Title:
Injection molds : 130 proven designs
Personal Author:
Edition:
3rd ed.
Publication Information:
Cincinnati, OH : Hanser Gardner, 2002
ISBN:
9781569903162
Subject Term:
Available:*
Library | Item Barcode | Call Number | Material Type | Item Category 1 | Status |
|---|---|---|---|---|---|
Searching... | 30000010101458 | TP1150 G37 2002 | Open Access Book | Book | Searching... |
On Order
Table of Contents
| 1 Principles of Mold Design | p. 1 |
| 1.1 Types of Injection Molds | p. 1 |
| 1.2 Types of Runners and Gates | p. 2 |
| 1.2.1 Solidifying Systems | p. 2 |
| 1.2.2 Hot Runner Systems | p. 6 |
| 1.2.3 Cold Runner Systems | p. 10 |
| 1.2.3.1 Molds for Processing Elastomers | p. 10 |
| 1.2.3.2 Molds for Processing Thermosets | p. 11 |
| 1.3 Temperature Control in Injection Molds | p. 14 |
| 1.4 Types of Ejectors | p. 16 |
| 1.5 Types of Undercuts | p. 18 |
| 1.6 Special Designs | p. 18 |
| 1.6.1 Molds with Fusible Cores | p. 18 |
| 1.6.2 Prototype Molds of Aluminum | p. 18 |
| 1.6.3 Prototype Molds Made of Plastics | p. 19 |
| 1.7 Status of Standardization for Injection Molds | p. 19 |
| 1.7.1 Standardized Mold Components (as of Mid-2005) | p. 20 |
| 1.7.2 Standardized Electrical Connections for Hot Runner Molds | p. 20 |
| 1.7.3 Terminology Standards for Injection Molds | p. 20 |
| 1.7.3.1 DIN ISO 12165 "Tools for Molding-Components of Compression and Injection Molds and Die-Casting Dies" | p. 20 |
| 1.7.3.2 DIN 16769 "Components for Gating Systems - Terms" | p. 21 |
| 1.7.4 DIN ISO 16916 "Tools for Molding - Tool Specification Sheet for Injection Molds" | p. 22 |
| 1.8 Standard Mold Components | p. 22 |
| 1.9 Injection Mold for Producing Test Specimens from Thermoplastic Resins | p. 22 |
| 1.10 Materials Selection | p. 23 |
| 1.10.1 General Requirements for Materials | p. 23 |
| 1.10.2 Tool Steels | p. 24 |
| 1.10.2.1 Case-Hardening Steels | p. 24 |
| 1.10.2.2 Prehardened Steels | p. 24 |
| 1.10.2.3 High-Speed Steels | p. 26 |
| 1.10.2.4 Corrosion Resistant Steels | p. 26 |
| 1.10.2.5 Powder-Metallurgical (PM) Steels | p. 27 |
| 1.10.2.6 Cast Ferrous Materials | p. 27 |
| 1.10.3 Non-Ferrous Metals | p. 27 |
| 1.10.3.1 Aluminum Alloys | p. 27 |
| 1.10.3.2 Titanium Alloys | p. 28 |
| 1.10.3.3 Copper Alloys | p. 28 |
| 1.10.4 Anorganic Nonmetallic Materials | p. 29 |
| 1.10.4.1 Ceramic Materials | p. 29 |
| 1.10.5 Surface Treatment Methods | p. 29 |
| 1.10.5.1 Nitriding | p. 30 |
| 1.10.5.2 Carburizing | p. 30 |
| 1.10.5.3 Hard Chrome Plating | p. 30 |
| 1.10.5.4 Hard Nickel Plating | p. 30 |
| 1.10.5.5 Hard Materials Coating | p. 31 |
| 1.11 Materials Properties under Mechanical Stress | p. 32 |
| 1.11.1 Notch Effect under Static Stress | p. 32 |
| 1.11.2 Notch Effect under Dynamic Stress | p. 33 |
| 1.12 Thermal Insulation and Reflector Plates | p. 34 |
| References in Chapter 1 | p. 35 |
| 2 Special Design Features of the Example Molds | p. 37 |
| 3 Examples | p. 41 |
| 3.1 Single-Cavity Injection Mold for a Polyethylene Cover | p. 41 |
| 3.2 Two-Cavity Injection Mold for Elbow Connector Made from PA 66 | p. 43 |
| 3.3 Injection Mold for the Body of a Tape-Cassette Holder Made from High-Impact Polystyrene | p. 46 |
| 3.4 Five-Cavity Injection Mold for Tablet Tubes Made from Polystyrene | p. 48 |
| 3.5 Four-Cavity Injection Mold for a Polyamide Joint Element | p. 50 |
| 3.6 Mold Base with Interchangeable Inserts to Produce Standard Test Specimens | p. 52 |
| 3.7 Two-Cavity Rotary Core Mold for a Polyacetal Pipe Elbow | p. 54 |
| 3.8 Hot Runner Injection Mold for Car Front Fender | p. 58 |
| 3.9 Injection Mold for Magnifying Glass Frame with Handle | p. 60 |
| 3.10 16-Cavity Hot-Runner Mold for Cover Caps with Segmented Internal Contours Made from Polypropylene (PP) or Polyethylene (PE) | p. 62 |
| 3.11 Four-Cavity Injection Mold for a Housing Made from Acrylonitrile-Butadiene-Styrene (ABS) | p. 64 |
| 3.12 Four-Cavity Injection Mold for a Nozzle Housing Made from Polyamide | p. 66 |
| 3.13 Single Split Cavity Mold for a Threaded Plug Made from Polyacetal (POM) | p. 68 |
| 3.14 Demolding a Polyethylene Container with External Undercuts | p. 70 |
| 3.15 Injection Mold with Reduced Opening Stroke for Milk Crates from Polyethylene | p. 70 |
| 3.16 Two-Cavity Injection Mold for Recessed Refrigerator Handles Made from Polyamide | p. 72 |
| 3.17 Injection Mold for a Grass Catcher Made from Polypropylene | p. 75 |
| 3.18 Injection Mold for Hose Connectors Made from Polyamide 6.6 | p. 77 |
| 3.19 Two-Cavity Injection Mold for the Coil Form of an Auxiliary Relay | p. 79 |
| 3.20 Single-Cavity Hot-Runner Mold for Business Card Boxes Made from Polypropylene | p. 81 |
| 3.21 8-Cavity Injection Mold for Threaded Rings Made from Polyacetal (POM) | p. 83 |
| 3.22 Mold for a Pump Housing and Pump Piston Made from Polyacetal | p. 85 |
| 3.23 Hot-Runner Injection Mold for Two Film Spools Made from High-Impact Polystyrene | p. 87 |
| 3.24 Injection Mold for an Angle Fitting from Polypropylene | p. 90 |
| 3.25 Mold for Bushings from Polyamide with Concealed Gating | p. 90 |
| 3.26 Injection Mold for the Valve Housing of a Water-Mixing Tap Made from Polyacetal | p. 91 |
| 3.27 Mold for a Lid with Three Threads Made from Polyacetal | p. 93 |
| 3.28 Two-Cavity Injection Mold for Coupling Sleeves Made from Polyamide | p. 95 |
| 3.29 Injection Mold for the Housing of a Polypropylene Vegetable Dicer | p. 97 |
| 3.30 Two-Cavity Injection Mold for a Polypropylene Toy Tennis Racket | p. 101 |
| 3.31 Two Injection Molds with Two-Step Ejection Process for Housing Components from Polycarbonate | p. 103 |
| 3.32 Injection Mold for a Polypropylene Container with a Threaded Neck | p. 107 |
| 3.33 Three-Plate Injection Mold with Stripping Device for a Precision Magazine | p. 109 |
| 3.34 6-Cavity Metal-Powder Injection Mold (MIM) for Transport Fasteners | p. 111 |
| 3.35 Mold for a Polyamide V-Belt Pulley | p. 113 |
| 3.36 2 x 8-Cavity Hot-Runner Stack Mold for Yoghurt Cups Made from Polypropylene | p. 115 |
| 3.37 2 x 2-Cavity Stack Mold for Covers Made from Polypropylene | p. 117 |
| 3.38 2 x 5-Cavity Stack Mold for Cases Made from Polypropylene | p. 119 |
| 3.39 16-Cavity Hot-Runner Mold for Packaging of Medical Parts made from Polypropylene | p. 123 |
| 3.40 Hot-Runner Stack Mold for a Water Distribution Block Made from Polypropylene | p. 126 |
| 3.41 2 x 8-Cavity Stack Mold for Lozenge Box Made from Polystyrene | p. 131 |
| 3.42 Two-Cavity Injection Mold for a Tail Light Housing Made from ABS | p. 134 |
| 3.43 2 x 2-Cavity Stack Mold with a Hot-Runner System for Runnerless Molding of Polystyrene Container Lids Using Direct Edge Gating | p. 138 |
| 3.44 2 x 4-Cavity Hot-Runner Stack Mold for Dessert Cups Made from Polypropylene | p. 142 |
| 3.45 Hot-Runner Mold for Bumper Fascia Made from Thermoplastic Elastomer | p. 144 |
| 3.46 Four-Cavity Hot-Runner Mold for Threaded Covers Made from SAN | p. 146 |
| 3.47 Two-Cavity Hot-Runner Mold for Trim Bezels Made from ABS | p. 148 |
| 3.48 Four-Cavity Hot-Runner Mold for Control Flap Made from Polyacetal Copolymer | p. 150 |
| 3.49 64-Cavity Hot-Runner Mold for Seals Made from Thermoplastic Elastomer (TPE) | p. 152 |
| 3.50 Eight-Cavity Hot-Runner Mold for PP Toothpaste Dispenser | p. 154 |
| 3.51 2-Cavity Hot-Runner Mold for Polyethylene Jars | p. 156 |
| 3.52 Two-Cavity Hot-Runner Mold for Production of Connectors Made from Polycarbonate | p. 159 |
| 3.53 Four-Cavity Hot-Runner Unscrewing Mold for Cap Nuts Made from Polyacetal (POM) | p. 161 |
| 3.54 Four-Cavity Hot-Runner Mold with a Special Ejector System for a Retainer Made from Polypropylene | p. 163 |
| 3.55 Example 55, 2 x 16-Cavity Two-Component Injection Mold for Microswitch Covers Made from Polyamide and Thermoplastic Elastomer | p. 167 |
| 3.56 32-Cavity Hot-Runner Mold for Production of Packings Made from Polyethylene | p. 171 |
| 3.57 12-Cavity Hot-Runner Mold with Edge Gates for Bushings Made from Polyacetal Copolymer | p. 173 |
| 3.58 Single Injection Mold for Sleeves Made from Glass-Fiber and Talcum Reinforced PA 66 | p. 175 |
| 3.59 Two-Component Injection Mold for Drink Can Holders Made from Polypropylene and Ethylene-Propylene Terpolymer | p. 177 |
| 3.60 Hot-Runner Mold for Polypropylene Clamping Ring with Internal Undercut around the Circumference | p. 180 |
| 3.61 Injection Mold for Compact Discs Made from Polycarbonate | p. 183 |
| 3.62 Single-Cavity Injection Compression Mold for a Cover Plate Made from Unsaturated Polyester Resin | p. 185 |
| 3.63 Two-Cavity Injection Compression Mold for a Housing Component Made from a Thermosetting Resin | p. 187 |
| 3.64 Injection Compression Mold for a Plate Made from Melamine Resin | p. 189 |
| 3.65 Five-Cavity Unscrewing Mold for Ball Knobs Made from a Phenolic Resin | p. 190 |
| 3.66 Four-Cavity Injection Mold for a Thin-Walled Housing Made from a Phenolic Resin | p. 191 |
| 3.67 Thermoset Injection Mold for a Bearing Cover Made from Phenolic Resin | p. 194 |
| 3.68 6-Cavity Hot-Runner Mold for Coffee Cup Covers Made from Polypropylene | p. 196 |
| 3.69 Two Injection Molds for Overmolding of Polyamide Tubing for Automobile Power Window Operators | p. 200 |
| 3.70 Single-Cavity Injection Mold for a Housing Base Made from Polycarbonate | p. 202 |
| 3.71 Connector with Opposing Female Threads Made from Glass-Fiber-Reinforced Polyamide | p. 204 |
| 3.72 Cylindrical Thermoplastic Container with Reduced-Diameter Opening - A Study in Part Release | p. 206 |
| 3.73 Single-Cavity Injection Mold for a Lighting Fixture Cover Made from Polymethylmethacrylate (PMMA) | p. 208 |
| 3.74 Injection Mold for a Housing with a Thread Insert Made from Polycarbonate | p. 210 |
| 3.75 Mold for Long, Thin, Tubular Parts Made from Polystyrene | p. 212 |
| 3.76 Insulated Runner Mold for Three Specimen Dishes Made from Polystyrene | p. 214 |
| 3.77 Single-Cavity Injection Mold for a Polypropylene Emergency Button | p. 216 |
| 3.78 Eight-Cavity Injection Mold for Battery Caps with Undivided External Thread and Sealing Cone Made from Polypropylene | p. 218 |
| 3.79 Injection Mold for a Curved Pouring Spout Made from Polypropylene | p. 220 |
| 3.80 Injection Mold for an ABS Goggle Frame | p. 222 |
| 3.81 4-Cavity Hot Runner Mold for Front Ring | p. 224 |
| 3.82 Two-Cavity Two-Component Injection Mold for a PC/ABS Bezel with a PMMA Window | p. 227 |
| 3.83 Two-Cavity Injection Mold for Runnerless Production of Polycarbonate Optical Lenses | p. 229 |
| 3.84 Injection Mold with Hydraulic Core Pull for a Cable Socket | p. 231 |
| 3.85 Four-Cavity Injection Mold for Pipets Made from PMMA | p. 233 |
| 3.86 Two-Cavity Mold for Water Tap Handles Made from PMMA | p. 235 |
| 3.87 Two-Cavity Injection Mold for the Automatic Molding of Conveyor Plates onto a Wire Cable | p. 237 |
| 3.88 20-Cavity Hot-Runner Mold for Producing Curtain-Ring Rollers Made from Polyacetal Copolymer | p. 239 |
| 3.89 Injection Mold with Attached Hydraulic Core Pull for Automatic Measuring Tubs Made from PC | p. 241 |
| 3.90 48- and 64-Cavity Hot-Runner Molds for Coating Semi-finished Metal Composite with Liquid Crystalline LCP Polymer (Outsert Technology) | p. 243 |
| 3.91 24-Cavity Hot-Runner Injection Mold for Polyacetal Spool Cores | p. 247 |
| 3.92 Two-Cavity Hot-Runner Mold for Loudspeaker Covers Made from Polyacetal | p. 249 |
| 3.93 Injection Mold with Air Ejection for Polypropylene Cups | p. 251 |
| 3.94 Molds for Manufacturing Optical Lenses Made from PC | p. 253 |
| 3.95 Two-Cavity Injection Mold for a Polycarbonate Steam Iron Reservoir Insert | p. 255 |
| 3.96 Injection Mold with Pneumatic Sprue Bushing for a Headlight Housing Made from Polypropylene | p. 258 |
| 3.97 Injection Mold for a Mounting Plate (Outsert Technique) | p. 261 |
| 3.98 Twelve-Cavity Hot-Runner Mold for a Polyphthalamide (PPA) Microhousing | p. 263 |
| 3.99 Two-Cavity Injection Mold for Handle Covers Made from Glass-Fiber-Reinforced Polyacetal | p. 265 |
| 3.100 Four-Cavity Injection Mold for Thin-Walled Sleeves Made from Polyester | p. 268 |
| 3.101 Injection Mold for a Microstructure Made from POM | p. 270 |
| 3.102 Injection Mold for Production of Adjustable Climate Control Vents via 3-Shot Molding | p. 272 |
| 3.103 Two-Cavity Hot-Runner Injection Mold for an ABS Cover | p. 276 |
| 3.104 Six-Cavity Injection Mold for Retaining Nuts Made from Polyamide with Metal Inserts | p. 278 |
| 3.105 Single-Cavity Injection Mold for a Switch Housing Made from Polyacetal | p. 280 |
| 3.106 Single-Cavity Injection Mold for a Snap Ring Made from Polyacetal | p. 282 |
| 3.107 Single-Cavity Hot-Runner Injection Mold for High-Density Polyethylene (PE-HD) Trash Can Lids | p. 284 |
| 3.108 Single-Cavity Hot-Runner Injection Mold for an Air Vent Housing Made from Acrylonitrile Butadiene Styrene (ABS) | p. 287 |
| 3.109 Single-Cavity Hot-Runner Injection Mold for an ABS Housing | p. 290 |
| 3.110 Single-Cavity Runnerless Injection Mold for a Polystyrene Junction Box | p. 292 |
| 3.111 Four-Cavity Hot-Runner Injection Mold for a Polyamide 6,6 Joining Plate | p. 294 |
| 3.112 2 x 4-Cavity Hot-Runner Stack Mold for Hinged Covers | p. 296 |
| 3.113 16-Cavity Mold with Cold-Runner System for Liquid Silicone Rubber (LSR) Caps | p. 298 |
| 3.114 Two-Cavity Injection Mold for a Styrene-Acrylonitrile Safety Closure | p. 300 |
| 3.115 Four-Cavity Unscrewing Mold for Threaded Polypropylene Closures | p. 302 |
| 3.116 Four-Cavity Injection Mold for Polyester Dispenser Heads | p. 304 |
| 3.117 Two-Cavity Injection Mold for PMMA Lighting Fixture Cover | p. 306 |
| 3.118 Two-Cavity Injection Mold for Polyacetal Hinges | p. 308 |
| 3.119 Eight-Cavity Injection Mold for PE-HD Threaded Caps | p. 310 |
| 3.120 4-Cavity Hot-Runner Mold for Connectors Made from Polystyrene | p. 312 |
| 3.121 Single-Cavity Mold for a Polypropylene Cutlery Basket | p. 314 |
| 3.122 Two-Cavity Injection Mold for Cover Plates Made from Polyacetal | p. 318 |
| 3.123 Single-Cavity Injection Mold for a Joystick Baseplate Made from PA 66 | p. 320 |
| 3.124 Single-Cavity Injection Compression Mold for Thermoset V-Belt Pulley (Injection Transfer Mold) | p. 323 |
| 3.125 16-Cavity Hot-Runner Mold for Paperclips Made from ABS | p. 325 |
| 3.126 Single-Cavity Injection Mold for a PE-HD Clothes Hanger Produced via Gas-Assisted Injection Molding | p. 327 |
| 3.127 Single-Cavity Injection Mold for a Syringe Shield Produced via Metal Injection Molding (MIM) | p. 329 |
| 3.128 Three-Station Mold for a Handtool Handle Made from PP/TPE | p. 331 |
| 3.129 Four-Cavity Injection Mold for Couplings Produced via Metal Injection Molding (MIM) | p. 334 |
