Multi-Station Injection Mold With Transfer Mechanisms
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Solution Overview
Problem
Existing complex injection molding systems are inefficient, require significant space, and often involve multiple machines and robots to manage multiple molds, leading to inactive molding stations during the manufacturing process.
Innovation Solution
A mold with movable core and cavity sides and transfer mechanisms that allow simultaneous mold inputs at each station, enabling the creation of complex plastic parts with multiple components by transferring parts between stations along multiple planes, ensuring no station remains idle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple plastic injection machines and molds are used to manufacture complex plastic devices, then the manufacturing capability is improved, but the device complexity and space requirement increase significantly
Solution Approach 1:
The patent merges multiple molding operations into a single integrated mold with multiple stations. Each station can perform different molding operations simultaneously, eliminating the need for multiple separate injection machines and molds. This consolidation reduces system complexity while maintaining the ability to manufacture complex plastic devices with multiple materials and components.
Solution Approach 2:
The single mold is designed with multi-functionality, where each station can perform various molding operations including injection molding, assembly, and finishing. The mold serves multiple purposes simultaneously, reducing the need for specialized equipment for each operation and thereby reducing overall system complexity.
2Adaptability or versatility
If multiple plastic injection machines and molds are used to manufacture complex plastic devices, then the manufacturing capability is improved, but the space requirement increases significantly
Solution Approach 1:
The patent merges multiple molding operations into a single integrated mold with multiple stations. Each station can perform different molding operations simultaneously, eliminating the need for multiple separate injection machines and molds. This consolidation reduces system complexity while maintaining the ability to manufacture complex plastic devices with multiple materials and components.
Solution Approach 2:
The patent utilizes a multi-level or multi-dimensional arrangement of stations within the single mold. By organizing stations in three-dimensional space rather than requiring separate machines in linear arrangement, the design achieves high manufacturing capability within a compact footprint, significantly reducing space requirements.
3Adaptability or versatility
If complex molding systems with multiple stations are used, then the manufacturing capability is improved, but the efficiency decreases due to inactive stations
Solution Approach 1:
The patent implements a continuous cyclic process where stations operate in sequence rather than simultaneously. One station is injected while another is being emptied or is being prepared for the next cycle. This continuous operation ensures that all stations remain actively engaged in the molding process, eliminating idle time and maximizing productivity while maintaining the ability to manufacture complex devices.
Solution Approach 2:
The patent employs periodic action where stations cycle through injection, filling, assembly, and ejection operations in a coordinated sequence. This periodic operation allows each station to be actively utilized during different phases of the cycle, ensuring continuous productive action across all stations and improving overall system efficiency.
Data Source
AI summary
The invention is a method for preparing a finished part in a mold wherein the finished part includes n mold inputs, the method comprising the steps of (a) providing a mold having n mold stations, (b) simultaneously adding a mold input at each mold station to create a finished part and n−1 part portions, (c) removing the finished part and each part portion from each mold station, (d) transferring the finished part to a finished part holding area and transferring each part portion to a different mold station, and (e) repeating steps (b) through (d).