超厚壁聚合物光学产品多次注射-压缩成形技术研究  

Multilayer Injection-compression Molding Process of Ultra-thick-walled Polymer Optical Products

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作  者:高若翔 焦晓龙 阮剑波 陈豪[1] 周期峰 赵朋[1] GAO Ruo-xiang;JIAO Xiao-long;RUAN Jian-bo;CHEN Hao;ZHOU Qi-feng;ZHAO Peng(School of Mechanical Engineering,Zhejiang University,Hangzhou 310030,China;Haitian Plastic Machinery Co.,Ltd.,Zhejiang Ningbo 315821,China;Hangzhou Yusei Machinery Co.,Ltd.,Hangzhou 311241,China)

机构地区:[1]浙江大学机械工程学院,杭州310030 [2]海天塑机集团有限公司,浙江宁波315821 [3]杭州友成机工有限公司,杭州311241

出  处:《精密成形工程》2023年第9期47-56,共10页Journal of Netshape Forming Engineering

基  金:宁波市科技创新2025重大专项(2021Z044);宁波市科技创新2025重大专项(2023Z029);浙江省“尖兵”“领雁”研发攻关计划(2022C01069)。

摘  要:目的针对聚合物材料在注射成形过程中密度变化大,在成形超厚壁光学产品时容易产生收缩、气泡等缺陷,难以满足高性能成形需求等问题,提出了一种新型多次注射-压缩成形工艺,并研究了成形次数、压缩距离等参数对厚壁光学产品成形形变和双折射的影响规律。方法设计并制造了相应的多次注射-压缩成形模具,将超厚产品分解为若干个薄壁制件,通过连续多次注射可以实现任意厚度与分层方式的产品成形,从而实现厚壁光学产品的成形,最大成形厚度可达100 mm。在此基础上,通过实验对多次注射-压缩成形的关键参数进行了研究。结果多次注射可改变产品的变形形式,由单次注射产品的翘曲形变转变为收缩形变,且形变值减小达70.3%。随着压缩距离的增大,产品形变呈现先减小后增大的趋势,单次注射-压缩成形产品形变值最大可减小32.7%,而多次注射-压缩产品最小收缩形变值仅为未压缩产品的1.1%。此外,与注射成形相比,压缩工艺可以减小产品的双折射,而压缩距离对双折射的影响不显著。结论多次注射可以对单次注射成形缺陷进行补偿。通过注射-压缩成形工艺,可显著减小产品的形变,同时提高光学性能,实现超厚壁光学产品的高性能成形。Due to the large density changes in the injection molding process of polymer materials,defects such as shrinkage and bubbles are prone to occur during molding of ultra-thick-walled optical products,and it is difficult to meet the high-performance molding requirements.For this reason,the work aims to propose a novel multilayer injection-compression molding process and study the effect of injection times,compression distance and other parameters on the deformation and birefringence of thick-walled optical products.A novel multilayer injection-compression mold was designed and manufactured,which de-composed ultra-thick products into several thin-walled parts.Through continuous multilayer injections,the process achieved the molding of products with any desired thicknesses and layering scheme,enabling the fabrication of thick-walled optical products with a maximum thickness up to 100 mm.The key parameters of multilayer injection-compression molding were experimentally studied.Multilayer injections could change the deformation form of the products,from warping deformation of single injection products to shrinkage deformation,and the deformation value was reduced by 70.3%.As the compression distance increased,the deformation of the products presented a trend of decreasing firstly and then increasing.The deformation value of single injec-tion-compression molding products could be reduced by a maximum of 32.7%,while the minimum shrinkage deformation of multilayer injection-compression products was only 1.1%of uncompressed products.In addition,compared with injection molding,the compression process could reduce the birefringence of the products,but the compression distance had no signifi-cant effect on the birefringence.Multilayer injections can realize the compensation for defects in single injection molding.At the same time,through the injection-compression molding process,the deformation of the products can be significantly reduced,and high-performance molding of ultra-thick-walled optical products can be realized.

关 键 词:多次注射 超厚壁产品 注射-压缩 收缩形变 模具设计 

分 类 号:TQ320.66[化学工程—合成树脂塑料工业]

 

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