Mold Insert Segmentation for Valve Gate Interference
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Solution Overview
Problem
Conventional methods using hot runners with valve gate systems face challenges in supporting complicated molding due to interference between the gate-closing valve and the mold insert, which hinders the mold insert from sliding freely.
Innovation Solution
An article manufacturing method and apparatus that involves molding a first product by closing a first mold onto a second mold, injecting molten resin, joining the first product with a second molded product, separating and moving the first mold insert to a position where the products face each other, allowing for complicated molding without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a valve gate system is used in a hot runner to prevent dripping and stringing of molten resin, then product quality is improved, but the gate-closing valve interferes with the mold insert and hinders free sliding
Solution Approach 1:
The mold insert is divided into a movable portion and a fixed portion. The movable portion can slide relative to the fixed portion, allowing the mold insert to move away from the injection unit when needed. This segmentation enables the mold insert to avoid interference with the gate-closing valve while maintaining the benefits of the valve gate system.
Solution Approach 2:
The mold insert is designed with dynamic movement capability, transitioning from a static to a dynamic configuration. The movable portion slides along the moving mold to adjust its position, enabling it to move away from the injection unit during certain phases of the molding cycle to avoid interference with the gate-closing valve.
2Ease of operation
If the mold insert is made movable to avoid interference with the gate-closing valve, then ease of operation is improved, but the device complexity increases
Solution Approach 1:
The mold insert is segmented into movable and fixed portions that slide relative to each other along the moving mold. This segmentation allows the insert to move when needed while keeping the overall structure relatively simple by utilizing the existing moving mold framework.
Solution Approach 2:
The movable portion of the mold insert serves multiple functions: it acts as a mold cavity during injection and as a sliding mechanism to avoid interference with the gate-closing valve. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity.
3Adaptability or versatility
If complicated molding is performed with multiple injection units, then product versatility is improved, but the gate-closing valve interferes with the mold insert sliding
Solution Approach 1:
The mold insert is divided into a movable portion and a fixed portion, where the movable portion can slide along the moving mold. This segmentation allows the mold insert to move away from the injection unit when needed, enabling complicated molding operations with multiple injection units without interference from the gate-closing valve.
Solution Approach 2:
The mold insert incorporates dynamic movement capability through its movable portion that slides relative to the fixed portion. This dynamic design allows the insert to adjust its position during the molding cycle, accommodating complicated molding operations while avoiding interference with the gate-closing valve.
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
Enables the support of complicated molding processes using hot runners with valve gate systems by allowing the mold insert to slide freely, thereby improving productivity and reducing waste.
Implementation Method 1
injecting molten resin into a first mold insert (37) of the first mold (34), with at least one injection unit (30) being provided at the first mold (34) injecting the molten resin
Implementation Method 2
a valve gate system, where the gate is opened before injection and closed after injection
Data Source
AI summary
Provided are an article manufacturing method and a manufacturing apparatus that can support complicated molding in molding performed using a hot runner with a valve gate system, with the method including molding a first product by closing a first mold onto a second mold and injecting molten resin into a first mold insert of the first mold, with at least one injection unit provided at the first mold injects the molten resin; joining the first product to a second molded product at the second mold; separating a first plate including the first mold insert from the first mold as the first mold and the second mold are opened; and moving the first mold insert to a position where the first product and the second molded product face each other.