Tool Making Process: CNC milling, EDM/wire EDM machining Part Making Process: Plastic Injection Molding Mold Material: 718H Steel Part Materials: ABS+TPE

About this product

The customer needs to make a wireless charger that can be installed on the desk, which is not only a wireless charger, but also has a USB interface, which is similar to a sensor.  It is very powerful and is mainly used in office spaces. It can reserve space and accurately find users. It is a new type of intelligent office product.

About the client

The client is from New Zealand and has over 20 years of experience in the IT industry developing hardware, software and IP network solutions for large multinational and local companies. This product is a smart accessory designed by the customer for the office. The product consists of two parts. The material of the main part is ABS, and the ring on this accessory is made of TPE soft rubber material.

About The Project

In this project, in order to meet the customer's requirements, we need to solve these problems:

1. The color of the product requested by the customer is white, so for the soft rubber part, we should choose the color matching as close as possible.

2. Because the entire color of the product is white, but in the process of use, the white color is easy to turn yellow.

3. The compatibility of ABS material and TPU material needs to be considered;

4. Solve the problem of the edge of the lagging.

Challenges

TPE overmolding with ABS

In order to ensure good adhesion between the two materials, we need to consider many factors.

1. TPE-encapsulated plastic bonding mechanism: TPE and plastic have similar polarities, not all TPE can be bonded with plastic ABS, PC, PP and other excellent plastics. If the adhesion between the two plastics is to occur, the formulation of the TPE soft compound is very particular. Different hard plastic varieties usually require different formulations and physical properties of TPE soft rubber.

2. The primary factor affecting the bonding effect of secondary injection molding: suitable injection molding temperature.

3. The second influencing factor of the bonding effect: the surface tension of the hard plastic material.

Common plastics, such as PP, ABS, PC, etc., have moderate surface tension. In the molten state, TPE can quickly spread on the surface of these materials and achieve bonding.

The problem of the burring of TPE

Whether the viscosity is too high or too low may cause product flash.

Solution: 1. Attention should be paid to improving the precision of the mold, reducing the mold gap, and increasing the clamping force.

2. Appropriately reduce the amount of glue shot and the temperature of the melt.

3. Reduce the forward time of the screw and reduce the injection speed.

White ABS material yellowing problem

Generally, white materials will inevitably turn yellow during long-term use.

Solution: Use UV-resistant ABS material and add antioxidants to improve it.

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