微孔发泡注射成型充模流动及工艺研究
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摘要
本文针对一种全新的聚合物注射成型工艺—微孔发泡注射成型技术进行了研究，这种技术有着传统工艺不具备的优点，它能够大幅度减少制品重量、提高尺寸稳定性、减小产品变形等，此外它对注塑机所需的注射压力和锁模力吨位的要求也更小，甚至不需要保压阶段。目前国内外对微孔发泡注射成型机理研究的可见报道还极为少见，因而对该技术的成型机理进行研究显得很有必要。本文主要对以下工作进行了研究：
1．以注射矩形薄板制品的聚合物熔体充模流动过程和泡孔长大为研究对象，把微观两相流看成宏观单相流，采用泡孔单元模型并根据流体力学基本方程建立了泡孔长大的数学模型，使用有限元软件MPI对微孔发泡注射成型工艺进行了数值模拟；
2．分析了微孔发泡注射成型工艺与传统工艺的差异，主要包括：注射时间、速度场、温度场、熔体压力场；研究了微孔发泡注射成型工艺泡孔内压力、泡孔半径及分布的变化趋势及规律；比较了N_2和CO_2作为发泡剂对熔体流动性和最终泡孔大小及分布的影响。分析了研究结果产生的理论本质；
3．采用单因素试验法研究了微孔发泡注射成型工艺制品的最终泡孔尺寸与影响因素之间的关系，得到了主要影响因素对最终泡孔尺寸的影响规律，从机理层面分析了其产生的原因。
An innovative technology, microcelluar foam injection molding process which have some virtue contrasting with conventional process such as reducing production weight greatly, improving dimension stability, reducing production distortion etc, in addition, do not need higher injection pressure for requirement of injection machine and can lower clamp tonnage, especially eliminate the pack and hold phase is studied. So far, there is few reported work for the mechanism of microcellular foam injection molding process, so it seems extremely important to do some research about it. This paper mainly includes these aspects as below:
1. In this paper, the polymer melt flow in rectangle sheet mould and bubble growth have been studied by means of having microcosmic two phase liquid as macroscopical single phase liquid and appling the bubble cell model and mathematical model based on the basic equations of hydrodynamics. Finite Element software MPI is used for the numerical simulation of microcellular foam injection molding process.
2. Have analysed the difference between microcellular foam injection molding process and conventional process, mainly involves: injection time, velocity field, temperature field, pressure field of the melt; have studied the variety trend and rule of the pressure in bubble, the bubble radius and its distribution for microcellular foam injection molding process; N2 has been compared with CO_2 as vesicant for melt fluidness, bubble radius and its distribution. All research results have been analysed from theory essence.
3. Single factor method has been used for studing the relationship between the final bubble radius and its effect factors, conclusions have been drawn. The cause why the conclusions can be drawn has been analysed based on the mechanism.
1．以注射矩形薄板制品的聚合物熔体充模流动过程和泡孔长大为研究对象，把微观两相流看成宏观单相流，采用泡孔单元模型并根据流体力学基本方程建立了泡孔长大的数学模型，使用有限元软件MPI对微孔发泡注射成型工艺进行了数值模拟；
2．分析了微孔发泡注射成型工艺与传统工艺的差异，主要包括：注射时间、速度场、温度场、熔体压力场；研究了微孔发泡注射成型工艺泡孔内压力、泡孔半径及分布的变化趋势及规律；比较了N_2和CO_2作为发泡剂对熔体流动性和最终泡孔大小及分布的影响。分析了研究结果产生的理论本质；
3．采用单因素试验法研究了微孔发泡注射成型工艺制品的最终泡孔尺寸与影响因素之间的关系，得到了主要影响因素对最终泡孔尺寸的影响规律，从机理层面分析了其产生的原因。
An innovative technology, microcelluar foam injection molding process which have some virtue contrasting with conventional process such as reducing production weight greatly, improving dimension stability, reducing production distortion etc, in addition, do not need higher injection pressure for requirement of injection machine and can lower clamp tonnage, especially eliminate the pack and hold phase is studied. So far, there is few reported work for the mechanism of microcellular foam injection molding process, so it seems extremely important to do some research about it. This paper mainly includes these aspects as below:
1. In this paper, the polymer melt flow in rectangle sheet mould and bubble growth have been studied by means of having microcosmic two phase liquid as macroscopical single phase liquid and appling the bubble cell model and mathematical model based on the basic equations of hydrodynamics. Finite Element software MPI is used for the numerical simulation of microcellular foam injection molding process.
2. Have analysed the difference between microcellular foam injection molding process and conventional process, mainly involves: injection time, velocity field, temperature field, pressure field of the melt; have studied the variety trend and rule of the pressure in bubble, the bubble radius and its distribution for microcellular foam injection molding process; N2 has been compared with CO_2 as vesicant for melt fluidness, bubble radius and its distribution. All research results have been analysed from theory essence.
3. Single factor method has been used for studing the relationship between the final bubble radius and its effect factors, conclusions have been drawn. The cause why the conclusions can be drawn has been analysed based on the mechanism.
引文
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[27] Nam. P. Suh, Innovation in Polyper Processing. 1996, New York: Hanser Publication.
[28] 剧志民，李晓艳，马骏骄，李闯，塑料注射成型新技术—微孔发泡技术的应用．塑料科技，2002．150(4)：13-16．
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