Modular End Welding Mold for Injection Sealing Profiles

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Solution Overview

Problem

Existing end welding mold technologies for car window profiles require frequent changes and separate spare parts for different materials, leading to increased labor costs, extended installation times, and higher energy consumption, with no added value and posing ergonomic risks.

Innovation Solution

A modular end welding mold with changeable mold cores and standardized bottom and top plates, utilizing either a hot or cold runner system, allows for efficient production and reduced spare parts inventory, minimizing labor and energy usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate molds and runner systems are used for different materials (TPE/TPV/EPDM), then material-specific molding requirements are met, but spare parts inventory costs and device complexity increase

Engineering Contradiction:

Improvematerial-specific molding qualityVSAvoidnumber of separate molds and runner systems

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mold is designed with a universal structure that can accommodate different materials (TPE, TPV, EPDM) through interchangeable insert sets. The standardized cavity and runner system serve multiple material types, eliminating the need for completely separate molds for each material while maintaining material-specific molding requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mold is divided into modular components: a standardized base structure (cavity, runner system) and interchangeable insert sets specific to each material type. This segmentation allows the common parts to remain fixed while only replacing material-specific inserts, reducing spare parts inventory while maintaining material optimization.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If frequent mold changes are performed for different references, then production flexibility is improved, but installation time and labor costs increase

Engineering Contradiction:

Improveproduction flexibility for different referencesVSAvoidinstallation and changeover time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The mold is segmented into a permanent standardized base and interchangeable insert sets. Only the inserts need to be changed for different references, not the entire mold. This dramatically reduces changeover time while maintaining full production flexibility across different profile types and materials.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized cavity and runner system serve as a universal base that works with all insert sets. This universality allows quick reference changes by simply swapping inserts rather than installing completely different molds, reducing installation time while maintaining adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If standardized mold components are used across different materials, then spare parts inventory is reduced, but material-specific optimization may be compromised

Engineering Contradiction:

Improvespare parts inventoryVSAvoidmaterial-specific molding performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The mold separates material-specific elements (inserts) from universal elements (cavity, runner system). The standardized cavity and runner reduce spare parts inventory, while material-specific inserts maintain optimized performance for each material type. Only the inserts need to be material-specific, not the entire mold system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized base structure provides a universal platform that works with all materials, reducing the need for multiple complete mold sets. Material-specific performance is maintained through specialized inserts that can be paired with the universal base, optimizing both inventory reduction and material performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 significantly reduces production costs, installation time, and occupational risks while optimizing energy consumption and material use, enabling quicker mold design and production with fewer spare parts and improved ergonomics.

Implementation Method 1

by using material paste transferred by a hot runner system or a cold runner system

Methodology Applied

Scientific EffectHot runner system:

Implementation Method 2

by using material paste transferred by a hot runner system or a cold runner system

Methodology Applied

Scientific EffectCold runner system:

Implementation Method 3

injection method by using material paste transferred by a hot runner system or a cold runner system

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentEP3941708B1Mold structure for injection end welding in sealing profiles

Publication Date: 2024.10.30 STANDARD PROFIL EGE OTOMOTIV SANAYI VE TICARET ANONIM SIRKETI

Figure 1
Figure 2~3

AI summary

The invention relates to an end welding mold (10) for providing end welding in all moving or fixed glass profiles (50) of vehicles via injection method, comprising at least one mold core (14) providing geometric shaping of the paste which is transferred by the a hot runner system (20) or a cold runner system (30), which is changeable depending on different end welding references. It could also be applied to dynamic sealings ends (eg. door seals) on cars if they have an end moulding.