Resin Design Mold

HIVEC Inc.
Hiroshima Vehicle Engineering Company
◆What is Mold? 2

In simple terms, the mold is a metal mold for producing product

Mold is not necessary to make only one product
Molds are necessary to make large quantities of the sampe shape.
Because it is made in large quantities of the same shape.

※Many molds are used even in the immediate vicinity.

Example : “Taiyaki”
This is also a fine mold. To pour flour and other materials into
a metal mold and bake and harden.

©2011 HIVEC Inc.

Image of Mold Forming
・ Please imagine the dessert pudding. If you turn the case upside
down. Pudding comes out （ Image 1).
・ But what happens if the pudding is changed to the shape shown
in the figure below?
Pudding will not come out even if the case is upside down.
(Image 2 ）
・ To remove the pudding from the case without breaking it,
remove the case at the position shown in the figure. It is
necessary to divide. （ Image 3 ）

Image ２ Image ３
Image １

©2011 HIVEC Inc.

 4

In other words, depending on the design of the pudding, the

mold (here the pudding case)
This means that molds that cannot be made will be
complicated.
If the mold becomes complicated, the cost of the mold will
naturally increase.
As mold costs increase, product prices must increase.

©2011 HIVEC Inc.

◆Various types of molds
・ Made by applying pressure to the plastic material and
injecting it into the mold
Plastic mold, Mainly car interior / exterior parts, daily necessities
etc.
・ Press mold made by pressing a metal plate ... Auto body
◆Material Used
・ Plastic
Resin Pellets
・ Metal （ Plastic ）
・ Synthetic rubber
・ Glass

Rolling roll （ Stell ） Styrene, Butadine Silica sand, soda ash, dolomite
（ Metal ） （ Synthetic Rubber) Coal stone, borosilicate (Glass)
Many of the products and parts are produced in molds.
What molds are used to produce products and parts,
The type varies depending on the material used and purpose.
The following five molds are the main types.

 Mold for plastic (resin mold)

... Automobile interior / exterior parts (pampers, impellers, pillars, etc.),
electrical appliances etc.
 Press die
... Cars, train bodies, electrical appliances (large TV covers etc) etc.
 Die casting mold
... Body of camera, body of electric tool, toy (carpenter) etc.
 Casting Mold
... Automotive ENG parts (ENG block, TM case,diff, valve etc) etc.
 Forging Mold
... Autoparts (piston, etc), gears.

※In addition to molds, rubber molds, glass molds, powder jig molds,
There are molds for ceramics.
※Plastic molds (resin molds) are explained.
・ Plastic mold （ resin mold ）：
Can create complex shapes, such as automobile parts
(interior and exterior) and home appliances
Used in a wide range of fields.
When producing plastics, injection molding, compression
molding, vacuum molding, etc.
There are various production methods
◆What is injection molding?
Plastic heat and melt, apply injection pressure and push into mold,
Molding the product.

Application: Automotive interior / exterior parts, etc.

◆What is vacuum forming?
Heat and soften pre-extruded films and sheets,
This is one of the typical molding methods for plastic molding that adheres
closely to the mold.
Compared to injection molding, etc., it takes less cost and time to
manufacture the mold.
It is possible to correspond to various shapes and designs

Application: The most suitable method for making plate-shaped or

cover-shaped objects.
Plastic plates such as egg cases and convenience store lunches.
Car bumpers, light covers, etc.

Vending machine Egg case

cover

Plastic Plate Bumper/light cover

◆What is female type (male pulling) and male type (female pulling)?
By simply forming a thermoplastic sheet using heat and atmospheric pressure,
Clamp the hard sheet to the frame suspended above the mold, soften it by heatin
Next, a vacuum is applied between the sheet and the mold, and the sheet
is brought into close contact with the mold as it is.
Cooling and forming into a three-dimensional shape.

The basic molding process is the next stage.

”Heating → Softening → Molding
(Suction, <stretching assistance>, pressurization) → Cooling → Curing”

Epidermal PVC part

Front door trim Card reader

(Male type) (Female type)
◆Male molding (male pulling) ： drape forming
• Place the plastic sheet material, which has been softened by combustion,
on the female mold (concave mold) and vacuum it.
• Molding. Between the sheet material and the female mold from the fine holes
provided in the female mold
• A method of sucking out air and sucking the sheet material directly onto
the female mold. In many cases, the mold surface
• Since it becomes a design surface, the design can be accurately transferred
and sharp lines can be processed.
• In addition, a pattern is directly applied to the sheet material by applying
a pattern such as a wrinkle on the mold surface.
• You can also. Vacuum drilling on the mold surface that is not transferred to
the sheet material
• It is necessary to examine and confirm the number of holes and the position
of the holes.
 11

【 merit 】
・ When aesthetics of the package
surface is required
・ The inner dimension of the Vacuum
hole molding
molded product is in contact with
the mold, so the inner dimension is (Reference)
highly accurate. Back side of door trim
・ Thick molded products can be obtained,
but the side wall becomes thinner

©2011 HIVEC Inc.

◆ Female mold molding (female pulling) Straight molding. Straight forming
Fix the thermoplastic resin sheet with a clamp frame and heat soften it,
Next, the mold is raised, and the air in the sheet and mold is discharged and
molded.
In the case of compressed air molding, the periphery of the mold is sealed and
covered with a frame to apply compressed air.
Blow in and press mold
【 Merit 】
・ External dimensions are high because the outer surface of the molded
product is in contact with the mold.
・ Deep drawing is not possible. About 1/2 is the limit for the frontage of the
molded product.
・ There are many uneven thicknesses, especially the bottom corners
become thinner.
・ Easy to pick many
◆What is blow molding?
Melt pellet-shaped plastic raw material with a blow molding machine,
Pipe shape (commonly called parison). Called the hot parison method.
Blow molding is a product that is inflated with air.
What is cooled in the mold becomes the product shape.

Applications: Daily necessities (Pet bottles, mayonnaise containers, plastic tanks, etc.)
Automotive parts (fuel tanks, air conditioners and ducts)

Pet Bottle Politank

Fuel Tank Air Condact

◆What is compression molding?
• Put the weighed molding material into the heated mold cavity (cavity)
• Pressurize with a compression molding machine to cure.
• Productivity is not good compared to other molding methods,
but large size and high strength.
• Suitable for products that require heat resistance.
• However, it is difficult to obtain dimensional accuracy in the thickness direction,
the burr is thick, and time is required for finishing.
• Inappropriate for complex shapes. Also, there are disadvantages that
cannot be unmanned.

Application: Often used for glass fiber reinforced moldings.

Electrical equipment (terminal block etc), industrial equipment (bench etc)

Terminal block Bench

Rubber Bush
◆Mold structure
Explains the most typical injection molds for plastic molds and their molds.
◆ Mold structure
2 plate mold: mold (fixed side fixed to injection molding machine) and
This is a mold that is divided into two cores (movable molds that operate
when the mold is opened and closed).
* The convex part is shortened by the core (Core) and the concave part is
shortened by the cavity (Cavity = hole).
Sometimes called “Cabinet”.
A cavity is created by combining the cavity and the core.
The molded product is completed by injecting plastic.

The cavity is always the fixed side, and the core is the movable side.
◆４ Plastic products are completed in one process

Process 1 Clamping Clamping

... Close the opened mold with a clamping device.
Process 2 Injection plastic filling
... Plastic melted in a closed mold
Fill with injection molding machine
Process 3 Cooling Cooling of molded product
... After filling the plastic in the mold for a certain time
Cool down.
Process 4 Ejection Removal of molded product (extrusion by ejector pin)
... When cooling is complete, open the mold and remove the molded product.
・ Because the melting temperature differs depending on the plastic, the
"temperature of the injection molding machine"
細 It is necessary to set detailed conditions such as “mold temperature” and
“injection speed”. *
→ Molding conditions
-Since the mold is metal, it is easy to transmit heat. (Around 200 ℃)
Make a cooling hole in the mold and pass water or oil through the hole to
reduce the temperature of the entire mold.
It can be controlled.
-The surface side of the product is a cavity. And as an inner product
The invisible part is the core.
As soon as the mold opens, the part will leave the cavity. 。

・ When the mold opens, the molded product will stick to the core.
After the mold is fully opened, the pin that projects the molded
product on the core side
Removed from the mold.
◆Fill the mold with plastic
Fill plastic parts in the mold directly from the injection molding machin
I can not do it.
Passed the following three passages until the plastic arrived in the sh
Later, plastic flows into the cavity that becomes the product of the mo
It becomes.

1) Spool: passage through which plastic flows

2) Runner: The gate is the entrance to the molded product
(Generally thicker than the thickness of the molded product)
3) Gate: Entrance to the molded product
(Incoming speed increases when gate size is reduced)
◆Type of gate

・ Direct gate: Direct gate can be directly molded without runners.

This is a gate system that connects from the spool.
・ It is easy to apply molding pressure and is suitable for large molded
products and thick molded products.
・ Because large traces of gate remain, finishing after gate cut is required.
- Bring the gate position to the part hidden as the product surface as much
as possible.
・ Side gate: Gate system (standard gate system) placed next to the molded
product
Since the gate size can be set large, the molding pressure is relatively high
It will be easier. Like the direct gate, the gate remains,
Finishing after gate cut is required.
・ Film gate: A thin film gate system that is arranged along the molded product.
This gate method is suitable for thin-walled products with a wide width.
◆ Processing of undercut shape
* Undercut means “a shape that cannot be removed by normal movement”.

Normal mold movement is: mold closes → resin is injected → mold opens
→ The product is pushed out, but if there is an undercut, the product is pushed
out
Since it gets caught in the process, the product cannot be removed from
the mold.
Therefore, it is necessary to set another mechanism.

In the egg-shaped case below, the next part is undercut (Figure A, 1).
There are mainly the following methods for undercut processing.
• slide core
• Inclined core (loose core)
• Vertical push-up unit
• Elastic core
• Nakako
• Unreasonable

図A
◆Slide core operation

1. Fig. 5 shows the resin filled in the mold with the resin filled in the mold.
The mold is closed.
2. Angular pins lower the slide core.
When the mold starts to open, the angular pins set diagonally lower the slide core (Fig. 6).
3. The slide core is completely removed from the product section.
When the mold is fully opened, the slide core is completely removed from the product section
(Fig. 7).
4. The product is pushed out by the extrusion mechanism.
After the slide core is removed from the product section, the product is removed by an ejector
mechanism such as an ejector pin. Stick out (Fig. 8).
5. Close the mold.
After removing the product, close the mold. At this time, the slide core is also moved by
the angular pin. Return to the original position. Resin is filled again, and the product
starts by repeating the movement from 1.
It will be molded.

Angularpin

Slide Core
◆Inclined core
As shown in Fig. 1, the undercut toward the inside of the product
The undercut is processed using a so-called processing method.
Also called “Loose Core”. The specific structure looks like Figure 2.

・ Inclined core: Frame set in the undercut part. This inclined core
Undercut is processed by moving it.
・ Slide unit: Undercut for protruding plate movement (ejector stroke)
This unit is used to convert the direction you want to process.
This unit may be made by each mold manufacturer,
Mold parts manufacturers also have standard parts.
・ Shaft: A pin that connects the tilting piece and the slide unit.
◆Inclined core operation

1. The resin is filled in the mold. The mold is closed (Figure 3).
2. The mold opens. At this point, there is no change in the tilted core (Figure 4).
By the way, in the case of the slide core described previously, undercut processing
is performed at this point.
3. The protruding plate moves to remove the product. Here by the shaft and slide core
unit,
The inclined core connected to the protruding plate starts to move (Figure 5).
The inclined core does not move straight like a protruding pin, but on a shaft set at an
angle.
It moves along the direction.
4. When the protruding plate is fully moved, the inclined core is completely removed
from the undercut (Fig. 6).
5. After removing the product, the protruding plate returns and the mold closes.
When the protruding plate returns, the inclined core
Return to position. Resin is filled again, and the product starts by repeating the movement from
1. It will be molded.
◆Nested structure
Another part of the mold that fits into the cavity. *
”Die is often“ unnested ”because it is often impossible to
integrally process the mold.
(= Divide the mold and make it).

For example, specification differences such as with or without holes

Used to create a shape by making the convex shape a separate part.
This separate part is called "nesting".

SEAT BAELT 用穴

GRAN CTR PLR UPR

Reference document
 The following pages are explained in the design section

2. When the amount of undercut is large or depending on the product shape,

It may be moved by a hydraulic cylinder or an air cylinder.
However, this time, we will use a general “angular pin” as the means.
∙ As shown in Fig. 4, the angular pin is set obliquely with respect to the fixed
side.

When the mold opens, along this angular pin set diagonally,
S Slide core moves (lowers).
This operation allows you to remove the hole-shaped undercut.
◆ Movement amount of slide core
• The amount of movement of the slide core is “undercut amount + α” (Fig. 9).
Undercut Make 5-10mm larger than the amount.
The amount of movement depends on the length and angle of the angular pin.
Therefore, it is decided.

・ If the amount of movement of the slide core is insufficient, the slide core will be
caught in the undercut.Therefore, care should be taken because it may cause damage
to the molded product and mold.

・ The angle of inclination of the angular pin is limited to about 25 degrees at

the maximum. Make this bigger If it is too much, the resistance applied to the angular
pin at the time of mold opening will increase. There is a risk of damage.
◆Inclined core travel
• As with the slide core, the amount of undercut + α
• 5 Make it 5-10mm larger than the amount of undercut (Fig. 7).
• The amount of movement is the amount of movement of the protruding
plate (ejector stroke) and the shaft
• Depends on the angle.
• The larger the amount of movement of the protruding plate, the more the
shaft angle
• The larger the size, the more the tilted core moves.
• If there is not enough amount of movement of the inclined core, the inclined
core will be in the undercut part.
• It will get caught and cause damage to the molded product and mold
Please be careful.