CN1671534A - 多层塑料制件的注塑方法及由其制成的多层塑料制件 - Google Patents

多层塑料制件的注塑方法及由其制成的多层塑料制件 Download PDF

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CN1671534A
CN1671534A CNA038182882A CN03818288A CN1671534A CN 1671534 A CN1671534 A CN 1671534A CN A038182882 A CNA038182882 A CN A038182882A CN 03818288 A CN03818288 A CN 03818288A CN 1671534 A CN1671534 A CN 1671534A
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普雷德拉格·佩索维克
沃因·佩索维克
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14598—Coating tubular articles
    • B29C45/14614—Joining tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5221—Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/55—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles sealing elements being incorporated into the joints, e.g. gaskets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1657—Making multilayered or multicoloured articles using means for adhering or bonding the layers or parts to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7316—Surface properties
    • B29C66/73161—Roughness or rugosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
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Abstract

本发明涉及多层塑料制件注塑的构造和过程。所述过程首先注塑出带有条形凸起12的层1。在闭合的制件结构中，通过带有联结器的进口13或任何其它公知方法，将层1的节段1’、1″接合成一个骨架，所述节段1’、1″具有通过一个实体模芯或任何其它公知方法成形的孔道11。接着，将首先成形的层1精准地置于下一个模具中，在整个外表面或外表面的一部分上注塑出另一层，即层2，所述层2的反向的凸条21填入凸条12之间的凹洞中，凸条22从层2的表面上突起。接着将覆盖模塑上层2的层1置于下一个模具中，重复整个过程，直到注塑出希望的层n，所述层n的凸条n1填入前一层的凹洞或凹痕中，同时在层n的表面上制出凹槽nu。将包含所有先前各层的层n置于最后一个模具中，在此注塑出遮盖的最后的薄层p，所述层p的凸脊pi填入层n的凹槽nu中，同时层p的外表面，即制件的外表面，为平滑、或粗糙(如需要)，或制成一个希望的样式或图案。

Description

多层塑料制件的注塑方法及由其制成的多层塑料制件
技术领域
本发明涉及塑料物质以及塑性状态材料的加工和处理，同时涵盖多层制件。
依据国际专利分类法(IPC)，本发明归入：B 29C 45/14类，有关插入件的注射成型；B 29C 45/16类，有关多层或多色制品的注射成型；B 29 C 63/00类，有关预制层的覆盖模塑(over-molding)；B 23B 33/00类，关于多层制件。
背景技术
本发明解决了多层注塑方面的问题，从而以这种方法制成的制品具有良好的机械性能(比如抗冲击、抗划伤和抗断裂)以及良好的观赏和装饰性(比如表面光泽好或触摸柔软)，并且制造成本不高。通过在各层上采用带有凸条、凹槽、凹痕、凸起或者平滑的接合面，对单层进行制作和设计、对同一层或者薄厚层之间的组件进行结构性接合、以及确定注塑的过程，进而在若干个模具中将适宜的相容性材料依次进行注塑，由此达到了上述目的。
在原专利申请P-571/02中，已对技术问题详细地进行描述。另外，对于相关领域的技术，有必要指出以下已公布的美国专利文献：
参考引用：美国专利：
1、3,947,177(06/09/1974)-《热塑性多层体的注塑装置/ApparatusFor Injection Molding Of Multi-Layer Bodies Of Thermoplastic》
2、4,840,553(20/09/1988)-《多层树脂模塑的金属模具结构/MetalMold Structure For Molding Multi-Layer Resin》
3、4,931,246(19/09/1986)-《多层制品的注塑方法/Method ForInjection Molding Multi-Layer Articles》
4、5,141,695(08/09/1987)-《多层底部型坯的注塑方法/Injection Molding Method For Multi-Layer Bottomed Parisons》
5、5,667,819(04/11/1994)-《多层制品的注塑装置/Apparatus ForInjection Molding Of Multi-Layer Objects》
6、5,851,456(28/03/1997)-《制造多层制件的方法/Method ForManufacturing A Multi-Layer Product》
7、6,129,960(10/10/2000)-《多层塑料注塑和注坯吹塑的方法和装置以及所述方法和装置制出的制品/Methods And ApparatusFor Injection Molding And Injection Blow Molding Multi-LayerPlastic And Articles Made Thereby》
所有引用的专利都涉及同步注塑多层物件的装置和方法。模塑多层物件的此种方法使用了极其复杂的装置和模具、以及复杂的多管喷嘴。此外，需要对要被模塑成各层的材料的粘度、流动和温度进行极其复杂的控制，所有这些均使整个方法更为复杂，因而导致不精确、低效率和成本增加。某些提到的方法还兼用了注塑和吹塑两种方法。
通常地，所述方法能对其层厚大体一致的不同材料的若干层进行注塑或吹塑。但在所有上述的技术中，事实上不可能将剖面(即多层体的层厚)增加几倍到几十倍，除非对过程的技术和工艺要求降低标准，所述的过程技术和工艺要求包含有：行业孔道尺寸，如有，则还包含组件的尺寸、美观性、机械性能，各层材料密度的一致性，塑料物质加工工艺(注塑层的加工和冷却时间)。
发明内容
本发明涉及多层塑料制件的注塑过程。依据原专利申请P-571/02，技术方案的特征在于材料和各层中材料的组合，取决于卫生用水设施的卫生方面的技术要求。所述申请还涉及其他技术和工艺要素，以及涉及未用于卫生用水产品工艺方面制造过程的、而是受控于严格和精确的技术和工艺要求的最终制件。
本发明完全以描述于P-571/02申请中的发明为基础、并完全涵盖了有关所使用的材料及材料组合的相同的工艺加工过程，然而，本发明精确地明确了多层制件的设计及其制造方法。
依据本发明，所述过程的特征在于：在已经模塑的层上依次地注塑出另一层(薄层或厚层)，如果第一层为闭合结构的组件时，则所述的第一层在带有一个实体模芯的模具中进行注塑，如果第一层为通过公知方法制成的敞开结构的组件时，则不带模芯。这个过程可注塑出n层，取决于最终制件的技术和工艺要求参数组。
制件本身的构造的特征在于具有若干层及其厚度、若干层(接合面)之间的结构性接合、各层之间的接合面的特性(粗糙度)以及第一层的构造，取决于最终制件的参数组。各层之间的接合面(所述各层为一层在另一层之上注塑而成)可以是平滑或粗糙。在涉及薄层时，表面粗糙度可由凸起和凹槽确定，而在涉及厚层时，则由凸条结构确定。
在涉及闭合制件体时，其大多具有复杂形状，要求具有密封性(密闭及防水)，由此第一层必须制成若干节段，所述节段以若干种方法接合，然后在另一个模具中覆盖模塑出另一层。
相对于本领域的现有技术状态，已在专利申请P-571/02中详细地进行了描述，依据本发明，多层塑料制件的注塑的构造和过程的优点是显而易见的。
此外，应该强调的是，在单层的厚度、或整个制件的厚度实际上不受限制的情况下，本发明在符合最为严格的技术、工艺和卫生要求方面，具有无限的可能性，与此同时，并未对过程的技术和工艺要求降低标准，所述的过程技术和工艺要求包含有：行业孔道尺寸，如有，则还包含组件的尺寸、美观性、机械性能，各层材料密度的一致性，塑料物质加工工艺(注塑层的加工和冷却时间)。
附图说明
本发明通过参考附图进行详细描述，其中：
图1为闭合结构的多层制件的剖面图；
图2为敞开结构的多层制件的剖面图；
图3为三层制件的剖面图；
图4为二层制件的剖面图；
图5-8为具有突起、凹痕以及平滑表面的薄层的剖面图；
图9-12为带有凸条结构(凸条之间为凹槽)的厚层的剖面图；
图13-28为薄层和厚层上凸起和凹痕的若干种可能形状及其表面布置；
图29为带有直立凸条的条形结构；
图30为带有环形凸脊(ridges)的条形结构；
图31为网状凸条结构；
图32为在第一层组件上接有一个‘O’形塞环的制件的剖面图；
图33为在第一层组件上未接一个‘O’形塞环的制件的剖面图。
具体实施方式
多层塑料制件的注塑(injection molding)过程为：注塑层1，如果所述层1是闭合制件的一个组件(见图1)，则注塑层1的节段1’和1″。在层1的外表面上形成有凸条12。通过模具中的一个实体模芯、或者是通过一些其他方法，制成了节段1’和1″中的孔道11，孔道11多半用作输送流体，因而要求其由防水材料制成，并且节段1’和1″的接合处要密封严实。因而，节段1’和1″能以各种方法接合，接合处可拆或不可拆均可，但必须是密封的。通过在进口13处插上一个‘O’形塞环14、或扣件/联接器，形成了节段1’和1″之间的可拆接合，也可在进口13处，通过胶合、熔接、摩擦焊接或超声焊接，形成了不可拆接合(见图32、33)。
以这种方法制成的层1，其构成了制件的骨架，将被非常精准地置于下一个模具中，并在其表面上注塑出另一层、即层2，所述层2的凸条21和凹槽填入层1的凸条12之间的凹槽中。通过这种方法，即可在层1和层2之间获得一个密实的结构体(见图1-4)。凸条22从层2的表面上突起。将已构成密实一体的层1和层2放置在下一个模具中，进行层3的注塑。重复该过程若干次，直到注塑出希望的层n，所述层n的外表面上具有凸脊ni或凹槽nu。在层n上，注塑出薄的最后一层p，层p的凹槽pi或凸脊pu填入层n的凸脊nu或凹槽ni中，从而在最后的厚层n和遮盖的薄层p之间，制成了一个均质的结构体。外面的、最后的层p可以为任何颜色，或者是透明，从而可以露出层n的颜色。对于表面特性方面，其可为平滑光亮、或粗糙或者制成一个希望的样式，取决于其用途和设计宗旨。
在敞开结构的制件中(见图2)，注塑过程相同，区别在第一层，其制成一体而非数个节段。另外，如果不覆盖上另一层，其表面的一面可以构成最终表面，但不一定，取决于其用途。
层1-n可制成薄层ts(见图5-8)，或厚层ds(见图9-12)，或两者的组合，然而遮盖层通常制成薄的。薄层ts大概0.5-6毫米厚，厚层ds大概4-30毫米厚。
薄层ts的表面可以是带有凸起tsi和凹槽tsu的平滑面，或是两者的任意组合的平滑面(见图13-28)。凸起tsi和凹槽tsu制成圆形、方形或任何其他几何图形，并且以棋盘模式或任何其他几何对称或非对称布置方式分布在表面上。
厚层ds的表面可以是带有凸脊dsi和凹槽dsu(见图13-28)、或条形凸脊ds1、ds2(见图29-31)的平滑面，或是所有样式的任意组合的平滑面。条形凸脊ds1、ds2可为方形、矩形、三角形、不规则四边形、半圆形或任何其他适宜的几何图形。其以平行脊线的方式布置在组件层的表面上，所述平行脊线为直立、弯曲、或为网状样式‘m’，或者任何其他表面分布方式。
依据上述的过程，很明显地，不对形状、厚度、层数和材料类型的可能组合加以限制的情况下，多层制件的制造的可变化性是巨大的，尽管如此，其并未脱离本发明的范围。

Claims (7)

1、多层塑料制件的注塑过程，所述过程依据原专利申请P-571/02进行彻底地论述，其中：首先，将层1注塑成具有条形凸起(12)，在闭合结构中，通过进口(13)以联接器或任何其它公知方法，将层1的节段1’、1″接合成一个骨架，所述节段1’、1″具有通过一个实体模芯或任何其它公知方法成形的孔道(11)，接着，将由此制成的首先成形的层1精准地置于下一个模具中，在整个外表面或外表面的一部分上注塑出另一层，即层2，所述层2的反向的凸条(21)填入凸条(12)之间的凹洞中，凸条(22)从层2的表面上突起；由此，层1被层2覆盖模塑，接着，将其置于下一个模具中，重复整个过程，直到注塑出希望的层n，所述层n的凸条n1填入前一层的凹洞或凹痕中，同时在层n的表面上制出凹槽nu；将包含所有先前各层的层n置于最后一个模具中，在此注塑出遮盖的最后的薄层p，所述层p的凸脊pi填入层n的凹槽nu中，同时层p的外表面，即制件的外表面，为平滑、或粗糙(如需要)，或制成一个希望的样式或图案。
2、依据权利要求1所述的敞开结构的多层塑料制件的注塑过程，其中具有条形凸起(12)的层1被层2覆盖模塑，并且重复该过程直到制成希望的层n，或遮盖层/最终层p，其中层1-n制成薄层ts或者厚层ds，并且受控于技术要求、工艺要求和规格参数，而遮盖层/最终层p则依据美学要求进行模塑。
3、依据权利要求1或2所述的多层塑料制件的设计，其中薄层ts的上表面和下表面模塑成平滑状、或带有凸起tsi、或带有凹槽tsu，和/或所述带有凸起和凹槽的表面的任意组合。
4、依据权利要求1或2或3所述的多层塑料制件的设计，其中厚层ds的上表面和下表面模塑成平滑状、或带有凸起dsi、或带有凹槽dsu、带有凸条ds1、ds2、或所述样式的任意组合。
5、依据权利要求4所述的多层塑料制件的设计，其中凸起或凸条(tsi、dsi)和凹痕或凹槽(tsu、dsu)制成圆形、方形或任何其他几何图形，并且以棋盘模式，斜对，或任何其它形状、形式或样式分布。
6、依据权利要求5所述的多层塑料制件的设计，其中条形凸起ds1、ds2为方形、矩形或任何其它几何图形的断面状，以平直的凸线模式、随意模式、或网状样式‘m’的方格交叉式、或任何其它表面分布方式分布在层1-n的表面上。
7、依据权利要求1所述的多层塑料制件的设计，其中通过在进口(13)处插上一个‘O’形塞环14、或联接器，层1的节段1’和1″以可拆方式接合，或者以联接器连接或者通过在进口13的接合点进行胶合、熔接、摩擦焊接或超声焊接，以不可拆方式接合。
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