A15 电热式变模温控制技术应用

Electrically heating reaches Everywhere in the mold

An electrically heating reaches the deep part of the mold and heats the whole parts of the mold evenly. And to keep the whole mold warm evenly the mold might be made by the metal with high diffusivity. Table 2 shows how the works in the wonder injection molding with E-MOLD Process.

The Slits of non flow thickness

Table 1 shows the typical thickness of the molten resin does not flow in from the general guide book of General Electric Ltd. In order to supply the electrically heating into the heating area evenly and protect the flowing the molten resin passing it the slits of non flow thickness must be distributed over the molds and be connected to the plate from electric micro heater. Adequately distributed slits supply the gas flame evenly over whole the mold part. These concepts are opened by patent application of International Patent Cooperation Treaty.

No loose time process control

As presented by Sued Kunststoff Zentrum(SKZ) in Germany with 30mm thick Steel plate and cooling channel in 11mm deep from 300C of surface temperature it drops to 180C in 3 seconds and to 35C in 10 seconds. Accordingly cutting off the loose time between finishing heating and injecting the molten resin is essential point in this process. In E-MOLD Process this loose time does not exist by supplying the micro heater supply with automatic controller and allows keeping electrically heating till just before the injecting the molten resin.

Figure 1 shows the status of heating with the micro heater when the mold plate open and Figure 2 shows the status of injecting molten resin into the mold cavity just after heating in no loose time when the electrically heating close.

Cooling

Combining conventional water-cooling and air cooling through mold plate supply channel reduces the cooling time dramatically. And the energy accumulated in the thin skin of the mold is enough small to be removed in a few seconds as well. Consequently the cooling time of E-MOLD injection process is to be not longer than that of conventional injection process and even shorter.

Experiments

Wonder injection molding with E-MOLD Process deletes all the restrictions of former injection molding process and recent developing new injection molding method. The new and key point is that the mold surface temperature should be kept at the same temperature of the molten resin and even higher as allowed during the molten resin filled in the cavity of molds. With E-MOLD Process in order to produce shiny surface of 30% glass fiber reinforced Polycarbonate in the 1.5mm thick and L/t of 145, the skin of the molds was heated up to 300C in 15 seconds with micro heater supplied through non flow slits into the molds with the molding condition of 45 MPa of injection pressure and 15 seconds of cooling time and 305 C of the resin temperature. In conventional process it used to be 80C of mold temperature and 145 MPa of injection pressure and 15 seconds of cooling time.

Conclusions

Consequently the Wonder Injection Molding with E-MOLD Process might substitute in the most perfect way the high pressure injection-compression molding, low pressure injection molding the high speed-high pressure injection molding, the Bright Surface molding and no weld and no painting molding with the perfect quality and the satisfying productivity.

Future Research and DevelOPMent

Research and development should be directed toward the understanding of the fundamental theory and building up the experimental data in various yields and classifying the advantage of Wonder injection molding with E-MOLD Process with practical experiment and data.

The modifications method of the resins are considered to be carried on because some additives plates out to mold and is burned by electrically heating and makes pollution and strength and thermal properties are going to be the key point of the resin formulation without any concerning about fluidity in Wonder injection molding with E-MOLD Process.

Research about the improvement of the thermal properties and physical properties of injection molded parts will let us get the applicable design concepts with Wonder injection molding with E-MOLD Process.

A computer simulation program for the Wonder injection molding with E-MOLD Process will release a lot of indication of applications and trouble solving methods. (10)

In order to complete this technique commercially the mold design and mold manufacturing skill development and processing skill development removing skill of micro heater treatments and must be concretely followed.