Injection Molding for High-Precision Package Formation

Injection mold with compensating volumes to ensure uniform filling of cavities when manufacturing injection-molded parts using a shared injection site and distribution channel. The mold has separate inserts with cavities for the parts. At least one insert has an additional compensating volume in the distribution channel leading to the cavity. The compensating volume is sized so the total volume of the cavity plus compensating volume is the same for all inserts connected to the shared channel. This balances injection volumes to prevent unreliable filling when different parts are molded simultaneously.

Source

High-precision injection molding process for making green drinking water bottles that ensures accurate and consistent product quality. The process involves using advanced control techniques to precisely manage injection molding parameters like position, pressure, temperature, and flow rate. The mold is fixed in position and the injection machine receives commands from a computer to inject, cool, and eject the bottles. Sensors monitor parameters like screw position and liquid temperature. The computer adjusts the molding process steps until the product meets specified accuracy requirements. This provides high-precision molding for green drinking water bottles compared to conventional injection molding.

Source

Injection molding method for making containers with thin walls and high aspect ratios (long/short) without requiring high injection pressures. The method involves using an injection mold with two movable mold parts and one stationary part. The injection gate is close to the first movable mold part and far from the second movable part. This allows filling with lower pressure as the mold cavity width is initially smaller. After injection, the first mold part moves forward to enlarge the cavity opposite the gate. This increases the aspect ratio gradually during curing. This stepwise increase avoids overfilling the initial narrow section. The second part then moves forward to fill the expanded cavity.

Source

In-mold binding of substrates to molded articles to avoid displacement during injection molding. A flow deflector in the mold deflects the molten plastic flow over the substrate leading edge, preventing head-on contact. This forms a temporary air pocket that fills as the flow spreads from the center. This prevents substrate displacement during injection. The deflector can be dynamic. Alternatively, stabilizing the substrate edge prevents small imperfections being lifted by the flow. This allows in-mold binding without discontinuities or gaps.

Source

Injection molding process and device for creating a resin molded product with an integral sealed mounting area. The molding process involves injecting resin into a mold with a sliding member that can move into a hole near the opening. This allows the resin to fill and seal the area around the opening as the sliding member approaches. The resin cures to create a coating layer on the main body with an integrated sealed mounting area. This prevents water ingress into the molded product if a separate mounting part is added later. The mold design allows the sliding member to access the hole near the opening to seal it during molding.

Source

Preventing material leakage when forming multi-component injection molded parts by using a sealing element on the preform before injecting the second component. The sealing element can be a lip formed with the preform or applied separately. It engages surfaces when the mold expands to prevent spray material from the second component leaking into the cavity. This avoids issues like burrs and spattering from the second component penetrating the preform or mold joints.

Source

Injection molding a closure element for containers with thin spots that allows integrally molding the closure onto the container opening instead of using separate films. The thin spots have minimum wall thicknesses that enable using higher-viscosity plastics compared to prior injection molding methods. This allows processing materials like polypropylene and HDPE that have better barrier properties against oxygen, water vapor, and flavors. The thin spots break under pressure and temperature after molding to form the container-opening closure. This eliminates the need for separate films, reduces costs, improves recyclability, and prevents loosening of the closure over time.

Source

Flexible silicone mold for injection molding thermoplastics that allows reproduction of plastic parts using a flexible mold instead of a rigid metal one. The mold is made of vulcanized silicone and has a circular shape with a lower base and upper lid joined by fasteners. The flexible mold allows radial filling of the plastic material and has tiny ducts to prevent bubbles or cracks during filling. The flexible mold enables reproduction of plastic parts using thermoplastic materials like polyamides without requiring a rigid metal mold.

Source

Injection molding method and part with an insert that enables encapsulating sensitive inserts like foams or pressure-sensitive materials without damaging them. The method involves compressing a press-fit area of the insert between the mold halves before injection molding. This compresses the press area more than the core area. This allows the core area to provide a barrier to the injection molding material without compressing as much. The compressible material around the core prevents high pressures/temperatures from reaching and damaging the core during injection molding. After molding, the compressible material is compressed back to its original shape around the core.

Source

Producing molded containers with a label that cannot be peeled off or damaged by external forces. The process involves injecting a first plastic into a mold with a sheet-like label element resting against the inner wall. The label protrudes with 3D elements into the mold cavity. A core is inserted to form the inner wall. Injecting the first plastic surrounds the label elements and connects to the sheet. Then transferring the protrusion into a second mold cavity with an inner wall to inject the second plastic. The label adheres to the outer surface. The final molded part has a label sandwiched between the inner and outer walls, encapsulated by the first plastic and bonded to the outer wall.

Source

Insert molding method to attach films or sheets to molded articles like sealing strips and guide grooves for vehicles without gaps or deformation. The method involves temporarily fixing the film to the mold using adhesive before injection molding. This allows the molten material to contact and melt the film to weld it to the main body as it fills the mold. This ensures a secure bond between the film and molded article without gaps or deformation.

Source

A two-step molding process to create products like bottle closures with enhanced properties and decoration compared to conventional multi-component molding. The process involves injecting two different polymer materials into separate molds, forming the first part of the product in one mold, then moving it to the second mold to inject the second material and complete the product. This allows customization of each component before assembly. The sequential injection and separate molding steps improve properties like strength and eliminate seams. Decorations can be added in the first mold before transfer.

Source

Encapsulating electronic components in injection molded plastic to improve sealing without additional steps. The component is fixed in the mold with a removable pin. Plastic is injected around it. The pin is retracted, compressing the plastic around the component's attachment points to seal against weld lines. This eliminates the need for separate potting to seal the molded plastic.

Source

Method to produce injection molded parts with integrated septums that reduces material damage and contamination compared to traditional methods. The steps are: providing a septum, providing an injection mold, injecting the molding material, positioning the septum in the mold before or after injection, and cooling and ejecting the molded part. When positioned before injection, the septum is molded around the part during cooling. When positioned after injection, the septum is placed on the part while the material is still soft. This directly connects the septum to the molded part, eliminating the need for separate securing steps.

Source

Injection molding method for manufacturing external housings of RFID tags and wireless devices that provides a continuous molded body with improved strength, chemical resistance, and sealing around through holes. The method involves injection molding the housing in a single step using a specialized mold design. The mold has protrusions that extend into the through hole of the electronic assembly during molding. This allows the molded plastic to completely fill and seal around the through hole without any separate steps or discontinuities. The molding process uses glass-filled plastics to further enhance the housing properties.

Source