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1、Athin-wallrevolutionisrisingcarefullyBy:RobertNeilleyFirstshowninaNetstalSynergymachineintheU.K.,thissingle-cavitydevelopmenttoolmadebyStackTeckcutthecycletimefora200-mlthin-wallcupbymorethanhalfandusedlessmaterialtodoit.Im-Pakusesashotpotatopthestationaryp
2、lateforcontrolledinjection.Thefullshotenterswhilethemoldisclosingandformsabillet.Theclosingcoreforcesmaterialupthesidewalls.Moldclosurelimitstheflow.Im-PaksaysL/Tratioscanbelonger,wallsandbasethinner,andtherimandstackingshoulderthickerwithoutdeformation.The
3、injection-compressionmoldtechnologythatU.K.-basedIm-PakTechnologiesisaimingatthin-wallpolypropylenecontainershasbeengaininggroundsinceitslaunchatNPE2003,andforgoodreason.Itcouldcutalready-fastthin-wallcycletimesinhalf.Tellmostpackagingmoldersyoucancutacycle
4、by5%andyouhavetheircloseattention;50%cancausehyperventilation.Im-Pakanditsdevelopmentpartner,moldmakerStackTeck(Brampton,ON),aretakingcaretonotoverhypeit.Aquickexample:Asingle-cavitydevelopmentmoldbuiltbyStackTeckwillmakea200-mlPPdrinkingcupin3to3.5secondsu
5、singnormaltechnology.WithIm-Pak抯technologyitcanrunat2seconds,andusessignificantlylessmaterialpercupwhiledoingit.IntoaClosingMoldIm-Pak抯technologyusesashootingpotatopthestationarymoldplatetoinjectafullshotofmaterialintothecavityasthecoresideisclosing.Themate
6、rialformsabilletinthebaseofthecoreandthenisforcedupthesidesofthemoldathighspeedbytheforceoftheenteringcore.Themoldclosesoffbeforematerialcanflashthroughthetop.DavidChiddy,whoheadsupsalesandmarketingforIm-Pak,saystheprocessislikethemovementsequenceofatogglem
7、achine:fastacceleration,last-momentslowdown,closing.Toensureprecisefilling,eachcavityhasitsownshotpot,andChiddysaysthecavitynumberistheoreticallyunlimitedsincetheshotpotseliminatetheneedtobalancethehotrunners.Injectionpressureisabout500bar(7250psi),compared
8、withabout2400bar(34,800psi)inconventionalmolding.Materialprocessingcanbedoneatamuchlowertemperaturethaninconventionalmolding.StandardPPcanbeprocessedatabout165篊ratherthanthemorenormal230篊,andalower-MFI