The Injection Molding Process for a Toilet Cover

Toilet covers are bathroom products. Now China's bathroom products are mainly distributed in three regions. The first one is the regions of Xiamen and Zhangzhou in Fujian, the second one Cixi, Yuyao and Hangzhou in Zhejiang and the third one Foshan and Zhongshan in Guangdong.
 
A toilet cover belongs to bathroom products, and the bathroom industry is a major category of the plastic injection industry. The main plastic parts in the toilet such as toilet covers and toilet seats are mainly processed by injection molding. The injection molding process is the most important processing method in the plastics industry. Resources, manufacturing processes, quality difficulties, cost prices and markets of toilet covers are discussed in this article.
 

1. Required resources in the production of toilet covers
Machines for the injection molding process
The machine required for toilet cover products is an injection molding machine with 700 tons or over 800 tons.
 
Materials for the injection molding process
There are mainly four types of plastic materials for toilet covers, such as urea-formaldehyde resin, PP, ABS and PVC.
 
① PP
The PP material appears first, and it has advantages of being cheap and easy to process. However, its aging resistance is not good. It will age very badly after two to three years. In addition, the PP material is soft and its scratch resistance is not good.
 
② Urea-formaldehyde resin
Urea-formaldehyde resin is very special in plastics. It doesn't belong to thermoplastic resin and is thermosetting resin. Urea reacts with formaldehyde to form polymers, which has high strength, oil resistance and good scratch resistance. However, it has shortcomings of inconvenient processing, high costs, poor toughness, brittleness, poor dyeability and not being environmental-friendly. This is the reason why the ABS is promoted.
 
③ ABS resin
The ABS is characterized by easy processing, good environmental protection and moderate strength, but its scratch resistance is not as good as urea-formaldehyde resin.
 
④ PVC resin
The processability of PVC resin in plastic materials is not good, but its price is low. At the same time, it has good dyeability and can transfer print various patterns. The low price is also the outstanding feature of PVC toilet covers. This kind of toilet cover has disadvantages of being soft, not environmentally friendly and poor scratch resistant.
 
Generally speaking, in the field of bathroom toilet covers, urea-formaldehyde resin is the most high-end, followed by the ABS and PP, and the PVC is the worse.
 
Molds for the injection molding process
Molds are also necessary for making toilet covers. The mold used for toilet covers is required to have high gloss, so materials of mold cores should be good. However, the product shape is simple; the mold is easy to process and the labor cost is low.
 
2. Manufacturing process of the injection molding process
The production process is very simple, basically the injection molding process (Die-cast is adopted for urea-formaldehyde resin). Then, a small number of products are processed by post-processing such as printing and transfer printing in order to increase the visual effect of the surface.
 
3. Difficulties of quality
The main difficulty in the quality of toilet cover products is the appearance, and the requirements for assembly indicators are not high. In addition, the strength and antibacterial properties belong to the design category and have little to do with production. The appearance quality of the toilet cover is very troublesome in production. There are many defects in injection molding production, including flow lines, poor melting, black spots, black lines, color differences and burning. High-end toilet covers are not allowed to have black spots with 3*0.08mm, so the investment for the production environment of high-end products are great, which increases the price.