US20090065973A1 - Apparatus and method for manufacturing multi-component plastic molded parts - Google Patents

Apparatus and method for manufacturing multi-component plastic molded parts Download PDF

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Publication number
US20090065973A1
US20090065973A1 US12/243,609 US24360908A US2009065973A1 US 20090065973 A1 US20090065973 A1 US 20090065973A1 US 24360908 A US24360908 A US 24360908A US 2009065973 A1 US2009065973 A1 US 2009065973A1
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Prior art keywords
molds
platen
platens
cycle
parting planes
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Ludwig Jung
Marco Gruber
Andreas Reitberger
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KraussMaffei Technologies GmbH
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KraussMaffei Technologies GmbH
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Publication of US20090065973A1 publication Critical patent/US20090065973A1/en
Priority to US13/327,045 priority Critical patent/US8414813B2/en
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Assigned to KRAUSSMAFFEI GMBH reassignment KRAUSSMAFFEI GMBH MERGER (SEE DOCUMENT FOR DETAILS). Assignors: KRAUSSMAFFEI TECHNOLOGIES GMBH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1615—The materials being injected at different moulding stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/03—Injection moulding apparatus
    • B29C45/04—Injection moulding apparatus using movable moulds or mould halves
    • B29C45/0441—Injection moulding apparatus using movable moulds or mould halves involving a rotational movement
    • B29C45/045—Injection moulding apparatus using movable moulds or mould halves involving a rotational movement mounted on the circumference of a rotating support having a rotating axis perpendicular to the mould opening, closing or clamping direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1671—Making multilayered or multicoloured articles with an insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1615—The materials being injected at different moulding stations
    • B29C2045/1617—The materials being injected at different moulding stations using stack moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1615—The materials being injected at different moulding stations
    • B29C45/1628—The materials being injected at different moulding stations using a mould carrier rotatable about an axis perpendicular to the opening and closing axis of the moulding stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/32—Moulds having several axially spaced mould cavities, i.e. for making several separated articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • B29C45/561—Injection-compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/84—Safety devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/246—Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material

Definitions

  • the present invention relates to an apparatus and method for manufacturing multi-component plastic molded parts.
  • a preform is made from a first component in a first cavity.
  • the second component is molded onto the preform in a second cavity.
  • the individual components can be made of different thermoplastics and may have different colors. Certain components may also be provided with filler material. Instead of thermoplastic components, polyurethane (PUR) components can be provided. It is also known to manufacture multi-component plastic molded parts having a thermoplastic component and a PUR component.
  • German patent DE 196 50 854 discloses a method and an apparatus for manufacturing multi-component plastic molded parts using rotary table techniques.
  • An injection-molded plastic part is hereby coated with at least one layer of a 2-component thermoset. Both components are successively molded in the same mold in a cycle-synchronous manner.
  • a base plate is hereby used which carries two identical half-molds side-by-side. The base plate is supported for rotation about a horizontal and longitudinal machine axis.
  • Female molds of an injection molding machine and a RIM apparatus are arranged opposite the half-molds. After the injecting molding machine injects thermoplastic material, the base plate is rotated by 180° about the horizontal and longitudinal machine axis. In the next cycle, a new thermoplastic part is molded and the thermoplastic part of the first cycle is coated with the 2-component thermoset.
  • RIM apparatuses are known and essentially include conveying and metering devices for individual chemicals to be processed, such as polyol, polyisocyanate, and possible additives, such as dyes, foaming agents, etc.
  • a sliding table for the fixed half-mold is provided at the fixed side of the clamping unit in order to move the fixed half-mold from the position “injection molding” to the position “PUR molding”, and vice versa.
  • a carrier such as a carrier made of polyamide plastics is pre-molded.
  • the mold opens and the sliding table moves to the position “PUR molding”. After the mold closes, the PUR molding skin is injected into the enlarged cavity via the mixing head that is connected with the RIM mixing and metering unit.
  • a middle platen often called a reversing plate, is hereby rotatably supported between two outer platens. After the preform is produced in the first parting plane, the middle platen transports the preform to the second parting plane. There, the second component is molded onto the preform.
  • WO 03/013824 discloses manufacturing of multi-component plastic molded parts from a thermoplastic carrier and a PUR molding skin using the reversing plate techniques.
  • a machine frame movably supports two outer platens.
  • a supporting frame is mounted on the machine bed between the two outer platens.
  • a middle platen is supported for rotation about a vertical rotation axis.
  • the middle platen can be plate-shaped and receive two half-molds. Alternatively, the middle platen can be cube-shaped so as to receive four half-molds.
  • a suitable drive-and-locking-assembly can move the outer platens towards and away from the middle platen and lock the platens.
  • one of the outer platens can be coupled with an injection unit for the thermoplastic base component, and the other outer platen can be coupled with a RIM apparatus.
  • Handling robots such as a processing robot and a removal robot, can be provided to the side of the clamping unit.
  • the processing robot can treat the surface of the base component.
  • the base component is made of thermoplastic material and is injection-molded on the side of the injection unit.
  • the clamping unit is opened and the just molded base component is surface-treated.
  • the platen is rotated by 180°, and the half-molds are closed again.
  • thermoplastic base component is molded on the side of the injection unit, whereas, on the opposite side, a PUR reaction mixture is injected into the mold via a mixing head and a PUR skin is formed on the surface of the base component.
  • a method of making multi-component plastic molded parts using an apparatus which includes two outer platens with outer first half-molds, and a middle platen with middle second half-molds interacting with the first half-molds such as to define cavities in two parting planes for injection of a plastic melt and/or a PUR mixture, includes the steps of allowing one of the first and second half-molds to move in increments in relation to the other one of the first and second half-molds to thereby form different cavities in two parting planes from cycle to cycle, producing in a first cycle preforms in the cavities respectively formed in the two parting planes between respective ones of the first and second half-molds, holding the preforms in one of the first and second half-molds as the other one of the first and second half-molds moves in increments and injecting further components into the cavities formed in the two parting planes from cycle to cycle, and allowing from cycle to cycle to execute a pretreatment or another process
  • an apparatus for making multi-component plastic molded parts includes two outer platens having outer half-molds, a middle platen positioned between the outer platens, a clamping unit for closing and locking four of the half-molds of the outer platens and the middle platen at one time to thereby define two parting planes, wherein the middle platen carries at least two of a first type of half-molds that are different from each other and at least two of a second type of half-molds that are different from each other so as to successively form in the parting planes with the half-molds of the outer platens different cavities while leaving free half-molds for allowing pretreatment or a further process step, and wherein the outer half-molds are constructed for holding molded parts.
  • an apparatus for making multi-component plastic molded parts includes two outer platens, each having mounted thereon a plurality of half-molds, a middle platen positioned between the outer platens, a clamping unit for closing and locking four of the half-molds of the outer platens and the middle platen at one time to thereby define two parting planes, wherein the middle platen has a plurality of mold halves which are constructed to hold molded parts, wherein the outer platens move in increments in relation to the middle platen to thereby form, from cycle to cycle, different cavities in the two parting planes and leaving free half-molds for allowing pretreatment or a further process step.
  • the present invention resolves prior art shortcomings by allowing several production steps to be successively executed in both parting planes. This causes an increase in the cycle period. Still, as two molded plastic parts are produced in each cycle, the cycle period per molded part is less than when applying reversing plate techniques.
  • the thermoplastic preforms may be flooded with a PUR component.
  • the second thermoplastic component may be molded onto the preform.
  • the preform may be produced from a first PUR mixture and subsequently flooded with a second PUR mixture. Additional, different cavities may be formed and additional components may be added in further cycles. Additional thermoplastic components can be molded and/or additional PUR mixtures may be provided for flooding purposes.
  • Various pretreatments in the free half-molds of the middle platen may be made during the production process of the preforms and/or during the flooding or molding onto the preforms.
  • a mold release agent may be added into the free PUR half-mold or into the free PUR half-molds, for example via a spraying process. Furthermore, there is sufficient time for the mold release agent to vent, without causing an increase in the cycle period. Also, the mold release agent may be vented in a targeted manner, e.g., by using air to blow the PUR half-mold clear. Alternatively, PUR residues may be removed by cleaning the free half-molds, e.g., by means of rotating brushes or by means of a plasma process, etc.
  • the PUR half-molds may be dyed before the PUR addition.
  • the dye bonds with the subsequently introduced PUR material.
  • coated components can be produced in the mold (also known as In Mold Coating (IMC) process).
  • IMC In Mold Coating
  • varnish may be added into the free PUR half-mold for an In Mold Coating process while, in a first cycle, a plastic base component is molded. In the second cycle, PUR material is flooded between the base component and the coated PUR half-mold. In this manner, an additional surface finish (coat of varnish) may be realized cycle-synchronously with a 2-component process.
  • inserts and/or decoration materials such as fabrics, foils, etc. may be inserted and affixed for the subsequent processes.
  • a PUR coating may then be introduced between the insert (e.g., a foil) and the plastic carrier. It is hereby advantageous that the PUR material build up only a low internal mold pressure so as to be prevented from damaging the insert. This method is of particular advantage when sensitive decoration materials and varnished foils are involved.
  • the insert because of the insert, there is no need to add a mold release agent for the PUR half-mold. It is also possible to position the inserts only on areas of the surface of the PUR half-mold. This allows for production of a surface comprised of the insert material and the inserted PUR material.
  • the present invention is also advantageous with respect to producing a pair of plastic molded parts, comprised of a right part and a left part. Such a pair may be produced in each cycle if the right part is produced in the one parting plane and the left part is produced in the other parting plane. This can be done simultaneously and in the same cycle.
  • the middle platen may have a prism-shaped configuration with more than four mold platen areas.
  • the middle platen may be hexagonal or octagonal with six or eight mold platen areas, respectively.
  • Suitable combinations of injection units and PUR mixing heads are provided at the outer platens and/or the outer half-molds, depending on the application.
  • the production of multi-component plastic molded parts from a thermoplastic base component that is to be flooded with a PUR component may involve the provision of known injection units on the outer platens and their docking to the outer half-molds, while the mixing heads for flooding with a PUR mixture may be docked laterally at the outer half-molds, for example in an “L” position with respect to the respective injection unit or in a vertical position.
  • the mixing heads may be securely mounted on the half-molds or, using suitable robots, may be docked onto the half-molds, for example, only for the time period of flooding the preform with the PUR mixture.
  • a single PUR metering facility may supply the PUR mixture to multiple PUR mixing heads. Of course, it is also conceivable to provide each mixing head with its own PUR metering facility.
  • further injection units may be provided in an L-position, a piggyback position, or a vertical position, in addition to the injection units at the outer platens.
  • a suction or exhaust device may be provided above the area of the free half-molds of the middle platen and/or the outer platens.
  • FIG. 1 shows a perspective view of an injection molding machine in accordance with an exemplary embodiment of the present invention
  • FIG. 2 shows a perspective top view of a module frame of the injection molding machine of FIG. 1 ;
  • FIG. 3 shows a sectional view of a turntable or rotary table of the module frame illustrated in FIG. 2 ;
  • FIG. 4 is a schematic illustration of a starting position of a clamping unit, with confronting half-molds in open position;
  • FIG. 5 is a schematic illustration of the clamping unit in closed position, with the confronting half-molds being closed;
  • FIG. 6 is a schematic illustration of an opening movement of the clamping unit
  • FIG. 7 is a schematic illustration of a counterclockwise rotation of a middle platen of the injection molding machine of FIG. 1 to confront different half-molds;
  • FIG. 8 is a schematic illustration of the clamping unit in closed position, with the confronting half-molds of FIG. 7 being closed and locked;
  • FIG. 9 is a schematic illustration of removal of different finished components from the half-molds.
  • FIG. 10 is a schematic illustration of a clockwise rotation of the middle platen to confront different half-molds
  • FIG. 11 is a schematic illustration of a pretreatment at free half-molds
  • FIG. 12 is a schematic illustration of one parting plane remaining unused
  • FIG. 13 is another schematic illustration of one parting plane being unused
  • FIG. 14 shows a schematic illustration of an apparatus according to the present invention, having incorporated a safety device
  • FIG. 15 shows a schematic illustration of a variation of a rotatable middle platen
  • FIG. 16 shows a schematic illustration of an apparatus according to the present invention, having a linearly movable middle platen
  • FIG. 17 shows a schematic illustration of an apparatus according to the present invention, having a fixed middle platen and outer sliding tables.
  • FIG. 1 there is shown an injection molding machine 1 having a machine bed 35 , a fixed platen 2 , a movable platen 4 , and a cube-shaped middle platen 6 between the platens 2 , 4 .
  • the platens 2 , 4 support half-molds 3 , 5 , respectively, which, together with half-molds of the platen 6 , form cavities.
  • the movable platen 4 is moved towards or away from the platen 2 via tie-bars 8 that are extended through the fixed platen 2 .
  • a drive 10 to move the platen 4 , and injection units 7 , 9 .
  • the injection unit 7 is supported on a frame 11 which is mounted to the movable platen 4 , whereas the injection unit 9 is supported on the machine bed 35 .
  • a first PUR mixing head 12 is docked to the movable half-mold 5 and connected to a first PUR metering facility 13 .
  • a second PUR mixing head 14 is docked to the fixed half-mold 3 and connected to a second PUR metering facility.
  • the entire assembly comprised of the drive 10 and the platens 2 , 4 , 6 is supported on a module frame 20 , which, in turn, is mounted on the machine bed 35 of the injection molding machine.
  • FIG. 2 shows a perspective top view of details of the module frame 20
  • FIG. 3 shows a sectional view of a turntable 36 in the module frame 20
  • the module frame 20 supports a base plate 26 for movement in linear guides 22 .
  • the base plate 26 may be moved hereby in the longitudinal direction of the machine via hydraulic cylinder 24 or spindle drives or in some similar manner.
  • the base plate 26 supports the turntable 36 , which is rotatably supported on the base plate 26 via suitable bearings.
  • the upper side of the module frame 20 has sliding guides 28 for the movable platen 4 .
  • a strut 30 receives the fixed platen 2 .
  • Struts 32 , 34 close the module frame 20 to the outside and may, for example, support the plate of the drive.
  • the rotatably supported turntable 36 may be driven, for example, via a gear ring and an intermeshing bevel that meshes with the gear ring, as is known in international publication WO 01/10624 A1.
  • FIGS. 4 to 10 show schematic illustrations of the process sequence.
  • FIG. 4 shows a starting situation at the beginning of a cycle, in which the clamping unit of the injection molding machine is open. Subsequently, the clamping unit is closed by a closing movement, as indicated by the arrows, and then locked. This situation is shown in FIG. 5 .
  • the half-molds A 1 and A 2 now form a first cavity A 1 +A 2 in the first parting plane (parting plane A) for producing a preform of the component A.
  • the half-molds B 1 and B 2 form a first cavity B 1 +B 2 in the second parting plane (parting plane B) for producing a preform of the component B.
  • thermoplastic melt is injected into the thus-formed cavities, and preforms for the components A and B are produced.
  • a pretreatment may be performed in the free half-molds A 3 and B 3 via robots 16 and 17 and their gripper and pretreatment units 18 , 19 .
  • a mold release agent may be sprayed onto the surfaces of the half-molds A 3 , B 3 .
  • the clamping unit is opened by an opening movement ( FIG. 6 ), with the preforms remaining attached to the outer half-molds A 1 , B 1 .
  • the middle platen 6 is rotated by 90°, counterclockwise, as shown in FIG. 7 , or clockwise, as shown in FIG. 10 , and the clamping unit is closed and locked again, resulting in a situation as shown in FIG. 8 .
  • the half-molds A 3 , A 1 and the half-molds B 3 , B 1 now form new cavities, respectively, in which the thermoplastic preforms are situated.
  • the thermoplastic preforms can now be flooded with a PUR molding skin.
  • the clamping unit can be opened and the finished components A, B can be removed from the half-molds A 1 , B 1 .
  • FIG. 9 which also schematically shows that the components A and B are different.
  • the A component may be the left part and the B component may be a right part of a pair of plastic molded parts, such as the left and right door lining of a car door.
  • the middle platen 6 is rotated back by 90° and the clamping unit assumes its starting position again, as shown in FIG. 4 . A new cycle may now begin.
  • a suction device may be arranged outside the clamping unit above the lateral area of the half-molds A 3 , B 3 in FIG. 4 . This ensures that gases produced by the mold release agent gases and, optionally, varnish are exhausted to comply with safety guidelines, when the half-molds A 3 , B 3 are used PUR half-molds.
  • both components A and B be removed simultaneously.
  • only the parting plane B may be opened, and the parting plane A may be kept closed. This may be necessary if the PUR mixtures in the two parting planes A and B have different reaction times and/or if the thermoplastic components require different cooling periods. In this manner, the two components A and B may be removed by the same robot, which is successively moved into the parting planes A, B to the half-molds A 1 and B 1 .
  • the free half-molds may be cleaned.
  • PUR processing it is repeatedly necessary to clean the PUR half-molds, since PUR processing results in deposits on the mold surface.
  • Mold areas or mold-halves may be cyclically cleaned using a plasma process, for example. It is also possible to apply a varnish for an In Mold Coating process in this cycle. It is also possible to place inserts or decoration materials such as fabrics or foils in the free half-molds and to secure them there.
  • the finished component then comprises the two plastic components and the insert or the decoration material.
  • additional injection units may be provided in a known manner in an L-position, a piggyback position or a vertical arrangement on the two platens.
  • two different components may be produced (left component and right component), whereas, conventionally, two machines are necessary. Only one mold set having three half-molds per component is needed. In a standard reversing plate application, at least four half-molds are needed. As a result, the mold cost per component is significantly minimized.
  • Removal devices may be mounted on the fixed and/or the movable platen. It is further possible to mount a single removal device, e.g., a 6-axis-robot, on the middle platen. In this manner, one removal device can be used for both parting planes A and B.
  • a single removal device e.g., a 6-axis-robot
  • FIG. 11 shows schematically the presence of a heat pretreatment at the free half-molds A 2 , B 2 .
  • the two laterally positioned robots 16 , 17 have radiant heaters 35 , 36 by means of which heating fields 37 , 38 can be generated.
  • the radiant heaters 35 , 36 may perform a pretreatment of the entire areas or of partial areas of the free half-molds A 2 , A 3 , B 2 and B 3 , while, simultaneously, an injection molding process and/or a PUR molding process is performed in the respectively closed half-molds.
  • thermoplastic preform is flooded with a PUR mixture
  • preheating of the entire areas or of partial areas of the PUR half-molds A 3 , B 3 is advantageous because the PUR reaction may then be accelerated and improved PUR surfaces may be realized.
  • the PUR half-mold cools down again to a temperature that is preset by a medium for maintaining a temperature so as to carry off the reaction heat and to prevent the thermoplastic preform from excessively heating up.
  • FIGS. 12 and 13 show exemplary embodiments of the invention wherein one parting plane remains free.
  • a dummy mold 39 (B 1 D) is mounted on the fixed platen 2 in the parting plane of the half-molds B.
  • the half-molds B 2 , B 3 are not needed.
  • dummy molds 40 (B 2 D) and 41 (B 3 D) are mounted on the middle platen 6 .
  • the half-mold B 1 is not needed. However, it is also possible to replace all three half-molds B 1 , B 2 and B 3 with respective dummy half-molds B 1 D, B 2 D, and B 3 D.
  • the working plane may be continued to be operated with the A-molds and, simultaneously, the B-molds outside the injection molding machine may be examined or processed, e.g., to correct surface defects.
  • the dummy molds serve as place holders for the actual B-molds.
  • FIG. 14 shows an exemplary embodiment of the invention having a safety device.
  • the apparatus according to the invention is surrounded by a safety fence 43 on the operator side, and a safety fence 42 opposite to the operator side of the apparatus.
  • the safety fences 42 , 43 include safety doors 44 , 45 .
  • the two safety fences abut at positions 46 , 47 and may be connected with each other there so as to form a closed safety area.
  • only one safety fence may be provided that has one or more safety doors.
  • Parts of the injection molding machine may protrude from the safety fence where the safety fences abut (positions 46 , 47 ), for example parts of the respective plasticizing units.
  • additional safety measures may be provided.
  • light barriers 48 , 49 may be provided, which substantially include a light source 50 and a receiver or detector 51 , and which are connected to a control unit for the safety measures via wires (not shown).
  • a safety assembly 52 may be provided, for example two switches 52 a , 52 b arranged at a certain distance from each other and which only generate a release signal to operate the machine if they are actuated simultaneously. The distance of the two switches 52 a , 52 b is chosen such that the operator may actuate the switches 52 a , 52 b simultaneously only with spread arms.
  • FIG. 15 shows schematically an exemplary embodiment of a rotatable middle platen 60 , wherein more than four half-molds per parting plane are provided, namely A 2 , A 3 , A 4 and A 5 for the unillustrated half-mold A 1 , and B 2 , B 3 , B 4 and B 5 for the unillustrated half-mold B 1 .
  • FIG. 16 shows schematically an exemplary embodiment of the present invention having a linearly movable middle platen 61 that has two parallel platen areas, e.g., in the form of a rectangular mold mounting plate.
  • the half-molds A 2 , A 3 , . . . B 2 , B 3 , . . . may be affixed on both sides of this middle platen and may engage with the outer half-molds A 1 and B 1 so as to form different cavities from cycle to cycle.
  • the middle platen 61 is fixed with respect to the longitudinal direction of the machine, whereas the outer platens 62 and 63 with the outer half-molds A 1 and B 1 may be moved in the longitudinal direction of the machine.
  • the middle platen 61 is movable perpendicularly to the longitudinal axis of the machine, e.g., horizontally or vertically, so that, from cycle to cycle, the half-molds A 2 , A 3 . . . and B 2 , B 3 , . . . and the outer half-molds A 1 and B 2 may be brought together. It is also possible to provide a fixed outer platen and a movable outer platen, in which case the middle platen 61 is movable in the longitudinal direction of the machine.
  • FIG. 17 shows schematically another exemplary embodiment of the present invention, wherein the half-molds A 1 , B 1 are mounted on a fixed middle platen 66 , and wherein the additional half-molds A 2 , A 3 , . . . and B 2 , B 3 , . . . are mounted on outer sliding tables 64 and 65 .
  • the outer sliding tables 64 and 65 are movably mounted to the outer platens 62 and 63 and may be moved together with the outer platens 62 and 63 .
  • a suitable apparatus thus includes two outer platens having outer half-molds and a middle platen having intermediate or middle half-molds. Further, provided is a clamping unit for closing and locking four half-molds, wherein two parting planes are formed.
  • the half-molds are hereby arranged in such a manner that, from cycle to cycle, successively different cavities are simultaneously formed in both parting planes.
  • the A half-molds (A 1 , A 2 , A 3 , . . . ) are brought together, and in the other parting plane, the B half-molds (B 1 , B 2 , B 3 , . . .
  • the cavities A 1 +A 2 , A 1 +A 3 , A 1 +A 4 , . . . are formed, and, in the other parting plane, the cavities B 1 +B 2 , B 1 +B 3 , B 1 +B 4 , . . . are formed.
  • the A and B half-molds may be configured so as to produce identical or different molded parts.
  • a right part and a left part of a pair of molded parts may be involved, for example, such as parts of a door lining of an automobile.
  • injection units and/or PUR facilities may be provided which are docked onto or can be docked onto the platens and/or the half-molds.
  • the middle platen 6 may have at least two A half-molds (A 2 , A 3 , . . . ) that are different from each other and at least two B half-molds (B 2 , B 3 , . . . ) that are different from each other.
  • the outer half-molds A 1 and B 1 are mounted on the outer platens 2 , 4 , which can be embodied as classic mold platens, for example.
  • successively different cavities may be formed from cycle to cycle: A 1 +A 2 , A 1 +A 3 , . . . in the one parting plane and B 1 +B 2 , B 1 +B 3 , . . . in the other parting plane.
  • the half-molds are constructed in such a manner that they can hold the preforms in them.
  • the middle platen 6 may be rotatable.
  • the middle platen 6 may be cube-shaped or prism-shaped, and rotatable about a vertical or horizontal axis so that the different cavities may be formed from cycle to cycle in the two parting planes.
  • the middle platen may be plate-shaped or similarly shaped and includes two parallel platen areas, with the A half-molds (A 2 , A 3 , . . . ) relating to or assigned to the first A half-mold (A 1 ) being arranged on the one platen area, and the other B half-molds (B 2 , B 3 , . . . ) relating to or assigned to the first B half-mold (B 1 ) being arranged on the other platen area.
  • the middle platen 6 moves vertically with respect to the longitudinal axis of the machine, from cycle to cycle, so that, from cycle to cycle, different cavities can be formed in the two parting planes.
  • the functions of the middle platen 6 and the outer platen 2 , 4 can also be reversed. Accordingly, the first A half-mold A 1 and the first B half-mold B 1 are arranged on the middle platen 6 , whereas the other A half-molds (A 2 , A 3 , . . . ) are arranged on one of the outer platens 2 , 4 and the other B half-molds (B 2 , B 3 , . . . ) are arranged on the other one of the outer platens 2 , 4 .
  • the two outer platens 2 , 4 can be linearly moved in increments and/or rotated about a horizontal axis in increments so that different cavities are formed in both parting planes, from cycle to cycle.
  • the platens may be sliding tables or turntables which, in turn, may be mounted on the outer platens.
  • a suitable apparatus includes a fixed platen and a movable platen (the outer platens) arranged on a machine bed, between which the middle platen is moved on a sliding table in the longitudinal direction of the machine and between which the middle platen is pivotable around a vertical axis.
  • the middle platen is cube-shaped and carries four half-molds (A 2 , A 3 , B 2 , B 3 ). Two adjacent ones of these half-molds (A 2 , A 3 or B 2 , B 3 ) relate to or are assigned to an outer platen to form cavities of different size.
  • the outer half-molds are shaped in such a manner that the preform remains therein.
  • the middle platen is cube-shaped and carries four half-molds (A 2 , A 3 , B 2 , B 3 ). Two adjacent ones of these half-molds (A 2 , A 3 or B 2 , B 3 ) relate to or are assigned to an outer platen.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
US12/243,609 2006-04-06 2008-10-01 Apparatus and method for manufacturing multi-component plastic molded parts Abandoned US20090065973A1 (en)

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DE102006016200A DE102006016200A1 (de) 2006-04-06 2006-04-06 Verfahren und Vorrichtung zur Herstellung von mehrkomponentigen Kunststoff-Formteilen
PCT/EP2007/053264 WO2007113305A1 (de) 2006-04-06 2007-04-03 Verfahren und vorrichtung zur herstellung von mehrkomponentigen kunststoff-formteilen

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CN118493740A (zh) * 2024-07-08 2024-08-16 江苏施密特汽车部件科技有限公司 一种用于汽车零部件生产的注塑成型装置及方法

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Publication number Publication date
ATE514541T1 (de) 2011-07-15
WO2007113305A1 (de) 2007-10-11
US20120086141A1 (en) 2012-04-12
US8414813B2 (en) 2013-04-09
CN101400498B (zh) 2013-03-27
DE102006016200A1 (de) 2007-10-11
WO2007113305A9 (de) 2007-11-29
EP2004380A1 (de) 2008-12-24
CN101400498A (zh) 2009-04-01
EP2004380B1 (de) 2011-06-29

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