顺序共注成型的实验研究

研究了顺序共注成型中几个主要工艺参数——流变性能、壳层预填充量、延迟时间对成型的影响，分析造成熔体前沿突破的原因，提出工艺设计的指导原则。     

夹芯注最小壳层预填充量的预测及其误差分析

顺序共注射模塑中的芯层熔体前沿冲破是造成共注制品报废的重要原因之一,合理控制壳层预填充量可预防此现象发生。从运动学角度探讨芯层熔体冲破的影响因素,建立预测最小壳层预填充量的方程,并在Moldflow平台上进行验证。发现芯壳层熔体黏度比R较小时,该方程的预测值相对数值模拟结果偏大;反之亦然。     

板厚对夹芯注射成型芯层物料填充能力的影响

基于Cross-WLF黏度控制方程,构建了3种典型夹芯注射成型芯/壳层物料组合,并研究了不同物料组合时板厚对芯层物料填充能力的影响。研究表明,调整板厚将使芯、壳层熔体流动状态和黏度发生变化,但上述变化因物料组合不同而呈现显著的差异性:当芯层熔体流动指数相对壳层熔体更大时,随板厚增大,芯/壳层熔体黏度比(R)减小,芯层物料填充能力降低;当芯层熔体流动指数相对壳层熔体更小时,随板厚增大,R增大,芯层物料填充能力升高;当芯、壳层熔体流动指数相当时,上述现象均不明显。     

共注塑中最小壳层预填充量预测方程的建立

顺序共注射模塑中的芯层熔体前沿冲破是造成共注制品报废的重要原因之一,合理控制壳层预填充量可预防此现象发生.从运动学角度探讨芯层熔体冲破的影响因素,建立预测最小壳层预填充量的方程,并在Moldflow平台上进行验证.     

熔体粘度对共注成型影响机理的研究

本文在共注成型多相分层流动充模成型机理的基础上，揭示了芯壳层熔体粘度对共注成型的分层界面形貌和芯层熔体前沿突破的影响，并模拟了芯壳层熔体粘度比对共注成型的影响，建立了芯壳层熔体粘度比与分层界面和前沿移动界面形貌的关系。本文的模拟研究结果与一些文献的实验结果相吻合。     

顺序共注成型芯层熔体前沿突破的数值模拟研究

基于Hele-Shaw流动模型，运用CAE技术，模拟了聚合物流变性能及重要工艺参数对顺序共注成型芯层熔体前沿突破过程的影响，并用流变学理论揭示其影响机理。     

工艺参数对顺序共注成型的影响

基于Hele-Shaw模型，采用CAE技术，模拟了顺序共注成型中几个重要工艺参数——温度、壳层预填充量、注射速度等对其成型过程的影响。并用流变学理论进行分析，揭示了各工艺参数对顺序共注成型的影响机理。     

夹芯注壳层熔体最小预注量的计算与验证

在夹芯注射成型中为了更多地填充价格较低的芯层材料,需在不发生芯层熔体前沿冲破的前提下,找到壳层熔体最小预注量。从运动学角度探讨芯层熔体前沿冲破过程,建立了快速计算壳层熔体最小预注量的数学方程;利用Co-Injection模块,针对具体塑料件进行试验验证,并利用二次迭代法可大幅减少计算值与实际值的偏差。     

共注成型芯层熔体前沿突破研究

在塑料共注成型中，芯层熔体前沿突破是导致废品的主要原因，其成型机理至今尚未弄清。为此就聚合物流变性能参数和工艺参数对芯层熔体前沿突破的影响进行了实验研究和数值模拟，建立了聚合物流变性能参数、工艺参数与芯层熔体前沿突破的规律性关系，并结合流变学理论揭示了其影响机理。     

聚合物流变性能对共注射成型的影响

在共注射成型多相分层流动充模成型机理的基础上，揭示了芯壳层熔体对共注射成型的分层界面形貌和芯层熔体前沿突破的影响，并模拟了芯壳层熔体粘度比对共注射成型的影响，建立了芯壳层熔体粘度与分层界面和前沿移动界面菜貌的关系。本文的模拟研究结果与一些文献的实验结果相吻合。     

Modeling and simulation of material distribution in the sequential co-injection molding process

In co-injection molding, the properties and distribution of polymers will affect the application of products. The focus of this work is to investigate the effect of molding parameters on the skin/core material distribution based on three-dimensional (3-D) flow and heat transfer model for the sequential co-injection molding process, and the flow behaviors and material distributions of skin and core melts inside a slightly complex cavity (dog-bone shaped cavity) are predicted numerically. The governing equations of fluids in mold are solved by finite volume method and Semi-Implicit Method for Pressure Linked Equations (SIMPLE) algorithm on collocated meshes, and the domain extension technique is employed in numerical method for this cavity to assure that the numerical algorithm is implemented successfully. The level set transport equation which is used to trace the free surfaces in co-injection molding is discretized and solved by the 5th-order Weighted Essentially Non-Oscillatory (WENO) scheme in space and 3rd-order Total Variation Diminishing Runger-Kutta (TVD-R-K) scheme in time respectively. Numerical simulations are conducted under various volume fraction of core melt, skin and core melt temperatures, skin and core melt flow rates. The predicted results of material distribution in length, width and thickness directions are in close agreement with the experimental results, which indicate that volume fraction of core melt, core melt temperature and core melt flow rate are principal factors that have a significant influence on material distribution. Numerical results demonstrate the effectiveness of the 3-D model and the corresponding numerical methods in this work, which can be used to predict the melt flow behaviors and material distribution in the process of sequential co-injection molding.     

气辅对L形异型材包覆共挤胀大影响的数值模拟

采用PTT本构方程,运用有限元方法对低密度聚乙烯/高密度聚乙烯（PE-LD/PE-HD）熔体的包覆共挤过程进行了三维等温黏弹数值模拟。对比分析了2种熔体在传统和气辅包覆共挤过程中挤出胀大及在不同条件下气辅包覆共挤熔体的挤出胀大。结果表明,气辅包覆共挤过程中,当芯层与壳层熔体的单位体积流率相等时,整体、芯层及壳层胀大率不随松弛时间的增加而变化,一直保持为零,而当芯层与壳层熔体的单位体积流率不等时,单位体积流率较大的熔体表现为挤出胀大,较小的表现为挤出收缩。     

Composite droplets with core/shell morphologies prepared from HDPE/PS/PMMA ternary blends by twin‐screw extrusion

Ternary blends of PS and PMMA in a PE matrix were prepared by twin‐screw extrusion to investigate the core/shell encapsulation phenomenon in the composite droplet. The PS was found to encapsulate the PMMA to form composite droplets within the PE matrix as expected from the spreading coefficient theory. The effects of dispersed phase concentration, viscosity ratio, feeding sequence and twin‐screw operating conditions were investigated. The blend morphology was observed by scanning electron microscopy after selective extraction of either PS or PMMA, and average core and composite droplet diameters were determined by image analysis. Although it is known that the structure of composite droplet blends can be substantially altered through control of the volume fraction of the components in the dispersed phase, this study demonstrates that blends with a 1:1 composite droplet volume fraction are relatively stable to large variations in the minor phase viscosities and processing conditions. Twin‐screw extrusion thus provides a highly robust technique for the melt processing of blends possessing composite droplet morphologies. Polym. Eng. Sci. 44:749–759, 2004. © 2004 Society of Plastics Engineers.     

中空微珠的分散性对聚丙烯/中空微珠复合体系流动行为的影响

通过电子显微镜观测聚丙烯/中空微珠(HGB)复合体系的微观形貌图;分析了HGB在聚合物基体中的分散状况。结果显示:随着填充物的体积分数增大及粒径的减小,复合体系中HGB的数量明显增加,出现了一定程度的团聚现象。PP/HGB流动曲线呈很好的线性,线性相关系数均大于0.99,说明熔体的黏度变化平稳,也表明HGB的分散均匀,团聚现象不严重。随着HGB的体积分数增大或粒径降低,HGB团聚现象有一定增加,使得"摩擦损耗"作用及"剪切损耗"作用增大,体系黏度也随之增大。随着HGB粒径的增大,体系流动能力增强,弱化了HGB的隔热效应,提高了熔体的温敏性,即:黏流活化能增大。     

微孔发泡注射成型与传统注射成型的对比分析

通过微孔发泡注射成型和传统注射成型定量对比分析,系统分析了两种成型在翘曲变形、体积收缩、残余应力、温度场分布等方面的本质区别,并基于流变学理论,揭示了微孔发泡注射成型的成型机理。结果表明,微孔发泡注射成型的翘曲变形、残余应力、成型压力和成型时间明显小于传统注射成型的,且微孔发泡注射成型的翘曲变形和残余应力随着开始发泡的熔体预填充体积分数减小而减小,微孔发泡注射成型的熔体温度在浇口附近低于传统注射成型熔体温度,而在远离浇口处则要高。     

硅藻土含量及粒径对聚丙烯复合材料流动特性的影响

应用熔体流动速率仪测量了3种硅藻土填充聚丙烯复合材料的熔体体积流动速率(MVR),以考察填料含量和粒径对复合体系流动特性的影响。结果表明:复合材料的MVR随着温度的提高和载荷的增加而呈非线性函数形式增大;而随着填料体积分数和粒径的增加而下降。     

夹芯注塑充模过程的计算机可视化模拟分析--制品形状和浇口位置对芯层熔体前缘冲破的影响

采用Moldtlow公司MPI软件中的Co-injection分析模块，对夹芯注塑成型过程进行动态模拟分析，揭示矩形制品的形状及浇口位置对夹芯注塑充模过程中芯层熔体前缘冲破的影响规律。实验发现：矩形制品厚度的增加和宽度的减小可以提高前缘冲破时刻芯层熔体的体积分数(N值)；制品长度对前缘冲破的影响存在一个最佳值，在小宽度情况下，长宽比增加N值也随之增加；选择高的充模流速和进料方向平行于熔体流动方向的浇口位置都会有利于芯层熔体的充模过程。     

明胶对明胶/壳聚糖共混膜性能影响的研究

采用溶液共混法制备出了一系列明胶／壳聚糖共混膜,并考察了制备条件对膜性能的影响。结果表明：明胶的溶解方式对吸水率和溶胀比影响很小;随明胶分子量增加,共混膜的吸水率和孔洞体积增大;而随共混体系中明胶质量分数的增加,吸水率和孔洞体积亦增加,但溶胀比下降。