[PPT] - Collapsible Core Molds and Energy Savings Plastics Caps & PowerPoint Presentation

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Collapsible Core Molds and Energy Savings

Plastics Caps & Closures Conference Chicago, Sept 17th, 2015

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Collapsible Core History

Developed in 1968 by George Roehr
Roehr Tool has been the industry leader in c-core technology
Manufactured in MA, USA
Progressive Components purchased Roehr Tool in 2006
Added mechanical line of Dove Tail Cores in 2009

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Types of Collapsing Core

Spring / Flexing Steel Type Mechanical / Dovetail Type

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DT Core Applications

Primary Markets

Packaging, caps and closures
Medical caps and fittings
Plumbing fittings
Irrigation products
Electrical connectors and fittings

Materials and Temperatures

From simple Olefins & ABS to more demanding resins like PVC
r PA+GF
Cores can be built to work with high temperature resins

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Collapsible Core Trend

Industry perception of C-Cores in the past, “Option 3” behind:

Jump or strip thread usually being the simplest method, but limits part

design and can create part quality issues

Unscrewing with its rather complex and multi-component tools, long

molding cycle times, high maintenance and only valid for threads Game has changed

In tough economic times traditional methods are challenged
Dove Tail Core, a fully-mechanical collapsible core that overcomes

many misconceptions and limitations Result: increased performance and optimized part design

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DT Core Construction

Exploded view

(11-piece assembly)

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DT Core Construction

Collapsing Segments

Material: 1.2363, 55-57 HRC

Designed to mechanically collapse when the

center pin is withdrawn

The fit between the segments is controlled to

permit flash-free molding

Center Pin

Material: 1.2379, 59-61 HRC

Serves to expand the segments of the core to

their molding position

The pin may be flush to the core face
Integrated cooling line

Carrier Assembly

Material: 1.2379, 59-61 HRC

Mounts DT Core assembly to the mold

carrier plate

Provides guided and anti-rotational segment

movement

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DT Core Range

Customs & Pre-Engineered Standards

Ranging from Ø7mm - Ø250mm

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Part Optimization

Part Design Advantages

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Part Geometry

Protruding Features

Parts with features like seals on

closures typically can’t be done with collapsing cores

Exceptions include designs where

the core, at the end of its collapse stroke, has resulting “Free Space” between the core and the protruding feature

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Part Geometry

Pancake Core

Used for seal ring applications and witness line free parts.
Pancake diameter must be smaller than undercut diameter for ejection.

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Part Geometry

Undercuts

Full diameter undercuts are common for threads, O-ring grooves or

snap features

Segmented undercuts and internal geometrical features are possible,

although need to be aligned with segment axes and correctly drafted

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Collapse Movement

Collapse Range

Typical collapse: 5-7% per side(min 1mm per side for diameter

20mm)

Max collapse area is produced at mid section of wide segments
Min collapse points are at intersection of wide segment edges

Calculating required collapse

vs. undercut depth
Undercut + Shrinkage + Clearance

= Total Collapse Required

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Part Retention

Retention Sleeve(reg. patent)

Some designs require a feature to prevent part from hanging on one
f the segments during collapse, which leads to part damage
Retention sleeve is integrated into the DT core and independent of

the stripper, so the part is secured during collapse but easy to eject

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Quick Lock System

Assembly in the Mold: Quick Lock(reg. patent)

Makes DTs removable from parting line for maintenance or conversion

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1 - Mold Open 2 – Collapse 3 - Eject

Mold Design & Sequencing

Staging methods

Press KO with latch lock
Hydraulic cylinders
Press open and close

Side Action Cam or hydraulic actuation is possible

Molding Position Collapse and Retract

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Mold Design & Sequencing

Front Half actuation

Actuation similar to 3-plate runner split before

main parting line opens

Molding Position Collapse on Mold Open

Reverse Gate

Gating through the Center Pin

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DT Core Mold vs. Unscrewing Mold

Simplified Mold Design
Easier Mold Set-Up
Sequencing Options
Less Maintenance
Better Part Quality
Improved Part Design
Reduced Cycle Time
Reduced Carbon Footprint

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Cost Saving Calculation

Region: NA ($/lb)

MFG Costs and Capacity

Unscrewing Mold DT Core Gains 1: Cycle Time, Eff, QA DT Core Gains 2: + Smaller Press DT Core Gains 3: + Less Cavities Part Cost: Annual Volume 15,000,000 15,000,000 15,000,000 15,000,000 Resin Price ($/lb) 1 1 1 1 Part Weight (g) 2 2 2 2 Molding: Mold Type Unscrew DT Core DT Core DT Core Cycle Time (s) 12.0 8.4 8.4 8.4 Cavitation 16 16 16 12 Productivity 80% 90% 90% 90% Threaded Core Cost 900 3200 3200 3200 Press Rate ($/hr) 50 50 40 40 Maintenance Hrs/year 84 42 42 42 Quality, % defect 1.0% 0.3% 0.3% 0.3% Assumptions: Production Hrs per Week 96 96 96 96 Production Weeks per Year 45 45 45 45 Toolroom Rate 50 50 50 50 Overhead (% upcharge) 25% 25% 25% 25% Molder's Profit Margin (%) 20% 20% 20% 20% Result: Unscrewing Mold DT Core Gains 1: Cycle Time, Eff, QA DT Core Gains 2: + Smaller Press DT Core Gains 3: + Less Cavities Part Cost ($/1000) 26.1 18.8 16.3 19.6 Capital Cost Est ($) 141,000 155,200 155,200 116,400 Capacity 16,588,800 26,660,571 26,660,571 19,995,429 Maint & QA Cost 8120.876927 2803.526523 2712.38069 2833.908468 Savings: DT Core Gains 1: Cycle Time, Eff, QA DT Core Gains 2: + Smaller Press DT Core Gains 3: + Less Cavities Annual Part Savings ($) 115,994 152,544 103,811 ROI (1 Yr Savings) 101794.4337 138343.9129 128411.274 ROI 5 Yr ($) 565,772 748,520 543,656 Capacity Gain 10071771.43 10071771.43 3406628.571

26.1 18.8 16.3 19.6

UNSCREWING MOLD DT CORE GAINS 1: CYCLE TIME, EFF, QA DT CORE GAINS 2: + SMALLER PRESS DT CORE GAINS 3: + LESS CAVITIES

Part Cost ($/1000)

115,994 152,544 103,811

DT CORE GAINS 1: CYCLE TIME, EFF, QA DT CORE GAINS 2: + SMALLER PRESS DT CORE GAINS 3: + LESS CAVITIES

Annual Part Savings ($)

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Cost Saving Calculation

141,000 155,200 155,200 116,400

UNSCREWING MOLD DT CORE GAINS 1: CYCLE TIME, EFF, QA DT CORE GAINS 2: + SMALLER PRESS DT CORE GAINS 3: + LESS CAVITIES

Capital Cost Est ($)

565,772 748,520 543,656

DT CORE GAINS 1: CYCLE TIME, EFF, QA DT CORE GAINS 2: + SMALLER PRESS DT CORE GAINS 3: + LESS CAVITIES

ROI 5 Yr ($)

Region: NA ($/lb)

MFG Costs and Capacity

Unscrewing Mold DT Core Gains 1: Cycle Time, Eff, QA DT Core Gains 2: + Smaller Press DT Core Gains 3: + Less Cavities Part Cost: Annual Volume 15,000,000 15,000,000 15,000,000 15,000,000 Resin Price ($/lb) 1 1 1 1 Part Weight (g) 2 2 2 2 Molding: Mold Type Unscrew DT Core DT Core DT Core Cycle Time (s) 12.0 8.4 8.4 8.4 Cavitation 16 16 16 12 Productivity 80% 90% 90% 90% Threaded Core Cost 900 3200 3200 3200 Press Rate ($/hr) 50 50 40 40 Maintenance Hrs/year 84 42 42 42 Quality, % defect 1.0% 0.3% 0.3% 0.3% Assumptions: Production Hrs per Week 96 96 96 96 Production Weeks per Year 45 45 45 45 Toolroom Rate 50 50 50 50 Overhead (% upcharge) 25% 25% 25% 25% Molder's Profit Margin (%) 20% 20% 20% 20% Result: Unscrewing Mold DT Core Gains 1: Cycle Time, Eff, QA DT Core Gains 2: + Smaller Press DT Core Gains 3: + Less Cavities Part Cost ($/1000) 26.1 18.8 16.3 19.6 Capital Cost Est ($) 141,000 155,200 155,200 116,400 Capacity 16,588,800 26,660,571 26,660,571 19,995,429 Maint & QA Cost 8120.876927 2803.526523 2712.38069 2833.908468 Savings: DT Core Gains 1: Cycle Time, Eff, QA DT Core Gains 2: + Smaller Press DT Core Gains 3: + Less Cavities Annual Part Savings ($) 115,994 152,544 103,811 ROI (1 Yr Savings) 101794.4337 138343.9129 128411.274 ROI 5 Yr ($) 565,772 748,520 543,656 Capacity Gain 10071771.43 10071771.43 3406628.571

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Energy Savings

The use of DT Core molds allows for two things when compared to typical hydraulic unscrewing molds:

1. Since DT Core molds do not require a secondary hydraulic core pull, the molds are ideal to run in the

latest all electric presses.

2. DT Core molds are much smaller and compact allowing to be run in a smaller press with the same
cavitation. Often times a mold that would need to run in a 300t press can now be run in a 200t press.

kWh usage varies between machine manufacturers but on an estimation, all-electric machines will use 1/3rd less energy than its hydraulic counterpart. In addition, the savings of being able to run in a smaller tonnage machine result in considerable energy saving per press. Multiply that by a company running 10, 20 or even more machines and the savings can have a great positive impact on the company’s bottom line.

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Prototype Options

ProtoBridge

Pre-engineered 4 cavity molds, designed for convertibility and

capable of production volumes

Intended for customers looking to trial DT Cores, proving out part and

mold design as well as production capabilities

Protobridge molds can be inserted to trial customer’s own application

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DT Core Value Proposition

Value Proposition

Capable of doing parts most of the common technologies can’t do.
DT Cores provide numerous advantages over Jump Thread and

Unscrewing Molds. Primary benefits to OEMs & Molders:

Savings increase through faster cycle time, simplified tooling

& easier maintenance

Part design optimization to gain advantage over competition

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DT Core Videos

DT Videos

4 cavity, 28mm
8 cavity, 15mm
12 cavity, dosing cap
32 cavity, 22mm

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RTC Media

Roehr Tool Website: www.roehrtool.com

Animations
Monthly Newsletter
Resources Page

YouTube: http://www.youtube.com/RoehrTool Facebook: https://www.facebook.com/pages/Roehr-Tool-Corporation/450487311670767 LinkedIn: http://www.linkedin.com/company/roehr-tool-corporation