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Standard structural elements are prepared into semi-finished products that fulfill the geometrical outlines of finished products, thus significantly shortening manufacturing mold delivery time.The comparison between the modularity design mold development process and the conventional process. Standard structural elements are fast to produce since they are pre-manufactured into general shapes and require minimal manufacturing to yield a finished product. The geometrical design of the beverage containers examined in this study. The mold insert that best
correspondents with the product shape has a simple geometrical shape. For example, the cylinder and the cuboid represent cup-type and basin-type containers,respectively. The remaining components are modularized to facilitate their effective integration into a complete set of injection molds in a manner similar to stacking playing blocks.
3.3.2 Assembly design of structural unit
Hundreds of structural elements are involved in new product development, each containing numerous dimensions. Assembling such a sophisticated system may frequently fail because of small mistakes occurring in dimensions. This study defines dimensions involving structural elements with mutual assembly relationships as union dimensions. These dimensions are simplified to a fool-proofing effect. Procedures for assembling structural elements are introduced below:
(1) Direction of module assembly—Two lines are used to separate a mold into four assembly modules. The first line is the parting line defining the female and male molds. The second line defines the boundary between
the front and rear hot-runner plates. The sequence of assembly follows the order of male mold, female mold, front hot-runner plate, and rear hot-runner plate.
(2) Direction of assembly units—Each unit belonging to the above-mentioned four assembling modules is assembled in a sequence, namely, confirming the appearance dimensions of injection-molded parts,
further confirming the product-related dimensions of the mold insert and mold cavity, fixing the mold insert with the clamping module, identifying the dimension of the hot-runner module using the structural components of the female mold, calculating the precise dimensions of the clamping plates, and finally selecting the injection molding machine specifications. The assembling sequence primarily follows product, mold insert, clamping plate, and injection molding machine.
3.4 Standardization of structural unit
As for the structural units of beverage-container injection molds, the concept of product families is further introduced to increase the commonality and exchangeability among various functional units. Figure 4 illustrates an example of mutually substitutable cooling systems. Furthermore, Fig. 5 shows the design of various ejection systems used for
product families.
3.4.1 Design of cooling system
The cooling system comprises two units: male mold cooling unit and female mold cooling unit. The male mold cooling unit includes fountain, double spiral, single spiral, nd block plate types listed in descending sequence of cooling efficiency. Based on manufacturing cost and cooling
effect, the double spiral type is prioritized. As to the female mold cooling unit, it includes multi-segment, block plate, U shape, and linear types listed in descending sequence of cooling efficiency. Based on manufacturing cost and cooling effect, block plate is prioritized.
3.4.2 Design of ejection mechanism
The beverage container is normally thin-walled and the ideal ejection mechanism is an air ejector, based on the desirability of preventing damage to injection-molded parts.As for injection molding materials with high shrinkage, the ejector plate can be selected to smoothly separate the products and mold. The air ejector design incorporates two air outlets around the mold insert, namely, one L-type outlet and one line-type outlet. The air in the L-type outlet enters the periphery of the mold insert and separates the injectionmolded parts from the mold insert. The air in the line-type outlet is then injected into the bottom of the parts to eject