Multi-Layer Molded Tool Insert Production
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Solution Overview
Problem
Existing methods for producing inserts for tool cases, drawers, and assortment boxes are inefficient and costly, as they require separate production and assembly of layers, which can lead to errors and increased time and energy consumption.
Innovation Solution
A method for producing an insert in a single mold, where the insert is constructed from at least two layers, with the first layer being produced on the bottom of the mold and the second layer being produced on top of the first layer, allowing for reliable bonding without the need for adhesives and reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layers are produced separately and assembled with adhesives, then manufacturing flexibility is maintained, but production time and energy consumption increase
Solution Approach 1:
The patent combines multiple production steps (producing first layer, producing second layer, bonding layers) into a single integrated process within one mold. The first layer is produced in the mold, then the second layer is produced directly on top of it in the same mold without removal or adhesive application, eliminating separate assembly operations and reducing production time.
Solution Approach 2:
The first layer is produced and positioned in the mold in advance, creating a prepared surface that enables immediate production of the second layer. This preliminary positioning eliminates the need for subsequent alignment and adhesive application steps, directly reducing production time and energy consumption.
2Reliability
If layers are produced separately and glued together, then material selection flexibility is maintained, but assembly errors and production costs increase
Solution Approach 1:
The production and bonding operations are merged into a single integrated process. Both layers are produced in the same mold with direct contact between layers, eliminating the separate gluing operation and associated errors. The bonding occurs automatically during the production process itself.
Solution Approach 2:
The first layer's surface serves its dual function as both the finished surface and the bonding surface for the second layer. The surface is designed to enable direct bonding without requiring additional adhesive materials or complex assembly procedures, allowing the layer itself to facilitate its own bonding.
3Ease of operation
If a release agent is applied to the first layer, then the first layer can be removed from the mold, but bonding reliability between layers decreases
Solution Approach 1:
The patent eliminates the mold release step by keeping both layers in the same mold throughout production. The first layer never needs to be removed from the mold, so no release agent is required. This continuous in-mold production ensures direct, reliable bonding between layers without contamination from release agents.
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 method simplifies and cost-effectively produces inserts with layers of different materials, eliminating errors and reducing energy consumption, while ensuring reliable bonding and efficient clamping force for holding tools and small parts.
Implementation Method 1
the solidification of at least one surface of the first layer which is opposite the bottom of the mold
Implementation Method 2
it is sufficient that only the surface of the first layer, to which the second flowable material is applied, is sufficiently solidified
Implementation Method 3
the first layer and the second layer can bond reliably to one another... the first and second layers bond reliably without the addition of adhesive
Implementation Method 4
the second material is introduced onto the surface of the first layer and the second layer is produced by foaming the second material
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing an insert (10) for a tool case, a drawer, an assortment box or the like, in a mold, wherein the mold has substantially the dimensions of the finished insert (10), wherein the insert (10) has a top side, a bottom side and recesses extending from the top side for arranging small parts, tools and the like, and wherein the insert is constructed from at least two layers arranged one above the other and connected to one another, wherein the production of a first layer (14) of the insert is provided on the bottom of the mold and the production of a second layer (16) of the insert is provided in the mold on the first layer.