Injection Mold Carriage Blade for Plastic Offcut Separation
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Solution Overview
Problem
Existing methods for manufacturing plastic parts often result in imperfections at the injection threshold, leading to offcuts that are not recoverable and pose safety risks during manual removal, increasing production time and costs.
Innovation Solution
A method and device that incorporate a pusher mechanism with a rod and spring to eject and reuse plastic from the injection channel, allowing for controlled separation and recovery of offcuts, eliminating imperfections at the injection threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual removal of defects at the injection threshold is performed, then imperfections are eliminated, but production time increases and safety risks arise
Solution Approach 1:
The patent applies preliminary action by automatically removing defects at the injection threshold during the injection process itself, rather than performing manual removal afterward. The system uses a control unit to detect excess material and activate a cutting mechanism that trims the defect while the plastic is still in the mold, eliminating the need for separate manual cleanup operations and reducing total production time
Solution Approach 2:
The system implements self-service by enabling the mold to automatically detect and remove its own defects without external manual intervention. The control unit monitors the injection process, identifies excess material at the threshold, and triggers an automated cutting mechanism that cleans up the defect, allowing the mold to service itself and eliminate quality issues without operator involvement
2Manufacturing precision
If manual removal of defects is performed, then imperfections are eliminated, but safety risks increase due to sharp tools
Solution Approach 1:
The system implements self-service by enabling the mold to automatically detect and remove its own defects without external manual intervention. The control unit monitors the injection process, identifies excess material at the threshold, and triggers an automated cutting mechanism that cleans up the defect, allowing the mold to service itself and eliminate quality issues without operator involvement
Solution Approach 2:
The patent replaces manual mechanical operations with an automated mechanical system. Instead of operators using sharp tools to remove defects, the system employs a controlled cutting mechanism activated by the control unit, which precisely trims excess material at the injection threshold without requiring human contact with sharp objects
3Device complexity
If offcuts are not recovered, then production process is simpler, but material loss increases
Solution Approach 1:
The patent applies the discarding and recovering principle by implementing a system that collects offcuts generated during the injection and trimming processes. The control unit activates mechanisms to gather excess material and trimmed portions, storing them in a collection container within the mold assembly, enabling subsequent reuse or proper disposal and reducing overall material waste
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 enables efficient recovery and reuse of plastic, reducing production time and safety hazards while minimizing imperfections in the final product.
Implementation Method 1
a spring is mounted around the rod, the actuator compressing the spring during the ejection step
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method and device for manufacturing a plastic part, employing an injection mold comprising first (14) and second (16) parts, defining between them a molding cavity (26), and a carriage (18) comprising a blade (32). The carriage (18) and the second part (16) define between them an injection channel (38) comprising an inlet. The molding cavity (26) and the injection channel (38) communicate at a contact zone. The method comprises the following steps: - injecting plastic into the injection channel and the molding cavity through the inlet, - moving the carriage (18), the blade (32) cutting the plastic at the contact zone, the plastic injected into the molding cavity (26) and the plastic injected into the injection channel (38) being separated after the carriage (18) moves, the plastic injected into the injection channel remaining in contact with the carriage (18).