CN104302457B - 用于制造具有注射包覆模制插件的观察屏的方法 - Google Patents
用于制造具有注射包覆模制插件的观察屏的方法 Download PDFInfo
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Abstract
本发明涉及用于制造具有注射包覆模制插件(9)的观察屏(3)的方法。所述方法包括以下步骤:将要被包覆模制的插件(9)布置在注射模具(1)中;通过至少一个吸入口(21)保持插件(9);将热塑性材料注射到模具(1)中,用于形成用于观察屏的机械基体层;并将由此形成的观察屏(3)从模具去除。
Description
技术领域
本发明涉及一种用于制造具有注射包覆模制插件的观察屏的方法,特别是用于偏振观察屏,还涉及通过所述方法获得的观察屏和用于执行该方法的模具。
背景技术
更具体地,具有注射包覆模制插件的观察屏,特别是利用本发明方法获得的偏振屏可用在安装架或框架上,以形成面罩,其例如用于参加诸如滑雪的一些运动、用于夜间驾驶、用于摩托车头盔或用于保护护目镜。
并入偏振滤波器的偏振面罩非常普遍,且例如用于在诸如海或雪地区域的地点处进行的所有活动,那些区域具有强光反射区。这是因为,这些强反射可损害视力,且在一些情况下导致炫目。面罩还高度有益于驾驶车辆,因为它们使得可以限制或甚至消除在风挡上察觉到的寄生反射。
在这些面罩中使用偏振滤波器,其大体制造为聚乙烯醇(或PVA)聚合物膜的形式。这样的偏振膜传统上通过将双向色性碘晶体和/或双向色素(dichroic pigment)的分子并入在基于聚乙烯醇聚合物的膜中,然后通过单轴向地拉伸膜以便使双向色性碘晶体和/或双向色素的分子沿拉伸方向取向而获得。双向色素是指,可具有分子或晶体特性且针对特定空间取向可选择地吸收可视电磁辐射的物质。由此获得的偏振膜是廉价的,且具有与许多应用(特别是眼科应用)相匹配的光学质量。
PVA膜随后被覆盖有一或多层保护材料,以便形成插件,其将通过注射例如热塑性材料(诸如聚碳酸酯(PC)或聚酰胺(PA)(诸如尼龙))而在模具中被包覆模制。
由此,由CTA-PVA-CTA(CTA表示三醋酸纤维素)、PC-PVA-PC、CTA-PVA-PC、CTA-PVA-PA构成的插件是已知的,插件的第一层是当面罩被穿戴时意图距眼睛最远的层,第三层是最靠近用户眼睛的层。
目前,对于制造来说,插件布置在模具中,且经由周边被机械地在四端保持在位。
文献EP 0940244披露了一种制造透镜的方法,其中,多个吸入口用于保持插件,这些口围绕最终成品分布。
但是,已经发现难以建立保持系统,且在注射包覆模制期间,保持系统可导致插件内的张力,该张力对观察屏的光学质量有影响。
发明内容
本发明的一个目的是提供一种用于制造具有注射包覆模制插件的观察屏的方法,其至少部分地减轻上述缺点。
为此,提供一种用于制造具有注射包覆模制插件的观察屏的方法,包括以下步骤:
-将要被包覆模制的插件布置在注射模具中,
-利用并入到注射模具中的至少一个吸入口保持插件,
-将热塑性材料注射到模具中,以形成支撑观察屏的机械支撑层,
-使由此形成的观察屏脱模,
其特征在于,模具仅具有一个吸入口,其位于区域中,该区域就相关观察屏而言对应于容纳用户鼻子的挖切部分。
根据一个方面,吸入口包括低孔隙率金属插件,该插件防止注射的热塑性材料被吸入,且该插件并入在注射模具的凹部分中。
吸入口可具有7.5mm至10mm之间的横向直径,优选地为9mm。
吸入口的金属插件可具有低于200μm的孔。
典型地,吸力在0.02至0.085MPa之间。
根据另外的方面,插件的尺寸小于成品观察屏的尺寸。
用于注射热塑性材料的注射口关于插件定位在边缘上,靠近吸入口且关于后者定心。
包覆模制热塑性材料可以是聚碳酸酯或聚酰胺。
插件可由三层形成,中间层由聚乙烯醇(PVA)聚合物制成,两个外层的一个或两个由三醋酸纤维素、聚碳酸酯或聚酰胺制成。
本发明的另一主题是利用前述方法获得的观察屏,其相继地包括具有热塑性材料且形成观察屏后部面的机械支撑层、由聚乙烯醇聚合物制成的中间层、和由热塑性材料制成的且形成观察屏前部面的外层。
本发明的另一主题是用于模制具有包覆模制插件的观察屏的注射模具,包括凸部分和凹部分,其特征在于,凹部分在就相关观察屏而言对应于容纳用户鼻子的挖切部分的部分中具有用于将插件保持在位的吸入口。
热塑性材料注射口例如关于插件定位在边缘上,靠近吸入口且关于后者定心。
附图说明
根据以下附图,本发明的其他特征和优势将从本发明的一个特定非限制性实施例的以下描述显现。
图1是模具的示意性横截面,
图2是根据本发明的观察屏的前视图,
图3是根据图2的观察屏的沿图2的线A-A的横截面,和
图4是根据图2的观察屏的透视图。
具体实施方式
在所有附图中,相同的元件具有相同的附图标记。
图1是用于具有包覆模制插件的观察屏3(见图4)的注射模制的模具1的横截面。该模具1包括凹部分5和凸部分7。
如图1可见,插件9(粗线)布置在模具1中。该插件9是弯曲的,且其尺寸小于凹形部11的尺寸,使得模具的顶部边缘13和底部边缘15(当在图中观察的)没有与插件9接触。插件9因此具有的尺寸小于成品屏的尺寸(见图2),这是有利的,因为其通过与现有技术方法相比节省了插件的很大的表面面积。
凹部分5在其下部分(在图中观察时)中具有吸入口21,该吸入口并入到模具1中并连接到真空泵23,所述下部分就相关观察屏而言,对应于容纳用户的鼻子的挖切部分17(见图2)。当真空泵操作时,插件9通过吸力机械地保持抵靠凹部分5。
在所示实施例中,仅提供了一个吸入口,其位于区域17中,该区域17就相关观察屏而言对应于容纳用户鼻子的挖切部分。
吸入口例如包括低孔隙率金属插件,该插件防止注射的热塑性材料被吸入,且该插件并入在注射模具1的凹部分5中。
作为例子,金属插件具有在7.5mm至10mm之间的横向直径,优选地为9mm。
金属插件的孔低于200μm,例如30至100微米。
插件9可被弯曲,例如通过热成型,预先在插入模具之前,或一旦在其处于模具中时且在热塑性材料被注射之前可通过热成型被弯曲。
插件可由三层形成,中间层由聚乙烯醇(PVA)聚合物制成,两个外层的一个或两个由三醋酸纤维素(CTA)、聚碳酸酯(PC)或聚酰胺(PA)制成。由此,由CTA-PVA-CTA、PC-PVA-PC、CTA-PVA-PC、CTA-PVA-PA构成的插件是可预见的,插件的第一层是当面罩被穿戴时意图距眼睛最远的层,第三层是最靠近用户眼睛的层。
另外,该图1示出用于注射热塑性材料的注射口25,所述热塑性材料例如聚碳酸酯或聚酰胺(例如尼龙),其例如具有“晶体”特性,即透明但无着色的,或替换的是有着色/有色的。
该热塑性材料注射口25关于插件9定位在边缘上,靠近吸入口21且关于后者定心。
根据本发明的方法如下进行:
要被包覆模制的插件9布置在注射模具1中,插件已经预先通过热成型弯曲,以便最好地紧靠模具1的凹部分。
在此之后为了将插件9保持在模具1中,真空泵23开启,且产生真空,其牢牢地夹持插件抵靠模具1的凹部分的壁。
作为例子,吸力在0.02至0.085MPa之间。
接下来,模具1的凸部分7关于凹部分5定位,留出要被热塑性材料填充的间隙,且诸如聚碳酸酯或聚酰胺(例如尼龙)这样的热塑性材料经由口25注射到模具1中,以形成支撑观察屏3的机械支撑层。
最后,由此形成的观察屏3被脱模。
图2示出成品观察屏3,其可用作面罩,例如用于参加诸如滑雪的一些运动、用于夜间驾驶、用于摩托车头盔或用于保护护目镜。
圆圈27在此清晰可见,且表示吸入口21的线。但是,这不是重要的,因为观察屏3在部分17中被切割,以容纳用户的鼻子。
该图2还示出箭头29,其表示热塑性材料注射口25。因此可以看出,该口相对于吸入口21定心。
该挖切部的优点在于,插件中的机械张力的产生被减小,所有张力集中在要被切掉的区域17中。
图3显示了观察屏3的横截面,图4示出其透视图。
当然,观察屏的后部面和前部面可潜在地用通常用在光学屏的领域中的任何涂层覆盖,以便提供附加功能。可施加到屏的一个面和/或另一个面上的功能涂层的非限制例子包括,额外地赋予冲击抗性的涂层、赋予抗反射涂层的功能的涂层、硬涂层、清洁涂层、防雾涂层、抗静电涂层或这些功能的一些的组合。
因此应意识到,该方法使得可以产生高质量的观察屏,特别是避免在热塑性材料注射时产生的表面张力导致的以及在多个周边点处被保持时导致的屏的光学质量损害。
具体地,根据本发明的方法还允许插件9准确地顺应模具1的凹部分5的形状或腔体,且没有张力地实现这一点。这是重要的,因为热成型并非完美地球形且与腔体为相同的半径。由于本发明的方法,作为结果,通过没有阻力顺应腔体形状的插件,在填充期间在热材料流动中没有急动(jerkiness),该急动可导致可见缺陷(纹路、变形等),且该方法还限制张力。
当然,本发明不限于所述实施例,但涵盖落入权利要求所限定的本发明范围的任何变体。
Claims (13)
1.一种用于制造具有注射包覆模制的插件(9)的观察屏(3)的方法,包括以下步骤:
-将要被包覆模制的插件(9)布置在注射模具(1)中,
-利用并入到注射模具(1)中的吸入口(21)保持插件(9),
-将热塑性材料注射到模具(1)中,以形成支撑观察屏的机械支撑层,
-将由此形成的观察屏(3)脱模,
其特征在于,模具仅具有一个吸入口(21),其位于区域(17)中,该区域就相关观察屏而言对应于容纳用户鼻子的挖切部分,吸入口(21)包括低孔隙率金属插件。
2.如权利要求1所述的方法,其特征在于,该插件防止注射的热塑性材料被吸收,且该插件并入在注射模具(1)的凹部分(5)中。
3.如权利要求2所述的方法,其特征在于,吸入口(21)具有7.5mm至10mm的横向直径。
4.如权利要求2所述的方法,其特征在于,吸入口(21)具有9mm的横向直径。
5.如权利要求2或3所述的方法,其特征在于,吸入口(21)的金属插件的孔隙率低于200μm。
6.如前述权利要求1-4中的任一项所述的方法,其特征在于,吸入口(21)的吸力为0.02至0.085MPa。
7.如前述权利要求1-4中的任一项所述的方法,其特征在于,将要被包覆模制的插件(9)的尺寸小于成品观察屏(3)的尺寸。
8.如前述权利要求1-4中的任一项所述的方法,其特征在于,用于注射热塑性材料的注射口(25)关于将要被包覆模制的插件(9)定位在其边缘上,靠近吸入口(21)且关于吸入口(21)定心。
9.如前述权利要求1-4中的任一项所述的方法,其特征在于,包覆模制热塑性材料是聚碳酸酯或聚酰胺。
10.如前述权利要求1-4中的任一项所述的方法,其特征在于,将要被包覆模制的插件(9)由三层形成,中间层由聚乙烯醇(PVA)聚合物制成,两个外层的一个或两个由三醋酸纤维素、聚碳酸酯或聚酰胺制成。
11.一种利用如前述权利要求中任一项所述的方法获得的观察屏(3),其相继地包括由热塑性材料构成且形成观察屏后部面的机械支撑层、由聚乙烯醇聚合物制成的中间层、和由热塑性材料制成的且形成观察屏前部面的外层。
12.一种用于模制具有包覆模制插件的观察屏(3)的注射模具(1),包括凹部分(5)和凸部分(7),其特征在于,模具包括仅一个吸入口(21),该吸入口用于保持插件(9)且位于凹部分(5)的区域(17)中,该区域就相关观察屏(3)而言对应于容纳用户鼻子的挖切部分(17),吸入口(21)包括低孔隙率金属插件。
13.如权利要求12所述的注射模具,其特征在于,热塑性材料注射口(25)关于将要被包覆模制的插件(9)定位在其边缘上,靠近吸入口(21)且关于吸入口(21)定心。
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PCT/EP2013/054666 WO2013132037A1 (fr) | 2012-03-08 | 2013-03-07 | Procede de realisation d'un ecran de vision a insert surmoule par injection |
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