Mold Device Integrating Fiber Mat Pressing and Injection Molding
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Solution Overview
Problem
Current methods for producing fiber-reinforced supports with integrated add-on pieces for decorative vehicle parts require multiple process steps and tools, leading to inefficient integration and increased production costs, with a need for improved durability and connection between the add-on elements and the mat.
Innovation Solution
A device combining pressing and injection-molding tools with movable tool components allows for simultaneous production of a fiber-reinforced support and add-on pieces, using a nozzle to inject synthetic material into the mat, creating a strong bond between the add-on pieces and the support without additional tools or process steps, reducing weight and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple process steps and tools are used for producing fiber-reinforced supports with add-on pieces, then the integration between support and add-on pieces can be achieved, but the production complexity and costs increase
Solution Approach 1:
The patent combines multiple production steps (molding the support, creating cavities, injecting synthetic material for add-on pieces) into a single integrated device. The device includes a pressing unit for molding the fiber-reinforced support and an injection unit that can inject material into cavities formed in the support, eliminating the need for separate tools and process steps while maintaining high integration quality
Solution Approach 2:
The pressing device is designed with multi-functionality, serving both as a molding device for the fiber-reinforced support and as an injection device for creating add-on pieces. The device can form cavities in the support and subsequently inject synthetic material into these cavities, allowing one device to perform multiple functions that traditionally required separate equipment
2Reliability
If additional process steps and devices are used to improve integration between pressed mat and function parts, then the connection quality improves, but the production time and complexity increase
Solution Approach 1:
The device performs preliminary actions by forming cavities in the fiber-reinforced support during the molding process itself, before the injection of synthetic material. This preliminary cavity formation is integrated into the molding step, eliminating the need for separate preparation steps and reducing overall production time while ensuring durable connections
3Adaptability or versatility
If function elements are injection-molded to natural fiber mat in separate steps, then the production flexibility is maintained, but the integration quality and durability decrease
Solution Approach 1:
The patent merges the molding of the fiber-reinforced support and the injection of add-on pieces into a single simultaneous process using one device. The support is molded and cavities are formed and filled with synthetic material for add-on pieces in an integrated sequence, ensuring durable integration while maintaining production flexibility through the device's design
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 improved integration and adhesion of add-on pieces with the support, reducing production complexity and costs, while ensuring a durable connection without the need for additional bonding agents, and allowing for design flexibility with minimal additional production effort.
Implementation Method 1
a nozzle is provided in one of the two tool components, through which liquid synthetic material is pressed onto the inserted mat in such a fashion that the synthetic material melt penetrates the inserted mat and reaches a cavity on the opposite side
Implementation Method 2
the mat can be heated in advance or with a heating device that is integrated into one or both of the tool components
Data Source
AI summary
Device and method for the production of a mold having a fiber-reinforced support and connected therewith at least one add-on piece featuring synthetic material, with the device having at least one first tool component (10) and a second tool component (20), at least one of which is movable relative to the other; in this way, the device can be opened to insert a fiber-reinforced mat (30) between the respective pressing surfaces (11, 21) of the two tool components (10, 20), and closed for pressurizing and molding the mat (30), which produces the fiber-reinforced support, and with the second tool component (20) having at least one nozzle (22) to supply a liquefied synthetic material, and the first tool component (10) having at least one cavity (12) away from the nozzle to form the add-on piece, characterized in that the second tool component (20) has at least one cavity (24) at the nozzle so that the add-on piece can be produced and integrated by introducing synthetic material through the nozzle (22) and through the mat (30) into the cavity (12) away from the nozzle and the cavity (24) at the nozzle and hardening it therein.