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Heat Seal Pins

Plastic Molding - Heat Seal Pins

Situation:

• A major manufacturer of LCD televisions is using a heat-sealed pin system to bond two pieces of the front cabinet panel. There are 10-15 heat seal pins per jig depending on panel size. • The manufacturer encountered severe sticking of the resin to the heat seal pin resulting in waste and stoppage. Production was less than 50% of the goal. • A Teflon coating was applied to attempt to improve the situation. With the Teflon coating: • Production increased but to only 60% of the production goal. • 2 stoppages per shift were required to manually remove waste resin and apply an additional mold release agent to the pins. • The Teflon coating required complete repolishing and reapplication every 2 to 3 weeks, at a cost of $7,000.

Requirements:

• Operate at or above a temperature of 185°C continuously. • Increase production at least 25% over current situation. • Not change pin cavity geometry to ensure conformance to design specifications. • Net cost reduction relative to Teflon coating and downtime.

Results:

Dicronite dry lubrication is being applied to the cavity and sliding surfaces of the pins. As a result: • Production throughput has increased by over 28% and scrap rates have decreased. • Production stoppages and secondary release agent usage have been eliminated. • Higher operating temperatures (>185°C) are being used, allowing production staff to further optimize production. • Coating operating costs were reduced by greater than 50%. Dicronite dry lubrication has been incorporated into the facility-wide regular preventative maintenance program.

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