Chapter V Other types of injection molding

This chapter contains the basic structure and working principle of hot runner

injection molding; function of each component of the hot runner system, structural

requirements and design methods; hot runner injection molding temperature

regulating system design. Secondary injection mold ejection mechanism, fixed,

movable die bidirectional sequential pushing mechanism, the release mechanism

with a threaded plastic parts.

Second, learning objectives and requirements

In this chapter, we should grasp the overall structure and design

of hot runner system hot runner injection mold. Further, since the

plastic parts of the special structure such that ordinary ensure

reliable ejection mechanism is not introduced, the introduction of a

complex mechanism must be employed. In this chapter, we should have

introduced complex injection molds commonly used form of organization

and design methods.

Third, the focus of this chapter, difficulties:

Design of the hot runner injection molding hot runner system, the
overall structure and, complicated pushing mechanism commonly used
form and design method.

1, hot runner injection molding

(1) hot runner gating system

No runner gating system known as runner gating system.

Hot runner system and the difference between the general casting gating

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systems is that, in the whole production process, the plastic in the gating system is

always in a molten state, a small pressure loss, low-pressure injection can be

achieved for the multi-point gate, large multi-cavity mold and plastic parts in

addition, such a system is not pouring gating system condensate material,

waste-free process, eliminating the step of removing the gate, saving manpower

and material resources.

When the hot runner gating system formed plastic parts, plastic parts required

material properties have a strong adaptability.

① The melting temperature of thermal stability of a wide range of plastics, a

small viscosity changes, insensitive to temperature change, having a good

fluidity at lower temperatures, at higher temperatures hardly thermally

decomposed.

② A pressure-sensitive plastic does not flow when the injection pressure is

not applied, but the lower injection pressures applied to plastic parts will

flow.

③ Curing temperature and higher heat distortion temperature plastic can be

cured at a relatively high temperature, shorten the molding cycle.

④ Both small heat capacity rapid cooling, can quickly melted.

⑤ Good resin thermal conductivity of heat can pass quickly brought mold to

accelerate curing.

In principle, as long as the plastic mold design and performance combined

with virtually all thermoplastic hot runner injection molding can be employed, but

in the most hot runner injection molding applications are polyethylene,

polypropylene, polystyrene, polyacrylonitrile, polyvinyl chloride, ABS and the

like.

And processing must be divided into runner runner runner, known as

semi-insulating runner interposed therebetween.

(2) hot runner injection molding works

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 When injected, molten plastic flows through the sprue bushing, the nozzle

and the manifold into the mold cavity, the manifold is provided with electric

heating coil for heating, to ensure that the temperature of the molten plastic, the

nozzle without the heating means, the temperature of which is obtained by heat

conduction . Good thermal conductivity of the nozzle material should be used.

When injected, there is a portion between the template and the molten plastic

flows into the nozzle set, forms a heat insulation layer to ensure that there is

sufficient temperature at the nozzle. By the top manifold plate and the positioning

pins casings, pressed by the compression screw, and make the appropriate

adjustment. Insulating panel for thermal insulation between a given template and

the manifold, in order to maintain their proper temperature. After injection, the

mold is opened, the gate is pulled down, gripping the plastic member on the core.

When the movable die to a certain partially open position, the injection machine

fix both sides of the plate member pushing mast, then parts prolapse. Controlling a

moving distance of the stopper pin pusher plate.

(3) the hot runner nozzle

① Direct contact nozzle

The nozzle of external heating, internal passage coarse.

② Insulating nozzle

The nozzle thermal plastic insulating layer and the mold cavity plate, used

with good thermal conductivity beryllium copper alloy.

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 ③ Heat nozzle

Heat nozzle is disposed inside the nozzle of the heating bar of the plastic

within the nozzle is heated. Heating rods mounted in the central torpedo, which is

heated by the power voltage regulator. Torpedo around the melt passage gap is

usually 3 ~ 5 mm. Gap is too small, the flow resistance, fast heat dissipation; gap

is too large, the temperature difference between the radial melt, and the size of the

structure is large.

④ Valve hot runner nozzle

A nozzle disposed in the valve body can be controlled in opening and closing

the gate valve be opened at the time of injection holding pressure, closing during

the cooling phase. This prevents the melt drawing and Tuan mouth salivation,

particularly suitable for low viscosity plastic. Stuffy hot runner nozzle into the

valve opening and closing by a driving mode types: one is driven by the pressure

of the melt; the other is driven by hydraulic pressure cylinder.

⑤ Heat pipe hot runner

Super heat pipe is a thermally conductive element, which is an integrated

liquid evaporation and condensation and capillary design principles. Typically the

diameter of 2 ~ 8 mm, length of 40 ~ 200 mm, the heat capacity of the same

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diameter copper rod is several hundred thousand times comes first, which is made

of brass seal, the heat transfer medium was added in a vacuum state, the hot end

evaporating section of the heat transfer medium at a higher temperature of boiling,

evaporation, an adiabatic section to the condensing section by flowing an

exotherm and then condensed into liquid. Core sleeve tube the fine wire structure,

plays a capillary suction, the heat transfer medium is recycled back to the

evaporation stage, the process will continue to both ends of the heat pipe

temperature equilibrium.

(4) hot runner injection mold structure

Hot runner injection molding injection mold is made tends drawer, as

compared with ordinary injection molding hot runner injection molding has many

advantages, hot runner injection molding material savings, higher productivity,

more extensive application. Hot runner injection molding can be divided into

absolute hot runner injection molding hot runner injection molding and

processing.

① Structure and composition:

Molding Parts

Gating system insulation panels, electric heating coil, the manifold, sprue

bushing, nozzle, seals

The guide bore in the guide portion of the guide post, and a stationary

platen pusher plate

Release means pusher plate

Structural components

② Absolutely hot runner injection molding

Insulation Runner runner injection molding is quite thick cross-section, so

that, using a plastic can be worse than the metal heat conductivity properties. So

that the plastic flow path close to the inner wall of condensing into a fully cured or

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semi-molten layer, functions as the heat insulating effect, and the central portion

of the plastic flow channel remains in a molten state during continuous injection,

the molten plastic flow path through the central portion of the smooth filling cavity.

Since no additional heating flow channel, wherein the solidifiable material into the

required injection molding cycle is short.

Wells nozzle

Wells nozzle and the flow path, it is the most simple structure suitable for

single-cavity hot runner absolute. Wells nozzle which is provided with a sprue cup

between the injection machine nozzle and the mold population, using the outer cup

insulating air gap. During injection, the melt in contact with the borehole wall

rapidly cured to form a heat insulating layer, so that the melt located in the central

portion to maintain a good fluidized state, under the action of the injection

pressure of the melt through the cavity filling point gate . When the pit using an

injection molding nozzle, the injection molding cycle is generally not more than

20 s.

Ding injection machine nozzle for extending into the sprue cup when

its length is determined by half the pit by a concave spherical cup

of r, should be well attached to bothCo. Stocker well not be too large

in diameter, the melt back pressure to prevent back leakage of the

nozzle material.

Multi-cavity hot runner must

Multi-cavity hot runner must be divided into direct point-gated

and gated two types. Shunt its circular cross section, the diameter

often take 16-32 mm, the molding cycle is longer, the larger diameter.

An air gap is provided between the runner plate and the stationary

platen, and to reduce bothThe contact area, in order to prevent the

heat transmitted to the shunt plate is stationary platen, cooling and

sizing the influence of plastic parts.

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 ③ Add hot runner injection molding
Plus simply referred to as hot runner injection molding hot runner
injection molding fork. Plus hot runner means a heater disposed within
the gating system remains molten plastic to ensure normal injection
molding intoRow. Since the flow passage can effectively maintain
constant temperature, the pressure in the flow channel can be a good
transfer, small pressure loss, can be appropriate to reduce the
injection pressure and temperature, reduce the residual stress within
the plastic article. Add hot runner mold heating temperature higher
control accuracy.

Plus single-cavity hot runner

Plus a single cavity hot runner nozzle structure extending employed,
it is the normal injection machine nozzle and sprue elongated straight
upper mold portionA nozzle connected to contact with heater nozzle
itself, the feed point gate cavity. Between the nozzle and the mold to
take effective thermal insulation measures to prevent the heat
transmitted to the nozzle die.
With a band heater and a temperature measuring nozzle extends, the

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control means. Usually the nozzle temperatureA cylinder temperature of
higher than5 ℃ ~ 20 ℃. Nozzle and the mold should minimize contact
time and the contact area, generally an injection-holdingAfter pressing
the nozzle should be removed from the mold. An air gap or may be used
to reduce the contact area of the plastic layer. Usually the nozzle
should credits  0.8 ~ 1.2 mmDiameter point gate.

Plus multi-cavity hot runner.

Runner multi-cavity system consists of three parts, the main

passage, the manifold plate and nozzle.

(5) a hot runner injection mold structure typically

Washer outer cover required smooth surface appearance, no gate mark

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and the push rod, and therefore to plastic in the mold upside down,

such asunderMapFig. Release plastic parts to which the fixed mold side,

therefore. Side of the fixed mold large in size. The ordinary sprue,

runner system condensate material lot, and inconvenient to remove, so

a hot runner sprue bush8 with the outside of a plurality of sets of

electrically heating coilHeated sprue bush, between the mold and the

sprue bush template using the heat insulating air gap. Since the sprue

bush too elongated, intermediate position increases the collar9, a

sprue bush for positioning. When the injection mold, the sprue bush

8 by the melt into the mold cavity. After the injection mold fightOpen,

open to a certain distance when the pull tabThe push member 13 movable

plate 12 Release article, whileThe reset lever is connected by a screw

pusher plate3 fixed plate pulls the push rod 5 moves, the push rod 6

Release article.

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2, with the introduction of the secondary injection molding mechanism

Some plastic parts either single or polyhydric Release mechanism, since a

special shape or automated production, is still difficult to remove or can not fall

off after a release operation is completed from the mold cavity, then it is necessary

to add a release Release off operation to make plastic parts; sometimes avoid a

de-molding excessive force, the second release Release also be employed to

ensure the quality of plastic, such a mechanism referred to as secondary ej ection

mechanism. Release of the secondary push plate means is divided into single and

double quadratic Release push plate mechanism.

(1) Release single secondary push plate mechanism

Common form of

① Spring-secondary institutions to launch

Secondary Release mechanism spring force of the compression spring

member pushes the push plate live, not with the pusher plate moves together with

the movable mold so that the plastic parts coming out from the core, to achieve a

launch operation; continue mold, injection mast top moving the push plate, and

then push the push member from the lake plastic plate cavity by the push rod, to

complete the introduction of the second operation.

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 ② Pendulum block-type secondary institutions to launch

Release of the secondary pendulum-block complete pendulum swing

mechanism using the second block operation introduced.

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 ③ Wedge Slipper secondary institutions to launch

Wedge Slipper secondary institutions to use the introduction of the wedge on

the slide mold forcing horizontal motion to complete the second launch action.

④ Ball-type secondary institutions to launch

Release mechanism using a ball-type secondary balls located Release

secondary position control operation.

⑤ Slipper secondary institutions to launch

Release mechanism using the slide-type secondary angle pin driving the

secondary ejection process is completed slider.

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 (2) Release of the secondary push plate mechanism bis

Dual Release secondary push plate means is two sets of the push plate in a

mold, which are driven by a set of Release Release of parts to achieve the release

operation of the secondary molded member. Commonly used secondary push-push

plate pushing mechanism are: spring-loaded type secondary ejection mechanism,

the secondary pendulum Release hook mechanism, the second character pendulum

rod pushing mechanism, jaw-type secondary ejection mechanism.

① Secondary Release spring-loaded mechanism of Formula

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② Pendulum hook secondary institutions to launch

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③ Placed leveraged secondary institutions to launch

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3, the order of the introduction of injection molding mechanism

A single set of the secondary push plate means is introduced in Release

means is provided only means a group of the push plate and the push rod fixed

plate, while the other one is introduced by the movement of special parts to

achieve. Second spring means is a single-Release secondary push plate pushing

mechanism, in addition to conventional single push plate there is a secondary

mechanism Release: Release second wedge type slide mechanism, the secondary

pendulum rod type block Release mechanism, U-shaped second rack pushing

mechanism limits, the secondary slide type mechanism or the like introduced.

① Sequential Release spring mechanism

② Put the order to launch the hook mechanism

③ Roller hook-type sequence agency launched

④ Slider-style launch mechanism

4, a threaded plastic parts with release

Male and female threads exceptionally on the two kinds of plastic parts.

Forming external threads easier, usually formed by the slider, the slider is opened

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after molding, plastic parts can be removed. Events may be used to shape an

external thread-ring, plastic parts after molding removed from the mold together

with the movable ring and the rotary ring in the event off the outer mold, plastic

parts obtained with an external thread. When the internal threads on the plastic

parts forming the mold space is limited. So the stripping approach is more

complex, common forms are:

Outer (1) moving core mold Unscrewing

Thread molding plastic parts, into the first moving core mold, after molding

plastic parts with the movable core is removed from the mold and then rotating the

moving core extrusion, to give the member with threaded plastic. This way of

stripping a simple structure, but low productivity, operating large labor intensity, is

only applicable to small batch production.

(2) Forced Unscrewing

After the plastic parts with an internal thread formed on the thread gripping

the core, the push rod under the effect of the introduction of the injection machine

pushes the pusher plate means, the force coming out from the threaded plastic core.

Threaded forced methods are limited to certain conditions: First, the plastic should

be flexible polyolefin plastic; secondly, should be semi-circular threaded coarse

thread, the thread height of less than 25% of the thread diameter.Furthermore,

plasticMember must have sufficient thickness can be absorbed by the

elastic deformation.

(3) to be pulled out inside thread

For some less demanding internally threaded plastic parts, may beIn

the internal threads on the circumference is divided into three partial

sections, corresponding to three inner suction slider is made of molded

on a mold.

(4) rotating mold Unscrewing

Many plastic parts to be used internally threaded rotate the inner

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moldProlapse. Unscrewing using a rotary manner, relative movement and

the axial relative rotation between the plastic parts have a

circumferential threaded core, therefore, must have a plastic screw

rotation stopping structure, as536 shown in FIG. 5 36a is a convex

surface of the outer plastic flute detent member shown;Map5 36b is

disposed recess in the surface of the plastic stopper shown in rotation;

FIG. 5 36e is provided on the end surface detent projections plastic

parts shown in FIG.

Rotating the mold used Unscrewing mechanism has:

① Manual rotation Unscrewing

② Gear rack Unscrewing

5, fixed, two-way order Release mechanism movable die design

In the design of the mold, in principle, should be left in the plastic parts of the

movable die, the movable die design introduced in the apparatus, so that plastic

parts coming out. Sometimes special shape since the plastic parts, plastic parts will

remain in both the fixed mold side, it is also possible to stay in the side of the

movable die, the movable case will launch means on the mold plastic parts can not

be reliably introduced. To solve this problem should be taken to set up agencies

launched simultaneously in the fixed mold and the movable mold method, an

increase of a sub-surface in the fixed mold section, make sure that the parting

surface from the first set to open in the mold, so start with a given plastic parts on

release from the die core or cavity and then when the main sub-surface type,

plastic parts can be reliably left movable mold portion, and finally introduced by

the movable die plastic parts Release mechanism, which is fixed, the movable die

bidirectional order push-out mechanism.

Fixed, movable die bidirectional design order Release mechanism comprising:

a spring mechanism bidirectional Release order, the order of the pendulum hook

bidirectional Release mechanism, the slider mechanism bidirectional Release order,

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the order of the bidirectional guide column Release mechanism or the like.

6, a thermosetting plastic injection molding

Mainly thermoset plastic and compression method of an

injection-molding process is complicated to operate these two methods,

the molding cycle is long, greenLow productivity, high labor intensity,

fragile molds, forming unstable quality. Thermosetting plastic molded

articles by injection method could be a major overhaul of the

thermosetting plastics molding technique, which has a simplified

process operation, shorten the molding cycle, improve production

efficiency(5 to 20 times), reduce labor intensity and improve product

quality, long die life (about 10 to 30 million times) and the like

preferablypoint. But this material to the forming station Qi higher,

the most commonly used filler is wood or cellulose phenolics,

aminoplasts addition, unsaturated polyesters and epoxy resins.

(1) Thermosetting plastic injection molding process points

① Injection pressure and injection speed

The thermosetting material in the injection barrel towel should

be in the lowest viscosity in a molten state, the molten plastic flows

through the high-speed small-sectionThe nozzle and the mold casting

system, from temperature60 ℃ ~ 90 ℃ instantaneously increased to

about 130 ℃, reaches a critical state of cure. ThisConverting the feed

point mobility is optimal state. Middle homosexual due to thermal

plasticAbout 40% filler. Viscosity and friction thanLarge, the

injection pressure increases correspondingly, about half the injection

pressure to overcome the frictional resistance to be consumed in the

gating system, it is generally up to the injection pressure100 ~ 170

MPa, the injection speed is often used 3 ~ 4 5.m / s.

② Holding pressure and dwell time

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 Dwell pressure and dwell time directly affects the size of the mold

cavity pressure and the plastic parts feeding and density. The holding

pressure can be usedSlightly lower than the injection pressure, dwell

time is reduced slightly more than the thermoplastic plastic injection,

usually taken5 ~ 20s.

③ Back pressure and screw speed

Thermosetting plastic injection, screw back pressure is not too

large, otherwise the material in the screw will be long-range

compression, guideInduced premature hardening of the melt and

injection difficulties occur, so the back pressure than normal hours

to obtain a thermoplastic injection, approximately3.4 ~ 5.2 MPa, and

when the movable shoulder screw can be close to the value 0. The screw

speed is generallyin30 ~ 70 r / rain.

④ Forming cycle

Thermosetting plastic injection molding cycle, the most important

is to ask the injection time setting and hardening. There are also dwell

timeAnd the mold pick time. Injection time domestic thermoset injection

materials2 ~ 10 s, dwell time is about 5 ~ 20 s, hardeningSetting

timeSelect the 15 ~ 100 s, total molding cycle takes about 45 ~ 120

s, the cured thermoset setting time, not onlyTo consider the shape of

the structure, complexity and size of the wall thickness of plastic

parts, but also pay attention to the quality of the material is good

or bad, in particular to determine when the hardening time, should pay

attention to this problem in accordance with the maximum wall thickness

of plastic parts. After filling material injection made generally

according to the curing time can be a maximum wall thickness of plastic

parts, press8 ~ 12 s / ram hardening rate is calculated.

⑤ Back pressure and screw speed, the molding cycle and exhaust

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 Injecting a thermosetting material in the curing reaction, it will

produce low molecular gases and condensed water, must have good exhaust

cavity junctionConfiguration, otherwise it will leave air bubbles and

flow marks on the plastic surface. Thickness of plastic parts, in the

injection molding operation, the relief measures may also deflated

mold.

(2) Introduction thermosetting plastic injection mold

Structure of a typical thermosetting plastic injection mold 41 in

FIG. 5, which is similar to thermoplastic injection mold structure,

comprisingGating system, cavity, core, guide means, pushing mechanism,

side action mechanism or the like, which is mounted on an injection

method is also the same machine. What follows is a brief introduction

to the thermoplastic injection mold different places certain

requirements.

① Gating system design

Because thermosetting plastic molded in the cylinder is not heated

to a sufficient temperature (preventing pre-cured), it is desirable

sprueThe cross-sectional area to be smaller in order to increase

friction, general sprue cone angle2 ° ~ 4 °. In order to increase

the surface area of the shuntConducive to heat, generally in the shunt

path of a circular or trapezoidal cross-section, the depth may be

suitably shunt taken at the same smaller cross-sectional area.

Selecting the type and location of the gate is substantially the same

principles and the thermoplastic injection molding, i.e. point gate

size is not too small, usually not less than1.2 mm, the depth of the

side gate in 0.8 ~ 3 mm were selected in order to prevent the melt

temperature rise is too large, the acceleration of chemical

cross-Linking reaction proceeds, so that viscosity increase, filling

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problems occur.

② Ejecting mechanism

Because thermosetting plastics melting temperature lower than the

curing temperature, the material under certain conditions of molding

fluidity. Can flowGap becomes small burrs, therefore, should improve

the manufacturing precision of clamping the mold, to avoid the use

pusher plate pushing mechanism at the same time minimize the use of

mosaic part.

③ Position of the cavity arrangement

Because thermosetting plastics Feng exit pressure, will produce

more flash and burrs in the mold parting plane between Ping Heng

uneven.Thus, when the position of the cavity are arranged in the center

of the projection area of the parting line should coincide with the

center of the mold clamping force engagement injection machine.

Thermosetting plastic injection mold cavity temperature of different

parts of the vertical position of the respective cavity or cavities

of the same distribution of a great impact, because it is natural

convection, hot air impact results by the upward movement, the test

shows that the upper portion of the heat absorbed by the underlying

part of the difference can be twice as much. Therefore, to improve this

situation, a multi-cavity arrangement should minimize the distance

between the upper and lower cavities.

④ Mold material

Thermosetting plastic injection molding mold part (cavity and core)

due to the plastic filler scouring action need wearOf good material,

while the need to lower surface roughness, chrome portion is preferably

formed to prevent corrosion.

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