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如何制造高光無痕的注塑件?

高光注塑技術(shù)又稱快速熱循環(huán)注塑技術(shù)，使用此技術(shù)可以很好地復(fù)制模具表面的任何形狀，使制品件表面無熔痕，表面高光達(dá)到鏡面效果;提高塑件強(qiáng)度和表面硬度;使薄壁成型提高注塑流動(dòng)性，提高產(chǎn)品品質(zhì)和強(qiáng)度;使厚壁成型注塑周期可降低60%以上;無需后續(xù)環(huán)境污染嚴(yán)重噴涂工藝，可減少工藝流程，節(jié)省能源與材料。

這樣可以直接降低塑料制品的成本，也能更好的保護(hù)環(huán)境和操作人員的人身健康。

高光注塑的工藝原理：

在合模前及合模過程中對(duì)模具進(jìn)行加溫、合模完成后，溫度達(dá)到設(shè)定條件即進(jìn)行注射。注射過程中模具繼續(xù)維持高溫，這樣可以使膠料注射時(shí)在模具內(nèi)保持很好的流動(dòng)性。注射完成，在保壓冷卻時(shí)，則對(duì)模具進(jìn)行降溫處理，又可以大大縮短制品的冷卻時(shí)間，從而提高生產(chǎn)效率。

傳統(tǒng)的做法是采用模溫機(jī)對(duì)模具進(jìn)行加溫，但這種方法的不足之處如下：

1.無法滿足高光注塑中快速升溫及快速降溫的需要;

2.升溫幅度較小，制品表面的熔接痕只能得到減輕而無法消除;

3.由于塑料硬度越高，流動(dòng)性越差。因此采用此種工藝制品表面的硬度只能達(dá)到HB級(jí)無法滿足實(shí)際使用需要;

4.模具升溫時(shí)受熱膨脹，降溫時(shí)又會(huì)收縮，使鎖模力很不穩(wěn)定。容易造成制品打不滿，燒焦，內(nèi)應(yīng)力大等各種缺陷。

而在此工藝基礎(chǔ)上發(fā)展而來的蒸汽高光注塑技術(shù)則針對(duì)以上缺陷分別做了改進(jìn)：

1.此技術(shù)在模具中開水管，需要升溫時(shí)通蒸汽，需要降溫時(shí)通冷水，冷卻完畢后，可以用壓縮空氣將殘留水分吹出，以確保能實(shí)現(xiàn)快速升溫、降溫;

2.以最大程度地消除熔接痕夾、水紋、缺膠等各種制品故障;

3.由于升溫幅度較大、以使用H甚至2H硬度級(jí)別的塑料，使制品表面硬度大大提高;

4.由于在模具內(nèi)部開設(shè)管道時(shí)，只對(duì)模具內(nèi)表面進(jìn)行升溫或降溫，模具的整體膨脹較小，因此減少了由于鎖模力的不穩(wěn)定而帶來的各種制品缺陷。

要生產(chǎn)出高品質(zhì)的高光制品，需要注塑機(jī)、模具、溫控設(shè)備高光制品專用塑料、以及鍋爐、冷卻裝置等方面相配合：

1.塑機(jī)的配置

①鎖模機(jī)構(gòu)剛性要好;由于整個(gè)生產(chǎn)過程中要不停地升溫和降溫。因此要求注塑機(jī)的鎖模機(jī)構(gòu)必須剛性、強(qiáng)度要好、以確保鎖模力的準(zhǔn)確與穩(wěn)定。從而保證制品的表面質(zhì)量。

②選用大鎖模的注塑機(jī)：使用此工藝時(shí)由于無法再使用氣體輔助注射，因此生產(chǎn)制品所需要的鎖模力會(huì)比較大。

③根據(jù)情況選用較小的射膠量：如生產(chǎn)平板電視機(jī)、液晶顯示屏外框等產(chǎn)品時(shí)，不需要較大射膠量，在選擇注塑機(jī)時(shí)盡量選擇小射膠量的注塑機(jī)。制品實(shí)際重量在注塑機(jī)理論射膠量的30%～80%之間最佳。如機(jī)器射膠量過大，膠料在料筒內(nèi)停留時(shí)間長容易分別分解，制品表面會(huì)產(chǎn)生銀絲等缺陷。

④配備專用螺桿生產(chǎn)高光制品所用到的塑料硬度較高，其熔融指數(shù)相對(duì)較低，因此要求螺桿塑化要好。同時(shí)螺桿的剪切又不能太大，否則膠料會(huì)容易分解。

2.模具的配置

①模具內(nèi)表面要求非常高的光潔度，以確保制品的表面質(zhì)量;

②模具內(nèi)部開設(shè)管道必須合理，以確?？梢钥焖偕郎睾徒禍?

③模具內(nèi)部的管道應(yīng)該導(dǎo)熱性能良好;

④由于生產(chǎn)過程中需要不停加溫及降溫，模具選用的鋼材要好;

⑤在使用過程中要尤其注重模具的保養(yǎng)，確保干燥，無塵。

3.溫控設(shè)備的配置

①溫度控制要非常準(zhǔn)確，這是制品質(zhì)量的重要保證

②溫控設(shè)備的反應(yīng)要非?？煲员ＷC較高的生產(chǎn)效率

4.專用塑料

生產(chǎn)表面質(zhì)量較高的產(chǎn)品時(shí)，常用的塑料有ABS、PC+ABS或PMMA+ABS。其中，ABS的硬度最低，PMMA+ABS的硬度最高，可達(dá)H、甚至2H。但硬度越高，熔融指數(shù)也相對(duì)越低。流動(dòng)性會(huì)變差，因此可根據(jù)生產(chǎn)需要選取適當(dāng)?shù)乃芰稀?br />
蒸汽無痕高光注塑技術(shù)大大改善了制品的表面質(zhì)量和表面強(qiáng)度，并可取消后續(xù)的噴涂或噴漆等工藝、既保護(hù)了環(huán)境和操作人員的人身健康，又因減少工藝流程，省去了昂貴的二次加工費(fèi)用，在大幅度降低生產(chǎn)成本的同時(shí)，節(jié)省能源與材料。

部分型號(hào)部分物性表

EVA (ethylene vinyl acetate copolymer /1045/ Nuoxuemu chemical #)
Use: Film
Feature remark: VAC content 2%
Important parameters: melt flow rate: 0.5 g/10min
Manufacturer: Nuoxuemu chemical company
EVA (ethylene vinyl acetate copolymer /3507/ Nuoxuemu chemical #)
Use: Film
Feature remark: VAC content 5%
Important parameters: melt flow rate: 0.3 g/10min
Manufacturer: Nuoxuemu chemical company
EVA (ethylene vinyl acetate copolymer #) /3124/ DuPont dow
Use: hot-melt
Characteristic notes: line speed and film thickness
Important parameters: melt flow rate: 7 g/10min density: 0.93 g/cm3 VEKA softening point: 77 C
Manufacturer: Dow DuPont Co
EVA (ethylene vinyl acetate copolymer #) /1061/ America Serra nice
Use: Film
Important parameters: melt flow rate: 0.3 g/10min density: 0.924 g/cm3 tensile strength: 19 MPa breaking elongation: 560% VEKA softening point: 92 C
Manufacturer: Celanese Co of the United States
EVA (ethylene vinyl acetate copolymer #) /1070/ America Serra nice
Use: other
Important parameters: melt flow rate: 2.8 g/10min density: 0.931 g/cm3, tensile strength: 14 MPa, elongation at break: 690% VEKA softening point: 81 C embrittlement temperature: -85 C.
Manufacturer: Celanese Co of the United States
EVA (ethylene vinyl acetate copolymer #) /1241/ America Serra nice
Use: other
Important parameters: melt flow rate: 10 g/10min density: 0.932 g/cm3, tensile strength: 13 MPa, elongation at break: 710% hardness: 40 VEKA softening point: 72 C embrittlement temperature: -76 C.
Manufacturer: Celanese Co of the United States
EVA (ethylene vinyl acetate copolymer #) /1645/ America Serra nice
Use: other
Important parameters: melt flow rate: 28 g/10min density: 0.936 g/cm3 tensile strength: 11 MPa breaking elongation: 700% hardness: 35 VEKA softening point: 61 C
Manufacturer: Celanese Co of the United States
EVA (ethylene vinyl acetate copolymer #) /2850A/ America Serra nice
Use: other
Important parameters: density: 0.941 g/cm3 tensile strength: 2 MPa fracture elongation: 350% flexural modulus: 11 MPa hardness: 12
Manufacturer: Celanese Co of the United States
EVA (ethylene vinyl acetate copolymer #) /FL 01418/ Mobil Exxon
Use: other
Important parameters: hardness: 87 VEKA softening point: 52 C
Manufacturer: Exxon Mobil Corp
EVA (ethylene vinyl acetate copolymer #) /VH620S/ Japan Sea
Use: other
Important parameters:
Manufacturer: Japan Offshore Oil Resources Development Co., Ltd.
EVA (ethylene vinyl acetate copolymer # atofina) /20-20/
Use: other
Important parameters: melt flow rate: 20 g/10min density: 0.94 g/cm3, tensile strength: 12.5 MPa, elongation at break: 650% hardness: 84 VEKA softening point: 49 C filling content: 20%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /28-420/
Use: other
Important parameters: melt flow rate: 420 g/10min density: 0.95 g/cm3, tensile strength: 2.5 MPa, elongation at break: 850% hardness: 62 VEKA softening point: 40 C filling content: 28%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /28-800/
Use: other
Important parameters: melt flow rate: 800 g/10min density: 0.95 g/cm3, tensile strength: 1.5 MPa, elongation at break: 300% hardness: 57 VEKA softening point: 40 C filling content: 28%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /33-25/
Use: other
Important parameters: melt flow rate: 25.5 g/10min density: 0.96 g/cm3, tensile strength: 12 MPa, elongation at break: 900% hardness: 66 VEKA softening point: 40 C filling content: 33%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /33-45/
Use: other
Important parameters: melt flow rate: 43 g/10min density: 0.96 g/cm3, tensile strength: 10.5 MPa, elongation at break: 900% hardness: 64 VEKA softening point: 40 C filling content: 33%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /33-400/
Use: other
Important parameters: melt flow rate: 400 g/10min density: 0.96 g/cm3, tensile strength: 2.5 MPa, elongation at break: 900% hardness: 45 VEKA softening point: 40 C filling content: 33%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /40-55/
Use: other
Important parameters: melt flow rate: 55 g/10min density: 0.96 g/cm3, tensile strength: 5 MPa, elongation at break: 1000% hardness: 46 VEKA softening point: 40 C filling content: 39.5%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /28-05/
Use: other
Important parameters: melt flow rate: 6.5 g/10min density: 0.95 g/cm3, tensile strength: 33 MPa, elongation at break: 850% hardness: 82 VEKA softening point: 43 C filling content: 28%
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /28-150/
Use: hot-melt
Important parameters: melt flow rate: 155 g/10min density: 0.95 g/cm3, tensile strength: 6 MPa, elongation at break: 850% hardness: 70 VEKA softening point: -40 C filling content: 27.5%.
Manufacturer: France atofina company
EVA (ethylene vinyl acetate copolymer # atofina) /28-25/
Use: other
Important parameters: melt flow rate: 25.5 g/10min density: 0.95 g/cm3, tensile strength: 13 MPa, elongation at break: 850% hardness: 76 VEKA softening point: 41 C filling content: 28%
Manufacturer: France atofina company