CN107672146B - 一种聚乙烯发泡棉的造型加工工艺 - Google Patents
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Abstract
一种聚乙烯发泡棉(ＥＰＥ珍珠棉)的造型加工工艺包括以下工序，备料工序，把材料切片、冲裁加工成合适大小的毛坯料；开模工序，制作型腔和目标产品形状一致的模具，开模过程中要考虑具体形状安排制作排气孔或者抽真空装置；塑形和定型工序，通过把毛坯材料加热后用模具压成型，并且冷却定型，在压制的过程中要排气或者抽真空使之和模具吻合制作出半成品；整理工序，把成型好的半成品拿出模具，修整成产品的工序；本发明造型加工工艺，能够把此材料比较方便的加工成各种特别造型的产品，减少了人工成本，避免了使用胶水，减少了环境污染，提高了工作效率，突破了该产品推广程度不够的瓶颈，扩大了使用范围。
Description
技术领域
本发明属于聚乙烯发泡棉的再加工技术领域，具体涉及的是一种聚乙烯发泡棉(ＥＰＥ珍珠棉)的造型加工工艺。
背景技术
聚乙烯发泡棉是非交联闭孔结构，又称 EPE 珍珠棉 , 是一种新型环保的包装材料；它由低密度聚乙烯经物理发泡产生无数的独立气泡构成；克服了普通发泡胶易碎、变形、恢复性差的缺点；具有隔水防潮、防震、隔音、保温、韧性强、循环再造、环保、抗撞力强等诸多优点，亦具有很好的抗化学性能，是传统包装材料的理想代替品，可是目前的造型基本都是用冲裁，贴合以及打磨的方式造型加工造型，人工成本比较高，并且需要使用胶水，增加浪费和环境污染，成本过高，并且很难造出特别的形状，是此材料应用推广的一个瓶颈。
发明内容
本发明的目的在于克服现有聚乙烯发泡棉造型技术的不足，提供一种减少人工成本，杜绝胶水使用，可以制作出来特别形状的聚乙烯发泡棉(ＥＰＥ珍珠棉)的造型加工工艺。
本发明技术方案是：一种聚乙烯发泡棉(ＥＰＥ珍珠棉)的造型加工工艺，其特征在于：包括以下步骤，
第一步，备料工序，将聚乙烯发泡棉进行切片处理，其切片处理程度比目标产品厚度厚1-10毫米，冲裁到比目标产品形状大1-30毫米的毛坯料；
第二步，开模工序，根据目标产品的具体造型不同，开发制作成型腔和目标产品一致的二方向开，三方向开或者多方向开的模具；此模具制作时根据产品不同的造型制作排气孔，或者制作抽真空的装置；
第三步，塑形工序，把第一步制作的聚乙烯发泡棉毛坯料先在80度-130度加热，并恒定30秒到300秒，或者用烘箱加热到80度-130度恒定30秒到300秒后放进第二步制作的特定模具内后，模具用6吨到120吨之间的压力压死定型到使得材料变成可塑的状态；
第四步，定型工序，聚乙烯发泡棉毛坯料变成可塑状态后，模具关模的同时根据具体造型的需要排气或者抽真空反向增压使得毛坯料到位，使之和模具吻合，再把连同里面的加热到位的毛坯料的模具在保持压力的状态下冷却到50度-零下50度之间定型10秒到600秒，使得聚乙烯发泡棉毛坯料全部冷却到20左右以下保持10秒以上使得定型成功；
第五步，整理工序，把塑形定型成功的半成品从模具内起出，可以用修边机或者制作冲刀冲裁，或者人工修剪，激光切割等方式修剪掉多余的毛边，产品辅助部分，使之成为最终成品。
本发明的有益效果在于：与现有技术相比，本发明利用聚乙烯发泡棉材料在80度—130度之间开始变得不稳定但是性能不会改变的物理特性，通过模具内加压力冷却后再次塑形方法，并且通过对此材料的非交联闭孔结构的物理特性使用了排气，或者抽真空的方式让模具内毛坯材料向模具方向增加压力，使之完全和模具的造型相吻合的方法，使得此材料可以比较方便的制作出各种不同的特别造型的产品，大量节省了人力，提高工作效率，杜绝使用胶水，减少环境污染，突破了加工困难推广程度不够的瓶颈，增加了材料的使用范围。
具体实施方式
一种聚乙烯发泡棉(ＥＰＥ珍珠棉)的造型加工工艺，具体包括以下步骤，
第一步，备料工序，聚乙烯发泡棉又称ＥＰＥ珍珠棉的备料，即把聚乙烯发泡棉切片到比目标产品厚度增加1-10毫米，具体增加厚度需要根据目标产品的具体厚度来确定，冲裁到比目标产品形状大1-30毫米的毛坯料，具体大多少需要根据目标产品的具体大小和形状来确定；
第二步，开模工序，根据目标产品的具体造型不同开发制作成二方向开，三方向开以致多方向开的型腔和目标产品一致的模具；此模具制作时要考虑根据产品不同的造型，合理安排模具开模结构，在对应的材料比较难达到的位置制作排气孔，材料特别难达到的地方需要安排制作抽真空装置，增加材料吻合模具的力量，让产品塑形效果更加理想，模具可以用铜，铁，铝，或者合金材料制造，根据产品的需求可以用特氟龙，电镀，喷砂等工艺提高产品表面效果；
第三步，塑形工序，把聚乙烯发泡棉毛坯料根据需要加热到80度—130度恒定30秒到300秒，或者用烘箱加热到80度—130度恒定30秒到300秒后放进模具，具体工作温度需要根据具体材料的特性调整，加热时间根据具体产品形状调整，模具用6吨到120吨之间的压力压死定型，使用压力大小要根据产品大小调整，可以使用油压机，空气压力机，或者机械杠杆等方式达到目的；
第四步，定型工序，模具关模的同时根据具体造型的需要排气或者抽真空增压使得毛坯料到位，和模具型腔吻合，需要加排气孔或抽真空加压根据具体产品造型确定，再把里面有加热到位的毛坯料的模具再保持压力的状态下冷却到50度—零下50度之间定型10秒到600秒，使得聚乙烯发泡棉毛坯料全部冷却到20度左右保持10秒以上进行定型，定型温度和时间需要根据产品的大小和形状、材料本身的特性调整，使得定型成功基本和目标产品一致，变成半成品；
第五步，整理工序，把塑形定型成功的半成品从模具内起出，修剪掉多余的毛边，产品辅助部分，有多少毛边和具体的不需要的产品辅助部分根据产品的造型的不同，在制造模具的时候确定，可以用修边机或者制作冲刀冲裁，或者人工修剪，激光切割等方式使之成为成品。
Claims (1)
1.一种聚乙烯发泡棉的造型加工工艺，其特征在于：包括以下步骤，
第一步，备料工序，将聚乙烯发泡棉进行切片处理，将聚乙烯发泡棉切片到比目标产品厚度厚1-10毫米，冲裁成比目标产品形状大1-30毫米的毛坯片料；
第二步，开模工序，根据目标产品的具体造型，制作成型腔和目标产品一致的二方向开、三方向开或者多方向开的模具，模具表面进行电镀或喷砂处理；在模具中材料比较难到达的位置制作排气孔，在材料特别难到达的位置制作抽真空的装置；
第三步，加热工序，把第一步制作的毛坯片料先在80度-130度的温度下加热，并恒定30秒到300秒；
第四步，塑形工序，把加热后的毛坯片料放进第二步制作的模具内，用6吨到120吨之间的压力压死模具，定型到使得材料变成可塑的状态；
第五步，定型工序，聚乙烯发泡棉毛坯片料变成可塑状态后，模具关模的同时根据具体造型的需要排气以及抽真空反向增压使得材料到达比较难到达和特别难到达的位置，使之和模具吻合，再把里面具有加热到位的材料的模具在保持压力的状态下冷却到50度-零下50度之间定型10秒到600秒，使得聚乙烯发泡棉全部冷却到20度以下保持10秒以上，使得定型成功；
第六步，整理工序，把塑形定型成功的半成品从模具内起出，用修边机修边或者用冲刀冲裁，或者采用人工修剪或激光切割的方式修剪掉多余的毛边和产品辅助部分，使之成为最终成品。
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| CN104175566A (zh) * | 2014-08-29 | 2014-12-03 | 深圳市欣佳昱橡塑有限公司 | 复合材料异形产品成型工艺 |
| CN105082444A (zh) * | 2015-07-15 | 2015-11-25 | 浙江三箭工贸有限公司 | 饰板压模方法 |
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