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PC注塑工艺
PC性能优异，透明度较高，冲击韧性好，耐蠕变，使用温度范围宽。
PC的工艺特性：熔融粘度对剪切率的敏感性小，而对温度的敏感性大，无明显熔点，熔融体粘度较高，高温下树脂易水解，制品易开裂。
针对这些特性，我们特别要注意区别对待：
要增加熔体的流动性，不是用增大注射压力而应采用提高注射温度的办法来达到;
要求模具的流道、浇口短而粗，以减少流体的压力损失，同时要较高的注射压力;
树脂在成型加工之前需进行充分的干燥处理，使其含水量控制在0.02%以下;
此外，在加工过程中对树脂还应采取保温措施，以防重新吸湿;
不仅需要合理的制品设计，还应正确掌握成型工艺，如提高模具温度，对制品进行后处理等可以减少或消除内应力。视产品的不同状况及时调正工艺参数。
下面我们聊聊成型工艺：
1.原料干燥
PC类塑胶，即使遇到非常低之水份也会产生水解而断键、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。
PC对水极其敏感，所以注塑前必须充分干燥，使其含水量降低到0.02%以下，PC一般干燥条件：100~120℃，时间至少4小时以上;
2.注射温度
注射温度必须综合制品的形状、尺寸，模具结构。制品性能、要求等各方面的情况加以考虑后才能作出。
一般在成型中选用温度在270~320℃之间，过高的料温如超过340℃时，PC将会出现分解，制品颜色变深，表面出现银丝、暗条、黑点、气泡等缺陷，同时物理机械性能也显著下降。PC对温度也很敏感，熔体粘度随温度升高而明显下降，料筒温度250~320℃.(最好不要超过350℃)，适当提高温度料筒温度对PC塑化有好处。必要时内应力退火，烘炉温度125~135℃，时间2小时，自然冷却到常温。
3.注射压力
对PC制品的物理机械性能，内应力、成型收缩率等有一定的影响对制品的外观及脱模性有较大的影响，过低或过高的注射压力都会使制品出现某些缺陷，一般注射压力控制在80-120MPa之间，对薄壁，长流程，形状复杂，浇口较小的制品，为克服熔体流动的阻力，以便及时充满模腔，才选用较高的注射压力(120-145MPa)。从而获得完整而表面光滑的制品。
流动性差，需用高压注射，但需顾及胶件残留大的内应力(可能导致开裂)，注射速度：壁厚取中速，壁薄取高速。
4.保压压力及保压时间
保压压力的大小及保压时间的长短对PC制品的内应力有较大的影响，保压压力过小，补缩作用小易出现真空泡或表面出现缩凹，保压压力过大，浇口周围易产生较大的内应力，在实际加工中，常以高料温，低保压的办法来解决。保压时间的选择应视制品的厚薄，浇口大小，模温等情况而定，一般小而薄制品不需很长的保压时间，相反，大而厚的制品保压时间应较长。保压时间的长短可通过浇口封口时间的试验予以确定。
5.注射速度
对PC制品的性能无十分明显的影响，除了薄壁，小浇口，深孔，长流程制品外，一般采用中速或慢速加工，最好是多级注射，一般采用慢-快-慢的多级注射方式。
6.模具温度
模温控制：85~120℃，一般控制在80-100℃就可以，对形状复杂，较薄，要求较高的制品，也可提高到100-120℃，但不能超过模具热变形温度。模温高以减少模温及PC料温的差异，可以降低制件的内应力。
7.螺杆转速与背压
由于PC熔体粘度较大，从有利塑化，有利排气，有利塑机的维护保养，防止螺杆负荷过大，对螺杆的转速要求不可太高，一般控制在30-60r/min为宜，而背压控制在注射压力的10-15%之间为宜。
8.助剂的使用
PC在注塑过程中要严格控制脱模剂的使用，同时再生料的使用不能超过三次，使用量应为20%左右。
9.PC注塑，对模具要求较高：
1)设计尽可能粗而短，弯曲位少的流道，用圆形截面分流道及流道研磨抛光等为使降低熔料的流动阻力.
2)注射浇口可采用任何形式的浇口，但入水位直径不小于1.5mm.
10.对生产PC制品的塑机要求
要求制品的最大注射量(包括流道、浇口等)应不大于公称注射量的70-80%;
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GUANGDA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。
11.PC注塑后处理：用PE料过机
部分型号部分物性表
LDPE (low density polyethylene LDPE # /NA 952-083x01/ Leander Basil)
Use: other
Note: the characteristics of food contact acceptable, good generalization, good processability, good toughness, homopolymer,
Important beters: melt flow rate: 2 g/10min tensile strength: 15.9 MPa breaking elongation: 650% VEKA softening point: 85 C
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene LDPE # /NA 980/ Leander Basil)
Use: other
Characteristic notes: acceptable in contact with food, good impact resistance, good melt strength, high definition
Important beters: melt flow rate: 0.25 g/10min density: 0.92 g/cm3, tensile strength: 19 MPa, elongation at break: 430% hardness: 45 VEKA softening point: 93 C embrittlement temperature: -75 C.
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene LDPE # /LF-0219 Canada NOVA Series/)
Use: other
Feature notes: acceptable food contact, good heat seal, good processing, good toughness, high rotation difference, low density, reusable material
Important beters: melt flow rate: 2.3 g/10min density: 0.918 g/cm3 tensile strength: 11 MPa breaking elongation: 250%
Manufacturer: NOVA chemical, Canada
LDPE (low density polyethylene LDPE # /L2560S/ Leander Basil)
Use: other
Feature notes: acceptable food contact, good heat seal, good strength, high definition, low flow rate
Important beters: melt flow rate: 0.6 g/10min density: 0.925 g/cm3 tensile strength: 11 MPa breaking elongation: 120%
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene # LDPE) /QLT02/ Qilu Petrochemical
Use: other
Feature notes: characteristics: non-toxic, tasbess, and luster free cylindrical particles. It has good elongation and electrical insulation. The crystallinity is 55-65%, and the melting point is 108-126 degrees.
Important beters: melt flow rate: 0.5 g/10min density: 0.921 g/cm3 tensile strength: 9 MPa breaking elongation: 450%
Manufacturer: Sinopec Qilu Limited by Share Ltd
LDPE (low density polyethylene LDPE # /PE3420F/ Leander Basil)
Use: medical grade
Characteristic notes: high rigidity, epoxy ethane disinfection, good chemical resistance and high heat resistance
Important beters: melt flow rate: 0.9 g/10min density: 0.933 g/cm3 tensile strength: 15 MPa breaking elongation: 11% VEKA softening point: 111 C
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene # LDPE) /2202-PN/ Repsol of Spain
Use: other
Feature notes: antioxidants, acceptable in contact with food, good processing perbance, good weatherability, high molecular weight, high viscosity
Important beters: melt flow rate: 0.25 g/10min density: 0.932 g/cm3 tensile strength: 11 MPa breaking elongation: 500% VEKA softening point: 92 C
Manufacturer: YPF of Spain
LDPE (low density polyethylene # high-pressure polyethylene) /30/ Croatia DIOKI
Use: film grade
Characteristic notes: good rigidity, optical properties, high gloss, good machinability, good peeling, compliance of food contact, and no additives
Important beters: melt flow rate: 0.9 g/10min density: 0.923 g/cm3 tensile strength: 18 MPa breaking elongation: 220% hardness: 45 VEKA softening point: 94 C
Manufacturer: Croatia DIOKI company
LDPE (low density polyethylene LDPE # /NA373242/ Leander Basil)
Use: film grade
Characteristic notes: low friction coefficient, good rigidity, smoothness, homopolymer, good impact resistance, high definition, and compliance of food contact
Important beters: melt flow rate: 3 g/10min density: 0.924 g/cm3 tensile strength: 18.6 MPa breaking elongation: 200%
Manufacturer: Liane Basel Industrial Corporation
LDPE (low density polyethylene LDPE /LB7000/LG chemical #)
Use: packaging container plastic packaging
Characteristic notes: mainly used for extrusion, coating equipment, and excellent bonding strength and neckin for paper on cardboard and other substrates
Important beters: melt flow rate: 7 g/10min density: 0.917 g/cm3, tensile strength: 11.8 MPa, elongation at break: 500% bending modulus: 176.5 MPa hardness: 43 VEKA softening point: 83 degrees.
Manufacturer: Korea LG chemical company
LDPE (low density polyethylene LDPE # /LD136.MN/ Mobil Exxon)
Use: film grade
Feature notes: good transparency. Additives: anti adhesion agent, smoothing agent, 1500ppm; 750ppm; heat stabilizer, a. Product trademark: ExxonMobil
Important beters: melt flow rate: 2 g/10min density: 0.921 g/cm3 tensile strength: 19.2 MPa breaking elongation: 540%
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /LD136.NI/ Mobil Exxon)
Use: film grade
Feature notes: good transparency. Additives: anti adhesion agent, smoothing agent, 450ppm; 500ppm; heat stabilizer, a. Product trademark: ExxonMobil
Important beters: melt flow rate: 2 g/10min density: 0.921 g/cm3 tensile strength: 19.2 MPa breaking elongation: 540%
Manufacturer: Exxon Mobil Corp
LDPE (low density polyethylene LDPE # /LD156BW/ Mobil Exxon)
Use: film grade
Characteristic notes: good mechanical properties, hardness and optical properties. Additives: anti adhesion agent, smoothing agent, no; no; heat stabilizer, a. Product trademark: ExxonMobil
Important beters: melt flow rate: 0.75 g/10min density: 0.9255 g/cm3 tensile strength: 25 MPa breaking elongation: 560%
Manufacturer: Exxon Mobil Corp
LDPE (low density)
