Automated Decorative Insert Placement in Injection Molding

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Solution Overview

Problem

Existing methods for producing injection molded parts with decorative inlays struggle to precisely place and integrate very small decorative parts, leading to time-consuming manual processes and issues with residual adhesive traces on transparent plastics.

Innovation Solution

A method where small decorative parts are removed from a strip element using a release stamp and held in position within the injection mold by a positioning stamp, allowing precise placement and integration during the injection molding process, eliminating the need for external adhesive application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual processes are used to place small decorative parts, then placement can be performed, but the process becomes time-consuming and less precise

Engineering Contradiction:

Improveplacement precisionVSAvoidprocess time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical placement with an automated stamping mechanism. The stamping device with positioning stamp and release stamp automatically places decorative parts onto the carrier film within the mold cavity, eliminating manual operations and achieving both high precision and automation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The stamping device performs self-positioning through the interaction between the positioning stamp and release stamp. The decorative part is automatically positioned and transferred without external intervention, as the stamps work together to guide and secure the part in the correct location.

Inventive Principle:

Principle #25Self-service

2Reliability

If adhesive is used to fix decorative parts, then parts can be secured, but adhesive residue appears on transparent plastics

Engineering Contradiction:

Improvefixing reliabilityVSAvoidadhesive residue

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and eliminates the adhesive application step from the process. Instead of using adhesive to fix decorative parts, the invention uses a mechanical stamping system that positions and secures parts through physical means, completely removing the source of adhesive residue.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The carrier film acts as an intermediary between the decorative part and the final product. The decorative part is positioned on the carrier film using the stamping device, and the carrier film itself is then integrated into the molded part, eliminating the need for direct adhesive bonding.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If external adhesive application is used, then decorative parts can be fixed, but additional process steps are required

Engineering Contradiction:

Improvefixing capabilityVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the decorative part fixation process with the injection molding process itself. The stamping device is integrated into the mold, and the positioning and fixation of decorative parts occur during the molding cycle, eliminating separate external adhesive application steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The decorative parts are positioned and secured on the carrier film before the injection molding process begins. The stamping device performs preliminary positioning during mold closure, so that when injection occurs, the parts are already in their final positions without requiring subsequent adhesive application.

Inventive Principle:

Principle #10Preliminary action

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

Enables precise and automatic placement of small decorative parts, preventing adhesive residue and allowing for transparent and transilluminated surfaces, enabling complex designs like lettering without metal foil bridges, enhancing the aesthetic and functional capabilities of injection molded parts.

Implementation Method 1

small decorative parts (5) are removed from a strip element (6) by a release stamp (8)

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 2

held in position within the injection mold by a positioning stamp (9)

Methodology Applied

Scientific EffectMechanical contact and positioning: Mechanical Force

Implementation Method 3

injecting a liquid thermoplastic injection molding material into the mold cavity

Methodology Applied

Scientific EffectPressure injection: Pressure Increase

Implementation Method 4

the liquid injection molding material pressing the IML molded part against the IMD film in the mold cavity

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 5

opening the injection molding device after a cooling time of the molded part

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentEP3127679B1Device and method for producing a plastic injection moulding part with decorative insert

Publication Date: 2018.09.26 VEESER PLASTIC WERK

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AI summary

The invention relates to a device and a method for producing a molded part provided with at least one decorative element, comprising an injection mold and a feeding device for the molded part, wherein the injection mold comprises at least one die. According to the invention, a release plunger (8) is provided, which is arranged such that it penetrates a first die (3.1) and removes the decorative element (5) from a strip element (6) inserted into the injection mold (2) within the injection mold (2).