Vertical Injection Molding Machine for Power Cord Molding : Factors to Consider

2023-04-24 | Article
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In this article, we will provide you with expert tips on how to select the perfect vertical injection molding machine for power cord, C type, connector, charger, electrical plug. Our guide covers essential factors to consider, must-have features to look for, common injection molding machine types, and basic maintenance and troubleshooting advice.

As you may know, Power Plug Insert Molding is a process of molding a plastic material over an existing plug or connector, creating a protective and functional cover around it. Vertical injection molding machines are highly preferred for this application due to their ability to offer precise control over temperature and pressure levels within the cavity where the material is injected.

So, if you're interested in improving your Power Cord or plug Molding process, be sure to read on ! Our tips will help you choose the right injection molding machine for your needs and ensure that your plug, cable or connector production runs smoothly.

USB Cable Plug Connector Injection Molding Basics

Insert molding is a manufacturing process where a pre-made component is inserted into a mold, and then a molten material is injected into the mold to create a final product. Let’s take USB molding as an example.

The steps to make a USB by insert molding are as follows:

  • 1. Create a mold for the USB casing that will fit the pre-made USB connector. The mold should have a cavity that allows the connector to be inserted.

  • 2. Set up the vertical injection molding machine with the mold. Normally 15 to 30-ton injection molding machines are required according to your different mold cavities designs.

  • 3. Preheat the mold and the material to the appropriate temperature. The mold and material need to be heated to a specific temperature range to ensure that the plastic material melts and flows smoothly into the mold, resulting in a high-quality finished product. One critical step in the injection molding process is preheating the mold and the plastic material to the appropriate temperature. The mold and material need to be heated to a specific temperature range to ensure that the plastic material melts and flows smoothly into the mold, resulting in a high-quality finished product.

  • 4. Insert the pre-made USB connector into the mold cavity.

  • 5. Inject the molten material into the mold cavity using the injection molding machine.

  • 6. Allow the material to cool and solidify around the USB connector.

  • 7. Eject the finished USB from the mold.

  • 8. Test the USB to ensure it functions properly.

With these steps, you can create a USB by insert molding. It's important to note that the exact process may vary depending on the specific materials and equipment used.

Factors to Consider

Selecting the right vertical injection molding machine is essential for achieving high-quality results and cost reduction in the production of USB/Cable/Plug/Connector/Charging items. This is because the machine's precision control over temperature and pressure levels inside the cavity where the material is injected can significantly impact the quality and consistency of the final product. Choosing the wrong machine can result in inefficiencies, defects, and downtime, leading in lost time and money. By selecting the appropriate vertical injection molding machine, you can ensure an efficient and cost-effective production method that yields high-quality connectors with tight tolerances. Ultimately, this leads to increased satisfaction and profitability.

To ensure that the machine meets your production needs and requirements, several factors must be considered, including :

1. Mold

  • Mold Size

    In power cord injection molding, mold size plays a crucial role in determining the final product's quality and cost-effectiveness. Selecting the appropriate mold size is essential to produce power cords that meet the required specifications. A mold that is too small may result in a final product that is not of the desired size or shape. Conversely, a mold that is too large may lead to material wastage and higher costs.

    Furthermore, the mold size for power cord injection molding can also vary depending on the monthly production capacity required. If there is a higher demand for power cords each month, then the mold's cavity size and overall dimensions would typically be larger, and the mold may have multiple cavities to accommodate a higher production rate.

  • Mold Design

    Mold design is another critical factor in power cord injection molding that significantly impacts the quality of the final product, production efficiency, and overall cost-effectiveness. One popular mold design for power cords features 2-3 changing bars, allowing operators to load and unload outside the mold. This design offers two primary benefits : it provides more cooling time for the PVC material, leading to a better final product, and the changing bars make loading and unloading faster and more efficient, improving production rates.

2. Materials

Power cords and plugs are typically crafted from thermoplastics, such as polyvinyl chloride (PVC). PVC is widely preferred due to its impressive electrical insulation, chemical resistance, UV-ray resistance, and flexibility. It can be easily processed using injection molding, making it a cost-effective choice. However, in recent years, there has been growing concern about the environmental impact of PVC. To mitigate this issue, some manufacturers have begun using alternative materials such as biodegradable polymers or recycled materials for injection molding. By using eco-friendly materials, manufacturers can help reduce the environmental footprint of power cords. It is worth noting that the choice of vertical injection molding machines at Taiwan Kinki remains unaffected, regardless of the eco-friendly material used.

3. Speed

Machine speed is another critical factor that can impact production. A machine that runs too slowly may not be capable of producing enough parts to meet production requirements, while a machine that runs too quickly can lead to quality problems. For instance, if the machine speed is too slow, it may cause undesirable flow marks on the surface of the molded product. Therefore, finding the optimal machine speed that balances the desired production rate and quality standards is essential. Achieving this requires careful attention to detail and a thorough understanding of the production requirements. You must take into account the specifications of the plastic material, the design of the mold, and the desired output rate to determine the optimal machine speed for power plug injection molding.

4. Maintenance

Lastly, it is necessary to consider the maintenance requirements of the machine. The machine should be simple to maintain and repair to ensure that any issues can be quickly addressed, minimizing downtime and reducing production costs.

Key Features to Look for When Selecting an Injection Molding Machine for Electric Plugs or Cables

Top features to consider when choosing a vertical injection molding machine include high injection speed and pressure control, advanced control systems for precise temperature regulation, modular designs for flexibility in mold sizes, user-friendly interfaces and automation, and efficient hydraulic systems for reduced maintenance and downtime.

  • 1. High injection speed and pressure control to ensure efficient and effective production.

  • 2. A large ratio between screw length and diameter (L/D) for better melt quality, reduced risk of material degradation, and improved part consistency.

  • 3. A dual-cylinder balanced injection system for smooth and powerful injection, minimizing the risk of flash and short shots.

  • 4. Equipped with the microcomputer to display faults automatically, for easy inspection and maintenance.

  • 5. The open-die design features a straight-pressure type lock cylinder for fast drop and clamping, or low speed and pressure clamping to increase the mold's lifespan.

  • 6. Advanced control systems for precise temperature regulation.

  • 7. Modular designs for flexibility in mold sizes.

  • 8. User-friendly interfaces and automation.

Read also : How to Select Vertical Injection Molding Machines for Automotive Parts?

Common Types of Vertical Injection Molding Machines for Plug Molding

The KC Series Vertical Injection Molding Machine is a popular model specifically designed for power plug molding. Its unique vertical mold clamp and horizontal injection feature a no-post design, allowing it to be open on three sides, making it suitable for power cords and other medium-sized products.

The C-shaped structure and one-step operation of the machine minimize the possibility of deformation caused by high pressure, resulting in perfectly molded power cords, cables, plugs, or USB, free of any defects. The direct-pressure mold clamp and twin-cylinder injection system of the machine ensure long-lasting durability and exceptional precision.

To download the specification of vertical injection molding machines, please visit our website.

Maintenance and Troubleshooting Tips for Vertical Injection Molding Machines

Regular maintenance is crucial for the longevity and optimal performance of vertical injection molding machines used in plug molding. This includes regular cleaning, lubrication, inspection, calibration, and troubleshooting. By following these tips, you can prevent wear and tear, ensure consistent product quality, and avoid costly downtime. Remember that a well-maintained machine leads to increased profitability and customer satisfaction.

Vertical Injection Molding Machines consist of three key components: mechanical mechanisms, electronic components, and hydraulic systems. Troubleshooting is a crucial step in quickly resolving any issues with the Injection Molding Machine. As a renowned manufacturer of Rubber Vertical Injection Molding Machines, Taiwan Kinki Machinery provides solutions to the 4 most common problems that arise with Injection Moulding Machines, such as issues with the motor and hydraulic pump.

Read also : Why Injection Molding Backpressure is the Key to Prevent Bubbles & Shrinkage?

Why You Should Work with Taiwan Kinki For Your Plug Molding Projects

Leveraging over 35 years of experience, Taiwan Kinki Machinery creates high-quality, industry-compliant vertical injection molding machines for a wide range of applications for plug molding. Our injection molding machines are capable of producing high-quality products with exceptional precision, durability, and consistency. To learn more about our injection molding capabilities, and step-by-step guides on how to select the right injection molding machine, please contact us today.

How to Select a Right Vertical Injection Molding Machine?