JP5290388B2 - Thin-walled molding method - Google Patents

Thin-walled molding method Download PDF

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JP5290388B2
JP5290388B2 JP2011270014A JP2011270014A JP5290388B2 JP 5290388 B2 JP5290388 B2 JP 5290388B2 JP 2011270014 A JP2011270014 A JP 2011270014A JP 2011270014 A JP2011270014 A JP 2011270014A JP 5290388 B2 JP5290388 B2 JP 5290388B2
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screw
pressure
injection
step
molten resin
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JP2012144042A (en
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浩一 児玉
靖彦 澤田
圭呉 須佐
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株式会社日本製鋼所
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Priority claimed from KR1020120060859A external-priority patent/KR101394846B1/en
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a forming method of a thin-walled molded product capable of forming a light guide plate for a liquid crystal of a medium or larger size. <P>SOLUTION: A thin-walled molded product is formed by using an injection device (2) composed of a heating cylinder (5) and a screw (6). Firstly, dies (20, 21) are placed in a state of being opened by a predetermined amount, and a screw (6) is driven in the axial direction to inject molten resins in cavities. The dies (20, 21) are clamped to compress the injected molten resins. During compression, the screw (6) is retracted by a predetermined time to lower the resin pressure of the molten resins in the cavities. Thereafter, a driving force in the axial direction is applied to the screw (6) to perform the pressure application of applying the predetermined resin pressure to the molten resins. The drive of the screw (6) during the pressure application may be subject to speed control, and then, switched to pressure control. <P>COPYRIGHT: (C)2012,JPO&amp;INPIT

Description

  The present invention relates to a molding method for molding a thin-walled molded article in an injection molding machine, and relates to a molding method for a thin-walled molded article suitable for molding a light guide plate used for liquid crystal, although not limited thereto. is there.

  An injection molding machine is composed of a pair of molds, a mold clamping apparatus for clamping these molds, an injection apparatus for melting a resin material and injecting the resin material into the mold, as is well known in the art, and the injection apparatus is a cylinder. The screw is driven in the cylinder in the axial direction and the rotational direction. When a pair of molds are clamped by the mold clamping device and the molten resin measured in the cylinder is injected by driving the screw in the axial direction, the cavity is formed in the mold. When the mold is opened after cooling and solidification, a molded product is obtained.

  By the way, in a mold for molding a so-called thin-walled molded product that is thin compared to its size, such as a light guide plate used for liquid crystals, the gap or thickness of the cavity is thin. The flow resistance of the resin is large. If it does so, the molten resin inject | emitted from an injection apparatus will be hard to fully fill in a cavity, and transferability will also fall. A so-called injection compression molding method is well known as a molding method for molding such a thin molded product. Patent Document 1 describes an example of such an injection compression molding method.

JP 2008-302686A

  Patent Document 1 describes a molding method for molding a light guide plate, but the mold used in this molding method is such that the cavity forming surface of the movable mold is compared to the cavity forming surface of the fixed mold. The distance can be made variable. That is, the thickness of the cavity can be made variable. In the method described in Patent Document 1, the mold is closed in a state where the thickness of the cavity is increased by 0.2 to 0.5 mm from the thickness of the finally obtained light guide plate. That is, the mold is slightly opened. In this state, molten resin is injected into the cavity, and mold clamping is started during or after injection. Clamping is completed after the end of injection. This compresses the molten resin and pushes it into the cavity. When the mold is opened after cooling and solidification, a light guide plate having a desired thickness can be obtained.

  In a general injection molding machine, the screw can be switched between screw speed control and driving force control, thereby controlling the speed at which the molten resin is injected and controlling the injection pressure or resin pressure. it can. Various controls such as mold clamping force and screw speed can be controlled based on the screw position or based on time. In such an injection molding machine, when the above-described injection compression molding method is performed, control is performed as shown in FIG. In FIG. 5, the horizontal axis represents the screw position or time. At first, control is started based on the screw position. The screw is controlled by the screw speed until the pressure holding process is started. At the start of injection, that is, when the screw position is at the initial position 51, the target value of the screw speed, that is, the speed command 52 starts control with a relatively small value 62, and the speed of the molten resin to be injected is reduced. At this time, the injection pressure 53 is also small. The mold clamping force 54 is a relatively small value 63 because the mold is only kept slightly open. When the screw position reaches the position 55, the speed command 52 is set to a high value 64 to increase the speed of the injected molten resin. The injection pressure 53 is increased. When the screw position reaches the position 56, the speed command 52 is set to a larger value 65, and at the same time, the mold clamping force 54 is controlled to gradually increase. That is, the mold is gradually clamped. As a result, the molten resin injected into the cavity is compressed and filled into the cavity. When the injection is completed, that is, when the screw position reaches the holding pressure switching position 58, the control based on the screw position is switched to the control based on the elapsed time. The screw is switched from screw speed control to driving force control, that is, injection pressure or resin pressure control. The mold clamping is completed with a slight delay in holding pressure switching, and the mold clamping force 54 is controlled to be a constant value 68 until the holding pressure is finished. After the holding pressure is switched, the injection pressure 53, that is, the resin pressure 53 is controlled so as to become a predetermined target value 66. However, the resin pressure 53 gradually decreases after reaching the holding pressure and reaches the target value 66. When the predetermined time 59 elapses, the resin pressure 53 is controlled to become a slightly lower target value 67. When the predetermined time 61 elapses and the molten resin is solidified and cooled, the holding pressure is finished.

  If molding is performed by a so-called injection compression molding method such as the method described in Patent Document 1, the molten resin is filled in every corner of the cavity, and a thin molded product having excellent transferability can be obtained. However, there are also problems, particularly when a thin molded product having a very large molded product compared to the thickness is formed. In the injection compression molding method, when compressed by mold clamping, the molten resin flows from the vicinity of the center of the cavity toward the periphery. Since the flowing molten resin has a flow resistance between the wall surface of the cavity, the pressure of the molten resin becomes uneven in the molded product. That is, while the resin pressure is low in the periphery of the molten resin, the vicinity of the center, that is, the vicinity of the gate is in a high pressure state. As indicated by reference numeral 69 in the graph of FIG. 5, it can be seen that the injection pressure 53 after the holding pressure switching is high and the resin pressure in the vicinity of the gate is high. In the case of a molded product that is very large compared to the wall thickness, the deviation of the resin pressure is large. As a result, a large residual stress remains in the obtained molded product, and the vicinity of the center portion becomes thick or deforms, and a molded product having a desired quality cannot be obtained. The example described in Patent Document 1 is a relatively small problem because it is a small light guide plate for a mobile phone, but there is a problem when a light guide plate for a medium or larger liquid crystal television is formed. In the case of the light guide plate, if the thickness is not uniform, the optical characteristics deteriorate and cannot be used. In the case of forming a medium-sized or larger light guide plate, conventionally, it is necessary to increase the thickness so that such a problem does not occur, resulting in an increase in weight.

  An object of the present invention is to provide a method for forming a thin-walled molded product that solves the above-described problems, and specifically, in the case of obtaining a molded product that is very large compared to the wall thickness. However, an object of the present invention is to provide a molding method capable of obtaining a high-quality thin-walled molded product without residual stress remaining in the molded product or changing the thickness. Although not limited, it is also an object of the present invention to provide a molding method capable of forming a light guide plate for liquid crystal of medium size or larger with a thin wall thickness that has not been conventionally used.

In order to achieve the above object, the present invention is configured as a molding method using an injection device including a heating cylinder and a screw or a plunger provided in the heating cylinder so as to be axially drivable. In this molding method, first, the mold is opened in a predetermined amount, and the screw or plunger is driven in the axial direction to inject molten resin into the mold cavity. The mold is clamped to compress the injected molten resin. During this compression, the screw or plunger is retracted for a predetermined time to reduce the resin pressure of the molten resin in the cavity. Thereafter, a predetermined resin pressure is applied to the molten resin by applying an axial driving force to the screw or plunger. That is, pressure is maintained. In this way, a thin molded product is formed. The screw or plunger is driven during this holding pressure by controlling the pressure so that the resin pressure becomes a predetermined pressure after speed control is performed for a predetermined time immediately after the pressure holding starts and the resin pressure is recovered in a short time. Transition.

Thus, in order to achieve the above object, the invention according to claim 1 uses an injection device comprising a heating cylinder and a screw or a plunger provided in the heating cylinder so as to be axially drivable. A molding method for molding a thin-walled molded article, wherein the molding method is an injection in which a mold is opened by a predetermined amount and the screw or plunger is driven in the axial direction to inject molten resin into a cavity of the mold. A step of compressing the injected molten resin by clamping the mold, and a step of retracting the screw or the plunger for a predetermined time in parallel with the compression step to move the molten resin in the cavity A depressurizing step for lowering the resin pressure, and after the depressurizing step, an axial driving force is applied to the screw or the plunger to apply a predetermined resin pressure to the molten resin. A step, Ri Tona, wherein when driving the screw or the plunger in the pressure-holding step in the axial direction, and speed control such that the process started with the target speed for a predetermined time, pressure, as then becomes the target resin pressure It is configured as a molding method of a thin molded product characterized by controlling .
According to a second aspect of the present invention, in the method of the first aspect, the compression step is configured to start before the end of the injection step.
According to a third aspect of the present invention, in the method according to the first or second aspect, the pressure releasing step is a time control that controls the screw or the plunger based on an elapsed time from the end of the injection step. Configured to be.

As described above, the present invention is configured as a molding method using an injection device including a heating cylinder and a screw or a plunger that is provided so as to be axially drivable in the heating cylinder. It can be formed by a general injection device. An injection step of injecting molten resin into the cavity of the mold by driving the screw or plunger in the axial direction with the mold opened by a predetermined amount, and the molten resin injected by clamping the mold A compression process for compressing, a pressure release process for reducing the resin pressure of the molten resin in the cavity by retracting the screw or plunger for a predetermined time in parallel with the compression process, and an axial drive to the screw or plunger after the pressure release process A thin molded product is formed by a pressure-holding step in which a predetermined resin pressure is applied to the molten resin by applying a force. That is, since the injection process and the compression process are provided, a certain amount of thin-walled molded product can be obtained as in the conventional injection compression molding method. Further, in the present invention, since the pressure releasing step in the mold is performed in parallel with the compression step, it is possible to alleviate the uneven pressure distribution of the molten resin generated in the cavity in the compression step. In other words, it is possible to prevent residual stress from remaining and uneven thickness. Thus, even a thin molded product that could not be molded conventionally, that is, a thin molded product that is extremely thin compared to its size, can be molded with high accuracy. For example, in the case of a medium-sized liquid crystal light guide plate, the thickness can be reduced by 30% compared to the conventional thickness. According to the present invention, when the screw or plunger is driven in the axial direction in the pressure holding process, the speed is controlled so that the target speed is reached for a predetermined time from the start of the process, and then the pressure is controlled so that the target resin pressure is reached. It is configured. Then, even if the molten resin is returned to a slightly larger amount in the heating cylinder in the depressurization step, the molten resin can be quickly pushed back into the cavity by speed control, so that the resin pressure is recovered in a very short time. Thereafter, the pressure is controlled so that a desired resin pressure is obtained, so that the pressure-holding process is stabilized, and a molded product having excellent accuracy can be obtained. According to another invention, since the compression process is configured to start before the end of the injection process, the injection process and the compression process can be performed smoothly, and the molding cycle can be shortened. According to still another invention, the pressure release process is configured to be a time control for controlling the screw or the plunger based on the elapsed time from the end of the injection process. Time control can be managed by a timer, and an effect that can be easily implemented is obtained.

It is a figure showing typically the electric injection molding machine concerning an embodiment of the invention. It is a flowchart explaining the shaping | molding method which concerns on embodiment of this invention. It is a graph which shows changes, such as screw speed, injection pressure, and mold clamping force, when the molding method concerning an embodiment of the invention is carried out. It is a graph explaining the shaping | molding method which concerns on the 2nd Embodiment of this invention, and is a graph which shows changes, such as a screw speed in a predetermined process, injection pressure, and mold clamping force. It is a graph which shows changes, such as screw speed, injection pressure, and mold clamping force, when the conventional injection compression method is carried out.

  The molding method of the thin molded product according to the present embodiment can be performed by a conventionally known injection molding machine. In the present embodiment, a method of forming a light guide plate for liquid crystal of medium size or larger with the electric injection molding machine 1 will be described. The electric injection molding machine 1 will be schematically described. The electric injection molding machine 1 is also composed of an injection device 2 and a mold clamping device 3, as is well known in the art, and is shown in FIG. The injection device 2 includes a heating cylinder 5 and a screw 6 provided in the heating cylinder 5, and an injection nozzle 7 is provided at the tip of the heating cylinder 5. A band heater 8 is wound around the outer peripheral surface of the heating cylinder 5, and a hopper for supplying a resin material into the heating cylinder 5 is provided near the rear end. The hopper is not shown in FIG. The screw 6 can be driven in the rotational direction by a driving mechanism (not shown) and can be driven in the axial direction. When driven in the axial direction, the screw 6 can be controlled by the speed of the screw 6 or by the driving force. It can be done. As is well known in the art, the mold clamping device 3 also has a stationary platen 10, a movable platen 11 that is opened and closed with respect to the stationary platen 10, a mold clamping housing 12, and the movable platen 11 and the stationary platen 10 and the mold. Are connected to the clamping housing 12 and a toggle mechanism 15 provided between the stationary platen 10 and the mold clamping housing 12. The mold clamping housing 12 is provided with a drive mechanism including a ball screw 16, a ball nut 17 screwed into the ball screw 16, a predetermined gear for driving the ball nut 17, and a servo motor 18. The toggle mechanism 15 is driven by the mechanism so that the mold can be opened and closed.

  In such a mold clamping device 3, the fixed side mold 20 and the movable side mold 21 according to the present embodiment are attached to the fixed platen 10 and the movable platen 11, respectively. These molds 20 and 21 are molds for forming a light guide plate. The fixed mold 20 has a recess, and the movable mold 21 has a core corresponding to the recess. When the movable mold 21 is closed with respect to the fixed mold 20, the core is inserted into the recess to form a cavity for forming the light guide plate. However, when the molds 20, 21 are slightly opened, the cavity is formed. The gap, i.e., the thickness, increases in accordance with the amount of mold opening. A hydraulic cylinder 22 is embedded in a surface of the upper part of the movable mold 21 facing the fixed mold 20. The piston rod 23 of the hydraulic cylinder 22 comes into contact with the stationary mold 20 in a state where the molds 20 and 21 are slightly opened. In the present embodiment, the hydraulic cylinder 22 is driven so as to maintain the parallelism of the molds 20 and 21 with high accuracy. As a result, the molds 20 and 21 can be clamped without falling down.

  A cutout 24 into which the injection nozzle 7 is inserted is opened in the stationary platen 10 of the mold clamping device 3. The injection device 2 is inserted from the back surface of the fixed platen 10, and the injection nozzle 7 touches the sprue of the fixed mold 20. Although not shown in FIG. 1, the electric injection molding machine 1 according to the present embodiment is also provided with a controller, and each device is controlled by the controller.

A molding method according to the first embodiment in which a light guide plate is molded by the electric injection molding machine 1 will be described with reference to FIGS. 2 and 3.
In the injection device 2, the heating cylinder 5 is heated by the band heaters 8, 8,..., The screw 6 is rotated, and the resin material is supplied from the hopper. Then, the resin material is melted by the heat generated by the band heaters 8, 8,... And the heat generated by the shearing of the screw 6, and is measured at the tip of the heating cylinder 5. When the screw 6 is retracted by a predetermined length due to the molten resin to be weighed, the weighing is completed (step S1).

  The mold clamping device 3 is driven to drive the molds 20 and 21 in the mold closing direction. Then, the molds 20 and 21 are slightly opened (step S2). Since the molds 20 and 21 are not closed, the mold clamping force 28 has a relatively low value 41 as shown in the graph of FIG. The screw 6 is driven in the axial direction to start the injection process (step S3). The screw 6 is controlled by its speed, that is, the screw speed during the injection process. The screw speed command, that is, the speed command 27 is set based on the position of the screw 6. That is, control is performed based on the screw position. The speed command 27 is set to the low speed 38 until the molten resin after the injection starts reaches the gate, that is, the position of the screw 6 is between the start position 30 and the position 31. Therefore, the molten resin is injected at a low speed. After the molten resin reaches the gate, it is injected at a medium speed in accordance with a speed command 27 set at a medium speed 39. The injection pressure 26 gradually increases from the start of the injection process, but the mold clamping force 28 is maintained at a substantially constant value 41. At this time, the cavities of the molds 20 and 21 are filled with molten resin, but are in a short shot state as shown in FIG.

  When the screw 6 reaches the predetermined position 32, the compression process is started (step S4). That is, the mold clamping device 3 is driven to gradually close the mold. This compresses and spreads the molten resin in the cavity. The mold clamping force 28 increases. In the present embodiment, after the screw 6 reaches the position 32, the speed command 27 is set to the high speed 40, and the molten resin is injected at a high speed. That is, the injection is continued even after the compression process is started. When the screw 6 reaches the holding pressure switching position 33, the injection process is terminated (step S5). That is, the speed command 27 of the screw 6 is set to zero, the injection of the molten resin is stopped, and the injection process is finished. Thereafter, the screw 6 is controlled based on the elapsed time from the end of the injection process. That is, it shifts to time control.

  After completion of the injection process, the screw 6 is retracted at a predetermined speed for a short time during the compression process. That is, a pressure release process is performed (step S6). When the molten resin is spread into the cavity in the compression process, the molten resin in the center, that is, in the vicinity of the gate, has a higher pressure than the surroundings, and there is a significant bias in the pressure distribution. The pressure of the nearby molten resin decreases. This alleviates the non-uniformity in the pressure distribution of the molten resin. In the graph of FIG. 3, as indicated by reference numeral 43, a state in which the injection pressure 26 is rapidly decreased is shown. The compression process ends after the end of the depressurization process (step S7). That is, the mold clamping is completed, and the mold clamping force 28 reaches the maximum value 42. The molten resin is filled to every corner of the cavity. After the completion of the pressure release process or after the compression process, the pressure holding process is started (step S8). That is, when the molten resin in the cavity is cooled, the screw 6 is driven at a predetermined back pressure to apply a predetermined resin pressure 44 to prevent sink marks. When the predetermined time 34 has elapsed and the molten resin has cooled to some extent, the pressure of the molten resin is lowered as indicated by reference numeral 45. When the cooling time 35 has elapsed and the resin has solidified and cooled, the pressure holding process is terminated.

  In general, in the pressure holding step, the pressure is controlled so that a desired resin pressure 44 is obtained by controlling the driving force of the screw 6. That is, torque control is performed on the servo motor that drives the screw 6. If the amount of resin that returns to the heating cylinder 5 due to the retraction of the screw 6 in the pressure release process is appropriate, there is no problem because the target resin pressure is quickly reached in the pressure holding process. However, when a large amount of resin returns into the heating cylinder 5 in the pressure release process, the resin pressure does not increase unless the screw 6 is driven in the axial direction to some extent and the molten resin is not pushed into the cavity. In this case, if the screw 6 is driven only by pressure control, the responsiveness is poor, and it takes time to obtain a desired resin pressure, which affects the quality of the molded product. A molding method according to the second embodiment, which can avoid this phenomenon, will be described with reference to FIG. FIG. 4 is a graph obtained by enlarging the section indicated by the symbol A in the graph of FIG. 3 in the horizontal axis direction. The molding method according to the second embodiment differs from the molding method according to the first embodiment already described only in the pressure holding step. Therefore, only the pressure holding process will be described. In the molding method according to the second embodiment, when the pressure holding process is started, the speed of the screw 6 is controlled for a set short time. In FIG. 4, a speed command 27 ′ for the screw 6 is set as indicated by reference numeral 47. The screw 6 is driven in the axial direction so that the set target speed is achieved, and the resin pressure increases in a very short time. Thereafter, the drive of the screw 6 is shifted to pressure control. Then, the desired resin pressure 44 can be obtained in a short time.

  The molding method according to the present embodiment can also be implemented in other injection molding machines. For example, the present invention can also be implemented in a hydraulic injection molding machine, and can also be implemented in the same manner even when the injection device is constituted by a heating cylinder and a plunger driven in the axial direction in the heating cylinder. Various modifications can be made to the molding method according to the present embodiment. For example, in the present embodiment, the compression process is described as starting before the injection process ends, but may be started after the injection process is completed. In addition, the speed command is set to 3 stages in the injection process, and the resin pressure is set to 2 stages in the pressure holding process. However, each of these may be set to 1 stage or more stages. Also good.

DESCRIPTION OF SYMBOLS 1 Electric injection molding machine 2 Injection device 3 Mold clamping device 5 Heating cylinder 6 Screw 7 Injection nozzle 10 Fixed platen 11 Movable platen 12 Clamping housing 13 Tie bar 15 Toggle mechanism 20 Fixed side die 21 Movable side die

Claims (3)

  1. A molding method for molding a thin molded article using an injection device comprising a heating cylinder and a screw or plunger provided so as to be axially drivable in the heating cylinder ,
    The molding method includes an injection step of injecting molten resin into a cavity of the mold by driving the screw or plunger in the axial direction with the mold opened by a predetermined amount, and clamping the mold to A compression step of compressing the injected molten resin, a pressure releasing step of reducing the resin pressure of the molten resin in the cavity by retracting the screw or the plunger for a predetermined time in parallel with the compression step; a pressure holding process to apply a predetermined resin pressure to the screw or the molten resin over the axial direction of the drive force to the plunger after the punching step, Ri Tona,
    When the screw or the plunger is driven in the axial direction in the pressure-holding step, speed control is performed so that the target speed is reached for a predetermined time from the start of the process, and then pressure control is performed so that the target resin pressure is reached. Molding method for thin molded products.
  2.   The method according to claim 1, wherein the compression step is started before the end of the injection step.
  3.   3. The method according to claim 1, wherein the depressurizing step is a time control for controlling the screw or the plunger based on an elapsed time from the end of the injection step. Molding method.
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JP2011270014A JP5290388B2 (en) 2010-12-20 2011-12-09 Thin-walled molding method
KR1020120060859A KR101394846B1 (en) 2011-12-09 2012-06-07 Molding method of thin molded article
TW101121274A TWI508842B (en) 2011-12-09 2012-06-14 Forming method of thin-walled molded article
CN201210209761.9A CN103158236B (en) 2010-12-20 2012-06-19 The manufacturing process of thin formed products

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JP6438215B2 (en) * 2014-05-21 2018-12-12 東洋機械金属株式会社 Injection molding machine and operation control method thereof
JP5877882B2 (en) 2014-07-17 2016-03-08 ファナック株式会社 Pressure control device for injection molding machine
DE102014018495A1 (en) * 2014-12-16 2016-06-16 Gebr. Krallmann Gmbh Method for producing a multilayer plastic lens
JP6137368B1 (en) * 2016-03-24 2017-05-31 宇部興産機械株式会社 Mold clamping control method of injection molding machine having toggle type mold clamping mechanism
JP6594284B2 (en) * 2016-10-18 2019-10-23 株式会社日本製鋼所 Operation method of plasticizing injection device
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JP2003191300A (en) * 2001-12-26 2003-07-08 Toshiba Mach Co Ltd Method for injection compression molding of thin molded article and its apparatus
JP2004202731A (en) * 2002-12-24 2004-07-22 Sumitomo Chem Co Ltd Method for manufacturing large-sized light guide plate
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