China WEL Techno Co., LTD. company news

        Batteries are indispensable in the operation of most electronic devices,providing the necessary power supply.In the connection between batteries and circuits,the battery spring is a crucial component,although it may not be visually prominent.Its primary function is to ensure a stable connection between the battery and the circuit,thereby guaranteeing the smooth flow of electric current.Below is a detailed introduction to the material selection and surface treatment processes for battery springs.      Material Selection   1, Phosphor Bronze:This is the most commonly used material for battery springs and is widely applied in various consumer electronics and battery cases.Phosphor bronze offers good electrical conductivity and elasticity,providing stable contact pressure and durability.Additionally,its corrosion resistance ensures reliable performance in various environments.   2, Stainless Steel:When cost is a significant consideration,stainless steel is an economical alternative.It has high strength and corrosion resistance but relatively poor electrical conductivity.Therefore,stainless steel battery springs are typically used in applications where electrical conductivity is not a primary concern.   3, Beryllium Copper:For applications requiring higher electrical conductivity and elasticity,beryllium copper is an ideal choice.It not only has excellent electrical conductivity but also possesses good elastic modulus and fatigue resistance,making it suitable for high-end electronic products.   4, 65Mn Spring Steel:In some special applications,such as the heat sinks of laptop graphics cards,65Mn spring steel may be used for battery springs.This material has high strength and elasticity,maintaining stable performance under significant loads.   5, Brass:Brass is another commonly used material for battery springs,offering good electrical conductivity and machinability.It is typically employed in applications where both cost and electrical conductivity are important considerations.     Surface Treatment   1, Nickel Plating:Nickel plating is a common surface treatment method that enhances the corrosion resistance and wear resistance of battery springs.The nickel layer also improves electrical conductivity,ensuring good contact between the battery spring and the battery.   2, Silver Plating:Silver plating can further improve the electrical conductivity and oxidation resistance of battery springs.Silver has excellent electrical conductivity,reducing contact resistance and ensuring stable current transmission.However,the cost of silver plating is relatively high,usually applied in situations where high electrical conductivity is required.   3, Gold Plating:For high-end products,gold plating is an ideal surface treatment.Gold has exceptional electrical conductivity and oxidation resistance,providing long-term stable electrical performance.The gold layer also prevents oxidation and corrosion,extending the service life of the battery spring.     Future Trends   As electronic products continue to evolve towards miniaturization and higher performance,the design and manufacturing of battery springs are also advancing.In the future,there may be the emergence of more high-performance materials and advanced surface treatment technologies to meet higher performance requirements and more complex application environments.For instance,the application of nanomaterials could further enhance the electrical conductivity and mechanical properties of battery springs,while environmentally friendly surface treatment processes will focus more on reducing environmental impact.Additionally,with the proliferation of smart electronic devices,the design of battery springs will increasingly emphasize intelligence and integration to achieve better user experiences and higher system performance.

Common Issues and Solutions in UV Coating Process During the coating process,there are often many issues with the UV coating process.Below is a list of these issues along with discussions on how to resolve them:   Pitting Phenomenon Causes: a.Ink has undergone crystallization. b.High surface tension,poor wetting of the ink layer. Solutions: a.Add 5%lactic acid to the UV varnish to break the crystallized film or remove the oil quality or perform a roughening treatment. b.Reduce surface tension by adding surfactants or solvents with lower surface tension.   Streaking and Wrinkling Phenomenon Causes: a.UV varnish is too thick,excessive application,mainly occurring in roller coating. Solutions: a.Reduce the viscosity of the UV varnish by adding an appropriate amount of alcohol solvent to dilute it.   Bubbling Phenomenon Causes: a.Poor quality of the UV varnish,which contains bubbles,often occurring in screen coating. Solutions: a.Switch to high-quality UV varnish or let it stand for a while before use.   Orange Peel Phenomenon Causes: a.High viscosity of UV varnish,poor leveling. b.Coating roller is too coarse and not smooth,with excessive application. c.Uneven pressure. Solutions: a.Reduce viscosity by adding leveling agents and appropriate solvents. b.Select a finer coating roller and reduce the application amount. c.Adjust the pressure.   Sticky Phenomenon Causes: a.Insufficient ultraviolet light intensity or too fast machine speed. b.UV varnish has been stored for too long. c.Excessive addition of non-reactive diluents. Solutions: a.When the curing speed is less than 0.5 seconds,the ultraviolet light power should be no less than 120w/cm. b.Add a certain amount of UV varnish curing accelerator or replace the varnish. c.Pay attention to the reasonable use of diluents.   Poor Adhesion,Inability to Coat or Mottling Phenomenon Causes: a.Crystallized oil or spray powder on the surface of the printed material, b.excessive ink and drying oil in the water-based ink. c.Too low viscosity of UV varnish or too thin coating. d.Too fine an anilox roller. e.Inappropriate UV curing conditions. f.Poor adhesion of the UV varnish itself and poor adhesion of the printed material. Solutions: a.Eliminate the crystallized layer,perform roughening treatment or add 5%lactic acid. b.Choose ink auxiliaries that match the UV oil process parameters,or wipe with a cloth. c.Use high-viscosity UV varnish and increase the application amount. d.Replace the anilox roller that matches the UV varnish. e.Check if the ultraviolet mercury lamp tube is aged,or if the machine speed is not suitable,and choose appropriate drying conditions. f.Apply a primer or replace with special UV varnish or choose materials with good surface properties.   Lack of Gloss and Brightness Causes: a.Too low viscosity of UV varnish,too thin coating,uneven application. b.Rough printing material with strong absorption. c.Too fine an anilox roller,too little oil supply. d.Excessive dilution with non-reactive solvents. Solutions: a.Appropriately increase the viscosity and application amount of UV varnish,adjust the application mechanism to ensure even application. b.Choose materials with weak absorption,or apply a primer first. c.Increase the anilox roller to improve oil supply. d.Reduce the addition of non-reactive diluents such as ethanol.   White Spot and Pinhole Phenomenon Causes: a.Too thin application or too fine an anilox roller. b.Inappropriate selection of diluents. c.Excessive surface dust or coarse spray powder particles. Solutions: a.Select appropriate anilox rollers and increase the coating thickness. b.Add a small amount of smoothing agent and use reactive diluents that participate in the reaction. c.Maintain surface cleanliness and environmental cleanliness,do not spray powder or spray less powder or choose high-quality spray powder.   Strong Residual Odor Causes: a.Incomplete drying,such as insufficient light intensity or excessive non-reactive diluents. b.Poor antioxidant interference capability. Solutions: a.Ensure thorough curing and drying,choose appropriate light source power and machine speed,reduce or avoid the use of non-reactive diluents. b.Strengthen the ventilation and exhaust system.   UV Varnish Thickening or Gelation Phenomenon Causes: a.Excessive storage time. b.Incomplete light avoidance during storage. c.Storage temperature is too high. Solutions: a.Use within the specified time,generally 6 months. b.Strictly store in a light-avoiding manner. c.The storage temperature must be controlled around 5℃25℃.   UV Curing and Automatic Bursting Causes: a.After the surface temperature is too high,the polymerization reaction continues. Solutions: a.If the surface temperature is too high,increase the distance between the lamp tube and the surface of the object being illuminated,and use cold air or a cold roller press.    

UV Paint and PU Paint   UV paint refers to a type of paint that uses ultraviolet light curing technology.This kind of paint must be exposed to ultraviolet light for 2 seconds on specialized equipment to fully cure.After curing,the surface of UV paint has a certain degree of hardness and wear resistance,with a hardness of 4H per unit area. PU paint,on the other hand,uses polyurethane paint. The main differences between the two are as follows: 1, Different processing methods. The light curing process used by UV paint is pollution-free during the application,making it more environmentally friendly than PU paint.From a factory processing perspective,it benefits the health of workers and the environment.From a production standpoint,it is a newer and more advanced product.However,for consumers,the solvents in the paint surface have already evaporated during the processing,so whether it is UV paint produced using the light curing process or PU paint produced using traditional methods,it does not pose a pollution hazard to the user. In terms of process,UV paint has a better gloss. 2,In terms of use,the hardness and wear resistance of UV paint are superior to those of PU paint.

The Basic Principles of Plastic Electroplating Part Design(Water Plating)   Electroplated parts have many special design requirements in the design process,which can be summarized as follows: • The substrate is best made of ABS material,as ABS has good adhesion of the coating after electroplating,and it is also relatively inexpensive. • The surface quality of the plastic part must be very good,as electroplating cannot cover up some of the defects from injection molding,and it often makes these defects more apparent.     When designing the structure,there are several points to pay attention to in terms of appearance suitability for electroplating treatment: • Surface protrusions should be controlled between 0.1 to 0.15mm/cm,and sharp edges should be avoided as much as possible. • If there is a design with blind holes,the depth of the blind hole should not exceed half of the hole's diameter,and do not make demands on the color of the bottom of the hole. • Appropriate wall thickness should be used to prevent deformation,preferably between 1.5mm and 4mm.If it is necessary to make it thinner,reinforcement structures should be added in corresponding positions to ensure that the deformation during electroplating is within a controllable range. • In the design,the needs of the electroplating process should be considered.Since the working conditions of electroplating are generally at temperatures between 60 to 70 degrees Celsius,under hanging conditions,it is difficult to avoid deformation if the structure is not reasonable.Therefore,attention should be paid to the position of the water mouth in the design of the plastic part,and there should be appropriate hanging positions to prevent damage to the required surface when hanging,as shown in the following figure,the square hole in the middle is specifically designed for hanging. • Additionally,it is best not to have metal inserts in the plastic part,as the coefficients of thermal expansion are different between the two materials.When the temperature rises,the electroplating solution can seep into the gaps,causing certain impacts on the structure of the plastic part.

          In product design,buttons play a crucial role;they are not only an essential medium for user interaction with the product but also directly affect the user experience.Below are some button design cases we have encountered in plastic product design,along with some design considerations,while integrating the philosophy of WELTECHNO(Weile Technology).  

       In product design,buttons play a crucial role;they are not only an essential medium for user interaction with the product but also directly affect the user experience.Below are some button design cases we have encountered in plastic product design,along with some design considerations,while integrating the philosophy of WELTECHNO(Weile Technology).    

           In product design,buttons play a crucial role;they are not only an essential medium for user interaction with the product but also directly affect the user experience.Below are some button design cases we have encountered in plastic product design,along with some design considerations,while integrating the philosophy of WELTECHNO.   •Classification of Plastic Buttons: •Cantilever Buttons:Fixed by a cantilever to secure the button,suitable for scenarios requiring a larger stroke and good tactile feel. •Seesaw Buttons:Often come in pairs,working on a principle similar to a seesaw,triggered by rotating around the protruding column in the middle of the button,suitable for designs with space constraints. •Inlaid Buttons:Buttons are sandwiched between the upper cover and decorative parts,suitable for products that require aesthetic and integrated design.   •Materials and Manufacturing Processes: •"P+R"Buttons:Plastic+rubber structure,where the keycap material is plastic and the soft rubber material is rubber,suitable for scenarios requiring a soft touch and good cushioning. •IMD+R Buttons:In-Mold Decoration(IMD)injection molding technology,with a hardened transparent film on the surface,a printed pattern layer in the middle,and a plastic layer on the back,suitable for products that need to be resistant to friction and maintain bright colors over time.   •Design Considerations: •Button Size and Relative Distance:According to ergonomics,the center distance of vertical buttons should be≥9.0mm,and the center distance of horizontal buttons should be≥13.0mm,with the minimum size of commonly used functional buttons being 3.0×3.0mm. •Design Clearance Between Buttons and the Base:Proper clearance should be left based on materials and manufacturing processes to ensure the button moves freely and rebounds smoothly. •Height of Buttons Protruding from the Panel:The height of ordinary buttons protruding from the panel is generally 1.20-1.40mm,and for buttons with a larger surface curvature,the height from the lowest point to the panel is generally 0.80-1.20mm.             Incorporating the philosophy of WELTECHNO into the design means that when we design plastic buttons,we focus not only on functionality and aesthetics but also on innovation,durability,and environmental friendliness.We are committed to creating plastic buttons that are both ergonomic and highly durable through advanced technology and materials,while reducing environmental impact and achieving sustainable development.With such a design philosophy,we hope to provide customers with practical and aesthetically pleasing products,enhancing user experience while also contributing to environmental protection.  

          In the plastic part manufacturing process,dimensional control is a key factor in ensuring product quality and functionality,while cost control is an important aspect of maintaining the competitiveness of the enterprise.As a plastic part manufacturer,WELTECHNO will achieve dimensional control and cost optimization through the following aspects:           •Part Structural Design:       •Simplified Design:By simplifying the part structure and reducing complex geometric shapes and features,the difficulty and cost of mold manufacturing can be reduced,while also simplifying the molding process to minimize dimensional deviations.        •Reasonable Tolerance Allocation:During the design phase,tolerances are allocated reasonably based on the functional requirements of the part.Key dimensions are strictly controlled,while non-critical dimensions can be appropriately relaxed to balance cost and quality.          •Material Selection:       •Shrinkage Rate Control:Select plastic materials with a stable shrinkage rate to reduce dimensional changes after molding and improve dimensional stability.       •Cost-Benefit Analysis:Choose materials with the highest cost-benefit ratio that meet performance requirements to control material costs.         •Mold Design:       •High-Precision Molds:Use high-precision mold manufacturing techniques,such as CNC machining and EDM,to ensure the precision of the mold,thereby controlling the dimensions of the parts.       •Multi-Cavity Molds:Design multi-cavity molds to increase production efficiency,reduce the cost per part,and ensure dimensional consistency by replicating consistent mold cavities.         •Molding Control:      •Temperature Control:Precisely control the temperature of the mold and material to reduce dimensional deviations caused by temperature changes.      •Pressure Control:Reasonably set injection pressure and holding pressure to ensure the material is fully filled in the mold and reduce dimensional changes caused by shrinkage.      •Cooling System:Design an effective cooling system to ensure uniform cooling of the parts and reduce dimensional deviations caused by uneven cooling.         •Process Monitoring and Quality Control:       •Real-Time Monitoring:Implement real-time monitoring during the production process,such as using sensors to monitor mold temperature and pressure,to ensure the stability of molding conditions.      •Automated Inspection:Use automated quality inspection equipment,such as CMM,to quickly and accurately detect part dimensions,and promptly identify and correct deviations.        •Cost Management:      •Production Efficiency Improvement:Improve production efficiency by optimizing production processes and reducing downtime,thereby reducing unit costs.      •Material Utilization:Optimize material utilization to reduce waste and material waste,thereby reducing material costs. •Long-Term Partnerships:Establish long-term partnerships with suppliers to obtain more favorable material prices and better services.         •Continuous Improvement:       •Feedback Loop:Establish a feedback loop from production to quality inspection,continuously collect data,analyze problems,and continuously improve the production process.       •Technology Updates:Invest in new technologies and equipment to improve production efficiency and product quality while reducing costs. Through the above measures,WELTECHNO can ensure precise control of plastic part dimensions while effectively managing costs and maintaining market competitiveness.         Dimension Tolerance Grades for Plastic Products Nominal Size Tolerance Grades 1 2 3 4 5 6 7 8 Tolerance Values -3 0.04 0.06 0.08 0.12 0.16 0.24 0.32 0.48 >3-6 0.05 0.07 0.08 0.14 0.18 0.28 0.36 0.56 >6-10 0.06 0.08 0.10 0.16 0.20 0.32 0.40 0.64 >10-14 0.07 0.09 0.12 0.18 0.22 0.36 0.44 0.72 >14-18 0.08 0.1 0.12 0.2 0.26 0.4 0.48 0.8 >18-24 0.09 0.11 0.14 0.22 0.28 0.44 0.56 0.88 >24-30 0.1 0.12 0.16 0.24 0.32 0.48 0.64 0.96 >30-40 0.11 0.13 0.18 0.26 0.36 0.52 0.72 1.0 >40-50 0.12 0.14 0.2 0.28 0.4 0.56 0.8 1.2 >50-65 0.13 0.16 0.22 0.32 0.46 0.64 0.92 1.4 >65-85 0.14 0.19 0.26 0.38 0.52 0.76 1 1.6 >80-100 0.16 0.22 0.3 0.44 0.6 0.88 1.2 1.8 >100-120 0.18 0.25 0.34 0.50 0.68 1.0 1.4 2.0 >120-140   0.28 0.38 0.56 0.76 1.1 1.5 2.2 >140-160   0.31 0.42 0.62 0.84 1.2 1.7 2.4 >160-180   0.34 0.46 0.68 0.92 1.4 1.8 2.7 >180-200   0.37 0.5 0.74 1 1.5 2 3 >200-225   0.41 0.56 0.82 1.1 1.6 2.2 3.3 >225-250   0.45 0.62 0.9 1.2 1.8 2.4 3.6 >250-280   0.5 0.68 1 1.3 2 2.6 4 >280-315   0.55 0.74 1.1 1.4 2.2 2.8 4.4 >315-355   0.6 0.82 1.2 1.6 2.4 3.2 4.8 >355-400   0.65 0.9 1.3 1.8 2.6 3.6 5.2 >400-450   0.70 1.0 1.4 2.0 2.8 4.0 5.6 >450-500   0.80 1.1 1.6 2.2 3.2 4.4 6.4 Notes: 1. This standard divides the accuracy grades into 8 levels, from 1 to 8. 2. This standard only specifies tolerances, and the upper and lower deviations of the basic size can be allocated as needed. 3. For dimensions without specified tolerances, it is recommended to use the 8th grade tolerance from this standard. 4. The standard measurement temperature is 18-22 degrees Celsius, with a relative humidity of 60%-70% (measurements taken 24 hours after the product is formed).

Hardness is a measure of a material's resistance to local deformation,particularly plastic deformation,indentation,or scratching,and is an indicator of the material's softness or hardness.The measurement methods for hardness mainly include indentation,rebound,and scratch methods.Among them,HRC,HV,and HB are three commonly used hardness indicators,representing Rockwell hardness on the C scale,Vickers hardness,and Brinell hardness,respectively.Here is an introduction to these three types of hardness,their application scenarios,and their relationship with tensile strength: 1.HRC(Rockwell Hardness C scale) • Definition:In the Rockwell hardness test,a diamond cone indenter is used to measure the depth of plastic deformation of the indentation to determine the hardness value. • Application Scenario:Mainly used for measuring harder materials,such as heat-treated steel,bearing steel,tool steel,etc. • Relationship with Tensile Strength:When the hardness of steel is below 500HB,the tensile strength is directly proportional to the hardness,i.e.,[text{Tensile Strength(kg/mm²)}=3.2timestext{HRC}]. 2.HV(Vickers Hardness) • Definition:Vickers hardness uses a diamond square pyramid indenter with a relative face angle of 136°,pressing into the material surface with a specified test force,and the hardness value is represented by the average pressure on the unit surface area of the square pyramid indentation. • Application Scenario:Suitable for measuring various materials,especially thinner materials and surface hardening layers,such as carburized and nitrided layers. • Relationship with Tensile Strength:There is a certain corresponding relationship between hardness value and tensile strength,but this relationship is not valid in all scenarios,especially under different heat treatment conditions. 3.HB(Brinell Hardness) • Definition:Brinell hardness uses a hardened steel ball or tungsten carbide ball of a certain diameter to press into the surface of the metal to be tested with a certain test load,measuring the diameter of the indentation on the surface,and calculating the ratio of the spherical surface area of the indentation to the load. • Application Scenario:Generally used when the material is softer,such as non-ferrous metals,steel before heat treatment,or steel after annealing. • Relationship with Tensile Strength:When the hardness of steel is below 500HB,the tensile strength is directly proportional to the hardness,i.e.,[text{Tensile Strength(kg/mm²)}=frac{1}{3}timestext{HB}]. Relationship between Hardness and Tensile Strength There is an approximate corresponding relationship between hardness values and tensile strength values.This is because the hardness value is determined by the initial plastic deformation resistance and the continued plastic deformation resistance.The higher the strength of the material,the higher the plastic deformation resistance,and the higher the hardness value.However,this relationship may vary under different heat treatment conditions,especially in the low-temperature tempering state,where the distribution of tensile strength values is very scattered,making it difficult to accurately determine. In summary,HRC,HV,and HB are three commonly used methods for measuring material hardness,each applicable to different materials and scenarios,and they have a certain relationship with the material's tensile strength.In practical applications,the appropriate hardness test method should be chosen based on the characteristics of the material and the testing requirements.     Hardness Comparison Chart Tensile Strength N/mm² Vickers Hardness Brinell Hardness Rockwell Hardness Rm HV HB HRC 250 80 76   270 85 80.7   285 90 85.2   305 95 90.2   320 100 95   335 105 99.8   350 110 105   370 115 109   380 120 114   400 125 119   415 130 124   430 135 128   450 140 133   465 145 138   480 150 143   490 155 147   510 160 152   530 165 156   545 170 162   560 175 166   575 180 171   595 185 176   610 190 181   625 195 185   640 200 190   660 205 195   675 210 199   690 215 204   705 220 209   720 225 214   740 230 219   755 235 223   770 240 228 20.3 785 245 233 21.3 800 250 238 22.2 820 255 242 23.1 8350 260 247 24 850 265 252 24.8 865 270 257 25.6 880 275 261 26.4 900 280 266 27.1 915 285 271 27.8 930 290 276 28.5 950 295 280 29.2 965 300 285 29.8 995 310 295 31 1030 320 304 32.2 1060 330 314 33.3 1095 340 323 34.4 1125 350 333 35.5 1115 360 342 36.6 1190 370 352 37.7 1220 380 361 38.8 1255 390 371 39.8 1290 400 380 40.8 1320 410 390 41.8 1350 420 399 42.7 1385 430 409 43.6 1420 440 418 44.5 1455 450 428 45.3 1485 460 437 46.1 1520 470 447 46.9 15557 480 -456 47 1595 490 -466 48.4 1630 500 -475 49.1 1665 510 -485 49.8 1700 520 -494 50.5 1740 530 -504 51.1 1775 540 -513 51.7 1810 550 -523 52.3 1845 560 -532 53 1880 570 -542 53.6 1920 580 -551 54.1 1955 590 -561 54.7 1995 600 -570 55.2 2030 610 -580 55.7 2070 620 -589 56.3 2105 630 -599 56.8 2145 640 -608 57.3 2180 650 -618 57.8   660   58.3   670   58.8   680   59.2   690   59.7   700   60.1   720   61   740   61.8   760   62.5   780   63.3   800   64   820   64.7   840   65.3   860   65.9   880   66.4   900   67   920   67.5   940   68

Injection molding defects and abnormalities are ultimately reflected in the quality of the injection molded products.The defects of injection molded products can be divided into the following points: (1)Insufficient product injection; (2)Product flashing; (3)Sink marks and bubbles in the product; (4)Weld lines on the product; (5)Brittle product; (6)Discoloration of plastic; (7)Silver streaks,patterns,and flow marks on the product; (8)Murkiness at the product gate area; (9)Warping and shrinkage of the product; (10)Inaccurate product dimensions; (11)Product sticking to the mold; (12)Material sticking to the runner; (13)Nozzle drooling.   Below is a detailed description of the causes and solutions for each issue.     1.----- How to Overcome Insufficient Product Injection Insufficient product material is often due to the material curing before filling the mold cavity,but there are many other reasons.   (a)Equipment causes: ① Interruption of material in the hopper; ② Partial or complete blockage of the hopper neck; ③ Insufficient material feed; ④ Abnormal operation of the material feed control system; ⑤ Too small plasticizing capacity of the injection molding machine; ⑥ Injection cycle abnormalities caused by equipment.   (b)Injection molding conditions causes: ① Too low injection pressure; ② Too much loss of injection pressure during the injection cycle; ③ Too short injection time; ④ Too short full pressure time; ⑤ Too slow injection rate; ⑥ Interruption of material flow in the mold cavity; ⑦ Uneven filling rate; ⑧ Injection cycle abnormalities caused by operating conditions.   (c)Temperature causes: ① Increase the barrel temperature; ② Increase the nozzle temperature; ③ Check the millivoltmeter,thermocouple,resistance heating coil(or far-infrared heating device),and heating system; ④ Increase the mold temperature; ⑤ Check the mold temperature control device.   (d)Mold causes: ① Too small runner; ② Too small gate; ③ Too small nozzle hole; ④ Unreasonable gate position; ⑤ Insufficient number of gates; ⑥ Too small cold slug well; ⑦ Insufficient venting; ⑧ Injection cycle abnormalities caused by the mold;   (e)Material causes:The material has poor flowability.     2.----- How to Overcome Product Flashing and Overflow: Product flashing is often caused by mold defects,other causes include:injection force greater than locking force,material temperature too high,insufficient venting,overfeeding,foreign objects on the mold,etc.   (a)Mold issues: ① Cavity and core not tightly closed; ② Cavity and core misalignment; ③ Templates not parallel; ④ Template deformation; ⑤ Foreign objects fallen into the mold plane; ⑥ Insufficient venting; ⑦ Vent holes too large; ⑧ Injection cycle abnormalities caused by the mold.   (b)Equipment issues: ① The projected area of the product exceeds the maximum injection area of the injection molding machine; ② Incorrect installation adjustment of the injection molding machine templates; ③ Incorrect mold installation; ④ Locking force cannot be maintained; ⑤ Injection molding machine templates not parallel; ⑥ Uneven deformation of tie bars; ⑦ Injection cycle abnormalities caused by equipment.   (c)Injection molding conditions issues: ① Too low locking force; ② Too high injection pressure; ③ Too long injection time; ④ Too long full pressure time; ⑤ Too fast injection rate; ⑥ Uneven filling rate; ⑦ Interruption of material flow in the mold cavity; ⑧ Overfeeding control; ⑨ Injection cycle abnormalities caused by operating conditions.   (d)Temperature issues: ① Too high barrel temperature; ② Too high nozzle temperature; ③ Too high mold temperature.   (e)Equipment issues: ① Increase the plasticizing capacity of the injection molding machine; ② Make the injection cycle normal;   (f)Cooling conditions issues: ① Parts cool in the mold for too long,avoid shrinkage from outside to inside,reduce mold cooling time; ② Cool the parts in hot water.     3.----- How to Avoid Sink Marks and Blowholes in Products Sink marks in products are usually due to insufficient force on the product,insufficient material filling,and unreasonable product design,often appearing in thick wall parts near thin walls.Blowholes are caused by insufficient plastic in the mold cavity,the outer circle of plastic cools and solidifies,and the internal plastic contracts to form a vacuum.Mostly due to hygroscopic materials not being dried well,and residues of monomers and other compounds in the material.To determine the cause of blowholes,observe whether the bubbles in the plastic product appear instantly when the mold opens or after cooling.If they appear instantly when the mold opens,it is mostly a material issue;if they appear after cooling,it belongs to the mold or injection molding conditions issue.   (1)Material issues: ① Dry the material; ② Add lubricants; ③ Reduce volatiles in the material.   (2)Injection molding conditions issues: ① Insufficient injection volume; ② Increase injection pressure; ③ Increase injection time; ④ Increase full pressure time; ⑤ Increase injection speed; ⑥ Increase injection cycle; ⑦ Injection cycle abnormalities caused by operating reasons.   (3)Temperature issues: ① Material too hot causing excessive shrinkage; ② Material too cold causing insufficient compaction of the material; ③ Mold temperature too high causing the material at the mold wall not to solidify quickly; ④ Mold temperature too low causing insufficient filling; ⑤ Local overheating spots on the mold; ⑥ Change cooling plans.   (4)Mold issues: ① Increase the gate; ② Increase the runner; ③ Increase the main runner; ④ Increase the nozzle hole; ⑤ Improve mold venting; ⑥ Balance filling rates; ⑦ Avoid interruption of material flow; ⑧ Arrange the gate to feed into the thick wall part of the product; ⑨ If possible,reduce the difference in product wall thickness; ⑩ Injection cycle abnormalities caused by the mold.   (5)Equipment issues: ① Increase the plasticizing capacity of the injection molding machine; ② Make the injection cycle normal;   (6)Cooling conditions issues: ① Parts cool in the mold for too long,avoid shrinkage from outside to inside,reduce mold cooling time; ② Cool the parts in hot water.     4.-----How to Prevent Weld Lines(Butterfly Lines)in Products Weld lines in products are usually caused by low temperature and low pressure at the seam.   (1)Temperature issues: ① Too low barrel temperature; ② Too low nozzle temperature; ③ Too low mold temperature; ④ Too low mold temperature at the seam; ⑤ Uneven plastic melt temperature.   (2)Injection issues: ① Too low injection pressure; ② Too slow injection speed.   (3)Mold issues: Poor venting at the seam; Poor venting of the part; Too small runner; Too small gate; Too small diameter of the three-strand runner inlet; Too small nozzle hole; The gate is too far from the seam,consider adding auxiliary gates; The product wall is too thin,causing premature curing; Core shift,causing one-sided thinness; Mold shift,causing one-sided thinness; The part is too thin at the seam,thicken it; Uneven filling rates; Interruption of material flow.   (4)Equipment issues: ① Too small plasticizing capacity; ② Too much pressure loss in the barrel(piston-type injection molding machine). (5)Material issues: ① Material contamination; ② Poor flowability of the material,add lubricants to improve flowability.   5.-----How to Prevent Brittle Products Brittleness in products is often due to the degradation of materials during the injection molding process or other reasons.   (1)Injection molding issues: The barrel temperature is low;increase the barrel temperature; The nozzle temperature is low;increase it; If the material is prone to thermal degradation,reduce the barrel and nozzle temperatures; Increase the injection speed; Increase the injection pressure; Increase the injection time; Increase the full pressure time; The mold temperature is too low;increase it; High internal stress in the part;reduce internal stress; The part has weld lines;try to reduce or eliminate them; The screw rotation speed is too high,causing material degradation.   (2)Mold issues: ① The part design is too thin; ② The gate is too small; ③ The runner is too small; ④ Add reinforcements and fillets to the part.   (3)Material issues: ① Material contamination; ② The material is not dried properly; ③ Volatiles in the material; ④ Too much recycled material or too many recycling times; ⑤ Low material strength.       (4)Equipment issues: ① The plasticizing capacity is too small; ② There are obstacles in the barrel that cause material degradation.     6.----- How to Prevent Plastic Discoloration Material discoloration is usually due to charring,degradation,and other reasons.   (1)Material issues: ① Material contamination; ② Poor material drying; ③ Too many volatiles in the material; ④ Material degradation; ⑤ Pigment decomposition; ⑥ Additive decomposition.   (2)Equipment issues: ① The equipment is not clean; ② The material is not dried cleanly; ③ The ambient air is not clean,with pigments floating in the air and depositing on the hopper and other parts; ④ Thermocouple malfunction; ⑤ Temperature control system malfunction; ⑥ Damage to the resistance heating coil(or far-infrared heating device); ⑦ Obstacles in the barrel causing material degradation.   (3)Temperature issues: ① The barrel temperature is too high;reduce it; ② The nozzle temperature is too high;reduce it.   (4)Injection molding issues: ① Reduce the screw rotation speed; ② Decrease the back pressure; ③ Decrease the locking force; ④ Reduce the injection pressure; ⑤ Shorten the injection pressure time; ⑥ Shorten the full pressure time; ⑦ Slow down the injection speed; ⑧ Shorten the injection cycle.   (5)Mold issues: ① Consider mold venting; ② Increase the gate size to reduce shear rate; ③ Increase the nozzle hole,main runner,and runner sizes; ④ Remove oils and lubricants from the mold; ⑤ Change the mold release agent.   Additionally,high-impact polystyrene and ABS can also discolor due to stress if the internal stress in the part is high.     7. ----- How to Overcome Silver Streaks and Mottling in Products (1)Material issues: ① Material contamination; ② Material not dried; ③ Inhomogeneous material particles.   (2)Equipment issues: ① Check for obstacles and burrs in the barrel-nozzle flow channel system that affect material flow; ② Drool,use a spring nozzle; ③ Insufficient equipment capacity.   (3)Injection molding issues: ① Material degradation,reduce screw rotation speed,reduce back pressure; ② Adjust injection speed; ③ Increase injection pressure; ④ Extend injection time; ⑤ Extend full pressure time; ⑥ Extend injection cycle.   (4)Temperature issues: ① Barrel temperature too low or too high; ② Mold temperature too low,increase it; ③ Uneven mold temperature. ④ Nozzle temperature too high causes drool,reduce it.   (5)Mold issues: ① Increase the cold slug well; ② Increase the runner; ③ Polish the main runner,runner,and gate; ④ Increase the gate size or change to a fan gate; ⑤ Improve venting; ⑥ Increase mold cavity surface finish; ⑦ Clean the mold cavity; ⑧ Excessive lubricant,reduce it or change it; ⑨ Remove condensation in the mold(caused by mold cooling); ⑩ Material flow through depressions and thick sections,modify the part design; Try localized heating of the gate.     8.-----How to Overcome Murkiness at the Gate Area of the Product The appearance of streaks and murkiness at the gate area of the product is usually caused by"melt fracture"when the material is injected into the mold.   (1)Injection molding issues: ① Increase the barrel temperature; ② Increase the nozzle temperature; ③ Slow down the injection speed; ④ Increase the injection pressure; ⑤ Change the injection time; ⑥ Reduce or change the lubricant.   (2)Mold issues: ① Increase the mold temperature; ② Increase the gate size; ③ Change the gate shape(fan gate); ④ Increase the cold slug well; ⑤ Increase the runner size; ⑥ Change the gate position; ⑦ Improve venting.   (3)Material issues: ① Dry the material; ② Remove contaminants from the material.     9.----- How to Overcome Warping and Shrinkage of the Product Warping and excessive shrinkage of the product are usually due to poor product design,poor gate location,and injection molding conditions.Orientation under high stress is also a factor.   (1) Injection molding issues: Extend the injection cycle; Increase injection pressure without overfilling; Extend injection time without overfilling; Extend full pressure time without overfilling; Increase injection volume without overfilling; Reduce material temperature to reduce warping; Keep the amount of material in the mold to a minimum to reduce warping; Minimize stress orientation to reduce warping; Increase injection speed; Slow down the ejection speed; Anneal the part; Normalize the injection cycle.   (2)Mold issues: ① Change the gate size; ② Change the gate position; ③ Add auxiliary gates; ④ Increase the ejection area; ⑤ Maintain balanced ejection; ⑥ Ensure sufficient venting; ⑦ Increase wall thickness to strengthen the part; ⑧ Add reinforcements and fillets; ⑨ Check mold dimensions.   Warping and excessive shrinkage are contradictory to material and mold temperatures.High material temperature results in less shrinkage but more warping,and vice versa;high mold temperature results in less shrinkage but more warping,and vice versa.Therefore,the main contradiction must be resolved according to the different structures of the parts.   10.----- How to Control Product Dimensions Variations in product dimensions are due to abnormal equipment control,unreasonable injection molding conditions,poor product design,and changes in material properties.   (1)Mold issues: ① Unreasonable mold dimensions;② Deformation of the product when ejected; ③ Uneven material filling; ④ Interruption of material flow during filling; ⑤ Unreasonable gate size; ⑥ Unreasonable runner size; ⑦ Injection cycle abnormalities caused by the mold.   (2)Equipment issues: ① Abnormal feeding system(piston-type injection pressure machine); ② Abnormal stop function of the screw; ③ Abnormal screw rotation speed; ④ Uneven back pressure adjustment; ⑤ Abnormal hydraulic system check valve; ⑥ Thermocouple malfunction; ⑦ Abnormal temperature control system; ⑧ Abnormal resistance heating coil(or far-infrared heating device); ⑨ Insufficient plasticizing capacity; ⑩ Injection cycle abnormalities caused by equipment.   (3)Injection molding condition issues: ① Uneven mold temperature; ② Low injection pressure,increase it; ③ Insufficient filling,extend injection time,extend full pressure time; ④ Barrel temperature too high,reduce it; ⑤ Nozzle temperature too high,reduce it; ⑥ Injection cycle abnormalities caused by operation.   (4)Material issues: ① Variations in material properties for each batch; ② Irregular particle size of the material; ③ Material is not dry.     11.----- How to Prevent Products from Sticking to the Mold Products sticking to the mold are mainly due to poor ejection,insufficient feeding,and incorrect mold design.If the product sticks to the mold,the injection molding process cannot be normal.   (1)Mold issues:If the plastic sticks to the mold due to insufficient feeding,do not use an ejection mechanism;remove reverse cutting edges(depressions); Remove chisel marks,scratches,and other injuries; Improve the smoothness of the mold surface; Polish the mold surface in the direction consistent with the injection direction; Increase the draft angle; Increase the effective ejection area; Change the ejection position; Check the operation of the ejection mechanism; In deep core pulling mold,enhance vacuum destruction and air pressure core pulling; Check for mold cavity deformation and mold frame deformation during the molding process;check for mold shift when opening the mold; Decrease the gate size; Add auxiliary gates; Rearrange the gate position,(13)(14)(15)aim to reduce the pressure in the mold cavity; Balance the filling rate of multi-cavity molds; Prevent injection interruption; If the part design is poor,redesign; Overcome injection cycle abnormalities caused by the mold.   (2)Injection issues: ① Increase or improve mold release agents; ② Adjust material feed quantity; ③ Reduce injection pressure; ④ Shorten injection time; ⑤ Reduce full pressure time; ⑥ Lower mold temperature; ⑦ Increase injection cycle; ⑧ Overcome injection cycle abnormalities caused by injection conditions.   (3)Material issues: ① Clear material contamination; ② Add lubricants to the material; ③ Dry the material.   (4)Equipment issues: ① Repair the ejection mechanism; ② If the ejection stroke is insufficient,extend it; ③ Check if the templates are parallel; ④ Overcome injection cycle abnormalities caused by equipment.       12.-----How to Overcome Plastic Adhesion to the Runner Plastic adhesion to the runner is due to poor contact between the gate and the nozzle arc surface,the gate material not being ejected with the product,and abnormal feeding.Usually,the diameter of the main runner should be large enough so that the gate material is not fully cured when the part is ejected.   (1)Runner and mold issues: ① The runner gate must mate well with the nozzle; ② Ensure the nozzle hole is not larger than the runner gate diameter; ③ Polish the main runner; ④ Increase the taper of the main runner; ⑤ Adjust the diameter of the main runner; ⑥ Control the runner temperature; ⑦ Increase the pull force of the gate material; ⑧ Lower the mold temperature.   (2)Injection conditions issues: ① Use runner cutting; ② Reduce injection feeding; ③ Lower injection pressure; ④ Shorten injection time; ⑤ Reduce full pressure time; ⑥ Lower material temperature; ⑦ Lower barrel temperature; ⑧ Lower nozzle temperature;   (3)Material issues: ① Clean material contamination; ② Dry the material.     13.----- How to Prevent Nozzle Drool Nozzle drool is mainly due to the material being too hot and the viscosity becoming too low.   (1)Nozzle and mold issues: ① Use a spring needle valve nozzle; ② Use a nozzle with a reverse angle; ③ Reduce the nozzle hole size; ④ Increase the cold slug well.   (2)Injection conditions issues: ① Lower the nozzle temperature; ② Use runner cutting; ③ Lower the material temperature; ④ Lower the injection pressure; ⑤ Shorten the injection time; ⑥ Reduce full pressure time.   (3)Material issues: ① Check for material contamination; ② Dry the material.