Injection molding device and injection molding process for the production of multi-component plastic molded parts

Abstract

Injection molding apparatus for producing a plastic molded part comprising a first component, a second component and a third component (400), which has: a first mold plate (100, 100') with at least 3 first mold cavities (110, 120, 130; 110', 120', 130'), a second mold plate (200, 200') with at least 3 second mold cavities (210, 220, 230; 210', 220', 230') which, in the closed state, interacts with the first mold plate (100; 100') in the production of the plastic molded part (400) and, in the open state, is rotatable relative to the first mold plate (100, 100'); wherein which include at least 3 second mold nests (210, 220, 230; 210', 220', 230'): in one case A) at least two second mold cavities (210, 220) for injection molding the first component (1K) and at least one second mold cavity (230) for injection molding the third component (3K) or in case B) at least two second mold cavities (220', 230') for injection molding the second component (2K) and at least one second mold cavity (210') for injection molding the first component (1K), and wherein the at least 3 first mold cavities (110, 120, 130; 110', 120', 130') comprise at least two first mold cavities (120, 130; 110', 120') each connected to two plastic feeds for introducing plastic in case A) the second component and the third component or in case B) the first and the second component.

Description

[0001] The invention relates to an injection molding device and an injection molding method for producing plastic molded parts comprising at least three plastic components.

[0002] The production of such multi-component plastic molded parts can be carried out using a rotary table injection molding machine on a multi-component machine. Rotary table injection molding machines have mold plates that can rotate relative to one another. One of the mold plates is usually held in a rotationally fixed manner in the multi-component machine, while the other mold plate can rotate relative to the fixed mold plate when open. In 3K injection molding, the rotatable mold plate has three mold cavities arranged at 120° to one another, each of which forms cavities for the base body of the molded part to be produced and is designed identically. The fixed mold plate also has three mold cavities, each of which is provided with a plastic feed (1K, 2K, or 3K), is designed differently, and allows the injection of the base body (1K) or the injection of the second component (2K) or the third component (3K).

[0003] The production process includes a successive rotation of the rotatable mold plate relative to the fixed mold plate, whereby the pre-products located in the cavities of the first mold plate (1K base body or 1K base body with molded-on second component 2K or finished 3K component) are each repositioned relative to the fixed mold plate in order to carry out the next production step.

[0004] Difficulties arise with such a process, for example, when a component is to be injected onto both sides of the base body of the plastic molded part.

[0005] EP 0 671 251 A1 describes an injection molding device with a stationary mold and a rotary table, with which three or more component plastic molded parts can be produced. The stationary mold has mold parts with different contour surfaces for producing the respective components of the plastic molded part.

[0006] DE 10 2012 107 171 A1 discloses a clamping unit for an injection molding machine for producing multi-component plastic molded parts with a rotary table that allows rotation of a mold part in both directions.

[0007] DE 44 08 426 A1 discloses a method for producing a 3-component plastic article by 3-stroke injection molding.

[0008] One object underlying the invention can be seen in the provision of an injection molding apparatus that enables the simple and process-efficient production of at least three-component plastic molded parts. Furthermore, the invention aims to provide an injection molding method for producing such a plastic molded part comprising at least three components, which allows the production of a plastic molded part during each closing and opening process of the mold plates.

[0009] The problem underlying the invention is solved by the features of the independent claims. Advantageous embodiments and further developments are the subject of the dependent claims.

[0010] Accordingly, an injection molding device for producing a plastic molded part comprising a first component, a second component, and a third component has a first mold plate with at least three first mold cavities. The injection molding device further comprises a second mold plate with (likewise) at least three second mold cavities. In the closed state, the second mold plate cooperates with the first mold plate during the production of the plastic molded part and, in the open state, is rotatable relative to the first mold plate. The at least three second mold cavities (of the second mold plate) comprise, in case A), at least two second mold cavities for injection molding the first component and at least one second mold cavity for injection molding the third component, or in case B), at least two second mold cavities for injection molding the second component and at least one second mold cavity for injection molding the first component.

[0011] By providing differently designed mold cavities on the second mold plate, it is possible to inject a component onto a side of a base body of the plastic molded part facing the second mold plate.

[0012] The at least three first mold cavities (of the first mold plate) comprise at least two first mold cavities, each of which is connected to two plastic feeds for introducing plastic in case A) the second component and the third component, or in case B) the first and the second component. Thus, in these mold cavities, different plastic components can be selectively injection-molded onto a base body of the plastic molded part to be produced. This means that the provision of differently designed mold cavities on the first mold plate enables injection of a component onto a side of a base body of the plastic molded part facing the first mold plate.

[0013] The at least three first mold cavities can further comprise at least one first mold cavity which is connected to only one plastic feed for introducing plastic in case A) the first component, i.e. for example the base body, or in case B) the third component. This means that in case A), for example, a first mold cavity is used to produce the base body of the plastic molded part, while at least two further mold cavities alternately add the second or the third component to the plastic molded part to be produced. In case B), for example, two first mold cavities are used alternately to produce the base body and to inject the second component onto the base body, while a first mold cavity adds the third component to the plastic molded part to be produced.

[0014] The plastic feeds for the first, second, and third components can be formed in or on the first mold plate. In particular, all plastic feeds can be formed in or on the first mold plate.

[0015] For example, no plastic feeds for the first, second, or third component may be formed in or on the second mold plate. In particular, no plastic feeds at all may be realized in or on the second mold plate. However, it is also possible for plastic feeds for the first and / or the second and / or the third component to be incorporated into the second mold plate. In particular, it may be advantageous from a space and / or cost perspective if, in case A), plastic feeds for the first and second components are formed in or on the first mold plate and a plastic feed for the third component is formed in or on the second mold plate.

[0016] The injection molding device can be designed to change the direction of rotation of the second mold plate relative to the first mold plate during operation after one or more closing and opening operations. In particular, the direction of rotation can be changed after each closing and opening operation, with the angle of rotation always being 120°.

[0017] The injection molding device can be designed to produce a plastic molded part in which the first component (for example base body) is arranged between the second component and the third component.

[0018] An injection molding method for producing a plastic molded part comprising a first component, a second component, and a third component is carried out on an injection molding device comprising a first mold plate and a second mold plate, wherein the first mold plate has at least three first mold cavities, the second mold plate has at least three second mold cavities, and the first mold plate, in the closed state, cooperates with the second mold plate during production of the plastic molded part and, in the open state, is rotatable relative to the first mold plate. The method comprises alternately rotating the second mold plate relative to the first mold plate in different directions of rotation between one or more successive closing and opening operations of the mold plates.

[0019] The injection molding process comprises the injection molding of the first component to produce a 1K precursor, the second component onto a previously manufactured 1K precursor to produce a 1K+2K precursor, and the third component onto a previously manufactured 1K+2K precursor to produce the plastic molded part. In case A), the process can be carried out such that 1K+2K precursors and finished 3K molded components are produced alternately in two mold cavities of the first mold plate. In case B), the process can be carried out such that 1K precursors and 1K+2K precursors are produced alternately in two mold cavities of the first mold plate.

[0020] This means that in case A) the component removal can also take place alternately at different mold cavities of the first mold plate.

[0021] The method can be designed in such a way that in case A) the 1K+2K precursor product remains in a first mold cavity of the first mold plate when the second mold plate is rotated relative to the first mold plate.

[0022] The method can be designed in such a way that in case B) the 1K+2K precursor product is located in a second mold cavity of the second mold plate when the second mold plate is rotated relative to the first mold plate.

[0023] In particular, the method may comprise rotating the second mold plate relative to the first mold plate in alternating directions of rotation after each closing and opening operation.

[0024] For example, the process can be designed to produce one plastic molded part per closing and opening process of the mold plates. In this respect, the process demonstrates high efficiency in component production.

[0025] For example, an injection molding process disclosed herein may include the following steps: a) Closing the mold plates; b) injection moulding of the first component to produce a 1K precursor, the second component to a previously produced 1K precursor to produce a 1K+2K precursor, and the third component to a previously produced 1K+2K precursor to produce the plastic moulded part; c) Opening the mold plates; d) removal of the plastic moulded part; e) rotating the second mold plate relative to the first mold plate in one direction of rotation; f) closing the mold plates; g) injection moulding of the first component to produce a 1K pre-product, the second component to the previously produced 1K pre-product to produce a 1K+2K pre-product, and the third component to the previously produced 1K+2K pre-product to produce another plastic moulded part; h) opening the mold plates; i) removal of the further plastic moulded part; j) rotating the second mold plate relative to the first mold plate in the opposite direction to the direction of rotation; and k) continuing the process sequence with step a).

[0026] In the following, exemplary embodiments are explained with reference to the drawings. Identical or corresponding parts are provided with the same reference numerals. Features of the illustrated exemplary embodiments may be selectively combined with one another, provided they are not alternative or technically exclusive features. Furthermore, features of the exemplary embodiments may be selectively omitted, provided they are not described in the description as mandatory features.

[0027] Fig. 1 shows a first mold plate of an exemplary injection molding apparatus in plan view according to a first embodiment.

[0028] Fig. 2 shows a second mold plate of an exemplary injection molding apparatus in plan view according to the first embodiment.

[0029] Fig. 3A to 3K illustrate steps of a process flow for producing a three-component plastic molded part, wherein the Fig. 3A to 3G the start phase and the Fig. 3H to 3K show the continuous cycle of an exemplary manufacturing process.

[0030] Fig. 4A shows an exemplary three-component plastic molded part in perspective top view.

[0031] Fig. 4B shows that Fig. 4A shows an exemplary plastic molded part in longitudinal and / or cross-sectional view.

[0032] Fig. 5 shows a first mold plate of an exemplary injection molding apparatus in plan view according to a second embodiment.

[0033] Fig. 6 shows a second mold plate of an exemplary injection molding apparatus in plan view according to the second embodiment.

[0034] After the Fig. 4A and Fig. 4B, a multi-component plastic molded part 400 can comprise a first component 1K, a second component 2K, and a third component 3K. The multi-component plastic molded part 400 thus has at least three plastic components. It is referred to below as a 3K plastic molded part 400, although this designation does not exclude the possibility that the 3K plastic molded part also contains further plastic components (i.e., for example, a fourth plastic component, a fifth plastic component, etc.).

[0035] The first plastic component 1K can, for example, be the base body of the 3K plastic molded part 400. The first plastic component 1K can, for example, consist of a transparent plastic material and can, for example, be flat. An opaque first plastic component 1K is also possible.

[0036] The second plastic component 2K can be molded onto a first main surface of the first component 1K. For example, the second plastic component 2K can be a mounting structure (e.g., a so-called black border) by means of which the first plastic component 1K can be mounted in an installation position (e.g., in a body opening of a motor vehicle). The second plastic component 2K can partially cover the first main surface of the first plastic component 1K (e.g., in the form of separate local mounting points or optical elements, or in the form of a surrounding frame) or even cover the entire surface.

[0037] The third plastic component 3K can, for example, extend over a second main surface of the first plastic component 1K opposite the first main surface and optionally also over side wall regions of the first plastic component 1K. The third plastic component 3K can, for example, be a full-surface coating (e.g., coating) of the first plastic component 1K. For example, highly transparent PUR plastics can be used, which, for example, create an optical depth effect and surface protection. However, the third plastic component 3K can also be in a form other than that shown in the Fig. 4A-4B. For example, the third plastic component 3K may also be a structural component such as a frame, a reinforcing structure, etc., whereby, to avoid repetition, reference is made to the description of the second plastic component 2K.

[0038] The 3K plastic molded part 400 can, for example, be a glazing element, e.g., automotive glazing, or a body and / or glazing part, e.g., of a motor vehicle. It can also, in particular, be a design or visible part for the interior of a motor vehicle, especially a design or visible part that is touched by a passenger, for example, and therefore needs to be protected against signs of wear, for which the third component, 3K, is required.

[0039] Fig. Figure 1 shows a first example of a first mold plate 100 of an injection molding device in plan view. In the example shown here, the first mold plate 100 has three mold cavities 110, 120, 130, which are arranged in Fig. 1 are shown schematically. The mold cavities 110, 120, 130 can be aligned radially with a center point M of the first mold plate 100 and arranged circumferentially at 120° to each other.

[0040] The mold cavity 110 can be a 1K mold cavity in which the first component 1K of the plastic molded part 400 is injection molded. The mold cavity 120 and the mold cavity 130 can be provided for injection molding the second component 2K and enable a plastic feed for the injection molding of the third component 3K.

[0041] The mold cavities 120, 130 can be identical in terms of their contour surface and differ from the contour surface of the mold cavity 110.

[0042] As in Fig. As shown in Figure 1, the mold cavity 110 is connected to a plastic feed 115 for introducing plastic of the first component 1K. The mold cavities 120, 130 each have a plastic feed 125, 135 for introducing plastic of the second component 2K. Furthermore, plastic feeds 128 and 138 are provided for feeding plastic of the third component 3K.

[0043] The plastic feeds 128, 138 can, for example, connect to an edge region of the mold cavities 120 and 130, respectively, similar to a film gate, so that plastic of the third component 3K cannot get between the contour surface of the mold cavity 120 and 130 for injection molding the second component 2K and the injection-molded second component 2K of the plastic molded part. The plastic feeds 115, 125, 135 can, for example, connect to the respective mold cavities 110, 120, and 130 in an outer-edge or central region of the respective contour surfaces.

[0044] The plastic feeds 115, 125, 135 for injection molding the first 1K component and the second 2K component can be designed as hot runners. The plastic feeds 128, 138 for feeding the third 3K component can also be designed as hot runners, or other feeding technologies are also possible, for example, mixing systems for feeding (i.e., flooding the precursor with), for example, low-viscosity PUR plastics.

[0045] All plastic feeds 115, 125, 135, 128, 138 can be incorporated into the first mold plate 100 and serve to feed liquid plastic mass to the mold cavities during the filling process. In particular, the feed of the third component 3K can alternatively also be incorporated into the second mold plate 200 (for example, if the feed of the third component 3K is carried out by means of PUR flooding). In this case, the feed unit is only incorporated on the 3K mold cavity 230, since this moves with the rotation of the second mold plate 200 to the mold cavities 120 and 130. This enables a cost-effective and space-saving arrangement, since in comparison to the Fig. 1, a 3K feed unit is saved and, in addition, more space is available on the first mold plate 100 for the 2K plastic feeds 125, 135, which often have to be incorporated into the first mold plate 100 as hot runners, each with several distributed injection points to the 2K mold cavities 120, 130. In general, however, the feeds of the first component K1 and / or the second component K2 can also be incorporated into the second mold plate 200.

[0046] The plastics of the first component 1K, the second component 2K and the third component 3K can each be different from each other, whereby the difference can consist, for example, in the choice of material and / or in the optical properties (transparency, color, etc.).

[0047] The second mold plate 200 (see Fig. 2) also has a mold cavity 210, a mold cavity 220, and a mold cavity 230. The mold cavity 210 and the mold cavity 220 can have an identical contour surface for the injection molding of the first component 1K. The contour surface of the mold cavity 230 is designed differently from the mold cavities 210 and 220. In the example shown here, the mold cavity 230 is shaped with a contour surface for the injection of the third component 3K.

[0048] The injection mold comprising the mold plates 100, 200 can be a rotary table mold. This means that the two mold plates 100, 200 are mounted on mold plates (not shown) that are axially movable relative to one another and can also rotate relative to one another (in the open mold position). Typically, the first mold plate 100 is mounted in a rotary table injection molding machine in a rotationally fixed and, if necessary, fixed position, while the second mold plate 200 is rotatable and, if necessary, axially movable relative to the first mold plate 100. The rotation axis passes through the pivot point R of the second mold plate 200 and the center point M of the first mold plate 100.

[0049] The Fig. 3A to 3K illustrate, in a schematic and exemplary manner, manufacturing steps of a method for producing a 3K plastic molded part using the example of the mold plates 100, 200. To simplify the illustrations, only the mold cavities 110, 120, 130 and 210, 220, 230 are shown, but not the mold plates 100, 200. All Fig. 3A to 3K are oblique perspective views of the back of the first mold plate 100 (not shown). Also not shown are the plastic feeds 115, 125, 135, 128, 138 to the mold cavities 110, 120, 130 of the first mold plate 100.

[0050] Fig. Figure 3A shows the injection molding apparatus in the closed state. Cavities are formed between the mold cavities 110, 210, 120, 220, and 130, 230, respectively. A first 1K component (1K precursor) of the plastic molded part 400 is manufactured in the cavity between the mold cavities 110, 210. The cavities between the mold cavities 120, 220, and 130, 230 are empty during the initial phase of the production process.

[0051] The mold cavities 210, 220, 230 can be trough-shaped mold cavities, while the mold cavities 110, 120, 130 can be mold core-shaped mold cavities. Likewise, the mold cavities 210, 220, 230 can be mold core-shaped mold cavities, while the mold cavities 110, 120, 130 can be trough-shaped mold cavities - such an example is shown in the Fig. 5 and Fig. 6 is explained in more detail.

[0052] In the following, the position of mold cavity 110 is designated P1, the position of mold cavity 120 is designated P2, and the position of mold cavity 130 is designated P3. These positions P1 to P3 are fixed.

[0053] Fig. Figure 3B shows the opening of the mold plates 100, 200 (not shown). This separates the mold cavities 110, 210, 120, 220 and 130, 230, respectively. In the mold cavity 210, the Fig. 3A manufactured first component 1K (1K precursor).

[0054] Referring to Fig. 3C, the second mold plate 200 is rotated relative to the first mold plate 100 in a first rotation direction D1 (see arrow). The rotation occurs by 120°. If more than three mold cavities are provided per mold plate, the angle of rotation is also 120°.

[0055] Then the two mold plates 100, 200 are closed (see Fig. 3D). This creates cavities between the mold cavities 110, 220, 130, 210, and 120, 230.

[0056] At position P1 between mold cavities 110 and 220, another first component (1K precursor) is manufactured. In the same work step, at position P3, the second 2K component is injected onto the 1K precursor in mold cavity 210. At position P2, no injection molding process is performed during the start phase of this work step.

[0057] Then the two mold plates 100, 200 are opened again, see Fig. 3E. The first 1K component (1K precursor) just produced remains in the mold cavity 220 on the rotating side of the injection molding device. The 1K+2K precursor, which is in Fig. 3D by injecting the second component 2K onto the 1K precursor, remains in the mold cavity 130, i.e. at position P3 of the fixed side (also called nozzle side) of the injection molding device.

[0058] As in Fig. As shown in Figure 3F, the second mold plate 200 is then rotated back in the opposite direction D2 to the direction of rotation D1. This brings the mold cavities 110, 210 (at position P1), 120, 220 (at position P2), and 130, 230 (at position P3) back into alignment.

[0059] In the following step of the Fig. 3G, after closing the mold plates, a first 1K component (1K precursor) is manufactured at position P1. At position P2, a 1K+2K precursor is manufactured, i.e., the second 2K component is molded onto the previously manufactured 1K precursor. At position P3, the third 3K component is molded onto the previously manufactured 1K+2K precursor, creating a finished 3K plastic molded part.

[0060] As in Fig. 3H, the mold plates 100, 200 are then opened. The mold plate 100, 200 is ... Fig. The 1K pre-product manufactured at position P2 (see 3G) remains on the rotating side in mold cavity 210. The 1K+2K pre-product previously manufactured at position P2 remains in mold cavity 120 on the fixed side of the injection molding machine. The finished 3K plastic molded part is removed at position P3.

[0061] The mold plate 200 is now rotated by 120° in the direction of rotation D1, see Fig. 3I. The 1K precursor is thereby brought into position P3 and the mold cavity 230 for the production of the third component 3K is moved to position P2 opposite the mold cavity 120 in which the 1K+2K precursor is located.

[0062] After closing the mold plates 100, 200, Fig. 3J, the following injection molding processes are carried out: At position P1, component 1K is injected to produce a 1K precursor. At position P3, a 1K+2K precursor is manufactured by injecting the second component 2K. At position P2, a finished 3K plastic molded part is produced by injecting the third component 3K onto the already manufactured 1K+2K precursor.

[0063] That is, in Fig. 3J the position of the mold plates 100, 200 is identical to that in Fig. 3D, but in the continuous cycle ( Fig. 3J) different than in the starting phase ( Fig. 3D) at position P2 no “blind process” is carried out, but the third component 3K is injected.

[0064] The mold plates 100, 200 are then opened ( Fig. 3K). Again, the 1K precursor remains on the rotating side in mold cavity 220. The 1K+2K precursor at position P3 remains in mold cavity 130 on the fixed side of the injection molding device. The finished 3K plastic molded part is removed at position P2.

[0065] In the continuous cycle, the process then continues in the Fig. 3F with a reverse rotation D2 of the second mold plate 210.

[0066] From the above description, it can be seen that in this exemplary embodiment, at position P1, a first component (i.e., a 1K precursor) is manufactured in each work step. At positions P2 and P3, 1K+2K precursors and finished 3K molded components are produced alternately. By rotating the second mold plate 200 in the direction of rotation D1 and rotating the second mold plate 200 back in the opposite direction of rotation D2, the mold cavity 230 for injecting the third 3K component is always in exactly the rotational position (position P2 or position P3) in which the 1K+2K precursor was just manufactured (which always remains on the fixed side (first mold plate 100), i.e., is not moved).

[0067] In other words, in this embodiment, the 1K precursor is manufactured at position P1 and then moved either in the direction of rotation D1 or in the opposite direction of rotation D2 to positions P3 and P2, respectively. The 1K+2K precursor, however, remains on the fixed side (mold plate 100) of the injection molding machine, i.e., it is not moved during the entire process. Component removal occurs alternately at positions P2 and P3.

[0068] In the continuous cycle, one component is removed per work cycle (closing and opening process of the mold plates 100, 200), ie one finished 3K plastic molded part is produced per work cycle.

[0069] The Fig. 5 and Fig. 6 show a first mold plate 100' and a second mold plate 200' of an exemplary injection molding apparatus in plan view according to a second embodiment.

[0070] The second embodiment may differ from the first embodiment ( Fig. 1 and Fig. 2) in that the first mold plate 100' has mold cavities 110', 120', 130', which form different cavities (i.e., contour surfaces) compared to the mold cavities 110, 120, 130 of the first exemplary embodiment. For example, the mold cavity 110' forms a 1K cavity, the mold cavity 120' also forms a 1K cavity, and the mold cavity 130' forms a 3K cavity. The mold cavities 110', 120', 130' can be trough-shaped mold cavities, i.e., the first mold plate 100' can be formed as a trough mold plate.

[0071] With regard to the second mold plate 200', the second embodiment may differ from the first embodiment ( Fig. 1 and Fig. 2) differ in that the second mold plate 200' has mold cavities 210', 220', 230', which form different cavities (i.e., contour surfaces) compared to the mold cavities 210, 220, 230. For example, the mold cavity 210' forms a 1K cavity, the mold cavity 220' forms a 2K cavity, and the mold cavity 230' also forms a 2K cavity (i.e., provides correspondingly shaped contour surfaces). In this case, the mold cavities 210', 220', 230' can be mold core-shaped mold cavities, i.e., the second mold plate 200' can be formed as a mold core plate.

[0072] As in Fig. As shown in Figure 5, the mold cavities 110', 120' can be supplied with plastic feeds (e.g., hot runners) 115, 118, and 125, 128, respectively, for introducing the first and second plastic components, respectively, while a 3K feed 138 connects to the mold cavity 130'. Regarding the feeds (in particular, their design and incorporation into mold plates 100' or 200'), reference is made to the above explanations.

[0073] The process for producing the plastic molded part 400 using the mold plates 100', 200' is largely analogous to the process described on the basis of the Fig. 3A-3K, so to avoid repetition, reference is made to the above description. In particular, between one or more consecutive closing and opening operations of the mold plates 100', 200', the second mold plate 200' rotates in a different direction relative to the first mold plate 100'. The following special features are noted: First, a 1K component is manufactured between the mold cavities 110' and 210'. When the tool is subsequently opened, the 1K component remains in the first (e.g., trough-shaped) mold cavity 110' (unlike in the first embodiment).

[0074] The second mold plate 200' is then rotated by 120° (in the opposite direction to the Fig.3C). This brings the mold cavity 230' into position opposite the mold cavity 110'. The tool is closed, and in the mold cavity 230', the second 2K component is injected onto the first 1K component. The injection of the second 2K component takes place here in the second mold plate 200', i.e., the plastic molded part 400 is rotated 180° compared to the first embodiment and produced in the tool 100', 200'. In the start-up phase, the mold cavity 220', which is opposite the 3K mold cavity 130', is still empty at this time.

[0075] After the 1C+2C precursor has been produced between the mold cavities 110' and 230', the tool is opened and the second mold plate 200' is rotated back by 120°, so that the mold cavity 230' is again positioned opposite the mold cavity 130'. Unlike in the first embodiment, the 1C+2C precursor is carried along in the second mold plate 200' (in the mold cavity 230') during the reverse rotation.

[0076] Subsequently, the mold 100', 200' is closed, and the third 3K component is injected onto the 1K+2K precursor. The 1K+2K precursor is located in the mold cavity 230', and the third 3K component is injected (unlike in the first embodiment) into the first mold plate in the mold cavity 130'.

[0077] In the continuous cycle, the mold cavities 220', 230' of the second mold plate 200' alternately transport a prefabricated 1K+2K precursor to the mold cavity 130' of the first mold plate 100', in which the plastic molded part 400 is then completed and from which it is subsequently removed. At the same time, 1K precursors and 1K+2K precursors are alternately produced in the first mold cavities 110', 120' of the first mold plate 100'.

[0078] What both embodiments have in common is that the method comprises the steps: a) Closing the mold plates 100, 100' or 200, 200`; b) injection molding of the first component 1K to produce a 1K precursor, the second component 2K to a previously manufactured 1K precursor to produce a 1K+2K precursor, and the third component 3K to a previously manufactured 1K+2K precursor to produce the plastic molded part 400; c) Opening the mold plates 100, 200 or 100', 200`; d) removal of the plastic molded part 400; e) rotating the second mold plate 200, 200' relative to the first mold plate 100; 100' in one direction of rotation; f) Closing the mold plates 100, 200 or 100' 200`; g) injection molding of the first component 1K to produce a 1K precursor, the second component 2K to the previously manufactured 1K precursor to produce a 1K+2K precursor, and the third component 3K to the previously manufactured 1K+2K precursor to produce a further plastic molded part 400; h) Opening of the mold plates 100, 200 or 100', 200`; i) removal of the further plastic molded part 400; j) rotating the second mold plate 200, 200' relative to the first mold plate 100, 100' in the opposite direction to the direction of rotation; and k) Continuation of the process sequence with step a).

[0079] The described processes and injection molding systems can be expanded analogously to more than three plastic components. It is important that the injection molding process involves a cyclical change in the direction of rotation of the second mold plate during the continuous cycle.

Claims

[1] Injection molding device for producing a plastic molded part (400) comprising a first component, a second component and a third component, comprising: a first mold plate (100, 100') with at least 3 first mold cavities (110, 120, 130; 110', 120', 130'), a second mold plate (200, 200') with at least 3 second mold cavities (210, 220, 230; 210', 220', 230'), which in the closed state cooperates with the first mold plate (100; 100') in the production of the plastic molded part (400) and in the open state is rotatable relative to the first mold plate (100, 100'); wherein the at least 3 second mold cavities (210, 220, 230; 210', 220', 230') comprise: in one case A) at least two second mold cavities (210, 220) for injection molding the first component (1K) and at least one second mold cavity (230) for injection molding the third component (3K) or in a case B) at least two second mold cavities (220', 230') for injection molding the second component (2K) and at least one second mold cavity (210') for injection molding the first component (1K), and wherein the at least 3 first mold cavities (110, 120, 130; 110', 120', 130') comprise at least two first mold cavities (120, 130; 110', 120'), each of which is connected to two plastic feeds for introducing plastic in case A) the second component and the third component or in case B) the first and the second component. [2] Injection molding device according to claim 1, wherein the at least 3 first mold cavities (110, 120, 130; 110', 120', 130') further comprise at least one first mold cavity (110; 130') which is connected to only one plastic feed (115; 138) for introducing plastic in case A) of the first component (1K) or in case B) of the third component (3K). [3] Injection molding device according to one of the preceding claims, wherein plastic feeds (115, 118, 125, 128, 135, 138) for the first, second and third components are formed in or on the first mold plate (100, 100'). [4] Injection molding device according to one of the preceding claims, wherein no plastic feeds for the first, second and third components are formed in or on the second mold plate (200, 200'). [5] Injection molding device according to claim 1 or 2, wherein in case A) plastic feeds (115, 125, 135) for the first and second components are formed in or on the first mold plate (100) and a plastic feed for the third component (3K) is formed in or on the second mold plate (200). [6] Injection molding device according to one of the preceding claims, wherein the injection molding device is designed to change the direction of rotation of the second mold plate (200, 200') relative to the first mold plate (100, 100') after one or more, in particular after each closing and opening operation. [7] Injection molding device according to one of the preceding claims, wherein the injection molding device is designed to produce a plastic molded part (400) in which the first component (1K) is arranged between the second component (2K) and the third component (3K). [8] Injection molding method for producing a plastic molded part (400) comprising a first component, a second component and a third component by means of an injection molding device which comprises a first mold plate (100, 100') and a second mold plate (200, 200'), wherein the first mold plate (100, 100') has at least 3 first mold cavities (110, 120, 130; 110', 120', 130'), the second mold plate (200, 200') has at least 3 second mold cavities (210, 220, 230; 210', 220', 230'), and the second mold plate (200, 200') in the closed state cooperates with the first mold plate (100, 100') in the production of the plastic molded part (400) and in the open state relative to the first mold plate (100, 100') is rotatable; wherein the method comprises injection molding the first component (1K) to produce a 1K precursor, the second component (2K) onto a previously manufactured 1K precursor to produce a 1K+2K precursor, and the third component (3K) onto a previously manufactured 1K+2K precursor to produce the plastic molded part (400), the method comprises, between one or more successive closing and opening operations of the mold plates (100, 100'; 200, 200'), rotating the second mold plate (200, 200') relative to the first mold plate (100, 100') alternately in different directions of rotation, wherein in one case A) in two mold cavities (120, 130) of the first mold plate (100) 1K+2K pre-products and finished 3K molded components are produced alternately, or in a case B) in two mold cavities (110', 120') of the first mold plate (100') 1K pre-products and 1K+2K pre-products are produced alternately. [9] Injection molding method according to claim 8, wherein the method is designed to produce one plastic molded part (400) per closing and opening operation of the mold plates (100, 200). [10] Injection molding method according to claim 8 or 9, wherein in case A) the 1K+2K precursor remains in a first mold cavity (120; 130) of the first mold plate (100) when the second mold plate (200) is rotated relative to the first mold plate (100). [11] Injection molding method according to claim 8 or 9, wherein in case B) the 1K+2K precursor is located in a second mold cavity (220', 230') of the second mold plate (200') when the second mold plate (200') is rotated relative to the first mold plate (100'). [12] Injection molding process according to one of claims 8 to 11, wherein the process comprises the steps of: a) closing the mold plates (100, 100'; 200, 200'); b) injection molding the first component (1K) to produce a 1K precursor, the second component (2K) onto a previously manufactured 1K precursor to produce a 1K+2K precursor, and the third component (3K) onto a previously manufactured 1K+2K precursor to produce the plastic molded part (400); c) opening the mold plates (100, 200; 100', 200'); d) removal of the plastic moulded part (400); e) rotating the second mold plate (200, 200') relative to the first mold plate (100, 100') in a direction of rotation; f) closing the mold plates (100, 100', 200, 200'); g) injection molding the first component (1K) to produce a 1K precursor, the second component (2K) onto the previously manufactured 1K precursor to produce a 1K+2K precursor, and the third component (3K) onto the previously manufactured 1K+2K precursor to produce a further plastic molded part (400); h) opening the mold plates (100, 100'; 200, 200'); i) removing the further plastic moulded part (400); j) rotating the second mold plate (200, 200') relative to the first mold plate (100, 100') in the opposite direction to the direction of rotation; and k) Continuation of the process sequence with step a).

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