CN105050789B - 用于注射成型的模内装饰技术(imd)或模内镶件注塑(iml)过程的具有膜式浇口的熔化物输导系统 - Google Patents
用于注射成型的模内装饰技术(imd)或模内镶件注塑(iml)过程的具有膜式浇口的熔化物输导系统 Download PDFInfo
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Abstract
一种用于注射成型的扁平塑料部件(110)的模内装饰技术(IMD)或模内镶件注塑(IML)过程的熔化物输导系统(128),包括至少一个膜式联合部(130)和浇道(136),在联合部(130)和浇道(136)之间具有蓄积室(140),该蓄积室的截面与浇道(136)相比相对于被注射材料的流动方向横向地延伸。根据前述权利要求中任一所述的熔化物输导系统(128)所使用的模内装饰技术(IMD)或模内镶件注塑(IML)注射成型过程适合于制造触控显示面板,尤其是用来制造用于家用器具的显示面板。
Description
技术领域
本发明涉及一种用于注射成型的扁平塑料部件的模内装饰技术(IMD)或模内镶件注塑(IML)过程的熔化物输导系统,其具有至少一个带式或膜式联合部和一浇道,本发明还涉及一种使用这种熔化物输导系统的过程。
背景技术
模内装饰技术(IMD)或模内镶件注塑(IML)注射成型过程已被成功用于制造带整合的装饰层或膜的扁平塑料部件。通过将塑料注射到涂覆有粘合剂(IML)或载体膜(IMD)的膜上,膜(IML)或装饰层(IMD)被连接至塑料部件(例如显示窗)。对于模内镶件注塑过程(IML),注射成型工具的成型部分的表面被提供印刷的或装饰的膜,然后用塑料进行后注射(hinterspritzt)。对于模内装饰技术过程(IMD),装饰物借助于载体膜通过使用塑料熔化物的压力和温度被传送至塑料部件。载体膜在此不连接至塑料部件;仅传送载体膜上的装饰物。
最好的熔接在由涂料制造商推荐的处理温度下用后注射来实现。膜或装饰层到基底/塑料部件的粘合使用粘合剂来实现。良好的粘合联接也通过在印刷、干燥和后注射之间的短处理阶段来实现。粘合剂在塑料处理窗中通常表现出耐高温性,但是也对大剪切力和高剪切速度敏感,尤其是在浇口区域附近。
剪切速度是材料层流动通过流动通道的相对速度的量度。高剪切速度产生大剪切力,从而可使粘合剂被冲掉,因而导致塑料部件与膜或装饰部之间的不充分粘合。剪切力和剪切速度在塑料熔化物流动通过工具时产生。热量由于剪切而产生。随着注射成型工具中的空腔被填充,截面小的浇口通道引起材料的摩擦热量增加。因此,浇口通道不应太窄。另一方面,太宽的浇口通道增加了操作过程时间和浇口中的材料损失。
膜或带式浇口系统设置在用于扁平模制部分(比如显示单元和显示窗口)的部件上。膜或带式浇口系统可被设计成扇形的/梯形的,且通过熔化物输导系统中的浇道形成。浇道可以是粗的,且直接通向联合部,所述联合部形成了部件上的浇口连接部。
在厚壁部分的情况下,其出于结构和/设计相关因素而通过较薄壁来注射(例如,在用于洗涤器具的显示单元的情况下),传统的浇口系统具有局限性。透明度变化的塑料尤其被用于针对显示和操作元件的面板。其目的是实现一种具有良好光学品质的制成品,从而被覆盖的显示元件例如容易地可见。尤其削弱透明度或光学失真的条纹和标记是不期望的,且使得产品不合格。通常,也应避免在部件的可见表面中的浇口系统,从而浇口被布置在部件的边缘处。
在此产生的问题是,扁平部件的边缘区域通常端部是薄的,且因此仅允许在注射工具的构型中具有很窄联合部的熔化物输导系统。
图4a示出了使用传统过程制造的扁平部件10的视图。部件10包括膜24,所述膜24被后注射以塑料26。注射成型制造过程的浇口12仍联接至部件10。
图4b和4c示出了通过具有熔化物输导系统28的相应的注射成型工具20的示意性纵截面或剖面。膜24嵌入空腔22中,被后注射以塑料26。熔化物输导系统28具有注入口34和浇道36,通过注入口34和浇道36供送塑料熔化物。横向于熔化物流动方向延伸的缝状通路被设置为浇道36与空腔22之间的联合部30。在该联合部中凝固的材料在部件10上形成了浇口12的浇口连接部32,所述浇口连接部32必须被切断以制造部件10。
扇形的浇道36具有一截面,该截面横向于熔化流的流动方向延伸并平行于由部件10形成的平面定向。空腔22通过联合部30由浇道36在空腔22的整个或部分截面上被供给,如图4c以流动箭头所示。
这种过程和工具例如从Fraunhofer IWM(弗劳恩霍夫材料力学研究所)公开(Peter Stache,Sven Wüstenhagen;Halle,06.05.2009;http://www.designtransfair.de/_files/seminare/09-06/spritzguss.pdf)获知。
使用这种熔化物输导系统产生的问题是,由于联合部30的区域中或紧接着该区域之后的不充分的平衡,塑料物部分过早地凝固,从而减小了联合部30的流入截面,使得熔化物不能在整个宽度上均匀地流动到空腔22中。浇口连接部32过早地被部分地或完全地阻塞,因而封闭了联合部30的部分截面或整个截面。因此,增加的随后压力不能有效地补偿注射成型部分的体积收缩。
薄壁的注射成型部分还需要很快的注射速度和高注射压力,以便被完全地填充。随着薄流动路径区域通过浇口系统延伸到凸缘(如图3b所示)或整体塑料部件中,剪切力和剪切速度增加。所导致的剪切速度很高。高的剪切速度尤其导致条纹的形成。
即使在宽的联合部30的情况下,自由射流也可在浇口连接部32上形成。这在完成的部件10中产生了难看的标记,从而使得该部件不合用。并且在该区域中还可能产生大的剪切力,从而可引起粘合剂层受损,所述粘合剂层在塑料和膜或装饰部与膜上的结构(尤其是用于触敏式面板的电极结构)之间。
发明内容
本发明提供了一种在前述内容中提及的类型的、具有改进的注射表现的熔化物输导系统。
为此,提供了一种具有权利要求1的特征的熔化物输导系统。因此,熔化物输导系统在联合部与浇道之间具有蓄积室,所述蓄积室的截面横向于被注射材料的流动方向相对于浇道展宽。
蓄积室更有效地防止了可引起表面缺陷的自由射流。由于所产生的流动前沿轮廓,要被后注射的装饰部或膜也被间接地注射。这对于膜上的粘合剂、涂料层和/或传感器层具有特别的保持效果。流动到蓄积室中的塑料沉积在蓄积室外壁上并凝固。由于相对于工具作为热隔离体的塑料的自隔离效应,熔化物的路径保持敞开更长的时间。与传统构型不同的是,随后压力可更长地保持有效。剪切速度和剪切力由于蓄积室的更大容积而被降低。蓄积室中的熔化流也被规整化,且可在空腔中缓慢地和以层流方式传送。
蓄积室优选横向于熔化物流动方向具有大致棱柱体横截面形状的、尤其长方形的截面。蓄积室的特别的几何形状、尤其是蓄积室轮廓中的拐角有助于塑料在蓄积室外壁上沉积和凝固。然而,拐角也可被设计成具有倒圆形状。该构型也提供了蓄积室在熔化物流动上的影响和浇口中的材料损失之间的最佳比。
蓄积室有利地具有横向于熔化物流动方向的非对称截面。这防止了凝固的熔化物均匀地沉积在蓄积室中,从而使得熔化流被偏移。这使得熔化流进一步减慢,且防止了熔化物从分配通道以自由射流被直接注射到空腔中。最后,所述偏移还为熔化物建立了优选的定向,从而有助于使熔化物更有效地且更均匀地分布。
由于对于薄壁部分而言,需要高的注射压力以及快的注射速度,因此,例如由于剪切力而引起的过高压力损失将成为主要的缺点,因为存在不能充分快地填充空腔和一些熔化物在工具完全被填充之前就凝固的风险。将需要的更高压力来补偿压力损失和快速地完全填充模制件,但是这进而可增加剪切力并引起热问题。
本发明最小化了对于该类型熔化物输导系统的剪切和压力损失。
本发明还提供了一种用于制造触控显示面板的、具有改进的材料传送表现的模内装饰技术(IMD)或模内镶件注塑(IML)注射成型过程。为此,根据本发明提供了具有如权利要求5所述的特征的过程。
本发明的过程和设备特别有益地适合于制造触控式显示操作区或触摸显示屏,尤其是在家用器具、例如衣物处理器具(比如滚筒式干燥机和洗衣机或洗涤/干燥两用机)中。当注射设有功能层(比如装饰层、导体层、金属化层等)的膜时,尤其当膜以功能层向着塑料被注射时,与保持材料流动和降低剪切力相关的特别的优点具有特别有益的效果。本发明于是保证了可靠的注射,而没有损害功能层的风险。在功能层向着塑料的情况下进行注射还保证了永久的无差错操作,因为功能层在动作时不必直接受触摸,而是受膜保护。
附图说明
本发明的其他特征和优点还将体现在从属权利要求以及下文参照附图对实施例的描述,在附图中:
图1示出了通过具有本发明的熔化物输导系统的注射工具的一部分的示意性剖视图;
图2示出了图1的熔化物输导系统的详细放大图;
图3示出了根据本发明的过程制造的、具有浇口的部件的视图;以及
图4示出了根据现有技术的工具和用它制造的部件。
具体实施方式
图1的示意性剖视图示出了具有熔化物输导系统128的注射成型工具120的一部分。为清楚起见,图3还示出了使用工具120制造的、具有浇口112的相应的部件110。
注射成型工具120具有空腔122,膜124嵌入所述空腔122中。用塑料126对膜124进行后注射,从而使图3所示的部件110形成具有被注射的膜124的扁平面板形式。如图3b中通过图3a的部件110的截面A-A所示,膜124被后注射以一层塑料126,该层塑料126的厚度大于膜124的厚度。不同的是,在部件110的边缘处形成了薄的凸缘132,所述薄的凸缘132通过部件110的窄面上的、延伸的薄的膜式或带式浇口连接部133连接至浇口112。图3a示出了分离地围绕浇口连接部133的截面的部件110和浇口112。
工具120中的熔化物输导系统128具有注入口134和浇道136。浇道136被构造成以扇形形状扩展开的分配通道。浇道136在其侧部处具有成V形式的两个主流动通道138,主流动通道138的通流截面远远宽于扇形结构的其余部分,从而使得主流动通道138承担熔化物材料流动的较大部分。因此,浇道中的熔化物流动以如下方式被平衡:熔化物的流动前沿有利地在浇道136中均匀地传送。
熔化物输导系统128通过联合部130连通至空腔122。联合部130与空腔122之间的过渡部形成了完成后的部件110中的浇口连接部133。
蓄积室140设置在联合部130与浇道136之间。在所示出的实施例中,蓄积室140被构造成平行于联合部130延伸的腔室。熔化物的主流动方向在图1中以箭头示意性地示出,且基本上在图面中延伸。蓄积室横向于熔化物的流动方向(也就是在图面中)具有棱柱体横截面形状的截面,尤其是大致长方形的截面,如图1所示。浇道136通到棱柱形蓄积室140的第一纵向面144上。蓄积室140进而在相对的第一屏障壁146的边缘处通过联合部130通到空腔122中。第二屏障壁148靠近联合部130的开口延伸在屏障壁146与纵向面144之间。第二纵向壁142与第二屏障壁148相对地延伸。蓄积室的截面有利地是非对称的。也就是说,相邻的壁具有不同的宽度,从而该截面不是正方形或菱形,而是大致长方形或不规则四边形。这使得熔化流的有利的流动行为在蓄积室中产生,尤其也在联合部130之后在空腔122中产生,如图2所示。
图2示出了具有从联合部130到空腔122的过渡部的蓄积室140的详细放大图。熔化流的假设流动也在图2的详细视图中示意性地示出。
熔化流从分配通道136穿过蓄积室140通过联合部130流动至空腔122中,以便填充膜124后面的空间。流动截面在蓄积室140中的加宽使得熔化流在该区域中减慢速度。塑料在蓄积室140的边缘区域150、152中沉积在外壁上,且在所述区域中形成凝固区。
蓄积室140的构型,尤其是蓄积室140的非对称截面,意味着熔化流的流动前沿被间接地注射到膜上,注射在该膜后面进行。这对于膜上的功能层、装饰层、粘合剂等具有特别的保持效果。
图2清楚地示出了熔化流由于纵向面142、144和屏障壁146、148的非对称偏移而产生偏离。因此,特别有利地实现了膜的改进的非直接注射以及更大的保持效果。
也可在蓄积室140中有利地提供表面构型,尤其是一个或两个屏障壁146、148可选地连同一个或两个纵向面142、144,以便在熔化物输导系统中调整熔化流和实现改进的流动。例如,所述表面可设有纹路结构。这种粗糙化的表面可防止已经冷却了的塑料层被剪切力分离和被冲到空腔122中。
Claims (7)
1.一种用于注射扁平塑料部件(110)内设有功能层的膜的模内装饰技术(IMD)或模内镶件注塑(IML)过程的熔化物输导系统(128),具有至少一个带式或膜式联合部(130)和浇道(136),其特征在于,熔化物输导系统在联合部(130)和浇道(136)之间具有蓄积室(140),所述蓄积室(140)横向于被注射材料的流动方向相对于浇道(136)具有展宽的非对称的截面。
2.根据权利要求1所述的熔化物输导系统(128),其特征在于,所述蓄积室(140)横向于熔化物的流动方向具有大致棱柱体横截面形状的截面。
3.根据权利要求1或2所述的熔化物输导系统(128),其特征在于,所述蓄积室(140)具有非对称设置的屏障壁(146、148),在所述屏障壁之间所述蓄积室通到联合部,其中,屏障壁(146、148)使熔化流在蓄积室(140)产生偏移。
4.根据权利要求1或2所述的熔化物输导系统(128),其特征在于,所述浇道(136)形成扇形结构,所述扇形结构的扩展端通到所述蓄积室(140)。
5.根据权利要求1所述的熔化物输导系统(128),其特征在于,所述蓄积室(140)横向于熔化物的流动方向具有长方形的截面。
6.一种用于制造触控显示面板的模内装饰技术(IMD)或模内镶件注塑(IML)注射成型过程,其特征在于,使用根据前述权利要求中任一所述的熔化物输导系统(128)。
7.根据权利要求6所述的过程,其特征在于,该过程用来制造用于家用器具的显示面板。
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PCT/EP2014/055254 WO2014147008A1 (de) | 2013-03-22 | 2014-03-17 | Schmelzeleitsystem mit filmanguss für in-mold-deco ration (imd)- oder in-mold-labeling (iml)-verfahren zum spritzgiessen |
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DE1269328B (de) * | 1962-11-13 | 1968-05-30 | Hoechst Ag | Spritzgiessform fuer thermoplastische Kunststoffe zum Herstellen grossflaechiger Teile |
JPS5849170B2 (ja) * | 1977-10-25 | 1983-11-02 | 旭化成株式会社 | コ−トハンガ−型ゲ−トを有する射出成形用金型 |
DE3243991C2 (de) * | 1982-11-27 | 1985-01-10 | Karl 7298 Loßburg Hehl | Formschließeinheit mit einer Auswerfer-Antriebsvorrichtung |
JPS6140129A (ja) * | 1984-07-31 | 1986-02-26 | Dainichi Nippon Cables Ltd | シ−ルリング射出成形法 |
US5051741A (en) * | 1990-03-28 | 1991-09-24 | Wesby Philip B | Locating system |
AU3264693A (en) * | 1992-01-15 | 1993-08-03 | David Ian Leach | Method and apparatus for making a loudspeaker cone and surround assembly |
US5220863A (en) * | 1992-05-18 | 1993-06-22 | Westinghouse Air Brake Company | Conical diaphragm and method of making |
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US5955021A (en) * | 1997-05-19 | 1999-09-21 | Cardxx, Llc | Method of making smart cards |
US6841114B2 (en) * | 2001-03-28 | 2005-01-11 | Mitsubishi Cable Industries, Ltd. | Molding method and apparatus for resin long body |
DE10327453A1 (de) * | 2003-06-18 | 2005-01-27 | Bayer Materialscience Ag | Verbundsysteme zur Herstellung von dekorierten Kunststoffformteilen und ein Verfahren zur Herstellung der Verbundsysteme |
DE102004041833A1 (de) * | 2004-08-27 | 2006-03-02 | Leonhard Kurz Gmbh & Co. Kg | Dekorierter Spritzgussartikel, Verfahren zur Herstellung eines dekorierten Spritzgussartikels sowie Transferfolie zur Verwendung in einem derartigen Verfahren |
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US20110268923A1 (en) * | 2009-09-25 | 2011-11-03 | Tokai Rubber Industries, Ltd. | Resin molding method and resin molding |
JP5155992B2 (ja) * | 2009-12-18 | 2013-03-06 | 日本写真印刷株式会社 | 射出成形用金型 |
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