PC + IME + PUR composite molding technology

Abstract

The invention discloses a PC + IME + PUR composite molding technology which comprises the following process steps: step 1, opening a composite molding mold, and embedding an IME layer membrane into a PC injection molding cavity on a rear mold; 2, closing the mold, performing injection molding on a PC layer, cooling, opening the mold, and leaving a semi-finished product in a front mold cavity; thirdly, a large mold moving oil cylinder drives the rear mold to move horizontally, so that a PUR injection molding cavity in the rear mold is opposite to a cavity of the front mold, and cavity conversion and mold closing are completed; step 4, vacuumizing the PUR injection molding cavity; 5, carrying out injection molding on a PUR layer, cooling and opening the mold; 6, the product is taken out, the rapid pouring gate is removed, and then the product is placed on a conveying belt; and 7, the large mold moving oil cylinder drives the rear mold to move back, so that the PC injection molding cavity on the rear mold is opposite to the cavity of the front mold, cavity conversion is completed, and the steps 1-6 are repeated. According to the invention, the cavity conversion is realized through the movement of the rear mold, the multi-material composite injection molding integrated molding is realized in one set of mold, the time is saved, the reliability is realized, and the technical problems that the IME circuit is easy to damage during injection molding, the PC-PUR interface is layered and the like are solved.

Description

Technical Field

[0001] This invention relates to the field of integrated electronic component composite manufacturing technology, specifically to a PC+IME+PUR composite molding technology. Background Technology

[0002] With the development of society and the economy, the application of injection-molded products is becoming increasingly widespread, and their structures are becoming increasingly complex. Traditional plastic parts have simple structures and single components, which can no longer meet the needs of industrial applications. As the types of materials used increase, the demand for composite molded parts is rising. The industry has conducted extensive research on composite molding dies used to manufacture composite molded parts, but due to the complexity of the part structures and the differences in molding materials, there is currently a lack of specialized composite molding dies. Therefore, the composite molding technology for integrated composite molded parts is relatively backward and cannot meet the stringent requirements of development and application. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing background technology and provide a PC+IME+PUR composite molding technology.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is a PC+IME+PUR composite molding technology, which specifically includes the following process steps: Step 1: Open the composite molding mold and grab the IME layer film and embed it into the PC injection cavity of the rear mold of the composite molding mold.

[0005] Step 2: Close the composite molding mold, inject the PC layer, cool, open the mold, and leave the semi-finished product in the front mold cavity.

[0006] Step 3: The piston rod of the core-pulling cylinder on the rear mold retracts, and the large mold-moving cylinder drives the rear mold to move horizontally along the base plate, so that the PUR injection cavity on the rear mold is opposite to the cavity of the front mold; the piston rod of the core-pulling cylinder extends, and the mold closes.

[0007] Step 4: Vacuum the PUR injection molding cavity.

[0008] Step 5: Inject the PUR layer, cool, and open the mold.

[0009] Step six: The ejector plate ejects the molded product, the robot arm picks it up and removes the gate, and then places it on the output conveyor belt.

[0010] Step 7: The piston of the core-pulling cylinder on the rear mold retracts, and the large mold-moving cylinder drives the rear mold to move back along the base plate, so that the PC injection cavity on the rear mold is opposite to the front mold cavity. The piston rod of the core-pulling cylinder extends, and steps 1 to 6 are repeated.

[0011] Furthermore, the composite molding die includes a front mold and a rear mold that can be opened and closed relative to each other, wherein the front mold is provided with a front mold core, an ejector plate, a fixing block and a top plate from bottom to top, and the front mold core has a single front mold cavity on the side facing the rear mold.

[0012] The rear mold includes a base plate arranged from bottom to top and a movable rear mold core. The rear mold core is provided with PC injection cavities and PUR injection cavities arranged side by side. Both the PC injection cavity and the PUR injection cavity can be matched with the aforementioned front mold cavity to form a complete product injection cavity.

[0013] Furthermore, guide blocks are fixedly installed on the upper surface of the bottom plate of the rear mold, and the guide blocks include side guide blocks and bottom guide blocks. The side guide blocks are located outside the bottom guide blocks, and their cross-sections are inverted L-shaped structures with their lateral sections extending inward. Correspondingly, the side of the bottom fixing plate of the rear mold core is provided with a guide groove that matches the side guide blocks, and the lateral sections of the side guide blocks are installed in the guide grooves. The bottom surface of the fixing plate is also provided with a bottom guide groove that matches the bottom guide blocks, and the bottom guide blocks are slidably installed in the corresponding bottom guide grooves.

[0014] A large hydraulic cylinder for mold movement is fixedly installed on one end of the base plate, and the end of its piston rod is connected to the fixed plate at the bottom of the rear mold core, which can drive the rear mold core to slide back and forth along the guide block.

[0015] By using the above-mentioned rear mold setting, the rear mold is moved laterally in step three above, and the cavity is transformed, thereby realizing the separate injection molding of the PC layer and PUR layer, so that they cover the middle IME layer film, and thus forming a three-layer composite part.

[0016] Furthermore, the rear mold core is fixed with multiple fabric hanging needles around the PC injection molding cavity, and correspondingly, the front mold core is provided with multiple fabric hanging needle holes.

[0017] In step one above, the IME layer film is gripped and positioned by a robotic arm and then hung on a fabric hanging needle. The robotic arm includes a gripping end and a positioning end that are arranged opposite to each other. The gripping end is equipped with multiple suction cups on the same horizontal plane, which can realize the gripping of the IME layer film or the molded product.

[0018] Furthermore, the front mold cavity is provided with an undercut groove, and the side wall of the opposite PC injection molding cavity and its inner bottom surface are directly and smoothly transitioned, thereby realizing that the semi-finished product is left in the front mold cavity after mold opening in step two above.

[0019] Furthermore, the rear mold core is provided with a vacuuming mechanism on the side of the PUR injection molding cavity. The vacuuming mechanism includes an external air extraction pipe, an exhaust needle, and an exhaust needle core-pulling cylinder. The PUR injection molding cavity is provided with an exhaust hole, and the external air extraction pipe is connected to the upper part of the exhaust hole. The exhaust needle is slidably installed in the exhaust hole and can block the exhaust hole and the connection between the exhaust hole and the external air extraction pipe when it is pushed upward. The exhaust needle core-pulling cylinder is fixedly installed at the bottom of the rear mold core, and its piston end is connected to the bottom of the exhaust needle.

[0020] Furthermore, the front mold side of the composite molding die is provided with three water cooling pipes, including one for the front mold, one for the hot runner plate, and one for the hot runner system; the rear mold side of the composite molding die is provided with two water cooling pipes, including one for the PC injection cavity and one for the PUR injection cavity.

[0021] Furthermore, the cooling time in step two is 60-120 seconds; the cooling time in step five is 60-120 seconds.

[0022] Compared with existing technologies, this invention has the following advantages: Through multi-material co-molding, this invention achieves an integrated solution for structural strength, electronic integration, and surface protection, solving many technical problems such as easy damage during IME circuit injection molding, PC-PUR interface delamination, and transmittance mismatch. It is time-saving and reliable, and has great potential in the fields of flexible electronics and green manufacturing.

[0023] Products developed using this technology can be widely used in various industries, including transparent displays for smart cars, smart center consoles, smart home panels in the consumer electronics field, and instrument operation panels in the medical device field. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the process flow of the composite molding technology of the present invention; Figure 2 This is a schematic diagram of the composite molding die structure involved in the composite molding technology of this invention; Figure 3 This is a schematic diagram of the front mold side structure of the composite molding die in this invention; Figure 4 This is an enlarged view of a portion of the front model cavity in this invention; Figure 5 This is a schematic diagram of the rear mold side structure of the composite molding die in this invention; Figure 6 This is an enlarged view of a portion of the PC injection molding cavity in this invention; Figure 7 This is an enlarged view of a portion of the PUR injection molding cavity in this invention; In the diagram: 1. Front mold, 2. Rear mold, 11. Front mold core, 12. Ejector plate, 13. Fixing block, 14. Top plate, 15. Front mold cavity, 16. Undercut groove, 17. Ejector plate cylinder, 18. Front mold lifting module, 21. Rear mold core, 22. Fixing plate, 23. Bottom plate, 24. PUR injection cavity, 25. PC injection cavity, 26. Side guide block, 27. Bottom guide block, 28. Mold moving cylinder, 29. External air extraction pipe, 30. Fabric hanging needle. Detailed Implementation

[0025] It should be noted that in the description of this invention, terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are only used to facilitate the description of the structural relationship between the components in this invention and do not specifically mean that any component in this invention must have a specific orientation, be constructed and operated in a specific orientation, or be construed as a limitation of this invention.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0027] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings: A PC+IME+PUR composite molding technology mainly relies on a composite molding die and a corresponding hydraulic two-platen injection molding machine, combined with... Figure 2 As shown, the composite molding die includes a front mold 1 and a rear mold 2 that can open and close relative to each other, wherein the front mold 1 is a fixed mold, combined with... Figure 3 As shown, the assembly includes a top plate 14, a fixing block 13, an ejector plate 12, and a front mold core 11 arranged sequentially from top to bottom. The fixing block 13 is fixedly installed on the bottom surface of the top plate 14, and its interior is provided with injection molding pipelines, control pipelines, and cooling pipelines. Two support blocks are fixedly installed at the bottom of the fixing block 13, and the ejector plate 12 is slidably installed in the space between the two support blocks. Ejector plate cylinders 17 are fixedly installed on both ends of the fixing block 13, and their piston ends are fixedly connected to the ejector plate 12. The bottom of the ejector plate 12 is provided with multiple ejector rods. The bottom of the two support blocks is fixedly installed with the front mold core 11. The front mold core 11 has a single front mold cavity 15 on the side facing the rear mold 2. The periphery of the front mold cavity 15 is also provided with multiple positioning posts perpendicular to the front mold 1 to facilitate the mold alignment of the front mold 1 and the rear mold 2.

[0028] The aforementioned rear mold 2 is a moving mold, combined with Figure 5 As shown, the rear mold 2 includes a rear mold core 21, a fixing plate 22, and a base plate 23 arranged sequentially from top to bottom. The rear mold core 21 is fixedly installed above the fixing plate 22, and the fixing plate 22 is slidably installed on the base plate 23. A guide block is fixedly installed on the upper surface of the base plate 23. The guide block includes two side guide blocks 26 and two bottom guide blocks 27. The side guide blocks 26 have an inverted L-shaped cross-section and are fixedly installed on the upper surface of the base plate 23 by countersunk bolts. They are arranged at intervals along the length of the base plate 23, and the transverse sections of the side guide blocks 26 extend horizontally inward. The bottom guide blocks 27 are also fixedly installed on the upper surface of the base plate 23 by countersunk bolts, located between the two side guide blocks 26, and arranged parallel to them. The fixed plate 22 has a guide groove on its side wall, and the transverse section of the side guide block 26 is slidably installed in the corresponding guide groove. The fitting installation of the two can limit the fixed plate 22 and prevent it from detaching from the base plate 23. The bottom surface of the fixed block 22 has a bottom guide groove, and the bottom guide block 27 is slidably installed in the corresponding bottom guide groove. The fitting installation of the two can guide the movement of the fixed plate 22. A large mold moving cylinder 28 is fixedly installed at one end of the base plate 23, and the end of its piston rod is connected to the fixed plate 22, which can drive the fixed plate 22 to slide back and forth along the guide block. The rear mold core 21 has a PC injection cavity 25 and a PUR injection cavity 24 arranged side by side on the side facing the front mold 1. Both the PC injection cavity 25 and the PUR injection cavity 24 have positioning holes on their peripheries that are adapted to the positioning posts on the front mold 1. Both the PC injection cavity 25 and the PUR injection cavity 24 can mate with the front mold cavity 15 on the front mold 1 to form a complete product molding injection cavity. Figure 6 As shown, multiple fabric hanging needles 30 are fixedly provided on the periphery of the PC injection molding cavity 25, and correspondingly, multiple fabric hanging needle holes are provided on the front mold core 11.

[0029] Combination Figure 4 As shown, the front mold cavity 15 is provided with an undercut groove 16 according to the product structure; refer to Figure 6 and Figure 7 In contrast, the sidewall of the PC injection cavity 25 and its inner bottom surface have a direct and smooth transition, as do the sidewall of the PUR injection cavity 24 and its inner bottom surface.

[0030] Furthermore, multiple limit switches are fixedly installed on the base plate 23, and multiple limit blocks are fixedly installed on the base plate 23 at both ends of the guide block to limit the back-and-forth sliding position of the fixed plate 22.

[0031] The aforementioned composite molding dies are mostly used for horizontal assembly. In the aforementioned rear mold 2, the rear mold core 21 moves laterally along the guide block. The front mold lifting module 18 on the front mold 1 side is removed before injection molding, and the rear mold lifting module on the rear mold 2 side also needs to be removed before injection molding.

[0032] Combination Figure 1 As shown, a PC+IME+PUR composite molding technology includes the following process steps (where PC is a polycarbonate structural component, IME is an in-mold electronic functional layer, and PUR is a polyurethane protective coating): Step 1: The composite molding mold is in its initial state. The mold is opened, and the IME layer film is grasped and positioned by the robot and embedded into the PC injection cavity 25 of the rear mold 2. The IME layer film is then hung on the hanging needle 30.

[0033] Step 2: The composite molding mold is closed, and the PC injection cavity 25 and the front mold cavity 15 are aligned to form the first product injection cavity. Then, molten PC material is injected through the front mold side of the injection molding machine and cooled for 60-120 seconds to form a PC layer. At this time, the IME layer film is placed below the PC layer. Then the mold is opened. Since the front mold cavity 15 is provided with an undercut groove 16, the two side walls of the undercut groove 16 form a certain clamping force on the product, and the side wall of the PC injection cavity 25 and its inner bottom surface are directly and smoothly transitioned, so that the injection-molded semi-finished product is left in the front mold cavity 15.

[0034] Step 3: The piston rod of the core-pulling cylinder on the rear mold 2 retracts; then, the mold-moving cylinder 28 drives the rear mold core 21 to move along the guide block on the base plate 23, so that the PUR injection cavity 24 on the rear mold core 21 is opposite to the aforementioned front mold cavity 15, completing the cavity conversion; the piston rod of the core-pulling cylinder extends, and the mold closes again, the aforementioned PUR injection cavity 24 and the aforementioned front mold cavity 15 form the product molding injection cavity, and the aforementioned semi-finished product is placed inside it.

[0035] Step 4: Vacuuming the PUR injection molding cavity 24. The aforementioned rear mold core 21 is equipped with a vacuuming mechanism at the PUR injection molding cavity 24. This mechanism includes an external suction pipe 29, an exhaust pin, and an exhaust pin core-pulling cylinder. The PUR injection molding cavity 24 has an exhaust hole, vertically downwards. The external suction pipe 29 is horizontally positioned and connected to the upper part of the exhaust hole. The exhaust pin is slidably installed inside the exhaust hole; when pushed upwards, it blocks the exhaust hole and the connection between the exhaust hole and the external suction pipe 29. When pushed upwards, the exhaust pin is flush with the inner bottom surface of the PUR injection molding cavity 24. The exhaust pin core-pulling cylinder is fixedly installed at the bottom of the rear mold core 21, with its piston end connected to the bottom of the exhaust pin, enabling it to move the exhaust pin up and down within the exhaust hole. After the mold closes, the piston rod of the aforementioned venting pin core-pulling cylinder retracts, causing the venting pin to move downwards. The aforementioned venting hole is connected to the external air extraction pipe 29, and air is extracted outwards by an external motor, achieving vacuuming of the aforementioned PUR injection molding cavity 24. Subsequently, the piston rod of the venting pin core-pulling cylinder extends, causing the venting pin to block the venting hole.

[0036] Step 5: Molten PUR material is injected into the PUR injection cavity 24 through the rear mold using an external injection molding machine, and then cooled for 60-120 seconds. At this time, the PUR layer is placed below the IME layer film to form a three-layer composite molded part. Finally, the mold is opened, and the molded product is also placed in the front mold cavity 15.

[0037] Step six: The cylinder 17 of the ejector plate on the front mold side moves synchronously, and its piston rod extends outward, driving the ejector plate 12 to push downward. The ejector rod on the ejector plate 12 ejects the molded product, which is then picked up by the robot arm for rapid gate removal, and then placed on the output conveyor belt.

[0038] Step 7: The piston of the core-pulling cylinder on the rear mold retracts, and the large mold-moving cylinder 28 drives the rear mold core 21 to move back along the guide block on the base plate 23, so that the PC injection cavity 25 on the rear mold core 21 is opposite to the aforementioned front mold cavity 15. The piston rod of the core-pulling cylinder extends, and steps 1 to 6 are repeated to achieve continuous injection molding of the product.

[0039] The robotic arm mentioned in step one above includes a gripping end and a positioning end that are positioned opposite each other. The gripping end is equipped with multiple suction cups on the same horizontal plane, which can grasp IME layer films or molded products.

[0040] Furthermore, the front mold side of the composite molding die is provided with three water cooling pipes, including one for the front mold, one for the hot runner plate, and one for the hot runner system; the rear mold side of the composite molding die is provided with two water cooling pipes, including one for the PC injection cavity 25 and one for the PUR injection cavity 24.

[0041] For any mold structures not mentioned or described in detail in the above technical solutions, they can be achieved by adopting or referencing relevant technical features in existing technologies.

[0042] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A PC+IME+PUR composite molding technique, characterized by, The process comprises the following steps: Step one, open the composite molding die, grab the IME layer film and embed it into the rear mold PC injection cavity of the composite molding die; Step two, close the composite molding die, inject the PC layer, cool, open the mold, and leave the semi-finished product in the front mold cavity; Step three, retract the core-pulling oil cylinder piston rod on the rear mold, move the mold along the base plate with the rear mold, so that the PUR injection cavity on the rear mold is opposite to the front mold cavity; extend the core-pulling oil cylinder piston rod and close the mold; Step four, vacuum the PUR injection cavity; Step five, inject the PUR layer, cool, and open the mold; Step six, eject the molded product with the ejector plate, grab it with the manipulator to remove the gate, and then place it on the output conveyor belt; Step seven, retract the core-pulling oil cylinder piston on the rear mold, move the mold along the base plate with the rear mold, so that the PC injection cavity on the rear mold is opposite to the front mold cavity, extend the core-pulling oil cylinder piston rod, and repeat steps one to six.

2. A PC+IME+PUR hybrid molding technique according to claim 1, characterized in that: The composite molding die comprises a front mold and a rear mold that can be opened and closed relative to each other, wherein the front mold is provided with a front mold core, an ejector plate, a fixed block, and a top plate from bottom to top in sequence, and the side of the front mold core facing the rear mold is provided with a single front mold cavity; The rear mold comprises a base plate and a movable rear mold core provided in sequence from bottom to top, the rear mold core is provided with a PC injection cavity and a PUR injection cavity arranged side by side, and the PC injection cavity and the PUR injection cavity can be matched with the above-mentioned front mold cavity to form a complete product injection cavity.

3. A PC+IME+PUR hybrid molding technique according to claim 2, characterized in that: The upper surface of the base plate of the rear mold is fixedly installed with oppositely spaced guide blocks, the guide blocks comprise side guide blocks and bottom guide blocks, wherein the side guide blocks are located outside the bottom guide blocks, the cross section of the side guide blocks is in inverted L-shaped structure, and the horizontal section of the side guide blocks extends inward; Correspondingly, the side surface of the fixed plate at the bottom of the rear mold core is provided with a guide groove matched with the above-mentioned side guide blocks, and the horizontal section of the side guide blocks is installed in the guide groove; The bottom surface of the fixed plate is also provided with a bottom guide groove matched with the above-mentioned bottom guide blocks, and the bottom guide blocks are slidingly installed in the corresponding bottom guide grooves; One end of the base plate is fixedly installed with a mold-moving large oil cylinder, the piston rod of the mold-moving large oil cylinder is connected to the fixed plate at the bottom of the rear mold core, and the mold-moving large oil cylinder can drive the rear mold core to slide back and forth along the guide blocks.

4. A PC+IME+PUR hybrid molding technique according to claim 2, characterized in that: A plurality of cloth-hanging needles are fixedly arranged around the PC injection cavity of the rear mold core, and a plurality of cloth-hanging needle holes are arranged on the front mold core. The IME layer film is hung on the cloth-hanging needles after being grabbed and positioned by the manipulator in step one, and the manipulator comprises a grabbing end and a positioning end arranged oppositely, wherein the grabbing end is provided with a plurality of suction cups in the same horizontal plane, which can realize grabbing of the IME layer film or the molded product.

5. A PC+IME+PUR hybrid molding technique according to claim 2, characterized in that: A reverse-docking groove is arranged in the front mold cavity, and the side wall of the opposite PC injection cavity directly and smoothly transitions with the inner bottom surface.

6. A PC+IME+PUR hybrid molding technique according to claim 2, characterized in that: The rear mold core is provided with a vacuum extraction mechanism on the side of the PUR injection cavity, the vacuum extraction mechanism comprises an external air extraction pipeline, an exhaust needle and an exhaust needle core-pulling oil cylinder, the PUR injection cavity is provided with an exhaust hole, and the external air extraction pipeline is in communication with the upper portion of the exhaust hole; the exhaust needle is slidably installed in the exhaust hole and can block the exhaust hole and the communication position of the exhaust hole and the external air extraction pipeline when being pushed upward; and the exhaust needle core-pulling oil cylinder is fixedly arranged at the bottom of the rear mold core, and the piston end of the exhaust needle core-pulling oil cylinder is connected with the bottom of the exhaust needle.

7. A PC+IME+PUR hybrid molding technique according to claim 2, characterized in that: The front mold side of the composite forming mold is provided with three water cooling pipelines, one of which is a front mold pipeline, one is a hot runner plate pipeline and one is a hot runner system pipeline; and the rear mold side of the composite forming mold is provided with two water cooling pipelines, one of which is a PC injection cavity pipeline and one is a PUR injection cavity pipeline.

8. A PC+IME+PUR hybrid molding technique according to claim 7, characterized in that: The cooling time in the second step is 60-120s; and the cooling time in the fifth step is 60-120s.

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