96-Cavity Cap Mould
Professional Definition
Refers to a specialized injection mould for bottle caps with 96 cavities, representing one of the most efficient mould configurations in the current plastic cap industry, suitable for large-scale standardized production.
Core Technical Features
Technical Dimension | Detailed Specifications |
|---|
Mould Size | 850×850×600mm (typical specification) |
Injection Machine Requirement | 800-1200 tons clamping force |
Shot Weight | 800-1200g per cycle |
Mould Weight | 6-8 tons |
Cooling Channels | ≥12 independent circulation systems |
Hot Runner | Needle valve type, 96-point independent temperature control |
Daily Production Capacity | 600,000-1,000,000 pieces (24 hours) |
Structural Design Innovations
1. High-Density Cavity Layout
Adopts a "hexagonal honeycomb arrangement" structure:- Center distance: 28mm (28mm cap) / 32mm (30mm cap)- Row spacing: 24.2mm / 27.7mm- Total arrangement: 8 rows × 12 columnsAdvantages: ◼ Runner length variation < 3% ◼ Filling time difference < 0.15 seconds ◼ Temperature uniformity ±1.5°C
2. Layered Runner System
Main runner (primary): - Diameter: Φ16mm (inlet) → Φ10mm (outlet) - Length: 400-450mm - Taper: 1.2°Secondary runners (6 groups): - Each group serves 16 cavities - Diameter: Φ8mm → Φ5mm - "Fishbone" symmetrical distributionTertiary runners (96 branches): - Length: 40-50mm - Diameter: Φ3.5mm - Pressure balancing slots at the ends
3. Zoned Cooling Network
Cooling circuit configuration:├─ Central zone (16 cavities): Spiral water channels, Φ10mm├─ Middle zone (32 cavities): Annular water channels, Φ8mm├─ Edge zone (48 cavities): Grid water channels, Φ6mm└─ Gate zone: Independent rapid cooling, Φ6mmFlow control: - Total flow rate: ≥100 L/min - Temperature difference between zones: ≤2°C - Pressure loss: ≤0.15 MPa
Manufacturing Precision Control
1. Cavity Consistency Assurance
Cavity machining adopts group machining technology, completing all 96 cavities in a single setup
Cavity volume deviation: ≤±0.15%
Parting surface flatness: ≤0.02mm/300mm
Cavity positional accuracy: ±0.01mm
2. Hot Runner System Precision
Temperature control: - 96 independent temperature control zones - Each heating zone: 100-150W - Temperature control accuracy: ±0.5°C - Thermocouple response time: <0.5 secondsNeedle valve synchronization: - Opening time difference: <0.01 seconds - Stroke consistency: ±0.02mm - Sealing pressure: ≥60 MPa
Production Efficiency Optimization
1. Ultra-Short Molding Cycle
Process time distribution:├─ Injection time: 1.2-1.5 seconds├─ Holding time: 1.5-2.0 seconds├─ Cooling time: 3.0-3.5 seconds├─ Mold opening/closing time: 1.2-1.5 seconds└─ Ejection time: 0.5-0.8 secondsTotal cycle: 7.5-9.0 seconds per cycle
2. Quick Mold Change System
Mould pre-equipped with ISO standard locating rings
Hydraulic quick connectors (cooling/pneumatic)
Electrical integrated plug-in system
Mold change time: ≤15 minutes
Quality Assurance System
1. Online Inspection Configuration
Inspection Item Accuracy Requirement├─ Weight inspection ±0.005g├─ Dimensional inspection ±0.02mm├─ Sealing surface inspect Ra0.1μm├─ Thread inspection Go/no-go gauge 100%└─ Torque inspection 0.01 N·m
2. Mould Protection System
Cavity pressure monitoring (96 points)
Temperature abnormality warning
Automatic short-shot detection
Ejection failure protection
Economic Benefit Analysis
Item | Value | Industry Comparison |
|---|
Mould Investment | 800,000-1,200,000 RMB | 1.8× that of 32-cavity mould |
Cost per Piece | 0.02-0.04 RMB | 40-50% reduction |
Daily Output | 600,000-1,000,000 pieces | 300% increase |
Energy Consumption per 10k Pieces | 18-22 kWh | 35% reduction |
Investment Payback | 3-5 months | 40% shorter |
Labor Efficiency | 1 operator/3 machines | 200% improvement |
Application Areas
Drinking Water Industry
28mm/30mm standard bottle caps
Daily output meets 200,000-300,000 carton demands
Beverage Industry
Carbonated drink caps
Juice drink caps
Sports drink caps
Edible Oil Packaging
33mm oil bottle caps
38mm barrel caps
Technical Challenges and Breakthroughs
Challenge 1: Melt Flow Balance
Solution: - Mold flow simulation optimization for runners - Melt buffer compensation slots - Increase temperature by 0.5-1.0°C for end cavities
Challenge 2: Cooling Uniformity
Solution: - Conformal cooling channel design - Zoned adjustable flow rates - Enhanced cooling for end zones
Challenge 3: Synchronized Ejection
Solution: - 96-point hydraulic synchronization system - Ejector position sensors - Graded ejection speed control
Maintenance Specifications
Daily Maintenance (per shift)
1. Clean parting surfaces (every 2 hours)2. Check hot runner temperature (every 4 hours)3. Lubricate moving parts (per shift)4. Record production data (per cycle)
Regular Maintenance
┌─ Every 100,000 cycles: Inspect seals├─ Every 300,000 cycles: Inspect cavity dimensions├─ Every 500,000 cycles: Replace wear parts└─ Every 1,000,000 cycles: Complete disassembly inspection
