Movable Partition Injection Mould for Multi-Component Welding
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Solution Overview
Problem
The existing injection moulding processes for multi-component products, such as car door interiors, are inefficient due to high production costs and time requirements, particularly when dealing with components of different materials and colors, as they necessitate multiple moulds and assembly stations, and face challenges like material shrinkage and overheating blades.
Innovation Solution
A mould design featuring movable parts, including a sliding block and blades, that allows for the creation of multiple cavities within a single mould, enabling the injection and welding of multiple components in a single process, reducing the need for additional moulds and simplifying the internal structure, while avoiding the creation of physical third cavities, thus minimizing production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate moulds and assembly stations are used for multi-component products, then each component can be manufactured with high precision, but production time and costs increase significantly
Solution Approach 1:
The patent combines multiple separate moulding processes and assembly operations into a single integrated injection moulding process. Multiple components of different materials and colors are moulded simultaneously in one mould and assembled automatically during the injection process, eliminating the need for separate moulds and assembly stations, thereby significantly reducing production time while maintaining component precision
Solution Approach 2:
The injection mould is designed with multi-functional capabilities to perform multiple operations simultaneously. The mould can inject different materials into different cavities, form multiple components in various configurations (side-by-side, stacked, nested), and perform assembly operations all within a single device, replacing what previously required multiple specialized moulds and assembly equipment
2Device complexity
If blade moulding is used to reduce mould quantity, then production costs decrease, but blades overheat and expand causing interstices and jamming
Solution Approach 1:
The patent employs movable partitions that can dynamically change position during the injection process. These partitions move to create different cavity configurations (side-by-side, stacked, nested) and can be repositioned between injection cycles, allowing the mould to adapt to different production requirements without requiring multiple fixed moulds, thereby reducing device complexity while maintaining operational reliability
Solution Approach 2:
The patent changes the physical state and positioning parameters of the partition walls during the injection process. By controlling the movement and position of partitions at different stages, the mould can create various cavity arrangements and prevent overheating-related issues by optimizing material flow and cooling parameters dynamically
3Productivity
If translation moulding is used to reduce production time, then fewer assembly stations are needed, but material shrinkage causes coupling difficulties
Solution Approach 1:
The patent performs preliminary assembly actions during the injection process itself. Components are positioned and assembled while still in a molten or semi-molten state, allowing for automatic alignment and coupling before complete solidification. This preliminary assembly eliminates subsequent coupling difficulties that would arise from shrinkage, as the components are locked into place while more pliable
4Productivity
If rotation sandwich moulding is used to save time, then fewer assembly operations are required, but shrinkage still complicates coupling with the second matrix
Solution Approach 1:
The patent merges the moulding of multiple layers and components into a single integrated process. Instead of sequentially moulding layers in separate operations that require complex coupling, the invention moulds all layers and components simultaneously in one injection cycle, with internal partitions and movable walls creating the necessary cavity structures, thereby eliminating coupling complexity while maintaining time efficiency
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 enables the production of multi-component products with reduced production time and costs, improved adhesion between components, and the ability to create complex designs, while ensuring compatibility and recyclability of thermoplastic materials, by allowing for the injection and welding of multiple components in a single mould without the need for additional moulds or assembly stations.
Implementation Method 1
the movable parts are movable into a first configuration, in which at least two distinct mould cavities are made in the mould, and into a second configuration, where, once it has been achieved, they make at least a third cavity in the mould communicating with the other cavities
Implementation Method 2
injection of plastic materials into said cavities in succession or simultaneously
Implementation Method 3
successive or simultaneous injection of plastic materials into said cavities to form the successive or simultaneous components of the manufactured product
Data Source
Figure 1~3
Figure 2
Figure 4~7
AI summary
Method for moulding a multi-component manufactured product(l?) through. injection of plastic materials in a mould (5) comprising on the inside one or more movable parts,, characterised in that the movable parts are moved into a first configuration in which at least two distinct mould cavities (22, 24) are made in the mould, plastic material is injected into each of the two distinct mould cavities to form two components (12, 14b) of the manufactured product, the movable parts are moved into a second configuration, in which they make at least a third cavity (26) in the mould the walls of which at least partially consist of the two components already injected, plastic material is injected into the third mould cavity to form a third component (16) of the manufactured product that is thus welded to the first two.