Injection Molding Apparatus Integrating Wind Noise Elimination Member
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Solution Overview
Problem
Existing methods for manufacturing injection molded articles, such as those attached to vehicle door mirrors, face challenges in integrating wind noise and light leakage elimination members during the manufacturing process, leading to increased material costs, assembly time, and potential product variations due to separate retrofitting processes.
Innovation Solution
An apparatus and method that perform primary, secondary, and tertiary injections within the same molds to integrate two components and mold a wind noise and light leakage elimination member without removing the article, utilizing a turntable with multiple molds and injection devices to inject resin for integration and surface molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the elimination member is retrofitted after injection molding in a separate process, then the integrated molding of two members can be achieved, but material costs and assembly man-hours increase
Solution Approach 1:
The patent merges the elimination member molding process with the main injection molding process by integrating the elimination member mold into the existing mold system. The elimination member is molded simultaneously with the main article through coordinated injection sequences, eliminating the need for separate retrofitting operations and reducing both material costs and assembly man-hours.
Solution Approach 2:
The elimination member is molded in advance during the same injection cycle as the main article, rather than being added later. The mold system is configured to form the elimination member cavity along with the main article cavity, allowing the elimination member to be prepared and attached in a single manufacturing pass.
2Extent of automation
If an automatic assembly machine is used to assemble the elimination member, then assembly automation is achieved, but investment cost increases and man-hours increase for complex shapes
Solution Approach 1:
The patent combines the elimination member molding and assembly operations into the existing injection molding apparatus. The elimination member mold is integrated with the main mold, and the injection system is configured to fill both cavities in sequence. This approach achieves automation without requiring a separate automatic assembly machine, thereby avoiding additional investment costs and device complexity.
Solution Approach 2:
The injection molding apparatus is made multi-functional by enabling it to perform both the main article molding and the elimination member molding within the same cycle. The mold system and injection system are configured to handle multiple functions simultaneously, eliminating the need for dedicated assembly equipment.
3Ease of manufacture
If the elimination member assembly is performed in a separate process after secondary injection, then the integrated molding of two members is achieved, but intermediate inventory is generated and product quality varies
Solution Approach 1:
The patent merges the secondary injection process with the elimination member molding process. The mold system is configured to perform the secondary injection to integrate the two main members while simultaneously forming the elimination member in the same cycle. This eliminates intermediate inventory generation and ensures consistent product quality by completing all operations in a single controlled process.
Solution Approach 2:
The manufacturing process maintains continuity by performing the elimination member molding without interrupting the secondary injection process. The injection system continuously fills the mold cavities in the optimized sequence, eliminating pauses and transfers that would generate intermediate inventory and cause product variation.
4Productivity
If the molded article is removed from molds after secondary injection, then the integrated molding is completed, but the risk of foreign matter adhesion and product variation increases
Solution Approach 1:
The patent combines the elimination member molding with the secondary injection process, allowing the molded article to remain in the mold until all operations are complete. The mold system is configured to perform secondary injection and elimination member molding in sequence without removing the article, thereby maintaining product quality stability while preserving manufacturing efficiency.
Data Source
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AI summary
An injection molding apparatus (30) includes a turntable (5); first, second, and third molds disposed on the turntable (5); fourth, fifth, and sixth molds for opening and clamping the first, second, and third molds; and a first injection device (12), a second injection device (13), and a third injection device (14) for injecting a resin into the molds. Furthermore, the second injection device (13) and the third injection device (14) each include two injection ports, one of the two injection ports works as an injection port for primary and secondary injection, and the other is an injection port for a tertiary injection for injecting the resin along the outer peripheral portion of either one of a first member and a second member.