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亚克力【PMMA】注塑工艺
PMMA俗称有机玻璃、亚克力等。化学名为聚甲基丙烯酸甲酯。由于PMMA表面硬度不高、易擦毛、抗冲击性能低、成型流动性能差等缺点，PMMA的改性相继出现。如甲基丙烯酸甲酯与苯乙烯、丁二烯的共聚，PMMA与PC的共混等。372有机玻璃就是甲基丙烯酸甲酯与苯乙烯进行共聚而得。如果在372有机玻璃中加入少量的丁腈橡胶（约50%）即可成373有机玻璃。PMMA的流动生比PS、ABS差，熔体粘度对温度的变化比较敏感，在成型过程中，主要从注射温度着手来改变熔体粘度。PMMA为无定形聚合物，熔化温度大于160℃，分解温度达270℃。
二、注塑成型工艺
1、塑料的处理
PMMA具有一定的吸水性，其吸水率达0.3-0.4%，而注塑须在0.1%以下的温度，通常是0.04%。水份的存在使熔体出现气泡、气纹，透明度降低等。所以要进行干燥处理。干燥温度80-90℃，时间为3小时以上。回收料在某些情况下可100%的使用，实际份量要视品质要求而定，通常可过30%，回收料要避免污染否则会影响透明度和成品的性质。
2、注塑机选用
PMMA对注塑机有特别要求，因为其熔体粘度大，需要较深的螺槽的螺杆和较大直径的射嘴孔；如果对制品的强度要求较高，则要用较大长径比的螺杆实行低温塑化。另外PMMA一定要用干燥料斗贮料配合机台同时生产使用。
3、模具及浇口设计
模具温度可为60℃-80℃，主流道的直径应配合内锥度，最佳的角度是5°至7°，若要注塑4mm或以上制品，角度应为7°，主流道直径达8至10mm，浇口的整体长度不要超过50mm。对于壁厚小于4mm的制品，流道直径应为6-8mm。
对于壁厚大于4mm的制品，流道直径应为8-12mm
对边形、扇形及垂片形浇口深度应为0.7至0.9t（t为制品壁厚度），针形浇口的直径应为0.8至2mm；低粘度的应选用较小的尺寸。常见的排气孔有0.05至0.07mm深、6mm宽。
脱模斜度为30′-1°型腔部分35′-1°30°之间。
4、熔胶温度
可用对空注射法量度：由210℃-270℃不等，具体视供应商提供的资料而定。
5、注射温度
可用快速注射，但要避免产生高度内应力，宜用多级注射，如慢-快-慢等，注塑厚件时，则采用高压慢速。
6、滞留时间
若温度为260℃，滞留时间最多不超过10分钟，若温度为270℃，滞留时间不能超过8分。
部分型号部分物性表
| Physical Properties | Metric | English | Comments |
|---|---|---|---|
| Specific Gravity | 0.960 g/cc | 0.960 g/cc | ASTM D792 and ISO 1183 |
| Mechanical Properties | Metric | English | Comments |
| Hardness, Shore A |
60 @Time 15.0 sec |
60 @Time 0.00417 hour |
2 mm; ISO 868 |
| Tensile Strength at Break | 5.10 MPa | 740 psi | Across Flow; ASTM D412 and ISO 37 |
| Tensile Stress |
1.90 MPa @Strain 100 % |
276 psi @Strain 100 % |
Across Flow; ASTM D412 and ISO 37 |
| Elongation at Break | 450 % | 450 % | Across Flow; ASTM D412 and ISO 37 |
| Compression Set |
16 % @Temperature 23.0 °C, Time 79200 sec |
16 % @Temperature 73.4 °F, Time 22.0 hour |
ASTM D395B Type 1 and ISO 188 Type A |
|
35 % @Temperature 70.0 °C, Time 79200 sec |
35 % @Temperature 158 °F, Time 22.0 hour |
ASTM D395B Type 1 and ISO 188 Type A | |
|
42 % @Temperature 100 °C, Time 79200 sec |
42 % @Temperature 212 °F, Time 22.0 hour |
ASTM D395B Type 1 and ISO 188 Type A | |
|
47 % @Temperature 100 °C, Time 1.08e+6 sec |
47 % @Temperature 212 °F, Time 300 hour |
ASTM D395B Type 1 and ISO 188 Type A | |
LDPE (low density polyethylene LDPE # /E MGNX 23-D006-1/ Leander Basil)
Uses: other
Characteristic note: good corrosion resistance
Important beters: melt flow rate: 0.75 g/10min density: 0.922 g/cm3 VEKA softening point: 90 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene LDPE #) /A2920M/ Leander Basel
Uses: other
Features: antioxidants, good adhesion, low temperature flexibility
Important beters: melt flow rate: 7 g/10min density: 0.927 g/cm3 hardness: 38 VEKA softening point: 72 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene # high pressure polyethylene) /M23N430/
Uses: other
Characteristic notes: good thermal sealing properties, high purity and very low levels of gel
Important beters: melt flow rate: 7.5 g/10min density: 0.923 g/cm3 tensile strength: 10.5 MPa elongation at break: 500% hardness: 48 VEKA softening point: 90 DEG C
Manufacturer: Ineos
LDPE (low density polyethylene # LDPE) /2335FG/ Repsol of Spain
Uses: other
Features note: antioxidants, acceptable handling properties for food, good processing properties, slip
Important beters: melt flow rate: 3.5 g/10min density: 0.923 g/cm3 tensile strength: 17 MPa, elongation at break: 200%, hot debation temperature: 152.5 DEG C, light transmittance: 8%
Manufacturer: YPF of Spain
LDPE (low density polyethylene # LDPE) /CA-2111A/ Repsol of Spain
Uses: other
Features: antioxidants, good resistance to heat aging, good stability, UV absorption
Important beters: melt flow rate: 0.4 g/10min density: 0.948 g/cm3, elongation at break: 500%, hot debation temperature: 200 DEG C
Manufacturer: YPF of Spain
LDPE (low density polyethylene LDPE # /NA334000/ Leander Basil)
Uses: other
Characteristic note: food contact is acceptable, good precipitation, good processing, homopolymer
Important beters: melt flow rate: 6 g/10min density: 0.919 g/cm3 tensile strength: 15.2 MPa elongation at break: 300% VEKA softening point: 85 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene # high-pressure polyethylene) /F0421D/ Brazil Braskem
Application: film grade
Characteristic note: product trademark Braskem, high mechanical and impact strength, good processability, tightness and contrb
Important beters: melt flow rate: 0.38 g/10min density: 0.921 g/cm3 tensile strength: 11 MPa, elongation at break: 400%, embrittlement temperature: -68
Manufacturer: Brazil chemical company
LDPE (low density polyethylene # high-pressure polyethylene) /1840F/ West Lake
Uses: other
Features: good printability, acceptable food contact, good impact resistance, good processing, good tear strength, high definition
Important beters: melt flow rate: 2.5 g/10min density: 0.921 g/cm3 tensile strength: 24 MPa elongation at break: 300% VEKA softening point: 94 DEG C
Manufacturer: West Lake Chemical Co., Ltd.
LDPE (low density polyethylene LDPE /LD2203/ Australia Qenos #)
Uses: other
Characteristic note: good flexibility, good processing, high definition, high impact resistance, low slip
Important beters: melt flow rate: 0.8 g/10min density: 0.922 g/cm3 tensile strength: 8 MPa, elongation at break: 650% hardness: 43
Manufacturer: Australia Qenos company
LDPE (low density polyethylene # high-pressure polyethylene) /TU8091/ Brazil Triunfo
Uses: other
Features: antioxidant, good impact resistance, good processing, good thermal stability, good anti UV, ultra high molecular weight
Important beters: density: 0.923 g/cm3 tensile strength: 11 MPa elongation at break: 630% VEKA softening point: 96 DEG C
Manufacturer: Brazil Triunfo company
LDPE (low density polyethylene # high-pressure polyethylene) /TX7001/ Brazil Triunfo
Uses: other
Features: food contact is acceptable, good dimensional stability, good processing, advanced cultural rights (stress, crack resistance), ultra high molecular weight
Important beters: melt flow rate: 0.12 g/10min density: 0.922 g/cm3 tensile strength: 11 MPa elongation at break: 630% VEKA softening point: 95 DEG C
Manufacturer: Brazil Triunfo company
LDPE (low density polyethylene LDPE # /PH27D630/ America Ineos)
Uses: other
Remarks: additives free, good flexibility, good processing, low density, soft, steam sterilization
Important beters: melt flow rate: 0.3 g/10min density: 0.927 g/cm3, hardness: 52, hot debation temperature: 51 DEG C
Manufacturer: America Ineos
LDPE (low density polyethylene LDPE # /PH30D630/ America Ineos)
Uses: other
Remarks: additives free, good flexibility, good processing, low density, soft, steam sterilization
Important beters: melt flow rate: 0.3 g/10min density: 0.93 g/cm3, hardness: 53, hot debation temperature: 54 DEG C
Manufacturer: America Ineos
LDPE (low density polyethylene # LDPE) /534A/ DuPont dow
Uses: other
Note: the excellent characteristics of downsizing and packaging application of extrusion resin slip additives and additives, anti adhesion agent medium level 21 CFR 177.1520 (c) 2.1
Important beters: melt flow rate: 2 g/10min density: 0.923 g/cm3 tensile strength: 19 MPa, elongation at break: 540%
Manufacturer: Dow DuPont Co
LDPE (low density polyethylene # LDPE) /641I/ DuPont dow
Uses: other
Note: with the characteristics of downsizing very good application and excellent toughness of resin film. It contains anti slip additives and additives with low levels of anti adhesion agents
LDPE (low density polyethylene LDPE # /M2512/ Leander Basil)
Application: film grade
Characteristics: good rigidity, good optical perbance, good impact resistance, and good compliance of food contact
Important beters: melt flow rate: 1.2 g/10min density: 0.925 g/cm3 tensile strength: 23.1 MPa, elongation at break: 330%
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene # LDPE) /HP2027N/ SABIC of Saudi Arabia
Application: film grade
Characteristics: low density, high rigidity, good optical perbance, good peeling off, good heat sealing property, and good compliance of food contact
Important beters: melt flow rate: 2 g/10min density: 0.927 g/cm3 notched impact strength: 110 tensile strength: 25 MPa, elongation at break: 350% VEKA softening point: 100 DEG C
Saudi Basic Industries, Inc.
LDPE (low density polyethylene # LDPE) /HP4027N/ SABIC of Saudi Arabia
Application: film grade
Characteristics: low density, high rigidity, good optical perbance, good peeling off, good heat sealing property, and good compliance of food contact
Important beters: melt flow rate: 4 g/10min density: 0.927 g/cm3 notched impact strength: 90 tensile strength: 20 MPa, elongation at break: 350% VEKA softening point: 97 DEG C
Saudi Basic Industries, Inc.
LDPE (low density polyethylene LDPE /FF29/ Italy's #)
Application: film grade
Characteristics: good melt strength, good foam stability, easy thermal shrinkage and good mechanical properties.
Important beters: melt flow rate: 0.6 g/10min density: 0.921 g/cm3 tensile strength: 25 MPa elongation at break: 600% VEKA softening point: 91 DEG C embrittlement temperature: -75 DEG C
Manufacturer: Italy Eni
LDPE (low density polyethylene LDPE /FF20/ Italy's #)
Application: film grade
Characteristics: good melt strength, good foam stability, easy thermal shrinkage and good mechanical properties.
Important beters: melt flow rate: 0.8 g/10min density: 0.921 g/cm3 tensile strength: 22 MPa elongation at break: 650% VEKA softening point: 91 DEG C embrittlement temperature: -75 DEG C
Manufacturer: Italy Eni
