CN109514805B - 生产由注射模制的塑料材料制成的中空物品的方法和装置 - Google Patents

生产由注射模制的塑料材料制成的中空物品的方法和装置 Download PDF

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CN109514805B
CN109514805B CN201811100768.0A CN201811100768A CN109514805B CN 109514805 B CN109514805 B CN 109514805B CN 201811100768 A CN201811100768 A CN 201811100768A CN 109514805 B CN109514805 B CN 109514805B
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plastic material
needle valve
injector
injection
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M.巴佐
M.罗希
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Inglass SpA
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Abstract

用于借助模具（1）生产由注射模制的塑料材料制成的中空物品（C）的方法和装置，所述模具（1）具有铸模（3）和包括针阀（8）的至少一个注射器（6），型芯（4）插入铸模（3）中，所述针阀（8）可在关闭位置和打开位置之间移动以将加压的塑料材料注射到所述铸模（3）和所述型芯（4）之间所构成的空间中。在注射期间，检测所述型芯（4）的任何挠曲变形并且以控制的方式使所述注射器（6）的或每个注射器（6）的所述针阀（8）移动以调节所述所注射的塑料材料的压力和流率，以便减小或消除这种变形。

Description

生产由注射模制的塑料材料制成的中空物品的方法和装置
技术领域
本发明总体关于塑料材料的注射模制，并且它尤其关于用于生产由注射模制的塑料材料制成的中空物品的方法和装置。
背景技术
通常借助模具来实施由塑料材料制成的中空物品的注射模制，所述模具具有限定型腔的铸模，型芯插入所述型腔中。包括可在关闭位置和打开位置之间移动的针阀的至少一个注射器将加压的塑料材料注射到模具和型芯之间所构成的空间中。由流体致动器或电动致动器实施注射器的针阀的位移，在第二种情况下，例如由旋转马达来实施，如申请人的文献US-9102085中所描述和说明的。
在注射模制中空物品尤其是具有细长形状且具有薄壁的中空物品时，出现关于如下事实的问题：在填充模具和型芯之间所构成的空间的步骤期间，由于所注射的塑料材料的不可避免的不平衡以及以不平衡的方式作用在型芯的一侧上和相对侧上，型芯可能发生位移或挠曲变形。
型芯的位移或变形导致几个缺点，比如型芯可能破裂、所模制的部件的美学缺陷，以及最重要的，这些部件由于不能满足相关设计标称厚度要求而导致的结构缺陷。
模制专家目前在型芯中和铸模中使用不同的传感器并且基于并置的传感器之间的压力差或基于传感器所达到的最大值来限制注射。然而，这仅具有在注射和注射后的步骤期间避免破坏的唯一目的，例如由于不能抽出部件并且不能控制型芯变形的事实。
多年以后，申请人已经设计并开发了被称为FLEXflow®的伺服驱动充填系统，该系统确保了在模制过程期间对所注射的材料的压力和流动的精确控制。尤其是，电子控制注射器的或每个注射器的致动器使得以可编程的方式来调节针阀的位置、速度和加速度，以便调节所注射的塑料材料的压力和流动速率。
发明内容
本发明的目的是通过使前述的伺服驱动充填方法应用到并适合于中空物品的注射模制来以有效的方式克服上文描述的技术问题，并以此消除前述的缺点。
以达到这样的目的为目标，根据第一方面，本发明实现了开始所定义的类型的注射模制方法，该方法的主要特点在于这样的事实：在注射期间，检测型芯的挠曲变形并且存在注射器的或每个注射器的针阀的受控的位移，并且通过调节所述针阀的位置、速度、加速度和行程中的至少一者来实施位移控制直到减小和消除这样的变形。
以检测型芯的挠曲变形为目标，本发明实现了测量型芯的任何变形或测量型芯的自由端的位置，并可能结合对所注射的塑料材料的压力的检测。
在本发明的优选实施例中，借助定位在型芯的相对两侧处的至少一对注射器发生塑料材料的注射。
由于这个解决方案的想法，在受控地填充铸模和型芯之间所构成的空间的步骤期间，消除了不平衡和因此造成型芯的弯曲，因此避免了可能的破裂并因此消除了模制物品的美学和结构缺陷。尤其是，可以精确地满足设计标称厚度要求。
根据另一方面，本发明关于用于实施本方法的装置，其主要特征在于，所述装置包括至少一个传感器，所述传感器适合于在注射期间检测型芯的挠曲变形并且连接到电子控制单元，所述电子控制单元构造成通过调节针阀的位置、速度、加速度和行程中的至少一者来执行注射器的或每个注射器的针阀的受控的位移，直到减小或消除任何变形。
以实施本发明为目标，所述模制装置可以包括一个或多个注射点、或一个或多个注射器，所述注射器的针阀由气动致动器、液压致动器或电动致动器致动，并且在所述模制装置中可以借助所述型芯的基部的至少一个变形换能器和/或所述型芯的自由端的至少一个位置换能器并可能结合所注射的塑料材料的压力换能器来实施型芯变形检测。例如感应类型或等同类型的位置换能器可以定位在所述型芯的自由端附近或在铸模上或在所述铸模和所述型芯之间所构成的空间中。
附图说明
现将仅通过非限制性的示例参考附图来详细描述本发明，其中：
图1是根据本发明的实施例的注射模制装置的局部截面示意性视图。
图2、3、4、5和6是举例说明根据现有技术的注射方法和相关缺点的示意图。
图7、8、9、10和11是类似于图2-6的示意图但关于本发明的示意图，以及
图12是使用根据本发明的注射模制方法和装置所得到的中空物品的示例的示意性透视图。
具体实施方式
接下来的描述涉及借助注射模制来生产由塑料材料制成的中空物品，比如图12示意性表示并用C指示的中空物品：它是具有细长形状（例如长度等于350 mm）和薄壁（例如标称厚度等于2 mm）的容器。
使用图1示意性表示的装置来生产容器C，该装置包括具有型腔2、铸模3、型芯4和用于将塑料材料注射到空间中的系统的模具1，型芯4可以与铸模（3）联接以界定对应于容器C的形状的所述空间。
所述注射系统通常包括由压力机供应并在所图示的示例的情况下连接到一对注射器6的热流道或热室5，这一对注射器6相对模具1的型腔2布置在相对两侧上。应当注意到，注射器的数量和布置可以与示例中所图示的注射器的数量和布置不同。
每个注射器6以本身已知的方式包括喷嘴7，在喷嘴7中存在可轴向移动的针阀8，针阀8可在完全关闭的位置和用于将加压的塑料材料注射到铸模3和型芯4之间所构成的空间中的最大开口位置之间移动。每个针阀8的位移由流体或更方便地电力类型（例如旋转类型）的相应的致动器9来控制，借助电子控制单元10来控制致动器9。
控制单元10被编程以便控制每个致动器9，并因此控制每个注射器6，以便调节由其注射的塑料材料的压力和流率。该控制尤其可实现在填充步骤期间对针阀8的位置、速度、加速度和行程的调节。
图2和3是示出了根据现有技术提供的用于模制比如容器C的物品的注射方法的示意图。这些方法不能实现前述电子单元10对注射器的控制，因此在流率和压力方面，两个注射器以相同的方式注射塑料材料。尤其是，图2的示意图（在图2中，虚构地示出两个注射器在不同的时间打开，然而它们实际上同时打开）示出在打开步骤期间两个注射器的针阀的作为时间的函数的位置，型芯4的随时间增大的弯曲或非受控的挠曲变形对应于该位置。在注射结束时，型芯4具有由图4以虚构的放大形式表示的弯曲的构造，该构造相对于没有弯曲的状态具有例如大于0.3 mm的位移。由于这种变形，在注射结束时从模具移除的容器C具有图5和6举例说明的结构缺陷：容器C的对应于型芯4的挠曲变形的内面的较大部分（图5）具有从容器C的端部边缘朝着底部逐渐减小的厚度，同时对应于型芯4的挠曲变形的外面侧的其它较大壁则对应地具有从容器C的端部边缘朝着其底部壁逐渐增大的厚度。在标称壁厚度等于2 mm时，较少或过量的压力变化可能因此也大大高于10%，并且这可能是不能接受的。
图7-11是关于本发明的对应于图2至6的示意图，即借助由电子单元10执行的对每个注射器6的针阀8的位移的控制。这种针对每个致动器9单独实施的控制与相应的针阀8的位置、速度、加速度和行程有关并且它基于来自适合于检测型芯4在注射期间的挠曲变形的换能器的信号
这种换能器可以是多种类型的并且它们可以设置在不同的区域中。就类型而言，可以使用型芯的基部的一个或多个变形换能器，比如图1中用11扼要表示的换能器，或型芯的自由端的一个或多个位置换能器（例如感应式传感器），也可以将它们彼此组合甚至与所注射的塑料材料的一个或多个压力换能器组合。就它们的位置而言，除了已经指出的以外，换能器可以设置在型芯4上、铸模3上以及铸模3和型芯4之间所构成的空间中。
因此由电子单元10实施的控制使得校正并消除型芯4的可能检测到的弯曲，因此通过作用于由一个和/或另一个注射器6供应的塑料材料的流率和压力而使型芯4回到其没有弯曲的状态。
图8的示意图示出了校正示例：在达到最大值时，在接近注射的最后步骤抵消并消除型芯4的被检测到的变形，以便使型芯4回到图9表示的初始的没有弯曲的状态。因此，如图10和11所指出的，容器C的较大壁的厚度几乎是恒定的并且大致对应于设计标称值（2mm）。
明显地，在不偏离随后的权利要求中所描述的本发明的保护范围的情况下，用于实施根据本发明的方法的装置的构造细节和实施例可以相对已经描述和说明的内容广泛地变化。因此，例如，如之前阐明的，注射器的数量和位置将取决于待模制的物品的形状和尺寸。在小尺寸物品的情况下，所述注射器甚至可以是一个。
此外，尽管描述明确提及完全自动的控制过程，但是本发明的保护范围也覆盖半自动或手动的方法，在这些方法中例如实施了检测任何变形的第一注射、如果必要的话修正注射器的或每个注射器的参数，并且然后再次实施注射、再次检测任何变形并且如果必要的话实施对注射参数的随后的调节，直到消除变形。

Claims (10)

1.一种借助模具（1）来生产由注射模制的塑料材料制成的中空物品（C）的方法，所述模具（1）具有限定型腔（2）的铸模（3）和至少一个注射器（6），型芯（4）插入所述型腔（2）中，所述注射器（6）包括可在关闭位置和打开位置之间移动以将加压的塑料材料注射到所述铸模（3）和所述型芯（4）之间所构成的空间中的针阀（8），并且其中以控制的方式致动所述注射器（6）的或每个注射器（6）的所述针阀（8）的位移以便调节所注射的所述塑料材料的压力和流率，其特征在于，在注射期间检测型芯（4）的任何挠曲变形并且通过调节所述针阀的位置、速度、加速度和行程中的至少一者来致动所述注射器（6）的或每个注射器（6）的所述针阀（8）的受控的位移直到减小或消除这种变形，
其中，为了检测所述型芯（4）的挠曲变形，测量所述型芯（4）的自由端的位置。
2.根据权利要求1所述的方法，其特征在于，为了检测所述型芯（4）的挠曲变形，测量所述型芯（4）的基部的变形、所注射的所述塑料材料的压力中的一者或它们的组合。
3.根据权利要求1或权利要求2所述的方法，其特征在于，借助位于所述型芯（4）的相对两侧处的至少一对注射器（6,6）来实施注射。
4.一种塑料材料注射模制装置，包括模具（1），所述模具具有限定型腔（2）的铸模（3）、包括针阀（8）的至少一个注射器（6）、用于控制所述针阀（8）的位移的致动器（9）和电子单元（10），型芯（4）插入所述型腔（2）中，所述针阀（8）可在关闭位置和打开位置之间移动以将加压的塑料材料注射到所述铸模（3）和所述型芯（4）之间所构成的空间中，所述电子单元（10）操作地连接到所述致动器（9）以便使所述针阀（8）以受控的方式移动并且调节所注射的所述塑料材料的压力和/或流率，其特征在于，所述装置包括至少一个传感器（11），所述传感器（11）设计成检测所述型芯（4）在注射期间的任何挠曲变形并且连接到所述电子单元（10），所述电子单元（10）构造成通过调节所述针阀的位置、速度、加速度和行程中的至少一者来执行所述注射器（6）的或每个注射器（6）的所述针阀（8）的受控的位移直到减小或消除这种变形。
5.根据权利要求4所述的装置，其特征在于，所述至少一个传感器选自所述型芯（4）的基部的变形换能器（11）、所述型芯（4）的自由端的位置换能器、所注射的所述塑料材料的压力换能器或它们的组合。
6.根据权利要求5所述的装置，其特征在于，所述型芯（4）的自由端的所述位置换能器是感应类型的。
7.根据权利要求4至6中的任一项所述的装置，其特征在于，所述至少一个传感器定位在所述型芯（4）上。
8.根据权利要求4至6中的任一项所述的装置，其特征在于，所述至少一个传感器安装在所述铸模（3）上。
9.根据权利要求4至6中的任一项所述的装置，其特征在于，所述至少一个传感器定位在所述铸模（3）和所述型芯（4）之间所构成的空间中。
10.根据权利要求4至6中的任一项所述的装置，其特征在于，所述装置包括位于所述型芯（4）的相对两侧的至少一对注射器（6,6）。
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