IMD Mold Core for Film-Decorated Parts with Recesses
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Solution Overview
Problem
The existing IMD technology faces challenges in producing film-decorated plastic parts with recesses on the visible surface, as the thin IMD films are not stretchable enough to accommodate deep recesses without damaging the lacquer layer, leading to the need for more complex and costly insert molding processes.
Innovation Solution
An IMD mold design where the mold core forms the negative shape of the recess and is separate from the half-molds, allowing the IMD film to be passed through with minimal stretching, and the mold core can be removed during demolding, enabling the production of parts with tapered recesses without damaging the film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If IMD technology is used to produce film-decorated plastic parts with deep recesses, then the production cost is reduced and process is simplified, but the thin IMD film cannot accommodate deep recesses without stretching and damaging the lacquer layer
Solution Approach 1:
The mold core is separated from the half-mold structure, allowing it to be independently positioned and removed. This segmentation enables the mold core to form deep recesses without requiring the entire half-mold to move, thereby minimizing film stretching while maintaining the ability to produce complex geometries.
Solution Approach 2:
The mold core is designed to be movable relative to the half-mold, allowing it to be inserted and removed dynamically during the molding process. This dynamic configuration enables the system to adapt to different part geometries with recesses while keeping the film stretching to a minimum.
2Shape
If a mold core is attached to the half-mold facing the film to create recesses, then the recess shape is defined, but the film is overstretched or damaged during demolding
Solution Approach 1:
The mold core is extracted from the half-mold structure and positioned independently within the cavity. This extraction allows the mold core to define the recess shape without being rigidly attached to the half-mold, enabling the film to be released from the mold core during demolding without excessive stretching or damage.
Solution Approach 2:
The mold core acts as an intermediary element between the half-mold and the film. It defines the recess geometry while being independently removable, serving as a temporary form-giving element that can be extracted without damaging the film during the demolding process.
3Reliability
If insert molding is used instead of IMD technology for parts with recesses, then the film stretching problem is avoided, but the production cost and process complexity increase
Solution Approach 1:
The modified IMD mold system achieves multi-functionality by combining the capabilities of both IMD technology and insert molding. The independently removable mold core enables the production of parts with deep recesses using IMD technology, eliminating the need to switch to more complex insert molding processes for specific part geometries.
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 allows for the cost-effective production of film-decorated plastic parts with recesses by minimizing film stretching and enabling the use of IMD technology for parts that previously required insert molding, maintaining a uniform appearance and reducing production costs.
Implementation Method 1
After closing the IMD mold, the film is back-injected with plastic, whereby the film is pressed against the half-mold facing the film under the effect of the injection pressure
Data Source
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AI summary
Specified is an IMD mold (5) for producing a film-decorated plastic part (18). The IMD mold (5) comprises a half mold (10) facing the film and a half mold (7) facing away from the film, which half molds, in a closed state, enclose a cavity (16). The IMD mold (5) furthermore comprises a mold core (11) which extends all the way through the cavity (16) and which is separate from the two half molds (7, 10). Also specified is an injection molding device (1) which, in addition to the IMD mold (5) described above, comprises means (12) for guiding the IMD film (14) between the half molds (7, 10) and means (17) for inserting the mold core (11) into, and removing the mold core (11) from, the half mold (7) facing away from the film. Here, the mold core (11) is shaped such that it tapers toward the rear surface (44) thereof which is situated opposite the front surface (27), and/or such that the cavity (16) undercuts the rear surface (44) of the mold core (11). Furthermore, the mold core (11) can be removed from the half mold (10) facing the film before or during the removal of the plastic part (18) from the mold. To produce a film-decorated plastic part (18) by means of the IMD mold (5), the mold core (11) is inserted into the half mold (7) facing away from the film when the half molds (7, 10) are in an open state, and the half molds (7, 10) are moved from the open state into a closed state so as to clamp the IMD film (14), such that the IMD film (14) is led through between the front surface (27) of the mold core (11) and the half mold (10) facing the film. Subsequently, to form the plastic part (18), a molten plastic compound (K) is injected into the cavity (16) formed between the half molds (7, 10). After solidification of the plastic mass (K), the half molds (7, 10) are returned to the open state, whereupon the mold core (11) is removed from the half mold (7) facing away from the film, and the plastic part (18) formed by the solidified plastic compound (K) is removed from the half mold (7) facing away from the film.