Segmented Punch for Compression-Molded Parts With Injection Cavities
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Solution Overview
Problem
The existing methods for producing molded parts with openings, such as motor vehicle paneling components, require precise positioning of the blank, which is time-consuming and expensive, and often result in increased weight when larger openings are made to accommodate complex functional elements.
Innovation Solution
A device with movable upper and lower tools, where the stamping section can be fastened or separated from the receiving section, allowing for the creation of openings without precise blank positioning, enabling direct injection molding of functional elements onto the blank within the formed injection molding cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the blank is positioned precisely in the device, then the transition and connection between the blank and injection-molded functional elements are secure, but the production process becomes time-consuming and expensive
Solution Approach 1:
The device is segmented into two independent functional systems: (1) a compression molding system with upper and lower tools for forming the blank, and (2) an injection molding system with injection nozzle and cavity for creating functional elements. This segmentation allows each system to operate independently without requiring precise positioning between them, resolving the contradiction between connection reliability and positioning time.
Solution Approach 2:
The invention introduces an intermediary mechanism - the injection-molded functional elements themselves - that directly connects to the compression-molded blank. The functional elements act as a bridge between the two molding processes, establishing secure connections without requiring precise pre-positioning of the blank, thus eliminating time-consuming positioning steps while maintaining connection reliability.
2Adaptability or versatility
If the opening is made larger to accommodate complex functional elements, then the functional requirements are met, but the weight of the molded part increases
Solution Approach 1:
The invention changes the parameter of opening size dynamically based on functional requirements. The injection molding process allows functional elements to be created with varying sizes and complexities directly within the compression-molded blank, enabling large-area openings when needed without permanently increasing the base weight of the molded part structure. The functional elements are precisely formed only where required.
3Productivity
If the number of work steps is reduced for cost-effective production, then the production efficiency increases, but the precision and quality of the molded part may be compromised
Solution Approach 1:
The invention merges two previously separate processes (compression molding and injection molding) into a single integrated device and process flow. The compression molding of the blank and the injection molding of functional elements occur in sequence within the same device without requiring intermediate positioning or transfer steps. This merging maintains high precision for both processes while improving productivity by eliminating redundant work steps.
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 simplifies and cost-reduces the production process by eliminating the need for exact blank positioning, allows for larger-area openings, and facilitates the injection of functional elements directly onto the boundary surfaces, while maintaining the lightweight advantage of molded parts.
Implementation Method 1
The injection molding cavity is filled with an injection-mouldable plastic and is cured, so that the functional elements are injected directly onto the blank
Implementation Method 2
the upper tool and the lower tool being movable relative to one another in order to bring the molded part into the desired shape
Data Source
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AI summary
The present invention relates to a device for producing a compression molded part (38) having at least one opening, comprising an upper tool (12) and a lower tool (14), wherein the upper tool (12) and the lower tool (14) are movable relative to each other in order to bring the compression molded part (38) into the desired shape, the upper tool (12) or the lower tool (14) forms a punch (16) for providing the opening of the compression molded part (38), and the punch (16) comprises a receiving section (18) and a punch section (20), the punch section (20) being optionally attachable to the upper tool (12) or to the lower tool (14) by a locking device (22), and the punch section (20) forming an injection molding cavity (30) with the receiving section (18) when the punch section (20) is attached to the receiving section (18). The invention also relates to a corresponding method.