insert molding is a process where the prepared material is loaded into the mold and the resin is injected, and the molten material is joined and solidified to form the product.
Out-of-sert molding refers to the process of molding embedded at a part of the metal surface.
The above two forming methods are essentially the same. Its characteristics are as follows.
1. The combination of resin’s formability, bending and metal’s rigidity, strength and heat resistance can be solidly made into complex and sophisticated metal-plastic integrated products.
2. In particular, the combination of insulating properties of resin and channel electrical properties of metal is used to make the molding products to meet the basic function of electrical products.
3. The pre-forming combination of multiple inserts makes the post-engineering of product unit combination more reasonable.
4. The embedded products are not limited to metal, but also cloth, paper, wire, plastic, glass, wood, coil, electrical parts, etc.
5. For the rigid forming products and the flexural elastic forming products on the rubber sealing gasket, the complex operation of placing the ring can be saved after the product is made by injection molding on the matrix, which makes the automatic combination of the last process easier.
6. Because it is the joint of the molten material and the metal insert, compared with the pressing molding method, the metal insert gap can be designed more narrow, and the reliability of the composite product molding is higher.
7. Such products as susceptible to breakage (such as glass, coils, and electrical parts) can be sealed and fixed by appropriate resins and forming conditions.
8. Select the appropriate mold structure, the insert can also be completely sealed into the resin.
9. After forming the insert, a product with a hollow recess can also be made by a core-removing process.
10. The combination of vertical injection molding machine and manipulator, insert product whole column device, etc., insert molding engineering can realize automatic production.
Points for attention in design and selection of automatic insert forming system
1. Metal insert molding is easy to produce uneven shrinkage rate, should be done in advance of the important parts of the shape, dimensional accuracy limit test.
2. The metal insert is easy to deform and shift during the injection process, so the mold composition and the design of the mold shape which is easy to keep the metal insert should be fully considered. For products whose insert shape cannot be changed, prior testing is indispensable.
3. The arrangement and separation of metal inserts and the use of conveyor under the occasion, the contact between the metal inserts and the inserts and the vibration ball, will cause subtle damage to the surface of the inserts, and affect the quality of the product. The permissible limit of quality should be confirmed in advance.
4. The zigzag, warpage, thickness difference, diameter difference and thickness difference caused by gold processing of metal inserts should be determined in advance. On this basis, the matching design of the automatic device and the design of the mold structure are carried out.
5. The predictable matters that restrict the mold construction, such as the mold gate location and forming cycle, should be solved in advance or have corresponding improvement countermeasures as far as possible.
6. Check whether the metal inserts need to be preheated or dried. The purpose is to ensure the quality of products and the stability of molding.
7. Various detection devices set in the mold are used to ensure the stability of the molding action under the influence of environmental conditions such as heat, force and vibration of the mold. It should be confirmed whether to use them.
8. In order to avoid the accumulation of metal inserts, molding pieces in the mold cavity, if necessary can be assembled air blowing device.
9. Due to the high investment price of the system equipment, it is necessary to fully consider whether the production capacity of the equipment can be ensured before use. In the case of a dedicated machine, it is necessary to ensure that the product can be continuously produced in several years without formal update.
10. In the case of universal machine, it is necessary to confirm how many combinations of multi-variety and low-batch inserts are produced. If the overall cannot guarantee mass production, the recovery of the fixed assets of each product is difficult. In this case, a part of the device needs to be replaced, which can be adapted to the requirements of variety renewal within a certain range.
11. The accuracy of the metal insert, the shape of the insert, whether the mold is conducive to the insert forming and the shape of the molding product and other factors and technical skills determine the molding rate, production and molding cost conditions.
12. The effective combination of injection machine, mold and automatic device and how to play the function in a short time is the key to determine the automatic insert molding system. It is recommended that you consult with manufacturers with considerable achievements and experience.
