• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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  • 优先权
    • 专利摘要:
    A method for producing an injection-molded part (10), in particular an optical element, wherein at least two spray stations (2) a spray mass is poured by means of at least two injection processes, wherein a pre-molded part (4) produced in one of the least twelve spraying operations between the at least two injection processes in a cooling station (5) is carbonized.
    公开号:AT514019A1
    申请号:T238/2013
    申请日:2013-04-02
    公开日:2014-09-15
    发明作者:Josef Dipl Ing Giessauf；Christian Maier
    申请人:Engel Austria Gmbh；
    IPC主号:
    专利说明:

    02/04/2013 10:08 + 43-512-583408 TORGGLER & HQFINGER P. 06/40 «» • • • • • • • • • • • • • • • • • • • • • • • • • 99 • • • «• • • • • • • • • • • • • •« «9 9 • · · ···································································
    The present invention relates to a method for producing an injection-molded part according to the features of the preamble of claim 1 and to an apparatus for producing an injection-molded part according to the features of the preamble of claim 10.
    In particular, in the injection molding of optical elements (for example bulbs), it is known prior art to inject the injection-molded parts to be produced in several layers or steps (for example from AT 505 321 A1). This has some advantages. On the one hand results in an improved contour fidelity by compensation of sink marks of a previously sprayed layer. In addition, there is a reduction of the required Formauftreibdruckes. Furthermore, there is a shortening of the cycle time, since the cooling time increases quadratically with the wall thickness of the sprayed layer. This is set out, for example, in WO 2012/069590 A1. The sum of the cooling times when spraying with multiple layers is thus smaller than with spraying in one piece. This will be explained in more detail below.
    In general, it can be assumed that the required cooling times should be the same for all stations. Especially if all stations are arranged in a tool or a machine, this is advantageous.
    The cooling time tk is proportional to the square of the wall thickness, so using a proportionality factor A we have / * = A - s1.
    Outer layers are cooled in the tool only one side, in contrast to the first produced inside layer. The cooling time of a one-side cooled layer is approximately equal to the cooling time of a twice as thick cooled on both sides of the layer. In order to achieve the same cooling times, an outer layer may therefore have only half the wall thickness of the inner layer. For a three-layered injection molded part with the total wall thickness s, a layer thickness distribution of S2 = V * s, Si " % s, S3 *% s 02/04/2013 11:17
    No .: R596 2/39 P.0067040 02/04/2013 10:08 + 43-512-583408
    TORGGLER & HOFINGER p. 07/40 W 9 Ψ W »··· '·« ·· • * Φ ·· ·· «« * * · · · · · · · · ···· ··· * * ·· ··· 2, (S2, s3 etc, denote the layer thicknesses of the outer layers, Si the inner layer, s denotes a total thickness.)
    Similarly, in an injection molded part of 2n + 1 layers, the thickness of the first (inner) layer may be assumed to be -i, the thickness of all subsequent w + 1
    Layers with --n is a natural number greater than or equal to 1, the 2 ^ + 1) indicates how often a pre-molded part is subsequently over-injected on both sides. To assess the cycle time spam, the sum of the cooling times of the individual stations can be used. Although the individual cycle times can run in parallel, each station still requires space in the tool and in one machine - this space could have been used in conventional single-layer technology to accommodate additional cavities.
    Assuming that the cooling time of the outer layers s2 and s3 by the one-sided cooling of the cooling time of a twice as thick layer corresponds, is now the sum of the cooling times in a three-layer injection molded part h +
    = 2 A-
    wherein the cooling time of the layers s2 and s3 must be taken into account only once, since the cooling takes place simultaneously and in the same station.
    It can be seen that the total cooling time for the individual layers is only half the cooling time t "* = A -s2 of a single-layer injection-molded part. For n layers:
    The total cooling time is now only a fraction of 1 / (n + 1) of the cooling time of the single-layer injection-molded part. P.007 / 040 02/04/2013 11:17 No .: R596 3/39 08/40 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER S. • · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · «3
    In addition to the obvious improvement in productivity, this shortened cycle time also has the advantage, for example, that the residence time of the material in the screw lead is shortened
    Despite this shortening of the cooling time, this still accounts for a considerable proportion of the total cycle time.
    The object of the invention is to provide a method and a device which allow a further shortened cycle time in the production of multi-step molded parts.
    This object is achieved by a method having the features of claim 1 and of claim 10
    This is done by cooling a pre-molded part produced in one of the at least two injection processes between the at least two injection processes in a cooling station. Because during the time in which the preform dwells in the cooling station, more preforming can already be made in the spray station in question. In other words, a shortening of the cycle time-relevant dwell time of the pre-molded parts in the spray stations is achieved by a longer cooling of the pre-molded parts outside the spray stations. The invention is therefore based on the surprising finding that even a very early demoulding of the pre-molded parts does not affect the quality of the end product.
    In principle, the invention can be applied to any spray mass, that is to say any material which can be processed in an injection molding machine. Although, for example, metals, ceramics and even pharmaceutical active ingredients can be processed in this way, reference is made in this document for the sake of simplicity to a manufactured from a plasticized plastic injection molded part, without this being limiting. 02/04/2013 11:18
    No .: R596 4/39 P.008 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER 09/40 4
    It is not essential for the purposes of the invention according to which injection process the cooling station is scheduled. Of course, it is also possible to provide cooling in a cooling station more than once in the production of an injection molded part in more than two spraying operations.
    Advantageous developments and embodiments of the invention are defined in the dependent claims.
    The exact configuration of the cooling station is not essential to the invention. The cooling station can be realized, for example, by holding the preform by a handling robot, wherein the preform cools off from the ambient air. It can also be provided active cooling by a cooling medium in the cooling station. It is also conceivable, for example, that the pre-molded part is moved in a certain range and is exposed in this way to a cooling air flow.
    In the production of optical elements, transparent plastics are preferably processed. Examples are PC, PMMA, COC, COP and amorphous PA. However, the described invention can also be used for other injection-molded parts and materials. In particular, elastic materials such as thermoplastic elastomers can be processed.
    In a preferred embodiment, the device according to the invention is located in a clean room or a clean room, in order to avoid deposition of dust on the pre-molded parts.
    In a further preferred embodiment it is provided that an embossing punch is retracted in a mold half, whereby an enlarged cavity is released for subsequent overmolding.
    It can be provided that the same plasticized plastic is processed in the at least two injection processes, whereby aberrations are avoided, for example, in optical elements. This is not mandatory 02/04/2013 11:18
    No: R596 5/39 P.009 / 040 02/04/2013 10:08 + 43-512-583408 TQRGGLER & HOFINGER 10/40 5 necessary. Of course, optical elements or similar can also be used. are made in which layers of different injection-moldable materials are provided.
    In a preferred embodiment, the preform is cooled for an integer multiple of a cycle time for the injection operations in the cooling station. During the cooling in the cooling station, further injection molding operations for further injection molded parts particularly preferably take place.
    In a multiple injection, it is not significant for the invention, whether one or more times is added. SDritzaussteile. Schichtenaufteiluna
    The invention is preferably applicable to thick-walled Spritzgussterie, such as optical lenses.
    The invention is also preferably applicable to injection molded parts with large differences in wall thickness. If an injection molded part is injection-molded in a rather thin-walled region, its rapid solidification often makes it impossible to maintain the holding pressure over this thin-walled region as long as would be required for the shrinkage compensation of the thick-walled region.
    The thick-walled areas are at least partially sequentially layered hergeste. The time sequence of the layer production can be designed so that a structure from the inside out. An odd number of layers preferably results - an internal pre-molded part is over-injected at least partially n times on both sides, so that a layer number of 2n + 1 results.
    The first (internal layer in the finished part) only has to solidify in the tool to such an extent that problem-free demolding and later insertion into another cavity is possible. If one assumes now again that the cooling times in 02/04/2013 11:18
    No .: R596 6/39 P.010 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER 11/40
    6 should be the same for each station, it makes sense, the wall thickness of the first - cooled on both sides - layer now more than twice as large as the wall thickness of the subsequent layer to assume. For a three-layer construction of a molding with total wall thickness s, the following layer division can accordingly be selected: s2 < % s, Si > % s, s3 < 7a s.
    Cycle time determining are now only the wall thicknesses of the outer layers, since the cooling of the inner layer takes place only partially in the spray area of a machine.
    If, for example, a layer distribution of s2 * 1/8 S, Si = 3/4 s, s3 = 1/8 $ is selected for the three-layer structure, then the sum of the cycle time-determining cooling times results with
    It is therefore required in this embodiment compared with the single-layer injection molded part only one eighth of the cycle time-determining cooling time, the rest of the cooling takes place outside the spray area.
    Required tools. Cavities. machinery
    Preferably, an injection mold with at least one cavity for producing the preform, and at least one further cavity for producing the finished part is used, the total volume of the cavity for the finished part is greater than that of the cavity for the pre-molded parts. Of course, the tool can have any technically meaningful number of subjects. It is also possible that the cavities for pre-molding ring and finished part are arranged in different tools. These tools can all be operated in one machine or in different ones. For three-layer injection-molded parts, the entirety of the cavities for producing the pre-molded parts is also referred to below as the first station, those for the production of the finished parts as the second station. In the case of an injection-molded part composed of five layers, in this embodiment, therefore, the result would be 02/04/2013 11:19
    No .: R596 7/39 P.011 / 040 02/04/2013 10:08 + 43-512-583408 TQRGGLER & HOFINGER p. 12/40 • · · · · · · · · · ···· • « 9 9 9 9 ············································································································································································································································ · 7 first station produce a pre-molded part, this at least partially over-spray on both sides in the second station, and at least partially overspray again in a third station. This nomenclature takes into account the case where one top and one bottom layer are produced in the same station and in the same cycle. The gating of the upper and lower layers can take place via the same gate or gate, or even separately from each other.
    Alternatively, it is also conceivable to produce upper and lower layers in each case in separate stations, ie one after the other.
    procedure
    The following is a detailed description of a procedure in a particularly preferred embodiment. First injection moldings are produced by injecting injection-moldable material into the cavities of the first station provided for this purpose, and these are cooled in the mold to such an extent that they are sufficiently stable for demoulding. The dimensional stability is generally given when the sprue and - if present - supernatants of the injection molded part are cooled to a temperature at least below the glass transition temperature of the plastic. In addition, the solidified edge layer in the thick-walled area of the injection-molded part (in the case of optical lenses, that is usually the optically effective area of the lens) must have reached a certain minimum thickness for dimensional stability. This minimum thickness is reached when demolding and subsequent insertion of the preform into the second station is possible.
    The pre-molded part is then removed from the cavity with a transport device, for example a robot, and transported to a cooling station. In a preferred case, the cooling station does not have to meet any special requirements; the parts are stored there only for a certain time and cool down in the ambient air. In the manner described, a plurality of pre-molded parts are now produced, and stored in order in the cooling station. If there are a defined number of preforms, the preform manufactured first is used by the transport device after the next opening of the tool in the second station. There he will be in the following 02/04/2013 11:19
    No.: R596 8/39 P.012 / 040 + 43-512-583408 02/04/2013 10:08 TORGGLER & HOFINGER p. 13/40 + 43-512-583408 02/04/2013 10:08 TORGGLER & HOFINGER p. 13/40 ······ • ♦ · • * ··· • · · · • · * * ·· «············································· '♦ · • · ♦ * ··· ♦ ···· 8
    Injection molding on both sides at least partially overmoulded, thereby creating a finished injection molded part. Alternatively, the injection-molded part can also be used as often as desired in another cavity and re-injection-molded. In between, it may be necessary, but not necessarily, to cool again outside the cavity. It is irrelevant in the context of the invention, after soft layer and how often the cooling takes place outside the cavity. "Outside the cavity " does not necessarily mean that the pre-molded part must be completely removed from the cavity. The cavity is formed for example by two mold inserts, one in the fixed, the other arranged in the movable half of the farm. The mold insert in the movable mold half can be executed several times. After the production of a preform this mold insert can be brought together with the pre-molded part in a different position, at the same time a further embodiment of the mold insert in the movable mold half is brought into the injection position. This can be done with the usual equipment known from multi-component injection molding (e.g., turntable, sliding table, rotatable center plate, rotatable cube tool). In these cases, the preform would be cooled on one side further in the tool, on the other side in the air. In this case, for example, by returning a movable core in that mold half in which the Spritzgussteii remains in the tool, a cavity for the subsequent overmolding can be provided.
    If the cooling station is characterized by a defined spatial area, the preform can be deposited with a robot in the cooling station. A transport device other than a robot is also possible, for example an index plate which removes the preform from the first station and after a cooling phase outside a spray Station in the second station.
    The ambient medium in the cooling outside a spray station is in a preferred embodiment air. However, any other suitable gaseous, liquid (water) or solid medium may be used. For the purposes of the invention, it is merely provided that the cooling takes place outside a spraying station. 02/04/2013 11:20
    No .: R596 9/39 P.013 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HQFINGER p. 14/40 • • • • * »· · · · • •% · · • · • "it I· • " * * · · * • •
    In a preferred embodiment, a new pre-molded part is produced again in the same cycle. The production of pre-molded part and finished part thus take place substantially parallel, ie in the same cycle.
    Number of injection units
    As already described, the production of the layers can take place in one or more machines. If production is to be carried out in one machine, it can be equipped with one, two, three or more injection units.
    In the following, some preferred options for producing a 3-layer injection-molded part with a machine are explained:
    The filling of the layers may be simultaneous or sequential depending on the number of syringe inerts, the gate design, and existing closure mechanisms in the tool.
    If three injection units, each with separate connections to the three layers, are available, the filling operations can be started simultaneously or with a time delay and with different parameters (speeds, pressures, times). This variant allows the most degrees of freedom due to the independent filling. Especially in the outer layers, different screw advance velocity profiles and / or pressure profiles may be required to avoid flow lines. It is particularly preferred to match the filling processes of the two outer layers to one another in such a way that a balance of forces prevails in the cavity. In some cases, the force on the pre-molded part may be substantially greater during overmolding than on the other side, causing it to shift , could lead to deformations or breakage of the pre-molded part. 02/04/2013 11:20
    No .: R596 10/39 P.014 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER 5. 15/40
    If only one injection unit and no closure mechanism is available in the mold for the individual cavities or layers, then the two-sided filling must take place with a common screw advance velocity profile and / or pressure profile. The equilibrium of forces described above can already be ensured during tool construction by rheological balancing of the sprues and cavities.
    If an injection unit and a closure mechanism are available for each cavity / layer, at least the start and stop times of the mold filling operations can be selected independently of one another. Cooling time spam by low mold temperature
    Smaller or local deformations on the pre-molded part, such as shrinkage sink marks, are not a problem with this method, since they are compensated in the subsequent overmolding in the subsequent station. This makes it possible to operate the first station with tool temperatures that are so low that a perfect shaping of the component contour is not guaranteed. Moreover, it is not absolutely necessary that the surface of the cavity of the pre-molded part has an optical surface, such as a high-gloss polish.
    Often thick-walled injection-molded parts, such as optical lenses have comparatively thin-walled areas, such as peripheral edges, fastening or design elements. It may be advantageous not to overspray these areas in another station, but to finish in the first station. Such areas may then be used in another station for fixing the preform. EP 2 402 140 A1, for example, discloses an optical lens with peripheral edge, which is used in the subsequent process cycle for holding and positioning the preform
    These areas therefore have no optical function in the case of optical lenses, but have some requirements for surface quality, dimensional accuracy, 02/04/2013 11:20
    No .: R596 11/39 P.015 / 040 02/04/2013 10:08 + 43-512-583408
    • mechanical properties or the like. In this case, a low mold temperature may prove disadvantageous. It may therefore be necessary to operate the cavities for preform and for the subsequent layers substantially at the same mold temperature.
    The lower mold temperature can also adversely affect the internal properties of the molded part.
    According to the invention, part of the cooling of the preform takes place after demolding from the cavity. In contrast to cooling in the tool, cooling outside has no influence on the cycle time. Therefore, a low cycle time can be achieved even at high temperatures of the cavities of the preform.
    It can therefore - but not necessarily - all stations of the tool to be operated with the same tool temperature. As a result, temperature gradients and thermal stresses in the tool caused by different temperature control are avoided - more homogeneous temperature distribution, lower energy consumption, and possibly a smaller number of temperature control units are the result.
    Bonding of the layers
    Depending on the injection molding material used, a certain minimum temperature, in particular a certain minimum surface temperature of the pre-molding, may be necessary in order to achieve, on the one hand, good adhesion to the next layer and, on the other hand, low residual stresses in the injection-molded part.
    The cooling in the air is slower compared to the cooling in the tool, therefore, the temperature gradient between the component center and component surface is lower. In other words, when a defined temperature T * is reached in the center of the molded part, the temperature at the surface of the injection-molded parts is comparatively higher and the temperature distribution along a cross-section of the section 02/04/2013 11:21
    No .: R596 12/39 P.016 / 040 17/40 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER S. • · · · · «··· ♦ ♦ | f «··················································································································································
    Injection molding more homogeneous if the cooling takes place in the ambient air instead of in the tool.
    When using a thermoplastic as an injection molding material, the contact temperature at the boundary layer between the cooled pre-molded part and the melt flowing in the other station should advantageously be in the range or above the glass transition temperature or crystalline melting temperature of the thermoplastic. When the same injection molding material is used, the contact temperature corresponds to the average of the temperatures of both contact partners.
    Nevertheless, it may be advantageous for long cooling outside the cavity to heat at least that portion of the surface which is to be subsequently overmolded in a targeted manner. This heating can take place, for example, by means of infrared radiators or by any other known methods.
    cleanliness
    It may be advantageous to avoid contamination on surfaces of the pre-molded parts, as they remain permanently in the component by the subsequent overmolding. Therefore, it is recommended that the entire production plant, the area of the cooling station and / or the removal area and / or the tool area be designed as a clean room or a clean room. But it can also be installed on the area to be protected a laminar flow box.
    Alternatively, the cooling station and / or the removal area and / or the tool area can be surrounded with a largely enclosed housing.
    Avoiding convection. Producing Controlled Convection It may also be advantageous that the amount of heat dissipated from the preform by free or forced convection is reproduced from cycle to cycle. Uncontrolled air flows, e.g. through open hall doors, in addition to the risk of contamination, it should also be advantageously avoided with regard to the changed convection. An enclosure of the cooling station and / or 02/04/2013 11:21
    No .: R596 13/39 P.017 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER p. 18/40 • · · '· • ·
    13
    Removal area and / or the tool area to avoid uncontrolled convection can remedy this situation.
    Alternatively, to avoid forced convection but such can also be used specifically for faster and controlled cooling of the preform. Any suitable - preferably gaseous - medium, in particular air, can be used for this purpose. It may also be useful to temper this medium in order to control or regulate the course of cooling. In this case, sensors for measuring the temperature of the preform in the cooling station is useful. In general, sensors for the measurement, documentation and control or regulation of the ambient conditions (temperature, humidity, flow velocity, ...) in the cooling station can be advantageous. Cooling station as ..Kllmabox "
    In order to influence the temperature profile of the preform even better, the environmental conditions in the cooling station can be made temporally and / or locally variable.
    For example, the preforms can be conveyed in the cooling station with a conveyor belt or other means for transporting the preforms through different zones, in particular temperature zones and or media flow zones. The temperature profile can be selected as falling, rising, or following any profile. Here, a targeted heating of the surface of the preform can be done prior to introduction into a further injection station.
    Instead of moving the pre-molded parts to different zones, it is also conceivable to let them rest at a defined location, and there
    Environmental conditions change with time. Cooling or tempering by heat conduction 02/04/2013 11:21
    No .: R596 14/39 P.018 / 040 19/40 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER. S •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
    The temperature profile of the preform can also be influenced in a targeted manner by heat conduction. By way of example, placing the preform on a tempered plate can serve. This plate may also be parts of a previously mentioned device for transporting pre-molded parts within the cooling station.
    Isolation of the surface
    It can also prove to be beneficial to ensure the slowest possible heat dissipation in the cooling station, for example by isolating the surface of the pre-molded part. This achieves a better alignment of the temperature between the component center and the surface.
    Further advantages and details are apparent from the figures and the associated description of the figures.
    2 shows schematically a device according to the invention with a middle plate tool and a handling robot, FIG. 3 shows schematically a device according to the invention with a rotary cube tool, FIG. 4 6 is an illustration of a handling robot, FIGS. 7a to 7c are schematic sectional views of an injection molding tool of a device according to the invention, FIGS. 8a to 8f show several sectional views of the tool Fig. 7a to illustrate the method according to the invention, Fig. 9 is a table to illustrate the manufacturing process in mass production, 02/04/2013 11:22
    Nr: R596 15/39 P.019 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER p. 20/40 »· · · · · · ····· · ··· · · · · · · · · «· · 15
    Fig. 10a to 10e are timing diagrams for various embodiments of the
    Process flow
    Fi9-11 © in temperature diagram of a cooling according to the invention of a preform as well as
    FIG. 12 shows a temperature diagram for comparing the temperatures at different take-off times for the pre-molded part.
    FIG. 1 a shows a preform 4, FIG. 1 b shows an injection molded part 10 produced from the preform 4. Also shown are the total thickness s of the lens and the layer thickness s, the preform 4 and the layer thicknesses S2 and S3 of the further layers 11.
    The ratio of the thicknesses of the thickest regions to the thinnest regions of the injection-molded part 10 is approximately s / d * 4.3 here.
    For the sake of graphic simplicity, the outer layers 11 are symmetrically drawn, which is not essential to the invention. In the concrete case of application, complete symmetry between outer layers 11 will even be the exception.
    In the figures 1, the pre-molded part 4 is a single layer. In particular, in the case of an injection-molded part with more than two layers 11, the pre-molded part 4 itself can also be multilayered.
    Fig. 2 shows an embodiment of a device according to the invention, which has a center plate 12 and two injection units 13. A transport device 3, which in this case is designed as a handling robot 9, transports pre-molded parts 4 between the spray stations 2 and the cooling station 5, in which some pre-molded parts 4 dwell for cooling.
    Figure 3 shows an embodiment of the invention with a cavity-forming tool part 8, which takes over the transport function by rotation (cube indicated by an arrow.) The cooling station 5 is considered to be of one in 02/04/2013 11:22
    No .: R596 16/39 P.020 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLERSHOFINGER s. 21/40 02/04/2013 10:08 + 43-512-583408 TORGGLERSHOFINGER s. 21/40 · • · # · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 16
    Representation overhead form half formed on one side of the cube. Also in this embodiment, an injection unit 13 is provided for each spray station 2.
    FIG. 4 shows an embodiment of the invention with two injection molding machines 7, a cooling station 5 arranged therebetween and a transport device 3, which is designed as a handling robot 9. Some preforms 4 cool in the cooling station 5. By way of example, an injection molding machine 7 with (schematically illustrated) hydraulic closing unit 15 and an injection molding machine 7 with (schematically illustrated) electric toggle clamping unit 15 are shown. The design of the closing unit 15 is of course not significant to the invention.
    Figure 5 shows a somewhat more detailed representation of an injection molding machine 7 with a closing unit 15 (in this case, an electric toggle locking unit) and an injection unit 13. The injection station 2 is formed by the two halves of the injection mold 6.
    FIG. 6 shows a handling robot 9. These handling robots 9 can be designed very differently, as can be seen from the embodiments of Figure 2 and Figure 4. The cooling station 5 is in this case a passive, in which only pre-molded parts 4 and cool the ambient air.
    FIG. 7c shows a schematic plan view of an injection mold 6 in which there is one injection station each comprising a cavity 14 for producing preforms 4 and finished injection-molded parts 10. Figure 7a shows a sectional view of the plane A of Figure 7c. In the second station shown on the right, the pre-molded part previously produced in the first station shown on the left is over-injected on the top and bottom sides. The gating of the upper and lower layer takes place via a common sprue. Figure 7b shows a sectional view of the plane B of Figure 7c.
    FIGS. 8 serve to illustrate a method sequence according to the invention using an injection molding tool 6 from FIGS. 7a to 7c. 02/04/2013 11:22
    No.: R596 17/39 P.021 / 040 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER 22/40 p. 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER 22/40 S. e ······························································································································································································································· · • 9 9 9 9 # • · • 9 · 99 · • 9 9 • 9 • 9 9 ·· 17
    In Figure 8a, the tool 6 is closed, wherein a pre-molded part 4 and an injection molded part 10 rest in the cavities 14 of the tool 6. The mold 6 is now opened, which is shown in Figure 8b.
    A transport device 3 - here a handling robot 9 - is introduced into the resulting gap, which carries from the cooling station 5, not shown, a cooled pre-molded part 4 (Figure 8c). As shown in FIG. 8d, the handling robot 9 picks up the pre-molded part 4 and the injection-molded part 10 from the mold half of the tool 6. The preform 4 and the injection-molded part 10 are removed from the mold and at the same time the preform 4 entrained by the handling robot 9 is inserted into the other mold half of the tool 6 (FIG. 8e). Here, the supernatant shown in the drawing on the right of the injection molded part as shown in Fig. 7b is executed, so that the pre-molded part is fixed on both sides.
    The handheld robot 9 then moves away and the mold 9 is closed (FIGS. 8f). The preform, previously cooled in the cooling station 5, not shown, is held by a projection in the second spray station. Plasticized plastic can now be introduced into both cavities 14, as a result of which the situation from FIG. 8 a is present again.
    It should be noted that the cavity 14 shown in FIG. 8f is delimited by the two halves of the molding tool 6 as well as by the preform 4,
    In FIG. 9, the process sequence for mass production is broken down by injection molding parts and cycle number. For example, in the fourth cycle, the pre-molded part 4 of the injection-molded part with number # 4 is produced (process step S1). Thereafter, it is cooled for three cycles in the cooling station 5 (process steps K). Finally, in cycle # 8, the pre-molded part 4 is overmolded and the finished injection-molded part is completed (process step S2).
    In other words, in cycle # 5, the preform 4 of the fifth injection molded part is injected (S1), the molded articles 4 of the injection molded parts # 2 to # 4 cooled (K), and the injection molded part # 1 completed (S2). 02/04/2013 11:23
    No .: R596 18/39 P.022 / 040 02/04/2013 10:08 + 43-512-583408 TORGQLER & HÜFINGER p. 23/40 • · «·» · · · · · ····· ·· ♦♦ · #
    18
    FIGS. 10a to 10e show timing diagrams for various embodiments of the process sequence. In each case, the processes for an example with three cavities 14, which are numbered as K1, K2 and K3, are shown. In each of the three cavities, a layer is produced. In these five examples, K1 always forms the pre-molded part 4. The injection of the three cavities (K1, K2, K3) takes place separately in this example. The second (K2) and third (K3) cavities can be formed in a common injection station 2, in which case they are separated from one another by the inserted preform 4. Alternatively, the second and third cavities (K2, K3) can also be embodied in separate spray stations 2.
    If only one injection unit 13 and no closure mechanisms are present, the injection phases E1 and the post-pressure phases N1 are synchronous for the cavities (K1, K2, K3) (FIG. 10a). However, since the requirements for the spray profiles for the different layers 11 generally differ significantly, often other process configurations are more efficient.
    FIG. 10b shows an example with a spray unit 13 and closure mechanisms for each cavity (K1, K2.K3). Since the spray pattern for the middle layer will differ most from those of the outer layers 11, only the latter will be performed simultaneously. A cycle for a cavity (K1, K2, K3) consists of the opening of the shutter mechanism (VO), an injection phase E1, a holding pressure phase N1 and the closing of the shutter mechanism (W). FIG. 10c shows a process execution with two injection units 13 but without closure mechanisms. Here, the injection phase E1 for the first injection unit 13 and the injection phase for the second injection unit 13 may be performed simultaneously. The same applies to the emphasis phases N1 and N2.
    FIG. 10d shows a mixed form in which two injection units 13 and closure mechanisms are available on the cavities K1 and K2. P.023 / 040 02/04/2013 11:23 No: R596 19/39 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER p. 24/40 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER p. 24/40 • · • ··· ···· • · • ··· * ·
    19 • · '• ·
    FIG. 10e shows an ideal situation with three injection units 13. Closure mechanisms are no longer absolutely necessary in this case since the injection phases E1, E2 and E3 as well as the post-pressure phases N1, N2 and N3 for the three injection units 13 can be controlled or controlled separately by them ,
    FIG. 11 is a temperature diagram in which the temperature profile on the surface of the pre-molded part 4 can be read from the time of removal from a cavity 14 (see FIGS. 8a to 8f) until it is inserted into the cavity 14 for extrusion-coating the pre-molded part 4. This course was measured on a preform 4 with 15 mm thickness, which was made of polycarbonate, with a cooling in ambient air. The temperature at the time of demoulding is designated T1. The temperature at the time of insertion into the next cavity 14 is denoted by T2
    FIG. 12 shows the surface temperature as a function of the time during cooling in air for a 15 mm thick preform 4, which was taken after 25 s (upper curve) and after 130 s (lower curve). After a cooling time of dT = 262 s in the air, the preform 4 taken out early has the same surface temperature as the preform 4 removed later.
    Innsbruck, 2nd April 2013 P.024 / 040 02/04/2013 11:23 Nr .: R596 20/39
    权利要求:
    Claims (18)
    [1]
    s. 7374332/32 25/40 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER • · # · · · · · · · · · · · · · · · · · · · · · · · · · « 1. A method for producing an injection-molded part (10), in particular an optical element, wherein at least two injection stations (2) a spray mass by means of at least two injection processes is poured, characterized in that a produced in one of the at least two injection molding preform (4) between the at least two injection processes in a cooling station (5) is cooled.
    [2]
    2. The method according to claim 1, characterized in that a lens is produced as an injection molded part (10).
    [3]
    3. The method according to claim 1 or 2, characterized in that in the at least two injection processes at least two layers (11,4) of the injection molded part (10) are injected.
    [4]
    4. The method according to claim 3, characterized in that for producing a (2n + 1) -layered injection molded part (10) in a first of the at least two spraying operations, a first layer (4) is injected and in n further or in 2n further at least two injection processes 2n further layers (11) are sprayed, wherein preferably maximum thicknesses of each two to be sprayed in the further spraying processes layers (11) are substantially equal.
    [5]
    5. The method according to claim 4, characterized in that the 2n to be sprayed in the further spraying operations layers (11) with layer thicknesses (s2, 1 s3), which smaller than - a total thickness (s) of the injection molded part 2 (n + l) (10) is, be injected or that a layer thickness (si) of the preform (4) is greater than -. times a total thickness (s) of the injection molded part (10). (n + 1)
    [6]
    6. The method according to any one of claims 1 to 5, characterized in that the pre-molded part (4) in the cooling station (5) is cooled so that a first 02/04/2013 11:24 No .: 21/39 R596 P. 025/040 p. 26/40 73743 32/32 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOFINGER • · · · · t · t · · · · · · · · · · · · · The temperature (T1) of the pre-prong (4) immediately after a first spraying operation is at least 5 " C, preferably 10 ° C, is higher than a second temperature (T2) of the pre-molded part (4) immediately before a second injection process.
    [7]
    7. The method according to any one of claims 1 to 6, characterized in that an injection molded part (10) is produced, which has a total thickness (s) of more than 5 mm, preferably more than 10 mm
    [8]
    8. The method according to any one of claims 1 to 7, characterized in that an injection molded part (10) is produced, which has different strengths, wherein ratios of the thickness of the thickest areas to thinnest areas more than 1.5: 1, preferably more than 2 , 5: 1.
    [9]
    9. The method according to any one of claims 1 to β, characterized in that in the at least two injection processes, the same injection molding compound is processed.
    [10]
    10. An apparatus for producing an injection-molded part (10), in particular an optical element, from a spray mass with at least two spray stations (2) and a transport device (3) for transporting a pre-molded part (4) produced in a first of the at least two spray stations (2). to a second of the at least two spray stations (2), characterized in that the protrusion (4) can be transported by the transport device (3) into a cooling station (5) and that the pre-molded part (4) is cooled in the cooling station (5). by the transport device (3) to the second injection station (2) is transportable.
    [11]
    11. The device according to claim 10, characterized in that the at least two spray stations (2) in at least one mold (6) at least one injection molding machine (7) are arranged. P.026 / 040 02/04/2013 11:24 no .: R596 22/39 02/04/2013 10:08 + 43-512-583408 TORGGLER & HOF INGER p. 27/40 ·. · · ♦ • * · • · · · • · "" · ···· ·· * · • · * ♦ ♦ · · "" · "• · ·· * 73743 32/32
    [12]
    12. The apparatus of claim 10 or 11, characterized in that a kavitätenbüdendes tool part (8) on which the pre-molded part (4) is arranged, by means of the transport device (3) is transportable.
    [13]
    13. The apparatus according to claim 12, characterized in that the at least two Sprftzstatronen (2) and the cooling station (5) are arranged on a rotary cube or an index plate.
    [14]
    14. Device according to one of claims 10 to 13, characterized in that the at least two spray stations (2) are arranged on a central plate (12).
    [15]
    15. Device according to one of claims 10 to 14, characterized in that for transporting the pre-molded part (4) a handling robot (9) is provided.
    [16]
    16. Device according to one of claims 10 to 15, characterized in that the cooling station (5) as a passive cooling station (5) by means of ambient air or active cooling station (5) using a cooling medium - preferably air or water - is formed.
    [17]
    17. The device according to one of claims 10 to 16, characterized in that a surface of the pre-molded part (4) after cooling in the cooling station (5) is heatable in a surface heating station.
    [18]
    18. Device according to one of claims 10 to 17, characterized in that an injection molded part (10) can be produced, which has different strengths, and at one of the at least two spray stations (2) the injection molding compound at a region of low thickness of the pre-molded part (4). can be fed. Innsbruck, on April 2, 2013 02/04/2013 11:24 no .: R596 23/39 P.027 / 040
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    ATA238/2013A|AT514019B1|2013-04-02|2013-04-02|Method and device for producing an injection-molded part|ATA238/2013A| AT514019B1|2013-04-02|2013-04-02|Method and device for producing an injection-molded part|
    DE102014004766.0A| DE102014004766A1|2013-04-02|2014-04-01|Method and device for producing an injection-molded part|
    US14/243,341| US10183429B2|2013-04-02|2014-04-02|Method and device for the production of an injection-moulded part|
    CN201410331919.9A| CN104149264B|2013-04-02|2014-04-02|Method and apparatus for manufacturing injection molding member|
    PCT/AT2014/000067| WO2014161014A1|2013-04-02|2014-04-02|Method and apparatus for producing a multilayer injection moulding with interstage cooling|
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    KR1020147012140A| KR20150101918A|2013-04-02|2014-04-02|Method and device for the production of an injection-moulded part|
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