Movable Mold Segmentation for Polymer Part Solidification
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Solution Overview
Problem
Current methods for manufacturing polymer parts, especially thicker ones, require large multi-cavity tools and long solidification cycles, leading to increased unit costs and the need for intermediate storage, which is undesirable for medical parts due to contamination and handling risks.
Innovation Solution
A method and system that uses a mold with movable parts to allow for simultaneous production of parts with different geometries and solidification times, reducing the need for large tools and intermediate storage by moving parts between injection and solidification cavities, enabling rapid production with compact tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large multi-cavity tools are used to produce thicker parts in very large series, then productivity is improved, but device complexity and tooling footprint increase
Solution Approach 1:
The mold is divided into two independent parts: a first mold part with injection cavities and a second mold part with solidification cavities. This segmentation allows thick parts to be produced in series through multiple solidification cycles, achieving high productivity without requiring a single complex multi-cavity tool.
Solution Approach 2:
The invention transitions from a single-plane mold structure to a two-stage process involving injection and solidification in separate mold parts. This dimensional and process separation enables serial production of thick parts while maintaining compact tooling footprint.
2Productivity
If intermediate storage of parts is implemented to balance production rates, then productivity is improved, but loss of substance increases due to packaging and handling
Solution Approach 1:
The system maintains continuous production flow by having the first mold part continuously inject parts into the second mold part for solidification. This eliminates interruptions and the need for intermediate storage, preventing material loss from packaging and handling while maintaining balanced production rates.
3Productivity
If intermediate storage and handling of parts are performed, then productivity is improved, but reliability decreases due to contamination risks
Solution Approach 1:
The direct transfer system maintains continuous production flow without intermediate storage, eliminating handling steps that could introduce contamination. This ensures high reliability by keeping parts in a controlled environment from injection through solidification to ejection.
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 approach allows for rapid production of parts with longer solidification times using simple tools, minimizing intermediate storage and handling, thus reducing contamination and handling risks, particularly beneficial for medical and pharmaceutical applications.
Implementation Method 1
moving one of the mold parts relative to the other, the part thus formed remaining connected to the second mold part
Implementation Method 2
forming a first part in a first injection cavity, moving one of the mold parts relative to the other, the first part remaining connected to the second mold part, closing the mold in a second position in which the two mold parts form at least one second injection cavity and a first solidification cavity in which the first part is placed, injecting material into the second injection cavity so as to form a second part and simultaneously solidifying the first part placed in the first solidification cavity
Data Source
Figure 1A~1D
Figure 2~3
Figure 4A1~4D2
AI summary
A method for producing parts from polymer in a mould comprising first and second mould portions that can be moved relative to each other, comprising: - closing (202) the mould in order to form a first injection cavity connected to an injection device by the first mould portion, - injecting (204) material into the first injection cavity in order to form a first part, - moving (206) one of the mould portions relative to the other, the first part remaining connected to the second mould portion, - closing (208) the mould to form: a second injection cavity connected to the injection device by the first mould portion, and a first solidification cavity in which the first part is disposed, - injecting (210) material into the second injection cavity to form a second part and simultaneously solidifying the first part disposed in the first solidification cavity.