Multi-Plate Injection Mold for Simultaneous Part Processing
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Solution Overview
Problem
Existing methods for producing multi-component parts with a functional part made of metal or metal alloy encapsulated in plastic are inefficient, resulting in increased cycle times due to the need for extensive mold reconfiguration and handling processes.
Innovation Solution
The injection mold design incorporates syringe mandrels and injection mandrels that form hollow-cylindrical mold openings with a central mold plate, allowing for simultaneous injection and removal of multi-component parts through two opening areas, reducing cycle time and enabling precise handling with a removal gripper and functional part carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional injection mold with single opening area is used, then the structure is simple, but the production cycle time increases due to sequential operations
Solution Approach 1:
The injection mold is segmented into multiple independent opening areas (first opening area and second opening area), each capable of independent operation. This allows simultaneous injection and removal operations to occur in parallel, reducing the overall production cycle time while maintaining manageable structural complexity through modular design
2Ease of operation
If functional parts are manually inserted into the mold, then the handling is simple, but the production efficiency decreases
Solution Approach 1:
The system employs automated functional part carriers that self-load functional parts from storage and automatically position them in the mold openings. The removal gripper similarly autonomously extracts finished multi-component parts. This automation eliminates manual intervention while maintaining ease of operation through programmable control, significantly boosting production efficiency
3Adaptability or versatility
If extensive mold reconfiguration is performed between cycles, then the mold can accommodate different functional parts, but the cycle time increases
Solution Approach 1:
The mold design incorporates dynamically adjustable elements including movable mold plates and interchangeable inserts that can be quickly reconfigured between production cycles. The functional part carriers are similarly designed to adapt to different functional part geometries. This dynamic flexibility allows rapid changeover without extensive reconfiguration, maintaining versatility while minimizing cycle time extension
Data Source
Figure 1~2
Figure 3~4
AI summary
A device (1) for injection molding a plastic molded part (2) onto a functional part (3) to form a multi-component part (4) has an injection mold (5) which has a mold opening for partially receiving the functional part (3). The injection mold (5) in turn has at least three mold plates (6a, 6b, 6c) which are adjustable between a closed injection position and a machining position with the mold plates (6a, 6b, 6c) spaced apart from each other. A functional part carrier (13) is provided between a functional part supply (12) and a first opening area (7a) between two mold plates (6b, 6c) in their processing position for transferring the functional parts (3) from the functional part supply (12) to one of the mold plates (6c), as well as a removal gripper (19) for removing the multi-component part (4) from a second opening area (7b) between two mold plates (6a, 6b) (Figure 3).