Research On Bi-color High-glossinjection Molding Technology Based On Air-condition Remote Control

Bi-color high-gloss injection molding is also called the two-component rapid heatcycling injection molding technology or double color highlights non-mark injectionmolding technology.In2009,Hisense mould company developed the first double-colorhigh-gloss injection mould in domestic.Using Bi-color high-gloss injection can not onlymake the product appearance beatutful,but also can eliminate the weld mark,silversilking, reduce the warp degrees and can save time and protect environment throughexempt spraying process. The key technology in the remote control productssuch asgating system, Bi-color injection molding process was studied and the high-glossinjection molding effects on the quality of products was dicussed.The main researchcontents in this papers are as follows:①Design and optimize the gate location,runner system of double color high-glossremote control products. Design the gate and runner system based on the criteria of gatedesign and principles of runner system and CAE simulation and verification analysiswas carried on.The first molding of outer layer PC material was determined with2pointgate to fill, the gate size is1.2mm. The second molding of inner layer ABS material wasidentified with2submarine gateto fill, the gate size is1.8mm. The mould with onemodule and four cavities.②The determination of the Bi-color molding parameters (injection time, melttemperature, mold temperature) and the optimization of pressure curve. According tothe rule of flow in mold flow to adjustthe molding parameters based on moldingwindow analysis, After that, PC material processing parameters can be obtained: moldtemperature104℃, melt temperature320℃, injection time1.4s and ABS material moldtemperature55℃, melt temperature240℃, injection time2.2s. The pressure curve wasoptimized by BP neural network and genetic algorithm, and the optimize holdingpressure parameters can be obtained as follows: PC material packing pressure82.9Mpa,packing time7.6s and ABS material packing pressure38.9Mpa, packing time1.6s.③Influence of rapid heat cycling molding parameters on the cavity surfacetemperature and parameters optimization.The temperature of the cavity increases withthe increasing steam temperature and cooling medium temperature, decreases with theincresing cool medium pressure and packing time. And get the optimized parameters issteam temperature180℃, cooling medium temperature25℃, cooling medium pressure 10bar, the holding time of the cooling medium pressure8s.④Participate in mould design and development and assist the operator to test thedie based on the optimized double color molding parameters and heating/coolingparameters. As a result, the double color high-gloss remote control products is producedsuccessfully.