In-Mold Spraying System With Double-Inclined Mixing Nozzle
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Solution Overview
Problem
Existing in-mold spraying systems for automotive interior components are cumbersome, with complex equipment and processes, leading to unstable jet flow and reduced quality due to compact configurations and the need for multiple equipment transfers, resulting in low efficiency and inconsistent PU coating quality.
Innovation Solution
An in-mold spraying system with a double-inclined mixing nozzle and three half-molds that form two cavities, allowing for simultaneous injection of substrate and PU coating without additional low-pressure parts, using a unique lateral sealing structure to stabilize jet flow and improve consistency, and incorporating air-cooled heating for environmentally friendly operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conventional processing method is used to inject semi-finished plastic parts first and then transfer to other stations for PU layer processing, then the PU coating can be applied, but the production cycle becomes long and the process becomes complicated
Solution Approach 1:
The patent combines the substrate injection and PU coating processes into a single integrated in-mold spraying system. The mixing nozzle is directly installed in the mold cavity, allowing both processes to occur in one location without transferring parts between stations, thus resolving the contradiction between maintaining PU coating quality and reducing production cycle time
2Manufacturing precision
If a manipulator is used to move plastic parts between fixed mold bases, then the PU coating can be applied, but the position of plastic parts changes and the process becomes more complicated with lower efficiency
Solution Approach 1:
The patent integrates the mixing nozzle directly into the mold cavity, eliminating the need for external manipulators and part transfer operations. This consolidation maintains part position stability and simplifies the overall process while ensuring consistent PU coating quality
3Volume of moving object
If the high-pressure pump is arranged with the injection molding machine and constructed to be compact and highly integrated, then the equipment space is reduced, but it affects the final coating quality
Solution Approach 1:
The patent segments the high-pressure pump from the injection molding machine, placing it on an independent base plate rather than integrating it into the machine structure. This separation prevents interference with the coating process while still achieving compact overall layout, thus resolving the contradiction between equipment compactness and coating quality
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
The system achieves high surface quality and efficiency by stabilizing jet flow, reducing equipment costs, and simplifying the process, enabling two working steps in one station with improved production efficiency and reduced maintenance costs.
Implementation Method 1
incorporating air-cooled heating for environmentally friendly operation
Data Source
AI summary
For in mold spraying, a double-inclined mixing nozzle is connected obliquely and fixedly with a side surface of a third half-mold through a lateral sealing structure and connected with a side surface of a first half-mold in an inclined and sealing manner, side faces of a first half-mold and the third half-mold are respectively provided with installation inclined surfaces. A lateral sealing structure includes a mounting plate and a sealing member. The sealing member is sleeved on the double-inclined mixing nozzle and is in transition fit with the double-inclined mixing nozzle and the mounting plate respectively. A butt sealing groove provided on the installation inclined surface of the first half-mold and is in sealing fit with the mounting plate.