WO2015051271A1

WO2015051271A1 - Double die rotate molding

Info

Publication number: WO2015051271A1
Application number: PCT/US2014/059095
Authority: WO
Inventors: Timothy Francis O'BRIEN; Daniel Vern Beckley; Anthony John POVINELLI; Lonnie ADKINS
Original assignee: Magna International Inc.
Priority date: 2013-10-04
Filing date: 2014-10-03
Publication date: 2015-04-09

Abstract

A process and molding assembly (100) for molding at least two parts having a seal of a final molded assembly (10). Each half of a main mold has a rotational section for rotating a pair of part cavities. A first half of the mold has two first cavities (104) of a first part (12) which rotate 180 degrees each cycle and also one first stationary core (114) of a second part (14). The second half of the tool has one second stationary core (116) of the first part and two second cavities (108) of the second part which rotate 180 degrees each cycle. The center section of the molding assembly molds a seal (16) between the first (12) and second parts (16). At each cycle of the molding assembly, one first part (12), one second part (16), and one seal (16) is molded.

Description

DOUBLE DIE ROTATE MOLDING

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a PCT International Patent Application and claims benefit of United States Provisional Patent Application No. 61/886,956 filed October 4, 2013. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a process and molding assembly operable for manufacturing a final assembly having a hollow portion.

BACKGROUND OF THE INVENTION

Processes for the manufacturing of parts that are hollow in order to give higher structural modulus are problematic. Generally, die slide injection, vibration welding, snap fit, hot plate, or infrared (IR) welding for manufacturing parts are disadvantageous. Such conventional processing requires more steps than desirable, and are known to be more complex, time consuming, prone to fault conditions, labor intensive, expensive, and/or can adversely affect line capacity / volume throughput. In known processes parts are not simultaneously molded and/or secondary processing is required, e.g., for bonding, etc.

Accordingly, a process and molding assembly is desired which is operable for molding a final assembly that reduces or eliminates these known disadvantages, including molding time, and also that eliminates secondary processing.

SUMMARY OF THE INVENTION

The present invention is directed to a process and molding assembly operable for molding at least two product halves having at least one seal into a final assembly simultaneously. In general, the molding assembly includes at least two multi-cavity rotational sections and at least two stationary cores operable to mold a final assembly that has the two halves that are sealed together and form at least one hollow portion. The present invention eliminates secondary processing and also bonds the at least two product halves together while using a press or main mold. There is provided a main mold having a first half and a second half. Each of the first and second halves include a rotatable section that is capable of selectively rotating at least one pair of part cavities. The first half of the main mold has at least two first cavities of a first part which selectively rotate at each cycle and also at least one first stationary core of a second part. The second half of the main mold has the opposite; at least two second cavities of the second part which selectively rotates at each cycle and at least one second stationary core of the first part. At each cycle of the press, at least one first part, at least one second part, and at least one seal, preferably, at least two seals, are molded using simultaneous shots of at least one material.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

Fig. 1 is an exploded view of a final molded assembly having a first part, second part, and bonding features, in accordance with the present invention;

Fig. 2 is a perspective view of the final molded assembly, in accordance with the present invention;

Fig. 3 is a top plan view depicting a molding assembly schematic with portions removed for clarity, in accordance with the present invention; and

Fig. 4 is a cross sectional view of the molding assembly of Fig. 3 in a closed position with the first part, second part, and final molded assembly with seals formed therein, in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

A process and molding assembly operable for molding at least two part halves and seal of a final molded assembly simultaneously and that eliminates secondary processing is provided. The final molded assembly is a molded structural hollow component. An injection press is used to mold at least three shots of material at a time, e.g., for a first part half, second part half, and bonding shot(s). The present invention is operably suitable for various hollow part applications and adjustable depending upon particular applications. Referring generally to Figures 1 - 4, a process operable for molding at least two parts and a seal of a final molded assembly 10 simultaneously and that eliminates secondary processing and a molding assembly for same, in accordance with the present invention is illustrated. In Fig. 3 a top plan view depicting a molding assembly schematic to illustrate an exemplary molding assembly and process is shown.

Referring to Figures 1-4 generally, and more particularly to Figures 1 -2, there is provided an exemplary final molded assembly, shown generally at 10, having a first part 12 bonded to a second part 14 by at least one strip of material, preferably, at least two strips of material 16. Most preferably, at least two bonding shots 16 of material form a seal and bonds the first and second parts 12,14 together in at least two locations. The first part 12 has at least one pair of first flange portions 18 and the second part 14 has at least one pair of second flange portions 20. At least one pair of recesses 22 or notches are formed at least partly along the edge of the flange portions 20 of the second part 14. The bottom surface of the first flange portions 18 of the first part 12 are substantially planar. When the first and second pairs of flange portions 18,20 of the first and second parts 12,14 are aligned and brought into juxtaposed position, a pair of channels 24 is thereby formed along the edge of both sides of the final molded assembly 10. The bonding shots 16 or seals are located within the pair of channels 24 to bond the flange portions 18,20 of the first and second parts 12, 14 to one another forming the final molded assembly 10.

Preferably, the first part is a top part and the second part is a bottom part in the final molded assembly 10. The first and second parts 12,14 also have a centrally located first and second curved portion 26,28, respectively, such that when the first and second parts 12, 14 are bonded together a hollow portion 30 is provided. The hollow portion 30 extends along the longitudinal axis of the final molded assembly 10 and is open on both ends. It is appreciated that alternatively shaped one or more first and second parts 12, 14 are contemplated suitable for creating a hollow structure, dependent upon particular applications.

Referring generally to Figures 1-4, and more particularly to Figures 3-4, there is provided a molding assembly, generally shown at 100. The molding assembly 100 has a main mold including a first half, generally shown at 102, having at least two first cavities, generally shown at 104, and a second half, generally shown at 106, having at least two second cavities, generally shown at 108. The first half 102 also includes a first rotatable section, generally shown at 1 10, having the first cavities 104 operably mounted or integrally formed therein. The second half 106 also includes a second rotatable section, generally shown at 1 12, having the second cavities 108 operably mounted or integrally formed therein. The first half 102 further includes at least one first stationary core, generally shown at 1 14, and the second half 106 further includes at least one second stationary core, generally shown at 116.

The first stationary core 1 14 is operably shaped, e.g., to include a protruding curved portion and protruding edge portions, such that when the press is closed the first stationary core 1 14 operably protrudes a predetermined amount into another one of said at least two second cavities 108, e.g., the outer second cavity on the rotary table 1 12, and material is injected into that second cavity 108 to form the second part 14.

The second stationary core 1 16 is operably shaped, e.g., to include a protruding curved portion, such that when the press is closed the second stationary core 116 operably protrudes a predetermined amount into another one of said at least two first cavities 104, e.g., the outer first cavity 104 on the rotary table 1 12, and material is injected into that first cavity 104 to form the first part 12.

The first and second rotatable sections 1 10, 12 are operably coupled within the press to selectively rotate the at least two first cavities and at least two second cavities, respectively, in unison when the press is not closed. Most preferably, the first and second rotatable sections 1 10,1 12 are rotary tables operably configured for rotating the cavities a predetermined amount, e.g., rotating each cavity 360 degrees at 180 degree increments, as will be explained in greater detail below. The rotatable sections 1 10, 1 12 are located on operably spaced adjacent parallel planes, e.g., providing an upper rotary table and lower rotary table, and are positioned to provide a predetermined amount of overlap relative to each other. A central section, generally shown at 122, of the molding assembly 100 is where the two rotatable sections 1 10,1 12 overlap.

The first part 12 is selectively injection moldable within the at least two first cavities 104 and the second part 14 is selectively injection moldable within the at least two second cavities 108. The first and second parts 12,14, e.g., one first part and one second part, remain with the respective cavities when the press is opened after molding and as the first and second rotatable sections 1 10,1 12 rotate to the overlapping position. Thus, the first half 102 of the molding assembly 100 has at least two first cavities 104 for the first part 12 which selectively rotate (R in Fig. 3) at each cycle, e.g., 180 degrees and also at least one first stationary core 1 14 operably mounted to or integrally formed with a first body portion 1 18 that does not rotate; while the second half 106 of the molding assembly 100 has at least two second cavities 108 for the second part 14 which selectively rotate (R in Fig. 3) at each cycle, e.g., 180 degrees, and also at least one second stationary core 1 16 operably mounted to or integrally formed with a second body portion 120 that does not rotate.

The first and/or second body portion 118,120 are/is operably coupled to an actuator and control unit to selectively open and close the press. When opened a predetermined amount to an open position, the first and second rotatable sections 1 10,1 12 have clearance to rotate unobstructed. When in the closed position, one of the at least two first cavities 104 and one of the at least two second cavities 108 overlap and align with one another at the central section 122, and since these cavities already contain a prior formed first and second part 12, 14, these cavities are positioned such that the first and second parts 12,14 are in contact when the press is in this closed position for bonding. When closed to a closed position (see Fig. 4) the first stationary core 114 and another one of the at least two second cavities 108, e.g., outward second cavity 108, are aligned and operably positioned for injection of molten material into the outer second cavity 108 to form the second part 14. When in the closed position, the second stationary core 1 16 and another one of the at least two first cavities 104, e.g., outer first cavity 104, are also aligned and operably positioned for injection of molten material, preferably the same material as the second part 14, into the first cavity 104 to form the first part 12.

At each cycle of the press at least one first part, at least one second part, and at least one seal, preferably, at least two seals are molded using simultaneous shots of materials. The central section 122 of the mold assembly 100 where the first and second rotatable sections 110,1 12 overlap is where the two halves 12, 14 are sealed together. The first and second rotatable sections 1 10, 1 12 are operable to rotate in unison and align one of the first cavities 104 containing a first part 12 with one of the second cavities 108 containing a second part 14. The press is operably closed, e.g., by actuation of the first and/or second body portions 118, 120, bringing the first and second parts 12,14 into contact at the overlapping position and material is injected into the pair of channels 24 to bond the parts forming the final molded assembly 10. The molding assembly 100 has an ejector operable to eject the final molded assembly 10 from the central section 122 of the molding assembly 100.

At each cycle of the molding assembly 100, one first part, one second part, and two seals 16 are molded; preferably, using glass-filled (GF) Nylon for each of the three simultaneous shots. Alternatively, additional cavities and arrangements suitable for molding two or more first parts, second parts and bonding shots for two or more final molded assemblies 10 simultaneously is contemplated.

Referring to Figs. 3-4 generally, a process for molding a final molded assembly 10, in accordance with the present invention is provided. An exemplary molding sequence includes molding of a plurality of parts simultaneously in the molding assembly 100. When the first and second rotatable sections 10,112 are rotated to a first position (indicated by 1 and 2 in Fig. 3), the press is then closed. At the first cycle, material, preferably, the same material, is simultaneously injected into the first cavity 104 of the first part 12 at position "1" and into the second cavity 108 of the second part 14 at position "2".

The molding assembly 100 is then moved to the open position. The first part 12 remains with the first cavity 104 on the upper rotatable section 110 and the second part 14 remains with the second cavity 108 on the lower rotatable section 112. The first and second rotatable sections 110, 112 are rotated the same predetermined amount, e.g., 180 degrees clockwise, bringing the first and second cavities 104,108 with the first and second parts 12,14 into alignment at position "3" of the central section 122 where the first and second rotatable sections 110,112 overlap.

The press is then moved to the closed position. Material, preferably, the same material, is simultaneously injected into the first cavity 104 of the first part 12 at position "1", into the second cavity 108 of the second part 14 at position "2", and additionally into the channels 24 of the molded assembly at position "3". This bonding shot 16 delivered into the channels 24 at position "3" creates a seal along both edges of the final molded assembly 10. The press is then moved to the open position. The final molded assembly 10 is operably ejected from position "3".

The sequence is then repeated, with the first step being the first and second rotatable sections 1 10, 1 12 are rotated the same predetermined amount, e.g., both 180 degrees clockwise or counterclockwise, bringing the first and second cavities 104,108 with the molded first and second parts 12, 14 into alignment at position "3" of the central section 122, while bringing the now empty first and second cavities 104,108 back to position "1 " and position "2", respectively.

It is understood that the final molded assembly 10 can have any other configuration suitable for molding at least two parts and a seal in accordance with the present invention to provide a hollow portion and that eliminates secondary processing. The final molded assembly 10 most preferably has at least one hollow portion to provide higher structural modulus. By way of non-limiting example, the final molded assembly 10 can be used as a structural member to bear larger structural loads and/or be more rigid or stiff, e.g., to support components connected to the final molded assembly 10 or to support attachment to a vehicle and/or carry loads.

The description of the invention is merely exemplary in nature and, thus, variations thai do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1. A method of molding a final molded assembly having at least one hollow portion therein, comprising the steps of:

providing a main mold including a first half having a first rotatable section with at least two first cavities and at least one first stationary core, and a second half having a second rotatable section with at least two second cavities and at least one second stationary core;

providing a first body portion operably coupled to said first rotatable section and said at least one first stationary core;

providing a second body portion operably coupled to said second rotatable section and said at least one second stationary core, where said first body portion and/or second body portion is/are operably mounted for moving said first and second halves between an open position and a closed position;

injecting molten material when said main mold is in said closed position into at least one of said at least two first cavities and simultaneously into at least one of said at least two second cavities forming a first part and a second part, respectively; rotating sard first and second rotatable sections a predetermined amount when in said open position;

injecting molten material when said main mold is in said closed position into another one of said at least two first cavities at a first position to form another first part, into another one of said at least two second cavities at a second position to form another second part, and into at least a third position such that at least one seal is formed between said first and second parts at said third position forming said final molded assembly.

2. The method of molding a final molded assembly of claim 1 , further comprising operably ejecting said final molded assembly from said third position.

3. The method of molding a final molded assembly of claim 2, further comprising the steps of:

moving said molding assembly to said open position before ejecting said final molded assembly; rotating said first and second rotatable sections 180 degrees;

moving said molding assembly to said closed position; and

injecting molten material simultaneously into said first, second and third positions to form another first part, another second part, and another sealed final molded assembly, respectively.

4. The method of molding a final molded assembly of claim 1 , wherein said molten material is injected into at least said first, second, and third positions simultaneously such that at each cycle a seal, one first part, and one second part is molded.

5. The method of molding a final molded assembly of claim 1 , wherein said first and second rotatable sections rotate said at least two first cavities and said at least two second cavities 180 degrees, respectively, at each cycle.

6. The method of molding a final molded assembly of claim 1 , wherein said first rotatable section and said second rotatable section are operably mounted for selectively rotating simultaneously when said molding assembly is in said open position.

7. The method of molding a final molded assembly of claim 6, wherein said first and second rotatable sections are located on operably spaced adjacent parallel planes and positioned to provide a predetermined amount of overlap relative to each other creating a center section for molding said seal between said first and second parts at said third position.

8. The method of molding a final molded assembly of claim 7, wherein said first rotatable section and said second rotatable section are rotating tables.

9. The method of molding a final molded assembly of claim 7, wherein rotating said first and second rotatable sections a predetermined amount further comprises:

rotating said first rotatable section and said second rotating section until one of said at least two first cavities and one of said at least two second cavities are aligned with one another at said center section of said molding assembly, such that also said another one of said at least two first cavities is aligned with said at least one second stationary core at said first position while said another one of said at least two second cavities is aligned with said at least one first stationary core at said second position;

wherein when said molding assembly is moved to said closed position, said first and second stationary cores operably protrude a predetermined amount into said second and first cavities at said second and first positions, respectively, and said molten material is injected into said second and first cavities at said second and first positions to form said second and first parts, respectively.

10. The method of molding a final molded assembly of claim 1 , wherein said molten material is operably injected into the pair of channels formed when said first and second parts are in contact at said third position to bond said first and second parts forming said final molded assembly.

11. The method of molding a final molded assembly of claim 1 , wherein said molten material is glass filled nylon.

12. A method of molding a final molded assembly having a hollow portion, comprising the steps of:

providing a first half of a mold having a first rotatable section with at least two first cavities and at least one first stationary core,

providing a second half of a mold having a second rotatable section with at least two second cavities and at least one second stationary core, wherein a central section of said molding assembly where said first rotatable section and said second rotatable section overlap allows alignment and positioning of one of said at least two first cavities with one of said at least two second cavities to mold a seal between a first part and a second part;

moving said first and second halves to said closed position; injecting molten material simultaneously into another one of said at least two first cavities at a first position to form a first part and into another one of said at least two second cavities at a second position to form a second part;

moving said first and second halves to said open position;

rotating said first and second rotatable sections 180 degrees;

moving said first and second halves to said closed position;

injecting molten material simultaneously into said another one of said at least two first cavities at said first position to form another first part and into said another one of said at least two second cavities at said second position to form another second part, and into at least a third position in said central section to mold a seal between said first and second parts forming said final molded assembly;

wherein at each cycle one first part, one second part, and one seal is molded.

13. The method of molding a final molded assembly of claim 12, further comprising operably ejecting said final molded assembly from said third position before repeating said cycle.

14. The method of molding a final molded assembly of claim 12, wherein said first rotatable section and said second rotatable section are operably mounted for selectively rotating simultaneously when said molding assembly is in said open position.

15. The method of molding a final molded assembly of claim 12, wherein said first and second rotatable sections are located on operably spaced adjacent parallel planes and positioned to provide a predetermined amount of overlap relative to each other creating said center section for molding said seal between said first and second parts at said third position.

16. The method of molding a final molded assembly of claim 12, wherein said first rotatable section and said second rotatable section are rotating tables.

17. The method of molding a final molded assembly of claim 12, wherein rotating said first and second rotatable sections further comprises:

18. The method of molding a final molded assembly of claim 12, wherein said molten material is operably injected into the pair of channels formed when said first and second parts are in contact at said third position to bond said first and second parts forming said final molded assembly.

19. The method of molding a final molded assembly of claim 12, wherein said molten material is glass filled nylon.

20. A molding assembly for molding a final molded assembly with a hollow structure, comprising:

a first half having a first rotatable section with at least two first cavities and at least one first stationary core;

a second half having a second rotatable section with at least two second cavities and at least one second stationary core, wherein said first rotatable section and said second rotatable section are operably rotatably mounted for overlapping one another a predetermined amount when said molding assembly is in an open position to bring one of said at least two first cavities and one of said at least two second cavities into alignment, said one first cavity including a first part previously molded therein and said one second cavity including a second part previously molded therein;

a first body portion and a second body portion, wherein said first body portion and/or second body portion is/are operably mounted for moving said first and second halves between said open position and a closed position;

wherein when in said closed position, the first and second parts within said one first cavity and said one second cavity, respectively, contact each other at a third position, said second stationary core and another one of said at least two first cavities operably align within a first position, and said first stationary core and another one of said at least two second cavities operably align at a second position, such that when material is operably injected simultaneously to said first, second and third positions, respectively, another first part is formed in said another one of said at least two first cavities at said first position, another second part is formed in said another one of said at least two second cavity at said second position, and a seal is formed between said first and second parts at said third position finishing said final molded assembly.