WO2002020240A1 - Procede et dispositif pour le formage sous pression - Google Patents

Procede et dispositif pour le formage sous pression Download PDF

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Publication number
WO2002020240A1
WO2002020240A1 PCT/US2000/023909 US0023909W WO0220240A1 WO 2002020240 A1 WO2002020240 A1 WO 2002020240A1 US 0023909 W US0023909 W US 0023909W WO 0220240 A1 WO0220240 A1 WO 0220240A1
Authority
WO
WIPO (PCT)
Prior art keywords
substrate
forming
injection molding
cutting
injection
Prior art date
Application number
PCT/US2000/023909
Other languages
English (en)
Inventor
Kurt F. Eschenfelder
Loren R. Johansen
Michael D. Mcelhatton
Robin J. Reis
Michael J. Ruminski
Daniel L. Dunst
Original Assignee
Serigraph, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Serigraph, Inc. filed Critical Serigraph, Inc.
Priority to PCT/US2000/023909 priority Critical patent/WO2002020240A1/fr
Priority to AU2000270950A priority patent/AU2000270950A1/en
Priority to AU2001226363A priority patent/AU2001226363A1/en
Priority to PCT/US2001/000607 priority patent/WO2002020241A1/fr
Publication of WO2002020240A1 publication Critical patent/WO2002020240A1/fr

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Classifications

    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/40—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
    • 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • B29C2045/14245—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity using deforming or preforming means outside the mould cavity
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • 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
    • B29C45/40—Removing or ejecting moulded articles
    • B29C45/42—Removing or ejecting moulded articles using means movable from outside the mould between mould parts, e.g. robots
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3431—Telephones, Earphones

Definitions

  • the present invention relates generally to in-mold decorating methods and apparatus for manufacturing deep-drawn injection molded pieces with printing thereon, sometimes called applique products, and more particularly to a pressure forming method and apparatus for use in an injection molding machine to simultaneously perform the multiple functions of forming, cutting, and molding of deep-drawn injection molded pieces.
  • In-mold decorating is known in the prior art.
  • a substrate may be printed or decorated by applying ink thereto to provide a desired graphic, such as lettering, designs, logos, etc.
  • the printed substrate can then be pattern-cut, e.g. by die cutting, to define the perimeter of a product, remove excess material, or provide cut-outs.
  • the printed and pattern-cut substrate is then sent to a former, where the substrate is typically manually fed into a forming machine for forming the substrate into a product shape.
  • the formed substrate is then typically manually fed into an injection molding machine for molding the formed part.
  • molten resin is injected into a closed mold containing the printed and pattern-cut substrate.
  • the mold is allowed to cool and then opened to yield an injection molded piece integral with the substrate. Further cutting of the substrate may be performed during or after the injection molding process.
  • Various printing layers, decorative graphics, or overlays may be applied to the substrate through known printing methods to yield the final decorated injection molded product.
  • the pattern-cutting step also separates the pieces from the web to provide separate individual pieces which are typically individually loaded into the for ⁇ jng> machine and merrrrjection molding machine.
  • An example of a forming machine for producing deep-drawn formed plastic pieces is shown in U.S. Patent Nos. 5,108,530 and 5,217,563 to Niebling et al. The forming machine disclosed in these patents is used for deep-drawing decorated plastic sheets by placing the sheets into a mold, closing the mold, injecting compressed air into the mold, and opening the mold to remove the formed pieces.
  • the fluid pressure medium is applied directly to the sheet material, while the sheet is molded against the protruding portions of the mold cavity.
  • the forming is conducted at an operating temperature below the softening temperature of the sheet material and at a fluid medium pressure of more than 20 bars.
  • the formed pieces may then be placed into an injection molding machine where resin may be injection molded onto the deep-drawn pieces.
  • the multi-purpose processing apparatus of the present invention allows for multiple operations to be performed within the injection molding machine, eliminating the need for a separate forming or cutting machine.
  • the present invention provides an improvement on our earlier invention described in U.S.
  • Patent Application Serial No. 09/411,292 entitled, “Multi-Purpose Processing Apparatus,” the disclosure of which is incorporated herein by reference.
  • the purpose of the earlier invention is for forming shallower parts using a two-sided, matched face, forming tool.
  • the clamping pressure of the injection molding machine is used for closing the forming tool, and thus forming parts with the closing pressure of the forming tool.
  • the earlier invention concentrates on producing parts with shallow draw depths and planar geometries with gentle radii.
  • the present invention provides the inclusion of a pressure forming apparatus on an injection molding machine for reducing the manufacturing costs associated with manufacturing deep-drawn injection molded decorated parts.
  • the present invention utilizes a different method and apparatus for forming deep-drawn decorated parts.
  • the present invention uses a forming tool having a forming chamber on one side and a pressure chamber on the other side, which is in communication with a pressure medium.
  • forming is accomplished by injecting the pressure medium into the pressure chamber to form the part on a forming surface of a removable forming tool insert attached to the first part of the forming tool.
  • the clamping pressure of the injection molding machine is used to contain the pressure medium in the pressure chamber.
  • the pressure forming method and apparatus of the present invention provides the ability to produce complex three-dimensionally shaped parts with deeper draws.
  • the present invention eliminates the individual loading of separate pieces into the mold, significantly reducing loading time and hence reducing cycle time, which in turn increases efficiency and through-put, further reducing manufacturing costs.
  • the present invention enables the substrate to be loaded into the apparatus in a single insertion step.
  • the present invention provides a multi-purpose processing apparatus which is able to perform both a forming operation and an injection molding operation on an injection molding machine.
  • the apparatus of the present invention eliminates the need for a separate forming machine and combines the distinct steps of forming, cutting and injection molding into one machine.
  • the multi-purpose apparatus results in a process, which combines the three steps of forming, cutting and injection molding into one continuous operation performed within the injection molding machine.
  • the apparatus allows the three steps of forming, cutting and molding to be performed simultaneously as parts are fed into the multi-purpose apparatus. It also eliminates the manual handling of the parts between steps.
  • the pressure forming apparatus is built into a substantially conventional injection molding machine.
  • the forming apparatus is preferably mounted to a quick change mounting plate, but may be mounted directly to both platen surfaces of the injection molding machine.
  • the apparatus has a first portion which performs the forming operation and a second portion which performs the cutting and molding operation.
  • the forming operation is typically done by pressure forming.
  • the forming operation utilizes unused space within the injection molding machine, as well as the clamping pressure already supplied by the injection molding machine.
  • Cutting of a substrate on the apparatus of the present invention may take place prior to forming, during forming, between forming and molding, during molding, and/or after molding.
  • the cutting operation is optional.
  • the apparatus may be set up to perform a cutting operation at virtually any time during the process. However, a cutting operation is preferably performed between forming and molding.
  • the process begins with a sheet or web of printed material being fed into the multi- purpose processing apparatus by a feed system. After a portion of the sheet or web is formed, it is advanced to a cutting and/or molding operation within the injection molding machine. As the formed portion is cut and/or molded, a new portion is advanced to the forming operation and formed simultaneously with the portion being cut and/or molded.
  • the cutting and/or molding operation can be set up to either cut the sheet or web prior to molding or as part of the molding process. The process continues, forming multiple finished parts without having to manually handle the parts between processing steps.
  • the present invention eliminates many of the steps by allowing the sheet or web of printed material to flow directly between a forming process, a cutting process, and/or a molding process, without any manual intervention. Therefore, the typical steps required for'an in mold decorated part before the part gets to an injection molding machine, i.e., forming and cutting, are not necessary. Separate forming, cutting and injection molding operations are no longer required, as these operations are performed within the same injection molding machine.
  • the forming apparatus includes a forming tool having a first part on the forming chamber side and a second part on the pressure chamber side opposite the forming chamber side. Both parts of the forming tool include openings extending therethrough to provide a path for a pressure medium to be applied to the pressure chamber to form a substrate or web material on the surface of the first part.
  • the first and second parts of the forming tool have designated surfaces that face each other for engaging the substrate or web material between the designated surfaces and forming a seal when the forming tool is closed by the clamping pressure of the injection molding machine.
  • the closed forming tool creating a pressure chamber where a pressure medium is injected into the pressure chamber through the openings in the parts of the forming tool to force the substrate or web material against the surface of the first part in the forming chamber of the forming tool.
  • FIG. 1 is a top view of a substrate with printing thereon prior to forming, cutting and molding in accordance with the method and apparatus of the present invention
  • FIG. 2 is a perspective view of the substrate of FIG. 1 after forming in accordance with the method and apparatus of the present invention
  • FIG. 3 is a cross-sectional view of the formed substrate taken along line 3-3 of FIG. 2;
  • FIG. 4 is a perspective view of the substrate of FIG. 2 after cutting and molding in accordance with the method and apparatus of the present invention;
  • FIG. 5 is a cross-sectional view of the molded substrate taken along line 5-5 of FIG. 4;
  • FIG. 6 is a side view of an injection molding machine including a multi-purpose processing apparatus constructed according to a first embodiment of the invention;
  • FIG. 7 is a side view of an injection molding machine including a multi-purpose processing apparatus constructed according to a second embodiment of the invention.
  • FIG. 8 is a side view of the forming tool of the apparatus of FIGS. 6 and 7 in an open position prior to forming a substrate;
  • FIG. 8 A is a more detailed view of the forming tool of FIG. 8;
  • FIG. 9 is a side view of the forming tool of FIG. 8 in a closed position clamping a substrate between the halves of the forming tool;
  • FIG. 10 is a side view of the forming tool of FIG. 9 in a closed position forming the substrate; and FIG. 11 is a side view of the forming tool of FIG. 10 in an open position releasing the formed substrate to the cutting and injection molding portions of the apparatus.
  • the present invention pertains to a multi-purpose processing apparatus mounted to an injection molding machine, shown generally in FIGS. 6 and 7.
  • the multi-purpose processing apparatus is able to perform forming operations, cutting operations, and injection molding operations simultaneously for manufacturing in-mold decorated parts on an injection molding machine.
  • Using the method and apparatus of the present invention eliminates the need for a separate forming machine, and eliminates the pre-injection molding steps and costs associated with using such a machine for making in-mold decorating parts.
  • an injection molding machine 10 including a multipurpose processing apparatus 12 constructed in accordance with a first embodiment of the invention.
  • the injection molding machine 10 is one as is known in the art, such as those manufactured by Van Dorn Demag Corporation, Cincinnati Milacron, Inc., or Engel Machinery, Inc.
  • the injection molding machine 10 includes a movable platen 14, a stationary platen 16, a web feed system 18 for feeding a web of material through the multi-purpose processing apparatus 12, and an injection system 20 for injecting plastic resin into an injection mold as is known in the art.
  • the movable platen 14 includes a movable mounting plate 22 mounted to the surface of the movable platen 14.
  • the stationary platen 16 includes a stationary mounting plate 24 mounted to the surface of the stationary platen 16 of the injection molding machine 10.
  • the movable mounting plate 22 and stationary mounting plate 24 are a standard mounting plates for use in injection molding machines.
  • the stationary mounting plate 24 is rectangular in shape
  • the movable mounting plate 22 includes a rectangular- shaped portion 26 substantially identical to the shape of the stationary mounting plate 24, with extensions 28, 30, on each end of the rectangular-shaped portion 26 for use with the web feed system 18.
  • the web feed system 18 is mounted to the movable mounting plate 22, and includes a top roll mount 32 attached to the end of the top extension 28, and a bottom roll mount 34 attached to the end of the bottom extension 30 of the movable mounting plate 22 for holding a supply of printed web material in roll form.
  • a supply reel 36 of printed or decorated material 44 in roll form is rotatably mounted to the top roll mount 32, while an end reel 38 is rotatably mounted to the bottom roll mount 34, to collect the waste if cutting is performed on the web material 44, or to retain the formed and molded parts, still in web form, if cutting is not performed.
  • At least two tensioning mechanisms 40, 42, of generally conventional construction are provided and positioned on the movable mounting plate 22 to feed and guide the printed web material 44 from the supply reel 36 through the multi-purpose processing apparatus 12 to the end reel 38.
  • the injection system 20 is used for injecting molten plastic resin into an injection mold on the injection molding machine.
  • granular plastic material is supplied to a hopper 46 connected to a heating barrel 48 for melting the granular material into a molten resin.
  • the heating barrel 48 includes a plasticating screw 50 inserted therein and rotated by a screw drive motor 52 which is controlled by an injection controller 54 for forcing the molten resin into the injection mold.
  • the rotating plasticating screw 50 moves the molten resin through the heating barrel 48 and into an injection nozzle 56 at one end of the plasticating screw 50 for injecting the molten resin into the injection mold.
  • the multi-purpose processing apparatus 12 includes a forming tool 58 for performing a forming operation and an injection mold 60 for performing a simultaneous molding operation on the printed or decorated web of material 44.
  • the forming tool 58 and the injection mold 60 are preferably mounted to the mounting plates 22, 24 of the movable platen 14 and the stationary platen 16. Alternatively, the forming tool 58 and the injection mold 60 may be mounted directly to the platen surfaces.
  • the forming tool 58 is generally positioned above or upstream of the injection mold 60.
  • the forming tool 58 includes two main parts, a first part 62 attached to the mounting plate 24 of the stationary platen 16, and a second part 64 attached to the mounting plate 22 of the movable platen 14.
  • the movable platen 14 is controlled by a clamping mechanism 66, which moves the movable platen 14 toward and away from the stationary platen 16.
  • the first part 62 and the second part 64 have opposing surfaces 68 and 70 for engaging the web material 44 during closing of the forming tool parts 62, 64.
  • the surfaces 68 and 70 face each other such that when the forming mold 58 is closed, surfaces 68 and 70 substantially engage each other with the web material 118 in-between, creating a pressure chamber 72 between the parts 62, 64 as shown in FIG. 9.
  • the injection mold 60 is positioned below or downstream of the forming mold portion 58.
  • the injection mold 60 includes a core part 74 attached to the mounting plate 24 of the stationary platen 16, a center plate 76 mounted to the core part 74 with ejectors for ejecting the molded substrate, and a cavity part 78 attached to the mounting plate 22 of the movable platen 14.
  • the mold components including the forming mold components are generally constructed of steel.
  • at least one cutting operation is also performed when making deep-drawn injection molded parts.
  • a cutting operation may occur prior to the forming operation, during the forming operation when the forming tool parts are opening, between the forming and molding operations, during the injection molding when the mold halves are closing or opening, and/or after the injection molding operation.
  • Operation of the multi-purpose apparatus 12 begins with the supply reel 36 of printed or decorated web material 44 being fed through the tensioning mechanism 40 and into the forming tool 58 for forming portions of the material for making in-mold decorated parts.
  • the printed web material is advanced further, thereby feeding the just-formed part into the injection mold 60 and a non-formed part into the forming tool 58.
  • the just-formed part is then injection molded in the injection mold 60, as is known in the art, while the newly advanced portion of printed material in the forming tool 58 is simultaneously fomied.
  • the injection mold is filled with molten resin as the plasticating screw 50 moves forward, or leftward as depicted in FIG. 6, forcing molten resin into the closed mold, held closed by clamping pressure of approximately 50 to 2000 tons by the clamping mechanism 66.
  • the molten resin is typically formed from granular plastic material, melted to between 350 and 900 degrees Fahrenheit which is forced into the mold cavity at a pressure of between 1,000 and 30,000 pounds per square inch (psi). After the cavity of the mold is full, additional plastic may be compressed into the cavity to help offset the shrinkage that typically occurs during cooling.
  • the plastic in the mold is cooled by supplying coolant through cooling passages in the mold.
  • FIG. 7 shows a second embodiment of an injection molding machine 80 including a multi-purpose processing apparatus 82 constructed in accordance with an alternative embodiment of the present invention.
  • the first embodiment shown in FIG.6, includes a web feed system for feeding a continuous web of printed or decorated material through the multi-purpose processing apparatus
  • the second embodiment includes a sheet feed system for feeding individual sheets of printed or decorated material through the multi-purpose processing apparatus.
  • the sheets 86 are automatically fed into the machine 80 using an attached robot 84. The sheets 86 then automatically travel through the multi-purpose processing apparatus by or through the use of the injection molding machine's robot 84.
  • the injection molding machine 80 includes a movable platen 14, a stationary platen 16 and an injection system 20 for injecting plastic resin into the injection mold.
  • the movable platen 14 and stationary platen 16 include mounting plates 22, 24 for mounting the multi-purpose processing apparatus including a forming tool 58 and an injection mold 60.
  • a sheet of printed material 86 is positioned within the multi-purpose processing apparatus 82.
  • the injection system 20 like FIG. 6, includes a hopper 46 connected to a heating barrel 48 for melting granular plastic material into a molten resin.
  • the heating barrel 48 includes a plasticating screw 50 inserted therein and rotated by a screw drive motor 52 which is controlled by an injection controller 54.
  • the rotating plasticating screw 50 moves the molten resin through the heating barrel 48 and into an injection nozzle 56 at one end of the plasticating screw 50 for injecting the molten resin into the injection mold 60.
  • FIGS. 8-11 illustrate a plurality of detailed views of a forming tool 58 of the multipurpose processing apparatus 12, 82 shown in FIGS. 6 and 7, in its various stages of operation.
  • FIG. 8 illustrates the forming tool 58 in an open position prior to insertion of a substrate to be formed.
  • the forming tool 58 includes two main parts, a first part 62 attached to the stationary platen 16, and a second part 64 attached to the movable platen 14.
  • the first part 62 and the second part 64 have opposing surfaces 88 and 90 for engaging a substrate during closing of the forming tool parts 62, 64.
  • the surfaces 88 and 90 face each other such that when the forming tool parts 62, 64 are closed, surfaces 88 and 90 substantially engage each other with the substrate in-between, creating a pressure chamber 72, as shown in FIG. 9.
  • Each of the opposing surfaces 88, 90 include a top portion 92, 94 and a bottom portion 96, 98 for engaging the substrate during closing of the parts 62, 64.
  • the surfaces 88, 90 face each other such that when the parts 62, 64 are closed, surfaces 92, 94 and 96, 98 substantially engage each other with the substrate in-between, creating a seal, and forming the pressure chamber 72 between the surfaces 88, 90 of the first part 62 and the second part 64, as shown in FIG. 9.
  • the forming tool 58 further includes a plurality of openings 100 extending through the platens 16, 14, and the first part 62 and the second part 64 to the pressure chamber 72 for applying a pressure medium into the pressure chamber 72 for forming appliques and substrates in the pressure chamber 72.
  • Forming is typically accomplished through forming pressure utilizing a pressure medium, such as a pressurized gas or liquid.
  • the pressure forming operation could be a cold forming operation where the printed or decorated substrate, not having been heated in any way, is inserted into the forming tool and clamping pressure is applied to seal the substrate in the pressure chamber. The pressure medium is then injected into the chamber to form the part against the forming tool.
  • Heat forming can also be used. Heat forming utilizes heating and cooling circuits to heat the forming tool parts and/or the pressure medium.
  • the clamping pressure necessary for a forming operation is already supplied by the clamping mechanism of an injection molding machine.
  • FIG. 8 A illustrates a more detailed view of the forming tool 58 and its first and second parts 62, 64 attached to the platens 16, 14.
  • the first part 62 is separated into two different heat zones 102, 104 by a separating member 110 inserted within the first part 62 of the forming tool 58.
  • the second part 64 is also separated into two different heat zones 106, 108 by a separating member 112 inserted within the second part 64 of the forming tool 58.
  • At least one of the heat zones 102, 106 in each of the parts 62, 64 includes a plurality of heating coils 114 snaking through the heat zones 102, 106 in a serpentine fashion.
  • the heating coils 114 are preferably inserted within the first heat zone 102 closest to the stationary platen 16 in the first part 62, and the first heat zone 106 closest to the movable platen 14 in the second part 64.
  • the first part 62 includes a forming tool insert 116 removably attached to the second heating zone 104 of the first part 62 for forming the shape of the substrate or web of material. Each removable tool insert, 116 is unique to the finished part is being used to create.
  • the forming tool 58 is shown in a closed position with an applique or substrate 118 engaged between the surfaces 92, 94 and 96, 98 of the first part 62 and second part 64.
  • the first part 62 and second part 64 are clamped together by the clamping mechanism 66 of the injection molding machine 10, 80 as shown in FIGS. 6 and 7.
  • the exposed surfaces 92, 96 of the first part 62 engage a first side 120 of the substrate 118
  • the exposed surfaces 94, 98 of the second part 64 engage a second 122 side of the substrate 118.
  • a compressor or pressure source 124 is coupled to the plurality of openings 100 in the platens 14, 16 and forming tool 58 through first and second conduits 126, 128 for injecting a pressure medium into the pressure chamber 72 of the closed tool 58.
  • a first valve 130 is positioned between the first and second conduits 126, 128 for controlling the flow of the pressure medium into the openings 100 in the first 62 and second 64 parts of the forming tool 58.
  • a second valve 132 is positioned in the second conduit 128 for controlling the flow of the pressure medium into the opening 100 in the first part 62 of the forming tool 58, and to vent pressure from the pressure chamber 72.
  • the pressure medium forces the substrate 118 against the surface 88 of the removable tool insert 116 of the forming tool, as shown in FIG. 10.
  • approximately 80 to 2000 psi of forming pressure is injected into the first conduit 126 through opening 100 on the second part 64 of the forming tool 58 for forming the applique or substrate 118 against the surface 88 of the forming tool.
  • the first valve 130 between the first conduit 126 and the second conduit 128 is closed to allow the pressure medium to enter the pressure chamber 72.
  • the second valve 132 on the second conduit 128 is opened to the atmosphere to allow air to vent out from the forming chamber through the valve 132.
  • FIG. 11 shows the forming tool 58 in an open position after the substrate 118 has been formed by the pressure medium.
  • the substrate 118 takes the shape of the surface 88 of the forming tool insert 116. After forming, the substrate 118 may go through a cutting operation, or proceed directly to the injection mold 60 for undergoing an injection molding operation.
  • the forming tool 58 or the injection mold 60 may include cutting means provided by cutting inserts for cutting the substrate 118 while the substrate 118 is moving from the forming operation to the molding operation in the injection molding machine.
  • FIGS. 1-5 illustrate the various stages of producing an in-mold decorated part.
  • FIG. 1 shows a substantially flat substrate 134 having markings 136 of a finished product and two indexing holes 138 for properly registering the substrate 134 on the injection molding machine of the present invention.
  • the substrate 134 is typically printed or decorated with graphics such as letters, numbers, designs or other markings by various printing methods, such as silk screen printing, offset printing, flexographic printing, painting, digital printing, as well as other methods.
  • both the front and back surfaces of the substrate 134 can be printed or decorated.
  • the substrate 134 is typically flat before it is placed into a forming tool or an injection mold.
  • the substrate 134 is preferably made of a plastic material, but may be made of other materials, and is typically supplied in sheet or roll form varying in thickness from 0.005 inch to 0.06 inch.
  • the plastic material comprising the substrate may include polypropylene, polycarbonate, acrylic, vinyl, polyester, polystyrene, acrylonitrile butadiene styrene (ABS), polyethylene and others.
  • the substrate my comprise non-plastic materials as well, such as malleable metal, fabrics, leather, or paper-based materials.
  • the flat substrate 134 is placed into the forming tool of the invention and formed by a pressure medium acting on the substrate to force the substrate against the surface of the forming tool insert.
  • the forming tool insert is in the shape of a cellular telephone cover. Therefore, the substrate 134 takes the shape of a cellular phone cover, as shown in FIG. 2.
  • a cross-sectional view of a portion of the formed substrate 134 is shown in FIG. 3.
  • the substrate 134 may also be pattern-cut e.g. by die cutting, along cut-lines to remove excess material, provide cut-outs, and define the perimeter of the final product.
  • the pattern-cutting step separates such pieces from the web to provide separate individual pieces, which are placed or fed into an injection mold.
  • the pattern-cut substrate will appear similar to the finished product shown in FIG. 4.
  • FIGS. 2 and 3 the substrate 134 is then placed or fed into an injection mold for an injection molding operation.
  • an additional layer of material 160 is formed on the back or front surface of the substrate 134 as shown in FIGS. 4 and 5.
  • FIG. 5 is a cross-sectional view of the formed, cut and injection molded substrate 134.
  • the finished product, a cellular phone cover, is just one example of what one may produce using the method and apparatus of the present invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé et un dispositif pour le formage sous pression dans une machine de moulage par injection (10), permettant d'exécuter simultanément les opérations suivantes: formage, découpe et moulage de pièces moulées par injection à formage profond. On élimine le chargement individuel de pièces multiples distinctes dans le moule, et il en résulte un gain de temps au chargement, une réduction de cycle et une augmentation du rendement. Le dispositif comprend un outil de formage à première et seconde parties, pour l'exécution d'une opération de formage sur un substrat. Le dispositif comprend en outre un moule par injection ayant une partie centrale et une cavité de moulage pour substrat préalablement formé dans l'outil de formage. Le dispositif place l'outil de formage dans un espace non utilisé à l'intérieur de la machine à mouler par injection (10), ce qui permet d'utiliser la pression de serrage au moulage pour fermer l'outil et d'obturer la chambre de pression, tandis que le substrat est maintenu dans la chambre et qu'un moyen de pression est utilisé pour le formage du substrat dans l'outil. Le dispositif permet de conduire un procédé qui combine le formage, la découpe et le moulage par injection d'un substrat, selon un processus continu sur machine de moulage par injection (10).
PCT/US2000/023909 2000-09-01 2000-09-01 Procede et dispositif pour le formage sous pression WO2002020240A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
PCT/US2000/023909 WO2002020240A1 (fr) 2000-09-01 2000-09-01 Procede et dispositif pour le formage sous pression
AU2000270950A AU2000270950A1 (en) 2000-09-01 2000-09-01 Pressure forming method and apparatus
AU2001226363A AU2001226363A1 (en) 2000-09-01 2001-01-09 Thermoforming method and apparatus for use in an injection molding machine
PCT/US2001/000607 WO2002020241A1 (fr) 2000-09-01 2001-01-09 Procede et appareil de thermoformage utilise dans une machine de moulage par injection

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2000/023909 WO2002020240A1 (fr) 2000-09-01 2000-09-01 Procede et dispositif pour le formage sous pression

Publications (1)

Publication Number Publication Date
WO2002020240A1 true WO2002020240A1 (fr) 2002-03-14

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Application Number Title Priority Date Filing Date
PCT/US2000/023909 WO2002020240A1 (fr) 2000-09-01 2000-09-01 Procede et dispositif pour le formage sous pression

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Country Link
AU (2) AU2000270950A1 (fr)
WO (1) WO2002020240A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007100522A1 (fr) * 2006-02-24 2007-09-07 Dow Global Technologies Inc. Procedes de formation de pieces moulees dotees de zones de surface en tissu
CN106217761A (zh) * 2016-08-05 2016-12-14 中山市恒辉自动化科技有限公司 一种耳机插头注塑自动化装置
CN111113802A (zh) * 2019-12-27 2020-05-08 河源中光电通讯技术有限公司 自动上下料注塑机

Citations (6)

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Publication number Priority date Publication date Assignee Title
US4797244A (en) * 1982-09-29 1989-01-10 American National Can Company Multiwalled container and method of making same
US5401457A (en) * 1992-08-04 1995-03-28 Valyi; Emery I. Process for forming a color coated article
US5759477A (en) * 1996-12-13 1998-06-02 Green Tokai Co. Ltd. Method of making fused film plastic parts
US5776411A (en) * 1994-06-21 1998-07-07 Dai Nippon Printing Co., Ltd. Simultaneous injection molding and patterning method using heating body with non-parallel heating and non-heating positions
US5960527A (en) * 1986-10-28 1999-10-05 Rexam Industries Corp. Method of injection molding plastic automobile body parts with integral weatherable pigmented film surface
US6045738A (en) * 1996-10-31 2000-04-04 Dai Nippon Printing Co., Ltd. Sheet-decorating injection molding method

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4797244A (en) * 1982-09-29 1989-01-10 American National Can Company Multiwalled container and method of making same
US5960527A (en) * 1986-10-28 1999-10-05 Rexam Industries Corp. Method of injection molding plastic automobile body parts with integral weatherable pigmented film surface
US5401457A (en) * 1992-08-04 1995-03-28 Valyi; Emery I. Process for forming a color coated article
US5776411A (en) * 1994-06-21 1998-07-07 Dai Nippon Printing Co., Ltd. Simultaneous injection molding and patterning method using heating body with non-parallel heating and non-heating positions
US6045738A (en) * 1996-10-31 2000-04-04 Dai Nippon Printing Co., Ltd. Sheet-decorating injection molding method
US5759477A (en) * 1996-12-13 1998-06-02 Green Tokai Co. Ltd. Method of making fused film plastic parts

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007100522A1 (fr) * 2006-02-24 2007-09-07 Dow Global Technologies Inc. Procedes de formation de pieces moulees dotees de zones de surface en tissu
CN106217761A (zh) * 2016-08-05 2016-12-14 中山市恒辉自动化科技有限公司 一种耳机插头注塑自动化装置
CN111113802A (zh) * 2019-12-27 2020-05-08 河源中光电通讯技术有限公司 自动上下料注塑机

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AU2000270950A1 (en) 2002-03-22
AU2001226363A1 (en) 2002-03-22

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