塑膠射出成型模具Plastics Injection Mold綱要1.模具結構(Mold Structure)2.流道系統（Runner System）3.冷卻系統（Cooling System）4.頂出系統（Ejection System）5.模具種類(Type of Mold)模具的構造Mold Structure模具的構造主要可分為下列五部分：1.模座（Mold Base)2.型腔（Cavity）3.流道系統（Runner System）4.冷卻系統（Cooling System）5.頂出系統（Ejection System）型腔Cavity射出成型模是由一組部件組成的總成。部件中有一稱為型腔者，熔體注入其中，繼之以冷卻定型。型腔是由兩部分組成：1.母模；給予成型零件的外部造型，2.公模；給予成型零件的內部造型。The injection mold is an assembly of parts containing within it a ‘cavity’into which melt is injected, cooled and formed. The cavity is formed by two mold members: 1. The cavity, which isthe female portion of the mold, gives the part its external form, 2. The core, which is the male portion of the mold, forms the internal shape of the part.公和母模板Core and Cavity Mold Plate公模仁和母模仁Core and Cavity Mold Inserts分模面Parting Surface模具的分模面是模板和模穴鄰接的部分，這部分面對面接觸，以形成密封，以防熔體自腔型溢出。分模面可分為平面或非平面，後者又可分為階梯狀、輪廓狀或斜角狀。The parting surfaces of a mold are those portions of both mold plates, adjacent to the cavities, which butt together to form a seal and prevent the loss of melt from the cavity. Theparting surface can be classified as either flat or non-flat. The later one can be further classified as either stepped, profiled and angled.澆注系統Runner System在射出成型模中以流路將(射出成型機的)噴嘴和型腔連接起來。此一流路稱為澆注系統，一般包含了豎澆道、流道和澆口。A flow-way is provided in the injection mold to connect the nozzle (of the injection machine) to each cavity. This flow-way is termed the feed system. Normally the feed system comprises a sprue, runner and gate.澆注系統Runner System豎澆道Sprue澆口Gate主流道Main Runner成品Part冷料井Cold Slug Well支流道Branch Runner冷流道和熱流道Cold Runner and Hot Runner冷流道和成型零件一塊兒冷卻、固化、成型和頂出。熱流道連接噴嘴與型腔(或冷豎澆道或冷流道)，維持在熔融狀態下，可以間歇性的注入型腔。Cold runner is cooled, solidified, formed and ejected, with parts. Hot runner, connecting nozzle and cavities (or cold spruesor cold runners), is maintained at a melt and can be fed intermittently into the cavities.流道設計考慮(1)••••••••••單模穴或多模穴冷流道系統或熱流道系統自然平衡或人工平衡流道(多模穴模具)澆口數目澆口位置澆口形狀澆口尺寸流道配置(多模穴模具)流道截面形狀流道尺寸流道設計考慮(2)••流道系統與成品重量比例流道系統對成品品質的影響•••••••••熔膠在模穴流動充填的方式射出壓力、保壓壓力熔膠溫度縫合線的控制空氣包陷的形成排氣孔道位置美觀避免短射充填不足避免不均衡擠壓••流道系統與頂出機構的配合節省塑料排氣系統Venting System當熔體進入型腔，空氣被置換。為了使空氣得以逃逸，一條淺的排氣口可以加工在模面上。排氣道也可穿過模板，比如說，在必要的位置加頂出銷，頂出銷和模板孔之間的小間隙就足以讓空氣逃逸。When melt enters a cavity, air is displaced. In order to let air escape, the surface vent, a shallow slot, can be machined into the mold plate. The vent can also be provided through the mold plate, e.g. incorporating an ejector pin in the required position. The minute gap between the ejector pin and the mold plate hole is sufficient to allow the air to escape.冷卻系統Cooling System熱的熔體在型腔內冷卻、固化和定型。為了維持模具和熔體間的溫度差，冷卻液在模具內的孔道循環。連接整個軟管和孔道的系統叫作迴路。Hot melt is cooled, solidified and formed in the cavity. To maintain the required temperature difference between the mold and the melt, coolant is circulated through holes or channels within the mold. The complete system of connecting holes and channels is called circuit.冷卻系統（含模溫控制器）示意圖Cooling System冷卻系統的組成Construction of Cooling System•••••••模溫控制機(Temperature Controlling Unit)幫浦(Pump)配管(Piping)供水岐管(Supply Manifold)連接軟管(Connection Hose)模具內之冷卻管路(Cooling Channel)集水岐管(Collection Manifold)冷卻系統Cooling System冷卻製程相關參數Relevant Processing Parameters 五大類別•熔膠與成型品幾何特性•塑膠熱物性質(密度、比熱和熱傳導係數)•成品厚度及幾何•模具材質•模座材料與熱物性質•模穴崁塊材料與熱物性質•冷卻管路設計-冷卻管路佈置、種類與尺寸•冷卻液性質-冷卻液熱物性質與流變性質•冷卻操作條件-冷卻液溫度、頂出溫度(冷卻時間)•其它-接觸熱阻(Contact Thermal Resistance)整體影響效益-模具溫度與分佈紊流和層流Turbulent and Laminar Flows紊流Turbulent Flow層流Laminar Flow雷諾數Reynolds Number雷諾數(無因次)Reynolds number (dimensionless)密度density (g/cm3)直徑diameter (cm)速度velocity (cm/sec)黏度viscosity (poise or dyne-sec/cm2 or g/cm-sec)理論上最短冷卻時間Min. Possible Cooling Time理論上最短冷卻時間the min. possible cooling time產品最大厚度the max. part thickness熔膠的熱擴散度thermal diffusivity of the melt射出溫度injection temp.冷卻液溫度coolant temp.頂出溫度ejection temp.冷卻裝置Cooling Devices直線式圓管直線式方管環型圓管冷卻裝置Cooling Devices檔板(Baffle)噴流管(Bubbler)吸熱管(Heat Pipe)冷卻管道佈置Cooling Channel Layout入口Inlet出口Outlet出口Outlet入口Inlet冷卻孔道直徑、深度和節距建議值Recommended Diameter, Depth and PitchD : 直徑為10至14mm Diameter of Cooling Channel, 10 to 14 mmd : 深度為D至3DDepth, D, to 3DP : 節距為3D至5D Pitch, 3D to 5D冷卻時間和厚度分佈Cooling Time and Thickness Profile差的設計Bad Design好的設計Good Design頂出系統Ejector System材料固化時會收縮，這意味著零件會收縮在(形成零件的)公模仁上。射出成型機上的一些設備是用來自動啟動頂出系統的，這些設備置於可動模板之後。成型後的零件可以此一頂出系統自公模仁頂出。Material contracts as it solidify, which means that the part will shrink on to the core which forms it. Facilities are provided on the injection machine for automatic actuation of an ejector system, and this is situated behind the moving platen. The molded part can be ejected from the core by the ejector system.標準模座Standard Mold Base標準模座定義為標準模具零件的套裝總成，這些零件採用一些標準的型式，以便大量生產和降低成本。這種模座可以裝配好的模具單元形式購得，這種模具單元中的模板是不含型腔的，型腔則是留給專業模具廠去加工。A standard mold base is defined as an assemblage of standard mold parts, adopting some form of standardisation in order to manufacture them in quantity at a reduced cost. The mold base can be purchased as an assembled mold unit. The plates in this mold unit do not contain cavity form, as this aspect of mold manufacture is left to the specialist mold maker.標準模座Standard Mold Base模具種類Type of Mold•兩板模(Two Plate Mold)•三板模(Three Plate Mold)•螺旋模具(Unscrewing Mold)兩板模Two Plate Mold兩板模-母模側視圖“A”Half Plan View (1)1.Leader Pins/Bushings 4.Spure2.Mold Base Screws 5.Eye Bolts3.Jiffy Connectors兩板模-母模側視圖“A”Half Plan View (2)6.Locating Ring7.Cavity8.Clamping Slots兩板模-公模側視圖“B”Side Plan View(1)1.Support Pillars 3.Return Pins2.Grease Fittings 4.Leader Pinbushings兩板模-公模側視圖“B”Side Plan View(2)5.Guided Ejection 7.Jiffy Connectors6.Hollow Dowel 8.SpurePuller兩板模-公模側視圖“B”Side Plan View(3)9.Ejector Pins 10.Core兩板模Top View (1)1.Top Clamp Plate 4.Support Plate2.”A”Plate 5.Ejector Rails3.”B”Plate 6.-7. Ejector Plate兩板模Top View (2)8.Mold Base Screws9.Water Lines10.Hollow Dowel11.Camping Slots12.Bottom Clamp Plate13.Mold Base Screws14.Ejector Housing兩板模Top View (3)15.Support Pillars 18.MKO Studs16.-17.Guided Ejection滑塊系統（1）Two Plate Mold-Slide (1)1.Horn Pin 3.Slide2.Heel Blocks滑塊系統（2）Two Plate Mold-Slide（2）4.Wear Plate5.Spring Ball Plunger兩板模作動順序(1st)Two Plate Mold’s Sequencing(1st)兩板模作動順序(2nd)Two Plate Mold’s Sequencing(2nd)頂出機構（1）Stripper Plate Mold (1)1.Stripper Plate2.Stripper Plate Bushing3.Leader Pin and Bushing頂出機構（2）Stripper Plate Mold (2)4.SpruePuller Pin 7.Dowel Pin5.SpruePuller Bushing 8.Spirolox6.Stripper兩板模-頂出機構作動順序(1st)Stripper Plate Mold’s Sequencing(1ST)兩板模-頂出機構作動順序(2nd)Stripper Plate Mold’s Sequencing(1st)三板模Three Plate Mold三板模(1)Three Plate Mold (1)1.Stripper Bolt 4.Extension Nozzle SprueWear Bushing2.Urethane Spring 5.Extension Nozzle SprueBushing3.Stripper Bolt 6.Gate Drop Puller Pin三板模（2）Three Plate Mold (2)7.Gate Drop Puller Pin Bushing 11.Runner Plate8.Leader Pin 12.Cavity Plate Leader Pin Bushing9.Leader Pin Bushing 13.Hollow Dowel10.Runner Stripper Plate 三板模作動順序(1st)Three Plate Mold’s Sequencing(1st)三板模作動順序(2nd)Three Plate Mold’s Sequencing(2nd)三板模作動順序(3rd)Three Plate Mold’s Sequencing(3rd)三板模作動順序(4th)Three Plate Mold’s Sequencing(4th)螺旋模具Unscrewing Mold螺旋模具（1）Unscrewing Mold (1)1.Cam Followers 2.Stripper-(Grabber)-Rings3.Cam Bars螺旋模具(2)Unscrewing Mold (2)1.Racks 4.Thrust-Needle Bearings 2.Rack Wear Plates 3.Threaded Core5.Roller Bearings螺旋模具-上視圖(1)Unscrewing Mold 1.Threaded Core 3.Cam Bar Wear Plates2.Bubbler Tube 4.Cam Bars螺旋模具-上視圖（2）Unscrewing Mold 5.Cam Followers 7.Hot Drops8.Hot Manifold 6.COOLED GATE INSERT 9.Manifold SprueBushing螺旋模具作動順序(1st)Unscrewing Mold’s Sequencing (1st)螺旋模具作動順序（2nd)Unscrewing Mold’s Sequencing (2nd)
