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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，使注塑料時既能充滿模，又不會產(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，加熱后會引起原料的變質(zhì)，所以一定要做干燥處理。在注塑的時候，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，可用PE、PS等樹脂清洗螺桿。

當(dāng)臨時停機(jī)時，為防止原料在高溫下停留的時間過長，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注射;

保壓時間和成型周期：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，一般注塑的時候應(yīng)盡量少用脫模劑;當(dāng)用回用料時不得大于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;PC應(yīng)在清潔空氣、甘油、液體石臘等加熱110-135℃，時間按產(chǎn)品而定，最高需要10多小時。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。

部分型號部分物性表

ABS (acrylonitrile / butadiene / styrene copolymer #) /H702/ ABS
Use: other
Characteristic notes: good flow and moderate heat resistance
Important parameters: melt flow rate: 16 g/10min density: 1.04 g/cm3, molding shrinkage: 0.55% notched impact strength: 17 bending strength: 73 MPa bending modulus: 2450 MPa hardness: 105 VEKA softening point: 104 DEG heat deforming temperature: 99 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H802/ ABS
Use: other
Characteristic notes: good flow and high heat resistance
Important parameters: density: 1.05 g/cm3, molding shrinkage: 0.55% notched impact strength: 15 bending strength: 80 MPa bending modulus: 2700 MPa, VEKA softening point: 109 DEG heat deforming temperature: 101 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /M305/ ABS
Use: other
Characteristic notes: good dimensional stability
Important parameters: melt flow rate: 12 g/10min density: 1.05 g/cm3, molding shrinkage: 0.65% notched impact strength: 21 bending strength: 68 MPa bending modulus: 2300 MPa hardness: 95 VEKA softening point: 99 DEG heat deforming temperature: 94 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /SAN ABS 51/
Use: other
Important parameters: melt flow rate: 15 g/10min density: 1.08 g/cm3, molding shrinkage: 0.35% notch impact strength: 2 elongation at break: 3.8% flexural strength: 125 MPa flexural modulus: 3900 MPa hardness: 126 VEKA softening point: 106 DEG heat deformation temperature: 102 degree light transmittance: 87.5%.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer # fuyuda plasticizing) /ABS-F1/
Use: other
Feature notes: the flame retardant ABS modified by highly efficient composite flame retardant has the characteristics of less flame retardant and better flame retardancy. Besides maintaining high strength, high modulus and excellent surface gloss, ABS also improves the processing fluidity of ABS.
Important parameters: melt flow rate: 3.5 g/10min density: 1.165 g/cm3, notched impact strength: 60 tensile strength: 55 MPa, elongation at break: 25% flexural strength: 80 MPa, bending modulus: 2500 MPa, hot deformation temperature: 78 degrees.
Manufacturer: Cixi Fuda plasticizing Co., Ltd.
ABS (acrylonitrile / butadiene / styrene copolymer #) /633/ ABS
Use: other
Feature preparation: 633 resin is a universal injection grade ABS resin (acrylonitrile, butadiene, styrene). High glossiness and good fluidity
Important parameters: melt flow rate: 15 g/10min density: 1.05 g/cm3, molding shrinkage: 0.5% notched impact strength: 347 tensile strength: 41.3 MPa, bending strength: 65.5 MPa, bending modulus: 2200 MPa hardness: 109 VEKA softening point: 106 DEG heat deformation temperature: 85 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /451/ ABS
Use: other
Characteristic notes: medium lustre, medium heat resistance, medium impact resistance
Important parameters: melt flow rate: 7 g/10min density: 1.07 g/cm3, molding shrinkage: 0.5% notched impact strength: 176 tensile strength: 43.4 MPa flexural strength: 72.4 MPa bending modulus: 2690 MPa hardness: 113 hot deformation temperature: 85 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /E112LG/ ABS
Use: other
Characteristic notes: low gloss
Important parameters: melt flow rate: 6 g/10min density: 1.04 g/cm3, molding shrinkage: 0.65% notched impact strength: 8 bending strength: 43 MPa bending modulus: 1500 MPa hardness: 65 VEKA softening point: 98 DEG heat deforming temperature: 95 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2L-AT/ ABS
Use: other
Important parameters: melt flow rate: 45 g/10min density: 1.05 g/cm3 notch impact strength: 10 VEKA softening point: 96 C thermal deformation temperature: 92 centigrade
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H605/ ABS
Use: other
Characteristic notes: good flow and high heat resistance
Important parameters: melt flow rate: 25 g/10min density: 1.05 g/cm3, molding shrinkage: 0.5% notched impact strength: 17 bending strength: 72 MPa bending modulus: 2400 MPa hardness: 105 VEKA softening point: 101 DEG heat deforming temperature: 98 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2M-AT/ ABS
Use: other
Important parameters: melt flow rate: 22 g/10min density: 1.04 g/cm3 notch impact strength: 22 VEKA softening point: 95 C thermal deformation temperature: 92 centigrade
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /450/ ABS
Use: other
Characteristic notes: medium impact strength, high fluidity, high gloss
Important parameters: melt flow rate: 27 g/10min density: 1.05 g/cm3, molding shrinkage: 0.5%, tensile strength: 34 MPa, elongation at break: 20% bending strength: 71 MPa, bending modulus: 2400 MPa hardness: 113 VEKA softening point: 99 DEG heat deformation temperature: 92 degrees.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /M202AS/ ABS
Use: other
Characteristic note: electrostatic function
Important parameters: melt flow rate: 32 g/10min density: 1.05 g/cm3, molding shrinkage: 0.55% notched impact strength: 15 bending strength: 70 MPa bending modulus: 2300 MPa hardness: 100 VEKA softening point: 100 DEG heat deforming temperature: 94 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H701/ ABS
Use: other
Characteristic notes: moderate heat resistance, high impact resistance
Important parameters: melt flow rate: 8 g/10min density: 1.04