空调座盖塑件模内装饰成型工艺与模具设计  

In mold decoration molding process and mould design for air-conditioning seat-cover

作　　者：谢茂青 王雷刚[2] XIE Maoqing;WANG Leigang(Hangzhou Polytechnic,Hangzhou 311402,China;School of Materials Science and Engineering,Jiangsu University,Zhenjiang 212013,China)

机构地区：[1]杭州科技职业技术学院,杭州311402 [2]江苏大学材料科学与工程学院,江苏镇江212013

出　　处：《工程塑料应用》2024年第8期117-125,共9页Engineering Plastics Application

基　　金：2024年度浙江省软科学研究项目(2024C35071);2024年度杭州市软科学研究项目(20240834M05)。

摘　　要：针对空调座盖采用塑件模内装饰(IMD)方式进行成型的要求,为其设计了一种基于高压成型3D膜片镶件的IMD成型工艺用于该塑件的成型。工艺中,IMD塑件的保护层3D膜片镶件使用0.25 mm聚甲基丙烯酸甲酯(PMMA)薄膜高压压制+真空吸附3D成型,内衬使用聚碳酸酯/丙烯腈-丁二烯-苯乙烯共聚物(PC/ABS)合金注塑成型。所设计的IMD工艺路径包括9道工序。其中3D膜片镶件高压成型模具为一种模具闭合后具备膜片上表面高压压制和下表面真空吸附能力的双作用成型凸模,对应的高压成型工艺参数为:成型压力(35±1)Kg/保压时间(7.0±1)s/模具温度183℃。内衬的注塑成型中,内衬注塑模具为一种两板式单浇口热流道倒装模具,3D膜片镶件在型腔镶件内的定位依靠2个定模限位滑块进行定位,塑件的脱模由倒装模具动模内设置的2个油缸驱动推板及其上的10个斜顶和14根顶针共同顶出来实现。运用CAE软件Moldflow中“重叠注塑”分析序列对内衬的注塑成型进行了内衬/3D膜片镶件之间的重叠注塑成型仿真优化分析,优化结果为:内衬模腔注塑时,热浇口直径取Ø4 mm,模温79℃,熔料温度260℃,注塑压力90 MPa,保压分4段保压,分别为40 MPa-2 s/30 MPa-2 s/15 MPa-2 s/10 MPa-1.5 s。Aimed at the requirement of using plastic in-mold decoration(IMD)for the molding of an air-conditioning seatcovers,IMD molding process based on high-pressure forming 3D-film-insert was designed for the molding of this IMD plastic part.In the process,the protective layer 3D-film-insert of IMD plastic parts was formed by high-pressure pressing and vacuum adsorption 3D molding of 0.25 mm polymethyl methacrylate(PMMA)film,and the inner lining was formed by injection molding of polycarbonate/acrylic nitrile butadiene styrene copolymer(PC/ABS)alloy.The designed IMD process path includes 9 processes.The designed high-pressure molding mold for 3D-film-insert is a double acting convex mold that has the ability of high-pressure pressing on the upper surface of the film and vacuum adsorption on the lower surface after the mold is closed.The corresponding highpressure molding process parameters are:molding-pressure(35±1)kg/holding-time(7.0±1)s/mold-temperature183℃.In the injection molding of the inner lining,the inner lining injection mold is a two-plate single-gate hot-runner inverted mould.The positioning of the 3D-film-insert in the mould cavity is achieved by two fixed mould limit-sliders.The demoulding of the plastic part is achieved by driving the ejector plate,10 lifters,and 14 ejectors together with two hydraulic-cylinders set in the moving mold of the inverted mold.The simulation optimization analysis of overlapping injection molding between inner lining/3D-film-insert was carried out by using CAE software Moldflow“Overlap Injection Molding”analysis sequence for the injection molding of the inner lining.The optimization results show that during the injection molding of the inner lining cavity,the diameter of the hot-gate is taken asØ4 mm,the mould temperature was 79℃,the melt temperature is 260℃,the injection pressure is 90 MPa,and the pressure is maintained in four stages,which are 40 MPa-2 s/30 MPa-2 s/15 MPa-2 s/10 MPa-1.5 s,respectively.

关 键 词：空调座盖 IMD/IMF 膜片高压成型 重叠注塑CAE分析 IMD注塑模 聚甲基丙烯酸甲酯 聚碳酸酯/丙烯腈-丁二烯-苯乙烯共聚物 

分 类 号：TG243[金属学及工艺—铸造]