Injection molding dust-free purification workshop: Where are the key points of construction? How can the difficulties be overcome? The analysis is thorough

Injection molding is a process for shaping industrial products and is a relatively common industrial molding application in various manufacturing industries at present. Generally, it is divided into two methods: rubber injection molding and plastic injection molding. Injection-molded products are widely used, such as mobile phones, laptops, medical devices, communications, micro-motors, computers, electrical appliances, electronics, toys, watches, lighting fixtures, and so on. In the ordinary injection molding workshops of traditional industries, there is no need for air purification treatment in the workshops. At present, only some industries that require high-precision, fine or dust-free and sterile injection molding processes need to be produced in dust-free and clean injection molding purification workshops. With the continuous upgrading of the industry, injection molding purification workshops will develop into a future trend.

When our purification engineers need to design a purification workshop, they first understand the industry characteristics of the user and conduct an actual site investigation and understanding of the factory workshop. Therefore, a thorough understanding of the injection molding process flow, injection molding production equipment and the environment is very necessary.

According to the "Code for Design of Clean Rooms", the design of injection molding purification workshops is based on the matching of the injection molding industry process, fully considering the user requirements of the cooling water system, equipment power distribution system, compressed air system, crane layout, air conditioning and ventilation system, automatic feeding system, and automatic conveyor belt system. It is also necessary to take into account the overall factory planning of the subsequent processes such as the screen printing workshop, spraying workshop and coating workshop, and carry out professional dust-free purification design. Professional design of injection molding purification workshop, key points to note

1. The injection molding machine generates a lot of heat

The injection molding industry is characterized by the fact that injection molding equipment generates a large amount of heat energy, causing the internal temperature of the workshop to rise. Therefore, when selecting and designing air conditioning for a purification injection molding workshop, it is essential to focus on calculating the total cooling capacity, thoroughly considering the maximum heat generation of the injection molding machine and the number of workshop staff, leaving sufficient margin. Otherwise, if the cooling capacity is insufficient in summer, the temperature and humidity will not meet the design requirements, and the temperature cannot be reduced, which will affect the production environment of the workshop.

Similarly, injection molding machines generate a considerable amount of heat. In southern regions, cooling needs to be turned on for most of the spring, summer, autumn and winter, while in other workshops, heating is required during winter. The operation modes of the two types of purification air conditioning systems are exactly opposite. The design requires thorough and careful consideration by purification engineers!

2. Injection molding generates waste gas

In the working area of injection molding machines, a certain amount of odorous gas will be produced during the operation of the equipment. As the injection molding purification workshop is a relatively enclosed space on all sides, it is not conducive to the discharge of exhaust gas. Therefore, when designing, it is necessary to consider the local design of strong exhaust ventilation to promptly extract and remove the odorous gas, reduce its spread and interference to other working areas, and avoid causing harm to human health.

3. High-cleanliness spray painting area

If the injection molding process is followed by a painting process, the painting area has higher requirements for the air cleanliness of the workshop environment compared to other working areas in the injection molding purification workshop. It is even more necessary to strictly control dust particles. Therefore, the local design of the painting area generally needs to reach a static level of 1000 or even 100 to minimize the interference of fine dust particles on the surface quality of the painting process. Ensure the smoothness of the product. At the same time, the spray painting area will produce a large amount of paint odor. An independent exhaust and purification system should be set up, and the paint should be purified and filtered in an environmentally friendly manner before being discharged. It should comply with the requirements of the environmental protection management department of the area where the factory is located.

4. High heat in the baking area

The baking area for injection molding is equipped with oven devices. When the oven door is opened, a large amount of heat energy will be generated. To avoid air flow disorder in the injection molding workshop, corresponding exhaust ventilation should be designed to promptly remove the heat from the oven.

5. Negative pressure design

As mentioned above, both the baking area and the spray painting area generate considerable heat. To prevent heat from being discharged and causing air flow disorder, the air flow organization in the room should be designed as negative pressure (relative to the adjacent clean area), so that the air flow only enters and does not exit.

As injection molding production basically requires continuous operation for 24 hours, otherwise it will cause serious waste of raw materials. When designing an injection molding workshop, it is necessary to ensure smooth production operation. According to the injection molding process, the operation processes of each link and position in areas such as the raw material room, scrap room, batching room, production site, post-processing area, tool room, semi-finished product area, and office should be smooth. It is also convenient for staff to supervise and coordinate production.

As an application of the purification workshop, the basic purification parameters of the injection molding purification workshop are not significantly different from those of other industries. They will not be elaborated in detail and are briefly described as follows:

Air change rate: 10 to 15 times per hour for 100,000 grade. 10,000-level: 15 to 25 times per hour; 1000-level: 50 to 52 times per hour; The cross-sectional wind speed of the 100-level operation console is 0.25-0.35m/s.

Pressure difference: ≥5Pa between the main workshop and adjacent rooms.

Temperature: > 16℃±2℃ in winter; Summer < 26℃±2℃;

Relative humidity: 45-65% (RH)

Noise ≤65dB (A);

Fresh air supply volume: 20% - 30% of the total supply air volume.

The injection molding purification workshop involves multiple specialties such as refrigeration, heating, pure water, compressed air, vacuum, air conditioning, process cooling water, nitrogen, oxygen, fire protection, power distribution, automatic control, communication, and purification decoration. The key and difficult points of the design are all in the areas of heat and waste gas treatment.