1. The Merits of Gas-Venting Conducted in a State of Atmospheric Vacuum
Through the absorption of vented gases by a vacuumous state, if pressure within the mold does decrease, even if resins were injected into the mold, there would not be an increase in internal pressures. To wit, this therefore enables injections of resins to occur at the highest possible speeds. As such, because equipment operators can freely set the injection speed of equipment and select the optimum injection speeds for specific molds, it becomes possible to conduct ongoing injection-molding operations under optimum conditions, with instances of malformations reducing drastically to 1 per 300,000 pieces. Clearly, if malformations can be effectively decreased to zero, it means that greater profitability can be achieved. At the same time, savings can be realized with regard to customer oil resources and energy wastage prevention. Therefore, the "Zero Air Injection-Molding System" is an injection-molding technology that responds to the changing times. It also generates significant profitability gains, also contributing to a reduction in CO
2 omissions, and saving oil resources.
2. The "Zero Air Injection-Molding System" addresses the following malformation issues:
(1) |
Singed resins ← This does not occur because there is no gas compression within molds when using the "Zero Air Injection-Molding System." |
(2) |
Weld lines ← This does not occur because there are no gases present in welded parts when using the "Zero Air Injection-Molding System." |
(3) |
Transfer defects ← This does not occur because there are no gaseous layers present between the surface of the mold and injected resins when using the "Zero Air Injection-Molding System." |
(4) |
Short mold ← This does not occur because optimum injection speeds can be employed when using the "Zero Air Injection-Molding System." |
(5) |
Bubbling ← This does not occur because there are no gases surrounding injected resins when using the "Zero Air Injection-Molding System." |
(6) |
Tarnishing of Resin Surface ← This does not occur because there are no gaseous layers present between the surface of the mold and injected resins when using the "Zero Air Injection-Molding System." |
(7) |
Burring ← This does not occur because excess injection pressure isn't required for gas-venting when using the "Zero Air Injection-Molding System." |
3. Merits of Introducing the "Zero Air Injection-Molding System"
(1) |
Essential when conducting thin-wall, high-speed injection-molding activities |
(2) |
Shortened Cycles Since no gaseous layers exist between the surface of molds and resins, cooling efficacy is enhanced. For the same reason there is an elimination of transfer malformations. |
(3) |
Mold cleaning systems frequencies decrease to 1/3 – 1/6 of what is required when not using the "Zero Air Injection-Molding System." For this reason, the "Zero Air Injection-Molding System" could be considered as essential when conducting high-cycle molding operations. |
4. Reduced Size of Injection-Molding Machinery
Compared to when "natural ventilation" is deployed, the "Zero-Air Injection–Forming System" allows for the injection of resins at an injection pressure that is 30% reduced. With equipment that offers a plasticizing capacity, molding of resins is possible with a smaller mold-locking force than is required when using "natural ventilation."
5.Revising Molds to Handle Vacuums
Revising existing mold structures (e.g. cavity air-tightness, gas-venting designs and vacuum-circuitry) is required for vacuum-venting. In the texts that are provided to customers, we incorporate a knowledge of such matters that has been gained over 25 years of experience.