注塑技术支持1---LCP.doc

HOME Technical support Molding technology Molding technology for VECTRASafetyPredryingSelection of Molding MachineMolding ConditionsUse of RegrindSelection of Molding MachineMold Designing 1Safety1.1Safety PrecautionsThere is no danger in molding VectraTM so long as the general safety rules of molding operation are observed. However, like all other plastics, VectraTM produces decomposed substances when heated to a very high temperature. If ventilation is inadequate, such decomposed substances are built up to cause hazardous conditions to health. So, suitable ventilation is recommended.Do not raise the polymer temperature over 350 for VectraTM of A, B and C grades and 370 for E grades in order to prevent thermal decomposition, gas emission and pressure build up in the cylinder. These temperatures are much higher than the given molding conditions that it is normally unnecessary to heat the material at such temperatures. When molding is interrupted for a short time, it is possible to leave the material at the molding temperature, but when restarting, such a material must be thoroughly purged. When molding is interrupted for longer than 30 minutes, lower the temperature 50 below the molding temperature.Before feeding pellets or starting the screw, allow sufficient time for cylinder heating, or wait until the temperature reaches the point 10 below the molding temperature of each grade. Operators must wear protective goggles (especially when purging). Wear hand gloves when handling a hot mold. When the machine is stopped, withdraw the injection unit to keep away from the mold to prevent solidification of the material in the nozzle section. 1.2Starting and Stopping the Molding Machine and Exchanging the Molding Material1.2.1Stopping the Molding MachineAfter purging VectraTM, and while retaining the VectraTM molding temperature, the cylinder should be purged with a resin with the same molding temperature and good thermal stability. (Polypropylene, high-density polyethylene or acrylic type purging materials on the market are recommended.) If VectraTM is to be subsequently molded, the cylinder can be purged with VectraTM. (Confirm the molding temperature ranges of the grades.)1.2.2Starting the Molding MachineIn starting up a machine containing another resin that is stable within the VectraTM molding temperature range, the cylinder temperature can be raised to this level and purging can be done with VectraTM. VectraTM, however, has a very low melt viscosity, which makes purging difficult, so that very thorough purging is required. For efficient purging, first purge with glass fiber filled polycarbonate, then with VectraTM.When the resin remaining in the cylinder has the different molding temperature range, the following steps should be carried out: Set the cylinder temperature at the molding temperature of the remaining resin.Purge the cylinder with purging material that has good thermal stability and can be used in the molding temperature ranges of both VectraTM and the remaining resin (for example, polypropylene, high-density polyethylene, or polycarbonate, as the case may be).Change the cylinder temperature at the VectraTM molding level and purge the cylinder again according to the instructions for a resin stable in the VectraTM molding temperature range.In most cases, when VectraTM is the resin remaining in the cylinder, it is possible to raise the cylinder temperature to the VectraTM molding level and to purge with VectraTM. However, as the molding temperature ranges of VectraTM grades differ, confirm the molding temperature ranges of remaining VectraTM grade and purging VectraTM grade prior to purging. If the remaining resin is VectraTM, but is of a different grade and has a different molding temperature range from the replacement VectraTM, purge the cylinder as with any other resin that has a different molding temperature range.1.2.3Changing the Molding MaterialWhen the resin has the same molding temperature range as VectraTM, purge the cylinder at the molding temperature, following the same procedures used in starting and stopping the molding machine.When the resin cannot be placed under the same molding condition, it is recommended to purge the cylinder with a resin that can be used at the molding temperatures of both VectraTM and the replacement, and has good thermal stability (e.g. polypropylene or high-density polyethylene).Then set the cylinder temperature at the replacement resin molding level.When the resin remaining in the cylinder has a higher viscosity than that of VectraTM, it is quite difficult to replace it with VectraTM. Very thorough purging is required.1.2.4OtherIf VectraTM remains in the cylinder for a long time, degradation and contamination may occur. Very thorough purging is required.When it is difficult to purge dark colored materials such as black coloring materials, purging should be done with glass fiber filled polycarbonate, then with polyethylene resin. Repeat purging with GF filled polycarbonate and then polyethylene is recommended. It is more effective if the new purging material is fed into the cylinder after completely purging the previous material. The data shown in this home page are based on our accumulated experience and laboratory data, and not always directly applicable to your products used under different conditions. Therefore, we can not guarantee that the contents of this home page are directly applicable as they are to the specific condition in our customers, and we appreciate your final decision on the use of these data.HOME 技术支持 成形技术 Vectra成形技术 安全与材料切换安全与材料切换预备干燥成型机的选定成型条件再生成型加工特性模具设计1安全1.1安全注意事项只要遵守成型行业的一般安全注意事项，VectraTM的成型就不会有特别的危险。但是，VectraTM也与其它塑料相同，加热到非常高的温度时就会产生分解物。如果换气不充分，有时这些分解物就会蓄积，损害卫生安全。因此，建议您进行切实的换气。为了防止热分解以免产生气体或在料筒内产生压力，请勿将A、B、C、D品种提高到350；EiE品种提高到370；TS品种提高到385以上。这些温度比通常的成型温度高得多，成型时不必提高到上述温度。虽然成型中断时可以在成型温度下短时间放置，但再次开始时，请务必进行充分的置换。另外，放置时间超过半个小时时，务请比成型温度降低50左右。在提供粒料、驱动螺杆之前，务请对料筒给予充分的加热时间，使各品种至少达到比其成型温度低10的温度。务请作业者佩带防护眼镜（特别是置换时）。另外，装卸热模具等部件时，务请佩带防护手套。成型中止期间，务请后退注射组件，以免因与模具接触而造成喷嘴固化。 1.2成型机的停机、开机与材料切换（1）成型机的停机以VectraTM成型时的料筒温度置换出、VectraTM之后，建议在VectraTM的成型温度下以热稳定性好的树脂（例如，聚丙烯、高密度聚乙烯或市场销售的丙烯酸系置换材料）进行置换。继续进行VectraTM成型时，也可只进行VectraTM置换。（2）成型机的开机料筒内的树脂如果在Vectra TM成型温度范围是稳定的，用VectraTM进行置换、则可直接升高到Vectra TM成型温度。但另一方面、VectraTM的粘度非常低，难以将料筒内残留的树脂完全置换干净，故需要进行充分的置换。作为有效的置换方法，首先用含有玻璃纤维的聚碳酸酯树脂进行置换，然后再用VectraTM进行置换，这样可使置换变得容易。当树脂的成型温度范围与Vectra TM不同时，先将料筒温度改为料筒内树脂的成型温度，然后用可在VectraTM的成型温度和料筒内树脂的成型温度下成型、且热稳定性好的树脂（例如，聚丙烯或高密度聚乙烯，有时用聚碳酸酯等树脂）进行置换，最后将温度设定到Vectra TM的成型温度。前面提到了在VectraTM的成型温度范围内热稳定性好的树脂，建议进行与这种树脂场合相同的置换。料筒内的树脂如果在VectraTM一般直接升温至VectraTM的成型温度，也可在VectraTM中进行置换。但是当VectraTM的成型温度范围与各品种不同时，要先确认使用温度范围。在VectraTM使用温度不同时，请在前述的成型温度范围内依不同树脂进行置换。（3）树脂的切换以成型的停止与开始方法为参考，当树脂可直接置换VectraTM时，务请保持料筒温度，直接进行置换。当树脂不可直接置换Vectra TM时，建议您用可在VectraTM的成型温度和切换树脂的成型温度下使用、且热稳定性好的树脂（例如，聚丙烯或高密度聚乙烯等）进行置换，然后将温度设定到成型温度。特别是置换为VectraTM时，如果剩余树脂比VectraTM粘度高，则VectraTM置换困难，需要进行切实的置换。（4）其它Vectra TM长时间滞留在料筒内，就会劣化，有时还会变成其它物质。此时，需进行充分的置换。对于黑色等难以排净的深色材料，建议先用玻璃纤维增强的聚碳酸酯，然后用聚乙烯置换，而且用两者交替反复进行置换。置换时，料筒内前一种置换材料完全排出后，再加入后一种置换材料，这样会更有效果。 HOME Technical support Molding technology Molding technology for VECTRASafetyPredryingSelection of Molding MachineMolding ConditionsUse of RegrindMolding PropertiesMold Designing 2PredryingThough a moisture proof package is adopted, the material is of a polyester type polymer, so it is advised to predry before molding. The drying conditions are: Temperature:140160Time:More than 4hours (max. 24hours)For drying, a shelf type air dryer and hopper dryer are suitable. When using either one, the hot air temperature and velocity must be regulated for uniform drying under the conditions described above. Especially when using a hopper dryer, it is necessary to pay attention not to have a short pass and the pellet temperature must not be the set temperature but the temperature described above. A dehumidifying dryer gives good results. It is also advised to use a hopper dryer during the molding in order to avoid reabsorption of moisture. The data shown in this home page are based on our accumulated experience and laboratory data, and not always directly applicable to your products used under different conditions. Therefore, we can not guarantee that the contents of this home page are directly applicable as they are to the specific condition in our customers, and we appreciate your final decision on the use of these data.HOME 技术支持 成形技术 Vectra成形技术 预备干燥安全及材料切换预备干燥成型机的选定成型条件再生成型加工特性模具设计2预备干燥虽然VectraTM的吸湿量非常低，例如A950在23、50RH条件下的平衡吸湿量约为0.03（300ppm），并且实行了防湿性包装，但它毕竟是聚酯系材料，所以成型前，请务必进行预备干燥。干燥条件如下：温度：140170时间：4小时以上（最长可到24小时）设备宜采用架式通风干燥机或料斗式干燥机，但是无论哪一种均务请调节热风温度和风量，使粒料在前述条件下得到均匀的干燥。特别是采用料斗式干燥机时，注意不要产生风量短路，同时，粒料的实际温度而不是设定温度要达到上述温度。如果使用除湿型干燥机，则可取得更好的效果。另外，为了防止再度吸湿，建议成型中也请使用料斗式干燥机HOME Technical support Molding technology Molding technology for VECTRASafetyPredryingSelection of Molding MachineMolding ConditionsUse of RegrindMolding PropertiesMold Designing 3Selection of Molding MachineVectraTM is available for molding on any conventional screw type molding machine. The cylinder temperature for VectraTM in general can be set at 350 at the highest, therefore, the heater capacity of the conventional molding machine has no problem.For the capacity of the plasticating unit, it is taken into consideration that the shot weight be 50 to 75% of the capacity of the molding machine. This is applicable to all polymers that an unusually great injection capacity for the shot weight of the product will extend the polymer retention time, which is obviously undesirable.For molding of VectraTM, any conventional open nozzle is usable. Generally speaking, the open nozzle has the least pressure loss at the nozzle section and it is not necessary to consider reliability of mechanical actions, therefore it is recommended to use this wherever possible.However, VectraTM is a high flow material, so setting the cylinder temperature too high to obtain higher flow may result in drooling although it depends on the molding conditions.It is also advised to take into consideration that the use of a shut-off nozzle will prevent this phenomenon and afford a surplus in molding conditions. The reverse taper nozzle, such as the one used for nylon, and thin nozzle can also be used successfully.Nozzle heaters must be controlled by an independently built controller. If drooling and melt spinning occur, lower the nozzle temperature.As VectraTM solidifies fast and releases from the mold easily, high cycle molding is possible. In order to take advantages of such characteristics, a machine of high plasticizing capacity is suitable. Screws as described below are suitable in most cases.Screws having a metering zone of a constant groove depth at the tip.Screws having a well constructed check valve.Long feed type screws. The data shown in this home page are based on our accumulated experience and laboratory data, and not always directly applicable to your products used under different conditions. Therefore, we can not guarantee that the contents of this home page are directly applicable as they are to the specific condition in our customers, and we appreciate your final decision on the use of these data.HOME 技术支持 成形技术 Vectra成形技术 成型机的选定安全及材料切换预备干燥成型机的选定成型条件再生成型加工特性模具设计3成型机的选定VectraTM可用普通的螺杆式成型机成型。虽然料筒温度因VectraTM的品种类型而异，但最高达到380即可，所以普通成型机的加热容量没有问题。一次注射重量为成型机能力的5075，请将此数值作为可塑化组件尺寸的大致目标。VectraTM可用普通的开式喷嘴成型。一般而言，开式喷嘴的压力损失最小，且不需要考虑机械动作的可靠性，因此推荐您尽可能采用这种喷嘴。但是，由于Vectra TM的流动性好，所以在有些成型条件，特别是为了得到更高的流动性而设定较高料筒温度的条件下，会发生流涎现象。采用闭式喷嘴，可防止这种现象。请用独立的控制器控制喷嘴加热器。发生流涎或拉丝现象时，有效的对策就是降低喷嘴温度。VectraTM的固化速度快、脱模性能好，故可实现短周期成型。为了发挥这一优点，宜采用塑化能力高的喷嘴。螺杆一般宜采用以下形状。螺杆前端有多个螺纹的、沟槽深度一定的计量区有整备良好的逆流防止阀长进料式HOME Technical support Molding technology Molding technology for VECTRASafetyPredryingSelection of Molding MachineMolding ConditionsUse of RegrindMolding PropertiesMold Designing 4 Molding Conditions4.1 Recommended Molding Conditions(1) Cylinder temperatureTable 4-1 Cylinder Temperature () for Molding Vectra by GradeGradeRecommended Cylinder TemperatureA grade(NH) 290-290-280-270 B grade(NH) 300-300-290-280 C grade(NH) 330-330-320-310 D grade(NH) 320-320-310-300 Ei grade(NH) 350-350-340-330 S grade(NH) 370-370-360-350 T grade(NH) 380-380-370-360 i. The cylinder temperature is set according to the recommended standard. It may be changed within the range from 10 to 20 depending on the molding state. ii. If stringiness or drooling occurs, lower only the nozzle temperature by 10 to 20. iii. If unstable metering occurs, flat or upward slope setting as shown below is recommended for cylinder temperature setting. Example) In case of E130i : (NH) 350-350-350-350 (Flat)(NH) 350-350-360-370 (Upward slope)(2) Other Molding ConditionsTable 4-2 Other Molding ConditionsItemRecommended RangeMolding Temperature80 - 120 Injection Speed100 - 300mm/secDwelling Pressure30 - 50MPaScrew Rotation100 - 200 r.p.mScrew Back Pressure0 - 2MPai. There is no problem when the mold temperature is normally 80. If there is any problem in appearance such as surface roughness and gloss, a higher temperature is recommended. ii. With regard to injection speed, a relatively high speed is recommended. Please note that insufficient mold filling or high filling pressure may occur at low speed. iii. The dwelling pressure is intended not only to hold but also to compensate. Accordingly, it is recommended to apply a certain degree of pressure. iv. With regard to screw rotation, there is no problem in using high-speed rotation for a speedup in cycle time or measurment stability. 4.2Retention Time in CylinderWhen the cylinder temperature is set at 300, the influences of the retention time of polymer in the cylinder upon mechanical properties (tensile strength and elongation at break) and hue are shown in Fig. 4-1 to 4-3. The GF filled A130 shows nearly no degradation within 60 minutes of retention. The change (E) in hue is relatively small for A130.4.3Injection Pressure and Speed, Molding Cycle The optimum injection pressure depends upon the grade of material, product shape, mold design (especially sprue, runner and gate) and molding conditions. For VectraTM, however, each grade has a very low melt viscosity and, therefore, is normally available for molding at a much lower pressure than those applied for other thermoplastic polymers. It is better to start the molding at a low pressure, which is then gradually raised. In most cases, the resin pressure of 15 MPa to 45 MPa is adopted for molding. Furthermore, as VectraTM has fast solidifying speed, fast injection speed may produce better results in most cases.Molding cycle varies according to size, shape, and wall thickness of molded parts, mold construction and molding conditions. As VectraTM has good flowability, the filling time is short and because of low latent heat of melting, it solidifies quickly, therefore, molding at a veryhigh cycle is possible. The typical molding cycle is 10 to 40 sec. The data shown in this home page are based on our accumulated experience and laboratory data, and not always directly applicable to your products used under different conditions. Therefore, we can not guarantee that the contents of this home page are directly applicable as they are to the specific condition in our customers, and we appreciate your final decision on the use of these dataHOME 技术支持 成形技术 Vectra成形技术 成型条件安全及材料切换预备干燥成型机的选定成型条件再生成型加工特性模具设计4. 成型条件4.1 推荐成型条件 （1）机筒温度表4-1 各个等级的成型机筒温度（C）等级推荐机筒温度等级A(NH) 290-290-280-270 C等级B(NH) 300-300-290-280 C等级C(NH) 330-330-320-310 C等级D(NH) 320-320-310-300 C等级Ei(NH) 350-350-340-330 C等级S(NH) 370-370-360-350 C等级T(NH) 380-380-370-360 Ci. 机筒温度设定便是所推荐的标准。也可根据成型状态在10-20C的范围内进行更改。 ii. 发生拉丝、流涎等现象时，请仅将喷嘴温度调低10-20C。 iii. 发生计量不良时，建议采用如下所示的平直或反斜设定。 例) 对于E130i （NH)350-350-350-350 C （平直）（NH)350-350-360-370 C （反斜）（2）其他成型条件 表4-2 其他成型条件 项目推荐范围模具温度80 - 120 C注射速度100 - 300mm/sec保压压力30 - 50MPa螺杆转速100 - 200 r.p.m螺杆背压0 - 2MPai. 模具温度为80C时通常不会出现问题。如果有表面粗细度、光泽等外观方面的问题，则建议采用高温。 ii. 建议采用较高的注射速度。需要注意的是，低速时有时会出现填充不足或填充压力偏高等现象。 iii. 保压压力意味着既要保持又要补充，因此建议施加适当压力。 iv. 螺杆转速有助于提高周期和计量的稳定性，因此可使用高转速。 4.2料筒内滞留 将料筒温度设定为300时，料筒内滞留时间给机械特性（拉伸强度和断裂点伸长率）及色相带来的影响如图4-14-3所示。从中可见，玻璃纤维增强的A130 60分钟之内的滞留几乎不会降低机械特性。色相的变化（E）连A130也比较微小。4.3注射压力、注射速度及成型周期最佳注射压力因材料品种、制品形状、模具设计（特别是直浇口、流道、浇口）及其它成型条件而异。然而，任一品种的VectraTM的熔融粘度都非常低。因此，一般可用比普通热塑性树脂低得多的压力进行成型。最佳的方法就是用低压力开始成型，逐渐提高压力来完成成型。几乎所有的成型品均用15Mp45Mp的树脂压力来进行成型。另外，Vectra TM的固化速度快，所以用快的注射速度才能得到好的成型结果。成型周期因成型品的大小、形状、厚度、模具结构及成型条件等因素而异，然而如前面所述，一般的VectraTM因流动性好而充填时间短，同时，因熔融潜热低而固化速度快。所以，可用非常短的周期进行成型，典型的成型周期为1030秒HOME Technical support Molding technology Molding technology for VECTRASafetyPredryingSelection of Molding MachineMolding ConditionsUse of RegrindMolding PropertiesMold Designing 5Use of Regrind5.1Use of RegrindVectraTM shows outstanding heat stability when molded under recommended molding conditions (See 5-1). In laboratory test, molding of 100% regrind obtained after repeatedly regrinding for five times still retains 85% to 100% of the initial values of strength and modulus. As for the notched Izod impact strength test, the unfilled A950, when reground 100% for five times and molded, still retained initial values, but