Tool Design - A Perfect Mold Design-Metal to plastic-2012 Award for Single component molding..

Brand Owner: Nissan

Designer: MPC, Inc.

Machinery Manufacturer:Demag Plastic Group

Materials: Solvay Specialty Polymers

Molder: MPC, Inc.

Moldmaker: Industrial Molds

Product Description:

                                               This Water Outlet Assembly was a metal to plastic conversion which integrated two components into one assembly. The thermoplastic replacement is a single molded product, delivering greater than 25% cost savings and a 450 gram weight reduction. This assembly is made possible through the development of a complex injection mold, incorporating multiple sequential valve gates to prevent material over-pack and gas entrapment. The ten male ports are created without a parting line usually required with conventional injection molding. Seamless hose joints are made possible through precision timing of multiple valve gates and multiple slide actions to properly form this complex product in one-piece. Scientific molding was used to activate the valve gates and monitor product quality. The molding process was combined with a robot to monitor and remove non-conforming product. The plastic product eliminates the need for 18 machining operations and eliminates two leak paths. This plastic product achieves machined metal tolerances right out of the mold without any secondary machining processes. The injection mold tooling will last the life of the five year program, with annual volumes of approximately 800,000 pieces. Traditional cast aluminum tooling needs replacement after approximately 100,000 cycles, which adds to the cost savings.

Why is the product innovative?

                                                                     This Water Outlet Assembly was a metal to plastic conversion which integrated two components into one assembly.  The thermoplastic replacement is a single molded product, delivering greater than 25% cost savings and a 450 gram weight reduction.  The plastic product eliminated the need for 18 machining operations and eliminated two leak paths.  This plastic product achieves machined metal tolerances right out of the mold without any secondary machining processes. The injection mold tooling will last the life of the five year program, with annual volumes of approximately 800,000 pieces.  Traditional cast aluminum tooling needs replacement after approximately 100,000 cycles, which adds to the cost savings.

The main function of the water outlet is to act as a manifold for the cooling system.  The water outlet features ten seamless barb ports that feed coolant to and from the transmission cooler, throttle cooler, heater core, oil cooler, and provides coolant to the radiator.    The outlet also includes a press-in place seal, sealed threaded insert, a wire harness bracket, an oil drip rail, and houses the thermostat.  The ten male ports are created without a parting line usually required with conventional injection molding.  Seamless barb joints are made possible through precision timing of multiple valve gates and multiple slide actions to properly form this complex product in one-piece.  

To successfully mold this water outlet requires precisely timed hydraulics and mechanical mechanisms, along with the study of the flow of plastic into the mold to optimize the filling of the cavity.  After the mold is closed the valve gate in location one is activated.  The molten plastic then passes over the transducer and the temperature sensor, which closes valve gate location one.  Valve gate location two activates, allowing the molten plastic to pass over the second transducer, which then closes valve gate location two.  During this time the part is allowed to cure for a period of time.  During the same time the mold is closed the slide pull sequencing begins.  Three custom cylinders are sequenced to pull past under cuts.  During this sequence six ports are released.  While the mold opens a mechanical slide action releases two additional ports.  The final two ports are released by a two stage Aside action.  A hydraulic slide action holds the part into place to allow for the remaining port cavities to be pulled.  The part is ejected into a robotic arm.   The valve gate hot runner system was paired with a complex hot oil cooling system.    

The valve gate sequencing prevents any material from over packing and any gas entrapment.  The precise timing of the two valve gates and multiple slide actions allow for the part to properly form.  Scientific molding process was used to precisely activate the valve gates and monitor product quality.  The molding process monitoring was combined with the press robot to monitor and deliver a defect free product.

The combination of sequencing, precision timing, multi slide actions, scientific molding process, and robotics resulted in a world class product.

              This Tool is a Very Big Challenge for the tool designer.CIPETIANs please note it out...