CN106142474B - 用于塑性材料的注射模制的方法和装置 - Google Patents
用于塑性材料的注射模制的方法和装置 Download PDFInfo
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Abstract
一种用于生产借助于多个注射器(A,B,C,D)将塑性材料注射至模具腔(S)中而模制的制品的模制方法,该多个注射器(A,B,C,D)在根据周期的电子控制下被电动地顺序地促动,该周期提供用于填充模具腔的步骤,之后跟着用于在模具腔中对塑性材料进行保压的步骤。各注射器(A,B,C,D)不考虑其相对于模具腔的位置及其打开速度,通过以下控制模式中的至少一种受到控制:‑在填充步骤中,将注射器从最大打开状态部分地关闭至更小地打开的状态,‑在保压步骤中,将注射器设定为部分打开状态且然后将注射器打开至更大地打开的状态。
Description
技术领域
本发明大体上涉及由注射模制的塑性材料制成的制品的生产,且更具体而言,涉及顺序注射模制(sequential injection molding)装置。
此种模制装置通常包括具有腔的模具、多个注射器,该多个注射器相对于模具的腔分别布置在中心、中间和端部位置且其促动是根据顺序周期模式来操作的。阀类型的注射器是由与熔融塑性材料分配器连接的喷嘴形成的,且在该注射器中,控制塑性材料从分配器到模具腔的引入的针阀可轴向地移动。
用于打开和关闭该针阀的位移,即,各注射器的打开和关闭,是通过流体促动器,或者根据当前的趋势、通过控制电子单元控制的相应电动促动器来操作的,该控制电子单元允许以最大的精确度改变针阀的位置且可能改变位移速度。电动促动器还可通过旋转电动马达来便利地构造,例如通过以本申请人名义的文献JP-06114887、US-7121820和EP-2679374描述和例示的。
背景技术
附图中的图1示意性地表示可借助于顺序注射模制获得的制品,其例如由相当大的主体构成,诸如例如用于机动车辆的扰流板S。扰流板S的形状明显地对应于模具腔,且用于顺序注射的注射器分别以A指示中心注射器,以B-C表示中间注射器,且以D表示端部注射器,端部注射器布置在模具腔的端部附近。
图2为示出用于获得制品S的常规顺序注射工艺方法的例子的图:该图作为时间的函数示出作为百分比表示的由注射器A、B、C和D的针阀采取的位置,从关闭位置“0”到最大开度位置“100”。如可观察到的,在腔填充步骤中,注射器例如在相应针阀的相同的速度或甚至是在不同的速度下,从中心注射器A开始以一连串(cascade)的方式打开,直到完全打开(100%)。在达到完全打开之后,所有的注射器被保持在此种位置中,直到该步骤的结束,以用于在模具腔中对塑性材料进行保压(packing),之后同时返回至关闭位置。
不同注射器的电动促动器的电子控制难以与实际工艺状态相关联,即,一系列的参数可随着操作状态、塑性材料的物理状态、和注射压力的变化而变化。
注射压力在各注射器的打开之前时是最大的,且相关阀的位移直到相当大的打开高度(在图2的情况中为完全打开)可能由于高压的突然释放而在模具浇口附近在模制件上引起表面缺陷。由此,这可能导致在工件的表面上生成可视的压力线或流线,并且特别是在要求高审美标准时,对其可接受性而言可能是决定性的。
与此同时,在保压步骤期间,提供正确的操作压力(特别是使模具腔内的压力大体上平衡,以优化工件的填充和固化)是合乎需要的。将注射器阀保持在完全打开位置不允许控制前述压力,除非损害精确度且仅通过模制装置的注射螺杆。
附图中的图3示出在注射器A,B,C,D的浇口处在模具腔中测量的压力趋势。显然在填充步骤中发生不均匀的值和相当大的压力变化,而在随后的保压步骤中,在测得的压力值之间观察到相当大的差异,在保压步骤中,所有的注射器如提到的那样被保持在完全打开状态下。这意味着腔的填充和模制制品的随后的固化不会是最佳的。
发明内容
本发明的目的在于通过有效地控制模具腔内中压力来优化填充或保压步骤或者填充和保压步骤二者,从而克服上述缺陷,以便极大地减少或甚至消除模制制品的上述表面缺陷。
为了实现该目的,根据第一方面,本发明涉及一种在权利要求1的前序部分中定义的类型的模制方法且其特征在于注射器(被认为是在顺序注射模制中使用的注射器集合中的通用注射器)不考虑其相对于模具腔的位置及其打开速度,通过以下模式中的至少一种而受到控制:
-在填充步骤中,将注射器从最大打开状态部分地关闭至更小地打开的状态;
-在保压步骤中,将注射器设定为部分打开状态且然后将注射器打开至更大地打开的状态。
根据一个特别有利的特征,在模制方法提供以前述方式中的二者来控制注射器的情况中,填充步骤中的更小地打开的状态对应于保压步骤中的部分打开状态。
本发明还涉及用于实现该方法的装置。
附图说明
在附图中:
-图1示意性地例示了借助于顺序注射而模制的制品,和注射器的相对布置,
-图2为表示根据前述现有技术的顺序注射方法的图,
-图3为表示与根据图2的现有技术的顺序注射对应的模具腔中的压力发展的图,
-图4为类似于图2的图,其示出在填充步骤期间,根据本发明的用于控制通用注射器的方法,
-图5为类似于图4的图,其示出在填充步骤期间,关于在顺序注射中涉及的所有注射器的第一控制方法,
-图6为类似于图5的图,其示出在保压步骤期间,根据本发明的用于控制通用注射器的第二方法,
-图7为类似于图6的图,其示出在保压步骤期间,应用于在顺序注射中所涉及的所有注射器的第二控制方法,
-图8示出图6的变形,
-图9示出图7的变形,且
-图10为类似于图3的图,其对应于根据本发明的方法。
具体实施方式
已在介绍部分中参照根据现有技术实现的顺序注射周期和在图3的图中示范的相对缺点描述了图1、2和3。
图4的图表表示在使用根据本发明的方法的填充步骤中,用于在顺序注射期间控制注射器A,B,C,D中的任一个的方法。应当观察到,如上面解释的,注射器设有相应的针阀,针阀可便利地借助于例如在之前提到的EP-2679374中描述和例示的类型的旋转电动马达,借助于相应的电动促动器在完全关闭位置和完全打开位置之间轴向地移动。电动马达又借助于电子控制单元而被促动,该电子控制单元构造成以根据本发明的原理来操作。
图4的图表作为时间的函数来表示任意注射器的针阀位置,不考虑其相对于模具的位置,且不考虑针阀的位移速度:例如,中间注射器B中的一个。相关针阀的位置作为完全打开位置的百分比而指示,从0至100%。
如可在图中观察到的,注射器B的阀从完全关闭位置打开至最大打开位置,并不一定与仅可在阀冲程的上死点处获得的最大开度一致。此种最大打开位置在所例示例子的情况中例如可为全开度的约50%,且如提到的,打开速度可为任意的,即,其并不需要在一定程度上是快速的。
由此,根据本发明的独特特性,在注射器的阀再次关闭直到更小地打开的位置(在这种情况中例如约为40%)之前,将最大打开位置维持以给定的时间周期(例如在填充步骤期间)。由此,已通过实验测试证明,在填充步骤期间,优化模具腔中的压力,以便在浇口处可在模制件的表面上观察到的压力线最小化或甚至完全消除。特别地,在顺序模制中,用于控制注射器的这种方法对避免相邻的高压力源的存在是特别有用的,相邻的高压力源甚至更可能导致模制制品上可见的压力线的集中。
图5例示了根据本发明的填充步骤中的控制方法,其应用于在图1中示范的构件的顺序模制:各种注射器A,B,C,D的阀被电子地控制,例如以便当打开或各随后的注射器(例如注射器C)处于最大打开状态时,将任一各之前的注射器(例如中间注射器B)的部分关闭设定达到更小地打开的状态,以避免两个高压的相邻注射点。在图5中指示的开度值仅是作为实例提供的。
图6的图表示在保压步骤期间,用于控制通用注射器(例如仍然是中间注射器B中的一个)的第二独特方法。如之前提到的,该图作为时间的函数表示作为完全打开位置的百分比从0至100%指示的注射器针阀的位置。
在填充步骤的结束时,注射器阀处于打开位置,例如,之前参照填充步骤描述的一个:根据本发明的另一独特方面,从该位置开始,注射器会进一步打开,直到更大的打开高度,通常总是部分的,且例如比在填充步骤中达到的最大开度小。以此方式,通过大体上平衡模具腔中的压力以便优化制品的形成和固化,注射器处的注射压力可进一步有效地得到控制。即便在该步骤中,从打开位置和速度可为任意的意义上说,注射器相对于模具腔的位置或是相关针阀的打开速度都不构成重要的或决定性的参数。
该注射器的更大开度的状态在整个保压步骤期间得到维持,在其结束时,使注射器到达完全关闭位置,即便是在该情况下也以任意的速度。
图7示出在顺序模制过程中,与在图1中例示的所有注射器A,B,C,D有关的保压步骤。如可观察到的,更大的打开程度对于端部注射器D可能是最大的,并且对于中间注射器C和B直到中心注射器A逐渐减小。
应当观察到,从仅一个或另一个可根据本发明来执行的意义上说,如上所述的关于填充步骤的第一控制方法和根据在本文中关于保压步骤描述的控制方法可相对于彼此独立地实现。然而,本发明还提供了实现二者的备选方案:在该情况下,填充步骤中的前述更小开度状态可便利地对应于在保压步骤开始时的部分打开状态,然后后面跟着前述更大打开状态。
备选地,在填充步骤的结束时,如果通用注射器的更小开度的状态精确地对应于在保压步骤期间待维持的最佳部分打开状态,则此种状态应无疑地在整个保压步骤期间得到维持,直到完全关闭。该情况参照通用注射器在图8中表示(例如,再次是中间注射器B中的一个),并且参照所有的注射器A,B,C,D在图9中表示。
图10的图表例示了在借助于注射器A、B、C和D,在根据本发明的填充步骤期间使用第一控制方法,并在根据本发明的保压步骤期间使用第二控制方法执行顺序注射的情况下,在模具腔中通过实验检测的压力趋势。清楚的是,相对于现有技术(图3),压力为更加均匀且一致,从而优化模制制品的形成和固化,因此达到显著改善的表面美学品质。
本发明的另一方面规定基于在成品元件上观察到的分析结果在相关的电子控制单元中自动地设定通用注射器打开和关闭周期(可通过其来控制工艺参数)。
用于实现该方法的模制装置通常应是常规的,且仅注射器的电子促动器的电子单元的构造应被设定为以便实现上述控制方法中的一者、另一者、或二者。
显然,本发明的细节可相对于已描述的和例示的广泛地变化,而不偏离通过以下权利要求限定的保护范围。
Claims (6)
1. 一种用于生产借助于多个注射器(A, B, C, D)将塑性材料注射至模具腔(S)中而模制的制品的模制方法,所述多个注射器(A, B, C, D)根据周期而在电子控制下被电动地顺序地驱动,所述周期对各注射器提供利用所述塑性材料填充所述模具腔的步骤,其中将所述多个注射器从完全关闭状态打开至最大打开状态,之后跟着在所述模具腔中对所述塑性材料进行保压的步骤,其中所述多个注射器被维持在打开状态且然后再次被关闭至完全关闭状态,其特征在于,所述多个注射器(A, B, C, D)不考虑其相对于所述模具腔(S)的位置及其打开速度二者,通过以下控制模式中的至少一者而受到控制:
- 在填充步骤中,将多个注射器从所述最大打开状态部分地关闭至更小地打开的状态,
- 在保压步骤中,将多个注射器设定为部分打开状态且然后将多个注射器打开至更大地打开的状态。
2.根据权利要求1所述的方法,其特征在于,通过两个所述模式来控制注射器。
3.根据权利要求2所述的方法,其特征在于,填充步骤中的多个注射器的所述更小地打开的状态对应于保压步骤中的所述部分打开状态。
4. 根据前述权利要求中的任一项所述的方法,其特征在于,在通过所述多个注射器(A, B, C, D)执行的顺序注射的过程中,填充步骤中的控制模式当随后的注射器正被朝所述最大打开状态打开时,将部分关闭提供至各注射器的所述更小地打开的状态。
5. 一种用于生产通过塑性材料的顺序注射而模制的制品的模制装置,包括具有腔(S)的模具、多个注射器(A, B, C, D),所述多个注射器(A, B, C, D)通过电子控制器而被电动地驱动,所述电子控制器构造成对各注射器执行利用所述塑性材料填充模具腔的步骤,其中将多个注射器从完全关闭状态打开至最大打开状态,之后跟着在所述模具腔中对所述塑性材料进行保压的步骤,其中将多个注射器维持在打开状态且然后再次关闭至完全关闭状态,其特征在于,所述电子控制器构造成以至于多个注射器不考虑其相对于所述模具腔(S)的位置及其打开速度,通过以下控制模式中的至少一者而受到控制:
- 在填充步骤中,将多个注射器从所述最大打开状态部分地关闭至更小地打开的状态,
- 在保压步骤中,将多个注射器设定为部分打开状态且然后将多个注射器打开至更大地打开的状态。
6.根据权利要求5所述的装置,其特征在于,各注射器包括针阀,所述针阀能够借助于相应的电动促动器而轴向地移位。
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