ProFoam注塑成型 - Vogel · ProFoam注塑成型 /ProFoam injection moulding 非传统的热塑性塑料物理发泡 Alternative to physical foaming of thermoplastics . Presentation

ProFoam注塑成型/ProFoam injection moulding

非传统的热塑性塑料物理发泡 Alternative to physical foaming of thermoplastics

Presentation selection


目录/Agenda

•原理/Fundamentals

•工艺-机器设备细节/Process-specific machine equipment

•玻纤增强的发泡注塑件/Foamed moulded parts with fibre reinforcement

•总结/Summary

2 © Copyright by ARBURG 2015


原理/Fundamentals

发泡注塑成型过程/Procedure during foam injection moulding


注射单元/Injection unit

混合/Mixing

模具/Mould

单相熔体 Homogeneous

solution 扩散/Diffusion

气泡成核 Nucleation

气泡核膨涨泡体固化

Cell growth fixing 发泡剂

Blowing agent

+

塑料/Plastic

加料/Loading

源自:IKV-塑料工艺学院/Source: IKV – Institute for Plastics Processing

原理/Fundamentals

结果:注塑件微观晶核结构/Result: Minute cell structures in the moulded part


原理/Fundamentals

发泡注塑成型的明显优势/Foam injection moulding offers clear advantages


+ • 减少缩痕,变形和内应力区域 Reduction of sink marks, distortion and areas of internal tension

• 减重/Weight savings

• 降低流动粘度/Reduced viscosity

• 更低的熔融温度,锁模力,注射压力 Lower melt temperature, locking force, injection pressure

• 可做不均匀壁厚的产品 Different wall thicknesses possible

• 降低循环时间/Cycle time reduction

- • 表面白花条纹 Streaky surfaces

• 机械强度可能下降 Possible reduction in mechanical properties

发泡的/foamed

发泡的/foamed

原理/Fundamentals

发泡注塑成型的要求/Requirements for foam injection moulding


注塑件 Moulded part

• 允许表面有白花*或者侵蚀现象 Streaky* or eroded surfaces permissible

• 允许机械性能*下降 Reduction of mechanical properties* permissible

• 厚壁特别厚时:冷却时间大大加长-过短的冷却时间会造成“起泡”现象 In the case of greater wall thicknesses: extreme increase in cooling time – subsequent “foaming” in the case of excessively short cooling time

模具 Mould

• 开放的热流道不可用 No open hot runners possible

• 排气好-不困气 Good ventilation – no air inclusions

• 良好的冷却/温度控制-特别是模仁附近Good cooling/temperature control – particularly in the vicinity of cores

* 程度取决于相应的件重多少/Extent depending on the relevant weight reduction

工艺-机器设备细节

Process-specific machine equipment

ProFoam注塑成型配置/Setup for ProFoam injection moulding

特点:简单并且有效的发泡技术/Characteristics: Simple and efficient foaming technology


注射单元中普通的3区段螺杆 Injection unit with normal three-zone screw

针阀式开关喷嘴 Needle-type shut-off nozzle

液体发泡剂 (N2 or CO2) Liquid propellant

(N2 or CO2)

专利的颗粒锁 Patented granulate lock

额外密封 Additional seal

液体发泡剂已经加到塑料粒子中 Liquid propellant is already added to the plastic granules

专利的颗粒锁/Patented granulate lock

连续供应材料和发泡剂 Provides a continuous supply of material and liquid propellant

工艺-机器设备细节 Process-specific machine equipment


储存仓 Storage chamber

密封舱/Lock chamber

• 恒定的发泡剂压力-注射单元中亦然 Constant blowing agent atmosphere– also in the injection unit

• 材料颗粒和气体混合 Granulate and melt are mixed with gas

供料 Material feed

材料从环境压力转移到发泡剂压力 Material is transferred from ambient pressure to blowing agent atmosphere

独立的颗粒密封锁控制器/Separate controller for granulate lock

•通过PIO集成到SELOGICA控制器 Integrated in SELOGICA via a programmable input/output

•颗粒密封锁灵活应用于各种 ALLROUNDER上 Flexible use of the granulate lock on several ALLROUNDERs

•操作简单 – 只多了一个发泡剂压力设定参数 Simple operation – only one additional setting parameter for blowing agent pressure

工艺-机器设备细节 Process-specific machine equipment


纤维增强的发泡产品 Foamed moulded parts with fibre reinforcement

可以提高的潜力/Possible improvement potential

In产品中添加长纤维来增加强度/creased strength through the use of longer fibres in the part


源自:Thomason和Vlug-纤维长度的的影响(PP/GF重量)/Source: Thomason and Vlug – Influence of fibre length (PP/GF qualitative)

标准

材料

特性

/Sta

ndar

dise

d m

ater

ial c

hara

cter

istic

s

纤维长度/Fibre length [mm] 0,1 1 0

0,2

0,6

0,8

1

10 100

0,4 刚度/Rigidity

韧性/Toughness

强度/Strength

GF-PP LGF-PP


ProFoam产品的弹性性能/Mechanically resilient parts – with ProFoam

较小的剪切能保留更长的纤维/Less shearing and therefore longer fibres in the part

11 © Copyright by ARBURG 2015 来自: SABIC

纤维

长度

/Fib

re le

ngth

[mm

]*

6.25

50 100

ProFoam发泡

致密材料/compact

150 250 300 200 纤维数量/Number of fibres

7.25

8.25

9.25

10.25

11.25

12.25

0

• 较小的熔体粘度/Less melt viscosity

• 标准的螺杆造型,无混炼头 Standard screw geometry without mixer


ProFoam产品的弹性性能/Mechanically resilient parts – with ProFoam


源自:SABIC/*纤维初始长度12.5mm(材料颗粒长度)/Source: SABIC / * Initial length of fibres 12.5 mm (granule length)

穿透能量/Puncturing energy [J/mm] 平均纤维长度/Mean fibre length [mm]*

0

4

1

3

2

0 减重/Weight reduction [%]

20 30 0

4

1

3

2

LGF-PP 20%

LGF-PP 30%

LGF-PP 40%

ProFoam发泡

致密材料/compact

应用案例/Examples of applications

气囊外壳/Airbag housing

减重要归功于ProFoam/Reduction in weight thanks to ProFoam


0

400

330 g

100

300

200

[g]

272 g

18%

致密产品Compact

ProFoam发泡

车载外壳/Kinematic housing

减重要归功于ProFoam/Reduction in weight thanks to ProFoam



致密产品Compact

ProFoam发泡

0

450

414 g

150

300

[g]

361 g

13%


车载外壳/Kinematic housing

发泡结构的计算机断层扫描/Computer tomogram of the foam structure


产品外层仍是致密材料 Outer layer of the component remains Compact

产品中增强的长纤维 Long fibres maintained in the part

产品中心均匀的发泡结构 Homogeneous foam structure in the centre of the part

ProFoam注塑成型提供新的选择性 ProFoam injection moulding offers new possibilities

•简单且有效的技术/Simple and efficient technology

- 机器可不受限制用作传统注塑生产 Machine can be used for compact injection moulding without limitation

- 仅增加一个液体发泡剂压力的设定参数 Just one additional setting parameter for liquid propellant pressure

•无损伤的工艺用作: Non-damaging processing of

- 热敏感塑料/thermally sensitive plastics

- 纤维增强塑料/fibre-reinforced plastics

•特别均匀的发泡结构 Extremely homogeneous foam structure

16

总结/Summary

© Copyright by ARBURG 2015

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非传统的热塑性塑料物理发泡/Alternative to physical foaming of thermoplastics


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Documents

ProFoam注塑成型 - Vogel · ProFoam注塑成型 /ProFoam injection moulding 非传统的热塑性塑料物理发泡 Alternative to physical foaming of thermoplastics . Presentation