Combined Pressing and Injection Molding Tool for Fiber-Reinforced Parts
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Solution Overview
Problem
Current methods for producing molded parts with fiber-reinforced carriers and attached plastic parts, such as decorative vehicle interior components, require multiple work steps and tools, leading to increased production costs and complexity, especially when integrating functional elements like stiffening ribs and fastening means.
Innovation Solution
A combined pressing and injection molding tool that allows for the simultaneous production of a fiber-reinforced carrier with integrated add-on parts, using a tool with movable components that can be opened and closed to form a three-dimensional contour, with nozzles for injecting liquefied plastic into the mat to create a mechanical connection and shape the functional elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressed carrier parts and functional elements are manufactured in separate work steps with different tools, then manufacturing precision and integration quality improve, but device complexity and production costs increase
Solution Approach 1:
The patent combines the pressing tool and injection molding tool into a single integrated device. The pressing tool includes a pressing element that can press the fiber mat against the carrier, while the injection molding tool includes a nozzle that can inject molten plastic through the pressed mat to form functional elements. This merging eliminates the need for separate tools and work steps, reducing device complexity while maintaining manufacturing precision through coordinated operation of the integrated components.
Solution Approach 2:
The pressing tool is designed with multi-functionality by incorporating both pressing capability and injection molding capability. The pressing element can perform the pressing operation, and the same tool structure accommodates the injection nozzle for forming functional elements. This universal design allows a single tool to perform multiple operations that previously required separate specialized tools, thereby reducing the number of tools needed while maintaining high integration quality.
2Manufacturing precision
If multiple separate tools and production facilities are used, then manufacturing precision is maintained, but production costs and manufacturing time increase
Solution Approach 1:
The patent merges the pressing operation and injection molding operation into a single integrated work step. The pressing element presses the fiber mat against the carrier while the injection nozzle simultaneously or sequentially injects molten plastic through the pressed mat. This combining of operations into one coordinated process maintains manufacturing precision while significantly improving productivity by eliminating the need for separate production facilities and multiple work steps.
Solution Approach 2:
The integrated tool enables continuous operation where the pressing and injection molding processes are performed in a continuous sequence without interruption or removal of the workpiece. The pressing element maintains pressure on the mat while the injection nozzle forms functional elements, creating a continuous useful action that improves production efficiency while maintaining precision through consistent process conditions.
3Manufacturing precision
If functional elements are added after pressing, then manufacturing precision of the carrier is improved, but the number of work steps and equipment increase
Solution Approach 1:
The patent performs the injection molding of functional elements during the pressing operation itself, rather than as a subsequent separate step. The injection nozzle is positioned to inject molten plastic through the fiber mat while it is being pressed against the carrier, forming functional elements such as stiffening ribs and fastening means directly during the pressing process. This preliminary action integrates both operations into one step, maintaining carrier quality while reducing the number of tools needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the number of tools and production costs, enables the formation of complex functional elements with a clean surface finish, and improves the integration of add-on parts with the carrier, while maintaining vacuum capability for subsequent lamination processes.
Implementation Method 1
a nozzle through which liquefied plastic can be injected onto the inserted mat in such a way that the preferably hot and pressurized melt penetrates the pressed or unpressed mat
Implementation Method 2
the preferably hot and pressurized melt penetrates the pressed or unpressed mat and enters a cavity formed in the other tool half
Implementation Method 3
Closing the tool components so that the mat is pressurized and compressed to produce the fiber-reinforced carrier
Implementation Method 4
the mat is pressurized and compressed to produce the fiber-reinforced carrier
Implementation Method 5
the injected plastic forms a bond with the polymer of the preferably heated mat. Furthermore, a mechanical bond, a kind of mechanical interlock, is formed along the entire thickness of the injected area of the mat
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
A device for producing a molded part with a fiber-reinforced support and an attachment part connected thereto. The support is made from a fiber-reinforced mat and the attachment part is made from a plastics material. The device includes a first tool component including a nozzle for supplying liquefied plastics material and a second tool component including a cavity for forming the attachment part. One of the first and second tool components is configured to be movable relative to the other one of the first and second tool components. The device is configured to receive the mat when the device is in an open state, and to place the mat under pressure and to compress the mat to produce the support when the device is in a closed state. The nozzle is configured to introduce the plastics material into the cavity through the mat to produce the attachment part.