CN101028739B - Air-auxiliary injection forming process of thermoplastic resin product - Google Patents
Air-auxiliary injection forming process of thermoplastic resin product Download PDFInfo
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- CN101028739B CN101028739B CN200610024165A CN200610024165A CN101028739B CN 101028739 B CN101028739 B CN 101028739B CN 200610024165 A CN200610024165 A CN 200610024165A CN 200610024165 A CN200610024165 A CN 200610024165A CN 101028739 B CN101028739 B CN 101028739B
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Abstract
A gas-aided injection moulding technology for manufacturing thermoplastic resin products includes such steps as adding supercritical N2 and/or CO2 to fused resin, stirring, filling compressed air in mould, injecting said resin mixture in the mould while controlling air pressure, cooling, and demoulding.
Description
Technical field
The present invention relates to a kind of gas-assisted injection molding method of thermoplastic articles, be particularly related to and a kind ofly before the molten resin material enters die cavity in the mould, join in the molten resin, after forming uniform molten resin/admixture of gas, be injected into forming method in the die cavity of the mould of having set up an abundant stable gas back-pressure with Compressed Gas with compressed nitrogen.
Technical background
In recent years, along with the extensive use of injection-molded item in various fields, for example household electrical appliance are (as TV, phone etc.) and mobile electronic equipment (as, laptop computer, mobile phone etc.) industry, business machine, auto parts and components manufacturing and dairy industry field etc. are considered for aspects such as the cost of goods and functions, more and more require goods thin-walled property and lightweight.Meanwhile, for the needs of combination assembling, to the dimensional accuracy of goods with and stability higher requirement is proposed; Also require goods to have high-quality surface quality (for example can directly spraying or print) to outside shell products.
When producing this class shell based article, need to adopt high injection pressure and dwell pressure to realize with traditional Shooting Technique, reach more than the 200MPa sometimes.The consequence of being brought is that the goods degree of orientation is big, goods are heavier, molding cycle is long, also has buckling deformation, defectives such as size instability.The shortcoming on the other hand that adopts this method is that the investment of injection-moulding device is big.For improving mold-filling capacity, sometimes adopt higher injection temperature, however inapplicable to thermally sensitive resin on the one hand, corresponding growth cool time on the other hand, the thermal shrinkage stress of goods increases, and can cause defectives such as product surface shrink mark, buckling deformation and poor dimensional precision equally.For eliminating defectives such as buckling deformation, local collapse, shrink mark, there is suggestion to use the extraneous gas moulding process.Wherein a kind of is that (pressure is about 20MPa with high pressure nitrogen again after the resin melting charge is injected in the die cavity, even higher) be injected into subregion between resin material and the mold cavity surface, thereby the resin material is pressed to the mold cavity surface of other direction so that this surface of goods obtains the surface of full no shrink mark, thermal contraction when the main purpose of this technology is the compensation cooling, to only needing ostentatious goods is resultful, but in that to produce stream long during than big thin-gage goods, still need to adopt other technological measures to realize that materials flow is full of die cavity, for example adopt high injection pressure etc.Therefore stream is long to have limitation during than the high goods of big dimensional accuracy to this technology producing.
As mentioned above, adopt the entity injection moulding to be difficult to deal with problems fully, product weight problem particularly, and the plastic products after the foaming are owing to comprise numerous abscesses, the goods of producing identical volume lack than closely knit material certainly, abscess-size is more little simultaneously, density is high more, the performance of foaming product is good more, performance change with respect to closely knit goods is also more little, and this is because plastic substrate has played leading role, yet traditional low-pressure structure foam process is difficult to the effectively size and the distribution of control abscess, for addressing these problems, there are many disclosed patent documentations to describe method and the technology that forms fine and closely woven abscess (bag expands poromerics) now.For example:
No. 4473665 (people such as MARTINI-Vvedensky of United States Patent (USP); On September 25th, 1984) description is used for making and has the process of diameter less than the foamable polymer of about 100 microns abscess.In this technology, the parent of material is in the blowing agent saturation state, and this material is placed under the high pressure, and pressure descends fast, so that blowing agent nucleation and for the formation of abscess creates conditions, then, material is distributed to keep the micropore of holding in advance by quick freezing.
United States Patent (USP) No. 5158986 (people such as Cha) has been described the use supercritical fluid and has been formed capillary copolymer material as blowing agent, realizes by quick pressure drop or Fast Heating.
No. the 5866053rd, United States Patent (USP) people such as () Park is described the continuous process that is used for forming the micropore microcellular foam, pressure on single phase soln of blowing agent and polymer is reduced rapidly, so that material forms enough highdensity complex, so that on final products, form microcellular structure.
In Chinese patent literature, method and some moulding process of injecting supercritical fluid have been disclosed among CN1174845C and the CN1325337A, claim the injection-molded item that to produce microporous foam, when producing thin-gage goods, can reduce or eliminate warpage and distortion especially, and can alleviate the weight of goods.By under supercriticality, adding by weight the molten resin that enters into plasticization unit less than the blowing agent between 0.08% blowing agent or 1% to 25% (nitrogen/or carbon dioxide), form homogeneous mixture or single phase soln, then in the nucleation path by quick pressure drop nucleation, be injected in the die cavity at last, because carbon dioxide/or nitrogen with after molten resin fully mixes, the viscosity of mixture significantly reduces, and injection stream very easily takes place in this mixture in the injection cavity filling process, thereby has defectives such as spraying spot and surface blister on the product surface; Simultaneously since resin flow in type in the flow process complex can grow up, abscess breaks at Liu Feng, thereby lira occurs inevitably, the defective appearance phenomenons that traditional foam process occurred such as Eight characters line.Abscess is grown up in flow process than increasing along with stream is long on the other hand, causes occurring interior bubble, the nest that contracts, explosion and short major defect such as penetrate, and the existence of these defectives has limited this The Application of Technology, particularly to the larger area goods.In patent disclosure CN1325337A, disclosed some methods that are similar to common notes and attempted to solve these blemish, yet be difficult to the amount of resin of control table cortex and prevent that epidermal area from being filled brokenly by foaming layer.
In Chinese patent literature CN1104316C, disclose a kind of method and attempted to solve the problem of aspects such as surface quality, adopt supercritical carbon dioxide and/or nitrogen to join and form mutual dissolved state in the continuous plastication device by the weight portion between 0.1-30, be injected into then in the mold cavity that is higher than the precompressed of supercriticality pressure, foam in die cavity inner control nucleation, but in implementing, it finds, the gas pressure of precompressed die cavity need surpass 8MPa to foam in the inhibition cavity filling process, yet consequently need very high injection pressure just can overcome high like this gas back-pressure and realize filling type, and limited loss of weight, so remaining very big stress of goods of moulding, to consume a large amount of gases simultaneously and carry out the die cavity precompressed, increase production cost.
A kind of foam process method that in Chinese patent literature CN01821564.5, discloses, claim that blowing agent (carbon dioxide or nitrogen) content is between 0.05% to 10%, but adopt the 7MPa or the carbon dioxide precompressed mold cavity of high pressure more equally, be used to control the peak foaming of die cavity stream; Adopt overflowing well technology to come the removal blow pressure simultaneously, shorten molding cycle and realize weight loss effect, yet in the long function that is difficult to realize overflowing well in than big goods of thin-gage goods or stream.
Summary of the invention
The objective of the invention is to be devoted to find a kind of cost-effective method to produce the shell based article, make the dimensional accuracy of goods high and stable, and the surface quality excellence, weight is starkly lower than the goods of traditional entity injection mo(u)lding.Technology of the present invention is by utilizing the low-viscosity and the characteristic that can easily form uniform small abscess behind overcritical nitrogen and/or carbon dioxide and molten resin formation mixture, utilize the gas back-pressure control cavity filling process of lower pressure then, produce shell based article cost-effectively with various high-qualitys.
The object of the invention realizes being finished by following technical scheme:
Method technology of the present invention may further comprise the steps:
1) before resin is plastified and is injected into the die cavity of mould, in molten resin, inject and mix overcritical nitrogen and/or carbon dioxide, the supercritical gas injection rate count by weight percentage into the molten resin amount 0.08% to 5% between, form uniform molten resin/admixture of gas, comprise homogeneous single phase solution;
2) before in the die cavity that molten resin/admixture of gas is injected into mould, in mold cavity, inject Compressed Gas and be based upon 0.6MPa to stable back-pressure pressure between the 5MPa;
3) with a stable injection pressure that is higher than gas pressure in the die cavity with volume be the molten resin/admixture of gas injection molding process of moulded products die cavity volume of 85-100% in the die cavity of mould, and control 2) described in gas pressure is fully stable finishes up to the resin compound injection;
4) the gas back-pressure in the quick removal die cavity, and cooling forms goods.
Wherein, the nitrogen amount of step 1) injection is 0.1%～2% scope by weight percentage; In the step 1) molten resin have one at 5MPa to a pressure stable between the 30MPa, the pressure that is injected into nitrogen in the molten resin and/or carbon dioxide is to surpass the pressure 0.50MPa of molten resin to a steady pressure between the 0.65MPa, and the temperature of nitrogen and/or carbon dioxide is a stable temperature below 200 ℃ more than 20 ℃; Molten resin has a preferred pressure stable between 10-20MPa in the step 1); Step 2) make and set up a stable back-pressure pressure in the die cavity, this gas back-pressure pressure preferably at 0.8MPa between the 3.5MPa; Step 2) make and set up a stable back-pressure pressure in the die cavity, this gas back-pressure pressure more preferably at 1MPa between the 2MPa; Described step 2) gas that injects in die cavity in is nitrogen and/or carbon dioxide; Described mould comprises the die cavity of moulded products, the sealing system of on die joint, installing, die cavity from cast gate farthest the position or the position of filling type at last be provided with slit; Described mould comprises the die cavity of moulded products, the sealing system of on die joint, installing, die cavity from cast gate farthest the position or the position of filling type at last be provided with the mold cavity surface that one or more porous materials are made.
Advantage of the present invention be realize on the one hand molten resin/admixture of gas can be under the uniform pressure state steadily filling die cavity and control filling velocity, the gas that remains on the other hand in the molten resin is in stable condition in cavity filling process, can not overflow.Because after cavity filling process neutralization is filled type and is finished, can solidify with the molten resin/admixture of gas that contacts of the lower mold cavity surface of temperature in advance, gas can't be separated out, thereby the surface does not have the being seen defective of foaming.And after changing pressure state (after being quick removal gas back-pressure), gas can be overflowed in molten resin/admixture of gas, assembles evenly tiny bubble of formation, is distributed in the matrix of polymer the stress in contraction that produces when replenishing cooling and the elimination goods.
Description of drawings
Fig. 1 is a kind of gas assistant injection molding system exemplary plot;
Fig. 2 a shows be matched moulds after, in mould, annotate back pressure gas;
Fig. 2 b shows injection molten plastic mixture in die cavity;
Fig. 2 c shows that the molten plastic mixture is full of die cavity, then removal die cavity internal gas pressure;
After Fig. 2 d shows cooling, the goods demoulding.
Fig. 3 a shows three kinds of pressure-time curve examples in the gas assisted molding to Fig. 3 c
The specific embodiment
Feature of the present invention and correlated characteristic thereof are described further by embodiment below in conjunction with accompanying drawing, so that technical staff's understanding.
Show that as accompanying drawing wherein the label of 1-17 is represented respectively: goods, 16-die cavity, 17-sealing system after 1-high-pressure air source, 2-gas pressure regulator, 3-gas syringe or gas injection section, 4-melting material pressure sensor, 5-blender, 6-injection nozzle, the interior gas pressure sensor of 7-die cavity, 8-gas injection and exhaust passage, 9-plasticizing/injecting unit drive system, 10-plasticized screw, 11-machine barrel, 12a-solid plate, 12b-moving platen, 13a-half module (deciding), 13b-half module (moving), 14-gases at high pressure pipeline, the 15-moulding.
Gas pressure-time as described herein is controlled by gas pressure regulator 2; Molten resin pressure is controlled by injection machine.Simultaneously gas pressure regulator 2 can receive the pressure of handling gas pressure sensor 8 actual measurements in melting material pressure sensor 4 and the die cavity, can further handle and carries out corresponding control for the control system of injection machine after the processing.The control system of gas pressure regulator 2 and injection machine can interconnect, and realizes process cycles control.
Moulding process of the present invention is fit to the thermoplastic resin of all injection moldables, comprise thermoplastic materials such as polyethylene, polypropylene, polyvinyl chloride, acrylic resin, styrene resin, polyethylene terephthalate, polybutylene terephthalate, polyacrylate, polyphenylene oxide resin, modified polyphenylene ether resin, full-aromatic polyester, polyacetal resin, polycarbonate, PEI, polyether sulfone, polyamide-based resin, polysulfones, polyether-ketone, and the mixture that mixes its one or more.
For embodying the present invention well, design a secondary mould, in a cavity dimension is arranged is the plate parts that 500mm is long, 125mm is wide, 2.3mm is thick, be the bending structure at the two ends of length direction, shape shown in goods among Fig. 2 15, cast gate is positioned at the center of goods.Seal groove is offered in outside at die cavity, is used to install O-ring seals.Offer air inlet/exhaust passage 8 at the length direction two ends, and link together, and be connected with gas pressure regulator 2 at mould.Gas pressure sensor 7 is installed in gas passage 8 to be used for measuring the gas back-pressure pressure of die cavity and to feed back to gas pressure regulator 2.Gas pressure regulator 2 is connected with the control system of injection moulding machine, is used for mutual exchange parameter and signal.
Injection machine is the F2 series machine of eastern magnificent machines corporation, 250 tons of clamp forces, and screw slenderness ratio is 22: 1.Through transforming, at the preformed metering section gas injection device 3 is installed, and melting charge pressure sensor 4 is installed, and static blender 5 and hydraulic pressure shutoff type nozzle 6 are installed at the downstream direction of gas injection device 3.This gas injection device 3, pressure sensor 4 and hydraulic pressure shutoff type nozzle 6 are connected with gas pressure regulator 2.And gas pressure regulator 2 is connected with high-pressure air source 1, is used for to gas injection device 3 and die cavity air feed and controls.
Implementing the used raw materials for plastics production of this technology is HIPS (Starex).
1) before resin is plastified and is injected into the die cavity of mould, in molten resin, inject and mix overcritical nitrogen, the supercritical gas injection rate is counted by weight percentage and is 0.08% of molten resin amount, forms uniform molten resin/admixture of gas;
2) before in the die cavity that molten resin/admixture of gas is injected into mould, in mold cavity, inject the back-pressure pressure that Compressed Gas is based upon 0.6MPa;
3) with a stable injection pressure that is higher than gas pressure in the die cavity with volume be the molten resin of 85% moulded products die cavity volume and nitrogen mixture injection molding process in the die cavity of mould, and control 2) described in gas pressure is fully stable finishes up to the resin compound injection;
4) the gas back-pressure in the quick removal die cavity, and cooling forms goods.
Wherein, the nitrogen amount of step 1) injection is 0.1%～2% scope by weight percentage; Molten resin has a pressure stable at 15MPa in the step 1), and the nitrogen gas pressure that is injected in the molten resin is a steady pressure that surpasses the pressure 0.50MPa of molten resin, and the temperature of nitrogen is 20 ℃; Step 2) make and set up a stable back-pressure pressure in the die cavity, this gas back-pressure pressure is preferably at 3MPa; Described mould comprises the die cavity of moulded products, the sealing system of on die joint, installing, die cavity from cast gate farthest the position or the position of filling type at last be provided with slit.
Adopt similarly to Example 1 method, mould and material, will be injected into when preformed measures just that gas in the molten resin material changes into is 1% overcritical nitrogen (temperature is 40 ℃) by weight.At this moment the nitrogen with 3MPa charges into the die cavity precompressed, with the injection pressure injection of 90MPa.And goods is surperficial full bright and clean, does not have the foaming defective.Through weighing, goods heavily are about 161 grams.The gas back-pressure that reduces in the die cavity arrives 1MPa, and the injection pressure injection moulding with 85MPa also can obtain the good goods of surface quality, and the weight of goods drops to about 152 grams simultaneously.Further the nitrogen pressure in the die cavity is reduced to about 0.7MPa, injection pressure is reduced to 80MPa also can realizes filling fully type, product weight can be further reduced; But the surface is prone to phenomenons such as radiation line.
Adopt similarly to Example 1 method, mould and material, will be injected into when preformed measures just that gas in the molten resin material changes into is 0.2% overcritical nitrogen (temperature is 40 ℃) by weight.At this moment the nitrogen with 0.8MPa charges into the die cavity precompressed, just can finish with the injection pressure of 80MPa and fill type.And goods is surperficial full bright and clean, does not have the foaming phenomenon.Through weighing, goods heavily are about 152 grams.
If but removed gas back-pressure in the die cavity, can realize filling type, but there is the defective of tangible structure foaming on the surface with the pressure of 80MPa.
Claims (8)
1. the gas-assisted injection molding method of a thermoplastic articles is characterized in that, described method may further comprise the steps:
1) before resin is plastified and is injected into the die cavity of mould, in molten resin, inject and mix overcritical nitrogen and/or carbon dioxide, the supercritical gas injection rate count by weight percentage into the molten resin amount 0.08% to 5% between, form uniform molten resin/admixture of gas, comprise homogeneous single phase solution;
2) before in the die cavity that molten resin/admixture of gas is injected into mould, in mold cavity, inject Compressed Gas and be based upon 0.6MPa to stable back-pressure pressure between the 5MPa;
3) with a stable injection pressure that is higher than gas pressure in the die cavity with volume be the molten resin/admixture of gas injection molding process of moulded products die cavity volume of 85-100% in the die cavity of mould, and control 2) described in gas pressure is fully stable finishes up to the resin compound injection;
4) the gas back-pressure in the quick removal die cavity, and cooling forms goods.
2. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1 is characterized in that, the nitrogen amount that step 1) is injected is 0.1%～2% scope by weight percentage.
3. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1, it is characterized in that, in the step 1) molten resin have one at 5MPa to a pressure stable between the 30MPa, the pressure that is injected into nitrogen in the molten resin and/or carbon dioxide is to surpass the pressure 0.50MPa of molten resin to a steady pressure between the 0.65MPa, and the temperature of nitrogen and/or carbon dioxide is a stable temperature below 200 ℃ more than 20 ℃.
4. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1 is characterized in that, molten resin has a pressure stable between 10-20MPa in the step 1).
5. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1 is characterized in that step 2) make and set up a stable back-pressure pressure in the die cavity, this gas back-pressure pressure at 0.8MPa between the 3.5MPa.
6. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1 is characterized in that step 2) make and set up a stable back-pressure pressure in the die cavity, this gas back-pressure pressure at 1MPa between the 2MPa.
7. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1 is characterized in that, described step 2) in the gas that in die cavity, injects be nitrogen and/or carbon dioxide.
8. the gas-assisted injection molding method of a kind of thermoplastic articles as claimed in claim 1, it is characterized in that, described mould comprises the die cavity of moulded products, the sealing system of on die joint, installing, die cavity from cast gate farthest the position or the position of filling type at last be provided with slit.
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| AT520733B1 (en) | 2018-04-25 | 2019-07-15 | Engel Austria Gmbh | Method for determining a solution state of a gas |
| CN111791445B (en) * | 2019-04-05 | 2022-03-22 | 恩格尔奥地利有限公司 | Method for determining a target value for a state variable of a mixture |
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| CN112959635A (en) * | 2021-02-19 | 2021-06-15 | 北京中拓模塑科技有限公司 | Injection molding method for thermoplastic resin product |
| CN112959594A (en) * | 2021-02-19 | 2021-06-15 | 北京中拓模塑科技有限公司 | Injection molding system and method for thermoplastic resin articles |
| CN113715248A (en) * | 2021-03-17 | 2021-11-30 | 山东大学 | Lightweight polymer microcellular foaming injection molding process, device and application |
| CN113334689B (en) * | 2021-06-02 | 2023-04-25 | 东莞东裕塑胶制品有限公司 | Injection molding machine |
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| CN1230915A (en) * | 1997-05-21 | 1999-10-06 | 旭化成工业株式会社 | Method for injection molding of thermoplastic resins |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1230915A (en) * | 1997-05-21 | 1999-10-06 | 旭化成工业株式会社 | Method for injection molding of thermoplastic resins |
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