| A. Double color
mould£ºTwo plastic materials are mould together on one moulding
machine and formed in two steps, but the mould is output for
one time. Normally this kind of plastic moulding process is
also called double-material moulding and is always done by
one set of mould, special two-color moulding machine is required.
B. Over mould (double injection)£ºTwo different
plastic materials are not necessarily mould on one moulding
machine, two step forming is adopted; Product is taken out
from one set of mould, then put into another set of mould
for second step forming. Thus this kind of moulding process
is always formed by two sets of moulds, and no special double
color moulding machine is required.
Overview of double injection mould (over
mould) and double color mould:
A,During design of double mould, position of hard plastic
part shall be considered. Reliable sealing gel shall be
applied and back draft hole shall be made on the rubber
part to prevent drawing deformation.
B,Double color mould is becoming increasingly prevailed
in the market nowadays. This technique can make more beautiful
product appearance, and is convenient for color changing
without painting, however it also delivers high cost and
high technical requirements.
1. Shapes of the two cavities are different for forming
of one kind of product separately. But the shapes of cores
for them are completely the same.
2. The cavity and core moulds must be able to engaged with
each other after having rotated for a angle of 180¡ã. In
design stage this check must be conducted.
3. Pay attention to the position of ejector pin hole, and
the minimum distance is 210mm. For larger mould, the quantity
of ejector pin holes shall be increased accordingly. Besides,
since thimbles attached to the moulding machine are not
long enough, thus lengthened thimbles must be designed for
our moulds. The thimbles shall extend from the mould base
bottom plate by about 150mm.
Two position rings must be designed on the rear mould base
plate.
4. The overall thickness of the front mould panel plus A
plate shall be not less than 170mm. Please carefully check
other reference data of this type of moulding machine, e.g.
maximum molarity thickness, minimum molarity thickness,
ejector stick hole distance etc.
5. Water spout of three-plate mould shall be designed for
automatic knockout type. Pay special attention to whether
the knockout of flexible-flue water spout is reliable.
6. The depth of the front SPRUE shall not exceed 65mm. The
distance from the top of the upper£¨big water spout£©SPRUE
to mould center shall be not less than 150mm.
7. During the design of cavity for the second step moulding,
in order to avoid any damage by the cavity to the formed
gel mould in the first step, part of vacuity can be designed.
However, strength of each sealing gel position must be considered
sincerely, i.e.: During moulding, is it possible to happen
plastic rubber deformation under big moulding pressure thus
leading to series defects?
8. During moulding, product dimensions after the first-time
moulding can be a little bit larger, thus to press tightly
with another cavity during the second-step moulding to result
in good plastic sealing effect.
9. Pay attention to whether any impact to the first-step
formed product and thus lead to its displacement can be
resulted owing to flow of plastic during the second-step
moulding£¿ If there is this possibility, measures must be
taken to improve it.
10. Before closing of A and B plates, measures must be taken
to close A, B plates before the slider or LIFET of the front
mould return to its original position, otherwise, the product
will be damaged.
11. Water circulation for both cavities and cores shall
be sufficient, uniform.
12. In 99% cases, hard plastic part of the product is mould
at first, then the soft plastic part because soft plastic
is easy to be deformed.
13. In order to make these two kinds of plastic materials
¡°bond¡± with each other more tight, ¡°viscosity¡± between materials
and surface roughness of mould shall be considered.
Two-color moulding has special TPU£»While the more smooth
of mould surface is, the more tight they will ¡°stick to¡±
each other.
14. Keep an eye on positioning of the front and rear moulds;
Obliqueness of all insert and slope surfaces shall be large
enough (more than 0.1mm).
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