Major Breakthrough Inventions for Injection Molding

Major Breakthrough Inventions in Injection

Molding

Lih-Sheng (Tom) Turng1

Suresh Shah2

Hanxiong Huang31University of Wisconsin-Madison

2Delphi Thermal System3South China University of Technology

Injection Molding

• One of most important polymer processing methods

• Processes more than one-third of thermoplastics• More than half of polymer-processing equipment• No. 1 in employment and product shipments

Historical Developments of Injection Molding

DisclaimersIncomplete and not meant to be exhaustive

Acknowledgements & References• Dr. Chi-Kai Shih & Fundamental Forum Committee• J. F. Chabot & R. A. Malloy, J. of Injection Molding Technology,

1(1), p. 1, 1997• P. J. Gramann & T. A. Osswald, Chap. 1, Injection Molding

Handbook, 1st & 2nd ed., Hanser, 2001 & 2007• Dr. Don Rosato (personal communications)• D. V. Rosato & D. V. Rosato, Injection Molding Handbook, Van

Nostrand Reinhold, 1986• J. Avery, Injection Molding Alternatives, Hanser, 1998• Companies that produced and provided the example parts• U.S. Patent and Trademark Office

Timeline of Machine/Equipment Development

1849Sturgiss

1856Pelouze

Die casting machines

1872Hyatt

1st plastics injection machine

1870Smith & Locke

Die casting machine

1869Hyatt

Processed Celluloid

John Wesley Hyatt 1837 -1920

Picture from the National Inventors Hall of Fame


1849Sturgiss

1856Pelouze


1872Hyatt


1870Smith & Locke

Die casting machine

1869Hyatt

Processed Celluloid


1849Sturgiss

1856Pelouze


1872Hyatt


1870Smith & Locke

Die casting machine

1869Hyatt

Processed Celluloid

1904GaylordInjection molding process

(for amber products)

1903RichardsFledgling injection machine


1849Sturgiss

1856Pelouze


1872Hyatt


1870Smith & Locke

Die casting machine

1869Hyatt

Processed Celluloid




1926Eckart & Ziegler1st commercial

Injection machine

(Germany)

1923Grotelite Co.1st U.S. built

injection machine

1926Grotelite Co.

1st fully automatic injection machine


1849Sturgiss

1856Pelouze


1872Hyatt


1870Smith & Locke

Die casting machine

1869Hyatt

Processed Celluloid




1926Eckart & Ziegler1st commercial

Injection machine

(Germany)

1923Grotelite Co.1st U.S. built

injection machine

1926Grotelite Co.

1st fully automatic injection machine


1928Husted

Multiple-cylinder injection machine

1932Gastrow

Torpedo heating cylinder

1930Shaw

1st hydraulic Injection machine

New thermoplastics: vinyl, acrylics, polystyrene

1930’s


1928Husted


1932Gastrow


1930Shaw



1930’s

Piperoux/Shaw & Huges

Mold clamping systems

1935Index Machine

Corp.1st clock-

controlled auto. machine

1935HPM

Hydro-Power Plastic

Extrusion Molding Press

1930’s


1928Husted


1932Gastrow


1930Shaw



1930’s

Piperoux/Shaw & Huges

Mold clamping systems

1936Burrough

Two-stage plunger-plunger

Injection machine

1935Index Machine

Corp.1st clock-

controlled auto. machine

1935HPM

Hydro-Power Plastic

Extrusion Molding Press

1930’s

“Petrothene Polyolefins: A Processing Guide,” 3ed., U.S. Industrial Chemicals Co., New Yory, 1965


1943Beck (BASF)

1st Reciprocating screw injection

machine


1943Beck (BASF)


machine

1948Hendry/Jackson

& Church Co.Two-stage

screw-plunger injection machine

1948Gits Molding

Corp.Multiple-shot

injection machine

1946HendryScrew

injection machine

“Petrothene Polyolefins: A Processing Guide,” 3ed., U.S. Industrial Chemicals Co., New Yory, 1965


1943Beck (BASF)


machine

1952Willert

Reciprocating screw injection

machine

1948Hendry/Jackson



1948Gits Molding

Corp.Multiple-shot

injection machine

1946HendryScrew

injection machine


1943Beck (BASF)


machine

1946HendryScrew

injection machine

1952Willert

Reciprocating screw injection

machine

1953Lewis Welding &

Engineering Corp.New “Hydra-Lock” clamping system

1948Hendry/Jackson



1948Gits Molding

Corp.Multiple-shot

injection machine

1953George S. Scott

Mfg. Co.Restricted

gating system

Modern Injection Molding Machines

All-electric injection molding machines

Multi-color and multi-component machines

Source: Milacron

Driving Forces for Variants of Conventional Molding Technologies

• Low System Cost and Low Weight (Strong driver for automotive)

• Product Differentiation with Functionality• Appearance with Functionality• Quick Change in Product Designs – Short Lead Time• System Integration and Greater Modularization• Harmony and Craftsmanship• Safety• Design Freedom• Sustainability and Environment• Lean Manufacturing

Emerging New Injection Molding Processes

Emerging New Injection Molding Processes• Multi-Component Molding (Polymer-Polymer)

• Multi-material (soft/hard), Multi-color molding• Co-Injection Molding• Thermoset/thermoplastic molding• Combination processes (Mulit-material with fluid assist, Multi-material with co-injection and fluid

assist, Multi-material with LSM molding, Multi-material with MuCell process)• Multi-Component Molding (Polymer-Fluid)

• Gas Assist Water Assist Projectile • In-Mold Processing

• Insert Molding and in-mold lamination (sheet, textile, paint film)• In Mold Assembly• Rotating Stack Technology, and In-mold Painting Process

• Hybrid Technology• Plastic/Metal, Plastic/Nano-metal coating• Plastics/Plastics• 3-D MID (Molded Interconnect Devices)

• Foam Molding• Micro-cellular Foaming Processes (MuCell)• Structural Foam Molding

• Thin wall Molding (Large part and Small parts)• Hollow Article Molding

• Injection Blow Molding• Die sliding technology

• In-Line Compounding (IMC)/ Injection Molding (Material formulation and molding in a single step)• Injection-Compression Molding and Expansion Injection Molding• Micro-molding/Nano-molding• Metal and Ceramic Injection Molding (Magnesium and Powder Metal Molding)• Thermoset Injection Molding (BMC and ZMC)