Electronic Molding

Consumer electronics refers to audio and video products for personal and home related broadcast and television, while electronics mould including: TV mould, DVD player (VCD, SVCD, DVD) mould, video recorder mould, camcorder mould, radio mould, tape recorder mould, and stereos mould , record player mould, CD player (CD) mould etc. In some developed countries, telephones, personal computers, home office equipment, home electronic health care equipment, and automotive electronics are also included in consumer electronics. With development of technology and emergence of new products and new applications, digital cameras, mobile phones, PDAs and other products are also emerging consumer electronics products.

While metal structural parts of consumer electronic products refer to hardware components that protect and support high dimensional accuracy, high surface quality and high performance in consumer electronic products. There are many kinds of products, which are an important part of consumer electronic products. Consumer electronics metal structural parts are important components of consumer electronics. They are designed and manufactured to account for about one-half of the mobile consumer electronics development cycle, and their cost accounts for about 15% cost of mobile consumer electronics materials.

According to division of raw materials, mould for structural components of consumer electronics are mainly divided into mold of ABS engineering plastic parts, mould of polycarbonate parts, metal parts mould and so on, among which metal parts mainly include mold of magnesium alloy parts and stainless steel parts. For a long time, ABS engineering plastics are the main material of structural components of consumer electronics, but plastic structural parts generally have shortcomings of poor durability. Metal structural parts are favored by consumers due to their thin material, high strength support, good texture and fast heat dissipation. In the past two years, It has increasingly used in high-end products for consumer electronics manufacturers.

With the development of light, thin, fashionable and differentiated components of consumer electronic products, metal structural parts have gained obvious advantages in the market due to their high strength, good toughness, fast heat dissipation, light weight and good texture. Mainstream development trends. With the development of new processing technologies, processes and consumer acceptance, application of new material structural components will also occupy a place in the future.

Rapid development of global consumer electronics market has provided a broad market space for  development of metal structural parts mould industry of consumer electronics products, and the industry scale has expanded rapidly. At the same time, trend of diversified, personalized, thin and light appearance of smart terminals for consumer electronics products, as well as the structural complexity caused by the rise of wearable devices, continues to raise the technical level, innovation capability and production process of metal structural parts mold industry. The demand for metal structural parts mold market of consumer electronics products is booming and rapid development.

With increasing consumption level of people, demand for consumer electronic products is expanding, product upgrading is accelerating, scale of the consumer electronics market continues is growing, and mold-related industries are rapidly moving forward. Data show that in 2015, global consumer electronics market, driven by rapid growth of smartphones, tablets, PCs and other terminal devices, reached nearly 790 billion euros, an increase of 1.5% over the previous year.

The scale of China’s electronic information industry continues to grow, forming a relatively complete manufacturing system and industry supporting infrastructure. According to the National Bureau of Statistics, in 2015, China’s electronic information industry sales revenue reached 15.4 trillion yuan, an increase of more than 10.4%; China’s above-scale electronic information manufacturing industry achieved sales value of 113,294.6 billion yuan, an increase of 9.0%. The output of major products such as mobile phones and integrated circuits reached 1.81 billion and 108.72 billion, respectively, up 7.8% and 7.1% year-on-year. Consumer electronics production, such as mobile phones, personal computers and tablets, accounted for more than 50% of global production, ranking firmly in the world. During the “Thirteenth Five-Year Plan” period, demand for mold in the consumer electronics industry will continue to show a steady upward trend.

Tips about two shot moulds

double-shot moldingMulti-color multi-material injection molding process refers to combination of several kinds of plastics into multi-functional parts in one manufacturing process or one production unit. This technology uses a variety of materials for injection molding, and combines characteristics of different materials in the molding process for assembly or other suitable bonding methods to improve functionality and aesthetics of product, provide significant potential savings and new design possibilities.

Necessary conditions for two-color injection

Paired materials for two-color injection molding must meet two basic compatibility conditions, namely, adhesive compatibility and process compatibility.

Two-color injection molding also puts new demands on the injection equipment. For injection unit, parallel parallel, parallel, horizontal and vertical L-type, Y-type co-directional single-cylinder injection structures can be used. For the mixing nozzle, special nozzles such as patterns, waves, flow marks, gradients, and interlayers can be selected. In terms of clamping, a standard type, vertical rotary type, horizontal rotary type, rotary shaft type, robot rotary type can be selected. In terms of feeding, in addition to standard hydraulic motor drive, an ESD (Electric Screw Drive) electric charging structure is also available. For the oil circuit, ACC accumulator high-speed injection and closed circuit design can be provided.

One of key factors in two-color injection is variability of computer control programs. Because even the same type of multi-color products, if you use different mold designs, you must match different electronic control programs. After purchasing a multi-color injection molding machine, if a new mold design is encountered, an excellent multi-color injection molding machine supplier can quickly upgrade existing machine to meet the injection molding requirements.

New developments in technology

In combination with observation of two-color injection molding in recent years, European and American manufacturers have upgraded to several basic molding technologies in addition to traditional multi-color products such as automotive lamp mould, air-conditioning panel mould, and TV frame mould in the field of multi-color injection molding. The “combination” presentation, such as two-color molding and in-mold labeling (IML), two-color molding and in-mold assembly (IMA), two-color molding and stacking mold (Stack Mold), two-color molding plus IML plus IMA plus layer mold, Two-color molding plus sandwich injection can be done on an injection molding machine. Therefore, multi-color injection molding technology is getting more and more attention, It not only can present multi-color technology, but also combined with other technologies to create higher efficiency, which is challenge that next stage of industry must meet.

Multi-color molding technology for headlights

With the development of national economy, automotive industry has become the pillar industry of our country. The rapid development of current automotive industry has placed increasing demands on automotive lighting.

The quality of automotive lighting is very important for driving safety, so regulations of all countries in the world have strict requirements for automotive lighting. The design of luminaire not only should meet the requirements of regulatory safety, but also meet some other requirements. For example, the exterior should be integrated with appearance of the entire car, beautiful and practical, and meet aerodynamic requirements, so that drives and passengers feel comfortable and convenient. Therefore, design technology of lamp is also changing with the development of automotive industry.

Material and process characteristics of lamp

The lamp is generally composed of a base and a lamp shelling. The material of base is usually a thermosetting material – BMC (bump molding compound), and lamp shelling can be processed from PMMA, PP, abs, etc., usually two or three colors. In the production process of two-color lamp, special attention should be paid to injection part of two-color injection molding machine. The center distance between two screws should correspond to center distance of two shot mould. There are also the following important points that need to be strengthened:

The influence element of stable formation of lamp

(1) Two-color injection control unit response: excessive switching point, noise interference, unstable command output, unstable temperature; (2) noise of hydraulic system: pressure instability, valve positioning quality, hysteresis, tubing damping change; (3) Differences in mechanical system: oil seal internal leakage, damping, friction difference, screw check valve positioning, anti-reverse effect; (4) plasticization unevenness: plasticized product difference; (5) mold temperature control.

Car light emission countermeasures

(1) Charring – reduce the injection pressure, multi-stage deceleration injection, mold vacuum; (2) Silver pattern – thoroughly dry plastic particles, increase back pressure, reduce the melting temperature, reduce the rate of fire; (3) Bubbles – Increase back pressure, reduce melt temperature, use dehumidifier dryer to increase gate or runner size; (4) Bond line – increase melt temperature, increase fill speed, increase exhaust and mold temperature; (5) Burr – lifting clamping force, reducing filling pressure, reducing melt temperature; (6) Shrinking – uniform thickness design, increasing pressure and time, and replacing the check valve.

Frequently asked questions for design of plastic tube set for headlights

(1) The screw is not idling; (2) Torque required by screw is too large to rotate; (3) Plastic is not completely melted; (4) Unstable screw measurement; (5) uneven plastic mixing; (6) Temperature is easy to rise for low temperature plastic; (7) Bubbles in the molded product; (8) Molded product is easy to vomit and turn yellow; (9) The screw is easy to corrode, wear and has a short service life.

Main design focus of screw material tube set

Plastic plasticized screw material tube set is the heart component of injection molding machine, and is responsible for functions of conveying, melting, mixing and measuring plastic raw materials. Therefore, plastic plasticizing screw is closely related to the quality of the molded product. Main purpose of modified plasticizing screw is: (1) improve shear mixing; (2) uniform mixing; (3) improve plasticizing ability; (4) ensure melt temperature uniformity.

Taillight special screw design focus

(1) L/D ratio: 21~23; (2) Surface roughness of two-color injection molding needs to be extremely smooth to avoid accumulation; (3) Increase corrosion resistance of plating layer; (4) Two-color injection compression ratio: 2:3; Feeding Section: about 50%: Compression section: about 30%; Metering section: about 20%.

To make a set of two shot mold, it can be said that design accounts for 50%. According to industry insiders, scope of mold design process requirements is very wide. In addition to requiring design engineers to have rich theoretical knowledge and experience in molds, it is also very important to review and think before design:

1, Proofreading review —-Before two shot mold design is completed, customers and related personnel must be collated to conduct a proofreading review to comprehensively check the overall structure, processing feasibility and omissions in the drawing process, solicit customer opinions and avoid design errors such as a difficult mold manufacturing, use or even scrap.

2, Mould drawing —- Drawing a mould drawing according to above concept including group diagrams, parts drawings and related processing drawings. In the drawing process, the coordination between various systems of the mold is also needed to further improved to perfection.

3, Processing methods —- all two shot mold design must be considered feasibility of mould processing, then it has practical value. Otherwise it will leave on-site mold manufacturing experience and become a failed design.

4, Cooling —- Cooling has a great influence on the production of mold. While design work is complicated: it is necessary to consider cooling effect and cooling consistency, and also consider influence of cooling system on the overall structure of mold.

5, Exhaust — It is essential to ensure quality of product , use a variety of forms for exhaust, pay attention to prevent product vacuum adsorption and mold can not be opened.

6, Ejection —- multiple ways. ejector pin, Flat tip. Ejector sleeve. Pallet. Slider. Two segment ejection. Oil (gas) pressure. Pay attention to demoulding balance, mold strength, appearance, function, and cooling effect.

7, Undercut —- sliders, oil (gas) cylinders, motors, obilique tip, forced demoulding and other special methods. this part changes the most, and it is the most complicated design.

8, Mold insert —- must consider appearance, processing methods, two shot mold strength, demoulding mode, cooling method, fluidity, exhaust and other issues.

9, Parting surface —- An important part of design and process of plastic molds, which is flexibly used by designers, must consider appearance of product, ejection method, mold processing, etc.

10, Gate mode —- a wide variety, depending on the needs, must pay attention to whether the gate has appearance requirements and flow, balance, combined with lines, exhaust and other issues, gate model size is enough to fill the entire product.

11, Way of runner —- hot runner, adiabatic runner, no runner, direct injection (2 plate mold), indirect injection (3 plate mold) and other ways.

12, Cavity and its arrangement —- determined by projected area, shape, precision, output and efficiency of the product. All aspects are coordinated and constrained, and various considerations are made to achieve an optimal combination and to determine mold base and standard parts.

13, Forming machine specifications —- Understand clamping pressure, injection capacity, mold height, positioning ring size, nozzle radius, and pin hole position.

14, Molding material —- Correctly select the mold steel according to different plastics and product requirements to achieve quality and two shot mold life requirements, which requires designers to have a good understanding of plastic and steel.

15, Confirm material of product — The variety of plastic materials, determine the material to determine the shrinkage rate, understand the fluidity to determine the nozzle and sprue design.

16, Understand product drawing —- If it is suitable for a two-color mold opening: demoulding slope, shrinkage deformation, and if it can be ejected.