Luggage Shell Injection Mold with Fused Diaphragm
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Solution Overview
Problem
Conventional injection molding of luggage shells results in products with limited color diversity and poor abrasion resistance, leading to easily scratched and low-quality finishes.
Innovation Solution
The method involves using an injection mold with a shell diaphragm inside, where the diaphragm is obtained through blistering molding and fused with the plastic, allowing for varied colors and materials, and surface hardening treatments to enhance abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional injection molding is used, then the manufacturing process is simple, but the luggage shell has single color and poor abrasion resistance
Solution Approach 1:
The patent embeds a diaphragm structure within the injection mold cavity. This nested diaphragm can be made of different materials and colors, allowing the luggage shell to incorporate multiple colors and textures while maintaining a relatively simple overall mold structure. The diaphragm is positioned within the mold cavity and works in conjunction with the injection molding process to create multi-colored products.
Solution Approach 2:
The patent uses composite materials by combining the diaphragm material with the injected plastic material. The diaphragm can be made from various materials (metal, plastic, fabric) and colors, while the plastic is injected through the sprue system. This creates a composite structure that enables color diversity and improved abrasion resistance without requiring completely different mold designs for each color variation.
2Reliability
If traditional injection molding is used, then the production process is straightforward, but the appearance is easily scratched and quality is poor
Solution Approach 1:
The diaphragm is pre-installed in the mold cavity before the injection molding process begins. This preliminary action allows the diaphragm to serve as a reinforcement layer or surface treatment that is already in place when the plastic is injected. The diaphragm can be made from abrasion-resistant materials or coated with protective layers, providing scratch resistance from the outset without requiring additional post-processing steps.
Solution Approach 2:
The diaphragm acts as a flexible shell or thin film within the mold cavity that can be made from various materials including metal foils, plastic films, or fabric layers. This flexible element provides a protective surface that resists scratching and improves the overall quality of the luggage shell appearance. The diaphragm can be conformally fitted to the mold cavity and maintains its protective function throughout the injection process.
3Adaptability or versatility
If conventional molding is used, then the process is efficient, but color fading occurs and product diversity is limited
Solution Approach 1:
The patent segments the color and material composition into separate components: the diaphragm layer and the injected plastic layer. Each layer can be independently designed, selected, and manufactured with different colors and materials. This segmentation allows for greater product diversity as different diaphragm-plastic combinations can be used for different product variants, while also improving color fastness since the diaphragm acts as a stable base layer that resists fading.
Solution Approach 2:
The patent enables parameter changes in color and material composition by varying the diaphragm properties while maintaining the same injection molding process. The diaphragm can be manufactured in different colors, materials, and thicknesses, allowing the same mold to produce diverse products with different color fastness characteristics. This parameter variation approach maintains manufacturing efficiency while enabling product diversity and improving color reliability.
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 increases color diversity and improves the durability of the luggage shells by preventing color fading and enhancing surface resistance, resulting in higher-quality products with reduced marks and fusion lines.
Implementation Method 1
heating the diaphragm or the sheet and performing the blistering molding through the concave mold to obtain the shell diaphragm
Implementation Method 2
the shell diaphragm is attached or dissolved in the surface of the injected plastic, such that the shell diaphragm is fused with the plastic
Data Source
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AI summary
Provided are an injection molding method, an injection mold, and a luggage shaping mold. The method includes: obtaining (S1) an injection mold having a shell diaphragm placed inside; closing (S2) the injection mold and starting injection molding; performing (S3) the injection molding to obtain a luggage shell; and opening (S4) the injection mold to take the luggage shell. In this way, diversity of luggage design may be improved, the luggage may be more resistant to abrasion, and the problem that the appearance of the traditional injection molded luggage shell has marks and fusion lines may be solved.