Research On The Uv Curing Manufacture Of Plastic Products With Micro Features

With the development of injection molding technology the products manufactured by injection molding has been used in various fields, meanwhile, the micro-products manufactured by micro-injection molding has higher accuracy than before, but suing the traditional injection molding to fabricate products must be in the condition of high temperature and high pressure, thus the cost will be raised undoubtedly. And even the process conditions are satisfied, the parts can not sharp well because the tiny change of the environment condition. Taking these into account, the UV curing technology and injection molding technology were combined to put forward the concept of ultraviolet photochemical production. And the main research results as follows:1. The new UV curing chemical manufacturing method was put forward for the first time, and the platform using in the experiments was established.The UV micro layer curing principle was put forward according to the UV material characteristics, and the experiment have been carried on to testify the correct of this principle. Meanwhile, the mold have been designed and processed according to the micro layer principle, the characteristic of the UV material and the mold already have. At the same time, the mold core have been processed in two method-laser sharp and micro milling.2. This research reveals that inherent law between the micro-structure sharp, internal form of the part and the UV process conditions.In the paper, the UV curing injection mold parameters have been proposed, and the experiments have been conducted on the basis of formability of the UV curing injection mold. At the same time, the internal form of the products curing in different process parameters have been shot, and then the best process parameters have been point out. When experiment is carried on in the packing pressure of0.5MPa, and the UV material temperature of35℃, the whole weight of20products reach it maximum, meanwhile there is no flaws as bubble or infilling appears in the products.When the packing pressure is0.5MPa, UV material forming conditions of temperature of35℃, the maximum of20products total weight7.24g, and under the condition of the process, best products microstructure of internal form, no bubble, filling the existence of defects such as incomplete.3. The replication fidelity was set as the assessment criteria for the microstructure quality, and the experiment have been done to point out the inherent law between UV parameters, UV material character, injection molding parameters and the micro structure quality. UV monomer content, type in the UV material and other injection molding process parameters have been separately tested to point out the incidence for the integrity and height replication fidelity of the microstructure.The experimental results show that the UV curing injection molding formability increases as the UV intensity increase, the UV dose increase and the decrease distance between mold surface and the UV device. The high UV intensity can make the UV curing process more quickly, thus mold formability became well as the same time; the more UV dose be input the more sufficient react.The gas bubbles will cannot be put out in the injection process when the packing pressure is relative low; the UV material will spill from the micro gap between the glass and the mold plate when packing pressure is relatively high. There is little defect appear when the medium packing pressure is applied, so the micro feature and the internal form is reach the best state. When the UV material temperature is low, the cavity pressure will be relatively high and defects like short filling will turn up; When the UV material temperature is high, the cavity pressure will be relatively low so the overflow phenomenon of the UV material will appears. The medium UV material temperature applied in the experiment can make the micro feature and the internal form turning into its best state. The result from the apparent measuring instrument show that the replication fidelity will reduce when the active groups in the monomer increase, and with the monomer content rising in the UV material, the replication fidelity reduce in the beginning and then remain unchanged. The changed in the kind of the monomer and the content of the monomer in the UV material will lead to the structure changing in the reacted UV material products. The result from the image measuring instrument show that as the UV dose increase the integrity and the replication fidelity will improve, meanwhile with the UV material temperature be raised the replication fidelity of the micro feature became better best the integrity of the micro feature unchanged all the time. The more UV dose is applied in the curing process, the high strength the micro feature have; the UV temperature increase only accelerates the speed of the UV curing reaction.