Apparatus for transferring a component portion of an injection molded plastic component from a first state to a second state

Abstract

Apparatus for transferring at least one component portion of an at least partially undercut injection molded plastic component, particularly a window frame trim component, from a first state, in which the at least one component portion has a geometric deviation from a component-specific reference state, to a second state, in which the at least one component portion has no geometric deviation from the component-specific reference state.

Claims

1. Apparatus for transferring at least one component portion of an at least partially undercut injection molded plastic component, particularly a window frame trim component, from a first state, in which the at least one component portion has a geometric deviation from a component-specific reference state, to a second state, in which the at least one component portion has no geometric deviation from the component-specific reference state, the apparatus comprising: an actuation device comprising at least one first actuation element configured to exert a transfer force to the at least partially undercut injection molded plastic component, particularly the window frame trim component, having at least one component portion having the first state, in which the at least one component portion has the geometric deviation from the component-specific reference state so as to transfer the at least one component portion from the first state to the second state, in which the at least one component portion has no geometric deviation from the reference state, and a control unit which is configured to control operation of the actuation device or the at least one first actuation element, respectively, so that the transfer force to be exerted on the least partially undercut injection molded plastic component is applied only after removing of the component from an injection molding tool.

2. Apparatus according to claim 1, wherein the actuation device further comprises at least one further actuation element configured to exert a transfer force to the at least partially undercut injection molded plastic component having the at least one component portion having the first state, in which the at least one component portion has the geometric deviation from the component-specific reference state so as to transfer the at least one component portion from the first state to the second state, in which the at least one component portion has no geometric deviation from the reference state.

3. Apparatus according to claim 2, wherein the at least one further actuation element is arrangeable or arranged opposite to the at least one first actuation element, whereby a receiving gap for receiving a respective component portion between the at least one first actuation element and the at least one further actuation element is defined between the at least one first actuation element and the at least one further actuation element.

4. Apparatus according to claim 2, further comprising at least one counter bearing element assignable or assigned to the at least one first actuation element and/or to the at least one further actuation element, wherein the at least one counter bearing element is arrangeable or arranged opposite to the at least one first actuation element or the at least one further actuation element, whereby a receiving gap for receiving a respective component portion between the at least one counter bearing element and the first actuation element or the at least one further actuation element is built between the at least one counter bearing element and the at least one first actuation element or the at least one further actuation element.

5. Apparatus according to claim 2, wherein the at least one first actuation element and/or the at least one further actuation element is moveably supported between at least one first orientation and/or position in which a respective transfer force is exertable on a respective plastic component and a second orientation and/or position in which a respective transfer force is not exertable on a respective plastic component.

6. Apparatus according to claim 2, wherein the at least one first actuation element and/or the at least one further actuation element is provided with at least one transfer force transfer portion which is configured to contact a respective component portion so as to exert the transfer force to the plastic component.

7. Apparatus according to claim 6, wherein the at least one force transfer portion is at least partially provided with a shape, particularly a contour, which corresponds to the shape, particularly the outer contour, of the component portion on which the transfer force is to be exerted during operation of the apparatus.

8. Apparatus according to claim 6, wherein the at least one force transfer portion is moveably supported between at least two positions relative to a base body of the at least one first actuation element and/or the at least one further actuation element so as to be adaptable to a specific shape, particularly a specific outer contour, of the component portion on which the transfer force is to be exerted during operation of the apparatus.

9. Apparatus according to claim 1, further comprising a support device comprising at least one support element configured to support the or a respective plastic component during operation of the apparatus.

10. Apparatus according to claim 9, wherein the at least one support element is provided with at least one support portion which is configured to contact a respective component portion so as to support the plastic component during operation of the apparatus.

11. Apparatus according to claim 10, wherein the at least one support portion is at least partially provided with a shape, particularly a contour, which corresponds to the shape, particularly the outer contour, of the component portion of the plastic component during operation of the apparatus.

12. Apparatus according to claim 10, wherein the at least one support portion is moveably supported between at least two positions relative to a base body of the at least one support element so as to be adaptable to a specific shape, particularly a specific outer contour, of the component portion on which the transfer force is to be exerted during operation of the apparatus.

13. Apparatus according to claim 1, comprising a base structure, particularly built as or comprising a base plate, the base structure comprising at least one connection interface configured to detachably connect the at least one first actuation element and/or the at least one further actuation element and/or the at least one support element with the base structure.

14. Apparatus according to claim 13, wherein the at least one first actuation element and/or the at least one further actuation element is mounted on an actuation element mounting structure, the actuation element mounting structure comprising at least one connection interface face configured to co-act with the at least one connection interface of the base structure, and/or the at least one support element is mounted on a support element mounting structure, the support element mounting structure comprising at least one connection interface configured to co-act with the at least one connection interface of the base structure.

15. Method for transferring at least one component portion of an at least partially undercut injection molded plastic component from a first state, in which the at least one component portion has a geometric deviation from a component-specific reference state, to a second state, in which the at least one component portion has no geometric deviation from the reference state, comprising: exerting with the at least one first actuation element of the actuation device of the apparatus according to claim 1, a transfer force to the at least partially undercut injection molded plastic component having the at least one component portion having the first state, in which the at least one component portion has the geometric deviation from the component-specific reference state so as to transfer the at least one component portion from the first state to the second state, in which the at least one component portion has no geometric deviation from the reference state.

Description

(1) Exemplary embodiments of the invention are described with reference to the FIG., whereby:

(2) FIG. 1, 2 each shows a principle drawing of an apparatus according to an exemplary embodiment;

(3) FIG. 3-5 each show an enlarged view of the details III-V of FIG. 2;

(4) FIG. 6 shows a principle drawing of a support structure according to an exemplary embodiment; and

(5) FIG. 7 shows a principle drawing of an undercut plastic component according to an exemplary embodiment.

(6) FIG. 1, 2 each shows a principle drawing of an apparatus 1 according to an exemplary embodiment of the present invention. The apparatus 1 is an apparatus for transferring one or more component portions 2-4 (FIG. 2-5) of an undercut injection molded plastic component 5 from a first state (indicated with continuous line in FIG. 3-5), in which a respective component portion 2-4 has a geometric deviation from a component-specific reference state, to a second state (indicated with a dotted line in FIG. 3-5), in which a respective component portion 2-4 has no geometric deviation from the component-specific reference state. The apparatus 1 is thus, configured to transfer a respective component portion 2-4 of an undercut plastic component 5 from a first state, in which a respective component portion 2-4 has a geometric deviation from a component-specific reference state, to a second state, in which a respective component portion 2-4 has no geometric deviation from the component-specific reference state.

(7) In either case, the first state of a respective component portion 2-4 may thus, be deemed or denoted as a deviation state (undesired), the second state of a respective component portion 2-4 may thus, be deemed or denoted as a target state (desired).

(8) The geometric deviation of a respective component portion 2-4 typically, results from removing plastic component 5 from an injection molding tool.

(9) An exemplary embodiment of a respective plastic component 5 is shown in FIG. 7 in a frontal view. As is apparent from FIG. 7, the plastic component 5 is a thin-walled automotive component, i.e. a window frame trim component. The wall thickness of the plastic component 5 is typically, does not exceed 2 mm, particularly 1 mm. In the exemplary embodiment of the FIG., the plastic component 5 has a U-shaped cross-section (see FIG. 3-5). Yet, plastic components 5 having other cross-sections are conceivable.

(10) The plastic component 5 can be made of a PP or a PP-blend or PA or a PA-blend, for instance. In either case, the plastic material building the plastic component 5 can comprise a certain amount of fibers, such as glass fibers, for instance. The amount of glass fibers can range between 10-30 vol.-%, for instance.

(11) The apparatus 1 comprises an actuation device 6. As is apparent from FIG. 1, 2, the actuation device 6 comprises a number of actuation elements 7a-7c. Particularly, the actuation device 6 comprises three actuation elements 7a-7c, i.e. a first actuation element 7a, a second actuation element 7b, and a third actuation element 7c in the exemplary embodiments of the FIG. One of the actuation elements 7a-7c may be deemed or denoted as a first actuation element, other actuation elements may be deemed or denoted as further actuation elements.

(12) Each actuation element 7a-7c is configured to exert a transfer force F (see arrows in FIG. 3-5) to a respective plastic component 5 having a respective component portion 2-4 having a first state, in which the respective component portion 2-4 has a geometric deviation from a component-specific reference state so as to transfer the respective component portion 2-4 from the first state to a second state, in which the respective component portion 2-4 has no geometric deviation from the reference state. Each respective actuation element 7a-7c is particularly, configured to exert a respective transfer force F to a respective component portion 2-4 having a first state, in which the respective component portion 2-4 has a geometric deviation from a component-specific reference state, so as to transfer the respective component portion 2-4 from the first state to a second state in which the respective component portion 2-4 has no geometric deviation from the reference state.

(13) In the exemplary embodiments of the FIG., each actuation element 7a-7c is assignable or assigned to a specific component portion 2-4 of the plastic component 5. As is apparent from FIG. 2, actuation element 7a is assignable or assigned to component portion 2, actuation element 7b is assignable or assigned to component portion 3, and actuation element 7c is assignable or assigned to component portion 4.

(14) As is apparent from FIG. 1-5, the apparatus 1 may further comprise counter bearing elements 8a-8c assignable or assigned to respective actuation elements 7a-7c. The counter bearing elements 8a-8c are arrangeable or arranged (essentially) opposite to respective actuation elements 7a-7c. A receiving gap 9a-9c for receiving a respective component portion 2-4 between respective counter bearing elements 8a-8c and a respective actuation elements 7a-7c may be built or defined between respective counter bearing elements 8a-8c and assigned actuation elements 7a-7c (see FIG. 1).

(15) The actuation elements 7a-7c typically differ from respective counter bearing elements 8a-8c in that the actuation elements 7a-7c can be (actively) moved relative to a respective component portion 2-4 during operation of the apparatus 1 (as indicated in FIG. 3-5), whereas respective counter bearing elements 8a-8c cannot be (actively) moved relative to a respective component portion 2-4 during operation of the apparatus 1.

(16) As such, the actuation elements 7a-7c are moveably supported relative to a respective component portion 2-4 during operation of the apparatus 1. Particularly, the actuation elements 7a-7c are moveably supported between at least one first position (see FIG. 3-5) in which a respective transfer force F is exertable or exerted on a respective component portion 2-4 and a second position in which a respective transfer force F is not exertable or exerted on respective component portions 2-4.

(17) As is further apparent from FIG. 1, 2, the actuation elements 7a-7c may be provided with transfer force transfer portions 14a-14c which are configured to (mechanically) contact a respective component portion 2-4 so as to exert the transfer force F to the respective component portions 2-4. A respective transfer force transfer portion 14a-14c is typically, the portion of a respective actuation element 7a-7c which (directly) contacts a respective component portion 2-4 during operation of the apparatus 1. A respective transfer force transfer portion 14a-14c is thus, the portion of a respective actuation element 7a-7c with which the transfer force F is exerted on the respective component portion 2-4 during operation of the apparatus 1. Hence, a respective transfer force transfer portion 14a-14c is typically, provided at a free (distal) end of a respective actuation element 7a-7c.

(18) As is also apparent from the FIG., a respective force transfer portion 14a-14c may be provided with a shape, particularly a contour, which corresponds to the shape, particularly the outer contour, of the component portion 2-4 on which the transfer force F is to be exerted during operation of the apparatus 1. As such, a respective force transfer portion 14a-14c may have an individual design chosen under consideration of the shape of a respective component portion 2-4.

(19) Respective force transfer portions 14a-14c may be moveably supported between at least two positions relative to a base body of a respective actuation element 7a-7c so as to be adaptable or adapted to a specific shape, particularly a specific outer contour, of the component portion 2-4 on which the transfer force F is to be exerted during operation of the apparatus 1.

(20) As is apparent from the FIG., the apparatus 1 may further comprise a support device 15 comprising support elements 16a-16c configured to support the or a respective plastic component 5 during operation of the apparatus 1. The support elements 16a-16c may be provided as the aforementioned counter-bearing elements 8a-8c, or vice versa.

(21) As is further apparent from the FIG., a respective support element 16a-16c may be provided with at least one support portion 17a-17c which is configured to contact a respective component portion 2-4 so as to support the plastic component 5 during operation of the apparatus 1. A respective support portion 17a-17c is typically, the portion of a respective support element 16a-16c which (directly) contacts a respective component portion 2-4 during operation of the apparatus 1. A respective support portion 17a-17c is thus, the portion of a respective support element 16a-16c which support a respective component portion 2-4 during operation of the apparatus 1. Hence, a respective support portion 17a-17c is typically, provided at a free (distal) end of a respective support element 16a-16c.

(22) Respective support portions 17a-17c may be provided with a shape, particularly a contour, which corresponds to the shape, particularly the outer contour, of the component portion 2-4 which is supported or which is to be supported during operation of the apparatus 1. As such, a respective support portion 17a-17c may have an individual design chosen under consideration of the shape of a respective component portion 2-4.

(23) Respective support portions 17a-17c may be moveably supported between at least two positions relative to a base body of a respective support element 16a-16c so as to be adaptable or adapted to a specific shape, particularly a specific outer contour, of the component portion 2-4 which is supported or which is to be supported during operation of the apparatus 1.

(24) As is apparent from FIG. 1, 2, the apparatus 1 may comprise a drive device 10 comprising drive elements 11a-11c assignable or assigned to the respective actuation elements 7a-7c. The drive elements 11a-11c, which may be built as or comprise a drive motor, particularly a linear drive motor, such as an electric motor, for instance may be configured to generate a drive force so as to move the respective assigned actuation element 7a-7c the at least one first position and the second position, or vice versa. The drive elements 11a-11c are thus, coupled with respective assigned actuation elements 7a-7c so as to apply the drive force on the respective assigned actuation element 7a-7c which results in a motion of the respective actuation element 7a-7c between the at least one first and second position, or vice versa.

(25) Coupling between respective drive elements 11a-11c and respective assigned actuation elements 7a-7c may be realized by respective coupling structures 12 comprising at least one coupling element 13a-13c. Respective coupling elements 13a-13c are configured to couple respective drive elements 11a-11c with respective actuation elements 7a-7c. As is apparent from FIG. 1, 2, respective coupling elements 13a-13c can be built as or comprise a mechanical coupling element such as a plunger element, for instance.

(26) As is further apparent from FIGS. 1, 2, and 6, the apparatus 1 may comprise a base structure 18, particularly built as or comprising a base plate. The base structure 18 comprises connection interfaces 19a-19n configured to detachably connect respective actuation elements 7a-7c and/or support elements 16a-16c with the base structure 18. As is apparent from FIG. 6, the base structure 18 comprises a plurality of respective connection interfaces 19a distributed at pre-definable or pre-defined different positions across a surface of the base structure 18. A respective connection interface 19a-19n may be a mechanical connection interface, e.g. a connection interface allowing for a mechanical connection of a respective actuation element 7a-7c or a respective support element 16a-16c with the base structure 18. The connection interfaces 19a-19n are exemplarily shown as connection stubs in the FIG. Merely as an example, a mechanical connection interface may allow for a bolted connection or a clamped connection. Other connection interfaces, e.g. magnetic connection interfaces, are conceivable as well.

(27) FIGS. 1, 2, and 6 further show that the actuation elements 7a-7c may be mounted on an actuation element mounting structure 20a, b, e.g. a mounting plate. The actuation element mounting structure 20a, b may comprise a connection interface face configured to co-act with at least one connection interface 19an of the base structure 18. Likewise, the support elements 16a-16c may be mounted on a support element mounting structure 21a, b, e.g. a mounting plate. The support element mounting structure 21a, 21b may comprise a connection interface configured to co-act with at least one connection interface 19a-19n of the base structure 18. Hence, by co-acting or interacting of respective connection interfaces, respective actuation elements 7a-7c and/or respective support elements 16a-16c may be deliberately connectable or connected at different orientations and/or positions on the base structure 18 providing the apparatus 1 with a high degree of flexibility and/or modularity. As is particularly, apparent from FIG. 6, the actuation element support structure 20a, b and the support element mounting structure 21a, b can be the same component.

(28) Operation of respective drive elements 11a-11c is typically, controlled by a hardware- and/or software embodied control unit (not shown), e.g. a microprocessor, computer, etc., of the actuation device 6 or apparatus 1, respectively. The control unit may be particularly, configured to operate respective drive elements 11a-11c dependent or independent from each other, i.e. particularly synchronously or asynchronously.

(29) The control unit may be particularly, configured to operate respective drive elements 11a-11c dependent or independent from each other, i.e. particularly synchronously or asynchronously.

(30) The control unit may be associated with a communication unit (not shown) allowing for locally or globally communicating with other control units of a manufacturing environment for manufacturing plastic components 5.

(31) The control unit may be configured so as to allow for an at least semi-automated operation of the apparatus 1.

(32) Even though not depicted in the FIG., actuation elements 7a-7c may be arrangeable or arranged in an (essentially) opposite arrangement so that oppositely arranged actuation elements 7a-7c may exert a transfer force F on the same component portion 2-4 of a respective plastic component 5. Thus, according to another exemplary arrangement, two actuation elements 7a-7c may be arrangeable or arranged in an opposite arrangement. Thereby, a respective receiving gap 9a-9c for receiving a respective component portion 2-4 between the respective actuation elements 7a-7c may be built or defined between the respective actuation elements 7a-7c.

(33) Even though not depicted in the FIG., the apparatus 1 may comprise at least one detection device being configured to detect an operational state, e.g. a force exertion state, a motion state, etc. of the actuation device 6 and at least one actuation element 7a-7c, respectively. A respective detection device may thus, comprise at least one detection element, e.g. a sensing element, allowing for a detection of at least one operational state of the actuation device 6 and at least one actuation element 7a-7c, respectively. Additionally or alternatively, a respective detection device may be configured to detect chemical and/or physical and/or geometric properties of a respective component portion 2-4 or the plastic component 5, respectively. A respective detection device may thus, comprise at least one detection element, e.g. an optical detection element, such as a camera, a temperature detection element, such as a temperature sensor, etc., allowing for detection of at least one chemical and/or physical and/or geometric property of a respective component portion 2-4 or the plastic component 5, respectively.

(34) The apparatus 1 allows for implementing a method for transferring at least one component portion 2-4 of an at least partially, particularly completely, undercut plastic component 5, e.g. a window frame trim component, from a first state, in which the at least one component portion 2-4 has a geometric deviation from a component-specific reference state, to a second state, in which the at least one component portion 2-4 has no geometric deviation from the reference state.

(35) The method comprises exerting with at least one actuation element 7a-7c of an actuation device 6, a transfer force F to a plastic component 5 having at least one component portion 2-4 having a first state, in which the at least one component portion 2-4 has a geometric deviation from a component-specific reference state so as to transfer the component portion 2-4 from the first state to a second state, in which the component portion 2-4 has no geometric deviation from the reference state.

(36) The method can be implemented as a sub-method of a superordinate method of manufacturing an at least partially, particularly completely, undercut plastic component 5, particularly a window frame trim component.

(37) The superordinate method comprises manufacturing a respective plastic component 5 by injection molding, removing the injection molded plastic component 5 from an injection molding tool, whereby the plastic component 5 comprises at least one component portion 2-4 which is in a first state, in which the at least one component portion 2-4 has a geometric deviation from a component-specific reference state, arranging the plastic component 5 in an apparatus 1, and exerting with at least one actuation element 7a-7c of an actuation device 6 of the apparatus 1, a transfer force F to the plastic component 5 so as to transfer the component portion 2-4 from the first state to a second state, in which the component portion 2-4 has no geometric deviation from the reference state.

(38) The exerting step is typically, performed directly after, e.g. within a time window of at most 30 seconds, particularly at most 20 seconds, preferably at most 10 seconds, removing of the plastic component 5 from the injection molding tool.