Battery covers and cases are one of the resinized automotive parts. Some of these covers are very large (1600 mm x 1300 mm) and require a 7000-ton class molding machine for the projected area alone. However, we have only a 2000-ton class molding machine at our factory in Japan, so it is impossible to mold these products by ordinary injection molding.
For this type of product shape, purchasing a new molding machine would be costly and would increase the unit cost of the product. However, according to our calculations, a 2,000-ton class molding machine would not be able to accommodate this type of product.
Therefore, we have developed a method to fill each area of the molded product, and by controlling the filling area sequentially, we have been able to achieve the following
We have achieved our goal of less than 2000 tons of mold clamping tonnage.
We call this approach block forming, and in this case we were able to achieve molding at a maximum clamping tonnage of 1660 tons.
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