TWI613058B - 用於射出成型或壓花/壓印之方法及裝置 - Google Patents
用於射出成型或壓花/壓印之方法及裝置 Download PDFInfo
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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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
- B29C33/06—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using radiation, e.g. electro-magnetic waves, induction heating
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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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/72—Heating or cooling
- B29C45/73—Heating or cooling of the mould
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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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/52—Heating or cooling
-
- 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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
- B29C53/04—Bending or folding of plates or sheets
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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
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/002—Component parts, details or accessories; Auxiliary operations
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
- B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
- B29C2033/385—Manufacturing moulds, e.g. shaping the mould surface by machining by laminating a plurality of layers
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
- B29C2043/023—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves
- B29C2043/025—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves forming a microstructure, i.e. fine patterning
-
- 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
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
- B29K2105/256—Sheets, plates, blanks or films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2909/00—Use of inorganic materials not provided for in groups B29K2803/00 - B29K2807/00, as mould material
- B29K2909/02—Ceramics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
- B29K2995/0005—Conductive
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
- B29K2995/0007—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
- B29K2995/0008—Magnetic or paramagnetic
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Abstract
本發明係關於一種具有用於加熱一作用工具表面之構件之用於射出成型或壓花/壓印之工具,該構件包含用於在毗鄰於該作用工具表面之一導電頂部層中產生一振盪磁場之一線圈,及位於線圈載體層與該頂部層之間的一導電中間層(23)。一熱阻層(29)位於該中間層與該頂部層之間且包括一陶瓷材料熱噴塗層,在自該作用工具表面觀看時,該陶瓷材料熱噴塗層係接合至該熱阻層下方之層。
Description
本發明係關於一種包括一加熱裝置之工具,諸如一射出成型工具或一壓花/壓印工具。藉助於加熱一作用工具表面之若干層之一堆疊而達成加熱,且該層堆疊包括:一線圈載體層,其包含用於產生一振盪磁場之至少一個繞組線圈;一導電頂部層,其毗鄰於該作用工具表面;一背托層,在自該頂部層觀看時其定位於該線圈載體層下方,該背托層電連接至該頂部層且具有低於該頂部層之一電阻率;一導電中間層,其位於該線圈載體層與該頂部層之間,其中該中間層具有低於該頂部層之一電阻率;及一熱阻層,其介於該中間層與該頂部層之間。
此一裝置在WO-2013/002703-A1中提出,其中該裝置可用於(例如)以精細表面圖案將光學裝置壓花。關於此等工具之一個問題係如何以一高效方式產生一工具。
因此,本發明之一個目標係達成可以一較高效方式產生之一工具。以如技術方案1中所定義之一工具達成此目標。更具體而言,在係為最初所提及種類之一工具中,熱阻層係一陶瓷材料熱噴塗層,在自作用工具表面觀看時,該陶瓷材料熱噴塗層係接合至該熱阻層下方
之層。此產生中間層及該中間層之至少上部部分,該中間層與該熱阻層一起經塗佈為一單個單元。
為產生具有一經壓花表面圖案之平坦產品,該中間層之該頂部表面可係平坦的,且頂部上之該熱阻層可經機械加工成一平坦形狀。此提供補償(例如)該中間層之製造公差之一機會。
另一選擇係,該熱阻層可經機械加工成偏離一平坦、平坦形狀的一個三維形狀。此亦允許產生非平坦之最終產品。
另一選擇係,可將該中間層之該頂部表面機械加工成偏離一平坦形狀之一個三維形狀,且將具有均勻厚度之一熱阻層施加於該中間層之該頂部表面上方。此允許壓印一個三維(非平坦)產品同時維持一均勻厚之熱阻層。
該陶瓷材料熱噴塗層可包括氧化釔穩定氧化鋯YSZ,已發現,YSZ適合於熱噴塗及後續機械加工兩者。
亦已考量一種用於壓花/壓印兩個工具半體之間的一坯料之方法,其中該方法包含用一線圈載體層中之至少一個繞組線圈在該等工具半體中之至少一者中產生一振盪磁場,使得經由該頂部層與該線圈載體層之間的一導電中間層在毗鄰於面對該坯料之一作用工具表面之一導電頂部層中產生熱。一熱阻層位於該中間層與該頂部層之間且該等工具半體被壓印在一起,其中該方法包含將該坯料彎曲成沿三個維度延伸之一形式,該形式經機械加工成該熱阻層。此允許藉由壓印產生一個三維(亦即非平坦)產品。
1‧‧‧坯料
3‧‧‧工具半體
5‧‧‧工具半體
7‧‧‧加熱裝置
9‧‧‧熔融樹脂
11‧‧‧腔
15‧‧‧工具半體
17‧‧‧工具半體
19‧‧‧感應線圈/繞組線圈/線圈
21‧‧‧線圈載體層
23‧‧‧導電中間層/電作用中間層/作用中間層
25‧‧‧頂部層
25’‧‧‧頂部層/成品頂部層
27‧‧‧背托層
29‧‧‧熱阻層
29’‧‧‧熱阻層
31‧‧‧作用工具表面/作用表面
33‧‧‧連接件
35‧‧‧長邊
37‧‧‧短邊
39‧‧‧電流
40‧‧‧電流
51‧‧‧塗佈材料
53‧‧‧加熱裝置
55‧‧‧熔融粒子
57‧‧‧頂部層坯料
圖1示意性地圖解說明用於壓花/壓印一坯料之一工具。
圖2示意性地圖解說明用於射出成型之一工具。
圖3示意性地圖解說明經設計以提供一工具表面之高效加熱之若干層之一堆疊。
圖4示意性地圖解說明圖3之層中之電流之誘發。
圖5圖解說明用於將一熱阻層熱噴塗至若干層之一堆疊上之一程序。
圖6展示如圖5中所產生之一層經機械加工成一平坦形狀。
圖7展示其中達成一3維形狀之一第一情形。
圖8展示其中達成一3維形狀之一第二情形。
圖9A至圖9C圖解說明用於將一頂部層施加至一3維熱阻層之一種方法。
圖10圖解說明噴塗於一作用中間層上,具有一3維表面之一熱阻層。
本發明係關於以供用於形成樹脂或塑膠材料之裝置及方法。以下說明將主要闡述用於壓花塑膠坯料而(如熟習此項技術所認識到)可同樣應用於射出成型及其他製程(諸如吹製成型)之一系統。WO-2013/002703-A1闡述用於壓花/壓印一坯料或用於射出成型之一裝置。如圖1中所圖解說明,此一裝置可具有兩個工具半體3、5。該兩個工具半體中之每一者或一者可具備一加熱裝置7。在壓花時,藉由將熱及壓力施加於一工具中(亦即將該等半體抵靠彼此而壓印同時加熱面對坯料1之半體之作用表面處之該等半體)而在一定程度上重塑坯料1(一固體塑膠件)。通常,將一表面圖案施加於一個或兩個表面上。
其中可使用此技術之一項實例係在產生用於背光平面螢幕LCD電視螢幕之光導時。然後在其一個平坦表面上提供具有一精細表面圖案之一透明矩形塑膠薄層。當照射該薄層之一邊緣時,表面圖案使所射入光離開光導,均勻地在該表面上方。可藉由係在作用表面處面對坯料之一工具半體之層之一壓模/頂部層達成此一圖案。亦可設想藉助
壓花產生之其他產品,例如菲涅耳(Fresnel)透鏡。除提供表面圖案(壓花)外或作為對此之一替代方案,亦可(例如)彎曲一坯料(壓印)。藉助主動加熱及冷卻提供相對短之週期時間,此意指與在不使用主動加熱及視情況冷卻時相比,裝置具有一較高輸出。裝置之使用決不限於產生光學組件。
所揭示之加熱及冷卻功能結合射出成型亦可係有用的。於是,如圖2中示意性地圖解說明,熔融樹脂9經射入至在兩個工具半體15、17之間形成之一腔11中。工具半體之加熱及冷卻可允許形成較薄結構,且可縮短一生產週期以改良輸出。
供參考,圖3示意性地且以剖面圖解說明如在WO-2013/002703-A1中所闡述之若干層之一堆疊。該堆疊經設計以提供對一作用工具表面31之高效加熱。一作用工具表面意指與待重塑之塑膠或樹脂接觸之一表面。該層堆疊具有一感應線圈19,該感應線圈可用以提供工具加熱。該堆疊具有一線圈載體層21、一電作用中間層23、一頂部層25、一背托層27及一熱阻層29。
本發明在一很大程度上針對於採用此一熱阻層29之經改良方式。
線圈載體層21包含繞組線圈19且由具有高相對磁導率(例如在室溫下為300)及極高電阻率(例如2.5×10-3Ωm)之一材料製成。因此,該材料係在任何更大程度上易於傳導磁場但不輸送電流之一材料。此意指線圈載體層21將把由線圈19在其中產生之磁場輸送至其他層且使該磁場成形,而不在線圈載體層21本身中誘發任何實質渦流。線圈19經放置於線圈載體中之開放凹槽中且提供線圈載體之表面上方之場之一均勻分佈。PERMEDYN MF1(商標)被視為用於線圈載體層之一種適合材料且涉及由一電絕緣樹脂燒固在一起之鐵磁材料之顆粒。一般而言,線圈載體厚度通常可處於10mm至30mm之範圍內。
電作用中間層23包括具有極低電阻率(通常1×10-8Ωm至3×10-8Ωm或更小)之一金屬,諸如銅或鋁。此層經表示為作用的,此乃因線圈在其中誘發經輸送至頂部層之電流。然而,由於電阻率係如此低,因此在任何更大程度上彼等電流在作用中間層中不產生熱。該層之厚度通常可係10mm至30mm,相對磁導率可接近於1(非鐵磁性)且導熱率通常可係100W/m/K至400W/m/K。
頂部層25可包括具有高於作用中間層23之電阻率之一金屬。由於電阻率係較高的,因此此係其中將自由線圈19誘發且經由作用中間層23之渦電流產生熱之層。
頂部層部分可係非鐵磁性,且電阻率通常可處於自1×10-7Ωm至1×10-6Ωm之範圍內。因此,頂部部分係導電的,但明顯不如中間層導電。鎳(一個適合之頂部層選擇)係鐵磁性。因此,面對線圈之鎳子層之表面(而非作用表面)將被加熱,此係該層為何可較佳係薄的之一個原因。另一原因係電鍍厚材料係耗費時間的。
在自面對待處理之樹脂或坯料之作用表面31觀看時,在線圈載體層21之另一側上提供一背托層27(例如2mm至15mm厚),且背托層27可由類似於作用中間層23之一材料製成。如在圖3中示意性地圖解說明,背托層27藉助於一連接件33電連接至頂部層25。
一熱阻層29經放置於作用中間層23與頂部層25之間。熱阻層29用以在一定程度上阻擋熱自頂部層25至作用中間層23之輸送,使得頂部層25可達到一較高峰值溫度。在不具有此層之情況下,將在一週期期間於頂部層中達到一較低峰值溫度,此乃因然後較多熱連續地自頂部層25移除且經輸送至作用中間層23。
在高頂部溫度(厚)與短週期時間(薄)之間的一折衷中選擇熱阻層之厚度。就電而言,該層可係絕緣的且導熱率通常可係約1W/m/K。相對磁導率可接近於1(非鐵磁性)。
熱阻層亦使鐵磁性頂部層(諸如鎳)之使用變得問題較少。由於鐵磁性材料中之集膚效應,因此將主要加熱頂部層面對線圈之側。然而,由於熱阻層,此熱能量將因此得以輸送至作用表面而非輸送至作用中間層。
圖4示意性地圖解說明圖3之層中之電流之誘發,圖3之堆疊處於一分解透視圖中。在所圖解說明情形中,頂部層25係具有一930mm之長邊35及一520mm之短邊37之矩形。其他層具有對應格式。線圈載體層21纏繞有一線圈19,該線圈具有沿平行於矩形之短邊37之方向之繞組,亦即繞組匝位於長邊處。
當一高頻率AC脈衝經施加至線圈19時,對應於線圈19中之電流之一電流39將在作用中間層23之下部表面中誘發。在一實例中,每一工具半體可具有七個線圈,每一線圈具有經同步饋送之22個繞組匝,在壓花期間每一線圈具有一25kW/25kHz/10秒脈衝。因此在作用中間層中形成的此電流將在作用中間層23之表面處形成一閉合電流迴圈,該閉合電流迴圈在作用中間層23之下部表面處與鄰近線圈電流反平行延展且在上部(在自頂部層25觀看時)表面處與鄰近線圈電流平行延展。彼等電流在作用中間層之長邊處係互連的,且由於集膚效應所致電流主要駐存於緊鄰近作用中間層表面處。作用中間層23之頂部表面中之AC電流將繼而在頂部層25中誘發一電流40。當頂部層25具有一較高電阻率時,此層將形成大量熱。藉助連接件33,頂部層在其長邊處連續地或以某些間隔電連接至背托層27以允許此電流在整個頂部層表面上方流動。
線圈載體之背側處之線圈將類似於在作用中間層中而在背托層27中誘發一電流。此電流將與電流40具有相同方向且將與電流40疊加。由於其低電阻率,因此將在背托層27中產生極少熱。
作用中間層23可具備冷卻管道(未展示)以允許模具或工具之冷
卻。管道可輸送一冷卻介質,諸如水或油。流動可係連續的,或可係脈衝式以便在一生產週期之僅一個相位期間提供冷卻。
在本發明中,熱阻層經改良。在WO-2013/002703-A1中使用一固體玻璃層,且另一選項將係施加具有一低導熱率係數(此將允許使用一薄層)之一薄塑膠層,諸如一個聚醯亞胺薄膜。在本發明中,使用一不同方法。
熱阻層經提供為一陶瓷層,該陶瓷層藉助熱噴塗施加為一塗層。一個適合之材料選擇係氧化釔穩定氧化鋯YSZ,諸如METCO 204-TBC(商標)。該層然後可經機械加工成一所要形狀。由於此程序,熱阻層將得以經接合至下方之層(在自頂部層觀看時),亦即通常經接合至作用中間層。此產生至少中間層之上部部分及該中間層與其以及頂部層一起經塗佈為一單個單元之熱阻層。彼單個單元在一壓印中可被高效替換以便自產生一種類型之產品改變至另一類型。
圖5圖解說明用於將一熱阻層熱噴塗至若干層之一堆疊上之一程序。一塗佈材料51藉助於一加熱裝置53經加熱以熔融且熔融粒子55經加速以便以熔融形式與其應該覆蓋之基板(在此情形中為作用中間層23)碰撞。此意指,與先前熱阻層相比該層變成接合至基板層。熱噴塗本身對熟習此項技術者係眾所周知的且將不會較詳細地闡述。不同技術使用不同方式存在以熔融並加速朝向一基板之熔融材料之滴。
毋庸置疑,經噴塗層將係不均勻的,但已展示,此一層可藉助於如圖6中示意性地圖解說明之習用機械加工技術經機械加工成一平坦形狀。
如圖7中之剖面中所展示,可達成一3維形狀,亦即非平坦形狀。因此,取代僅刻印一表面圖案,該配置可用以將一坯料彎曲成一所要形狀,或用以使非平坦結構射出成型。此係關於使用一經噴塗陶
瓷材料之又一優點。舉例而言(且如示意性地圖解說明),可達成具有圓形隅角之一矩形淺碗形狀,此可產生(例如)一電子裝置之一殼體之一部分。然而,如圖8中所圖解說明,可產生一任意形狀,只要其將適合於壓印/壓花或射出成型即可。亦可將一非平坦形狀應用至一經加強塑膠材料或一經層壓塑膠材料之一坯料。
圖9A至圖9C圖解說明用於將一頂部層施加至一3維熱阻層之一種方法。在此所圖解說明情形中,應將一頂部層25’如圖7中所展示而施加於一熱阻層上。一頂部層坯料57經機械加工成圖9A中所展示之鏡射熱阻層29’之形狀之一形式,且隨後(例如)藉助於一導熱膠經接合至彼層,如圖9B中所圖解說明。然後,經施加頂部層坯料在外側上經機械加工以形成一完成頂部層25’。作為一替代形式,可藉由熱噴塗將頂部層施加至一經機械加工熱阻層。不同鋼合金允許此施加。
圖10圖解說明噴塗於一作用中間層23上,具有一經機械加工3維表面形狀之一熱阻層29。此係在藉助於熱噴塗施加熱阻層時變成可用之另一選項。參考圖10,兩個工具半體皆可以一類似方式經設計,且此亦適用於結合圖6至圖9C所闡述之變化形式。如所圖解說明,熱阻層可經機械加工成一均勻厚度,使得其沿循下方之作用中間層之形狀。此可係有利的,此乃因然後可達成一較均勻頂部層峰值溫度,且與若熱阻層厚度在作用表面上方變化相比,作用表面將更均勻地冷卻。
關於熱噴塗之另一優點係其可替代地補償該熱噴塗施加至其之一並非完全平坦基底。舉例而言,若作用中間層包括在不同段之間具有接點之單獨區段,則經噴塗層可補償(例如)接點處之間隙。
取決於熱阻層之導熱特徵及熱阻層在其中使用之應用,熱阻層之厚度可(例如)處於0.5mm至5mm之範圍內。
本發明並不限於上文所闡述實施例。本發明可在隨附申請專利範圍之範疇內以不同方式變化及更改。
19‧‧‧感應線圈/繞組線圈/線圈
21‧‧‧線圈載體層
23‧‧‧導電中間層/電作用中間層/作用中間層
25‧‧‧頂部層
27‧‧‧背托層
29‧‧‧熱阻層
31‧‧‧作用工具表面/作用表面
33‧‧‧連接件
Claims (7)
- 一種包括一加熱裝置之諸如一射出成型工具或一壓花/壓印工具之工具,該加熱裝置包含用於加熱一作用工具表面之若干層之一堆疊,該堆疊包括:一線圈載體層(21),其包含用於產生一振盪磁場之至少一個繞組線圈,一導電頂部層(25),其毗鄰於該作用工具表面,一背托層(27),在自該頂部層觀看時其定位於該線圈載體層下方,該背托層電連接至該頂部層且具有低於該頂部層之一電阻率,一導電中間層(23),其位於該線圈載體層與該頂部層之間,其中該中間層具有低於該頂部層之一電阻率,及一熱阻層(29),其介於該中間層與該頂部層之間,其特徵在於該熱阻層(29)係一陶瓷材料熱噴塗層,在自該作用工具表面觀看時,該陶瓷材料熱噴塗層係接合至該熱阻層下方之層。
- 如請求項1之工具,其中該中間層之頂部表面係平坦的。
- 如請求項2之工具,其中該熱阻層經機械加工成一平坦形狀。
- 如請求項3之工具,其中該熱阻層經機械加工成偏離一平坦形狀之一個三維形狀。
- 如請求項1之工具,其中該中間層之該頂部表面經機械加工成偏離一平坦形狀之一個三維形狀,且具有均勻厚度之一熱阻層施加於該中間層之該頂部表面上方。
- 如請求項1至5中任一項之工具,其中該陶瓷材料熱噴塗層包括氧化釔穩定氧化鋯YSZ。
- 一種用於壓花/壓印兩個工具半體(3、5)之間的一坯料(1)之方 法,其中該方法包含:用一線圈載體層(21)中之至少一個繞組線圈在該等工具半體中之至少一者中產生一振盪磁場,使得經由毗鄰於面對該坯料之一作用工具表面之一導電頂部層(25)與該線圈載體層之間的一導電中間層(23)在該頂部層中產生熱,其中一熱阻層(29)位於該中間層與該頂部層之間,且其中該等工具半體被壓印在一起,該方法之特徵在於將該坯料(1)彎曲成沿三個維度延伸之一形式,該形式經機械加工成該熱阻層(29)。
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US5783259A (en) * | 1994-12-05 | 1998-07-21 | Metallamics, Inc. | Method of manufacturing molds, dies or forming tools having a cavity formed by thermal spraying |
WO2013002703A1 (en) * | 2011-06-28 | 2013-01-03 | Tctech Sweden Ab | Device and method for heating a mould or tool |
Also Published As
Publication number | Publication date |
---|---|
CN106660229A (zh) | 2017-05-10 |
WO2015197415A2 (en) | 2015-12-30 |
WO2015197415A3 (en) | 2016-03-17 |
EP2960035A1 (en) | 2015-12-30 |
JP2017527459A (ja) | 2017-09-21 |
US20170190089A1 (en) | 2017-07-06 |
MX2016017347A (es) | 2017-09-05 |
KR20170026550A (ko) | 2017-03-08 |
TW201615373A (zh) | 2016-05-01 |
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