The hot runner role in injection molding

80 %of life goods need to through the injection molding

Mold is closely related to our life, More than 90% of the life of the article to be processed through the die is made,While 80% of goods go through the plastic molding, plastic mold temperature should reach 300 ℃ or more. Due to the special shape of the plastic mold, with traditional insulation materials can not be insulated on the lower mold high temperature heat loss of a great, severe heat loss, high temperature metal mold thermal fatigue loss is large, and so on. Plastic mold heat great loss, not only directly increase the cost of production, but also due to frequent replacement of the mold caused by mass production line shut down frequently result in greater economic losses.

Hot runner injection molding is used in conjunction with the mold, and play a very important role, such as in the production of ultra-thin plastic injection parts, by using the runner can easily produce high-precision, high-quality products out; for illiquid injection molding material by using a runner can improve the flow of raw materials, to ensure smooth production of injection molding; for some large plastic parts such as car bumpers and door panels, rear shell TV, air conditioning and so on through the hot runner can shell very difficult injection molding becomes relatively simple.

Ues hot runner to reduce injection molding products cost

In the multi-cavity injection mold, the lack of hot runner molding is difficult, it can be said so far is to ensure the hot runner runner balance of the best technology. Because of the presence of plastic hang shear forces in the flow, regardless of the geometry of a mold having more than a reasonable balance, the weight of the molded product is difficult to come out of the same, especially in terms of multi-cavity molds.

For plastics processors, as long as there is a certain volume of injection molding using a hot runner it is quite economical, because the hot runner nozzle to help businesses get rid of in the production of injection molding, which not only saves raw materials, and to cut labor costs and make products more perfect appearance. We all know that in most cases the drain can not be reused, if not at times the weight of the hot runner nozzle and the weight of the product is almost, if the traditional way means that the injection nozzle producing a product must be a product of almost a waste of raw materials as waste, and therefore only this not only saves raw materials, and to cut labor costs, but also make the product more perfect and beautiful. In addition, the runner also help reduce mold wear, extend die life. In general, the hot runner mold life is twice as small inlet of the mold.

Our company offers a reasonable solution

Runner simple composition, but each component plays an important role. Generally good quality hot runner design and structure of the material requirements are very high. We can according to the customer's product, the design a reasonable solution, to ensure the hot runner injection molding system can play a maximum efficiency. As our company uses Han Guorui runner, the choice of heaters and temperature line all imported from South Korea, the steel used for all materials imported from Japan, which is to ensure the quality of these hot runner prerequisite.

Rapid Prototyping Manufacturing

Rapid Prototyping (Rapid PrototypingManufacturing, abbreviated RPM), high-tech manufacturing technology is based on a material deposition method, it is considered the last 20 years, a major achievement in the field of manufacturing. It combines mechanical engineering, CAD, reverse engineering, layered manufacturing technology, numerical control technology, materials science, laser technology in one automatically, directly, quickly and accurately convert design to prototype with a certain function or direct manufacturing of parts , so as part prototyping, calibration, etc. the new design provides a cost-effective means of achieving. That is, rapid prototyping technology is the use of three-dimensional CAD data, through rapid prototyping machine, the stacked layers of material into a physical prototype.

Rapid Prototyping Features

(1) prototyping materials used are not limited to, a variety of metallic and non-metallic materials can be used;

(2) prototype reproducibility, high interchangeability;

(3) regardless of the manufacturing process prototyping geometry, more favorable when machining complex surfaces;

(4) Processing cycle is short, low-cost, independent of the degree of cost and complexity of products, general manufacturing costs by 50%, saving more than 70% of the processing cycle;

(5) a high degree of technology integration, to achieve the integration of design and manufacturing;

The practical application of rapid prototyping technology, mainly in the following aspects:

(1) Application of the new product design process of rapid prototyping technology to build a new product development model for industrial product design and development staff. The use of RP technology to quickly, directly and accurately design ideas into physical model has a certain function (sample), which not only shorten the development cycle and reduce development costs, but also enable enterprises occupy the first in the fierce competition in the market machine.

(2) in the field of machinery manufacturing technology due to RP own characteristics, so that it is in the manufacture of machinery for a wide range of applications, used for manufacturing a single-piece, small batch manufacturing metal parts. Some special complex parts, because only single-piece production, or less than 50 small quantities, usually can be molded directly by RP technology, low cost, short cycle.

(3) rapid tooling traditional mold for a long time and high cost. The rapid prototyping technology with traditional mold manufacturing technology, can greatly shorten the development cycle of the mold manufacturing, increased productivity, it is an effective way to mold design and manufacturing weaknesses addressed. Rapid Prototyping technology in mold manufacturing can be divided into direct and indirect molding molding two types of direct molding is the use of RP technology directly stacked to create a mold, indirect molding is a rapid prototyping system first part, and then copy the parts obtain the desired mold.

Rapid Prototyping Development Direction

From the current status of research and application of RP technology point of view, further research and development of rapid prototyping technology, mainly in the following aspects:

（1）Rapid development of good performance molding material, such as low cost, easy to shape, small deformation, high strength, durability and non-polluting molding material.

(2) increase the processing speed RP system and open up a parallel process for manufacture.

(3) rapid prototyping systems to improve reliability, increase their productivity and production of large capacity, optimize the device structure, in particular to improve the forming precision, surface quality, mechanical and physical properties of the member, provide a basis for further mold and functional assays .

（4）RPM high-performance software the development of rapid prototyping. Improve the speed and accuracy of data processing, research and development of the use of the original CAD data directly slice of ways to reduce the STL format conversion generated by the slicing process and loss of accuracy.

IML (In Mold Label) technology introduction

IML's Chinese name: injection mold inserts its remarkable features is the process: the surface is a layer of hardened transparent film, the middle layer is printed patterns, the back is plastic layer, since the ink in the middle, the product can prevent surface scratches and abrasion, and can be difficult to maintain long-term bright colors fade.

                                                         

IML technology introduction

                                             

Keywords: IML IMD molding process

The concept of IML

IMD (In-Mold Decoration) Film is a film placed in the injection mold decorated plastic exterior surface of the new technology. Currently IMD has two manufacturing methods, one is to be made into a film Film printed circulation drum roll band, mounted in the injection molding machines and injection molds, as Label label affixed to the front surface of the mold fully automatic cycle with mobile production out; that is, people called IMD (injection transfer in the mold).

Another is to pass a good film printing Film Forming molding machine, then placed after the cut produced in the injection mold. That is called IML (in mold foil injection). This Film can generally be divided into three layers: a substrate (typically PET), an ink layer (INK), gluing material (mostly a special adhesive).

When the injection is completed, the adhesive effect makes plastic Film and closely integrated, because of their positive surface covered with wear-resistant protective film on the outermost layer of PET, there is abrasion and scratch effect, the surface hardness reach 3H, and will feel more brighter. Wherein the molding material is more PC, PMMA, PBT, and so on. As shown below:

IML process step

Conference materials --- --- flat printing ink drying protective film stickers fixed --- --- --- punching positioning holes cut peripheral shape thermoforming --- --- material injection molding process as follows: specific instructions as follows:

1) Conference materials: Film roll of the film has been cut into a square block sizes designed for printing, molding process used.

2) flat printing: according to the requirements of icons, text manufactured Philippine forest belt, cut a good film on the square block printing Film icon, text.

3) Fixed ink drying: The printed film Film square placed in a high temperature oven drying, aimed at fixing IML ink.

4) Protective Film: Avoid red when positioning hole step to get to spend a good film Film printed surface, and sometimes need to paste single or double layer of protective film.

5) positioning hole punch: positioning hole thermoformed certain quasi-hub. Positioning hole cutting operations sometimes also punched in advance.

6) Thermoforming (high or copper mold): After the printed film is heated with a high-pressure molding machine or mold in the warm-up state.

7) Cut the peripheral shape: the scrap molding good stereoscopic film cut off.

8) Injection material: the three-dimensional shape after molding die in front of exactly the same film placed on the front mold, injection molded IML products.

IML technology advantages and disadvantages

Advantages:

1) Film production cycle is short, the performance of multiple colors;

2) in the production of patterns and colors can be changed at any time;

3) IML outermost layer is FILM, silkscreen ink on the intermediate layer, smooth surface appearance, the more light touch, with excellent scratch resistance;

4) Number of IML production volume is very flexible and suitable for many varieties of small production

Disadvantages:

1) pre-long period;

2) easy to produce the film off, distortion, etc.;

3) poor product rate

Injection mold manufacturing characteristics and requirements

Plastic mold production of general machinery products in common, and also that its particularity. Compared with the general machinery manufacturing, mold manufacturing is generally difficult, especially precision molds. As a special technical equipment, tooling and production process are the characteristics of the following aspects.

1. Precision mold manufacturing, high quality requirements, not only requires high precision, but also processing the surface of good quality. In general, the working part of the mold manufacturing tolerances should be controlled within ± 0.011mm, and some even claim within the micron range, surface defects after mold processing requirements are very strict, and the surface roughness of the working part of Ra <0.8 um.

2. The complex shape of the working part of precision molds are generally two or three dimensional complex surface (especially the cavity mold), rather than the general machining of simple geometric profile.

3. The mold as a single piece, production of many varieties of each pair of mold can only produce a certain shape, size and accuracy parts. In the manufacturing process as much as possible the use of common tools, common measuring tools and instruments, as much as possible to reduce the number of special tools. In the manufacturing process of the step arrangement requires relatively concentrated, in order to ensure the quality and accuracy mold, simplify management and reduce the process cycle time.

4. The high hardness of the material is actually a plastic mold machining tool, its high hardness, are generally made of hardened alloy tool steel or carbide and other materials, if manufactured using conventional machining methods, tend to difficult, so mold processing method different from the general machining.

5. Due to the short production cycle and accelerate the upgrading of increasingly fierce market competition, requiring mold production cycles are getting shorter. Mold production management, design and technological work should meet this requirement, to improve the mold design, manufacturing and standardization, in order to shorten the manufacturing cycle.

6. When a complete set of production parts need more deputy mold, a mold before the manufactured products are mutually implicated restrict Yi blank mold, mold parts, and only eventually qualified parts, which was a series of mold considered qualified. In the production and scheduling of the mold must take full account of this characteristic.

Now Plastic Manufacturing on the Rise in China

The world of plastic products manufacturing has come a long way since the 1860s — and rapidly growing companies like CN-MOULDING are proof. While John Wesley Hyatt may not have realized it when he first experimented with cellulose nitrate in the late 1800s, the substance he discovered has since become a major part of everyday life in the China.

“Today’s plastics are one of the most used materials on a volume basis in China. industrial and commercial life,” says PlasticsIndustry.org. “(They are) broadly integrated into today’s lifestyle and make a major, irreplaceable contribution to virtually all product areas.”

The two main types of plastics are thermoplastics and thermosets, the first of which is used to create many of the most common industrial, consumer and commercial products on the market today. What turns the plastic into a useful product is a process called injection molding, a high-production process originally launched in the late 1940s by American inventor James Watson Hendry.

Here’s how injection molding works: manufacturers inject the thermoplastic into a mold where it can set and form into the size and shape desired. While the process is fairly simple in concept, it offers a wide range of advantages, like higher production rates, lowered labor costs and reduced waste. And today’s businesses are increasingly moving their injection molding back to the China, to companies like CN-MOULDING, to experience further benefits like lowered freight costs, faster turnaround times, easier face-to-face meetings and quicker access to inventory. Choosing to do plastic products manufacturing within the China. means freed-up resources, lower lag times, and more convenience when making product adjustments or changes.

“CN-MOULDING plastic products manufacturing provides all kinds of benefits to world companies,” said Kenny Han, a vice president at CN-MOULDING. “It’s much simpler to communicate, make changes, view samples and so on — not to mention cheaper and more efficient in the process.”

This increasing push for onshoring shows that China plastic products manufacturing is booming — and there are other evidences in place, too. Injection molding and 3D printing is a hot trend in the plastics industry today, being used for everything from military equipment to medical devices. Network World says 3D printing is “the hottest new technology on the IT landscape,” offering further proof that China plastic manufacturing continues to grow.

Injection molding process

The injection molding process can be roughly divided into the following six stages

Clamping, glue, pressure maintaining and cooling, mould and products.

The above process again and again, can batch periodically to produce products. Thermosetting plastic and rubber molding including the same process, but a thermoplastic material barrel temperature is low, the injection pressure is higher, the mould is heated, finished material injection in the mold of the subject to curing or curing process, and then strike off membrane.

The trend of the current processing technology is developing towards the direction of the high and new technology, these technologies include: micro injection molding, high filling compound injection, water injection, mixed with a variety of special injection molding process, foam injection molding, mold technology, simulation technology, etc.

The temperature control

Injection molding equipment and mold

1．nitrogen-treated barrel temperature, injection molding process, the need to control the temperature of the cylinder temperature, nozzle temperature and mould temperature, etc. The first two main influence plastic plasticizing temperature and flow, and then a temperature is mainly influence plastic flow and cooling. Each kind of plastic flow with different temperature, the same kind of plastic, due to different sources or brand, the flow temperature and decomposition temperature is little different, this is due to the different average molecular weight and molecular weight distribution, plastic in different type of injection machine of plasticizing process is also different, so choose the cylinder temperature is not the same.

2. The nozzle temperature, nozzle temperature is usually slightly lower than expected tube maximum temperature, this is to prevent the molten material in straight through the nozzle may be "salivate phenomenon". Nozzle temperature also cannot too low, otherwise will cause early setting of melting and the nozzle clogging, or due to early coagulation material into the cavity affect the performance of the products.

3．Pictures of mold temperature, mold temperature inner performance and apparent impact on the quality of products. Mold temperature is determined by the size of the plastic, of crystalline products and structure, performance requirements, and other process conditions (melt temperature, injection speed and injection pressure, molding cycle, etc.).

Pressure control

In the process of injection molding pressure including plasticizing and injection pressure, and directly affects the quality of plasticizing and plastic products.

1．plasticizing pressure: (back pressure) adopts screw injection machine, screw at the top of the molten material in the screw rotating back pressure is called the plasticizing, which is also called back pressure. The size of the pressure can be found on the overflow valve to adjust the hydraulic system. In injection, the size of the plasticizing pressure is depending upon the design of the screw, the product quality requirements, and the type of plastic and needs to change, if the situation and the screw rotation speed is constant, increase plasticizing pressure will strengthen shearing action, which will raise the temperature of the melt, but will reduce the plasticizing efficiency, increase the current and leakage flow, increase the driving power.

In addition, increase plasticizing pressure often can make the melt temperature uniformity, color mixing and discharge gas in the melt. general

Injection molding in the operation of the pressure curve, the plasticizing pressure shall be on the premise of guarantee the products quality is lower, the better, the specific values are vary with the varieties of the plastic, but usually rarely more than 20 kg/cm2.

2. Injection pressure: in the current production, almost all the injection pressure of injection machine are in piston or screw at the top of the plastic

On the pressure (by oil pressure conversion) shall prevail. Injection pressure in injection molding, the role of is, to overcome the flow resistance of plastic flowing from cylinder cavity, given the rate of molten material molding and compaction of molten material.

CN-MOULDING shows how internet can be used to deliver custom mold manufacturer service around the world

CN-MOULDING offers plastic molding services for various industries, such as automotive, electronics, home appliances and others around the world using the internet.

China based CN-MOULDING believes in using the latest technologies to develop and deliver plastic molds to their industrial clients across the world. The company now uses the internet to build custom molds as per client specifications and reduces the time and cost of designing and engineering molds.

Offering their efficient plastic injection molding service through the internet, CN-MOULDING allows customers to send drawings via email. Based on the drawing, they provide quotation for the molding project within twenty-four hours, and the workers of CN-MOULDING provide the mold drawing for approval after receiving the Purchase Order from the customer. Once the drawing is approved by the customer, they start manufacturing the mold and send it for the customer's approval again. When the customer approves the sample mold and makes the payment, the production of mold is started. Thereafter, the mold is shipped to the customer.

The spokesperson of the company reveals that their CN-MOULDING Mould development and delivery process has been liked by several customers around the world. The internet based process is much faster and helps deliver the product as per the customer's specification. With a strict drawing and sample approval process, the product precisely meets the customer requirements. Moreover, they have a worldwide product delivery mechanism to ship products anywhere in the world.

CN-MOULDING maintains a systematic and transparent PO procedure that allows customers to put a control on the product quality, cost and the production cycle. The faster is the approval process, the quicker will be the design and development of the plastic mold. The company has a vast experience in the injection molding and designing and engineering of molds for a number of industries. This is the reason why an industrial client can rely on their production technology and the product quality.

Using the internet, CN-MOULDING intends to offer convenience and a simple way of getting custom molds for industries around the world.