Mold design optimization strategy in the production of PC lamp base injection molding accessories

Common problems in the injection molding process, such as large product shrinkage and unstable dimensions, often become bottlenecks that restrict product quality and production efficiency. In response to these problems, optimizing mold design, especially adding a cooling system and rationally designing the mold cavity and cooling channel, has become the key to improving the quality of PC desk lamp base injection molding accessories.

1. The importance of mold cooling system
During the injection molding process, the plastic melt is injected into the mold cavity and quickly cooled and solidified into the desired shape. In this process, the cooling rate directly affects the shrinkage rate, internal stress distribution and final dimensional accuracy of the product. For PC materials, due to their high thermoplasticity and low thermal conductivity, if the cooling is uneven or too slow, it is easy to cause local shrinkage of the product, deformation or surface defects. Therefore, optimizing mold design and adding an efficient cooling system have become effective means to reduce shrinkage and improve product quality.

2. Design and implementation of cooling system
Cooling channel layout: The design of the cooling channel should follow the principle of "fast and uniform" to ensure that the plastic melt can dissipate heat quickly and evenly during the solidification process. This requires mold designers to accurately calculate the location, number and diameter of cooling channels according to product shape, wall thickness and material properties to achieve optimal distribution and reflux of fluids and avoid the formation of "hot spots" or "cold spots".
Cooling medium selection: Common cooling media are water and oil. Water has high thermal conductivity and is suitable for rapid cooling; while oil can maintain stable fluidity at higher temperatures and is suitable for occasions with more stringent temperature control requirements. According to the characteristics of PC materials and production requirements, reasonable selection of cooling media can further improve cooling efficiency.
Temperature control system integration: Combined with advanced temperature control systems, such as PID thermostats, precise temperature control of cooling media can be achieved to ensure that the mold temperature remains constant throughout the production process, further reducing product shrinkage differences caused by temperature changes.
3. Reasonable design of mold cavity and cooling channel
In addition to the cooling system, the design of the mold cavity and the coordination of the cooling channel are also important factors affecting the uniformity of product cooling.
Cavity structure optimization: The design of the mold cavity should minimize the plastic flow resistance, ensure that the melt can be filled smoothly, and avoid local overheating or insufficient cooling due to uneven flow. At the same time, reasonable draft angle and wall thickness design are also the key to ensure smooth demolding of products and reduce shrinkage.
Matching of cooling channels and cavities: The cooling channels should be as close as possible to areas with thicker wall thickness of the product to accelerate the cooling rate of these areas, reduce the temperature difference between the inside and outside, and avoid local shrinkage. At the same time, by adjusting the shape and direction of the cooling channel, the flow direction of the plastic melt can be guided to promote the effective discharge of internal heat.
Simulation analysis and verification: Using CAE (computer-aided engineering) software for injection molding simulation can predict the flow, temperature distribution and shrinkage of plastics, providing a scientific basis for the optimization of mold design. Through repeated iterative simulation and experimental verification, the mold design is continuously optimized until the best cooling effect and product quality are achieved.