Moulding Method for Insert Components with Integrated Edges
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Solution Overview
Problem
The existing moulding method for components with a body and covering or insert, such as fabric or leather, results in significant production waste and high processing costs due to multiple phases of excess material removal and subsequent cutting and attachment processes.
Innovation Solution
A moulding method where an insert is attached to the mould using a suction device and a moving block, with a cursor tautening the insert and making holes to separate injection chambers, allowing for simultaneous injection of plastic material into both chambers through the insert, eliminating the need for post-mould processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insert surface is made bigger than the component body surface to ensure complete coverage, then the covering quality is improved, but production waste increases due to excess material that must be removed
Solution Approach 1:
The insert is pre-tautened within the mould cavity using a cursor mechanism before injection, ensuring it is properly positioned and tensioned. This preliminary action eliminates the need for post-mould cutting operations, as the insert edges are already precisely aligned with the component body outline, thus preventing material waste while maintaining covering quality
Solution Approach 2:
The traditional mechanical system of over-size insert + post-mould cutting is replaced by a pneumatic/hydraulic system using a cursor that applies controlled pressure to tauten the insert in-situ. This substitution allows precise positioning without excess material, eliminating the need for secondary cutting operations and reducing waste
2Manufacturing precision
If multiple processing phases including cutting and attachment stations are used to remove excess covering, then the component quality is improved, but processing costs and time increase
Solution Approach 1:
The patent merges the insert positioning, tautening, and edge alignment functions into a single integrated cursor mechanism that operates within the mould during the injection process. This consolidation eliminates the need for separate cutting and attachment stations, reducing processing time and improving productivity while maintaining component quality through precise in-mould positioning
Solution Approach 2:
The cursor mechanism serves multiple functions simultaneously: it positions the insert, tautens the covering material, aligns the edges with the component outline, and prevents material displacement during injection. This multi-functionality replaces what would traditionally require multiple separate processing stations, thereby reducing overall processing time and improving productivity
3Manufacturing precision
If the insert is blocked at its fastenings during mould closing, then the insert positioning is improved, but the complexity of the mould structure increases due to additional blocking mechanisms
Solution Approach 1:
The patent extracts the complex blocking mechanism from the mould structure and replaces it with a simple suction device that attaches the insert to the punch surface through vacuum pressure. This extraction simplifies the mould structure while maintaining precise insert positioning, as the suction device provides sufficient holding force without requiring additional blocking components
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 method reduces production waste and costs by producing a complete, ready-to-assemble component with no excess material removal required, as the edges are integrated within the moulded piece, streamlining the manufacturing process.
Implementation Method 1
the insert 24 is attached to the inside of the mould 4 by means of a suction device 44 able to create negative pressure between an attachment portion 48 of the insert 24 and the punch 32
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Moulding method of a component (8) with a component body (12) and at least one insert (24) able to be at least partially included in the component body (12). The method comprises the phases of making a first injection in a first injection chamber (36) separated from a second injection chamber (40) by means of the insert (24). Subsequently at least one hole is made in the insert (24) to place the second injection chamber (40) in communication with the first moulded portion (16) and a second injection of plastic material is made inside the second injection chamber (40). The material injected traverses at least- one hole so as to join the second moulded portion (20) to the first moulded portion (16) and to include the portion of insert (24) lodged in the second injection chamber (40).