MOLD BUILDING STANDARDS

Revised Date:January 29, 2004

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1.0 PurposeThese Specification have been written to provide mold sources with the

information required to build injection molds for CEI to meet the standards of

CEI

- These specifications are not intended to limit or inhibit the

development of molds.

2.0 Scope:

Applies to all new tooling for internal injection molding.

3.0 Definitions:

Rc = Rockwell Hardness

NPT = National Standard Pipe Taper

SPI = Society of Plastic Industry

JIS = Japan Industrial standard

4.0 Instruction:

4.1 General:

CEI depends heavily on its vendors for design and workmanship resulting in a

high-class injection mold. In order to help the vendor understand the type of mold

required, the following general guidelines and specifications are provided. These

general guidelines will aid in the manufacturing process at CEI but may not be

feasible at all times. Any deviations or changes recommended by the vendor will

be considered by CEI and noted on the Injection Mold Kick-Off form when

applicable. The Kick-Off form (WI 0906.630 F-1) will be utilized to start

production tooling. The vendor will sign and return a copy of the Kick-Off form

if all specifications are agreed to.

4.2 Mold drawings:

4.2.1 Preliminary

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The tool vendor will submit a copy of preliminary drawings to be

reviewed by CEI. Upon approval, these drawings will be returned within

1 week with any changes required by CEI.

4.2.2 Final

The tool vendor will provide a final set of detailed drawings after approval

of the mold. At the time of tool transfer, vendor must send

One (1) set have complete, accurate and reproducible detailed final design

plots (not copies), as well as electronic data on compact disk, in UG and

native format to CEI (ATTN: Jon_Mench@ceiltd.com)

Final mold design drawing must include:

Complete stock /detail list

Mold base assembly with cross-sections through mechanical features

Completely dimensioned mold base plates

Movable and fixed core inserts assembly from both parting line (PL) and reverse

side

Completely dimensioned core and cavity inserts, including vent dimensions

All tool designs must be in metric. Material shrink rate MUST be on every

drawing. All drawings must be on standard format with the title block filled in

completely and correctly. All designs are to be completely detailed, ballooned, and

stocklist provided. All geometry data to be drawn in full scale in CAD file (except

blow-ups), plotting to be 1:1, 2:1, 4:1 and etc.

Vendor who does mold design using AutoCad®/CadKey®/MasterCam

/Catia® /Unigraphics® / Pro-Engineer® should send CEI electronic file in native

format. Vendors who use other CAD software systems must send CEI electronic file

in UG format.

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Vendor must record all the design and/or manufacturing changes during the mold

building process. Mold design plots and electronic data must be updated to the actual

steel.

4.3 Progress Reports:

After the tool has been kicked off and the Kick-Off form has been agreed to,

weekly progress reports are required indicating status of the tool and the

percentage completion.

4.4 Mold Build Requirements:

Mold vendor must complete the flow mold analysis and send the result to CEI for

review before any mold design activity is taken place.

The mold source will provide successful samples for CEI.

- The first sample must prove mold function.

- The second sample part must meet appearance requirements.

- The third sample will be for CMM layout and CEI expected vendor

layout the part with 100% in spec before mold shipment.

Mold source to CMM the part, check steel core, and cavity.

- CEI will provide checkpoints.

- Layout results to be provided prior to mold shipment

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4.5 Material:

All inserts are to be constructed out of S7 or H13 hardened to 48-56 Rc. Other

material may be agreed upon and approved by noting on the approval of the mold

drawings.

4.6 Ejection:

Molds must be able to accommodate ejector rod sizes and positions from SPI and

JIS specifications (platen layouts provided as needed). When possible, ejectors

knockout positions are to be designed in the center and vertical positions for SPI

and JIS platten standards. All ejector systems are to be spring loaded and

returned. Knockout studs must be mounted on the ejector plate and be flush with

the clamping plate to reduce ejector rod travel.

160T Sumitomo Platens

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4.7 Cooling:

All molds should be designed to encompass as much cooling as possible. Water

circuits should be designed so that entry and exits are out of the non-operator side

of the mold when in the press whenever this is feasible.

All water connections should be 1/8" NPT and 1/4" NPT.

Fittings should be 200 series.

Any couplings on the bottom of the mold should be recessed below the mold

surface. No more than eight water circuit connections are to designed or used.

Molds with fittings installed must fit between the machine tie bars (may require

fittings to be recessed).

Water lines should be stamped IN and OUT on the non-operator side or top and

bottom of the mold.

Water diagram should be mounted on the non-operator side.

4.8 Runners and Gates:

All runners should be balanced regardless of mold type. All three plate molds

have the runners removed by robots. Puller rods should be built inside the mold.

The runners should be designed to stay in position (no rotation) for the robot to

grip and remove.

4.9 Surface finish:

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The surface finish required will vary by part type. Other non-specified finish

must meet SPI class 3 specification unless noted otherwise or the function of the

tool requires better.

4.10 Miscellaneous:

4.10.0 Mold strap should be on the side of the mold and is required on all molds.

4.10.1 All sprue-bushing radii must be 1/2" and no deeper than 2 in.

4.10.2 Pry bar slots are required to separate all plates.

4.10.3 All nozzle orifices are to be no smaller than 1/8".

4.10.4 Shot counters are required on all molds.

These should be recessed on the operator side when possible.

When not possible, externally mounted counters on the operator side or

top are acceptable. Counter should be Progressive component model #

CVPL-100, CVEX-100 or equivalent.

4.10.5 All molds are to have Identification tags mounted on the operator side of

the mold. Tags and information for tags will be supplied by CEI. Mold

weight (in pounds) and vendor job number should be engraved on the side

of the mold.

4.10.6 Locating rings are JIS and SPI standards.

CEI is using Nissei, Sumitomo, and Fanuc.

Locating ring holes diameter for 40 T, 50T, 55T, 75T, 80T, 100T are 4

inches.

Locating ring holes diameter for 160T & 180 T are 120 mm.

Locating rings must protrude a minimum of 1/2” from clamp plate.

4.10.7 Clamping Plate thickness to be less than 1".

4.10.8 Core pins that build with the purpose to eliminate voids should have

chamfers at its diameter transitions (larger to smaller dia)

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4.10.9 Final approved prints are to be supplied to CEI on 11"X17" media (2

copies). Electronic .dwg files of the mold design are also preferred.

4.10.10 All cavities are to be marked by sequential numbers. The location

of number will be approved on mold drawings. The order of cavity

location should be as shown below.

4.10.11 For hot runner molds, CEI is using Husky Hot Runner System.

- For glass filled material replaceable gate inserts (D2) must be used.

- All electrical connections and boxes must be mounted in a secure and

protected fashion to prevent damage.

- All electrical connections and boxes should be mounted on the top of the

mold whenever possible

-Alternate location is on the side opposite the operator (Helpers Side)

All cavity zone numbers must match cavity numbers. (Figure#1, See

attachment, A-11)

- CEI have been using “J Type thermocouple”

CEI had four different kinds of hot runner temperature controller

a) Husky Hot Runners Temperature Controller:

4 Zones – Main 1 – Sprue 1

Model: GLC2K- Pronto – 6

Serial #: 1201-22006-03

Voltage: 240 Phase: 3 Amp: 30

24 -24 Sprongs

b) Mold – Master Hot Runners Temperature Controller:

1 Zone

Model: TM01220A10

Serial #: TM9834031

Supply Volts: 220

Phase: 1

Hz 50/60

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Full Load Amps 15-------6 Sprong

1 Zone

Model: TM01220A10

Serial #: TM9839044

Supply Volts: 220

Phase: 3

Hz 50/60

Full Load Amps 15-------6 Sprongs

12 Zones

Model: SM0200000008

Serial #: SM9823175

Supply Volts: 220

Phase: 3

Hz 50/60

Full Load Amps 40------24 –24 Sprongs

c) DME Hot Runners Temperature Controller:

1 Zone

240 VAC 15 AMPS 6 sprongs

Model: MFPIG

Serial #: FG 24190

Wire Configuration System Voltage

1 3 wire 208-240 VAC

8 Zones

240 VAC 15 AMPS each 16 Sprongs - 16 Sprongs

Model: MFP8GCV

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Serial #: FC-35802

50 AMP

Wire Configuration System Voltage

3 4 wire 208-240 VAC

12 Zones

240 VAC 15 AMPS each 24 Sprongs - 24 Sprongs

Model: MFP12GCV

Serial #: F3-37490

50 AMP

Wire Configuration System Voltage

3 4 wire 208-240 VAC

d) SEIKI Hot Runners Temperature Controller (Valve & Spear System):

8 Zones

Model: SPM08TP04KJ

Serial #: 80040

Voltage: 240 VAC KVA: 22

Freg: 50/60

Phase: 3

24 – 24 Sprongs

4.10.12Eye bolt holes will be as specified below:

Up to 375# M12

376# to 1000# M16

1000# to 3500# M22

4.11 Record:

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Injection mold kick-off record is kept by SLP 1601.400.

5.0 References:

5.1 SLP 1601.400 : Control of Quality Records

6.0 Attachments:

6.1 (A-1): Injection Mold Kick Off Form, (WI 0906.630 F-1)

6.2 (A-11) : Figure#1

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