PLASTIC AND RUBBER INJECTION MOLDING 2018

CHAPTER 1

ABOUT THE COMPANY/ORGANIZATION

INTRODUCTION

TOYODA GOSEI SOUTH INDIA PRIVATE LIMITED (TGSIN) was

established in 1998. TGSIN company started with Toyota Kirloskar Motor (TKM) as
Tier 1 Supplier. Initially Established in 1949 and headquartered in Kiyosu, Aichi
Prefecture, Japan, Toyoda Gosei is a leading specialty manufacturer of rubber and plastic
automotive parts and LEDs. Today, the Toyoda Gosei group provides a broad range of
high-quality products internationally, with a network of approximately 100 plants and
offices in 18 countries and regions. Through its flexible, integrated global supply system
and leading-edge technologies for automotive safety, comfort, and environmental
preservation, Toyoda Gosei is a global supplier that aims to deliver the highest levels of
satisfaction to customers worldwide. company expanded Business in line with TKM
Expansion. Interior Part painting facility added in the Year 2010, company expanded
Safety system Business. company added PU Steering Wheel, Driver Air Bag & Passenger
Air Bag.

TOYODA GOSEI SOUTH INDIA PRIVATE LIMITED (TGSIN) is a joint venture

between TG, Japan (Toyoda Gosei, Japan) & TTC , Japan ( Toyota Tsusho Corporation,
Japan).

Toyoda Gosei head office in Kiyoshu, Aichi, Japan.

It is classified as Non-govt Company and is registered at Registrar of Companies,

Bangalore. Its authorized share capital is Rs. 304,000,000 and its paid up capital is Rs.
304,000,000.It is inolved in Manufacture of rubber products. Toyoda Gosei Co., Ltd. has
acquired the equity shares of Kirloskar Systems Ltd. (KSL; Bangalore, Karnataka, India)
in TG Kirloskar Automotive Pvt. Ltd., a Toyoda Gosei production subsidiary that had
been jointly owned with KSL and Toyota Tsusho (Nagoya, Japan). The name of the
company was then changed to Toyoda Gosei South India Pvt. Ltd. (TGSIN).TGSIN
produces automotive steering wheels, airbags and other safety systems, as well as interior

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and exteriors such as instrument panel components. The Indian market is expected to
continue growing in the future, and Toyoda Gosei aims to actively expand its facilities.
TGSIN has started the plants in various locations India apart from Bengaluru, in Gujarat,
Delhi, and Japan international market.

1.1 Origins of Toyoda Gosei company name:

The name ―Toyoda‖ comes from our historical roots in the region famous for Sakichi
Toyoda, the prominent Japanese inventor who established Toyoda Industries, and his son
Kiichiro Toyoda, the founder of Toyota Motor Corporation. It is also linked to our
achievements as the core nonmetallic division of the Toyota Group.

The Japanese word ―Gosei‖ means ―synthesis‖ and is used in our company name with
respect to the main materials we use and our principle of creating new things. On a basis
of elastic ―Synthetic rubber‖ and flexible ―Synthetic plastic‖, we combine materials
together to make automotive parts with high function and quality.

1.2 Symbolic hexagon in company logo

The company logo was modeled after the ―benzene nucleus,‖ a chemical compound
consisting of six carbon atoms. Even very active and unstable chemical substances
become stable in a hexagonal form, and the logo symbolizes our vigor and stability.

Toyoda Gosei is a top manufacturer of rubber and plastic automotive parts and LEDs,
with global operations by 67 group companies in 18 countries and regions. We are

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undertaking a variety of activities to earn the trust of society, focusing on the four main
areas of― Environmental preservation,‖― Development of people and workplaces that
support our business,‖― Building livable communities,‖ and― Compliance.‖ For
environmental preservation, we work hard as a manufacturer specializing in the rubber
and plastic fields to develop products that contribute to lighter weight vehicles. At the
same time, we are promoting efforts for a low energy society through all our business
activities, from purchasing to manufacturing and delivery. In February 2016 we
established the― TG 2050 Environmental Challenge‖ as an expression of our commitment
to environmental activities now and into the future. The TG 2050 Environmental
Challenge sets ambitious targets of reducing CO2 emissions and water usage in our
business activities, ultimately approaching zero. We are also continuing our Plant
Afforestation Activities globally to support the earth‘s environment. So far, we have
planted a total of 290,000 trees in 25 locations worldwide. This effort has been
recognized with placement in the top 20 in Japan for 10 consecutive years in the Nikkei
Environmental Management Survey. To develop people and workplaces that support
our business, we established the TG Learning Center in January 2017. The TG Learning
Center will serve as a focus of

our efforts to develop personnel who can act globally. As our workload increases with the
global expansion of our business, we will strive for greater efficiency as one part of
reforms to the way we work, utilizing IT tools and eliminating waste from meetings,
reports and other activities so that all employees can dedicate themselves to their primary
business. We have also established the― Five executive conditions manifesto‖ for the
creation of a culture where all employees can work with vitality and a sense of unity, free
to discuss anything with each other. This change will be led by executives and managers.
Employee health maintenance is another issue for management, and as a result of strong
efforts to promote employee health we were selected as a 2017 Outstanding health
management corporation‖ by the Ministry of Economy, Trade and Industry of Japan.
To build livable communities, employees at TG Group companies around the world are
making efforts to contribute to their communities and grow together with strong local
roots. The foundation for all of these activities is compliance. To maintain the trust of
society as a company of integrity, we believe not only legal compliance but high ethical

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standards by each and every one of our employees are crucial, and we will continue to
educate employees throughout the Toyoda Gosei Group. We will do our utmost to
contribute to sustainable societies globally through our business activities, and grow
together with the societies where we make our home. We look forward to continuing to
serve our customers and communities. Toyoda Gosei South India Private Limited's
Annual General Meeting (AGM) was last held on 05 June 2018 and as per records from
Ministry of Corporate Affairs (MCA), its balance sheet was last filed on 31 March 2018.

Kiyosu, Japan, January 13, 2015: To strengthen its technical development operations in
the China region, Toyoda Gosei Co., Ltd. relocated the regional headquarters for its
automotive parts business (Toyoda Gosei (Shanghai) Co., Ltd., short name Shanghai TG)
to a larger space in January 2015. In addition to the Shanghai TG regional headquarters,
Toyoda Gosei has regional production operations in nine locations in the cities of Tianjin,
Zhangjiagang, Fuzhou, and Foshan, plus Taiwan, to provide rubber and plastic parts for
the local operations of Toyota Motor Corporation and other automakers.

Shanghai TG‘s new location has floor space about four times larger than its previous
office and includes a test area. The aim of this move is to create a technical development
system that can respond swiftly to the needs of local customers. The new test area has
been outfitted with equipment to evaluate interior and exterior products, airbags and other
products, and to evaluate rubber and plastic materials. Within three years the number of
engineering employees is set to double to approximately fifty, including those engaged in
product design at branch locations in Tianjin and Foshan.

Toyoda Gosei will continue to strengthen its technology and development systems
globally to be a first-choice supplier to customers worldwide.

Kiyosu, Japan, April 13, 2015: Toyoda Gosei Co., Ltd. will exhibit at the 16th Shanghai
International Automobile Industry Exhibition (Auto Shanghai 2015), to be held at the
National Convention and Exhibition Center in Shanghai, China on April 20-29, 2015.

Toyoda Gosei is specialist in the fields of rubber and plastics automotive parts and LEDs.
At Auto Shanghai 2015 our exhibits will be focused on products and technologies that

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contribute to environmental-friendliness, safety and comfort-all matters of increasing

importance to consumers.

The Toyoda Gosei booth will include a Wire-made Exhibition Car fitted with our
lightweight fuel filler pipe that is made of plastic instead of metal and our full-cover 360°
airbags that protect passengers from impacts from every direction. This model, exhibited
for the first time in China, lets viewers see exactly where Toyoda Gosei products fit on an
automobile. Also on display will be our latest console boxes for interior stylishness and
convenience.

Toyoda Gosei has thirteen business locations in the China region, where we are working
to actively grow our business. In January of this year we took steps to strengthen our
local technical development operations. We aim to continue meeting customer needs in
the growing Chinese market and further expand our business there.

Kiyosu, Japan, September 16, 2015: To strengthen its position in the growing Indian
automotive market, Toyoda Gosei Co., Ltd. has acquired the equity shares of Kirloskar
Systems Ltd. (KSL; Bangalore, Karnataka, India) in TG Kirloskar Automotive Pvt. Ltd.,
a Toyoda Gosei production subsidiary that had been jointly owned with KSL and Toyota
Tsusho (Nagoya, Japan). The name of the company was then changed to Toyoda Gosei
South India Pvt. Ltd. (TGSIN).

TGSIN produces automotive steering wheels, airbags and other safety systems, as well as
interior and exteriors such as instrument panel components. The Indian market is
expected to continue growing in the future, and Toyoda Gosei aims to actively expand its
presence there.

Kiyosu, Japan, May 14, 2015: Toyoda Gosei Co., Ltd. has developed low loss
semiconductor device technologies for high power application such as rectifiers and
switching transistors. These technologies use gallium nitride, a key material in blue LEDs
that also has the superior characteristic of being able to withstand high voltages.

Application of the new technology to devices such as the power control units used in
hybrid vehicles and power converters used in solar power systems is promising for the
development of smaller and more efficient devices.

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Toyoda Gosei began researching gallium nitride semiconductor power device

technologies in 2010, using the crystal growth technology it has cultivated since 1986 in
the development and production of blue LEDs. We have now developed a low loss metal-
oxide-semiconductor field effect transistor (MOFSET) that allows current flow only
when a signal is given to switch (gate). Otherwise no current flows even under high
voltage of 1200 V.
MOFSETs are a type of transistor used in power devices. Toyoda Gosei innovations
include a vertical structure so that current flows perpendicularly to the substrate with a
trench gate structure. In the laboratory we have achieved low loss characteristics of 1.8
mΩ-cm2resistance when current is flowing--a level that is among the highest in the
world.

Kiyosu, Japan, July 14, 2016: Toyoda Gosei Co., Ltd. is establishing a new plant in
Bawal in the Indian state of Haryana to meet the expected growth in demand for airbags
and other parts with expanding automobile production and stronger safety regulations in
India.

The new plant is being established as a branch of our Indian subsidiary Toyoda Gosei
Minda India Pvt. Ltd. (TGMIN), and will provide airbags, weatherstrips and other
automotive parts to local Japanese automakers from March 2017. The investment
associated with the new plant will be about 550 million rupees (approximately 900
million yen*).

*Calculated with 1 rupee = 1.6 yen

Kiyosu, Japan, November 24, 2016: Toyoda Gosei Co., Ltd. will exhibit at LED Expo
New Delhi 2016, the largest LED trade fair in India, to be held on December 2–
4 at Pragati Maidan in New Delhi.
Growing use of LED lighting is expected in India, and Toyoda Gosei will exhibit its
high-efficiency LEDs for lighting and show examples of their application (LED tube
lights for office use and ceiling lights for factories) with the aim of expanding LED sales
in this market. The exhibit will also include glass-encapsulated UV LEDs, sunlight
LEDs, and other industrial-use LED products, as well as LED radiator grille illumination

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and other automotive LED products that take advantage of our strengths as an automotive
parts supplier.
As a top manufacturer of LEDs, Toyoda Gosei aims to be a leading global supplier
through development of products that meet the needs of customers worldwide.

Image of booth

High-efficiency LEDs Glass-encapsulated UV LEDs

(3030 package)

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Kiyosu, Japan, January 29, 2018: Toyoda Gosei Co., Ltd. will make its inaugural
appearance at India‘s largest motor show, the 14th Auto Expo 2018 - Components, to be
held at the Pragati Maidan exhibition and convention center in New Delhi from February
8 to 11. The company will display its main products in the booth of Uno Minda Group,
its business partner in India.
In the area of safety, Toyoda Gosei will use a 360-degree full-surround passenger
protection concept model to show its various types of airbags, for which there is growing
demand in India, and millimeter wave radar compatible emblems that can be used in
driver assistance systems. Environmentally-friendly products on exhibit will include
lightweight plastic fuel filler pipes, which contribute to better fuel efficiency, and
headlamp LEDs for reduced power consumption.
Toyoda Gosei considers India to be an important market, and is taking aggressive steps to
strengthen its supply network there. This includes plans to start production of airbags and
other products in the fall of 2018 at a new Gujarat Plant in western India (Gujarat state),
its fifth location in the country. The company will continue to meet customer needs in
India with the aim of further growing its business.

Kiyosu, Japan, November 6, 2018: The Gujarat Plant of Toyoda Gosei Minda India Pvt.
Ltd. (TGMIN), an Indian subsidiary of Toyoda Gosei Co., Ltd., began operations in
October 2018.
The Gujarat Plant will supply airbags, the demand for which is growing with the
increasing automobile production and stricter safety regulations in India, plus supply
steering wheels, weatherstrips and other parts to Suzuki Motor Gujarat Pvt. Ltd.

India is a key market for Toyoda Gosei, and the company has been enhancing its
development and production network there, including the establishment of a new
technical and sales office (Gurugram Office) in a suburb of Delhi in April 2018. Toyoda
Gosei plans to increase its sales volume in India to 35 billion yen by fiscal 2025, more
than twice the current level.

Kiyosu, Japan, November 20, 2018: Toyoda Gosei Co., Ltd. held a ―TG Global Summit
2018‖ over four days starting on November 13, with approximately 130 top managers
from 65 Group companies in 17 countries. This was the company‘s third TG Global

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Summit. These summits began in 2013 as a way to build a common understanding among
Group companies of current business situations and issues, and foster solidarity.

Focuses this year were making sure that all Group companies understood the specific
efforts to achieve the management objectives laid out in the company‘s medium and
long-term business plan (2025 Business Plan), announced in May of this year, and to
share business plans and employee training programs in each international region.
Participants also toured the latest production lines at Toyoda Gosei‘s Morimachi Plant, its
mother plant for weatherstrip products, to learn the latest manufacturing technology in
Japan.
Toyoda Gosei is going all out as the Group to achieve sustainable growth into the future,
responding flexibly and rapidly to the huge changes taking place in the business
environment.
The Toyoda Gosei Group has grown to have 65 companies in 17 countries. Under the
company creed of "Boundless Creativity and Social Contribution," we grow our business
and contribute to society through the provision of mainly automotive products that use
rubber and plastics technology. Today, the automotive industry is in midst of a huge
transformation, including advances in autonomous driving and electrification. In order to
take this huge wave as an opportunity and achieve sustainable growth in the future by
responding flexibility and swiftly to changes in the business environment, in April 2018
we announced our medium-and -long term business plan, called the Business Plan 2025.
With the three pillars of "Venture into innovation, new mobility," "Strategy for growing
markets/fields," and "Innovative manufacturing at production sites," and the power of all
38,000 employees working together, we aim to grow as a global company that delivers
the highest levels of satisfaction to customers worldwide through safety, comfort, well-
being and the development.
Toyoda Gosei aims to grow as a global company that acts flexibly and swiftly in today‘s
dramatically changing business environment, delivering the highest levels of satisfaction
to customers worldwide through safety, comfort, well-being and the environment.
Venture into innovation, new mobility (New Technology New Products):
Commercialization in the new fields utilizing core technologies, Development of new
technologies and products coping with CASE, Strategies of modularization and system

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products.
Strategy for growing markets/fields(current products): Selection and concentration of
business resources, Make current products more highly value-added, Business plan
executions through cooperation with customers and business partners.
Innovative manufacturing at production sites(current products): Globally standardized
production know-how and processes, "Jidoka" and manpower saving utilizing IT,
Reduction of environmental burden by production engineering reform.
Knowledge cultivated in the fields of high polymers and LEDs and experience gained as
a world leader in the development of blue LEDs are used to create practical and
innovative new technology that will contribute to safety, comfort, well-being and the
environment.

■ e-Rubber
Next-generation concept model Next-generation rubber that functions with electricity
and mechanical force. Unprecedented light, soft ―artificial muscle‖ (actuators) and
sensors have been developed with the combination of Toyoda Gosei‘s technical strengths
in rubber and the materials patents of Advanced Softmaterials, Inc., a startup out of
Tokyo University.

■ GaN power semiconductors

Energy-saving key devices with the application of LED technology. Next-generation type
of power semiconductors (electronic components that convert/control power). Using the
gallium nitride (GaN) crystal growth technology cultivated in the development and
production of LEDs, we are developing products that contribute to more efficient and
smaller electronic devices.
Toyoda Gosei is pursuing a focused strategy of expanding its airbag business to meet
growing demand with stricter safety regulations worldwide; increasing its business in the
rapidly growing Indian and Chinese markets; selecting and concentrating management
resources; seeking thorough efficiency; and pursuing the advantages of scale.
New Car Assessment Programs (NCAP) are currently in place in western countries and

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Japan and are being introduced in many southeast Asia countries, India, China and
elsewhere. These regulations are becoming stricter each year, and demand for airbags is
predicted to continue growing. Toyoda Gosei is committed to meeting this demand.
The number of automobiles produced in India is rapidly increasing. In 2017 automobile
impact safety performance tests became mandatory, and in 2020 India will make its
domestic exhaust gas regulations stricter. Thus, we may expect growing demand for
safety and environmental products.
Automated and labor-saving processes are being put in place that use information
technology (IoT, AI) and other leading technology, and personnel who can analyze and
effectively use big data in conjunction with universities and other companies are being
trained.
Automated and labor-saving processes are being put in place that use information
technology (IoT, AI) and other leading technology, and personnel who can analyze and
effectively use big data in conjunction with universities and other companies are being
trained.
Compact and energy-saving equipment will be used to reduce CO2 emissions during
production. This leading-edge eco-plant is fitting as a plant producing a key component
of fuel cell vehicles (FCVs), which have been called the ultimate eco cars.
Development of people who can analyze various types of mass data obtained from
sensing technology in production processes. Processes are being put in place with sensing
that can reduce and predict loss.

1.3 Long-term environmental vision

Toyoda Gosei announced the TG 2050 Environmental Challenge, environmental
management efforts with an ultra-long-term vision. This is something that is common to
Toyota Group companies, but Toyoda Gosei‘s efforts have unique characteristics such as
an emphasis on environmental education and personnel development. The company‘s 6th
Environmental Action Plan, which continues to 2020, establishes detailed targets and its
systems and activities are highly regarded. I think the formulation of a specific plan will
be the key to how activities will progress after 2020. In formulating these plans, active
participation of the young people who will carry the company in 2030 or 2050 is

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essential. Creating a system that will allow young people to develop future plans and lead
activities will be important; it should also lead to edification of environmental awareness
in the company.

1.4 Expanding environmental preservation activities

Toyoda Gosei is outstanding not only in terms of formulating a long-term vision such as
that described above, but also in effective individual environmental preservation
activities that have range and depth. Their information disclosure also includes precise,
detailed explanations. They are not only moving steadily forward with target
management to contribute to low-carbon and recycling societies, but providing many
examples that will be useful to other companies and contributing to reducing the
environmental impact of society overall. These activities are beneficial not only
environmentally but also in terms of cost, and advancing environmental preservation
activities with consideration of their economic effect is an important strategy. To
effectively spread environmental preservation, the support of a budget is essential and the
activity can be continued from the time a benefit is first seen for an investment. I look
forward to the company creating such a virtuous cycle. Ongoing plant afforestation and
nature preservation activities with links to the community are also important in raising
the company‘s social value in the community, and I look forward to further enhancement
of these activities.

1.5 Environmental efforts in the supply chain

Toyoda Gosei emphasizes its relations with suppliers in conducting environmental
preservation activities. It is actively expanding these activities— promoting green
procurement, awarding suppliers for successes, and conducting seminars for suppliers.
Carrying out environmental preservation activities in cooperation with suppliers is a
crucial aspect of environmental management in all countries, and Toyoda Gosei‘s
activities are viewed very favorably. In the future, they will create mechanisms to more
actively advance these activities through joint work with suppliers, including overseas
suppliers. Publication of specific examples of cooperative work with suppliers would be
good reference for many other companies. In the future, I hope this will lead to specific

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reductions in CO2 with SCOPE 3.

1.6 Working for world standards

The level of Toyoda Gosei‘s environmental preservation activities is very high. Several
issues will need to be addressed to improve the Toyoda Gosei Report to the global
standard. First, environmental and social activity goals are described separately, but it
would be better to unify them with sustainability activities or CSR activities. One
effective method of doing this is to refer to GRI＊1 standards. With reference to those
standards, I think a materiality analysis that determines social environmental activity
priorities and investigation of environmental and social activity KPIs would be good.
There are many indicators in existence today, but if representative ones are selected, non-
financial KPI are positioned alongside financial KPI, and other index groups are arranged
based on them, they should be able to execute more consistent and systematic
management. The sustainable development goals (SDGs)＊2 adopted by the United
Nations in 2015 should also be useful in determining priorities. A comparison of the 17
goals and 169 targets of the SDGs and the social and environmental activities of Toyoda
Gosei will reveal many points of contact. I hope that will serve as a point of entry to
further development of activities.
＊1 The Global Reporting Initiative (GRI) is a set of standards for the preparation of
sustainability reports. Sustainability reports are spreading internationally. ＊2 Goals
adopted by the United Nations in 2015 with the aim of creating a sustainable society at
the international level.

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CHAPTER 2
ABOUT THE DEPARTMENT
Toyoda gosei develop and produce rubber and plastic automotive parts. Toyoda Gosei
provides products that contribute to the creation of safe and comfortable automobiles.

■ Automotive Parts
 Weather-strips: Door glass runs and Opening trim weatherstrips.
 Functional Components: Plastic fuel filler pipes, Turbo ducts and Brake hoses.
 Interiors and Exteriors: Instrument panel modules and components, Radiator
grilles and Console boxes.
 Safety Systems: Airbags, Steering wheels(with built-in airbags) and Pop-up hood
actuators.

■ Other Products
 LEDs: LEDs (light-emitting diodes) offer a number of advantages over
incandescent lights, including lower energy consumption, longer lifetime,
improved robustness and smaller size and are being increasingly used in OEM
automotive applications.LED that emits deep ultraviolet (UV-C) with a
bactericidal effect is used in sterilizing water (ensuring drinking water, water
purification).

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 Solar LEDs: Red, green, blue phosphor is irradiated with violet light to achieve a
color tone close to sunlight.

■ General Industry Products

 Air purifiers.
 Circulator.
 Industrial machinery parts.

2.1 Weather-strips: Weather-strips seal the gaps at door and window frames to keep
out wind, rain, and noise. These products are essential for comfortable cabin interiors.
 Opening trim weather-strips: Sponging processes for rubber using our materials
development and production technology reduce weight by about 30%. Our lineup
of fabric and other decorative variations is used where the parts are visible from
the vehicle cabin. These are rubber products affixed to the vehicle body, which
serve to protect the vehicle cabin from the elements. They are matched by
material and color to vehicle interior color variations.

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 Door weather-strips: These weatherstrips are affixed in the door opening via the
frame or clips, and serve to protect the vehicle cabin from the elements. They also
absorb impact when the door is opened and closed and help keep the vehicle cabin
quiet.

 3 Door glass runs: Weight has been reduced about 30% by switching from rubber
to rubber-plastic admixtures and adopting innovative design that allows certain
sections to be made thinner. Door glass runs are affixed via the frame to the
sliding portion of the window glass. They are composed mainly of EPDM rubber
and thermoplastic olefin (TPO), serving to protect the glass and ensure the smooth
operation of windows.

 Outer weather-strips.

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 Luggage weatherstrips: These are rubber products affixed to the body side of the
trunk, protecting the trunk interior from the elements. They also absorb impact
when the trunk is opened and closed and prevent backlash and rattle.

2.2 Functional Components: These rubber and plastic components support the
basic vehicle functions of driving, turning and stopping. Toyoda Gosei technology
ensures quality for these key safety-related parts.
 Fuel Tank Peripheral Parts:
 Fuel hoses and tubes: These rubber and plastic pipes send fuel to the engine and
fuel vapor to the atmosphere via the fuel vapor cleaner.

 Fuel filler caps: These caps are attached to prevent fuel leakage from the intake
port when the gas pump nozzle is inserted, by functioning as a seal.

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 Fuel filler lids: In addition to protecting the fuel intake port from dust and water,
fuel filler lids improve the aesthetic quality of the body and the ease of use of the
fuel intake cover.

 Locknuts/pump gaskets.
 Fuel filler hoses.
 Roll-over valves: Rollover valves have a sealing function that prevents fuel spills
from the fuel tank in the event of a vehicle rollover.

 Fill limit vent valves: These valves restrict the amount of fuel when the tank
becomes full, functioning to seal and prevent variation in fuel levels.

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 Inlet check valves: Check valves prevent fuel from flowing backwards out of the
fill tube opening when the tank becomes full.

 Hydrogen tank liners.

 Cap less fuel fillers: A device designed to make refueling more convenient by
simply inserting the nozzle without opening or closing the filler cap when
refueling.

 Plastic fuel filler pipes: Single-piece molding of sections with different

characteristics (flexible, rigid, and straight sections) assures the strength of these
pipes, while their multi-layer structure improves fuel resistance and durability.
These technologies have made it possible to reduce weight by nearly 50%
compared with previous metal pipes. These pipes convey fuel to the fuel tank.
They function for the smooth flow of fuel and to prevent backflow.

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2.3 Engine Peripheral Parts:

 Air cleaner hoses and Resonators: Air cleaner hoses are used in providing the
clean air needed for engine revolution. Resonators reduce the noise that is
generated when air is taken in.

 Ventilation hoses.
 Reservoir tanks.
 Turbo hoses.

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 Turbo ducts: Turbo ducts direct supercharging air to the engine by turbo to
improve engine power. They are pressure and heat resistant.

 Intake manifold gaskets.

 Noise absorbing air intake ducts: These ducts take in outside air needed in engine
revolution. Intake noise is reduced with the use of air permeable members in part
of the duct.

 Plastic water pipes: These pipes are placed around the engine. They include
several types with different functions. They are used for air conditioning, oil
cooling, turbo cooling, and other functions.

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 Constant velocity joint boots: These boots have a cylindrical, bellows shape and
are used to cover constant velocity joints, which turn and flex. They keep joint
lubricating grease in and water and dirt out.

 Cylinder head cover gaskets.

 Brake hoses: These hoses transmit hydraulic pressure in the body-side brake
system to the wheel-side brake system. They are flexible and highly durable so
that they can follow the movement of the wheels.

 Engine covers: By covering the top of the engine, these covers make the engine
compartment more aesthetically pleasing and reduce noise from the engine itself.

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 Plastic air pipes.

 Parts for hybrids and EVs:
 Radiator hoses: These hoses connect the engine and radiator for the circulation of
the coolant that is needed to cool the engine.

 Cooling ducts.
 Battery insulating plates.
 Inverter covers.

2.4 Chassis and Drive Train Parts:

 Constant velocity joint boots.

 Column hole.
 covers Speedometer gears.
 Transmission covers.
 Piston cups.
 Piston seals.
 Brake hoses: These are crucial parts in vehicle braking, and must pass a durability
test of more than 5 million repetitions.

2.5 Interiors and Exteriors: Interior and exterior parts contribute to comfortable
cabin spaces and attractive exteriors.

 Interiors: Instrument panel modules and components,

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 Instrument panel: Instrument panels, also called dashboards, are large

components that house instruments and meters, the audio system, glove box and
more.

 Defroster nozzles: These are outlets for air to defog the inside of the windshield.
They must function to control airflow for rapid defogging while also having a
compact shape.

 Ornamental panels.
 Cup holders: Cup holders are installed in various places in the vehicle cabin to
hold drinks. They must be strong, durable, convenient, and compact.

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 Meter clusters.
 Glove compartments: This is the large storage box set in front of the front
passenger seat. It is an important part that needs to be comfortable and easy to
open and close, as well as durable and safe in collisions.

 LED cabin lamps: These units illuminate the interior door handle area with a soft
light to improve visibility at night. They also give the interior cabin a cozy
atmosphere.

 LED lamp modules: LED units are used in illumination of various parts of the
vehicle, including floor lighting and compartment lighting. They are smaller and
consume less energy than conventional light bulbs.

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 Lighting illumination scuff plates: Scuff plates are attached to the door threshold
to prevent scuffs and scratches when people get in and out of the vehicle.
Illuminated scuff plates emit light by LED for decoration.

 Front pillar garnishes: These parts decorate the pillar between the windshield and
side window. They also function to absorb impact during collisions and cover side
curtain airbags.

 Assist grips: Passengers can hold on to these grips while riding in a vehicle to
support their posture. When not being used, the grips automatically fold into the
ceiling.

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 Grille illumination: These are fashionable radiator grilles that use LEDs as a light
source. They have a strong design element that balances performance at night and
attractiveness during the day.

 Radiator grilles: Radiator grilles are located on the front of the vehicle and are a
key part of the vehicle's "face." Their distinctive design and plating decoration
contribute greatly to the look of a vehicle.

 Console box: Console boxes sit between the front seats and function as storage
and an armrest. Various types of decoration are used on the upper panel, including
coatings and wood grain.

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 Center cluster: Center clusters are located in the center of the instrument panel,
and contain audio, navigation system, and air conditioning controls and switches.
They are one of the most defining elements in vehicle interior design.

 Registers: Registers efficiently direct the flow of air from the air conditioning unit
to the desired location. For this smooth operation is a must.

 Back door garnishes: These products are attached to the rear of a vehicle and have
a strong design element. They are placed so as to highlight the attractiveness of
the license plate lamb, door handle, and rear camera.

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 Exteriors:
 Radiator grilles: We satisfy all sorts of user design preferences with our
decorative technology, such as plating and painting, and molding technology.
 Back door garnishes.
 Wheel covers.
 Quarter vent ducts.
 Automotive headlamp LEDs:
 Shade.
 Lens.

2.6 Safety Systems: Toyoda Gosei has developed various airbags for full 360°
coverage to protect passengers from impacts on all sides. We also provide attractively
designed steering wheels.

 Airbags:
 Driver-side airbags: These airbags are installed in the center of the steering wheel.
They deploy during frontal collisions to protect the driver.

 Passenger-side airbags: These airbags are installed in the instrument panel on the
passenger side. They deploy during frontal collisions to protect the front
passenger.

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 Knee airbags: Knee airbags are installed below the steering column and the
instrument panel on the passenger side. They deploy during frontal collisions to
protect the driver's and passenger's legs.

 Seat cushion airbags: These airbags are installed under the front seats. They
deploy within the seat during frontal collisions to prevent occupants from sliding
forward.

 Side airbags: These airbags are installed mainly in the sides of seats. They deploy
during side collisions to protect the torso.

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 Rear-seat center airbags: These airbags are installed at the top of the rear seat
center. They deploy during side collisions to prevent the heads and shoulders of
rear seat passengers from colliding with each other.

 Rear-end impact airbags: These airbags are installed above the rear window. They
deploy during rear collisions to cover the rear window and protect the heads of
rear seat passengers.

 Curtain airbags: These airbags, developed with the use of deployment simulations
and other analysis and evaluation technologies, cushion impacts to the head
during side collisions. These airbags are installed in the roof above the side
window. They drop down and inflate during side collisions to protect occupants'
heads.

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 Pop-up hood actuators: These actuators are installed in the engine compartment.
They lift the hood during collisions with pedestrians to ensure a gap between the
hood and engine. This lessens the impact on the pedestrian's head.

2.7 Steering Wheels: lineup of attractively designed wooden, leather, and wood grain
steering wheels are used by a wide range of customers. Steering wheels are turned in
order to steer the vehicle. They consist of formed urethane over a metal core, with leather
or wood grain added in some cases for a more luxurious feel.

2.8 Products / Other Products:

 LEDs: LEDs with new added value are being developed.
 Solar LEDs: Red, green, blue phosphor is irradiated with violet light to achieve a
color tone close to sunlight.
 Deep ultraviolet LEDs (developed product): LED that emits deep ultraviolet (UV-
C) with a bactericidal effect is used in sterilizing water (ensuring drinking water,
water purification).

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2.9 General Industry Products: We have used our automotive parts and LED
technology to develop and produce products in various other fields.
 Industrial machinery parts (interior parts).
 Construction machinery parts (interior parts).
 Dynamic dampers for houses.
 Circulator.
 LED dynamo light.
 Air purifiers: We make more than 40 different variations in terms of function,
design and color. We design the case and perform assembly under contract.

2.10 R&D:
 Comprehensive Product Development System: Toyoda Gosei expertise is incorporated in
every step, from development through production.

 Planning.

 Development.

 Technical Design.

 Evaluation.

 Production.

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CHAPTER 3
TASKS PERFORMED
3.1 Introduction to injection molding
The injection machine is a machine that melt plasticize the molding material inside the
heating cylinder and inject this into the mold tool to create the molded product by
solidifying inside it. The injection machine is constructed of a mold clamping device that
opens and closes the mold tool, and device that plasticize and inject the molding material.
There are several types in the injection machine, and the difference is made by how these
two devices are arranged.

1. Horizontal injection machine: Both mold clamping device and injection device
compounded horizontally.

2. Vertical injection machine: Both mold clamping device and injection device
compounded vertically.

3. Two-color injection machine.

4. Rotary injection machine.

5. Low foam injection machine.

6. Multi material injection machine.

7. Sandwich injection machine.

3.2 Introduction to plastic injection molding process

One of the most common methods of converting plastics from the raw material form to
an article of use is the process of injection molding. This process is most typically used
for thermoplastic materials which may be successively melted, reshaped and cooled.
Injection molded components are a feature of almost every functional manufactured
article in the modern world, from automotive products through to food packaging. This
versatile process allows us to produce high quality, simple or complex components on a
fully automated basis at high speed with materials that have changed the face of
manufacturing technology over the last 50 years or so.

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The large and rapidly growing plastics products industry has very little representation in
the Southeast. Since plastics materials were originally substitutes for other materials, they
were first introduced largely into those areas of the North with established manufacturing
shops and technical experience. Because of the requirements and economics of the
plastics products industry and the buying habits of its customers, there is a large number
of small manufacturers today. They are still concentrated in the North, although
California also has a substantial number. Unlike most other industries, the plastics
products industry has not established branch plants in the Southeast. In fact, the industry
has very few branch plants anywhere, primarily because the typical individual company
is too small and too concerned with day-to-day problems to consider the advantages of
another plant location. The Southeast does appear to be a good location for plastics
products manufacturing, however, principally because of its substantial markets and its
attractive labor relations and costs.

There are two approaches which Carroll County can take to develop a plastics products
industry. First, local entrepreneurs can set up plastics products operations, or existing
manufacturers can diversify into a plastics products line. While this approach perhaps
offers the most immediate opportunity, investment in new or additional plant facilities

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and production equipment should not be considered without first obtaining reasonably
thorough technological knowledge of plant operations and plastics applications. Second,
local representatives can encourage existing manufacturers in the North and California to
establish branch plants in Carroll County. Because of the preoccupation of most
established manufacturers with operations in their present locations, this approach would
require extensive preparation and fact finding in order to spark the interest of those
companies which would profit from an expansion of production facilities into the
southeastern market. If this approach were pursued, Carroll County's presentation should
contain significant, well-documented advantages, not marginal or theoretical ones. Before
a substantial plastics products industry could be attracted, for example, it would probably
be necessary to train local workers in plastics technology at technical schools and
colleges in the area.

The rapid growth of the plastics products industry accounts in part for its attractiveness to
entrepreneurs. In 1938, suppliers to the fledgling plastics products industry produced 150
million pounds of synthetic resins and cellulosics. By 1954 the figure reached 2.9 billion
pounds. In the next seven years shipments grew by 130%. to 6.7 billion pounds. The
largest portion of recent consumption increases has been due to larger volume purchases
of thermoplastics -- the materials used in injection molding. Since 1950, about half of the
plastics products plants in the United States have used only injection-molding machinery;
a second large portion of the total has used injection-molding plus compression or
extrusion equipment.

3.3 Manufacturing operation

The operations required to produce plastics products by injection molding include (1)
preparation of the molding material, (2) melting the material, (3) forcing the material
through a nozzle and into a mold, (4) ejecting the molded product, and (5) machining and
finishing the product. Operations 1 through 4 may be performed without interruption on a
single combination of processing machinery.

Molding materials are frequently ready for immediate use when they are delivered by the
supplier, but they may require pre-molding preparation. Plastic material fed to the

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injection machine must be reasonably free of moisture if internal voids and surface
defects are to be avoided. Consequently, drying may be necessary to remove moisture
from the surface of molding resins or, in the case of such hygroscopic materials as nylon,
acrylics, and styrene blends, to drive out adsorbed water. Pre-molding preparation may
also require addition of colorants, lubricants, other resins, and scrap material which is to
be reworked. These materials are generally blended into the virgin resin in some sort of
tumbler. After any necessary preparation, the molding material is transferred, either
mechanically or manually, to a hopper which feeds the material to the heating cylinder of
the injection-molding machine. Heat and mechanical agitation convert the cold, granular
feed material into a homogeneous plastic melt of controlled viscosity. Temperature in the
cylinder is controlled by wraparound electrical resistance heaters. Mixing action is
provided by forcing the melt past baffles or spreaders or by use of a rotating screw
mechanism within the cylinder.

The plastic melt is forced through a nozzle and into the mold. Nozzle temperature is
controlled to allow continued clean shots of plastic into the mold without hardening and
breaking or drooling. The mold accepts a metered amount of plastic molding material and
cools it quickly and uniformly, usually by transferring the heat to water or some other
medium which is circulated through channels buried in the mold. When the molding
compound has set, the mold is opened and the molded part is forced out of the mold
cavity. Some molded articles require some form of machining or finishing.
Thermoplastics products can be machined with the same equipment used for wood or
metals, except that allowance must be made for the greater heat sensitivity of the plastics
product. They may be sawed, routed, drilled, turned, tapped, threaded, and sheared.
Articles may be finished by buffing and polishing if surfaces are cooled or kept in
constant motion, by tumble finishing, and by solvent polishing.

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Reciprocating screw injection molding unit

At this stage in the machine cycle the helical form injection screw (Figure 1) is in a
'screwed back' position with a charge of molten thermoplastic material in front of the
screw tip roughly equivalent to or slightly larger than that amount of molten material
required to fill the mold cavity. Injection molding screws are generally designed with
length to diameter ratios in the region of 15:1 to 20:1, and compression ratios from rear to
front of around 2 : 1 to 4 : 1 in order to allow for the gradual densification of the
thermoplastic material as it melts. A check valve is fitted to the front of the screw such as
to let material pass through in front of the screw tip on metering (material dosing), but
not allow material to flow back over the screw flights on injection. The screw is
contained within a barrel which has a hardened abrasion resistant inner surface.

Normally, ceramic resistance heaters are fitted around the barrel wall, these are used to
primarily heat the thermoplastic material in the barrel to the required processing
temperature and make up for heat loss through the barrel wall, due to the fact that, during
processing most of the heat required for processing is generated through shear imparted
by the screw. Thermocouple pockets are machined deep into the barrel wall so as to
provide a reasonable indication of melt temperature. Heat input can therefore be closed
loop controlled with a Proportional Integral and Derivative (PID) system. The screw
(non-rotating) is driven forward under hydraulic pressure to discharge the thermoplastic
material out of the injection barrel through the injection nozzle, which forms an interface
between barrel and mold, and into the molding tool itself.

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 Holding Pressure and Cooling

The screw is held in the forward position for a set period of time, usually with a molten
'cushion' of thermoplastic material in front of the screw tip such that a 'holding' pressure
may be maintained on the solidifying material within the mold, thus allowing
compensating material to enter the mold as the molded part solidifies and shrinks.
Holding pressure may be initiated by one of three methods: by a set time in seconds from
the start of the injection fill phase; by the position of the screw in millimetres from the
end of injection stroke; or by the rise in hydraulic pressure as measured by a pressure
transducer in the mold itself or in the injection hydraulic system.

As the material solidifies to a point where hold pressure no longer has an effect on the
mold packing, the hold pressure may be decayed to zero, this will help minimise residual
stresses in the resultant molding. Once the hold pressure phase has been terminated the
mold must be held shut for a set period of cooling time. This time allows the heat in the
molding to dissipate into the mold tool such that the molding temperature falls to a level
where the molding can be ejected from the mold without excessive distortion or
shrinkage. This usually requires the molding to fall to a temperature below the rubbery
transition temperature of the thermoplastic or Tg (glass transition temperature).
Depending on the type of plastic this can be within a few degrees or over a temperature
range. Mold temperature control is incorporated into the tool usually via channels for
pressurised water flow. The mold may be connected to a cooling unit or water heater
depending on the material being processed, type of component and production rate
required.

 Material Dosing or Metering

During the cooling phase, the barrel is recharged with material for the next molding
cycle. The injection screw rotates and, due to its helical nature, material in granule or
powder form is drawn into the rear end of the barrel from a hopper feed. The throat
connecting the hopper to the injection barrel is usually water cooled to prevent early
melting and subsequent material bridging giving a disruption of feed. The screw rotation
speed is usually set in rpm which is measured using a proximity switch at the rear of the

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screw. Screw rotation may be set as one constant speed throughout metering or as several
speed stages.

The material is gradually transferred forward over the screw flights and progressively
melted such that when it arrives in front of the screw tip it should be fully molten and
homogenised. The molten material transferred in front of the tip progressively pushes the
screw back until the required shot size is reached. Increased shear is imparted to the
material by restricting the backward movement of the screw, this is done by restricting
the flow of hydraulic fluid leaving the injection cylinder. This is referred to as `back
pressure' and it helps to homogenise the material and reduce the possibility of unmelted
material transferring to the front of the screw.

 Mold Open and Part Ejection

When the cooling phase is complete the mold is opened and the molding is ejected. This
is usually carried out with ejector pins in the tool which are coupled via an ejector plate
to a hydraulic actuator, or by an air operated ejector valve on the face of the mold tool.
The molding may free fall into a collection box or onto a transfer conveyer, or may be
removed by an automatic robot. In this latter case the molding cycle is fully automatic. In
semi-automatic mode, the operator may intervene at this point in the cycle to remove the
molding manually. Once the molding is clear from the mold tool, the complete molding
cycle can be repeated.

 Mold Design

Mold design is in itself an extremely diverse and complicated subject. However, it is

useful to understand basic design features and construction of simple injection mold
tools.

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Typical mold tool arrangement.

In this case the mold simply consists of two halves commonly referred to as the moving
(core) half and fixed (cavity) half. Starting from the injection side, a location ring is fitted
to the back of the rear backing plate, this locates and centralizes the mold into the fixed
platen. Through the locating ring a sprue bush can be seen. The sprue bush is profiled
with a radius to match up with the injection unit nozzle so that material can be directly
transferred from the injection unit through to the mold cavity. In the case of a single
impression (cavity) mold, the sprue may feed directly onto the component, in the case of
a multi impression mold, the sprue feeds onto a runner system machined into the tool face
that acts as a transfer system to the cavity for the molten material. Heated or hot runner
systems may be incorporated in the fixed half of the mold such that the sprue and runner
feed system is constantly molten and therefore not ejected at the end of the cycle. Instead
the molten material remaining in the hot runner system after injection of a component
forms part of the next shot. Many different types of gating may be used to connect the
runner system to the mold cavities. Gates are preferably as small as possible in order to
minimize the potential ‗witness‘ mark on the component.

It can be seen that a sprue and a cavity form in the mold creates the component shape,

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these may be machined directly into solid steel or aluminum plates, or made separately as
inserts which may be subsequently fitted to the core and cavity supporting plates. In this
particular example, hardened pins are used to eject the components from the mold, these
are fixed into a rear ejector plate which is connected to a hydraulic actuator behind the
moving platen. A profiled ejector pin behind the sprue bush ensures separation of sprue
from sprue bush when the mold opens and aids ejection of the runner system. Cooling
channels are machined into the core and cavity plates in order to remove the process heat
from the tool. The complete tool is held together with a system of spacer blocks, bolster
and backing plates such that it may be bolted directly to the machine platens and is
completely rigid and able to resist injection forces.

 Injection Molding Machine Selection Criteria

Machine selection, particularly for a range of component types can be quite difficult. It
is always wise to talk to machine suppliers in depth regarding overall machine
specifications. Rough guidelines do however exist to enable an estimation of machine
type and size required.

3.4 The Mold

The mold must fit within the available clamping area. This is usually determined by the
tie bar spacing on the machine restricting mold fitting and removal. Some machines
have retractable tie bars to assist mold changing. The clamp stroke available must be
able to accommodate the mold height or depth of mold and the required opening stroke
needed to eject the plastic component. For free fall ejection, the daylight between
platens must be greater than mold height plus twice the depth of component to be
ejected. It must be noted that this dimension will need to be considerably greater if for
instance, the component is removed by a robot, so as to allow access for the removal
head. It is always wise to allow plenty of room for man oeuvre for later machine
flexibility.

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 The clamping unit

The clamping unit must be able to supply enough locking force to keep the mold shut
during the injection phase, otherwise the mold will part and molten material will flash
over the mold split line. As a rough guide of thumb, parts with thin wall sections and
deep draw depths require approximately 3-4 tonnes per square inch or 0.5-0.6
tonnes/cm2, and parts with thick wall sections and shallow draw depths require
approximately 2 tonnes per square inch or 0.3 tonnes/cm2. To calculate the locking
force required for a particular component, this value must be multiplied by the
projected area of the component to obtain an overall value in tonnes. The projected
area of a component is taken as one side of the molding only, perpendicular to the
injection unit as oriented in the mold. For instance, a simple box housing of 3 mm wall
section having a top surface area of 120 cm2 will require at least 120 x 0.3 = 36 tonnes
of locking force.

 The Injection Unit

The injection unit must be capable of supplying the component shot weight (including
the sprue and runner system). The total shot weight should not exceed 90% of the
injection capacity of the machine. Injection capacities are usually quoted in grams of
polystyrene at a specific gravity of 1.03 g cm-3. If it is intended to process another
material, the injection unit shot weight should be recalculated using that particular
material's specific gravity.As metering or screw recovery must take place before
cooling time has elapsed and the mold opens, the injection unit (size of screw) must be
sized to allow this to happen. If recovery does not occur within the cooling period, the
overall cycle time will be unnecessarily increased. The maximum temperature possible
on the barrel must be great enough to melt the type of plastic being processed. The
barrel and screw must be specially treated if particularly abrasive materials are to be
processed, such as glass fiber filled polyamide (nylon). Also, the screw geometry must
be correct for processing specific materials, although general purpose designs are
available to cater for a range of commodity thermoplastics

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 Molding Quality
Thermoplastic moldings may contain many defects which are a result of bad mold
design, however, correct control of the injection molding process itself usually plays
the major part in achieving a good quality component. Basic part quality defects may
be as follows.

 Weld Lines

Weld lines are created when two or more cooling melt flow fronts meet within the
mold. This can be recognised on a molding as a hairline feature and occurs where melt
flow has been divided around an obstacle in the tool, such as a boss pin, and rejoins on
the other side. Weld lines locally reduce the mechanical properties of the material at
that point and care should be taken to position gating such that weld lines are
minimised. If they are unavoidable, they must be positioned in areas of least effect.
Melt flow software packages are of great assistance in this area for complex moldings.
Modification of process conditions such as increasing melt temperature, mold
temperature or injection speed may improve the situation but may create other
problems.

 Shrinkage

Shrinkage occurs as the thermoplastic cools in the mold. It is due, on a molecular level,
to the polymer chains relaxing (recoiling) and aligning themselves with adjacent
chains. Increased shrinkage occurs with more highly crystalline plastics (e.g.
polybutylene terephthalate, PBT) due to the formation of more dense crystal structures.
Sink marks may occur in plastic parts in areas of thicker cross section such as junctions
between side wall and base where the plastic is slower to cool. Higher mold
temperatures will allow the plastic to shrink more due to increased molecular energy
and subsequent ability to recoil. Higher packing pressures may compensate, as
shrinkage can be taken up with new melt (assuming the gate is still live).

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 Splash Marks

Splash marks occur as silver streaks on the molding surface. If any moisture is present
in the material, it is heated and conveyed into the mold cavity. At the point where
material enters the cavity (gate) there is a sudden decompression of the material and the
moisture will volatilise off causing the splash effect. This occurs particularly in
moisture attractive thermoplastics such as nylon (polyamide, PA) and polyacetal
(polyoxymethylene, POM).

 Distortion and Molded in Stress

Distortion and molded in stress may occur in molded components due to molecular
chain orientation. As the polymer is forced along small channels or cross sections, the
molecular chains become aligned and stretched. As the polymer cools, the molecules
try to relax to their preferred coiled state. As the cooling process is generally fast, the
extended molecular chains become 'frozen' in their uncoiled state. After molding, the
molecular chains still try to recoil and as a result the component may distort,
particularly in the case of semi-flexible polymers such as polyethylene. With more
rigid polymers, the distortion may not take place, however, the residual stress in the
plastic will lead to a reduction in important material properties such as impact strength.

3.5 Introduction to rubber injection molding

Based off of a process intended for the molding of plastics, injection molding of rubber
began in the mid 1960s. Rubber injection molding successfully alters the plastics
process by heating the rubber and placing it under significantly more pressure per
square inch of cavity surface in molding. This is different from the plastic injection
molding process where the materials are cooled under less pressure. Through various
innovations, injection molding has become one of the most efficient ways to create
molded rubber products in many cases.

The process of injection and injection-transfer molding starts with efficient material
preparation. To begin, the material is mixed in bulk and then stripped immediately into

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continuous approx. 1.25" wide & .375" strips. These strips are then fed into a screw
which, in turn, fills a barrel with the appropriate predetermined amount of rubber.

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3.6 Working procedure

The rubber injection molding process starts with an uncured rubber ribbon stock that is
fed into a rotating screw of the injection unit. A controlled amount of material is pulled
into the injection unit. Here the material is plasticized to a target elevated temperature.
The rubber material is then injected into the mold cavity through a runner and gate
system where it is held in the mold under high pressure and elevated temperature to
activate the cure system in the rubber compound (rubber is vulcanized). The cycle time
is established to reach an optimal level of cure. At the end of the cycle, the parts are
removed or ejected from the cavities and the next cycle begins.

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CHAPTER 4
CONCLUSION
Toyoda Gosei undertakes a range of efforts globally with an emphasis on environmental
preservation, development of people and workplaces that support our business, and
contributions to livable communities.
 Environmental Preservation: strive in all business activities to reduce
environmental impacts, starting with lightweight automotive parts that contribute
to better fuel efficiency.
 Development of People and Workplaces That Support Our Business: TGSIN aim
to create a dynamic corporate culture with a strong sense of unity, where all
employees can work in safety and health.
 Building Livable Communities: As a member of each of the communities where
TGSIN are located, will engage in various efforts for mutual growth.
 Governance: To continue earning the trust of society as a company of integrity,
we are strengthening TGSIN global efforts for legal compliance and working to
instill a strong sense of ethics in company employees.
 Got exposure in the automobile components manufacturing processing
techniques.

 Understood the concept of safety first and Quality must at TGSIN.

 Got an rich exposure in the field of automation.

 Understood the concept robot painting technology.

 Overall the internship programme gave tremendous knowledge in the field of

automobile.

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