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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 # /NA951000/ Leander Basil)
Uses: other
Characteristics note: good processing, good toughness, good precipitation, acceptable food contact, homopolymer
Important beters: melt flow rate: 2.2 g/10min density: 0.92 g/cm3 tensile strength: 13.6 MPa elongation at break: 600% VEKA softening point: 90 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene # LDPE) /2420 D/ Amir Kabir in Iran
Application: film grade
Characteristic note: good processability, good tear strength, good impact toughness
Important beters: melt flow rate: 0.25 g/10min density: 0.923 g/cm3 tensile strength: 20 MPa elongation at break: 500% VEKA softening point: 94 DEG C
Manufacturer: Iran, Amir, Kabir, Petrochemical Industries Co
LDPE (low density polyethylene # high-pressure polyethylene) /NA860241/ quantum chemistry
Uses: other
Features: antioxidant, dimensional stability, flow media, acceptable contact with food, high slip, good processability, good toughness
Important beters: melt flow rate: 24 g/10min density: 0.921 g/cm3 tensile strength: 8.48 MPa bending modulus: 221 MPa hardness: 44 VEKA softening point: 92 DEG C embrittlement temperature: -35 DEG C;
Manufacturer: quantum chemical company of America
LDPE (low density polyethylene # high-pressure polyethylene) /NA373242X01/ quantum chemistry
Uses: other
Characteristic note: high clarity, low friction, good impact resistance, slip, homopolymer, contact with food, acceptable
Important beters: melt flow rate: 3 g/10min density: 0.924 g/cm3 tensile strength: 17.2 MPa, elongation at break: 500%
Manufacturer: quantum chemical company of America
LDPE (low density polyethylene # LDPE) /CP-104/ Repsol of Spain
Uses: other
Characteristics: antioxidants, cross-bing, good processability, good surface finish, good thermal stability, ultra high molecular weight
Important beters: melt flow rate: 2 g/10min density: 0.92 g/cm3 tensile strength: 14 MPa elongation at break: 500% VEKA softening point: 91 DEG C
Manufacturer: YPF of Spain
LDPE (low density polyethylene LDPE # /LD202.48/ Mobil Exxon)
Uses: other
Characteristic note: high speed processing perbance, good heat sealing perbance. Additives: anti adhesion agent, smoothing agent, no; no; no heat stabilizer. Product trademark: ExxonMobil
Important beters: melt flow rate: 12 g/10min density: 0.915 g/cm3 VEKA softening point: 84 DEG C
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /LD252/ Mobil Exxon)
Uses: other
Characteristic note: good necking / drawing speed characteristics, excellent sensory perbance. Additives: anti adhesion agent, smoothing agent, no; no; no heat stabilizer. Product trademark: ExxonMobil
Important beters: melt flow rate: 3.8 g/10min density: 0.9225 g/cm3 VEKA softening point: 95 DEG C
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /LD637.LI/ Mobil Exxon)
Uses: other
Note: the characteristics of additives: anti adhesion agent, smoothing agent, no; 550ppm; heat stabilizer, No. Product trademark: ExxonMobil
Important beters: melt flow rate: 40 g/10min density: 0.922 g/cm3 tensile strength: 7.6 MPa elongation at break: 110% bending modulus: 279 MPa hardness: 43 VEKA softening point: 86 DEG C
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /LD152BW/ Mobil Exxon)
Application: film grade
Characteristic note: good toughness. Additives: anti adhesion agent, smoothing agent, no; no; heat stabilizer, a. Product trademark: ExxonMobil
Important beters: melt flow rate: 2.2 g/10min density: 0.933 g/cm3 tensile strength: 22 MPa, elongation at break: 600%
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /LD506.07/ Mobil Exxon)
Uses: other
Note: the characteristics of high velocity, additive: anti adhesion agent, smoothing agent, no; no; heat stabilizer, a. Product trademark: ExxonMobil
Important beters: melt flow rate: 33 g/10min density: 0.921 g/cm3 tensile strength: 8.1 MPa elongation at break: 130% bending modulus: 250 MPa hardness: 49 VEKA softening point: 91 DEG C
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /NA 362/ Leander Basil)
Uses: other
Characteristics: copolymer, in contact with food, acceptable, high impact resistance, high strength, low temperature toughness
Important beters: melt flow rate: 0.5 g/10min density: 0.926 g/cm3 tensile strength: 24.8 MPa elongation at break: 600% VEKA softening point: 87 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene # high-pressure polyethylene) /2420F/ Daqing petrochemical
Application: film grade
Properties: the product is good in processing without opening agent. Blown films have better heat sealing and optical properties.
Important beters: melt flow rate: 0.75 g/10min density: 0.923 g/cm3 notched impact strength: 130 tensile strength: 20 MPa, elongation at break: 600% VEKA softening point: 94 DEG C
Manufacturer: China Petroleum Daqing Petrochemical Co
LDPE (low density polyethylene LDPE #) Chevron /5561/ Phillips
Application: film grade
Characteristics: excellent optics, good impact strength, excellent processability, good thermal sealing characteristics, high friction coefficient
Important beters: melt flow rate: 1.3 g/10min density: 0.926 g/cm3 VEKA softening point: 100 DEG C
Manufacturer: Chevron Phillips chemical company (USA)
LDPE (low density polyethylene LDPE #) Chevron /5563/ Phillips
Application: film grade
special
LDPE (low density polyethylene # high-pressure polyethylene) /184MF/ West Lake
Uses: other
Features: good printability, food contact acceptability, good impact resistance, good processing, good tear strength, high definition, medium smooth
Important beters: melt flow rate: 2.5 g/10min density: 0.921 g/cm3 tensile strength: 172 MPa elongation at break: 300% VEKA softening point: 94 DEG C
Manufacturer: West Lake Chemical Co., Ltd.
LDPE (low density polyethylene LDPE # /NA340163/ Leander Basil)
Uses: other
Features: copolymer, food contact acceptable, good impact resistance, high definition, medium smooth
Important beters: melt flow rate: 1 g/10min tensile strength: 25.5 MPa, elongation at break: 340% VEKA softening point: 95 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene LDPE # /NA340185/ Leander Basil)
Uses: other
Features: copolymer, food contact acceptable, good impact resistance, high definition, high slip
Important beters: melt flow rate: 1 g/10min tensile strength: 25.5 MPa, elongation at break: 340% VEKA softening point: 95 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene LDPE # /E GGNX 18-D003/ Leander Basil)
Uses: other
Features: lasting, general use, high impact resistance, high strength
Important beters: melt flow rate: 0.3 g/10min density: 0.92 g/cm3 VEKA softening point: 94 DEG C
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene LDPE # /NA349013/ Leander Basil)
Application: film grade
Characteristic remarks: good impact resistance, good rigidity, good strength, high clarity, homopolymer
Important beters: melt flow rate: 2.5 g/10min density: 0.924 g/cm3 tensile strength: 11.7 MPa, elongation at break: 330%
Manufacturer: Basel industries, Inc.
LDPE (low density polyethylene LDPE # /NA 942/ Leander Basil)
Uses: other
Characteristic notes: acceptable for contact with food, good resistance to shock, puncture resistance,
Important beters: melt flow rate: 0.18 g/10min density: 0.918 g/cm3 tensile strength: 17.9 MPa, elongation at break: 750% hardness: 42, embrittlement temperature: -75
Manufacturer: Basel industries, Inc.
