How to use polycarbonate injection molding?
Polycarbonate Injection Molding
Details
Details:
Model
Material
Brand
Origin
Application
Booling-Injection-8
P20, 718, S136, 2738 etc
Booling
China
Automotive parts, industrial parts, medical parts, household
Polycarbonate polymer injection molding has great advantages in the medical industry. Among them, injection molding technology exists in infusion bottles, syringes, drug packaging bottles, etc., which can effectively protect the quality of drugs.
Advantages of Polycarbonate Injection molding：
- High Precision and Repeatability
- Low Cost per Part
- Fast Production Rate
- Wide Material Choice
- Little Waste
Related Hot Products
Polycarbonate Polymer injection molding mainly produces various plastic products, which are applied in various industries such as dairy products, industrial parts, electronic components, and automotive components. This process is an engineering technique that uses polymer materials (sometimes with various additives, additives, or modified materials) to transform them into products or practical materials.
The relationship between polymer injection molding and industrial product design is very close, and the selection of injection materials is also crucial (Such as thermosetting or thermoplastic injection molding) . If selected appropriately, high-quality and low-cost products can be obtained. The polymer materials used in polymer injection molding can be divided into natural polycarbonate polymer materials, synthetic polymer materials, and polymer composite materials. People’s use of polymers can be traced back to ancient times, such as wood, cellulose, cotton, silk, fur, etc. Synthetic polymer materials usually refer to plastics, rubber, chemical fibers, coatings, adhesives, etc. Although polymers are a relatively new type of material compared to metals, glass, ceramics, and other materials, their unique properties and advantages in processing and cost make them increasingly important in modern products. Taking polycarbonate plastic injection molding as an example, they are widely used in fields such as household appliances, automobiles, and electronic appliance manufacturing due to their easy processing, lightweight, high strength, good impact resistance, good insulation, and the ability to color arbitrarily and firmly.
The Characteristics of Polycarbonate Polymer Injection Molding Materials
Compared with metal materials, the mechanical properties of polymer materials used in polymer injection molding have the following characteristics:
- Low Strength and High Specific Strength
The tensile strength of polymer materials is lower than that of metals, with an average of around 100MPa. Even glass fiber-reinforced nylon has a tensile strength of only 200MPa, which is equivalent to the strength of ordinary gray cast iron. However, the density of polymer materials is only 1/4 to 1/6 of that of steel, so their specific strength is not lower than that of certain metals.
- High Elasticity and Low Elastic Modulus
High elasticity and low elastic modulus are unique properties of polymer materials. For example, rubber is a typical high elastic material, with an elastic deformation rate of 100%~1000% and an elastic modulus of only about IMPa. Bowling treatment is usually used to prevent plastic deformation of rubber, even if the molecular chains are cross-linked into a network structure. As the degree of vulcanization increases, the elasticity of rubber decreases, and the elastic modulus increases. Mildly crosslinked polymers exhibit typical high elasticity at temperatures above flight, with large elastic deformation, low elastic modulus, and varying elasticity with the temperature rises and increases. Plastic has no high elasticity because it is in a glass state, but its elastic modulus is also much lower than that of metal, about 1/100 of the metal’s elastic modulus.
- Viscoelasticity
Under external forces, polymers undergo both high elastic deformation and viscous flow, and their deformation is time-dependent. This phenomenon is called viscoelasticity, and the three phenomena of viscoelasticity in polymers are creep, stress relaxation, and internal friction. Creep is a phenomenon in which the strain increases with time under constant load, and it represents the shape stability of a material under certain external forces. Some polymer materials exhibit significant creep at room temperature, such as the elongation and bending of overhead PVC wire sleeves, which is known as creep. For polymer parts with high dimensional accuracy requirements, materials with high creep resistance should be selected to avoid early failure caused by creep, such as polycarbonate and polycarbonate.
- High Wear Resistance
The hardness of polymers is lower than that of metals, but their wear resistance is generally higher than that of metals, especially plastics. The friction coefficient of plastics is small, and some plastics can be used under dry friction conditions and have self-lubricating properties. Therefore, plastic products are widely used in the manufacturing of friction and wear parts such as bearings, shaft sleeves, and camshafts. Rubber, on the other hand, is suitable for producing wear-resistant parts that require a higher friction coefficient due to its larger friction coefficient, such as car tires and brake friction parts.
- High Insulation
Polymers are formed by covalent bonding and therefore cannot be ionized. They have low conductivity, low dielectric constant, low dielectric loss, and good arc resistance. The characteristic of good insulation depends on the absence of other impurities, and there are no ions or free electrons inside. Therefore, polymer materials such as plastic and rubber are the most critical insulation materials in the motor, electrical, power, and electronics industries.
- High Chemical Stability
Polymer compounds are covalently bonded, not easily ionized, and have no free electrons. Additionally, due to the entanglement of molecular chains, many functional groups of the chains are encapsulated inside, resulting in good chemical stability of polymer materials. They exhibit excellent corrosion resistance in acidic, alkaline, and other solutions. Polytetrafluoroethylene, known as the “king of plastics,” does not react with concentrated acids, bases, organic solutions, or strong oxidants at high temperatures, and has the best chemical stability.
The Application of Polycarbonate Polymer Injection Molding
Polycarbonate Polymer injection molding plays the most crucial role in industrial production and has a strong driving force for industrial development. With the increasing application of polymer materials, the research and development of polycarbonate polymer processing and molding technology is also becoming more and more in-depth. As an emerging technology, although its birth time is not long, it has strong application value and has achieved considerable achievements. Polymer processing and molding technology is a comprehensive process that combines multiple disciplines such as physics, chemistry, and biology. An important manifestation of China’s scientific and technological development is to strengthen research on this technology. This research product is applied in various fields, including:
- Construction field: Polycarbonate polymer materials can be used as insulation and sound insulation materials in the construction industry, as well as reinforcement materials in some modern building structures.
- Transportation: In vehicles such as cars, airplanes, and ships, polymer materials are often used to manufacture components such as car bodies, interiors, tires, etc. Reasonable use of polymer materials can reduce weight and achieve optimal product performance.
- Agriculture: In agriculture, polycarbonate polymer materials are commonly used to manufacture agricultural films, irrigation systems, etc., which helps improve agricultural production efficiency.
- Electrical and Electronics Industry: Polycarbonate polymers are widely used in wires, cables, electronic equipment casings, and circuit boards due to their excellent insulation properties.
- Medical field: Products produced from medical polymer materials have certain high precision and strength, and are used to manufacture various medical devices and equipment, such as artificial joints, heart valves, medical sutures, etc.
- Packaging industry: Polymer materials, especially plastics, are widely used for packaging products such as food, beverages, and pharmaceuticals.
- Textile industry: Due to the outstanding wear resistance and easy cleaning characteristics of polymer materials, synthetic fibers such as nylon and polyester are widely used in clothing manufacturing.
- Civil engineering: Geosynthetic materials are used in civil engineering, such as reinforcing soil, filtering, and drainage systems.
- Sports equipment: In sports equipment,polycarbonate polymer materials are used to manufacture sports shoes, rackets, sports mats, etc.
- Aerospace: High-performance polymer composite materials are used in structural components of aircraft and thermal protection systems of spacecraft.
- Environmental protection field: Used as filtering and adsorption materials in environmental protection technologies such as water treatment and air purification.
- Energy field: It is also applied in energy technologies such as solar cells, fuel cells, and battery separators.
- Information storage: Polymer materials also play an important role in information storage media such as optical discs and magnetic tapes.
- 3D printing: As a printing material in 3D printing technology, such as PLA, ABS plastic, etc.
- Biodegradable materials: used to produce biodegradable plastics and solve environmental plastic pollution problems.
The Process of Polycarbonate Polymer Injection Molding
Polycarbonate Polymer injection molding refers to the process of injecting a polymer with a certain shape into a mold cavity through pressure in a molten state, cooling and solidifying it, and then forming it. The process principle is to melt the solid polymer according to its melting point, inject it into the mold at a certain speed through the pressure of the injection machine, and cool the plastic through a water channel to obtain the same product as the designed mold cavity.
The complete injection process of polymer injection molding includes preparation before molding; Injection process; and Post-processing of products. The injection process generally includes feeding – plasticizing – injection – cooling – demolding
- Adding materials:
Due to the intermittent process of injection molding, quantitative (constant volume) feeding is required to ensure continuous and stable operation, uniform plastic plasticization, and ultimately obtain high-quality plastic parts.
- Plasticization:
The process in which the formed material polycarbonate is heated, compacted, and mixed inside the barrel of an injection machine, transforming from a loose powder or granular solid to a continuous homogenized melt.
- Injection:
The plunger or screw starts from the measuring position inside the barrel and applies high pressure through the injection cylinder and piston to quickly feed the plasticized plastic melt into the closed mold cavity through the nozzle at the front end of the barrel and the pouring system in the mold. Injection can be further divided into three stages: flow molding, pressure holding and contraction, and backflow.
- Cooling:
When the plastic polycarbonate in the pouring system freezes and no longer needs to be kept under pressure, the plunger or screw can be returned to remove the pressure of the plastic melt in the barrel, and new material can be added. At the same time, cooling media such as cooling water, oil, or air are introduced into the mold to further cool the mold. This stage is called cooling after the gate freezes. The cooling process starts from the injection of plastic melt into the mold cavity, which includes the period from mold filling, and pressure holding to before demolding.
- Demoulding:
The polycarbonate plastic part can be cooled to a certain temperature before opening the mold, and the plastic polycarbonate part is pushed out of the injection mold under pressure.
Related News
Applied’s expertise in modifying materials at atomic levels and on an ihdustrial scaleenables our customers to transform possibilities into reality.
