Overmolding Insert System with Overlapping Mold-Moving Assembly
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Solution Overview
Problem
Existing overmolding processes for inserts often require sequential execution of forming and overmolding operations, leading to increased cycle time, floor space, capital costs, and auxiliary operations, which can hinder efficient production.
Innovation Solution
A system that integrates a mold-moving assembly to overlap the operations of the insert-forming and overmolding stations, allowing for simultaneous or near-simultaneous execution of these processes, thereby reducing cycle time and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential execution of forming and overmolding operations is used, then equipment simplicity is maintained, but cycle time increases and productivity decreases
Solution Approach 1:
The patent combines the insert-forming station and overmolding station into a single integrated system with a shared mold assembly. The mold can perform both forming and overmolding operations without complete disassembly, allowing sequential operations to be merged into a coordinated process that reduces cycle time while maintaining manageable system complexity through modular design.
Solution Approach 2:
The system employs dynamic reconfiguration of the mold assembly between forming and overmolding stations. The mold can be rapidly repositioned and reconfigured for different operations, allowing the system to adapt dynamically between operations rather than requiring static dedicated equipment for each process step.
2Area of stationary object
If sequential execution of operations is used, then equipment simplicity is maintained, but floor space and capital costs increase
Solution Approach 1:
The mold assembly is designed as a universal component that can perform multiple functions - serving as both the forming mold and the overmolding mold. This multi-functionality eliminates the need for separate dedicated molds and equipment for each operation, reducing floor space requirements while the modular design keeps system complexity manageable.
Solution Approach 2:
By merging the forming and overmolding operations into a single integrated system with shared equipment and mold assemblies, the patent reduces the total floor space required compared to having separate sequential operations. The shared resources and coordinated process flow minimize space requirements while maintaining operational effectiveness.
3Loss of time
If sequential execution of operations is used, then process simplicity is maintained, but cycle time increases
Solution Approach 1:
The system prepares the mold assembly in advance for the next operation while the current operation is completing. During the cooling phase of one operation, the mold is pre-positioned and pre-configured for the subsequent operation, eliminating idle transition time and reducing overall cycle time without requiring overly complex automated systems.
Solution Approach 2:
The patent maintains continuous useful action by overlapping operations - while the insert is cooling in the forming station, the mold is being repositioned to the overmolding station. This overlapping of operations ensures that equipment is continuously productive rather than idle between steps, reducing cycle time while keeping the system design practical.
Data Source
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AI summary
Disclosed is a system. The system includes a mold-moving assembly that is cooperative with an insert-forming station to form an insert at least in part. The mold-moving assembly is also cooperative with an overmolding station to overmold another insert previously formed by the insert-forming station in cooperation with the mold-moving assembly. The mold-moving assembly, when so actuated, moves inserts between the insert-forming station and the overmolding station. Operation of the insert-forming station and operation of the overmolding station overlap one another at least in part.