Multi-Component Injection Mold Layout for Precise Sequential Forming
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Solution Overview
Problem
Existing injection molding devices for multi-component products are complex and inefficient, particularly in producing items like blood bags, beverage bags, and golf balls, which require precise integration of multiple components such as a bag, spout, and seal, or core and outer layers.
Innovation Solution
An injection molding device with a middle mold part between two outer mold parts, allowing for sequential injection of plastic materials into interconnected cavities, using a handling system to manage components and modules, and a rotating mechanism to form complex multi-component products efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate injection molding machines are used to produce multi-component products, then each machine can be optimized for specific components, but the overall device complexity and production time increase
Solution Approach 1:
The patent combines multiple injection molding machines into a single integrated device with a unified injection unit that can sequentially inject multiple components. The device features a single mold assembly with multiple cavities that can simultaneously or sequentially receive different plastic materials, eliminating the need for multiple separate machines while maintaining precise component integration through centralized control of the injection process
2Manufacturing precision
If multiple separate injection molding machines are used for multi-component products, then each component can be molded independently, but the production cycle time increases
Solution Approach 1:
The patent enables continuous production by allowing the injection of multiple components to occur in rapid succession within a single production cycle. The unified injection unit can switch between different plastic materials and inject them into different mold cavities without the setup time and transfer operations required when using multiple separate machines, thereby maintaining continuous useful action throughout the production process
Solution Approach 2:
The patent prepares multiple mold cavities in advance within the single mold assembly, each cavity pre-configured for a specific component. The injection unit is equipped with the capability to hold and switch between multiple plastic materials before the injection cycle begins, allowing all components to be molded in the correct sequence without delays for material changes or setup adjustments during production
3Device complexity
If a single injection molding device is used for multi-component products, then the device complexity is reduced, but the ability to handle different materials and components is limited
Solution Approach 1:
The patent designs the injection unit with universal capabilities to handle multiple types of plastic materials and configure the mold assembly to accommodate different component geometries. The single device can be programmed to perform various injection sequences and can switch between different material types, making it as versatile as multiple specialized machines while maintaining a simplified single-device architecture
Data Source
AI summary
An injection molding device with a middle mold part arranged in a first direction between first and second outer mold parts that are linearly movable with respect to the middle mold part in the first direction between open and closed positions. One or more side face regions of the middle mold part is configured to receive and hold in a lateral position a cavity module from outside of the injection mold during injection molding. A first cavity arranged in the cavity module at least in the closed position of the injection mold communicates with a first cavity half of a second cavity. At least one of the outer mold parts includes a second half of the second cavity, which interacts with the first half to form the second cavity to receive a liquefied plastic material and to form a second component interconnected to the first component.