CN114347375A - Thick-walled optical waveguide and layered injection molding method thereof - Google Patents
Thick-walled optical waveguide and layered injection molding method thereof Download PDFInfo
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- CN114347375A CN114347375A CN202111435262.7A CN202111435262A CN114347375A CN 114347375 A CN114347375 A CN 114347375A CN 202111435262 A CN202111435262 A CN 202111435262A CN 114347375 A CN114347375 A CN 114347375A
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Abstract
The invention relates to a thick-wall light guide part and a layered injection molding method thereof in the technical field of injection molding, which are formed by injection molding through a fixed die and a movable die and comprise the following steps: s1, profile division: dividing the profile of the thick-wall light guide into two parts, respectively marking the two parts as a first-layer profile and a final-layer profile, wherein the butt joint line of the first-layer profile and the final-layer profile is superposed with the contour line of the thick-wall light guide; s2, first-layer profile injection molding: the first-layer molded surface is formed in a first fixed station of the fixed die in an injection molding mode, and the first-layer molded surface is moved to a second fixed station of the fixed die through the movable die; s3, middle layer injection molding: sequentially injecting M layers of intermediate layers from a second fixed station to an N-1 fixed station of the fixed die; s4, final layer profile injection molding: and injection molding a final layer profile on an Nth fixed station of the fixed die, wherein the first layer profile is in butt joint with the final layer profile, and the middle layer is wrapped between the first layer profile and the final layer profile. The invention can eliminate the adverse effect on the light guide effect of the product of the thick-wall light guide piece due to the parting line.
Description
Technical Field
The invention relates to the technical field of injection molding, in particular to a thick-wall light guide and a layered injection molding method thereof.
Background
The thick-wall light guide block has the functions of enabling the appearance to be attractive and guiding light in the design of the car lamp with the LED as a light source. The injection molding cycle of the thick-walled plastic product of single-layer injection molding is long, the production efficiency is low, and the defects of sink marks and the like are generated because effective pressure maintaining can not be provided, so that the gate is enlarged for providing effective pressure maintaining, and the large gate brings obvious gate residual marks to the product, thereby bringing bad influence to optics and attractiveness. Single-layer injection molding, namely one-step injection molding, and the cooling period of the plastic product causes low production efficiency; pressure maintaining: if the mold cavity is not kept pressure after being filled, the product shrinks by about 25% in a large scale, and particularly, shrinkage marks are formed at the ribs due to excessive shrinkage.
In the prior art, the gate of single-layer injection molding is a side gate, and the pressure can be more and more increased along with the increase of the flowing length of the material, so that the pressure maintaining of the product is not facilitated, and the defects of shrinkage and the like are easily caused.
Through retrieval, the Chinese invention patent publication No. CN106738597B discloses a method for realizing three-layer four-station injection molding of a thick-wall part, and discloses a method for realizing three-layer four-station injection molding of a thick-wall part, wherein the injection molding sequence is as follows: firstly, injection molding the middle layer, then injection molding the upper side of the periphery of the middle layer, and finally injection molding the lower side of the periphery of the middle layer; arranging a fixed die and a movable die to realize injection molding; the fixed dies are uniformly arranged in four positions at a distance of 90 degrees, and the movable dies are uniformly arranged in four positions at a distance of 90 degrees. By repeated rotation, the products move and stay in a fixed mode in an exchange manner. The movable mold needs to rotate forward and backward, the product subjected to first injection molding is conveyed to the last station in the clockwise direction and the anticlockwise direction, and production starting is complex. The product is subjected to injection molding, moving mold, fixed mold and ejection, and the plastic product is repeatedly positioned, so that the positioning precision and positioning are ensured without damaging the product, which is a challenge. Although there are four stations in the above-mentioned scheme, but its product divides three injection molding to accomplish. However, the second and third injection molds are the top and bottom halves of the injection molded product, and the third injection mold does not increase the overall wall thickness. Second, three shots of the upper and lower halves of the product, respectively, create a parting line in the middle of the product, as shown in FIG. 1. Parting lines can affect optics and aesthetics.
For example, chinese patent publication No. CN105818325B discloses a thick plastic part surrounding type layered injection molding method, a mold structure thereof, and a lens product, wherein an intermediate plate is disposed between a fixed mold plate and a movable mold plate, the intermediate plate is rotated to perform a core rotation operation, an intermediate cavity in a cavity state after a part taking operation is rotated to a first station, and a product primary molding cavity is formed by closing the molds; and rotating the intermediate plate carrying the primary product mold to a second station, and closing the mold to form secondary mold forming cavities surrounding two sides of the primary product mold, so that multilayer injection molding is realized. The surrounding type layering scheme of the invention requires that special ribs are designed on the first layer for positioning, and the injection-molded first layer product needs to leave the cavity and return to the cavity, so that the precision of repeated positioning is a great test.
Disclosure of Invention
In view of the drawbacks of the prior art, it is an object of the present invention to provide a method for layered injection molding of thick-walled light guides.
According to the layered injection molding method of the thick-wall light guide part, provided by the invention, a fixed die and a movable die are adopted for injection molding, wherein the fixed die is provided with N groups of fixed stations, N is a natural number more than or equal to 3, and the layered injection molding method comprises the following steps:
s1, profile division: dividing a profile of the thick-wall light guide into two parts, respectively marking the two parts as a first-layer profile and a final-layer profile, wherein the first-layer profile and the final-layer profile are butted to form a frame structure of the thick-wall light guide, and a butt joint line of the first-layer profile and the final-layer profile is superposed with a contour line of the thick-wall light guide;
s2, first-layer profile injection molding: the first-layer molded surface is formed on a first fixed station of the fixed die in an injection molding mode, and the first-layer molded surface is moved to a second fixed station of the fixed die through the movable die;
s3, middle layer injection molding: sequentially injecting M layers of intermediate layers from a second fixing station to an N-1 fixing station of the fixed die, wherein M is a natural number larger than or equal to 1, one end of each layer of intermediate layer is in contact with the inner surface of the first-layer molded surface, the other end of each layer of intermediate layer extends towards the direction of the final-layer molded surface, the extending length of the other end of each layer of intermediate layer does not exceed the edge of the first-layer molded surface, and the movable die integrally moves a product formed on the N-2 fixing station to the N-1 fixing station;
s4, final layer profile injection molding: injection moulding on the Nth fixed station of cover half the end layer profile, the first layer profile with the butt joint of end layer profile, the intermediate level wrap up in the first layer profile with between the end layer profile.
In some embodiments, when the first layer profile, the intermediate layer and the final layer profile are injection-molded, the material temperature of the liquid material flowing from the feeding gate to the tail end is reduced by less than or equal to 10 ℃.
In some embodiments, the range of values for M is: m is more than or equal to 1 and less than or equal to 10, and the value of N is M + 2.
In some embodiments, the lamination of the M layers of the intermediate layer is unidirectional lamination.
In some embodiments, a plurality of sets of mold cavities are arranged on the fixing station, and the number of the mold cavities arranged on the first fixing station to the Nth fixing station is the same.
In some embodiments, a rotating station is arranged on the movable mold, a plurality of sets of mold cores are arranged on the rotating station, the number of stations of the rotating station is the same as that of the stations of the fixed station, and the mold cores and the mold cavities are arranged in a matched mode.
In some embodiments, each of the intermediate layer has a layer thickness and the final layer profile has a layer thickness that is less than the layer thickness of the initial layer profile.
In some embodiments, each of the intermediate layers has a layer thickness equal to a layer thickness of the final layer profile, and the layer thickness of the initial layer profile is 2 times the layer thickness of the final layer profile.
In some embodiments, when the first layer profile, the intermediate layer profile and the final layer profile are subjected to injection molding, the inlet and the outlet of the liquid material are selected at the thickest layer thickness of the layer and/or at the middle position close to the layer.
In some embodiments, the gate is a needle valve type point gate, and the aperture of the gate is 0.5-3.5 mm.
The invention also provides a thick-wall light guide part which is prepared by adopting the thick-wall light guide part layering injection molding method.
Compared with the prior art, the invention has the following beneficial effects:
1. according to the invention, the structure of the thick-wall light guide part is divided into the outer wrapping layer comprising the first layer profile and the final layer profile and the middle layer comprising the inner filling layer, so that parting lines among layers of the middle layer, between the middle layer and the first layer profile and between the middle layer and the final layer profile disappear, and the parting lines of the first layer profile and the final layer profile and the product contour line are superposed, so that the bad influence on the light guide effect of the product of the thick-wall light guide part formed by injection molding due to the parting lines is caused, and through layered injection molding, not only can the product eliminate sink marks, depressions and the like due to full pressure maintaining and feeding, but also the production efficiency is improved due to the shortened cooling time.
2. According to the invention, through the optimized design of the thickness of each layer in the layered injection molding process of the product, the cooling time of each layer of the product tends to be consistent, and the production efficiency is further improved.
3. According to the invention, the product is divided into the inlet gate structure and the optimized arrangement of the position in the injection molding process, so that the defects of serious sink marks, depressions and the like of the product are effectively avoided, and meanwhile, the attractiveness of the product is improved.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a schematic view of a parting line in the prior art;
FIG. 2 is a flow chart of the method of the present invention;
FIG. 3 is a schematic view of a layered injection molding process of the present invention;
FIG. 4 is a schematic view showing the position of an in-gate in the layered injection molding of the present invention;
FIG. 5 is a schematic view of a product structure of the lower injection molding of the present invention.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
Example 1
The invention provides a thick-wall light guide part layered injection molding method, which adopts a fixed mold and a movable mold for injection molding, wherein the fixed mold is provided with N groups of fixed stations, the value of N is a natural number which is more than or equal to 3, the matched fixed mold is matched with the fixed mold, the number of working positions of rotating stations arranged on the movable mold is the same as the number of fixed working positions on the fixed mold, simultaneously, each group of fixed stations of the fixed mold is provided with a mold cavity, each group of rotating stations is provided with a mold core matched with the mold cavity, each layer of products forming the thick-wall light guide piece are completed through a series of actions of matching a fixed mold and a movable mold, the specific action sequence comprises mold closing, injection molding, pressure maintaining, cooling, mold opening and ejection in sequence, after one layer of products are injection molded, and moving the upper layer of product to the next fixed station through the rotation of the movable die, and performing the actions of mold closing, injection molding, pressure maintaining, cooling, mold opening and ejection in a circulating manner until a thick-wall light guide product is formed on the Nth fixed station. Preferably, the group number of die cavities that set up on the fixed station is multiunit, and the looks adaptation, and the group number of the mold core that sets up on the rotation station also is multiunit, and the group number of die cavity and the group number looks adaptation of mold core, through the adaptation of the die cavity of multiunit and mold core promptly, can produce a plurality of thick wall light guides simultaneously, improves production efficiency. As shown in fig. 2, the specific split injection molding method comprises the following steps:
step S1, profile division: by profile is meant the respective faces of the thick-walled light guide to be injection molded, i.e. the six faces of the six views of the thick-walled light guide. According to the structural shape of the thick-wall light guide piece, the molded surface of the thick-wall light guide piece is divided into two molded surfaces, namely a first-layer molded surface and a final-layer molded surface, the first-layer molded surface and the final-layer molded surface are in butt joint to form the integral molded surface of the thick-wall light guide piece, the butt joint line of the first-layer molded surface and the final-layer molded surface is coincided with the contour line of the thick-wall light guide piece, and the parting line of the surface of the formed thick-wall light guide piece can be the contour line.
Step S2, injection molding of the first layer of molded surface: the first layer of molded surface is the first layer of the thick-wall light guide part and is also used as a substrate layer, injection molding is completed according to the actions of the fixed die and the movable die, and the first layer of molded surface is ejected out and moves to a die cavity on a fixed station forming the middle layer after moving through the rotation of the movable die.
Step S3, injection molding of the middle layer: the intermediate layer is a sandwich layer positioned between the first layer molded surface and the final layer molded surface, and the intermediate layer is completely wrapped by the first layer molded surface and the final layer molded surface. In the process of integrating the intermediate layer with the first-layer molded surface, due to the melting effect of the material temperature, the contact position of the inner surface of the first-layer molded surface and the side surface of the intermediate layer is integrated due to the melting effect of the material temperature, and a parting line between the first-layer molded surface and the intermediate layer is eliminated.
Preferably, the intermediate layer is designed to be a multilayer structure, and the number of the intermediate layer is M, wherein M is a natural number greater than or equal to 1. The shape and thickness of each interlayer are substantially the same, and the interlayer of the multilayer structure is connected in a unidirectional lamination mode, wherein the unidirectional lamination refers to a vertical lamination type structure formed in the same liquid flowing direction during injection molding. The intermediate layer adopts a multi-layer injection molding method, so that the cooling time of each layer of the product including the first layer molded surface and the final layer molded surface can be approximately the same, the phenomenon that the production beat is tired due to too large thickness of partial layer in the product can be avoided, and the production efficiency is improved. Further, the number of layers of the intermediate layer is 10 or less, that is, the value of M is less than 10, and it is particularly preferable that the value of M is selected from 2 to 6. Suitably, the value of the number of fixed stations N on the fixed film is 2 more than the number of layers in the intermediate layer, i.e. N equals M + 2.
Step S4, final layer profile injection molding: the fused body of the first layer of molded surface and the middle layer on the (N-1) th fixed station is moved to the (N) th fixed station through the movable die, injection molding is carried out through a glue inlet on a die cavity on the (N) th fixed station to form a final layer of molded surface, in the forming process of the final layer of molded surface, the residual side surface and/or end surface of the middle layer are respectively contacted with the inner surface of the final layer of molded surface and fused into a whole, so that a parting line does not exist between the middle layer of molded surface and the final layer of molded surface, the parting line of the first layer of molded surface and the final layer of molded surface is located on a product contour line, and the surface of the finally formed product thick-wall light guide part does not have a parting line.
By adopting the method, taking 2 layers as an example of the middle layer, the process of the layered injection molding of the thick-wall light guide is shown in fig. 2, wherein 1 is a first-layer molded surface, 2 is a first middle layer, 3 is a second middle layer, and 4 is a final-layer molded surface, the surface of the formed thick-wall light guide 5 has no parting line by adopting the design method, the parting line exists at two points b and c and is coincided with the contour line of the thick-wall light guide 5, the parting line in a real object diagram is shown in fig. 5, and the dotted line is the parting line and is coincided with the contour line.
According to the invention, the structure of the thick-wall light guide part is divided into the outer wrapping layer comprising the first layer profile and the final layer profile and the middle layer comprising the inner filling layer, so that parting lines among layers of the middle layer, between the middle layer and the first layer profile and between the middle layer and the final layer profile disappear, and the parting line of the first layer profile and the parting line of the final layer profile coincide with the product contour line, thus the adverse effect on the illumination effect caused by the existence of the parting line after the layered product is manufactured is eliminated, and through layered injection molding, not only can the product be eliminated from sink marks, depressions and the like due to the full pressure maintaining and feeding, but also the production efficiency is improved due to the shortened cooling time.
Preferably, in the injection molding process of the first layer of molded surface, each middle layer of molded surface and the final layer of molded surface, the temperature reduction range of the material of which the high-temperature liquid material flows from the feeding gate to the tail end is less than or equal to 10 ℃, the fusion connection between layers can be better realized, and the elimination effect of parting lines is further improved. For example, in the case of PMMA, the typical material temperature is 235 deg.C, the mold temperature is 75 deg.C, and the temperature of the flow front flowing to the end is not lower than 225 deg.C.
Example 2
The embodiment 2 is formed on the basis of the embodiment 1, and the cooling time of each layer of product tends to be consistent through the optimized design of the thickness of each layer in the layered injection molding process of the product, so that the production efficiency is further improved. Specifically, the method comprises the following steps:
the layer thickness of first floor's profile is greater than the thickness of each intermediate level and the thickness of final floor profile, the reason why the layer thickness of first floor profile sets up thickest lies in, there are two steel material cooling surfaces when forming first floor profile, the cooling rate is very fast, and it has only a steel material cooling surface as each intermediate level and final floor profile, another face is the plastic cooling surface, the heat-sinking capability of plastic is relatively weak, therefore, the thickness of each intermediate level and final floor profile all is less than the thickness of first floor profile, the temperature when making each layer of injection moulding from first floor profile to final floor profile can tend to unanimity. For example, typical die steels have a thermal conductivity of about 29w/m2C, and plastic PMMA has a thermal conductivity of typically no more than 0.25w/m2C, the former being 100 times that of the latter, and for simplicity, assuming no heat conduction at all on the side in contact with the plastic, the preferred thickness profile is the thickest thickness of the first layer of the product in order to approximate the cooling time of each layer. On the basis of the thickest profile of the first layer, the thickness of each layer of the middle layer and the thickness of the profile of the final layer can be the same or different, and when the appearance quality of the product is further improved, the thickness of the profile of the final layer can be thinner than that of each layer of the middle layer, so that better pressure maintaining and cooling time is obtained, and high appearance quality is further obtained; when the layer thickness of each intermediate layer and the layer thickness of the final layer molded surface are half of the layer thickness of the first layer molded surface, the cooling time from the first layer molded surface to the final layer molded surface is basically consistent, and the production efficiency can be improved to the greatest extent.
Example 3
the mold cavity is provided with a gate, when each layer is molded by injection, the material liquid is injected through the gate, and when each layer is molded by injection, the gate is positioned at the position with the thickest layer thickness of each layer of product, and most preferably, the gate is positioned close to the middle position of each layer of product, as shown in fig. 4, the gate positions of each layer represented by the four positions 6, 7, 8 and 9 are the positions with the thickest layer thickness and close to the middle position of the layer of product. By adopting the design, the plastic is filled from thick to thin, so that the problems of product stagnation and insufficient filling can be effectively solved, and the product can obtain sufficient pressure maintaining. The principle is as follows: the layered design, while hiding the parting line of the product in the corners of the product, adds challenges to the product shape of the first and last layers of profiles from the problem of the sharp edges that can cause under-filling or stagnant flow, mainly because the molten plastic is a fluid that preferentially goes to the condor major road when facing the crossroads and lacks interest in the small intestine. If the inlet gate is arranged on the side, the fluid is selected to be the intersection at the beginning of the flow, so that the sharp thin wall of the inlet gate cannot be filled later to generate stagnation, and the material can be frozen quickly because the sharp thin wall cannot be filled later to form a short shot or low-quality surface. After the design is adopted, namely the thin wall is placed at the tail end of filling, the fluid almost does not need to face the selection of the crossroad, so that the fluid can smoothly and stably fill each space, the pressure distribution of each layer of products in the filling process is uniform, the shrinkage ratio of the materials is consistent, and the defects of serious sink marks, depressions and the like of the products are effectively avoided.
More preferably, the inlet gate is a needle valve type point gate, and the aperture of the inlet gate is 0.5-3.5 mm. The inlet gate is a needle valve type point gate, so that the uniform filling and the sufficient pressure maintaining can be ensured, and compared with the problem that the inlet gate existing in the traditional side gate is easy to cause that the subsequent material cannot be supplemented into a mold cavity due to freezing, the labor or equipment investment for repairing and reducing the gate is saved by adopting the gate hole of the needle valve type point gate structure, and the visible residual gate trace is only limited to the gate hole with the last layer of hole diameter not larger than 3.5mm, namely the diagram of the inlet gate of the last layer is shown as 10 in figure 5, so that the great freedom is provided for the product design, and the attractiveness of the product is ensured.
In the description of the present application, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing the present application and simplifying the description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present application.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (10)
1. A thick-wall light guide part layering injection molding method is characterized in that a fixed die and a movable die are adopted for injection molding, wherein N groups of fixed stations are arranged on the fixed die, N is a natural number more than or equal to 3, and the method comprises the following steps:
s1, profile division: dividing a profile of the thick-wall light guide into two parts, respectively marking the two parts as a first-layer profile and a final-layer profile, wherein the first-layer profile and the final-layer profile are butted to form a frame structure of the thick-wall light guide, and a butt joint line of the first-layer profile and the final-layer profile is superposed with a contour line of the thick-wall light guide;
s2, first-layer profile injection molding: the first-layer molded surface is formed on a first fixed station of the fixed die in an injection molding mode, and the first-layer molded surface is moved to a second fixed station of the fixed die through the movable die;
s3, middle layer injection molding: sequentially injecting M layers of intermediate layers from a second fixing station to an N-1 fixing station of the fixed die, wherein M is a natural number larger than or equal to 1, one end of each layer of intermediate layer is in contact with the inner surface of the first-layer molded surface, the other end of each layer of intermediate layer extends towards the direction of the final-layer molded surface, the extending length of the other end of each layer of intermediate layer does not exceed the edge of the first-layer molded surface, and the movable die integrally moves a product formed on the N-2 fixing station to the N-1 fixing station;
s4, final layer profile injection molding: injection moulding on the Nth fixed station of cover half the end layer profile, the first layer profile with the butt joint of end layer profile, the intermediate level wrap up in the first layer profile with between the end layer profile.
2. The thick-walled light guide member layering injection molding method according to claim 1, wherein a magnitude of a drop in material temperature of the liquid material flowing from a feed gate to a tip end is 10 ℃ or less at the time of the injection molding of the first-layer profile, the intermediate layer, and the final-layer profile.
3. The thick-walled light guide of claim 1, wherein said range of values of M is: m is more than or equal to 1 and less than or equal to 10, and the value of N is M + 2.
4. The thick-walled light guide of claim 1, wherein said intermediate layers are laminated in a unidirectional manner.
5. The thick-walled light guide member layering injection molding method according to claim 1, wherein a plurality of sets of mold cavities are provided on the fixing station, and the number of mold cavities provided on the first fixing station to the nth fixing station is the same;
the movable die is provided with a rotating station, the rotating station is provided with a plurality of groups of die cores, the station number of the rotating station is the same as that of the fixed station, and the die cores are matched with the die cavities.
6. A thick-walled light guide as claimed in any one of claims 1 to 5, wherein the layer thickness of each of said intermediate layer and said final layer profile is less than the layer thickness of said initial layer profile.
7. A thick-walled light guide according to claim 6, wherein the thickness of each of the intermediate layers is equal to the thickness of the final layer profile, and the thickness of the first layer profile is 2 times the thickness of the final layer profile.
8. The method of claim 1 to 5 or 7, wherein the gate of the liquid material is selected to be at the thickest layer thickness of the layer and/or near the middle of the layer.
9. The thick-walled light guide member layer injection molding method according to claim 8, wherein the gate is a needle valve type gate, and the aperture of the gate is 0.5 to 3.5 mm.
10. A thick-walled light guide produced by the method of layered injection molding of a thick-walled light guide as claimed in any one of claims 1 to 9.
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| CN105818325A (en) * | 2016-04-01 | 2016-08-03 | 上海小糸车灯有限公司 | Thick wall plastic part surrounding type layered injection molding method and mold structure and lens product thereof |
| CN108081538A (en) * | 2018-02-09 | 2018-05-29 | 天津德迈特汽车零部件有限公司 | Lens of car light and penetrate horizontal turntable injection machine for producing the three of lens of car light |
| CN111775401A (en) * | 2019-04-03 | 2020-10-16 | 常州星宇车灯股份有限公司 | Thick wall lens injection mold that multistation layering was moulded plastics |
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| CN105818325A (en) * | 2016-04-01 | 2016-08-03 | 上海小糸车灯有限公司 | Thick wall plastic part surrounding type layered injection molding method and mold structure and lens product thereof |
| CN108081538A (en) * | 2018-02-09 | 2018-05-29 | 天津德迈特汽车零部件有限公司 | Lens of car light and penetrate horizontal turntable injection machine for producing the three of lens of car light |
| CN111775401A (en) * | 2019-04-03 | 2020-10-16 | 常州星宇车灯股份有限公司 | Thick wall lens injection mold that multistation layering was moulded plastics |
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