Rotating Mold Carrier for Multi-Component Plastic Injection
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Solution Overview
Problem
The existing methods for producing multi-component plastic moldings involve sequential manufacturing steps in two parting planes, leading to increased cycle time, and require multiple mold halves and complex machinery, which can be inefficient and costly.
Innovation Solution
A method and device utilizing a central mold carrier element with multiple mold halves that can be rotated and displaced to form different cavities in two parting planes, allowing for simultaneous production of two components per cycle with reduced tooling requirements and optimized cycle time, and incorporating features like in-mold coating and insert placement for enhanced surface finish and material integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If sequential manufacturing steps in two parting planes are used, then multi-component plastic moldings can be produced, but cycle time increases
Solution Approach 1:
The patent combines two separate sequential manufacturing steps into a single integrated injection molding process that produces multi-component plastic moldings in one cycle. The device integrates multiple cavities across two parting planes (first and second parting planes) that are simultaneously filled during one injection cycle, eliminating the need for sequential production and reducing cycle time while maintaining the ability to produce complex multi-component parts.
Solution Approach 2:
The injection molding device maintains continuous useful action by simultaneously filling multiple cavities in both parting planes during a single injection cycle. The mold halves and cavities are arranged such that all components are produced in parallel without interruption or sequential waiting, maximizing productivity and eliminating idle time associated with sequential manufacturing steps.
2Quantity of substance
If multiple mold halves and complex machinery are used, then multi-component plastic moldings can be produced, but tool costs increase
Solution Approach 1:
The injection molding device achieves multi-functionality by using a unified mold assembly with mold halves that can form multiple cavities across two parting planes. The same mold halves and injection system serve multiple purposes: producing different components (first and second components) with different materials (thermoplastic and PUR), different colors, and different properties all in one cycle, eliminating the need for separate dedicated tools for each component type.
Solution Approach 2:
The patent segments the mold into two parting planes with multiple cavities in each plane, allowing independent formation of different components. The first mold halves form cavities for first components while second mold halves form cavities for second components, enabling parallel production of multiple components with different materials and properties using a single integrated tooling system rather than multiple separate tools.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces cycle time per component, minimizes tool costs, and enables the production of complex parts like left-hand and right-hand pairs or main and accessory components with improved surface finishes and material integration, while maintaining safety and efficiency.
Implementation Method 1
a pre-moulded part is produced from a first component in a first cavity in a first cycle
Implementation Method 2
the second component is then injected onto this pre-moulded part in a second cavity
Data Source
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AI summary
A description is given of a method for producing multicomponent plastic mouldings, wherein two outer platens with outer mould halves and a central rotatable mould carrier element with at least four mould halves form cavities in two parting planes into which polymer melt and/or a PU mixture is injected. The invention is distinguished by the fact that at least two first mould halves (A2, A3) of the central mould carrier element, with different cavities, are brought together one after the other with the one outer mould half (A1) and at least two further mould halves (B2, B3) of the central mould carrier element, with different cavities, are brought together one after the other with the other outer mould half (B1), wherein the central mould halves (A2, A3, B2, B3) form different cavities one after the other in the two parting planes with the outer mould halves (A1, B1), wherein preforms are produced in the cavities (A1+A2, B1+B2) that are formed in the two parting planes in the first cycle and are held in the outer mould halves (A1, B1), and wherein the preforms are respectively provided with a further component in the cavities (A1+A3, B1+B3) formed in the two parting planes in a second cycle.