THICK PLASTIC PART AND METHOD OF MAKING AND TOOL

摘要

In some embodiments, a tool includes, in an injection molding machine, a movable internal core configured to receive a molded plastic layer thereon, the molded plastic layer having a thickness. The tool also comprises an injection nozzle configured to inject plastic material over the movable internal core to form the molded plastic layer; an ejection plate connected to the movable internal core; and multiple, movable support plates each having a thickness. The multiple, movable support plates are located behind the ejection plate. A movable support plate of the multiple, movable support plates is configured to determine the thickness of the molded plastic layer.

主权项

1. A thick plastic part made by the method comprising
a) injecting a first material onto an internal core of a tool to form a molded layer, wherein the internal core is connected to an ejector plate and support plates are located behind the ejector plate opposite the internal core; b) opening the tool and removing a first support plate from behind the ejector plate; c) closing the tool, wherein a gap having a thickness is created in the tool, the thickness of the gap being determined by the thickness of the first support plate removed in b); d) molding a second layer over the first layer and within the gap, the thickness of the second layer being determined by the thickness of the first support plate removed in b), to produce the plastic part; e) opening the tool and removing a second support plate from behind the ejector plate; f) closing the tool, wherein the ejector plate, the internal core, the first layer and the second layer move together to create a second gap in the tool, the thickness of the second gap being determined by the thickness of the second support plate; g) molding a third layer onto the second layer after the second layer has cooled, the third layer having a thickness which is determined by the thickness of the second support plate; and h) molding subsequent layers until a desired thickness is attained; wherein the plastic part has a thickness of greater than 5 mm.