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透明塑料制品注塑成型工艺
透明塑料由于透光率要高,必然要求塑料制品表面质量要求严格,不能有任何斑纹、气孔、泛白。雾晕、黑点、变色、光泽不佳等缺陷,因而在整个注塑过程对原料、设备。模具、甚至产品的设计,都要十分注意和提出严格甚至特殊的要求。其次由于透明塑料多为熔点高、流动性差,因此为保证产品的表面质量,往往要在机高温度、注射压力、注射速度等工艺参数作细微调整,使注塑料时既能充满模,又不会产生内应力而引起产品变形和开裂。因此从原料准备,对设备和模具要求、注塑工艺和产品的原料处理几方面都要进行严格的操作。
一、料的准备与干燥由于在塑料中含有任何一点杂质,都可能影响产品的透明度,因此和储存、运输。加料过程中,必须注意密封,保证原料干净。特别是原料中含有水分,加热后会引起原料变质,所以一定要干燥,并在注塑时,加料必须使用干燥料斗。还要注意一点的是干燥过程中,输入的空气最好应经过滤、除湿,以便保证不会污染原料。其干燥工艺如,透明塑料的干燥工艺:材料工艺干燥温度(℃)干燥时间(h)料层厚度(mm)备注pmma70~802~430~40pc120~130>6<30采用热风循环干燥pet140~1803~4采用连续干燥加料装置为佳
二、机筒、螺杆及其附件的清洁为防止原料污染和在螺杆及附件凹陷处存有旧料或杂质,特别热稳定性差的树脂存在,因此在使用前、停机后都应用螺杆清洗剂清洗干净各件,使其不得粘有杂质,当没有螺杆清洗剂时,可用pe、ps等树脂清洗螺杆。当临时停机时,为防止原料在高温下停留时间长,引起解降,应将干燥机和机筒温度降低,如pc、pmma等机筒温度都要降至160℃以下。(料斗温度对于pc应降至100℃以下)
三、在模具设计上应注意的问题(包括产品的设计)为了防止出现回流动不畅,或冷却不均造成塑料成型不良,产生表面缺陷和变质,一般在模具设计时,应注意以下几点。a=壁厚应尽量均匀一致,脱模斜度要足够大;b=过渡部分应逐步。圆滑过渡,防止有尖角。锐边产生,特别是pc产品一定不要有缺口;c=浇口。流道尽可能宽大、粗短,且应根据收缩冷凝过程设置浇口位置,必要时应加冷料井;d=模具表面应光洁,粗糙度低(最好低于0.8);e=排气孔。槽必须足够,以及时排出空气和熔体中的气体;f=除pet外,壁厚不要太薄,一般不得小于lmm。
部分型号部分物性表
Physical Properties
Metric
English
Comments
Specific Gravity
0.980 g/cc
0.980 g/cc
23°C; ASTM D792
Mechanical Properties
Metric
English
Comments
Hardness, Shore A
48
48
0.078 in; ASTM D2240
Tensile Strength at Break
4.00 MPa
580 psi
Across Flow; ASTM D412
Tensile Stress
1.40 MPa
@Strain 100 %
203 psi
@Strain 100 %
Across Flow; ASTM D412
Elongation at Break
400 %
400 %
Across Flow; ASTM D412
Thermal Properties
Metric
English
Comments
Flammability, UL94
HB
@Thickness 1.70 mm
HB
@Thickness 0.0669 in
HB
@Thickness 3.00 mm
HB
@Thickness 0.118 in
Descriptive Properties
Change in Mass in IRM 903 Oil at 257°F for 70 hr
0.35
Color
Black
Form
Pellets
LDPE (low density polyethylene # LDPE) /CP plastic 763F-01/ Schulman
Uses: other
Characteristic note: good heat sealing and processability
Important parameters: melt flow rate: 1 g/10min density: 0.918 g/cm3 tensile strength: 10 MPa elongation at break: 200% bending modulus: 207 MPa hardness: 42 VEKA softening point: 92 DEG C
Manufacturer: Schulman plastics
LDPE (low density polyethylene LDPE #) /DND2450/ Japan Younika
Uses: other
Features: hollow blow molding, good formability, good drug resistance, good transparency, good flexibility and good gloss
Important parameter: melt flow rate: 1.3 g/10min density: 0.92 g/cm3
Manufacturer: KK, Japan Ltd.
LDPE (low density polyethylene LDPE /F404-H/ Japan Sumitomo #)
Application: film grade
Characteristic feature: impact strength and smoothness is very good, the film thickness of 12.5-40 microns
Important parameter: melt flow rate: 3.5 g/10min density: 0.92 g/cm3
Manufacturer: Sumitomo Chemical Industries Ltd
LDPE (low density polyethylene LDPE #) /CA8200/ Borealis
Uses: other
Features: moisture resistance, recyclable materials, good heat sealing, good cohesiveness, low odor, no additives
Important parameter: melt flow rate: 7.5 g/10min density: 0.918 g/cm3
Manufacturer: Nordic Chemical Company Limited
LDPE (low density polyethylene # high-pressure polyethylene) /N150/ Shanghai petrochemical
Application: film grade
Characteristic note: polymer type: homopolymerization
Important parameters: melt flow rate: 1.5 g/10min density: 0.918 g/cm3 tensile strength: 12.5 MPa, elongation at break: 550%
Manufacturer: Sinopec, Shanghai petrochemical, Limited by Share Ltd
LDPE (low density polyethylene # LDPE) /2602TH33/ SABIC of Saudi Arabia
Application: film grade
Characteristic note: high optical performance and low coefficient of friction. Product trademark: SABIC
Important parameters: melt flow rate: 2.5 g/10min density: 0.926 g/cm3 notched impact strength: 20 tensile strength: 20 MPa, elongation at break: 500%
Saudi Basic Industries, Inc.
LDPE (low density polyethylene # high-pressure polyethylene) /LDF-250YZ/ Malaysia daito
Application: film grade
Characteristics: good mechanical properties and hardness
Important parameters: melt flow rate: 0.75 g/10min density: 0.922 g/cm3 notched impact strength: 4 tensile strength: 23 MPa, elongation at break: 560% VEKA softening point: 93 DEG C
Manufacturer: Malaysia daito company
LDPE (low density polyethylene # high-pressure polyethylene) /LDF-266YZ/ Malaysia daito
Application: film grade
Characteristics: good machinability and mechanical properties
Important parameters: melt flow rate: 0.25 g/10min density: 0.922 g/cm3 notched impact strength: 4 tensile strength: 19 MPa, elongation at break: 570% VEKA softening point: 100 DEG C
Manufacturer: Malaysia daito company
LDPE (low density polyethylene # LDPE) /PE-046/A/ Repsol of Spain
Application: film grade
Characteristic note: good machining, high definition
Important parameters: melt flow rate: 2 g/10min density: 0.92 g/cm3, elongation at break: 650% VEKA softening point: 90 DEG C
Manufacturer: YPF of Spain
LDPE (low density polyethylene # LDPE) /PE-063/A/ Repsol of Spain
Uses: other
Remark: food contact is acceptable and well processed
Important parameters: melt flow rate: 4 g/10min density: 0.92 g/cm3, elongation at break: 600% VEKA softening point: 88 DEG C
Manufacturer: YPF of Spain
LDPE (low density polyethylene # high-pressure polyethylene) /NA985107/ quantum chemistry
Uses: other
Features: copolymer, food, contact, acceptance, heat sealing, high impact resistance, film
Important parameters: melt flow rate: 0.25 g/10min density: 0.921 g/cm3 tensile strength: 19.3 MPa elongation at break: 500% VEKA softening point: 91 DEG C
Manufacturer: quantum chemical company of America
LDPE (low density polyethylene LDPE #) /3026HK/ Leander Basel
Application: film grade
Characteristic note: low friction, good processability and good rigidity
Important parameters: melt flow rate: 2 g/10min density: 0.927 g/cm3 tensile strength: 13 MPa elongation at break: 650% hardness: 51 VEKA softening point: 100 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene LDPE #) /2420H-TP/ Leander Basel
Application: film grade
Important parameters: melt flow rate: 2 g/10min density: 0.924 g/cm3 tensile strength: 12 MPa hardness: 48 VEKA softening point: 94 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene # LDPE) /PE-033/ Repsol of Spain
Uses: other
Features: antioxidants, food contact, acceptable, good processing
Important parameters: melt flow rate: 0.3 g/10min density: 0.922 g/cm3, elongation at break: 650% VEKA softening point: 94 DEG C
Manufacturer: YPF of Spain
LDPE (low density polyethylene # high-pressure polyethylene) /2426K/ Lanzhou petrochemical
Uses: film grade stretch stretch film, film grade - packaging film
Important parameters: melt flow rate: 3.7 g/10min density: 0.925 g/cm3 tensile strength: 9.9 MPa, elongation at break: 540%
Manufacturer: PetroChina Lanzhou Petrochemical Branch Company
LDPE (low density polyethylene LDPE #) /LD-01A/ Korea Dalin
Application: film grade
Characteristics: excellent impact resistance, excellent heat sealing property, excellent mechanical properties and processability.
Important parameters: melt flow rate: 0.25 g/10min density: 0.922 g/cm3 notched impact strength: 700 tensile strength: 21 MPa, elongation at break: 480%
Manufacturer: Korea Dalin Co.
LDPE (low density polyethylene # high-pressure polyethylene)