Injection moulding control

One limitation of epoxide moulding compositions is their short shelf life (typically 1-3 months), which necessitates strict stock control. The compounds may be compression, transfer or injection moulded, although compression moulding is preferred for long-fibre grades. 

Shear Controlled Orientation in Injection Moulding (SCORIM)... 

One of the major innovations in recent years is the use of pulsed pressure through the gates to introduce and control the orientation of the structure (or fillers) in injection moulded products. A special manifold is attached to the machine nozzle as illustrated in Fig. 4.46. This diagram relates to the double live feed of melt although up to four pistons, capable of applying oscillating pressure may be used. 

Shear controlled orientation in injection moulding (SCORIM) is based on the progressive application of macroscopic shears at the melt-solid interface during solidification in the moulding of a polymer matrix. 

Calendering can achieve surprising accuracy on the thickness of a sheet. Typically the tolerance is 0.005 mm but to achieve this it is essential to have very close control over roll temperatures, speeds and proximity. In addition, the dimensions of the rolls must be very precise. The production of the rolls is akin to the manufacture of an injection moulding tool in the sense that very high machining skills are required. The particular features of a calender roll are a uniform specified surface finish, minimal eccentricity and a special barrel profile ( crown ) to compensate for roll deflection under the very high presurres developed between the rolls. 

The application of instrumentation to the automatic control of a sequence of operations, e.g., injection moulding processes. Once the mould has been loaded with inserts (assuming a rubber to metal bonded part) into the press, the operation of a push-button starts the controller which closes the press, injects the rubber, controls the cure cycle, recharges the injection unit, opens the press, operates the ejectors and presents the mould for cleaning and loading of inserts. 

Simple ram machines are cheaper than screw machines having equivalent shot volumes. Although the simple ram injection moulding machine was once quite widely used it was generally obsolescent by 1977. Plasticisation by screw is quicker and more controllable than by heat conduction in simple ram machines. A higher and more uniform compound temperature and thus a more uniform viscosity is achieved. 

Control of the temperature of rubber compound whilst being processed in extruders and injection moulding machines is vital if the product from these processes is to be uniform in quality. Failure to control temperatures in processing equipment can lead to scorching of the compound as it emerges from the extruder die or injection machine nozzle. Most modem items of processing equipment are fitted to a temperature control unit using either oil or water as the circulatory medium. 

The iQ automotive battery incorporates a micro-chip which monitors and controls the electrochemical process of the lead-acid battery, as well as its physical environmental and operating conditions. The thermal insulation of the battery also plays an important role. Neopolen P, a thermoplastic particle foam from BASF which can be processed completely without blowing agents, was chosen for this application. The foamed battery container calls for a solid frame that can be mounted onto the car body, and this frame is configured as a solid PP injection-moulded article, and fused to the container. 

Medina, E.M.G. (1996) Alignment and management of talc platelets in polypropylene matrix by the application of shear controlled orientation injection moulding (SCORIM) technology. PhD thesis, Brunei University, UK... 

Developments in micro-processing have made it much easier to monitor and to control conditions in the course of manufacture, and to prepare and maintain written records. Injection moulding may be supervised with the help of melt thermocouples fitted in the nozzle, pressure transducers in the hydraulic line and in the mould, and a transducer to monitor linear movement of the screw. Information from these sensors may be displayed and depicted in relation to the control limits (upper and lower) and the operator thus made aware immediately of variations that could be significant. Conditions can be corrected more rapidly and if need be any mouldings that might not be satisfactory diverted for examination. Should the number of suspect products exceed a limit set in advance, a line can be shut down automatically. 

Figure 6 (a) Shear controlled orientation injection moulding (SCORIM). (b) Klockner puch-puir injection moulding... 

In this paper, all the blends and composites are designated by the type of matrix (G for the neat nylon, D for the 8 wt % rubber-modified nylon and N for the 20 wt % rubber-modified nylon), the concentration of fibres and the type of fibre/matrix interface (A or B). As an example, a material designed DlOB is a ternary blend made of DZ matrix and 10 wt% of type B fibres. After drying the specimens for 24 hours at 100°C, they were stored in plastic bags inside a desiccator. In comparison with freshly injection moulded samples, the moisture content in the specimens ready for mechanical testing is about 2 wt%. All the mechanical tests were conducted in an environmental chamber in controlled conditions a temperature of 20°C under a continuous argon flow. 

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