DSI Die-Slide Injection ｢ ｉｎ－ｍｏｌｄ ｂｕｉｌｄ－ｕｐ ｍｏｌｄｉｎｇ ｣ ｢ 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 ダイスライド機構を利用した射出成形機による Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan 1 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Application to Hollow Parts Application to Hollow Parts Conventional method to produce hollow parts: Conventional method to produce hollow parts: 従来の・・ Gas injection, Parison Parison blow blow Gas injection, molding, molding, but … … Lost core, Welding, but Lost core, Welding, Ｃｏｒｅ 2 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Gas Injection Gas Injection � Compressed gas is introduced inside melt injected resin during / after injection. � Uneven thickness. � Limitation of controlling thickness. 3 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
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 4
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 ! 5
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 6 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
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. 7 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Idea of DSI Mold Idea of DSI Mold DSI Operation DSI Operation Ｓｅｃｏｎｄａｒｙ Ｉｎｊｅｃｔｉｏｎ 成形品を作る 成形品 を金型 内に 残す 接合する 射出 融着 Ｐｒｉｍａｒｙ Ｉｎｊｅｃｔｉｏｎ 中空品が完成 8 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
DSI ｏｆ Ｏｐｅｒａｔｉｏｎ DSI ｏｆ Ｏｐｅｒａｔｉｏｎ １Ｕｎｉｔ／ｔｗｏ ｓｅｔｔｉｎｇ Ｉｎｊｅｃｔｉｏｎ ｃｏｎｄｉｔｉｏｎｓ ｍｏｌｄｉｎｇ Ｔｗｏ－ Color Molding ＤＳＩ－１Ｍ動作 １つの射出ユニットによる２回成形 型閉 １次・射出保圧 １次・冷却 型開 ＤＳ １ユニットの２条件制御 同材質の融着成形 事例１ 型閉 型開 ＥＪ ＤＳ ２次・射出保圧 ２次・冷却 ＤＳＩ－２Ｍ動作 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 型閉 １次・冷却 １次・Ａ射出保圧 型開 ＤＳ 事例２ 型閉 ２次・冷却 ２次・Ｂ射出保圧 型開 ＥＪ ＤＳ ＤＳＩ－２Ｍ動作 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 型閉 １次・Ａ射出保圧 １次・冷却 型開 ＤＳ ２材質の組立成形＆同・異材質融着成形 ２次・冷却 １次・Ｂ射出保圧 事例３ 型閉 ２次・冷却 ２次・Ａ射出保圧 型開 ＥＪ ＤＳ 型閉 ２次・Ｂ射出保圧 ２次・冷却 型開 ＥＪ ＤＳ 9 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Comparison of Hollow Molding Comparison of Hollow Molding Eliminating post-process Environmental problem Dimensional accuracy Characteristics Required equipment Limitation of shape Strength, property Limitation of resin Material loss Overall Cost Productivity Light weigh Mold cost Molding method 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 Injection Welding molding Hot plate weld C B B C B A B A D B B A 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 Assembling Tightening A B B C C A B A D B D A A: Excellent B: Good C: Fair D: Poor 10 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Joint Shape (a) Joint Shape (a) 内倒れ防止 � Typical shape with Prevention of Inward collapse collapse holder. � L shaped portion of 一次成形 Primary primary molded pieces are molding faced each other to prevent 二次成形 Secondary inward collapse against molding secondary injection. Ｂａｓｉｃ Ｆｏｒｍ Applicable to joint at center of hollow article 11 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Joint Shape ( ｂ ) Joint Shape ( ｂ ) 内倒れ防止排除 Release of prevention � This joint is located at Of inward collapse edge without collapse holder. � Limited shape and limited resin. 内倒れ防止 Prevention of Inward collapse 角部で接合する場合に採用 Ａｐｐｌｉｃａｂｌｅ ｔｏ ｊｏｉｎｔ ｃｏｒｎｅｒ ｓｅｃｔｉｏｎ 12 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
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) 13 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
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 14 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
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 15 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 成形品 Product ：エアーインテーク • Automobile Parts (Air Intake) 16 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product Ｐｒｏｄｕｃｔ 製氷容器 ； Refrigerator Part (Chiller Tank) Refrigerator Part (Chiller Tank) 17 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product Intake manifold 18 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product Intake manifold 19 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product Ｗａｓｈｅｒ Ｔａｎｋ 20 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 21 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product Ｄｏｏｒ ｍｉｒｒｏｒ Steering oil tank Ｉｎｔａｋｅ ｍａｎｉｆｏｌｄ Ｉｎｔａｋｅ ｍａｎｉｆｏｌｄ ｃｈａｍｂｅｒ DSI automobile Ｒｅｓｏｎａｔｏｒ ｃｈａｍｂｅｒ parts have been are adopted by 8 Ａiｒ Ｄｕｃｔ Japanese major car Ｒｅｓｏｎａｔｏｒ makers TOYOTA ・ Ｗａｓｈｅｒ NISSAN ・ HONDA ・ Ｉｎｒｅｔ MAZDA ・ MITSUBISHI ・ Air vent Lamp Emission control unit quarter DAIHATSU and Ｗａｓｈｅｒ ｔａｎｋ （ＲE） (Ｔｅｓｔｉｎｇ) SUBARU for Their ＡＴＦ Ｏｉｌ Ｆｉｌｔｅｒ 37car model 22 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 23 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 24 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 25 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 点滴用たこ管 人工透析ユニット 血液フィルター リンゲルキャップ 26 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product 27 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
Example of DSI product Example of DSI product ＤＳＩ ｍｏｌｄｉｎｇ Ｌａｍｐ inspection （動画データ） （動画データ） Stookless lamp inspection is conducted every molding cycle without conveying from injection area to other 28 Steel Works, Ltd. The Japan Steel Works, Ltd. The Japan
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