LIM & HCR Injection Molding Machine Thermosetting ... · Injection Molding Machine Thermosetting...

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LIM & HCRInjection Molding Machine

Thermosetting Injection Molding Machine(LIM & Rubber)

V-LINE is a registered trademark of Sodick Co., Ltd.

V-LINE® creates the value of the next generation.

vol.2

The combination of a thermosetting liquid material with

excellent characteristics and

Sodick's injection molding machine for thermosetting which

performs precise and stable molding provides new markets.

V-LINE®

Thermosetting Vertical Single Action

Injection Molding Machine

LS40EHV

V-LINE®

Thermosetting Horizontal Injection Molding Machine

GL30-LSR

Sodick's LIM Machine Leading Next Generation Market

2

Reference ClassificationLS Model

Machine for super-low viscosity [to 100 Pa・s]

LSR ModelStandard specification machine [100 to 2,000 Pa・s]

Injection control system Electric Servo Specification Hydraulic Pressure Linear Servo Specification

Plunger diameter (φ ) (mm) 16 22 12 16 22 25 28 32 40

Max. injection pressure (MPa) 40 20 288 262 260 240 240 220 210

The LIM (Liquid Injection Molding) is a processing method which performs injection molding of thermosetting liquid material with excellent characteristics.Molded products with a high shape degree of freedom realized by the high liquidity of the liquid material, and high defini-tion and high quality molded products can be acquired without foreign matter mixing in by using a tightly sealed mold.Particularly, the characteristics of silicone rubber material, such as high heat resistance and low temperature resistance, ex-cellent electrical characteristics and non-adhesiveness, and excellent physiological inactivity, has the potential of expanding its range of usage more than ever in a wide range of fields, including electrical components, heat dissipating components, medical equipment and automobile parts in the future.

The viscosity of thermosetting resins increases along with the progression of the polymerization reaction (increase in level of polymerization) even for the same material (same monomer), which decreases the flowability. Generally, resins with lower viscosity are liquids with sufficient flowability, which allows molding at low injection pressure. Resins with higher viscosity change to a rubbery state, which requires high injection pressure during molding.Sodick's injection molding machines for thermosetting are available in two types of injection specifications, an electro-motive type and a hydraulic type which supports an extensive range of viscosities from low viscosity to high viscosity.

LIM (Liquid Injection Molding)

Lineup of Thermosetting Injection Molding Machines

Horizontal Type: GL Series Vertical Type: EHV Series Vertical Type: VRE Series

GL30-LS/LSR LS40EHV LS40VRE

GL60-LSR LS75EHV LS75VRE

GL100-LSR

GL150-LSR

O-ring Baby bottles nipples Sheet lenses

LS/LSR Series supports liquid materials of an extensive range of viscosities from super-low viscosity to medium and high viscosity

3

V-LINE®

Reason why V-LINE® is Superior to Inline

■ Structure of V-LINE®

■ Actual Operation during Injection which Enables Reliable Filling

Since the entire operation of the V-LINE® is completely independent, the mold can be filled reliably with actually measured resin without leakage of the measured material.

In inline, the backflow of the resin occurs between the screw and backflow prevention check ring in the initial stage of injection.Since the amount of resin that backflows in uncontrollable, the amount cannot be fixed.

For this reason,

the actual filling amount varies in each shot in an inline.

The suck back in the V-LINE® uses the same principle as a syringe. Since the flow path is cutoff at the end of the screw and the injection plunger moves backwards, the pressure in the injection cylinder can be reduced reliably without transferring the material feed pressure to the injection cylinder side. The actual measured value sta-bilizes without resin leakage from the nozzle tip, or post-measurement phenomena.

■ V-LINE®

■ Inline

During measurement

Process from measurement to injection by V-LINE®

Constant injection volume

Backflow prevention Suck back Injection

Backflow is prevented at the end of the screw to reliably cutoff the flow path

Reliably reduces pressure by the suck back of the plunger

Backflow prevention + injection

Process from backflow prevention to injection by inline

Initial injection stage During injectionBackflow of resin(Backflow)

Check ring Check ring

4

Screw touch backflow prevention mechanism

Plasticization cylinder

Short feed screw

Injection cylinderInjection plunger

Shut-off nozzle(Optional)

After the screw moves forward to cutoff the flow, resin is injected by the plunger

Since the backflow prevention is completed by moving the screw body forward,there is no backflow prevention ring structure where the resin flows through a narrow flow path.

Backflow Prevention Mechanism

● The short flow path in the LIM dedicated injection unit makes assembly and disassembly easier which is excellent in maintainability.

● The screw portion and injection cylinder are independent, and the flow path is shut down by the feed screw except during measurement. For this reason, the residual pressure of the material while the material is being fed accumulates in the plasticizing cylinder.

* An electric servo injection specification is also available for the low viscosity material dedicated unit.

LIM Dedicated Unit

Outstanding Stability of V-LINE® System

■ Perfect Backflow Prevention Mechanism

■ Troubles caused by check ringDue to the structure, the leakage amount during injection and the sealability after backflow prevention is limited in the super-low viscosity range, as it is influenced by the viscosity of the material.

If the clearance between the backflow prevention ring and injection cylinder is reduced to increase the sealability, the ring and the inner wall of the cylinder will be worn which leads to scorching trouble (premature curing).

□ Backflow Prevention MechanismIn inline, back flow can be prevented by the check ring.The seating (backflow prevention) of the check ring is completed when the screw moves forward.

□ Seating condition of check ringIn the case of LIM, the pressure on the rear side of the screw becomes relatively high due to the material feed pressure from the feed unit. The seating of the check ring is completed by the pressure difference gener-ated before and after the ring.

Material feed pressure

The seating of the check ring opens by the ma-terial feed pressure.

High pressure

Low pressure

■ Troubles of check ring peculiar to LIM

Since the backflow prevention check ring remains open even after the measure-ment, the material moves after the measurement is completed by the residual pressure of the material fed by the pump, which makes it easier for post-mea-surement phenomenon to occur, and as a result the measurement value varies.

A shut-off nozzle cannot be used as a measure for this trouble.

Due to the check ring structure, there are limitations in the low viscosity range which can be molded in an inline.

■ Inline

● Backflow prevention mechanism of the V-LINE® type molding machine is simple and logical

● Completely prevents backflow by moving the screw a few millimeters only● Material does not backflow during the injection, because the flow path can

be shut down after the measurement is completed

The simple structure and operation of the V-LINE® completely prevents backflow, even with super-low viscosity materials.

■ V-LINE®

Before seating Check ring

Screw

After seating

Backflow

5

● Since the injection and screw portion are independent in the V-LINE® system, measurements can be performed for a multiple number of injections at once for molding.

● Improvement in two liquid feed amount control, variations in the mixing ratio, and poor kneading can be expected with mea-surement of a multiple number of injections at once.

V-LINE® Unique Fine Filling Volume Control Technology

Stability of Product Weight

V-LINE® 5 Technology

Average weight (1 cav) 0.8657 g

Range value 0.0085 g

Standard deviation 0.0019

Coefficient of variation 0.2157 %

Product name Ear plugs

Molding Machine GL30-LSR

Material LSR (Hardness 40)

No. of cavities 4 cavities

Filling rate 95% filling (Short-shot product)

Evaluation of product weight stability in 50 shot molding

0.95

0.9

0.85

0.8

0.751 　 5 　 1 0 　 1 5 　 2 0 　 2 5 　 3 0 　 3 5 　 4 0 　 4 5 　 5 0

Wei

ght (

g)

No. of Shots

In addition to thermoplastic resin molding, the features of the V-LINE® system can be demonstrated in thermosetting resin molding where the viscosity is stable for a relatively long period at room temperature, and maintains flowability from the feeding condition.

Plunger injection accuracy technology

Holding pressure control technology

Prolonged stable molding technology

Fine fill volume control technology

Low speed injection speed control technology

V-LINE®

5Technology

Sodick's unique plunger method with no backflow of resin allows for several injections by one measurement, which shortens the molding cycle time.

This is an example of molding by the V-LINE® without variations.

6

New mold se t t ing screenThree set t ing screens for in jec t ion, mold open/close, and temperature were in tegrated in to one screen.The basic se t t ings of a molding machine can be per formed in one screen.

■ New screen

50μsecond

Inject ion per formance Displays t rouble

locat ion

Troubleshoot ing funct ion

Saves past operat ion his tor y

Analys is suppor t

Not i f icat ion of maintenance period

Image saving feature

Maintenance suppor t

Saves an image of the screen and molding condi t ions

Mounts USB por ts

USB memory vers ion upgradeJapanese, Engl ish,

Chinese (2 Dialects ) , Korean

5- language suppor t

Features of IMC7 Controller

15 inch operation screen with improved visibility

Operation System Operating System

Electric hybrid direct pressure mold clamping Electric Hybrid Direct PressureMold Clamping

□ Features● Direct pressure mold clamping by the mold clamping cylinder, realizes uniform distribution of the mold clamping force.● Since the guide on the backmost part of the clamping mechanism and the guide of the movable platen maintain the mold open/close operation over a long

span, excellent straightness can be demonstrated.● There is no application of excessive clamping force, or effect from the distortion of the tie bars, because the movable platen does not move through the tie

bars.

PlatenEjection unit

Guide

Mold open/close AC motor

Guide Tie barMold clamping cylinder

The mold clamping accuracy is also an important point to realize burr-less molding. All of Sodick's injection molding machines including the injection unit, provide mechanisms that are suitable for thermosetting resins.

Operability which improves productivity "In-house Developed IMC7 Controller"

Adopt ion of a pic tograph panelThe opera t ion bu t tons are d i sp layed i n p i c t og raphs w h i c h s h o w t h e m o l d i n g opera t ion , to s imp l i f y the ope ra t i on o f t he mo ld ing machine.

■ Operat ion panel

Sodick's unique electric hybrid direct pressure mold clamping which uniformly distributes the mold clamping force, further realizes burr-less molding of liquid thermosetting resins.

7

LIM Mold

Product (Medical application check valve)

Fixed side (Cavity)

Movable side (Core)

Cold runner cooling circuit

Heat insulation plate

Heater

Air cylinder (Valve gate)

Cavity vacuumsuction

Air ejection (Blow)

● Advanced packing function which prevents leakage of liquid resin● Cold runner cooling circuit to prevent hardening in the core side mold● Heater for hardening in the cavity side mold● Heat insulation plates between the core side and cavity side● Air-blow for ejection

■ Features of LIM Mold

Configuration of LIM System

The basic configuration of the LIM system combines a pressure feed pump unit and a mixer (dynamic mixer), and supplies thermosetting resin which is completely mixed with two or more liquid materials to the injection unit.Also contact Sodick for peripheral equipment, such as the chiller which controls the tempera-tures of the injection unit and mold, and a vacuum pump for vacuuming the mold.

*2: Vacuum pump *1: Pressure feed pump (Main agent/Hardening agent)

*1: Chiller

*2: Mixer (Dynamic mixer)

*1: Customer prepared equipment *2: Optional equipment

8

O-ring Catheter balloons

■ Example of Molding Material ■ Example of Molding Process

Material dimensions

Diameter: φ100 to 130 mm

Length: 200 to 230 mm

Stuffer BOX

Stuffer BOX mounted position

Millable silicone rubber

This is a GUM specification machine equipped with a "stuffer BOX" which pushes in the millable silicone rubber.Injection molding process with high productivity can be realized with high quality millable silicone rubber that requires high injection pressure.

□ FeaturesThe millable silicone rubber is a heat-curable high viscous material blended with a curing agent (hardening agent), and is also called heat cured rubber (HCR).The material is composed of silicone having an intermediate structure between inorganic-organic, and has excellent fea-tures, such as high heat resistance, excellent low temperature resistance, high insulating properties, and high fire retar-dancy, etc. The needs of this material are expanding for water tight and airtight sealing materials used for gaskets and O-rings particularly, parts for medical equipment utilizing it's compatibility with the human body.

Sodick's V-LINE® Injection Molding Machine enables high injection pressure by a hydraulic injection unit that is ideal for the molding of millable silicone rubber, which is a high viscous material of 4,000 Pa-s or more.Unlike an in-line machine, there is no shearing effect by the check ring in the V-LINE® injection unit, and does not gen-erate scorching (premature curing). Since there is also no check valve which is adopted in other plunger units, there is no stagnation of the silicone rubber, and contamination can be suppressed.

●

●

GUM Specification Millable Type Silicone Rubber Molding

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GL Series

GL30-LS GL30-LSR GL60-LSR GL100-LSR GL150-LSR

Clamping Unit

Mold open / close system AC servo motor control

Clamping system Direct pressure locking type

Max. clamping force kN 294[392]* 294[392]* 588 980 1472

Tie-bar interval mm 310 x 310 310 x 310 360 x 320 460 x 420 560 x 520

Platen dimension mm 440 x 440 440 x 440 520 x 460 640 x 610 720 x 680Open daylight (Min. Mold Thickness + Maximum stroke) mm 550 550 650 800 900

Min./Max. mold thickness mm 150 / 360 150 / 360 200 / 390 250 / 550 250 / 600

Mold open / close force kN 6.8 / 13.6 6.8 / 13.6 9.9 / 19.8 9.9 / 19.8 14.2 / 28.5

Ejecting system AC servo motor controlEjector ejecting force / Ejection retention force kN 9.8 / 5.8 9.8 / 5.8 13.7 / 7.8 21.5 / 12.7 28.8/ 17.6

Ejector stroke mm 50 50 80 100 120

Screw Injection Unit

Compatible material viscosity (Guide) Pa・s 1 to 100 (Low viscosity) 100 up (Medium, high viscosity)

Screw/injection system Feed screw & plunger system

Injection drive system Electric injection Hydraulic injection

Screw rotation specification Electric Hydraulic

Screw diameter mm 22 14 22 14 22 28 28 28 40

Plunger diameter mm 16 22 12 16 22 12 16 22 28 28 28 40

Max. injection pressure MPa 40 20 288 262 260 288 262 260 240 240 240 210

Theoretical injection volume cm3 14 27 4.5 14 27 4.5 14 27 83 83 83 251

Injection rate cm3/s 2 3.8 22 40 76 22 40 76 123 123 123 251

Plunger stroke mm 70 40 70 40 70 135 135 135 200

Max. injection speed mm/s 10 200 200 200 200

Max. screw revolution rpm 100 200 200 200 200

Rated screw torque N.m 6.22 59 147 59 147 235 235 235 411No. of temperature display zones (Water temperature control) 2 2 2 2 2

Nozzle pressing force kN 4.9 4.9 4.9 6.8 15.7 15.7 15.7 19.6

Unit traveling stroke mm 280 220 320 400 365 365

Hydraulic Pressure / Air Pressure

For hydraulic pump motor capacity kW 3.0 3.0 3.0 4.4 4.4 4.4 6.0

Hydraulic circuit pressure MPa 15 15 15 15 15

Tank capacity ℓ 68 68 68 90 90 90

Motor capacity for AC servo kW 3.1 2.9 2.9 4.2 4.2 6.4

Machine Dimension / Weight

Machine Dimension (L x W x H) mm

3150×

1064×

1679

3150×

1064×

1679

3685×

1136×

1679

4030×

1227×

1792

4400×

1378×

1878

Machine weight kg 2000 2000 2700 2800 3100 5000 5100

*: Mold clamping force [392kN] is an optional specification.

Horizontal Type

Specification List

10

EHV Series VRE Series

LS40EHV LS75EHV LS40VRE LS75VRE

Clamping Unit

Mold open / close system AC servo motor control Hydraulic cylinder

Clamping system Mold downward direct pressure Direct pressure locking type

Max. clamping force kN 392 735 392 735

Tie-bar interval mm 360 x 360 450 × 450 - -

Platen dimension mm 520 x 520 670 × 670 - -

Max. mold size mm - 300 x 300 400 × 400

Max. mold weight kg - Lower mold 400kg x 2 sides

Turntable dimensions mm - 1016 1200Open daylight (Min. Mold Thickness + Maximum stroke) mm 500 550 400 500

Minimum mold thickness mm 250 250 200 250

Mold open / close force kN 12.0 / 24.0 17.6 / 35.1 (close) 17.3 / (open) 37.7 (close) 29.4 / (open) 49.0

Turntable drive system - Electric servo motor

Ejecting system AC servo motor controlEjector ejecting force / Ejection retention force kN 8.2 / 4.9 21.5 / 12.7 13.2 / 7.8 21.5 / 12.7

Ejector stroke mm 40 60 60 60

Screw Injection Unit

Compatible material viscosity (Guide) Pa・s 100 up (Medium, high viscosity)

Screw/injection system Feed screw & plunger system

Injection drive system Hydraulic injection

Screw rotation specification Hydraulic

Screw diameter mm 14 22 28 28 14 22 28 28

Plunger diameter mm 16 22 28 28 32 16 22 28 28 32

Max. injection pressure MPa 262 256 252 252 234 262 256 252 252 234

Theoretical injection volume cm3 14 27 83 83 108 14 27 83 83 108

Injection rate cm3/s 40 76 123 123 160 40 76 123 123 160

Plunger stroke mm 70 135 135 70 135 135

Max. injection speed mm/s 200 200 200 200

Max. screw revolution rpm 200 200 200 200

Rated screw torque N.m 105 186 245 235 105 186 245 235No. of temperature display zones (Water temperature control) 2 2 2 2

Nozzle pressing force kN 9.0 17.6 9.0 17.6

Unit traveling stroke mm 255 255 255 300

Hydraulic Pressure / Air Pressure

For hydraulic pump motor capacity kW 11.0 11.0 11.0 6.0

Hydraulic circuit pressure MPa MAX. 18.5 MAX. 18.5 MAX. 18.5 MAX. 20.7

Tank capacity ℓ 90.2 130.0 64.0 100.0

Motor capacity for AC servo kW 3.9 5.6 7.2 7.2

Machine Dimension / Weight

Machine Dimension (L x W x H) mm

1934×

1727×

3175

2138×

1811×

3672

2432×

1581×

2750

2432×

1581×

2900

2934×

1446×

3244

Machine weight kg 3000 3200 4800 3300 3500 5000

Vertical Type

Specifications

11

Material Supply Port

850

Mounting layout drawing

Mold installation face


Power supply socket

Air supply Rc1/4

OUT IN

Water supply Rc1/2

40302190 1757 53 1630 1725

55

62

8.5

58

0

87

0

87

0 72

0

φ12

0

51

7

10

97

59

8

12

26

.5

16

24

17

31

16

35

13

14

26

9

10

81

68

4

17

92

23

1

(Top O

f P

late

n)

17

09

(Top O

f C

ove

r)


3685

1895 1707 53 55

1400 1675




Power supply socketAir supply Rc1/4

OUT IN

Water supply Rc1/2

1484

(Top O

f P

late

n)

1671

1017

477

540 790

790

640

φ12

0

1575

1254

269

1679

1570

109

547

588.5

1135.5

231

700

1590

(Top O

f C

ove

r)

1219

495

1417

447

515

548.5

1650 55

IN

Air supply Rc1/4 Water supply Rc1/2

OUTPower supply socket

231

268

600

14351

679

1570

109

(Top O

f C

ove

r)

(Top O

f P

late

n)

1589

1444


942

3150

53

1063.5


560

120

1385

710

710

1180





Mold installation face Mold installation face

Power supply socketAir supply Rc1/4

OUT IN

Water supply Rc1/2

1180 1385

55

71

0

71

0 56

0

φ120

3150

1650 1417 53

54

8.5

49

54

47

94

2

51

5

10

63

.5

10

91

57

0

16

79

26

82

31

600

15

96

15

60

12

19 1

44

4(T

op O

f P

late

n)

15

89

(Top O

f C

ove

r)

Machine Dimensions & Installation Drawings

GL30-LS

GL30-LSR

GL60-LSR

GL100-LSR

GL150-LSR

Machine Dimensions & Installation Drawings

Unit: mm

Unit: mm

Unit: mm

Unit: mm

Unit: mm

12

509640430

200

1 B A

B A500

Max. mold open stroke250

25

Min. mold thickness

Ejector start position

100 400

A-A

460430

100150250300375450550640

120 120

8×φ12 H7 Depth 20

8-M10×1.5 Tap Depth 20

64-M16×2.0 Tap Depth 40

Mold installation surface


Bolt hole for take off robot

φ32

φ32

φ32

φ32

φ1.5

φ2.0

φ2.5

φ3.0

10

10

10

10

60

60

60

60

Outside diameterof cover

Diameter ofnozzle gate Sphier R

Main spec of nozzle (P28)

Extension

Fixed platenUnit strokeEjector stroke

B-BMovable platen

570

509 2424

Ejector rod end tapM12×1.75 Tap Depth 24


39

5

20

0

39

0

60

0

3-φ

22

5-φ

25

φ1

50

φ1

00

φ1

20

42

0

39

0

10

0

15

02

50

30

03

75

45

05

30

61

0

31

02

06

0

37

0

Resin feed, Tap size for hopper It differs depending on the material supply device.

Please contact us.

φ28

φ28

φ28

φ28

φ1.5

φ2.0

φ2.5

φ3.0

10

10

10

10

60

60

60

60



Main spec of nozzle (P12/P16/P22)

Extension

φ32

φ32

φ32

φ32

φ1.5

φ2.0

φ2.5

φ3.0

10

10

10

10

60

60

60

60



Main spec of nozzle (P28)

Extension

120 120 Mold installation surface

A-A

360

320

100

150

200250300350

410520

2-φ12 H7 Depth 20


64-M16×2.0 Tap Depth 32

Fixed platen

32

0

28

0

10

0

15

0

20

0

25

0

30

03

50

40

0

46

0

23

5




Please contact us.

20

60

450

Max. mold open stroke

200

15

Min. mold thickness

1


80

B A

B A

Ejector stroke

5-φ

25

φ1

00

φ8

0

3-φ

22

320

Unit stroke



45845824 24

520

310

310

200

490

46

027

0

20

0

33

53

10

Movable platenB-B

A

A

Main spec of nozzle (p28)Resin feed,tap size for hopper


Fixed platen

Movable platen

φ32

φ32

φ32

φ32

10

10

10

10

60

60

60

60

φ1.5

φ2.5

φ2.0

φ3.0

φ28

φ28

φ28

φ28

φ1.5

φ2.0

φ2.5

φ3.0

10

10

10

10

60

60

60

60



Main spec of nozzle (P12/P16/P22)

Extension



42642624 24

440

280

200

410

400Max. mold open stroke

150

20

Min. mold thickness

1


50B A

B A

Ejector stroke

5-φ

25

φ6

0

φ5

4

31

0

27

02

25

20

60

10

0

15

02

00

25

03

00

35

0

44

5

3-φ

22

280

270

100

150200250

300

350

440

120120

310

A-A

Fixed platen

Unit stroke

44

0

28

0

20

0

37

02

75

Movable platen

B-B

8-φ12 H7 Depth 20


48-M16×1.5 Tap Depth 32

Mold installation surface




Please contact us.

Mold Mounting Face Dimensions Drawings

GL30-LS,GL30-LSR

GL60-LSR

GL100-LSR

GL150-LSR

Mold Mounting Face Dimensions

Unit: mm

Unit: mm

Unit: mm

Unit: mm

13

Unit: mm

Unit: mm

Unit: mm

Unit: mm

LS40EHV LS40VRE

LS75VRELS75EHV

Machine Dimensions & Installation Drawings Machine Dimensions & Installation Drawings

14

Unit: mm

Unit: mm

Unit: mm

Unit: mm

LS40EHV LS40VRE

LS75VRELS75EHV

Mold Mounting Face Dimensions Drawings Mold Mounting Face Dimensions

15

Printed in Japan

3-12-1, Nakamachidai, Tsuzuki-ku, Yokohama, Kanagawa224-8522 JapanTEL: 81-45-942-3111 FAX: 81-45-943-7880

●�The export of Sodick's products and its related technologies (including software applications) is regulated under Japan's Foreign Exchange and Foreign Trade Control Law. In addition, because some of these products may be subject to re-export controls under the Export Administration Regulations (EAR) of the United States; please contact Sodick before offering or exporting these products overseas.

●This catalogue contains a photographic image that has been generated from 3DCG.●��Due to ongoing research, specifications are subject to change without prior notice.●The contents of this catalog is current as of July, 2017.

http://www.sodick.jp

R2003306.2017.07<00>

V-LINE® Thermosetting Injection Molding Machine (LIM & Rubber) vol.2

LIM & HCR Injection Molding Machine

LIM & HCR Injection Molding Machine Thermosetting ... · Injection Molding Machine Thermosetting...

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