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    • 专利摘要:
    "INJECTION MOLDING EQUIPMENT" This is a low constant pressure injection molding machine that forms molded parts by injection of molten thermoplastic material into a mold cavity at substantially constant low pressures of 41.4 MPa (6,000 psi) and less. As a result, the low constant pressure injection molding machine includes a mold formed of easily machined material that is less expensive and faster to manufacture than typical injection molds.
    公开号:BR112013029695B1
    申请号:R112013029695-0
    申请日:2012-05-21
    公开日:2020-11-10
    发明作者:Gene Michael Altonen；Ralph Edward Neufarth；Gary Francis Schiller
    申请人:Imflux, Inc；
    IPC主号:
    专利说明:

    TECHNICAL FIELD
    [0001] The present invention relates to apparatus and methods for injection molding and, more particularly, to apparatus and methods for producing injection molded parts at constant low pressure. BACKGROUND OF THE INVENTION
    [0002] Injection molding is a technology commonly used for the manufacture of high volume parts produced from material that can be cast, most commonly, parts produced from thermoplastic polymers. During a repetitive injection molding process, a plastic resin, most often in the form of small microspheres or pellets, is introduced into an injection molding machine that melts the resin microspheres under heat, pressure and shear. The resin, now molten, is forcibly injected into a mold cavity that has a particular cavity shape. The injected plastic is kept under pressure in the mold cavity, cooled, and then removed as a solidified part that has a shape that essentially repeats exactly the shape of the mold cavity. The mold itself can have a single cavity or multiple cavities. Each cavity can be connected to a flow channel through a port, which directs the flow of the molten resin into the cavity. A molded part can have one or more doors. It is common for large parts to have two, three or more ports, to reduce the flow distance the polymer needs to travel to fill the molded part. The one or multiple ports per cavity can be located anywhere in the geometry of the part, and have any cross-sectional shape as being essentially circular or being conformed to an aspect ratio of 1.1 or more. Thus, a typical injection molding procedure comprises four basic operations: (1) heating the plastic in the injection molding machine to allow it to flow under pressure; (2) injecting the molten plastic into a mold cavity, or cavities, defined between two mold halves that have been closed; (3) allowing the plastic to cool and harden in the cavity, or cavities, while kept under pressure; and (4) opening the mold halves to cause the part to be ejected from the mold.
    [0003] The molten plastic resin is injected into the mold cavity and the plastic resin is forcibly pushed through the cavity by an injection element of the injection molding machine, until the plastic resin reaches the location in the cavity furthest from the door. The resulting length and wall thickness of the part is a result of the shape of the mold cavity.
    [0004] Although it may be desirable to reduce the wall thickness of injected molded parts to reduce the plastic content and, thus, the cost of the final part, to reduce the wall thickness using a conventional injection molding process it can be an expensive and non-trivial task, particularly when wall thicknesses less than 15, 10, 5, 3 or 1.0 millimeters are projected. As a liquid plastic resin is introduced into an injection mold in a conventional injection molding process, the material adjacent to the cavity walls immediately begins to "freeze", or to solidify and cure. As the material flows through the mold, a boundary layer of material is formed against the sides of the mold. As the mold continues to fill, the boundary layer continues to thicken, ultimately preventing the material flow path and preventing additional material from flowing into the mold. The plastic resin that freezes on the mold walls is exacerbated when the molds are cooled, a technique used to reduce the cycle time of each part and increase the speed of the machine.
    [0005] It may also be desirable to design a part and the corresponding mold, so that the liquid plastic resin flows from the areas that have the greatest wall thickness towards the areas that have the least wall thickness. Increasing the thickness in certain regions of the mold can ensure that sufficient material flows into areas where strength and thickness are required. This "thick-to-thin" flow path requirement can contribute to inefficient use of plastic and result in higher part cost for injection molded part manufacturers, as additional material needs to be molded into parts where the material is unnecessary.
    [0006] A method to decrease the wall thickness of a piece is to increase the pressure of the liquid plastic resin as it is introduced into the mold. By increasing the pressure, the molding machine can continue to force liquid material into the mold before the flow path is impeded. Increasing pressure, however, has disadvantages in terms of both cost and performance. As the pressure required to mold the component increases, the molding equipment must be strong enough to withstand the additional pressure, which generally means, to be more expensive. A manufacturer may have to purchase new equipment to accommodate these higher pressures. In this way, a decrease in the wall thickness of a given part can result in significant capital expenditures to carry out manufacturing using conventional injection molding techniques.
    [0007] Additionally, when the liquid plastic material flows into the injection mold and quickly freezes, the polymer chains retain the high levels of stress that were present when the polymer was in liquid form. Frozen polymeric molecules retain higher levels of flow-induced orientation when molecular orientation is retained in the part, resulting in a frozen stressed state. These "in-mold" stresses can lead to parts that warp or sink after molding, which have reduced mechanical properties and have reduced resistance to chemical exposure. The reduced mechanical properties are particularly important for controlling and / or minimizing injection molded parts, such as thin-walled vats, live joint parts, and closing systems.
    [0008] In an effort to avoid some of the disadvantages mentioned above, many conventional injection molding operations use plastic material whose viscosity decreases under shear, to improve the flow of the plastic material within the mold cavity. As the plastic material, whose viscosity decreases under shear, is injected into the mold cavity, shear forces generated between the plastic material and the walls of the mold cavity tend to reduce the viscosity of the plastic material, thereby allowing the plastic material to flow more freely and easily into the mold cavity. As a result, it is possible to fill thin-walled parts quickly enough to prevent the material from freezing before the mold is completely filled.
    [0009] The reduction in viscosity is directly related to the magnitude of the shear forces generated between the plastic material and the feed system, and between the plastic material and the mold cavity wall. In this way, manufacturers of these materials whose viscosity decreases under shear and the operators of injection molding systems, have triggered higher injection molding pressures in an effort to increase shear, thereby reducing viscosity. Typically, injection molding systems inject the plastic material into the mold cavity at melt pressures of 103.4 MPa (15,000 psi) or more. Plastic material manufacturers whose viscosity decreases under shear teach injection molding operators to inject plastic material into the mold cavities above a minimum melt pressure. For example, polypropylene resin is typically processed at pressures greater than 41.4 MPa (6,000 psi) (the range recommended by polypropylene resin manufacturers is typically more than 41.4 MPa at about 103.4 MPa (6,000 psi) to about 15,000 psi.) Resin manufacturers recommend not to exceed the upper end of the strip. Press manufacturers and processing engineers typically recommend processing polymers whose viscosity decreases under shear at the upper end of the strip, or significantly above, to achieve potential. maximum viscosity reduction under shear, which is typically greater than 103.4 MPa (15,000 psi), to extract maximum thinning and better flow properties from the plastic material Thermoplastic polymers whose viscosity decreases under shear are generally processed in the range of more than 41.4 MPa to about 206.8 MPa (6,000 psi to about 30,000 psi).
    [00010] The molds used in injection molding machines need to be able to withstand these high melt pressures. In addition, the material that forms the mold must have a fatigue limit that can withstand the maximum cyclical stress for the total number of cycles that a mold is expected to perform over its lifetime. As a result, mold makers typically form the mold from materials that have high hardness, typically greater than 30 Rc, and more typically, greater than 50 Rc. These high-hardness materials are durable and equipped to withstand the high clamping pressures necessary to keep mold components pressed against each other during the plastic injection process. These materials with high hardness are also better able to resist the wear and tear that occurs due to the repeated contact between the molding surfaces and the polymer flow.
    [00011] High production injection molding machines (ie class 101 and class 102 molding machines), which produce thin-walled consumer products, exclusively use molds that have the majority of the mold produced from the materials with high hardness. High production injection molding machines typically produce 500,000 cycles per year or more. Industrial quality production molds should be designed to withstand at least 500,000 cycles per year, preferably more than 1,000,000 cycles per year, more preferably more than 5,000,000 cycles per year, and more preferably even more than 10,000. 000 cycles per year. These machines have multi-cavity molds and complex cooling systems to increase production rates. Materials with high hardness are better able to withstand repeated high pressure pressing operations than materials with less hardness. However, materials with high hardness, like most tool steels, have relatively low thermal conductivities, generally less than 34.6 W / (m * C) (20 BTU / HR FT ° F), which leads to long cooling times, as heat is transferred through the melted plastic material through the material with high hardness.
    [00012] In an effort to reduce cycle times, typical high production injection molding machines, which have molds made from materials with high hardness, include relatively complex internal cooling systems that circulate cooling fluid inside of the mold. These cooling systems accelerate the cooling of the molded parts, thus allowing the machine to complete more cycles in a given amount of time, which increases production rates and thus the total amount of molded parts produced. In some classes 101, more than 1 or 2 million cycles per year can be performed, these molds are sometimes called "ultra-high productivity molds". Class 101 molds that are used in presses of 400 tonnes or larger are sometimes referred to as "class 400" molds in the industry.
    [00013] Another disadvantage of using materials with high hardness for molds is that materials with high hardness, such as tool steels, are generally reasonably difficult to machine. As a result, well-known high-speed injection molds require extensive machining time and expensive machining equipment to form, and costly and time-consuming post-machining steps to relieve stresses and optimize material hardness. BRIEF DESCRIPTION OF THE DRAWINGS
    [00014] The modalities presented in the drawings are illustrative and exemplary in nature and are not intended to limit the subject defined by the claims. The following detailed description of the illustrative modalities can be better understood when read in conjunction with the following drawings, in which similar structures are indicated with similar reference numbers and in which: Figure 1 illustrates a schematic view of an injection molding machine , built according to the description; Figure 2 illustrates an embodiment of a thin-walled piece formed in the injection molding machine of Figure 1; Figure 3 is a graph of cavity pressure vs. time for the injection molding machine of Figure 1; Figure 4 is a cross-sectional view of an embodiment of a mold of the injection molding machine of Figure 1; Figure 5 is a perspective view of a supply system; Figures 6A and 6B are top and front views of a naturally balanced feeding system; Figures 7A and 7B are top and front views of another naturally balanced feeding system; Figure 8 is a top view of an artificially balanced feeding system that can be used on the injection molding machine of Figure 1; and Figures 9A and 9B are top views of unbalanced feed systems that can be used in the injection molding machine of Figure 1. DETAILED DESCRIPTION
    [00015] The modalities of the present invention generally relate to systems, machines, products and methods of producing products by injection molding and, more specifically, systems, products and methods of producing products by constant low pressure injection molding .
    [00016] The term "low pressure", as used here, which refers to the melting pressure of a thermoplastic material, means melting pressures in an vicinity of a nozzle on a 41.4 MPa injection molding machine (6,000 psi) and less.
    [00017] The term "substantially constant pressure", as used herein in relation to a melt pressure of a thermoplastic material, means that deviations from a pressure of the baseline melt do not produce significant changes in physical properties of the thermoplastic material. For example, "substantially constant pressure" includes, but is not limited to, pressure variations by which the viscosity of the molten thermoplastic material does not change significantly. The term "substantially constant" in this respect includes deviations of approximately 30% of a pressure For example, the term "a substantially constant pressure of approximately 31.7 MPa (4,600 psi)" includes pressure fluctuations within the range of about 41.4 MPa (6,000 psi) (30% above from 31.7 MPa (4,600 psi)) to about 22.1 MPa (3,200 psi) (30% below 31.7 MPa (4,600 psi). A melt pressure is considered to be substantially constant as long as the material pressure molten float no more than 30% with respect to the aforementioned pressure.
    [00018] Support for molten material, as used here, refers to the portion of an injection molding machine that contains the molten plastic in fluid communication with the nozzle of the machine. The molten material support is heated so that a polymer can be prepared and maintained at a desired temperature. The molten material support is connected to a power source, for example, a hydraulic cylinder or electric servomotor, which is in communication with a central control unit, and can be controlled to advance a diaphragm to force the molten plastic through the nozzle of the machine. The molten material then flows through the sprue system in the mold cavity. The molten material support can have a cylindrical cross section, or have alternative cross sections that will allow a diaphragm to force the polymer under pressures that can be in the range of as low as 0.69 MPa (100 psi) at pressures 275.8 MPa (40,000 psi) or more through the machine nozzle. The diaphragm can, optionally, be integrally connected to a reciprocating screw with flights designed to plasticize the polymeric material before injection.
    [00019] Referring to the Figures in detail, Figure 1 illustrates an exemplary constant low pressure injection molding apparatus 10, for producing thin-walled parts at high volumes (for example, a class 101 or 102 injection mold, or an "ultra-high productivity mold"). The injection molding apparatus 10 generally includes an injection system 12 and a pressing system 14. A thermoplastic material can be introduced into the injection system 12 in the form of thermoplastic pellets 16. Thermoplastic pellets 16 can be placed in a hopper 18, which feeds the thermoplastic pellets 16 into a heated cylinder 20 of the injection system 12. The thermoplastic pellets 16, after being fed into the heated cylinder 20, can be directed to the end of the heated cylinder 20 by a reciprocating screw 22. The heating of the heated cylinder 20 and the compression of the thermoplastic pellets 16 by the reciprocating screw 22, cause thermoplastic pellets 16 to melt, forming a molten thermoplastic material 24. The molten thermoplastic material is typically processed at a temperature of around 130 ° C up to about 410 ° C.
    [00020] The reciprocating screw 22 forces the molten thermoplastic material 24 towards a nozzle 26 to form a dose comprising thermoplastic material, which will be injected into a mold cavity 32 of a mold 28. The molten thermoplastic material 24 can be injected through a port 30, which directs the flow of the molten thermoplastic material 24 to the mold cavity 32. The mold cavity 32 is formed between the first and second mold parts 25, 27 of the mold 28 and the first and second mold parts 25.27 are held together under pressure by a press or pressing unit 34. The press or pressing unit 34 applies a pressing force in the range of approximately 6.89 MPa (1,000 psi) to approximately 41.4 MPa (6,000 psi) during the molding process, to hold the first and second mold parts 25, 27 together, while the molten thermoplastic material 24 is injected into the mold cavity 32. To withstand these pressing forces, the press system message 14 can include a mold frame and a mold base, the mold frame and the mold base being formed from a material that has a surface hardness greater than about 165 BHN and, preferably, less than 260 BHN, although materials having BHN surface hardness values greater than 260 can be used, provided the material is easily machined, as further discussed below.
    [00021] The mold may comprise a single mold cavity or a plurality of mold cavities. A plurality of mold cavities may comprise similar or dissimilar cavities, which will yield dissimilar parts. The mold may also comprise a grouped family of dissimilar cavities.
    [00022] Since the dose comprising the molten thermoplastic material 24 is injected into the mold cavity 32, the reciprocating screw 22 interrupts the forward path. The molten thermoplastic material 24 takes the form of the mold cavity 32 and the molten thermoplastic material 24 cools within the mold 28 until the thermoplastic material 24 solidifies. Once the thermoplastic material 24 has solidified, the press 34 releases the first and second mold parts 25, 27, the first and second mold parts 25, 27 are separated from each other, and the finished part can be ejected of the mold 28. The mold 28 can include a plurality of mold cavities 32 to increase overall production rates.
    [00023] A controller 50 is communicably connected to a sensor 52 and a screw control 36. Controller 50 may include a microprocessor, a memory, and one or more communication links. Controller 50 can be connected to sensor 52 and screw control 36 via wired connections 54, 56, respectively. In other embodiments, controller 50 can be connected to sensor 52 and screw control 56 via a wireless connection, a mechanical connection, a hydraulic connection, a pneumatic connection, or any other type of communication connection known to those with common skill in the art, which allow controller 50 to communicate with both sensor 52 and screw control 36. There may be intermediate operating units in the communications route between the sensor, controller and screw control.
    [00024] In the modality of Figure 1, sensor 52 is a pressure sensor that measures (directly or indirectly) the melt pressure of the melt thermoplastic material 24 at the nozzle 26. The sensor 52 generates an electrical signal that is transmitted to the controller 50. Controller 50 then commands screw control 36 to advance screw 22 at a rate that maintains a substantially constant melt pressure of molten thermoplastic material 24 at nozzle 26. Although sensor 52 can directly measure pressure of the melt, the sensor 52 can measure other characteristics of the melt thermoplastic material 24, such as temperature, viscosity, flow rate, etc., which are indicative of the melt pressure. Similarly, sensor 52 does not need to be located directly on nozzle 26, but instead sensor 52 can be located anywhere within injection system 12 or mold 28 that is fluidly connected to nozzle 26 Sensor 52 does not need to be in direct contact with the injected fluid and, alternatively, it may be in dynamic communication with the fluid and have the ability to capture fluid pressure and / or other fluid characteristics. If sensor 52 is not located inside nozzle 26, suitable correction factors can be applied to the measured characteristic to calculate the pressure of the molten material in nozzle 26. In other modalities, sensor 52 does not need to be arranged in a location that is connected fluidly to the nozzle. Instead, the sensor can measure the pressing force generated by the pressing system 14 on a mold dividing line between the first and second mold parts 25, 27. In one aspect, the controller 50 can maintain the pressure accordingly with sensor input 52.
    [00025] A sensor can be located near the filling end in the mold cavity. This sensor can provide an indication of when the mold front approaches the filling end in the cavity. The sensor can capture pressure, temperature, optically, or other means of identifying the presence of the polymer. When pressure is measured by the sensor, this measurement can be used to communicate with the central control unit to provide a "compaction pressure" target for the molded component. The signal generated by the sensor can be used to control the molding process, so that variations in material viscosity, mold temperatures, melting temperatures and other variations that influence the fill rate, can be adjusted by the central control. These adjustments can be made immediately during the molding cycle, or corrections can be made in subsequent cycles. In addition, it is possible to average several readings over several cycles, then used to make adjustments to the molding process by the central control unit. In this way, the current injection cycle can be corrected based on measurements that take place during one or more cycles at a point in the previous time. In one embodiment, you can average the sensing readings over many cycles in order to achieve process consistency.
    [00026] Although an active, closed-loop controller 50 is illustrated in Figure 1, other pressure regulating devices can be used instead of closed-circuit controller 50. For example, a pressure regulating valve (not shown) or a pressure relief valve (not shown), can replace controller 50 to regulate the melt pressure of the melt thermoplastic material 24. More specifically, the pressure regulating valve and pressure relief valve can prevent mold overpressurization 28. Another alternative mechanism to prevent mold overpressurization 28 is an alarm that is activated when an overpressurization condition is detected.
    [00027] Turning now to Figure 2, an exemplary molded piece 100 is illustrated. Molded part 100 is a thin-walled part. Molded parts are generally considered to be thin-walled when a length of a flow channel L divided by a thickness of the flow channel T is greater than 100 (i.e., L / T> 100). In some injection molding industries, thin-walled parts can be defined as parts that have an L / T> 200 or an L / T> 250. The length of the flow channel L is measured from a port 102 to an end of flow channel 104. Thin-walled parts are specifically prevalent in the consumer products industry.
    [00028] Thin-walled parts present certain obstacles in injection molding. Molded parts are generally considered to be thin-walled when a length of a flow channel L divided by a thickness of the flow channel T is greater than 100 (i.e., L / T> 100). For mold cavities that have a more complicated geometry, the L / T ratio can be calculated by integrating dimension T along the length of the mold cavity 32 from a port 102 to the end of the mold cavity 32, and determining the length longer flow rate from port 102 to the end of the mold cavity 32. The L / T ratio can then be determined by dividing the longest flow length by the average part thickness.
    [00029] For example, the fineness of the flow channel tends to cool the molten thermoplastic material before the material reaches the end flow channel 104. When this happens, the thermoplastic material freezes and no longer flows, resulting in a piece incomplete. To overcome this problem, traditional injection molding machines inject the molten thermoplastic material at very high pressures, typically greater than 103.4 MPa (15,000 psi), so that the molten thermoplastic material quickly fills the mold cavity before it has chance to cool and freeze. This is one reason why manufacturers of thermoplastic materials instruct to perform the injection at very high pressures. Another traditional reason why injection molding machines inject at high pressures is the greater shear, which increases the flow characteristics, as discussed above. These very high injection pressures require the use of very hard materials to form the mold 28 and the feeding system.
    [00030] Traditional injection molding machines use tool steels or other hard materials to produce the mold. Although these tool steels are robust enough to withstand very high injection pressures, tool steels are relatively unsatisfactory thermal conductors. As a result, very complex cooling systems are machined in the molds to optimize the cooling times when the mold cavity is filled, which reduces cycle times and increases mold productivity. However, these very complex cooling systems add a lot of time and costs to the mold production process.
    [00031] The inventors have found that thermoplastics whose viscosity decreases under shear (even thermoplastics whose viscosity decreases minimally under shear) can be injected into mold 28 at substantially constant low pressure, without any significant adverse effect. Examples of such materials include, but are not limited to, polymers and copolymers comprising polypropylene, polyethylene, thermoplastic elastomers, polyester, polystyrene, polycarbonate, poly (acrylonitrile-butadiene-styrene), poly (lactic acid), polyhydroxyalkanoate, polyamides, polyacetals, ethylene-alpha-olefin rubbers and styrene-butadiene-styrene block copolymers. In fact, parts molded at substantially constant low pressures exhibit some superior properties compared to the same part molded at conventional high pressure. This finding directly contradicts conventional knowledge within the industry that teaches that higher injection pressures are better. Without sticking to the theory, it is believed that injecting molten thermoplastic material into mold 28 at substantially constant low pressures, creates a continuous flow front of thermoplastic material that advances through the mold, from a door to a part further away from the mold cavity . By maintaining a low level of shear, the thermoplastic material remains liquid and fluid at much lower temperatures and pressures than is normally believed to be possible in conventional high pressure injection molding systems.
    [00032] Exemplary thermoplastic resins are provided, together with their recommended operating pressure ranges, in the following chart:



    [00033] Turning now to Figure 3, a typical pressure-time curve for a conventional high-pressure injection molding process, is illustrated by the dashed line 200. In contrast, a pressure-time curve for the constant low pressure injection molding shown, is illustrated by continuous line 210.
    [00034] In the conventional case, the pressure of the molten material is rapidly increased to well beyond 103.4 MPa (15,000 psi) and then maintained at a relatively high pressure, more than 103.4 MPa (15,000 psi), by a first time period 220. The first time period 220 is the filling time in which the molten plastic material flows into the mold cavity. Consequently, the pressure of the molten material is decreased and maintained at a lower, but still relatively high pressure, 68.9 MPa (10,000 psi) or more, for a second time period 230. The second time period 230 is a time of compaction in which the pressure of the molten material is maintained to ensure that all gaps in the mold cavity are filled. The mold cavity in a conventional high pressure injection molding system is loaded from the end of the flow channel back towards the door. As a result, plastic, in various stages of solidification, is compacted on top of each other, which can cause inconsistencies in the final product, as discussed above. In addition, plastic compaction in various stages of solidification results in some non-ideal material properties, for example, stresses under molding, sinking, and non-ideal optical properties.
    [00035] The injection molding system at constant low pressure, on the other hand, injects the molten plastic material into the mold cavity at a substantially constant low pressure for a single period of time 240. The injection pressure is less than 41, 4 MPa (6,000 psi). When using a substantially constant low pressure, the molten thermoplastic material maintains a front part of continuous molten material that advances through the flow channel, from the door towards the end of the flow channel. In this way, the plastic material remains relatively uniform at any point along the flow channel, which results in a more uniform and consistent final product. When filling the mold with a relatively uniform plastic material, the final molded parts form crystalline structures that have better mechanical and optical properties than conventionally molded parts. Furthermore, the surface layers of parts molded at constant low pressures exhibit different characteristics from the surface layers of conventionally molded parts. As a result, surface layers of parts molded under constant low pressure may have better optical properties than surface layers of conventionally molded parts.
    [00036] By maintaining a substantially constant and low melt pressure (for example, less than 41.4 MPa (6,000 psi)) within the nozzle, more machinable materials can be used to form the mold 28. For example, the mold 28 illustrated in Figure 1 can be formed from a material that has a milling index greater than 100%, a machining index per hole greater than 100%, an EDM wire machining index greater than 100%, a machining index by graphite heatsink EDM greater than 200%, or a machining index by copper heatsink EDM greater than 150%. Machining indexes are based on grinding, drilling, EDM wire, and dissipating EDM tests on various materials. The test methods for determining machining indexes are explained in more detail below. Examples of machining indices for a sample of materials are compiled below in Table 1.
    Table 1
    [00037] The use of easily machined materials to form the mold 28, results in very short manufacturing time and, thus, a decrease in manufacturing costs. Furthermore, these machinable materials, in general, have better thermal conductivity than tool steels, which increases cooling efficiency and reduces the need for complex cooling systems.
    [00038] When forming the mold 28 of these easily machinable materials, it is also advantageous to select easily machinable materials that have good thermal conductivity properties. Materials having thermal conductivities of more than 51.9 W / (m * C) (30 BTU / HR FT ° F) are particularly advantageous. For example, easily machined materials that have good thermal conductivities include, but are not limited to, Alcoa QC-10, Alcan Duramold 500, and Hokotol (available from Aleris). Materials with good thermal conductivity transmit heat from the thermoplastic material more efficiently outside the mold. As a result, simpler cooling systems can be used. In addition, non-naturally balanced feeding systems are also possible for use in the injection molding machines at constant low pressure described here.
    [00039] An example of a multi-cavity mold 28 is illustrated in Figure 4. Multi-cavity molds generally include a feed flow pipe 60 that directs molten thermoplastic material from the nozzle 26 to the individual mold cavities 32. Feed flow tubing 60 includes a sprue 62, which directs the molten thermoplastic material to one or more feed stream channels or channels 64. Each sprue can feed multiple mold cavities 32. In many high-pressure injection molding machines capacity, the sprues are heated to accentuate the fluidity of the molten thermoplastic material. Because the viscosity of the molten thermoplastic material is very sensitive to shear and pressure variations at high pressures (for example, above 68.9 MPa (10,000 psi)), conventional feed flow pipes are naturally balanced to maintain uniform viscosity. Naturally balanced feed flow pipes are pipes in which the molten thermoplastic material travels an equal distance from the sprue to any mold cavity. In addition, the cross-sectional shapes of each flow channel are identical, the number and type of turns are identical, and the temperatures of each flow channel are identical. Naturally balanced feed flow lines allow the mold cavities to be filled simultaneously so that each molded part has identical processing conditions and material properties. Naturally balanced supply lines are expensive to manufacture and, in some way, limit mold designs.
    [00040] Figure 5 illustrates an example of a naturally balanced feed flow pipe 60. The naturally balanced feed flow pipe 60 includes a first flow path 70 from sprue 62 to a first junction 72, the first of which is the first flow path 70 divides into second and third flow paths 74, 76, with the second flow path ending at a second port 78a and the third flow path 76 ending at a third port 78b, where each port serves the an individual mold cavity (not shown in Figure 5). Fused thermoplastic material that flows from sprocket 62 to the second port 78a or the third port 78b, travels the same distance, passes the same temperatures, and is subjected to the same flow areas of cross section. As a result, each mold cavity is simultaneously filled with molten thermoplastic material that has identical physical properties.
    [00041] Figures 6A and 6B schematically illustrate the naturally balanced pipe 60. The naturally balanced pipe 60 of Figures 6A and 6B is a multilevel pipe. Each flow path 74, 76 has identical characteristics at identical locations along the flow path. For example, after junction 72, each flow path narrows the same distance. In addition, each flow path serves an identical number of mold cavities 32. Naturally balanced flow pipes 60 are of critical importance for high pressure injection molding machines, to maintain identical plastic flow properties and to ensure uniform parts .
    [00042] Figures 7A and 7B illustrate another naturally balanced pipe 60. The naturally balanced pipe 60 of Figures 7A and 7B is a multilevel pipe.
    [00043] In contrast, Figures 8, 9A, and 9B illustrate unnaturally balanced pipes, with Figure 8 illustrating an artificially balanced pipe and Figures 9A and 9B illustrate unbalanced pipes.
    [00044] The injection molding machine at constant low pressure, presented in this document, allows artificially balanced pipes, and even unbalanced pipes, to be used due to the fact that thermoplastic materials injected at constant low pressure are not as sensitive to pressure differences or shear differences due to differences in flow channel characteristics. In other words, thermoplastic materials injected at constant low pressure retain almost identical material and flow properties, regardless of differences in length, cross-sectional area or flow channel temperature. As a result, the mold cavities can be loaded sequentially, instead of simultaneously.
    [00045] The artificially balanced tubing 160 of Figure 8 includes a sprayer 62, a first flow channel 174, and a second flow channel 176. The first flow channel 174 ends at a first port 178a and the second flow channel 176 ends at a second port 178b. The first flow channel 174 is shorter than the second flow channel 178 in this embodiment. Artificially balanced tubing 160 varies in other flow channel parameters (e.g., cross-sectional area or temperature), so that the material flowing through tubing 160 provides balanced flow to each cavity, similar to a naturally balanced tubing. In other words, the thermoplastic material flowing through the first flow channel 174 will have a melt pressure approximately equal to the thermoplastic material flowing through the second flow channel 176. As artificially balanced, or unbalanced, feed flow pipes can including flow channels of different lengths, an artificially balanced or unbalanced feed flow pipe can make much more effective use of space. In addition, the supply flow channels and corresponding heater band channels can be machined more efficiently. In addition, naturally balanced feed flow lines are limited to molds that have distinct even numbers of mold cavities (eg 2, 4, 8, 16, 32, etc.). Artificially balanced, and unbalanced, flow pipelines can be designed to deliver molten thermoplastic material to any number of mold cavities.
    [00046] The artificially balanced feed flow tubing 160 can also be constructed from a material that has high thermal conductivity to enhance the heat transfer to the thermoplastic material melted into hot springs, thereby enhancing the flow of the thermoplastic material. More specifically, the artificially balanced feed flow line 160 can be constructed from the same material as the mold to further reduce material costs and accentuate heat transfer within the entire system.
    [00047] Figures 9A and 9B illustrate unbalanced pipes 260. Unbalanced pipes 260 may include an odd number of mold cavities 232, and / or flow channels that have different shapes in cross section, different number and type of turns , and / or the different temperatures. In addition, unbalanced pipes 260 can feed mold cavities that have different sizes and / or shapes, as shown in Figure 9B. Testing methods for drilling and grinding machining capacity index
    [00048] The drilling and grinding machining capacity indices mentioned above in Table 1 were determined by testing representative materials in carefully controlled test methods, which are described below.
    [00049] The machining capacity index for each material was determined by measuring the spindle load required to drill or grind a piece of material with all other conditions of the machine (for example, stock feed rate, spindle rpm , etc.) being kept constant between the various materials. The spindle load is reported as a ratio of the spindle load measured to the maximum spindle torque load of 101.7 Nm (75 ft-lb) at 1,400 rpm for the drilling or grinding device. The percentage of the index was calculated as a ratio between the spindle load for 1117 steel and the spindle load for the test material.
    [00050] The test grinding or drilling machine was a Hass VF-3 Machining Center. Drilling conditions
    Table 2 Grinding conditions
    Table 3
    [00051] For all tests, "flood gust" cooling was used. The refrigerant was Koolrite 2290. EDM machining capacity index test methods
    [00052] The graphite and copper dissipative EDM machining capacity indices, mentioned above in Table 1, were determined when testing representative materials in a carefully controlled test method, which is described below.
    [00053] The EDM machining capacity index for the various materials was determined by measuring the time it took to burn an area (details below) on the various test metals. The percentage of machining capacity index was calculated as the ratio between the time it took to burn on 1117 steel and the time needed to burn the same area on the other test materials. EDM wire
    Table 4 EDM heatsink - graphite
    Table 5 EDM heatsink - copper
    Table 6
    [00054] The injection molding machines at constant low pressure presented advantageously use molds constructed from easily machined materials. As a result, the injection molding machines at constant low pressure presented are less expensive and faster to produce. In addition, the injection molding machines at constant low pressure presented are capable of employing more flexible support structures and more adaptable release structures, such as wider print roll widths, greater fixing bar spacing, elimination of fixing bars , lighter weight construction to facilitate faster movements, and unnaturally balanced feeding systems. In this way, the injection molding machines at constant low pressure can be modified to suit release needs and are more easily customized for particular molded parts.
    [00055] It should be noted that the terms "substantially", "about" and "approximately", unless otherwise specified, can be used in the present invention to represent the inherent degree of uncertainty that can be attributed to any comparison, value, measurement, or other quantitative representation. These terms are also used in the present invention to represent the degree to which a quantitative representation can vary from a stated reference without resulting in a change in the basic function of the subject in question. Unless otherwise defined in this document, the terms "substantially", "about" and "approximately" mean a comparison, value, measurement, or other quantitative representation that may be within 20% of the reference cited.
    [00056] It should now be apparent that the various modalities of the products illustrated and described in this document can be produced by an injection molding process at constant low pressure. Although particular reference has been made in this document to products to contain consumer products or to consumer products themselves, it should be apparent that the constant low pressure injection molding method discussed in this document may be suitable for use in conjunction with products for use in the consumer products industry, the food service industry, the transportation industry, the medical industry, the toy industry, and the like. In addition, the person skilled in the art will recognize that the teachings presented in this document can be used in the construction of stack molds, molds of multiple materials, including rotational and core rear molds, in combination with mold decoration, insert element molding, mold assembly, and the like. In addition, the person skilled in the art will recognize that the teachings presented in this document can be used in the construction of stack molds, molds of multiple materials, including rotational and core rear molds, in combination with mold decoration, insert element molding, mold assembly, and the like.
    [00057] All documents cited in the Detailed Description of the Invention are, in their relevant part, incorporated herein by way of reference. The citation of any document should not be interpreted as an admission that it represents prior art with respect to the present invention. If any meaning or definition of a term in this written document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this written document will take precedence.
    [00058] Although particular modalities have been illustrated and described in this document, it should be understood that several other changes and modifications can be made without deviating from the character and scope of the subject claimed. Furthermore, although several aspects of the claimed subject have been described in this document, such aspects need not be used in combination. Therefore, the attached claims are intended to cover all such changes and modifications that are within the scope of the claimed subject.
    权利要求:
    Claims (2)
    [0001]
    1. Injection molding apparatus (10) including: a support for molten material (12) for pressurizing molten plastic (24) prior to injection into a mold (28) having a plurality of mold cavities (32); an injection element (12) for applying force to the molten plastic to advance the molten plastic from the molten material support through a nozzle (26) and to the mold; a sensor (52) in dynamic communication with the molten material support to feel a pressure of the molten plastic in the nozzle; and wherein the apparatus further comprises: a controller (50) in communication with the sensor and the injection element, wherein the controller is configured to control the injection element to maintain a substantially constant melting pressure entering at least one cavity less than 41.37 MPa (6000 psi) in the nozzle, where the substantially constant pressure fluctuates less than 30% during filling, characterized by the fact that the mold has an average thermal conductivity greater than 51.9 W / (m * C) (30 BTU / HR FT ° F) and the mold has at least one of a grinding machining index greater than 100%, a drilling machining index greater than 100%, and a EDM wire machining index greater than 100%, and the at least one mold cavity in the plurality of mold cavities is a thin wall mold cavity having an L / T> 100.
    [0002]
    2. Injection molding apparatus according to claim 1, characterized in that the controller is configured to control the injection element to keep the melting pressure substantially constant, wherein the substantially constant pressure fluctuates less than 20 %.
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    同族专利:
    公开号 | 公开日
    JP5824143B2|2015-11-25|
    EP2709813A1|2014-03-26|
    EP2709813B1|2018-10-03|
    BR112013029695A2|2017-01-17|
    AU2012259036B2|2016-04-14|
    RU2013151838A|2015-06-27|
    JP2015520050A|2015-07-16|
    US20120328724A1|2012-12-27|
    PH12014502589A1|2015-01-12|
    CA2836783A1|2012-11-29|
    KR20140001251A|2014-01-06|
    US10076861B2|2018-09-18|
    RU2573483C2|2016-01-20|
    MX2013013589A|2014-01-08|
    CN103547430A|2014-01-29|
    US20120294963A1|2012-11-22|
    CA2836783C|2017-02-21|
    BR112014028693A2|2017-06-27|
    WO2012162218A1|2012-11-29|
    AU2012259036A1|2013-12-19|
    JP2014517784A|2014-07-24|
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    法律状态:
    2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-11-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-04-07| B25A| Requested transfer of rights approved|Owner name: IMFLUX, INC. (US) |
    2020-07-07| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-11-10| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 21/05/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201161488564P| true| 2011-05-20|2011-05-20|
    US61/488,564|2011-05-20|
    PCT/US2012/038774|WO2012162218A1|2011-05-20|2012-05-21|Apparatus and method for injection molding at low constant pressure|
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