CN113619054A - Thermoplastic resin substrate for curved mirror and preparation method thereof - Google Patents
Thermoplastic resin substrate for curved mirror and preparation method thereof Download PDFInfo
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- CN113619054A CN113619054A CN202010384262.8A CN202010384262A CN113619054A CN 113619054 A CN113619054 A CN 113619054A CN 202010384262 A CN202010384262 A CN 202010384262A CN 113619054 A CN113619054 A CN 113619054A
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- 239000000758 substrate Substances 0.000 title claims abstract description 72
- 229920005992 thermoplastic resin Polymers 0.000 title claims abstract description 66
- 238000002360 preparation method Methods 0.000 title claims abstract description 19
- 238000001746 injection moulding Methods 0.000 claims abstract description 20
- 230000003746 surface roughness Effects 0.000 claims abstract description 16
- 238000003825 pressing Methods 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 39
- 230000008569 process Effects 0.000 claims description 19
- 239000004417 polycarbonate Substances 0.000 claims description 16
- 229920000515 polycarbonate Polymers 0.000 claims description 16
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 14
- 239000011707 mineral Substances 0.000 claims description 14
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 13
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 238000003860 storage Methods 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 239000000463 material Substances 0.000 claims description 2
- -1 polyethylene terephthalate Polymers 0.000 claims description 2
- 239000010453 quartz Substances 0.000 claims description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 2
- 239000000454 talc Substances 0.000 claims description 2
- 229910052623 talc Inorganic materials 0.000 claims description 2
- 238000003384 imaging method Methods 0.000 abstract description 3
- 229920005989 resin Polymers 0.000 description 22
- 239000011347 resin Substances 0.000 description 22
- 238000000748 compression moulding Methods 0.000 description 12
- 230000000052 comparative effect Effects 0.000 description 11
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- 230000008020 evaporation Effects 0.000 description 11
- 230000006835 compression Effects 0.000 description 8
- 238000007906 compression Methods 0.000 description 8
- 238000002347 injection Methods 0.000 description 8
- 239000007924 injection Substances 0.000 description 8
- 238000012360 testing method Methods 0.000 description 7
- 230000008859 change Effects 0.000 description 6
- 230000003287 optical effect Effects 0.000 description 6
- 150000002500 ions Chemical class 0.000 description 5
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- 238000004519 manufacturing process Methods 0.000 description 4
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- 238000005498 polishing Methods 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 230000003190 augmentative effect Effects 0.000 description 2
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- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
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Images
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
-
- 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
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
-
- 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
- B29C45/78—Measuring, controlling or regulating of temperature
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
- G02B27/01—Head-up displays
- G02B27/0101—Head-up displays characterised by optical features
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/08—Mirrors
- G02B5/10—Mirrors with curved faces
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76498—Pressure
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76531—Temperature
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- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The invention relates to a thermoplastic resin substrate for a curved mirror, a preparation method thereof, the curved mirror comprising the thermoplastic resin substrate and a head-up display comprising the curved mirror. The preparation method comprises the following steps: A) the temperature of the mold of the injection molding machine is raised to 130-oC and closing the mold, B) injecting a molten thermoplastic resin into the mold cavity, C) applying a pressure of 300-700bar to said cavityAnd maintaining for a period of time of more than 5 seconds, D) stopping the application of pressure and reducing the temperature of the mould to 60-100 seconds within 10-50 secondsoC, and E) opening the mold and removing the molded thermoplastic resin substrate, wherein a gap of 0.3-1mm remains at the parting plane of the mold cavity before applying pressure to the cavity. The thermoplastic resin substrate has large size, high size stability and low surface roughness, can be applied to a future enhanced head-up display, and realizes large-area and long-distance projection and high-precision imaging, thereby meeting the requirements of future automobiles on driving safety and comfort.
Description
Technical Field
The invention belongs to the field of thermoplastic resin processing. In particular, the invention relates to a thermoplastic resin substrate for a curved mirror and a preparation method thereof.
Background
The head-up display for the automobile mainly has two functions: the first function is safety, the head-up display reduces the distraction of the driver and improves the safety of the driver, and the second function is to make the driving process more comfortable. Furthermore, the heads-up display places all information directly in the driver's line of sight, so critical situations can be identified and captured more quickly. As feedback on driving conditions and vehicle conditions improves, important information will not be easily missed.
The head-up display devices in use in the market mainly include a combined head-up display device and a front windshield type head-up display device. The front windshield head-up display is being recognized and applied by home and abroad automobile host factories, and becomes a standard configuration gradually.
The common front windshield head-up display can meet the requirements of 2-3 meters of imaging distance and 40 cm-20 cm of projection area.
However, the projection distance and the size of the displayed image of the current front windshield head-up display cannot meet the requirements of the future increasingly complex road environment on the head-up display, such as a longer projection distance and a longer and wider displayed image to make the driver have a more comfortable visual field and provide more information content at the same time. A new generation of augmented reality heads-up displays can move virtual information directly into the driver's line of sight and insert full color graphics into the real road view, producing images that are about 130 centimeters wide and over 60 centimeters high at distances of 7.5 meters or more from the driver's field of view.
In addition, the requirements for the surface roughness and the curved surface precision of the curved mirror are improved, and the original preparation and processing method is not suitable for the precision requirements of the curved mirror of the new generation.
Large-size curved mirrors with high dimensional stability and low surface roughness can only achieve the projection of larger-size images to greater distances. The preparation of a thermoplastic resin substrate for such a large-size curved mirror brings the following technical challenges compared to the thermoplastic resin substrate for a small-size curved mirror commonly used at present:
1. because the size of the concave mirror is greatly increased, the surface area of the concave mirror is increased by about 3 times, and the large-size design is easier to generate stress deformation than the original small-size design;
2. because the head-up display is arranged inside the instrument panel and is close to the engine, the size change caused by expansion with heat and contraction with cold can be caused by the change of high and low temperature;
3. the larger the surface area of the concave mirror, the higher the process requirements for processing Polycarbonate (PC) parts with a low roughness surface.
US 2014/0356551a1 discloses a thermoplastic shaped article with high surface quality which is manufactured by combining an injection molding process with dynamic temperature control of the mold and by means of a reinforced thermoplastic shaping composition.
JP55161621A discloses a concave board formed by using a convex mold having a surface roughness of 0.1S or less under direct pressure at a mold temperature of 20 to 40 ℃ lower than the thermal deformation point of a resin. Electrodeposition thickness of
Al or Cr to produce a concave mirror.
However, the prior art has not been able to provide large-sized curved mirrors with high dimensional stability and low surface roughness.
Therefore, the preparation of large-sized curved mirrors with high dimensional stability and low surface roughness becomes a key to the development of a new generation of augmented reality head-up displays. Further, it is necessary to prepare a substrate for a large-sized curved mirror having high dimensional stability and low surface roughness.
Disclosure of Invention
An object of the present invention is to provide a substrate for a large-sized curved mirror having high dimensional stability and low surface roughness.
It is another object of the present invention to provide a large-sized curved mirror having high dimensional stability and low surface roughness.
Therefore, according to a first aspect of the present invention, there is provided a method for producing a thermoplastic resin substrate for a curved mirror, comprising the steps of:
A) the mold of the injection molding machine is heated to the temperature of 130-190 ℃ and closed,
B) a molten thermoplastic resin is injected into the mold cavity,
C) a pressure of 300-700bar is applied to the chamber for a period of more than 5 seconds,
D) stopping the application of pressure to the cavity and reducing the temperature of the mold to a temperature in the range of 60-100 ℃, and
E) opening the mold and taking out the molded thermoplastic resin substrate,
wherein a gap of 0.3-1mm remains at the parting plane of the mold cavity prior to applying pressure to the cavity.
According to a second aspect of the present invention, there is provided a thermoplastic resin substrate produced according to the method of the first aspect of the present invention.
According to a third aspect of the present invention, there is provided a thermoplastic resin substrate for a curved mirror, characterized in that,
the length is 300-400mm, the width is 150-300mm, the thickness is 3-6mm,
the surface roughness is less than or equal to 10nm,
dimensional stability:
a) the peak surface area difference PV <25 μm (at 25 ℃);
b) after storage for 4 hours at 100 ℃, the peak surface area difference PV is <25 μm.
According to a fourth aspect of the present invention, there is provided a curved mirror including the thermoplastic resin substrate according to the third aspect of the present invention.
According to a fifth aspect of the invention there is provided a head-up display comprising a curved mirror according to the fourth aspect of the invention.
The thermoplastic resin substrate has large size, high dimensional stability, low surface roughness and high rigidity, can be applied to a future enhanced head-up display, and realizes large-area and long-distance projection and high-precision imaging, thereby meeting the requirements of future automobiles on driving safety and comfort.
Drawings
The invention will hereinafter be described by way of example with reference to the accompanying drawings, in which:
fig. 1 shows a schematic view of a mould which can be used for carrying out the process of the invention, wherein a: fixing a mold; b: moving the mold; c: pressing the frame; d: a flow channel; e: an oil cylinder; f: a cavity; g: a parting line.
Fig. 2 shows a schematic view of the injection-compression molding principle, wherein (i): the mould is in an open state; (ii) the method comprises the following steps Forming a cavity; (iii) the method comprises the following steps Injecting into a mold; (iv) the method comprises the following steps Compression molding; (v) the method comprises the following steps And opening the mold to take out the part.
Detailed description of the preferred embodiments
Various aspects of the invention and still further objects, features and advantages will be more fully apparent hereinafter.
Therefore, according to a first aspect of the present invention, there is provided a method for producing a thermoplastic resin substrate for a curved mirror, comprising the steps of:
A) the mold of the injection molding machine is heated to the temperature of 130-190 ℃ and closed,
B) a molten thermoplastic resin is injected into the mold cavity,
C) a pressure of 300-700bar is applied to the chamber for a period of more than 5 seconds,
D) stopping the application of pressure to the cavity and reducing the temperature of the mold to a temperature in the range of 60-100 ℃, and
E) opening the mold and taking out the molded thermoplastic resin substrate,
wherein a gap of 0.3-1mm remains at the parting plane of the mold cavity prior to applying pressure to the cavity.
The present inventors have conducted extensive studies and have aimed at providing a thermoplastic resin substrate for a curved mirror, which has the following characteristics,
the length is 300-400mm, the width is 150-300mm, the thickness is 3-6mm,
the surface roughness is less than or equal to 10nm,
dimensional stability:
a) the peak surface area difference PV <25 μm (at 25 ℃);
b) after storage for 4 hours at 100 ℃, the peak surface area difference PV is <25 μm.
According to the method, the problem of dimensional stability of the large-size curved mirror is solved by combining the thermoplastic resin, the compression injection molding process and the rapid cooling and rapid heating mold temperature control processing process, so that the stress distribution of the curved mirror in the molding process is more uniform, the dimensional stability is greatly improved, and the surface smoothness of the curved mirror is also greatly improved.
Preferably, the thermoplastic resin is a mineral-filled polycarbonate or a mineral-filled polycarbonate-polyethylene terephthalate blend.
Preferably, the mineral is selected from talc or quartz.
Preferably, the amount of the mineral is 10 to 30% by weight with respect to the total weight of the thermoplastic resin.
For mineral filled polycarbonate-polyethylene terephthalate (PET) blends, the weight ratio of polycarbonate to polyethylene terephthalate (PET) is preferably in the range of 90:10 to 60: 40.
Preferably, the thermoplastic resin has a low linear coefficient of thermal expansion, which is between 0.4 x 10-4-0.6*10-4In the range of/K.
Preferably, the thermoplastic resin has a low mold shrinkage of less than 0.6%.
Preferably, the thermoplastic resin has a relatively high temperature resistance, for example, a Heat Distortion Temperature (HDT) measured at 1.82MPa of greater than 105 ℃, preferably in the range of 110 ℃ and 130 ℃.
The injection compression molding process comprises the following steps:
injection compression molding is a combined molding technology of injection molding and compression molding, and is called secondary mold closing injection molding.
The injection compression molding can be performed by an existing injection molding machine.
The operation of injection-compression molding is mainly divided into two major steps, i.e., injection into a mold and compression molding.
Injecting into a mold: the mold is initially closed, preferably without completely closing the moving and stationary molds, but with a gap of some distance. Since the core portion of the mold has no step, the melt in the cavity does not leak even if the mold is not completely closed.
Compression molding: when the screw rod moves forward to reach the range of 50% -100% of the plasticizing amount, the second mold closing is carried out, the movable mold plate and the fixed mold plate are completely closed, and the molten material in the mold cavity obtains the accurate shape of the mold cavity under the compression action of the movable mold. And after the pressure on the die disappears after the plastic part is solidified, opening the die and ejecting the plastic part.
Injection compression molding is briefly described below with reference to fig. 1 and 2. It is to be understood that these drawings are merely illustrative and are not intended to be limiting of the process of the present invention.
Fig. 1 shows a schematic view of a mould which can be used for carrying out the process of the invention, wherein a: fixing a mold; b: moving the mold; c: pressing the frame; d: a flow channel; e: an oil cylinder; f: a cavity; g: a parting line.
FIG. 2 shows a schematic view of the principle of injection compression molding, wherein (i): the mould is in an open state; (ii) the method comprises the following steps Forming a cavity; (iii) the method comprises the following steps Injecting into a mold; (iv) compression molding; (v) the method comprises the following steps And opening the mold to take out the part.
Fig. 2(i) shows the mold in an open state.
Fig. 2(ii) shows that the movable mold b advances, stops at a certain distance from the fixed mold a, and then the pressing frame c advances and compacts toward the fixed mold a by the driving of the oil cylinder e. Thus, a cavity f with variable thickness is formed among the movable mold b, the fixed mold a and the press frame c.
Fig. 2(iii) shows that the resin melt is injected into the cavity f through the runner d.
Fig. 2(iv) shows that after or during the injection of the resin melt into the cavity f, the movable mold b is completely closed to complete the compression of the melt.
Fig. 2(v) shows that after a certain time of cooling, the movable mold b is opened and then the part is taken.
The time for raising the temperature of the mold of the injection molding machine to a temperature in the range of 130-190 ℃ is not particularly limited, and may be generally determined depending on the heating manner of the mold, and may be, for example, in the range of 10 to 200 seconds.
Preferably, a 0.6mm gap remains at the parting plane of the mold cavity before pressure is applied to the cavity.
Preferably, the gap at the parting plane of the mould cavity when pressure to the cavity is stopped is no more than 0.1mm, preferably 0 mm.
Preferably, in step B, the holding pressure of the screw at the time of injecting the molten thermoplastic resin into the cavity of the mold is in the range of 50 to 150bar, preferably 60 to 140bar, whereby the cavity pressure distribution is more uniform and the deformation of the product is less.
Preferably, in step B, the temperature of the molten thermoplastic resin is in the range of 270-310 ℃.
Preferably, in step C, the pressure is in the range of 300-600 bar.
Preferably, the dwell time is in the range of 5 to 50s, more preferably 10 to 40 s.
In step D, the time for lowering the mold of the injection molding machine to a temperature in the range of 60 to 100 ℃ is not particularly limited, and may be generally determined according to the cooling manner of the mold, and for example, may be in the range of 10 to 150 seconds.
In some embodiments, the thermoplastic resin used is a mineral filled polycarbonate/polyethylene terephthalate blend, and in step A, the mold is warmed to a temperature in the range of 130-160 ℃ and in step D, the mold is lowered to a temperature in the range of 80-90 ℃.
In some embodiments, the thermoplastic resin used is a mineral filled polycarbonate, and in step A, the mold is warmed to a temperature in the range of 140-190 ℃ and in step D, the temperature of the mold is lowered to a temperature in the range of 90-100 ℃.
Preferably, the core of the mold has good machinability and corrosion resistance, while having good polishing properties. For example, the core is made of die steel with the reference number of 1.2343 or 1.2343+ by the processes of high-speed milling, surface hardening and surface finish polishing.
Preferably, the surface hardness of the core of the mold reaches 50HRC or more.
Preferably, the surface finish level of the core of the mold is up to 10nm level or more.
According to a second aspect of the present invention, there is provided a thermoplastic resin substrate produced according to the method of the first aspect of the present invention.
In some embodiments, the thermoplastic resin substrate has the following features:
the length is 200-500mm, the width is 100-350mm, the thickness is 3-6mm,
the surface roughness is less than or equal to 10nm,
dimensional stability:
a) the peak surface area difference PV <25 μm (at 25 ℃);
b) after storage for 4 hours at 100 ℃, the peak surface area difference PV is <25 μm.
According to a third aspect of the present invention, there is provided a thermoplastic resin substrate for a curved mirror, characterized in that,
the length is 300-400mm, the width is 150-300mm, the thickness is 3-6mm,
the surface roughness is less than or equal to 10nm,
dimensional stability requirements:
a) the peak surface area difference PV <25 μm (at 25 ℃);
b) after storage for 4 hours at 100 ℃, the peak surface area difference PV is <25 μm.
According to a fourth aspect of the present invention, there is provided a curved mirror including the thermoplastic resin substrate according to the third aspect of the present invention.
In addition to the thermoplastic resin substrate according to the third aspect of the present invention, the curved mirror further comprises at least one reflective film disposed on the substrate, the reflective film being selected from the group consisting of an aluminum film, a copper film and an inorganic non-metallic film.
The inorganic non-metallic film can be an inorganic non-metallic film commonly used in the field of curved mirror preparation.
The reflective film may be applied by means commonly used in the art, such as evaporation, sputtering.
The thickness of the reflective film may be in the range of 30-300 nm.
In some embodiments, the resulting curved mirror has a reflectance of 85% or more for visible light in the range of 420-680 nm.
According to a fifth aspect of the invention there is provided a head-up display comprising a curved mirror according to the fourth aspect of the invention.
The terms "comprising" and "including" as used herein encompass the case where other elements not explicitly mentioned are also included or included and the case where they consist of the mentioned elements.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In the event that a definition of a term in this specification conflicts with a meaning commonly understood by those skilled in the art to which the invention pertains, the definition set forth herein shall govern.
Unless otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth herein are approximations that can vary depending upon the desired properties to be obtained.
Examples
The concept and technical effects of the present invention will be further described with reference to the following examples so that those skilled in the art can fully understand the objects, features and effects of the present invention. It should be understood that the examples are illustrative only and are not intended to limit the scope of the present invention.
Description of the main raw materials used:
PC-1: common polycarbonates from scientific polymers (china) ltd;
PC-2: filled grade polycarbonate/PET blends, UT235M from kostew polymers (china) ltd;
PC-3: filled grade polycarbonate, DS801 from kosa polymer (china) ltd.
The following are the performance data for the raw materials used:
CLTE: the linear thermal expansion coefficient is determined by ISO 11359-1, -2.
MVR ×: melt flow rate, determined using ISO 1133.
Tensile modulus, tensile strength: the test was carried out using ISO 527-1, -2.
Mold shrinkage ratio: test with acc.iso 2577.
Description of the experimental equipment used:
an injection molding machine: engel 650 injection molder.
A mold temperature controller: single ATT H2-200-48 mould temperature machine.
Injection molding: from kostew polymers (china) ltd, designed as 318mm 140.7mm 4mm concave mirrors.
The mold structure is as follows:
1. the mold is a 2-plate mold, the mirror surface mold core and the hot runner mechanism are arranged on the fixed side, and the compression mechanism and the ejection mechanism are arranged on the moving side.
2. The compression mechanism adopts a compression frame structure, the oil cylinder is used for controlling the compression frame to move forwards and backwards, and the maximum moving distance is 5 mm. The oil cylinder can provide 40 tons of clamping force to seal the cavity. Such a compression mechanism performs injection-molding operations in cooperation with an injection-molding program on an injection-molding machine.
3. The mold core is made of 1.2343 mold steel, and has good machining performance, corrosion resistance and polishing performance. The polishing level of the surface of the core can reach more than 10nm level.
4. And carrying out hardening treatment on the polished surface of the mold core to ensure that the surface hardness of the steel reaches 50 HRC. So that the steel resists abrasion of the polished surface by the plastic melt during the forming process.
5. The core of the movable mould and the fixed mould is provided with a processing rapid cooling and heating water path which meets the high temperature and high pressure condition of 200 ℃/22 bar.
The optical detection method comprises the following steps:
(1) measuring the PV value of the curved mirror by adopting a structured light scanner;
(2) measuring the roughness of the surface of the curved mirror by adopting a white light interferometer;
(3) the reflectance for visible light in the range of 420-680nm was measured using a Lamda750 spectrophotometer.
COMPARATIVE EXAMPLE 1(CE1)
The PC-1 resin was placed in a dehumidifying dryer and dried at 120 ℃ for 4 hours to reduce the moisture content of the PC-1 resin to 0.01 wt% or less.
A mold designed for a thermoplastic resin substrate having a thickness of 7mm was selected.
Firstly, the temperature of a mould of an injection molding machine is raised to 100-110 ℃, the mould is closed for the first time, and a gap of 0.6mm is reserved on the parting surface of a cavity. Then, the PC-1 resin melted at 280-300 ℃ was injected into the mold cavity with a holding pressure of 65 bar. A pressure of 600bar was applied to the cavity for a period of 30 seconds, at which the gap at the parting plane of the mould cavity was 0 mm. Then, the application of pressure to the cavity was stopped and the cavity temperature was lowered to 80-90 ℃ over a period of 20 seconds, the mold was opened and the molded thermoplastic resin substrate was taken out.
The substrate preparation process parameters are summarized in table 1.
The taken-out substrate was baked at 100 ℃ for 4 hours and then wiped with an ion wind gun for 5 seconds.
The substrates before and after baking were optically tested and the results are summarized in table 2.
Followed by a temperature of between 40 and 105 ℃ and 2 x 10E-3-3*10E-3And starting evaporation under vacuum degree, wherein the film layer is a metal aluminum film, and the thickness of the film layer is 150 nm. And obtaining the curved mirror after the evaporation.
COMPARATIVE EXAMPLE 2(CE2)
Comparative example 2 was conducted with reference to comparative example 1, except that a mold designed for a thermoplastic resin substrate having a thickness of 4mm was selected and the holding pressure of the screw was 130 bar.
The parameters of the substrate preparation process are summarized in table 1.
The optical test results of the resulting substrate and curved mirror are summarized in table 2.
COMPARATIVE EXAMPLE 3(CE3)
Comparative example 3 was conducted with reference to comparative example 1, except that a mold designed for a thermoplastic resin substrate having a thickness of 4mm was selected.
The parameters of the substrate preparation process are summarized in table 1.
The optical test results of the resulting substrate and curved mirror are summarized in table 2.
Example 1(E1)
The PC-2 resin is first placed in a dehumidifying dryer and dried at 120 ℃ for 4 hours to reduce the moisture content of the PC-2 resin to less than 0.01 wt%.
A mold designed for a thermoplastic resin substrate having a thickness of 4mm was selected.
Firstly, the temperature of a mould of an injection molding machine is raised to 140-160 ℃, the mould is closed for the first time, and a gap of 0.6mm is reserved on the parting surface of a cavity. Then, the PC-2 resin melted at 270-290 ℃ is injected into the cavity of the mold, and the holding pressure of the screw is 130 bar. A pressure of 600bar was applied to the cavity for a period of 30 seconds, at which the gap at the parting plane of the mould cavity was 0 mm. Then, the application of pressure to the cavity was stopped and the cavity temperature was lowered to 80-90 ℃ over a period of 40 seconds, the mold was opened and the molded thermoplastic resin substrate was taken out.
The taken-out substrate was baked at 100 ℃ for 4 hours and then wiped with an ion wind gun for 5 seconds.
The substrates before and after baking were optically tested and the results are summarized in table 2.
Followed by a temperature of between 40 and 105 ℃ and 2 x 10E-3-3*10E-3And starting evaporation under vacuum degree, wherein the film layer is a metal aluminum film, and the thickness of the film layer is 150 nm. And obtaining the curved mirror after the evaporation.
The resulting substrates were optically tested and the results are summarized in table 2.
Example 2(E2)
Example 2 was carried out with reference to example 1, except that the screw had a holding pressure of 65 bar.
The parameters of the substrate preparation process are summarized in table 1.
The optical test results of the resulting substrate and curved mirror are summarized in table 2.
COMPARATIVE EXAMPLE 4(CE4)
The PC-2 resin was placed in a dehumidifying dryer and dried at 120 ℃ for 4 hours to reduce the moisture content of the PC-2 resin to 0.01 wt% or less.
A mold designed for a thermoplastic resin substrate having a thickness of 4mm was selected.
Firstly, the temperature of the mold of the injection molding machine is raised to 140-160 ℃, and the mold is completely closed. Then, the PC-2 resin melted at 270-290 ℃ was injected into the mold cavity with a holding pressure of 65 bar. The resin cavity was held for a period of 30 seconds. The cavity temperature was then brought to 80-90 ℃ over a period of 40 seconds, the mold was opened and the molded thermoplastic resin substrate was removed.
The substrate preparation process parameters are summarized in table 1.
The taken-out substrate was baked at 100 ℃ for 4 hours and then wiped with an ion wind gun for 5 seconds.
The substrates before and after baking were optically tested and the results are summarized in table 2.
Followed by a temperature of between 40 and 105 ℃ and 2 x 10E-3-3*10E-3And starting evaporation under vacuum degree, wherein the film layer is a metal aluminum film, and the thickness of the film layer is 150 nm. And obtaining the curved mirror after the evaporation.
COMPARATIVE EXAMPLE 5(CE5)
Comparative example 5 was conducted with reference to example 1, except that a mold designed for a thermoplastic resin substrate having a thickness of 7mm was selected and the holding pressure of the screw was 65 bar.
The parameters of the substrate preparation process are summarized in table 1.
The optical test results of the resulting substrate and curved mirror are summarized in table 2.
Example 3(E3)
Before the PC-3 resin is melted and injected into a mold, the PC-3 resin is put into a dehumidifying dryer and dried at 120 ℃ for 4 hours, so that the moisture content of the PC-3 resin is reduced to 0.01 wt% or less.
A mold designed for a thermoplastic resin substrate having a thickness of 4mm was selected.
Firstly, the temperature of a mould of an injection molding machine is raised to 160-180 ℃, the mould is closed for the first time, and a gap of 0.6mm is reserved on the parting surface of a cavity. Then, the PC-3 resin melted at 280-300 ℃ is injected into the cavity of the mold, and the holding pressure of the screw is 130 bar. A pressure of 600bar was applied to the cavity for a period of 30 seconds, at which the gap at the parting plane of the mould cavity was 0 mm. Then, the application of pressure to the cavity was stopped and the cavity temperature was lowered to 90-100 ℃ over a period of 60 seconds, and the mold was opened and the molded thermoplastic resin substrate was taken out.
The substrate preparation process parameters are summarized in table 1.
The taken-out substrate was baked at 100 ℃ for 4 hours and then wiped with an ion wind gun for 5 seconds.
The substrates before and after baking were optically tested and the results are summarized in table 2.
Followed by a temperature of between 40 and 105 ℃ and 2 x 10E-3-3*10E-3And starting evaporation under vacuum degree, wherein the film layer is a metal aluminum film, and the thickness of the film layer is 150 nm. And obtaining the curved mirror after the evaporation.
The resulting substrates were optically tested and the results are summarized in table 2.
Example 4(E4)
Example 4 was carried out with reference to example 3, except that the screw had a holding pressure of 65 bar.
The parameters of the substrate preparation process are summarized in table 1.
The optical test results of the resulting substrate and curved mirror are summarized in table 2.
COMPARATIVE EXAMPLE 6(CE6)
Before the PC-3 resin is melted and injected into a mold, the PC-3 resin is put into a dehumidifying dryer and dried at 120 ℃ for 4 hours, so that the moisture content of the PC-3 resin is reduced to 0.01 wt% or less.
A mold designed for a thermoplastic resin substrate having a thickness of 4mm was selected.
Firstly, the temperature of the mold of the injection molding machine is raised to 160-180 ℃, and the mold is completely closed. Then, the PC-3 resin melted at 280-300 ℃ was injected into the mold cavity with a holding pressure of 65 bar. The resin was held in the cavity for a period of 30 seconds. The cavity temperature was then reduced to 90-100 ℃ over a period of 60 seconds, the mold was opened and the molded thermoplastic resin substrate was removed.
The substrate preparation process parameters are summarized in table 1.
The taken-out substrate was baked at 100 ℃ for 4 hours and then wiped with an ion wind gun for 5 seconds.
The substrates before and after baking were optically tested and the results are summarized in table 2.
Followed by a temperature of between 40 and 105 ℃ and 2 x 10E-3-3*10E-3And starting evaporation under vacuum degree, wherein the film layer is a metal aluminum film, and the thickness of the film layer is 150 nm. And obtaining the curved mirror after the evaporation.
As can be seen by comparing example 1(E1) with example 2(E2), the profile of the curved mirror machined with the mineral filled grade PC/PET blend is not susceptible to molding process parameters. For example, in the case of a large change in holding pressure, the change in the surface shape of the curved mirror is very small. This indicates that the forming process window for filled grade PC blend materials is large, and very good dimensional stability can be guaranteed during mass production.
As can be seen from the comparison between example 3(E3) and example 4(E4), the profile of the curved mirror machined with filled-grade PC is not easily affected by the molding process parameters. For example, in the case of a large change in holding pressure, the change in the surface shape of the curved mirror is very small. This indicates that the forming process window for a fill-grade PC is large, ensuring very good dimensional stability during mass production.
Although a few aspects of the present invention have been shown and discussed, it would be appreciated by those skilled in the art that changes may be made in this aspect without departing from the principles and spirit of the invention, the scope of which is therefore defined in the claims and their equivalents.
Claims (21)
1. The preparation method of the thermoplastic resin substrate for the curved mirror comprises the following steps:
A) the mold of the injection molding machine is heated to the temperature of 130-190 ℃ and closed,
B) a molten thermoplastic resin is injected into the mold cavity,
C) a pressure of 300-700bar is applied to the chamber for a period of more than 5 seconds,
D) stopping the application of pressure to the cavity and reducing the temperature of the mold to a temperature in the range of 60-100 ℃, and
E) opening the mold and taking out the molded thermoplastic resin substrate,
wherein a gap of 0.3-1mm remains at the parting plane of the mold cavity prior to applying pressure to the cavity.
2. The method of claim 1, wherein the thermoplastic resin is a mineral-filled polycarbonate material or a mineral-filled polycarbonate-polyethylene terephthalate blend.
3. The process according to claim 2, characterized in that the mineral is chosen from talc or quartz, preferably in an amount of 10-30% by weight with respect to the total weight of the thermoplastic resin.
4. A method according to claim 2 or 3, wherein the thermoplastic resin is a mineral filled polycarbonate-polyethylene terephthalate blend, preferably with a weight ratio of polycarbonate to polyethylene terephthalate (PET) in the range of 90:10 to 60: 40.
5. The method according to any one of claims 1 to 4, wherein the thermoplastic resin has a molecular weight in the range of 0.4 x 10-4-0.6*10-4Linear thermal expansion coefficient in the/K range.
6. The method of any of claims 1-5, wherein the thermoplastic resin has a mold shrinkage of less than 0.6%.
7. Process according to any one of claims 1 to 6, characterized in that the thermoplastic resin has an HDT, measured at 1.82MPa, of greater than 105 ℃, preferably in the range of 110 ℃ and 130 ℃.
8. A method according to any of claims 1-7, wherein the clearance at the parting plane of the mould cavity when the pressure application to the cavity is stopped is not more than 0.1mm, preferably 0 mm.
9. The process according to any one of claims 1 to 8, wherein in step B, the holding pressure of the screw at the time of injecting the molten thermoplastic resin into the mold cavity is in the range of 50 to 150 bar.
10. The process according to any one of claims 1 to 9, wherein in step C the pressure is in the range of 300 and 600 bar.
11. The process as claimed in any of claims 1 to 10, wherein the thermoplastic resin used is a mineral-filled polycarbonate/polyethylene terephthalate blend, and in step A the temperature of the mould is raised to a temperature in the range of 130 ℃ and 160 ℃ and in step D the temperature of the mould is lowered to a temperature in the range of 80 ℃ to 90 ℃.
12. The method as claimed in any one of claims 1 to 10, characterized in that the thermoplastic resin used is a mineral-filled polycarbonate, and in step a the temperature of the mould is raised to a temperature in the range of 140-190 ℃ and in step D the temperature of the mould is lowered to a temperature in the range of 90-100 ℃.
13. The method of any one of claims 1-12, wherein the core of the mold is machined from 1.2343 or 1.2343+ type mold steel.
14. The method of any of claims 1-13, wherein the core surface hardness of the mold is up to 50HRC or greater.
15. The method of any of claims 1-14, wherein the surface finish of the core of the mold is on the order of up to 10nm or more.
16. A thermoplastic resin substrate prepared by the method of any one of claims 1-15.
17. The thermoplastic resin substrate according to claim 16,
the length is 200-500mm, the width is 100-350mm, the thickness is 3-6mm,
the surface roughness is less than or equal to 10nm,
dimensional stability:
a) surface area difference peak PV <25 μm (at 25 ℃);
b) after 4 hours of storage at 100 ℃, the peak surface area difference PV was <25 μm.
18. A thermoplastic resin substrate for a curved mirror, characterized in that,
the length is 300-400mm, the width is 150-300mm, the thickness is 3-6mm,
the surface roughness is less than or equal to 10nm,
dimensional stability:
a) surface area difference peak PV <25 μm (at 25 ℃);
b) after 4 hours of storage at 100 ℃, the peak surface area difference PV was <25 μm.
19. A curved mirror comprising the thermoplastic resin substrate according to claim 18.
20. The curved mirror of claim 19, further comprising at least one reflective film disposed over said substrate, said reflective film selected from the group consisting of aluminum films, copper films, and inorganic non-metallic films.
21. A heads up display comprising the curved mirror of claim 19 or 20.
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010384262.8A CN113619054A (en) | 2020-05-08 | 2020-05-08 | Thermoplastic resin substrate for curved mirror and preparation method thereof |
| PCT/EP2021/058838 WO2021223947A1 (en) | 2020-05-08 | 2021-04-06 | Thermoplastic resin substrate for curved mirror and method for preparing the same |
| US17/914,404 US20230104677A1 (en) | 2020-05-08 | 2021-04-06 | Thermoplastic resin substrate for curved mirror and method for preparing the same |
| EP21717032.3A EP4146451A1 (en) | 2020-05-08 | 2021-04-06 | Thermoplastic resin substrate for curved mirror and method for preparing the same |
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| CN202010384262.8A CN113619054A (en) | 2020-05-08 | 2020-05-08 | Thermoplastic resin substrate for curved mirror and preparation method thereof |
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| CN113619054A true CN113619054A (en) | 2021-11-09 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024060050A1 (en) * | 2022-09-21 | 2024-03-28 | Ticona Llc | Projector for use in a head-mounted display system |
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