Insert Part Weld Molding Method Using Preheating Plate
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Solution Overview
Problem
Conventional insert part weld molding methods often result in unwelded portions at the circumferential edges of blow molded objects, particularly in the thickness direction, and high preheating temperatures can cause the insert parts to melt, leading to molding failures.
Innovation Solution
The method involves setting the molding surface of the mold higher than the weld surface of the insert part, using a preheating plate with superior thermal conductivity and a heat insulating plate to maintain temperature, and creating a level difference on the preheating plate to ensure a gapless or overhanging weld state between the parison and the insert part's circumferential edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preheating temperature and preheating plate temperature are set high to improve welding of the circumferential edge, then welding quality improves, but the insert part melts and molding failure occurs
Solution Approach 1:
The patent applies local quality by creating a level difference on the preheating plate surface, where the central region has a higher elevation than the circumferential edge region. This allows different thermal conditions and welding pressures to be applied to different locations: the central welding area receives higher temperature and pressure for reliable welding, while the circumferential edge area maintains lower temperature to prevent melting. The level difference structure enables spatial differentiation of thermal and mechanical parameters to simultaneously achieve both welding quality and prevent harmful melting.
2Ease of manufacture
If conventional welding method is used with chamfered circumferential edge, then welding bed contacts parison, but unwelded portions remain at the circumferential edge in thickness direction
Solution Approach 1:
The patent introduces a vertical dimension (level difference) to the traditionally two-dimensional welding interface. By elevating the central region of the preheating plate above the circumferential edge, the patent creates a three-dimensional welding geometry that forces the parison to wrap around and contact the insert part circumferential edge more completely. This dimensional change ensures that the welding interface extends through the entire thickness direction, eliminating unwelded portions while maintaining manufacturing simplicity.
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 approach reliably welds the insert part to the blow molded object, preventing unwelded areas and enhancing welding strength, impact resistance, and maintaining consistent temperature for improved results.
Implementation Method 1
a preheating plate which is made of a high thermal conducting material and which is to become a part of the molding surface of the mold is arranged in a vicinity of a portion where the parison and the circumferential edge of the insert part in the thickness direction thereof are welded
Implementation Method 2
a heat insulating plate is arranged between the preheating plate and the mold
Data Source
AI summary
To provide an insert part weld molding method for reliably welding an insert part to a blow molded object while preventing an unwelded portion from being created at a circumferential edge of the insert part in a thickness direction thereof. An insert part weld molding method welds a blow molded object to an insert part 3 set in a mold 7, wherein a molding surface 7a of the mold 7 is set higher than a front surface 6d of a portion to be welded of the insert part 3, and an entire surface of a circumferential edge 6b of the insert part 3 in the thickness direction thereof and a parison 11 of the blow molded object are brought into a gapless welded state. Also adopted is a method of suppressing a decrease in temperature of the insert part 3 by arranging a preheating plate 8 which is made of a high thermal conducting material and which is to become a part of the molding surface 7a of the mold 7 in a vicinity of a portion where the parison 11 and the circumferential edge 6b of the insert part 3 in the thickness direction thereof are welded, and arranging a heat insulating plate 9 between the preheating plate 8 and the mold 7.