Overmolding System Turret Block Transfer Mechanism
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Solution Overview
Problem
Current overmolding systems often require separate machines for forming and overmolding operations, which can increase cycle time and inefficiency, and lack a coordinated approach to move inserts between stations.
Innovation Solution
A system comprising an insert-forming station, an overmolding station, and a mold-moving assembly that cooperates with both stations to form and overmold inserts, with the mold-moving assembly facilitating the transfer of inserts between the two stations, allowing for overlapping operations to reduce cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate machines are used for forming and overmolding operations, then each machine can be optimized for its specific function, but the overall cycle time increases and system efficiency decreases
Solution Approach 1:
The patent combines separate forming and overmolding machines into a single integrated overmolding system that performs both operations sequentially in the same mold. The mold is configured to first form the insert, then overmold it with molding material, eliminating the need for separate machines and enabling overlapping operations to reduce cycle time
Solution Approach 2:
The mold serves multiple functions by first acting as a forming mold to create the insert, then as an overmolding mold to encapsulate the insert. This multi-functional approach allows a single mold to perform both forming and overmolding operations, improving system efficiency while maintaining functional optimization
2Device complexity
If forming and overmolding operations are performed sequentially in the same mold, then equipment complexity is reduced, but cycle time may increase without coordinated operation
Solution Approach 1:
The mold is prepared in advance with specific features that enable both forming and overmolding operations. The mold includes a cavity configured to receive molding material and form an insert, and is positioned on a platen that can be moved to coordinate with the injection molding machine, allowing seamless transition between operations
Solution Approach 2:
The system employs dynamic coordination between the mold positioner and injection molding machine through a controller. The mold can be moved between different positions (such as between a forming station and an overmolding station) and operations are timed to overlap, allowing the system to adapt its operation mode to minimize cycle time while maintaining simplicity
3Productivity
If a mold is moved between different stations, then operational flexibility and overlapping operations are enabled, but the system complexity increases
Solution Approach 1:
A mold positioner acts as an intermediary device between the forming station and overmolding station. This dedicated positioning mechanism coordinates the movement of the mold between stations and synchronizes with the injection molding machine operations, enabling flexible overlapping operations while managing system complexity through a specialized intermediary component
Data Source
Figure 1A
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AI summary
The present invention discloses a molding system having a turret block (moveable assembly) associated with a metal forming station and a overmoldmg station The metal forming station includes a collection of mold halves configured to only form an insert, and the overmoldmg station is only configured to overmold the insert After the insert is formed from the metal forming station, the turret is rotated ( 180°) to transfer the formed insert with one half of the forming mold to the overmoldmg station for forming a new overmoldmg cavity and a new insert forming cavity.