Resin design design 2

HIVEC Inc.
Hiroshima Vehicle Engineering Company
◆ appearance
１． Causes and countermeasures of molding defects that are required for initial quality.
* Describe the cause and countermeasures below.

2 ． Variation: The products produced vary in both external dimensions and surface
shape.
3 ． Thermal deformation: Select heat-resistant resin suitable for the environmental
temperature of parts
4. Aging over time: The chemical resin is subject to some external influences,
Degeneration and deformation with time.
5. Chemical resistance: Changes in mass, dimensions, color, appearance and
physical properties.
6. Decoration: There are fluid printing (hydraulic transfer), painting, simultaneous
molding, and embossing methods.
* Details of items 1-6 below
◆Details of main molding defects
・ Sink mark: Resin shrinkage difference due to uneven cooling of the surface
and inside. Caused by thick parts or ribs of molded parts
Surface dents.
As a countermeasure
⇒ Thinning of the back side of the thick part of the molded product
(1/2 or less of the base plate thickness).
Suppose 1/3 or less for PP and PPC ABS systems.

【 Measures 】
・ Weld line:
When two flows of melted resin material merge in the mold
The resin temperature between the ends of the molten resin becomes too low,
causing solidification
This is because it has started.
A linear mark that appears at the joint of the resin is the weld line.
Not only the appearance defect but also the strength will decrease.
About measures
⇒Measures are not possible with the shape, changing the gate position, sprue, runner,
Increase the cross-sectional area of the gate or shorten the sprue and runner. *
Also foresee with flow analysis

Flow analysis results, countermeasures

Weld line
・ Uneveness of gloss:
If there is a difference in the cooling rate of the resin or a difference in wall
thickness, the wall thickness part will be
Since the holding pressure works for a long time, the transfer state is improved
and the difference from the thin part is
It will come out.

About measures
⇒Abrupt shape of the transfer surface when the molten resin comes into
contact with the mold
Large change surface

艶ムラ
・ White:
The resin is stretched due to excessive force and becomes white like this
It is a phenomenon that changes color. Too much injection pressure during
molding and taper
It protrudes forcibly even though there is not enough
When it takes too much), the ejector pin that pushes out the product
It is possible that pressure has been applied to the color of white.

About measures
⇒ Distribute local load with ribs, thickening, etc.
Review the number, reduce the friction by polishing the mold, holding pressure
and holding time
Do not spend more than necessary, cool down longer, etc.
It can be considered.

White
・ SHOT SHOT ((short shot))
Because the air in the mold lost its escape and the air did not escape,
The resin does not reach the corner and does not flow.
The other is cooling and solidifying while the molten resin is flowing,
It is possible to solidify before going to the corner of the mold
About measures
Product side: Increase the thickness of the molded product.
Rib is provided around the part that does not flow easily.
Molding machine side: Review molding conditions and degas properly

SHOW SHOT
・ Jetting (Jetting Fiow)
A meandering “twisting pattern” appears on the surface of the molded product
The appearance is bad.
Fusion of resin that entered first into cavity and resin that entered later
悪 く Poor, meandering flow marks remain on the surface and solidify by cooling.
Endurance phenomenon (prone to appear in high viscosity materials such as ABS
resin and PE)

Toothpaste when the toothpaste tube is gripped

現象 Phenomenon injecting into the air in an unstable manner.

About countermeasures
⇒ Molding machine side: Review of molding conditions (injection speed, gate size)
Product side: Rib orthogonal to meandering line
Measures
Add a riv to go straight
Jetting
Difference between Flow Mark and Jetting
・ Flow marks Flow pattern
Typical flow patterns on the surface of molded products
Many things are mainly gates, but there are other molded products.
Swell pattern with large area on the surface of flow front and flat molded
product
There may be cases.
From Mark

What is the difference?

Both have traces of traces of molten resin remaining on the surface of the molded
product
・ ・ ・ The pattern is different due to the phenomenon and the injection speed is
affected.
Tended to be flow mark when slow and jetting when fast.
◆Thermal deformation
Because it is easily affected by the temperature and humidity used, the
environmental conditions
It is necessary to respond to changes.
Compared with metals, plastics generally have a coefficient of thermal
expansion
¡High flammability and low thermal conductivity and specific heat.
Also, the maximum usable temperature will be lower. Match parts by shape
That is difficult. Deformation due to linear expansion can be achieved by adding
fixed points and increasing rigidity.
Measures can be taken.

* Development such as thermal deformation simulation analysis has been

advanced.
At the design stage, heat is applied to the resin using simulation.
Simulation of how much the volume contracted or deformed
Can be used.
◆Deterioration with time
Resin, zat kimia, dipengaruhi oleh beberapa efek eksternal dan denatures dari waktu
ke waktu. Deformasi. Untuk PP (PPC), yang stabil secara material, efek kimianya adalah
Tidak. Heat Creep termal terjadi karena panas + beban. Secara khusus,
Sekalipun suatu beban diterapkan pada suhu tinggi untuk sesaat, itu akan dipulihkan, teta
Deformasi saat diterapkan pada suhu tinggi. Untuk meringankan ini, beri tekanan
Tidak ada pilihan selain mendistribusikan.
参考） GRAN CTR PLR LWR

・ About measures
⇒ Rib, with R

ﾘﾌﾞ
・ What is thermal creep?
When a load is continuously applied to plastic,
Deformation gradually proceeds (Fig. 1).
This phenomenon is called creep.
◆chemical resistance
With chemical resistance, after being immersed in a certain chemical for a
certain period of time,
· Does mass, dimensions, color, appearance, physical properties change?
Indicator for seeing whether or not.
* Chemical temperature is also an important factor in viewing chemical resistance.
So be careful.
The higher the number, the better the chemical
resistance.
◆Product variation
Even if the setting of the molding machine is the same,
∙ It occurs due to fluctuations between lots or molding shots.

As a cause
・ Variation of molding conditions such as uneven holding pressure, mold and
Resin temperature fluctuation.
(Molding environment is changed. In summer, temperature fluctuation is large
both in the morning and in the afternoon.)

・ Variation in melting temperature and filling amount.

* Therefore, the number of production start shots varies depending on

the product outline and surface shape.
捨 て Throw away about 5 shots from the start of production.
 ◆Decorative
Fluid printing (hydraulic transfer)
浮 か べ Floating a picture film on the surface of the water, the material to attach
the picture from above
Submerge and transfer the design to the material.
* After this top coat on the ink layer
(Protected with clear paint)

Points to remember:
-Wrinkles will appear in extremely hard corners such as 90 ° right angle corner
Material: ABS
Application: DOOR TRIM, INST, CONSOLE, etc.
Wood grain
decoration Wood grain
decoration

DOOR TRIM INST & CONSOLE

◆Decorative

·Painting
Use primer and pre-treatment to improve paint adhesion
Apply paint and dry after applying heat at room temperature or several tens of
degrees Celsius
Let me. ¡The paint performance is fully demonstrated if it is not completely cured
Can not. *

・ Uretan paint: Used for ABS resin

Because the resin molecules are tightly linked by urethane bonds
A coating film that has good adhesion and is hard and has excellent acid and
alkali resistance.
Form. (Nicknamed ABS material is good)

・ Acrylic paint: Used for olefin resin (PP)

Conventionally, since the material is difficult to adhere, the surface of the substrate
before painting
Polish the surface with a solvent such as toluene or xylene, which is highly soluble.
It was necessary to paint after processing. Also of top coat
The baking temperature was as high as 80-120 ° C.
A primer that can be used at 30-40 ° C has been developed.
*
Application: PP bumper system (using recycled material)
◆Simultaneous molding
One of resin molding methods, insert product in resin mold
After loading (metal parts, cloth, etc.), injecting resin into the mold,
The insert is wrapped in molten resin and solidified, and the resin and insert are
This is a method for making integrated composite parts.

reference
Nissan Maxima
FR DOOR TRIM
Purpose: For the purpose of decoration, the purpose of strength, the purpose of fastening
etc.
Also to increase the bonding strength.
important point
・ To contact with molten resin (220 ° -240 °)
Material selection that will not be affected.
・ Especially when inserting a cloth, if it is a pattern,
Trigger a “pattern bend”
・ In the case of insert molding, there is a case where the molding shrinks differently
from the simple resin.
◆Wrinkles (leather wrinkles, pears etc.)
This is one of the metal micro-fabrication methods for patterning metal surfaces.
Mainly chemical corrosion (chemical etching) to dissolve metal by chemicals
Also called.
Reference Nashiji

・ What is grain processing?

Various patterns such as geometric patterns can be reproduced on the mold surface.
In order to reproduce the real, three-dimensional texture that is closer to the real thing
Repeat transfer and corrosion. To reproduce any pattern
Processing principle is common.

[Transcription]
¡Acid-resistant ink prints with the basic pattern and pattern on the mold surface
Transcribed.
【 corrosion 】
The mold surface is corroded using acidic liquid. Metal due to corrosion
Removed and uneven on the mold surface.
[Finish]
Blasting with glass beads and sand. Gloss adjustment is complete.
Reference
・ Silver streak:
The phenomenon that countless silver stripes are formed on the surface of the
product.
I will be told. This is because in the resin molding process,
Bubbles (air, bubbles) are generated, and these bubbles are pulled together
with the resin during processing.
It will happen by being stretched. The surface of the resin appears to shine like
streaks
(Insufficient drying of resin)

About measures
Review of molding conditions of
molding machine

Lack of dryness Air entrainment Thermal decomposition

・ Color mixing
The remaining color change causes the wall to stay and changes the flow direction.
回 り Around corners and valve pins, resin solidified layer [nozzle part heat to
the molded product side
It is known that the resin is likely to stay in the “functions that cannot be communicated”.
These residence resins affect the color changeability of the resin,
Deteriorated as the residence time becomes longer, and foreign matter (black spots) is
mixed
Cause.

About measures
Periodic removal / discharge / residence on wall surface resin
Give back, move resin, discharge filter with its own shape
Catch and discharge (molding conditions)