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1、注塑产品轻薄化设计重点及相关问题诊断要领 徐 昌 煜 Charles Hsu 2012年6月14-15日上午9:00下午4:30 上海市闸北区恒丰路308号金水湾大酒店,1995年时， 郭台铭就强调：计算机与通讯结合的时代将要来临，而联机功能与轻薄短小乃产品开发的趋势。 虎与狐，郭台铭的全球竞争策略， p. 128 天下文化,“Best Optics： Thinner, Lighter and Hi-iMPact” 2004年3月19日上午杨欣晋博士在中原大学机械工程系的演讲 Dr. Hsinjin Yang (杨欣晋) Manager Optical Thermoplastics, Lens
2、 Materials and Technologies ESSILOR OF AMERICA, INC. (全世界最大光学镜片公司；年营业额：USD 2.7 Billions),消费电子市场对于更小、更轻、更紧密的计算机、移动电话和其他电子信息装置的需求成长快速，使得高功能的薄壁设计变得必要-这一要求对于材料商、 制品和模具设计工程师、模具厂、成型厂以及成型机暨附属设备制造厂都是一大挑战。 A rapid growth in demand in the consumer electronics market for smaller, lighter and tighter computers,
3、 cellular phones, and other electronic and communication devices necessitates high-performance housing designs with thinner wall sections - a critical requirement that is challenging material suppliers, part and mold designers, mold makers, and machine & auxiliary equipment manufacturers alike.,薄壁成型
4、技术 Thin-wall Molding Technology,Notebook Housing,Cell Phone Case,Connector, LCP-GF35, 过锡卤(260C)后鼓泡-针孔状-须用显微镜看(图中样品尚未过锡卤), 2012. 4. 17.SAMT上海培训,Speaker Cone,(0.075mm),Flower Pot 花盆,43% less energy than a hydraulic injection molding machine,Machine: Screw: Application: Diameter: Height: Flow length: W
5、all thickness: Material: Shot weight: Impressions: Injection time: Machine time: Cycle time:,Ergotech 200/560-840 EL-EXIS S 45 mm Length: 25 D flower pot 190 mm 130 mm 210 mm 0.42 mm PP 33.5 g 1-cavity 0.19 s 1.55 s 2.76 s,specific energy consumption 0.67 kWh/kg ( without heating ),Drinking Cup 饮料杯,
6、40 % less energy than a hydraulic injection moulding machine,Ergotech 200/560-840 EL-EXIS S 50 mm length: 25 D Drinking cups 70 mm 80 mm 105 mm 0.5 mm PS crystal-clear 61.2 g 6-cavity 0.22 s 1.64 s 3.7 s,Specific energy consumption 0.44 kWh/kg ( without heating),Machine: Screw: Application: Diameter
7、: Height: Flow length: Wall thickness: Material: Shot weight: Impressiions: Injection time: Machine time: Cycle time:,Dish 盘碟,Syringe Body 注射器筒身,Razor 剃须刀柄,Specific energy consumption (without heating) 0.36 kWh/kg,Machine: Ergotech 200/560-840 EL-EXIS S Screw barrel: 60mm Application: razor Flow len
8、gth: 96mm Wall thickness: 1.2-1.8mm Material: PS Shot weight: 136.7g Part weight: 3.1g Mould: 32-cavities Machine time: 1.69s Cycle time: 6.3s,对于可携式电子产品而言，薄壁使得重量变轻、尺寸减 小。 对固定式电子产品而言，薄壁使得用(塑)料减少、循环时间缩短，因而生产力提高。 For portable electronics, thinner wall sections reduce part weight and size. For stationar
9、y electronics, thin-wall technology can help enhance productivity by reducing plastic material cost and cycle time.,薄壁成型技术 Thin-wall Molding Technology,Parts with flow length/thickness ratio of more than 150 and wall thickness often below 2 mm Injection pressures over 2000 bar Injection speed of mor
10、e than 400 mm/s - FERROMATIC MILACRON -,薄壁成型技术 Thin-wall Molding Technology,就传统注射成型而言，实用的最小壁厚在0.75到1.00mm之间。 如果要采用更薄的壁厚，却又缺乏实际的经验，可以借助CAE作科学的决定。 For conventional injection molding, a practical minimum wall thickness is in the range of 0.75 to 1.00 mm. When thinner walls are required but actual exper
11、ience is absent, the minimum possible thickness can be scientifically determined by CAE.,薄壁成型技术 Thin-wall Molding Technology,产品设计中壁厚不均带来的麻烦比任何其他问题设计带来者都要严重，这对薄壁产品尤然。 这些麻烦包括了迟滞现象、熔接痕、气穴、短射、翘曲、缩痕、雾斑、喷流以及长的冷却时间等。 这些麻烦都可用CAE以直接或间接的方式预测。 A non-uniform wall thickness will cause more trouble than any other
12、 problems in part design. This is especially true to thin-wall part. The trouble, including hesitation, weld line, air trap, short shot, warpage, sink mark, blush, jetting and long cooling time, etc., can be predicted, directly or indirectly, by using CAE.,壁厚 Wall Thickness,设计高收缩率(结晶性)材料成型品时，设计者应将壁厚
13、变化限制在10%。 就低收缩率(非结晶性)材料而言， 许容壁厚变化可到25%。 While designing injection molded parts in high mold shrinkage factor (crystalline) materials, the designer should try to limit wall thickness variation to 10%. The allowable wall thickness variation for the low mold shrinkage factor (amorphous) materials can b
14、e up to 25%.,壁厚 Wall Thickness,冷却时间和厚度分布 Cooling Time and Thickness Profile,差的设计 Bad Design,好的设计 Good Design,肋壁厚 Wall Thickness, Rib,Conventional 2.0 to 3.2 mm,Thinwall: 1.2 to 2.0 mm 1.2 mm,螺柱壁厚 Wall Thickness, Bosses,Conventional 2.0 to 3.2 mm,Thinwall: 1.2 to 2.0 mm 1.2 mm,角板壁厚 Wall Thickness, Gu
15、ssets,Conventional 2.0 to 3.2 mm,Thinwall: 1.2 to 2.0 mm 1.2 mm,为了防止迟滞现象和短射，突出物(如肋、螺柱、角板等)的根部厚度可以等于其相接的壁厚。 当几何特征远离浇口时，传统设计规则可用。 In order to avoid hesitation and short shot, the thickness of the projections, e.g. rib, boss and gusset, at its root can be as thick as its adjacent wall section. When the
16、 projections are located far from gate, conventional design rules should be applied.,突出物厚度 Thickness of the Projections,当壁厚小于1.27mm时，流路末端保压不足，突出物的厚 度应设计为公称厚度的50%到60%。 浇口附近，保压压力 大，突出物的厚度可以设计为公称厚度的75%到100%。 When wall thickness is less than 1.27mm, packing pressure may not be enough at the end of the flow path. In these locations, projections should be designed to be 50 to 60% of the nominal thickness. Near the gate, packing pressure is high. Projection in this area can b
