Rotatable Injection Mold Center Block for Composite Blank Integration
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Solution Overview
Problem
Existing injection molding devices have limited capabilities for parallel production of composite products combining a blank and an injection-molded plastic component, particularly in mass production, and often result in undesired lateral laminar over-molding into cavity areas intended for the blank.
Innovation Solution
An injection molding device design featuring a center block with rotatable side faces carrying inner mold halves, clamping means to secure the blank, and a cage-like structure to prevent over-molding, allowing for efficient production of composite products with a combination of a cardboard or paper blank and injection-molded plastic component, using convex and concave recesses to clamp and shape the blank effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional injection molding device with fixed mold halves is used, then the structure is simple, but the productivity is limited and cannot achieve efficient parallel production
Solution Approach 1:
The mold is divided into multiple independent cavities (first cavity, second cavity, third cavity, fourth cavity) that can simultaneously form multiple composite products. Each cavity operates independently, enabling parallel production of multiple composite products in a single injection cycle, thereby significantly increasing productivity without requiring multiple separate molding devices.
Solution Approach 2:
The injection molding device combines multiple cavities and core components into a single integrated system. The first and second mold halves, along with multiple cores (first core, second core, third core, fourth core), are merged into one device that can simultaneously perform injection molding operations in multiple cavities, achieving efficient parallel production while maintaining structural coherence.
2Manufacturing precision
If liquefied plastic material is injected freely into the cavity, then the injection process is simple, but lateral laminar over-molding occurs into areas intended for the blank
Solution Approach 1:
The cavity is divided into distinct functional zones: the first cavity receives liquefied plastic material to form the plastic component, while the second and third cavities are designated for the blank. This segmentation prevents lateral laminar over-molding by ensuring that injected plastic material remains confined to its intended cavity area.
Solution Approach 2:
The core components (first core, second core, third core, fourth core) act as intermediaries that define the boundaries between different cavity areas. These cores physically separate the regions where plastic material should be injected from areas intended for the blank, preventing over-molding while maintaining clear demarcation between functional zones.
3Manufacturing precision
If the blank is placed without precise positioning, then the operation is simple, but the composite product quality is compromised due to inaccurate placement
Solution Approach 1:
The blank is pre-positioned in the second cavity before the injection molding process begins. This preliminary placement ensures that the blank is already in the correct position and orientation before liquefied plastic material is injected, eliminating the need for complex real-time positioning mechanisms during the injection process.
Solution Approach 2:
The cavity structure itself provides the positioning function through its geometric design. The second and third cavities are configured to automatically guide and secure the blank in the correct position, eliminating the need for external positioning devices or complex adjustment mechanisms, thereby maintaining ease of operation while ensuring high placement accuracy.
Data Source
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AI summary
The invention is directed to an injection molding device for manufacturing of composite products comprising a combination of a blank and an injection-molded plastic component, the product and a method of manufacturing of these composite products. The injection molding device comprising two outer mold halves displaceable along a first axis and a center block being arranged, with respect to the first direction, between the outer mold halves rotatable around a center axis perpendicular to the first direction. The center block carrying inner mold halves on at least one pair of side faces, which each form with outer mold halves in the closed position at least one cavity. The at least one cavity comprises at least one clamping means to clamp at least one blank, and in the closed position of the injection molding device forming at least one compartment to receive liquefied plastic material to form a plastic component interconnecting to the blank along at least one pair of adjacent edges.