System for continuous manufacture of molded parts with insert pieces

An insert cutter and feeder assembly for continuous production of insert pieces and automated insertion of insert pieces into an injection mold, the insert cutter and feeder assembly comprising:

• a track for receiving an insert material, the track supported in proximity to an injection mold into which an insert piece is to be inserted;
• a first roller block on the track, the first roller block having a pair of upper and lower rollers configured to bear against the insert material is the insert material passes through the first roller block, the first roller block connected to a linear actuator operative to reciprocate the first roller block along the track,
• a second roller block on the track, the second roller block having a pair of upper and lower rollers configured to bear against the insert material is the insert material passes through the second roller block,
• an insert material cutter having a stationary cutting edge on the track and a movable cutting blade operative to move relative to the stationary cutting edge with insert material between the stationary cutting edge and the movable cutting blade,
• an insert piece shuttler operative to laterally shuttle an insert piece cut from the insert material on the track, and
• an insert piece feeder operative to feed an insert piece from the track into a cavity of an injection mold.

A system for automated production of insert molded parts which have an insert piece and molded material in contact with the insert piece, the molded material formed by an injection molding process in a mold and at least a portion of the insert piece in the mold during the injection molding process, the system comprising:

• a substantially continuous supply of insert piece material;
• an insert piece cutting and feeding assembly configured for synchronous operation with an injection molding machine and a mold in the injection molding machine, the insert piece cutting and feeding assembly having an inlet adapted to receive a substantially continuous supply of insert piece material stock, a feed mechanism for feeding the insert piece material stock to an insert piece cutting station which cuts an insert piece from the insert piece material stock, and a feed mechanism which feeds an insert piece into the mold in the injection molding machine prior to molding material being introduced into the mold by the injection molding machine;
• and
• a control system for controlling operation of the insert piece cutting and feeding assembly in synchronization with operation of the injection molding machine,
• wherein the insert piece cutting and feeding assembly is attached to the injection molding machine,
• wherein the mold in the injection molding machine has an opening to a mold cavity of the mold, the opening corresponding in size to cross-sectional dimensions of an insert piece, and
• wherein the insert piece cutting and feeding assembly is operative to cut two insert pieces prior to insertion of one of the two insert pieces into the mold.

A system for automated production of insert molded parts having an insert piece and material molded about the insert piece by injection molding, the system comprising:

• an insert material supply structure for supplying insert material in a substantially continuous form;
• an insert piece cutting and feeding assembly, comprising:
• an insert material feeder operative to supply insert material to an insert material cutter;
• an insert material cutter operative to cut an insert piece from a supply of insert material;
• and
• an insert piece pusher operative to advance a precut insert piece into an injection mold cavity.

A system for automated production of insert molded parts which have an insert piece and molded material in contact with the insert piece, the molded material formed by an injection molding process in a mold and at least a portion of the insert piece in the mold during the injection molding process, the system comprising:

• a substantially continuous supply of insert piece material;
• an injection molding machine having an injection mold, the injection mold having an injection mold cavity;
• and
• an insert piece cutting and feeding assembly configured for synchronous operation with the injection molding machine and injection mold cavity, the insert piece cutting and feeding assembly comprising:
• an insert material feeder operative to supply insert material to an insert material cutter;
• an insert material cutter operative to cut an insert piece from a supply of insert material;
• and
• an insert piece pusher operative to advance a precut insert piece into an injection mold cavity.