Injection moulding system, and method for producing a multi-component injection-moulded part, computer program product, and storage medium

Abstract

The present invention relates to an injection moulding system for producing a multi-component injection-moulded part, the injection moulding system comprising: - a master mould (10) in which a first hot runner (11) for a first material (13) and a second hot runner (12) for a second material (14) are formed, - a rotating mould (15) which can be rotated relative to the master mould (10) and which can be rotated into a first rotational position (P1) and into a second rotational position (P2), wherein, in the first rotational position (P1), a first cavity (16) is formed between the master mould (10) and the rotating mould (15) in order to produce a preliminary injection-moulded part (21) and, in the second rotational position (P2), a second cavity (17) is formed between the master mould (10) and the rotating mould (15) in order to produce the multi-component injection-moulded part (20), and - a movement unit (18), by means of which at least one of the hot runners (11, 12) can be moved relative to the other hot runner (11, 12) in order to change an injection point. The invention also relates to a method and a computer program product for producing a multi-component injection-moulded part, and to a computer-readable storage medium on which the computer program is stored.

Description

[0001] Injection molding machine and process for producing a multi-component injection molded part, computer program product and storage medium

[0002] The present invention relates to an injection molding machine and a method for producing a multi-component injection molded part. The invention further relates to a computer program for executing the method and a computer-readable storage medium on which such a computer program is stored.

[0003] Various injection molding systems are known in the prior art, typically comprising multiple injection units. These systems enable the sequential or simultaneous injection of two or more materials into one or more cavities to produce complex parts with different material properties. Common designs include the use of rotary systems, index plate systems, or multi-chamber molds, which are designed to process different materials in a single injection molding cycle.

[0004] A challenge with existing injection molding systems lies in the precise control of injection parameters for different materials to ensure a uniform bond and high-quality surface finish of the final products. Existing systems are limited in their adaptability due to the complexity of the mold and the circular rotation of an index plate or rotary table for transferring parts during multi-component injection molding. As a result, index plate technology is rarely used in the main mold or only for very similar components. To produce different components, it is known to transfer parts within the injection molding system using robots. However, this is complicated and time-consuming. Furthermore, transferring parts increases the likelihood of producing rejects. Therefore, in the current state of the art, it is common practice to manufacture separate molds for multi-component molded parts.

[0005] The object of the present invention is to create improved devices and methods for producing multi-component injection molded parts.

[0006] The aforementioned problem is solved by the claims. In particular, the aforementioned problem is solved by the injection molding machine according to claim 1, as well as by the method, the computer program product, and the computer-readable storage medium according to the dependent claims. Further advantages of the disclosed technology will become apparent from the subclaims, the description, and the figures. Features described in connection with the injection molding machine also apply in connection with the method, the computer program product, and the storage medium, and vice versa, so that the disclosure always makes and / or can make reciprocal references to the individual aspects.

[0007] According to a first aspect of the present invention, an injection molding system for producing a multi-component molded part is proposed. The injection molding system comprises:

[0008] - a core tool in which a first hot runner for a first material and a second hot runner for a second material are designed,

[0009] - a rotary tool rotatable relative to the main tool, which can be rotated into a first rotational position and into a second rotational position, wherein in the first rotational position a first cavity for producing a preform is formed between the main tool and the rotary tool and in the second rotational position a second cavity for producing the multi-component injection molded part is formed between the main tool and the rotary tool and - a motion unit by means of which at least one of the hot runners can be moved relative to the other hot runner in order to change a injection point.

[0010] Within the scope of the invention proposed here, it was first recognized that movable hot runners in the mold base of an injection molding machine, which also features an index plate and / or a rotary table, can be implemented surprisingly easily. In particular, it was recognized that the injection molding machine with at least one movable hot runner in the mold base can still produce molded parts with satisfactory quality, high stability, and reliable centering. With the system proposed here, it is now also possible to change the relative position of the injection points to one another. This enables rapid setup changes on the injection molding machine without special peripheral equipment. Furthermore, a technology that has proven itself over many years in the area of ​​mold bases can be used. By eliminating the need for additional hot runners, material and costs can be reduced.Furthermore, the possibility of relative movement of the hot runners creates new and / or expanded design freedoms. The ability to injection-mold components in a manner suitable for plastics increases process reliability.

[0011] Moving one of the hot runners relative to the other hot runner can be understood to mean that at least one first hot runner is movable relative to at least one second hot runner and / or that at least one second hot runner is movable relative to at least one first hot runner. The first hot runner can be understood to be at least one first hot runner and / or several first hot runners. The hot runners can extend at least partially parallel to each other. The second hot runner can be understood to be at least one second hot runner and / or several second hot runners. The second hot runners can extend at least partially parallel to each other.

[0012] .. / 4 The multiple first hot runners and / or the multiple second hot runners can each be moved together relative to each other. The at least one first hot runner and the at least one second hot runner can also extend at least partially parallel to each other.

[0013] The injection molding system described here can be understood to be a multi-component injection molding system, for example, a 2K injection molding system. A 2K injection molding system is a special type of injection molding machine used to produce components from two different materials or colors in a single injection molding process. This technique allows the combination of materials with different properties, such as different hardness and / or different color. That is, the first and second materials can differ in their physical properties, such as color, hardness, and / or melting point, as well as in their chemical properties, such as flammability and / or resistance to acids or alkalis. The term "injection molding system" can also refer to an injection mold.

[0014] The term "mother mold" refers to a basic component of the injection molding machine. The mother mold can have a first cavity, which may be designed to be complementary and / or corresponding to a first cavity of the rotary tool, and a second cavity, which may be designed to be complementary and / or corresponding to a second cavity of the rotary tool. The mother mold can have a higher weight and / or a larger volume than the rotary tool.

[0015] The rotary tool may have a turntable and / or an index plate. The turntable and / or index plate may, for example, rotate 180° or 360°.

[0016] ...15 be designed to rotate. The injection molding machine may have a control unit that can be configured to rotate the rotary table and / or index plate by 180° from the first rotation position to the second rotation position or vice versa. However, the injection molding machine is not limited to this configuration. For example, it is possible that the control unit is configured to rotate the rotary table and / or index plate by less than 180° from a first rotation position to a second rotation position, a third rotation position, or to a further rotation position.

[0017] The rotary table and / or index plate can be understood as a moving element and / or unit of the injection molding machine used to move molded parts from one cavity to the next during the manufacturing process. In a 2K injection molding machine, the index plate can be used to rotate or move the preform after the first material has been injected into a position where the second material is injected. This enables precise positioning of the molded part for the next step in the manufacturing process.

[0018] According to one embodiment of the present invention, it is possible for the at least one hot runner to be movable relative to the other hot runner by means of the motion unit while the rotary tool is in the first rotational position and / or while the rotary tool is in the second rotational position. That is, the hot runners are movable not only during rotation of the rotary tool, but also when the rotary tool is stationary, and thus independently of any movement of the rotary tool relative to each other. This allows for particularly high manufacturing flexibility. For example, it is possible to move the second hot runner relative to the first hot runner...

[0019] ...16 move while the rotary tool is in the second rotation position and while an intermediate injection mold is cooling.

[0020] Furthermore, in the injection molding system proposed here, the at least one hot runner can be moved in a Y-direction and / or a Z-direction by means of the motion unit to change the injection point. The at least one hot runner is preferably at least partially linearly movable. Such a movement can be implemented relatively easily while the injection molding system remains relatively stable. The Y-direction can be understood as a direction corresponding to the direction of gravity and / or the counter-gravitational direction when the injection molding system is installed as intended. Furthermore, the at least one hot runner can be moved in a Z-direction and / or an X-direction by means of the motion unit to change the injection point. The Z-direction can be understood as a direction from the main mold to the rotary mold and / or from the rotary mold to the main mold.

[0021] In the injection molding system described here, the motion unit can be configured such that at least one hot runner can be moved over a distance of more than 5 mm by means of the motion unit. The motion unit can be configured, for example, to allow movement of up to, say, 100 mm in each of the Y-direction, the X-direction, and / or the Z-direction, with increments in a range between, say, 0.001 mm and 1 mm (e.g., 0.002 mm). Furthermore, the motion unit can be configured to allow movement of more than 5 mm, more than 10 mm, or more than 20 mm (e.g., 40 mm) in the Y-direction and / or the Z-direction. This allows for a high degree of variability in the production of different multi-component injection molded parts.

[0022] ...and simultaneously achieve high mechanical stability of the injection molding system. The motion unit can have a rail system by means of which different tool blocks of the main mold, in which different hot runners are designed, can be moved relative to each other.

[0023] The main tool of the injection molding machine described here can comprise a first tool block and a second tool block, wherein the first hot runner is located in the first tool block and the second hot runner is located in the second tool block, and wherein the motion unit is configured to move at least one of the tool blocks relative to the other hot runner. In this way, a particularly stable relative motion can be achieved relatively easily. In this configuration, one of the tool blocks can be considered a stationary tool block and the other a mobile and / or movable tool block. The stationary tool block can have a higher weight and / or a larger volume than the mobile tool block. The tool blocks can be configured to be displaceable relative to each other.The first tool block can contain multiple first hot runners, and the second tool block can contain multiple second hot runners. The first hot runners in the first tool block can be at least partially parallel to each other. The second hot runners in the second tool block can also be at least partially parallel to each other.

[0024] Furthermore, in the injection molding system described here, the motion unit can include a pneumatic unit by means of which at least one hot runner can be pneumatically moved relative to the other hot runner. It has been found that the hot runners are particularly easy to move using the pneumatic unit and

[0025] ... / 8 can nevertheless be moved relative to each other with the desired reliability. However, the injection molding machine can alternatively or additionally have a hydraulic unit and / or another motion unit for hydraulically, mechanically, electrically, and / or magnetically performing the relative movement between the hot runners. The pneumatic unit and / or the alternatively mentioned motion units can be configured to lift a component, and in particular a mold block with a mass of at least 50 kg or at least 100 kg, against the force of gravity.

[0026] Another aspect of the present invention relates to a method for producing a multi-component injection-molded part using an injection molding machine as described above. The method comprises the following steps:

[0027] - Injecting the first material through the first hot runner into the first cavity to produce a preform while the rotary tool is in the first rotation position,

[0028] - Rotating the rotary tool from the first rotation position to the second rotation position,

[0029] - Injecting the second material through the second hot runner at a first injection point into the second cavity to produce an intermediate mold part while the rotary tool is in the second rotation position,

[0030] - Moving the second hot runner relative to the first hot runner to change the first injection point to a second injection point that differs from the first injection point,

[0031] - Injecting the second material through the second hot runner at the second injection point into the second cavity to produce the multi-component injection molded part while the rotary tool is in the second rotation position.

[0032] ...19 An additional aspect of the invention relates to a method for producing a multi-component injection molded part using an injection molding machine as described above, comprising the steps:

[0033] - Injecting the first material through the first hot runner into the first injection point in the first cavity to produce a preform while the rotary tool is in the first rotation position,

[0034] - Moving the first hot runner relative to the second hot runner to change the first injection point to a second injection point that differs from the first injection point,

[0035] - Injecting the first material through the first hot runner at the second injection point into the first cavity to produce an intermediate mold part while the rotary tool is in the first rotation position,

[0036] - Rotating the rotary tool from the first rotation position to the second rotation position,

[0037] - Injecting the second material through the second hot runner into the second cavity to produce the multi-component injection molded part while the rotary tool is in the second rotation position.

[0038] The methods according to the invention thus offer the same advantages as those described in detail with reference to the injection molding system. Depending on the desired injection-molded component, different components can be fed into different cavities at different times and in different rotational positions of the rotary tool. The methods can be carried out by means of a control unit, in particular a computer-controlled control unit. The control unit can be suitable for this purpose.

[0039] ... / IO computing units, sensors, and actuators. The components of the control unit can be positioned and / or installed at a distance from each other.

[0040] Furthermore, the invention disclosed herein comprises a computer program product and a computer-readable, in particular non-volatile, storage medium on which the computer program product is stored. Thus, the computer program product and the computer-readable storage medium also offer the advantages described above. The computer program product can include instructions which, when executed by a computer, for example a central and / or decentralized control unit of the injection molding machine, cause the computer to carry out one of the proposed methods using the injection molding machine.

[0041] The computer program product can be implemented as machine-readable instruction code in any suitable programming language and / or machine language, such as Java, C++, C#, and / or Python. The computer program product can be stored on a machine-readable storage medium such as a data disk, removable drive, volatile or non-volatile memory, or onboard memory / processor. The instruction code can program a computer and other programmable devices, such as a control unit, to perform the desired functions. Furthermore, the computer program product can be made available on a network, such as the internet, from which it can be downloaded by a user as needed.The computer program product can be implemented using software, one or more special electronic circuits (i.e., in hardware), or in any hybrid form (i.e., using software components and hardware components). Further measures result from the following description of various embodiments, which are schematically illustrated in the figures. All features and / or advantages arising from the claims, the description, or the figures, including design details and spatial arrangements, can be significant both individually and in various combinations.

[0042] They each show schematically:

[0043] Fig. 1 shows an injection molding system according to a first embodiment in a first operating state,

[0044] Fig. 2 shows an injection molding system according to the first embodiment in a second operating state,

[0045] Fig. 3 shows an injection molding system according to the first embodiment in a third operating state,

[0046] Fig. 4 shows an injection molding system according to the first embodiment in a fourth operating state,

[0047] Fig. 5 shows a front view of a main tool of an injection molding machine according to a second embodiment,

[0048] Fig. 6 shows an injection molding system according to a third embodiment in a side view, Fig. 7 is a flowchart to explain a method according to one embodiment and

[0049] Fig. 8 shows a computer-readable storage medium with a computer program product stored on it according to one embodiment.

[0050] Elements with the same function and mode of operation are each provided with the same reference symbols in the figures.

[0051] Fig. 1 shows an injection molding machine 100 for producing a multi-component molded part 20. The injection molding machine 100 has a base mold 10 in which a first hot runner 11 for a first material 13 and a second hot runner 12 for a second material 14 are provided, the second material having different material properties than the first material. The injection molding machine 100 also has a rotary tool 15 that is rotatable relative to the base mold 10. The rotary tool 15 can be rotated into a first rotational position Pl, which is shown in Fig. 1 and Fig. 2, and into a second rotational position P2, which is shown in Fig. 3 and Fig. 4. The injection molding machine 100 has a computer-controlled control unit 40 (via computer program product 50) and an actuator (not shown in detail) by means of which the rotary tool 15 can be rotated into the desired rotational positions Pl and P2.In the first rotary position PI, a first cavity 16 is formed between the main tool 10 and the rotary tool 15, by means of which a preform 21 can be produced. In the second rotary position P2, a second cavity 17 is formed between the main tool 10 and the rotary tool 15, by means of which the desired multi-component injection molded part 20 can be produced. The injection molding machine 100 shown in Fig. 1 has a motion unit 18 by means of which the second hot runner 12 can be moved relative to the first hot runner 11 in order to change the injection point of the second hot runner 12 accordingly. The motion unit 18 includes a pneumatic unit 19 by means of which the second hot runner 12 can be moved pneumatically relative to the first hot runner 11. The second hot runner 12 can be displaced by the motion unit 18 by up to approximately 40 mm in the Y direction and up to approximately 10 mm in the Z direction. The mold base 10 shown has a first mold block 31 and a second mold block 32, wherein the first hot runner 11 is formed in the first mold block 31 and the second hot runner 12 is formed in the second mold block 32. To move the second hot runner 12 relative to the first hot runner 11, the second tool block 32 can be moved relative to the first tool block 31.

[0052] With reference to Figures 2 to 4 and Figure 7, a method for producing a multi-component molded part 20 using the injection molding machine 100 is described below. In a first step S1, as shown in Figure 2, a first material 13 is injected through the first hot runner 11 into the first cavity 16 to produce a preform 21. The rotary tool 15 is in its first rotation position PI. In a second step S2, the rotary tool 15 is rotated from the first rotation position PI to the second rotation position P2. This operating state of the injection molding machine 100 is shown in Figure 3. In a third step S3, a second material 14 is injected through the second hot runner 12 into the second cavity 17 at a first injection point to produce an intermediate molded part 22.In a subsequent fourth step S4, the second hot runner 12 is pneumatically moved upwards relative to the first hot runner 11 against the direction of gravity in order to move the first injection point into a second injection point that is located away from the first injection point. The second tool block 32 is moved upwards. In a fifth step S5, the second material 14 is injected again into the second cavity 17 in the relocated second hot runner 12 and at the resulting second injection point, in order to produce the final multi-component molded part 20. The rotary tool 15 remains in the second rotation position P2. The relocation of the second tool block 32 and the injection of the second material 14 into the second cavity 17 at the second injection point are shown in Fig. 4.

[0053] Fig. 5 shows a front view of a mold base of an injection molding machine 100 according to a second embodiment. As can be seen in Fig. 5, the upper first hot runners 11 in the upper second mold block 32 are displaceable relative to the lower second hot runners 12 in the first mold block 31.

[0054] Fig. 6 shows a side view of an injection molding machine 100 according to a third embodiment. The illustrated injection molding machine 100 has a stationary mounting plate 36 to which a mold base 10 is attached. The injection molding machine 100 also has a first exchangeable cassette 34 and a second exchangeable cassette 35. The first exchangeable cassette 34 is configured for producing a preform, and the second exchangeable cassette 35 is configured for producing an intermediate part and / or a final multi-component part. The illustrated injection molding machine 100 also has a rail system 24 for moving the first mold block 31, with the first hot runner 11 integrated therein, to the second mold block 32 in the Y-direction. Furthermore, the injection molding machine 100 has a first height adjustment unit 25 and a second height adjustment unit 26. The first height adjustment unit 25 is configured for height adjustment in the Z-direction.The second height adjustment unit 26 is configured for height adjustment in the Y direction. Fig. 8 shows a computer-readable and non-volatile storage medium 60 on which a computer program product 50 is stored. The storage medium 60 is in the form of a flash drive. The computer program product 50 comprises instructions which, when executed by a computer, for example a computer of the control unit 40, cause the computer program product 50 to perform a process for producing a multi-component injection molded part 20 in the injection molding machine shown.

[0055] The invention disclosed herein allows for further design principles in addition to those illustrated. That is to say, the invention should not be considered limited to the embodiments explained with reference to the figures. Reference symbol list

[0056] 10 main tool

[0057] 11 first hot runner

[0058] 12 second hot runner

[0059] 13 first material

[0060] 14 second material

[0061] 15 Rotary tools

[0062] 16 first cavity

[0063] 17 second cavity

[0064] 18 movement units

[0065] 19 pneumatic units

[0066] 20 Multi-component injection molded part

[0067] 21 Pre-sprue

[0068] 22 Intermediate splash

[0069] 24 rail system

[0070] 25 first height adjustment unit

[0071] 26 second height adjustment unit

[0072] 31 first tool block

[0073] 32 second tool block

[0074] 34 first interchangeable cassette

[0075] 35 second interchangeable cassette

[0076] 36 Mounting plate

[0077] 40 Control unit

[0078] 50 computer program product

[0079] 60 Storage medium

[0080] PI first rotation position

[0081] P2 second rotation position

[0082] 100 injection molding machines

[0083] ,.. / 17

Claims

Claims 1. Injection molding machine (100) for producing a multi-component injection molded part (20), comprising: - a main tool (10) in which a first hot runner (11) for a first material (13) and a second hot runner (12) for a second material (14) are designed, - a rotary tool (15) rotatable relative to the main tool (10), which can be rotated into a first rotation position (PI) and into a second rotation position (P2), wherein in the first rotation position (PI) a first cavity (16) for producing a preform (21) is formed between the main tool (10) and the rotary tool (15) and in the second rotation position (P2) a second cavity (17) for producing the multi-component injection molded part (20) is formed between the main tool (10) and the rotary tool (15) and - a motion unit (18) by means of which at least one of the hot runners (11, 12) can be moved relative to the other hot runner (11, 12) to change a injection point.

2. Injection molding machine (100) according to claim 1, wherein the at least one hot runner (11, 12) is movable relative to the other hot runner (11, 12) by means of the motion unit (18) while the rotary tool (15) is in the first rotation position (PI) and / or while the rotary tool (15) is in the second rotation position (P2).

3. Injection molding machine (100) according to one of the preceding claims, wherein the at least one hot runner (11, 12) is moved by means of the motion unit (18) to The injection point can be changed and moved in a Y direction and / or in a Z direction.

4. Injection molding machine (100) according to one of the preceding claims, wherein the at least one hot runner (11, 12) is movable by means of the motion unit (18) over a distance of more than 5mm.

5. Injection molding machine (100) according to one of the preceding claims, wherein the main tool (10) has a first tool block (31) and a second tool block (32), wherein the first hot runner (11) is configured in the first tool block (31) and the second hot runner (12) is configured in the second tool block (32) and wherein the motion unit (18) is configured to move at least one of the tool blocks (31, 32) relative to the other hot runner (11, 12).

6. Injection molding machine (100) according to one of the preceding claims, wherein the motion unit (18) has a pneumatic unit (19) by means of which the at least one hot runner (11, 12) is pneumatically movable relative to the other hot runner (11, 12).

7. Method for producing a multi-component injection molded part (20) using an injection molding machine (100) according to one of the preceding claims, comprising: - Injection of the first material (13) through the first hot runner (11) into the first cavity (16) to produce a preform (21) while the rotary tool (15) is in the first rotation position (PI), - 19 - - Rotating the rotary tool (15) from the first rotation position (PI) to the second rotation position (P2), - Injection of the second material (14) through the second hot runner (12) at a first injection point into the second cavity (17) to produce an intermediate molded part (22) while the rotary tool (15) is in the second rotary position (P2), - Moving the second hot runner (12) relative to the first hot runner (11) to change the first injection point to a second injection point that differs from the first injection point, - Injection of the second material (14) through the second hot runner (12) in the second injection point into the second cavity (17) to produce the multi-component injection molded part (20) while the rotary tool (15) is in the second rotary position (P2).

8. Method for producing a multi-component injection molded part (20) using an injection molding machine (100) according to any one of claims 1 to 6, comprising: - Injection of the first material (13) through the first hot runner (11) into the first cavity (16) at a first injection point to produce a preform (21) while the rotary tool (15) is in the first rotation position (PI), - Moving the first hot runner (11) relative to the second hot runner (12) to change the first injection point to a second injection point that differs from the first injection point, - Injection of the first material (13) through the first hot runner (12) in the second injection point into the first cavity (16) to produce an intermediate mold part (22) while the rotary tool (15) is in the first rotation position (PI), - 20 - - Rotating the rotary tool (15) from the first rotation position (PI) to the second rotation position (P2), - Injection of the second material (14) through the second hot runner (12) into the second cavity (17) to produce the multi-component injection molded part (20) while the rotary tool (15) is in the second rotary position (P2).

9. Computer program product (50), comprising instructions which, when the computer program product (50) is executed by a computer, cause it to perform the method according to one of claims 7 to 8 in an injection molding machine (100) according to one of claims 1 to 6.

10. Computer-readable storage medium (60) with a computer program product (50) stored thereon according to claim 9.

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