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| | The design of the four-component machine is similar to that of the three-component machine. In addition, a fourth injection unit is employed. In the case of the four-component machine, two injection units in a diagonal arrangement work horizontally through the fixed mounting platen, one unit injects vertically from above through the parting line, and the fourth injection unit is positioned in an L-configuration.
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This machine also consists of a standard two-component machine as well as a second machine with a machine base in an L-configuration. The four-component machine features a central control panel via which the control systems of both machines can be programmed. In the sequence diagram, these are linked via synchronisation points. This ensures a smooth overall cycle sequence of both machine control systems combining simultaneous and serial movements. It is possible to switch back and forth between the control systems by means of a button.
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With the four-component machine the injection units can, for instance, be arranged as follows.
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Two or four-station moulds can e.g. be used for four-component injection moulding applications.
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In the first process step, a pre-moulded part is initially created in a cavity through the simultaneous injection of three components, and then transferred to a second working position. For this step, the mould is opened, and the necessary change in position is completed by a rotary motion of 180°. After the mould is closed, the pre-moulded part is located in the second position for final injection with the fourth component. Simultaneous to this second step, the next pre-moulded part is already being created in the first mould cavity. During the next opening of the mould, the mould cavities are turned back by an alternating rotary motion. The finished part is now demoulded from the second cavity, while a new pre-moulded part is placed into position from the first cavity.
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Multi layer plastic parts, for example, can be produced with a four-station mould. The application of regranulated material and resistive layers which, for example, hinder the diffusion of oxygen is both possible and simple. The illustration depicts the step-by-step build-up of a four-layer moulded part. The innermost layer is produced at the first station. The mould then cycles through 90° one station further. There, the first component is encapsulated by the second. The mould half then rotates on to the third station, and finally to the fourth station for the final production stage. Once here, the outer protective layer, or the visible layer of the moulded part, is injected onto the part. After the cooling period has expired, the finished multi layer part can be demoulded from the cavity. In the current cycle, a completed moulded part is produced each time the mould opens.
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