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    當前位置: 首頁 » 賽普新聞中心 » 新聞資訊 » 行業動態 » 軟聚乙烯泡沫塑料滾塑工藝突破局限性

    軟聚乙烯泡沫塑料滾塑工藝突破局限性

    文章出處:   責任編輯:   發布時間:2015-10-27 20:27:00    點擊數:-   【

    為改進傳統軟聚乙烯泡沫塑料工藝的突出局限性,PolivinilRotomachinery公司開發了“一次投料”滾塑新工藝,用來生產聚乙烯結構泡沫塑料板。對此領域進行研究的興趣在于能在板的兩壁之間填充一種可改進板材各項性能的材料,這些性能主要有化學—物理性能(如隔熱性、比重、漂浮性等等)或機械性能(如抗振性、結構強度等)。除了能得到聚乙烯結構泡沫塑料產品外,對其感興趣的另一原因就是考慮物料的回收使用。

    傳統的“二次投料”工藝開始于將必需的一定量的物料投入模具成型塑件的外層(“表皮殼層”),一旦該物料在加熱爐內熔融就將模具從爐內取出并加入發泡劑(如:一種預混在聚乙烯中的粉末狀助劑),并立即重新置入加熱爐內完成整個成型周期(第二次熔融、冷卻等)。此工藝存在安全問題,因為對高溫模具的人工操作使成型周期延長,延長的時間長短與模具大小成正比,而且在表皮殼層與適于向下滴落的物料凝固以前必須中斷操作過程(模具越大這種現象越嚴重)。

    與“二次投料”工藝不同,“一次投料”法將兩種不同的聚乙烯原料放入模具,一種為粉狀聚乙烯,而另一種為混有發泡劑的小球狀聚乙烯。粉狀聚乙烯的熔點比發泡劑分解溫度低,且顆粒尺寸大小也不同,用來成型塑件的外表層。(粉狀聚乙烯的顆粒尺寸在500~1000微米,小球狀(混有發泡劑)聚乙烯顆粒尺寸為3~4毫米)。粉狀聚乙烯首先與模具粘附而小球狀聚乙烯繼續循環流動并不斷受熱,然后形成了塑件的表皮殼層接著進行發泡反應。

    物料在210℃下通過第一階段的熔融,軟聚乙烯泡沫塑料開始粘附在模具上,只有形成了塑件的表面殼層才向溫度為265℃的第二階段熔融推進,此時聚乙烯軟化形成球壁。由于發泡劑分解而產生內壓,這個過程一直持續到內壓與排氣口的大氣壓相平衡為止。小球狀聚乙烯顆粒依次發泡漲大,最后充滿整個型腔,通過冷卻后聚乙烯凝固。理想的工藝結果是2種物料在模塑階段完全分離,對發泡材料的控制通過調節加工溫度、熔融與冷卻時間、旋轉速度及排氣口位置。更進一步說,必須要避免的是在表皮殼層中粘合有小球狀聚乙烯顆粒,在通常條件下,由于發泡劑分解產生壓力,小球顆粒均勻受熱軟化、發泡。因此,如果塑件表皮殼層沒有熔融,除非小球完全包裹,小球狀聚乙烯顆粒就可能下沉(幾乎不可避免),加熱并使殼層與小球狀顆粒接觸處達到軟化點但還沒有發生膨脹,發泡劑只在殼層與小球接觸處分解(此處為后屈服點),在塑件表面留下可見的痕跡。

    滾塑工藝流程

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