Lightweight watertight structure and injection mold and manufacturing method thereof

Abstract

The invention relates to the field of mechanical structures, molds and manufacturing processes, in particular to a light-weight watertight structure, an injection mold of the light-weight watertight structure and a manufacturing method of the light-weight watertight structure. The lightweight watertight structure is provided with a skeleton structure layer, the upper surface of the skeleton structure layer is inclined and is provided with a first air cavity, an upper ring wall, a watertight structure groove and a drainage port, the lower surface of the skeleton structure layer is provided with a lower ring wall and a second air cavity, the air cavities are communicated, the watertight structure groove is filled with solidified flowable watertight glue, and the lower ring wall is sleeved with solidified foamable airtight glue; the invention further discloses an injection mold with the structure and a manufacturing method. The manufacturing method comprises the steps of mold preparation, double-color injection molding and single-color injection molding. The technical effects that the good watertight and airtight performance is achieved, the structure is light, and meanwhile the product forming quality and the production efficiency are guaranteed through the reasonable mold design and the manufacturing method are achieved.

Description

Technical Field

[0001] This application relates to the fields of mechanical structures, molds and manufacturing processes, and in particular to a lightweight watertight structure, its injection mold and manufacturing method. Background Technology

[0002] In the field of wading vehicles, the application of watertight structures is crucial. With the continuous development of automotive technology and the increasing demands of consumers for vehicle performance and safety, the performance requirements for watertight structures in wading vehicles are also becoming increasingly stringent. A good watertight structure can effectively protect the vehicle's internal electrical systems and mechanical components from water corrosion, extend the vehicle's lifespan, and improve its reliability and safety in wading scenarios. This is of great significance for ensuring the safety of passengers and the normal operation of the vehicle. At the same time, the automotive industry's requirements for energy conservation and emission reduction are also driving the development of watertight structures towards lightweight designs to reduce overall vehicle weight and improve energy efficiency.

[0003] In the conventional automotive field, several technical methods are typically employed to achieve waterproofing. One method involves using rubber gaskets, utilizing the elasticity of rubber to fill gaps between automotive components and prevent water ingress. Rubber gaskets offer flexibility and adaptability, accommodating various shapes and sizes to some extent, and are relatively easy to install. Another common method is using sealant. The sealant is applied to the areas requiring sealing and, after curing, forms a sealing layer. Sealant can fill complex gaps and achieve good sealing results even on irregular surfaces. Additionally, watertightness is achieved through tight mechanical connections, such as threaded connections or flange connections, increasing the tightness of the connection to prevent water leakage. Traditional watertight structures often employ multi-layered sandwich structures, which utilize the properties of multiple materials to block water ingress, thus improving watertight performance to a certain extent.

[0004] However, these existing conventional methods have significant drawbacks. Rubber gaskets are prone to aging and deformation, leading to a decline in sealing performance, and they only provide standard waterproofing; their sealing effect is insufficient in water-related conditions. Sealants may develop bubbles and cracks during curing, affecting the reliability of the seal, and controlling the curing time and quality of the sealant is difficult. While a tight fit in the mechanical structure can achieve watertightness to some extent, it often increases the weight of the structure, hindering lightweight automotive design and increasing manufacturing costs. Traditional multi-layer sandwich structures suffer from excessive material usage, high weight, and high cost, and demolding is also difficult. Furthermore, the flow control of watertight materials in traditional structures is imprecise, easily leading to incomplete seals or material waste. Summary of the Invention

[0005] In order to achieve good airtightness and watertightness in terms of structure, and at the same time facilitate manufacturing, this application provides a lightweight watertight structure, its injection mold and manufacturing method.

[0006] Firstly, this application provides a lightweight, watertight structure, employing the following technical solution: A lightweight watertight structure includes: a skeleton structure layer, the upper surface of which is inclined from the center outward, a first air cavity is provided at the center of the upper surface of the skeleton structure layer, an upper ring wall is provided around the first air cavity, the upper ring wall and the outer wall of the first air cavity form a watertight structure groove, the watertight structure groove is filled with a cured flowable watertight adhesive, the upper ring wall is provided with multiple drain ports, a lower ring wall is provided on the lower surface of the skeleton structure layer, the lower ring wall itself forms a second air cavity, the first air cavity and the second air cavity are connected, a cured foamed airtight adhesive is wrapped around the lower ring wall, the cured foamed airtight adhesive is bonded to the skeleton structure layer, and the foaming temperature of the cured foamed airtight adhesive is lower than the melting temperature of the cured flowable watertight adhesive.

[0007] By adopting the above technical solutions, the upper ring wall can ensure the sealing of the watertight material during the curing process and also make the contact area between the cured fluid watertight adhesive and the skeleton structure layer larger than the contact area with the mold, which facilitates demolding. During the electrophoresis coating of the vehicle body structure, the cured foamed gas-tight adhesive foams first when heated, which can seal the gap between the skeleton structure layer and the vehicle body structure. The cured fluid watertight adhesive flows later when heated than the cured foamed gas-tight adhesive foams. The time difference between the two allows the fluid watertight adhesive to seal the pores generated by the foaming of the gas-tight adhesive. The inclined setting of the upper surface of the skeleton structure layer can ensure the fluidity of the watertight material during the electrophoresis process in the use stage, and the drain port facilitates the outflow of the cured fluid watertight adhesive.

[0008] Optionally, the top wall of the first air chamber is horizontally arranged, and the top of the upper annular wall is at the same horizontal height as the top wall of the first air chamber.

[0009] By adopting the above technical solution, the top wall of the first air chamber is set horizontally and the top of the upper ring wall is at the same horizontal height as the top wall of the first air chamber, which makes the top of the watertight structure groove more regular and facilitates the uniform filling of the watertight adhesive in the watertight structure groove.

[0010] Optionally, a plurality of fixing posts are provided on the lower surface of the skeleton structure layer, the fixing posts are located on the outer side of the lower ring wall, and the cured foamed airtight adhesive is provided with fixing holes that cooperate with the fixing posts.

[0011] By adopting the above technical solution, the connection stability between the cured foamed airtight adhesive and the skeleton structure layer is enhanced by the cooperation of the fixing column and the fixing hole, making the two bond more tightly.

[0012] Optionally, the cured flowable watertight adhesive is provided with a curing block in the circumferential direction that matches the drain port.

[0013] By adopting the above technical solution, during the injection molding process, the watertight material fills to the drain port to form a solidified block, which can improve the bonding performance between the solidified fluidity watertight adhesive and the skeleton structure layer.

[0014] Optionally, a plurality of connecting posts are provided on the lower surface of the skeleton structure layer, and a connecting buckle is provided at the end of the connecting post away from the skeleton structure layer.

[0015] By adopting the above technical solution, the lightweight watertight structure can be easily connected and fixed to other components through connecting columns and connecting clips, which enhances the convenience and stability of structural installation.

[0016] Optionally, the cured foamed airtight adhesive is provided with a fixing groove that mates with the connecting column.

[0017] By adopting the above technical solution, the connecting column can be embedded in the fixing groove, making the connection between the cured foamed airtight adhesive and the skeleton structure layer more stable and enhancing the overall structural stability.

[0018] Secondly, this application provides a lightweight, watertight injection mold, employing the following technical solution: A lightweight, watertight injection mold includes a first upper mold, a moving mold, a second upper mold, and a stationary mold. The moving mold is provided with a skeleton molding groove for forming the skeleton structure layer. The center of the skeleton molding groove is provided with a cavity molding protrusion for molding the first cavity. The first upper mold is provided with a surface molding groove for molding the inclined structure of the upper surface of the skeleton structure layer. The center of the surface molding groove is provided with a cavity molding groove that cooperates with the cavity molding protrusion for molding the first cavity. The surface molding groove is provided with an upper ring molding groove for molding the upper ring wall. The skeleton molding groove is provided with a lower ring molding groove for molding the lower ring wall. The moving mold is provided with a plurality of first horizontal feeding channels connected to the skeleton molding groove and a first vertical feeding channel connected to the first horizontal feeding channels. The depth of the first horizontal feeding channel is the same as the depth of the first vertical feeding channel and is less than the depth of the skeleton molding groove. The first upper mold is provided with a first vertical feeding channel connected to the first vertical feeding channel. The stationary mold has a skeleton mounting groove for mounting the skeleton structure layer. The second upper mold has a positioning groove for mounting the inclined structure on the upper surface of the skeleton structure layer. The positioning groove has a watertight molding groove for molding and curing the flowable watertight adhesive. The contour of the watertight molding groove matches the contour of the upper ring wall. The skeleton mounting groove has an airtight molding groove for molding and curing the foamed airtight adhesive. The airtight molding groove has a lower ring positioning groove for mounting the lower ring wall. The skeleton mounting groove has an air cavity positioning protrusion for positioning the first air cavity. The stationary mold is provided with multiple second horizontal feeding channels connected to the airtight molding groove and a second vertical feeding channel connected to the second horizontal feeding channels. The depth of the second horizontal feeding channel is the same as the depth of the second vertical feeding channel and is less than the depth of the airtight molding groove, but greater than the depth of the skeleton mounting groove. The second upper mold is provided with multiple third horizontal feeding channels connected to the watertight molding groove and a third vertical feeding channel connected to the third horizontal feeding channel, and a second vertical feeding channel connected to the third vertical feeding channel.

[0019] By adopting the above technical solution, the injection mold, through the reasonable configuration of the first upper mold, moving mold, second upper mold, and stationary mold structure, and the skeleton molding groove and matching air cavity molding protrusion, upper ring molding groove, lower ring molding groove, and other structures at the moving mold, can accurately form key parts of the skeleton structure layer such as the first air cavity, upper ring wall, and lower ring wall. The interconnected first horizontal feeding channel, first vertical feeding channel, and first vertical feeding channel design can ensure that the skeleton material is evenly filled into the molding groove. The skeleton mounting groove at the stationary mold can accurately install the skeleton structure layer. The watertight molding groove and airtight molding groove can respectively form and cure the flowing watertight adhesive and the curing foamed airtight adhesive. The corresponding layout of the second horizontal feeding channel, second vertical feeding channel, third horizontal feeding channel, third vertical feeding channel, and vertical feeding channel ensures that the two types of adhesive are accurately filled into the corresponding positions.

[0020] Optionally, the moving mold is provided with a replacement groove for installing the lower mold of the snap-fit ​​design, the lower mold of the snap-fit ​​design is provided with a lower snap-fit ​​design groove for designing and connecting snap-fits, the skeleton design groove is provided with a connecting post design groove that communicates with the lower snap-fit ​​design groove, the first upper mold is provided with a replacement groove for installing the upper mold of the snap-fit ​​design, the upper mold of the snap-fit ​​design is provided with an upper snap-fit ​​design groove for designing and connecting snap-fits, the height of the lower mold of the snap-fit ​​design is less than the thickness of the moving mold, and the height of the upper mold of the snap-fit ​​design is greater than the thickness of the first upper mold; The stationary mold is provided with a replacement groove for installing the snap-on positioning lower mold, the snap-on positioning lower mold is provided with a lower snap-on positioning groove for installing the connecting snap-on, the skeleton mounting groove and the watertight molding groove are provided with connecting post positioning grooves for installing the connecting post, the second upper mold is provided with a replacement groove for installing the snap-on positioning upper mold, the snap-on positioning upper mold is provided with an upper snap-on positioning groove for installing the connecting snap-on, the height of the snap-on positioning lower mold is less than the thickness of the stationary mold, and the height of the snap-on positioning upper mold is greater than the thickness of the second upper mold.

[0021] By adopting the above technical solution, the replacement slot of the moving mold can be used to install the snap-fit ​​lower mold. The lower snap-fit ​​groove on the moving mold, in conjunction with the upper snap-fit ​​groove of the first upper mold, facilitates the molding of the connecting snap-fit ​​within the mold. The static mold and the second upper mold are respectively equipped with snap-fit ​​positioning lower and upper molds. Their lower and upper snap-fit ​​positioning grooves allow for accurate installation and positioning of the connecting snap-fit ​​in subsequent operations. The connecting post positioning grooves at the skeleton mounting groove and the watertight molding groove ensure accurate installation and positioning of the connecting post, guaranteeing the molding quality of the lightweight watertight structure. Furthermore, since the height of the lower snap-fit ​​groove is less than the thickness of the moving mold, the height of the upper snap-fit ​​groove is greater than the thickness of the first upper mold, the height of the lower snap-fit ​​positioning groove is less than the thickness of the static mold, and the height of the upper snap-fit ​​positioning groove is greater than the thickness of the second upper mold, the snap-fit ​​lower mold can be adjusted for easy demolding after injection molding.

[0022] Thirdly, this application provides a manufacturing method for a lightweight watertight structure, the manufacturing method comprising: S1, mold preparation, installing a snap-fit ​​lower mold on a moving mold, installing a snap-fit ​​upper mold on a first upper mold, installing a snap-fit ​​positioning lower mold on a stationary mold, installing a snap-fit ​​positioning upper mold on a second upper mold, and after installation, installing the first upper mold, the second upper mold and the moving mold on a two-color injection molding machine, and installing the stationary mold and the second upper mold on a single-color injection molding machine; S2, two-color injection molding, the moving mold and the first upper mold are closed, the skeleton material is injected into the first vertical feeding channel and fixed and shaped, the mold is opened after molding, the moving mold is rotated, the moving mold and the second upper mold are closed, the watertight material is injected into the second vertical feeding channel and fixed and shaped, to obtain the combined component of the skeleton structure layer and the cured flowable watertight adhesive. S3, monochrome injection molding, the combination of skeleton structure layer and cured flowable watertight adhesive is installed on the stationary mold, the second upper mold and the stationary mold are closed, airtight raw material is injected into the second vertical feed channel, and after molding, the material is demolded to obtain the lightweight watertight structure.

[0023] By adopting the above technical solution, the manufacturing method first prepares the molds by installing the various snap-fit ​​molding molds and positioning molds onto the corresponding upper and lower molds, and then installing the molds onto the two-color injection molding machine and the single-color injection molding machine to prepare for subsequent injection molding. Next, two-color injection molding is performed to ensure the precise molding of the skeleton structure layer and the cured flowable watertight adhesive. Finally, single-color injection molding is performed, and a lightweight watertight structure is obtained by injecting watertight material and molding and demolding. This achieves the step-by-step injection and molding of different materials, and can efficiently and accurately manufacture a lightweight watertight structure with watertight and airtight functions, thereby improving production efficiency and product quality.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. The combination of curing flowable watertight adhesive and curing foamed airtight adhesive enhances the watertightness of the airtight structure, protecting the automotive structure from water erosion when wading. During the electrophoresis coating of the vehicle body structure, the curing foamed airtight adhesive is heated and foamed to seal the gaps between the skeleton structure layer and the vehicle body structure. The curing flowable watertight adhesive flows after being heated and foamed, sealing the pores generated by the foaming of the curing foamed airtight adhesive, further enhancing the watertightness. 2. The first air chamber is connected to the second air chamber, which helps to reduce the structural weight and meets the requirements of lightweight automotive design; 3. It avoids problems such as aging and deformation of rubber gaskets, curing defects of sealant, large mechanical structure weight, and difficulties in demolding and waste of rubber material in traditional multi-sandwich structures, thus improving the reliability and stability of watertight structures. Attached Figure Description

[0025] Figure 1 This is a top view schematic diagram of the lightweight watertight structure provided in the embodiments of this application.

[0026] Figure 2 This is a bottom view of the lightweight watertight structure provided in the embodiments of this application.

[0027] Figure 3 This is a top view of the skeleton structure layer provided in the embodiment of this application.

[0028] Figure 4 This is a bottom view of the skeleton structure layer provided in the embodiment of this application.

[0029] Figure 5 This is a bottom view of the cured, flowable, watertight adhesive provided in the embodiments of this application.

[0030] Figure 6 This is a schematic diagram of the structure of the curing foamed airtight adhesive provided in the embodiments of this application.

[0031] Figure 7This is a schematic diagram of the structure of the moving mold provided in the embodiment of this application, in which the skeleton molding groove on the right side shows the situation when a skeleton structure layer is formed in the groove.

[0032] Figure 8 This is a schematic diagram of the structure of the first upper mold provided in the embodiment of this application.

[0033] Figure 9 This is a schematic diagram of the static mold provided in the embodiment of this application, showing the situation when the skeleton structure layer is installed in the skeleton mounting groove on the right.

[0034] Figure 10 This is a schematic diagram of the structure of the second upper mold provided in the embodiment of this application.

[0035] Explanation of reference numerals in the attached drawings: 1-Skeleton structure layer; 101-First air chamber; 102-Upper annular wall; 103-Drain port; 104-Lower annular wall; 105-Second air chamber; 106-Fixing column; 107-Connecting column; 108-Connecting buckle; 2-Cureable flowable watertight adhesive; 201-Cureable block; 3-Cureable foamed airtight adhesive; 301-Fixing hole; 302-Fixing groove; 4-Moving mold; 401-Skeleton molding groove; 402-Air cavity molding protrusion; 403-Lower ring molding groove; 404-First horizontal feed channel; 405-First vertical feed channel; 406-Connecting column molding groove; 5-First upper mold; 501-Surface molding groove; 502-Air cavity molding groove; 503-Upper ring molding groove; 504-First vertical feed channel; 6-Static mold; 601-Skeleton mounting slot; 602-Airtight molding slot; 603-Lower ring positioning slot; 604-Air cavity positioning protrusion; 605-Second transverse feed channel; 606-Second longitudinal feed channel; 607-Connecting column positioning slot; 7-Second upper mold; 701-Positioning groove; 702-Watertight molding groove; 703-Second vertical feed channel; 704-Third horizontal feed channel; 705-Third vertical feed channel; 8-Lower mold for buckle design; 801-Lower buckle design groove; 9-Upper mold for buckle design; 901-Upper buckle design groove; 10-Lower mold for buckle positioning; 1001-Lower buckle positioning groove; 11-Upper mold for buckle positioning; 1101-Upper buckle positioning groove. Detailed Implementation

[0036] The following is in conjunction with the appendix Figure 1-10 This application will be described in further detail.

[0037] This application discloses a lightweight watertight structure.

[0038] like Figure 1 and Figure 2 As shown, the lightweight watertight structure includes a skeleton structure layer 1, a curing flowable watertight adhesive 2, and a curing foamed airtight adhesive 3. The skeleton structure layer 1 serves as the basic support structure. The curing flowable watertight adhesive 2 fills the watertight structure groove of the skeleton structure layer 1, and the curing foamed airtight adhesive 3 is fitted over the lower ring wall 104 of the skeleton structure layer 1. Through this structural combination, the overall weight is reduced, and lightweighting is achieved.

[0039] like Figure 3 and Figure 4 As shown, the upper surface of the skeleton structure layer 1 is inclined outward from the center. This inclination facilitates the outflow of the cured, fluid watertight adhesive 2 when it melts upon heating during installation. A first air cavity 101 is located at the center of the upper surface of the skeleton structure layer 1, with its top wall horizontally positioned. This design ensures the stability and regularity of the air cavity. An upper annular wall 102 surrounds the air cavity, forming a watertight structural groove with the outer wall of the air cavity. The top of the upper annular wall 102 is at the same horizontal level as the top wall of the first air cavity 101. This design makes the structure of the watertight structural groove more regular, which is beneficial for the filling of the cured, fluid watertight adhesive 2. Multiple drain ports 103 are provided at the upper annular wall 102. These drain ports 103 can assist the cured, fluid watertight adhesive 2 in flowing out when it melts upon heating, further improving the watertight performance. A lower annular wall 104 is provided on the lower surface of the skeleton structure layer 1, and the lower annular wall 104 itself forms a second air cavity 105, which is connected to the first air cavity 101. The air cavity not only reduces the weight of the skeleton structure layer 1, but also plays a role in balancing pressure to a certain extent. A cured foamed airtight adhesive 3 is wrapped around the lower annular wall 104. The cured foamed airtight adhesive 3 is bonded to the skeleton structure layer 1, and the foaming temperature of the cured foamed airtight adhesive 3 is lower than the melting temperature of the cured flowable watertight adhesive 2.

[0040] In this embodiment, the skeleton structure layer 1 is made of PPA material. PPA material has a heat distortion temperature of over 280℃ and possesses excellent dimensional stability and chemical resistance, maintaining structural stability during electrophoresis without thermal deformation. The cured flowable watertight adhesive 2 is made of modified polyolefin, and the cured foamed airtight adhesive 3 is made of EVA foam. When subjected to electrophoretic heat, the cured foamed airtight adhesive 3 decomposes and generates gas within 3-5 minutes of electrophoresis, causing the material to rapidly expand and foam, filling the main part of the cavity and initially forming an airtight barrier. Simultaneously, it is necessary to firmly bond the skeleton structure layer 1 to the sheet metal; therefore, EVA foam is used as the cured foamed airtight adhesive 3. Besides the foaming rate, the final cell structure of the cured foamed airtight adhesive 3 is preferably a closed-cell structure, which effectively prevents water vapor penetration and provides more stable long-term airtightness. Therefore, in the subsequent 8-10 minutes, the curing flowable watertight adhesive 2 absorbs more heat and reaches a molten state, thus possessing good flowability to fill the gaps created by the rapid expansion and foaming of the curing foamed airtight adhesive 3. The curing flowable watertight adhesive 2 needs to possess permanent viscoelasticity, maintaining a certain degree of flexibility and adhesion even after curing, to adapt to possible slight vibrations or deformations of the structural components and ensure the durability of the seal. Therefore, modified polyolefin is used as the curing flowable watertight adhesive 2.

[0041] like Figure 1 , Figure 2 and Figure 6 As shown, multiple fixing posts 106 are provided on the lower surface of the skeleton structure layer 1. The fixing posts 106 are located outside the lower ring wall 104, and the cured foamed airtight adhesive 3 has fixing holes 301 that mate with the fixing posts 106. The cooperation between the fixing posts 106 and the fixing holes 301 can more firmly fix the cured foamed airtight adhesive 3 to the skeleton structure layer 1, preventing it from shifting during transportation. Multiple connecting posts 107 are also provided on the lower surface of the skeleton structure layer 1. The end of the connecting post 107 away from the skeleton structure layer 1 has a connecting buckle 108. The connecting posts 107 and the connecting buckle 108 can facilitate the connection of the lightweight watertight structure with other components. The cured foamed airtight adhesive 3 has a fixing groove 302 that mates with the connecting post 107. The fixing groove 302 can position and fix the connecting post 107.

[0042] In the actual foaming process, the skeleton structure layer 1 and the lower ring wall 104 can effectively prevent the foamed material from spreading upwards in a disorderly manner during the initial expansion and wrapping the watertight material, thereby ensuring that the watertight material has an independent space and path to flow in the subsequent stage; on the other hand, they can prevent the foamed material from invading the first air cavity 101 and the second air cavity 105 during the initial expansion, thereby ensuring that the watertight structure has an independent cavity.

[0043] like Figure 1 , Figure 2 and Figure 5 As shown, the cured, flowable watertight adhesive 2 is filled in the watertight structural groove, and a curing block 201 that mates with the drain port 103 is provided around its circumference. During the injection molding process, the watertight material fills to the drain port 103 to form the curing block 201, which can improve the bonding performance between the cured, flowable watertight adhesive 2 and the skeleton structural layer 1.

[0044] The implementation principle of a lightweight watertight structure in this embodiment is as follows: The lightweight watertight structure of this embodiment achieves lightweighting while maintaining structural strength through a unique skeleton structure layer 1 design, including an inclined upper surface, air cavities, and ring walls. A curable foamed airtight adhesive 3 is fitted over the lower ring wall 104. After foaming, it can tightly adhere to the skeleton structure layer 1 and the sheet metal components, providing both airtightness and mechanical bonding. A curable, fluid watertight adhesive 2 fills the watertight structure grooves, utilizing its fluidity to effectively fill the foamed cell structure, forming a reliable sealing layer after curing. Connecting posts 107 and snap-fit ​​structures facilitate the positioning of the structure and its connection with other components. The overall structural design is reasonable, and compared to traditional watertight structures, it shows significant improvements in watertight performance, lightweighting, and cost, solving problems such as aging, deformation, heavy weight, high cost, and poor sealing found in existing technologies.

[0045] This application also discloses a lightweight, watertight injection mold.

[0046] like Figures 7-10 As shown, the injection mold for a lightweight watertight structure includes a first upper mold 5, a moving mold 4, a second upper mold 7, and a stationary mold 6. The first upper mold 5 and the moving mold 4 work together to form the skeleton structure layer 1, while the second upper mold 7 and the stationary mold 6 work together to form a curable, flowable watertight adhesive 2 and a curable, foamable, airtight adhesive 3 on the skeleton structure layer 1. Through this mold combination and structural design, a lightweight watertight structure that meets the requirements can be precisely manufactured, improving production efficiency and product quality.

[0047] like Figure 7 and Figure 8As shown, the moving mold 4 is provided with a skeleton molding groove 401 for molding the skeleton structure layer 1, and a cavity molding protrusion 402 for molding the first air cavity 101 is provided at the center of the skeleton molding groove 401. The shape and size of the cavity molding protrusion 402 match the first air cavity 101 of the skeleton structure layer 1, ensuring that the molded first air cavity 101 meets the design requirements. The first upper mold 5 is provided with a surface molding groove 501 for molding the inclined structure of the upper surface of the skeleton structure layer 1, and a cavity molding groove 502 is provided at the center of the surface molding groove 501 to cooperate with the cavity molding protrusion 402 for molding the first air cavity 101. The inclination angle and shape of the surface molding groove 501 are consistent with the inclined structure of the upper surface of the skeleton structure layer 1. The cavity molding groove 502 cooperates with the cavity molding protrusion 402 to accurately mold the first air cavity 101. The surface molding groove 501 is provided with an upper ring molding groove 503 for molding the upper ring wall 102. The shape and size of the upper ring molding groove 503 match the upper ring wall 102 to ensure the molding quality of the upper ring wall 102. The skeleton molding groove 401 is provided with a lower ring molding groove 403 for molding the lower ring wall 104. The shape and size of the lower ring molding groove 403 match the lower ring wall 104 to ensure the molding quality of the lower ring wall 104. The moving mold 4 is provided with multiple first horizontal feeding channels 404 connected to the skeleton molding groove 401 and a first vertical feeding channel 405 connected to the first horizontal feeding channels 404. The depth of the first horizontal feeding channel 404 is the same as the depth of the first vertical feeding channel 405 and less than the depth of the skeleton molding groove 401. The first upper mold 5 is provided with a first vertical feeding channel 504 connected to the first vertical feeding channel 405. This feeding channel design allows the skeleton material to enter the skeleton molding groove 401 evenly, ensuring the molding quality of the skeleton structure layer 1.

[0048] like Figure 9 and Figure 10As shown, the stationary mold 6 has a skeleton mounting groove 601 for mounting the skeleton structure layer 1, and the second upper mold 7 has a positioning groove 701 for mounting the inclined structure on the upper surface of the skeleton structure layer 1. The positioning groove 701 has a watertight molding groove 702 for molding and curing the flowable watertight adhesive 2. The contour of the watertight molding groove 702 matches the contour of the upper ring wall 102, ensuring the accurate molding shape and position of the cured flowable watertight adhesive 2. The skeleton mounting groove 601 has an airtight molding groove 602 for molding and curing the foamed airtight adhesive 3. The airtight molding groove 602 has a lower ring positioning groove 603 for mounting the lower ring wall 104, and the skeleton mounting groove 601 has an air cavity positioning protrusion 604 for positioning the first air cavity 101. The design of these molding grooves and positioning structures ensures the accurate molding and installation of the cured flowable watertight adhesive 2 and the cured foamed airtight adhesive 3 on the skeleton structure layer 1. The stationary mold 6 is provided with multiple second horizontal feeding channels 605 connected to the airtight molding groove 602 and a second vertical feeding channel 606 connected to the second horizontal feeding channels 605. The depth of the second horizontal feeding channel 605 is the same as the depth of the second vertical feeding channel 606 and is less than the depth of the airtight molding groove 602, but greater than the depth of the skeleton mounting groove 601. The second upper mold 7 is provided with a second vertical feeding channel 703 connected to the second vertical feeding channel 606. It is also provided with multiple third horizontal feeding channels 704 connected to the watertight molding groove 702 and a third vertical feeding channel 705 connected to the third horizontal feeding channels 704. The second vertical feeding channel 703 is also connected to the third vertical feeding channel 705. This feeding channel design allows airtight and watertight materials to accurately enter the airtight molding tank 602 and watertight molding tank 702 at the two-color injection molding machine and the single-color injection molding machine, respectively, ensuring the molding quality of the cured foamed airtight adhesive 3 and the cured flowable watertight adhesive 2.

[0049] The moving mold 4 has a replacement slot for mounting the lower mold 8 for the snap-fit ​​design. The lower mold 8 has a lower snap-fit ​​design groove 801 for shaping the snap-fit ​​108. The skeleton design groove 401 has a design groove for the connecting post 107 that communicates with the lower snap-fit ​​design groove 801. The first upper mold 5 has a replacement slot for mounting the upper mold 9 for the snap-fit ​​design. The upper mold 9 has an upper snap-fit ​​design groove 901 for shaping the snap-fit ​​108. The height of the lower snap-fit ​​design groove 801 is less than the thickness of the moving mold 4, and the height of the upper snap-fit ​​design groove 901 is greater than the thickness of the first upper mold 5. With this design, the connecting post 107 and the connecting snap-fit ​​108 can be accurately formed. The stationary mold 6 has a replacement slot for mounting the snap-fit ​​positioning lower mold 10. The snap-fit ​​positioning lower mold 10 has a lower snap-fit ​​positioning groove 1001 for mounting the connecting snap-fit ​​108. The skeleton mounting groove 601 and the watertight molding groove 702 have connecting post 107 positioning grooves for mounting the connecting post 107. The second upper mold 7 has a replacement slot for mounting the snap-fit ​​positioning upper mold 11. The snap-fit ​​positioning upper mold 11 has an upper snap-fit ​​positioning groove 1101 for mounting the connecting snap-fit ​​108. The height of the lower snap-fit ​​positioning groove 1001 is less than the thickness of the stationary mold 6, and the height of the upper snap-fit ​​positioning groove 1101 is greater than the thickness of the second upper mold 7. The design of these positioning grooves ensures the accurate positioning of the connecting post 107 and the connecting snap-fit ​​108 during subsequent installation and molding processes.

[0050] The implementation principle of the injection mold for a lightweight watertight structure in this embodiment is as follows: Through a reasonable structural design and feed channel layout, the injection mold in this embodiment can accurately mold various components of the lightweight watertight structure. The cooperation between the first upper mold 5 and the moving mold 4 can accurately mold the skeleton structure layer 1, including structures such as air cavities, ring walls, connecting pillars 107, and connecting buckles 108. The cooperation between the second upper mold 7 and the moving mold 4 can accurately mold the cured, flowable watertight adhesive 2 on the skeleton structure layer 1. The cooperation between the second upper mold 7 and the stationary mold 6 can accurately mold the cured, foamed, airtight adhesive 3 on the combined component of the skeleton structure layer 1 and the cured, flowable watertight adhesive.

[0051] Meanwhile, the design of the lower mold 8 for snap-fit ​​shaping, the upper mold 9 for snap-fit ​​shaping, the lower mold 10 for snap-fit ​​positioning, and the upper mold 11 for snap-fit ​​positioning ensures the accuracy of the forming and positioning of the connecting pillar 107 and the connecting snap-fit ​​108. The entire mold system is rationally designed, which can improve production efficiency, ensure product quality, and solve the problems of difficult demolding and inaccurate forming in traditional mold forming, showing significant advantages compared with existing technologies.

[0052] This application also discloses a method for manufacturing a lightweight watertight structure.

[0053] The manufacturing method of lightweight watertight structures includes the following steps: S0, Mold Manufacturing: The first upper mold 5, moving mold 4, second upper mold 7, and stationary mold 6 all employ precision machining processes to ensure smooth, flawless surfaces. For example, CNC milling machines are used for roughing and finishing to ensure dimensional accuracy and surface finish. The mold body is made of high-strength alloy steel to improve durability and resistance to deformation. The molding area can be made of hard alloy material to extend the mold's service life, and electrical discharge machining can be used to ensure the forming accuracy of complex structures. After machining, the mold undergoes quenching and tempering to improve hardness and wear resistance. The surface is chrome-plated or nitrided to enhance corrosion resistance and wear resistance.

[0054] S1, Mold Preparation: Install the snap-fit ​​lower mold 8 onto the moving mold 4, the snap-fit ​​upper mold 9 onto the first upper mold 5, the snap-fit ​​positioning lower mold 10 onto the stationary mold 6, and the snap-fit ​​positioning upper mold 11 onto the second upper mold 7. After installation, install the first upper mold 5, the second upper mold 7, and the moving mold 4 onto the two-color injection molding machine, and install the stationary mold 6 and the second upper mold 7 onto the single-color injection molding machine. In this step, appropriate tools are required to accurately install each mold component into its corresponding position. During installation, ensure that the mold components are securely installed and accurately positioned to avoid displacement problems during subsequent injection molding.

[0055] S2, two-color injection molding: The moving mold 4 is closed with the first upper mold 5, and the skeleton material is injected into the first vertical feed channel 504 and fixed in shape. After molding, the mold is opened, the moving mold 4 is rotated, and the moving mold 4 is closed with the second upper mold 7. The watertight material is injected into the second vertical feed channel 703 and fixed in shape, resulting in a combined component of skeleton structure layer 1 and cured flowable watertight adhesive 2. When injecting the skeleton material and watertight material, appropriate pressure and speed should be set according to the parameters of the injection molding machine. The fixing time and temperature should be reasonably adjusted according to the characteristics of the material to ensure the molding quality of skeleton structure layer 1. Care should be taken during demolding to avoid damaging the combined component of skeleton structure layer 1 and cured flowable watertight adhesive 2.

[0056] S3, single-color injection molding: The combined component of the skeleton structure layer 1 and the cured, flowable, watertight adhesive 2 is installed on the stationary mold 6. The second upper mold 7 and the stationary mold 6 are closed, and the airtight material is injected into the second vertical feed channel 703. After molding, the material is demolded to obtain the lightweight watertight structure. The molding process of single-color injection molding must also ensure precision to prevent gaps from affecting the molding quality. When injecting the airtight material, attention should be paid to controlling the injection pressure and speed to ensure that the material can accurately fill the molding groove. The molding conditions should be adjusted according to the characteristics of the airtight material to ensure the curing effect while preventing foaming. Finally, during demolding, care should be taken to avoid damaging the molded lightweight watertight structure.

[0057] The implementation principle of the manufacturing method for a lightweight watertight structure according to an embodiment of this application is as follows: This manufacturing method can systematically manufacture a lightweight watertight structure through reasonable mold preparation, two-color injection molding, and single-color injection molding steps. The mold preparation step ensures the accuracy and integrity of the mold, providing a foundation for subsequent injection molding. The two-color injection molding step accurately molds the combined component of the skeleton structure layer 1 and the cured flowable watertight adhesive 2. The single-color injection molding step molds the cured foamed airtight adhesive 3 on the combined component of the skeleton structure layer 1 and the cured flowable watertight adhesive 2. Through this step-by-step injection molding method, the molding quality and structural accuracy of each component are guaranteed. The entire manufacturing method has a clear operation process, which can improve production efficiency and product quality, and solves the problems of inaccurate molding and low efficiency in traditional manufacturing methods. Compared with the prior art, it has significant improvements and advantages.

[0058] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A lightweight, watertight structure, characterized in that, include: A skeleton structure layer (1) is provided, the upper surface of which is inclined from the center outward. A first air cavity (101) is provided at the center of the upper surface of the skeleton structure layer (1). An upper ring wall (102) is provided around the first air cavity (101). The upper ring wall (102) and the outer wall of the first air cavity (101) form a watertight structural groove. The watertight structural groove is filled with a curable and fluid watertight adhesive (2). Multiple drain ports (103) are provided at the upper ring wall (102). A lower ring wall (104) is provided on the lower surface of the skeleton structure layer (1), and the lower ring wall (104) itself forms a second air cavity (105). The first air cavity (101) is connected to the second air cavity (105). The lower ring wall (104) is covered with a cured foamed airtight adhesive (3). The cured foamed airtight adhesive (3) is bonded to the skeleton structure layer (1). The foaming temperature of the cured foamed airtight adhesive (3) is lower than the melting temperature of the cured flowable watertight adhesive (2).

2. The lightweight watertight structure according to claim 1, characterized in that, The top wall of the first air chamber (101) is horizontally arranged, and the top of the upper ring wall (102) is at the same horizontal height as the top wall of the first air chamber (101).

3. The lightweight watertight structure according to claim 2, characterized in that, The lower surface of the skeleton structure layer (1) is provided with a plurality of fixing posts (106), the fixing posts (106) are located outside the lower ring wall (104), and the cured foamed airtight adhesive (3) is provided with fixing holes (301) that cooperate with the fixing posts (106).

4. The lightweight watertight structure according to claim 1, characterized in that, The curing fluid watertight adhesive (2) is provided with a curing block (201) in the circumferential direction that matches the drain port (103).

5. A lightweight watertight structure according to claim 1, characterized in that, The lower surface of the skeleton structure layer (1) is provided with a plurality of connecting posts (107), and the end of the connecting post (107) away from the skeleton structure layer (1) is provided with a connecting buckle (108).

6. A lightweight watertight structure according to claim 5, characterized in that, The cured foamed airtight adhesive (3) is provided with a fixing groove (302) that cooperates with the connecting column (107).

7. A lightweight, watertight injection mold, characterized in that, include: The upper mold (5), the moving mold (4), the upper mold (7), and the stationary mold (6) are as follows: The moving mold (4) is provided with a skeleton molding groove (401) for molding the skeleton structure layer (1). At the center of the skeleton molding groove (401) is a cavity molding protrusion (402) for molding the first cavity (101). The first upper mold (5) is provided with a surface molding groove (501) for molding the inclined structure of the upper surface of the skeleton structure layer (1). At the center of the surface molding groove (501) is a cavity molding groove (502) that cooperates with the cavity molding protrusion (402) for molding the first cavity (101). At the surface molding groove (501) is an upper ring molding groove (50) for molding the upper ring wall (102). 3) The skeleton molding groove (401) is provided with a lower ring molding groove (403) for molding the lower ring wall (104). The moving mold (4) is provided with a plurality of first horizontal feeding channels (404) connected to the skeleton molding groove (401) and a first vertical feeding channel (405) connected to the first horizontal feeding channels (404). The depth of the first horizontal feeding channel (404) is the same as the depth of the first vertical feeding channel (405) and less than the depth of the skeleton molding groove (401). The first upper mold (5) is provided with a first vertical feeding channel (504) connected to the first vertical feeding channel (405). The stationary mold (6) is provided with a skeleton mounting groove (601) for mounting the skeleton structure layer (1), and the second upper mold (7) is provided with a positioning groove (701) for mounting the inclined structure of the upper surface of the skeleton structure layer (1). The positioning groove (701) is provided with a watertight molding groove (702) for molding and curing the flowable watertight adhesive (2). The contour of the watertight molding groove (702) matches the contour of the upper ring wall (102). The skeleton mounting groove (601) is provided with an airtight molding groove (602) for molding and curing the foamed airtight adhesive (3). The airtight molding groove (602) is provided with a lower ring positioning groove (603) for mounting the lower ring wall (104). The skeleton mounting groove (601) is provided with an air cavity positioning protrusion (604) for positioning the first air cavity (101). The stationary mold (6) is provided with a plurality of second horizontal feeding channels (605) connected to the airtight molding groove (602) and a second vertical feeding channel (606) simultaneously connected to the second horizontal feeding channels (605). The depth of the second horizontal feeding channel (605) is the same as the depth of the second vertical feeding channel (606) and less than the depth of the airtight molding groove (602), but greater than the depth of the skeleton mounting groove (601). The second upper mold (7) is provided with a plurality of third horizontal feeding channels (704) connected to the watertight molding groove (702) and a third vertical feeding channel (705) connected to the third horizontal feeding channel (704), and a second vertical feeding channel (703) connected to the third vertical feeding channel (705).

8. The lightweight, watertight injection mold according to claim 7, characterized in that, The moving mold (4) is provided with a replacement groove for installing the buckle-shaped lower mold (8), the buckle-shaped lower mold (8) is provided with a lower buckle-shaped groove (801) for shaping and connecting buckles (108), the skeleton-shaped groove (401) is provided with a connecting post (107) shaped groove that communicates with the lower buckle-shaped groove (801), the first upper mold (5) is provided with a replacement groove for installing the buckle-shaped upper mold (9), the buckle-shaped upper mold (9) is provided with an upper buckle-shaped groove (901) for shaping and connecting buckles (108), the height of the buckle-shaped lower mold (8) is less than the thickness of the moving mold (4), and the height of the buckle-shaped upper mold (9) is greater than the thickness of the first upper mold (5); The stationary mold (6) is provided with a replacement groove for installing the snap-on positioning lower mold (10), the snap-on positioning lower mold (10) is provided with a lower snap-on positioning groove (1001) for installing the connecting snap-on (108), the skeleton mounting groove (601) and the watertight molding groove (702) are provided with a connecting post (107) positioning groove for installing the connecting post (107), the second upper mold (7) is provided with a replacement groove for installing the snap-on positioning upper mold (11), the snap-on positioning upper mold (11) is provided with an upper snap-on positioning groove (1101) for installing the connecting snap-on (108), the height of the snap-on positioning lower mold (10) is less than the thickness of the stationary mold (6), and the height of the snap-on positioning upper mold (11) is greater than the thickness of the second upper mold (7).

9. A method for manufacturing a lightweight watertight structure using an injection mold according to any one of claims 7-8, applied to any one of claims 1-6, characterized in that, The manufacturing method includes: S1, mold preparation: install the buckle-shaped lower mold (8) on the moving mold (4), install the buckle-shaped upper mold (9) on the first upper mold (5), install the buckle-positioning lower mold (10) on the stationary mold (6), install the buckle-positioning upper mold (11) on the second upper mold (7), and after installation, install the first upper mold (5), the second upper mold (7) and the moving mold (4) on the two-color injection molding machine, and install the stationary mold (6) and the second upper mold (7) on the single-color injection molding machine; S2, two-color injection molding, the moving mold (4) and the first upper mold (5) are closed, the skeleton material is injected into the first vertical feeding channel (504) and fixed and shaped, the mold is opened after molding, the moving mold (4) is rotated, the moving mold (4) and the second upper mold (7) are closed, the watertight material is injected into the second vertical feeding channel (703) and fixed and shaped, to obtain the combined component of the skeleton structure layer (1) and the cured flowable watertight adhesive (2); S3, monochrome injection molding, the combination of skeleton structure layer (1) and curing flowable watertight adhesive (2) is installed on the stationary mold (6), the second upper mold (7) and the stationary mold (6) are closed, airtight raw material is injected into the second vertical feed channel (703), and after molding, the lightweight watertight structure is obtained.

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