Manufacturing Polymer Components

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Manufacturing
Polymer Components
The outer casing is formed out of polystrene through the process of injection molding. The procedure begins with the mixing of polymer pellets with plastic agents and colourants. This mixture is then heated under 1000 atmospheric pressure to liquefy the polymers so they can then be injected into the cast mold via an injection plunger. Before this process can occur the two halves of the mold must be secured together and attached to the injection molding machine. The mold is held together during injection by hydraulically powered clamps which exert high pressure ensuring that the injected polymer fills the mold completely and it hold during the filling of the plastic resin. The polymer is injected into the mold very quickly under a large buildup of pressure which allows the material to be packed and held in the mold. The end closures of the torch are also are also injection molded using this process including the internal and external threads however this process is more time consuming than injection molding a standard hollow part. The polymer is then cooled by passing water through channels in the mold which hardens the plastic so the pressure can be released and the molds separated. In order to release the part from the mold an erection system is needed to be attached to the rear half of the mold which can supply adequate force. This force is needed due to shrinkage of the part during cooling which causes it to adhere to the mold. Once the part is separate from the mold any excess material, including that left in the channel feeding to the mold, must be trimmed using cutters. The completed plastic part is then removed and taken for finishing through several further operations involving polishing ...

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...h resulting in a minimal increase.

References
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EngineersGarage. 2012. “Insight – How Push Button Switch Works” Accessed May 20, 2014. http://www.engineersgarage.com/insight/how-push-button-switch-works
Demand Media. 2014. “How Do Push Button Switches Work in an Electrical Circuit?” Accessed May 20, 2014. http://www.ehow.com/how-does_5030234_push-switches-work-electrical-circuit.html#ixzz32Fmt1xt0
Randy Schueller. 2014. “How Products Are Made – Flashlight Torches.” Accessed May 10, 2014. http://www.madehow.com/Volume-6/Flashlight.html
Marwa Qaraqe, Mahmuduk Alam, Maryam Manojahri. 2007. “Components of a Flashlight.” Accessed May 10, 2014. http://hire-alam.weebly.com/uploads/4/4/1/5/4415828/components_of_a_flashlight_design_using_solidworks.pdf

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