PRODUCT OVERVIEW ① POROUS VENT ® BLOCK TYPE (POROUS METAL BLANK)
POROUS VENT ® BLOCK TYPE (POROUS METAL BLANK)
■ Overview
PRVT (Standard type) PRVB (Free designation type) PRVF (Free designation/6 F type)
● Features • A porous metal block insert blank developed for gas release applications.
• The product has a porous structure made from sintered stainless steel (SUS430 equivalent). • Effective for improving the transferability as well as appearance of molded products. • Gas can be released from any direction, making the product suitable for molded articles with complex shapes, or for evenly releasing gas from wide–area parts. • Mechanical machining and laser machining can be performed as necessary for the shape of the molded product.
A/B/T tolerance
Type Finishing
PRVT
+ 2 + 1
Six flats cutting
PRVB
● Examples of Molding
+ 0 .1 0
Six surface milling
PRVF
< Before use >
< After use >
A
T
M Material Stainless steel (SUS430 equivalent) H Hardness 400 –450 HV
■ Standard type
Reference value
• Product: Plastic case • Resin: PP • Application effects: Eliminate shorts at the tip of the ribs
Part Number
Linear Expansion Coefficient (10 –6 /K( ℃ ))
Tensile strength (MPa)
Thermal Conductivity (W/m ・ K)
A
B
T
Density (g/cm 3 )
Pore diameter (μm)
Type
50
50 75
50 50
100
50 75 100
■ For use
100
100 100 100
PRVT
6 .1 –6 .4 450 –480 10 –11 12 –12 .5
20
150
200 50
● Examples of Machining Conditions [Table 1] shows an example of NC cutting while [Table 2] shows an example of laser machining condition. Check your specific equipment, as other machining methods differ depending on the equipment. E Make sure to use water–based machining fluid during NC cutting. ● Post–Machining Treatment • Oil draining Always drain the oil at the time of machining by electric discharge, wire cutting, NC cutting, etc., because impregnation with machining fluid can cause ventilation failure and rust. Refer to [Table 3] for differences in ventilation with To increase the surface roughness, finish according to the following procedure. ① Polish once with a fine (#800 recommended) oil stone, then rotate 90 ° and polish a second time. ② Polish with an ultra–fine (#1200 recommended) oil stone. ③ Buff using a paste–type polishing agent (0.5 –1μm particle size recommended). If necessary, use even finer sandpaper (#2500) to polish further. and without oil drainage. • Polished finishing
[Table 2] Example of laser machining conditions (depth 0.01mm) Laser output (W) 9 Pulse frequency (kHz) 30 Feed speed (mm/sec) 800 Wavelength (nm) 1064 Offset (mm) 0.01 E Note that if the output is too strong, the elements evaporate from the surface layer and the corrosion resistance decreases.
[Table 1] Example of NC cutting conditions Cutting speed (m/min)
100
50
300
200 50
150
■ Free designation type
Revolution (rpm)
3000
Reference value
1mm increments
Part Number
Axial cutting depth (mm) Radial cutting depth (mm)
0.1
Linear Expansion Coefficient (10 –6 /K( ℃ ))
Tensile strength (MPa)
Thermal Conductivity (W/m ・ K)
Density (g/cm 3 )
0.25 0.16
A
B
T
Pore diameter (μm)
Type
Feed (mm/revolution)
Required tools • Material: Carbide + AlTiN coating • Type: 4 –flute radius R3 ( φ 16 ) • Applicable work material: Stainless steel (M grade)
PRVB PRVF
20
50–300
50–200
50–100
6 .1 –6 .4 450 –480 10 –11 12 –12 .5
E A ≧ B ≧ T
[Table 3] Ventilation by machining method (example)
Part Number – A – B – T PRVT20 – A50 – B75 – T50 PRVF20 – A121 – B76 – T51
Ventilation (ℓ/min ・ cm 2 )
Quotation
Final Machining Method
Order
Delivery
No oil drainage
With oil drainage
Electric discharge/wire cutting
1.24–1.30 0.55–0.61
3.30–3.60 0.70–0.75
NC cutting
■ For partial insertion
■ For full insertion E Avoid using for the exterior parts of mirror finished products, transparent items, etc.
3.30–3.60 ※ Oil drainage not required
Laser
Example
Machining conditions NC cutting: [Table 1 ] Laser: [Table 2] Measurement conditions • Test piece size: φ 20 x 10mm • Air pressure: 0.3 MPa
PRV □
■ Oil Drainage Method
Fixed side
Fixed side
(1) Air blowing Make air blowing holes ( ※ ) on the side opposite to the molded product surface, blow compressed air (factory air equivalent) at about 0.5 MPa for 5–10 minutes, and wipe off the dirt from the molded product surface with a rag. ※ Substitution is possible if the Porous Vent has gas release holes. It is more effective to heat below the melting temperature of the resin by using a heat gun.
(2) Ultrasonic cleaning (as required) Do ultrasonic cleaning for about 30 minutes–1 hour by heating to 50–60°C, using a water–soluble detergent for metals.
(3) Hot water washing Perform ultrasonic cleaning for five minutes in 50–60°C hot water before performing (1). Repeat until the water is no longer cloudy.
(4) Drying Dry for 1–2 hours in a drying oven kept at 150–160°C. If a drying oven is unavailable, perform (1) until moisture is no longer released. (Approximately 1–2 hours)
Molding PL Gas release hole
Movable side
Movable side
Gas release path
50‒60℃ Water-soluble metal detergent
■ When using • Since the entire surface is in a state of low ventilation at the time of shipment, it is necessary to open holes by wire cutting, electric discharge, cutting, etc. • Shave the rear surface to secure ventilation by making sure the Porous Vent walls are not too thick. • Grinding should be done so as to avoid ventilating the surface, other than for gas release. • Regular maintenance is required. Perform by referring to the methods on the left page. • For cooling, consider using a heat exchanger pipe (WHP) to avoid making water holes and let cooling water flow directly as there is a risk of water leakage. In that case, it is more effective to apply 0.05–0.1mm heat conducting grease (MTJ) between the Porous Vent and the cooling parts. • When installing ejector pins in the Porous Vent, sliding may cause the Porous Vent around the end surface of the ejector pin to wear, widening the mounting hole. Be careful as this will create burrs. • This product is made from rust–resistant materials. However, to prevent rusting, do not store in high–temperature/high–humidity environments or environments with fine dust. ■ How to mount 1 . Machine the Porous Vent to match the shape of the molded product. Refer to the left page for treatment after machining. 2 . Machine the mounting holes and gas release passage into the mold. Be sure to clean with air blowing when finished so that no particles remain, as they may cause clogging. 3 . If it is necessary to drive in the Porous Vent during installation, use a strike plate to ensure that the vents do not collapse. 4 . When checking the ventilation, apply acetone or alcohol to the surface of the molded product and blow from the opposite side. If bubbles emerge from the entire surface, the product is normal.
50‒60℃ Hot water
150‒160℃
● Maintenance Method
• Daily maintenance (in molding machinery) This method eliminates mild resin clogging. It is recommended at the completion of molding (or at the beginning) every day. 1. Spray alcohol on the surface while still mounted to the mold and immediately wipe off with a cloth. Repeat this 1–2 times. 2. Wipe the surface with a cloth moistened with alcohol while blowing compressed air through the gas release hole.
• Periodic maintenance (in molding machinery) This method eliminates medium resin clogging. It is recommended weekly. 1. Spray organic solvent on the surface while still mounted to the mold and immediately wipe off with a cloth. Repeat this 1–2 times. 2. Wipe the surface with a cloth moistened with organic solvent while blowing compressed air through the gas release hole. E Acetone is the recommended organic solvent, but the most suitable solvent depends on the specific resin. Contact the resin manufacturer for details.
• Periodic maintenance (disassembled from molding machinery) This method helps to loosen resin clogs that cannot be removed by daily or periodic maintenance. It is recommended during disassembly from the molding machinery. 1. Remove the Porous Vent from the mold and immerse it in the solvent appropriate for the resin used (acetone, etc.) for 12–24 hours. 2 . Execute the "Oil draining method" steps (1 ), (3 ) and (4 ) in order.
435
436
Powered by FlippingBook