Vanek Jiri, Ovsik Martin, Stanek Michal, Hanzlik Jan, Pata Vladimir
Faculty of Technology, Tomas Bata University in Zlin, Vavreckova 5669, 760 01 Zlin, Czech Republic.
Polymers (Basel). 2024 Aug 16;16(16):2318. doi: 10.3390/polym16162318.
This study investigates the challenges and potential of conventional injection molding for producing thick-walled optical components. The research primarily focuses on optimizing process parameters and mold design to enhance product quality. The methods include software simulations and experimental validation using polycarbonate test samples (optical lenses). Significant parameters such as melt temperature, mold temperature, injection pressure, and packing pressure were varied to assess their impact on geometric accuracy and visual properties. The results show that lower melt temperatures and higher mold temperatures significantly reduce the occurrence of dimensional defects. Additionally, the design of the gate system was found to be crucial in minimizing defects and ensuring uniform material flow. Effective packing pressure was essential in reducing volumetric shrinkage and sink marks. Furthermore, we monitored the deviation between the predicted and actual defects relative to the thickness of the sample wall. After optimization, the occurrence of obvious defects was eliminated across all sample thicknesses (lenses), and the impact of the critical defect, the sink mark on the planar side of the lens, was minimized. These findings demonstrate the substantial potential of conventional injection molding to produce high-quality thick-walled parts when these parameters are precisely controlled. This study provides valuable insights for the efficient design and manufacturing of optical components, addressing the growing demand for high-performance thick-walled plastic products.
本研究探讨了传统注塑成型在生产厚壁光学部件方面的挑战和潜力。该研究主要集中在优化工艺参数和模具设计以提高产品质量。方法包括使用聚碳酸酯测试样品（光学透镜）进行软件模拟和实验验证。对熔体温度、模具温度、注射压力和保压压力等重要参数进行了变化，以评估它们对几何精度和视觉性能的影响。结果表明，较低的熔体温度和较高的模具温度可显著减少尺寸缺陷的出现。此外，发现浇口系统的设计对于最小化缺陷和确保材料均匀流动至关重要。有效的保压压力对于减少体积收缩和缩痕至关重要。此外，我们监测了预测缺陷与实际缺陷相对于样品壁厚的偏差。经过优化，所有样品厚度（透镜）上明显缺陷的出现均被消除，并且关键缺陷——透镜平面侧的缩痕的影响被最小化。这些发现表明，当精确控制这些参数时，传统注塑成型在生产高质量厚壁部件方面具有巨大潜力。本研究为光学部件的高效设计和制造提供了有价值的见解，满足了对高性能厚壁塑料制品不断增长的需求。
