Local Injection Moulding for Vehicle Part Identification
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Solution Overview
Problem
Existing methods for attaching identification marks, such as logos, to vehicle parts in the injection moulding process are prone to dislodgement due to insecure adhesion, leading to identification issues.
Innovation Solution
A method and apparatus for locally applying an injection moulded part to a primary part using a moulding process where the part is sandwiched between a top and bottom mould, with resin being injected into a cavity to securely integrate the identification portion, allowing for multi-coloured designs and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If logos are simply attached to the surface of the vehicle part, then the identification mark can be applied to the part, but the logo may become easily dislodged or fall off
Solution Approach 1:
The patent merges the logo application process with the injection molding process by integrating the logo as a separate injection molded part that is then locally applied to the vehicle part. This combines two previously separate operations (logo attachment and part manufacturing) into a unified process, achieving both ease of manufacture and reliable adhesion through the chemical bonding of the resin to both surfaces.
2Reliability
If an injection molded part is locally applied to a finished production part, then secure integration is achieved, but the process complexity increases
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: first creating the vehicle part, then separately creating the logo as an injection molded part, and finally locally applying the logo to the vehicle part. This segmentation allows each component to be optimized independently while maintaining overall process reliability, with the resin injector system providing secure integration through localized resin injection.
3Adaptability or versatility
If multiple coloured resins are injected into the cavity, then multi-coloured designs are enabled, but the manufacturing process time increases
Solution Approach 1:
The patent enables continuous multi-colour resin injection by having the resin injector system inject different coloured resins into the cavity in sequence without removing the mold or resetting the system. The first coloured resin is injected into a first resin receiving hole, then the second coloured resin is injected into a second resin receiving hole, allowing multi-coloured designs to be created in a single continuous operation, minimizing cycle time extension.
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 solution provides a secure integration of identification portions with the finished production part, reducing the likelihood of separation and enabling a one-pass process for multi-coloured designs, thus enhancing part identification and durability.
Implementation Method 1
Resin is then injected into the cavity to locally apply the injection moulded part to the primary part
Implementation Method 2
In another aspect, the method further includes cooling the resin
Data Source
AI summary
The disclosure is directed at a method and apparatus for locally applying an injection moulded part to a primary part. The apparatus includes an injection moulding tool which includes a top and bottom mould which, when closed around the primary part, define a cavity into which resin can be injected. The cavity defined by the top and bottom moulds is smaller than a footprint of the primary part. In other words, the top and bottom moulds have a footprint which is less than a footprint of the primary part.