Insert injection molding device

Abstract

Insert injection molding device comprising: a lower form (100) which has a seat part on which an insert element (S) with a through hole (S1) is placed; an upper form (200) which is attached to the lower form (100) and designed to accommodate the insert element (S) placed on the seat part; and a first fastening part (300), comprising: a first head (310) which is provided in the lower form (100) and is inserted into the through hole (S1) of the insert element (S) when the insert element (S) is placed, and a first drive unit (320) designed to move the first head (310), wherein the first drive unit (320) is moved to set a length by which the first head (310) is inserted into the through hole (S1).

Description

BACKGROUND OF THE INVENTION Technical field

[0001] The present disclosure relates to an injection molding device. Description of the state of the art

[0002] Generally, roof racks are mounted symmetrically on opposite sides of a vehicle's roof panel to carry items onto the roof. An example of a roof rack is disclosed in KR 10 2011 0 019 680 A (titled "Side Bar Assembly of Roof Carrier for Vehicle").

[0003] In recent years, a technology for manufacturing roof racks using injection molding of a material such as plastic instead of aluminum has attracted attention for its lighter weight. In particular, there has been increasing research into a technology for injection molding or overmolding a reinforcing element to improve the strength of a plastic roof rack.

[0004] Meanwhile, in a device for insert injection molding of a roof beam, the mold position of a reinforcing element can change during the process due to the flow of a malleable material or an unexpected external impact. Consequently, the insert defect rate can be increased.

[0005] Document US 2004 / 0227272A1 is known, which shows an injection molding die and a method for casting a hollow component.

[0006] Furthermore, the documents JP H10-129 359 A and US 6 379 138 B1 should be mentioned. PRESENTATION OF THE INVENTION

[0007] The object of the present invention is to provide a device for the simplified manufacture of a roof rack.

[0008] One aspect of the present disclosure provides for an insert injection molding device for reducing or minimizing an insert defect rate by effectively fixing an insert element during the insert injection molding process.

[0009] According to one aspect of the present disclosure, an insert injection molding device comprises: a lower mold having a seat on which an insert element with a through-hole is placed; an upper mold attached to the lower mold to receive the insert element placed on the seat; and a first fastening part comprising a first head provided in the lower mold and inserted into the through-hole of the insert element when the insert element is placed, as well as a first drive unit that moves the first head. The first drive unit is moved to set a length by which the first head is inserted into the through-hole.

[0010] Further areas of application can be found in the description given here. BRIEF DESCRIPTION OF THE FIGURES

[0011] To make the disclosure easily understandable, various embodiments will now be described, with reference to the attached drawings as examples, in which Fig. 1 is a view of roof racks attached to a roof panel of a vehicle; Fig. 2 is a view that represents a design of the roof truss; Fig. 3 is a view which represents an embodiment of an exemplary insert injection molding device in an embodiment of the present disclosure; Fig. 4 is a detailed view showing a first fastening part in the Fig. 3 represents the injection molding device shown; Fig. Figure 5 is a detailed view showing a first drive unit in the first mounting part, which is in Fig. 4 is shown; Fig. Figure 6 is an exemplary view showing the first fastening element, which is in a lower form of the in Fig. 3 is provided for in the injection molding device shown; Fig. Figure 7 is an exemplary view showing a second fastening element, which is in an upper form of the in Fig. 3 is provided for in the injection molding device shown; Fig. 8 is a detail view which represents the shape of a first head that is inserted into an insert element when the insert element is placed; Fig. 9 is a detailed section view illustrating the insert element and the first head that is inserted into the insert element when the insert element is placed; Fig. 10 is a detailed view illustrating the shape of the first head when the first head is lowered; Fig. 11 is a detailed sectional view illustrating the insertion element and the first head when the first head is lowered; and Fig. 12 is a view that represents a design of a roof truss which is connected to the in Fig. The injection molding device shown in section 3 has been manufactured. DETAILED DESCRIPTION OF THE PREFERRED VERSION

[0012] The following description is exemplary in nature, intended to illustrate one embodiment. In all drawings, corresponding reference numerals indicate identical or corresponding parts and features.

[0013] This disclosure relates to an injection molding device. Exemplary embodiments of this disclosure are described in detail below with reference to the accompanying drawings, so that those skilled in the art, to whom this disclosure relates, can readily carry it out. However, this disclosure can be implemented in various embodiments and is not limited to those described herein. For the sake of simplicity, components irrelevant to the description are omitted from the drawings, and similar reference numerals denote similar components throughout the description.

[0014] Fig. Figure 1 is a view depicting roof racks attached to a vehicle's roof panel. Specifically, in Fig. 1 a roof rack 10 is fixedly installed by a fastening element (not shown) in a state in which a longitudinally extending rail 11, forming a main body, is attached to the roof 1 of a vehicle.

[0015] Fig. Figure 2 is a view that illustrates one design of the roof rack. More precisely, in Fig. 2 The roof support 10 from the prior art comprises the rail 11, stanchions 12 which are provided on opposite longitudinal end sections of the rail 11, covers 13 and supports 14. The rail 11, which has a uniform cross-sectional shape, is extruded from an aluminum material, and the stanchions 12, which are made of a synthetic resin, are injection molded due to the nature of their three-dimensionally curved surface shape.

[0016] Fig. Figure 3 is a view that represents an embodiment of an exemplary insert injection molding device in some embodiments of the present disclosure. Fig. 4 is a detailed view showing a first fastening part in the Fig. 3 represents the injection molding device shown. Fig. 5 is a detailed view showing a first drive unit in the first mounting part, which is in Fig. 4 is illustrated. Fig. 6 is an exemplary view showing the first fastening element, which is in a lower form of the in Fig. 3 shown in the injection molding device is provided. Fig. 7 is an exemplary view showing a second fastening element, which is in an upper form of the in Fig. 3 shown in the injection molding device is provided.

[0017] Fig. Figure 4 is a schematic view illustrating the insert injection molding device in an embodiment of the present disclosure.

[0018] With reference to Fig. 4 to 7 the insert injection molding device has the lower mold 100, the upper mold 200 and the first fastening part 300.

[0019] The lower form 100 has a seat part on which an insert element S with a through-hole S1 is placed. At least one through-hole S1 provided in the insert element S is a section into which a first head 310, described below, is inserted. If the insert element S has two or more through-holes S1, the through-holes S1 can be formed at mutually symmetrical positions on the insert element S.

[0020] The upper mold 200 is attached to the lower mold 100 to receive the insert element S, which is placed on the seat part. The upper mold 200 and the lower mold 100 can each have an injection part (not shown) through which a moldable material is injected. For example, when the upper mold 200 and the lower mold 100 are closed, the moldable material can be injected through the injection parts into a receiving chamber in which the insert element S is placed. The injected moldable material surrounds the insert element S and is cast into the seat at a predetermined temperature and pressure.

[0021] The first fastening part 300 comprises: the first head 310, which is provided in the lower form 100 and is inserted into the through hole S1 of the insert element S when the insert element S is placed; and the first drive unit 320 for moving the first head 310.

[0022] The first head 310 can protrude from the seat part towards the upper form 200. When the first head 310 is inserted into the through-hole S1 of the placed insert element S, the first head 310 can position and fix the insert element S.

[0023] The first drive unit 320 is moved to adjust the length by which the first head 310 is inserted into the through-hole S1. For example, the first drive unit 320 can move the first head 310 depending on whether the insert element S is in place or not. When the insert element S is in place, the first drive unit 320 can lower the first head 310 toward the lower form 100. In one embodiment, the insertion length becomes shorter when the first head 310 is lowered. The expression "becomes shorter" means that after moving the first head 310, the insertion length is shorter than before moving the first head 310.

[0024] In some embodiments of the present disclosure, when the first head 310 is lowered by the first drive unit 320, the first head 310 can be stopped by the through-hole S1. When the first head 310 is stopped by the through-hole S1, the first head 310 can push the insert element S towards the lower form 100, thereby increasing the force by which the insert element S is fixed.

[0025] In some embodiments of the present disclosure, the first drive unit 320 may comprise: a drive tooth element 321; a driven gear 322 which engages with the drive tooth element 321 and has a first surface 322a and a second surface 322b which faces away from the first surface 322a, and also has a step region which is concave from at least a partial region of the first surface 322a in the direction of the second surface 322b; a shaft 323 which is attached to the second surface 322b of the driven gear 322 and connected to the first head 310; and a support element 324 for supporting the first surface 322a of the driven gear 322. When the driven gear 322 rotates, a contact point between the support element 324 and the first surface 322a can be changed, and the first head 310 can be moved based on the contact point.

[0026] The contact point is continuously changed depending on the rotation of the driven gear 322. For example, if the contact point is located in a non-stepped region of the first surface 322a, the first head 310 cannot be moved, and if the contact point is located in the stepped region, the first head 310 can be moved. The movement refers to a movement in the vertical direction, and in the present disclosure, an upward movement refers to a movement in the direction of the upper shape 200 and a downward movement to a movement in the direction of the lower shape 100. Furthermore, the non-stepped region refers to a flat area, with the exception of the depression on the first surface 322a.

[0027] In some embodiments of the present disclosure, if the contact point is located in the step region, the first head 310 can be lowered. The interval by which the first head 310 is lowered is determined by the depth of the recess. That is, the first head 310 can be lowered by the same interval as the depth of the recess.

[0028] In one embodiment, the drive gear element 321 can be a rack that performs a linear motion, and the driven gear 322 can be a pinion that performs a rotary motion. The rack can perform a linear motion and the pinion a rotary motion. For example, when the rack moves forward, the pinion can rotate in a first direction, and when the rack moves backward, the pinion can rotate in a second direction opposite to the first.

[0029] The support element 324 can be arranged such that it is spaced apart from the driven gear 322, and the support element 324 can have a contact element 324a that projects from at least a portion of it and is brought into contact with the first surface 322a of the driven gear 322. The position of the contact element 324a is fixed on the support element 324. Since the position of the contact element 324a is fixed, a contact point between the first surface 322a and the contact element 324a depends on the rotation of the driven gear 322.

[0030] In some embodiments of the present disclosure, when the first head 310 is lowered, it can press the insert element S towards the lower form 100. When the first head 310 is lowered, at least a partial region of the first head 310 is brought into contact with a peripheral section of the through-hole S1. The peripheral section refers to an inner surface S2 of the insert element S (see Fig. 9 and Fig. 11). The first head 310 can push the insert element S towards the lower form 100 by coming into contact with the inner surface S2 of the insert element S.

[0031] In some embodiments of the present disclosure, the first head 310 can rotate about the center of the shaft 323 in a single motion. The first head 310 can rotate in the same direction as the direction of rotation of the driven gear 322, and the radius of rotation can be between 0° and 90°. As the first head 310 rotates, the contact element 324a can be brought into contact with the non-recessed area of ​​the driven gear 322. That is, if the contact point is located in the non-recessed area, the first head 310 can rotate, and if the contact point is located in the recessed area, the first head 310 can move downwards.

[0032] Fig. Figure 8 is a detailed view showing the shape of the first head that is inserted into the insert element when the insert element is placed, and Fig. Figure 9 is a detailed section view showing the insert element and the first head that is inserted into the insert element when the insert element is placed. Fig. Figure 10 is a detailed view showing the shape of the first head when the first head is lowered, and Fig. Figure 11 is a detailed section view showing the insert element and the first head when the first head is lowered.

[0033] In some embodiments of the present disclosure, relating to the Fig. 8 to 11, the first head 310, when inserted, can be lowered into a state in which it is rotated by a specific angle, based on the position of the first head 310. As in Fig. 10 and Fig. As shown in Figure 11, the first head 310, when inserted, can be brought into contact with the inner surface S2 of the insert element S when it is rotated by a specific angle based on the position of the first head 310. When the first head 310 is lowered while in contact with the inner surface S2 of the insert element S, the insert element S is pressed towards the lower form 100.

[0034] Furthermore, the first fastening part 300 can also include a fastening element 311 for fastening the first head 310 to the shaft 323. The fastening element 311 can, for example, be a fastening bolt.

[0035] In some embodiments of the present disclosure, when the insert element S is projected orthogonally onto a virtual plane parallel to a seating surface of the insert element S, at least a portion of the first head 310 may be located outside the through-hole S1, depending on the rotation. The portion located outside the through-hole S1 may be brought into contact with the inner surface S2 of the insert element S when the first head 310 is lowered. In another embodiment, in the case that the insert element S is projected orthogonally onto the virtual plane as described above, the first head 310 may be located inside the through-hole S1 when it is first inserted into the through-hole S1.

[0036] In another embodiment, the insert injection molding device can have a second fastening part 400. The second fastening part 400 can comprise: a second head 420, which is attached to the upper mold 200 and which secures the insert element S when the insert element S is in place; and a second drive unit 410, which moves the second head 420. The second fastening part 400 can secure the insert element S by pressing on an upper surface of the insert element S.

[0037] In some embodiments of the present disclosure, the second drive unit 410 can be a hydraulic cylinder. In one embodiment, the movement of the second drive unit 410 can be controlled by a controller with a timer function.

[0038] In another embodiment, the second fastening part 400 can move the second head 420 depending on whether or not the malleable material is introduced. In particular, when the malleable material is introduced, the second head 420 can be raised and spaced a certain distance from the insert element S. Conversely, when no malleable material is introduced, the second head 420 can be lowered and press down on the insert element S to fix it in place.

[0039] The insert injection molding device in an embodiment of the present disclosure can be a device for insert injection molding of a vehicle part, and the vehicle part can be a roof rack.

[0040] Fig. 12 is a view that represents a design of a roof truss, which is connected to the in Fig. The injection molding device shown in section 3 has been manufactured.

[0041] With reference to Fig. 12 The roof rack has a main body 1000, a hollow profile 2000 and a closure cap 3000.

[0042] The main body 1000 comprises a rail and support elements. The rail extends longitudinally and forms a single body, and the support elements are provided at opposite longitudinal end sections of the rail. For example, the support elements at the opposite longitudinal end sections of the rail can be integrally formed by the injection molding device described above.

[0043] The hollow profile 2000 can be the insert element S described above. In particular, the hollow profile 2000 extends along the longitudinal direction of the rail and is integrally formed within the rail. The hollow profile 2000 has one or more through-holes formed on a surface facing a vehicle roof panel. The surface facing the vehicle roof panel can be the same as the seat surface described above.

[0044] The hollow profile 2000 can serve as a reinforcing element to increase the strength of the main body 1000. Specifically, the rail can have a hollow section extending longitudinally, and the inner surfaces of the rail forming the hollow section can be in contact with the entire area of ​​an outer surface of the hollow profile 2000. Since the entire area of ​​the outer surface of the hollow profile 2000 is in contact with the inner surfaces of the rail, the strength of the main body 1000 can be improved. The hollow profile 2000 can be in the shape of a rod with a hollow section (an interior) running along its length. Furthermore, the length of the hollow profile 2000 can be equal to or shorter than the length of the rail.

[0045] The main body 1000 and the hollow profile 2000 can be molded simultaneously using insert molding. Since the main body 1000 and the hollow profile 2000 of the roof rack are integrally formed using insert molding, the number of processes (assembly / production) can be simplified, thus reducing manufacturing costs. Furthermore, the roof rack manufactured using insert molding offers a high degree of design freedom and a luxurious appearance.

[0046] The roof support can further include the end cap 3000, which is attached to at least one of the opposing longitudinal end sections of the hollow profile 2000 and is located inside the main body 1000. For example, the end caps 3000 can be attached to the opposing longitudinal end sections of the hollow profile 2000 to seal the interior of the hollow profile 2000. The hollow profile 2000 can be formed by injection molding, while the end caps 3000 are attached to the opposing longitudinal end sections of the hollow profile 2000. Since the end caps 3000 are injection molded in the state in which they are attached to the opposing longitudinal end sections of the hollow profile 2000, the end caps 3000 can be located inside the main body 1000 and may not be visible from outside the roof support.Since the end caps 3000 seal the interior of the hollow profile 2000, they serve to prevent the introduction of the moldable material of the rail into the interior of the hollow profile 2000 during insert injection molding. Furthermore, the size of the end caps 3000 can be larger than the diameter of the hollow profile 2000. The size of the end caps 3000 refers to the length in its longest dimension. Because the end caps 3000 are designed to be larger than the diameter of the hollow profile 2000, the coupling force between the main body 1000 and the hollow profile 2000 can be improved, thus preventing or avoiding separation of the hollow profile 2000 from the main body 1000 in the event of an external impact.Furthermore, the 3000 end caps can help to improve the settling of the 2000 hollow profile in the insert injection molding device described above during the insert injection molding process.

[0047] According to some embodiments of the present disclosure, the insert injection molding device can reduce or minimize an insert defect rate by effectively fixing the insert element during the insert injection molding process.

Claims

[1] Insert injection molding device comprising: a lower form (100) which has a seat part on which an insert element (S) with a through hole (S1) is placed; an upper form (200) which is attached to the lower form (100) and designed to accommodate the insert element (S) placed on the seat part; and a first fastening part (300), comprising: a first head (310) which is provided in the lower form (100) and is inserted into the through hole (S1) of the insert element (S) when the insert element (S) is placed, and a first drive unit (320) designed to move the first head (310), wherein the first drive unit (320) is moved to set a length by which the first head (310) is inserted into the through hole (S1). [2] Insert injection molding device according to claim 1, wherein the first drive unit (320) comprises: a drive tooth element (321); a driven gear (322) which engages with the drive gear element (321) and which has: a first surface (322a), and a second surface (322b) which is facing away from the first surface (322a) and has a step area which is concave from at least one part of the first surface (322a) to the second surface (322b); a shaft (323) which is attached to the second surface (322b) of the driven gear (322) and connected to the first head (310); and a support element (324) which is in contact with the first surface (322a) of the driven gear and is designed to support the driven gear, wherein a contact point between the support element (324) and the first surface (322a) is changed based on the rotation of the driven gear (322), and where the first head (310) is moved based on the contact point. [3] Insert injection molding device according to claim 2, wherein the first head (310) is lowered when the contact point is in the step area. [4] Insert injection molding device according to claim 2 or 3, wherein the drive tooth element (321) is a rack and the driven gear (322) is a pinion. [5] Insert injection molding device according to any one of claims 2 to 4, wherein: the support element (324) is arranged such that it is spaced apart from the driven gear, and the support element (324) has a contact element (324a) which projects from at least a part thereof and is brought into contact with the first surface (322a) of the driven gear (322). [6] Insert injection molding device according to one of claims 2 to 5, wherein the first head (310) is designed to rotate in a process of movement about a center point of the shaft (323). [7] Insert injection molding device according to claim 6, wherein at least a partial area of ​​the first head (310) is arranged outside the through-hole (S1) based on the rotation when the insert element (S) is projected orthogonally onto a virtual plane parallel to a seat surface of the insert element (S). [8] Insert injection molding device according to one of the preceding claims, wherein the first head (310) is configured to push the insert element (S) towards the lower mold (100) when the first head (310) is lowered. [9] Insert injection molding device according to one of the preceding claims, further comprising: a second fastening part (400), comprising: a second head (420) which is attached and designed in the upper form (200) to fix the insert element (S) when the insert element (S) is in place; and a second drive unit (410) designed to move the second head (420). [10] Insert injection molding device according to claim 9, wherein the second drive unit (410) is a hydraulic cylinder. [11] Insert injection molding device according to claim 9 or 10, wherein the second fastening part (400) is configured to move the second head (420) based on whether a moldable material is inserted or not. [12] Insert injection molding device according to claim 11, wherein the second head (420) is raised and spaced apart from the insert element (S) at a certain interval when the moldable material is inserted.

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