CN1853893A - 加工预制坯的方法和装置 - Google Patents

加工预制坯的方法和装置 Download PDF

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CN1853893A
CN1853893A CNA2006100752935A CN200610075293A CN1853893A CN 1853893 A CN1853893 A CN 1853893A CN A2006100752935 A CNA2006100752935 A CN A2006100752935A CN 200610075293 A CN200610075293 A CN 200610075293A CN 1853893 A CN1853893 A CN 1853893A
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prefabricated blank
inserts
negative pressure
plug
constitutes
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CN1853893B (zh
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莫德斯托·M·佩萨文托
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Husky Injection Molding Systems Ltd
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    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
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Abstract

本方法和装置用于加工由热塑性塑料制成的要被吹制成容器的预制坯。预制坯在一个第一生产步骤中在注塑膜片具区域内用注塑方法制造。预制坯至少局部由冷却装置施加作用。预制坯在负压作用下变形。为此冷却装置至少部分可以由多孔材料构成。

Description

加工预制坯的方法和装置
技术领域
本发明涉及一种用于由对热塑性塑料制成的预制坯进行加工的方法，该预制坯要吹塑成容器，其中预制坯在注塑模具中用注塑方法生产并且在从注塑模具取出后变形。
此外，本发明还涉及一种用于对由热塑性塑料制成的预制坯进行加工的方法，该预制坯要吹塑成容器并且在注塑模具中用注塑方法生产，在这个装置中预制坯至少被一个冷却装置冷却。
背景技术
例如在PCT-WO 97/39874中描述了一种加工由热塑性塑料制成的预制坯的方法。在这种方法中预制坯在从注塑模具中取出后被送进一个冷却套筒，并且通过对冷却套筒壁施加内压力而被挤压。从而在整个冷却过程中预制坯与冷却套筒的壁保持接触，因为通过作用的内压力预制坯由于冷却产生的收缩能够得到补偿。
在DE 41 28 438 A1中披露了一种在吹塑模具内把预制坯吹塑变形成容器。吹塑模设有与压力源连接的多孔的插塞。通过向多孔的插塞输送压缩空气制成一个压缩空气垫，这个压缩空气垫防止材料在吹塑模具的内表面上滑动时吹塑的容器的表面受到损伤。
发明内容
本发明的目的是，这样改进开始所述类型的方法，用较少的时间和简单的结构构造支持预制坯的加工。
这个目的按照本发明这样实现，预制坯在负压作用下变形。
本发明的其他目的是，这样设计一种开头所述类型的装置，用简单的装置技术结构以及装置的较小制造费用来支持对预制坯的加工。
这个目的按照本发明这样实现，冷却装置至少局部由一种多孔的材料构成。
紧接着注塑制造预制坯，通过负压的作用使预制坯变形带来一系列的优点。一个优点是，能够通过外部负压的作用向着冷却套筒壁牵拉预制坯，并从而在整个冷却过程中在预制坯和冷却套筒的壁之间保持直接的接触。
可以看到另外一个优点是，通过负压的作用预制坯可以相对预制坯的纵轴在纵向、在径向和/或在圆周方向变形，这样预制坯可以得到一个与注塑模具内腔轮廓不同的形状。特别想到的是，通过负压的作用到预制坯的壁上产生一个材料的分配，这对于随后吹制椭圆形的瓶子是有利的。用这个方法可以在预制坯的圆周方向上提供不同的壁厚。
另外一个优点是，通过负压的作用，不希望变形的或由注塑模具没有沿圆周完整变形的预制坯可以再变形。用这种方法有可能，把弯曲的预制坯校直或补偿预制坯的变形。特别想到的是，在使用按照本发明的方法和/或按照本发明的装置时，可以有意识的在注塑模具的范围内缩短循环时间或加大注塑模具几何形状的公差。在这样有意识地过早从模具中取出预制坯时，从模具中取出的过热的预制坯的扭曲变形或缩陷处的形成是可以接受的，因为预制坯的这些缺陷可以通过再变形和由于负压的作用而被补偿。非常昂贵的注塑模具可以用这种方法以提高的生产率使用。
典型的变形过程这样进行，负压在外面作用到预制坯上。
同样也有可能，负压在内面作用到预制坯上。
一种优选的应用是，预制坯在一个冷却装置内被施加负压。
一种廉价的负压供给可以这样实现，预制坯通过一种多孔材料被施加负压。
为了实现负压的均匀分布而建议，使负压通过负压管道供给多孔材料。
预制坯的加工可以这样得到支持，对预制坯局部用压力介质加载。
可以这样对加工过程施加附加的影响，对预制坯暂时地用压力介质加载。
这样实现改善的控制可能性，通过局部的多孔嵌件给预制坯施加负压。
沿着容纳预制坯的模腔的内部边界的局部不同压力条件的给定可以这样实现，局部多孔嵌件通过控制阀可部分预定地连接在压力源和负压源上。
预制坯从内向外的变形可以这样实现，使用一个多孔的内芯棒进行预制坯的变形。
这样支持局部的有限的材料变形，从内芯棒给预制坯施加一个局部的负压作用。
一种典型的应用是，预制坯的变形作为实施单级注坯吹塑-方法的中间步骤进行。
同样也可以考虑，预制坯的变形作为实施两级注坯吹塑-方法的中间步骤进行。
可以通过在冷却套筒的区域内设置多孔材料来实现一种有利的装置技术。
为了提供足够的机械稳定性而建议，把多孔材料做成由一个框架支承的嵌件。
通过在嵌件的区域内设置至少一条负压通道，使得在多孔材料内以低的流动阻力提供负压。
按照另外一种设计方案可以考虑，在框架的区域内设置至少一条冷却通道。
相对于外部环境的压力遮断可以通过在至少局部用密封件覆盖嵌件来实现。
为了使预制坯相对于多孔材料的嵌件具有压力支持的可移动性而建议，负压通道一直延伸到嵌件内腔的区域内。
有目标局部地预定所实现的压力比例的作用，通过至少局部用密封件覆盖内芯棒来实现。
在要使预制坯仅仅部分再变形时可以考虑，用密封件在圆顶(Kuppe)区域内覆盖内芯棒。
使预制坯再变形的另外一种变型方案是，内芯棒设有至少一个界定一个分配室的膜片。
一种典型的材料选择是，多孔材料由多孔金属构成。
特别好的导热性能通过用铝制造的多孔金属实现。
另外一种实施形式的变型是，多孔材料由烧结金属构成。
这些材料有从几个μm向上的可变的空隙尺寸可供使用。所选择的空隙尺寸越小，预制坯的表面质量越好。过微小的空隙尺寸导致高的压力/真空需求。此外过小的空隙容易被灰尘堵塞。
例如下面的多孔(可透气)材料可以在市场上购买到：
“METAPOR”PORTEC股份公司；
“ultraporex”超滤器国际股份公司；
“PorceraxII”国际铸钢公司；
“KuporexTM”KUBOTA公司；
附图说明
在附图中示意地示出本发明的实施例。附图中表示：
图1冷却装置的截面图，其中由一个多孔部件构成冷却套筒，
图2相对图1修改过的实施例，其中不仅负压而且过压都能通过多孔部件向预制坯的方向引导，
图3一种实施形式的截面图，其中使用了多个空间上相互分开的多孔嵌件，这些嵌件能够可控制地连接过压和/或负压，
图4装置的垂直截面的局部视图，其中一个用多孔材料制成的用于预制坯的内芯棒用于在预制坯纵轴线方向上部分的再变形，
图5相对于图4变化的实施形式，其中内芯棒用于预制坯的完全再变形，
图6相对于图5变化的实施形式，其中变形力通过安装在内芯棒上的膜片施加到预制坯上，
图7一个放置在用多孔材料制成的嵌件中的预制坯的横截面图，
图8对应于图7的在预制坯通过负压作用变形后的横截面图，以及
图9一个按照图8的变形的预制坯的以及一个对应的在预制坯吹塑变形后的椭圆形容器轮廓的示意横截面图。
具体实施方式
图1表示用于加工预制坯1的装置的横截面，该装置有一个框架2和一个由多孔材料构成的嵌件3。这里多孔材料的概念不仅包括开口孔的泡沫结构，也包括烧结材料的或类似的材料结构。由于高的导热能力，开口孔的金属泡沫，例如铝制的金属泡沫已证明是适用的。
预制坯1用热塑性材料，例如PET(聚对苯二甲酸乙二酯)制造，并且由一个侧壁4、一个支承圈5以及一个嘴部分6。预制坯1的内腔7沿着预制坯纵轴线8延伸。
一个负压通道9穿过框架2延伸，与在嵌件3内部的负压通道10连通。此外在嵌件3的区域内设置有冷却通道11，冷却介质可以通过冷却通道循环。在框架2的表面12的区域内嵌件3的表面被密封件13封闭，以防止在施加负压时从周围环境吸入空气。
预制坯1这样插入嵌件3的空腔14中，使支承环5紧靠在嵌件3的表面区域内。在对嵌件3施加负压时，位于预制坯1和空腔14之间的空气被吸出，而在预制坯1的内腔7的区域内的环境压力把预制坯1的侧壁4压向空腔14的分界面15。这样形成的材料接触使预制坯的冷却得到改善，并且有助于预制坯1具有分界面15的形状。
在图2的实施形式中，负压通道10延伸到嵌件3的空腔14。此外，冷却通道11设置在框架2的区域内。在框架2的区域内除负压通道9外还设置有一个通到嵌件3的压力介质接头17的压力介质通道16。压力介质管道与密封件13最好有一个小的间距。这样穿过空腔14向负压通道9的方向产生一个空气流，该空气流使预制坯1容易插进空腔14，并且避免由于分界面15接触而刮伤预制坯1。此外可以避免导致预制坯1不均匀冷却的预制坯1与嵌件3的不均匀的接触。
在图3的实施形式中，空腔14在框架2的区域内形成，并且在空腔14的分界面15区域内设置有许多个多孔的嵌件3。这里的多孔嵌件3在空间上相互分开。此外嵌件3分别与供气通道18连接，供气通道18能够通过控制阀19可预定地与压力源20或负压源21连接。在这个实施形式中负压通道9也延伸到空腔14的区域内。为了使预制坯1能容易地插进空腔14内，首先只有负压通道9抽成真空。一旦预制坯1完全位于空腔14内，负压源21就释放一个较高的负压，以便把预制坯1压在分界面15上。
在空间上相互分开的各个嵌件3形成能够引起预制坯1的局部变形或为预制坯1产生气垫的喷嘴式装置。特别也可以考虑，通过嵌件3可控制地供给热压缩空气，以局部地加热预制坯1从而实现预定的变形。
在图4的实施形式中，由多孔材料制成的内芯棒22对预制坯1加载。内芯棒22设有一个压力介质通道23。压力介质通道23根据相应控制提供过压或负压。为了避免压力损失，内芯棒22的外侧部分地配有密封件24。在图4的实施形式中，内芯棒22只是用于预制坯1例如在嘴部分6区域以及在侧壁4朝向嘴部分6一部分的区域内再变形。因此在圆顶25的区域内芯棒22也有一个密封件26。
在图5的实施形式中，内芯棒22设计用于将预制坯1沿着预制坯纵轴线8的整个长度再变形。因此内芯棒22具有一个相对于图4实施形式变型的轮廓。在这个实施形式中，在圆顶25的区域内不再需要密封件26。除了用内芯棒22给预制坯1加载外，按照图5的实施形式还可以实现一种从外部作用于预制坯1的空气冷却27。
在图6的实施形式中，压力介质通道23连接于由膜片29封闭的分配室28。在给压力介质通道23加压时，膜片29压向预制坯1的侧壁4并且使预制坯1变形。通过由膜片29产生的力，预制坯1能够或者被压向冷却套筒的内壁或者以规定的方式变形。
图7表示带有一个插入空腔14的预制坯1的嵌件3的横截面。嵌件3由框架2支承。
在施加负压之后，按图1的预制坯1向按照图8的预制坯变形。特别是由图8可以看出，通过在预制坯圆周方向上的变形可能产生不同的壁厚分布。按图8的预制坯形状特别适用于制造椭圆形的瓶子。
图9表示按图8的预制坯1变成一个具有椭圆形横截面的容器的容器轮廓30的配置。这样选择在预制坯1中的材料分布，在接着吹制的变形中只相对稍微伸长的那些区域，比在吹制变形中强烈伸长的那些区域更薄。通过相应的材料分布在一个吹制成的容器中能够得到非常均匀的壁厚分布以及由此均匀的材料特性。
在对嵌件3用负压和过压组合交替地加载时，可以这样用简单的方式进行材料清除，不放进预制坯1就施加压力介质把杂质吹走。预制坯1与内芯棒22的分离也可以通过给内芯棒22施加压力介质来实现。在组合使用由多孔材料制成的内芯棒22和嵌件3时，也可以通过外部施加负压使预制坯1与内芯棒22分离。

Claims (50)

1.一种用于加工注塑的热塑性塑料预制坯(1)的方法，所述预制坯供在后续的过程中吹塑成容器，所述方法包括以下的步骤，
注塑预制坯(1)；
在以下中至少之一中接收预制坯(1)：
-嵌件(3)，它具有一个限定一空腔的表面，该空腔构成为用于接收预制坯(1)的一个外部的部分；以及
-芯棒(22)，它具有一个构成为用于接收预制坯(1)的一个内部的部分的表面；
所述嵌件和芯棒的表面的至少一部分包括一种多孔材料；
通过经由多孔材料的负压的作用使接收到的预制坯(1)变形，以便把预制坯各部分中的至少一个部分拉到与其接触中；以及
其中，所述变形规定用于以下中至少之一：
补偿预制坯(1)中的在其注塑步骤中产生的缺陷；改变在预制坯(1)的壁中的材料圆周分布。
2.按照权利要求1所述的方法，其特征在于，通过负压通道(10)把负压供给多孔材料。
3.按照权利要求1或2所述的方法，其特征在于，所述嵌件和芯棒中的至少一个构成为包括一个密封件(12、22、23)，并且本方法还包括该步骤，即，与所述嵌件和芯棒中的至少一个合作来密封所述预制坯部分，以防止在施加负压时吸入周围空气。
4.按照权利要求1至3之一所述的方法，其特征在于，所述嵌件还包括一个延伸到空腔中的负压通道，并且本方法还包括该步骤，即，对预制坯相对于嵌件的压力-支持的移动性加以影响。
5.按照权利要求1至4之一所述的方法，其特征在于，所述嵌件还构成为一个冷却装置，并且本方法还包括该步骤，即，在其中冷却预制坯。
6.按照权利要求1至5之一所述的方法，其特征在于，所述嵌件构成为在其中包括一个冷却通道(11)。
7.按照权利要求1至6之一所述的方法，其特征在于，所述嵌件设置在一个框架(2)中。
8.按照权利要求7所述的方法，其特征在于，所述框架(2)构成为在其中包括一个冷却通道(11)。
9.按照权利要求1至6之一所述的方法，其特征在于，所述嵌件定位于一个冷却套筒中。
10.按照权利要求5所述的方法，其特征在于，该方法还包括该步骤，即，在冷却预制坯的整个冷却过程中保持预制坯的外部部分与嵌件的表面之间的直接接触。
11.按照权利要求1至10之一所述的方法，其特征在于，所述嵌件(3)和芯棒(22)中的至少一个连接于一个压力源，并且本方法还包括该步骤，即，通过过压作用使接收到的预制坯(1)变形。
12.按照权利要求1至11之一所述的方法，其特征在于，通过局部多孔的嵌件(3)将负压施加于预制坯(1)。
13.按照权利要求12所述的方法，其特征在于，通过控制阀(19)将局部多孔的嵌件(3)暂时和受控地连接于一个压力源(20)和一个或多个负压源(21)，并且本方法还包括该步骤，即，沿着嵌件的表面输入局部变化的压力条件。
14.按照权利要求1至13之一所述的方法，其特征在于，所述嵌件(3)还包括一个压力介质接头(11)，并且本方法还包括该步骤，即，引起一气流沿负压通道(9)的方向通过内腔(14)，以利于将预制坯(1)引进内腔(14)中。
15.按照权利要求1所述的方法，其特征在于，所述使预制坯变形的步骤规定用于重塑预制坯，以便补偿预制坯中的无意的缺陷，即，通过注塑模具没有被注塑到其完全的程度。
16.按照权利要求1所述的方法，其特征在于，所述使预制坯变形的步骤规定用于重塑预制坯，以便补偿预制坯中的有意的缺陷。
17.按照权利要求1所述的方法，其特征在于，所述芯棒构成为用于使预制坯局部有限地变形。
18.按照权利要求17所述的方法，其特征在于，芯棒的至少一些表面用密封件覆盖。
19.按照权利要求18所述的方法，其特征在于，所述密封件设定用于芯棒的圆顶，以便部分地重塑预制坯。
20.按照权利要求1所述的方法，其特征在于，所述芯棒包括至少一个膜片，它限定一个用于重塑预制坯的分配室。
21.按照权利要求1所述的方法，其特征在于，作为多孔材料，所述嵌件包括多孔金属、多孔铝制金属和烧结金属中的任意一种。
22.按照权利要求21所述的方法，其特征在于，所述多孔材料包括大于几微米的可变的空隙尺寸。
23.按照权利要求1所述的方法，其特征在于，还包括该步骤，即，通过嵌件的多孔元件将过压和负压施加于预制坯。
24.按照权利要求1所述的方法，其特征在于，所述用于改变在预制坯(1)的壁中的材料圆周分布的预制坯变形步骤是用于重塑预制坯，来实现预制坯的壁中的材料分布，以便通过吹塑来后续生产出椭圆形的瓶子。
25.按照权利要求1至24之一所述的方法，其特征在于，所述预制坯(1)的变形步骤在预制坯(1)吹塑步骤之前以一个单阶段注坯吹塑工艺实施。
26.按照权利要求1至24之一所述的方法，其特征在于，所述预制坯(1)的变形步骤在预制坯(1)吹塑步骤之前以一个双阶段注坯吹塑工艺实施。
27.一种用于加工注塑的热塑性塑料预制坯(1)的装置，所述预制坯供在后续的过程中吹塑成容器，所述装置包括以下中至少之一，
-嵌件(3)，它具有一个限定一空腔的表面，该空腔构成为用于接收预制坯(1)的一个外部的部分；以及
-芯棒(22)，它具有一个构成为用于接收预制坯(1)的一个内部的部分的表面；
所述嵌件和芯棒的表面的至少一部分包括一种多孔材料，用于通过经由多孔材料的负压的作用使接收到的预制坯(1)变形，以便把预制坯各部分中的至少一个部分拉到与其接触中；以及
其中，所述变形规定用于以下中至少之一：
补偿预制坯(1)中的在其注塑步骤中产生的缺陷；改变在预制坯(1)的壁中的材料圆周分布。
28.按照权利要求27所述的装置，其特征在于，通过负压通道(10)把负压供给多孔材料。
29.按照权利要求27或28所述的装置，其特征在于，所述嵌件和芯棒中的至少一个构成为包括一个密封件(12、22、23)，用于在其中密封所述预制坯部分，以防止在施加负压时吸入周围空气。
30.按照权利要求27至29之一所述的装置，其特征在于，所述嵌件还包括一个延伸到空腔中的负压通道，用于对预制坯相对于嵌件的压力-支持的移动性加以影响。
31.按照权利要求27至30之一所述的装置，其特征在于，所述嵌件还构成为一个冷却装置，用于在其中冷却预制坯。
32.按照权利要求31所述的装置，其特征在于，所述嵌件构成为在其中包括一个冷却通道(11)。
33.按照权利要求27至32之一所述的装置，其特征在于，所述嵌件设置在一个框架(2)中。
34.按照权利要求33所述的装置，其特征在于，所述框架(2)构成为在其中包括一个冷却通道(11)。
35.按照权利要求27至32之一所述的装置，其特征在于，所述嵌件定位于一个冷却套筒中。
36.按照权利要求27至35之一所述的装置，其特征在于，所述嵌件(3)和芯棒(22)中的至少一个构成为与一个压力源连接，以便通过过压作用使接收到的预制坯(1)变形。
37.按照权利要求27至36之一所述的装置，其特征在于，通过局部多孔的嵌件(3)将负压施加于预制坯(1)。
38.按照权利要求37所述的装置，其特征在于，通过控制阀(19)将局部多孔的嵌件(3)暂时和受控地连接于一个压力源(20)和一个或多个负压源(21)，用于沿着嵌件的表面输入局部变化的压力条件。
39.按照权利要求27至38之一所述的装置，其特征在于，所述嵌件(3)还包括一个压力介质接头(11)，用于引起一气流沿负压通道(9)的方向通过内腔(14)，以利于将预制坯(1)引进内腔(14)中。
40.按照权利要求27所述的装置，其特征在于，预制坯变形规定用于重塑预制坯，以便补偿预制坯(1)中的无意的缺陷，即，通过注塑模具没有被注塑到其完全的程度。
41.按照权利要求27所述的装置，其特征在于，预制坯变形规定用于重塑预制坯，以便补偿预制坯中的有意的缺陷。
42.按照权利要求27所述的装置，其特征在于，所述芯棒构成为用于使预制坯局部有限地变形。
43.按照权利要求42所述的装置，其特征在于，芯棒的至少一些表面用密封件覆盖。
44.按照权利要求43所述的装置，其特征在于，所述密封件设定用于芯棒的圆顶，以便部分地重塑预制坯。
45.按照权利要求27所述的装置，其特征在于，所述芯棒包括至少一个膜片，它限定一个用于重塑预制坯的分配室。
46.按照权利要求27所述的装置，其特征在于，作为多孔材料，所述嵌件包括多孔金属、多孔铝制金属、多孔钢制金属、多孔铜合金制金属和烧结金属中的任意一种。
47.按照权利要求46所述的装置，其特征在于，所述多孔材料包括大于几微米的可变的空隙尺寸。
48.按照权利要求27所述的装置，其特征在于，还包括通过嵌件的多孔元件将过压和负压施加于预制坯。
49.按照权利要求27所述的装置，其特征在于，所述表面构成为用于改变在预制坯(1)的壁中的材料圆周分布的预制坯变形，用于重塑预制坯，来实现预制坯的壁中的材料分布，以便通过吹塑来后续生产出椭圆形的瓶子。
50.一种包括按权利要求27至49中任一项所述的装置的注塑机。
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