plate 102 is mounted. A hot runner plate 103 is disposed between the panel 101 and the A plate 102, and a hot runner is disposed in the hot runner plate 103. A front mold core 104 is disposed in the A plate 102. Specifically, a mounting groove is provided on the A plate, and the front mold core is assembled in the mounting groove and fixed in the A plate. A boss 105 is provided in the middle of the front mold core 104. The boss 105 is a two-stage stepped boss. Its first-stage stepped surface is adapted to the substrate of the composite irregular part, and a needle valve is installed on the second-stage stepped surface and communicates with the hot runner. That is, the first-stage stepped surface is the central planar area of ​​the boss, and the second-stage stepped surface is an annular area surrounding the first-stage stepped surface, and its height is lower than that of the first-stage stepped surface. Obviously, the needle valves are evenly distributed along the periphery of the first-stage stepped surface. The boss 105 has a first strip groove 106 on its first stepped surface that corresponds to the groove on the composite shaped part substrate. Each first strip groove 106 is equipped with a rapid cooling / heating assembly 107. Specifically, there are three first strip grooves: two are arranged in parallel intervals, and the third is arranged perpendicularly to the two aforementioned first strip grooves. The rapid cooling / heating assembly 107 is fixedly installed in the first strip groove 106. The inner cavity of the rapid cooling / heating assembly 107 is connected to a cold medium inlet / outlet pipe and a hot medium inlet / outlet pipe. The top surface of the rapid cooling / heating assembly 107 has a forming groove to accommodate the groove of the composite shaped part. The front mold core 104 has positioning pins 108 corresponding to the annular insert, distributed along the periphery of the boss 105. Specifically, there are sixty-seven positioning pins. The rear mold 2 includes a base plate 201, on which a product ejection mechanism 202 is mounted. Specifically, the product ejection mechanism 202 includes a product ejection plate with multiple ejector pins, which is a conventional arrangement. A B plate 203 is provided on the product ejection mechanism 202, and a rear mold core 204 is disposed within the B plate 203. Specifically, a mounting groove is provided on the B plate, and the rear mold core is assembled into the mounting groove and fixed to the B plate. The rear mold core 204 is provided with three-level stepped cavities 205. The first-level stepped cavity 205a corresponds to the boss 105 (including the first-level stepped surface and the second-level stepped surface). The second-level stepped cavity 205b and the third-level stepped cavity 205c correspond to the front mold core 104. The height of the first-level stepped cavity 205a is lower than that of the second-level stepped cavity 205b and higher than that of the third-level stepped cavity 205c. The bottom of the third-level stepped cavity is provided with multiple vent holes 210 and multiple inserts 211. The design of the inserts is a conventional design in the mold field. They provide both the mold cavity surface and maintain the venting function of the vent holes. Multiple ejector pins provided by the ejection mechanism can pass through the rear mold core and are distributed at intervals along the second-level stepped cavity 205b.The first-stage stepped cavity 205a is provided with a second strip groove 206 that corresponds to the groove on the composite irregular part substrate and the first strip groove provided on the front mold core boss. Each second strip groove 206 is provided with a groove extrusion assembly 207 that can extend or retract. Specifically, the top surface of the groove extrusion assembly 207 is provided with forming ribs corresponding to the groove of the composite irregular part, and each groove extrusion assembly extends or retracts through multiple cylinders. In order to facilitate the positioning of the pre-set composite irregular part substrate, eight positioning holes 208 are provided in the first-stage stepped cavity 205a, and each positioning hole 208 is equipped with a positioning suction cup 209. The front mold 1 and the rear mold 2 are joined together. The first-level stepped cavity 205a corresponds to the boss 105, the second-level stepped cavity 205b, and the third-level stepped cavity 205c correspond to the front mold core 104. This makes the space enclosed by the periphery of the composite irregular part substrate, the first-level stepped cavity 205a, the second-level stepped cavity 205b, the second-level stepped surface of the boss, the front mold core, and the insert 211 form the outer frame forming cavity of the composite irregular part. The needle valve corresponds to the first-level stepped cavity 205a. Specifically, fourteen needle valves are connected to the hot runner. The extension end of the positioning needle 108 passes through the second-level stepped cavity 205b of the rear mold core, and the combination constitutes an integral forming mold. Example 2

[0024] The method for molding composite irregular parts using the integral molding die of Example 1 includes the following steps: 1) Take the substrate of the composite irregular part, place it in the first-level stepped cavity of the rear mold, and position it by adsorption through eight positioning suction cups; 2) Take sixty-seven ring inserts and place them around the boss of the front mold, and position them by passing a positioning pin through the inner hole of the ring insert. 3) The front mold and the rear mold are joined together so that the first-level stepped surface of the front mold boss contacts the substrate. 4) Introduce a heat medium, which is 100°C hot water, into the inner cavity of the rapid cooling and heating component to heat the corresponding position of the substrate to 100°C. 5) 30% PP+GF molten material is injected into the first-stage stepped cavity through the hot runner and the set needle valve. The molten material fills the entire outer frame forming cavity of the composite irregular part and wraps around the substrate. During the filling process, the generated gas is discharged from the mold through the vent hole and pressure is maintained. 6) The groove extrusion assembly moves toward the front mold and cooperates with the forming groove on the top surface of the rapid cooling and heating assembly to form three grooves on the substrate. The forming time is 30 seconds. A cold medium, which is room temperature water, is introduced into the inner cavity of the rapid cooling and heating assembly to complete the plasticization. 7) The front and rear molds open, and the ejector pins of the ejection mechanism push out the molded part.

Claims

1. A one-piece mould for the integral forming of a composite profiled part, comprising a front mould (1) and a back mould (2), characterised in that: The front mold (1) comprises a panel (101) on which an A plate (102) is installed, a hot runner plate (103) is arranged between the panel (101) and the A plate (102), a hot runner is arranged in the hot runner plate (103), a front mold core (104) is arranged in the A plate (102), a boss (105) is arranged in the middle of the front mold core (104), the boss (105) is a two-step boss, the first step surface of the boss (105) is adapted to the composite profiled part base plate, a needle valve is installed on the second step surface of the boss (105) and is communicated with the hot runner, a first slot (106) is arranged on the boss (105) and is adapted to the groove on the composite profiled part base plate, a rapid cooling and heating assembly (107) is assembled in each first slot (106), a positioning needle (108) corresponding to the annular insert is arranged on the front mold core (104) and is distributed along the periphery of the boss (105), The rear mold (2) comprises a bottom plate (201) on which a product ejection mechanism (202) is installed, a B plate (203) is arranged on the product ejection mechanism (202), a rear mold core (204) is arranged in the B plate (203), a three-step cavity (205) is arranged on the rear mold core (204), the height of the first step cavity (205a) is lower than that of the second step cavity (205b) and higher than that of the third step cavity (205c), and the third step cavity is provided with a vent hole (210) and an insert block (211), A second slot (206) is arranged in the first step cavity (205a) and is adapted to the groove on the composite profiled part base plate, a groove extrusion assembly (207) which can be extended or retracted is arranged in each second slot (206), The front mold (1) and the rear mold (2) are closed, the first step cavity (205a) corresponds to the boss (105) and the third step cavity (205c) corresponds to the front mold core (104), so that the space formed by the periphery of the composite profiled part base plate, the first step cavity (205a), the second step cavity (205b), the second step surface of the boss, the front mold core and the insert block (211) forms a composite profiled part outer frame forming cavity, and the combination constitutes an integral molding mold.

2. The one-piece molding die for a composite profiled member according to claim 1, characterized in that: A plurality of positioning holes (208) are arranged in the first step cavity (205a), and a positioning suction cup (209) is assembled in each positioning hole (208).

3. The one-piece molding die for a composite profiled member according to claim 1, characterized in that: The rapid cooling and heating assembly (107) is fixedly installed in the first slot (106), and the inner cavity of the rapid cooling and heating assembly (107) is communicated with a cold medium inlet and outlet pipeline and a hot medium inlet and outlet pipeline.

4. The one-piece molding die for a composite profiled member according to claim 3, characterized in that: A forming groove is arranged on the top surface of the rapid cooling and heating assembly (107) and is adapted to the groove of the composite profiled part.

5. The one-piece molding die for a composite profiled member according to claim 1, characterized in that: A forming rib corresponding to the groove of the composite profiled part is arranged on the top surface of the groove extrusion assembly (207).

6. The one-piece molding die for a composite profiled member according to claim 1, characterized in that: The extension end of the positioning needle (108) penetrates the second step cavity (205b) of the rear mold core.

7. A method of forming a composite profiled part using a one-piece mould according to any one of claims 1 to 6, characterised in that, The method comprises the following steps: 1) Take the base plate of the composite profiled part and place it in the first step cavity of the rear mold, and position it by the positioning suction cup; 2) Take a corresponding number of annular inserts and place them around the boss of the front mold, and position them by the positioning needle; 3) the front mold and the back mold are closed, so that the boss of the front mold contacts the substrate; 4) hot medium is introduced into the inner cavity of the quenching and heating assembly to heat the corresponding position of the substrate to 100℃; 5) PP+GF30% molten material is injected into the first stage stepped cavity through the hot runner, wrapped around the periphery of the substrate, and pressure is maintained; 6) the groove extrusion assembly moves towards the front mold and cooperates with the formed groove on the top surface of the quenching and heating assembly to form a groove on the substrate, cold medium is introduced into the inner cavity of the quenching and heating assembly, and the molding is completed; 7) the front mold and the back mold are opened, and the ejector pin of the ejector mechanism pushes out the molded part.

8. The method of claim 7, wherein, The hot medium of step 4) is 100℃ hot water, and the molding time of step 6) is 30s, and the cold medium is normal temperature water.

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