MOMENTARY SURFACE HEATED MOULD TOOL WITH GAS FLAME

Abstract: Momentary Mould Surface Heated with Gas Flame is the most effective method to heat up the mould tool most quickly and cool down it most quickly again. Using the gas flame for the mould tool heating the key concept of the invention. Gas flame can be kept in space without supporter and does not pollute the mould tool surface. Needle hole gas supply units is deviced in order to supply the gases into the room (6) between the open mould parts (1) without any restriction. The diameter of needle hole (5) is less than the dimension of non flow thickness of molten resin indicated for the component so that the gases pass it freely on one hand and molten resin does not pass it on the other hand. The needle hole (5) can be made directly on the mould tool base but for the convenience and cost effectiveness of numerous needle holes the assembling unit is devised. The multiple gas supplying unit is an alternative gas supplying unit for the mould tools which do not allow the needle hole gas supplying unit or have enough space for it. The diameter of the hole of multiple gas supplying unit can be big as wished because it does not contact the molten resin during the processing. In order to minimize the mould surface heating time with Momentary Mould Surface Heated with gas flame, the gas flame must be kept inside the room (6) between the properly closed mould parts (1).

Description: [Description] [Name of invention] MOMENTARY SURFACE HEATED MOULD TOOL WITH GAS FLAME [Technical Field] Plastic industry relates to three fields of technologies, resin technology, processing machine technology, mould tool manufacturing technology. The presented invention relates to plastic processing mould tools and specially to those assembled with needle hole gas supplier and multiple gas supply unit in order to heat the mould surface momentarily with gas flames. Every plastic resins might be applied for the plastic processing with this invented mould tools to produce plastic articles. [Background Art] The final product quality of plastic component is very much affected by three technologies of plastic industry individually. Among them tool technology is the more relies on trial-and- error experiences rather than the theorethical standards. The mostly difficult aspects of technology was the method how to heat up the mould as high as wanted and cool down it as quickly as possible. It is essential requirement to produce a excellent qualified plastic components by heating the mould without any cost increase. The flame made with gas fuel could be kept in the air without any supporter and create flame easily with flash and be extinguished by cutting the gas fuel supply on purpose. It is most convenient and simple and cheap method to heat up the mould and cool down quickly. The mould tools modified with needle hole gas supplier or multiple gas supply unit is invented to apply the gas flame to heat the mould surface freely and controllably. [Disclose of invention] MMSH mould tool with gas flame and MMSH plastic forming process to be a ideal plastic forming process which makes the mould surface temperature is controlled as high as necessary not less than the molten resin temperature and the molten resin fills into the cavity free from flow resistance. And it makes the surface of moulded products completely glossy without any gate mark, weld line, flow mark and roughness which is always seen on the ordinary plastic moulded products caused by stresses and temperature unconformity of the moulded products, these are produced when the warm molten resin is pushed into the mould cavity among the cold mould surface. Especially the time to heat up the mould surface 300 ° C does not exceed 10 seconds and it makes the entire mould surface to be heated constantly and cositantly by heating the mould surface only with the gas flame on it no matter how the temperature is high and how the mould tool is big and complicate. Heating the mould surface up not lower temperature than molten resin temperature eliminates not only completely all kinds of surface defect of plastic products but also enlarge the resin flow length in mould tool enomously as show in FIG.7. It enable to reduce a half of the component thickness by using strong and though materials with poor fluidity and eliminating the subsidiary ribs and bosses regardless the warpages and short shot. Accordingly the unit injection pressure could " be reduced enomously and save the energy and the machine investment. Eventually it cuts off a half of the plastic component cost. The invented MMSH mould tool with gas flame and MMSH plastic forming process could be adopted in every injection moulding processes and blow moulding process and every thermal forming processes. Especially for the fine texture injection moulding process for compact disc it reflects the fine texture precisely on the surface of compact disc and makes the best quality of compact disc. And the perfact surface of injection moulded plastic product eliminates the second treatments like as spray painting covering the flow marks and weld lines and it solves the extraordinary rough surface of the plastics made by gas assisted injection moulding process. In every inection moulding processes it makes the completely perfact surface products which eliminate expensive second treatments and eventually cut off the production cost. Up to now no scientist could avoid the molecular structuctual stresses in plastic injection moulded components. When the molten resin from 180 to 300 °C gets into the cavity of 40 ° C the front of fluid stays near to the gate and the following resin passes through the solid skin of former resin and the molecular structuctual stresses are generated. It caused the deformation and curvation of plastic injection moulded components afterward the complete solidification of products by itself. But the MMSH mould tool with gas flame and MMSH forming process get rid of the every unpredictable parameters and the molecular structure stresses in injection moulded components and unknown problems. It enable the theoretical analysis of ideal conditions of plastic injection moulding process and establish the fundamental theories of the plastic injection moulding process. Heating the mould surface above the temperature of molten resin and injecting the molten resin into these warm mould surfaces and placing the front resin of fluid far from the gate and latest parts of resin fluid near to the gate and cooling down the filled resin and mould surface in pararell. It does not create any weld line and flow mark and gate mark and sand surface even with poor resin and deformations and curvations caused by molecular structuctual stresses and create the perfactly glossy surface of the plastic injection moulded components. MMSH mould tool with gas flame and MMSH plastic forming process enlarge the flow length of molten resin approximately 30 times more than that of ordinary way. It allows placing numorous gates without restrictions of location and shape and producing perfact plastic surface injection moulded component and producing ultimately huge size of injection moulded plastic components and a very much thinner thickness of injection moulded plastic parts than that of ordinary way. And the tiny holes and complicate shapes of grille ventillations is no longer difficult to be produced without any short shot and surface defacts by MMSH mould tool with gas flame and MMSH injection moulding process. MMSH mould tool with gas flame and MMSH plastic forming process do not require materials modified by additives aimed for enhancing the fluidity of the resin at all which cause lots of side effect problems like as additive migration and gas marks on the moulded parts. A simple unadded resin of high mechanical strength and high heat resistance like as engineering plastics could be processed in a glossy injection moulded components without short shot problem inspite of very low fluidity with MMSH mould tool with gas flame and MMSH forming process. A simple injection moulding machine of approximately 30 times smaller clamping force than that of ordinary way can produce the same size as that of ordinary way by MMSH mould tool with gas flame and MMSH plastic injection moulding process and placing multiple gates with 30 times longer flow length than that of ordinary way. According to above explained effects of MMSH mould tool with gas flame and MMSH injection moulding process it cuts off more than a half of the production cost of plastic injection moulded parts thoroughly by cutting off a half of the wall thicknesses of components and reducing the defects and using small machine and a cheap unadded resin and in a simple and free design concept. And it does not increase production cycle time at all compare to ordinary way. No matter how big products and how deep and how complicate shape the mould tools are MMSH mould tool with gas flame is invented for the moud surface to be heated up to 300 °C and consistently in a few seconds through using needle hole gas fuel supply device or muliple gas supply unit adopting the heating technic of injecton moulding process and making the gas fuel flaming on the mould surface and making this flame to contact the other mould surface and keeping gas flame inside the mould tools. As shown in FIG.3 the needle hole gas fuel supply device consist of a fixing unit and a needle hole unit. The diameter of needle hole is less than the non flow thickness of the indicated polymer resin and the gas fuel and oxigen and air pass the hole but the molten resin do not pass it. Subject to mould design bigger diameter holes than the non flow thickness of polymer resin can be used, for instance, in case of locating the holes in the free space exterior of product cavity and interior of product cavity the holes are made with moving support and disappears from the product cavity when the mould tools are completely closed. As shown in FIG.2 in order to heat the mould surface as quickly as possible the gas flame should be made on the mould surface by using interior gas fuel supply unit and the gas flame should be kept in the narrow room between the two mould surface by flaming the gas fuel in a narrow gap between two mould parts. Simultanuosly inject the molten resin into the warm cavity without any waiting time after gas flame being extinguished. The interval between the gas flame being extinguised and injecting molten resin could be controlled in "0" by MMSH injection moulding process with gas fuel. The gap between two mould parts of which the room the gas flame could be controlled between 0 and 100 mm according to the mould shape and size and other parameter. As shown in FIG.4 the gas flame could be kept inside the mould cavity and it protect from the fire extending to outside of mould parts and use all the heat of gas flame only for heating the mould surface. The gas flame kept between two mould parts is called as a closed gas flame against the open flame which is open to air outside of mould. In order to make a closed gas flame and prevent the pollution on the mould surface the air or oxigen is supplyed into the mould cavity through the needle hole devices and other devices equipped in mould tools. The flame guards surrounding the mould parts are attached appropriately shape and size depend on the mould size and shape. For the modification for MMSH mould tool with gas flame of a ready made mould tool of which the thikness of mould is Tiot less than 15 mm the chilled water is hardly used for cooling the mould and recommanded to warm up the mould as high as possible in order not to increase the gas flame heating time. And as shown in FIG.7 the mould thickness of MMSH mould tool with gas flame should be as thin as possible in order to heat up the mould surface momentarily. In case of using the chilled water the channel of chilled is commonly used with gas fuel and air or oxigen supply channel as shown in FIG.5. But chilled water has to be circullated by suction pumping system but not the pressing pumping system in order to prevent the water leakage through the needle hole being conrolled by flow change valve sequenced to machine operation as shown in FIG.5. Igniting device on the bottom of the mould tool is installed and generate the gas flame between two mould surfaces when the gas fuel is supplied into the mould cavity as shown FIG.5. Natural gas fuel and methane and ethane and propane and buthane and penthane and acethylene and amonia gas and low molecular alcohols are used for gas fuel of MMSH forming process and the air and pure oxigen and dioxide hydrogen is used for making a perfact conbustion gas flame. The processing cycle of MMSH mould tool with gas flame and MMSH injection moulding process from being insatlled all the equipment correctly is described as followings. During closing two parts of mould tools hold the complete closing in a certain gap between two parts of mould tools. And supply the gas fuel and oxigen or air inside the room between two parts of mσuld tools through the gas fuel supply channel on the bottom of mould tool and needle hole supplying devices and simultaneously ignite the gas flame and generate a closed gas flame inside the room between two parts of mould tools and let the gas flame contact on the surface of product cavities on the mould. A few second later when the mould surface is heated up to required temperature close two parts of mould completely and cut off the gas and oxigen or air supply and simultaneously inject the molten resin into the product cavity. After filling the cavities completely with molten resin supply the cilled water wait for cooling till the resin is cold enough to be taken out. And open the two parts of mould tools and take out the plastic moulded components. And repeat the operation cycle getting the pefact injection moulded plastic products by MMSH mould tool with gas flame and MMSH injection moulding process. [Brief Discription of Drawing] FIG.l is for the typical injection machine and mould tool and shows the gas suppling device on the bottom of mould tool. FIG.2 is for the general design of MMSH mould tool with gas fuel(3) and oxigen and air(4) supply channels and needle holes (5) gas suppling and the cooling water channel(7) and the room(6 ) between two parts of mould tool for gas flame and the flame protectors(8). FIG.3 is for a common needle hole gas fuel suppling device through which the gas passes but the molten resin does not pass. It is consist of needle hole unit( l l ) and fixing unit( 12)r FIG.4 is for the gas flame protector keeping gas the gas flame inside the room of the two mould parts. FIG.4(a) is for the front view of the core part of mould and FIG.4(b ) is for the cavity part of mould. FIG.5 is for the line connection of the gas fuel supply channel and chilled water channel when two channel use the same path. FIG.6 is for a graph of comparision the temperatures of molten resins and mould surfaces between the normal injection moulding and the MMSH injection moulding process. FIG.6(a) shows the temperature gap between the mould surface and molten resin for ordinary injection moulding. FIG.4(b) shows the temperature gap for MMSH mould tool with gas flame and its process. FIG.7 is for a graph of heating time comparing closed flame and open flame. Heaing time is relats to the mould wall thickness. The fuel is acethylene for the graph and tool material is carbon steel. FIG.8 is for a computer simulated graph of comparing the resin flow lengthes between 40 ° C and 190 °C . The flow length of 190 ° C is 30 times bigger than that of 30 °C . FIG.9 is for the general design of multiple gas suppling unit with moving support. FIG.9(a) shows the multiple gas supplying unit is out of mould surface when the mould tool is open. FIG.9 (b ) shows the multiple gas supplying unit is buried into the mould when the mould tool is completely closed. Description of numbers in FIGURES. 1. Mould tools (movable body, fixed body). 2. A gas fuel suppling channel on the bottom of mould. 3. A gas fuel suppling pipe. 4. A oxigen and air suppling pipe. 5. A needle hole for gas suppling inside mould. 6. A room for gas flame between two mould parts which are stoped in approperiate distance. 7. A cooling water channel. 8. A flame protector. 9. A nozzle of injection machine. 10. A clamping unit of injection machine. 11. A needle hole part. 12. A fixing part for a needle hole part. 13. A igniting unit. 14. The inside of mould body. 15. A spring. 16. A moving support which moves up and down the multiple gas suppling unit. 17. A gas suppling hole of which the diameter is bigger than the non flow thickness of molten resin. [Best Mode for Carring Out the the Invention] Applying the MMSH mould tool with gas flame and injection moulding method with MMSH to compact disc driver is one of the industrial. A simple mould tool modification for compact disc driver by attaching the needle hole units on one side plate of mould is enough for the MMSH mould tool with gas flame. And heating up the mould surface to 200 °C for the injecting the molten resin with gas flame. It will improve the reflection of fine texture for the memory of compact disc driver and increase the production quantity up to 50% of present production and save the cost at this proportion. [Industrial Applicability] 1. Ready made mould tools could be modified simply inserting needle hole gas supply unit and/or multi gas supplying unit and apply gas flame to heat up the mould surface. It will improve the quality of plastic component and eliminate every problems of exsisting component. 2. TV housing mould designed with needle hole gas supply unit and multi gas supply unit and apply the gas flame to heat up the mould surface higher than glass transition temperature of applied resin. The TV cabinet housing component will reflect no weld line and flow mark and could be used without painting and designed 1.5mm of wall thickness. It will reduce the cost from 30% to 50% of the total cost of TV cabinet production.

Claims: [What is claimed for patent] l.The mould tools for injection moulding and injection blow moulding and thermal forming and vacuum forming which is designed a mould surface heating devices using gas flames equipped a needle hole gas fuel supplying devices and multiple gas and oxigen and air supplying unit attached on the moving support system. 2. The needle hole gas fuel and oxigen or air suppling unit which has a or some holes smaller than the non flow thickness of the resin through which the gas fuel and oxigen and air pass but the molten resin does not pass. 3. The device of multiple holes for gas fuel and oxigen and air attached on the moving support in the mould tool so that it come out of mould surface and supply the gases and buried under the mould when the mould tool is closed completely. 4. The plastic moulded products which are produced with the MMSH mould tools and MMSH forming process as described in clause 1 to 3.

Inventors: YIM SOOK-JIA, YIM, SOOK-JIA
Applicants: YIM SOOK JIA, YIM, SOOK-JIA
Application year: 1998
Main classification: B29C33
IPC codes: B29C33, B29C35, B29C45