Common Issues in Poor Molding
First, the amount of injection is insufficient. This can be caused by several factors: 1) the injection volume is too low, leading to poor plasticity; 2) there is not enough rubber feed; 3) the injection pressure is too low; 4) the rubber temperature is too cold; and 5) the injection speed is too fast.
Second, the finished product may have flash. This often occurs when: 1) the injection pressure is too high; 2) the mold closing pressure is too small; 3) the injection volume is excessive; 4) the second stage pressure time is too long; and 5) the injection speed is too fast.
Third, shrinkage can occur during the molding process. Common causes include: 1) low injection pressure; 2) the secondary pressure time is too short; 3) the injection speed is too slow; and 4) the compound temperature is too high.
Fourth, flow marks may appear on the surface of the product. This is usually due to: 1) low compound temperature, which reduces fluidity; 2) a slow injection speed; 3) low secondary pressure; and 4) a short secondary pressure time.
Fifth, air bubbles may form inside the molded part. This can happen if: 1) the injection pressure is too low; 2) the secondary pressure is also too low; 3) the secondary pressure time is too short; and 4) the injection speed is too fast.
Sixth, bending or deformation may occur. This is often caused by: 1) high injection pressure; 2) high secondary pressure; 3) long secondary pressure time; 4) low compound temperature; 5) slow injection speed; and 6) insufficient cooling time.
Power plugs can become hot during use, which is a common issue. For example, mobile phone chargers often get very hot at the plug end while charging. This heating is typically due to problems with the wiring inside the plug. To prevent overheating and potential burns, it's important that the wiring is properly secured, without twists, cracks, or uneven surfaces. The quality of the power plug is crucial for safety and performance.
When manufacturing a power cord plug, the internal wiring must be carefully handled. The plug should fit tightly, and the connections should be secure. Different inserts require specific molds, and using the wrong mold can lead to issues like loose connections or exposed copper wires. For instance, larger plugs, such as those used in South Africa, need thick copper wires to ensure a solid connection. If the customer requires a smaller wire diameter, the length of the stripped copper can be increased and folded in half to improve thickness and grip.
Another example is the British-style plug. When assembling, care must be taken with the copper head of the power cord. The length of the wire inserted into the plug should be correct, and the screw should be tightened properly. If it's too loose, the upper and lower covers of the plug might shift, leading to instability. In summary, if a plug becomes hot, it's either due to an overload current or a problem with the plug itself. Ensuring proper manufacturing and maintenance is key to avoiding these issues.
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