CN110625891B - 一种射出成形装置及其射出成形方法 - Google Patents

一种射出成形装置及其射出成形方法 Download PDF

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CN110625891B
CN110625891B CN201810784345.9A CN201810784345A CN110625891B CN 110625891 B CN110625891 B CN 110625891B CN 201810784345 A CN201810784345 A CN 201810784345A CN 110625891 B CN110625891 B CN 110625891B
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mold
injection molding
gas
base
die
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CN110625891A (zh
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林顺福
苏裕章
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Ruihuang Precision Industry Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
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    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/46—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles using fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0415—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by regulating the pressure of the material during or after filling of the mould, e.g. by local venting
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

发明提供一种射出成形装置，其主要包括：一上模座，该上模座设有一注料口；一上模仁设于该上模座内，其设有至少一射出口、一垫圈槽及一垫圈，该射出口连通该注料口；一下模座其可操作性地对合或分离于该上模座，该下模座设有至少一气体通道，该通道可供气体进出；以及一下模仁设于该下模座内，其随该下模座对合或分离于该上模仁，该下模仁设有一模穴及设有至少一异形风路连通该模穴及该气体通道，该下模仁为多孔性材质，其使该下模仁充满多个孔隙；该模穴内部会通过该气体通道经该异形风路预先注入气体，以使该模穴内部保持一预设压力或是让该气体溢散于该多个孔隙喷出，使一成品脱离该模穴。另外，本发明还提供一种射出成形方法。

Description

一种射出成形装置及其射出成形方法
技术领域
本发明涉及一种成形装置，尤其涉及一种射出成形装置及其射出成形方法。
背景技术
射出成形机又称为注塑机或射出机，主要是用来制造塑料产品的装置或机器，可由两个主要部分组成，分别为锁模单元及射出单元。
然而，一般现有技术中的热塑性聚氨酯弹性体橡胶(Thermoplasticpolyurethanes, TPU)原料必需进行烘料程序，以去除所含的水分，主要是为了避免原料在模具内成形时，水气会导致有气泡产生到成品表面，另物理发泡射出亦有相同的情形，进而造成产品表面粗糙，导致发泡成形后的初胚须再进行表面加工，才能克服前述问题，从而使得工艺增加。
且上述的射出成形方式，让将原料注入模具内加热发泡成形，其因不易控制模内的气体压力保持一致，导致发泡过程中气体与原料无法完全融合或气体与原料分离，进而使成品会有局部硬块问题与发泡不均匀产生。再者，当原料持续注入模具内部，而模具却未有效排气的状况下，则会形成产生充填不完全跟发泡孔隙难以控制的问题，即俗称的包风现象，此包风现象会提升成品的不合格率。
另外，为方便自模具内取出成品，现有技术中的方式是在模具内喷涂离型剂以防止成型材料附着于模具内壁，并设置一取出设备，将成品由模具内取出。然而离型剂可能残留于模具内壁，而影响后续的工艺，且喷涂及后续清除作业，皆使得工艺增加。因此，如何提供一种较佳的射出成形装置跟射出成形方法，实为当前重要课题的一。
发明内容
鉴于上述现有技术的缺点，本发明的一目的在于提供一种射出成形装置，其可令成形的成品表面平整光滑，且改善包风问题，并可缩短工艺。
本发明的另一目的在于提供一种射出成形装置方法，其原料不需通过烘干作业，而可节省前置作业的时间。
为达到上述的目的，依据本发明所提供的一种射出成形装置，其配合一射出机使用，尤其指超临界流体微发泡射出机与化学发泡射出机，该射出成形装置包括：
一上模座，设有一上模座凹槽及一注料口，该注料口与该射出机连接；一上模仁，设于该上模座凹槽内，该上模仁设有至少一射出口、一垫圈槽及一垫圈，该射出口连通该注料口；一下模座，可操作性地对合或分离于该上模座，该下模座设有一下模座凹槽及至少一气体通道，该气体通道可供气体进出；以及一下模仁，设于该下模座凹槽内，其随该下模座对合或分离于该上模仁，该下模仁设有一模穴，并且该下模仁设置有至少一异形风路连通该模穴及该气体通道，该下模仁为多孔性材质，该多孔性材质使得该下模仁充满多个孔隙。当该下模座对合于该上模座状态下，该模穴内部会通过该气体通道经该异形风路预先注入气体，以使该模穴内部保持一预设压力；当该射出机内的原料进入该模穴成形过程状态下，该气体可控制速率逐渐抽离该模穴，使原料完整填满该模穴；当该模穴内已成形一成品，且该下模座分离于该上模座状态下，该气体由该气体通道经该异形风路溢散于该多个孔隙喷出，使该成品脱离该模穴。
较佳地，本发明的射出成形装置还可包括一控制装置，控制气体进出量及时间，并能够调节该模穴内的压力，且该射出机受该控制装置控制原料进入该模穴内的流量。
较佳地，该上模座及该下模座还包括至少一冷却水路。
较佳地，该下模仁的该至少一异形风路由三维打印形成或以透气钢材加工形成。
较佳地，该异形风路包括至少一主风道及多个副风道，该主风道环设于该模穴周围及其底部，且连通该气体通道，各个副风道呈间隔排列于该主风道与该模穴之间，且各个副风道一端连通该主风道，另一端连通该模穴。
较佳地，该垫圈槽设置于该射出口的周围，该垫圈设于该垫圈槽内，且其一侧贴合该垫圈槽底部，并在该下模座对合于该上模座状态下，该垫圈另一侧贴合于该下模仁。
较佳地，该控制装置与该气体通道之间设有一防止该气体逆流的阀门。
较佳地，该射出成形装置还包括一感测该模穴内部压力的测压单元，该测压单元电性连接于该控制装置。
此外，本发明亦提供一种射出成形方法，其包括以下步骤：
将一成形模具装设于一射出机，该成形模具包括:
一上模座、一下模座、一上模仁及一下模仁，该上模座设有一注料口，该上模仁设于该上模座内，且该上模仁设有一射出口、一垫圈槽和一垫圈，该下模座至少设有一气体通道，该下模仁设于该下模座内，且设有一模穴以及至少一异形风路，该下模仁为多孔性材质，该多孔性材质使该下模仁充满多个孔隙；
预先对该模穴的内部注入气体，以形成一反压模具状态；
将原料倒入射出成形机料桶内，进入螺杆以使原料与超临界流体的氮气或二氧化碳混合后，由该注料口注入至该模穴内成形；
随注入原料的同时，同步控制模穴内气体的进出量，让其保持并控制一定的压力，并于射出结束时可控制并释放全部模腔内压力，进而帮助发泡成形，使其不产生包风现象。
控制该气体由该气体通道经该异形风路溢散于该多个孔隙喷出，使一成品容易可自动脱模。
附图说明
图1为依据本发明的较佳实施例，显示一种射出成形装置的立体分解示意图；
图2为依据本发明的较佳实施例，显示该射出成形装置的组合示意图；
图3为依据本发明的较佳实施例，显示图2所示的该射出成形装置的局部放大示意图；
图4为依据本发明的较佳实施例，显示该射出成形装置的下模仁的立体示意图；
图5为依据本发明的较佳实施例，显示图2的A-A剖面图；
图6为依据本发明的较佳实施例，显示图2的B-B剖面图；
图7为依据本发明的较佳实施例，显示该射出成形装置的方块示意图；
图8为依据本发明的较佳实施例，显示一种射出成形方法的步骤流程图。
附图标记说明
10、上模座；101、上模座凹槽；102、注料口；103、冷却水路；
104、第一对合面；20、上模仁；201、射出口；202、垫圈槽；
203、垫圈；204 、冷却回路；30、下模仁；301、模穴；
302、异形风路；3021、主风道；3022、副风道；303、冷却回路；
40、下模座；401、下模座凹槽；402、气体通道；
403、冷却水路；404、第二对合面；50、控制装置；51、气体装置；
52 、射出单元；53、测压单元；54、液体装置；55、模具；
56 、阀门。
具体实施方式
以下通过特定的具体实施例说明本发明的实施方式，熟本领域技术人员可由本说明书所公开的内容轻易地了解本发明的其他优点及功效。本发明亦可通过其他不同的具体实例加以施行或应用，本发明说明书中的各项细节亦可基于不同观点与应用在不悖离本发明的精神下进行各种修饰与变更。
请参阅图1至图6，本发明一较佳实施例的射出成形装置，其配合一射出机52使用，尤指MUCELL微发泡射出机或化学发泡射出机，该射出成形装置主要包括一上模座10、一上模仁20、一下模仁30以及一下模座40。
该上模座10一侧形成一第一对合面104，于该第一对合面104设有一上模座凹槽101，且于该上模座10另一侧设一注料口102，其中该上模座10的该注料口102与该射出机52一端连接。该上模仁20设于该上模座凹槽101中，且设有两个射出口201、一垫圈槽202及一垫圈203，其中各该射出口201连通该注料口102，在本实施例中，该上模仁20设有两个射出口201，但非用以限制其数量。再者，本发明不限制该上模仁20的材质，其可视产品结构需求，而令该上模仁20为多孔性材质，多孔性材质使该上模仁20充满多个孔隙。另外，该上模座10至少设有一冷却水路103，而该上模仁20至少设有一冷却回路204连通该上模座10的冷却水路103，配合图7所示，该冷却水路103连接一液体装置54，而令其内部的冷却液体(未图示)于该冷却水路103及该冷却回路204内部循环，借以保持该上模座10及该上模仁20于一默认的温度值内。再者，该上模仁20包括一垫圈槽202设置于该射出口201的周围，还包括一垫圈203设于该垫圈槽202内，且该垫圈203一侧贴合该垫圈槽202底部。
该下模座40一侧设有一第二对合面404，其可操作性地对合或分离于该上模座10的第一对合面104，于该第二对合面404设有一下模座凹槽401，且至少一气体通道402，该气体通道402可供一气体装置51的气体(未图示)进出。该下模仁30为多孔性材质，多孔性材质使该下模仁30充满多个孔隙，且该下模仁30随该下模座40对合或分离于该上模仁20，该下模仁30设于该下模座凹槽401中，且该下模仁30设有一模穴301，并设置有至少一异形风路302，本发明不限制该下模仁30的该异形风路302的形成方式，较佳以三维打印形成或以透气钢材加工形成。在本实施例中，该异形风路302包括至少一主风道3021及多个副风道3022，该主风道3021环设于该模穴301周围，且连通该气体通道402，各个副风道3022呈间隔排列于该主风道3021与该模穴301之间，且各个副风道3022一端连通该主风道3021，另一端连通该模穴301，上述仅为实施例之一，并非用以限制该异形风路302的结构。
另外，该下模座40至少设有一冷却水路403，而该下模仁30至少设有一冷却回路303连通该下模座40的冷却水路403，配合图7所示，该冷却水路403连接该液体装置54，而令其内部的冷却液体(未图示)于该冷却水路403及该冷却回路303内部循环，借以保持该下模座40及该下模仁30于一默认的温度值内。
配合图7所示，本发明还包括一控制装置50，其主要控制该气体装置51的气体进出量及时间、程序，并调节该模穴301内的压力，且该射出机52亦受该控制装置50控制其原料进入该模穴301内的流量与流速，而该控制装置50与该气体通道402之间还设有一阀门56，该阀门56主要是防止该气体逆流，而使该模穴301内压力产生变化；同时，本发明还包括一测压单元53电性连接于该控制装置50，其主要在感测该模穴301内部压力的变化，借以令该控制装置50可依据该测压单元53的数据变化而随时调节该模穴301内的压力，使其保持在默认值内。
呈上所述，当该下模座40对合于该上模座10状态下，该控制装置50会控制该气体装置51通过该气体通道402经该异形风路302预先注入气体，以使该模穴301内部保持一预设压力，且形成反压状态；值得一提的是，如图1所示，该垫圈槽202设置于该射出口201的周围，亦即，该垫圈203可框设于垫圈槽202内并贴合该上模仁20与该下模仁30，使该上模座10、下模座140合模时保持密闭空间，以利控制模穴301内压力的大小，因此，可有效地防止气体外泄。
当该射出机52内部的气液体混合物原料，由该注料口102注入至该模穴301内成形过程状态下，该模穴301内部压力会因原料的注入而产生变化，此时该控制装置50则会通过该测压单元53所检测的压力数据进行调节气体的流量。当原料逐渐填满该模穴301，此时该气体则随原料的注入而逐渐抽离该模穴301，令原料随抽离气体产生的引力，而完整地填满该模穴301，使得成品不会产生填充不满，俗称包风的状态。
再者，当该模穴301内已成形一成品(未图示)，且该下模座40分离于该上模座10状态下，该控制装置50会控制该气体由该气体通道402经该异形风路302溢散于该多个孔隙喷出，进而使该成品脱离该模穴301，相较于现有技术，本发明不须于模穴内喷涂离型剂及另外设置取出设备，即可令成品自动脱模，实则缩短了成形工艺。
图7显示本发明的射出成形装置的方块示意图。配合图7所示，该控制装置50控制该气体装置51、该射出机52、该测压单元53、该液体装置54、模具55以及一阀门56，其中该模具55指该上模座10、上模仁20、下模座40、下模仁30组合后状态，该控制装置50可控制气体进出量、程序及时间，并调节模穴301内的压力，当模穴301内超过预设的压力时，可通过至少一异形风路302的路径将气体抽离出去，而当模穴301内压力低于默认值时，亦可通过控制装置50来增加模穴301内的压力，进而可让该模穴301内保持有一定的压力。
反之，反压状态主要是针对表面光滑的成品，气体对由注入的混合物原料产生阻力，使混合物原料表面与气体形成相互抵触、受挤压而成光滑面，成形之后再由该控制装置50控制将压力自然溢散或抽出。
依据本发明的较佳实施例，若用于制作鞋垫，因为制作鞋垫所需原料比较偏软料，所以模穴内压力大概保持在7bar至9bar之间即可，若用在制作雪镜框，较需要用到硬料，所以模穴内压力大概会保持在60bar至70bar之间为最佳状态(会依据产品属性不同来设定压力值)。因此，当制造的产品不同时，模穴内的压力范围一般设定在2bar至100bar之间，但非限制本发明。
此外，如图8所示，本发明亦提供一种射出成形方法，包括以下步骤S81~S85：
步骤S81：将一成形模具装设于一射出机，该成形模具包括: 一上模座、一下模座、一上模仁及一下模仁，该上模座设有一柱料口，该上模仁设于该上模座内，且设有一射出口、一垫圈槽、一垫圈，该下模座至少设有一气体通道，该下模仁设于该下模座内，且设有一模穴以及至少一异形风路，该下模仁为多孔性材质，该多孔性材质使该下模仁充满多个孔隙。
步骤S82：预先对该模穴的内部注入气体，以形成一反压状态。
步骤S83：将原料倒入射出成形机料桶内，进入螺杆以使原料与超临界流体的氮气或二氧化碳混合后，通过该注料口注入至该模穴内成形。
步骤S84：随注入原料的同时，同步控制模穴内气体的进出量，让其保持并控制一定的压力，并于射出结束时可控制并释放全部模腔内压力，进而帮助发泡成形，使其不产生包风现象。
步骤S85：控制气体由该气体通道经该异形风路溢散于该多个孔隙喷出，使一成品自动脱模。
其中，步骤S81所述的射出机，尤指MUCELL微发泡射出机或化学发泡射出机，但非用以限制射出机的种类。而以MUCELL微发泡射出机或化学发泡射出机配合本发明的射出成形装置所成形的成品，其表面不产生气泡孔，而内部较现有技术中更为微细发泡，并使模具内不产生包风现象，以利成品形状完整性。
综上所述，依据本发明所提供的一种射出成形装置及射出成形方法，包括以下优点：
1. 可使成品表面平整光滑，例如:鞋底、鞋垫。
2. 可增加产品强度及耐震度，因成品整体发泡均匀，不会如现有技术有发泡不全、不均而产生硬块问题与难以控制发泡的问题。
3. 有效地改善包风问题，让其发泡完全。
4. 工序步骤节省很多，进而缩短产品制造时间。
5. 提高产能并节省成本，达到节能减碳。
显然，所描述的实施例仅仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。

Claims (9)

1.一种射出成形装置，其配合一射出机使用，其特征在于，该射出成型装置包括：
一上模座，该上模座设有一上模座凹槽及一注料口，该注料口与该射出机连接；
一上模仁，设于该上模座凹槽内，该上模仁设有至少一射出口、一垫圈槽及一垫圈，该射出口连通该注料口；
一下模座，能够操作性地对合或分离于该上模座，该下模座设有一下模座凹槽及至少一气体通道，该气体通道能够供气体进出；以及
一下模仁，设于该下模座凹槽内，其随该下模座对合或分离于该上模仁，该下模仁设有一模穴，并且设置有至少一异形风路，该异形风路包括至少一主风道及多个副风道，该主风道环设于该模穴周围，且连通该气体通道，各个副风道呈间隔排列于该主风道与该模穴之间，且各个副风道一端连通该主风道，另一端连通该模穴，该下模仁为多孔性材质，该多孔性材质使得该下模仁充满多个孔隙；
当该下模座对合于该上模座状态下，该模穴内部会通过该气体通道经该异形风路预先注入气体，能够使得该模穴内部保持一预设压力；
当该射出机内的原料进入该模穴成形过程状态下，该气体能够控制速率逐渐抽离该模穴，使得原料完整填满该模穴；
当该模穴内已成形一成品，且该下模座分离于该上模座状态下，该气体通过该气体通道经该异形风路溢散于该多个孔隙喷出，使该成品脱离该模穴。
2.如权利要求1所述的射出成形装置，其特征在于，该射出成形装置还包括一控制装置，该控制装置用于控制气体进出量及时间，并调节该模穴内的压力，且该射出机是受该控制装置控制原料进入该模穴内的流量。
3.如权利要求1所述的射出成形装置，其特征在于，该上模仁为多孔性材质，该多孔性材质使得该上模仁充满多个孔隙。
4.如权利要求1所述的射出成形装置，其特征在于，该下模仁的该至少一异形风路由三维打印形成或以透气钢材加工形成。
5.如权利要求1所述的射出成形装置，其特征在于，该垫圈槽设置于该射出口的周围，该垫圈设于该垫圈槽内，且其一侧贴合该垫圈槽底部，并在该下模座对合于该上模座状态下，该垫圈另一侧贴合于该下模仁。
6.如权利要求1所述的射出成形装置，其特征在于，该上模座及该下模座还包括至少一冷却水路。
7.如权利要求2所述的射出成形装置，其特征在于，该控制装置与该气体通道之间设有一防止该气体逆流的阀门。
8.如权利要求1所述的射出成形装置，其特征在于，该射出成形装置还包括一感测该模穴内部压力的测压单元，该测压单元与该控制装置电性连接。
9.一种射出成形方法，其特征在于，包括下列步骤：
将一成形模具装设于一射出机，该成形模具包括: 一上模座、一下模座、一上模仁及一下模仁，该上模座设有一注料口，该上模仁设于该上模座内，且该上模仁设有一射出口、一垫圈槽和一垫圈，该下模座至少设有一气体通道，该下模仁设于该下模座内，且该下模仁设有一模穴以及至少一异形风路，该异形风路包括至少一主风道及多个副风道，该主风道环设于该模穴周围，且连通该气体通道，各个副风道呈间隔排列于该主风道与该模穴之间，且各个副风道一端连通该主风道，另一端连通该模穴，该下模仁为多孔性材质，该多孔性材质使该下模仁充满多个孔隙；
预先对该模穴的内部注入气体，以形成一反压状态；
将原料倒入射出机料桶内，进入螺杆以使原料与超临界流体的氮气或二氧化碳混合后，通过该注料口注入至该模穴内成形；
随注入原料的同时，同步控制模穴内气体的进出量，让其保持并控制一定的压力，并于射出结束时能够控制并释放全部模腔内压力，进而帮助发泡成形，使得其不产生包风现象；
控制气体由该气体通道经该异形风路溢散于该多个孔隙喷出，使一成品自动脱模。
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