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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)量的要求必須嚴格，不能有任何斑紋、氣孔、泛白、霧暈、黑點、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，都要十分注意和提出嚴格甚至特殊的要求。

另外，由于透明PC+gf塑料多為熔點高、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行嚴格的操作。

1.原料的準備與干燥

由于在PC+gf塑料中含有任何一點雜質(zhì)，都可能影響產(chǎn)品的透明度，所以在儲存、運輸、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)，當沒有螺桿清洗劑時，可用PE、PS等樹脂清洗螺桿。

當臨時停機時，為防止原料在高溫下停留的時間過長，引起解降，應(yīng)將干燥機和機筒溫度降低，如PC+gf、PMMA等機筒溫度都要降至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)計時候，應(yīng)該注意以下幾點：

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;當用回用料時不得大于20%。

對于除PET外，制品都應(yīng)進行后處理，以消除內(nèi)應(yīng)力，PMMA應(yīng)在70-80t熱風循環(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，才能得到良好機械性能。

部分型號部分物性表

ABS (acrylonitrile / butadiene / styrene copolymer #) /150G22/ ABS
Use: other
Important parameters: melt flow rate: 8 g/10min density: 1.19 g/cm3, molding shrinkage: 0.25% notched impact strength: 16 tensile strength: 88 MPa, elongation at break: 5% bending strength: 120 MPa bending modulus: 5500 MPa VEKA softening point: 106 DEG heat deformation temperature: 115 degrees C
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /SHI-01/ in Lanzhou Petrochemical Company
Use: other
Characteristic notes: high adhesive ABS grafted powder developed by ourselves as a modifier for high impact ABS
Important parameters: melt flow rate: 0.7 g/10min
Manufacturer: PetroChina Lanzhou Petrochemical Branch
ABS (acrylonitrile / butadiene / styrene copolymer #) /PG ABS 298/
Use: other
Characteristic notes: good adhesion and moderate rigidity
Important parameters: melt flow rate: 5 g/10min density: 1.06 g/cm3 water absorption: 0.3% molding shrinkage: 0.5% notched impact strength: 171 tensile strength: 40 MPa flexural strength: 78.6 MPa bending modulus: 2830 MPa VEKA softening point: 97.8 DEG heat deformation temperature: 83.9 degrees C
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2K/ ABS
Use: other
Characteristic notes: impact resistance, low temperature
Important parameters: melt flow rate: 4 g/10min density: 1.03 g/cm3, molding shrinkage: 0.75% notched impact strength: 36 bending strength: 52 MPa bending modulus: 1700 MPa hardness: 70 VEKA softening point: 94 DEG heat deforming temperature: 93 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /E211 ABS LNS013/
Use: other
Characteristic notes: high heat resistance
Important parameters: melt flow rate: 6 g/10min density: 1.05 g/cm3, molding shrinkage: 0.65% notched impact strength: 20 bending strength: 73 MPa bending modulus: 2400 MPa hardness: 105 VEKA softening point: 108 DEG heat deforming temperature: 101 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /M406/ ABS
Use: other
Characteristic notes: good chemical resistance, high impact resistance
Important parameters: melt flow rate: 10 g/10min density: 1.02 g/cm3, molding shrinkage: 0.75% notched impact strength: 29 bending strength: 55 MPa bending modulus: 1800 MPa hardness: 74 VEKA softening point: 92 DEG heat deforming temperature: 91 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H606LS/ ABS
Use: other
Characteristic notes: high heat resistance, good ultraviolet resistance
Important parameters: melt flow rate: 12 g/10min density: 1.04 g/cm3, molding shrinkage: 0.5% notched impact strength: 19 bending strength: 72 MPa flexural modulus: 2500 MPa VEKA softening point: 101 DEG heat deforming temperature: 98 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /488/ ABS
Use: other
Characteristic notes: high gloss, good fluidity, good surface finish
Important parameters: melt flow rate: 6 g/10min density: 1.06 g/cm3, molding shrinkage: 0.5% notched impact strength: 294 tensile strength: 42.1 MPa, bending strength: 70.3 MPa, bending modulus: 2550 MPa hardness: 105 VEKA softening point: 101 DEG heat deformation temperature: 85 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /130/ ABS
Use: other
Characteristic notes: good chemical resistance, good processing performance, high rigidity, high strength and good toughness.
Important parameters: melt flow rate: 0.3 g/10min density: 1.05 g/cm3, notched impact strength: 347 tensile strength: 35.2 MPa flexural strength: 60.7 MPa bending modulus: 2140 MPa hardness: 103 thermal deformation temperature: 84.4 degrees.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /348/ ABS
Use: other
Characteristic notes: general use treatment methods: blow molding, calendering, casting, coating, extrusion, extrusion, injection, thermoplastic
Important parameters: melt flow rate: 5 g/10min density: 1.04 g/cm3, molding shrinkage: 0.5% notched impact strength: 214 tensile strength: 48.3 MPa, bending strength: 75.8 MPa, bending modulus: 2690 MPa hardness: 112 VEKA softening point: 107 DEG heat deformation temperature: 85.6 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /P2H-AT/ ABS
Use: other
Important parameters: melt flow rate: 37 g/10min density: 1.05 g/cm3, molding shrinkage: 0.5% notched impact strength: 16 bending strength: 70 MPa bending modulus: 2400 MPa hardness: 110 VEKA softening point: 98 DEG heat deforming temperature: 93 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /H607AS/ ABS
Use: other
Feature remark: antistatic function, high heat resistance
Important parameters: melt flow rate: 15 g/10min density: 1.04 g/cm3, molding shrinkage: 0.55% notched impact strength: 19 bending strength: 70 MPa flexural modulus: 2400 MPa VEKA softening point: 100 DEG heat deforming temperature: 96 C.
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /433/ ABS
Use: other
Characteristic notes: high gloss, high impact resistance and good fluidity
Important parameters: melt flow rate: 5 g/10min density: 1.05 g/cm3 molding shrinkage rate: 0.5% notched impact strength: 374 tensile strength: 42.1 MPa elongation: 30% bending strength: 72.4 MPa flexural modulus: 2620 MPa hardness: 109 VEKA softening point of 106 DEG C heat deformation temperature: 85 degrees
Manufacturer: Ineos ABS company
ABS (acrylonitrile / butadiene / styrene copolymer #) /Elite HH ABS 1891/
Use: other
Feature notes: low glossiness
Important parameters: melt flow velocity