A continuous inlay mold injection mold and process

Abstract

The application relates to a continuous inlay mold inner injection mold and process. Belonging to the technical field of loudspeaker accessory injection molds, the mold comprises an upper mold group, a lower mold group, a jacking mechanism and a pull winding mechanism. The injection area and the belt positioning area of the lower mold group are provided with mounting grooves, and a jacking column is arranged in the grooves. The jacking mechanism drives the vertical lifting of a material passing block through the cooperation of a driving body and a slope mechanism, so that the jacking column of the lower mold group is accurately jacked into or away from the first and second positioning holes on the material belt. The process flow comprises the steps of material belt passing, jacking column positioning injection, separation and automatic stepping. Through the precise mechanical interlocking of the jacking column and the positioning hole, the problem of high defective rate caused by the easy deviation and overturning of the extremely small size inlay under the injection force is effectively solved, and the positioning precision and the production automation degree are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the field of injection mold technology, specifically relating to a continuous in-mold injection mold and its process. Background Technology

[0002] As electronic products become thinner, smaller, and more integrated, the precision requirements for internal components and exterior decorative parts of audio equipment (such as Bluetooth speakers and smart headphones) are increasing. Inlays, as common structural components in audio equipment, are often fixed to the substrate inside the speaker using in-mold injection molding to achieve specific acoustic properties and mechanical strength.

[0003] The following are the main technical problems in the existing injection molding production process of audio inserts: 1. Positioning difficulties due to tiny size: Due to the limited internal space of speakers, the size of inserts is usually extremely small. During in-mold injection molding, the inserts need to be pre-positioned in a designated location within the mold cavity. For micro-inserts, continuous injection molding is prone to deviations during the coiling process.

[0004] 2. Displacement caused by injection molding force: During in-mold injection molding, molten plastic fluid is injected into the mold cavity at high pressure and high speed. Due to the light weight and small force-bearing area of ​​the insert, it is very easy to shift, flip, or misalign under the impact of the molten material.

[0005] 3. High defect rate: If the insert is not accurately positioned or shifts within the mold cavity, it will directly lead to defects such as exposed areas, incomplete sealing, structural interference, or appearance defects in the molded product. For extremely small parts, such offsets are often difficult to detect in real time during production, resulting in a large number of defective products, which seriously affects production efficiency and increases production costs.

[0006] In view of this, this solution was developed. Summary of the Invention

[0007] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a continuous in-mold injection mold and process for inserting a material strip, which can accurately position the material strip during in-mold injection.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a continuous in-mold injection mold for strip injection molding, wherein the strip includes a strip and a plurality of inlays connected to the strip, the strip has a first positioning hole spaced apart, and the inlay has a second positioning hole on the side near the strip, and includes an upper mold assembly, a lower mold assembly, a lifting mechanism and a winding mechanism. The lower module includes a lower mold base, a lower template is provided in the middle of the lower mold base, an injection molding area and a strip positioning area are formed on the lower template, an installation groove is formed on the injection molding area and the strip positioning area, and a top post is provided in the installation groove; The upper surface of the lower mold base has mounting notches on both sides. The lifting mechanism includes two material passing blocks and two lifting bodies. The two material passing blocks are respectively installed in the two mounting notches. The material passing blocks have material passing holes. The strip passes through the material passing hole of one material passing block, the injection area, and the material passing hole of the other material passing block in sequence. The two lifting bodies are installed on both sides of the lower mold base and drive the two material passing blocks to move up and down respectively. The strip moves up and down through the material passing blocks so that the ejector pin pushes into or away from the first positioning hole and the second positioning hole on the strip. The winding mechanism is used to pull the material strip to shift when the top column separates from the first positioning hole and the second positioning hole.

[0009] Furthermore, a connecting plate is formed between the two material passing blocks at a position corresponding to the material head. The connecting plate is disposed in the belt positioning area, and a corresponding hole is formed on the connecting plate that corresponds to the mounting groove in the belt positioning area.

[0010] Furthermore, the outer edge of the top column end face has a chamfer.

[0011] Furthermore, a pressure plate is provided at the upper end of the middle part of the connecting plate, and a gap is formed between the pressure plate and the connecting plate.

[0012] Furthermore, the material handling block includes a top cover and a base, and the bases of two material handling blocks are connected by a connecting plate. The top cover and the base are detachably connected.

[0013] Furthermore, the lifting body includes a lateral abutment block, a driving body, and a deflecting block. The lateral abutment block is installed on the outward side of the material passing block. The deflecting block is rotatably connected to the side wall of the lower mold base and located at the bottom end of the side of the lateral abutment block. The side of the lateral abutment block facing the deflecting block is a first inclined surface, and the side of the deflecting block facing the lateral abutment block is a second inclined surface. The first and second inclined surfaces are adapted to each other. The driving body drives the deflecting block to rotate and controls the lateral abutment block to rise and fall.

[0014] Furthermore, the lifting body also includes a mounting limit block, which is installed on the side of the lower mold base. The mounting limit block has a limiting groove that extends through both the upper and lower surfaces on its outward-facing side. The actuating block is located in the limiting groove, and the lateral abutment block extends into the limiting groove.

[0015] Furthermore, the injection molding area has two sets of injection molding modules, each set of injection molding modules has three injection molding stations, and each injection molding station has three spaced-apart limiting blocks near the belt positioning area, and the upper edge of the limiting blocks facing each other has a chamfer.

[0016] Furthermore, the upper module includes an upper mold base, and an upper template is provided on the lower surface of the upper mold base, with the upper template corresponding to the lower template.

[0017] A continuous in-mold injection molding process for insert-type bodies, employing a continuous in-mold injection mold for production, includes the following steps: S1. The strip passes through one of its feed holes, the injection area, the strip positioning area and another feed hole. The first positioning hole and the second positioning hole on the strip correspond to the mounting grooves formed on the injection area and the strip positioning area, respectively. S2. The lifting body moves down, causing the material strip to move down, so that the top column is pushed into the first positioning hole and the second positioning hole, the material strip is positioned, and the upper mold and lower mold are combined for injection molding. S3. After injection molding is completed, the upper mold moves upward, the lifting body moves upward, and the material strip moves upward, so that the top post and the first positioning hole and the second positioning hole are disengaged. The winding mechanism pulls the material strip forward a specified distance, and the above steps are repeated.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. Significantly improve positioning accuracy: By designing dedicated first and second positioning holes on the strip and insert, and setting top pillars in the injection area, the extremely small insert can achieve precise mechanical interlocking or self-alignment with the mold cavity, solving the problem of difficulty in observing and accurately fixing small parts during the mold closing process.

[0019] 2. Effectively resists high-pressure injection force: During injection molding, the ejector pins engage with the first and second positioning holes, creating a stable mechanical interlock between the insert and the mold. This structure effectively resists the impact force of high-speed injection of molten plastic, preventing the insert from shifting, flipping, or misaligning, thus ensuring a high degree of consistency in the position of the insert after molding.

[0020] 3. Relying on precise positioning and limiting structures, the system completely solves the appearance and functional defects caused by part displacement, such as exposed parts, incomplete sealing, and structural interference. This not only reduces the waste of raw materials but also avoids the production of large quantities of defective products, significantly reducing the company's overall production costs.

[0021] 4. Through the coordinated operation of the lifting mechanism (material guide block and lifting body) and the winding mechanism, automatic lifting and precise stepping of the material strip are achieved. The lifting body drives the smooth lifting and lowering of the lateral support block through the inclined plane, ensuring rapid switching of the material strip between positioning and conveying states, significantly improving production cycle time and automation level. Attached Figure Description

[0022] Figure 1This is a three-dimensional structural schematic diagram of a continuous inlay injection mold according to the present invention; Figure 2 For the present invention Figure 1 A partial three-dimensional structural diagram of the material strip at point A; Figure 3 This is a side view of the structure of the present invention; Figure 4 This is a three-dimensional structural diagram of the lower mold in this invention; Figure 5 For the present invention Figure 4 A partially enlarged structural diagram of the injection molding area and the belt positioning area at point B; Figure 6 This is a three-dimensional structural diagram of the material handling block in this invention.

[0023] The diagram shows the following markings: 1. Upper module; 11. Upper mounting plate; 12. Upper mold base; 13. Upper template; 2. Lower module; 21. Lower mold base; 22. Lower mounting plate; 23. Lower template; 231. Injection area; 2311. Limiting block; 232. Strip positioning area; 233. Top post; 234. Pressure plate; 3. Lifting mechanism; 31. Material passing block; 311. Connecting plate; 312. Strip groove; 313. Material passing hole; 314. Anti-warping block; 315. Top cover; 316. Base; 32. Lifting body; 321. Lateral abutment block; 322. Toggle block; 323. Mounting limit block; 4. Material strip; 41. Strip strip; 411. First positioning hole; 42. Inlay; 421. Second positioning hole; 43. U-shaped pin; 44. Sheet body. Detailed Implementation

[0024] To make the above features and advantages of the present invention more apparent and understandable, specific embodiments are described below in conjunction with the accompanying drawings for detailed explanation.

[0025] like Figures 1-6 As shown, this embodiment provides an in-mold injection mold with a continuous insert 42. The injection mold in this embodiment is used for injection molding of a strip 4. The strip 4 includes a strip 41 and multiple inserts 42 connected to the strip 41. Each insert 42 has two U-shaped pins 43 at its lower end. The strip 41 has spaced-apart first positioning holes 411, and the insert 42 has a second positioning hole 421 on the side near the strip 41. Multiple spaced-apart and downwardly extending sheets 44 are formed on the side of the strip 41 facing the insert 42. The injection mold includes an upper mold assembly 1, a lower mold assembly 2, a lifting mechanism 3, and a winding mechanism.

[0026] The upper module 1 includes an upper mounting plate 11 and an upper mold base 12. The upper mold base 12 is installed below the upper mounting plate 11. The upper surface of the upper mounting plate 11 is connected to the output end of the hydraulic cylinder. The lower surface of the upper mold base 12 is provided with an upper template 13.

[0027] The lower module 2 includes a lower mold base 21 and a lower mounting plate 22. The lower mold base 21 is mounted on the upper surface of the lower mounting plate 22. A lower template 23 is provided in the middle of the lower mold base 21. An injection molding area 231 and a strip positioning area 232 are formed on the lower template 23. The injection molding area 231 has two sets of injection modules. Each set of injection modules has three injection stations. Three spaced-apart limit blocks 2311 are formed near the strip positioning area 232 at each injection station. The upper edge of the limit block 2311 facing the same side has a chamfer. The chamfer design of its upper edge provides physical guidance for the U-shaped pin 43 to cut in, playing a preliminary limiting role. Mounting grooves are formed on the injection molding area 231 and the strip positioning area 232. A top post 233 is provided in the mounting groove. The outer edge of the end face of the top post 233 has a chamfer. The top post 233 is the key to achieving "zero displacement". The chamfered design of the outer edge of the end face of the top post 233 enables the top post 233 to have a self-correcting function when cutting into the positioning hole. Even if there is a slight initial deviation in the material strip 4, it can achieve secondary precise alignment through the chamfer guidance.

[0028] The upper mold base 12 and the lower mold base 21 are also provided with guide pillars commonly found in conventional molds, as well as injection ports provided on the upper mold plate 13. These are existing structures and will not be described in detail here.

[0029] The upper surface of the lower mold base 21 has mounting notches on both sides. The lifting mechanism 3 includes two material passing blocks 31 and two lifting bodies 32. The two material passing blocks 31 are respectively installed in the two mounting notches. Material passing holes 313 are formed on the material passing blocks 31. The strip 4 passes through the material passing hole 313 of one material passing block 31, the injection area 231 and the material passing hole 313 of the other material passing block 31 in sequence. The two lifting bodies 32 are installed on both sides of the lower mold base 21 and drive the two material passing blocks 31 to move up and down respectively. The strip 4 moves up and down through the material passing blocks 31 so that the top post 233 pushes into or away from the first positioning hole 411 and the second positioning hole 421 on the strip 4. Specifically, a connecting plate 311 is formed between the two material passing blocks 31 at the position corresponding to the material head. The connecting plate 311 is set in the strip positioning area 232. The connecting plate 311 has corresponding holes corresponding to the mounting groove in the strip positioning area 232. The bottom of the connecting plate 311 and the feed hole 313 are formed with the same strip groove 312, which is used to accommodate the sheet 44.

[0030] The feed block 31 includes a top cover 315 and a base 316. The base 316 is connected between two feed blocks 31 by a connecting plate 311. The top cover 315 and the base 316 are connected by screws. Preferably, a pressure plate 234 is provided at the upper end of the middle part of the connecting plate 311. A gap is formed between the pressure plate 234 and the connecting plate 311. The function of the pressure plate 234 is to prevent the feed belt 4 from jumping up and down.

[0031] Preferably, the top cover 315 is also provided with an anti-warping block 314 facing the belt positioning area 232. The anti-warping block 314 has a gap with the belt positioning area 232 and acts in the same way as the pressure plate 234.

[0032] The lifting body 32 includes a lateral abutment block 321, a driving body, a toggle block 322, and a mounting limit block 323. The lateral abutment block 321 is mounted on the outward side of the feed block 31. The toggle block 322 is rotatably connected to the side wall of the lower mold base 21 and located at the bottom end of the side of the lateral abutment block 321. The side of the lateral abutment block 321 facing the toggle block 322 is a first inclined surface, and the side of the toggle block 322 facing the lateral abutment block 321 is a second inclined surface. The first and second inclined surfaces are adapted to each other. The driving body drives the toggle block 322 to rotate and control the lateral abutment. The top block 321 rises and falls, driven by a drive motor. The mounting limit block 323 is installed on the side of the lower mold base 21. The outer side of the mounting limit block 323 has a limiting groove that runs through both the upper and lower sides. The toggle block 322 is located in the limiting groove, and the lateral abutment block 321 extends into the limiting groove. The function of the mounting limit block 323 is to prevent the drive motor from over-rotating and to reduce the cost of the drive motor. There is no need to select a high-precision drive motor; only an ordinary drive motor controlled synchronously by a synchronous encoder is required.

[0033] In this embodiment, two feed blocks 31 are installed in the mounting notches on both sides of the lower die base 21. The pressure plate 234 and the anti-warping block 314 on the connecting plate 311 maintain a specific gap with the material strip 4. This design forms a precision constraint channel, which forcibly constrains the material strip 4 to prevent it from jumping up and down or warping during high-speed winding, thus ensuring the flatness of the feed.

[0034] The pull-coil mechanism is used to pull the material strip 4 to shift when the top column 233 separates from the first positioning hole 411 and the second positioning hole 421. The pull-coil mechanism can be the existing common material strip 4 pull-coil mechanism. This solution does not improve it and will not be described in detail here.

[0035] This embodiment also provides an in-mold injection molding process for a continuous insert 42, which uses an in-mold injection mold for production and includes the following steps: S1. The strip 4 passes through one of its feed holes 313, injection area 231, strip positioning area 232 and another feed hole 313. The first positioning hole 411 and the second positioning hole 421 on the strip 4 correspond to the mounting grooves formed on the injection area 231 and the strip positioning area 232, respectively. The specific steps are as follows: remove the top cover 315 and the pressure plate 234 in the feed block 31, pass the strip 4 through, cover the top cover 315 and the pressure plate 234, and adjust the front and rear distance of the strip 4 so that the first positioning hole 411 and the second positioning hole 421 on the strip 4 correspond to the mounting grooves formed on the injection area 231 and the strip positioning area 232, respectively.

[0036] S2, the lifting body 32 moves down, causing the strip 4 to move down, so that the top post 233 is pushed into the first positioning hole 411 and the second positioning hole 421, the strip 4 is positioned, and the upper mold group 1 and the lower mold group 2 close for injection molding; the specific steps are as follows: when the work starts, the driving body rotates, and the upper end of the actuating block 322 moves from the low position of the first inclined plane to the high position. As the actuating block 322 rotates, the first inclined plane and the second inclined plane are completely tangent. At this time, the strip 4 moves down into place, and the first positioning hole 411 and the second positioning hole 421 on the strip hole and the insert 42 pass through the top post 233 to realize the limiting of the strip 4. The upper end of the top post 233 has a chamfer. When this action is completed, the top post 233 can also perform secondary positioning of the strip 4. Then the upper mold group 1 and the lower mold group 2 begin to close for injection molding.

[0037] S3. After injection molding is completed, the upper mold assembly 1 moves upward, the lifting body 32 moves upward, driving the material strip 4 upward, causing the top post 233 to disengage from the first positioning hole 411 and the second positioning hole 421. The pulling and winding mechanism pulls the material strip 4 forward a specified distance, and the above steps are repeated. The specific steps are as follows: the upper mold assembly 1 and the lower mold assembly 2 open, the drive body rotates, and the upper end of the actuating block 322 moves from the high position of the first inclined plane to the low position. As the actuating block 322 rotates, the material strip 4 moves upward and separates from the top post 233. Then the pulling and winding mechanism pulls the material strip 4 to move 6 working positions, and then the above actions are repeated.

[0038] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope. All such changes and modifications fall within the scope of the present invention as claimed, which is defined by the appended claims and their equivalents.

Claims

1. A continuous insert in-mold injection mold for strip injection molding, wherein the strip includes a strip and a plurality of inserts connected to the strip, the strip having spaced-apart first positioning holes, and the inserts having second positioning holes on the side near the strip, characterized in that: It includes an upper module, a lower module, a lifting mechanism, and a winding mechanism; The lower module includes a lower mold base, a lower template is provided in the middle of the lower mold base, an injection molding area and a strip positioning area are formed on the lower template, an installation groove is formed on the injection molding area and the strip positioning area, and a top post is provided in the installation groove; The upper surface of the lower mold base has mounting notches on both sides. The lifting mechanism includes two material passing blocks and two lifting bodies. The two material passing blocks are respectively installed in the two mounting notches. The material passing blocks have material passing holes. The strip passes through the material passing hole of one material passing block, the injection area, and the material passing hole of the other material passing block in sequence. The two lifting bodies are installed on both sides of the lower mold base and drive the two material passing blocks to move up and down respectively. The strip moves up and down through the material passing blocks so that the ejector pin pushes into or away from the first positioning hole and the second positioning hole on the strip. The pulling and winding mechanism is used to pull the material strip to shift when the top column separates from the first positioning hole and the second positioning hole; The lifting body includes a lateral abutment block, a driving body, and a deflector block. The lateral abutment block is installed on the outward side of the material passing block. The deflector block is rotatably connected to the side wall of the lower mold base and located at the bottom end of the side of the lateral abutment block. The side of the lateral abutment block facing the deflector block is a first inclined surface, and the side of the deflector block facing the lateral abutment block is a second inclined surface. The first inclined surface and the second inclined surface are adapted to each other. The driving body drives the deflector block to rotate and controls the lateral abutment block to rise and fall. The lifting body also includes a mounting limit block, which is installed on the side of the lower mold base. The mounting limit block has a limiting groove that extends through both the upper and lower surfaces on its outward-facing side. The actuating block is located in the limiting groove, and the lateral abutment block extends into the limiting groove.

2. The continuous inlay body injection mold according to claim 1, characterized in that: A connecting plate is formed between the two material passing blocks at a position corresponding to the material head. The connecting plate is set in the belt positioning area, and a corresponding hole is formed on the connecting plate that corresponds to the mounting groove in the belt positioning area.

3. The continuous inlay body injection mold according to claim 2, characterized in that: The outer edge of the top column end face has a chamfer.

4. The continuous inlay body injection mold according to claim 2, characterized in that: A pressure plate is provided at the upper end of the middle part of the connecting plate, and a gap is formed between the pressure plate and the connecting plate.

5. The continuous inlay body injection mold according to claim 2, characterized in that: The material handling block includes a top cover and a base. The bases of two material handling blocks are connected by a connecting plate, and the top cover and the base are detachably connected.

6. The continuous inlay body in-mold injection mold according to claim 1, characterized in that: The injection area has two sets of injection modules, each set of injection modules has three injection stations, and each injection station has three spaced-apart limiting blocks near the belt positioning area. The upper edge of the limiting blocks facing each other has a chamfer.

7. The continuous inlay body injection mold according to claim 1, characterized in that: The upper module includes an upper mold base, and an upper template is provided on the lower surface of the upper mold base, with the upper template corresponding to the lower template.

8. A continuous in-mold injection molding process for insert bodies, characterized in that: The production process utilizes a continuous in-mold injection mold as described in any one of claims 1-7, and includes the following steps: S1. The strip passes through one of its feed holes, the injection area, the strip positioning area and another feed hole. The first positioning hole and the second positioning hole on the strip correspond to the mounting grooves formed on the injection area and the strip positioning area, respectively. S2. The lifting body moves down, causing the material strip to move down, so that the top post is pushed into the first positioning hole and the second positioning hole, the material strip is positioned, and the upper mold and lower mold are combined for injection molding. S3. After injection molding is completed, the upper mold moves upward, the lifting body moves upward, and the material strip moves upward, so that the top post and the first positioning hole and the second positioning hole are disengaged. The winding mechanism pulls the material strip forward a specified distance, and the above steps are repeated.

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