气辅注射成型技术

氣輔注塑成型技術,Gas-assisted Injection,Moulding,Technology,短射工藝,Short Shot Process,二次氣體穿透,Secondary Gas,Penetration,熔膠注射,Polymer Injection,主要氣體穿透,Primary Gas,Penetration,型腔部份短射,Partial Shot,in Cavity,氣體注射,Gas Injection,氣體注射,Gas Injection,氣體：大多採用氮氣,Gas :Use Nitrogen,Mostly,氣體穿透熔膠的斷面圖,Cross-section of gas penetration through molten plastic,熔膠,Polymer,Melt,氣體,Gas,塑膠凝結層,Frozen Layer,of Polymer,模壁,Mould Wall,模壁,Mould Wall,氣輔注射成型,Gas-assisted Injection,Moulding,滿射工藝,Full Shot Process,熔膠,注射,Polymer Injection,初始氣體穿透,Initial Gas,Penetration,型腔滿射,“,Full”Shot,in Cavity,氣體注射,Gas Injection,氣體注射,Gas Injection,最終氣體穿透,Final Gas,Penetration,氣體：大多採用氮氣,Gas :Use Nitrogen,Mostly,傳統和氣輔注射成型的壓力分布,傳統注射成型,Conventional Injection,Moulding,氣輔注射成型,Gas-assisted Injection,Moulding,氣輔注射成型的優點,Merits of Gas-assisted,Moulding,低射壓、低鎖模力,Low injection pressure,low clamp force,壓力分布均勻、收縮均勻、殘餘應力低、不易翹曲、尺寸穩定,Even pressure distribution,even shrinkage,lower residual stress,less,warpage,more stable dimensions,消除縮痕、模面再現性高,Elimination of sink marks,better plastic mould surface replication,省塑料，可用強度和價格較低的塑料,Plastic material saving,replacement of stronger&more expensive plastic material,5.,可用強度和價格較低的模具金屬,(,如鋁,),Use of less strong and less expensive mould metal(e.g.aluminum),6.,厚薄件一體成型，減少模具和裝配線數目,Integration of thick and thin parts,less moulds and assembly lines needed,7.,可用較厚的肋、角板等補強件，提高製件剛性，使得製件公稱厚度得以打薄,Use of thicker stiffeners(e.g.ribs,gussets,etc.)which increases part stiffness and makes thinner nominal thickness possible,8.,增加設計自由度,More design flexibility,氣體進口位置,Gas Entrance Locations,經流,道,Through the Runner,直接進製品,Directly in the Part,經噴,嘴,Through the Nozzle,典型問題,Typical Problems,跑道現象,Race tracking effect,氣體穿透不佳,Poor gas penetration,氣體手指現象,Gas fingering,氣體吹穿,Gas blow out,製品表觀,Part surface appearance,跑道現象,Race Tracking Effect,氣體穿透不佳,Poor Gas Penetration,氣體手指現象,Gas Fingering,氣體吹穿,Gas Blow Out,短射法氣輔注射成型設計指南,Short Shot Gas-Assisted Injection,Moulding,Design Guide,選定一,非外觀面作為最後充填區,Select one non-appearance surface as the last filled area.,距離非外觀面最遠處定氣口位置。,Locate gas entrance where is the farthest from a non-appearance surface.,從氣口,(,上游,),到上述非外觀面,(,下游,),順流而下，勻稱的配置氣道以涵蓋整個製品面。,From(upstream)gas entrance to above-mentioned(downstream)non-appearance surface,layout gas channels to cover the whole part surface evenly.,短射法氣輔注射成型設計指南,Short Shot Gas-Assisted Injection,Moulding,Design Guide,氣道儘可能循二或多面交會處或粗厚處行，主氣道以一氣,(,口,),呵成,(,一氣道,),為原則。,Gas channel shall follow a line where two or more surfaces meet or where is thick.Each main gas channel,in principle,shall be penetrated by the gas from a specific gas entrance.,短射法氣輔注射成型設計指南,Short Shot Gas-Assisted Injection,Moulding,Design Guide,以上述非外觀面為最後充填區，定澆口位置。,Locate gates,targeting above-mentioned non-appearance surface as the last filled area.,微調澆口、氣口和氣道位置和尺寸，確保氣貫氣道，但不以鄰為壑。,Fine tune the location and dimensions of gates,gas entrances and gas channels to make sure gas will penetrate to the end,but not permeate to the neighborhood,of the gas channel.,短射法氣輔注射成型設計指南,Short Shot Gas-Assisted Injection,Moulding,Design Guide,氣輔設計原則,Design Principles for Gas -,asist,Mould Design,製品公稱厚度以不小於,2mm,為原則。但有薄到,0.75mm,厚度的氣輔塑件被開發出來。,氣體進口,(Gas Entrance),和澆口,(Gate),距離若大於,25mm,，,Shut-off valve,就不一定要裝。,溢流井的體積,=,流道去掉,23mm,塑膠皮層之斷面積,x,流道長度,2004.4.11.,徐昌煜摘錄自,”,氣體輔助射出成型手冊,“,(,塑膠世界雜誌社譯自日文書刊,)-,氣道,設計原則,Design Principles for Gas Channel Size,Large Channels,Short Gas Penetration,Increase Cycle Time,“Racetrack”Effect,Small Channels,Fingering Into Thin Walls,Uncontrolled Gas Penetration,Properly Sized Channels,Promote Gas Into All Desired Areas With Minimal Thin Wall Penetration,Typically 2-4 Times the Wall Thickness,氣道,設計原則,Design Principles for Gas Channel Size,氣道斷面任何尺寸不可大於,30mm,氣道斷面大小尺寸比應小於,2,氣道寬度一般是高度的,0.5,到,1.5,倍,氣道轉角內圓角半徑以大於,6mm,為原則,實驗表明：經穿透後的氣道壁厚度大約是直徑的,1/3,2004.4.11.,徐昌煜摘錄自,”,氣體輔助射出成型手冊,“,(,塑膠世界雜誌社譯自日文書刊,)-,短射法氣輔注射成型氣,道,尺寸指南,Gas Channel(used in Short Shot Method Gas-assisted Injection,Moulding,)Size Guideline,Poor Design,Good Design,x,2x to 4x,x,2x,Gas Penetration,Gas Penetration,3x,整合薄壁及厚壁的設計,避免閉路式氣道,Avoid Closed Loop Gas Channels,Solid plastic,避免氣道相鄰太近,Avoid Spacing Gas Channels Too Close Together,氣道,相鄰過近氣體會滲透到薄壁中,Gas will“finger”into thinwall areasif gaschannelsare too close together.,Gas,entrance,“Gas fingering”,Courtesy Power Line,mould Engineering,Ltd.,Pressure prior to gas transition for TV Bezel(1/2 model),Low pressure,area,30.00,0.00,7.50,15.00,22.50,Gas penetration for TV Bezel(1/2 model),Gas,entrance,Gas seeks,low pressure,areas,1.0000,0.0190,0.2642,0.5095,0.7547,熔膠前沿,推進,-,原始設計,Melt-front Advancement,Original Design,塑膠皮層比,-,原始設計,Skin-polymer Fraction,Original Design,熔膠前沿,推進,-,更改設計,Melt-front Advancement,Revised Design,塑膠皮層比,-,更改設計,Skin-polymer Fraction,Revised Design,