Integrated Stamping and Overmolding Mold for Composite Inserts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for overmolded composite material parts require multiple molds and machine tools, increasing production time and costs due to the need for separate stamping, machining, and overmolding steps.
Innovation Solution
A mold comprising complementary half-molds with a punch blade and pusher for simultaneous stamping, cutting, and overmolding of composite material inserts, allowing for a single tool to perform these operations and reduce the number of required tools and steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate molds and machine tools are used for stamping, machining, and overmolding, then each operation can be performed with dedicated equipment, but the manufacturing time increases and production costs increase
Solution Approach 1:
The patent combines stamping, machining, and overmolding operations into a single integrated mold. The mold includes a first half-mold with a punch for stamping and cutting, a second half-mold with a cavity for overmolding, and an injection system all integrated into one device. This allows all three operations to be performed sequentially in a single manufacturing cycle, eliminating the need for multiple separate molds and machine tools, thereby reducing manufacturing time while maintaining operation quality.
Solution Approach 2:
The integrated mold performs multiple functions: it stamps the composite material sheet into an insert, cuts the insert to the desired shape, and then overmolds the insert with additional material. The mold structure includes components that can execute these different operations, making a single device universal for tasks that traditionally required separate specialized equipment.
2Reliability
If multiple separate molds and machine tools are used for stamping, machining, and overmolding, then each operation can be performed with dedicated equipment, but the number of devices increases and manufacturing complexity increases
Solution Approach 1:
The patent combines stamping, machining, and overmolding operations into a single integrated mold. The mold includes a first half-mold with a punch for stamping and cutting, a second half-mold with a cavity for overmolding, and an injection system all integrated into one device. This allows all three operations to be performed sequentially in a single manufacturing cycle, eliminating the need for multiple separate molds and machine tools, thereby reducing manufacturing time while maintaining operation quality.
Solution Approach 2:
The integrated mold performs multiple functions: it stamps the composite material sheet into an insert, cuts the insert to the desired shape, and then overmolds the insert with additional material. The mold structure includes components that can execute these different operations, making a single device universal for tasks that traditionally required separate specialized equipment.
3Reliability
If multiple separate molds and machine tools are used for stamping, machining, and overmolding, then each operation can be performed with dedicated equipment, but the cost price of the final part increases
Solution Approach 1:
The patent combines stamping, machining, and overmolding operations into a single integrated mold. The mold includes a first half-mold with a punch for stamping and cutting, a second half-mold with a cavity for overmolding, and an injection system all integrated into one device. This allows all three operations to be performed sequentially in a single manufacturing cycle, eliminating the need for multiple separate molds and machine tools, thereby reducing manufacturing time while maintaining operation quality.
Solution Approach 2:
The integrated mold performs multiple functions: it stamps the composite material sheet into an insert, cuts the insert to the desired shape, and then overmolds the insert with additional material. The mold structure includes components that can execute these different operations, making a single device universal for tasks that traditionally required separate specialized equipment.
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 complexity and cost of manufacturing by integrating stamping, cutting, and overmolding into a single mold, resulting in a more economical and efficient production process for overmolded composite material parts.
Implementation Method 1
a punch blade carried by the end of a movable support, so as to be able to cut the insert made of composite material
Implementation Method 2
the pusher comprises at least one protrusion so as to push the cut-out scrap of the insert made of composite material inside said evacuation channel
Implementation Method 3
the pusher comes into leaktight contact with the blade and pushes back said blade and the support so as to seal the reception and overmolding space
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The present invention concerns a mould (1) for stamping and overmoulding a composite material insert (3), said mould (1) comprising first and second half-moulds (1a, 1b) that are complementary to each other and defining a space (5) for receiving and overmoulding the composite material insert (3): - the first half-mould (1a) comprising at least one opening (20) inside which a cutting die blade (24) is positioned, carried by the end of a mobile support (22), so as to be able to cut the composite material insert (3), said blade (24) also being flush with the wall of the opening (20), - the second half-mould (1b) comprising an opening (30), opposite the at least one opening (20), inside which there is positioned a pusher (32) in a shape that matches and is flush with the wall of the opening (30) and is mobile so as to be able to come into flush contact with the blade (24).