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透明聚碳酸酯PC加玻纖塑料件加工注意問題

透明塑膠PC+gf產(chǎn)品由于透光率要高，所以PC+gf塑料制品表面質(zhì)量的要求必須嚴(yán)格，不能有任何斑紋、氣孔、泛白、霧暈、黑點(diǎn)、變色、光澤不佳等缺陷，因而在整個(gè)注塑過程對原料、設(shè)備、模具、甚至產(chǎn)品的設(shè)計(jì)，都要十分注意和提出嚴(yán)格甚至特殊的要求。

另外，由于透明PC+gf塑料多為熔點(diǎn)高、流動(dòng)性差，因此為保證產(chǎn)品的表面質(zhì)量，往往需要較高的溫度，注射壓力、注射速度等工藝參數(shù)也要作細(xì)微調(diào)整，使注塑料時(shí)既能充滿模，又不會(huì)產(chǎn)生內(nèi)應(yīng)力而引起產(chǎn)品變形和開裂。

因此從原料準(zhǔn)備，對設(shè)備和模具要求、注塑工藝和產(chǎn)品的原料處理幾方面都要進(jìn)行嚴(yán)格的操作。

1.原料的準(zhǔn)備與干燥

由于在PC+gf塑料中含有任何一點(diǎn)雜質(zhì)，都可能影響產(chǎn)品的透明度，所以在儲(chǔ)存、運(yùn)輸、加料過程中都必須注意密封，保證原料的干凈。

特別是原料中含有水分，加熱后會(huì)引起原料的變質(zhì)，所以一定要做干燥處理。在注塑的時(shí)候，加料必須使用干燥的料斗。還要注意一點(diǎn)的是干燥的過程中，輸入的空氣最好應(yīng)經(jīng)過濾、除濕，以便保證不會(huì)污染原料。

2.機(jī)筒、螺桿及其附件的清潔

為防止PC+gf原料污染和在螺桿及附件凹陷處存有舊料或雜質(zhì)，特別在熱穩(wěn)定性差的樹脂存在，因此在使用前、停機(jī)后都應(yīng)用螺桿清洗劑清洗干凈各件，使其不得粘有雜質(zhì)，當(dāng)沒有螺桿清洗劑時(shí)，可用PE、PS等樹脂清洗螺桿。

當(dāng)臨時(shí)停機(jī)時(shí)，為防止原料在高溫下停留的時(shí)間過長，引起解降，應(yīng)將干燥機(jī)和機(jī)筒溫度降低，如PC+gf、PMMA等機(jī)筒溫度都要降至160℃以下(料斗溫度對于PC應(yīng)降至100℃以下)。

3.在模具設(shè)計(jì)上應(yīng)注意的問題

為了防止出現(xiàn)原料回流動(dòng)不暢，或冷卻不均造成塑料成型不良，產(chǎn)生表面的缺陷和變質(zhì)，一般在模具設(shè)計(jì)時(shí)候，應(yīng)該注意以下幾點(diǎn)：

壁厚應(yīng)盡量均勻一致，脫模斜度要有足夠大;

過渡部分應(yīng)圓滑，并逐步過渡，防止有尖角、銳邊產(chǎn)生，特別是PC+gf產(chǎn)品一定不要有缺口;

澆口、流道盡可能寬大、粗短，且應(yīng)根據(jù)收縮冷凝過程設(shè)置澆口位置，必要時(shí)應(yīng)加冷料井;

模具的表面應(yīng)光潔，粗糙度低(最好低于0.8);

排氣孔。槽必須要足夠，以及時(shí)排出空氣和熔體中的氣體;

除PET外，壁厚不要太薄，一般不得小于lmm。

4.注塑工藝方面應(yīng)該注意的問題

為了減少內(nèi)應(yīng)力和表面質(zhì)量缺陷，在注塑工藝方面應(yīng)注意以下幾方面的問題：

注射壓力：一般較高，以克服熔料粘度大的缺陷，但壓力太高會(huì)產(chǎn)生內(nèi)應(yīng)力造成脫模因難和變形;

注射速度：在滿足充模的情況下，一般宜低，最好能采用慢一快一慢多級(jí)注射;

保壓時(shí)間和成型周期：在滿足產(chǎn)品的充模，不產(chǎn)生凹陷、氣泡的情況下;宜盡量短，以盡量減低熔料在機(jī)筒停留的時(shí)間;

螺桿轉(zhuǎn)速和背壓：在滿足塑化質(zhì)量的前提下，應(yīng)該盡量低，為防止產(chǎn)生解降的可能;

模具溫度：制品的冷卻好壞，對質(zhì)量影響極大，所以模溫一定要能精確控制其過程，有可能的話，模溫宜高一些好。

5.其他方面的問題

由于為了要防上表面質(zhì)量惡化，一般注塑的時(shí)候應(yīng)盡量少用脫模劑;當(dāng)用回用料時(shí)不得大于20%。

對于除PET外，制品都應(yīng)進(jìn)行后處理，以消除內(nèi)應(yīng)力，PMMA應(yīng)在70-80t熱風(fēng)循環(huán)干燥4小時(shí);PC應(yīng)在清潔空氣、甘油、液體石臘等加熱110-135℃，時(shí)間按產(chǎn)品而定，最高需要10多小時(shí)。而PET必須經(jīng)過雙向拉伸的工序，才能得到良好機(jī)械性能。

部分型號(hào)部分物性表

ABS (acrylonitrile / butadiene / styrene copolymer #) /4105/ ABS
Use: other
Characteristic notes: moderate heat resistance, good impact resistance
Important parameters: melt flow rate: 12 g/10min, molding shrinkage: 0.7% notched impact strength: 42 bending strength: 70 MPa bending modulus: 2000 MPa hardness: 85 VEKA softening point: 106 DEG heat deforming temperature: 103 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /288/ ABS
Use: other
Characteristic notes: high flow and high glossiness
Important parameters: melt flow rate: 30 g/10min density: 1.05 g/cm3, molding shrinkage: 0.5% notched impact strength: 24 bending strength: 66 MPa flexural modulus: 2400 MPa VEKA softening point: 94 DEG heat distortion temperature: 76 C, transmittance: 95%.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2HE/ ABS
Use: other
Important parameters: melt flow rate: 7 g/10min density: 1.04 g/cm3 VEKA softening point: thermal deformation temperature at 99 C: 96 C
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /DP ABS M203FC/
Use: other
Important parameters: density: 1.05 g/cm3 notch impact strength: 16 VEKA softening point: thermal deformation temperature at 97 C: 94 C
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /E401/ ABS
Use: other
Important parameters: melt flow rate: 5 g/10min density: 1.04 g/cm3, molding shrinkage: 0.65% notched impact strength: 30 bending strength: 60 MPa bending modulus: 1900 MPa hardness: 85 VEKA softening point: 99 DEG heat deforming temperature: 94 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /4115/ ABS
Use: other
Characteristic notes: high heat resistance, high impact resistance
Important parameters: melt flow rate: 12 g/10min, molding shrinkage: 0.7% bending strength: 70 MPa, bending modulus: 2200 MPa hardness: 100 VEKA softening point: 116 DEG heat deforming temperature: 108 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2HGV/ ABS
Use: other
Important parameters: melt flow rate: 3 g/10min density: 1.16 g/cm3 notch impact strength: 6 VEKA softening point: 105 C thermal deformation temperature: 102 centigrade
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2MC/ ABS
Use: other
Important parameters: melt flow rate: 25 g/10min density: 1.04 g/cm3 notch impact strength: 24 VEKA softening point: 95 C thermal deformation temperature: 94 centigrade
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /DP ABS M202AS/
Use: other
Important parameters: melt flow rate: 37 g/10min density: 1.05 g/cm3 notch impact strength: 16 VEKA softening point: 95 C thermal deformation temperature: 92 centigrade
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /DP ABS M201AS/
Use: other
Important parameters: melt flow rate: 18 g/10min density: 1.05 g/cm3 notch impact strength: 19 VEKA softening point: 97 C thermal deformation temperature: 96 centigrade
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /KU 2-3051 (Cond) / Ineos ABS
Use: other
Feature remark: antistatic function, good impact resistance
Important parameters:
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /266/ ABS
Use: other
Characteristic notes: high clarity, good toughness
Important parameters: melt flow rate: 5 g/10min density: 1.08 g/cm3, molding shrinkage: 0.5% notched impact strength: 176 tensile strength: 29 MPa, elongation at break: 48% bending strength: 58.6 MPa bending modulus: 1770 MPa hardness: 108 thermal deforming temperature: 72.8 degrees.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H801/ ABS
Use: other
Characteristic notes: good flow and high heat resistance
Important parameters: melt flow rate: 9 g/10min density: 1.07 g/cm3, molding shrinkage: 0.6% notched impact strength: 30 bending strength: 77 MPa flexural modulus: 2300 MPa VEKA softening point: 105 DEG heat deforming temperature: 99 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H950/ ABS
Use: other
Characteristic notes: high heat resistance
Important parameters: melt flow rate: 4 g/10min density: 1.05 g/cm3, molding shrinkage: 0.6% notched impact strength: 17 bending strength: 80 MPa bending modulus: 2600 MPa hardness: 110 VEKA softening point: 113 DEG heat deforming temperature: 105 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /4000 ABS PG/
Use: other
Characteristic remark: heat resistance
Important parameters: melt flow rate: 7 g/10min density: 1.05 g/cm3, molding shrinkage: 0.65% notched impact strength: 23 bending strength: 73 MPa bending modulus: 2350 MPa hardness: 100 VEKA softening point: 107 DEG heat deforming temperature: 98 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /595CP/ ABS
Use: other
Feature remark: refrigerator anti CP
Important parameters: melt flow rate: 3 g/10min density: 1.05 g/cm3, notched impact strength: 25 tensile strength: 38 MPa, elongation at break: 25% bending strength: 70 MPa bending modulus: 2400 MPa hardness: 112 VEKA softening point: 102 DEG heat deformation temperature: 96 degrees C
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /SAN ABS C/
Use: other
Important parameters: melt flow rate: 23 g/10min density: 1.08 g/cm3 notch impact strength: 2 break