Two-Color Injection Mold Slide Mechanism for Simultaneous Material Bonding

Solution Overview

Problem

Conventional methods for producing two-color injection-molded parts are time-consuming and costly due to sequential injection processes and reduced adhesion strength between molding materials, as the second injection occurs after the first material has solidified.

Innovation Solution

A mold design with a slide mold that connects cavities when pressure exceeds a predetermined level, allowing simultaneous injection of different molding materials, where the first material infiltrates and bonds with an unsolidified portion of the second material during solidification, reducing cycle time and enhancing bonding strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If sequential injection process is used to produce two-color injection-molded parts, then the adhesion strength between molding materials is maintained, but the cycle time and manufacturing cost are increased

Engineering Contradiction:

Improveadhesion strength between molding materialsVSAvoidcycle time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The first molding material is injected and maintained in a semi-solidified state before the second injection, creating a preliminary bonding interface that enables strong adhesion while allowing simultaneous injection processes to reduce cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a movable partition wall that can dynamically adjust its position to control the flow and solidification of the first molding material, enabling the material to remain in an optimal bonding state during the injection process

Inventive Principle:

Principle #15Dynamics

2Strength

If sequential injection process is used to produce two-color injection-molded parts, then the adhesion strength between molding materials is maintained, but the manufacturing cost is increased

Engineering Contradiction:

Improveadhesion strength between molding materialsVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The first molding material is injected and maintained in a semi-solidified state before the second injection, creating a preliminary bonding interface that enables strong adhesion while allowing simultaneous injection processes to reduce cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a movable partition wall that can dynamically adjust its position to control the flow and solidification of the first molding material, enabling the material to remain in an optimal bonding state during the injection process

Inventive Principle:

Principle #15Dynamics

3Productivity

If simultaneous injection of different molding materials is used, then the cycle time is reduced, but the bonding strength between materials is reduced due to solidification

Engineering Contradiction:

Improveinjection speedVSAvoidbonding strength between materials

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The first molding material is injected and maintained in a semi-solidified state before the second injection, creating a preliminary bonding interface that enables strong adhesion while allowing simultaneous injection processes to reduce cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a movable partition wall that can dynamically adjust its position to control the flow and solidification of the first molding material, enabling the material to remain in an optimal bonding state during the injection process

Inventive Principle:

Principle #15Dynamics

4Productivity

If simultaneous injection of different molding materials is used, then the cycle time is reduced, but the adhesion strength between molding materials is reduced

Engineering Contradiction:

Improveinjection speedVSAvoidadhesion strength between molding materials

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The first molding material is injected and maintained in a semi-solidified state before the second injection, creating a preliminary bonding interface that enables strong adhesion while allowing simultaneous injection processes to reduce cycle time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a movable partition wall that can dynamically adjust its position to control the flow and solidification of the first molding material, enabling the material to remain in an optimal bonding state during the injection process

Inventive Principle:

Principle #15Dynamics

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 injection time by approximately 30% and increases bonding strength between materials, thereby decreasing manufacturing time and cost.

Implementation Method 1

a pressure difference between two kinds of molding materials, which are simultaneously injected, is induced so that one of the molding materials is infiltrated into and bonded to the other molding material during solidification

Methodology Applied

Scientific EffectPressure difference: Pressure Gradient

Data Source

PatentUS8858219B2Mold and method for producing two-color injection-molded parts

Publication Date: 2014.10.14 HYUNDAI MOTOR CO LTD

AI summary

A mold and a method for producing two-color injection-molded parts involves simultaneous injection of two kinds of molding material, in which a pressure difference between two kinds of molding materials is induced so that one of the molding materials is infiltrated into and bonded to the other molding material during solidification. The method for producing two-color injection-molded parts may include simultaneously injecting a first material and a second material to a first gate and a second gate to be filled in a first cavity and a second cavity, and closing the second gate such that the first molding material, which is not solidified, pushes a slide mold provided between a first mold block and a second mold block using a holing pressure of the first gate and is infiltrated into an unsolidified layer of the second molding material and solidified.