TWI660834B - 射出成形裝置及其射出成形方法 - Google Patents
射出成形裝置及其射出成形方法 Download PDFInfo
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- TWI660834B TWI660834B TW107121457A TW107121457A TWI660834B TW I660834 B TWI660834 B TW I660834B TW 107121457 A TW107121457 A TW 107121457A TW 107121457 A TW107121457 A TW 107121457A TW I660834 B TWI660834 B TW I660834B
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- cavity
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- injection
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- 239000007924 injection Substances 0.000 title claims abstract description 70
- 238000001746 injection moulding Methods 0.000 title claims abstract description 39
- 238000000034 method Methods 0.000 title claims description 10
- 239000011148 porous material Substances 0.000 claims abstract description 32
- 239000000463 material Substances 0.000 claims abstract description 13
- 239000007789 gas Substances 0.000 claims description 68
- 239000002994 raw material Substances 0.000 claims description 28
- 239000000498 cooling water Substances 0.000 claims description 12
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 4
- 239000012530 fluid Substances 0.000 claims description 4
- 238000005187 foaming Methods 0.000 claims description 4
- 238000010146 3D printing Methods 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 3
- 239000001569 carbon dioxide Substances 0.000 claims description 3
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- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 claims description 2
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- 229920003023 plastic Polymers 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Landscapes
- Engineering & Computer Science (AREA)
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- Manufacturing & Machinery (AREA)
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Abstract
本發明提供一種射出成形裝置，主要包括：一上模座設有一注料口；一上模仁設於該上模座內，其設有至少一射出口、一墊圈槽及一墊圈，該射出口係連通該注料口；一下模座其可操作性地對合或分離於該上模座，該下模座設有至少一氣體通道，該通道可供氣體進出；以及一下模仁設於該下模座內，其隨該下模座對合或分離於該上模仁，該下模仁設有一模穴及設有至少一異形風路連通該模穴及該氣體通道，該下模仁為多孔性材質，其使該下模仁充滿複數孔隙；該模穴內部會藉由該氣體通道經該異形風路預先注入氣體，以使該模穴內部保持一預設壓力或是讓該氣體溢散於該複數孔隙噴出，使一成品脫離該模穴。另外，本發明亦提供一種射出成形方法。
Description
本發明係關於一種射出成形裝置及其射出成形方法。
射出成形機又稱為注塑機或射出機，主要是用來製造塑料產品的裝置或機器，可由兩個主要部分組成，分別為鎖模單元及射出單元。
然而，一般習知熱塑性聚氨酯彈性體橡膠(Thermoplastic polyurethanes,TPU)原料必需進行烘料程序，以去除所含的水分，主要是為了避免原料在模具內成形時，水氣會導致有氣泡產生到成品表面，另物理發泡射出亦有相同的情形，進而造成產品表面粗糙，導致發泡成形後之初胚須再進行表面加工，才能克服前述問題，從而使得製程增加。
且上述的射出成形方式，係讓將原料注入模具內加熱發泡成形，其因不易控制模內的氣體壓力保持一致，導致發泡過程中氣體與原料無法完全融合或氣體與原料分離，進而使成品會有局部硬塊的問題產生。再者，當原料持續注入模具內部，而模具卻未有效排氣的狀況下，則會形成產生充填不完全，即俗稱的包風現象，此包風現象會造成成品的不良率。
另外，為方便自模具內取出成品，習知方式是在模具內噴塗離型劑以防止成型材料附著於模具內壁，並設置一取出設備，將成品由模
具內取出。然而離型劑可能殘留於模具內壁，而影響後續的製程，且噴塗及後續清除作業，皆使得製程增加。因此，如何提供一種較佳的射出成形裝置跟射出成形方法，實為當前重要課題之一。
鑒於上述習知技術的缺點，本發明之一目的在於提供一種射出成形裝置，其係可令成形之成品表面平整光滑，且改善包風問題，並可縮短製程。
本發明之另一目的在於提供一種射出成形裝置方法，其係原料不需經由烘乾作業，而可節省前置作業的時間。
為達到上述的目的，依據本發明所提供之一種射出成形裝置，其係配合一射出機使用，尤指超臨界流體微發泡射出機與化學發泡射出機，該射出成形裝置主要包括：一上模座，設有一上模座凹槽及一注料口，該注料口係與該射出機連結；一上模仁，設於該上模座凹槽內，該上模仁設有至少一射出口、一墊圈槽及一墊圈，該射出口係連通該注料口；一下模座，可操作性地對合或分離於該上模座，該下模座設有一下模座凹槽及至少一氣體通道，該氣體通道可供氣體進出；以及一下模仁，設於該下模座凹槽內，其隨該下模座對合或分離於該上模仁，該下模仁設有一模穴，並且設置有至少一異形風路連通該模穴及該氣體通道，該下模仁為多孔性材質，該多孔性材質使該下模仁充滿複數孔隙。當該下模座對合於該上模座狀態下，該模穴內部會藉由該氣體通道經該異形風路預先注入氣體，以使該模穴內部保持一預設壓力；當該射出機內之原料進入該模穴成形過程狀態下，該氣
體係逐漸抽離該模穴，使原料完整填滿該模穴；當該模穴內已成形一成品，且該下模座分離於該上模座狀態下，該氣體由該氣體通道經該異形風路溢散於該複數孔隙噴出，使該成品脫離該模穴。
較佳地，本發明的射出成形裝置復可包括一控制裝置，控制氣體進出量及時間，並調節該模穴內的壓力，且該射出機係受該控制裝置控制原料進入該模穴內之流量。
較佳地，該上模座及該下模座復可包括至少一冷卻水路。
較佳地，該下模仁之該至少一異形風路係由三維列印形成或以透氣鋼材加工形成。
較佳地，該異形風路包括至少一主風道及複數副風道，該主風道環設於該模穴周圍，且連通該氣體通道，各該副風道呈間隔排列於該主風道與該模穴之間，且各該副風道一端連通該主風道，另一端連通該模穴。
較佳地，該墊圈槽設置於該射出口的周圍，該墊圈設於該墊圈槽內，且其一側貼合該墊圈槽底部，並在該下模座對合於該上模座狀態下，該墊圈另一側貼合於該下模仁。
較佳地，該控制裝置與該氣體通道之間設有一防止該氣體逆流之閥門。
較佳地，更包括一感測該模穴內部壓力之測壓單元，該測壓單元係電性連接於該控制裝置。
此外，本發明亦提供一種射出成形方法，其包括以下步驟：將一成形模具裝設於一射出機，該成形模具包括：
一上模座、一下模座、一上模仁及一下模仁，該上模座設有一注料口，該上模仁設於該上模座內，且設有一射出口、一墊圈槽、一墊圈，該下模座至少設有一氣體通道，該下模仁設於該下模座內，且設有一模穴以及至少一異形風路，該下模仁為多孔性材質，該多孔性材質使該下模仁充滿複數孔隙；預先對該模穴的內部注入氣體，以形成一反壓模具狀態；將原料倒入射出成形機料桶內，進入螺桿以使原料與超臨界流體的氮氣或二氧化碳混合後，由該注料口注入至該模穴內成形；隨注入原料的同時，同步控制模穴內氣體的進出量，讓其保持並控制一定之壓力，並於射出結束時可控制並釋放全部模腔內壓力，進而幫助發泡成形，使其不產生包風現象；控制該氣體由該氣體通道經該異形風路溢散於該複數孔隙噴出，使一成品容易可自動脫模。
10‧‧‧上模座
101‧‧‧上模座凹槽
102‧‧‧注料口
103‧‧‧冷卻水路
104‧‧‧第一對合面
20‧‧‧上模仁
201‧‧‧射出口
202‧‧‧墊圈槽
203‧‧‧墊圈
204‧‧‧冷卻迴路
30‧‧‧下模仁
301‧‧‧模穴
302‧‧‧異形風路
3021‧‧‧主風道
3022‧‧‧副風道
303‧‧‧冷卻迴路
40‧‧‧下模座
401‧‧‧下模座凹槽
402‧‧‧氣體通道
403‧‧‧冷卻水路
404‧‧‧第二對合面
50‧‧‧控制裝置
51‧‧‧氣體裝置
52‧‧‧射出機
53‧‧‧測壓單元
54‧‧‧液體裝置
55‧‧‧模具
56‧‧‧閥門
圖1為依據本發明之較佳實施例，顯示一種射出成形裝置的立體分解示意圖；圖2為依據本發明之較佳實施例，顯示該射出成形裝置的組合示意圖；圖3為依據本發明之較佳實施例，顯示圖2所示之該射出成形裝置的局部放大示意圖；圖4為依據本發明之較佳實施例，顯示該射出成形裝置之下模仁的立體示意圖；
圖5為依據本發明之較佳實施例，顯示圖2的A-A剖面圖；圖6為依據本發明之較佳實施例，顯示圖2的B-B剖面圖；以及圖7為依據本發明之較佳實施例，顯示該射出成形裝置的方塊示意圖；以及圖8為依據本發明之較佳實施例，顯示一種射出成形方法的步驟流程圖。
以下係藉由特定的具體實施例說明本發明之實施方式，熟悉此技藝之人士可由本說明書所揭示之內容輕易地瞭解本發明之其他優點及功效。本發明亦可藉由其他不同的具體實例加以施行或應用，本發明說明書中的各項細節亦可基於不同觀點與應用在不悖離本發明之精神下進行各種修飾與變更。
請參閱圖1至圖6所示，係本發明一較佳實施例之射出成形裝置，其係配合一射出機52使用，尤指MUCELL微發泡射出機或化學發泡射出機，該射出成形裝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。
該上模座10一側形成一第一對合面104，於該第一對合面104設有一上模座凹槽101，且於該上模座10另一側設一注料口102，其中該上模座10之該注料口102係與該射出機52一端連結。該上模仁20設於該上模座凹槽101中，且設有二射出口201、一墊圈槽202及一墊圈203，其中各該射出口201係連通該注料口102，在本實施例中，該上模仁20係設有二個射出口201，但非用以限制其數量。再者，本發明不限制該上模仁20之材質，其可視產
品結構需求，而令該上模仁20為多孔性材質，多孔性材質使該上模仁20充滿複數孔隙。另外，該上模座10至少設有一冷卻水路103，而該上模仁20至少設有一冷卻迴路204連通該上模座10之冷卻水路103，配合圖7所示，該冷卻水路103係連結一液體裝置54，而令其內部之冷卻液體(未圖示)於該冷卻水路103及該冷卻迴路204內部循環，藉以保持該上模座10及該上模仁20於一預設之溫度值內。再者，該上模仁20具有一墊圈槽202設置於該射出口201的周圍，更具有一墊圈203設於該墊圈槽202內，且該墊圈203一側貼合該墊圈槽202底部。
該下模座40一側設有一第二對合面404，其可操作性地對合或分離於該上模座10之第一對合面104，於該第二對合面404設有一下模座凹槽401，且至少一氣體通道402，該氣體通道402可供一氣體裝置51之氣體(未圖示)進出。該下模仁30為多孔性材質，多孔性材質使該下模仁30充滿複數孔隙，且該下模仁30隨該下模座40對合或分離於該上模仁20，該下模仁30設於該下模座凹槽401中，且該下模仁30設有一模穴301，並設置有至少一異形風路302，本發明不限制該下模仁30之該異形風路302之形成方式，較佳係以三維列印形成或以透氣鋼材加工形成。在本實施例中，該異形風路302包括至少一主風道3021及複數副風道3022，該主風道3021環設於該模穴301周圍，且連通該氣體通道402，各該副風道3022呈間隔排列於該主風道3021與該模穴301之間，且各該副風道3022一端連通該主風道3021，另一端連通該模穴301，上述僅為實施例之一，並非用以限制該異形風路302之結構。
另外，該下模座40至少設有一冷卻水路403，而該下模仁30至少設有一冷卻迴路303連通該下模座40之冷卻水路403，配合圖7所示，該
冷卻水路403係連結該液體裝置54，而令其內部之冷卻液體(未圖示)於該冷卻水路403及該冷卻迴路303內部循環，藉以保持該下模座40及該下模仁30於一預設之溫度值內。
續請配合圖7所示，本發明更包括一控制裝置50，其主要係控制該氣體裝置51之氣體進出量及時間、程序，並調節該模穴301內的壓力，且該射出機52亦受該控制裝置50控制其原料進入該模穴301內之流量與流速，而該控制裝置50與該氣體通道402之間更設有一閥門56，該閥門56主要是防止該氣體逆流，而使該模穴301內壓力產生變化；又，更包括一測壓單元53電性連接於該控制裝置50，其主要係在感測該模穴301內部壓力之變化，藉以令該控制裝置50可依據該測壓單元53之數據變化而隨時調節該模穴301內之壓力，使其保持在預設值內。
呈上所述，當該下模座40對合於該上模座10狀態下，該控制裝置50會控制該氣體裝置51藉由該氣體通道402經該異形風路302預先注入氣體，以使該模穴301內部保持一預設壓力，且形成反壓狀態；值得一提的是，如圖1所示，該墊圈槽202設置於該射出口201的周圍，亦即，該墊圈203可框設於墊圈槽202內並貼合該上模仁20與該下模仁30，使該上、下模座10、40合模時保持密閉空間，以利控制模穴301內壓力之大小，因此，可有效地防止氣體外洩。
當該射出機52內部之氣液體混合物原料，由該注料口102注入至該模穴301內成形過程狀態下，該模穴301內部壓力會因原料的注入而產生變化，此時該控制裝置50則會透過該測壓單元53所檢測的壓力數據進行調節氣體的流量。當原料逐漸填滿該模穴301，此時該氣體則隨原料的注入而
逐漸抽離該模穴301，令原料隨抽離氣體產生的引力，而完整地填滿該模穴301，使得成品不會產生填充不滿，俗稱包風的狀態。
再者，當該模穴301內已成形一成品(未圖示)，且該下模座40分離於該上模座10狀態下，該控制裝置50會控制該氣體由該氣體通道402經該異形風路302溢散於該複數孔隙噴出，進而使該成品脫離該模穴301，相較於先前技術，本發明不須於模穴內噴塗離型劑及另外設置取出設備，即可令成品自動脫模，實則縮短了成形製程。
圖7顯示本發明之射出成形裝置的方塊示意圖。配合圖7所示，該控制裝置50係控制該氣體裝置51、該射出機52、該測壓單元53、該液體裝置54、模具55以及一閥門56，其中該模具55係指該上模座10、上模仁20、下模座40、下模仁30組合後狀態，該控制裝置50可控制氣體進出量、程序及時間，並調節模穴301內的壓力，當模穴301內超過預設的壓力時，可經由至少一異形風路302的路徑將氣體抽離出去，而當模穴301內壓力低於預設值時，亦可透過控制裝置50來增加模穴301內的壓力，進而可讓該模穴301內保持有一定的壓力。
反之，反壓狀態主要是針對表面光滑之成品，氣體對由注入之混合物原料產生阻力，使混合物原料表面與氣體形成相互抵觸、受擠壓而成光滑面，成形之後再由該控制裝置50控制將壓力自然溢散或抽出。
依據本發明之較佳實施例，若用於製作鞋墊，因為製作鞋墊所需原料比較偏軟料，所以模穴內壓力大概保持在7bar至9bar之間即可，若用在製作雪鏡框，較需要用到硬料，所以模穴內壓力大概會保持在60bar至70bar之間為最佳狀態(會依據產品屬性不同來設定壓力值)。因此，當製造的
產品不同時，模穴內的壓力範圍一般設定在2bar至100bar之間，但非限制本發明。
此外，如圖8所示，本發明亦提供一種射出成形方法，包括以下步驟S81~S85：
步驟S81：將一成形模具裝設於一射出機，該成形模具包括：一上模座、一下模座、一上模仁及一下模仁，該上模座設有一注料口，該上模仁設於該上模座內，且設有一射出口、一墊圈槽、一墊圈，該下模座至少設有一氣體通道，該下模仁設於該下模座內，且設有一模穴以及至少一異形風路，配合圖3至圖5所示，該異形風路302包括至少一主風道3021及複數副風道3022，該主風道3021環設於該模穴301周圍，且連通該氣體通道402，各該副風道3022呈間隔排列於該主風道3021與該模穴301之間，且各該副風道3022一端連通該主風道3021，另一端連通該模穴301，該下模仁為多孔性材質，該多孔性材質使該下模仁充滿複數孔隙。
步驟S82：預先對該模穴的內部注入氣體，以形成一反壓狀態。
步驟S83：將原料倒入射出成形機料桶內，進入螺桿以使原料與超臨界流體的氮氣或二氧化碳混合後，藉由該注料口注入至該模穴內成形。
步驟S84：隨注入原料的同時，同步控制模穴內氣體的進出量，讓其保持並控制一定之壓力，並於射出結束時可控制並釋放全部模腔內壓力，進而幫助發泡成形，使其不產生包風現象。
步驟S85：控制氣體由該氣體通道經該異形風路溢散於該複數孔隙噴出，使一成品自動脫模。
其中，步驟S81所述之射出機，係尤指MUCELL微發泡射出機或化學發泡射出機，但非用以限制射出機之種類。而以MUCELL微發泡射出機或化學發泡射出機配合本發明之射出成形裝置所成形之成品，其表面不產生氣泡孔，而內部較習知更為微細發泡，並使模具內不產生包風現象，以利成品形狀完整性。
綜上所述，依據本發明所提供的一種射出成形裝置及射出成形方法，具有以下優點：
1.可使成品表面平整光滑，例如：鞋底、鞋墊。
2.可增加產品強度及耐震度，因成品整體發泡均勻，不會如習知技術有發泡不全、不均而產生硬塊的問題。
3.有效地改善包風問題。
4.工序步驟節省很多，進而縮短產品製造時間。
5.提高產能並節省成本，達到節能減碳。
然而，上述實施例僅例示性說明本發明之功效，而非用於限制本發明，任何熟習此項技藝之人士均可在不違背本發明之精神及範疇下，對上述實施例進行修飾與改變。此外，在上述該些實施例中之元件的數量僅為例示性說明，亦非用於限制本發明。因此本發明之權利保護範圍，應如以下之申請專利範圍所列。
Claims (9)
- 一種射出成形裝置，其係配合一射出機使用，該射出成形裝置主要包括：一上模座，設有一上模座凹槽及一注料口，該注料口係與該射出機連結；一上模仁，設於該上模座凹槽內，該上模仁設有至少一射出口、一墊圈槽及一墊圈，該射出口係連通該注料口；一下模座，可操作性地對合或分離於該上模座，該下模座設有一下模座凹槽及至少一氣體通道，該氣體通道可供氣體進出；以及一下模仁，設於該下模座凹槽內，其隨該下模座對合或分離於該上模仁，該下模仁設有一模穴，並且設置有至少一異形風路連通該模穴及該氣體通道，該異形風路包括至少一主風道及複數副風道，該主風道環設於該模穴周圍，且連通該氣體通道，各該副風道呈間隔排列於該主風道與該模穴之間，且各該副風道一端連通該主風道，另一端連通該模穴，該下模仁為多孔性材質，該多孔性材質使該下模仁充滿複數孔隙；當該下模座對合於該上模座狀態下，該模穴內部會藉由該氣體通道經該異形風路預先注入氣體，以使該模穴內部保持一預設壓力；當該射出機內之原料進入該模穴成形過程狀態下，該氣體係逐漸抽離該模穴，使原料完整填滿該模穴；當該模穴內已成形一成品，且該下模座分離於該上模座狀態下，該氣體由該氣體通道經該異形風路溢散於該複數孔隙噴出，使該成品脫離該模穴。
- 如申請專利範圍第1項所述之射出成形裝置，其中，復包括一控制裝置，其係控制氣體進出量及時間，並調節該模穴內的壓力，且該射出機係受該控制裝置控制原料進入該模穴內之流量。
- 如申請專利範圍第1項所述之射出成形裝置，其中，該上模仁為多孔性材質，該多孔性材質使該上模仁充滿複數孔隙。
- 如申請專利範圍第1項所述之射出成形裝置，其中，該下模仁之該至少一異形風路係由三維列印形成或以透氣鋼材加工形成。
- 如申請專利範圍第1項所述之射出成形裝置，其中，該墊圈槽設置於該射出口的周圍，該墊圈設於該墊圈槽內，且其一側貼合該墊圈槽底部，並在該下模座對合於該上模座狀態下，該墊圈另一側貼合於該下模仁。
- 如申請專利範圍第1項所述之射出成形裝置，其中，該上模座及該下模座復包括至少一冷卻水路。
- 如申請專利範圍第2項所述之射出成形裝置，其中，該控制裝置與該氣體通道之間設有一防止該氣體逆流之閥門。
- 如申請專利範圍第2項所述之射出成形裝置，其中，更包括一感測該模穴內部壓力之測壓單元，該測壓單元係電性連接於該控制裝置。
- 一種射出成形方法，包括下列步驟：將一成形模具裝設於一射出機，該成形模具包括：一上模座、一下模座、一上模仁及一下模仁，該上模座設有一注料口，該上模仁設於該上模座內，且設有一射出口、一墊圈槽、一墊圈，該下模座至少設有一氣體通道，該下模仁設於該下模座內，且設有一模穴以及至少一異形風路，該異形風路包括至少一主風道及複數副風道，該主風道環設於該模穴周圍，且連通該氣體通道，各該副風道呈間隔排列於該主風道與該模穴之間，且各該副風道一端連通該主風道，另一端連通該模穴，該下模仁為多孔性材質，該多孔性材質使該下模仁充滿複數孔隙；預先對該模穴的內部注入氣體，以形成一反壓狀態；將原料倒入射出機料桶內，進入螺桿以使原料與超臨界流體的氮氣或二氧化碳混合後，藉由該注料口注入至該模穴內成形；隨注入原料的同時，同步控制模穴內氣體的進出量，讓其保持並控制一定之壓力，並於射出結束時可控制並釋放全部模腔內壓力，進而幫助發泡成形，使其不產生包風現象；控制氣體由該氣體通道經該異形風路溢散於該複數孔隙噴出，使一成品自動脫模。
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