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Why Use a Chiller During Injection Molding?
What is injection molding?
Injection molding is used to mass produce plastic parts. Put plastic pellets into the hopper of the injection molding machine, and the rotation of the screw will heat the pellets and melt them into liquid. The screw pushes forward to inject the liquid plastic into the mold. After the mold cools, the liquid inside will gradually solidify from the outside to the inside into the shape of the mold. Open the mold and you can take out the finished product. Plastic mobile phone cases, toys, home appliance shells, and automotive plastic parts are all made using this method.
Challenges of injection molding
Controllo della temperatura
If the melting temperature is too high, the plastic will easily decompose and burn; if the temperature is too low, the fluidity of the liquid plastic will deteriorate and it will not be able to fill the mold within the set time. If the mold temperature is too low, the cooling speed will be accelerated, causing uneven cooling speed inside and outside the product, resulting in product defects.
The outside of the product has solidified, but the inside may not have cooled yet. If the inside continues to cool and shrink, the surface will be pulled and deformed. In addition, if the molten plastic cools too quickly when flowing in the mold, the front section of the material will have cooled, but the back section of the material has not cooled sufficiently, and the color, gloss and thickness of the junction of the two sections of material will be inconsistent.
Fan or water pump abnormality
The structure of the product mold is complex, consisting of multiple precision parts such as the movable mold, fixed mold, slider, ejector, cooling channel, etc. The wear of any small part may cause product size deviation, poor ejection, mold jamming, and other problems. Every time the mold is opened and closed, injected and cooled, it will experience drastic temperature changes.
If the cooling temperature cannot be controlled well, the mold will frequently experience thermal expansion and contraction, accelerate metal fatigue, and easily cause problems such as cracking and misalignment. A medium-complex mold used to produce products of similar size to mobile phone cases and remote controls costs about $5,000 ~ $30,000, and has a lifespan of about 100,000 to 500,000 molds. Premature damage will cause production interruptions and additional economic losses.
Product defects
When buying plastic products, have you ever bought products with surface depressions, deformations, bubbles, excess material on the edges, or insufficient material? These are common product defects caused by poor cooling or improper mold temperature control that causes uneven temperature.
Cycle control
The injection molding cycle refers to the time it takes for all steps from the mold closing to the next closing, including injection, cooling, mold opening, and part removal. Reasonable cycle control can improve the production stability and production efficiency of the production line. Insufficient cooling will lead to product defects, and cooling for too long will waste time and reduce production capacity.
Chillers help injection molding process
Product quality
Chillers can help injection molding equipment always maintain the appropriate temperature, so that the mold is cooled at the same temperature every time. Avoid product defects and batch inconsistencies caused by temperature changes.
Equipment life
Frequent hot and cold shocks of the mold will cause problems such as cracks and poor precision. Chillers can help reduce thermal stress and reduce thermal fatigue. Abnormal temperature will force the injection molding equipment to shut down and interrupt production. The chiller can remove the heat generated by the equipment in time and reduce unplanned downtime.
Production efficiency
Cooling takes 40% to 70% of the entire injection molding cycle. Ensuring product quality while improving cooling efficiency can shorten the production cycle and increase output. The chiller has functions such as automatic temperature control, safety devices, and remote control, and can achieve 7×24 hours of operation without human intervention. It is an ideal partner for highly automated injection molding machines.
Invest in LNEYA injection molding chiller
If you are looking for a stable and efficient high-precision injection molding chiller, LNEYA provides you with professional selection suggestions and customized solutions. Our equipment has been used in the production workshops of many companies and has become the backing for stable process operation. Contact us to obtain product information and quotes.
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