注塑气辅技术指南
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气体辅助注塑成型
气体辅助注塑成型是从传统的注射成型发展而来的。它的工作原理是将高压氮气通过注塑喷嘴或气针射至模腔内。射入的气体会产生气泡，这个气泡将推动熔体塑料进入模具的末端从而产生中空截面。
气辅成型有很多工艺和设计特点，这些工艺和设计特点有助于满足应用要求。一些潜在的特性和优点如下：
Extend Design Guidelines
Troubleshooting
过程控制
厚壁形成
厚壁的控制
速度对厚壁的影响
零件的连贯性
厚壁和气体渗入的相互作用
发现并修理故障
About Gas Assist Injection Molding
Gas assist injection molding is a variation of conventional injection molding that can be easily retrofitted to an existing injection press by the addition of an auxiliary gas unit. The usual injection of molten plastic is assisted by the introduction of pressurized gas (usually nitrogen) into the mold. The gas produces a bubble which pushes the plasticinto the extremities of the mold creating hollow sections as the bubble propagates.
-增加结构件的强度/坚固度对质量的比值，
- Molding large cross-sections (parts consolidation)
-形成大型平板类零件
Lower Production Costs
降低生产成本
Short Shot Process With Hollow Sections Can Result in:
气辅成型的步骤
气辅成型可分为3个阶段：树脂注入，初始气体穿透和二次气体穿透（见图1）。
Stage 1: Resin Injection
–The polymer is injected into the mold as a short shot or partially packed cavity.
–
Injection Molding Gas Assist Technology Guide
气体辅助注塑成型技术指南
Contents
About Gas Assist Injection Molding
有关气体辅助注塑成型
Process Mechanics
Stages Biblioteka f Gas Assist Molding
The gas bubble extends as the part cools and the material shrinks. The extra cavity volume created as the material shrinks is taken up by the gas bubble. The pressure in the bubble also provides packing of the part during secondary gas penetration.
步骤二：
—在聚合物到达模具末端完成填充时，二次气体穿透过程随之开始。当零件冷却和材料收缩时，气泡将扩张。当材料收缩被气泡占据时，额外的型腔空间就会随之产生。在二次气体穿透期间，气泡中的压力提供了产品的保压。
Stage:阶段，melt:熔体, short shot:短射，melt front:熔体前端，solid layer：固化层，primary gas penetration：初始气体穿透，deforming melt:未成型熔体，molten layer：熔体层，gas front：气体前端，hollow core:气核，secondary gas penetration:二次气体穿透
图1：气辅成型的步骤
气体进入阻力最小的路径
The gas bubble propagates within the molten core along the path of least resistance through the cavity. This path is determined by lower pressures and higher temperatures. Lower pressure areas are determined by melt front location, cross-sectional area, and position of the polymer injection gate. Higher temperature areas occur in centers of thick sections, high-shear regions, and as a result of mold temperature variations.Higher temperatures also result in lower melt viscosities. During primary gas penetration, the gas bubble can only penetrate into areas of the part, where displaced polymer can flow easily to unfilled sections of the mold. The melt pressure variation within the cavity usually dominates the bubble propagation during primary gas penetration.
光滑表面外观可：
- Improved aesthetics vs. structural foam
-改善美观VS.结构泡沫
- Reduced secondary operations
-减少二次操作
Dimensional Stability
尺寸稳定性
Uniform Packing from Within the Cavity Can Result in:
Gas Channel Layout
Balancing of Polymer Fill
Gas Channel Size and Geometry
Channel System Design Procedure
Process Analysis
Part Analysis
Material Selection
Process Mechanics
过程机制
Stages of Gas Assist Molding
Gas assist molding can be divided into three stages: resin injection, primary gas penetration, and secondary gas penetration (See Figure 1).
扩大设计指南
Hollow Thick Parts or Thick Sections Within Parts Can Enable:
中空厚零件或厚截面可：
- Large ribs or flow leaders without process penalties
-厚筋或流向引导
- Higher stiffness-to-weight ratio in structured parts
Path of Least Resistance for Gas Penetration
Packing via Gas Assist
过程机制
气辅成型阶段
气体进入阻力最小的通道
气体保压
Process Methods
Process Sequence
Gas Injection Location
Gas Delivery System
–
步骤2：初步气体穿透
—气体被注入到熔芯中形成气泡。气泡占据了熔芯的一部分，并将树脂推入到未填充的型腔中从而完成型腔的填充。
Stage 3: Secondary Gas Penetration
– Secondary gas penetration begins at the end of the filling stage when the polymer has reached the end of the mold.
步骤1：树脂注入
-聚合物作为“短射”被注入到模腔中。
Stage 2: Primary Gas Penetration
–Gas is introduced into the molten core forming a bubble. The gas bubble displaces some of the molten core, pushing it into the unfilled cavity and completing the mold filling
目前，在塑料业使用着几种不同的气辅成型。它们的不同之处是由不同的气体注入方法和位置产生的。气体可通过机器喷嘴、流道系统、浇口、或通过恒定压力和体积直接注入模具型腔中。一些气体注射法有一种或更多的专利保护。在使用一种明确的气辅成型工艺前应获得一份合适的许可证。
气体辅助技术使采用CYCOLOY树脂制成的C&A塑料注塑成型成汽车上刹车块的操作变得更简易，同时还增加了零件的坚固度。
Gas assist molding offers a variety of process and design features which can help to meet application requirements.
Some of the potential features and benefits are listed below:
以下方法可提高工装设计自由度：
- Replacement of external hot and cold runners with interior gas channels
-将外部的冷热流道替换为内部的气道
Several variations of gas assist molding are used by the plastics industry. They are differentiated by the method and location of the gas injection into the polymer melt. The gas can be injected through the machine nozzle, runner system, sprue, or directly into the mold cavity under a constant pressure or a constant volume. Some gas injection methods are covered by one or more process patents. An appropriate licensing agreement must be obtained prior to utilizing a specific type of gas assist molding process.
短射和中空截面可：
- Lower clamp tonnage
-降低锁模力
- Lower injection pressures
-降低注塑压力
- Reduced cycle time vs. solid sections
-减少周期时间VS.固体截面
Smooth Surface Appearance Can Result in:
Secondary Operations
零件设计
零件类型
开放式通道零件的设计
气体通道布局
聚合物填充的均衡
气体通道尺寸和几何图形
通道系统设计程序
过程分析
零件分析
材料选择
二次操作
Mold Tool Design
Mold Materials
Tool Design
模具工装设计
模具材料
工装设计
Process Control
Wall Thickness Formation
Control of Wall Thickness
Effect of Viscosity on Wall Thickness
Part Consistency
Interaction of Wall Thickness with Gas Penetration
型腔内保压一致可：
- Reduced stress within part
-降低产品的内应力
- Reduced part warpage
-减少产品的翘曲
- Reduced sink marks Enhance
-减少凹痕
Enhance Flow/Tool Design
提高流动/工装设计
Tool Design Freedom Can Be Obtained by:
工艺方法
工艺顺序
气体注入位置
气体运送系统
Part Performance
Structural Performance
Part Stiffness
Part Strength
零件性能
结构性能
零件的坚固性
零件的强度
Part Design
Types of Parts
Design of Open Channel Parts
气体辅助注塑成型是从传统的注射成型发展而来的。它的工作原理是将高压氮气通过注塑喷嘴或气针射至模腔内。射入的气体会产生气泡，这个气泡将推动熔体塑料进入模具的末端从而产生中空截面。
气辅成型有很多工艺和设计特点，这些工艺和设计特点有助于满足应用要求。一些潜在的特性和优点如下：
Extend Design Guidelines
Troubleshooting
过程控制
厚壁形成
厚壁的控制
速度对厚壁的影响
零件的连贯性
厚壁和气体渗入的相互作用
发现并修理故障
About Gas Assist Injection Molding
Gas assist injection molding is a variation of conventional injection molding that can be easily retrofitted to an existing injection press by the addition of an auxiliary gas unit. The usual injection of molten plastic is assisted by the introduction of pressurized gas (usually nitrogen) into the mold. The gas produces a bubble which pushes the plasticinto the extremities of the mold creating hollow sections as the bubble propagates.
-增加结构件的强度/坚固度对质量的比值，
- Molding large cross-sections (parts consolidation)
-形成大型平板类零件
Lower Production Costs
降低生产成本
Short Shot Process With Hollow Sections Can Result in:
气辅成型的步骤
气辅成型可分为3个阶段：树脂注入，初始气体穿透和二次气体穿透（见图1）。
Stage 1: Resin Injection
–The polymer is injected into the mold as a short shot or partially packed cavity.
–
Injection Molding Gas Assist Technology Guide
气体辅助注塑成型技术指南
Contents
About Gas Assist Injection Molding
有关气体辅助注塑成型
Process Mechanics
Stages Biblioteka f Gas Assist Molding
The gas bubble extends as the part cools and the material shrinks. The extra cavity volume created as the material shrinks is taken up by the gas bubble. The pressure in the bubble also provides packing of the part during secondary gas penetration.
步骤二：
—在聚合物到达模具末端完成填充时，二次气体穿透过程随之开始。当零件冷却和材料收缩时，气泡将扩张。当材料收缩被气泡占据时，额外的型腔空间就会随之产生。在二次气体穿透期间，气泡中的压力提供了产品的保压。
Stage:阶段，melt:熔体, short shot:短射，melt front:熔体前端，solid layer：固化层，primary gas penetration：初始气体穿透，deforming melt:未成型熔体，molten layer：熔体层，gas front：气体前端，hollow core:气核，secondary gas penetration:二次气体穿透
图1：气辅成型的步骤
气体进入阻力最小的路径
The gas bubble propagates within the molten core along the path of least resistance through the cavity. This path is determined by lower pressures and higher temperatures. Lower pressure areas are determined by melt front location, cross-sectional area, and position of the polymer injection gate. Higher temperature areas occur in centers of thick sections, high-shear regions, and as a result of mold temperature variations.Higher temperatures also result in lower melt viscosities. During primary gas penetration, the gas bubble can only penetrate into areas of the part, where displaced polymer can flow easily to unfilled sections of the mold. The melt pressure variation within the cavity usually dominates the bubble propagation during primary gas penetration.
光滑表面外观可：
- Improved aesthetics vs. structural foam
-改善美观VS.结构泡沫
- Reduced secondary operations
-减少二次操作
Dimensional Stability
尺寸稳定性
Uniform Packing from Within the Cavity Can Result in:
Gas Channel Layout
Balancing of Polymer Fill
Gas Channel Size and Geometry
Channel System Design Procedure
Process Analysis
Part Analysis
Material Selection
Process Mechanics
过程机制
Stages of Gas Assist Molding
Gas assist molding can be divided into three stages: resin injection, primary gas penetration, and secondary gas penetration (See Figure 1).
扩大设计指南
Hollow Thick Parts or Thick Sections Within Parts Can Enable:
中空厚零件或厚截面可：
- Large ribs or flow leaders without process penalties
-厚筋或流向引导
- Higher stiffness-to-weight ratio in structured parts
Path of Least Resistance for Gas Penetration
Packing via Gas Assist
过程机制
气辅成型阶段
气体进入阻力最小的通道
气体保压
Process Methods
Process Sequence
Gas Injection Location
Gas Delivery System
–
步骤2：初步气体穿透
—气体被注入到熔芯中形成气泡。气泡占据了熔芯的一部分，并将树脂推入到未填充的型腔中从而完成型腔的填充。
Stage 3: Secondary Gas Penetration
– Secondary gas penetration begins at the end of the filling stage when the polymer has reached the end of the mold.
步骤1：树脂注入
-聚合物作为“短射”被注入到模腔中。
Stage 2: Primary Gas Penetration
–Gas is introduced into the molten core forming a bubble. The gas bubble displaces some of the molten core, pushing it into the unfilled cavity and completing the mold filling
目前，在塑料业使用着几种不同的气辅成型。它们的不同之处是由不同的气体注入方法和位置产生的。气体可通过机器喷嘴、流道系统、浇口、或通过恒定压力和体积直接注入模具型腔中。一些气体注射法有一种或更多的专利保护。在使用一种明确的气辅成型工艺前应获得一份合适的许可证。
气体辅助技术使采用CYCOLOY树脂制成的C&A塑料注塑成型成汽车上刹车块的操作变得更简易，同时还增加了零件的坚固度。
Gas assist molding offers a variety of process and design features which can help to meet application requirements.
Some of the potential features and benefits are listed below:
以下方法可提高工装设计自由度：
- Replacement of external hot and cold runners with interior gas channels
-将外部的冷热流道替换为内部的气道
Several variations of gas assist molding are used by the plastics industry. They are differentiated by the method and location of the gas injection into the polymer melt. The gas can be injected through the machine nozzle, runner system, sprue, or directly into the mold cavity under a constant pressure or a constant volume. Some gas injection methods are covered by one or more process patents. An appropriate licensing agreement must be obtained prior to utilizing a specific type of gas assist molding process.
短射和中空截面可：
- Lower clamp tonnage
-降低锁模力
- Lower injection pressures
-降低注塑压力
- Reduced cycle time vs. solid sections
-减少周期时间VS.固体截面
Smooth Surface Appearance Can Result in:
Secondary Operations
零件设计
零件类型
开放式通道零件的设计
气体通道布局
聚合物填充的均衡
气体通道尺寸和几何图形
通道系统设计程序
过程分析
零件分析
材料选择
二次操作
Mold Tool Design
Mold Materials
Tool Design
模具工装设计
模具材料
工装设计
Process Control
Wall Thickness Formation
Control of Wall Thickness
Effect of Viscosity on Wall Thickness
Part Consistency
Interaction of Wall Thickness with Gas Penetration
型腔内保压一致可：
- Reduced stress within part
-降低产品的内应力
- Reduced part warpage
-减少产品的翘曲
- Reduced sink marks Enhance
-减少凹痕
Enhance Flow/Tool Design
提高流动/工装设计
Tool Design Freedom Can Be Obtained by:
工艺方法
工艺顺序
气体注入位置
气体运送系统
Part Performance
Structural Performance
Part Stiffness
Part Strength
零件性能
结构性能
零件的坚固性
零件的强度
Part Design
Types of Parts
Design of Open Channel Parts