DEVICE AND METHOD FOR MANUFACTURING COMPOSITE PRODUCTS WITH AN INJECTION-MOLDED FEATURE

Abstract

The invention is directed to an injection molding device for manufacturing of composite products comprising a combination of a blank and an injection-molded plastic component, the product and a method of manufacturing of these composite products. The injection molding device comprising two outer mold halves displaceable along a first axis and a center block being arranged, with respect to the first direction, between the outer mold halves rotatable around a center axis perpendicular to the first direction. The center block carrying inner mold halves on at least one pair of side faces, which each form with outer mold halves in the closed position at least one cavity. The at least one cavity comprises at least one clamping means to clamp at least one blank, and in the closed position of the injection molding device forming at least one compartment to receive liquefied plastic material to form a plastic component interconnecting to the blank along at least one pair of adjacent edges.

Claims

1. An injection molding device (1), for manufacturing of composite products (2) comprising a combination of a blank (3) and an injection-molded plastic component (4), the injection molding device (1) comprising: a. a first outer mold half (5) comprising a first outer side face (6) and a second outer mold half (7) which is arranged displaceable with respect to the first outer mold half (5) in a first direction (x) between an open position and a closed position and comprising a second outer side face (8); and b. a center block (9) arranged, with respect to the first direction (x), between the first and the second outer mold half (5, 7) and in the open position of the injection molding device (1) being rotatable around a center axis (Z) arranged perpendicular with respect to the first direction (x); c. the center block (9) comprising at least one pair of center block side faces (10) each carrying an inner mold half (33) interacting in a closed position of the injection molding device (1) in a first separation plane (11) with the first outer mold half (5), respectively in a second separation plane (12) with the second outer mold half (7) forming in the closed position at least one first cavity (13) and at least one second cavity (14); d. at least one of the first and/or the second cavity (13; 14) comprising at least one clamping means (15) to clamp at least one blank (3), and in the closed position of the injection molding device (1) forming at least one compartment (16) to receive liquefied plastic material to form a plastic component (4) interconnecting to the blank (3) along at least one pair (18) of adjacent edges (17).

2. The injection molding device (1) according to claim 1, wherein in the closed position of the injection molding device (1) the at least one first cavity (13) and/or the least one second cavity (14) is formed by a convex core (19) and an operatively associated concave recess (20).

3. The injection molding device (1) according to claim 2, wherein at least one concave recess (20) is arranged on a side face (10) of the center block (9) and a thereto operatively associated convex core (19) is arranged on a side face (6, 8) of at least one outer mold half (5, 7).

4. The injection molding device (1) according to claim 2, wherein at least one convex core (19) is arranged on a side face (10) of the center block (9) and a thereto operatively associated concave recess (20) is arranged on a side face (6, 8) of at least one outer mold half (5, 7).

5. The injection molding device (1) according to claim 1, wherein the at least one clamping means (15) in the closed position is formed between the convex core (19) and the concave recess (20) by at least one protrusion arranged on the convex core (19) and/or the concave recess (20) in the closed position temporarily clamping the blank (3) between the convex core (19) and the concave recess (20).

6. The injection molding device (1) according to claim 2, wherein the at least one protrusion is arranged circumferential on the convex core (19) and/or the concave recess (20) delimiting the at least one compartment (16) for the liquefied plastic material.

7. The injection molding device (1) according to claim 1, wherein the convex core (19) and/or the concave recess (20) comprises holding means to temporarily hold the blank (3) at the thereto related side face (10) of center block (9) during rotation.

8. The injection molding device (1) according to claim 7, wherein the holding means are formed as a suction means and/or clamping means and/or friction means (24).

9. The injection molding device (1) according to claim 1, wherein the at least one compartment (16) has a cage-like structure (25) extending along the at least one pair (18) of adjacent edges (17) of the blank (3).

10. A composite product (2) comprising a blank (3) with at least one pair (18) of adjacent edges (17) and a plastic component (4) forming a cage-like structure along the at least one pair (18) of adjacent edges (17).

11. The composite product (2) according to claim 10, wherein a lid (26) interconnected to the cage-like structure (25) via a film hinge (27).

12. The composite product (2) according to claim 11, wherein the cage like structure (25) and/or the lid (26) comprises at least one an injection mark (28) of a sprue channel.

13. The composite product (2) according to claim 12, wherein the at least one injection mark (28) is arranged at the cage-like structure (25) and/or the lid (26).

14. The composite product (2) according to claim 10, wherein at least one pair (18) of adjacent edges (17) are interconnected to each other by an auxiliary flap (30).

15. The composite product (2) according to claim 10, wherein the cage-like structure (25) is made from a bio-degradable material.

16. A method for manufacturing composite products (2) comprising a combination of a blank (3) and an injection-molded plastic component (4) comprising the steps: a. providing an injection molding device (1) comprising: i. a first outer mold half (5) comprising a first outer side face (6) and a second outer mold half (7) which is arranged displaceable with respect to the first outer mold half (5) in a first direction (x) between an open position and a closed position and comprising a second outer side face (8); and ii. a center block (9) arranged, with respect to the first direction (x), between the first and the second outer mold half (5, 7) and in the open position of the injection molding device (1) being rotatable around a center axis (Z) arranged perpendicular with respect to the first direction (x); iii. the center block (9) comprising at least one pair of center block side faces (10) each carrying an inner mold half (33) interacting in a closed position of the injection molding device (1) in a first separation plane (11) with the first outer mold half (5), respectively in a second separation plane (12) with the second outer mold half (7) forming in the closed position at least one first cavity (13) and at least one second cavity (14); iv. at least one of the first and/or the second cavity (13; 14) comprising at least one clamping means (15) to clamp at least one blank (3), and in the closed position of the injection molding device (1) forming at least one compartment (16) to receive liquefied plastic material to form a plastic component (4) interconnecting to the blank (3) along at least one pair (18) of adjacent edges (17); and v. in the closed position of the injection molding device (1) the at least one first cavity (13) and/or the least one second cavity (14) is formed by a convex core (19) and an operatively associated concave recess (20); b. loading a blank (3) onto the convex core (19) or into the concave recess (20). c. rotating the center block (9) by 90°; d. closing the injection molding device (1); e. injecting liquefied plastic material into the at least one compartment (16); f. opening the injection molding device (1); g. rotating the center block (9) by 90°; and h. removing the composite product (2) comprising a combination of a blank (3) and an injection-molded plastic component (4).

17. A method for manufacturing composite products (2) according to claim 16, wherein the blank (3) is provided in a preformed or folded state, essentially in the shape of the composite product (2).

18. The method for manufacturing composite products (2) according to claim 17, wherein the preformed or folded state the blank (3) is prepared by interconnecting at least one pair (18) of adjacent edges (17) to each other by an auxiliary flap (30).

19. The method for manufacturing composite products (2) according to claim 16, wherein the blank (3) is folded into the folded state while it is loaded into the concave recess (20).

20. The method for manufacturing composite products (2) according to claim 19, wherein the blank (3) is pushed into the concave recess (20) by: a. the convex core (19); or b. a folding device arranged laterally adjacent the injection molding device (1) and comprising a perpendicular to the first direction (x) displaceable folding means.

21. The method for manufacturing composite products (2) according to claim 16, wherein in the closed position the blank (3) is temporarily clamped between the convex core (19) and the concave recess (20) by clamping means (15) of the injection molding device (1), said clamping means (15) being formed between the convex core (19) and the concave recess (20) by at least one protrusion arranged on the convex core (19) and/or the concave recess (20) in the closed position.

22. The method for manufacturing composite products (2) according to claim 16, wherein the blank (3) is temporarily held by holding means of the convex core (19) and/or the concave recess (20) at the thereto related side face (10) of center block (9) during rotation.

23. The method for manufacturing composite products (2) according to claim 16, wherein liquefied plastic material is injected by means of at least one sprue channel into the at least one compartment (16) of the first and/or the second cavity (13, 14) in order to form the injection-molded plastic component (4) of the composite product (2), leaving at least one injection mark (28) of a sprue channel.

24. The method for manufacturing composite products (2) according to claim 16, wherein the at least one pair (18) of adjacent edges (17) of the blank (3) are at least partially embedded in plastic material during injection.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0041] The herein described invention will be more fully understood from the detailed description given herein below and the accompanying drawings which should not be considered limiting to the invention described in the appended claims. The drawings are showing:

[0042] FIG. 1 shows a composite product comprising a combination of a blank and an injection-molded plastic component with a cutout section;

[0043] FIG. 2 shows the injection-molded plastic component of the composite product shown in FIG. 1;

[0044] FIG. 3 shows the preformed blank of the composite product shown in FIG. 1;

[0045] FIG. 4 shows an injection mold according to the invention in a perspective manner;

[0046] FIG. 5 shows an injection mold according to the invention in a perspective manner;

[0047] FIG. 6 shows a top view of an injection molding device according to FIG. 6 in a closed position;

[0048] FIG. 7 shows a sectional view of the injection molding device from FIG. 7; and

[0049] FIG. 8 shows a detailed view of FIG. 8.

DETAILED DESCRIPTION OF THE INVENTION

[0050] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all features are shown. Indeed, embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Whenever possible, like reference numbers will be used to refer to like components or parts.

[0051] FIG. 1 shows the composite product 2 formed as a container in a perspective view. The composite product comprises a combination of a blank 3 and an injection molded plastic component 4. The composite product further comprises a lid 26 interconnected to the plastic component 4 via a film hinge 27. The lid 26 comprises one an injection mark 28 of a sprue channel arranged on the inside in a closed state of the container.

[0052] FIG. 2 shows in a perspective view the plastic component 4 forming a cage-like structure 25 of the composite product 2 of FIG. 1. Interconnected via a film hinge 27 is a lid 26, also made from plastic material. The cage-like structure is closed as all end regions of all elongated sections are interconnected to a further section in this embodiment forming rectangular corners and no non-continuous sections are present.

[0053] FIG. 3 shows in a perspective view the blank 3 of the composite product 2 of FIG. 1. The blank 3 comprises a base segment 31 and four side segments 32 interconnected to the base segment 31 and extending upward therefrom. The pair 19 of adjacent edges 18 is interconnected to each other by an auxiliary flap 30 which thereby interconnects adjacent side segments 32. Shown is a blank 3 in a preformed or folded state with essentially the shape of the finished composite product 2 container. The auxiliary flaps 30 may be attached to a corresponding neighboring side segments 32 by means of an adhesive or by formfitting into an associated cutout in the corresponding neighboring side segment 32.

[0054] FIG. 4 and FIG. 5 are showing variations of the injection molding device 1 in a perspective view. A first outer mold half 5 having a first outer side face 6 and being arranged displaceable in a first direction X with respect to the first outer mold half 5 is a second outer mold half 7 having a second outer side face 8. The displacement allows a movement of the outer mold halves between an open position and a closed position. A center block 9 arranged, with respect to the first direction X, between the first outer mold half 5 and the second outer mold half 7. The center may be rotated around a center axis Z perpendicular to the first direction X in an open position of the injection molding device 1. The center block comprises two pairs of side faces 10 each side face 10 carrying an inner mold half 33. In a closed position inner mold halves 33 interact with the outer mold halves 5 and 7 in a first and second separation plane 11, 12 respectively in order to form a first and a second cavity, as shown in FIGS. 6-8. At least one of the first and the second cavity 13, 14 comprises clamping means to clamp a blank 3 in a closed position and forms a compartment in which liquefied plastic material is injected into in order to form a plastic component. The plastic component is interconnecting at least one pair of adjacent edges of the blank 3.

[0055] FIG. 4 further shows a convex core 19 arranged on a side face 10 of the center block 9 and a thereto operatively associated concave recess 20 is arranged on at least one outer mold half 5. In this variation of the invention a multiplicity of convex cores 19 is arranged on at least one side face 10 of the center block 9.

[0056] FIG. 5 further shows a concave recess 20 arranged on a side face 10 of the center block 9 and a thereto operatively associated concave recess 19 is arranged on at least one outer mold half 5. In this variation of the invention a multiplicity of concave recesses 20 is arranged on at least one side face 10 of the center block 9.

[0057] FIG. 6 shows the injection molding device of FIG. 5 in a closed position in a top view. Arranged between the outer mold halves 5 and 7 is the center block 9. The center block side faces facing the outer mold halves 5 and 7 are each carrying an inner mold half (not shown). These inner mold halves are interacting in a first separation plane 11 and in a second separation plane 12 with the respective outer mold halves 5 and 7 to form at least one first cavity and at least one second cavity. In this variation of the invention the inner mold halves are formed each by a multiplicity of concave recesses and the operatively associated outer mold halves 5 and 7 are each formed by a multiplicity of convex cores.

[0058] FIG. 7 shows a sectional view G of the injection molding device shown in FIG. 6. The sectional plane is parallel and next to the second separation plane 12 inside the center block 9. In this closed position the convex core 19 is inserted into the concave recess 20 forming a cavity having clamping means (not shown) to clamp at least one blank. When a blank is accommodated in the first and/or the second cavity at least one compartment is formed in the first and/or the second cavity. FIG. 8 shows a detailed view H of the sectional view of FIG. 7 with a compartment 16 formed by the second cavity 14 and a blank 3. The second cavity being formed by a convex core 19 arranged on the second outer side face 8 inserted into a concave recess arranged on the side face of the center block 9 facing the second separation plane 12.

[0059] A typical process for the production of a composite product 2 comprising a combination of a blank 3 and an injection-molded plastic component 4 comprises the following process steps:

[0060] (a) When the injection molding device 1 is closed (see FIG. 6) preformed blanks 3 are placed by a handling device (not shown) onto the inner mold halves 33 at a 0° position. The blanks are temporarily held by holding means (not shown) arranged on the inner mold half 33 carried by the respective side face 10 of the center block 9. These holding means can be formed by a roughened surface area as friction means or by holes connected to channels for air to hold the blanks by suction as suction means 23.

[0061] (b) Opening the injection molding device 1 (see FIG. 5) by moving the first and the second outer mold half 5, 7 apart from each other, away from the center block 9 arranged there between in a center position.

[0062] (c) Rotating the center block 9 around the center axis Z in a counter clock direction by an angle of 90° to a 90° position.

[0063] (d) After closing of the injection molding device 1 the first and the second cavity 13, 14 are formed by concave recesses 20 and convex cores 19 and the blanks 3 are clamped by the circumferential protrusion arranged on the convex core 19 and/or the concave recess 20. The Protrusion forms a cross sectional narrowing of the first and/or second cavity 13, 14 which presses the blank 3 and delimits at least one compartment 16.

[0064] (e) Injection molding the at least one plastic component 4 forming a cage-like structure 25 by injection of liquefied plastic material into the at least one compartment 16 of the first and/or the second cavity 13, 14.

[0065] (f) After sufficient curing of the plastic component 4, opening of the injection molding device 1 as described above and rotating the center block 9 by another 90° around the center axis to a 180° position or back to a 0° position. The composite products 2 comprising a combination of a blank 3 and an injection-molded plastic component 4 thereby remaining held by the holding means of the inner mold halves 33 of the center block 9.

[0066] (g) The handling device (not shown), which is preferably arranged laterally to the injection molding device 1 next to the 180° and/or 0° position, removes the finished composite products 2.

[0067] Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the Spirit and scope of the invention.