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CASE STUDY 2

Case Study Component :* Photo divider insert.
                                              Thin moulding  1.3mm two cavity
*Material :                             Currently Moulded in PS
*Case Study Materials :      PP – both cavities easily filled
                                              PC - With max injection conditions tool can only be partially filled

 

*

 

PC MFI 39 used

PC - With maximum injection conditions tool can only be partially filled

  • Using Ultramelt 3.5 seconds before injection and during initial injection tool can only be 70% filled. (160% increase in fill). Material still clear
  • *Therefore Ultrasonics must be kept on for longer during injection

At 280°c = 25% filled                  at 330°c = 70% filled

  •  

  • Using Ultramelt 3.5 seconds before injection and during full injection (23 sec) tool 100% filled. (350% increase in flow) BUT Material degrading witnessed
  • *
  • *280°C barrel temp
  • *70% Amplitude


     

  • *Using Ultramelt for 11 seconds during injection tool =  100% filled.
    (50% increase in flow) Full part with good clarity
  • *
  • *320°C barrel temp
  • *70% Amplitude

SUMMARY

  • *Case study part shows benefit to PC moulding with Ultramelt to achieve moulding
  • *50% increase in flow required to complete fill moulding.
  • *Material clarity maintained.
  • *Moulding cycle injection stage of 23 seconds required to achieve component.

    Trials have also been carried out on DVD grade Polycarbonate which will potentially offer great advantages to the DVD Manufacturers.

 

 

Click here to see further details of CASE STUDY 1

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