CN101642949A - Method for producing multilayer molded article and multilayer molded article - Google Patents
Method for producing multilayer molded article and multilayer molded article Download PDFInfo
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- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
The present invention provides a method for producing a large-sized multilayer molded article which is free from defects such as warpage, has uniform thickness of each layer, and is excellent in interlayer adhesion, and a good molded article thereof. A method for producing a multilayer molded article comprising at least two layers of resin materials, the method comprising: a step of injection molding a layer 1 by 1-time molding using a fixed mold and a movable mold; moving the movable mold to form a cavity for molding 2 times; and a step of injection molding a 2 nd layer by 2-pass molding so as to laminate the 1 st portion, thereby molding a multilayer molded article in which the 1 st layer and the 2 nd layer are fusion-bonded. In the injection molding step, at least one of the injection compression molding steps is performed to adjust the parallelism between the fixed mold and the movable mold by using the mold clamping mechanism at the four corners of the mold fixing plate, thereby maintaining the parallelism between the molds.
Description
Technical field
The present invention relates to the manufacture method of the multi-layer molded articles that constitutes by two-layer tree fat material at least and adopt the multi-layer molded articles of this method moulding.In more detail, relate to by making moveable die make the manufacture method that parallel advance and retreat move the multi-layer molded articles of the core back type that forms injection space with respect to fixed mould, and the multi-layer molded articles that adopts the manufacture method moulding of this multi-layer molded articles.
Background technology
In recent years, for the multifunction of seeking goods and high design and adopt circulation and do not have the saving resource of coating or the high added valueization of the goods of environmental protection etc., wishing each layer of goods given the goods design of difference in functionality.As the method for using this various kinds of resin forming materials multi-layer molded articles that constitutes by different materials, usually adopt rotary-type etc. the multi-layer forming method of core back type or core, as special method, can enumerate the multi-layer forming method of mold-slide injection (die slide injection).The advantage of core back type multi-layer forming method (referring to patent documentation 1) is, owing to constituting mould by 1 cavity and 1 core, it gets final product, thereby, to compare with other multicolour forming method, its die cost is low, and the action of multicolour forming machine is also simple simultaneously.
Yet, in the moulding product of lamination different materials, be that number and molding shrinkage are different because the line between the material expands, produce problems such as warpage sometimes.This warpage not only results from the difference of material physical properties, and the reason of the residual stress that takes place when the deviation of thickness of each layer and moulding are arranged etc., so, the multi-layer molded articles large-scale warpage big more tendency relatively that heals is arranged.Therefore, the multi-layer molded articles of the large-scale component of the buffer of automobile, fender, automotive deck roof etc. is difficult to adopt the method for prior art to obtain.
As the forming method that obtains large-scale moulding product, injection compression molding method (referring to patent documentation 2) has the advantage of the residual stress reduction that produces when making moulding.But, also not open so far, concerning large-scale multi-layer molded articles, owing to the inhomogeneities of thickness causes warpage and connects airtight bad problem.
Patent documentation 1:JP spy opens the 2005-88527 communique
Patent documentation 2:JP spy opens flat 1-264823 communique
Summary of the invention
The present invention In view of the foregoing finishes.The invention provides a kind of thickness that does not have bad phenomenon such as warpage, each layer evenly and the manufacture method of the large-scale multi-layer molded articles that does not have in the good prior art of the connecting airtight property of interlayer, and these good moulding product.
The inventor etc. have carried out concentrated research in order to achieve the above object; consequently find; in the operation of the multi-layer molded articles that injection mo(u)lding is large-scale; at least one operation; thereby be to adopt the clamping in four bights of mold fixed plate to adjust the injection compression molding that the depth of parallelism between fixed mould and the moveable die keeps the depth of parallelism between the mould; can obtain the good goods of goal of the invention thus, thereby finish the present invention.
Promptly, the invention provides the manufacture method of (1) a kind of multi-layer molded articles, it makes the multi-layer molded articles that is made of two-layer tree fat material at least, it is characterized in that this manufacture method comprises: use fixed mould and moveable die to pass through the operation of the 1st layer of 1 moulding injection mo(u)lding; Make moveable die move the operation that forms 2 forming hollow cavings; Thereby and the operation that melts the sticking multi-layer molded articles that forms by 2 moulding with the 2nd layer of moulding of form injection mo(u)lding of lamination on above-mentioned part 1 by part 1 and part 2.And, in the above-mentioned injection mo(u)lding operation, at least one operation, thus be to adopt the clamping in four bights of mold fixed plate to adjust the injection compression molding that the depth of parallelism between fixed mould and the moveable die keeps the depth of parallelism between the mould.
One of preferred implementation of the present invention, manufacture method for (2) a kind of multi-layer molded articles, it is the manufacture method of the described multi-layer molded articles of above-mentioned embodiment (1), wherein, keep the depth of parallelism between the mould to carry out injection compression molding, the depth of parallelism between this mould keeps by following manner, promptly
It is parallel when mobile that clamping in four bights of adopting mold fixed plate makes moveable die do with respect to fixed mould; the value of detecting from the relative position of the movable platen that detects and fixed head; calculate the average distance between moveable die and the fixed mould; the difference of the value of detecting of each clamping and average distance is added the integrated value of reducing to the command value that gives each clamping and feedback difference as correction and control, thereby keep the depth of parallelism between the mould.
One of preferred implementation of the present invention, manufacture method for (3) a kind of multi-layer molded articles, it is the manufacture method of the described multi-layer molded articles of above-mentioned embodiment (1), wherein, keep the depth of parallelism between the mould to carry out injection compression molding, the depth of parallelism between this mould keeps by following manner, promptly
It is parallel when mobile that clamping in four bights of adopting mold fixed plate makes moveable die do with respect to fixed mould; detect the mold clamping force in the clamping in above-mentioned four bights; calculate the mean value of these mold clamping forces that detect; the difference of the mean value of the target mold clamping force of predefined clamping and the above-mentioned mold clamping force that detects is added the integrated value of reducing to the command value that gives each clamping and feedback difference as correction and control, thereby keep the depth of parallelism between the mould.
One of preferred implementation of the present invention, manufacture method for (4) a kind of multi-layer molded articles, it is the manufacture method of any one described multi-layer molded articles in above-mentioned embodiment (1)～(3), wherein, when the glass transition temperature of the resin material that uses in 2 moulding is made as Tg, the surface temperature of the 1st layer cavity side be (Tg-20) (℃)～(Tg+50) (℃).
One of preferred implementation of the present invention, manufacture method for (5) a kind of multi-layer molded articles, it is the manufacture method of any one described multi-layer molded articles in above-mentioned embodiment (1)～(4), wherein, carry out injection compression molding in the following manner, that is, the cavity capacity of middle matched moulds state is 1.1～10.0 times of cavity capacity of final matched moulds state, and moveable die is that 5mm/ is more than second from the translational speed of middle matched moulds state when final matched moulds state moves.
One of preferred implementation of the present invention, manufacture method for (6) a kind of multi-layer molded articles, it is the manufacture method of any one described multi-layer molded articles in above-mentioned embodiment (1)～(5), and wherein, the thickness that constitutes each layer of multi-layer molded articles is 1mm～50mm; Or be the manufacture method of (7) a kind of multi-layer molded articles, it is the manufacture method of any one described multi-layer molded articles in above-mentioned embodiment (1)～(6), wherein, the thickness (Ta) that constitutes the thinnest part in each layer of multi-layer molded articles is more than 0.7 divided by the wall unevenness evenness (Ta/Tb) of the thickness (Tb) of thick.
One of preferred implementation of the present invention, manufacture method for (8) a kind of multi-layer molded articles, it is the manufacture method of any one described multi-layer molded articles in above-mentioned embodiment (1)～(7), wherein, the amount of warpage after multi-layer molded articles leaves standstill 24 hours under 23 ℃, relative humidity 50% condition is below the 150 μ m/mm.
One of preferred implementation of the present invention is the manufacture method of (9) a kind of multi-layer molded articles, and it is the manufacture method of any one described multi-layer molded articles in above-mentioned embodiment (1)～(8), and wherein, resin material is a thermoplastic resin; Or be (10) a kind of multi-layer molded articles, it is to obtain by in above-mentioned embodiment (1)～(9) any one; Or be (11) a kind of multi-layer molded articles, it adopts the manufacture method of any one the described multi-layer molded articles in above-mentioned embodiment (1)～(9) to obtain, is 15～300cm from watering (gate) to the length of flow of flow end, and the maximal projection area is 200～60000cm
2, and adopt thermoplastic resin molded.
One of preferred implementation of the present invention is (12) a kind of multi-layer molded articles, and it carries out thermal flexure processing, removes edge part or application obtains by the multi-layer molded articles to above-mentioned embodiment (10) or (11); Or be (13) a kind of multi-layer molded articles, it obtains by any one described multi-layer molded articles in above-mentioned embodiment (10)～(12) is carried out finishing.
Description of drawings
The profilograph of the mold closing mechanism of state when Fig. 1 is the beginning of expression moulding circulation.
Fig. 2 is the profilograph of the mold closing mechanism of the state of expression before by the beginning of the 1st layer of 1 moulding injection mo(u)lding or injection compression molding.
Fig. 3 is the profilograph of mold closing mechanism of the state of the 1st layer of expression injection mo(u)lding or injection compression molding.
Fig. 4 is that expression is opened and is used for the profilograph of mold closing mechanism of state that 2 forming mould are carried out the preparation of injection mo(u)lding or injection compression molding.
Fig. 5 is the profilograph of mold closing mechanism of the state of the 2nd layer of expression injection mo(u)lding or injection compression molding.
Fig. 6 is that the profilograph of mold closing mechanism that mould takes out the state of 2 formable layer product is opened in expression.
Fig. 7 is the front synoptic diagram (7-A) and the side view (7-B) thereof of the multi-layer molded articles made among the embodiment.
The explanation of Reference numeral
10 mold closing mechanisms
11 the 1st injection devices
12 the 2nd injection devices
13 fixed moulds
14 moveable dies
15 die devices
16 clampings
18 mold opening and closing devices
20 clamping close devices
21 fixed heads
22 movable platens
23 connecting rods
24 position sensors
25 guiding mechanisms
26 support plates
27 compress the chamber
28 open chamber
The 1st layer of the 2 formable layer product that 311 moulding obtain
The 2nd layer of the 2 formable layer product that 322 moulding obtain
332 formable layer product
34 the 1st layers gate portions
35 the 2nd layers gate portions
36 cut out the line (dotted line) of the section that is used to measure each layer thickness
37 measure the position (amounting to 16 places) of each layer thickness
The position of the resin filling part of 381 moulding (the resin filling part De Hen Trace that 1 moulding produces is hidden by the 2nd layer)
The resin filling part De Hen Trace that 392 moulding produce
The end limit of 40 flow end sides
41 cast gate side end edges
42 cut out the part (oblique line) of test piece
The specific embodiment
Manufacture method explanation embodiments of the present invention below by 2 formable layer product.But moulding product of the present invention are not limited to 2 formable layer product.
(structure of make-up machine)
The profilograph of the mold closing mechanism of state when Fig. 1 is expression moulding circulation beginning.Fig. 2 is the profilograph of the mold closing mechanism of the state of expression before by the beginning of the 1st layer of 1 moulding injection mo(u)lding or injection compression molding.Fig. 3 is the profilograph of mold closing mechanism of the state of the 1st layer of expression injection mo(u)lding or injection compression molding.Fig. 4 is that expression is opened and is used for the profilograph of mold closing mechanism of state that 2 forming mould are carried out the preparation of injection mo(u)lding or injection compression molding.Fig. 5 is the profilograph of mold closing mechanism of the state of the 2nd layer of expression injection mo(u)lding or injection compression molding.Fig. 6 is that the profilograph of mold closing mechanism that mould takes out the state of 2 formable layer product is opened in expression.
Mold closing mechanism 10 constitutes injection moulding machine with the 1st injection device 11 and the 2nd injection device 12.Mold closing mechanism 10 has: as the fixed head 21 of mold fixed plate, it has installed fixed mould 13; As the movable platen 22 of mold fixed plate, its installed moveable die 14 and relative with fixed head 21 to; Clamping 16, it is provided with near four bights as movable platen 22, constitutes by having the oil-hydraulic cylinder device that compresses chamber 27 and open chamber 28 etc.; Connecting rod 23, its bar by the oil-hydraulic cylinder device of clamping 16 prolongs and forms; Clamping close device 20, it is arranged on four jiaos of the fixed head 21 that is on connecting rod 23 extension sites, and is arranged on connecting rod 23 and is free unoccupied place to run through the peristome of the through hole of fixed head 21 side ends; Mold opening and closing device 18, it has the oil-hydraulic cylinder device or is made of servomotor and ball screw mechanism etc., is provided with in pairs on the top and bottom of fixed head 21 or table dorsal surface, make movable platen 22 with respect to fixed head 21 near or away from; And position sensor 24, it is in the guiding mechanism 25 enterprising line slips that are fixedly installed between fixed head 21 and the support plate 26.Position sensor 24, be installed in respectively movable platen 22 each clamping 16 near, can detect movable platen 22 in each bight with respect to the distance of fixed head 21.In addition, clamping 16 can be provided with on any mold fixed plate of fixed head 21, movable platen 22.
In addition, constitute die device 15 by fixed mould 13 and moveable die 14.And, also can be on 4 positions of said fixing mould 13 and moveable die 14 installation site sensor 24.
As the 1st injection device 11 in the injection moulding machine and the configuration mode of the 2nd injection device 12, for example, can enumerate 2 methods that the injection device level disposes side by side; An injection device stands vertically installation, the method for another horizontal arrangement; Method of 2 injection device levels and arranged perpendicular etc.Can use above-mentioned any method among the present invention.In addition, can setting independently in any one injection device, condition of molding carries out moulding.
As the formation of resin stream in the mould,, can also use the method that is filled to cavity by cold runner except being filled to the method for cavity by independently hot flow path menifold and each cast gate from a plurality of injection device injecting resins.Here, as the gate system that adopts hot flow path, can adopt inner mode of heating, external heat mode etc. any, and when adopting the external heat mode, also can use any modes such as open cast gate mode, hot edge-gated mode, valve gate mode, but from obtaining this some consideration of condition of molding scope widely, preferred valve cast gate mode.In addition, when adopting the hot flow path of valve gate mode,, can adopt containment member (packing) in order to prevent to spill the molten thermoplastic resin from the sliding part of valve gate.As the material that constitutes containment member, concrete, can enumerate acrylic rubber, silicone rubber, EP rubbers, acrylonitrile-butadiene rubber, fluorine-type resin, but consider, preferred silicone rubber and fluorine-type resin from excellent heat resistance.
(formation of 1 forming hollow caving)
Next, with the operation moulding example that preface describes 2 formable layer product with reference to Fig. 1～Fig. 6.Here, 1 moulding and 2 moulding all illustrate the situation of injection compression molding.In Fig. 1, the state when being in moulding circulation beginning.In Fig. 2, carrying out mould by mold opening and closing device 18 closes, by the blocking device that is provided with on the fixed head 21 connecting rod 23 is combined with fixed head 21, thus, moveable die 14, be in the middle matched moulds state that only has the middle matched moulds state and the redundance of the compression stroke part of the difference of final matched moulds state to open in the injection process, this state is as the time started point of moulding circulation.The so-called injection process here is meant, fills the extremely operation till the resin that this cavity is filled is finished supply of beginning from molten resin in the mould cavity suitable with goods.
The width of the compression stroke in the middle of setting in the matched moulds state, cavity capacity in the middle of making in the matched moulds state is preferably 1.1～10.0 times scope with respect to the cavity capacity in the final matched moulds state, more preferably 1.2～9.0 times scope especially is preferably 1.5～8.0 times scope.The width of the compression stroke in the middle matched moulds state because such as mentioned above wide, therefore, can reduce the injection moulding rate, the distortion etc. that makes moulding product well, injection device 11 does not use the high injection device of the cost of high speed and high pressure injection-type harmless yet.And, cavity capacity in the middle of above-mentioned in the matched moulds state is during less than 1.1 times of the cavity capacity in the final matched moulds state, in the injection process, when resin is filled in cavity, because high pressure concentrates near the resin of cast gate, so easily cause and the distortion of moulding product and the deviation of thickness when greater than 10.0 times, easily produce moulding bad phenomenon such as jet flow.
Also have, the stop position of the moveable die 14 in the middle matched moulds state, when each layer thickness of moulding product during for the thickness more than the regulation, it is stopped at only leave the middle matched moulds state that compression stroke redundance is partly opened, but make the position till moveable die 14 advances to final matched moulds operation.At injection process, moveable die 14 is subjected to injection pressure and retreats, and the enlarged cavity volume can be guaranteed compression stroke thereafter, thereby carries out injection compression molding.
(injection process of 1 moulding and compression section)
In Fig. 3, in the cavity that Fig. 2 forms from the 1st injection device 11 injecting molten resins.This operation is an injection process, ensuing operation or as with the latter half of injection process in the subsequent handling of part parallel, carry out compression section.In addition, when the injection process latter half begins parallelly compressed operation, detect the progressive position of screw rod, after the progressive position of screw rod reaches desired location, begin compression with clamping.Compression section compresses the volume that makes cavity by each clamping 16 and dwindles and melted material is extended in cavity, and the melted material that injection process is penetrated in this mode is filled in cavity and carried out.Thus, moulding is the 1st layer 31.
(the injection moulding rate of molten resin in the injection process)
At above-mentioned injection process, injecting molten resin in the cavity that forms from the 1st injection device 11 toward Fig. 2, its injection moulding rate is preferably 50～2000cm
3/ second, more preferably 100～1800cm
3/ second, especially be preferably 150～1500cm
3/ second.When the injection moulding rate is lower than 50cm
3During/second, toward the interior time lengthening of filling molten resin of cavity, resin temperature reduces and melt viscosity is too high when injection process proceeds to compression section, therefore, at compression section, be easy to generate the bad of insufficient fill (short shot) and flow mark bad orders such as (flow mark) and thickness or dimensional accuracy.In addition, surpass 2000cm when the injection moulding rate
3During/second, resulting moulding product are easily residual warpage, and because being involved in of air easily causes crazing bad orders such as (Silver streak).The so-called injection moulding rate here is to point to the resin capacity of injection in the mould cavity divided by stopping required resulting value of time from injection beginning to injection, might not be fixing speed.
(parallel control between the mould in the compression section)
At above-mentioned compression section, adopt the clamping in four bights of mold fixed plate to adjust the depth of parallelism of fixed mould and moveable die to keep the depth of parallelism between mould.The preferred following maintenance moveable die 14 and the method for the depth of parallelism between the fixed mould 13; promptly; detect relative position value of detecting of movable platen 22 and fixed head 21 by position sensor 24; thus; average distance between calculation moveable die 14 and the fixed mould 13; then, the difference of the value of detecting of each clamping and average distance is added the integrated value of reducing to the command value that gives each clamping 16 and feedback difference as correction and control.The result shows, because melted material at a high speed and evenly flow in the cavity, can become low distortion as the effect of compression forming and as the effect of parallel control thickness of slab be reached evenly simultaneously and form the 1st layer 31 accurately.
In addition; at above-mentioned compression section; the method of the depth of parallelism between the also preferred following maintenance mould; promptly; not that the movable platen 22 that detects by position sensor 24 and relative position value of detecting of fixed head 21 keep the depth of parallelism between mould; but; in that moveable die 14 is done with respect to fixed mould 13 is parallel when mobile; detect the mold clamping force in each clamping 16; calculate the mean value that these detect mold clamping force, add the integrated value of reducing to the command value that gives each clamping 16 and feedback difference as correction and control with the difference of the target mold clamping force of predefined clamping and the above-mentioned mean value that detects mold clamping force.In addition, for the depth of parallelism between the ground of precision more control mould, the method for also preferred both and usefulness.When Position Control and mold clamping force control (pressure control) both and time spent, can begin from middle matched moulds position average distance between moveable die 14 and fixed mould 13 advance to regulation apart from the time, or the mean value of the mold clamping force that detects to the regulation pressure the time, carry out parallel control by above-mentioned Position Control, after the pressure of distance of stipulating or regulation detects, carry out above-mentioned pressure control.Also can be undertaken controlling simultaneously and with Position Control and pressure again after the parallel control by Position Control.When adopting the control of Position Control and pressure at the same time, Position Control only adopts FEEDBACK CONTROL, and pressure control adopts at least a kind of FEEDBACK CONTROL and FEEDFORWARD CONTROL to carry out.
When only carrying out Position Control, also can outside following control, carry out FEEDFORWARD CONTROL, thereby also attention speed carry out matched moulds in the depth of parallelism that keeps between moveable die 14 and the fixed mould 13 to each clamping 16.Promptly; detect relative position value of detecting of movable platen 22 and fixed head 21 by position sensor 24; thus; average distance between calculation moveable die 14 and the fixed mould 13, and add as correction with the difference of the value of detecting of each clamping and average distance and to reduce to the command value that gives each clamping 16 and feed back poor integrated value and control.
In addition; in above-mentioned compression section; adjust the depth of parallelism between fixed mould and the moveable die for the clamping in four bights by mold fixed plate and keep the depth of parallelism between mould; also can preferably adopt clamping with 1 bight as active matched moulds (master), remaining clamping is as the active matched moulds-driven clamping system of its driven (slave) matched moulds.Particularly,, compare 2 more preferably above-mentioned methods for the large-scale multi-layer molded articles that requires more high-precision parallel control with active matched moulds-driven clamping system.
In compression section of the present invention, particularly when the large-scale multi-layer molded articles of moulding, matched moulds state and the maintenance from middle matched moulds state to the depth of parallelism between the mould between the final matched moulds state are important in the middle of it.Under most occasions, in order to obtain large-scale multi-layer molded articles, inevitable big weight mould is installed on movable platen 22 and the fixed head 21 carried out moulding, and along with the increase of mold weight, it is difficult that the maintenance of the depth of parallelism in each clamping 16 of make-up machine also becomes.In addition, the inclined to one side load that pressure took place when filling by resin also becomes the irregular reason of moulding product thickness, should influence remarkable especially in large-scale multi-layer molded articles.In addition, the maintenance of the depth of parallelism between mould is reached the more uniform pressure load of the resin in the mould.Therefore, when resin-carried pressure reaches low pressure as a whole, can provide a kind of distortion moulding product still less.When the depth of parallelism between mould was insufficient, the pressure of load produced local difference on the multi-layer molded articles in the moulding, becomes one of reason that deforms, and also became the reason of multi-layer molded articles warpage simultaneously.In addition, consider from the production efficiency aspect that the deviation of the depth of parallelism causes the blocking of mould (か じ り) etc., goods are difficult to produce in batches.
(translational speed of moveable die in the compression section)
In above-mentioned compression section; compress by each clamping 16 and cavity volume to be dwindled and melted material is extended in cavity; the translational speed of the moveable die during cavity filling in this way; be preferably 5mm/ more than second; more preferably 7.5mm/ especially is preferably 10mm/ more than second more than second.The moulding product that L/D is healed high, the more enlargement ratio of mould capacity that need be high, and the translational speed that will seek quickness.In order to reduce the distortion of moulding product, when the heat distribution of molten resin was narrow in cavity, the compression section that termination reaches the final matched moulds state of regulation was important.This translational speed is fast more, can corresponding big more compression stroke.Therefore, preferred translational speed is high as much as possible, and at present, in fact 40mm/ has reached the limit of device about second.As reach the 35mm/ level of second, can reach the speed control of sufficient precision.In addition, this translational speed is with removing divided by the compression required time from the compression stroke of the extremely final matched moulds state of middle matched moulds state and obtaining, and might not be fixing speed.In addition, above-mentioned compression stroke is big more, and the translational speed of mould is bigger, is easy to generate blocking of mould more, and therefore, being held in of the depth of parallelism is important and essential condition between the mould here.
(the pressurize operation of 1 moulding)
In above-mentioned compression section, compress by each clamping 16 and cavity volume to be dwindled and melted material is extended in cavity, in this way, and cavity filling, thus, the screen resilience of resin sharply rises.At this moment, also the control by clamping 16 can be switched to above-mentioned pressure control from above-mentioned Position Control.And when switching to pressure control, preferably controlling and pressing (surface pressure) in the cavity is 7～20MPa's.Usually, detect the oil pressure of oil-hydraulic cylinder or its pipe arrangement, mold clamping force is obtained surface pressure divided by the projected area of moulding product, but also the resin pressure sensor can be set in cavity.
This screen resilience is being applied under the suitable pressure status that overcomes this power, in order to keep the cavity capacity of final matched moulds state, compression section continue operation or with the parallel operation that continues of a part of the latter half of compression section, carry out the pressurize operation.By this pressurize operation, with extremely an amount of resin in the multi-layer molded articles capacity of uniform density filling purpose, form the warpage of multi-layer molded articles or be out of shape few preferred moulding product with injection device 11.To resin applied pressure (pressurization), be to produce by the power that each clamping 16 advances moveable die.In addition, the transmission of this power is carried out with direct contact of resin by these members that advance usually, but also can be undertaken by the pressure transmitting medium of fluid etc. is got involved between these.
As the suitable retention time of above-mentioned pressure, depend on the thickness of moulding product, thickness is thicker, and reasonable time is longer, and when being large-scale moulding product, this tendency is remarkable especially.The large-scale moulding product that the present invention relates to, when being t (mm) as the wall thickness of moulding product, this retention time is X (second), it is suitable then satisfying in the scope of following formula (I).For example, when preferred each layer thickness is the thickness of the median 25mm of 1mm～50mm scope among the present invention, preferred 760 ± 30 seconds scope.But, when with the heating ﹠amp; Cooling molding method etc. there is no this restriction for the Fast Heating cooling die temperature of representative is system and time spent.
X=(30 * t+10) ± 30 seconds (I)
(refrigerating work procedure of 1 moulding)
After above-mentioned pressurize operation, also can carry out the refrigerating work procedure of 1 moulding.In this refrigerating work procedure, as the glass transition temperature of the resin material that uses in 2 moulding during as Tg, the surface temperature of the 1st layer 31 cavity side preferably be cooled to (Tg-20) (℃)～(Tg+50) (℃), more preferably (Tg-10) (℃)～(Tg+45) (℃).The so-called glass transition temperature here is the glass transition temperature of measuring according to the method for JISK7121 regulation that can be familiar with in figure such as DSC.In addition, when the resin material that uses in 2 moulding is made of the resin more than 2 kinds etc., when showing 2 above glass transition temperatures, be meant maximum temperature wherein, when being a kind of resin, when glass transition temperature is 1, be meant this temperature.
The surface temperature of the 1st layer 31 cavity side is in when carrying out 2 moulding under the above-mentioned condition, the resin material that uses in 2 moulding, heat insulation by the 1st formable layer product 31 with moveable die 14, thus, even among Fig. 4 the 2nd layer 32 when being thin-walled, thereby also can make the formation of cured layer of resin slow and make the resin flow resistance reduce the improvement shaping thin wall.In addition, the 1st layer 31 and the 2nd layers 32 interface temperature is accumulated and is reached fully high temperature owing to the heat of resin, and thus, the connecting airtight property at this interface is also modified.
But to surpass the 1st layer of 31 hear resistance temperature that has be unfavorable because the surface temperature of the 1st layer 31 cavity side is set in, and therefore, preferably sets in the low temperature more than 10 ℃ of the glass transition temperature than the 1st layer 31.More preferably be set in than the low temperature more than 20 ℃ of this glass transition temperature.In this refrigerating work procedure, but both former state kept the pressure of pressurize operation, also can be in non-pressurized state, also can reduce pressure stage by stage at refrigerating work procedure.Owing to also control by Position Control or pressure during refrigerating work procedure, when the thickness of moulding product is thickness about 20mm～50mm,, also can prevent the generation of pore even the occasion of pore (ヒ ケ) easily takes place by clamping 16.
(formation of the cavity that 2 moulding are used)
In Fig. 4, show the operation that forms the cavity that 2 moulding use, that is, stop to supply with and pressing oil to reduce pressure simultaneously to the chamber 27 that compresses of each clamping 16, supply with to open chamber 28 and press oil, movable platen 22 is broken away from from fixed head 21.Whereby, moveable die 14 breaks away from predetermined distance from fixed mould 13, and cavity enlarges its volume once again.At this moment, the moving of moveable die 14, parallel carrying out on the mould land area of moveable die 14 and fixed mould 13 can be implemented the compression section of 2 moulding well thus, thereby be preferred.Even in this parallel control, also preferably adopt the method for the depth of parallelism between the maintenance mould that uses in the compression section.
The cavity of using with 1 moulding similarly, even in the cavity that 2 moulding are used, moveable die 14 also is in the redundance that only leaves in the injection process as middle matched moulds state and the compression stroke part of the difference of final matched moulds state and is in the middle matched moulds state of opening.The width of the compression stroke of middle matched moulds state, the cavity capacity in the middle of being set in the matched moulds state is 1.1～10.0 times a scope of the cavity capacity in the final matched moulds state, more preferably 1.2～9.0 times scope especially is preferably 1.5～8.0 times scope.
In addition, in the present embodiment, between fixed mould 13 and the 1st layer 31, form the cavity that 2 moulding are used, but also can be at fixed mould 13 1 sides residual the 1st layer 31 and 2 moulding of formation are used between moveable die 14 is with the 1st layer 31 cavity.At this moment, the 2nd injection device 12 also can be arranged on the rear side of movable platen 22.At this moment, on the movable platen 22, also the hole that can insert the 2nd injection device 12 similarly is set with fixed head 21.In addition, thereby the formation method of the cavity of using as 2 moulding also can also make a part of parts (block) of mould be moved to form the cavity that 2 moulding are used when moveable die 14 moves.
(2 moulding)
In Fig. 5, the cavity injecting molten resin that to Fig. 4, forms from the 2nd injection device 12.This operation is the injection process of 2 moulding, by action equally among following and Fig. 3, carries out the 2nd layer 32 compression section and pressurize operation.In addition, even in this operation, also must adopt the method for the depth of parallelism between the maintenance mould that uses in the compression section of 1 moulding.
In the refrigerating work procedure in 2 moulding, be cooled to the desirable temperature that goes out to have 2 formable layer product 33 among Fig. 5 of the 1st layer 31 and the 2nd layers 32.Usually, below the temperature of its loading bending, promptly can take out, but when the time for large-scale moulding product, sometimes owing to deadweight produces crooked, so, preferably take out hanging down than loading flexure temperature under 30～60 ℃ the temperature from the production efficiency consideration.In addition, the so-called loading flexure temperature here is to adopt the method for JIS K7191-1/2 regulation to measure, and is not to measure the 1st layer or measure the 2nd layer separately separately, but represents the loading flexure temperature of the integral body of 2 formable layer product 33.In this refrigerating work procedure, but both former state kept the pressure of above-mentioned pressurize operation, also can be the state of not exerting pressure, and also can reduce pressure stage by stage further in refrigerating work procedure.
(the taking-up operations of 2 formable layer product)
In Fig. 6, stop to press oil to reduce pressure to chamber 27 supplies that compress of clamping 16, supply with to open chamber 28 and press oil, carry out the demoulding of moulding product, then, make movable platen 22 open to assigned position with apparatus for closing of mold 18.Next, movable platen 22 by the not shown device for ejecting that is provided with on the movable platen 22, makes 2 formable layer product 33 outstanding from moveable die 14, the operation of taking out 2 formable layer product 33 after assigned position stops.
After 2 formable layer product 33 take out the operation termination, movable platen 22 advances mobile with respect to fixed head 21, make moveable die 14 be in the middle matched moulds state of only opening as the middle matched moulds state and the redundance of the compression stroke part of the difference of final matched moulds state, form the preceding state of beginning of another 1 moulding, as shown in Figure 2.
(thickness of each layer)
In the manufacture method of multi-layer molded articles of the present invention, can make various moulding product, the thickness that preferably is suitable for making each layer that constitutes multi-layer molded articles is the multi-layer molded articles of 1～50mm.Each layer has the multi-layer molded articles of this thickness, has the advantage that can effectively adopt injection compression molding.In addition, each layer thickness that more preferably constitutes multi-layer molded articles is 2～45mm, and especially preferred is that each layer thickness that constitutes multi-layer molded articles is the multi-layer molded articles of 3～40mm.The thickness of the multi-layer molded articles integral body that obtains as the manufacture method by multi-layer molded articles of the present invention is preferably 2～150mm, and more preferably 2～135mm especially is preferably 2～120mm.
When each layer thickness during less than 1mm, in the large-scale moulding product as object of the present invention, the flow resistance of molten resin significantly uprises, therefore, in above-mentioned injection process and compression section, multi-layer molded articles is applied uneven pressure, to the inhibition of the distortion of warpage etc. or distortion difficulty very.When greater than 50mm, in refrigerating work procedure, the temperature that is cooled to take out multi-layer molded articles needs long-time, production efficiency significantly reduces, and, along with cooling, the control difficulty of the so-called pore that the thickness direction of moulding product shrinks, therefore, the thickness evenness of each layer of purpose multi-layer molded articles of the present invention can be impaired.
Each layer thickness of the what is called here is meant, cuts out the section of the multi-layer molded articles that obtains, the mean value of calculating with the thickness of each layer more than mensuration such as slide measure 10 places with handsaw etc.
(thickness evenness of multi-layer molded articles)
The multi-layer molded articles that obtains among the present invention, preferably constituting in each layer of multi-layer molded articles the thickness (Ta) of thin part is more than 0.7 divided by the wall unevenness evenness (Ta/Tb) of the thickness (Tb) of thick, more preferably has the thickness evenness more than 0.75.Multi-layer molded articles for large-scale components such as the buffer of for example automobile that obtains having this thickness evenness, fender, automotive deck roofs; the advantage that adopts injection compression molding method of the present invention is extremely effective; promptly; the clamping in four bights by mold fixed plate is adjusted the depth of parallelism between fixed mould and the moveable die; thus, the depth of parallelism between the maintenance mould.As the wall unevenness evenness of thickness evenness index, the thickness of wall unevenness evenness=1 o'clock each layer is even fully, more is similar to 1, and the quality of multi-layer molded articles is better.In addition, when wall unevenness evenness less than 0.7 the time, strengthen from distortion such as the warpage of thickness deviation and the influence distorted, the dimensional accuracy of multi-layer molded articles is significantly impaired.
The thickness of thin part and the thickness of thick in each layer of what is called here, be meant, cut out the section of the multi-layer molded articles that obtains with handsaw etc., measure each layer thickness more than 10 places as female sample, therefrom the thickness of the thinnest part and thick in each of Chou Chuing layer with slide measure etc.
(amount of warpage of multi-layer molded articles)
The multi-layer molded articles that obtains among the present invention, have be preferably the amount of warpage of multi-layer molded articles after placing 24 hours under 23 ℃, the condition of relative humidity 50% below the 150 μ m/mm, the dimensional stability below the 125 μ m/mm more preferably.Multi-layer molded articles for large-scale components such as the buffer of for example automobile that obtains having this dimensional stability, automobile fender, automotive deck roofs; the advantage that adopts injection compression molding method of the present invention is extremely effective; that is, the clamping in four bights by mold fixed plate is adjusted the depth of parallelism between fixed mould and the moveable die and is kept the depth of parallelism between the mould.When this amount of warpage during greater than 150 μ m/mm, the dimensional accuracy of multi-layer molded articles is impaired greatly, and when this amount of warpage during greater than 200 μ m/mm, the interface of each interlayer is applied result from the load of this warpage, makes the connecting airtight property reduction of each interlayer.
Here the amount of warpage said multi-layer molded articles is placed 24 hours under 23 ℃, the condition of relative humidity 50% after, be meant the amount of warpage of the moulding product of obtaining by following manner, that is, multi-layer molded articles was placed 24 hours under above-mentioned constant temperature and humidity, then, use tabular anchor clamps, the flow end side end edge of multi-layer molded articles, connect airtight with the not damaged degree of moulding product and to be fixed on the platform, measure the height of cast gate side end edge with slide measure, thus, obtain the amount of warpage of moulding product.Using tabular anchor clamps that the flow end side end edge of multi-layer molded articles is connected airtight width on platform, is for to connect airtight 20% width from flow end side end edge to cast gate side end edge direction with respect to the length from the flow end side end edge to the cast gate side end edge.
(resin material)
Operable resin material in the forming method of the present invention preferably uses thermoplastic resin.As thermoplastic resin, for example, can enumerate polyvinyl resin, acrylic resin, polystyrene resin, polyacrylic acid styrene resin, ABS resin, AS resin, AES resin, ASA resin, SMA resin, polyalkyl methacrylate resin etc. and be the common plastics of representative; Polyphenylene oxide resin, acetal resin, polycarbonate resin, poly terephthalic acid alkylidene diester resin, polyamide, cyclic polyolefin resin, polyarylate resin (amorphism polyarylate, liquid crystal liquid crystal property polyarylate) etc. are the engineering plastics of representative; Polyether-ether-ketone, PEI, polyamidoimide etc. are the various TPIs of representative; So-called super engineering plastics such as polysulfones, polyether sulfone, polyphenylene sulfides etc.In addition, can also adopt styrene analog thermoplastic elastomer, olefin hydrocarbons thermoplasticity elastic body, polyamide-based thermoplastic elastomer (TPE), polyesters thermoplastic elastomer (TPE), polyurethanes thermoplastic elastomer (TPE) etc. to be the thermoplastic elastomer (TPE) of representative; Foaming Merlon, polyurathamc, expanded polystyrene (EPS), expanded polypropylene etc. are the foaminess thermoplastic resin of representative.These thermoplastic resins all can be used to constitute each layer and the other parts of multi-layer molded articles such as the 1st layer, the 2nd layer to be used.
Here said other parts, be meant, for example, after forming the 1st layer the tabular moulding product of synthetic resin moulding polycarbonate resin, adopt the multicolour forming method, thermoplastic elastomer (TPE) such as molding of polyester class elastomer again thereafter, utilizes forming method of the present invention around it, on polycarbonate resin, form the situation of plexiglass layer, in this case, be equivalent to thermoplastic elastic body portion with this layer structure-irrelevant.
In addition, as resin material of the present invention, can suitably select above-mentioned thermoplastic resin mixing use according to the application target of multi-layer molded articles.In addition, in resin material of the present invention, can cooperate additive commonly used, for example heat stabilizer, releasing agent, infrared absorbent, ultra-violet absorber, antioxidant, light stabilizer, blowing agent, reinforcing agent (talcum, mica, clay, wollastonite, calcium carbonate, glass fibre, bead, the glass balloon, the felting fiber, sheet glass, carbon fiber, the carbon element sheet, the carbon black pearl, carbon black felting fiber, sheet metal, metallic fiber, the glass fibre of metal coating, the carbon fiber of metal coating, the sheet glass of metal coating, silica, ceramic particle, ceramic fibre, the aromatic polyamides particle, aramid fibre, the polyarylate fiber, graphite, conductive carbon black, various palpus crystalline substances etc.), fire retardant (halogen class, phosphoric acid ester, metallic salt, red phosphorus, the silicon class, the fluorine class, metal hydrate class etc.), colouring agent (carbon black, the pigment of titanium oxide etc., dyestuff), light diffusing agent (acrylic acid crosslinked particle, the silicon crosslinked particle, sheet glass as thin as a wafer, calcium carbonate particle etc.), fluorescent whitening agent, light-storing paint, fluorescent dye, antistatic additive, flow ability modifying agent, the nucleus agent, inorganic and organic antibacterial agent, photochemical catalyst class anti-fouling agent (particulate titanium dioxide, particulate oxide zinc etc.), graft rubber is the modified impact agent of representative, photochromic agent.
Wherein, in the present invention, preferred particularly outward appearance and mechanical strength or excellent heat resistance or marresistance and the also good thermoplastic resin of solvent resistance be used for the 1st layer.As this thermoplastic resin, for example, can enumerate the mixture of polycarbonate resin self or polycarbonate resin and mylar etc., consider from good this point of solvent resistance, more preferably the mixture of polycarbonate resin and mylar.To the method for making and the characteristic of this thermoplastic resin, for example, in TOHKEMY 2007-23118 communique and TOHKEMY 2002-265769 communique etc., be documented.
In addition, among the present invention, the preferred particularly good thermoplastic resin of impact absorbency is used for the 2nd layer.As this thermoplastic resin, can enumerate foaminess thermoplastic resins such as foaming Merlon, polyurathamc, expanded polystyrene (EPS), expanded polypropylene, or the thermoplastic elastomer (TPE) of styrene analog thermoplastic elastomer, olefin hydrocarbons thermoplasticity elastic body, polyamide-based thermoplastic elastomer (TPE), polyesters thermoplastic elastomer (TPE), polyurethanes thermoplastic elastomer (TPE) etc., but from above-mentioned the 1st layer the thermoplastic resin that uses have this point of good connecting airtight property to consider, preferred expanded polystyrene (EPS) and polyesters thermoplastic elastomer (TPE), more preferably polyesters thermoplastic elastomer (TPE).To the method for making and the characteristic of this polyesters thermoplastic elastomer (TPE), for example, in the flat 10-330605 communique of TOHKEMY, be documented.
(multi-layer molded articles)
Here, the multi-layer molded articles by die device 15 moulding is described.Multi-layer molded articles in the manufacture method of the present invention, preferably the length of flow from cast gate to flow end is 15～300cm, and its maximal projection area is 200～60000cm
2The invention provides the multi-layer molded articles that warpage in a kind of large-scale moulding product is little and have good connecting airtight property.Consider that from bringing into play effect of the present invention better multi-layer molded articles be that the length of flow from cast gate to flow end is 30～250cm, and its maximal projection area is 1000～40000cm
2Multi-layer molded articles.
(2 processing of multi-layer molded articles)
Multi-layer molded articles of the present invention, also can be after moulding through thermal flexure or remove the marginal portion is shaped to regulation for 2 manufacturing procedures of representative shape.
The method of carrying out thermal flexure is not particularly limited; as this method; for example; can adopt and implement mould, wooden model or the resin mold etc. that cutter is processed into desirable shape in advance; by (general under near the temperature the glass transition temperature of this synthetic resin substrate), pressurization or decompression (under the vacuum) under heating environment, adopt above-mentioned mould etc. this multi-layer molded articles to be carried out the method for figuration.
In addition, the method for removing edge part is not particularly limited,, can adopts any of machining method, the process of chopping and punching method as this method.As the machining method, can enumerate and adopt various cutting elements such as hollowing out empty plane, slotting cutter, milling cutter and rotation planing tool, adopt NC capstan, facing cutter and NC machine tools with automatic tool changer (machining center) etc. to carry out the method for machining.When adopting the process of chopping, can adopt cut-out by cutlery, the cut-out by abrasive material, shear and cut off, cut off and discharge is cut off etc. by heating and melting.Wherein, adopt machine usually, consider preferred machining method from cutting precision and good this point of speed.In addition, cutting also can adopt any method of complete DRY CUTTING, wet type cutting and half dry type cutting to carry out.
(finishing of multi-layer molded articles)
Multi-layer molded articles of the present invention, its surface can be provided with the various functional layers that comprise dyed layer or hard conating etc.As this functional layer, can enumerate patterned layer, conductive layer (heating layer, electromagnetic wave absorbing layer, antistatic layer), hydrophobic oleophobic layer, hydrophilic layer, UV-absorbing layer, infrared ray absorbing layer, breaking prevents layer and metal level (coat of metal (metallizing)) etc.These functional layers can be at hard coating surface, and the moulding product of hard conating opposite side surface, constitute between the top layer of a part between interlayer, prime coat and the moulding product surface of each layer of multi-layer molded articles and prime coat and hard conating setting on the part etc.
Above-mentioned patterned layer forms by printing usually.As printing process, can make photogravure, offset printing, aniline printing, do the known printing processes of prior art such as hectographic printing (dry offset), liner printing, serigraphy according to article shape and printing purposes.
Formation as the printing-ink that uses in the printing, can use as the printing ink of principal component as resinae and oils etc., as resinae, can use rosin, albertite, shellac, copal natural resin or phenols and derivatives thereof such as (Copalresin), amino resin, butylation urea, melmac, the polyesters alkyd resins, styrene resin, acrylic resin, phenolic resins, epoxy resin, polyamide, polycarbonate resin, saturated polyester resin, the amorphism polyarylate resin, the amorphous polyolefins resin, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer, butyral resin, methylcellulose resin, ethyl cellulose resin, synthetic resin such as polyurethane resin.When the high ink composition of essential hear resistance, preferably enumerate with the printing-ink as adhesive such as polycarbonate resin and amorphism polyarylate resin.In addition, can adopt pigment or dyestuff etc. that printing-ink is adjusted to desirable color.
Embodiment
With embodiment, comparative example, further specify the present invention and effect thereof below, but the present invention is not subjected to any qualification of these embodiment etc.
(1) thickness: the oral-lateral that waters that cuts out the multi-layer molded articles (long 1800mm) with shape shown in Figure 7 with handsaw closely is close to flow end side section (37) nearby, from water oral-lateral closely be close to the flow end side nearby be at interval with 120mm, measure the thickness of each layer at 16 places with slide measure, calculate its mean value.
(2) wall unevenness evenness: for the average thickness value of each layer of obtaining multi-layer molded articles, with the thickness of each layer at above-mentioned 16 places that measure as female sample, extract in each layer the thickness (Ta) of thin part and the thickness (Tb) of thick out, with the thickness (Ta) of the thinnest part thickness (Tb), obtain the wall unevenness evenness (Ta/Tb) of each layer divided by thick.Wall unevenness evenness=1 o'clock, it is even that each layer thickness reaches.
(3) amount of warpage of multi-layer molded articles: multi-layer molded articles with shape shown in Figure 7, under 23 ℃, the condition of relative humidity 50%, left standstill 24 hours, then, use tabular anchor clamps, connect airtight the flow end side end edge (40) of multi-layer molded articles, be fixed on the platform, by measure the height of cast gate side end edge (41) with slide measure, obtain the amount of warpage of moulding product.In addition, using tabular anchor clamps to make the flow end side end edge of multi-layer molded articles connect airtight width on platform, is for to connect airtight 20% width from flow end side end edge to cast gate side end edge direction with respect to the length from the flow end side end edge to the cast gate side end edge.
(4) the connecting airtight property of interlayer of multi-layer molded articles: the test piece (42) that cuts out long 150mm * wide 150mm from multi-layer molded articles with shape shown in Figure 7, the TSA-101L that adopts ェ ス ペ ッ Network (strain) to make carries out the thermal shock evaluation according to MIL-STD-202G-A.Every circulation is taken out test piece 10 times, with the naked eye estimates to have or not splitting.
Zero: the 100 times circulations, splitting is found at the end
△: find splitting from being circulated to for the 50th time between the 90th circulation
*: to the 40th circulation discovery splitting
Embodiment 1
According to following operation moulding 2 formable layer product.
As the PC/PET class alloy resin particle of the 1st layer of resin material that uses in 1 moulding, in 110 ℃ of dryings 5 hours.In addition, as the TPE resin particle of the 2nd layer of resin material that uses in 2 moulding, in 80 ℃ of dryings 5 hours.These 2 kinds of resin materials, employing has the large-scale make-up machine (MDIP2100 of the injectable compression forming of 4 parallel controlling organizations, maximum clamping force 33540kN, (strain) name mechanism is done manufacturing), carry out injection compression molding, produce the large-sized multiple layer moulding product of thickness 9.8mm shown in Figure 7 (the 1st layer of 7.0mm, the 2nd layer of 2.8mm), long 1800mm (when containing gate portions (35), being 1940mm), wide 1200mm.This make-up machine, having can be the dry respectively loading hopper drier unit of 2 kinds of resin materials, and this dried particle is supplied to the make-up machine supply port and carries out moulding by compressed air delivery.The valve gate type hot flow path (diameter 8mm φ) that runner adopts HOTSYS society to make.
The condition of molding of 1 moulding is: 290 ℃ of the center housing temperatures of the 1st injection device; 290 ℃ of the design temperatures of hot flow path; Mold temperature is that 80 ℃, fixation side are 70 ℃ in movable side; The injection moulding rate is 660cm
3/ second; Compression stroke is 21.0mm; Mould translational speed from middle matched moulds state to final matched moulds state is 10mm/ second; And the dwell time is 220 seconds.Begin mould compression, overlapping (over lap) 0.5 second when finishing approaching to fill.Valve-off cast gate immediately after filling is finished forms molten resin is not backflowed to the condition of cylinder body from cast gate.The pressure of compression section is 17.2MPa, and the pressure of pressurize operation remains on half pressure of this pressure.The parting surface of moveable die forms not the parting surface state of contact with fixed mould on final progressive position.Under this condition of molding, the cavity capacity of middle matched moulds state is 4.0 times of cavity capacity of final matched moulds state.Under this condition of molding, in the pressurize operation, the surface temperature of the 1st layer cavity side can be reduced to 90 ℃ of purpose temperature, thereby, do not establish refrigerating work procedure.In addition, the surface temperature of the 1st layer cavity side is interrupted moulding after the pressurize operation of 1 moulding stops, measure with land surface pyrometer.In addition, in this moulding, adopt this 4 parallel controlling organizations, the tan θ that represents tilt quantity and twist angle is maintained at about below 0.000025.
The condition of molding of 2 moulding is: the center housing temperature of the 2nd injection device is 240 ℃; The hot flow path design temperature is 240 ℃; The injection moulding rate is 300cm
3/ second; Compression stroke is 3.5mm; Mould translational speed from middle matched moulds state to final matched moulds state is 5mm/ second; And the retention time is 130 seconds.Begin mould compression, overlapping 0.5 second when finishing approaching to fill.Valve-off cast gate immediately after filling is finished forms molten resin and does not backflow to the condition of cylinder body from cast gate.Cavity internal pressure (surface pressure) during compression is 10.0MPa, keeps this pressure in the dwell time.The parting surface of moveable die forms not the parting surface state of contact with fixed mould on final progressive position.Under this condition of molding, the cavity capacity of middle matched moulds state is 2.2 times of cavity capacity of final matched moulds state.
The 2 formable layer product that taking-up obtains leave standstill under 23 ℃, the condition of relative humidity 50% and fully cooled off in 24 hours, then, estimate according to above-mentioned assessment item, and evaluation result is shown in table 1.
" relative position " in four parallel controls in the table 1; be expression " in compression section; the depth of parallelism between this mould keeps by following manner; promptly; it is parallel when mobile that the clamping in four bights of adopting mold fixed plate makes moveable die do with respect to fixed mould;, add reduce to the command value that gives each clamping and also feed back poor integrated value and control the difference of the value of detecting of each clamping and average distance " as correction from the movable platen that detects value of detecting; calculate the average distance between moveable die and the fixed mould with the relative position of fixed head.
Embodiment 2
Except will use, adopt the mold clamping force mode and the condition shown in the condition of molding employing table 1 of the depth of parallelism between this mould of maintenance after 5 hours in drying under 120 ℃ as the foaming PC resin particle of the 2nd layer of resin material that uses in 2 moulding, all similarly to Example 1, carry out the moulding of 2 formable layer product.The evaluation result of resulting 2 formable layer product is shown in table 1.Wherein, in compression section; this mold clamping force mode is as follows; promptly; it is parallel when mobile that clamping in four bights of adopting mold fixed plate makes moveable die do with respect to fixed mould; detect the mold clamping force in the clamping at above-mentioned 4 places; calculate the mean value of these mold clamping forces that detect, the difference of the mean value of the target mold clamping force of predefined clamping and the above-mentioned mold clamping force that detects is added the integrated value of reducing to the command value that gives each clamping and feedback difference as correction and control.
Except the PC/PET class alloy resin of the 2nd layer of resin material that will use after dry 5 hours down in 120 ℃ as the PC resin particle of the 1st layer of resin material that uses in 1 moulding, use in will be as 2 moulding in 110 ℃ use after dry 5 hours down and condition of molding employing table 1 shown in condition, all similarly to Example 1, carry out the moulding of 2 formable layer product.The evaluation result of resulting 2 formable layer product is shown in table 1.
Embodiment 4
Except moveable die being retreated once again and adopting PC/PET class alloy resin to form the condition shown in the 3rd layer and the condition of molding employing table 1 according to the 1st layer condition of molding, all similarly to Example 1, carry out the moulding of 3 formable layer product.The evaluation result of resulting 3 formable layer product is shown in table 1.Under this condition of molding, the surface temperature that the pressurize operation of 2 moulding stops the 2nd layer of cavity side of back mensuration is 110 ℃.
Embodiment 5
The method of the depth of parallelism except between following maintenance mould and condition of molding adopt the condition shown in the table 1, all similarly to Example 1, carry out the moulding of 2 formable layer product.The evaluation result of resulting 2 formable layer product is shown in table 1.In the compression section; adjust the depth of parallelism between the depth of parallelism maintenance mould of fixed mould and moveable die for the clamping in four bights by adopting mold fixed plate; employing makes the clamping in 1 bight as all the other active matched moulds as its driven matched moulds of active matched moulds-driven clamping system, as the method that keeps the depth of parallelism between mould.
Adopt active matched moulds-driven clamping system to carry out compression section, the amount of warpage of multi-layer molded articles is 162 μ m/mm, and is bigger than the amount of warpage of the multi-layer molded articles that obtains among the embodiment 1～4.In addition, the connecting airtight property of the multi-layer molded articles that obtains among the connecting airtight property of interlayer of multi-layer molded articles and the embodiment 1～4 is compared, and becomes bad some.In practicality, this amount of warpage and connecting airtight property are in admissible scope.
Comparative example 1
Except compression section does not adopt the method and the condition shown in the condition of molding employing table 1 of the depth of parallelism of control mould, all with the moulding of carrying out 2 formable layer product equally of embodiment 1.The evaluation result of resulting 2 formable layer product is shown in table 1.
Since do not carry out the control of the depth of parallelism between mould at compression section, the influence of the inclined to one side load that the pressure the when resin of middle matched moulds state is filled takes place, and the thickness of multi-layer molded articles becomes inhomogeneous.In addition, the pressure that the multi-layer molded articles in the moulding is applied load produces local difference, consequently, the amount of warpage of multi-layer molded articles is strengthened.
Comparative example 2
Except that injection compression molding changes the condition shown in injection mo(u)lding, the condition of molding employing table 1 into, all similarly to Example 1, carry out the moulding of 2 formable layer product.The evaluation result of resulting 2 formable layer product is shown in table 1.
" insufficient fill " in the evaluation result of table 1 is to represent that complete filling is not to the flow end side end edge of mould owing to molten resin, and the part of multi-layer molded articles shortcoming forms incomplete state.
In addition, each composition of the symbolic representation in the above-mentioned table is as follows.
PC: polycarbonate resin particle (パ Application ラ ィ ト L-1225ZL100 (trade name), Supreme Being people change into (strain) and make)
PC/PET: the PC/PET class alloy resin particle that constitutes as wollastonite 10 weight portions of inorganic filler, polycarbonate resin 60 weight portions and pet resin 30 weight portions
TPE: polyesters thermoplastic elastomer resin particle (ヌ-ペ ラ Application Q4130AN (trade name), Supreme Being people change into (strain) and make)
Foaming PC: with respect to polycarbonate resin particle (パ Application ラ ィ ト L-1225ZL100 (trade name), Supreme Being people changes into (strain) and makes) 100 weight portions add mineral-type blowing agent (セ Le マ Le Network MB9082 (trade name), three associations change into (strain) and make) 2.5 weight portions and are mixed the foaming polycarbonate resin particle that obtains.
The industry practicality
According to the present invention, a kind of multi-layer molded articles that passes through the injection moulding moulding with thin-walled layer can be provided, Can provide further that a kind of not have the bad phenomenon such as warpage and distortion and connecting airtight property of interlayer also good many The formable layer product. This forming method particularly is suitable for instrument panel and door-plate, back door, center-control platform etc. Automobile field parts; Wash face cosmetic platform and bathroom sales counter (bath counter), bath, the bathroom is deposited The dwelling house apparatus field such as plate parts; The daily necessities fields such as bucket and clothing kitchen; TV and computer are with housing etc. Household electrical appliances, OA instrument field etc. need to have in the field of massive article of sandwich construction and use, therefore, Its industrial effect is very big.
Claims (13)
1. the manufacture method of a multi-layer molded articles is made the multi-layer molded articles that is made of two-layer tree fat material at least, it is characterized in that this manufacture method comprises:
Use fixed mould and moveable die, and pass through the operation of the 1st layer of 1 moulding injection mo(u)lding; Moveable die is moved, thereby form the operation of 2 forming hollow cavings; And by 2 moulding, on above-mentioned the 1st layer with the 2nd layer of the form injection mo(u)lding of lamination, thereby moulding by the 1st layer with the 2nd layer of molten operation of gluing the multi-layer molded articles that forms,
And; in the above-mentioned injection mo(u)lding operation; at least one operation is an injection compression molding; described injection compression molding is to adjust the depth of parallelism between fixed mould and the moveable die by the clamping in four bights of mold fixed plate, thereby keeps the injection compression molding of the depth of parallelism between the mould.
2. according to the manufacture method of the described multi-layer molded articles of claim 1; wherein; it is parallel when mobile that clamping in four bights of adopting mold fixed plate makes moveable die do with respect to fixed mould; the value of detecting from the relative position of the movable platen that detects and fixed head; calculate the average distance between moveable die and the fixed mould; the difference of the value of detecting of each clamping and average distance is added the integrated value of reducing to the command value that gives each clamping and feedback difference as correction and control, thereby keep the depth of parallelism between the mould to carry out injection compression molding.
3. according to the manufacture method of the described multi-layer molded articles of claim 1, wherein,
It is parallel when mobile that clamping in four bights of adopting mold fixed plate makes moveable die do with respect to fixed mould; detect the mold clamping force in the clamping in above-mentioned four bights; calculate the mean value of these mold clamping forces that detect; the difference of the mean value of the target mold clamping force of predefined clamping and the above-mentioned mold clamping force that detects is added the integrated value of reducing to the command value that gives each clamping and feedback difference as correction and control, thereby keep the depth of parallelism between the mould to carry out injection compression molding.
4. according to the manufacture method of any one described multi-layer molded articles in the claim 1～3, wherein, when the glass transition temperature of the resin material that uses in 2 moulding was made as Tg, the surface temperature of the 1st layer cavity side was (Tg-20) ℃～(Tg+50) ℃.
5. according to the manufacture method of any one described multi-layer molded articles in the claim 1～4, wherein, carry out injection compression molding in the following manner, that is,
The cavity capacity of middle matched moulds state is 1.1～10.0 times of cavity capacity of final matched moulds state, and moveable die is that 5mm/ is more than second from the translational speed of middle matched moulds state when final matched moulds state moves.
6. according to the manufacture method of any one described multi-layer molded articles in the claim 1～5, wherein, the thickness that constitutes each layer of multi-layer molded articles is 1mm～50mm.
7. according to the manufacture method of any one described multi-layer molded articles in the claim 1～6, wherein, the thickness T a that constitutes the thinnest part in each layer of multi-layer molded articles is more than 0.7 divided by the wall unevenness evenness Ta/Tb of the thickness T b of thick.
8. according to the manufacture method of any one described multi-layer molded articles in the claim 1～7, wherein, the amount of warpage multi-layer molded articles leaves standstill 24 hours under 23 ℃, the condition of relative humidity 50% after is below the 150 μ m/mm.
9. according to the manufacture method of any one described multi-layer molded articles in the claim 1～8, wherein, resin material is a thermoplastic resin.
10. multi-layer molded articles, it obtains according to any one described manufacture method in the claim 1～9.
11. according to the described multi-layer molded articles of claim 10, wherein, the length of flow from cast gate to flow end is 15～300cm, and its maximal projection area is 200～60000cm
2
12. a multi-layer molded articles, it is by implementing thermal flexure processing or remove edge part processing to obtain to claim 10 or 11 described multi-layer molded articles.
13. a multi-layer molded articles, it obtains by any one described multi-layer molded articles in the claim 10～12 is carried out finishing.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
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| JP2008040124 | 2008-02-21 | ||
| JP2008200573 | 2008-08-04 | ||
| JP2008200573A JP5162364B2 (en) | 2008-02-21 | 2008-08-04 | Multilayer molded article manufacturing method and multilayer molded article |
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| CN101642949A true CN101642949A (en) | 2010-02-10 |
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| CN200910008310A Pending CN101642949A (en) | 2008-02-21 | 2009-02-20 | Method for producing multilayer molded article and multilayer molded article |
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| CN (1) | CN101642949A (en) |
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| JP2001225348A (en) * | 2000-02-15 | 2001-08-21 | Teijin Chem Ltd | Molding method and molded article |
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| CN105383022A (en) * | 2014-08-28 | 2016-03-09 | 恩格尔奥地利有限公司 | Forming part manufacturing method and forming machine |
| CN105383022B (en) * | 2014-08-28 | 2017-12-01 | 恩格尔奥地利有限公司 | Molding part manufacture method and forming machine |
| CN106217757A (en) * | 2016-09-07 | 2016-12-14 | 微鲸科技有限公司 | The manufacture method of multi-layer injection molding structural member |
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| CN108422633B (en) * | 2017-02-15 | 2021-05-28 | 恩格尔奥地利有限公司 | Rodless clamping unit for a molding machine |
| CN109386816A (en) * | 2017-08-09 | 2019-02-26 | 株式会社小糸制作所 | Light guide and lamps apparatus for vehicle |
| CN108454006A (en) * | 2018-03-27 | 2018-08-28 | 上海小糸车灯有限公司 | The method for solving multi-layer injection molding part iridescence |
| CN109571828A (en) * | 2018-11-21 | 2019-04-05 | 青岛科技大学 | A kind of fluid pressure type rubber air spring capsule-free vulcanization machine and vulcanization process |
| CN112677402A (en) * | 2019-10-17 | 2021-04-20 | 株式会社瑞延理化 | Method for manufacturing radar wave-transparent cover plate |
Also Published As
| Publication number | Publication date |
|---|---|
| JP5162364B2 (en) | 2013-03-13 |
| JP2009220554A (en) | 2009-10-01 |
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