One Shot Molding Apparatus for Trim Component Rim Precision
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Solution Overview
Problem
Conventional methods for producing trim components with injection molded rims require two separate molding processes, leading to increased capital and labor costs, and often result in inconsistent and unpredictable rim dimensions due to material deformation during press molding.
Innovation Solution
A single 'one shot' molding apparatus that integrates press molding and injection molding in a single station, allowing for automated formation of a trim component with a uniformly dimensioned injection molded rim on one or multiple sides, without manual handling, and ensures precise cutting of the edge portion to prevent material deformation-induced variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two separate molding processes (press molding followed by injection molding) are used to produce trim components with injection molded rims, then the rim can be formed on the trim component, but capital costs and labor costs increase
Solution Approach 1:
The patent combines press molding and injection molding into a single integrated molding apparatus. The apparatus includes a press molding unit with upper and lower molds, and an injection molding unit with an injection mold that can be positioned around the press-molded trim component body. This integration allows both processes to occur in one station, eliminating the need for separate equipment and reducing capital and labor costs while maintaining rim dimension consistency through automated positioning and molding.
2Ease of manufacture
If material deformation during press molding is allowed to occur naturally, then the trim component can be formed, but rim dimensions become inconsistent and unpredictable
Solution Approach 1:
The patent performs preliminary cutting of the trim component body edge before the injection molding step. The cutting unit cuts the edge portion of the press-molded trim component body to a predetermined shape and size before the injection mold is positioned around it. This preliminary action ensures that the edge configuration is established early, preventing deformation-induced variations during subsequent steps, while the entire process remains automated without manual handling.
3Strength
If the trim component body is compressed during injection molding, then the injection molded rim can be formed, but material deformation occurs causing rim dimension variations
Solution Approach 1:
The patent employs dynamic positioning and selective compression control. The injection mold is positioned around the trim component body after the press molding step, and compression is applied only at specific locations and times during the injection molding process. This dynamic control ensures adequate bonding of the injection molded rim to the trim component body while preventing excessive compression that would cause material deformation and rim dimension variations.
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 production costs, ensures a neat and consistent edge configuration, and enhances the bonding of the injection molded rim by preventing material compression during injection molding, resulting in a more durable and aesthetically pleasing trim component.
Implementation Method 1
an injection molding material is injected through an injection channel into the injection molding cavity so as to form an injection molded rim onto an exposed part of an edge portion of the trim component body
Implementation Method 2
a sheet material is provided between a first mold tool and a second mold tool. The first and second mold tools are closed relative to one another, thereby press molding the sheet material in a press molding cavity defined between the first and second mold tools
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 2D~2E
AI summary
A one shot molding apparatus and method press mold a trim component body between upper and lower molds, and injection mold a plastic rim onto an edge of the trim component body using an additional edge molding tool, in a single molding apparatus in a single molding cycle. The edge molding tool may have a cutting edge that cooperates with a counter edge on the upper or lower mold to remove excess material and form a precise cut edge of the trim component body before forming the molded rim. The edge molding tool is movable relative to the upper and lower molds in a direction parallel or perpendicular or oblique relative to a motion direction of the upper and lower molds. Additional movable nested tools can be provided on the upper and/or lower mold to achieve greater adaptability of the injection molding cavity. The rim can be molded onto the cut edge, and molded around the edge onto the back and/or front side of the trim component body. The trim component may be a trim panel for the interior of a motor vehicle.