Eight plastic injection molding technology and its characteristics

【塑料注塑】八大塑料注塑成型技术及其特点

Gas-assisted injection molding (GaIM)

Forming principle:

Gas-assisted molding (GaIM) refers to the injection of high-pressure inert gas when the plastic is filled into the cavity (90%~99%). The gas pushes the molten plastic to continue to fill the full cavity, and the gas pressure is used instead of the plastic pressure-holding process. An emerging injection molding technology.

Features:

Reduce residual stress and reduce warpage;

Eliminate the sag marks;

Reduce the clamping force;

Reduce the length of the flow channel;

Save material;

Shorten production cycle time;

Extend the life of the mold;

Reduce the mechanical loss of the injection molding machine;

It is applied to finished products with large thickness variations.

GaIM can be used to produce tubular and rod-shaped articles, sheet-like articles, and complex articles with uneven thickness.

Water-assisted injection molding (WaIM)

Forming principle:

Water-assisted injection molding (WaIM) is in GaIM

An auxiliary injection molding technology developed on the basis of the principle and process is similar to GaIM. WaIM replaces GaIM's N2 with water as a medium for evacuating, penetrating the melt and transmitting pressure.

Features: Compared with GaIM, WaIM has many advantages. The thermal conductivity and heat capacity of water are much larger than N2, so the product has a short cooling time and can shorten the molding cycle; water is cheaper than N2 and can be recycled; water is incompressible. Sexuality, not easy to appear finger effect, the wall thickness of the product is relatively uniform; the gas easily penetrates or dissolves into the melt to make the inner wall of the product rough, and it generates bubbles to the inner wall, and the water is not easy to penetrate or dissolve into the melt, so it can be made A product with a smooth inner wall.

Precision injection

Forming principle:

Precision injection molding refers to a type of injection molding technology that can form products with inherently high quality, dimensional accuracy and surface quality. The dimensional accuracy of the plastic products produced can reach 0.01 mm or less, usually between 0.01 and 0.001 mm.

Features:

The dimensional accuracy of the parts is high, and the tolerance range is small, that is, the high-precision size limit precision plastic parts can be within 0.03mm, and some even down to the micron level, and the inspection tool depends on the projector.

High repeatability of the product

The main performance is that the weight deviation of the workpiece is small, and the weight deviation is usually below 0.7%.

The material of the mold is good, the rigidity is sufficient, the dimensional accuracy of the cavity, the smoothness and the positioning accuracy between the templates are high.

Precision injection equipment

Precision injection molding process

Precise control of mold temperature, molding cycle, part weight, and molding process.

Suitable precision injection molding materials such as PPS, PPa, LCP, PC, PMMa, Pa, POM, PBT, glass fiber or carbon fiber engineering materials.

Precision Injection Molding is widely used in precision injection molding in areas such as computers, mobile phones, optical discs and other microelectronic products that require high quality uniformity, external dimensional accuracy and surface quality in injection molded products.

Micro injection molding

Forming principle:

Due to the small size of the plastic parts, the micro-injection molding has a significant influence on the dimensional accuracy of the product, so the control accuracy of the process parameters such as metering, temperature and pressure is very high. The measurement accuracy should be accurate to milligrams, the barrel and nozzle temperature control accuracy should reach ±0.5 °C, and the mold temperature control accuracy should reach ±0.2 °C.

Features:

Simple molding process

Stable plastic parts

high productivity

Low manufacturing cost

Easy to implement batch and automated production

Microplastic parts produced by micro-injection molding are increasingly used in micro-pumps, valves, micro-optics, microbial medical devices, and microelectronics.

Microporous injection

Forming principle:

The micro-hole injection molding machine has one more gas injection system than the ordinary injection molding machine, and the foaming agent is injected into the plastic melt through the gas injection system, and forms a homogeneous solution with the melt under high pressure. After the gas-dissolved polymer melt is injected into the mold, the gas rapidly escapes from the melt due to the sudden drop in pressure, forming a bubble nucleus, and growing to form micropores, and the microporous plastic is obtained after the setting.

Features:

The thermoplastic material is used as a matrix, and the intermediate layer of the product is densely packed with closed micropores having a size of from ten to several tens of micrometers.

The micro-foam injection molding technology breaks through the limitations of traditional injection molding. On the basis of basically ensuring the performance of the product, the weight and molding cycle can be significantly reduced, the clamping force of the machine is greatly reduced, and the internal stress and warpage are small. The straightness is high, there is no shrinkage, the size is stable, and the molding window is large.

Micro-porous injection molding has an unique advantage in comparison with conventional injection molding in the production of high-precision and expensive materials, and has become an important direction in the development of injection molding technology in recent years.

Vibration injection

Forming principle:

Vibration injection molding is an injection molding technique that improves the mechanical properties of a product by superimposing the vibration field during the melt injection molding process to control the polymer condensed structure.

Features:

After the vibration force field is introduced in the injection molding process, the impact strength and tensile strength of the product increase, and the molding shrinkage rate decreases. The screw of the electromagnetic dynamic injection molding machine can axially pulsate under the action of the electromagnetic winding, so that the melt pressure in the cylinder and the cavity periodically changes, the pressure pulsation energy homogenizes the melt temperature and structure, and reduces the melt. Viscosity and elasticity.

In-mold decoration injection

Forming principle:

The decorative pattern and the functional pattern are printed on a foil film by a high-precision printing machine, and the foil is sent into a special molding die by a high-precision foil feeding device to be accurately positioned, and then the high temperature and high pressure of the plastic material are emitted. . The transfer of the pattern on the foil film to the surface of the plastic product is a technique for integrally forming the decorative pattern and the plastic.

Features:

The surface of the finished product can be solid or have a metallic or wood grain effect and can also be printed with graphic symbols. The surface of the finished product is not only bright, delicate and beautiful, but also resistant to corrosion, abrasion and scratches. IMD can replace the traditional painting, printing, chrome plating and other processes used after the release of the product.

In-mold decorative injection molding can be used to produce automotive interior and exterior parts, panels and displays for electrical and electronic products.

Common injection molding

Forming principle:

Co-injection molding is a technique in which at least two injection molding machines inject different materials into the same mold. The two-color injection molding is actually an in-mold assembly or in-mold welding insert molding process. It first injects a part of the product; after cooling and solidification, the core or cavity is switched, and the rest is injection molded, and embedded in the first part; after cooling and solidification, a product having two different colors is obtained.

Features:

Co-injection can impart multiple colors to the article, such as two-color or multi-color injection molding; or impart various properties to the article, such as soft and hard co-injection; or reduce product cost, such as sandwich injection molding.

Injection CaE

principle:

Injection molding CaE technology is based on the basic theory of plastic processing rheology and heat transfer, using computer technology to establish the mathematical model of flow and heat transfer of plastic melt in the mold cavity, to achieve dynamic simulation analysis of the molding process, to optimize the mold Provide basis for product design and optimization of molding process plan.

Features:

Injection molding CaE can quantitatively and dynamically display the velocity, pressure, temperature, shear rate, shear stress distribution and orientation of the filler when the melt flows in the casting system and the cavity, and can predict the position and size of weld lines and cavitation. The shrinkage rate, warpage deformation and structural stress distribution of the plastic parts are predicted to judge whether the given mold, product design and molding process plan are reasonable.

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