Tappetino personalizzato in silicone resistente al calore | Progetto tedesco 2023
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Prodotto |
Rectangular Ribbed Silicone Heat-Resistant Mat |
|---|---|
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Quantità di ordine |
Ordine iniziale: 12,000 pezzi |
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Materiale |
Silicone solido per uso alimentare |
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Specifiche chiave |
Durezza: Riva A45 Resistenza alla temperatura : da -40 °C a 230 °C |
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Certificazione |
GB 4806.11, FDA, LFGB |
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Tempi Di Consegna |
Valutazione DFM: 24h |
Dettagli del progetto
A German kitchenware brand wanted to develop a flat silicone heat-insulating mat suitable for family dining tables, kitchen baking, and everyday heat insulation. However, the client’s original design sample had three main problems: warped edges, insufficient anti-slip properties, and easy tearing upon demolding.
Z.S.R’s engineering team conducted a DFM (Progettazione per la produzione) evaluation of the customer-supplied samples within 24 hours, proposing optimization solutions for the mat surface, edge structure, and venting system.
In base ai risultati del DFM, il progetto è passato alla realizzazione degli stampi e alla produzione dei campioni, seguite dalla verifica della qualità del primo lotto prima della produzione di massa.
Dati di consegna
Valutazione DFM in ambito ingegneristico
Thickened Rounded Edges + Stress Relief Grooves
Z.S.R adopts a multi-cavity mold with symmetrical runners, and the injection points are evenly distributed along the cavity edges. The right angles around the mat are changed to R3.0 mm rounded corners, the edges are thickened to 2.8 mm, and the corners use R3.5 mm rounded transitions to form a one-piece thickened edge. A 0.3 mm deep stress relief groove is added to the inner side of the thickened edge.
Multi-cavity balanced injection ensures uniform pressure distribution within the mold cavity, reducing stress imbalance caused by post-molding variations. The stress relief grooves on the back provide directional channels for releasing shrinkage stress without affecting the finished product’s appearance and feel. During the cooling process of a flat, thin mat, the shrinkage rate between the center and edges is inconsistent, and the released residual stress can easily cause the mat’s edges to warp. The 3.0 mm rounded corners combined with thickened edges form a frame that improves the mat’s resistance to deformation.
Anti-slip Stripes on the Plane
To improve the mat’s anti-slip properties, engineers added parallel stripes 0.8 mm high and 3 mm spaced along the short side of the mat, with semi-circular transitions in the stripe cross-sections.
Smooth silicone mats have a low coefficient of friction when in contact with objects, making them prone to sliding. Parallel stripes increase contact resistance, while the semi-circular stripe cross-section avoids stress concentration at the roots of right-angle stripes, improving the mat’s anti-slip and durability.
Optimized Mold Venting and Demolding Structure
Engineers added Scanalature di microventilazione da 0.02 mm in the dead corners of the planar cavity to expel trapped air. To prevent the material from tearing due to excessive contact with the sharp corners of the mold cavity during mold opening, the right-angled edges of the mat were eliminated.
The venting grooves within the cavity help expel trapped air, preventing air bubbles and material shortages during demolding. Right-angled edges of the rubber material tend to adhere too tightly to the sharp corners of the mold cavity during demolding, easily tearing under strong pulling. The 3.0 mm rounded corners eliminate stress concentration, effectively reducing the demolding defect rate.
Realizzazione di stampi, produzione di campioni e verifica della qualità
Lavorazione dello stampo
Il gruppo ZSR è dotato di 10 centri di lavoro CNC avanzati and 4 macchine EDM, capable of creating molds for solid silicone mats.
Stampaggio in silicone
La produzione è supportata da 48 macchine per stampaggio a caldo, 12 macchine per lo stampaggio di liquidie 13 presse ad iniezione utilizing a one-piece solid silicone molding method to produce silicone heat-resistant mats. Over 10 printing and spraying production lines also allow for printing logos or patterns on the silicone mats.
Vulcanizzazione secondaria
After molding, the silicone heat-resistant mats undergo secondary vulcanization at 200°C per 2 ore.
The secondary curing process removes small volatile molecules from the silicone, reduces product odor, and ensures the mats meet food contact standards.
Ispezione di qualità
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Test |
Condizioni dell'oggetto |
Criteri di accettazione |
Risultato |
|---|---|---|---|
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Test di fatica per piegatura |
Repeatedly fold the mat 5,000 times |
No cracks or visible stress whitening |
Passare |
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Test di durezza |
Measured at room temperature using a Shore A durometer |
45 Riva A |
Passare |
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Ispezione dimensionale |
Full dimensional measurement using digital calipers |
Overall dimensional tolerance: ±0.3 mm |
Passare |
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Prova di ciclismo termico |
50 heating and cooling cycles between -40°C and 230°C |
No deformation, cracking, or delamination |
Passare |
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Test di migrazione a contatto con gli alimenti |
Tested in accordance with applicable GB 4806.11, FDA, and LFGB requirements |
Heavy metal and volatile substance migration levels within applicable limits; no unacceptable migration |
Passare |
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Prova di resistenza alla trazione |
Tested using a universal testing machine |
Tensile strength ≥ 8 MPa; no rupture |
Passare |
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Anti-Slip Friction Test |
Friction coefficient tested on a dry tabletop |
Coefficient of friction ≥ 0.45; no sliding under heavy loads |
Passare |
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Ispezione visuale |
Ispezione visiva e tattile |
No bubbles, incomplete filling, obvious flash, or black spots |
Passare |
The production samples passed the specified folding fatigue, hardness, dimensional, thermal cycling, food contact, tensile strength, anti-slip friction, and visual inspections. In particular, no cracks or stress whitening was observed after 5,000 cicli di piegatura.
prodotto correlato
Recensioni e feedback dei clienti
After receiving 12,000 mats, the customer provided positive feedback: “Hello! Yes, I received the mats, they look fantastic, we love them, and I can’t wait to show them to my customers.” Following this, the customer achieved good sales results and placed a repurchase order for 30,000 more.
Custom Silicone Heat-Resistant Mat
OEM & ODM solutions for brands, retailers, wholesalers, and Ecommerce sellers. Food-grade silicone heat-resistant mats with FDA/LFGB compliance.
Altro progetto
Per la produzione su scala industriale, ZSR Group offre anche un servizio dedicato di stampaggio a compressione del silicone per la realizzazione di componenti in silicone personalizzati.
