Global and China Injection Molding Machine Industry Report, 2014-2016

Injection molding machine is the most crucial plastic processing machinery, accounting for 60%-85% in developed countries, and it finds application mainly in fields like automobile, household appliances, food & beverage packaging, plastic building materials, and electronic communications.

China injection molding machine industry has grown bigger and stronger along with rapid development of downstream sectors, becoming the world's largest producer and consumer of injection molding machine. In 2010, China's injection molding machine sales exceeded RMB20 billion for the first time and approximatedRMB25.5 billion in 2013, the best since financial crisis, and it is expected to reach RMB30 billion or so in 2016.

At present, nearly 30% of China-made injection molding machines are exported. Customs data show that,China exported 25,082 injection molding machines in 2014, a year-on-year rise of 9.2%, generating export value of USD1.01 billion, up 9.1% from a year earlier.

In recent years, driven by demands from energy conservation and environmental protection, all-electric injection molding machine, electro-hydraulic injection molding machine, and two-platen injection molding machine have gradually become R&D and promotion priorities. It is noteworthy that more and more injection molding machines are two-plate ones. By early 2014, Chen Hsong Holdings, Haitian International Holdings, and Guangzhou Borch Machinery all had independently developed two-platen ultra-large injection molding machines with clamping force of 6,500 tons and above.

Global and China Injection Molding Machine Industry Report, 2014-2016 focuses on the following:
Size, structure, and major manufacturers of global injection molding machine market;
Policy environment and industry environment for injection molding machine in China;
Production, sales, import & export, and competitive landscape of injection molding machine in China;
Development of product segments, including all-electric injection molding machine, all-hydraulic injection molding machine, two-platen injection molding machine;
Development of injection molding machine in major provinces and cities, covering Zhejiang, Shenzhen, andJiangsu; 
Operation, injection molding machine business, and development strategy of 9 global and 15 Chinese injection molding machine manufacturers.

Haitian International Holdings: the largest injection molding machine manufacturer in China and even in the world; output of 27,000 injection molding machines in 2013, over 30% of China's total output.

Chen Hsong Holdings: the second largest injection molding machine manufacturer in China; focuses on large and medium-sized injection molding machines, which take up more than 50% of the company's revenue; developed supermaster 6,500-ton servo drive two-platen injection molding machine in 2014 after the launching of 4,500-ton ultra large two-platen injection molding machine in 2013. 

Engel: a major injection molding machine manufacturer in Europe, with injection molding machine production bases in Australia, Czech Republic, Germany, China, and South Korea; established second injection molding machine plant in Changzhou (China) in Mar. 2013, branded as "Wintec", which started production in Jul. 2014, with annual capacity of 300 units.

Sumitomo (SHI) Demag: formed by the injection molding activities of Sumitomo Heavy Industries (SHI) and those of Demag Plastics Group; has wholly-owned subsidiary in Ningbo, China, mainly producing precision injection molding machines; with the aim of expanding capacities in China, it invested EUR7 million to build new plants, which saw foundation-laying ceremony in Apr. 2014 and is scheduled to go into operation in Jul. 2015, with annual capacity of 1,000 injection molding machines then.

Milacron: a major injection molding machine manufacturer in America; has production bases in Jiangyin (China), manufacturing mainly ELEKTRON all-electric injection molding machine and MAXIMA large two-platen injection press; invested USD4 million-USD5 million in 2014 for capacity expansion, with current capacity lifted from 200-300 units to 950 units.

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Influence of precision injection mold What are the reasons

Mold designers must have extensive experience in the design and injection molding, we must consider the relationship between these factors and the apparent factor and injection conditions, such as the injection pressure and cavity pressure and filling speed, injection melt temperature and mold temperature, mold Structure and gate form and distribution, as well as affect the gate cross-sectional area, wall thickness, the plastic material content of the reinforcing filler, the plastic material of the crystallization degree of orientation and other factors. Also due to the above factors of different plastic materials, or other molding conditions such as temperature, humidity, and continues to crystallize, after the change of the injection molding machine varies.

    In related factors among precision injection mold is the key to meet the quality requirements of precision plastic products obtained. Mold design, mold design is reasonable will directly affect the quality of plastic products. Due to the size of the mold cavity is coupled by a required dimension of plastic shrinkage of the material used to obtain, and shrinkage often is a number in a plastic manufacturer or plastic sheets recommend a range, it is not only the gate of the mold form , gate location and distribution, but also to plastic crystal orientation (anisotropy), the shape of plastic products, the size of the distance and location of the gate. The main factors affecting the plastic shrinkage, including heat shrink, shrink phase transition, orientation shrinkage, compressive shrinkage and elastic recovery, and these factors with precision injection molding products, conditions or operating conditions.

    Because the plastic injection molding process is a process from the solid (powder or pellets) to liquid (melt) ED solid (product) change. From pellets to melt, and then, from the middle to the role of the product after the melt temperature field, flow field and density field and so on. Under the combined effect of these fields, a different plastic (thermosetting or thermoplastic, crystalline or amorphous, reinforced or non-reinforcing type, etc.) have a different morphology and rheological properties of polymers. All these factors affect the "field" is bound to affect the physical and mechanical properties of plastic products, size, shape, accuracy and visual quality.

    Thus, the intrinsic link process factors and polymer properties, morphology and plastic products will be demonstrated by between plastic products. These analyzes clearly intrinsically linked to reasonably prepared for the injection molding process, the rational design drawings in accordance with manufacture of molds, as well as a reasonable choice of injection molding equipment are important. Precision injection molding and injection molding in ordinary injection pressure and injection rate is also different, precision injection often used high or ultra-high pressure injection, high speed injection molding to obtain a smaller shrinkage.

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Four Steps Detailed injection mold maintenance

Any items require maintenance to prolong its service life, and now I will introduce the injection mold maintenance steps below.

    Responsible business should first understand the basic situation of the mold, as first deputy dies should give each card with biographical detail records, statistics of its use, care (lubrication, cleaning, rust) and damage, which can be found whereby parts, components have been damage, wear extent size to provide discovery and problem-solving information, and molding process parameters of the mold, the product of the materials used to shorten the mold test time and increase productivity.

    Processing enterprises should be under the injection molding machine, mold normal operation, the test performance of various molds and molded plastic parts last measured dimension, you can determine the current state of the mold through the information to find out the cavity, core cooling systems and sub-surface damage, such as where, according to information provided by the plastic parts, you can determine the status of the mold damage and repair measures.

    To die several important parts to focus track testing: top out, the role of the guide member is to ensure that the opening and closing movement of the mold and the top of the plastic parts, if any of these positions due to injuries and stuck, will lead to shutdown, it should be kept mold thimble, lubrication guide post (to choose the most suitable lubricant), and regularly check thimble, guide posts, etc. are deformed and surface damage, once discovered, to be replaced; after the completion of a production cycle, to work on the mold surface sports, professional guide member coated anti-rust oil, in particular should pay attention to the strength of the stretch with a gear rack mold bearing parts and springs mold protection, to ensure that it is always in top working condition; as production lasted cooling channels easily deposited scale, rust, silt and algae, so that the cooling passage section becomes smaller, the cooling channel narrows significantly reduce the rate of heat exchange between the coolant and the mold, increasing production costs, so clean-up of the flow channel attention should be paid; for hot runner mold, the maintenance of heating and control systems help prevent the production of faults, and therefore particularly important. Therefore, all deal with the end of each production cycle with a heater on the mold, rod-type heater, heated probe and thermocouple measurements with an ohmmeter, if damaged, must be replaced, and the mold resume comparison, make a record, so that timely detection of problems, take countermeasures.

    So do the last part of the mold surface is maintained, and the so-called surface is to prevent corrosion, and therefore, the choice of a suitable, high-quality, professional-rust oil is particularly important. When the mold production tasks, should be taken different ways, depending on the injection carefully remove residual injection, available copper, copper and professional mold cleaners remove residual mold injection molding and other sediments, and air dried. Disable wire, steel bars and other hard objects to clean up, so as not to scratch the surface. If rust corrosion caused by injection, to use a grinder polishing and spray on a professional anti-rust oil, and then the mold in a dry, cool, no dust at the store.

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How should prevent streaks injection mold defects

Injection mold stripe defects occur is very serious matter, mild damage the injection mold, serious will completely scrapped. Correct injection mold design, meticulous processing, reasonable repair mode, timely nitride is a key measure to prevent tissue streak defects.

      The mold should be strictly in accordance with the drawings request processing, with particular attention to improving surface finish and mold bridge shunt hole was dripping shape, improving the state of solid metal flow, reduce friction heat;

      For organizations fringes generated when the injection mold extrusion, mold repair work should go to the scene to understand the injection mold the material circumstances, to determine the correct repair mode programs; mold repair work personally observe the instantaneous state of the material profiles observed profiles than the material feed up determine the effect of the program is much better repair mode;

      Injection mold according to regulations in a timely manner nitride, ensuring a reasonable flow of state of solid metal.

      Correct injection mold design, rational distribution of the vent hole, reasonably determine the length of the work zone, and the change in length of the transition, the bridge dripping mold shape, reasonable welding angle, so that the weld point falls flat on welding chamber, to ensure the mold core When head stiffness, strength and deepen the depth of welding chamber or expanded welding chamber of basal area, if necessary, the use of "Shen Bridge", is the basis of organizational measures to prevent streaks defects.

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Encapsulation molding compound

With highly integrated IC, the chip and the package size is increased, the shell of the encapsulation layer, and to further reduce the price request for a higher molding and comprehensive requirements, as follows.

1) moldability fluidity, curability, mold release properties, mold contamination habits, metal abrasion resistance, storage stability of the material, and so the appearance of the package.

(2) Heat resistance

(3) Moisture Resistance

(4) corrosion resistance

(5) adhesive

(6) The electrical characteristics under a variety of environmental electrical insulation, high-frequency characteristics, charging and so on.

(7) mechanical properties of tensile and flexural properties (strength and elastic retention of the green temperature), impact strength.

(8) Other printability (ink, laser), flame resistance, soft, elastic, non-toxic and low-toxicity, low cost, color and so on.

From the integrated nature of the substrate, the current IC package with more o-cresol formaldehyde epoxy resin system, but because of the characteristics of epoxy resin, making the temperature resistance, technology, curing conditions, mobility package , shrinkage of the cured product, there are some applications disadvantages. To solve these problems Fu Chen Shanghai Chemical Company has developed a new packaging insulating resin, the resin has good technology to facilitate curing, good liquidity, low cure shrinkage characteristics of epoxy resin has been widely alternatives become the new darling of the industry.

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Daily plastic products

1, PET, polyethylene terephthalate

Main applications:

The most common use as beverage bottles and other transparent screen protection film protective film. PET can also be spinning, that is, we often say polyester. In addition there are many engineering applications PET

Caution:

Non-toxic, but the synthesis process may remain single, low molecular weight oligomers and side reaction products such as diethylene glycol, these are some toxic, PET raw material for beverage bottles countries have strict standards.

PET plastic higher melting point. But generally do not recommend reusing bottles, especially for loading water. Since PET bottles are generally thin, manufactured using blow molding method, when the bottle is heated to about 90 ℃ rearrange, and the internal stress due to the role of PET molecular chains, and the contraction distortion of the bottle experience, this time using easily result in burns. The higher temperatures will increase the risk of harmful substances in the material eluted.

2, PE, polyethylene (high density polyethylene: HDPE; low density polyethylene: LDPE)

Main applications:

PE is currently the most widely used plastic, with different modification methods, PE can be used in all aspects of daily life. More representative, including plastic buckets, film, paper cups wall, pipes and cable jacket and so on.

Caution:

PE itself is non-toxic. However, the production will be used in processing or modification of some additives, such as fillers, pigments or stabilizing aid. Some additives are toxic. Since PE products will soften or even melt at higher temperatures, you should try to avoid higher water temperatures under 100 ℃.

3, PVC, polyvinyl chloride

Main applications:

PVC is now used for the manufacture of some cheap leather, floor mats, water pipes, etc.; due to its good electrical performance has a certain self-retardant properties, is widely used in the manufacture of wire and cable sheath. In addition, PVC is widely used in industrial fields, especially for acid corrosion in high demand areas.

Caution:

PVC production uses a lot of plasticizer (plasticizer such as DOP) and heat stabilizers containing heavy metals, and the synthesis process is difficult to eliminate the presence of free monomers, which are considered to be toxic. So PVC in contact with the human body, especially in medicine and food applications, is gradually being replaced by PP, PE.

PVC is a non-high-temperature plastic, can not be used at higher temperatures.

4, PP

   Main applications:

   PP is also very broad range of use, everyday items such as packaging, toys, basins, buckets, hangers, cups, bottles, etc.; engineering applications such as car bumpers. PP spun yarn is known as polypropylene, textiles, non-woven fabrics, ropes, nets and other products are common.

Caution:

 PP and PE processing methods and the use of similar, itself non-toxic. Possible threats from the processing and modification additives. Especially due to poor weather PP, used in the production of anti-aging agent may contain heavy metals. Products compared to PE, PP products slightly better heat resistance, typical Lock & Lock glass using temperature can reach 110 ℃, but then there is a high temperature melting softening and dangerous, and should be avoided.

5, PS

Main applications:

Cheap transparent products, foam, CD boxes, cups, snack, insulation lining and so on.

Caution:

Toxic materials for the synthesis of polystyrene by appropriate synthesis process, has very little residual monomer polystyrene, glass, etc. but now has very little use of this material. Polystyrene flammable, especially after PS foam. Combustion will produce large amounts of toxic gases. In some high-level house on fire incidents, due to the insulating layer materials using a PS foam board is widely used, a lot of smoke and toxic gases generated by the fire became the main reason leading to a large number of casualties.

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Plastic injection mold problem

Contraction marks

First, the injection characteristics of the surface defects often associated with marks, but also to the surface of the plastic from the mold shrinkage from the formation.

 Second, the reasons for problems that may occur

(1) The melting temperature is not too high or too low.

(2) Insufficient mold cavity plastic.

(3) When the cooling phase the contact surface of the plastic to overheat.

(4) Runners unreasonable, gate-section is too small.

(5) The die temperature is adapted to the characteristics of the plastic.

(6) The product structure is irrational (strengthened into ancient too high, too thick, obviously varying thickness).

(7) The cooling effect is good, continue to shrink after product release.

Third, the remedies

(1) Adjust the plunger cylinder temperature.

(2) The adjustment screw speed to obtain the correct screw surface speed.

(3) Increase the amount of injection. (

4) ensure the use of proper litter; increase screw forward time; increased injection pressure; increase injection speed.

(5) Check the stop valve is installed correctly, because the non-normal operation will lead to pressure loss.

(6) Reduce the mold surface temperature.

(7) Correction runner to avoid excessive pressure loss; according to actual needs, and expand the cross-sectional dimensions.

(8) The appropriate mold temperature control depending on the characteristics of the plastic and the product structure.

(9). Improve the product structure in the permit.

(10) Try to make the product has adequate cooling

Warpage of plastic parts

First, the characteristics of injection molded parts defects similar to the shape of the mold cavity is a twisted version but the shape of the mold cavity

Second, the reasons for problems that may occur

(1). Bend because there are too many internal stress within the injection molded parts.

(2) mold filling speed.

(3) Insufficient mold cavity plastic.

(4) plastic temperature is too low or inconsistent.

(5) at the top of injection molded parts too hot out.

(6). Cooling inadequate or move, scheduled to die temperature is inconsistent.

(7). Injection irrational structure (such as ribs concentrated on one side, but far away).

Third, the remedies

(1) Reduce the injection pressure.

(2) Reduce the screw forward time.

(3) Increase the cycle time (especially cooling time). From the mold after (especially thick injection molded parts) top out immediately immersed in warm water (38oC) makes injection molded parts to cool slowly. (4) Increase the injection speed.

(5) Increasing the temperature of the plastic.

(6) cooling equipment.

(7) appropriate to increase or improve the cooling conditions of the cooling time, as far as possible to ensure dynamic and stationary die mold temperature consistent.

(8) In accordance with the actual situation of improving the structure of plastic parts in the permit. Plastic injection filling defect characteristics dissatisfied injection molding process is not complete, because the cavity does not fill plastic injection molding process or lack of certain details.

Second, the reasons for problems that may occur

(1) Insufficient injection speed.

(2). Shortage of plastic.

(3) The screw at the end of the trip did not leave a screw litter.

(4) Changes in operating time.

(5). Plunger cylinder temperature is too low.

(6) lack of injection pressure.

(7) Nozzle partially blocked.

(8) or plunger nozzle heater does not work outside the cylinder.

(9). Injection time is too short.

(10) plastic hose attached to the hopper wall.

(11). Injection molding machine capacity is too small (ie, weight or plasticizing injection capacity).

(12) The mold temperature is too low.

(13) There is no clean up mold of anti-rust oil.

(14). Retaining ring is damaged, there is melt back phenomenon.

Third, the remedies

(1) Increase the injection speed.

(2) checks the amount of plastic in the hopper.

(3) Check whether the correct set of injection stroke, needed to be changed.

(4) Check the check valve wear or cracks.

(5) Check the operation is stable.

(6) Increase melt temperature.

(7) Increased back pressure.

(8) Increase the injection speed.

(9) Check the nozzle hole there is no foreign body or plasticizing plastics.

(10) Check all heaters outer layer ammeter test energy output is correct.

(11) Increase screw forward time.

(12). Increased cooling capacity hopper throat area, or lower the temperature after the plunger cylinder area.

(13). Using large injection molding machine.

(14) The appropriate mold temperature rises.

(15). Cleaned rust clean the mold.

(16). Inspection or replacement.

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Functions and types of electronic packaging

Depending on the encapsulating material, the electronic package may be divided into plastic packaging, ceramic packaging, and metal packages of three. Of which the latter two for hermetic package, mainly for the aerospace, aviation and military fields, and is widely used in plastic packaging civilian areas. Due to the low cost of materials of the plastic-encapsulated semiconductor chip, and is suitable for large-scale automated production of recent years, both transistors or integrated circuits are increasingly made ​​of plastic package, ceramic and metal packaging is rapidly reduced. Now, more than 90 percent of the semiconductor devices are used plastic packaging, plastic packaging materials and more than 90% of epoxy molding compound, indicating that epoxy molding compound has become one of the important pillars of the semiconductor industry.

Currently IC forward high integration, cabling miniaturization, chip and surface mount large-scale technological development, and this adaptation of plastic materials research and development trend is to make materials with high purity, low stress, low inflation, a low-rays, high heat and other performance characteristics. Select the principles used in plastic packaging resins are:

(1) in a wide temperature and frequency range, has excellent dielectric properties.

(2) has good heat resistance, cold resistance, moisture resistance, air resistance, radiation resistance and heat dissipation.

(3) a metal having a coefficient of thermal expansion substantially matches the non-metallic material, good adhesion.

(4) the rate of shrinkage during curing to be small, the size should be stable.

(5) contamination of the semiconductor surface of the device and can not have good processability.

  Epoxy molding compound is an epoxy resin and a curing agent component composed of a phenolic resin molding powder, which under the action of heat to become crosslinked or cured thermoset plastic, in the injection molding process which will be embedded in a semiconductor chip, and give it some structure shape, plastic encapsulated semiconductor devices become.

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Plastic parts of the screen printing

Printing plastic parts, plastic products, secondary mechanic (or reprocessing) one. The so-called secondary processing is in the plastics injection molding, once again decorative surface treatment, such as: plastic plating, plastic coating, plastic stamping, plastic printing and so on. So to secondary plastics processing, mainly by the performance of the plastic itself, the decision, such as dyeing it relatively simple, and the color of the light fastness is also poor. To compensate for these shortcomings, improving the appearance of decorative plastic products, on the need for secondary processing.

Plastic components of electronic products screen printing electronic products, especially radio products such as radios, tape recorders, televisions, etc., for the appearance of the requirements are high. After the plastic screen printing development for decoration brings the convenience of electronic products, so in recent years, a variety of electronic products, domestic plastic silkscreen been widely used.

    

Screen-printed plastic signs in recent years, after the plastic signs and plastic molding decorative silk screen graphic text components developed rapidly. As in PVC hard board (PVC plates), polycarbonate, ABS, acrylic, modified polystyrene plastic pieces were pressed on the screen printing, has been widely used, and achieved good decorative effect and economic Benefit

Soft and hard plastic parts screen printing

① plastic hose of silk. There are several ways to print plastic hose, the main method of heat transfer method. A thermal transfer method is a sublimation dye ink or other material, the graphic printed on the transfer paper before and then bonded together with the substrate, the transfer sheet is heated from the back, so that the dye sublimation and the paper Graphic transferred onto substrates. After the surface treatment of plastic hose, a hose and a piece of transfer paper from between the heated iron by heating iron transfer paper into the hose, heated to complete the transfer. After the transfer tube into the drying apparatus, the drying temperature is generally about 65 ℃.

② soft plastic screen printing. Used for the production of soft plastic toys, such as inflatable cartoon toys. Usually the first on the soft plastic sheet printing pattern, then cut, the production of synthetic heat. The material thickness is 0.8 ~ 3.0mm. If the screen printing two or more colors, most plastics have a telescopic, second track error occurs chromatic color and the first color. This chromatic error commodity lost its value can not be qualified as shelves. To this end, multicolor printing can only be taken

Soft plastic can be fixed with a long presses and no other way. For long-Taiwan printing, adhesive substrates to use fixed. You must use non-toxic toys printing standards prescribed harmless ink.

③ rigid plastics printing. There are two types of hard rigid plastics sheet and a molded article. Tickets, signs, instrument dials, cosmetic containers are made of hard plastic.

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Injection molding process related failures

In the plastics machining, often encounter a variety of plastics processing failures which express what kind of plastic machinery industry jargon used in more precise

One owed ​​Note: In plastics processing, due to the cavity filled with discontent, leading to incomplete shape plastic parts incomplete phenomenon.

2, flash flash: Plastics Processing molding process, the overflow into the gap between the mold clamping surface and keep the remaining material in the plastic parts.

3, weld lines: a linear traces of plastic surface is determined by injection or extrusion material diversion of several streams in the desert with the confluence of the melt is not fully fused at the interface, they can not fused into one, resulting in fusion imprinting, affecting the appearance quality and mechanical properties of plastic parts.

4, the wave and current marks: As the melt flows in the mold cavity inappropriate, leading to produce plastic sheet ring, spiral or waveform cloudy uneven defect.

5, the surface opacity: Refers to produce plastic surface cracks and voids formed thereby damaged. Phenomenon due to the mechanical properties of the plastic below the stress caused by prolonged or repeated application of plastic parts external or internal cracks called stress cracking; due to plastic parts to withstand constant load acting a certain time at a specific temperature and a sudden burst of full-END the phenomenon known as stress cracking; certain thermoplastic member Overexposure of cracks occurring at higher temperatures is called thermal stress cracking and rupture.

6, fracturing: the resin layer covering the surface by means of a crack can be seen clearly laminated plastic layer or layers than the outer reinforcing material has.

7, ruffling: laminated plastic surface rupture and produce a defect clearly separated.

8, wrinkles: plastic processing, plastic surface layer or layers appear appearance defects creases or wrinkles.

9, cracking and whitening: the more obvious plastic surface micro cracks produced called cracking, and cracking similar bleaching cream called micro-cracks, cracks and micro cracks albino are no cracks. When the plastic is exposed to a chemical in the environment or in stress conditions, will produce environmental stress cracking.

10, silver pattern: plastic surface direction along streams produced silver needle white frost generally fine lines.

11 stripes: plastic surface or internal defects in the presence of linear stripes.

12, markings: Due to poor mixing and pigment dispersion or other causes dark spots produced plastic surface defects mica sheet.

13, orange peel: plastic parts, such as orange peel-like surface uneven appearance defects.

14, the cell stripes: refers to the foam, its inherent structural differences great cell cell layer.

15, black spots: in plastic molding process, melt overheating under high temperature and pressure conditions of decomposition, resulting in a black plastic surface to produce carbonation points.

16, white spots or bright spots: a transparent or translucent plastic film, sheet or plastic memory without fully plasticized particles, you can see a white light transmittance grain point, the point of this grain is called "fish-eye . "If the material is opaque or colored, this point is called grain white spots or bright spots.

17, pitting: Rules plastic surface appear or irregular small crater, its depth and width are usually about the same.

18, filling the spot: plastic parts in obvious scarring due to the presence of asbestos, such as flour or fillers caused.

19, dark spots: appear in the fabric of the substrate laminate structure dark stain.

20, and the charred spots paste: plastic processing, the molding conditions at high temperature and pressure, defects due to overheating of the melt decomposition carbonization, carbonized coke blend in the melt material, and the plastic surface is formed inside the scar.

21, the bubble: in plastic processing mold filling process, if a large number of residual gas in the melt, or air in the cavity is not completely drained, making the interior molding of plastic parts after the formation of clusters of smaller pores or defects.

22, vacuum bubbles or dark bulbs: When plastic parts in plastic processing cooled and solidified, due to the different cooling rates inside and outside, and sometimes the outer surface has cooled and solidified, but the interior is still in the melt state, once the central part of the cooling contraction, the internal plastic parts will produce a vacuum holes, these holes are generally called vacuum bubbles or dark bulbs, also known as shrinkage.

23, the pinhole: plastic sheet or film in the presence of pinhole defects in the size of the through hole.

24, foam collapse: the foam during the manufacturing process due to the destruction of the cell structure caused by the increase in the local density of defects.

25, recesses and deflated: cooling the plastic parts in the plastic processing process, since the cooling surface to be cooled and solidified after curing, or wall thickness of the inner portion, so that the volume contraction, contraction velocity inconsistencies outside the plastic surface of an internal pull member stretch forming depressions, producing shallow pits or lacunae.

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Injection mold surface treatment

Injection mold surface treatment

What methods of injection mold parts surface treatment? In the working process of the injection mold parts on the surface of the working condition is bad, so it's easy to damage, therefore, need for some parts surface to surface treatment, for local enhancement.

The effect of surface treatment (1) parts

In mould processing, surface treatment can make the parts for the following properties: increasing surface hardness, increase the compressive strength, abrasion resistance, improve the corrosion resistance and improve the sliding, etc.

(2) parts surface treatment methods

Surface treatment method are many, but for the mold parts, main methods of surface treatment are the following.

1) carburizing. Carburizing is to the steel surface infiltration carbon atoms. It is to put the parts into can release the active carbon atom medium, heat insulation, make activated carbon atoms permeability and the surface of the steel. Its purpose is to improve the surface of the carbon content, the subsequent heat treatment, the surface hardness increased, while the core remains resilient. Therefore, carburizing steel must be 0.15% ~ 0.25% (mass fraction), the carbon content of mild steel. Methods include solid carburizing, carburizing liquid carburizing and gas carburizing, is widely used gas carburizing.

2) nitriding (also called nitride). Nitriding is to the steel surface infiltration nitrogen atoms. Its purpose is to improve the parts table surface hardness, wear resistance, corrosion resistance and fatigue strength. At present, the most widely used method of nitriding is gas nitriding. It is to put the parts into the airtight furnace, the ventilation with NH3, heating to 500 ~ 600 ℃, the ammonia decomposition of reactive nitrogen atoms, the nitrogen atom is easy to be absorbed by the workpiece surface and spreading inside, forming a nitride layer, nitriding layer is 0.1 ~ 0.6 mm. Nitriding layer has high hardness and excellent dimensional stability, and can noticeably improve wear resistance and fatigue strength, corrosion resistance has greatly improved. In the mold processing, almost all steel nitriding processing. But it's a longer production cycle, high cost.

3) hard chromium plating. Hard chrome plating is will adopt the method of plating chromium plating on surface of parts, thereby gaining the surface of the hard and wear resistant, it to contain the abrasive plastic molding parts, hard chromium plating layer is very effective. In addition, the hard chromium layer can not only reduce the wear and tear, and can significantly improve the corrosion resistance of parts. Can also be used when repair the wear surface hard chromium plating method processing.

4) hard nickel plating. Hard nickel plating is to use chemical method will nickel plating layer on surface of parts. In the process, deposition of nickel layer does not use imposed by the electron flow, so you don't happen like electroplating on the edge, especially along the edge to form different thickness of electroplating film formation (edge) of the phenomenon. This method of nickel plating in the hole, opening and the place such as contour surface defects will not appear. The nickel plating layer often about 40 microns thick, it can form has good corrosion and wear resistance of the surface.

5) coated hard layer. In order to make the part surface with a high wear resistance and corrosion resistance, there is a new technology is in the surface coated with titanium nitride and similar material for grass-roots approach, it is easy to operate, and the effect is very good.

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Packaging technology

The so-called "Packaging Technology" integrated circuit with an insulating plastic or ceramic material packaging technology. The CPU, for example, actually see the size and appearance of the CPU core is not really the size and appearance, but the CPU core and other components of the product after packaging. Packaging technology package is a must for the chip, is also essential. Because the chip must be isolated from the outside world, in order to prevent corrosion of impurities in the air caused by the electrical circuit chip performance degradation. On the other hand, after the chip package and easier to install and transport. Since the quality of packaging technology also play a direct impact on the performance of the chip itself and connected thereto PCB design and manufacture (printed circuit board), so it is crucial.

Packaging can also be said that with the installation of a semiconductor integrated circuit chip shell, it not only plays placed, fixed, sealing, protecting the chip and the enhanced role of thermal performance, but also to communicate with the outside world circuit chip bridge - chip contact with the package leads are connected to the housing pins, which also connect to the other device via a wire to a printed circuit board. Thus, for many IC products, packaging technology are very crucial part.

CPU is used in multi-packaging packaged in plastic or ceramic insulating materials, to improve the chip acts as a sealing and electric properties. Now that the frequency of the processor chip increasing, more powerful, more and more pin count, package shape is also constantly changing.

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Injection products quality inspection methods

Whether produced after injection products meet quality standards, must be tested, a common quality test methods are the following two.

(1) full inspection

The so-called full inspection is individually tested for injection products, we have talked about "full" refers to the number of all the plastic parts produced, rather than the entire value of the quality characteristics tested. In determining the test items, test cost is usually lower or greater impact on the quality of the quality characteristics of the implementation of full inspection, such as plastic parts Dimensions test is easier and can be fully tested, and the requirements of the position and some plastic parts crucial, a great impact on the quality, but also the need for full inspection. Not plastic parts for each test must be carried out in full, as it is too time-consuming and laborious. Usually occurs when the following conditions using full inspection.

1) found that more unqualified plastic parts, plastic parts or the whole batch are unqualified, the need for follow-up products for full inspection.

High single value 2) injection products, even when a scrap will bring great losses.

3) If the product quality problems, give people life safety or safety hazard when great.

(2) sampling inspection

The so-called sampling inspection,, is from a group of randomly selected plastic part of the test conducted. By this test section of plastic parts extracted to make the evaluation of quality of these plastic parts. Compared with the full inspection sampling inspection, it tested a small number of plastic parts, low-cost test, test speed. Sampling inspection and batch size of the number of samples, volume, sample quantity; small quantities, less sampling; as long as the appropriate number of samples, the test results have a high accuracy. Usually by random checks in the following cases.

1) Some of the plastic parts of the mechanical and physical properties of the need for destructive testing, this will bring damage to the plastic parts.

2) more than the mass production of plastic parts, plastic parts produced quantity particularly large, want to save test time and test costs.

3) the production of raw materials in plastic parts, there are a lot of raw material is powdered, granular or liquid form, the raw material for these multi-use sampling. Compared with the full inspection sampling inspection, although there are a small number of test and low test cost advantages, but also the following problems: First, when the second installment of the plastic parts, even after sample testing has been considered qualified, can not believe that this batch of plastic parts plant each plastic parts are qualified, which may also exist a very small amount of non-conforming product. Second, the sample tests will inevitably appear judgmental errors, this is the vast majority of qualified products, due to sampling bias, but judged unqualified; or could have been substandard goods, has become qualified. Therefore, in order to determine the probability of error is controlled within a reasonable range, often need to coordinate the use of mathematical statistics methods.

In short, the full inspection and sampling test has its own characteristics, and applications and problems also vary, depending on the circumstances test methods should be chosen to adapt. Mostly due to the injection mold products for mass production, it is more to take sample tests

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Injection Molding: New Twists for a Mainstream Technology

When it comes to manufacturing technologies, the choices are many and their number seems to grow daily. They include machining, laser cutting, water cutting, stamping, die casting, and various forms of 3D printing. Despite its age -- well over 100 years -- injection molding is still a “go-to” technology for producing plastic parts. No other technology offers as wide a selection of materials, and the cost per part plummets once a mold has been made.

Molding is a broad term covering a variety of methods including injection, extrusion, compression, roto-molding, silicone molding, and blow molding. Injection molding is among the most flexible of these. It entails forcing molten resin into a mold, allowing it to solidify, and then opening the mold to eject the finished product.

The injected material can be a thermoset, which hardens permanently when heated and cannot be remelted; or thermoplastic, which liquefies when heated or reheated and hardens when cooled. While thermosets are used in a variety of applications, thermoplastic is often preferred for its ease of recycling and the vast variety of thermoplastic resins available.

This article will touch on injection molding’s place in the continuum of industrial production processes and its strengths, particularly in terms of expanded material options. It will address how materials, design, moldability, and process details affect injection molded parts and their quality.

The range of thermoplastic materials options is a boon for developers, but it can be bewildering as well. With hundreds of resins to choose from -- both individual polymers and blends -- resin can fit the most specific requirements and become a key aspect of the finished product’s performance. Characteristics like strength, flexibility, color, or transparency may be simple to identify, but resins may also be chosen for other characteristics.

Depending on the application, resins can also be selected for their resistance to chemicals or UV light, response to temperature and humidity, or electrical properties. If parts include bearing surfaces, resin may be chosen for their lubricity, and if parts will be subject to rough handling, abrasion resistance may be critical.

Parts may have cosmetic needs like the ability to hold a high polish, and can also include features like living hinges, which are designed to be flexed repeatedly without breaking. Moldability varies among resins. Some flow easily through narrow areas that would be difficult for other resins to traverse. In some cases, the solution to this variability is an altogether different resin; in others the answer is to keep the same resin but change the design of the part. Of course, there’s also cost to consider, which becomes increasingly important as the size of the part and the production volume increase.

Even these choices would be relatively simple if a part only had to meet one criterion. But in real-world design that’s rarely the case. One part might have to be both strong and transparent, while another must be flexible and able to withstand contact with solvents.

With thousands of materials to choose from, virtually any imaginable combination of characteristics is available in some resin or blend; the challenge is in finding it. The MatWebonline materials database provides data on more than 50,000 thermoplastic materials. Without having to register, users can search for resins by up to three out of several dozen possible properties and see detailed spec sheets on resins that meet those criteria. Free registration allows more advanced searches. Narrowing down a list of materials begins with listing your requirements in order of priority and using those criteria to reduce the list of candidates to a workable number. Final choices may require functional testing of prototypes. For specialized material needs, compounders like RTP compound custom variations of dozens of basic resins.

Clearly, the needs of the product itself will guide the design of a plastic part, but both the material being molded and the molding process itself can impact design choices. A stronger material can allow features to be smaller or thinner. A filled material, however, like glass-filled nylon, can greatly improve strength but may impact a part’s cosmetics, increase the likelihood of warp, or cause flow problems around part features like through holes. The flexibility of a resin will affect the dimensions of moving parts like clips or hinges, and can even affect whether such features will work at all.

Final choices regarding design and material often depend on the testing of prototypes, but preliminary decisions can often be made before prototyping even begins. Finite element analysis (FEA) software, available in standalone form or incorporated into design software, allows simulation and virtual testing of a design in a specific material. The results can suggest design changes or material choices, speeding up the whole development process.

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Injection Molding Adapts to a More Interconnected World

Plastic, rubber, and metal injection molding and, more recently, rapid molding techniques have been major contributors in global manufacturing. A variety of processes and equipment can be used, depending on volumes, materials and turnaround time, and whether parts are prototypes or finished ones. The rise of rapid molding for fast delivery of high-mix, low-volume products and prototypes, and new ways to make molds such as 3D printing, are changing the way design engineers use injection molding in product development and production planning.

Droduct manager for the cnmould service of fast-turn molding company cnmoulding molding services can be classified into three different types: traditional high-volume molders; a broad group of lower-cost, high-volume molding services typically located offshore; and rapid molders, a more recent phenomenon.

Traditional molders are usually full-service suppliers. "They are all about injection molding tools that last forever, and about speeding up injection," he said. "They do a lot of value-add services like assembly or painting." Tooling used by these services tends to be made of hardened steel; hundreds of thousands to tens of millions of parts are made from multi-cavity production molds.

Rapid molding is newer, and something Proto Labs helped pioneer. It serves the need for making multiple variations of a single product in somewhat lower volumes -- 25 to 1,000 units instead of 100,000 or more, said Barsness. These products and all their components must be prototyped exactly, in all those variations, using exactly the materials they will be produced with.

The resulting increase in SKU proliferation is caused by several colliding trends. First, globalization has produced effects, as described by Barsness. "Say you make a household product or a communications device, and you want to sell it around the world," he said. "Your market used to be the US, but now there's the Chinese market and other countries, like Brazil. Customers in those countries have different values and tastes, whether it's a car or a thermostat." Those countries also have different regulations, such as those for safety, and different specifications, such as for electrical voltage, which effect part variations.

Trends related to energy and environmental friendliness are also driving changes in product designs. "Lightweighting is major, especially in anything that moves," said Barsness." Also, LEDs are being used everywhere for their ability to reduce the power, size, and cost of lighting, and they can be packaged almost any way imaginable. On many of these LED-enabled products, the entire assembly can include five to 10 different injection molded parts.

A third set of changes is due to increases in product connectivity and automation. The Internet of Things has engineers putting sensors on just about anything, from household appliances to industrial products. "Now the design engineer has to get 10 different prototypes of 10 different products for 10 different countries, all of them have LEDs, and they've all got to talk to the Internet," Barsness remarked. This is where rapid molding services come in.

Rapid molding tooling is typically "soft," represented by aluminum instead of steel, for a much lower cost. Rapid molding, of course, has a much faster turnaround. A traditional molder, using a high-volume production mold, could typically take a few months to deliver entire part runs, but the average rapid injection molder delivers parts in 25 to 45 days. Proto Labs' service promises one to 15 days.

Before rapid molding begins, prototypes are also made with production-grade materials. Typically, a customer sends three to five iterations of a design, and Proto Labs cuts a different mold each time. The industries Proto Labs serves tend to be those with some regulation or a high amount of product churn.

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Advantages of plastic medical devices

Use plastic equipment called a major initiative of the medical profession. From drug and pharmaceutical packaging products, to syringes, tubes, surgical instruments and other disposable medical equipment can be seen in the presence of plastic instruments.

Disposable medical device market demand potential is so great why, largely because of its advantage following aspects:

1, light weight, and effort, help reduce fatigue caused by surgery doctor for a long time. More suitable for human blood and muscle tissue, so the more effective.

2, tough is good, anti-permeable, durable, plastic parts can also be used normally at high temperatures.

3, transparent, medical procedures can be better observed, especially during surgery.

4, easy to shape, suitable for the production of a variety of shapes, complex medical equipment and supplies, and simply use the low-cost production process. Use disinfectant or sterilizing temperature corrosion does not occur, or color change phenomenon.

5, compared to metals and other raw materials, low cost, suitable for the production of disposable consumables, and after sterilization of packaging materials used to help reduce the risk of infection.

6, as compared with ceramic or the like brittle glass material, a more secure, especially as packaging material.

With the increase of the proportion of population growth and an aging population, the demand for plastic medical equipment continued to expand, particularly into the body of the equipment. The use of medical equipment to diversify from a single, volume size is shrinking, now one can replace equipment more than the previous equipment. Because many outstanding advantages of plastic medical equipment, pharmaceutical industry in the future course of development, its market share and influence will grow.

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difference between the Color mold and the overmolding

A. color mold: two on the same plastic material injection molding machine, a two-molding, but the product only once a die mold. In general this is also called double injection molding process is usually done by a mold, and the need for specialized color injection molding machine. B. encapsulated mold (secondary molding): two plastic materials are not necessarily on the same injection molding machine, a two-molding; the product is removed from the mold of a mold, then put another set mold for a second injection molding. So, in general this molding process is usually done by two sets of molds, without the need for a dedicated two-color injection molding machine. Color die and overmolding Overview:

overmolding design should pay attention to locate hard plastic pieces, you need to do can be a sealed plastic and rubber parts in the anti-gradient holes to prevent pulling plastic deformation.

Color mold growing popularity on the market today, in this process can make the product look more beautiful, easy to change colors and you can not spray, but expensive, technically demanding.

1.Cavity two shapes are different, each forming one kind of product. The two shapes Core exactly the same.

2. Before the mold after mold after the center of rotation 180o, must match. This action must be done to check the design. 3. Note that the top position of the pinhole, the minimum distance 210mm. A large number of top mold shall be appropriate to increase the stick hole. Moreover, since the injection molding machine itself comes with a thimble is not long enough, so we must be designed to lengthen mold thimble, thimble grow mold base plate about 150mm.

Must be designed 2 3. After locating ring mold base plate.

4. The total thickness of the front panel plus A plate mold of not less than 170mm. Please carefully review this type of injection molding machines other reference data, for example, the maximum capacity of the mold thickness, the minimum thickness tolerance mode, the top rod hole distance.

5. The three-plate mold outlet preferably designed to be automatic ejection action. Pay particular attention to the release of soft outlet whether action *.

6. The front side SPRUE depth of not more than 65mm. On the side (large outlet) Top SPRUE distance from the center of the mold base to not less than 150mm.

7. In the second injection CAVITY design, in order to avoid CAVITY plug (or rub) injury has been forming a good product first plastic bits, you can avoid the empty part of the design. However, the intensity must be carefully considered every sealed plastic bits, namely: in injection molding, whether there will be at high injection pressure, the plastic deformation occurs, resulting in possible second injection may be generated batch front

  8. injection molding, injection molding products for the first time can be slightly larger size to make it in the second molding presses with another CAVITY tighter in order to achieve the role of sealant.

9. Note that in the second injection, the plastic flow of whether the first impulse has been forming a good product to glue bit deformed? If there is a possibility, must find ways to improve.

10. Before A, B plate clamping, pay attention to whether or Lifter front mold Slider will be reset and the crushed product? So, we must find ways to make the A, B board first mold, mold SLIDER before or after LIFET to reset.

11. The two CAVITY and CORE's carrying water arrangement as fully as possible, and the balance, the same.

12.99% of injection molded hard plastic case is the first part of the product, and then injection molded soft part of the product. Because soft deformation.

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Common blister material characteristics and application scope

Blister: A plastic processing technology, the main principle is flat plastic sheet is heated to soften hard after vacuum adsorption on the surface of the mold after cooling molding, widely used in plastic packaging, lighting, advertising, decoration and other industries.

Blister packaging: blister technology to produce plastic products, and use the appropriate equipment for product packaging in general. Plastic packaging products mainly include: blister, trays, plastic boxes, synonyms are: vacuum cover, blister and so on. Blister packaging equipment including: plastic molding machines, presses, sealing machine, high frequency machine, folding machine. Package formed packaging products can be divided into: card, blister card, double blister, half blister, folded blister, folded blister and so on.

Blister: Blister process will be transparent sheet made of hard plastic convex shape specific transparent plastic cover on the product surface, play a role in protecting and beautifying products. Also known as blister, vacuum hood

Tray: also called plastic Neto, using plastic sheets made of hard plastic craft plastic specific groove, the product is placed in the groove, played the role of protecting and beautifying products.

Flocking Neto: a plastic tray using special materials, the ordinary hard plastic surface layer of glue velvet material, so that the tray surface kind of velvet touch, to improve packaging grades.

Antistatic tray: a plastic tray using special materials, the resistance of the material surface is less than 11 ohm power 10. Mainly used in plastic trays electronics, IT products.

Plastic mold: plastic mold production, lowest cost plaster mold, followed by electroplating copper mold, the most expensive aluminum mold. Die drilled holes for vacuum heat of adsorption of hard film to form plastic products.

Plastic molding: that we often talk about plastic, plastic molding machine uses heat to soften the hard piece of plastic in the mold surface adsorption, after cooling, the formation of concave and convex shapes of plastic.

Blister cutting: plastic molded plastic products, after punch, large sheets of sheet cut into a single product with a die cutter.

Flap: Plastic packaging products there is a call card packaging, blister needs to be three sides by folding machine to fold back, so the next step in a package, the paper card into the fold to form card packaging .

Heat sealing: a blister packaging technology, with a sealing machine plastic surface coated with oil paper card and blister heat sealing together to form a blister card packaging.

High frequency sealing: a blister packaging technology, with a high frequency machine generates high frequency, bonded together between the bubble and blister shell to form a double blister packaging.

  

Ultrasonic sealing: a blister packaging technology, the use of ultrasound machines to produce ultrasound, will blister and bubble shell bonded together to form a double blister packing, and sealing the difference is that the high-frequency ultrasound can not only sealed PVC, PETG material, PET material is also closed, but the product is not encapsulated EM damage, especially for packaging of electronic products; deficiency is that only the ultrasonic sealing dot interval, a time and is generally a straight edge seal.

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