Gravity-Driven Insert Feeding in Injection Mold Half
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Solution Overview
Problem
The complex and cost-intensive handling and positioning of inserts in injection molding tools lead to long cycle times and significant space requirements, making the production of injection molded parts with integrated inserts inefficient.
Innovation Solution
A tool half for injection molding machines featuring a mold area with a vertical feed channel and a positioning unit that uses gravity to convey inserts to a predetermined injection molding position, eliminating the need for external conveying means and allowing for reliable and space-saving integration of inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex handling and positioning systems are used for inserts, then positioning precision is improved, but device complexity and cost increase
Solution Approach 1:
The mold half is divided into functional zones: a receiving area for insert storage and a mold area for injection molding. The feed channel is segmented into a vertical section for gravity feeding and a horizontal section for positioning. This segmentation allows each zone to perform its specific function with simple structures, avoiding the need for complex integrated handling systems.
Solution Approach 2:
The feed channel is designed with a vertical section that allows inserts to move from the receiving area to the mold area purely under gravity. By creating a gravity-driven flow path, the system eliminates the need for mechanical conveying means, reducing device complexity while maintaining positioning precision through the controlled gravitational feed.
2Reliability
If external conveying means are used for inserts, then insert feeding reliability is improved, but space requirements and cost increase
Solution Approach 1:
The feed channel is integrated directly into the mold half structure, merging the conveying function with the mold body. The vertical feed channel occupies minimal space within the mold half while providing reliable insert feeding through gravity. This integration eliminates the need for separate external conveying devices, reducing space requirements while maintaining feeding reliability.
Solution Approach 2:
The system uses gravity as a free resource to drive insert feeding through the vertical feed channel. Inserts automatically move from the receiving area to the mold area without requiring external power sources or mechanical actuators. This self-service mechanism ensures reliable feeding while minimizing space and cost.
3Manufacturing precision
If complex positioning systems are used, then insert positioning accuracy is improved, but cycle time increases
Solution Approach 1:
Inserts are stored in advance in the receiving area, prepared for feeding. The vertical feed channel is pre-configured to guide inserts directly to the mold area. This preliminary arrangement eliminates the need for complex real-time positioning operations during the injection molding cycle, maintaining positioning accuracy while minimizing cycle time.
Solution Approach 2:
The gravity-driven vertical feed channel provides continuous, passive insert movement to the mold area. This eliminates the need for active positioning mechanisms that would require energy input and control time during each cycle. Inserts are continuously available at the mold area ready for immediate use, reducing cycle time while maintaining positioning accuracy through the fixed feed channel geometry.
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 enables the production of injection molded parts with integrated inserts in a simpler, more efficient manner, reducing cycle times and eliminating the need for costly peripherals, while allowing for flexible application on various injection molding machines.
Implementation Method 1
Through the feed channel, it is possible to feed the insert into the interior of the tool half. Due to the fact that the feed channel extends in the vertical direction through the mold half, no conveying means or the like are required to move the insert inside the mold half to the conveying channel. The feed channel can also run obliquely, so it does not have to run purely in the vertical direction. What is essential for the feed channel is that it runs in such a way that the insert part can reach the receiving area of the conveying channel through the feed channel purely due to the force of gravity.
Data Source
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AI summary
The invention relates to a mold half (12) for an injection molding machine (10) for producing an injection-molded part with at least one insert (32), comprising a molding area (28) that forms at least part of a cavity (30) for the injection-molded part; a conveying channel (36) extending inside the mold half (12) and through the molding area (28); a feed channel (38) designed for feeding the insert (32) into the mold half (12), which extends vertically through the mold half (12) and opens into a receiving area (40) of the conveying channel (36);A positioning unit (42) designed to receive the insert (32) by moving it from a demolding position to an injection position when the insert is located in the receiving area (40) of the conveying channel (36), and to convey the received insert (32) from the receiving area (40) to an injection molding position in the area of the molding area (28); a sensor system designed to determine the position of the insert (32) and/or the positioning unit (42) and to transmit corresponding position signals to a control unit of the mold half (12), which is configured to control the positioning unit (42) for conveying the insert (32) into the injection molding position based on the sensor signals. The invention further relates to a method for producing an injection molded part with at least one insert (32).