Movable Cavity Wall Injection Mold for Insert Edge Fixation
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Solution Overview
Problem
Existing methods for injection molding a plastic body onto an insert's edge region face challenges with dimensional stability and pressure during the process, often resulting in an uncontrolled push-away of materials, requiring complex multi-part molds to ensure a reliable connection.
Innovation Solution
A method involving an injection mold with a movable cavity-forming wall that exposes additional volume, allowing the polymer melt to first push one side surface of the edge region against the mold part, ensuring it is held until the cavity is filled, and then filling the exposed volume, eliminating the need for multiple movable parts and enhancing control over the melt flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-part injection mold is used to fix the edge region, then the connection reliability between insert and plastic body is improved, but the device complexity increases
Solution Approach 1:
The injection mold is divided into a fixed mold part and a movable mold part. The movable mold part can be displaced during the injection process to expose additional cavity volume, allowing the edge region to be held against the fixed mold part while enabling complete cavity filling. This segmentation resolves the contradiction by providing reliable edge region fixation without requiring a complex multi-part mold structure.
2Stability of the object's composition
If the edge region is held against the mold part during injection, then the dimensional stability is improved, but the pressure control during injection becomes more difficult
Solution Approach 1:
The movable mold part is designed to be displaced during the injection process, creating a dynamic system that adapts to the injection pressure. The movable part can move to accommodate pressure variations while maintaining edge region fixation, thereby resolving the contradiction between dimensional stability and pressure control by introducing controlled movement into the otherwise static mold structure.
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 ensures a strong and reliable connection between the insert and the plastic body, maintaining stability even if the edge region is partially pushed away, with the plastic body enclosing the insert on three sides, and can be applied to flexible or thin-walled materials.
Implementation Method 1
injecting a polymer melt into the cavity at an injection point, so that the polymer melt first flows onto the second side surface of the edge region, which faces away from the movable mould part, and pushes the first side surface of the edge region, which faces the movable mould part, onto the movable mould part
Data Source
AI summary
A method for producing a product comprising an insert part with an edge reinforced by a plastic body injection-moulded onto the edge includes: providing an injection moulding tool comprising a cavity, a cavity-forming wall formed by a movable tool part which is movable such that when the movable tool part is moved away, a volume of the cavity is released; inserting the insert into the injection moulding tool such that the edge region to be injection-moulded is arranged in the cavity of the injection moulding tool; injecting plastic melt into the cavity so that it flows against a lateral surface facing away from the movable tool part, and presses another lateral surface of the edge region facing the movable tool part against the movable tool part until the cavity is filled with the plastic melt; and moving the movable tool part away and filling the released volume of the cavity.