Manufacturing method of injection-molded receiver net plastic part

Abstract

The invention discloses a method for manufacturing an injection-molded receiver net plastic part, which comprises the following steps of: heating and melting a polymer melt through a feeding structure, injecting the polymer melt into a mold to obtain the receiver net plastic part, and quickly cooling a sound outlet hole of the receiver net plastic part by adopting preset high-temperature circulating liquid cooling in a first cooling stage through dynamic cooling treatment; the rigidity of the micropore area is effectively improved, the problem of micropore structure deformation caused by non-uniform cooling is reduced, polymer melt in the sound outlet hole area can be cured in time through rapid cooling, excessive shrinkage is avoided, and therefore the total shrinkage rate of the sound outlet hole is remarkably reduced; and in the second cooling stage, cold air is sprayed at the preset low temperature to slowly cool the outer surface of the receiver net plastic part, the toughness of the outer layer structure is enhanced, the differentiated cooling modes are accurately regulated and controlled according to different requirements of the inner and outer structures of the receiver net plastic part, uniform distribution of the shrinkage rate in the whole cooling process is achieved, and the product quality is improved. The problem that the overall shrinkage rate is too large due to a traditional cooling mode is effectively solved.

Description

Technical Field

[0001] The invention relates to the technical field of injection molding technology, and in particular to a method for manufacturing an injection-molded receiver net plastic part. Background Art

[0002] Injection molding is a highly efficient plastic parts production method widely used in modern manufacturing, especially in the consumer electronics, automobile, medical equipment and other industries. The injection molding process has been widely recognized for its high precision and high efficiency. In the consumer electronics industry, the receiver mesh plastic parts are an important part of mobile phones, headphones and other devices. Their quality directly affects the acoustic performance and user experience of the equipment. Therefore, the production of receiver mesh plastic parts requires extremely high processing accuracy and reliable control of the microporous structure to ensure that the product has good acoustic permeability and mechanical strength. For injection molded workpieces such as receiver mesh plastic parts, which have multiple sound outlets, the existing technology usually uses a fixed temperature coolant to cool the injection mold as a whole, and then directly exposes the plastic part to the air for natural cooling. However, the fixed temperature coolant cannot perform differentiated treatment on the internal and external structures of the receiver mesh plastic part, resulting in too fast or insufficient cooling of the microporous structure, making it easy for the sound outlet to shrink too much during the cooling process, resulting in too large a shrinkage rate of the receiver mesh plastic part as a whole, which in turn affects its performance and cannot meet high-quality acoustic requirements and cannot adapt to the application needs of high-precision electronic products.

[0003] Therefore, it is necessary to provide a method for manufacturing an injection-molded receiver net plastic part to solve the problem of excessive overall shrinkage rate caused by overall cooling in the injection molding manufacturing process of the receiver net plastic part. Summary of the invention

[0004] The main purpose of the present invention is to provide a method for manufacturing an injection molded receiver mesh plastic part, aiming to solve the technical problems mentioned in the above background technology.

[0005] The present invention adopts the following technical solutions: A method for manufacturing an injection-molded receiver net plastic part, comprising: S100: providing an injection molding device, the injection molding device comprising a feeding structure, a molding nozzle and a mold, the molding nozzle comprising a feeding pipe, a discharging pipe and a transition flow channel portion with controllable length, the feeding pipe being in communication with the feeding structure, the discharging pipe being in communication with the mold, and two ends of the transition flow channel portion being connected to the feeding pipe and the discharging pipe respectively; S200: heating the preset formula mixture to a molten state through the feeding structure to form a molten polymer melt; S300: adjusting the length of the transition flow channel portion to a preset length, and injecting the polymer melt into the mold to obtain a receiver mesh plastic part, wherein the mold is provided with a cavity with a microneedle structure; S400: dynamically cooling the receiver mesh plastic part, including a first cooling stage, rapidly cooling the sound outlet of the receiver mesh plastic part by circulating liquid cooling at a preset high temperature to improve the structural rigidity of the sound outlet, and performing a second cooling stage on the receiver mesh plastic part, spraying cold air on the outer surface of the receiver mesh plastic part at a preset low temperature to slowly cool the outer layer structure to enhance the toughness of the outer layer structure; S500: Obtain the shrinkage rate of the earpiece mesh plastic part after dynamic cooling treatment, and determine whether the shrinkage rate is greater than a preset target. If so, increase the length of the transition flow channel portion, increase the discharge temperature of the feeding structure, and re-mold the earpiece mesh plastic part. If not, perform shaping treatment on the earpiece mesh plastic part after dynamic cooling treatment.

[0006] Further, the preset formula mixture includes PC material and additives, and the additives include acoustic modifiers, impact resistant agents and processing aids; The acoustic modifier is a mixture of one or more of siloxane, phosphate or fatty acid ester compounds; The impact-resistant agent is a mixture of one or more of an acrylic impact-resistant modifier, an ethylene-methacrylic acid copolymer, or a styrene-butadiene-styrene copolymer; The processing aid is a mixture of one or more of dibutyl phthalate, oxidized polyethylene wax or amide wax.

[0007] Furthermore, the step of heating the preset formula mixture to a molten state through the feeding structure to form a molten polymer melt specifically includes: S210: uniformly mixing the PC material in the preset formula mixture with the acoustic modifier, the impact resistant agent and the processing aid to obtain a mixed base material; S220: adding the mixed base material into the feeding structure, wherein the feeding structure is provided with a heating unit and a vacuum degassing unit, and heating the mixed base material to 240° C. to 300° C. by the heating unit to melt the mixed base material and remove initial moisture and volatile impurities; S230: During the heating process, the melt is dynamically stirred at a first preset rotation speed and a first preset frequency to eliminate the temperature difference between the mixed base material particles and form a uniform polymer melt; S240: maintaining the polymer melt at a predetermined temperature for a predetermined time by the heating unit, and stirring the polymer melt at a second predetermined rotation speed and a second predetermined frequency to maintain the flow stability of the polymer melt.

[0008] Furthermore, the step of adjusting the length of the transition channel portion to a preset length and injecting the polymer melt into the mold to obtain the receiver mesh plastic part specifically includes: S310: calculating a preset length of the transition channel portion according to the target structure and material properties of the receiver mesh plastic part, and adjusting the transition channel portion to the preset length through a control device; S320: pushing the molding nozzle to dock the molding nozzle with the inlet of the mold cavity; S330: starting the feeding structure to inject the molten polymer melt into the mold cavity of the mold through the transition flow channel portion and the molding nozzle; S340: After the injection molding is completed, the clamping force of the mold is maintained until the polymer melt is initially cooled and shaped; S350: Pushing out the molding nozzle from the mold cavity entrance of the mold, releasing the mold clamping force of the mold, opening the mold, and taking out the molded receiver net plastic part.

[0009] Further, the control device includes an electric servo system and a temperature sensor, the electric servo system includes a servo motor, a control module and a position sensor, the driving end of the servo motor is connected to the transition flow channel portion, and is used to drive the extension and retraction of the transition flow channel portion, the position sensor is electrically connected to the servo motor, and is used to feedback the current position of the transition flow channel portion, and the control module is electrically connected to the servo motor, and is used to adjust the motion trajectory of the servo motor according to a set preset length; The temperature sensor is disposed outside the transition flow channel portion, and the temperature sensor is electrically connected to the control module.

[0010] Furthermore, step S400 specifically includes: S410: placing the formed receiver mesh plastic part in a cooling treatment system; S420: Entering the first cooling stage, adjusting the cooling treatment system to a preset high temperature, and rapidly cooling the sound outlet of the earpiece mesh plastic part through a circulating liquid cooling system, wherein the liquid cooling system includes a circulating liquid cooling nozzle and a temperature control unit, and the temperature control unit controls the temperature of the coolant sprayed by the circulating liquid cooling nozzle; S430: After the first cooling stage is completed, the second cooling stage is entered, the cooling treatment system is adjusted to a preset low temperature, and the humidity of the cooling treatment system is controlled to a preset range; S440: In the second cooling stage, cold air is sprayed on the outer surface of the receiver mesh plastic part through a cold air multi-point spray system to uniformly and slowly cool it, wherein the cold air multi-point spray system includes a cold air nozzle and a pressure control unit, and the pressure control unit controls the pressure of the cold air sprayed by the cold air nozzle; S450: monitoring the surface temperature of the earpiece mesh plastic part in real time, and stopping spraying cold air when the surface temperature evenly reaches a preset target temperature.

[0011] Furthermore, the step of obtaining the shrinkage rate of the receiver mesh plastic part after the dynamic cooling treatment specifically includes: S510: respectively obtaining a measured weight value of the earpiece mesh plastic part and measured dimensions of the sound outlet hole and the outer structure of the earpiece mesh plastic part; S520: Calculate the deviation between the measured weight value and the standard weight value as the weight shrinkage rate, and calculate the deviation between the measured size and the standard size as the size shrinkage rate; S530: performing weighted processing on the weight shrinkage rate and the size shrinkage rate respectively, and comprehensively calculating the shrinkage rate of the earpiece mesh plastic part.

[0012] Furthermore, the step of shaping the receiver mesh plastic after the dynamic cooling treatment specifically includes: S710: placing the receiver mesh plastic after dynamic cooling in a shaping device, wherein the shaping device includes a temperature control chamber and an airflow regulating unit; S720: slowly heating the receiver mesh plastic part in the shaping device to eliminate its internal stress; S730: After reaching the preset molding temperature, maintaining the preset molding time, and controlling the air flow speed and direction in the molding chamber through the air flow adjustment unit to stabilize the shape of the earpiece mesh plastic part; S740: slowly cooling the receiver mesh plastic part to room temperature to complete the shaping process.

[0013] Further, the mold comprises a cavity component and a core component, the cavity component is provided with the cavity with the microneedle structure, and the core component cooperates with the cavity component to form an injection cavity; The molding nozzle is also provided with a hot runner manifold, which is arranged in the feed pipe and is used to distribute the molten polymer melt to multiple branch ports of the discharge pipe, wherein the branch ports are evenly connected to the injection cavity to allow the polymer melt to flow in evenly.

[0014] The present invention also provides an injection molded receiver mesh plastic part, which is realized by the injection molded receiver mesh plastic part manufacturing method as described in any of the above items, comprising a receiver mesh plastic part body, the upper end surface of the receiver mesh plastic part body is evenly provided with a plurality of through holes, and the upper end surface of the receiver mesh plastic part body is provided with a fillet with a radius of 0.05 mm, and the thickness between the side wall of the receiver mesh plastic part body and the side wall of the through hole is set to 0.1 mm.

[0015] Beneficial effects: In the present invention, after the molten polymer melt is heated by the feeding structure and injected into the mold to obtain the earpiece mesh plastic part, a dynamic cooling treatment is performed. In the first cooling stage, the sound outlet of the earpiece mesh plastic part is quickly cooled by circulating liquid cooling with a preset high temperature, which effectively improves the rigidity of the microporous area and reduces the deformation of the microporous structure caused by uneven cooling. The rapid cooling can solidify the polymer melt in the sound outlet area in time to avoid excessive shrinkage, thereby significantly reducing the overall shrinkage rate at the sound outlet. In the second cooling stage, the outer surface of the earpiece mesh plastic part is slowly cooled by spraying cold air at a preset low temperature, thereby enhancing the toughness of the outer layer structure. The differentiated cooling method is precisely regulated according to the different requirements of the internal and external structures of the earpiece mesh plastic part to achieve a uniform distribution of the shrinkage rate during the overall cooling process, effectively solving the problem of excessive overall shrinkage caused by traditional cooling methods, while avoiding problems such as surface cracks and warping caused by too fast cooling, improving the acoustic performance of the earpiece mesh plastic part, ensuring the dimensional stability and structural integrity of the earpiece mesh plastic part, and better adapting to the application requirements of high-precision electronic products. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic flow chart of a method for manufacturing a receiver net plastic part by injection molding of the present invention; Figure 2 It is a structural schematic diagram of the receiver mesh plastic part of the second embodiment of the present invention.

[0017] Among them: 1. The receiver net plastic body; 2. The through hole; 3. The rounded corner.

[0018] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0019] It should be understood that the specific embodiments described herein are only used to explain the present invention, and are not used to limit the present invention.

[0020] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0021] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0022] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0023] Embodiment 1 Reference Figure 1 The present invention provides a method for manufacturing an injection-molded receiver net plastic part, comprising: S100: providing an injection molding device, the injection molding device comprising a feeding structure, a molding nozzle and a mold, the molding nozzle comprising a feeding pipe, a discharging pipe and a transition flow channel portion with controllable length, the feeding pipe being in communication with the feeding structure, the discharging pipe being in communication with the mold, and two ends of the transition flow channel portion being connected to the feeding pipe and the discharging pipe respectively; S200: heating the preset formula mixture to a molten state through the feeding structure to form a molten polymer melt; S300: adjusting the length of the transition flow channel portion to a preset length, and injecting the polymer melt into the mold to obtain a receiver mesh plastic part, wherein the mold is provided with a cavity with a microneedle structure; S400: dynamically cooling the receiver mesh plastic part, including a first cooling stage, rapidly cooling the sound outlet of the receiver mesh plastic part by circulating liquid cooling at a preset high temperature to improve the structural rigidity of the sound outlet, and performing a second cooling stage on the receiver mesh plastic part, spraying cold air on the outer surface of the receiver mesh plastic part at a preset low temperature to slowly cool the outer layer structure to enhance the toughness of the outer layer structure; S500: Obtain the shrinkage rate of the earpiece mesh plastic part after dynamic cooling treatment, and determine whether the shrinkage rate is greater than a preset target. If so, increase the length of the transition flow channel portion, increase the discharge temperature of the feeding structure, and re-mold the earpiece mesh plastic part. If not, perform shaping treatment on the earpiece mesh plastic part after dynamic cooling treatment.

[0024] In the above embodiment, S100 provides a set of injection molding devices suitable for injection molding of earpiece net plastic parts, which includes a feeding structure, a molding nozzle and a mold. Among them, the feeding structure is used to store and convey a preset formula mixture; the molding nozzle includes a feeding pipe, a discharging pipe and a transition flow channel portion with controllable length. The feeding pipe is connected to the feeding structure and is responsible for receiving and conveying the polymer melt in a molten state; the discharging pipe is connected to the mold and is responsible for injecting the melt into the mold; the transition flow channel portion adjusts the length through an electric servo device to achieve dynamic adjustment of the melt flow path and pressure. A cavity with a microneedle structure is provided in the mold for forming a microporous structure of a sound hole.

[0025] In S200, the preset formula mixture is heated to a molten state through the feeding structure, and the preset formula mixture is added to the feeding structure. The formula mixture may include PC material, acoustic modifier, impact resistant agent and processing aid. The mixture is heated by the heating unit in the feeding structure, and the heating temperature is usually set between 240℃ and 300℃ to ensure uniform melting of the polymer melt. At the same time, a vacuum degassing unit is set in the feeding structure to continuously remove moisture and volatile impurities in the mixture to avoid the impurities from having adverse effects on the microporous structure after molding.

[0026] In S300, the length of the transition flow channel is adjusted, and the polymer melt is injected into the mold. According to the target structure and material properties of the earpiece mesh plastic part, the length of the transition flow channel is adjusted to the preset length by controlling the servo system to optimize the melt flow path. The injection molding equipment is started to inject the molten polymer melt into the cavity in the mold through the discharge pipe of the molding nozzle. The microneedle structure array set in the cavity can directly form the microporous structure of the sound hole during the injection molding process. After the injection molding is completed, the mold clamping force is maintained for a period of time to allow the polymer melt to initially cool and shape in the cavity.

[0027] In S400, the receiver mesh plastic is dynamically cooled. In the first cooling stage, the receiver mesh plastic formed in the mold is placed in a preset high temperature environment (50°C~70°C), and the sound outlet of the receiver mesh plastic is quickly cooled by a circulating liquid cooling system. The circulating liquid cooling system uses a temperature-controllable coolant, and the coolant temperature is maintained within a preset range by a control unit. Rapid cooling improves the structural rigidity of the sound outlet and reduces the thermal stress and shrinkage rate of the microporous area. Second cooling stage: After the first cooling, the receiver net plastic parts are transferred to the low temperature cooling area, and the outer surface of the plastic parts is slowly cooled by the cold air multi-point injection system. The cold air temperature is controlled at 10℃~20℃, and the pressure and angle of the injection system are adjusted to ensure that the outer layer structure is cooled evenly, thereby enhancing its toughness and avoiding surface cracks or warping.

[0028] The shrinkage rate after dynamic cooling treatment is obtained in S500. After cooling is completed, the key parameters of the receiver net plastic part are measured using a measuring tool (such as a micrometer or an electronic scale). The total weight, sound hole diameter, outer layer thickness and other dimensional data are measured respectively, and the actual weight shrinkage rate and dimensional shrinkage rate are calculated. According to the preset weighted model, these shrinkage rates are comprehensively calculated to obtain the overall shrinkage rate of the receiver net plastic part.

[0029] If the shrinkage rate is greater than the preset target, adjust the process parameters and re-mold. If the shrinkage rate of the earpiece net plastic part is greater than the preset target, the injection molding process parameters need to be adjusted, including extending the length of the transition runner to increase the stability of the melt flow, and appropriately increasing the discharge temperature of the feeding structure to enhance the melt fluidity. After the adjustment is completed, re-injection molding to optimize product quality.

[0030] If the shrinkage rate is less than or equal to the preset target, the shaping process is carried out. If the shrinkage rate of the earpiece net plastic part is less than or equal to the preset target, it is placed in the shaping device for shaping. First, the plastic part is slowly heated to eliminate the internal residual stress, then kept at the preset shaping temperature for a certain period of time, and finally slowly cooled to room temperature to complete the shaping process to ensure the structural stability and dimensional accuracy of the plastic part.

[0031] Furthermore, after the molten polymer melt is heated by the feeding structure and injected into the mold to obtain the earpiece mesh plastic part, a dynamic cooling treatment is performed. In the first cooling stage, the sound outlet of the earpiece mesh plastic part is quickly cooled by circulating liquid cooling with a preset high temperature, which effectively improves the rigidity of the microporous area and reduces the deformation of the microporous structure caused by uneven cooling. The rapid cooling can solidify the polymer melt in the sound outlet area in time to avoid excessive shrinkage, thereby significantly reducing the overall shrinkage rate at the sound outlet. In the second cooling stage, the outer surface of the earpiece mesh plastic part is slowly cooled by spraying cold air at a preset low temperature, thereby enhancing the toughness of the outer structure. The differentiated cooling method is precisely regulated according to the different requirements of the internal and external structures of the earpiece mesh plastic part to achieve a uniform distribution of the shrinkage rate during the overall cooling process, effectively solving the problem of excessive overall shrinkage caused by traditional cooling methods, while avoiding problems such as surface cracks and warping caused by too rapid cooling, improving the acoustic performance of the earpiece mesh plastic part, and ensuring the dimensional stability and structural integrity of the earpiece mesh plastic part, so as to better meet the application requirements of high-precision electronic products.

[0032] In one embodiment, the predetermined formula mixture includes PC material and additives, wherein the additives include an acoustic modifier, an impact resistant agent, and a processing aid; The acoustic modifier is a mixture of one or more of siloxane, phosphate or fatty acid ester compounds; The impact-resistant agent is a mixture of one or more of an acrylic impact-resistant modifier, an ethylene-methacrylic acid copolymer, or a styrene-butadiene-styrene copolymer; The processing aid is a mixture of one or more of dibutyl phthalate, oxidized polyethylene wax or amide wax.

[0033] In this embodiment, it is further specified that the preset formula mixture includes PC material and additives, and the additives include acoustic modifiers, impact resistant agents and processing aids; PC material is used as the main carrier of the earpiece mesh plastic part, and the additives can optimize various performances.

[0034] The acoustic modifier is a mixture of one or more of siloxane, phosphate or fatty acid ester compounds, which can effectively improve the acoustic properties of the receiver mesh plastic, reduce noise, and enhance the clarity and fidelity of sound. By precisely controlling the ratio of siloxane, phosphate or fatty acid ester compounds, the adjustment of sound propagation characteristics can be further refined to achieve the best hearing effect.

[0035] The impact-resistant agent is a mixture of one or more of acrylic impact-resistant modifiers, ethylene-methacrylic acid copolymers or styrene-butadiene-styrene copolymers. These impact-resistant agents can significantly improve the impact resistance of the receiver mesh plastic parts, making them less likely to be damaged when impacted by external forces, thereby extending the service life of the product.

[0036] The processing aid is a mixture of one or more of dibutyl phthalate, oxidized polyethylene wax or amide wax. These additives help to improve the fluidity and processing performance of plastics, reduce energy consumption during injection molding, reduce mold wear, and improve production efficiency and product quality.

[0037] In one example, the step of heating the preset formula mixture to a molten state through the feeding structure to form a molten polymer melt specifically includes: S210: uniformly mixing the PC material in the preset formula mixture with the acoustic modifier, the impact resistant agent and the processing aid to obtain a mixed base material; S220: adding the mixed base material into the feeding structure, wherein the feeding structure is provided with a heating unit and a vacuum degassing unit, and heating the mixed base material to 240° C. to 300° C. by the heating unit to melt the mixed base material and remove initial moisture and volatile impurities; S230: During the heating process, the melt is dynamically stirred at a first preset rotation speed and a first preset frequency to eliminate the temperature difference between the mixed base material particles and form a uniform polymer melt; S240: maintaining the polymer melt at a predetermined temperature for a predetermined time by the heating unit, and stirring the polymer melt at a second predetermined rotation speed and a second predetermined frequency to maintain the flow stability of the polymer melt.

[0038] In the above embodiment, a mixed base material is obtained in S210. The heating unit of the feeding structure described in S220 can be electrically heated or oil heated to ensure that the mixed base material can be uniformly and effectively heated to a molten state. The vacuum degassing unit removes bubbles and volatile impurities generated during the melting process by vacuuming to ensure the quality of the final product.

[0039] The dynamic stirring mentioned in S230 is achieved by a specific stirring device, which can automatically adjust the rotation speed and frequency according to the viscosity and temperature of the melt to ensure that the temperature difference between the mixed base material particles is effectively broken, thereby obtaining a uniform polymer melt.

[0040] The preset holding time in S240 is to allow the polymer melt to achieve sufficient thermal stability and flow stability without degradation. The stirring of the second preset rotation speed and the second preset frequency helps to maintain the homogeneous state of the melt and prevent stratification or crystallization due to uneven temperature or long-term standing.

[0041] In the above embodiment, the mixing process of the mixed base material in S210 is crucial because it directly affects the performance of the final product. The mixing process needs to be carried out in a dust-free and constant temperature environment to avoid any possible contamination or temperature fluctuations that may affect product quality.

[0042] In one embodiment, further specific description is given, the step of adjusting the length of the transition flow channel portion to a preset length and injecting the polymer melt into the mold to obtain the receiver mesh plastic part specifically includes: S310: Calculate the preset length of the transition channel portion according to the target structure and material properties of the earpiece mesh plastic part, and adjust the transition channel portion to the preset length through the control device; when calculating the preset length, the control module will comprehensively consider factors such as the geometric dimensions of the earpiece mesh plastic part, the flow characteristics of the material, and the cooling efficiency of the mold to ensure that the final product meets the design requirements.

[0043] S320: Pushing the molding nozzle to dock the molding nozzle with the mold cavity entrance of the mold; the docking of the molding nozzle with the mold cavity entrance needs to be precisely controlled to avoid melt leakage or plastic part defects caused by position deviation.

[0044] S330: Start the feeding structure to inject the molten polymer melt into the mold cavity through the transition flow channel and the molding nozzle; after the feeding structure is started, the control module will monitor the injection pressure and speed of the melt in real time to ensure that the melt can smoothly pass through the transition flow channel and the molding nozzle and be evenly filled into the mold cavity.

[0045] S340: After the injection molding is completed, the clamping force of the mold is maintained until the polymer melt is initially cooled and shaped; S350: Pushing out the molding nozzle from the mold cavity entrance of the mold, releasing the mold clamping force of the mold, opening the mold, and taking out the molded receiver net plastic part.

[0046] In one embodiment, the control device includes an electric servo system and a temperature sensor, the electric servo system includes a servo motor, a control module and a position sensor, the driving end of the servo motor is connected to the transition flow channel portion, and is used to drive the extension and retraction of the transition flow channel portion, the position sensor is electrically connected to the servo motor, and is used to feedback the current position of the transition flow channel portion, and the control module is electrically connected to the servo motor, and is used to adjust the motion trajectory of the servo motor according to a set preset length; The temperature sensor is disposed outside the transition flow channel portion, and the temperature sensor is electrically connected to the control module.

[0047] In the above embodiment, the temperature sensor is used to monitor the temperature of the transition flow channel in real time to ensure that the temperature of the polymer melt is kept within an appropriate range during the injection molding process to prevent the melt from being overheated or insufficiently cooled, thereby affecting the quality of the plastic part. In addition, the control module is also electrically connected to the feeding structure and can automatically adjust the feeding speed and pressure according to the temperature and position information of the transition flow channel to ensure uniformity and consistency when the melt is injected into the mold cavity.

[0048] In one embodiment, step S400 specifically includes: S410: placing the formed receiver mesh plastic part in a cooling treatment system; S420: Entering the first cooling stage, adjusting the cooling treatment system to a preset high temperature, and rapidly cooling the sound outlet of the earpiece mesh plastic part through a circulating liquid cooling system, wherein the liquid cooling system includes a circulating liquid cooling nozzle and a temperature control unit, and the temperature control unit controls the temperature of the coolant sprayed by the circulating liquid cooling nozzle; S430: After the first cooling stage is completed, the second cooling stage is entered, the cooling treatment system is adjusted to a preset low temperature, and the humidity of the cooling treatment system is controlled to a preset range; S440: In the second cooling stage, cold air is sprayed on the outer surface of the receiver mesh plastic part through a cold air multi-point spray system to uniformly and slowly cool it, wherein the cold air multi-point spray system includes a cold air nozzle and a pressure control unit, and the pressure control unit controls the pressure of the cold air sprayed by the cold air nozzle; S450: monitoring the surface temperature of the earpiece mesh plastic part in real time, and stopping spraying cold air when the surface temperature evenly reaches a preset target temperature.

[0049] In S410, the cooling treatment system may be a continuous cooling system having a plurality of cooling zones, and each cooling zone may independently control temperature and humidity to meet cooling requirements at different stages.

[0050] In S420, the preset high temperature is usually set between 50°C and 100°C to ensure that the earpiece mesh plastic part is cooled down quickly in a short time, thereby reducing the generation of internal stress.

[0051] In S430, the preset low temperature is generally lower than the room temperature, for example, between 10°C and 25°C, to further stabilize the size and shape of the plastic part. At the same time, humidity control is to prevent condensation on the surface of the plastic part due to rapid cooling, which affects the appearance and quality of the plastic part.

[0052] In the S440, the cold air multi-point injection system is designed to achieve uniform cooling of the outer surface of the receiver net plastic part. By precisely controlling the number, position and injection angle of the cold air nozzles, the cooling uniformity of each part of the plastic part can be ensured to avoid deformation of the plastic part due to local overcooling.

[0053] In the S450, real-time monitoring of the surface temperature of the receiver net plastic is achieved through temperature sensors, which are distributed at key locations of the receiver net plastic to ensure the accuracy of temperature data. When the temperature of all monitoring points reaches the preset target temperature, the system automatically stops spraying cold air to prevent damage to the plastic parts caused by overcooling.

[0054] In addition, the entire cooling process can be automatically managed through a computer control system to ensure that each step is carried out in accordance with predetermined parameters, thereby improving production efficiency and consistency of product quality.

[0055] In one embodiment, the step of obtaining the shrinkage rate of the receiver mesh plastic part after the dynamic cooling process specifically includes: S510: respectively obtaining a measured weight value of the earpiece mesh plastic part and measured dimensions of the sound outlet hole and the outer structure of the earpiece mesh plastic part; S520: Calculate the deviation between the measured weight value and the standard weight value as the weight shrinkage rate, and calculate the deviation between the measured size and the standard size as the size shrinkage rate; S530: performing weighted processing on the weight shrinkage rate and the size shrinkage rate respectively, and comprehensively calculating the shrinkage rate of the earpiece mesh plastic part.

[0056] In the above embodiment, in S510, obtaining the measured weight value and measured size of the earpiece mesh plastic part is completed by a high-precision electronic scale and precision measuring tools. These tools can ensure the accuracy of the measurement data, thereby providing a reliable basis for the subsequent calculation of the shrinkage rate. When measuring the weight value, it is necessary to ensure that the earpiece mesh plastic part is placed on the electronic scale without any external force to avoid any possible measurement error.

[0057] In S520, when calculating the weight shrinkage rate and the size shrinkage rate, the standard weight value and the standard size must be determined first. These standard values ​​are pre-set according to the design drawings and product specifications, and they represent the weight and size of the plastic parts under ideal conditions. The deviation value is calculated by comparing the actual measured value with the standard value. The positive and negative and size of the deviation value can intuitively reflect the shrinkage of the plastic part during the cooling process.

[0058] In S530, weighted processing of weight shrinkage rate and size shrinkage rate is to comprehensively consider the impact of different factors on the shrinkage rate. For example, the size change of certain parts may have a greater impact on the overall performance, so a higher weight should be given. Through weighted processing, a more comprehensive and accurate shrinkage rate can be obtained, providing an important reference for subsequent quality control and process adjustment.

[0059] In one embodiment, the step of shaping the receiver mesh plastic after the dynamic cooling process specifically includes: S710: placing the receiver mesh plastic after dynamic cooling in a shaping device, wherein the shaping device includes a temperature control chamber and an airflow regulating unit; S720: slowly heating the receiver mesh plastic part in the shaping device to eliminate its internal stress; S730: After reaching the preset molding temperature, maintaining the preset molding time, and controlling the air flow speed and direction in the molding chamber through the air flow adjustment unit to stabilize the shape of the earpiece mesh plastic part; S740: slowly cooling the receiver mesh plastic part to room temperature to complete the shaping process.

[0060] In the above embodiment, in S710, the temperature control chamber is designed to accurately control the internal temperature to ensure that the earpiece mesh plastic is in the best temperature environment during the entire molding process. The temperature sensor in the chamber monitors the temperature changes in real time and is connected to the control system to ensure that the temperature fluctuation remains within the set range.

[0061] In S720, the slow heating step is crucial. Too fast a heating speed may cause excessive temperature gradients on the surface and inside of the plastic part, resulting in new stress or deformation. By precisely controlling the heating rate, it is possible to ensure that the internal stress of the plastic part is evenly released, avoiding deformation of the plastic part caused by stress concentration.

[0062] In S730, the preset molding temperature and time are pre-set according to the material characteristics and design requirements of the receiver net plastic part. During the molding process, the airflow adjustment unit can effectively avoid unnecessary distortion or deformation of the plastic part by accurately controlling the airflow speed and direction, thus ensuring the shape and size accuracy of the plastic part.

[0063] In S740, the slow cooling step is to prevent the plastic parts from generating internal stress or deformation due to excessive temperature gradient during the cooling process. By controlling the cooling rate, it is possible to ensure that the plastic parts remain stable during the cooling process and ultimately achieve the desired shape and dimensional accuracy.

[0064] In the above embodiment, through steps S710 to S740, the receiver mesh plastic part is subjected to precise temperature control and airflow regulation in the shaping device, and finally a finished product with stable shape and precise size is obtained. This shaping treatment method not only improves product quality, but also provides reliable guarantee for subsequent assembly and use.

[0065] In one embodiment, for further explanation, the mold includes a cavity component and a core component, the cavity component is provided with the cavity with the microneedle structure, and the core component cooperates with the cavity component to form an injection cavity; The molding nozzle is also provided with a hot runner manifold, which is arranged in the feed pipe and is used to distribute the molten polymer melt to multiple branch ports of the discharge pipe, wherein the branch ports are evenly connected to the injection cavity to allow the polymer melt to flow in evenly.

[0066] Embodiment 2 refer to Figure 2 The present invention also provides an injection molded receiver mesh plastic part, which is realized by the injection molded receiver mesh plastic part manufacturing method as described in any of the above items, including a receiver mesh plastic part body 1, wherein the upper end surface of the receiver mesh plastic part body 1 is evenly provided with a plurality of through holes 2, and the upper end surface of the receiver mesh plastic part body 1 is provided with a fillet 3 with a radius of 0.05 mm, and the thickness between the side wall of the receiver mesh plastic part body 1 and the side wall of the through hole 2 is set to 0.1 mm.

[0067] In the above embodiment, the plurality of through holes 2 are the sound outlet holes of the receiver net plastic part. The manufacturing process of the receiver net plastic part not only focuses on the shape and dimensional accuracy of the plastic part, but also pays special attention to the surface quality and internal structure of the plastic part. By optimizing the injection molding process parameters, such as injection pressure, holding time, and cooling time, the uniform stress distribution inside the plastic part is ensured, and deformation or cracking of the plastic part caused by stress concentration is avoided.

[0068] To ensure that the hand will not be scratched, the upper end surface of the receiver mesh plastic body 1 is provided with a fillet 3 with a radius of 0.05 mm; the thickness between the side wall of the receiver mesh plastic body 1 and the side wall of the through hole 2 is set to 0.1 mm, specifically the wall thickness of the side wall of the sound outlet.

[0069] In addition, after the plastic parts are formed, the surface of the plastic parts is treated by sandblasting or chemical etching to improve its surface roughness and enhance the adhesion with the subsequent coating or decorative layer. This surface treatment not only improves the appearance texture of the receiver net plastic parts, but also enhances its durability and wear resistance in actual use. Specifically, different surfaces are treated with A1 mirror and Fresnel pattern, and the bone position and demoulding direction are treated with light saving.

[0070] Finally, a series of rigorous inspections and tests are carried out to ensure that each receiver mesh plastic part meets the design requirements and quality standards. These inspections include dimensional accuracy inspection, surface quality inspection, mechanical property testing, etc., to ensure that the receiver mesh plastic part can perform at its best when assembled into the final product.

[0071] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for manufacturing an injection molded receiver net plastic part, characterized in that: include: S100: providing an injection molding device, the injection molding device comprising a feeding structure, a molding nozzle and a mold, the molding nozzle comprising a feeding pipe, a discharging pipe and a transition flow channel portion with controllable length, the feeding pipe being in communication with the feeding structure, the discharging pipe being in communication with the mold, and two ends of the transition flow channel portion being connected to the feeding pipe and the discharging pipe respectively; S200: heating the preset formula mixture to a molten state through the feeding structure to form a molten polymer melt; S300: adjusting the length of the transition flow channel portion to a preset length, and injecting the polymer melt into the mold to obtain a receiver mesh plastic part, wherein the mold is provided with a cavity with a microneedle structure; S400: dynamically cooling the receiver mesh plastic part, including a first cooling stage, rapidly cooling the sound outlet of the receiver mesh plastic part by circulating liquid cooling at a preset high temperature to improve the structural rigidity of the sound outlet, and performing a second cooling stage on the receiver mesh plastic part, spraying cold air on the outer surface of the receiver mesh plastic part at a preset low temperature to slowly cool the outer layer structure to enhance the toughness of the outer layer structure; S500: Obtain the shrinkage rate of the earpiece mesh plastic part after dynamic cooling treatment, and determine whether the shrinkage rate is greater than a preset target. If so, increase the length of the transition flow channel portion, increase the discharge temperature of the feeding structure, and re-mold the earpiece mesh plastic part. If not, perform shaping treatment on the earpiece mesh plastic part after dynamic cooling treatment.

2. A method for manufacturing an injection molded receiver mesh plastic part according to claim 1, characterized in that: The preset formula mixture includes PC material and additives, wherein the additives include an acoustic modifier, an impact resistant agent and a processing aid; The acoustic modifier is a mixture of one or more of siloxane, phosphate or fatty acid ester compounds; The impact-resistant agent is a mixture of one or more of an acrylic impact-resistant modifier, an ethylene-methacrylic acid copolymer, or a styrene-butadiene-styrene copolymer; The processing aid is a mixture of one or more of dibutyl phthalate, oxidized polyethylene wax or amide wax.

3. The method for manufacturing an injection molded receiver mesh plastic part according to claim 2, characterized in that: The step of heating the preset formula mixture to a molten state through the feeding structure to form a molten polymer melt specifically includes: S210: uniformly mixing the PC material in the preset formula mixture with the acoustic modifier, the impact resistant agent and the processing aid to obtain a mixed base material; S220: adding the mixed base material into the feeding structure, wherein the feeding structure is provided with a heating unit and a vacuum degassing unit, and heating the mixed base material to 240° C. to 300° C. by the heating unit to melt the mixed base material and remove initial moisture and volatile impurities; S230: During the heating process, the melt is dynamically stirred at a first preset rotation speed and a first preset frequency to eliminate the temperature difference between the mixed base material particles and form a uniform polymer melt; S240: maintaining the polymer melt at a predetermined temperature for a predetermined time by the heating unit, and stirring the polymer melt at a second predetermined rotation speed and a second predetermined frequency to maintain the flow stability of the polymer melt.

4. The method for manufacturing an injection molded receiver mesh plastic part according to claim 1, characterized in that: The step of adjusting the length of the transition flow channel portion to a preset length and injecting the polymer melt into the mold to obtain the receiver mesh plastic part specifically includes: S310: calculating a preset length of the transition channel portion according to the target structure and material properties of the receiver mesh plastic part, and adjusting the transition channel portion to the preset length through a control device; S320: pushing the molding nozzle to dock the molding nozzle with the inlet of the mold cavity; S330: starting the feeding structure to inject the molten polymer melt into the mold cavity of the mold through the transition flow channel portion and the molding nozzle; S340: After the injection molding is completed, the clamping force of the mold is maintained until the polymer melt is initially cooled and shaped; S350: Pushing out the molding nozzle from the mold cavity entrance of the mold, releasing the mold clamping force of the mold, opening the mold, and taking out the molded receiver net plastic part.

5. The method for manufacturing an injection molded receiver mesh plastic part according to claim 4, characterized in that: The control device includes an electric servo system and a temperature sensor. The electric servo system includes a servo motor, a control module and a position sensor. The driving end of the servo motor is connected to the transition flow channel portion to drive the extension and retraction of the transition flow channel portion. The position sensor is electrically connected to the servo motor to feedback the current position of the transition flow channel portion. The control module is electrically connected to the servo motor to adjust the motion trajectory of the servo motor according to a set preset length. The temperature sensor is disposed outside the transition flow channel portion, and the temperature sensor is electrically connected to the control module.

6. The method for manufacturing an injection molded receiver mesh plastic part according to claim 1, characterized in that: Step S400 specifically includes: S410: placing the formed receiver mesh plastic part in a cooling treatment system; S420: Entering the first cooling stage, adjusting the cooling treatment system to a preset high temperature, and rapidly cooling the sound outlet of the earpiece mesh plastic part through a circulating liquid cooling system, wherein the liquid cooling system includes a circulating liquid cooling nozzle and a temperature control unit, and the temperature control unit controls the temperature of the coolant sprayed by the circulating liquid cooling nozzle; S430: After the first cooling stage is completed, the second cooling stage is entered, the cooling treatment system is adjusted to a preset low temperature, and the humidity of the cooling treatment system is controlled to a preset range; S440: In the second cooling stage, cold air is sprayed on the outer surface of the receiver mesh plastic part through a cold air multi-point spray system to uniformly and slowly cool it, wherein the cold air multi-point spray system includes a cold air nozzle and a pressure control unit, and the pressure control unit controls the pressure of the cold air sprayed by the cold air nozzle; S450: monitoring the surface temperature of the earpiece mesh plastic part in real time, and stopping spraying cold air when the surface temperature evenly reaches a preset target temperature.

7. The method for manufacturing an injection molded receiver mesh plastic part according to claim 1, characterized in that: The step of obtaining the shrinkage rate of the receiver mesh plastic part after the dynamic cooling treatment specifically includes: S510: respectively obtaining a measured weight value of the earpiece mesh plastic part and measured dimensions of the sound outlet hole and the outer structure of the earpiece mesh plastic part; S520: Calculate the deviation between the measured weight value and the standard weight value as the weight shrinkage rate, and calculate the deviation between the measured size and the standard size as the size shrinkage rate; S530: performing weighted processing on the weight shrinkage rate and the size shrinkage rate respectively, and comprehensively calculating the shrinkage rate of the earpiece mesh plastic part.

8. The method for manufacturing an injection molded receiver mesh plastic part according to claim 1, characterized in that: The step of shaping the receiver mesh plastic after the dynamic cooling treatment specifically includes: S710: placing the receiver mesh plastic after dynamic cooling in a shaping device, wherein the shaping device includes a temperature control chamber and an airflow regulating unit; S720: slowly heating the receiver mesh plastic part in the shaping device to eliminate its internal stress; S730: After reaching the preset molding temperature, maintaining the preset molding time, and controlling the air flow speed and direction in the molding chamber through the air flow adjustment unit to stabilize the shape of the earpiece mesh plastic part; S740: slowly cooling the receiver mesh plastic part to room temperature to complete the shaping process.

9. The method for manufacturing an injection molded receiver mesh plastic part according to claim 1, characterized in that: The mold comprises a cavity component and a core component, the cavity component is provided with the cavity with the microneedle structure, and the core component cooperates with the cavity component to form an injection cavity; The molding nozzle is also provided with a hot runner manifold, which is arranged in the feed pipe and is used to distribute the molten polymer melt to multiple branch ports of the discharge pipe, wherein the branch ports are evenly connected to the injection cavity to allow the polymer melt to flow in evenly.

10. An injection molded receiver mesh plastic part, characterized in that: The manufacturing method of the receiver mesh plastic part by injection molding as claimed in any one of claims 1 to 9 is adopted, comprising a receiver mesh plastic part body, the upper end surface of the receiver mesh plastic part body is evenly provided with a plurality of through holes, and the upper end surface of the receiver mesh plastic part body is provided with a fillet with a radius of 0.05 mm, and the thickness between the side wall of the receiver mesh plastic part body and the side wall of the through hole is set to 0.1 mm.

Images