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How are wires injection molded?

MINHUI will share with you how wires are molded to obtain their necessary protective layer through injection molding technology.

I. Purpose of Wire Injection Molding

Before delving into the specific injection molding process, it is important to understand why we need to mold wires. In short, wire injection molding is done to provide a plastic coating for exposed wires. This serves several purposes:

– Protect the wire from physical damage.

– Isolate the conductive material to prevent electric shocks and short circuits.

– Improve the durability and lifespan of the product.

II. Material Selection

The materials commonly used for injection molding are thermoplastics such as PVC (Polyvinyl Chloride) or PE (Polyethylene). These materials soften and become flowable when heated to a certain temperature, and solidify into a solid form when cooled.

III. Injection Molding Process

1. Material Preparation and Drying

Firstly, the selected plastic raw material particles need to undergo drying treatment to remove any moisture, preventing the formation of bubbles or cracks during the injection molding process.

2. Wire Preparation

The copper or aluminum core of the wire needs to be cleaned to ensure there are no traces of oil or debris that could affect the quality of the final product.

3. Injection Molding Machine Setup

The injection molding machine is the main equipment used for the injection molding process. Proper temperature, pressure, and speed settings are required, which may vary depending on the materials used and the diameter of the wire.

4. Plastic Melting and Injection

The plastic raw material is placed into the hopper of the injection molding machine and heated to a molten state. It is then injected into the mold through a screw inside the machine, with the wire passing through the mold. The injected material forms a uniform protective layer around the wire core under high pressure.

5. Cooling and Solidification

The molten plastic injected into the mold needs to cool and solidify inside the mold. This process cools the plastic into a solid state, forming the insulation layer of the wire.

6. Demolding and Inspection

The cooled wire, now with its new plastic coating, is removed from the mold. At this stage, its appearance and dimensions are inspected to ensure it meets the quality standards.

7. Post-processing

Some wires may require additional post-processing steps, such as printing, cutting, or other procedures to meet specific application requirements.

IV. Quality Control

Quality control plays a crucial role throughout the entire process. Negligence at any stage can result in substandard products. Various inspection methods, including but not limited to electrical testing, dimensional measurements, and physical performance tests, are performed to ensure the quality of the wire.

In conclusion, through careful design and precise control, injection molding can provide wires with a high-quality and high-performance protective layer.

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