TPU瓶身外观不良解决过程——模具行业从业者必备知识手册
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<p>改善前</p>
<p>!<a href="upload://m5ZaQ12TLlNrLDKwh2EcOfSW0Oa.jpeg">image|162x237</a></p>
<p>改善后</p>
<p>!<a href="upload://iRZ1Wv4UPQVX1dXIDusj42e7kuX.jpeg">image|554x290</a></p>
<p>进胶方案示意图：</p>
<p>!<a href="upload://n7n3SNImo0HPfAdCpax8LwN29L0.jpeg">image|402x489</a></p>
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<p>踩过坑的来评论区说说。</p> -
<p>产品结构构成：卡扣（奇美ABS材料），瓶身（TPU材质，配方软硬度可调，跟硅胶类似，本案调的硬度是HA70±5度）；卡圈（PC材料）</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/ee1f4ab0d11ace28c69bcd3d4d1d96eea20e736c.jpeg" data-download-href="https://www.mj7.cn/uploads/default/ee1f4ab0d11ace28c69bcd3d4d1d96eea20e736c" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/ee1f4ab0d11ace28c69bcd3d4d1d96eea20e736c.jpeg" alt="image" data-base62-sha1="xYwGaTI83Z8dRcHieFCfAnm76PO" width="427" height="457"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">427×457 44.9 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p>模具进胶方案如上面所示意。整体成型工艺方案，采用包胶模成型方式，不用双色模（成本和技术方案复杂原因不采用）。总共开三副模具，其中卡扣模具和卡圈模具为零件模，而瓶身模具才是包胶模。所谓的零件模，就是只成型零件（不带任何嵌件），包胶模就是指要把嵌件（含金属和非金属）放进模具，然后生产出来的产品包含嵌件。</p>
<p>具体的模具结构和图片就略过，跟主题关系不大。</p>
<p>TO试模，两副零件模正常。包胶模出了如下问题：1.出模异常，粘前模，（软胶产品出模一向都比较复杂，除非有类似产品经验，否则想从设计上一步到位有难度）；2.不能自动顶出，跟粘前模有关；3.外观流痕发亮严重（黑色产品明显，米白色产品可以接受），详见下图。</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/c898464f4d5dad996aec2fc22b36cdf7e9ddc93f.jpeg" data-download-href="https://www.mj7.cn/uploads/default/c898464f4d5dad996aec2fc22b36cdf7e9ddc93f" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/c898464f4d5dad996aec2fc22b36cdf7e9ddc93f.jpeg" alt="image" data-base62-sha1="sCxJWtevshIgEZ2R8tIFOK7eUFN" width="276" height="295"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">276×295 16.8 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/035c2ef89df6824fc9ccf78b90e751c6a12b2a49.jpeg" data-download-href="https://www.mj7.cn/uploads/default/035c2ef89df6824fc9ccf78b90e751c6a12b2a49" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/035c2ef89df6824fc9ccf78b90e751c6a12b2a49.jpeg" alt="image" data-base62-sha1="tIVWDqw5pJGThVi3bEHf3WeEQ1" width="235" height="294"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">235×294 17 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p> -
<p>针对以上出现的三个问题，第一个问题的解决方案，因为前面出模时有真空，导致产品被吸在前模（拔模加大会影响外观，看起来不是圆柱体，成锥体了，客人不能接受）。后模型芯加倒扣，把产品拉回后模，便后续的顶出机构发挥作用。具体产品结构的更改位置见下图，箭头所指，一圈一圈。因为这个内腔主要是放液体，又不是外观面，用户可以接受。问题解决。</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/5c6a5aaad96ccc037d2aeeb267fb17fdb7795d22.jpeg" data-download-href="https://www.mj7.cn/uploads/default/5c6a5aaad96ccc037d2aeeb267fb17fdb7795d22" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/5c6a5aaad96ccc037d2aeeb267fb17fdb7795d22.jpeg" alt="image" data-base62-sha1="dbxMYUhY3iysiTywrUzN83P08nw" width="554" height="375"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">554×375 41 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p>第二个问题的解决方案：由于产品没有粘前模了，顶出产品就是顺理成章。但是这个产品的外观要求比较高，不能采用顶出自动掉落的方式生产，因为会导致外观面撞划伤。所以只能把产品顶出方便人工取出的状态，由工人手取下来。效率慢，不能全自动生产。问题算是解决了。</p> -
<p>第三个问题的解决方案：首先这种现象的成因一般都是跟浇口有关。在这里你们会看到，在进胶时，是从壁厚薄的地方开始进胶，然后再到壁厚厚的地方，如下图所示。</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/1627c7a2088a3117cff002482b3c2912e9b93890.jpeg" data-download-href="https://www.mj7.cn/uploads/default/1627c7a2088a3117cff002482b3c2912e9b93890" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/1627c7a2088a3117cff002482b3c2912e9b93890.jpeg" alt="image" data-base62-sha1="39ZJoCR4QVQqkUTIaNg52K8a9RC" width="554" height="355"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">554×355 38.7 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p>这种情况的入胶，在壁厚薄处进胶速度快，再加有拐角，会导致这附近温度高，压力高，导致对模具型腔的表面复制得更好更细腻，胶料结构变化，局部产品外观就会变亮。<br>
解决的问题的原则是，哪里出现的问题就针那个地方进行研究方案。所以，壁厚薄的地方看能不能加厚点，附近的模具温度能不能控下来稳定，而不能一直处于高温。最后拿出的方案，就是更改卡扣的结构，使包胶件的进料壁厚变大。具体修改情况见下图。</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/c5116205bbfb38129d515d8a9a4d08f6d974d2b9.jpeg" data-download-href="https://www.mj7.cn/uploads/default/c5116205bbfb38129d515d8a9a4d08f6d974d2b9" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/c5116205bbfb38129d515d8a9a4d08f6d974d2b9.jpeg" alt="image" data-base62-sha1="s7liRZSD8kPTfPoZTpPpealrAF3" width="554" height="237"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">554×237 19.8 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p> -
<p>实际3d档如下：</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/f28aae3cd3f14547b8b526217b46595ffa8e0cc3.jpeg" data-download-href="https://www.mj7.cn/uploads/default/f28aae3cd3f14547b8b526217b46595ffa8e0cc3" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/f28aae3cd3f14547b8b526217b46595ffa8e0cc3.jpeg" alt="image" data-base62-sha1="yBCFwjDXZtC5B0eJ7h2KVa1Ppg7" width="554" height="234"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">554×234 20.5 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p>修改后的整体结构图如下：</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/b2deef28b82532edcde248746b8f210ed953ca1d.jpeg" data-download-href="https://www.mj7.cn/uploads/default/b2deef28b82532edcde248746b8f210ed953ca1d" title="image"><img src="https://www.mj7.cn/uploads/default/optimized/1X/b2deef28b82532edcde248746b8f210ed953ca1d_2_423x500.jpeg" alt="image" data-base62-sha1="pwmCH0Ow4pLRus6HQeH0xnDrdgh" width="423" height="500" srcset="https://www.mj7.cn/uploads/default/optimized/1X/b2deef28b82532edcde248746b8f210ed953ca1d_2_423x500.jpeg, https://www.mj7.cn/uploads/default/original/1X/b2deef28b82532edcde248746b8f210ed953ca1d.jpeg 1.5x, https://www.mj7.cn/uploads/default/original/1X/b2deef28b82532edcde248746b8f210ed953ca1d.jpeg 2x" data-dominant-color="986D78"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">466×550 63.7 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p>实际改模好后，试出来的产品：</p>
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/85f50e2827665706919e35fc01aa44ccadcfa1e8.jpeg" data-download-href="https://www.mj7.cn/uploads/default/85f50e2827665706919e35fc01aa44ccadcfa1e8" title="image"><img src="https://www.mj7.cn/uploads/default/optimized/1X/85f50e2827665706919e35fc01aa44ccadcfa1e8_2_354x500.jpeg" alt="image" data-base62-sha1="j72wZveQLUlYUSpNcW5A9MHOVvy" width="354" height="500" srcset="https://www.mj7.cn/uploads/default/optimized/1X/85f50e2827665706919e35fc01aa44ccadcfa1e8_2_354x500.jpeg, https://www.mj7.cn/uploads/default/original/1X/85f50e2827665706919e35fc01aa44ccadcfa1e8.jpeg 1.5x, https://www.mj7.cn/uploads/default/original/1X/85f50e2827665706919e35fc01aa44ccadcfa1e8.jpeg 2x" data-dominant-color="474240"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">507×716 55.1 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p> -
<p><div class="lightbox-wrapper"><a class="lightbox" href="https://www.mj7.cn/uploads/default/original/1X/e04d4af8741d853483ca2bdd088843d3488c8d16.jpeg" data-download-href="https://www.mj7.cn/uploads/default/e04d4af8741d853483ca2bdd088843d3488c8d16" title="image"><img src="https://www.mj7.cn/uploads/default/original/1X/e04d4af8741d853483ca2bdd088843d3488c8d16.jpeg" alt="image" data-base62-sha1="w0gyg1uz4PNbBQAHxFvleWt66j4" width="554" height="283"><div class="meta"><svg class="fa d-icon d-icon-far-image svg-icon" aria-hidden="true"><use href="#far-image"></use></svg><span class="filename">image</span><span class="informations">554×283 38.3 KB</span><svg class="fa d-icon d-icon-discourse-expand svg-icon" aria-hidden="true"><use href="#discourse-expand"></use></svg></div></a></div></p>
<p>跟原来的外观对比，已经改善很多，客人也可以接受。<br>
第三个问题也算是较完美的解决了。</p>
