eMold 사출성형 Clash Pad제조기술 자동차의 내장용 부품 중 충돌 시 충격흡수 목적으로 soft skin을 덧씌우는 Clash Pad 부품들을 사용하고 있다. 이 Clash Pad는 PSM(Powder Slush Molding)이라는 공법으로 제조하여 왔는데 이는 전주금형을 적외선 가열하여 250°C까지 가열하고 상온으로 냉각하는 방법을 사용한다. eMold공법으로 금형온도 150°C에서 사출성형하는 공법으로 이 Clash Pad를 제조하는 것이 가능해 졌다. 따라서 과거 30분이상 소요되던 사이클타임을 1분 정도로 줄이는 것과 더불어 큰 폭의 원가절감이 가능하다.

eMOLD IP Skin Injection Molding NADA INNOVATION

1. IP Skin Processes(Soft type) 1 Powder Slush Molding 2 Vacuum Forming Spray Skin Reaction Injection molding Laminating Vacuum Form Laminate Insert Molding Leather Wrapping Existing Processes Light, Soft, ECO Friendly Development Cost Down & Process Simplification

2. eMOLD IP Skin Injection molding Improvement <Cost Down> Process cost ↓, Tool life ↑, C/T ↓, Defect Loss↓ Eliminating Urethane Foam <Quality Improvement> Paint X, Primer X, Invisible PAB Soft Touch<chamois>, Stiffness, Perfect Matt Surface <Simplification> eMOLD Tool Common Injection Machine is OK

eMold Injection Molding Short Shot Surface defects (weld line, flow mark) Tough Surface Releasing Deformation Thin wall Filling (less than 1mm) Perfect Surface quality & No Paint Perfect Matt Surface (gloss rate 0.3) Real Chamois Feeling Convention Injection Molding eMold Injection Molding

3. eMOLD Injection molding VS PSM Process Equipment Investment PSM Machine only N/A General Injection machine 3,000 Ton Convertible eMOLD controller Tool Cost Electroforming 300KⅩ6=USD1.8Mil. eMOLD tool Less than USD Mil. Cycle time 10 Min. Less than 1.5 Min. Tool Life 25,000 shots Over 300,000 shots Energy Consumption Tool Temp. 480 °F (250°C) 77 °F ( 25°C) Tool Temp. 198 °F (110°C) 86 °F ( 30°C) Usable Resins PVC, TPU TPU,TPV,TPO, etc. Part cost 30~50% less than PSM cost

4. Actual Reference Injection machine : 3,000 ton Resins : TPU, TPV, TPO Cycle Time : 70~ 90 sec Tool Temp. : 30 ⇔120 ℃ Chiller Temp.: 20 ℃ Part size : 1,800 Ⅹ450Ⅹ200 Part Thickness :1mm No coating No Primer (for Form) Invisible PAB

4-1. eMold Tool specification Banding Heater Type Quantity : 93ea Heater size : 5x5(Square) Core material : HP4M 1600mm 800mm Heating Core Crash Pad 1.0mm 520mm Visible Surface Section View Banding Heater

4-2. Assessments Perfect Filling Perfect Surface Weld line, Flow mark are disappeared Perfect Matt Surface Various Material is adoptable Surface Temp. Distribution ⇒ less than 5℃