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Ultrasonic-assisted molding of precisely-shaped articles and methods

A technique for moulding, moulding articles, applied in the field of ultrasonic assisted injection moulding

Inactive Publication Date: 2013-12-11
3M INNOVATIVE PROPERTIES CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Molding and subsequent machining and handling of molded articles with delicate structures formed in or on them can be challenging

Method used

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  • Ultrasonic-assisted molding of precisely-shaped articles and methods
  • Ultrasonic-assisted molding of precisely-shaped articles and methods
  • Ultrasonic-assisted molding of precisely-shaped articles and methods

Examples

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example 1

[0158] Example 1 illustrates a presently preferred embodiment of the present disclosure, determined under the following conditions:

[0159] 1.45% (0.35 mil or 8.75 microns peak-to-peak) of sonotrode amplitude

[0160] 2.20 seconds ultrasonic time

[0161] 3.70 seconds heating time

[0162] 4.115 seconds heater delay time

[0163] Acrypet WF-100 (Test 1) and Arkema V825-100 (Test 2) were used separately in this example.

[0164] Figure 5A is an exemplary process time diagram for an ultrasonic assisted molding process according to certain embodiments of the present disclosure. Figure 5A The timing charts shown in describe the times for delaying the application of ultrasonic vibrational energy and delaying the application of electrical energy to a resistive cartridge heater. When the two halves of the mold are closed, a proximity switch is used to pre-trigger the ultrasonic horn to apply ultrasonic vibration energy to the mold. By closing the switch when the two halves o...

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Abstract

An ultrasonic-assisted injection molding system and method for making precisely- shaped articles. A source of ultrasonic energy is positioned to apply vibrational energy to a mold cavity connected to at least one gate in flow communication with a source of molten (co)polymer. The mold is heated to a temperature of 104-116 DEG C, and the molten (co)polymer is injected into the mold cavity. After cooling the mold until the molten (co)polymer within the gate has solidified, ultrasonic energy is applied to the mold without remelting the solidified (co)polymer within the gate until the temperature increases to 116-122 DEG C, thereby substantially relieving flow induced stresses. The mold is then cooled until the temperature decreases to 101-107 DEG C, and is thereafter heated until the temperature increases to 116-122 DEG C, thereby substantially relieving any thermally induced stresses. The mold is cooled until the molten (co)polymer has solidified, thereby forming a precision molded plastic optical element.

Description

[0001] Cross references to related patent applications [0002] This application claims the benefit of US Provisional Patent Application No. 61 / 452,925, filed March 15, 2011, the disclosure of which is incorporated herein by reference in its entirety. technical field [0003] The present disclosure relates to ultrasonic-assisted molding methods and related precisely-shaped molded articles, and more particularly to ultrasonic-assisted injection molding methods for making precisely-shaped optical components. Background technique [0004] Moldings are well known and widely used. Molding and subsequent machining and handling of molded articles having delicate structures formed in or on them can be challenging. Injection molding of small precision parts is usually accomplished by injecting molten (co)polymer into the mold cavity, applying additional heat to the molten (co)polymer while the molten (co)polymer is in the mold cavity. (co)polymer enough time for the molten (co)pol...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B29C45/78B29C45/72
CPCB29C45/0025B29C45/568B29C45/7207B29C45/73B29C2045/7393B29L2011/00B29C45/72B29C45/78C08F220/06
Inventor 斯坦利·伦登丹尼斯·E·弗格森唐纳德·L·泊察尔特约瑟夫·S·沃纳蒂莫西·J·罗韦尔彼得·T·本松萨蒂德尔·K·纳亚尔
Owner 3M INNOVATIVE PROPERTIES CO