Temperature controlled molding of composite components

摘要

Systems and processes that limit distortion of inserts (e.g., previously formed parts) in insert molding and overmolding processes. Initially, a mold may be closed (e.g., clamped) about an insert with the mold at a first temperature. After closing the mold about the insert, the mold is heated up to a second temperature (e.g., a temperature suitable for injection of the molding material) and filled with the molding material to contact (e.g., encapsulate) the insert. After the mold has been cooled, the mold may be opened and the finished part (including the insert and the solidified molding material) removed (e.g., ejected). The process may be repeated for additional finished parts. Closing the mold about the insert before heating the mold to the injection temperature advantageously limits distortion of the insert that would otherwise occur by placing the insert into the mold with the mold already at the injection temperature.

主权项

1. An injection molding process, comprising:
obtaining a previously-formed part; preheating a mold to a first temperature such that when the mold is at the first temperature, the mold does not cause distortion to the previously-formed part upon contact with the mold, wherein the mold includes a stationary injection mold with at least one sprue through which molding material enters, and a moveable ejector mold that is moveable relative to the injection mold; placing the previously-formed part into a cavity of the mold when the mold is at the first temperature; closing the mold about the previously-formed part; heating, after the closing, the mold from a the first temperature up to a second temperature; filling, while at the second temperature, the cavity with molding material such that the molding material contacts the previously-formed part; after the filling, maintaining, while at the second temperature, a holding pressure on the previously-formed part with first and second molding members of the mold; cooling the mold from the second temperature down to a third temperature that is lower than the first temperature; moving the ejector mold away from the injection mold as a finished part remains on the ejector mold, wherein the finished part including the previously-formed part and the injected molding material; and using ejector pins that are a part of the mold to eject the finished part off the ejector mold.