WO2018143900A1 - Production method preventing micro-scratches on plastic patterned surfaces - Google Patents

Production method preventing micro-scratches on plastic patterned surfaces Download PDF

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Publication number
WO2018143900A1
WO2018143900A1 PCT/TR2017/050051 TR2017050051W WO2018143900A1 WO 2018143900 A1 WO2018143900 A1 WO 2018143900A1 TR 2017050051 W TR2017050051 W TR 2017050051W WO 2018143900 A1 WO2018143900 A1 WO 2018143900A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
production method
filled
stage
carried out
Prior art date
Application number
PCT/TR2017/050051
Other languages
French (fr)
Inventor
Ediz ALTUN
Original Assignee
Toyota Boshoku Türkiye Otomotiv Sanayi Ve Ticaret Anonim Sirketi
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 Toyota Boshoku Türkiye Otomotiv Sanayi Ve Ticaret Anonim Sirketi filed Critical Toyota Boshoku Türkiye Otomotiv Sanayi Ve Ticaret Anonim Sirketi
Priority to EP17712265.2A priority Critical patent/EP3562643A1/en
Priority to PCT/TR2017/050051 priority patent/WO2018143900A1/en
Publication of WO2018143900A1 publication Critical patent/WO2018143900A1/en

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Classifications

    • 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
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/7693—Measuring, controlling or regulating using rheological models of the material in the mould, e.g. finite elements method
    • 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
    • B29C45/0025—Preventing defects on the moulded article, e.g. weld lines, shrinkage marks

Definitions

  • the invention relates to a production method applying novel operation steps and processes in plastic injection system preventing micro-scratches formed on patterned surfaces during production of vehicle interior plastic parts.
  • the polymer raw material is melted by using injection machine and mould filling is performed under a certain pressure. Afterwards, the pattern geometry is copied by applying backpressure onto the material which is filled.
  • this pressure is not given exactly, the molten material that does not penetrate into the surface causes fluctuation of the surface.
  • excessive pressure also makes it difficult for the material to be separated from the surface after cooling.
  • the deep contact of the plastic material with the sharp steel surface causes scratches.
  • the invention relates to a patterned plastic surface production method, which meets the above said requirements, eliminates all of the drawbacks, and brings some additional advantages.
  • the main purpose of the invention is to optimize the plastic pressure and temperature in the mould, thanks to the production method used.
  • a purpose of the invention is to remove cosmetic faults of vehicle interior patterned plastic parts in the automotive sector, thanks to the method used.
  • Another purpose of the invention is to prevent labour losses and economic losses by providing quality and error-free products.
  • a purpose of the invention is to ensure the desired level in patterned plastic surface brightness, body mounting tolerances, and targeted weight, thanks to the method used.
  • the present invention is a patterned plastic surface production method by means of an injection system and a closure system, and it is characterized in that; it comprises the operation steps of:
  • a mould filling analysis which consists of the steps of determining the required pressure value in the closure system, selecting the distance between the hot runners, selecting the number of hot runners, and selecting the mould steel temperature variation interval,
  • a filling stage is carried out, in which ninety five percent of the volume of the patterned plastic surface is filled, in order to control of the mould filling analysis,
  • an ironing stage is carried out, in which the remaining portion is filled with pressure and the pattern surface is copied,
  • Figure 1 is a two-dimensional view of the injection system and the closure system which allow the production of the patterned plastic surface according to the invention.
  • Figure 2 is a schematic view showing the production method steps of the patterned plastic surface according to the invention.
  • FIG. 1 is a two-dimensional view of the injection system (200) and the closure system (300) which allow the production of the patterned plastic surface (100) according to the invention.
  • the invention allows removing cosmetic faults of vehicle interior patterned plastic parts in the automotive sector, preventing micro-scratches formed on the pattern surfaces of vehicle interior plastic parts, and optimizing the plastic pressure and temperature in the mould, thanks to the production method used.
  • the invention relates to a patterned plastic surface (100) production method by means of an injection system (200) and a closure system (300).
  • a mould filling analysis (A) is carried out which consists of the steps of determining the required pressure value in the closure system (300), selecting the distance between the hot runners, selecting the number of hot runners, and selecting the mould steel temperature variation range.
  • the injection stage (B) is carried out where pressure-velocity profiles are applied until the geometry of the patterned plastic surface (100) is filled up to hundred percent.
  • a filling stage (C) takes place, where ninety five percent of the volume of the patterned plastic surface (100) is filled.
  • ironing operation (D) is carried out, in which the remaining portion is filled with pressure and the pattern surface is copied.
  • cooling stage (E) takes place, in which the patterned plastic surface (100) is kept in the mould for solidification.
  • a sensor (303) is found, which provides the measurement of the temperature and pressure values from the male mould (301 ) surface, for the patterned plastic surface (100) production method closure stage (F), in which the female mould (302) and the male mould (301 ) are combined and the required tonnage is applied.
  • the production method of the patterned plastic surface (100) consists of the steps of mould design changes and plastic injection process parameter improvements.
  • Mould Design mould filling analysis is performed by using the CAD data of the product to be produced. The purpose of this analysis is to ensure that error modes are monitored before the pattern is formed. Filling, pressure, temperature, etc. values are checked. Filling can be done with the desired number of runners, such as 2, 3, 10 etc. Factors affecting the pressure value are the number of runners, runner diameter, melt temperature, distance between the runners, and material wall thickness. Simulation is repeated in different combinations by entering appropriate values for runner diameter and number of runners.
  • the required pressure value in the closure system (300) is selected to be in the range of 30 MPa to 40 MPa, the distance between hot runners in the range of 150 mm to 300 mm, and the mould steel temperature variation between +5 ° C to -5 ° C. Once these values are rea ched, the situation analysis is completed. Then moulding operation starts.
  • An injection system (200) and a closing system (300) are found to perform the moulding process.
  • the injection system (200) is melted due to the friction energy generated during rotation of the material conveying component (206) in the form of plastic granules (201 ) and the heat energy of the heater components (203).
  • the conveying component (206) is found in a barrel (202).
  • the plastic granules (201 ) are dropped into the barrel (202) through the inlet chamber (205) conveying the plastic granules (201 ) on the barrel (202), and then placed at the tip part in molten form with the rotation of the conveying component (206).
  • the screw-form conveying component (206) is placed on the female mould (302) surface.
  • the closure system (300) consists of the female mould (302) and the male mould (301 ) sections.
  • the female mould (302) is a patterned surface, while the male mould (301 ) is a patternless surface.
  • the female mould (302) and the male mould (301 ) are closed to apply a certain closure force. This force is directly proportional to the projection area of the part and the viscosity of the material.
  • a single sensor (303), measuring the pressure and temperature, is found on the surface of the male mould (301 ) and flashes with the generated force.
  • the molten material is filled into the mould by using the conveying component (206) mould interior hot runner manifold.
  • the pre-simulated flow profile is applied sequentially in order to eliminate visual problems. The above given values are entered. The filling takes place continuously in one direction and is carried out by sequential runner operation.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

The invention is a patterned plastic surface (100) production method, and it is characterized in that; it comprises the operation steps of : carrying out a mould filling analysis which consists of the steps of determining the required pressure value in the closure system (300), selecting the distance between the hot runners, and selecting the number of hot runners, carrying out an injection stage where pressure-velocity profiles are applied until the geometry of the relevant part is filled up to hundred percent, a filling stage is carried out, in which ninety five percent of the volume of the relevant part is filled, after the ninety-five percent part of the relevant part is filled, an ironing operation is carried out, in which the remaining portion is filled with pressure and the pattern surface is copied, a cooling stage is carried out, in which the relevant part is kept in the mould for solidification, a closure stage is carried out, in which the female mould (302) and the male mould (301) are combined and the required tonnage is applied.

Description

PRODUCTION METHOD PREVENTING MICRO-SCRATCHES ON
PLASTIC PATTERNED SURFACES
DESCRIPTION
The Related Art
The invention relates to a production method applying novel operation steps and processes in plastic injection system preventing micro-scratches formed on patterned surfaces during production of vehicle interior plastic parts.
The Prior Art
In the prior art pattern-forming operations on vehicle interior plastic surfaces, first of all, steel surface is processed in CNC, and then the pattern-forming film layer is applied on the steel via masking operation. Afterwards, the steel is melted in the acid pool to form a visually patterned surface. After this process, micro-level bumps, recesses and protrusions are formed on the steel. With this process, mould is formed for the patterned surface of the plastic.
In the prior art, after the mould is formed, the polymer raw material is melted by using injection machine and mould filling is performed under a certain pressure. Afterwards, the pattern geometry is copied by applying backpressure onto the material which is filled. Here, if this pressure is not given exactly, the molten material that does not penetrate into the surface causes fluctuation of the surface. At the same time, excessive pressure also makes it difficult for the material to be separated from the surface after cooling. Here, the deep contact of the plastic material with the sharp steel surface causes scratches.
In the known state of the art, the pressure in the plastic cannot be flexibly adjusted due to the mould structure. This causes the pressure to be too high and the part to be burred and subjected to micro-scratches. Another problem is that incomplete filling occurs due to too low pressure, and therefore the strength is reduced and the pattern surface cannot be copied exactly. As a result of said problems, defective parts are produced, which results in labour and time losses and economic losses.
Description of the Invention
The invention relates to a patterned plastic surface production method, which meets the above said requirements, eliminates all of the drawbacks, and brings some additional advantages.
The main purpose of the invention is to optimize the plastic pressure and temperature in the mould, thanks to the production method used.
A purpose of the invention is to remove cosmetic faults of vehicle interior patterned plastic parts in the automotive sector, thanks to the method used.
Another purpose of the invention is to provide quality production by achieving the required dimensional and visual quality conditions.
Another purpose of the invention is to prevent labour losses and economic losses by providing quality and error-free products. A purpose of the invention is to ensure the desired level in patterned plastic surface brightness, body mounting tolerances, and targeted weight, thanks to the method used.
In order to achieve the above said purposes which would be understood better with the below given detailed description, the present invention is a patterned plastic surface production method by means of an injection system and a closure system, and it is characterized in that; it comprises the operation steps of:
- carrying out a mould filling analysis which consists of the steps of determining the required pressure value in the closure system, selecting the distance between the hot runners, selecting the number of hot runners, and selecting the mould steel temperature variation interval,
- carrying out an injection stage where pressure-velocity profiles are applied until the geometry of the patterned plastic surface is filled up to hundred percent,
- a filling stage is carried out, in which ninety five percent of the volume of the patterned plastic surface is filled, in order to control of the mould filling analysis,
- after the ninety-five percent part of the patterned plastic surface is filled, an ironing stage is carried out, in which the remaining portion is filled with pressure and the pattern surface is copied,
- a cooling stage is carried out, in which the patterned plastic surface is kept in the mould for solidification,
- a closure stage is carried out, in which the female mould and the male mould are combined and the required tonnage is applied.
The structural and characteristic features of the invention and all of its advantages shall be understood better with the figures and the detailed description given below in reference to the figures. Therefore, the assessment should be made by taking into account the said figures and detailed explanations.
Figures for Better Understanding of the Invention
Figure 1 ; is a two-dimensional view of the injection system and the closure system which allow the production of the patterned plastic surface according to the invention. Figure 2; is a schematic view showing the production method steps of the patterned plastic surface according to the invention.
Reference Numbers
100- Patterned plastic surface
200- Injection system
201 - Plastic granule
202- Barrel
203- Heater component
204- Drive component
205- Inlet chamber
206- Conveying component
300- Closure system
301 - Male mould
302- Female mould
303- Sensor
A- Mould filling analysis
B- Injection stage
C- Filling stage
D- Ironing
E- Cooling stage
F- Closure stage
Detailed Description of the Invention Figure 1 ; is a two-dimensional view of the injection system (200) and the closure system (300) which allow the production of the patterned plastic surface (100) according to the invention. The invention allows removing cosmetic faults of vehicle interior patterned plastic parts in the automotive sector, preventing micro-scratches formed on the pattern surfaces of vehicle interior plastic parts, and optimizing the plastic pressure and temperature in the mould, thanks to the production method used.
The invention relates to a patterned plastic surface (100) production method by means of an injection system (200) and a closure system (300). A mould filling analysis (A) is carried out which consists of the steps of determining the required pressure value in the closure system (300), selecting the distance between the hot runners, selecting the number of hot runners, and selecting the mould steel temperature variation range. Afterwards, the injection stage (B) is carried out where pressure-velocity profiles are applied until the geometry of the patterned plastic surface (100) is filled up to hundred percent. In order to control of the mould filling analysis, a filling stage (C) takes place, where ninety five percent of the volume of the patterned plastic surface (100) is filled. After the ninety-five percent part of the patterned plastic surface (100) is filled, ironing operation (D) is carried out, in which the remaining portion is filled with pressure and the pattern surface is copied. Afterwards; cooling stage (E) takes place, in which the patterned plastic surface (100) is kept in the mould for solidification. A sensor (303) is found, which provides the measurement of the temperature and pressure values from the male mould (301 ) surface, for the patterned plastic surface (100) production method closure stage (F), in which the female mould (302) and the male mould (301 ) are combined and the required tonnage is applied.
The production method of the patterned plastic surface (100) consists of the steps of mould design changes and plastic injection process parameter improvements. Mould Design; mould filling analysis is performed by using the CAD data of the product to be produced. The purpose of this analysis is to ensure that error modes are monitored before the pattern is formed. Filling, pressure, temperature, etc. values are checked. Filling can be done with the desired number of runners, such as 2, 3, 10 etc. Factors affecting the pressure value are the number of runners, runner diameter, melt temperature, distance between the runners, and material wall thickness. Simulation is repeated in different combinations by entering appropriate values for runner diameter and number of runners. In the mould filling analysis method step of the patterned plastic surface (100) production method, the required pressure value in the closure system (300) is selected to be in the range of 30 MPa to 40 MPa, the distance between hot runners in the range of 150 mm to 300 mm, and the mould steel temperature variation between +5 ° C to -5 ° C. Once these values are rea ched, the situation analysis is completed. Then moulding operation starts.
An injection system (200) and a closing system (300) are found to perform the moulding process. The injection system (200) is melted due to the friction energy generated during rotation of the material conveying component (206) in the form of plastic granules (201 ) and the heat energy of the heater components (203). In the injection system (200), the conveying component (206) is found in a barrel (202). By means of the heater components (203) found on the barrel (202), the plastic granules (201 ) are dropped into the barrel (202) through the inlet chamber (205) conveying the plastic granules (201 ) on the barrel (202), and then placed at the tip part in molten form with the rotation of the conveying component (206). Afterwards, with the motion provided by the drive component (204) at the tip of the barrel (202), the screw-form conveying component (206) is placed on the female mould (302) surface.
The closure system (300) consists of the female mould (302) and the male mould (301 ) sections. The female mould (302) is a patterned surface, while the male mould (301 ) is a patternless surface. The female mould (302) and the male mould (301 ) are closed to apply a certain closure force. This force is directly proportional to the projection area of the part and the viscosity of the material. A single sensor (303), measuring the pressure and temperature, is found on the surface of the male mould (301 ) and flashes with the generated force. After the pressure is applied, the molten material is filled into the mould by using the conveying component (206) mould interior hot runner manifold. The pre-simulated flow profile is applied sequentially in order to eliminate visual problems. The above given values are entered. The filling takes place continuously in one direction and is carried out by sequential runner operation.

Claims

A production method preventing micro-scratches formed on patterned plastic surfaces (100) in plastic injection systems (200), and it is characterized in that; it comprises the operation steps of:
- carrying out a mould filling analysis (A) which consists of the steps of determining the required pressure value in the closure system (300), selecting the distance between the hot runners, selecting the number of hot runners, and selecting the mould steel temperature variation range,
- carrying out an injection stage (B) where pressure-velocity profiles are applied until the geometry of the patterned plastic surface (100) is filled up to hundred percent,
- a filling stage (C) is carried out, in which ninety five percent of the volume of the patterned plastic surface (100) is filled, in order to control of the mould filling analysis,
- after the ninety-five percent part of the patterned plastic surface (100) is filled, an ironing operation (D) is carried out, in which the remaining portion is filled with pressure and the pattern surface is copied,
- a cooling stage (E) is carried out, in which the patterned plastic surface (100) is kept in the mould for solidification,
- a closure stage (F) is carried out, in which the female mould (302) and the male mould (301 ) are combined and the required tonnage is applied.
The production method according to Claim 1 , and it is characterized in that; it comprises the operation step of the required pressure value within said closure system (300) being in the interval of about 30 MPa to 40 MPa.
The production method according to Claim 1 , and it is characterized in that; it comprises the operation step of the distance between the hot runners being in the interval of about 150 mm to 300 mm. The production method according to Claim 1 , and it is characterized in that; it comprises the operation step of the number of hot runners being in the interval of about a minimum of 6 and a maximum of 10.
The production method according to Claim 1 , and it is characterized in that; it comprises the operation step of the mould steel temperature variation interval being in the range of about +5 °C to -5 <C.
The production method according to Claim 1 , and it is characterized in that; it comprises the operation step of carrying out the cooling stage, in which the patterned plastic surface (100) is kept in the mould for solidification, at a maximum of 60 <C temperature.
The production method according to Claim 1 , and it is characterized in that; it comprises the operation step of measuring the required temperature and pressure values by means of a sensor (303) on the male mould (301 ) surface.
PCT/TR2017/050051 2017-02-06 2017-02-06 Production method preventing micro-scratches on plastic patterned surfaces WO2018143900A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP17712265.2A EP3562643A1 (en) 2017-02-06 2017-02-06 Production method preventing micro-scratches on plastic patterned surfaces
PCT/TR2017/050051 WO2018143900A1 (en) 2017-02-06 2017-02-06 Production method preventing micro-scratches on plastic patterned surfaces

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/TR2017/050051 WO2018143900A1 (en) 2017-02-06 2017-02-06 Production method preventing micro-scratches on plastic patterned surfaces

Publications (1)

Publication Number Publication Date
WO2018143900A1 true WO2018143900A1 (en) 2018-08-09

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Country Status (2)

Country Link
EP (1) EP3562643A1 (en)
WO (1) WO2018143900A1 (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004079341A2 (en) * 2003-03-03 2004-09-16 Moldflow Ireland Ltd. Apparatus and methods for predicting properties of processed material
DE102014015088A1 (en) * 2014-10-11 2015-04-23 Daimler Ag Method for determining a nozzle positioning for the production of a plastic injection-molded component, and method for producing a plastic injection-molded component
DE102015107025A1 (en) * 2015-05-06 2016-11-10 BT Bayern Treuhand Management & Technologie AG Determination and display of process parameter values in an injection molding process

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004079341A2 (en) * 2003-03-03 2004-09-16 Moldflow Ireland Ltd. Apparatus and methods for predicting properties of processed material
DE102014015088A1 (en) * 2014-10-11 2015-04-23 Daimler Ag Method for determining a nozzle positioning for the production of a plastic injection-molded component, and method for producing a plastic injection-molded component
DE102015107025A1 (en) * 2015-05-06 2016-11-10 BT Bayern Treuhand Management & Technologie AG Determination and display of process parameter values in an injection molding process

Also Published As

Publication number Publication date
EP3562643A1 (en) 2019-11-06

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