DSI Die-Slide Injection - - PowerPoint PPT Presentation

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DSI Die-Slide Injection - - PowerPoint PPT Presentation

Jan 26, 2023 150 likes •610 views

DSI Die-Slide Injection

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｢ｉｎ－ｍｏｌｄ ｂｕｉｌｄ－ｕｐ ｍｏｌｄｉｎｇ｣

ダイスライド機構を利用した射出成形機による

｢ｉｎ－ｍｏｌｄ ｂｕｉｌｄ－ｕｐ ｍｏｌｄｉｎｇ｣

ダイスライド機構を利用した射出成形機による The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

DSI

Die-Slide Injection The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

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Application to Hollow Parts Application to Hollow Parts

Conventional method to produce hollow parts: Conventional method to produce hollow parts: Gas injection, Gas injection, Parison Parison blow blow molding, molding, Lost core, Welding, Lost core, Welding, but

but … …

Ｃｏｒｅ

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

従来の・・

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Gas Injection Gas Injection

Compressed gas is introduced inside melt injected resin during / after injection. Uneven thickness. Limitation of controlling thickness.

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Welding Method Welding Method

2 pieces are molded and welded / adhered. Ultrasonic welding, Vibration welding, … Welding area should be flat. Difficult temperature control at welding. Long processing time. Large energy consumption. Multiple processes.

Ｄｉｅ

Ａｃｔｉｏｎ Ｐｒｏｄｕｃｔｓ

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Application to Hollow Parts Application to Hollow Parts

Can they make such hollow parts? Rib and boss inside. Controlled thickness. Fully enclosed shape. Smooth inside surface

DSI can do ! DSI can do !

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

DSI for Hollow Parts DSI for Hollow Parts

One injection molding machine and one mold can make hollow molded parts. Complicated shape with rib and boss inside. Inserted & hollow parts. 50 to 100% higher joint strength than vibration welding. Precise parts, and moreover

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

DSI for Hollow Parts DSI for Hollow Parts

Less processing than lost core and blow. Molded without exposed outside until final parts.

  • - Clean molding such as filter insertion.

Desirable thickness at any portion. 3 dimensional joint.

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成形品を作る 接合する 中空品が完成 射出 融着 成形品 を金型 内に 残す

Idea of DSI Mold Idea of DSI Mold DSI Operation DSI Operation

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd. Ｐｒｉｍａｒｙ Ｉｎｊｅｃｔｉｏｎ Ｓｅｃｏｎｄａｒｙ Ｉｎｊｅｃｔｉｏｎ

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ＤＳＩ－１Ｍ動作 ＤＳＩ－２Ｍ動作 ＤＳＩ－２Ｍ動作

型閉 １次・射出保圧 １次・冷却 型開 ＤＳ 型閉 ２次・射出保圧 ２次・冷却 型開 ＥＪ １つの射出ユニットによる２回成形 １ユニットの２条件制御 同材質の融着成形 型閉 １次・冷却 型開 ＤＳ ＤＳ 型閉 ２次・Ｂ射出保圧 ２次・冷却 型開 ＥＪ １次・Ａ射出保圧 ２つの射出ユニットによる各１回成形 １ユニットの１条件制御 同・異材質の融着成形 ２つの射出ユニットによる各２回成形 ２ユニットの２条件制御 ２材質の組立成形＆同・異材質融着成形 型閉 １次・冷却 型開 ＤＳ １次・Ａ射出保圧 １次・Ｂ射出保圧 ＤＳ 型閉 ２次・Ａ射出保圧 ２次・冷却 型開 ＥＪ ＤＳ 型閉 ２次・Ｂ射出保圧 ２次・冷却 型開 ＥＪ ２次・冷却 ＤＳ

１Ｕｎｉｔ／ｔｗｏ ｓｅｔｔｉｎｇ Ｉｎｊｅｃｔｉｏｎ ｃｏｎｄｉｔｉｏｎｓ ｍｏｌｄｉｎｇ

事例３ 事例２ 事例１

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

DSI ｏｆ Ｏｐｅｒａｔｉｏｎ DSI ｏｆ Ｏｐｅｒａｔｉｏｎ

Ｔｗｏ－ Color Molding

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Comparison of Hollow Molding Comparison of Hollow Molding

Characteristics Molding method Limitation of shape Limitation of resin Dimensional accuracy Strength, property Light weigh Mold cost Required equipment Productivity Eliminating post-process Environmental problem Material loss Overall Cost Lost core A B B B C B D D D D C D Core Core slide D A B B B B B B B B B B Blow D C D C B A C C D B D A Hollow molding Gas inject D C D C C B C B B B B B

DSI B B A B A B B B A B B A

2 shell C B B C C B C D B B B B Vibration weld C B B C B A B A D B B A Friction weld C B B C B A B A D B B A Hot plate weld C B B C B A B A D B B A Welding Ultrasonic weld D B B C B A B A D B B A Welding A B B B C A B A D B C A Injection molding Assembling Tightening A B B C C A B A D B D A A: Excellent B: Good C: Fair D: Poor

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Joint Shape (a) Joint Shape (a)

Typical shape with collapse holder. L shaped portion of primary molded pieces are faced each other to prevent inward collapse against secondary injection.

内倒れ防止 Prevention of Inward collapse

Ｂａｓｉｃ Ｆｏｒｍ Applicable to joint at center of hollow article

二次成形 Secondary molding 一次成形 Primary molding

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Joint Shape (ｂ) Joint Shape (ｂ)

This joint is located at edge without collapse holder. Limited shape and limited resin.

内倒れ防止 Prevention of Inward collapse 内倒れ防止排除 Release of prevention Of inward collapse 角部で接合する場合に採用 Ａｐｐｌｉｃａｂｌｅ ｔｏ ｊｏｉｎｔ ｃｏｒｎｅｒ ｓｅｃｔｉｏｎ

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Joint Shape (ｃ) Joint Shape (ｃ)

This joint is hidden inside primary molded parts. Used for DSI demonstration parts at NPE2000. Limited shape and resin.

Releasing the inward collase prevention ａｎｄ jointed at inner position (Shape and material are limited)

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Joint Shape (ｄ) Joint Shape (ｄ)

Joint with insert piece. Inner space of hollow parts is divided to 2 section by an insert.

Double-shell hollow article is made by DSI＋insert

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

成形品 Product：排水弁（洗濯機部品） Washing Machine Parts (Drain Valve) 樹脂；ＰＰ 製品重量；１３０ｇ

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

  • 成形品 Product：エアーインテーク

Automobile Parts (Air Intake)

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

Ｐｒｏｄｕｃｔ ； 製氷容器 Refrigerator Part (Chiller Tank) Refrigerator Part (Chiller Tank)

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

Intake manifold

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

Intake manifold

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

Ｗａｓｈｅｒ Ｔａｎｋ

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

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Ｉｎｔａｋｅ ｍａｎｉｆｏｌｄ Ｉｎｔａｋｅ ｍａｎｉｆｏｌｄ

ｃｈａｍｂｅｒ

Emission control unit （ＲE） Ｗａｓｈｅｒ ｔａｎｋ

Ｒｅｓｏｎａｔｏｒ ｃｈａｍｂｅｒ

Ａiｒ Ｄｕｃｔ

Ｒｅｓｏｎａｔｏｒ

Steering oil tank Air vent quarter (Ｔｅｓｔｉｎｇ) Ｗａｓｈｅｒ Ｉｎｒｅｔ

Ｄｏｏｒ ｍｉｒｒｏｒ

ＡＴＦ Ｏｉｌ Ｆｉｌｔｅｒ

DSI automobile parts have been are adopted by 8 Japanese major car makers TOYOTA・

NISSAN・HONDA・ MAZDA・MITSUBISHI・ DAIHATSU and SUBARU for Their

37car model

Example of DSI product Example of DSI product

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Lamp

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

血液フィルター 点滴用たこ管 リンゲルキャップ 人工透析ユニット

Example of DSI product Example of DSI product

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

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ＤＳＩ ｍｏｌｄｉｎｇ Ｌａｍｐ inspection

（動画データ） （動画データ）

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product Example of DSI product

Stookless lamp inspection is conducted every molding cycle without conveying from injection area to other

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ＧＯＯＤ ＮＯ ＧＯＯＤ

ＤＳＩ （Ｉｎｊｅｃｔｉｏｎ ｗｅｌｄｉｎｇ） Ｖｉｂｒａｔｉｏｎ ｗｅｌｄｉｎｇ

Look actual parts！サンプルをご確認下さい

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of DSI product ｆｅａｔｕｒｅｓ Example of DSI product ｆｅａｔｕｒｅｓ

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Injection Molding ⇒ Ｄｉｅ Ｓｌｉｄｅ ⇒Sputter film Ｉｍａｇｅ ｓａｍｐｌｅ

Processes in the DSI in-mold sputtering molding Process

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Processes in the DSI in-mold sputtering molding system

Ｆｉｘｅｄ ｄｉｅ

Ｓｌｉｄｉｎｇ ｄｉｅ

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Processes in the DSI in-mold sputtering molding system

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Machine of M-DSI Machine of M-DSI

2 injection units for co-injection, ranging from 120 tons to 950 tons.

Ａｕｘｉｌｉａｒｙ ｕｎｉｔ Ｍａｉｎ ｕｎｉｔ Ｊ２２０ＥＬⅢ－２Ｍ

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電動工具 ピンクの硬い樹脂の上に 柔らかい白の樹脂を積層 硬質 軟質

2 Color Molding Ｍ－ＤＳＩ ｐｒｏｃｅｓｓ 2 Color Molding Ｍ－ＤＳＩ ｐｒｏｃｅｓｓ

Multi layer Ｄｉｅ Ｓｌｉｄｅ Ｉｎｊｅｃｔｉｏｎ （Ｍ－ＤＳＩ）

The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of Ｍ－DSI product Example of Ｍ－DSI product

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Other multi layer molding Other multi layer molding

After 1st shot mold is turned to change cavities, then 2nd shot (mold table turns on movable platen : rotary type, or movable platen faces to the other side : opposite type). Difficult for complicated (need core puller) product. Machine requires a larger platens due to mold mounting space. Unbalanced force on platen.

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Unbalanced Force Unbalanced Force

Mold can’t be located at center so that unbalanced force occurs on platen.

金型が型盤中央に位置する。 1次成形が中央にある。 バランスが良い。大型製品対応可能。高効率成形 金型を型盤中央に位置不可・1次成形が偏心・反転によ りコアﾌﾟﾗｰ対応困難複雑形状対応不可・アンバランス

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

M-DSI Ｓｙｓｔｅｍ M-DSI Ｓｙｓｔｅｍ

Cavity slides after 1st shot for 2nd shot. 3 cavities on stationary side, and 2 on movable, switching runner (Double M-DSI). 2 cavities on stationary side and 1 on movable (Single M-DSI).

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Example of Double M-DSI Product Example of Double M-DSI Product

Ｐｒｉｍａｒｙ Ｍｏｌｄ （PA6-30GF） Ｓｅｃｏｎｄａｙ Ｍｏｌｄ（ＴＰＵ）

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Example of Single M-DSI Product Example of Single M-DSI Product

Automobile Part (Seat Part)

Ｓｅｃｏｎｄａｙ Ｍｏｌｄ（ＰＰ） Ｐｒｉｍａｒｙ Ｍｏｌｄ （ＴＰＯ）

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

Comparison of 2 Color Molding Comparison of 2 Color Molding

Items Method Limitation of product shape Generality Mold set up time Productivity Manufacturing cost of mold Application of automation Total cost Rotary type B C D C C C C Opposite platen type A D D C C C D Core back type D A A B C B B M-DSI A A A A B B A A: Excellent B: Good C: Fair D: Poor

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The Japan The Japan Steel Works, Ltd. Steel Works, Ltd.

DSI history

1986 : DSI method was planed and its patent was applied. 1990 : A controller for 2 molding condition started to be developed. 1990 : First mold (check valve) was made and DSI method has been studied and developed. 1990 : Test mold (pressure container) was built to examine joint strength. 1991 : DSI patent registered in Japan. 1992 : Study of burst test started. 1992 : Development of 2 color DSI machine started. Also larger size machine in line up. 1994 : Study of DSI joint shape was settled. Pressure resistent of PA66 achieved 170psi. 1995 : Mold to evaluate application to intake manifolds was built and study started. 1996 : USA patent pending 2000 : Debut at NPE2000.

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DSI

Die-Slide Injection

The Japan Steel Works The Japan Steel Works Ｔｈａｎｋ Ｙｏｕ Ｖｅｒｙ ｍｕｃｈ

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