IT 2024 Plastic Industry PDF

2024. Oct. 4th Batch Inherent Technology Plastic Industry 1 Plastic manufacturing process 1) Application property 2) Material selection 3) Fixing molding method...

2024. Oct. 4th Batch Inherent Technology Plastic Industry 1 Plastic manufacturing process 1) Application property 2) Material selection 3) Fixing molding method 5) Setting of 7) Additional 4) Production of mold 6) Molding molding condition processing 8) Inspection 9) Packing © 2021 Atlas Copco 2  Classification of Plastic better heat resistance, Plastics chemical resistance, mechanical strength Thermosetting Thermoplastic (Can not be melted) (Can be melted) ©2015 ISETAN MITSUKOSHI Semi-Crystalline Amorphous (Structured) (No structured) Nisshin Seifun Group Inc. Crystal part hard, tough, highly transparency, heat-resistant excellent impact resistance 3  Thermosetting Thermoplastic Phenol Formaldehyde resin (PF) Polyethylene (PE) Epoxy resin (EP) High Density Polyethylene (HDPE) Melamine resin (MF) Medium Density Polyethylene (MDPE) Urea Formaldehyde Resin (UF) Low Density Polyethylene (LDPE) Unsaturated Polyester Resin (UP) Polypropylene (PP) Alkyd Resin (AR) Polyvinylchloride (PVC) Polyurethane Resin (PUR) Polyvinylidene chloride (PVDC) Polyimide (PI) Polystyrene (PS) Polyvinyl acetate (PVAc) Polytetrafluoroethylene (PTFE) Acrylonitrile/Butadiene/Styrene Resine (ABS) Styrene Acrylonitrile copolymer (SAN) Polymethyl methacrylate (PMMA） 4  1) Application property -Grasp the required performances for the Required characteristic values product Items Contents Loading size, Loading type (short-time or long-time, repeated or not), Strength Loaded speed, Type of stress Dimensional tolerance, Dimensional stability (Creep, Thermal expansion, Size Dimensional change by absorbing moisture) Appearance Color, Gloss, Wrinkle pattern Electrical properties, Abrasion resistance, Surface hardness, Function Optical performance, Chemical resistance, Heat resistance, etc. Secondary Need for joining, Decorating, Machining manufacturing Application Where it is used. (Temperature, Moisture, Outside, Application time, etc.) condition © 2016-2021 Others Recyclable? Disposability? Economical? Qefira 5  Mini Work shop Required performances for the product 6  ©2024 wirecable-sales.com © Evergreen Marketing Co.,Ltd. © LY Corporation Wire cable Plastic bag Shoes ©2024MOTA, inc ©1994-2022 FUJITSU ©ASKUL Corporation Car Bumper Lap Top PC Gardening chair 1) Application property Secondary Application Strength Size Appearance Function Manufacturi Others condition ng Electrical Recyclable Loading Dimensio properties, type nal Abrasion ? Items Dimension Dimensio Where it is used. resistance, Surface Loading short-time Loaded Type of change Wrinkle (Temperature, Moisture, Disposabili Applicable al nal Color, Gloss, hardness, Optical size or long-time, speed stress by pattern Outside, Application time, performance, ty? plastics tolerance stability etc.) repeated or absorbing Chemical Economica not moisture resistance, Heat resistance, etc. l? weight Temp:-40~120℃ long (~20 not no colore Electrical Moisture:~100% Wirecable ~10kg long-time on the required no no Printing Outside/Inside Recyclable PV,PE, PU years) needed change d properties cable Application time:~30 years Plastic bags Shoes Car Bumper Laptop PC Gardening chair 8 2) Material selection -Required performance -Select the resin to fit the product -Resin characteristic -Availability -Cost performance 1) Stiffness: The extent to which an object resists deformation in response to an applied force or load 2) Ductility: The mechanical property commonly described as a material's amenability to drawing or expanding 3) Impact resistance: The ability of a material to absorb energy and plastically deform without fracturing 4) Thermostability: The quality of a substance to resist irreversible change in its chemical or physical structure 9 2) Material selection Confirmation Items Contents characteristics Color Material yellowing / Color change Appearance Gloss Surface glossiness (with gloss meter), reflectance (with reflectometer) Surface state Surface roughness (with surface roughness meter) Heat stability Measurement with Thermobalancer, Differential Scanning Calorimeter Flowability Confirmation of Melt flow rate, Melt Viscosity Characteristic Molding Hydrolysis Confirmation of related data such as pre-drying conditions Processability Crystalline Crystallinity, crystallization rate Mold shrinkablility Confirmation of molding shrinkage Releasablity Confirmation of Releasability resistance 10 2) Material selection Select a suitable resin from the dictionary for resins, a leaflet, a catalog or the product information on the web of plastic materials producer. Required performances for the product -Price of resin Basic physical -Availability characteristics of resin Resin Appearance & Molding Physical property data processability of each resin 11 2) Material selection ＜Physical property data of each resin＞ “Curbell Plastics, Inc.” in US 12 2) Material selection “Curbell Plastics, Inc.”13 in US ©2021 Curbell Plastics 2) Material selection ©2021 Curbell Plastics 14 2) Material selection Plastic Material Selection Guide (at Curbell Plastics) 15 3) Fixing molding method -Select the molding method to fit resin & -Type of resin product -Shape of the product Choose a suitable molding method for the product. (The molding method is almost determined by the type of resin.) Molding Main shape (Example of application) Applicable plastic method Injection Various shapes Thermosetting, Thermoplastic Extrusion Products with a constant sectional shape (Round bars, pipes, films, sheets, etc.) Thermoplastic Blow Bottle shape Thermoplastic Compression Thick wall products（Possible for the goods with insert parts） Thermosetting, Thermoplastic Transfer Thick wall products（Possible for the goods with insert parts） Thermosetting, Thermoplastic Laminating Laminated plates, laminated pipes, laminated rods, printed wiring boards Thermosetting Casting Sheet, Film, Plastic block (Figurines made of acrylic resin, insect specimens, etc.) Thermosetting, Thermoplastic Powder Large containers (drinking water tanks, automobile gasoline tanks, water tank, etc.) Thermoplastic Calender Sheet, Film Thermoplastic Insulation material (for refrigerators), (automobile bumpers, various cushioning Cellular Thermosetting, Thermoplastic materials, sponges) Vacuum Various food containers (cup noodles, etc.), tray shape (refrigerator interior parts, Thermoplastic /Pressure automobile interior parts, trays for transporting precision parts, etc.) FRP Various FRP products Thermosetting, Thermoplastic 16 3) Fixing molding method ○：applicable △：partly applicable Vacuum Molding method Injection Extrusion Blow Compression Transfer Laminating Casting Calender Powder Cellular /Pressure Plastic material Polyethylene (PE) ○ ○ ○ △ ○ ○ ○ △ Polypropylene (PP) ○ ○ ○ △ △ ○ ○ Polystyrene (PS) ○ ○ △ △ ○ ○ △ AS Resin（AS) ○ ○ Acrylonitrile/Butadiene/Styrene Resine (ABS) ○ ○ △ △ △ ○ △ Thermoplastic Polyvinylchloride (PVC) ○ ○ ○ △ ○ ○ ○ Methacryl resin(PMMA) ○ ○ △ △ ○ △ △ Polyester（PET） ○ ○ Polyamide(PA) ○ ○ △ △ △ Polycarbonate(PC) ○ ○ ○ △ △ △ Polyacetal(POM) ○ △ △ △ △ Polyphenylenether(PPE) ○ ○ △ △ ○ Polyester（PBT） ○ ○ Fluoro resin (PTFE/PFE) ○ ○ ○ ○ ○ ○ ○ Thermosetting-plastic Phenol Formaldehyde (PF) △ △ Urea Formaldehyde Resin (UF) ○ ○ △ △ Melamine resin(MF) ○ ○ △ Epoxy resin(EP) ○ ○ ○ ○ △ Unsaturated Polyester (UP) ○ ○ ○ ○ △ △ Polyurethane Resin (PUR) ○ △ ○ ○ Diarylphthalete resin(DAP) ○ ○ ○ △ △ 17 Silicon resin(SI) △ ○ ○ ○  3) Fixing molding method Type of Softening method Hardening Molding method Outline of Molding plastic the materials method Injected melted materials Melted materials Injection molding with compression into a Cooled in hot cylinder mold Extrusion Melted materials Extruded melted materials Cooled molding in heated cylinder into a mold Thermo- Melted material & Blown melted materials Blow molding dripped in a Cooled plastic cylindrical form with air in a mold Vacuum / Air Heated plastic Pushed or vacuumed Cooled pressure molding sheet softened sheet on a mold Others *) *) Rolling method, Casting molding, Cellular molding, Powder molding, etc) Thermo- Compression Pre-heated Heated and compressed Polymer- Setting molding materials materials in a mold ization plastic 18 3) Fixing molding method Type of Merits Demerits Molding Injection -A typical mass production molding method -Expensive molding machine molding -Molding speed is fast. -Adjustment of mounting the mold and the cleaning -Applicable for various shapes of products the inside of the cylinder are complicated in small lot -Many types of resins can be applied. multi-production -Easy post-finishing work -In case of the high thickness of the molded product, -Molding of thermosetting plastic and FRP is the shrinkage marks and dents are esay to occur. possible Extrusion -Applicable for many molded products (ex. molding Sheet/film, Pipes, Pipes) -The product shape is restricted. -The mold structure is simple. -Not good for small quantity production -The molding machine is inexpensive. -Suitable for thick molding products Blow modling -A typical mass production molding method for -Not good for small quantity production bottles -Finishing processing other than the product part is -The mold structure is simple. required. -The molding machine is inexpensive. -Difficult to obtain the accuracy of wall thickness. -Thin-walled molding is possible. 19 4) Production of Mold -Produce the mold for the product -Life time of mold -Releasability -Complexity 1) Designing the mold 2) Pre-manufacturing the mold - 3) Some trial productions*) of the plastic product are done by using the pre-manufactured mold. 4) The mold is finalized to be applied for the plastic mas-production. *) When CAE (=Computer Aided Engineering) is used for designing the mold, the trial production will be omitted. Traditional mold designing method Current mold designing method Design Design Mold Premanufacturing CAE*) *) Computer Aided Engineering Trial production Mold Mold Manufacturing Manufacturing Mas production Mas production 20  4) Production of Mold 4-1) Important points for producing molds 1) Life time of mold The life time of the mold has a great influence on the equipment cost. 2) Releasability The removing work of the molded products from the mold (=Releasability) has a great influence on the productivity. 3) Complexity The mold becomes more expensive depending on the complexity in the shape. 4-2) Designing Mold 4-2-1)Check items -Mold temperature -Resin flow -Existence of Insert goods -Removal procedure of molded products -Degassing method -Necessity of finishing process -Cooling system © 2019 i-maker.inc 4-2-2) Others -Make the mold structure as simple as possible and make it as light as possible. -The molded product can be easily taken out and burrs are less likely to occur. 21 -To make fine adjustments such as repairs possible.  4) Production of Mold 4-3) Materials for molds alloy steel, hardened steel, stainless steel, beryllium steel, zinc alloy, cast iron, brass (in the case of special molds), etc. From these various metals, the suitable materials should be selected by considering the following points. -Size and manufacturing cost of the mold -Number of manufacturing products -Molding pressure etc. 4-4) Compatibility with molding resin The mold may corrode depending on the molding resin. Stainless steel is corrosion resistant, but when using normal steel, chrome plating is required. The compatibility with the resin should be tested. 22 5) Molding -The plastic product are molded. Melting temperature Machine manufacturing condition 1) Plastic pellets & plastic compounds*) are mixed. *) Base resin + Additives (Anti-oxidants, UV-stabilizer, Antistatic agent, Glass fiber) 2) They are melted and formed in the molding machine. 3) Cooled to be harden 4) Separated from the mold See each molding method on the following slides. 6-1) Injection Molding 6-2) Extrusion Molding 6-3) Blow molding Mixing of Plastic pellets & plastic compounding 23 At a plastic bottle company in Vietnam 5) Molding 5-1) Injection Molding (C) 2021 Nature3D 24 https://youtu.be/b1U9W4iNDiQ 5) Molding 5-1) Injection Molding © SANKO Co.,Ltd. © SANKO Co.,Ltd. 25 5) Molding 5-1) Injection Molding Sprue Runner Sprue Gate Runner Gate Product Product The parts of “Sprue” and “Runner” are disposed or recycled by mixing with new pellets (The mixing ratio of the recycled materials is about 30 %). 26 5) Molding 5-1) Injection Molding (C) 2021 Nature3D (1) The raw materials/Pellets fall down to the hopper. (2) They are sent forward by rotating the screw in the cylinder. (3) The pellets are plasticized by the heater in the cylinder. (4) They are stored in the front part of the molding machine by the rotation of the screw. (5) The molten resin is injected into the cavity in the mold at high speed and high pressure with a screw. (6) After pressurizing, cooling and solidifying in the cavity. (7) Open the mold and stick out the product with the ejector pin to take it out. 27 5) Molding https://youtu.be/b1U9W4iNDiQ 5-1) Injection Molding “The Principle of Injection Molding” 28 5) Molding 5-1) Injection Molding ★→3) Fixing molding method (1) Select pellets that are easy to fall off from the hopper. (2) Note that the residual stress is concentrated at the gate part where the resin is injected into the cavity, so cracks may occur in the product. (3) Since the molded products shrink*), the inspection is performed after leaving for a certain period of time. (4) For water-absorbent resins such as polyamide, pay attention to dimensional changes due to water absorption. ＊Shrinkage rate Type Plastic Shrinkage Rate PE 1.5 ~ 4.0 % Crystalline Plastics PP 1.0 ~2.5 % PA 1.0 ~ 2.2 % PVC 0.2 ~0.7 % Amorphous Plastics PS 0.4 ~ 0.7 % ABS 0.4 ~ 0.6 % 29 Mini Case Study 30 5) Molding 6-1) Injection Molding Risks/Problems Causes Countermeasures Burr: Resin sticks out of the right shape Sink: The surface of the molded product is dented. © 2021 KEYENCE CORPORATION. Short shot: A part of the molded product is chipped and the shape becomes incomplete. © 2021 KEYENCE CORPORATION. Warp: The molded goods is distorted in one direction. © 2021 KEYENCE CORPORATION. After cutting, the The injection gate part is not Adjust the injection time and mold solidified resin remains solidified. opening speed. at the gate portion of the molded product. 31 © 2021 KEYENCE CORPORATION. 5) Molding 5-2) Extrusion Molding 1) Profile extrusion Molding 2) T-Die extrusion Molding Extrusion molding 3) Inflation Molding 4) Extrusion coating Molding 5) Co-extrusion Molding 32  5) Molding 5-2) Extrusion Molding 1) Profile extrusion Molding © 2021 Everplast Built with GeneratePress © 2021 KEYENCE CORPORATION. Extruder Cutting Pick-up Cooling Sizing Die Screw Hopper Machine Machine Machine Die Heater © 2021 KEYENCE CORPORATION. Heat cylinder (1) The raw materials/Pellets fall down to the hopper. (2) They are sent forward by rotating the screw in the cylinder. (3) The pellets are plasticized by the heater in the cylinder. (4) The molten resin is pushed out through the die to the cooling machine. (5) The shaped resin through the die is cooled to harden by air or water (cold roll for T-Die extrusion) (6) The hardened resin is drown by the pick-up machine. 33 (7) The cutting machine cuts the molded product. Copyright (C) SEKISUI CHEMICAL CO., LTD 5) Molding 1) Profile extrusion Molding https://youtu.be/zcBv_JvFDBI 5-2) Extrusion Molding 34 5) Molding 5-2) Extrusion Molding 2) T-Die extrusion Molding Die (T-Die) Extruder Cold roll Cutting © SANKO Co.,Ltd. Pick-up Machine © SANKO Co.,Ltd. Plastic Sheet 35 5) Molding 5-2) Extrusion Molding 2) T-Die extrusion Molding Die (T-Die) Extruder Cutting Cold roll Pick-up Machine © SANKO Co.,Ltd. © SANKO Co.,Ltd. Plastic Sheet 36 5) Molding https://youtu.be/GDm8hz9xTjc 5-2) Extrusion Molding 2) T-Die extrusion Molding 37 5) Molding 5-2) Extrusion Molding 3) Inflation Molding Clamping roller Guid plate Inflation/Cooling Hopper Air Bubble Winder Extruder Cooling ring Die © 2019 i-maker.inc Air Inlet Heat cylinder Heater © 2021 KEYENCE CORPORATION. Air Screw 38 5) Molding https://youtu.be/W6V0w-ajtN8 5-2) Extrusion Molding 3) Inflation Molding 39 5) Molding 5-2) Extrusion Molding ★→3) Fixing molding method 1) The extruded resin shrinks due to cooling and solidification, but it may not shrink uniformly. Therefore, if the die has a shape similar to the product, it may be deformed and the product as designed may not be obtained. Especially in the case of rubber extrusion molding, the die shape and the extruded rubber shape do not match. Therefore, when designing a die, the shape of the die is determined by making fine adjustments while actually conducting an extrusion experiment. 2) As a cause of deformation, resin may adhere to the die, so die design is important. 3) In the case of molding a thick-walled molded product, it is required that “voids” are not generated inside the molded product and that internal strain should be minimized. Overfilling the resin can prevent the formation of voids, but overfilling will cause "internal distortion". Therefore, it is necessary to set the optimum conditions for the resin melting temperature, cooling rate, extrusion pressure, and pick-up rate. 40 5) Molding 5-2) Extrusion Molding / Profile extrusion Molding Risks/Problems Causes Countermeasures Die mark 1)Slits and flowing surfaces are 1)Avoid the resin that gets the die © Sankyo kasei scratched when cleaning or marks easily. assembling the die. 2)Periodical maintenance & check 2)Resin adheres due to foreign matter, of the die burning, plate-out, etc. Sizing mark 1)Scratch the molded surface during 1)Improve the operation skill for © Sankyo kasei cleaning the sizing die or molding. cleaning the sizing die 2)Foreign matters & vacuum slit 2)Periodical maintenance & check shavings collected on the molding of the sizing die surface make scratches. White streak 1)The dispersion state of the resin is 1)Change the resin © Sankyo kasei poor. 2)Improve the mold structure 2)In two-layer molding (two-color 3)Adjust the pick-up roller molding) products, occur due to tightening force problems with the mold structure. 3)Tighten the pick-up roller too tightly 41 5) Molding 5-3) Blow Molding 1) Extrusion Blow Molding (Hot Parison method / Direct blow molding) Blow molding 2) Injection Blow Molding 3) Stretch Blow Molding 42 5) Molding 5-3) Blow Molding 1) Extrusion Blow Molding (Hot Parison method / Direct blow molding) Air is blown directly into the melt-extruded parison before it cools. Plunger Accumulator Air Blow Die (1) The raw materials/Pellets fall down to the hopper. (2) They are sent forward by rotating the screw in the cylinder. (3) The pellets are plasticized by the heater in the cylinder. Die head (4) The plasticized resin is sent to the plunger. (5) The plunger pushes out the plasticized resin through Extruder the die into the mold. Blow pin (6) The air is blown into the mold to inflate the plasticized resin. Blow mold (7) The molded product is cooled to harden in the mold. (8) The hardened resin is separated from the mold. Hot © SANKO Co.,Ltd. Parison © SANKO Co.,Ltd. 43  5) Molding 5-3) Blow Molding 1) Extrusion Blow Molding (Hot Parison method / Direct blow molding) At a plastic bottle company in Vietnam 44 5) Molding https://youtu.be/236PlbUf2HQ 5-3) Blow Molding 1) Extrusion Blow Molding 45 5) Molding https://youtu.be/oY7hyuMHm68 5-3) Blow Molding 1) Extrusion Blow Molding 46 Mini Case Study 47 5) Molding 5-3) Blow Molding / Extrusion Blow Molding Risks/Problems Causes Countermeasures Uneven thickness Rough surface of molded goods (bottles) The molded product is deformed in the mold. 48 5) Molding 5-3) Blow Molding 2) Injection Blow Molding 1) After molding a bottomed parison by injection molding, it is taken out from the injection molding die. 2) Transferred to a blowing die 3) Blown with air, and molded into a bottle shape. Compared to extrusion blow molding, it is a manufacturing method that is superior in bottle quality such as dimensional accuracy and mass productivity. Transferred Parison Air © What an Interesting World © 株式会社日立ハイテク 2020 Bottomed parison Blow mold Molded bottle 49 5) Molding 2) Injection Blow Molding https://youtu.be/pN-MWbcE_vM 5-3) Blow Molding 50 5) Molding 2) Injection Blow Molding https://youtu.be/mWGWejhZKgc 5-3) Blow Molding 51 5) Molding 5-3) Blow Molding / Injection Blow Molding Risks/Problems Causes Countermeasures 1)High moisture in the pellets Dry the pellets 2)Bubbles in the pellets Check the air vent (cylinder temperature) at the bottom of the hopper 3) Resin overheating or too long Check the heating temperature of the cylinder Bubble in molded residence time in the and head goods (=Void) accumulator 4)The thickness of the molded Make the thickness as thin as possible product is too thick. 5)Lack of air vents on the mold Add air vents more on the mold 6)Sprue, runners, gate are thin. Make the sprue, runners, gate bigger. 52 Bubble problem in Preform “Roha Pack PLC” 53  5) Molding 5-3) Blow Molding 3) Stretch Blow Molding 1) After molding a bottomed parison by injection molding, it is taken out from the injection molding die. 2) Transferred it (=cold parison) to a blowing die 3) In the blowing die, the cold parison is heated to plasticize. 4) The parison is stretched in the axial direction with the stretching rod in the blow mold. 5) Stretched in the radial direction through the blow process 6) Cool the molded product. 7) Released from the mold. © 株式会社日立ハイテク 2020 1 3 2 4 5 6 © 2019 i-maker.inc Heated Stretched in Transferred Blow & Cool Released Finished the axial Cold parison to the mold 54 direction 5) Molding https://youtu.be/arMY8Mly0v0 5-3) Blow Molding 3) Stretch Blow Molding / Hot parison method 55 5) Molding https://youtu.be/so9OyGGlCv4 5-3) Blow Molding 3) Stretch Blow Molding / Cold parison method 56 5) Molding 5-3) Blow Molding / Stretch Blow Molding Risks/Problems Causes Countermeasures 1) Low preform stretching Increase the resin temperature, reheating temperature temperature, injection mold temperature, etc. The injection cooling time should be short The bottom of the and the reheating time should be long. preform(parison) will fall 2) High temperature at the Raise the temperature of areas other than the out. bottom of the preform bottom to achieve balance. 3)The speed of the stretching Reduce the speed of the stretching rod rod is too fast. 1)Reheating temperature is too Lower the temperature of the heating pot high 2)Reheating time is too long Shorten the reheating time. Poor transparency of 3)Moisture contained in blowing Remove moisture with air dryer bottle air 4)Rough surface of blow mold Improve polishing of mold surface 57 5) Molding 5-3) Blow Molding ★→3) Fixing molding method 1) Extrusion Blow Molding : -The surface of the part is often required to have a beautiful luster. The inner surface of the cavity must be thoroughly polished. -The inner part is just pressurized with compressed air. Therefore the fine control of inner surface & the wall thickness is difficult because there is no contact surface for the mold. -In blow molding of beverage containers, it is common to take a large number of pieces, and high cycles are required. Therefore it is necessary to devise a cooling and temperature control function for the mold. 2) Injection Blow Molding The production speed of the blow molding machine is much slower than that of the injection molding machine. Therefore the injection molding machine cannot be utilized efficiently together with the blow molding machine. 3) Stretch Blow Molding The parison, which is stretched axially by the stretching rod in the blowing mold, is also stretched diametrically in the blowing process, resulting in a biaxially stretched bottle which has increased strength. 58 6) Additional processing -Put the added value on the product -Binding -Decoration -Mechanical manufacturing Many methods are applied as follows. -Combining each molded product -Integrating with different materials such as metals -Increasing the appearance value of the molded product -Improving the strength of the molded product -Other processing that cannot be done in the primary processing (see next slide) 59 6) Additional processing Kinds of Secondary Practical examples Appliable Resins Comments treatment Hard material (Thermoplastic) with Ultrasonic welding good propagation property by Small size molded goods ultrasonic vibration High frequency welding Only vinyl chloride resin Sheet type molded goods Fused Induction welding Whole thermoplastic Metal inserted molded goods connection Light transmission resin + Light Laser beam welding Molded goods with any shapes (Welding) absorbable resin Outside thermal welding (Hot air Whole thermoplastic Molded goods with any shapes welding/Hot plate welding) Restricted by the connecting Friction welding Whole thermoplastic Binding shape Adhesive connection (mainly different All resins materials) ・Easily connected than the fused Glued Solvent connection (Connected by connection method connection solublized the connection parts/Mainly Only Solvent soluble resin ・Molded goods with any shapes adhered bewteen the same type of resin) ・Jointed with screws, rivets, bolts, Connection with different materials Included the method that metal Mechanical nuts, etc. (ex. Metals) parts are inserted after the connection ・Jointed by snap-fit, etc. using the Almost all resins primary manufacturing elasticity of plastic Painting, printing, plating, physical Solvent degreasing and various Decoration vapor deposition (PVD), hot stamping, Almost all resins surface modification treatments etc. may be required. Mechanical Lathe processing, milling, drilling, Cutting, drilling, slicing, bending, etc. Almost all resins 60 manufacturing etc.  6) Additional processing Plastic backet + Metal handle Plastic Bottle + Label 61 At a plastic bottle company in Vietnam 6) Additional processing Risks/Problems Causes Countermeasures Depends on the processing 62  7) Inspection -Check the appearance & the function of the -Appearance manufactured product -Function Depends on the product (Mechanical, Visual inspection / Total or Sampling Inspection) 1) Appearance - Size: Aging change is caused by the residual strain*) originated from the residual stress*) in the molded plastic goods. The molded goods are usually sized more than a day after removal from the mold. This is because the crystallinity of the plastic increases and the dimensions change. When measuring the dimensions of molded goods, measure not only one but multiple. Also, observe the dimensional changes over a few days to check its stability. -Stain, Gel, Impurities, Pinhole, Scratch, Void, Surface, Blot, Line, etc. *) “Annealing treatment" is a process that removes residual stress and strain by placing the finished molded product in a dedicated oven and heat-treating it. It is very effective for the molded products with thick wall. 2) Function test depends on the application use ex. Plastic bottle: Pin hole check by Pressure check machine 63 7) Inspection Risks/Problems Causes Countermeasures The product is out of specification. 1)The worker doesn’t have 1)Training workers (ex. The plastic bottle has a enough ability for the inspection. 2)Introduce a inspection pinhole.) equipment. (ex. Air Leak tester for the pinhole) 64  8) Packing -Pack the product -Package material -Storage Depends on the product Plastic drums Plastic bottles Covers for Plastic drum At a plastic bottle company in Vietnam 65 8) Packing Risks/Problems Causes Countermeasures Packing materials are 1)The worker operates roughly to 1)Training of workers broken. break them. 2) Certify the inspection of packing 2)Broken packing materials are materials. delivered. 66 END 67 Appendix 68 4) Extrusion coating Molding Hopper Winding drum Water bath Wire rope Extruder Coating wire rope Step roller Caterpillar Supply drum Pressure type Tube type © 日本スエーヂ工業株式会社 69 5) Co-extrusion Molding Soft Plastic Soft Plastic Bendable Hard Plastic Soft Plastic Hard Plastic Hard Plastic Seiki Industries Co.Ltd 70  Punch Thermosetting resin Molded product Die © 株式会社日立ハイテク 2020 71  Plunger Sprue Cull Transfer pot Tablet Molded Cavity product Ejector pin © 株式会社日立ハイテク 2020 72  Material (cloth, paper) impregnated with resin Heating Compressing © 株式会社日立ハイテク 2020 73  ① Basic form ② Pour a resin ③ Separate the mold ④ Pour a resin into © 株式会社日立ハイテク 2020 ⑥ Finish the prepared mold 74  Resin powder Mold ① Charging ② Multi-axis rotation under heating Molded product ③ Cooling ④ Releasing © 株式会社日立ハイテク 2020 75  Adjust the thickness of the molded product through the cooling rollers Winding up with winding roller Rolled through heated rollers © 株式会社日立ハイテク 2020 76  Vacuum ② Injection & ③ Core back ④ Opening die ① Closing die Filling ④ Cooling & Ejection Forming skin Expanding Die layer volume © 株式会社日立ハイテク 2020 77  sheet Heater Heater sheet sheet Die Die Heater Heater ① Heating sheet ① Heating sheet ② Setting sheet ② Setting sheet clamp Adhered Cooling on die sheet sheet Vacuum Air Air Air Air ③ Molding by vacuum ④ Releasing after cooling ③ Molding by vacuum ④ Releasing © 株式会社日立ハイテク 2020 78 2020 © 株式会社日立ハイテク