Platens molds

In the classical IM elastomer processing, a so-called hot runner manifold is used for distributing the mixture from the injection nozzle of the injection unit to the individual cavities. The elastomer, which is located in the hot runner manifolds after the filling cavities, cures and is removed after opening the mold. To make this possible, the molds are designed as three-platen molds. The hot runner is located in the first parting plane, and the products are located in the second parting plane. 

A separate mention is merited for a special molded hardboard product. These are made by a process in which either a fiber mat or hardboard panel is placed between two shaped platens and press-molded to a three-dimensional configuration. The most common resulting shape is a doorskin which resembles a wood panel door. The doorskins are bonded to wood frames to make an excellent, attractive, and relatively inexpensive door. This ftber/panel mol ding process is also used to make a wide variety of molded interior linings used in automobile manufacture. 

A small amount of particleboard is made with a fire-retardant treatment for use in locations where codes require this material, as in some offices and elevators. Particleboards receive overlay and finishing treatments with ease. Wood veneers, melamine overlays, printed paper overlays, vinyl overlays, foils, and direct grain printing can all be done quite simply. A small amount of particleboard is also made in the form of shaped, molded articles such as furniture parts, paper roU plugs, bmsh bases, and even toilet seats. There is another small increment of particleboard made by the extmsion process. These products are made in small captive operations owned by furniture manufacturers which consume all of this production in their furniture. The extmsion process differs from conventional flat-pressed particleboard in that the wood furnish is forced between two stationary heated surfaces. The mats are formed from one edge and this edge is alternately formed and pushed between the heated platens, which are maintained at a distance equal to the thickness of board produced. This is an old, slow, small-scale process, but is stiU in use in at least one location. 

Because cycle time to inject, flow, set, open, eject, and close is finite, and the face area or platen size is limited, the effective mol ding area is increased by increasing the number of mold cavities so that the number of finished pieces per cycle may be multipHed many times. 

Fig. 13. Injection molding machine A, hydiaulic motoi foi turning the screw B, hydraulic cylinder and piston allowing the screw to reciprocate about three diameters C, hopper D, injection cylinder (a single-screw extmder) E, no22le F, fixed platen G, tie rods H, mold I, movable platen , hydraulic cylinder and piston used to move the movable platen and supply the force needed to keep the mold closed and K, machine base.

When the mold is opened, the part should be easily removable. Cavities are made with a slight taper to reduce frictional drag of the part on the mold. The half of the mold attached to the movable platen is equipped with ejector pins, which push the part out of the cavity while the mold is being opened. When the mold is closed, the pins are flush with the cavity surface. Release agents or lubricants facilitate ejection and shorten the mol ding cycle. Some complex parts require that the mold open in several directions in addition to the direction of the platen movement. For a threaded part, eg, a bottle cap, part of the mold must be rotated to remove the article from the mold. 

The variation in temperature across the top and bottom halves of the mold is a function of the press platen size, the flatness of the mold and platen surfaces at the two mold/platen interfaces, the mold construction, and the platen heating system. The larger the platen size, the more difficult it is to maintain a constant temperature across the platen. Therefore, one solution to the problem is to use a large number of molding presses with a relatively small platen size, for example, four presses with platens 355 x 355 mm will have approximately the same production capacity as one press with a 710 x 710 mm platen. In reality, for high-volume production, large presses are more economical from the cost point of view and the floor space required. 

The pressure distribution across the mold is a function of both the mold surface and the platen flatness. The larger the mold size and the platen, the more difficult it is to maintain the high degree of flatness required. The mold and platen flatness is also critical in the area of heat transfer from the platen to the mold itself. 

Add wood furnish (384 g, moisture content 6.02%) to the bowl of a rotary blade paddle mixer (such as a Kitchen-Aid KSM90) and agitate at the lowest speed setting. Add Mondur 541 (7.39 g, 1.9% w/w, a polymeric diphenylmethane diisocyanate of 31.5% NCO, Bayer) dropwise over a 5-min period using a disposable syringe. Continue blending for an additional 10 min and then transfer the blend to an 8 x 8 x 2 -in. metal form at the bottom of which is a metal plate which fits inside. The resin-coated furnish is evenly spread inside the form and another metal plate is placed on top. All parts of the form and plates are presprayed with mold release. The completed form assembly is placed into a hydraulic press (such as a model PW-22 manufactured by Pasadena Hydraulics) with platens heated at 350°F. The furnish is then pressed between the two form plates to a thickness of j in. Press controls are used to ensure consistency of board thickness. The assembly is heated for 4 min. before demolding the cured wood panel. 

Polymer Processing. Polymer films were cast in trimethylsilyl coated glass molds from membrane filtered 15% (w/v) methylene chloride or chloroform solutions. Transparent films were obtained which were dried to constant weight in high vacuum. Rectangular strips or round disks were cut from the films. For compression molding a Carver laboratory press equipped with thermostated, heated platens was used. Polymers were placed in a stainless steel mold and heated to 40 °C above their glass transition temperature. Then a load of 1-2 tons was applied for 5 min. 

Preparation of Samples for Flammability Testing. Samples of the phosphorus containing terepolymers and of the polymer blends were converted to film by compression molding on a Carver Laboratory Press with electrically heated platens. The films were prepared at 250°C and 20,000 lb. pressure, using a 10 mil thick frame mold. Samples (2" x 1/4") were cut from this film for flammability testing. 

Once the platens (or mold) are opened, the laminate freely warps. The curvature that develops can be found by applying the moments found earlier in Equation 8.30 to the laminate. 

In this process, the polyurethane mix is poured into a mold that can be placed into a compression molding press with heated platens. The material is allowed to gel, and a top plate is placed on the material. The molding press is fully closed. The pressure applied is normally on the order of 1.50 to 2.0 MPa (250-300 psi) based on the projected area of the molding e.g., a parts plan area is 300 x 400 mm in size. Its area is 0.300 x 0.400 m2 = 0.12 m2 therefore, a pressure of 1.500 x 0.12 = 0.18 MPa on the mold is required. The molds must be capable of withstanding the direct heat and pressure of the press. Aluminum or steel molds are preferred for this process. 

Thermal History. The polyethylene was molded at 175°C. for varying lengths of time, then cooled by circulating cold water through the press platens. The rate of cooling had no apparent effect on either the mechanical strength of the surface region or the wettability. 

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