Rotary Injection Mold with Transfer Loader
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Solution Overview
Problem
Conventional rotary plastic injection molds require multiple successive injection operations, leading to laborious production cycles, increased maintenance costs, and precision loss due to part transfers between molds.
Innovation Solution
An integrated injection mold design with rotating stations and a transfer loader that allows for simultaneous injection and transfer within the same mold, eliminating the need for external part transfers and maintaining precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple successive injection operations are performed in separate molds with robot transfers, then complex multi-material parts can be produced, but production cycle time increases and precision is lost due to transfers
Solution Approach 1:
The patent combines multiple injection stations and transfer zones into a single integrated rotary mold system. The mold includes a first injection station, a second injection station, and transfer zones all mounted on a rotating carousel, allowing multiple injection operations to occur within one continuous cycle without external robot transfers, thereby reducing cycle time while maintaining multi-material production capability
Solution Approach 2:
The patent employs a rotary mold system where the mold rotates to dynamically position different stations at the working position. The rotation mechanism allows seamless transition between injection stations and transfer zones, enabling continuous multi-material part production with reduced idle time compared to static separate mold systems
2Adaptability or versatility
If part transfer robots are used to move preforms between molds, then production flexibility is improved, but maintenance costs and complexity increase
Solution Approach 1:
The transfer zones are integrated directly into the rotary mold structure, eliminating the need for external robot systems. The mold itself performs the transfer function through its rotation mechanism, reducing device complexity and maintenance requirements while maintaining production flexibility through the modular station design
Solution Approach 2:
The rotary mold system is self-sufficient, performing both injection and transfer operations within the same system. The mold rotates to automatically position preforms and parts at the appropriate stations, eliminating dependence on external robot systems and reducing maintenance burden
3Adaptability or versatility
If preforms are transferred between separate molds, then different injection operations can be performed, but docking precision is altered and accuracy is lost
Solution Approach 1:
Multiple injection stations and transfer zones are integrated into a single rotary mold, allowing different injection operations (e.g., preform injection, overmolding, insert injection) to be performed in sequence without removing the preform from the mold system. This maintains docking precision by keeping the preform in a controlled environment throughout the entire manufacturing process
Solution Approach 2:
The rotary mold dynamically positions the preform at different stations during rotation, allowing various injection operations to be performed while maintaining precise positioning. The continuous rotation ensures the preform remains securely held and properly oriented throughout the process, preserving docking accuracy
Data Source
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AI summary
The invention relates to an injection mold (1) comprising at least a first station (101) for injecting a first part of a part, at least a second station (102) for injecting a second part of a part, a first loader (5) comprising at least a first molding cavity (9), said first loader (5) being mobile at least in rotation between the first injection station (101) and a first transfer and/or assembly zone (T1), a second loader (6) comprising at least a first molding cavity (10), said second loader (6) being mobile at least in rotation between the second injection station (102) and a second transfer and/or assembly zone (T2), characterized in that the injection mold (1) comprises at least one transfer loader (7), mobile at least in rotation between the first transfer and/or assembly zone (T1) and the second transfer and/or assembly zone (T2).