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PC材料的注塑工艺、PC材料注塑机
pc材料是工程塑料中的一种，由于它自身的特性跟优点，被人们广泛的使用。Pc它是一种综合性能优良的非晶型热塑性树脂，它的优点是，具有耐化学腐蚀性、耐热性和耐寒性。更重要是它可以自熄，阻燃、无毒等。
PC类塑胶即使遇到非常低之水份亦会产生水解而断键、分子量降低和物性强度降低之现象。因此在成型加工前，应严格地控制聚碳酸酯之水份在0.02%以下，以避免成型品的机械强度降低或表面产生气泡、银纹等之异常外观。为避免水份所产生异常之情况，聚碳酸酯在加工前，应先经热风干燥机干燥三至五小时以上，温度设定为120℃，或者经除温干燥机来处理水份，但除湿空气在漏斗入口处应有-30℃之露点。
注塑成型:
为满足各种注塑成型工艺的需求，聚碳酸酯有不同熔融指数的规格。通常熔融指数介于5至25g/10min皆可适用于注塑成型。但是其最佳加工条件因注塑机种类、成型品之形状以及聚碳酸酯规格之不同，而有相当之差异，应依据实际情形加以调整。
1.注塑机选择要点:
锁模压力：以成品投影面积每平方公分乘0.47至0.78吨（或每平方寸乘3至5吨）。
机台大小：成品重量约为注塑机容量的40至60%为最佳，如机台以聚苯乙烯来表示其容量(盎斯)时，需减少10%，始为使用GUANG DA之容量。1盎斯=28.3公克。
螺杆：螺杆长度最少应有15个直径长，其L/D为20：1最佳。压缩比宜为1.5：1至30：1。螺杆前端之止流阀应采用滑动环式，其树脂可流动间隙最少应有3.2MM。
喷嘴：尖端开口最少应有4.5MM(直径)，若成品重量为5.5KG以上，则喷嘴直径应有9.5MM以上。另外，尖端开口需比浇口直径少0.5至1MM，且段道愈短愈好，约为5MM。
2.成型条件要点：
熔融温度与模温：
最佳的成型温度设定与很多因素有关，如注塑机大小、螺杆组态、模具及成型品的设计和成型周期时间等。一般而言，为了让塑料渐渐地熔融，在料管后段/进料区设定较低的温度，而在料管前段设定较高的温度。但若螺杆设计不当或L/D值过小，逆向式的温度设定亦可。
模温方面，高温模可提供较佳的表面外观，残留应力也会较小，且对较薄或较长的成型品也交易填满。而低模温则能缩短成型周期。
螺杆回转速度：建议40至70rpm，但需视乎机台与螺杆设计而调整。
注塑压力：而最高为了尽速填满模具，注塑压力愈大愈好，一般约为850至1，400KG/CM2，可达2，400KG/CM2。
背压：一般设定愈低愈好，但为求进料均匀，建议使用3至14KG/CM2。
注塑速度：射速与浇口设计有很大关系，使用直接浇口或边缘浇口时，为防止日晖现象和波流痕现象，则应用较慢之射速。另外，如成品厚度在5MM以上，为避免气泡或凹陷，慢速射出会有帮助。
一般而言，射速原则为薄者快，厚者慢。
从注塑切换为保压之保，保压要尽量低，以免成型品发生残留应力。而残留应力可用退火方式来去除或减轻；条件是120至130℃约三十分钟至一小时。
3.料筒清扫:
（1） 在聚碳酸酯的成型温度下，加入清洗料(通用级聚苯乙烯或透苯)，连续射出二十至三十次。
（2） 将机台后退，续将清洗料空射，直至射出的清洗料开始膨胀起泡。
（3） 将料筒温度重新设定到200至230℃。
（4） 继续将清洗料空射，直到清洗料熔胶温度达260℃且外表看起来很干净透
部分型号部分物性表
LDPE (low density polyethylene LDPE #) /N 103X/ Sasol of South Africa
Use: film grade
Characteristic notes: antioxidant function, good processing perbance, good tearing strength, high impact resistance
Important beters: melt flow rate: 0.3 g/10min density: 0.921 g/cm3
Manufacturer: Sasol, South Africa
LDPE (low density polyethylene # LDPE) /XJF46/60/ Sasol of South Africa
Use: other
Characteristic notes: antioxidant, good heat seal, high definition medium anti adhesion agent
Important beters: melt flow rate: 2 g/10min density: 0.922 g/cm3 tensile strength: 21 MPa breaking elongation: 660%
Manufacturer: Sasol, South Africa
LDPE (low density polyethylene LDPE #) Chevron /5570/ Phillips
Use: film grade
Characteristic notes: good optical perbance, good impact strength and good processing perbance
Important beters: melt flow rate: 1.3 g/10min density: 0.925 g/cm3
Manufacturer: Chevron Phillips chemical company (USA)
LDPE (low density polyethylene LDPE #) Chevron /5754/ Phillips
Use: film grade
Characteristic notes: excellent impact strength, high definition, low friction coefficient
Important beters: melt flow rate: 0.8 g/10min density: 0.923 g/cm3
Manufacturer: Chevron Phillips chemical company (USA)
LDPE (low density polyethylene LDPE #) Chevron /M248/ Phillips
Use: other
Characteristic notes: excellent thermal stability, good processing property, excellent melt strength
Important beters: melt flow rate: 9 g/10min
Manufacturer: Chevron Phillips chemical company (USA)
LDPE (low density polyethylene LDPE # /PE Chevron 1010/ Phillips)
Use: other
Characteristic notes: excellent processing perbance, high temperature extrusion stability
Important beters: melt flow rate: 10 g/10min density: 0.917 g/cm3 tensile strength: 9.3 MPa breaking elongation: 650% VEKA softening point: 128 C
Manufacturer: Chevron Phillips chemical company (USA)
LDPE (low density polyethylene LDPE # /PE Chevron 1013/ Phillips)
Use: other
Characteristic notes: excellent processing perbance, high temperature extrusion
Important beters: melt flow rate: 13 g/10min density: 0.917 g/cm3 tensile strength: 9.3 MPa breaking elongation: 650% VEKA softening point: 128 C
Manufacturer: Chevron Phillips chemical company (USA)
LDPE (low density polyethylene LDPE # /LD 105.BR/ Mobil Exxon)
Use: film grade
Characteristic notes: excellent clarity and good stiffness
Important beters: melt flow rate: 2 g/10min density: 0.923 g/cm3 tensile strength: 21 MPa breaking elongation: 570% VEKA softening point: 97.8 C
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /YR92866/ Leander Basil)
Use: other
Characteristic notes: antioxidants, copolymers
Important beters: melt flow rate: 0.48 g/10min density: 0.94 g/cm3 tensile strength: 19.3 MPa breaking elongation: 730% embrittlement temperature: -76 C
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene LDPE # /NA270001/ Leander Basil)
Use: other
Feature notes: acceptable food contact
Important beters: melt flow rate: 70 g/10min density: 0.915 g/cm3 tensile strength: 7.31 MPa breaking elongation: 100% flexural modulus: 123 MPa hardness: 49
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene LDPE # /2007H/ Leander Basil)
Use: other
Feature remark: rapid prototyping cycle, good flexibility, low density
Important beters: melt flow rate: 1.5 g/10min density: 0.92 g/cm3 hardness: 45 VEKA softening point: 88 C
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene LDPE #) /33AC/ Leander Basel
Use: other
Characteristic notes: good thermal seal, advanced cultural rights (stress crack resistance)
Important beters: density: 0.922 g/cm3 hardness: 46 VEKA softening point: 93 C
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene # LDPE) /SU 1018/ TPI in Thailand
Use: other
Characteristic notes: good machinability, good fluidity, low contractility
Important beters: melt flow rate: 45 g/10min density: 0.916 g/cm3 tensile strength: 7.5 MPa breaking elongation: 170% hardness: 48 VEKA softening point: 78 C
Manufacturer: Thailand TPI Polene Co., Ltd.
LDPE (low density polyethylene # high-pressure polyethylene) /UB-2304AT/01/ Brazil Quattor
Use: other
Characteristic notes: good processing, super high molecular weight, slip
Important beters: melt flow rate: 0.42 g/10min density: 0.923 g/cm3 tensile strength: 15 MPa breaking elongation: 670% VEKA softening point: 97 C
Manufacturer: Quattor Petrochemical Industries Co, Brazil
LDPE (low density polyethylene LDPE # /F FN51000/ Leander Basil)
Use: other
Important beters: melt flow rate: 4.7 g/10min density: 0.923 g/cm3, tensile strength: 12.4 MPa elongation at break: 550% bending modulus: 276 MPa hardness: 53 VEKA softening point: 97 C embrittlement temperature: -76 C
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene # LDPE) /F 7018/ Braskem in Brazil
Use: other
Feature remark: product trademark Braskem, excellent processing perbance and low temperature of sealing. It does not contain additives
Important beters: melt flow rate: 7 g/10min density: 0.918 g/cm3 tensile strength: 10 MPa breaking elongation: 400% VEKA softening point: 88 C embrittlement temperature: -68 C
Manufacturer: Brazil chemical company
LDPE (low density polyethylene # high pressure polyethylene) /2102TN
