CN105538603A - 一种新型气体辅助成型工艺 - Google Patents
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- 239000004033 plastic Substances 0.000 claims abstract description 42
- 238000002347 injection Methods 0.000 claims abstract description 37
- 239000007924 injection Substances 0.000 claims abstract description 37
- 238000001746 injection moulding Methods 0.000 claims abstract description 29
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 15
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- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 8
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 8
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 8
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- 239000004926 polymethyl methacrylate Substances 0.000 claims description 6
- SNIOPGDIGTZGOP-UHFFFAOYSA-N Nitroglycerin Chemical group [O-][N+](=O)OCC(O[N+]([O-])=O)CO[N+]([O-])=O SNIOPGDIGTZGOP-UHFFFAOYSA-N 0.000 claims description 5
- 238000007664 blowing Methods 0.000 claims description 5
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- 239000000498 cooling water Substances 0.000 claims description 5
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- 230000001788 irregular Effects 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 229940073020 nitrol Drugs 0.000 claims description 5
- 238000005457 optimization Methods 0.000 claims description 5
- 238000010025 steaming Methods 0.000 claims description 5
- 230000001052 transient effect Effects 0.000 claims description 5
- 239000004952 Polyamide Substances 0.000 claims description 4
- 229920002647 polyamide Polymers 0.000 claims description 4
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- 238000005299 abrasion Methods 0.000 abstract 1
- 230000002035 prolonged effect Effects 0.000 abstract 1
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- 230000035515 penetration Effects 0.000 description 3
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- 230000000630 rising effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1703—Introducing an auxiliary fluid into the mould
- B29C45/1704—Introducing an auxiliary fluid into the mould the fluid being introduced into the interior of the injected material which is still in a molten state, e.g. for producing hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/78—Measuring, controlling or regulating of temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76498—Pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76531—Temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76551—Time
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76551—Time
- B29C2945/76561—Time duration
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
- B29K2033/04—Polymers of esters
- B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2055/00—Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
- B29K2055/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
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Abstract
本发明公开了一种新型气体辅助成型工艺,包括如下步骤:开始注塑前预处理、合模注塑、冷却和开模等。本发明减少残余应力、降低翘曲问题,消除凹陷痕迹;缩短生产周期时间,传统的气辅成型由于塑件筋位厚、柱位多,很多时候都需要一定的注射、保压来保证塑件定型,该气辅成型的塑件,塑件外表看似很厚胶位,但由于内部中空,因此冷却时间比传统实心塑件短,总的周期时间因保压及冷却时间减少而缩短;同时本发明降低注塑机机械损耗,由于注射压力及锁模力降低,注塑机各主要受力塑件等所承受的压力亦相应降低,因此各主要塑件的磨损降低,寿命得以延长,减少维修及更换的次数。
Description
技术领域
本发明涉及注塑成型工艺技术领域,尤其涉及一种新型气体辅助成型工艺。
背景技术
气体辅助注射成型(简称气辅成型)是一种新型的聚合物成型工艺。该工艺先将聚合物熔体部分或全部注入模腔,紧接着把压缩空气注入到聚合物熔体内部来推动塑料熔体充满整个模腔,形成中空气道。与传统注塑成型工艺相比,气辅成型可以提高产品表面质量、减少翘曲变形、降低锁模力、减轻制品重量、节省费用。但另一方面,气辅成型工艺参数的增多导致其工艺更加难于控制,实际生产中工艺参数的波动、噪声因素的存在也会导致气辅成型废品率的上升。
气辅注射尽管具有许多的优点,但不可避免的也存在着一些缺陷。气辅注射成型中许多技术必须获得专利使用许可;气道的设计不当会导致气体穿透不顺畅等问题,从而使得生产不稳定,严重影响生产率;排气孔设置不当会影响制品的表面质量;需要注射机具有较高的控制精度,以适应培体预注射量和气体注射的控制;工艺参数增加且制品对工艺参数的敏感性大大提高。因此,各工艺参数对最终制品的影响关系更加复杂。因此,需要对气辅成型工艺进行优化处理来解决上述问题的不足。
发明内容
本发明的目的是为了解决现有技术中存在的缺点,而提出的一种新型气体辅助成型工艺。
为了实现上述目的,本发明采用了如下技术方案:
本发明提出了一种新型气体辅助成型工艺,包括如下步骤:
S1、开始注塑前,将模具固定于注塑机,在合模前对模具进行预热,模具预热温度为80-90℃,注射机料筒塑料熔体温度区间设定为240-280℃;
S2、合模时,将温度为160-170℃,压力为30-36MPa的高温蒸汽通过优化后的非规则水道,对模具进行瞬间加热至110-120℃,塑料原料从注射机的料斗进入料筒,经加热熔融及螺杆转动塑化成黏流态熔体,后由螺杆的推动下通过喷嘴注入模具型腔;
S3、合模完成后,注射机对模具进行注射,通过注塑成型机给出开模信号,锅炉输送高温蒸汽进入模具蒸汽管路中,此时蒸汽压力的压力值为10-12MPa,蒸汽温度为160-1700C,气体延迟时间2-3s,充蒸汽时间是12-18s,保证模具温度达到125-1450C之间并利用蒸汽进行保持,同时将信号反馈给注塑成型机允许塑料注射,塑料熔体进入模具型腔,注塑完成后,锅炉停止供给蒸汽,同时压缩空气进入模具蒸汽管路中,此时压缩空气压力为8MPa,清除因蒸汽热能释放所产生的冷凝水,并进行回收;
S4、冷却阶段时,采用冷却水塔所控制的4-10℃冷水,用高压水泵往模具水道高速注射冷却水;冷却完成后向模具水道中吹入温度为25-30℃的空气,将模具水道中的冷水吹出模具,以便于下一注塑循环正常进行;
S5、开模后,模具吹气道自动以0.2-0.4Mpa的空气压力对模具进行清理杂质和干燥处理。
优选的,所述锅炉为2T高压蒸汽锅炉。
优选的,所述塑料原料为聚甲基丙烯酸甲酯(PMMA)或丙烯腈-丁二烯-苯乙烯共聚物(ABS)或聚酰胺(PA)。
优选的,所述喷嘴为Nitrol喷嘴。
本发明提供的一种新型气体辅助成型工艺,与现有技术相比,本发明是一种新型气体辅助成型工艺,本发明的最优工艺参数组合为熔体温度274.3℃,气体注射压力35.0MPa,气体延迟时间2.3s,气体注射时间12.4s,工艺参数增加且制品对工艺参数的敏感性大大提高,在该工艺参数下能够避免气体穿透不顺畅等问题,从而使得生产稳定,提高生产率;排气孔设置不当会影响制品的表面质量;与传统的气辅成型过相比,本发明减少残余应力、降低翘曲问题,消除凹陷痕迹;缩短生产周期时间,传统的气辅成型由于塑件筋位厚、柱位多,很多时候都需要一定的注射、保压来保证塑件定型,该气辅成型的塑件,塑件外表看似很厚胶位,但由于内部中空,因此冷却时间比传统实心塑件短,总的周期时间因保压及冷却时间减少而缩短;同时本发明降低注塑机机械损耗,由于注射压力及锁模力降低,注塑机各主要受力塑件等所承受的压力亦相应降低,因此各主要塑件的磨损降低,寿命得以延长,减少维修及更换的次数。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合具体实施例,对本发明进行进一步详细说明。此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。
实施例1
一种新型气体辅助成型工艺,包括如下步骤:
S1、开始注塑前,将模具固定于注塑机,在合模前对模具进行预热,模具预热温度为80℃,注射机料筒塑料熔体温度的设定为240℃;
S2、合模时,将温度为160℃,压力为30MPa的高温蒸汽通过优化后的非规则水道,对模具进行瞬间加热至110℃,聚甲基丙烯酸甲酯(PMMA)原料从注射机的料斗进入料筒,经加热熔融及螺杆转动塑化成黏流态熔体,后由螺杆的推动下通过Nitrol喷嘴注入模具型腔;
S3、合模完成后,注射机对模具进行注射,通过注塑成型机给出开模信号,2T高压蒸汽锅炉输送高温蒸汽进入模具蒸汽管路中,此时蒸汽压力的压力值为10MPa,蒸汽温度为1600C,气体延迟时间2s,充蒸汽时间是12s,保证模具温度达到1250C之间并利用蒸汽进行保持,同时将信号反馈给注塑成型机允许塑料注射,塑料熔体进入模具型腔,注塑完成后,2T高压蒸汽锅炉停止供给蒸汽,同时压缩空气进入模具蒸汽管路中,此时压缩空气压力为8MPa,清除因蒸汽热能释放所产生的冷凝水,并进行回收;
S4、冷却阶段时,采用冷却水塔所控制的4℃冷水,用高压水泵往模具水道高速注射冷却水;冷却完成后向模具水道中吹入温度为25℃的空气,将模具水道中的冷水吹出模具,以便于下一注塑循环正常进行;
S5、开模后,模具吹气道自动以0.2-0.4Mpa的空气压力对模具进行清理杂质和干燥处理。
实施例2
一种新型气体辅助成型工艺,包括如下步骤:
S1、开始注塑前,将模具固定于注塑机,在合模前对模具进行预热,模具预热温度为85℃,注射机料筒塑料熔体温度的设定为274.3℃;
S2、合模时,将温度为165℃,压力为35.2MPa的高温蒸汽通过优化后的非规则水道,对模具进行瞬间加热至112.3℃,丙烯腈-丁二烯-苯乙烯共聚物(ABS)原料从注射机的料斗进入料筒,经加热熔融及螺杆转动塑化成黏流态熔体,后由螺杆的推动下通过Nitrol喷嘴注入模具型腔;
S3、合模完成后,注射机对模具进行注射,通过注塑成型机给出开模信号,2T高压蒸汽锅炉输送高温蒸汽进入模具蒸汽管路中,此时蒸汽压力的压力值为10-12MPa,蒸汽温度为1650C,气体延迟时间2.3s,充蒸汽时间是12.4s,保证模具温度达到1300C之间并利用蒸汽进行保持,同时将信号反馈给注塑成型机允许塑料注射,塑料熔体进入模具型腔,注塑完成后,2T高压蒸汽锅炉停止供给蒸汽,同时压缩空气进入模具蒸汽管路中,此时压缩空气压力为8MPa,清除因蒸汽热能释放所产生的冷凝水,并进行回收;
S4、冷却阶段时,采用冷却水塔所控制的6℃冷水,用高压水泵往模具水道高速注射冷却水;冷却完成后向模具水道中吹入温度为25℃的空气,将模具水道中的冷水吹出模具,以便于下一注塑循环正常进行;
S5、开模后,模具吹气道自动以0.2-0.4Mpa的空气压力对模具进行清理杂质和干燥处理。
实施例3
一种新型气体辅助成型工艺,包括如下步骤:
S1、开始注塑前,将模具固定于注塑机,在合模前对模具进行预热,模具预热温度为90℃,注射机料筒塑料熔体温度的设定为280℃;
S2、合模时,将温度为170℃,压力为36MPa的高温蒸汽通过优化后的非规则水道,对模具进行瞬间加热至120℃,丙烯腈-丁二烯-苯乙烯共聚物(ABS)原料从注射机的料斗进入料筒,经加热熔融及螺杆转动塑化成黏流态熔体,后由螺杆的推动下通过Nitrol喷嘴注入模具型腔;
S3、合模完成后,注射机对模具进行注射,通过注塑成型机给出开模信号,2T高压蒸汽锅炉输送高温蒸汽进入模具蒸汽管路中,此时蒸汽压力的压力值为12MPa,蒸汽温度为1700C,气体延迟时间3s,充蒸汽时间是18s,保证模具温度达到1450C之间并利用蒸汽进行保持,同时将信号反馈给注塑成型机允许塑料注射,塑料熔体进入模具型腔,注塑完成后,2T高压蒸汽锅炉停止供给蒸汽,同时压缩空气进入模具蒸汽管路中,此时压缩空气压力为8MPa,清除因蒸汽热能释放所产生的冷凝水,并进行回收;
S4、冷却阶段时,采用冷却水塔所控制的10℃冷水,用高压水泵往模具水道高速注射冷却水;冷却完成后向模具水道中吹入温度为30℃的空气,将模具水道中的冷水吹出模具,以便于下一注塑循环正常进行;
S5、开模后,模具吹气道自动以0.2-0.4Mpa的空气压力对模具进行清理杂质和干燥处理。
综上所述:与现有技术相比,本发明是一种新型气体辅助成型工艺,本发明的最优工艺参数组合为熔体温度274.3℃,气体注射压力35.2MPa,气体延迟时间2.3s,气体注射时间12.4s,工艺参数增加且制品对工艺参数的敏感性大大提高,在该工艺参数下能够避免气体穿透不顺畅等问题,从而使得生产稳定,提高生产率;排气孔设置不当会影响制品的表面质量;与传统的气辅成型过相比,本发明减少残余应力、降低翘曲问题,消除凹陷痕迹;缩短生产周期时间,传统的气辅成型由于塑件筋位厚、柱位多,很多时候都需要一定的注射、保压来保证塑件定型,该气辅成型的塑件,塑件外表看似很厚胶位,但由于内部中空,因此冷却时间比传统实心塑件短,总的周期时间因保压及冷却时间减少而缩短;同时本发明降低注塑机机械损耗,由于注射压力及锁模力降低,注塑机各主要受力塑件等所承受的压力亦相应降低,因此各主要塑件的磨损降低,寿命得以延长,减少维修及更换的次数。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (4)
1.一种新型气体辅助成型工艺,其特征在于:包括如下步骤:
S1、开始注塑前,将模具固定于注塑机,在合模前对模具进行预热,模具预热温度为80-90℃,注射机料筒塑料熔体温度区间设定为240-280℃;
S2、合模时,将温度为160-170℃,压力为30-36MPa的高温蒸汽通过优化后的非规则水道,对模具进行瞬间加热至110-120℃,塑料原料从注射机的料斗进入料筒,经加热熔融及螺杆转动塑化成黏流态熔体,后由螺杆的推动下通过喷嘴注入模具型腔;
S3、合模完成后,注射机对模具进行注射,通过注塑成型机给出开模信号,锅炉输送高温蒸汽进入模具蒸汽管路中,此时蒸汽压力的压力值为10-12MPa,蒸汽温度为160-1700C,气体延迟时间2-3s,充蒸汽时间是12-18s,保证模具温度达到125-1450C之间并利用蒸汽进行保持,同时将信号反馈给注塑成型机允许塑料注射,塑料熔体进入模具型腔,注塑完成后,锅炉停止供给蒸汽,同时压缩空气进入模具蒸汽管路中,此时压缩空气压力为8MPa,清除因蒸汽热能释放所产生的冷凝水,并进行回收;
S4、冷却阶段时,采用冷却水塔所控制的4-10℃冷水,用高压水泵往模具水道高速注射冷却水;冷却完成后向模具水道中吹入温度为25-30℃的空气,将模具水道中的冷水吹出模具,以便于下一注塑循环正常进行;
S5、开模后,模具吹气道自动以0.2-0.4Mpa的空气压力对模具进行清理杂质和干燥处理。
2.根据权利要求1所述的一种新型气体辅助成型工艺,其特征在于:所述锅炉为2T高压蒸汽锅炉。
3.根据权利要求1所述的一种新型气体辅助成型工艺,其特征在于:所述塑料原料为聚甲基丙烯酸甲酯(PMMA)或丙烯腈-丁二烯-苯乙烯共聚物(ABS)或聚酰胺(PA)。
4.根据权利要求1所述的一种新型气体辅助成型工艺,其特征在于:所述喷嘴为Nitrol喷嘴。
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