Multi-Cavity Mold Core Member for Integrated Vehicle Door Trim
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Solution Overview
Problem
The existing methods for manufacturing vehicle door trims are time-consuming and require multiple injection molding machines, as they involve thermally bonding or screwing together multiple pieces of injection molded plastic, which are made separately.
Innovation Solution
An apparatus comprising first and second molds with a core member that allows for simultaneous injection of different colored resins into interconnected cavities, where the core member blocks and unblocks fluid communication to create a single molded product, including a heater for mixing the resins, enabling the production of integrated vehicle door trim pieces in a single molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple pieces of injection molded plastic are thermally bonded or screwed together, then the vehicle door trim can be manufactured with different colors and designs, but the production time increases and multiple injection molding machines are required
Solution Approach 1:
The patent merges multiple injection molding operations into a single simultaneous operation by providing a multi-cavity mold with first, second, and third cavities. Different colored resins are injected simultaneously into these cavities through separate nozzles, and the resulting trim pieces are integrated into a single molded product, eliminating the need for sequential production and assembly of multiple pieces.
Solution Approach 2:
The mold is segmented into multiple independent cavities (first, second, and third cavities) that can be filled simultaneously with different colored resins. This segmentation allows each cavity to produce different colored trim pieces that are then integrated, achieving color variety without requiring multiple separate molding operations.
2Ease of manufacture
If multiple pieces are manufactured separately and then assembled, then each piece can be optimized for specific functions, but the manufacturing complexity and assembly requirements increase
Solution Approach 1:
The patent combines multiple separately manufactured trim pieces into a single integrated molded product by using a multi-cavity mold system. The first, second, and third cavities produce different functional components that are thermally bonded together during the same molding cycle, creating one piece that eliminates subsequent assembly operations while maintaining functional optimization.
Solution Approach 2:
The mold design incorporates preliminary positioning features and thermal bonding mechanisms that prepare and pre-position the different trim pieces during the molding process itself. The core member and its passage facilitate the thermal bonding of different cavities' outputs before ejection, performing the assembly action during manufacturing rather than as a separate subsequent step.
3Productivity
If a single molded product is produced, then production time is reduced and assembly is eliminated, but the complexity of the molding apparatus increases
Solution Approach 1:
The molding apparatus is segmented into multiple independent cavity systems (first, second, and third cavities with their respective nozzles) that operate simultaneously. This segmentation allows each cavity to be filled independently with different colored resins, enabling high productivity through parallel production while maintaining manageable complexity through modular design.
Solution Approach 2:
The core member acts as an intermediary element that facilitates the thermal bonding between different cavities. Its passage allows thermal energy to transfer and bond the trim pieces from different cavities together, enabling the integration of multiple pieces into a single molded product without requiring complex external assembly mechanisms.
4Adaptability or versatility
If different colored resins are injected simultaneously, then color variety is achieved in a single process, but the risk of resin mixing increases
Solution Approach 1:
The injection system is segmented into separate nozzles for each cavity, with the first nozzle injecting into the first cavity, the second nozzle into the second cavity, and the third nozzle into the third cavity. This spatial segmentation of injection paths prevents resin mixing during the injection process while allowing simultaneous injection of different colored resins, maintaining color separation precision.
Solution Approach 2:
The patent replaces mechanical assembly of different colored pieces with a thermal bonding process that occurs after simultaneous injection. The core member's passage facilitates thermal bonding that fuses the differently colored trim pieces together, eliminating the need for mechanical fastening and ensuring precise color boundaries without mixing.
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 reduces production time and eliminates the need for separate assembly by producing a single, integrated vehicle door trim from multiple pieces in a single molding process, allowing for different colors and improved resin mixing.
Implementation Method 1
The resins may further be heated during injecting of the third resin.
Implementation Method 2
The core member is slidable within the core passage to provide or block the fluid communication between the cavities
Data Source
AI summary
A first mold has a core passage, and first and second cavities in fluid communication with each other at the core passage. A second mold has first and second nozzles therein that inject first and second resins to the first and second cavities, respectively. The core member is slidable within the core passage to provide or block the fluid communication between the cavities, and has a third nozzle therein to inject a third resin to the core passage. The first and second resins are injected into the cavities. The core member is moved to block the fluid communication between the cavities, before injecting the first and second resins is completed. The third resin is injected while moving the core member to provide the fluid communication, after injecting the first and second resins is completed. The molds are separated, thereby yielding a single molded product, such as a vehicle door trim.