Integrated Mold Half for Insert Positioning
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Solution Overview
Problem
The complex and cost-intensive process of handling and positioning bush-like inserts in injection molding machines leads to long cycle times and high space requirements, making it challenging to produce injection molded parts with integrated inserts efficiently.
Innovation Solution
A mold half for injection molding machines equipped with a conveyor channel and a positioning unit that feeds and positions bush-like inserts within the mold area, eliminating the need for external conveyors and allowing for automatic and reliable placement of inserts during the injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external conveyors and complex peripherals are used to handle and position inserts, then the inserts can be fed into the mold cavity, but the device complexity and space requirements increase significantly
Solution Approach 1:
The patent integrates the insert feeding mechanism directly into the mold half, merging the functions of insert storage, conveyance, and positioning into a single integrated unit. The conveyor channel is embedded within the mold half structure, eliminating the need for separate external conveyors and complex peripheral devices, thus reducing device complexity while maintaining insert feeding capability
Solution Approach 2:
The mold half is designed to perform multiple functions: it serves as both the forming tool and the insert feeding mechanism. The positioning unit integrated into the mold half can handle multiple inserts sequentially, providing universal functionality for insert placement without requiring dedicated external handling systems for each insert
2Ease of manufacture
If external conveyors and complex peripherals are used to handle and position inserts, then the inserts can be fed into the mold cavity, but the space requirements for the injection molding machine increase
Solution Approach 1:
The conveyor channel is integrated within the mold half structure, combining the insert conveyance function with the mold body. This eliminates the need for separate external conveyor systems that would occupy additional space around the injection molding machine, thus reducing the overall space requirement while maintaining insert feeding capability
Solution Approach 2:
The insert feeding mechanism is nested within the mold half structure. The conveyor channel is embedded inside the mold half, and the positioning unit is integrated into the same structure, creating a compact nested arrangement that minimizes the space occupied by the injection molding machine while providing complete insert handling functionality
3Manufacturing precision
If complex peripherals are used to handle and position inserts, then the inserts can be accurately positioned in the mold cavity, but the cycle time increases
Solution Approach 1:
Multiple inserts are pre-positioned in the conveyor channel within the mold half before the injection molding cycle begins. The positioning unit is pre-configured with the exact positioning locations for each insert. During the injection cycle, the positioning unit can quickly transfer inserts from their pre-positioned locations to the mold cavity without requiring complex real-time adjustments, thus maintaining high positioning accuracy while reducing cycle time
Solution Approach 2:
The positioning unit is designed to move dynamically between different positioning locations during the injection cycle. It can quickly transition between positions to place multiple inserts in sequence, providing the flexibility needed for accurate positioning while minimizing the time required for insert placement, thus improving productivity without sacrificing positioning precision
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 solution enables the production of injection molded parts with integrated bush-like inserts in a space-saving and cost-effective manner, reducing cycle times and eliminating the need for complex peripherals, while allowing for easy integration of multiple inserts and control of the feeding and positioning process.
Implementation Method 1
a feed channel (38) designed to feed the insertion part (32) into the tool half (12), which extends vertically through the tool half (12) and flows into a pick-up area (40) of the conveying channel (36)
Data Source
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AI summary
The invention relates to a mold half (12) for an injection molding machine (10) for producing an injection-molded part with at least one bushing-like insert (32), comprising: a molding area (28) which forms at least part of a cavity (30) for the injection-molded part; a conveying channel (36) extending inside the mold half (12) and through the molding area (28); a feed channel (38) designed for feeding the insert (32) into the mold half (12), which extends vertically through the mold half (12) and opens into a receiving area (40) of the conveying channel (36);A positioning unit (42) designed to penetrate an opening (52) of the insert (32) by moving from a demolding position to an injection position, thereby receiving the insert (32) when it is arranged in the receiving area (40) of the conveying channel (36), and to convey the received insert (32) from the receiving area (40) to an injection molding position in the area of the mold (28). The invention further relates to a method for producing an injection molded part with at least one bushing-like insert (32).