过渡到室外电气外壳和光纤盒为塑料

塑料注射成型manufacturing | Tenere

September 17, 2021

设计户外电气外壳或光纤盒?可能有一些很好的理由从金属转变为塑料,但是首先与两者兼而有之的制造商进行交谈是一个好主意。

光纤塑料注射成型Critical Infrastructure

无论您是住在公寓楼,郊区的房屋,还是山上美丽而美丽的房子里,我们每个人都无法生存一件事:电力。尽管经常被忽略,但发电所需的关键组件之一是挂在该国每栋建筑物的一侧的接线箱。在这里,街道上的重规线被分成用于为烤面包机,冰箱,电视机和其他我们都熟悉的现代便利设施的较小电气运行。冒着听起来像船长明显的风险,没有电盒,我们就在黑暗中。


建立连接

Similarly obvious statements can be said about many of these outdoor applications. These include the fiber optic termination boxes seen on the outside of large commercial facilities and schools, and at the ends of long cable runs from our internet service providers (ISPs). As with the household electrical example just given, underground fiber optics cable containing dozens or perhaps hundreds of strands feeds into these junction boxes before being connected to splice trays for distribution to the consumer. To anyone surfing the Internet or binging on Netflix, these robust fiber connections are every bit as important as online pizza delivery.

Such connections will soon be even more important. As 5G technology expands over the coming years, these splice boxes and other types of fiber infrastructure will become increasingly necessary to meet our population's demand for high-speed Internet and cellular communications. And whilenationwide fiber optic deployment承诺将成为一项巨大的承诺,同样至关重要纤维外壳。问题就变成了:成本效益生产这些组件的最佳方法是什么?

While we’re on the topic, it might be time to ask the same question about the electrical boxes and other fabricated enclosures just mentioned, particularly the materials used to make them. For example, these wall mount enclosures are typically made of carbon steel. But because such outdoor electrical components are...well, outside, they must be protected from the wind, sun, rain, and snow. Further, no one wants to see a big, ugly metal box hanging from the side of their house, so they must be pleasant to look at. The solution is to paint or powder coat them, yet this adds expense and lead-time to the product. In addition, these finishes—though durable—tend to lose their luster over the long run.

Stainless steel is one alternative. It’s attractive and doesn’t corrode like low carbon steel, although it is relatively expensive, a not-insignificant factor with higher production volumes. Yes, stainless might make great sense for a自定义服务器外壳在海军船或风电场或太阳能安装,但对于大多数住宅和商业用途而言,这是成本良好的。怎么办?

内部注射机器

高科技世界的注射成型

与现代世界中许多其他事物一样,该解决方案是塑料,或更具体地说,是注射塑料的。bob sports 在户外电气外壳,光纤盒和类似的高科技上,大批量组件在许多方面都很有意义。但是,过渡到注射成型要求产品工程师学习一套全新的设计原则,更不用说在他们可用的各种聚合物中获得处理。

让我们从原则开始,其中许多是在此中描述的design for moldabilityarticle. Chief among these recommendations is the need for uniform wall thicknesses. Because injection molding works by forcing molten plastic into a machined mold cavity, it’s critical that the material flow in as uniform a manner as possible. If one section is much thinner than another, the plastic in that area will cool more quickly, leading to warpage.

同样,过于厚的区域容易出现一种称为水槽的现象,就像其名称所描述的那样。为了获得最佳效果,所有壁厚应在标称的15%左右的时间内,对于不可避免的强壮区域,例如安装的老板,使用蜂窝状图案或一系列肋骨来减少所需的材料量而不牺牲强度。这样做还将有助于减少成型时间和材料使用,这两者都会导致较低的成本。

另一个重要的设计考虑因素是草稿角度。为了释放电气外壳或生产的任何其他部分,塑料注射模具要求垂直于分隔线的霉菌腔的壁是锥形的。最小值为每侧1°,尽管3°更好,最佳5°。对于特别复杂的零件设计或应用表面纹理的地方,可能需要更多的草稿。如有疑问,请与您的制造合作伙伴联系。

在整个设计过程中,最后一个建议是很好的建议,因为塑料注射成型还有很多。锋利的角落通常是禁忌。从一个区域到另一个区域的急剧过渡也是如此。缩减增加了霉菌的复杂性,增加了工具成本。公司徽标和文本很好,但应放置在平行于隔线的非选拔表面上。肋骨和僵局等高高的功能应在周围放置支撑,以提高刚性。

Plastic Polymer

塑料材料考虑

Above all, remember that these are not stamped, formed, and welded components. Design considerations for plastic are going to be very different to accommodate for shrinkage, remove any concerns of warpage and hit critical tolerances. That said, plastic injection molding is an extremely viable alternative to traditional sheet metal products, (like electrical enclosures and fiber optic boxes), albeit at the higher production quantities needed to justify the tooling investment.

那把我们带到了塑料上。您要使用哪种?要回答这个问题,您应该首先列出申请要求。内阁的“入口保护”或IP评分是什么?是否需要易燃性评级?户外敞口的紫外线评级如何?如果外壳将用于医疗或食品加工环境中,FDA和NSF合规性是否要求?那产品的机械性能或电导率呢?

似乎材料选择几乎与设计过程一样复杂。ABS,尼龙,聚碳酸酯,PVC和TPU - 这些只是用于电交界盒,光纤外壳和其他室外应用的一些更常见的聚合物。更复杂的问题是所有可用的填充物和添加剂。玻璃和纤维等材料通常混合在一起以增强强度和韧性,而火焰阻燃剂,抗抗酸剂和紫外线吸收剂也很普遍。

最后,不要忘记塑料注射模制零件的另一个大优势。除了其更大的设计灵活性,耐用性,较低的重量和零件价格外,这些和其他组件还可以用近乎颜色的颜色制成(即使灰色,黑色和白色似乎也是最受欢迎的)。但是,这些着色剂和所有其他添加剂刚刚描述的所有添加剂都会影响塑料的可可性,美学价值,价格标签和交货时间。同样,与您的制造合作伙伴交谈,最好是同时使用金属和塑料的合作伙伴。他们是专家。

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