WO2022148247A1 - 电伺服驱动热流道模具的塑料件成形方法 - Google Patents

电伺服驱动热流道模具的塑料件成形方法 Download PDF

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WO2022148247A1
WO2022148247A1 PCT/CN2021/140814 CN2021140814W WO2022148247A1 WO 2022148247 A1 WO2022148247 A1 WO 2022148247A1 CN 2021140814 W CN2021140814 W CN 2021140814W WO 2022148247 A1 WO2022148247 A1 WO 2022148247A1
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Prior art keywords
gate
mold
plastic part
cavity
part forming
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PCT/CN2021/140814
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English (en)
French (fr)
Inventor
胡学川
李力
周建军
赵义祥
赵兵
罗刚
李晓帆
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重庆平伟汽车零部件有限公司
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Publication of WO2022148247A1 publication Critical patent/WO2022148247A1/zh

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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
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/2701—Details not specific to hot or cold runner channels
    • B29C45/2708—Gates
    • 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
    • B29C33/3835—Designing moulds, e.g. using CAD-CAM
    • 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
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2806—Closure devices therefor consisting of needle valve systems
    • 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
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2806—Closure devices therefor consisting of needle valve systems
    • B29C45/281—Drive means therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3044—Bumpers

Definitions

  • the invention relates to the field of molding technology and mold manufacturing, in particular to a molding method for plastic parts.
  • the pneumatic or hydraulic needle valve hot runner technology is usually used for mold design.
  • the position of the gate can realize the balanced filling of the molten plastic fluid in the mold cavity, so as to complete the injection molding of the product.
  • the present invention provides a method for forming a plastic part of an electric servo-driven hot runner mold.
  • a method for forming a plastic part of an electric servo-driven hot runner mold the key of which is to carry out the following steps:
  • Step 1 Design a plastic part forming mold according to the target plastic part, and the plastic part forming mold is provided with a cavity for forming the target plastic part;
  • Step 2 A gate is set on the plastic part forming mold, the inner ends of the gate are respectively connected to the cavity, and a gate is respectively set on the plastic part forming mold corresponding to each of the gates valve needles, the gate valve needles are respectively used to control the opening and closing of the corresponding gates, and a servo motor is respectively provided on the plastic part forming mold corresponding to each of the gate valve needles, and the servo motors are respectively Control the corresponding gate valve needle to advance and retreat;
  • Step 3 Set the melt filling scheme; make the melt reach the gate position through the runner, control the corresponding servo motor, and place the gates in order from the middle of the cavity to the edge of the gate. open so that the melt fills the cavity;
  • Step 4 Pressure maintaining, cooling, mold opening, and mold release.
  • Figure 1 is a schematic structural diagram of the front bumper central support
  • Fig. 2 is the PP front protection central support that adopts the technology of the present invention to manufacture
  • Fig. 3 is the detailed schematic diagram at 2A of Fig. 2;
  • Fig. 4 is the detailed schematic diagram at 2B of Fig. 2;
  • Fig. 5 is the PP front protection central bracket manufactured by the traditional process
  • Fig. 6 is the detailed schematic diagram at 5A of Fig. 5;
  • FIG. 7 is a detailed schematic diagram at 5B of FIG. 5 .
  • a method for forming a plastic part of an electric servo-driven hot runner mold is carried out according to the following steps:
  • Step 1 Design a plastic part forming mold according to the target plastic part, and the plastic part forming mold is provided with a cavity for forming the target plastic part;
  • Step 2 A gate is set on the plastic part forming mold, the inner ends of the gate are respectively connected to the cavity, and a gate is respectively set on the plastic part forming mold corresponding to each of the gates valve needles, the gate valve needles are respectively used to control the opening and closing of the corresponding gates, and a servo motor is respectively provided on the plastic part forming mold corresponding to each of the gate valve needles, and the servo motors are respectively Control the corresponding gate valve needle to advance and retreat;
  • Step 3 Set the melt filling scheme; make the melt reach the gate position through the runner, control the corresponding servo motor, and place the gates in order from the middle of the cavity to the edge of the gate. open so that the melt fills the cavity;
  • Step 4 Pressure maintaining, cooling, mold opening, and mold release.
  • a front bumper central support (referred to as: front bumper central support, made of PP), as shown in Figure 1, includes an upper beam and a lower beam located directly below the upper beam; the upper beam and the lower beam are There are eight vertical slats distributed between them, and the upper and lower ends of the vertical slats are respectively connected with the upper beam and the lower beam.
  • the apparent length of the front bumper central support is 100-120 cm, the apparent width is 20-30 cm, and the apparent thickness is 12-15 cm, and the wall thickness of the front bumper central support is 1-3 mm; the above-mentioned apparent length refers to The distance between the two farthest points in the length direction. Similarly, the apparent width and the apparent thickness refer to the distance between the two farthest points in the width and thickness directions, respectively.
  • Step 1 Design a molding die according to the PP front protection central support, the target plastic part is roughly an axisymmetric structure, and the molding die is provided with a symmetrical cavity for molding the PP front protection central support;
  • Step 2 A gate is set on the molding die, the inner ends of the gate are respectively connected with the symmetrical cavity, and a gate valve pin is respectively set on the molding die corresponding to each gate, The gate valve pins are respectively used to control the opening and closing of the corresponding gates, and a servo motor is respectively provided on the molding die corresponding to each gate valve pin, and the servo motors respectively control the corresponding gate valve pins.
  • the gate includes a center gate and a side gate, the center of the center gate is located on the symmetry axis of the symmetrical cavity, and a plurality of the side gate, the gate valve needle corresponding to the center gate is the center valve needle, and the gate valve needle corresponding to the side gate is the side valve needle;
  • the simulation analysis is carried out by Moldflow software to obtain the best mold flow filling scheme, and it is determined that the central gate is one and the side gates are two; all the gates are located in the symmetrical cavity for forming.
  • the two lateral gates are symmetrically distributed on both sides of the central gate, and the distance between the lateral gate and the central gate in the length direction is 25-30 cm.
  • the distance between the lateral gate and the central gate in the width direction is 0-5 cm, and the cross-sectional area of the gate is 20 mm 2 .
  • Step 3 Fill the melt; make the melt reach the gate position through the runner, first control the corresponding servo motor to open the center gate, and the melt first enters the symmetrical gate through the center gate cavity;
  • the corresponding servo motor is controlled to retract the center valve needle to open the center gate;
  • the retraction rate of the center valve needle is 45-55mm/s, and the retraction amount is 16-20mm ;
  • the two lateral valve needles After 0.5-1.5s (delay time), the two lateral valve needles start to retract at the same time to open the lateral gate.
  • the retraction rate of one of the lateral valve needles is 35-45mm/s, and the retraction amount is 13-17mm; 7mm, then retract 13-17mm at a retraction rate of 40-50mm/s.
  • Step 4 Press the parameters listed in the table below to maintain pressure
  • Step 6 Open and close the mold according to the parameters listed in the table below
  • FIG. 2 The obtained photo of the actual product is shown in FIG. 2
  • FIG. 3 and FIG. 4 are the detailed schematic diagrams at 2A and 2B in the actual photo of the product corresponding to FIG. 2 , respectively.
  • Example 2 The front bumper center bracket in Example 2 is processed by traditional processing technology. The difference from Example 2 is that the servo motor is replaced with a cylinder, and the cylinder is used to drive the gate valve needle to retract uncontrollably, resulting in The physical photo of the product is shown in Figure 5, and Figures 6 and 7 are the detailed schematic diagrams at 5A and 5B in the physical photo of the product corresponding to Figure 5, respectively.
  • Figures 3 and 6 correspond to the same parts of the front protection central bracket;
  • Figures 4 and 7 correspond to the same parts of the front protection central bracket.
  • Figure 3 shows blurred welding marks, Figure 6 shows obvious welding marks;
  • Figure 4 shows no whitening temperature difference line, and
  • Figure 7 shows a slight whitening temperature difference line.
  • the hot runner is driven by electric servo, the speed and position can be adjusted, it can be controlled in multiple stages, the process adjustment range is wide, the control is precise, the time control or position control is not affected by unstable air pressure or poor oil pressure sealing , No delay for multi-point hot runner control, for adjusting the temperature difference line or weld line of plastic products, sun spot or bubbles near the gate, cold material, silver wire, sink mark, bulge, warpage caused by excessive internal stress of the product Defects such as deformation have obvious effects.
  • the appearance of plastic products is easy to ensure, and it is very suitable for the molding control of high-demand plastic products of multi-cavity molds.

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

Abstract

本发明公开了一种电伺服驱动热流道模具的塑料件成形方法，首先设计塑料件成型模具，模具内有型腔；在塑料件成型模具上设置浇口，对应每个浇口分别设置浇口阀针和伺服电机，伺服电机分别控制对应的浇口阀针进退，使熔体经浇口先后缓慢进入型腔；最后经保压、冷却、开模、脱模即得到产品。采用本发明的显著效果是采用伺服电机控制的浇口阀针速度和位置可以调节，可以分段精确控制，不受气压不稳定或油压密封性不好影响，对于多点热流道控制不会延迟，对于调节塑料制品的温差线、熔接痕、产品内应力过大产生的翘曲变形等缺陷有明显的效果，塑料制品外观易于保证，非常适合多腔模的高要求的塑料制品的成型控制。

Description

电伺服驱动热流道模具的塑料件成形方法 技术领域
本发明涉及成型工艺及模具制造领域，特别是涉及一种塑料件的成形方法。
背景技术
当前汽车、电子类塑料产品越来越多，对产品的外观及精度要求也越来越高，常规传统的模具设计及常规的注塑工艺成型不能满足用户的需求。
通常情况下，对于特别大或长或外观质量要求高的汽车、电子类塑料产品，通常采用气动或油压针阀式热流道技术来进行模具设计，通过Moldflow软件模拟分析，布置合理的多热流道浇口位置，实现熔融的塑料流体在模具型腔内均衡充填，从而完成产品的注塑成型。但是采用这种气动或油压针阀式热流道技术，由于气动或油压推动阀针是瞬间打开或关闭，熔体在打开瞬间急速充填型腔，打开瞬间熔体所受的剪切率也较高，故仍旧有些不良缺陷出现在产品表面上，如产品表面出现明显的温差线或熔接痕、太阳斑或浇口附近气泡、冷料、银丝、缩痕、鼓包、产品内应力过大等缺陷，若注塑完成后产品还需后续的表面处理，如喷涂、电镀、烫印等等，这些缺陷在经过表面处理后，缺陷不但不能掩盖，反而会放大缺陷，看起来更加明显，不能满足用户的需求。
为此，我们急需寻求一种新技术来弥补当前的不足，解决当前的缺陷，满足需求，减少人工成本及报废率，提升产品质量。
发明内容
有鉴于此，本发明提供了一种电伺服驱动热流道模具的塑料件成形方法。
其技术方案如下：
一种电伺服驱动热流道模具的塑料件成形方法，其关键在于按以下步骤进行：
步骤一、依照目标塑料件设计塑料件成型模具，该塑料件成型模具内设有用于成型所述目标塑料件的型腔；
步骤二、在所述塑料件成型模具上设置浇口，所述浇口的内端分别与所述型腔接通，在所述塑料件成型模具上对应每个所述浇口分别设置浇口阀针，所述浇口阀针分别用于控制对应的所述浇口开闭，在所述塑料件成型模具上对应每个所述浇口阀针分别设有伺服电机，所述伺服电机分别控制对应的所述浇口阀针进退；
并通过Moldflow软件进行模拟分析，得到最佳的模流充填方案，由此确定所述浇口的数量以及位置，对应所述型腔的中部和其边缘部分分别设有所述浇口；
步骤三、设定熔体填充方案；使熔体经流道到达所述浇口位置，控制对应的所述伺服电机，将所述浇口按照从所述型腔的中部向其边缘的顺序依次打开，使熔体填充所述型腔；
步骤四、保压、冷却、开模、脱模。
附图说明
图1为前保险杠中央支架的结构示意图；
图2为采用本发明工艺制造得到的PP前保中央支架；
图3为图2的2A处的细节示意图；
图4为图2的2B处的细节示意图；
图5为采用传统工艺制造得到的PP前保中央支架；
图6为图5的5A处的细节示意图；
图7为图5的5B处的细节示意图。
具体实施方式
以下结合实施例和附图对本发明作进一步说明。
实施例1：
一种电伺服驱动热流道模具的塑料件成形方法，按以下步骤进行：
步骤一、依照目标塑料件设计塑料件成型模具，该塑料件成型模具内设有用于成型所述目标塑料件的型腔；
步骤二、在所述塑料件成型模具上设置浇口，所述浇口的内端分别与所述型腔接通，在所述塑料件成型模具上对应每个所述浇口分别设置浇口阀针，所述浇口阀针分别用于控制对应的所述浇口开闭，在所述塑料件成型模具上对应每个所述浇口阀针分别设有伺服电机，所述伺服电机分别控制对应的所述浇口阀针进退；
并通过Moldflow软件进行模拟分析，得到最佳的模流充填方案，由此确定所述浇口的数量以及位置，对应所述型腔的中部和其边缘部分分别设有所述浇口；
步骤三、设定熔体填充方案；使熔体经流道到达所述浇口位置，控制对应的所述伺服电机，将所述浇口按照从所述型腔的中部向其边缘的顺序依次打开，使熔体填充所述型腔；
步骤四、保压、冷却、开模、脱模。
实施例2：
一种前保险杠中央支架(简称：前保中央支架，材质为PP)，如图1所示，其包括上横梁、以及位于该上横梁正下方的下横梁；所述上横梁和下横梁之间分布有八个竖向条板，所述竖向条板的上、下两端分别与所述上横梁和下横梁连接，所述前保险杠中央支架为大致左右对称的轴对称结构，所述前保险杠中央支架的外观长度为100-120cm、外观宽度为20-30cm、外观厚度为 12-15cm，所述前保险杠中央支架的壁厚为1-3mm；以上所称外观长度是指长度方向上的相距最远两点之间的距离，同理，外观宽度、外观厚度分别指宽度、厚度方向上的相距最远两点之间的距离。
以上前保中央支架的成形方法按以下步骤进行：
步骤一、依照PP前保中央支架设计成型模具，该目标塑料件大致为轴对称结构，该成型模具内设有用于成型所述PP前保中央支架的对称型腔；
步骤二、在所述成型模具上设置浇口，所述浇口的内端分别与所述对称型腔接通，在所述成型模具上对应每个所述浇口分别设置浇口阀针，所述浇口阀针分别用于控制对应的所述浇口开闭，在所述成型模具上对应每个所述浇口阀针分别设有伺服电机，所述伺服电机分别控制对应的所述浇口阀针进退；
所述浇口包括中心浇口和侧向浇口，所述中心浇口的中心位于所述对称型腔的对称轴上，在所述对称型腔的对称轴两侧对称分布有多个所述侧向浇口，所述中心浇口对应的浇口阀针为中心阀针，所述侧向浇口对应的浇口阀针为侧向阀针；
通过Moldflow软件进行模拟分析，得到最佳的模流充填方案，确定所述中心浇口为一个，所述侧向浇口为两个；所有所述浇口位于所述对称型腔用于成型所述上横梁部位的外侧，两个所述侧向浇口对称分布在所述中心浇口两侧，所述侧向浇口与所述中心浇口在长度方向的距离为25-30cm，所述侧向浇口与所述中心浇口在宽度方向的距离为0-5cm，所述浇口的截面积为20mm 2。
步骤三、填充熔体；使熔体经流道到达所述浇口位置，首先控制对应的所述伺服电机，使所述中心浇口打开，熔体先经所述中心浇口进入所述对称型腔；
再控制其他对应的所述伺服电机，使所述侧向浇口打开，熔体再经所述侧向浇口进入所述对称型腔；
具体的，控制对应的所述伺服电机，使所述中心阀针回缩从而打开所述中心浇口；所述中心阀针的回缩速率为45-55mm/s，回缩量为16-20mm；
在0.5-1.5s(延迟时间)后，再使两个所述侧向阀针同时开始回缩从而打开所述侧向浇口。其中一个所述侧向阀针的回缩速率为35-45mm/s，回缩量为13-17mm；另一个所述侧向阀针先以15-25mm/s的回缩速率回缩3-7mm，再以40-50mm/s的回缩速率回缩13-17mm。
所述中心阀针和所述侧向阀针向的延迟时间、回缩速率、回缩量统计如下表所示：
伺服热流道顺序阀时间设定
Figure PCTCN2021140814-appb-000001
步骤四、按下表所列参数进行保压
保压设定 压力(bar) 速度(％) 保压时间(s)
保压一段 40±10 20±5 4.±1
步骤五、按下表所列参数进行冷却
冷却时间(s) 15±2
步骤六、按下表所列参数进行开合模
Figure PCTCN2021140814-appb-000002
步骤七、按下表所列参数进行脱模
Figure PCTCN2021140814-appb-000003
由此得到的产品实物照片如图2所示，图3和图4分别为图2对应的产品实物照片中2A、2B处的细节示意图。
实施例3：
采用传统加工工艺加工实施例2中的所述前保险杠中央支架，其与实施例2的不同在于将伺服电机换为气缸，采用气缸带动浇口阀针使其不受控的回缩，得到的产品实物照片如图5所示，图6和图7分别为图5对应的产品实物照片中5A、5B处的细节示意图。
根据实施例2和3的对比可以看出：图3和图6对应前保中央支架的相同部位；图4和图7对应前保中央支架的相同部位。图3显示出焊接痕模糊，图6显示出焊接痕明显；图4显示出无发白温差线，图7显示出轻微的发白温差线。
有益效果：采用电伺服驱动热流道，速度和位置可以调节，可以分多段控制，工艺调节范围较宽，控制精确,分时间控制或位置控制，不受气压不稳定或油压密封性不好影响，对于多点热流道控制不会延迟，对于调节塑料制品的温差线或熔接痕、太阳斑或浇口附近气泡、冷料、银丝、缩痕、鼓包、产品内应力过大产生的翘曲变形等缺陷有明显的效果。塑料制品外观易于保证，非常适合多腔模的高要求的塑料制品的成型控制。
最后需要说明的是，上述描述仅仅为本发明的优选实施例，本领域的普通技术人员在本发明的启示下，在不违背本发明宗旨及权利要求的前提下，可以做出多种类似的表示，这样的变换均落入本发明的保护范围之内。

Claims (1)

  1. 一种电伺服驱动热流道模具的塑料件成形方法，其特征在于按以下步骤进行：
    步骤一、依照目标塑料件设计塑料件成型模具，该塑料件成型模具内设有用于成型所述目标塑料件的型腔；
    步骤二、在所述塑料件成型模具上设置浇口，所述浇口的内端分别与所述型腔接通，在所述塑料件成型模具上对应每个所述浇口分别设置浇口阀针，所述浇口阀针分别用于控制对应的所述浇口开闭，在所述塑料件成型模具上对应每个所述浇口阀针分别设有伺服电机，所述伺服电机分别控制对应的所述浇口阀针进退；
    并通过Moldflow软件进行模拟分析，得到最佳的模流充填方案，由此确定所述浇口的数量以及位置，对应所述型腔的中部和其边缘部分分别设有所述浇口；
    步骤三、设定熔体填充方案；使熔体经流道到达所述浇口位置，控制对应的所述伺服电机，将所述浇口按照从所述型腔的中部向其边缘的顺序依次打开，使熔体填充所述型腔；
    步骤四、保压、冷却、开模、脱模。
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