Auto mold - high thermal conductivity copper alloy mold

High thermal conductivity copper alloy mold manufacturing plant can have higher production efficiency, both to save money, but also improve product quality. Some car bumpers and instrument panels manufacturing companies have used this kind of material the mold and has achieved significant production efficiency.

With the normal industrial / die steel compared to copper-based alloys due to the high cost of production in the mold, therefore, a lot of mold factory has yet to find a better way to make a rational use of high thermal conductivity copper alloy materials, But in fact, the use of high thermal conductivity of copper alloys to save time and efficiency benefits of such areas is very significant.

In this paper to explore the high thermal conductivity copper alloy is a copper-based materials, alloys and manufacturing techniques by the method of combining, it is necessary to keep copper inherent characteristics of the high thermal conductivity, but also it has a certain hardness to be able to let in a production environment for a variety of processing conditions.

The main advantage of copper alloy

In the injection mold in the use of high thermal conductivity of copper alloys include the following special advantages:

A, thermal diffusivity properties

Plastic in the mold of the injection molding process, the high thermal conductivity copper alloy will absorb a large amount of heat, of course, its initial absorption of heat is a key factor, while the latter will rely mainly on thermal cooling system. In each plastic injection process, heat is absorbed the initial rate of high thermal conductivity copper alloy to play a role in a real place.

2, polished performance

In contact with plastic packaging used in the production process of high thermal conductivity copper alloy molds, its excellent polishing performance has been proven in practice. In a highly polished high thermal conductivity copper alloy inserts in the future, you can create high-quality transparent plastic packaging, to meet the inspection through the packaging production needs. Practice has proved that this inserts polished steel inserts longer than the time required to finish four times faster, work cycle, but it can reduce 57%.

3, coating

In order to improve the wear resistance, high thermal conductivity copper alloy surface can be easily coated with a layer of non-plated nickel coating, hard chrome coating, PVD coating (physical vapor deposition layer), or CVD coating (chemical vapor deposition layer), so that the hardness of the surface coating to achieve 60 ~ 90 HRC. Non-plated nickel coating can make uniform the thickness of the coating to penetrate into every hole, but its essence is not as galvanizing process, as is also not as hard as chrome plating process. In order to facilitate the plastic mold release, non-plated nickel coating with PTFE (PTFE) or a combination of boron nitride materials. PTFE or boron nitride coated with non-plated nickel coating the surface of the mold parts are very smooth as if coated Feizao Mo in general, it will not make already-formed plastic pieces glued to the mold, the mold release very easily.

Of course, the use of high thermal conductivity copper alloy molds, there are some limitations, such as eliminating stress or annealing (the only way to maintain the hardness of the material characteristics) should be placed in a long time to avoid mold temperatures above 900 ¡ã F being.

Applications and Benefits

Based on the above characteristics, in the following applications can be considered within the scope of use of high thermal conductivity of copper alloys:

<1> injection mold core and cavity-type, Core plugs and cooling plate;

<2> composite plastic profile extrusion die used in the process: here the use of high thermal conductivity copper alloy mold can make to improve the thermal conduction velocity, but also can improve part of the dimensional stability;

<3> production of liquid packaging bottle blow mold;

<4> Injection nozzles: the use of high thermal conductivity copper alloy, due to the thermal conduction time is short, to maintain a uniform temperature can greatly simplify the entire temperature control system, thereby reducing energy costs.

In the injection mold can consider the application of copper alloys are mainly the following reasons:

<5> in the application of a high thermal conductivity copper alloy, the mold cooling rate has greatly improved the production cycle can be shortened at least 20% (according to some users said the production cycle can be shortened or even 80%);

<6> As production cycles shorten working hours, so each class produced a significant increase in the number of parts, productivity can increase at least 25%, according to auto headlights industry some users say that their productivity and even increased by 500%;

<7> As the cooling rate increased, the mold temperature decreases rapidly, forming part of the time, so die in the "hot spots" caused by the amount and extent of the damage can be reduced, thus greatly improved the quality of parts, significantly reduced the rate of deformation of scrap ;

<8> scrap rate reduction also indicates that a part of each after each injection molding quality is more stable;

<9> due to the high thermal conductivity copper alloy with a super heat conduction properties (in general, its thermal conductivity than steel, high-five to 10 times), die in the heat sensitive areas can be quickly disseminated to go out, so direct contact with part of the mold and parts the complexity of the cooling can reduce the number of channels or directly to eliminate;

<10> As the mold cooling channels to reduce the number of mold processing costs can be greatly reduced cost - and cooling the tool steel die slow compared to the manufacturing cost can be reduced four times.

The above examples illustrate, using the high thermal conductivity copper alloy cores later to save time and costs arising from its benefits.

Bumper in the automotive manufacturing process, aluminum bronze inserts can be applied to the steel into molds, and some manufacturers even use the full range of high thermal conductivity copper alloy cores and cavities to produce their bumper.

Car dashboard can also be used include aluminum bronze inserts in the mold production, and production of steel used in plug-ins compared to the thermal conductivity was increased by 3 times.

Conclusion

To make today's mold shop can maintain a competitive capacity to enable the world to compete with low-cost production areas, the user may consider the use of injection mold production rate of high thermal conductivity copper alloy, this aspect is very important thought , because the high thermal conductivity copper alloy mold processing plant can have higher productivity, both to save money, but also improve product quality.