System for continuous manufacture of molded parts with...

Details System for continuous manufacture of molded parts with... System for continuous manufacture of molded parts with...

1999-09-22

2001-08-07

Heitbrink, Tim (Department: 1722)

Plastic article or earthenware shaping or treating: apparatus

Distinct means to feed, support or manipulate preform stock...

Female mold type means

C425S129100

Reexamination Certificate

active

06270332

ABSTRACT:

FIELD OF THE INVENTION
The present invention pertains generally to manufacture of parts by injection molding and, more particularly, to continuous molding of parts which have a separate insert piece which is inserted into a mold cavity prior to injecting the mold.
BACKGROUND OF THE INVENTION
Insert molding, as referred to herein, generally refers to the practice of molding a material about or around a separate piece, so that the molded material is integral with, bonded to, or partially or completely surrounds or encapsulates the separate insert piece in a finished part. To accomplish this, the insert piece must be inserted into the cavity of a mold, such as a plastic injection mold or casting mold, prior to injecting the mold with a molding material. A new insert piece must be inserted into the mold at the start of each mold cycle. Typically, the insert is positioned in the mold by hand or by robot, during the period when the mold is opened between injection/compression cycles. Of course, this additional operation per part greatly reduces the rate of mass production.
In continuous production of insert molded parts, the insert pieces must be arranged for rapid and continuous insertion into a mold. Small insert pieces may be arranged upon racks, or stacked in a magazine which feeds into the mold cavity. The insert piece supply system be constantly re-stocked and monitored throughout the production process. Typically, the insert pieces are manufactured in an operation completely separate from the molding operation, and then arranged for continuous insert molding production. This amounts to two different manufacturing operations in order to produce a single finished part.
SUMMARY OF THE INVENTION
The present invention provides an automated system for the continuous production of plastic injection molded parts which include an insert part cut from a continuous feed of insert stock material. In accordance with one general aspect of the invention, there is provided a system for automated molding of parts around insert pieces which are continuously fed, cut and inserted into a die in an injection molding machine. In accordance with a more particular aspect of the invention, there is provided a system for continuous production of insert molded parts, wherein each part has a flexible insert piece cut from a continuous strand and fed into an injection molding machine, and wherein the part is formed by injection of plastic molding material around the insert piece. The continuous cutting and feeding of the insert pieces from a supply source enables uninterrupted production of insert molded parts, eliminating many of the intermediate steps in prior production processes.
In one particular application of the invention, there is provided one or more reels for spooling up of a continuous strand of material from which insert pieces are cut for insertion into an injection mold. In a preferred embodiment, the reel has multiple spool channels for receiving multiple strands of insert material, for simultaneous feeding into multiple mold cavities. The reels are rotationally mounted and driven for continuous feed according to a rate of injection mold operation. A cutting and feeding assembly is adapted for operative association with an injection molding machine, and operates to cut insert pieces from the reel-fed supply of material, and insert the pieces into an injection mold. In one particular embodiment of the insert piece cutting and feeding assembly, the insert material is fed through roller blocks which grip the material and hold it in position for severing an insert piece by a cutting station. The severed insert piece is then advanced through the feeder assembly and inserted into a mold cavity. The mold is then closed about the insert, and molding material is injected and molded around the insert to form an insert molded part.
These and other aspects of the invention are herein described in detail with reference to the accompanying Figures.


REFERENCES:
patent: 4216184 (1980-08-01), Thomas
patent: 5415536 (1995-05-01), Ohno

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