Automated Double Injection Molding for Vehicle Parts

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Solution Overview

Problem

The existing double injection molding process for vehicle air conditioner components, such as doors, is inefficient due to manual operations, leading to high product defect rates and reduced productivity, as primary injection molding of openable plates and secondary injection molding of sealing portions are performed manually, resulting in irregular processing.

Innovation Solution

A double injection molding system that automates the manufacturing of four molded products simultaneously, comprising a first molding device for plastic injection of openable plates, a second molding device for rubber injection of sealing portions, and a transport device with a moving head and adjustable stretchable rod to facilitate continuous and automatic production, including jigs for precise handling and mounting of components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual operations are used for primary injection molding and secondary injection molding, then the process can be performed with simple equipment, but the productivity is reduced and product defect rate increases

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidmolding system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the first molding device and second molding device into an integrated automated system where the transport device seamlessly connects both molding operations. The first jig and second jig work in coordination to transfer openable plates from primary molding to secondary molding automatically, eliminating manual intervention and enabling continuous production of four molded products simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transport device is configured to prepare and position the first jig and second jig in advance for each molding cycle. The stretchable rod pre-adjusts the position of the first jig before primary injection molding, and the rotatable connection of the second jig is pre-configured to receive openable plates immediately after molding, ensuring no waiting time and maintaining continuous automated operation.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If manual operations are used for transporting openable plates between molding devices, then the system structure can be simple, but the manufacturing process proceeds irregularly and defect rate increases

Engineering Contradiction:

Improveproduct defect rateVSAvoidtransport device complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical operations with an automated mechanical transport system. The moving head with stretchable rod and coordinated jigs create a deterministic mechanical system that precisely positions and transfers openable plates between molding devices, eliminating the variability and irregularity introduced by manual operations while maintaining structural feasibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The first jig and second jig serve as intermediary devices between the first molding device and second molding device. These jigs with adsorption members automatically grasp, transport, and position openable plates, ensuring consistent and reliable transfer without manual intervention, thereby reducing defect rates caused by irregular manual handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If four cavities are used in both molding devices for simultaneous molding, then the productivity is enhanced, but the device complexity and coordination requirements increase

Engineering Contradiction:

Improvebatch manufacturing capacityVSAvoidmold and jig coordination complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the molding process into distinct first and second molding devices, each with four cavities for simultaneous molding. The transport device is also segmented with separate first and second jigs that independently handle the transfer of molded plates, allowing each component to be optimized for its specific function while maintaining overall system productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first jig and second jig are designed with universal functionality to handle multiple tasks: the first jig both removes plates from the first molding device and positions them for the second molding device, while the second jig both receives plates and removes finished products. This multi-functionality reduces the number of separate components needed while maintaining the four-cavity simultaneous molding capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11485059B2Double injection molding system that can automatically produce vehicle injection-molded parts four at a time continuously

Publication Date: 2022.11.01 JEONG-HEON KWAK

AI summary

Provided is a double injection molding system capable of continuously and automatically manufacturing four molded products for a vehicle at a time, the double injection molding system including: a first molding device which molds the openable plates of the molded products for a vehicle through injection of plastic; a second molding device which receives the openable plates and molds the sealing portions through injection of rubber around the openable plates to finish the molded products; and a transport device which takes out the openable plates formed by the molding device and transports the openable plates, to the second molding device, so that the double injection molding process of the openable plates and the sealing portions is automated to secure product reliability and to improve productivity.