Multiple-material injection molding
View Patent ↗A method and apparatus for creating distinct zones in a mold that can be separately filled, particularly with different materials. A molded barrier is created within the mold and the mold is configured so that the barrier separates zones in a mold cavity. Different materials may then be injected into the separate zones to create a molded article constructed of multiple materials.
1. A method of injection molding a molded article, comprising the steps of:
providing a closed mold having a mold cavity;
creating an enclosed barrier molding portion within the mold cavity;
injecting a barrier material into the barrier molding portion to create a barrier;
configuring the mold while the mold remains closed such that the barrier is located in a barrier receiving portion and isolates a first empty zone of the mold cavity from a second empty zone of the mold cavity, the barrier having a portion that is located between the first and second empty zones and a further portion that is raised above and partially overlaps each of the first and second empty zones;
injecting a first material into the first empty zone; and
injecting a second material into the second empty zone.
2. The method of claim 1 , further comprising the steps of: opening the mold; and ejecting the molded article.
3. The method of claim 1 , wherein the barrier material and the first material are the same.
4. The method of claim 1 , wherein the barrier material and the second material are the same.
5. The method of claim 1 , wherein the step of configuring the mold comprises the steps of:
retracting a barrier core configured to extend longitudinally into a pocket of the mold cavity to create the barrier molding portion; and
applying a pressurized fluid to the barrier.
6. The method of claim 1 , wherein the step of configuring the mold comprises the steps of:
retracting a barrier shut-off that is configured to extend transversely across a pocket of the mold cavity to form the barrier molding portion; and
extending a barrier core.
7. The method of claim 1 , wherein the step of configuring the mold comprises the steps of:
retracting a barrier guide configured to extend longitudinally into a pocket of the mold cavity to form the barrier molding portion; and
extending a barrier positioner.
8. The method of claim 1 , wherein the step of configuring the mold comprises the step of:
retracting a plurality of barrier molding portion side walls.
9. A method of injection molding a molded article, comprising the steps of:
providing a closed mold having a mold cavity and a retractable barrier core; creating an enclosed barrier molding portion within the mold cavity by extending the barrier core;
injecting a barrier material into the barrier molding portion to create a barrier;
positioning the barrier into a barrier receiving portion of the mold cavity while the mold remains closed such that the barrier isolates a first empty portion of the mold cavity from a second empty portion of the mold cavity by retracting the barrier core and injecting pressurized fluid into the barrier molding portion;
injecting a first material into the first empty portion;
injecting a second material into the second empty portion;
opening the mold; and
ejecting the molded article by extending a plurality of ejector pins.
10. A method of injection molding a molded article, comprising the steps of:
providing a closed mold having a mold cavity;
creating an enclosed barrier molding portion within a pocket of the mold cavity;
injecting a barrier material into the barrier molding portion to create a barrier;
moving the barrier into a barrier receiving portion while the mold remains closed such that the barrier isolates a first empty zone of the mold cavity from a second empty zone of the mold cavity;
injecting a first material into the first empty zone;
injecting a second material into the second empty zone.
11. The method of claim 10 , wherein the step of moving the barrier comprises the steps of:
retracting a barrier core configured to extend longitudinally into a pocket of the mold cavity to create the barrier molding portion; and applying a pressurized fluid to the barrier.
12. The method of claim 10 , wherein the step of moving the barrier comprises the steps of:
retracting a barrier shut-off that is configured to extend transversely across a pocket of the mold cavity to form the barrier molding portion; and extending a barrier core.
13. The method of claim 10 , wherein the step of moving the barrier comprises the steps of:
retracting a barrier guide configured to extend longitudinally into a pocket of the mold cavity to form the barrier molding portion; and extending a barrier postioner.
14. A method of injection molding a molded article, comprising the steps of:
providing a closed mold having a mold cavity and retractable barrier side walls;
creating an enclosed barrier molding portion within the mold cavity by extending the barrier side walls;
injecting a barrier material into the barrier molding portion to create a barrier;
retracting the barrier side walls while the mold remains closed such that the barrier isolates a first empty portion of the mold cavity from a second empty portion of the mold cavity;
injecting a first material into the first empty portion;
injecting a second material into the second empty portion;
opening the mold; and
ejecting the molded article by extending a plurality of ejector pins,
wherein creating the enclosed barrier molding portion includes creating a barrier molding portion that is between the first empty portion of the mold cavity and the second empty portion of the mold cavity and a further barrier molding portion that is raised above and partially overlaps each of the first empty portion ofthe mold cavity and the second empty portion of the mold cavity.