Tool for forming an injection molded composite construct
A structure is injection molded onto a group of panels to form a container. The container has a tray and an injection-molded feature. The tray has a plurality of side panels that extend at least partially around, and at least partially define, a cavity of the container. The tray has a plurality of multi-part flanges with at least one of the multi-part flanges including a lower flange portion and an upper flange portion. The injection-molded feature has band that is injected molded onto the lower flange portion and the upper flange portion. An injection-molded strip extends along and at least partially defines the corner of the container. The strip extends downward from the inner portion of the band in the elongate corner of the container. A tool is also disclosed for forming the container.
1. A tool for forming a container, the tool comprising:
a cavity operable to receive a blank, the cavity comprising a corner and having at least one sidewall for forming at least one sidewall of the container and at least one flange wall for forming at least one flange of the container;
a core operatively connected to the cavity, the core operable to enter the cavity to at least partially form the blank into the container;
an injection cavity at least partially formed from the cavity and the core, the injection cavity being for receiving liquid resin and directing liquid resin around at least a portion of the perimeter of the blank and forming an injection-molded band on the at least one flange of the container, the injection cavity comprising an advanced-flow section and a delayed-flow section, the corner of the cavity forming a portion of the advanced-flow section and the advanced-flow section having a greater cross-sectional area than the delayed-flow section, the advanced-flow section being located adjacent the at least one sidewall of the cavity and the delayed-flow section extending outwardly from the advanced-flow section beyond the at least one flange wall, the delayed-flow section comprising an elongate portion that extends outwardly from an edge of the at least one flange of the container, the corner of the cavity forms an injection-molded strip that extends from the injection-molded band and at least partially defines a corner of the container, the corner of the cavity comprises a cutout for facilitating flow of resin into the advanced-flow section at the corner of the cavity.
2. The tool of claim 1 wherein the advanced-flow section is configured to permit a higher flow rate of resin flow than the delayed-flow section.
3. The tool of claim 1 comprising an injection port for the flow of resin into the injection cavity, the corner of the cavity is a first corner and the cavity further comprises a second corner, a third corner, and a fourth corner, the second corner of the cavity defines a second corner of the container and comprises a cutout for facilitating the flow of resin into the advanced-flow section at the second corner of the cavity.
4. The tool of claim 3 wherein the first corner of the cavity and the second corner of the cavity are both located farther away from the injection port than the third corner of the cavity and the fourth corner of the cavity.
5. The tool of claim 1 wherein the delayed-flow section comprising an elongate portion that extends outwardly from an edge of the at least one flange of the container.