Packaging technology

The so-called "Packaging Technology" integrated circuit with an insulating plastic or ceramic material packaging technology. The CPU, for example, actually see the size and appearance of the CPU core is not really the size and appearance, but the CPU core and other components of the product after packaging. Packaging technology package is a must for the chip, is also essential. Because the chip must be isolated from the outside world, in order to prevent corrosion of impurities in the air caused by the electrical circuit chip performance degradation. On the other hand, after the chip package and easier to install and transport. Since the quality of packaging technology also play a direct impact on the performance of the chip itself and connected thereto PCB design and manufacture (printed circuit board), so it is crucial.

Packaging can also be said that with the installation of a semiconductor integrated circuit chip shell, it not only plays placed, fixed, sealing, protecting the chip and the enhanced role of thermal performance, but also to communicate with the outside world circuit chip bridge - chip contact with the package leads are connected to the housing pins, which also connect to the other device via a wire to a printed circuit board. Thus, for many IC products, packaging technology are very crucial part.

CPU is used in multi-packaging packaged in plastic or ceramic insulating materials, to improve the chip acts as a sealing and electric properties. Now that the frequency of the processor chip increasing, more powerful, more and more pin count, package shape is also constantly changing.

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Injection products quality inspection methods

Whether produced after plastic  injection products meet quality standards, must be tested, a common quality test methods are the following two.

(1) full inspection

The so-called full inspection is individually tested for injection products, we have talked about "full" refers to the number of all the plastic parts produced, rather than the entire value of the quality characteristics tested. In determining the test items, test cost is usually lower or greater impact on the quality of the quality characteristics of the implementation of full inspection, such as plastic parts Dimensions test is easier and can be fully tested, and the requirements of the position and some plastic parts crucial, a great impact on the quality, but also the need for full inspection. Not plastic parts for each test must be carried out in full, as it is too time-consuming and laborious. Usually occurs when the following conditions using full inspection.

1) found that more unqualified plastic parts, plastic parts or the whole batch are unqualified, the need for follow-up products for full inspection.

High single value 

2) injection products, even when a scrap will bring great losses.

3) If the product quality problems, give people life safety or safety hazard when great.

(2) sampling inspection

The so-called sampling inspection,, is from a group of randomly selected plastic part of the test conducted. By this test section of plastic parts extracted to make the evaluation of quality of these plastic parts. Compared with the full inspection sampling inspection, it tested a small number of plastic parts, low-cost test, test speed. Sampling inspection and batch size of the number of samples, volume, sample quantity; small quantities, less sampling; as long as the appropriate number of samples, the test results have a high accuracy. Usually by random checks in the following cases.

1) Some of the plastic parts of the mechanical and physical properties of the need for destructive testing, this will bring damage to the plastic parts.

2) more than the mass production of plastic parts, plastic parts produced quantity particularly large, want to save test time and test costs.

3) the production of raw materials in plastic parts, there are a lot of raw material is powdered, granular or liquid form, the raw material for these multi-use sampling. Compared with the full inspection sampling inspection, although there are a small number of test and low test cost advantages, but also the following problems: First, when the second installment of the plastic parts, even after sample testing has been considered qualified, can not believe that this batch of plastic parts plant each plastic parts are qualified, which may also exist a very small amount of non-conforming product. Second, the sample tests will inevitably appear judgmental errors, this is the vast majority of qualified products, due to sampling bias, but judged unqualified; or could have been substandard goods, has become qualified. Therefore, in order to determine the probability of error is controlled within a reasonable range, often need to coordinate the use of mathematical statistics methods.

In short, the full inspection and sampling test has its own characteristics, and applications and problems also vary, depending on the circumstances test methods should be chosen to adapt. Mostly due to the injection mold products for mass production, it is more to take sample tests

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Injection Molding: New Twists for a Mainstream Technology

When it comes to manufacturing technologies, the choices are many and their number seems to grow daily. They include machining, laser cutting, water cutting, stamping, die casting, and various forms of 3D printing. Despite its age -- well over 100 years -- injection molding is still a “go-to” technology for producing plastic parts. No other technology offers as wide a selection of materials, and the cost per part plummets once a mold has been made.

Molding is a broad term covering a variety of methods including injection, extrusion, compression, roto-molding, silicone molding, and blow molding. Injection molding is among the most flexible of these. It entails forcing molten resin into a mold, allowing it to solidify, and then opening the mold to eject the finished product.

The injected material can be a thermoset, which hardens permanently when heated and cannot be remelted; or thermoplastic, which liquefies when heated or reheated and hardens when cooled. While thermosets are used in a variety of applications, thermoplastic is often preferred for its ease of recycling and the vast variety of thermoplastic resins available.

This article will touch on injection molding’s place in the continuum of industrial production processes and its strengths, particularly in terms of expanded material options. It will address how materials, design, moldability, and process details affect injection molded parts and their quality.

The range of thermoplastic materials options is a boon for developers, but it can be bewildering as well. With hundreds of resins to choose from -- both individual polymers and blends -- resin can fit the most specific requirements and become a key aspect of the finished product’s performance. Characteristics like strength, flexibility, color, or transparency may be simple to identify, but resins may also be chosen for other characteristics.

Depending on the application, resins can also be selected for their resistance to chemicals or UV light, response to temperature and humidity, or electrical properties. If parts include bearing surfaces, resin may be chosen for their lubricity, and if parts will be subject to rough handling, abrasion resistance may be critical.

Parts may have cosmetic needs like the ability to hold a high polish, and can also include features like living hinges, which are designed to be flexed repeatedly without breaking. Moldability varies among resins. Some flow easily through narrow areas that would be difficult for other resins to traverse. In some cases, the solution to this variability is an altogether different resin; in others the answer is to keep the same resin but change the design of the part. Of course, there’s also cost to consider, which becomes increasingly important as the size of the part and the production volume increase.

Even these choices would be relatively simple if a part only had to meet one criterion. But in real-world design that’s rarely the case. One part might have to be both strong and transparent, while another must be flexible and able to withstand contact with solvents.

With thousands of materials to choose from, virtually any imaginable combination of characteristics is available in some resin or blend; the challenge is in finding it.

Clearly, the needs of the product itself will guide the design of a plastic part, but both the material being molded and the molding process itself can impact design choices. A stronger material can allow features to be smaller or thinner. A filled material, however, like glass-filled nylon, can greatly improve strength but may impact a part’s cosmetics, increase the likelihood of warp, or cause flow problems around part features like through holes. The flexibility of a resin will affect the dimensions of moving parts like clips or hinges, and can even affect whether such features will work at all.

Final choices regarding design and material often depend on the testing of prototypes, but preliminary decisions can often be made before prototyping even begins. Finite element analysis (FEA) software, available in standalone form or incorporated into design software, allows simulation and virtual testing of a design in a specific material. The results can suggest design changes or material choices, speeding up the whole development process.

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Injection Molding Adapts to a More Interconnected World

Plastic, rubber,   injection molding , more recently, rapid molding techniques have been major contributors in global manufacturing. A variety of processes and equipment can be used, depending on volumes, materials and turnaround time, and whether parts are prototypes or finished ones. The rise of rapid molding for fast delivery of high-mix, low-volume products and prototypes, and new ways to make molds such as 3D printing, are changing the way design engineers use injection molding in product development and production planning.

Droduct manager for the cnmould service of fast-turn molding company cnmoulding molding services can be classified into three different types: traditional high-volume molders; a broad group of lower-cost, high-volume molding services typically located offshore; and rapid molders, a more recent phenomenon.

Traditional molders are usually full-service suppliers. "They are all about injection molding tools that last forever, and about speeding up injection," he said. "They do a lot of value-add services like assembly or painting." Tooling used by these services tends to be made of hardened steel; hundreds of thousands to tens of millions of parts are made from multi-cavity production molds.

Rapid molding is newer, and something Proto Labs helped pioneer. It serves the need for making multiple variations of a single product in somewhat lower volumes -- 25 to 1,000 units instead of 100,000 or more, said Barsness. These products and all their components must be prototyped exactly, in all those variations, using exactly the materials they will be produced with.

The resulting increase in SKU proliferation is caused by several colliding trends. First, globalization has produced effects, as described by Barsness. "Say you make a household product or a communications device, and you want to sell it around the world," he said. "Your market used to be the US, but now there's the Chinese market and other countries, like Brazil. Customers in those countries have different values and tastes, whether it's a car or a thermostat." Those countries also have different regulations, such as those for safety, and different specifications, such as for electrical voltage, which effect part variations.

Trends related to energy and environmental friendliness are also driving changes in product designs. "Lightweighting is major, especially in anything that moves," said Barsness." Also, LEDs are being used everywhere for their ability to reduce the power, size, and cost of lighting, and they can be packaged almost any way imaginable. On many of these LED-enabled products, the entire assembly can include five to 10 different injection molded parts.

A third set of changes is due to increases in product connectivity and automation. The Internet of Things has engineers putting sensors on just about anything, from household appliances to industrial products. "Now the design engineer has to get 10 different prototypes of 10 different products for 10 different countries, all of them have LEDs, and they've all got to talk to the Internet," Barsness remarked. This is where rapid molding services come in.

Rapid molding tooling is typically "soft," represented by aluminum instead of steel, for a much lower cost. Rapid molding, of course, has a much faster turnaround. A traditional molder, using a high-volume production mold, could typically take a few months to deliver entire part runs, but the average rapid injection molder delivers parts in 25 to 45 days. Proto Labs' service promises one to 15 days.

Before rapid molding begins, prototypes are also made with production-grade materials. Typically, a customer sends three to five iterations of a design, and Proto Labs cuts a different mold each time. The industries Proto Labs serves tend to be those with some regulation or a high amount of product churn.

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Advantages of plastic medical devices

Use plastic equipment called a major initiative of the medical profession. From drug and pharmaceutical packaging products, to syringes, tubes, surgical instruments and other disposable medical equipment can be seen in the presence of plastic instruments.

Disposable medical device market demand potential is so great why, largely because of its advantage following aspects:

1, light weight, and effort, help reduce fatigue caused by surgery doctor for a long time. More suitable for human blood and muscle tissue, so the more effective.

2, tough is good, anti-permeable, durable, plastic parts can also be used normally at high temperatures.

3, transparent, medical procedures can be better observed, especially during surgery.

4, easy to shape, suitable for the production of a variety of shapes, complex medical equipment and supplies, and simply use the low-cost production process. Use disinfectant or sterilizing temperature corrosion does not occur, or color change phenomenon.

5, compared to metals and other raw materials, low cost, suitable for the production of disposable consumables, and after sterilization of packaging materials used to help reduce the risk of infection.

6, as compared with ceramic or the like brittle glass material, a more secure, especially as packaging material.

With the increase of the proportion of population growth and an aging population, the demand for plastic medical equipment continued to expand, particularly into the body of the equipment. The use of medical equipment to diversify from a single, volume size is shrinking, now one can replace equipment more than the previous equipment. Because many outstanding advantages of plastic medical equipment, pharmaceutical industry in the future course of development, its market share and influence will grow.

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difference between the two-color mold and the overmolding

A. two-color mold: two on the same plastic material injection molding machine, a two-molding, but the product only once a die mold. In general this is also called double injection molding process is usually done by a mold, and the need for specialized color injection molding machine. B. encapsulated mold (secondary molding): two plastic materials are not necessarily on the same injection molding machine, a two-molding; the product is removed from the mold of a mold, then put another set mold for a second injection molding. So, in general this molding process is usually done by two sets of molds, without the need for a dedicated two-color injection molding machine. Color die and overmolding Overview:

overmolding design should pay attention to locate hard plastic pieces, you need to do can be a sealed plastic and rubber parts in the anti-gradient holes to prevent pulling plastic deformation.
Color mold growing popularity on the market today, in this process can make the product look more beautiful, easy to change colors and you can not spray, but expensive, technically demanding.

1.Cavity two shapes are different, each forming one kind of product. The two shapes Core exactly the same.

2. Before the mold after mold after the center of rotation 180o, must match. This action must be done to check the design. 3. Note that the top position of the pinhole, the minimum distance 210mm. A large number of top mold shall be appropriate to increase the stick hole. Moreover, since the injection molding machine itself comes with a thimble is not long enough, so we must be designed to lengthen mold thimble, thimble grow mold base plate about 150mm.

Must be designed 2 3. After locating ring mold base plate.

4. The total thickness of the front panel plus A plate mold of not less than 170mm. Please carefully review this type of injection molding machines other reference data, for example, the maximum capacity of the mold thickness, the minimum thickness tolerance mode, the top rod hole distance.

5. The three-plate mold outlet preferably designed to be automatic ejection action. Pay particular attention to the release of soft outlet whether action *.

6. The front side SPRUE depth of not more than 65mm. On the side (large outlet) Top SPRUE distance from the center of the mold base to not less than 150mm.

7. In the second injection CAVITY design, in order to avoid CAVITY plug (or rub) injury has been forming a good product first plastic bits, you can avoid the empty part of the design. However, the intensity must be carefully considered every sealed plastic bits, namely: in injection molding, whether there will be at high injection pressure, the plastic deformation occurs, resulting in possible second injection may be generated batch front

8. injection molding, injection molding products for the first time can be slightly larger size to make it in the second molding presses with another CAVITY tighter in order to achieve the role of sealant.

9. Note that in the second injection, the plastic flow of whether the first impulse has been forming a good product to glue bit deformed? If there is a possibility, must find ways to improve.

10. Before A, B plate clamping, pay attention to whether or Lifter front mold Slider will be reset and the crushed product? So, we must find ways to make the A, B board first mold, mold SLIDER before or after LIFET to reset.

11. The two CAVITY and CORE's carrying water arrangement as fully as possible, and the balance, the same.

12.99% of injection molded hard plastic case is the first part of the product, and then injection molded soft part of the product. Because soft deformat 

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Common blister material characteristics and application scope

Blister: A plastic processing technology, the main principle is flat plastic sheet is heated to soften hard after vacuum adsorption on the surface of the mold after cooling molding, widely used in plastic packaging, lighting, advertising, decoration and other industries.

Blister packaging: blister technology to produce plastic products, and use the appropriate equipment for product packaging in general. Plastic packaging products mainly include: blister, trays, plastic boxes, synonyms are: vacuum cover, blister and so on. Blister packaging equipment including: plastic molding machines, presses, sealing machine, high frequency machine, folding machine. Package formed packaging products can be divided into: card, blister card, double blister, half blister, folded blister, folded blister and so on.

Blister: Blister process will be transparent sheet made of hard plastic convex shape specific transparent plastic cover on the product surface, play a role in protecting and beautifying products. Also known as blister, vacuum hood

Tray: also called plastic Neto, using plastic sheets made of hard plastic craft plastic specific groove, the product is placed in the groove, played the role of protecting and beautifying products.

Flocking Neto: a plastic tray using special materials, the ordinary hard plastic surface layer of glue velvet material, so that the tray surface kind of velvet touch, to improve packaging grades.

Antistatic tray: a plastic tray using special materials, the resistance of the material surface is less than 11 ohm power 10. Mainly used in plastic trays electronics, IT products.

Plastic mold: plastic mold production, lowest cost plaster mold, followed by electroplating copper mold, the most expensive aluminum mold. Die drilled holes for vacuum heat of adsorption of hard film to form plastic products.

Plastic molding: that we often talk about plastic, plastic molding machine uses heat to soften the hard piece of plastic in the mold surface adsorption, after cooling, the formation of concave and convex shapes of plastic.

Blister cutting: plastic molded plastic products, after punch, large sheets of sheet cut into a single product with a die cutter.

Flap: Plastic packaging products there is a call card packaging, blister needs to be three sides by folding machine to fold back, so the next step in a package, the paper card into the fold to form card packaging .

Heat sealing: a blister packaging technology, with a sealing machine plastic surface coated with oil paper card and blister heat sealing together to form a blister card packaging.

High frequency sealing: a blister packaging technology, with a high frequency machine generates high frequency, bonded together between the bubble and blister shell to form a double blister packaging.

  

Ultrasonic sealing: a blister packaging technology, the use of ultrasound machines to produce ultrasound, will blister and bubble shell bonded together to form a double blister packing, and sealing the difference is that the high-frequency ultrasound can not only sealed PVC, PETG material, PET material is also closed, but the product is not encapsulated EM damage, especially for packaging of electronic products; deficiency is that only the ultrasonic sealing dot interval, a time and is generally a straight edge seal.

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