WO2009048423A1 - Procédé et appareil pour mouler des articles - Google Patents

Procédé et appareil pour mouler des articles Download PDF

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Publication number
WO2009048423A1
WO2009048423A1 PCT/SG2007/000348 SG2007000348W WO2009048423A1 WO 2009048423 A1 WO2009048423 A1 WO 2009048423A1 SG 2007000348 W SG2007000348 W SG 2007000348W WO 2009048423 A1 WO2009048423 A1 WO 2009048423A1
Authority
WO
WIPO (PCT)
Prior art keywords
cavity
tool
core
article
movable cavity
Prior art date
Application number
PCT/SG2007/000348
Other languages
English (en)
Inventor
Qingfa Li
Original Assignee
Agency For Science, Technology And Research
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Agency For Science, Technology And Research filed Critical Agency For Science, Technology And Research
Priority to PCT/SG2007/000348 priority Critical patent/WO2009048423A1/fr
Publication of WO2009048423A1 publication Critical patent/WO2009048423A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/02—Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • 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
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression 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
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • B29C2045/5695—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding using a movable mould part for continuously increasing the volume of the mould cavity to its final dimension during the whole injection step

Definitions

  • This invention relates to a moulding method and apparatus for forming articles and refers particularly, though not exclusively, to such a method and apparatus for producing thin hollow tubes and plates.
  • a sliding sleeve with a core For the production of articles such as ceramics tubes and tubes with multiple holes, there is a known method using a sliding sleeve with a core.
  • the core blocks a portion of the flow path of the material entering the mould (forming the holes), while the sliding sleeve helps to keep the core in position to minimize thermal and bending stresses within the formed tubes, reducing problems of distortion and deformation.
  • the core can have one or many pins, depending on the number of holes to be formed, and the resultant article has good material uniformity throughout, even for articles with high aspect ratios.
  • tape casting may be used.
  • thin layers of ceramic-loaded polymers are rolled out and can be used as single layers or can be stacked and laminated into multilayered structures. They may be in batch or continuous casts.
  • the prime dried thickness range for tape casting is reported to range from 5 microns to slightly over lmm.
  • a method of moulding an article comprises injecting a material into a cavity of a die set comprising a movable cavity tool and a stationary cavity tool; advancing the movable cavity tool relative to the stationary cavity tool while injecting the material so that the cavity elongates together with formation of at least a first portion of the article, the movable cavity tool receiving and retaining injected material as the cavity elongates.
  • the method may further comprise injecting a second material into the cavity of a die set; advancing a second movable cavity tool while injecting the second material so that the cavity expands together with formation of at least a second portion of the article, the second movable cavity tool receiving and retaining the second injected material as the cavity expands.
  • the apparatus comprises a die set having a cavity, the die set comprising a movable cavity tool and a stationary cavity tool configured to form the cavity therebetween, the movable cavity tool being movable relative to the stationary cavity tool.
  • the movable cavity tool being configured for elongating the cavity during injection of a material to form at least a first portion of the article, and for receiving and retaining injected material as the cavity elongates.
  • the apparatus may further comprising a second movable cavity tool for expanding the cavity during injection of a second material to form at least a second portion of the article; the second movable cavity tool receiving and retaining the second injected material as the cavity expands.
  • the cavity may include a core for forming at least one elongate opening in the article.
  • the core may be attached to the movable cavity tool.
  • the core may comprise a plurality of pins for forming a plurality of elongate openings in the article.
  • the core may be slideably supported by a core support to minimize bending of the core during injection of the material.
  • the core support may be integral with the stationary cavity tool.
  • the core support may include at least one extension for additional support of the core.
  • the movable cavity tool may be advanced by pressure of the material being injected into the cavity.
  • the material may be injected at an angle less than 90° to provide a force component in the direction of advancing the movable cavity tool.
  • the angle may range from 25° to 60°.
  • the movable cavity tool may be advanced by mechanical actuation of the movable cavity tool.
  • the article may be a thin plate.
  • the thin plate may comprise at least one through channel and/or at least one surface channel.
  • Figure 1 is a schematic cross-section of an exemplary embodiment at the beginning of the moulding process
  • Figure 2 is a schematic cross-section of the embodiment of Figure 1 during the moulding process
  • Figure 3 is a schematic cross-section of the embodiment of Figures 1 and 2 at the end of the moulding process;
  • Figure 3 A is a schematic cross-section of an alternative exemplary embodiment with a core during the moulding process;
  • Figure 4 is a schematic close-up cross-section of the embodiment of Figure 2;
  • Figure 5 is a perspective view of a core support
  • Figure 6 is a schematic perspective view of an exemplary embodiment of the cavity tools
  • Figure 7 is a schematic perspective view of another exemplary embodiment of the cavity tools.
  • Figure 8 is a schematic perspective view of a further exemplary embodiment of the cavity tools
  • Figure 9 is a schematic side view of yet another exemplary embodiment of the cavity tools
  • Figure 10 is a schematic side view of a still further exemplary embodiment of the cavity tools
  • Figure 11 is a collage of perspective views of products able to be produced by the process.
  • Figure 12 is a schematic illustration of the process steps with an exemplary embodiment.
  • FIGS. 1 to 3 show a die set 10 that forms a cavity 12 in which a green article is to be formed (prior to debinding and sintering).
  • the die set 10 includes a movable cavity tool 14 and a stationary cavity tool 15.
  • the movable cavity tool 14 is supported by a base plate 18. Bearings 20 between the base plate 18 and the movable cavity tool 14 facilitate smooth movement of the movable cavity tool 14 between the base plate 18 the stationary tool 15.
  • clamping force on the die set 10 is not directly applied to the movable cavity tool 14.
  • the movable cavity tool 14 has a head 17 to substantially seal with the stationary cavity tool 15, while a gap between a tail 19 of the movable cavity tool 14 and the stationary cavity tool 15 forms the cavity 12.
  • a material 16 from feedstock in a material barrel 21 is injected via a runner 26 through a gate 27 into the cavity 12 (100, Figure 12).
  • the material 16 may be injected by means such as a powder injection moulding machine, or a hydraulic press.
  • the runner 26 may take the shape of a nozzle or a slot covering a part or a whole width of the article to be formed.
  • the movable cavity tool 14 While the material 16 is being injected, the movable cavity tool 14 is advanced relative to the stationary cavity tool 15 (as indicated by the arrow) so that the cavity 12 elongates (102, Figure 12). Newly injected material is preferably continuously received and retained by a receiving section 24 on the tail 19 of the movable cavity tool 14. The receiving section 24 is always directly at the site of the injection gate 27.
  • the receiving section 24 is continuously moving back along the tail 19 during injection. There is thus practically no pressure gradient in the material 16 within the cavity 12 since the receiving section 24 is always a "fresh" location on the tail 19 of the movable cavity tool 14. In this way, the material 16 can readily fill the cavity 12 under relatively low injection pressure for a theoretically infinite length of the cavity 12.
  • This method and apparatus are thus particularly suitable for producing high-aspect-ratio (i.e. long and thin) articles such as thin plates and other articles with highly uniform walls that are just tens of microns thick or up to millimetres thick with uniform stress distribution along the length of the article.
  • Green articles such as sheets produced by this method and apparatus can be uniform with isotropical shrinkage.
  • the movable cavity tool 14 may be advanced simply by pressure of the injected material 16 acting against the head 17 of the movable cavity tool 14. This is facilitated by having the runner 26 at an injection angle ⁇ less than 90°, more preferably between 25° and 60°, to provide a force component in the direction of the arrows on Figures 1 and 2.
  • the movable cavity tool 14 may be advanced by simple mechanical actuation. A combination of material pressure and mechanical actuation may also be used.
  • the cavity may include a core 22.
  • the core 22 is attached to the movable cavity tool 14 so that it advances together with the movable cavity tool 14 during moulding.
  • Figure 3 A shows an alternative exemplary embodiment of the movable cavity tool 14 with attached core 22, movable together relative to the stationary cavity tool 15. This embodiment may be used for the formation of cylindrical and other shaped articles, including tubes.
  • the core 22 may be supported by a core support 28, as shown close up in Figure 4.
  • the core support 28 may be separate or integral with the stationary cavity tool 15.
  • the core support 28 is for minimising bending of the core 22 due to downward pressure of the material entering from the runner 26 in the direction as shown by the arrow in Figure 4.
  • the core 22 may comprise a plurality of pins so that a plurality of elongate openings is formed in the green article.
  • the core support 28 may comprise an appropriate number of elongate openings 29 therein for slideably supporting the pins of the core 22.
  • the core support 28 may include at least one extension 30 to provide additional support to the core during material filling, as shown in Figure 5.
  • the length of each extension 30 is preferably about or greater than the width of the runner 26.
  • articles of various shapes and sizes having a varying number of openings therein may be formed. By controlling the length and positioning of the core 22, the openings may be through or blind holes as desired.
  • Figures 6 to 10 show various exemplary embodiments of the cavity tools 14, 15.
  • the stationary cavity tool 15 as shown is simplified for clarity.
  • the movable cavity tool 14 is a relatively simple plate for producing thin sheets.
  • the movable cavity tool 14 has additional side walls 14s.
  • the cavity tools 14, 15 allow for the formation of thin walled tubes.
  • the side walls 14s are an example of a design variation to help control external wall thickness of the green article formed.
  • the movable cavity tool 14 comprises a first movable cavity tool 14a and a second movable cavity tool 14b.
  • the movable cavity tools 14a, 14b can be independently advanced for the injection of the same or different materials associated with each movable cavity tool 14a or 14b.
  • a first material is injected into the cavity 12 (100, Figure 12) while only the first movable cavity tool 14a is advanced (102, Figure 12).
  • a second material is injected into the cavity 12 (103, Figure 12).
  • the first material is of sufficient solidity to minimize transference at the interface of the first and second materials.
  • the second material is being injected, only the second movable cavity tool 14b is advanced so that the cavity 12 expands (104, Figure 12).
  • the second material fills the expanded cavity alongside the first material 16, thus coping with any irregularities in the interface surface of the two materials. In this way, a green article having a first portion made of the first material and a second portion made of the second material can be formed.
  • Figure 9 shows the two movable cavity tools 14a, 14b in an alternative configuration, with the first movable cavity tool 14a atop the second movable cavity tool 14b, and the stationary cavity tool 15 in between.
  • This configuration is suitable for the production of articles comprising double layer sheets, with each sheet ranging from hundreds of microns to millimetres thick. Each sheet may be made of the same or of different materials.
  • the injections gates are preferably coplanar with each sheet to be formed, such that sheet thickness is dependent on sheet width.
  • Embodiments having two movable cavity tools may also comprise a plurality of pins for forming elongate openings in the green article.
  • a number of the plurality of pins may be attached to the first movable cavity tool 14a, while another number of the plurality of pins may be attached to the second movable cavity tool 14b.
  • both the first portion and the second portion of the green article formed can have elongate openings therein depending on the number and location of the pins.
  • Articles having additional features such as surface or through channels may also be formed using appropriately styled cavity tools 14, 15.
  • Figure 10 shows an exemplary embodiment comprising protrusions 36 on the movable cavity tool 14.
  • Corresponding recesses 38 on the stationary cavity tool 15 may be provided.
  • surface or through channels may be formed in the moulded article.
  • protrusions may be provided on the stationary cavity tool 15 while corresponding recesses are provided on the movable cavity tool 14.
  • the first material and the second material may be different, or they may be the same material but having different material properties such as different particle size.
  • the first material and the second material may have different percentage volume or particle size of the same or different ceramic particles in a polymer binder.
  • the polymer binder for example wax in the feedstock, may provide a self lubricating effect to facilitate material flow in the cavity during moulding.
  • a limited mixing of the two materials at the interface between the first portion and the second portion of the green article during moulding may also be advantageous. Mixing at the interface may promote better fusion of the two portions upon sintering.
  • multiple movable cavity tools may be provided to form green articles having more than two portions, each portion having a different material property from the others.
  • Cores having various cross- sectional shapes and sizes and numbers of pins may be provided in various combinations with various numbers of movable cavity tools having various cross- sectional shapes and sizes, so that different complex structures having reduced thickness may be formed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention porte sur un appareil pour mouler un article, l'appareil comprenant un ensemble filière ayant une cavité; un outil à cavité mobile pour allonger la cavité pendant l'injection d'un matériau afin de former au moins une première partie de l'article; l'outil à cavité mobile recevant et retenant le matériau injecté à mesure que la cavité s'allonge. L'invention porte également sur un procédé correspondant.
PCT/SG2007/000348 2007-10-12 2007-10-12 Procédé et appareil pour mouler des articles WO2009048423A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/SG2007/000348 WO2009048423A1 (fr) 2007-10-12 2007-10-12 Procédé et appareil pour mouler des articles

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/SG2007/000348 WO2009048423A1 (fr) 2007-10-12 2007-10-12 Procédé et appareil pour mouler des articles

Publications (1)

Publication Number Publication Date
WO2009048423A1 true WO2009048423A1 (fr) 2009-04-16

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ID=40549416

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SG2007/000348 WO2009048423A1 (fr) 2007-10-12 2007-10-12 Procédé et appareil pour mouler des articles

Country Status (1)

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WO (1) WO2009048423A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2712721A1 (fr) * 2012-09-28 2014-04-02 Hollister Incorporated Procédé et appareil de moulage par injection d'un article creux allongé
WO2014052770A1 (fr) * 2012-09-28 2014-04-03 Hollister Incorporated Procédé et appareil de moulage par injection d'un article creux allongé
WO2018114563A1 (fr) * 2016-12-20 2018-06-28 Leoni Kabel Gmbh Procédé de fabrication d'une pièce allongée au moyen d'un élément de centrage
WO2018114561A1 (fr) * 2016-12-20 2018-06-28 Leoni Kabel Gmbh Moulage d'une pièce allongée au moyen d'un élément de centrage
JP2020511341A (ja) * 2017-03-20 2020-04-16 シュタイナー，ゴットフリード コンポーネントまたはプロファイルを製造するための方法および装置
US10875224B2 (en) 2015-08-28 2020-12-29 Hollister Incorporated Method and apparatus for molding an elongated hollow article

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4849151A (en) * 1986-12-19 1989-07-18 Matsushita Electric Industrial Co., Ltd. Method of molding plastic and injection compression molding apparatus using elongatable tie bars
US5176859A (en) * 1989-12-08 1993-01-05 Philips And Du Pont Optical Company Apparatus/and method for controlling an injection molding process producing a molded part
US5656234A (en) * 1994-08-12 1997-08-12 Mitsubishi Gas Chemical Company, Inc. Mold apparatus and injection molding method for producing hollow-structured article by injection molding
US6197245B1 (en) * 1997-08-04 2001-03-06 Sumitomo Chemical Company, Ltd. Process for producing hollow resin molded article
WO2007129992A1 (fr) * 2006-05-08 2007-11-15 Agency For Science, Technology And Research Manchon de moulage et procede de moulage

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4849151A (en) * 1986-12-19 1989-07-18 Matsushita Electric Industrial Co., Ltd. Method of molding plastic and injection compression molding apparatus using elongatable tie bars
US5176859A (en) * 1989-12-08 1993-01-05 Philips And Du Pont Optical Company Apparatus/and method for controlling an injection molding process producing a molded part
US5656234A (en) * 1994-08-12 1997-08-12 Mitsubishi Gas Chemical Company, Inc. Mold apparatus and injection molding method for producing hollow-structured article by injection molding
US6197245B1 (en) * 1997-08-04 2001-03-06 Sumitomo Chemical Company, Ltd. Process for producing hollow resin molded article
WO2007129992A1 (fr) * 2006-05-08 2007-11-15 Agency For Science, Technology And Research Manchon de moulage et procede de moulage

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2712721A1 (fr) * 2012-09-28 2014-04-02 Hollister Incorporated Procédé et appareil de moulage par injection d'un article creux allongé
WO2014052770A1 (fr) * 2012-09-28 2014-04-03 Hollister Incorporated Procédé et appareil de moulage par injection d'un article creux allongé
US9662817B2 (en) 2012-09-28 2017-05-30 Hollister Incorporated Method and apparatus for injection moulding of an elongated hollow article
US10875224B2 (en) 2015-08-28 2020-12-29 Hollister Incorporated Method and apparatus for molding an elongated hollow article
US11701807B2 (en) 2015-08-28 2023-07-18 Hollister Incorporated Apparatus for molding an elongated hollow article
WO2018114563A1 (fr) * 2016-12-20 2018-06-28 Leoni Kabel Gmbh Procédé de fabrication d'une pièce allongée au moyen d'un élément de centrage
WO2018114561A1 (fr) * 2016-12-20 2018-06-28 Leoni Kabel Gmbh Moulage d'une pièce allongée au moyen d'un élément de centrage
CN110267789A (zh) * 2016-12-20 2019-09-20 莱尼电缆有限公司 使用定心元件制造长型部件的方法
JP2020511341A (ja) * 2017-03-20 2020-04-16 シュタイナー，ゴットフリード コンポーネントまたはプロファイルを製造するための方法および装置
JP7049753B2 (ja) 2017-03-20 2022-04-07 シュタイナー，ゴットフリード コンポーネントまたはプロファイルを製造するための方法および装置

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