eMold 사출성형 Clash Pad제조기술

Presentation on theme: "eMold 사출성형 Clash Pad제조기술"— Presentation transcript:

1 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.

2 eMOLD IP Skin Injection Molding
NADA INNOVATION

3 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

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5 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

6 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

7 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

8 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

9 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

10 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℃