Foam Overmolding Tool Sensor Positioning
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Solution Overview
Problem
Existing foam overmolding processes for connecting sheet metal insert parts to panes are prone to errors due to incorrect positioning, leading to scrap production, and lack reliable detection methods for ensuring accurate placement.
Innovation Solution
A molding tool equipped with inductive sensors that detect the presence and correct position of sheet metal insert parts, eliminating the need for mechanical position checking means and ensuring accurate foam overmolding by initiating the process only when all sensors signal correct positioning, while protecting the sensors from contamination and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical position checking means (pins) are used to ensure correct positioning of sheet metal insert parts, then positioning reliability is improved, but device complexity increases and the risk of contamination to the foam overmolding process increases
Solution Approach 1:
The patent replaces mechanical position checking means (pins engaging positioning holes) with an inductive sensor system that detects the presence and position of sheet metal insert parts through the pane without mechanical contact. This substitution eliminates the complexity of mechanical positioning mechanisms while maintaining or improving positioning reliability through non-contact sensing.
Solution Approach 2:
The patent introduces an inductive sensor as an intermediary detection device that can sense the position of sheet metal insert parts through the pane material without direct contact. This intermediary sensor system provides reliable detection while avoiding contamination risks associated with mechanical means that would contact the foam overmolding area.
2Measurement precision
If sensors are placed close to the pane for accurate detection, then measurement precision is improved, but the sensors are exposed to contamination and excessive heat from liquid plastic
Solution Approach 1:
The patent uses the pane itself as an intermediary medium that allows inductive sensor signals to pass through while protecting the sensor from direct exposure to contamination and heat. The sensor detects sheet metal insert parts through the pane material, maintaining measurement precision while the pane acts as a protective barrier against harmful factors from the foam overmolding process.
Solution Approach 2:
The patent replaces direct mechanical contact sensing with inductive sensing through the pane, allowing accurate detection of sheet metal insert parts without exposing sensors to the harsh environment of liquid plastic and foam overmolding. The inductive field can penetrate the pane material to detect metal positions while the sensor remains protected on the opposite side.
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 solution enhances process reliability, reduces rejects, and conserves resources by ensuring flawless series production, providing economic and environmental benefits, and allows for precise positioning and thermal insulation.
Implementation Method 1
The at least one sensor, which is designed, in particular, as an inductive sensor, makes it possible to detect the presence and the correct position of each sheet metal insert part through the pane
Data Source
AI summary
The invention relates to a molding tool having a tool upper part (10) and a tool lower part (20), having a glass pane (30) arranged between tool upper part (10) and tool lower part (20) and at least one sheet metal insert part (32; 321, 322, 323, 324) that can be connected to the glass pane (30) by means of foam overmolding (36) made of plastic. For an increased process reliability when connecting sheet metal insert parts (32; 321, 322, 323, 324) to panes (30), the invention provides that at least one sensor (40) for detecting the position of the sheet metal insert part (32; 321, 322, 323, 324) is arranged on the tool upper part (10) and/or the tool lower part (20) on the side of the glass pane (30) that is located opposite the at least one sheet metal insert part (32; 321, 322, 323, 324).