新能源汽车PC灯罩的注塑模具设计

Design of injection mould for PC lampshade of new energy vehicles

针对某款新能源汽车聚碳酸酯(PC)灯罩的结构特点,模具采用一模两腔“L+R”形式的型腔布局。通过对产品成型的CAE分析,模具采用两组针阀式的热流道结构。根据产品外表面局部多处内凹的特征,对定模设计了结构紧凑的“弹块+斜导柱”的脱模结构,并通过机械拉钩机构保证弹块工作的可靠性。由于产品为透明塑件,因此对产品内表面的质量要求也高,又由于其结构较为复杂,产品有多处安装定位特征,对动模采用“斜导柱+滑块+成型块”的联动抽芯结构。在顶出系统方面采用了“方直顶杆+导向块+大顶块”的方式,成功解决产品顶出困难的问题。在冷却系统方面,各个大弹块及大顶块中都设有直径8 mm的独立水路,其余部位设计为直径11.5 mm的水路,将产品包在中间,组成“随形水路”。模具投产后,各抽芯及顶出机构运行平稳,产品各项参数均符合要求,证明各机构设计合理,安全有效。

Based on the structural characteristics of a polycarbonate(PC)lampshade for a certain new energy vehicle,the mould adopted the cavity layout of“L+R”form with one mould and two cavities.Through CAE analysis of the product forming,the mould adopted two sets of needle valve hot runner structures.Based on the local concave features on the outer surface of the product,a compact demolding structure of"spring block+inclined guide pillar"was designed in the fixed mold,and the reliability of the spring block's operation was ensured through a mechanical hook mechanism.As the product is a transparent plastic part,the quality requirements for the inner surface of the product are also high.Due to the complex structure,the product has multiple installation and positioning features,the dynamic mold adopted a linked core pulling structure of"inclined guide pillar+slider+forming block".In terms of the ejection system,the method of"square top rod+guide block+large top block"was adopted,successfully solving the problem of difficult product ejection.In terms of cooling system,independent waterways with a diameter of 8 mm were installed in each large projectile and top block,while the rest of the parts were designed as waterways with a diameter of 11.5 mm,the product was packaged in the middle to form a"conformal waterway".After the mould was put into production,each core pulling and ejection mechanism operated smoothly,and all product parameters met the requirements,proving that the design of each mechanism was reasonable,safe and effective.