CN114347376A - Injection molding device and method for thick-wall light guide - Google Patents
Injection molding device and method for thick-wall light guide Download PDFInfo
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- CN114347376A CN114347376A CN202111435288.1A CN202111435288A CN114347376A CN 114347376 A CN114347376 A CN 114347376A CN 202111435288 A CN202111435288 A CN 202111435288A CN 114347376 A CN114347376 A CN 114347376A
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 60
- 238000000034 method Methods 0.000 title abstract description 15
- 239000000047 product Substances 0.000 claims abstract description 139
- 239000012467 final product Substances 0.000 claims abstract description 3
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Abstract
The invention relates to an injection molding device and method for a thick-wall light guide in the technical field of injection molding, comprising a fixed die and a movable die; the fixed die is provided with N groups of fixed stations at equal intervals along the circumferential direction, wherein N is a natural number greater than 1, the movable film is provided with movable stations, and the number and the position of the movable stations are matched with those of the fixed stations; each group of fixed stations forms a layer of structure of a product, the products of the (N-1) th group of fixed stations are brought onto the (N) th group of fixed stations through the movable stations, the product layers formed on the (N) th group of fixed stations cover the products formed on the (N-1) th group of fixed stations and are integrated, and the final product is of an N-layer structure. The invention adopts ingenious layered design, and the direct needle valve type point gate is applied to injection molding of each layer, thereby greatly reducing the forming period, greatly increasing the production efficiency, and skillfully hiding the mold parting and clamping line without influencing the appearance.
Description
Technical Field
The invention relates to the technical field of injection molding, in particular to an injection molding device and method for a thick-wall light guide piece.
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, a gate for single-layer injection molding is a side gate, and the defects that the pressure is reduced more and more along with the increase of the flowing length of a material, the pressure maintaining of a product is not facilitated, and the shrinkage is easy to generate are overcome.
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, the three injections each produce a parting line in the middle of the product by injecting the upper and lower halves of the product. 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 defects in the prior art, the invention aims to provide an injection molding device and method for a thick-wall light guide.
The invention provides a thick-wall light guide injection molding device, which comprises a fixed die and a movable die;
the fixed die is provided with N groups of fixed stations at equal intervals along the circumferential direction, wherein N is a natural number greater than 1, the movable film is provided with movable stations, and the number and the position of the movable stations are matched with those of the fixed stations;
each group of fixed stations forms a layer of structure of a product, the products of the (N-1) th group of fixed stations are brought onto the (N) th group of fixed stations through the movable stations, the product layers formed on the (N) th group of fixed stations cover the products formed on the (N-1) th group of fixed stations and are integrated, and the final product is of an N-layer structure.
In some embodiments, each set of fixed stations is provided with the same number of mold cavities, each mold cavity is provided with a pouring hole, and the pouring holes are selected to be close to the middle position of each layer of products;
the N groups of fixed stations are respectively marked as a first fixed station to an Nth fixed station, and the die cavities on the first fixed station to the Nth fixed station are respectively a first die cavity to an Nth die cavity.
In some embodiments, the via is selected at the position where the layer thickness is the thickest and/or near the middle of each layer of product.
In some embodiments, the first mold cavity forms a first layer of the product, and the second mold cavity through the nth mold cavity form a second layer of the product through an nth layer of the product, respectively, the first layer of the product having a greatest thickness.
In some embodiments, the thickness of the product second layer to the product nth layer is the same, and the thickness of the product first layer is twice the thickness of the product second layer.
In some embodiments, the number of mold cavities in each set of said stationary stations is between 1 and 5 pairs.
In some embodiments, the gate is a circular hole, and the diameter of the gate is 0.5-3.5 mm.
In some embodiments, N has a value of 3, 4, 6, or 8.
The invention also provides an injection molding method of the thick-wall light guide, and the injection molding device of the thick-wall light guide comprises the following steps:
s1, a first layer injection molding step of the product: injecting a thermoplastic material in a molten state into the first mold cavity through the gate opening of the first mold cavity to form a first layer of the product;
s2, performing injection molding on a second layer of the product: the movable station and the first die cavity are matched, the first layer of the product is brought into the second die cavity through the rotation of the movable station, a thermoplastic material in a molten state is injected into the second die cavity through a casting hole in the second die cavity to cover the first layer of the product, and the first layer of the product and the second layer of the product are combined into a whole while the second layer of the product is formed;
s3, injection molding of the Nth layer of the product: and the movable station and the N-1 die cavity are matched, the combined body from the first layer to the N-1 layer of the product is brought into the N die cavity through the movable station, and a thermoplastic material in a molten state is injected into the N die cavity through a casting hole on the N die cavity to cover the N-1 layer, so that the product with an N-layer structure is formed while the N layer of the product is formed.
In some embodiments, the material temperature of the thermoplastic material in a molten state flowing from the gate to the end of the gate decreases by 10 ℃ or less when the first layer to the nth layer of the product are injection molded.
Compared with the prior art, the invention has the following beneficial effects:
1. this design is through adopting ingenious layered design with the thick wall product, not only makes the parting die clamp line by ingenious hidden can not influence pleasing to the eye, brings the very big reduction of shaping cycle, and production efficiency greatly increases.
2. According to the invention, the direct needle valve type point gate is applied to each layer of injection molding, no extra equipment or manual input is needed for trimming the gate, and no uneven trace after trimming the side gate is generated. Meanwhile, the industrial production target of high quality, low cost and high efficiency is realized.
3. According to the invention, the pressure maintaining time of the material can be greatly prolonged by arranging the pouring hole in the middle, the pouring hole is always kept in a passage state in the whole injection molding process, the material can be effectively supplemented in the contraction process all the time, and the defects of sink marks, depressions and the like can be effectively avoided.
4. The invention makes the position of the pouring hole close to the middle position of each layer of products and at the position with the thickest layer thickness, and by adopting the design, the shape of the tip is positioned at the tail end of filling, and plastic can be filled from thick to thin, thereby effectively solving the problems of product stagnation and insufficient filling, and simultaneously ensuring that the products can obtain sufficient pressure maintaining.
5. By adopting the invention, the movable side mold only needs to rotate 90 degrees in one direction without reversing, the control is simple, the production is easy, and the injection molded product is always left on the movable side without the problem of repeated positioning, thereby ensuring the product quality.
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 schematic plan view of the stationary mold of the present invention;
FIG. 3 is a schematic plan view of the movable mold of the present invention;
FIG. 4 is an isometric view of a thick-walled light guide formed using the techniques of the present invention;
FIG. 5 is a front view of a thick-walled light guide formed using the techniques of the present invention;
FIG. 6 is a side view of a thick-walled light guide formed using the techniques of the present invention; fig. 7 is a schematic view of the layered structure of the product of the present invention and the structure of the needle valve type point gate.
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 injection molding device which comprises a fixed die and a movable die, wherein N groups of fixed stations are arranged on the fixed die, the N groups of fixed stations are uniformly arranged along the circumferential direction of the fixed die, corresponding die cavities are arranged on the fixed stations, the number of the die cavities on each group of fixed stations is the same and is multiple, the operation efficiency can be effectively improved, and the number of the die cavities on each group of fixed stations is preferably 2-5 pairs, particularly preferably 3 pairs. The movable mold is provided with movable stations, the number of the movable stations on the movable mold and the corresponding structural arrangement are matched with the number of the fixed stations on the fixed mold and the structural arrangement, so that a product formed on the previous fixed station can be brought into the next fixed station by the movable stations when the movable stations rotate once, and a product with a multilayer structure is formed.
Each die cavity is provided with a pouring hole, the die cavity is filled with thermoplastic materials in a molten state through the pouring holes to form product layers, and the pouring holes of the die cavities on each group of fixed stations are selected to be close to the middle position of each layer of products. In the process of layering injection molding, when the product layer on the Nth layer is placed on the (N-1) th layer through the pouring hole, injected liquid plastic can form the product layer on the Nth layer, and the temperature of the injected liquid plastic is integrated with the plastic which is not safely cooled on the product layer on the (N-1) th layer, so that experiments prove that parting lines can be well fused when the temperature of the material flows from the pouring gate to the tail end and drops by less than or equal to 10 ℃. For example, a typical PMMA forming temperature of 235 degrees is sufficient as long as the temperature of the down stream does not drop below 225 degrees, whereas for semi-crystalline materials a temperature drop of within 5 degrees is generally required. In addition, the parting line is skillfully arranged at the corner of the product, so that the parting line only exists at the corner of the product, and compared with the parting line of the product in the prior art which is generally generated at a certain position with visible appearance, such as the parting line a in fig. 1, the layered design adopted by the invention can achieve good aesthetic and optical effects. The pressure maintaining time of the material can be greatly prolonged by arranging the pouring hole in the middle, the pouring hole is always kept in a channel state in the whole injection molding process, the material can be effectively supplemented all the time in the contraction process, the defects of sink marks, depressions and the like can be effectively avoided, the reason is mainly that the pouring hole is arranged in the middle position, the distance from the material to any far end in the flowing process can be basically the same, and therefore the pressure distribution is uniform.
Further, while the layered design may hide the parting line of the product at the corners of the product, the layered design adds challenges to the product shape of the first and last layers from the problem that sharp edges may cause underfilling or stagnation, primarily because the molten plastic is a fluid that preferentially rushes toward the great Congzhou tract and lacks interest in the small Caprae Seu Ovis tract when confronted with an intersection. If the gate is set sideways, the intersection is selected by the fluid at the beginning of the flow, so that the sharp thin wall near the gate is not filled later and stagnation occurs. Since the filling is not available later, this portion of the material can freeze up very quickly, resulting in short shots or poor quality facets. The design is that the pouring hole is arranged at the position close to the thickest layer of each layer of product, and particularly preferably, the position of the pouring hole also meets another standard, namely, the pouring hole is arranged at the middle position of each layer of product, namely, the position of the pouring hole is close to the thickest layer of each layer of product and is also arranged at the middle position of the layer.
For the formed part per se, when the formed part is cooled, the first layer of product has two rigid material cooling surfaces, and the cooling speed is higher; only one side of the second layer of products is cooled by steel materials, and the other side of the second layer of products is cooled by plastic surfaces, so that the heat dissipation capacity of the plastic is weaker, and the thickness of the second layer of products is set to be lower than that of the first layer of products, namely the thickness of the first layer of products is the largest. On the basis of the thickest first layer, the thickness of each layer of the intermediate layer can be the same as or different from that of the last layer, and when the appearance quality of the product is further improved, the thickness of the last layer can be thinner than that of each layer of the intermediate layer, so that better pressure maintaining and cooling time is obtained, and high appearance quality is further obtained; when the thickness of each intermediate layer and the thickness of the last layer are half of the thickness of the first layer, the cooling time from the first layer to the last layer is basically consistent, and the production efficiency can be improved to the maximum extent. For example, typical die steels have a thermal conductivity of about 29w/m2C, the thermal conductivity of the plastic PMMA is usually not higher than 0.25w/m2C. The former is 100 times the latter, and for simplicity, assuming no heat conduction at all on the side in contact with the plastic, in order to approximate the cooling time of each layer, the preferred thickness profile is the thickest of the first layer of the product and 2 times that of each of the latter layers.
In the above, the pouring hole is a circular hole, and the aperture range is between 0.5-3.5mm, and the preferable value is 2-2.5mm, so that the production efficiency and the product quality are both good. The pouring hole is needle valve formula point runner, not only can ensure to fill evenly, when the pressurize is abundant, the problem that the gate that advances that exists for traditional side runner causes follow-up material can't be mended into the mould die cavity because of freezing easily, the pouring hole of adopting needle valve formula point runner structure has saved the manual work or the equipment input of repairing and reducing the runner promptly, also can make the remaining vestige of visible runner be limited to the pouring hole that the aperture of last layer is not more than 2.5mm only, very big freedom is provided for product design, the pleasing to the eye degree of product has been ensured.
The following description takes an example that 4 groups of fixed stations are arranged on the fixed die, a die cavity with 3+3 holes is arranged on each group of fixed stations, every 1+1 hole is 1 pair, the fixed die is adaptive, 4 groups of movable stations are also arranged on the movable die, and a die core with 3+3 holes is arranged on each group of movable stations as an example:
fig. 2 is a plan view of a structure of a fixed mold, four groups of fixing stations are arranged on the fixed mold, and are respectively marked as a first fixing station 15, a second fixing station 16, a third fixing station 17 and a fourth fixing station 18, four screws are arranged between the four groups of fixing stations, and are respectively marked as a first screw 11, a second screw 12, a third screw 13 and a fourth screw 14, wherein the first screw 11 controls injection molding of a first layer of a product, the second screw 12 controls injection molding of a second layer of the product, the third screw 13 controls injection molding of a third layer of the product, and the fourth screw 14 controls injection molding of a fourth layer of the product. The first fixed station 15, the second fixed station 16, the third fixed station 17 and the fourth fixed station 18 are respectively provided with mold cavities with the same number and positions, which are respectively marked as a first mold cavity 19, a second mold cavity 20, a third mold cavity 21 and a fourth mold cavity 22, and the first mold cavity 19, the second mold cavity 20, the third mold cavity 21 and the fourth mold cavity 22 are respectively provided with needle valve type point gates close to the middle positions and the thickest layer thickness positions thereof, and are respectively marked as a first gate hole 23, a second gate hole 24, a third gate hole 25 and a fourth gate hole 26. Fig. 3 is a plan view showing the structure of a movable mold on which a first movable station 27, a second movable station 28, a third movable station 29, and a fourth movable station 30 are provided, and the four groups of movable stations of the first movable station 27 to the fourth movable station 30 are identical in shape. The working principles of the fixed die and the movable die are as follows:
after the injection mold is opened, the injection-molded product is left at the movable station, the movable station rotates 90 degrees anticlockwise, the first movable station 27 brings the first layer of product in the first mold cavity 19 into the second mold cavity 20, simultaneously, the second movable station 28 brings the fused body of the first layer of product and the second layer of product in the second mold cavity 20 into the third mold cavity 21, the third movable station 29 brings the fused body of the first layer of product, the second layer of product and the third layer of product in the third mold cavity 21 into the fourth mold cavity 22, the fourth movable station 30 ejects the product with the four-layer structure in the fourth mold cavity 22 out of the fixed mold 2, the product is taken out of the mold by the manipulator, and the like, and the cycle production is continuously carried out.
Taking the maximum wall thickness of a single product shown in fig. 4, 5 and 6 as an example, four-layer injection molding is adopted, the gate of each layer is selected at the position where the thickness of the part layer shown by 7, 8, 9 and 10 in the middle of the product is the thickest, as shown in fig. 7, the formed product only has parting lines at two corners 1 and 2, the influence on the optical function is minimized, the appearance is attractive, in addition, the mold forming period is reduced from 25-30 minutes to about 250 seconds, and the production efficiency is improved by 6-8 times.
Example 2
s1, a first layer injection molding step of the product: injecting a thermoplastic material in a molten state into the first mold cavity through the gate opening of the first mold cavity to form a first layer of the product;
s2, performing injection molding on a second layer of the product: the movable station and the first die cavity are matched, the first layer of the product is brought into the second die cavity through the rotation of the movable station, and the thermoplastic material in a molten state is injected into the second die cavity through the pouring hole on the second die cavity to cover the first layer of the product, so that the first layer of the product and the second layer of the product are combined into a whole while the second layer of the product is formed;
s3, an Nth layer injection molding step: and the movable station and the N-1 die cavity are matched, the combined body from the first layer to the N-1 layer of the product is brought into the N die cavity through the movable station, and the thermoplastic material in a molten state is injected into the N die cavity through a casting hole on the N die cavity to cover the N-1 layer, so that the product with the N layer structure is formed while the N layer of the product is formed.
The die cavities with the same number are arranged on each group of fixed stations, the die cavities are provided with the gate holes, and the gate holes of the die cavities on each group of fixed stations are selected to be located at the position with the thickest layer thickness when being close to the middle position of each layer of products.
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 injection molding device is characterized by comprising a fixed mold and a movable mold;
the fixed die is provided with N groups of fixed stations at equal intervals along the circumferential direction, wherein N is a natural number greater than 1, the movable film is provided with movable stations, and the number and the position of the movable stations are matched with those of the fixed stations;
each group of fixed stations forms a layer of structure of a product, the products of the (N-1) th group of fixed stations are brought onto the (N) th group of fixed stations through the movable stations, the product layers formed on the (N) th group of fixed stations cover the products formed on the (N-1) th group of fixed stations and are integrated, and the final product is of an N-layer structure.
2. The thick-walled light guide injection molding device according to claim 1, wherein each set of the fixed stations is provided with the same number of mold cavities, and the mold cavities are provided with casting holes which are selected to be close to the middle of each layer of products;
the N groups of fixed stations are respectively marked as a first fixed station to an Nth fixed station, and the die cavities on the first fixed station to the Nth fixed station are respectively a first die cavity to an Nth die cavity.
3. A thick-walled light guide injection molding apparatus as claimed in claim 2, wherein said gate is selected at the position where the layer thickness is the thickest and/or near the middle of each layer of product.
4. The thick-walled light guide injection-molding device according to claim 3, wherein said first cavity forms a product first layer, and said second cavity to said Nth cavity form a product second layer to a product Nth layer, respectively, the thickness of said product first layer being the largest.
5. The thick-walled light guide injection molding device of claim 4, wherein the thickness of the product second layer to the product Nth layer is the same, and the thickness of the product first layer is twice the thickness of the product second layer.
6. A thick-walled light guide injection molding apparatus as claimed in claim 2, wherein the number of mold cavities in each set of said fixing stations is 1-5 pairs.
7. The thick-walled light guide injection molding device according to claim 2, wherein the sprue is a circular hole, and the bore diameter of the sprue is 0.5-3.5 mm.
8. A thick-walled light guide injection molding apparatus as claimed in any one of claims 1 to 7, wherein said N has a value of 3, 4, 6 or 8.
9. A thick-walled light guide injection molding method, characterized by using the thick-walled light guide injection molding apparatus according to any one of claims 2 to 8, comprising the steps of:
s1, a first layer injection molding step of the product: injecting a thermoplastic material in a molten state into the first mold cavity through the gate opening of the first mold cavity to form a first layer of the product;
s2, performing injection molding on a second layer of the product: the movable station and the first die cavity are matched, the first layer of the product is brought into the second die cavity through the rotation of the movable station, a thermoplastic material in a molten state is injected into the second die cavity through a casting hole in the second die cavity to cover the first layer of the product, and the first layer of the product and the second layer of the product are combined into a whole while the second layer of the product is formed;
s3, injection molding of the Nth layer of the product: and the movable station and the N-1 die cavity are matched, the combined body from the first layer to the N-1 layer of the product is brought into the N die cavity through the movable station, and a thermoplastic material in a molten state is injected into the N die cavity through a casting hole on the N die cavity to cover the N-1 layer, so that the product with an N-layer structure is formed while the N layer of the product is formed.
10. The injection molding method for a thick-walled light guide according to claim 9, wherein a material temperature drop of the thermoplastic material in a molten state flowing from the gate to the tip end is 10 ℃ or less when the first layer to the nth layer of the product are injection molded.
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| CN209955182U (en) * | 2019-04-03 | 2020-01-17 | 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 |
| CN209955182U (en) * | 2019-04-03 | 2020-01-17 | 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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