Car lights are mainly used for lighting, which can be said to be the eyes of cars. Car lights are the collective name for all car lighting systems. The appearance of automobile lights has high requirements, and several important parts are transparent parts and electroplated parts. It can be said that the most demanding part of the car's appearance is the lamp. Therefore, the requirements for mold design and production are extremely high. The main lighting of a general car is the front and rear headlights. Different car series have different configurations of lights, and the same car series are different according to the height configuration. The main parts that make up the front and rear lights of the car are: left and right lenses, left and right decorative frames, left and right lamp housings, left and right reflectors, etc.
Lens (Material: Transparent PC): Steel CAV / COR: NAK80 or S136H (HRC33-37), the hardness of the cavity and core is staggered. The product is highly polished, can't pass the whetstone, save the mold to 1000# sandpaper and then polish.
The decorative frame ( Material PBT ): Mold Steel: CAV: NAK80 or S136H (HRC33-37), COR: forged steel HRC31-35, the product is highly polished, can not pass whetstone save the mold to 1000# sandpaper and then polish. The cavity side ( reflective surface) can not be welded.
Reflector (Material BMC): The cavity and core are made of 8407 steel (to achieve a high polishing effect), the cavity steel is HRC46-50, and the core steel is HRC44-48. The cavity side (reflecting surface) is high polished, and can not pass the whetstone, save the mold to 1000# sandpaper and then polish, the core side is generally 600# polished.
|Description||Automotive lights Injection Mold|
|Mold base||LKM; HASCO; DME, etc|
|Mold cavity&core steel||P20,2738,718H,738H,NAK80,SKD61,E420,etc.|
|Nos of Cavity||Single or Multi|
|Hot runner brand||YUDO, HUSKYFISA, HASCO, MOLD-MASTER|
|Product material||ABS,PP,PE,POM,PMMA,PC etc|
|Mold life||100k-500k shots|
|Manufacture time (day)||30-45 days|
|Packing||Vacuum+plywood wooden box|
|Packing||Vacuum+plywood wooden box|
Plastic features: transparent color, high requirements for the appearance surface, no spots/gate/marks, no bubbles/ fog halo/shrinkage mark/ welding lines, and other forming defects.
In view of the plastic color transparent, the use of an ordinary runner can avoid the plastic color difference, improve transparency, coupled with the plastic surface is not allowed to have gate marks, so use the side gate gating system.
The mold adopts the combined cooling system of "vertical cooling water pipe, inclined cooling lines, and splice water well", and the waterway is arranged along the cavity, effectively ensuring the precision of the plastic parts and the labor productivity of the mold. The plastic parts are ejected out by an ejector block, which is not only stable but also leaves no influence on the appearance of the product.
In the molding of transparent mold, the design of the exhaust system is very important, such as poor exhaust, will seriously affect the quality of plastic parts, in view of the product material for PC, exhaust front-end design for 0.02mm, around the product according to CAE analysis of reasonable design exhaust, reduce the bubble or air trapping caused by local burns and other problems during injection molding.
The automobile headlight decorative frame is one of the most important parts of the headlight, the appearance requirements are strict, the mold needs electroplating treatment. For the automobile headlight decorative frame mold, the design should pay attention to the following points:
Electroplating parts first to avoid welding lines, because electroplating parts have any welding lines will appear, affecting the appearance of plastic parts, the design of the gating system to avoid welding lines, if the welding line is inevitable, it is necessary to try to get it to the non-appearance area, the gating system design to pass the mold flow analysis verification.
The surface of the decorative frame is generally designed with a pattern. When designing the mold, we should pay attention to the depth of the pattern of the plastic parts, which is generally easy to produce flow lines.
Plastic parts material molding process range is small, plastic parts surface easy to produce bright spots and difficult to control. When the mold gating system is designed, the runner should be thick and large, and the gate should be fan-shaped. The maximum width of the gate is about 35~40mm, which is conducive to melt filling.
Decorative frame plastic parts are easy to appear the phenomenon of sticking cavity side of the mold, to solve the plastic parts of the early design prevention is generally:
In the plastic parts easy to stick to the mold packing force of the inner side of the design of the inverted buckle, the depth of the inverted buckle is 0.5~1mm, the inverted buckle is designed near the rounded corner of the plastic parts.
Reinforcing ribs shall be designed on the inner side of the plastic parts corresponding to the large packing force of the cavity side of the mold, and an undercut shall be designed on the pushrod. According to the characteristics of the plastic parts, in the 6 LED light area inside plastic parts to design reinforcing ribs and BOSS column, to avoid deformation of the plastic parts.