Mold Carrier Module Integration for In-Mold Decoration
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Solution Overview
Problem
The production of plastic components using in-mold decoration methods is hindered by the sensitivity of the components during transport and processing, requiring complex and costly packaging to protect them from external influences, which is not environmentally friendly.
Innovation Solution
A method and device that utilize movable mold carriers with multiple modules to integrate injection-molding and flooding stations in a single device, allowing for in-line production without the need for separate transportation, by combining upper and lower mold modules to form workstations for injection molding and subsequent application of protective layers directly within the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plastic components are produced using in-mold decoration methods, then the components achieve decorative surface quality, but the components become sensitive to external influences during transport and processing
Solution Approach 1:
The patent combines the injection-molding process with the flooding process in a single integrated device. The injection-molding unit produces the plastic component with decorative surface, and the flooding unit immediately applies a protective layer to the same component without removal or transport. This merging eliminates the vulnerability period during separate transport while maintaining both decorative quality and protection.
2Reliability
If plastic components are transported from injection-molding device to flooding device for protective layer application, then the components receive protective coating, but complex packaging is required which increases costs and time
Solution Approach 1:
The patent integrates the flooding unit directly with the injection-molding unit in a single device. The component remains in the injection-molded state and is immediately transferred to the flooding unit within the same device, eliminating the need for intermediate packaging and separate transport. This reduces device complexity while ensuring reliable protective layer application.
Solution Approach 2:
The protective layer application is performed immediately after injection molding while the component is still in the device, before any removal or transport occurs. This preliminary action eliminates the need for protective packaging that would otherwise be required during transport, reducing both packaging complexity and associated costs.
3Ease of manufacture
If separate injection-molding and flooding devices are used, then each device can be optimized for its specific function, but transportation infrastructure and packaging are required which reduce efficiency
Solution Approach 1:
The patent merges the injection-molding device and flooding device into a single integrated unit with multiple units that can be moved between predetermined positions. Each unit retains its functional optimization while operating within the same device framework. The mobile carriers allow the injection-molding unit and flooding unit to be positioned adjacent to each other, enabling continuous production without transport interruptions and thereby maintaining high productivity.
Data Source
AI summary
A method for producing a component, wherein in the method the following steps are carried out, in particular in the following sequence: providing at least one upper mold carrier and at least one lower mold carrier, wherein the at least one upper mold carrier has at least two upper mold modules and the at least one lower mold carrier has at least one lower mold module; moving the at least one upper mold carrier and/or the at least one lower mold carrier in at least one direction into at least one predetermined position; combining a first upper mold module of the at least two upper mold modules of the at least one upper mold carrier and a first lower mold module of the at least one first lower mold module of the at least one lower mold carrier in the at least one predetermined position such that one or more work stations for carrying out at least one step for producing the component are formed; carrying out the at least one production step to form the component, as well as a device for producing a component.