Glass encapsulation

Glass encapsulation refers to the process of sealing an object or material inside a glass enclosure or capsule. This process is commonly used in the manufacturing of electronic components, such as semiconductors, LEDs, and sensors, to protect them from environmental factors like moisture, dust, and temperature fluctuations.

The encapsulation process typically involves placing the electronic component or material in a mold, and then injecting a liquid glass material into the mold to completely cover and encase the object. The glass is then heated to a high temperature to harden and fuse it together, creating a hermetic seal around the encapsulated object.

The benefits of glass encapsulation include improved durability and longevity of electronic components, as well as increased resistance to environmental factors. Additionally, glass is a highly transparent material, which allows for the transmission of light and signals through the encapsulation, making it suitable for applications like optical sensors and displays.

Encapsulation process in injection molding

Encapsulation process or glass encapsulation.

Encapsulation process is the process to adding the plastic on glass periphery. In other way ,glass used like as insert in mould & inject the material through the injection molding machine.

Glass to PVC adhesion.

We use solution of primer for adhesion of glass to PVC Which is 1500A,1500B&MEK

Glass to TPV adhesion.

 we use  solution of  primer for  adhesion of glass & TPV-

   1680A +1680 B+1680 C

Procedure 

before encapsulation  we need to  apply the primer on glass then it goes in dryer after drying  it ready  for  use as insert  in mould ,and also use child parts as per requirement and start the injection .after injection do the inspection  & it need to trimming  means de flashing & inspection after inspection  it will dispatch .

Injection moulding history and type

                                        INJECTION MOULDING

*Historical Background
* A single-action hydraulic injection machine was designed in the U.S.A.
in 1870 by Hyatt
*Heating-cylinder design was first recognised in a patent issued to Adam
Gastron in 1932.
*Large-scale development of injection moulding machinery design
towards the machines we know today did not occur until the 1950's in
Germany
           @ InjectionMouldingProcess
– Over View
Solid Wide neck, Flat Product is made like bucket, cabinets, Automobile &
Industrial parts etc…. by injecting molten thermoplastic material in to a
closed mould which is relatively cool.

*Type of Injection Moulding Machine

* Hand Injection Moulding M/C
* Plunger type Injection Moulding M/C
*Reciprocating Screw Type Injection Moulding M/C

                          @Hand Injection Moulding Machine

vertical machine consists of Barrel, Plunger, Band Heaters along with energy
regulator, Rack & Pinion system for Injecting the material by the plunger, a
torpedo and nozzle.

 Plunger Type Injection 

Moulding Machine
Vertical & Horizontal Plunger Type Injection Moulding Machine

 The Reciprocating Screw

 The feeding zone
 The compressing (or transition) zone
 The metering zone

Water assist injection molding (WAIM)

Water Assisted Injection Moulding (WAIM) is a new development in the field of Injection Moulding and said to be an alternative to Gas Assisted Injection Moulding (GAIM). Using this process, Tubular hollow parts and Rod shaped products can be manufactured cost effectively.

This idea of Injection of Fluids (Water or Oil) was proposed in 70’S but at that time, the use of water did not succeed satisfactorily, due to difficulty in achieving high flow rates and pressure.

Recently, IKV (Institution for Kunststoffverarbeitung), Germany in association with finders Anglagentechnik has developed a Proto type production line (Demonstration Plant ) and carried out water injection successfully

INJECTION MOULDING & PLASTICS DEFECTS (DEFECTS IN PLASTICS ),injection molding defects ,air bubble in plastics,air bubble in injection moulding ,short shot in plastices,flow mark in injection moulding,silver mark in injection molding

,INJECTION MOULDING 

Injection moulding(molding) is a manufacturing process for producing parts by injecting molten material into a mould. Injection moulding can be performed with a host of materials mainly including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers.

Most important things in injection molding is defects.

• Flash

• Short

• Sink mark

• Warpage

• Silver 

• Flow mark

• Burn mark

• Air bubble

• Flash-

 when molded part dimension increase or excess material  on parting line  after moulding ,its called flash.

cause or reason of  flash  

1.  excess  material volume
2. high injection pressure
3. high  barrel temp.
4. high mould/mold temp.
5. mould/mold wear out .
6. high holding  pressure
7. insufficient clamp pressure  

remedies of  flash in injection molding

1. increase the clamp pressure
2. reduce the injection pressure
3. check the barrel temp. & set it as per material required processing temp.
4.  check mould condition if wear out  then  do the lessor or required welding 
5. reduce the holding pressure
6. reduce the material volume .

• Short -

when the part not  completed or it not take mould shape  after  molding ,then it called short-shot problem .simply we say part not  completed during  injection it called short shot .

cause or reason of  short -shot

1. low injection pressure
2. low melting temperature
3. insufficient shot volume 
4. centering out
5. ring plunger wear out

remedies of  short -shot in injection molding(plastics)

1. increase the  injection pressure
2. increase the melting temperature
3. increase the  material volume
4. check leakage between nozzle & sprue  if centering out then correct it .
5. last option  check the ring plunger may be material go backward through ring plunger during injection . 

• sink mark  in injection molding plastics parts

if we found waviness  or like a miner depth on flat surface of parts after injection in plastics part  its called sink mark or shrinkage .it may  occur where the wall is thicker .

cause or reason of sink mark

1. low injection pressure
2. low holding pressure
3.  low/high mould/mold temperature
4. mould cooling channel block
5. material processing temp. too high
6. thickness of wall

  remedies of  sink mark in injection molding(plastics parts ) 

1. increase injection pressure
2. increase packing /holding pressure
3. set the mould temperature as per required temperature
4. clean mould cooling channel
5. check material processing temperature & reduce as per  required temp.
6. and the last option if problem not control then  reduce the thickness by providing ribs with 7 dgree method. 

• Silver mark or silver  streak

when formed Spatter lines on the surface of the plastics parts after moulding along the direction of material  flow are called silver marks or silver streak.

cause or reason of silver mark

1. raw material contains water
2. excess material temperature (melt decomposition)
3. material containing filler.
4. oil or water in mold surface.
5. injection speed Too fast  (shear decomposition or air entrainment)
6. colour powder has poor temperature resistance.
7. air trapped in barrel

remedies of  silver mark in injection molding or plastics parts )

1.  Dry  raw material in dryer  (within allowed moisture content)
2. reduce the melt temperature
3. reduce the lubricants  filler or replace with other additives.
4. clean the over all mold cavity & runner path with alcohol.
5. reduce the injection speed
6.  use color residence with higher temperature resistance.
7. increase the back pressure .