A multi-station multi-point injection molding process apparatus

Abstract

This invention provides a multi-unit, multi-point injection molding process equipment, comprising a side-entry injection system, a double-action vertical injection system, and a side-entry metal injection system corresponding to different injection processes. It can complete the co-injection process of mixed materials with multiple runners and gates, achieving efficient and precise molding of complex mixed material parts while maintaining low production costs. The position, quantity, specifications, and mold type of each injection system in the equipment can be flexibly adjusted according to the design requirements of different products. Combined with comprehensive process flow control, it enables rapid production line adjustments and large-scale production of multiple product types.

Description

Technical Field

[0001] This invention belongs to the technical field of multi-component mixed material co-injection molding equipment, specifically relating to a multi-unit, multi-point injection molding process equipment. Background Technology

[0002] Multi-material co-injection molding can integrate metals, plastics, and composites into a single component, enabling the component to possess both complex structural designs and multi-regional functional differentiation, meeting the manufacturing needs of many cutting-edge fields such as aerospace, new energy vehicles, and medical devices. However, existing technologies require separate steps for different processes such as metal injection, die casting, and non-metal injection molding, resulting in complex work involving station and mold disassembly / switching and readjustment of temperature and pressure conditions. Some existing technologies, such as the applicant's previous Chinese patents CN116475292B and CN116812016B, provide technical solutions for completing thermal expansion, metal injection, and non-metal injection molding within the same mold, innovatively reducing the total number of mold opening and closing operations to only one. However, they do not achieve simultaneous execution of different injection processes, have relatively stringent reaction condition control, and involve long heating and cooling waiting times, thus leaving room for improvement in production efficiency and cost. Furthermore, the existing architecture of a single-mold main unit with a small number of injection units is only suitable for processing single-type products; if the product design is changed, a new mold must be created. The anti-interference ability of different processes when executed in sequence is also poor. Any problem in any process will affect the subsequent processes and the quality of the finished product, which makes it difficult to reduce the cost when using this process. Summary of the Invention

[0003] In view of the above, and in response to the technical problems existing in this field, the present invention provides a multi-unit, multi-point injection molding process equipment, including: a positioning worktable, a side-entry injection system, a double-action vertical injection system, and a side-entry metal injection system; The positioning worktable is used to fix and support the side-entry injection molding system, the dual-action vertical injection system, and the side-entry metal injection system. Side-entry injection molding system, double-action vertical injection system and side-entry metal injection system all include hydraulic clamping unit with the same structure. The frame of the hydraulic clamping unit is composed of an upper plate, a back plate and a bottom plate forming a C-shaped structure. The clamping cylinder is installed above the upper plate. The clamping mechanism of each system is located in front of the back plate, between the upper plate and the bottom plate and connected to the clamping cylinder. The mold is set on the bottom plate. The side-entry injection molding system also includes a material storage and injection system unit located behind its frame back plate; the dual-action vertical injection system also includes an energy storage die casting unit located behind its frame back plate; the side-entry metal injection system also includes a material storage and slurry injection system unit located behind its frame back plate.

[0004] Furthermore, each system's frame base plate is equipped with positioning and clamping slots for installing and moving molds.

[0005] Furthermore, the material storage and injection system unit, the energy storage die casting unit, and the material storage and slurry injection system unit all contain multiple injection points.

[0006] Furthermore, the equipment also features a global collaborative closed-loop control system, which comprehensively controls the molding and injection process of each system, as well as conditions such as pressure and temperature.

[0007] Accordingly, the present invention also provides a multi-machine, multi-point injection molding process using the above-mentioned equipment, specifically including the following steps: S1. Select the injection molding, die casting, or metal injection materials and the blank to be injected; S2. Pre-treat the selected materials; after setting the position of each system on the positioning worktable, fill the barrel of each system with protective gas, and install the corresponding mold in its respective hydraulic mold closing unit. Open the mold to perform preheating treatment and spray the release agent. S3. Place the blank into the mold cavity, complete the surface positioning, and then close and lock the mold. S4. Each system injects the corresponding material into different points on the blank, which can be done simultaneously or in stages according to actual needs. S5. Each system performs graded and coordinated pressure holding to ensure that the component is compressed within the cavity; S6. After in-mold cooling, open the mold and remove the one-piece molded component containing different materials.

[0008] The multi-point injection molding equipment provided by this invention includes side-entry injection systems, dual-action vertical injection systems, and side-entry metal injection systems corresponding to different injection processes. It can complete the co-injection process of mixed materials with multiple runners and gates, achieving efficient and precise molding of complex mixed material parts while maintaining low production costs. The position, quantity, specifications, and mold type of each injection system in the equipment can be flexibly adjusted according to the design requirements of different products. Combined with comprehensive process flow control, it enables rapid production line adjustments and large-scale production of multiple product types. Attached Figure Description

[0009] Figure 1 A three-dimensional structural diagram of the multi-point injection molding process equipment provided by the present invention; Figure 2 A three-dimensional view of the side-entry injection molding system structure; Figure 3 Three-dimensional and front views of the structure of the dual-motion vertical injection system; Figure 4 Three-dimensional and front views of the side-entry metal injection system structure; Figure 5 A structural diagram of an integrated automotive A-pillar component manufactured using the system provided by this invention; Figure 6 A flowchart illustrating a multi-machine, multi-point injection molding process performed using the system provided by this invention; Figure 7 This is a diagram showing the structural changes of a one-piece automotive A-pillar component before and after the method was implemented. Detailed Implementation

[0010] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0011] The present invention provides multiple multi-point injection molding process equipment, such as Figure 1 As shown, it includes: a positioning worktable 1, a side-entry injection molding system 2, a double-action vertical injection system 3, and a side-entry metal injection system 4; Among them, the positioning worktable 1 is used to fix and support the side-entry injection molding system 2, the double-action vertical injection system 3, and the side-entry metal injection system 4. The position of each system on the positioning worktable 1 can be flexibly set according to the product design and the process to be performed. like Figure 2-4 As shown, the side-entry injection system 2, the double-action vertical injection system 3, and the side-entry metal injection system 4 all include hydraulic clamping units 2-2, 3-2, and 4-2 with the same structure. The frame of the hydraulic clamping unit is composed of an upper plate, a back plate, and a bottom plate forming a C-shaped structure, which overcomes the problem of existing clamping unit frames containing multiple tie rods obstructing the mold and improves the convenience of disassembling and replacing the mold. Hydraulic cylinders 2-4, 3-4, and 4-3 are installed above the upper plate. The clamping mechanisms 2-3, 3-4, and 4-4 of each system are located in front of the back plate, between the upper plate and the bottom plate, and connected to the hydraulic cylinders. The mold is set on the bottom plate. The side-entry injection system 2 also includes a material storage and injection system unit 2-1 located behind its frame back plate; the dual-action vertical injection system 3 also includes an energy storage die casting unit 3-1 located behind its frame back plate; the side-entry metal injection system 4 also includes a material storage and slurry injection system unit 4-1 located behind its frame back plate.

[0012] In a preferred embodiment of the present invention, each system's frame base plate is provided with a positioning and clamping groove for mounting and moving the mold.

[0013] In a preferred embodiment of the present invention, the material storage and injection system unit 2-1, the energy storage die casting unit 3-1, and the material storage and slurry injection system unit 4-1 all include multiple injection points to realize multi-channel and multi-gate injection in injection molding, metal die casting, and injection processes. This improves the adaptability to the melt rheological characteristics and mold filling requirements of different regions of the cavity, and avoids molding defects such as insufficient mold filling, uneven melt front temperature, poor mechanical properties of weld lines, and stress concentration in the part that are common when using a single gate method.

[0014] In a preferred embodiment of the present invention, the device also has a global collaborative closed-loop control system for comprehensively controlling the mold-closing injection process and conditions such as pressure and temperature of each system.

[0015] Accordingly, the present invention also provides a multi-machine, multi-point injection molding process utilizing the aforementioned equipment, such as... Figure 6 As shown, the specific steps include: S1. Material selection: Based on the product design, select injection molding material PA6+GF60, die casting material A380 aluminum alloy, and magnesium alloy injection material AZ91D; the blank to be injected is a hot-blown automotive A-pillar tube blank 5-1 made of BR1500HS material with a thickness of 2.0mm. S2. Dry the injection-molded plastic granules, remelt the die-cast aluminum alloy in advance, refine, degas and remove slag, and seal, dehumidify and preheat the magnesium alloy granules; after setting the position of each system on the positioning worktable according to the design structure of the blank and the part to be formed, fill the barrel of each system with protective gas (nitrogen or inert gas), and install the corresponding mold in its respective hydraulic mold closing unit, open the mold to perform preheating treatment and spray mold release agent; S3. Place the blank 5-1 into the mold cavity, and close and lock the mold after completing the surface positioning. S4. Each system injects the corresponding material into different points on the blank 5-1. This can be done simultaneously or in stages as needed. S5. Each system performs graded and coordinated pressure holding for 5-10 seconds to allow component 5 to be fed back within the cavity; S6. After in-mold cooling, open the mold and remove the product. Figure 5 The A-pillar component 5 shown includes a plastic airbag mounting bracket 5-4, an aluminum alloy B-pillar connecting bracket 5-3, and a magnesium alloy front crossbeam bracket 5-2.

[0016] Figure 7 The diagram illustrates the structural transformation process of a component from raw material to final product. It also shows that the relative positions and specifications of each system during process execution can be flexibly adjusted according to actual needs. For larger components, the number of different systems can also be increased.

[0017] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0018] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0019] It should be understood that the sequence number of each step in the embodiments of the present invention does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0020] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-unit, multi-point injection molding process equipment, characterized in that: This includes a positioning worktable, a side-entry injection system, a dual-action vertical injection system, and a side-entry metal injection system; The positioning worktable is used to fix and support the side-entry injection molding system, the dual-action vertical injection system, and the side-entry metal injection system. Side-entry injection molding system, double-action vertical injection system and side-entry metal injection system all include hydraulic clamping unit with the same structure. The frame of the hydraulic clamping unit is composed of an upper plate, a back plate and a bottom plate forming a C-shaped structure. The clamping cylinder is installed above the upper plate. The clamping mechanism of each system is located in front of the back plate, between the upper plate and the bottom plate and connected to the clamping cylinder. The mold is set on the bottom plate. The side-entry injection molding system also includes a material storage and injection system unit located behind its frame back plate; the dual-action vertical injection system also includes an energy storage die casting unit located behind its frame back plate; the side-entry metal injection system also includes a material storage and slurry injection system unit located behind its frame back plate.

2. The multi-point injection molding process equipment as described in claim 1, characterized in that: Each system's frame base plate is equipped with positioning and clamping slots for installing and moving molds.

3. The multi-point injection molding process equipment as described in claim 1, characterized in that: The material storage and injection system unit, the energy storage die casting unit, and the material storage and slurry injection system unit all contain multiple injection points.

4. The multi-point injection molding process equipment as described in claim 1, characterized in that: The equipment also features a global collaborative closed-loop control system, which comprehensively controls the molding and injection process, as well as pressure and temperature conditions, for each system.

5. A multi-unit, multi-point injection molding process using the equipment described in any one of claims 1-4, specifically comprising the following steps: S1. Select the injection molding, die casting, or metal injection materials and the blank to be injected; S2. Pre-treat the selected materials and prepare the equipment and molds; S3. Place the blank into the mold cavity, complete the surface positioning, and then close and lock the mold. S4. Each system injects the corresponding material at different points on the blank; S5. Each system performs graded and coordinated pressure holding to ensure that the component is compressed within the cavity; S6. After in-mold cooling, open the mold and remove the one-piece molded component containing different materials.

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