Composite Mould Interchangeable Modules Glazing Profile
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Solution Overview
Problem
The existing processes for manufacturing glazing profiles on glass panes are inefficient for producing low-volume parts, as they require frequent tool changes and downtime, leading to high production costs due to the need for expensive injection moulding machines and labor, especially when producing different shapes or sizes of glazings.
Innovation Solution
A composite mould with interchangeable modules allows for the simultaneous moulding of different glazing profiles onto glass panes of varying configurations using a single moulding operation, enabling the production of multiple parts with similar cycle times and reducing the need for frequent tool changes by using a single injection unit for each mould module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection moulding is used to manufacture glazing profiles, then manufacturing precision and production rate are improved, but device complexity and tooling cost increase
Solution Approach 1:
The injection mould is divided into a fixed mould part and a movable mould part, allowing independent manipulation of each section. This segmentation enables the movable part to be removed and replaced without affecting the fixed part, reducing tooling complexity while maintaining manufacturing precision.
Solution Approach 2:
The mould design incorporates a movable mould part that can be dynamically removed and replaced on the injection moulding machine. This dynamic capability allows quick changes between different glazing profile configurations, reducing device complexity while maintaining high manufacturing precision through consistent mould quality.
2Manufacturing precision
If injection moulding is used to manufacture different glazing profiles, then manufacturing precision is improved, but loss of time due to tool changes increases
Solution Approach 1:
By segmenting the mould into fixed and movable parts, the movable part can be quickly removed and replaced without affecting the fixed part. This enables rapid tool changes between different glazing profile configurations, significantly reducing downtime while maintaining consistent manufacturing precision.
Solution Approach 2:
Different movable mould parts are prepared in advance for different glazing profile configurations. When a tool change is needed, the pre-prepared movable part is simply swapped in, eliminating the need for time-consuming on-site adjustments and maintaining high manufacturing precision immediately.
3Productivity
If production rate is increased to reduce costs, then productivity is improved, but device complexity and initial investment increase
Solution Approach 1:
The movable mould part design enables dynamic reconfiguration of the injection mould for different glazing profiles. This allows a single injection moulding machine to efficiently produce multiple product variants at high production rates, increasing productivity without requiring additional complex machinery for each product type.
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 increases production efficiency and reduces costs by allowing low-volume parts to be manufactured with economies of scale similar to high-volume parts, minimizing downtime and storage needs, while optimizing the use of expensive machinery and labor.
Implementation Method 1
supplying liquid plastics moulding material into the mould cavities of the mould concurrently
Implementation Method 2
allowing the elastomeric material to set
Data Source
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AI summary
Process and Apparatus for Moulding a Glazing Profile onto a Glazing A process for manufacturing at least two different discrete edge encapsulated glazings (50) comprising panes of glass (51) of different configuration, the process comprising moulding a glazing profile (52) onto at least part of the periphery of each pane of glass in a composite mould (20, 30).This composite mould comprises multiple different interchangeable mould modules (26, 27; 36, 37), each mould module comprising at least one mould cavity,and the composite mould therefore has two or more mould cavities (21, 22; 31, 32) which are configured differently to receive different panes of glass. Fluid elastomeric material is injected into the at least two different mould cavities at the same time, so that a glazing profile is moulded onto each of the two different panes of glass concurrently. An injection moulding apparatus (1) comprising the composite mould may have multiple injection systems (2) for the different mould cavities, allowing different moulding materials to be used. The apparatus also includes a clamp unit (3) having platens (5, 6) to which the multiple mould modules are attached.