Injection Molding Sequence for Foamed Multi-Property Parts

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Solution Overview

Problem

Existing injection molding systems struggle to create foamed articles with varying properties across different portions, limiting the structural and functional diversity of the final product.

Innovation Solution

The method involves using multiple molds and components that can be attached and detached in specific sequences to form articles with distinct properties by injecting and foaming flowable materials within defined cavities, allowing for the attachment of components during and after disengagement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single mold cavity is used for injection molding, then the manufacturing process is simple, but the article cannot have different portions with different physical or functional properties

Engineering Contradiction:

Improveproperty variation across article portionsVSAvoidmold structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mold is divided into multiple independent mold cavities (first mold cavity, second mold cavity, third mold cavity) that can be selectively engaged with the injection molding device. Each cavity can form components with different properties, allowing the final article to have varying physical or functional characteristics across different portions while maintaining a modular mold structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different mold cavities are configured to produce components with specific local properties. The first mold cavity forms a first component with certain properties, the second mold cavity forms a second component with different properties, and the third mold cavity forms a third component with yet another set of properties. This enables each portion of the final article to have optimized local quality tailored to its specific function.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If multiple components are formed separately and then attached, then the article can have complex structures with varied properties, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvestructural complexityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The injection molding device is configured to engage multiple mold cavities simultaneously or in sequence, allowing separate components to be formed and attached in an integrated manufacturing process. The device can inject material into different cavities and facilitate attachment of the formed components, combining multiple manufacturing operations into a single coordinated process rather than requiring separate molding and assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold cavities are pre-configured with attachment features and positioning mechanisms that enable components to be attached during or immediately after the molding process. The first component, second component, and third component are formed with predetermined attachment interfaces, allowing them to be connected in a predetermined arrangement without requiring additional complex assembly operations.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If components are attached during mold disengagement, then the article can be formed efficiently, but precise control of attachment timing and positioning is required

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidattachment timing and positioning control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The mold cavities and components are designed with dynamic attachment mechanisms that automatically engage and position components during the natural disengagement motion of the mold. The attachment features include movable elements, flexible connectors, or self-aligning interfaces that accommodate the dynamic motion of mold opening while ensuring precise component positioning and secure attachment without requiring external control systems.

Inventive Principle:

Principle #15Dynamics

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 enables the creation of articles with varying properties by ensuring components are attached post-foaming, facilitating the production of complex structures with enhanced performance characteristics.

Implementation Method 1

foaming the flowable material to form a second component

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentEP4674586A1Injection molding method

Publication Date: 2026.01.07 KING STEEL MACHINERY CO LTD

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AI summary

An injection molding method is provided. The injection molding method includes: providing a first mold, a second mold, a third mold fixedly attached to the second mold, and a first component at least partially surrounding the third mold; engaging the first mold with the second mold to form a mold cavity defined by the first mold, the second mold, the third mold and the first component; injecting a flowable material into the mold cavity; foaming the flowable material to form a second component; disengaging the first mold from the second mold; and detaching the first component and the second component from the third mold, wherein during and after the disengagement and the detachment, the second component is attached to the first component.