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RFQ

Plastic Molding Heat Seal Pins

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Situation:

A major manufacturer of LCD televisions is using a heat-sealed pin system to bond two pieces of the front cabinet panel. The manufacturer encountered severe sticking of the resin to the heat seal pin resulting in waste and stoppage. Production was less than 50% of the goal.

A Teflon coating was applied to attempt to improve the situation. With the Teflon coating production increased, but to only 60% of the production goal and with 2 stoppages per shift required to manually remove waste resin and apply an additional mold release agent to the pins. The Teflon coating required complete re-polishing and re-application every 2 to 3 weeks, at a cost of $7,000.

The manufacturer wanted a coating that could operate at or above a temperature of 185°C continuously, increase production at least 25% over current situation, not change pin cavity geometry to ensure conformance to design specifications, and reduce net cost relative to Teflon coating and downtime.

Testing:

DICRONITE® dry lubrication was applied to the cavity and sliding surfaces of the pins in place of the Teflon coating.

Results:

  • Production throughput increased by over 28%
  • Scrap rates decreased
  • Production stoppages and secondary release agent usage were eliminated
  • Higher operating temperatures (>185°C) could be used, allowing further optimization of production
  • Coating operating costs were reduced by greater than 50%

DICRONITE® has been incorporated into the facility-wide preventative maintenance program.

© Lubrication Sciences International, Inc., 2023. Dicronite® and DL-5® are registered trademarks of Lubrication Sciences International, Inc.

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Sliding Wear

Sliding wear occurs when two surfaces slide against one another causing material loss to one or both surfaces. Over time, this can result in component failures, additional maintenance, and costly down time.  

Coating components with Dicronite® can help minimize this wear and reduce the need for maintenance and down time.

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Tight Tolerance Lubrication

Extremely tight tolerances can present challenges when lubricants or coatings are needed to reduce friction. Many products are available to help reduce friction, but in the case of very tight tolerances, few can be integrated without the need for adjustments.

Dicronite® has an average thickness of 0.5 microns (0.00002 inch) or less. This precision thin film allows users to incorporate Dicronite® on designs with tight tolerances without the need for design or manufacturing changes.

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Vacuum Environment Lubrication

Vacuum environments present a challenge for lubrication. Many conventional lubricants aren’t effective under vacuum and are largely vaporized.

Dicronite® can be used in vacuum to reduce friction where other lubricants can’t function. The outgassing of Dicronite® under vacuum conditions is well below screening levels for spacecraft materials per ASTM E595.

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Energy Lost to Friction

Friction is wasted energy! Systems with critical mechanical power output need to be extremely efficient.

Dicronite® optimizes mechanical efficiency by reducing friction losses and can even work in tandem with existing lubrication to further optimize efficiency.

Dicronite® is especially useful in precision systems, extreme environments, or where minimizing size and weight is vital.

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Fretting

Fretting is a unique form of sliding wear that occurs when contact surfaces oscillate over a very small range of motion. Although it may seem minor, this surface wear can ultimately lead to fatigue cracking and devastating damage.

Dicronite® helps remedy fretting by providing lubrication at contact surfaces. This effectively reduces the wear and surface stresses that cause so much damage.

Dicronite® can be integrated into existing designs and assemblies without any other adjustments for seamless reduction of fretting wear.

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Extreme Temperature Lubrication

Extreme low or high temperatures can be challenging environments for lubrication. At low temperatures, conventional lubricants may be too viscous to be effective, while extreme high temperatures can result in breakdown of the lubricant.

Dicronite can be used in extreme environments to ensure effective lubrication while also being used in combination with oils and greases.

Dicronite is stable across a wide temperature range:

  • up to approximately 538°C (1000°F) in air
  • up to approximately 1316°C (2400°F) in vacuum
  • down to approximately -188°C (-305°F)

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Excessive Heat from Friction

As friction in an assembly generates heat, elevated temperatures can result in unwanted operating conditions.

This can cause overheating and accelerate the breakdown of materials, resulting in costly maintenance and down time or destructive failure.

Proper lubrication can help minimize friction, reduce heat, and increase mechanical efficiency. Coat parts with Dicronite® to avoid excessive maintenance and ensure components will run as efficiently as possible.

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