Integrated Contact Heating for Thermoplastic Mats in Injection Molding
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Solution Overview
Problem
Existing methods for manufacturing composite parts with shaped plates and plastic functional parts face inefficiencies due to long transfer paths between heating units and press-injection molding tools, leading to energy expenditure and potential material quality issues, as well as the need for separate heating and molding tools.
Innovation Solution
A device and method where the heating unit is integrated into the press-injection molding tool, allowing for simultaneous heating and shaping, reducing transfer paths and eliminating the need for separate heating presses, with thermal insulation to control temperatures and improve handling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate heating press is used to heat the plate blank before molding, then the plate blank can be heated to the required temperature, but long transfer paths are required between the heating press and the press-injection molding tool, leading to energy loss and potential cooling of the plate blank
Solution Approach 1:
The heating device is integrated directly into the press-injection molding tool, combining the heating function and molding function into a single unified system. This eliminates the separate heating press and the transfer path between heating and molding operations, preventing energy loss and temperature drop during transfer while maintaining the required plate blank temperature for molding
Solution Approach 2:
The press-injection molding tool is designed to perform multiple functions: it serves as both the molding device and the heating device. The heating装置 integrated into the molding tool can heat the plate blank to the required temperature and then immediately proceed with the molding operation, eliminating the need for separate heating equipment and reducing energy loss
2Temperature
If a separate heating press is used, then heating can be performed, but additional equipment and transfer mechanisms are required, increasing device complexity
Solution Approach 1:
The heating device and molding tool are merged into a single integrated system. The heating装置 is built into the press-injection molding tool, eliminating the need for a separate heating press and the complex transfer mechanisms required to move the plate blank between heating and molding operations, thus reducing overall device complexity
Solution Approach 2:
The press-injection molding tool is designed as a multi-functional device that performs both heating and molding operations. This universal design eliminates the need for multiple separate tools (heating press and molding tool), simplifying the overall equipment configuration and reducing device complexity
3Temperature
If the plate blank is pre-heated to a higher temperature to compensate for cooling during transfer, then the required temperature can be maintained in the molding tool, but greater energy expenditure is required and material quality may be impaired
Solution Approach 1:
By integrating the heating device into the molding tool, the heating and molding operations are combined into a single continuous process. The plate blank is heated to the exact required temperature immediately before molding without prolonged exposure to high temperatures, minimizing energy expenditure and preventing material quality impairment that would result from excessive pre-heating
4Manufacturing precision
If separate heating and molding tools are used, then each tool can be optimized for its specific function, but the transfer path between tools increases cycling time
Solution Approach 1:
The heating function and molding function are combined into a single integrated press-injection molding tool. This eliminates the transfer time between separate heating and molding tools, reducing the overall cycling time while maintaining manufacturing precision through the specialized design of the integrated heating装置 within the molding tool
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 integration reduces energy costs, minimizes temperature loss during transfer, and shortens cycling times, enabling more efficient production of composite parts with improved material quality and simplified tool design.
Implementation Method 1
In prior art it is known for this to use separate heating presses with contact heating or infrared heating
Implementation Method 2
In prior art it is known for this to use separate heating presses with contact heating or infrared heating
Implementation Method 3
with thermal insulation to control temperatures and improve handling efficiency
Data Source
AI summary
The invention proposes a device for manufacture of a composite piece, which exhibits a shaped plate and at least one plastic functional piece molded on to the shaped plate. The device has a heater for heating a plate blank; a shaping tool with at least two shaping elements and for admitting and shaping of the plate blank, to bring the plate blank into a desired shape and thus to manufacture the shaped plate; means for insertion of a shaped mass into the shaping tool for molding the plastic functional piece onto the shaped plate in the shaping tool to manufacture the composite piece, wherein the shaping tool is so configured that after the shaping of the plate blank, at least one cavity remains, in which the plastic functional piece is shaped; and a closing unit for opening and closing the shaping tool; wherein the heater is integrated into the closing unit and the closing unit is furnished to open and close the heater.