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PVC塑料注塑成型工藝過程分析

pvc也叫做硬PVC，它主要是氯乙烯單體經(jīng)過聚合反應(yīng)之后而做成的一種無定形熱塑性樹脂，在通過添加一定的添加劑，例如穩(wěn)定劑、潤滑劑、填充劑等組合而成的一種產(chǎn)品。

除了用添加劑之外，還采用了與其它樹脂進(jìn)行共混改性的相關(guān)辦法，使它更加具有明顯的實(shí)用價(jià)值。這些樹脂有CPVC、PE、abs、EVA、MBS等。

UPVC的熔體粘度較高，流動(dòng)性較差，即使提高注射壓力以及熔體溫度，流動(dòng)性的變化也較小大。此外，樹脂的成型溫度與熱分解溫度非常接近，可以進(jìn)行成型的溫度范圍較窄，它是一種比較難于成型的材料。

1、塑料的處理

處于室溫24小時(shí)之后，吸水量如果是少于0.02%的話，就會(huì)形成無須烘干的情況。如過必須要進(jìn)行干燥處理，可以放到60-70℃的熱氣爐3小時(shí)，或著80℃的干燥機(jī)大概1-1.5小時(shí)。

回收料最多可以用20%與新料進(jìn)行混合，回收料的用量要看制品的最終用途而確定。濫用回收料可能會(huì)導(dǎo)致注塑工作失敗，不單是回收了的成分過多，更多的原因是因?yàn)槲锪辖?jīng)過多次再加工處理?；厥樟厦慷嗷厥找淮钨|(zhì)量會(huì)出現(xiàn)逐漸下降的狀況。

2、注塑機(jī)選用

UPVC因?yàn)槿垠w粘度較較大、所以分解較為容易，分解產(chǎn)物對(duì)于鐵有著較大的腐蝕作用，其注塑成型必須要用專用的塑化部件和溫控系統(tǒng)。

華美達(dá)在產(chǎn)品覆蓋的每一種鎖模力型號(hào)，都有專門的UPVC塑化注射系統(tǒng)，并配合UPVC管件產(chǎn)品抽芯的要求備有專用的安全門裝置。一般情況下只要注射量可以滿足重量要求，選用這一系列UPVC專用注塑裝置可以成型出高質(zhì)量的產(chǎn)品。

3、模具及澆口設(shè)計(jì)

模具溫度可以設(shè)置為40℃。而且流道整個(gè)長度一定要短，直徑則要比較大，用來逐漸減小壓力損失以及保壓能傳遞到模腔。澆口越短越好，模切面一定要圓形，射嘴口的直徑最小是6mm，成圓錐形，內(nèi)角成5。

主流道的模切面也要圓形，與冷料井組合而成，通過切面半徑連接主流道和澆口，直徑可為7mm。

澆口應(yīng)用切圓面形的半徑連接塑件，越短越好，模切面要順滑。

冷料井可防止半凝固的物料進(jìn)入模腔，它的重要性常被忽略。

澆口的位置要正確，使物料在流道上順利流動(dòng)，不會(huì)停留在尖角、碎片和金屬的痕跡里，以免出現(xiàn)壓縮或減壓的情況，應(yīng)保持流道順滑流暢。

模具應(yīng)用不銹鋼鑄造，鉻的含量至少13%，最好16%，洛氏硬度至少有55，硬鋼模具可經(jīng)鍍鉻處理，形成保護(hù)作用。

生產(chǎn)完后，應(yīng)用溫和的堿液小心將模面清洗干凈后再噴上油質(zhì)噴霧或硅質(zhì)噴霧。

4、熔膠溫度

可用空射法度量，由185-205℃不等。從射出的物料光滑程度可得知UPVC的準(zhǔn)確熔膠溫度。如物料在射出后粗糙不平，就證明物料并非均一(塑化不足)，表示所定的溫度太低;如射出后起泡沫并冒出大量煙霧，就表示溫度過高。

5、注射速度

射速要慢，否則過分剪切會(huì)使物料降質(zhì)，利用UPVC生產(chǎn)極度光滑的厚壁制品時(shí)，應(yīng)采用多級(jí)注塑模具填充速度。

6、螺桿轉(zhuǎn)速

應(yīng)該進(jìn)一步配合模塑周期而確定螺桿轉(zhuǎn)速。螺桿面速度不要超過0.15-0.2m/s

7、背壓

背壓可以達(dá)到150bar，當(dāng)然數(shù)據(jù)是越低越好，常見的數(shù)值是5bar。

8、滯留時(shí)間

在200℃的溫度之下，機(jī)筒滯留時(shí)間大多不能超過5分鐘。當(dāng)溫度是210℃，機(jī)筒滯留時(shí)間就不可以超過3分鐘。

以上就是UPVC塑料原料的注射成型工藝分析匯總，提醒大家的是在注射速度以及背壓方面需要的別注意。

部分型號(hào)部分物性表

EVA (ethylene vinyl acetate copolymer #) /MQ 40/ of Italy
Use: other
Characteristic notes: high fluidity and high elasticity
Important parameters: melt flow rate: 12 g/10min tensile strength: 4 MPa flexural modulus: 40 MPa hardness: 33 VEKA softening point: 56 C embrittlement temperature: -80 C
Manufacturer: Italy Eni
EVA (ethylene vinyl acetate copolymer #) /HM-728/ Brazil Braskem
Use: Film
Characteristic notes: foamed, good flexibility, high ESCR, medium molecular weight
Important parameters: melt flow rate: 6 g/10min density: 0.95 g/cm3 hardness: 80
Manufacturer: Brazil chemical company
EVA (ethylene vinyl acetate copolymer #) /3169Z/ DuPont dow
Use: Film
Note: the characteristics of slip agent, agent, heat stabilizer, antioxidant BHT
Important parameters: melt flow rate: 1.5 g/10min density: 0.95 g/cm3 VEKA softening point: 68 centigrade filler content: 18%
Manufacturer: Dow DuPont Co
EVA (ethylene vinyl acetate copolymer #) /ER200V-3/ Japan Sea
Use: other
Important parameters: melt flow rate: 2.8 g/10min density: 0.94 g/cm3 tensile strength: 15 MPa breaking elongation: 760% flexural modulus: 59 MPa hardness: 37
Manufacturer: Japan Offshore Oil Resources Development Co., Ltd.
EVA (ethylene vinyl acetate copolymer #) /LV372/ Japan JPC
Use: other
Characteristic notes: luster, high, machinability, good, clear, high, general purpose
Important parameters: melt flow rate: 12 g/10min flexural modulus: 50 MPa hardness: 36 VEKA softening point: 58 C embrittlement temperature: -70 C
Manufacturer: JPC company, Japan
EVA (ethylene vinyl acetate copolymer #) /AZ FC 200/ API in Italy
Use: other
Characteristic notes: crosslinkable
Important parameters: density: 0.21 g/cm3 tensile strength: 2 MPa breaking elongation: 230% hardness: 45
Manufacturer: Italy API company
EVA (ethylene vinyl acetate copolymer #) Exxon chemical /UL728CC3/
Use: Film
Feature remark: VAC content 28%
Important parameters: melt flow rate: 7 g/10min density: 0.955 g/cm3
Manufacturer: Exxon Chemicai Company
EVA (ethylene vinyl acetate copolymer #) Exxon chemical /UL00730CC3/
Use: Film
Feature remark: VAC content 30%
Important parameters: melt flow rate: 7 g/10min density: 0.953 g/cm3
Manufacturer: Exxon Chemicai Company
EVA (ethylene vinyl acetate copolymer #) Exxon chemical /UL00909CC1/
Use: other
Feature remark: VAC content 9%
Important parameters: melt flow rate: 9 g/10min density: 0.926 g/cm3
Manufacturer: Exxon Chemicai Company
EVA (ethylene vinyl acetate copolymer #) /E060A/ Han Hua Total
Use: Film
Characteristic notes: characteristics: transparency, good processing and molding
Important parameters: melt flow rate: 0.8 g/10min filler content: 6%
Manufacturer: Han Hua Total Ltd.
EVA (ethylene vinyl acetate copolymer #) /E153A/ Han Hua Total
Use: Film
Feature remark: characteristics: transparency, good processing and molding.
Important parameters: melt flow rate: 1.2 g/10min filler content: 15%
Manufacturer: Han Hua Total Ltd.
EVA (ethylene vinyl acetate copolymer #) /E210F/ Han Hua Total
Use: foaming
Characteristic notes: characteristics: good activity and processability.
Important parameters: melt flow rate: 2.5 g/10min filler content: 21%
Manufacturer: Han Hua Total Ltd.
EVA (ethylene vinyl acetate copolymer #) /7620M/ Taiwan plastic
Use: other
Feature remark: characteristics: good processing and pledged.
Important parameters: melt flow rate: 9 g/10min density: 0.93 g/cm3, tensile strength: 12 MPa, elongation at break: 700% bending modulus: 23 MPa hardness: 96 VEKA softening point: 73 C, embrittlement temperature: -70 C, filler content: 9%.
Manufacturer: Limited by Share Ltd of Taiwan plastic industry
EVA (ethylene vinyl acetate copolymer # polyolefin /K3212/ Singapore)
Use: foaming
Characteristic notes: good elasticity
Important parameters: melt flow rate: 3 g/10min density: 0.94 g/cm3 tensile strength: 19 MPa breaking elongation: 800% embrittlement temperature: -75 C
Manufacturer: Singapore polyolefin Private Companies
EVA (ethylene vinyl acetate copolymer #) /3044/ Mubolaikesi snow
Use: Film
Characteristic notes: VAC content 3%, extrusion and film grade, high transparency, toughness
Important parameters: melt flow rate: 1.5 g/10min density: 0.927 g/cm3
Manufacturer: United States snow Mubolaikesi company
EVA (ethylene vinyl acetate copolymer #) /V2510J/ Yangzi BASF
Use: other
Important parameters: melt flow rate: 2.7 g/10min tensile strength: 10 MPa breaking elongation: 500% VEKA softening point: 86 centigrade filler content: 3%
Manufacturer: Yangzi Petrochemical BASF Co., Ltd.
EVA (ethylene vinyl acetate copolymer #) /E167L/ Han Hua Total
Use: other
Important parameters: melt flow rate: 16 g/10min tensile strength: 9.8 MPa elongation at break: 600% bending modulus: 107.8 MPa hardness: 15 VEKA softening point: 51 DEG heat deforming temperature: 87 C, embrittlement temperature: -70 C.
Manufacturer: Han Hua Total Ltd.
EVA (ethylene vinyl acetate copolymer #) /1010 VN 3/ France Total
Use: Film
Characteristic notes: high transparency and high mechanical properties
Important parameters: melt flow rate: 1.5 g/10min density: 0.929 g/cm3 tensile strength: 28 MPa breaking elongation: 600% VEKA softening point: 82 C
Manufacturer: Total Petrochemical Industries Co
EVA (ethylene vinyl acetate copolymer #) /1402/ America flintcomb ash
Use: Film
Feature notes: excellent optical performance, toughness and elasticity, good thermal seal performance
Important parameters: melt flow rate: 1.3 g/10min density: 0.924 g/cm3 tensile strength: 14 MPa