Summary Of Automobile Headlight Lens Mould Technology

Summary of automobile headlight lens mold technology

Automobile headlight lens mold manufacturing plant

Car headlight lens, also known as light distribution lens, is the transparent part outside the car headlight. The internal and external surfaces require high transparency.

Characteristics of plastic parts: The color is transparent, and the appearance is very demanding. Spots, gate and push rod marks are not allowed, and the less bubbles, halos, shrinkage depressions, weld lines, and other molding defects are allowed.

In view of the transparent color of the plastic parts, ordinary runners are used to avoid the color difference of the plastic parts and increase the transparency. In addition, the appearance of the plastic parts is not allowed to have gate marks, so the side gate pouring system is adopted.

The precision mold adopts the combined cooling system of "vertical cooling water pipe, inclined cooling water pipe, and partition well". The water channels are arranged along the cavity, which effectively guarantees the accuracy of plastic parts and the labor productivity of the mold. The plastic parts are pushed out by the push block, which is not only stable, but also the traces of the line will not affect the appearance of the product.

The design of the exhaust system is very important in the mold of the forming transparent chamber. If the exhaust is not good, it will seriously affect the quality of the plastic parts. Since the product material is PC, the exhaust front is designed to be 0.02mm. Refer to CAE analysis for the product. Reasonable design of venting can reduce local burnout caused by bubbles or trapped air during injection molding.

Specializing in the production of automobile lamp molds, automobile headlamp lens molds, automobile headlamp decorative frame molds, and automobile lamp reflector molds.

Introduction to high-quality automotive headlight products and mold structure technology        

Summary of automobile headlight lens mold technology

The lateral core-pulling mechanism is the most important core structure of the mold. The mold cleverly uses the inner core-pulling mechanism of "T-slot guide block + oblique inner sliding block" to successfully solve the problem of lateral parting of transparent parts on the surface of plastic parts. The problem of the next trace. The mold adopts an ordinary pouring system and feeds by fan-shaped gate tower. Compared with the previous hot runner pouring system, it not only greatly reduces the cost, but also has better light transmittance of the lamp lens. The mold adopts a combined cooling system of "vertical cooling water pipe + inclined cooling water pipe + spacer water well". The water channels are arranged along the cavity, and the molding cycle is successfully controlled within 35 seconds, which effectively guarantees the accuracy of the plastic parts and the labor of the mold productivity. The plastic parts are pushed out by pushing blocks, which is not only stable, but also the traces left have no effect on the appearance.   All the quality indicators of plastic parts meet the design requirements, which is a successful example of large, complex and long-life injection mold design.  Automotive headlight decorative frame mold technology summary   Automotive headlight decorative frame is one of the most important parts of the car lamp, the appearance requirements are strict, and the mold needs to be electroplated. For automobile headlight decorative frame molds, the following points should be paid attention to when designing: (1) Welding lines should be avoided first for electroplated parts, because any welded lines on electroplated parts will appear and affect the appearance of plastic parts. When designing the pouring system Avoid welding lines. If welding lines are unavoidable, try to drive them to non-appearance areas, and pass mold flow analysis and verification before pouring system design.   

(2) The surface of the decorative frame is generally designed with patterns. When designing the mold, pay attention to the depth of the pattern of the plastic part, which is generally easy to produce flow lines. (3) The molding process range of plastic parts is small, and the surface of plastic parts is easy to produce bright spots and is difficult to control. When designing the mold gating system, the runner should be thick and large. The gate adopts a fan-shaped gate, and the maximum gate width is about 35~40mm, which is good for melt filling. (4) Decorative frame plastic parts are prone to sticking to the mold. The pre-design precautions to solve the sticking mold of plastic parts are generally: (1) Design an inverted pattern on the inner side of the plastic part that is easy to stick to the mold and has a large tightening force. The depth of the undercut pattern is 0.5~1mm, and the undercut pattern is designed near the rounded corner of the plastic part. (2) Where the plastic part has a large fixed mold packing force, the inner side of the corresponding plastic part is designed with stiffeners, and an inverted hook is designed on the push rod. According to the characteristics of this plastic part, reinforcement ribs and BOSS columns (commonly known as Si tube columns) should be designed on the inner side plastic parts of the 6 LED lamp areas to avoid deformation of the plastic parts. In the mold design, the area with large holding force of the plastic part is more than 5 degrees, and the 0.5mm deep inverted pattern is designed on the movable mold side, so the mold ejection and ejection are smooth, and the movement of each mechanism is smooth. The mold is safe, stable and reliable, and the mold does not have the phenomenon of sticking, which successfully solved the problem of sticking of such plastic parts. After the trial production of the mold of this model, the loading effect is good and the size is stable. The facelifted car lights have been recognized and praised by customers at the auto show, creating certain economic benefits for customers. Summary of automobile headlight lamp shell mold technology   The plastic parts of automobile lamp shells are prone to sticking molds. The pre-design preventions to solve the sticking molds of automobile lamp shell plastic parts are generally: 1. Check the plastic parts tightly before mold design Whether the demolding slope of the strong area is greater than 3 degrees, try to design it at 5 degrees or more to avoid dragging the fixed mold and plastic parts. 2. Design an inverted buckle pattern on the inner side of the plastic part where it is easy to stick to the mold and have a large packing force. The depth of the inverted buckle pattern is 0.5~1mm, and the inverted buckle pattern is designed near the round corner of the plastic part. 3. Where the plastic part has a large clamping force, the inner side of the corresponding plastic part is designed with stiffeners, or an inverted hook is designed on the push rod. In the mold design, the area with large holding force of the plastic part is more than 5 degrees, and the 0.5mm deep inverted pattern is designed on the movable mold side, so the mold ejection and ejection are smooth, and the movement of each mechanism is smooth. The mold is safe, stable and reliable, and the mold does not have the phenomenon of sticking, which successfully solved the problem of sticking to the lamp shell plastic parts. After the trial production of the mold of this model, the loading effect is good and the size is stable. ‘

Summary of mold technology for automobile headlight reflector 

For automobile lamp reflector molds, the main design points are as follows: (1) Special injection molding process equipment is required, and injection molding machines dedicated to the production of BMC plastics must be used, which requires very strict injection molding process equipment. (2) BMC materials are extremely hard plastics. In the mold design, the heating system and the parting surface design discharging system need to be designed. The molded parts must be quenched to improve wear resistance and mold life. (3) The reflector plastic part is a device to prevent direct light from being used on car lights, reflect the light and avoid direct light, and the light distribution requirements are strict. Plastic parts are the most important appearance parts of automobiles. There are many patterns on the surface of the plastic parts for the purpose of decoration and beauty. (4) The ejection system of the mold design of BMC material should be balanced, and the push rod specification should be designed as large as possible, and the quantity should be as large as possible, otherwise it will cause difficulty in demolding the plastic part. (5) Because the demoulding slope of high-gloss electroplated parts is too small, it will cause demoulding difficulties, so the demoulding slope of the side wall of the reflector plastic part should be designed as large as possible. Generally, it is recommended to be 5°~10°. when

However, the premise is that the function and shape of the plastic part cannot be affected. (6) Plastic parts cannot have sharp corners, and all corners need to be designed with rounded corners, because the molded parts of the mold are prone to stress cracking after quenching. (7) Note that the left and right reflector cap holes and the surface patterns of the plastic parts are horizontally shifted, and cannot be designed to be mirror-symmetrical, because the bulb and the cap are not divided into left and right, and the other features are mirror-symmetrical.