Injection mold for ultra thin wall components

Patent metadata

Field	Value
Publication number	US-10464244-B2
Application number	US-201715433219-A
Country	US
Kind code	B2
Filing date	Feb 15, 2017
Priority date	Feb 15, 2017
Publication date	Nov 5, 2019
Grant date	Nov 5, 2019

Abstract

An improved injection mold for forming an injection molded component. The injection mold includes a main cavity block and a main core block that are moveable with respect to one another. The main cavity block has a cavity block mating face that includes a first mold surface and the main core block has a core block mating face that includes a second mold surface. A plurality of induction heating coils extend within the main cavity block and a plurality of gas inlet channels extend through the main core block. The second mold surface includes a plurality ridges that cooperatively form a continuous gas flow path that is disposed in fluid communication with the plurality of as inlet channels. The continuous gas flow path follows a serpentine shape to provide even and uninterrupted gas flow across the second mold surface.

First claim

What is claimed is:

1. An injection mold for forming an injection molded component comprising:
a main cavity block having a cavity block mating face and a cavity block distal face, said cavity block mating face including a first mold surface;
a main core block having a core block mating face and a core block distal face, said core block mating face including a second mold surface;
at least one of said main core block and said main cavity block being moveable so as to define a closed position and an ejection position of the injection mold;
at least part of said cavity block mating face abutting at least part of said core block mating face when said main cavity block and said main core block are arranged in said closed position with said first and second mold surfaces cooperatively defining a mold cavity therebetween and said cavity block mating face and said core block mating face being spaced apart when said main cavity block and said main core block are arranged in said ejection position;
a plurality of induction heating coils extending within said main cavity block that are positioned between said first mold surface and said cavity block distal face;
a plurality of gas inlet channels extending through said main core block to said second mold surface;
said second mold surface including a plurality ridges that cooperatively form a continuous gas flow path that is disposed in fluid communication with said plurality of gas inlet channels, said plurality of ridges being arranged such that said continuous gas flow path follows a serpentine shape across said second mold surface to provide uninterrupted gas flow across said second mold surface.

2. The injection mold as set forth in claim 1 , further comprising:
a core clamp plate spaced from said core block distal face to define an ejector cavity between said core clamp plate and said core block distal face; and
at least two ejector support rails extending between and connecting said core clamp plate and said core block distal face.

3. The injection mold as set forth in claim 2 , further comprising:
a plurality of ejection guide pins extending through said ejector cavity between said core clamp plate and said core block distal face, said plurality of ejection guide pins being parallel with one another.

4. The injection mold as set forth in claim 3 , further comprising:
an ejector plate disposed in said ejector cavity between said at least two ejector support rails and between said core clamp plate and said core block distal face, said ejector plate including a plurality of ejector plate guide holes, and said plurality of ejection guide pins extending through and being slidingly received in said plurality of ejector plate guide holes such that said ejector plate is moveable within said ejector cavity between said core clamp plate and said core block distal face.

5. The injection mold as set forth in claim 4 , further comprising:
a retainer plate disposed in said ejector cavity between said at least two ejector support rails, said retainer plate including a plurality of retainer plate guide holes, and said plurality of ejection guide pins extending through and being slidingly received in said plurality of retainer plate guide holes such that said retainer plate is moveable within said ejector cavity between said core clamp plate and said core block distal face.

6. The injection mold as set forth in claim 5 , further comprising:
a plurality of ejection return pins extending from said retainer plate, said main core block including a plurality of ejection return pin holes extending into said main core block from said core block distal face, and said plurality of ejection return pins extending into and being slidingly received in said plurality of ejection return pin holes in said main core block.

7. The injection mold as set forth in claim 1 , further comprising:
a plurality of leader guide pins extending outwardly from said cavity block mating face, said plurality of leader guide pins being parallel to one another; and
a plurality of leader guide pin holes extending inwardly into said main core block from said core block mating face.

8. The injection mold as set forth in claim 7 , wherein said plurality of leader guide pins extend into and are slidingly received in said plurality of leader guide pin holes in said main core block such that said main core block is moveable with respect to said main cavity block between said closed position and said ejection position along an actuation direction that is parallel to said plurality of leader guide pins.

9. The injection mold as set forth in claim 1 , further comprising:
a cavity clamp plate spaced from said cavity block distal face to define an injection manifold between said cavity clamp plate and said cavity block distal face; and
at least two manifold spacer rails extending between and connecting said cavity clamp plate and said cavity block distal face.

10. The injection mold as set forth in claim 1 , wherein said main cavity block has a plurality of cooling channels extending within said main cavity block that are disposed between said cavity block mating face and said cavity block distal face.

11. The injection mold as set forth in claim 1 , wherein said plurality of ridges form a zig-zag pattern on said second mold surface.

12. The injection mold as set forth in claim 1 , wherein said first mold surface is smooth.

13. The injection mold as set forth in claim 1 , wherein said first mold surface has a concave shape and said second mold surface has a convex shape.

14. The injection mold as set forth in claim 1 , wherein said second mold surface has a predetermined surface area and wherein said plurality of ridges and said continuous gas flow path extend across more than 50 percent of said predetermined surface area of said second mold surface.

Assignees

• Fca Us Llc

Inventors

• Aquilina Daniel
• Finn Gregory J
• Shah Ketan
• Olar David V
• Compeau David E

Classifications

• B29C45/26

  Moulds · CPC title

• B29C45/174 Primary

  Applying a pressurised fluid to the outer surface of the injected material inside the mould cavity, e.g. for preventing shrinkage marks · CPC title

• B29C2045/7368

  combining a heating or cooling fluid and non-fluid means · CPC title

• B29C45/401

  Ejector pin constructions or mountings · CPC title

• B29C45/73

  of the mould {(B29C45/2642 and B29C45/2737 take precedence)} · CPC title