Plastic Mould

Plastic injection moulding companies future developments

admin — Thu, 06 Jan 2011 08:29:00 +0000

Plastic injection moulding industry is now facing the very heavy competition, most of the plastic injection moulding companies are working on mercy profits and low technologies. The market can estimate the moulded plastic components price by the weight. For example currenly in China, the ABS moulded parts was calculated by material cost plus moulding cost RMB3.5 to RMB4.0 per kg. Such transparent cost made the plastic moulding companies too much limitations. The question is that how to come out such passive situation?

As you know, the plastic injection moulding cost was combined as below:

•plastic material cost
•electricity power cost
•labour cost
•depreciation of machinery
•plant costs
•water cost
•packaging cost
•transportation cost
•mould and machine’s repairing and maintain cost
•various manage shortage wasting cost
In order to get more profits, we have to try our best to reduce or avoid above various costs.
For example if you have 20 sets of injection moulding machines, and your moulded components are selling well in short supplying. Then it is easy for you to make the improvements of your production capacity.
-run the injection moulding machines each day 24 hours.
-speed up all the moulding machines. For this point you need to be sure that your machines are suitable for high speed running, and if your moulds are suitable for high speed running, if the cooling water are in high pressure and the chilling system in effective enough.
-even if your machine are high speed, but if you are in shortage of automation system in your injection moulding plants, then you need a lot of labour to pick up the moulded plastic components from the machine and you need to stack or collect them before packing…all these need labours and this will reduce the production capacity, in the same time the labour cost will be highly increased.
-if the moulds are not well made, then you need to put a lot of labour onto the moulded components treatments such like flashes cutting……
Abvoe 4 points we call them high efficiency method. High efficiency is equal energy saving, labour saving,resource conservation

Below points are related to vaiours cost saving.
-the injection moulding machines have very heavy electricity power consuming, now there are many different types of energy saving machines such like variable pump injection moulding machine, servo motor injection moulding machine, roboshot injection moulding machine. If you update your machines, you can save energy by 30 to 50% monthly or annually.
-by use precise high speed injection moulding machines and injection mould to save energy.
-by use high speed injection moulding machines and injection mould to reduce the substandard products to save energy and material wastage.
-by use good quality injection moulding machines and injection mould to reduce the repairing or maintain cost.
-by use the good quality injection moulding machines and moulds to avoid the production shutdown, in this way to increase unit time’s production capaicty.

Plastic injection moulding system including machine, mould, operators and other related device. If any of them not meet the production requirements, it will effect the production. For example, if the mould is not efficiency, such like, cold runner with big gate tails, cooling not good, guiding system is not accurate, hot runner system color changing is not fast… all these will increase the difficulties of the injection moulding, also will cause a lot of wasting of material, energy and labours…

Someone maybe will ask that if we improve the machines, moulds, managements, then we can be invincible forever? My personal suggestions for the plastic moulding companies: we need to do RND for plastic design and also if possible, we produce some products which is high technologies with the some innovations, such like two colors injection, gas injection moulding, injection moulded and assembling…while not injection shot and selling.

The Best Way to Vent a Portable Air Conditioner to the Outside

admin — Wed, 22 Dec 2010 01:38:37 +0000

Air Conditioner Accessories

Portable air conditioners are both convenient and easy to setup. You don’t need any special duct work, wiring or drainage lines installed, but you must properly vent the unit before using it. Portable air conditioners extract hot air from the room or space and this air must be pushed out of the unit in order for the cooling process to begin. Venting a portable air conditioner is not difficult if you have the right instructions.
.Setting Up the Portable Air Conditioning Unit
Unpack the unit and spread out any accessories that are part of the device. You should see a vent hose, exhaust connector and a window adapter kit. Those three parts are what you need to vent your portable air conditioning unit. Place the unit close to a window that has an outlet under it. Next, slide the exhaust connector over the discharge opening on the back of the unit. Then connect the vent hose to the exhaust connector.
Venting the Portable Air Conditioning Unit
Open the window by the air conditioning unit and fit the window adapter kit into the window. You may have to extend the length of the window kit and/or cut the unit with a utility knife to fit your widow. You want the window kit to fit tightly in the window. Then connect the vent hose to the window kit adapter and shut the window. Fill any cracks present around the window kit and window with caulking. Finally, go outside and install a “bird blocker” screen over the vent so nothing can get into the vent hose.
Using the Portable Air Conditioning Unit
Make sure the vent house is straight and no creases or bends are present. Plug the portable air conditioner unit’s power cord into a wall outlet and turn on the unit. Do not use an extension cord to power the unit. Set the temperature setting to about 65 degrees F so the room can start cooling. Most units have a water drip pan that is easily removed and emptied. Generally when the water drip pan becomes full, the unit will shut off and give a warning code on the display present on the unit. See the instruction manual that came with the portable air conditioning unit for more information on the display.

How to Use an Extruder for Injection Molding

admin — Fri, 10 Dec 2010 03:26:16 +0000

Those proficient in the art of injection molding know how to design hollow objects out of thermoplastic. This occurs when you bring hot plastic tubes together that contain an opening in one end along with the insertion of air on the opposite end to modify the tube’s shape. When you know how to use an extruder, you can create plastic in any shape you choose.
instructions

1.1
Use your extruder to inject the thermoplastic that you want to melt in a cavity of steel. This type of steel mode, known as a parison, creates something that looks like a test tube.

2.2
Transfer the item you just created with a core rod to the subsequent part of the process.

3.3
Take your container, while it remains on the core rod, and move it to a location that you choose. Eject it from your mold.

An important air conditioner accessory to keep it safe

admin — Tue, 07 Dec 2010 02:00:11 +0000

You may overlook the importance of air conditioner covers, but they are one of the key air conditioner accessories, which a user must provide for the safety of the unit.

Remember, it is very important that your air conditioning unit is kept far away from sources of extreme heat in order to ensure its efficiency. The outdoor component or outside portion of the air conditioning unit must be properly protected from the sun. Air conditioner covers are important because they play a major role in protecting the air conditioner from the excessive heat of the sun, which would have a negative impact on their operating cycle.

The covers also protect the unit from dust, leaves and other harmful intruding objects, which may be sucked in by the blower or fan. An air conditioner cover protects the unit even during winter. It is advisable that the unit is safely stored during the cold season, but if you do not have the necessary storage area – since it would occupy a lot of precious space in your office or home – having them covered helps.

The air conditioner covers are vital accessories to keep them safe and to ensure their long life.

How to Replace a Central Air Conditioner Filter

admin — Thu, 02 Dec 2010 07:02:37 +0000

Air Conditioner Filter

Central air conditioning units require continued maintenance to ensure that they run efficiently and properly. Central air conditioning filters should be replaced at the beginning of each new season, typically winter and summer. Neglecting to replace the filter can cause damage to your unit and decrease the air quality inside your home. You can purchase a replacement air filter for your system at any local hardware shop or Wal-Mart. Replacing your filter involves only a few steps.
1.Disconnect power on your central air conditioning unit by turning off the circuit breaker that controls the furnace and unit.
2.Locate the central air unit outside your house and remove all debris from around your unit. Straighten any bent cooling fins, located around the outside perimeter of the unit, and wash with a garden hose on low pressure.
3.Locate the furnace and remove the old, dirty filter. Remove the screws holding the filter cover in place and keep them in a safe place. The filter cover is located where the furnace meets the air duct and is labeled “filter”. Remove the filter cover in the venting duct and pull out the filter.
4.Slide in a replacement filter and replace the filter cover. Follow the arrows printed on the filter replacement to ensure you place it in the correct direction. Replace and tighten the screws to ensure the cover is secure in place.
5.Turn on the circuit breaker to restore power. Your central air conditioning unit is now ready for another season.

Plastic Injection Mold Troubleshooting

admin — Wed, 01 Dec 2010 03:26:08 +0000

Troubleshooting a plastic injection mold is essential to ensure the proper manufacturing of plastic materials and proper functioning of injection machinery and molds. Problems sometimes arise in the process of mixing, molding or heating the plastic shot. Most plastic injection mold troubleshooting techniques are easy to follow and quick to perform to fix common problems.
.Proper-Sized Moldings
Always use enough plastic shot to create a material that is the proper length and thickness. If moldings are short, increase the feed settings on the injection machine and check that the plasticizing rate is sufficient for the task. If the plastic shot freezes before the mold finishes filling, increase the speed, pressure and time of the injection. Raise the temperature of the mold and the plastic shot. Check for sufficient venting.
Poor Quality Molding
If the mold delaminates, check for debris in the injectors and purge the machine. Raise the temperature of the mold and the plastic shot. Lower the speed of injection. If flashing occurs, then turn off, realign and reface the mismatched mold faces. Check that the surface of the mold is flat, clean its surface and check that its shutoff is operable. If the mold opens while under pressure, lower the peak cavity pressure and the fill rate. Increase the pressure of the mold’s clamp and increase the size of the gate to lower the filling pressure. Check that the runners and gates are in balance. If the melt viscosity is too low, lower the temperature of the material and the injection speed.
Machinery
If the materials do not weld when they converge, raise the temperature of the mold and the material and raise the injection speed. Change the gate to prevent interfacing flows that travel over longer distances than other flows. Raise the cooling time and lower the temperature of the mold and the material to allow for sufficient cooling. To prevent excessive shrinkage, increase the feed setting, raise the pressure hold-on time and raise the injection pressure. Decrease the temperature of the mold and the material and check that the machine’s capacity is sufficient.
Imperfections in the Material
Eliminate warping of the material by lowering the injection pressure and raising the injection speed and the temperature of the both the material and the mold. Use a higher grade melt flow index (MFI) if possible. If the material contains alternating glossy and dull patches, check that the mold is still in good condition and polish the surface. If the material cools at uneven temperatures, raise the temperature of the nozzle. Use a shorter extension nozzle or sprue. If the material has scabs, lower the temperature of the mold and the material. Position the water inlet at the gate and use additional cooling circuits. If the material has an odor, lower the temperature of the material. Check the hot runner system and the barrel for debris. Allow the material to cool in air before packing it. Use a higher grade MR. Eliminate burn marks by lowering the pressure of the speed cavity. Lower the injection speed and the melt temperature. Check for adequate venting at the gate.
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Helmet Safety Programs

admin — Tue, 30 Nov 2010 01:12:32 +0000

•According to former U.S. Surgeon General C. Everett Koop M.D.,a helmet worn properly while operating a bicycle or other form of human-powered transportation can reduce brain injury and death by 88 percent. However, only 15 to 25 percent of children actually wear helmets. To combat the problem, several programs exist that encourage proper helmet usage.
Think Positive
•The Brain Injury Association of New Jersey has a helmet safety program called Think Positive. Think Positive is a step-by-step program that rewards children for wearing their helmet while operating a bicycle, skateboard, scooter or skates. The program is implemented by police officers who offer positive reinforcement to children they observe properly wearing a helmet. The police officers hand out positive tickets that include information about helmet safety and a reward donated from a local community business such as a coupon for ice cream or a slice of pizza.
Lids on Kids
•The National Ski Areas Association developed a website to encourage proper ski and snowboard helmet use for kids. Called Lids on Kids, the program teaches parents about winter sport helmet safety. Helmets are not required for kids who snowboard and ski, but Lids on Kids and the NSAA strongly recommend a properly fitting helmet for children as to prevent brain damage or injury.
Emergency Helmet ID Safety Program
•The Emergency Helmet ID Safety Program consists of H.E.L.P. safety stickers worn in a person’s helmet. H.E.L.P. stands for the Helmet Emergency Lifesaving Profile, and the stickers provide information about basic first aid, CPR steps and allergy and medical alerts. A sticker is placed outside of the helmet to alert someone an informational sticker is located inside. In the event of an emergency, the stickers provide a guide for any bystander to aid a helmet-wearing victim until emergency responders arrive.

What Is Injection Molding Used for?

admin — Mon, 29 Nov 2010 07:39:18 +0000

Injection molding is used for manufacturing plastic, rubber and metal. Materials are fed through a heated barrel in the machine and forced into a mold where it will cool and take its shape. An injection molding machine can stamp out metal car shell parts, rubber valve steam seals, and even plastic toys for kids.
.Plastic
Injection molds uses plastic to make toys for children, milk containers and movie cases. It also makes other plastic products such as combs, kitchen utensils and dust pans.
Rubber
Injection molds make many rubber automobile parts. It makes valve steam seals and oil seals for the engine. It also makes earplugs, rubber hoses and telecommunications items.
Metal
Injection molds can stamp out small to large items. It can stamp out automobile parts from spark plugs and floor pans to ball bearings. It also can stamp out items like TV hangers and knitting needles.
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Defects in Plastic Molding

admin — Wed, 24 Nov 2010 05:51:45 +0000

Plastic injection molding is an effective manufacturing process for making plastic products. A high pressure injector squeezes molten thermoset or thermoplastic resin into a pre-cast steel die, where the resin is allowed to set and form into a proper state. It is an efficient mode of production that can produce short and long runs to tight tolerances. Depending on the type of plastic or foam used, the material can range from very durable to soft and malleable.

However, as with any manufacturing process, problems can arise due to machine, material and human error. Troubleshooting common errors can alleviate the frequency of these situations, however, and being prepared can foster a smoother manufacturing run.

Common Defects

* Blister

A blister is a raised area on the plastic surface, very similar to the medical condition of the same name. It is generally the product of too much heat on the tool or by inadequate cooling or venting. Depending on the type of tool, you can also find areas where full coverage is not working. For instance, if the injector has a flow pattern issue, it might not inject all the resin at once, allowing air bubbles to enter the molten resin. A hot runner tool might also suck air into the die because of area constriction, slowing the passage of the resin.

* Burn Marks

Burn marks are generally caused by problems similar to blistering. They manifest as literal burn marks on the plastic, black discolorations that resemble scorches. The general cause of burn marks is improper ventilation for the resin. When this happens, the burns are usually located in the position farthest away from the ventilation gate. Another cause might be that the resin is getting trapped in the injector and heating too long. Cleaning the tool often solves this problem.

* Burrs

A common problem in many types of machining, burrs appear on injected plastic products when extra pieces or scraps are attached to the finished piece. A common, everyday occurrence of burrs can be found on green plastic Army men, who often have little extra pieces on their heads or thin sheets of plastic connecting their arms to their bodies. Burrs are usually a result of dull or inaccurately cut dies or molds. Sharpening or cleaning the dies are typically the most effective ways to remedy the situation.

* Embedded contaminates

Then there is detritus in the finished product, it means that contaminates have somehow worked their way into the resin. A full cleaning of the machine may be necessary to find the source.

* Flow marks

Flow marks are look like discolored lines or patterns on the finished product. When they occur, your injector might be functioning at too low a temperature. The gate might also not be properly ventilating the mold.

* Lamination

This occurs when contaminates are introduced into the mold or resin but manifest as shiny flake layers in the wall of the part. These are a sign that purging compound was accidentally left in the mold.

* Sink marks

Sink marks are small holes or depressions, similar to tiny potholes, in the surface of the piece. There are a number of reasons they might appear. First, the material might simply be insufficient for the job. A cause that is easier to remedy is temperature variation, such as too short cooling time or too high melt and mold temperatures. The mold design can contribute to these causes, so it might be necessary to start from scratch.

* Short mold

A “short mold” refers to a mold that is not completely filled, leading to deformation or “shortened,” parts. This occurs when the resin cannot fill the mold due to blockage, bottlenecking or injection that is either too fast or too slow.

How to Change Air Conditioner Filter

admin — Fri, 19 Nov 2010 07:33:14 +0000

Now, you know how often to change air conditioner filter and why such replacement is necessary. The following are some guidelines regarding how to change air conditioner filter.
* Shut off the air conditioning system and try to locate the filter. In case of a furnace system, the air filter can be found attached to the AC unit itself, but, in a forced air system, air filter is usually located over a vent, through which the air is taken in. Mostly, the filter will be covered by a metal grill.
* Once you locate the air filter, check its size, which may be noted on the side of the device, or else call up the manufacturer for the details of the air filter installed in your air conditioning system.
* As you get the dimensions of the air filter in the system, purchase a new one of the same size. There are many types of air conditioner filters and you can choose the one best suited for you. Those who live in warm and dusty climates may go for more efficient filters.
* Before removing the old filter from the system, you have to note how the filter is attached to the system and make sure to mark the direction of airflow (look for similar markings on the old filter). Such details may be needed when you have to fix the new filter.
* Remove the old filter from the system and clean the grill with a vacuum cleaner. Now, fix the new air filter, in the same way as the old one was attached to the system. Take care of the right airflow direction, while fitting the new air filter. Once the new air filter is fixed, close the covering of the filter carefully.