Co-moulded Reflective Edge Mudguard Injection Moulding
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Solution Overview
Problem
Existing mudguards for industrial vehicles face issues with reflective edges detaching due to environmental factors and co-moulding causing distortions and visible imperfections.
Innovation Solution
A method of injection moulding a mudguard with a precise sequence using a mould shaped as a circular crown, injecting a main body and a contrasting side edge in different materials, ensuring even distribution and precise dimensional control to maintain reflective capacity and aesthetic quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If reflective strips are glued along the outer edge of the wheel guard, then the outline visibility is improved, but the strips come unstuck over time due to water, mud, pebbles, and atmospheric elements
Solution Approach 1:
The patent merges the reflective function with the mudguard structure by co-moulding the reflective edge directly into the mudguard body. This integration eliminates the adhesion problem of glued strips while maintaining high visibility through the reflective properties of the integrated edge.
Solution Approach 2:
The patent uses composite materials by incorporating reflective particles or layers into the moulding process. The edge is created with a composition that includes reflective elements mixed with the base material, providing both structural integrity and reflective visibility without requiring separate adhesive applications.
2Illumination intensity
If the edges are painted with high-visibility colours, then the reflective capacity is improved, but the paint deteriorates and detaches from the body over time
Solution Approach 1:
The patent combines the reflective coating function with the structural moulding process. Instead of applying paint separately, the reflective properties are integrated into the moulding itself, eliminating the deterioration and detachment issues associated with painted surfaces.
Solution Approach 2:
The patent changes the parameter of how reflectivity is achieved - from surface coating (paint) to bulk material property (co-moulded reflective particles or layered structure). This fundamental parameter change ensures the reflective capacity is inherent to the material structure rather than a removable surface layer.
3Reliability
If co-moulding is used to obtain the reflective edge, then the reflective capacity is maintained, but significant distortions occur due to the wide arched shape and reduced thickness
Solution Approach 1:
The patent segments the moulding process into multiple stages or uses a multi-cavity mould design. By dividing the moulding operation, the process can accommodate the wide arched shape with reduced thickness without causing distortions, while still achieving co-moulded reflective edges in each segment.
Solution Approach 2:
The patent employs preliminary actions in the mould design, such as pre-formed inserts or pre-positioned reflective materials within the mould cavity. This preliminary preparation allows the subsequent moulding process to achieve precise geometrical accuracy without distortions, even for complex arched shapes.
4Manufacturing precision
If precise dimensional control is implemented, then the component size is controlled, but injection points and moulding streaks become visible imperfections
Solution Approach 1:
The patent extracts or removes the visible injection points and streaks from the finished product. This is achieved through mould design features such as hidden injection gates, sub-surface injection points, or post-moulding extraction processes that eliminate visible imperfections while maintaining precise dimensional control.
Solution Approach 2:
The patent uses intermediary elements in the moulding process, such as mediator materials or intermediate processing steps, to prevent the formation of visible injection points and streaks. These intermediaries allow the material to flow and set in a way that masks or eliminates surface imperfections while achieving precise dimensions.
Data Source
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AI summary
A method for injection moulding of a vehicle mudguard (4) comprising the steps of: - providing a mould (8) for making a mudguard (4), said mould (8) delimiting an injection chamber (12) having the substantial shape of a circular crown around a central axis (X-X), the injection chamber (12) extending from an inner side (16) to an outer side (20), parallel to said central axis (X-X), - preparing a first injection site (32) for injection of a main body (36) of the mudguard (4) with a first material and/or a first colour, - arranging a second injection site (40) for injection of a side edge (44) in a second material and/or a second colour different from the first material and/or first colour of the main body (36), - wherein the first and second injection sites (32,40) are arranged at said opposite inner and outer sides (16,20) respectively, - wherein the method comprises the step of first injecting the main body (36) and then the side edge (44) from the respective injection sites (32,40).