Report Passcard mold failure champagne cup Ideplas

14 December 2015
Mould

Model 2N016-D001 4CAV

Date: 2015/06/10

With the modifications made on this mould, we take few weeks to adjust the process but before of these
failures specified in this document, the mould was working in production in auto mode properly 3 weeks
until the 27 november.

Failure November 27, 2015

This damaged happened because the Heating zone 3 was damaged stopping to heat during working, so
this cavity got cold, and the plastic injection was forced to get out to other zones going inside the mould
filling the wiring spaces of the heaters and the manifold.
The mold main nozzle is right and any part in the mould is broken inside.

To repair that failure we cleaned all the plastic inside and then we repair the wiring of all the heaters of
the manifold and thermocouples, and we changed the broken heater # 3.

Cleaning all the plastic with careful to safe the wiring we spend a whole week, after that having the
mould clean we check the gap until the nozzle H3 and the cavity and but we find 0.05 mm in the ring of
adjustment.
In order to prevent an escape of material inside the heater and manifold zones we modified the 4 nozzles,
welding a silver ring in the adjustment point, having finally a 0.01mm gap to the cavity sealing properly.

We reassembly the mould after those changes and we tried it in production again.

Failure December 11, 2015

Starting to test the mould in the Ideplas, it started fine doing the 4 cavities, but after 10 injections approx.,
the cavity number 3 stopped looking like blocked in the needle valve.
Looking that cavity we found the needle valve lowered inside, even when the others were right outside.
We have decided to dismount the mould and open it again to check the trouble.

Opening the mould we found two cavities with material backward in the heater place, cavity 1 and 3.
We dont understand why if the adjustment ring in the gap was almost zero, the material still leaking
backward, we checked the top Nozzle ring but it looks fine.
In the cavity number three the needle valve was blocked backward, so we take out the needle valve, and
we saw that the piston H.07 have a gap between the needle valve H.01 really big, and the others 3 pistons
not.
So we think that the inner gap of the piston have caused the blocked backward during forward movement,
we can replace the needle valve, we still having it in the spare parts.

Concluding we have 2 troubles the first one is that injecting the material, it can go backward in the heater
zone of the nozzles but we dont understand why if the sealing ring in the top of the nozzle doesnt seal
properly.
The second is that we need to change the piston, all the sealings and needle valve to prevent the blocking
trouble of the valve during working

Julian Idrraga
Chief of Technical service
Plastics divisin.