In-Mold Assembly of Plastic Parts Using Rotating Turrets
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Solution Overview
Problem
Current methods for manufacturing composite injection-molded parts with movable components are inefficient, requiring separate forming and assembly steps that increase production cycle times and costs, and existing in-mold assembly techniques have limitations such as thermal bonding issues and long cycle times.
Innovation Solution
An injection-molding and assembly apparatus that forms and assembles multiple parts within the mold using turrets and actuators to mechanically join components, eliminating separate assembly steps and enabling the production of complex assemblies with moving parts, including the use of displacement actuators and assembly apparatus to align and assemble parts without thermal bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate forming and assembly steps are used to manufacture composite part assemblies, then manufacturing precision and reliability can be maintained, but productivity decreases and loss of time increases
Solution Approach 1:
The patent combines the forming and assembly operations into a single integrated in-mold assembly process. Multiple component parts are formed and assembled within the same mold cavity during one injection cycle, eliminating the need for separate forming and assembly steps. This merging of operations maintains manufacturing precision while significantly improving productivity by reducing the number of production steps and cycle time.
2Productivity
If in-mold assembly is used to form and assemble parts before ejection, then productivity improves, but device complexity increases due to multiple rotating tools and coordinated movement requirements
Solution Approach 1:
The patent divides the mold into multiple independent cavities, with each cavity capable of forming and assembling a complete composite part assembly independently. This segmentation allows parallel production of multiple assemblies simultaneously, improving productivity while keeping each individual mold cavity relatively simple in structure, avoiding the need for complex coordinated movement of multiple rotating tools.
3Ease of manufacture
If thermal bonding is used to join parts in in-mold assembly, then ease of manufacture improves, but loss of time increases due to cooling requirements and cycle time extensions
Solution Approach 1:
The patent replaces thermal bonding with mechanical joining methods such as snap-fits, bayonet mounts, or mechanical interlocks that are formed during the injection molding process. These mechanical features allow parts to be assembled and secured without heating, eliminating the need for extended cooling cycles and reducing overall cycle time while maintaining ease of manufacture through automated in-mold assembly.
Data Source
AI summary
Method and apparatus for molding and assembling a composite part assembly in, for example, a plastic injection-molding machine. Complementary mold portions associated with a mold plate and rotatable turret form plural parts. Assembly apparatus associated with the turret assembles the plural parts into an assembly. A further turret may be provided to add a complementary part to the assembly to make a final assembly. The method includes manufacture of composite part assemblies and final assemblies.