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热塑性塑料注塑成型管材原理认识
1.1 塑料的定义: 塑料基础知识 塑料是以高分子树脂为主要成分,在一定条件下(如温度,压力等)可塑制成一定形状且在常温下保 持形状不变的材料. 塑料它可以是纯的树脂,也可以是加有各种添加剂的混合物,添加剂的是用来改善纯树脂的物理机械 性能,改善加工性能或者为了节约树脂.
1.2 塑料的组成: 塑料都以合成树脂(极少天然树脂)为基本原料,并可能加入填料,增塑剂,染料,稳定剂,润滑剂 等各种辅助料而组成.因此,不同品种牌号的塑料,由于选用树脂及辅助料的性能,成分,配比及塑料生 产工艺不同,则其使用及工艺特性也各不相同.
1.3 塑料的分类:
1.3.1 按受热时的行为分:
a) 热塑性塑料 加热时变软以至流动,冷却变硬成型出产品,这种过程是可逆的,可以反复进行.聚乙烯,聚丙烯, 聚氯乙烯,聚苯乙烯,聚甲醛,聚碳酸酯,聚酰胺,丙烯酸类塑料,其它聚烯烃及其共聚物,聚砜,聚苯 醚,氯化聚醚等都是热塑性塑料.热塑性塑料中树脂分子链都是线型或带支链的结构,分子链之间无化学 键产生,加热时软化流动,冷却变硬的过程是物理变化.
b) 热固性塑料 第一次加热时可以软化流动,加热到一定温度,产生化学反应,交联固化而变硬,这种变化是不可逆 的,此后,再次加热时,已不能再变软流动了.正是借助这种特性进行成型加工,利用第一次加热时的塑 化流动,在压力下充满型腔,进而固化成为确定形状和尺寸的制品.这种材料称为固性塑料. 热固性塑较 的树脂固化前是线型或带支链的,固化后分子链之间形成化学键,成为三度的网状结构,不仅不能再熔融, 在溶剂中也不能溶解.酚醛,脲醛,三聚氰胺甲醛,环氧,不饱和聚酯,有机硅等塑料,都是热固性塑料.
1.3.2 按树脂合成时的反应类型分 :
a) 聚合型塑料 热塑性塑料注塑成型树脂是由聚合反应制得.这种树脂一般是由含有不饱和键,主要是双键的单体,借双键打开生成的, 反应过程中无低分子产物释出.聚烯烃,聚卤代烯烃,聚苯乙烯,聚甲醛,丙烯酸类塑料都属于聚合型塑 料.聚合型塑料都是热塑性塑料.
b) 缩聚型塑料 树脂是由缩聚反应制得.这种树脂一般是由含有某种官能团(一般少含有两个官能团)的单体,借官能团之间的反应使单体连接起来而形成的.
1.3.3 按塑料中树脂大分子的有序状态分:
a) 无定形塑料 树脂大分子的排列是无序的.这种塑料,由于树脂分子链的结构特点,或因热力学原因,或成型过程 工艺条件范围的限制,分子链不会产生有序的整齐堆砌形成结晶结构,而呈现无规则的随机排列.在纯树 脂状态,这种塑料是透明的.
b) 结晶型塑料 树脂大分子排列呈现出有序晶相.从熔融状态冷却变为制品过程中,树脂的分子链能够有序地紧密堆 砌产生结晶结构的.一般所谓的结晶型塑料,实际上都是半结晶的,不像低分子晶体(例如 NaCl)那样能 产生 100%的结晶度.树脂大分子链排列呈现出无定形相与结晶相共存的状态.成型条件对结晶度和晶态结 构有明显影响,从而对制品性能有明显影响.结晶结构只存在于热塑性塑料中.
1.3.4 按性能和应用范围分:
a) 通用塑料 通用塑料是指生产量大,货源广,价格低,适于大量应用的塑料.通用塑料一般皆具有良好的成型工 艺性,可采用多种工艺成型出多种用途制品.一般说,通用塑料不具有突出的综合力学性能和耐热性,不 宜用于承载要求较高的结构件和在较高温度下工作的耐热件.但通用塑料的各品种,都有各自的某些优异 性能,使它具有广泛用途.聚乙烯,聚氯乙烯,聚苯乙烯,聚丙烯,酚醛塑料合称五大通用塑料.其它聚 烯烃,乙烯基塑料及其共聚物与改性材料,丙烯酸塑料,氨基塑料等也都属于通用塑料.
b)工程塑料 工程塑料是指那些具有突出力学性能,耐热性,或优异耐化学试剂,耐溶剂性,或在变化的环境条件 下可保持良好绝缘介电性能的塑料.工程塑料一般可以作为承载结构件,高温环境下的耐热件和承载件, 高温条件,潮湿条件,大范围的变频条件下的介电制品和绝缘用品.工程塑料的生产批量小,价格也较昂 贵,用途范围相对狭窄,一般都是按某些特殊用途生产一定批量的材料.现有的工程塑料主要品种有聚酰 胺,聚碳酸酯,聚甲醛,聚苯醚,ABS,PET,PBT,聚砜,聚苯硫醚,氯化聚醚,聚酰亚胺,聚醚醚酮, 氟塑料,超高分子量聚乙烯,环氧塑料和不饱和聚酯等. 此外还有具有某种特殊功能,适于某种特殊用途的特种工程塑料,例如用于导电,压电,热电,导磁, 感光,防辐射,光导纤维,液晶,高分子分离膜,专用于摩擦磨损用途等塑料. 特种工程塑料又称功能塑 料.特种工程塑料的主要成分是树脂,有些是专门合成的特种树脂,但也有一些是采用上述通用塑料或工 程塑料用树脂经特殊处理或改性后获得特殊性能的.
2.塑料的基本性能
2.1 质轻,比强度高塑料质轻,一般塑料的密度都在 0.9 ~ 2.3 g/cm 之间,只有钢铁的 1/8,铝的 1/2 左右,而各种泡 沫塑料的密度
更低,约在 0.1 ~ O.5 g/cm之间. 比强度是按单位质量计算的强度,有些增强塑料的比强度接近甚至超过钢材.例如合金钢材,其单位
质量的拉伸强度为 160 兆帕,而用玻璃纤维增强的塑料可达到 170 ~ 400 兆帕. 一般而言,多数塑料的比强度与金属在同一数量级,
比刚度低于金属数倍至一个数量级,但某些结构泡沫塑料,比刚度可与 金属媲美.用高模量增强剂增强后,某些塑料的比刚度可以超过
金属.
2.2 优异的电绝缘性能 几乎的塑料都具有优异的电绝缘性能,如极小的介电损耗和优良的耐电弧特性,这些性能可与陶
瓷媲美.
2.3 优良的化学稳定性能 一般塑料对酸碱等化学药品均有良好的耐腐蚀能力,是聚四氟乙烯的耐化学腐蚀性能比还要 好,
甚至能耐 " 王水 " 等强腐蚀性电解质的腐蚀,被称为"塑料王".
2.4 减摩,耐磨性能好 大多数塑料具有优良的减摩,耐磨和自润滑特性.许多工程塑料制造的耐摩擦零件就是利用塑料的这 些特性,在耐磨塑料中加入某些固体润滑剂和填料时,可降低其摩擦系数或进一步提高其耐磨性能.
2.5 透光及防护性能 多数塑料都可以作为透明或半透明制品,其中聚苯乙烯和丙烯酸酯类塑料象玻璃一样透明.有机玻璃 化学名称为聚甲基丙烯酸甲酯,可用作航空玻璃材料.聚氯乙烯,聚乙烯,聚丙烯等塑料薄膜具有良好的 透光和保暖性能,大量用作农用薄膜.塑料具有多种防护性能,因此常用作防护保装用品,如塑料薄膜, 箱,桶,瓶等。
部分型号部分物性表
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Physical Properties
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Metric
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English
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Comments
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Density
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1.32 g/cc
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0.0477 lb/in3
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Melt Density
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1.12 g/cc
@Temperature 250 °C
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0.0405 lb/in3
@Temperature 482 °F
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Water Absorption
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0.40 %
@Thickness 2.00 mm
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0.40 %
@Thickness 0.0787 in
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Moisture Absorption
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0.200 %
@Thickness 2.00 mm
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0.200 %
@Thickness 0.0787 in
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Viscosity Test
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150 cm3/g
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150 cm3/g
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Linear Mold Shrinkage, Flow
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0.017 cm/cm
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0.017 in/in
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Linear Mold Shrinkage, Transverse
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0.015 cm/cm
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0.015 in/in
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Melt Flow
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10 g/10 min
@Load 2.16 kg,
Temperature 250 °C
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10 g/10 min
@Load 4.76 lb,
Temperature 482 °F
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Mechanical Properties
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Metric
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English
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Comments
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Tensile Strength, Yield
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58.0 MPa
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8410 psi
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Elongation at Break
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>= 50 %
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>= 50 %
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Elongation at Yield
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5.0 %
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5.0 %
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Tensile Modulus
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2.60 GPa
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377 ksi
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0.181 GPa
@Temperature 150 °C
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26.3 ksi
@Temperature 302 °F
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0.333 GPa
@Temperature 90.0 °C
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48.3 ksi
@Temperature 194 °F
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2.358 GPa
@Temperature 23.0 °C
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342.0 ksi
@Temperature 73.4 °F
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3.024 GPa
@Temperature -40.0 °C
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438.6 ksi
@Temperature -40.0 °F
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Flexural Modulus
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2.40 GPa
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348 ksi
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Charpy Impact Unnotched
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NB
@Temperature 23.0 °C
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NB
@Temperature 73.4 °F
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LDPE (low density polyethylene LDPE #) /SGD4960/ Braskem
Uses: other
Remarks: high rigidity, high impact resistance
Important beters: melt flow rate: 0.7 g/10min density: 0.961 g/cm3 tensile strength: 22 MPa bending modulus: 1600 MPa hardness: 64 VEKA softening point: 128 degrees of hot debation temperature: 79 degrees centigrade
Manufacturer: American Braskem company
LDPE (low density polyethylene LDPE /AVPE LD #) 300-1/ Aaron
Uses: other
Important beters: melt flow rate: 26 g/10min density: 0.921 g/cm3 molding shrinkage: 1.5% tensile strength: 22.8 MPa bending modulus: 331 MPa, hot debation temperature: 72.8 DEG C
Manufacturer: Aaron industries, Inc.
LDPE (low density polyethylene # high-pressure polyethylene) /LFI2119/ Iran petrochemical
Application: film grade
Characteristic note: good elasticity, extrusion behavior and excellent mechanical properties
Important beters: melt flow rate: 1.9 g/10min density: 0.921 g/cm3 tensile strength: 13 MPa, elongation at break: 150%
Manufacturer: Iran national Petrochemical Industries Co
LDPE (low density polyethylene # high-pressure polyethylene) /2420D/ Daqing petrochemical
Application: film grade
Important beters: melt flow rate: 0.32 g/10min density: 0.923 g/cm3 tensile strength: 14.2 MPa, elongation at break: 490%
Manufacturer: China Petroleum Daqing Petrochemical Co
LDPE (low density polyethylene # high-pressure polyethylene) /UB-600C/ Brazil Quattor
Uses: other
Characteristic note: good processing
Important beters: melt flow rate: 0.3 g/10min density: 0.92 g/cm3 tensile strength: 14 MPa elongation at break: 720% VEKA softening point: 92 DEG C
Manufacturer: Brazil Quattor Petrochemical Industries Co
LDPE (low density polyethylene # high pressure polyethylene) /LD1403AA/
Uses: other
Characteristic note: homopolymer, low slip, super high impact resistance
Important beters: melt flow rate: 0.2 g/10min density: 0.923 g/cm3, elongation at break: 280% VEKA softening point: 97 DEG C
Manufacturer: Ineos
LDPE (low density polyethylene # high pressure polyethylene) /PH23T630/
Uses: other
Feature note: good flexibility
Important beters: melt flow rate: 22 g/10min density: 0.923 g/cm3, elongation at break: 130% hardness: 49 VEKA softening point: 92 degrees of hot debation temperature: 49 degrees centigrade
Manufacturer: Ineos
LDPE (low density polyethylene # high-pressure polyethylene) /1700 MN 18 C/ France akema
Uses: other
Important beters: melt flow rate: 92.1 g/10min density: 0.919 g/cm3, water absorption: 0.01% oxygen index: 18% tensile strength: 8 MPa, elongation at break: 50% VEKA softening point: 80 DEG C
Manufacturer: Arkema
LDPE (low density polyethylene LDPE #) /FE 8000/ France akema
Application: film grade
Important beters: melt flow rate: 1.05 g/10min density: 0.924 g/cm3, water absorption: 0.01% oxygen index: 18% tensile strength: 1.05 MPa, elongation at break: 12%, VEKA softening point: 98 degrees of hot debation temperature: 41 degrees centigrade
Manufacturer: Arkema
LDPE (low density polyethylene # high-pressure polyethylene) /SPB681/ Brazil Braskem
Uses: other
Characteristic note: good peeling off, without additives, solidifying point at low speed
Important beters: melt flow rate: 3.8 g/10min density: 0.922 g/cm3 tensile strength: 20 MPa, elongation at break: 1100%
Manufacturer: Brazil chemical company
LDPE (low density polyethylene # high-pressure polyethylene) /LD4003/ Brazil Braskem
Uses: other
Properties: smoothness, optical properties, resistance to caking, processability, good
Important beters: melt flow rate: 1.9 g/10min density: 0.922 g/cm3 tensile strength: 20 MPa, elongation at break: 920%
Manufacturer: Brazil chemical company
LDPE (low density polyethylene LDPE /205/ Toyo #)
Uses: other
Characteristics: flat rolling, good processability, low water vapor permeability, good heat sealing property
Important beter: melt flow rate: 3 g/10min density: 0.924 g/cm3
Manufacturer: Toyo Textile Co., Ltd.
LDPE (low density polyethylene LDPE /MB7000/LG chemical #)
Uses: other
Features: fluidity, easy mix rubber.
Important beters: melt flow rate: 7 g/10min density: 0.919 g/cm3 tensile strength: 13 MPa elongation at break: 520% VEKA softening point: 85 DEG C embrittlement temperature: -78 DEG C
Manufacturer: Korea LG chemical company
LDPE (low density polyethylene LDPE /FB0300/LG chemical #)
Application: film grade
Features: resistance to cracking and good heat shrinkage.
Important beters: melt flow rate: 0.3 g/10min density: 0.92 g/cm3 notched impact strength: 400 tensile strength: 17 MPa, elongation at break: 650% VEKA softening point: 95 DEG C embrittlement temperature: -76 DEG C
Manufacturer: Korea LG chemical company
LDPE (low density polyethylene LDPE #) /BC100/ Hyundai
Purpose: wire and cable
Characteristic note: Type: wire and cable
Important beters: melt flow rate: 0.3 g/10min density: 0.919 g/cm3 tensile strength: 17 MPa elongation at break: 700% hardness: 50 VEKA softening point: 94 DEG C
Manufacturer: Korean Modern Petrochemical Corporation
LDPE (low density polyethylene # LDPE) /5321FOAM/ Korea China
Uses: other
Features: extrusion, foaming, processability, softness, impact absorption
Important beters: melt flow rate: 3 g/10min density: 0.92 g/cm3 tensile strength: 11 MPa, elongation at break: 670% hardness: 48 VEKA softening point: 88 DEG C embrittlement temperature: -76 DEG C
Manufacturer: Han Hua comprehensive chemical Co., Ltd.
LDPE (low density polyethylene # LDPE) /5316/ Korea China
Application: film grade
Features: transparency, mechanical properties and processability of excellent products
Important beter: melt flow rate: 0.8 g/10min
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