Automotvie air conditioner outlet mold

What are the main components of the air outlet? there are mainly housing,front vane,rear vane,thumbwheel and side knob etc.

The most important component is the housing, which is also the most complex part of the entire project. The size and structure of the mold are of the utmost importance. Therefore, the product analysis of the housing is extremely crucial in the early stage. Otherwise, if the mold is made later and the analysis is not done properly, all the previous efforts may be wasted. So, we conducted a lot of checks and detailed analyses in the DFM analysis.
Material:PP+40TD
Steel: 1.2344 HRC48-52
Mold life:100 0000
Hot runner: Incoe two hot valve gates direct into the part surfaces
DFM Analysis

Mold design

In order to prevent the product from sticking at the position, we added spring push pins on the slider position to improve and avoid the sticking issue, thus preventing the product from deforming.

Taking into account the assembly function requirements of the product, this red surface must not have any draft angles in the direction of slider side. Therefore, in order to disregard the cost of the mold, we have designed two sliders at this red position, which is a collapse structure. The position will first be separated from this hole, and then the entire part will be detached together. This way, it can better meet the product requirements. This surface does not need to be modified, as it can avoid assembly problems caused by angle issues.

Early product design is extremely critical, especially in terms of improving product deformation. Since the housing needs to be assembled with blades, it has strict dimensional requirements for product length and the aperture size of the vanes. Therefore, these key factors must be fully considered in the early stage of mold flow analysis and mold design. Otherwise, it will easily lead to dimensional defects in mass production and failure to produce high-quality finished products.
1， An adequate water supply system in the inside slider area

2， According the mold flow,suggest to modify the part with even wall thickness
3， The very importance point on the part design, designed difference thickness on the 4 corners, This will effectively prevent the product from shrinking or deforming. By reducing the material at the four corners, the direction of shrinkage after injection molding can be changed. The four thin areas will cool down first, which can significantly improve the shrinkage on the side larger surfaces. This modification is extremely important. Without this experience, the product is usually made with uniform wall thickness, as the mold flow analysis theory requires the product to have uniform wall thickness. We have conducted a lot of verification and repeated tests at this point. This solution is very effective and is based on years of company experience. The customer particularly recognizes and approves of this modification suggestion, and it will not affect the product’s strength.