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PVC塑料注塑成型工藝過(guò)程分析

pvc也叫做硬PVC，它主要是氯乙烯單體經(jīng)過(guò)聚合反應(yīng)之后而做成的一種無(wú)定形熱塑性樹脂，在通過(guò)添加一定的添加劑，例如穩(wěn)定劑、潤(rùn)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(wú)須烘干的情況。如過(guò)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(guò)多，更多的原因是因?yàn)槲锪辖?jīng)過(guò)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(zhǎng)度一定要短，直徑則要比較大，用來(lái)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(guò)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(guò)高。

5、注射速度

射速要慢，否則過(guò)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(guò)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(guò)5分鐘。當(dāng)溫度是210℃，機(jī)筒滯留時(shí)間就不可以超過(guò)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 #) /V3110F/ Yangzi BASF
Use: other
Important parameters: melt flow rate: 0.75 g/10min tensile strength: 30 MPa breaking elongation: 500% VEKA softening point: 88 centigrade filler content: 5%
Manufacturer: Yangzi Petrochemical BASF Co., Ltd.
EVA (ethylene vinyl acetate copolymer #) /V5110F/ Yangzi BASF
Use: other
Important parameters: melt flow rate: 0.75 g/10min tensile strength: 10 MPa breaking elongation: 550% VEKA softening point: 66 centigrade filler content: 18%
Manufacturer: Yangzi Petrochemical BASF Co., Ltd.
EVA (ethylene vinyl acetate copolymer #) /V4110F/ Yangzi BASF
Use: Film
Important parameters: melt flow rate: 0.75 g/10min tensile strength: 20 MPa breaking elongation: 550% VEKA softening point: 72 centigrade filler content: 14%
Manufacturer: Yangzi Petrochemical BASF Co., Ltd.
EVA (ethylene vinyl acetate copolymer #) /V3610F/ Yangzi BASF
Use: other
Important parameters: melt flow rate: 0.75 g/10min tensile strength: 20 MPa breaking elongation: 500% VEKA softening point: 83 centigrade filler content: 9%
Manufacturer: Yangzi Petrochemical BASF Co., Ltd.
EVA (ethylene vinyl acetate copolymer # Lotte chemical /VC590/)
Use: wire and cable material
Characteristic notes: technological and electrical characteristics
Important parameters: melt flow rate: 4 g/10min density: 0.952 g/cm3 tensile strength: 19 MPa breaking elongation: 800% hardness: 30 VEKA softening point: 47 C
Manufacturer: Korean Music Corporation
EVA (ethylene vinyl acetate copolymer # Lotte chemical /VC640/)
Use: wire and cable material
Characteristic notes: technological and electrical characteristics
Important parameters: melt flow rate: 6 g/10min density: 0.935 g/cm3 tensile strength: 19 MPa breaking elongation: 800% hardness: 40 VEKA softening point: 61 C
Manufacturer: Korean Music Corporation
EVA (ethylene vinyl acetate copolymer #) /1257/ America flintcomb ash
Use: other
Characteristic notes: excellent balance optics and strength, well sealed heat resistance
Important parameters: melt flow rate: 2.5 g/10min density: 0.923 g/cm3 tensile strength: 12 MPa breaking elongation: 600% hardness: 47 VEKA softening point: 95 C
Manufacturer: American flint Hill resources
EVA (ethylene vinyl acetate copolymer #) /EB591/ West Lake
Use: other
Characteristic notes: good toughness and good heat sealing characteristics. Excellent low temperature brittleness properties
Important parameters: melt flow rate: 2 g/10min density: 0.931 g/cm3 tensile strength: 23 MPa breaking elongation: 950%
Manufacturer: West Lake Chemical Co., Ltd.
EVA (ethylene vinyl acetate copolymer #) /FC45/ Italy
Use: Film
Characteristic notes: good optical properties, resistance to impact, low creep
Important parameters: melt flow rate: 0.3 g/10min tensile strength: 30 MPa fracture elongation: 650% hardness: 40 VEKA softening point: 73 C embrittlement temperature: -80 C
Manufacturer: Italy Eni
EVA (ethylene vinyl acetate copolymer #) /FF35/ Italy
Use: Film
Characteristic notes: good fracture mechanical properties and sealing properties
Important parameters: melt flow rate: 0.7 g/10min tensile strength: 28 MPa fracture elongation: 650% hardness: 42 VEKA softening point: 75 C embrittlement temperature: -80 C
Manufacturer: Italy Eni
EVA (ethylene vinyl acetate copolymer #) /MH 40/ of Italy
Use: other
Characteristic notes: high elasticity and good mechanical properties
Important parameters: melt flow rate: 1.8 g/10min tensile strength: 5.6 MPa flexural modulus: 40 MPa hardness: 36 VEKA softening point: 62 C embrittlement temperature: -80 C
Manufacturer: Italy Eni
EVA (ethylene vinyl acetate copolymer #) /HN 70/ of Italy
Use: hot-melt
Characteristic notes: medium fluidity and high stickiness
Important parameters: melt flow rate: 6 g/10min tensile strength: 2.7 MPa elongation at break: 400% bending modulus: 15 MPa hardness: 31 VEKA softening point: 45 C embrittlement temperature: -80 C.
Manufacturer: Italy Eni
EVA (ethylene vinyl acetate copolymer #) /3173SHB/ DuPont dow
Use: Film
Note: the characteristics of smooth opening agent agent, heat stabilizer, antioxidant BHT
Important parameters: melt flow rate: 2.5 g/10min density: 0.95 g/cm3 VEKA softening point: 65 Centigrade filler content: 18%
Manufacturer: Dow DuPont Co
EVA (ethylene vinyl acetate copolymer #) /E053/ Han Hua Total
Use: Film
Characteristic notes: good transparency, processability and tensile strength
Important parameters: melt flow rate: 3 g/10min density: 0.928 g/cm3
Manufacturer: Han Hua Total Ltd.
EVA (ethylene vinyl acetate copolymer #) /LD 768.MJ Molding/ Mobil Exxon
Use: other
Important parameters: melt flow rate: 2.3 g/10min tensile strength: 9.45 MPa fracture elongation: 800% flexural modulus: 31 MPa hardness: 28 VEKA softening point: 49 C
Manufacturer: Exxon Mobil Corp
EVA (ethylene vinyl acetate copolymer #) /48/9900 CP/80/ Italy problem
Use: other
Characteristic notes: heat conduction
Important parameters: density: 2.66 g/cm3 molding shrinkage: 0.55% VEKA softening point: 35 C thermal deformation temperature: 50 C
Manufacturer: Italy La title company
EVA (ethylene vinyl acetate copolymer #) /HLP 200/ API in Italy
Use: other
Characteristic notes: luster, good flexibility in crosslinkable
Important parameters: density: 0.2 g/cm3 tensile strength: 2 MPa breaking elongation: 220% hardness: 37
Manufacturer: Italy API company
EVA (ethylene vinyl acetate copolymer #) /NUC-3765D/ Japan Younika
Use: other
Feature notes: Slip level:N
Important parameters: Melt