纳米Al2O3/玻璃纤维/聚对苯二甲酸丁二醇酯复合材料非等温结晶行为研究--(Ⅰ)结晶与熔融行为

通过熔融共混法制备了纳米A l2O3/玻璃纤维(GF)/聚对苯二甲酸丁二醇酯(PBT)复合材料,利用差示扫描量热仪(DSC)对其非等温结晶过程、熔融行为及结晶度进行了研究。结果发现,纳米A l2O3粒子的异相成核作用有利于复合材料结晶速率的增加,使得非等温结晶温度提高,双熔融峰现象中的低温熔融峰的熔融温度也有所提高。同时,在PBT基体中,纳米A l2O3粒子在一定程度上可以改变玻璃纤维对复合材料结晶行为的影响而使结晶度发生改变。     

Visualization of counter pressure mechanism in gas-assisted injection molding process

Abstract

Gas-assisted injection molding (GAIM) refers to injecting gas into the short shot melt during the filling stage. Compressed gas is used as the medium to push the melt and to provide the packing pressure. In GAIM, the hollow area and penetration length are the main factors that will affect the quality of molded parts. This study has applied a Gas Counter Pressure (GCP) mechanism and has discussed the effect of GCP in the GAIM process with in-mold visualization of this complex molding flow. This study introduces a counter pressure mechanism in a thick paper-clip-shaped cavity design. The flow field under different counter pressure conditions is observed by high-speed photography, the fiber orientations are analyzed with SEM, and the affected penetration length and hollow area are measured relatively. The experimental results show that when the GCP is applied to GAIM, although the hollow area is reduced, the penetration length will be increased, so as to make the quality of molded part more uniform and reduce the shrinkage. And a quantitative measuring method of two-stage penetration time span is proposed to get more in-depth discussion about the interactions between GCP and GAIM.     

变模温与型腔气体反压辅助微孔发泡注塑技术及其产品内外泡孔结构演变

建立了一种变模温和型腔气体反压协同控制的微孔发泡注塑技术,研制了相应的变模温控制系统与型腔气体反压控制系统,构建了变模温与型腔气体反压辅助微孔发泡注塑试验线,并对变模温与型腔气体反压作用下的产品内外泡孔结构演变进行了研究。结果表明,变模温与型腔气体反压辅助工艺单独施加于微孔发泡注塑技术时,对其产品内外泡孔结构均具有双重影响:变模温可以改善产品大部分的表面形貌,但其对填充过程中的熔体发泡影响不大;型腔气体反压可以基本抑制填充过程中的熔体发泡,但却对产品内部泡孔密度有比较明显的降低影响。通过变模温与型腔气体反压的协同控制,可以实现微孔发泡注塑产品表面气泡形貌和内部泡孔结构的良好调控。     

Flow-induced fiber orientation in gas-assisted injection molded part

Polyamide 66 with 33 wt.% glass fiber (DuPont, Zytel 70G33) was molded by gas-assisted injection molding (GAIM). Scanning electron microscope (SEM) micrographs indicated that fibers orientated notably in the core layer and slightly in the region near the mold wall, but aligned disorderly in the region near the gas channel. However, fibers orientated remarkably in the center of the thickness of the GAIM part, which was greatly different from the fiber orientation behavior in the samples molded by the conventional injection molding (CIM) and the water-assisted injection molding (WAIM) as reported in the literatures. Combining with a previous simulation dealing with gas penetration, the mechanisms for fiber orientation in the GAIM part are also discussed.     

Scratch resistance of polycarbonate containing ZnO nanoparticles: effects of sliding direction

Abrasive wear resistance of injection molded polycarbonate (PC) and polycarbonate + zinc oxide nanocomposites containing 0.5 wt% ZnO nanoparticles was determined as a function of the sliding direction with respect to injection flow. First we have performed single scratch testing under progressively increasing the load applied. Then sliding wear testing consisting of 15 successive scratches along the same groove was performed. Neat PC shows anisotropic behavior, with instantaneous penetration depth more than 50% higher in the direction parallel to the melt injection flow than in the transverse direction. Viscoelastic recovery after scratching of neat PC is also higher in the longitudinal than in the transverse direction, hence final residual depth values are similar in both directions. The addition of ZnO nanoparticles reduces the instantaneous penetration depth in the longitudinal direction but lowers viscoelastic recovery so that the residual depth is large. In the transverse direction, the scratch resistance is similar for neat PC and the nanocomposite. Dynamic mechanical analysis, SEM/FIB results and wear mechanisms from SEM observations of wear scars are discussed. Below the glass transition region the nanocomposite has distinctly higher storage modulus E' than PC--a clear reinforcement effect. However, the addition of ZnO nanoparticles to the polymer increases the material brittleness at room temperature by a factor of 2.72.     

短玻纤增强聚丙烯注射压力对微观结构和力学性能影响

报道了短玻纤增强聚丙烯复合材料中玻纤及注射压力对材料微观结构和力学性能的影响规律。实验结果表明: 随着玻纤含量提高, 复合材料的拉伸强度提高, 而断裂伸长率、冲击强度和熔体流动速率则下降。注射压力提高, 拉伸试样芯层中玻纤的平均取向角下降, 取向度提高, 因而拉伸强度增大, 冲击强度下降。皮层结构中玻纤沿熔体流动方向高度取向。聚丙烯球晶尺寸随玻纤含量增加而变小, 规整度也变差, 至40% 时, 聚丙烯已难以形成规整的球晶结构。     

工艺参数对聚甲醛微注塑制品力学性能的影响机理EI北大核心CSCD

基于单因素实验,研究工艺参数对不同厚度聚甲醛(POM)微注塑制品屈服应力、弹性模量、断裂强度和断裂伸长率等力学性能指标的影响,并基于制品形态结构分析工艺参数对制品力学性能的影响机理。实验结果表明,随着注射速度的增大,1.0mm厚微制品的皮层厚度减小,过渡层厚度增加,结晶度增大,综合效应使得屈服应力、断裂强度和弹性模量增大,断裂伸长率减小;0.2mm厚微制品的皮层厚度占主导地位,其力学性能是由皮层的力学性能决定,皮层厚度先增大后减小使得屈服应力、断裂强度和弹性模量先增大后减小,断裂伸长率先减小后增大。随着熔体温度的升高,1.0mm厚微制品的分子链取向度减小,皮层厚度减小,收缩量增大,使得屈服应力、断裂强度和弹性模量减小,断裂伸长率增大;而0.2mm厚微制品的皮层减小,但过渡层增加,结晶度增大,且补料更充分,综合作用使得屈服应力、断裂强度和弹性模量增大,断裂伸长率减小。随着模具温度的升高,1.0mm厚微制品的皮层比例减小,结晶度增大,结晶度影响占主导,使得屈服应力、断裂强度和弹性模量逐渐增大,断裂伸长率减小;而0.2mm厚微制品的皮层厚度占主导,皮层厚度明显减小使得屈服应力、断裂强度和弹性模量减小,断裂伸长率增大。     

Plastic Injection Molding of High-Aspect Ratio Micro-Rods

Technological advancements have led to an increase in demand for fabrication of small and cheap miniature components or parts, especially in the medical and electronic fields. In this research work, micro-rods of varying lengths and diameters were molded using a specially designed tabletop injection molding machine. The main purpose was to investigate whether complete filling of the microcavities was possible and whether small cavity openings will restrict melt flow into the cavities.

Process parameters, such as injection pressure, mold temperature and melt temperature were varied. The micro-rods obtained were analyzed with Scanning Electron Micrographs (SEM). The results showed that injection pressure was the most important parameter for microinjection molding. The use of a vacuum system also yielded better results.     

Plastic Injection Molding of High-Aspect Ratio Micro-Rods

Technological advancements have led to an increase in demand for fabrication of small and cheap miniature components or parts, especially in the medical and electronic fields. In this research work, micro-rods of varying lengths and diameters were molded using a specially designed tabletop injection molding machine. The main purpose was to investigate whether complete filling of the microcavities was possible and whether small cavity openings will restrict melt flow into the cavities.

Process parameters, such as injection pressure, mold temperature and melt temperature were varied. The micro-rods obtained were analyzed with Scanning Electron Micrographs (SEM). The results showed that injection pressure was the most important parameter for microinjection molding. The use of a vacuum system also yielded better results.     

Morphological comparison of isotactic polypropylene molded by water-assisted and conventional injection molding

It is well known that water-assisted injection molding (WAIM) process can be fulfilled based on the melt filling stage of conventional injection molding (CIM) process. However, due to the different physical fields involved during WAIM and CIM processes, WAIM part should exhibit unique morphological features compared with the CIM one. In this study, isotactic polypropylene (iPP) parts were prepared by WAIM and CIM, respectively, and their comparative study on morphology were therefore carried out by means of polarized optical microscopy (POM) and two-dimensional (2D) wide-angle X-ray diffraction (WAXD). POM observations illustrated that the WAIM part exhibits a “skin–core–water channel” structure, while the CIM part shows a typical “skin–core” structure. 2D-WAXD results showed obvious arclike reflections in each position along thickness direction of the WAIM part, indicating a pronounced molecular orientation. Furthermore, a parent–daughter model (or branched shish-kebab structure) appears at 0 and 100 μm for both the parts, and the fraction of daughter lamellae for WAIM part is lower than that of CIM part. As for the 1D-WAXD curves, it is noticed that there is a very tiny (300) reflection of β-form in the CIM part, while it is invisible in all positions of the WAIM part. In addition, the crystallinity and crystalline size L of CIM part are found to be higher than that of WAIM part. Those results demonstrate that water penetration and rapid cooling rate have a significant effect on the morphological features of WAIM part.     

气辅成型工艺参数交互作用对气指缺陷的影响

采用正交实验方法和数值模拟方法对气辅成型制品“气指”缺陷进行了研究。研究了熔体温度与气体注射延迟时间、熔体温度与气体注射压力及气体注射延迟时间与气体注射压力三对工艺参数的交互作用对气辅成型制品“气指”缺陷的影响关系。结果表明:熔体温度与气体注射延迟时间的交互作用对“气指”影响较为严重,其它两对工艺参数对“气指”的影响较小。较长的延迟时间可以减轻气指的程度,但延时过长会造成气体无法穿透或穿透不足等问题,因此选择合适的熔体温度和气体延时组合尤为重要。     

MAH对干法酯化淀粉/PLA复合材料性能的影响

以玉米淀粉和马来酸酐(MAH)为原料,通过干法合成MAH酯化淀粉,通过熔融挤出法制备酯化淀粉/聚乳酸(PLA)复合材料.研究了MAH用量对复合材料结晶度和相容性的影响,同时考察了相容性和结晶度的变化对复合材料热性能、熔融流动性能、力学性能、耐水性能和流变性能的影响.FTIR结果证明通过干法成功合成了MAH酯化淀粉.酯化淀粉的取代度随MAH用量增多逐渐增大,反应效率高达90%.XRD和DSC结果表明:随着MAH用量增多,酯化淀粉/PLA复合材料的结晶度逐渐降低,淀粉和PLA的相容性逐渐提高.结晶度的降低和相容性的提高使复合材料的玻璃化转变温度逐渐降低,熔融流动性提高,耐水性提高.在力学性能和流变性能受相容性和结晶度的共同影响下,酯化淀粉中MAH用量从0增加到1.0wt%时,复合材料拉伸强度、弯曲强度、储能模量和复数黏度都逐渐增大,MAH用量超过1.0wt%后,性能逐渐降低.     

Prediction of fiber orientation structure for injection molded short fiber composites

Structure of fiber orientation in injection molded short fiber composites is predicted by the numerical analysis. To analyze the packing stage as well as the filling stage, a compressible generalized Hele-Shaw model is adopted. A numerical scheme free from coordinate transformation is developed for three-dimensional shell-like geometry. Flow-induced fiber orientation can be predicted by solving evolution equations for the orientation tensor with a suitable closure approximation. Fibers are mainly oriented toward the flow direction near the top cavity wall due to high shear rates, while they are randomly oriented near the centerline of cavity where low shear rates prevail. Thus, the molded parts show the skin-core structure of orientation. Structure of fiber orientation continues to change during the packing stage due to additional velocity gradients – which are likely to align fibers more towards the flow direction. Electronic Publication     

微发泡注塑成型PC制件的表面缺陷及形态分析

微发泡注塑成型制品常有漩涡状流痕和银纹两类表面缺陷。漩涡状流痕与均相溶液的流动形态关系密切,多在浇口附近;而银纹多在远离浇口处。文中利用扫描电子显微镜(SEM)对微发泡注塑成型聚碳酸酯(PC)制品的漩涡状流痕、银纹及泡孔形态进行观察,发现微孔形态和表面缺陷之间存在如下关系:漩涡状流痕对应的气泡剪切变形较小,而银纹相关的气泡剪切变形较大;根据气泡SEM的形态,银纹可细分为银带纹、银丝纹。剪切变形大、不破裂气泡表面形成银带纹,破裂则形成银丝纹。     

PBT/BA-MMA-AA三元共聚物共混物的结晶行为和结晶动力学

考察了聚对苯二甲酸丁二醇酯(PBT)／“壳-棱”型丙烯酸丁酯-甲基丙烯酸甲酯-丙烯酸三元共聚物(BA-MMA-AA)共混物的熔融和结晶行为。研究显示，BA-MMA-AA含量较低时，BA-MMA-AA中羧基对PBT分子链的干扰导致了共混物中PBT的熔点和结晶度下降；随BA-MMA一从含量的提高，其异相成棱作用导致PBT的成棱速率和结晶速率提高，从而提高了共混物中PBT的熔点和结晶度．采用Avrami方程分析了试共混物的等温结晶动力学参数，发现共混物的结晶速率常数K显著变小，最大结晶速率时间tmax和半结晶时间t1/2均变短，表明加入BA-MMA-AA使PBT的成棱速率和结晶速率得到提高。     

Influence of process parameters on the thermostamping of a [0/90]12 carbon/polyether ether ketone laminate

In this study, an experimental evaluation of the thermostamping process was made for a 3D part molded with a [0/90]₁₂ laminate composed of unidirectional carbon fiber/polyether ether ketone (CF/PEEK) plies. Using the Taguchi method, the effect of four operational parameters on the part thickness, interlaminar shear strength and the degree of crystallinity were investigated. These parameters are the preheating temperature in the oven, the mold temperature, the oven to mold transfer time and the stamping pressure. The results show that the mold temperature and stamping pressure have a significant effect on part consolidation. In addition, the interlaminar shear strength, measured at the base of the molded part, was higher for thinner parts compared to those having a greater thickness. These results were also confirmed by Differential Scanning Calorimetry analysis, which show that the degree of crystallinity is higher for thinner parts.     

水辅助注塑制件壁厚分析

根据水辅助注塑技术应用短射法成型中空圆管制品的聚合物熔体流动的基本特征,把水辅助注塑充模阶段聚合物熔体流动行为简化为等温条件下幂率流体的稳态流动,应用流体力学理论,对圆管水辅助注塑中影响制件壁厚的因素进行分析。结果表明,制件的壁厚主要由水与熔体界面处的压力梯度和熔体前端压力梯度的比值确定,同时制件壁厚也受熔体的流变性能影响。     

FM全新卡车顶篷把手气辅成型技术

研究了气辅成型过程中气体穿透聚合物熔体的扩散特征和气.熔界面形态.以FM全新卡车顶篷把手为典型件进行气辅成型实验研究,研究了气体保压压力、熔体温度、气体保压时间、气体注射延迟时间四个重要工艺参数对气熔界面的影响规律.结果表明,在气体注射点近区,气体对聚合物熔体冲击程度较大.呈现出复杂流动形态及扩散特征;低的保压压力和熔体温度,较短的保压时间和较长的气体注射延迟时间可获得较好的气熔界面.     

Morphology-tensile behavior relationship in injection molded poly(ethylene terephthalate)/polyethylene and polycarbonate/polyethylene blends (I) Part I Skin-core Structure

The skin-core structure of injection molded poly(ethylene terephthalate) (PET)/polyethylene (PE) and polycarbonate (PC)/PE blends was investigated. The results indicate that both shape and size of the PET and PC phases depended not only on the nature properties of PET/PE and PC/PE blends, but also on the injection molding parameters such as injection speed and the positions in the molded bars. The morphology in the section perpendicular to the melt flow direction included four layers, surface, sub-skin, intermediate layers as well as core zone. The surface layer was ignored in the present study. The sub-skin layer contained more or less fibrous structure and its thickness gradually decreased along the molded bar from the gate toward the non-gate end. At the same injection speed, the concentration of the injection-induced fibers in PC/PE blend was much higher than that in PET/PE blend. In the core region, the dispersed phase was mainly composed of spherical particles whose diameter increased along the melt flow pathway. Between these two layers, there was an intermediate layer where the dispersed particles mainly assumed the form of fibers, ellipsoids or spheres. Generally, no matter whether the dispersed particles were elongated or not during injection molding, the PET particles were larger than PC ones.     

GMT流动成型纤维取向研究

GMT材料流动成型后玻纤在平面内发生取向，导致模压件呈各向异性，本研究从成型后制品上取样烧尽树脂，由扫描仪获取纤维数值图像，用Photoshop软件将图像反相，增强，再利用MATLAB软件确定纤维取向分布，研究表明，GMT单向流动成型时纤维沿流动方向取向，随流动距离增大，取向趋向更为明显，而均匀双向拉伸流动纤维取向程度较小，与片材相比，材料力学性能沿取向方向增大，但垂直取向方向材料性能变差。