Door Trim Injection Mould
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door trim injection mold tooling

Door Trim Injection Mould

Pictures on show are door trim injection moulds and products for different car brands like Ford, JMC and Lifan. There are several technique difficulties for plastic door panel mold fabrication and here we would like to share cases for horn mesh.

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Product Introduction

Door Trim Mould Horn Mesh Problem

Table bellow shows summary about horn mesh for some door panel mold projects.

Project description	Q42	U375	CA10	V362	N330
A1 Fixed half	5°	7°	5°	6°	5°
A2 Moved half	3°	3°	3°	3°	1°
B	ø1.3	ø2	ø1.8	Ø2.6	ø1.4
C	Ø1.5	ø2.4	ø2	ø2.8	Ø1.7
D	0.43	0.91	0.67	0.8	0.65
E	1	2	1.25	1.4	1
F	0.7	1	1.25	1.4	1
Try-out	Low strength for mesh hole and height not enough at core side but can’t modify for mesh electrode can’t be molded	ok	ok	ok	Angle changed to 3° for the moved half
Gap between meshes	1.8	3.3	2.8	3.7	2.8
Segment difference between core&cavity	0.1	0.15	0.1	0.1	0.1

According to cases above we can have a conclusion that for the mesh angle in the fixed half should be over 5° and in the moved half over 3°.

	As mesh holes are too many too small, etching is not a choice, while using electrode can make even spark marks as appearance required. Due to its number and rough surface, holes angle in the fixed half over 5° and in the moved half over 3° is qualified.
	There is no segment difference designed by some customers for mesh between mold cavity and core, so negotiation is necessary. Better to have mesh diameter 0.1mm more at core than at cavity because there could be mismatches.
	Some customers would like to have mesh all at cavity side, so the inclination should be over 7° for single side, but the risk of mesh being stuck in cavity must be noticed to customer.
	Non complete holes with dimension less than 0.7mm should be blocked because electrode process can not make it.
	Holes whose dimension between 0.7mm~1.2mm should be made by depth of about 0.5mm and those over 1.2mm are ok with normal depth.

Horn Mesh Insert Process

The mesh hole concentricity has influence on sound pass volume and appearance, so it should be taken consideration of performance and function during design phase. Normally the bigger end of mesh hole should be 0.1mm more in diameter than the smaller end, within which the machining would not influence the connecting. Thus the mesh part requires high quality of the door trim injection mould machining, fitting, assembly, injection molding and cooling. To make inserts for the mesh at both cavity and core side is a better choice and convenient for process adjustment during molding.

9(001)(001)

Product

10(001)(001)

Insert

To make more than one direct surface at insert bottom for machine datum. E.g. as it has winding side fitting surface, leave 15~20mm at top for sealing-off and gap at bottom so it needs direct surface fitting to make insert steady. Bottom dimension should fit fixture.

11(001)(001)

Core Side

12(001)(001)

Mesh Insert Fixture

As the mesh hole inserts need long machining time and lots of venting insert pins are required, To make mesh hole insert fixtures by diameter up to 152mm is a good choice that the cycle time and insert pin hole precision can be guaranteed.

13(001)

14(001)

Core side mesh inserts all have fixtures and machining & fitting with the fixture. To guarantee the precision and reduce cycle time, if the mold height is not enough, spacer block is needed, also convenient to process electrode for making ejector pin and insert pin.

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