Injection Molding Turntable with Integrated Injection Devices
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Solution Overview
Problem
Existing methods for producing injection molded bodies, such as side turn lamps, face inefficiencies and increased costs due to the need for repeated primary and secondary injection molding processes, particularly when trying to integrate components made of different materials.
Innovation Solution
A device and method utilizing a turntable that rotates 120 degrees to position molds and injection devices for sequential primary and secondary injection molding, allowing for simultaneous integration of first and second members made of different materials, with specific mold configurations and control units to manage the injection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If secondary injection is performed for integration after primary injection using sequential processes, then integration of first and second members is achieved, but production efficiency is low and costs increase
Solution Approach 1:
The patent combines primary injection and secondary injection processes into a single integrated injection unit that performs both operations simultaneously. The first and second injection devices are integrated into one unit with a shared injection mechanism, allowing resin to be injected into both cavities at the same time, thereby eliminating sequential processing and improving production efficiency while maintaining integration capability.
Solution Approach 2:
The patent implements continuous production by maintaining injection operations without interruption. The integrated injection unit keeps both injection devices operating continuously throughout the molding cycle, with resin being injected into both cavities simultaneously and continuously, eliminating idle time between primary and secondary injection operations.
2Device complexity
If a single injection device is used for both primary and secondary injection, then device complexity is reduced, but adaptability to different material combinations is limited
Solution Approach 1:
The integrated injection unit is designed with multi-functionality to handle different material combinations. It incorporates both a first injection device for primary injection and a second injection device for secondary injection, along with a resin supply system that can provide different resin types to each device. This universal design allows the same unit to produce various injection molded bodies with different material combinations (same materials or different materials) without requiring separate dedicated devices.
3Ease of operation
If molds are configured for contact and separation operations, then workability is improved, but device complexity increases
Solution Approach 1:
The patent divides the mold system into multiple independent components: first and second molds for primary injection, and third and fourth molds for secondary injection. Each mold can be opened and closed independently, allowing flexible configuration for different production needs. This segmentation enables improved workability by allowing selective mold operations while managing complexity through modular design where each mold unit is relatively simple and standardized.
Data Source
AI summary
The present invention addresses the problem of manufacturing first and second members with different materials when molding injection molding body one after another using first to third molds disposed at 120 degrees from each other on a turntable that performs reciprocating motion at 120 degrees and using fourth to sixth molds provided opposite to the first to third molds, respectively. According to the solution, first to third injection devices are disposed on the sides of fourth to sixth molds, respectively, the first injection device is caused to perform primary injection to mold a first member, and the second and third injection devices are caused to perform primary injection to mold a second member and secondary injection to integrate the first and second members with each other, whereby the first and second members can be manufactured with different materials one after another.