聚氨酯反应体系的固化和温度

采用n级反应动力表示式和热传导方程建立了描述聚氨酯反应模塑（RIM）体系固化和温度的方法,并进行了相应的理论计算,结果表明：催化剂浓度,模具温度对固化过程和体系最大温度均有明显影响;反应物料的温度对体系的最大温度有影响,但对体系固化时间影响不大。厚模具内部的温度场接近绝热性质,其历史可用来确定反应动力和热力的相关参量。     

Moldflow软件对轿车水箱盖注射成型模具温度的优化

用Moldflow软件优化轿车水箱盖注射成型的模具温度。结果表明：模具温度在175 ℃时，胶料充模时间短，充模结束时的体积固化率小，充模后35 s时的体积固化率大。Moldflow软件可以优化橡胶制品的注射成型工艺，缩短工艺和模具设计周期，提高生产效率和产品质量。     

注射成型工艺条件对聚丙烯制品光泽度的影响

通过一次因子法确定了Taguchi法的试验因子,采用Taguchi法对试验因子进行权重分析与优化,并进一步研究了注射成型工艺条件对聚丙烯制品光泽度的影响。结果表明,在注射成型过程中,提高熔体温度、模具温度、保压压力及注射速率都有助于提高制品的光泽度,同时也会提高制品的拉伸强度和弯曲强度,但会降低缺口冲击强度。影响聚丙烯制品光泽度的最显著因素是熔体温度。影响因子的权重大小顺序为：熔体温度、模具温度、保压压力、注射速率。     

交联聚乙烯滚塑成型加热阶段时温等效性分析

论述了交联聚乙烯(XLPE)滚塑成型模具内,温度随加热设置最高温度和加热时间的变化,及其对制品交联度和冲击强度性能的影响。从动态扫描量热曲线和分段取样观察发现,XLPE滚塑经历预热、熔融、排气、交联、降温、结晶和定型阶段,逐层熔融粘附到模具上的物料随加热时间延长呈现线性增加;XLPE快速交联发生在157~185℃,交联度从7%增加到60%。从实验中物料最高温度和制品性能角度考察,加热温度升高10℃与加热时间延长1 min产生效果几乎相同,这种等效性说明适度提高加热温度可缩短滚塑周期。     

微孔塑料注射成型制品体积收缩与翘曲变形数值分析

采用Moldflow软件，通过微孔注射成型过程的数值模拟，系统研究了熔体注射温度、模具温度对其体积收缩、翘曲变形和残余应力的影响规律，并基于流变学理论，揭示了其影响机理。研究结果表明，随着熔体注射温度和模具温度增加，微孔注射制品翘曲变形和残余应力均增加，成型制品的体积收缩随着熔体注射温度升高而增加，而随着模具温度升高而减小。本研究为微孔注射成型工艺和模具的设计提供理论指导。     

长玻纤增强聚甲醛注塑成型工艺的研究

制备了长玻璃纤维(LGF)增强聚甲醛(POM)复合材料。通过6因素2水平的正交试验,探讨了注射压力、注射速度、模具温度、保压压力、保压时间、冷却时间等工艺条件对LGF增强POM复合材料的制品表观和拉伸强度的影响。结果表明:注射压力、注射速度、保压时间和模具温度等4个工艺条件对LGF增强POM制品表观和拉伸强度的影响最大,当注塑成型条件分别为料筒温度180¹90℃、注射压力60 MPa、注射速度60 mm/s、模具温度80℃、保压时间15 s时,制品具有最佳的表观和力学性能。     

基于微注射成型的微连接器工艺实验研究

基于正交实验设计方法,对微连接器在不同的微注射成型工艺参数下的充填情况进行研究,选择制品的质量作为实验指标,确定模具温度、熔体温度、注射速度、保压压力、保压时间、冷却时间等6个工艺参数为实验因素,通过对实验数据进行极差分析,得到了各因素对指标值的影响的主次顺序。实验结果表明,模具温度是影响制品质量精度的主要工艺参数因素,而冷却时间的影响最小。通过因素水平影响趋势图分析,得出了微连接器的最优工艺参数组合方案为模具温度80 ℃、熔体温度335 ℃、注射速度100 mm/s、保压压力20 MPa、保压时间1.5 s、冷却时间3.0 s,为微型器件生产中的工艺设计提供了理论依据和实际指导。     

玻璃纤维增强聚丙烯制品翘曲变形的研究

针对玻璃纤维增强聚丙烯(PP/GF)注射成型制品存在的翘曲变形缺陷,研究了注射工艺参数如模具温度、喷嘴温度、注射速率、保压压力和保压时间对制品成型收缩率及翘曲的影响。结果表明,随着模具温度、喷嘴温度和保压压力的降低,制品的翘曲减小;适当提高注射速率和减少保压时间也可减小制品翘曲。     

影响注射成型冷却时间的因素分析

介绍了一种估算注射成型过程中冷却时间的数学公式，并用它和CAE软件一起，以一平面薄板为例，全面讨论了冷却管道和制品距离、不同塑料材料和不同制品厚度、开模温度、模具热传导率、冷却介质（水）初始温度对冷却时间的影响程度，得出最大的影响因素是制件的厚度，开模温度及冷却水温度。     

浇注型聚氨酯弹性体合成工艺试验

以聚醚多元醇3010,甲苯二异氰酸酯,1,4-丁二醇和催化剂为原料,采用一步法来制备浇注型聚氨酯弹性体.研究了工艺条件(不同固化温度、固化时间和初始反应温度)以及浇注成型产生的缺陷对聚氨酯弹性体力学性能的影响.结果表明:采用固化温度为140℃,固化时间为4 h和初始反应温度为50～60℃的合成工艺条件时,聚氨酯弹性体的综合性能达到最佳,并且能够解决浇注成型时所产生的缺陷,可使产品的综合性能得以提高.     

Analysis of reaction injection molding process of polyurethane-unsaturated polyester blends. Part I: Computer simulation

A computer simulation model was developed to analyze the reaction injection molding (RIM) process of polyurethane and unsaturated polyester blends. The reaction kinetics and viscosity functions of each component were obtained through actual experiments, and a mathematical scheme for numerical calculation was set up in cylindrical coordinates to predict the temperature and conversion profiles within a disc-type mold. The temperature change calculated from the simulation was compared with the temperature rise measured in actual RIM experiments. The effects of the feed temperature, wall temperature, and catalyst levels on the maximum exothermic temperature and the demolding time were evaluated in a search for the optimum processing conditions.     

Three-dimensional modeling of reaction injection molding. I

In this research a model to simulate both the filling the curing stages of a reaction injection molding (RIM) process in complex three-dimensional molds is developed. This model can be used to predict not only the temperature and conversion changes with time but also the front position during filling. Using given physical and chemical properties of the RIM system, moldability can be determined in advance. The numerical techniques used in this research include adaptation of the SIMPLE algorithm developed by Patankar for a moving-front, two-phase system with non-negligible inertial effects, and exothermic chemical reaction. The model predictions of temperature and conversion compare favorably with available data on simple two-dimensional molds. The ability of the model to predict the dynamics of filling in more complicated molds was verified by comparison to mold filling experiments with water and a polyurethane foam.     

Engineering analysis of reaction injection molding process of nylon 6

A computer simulation model was established to analyze the reaction injection molding process of nylon 6. A numerical calculation was carried out to predict the temperature, conversion, and crystallinity profile within a disc type mold. The effects of the feed temperature, wall temperature, and overall reaction constant on the eject time were discussed for searching the optimum processing conditions.     

Structure-Property-Processing relationships of polyurethane-polyester interpenetrating polymer networks

Interpenetrating polymer networks of polyurethane and unsaturated polyester were prepared by reaction injection molding (RIM) and transfer molding. The structures of the molded samples were analyzed by electron microscopy and dynamic mechanical analysis. It was found that polymer morphology and dynamic mechanical properties depend strongly on the molding temperature, reaction rate and reaction sequence. Simplified structure models based on Takayanagi's model and sample morphology can predict the storage modulus reasonably well but not the tanδ.     

Moldability diagrams for the reaction injection molding of a polyurethane crosslinking system

A trial and error approach reflects the state of the art in reaction injection molding. Material and process parameters determine the “moldability” of a specific system in a particular application. The concept of “molding areas” on the critical parameters plane can be extended form thermoplastic injection molding (TIM) to reaction injection molding (RIM). In this work moldability diagrams for the filling and curing stages of a RIM process are obtained based on a simplified engineering approach. The key process parameters chosen for the filling stage are initial material temperature and filling time. In the curing stage, the critical parameters are considered to be mold wall temperature and demold time. Experimental results obtained on a laboratory-scale RIM machine on a Crosslinking polyurethane system are used to check the validity of the predicted molding areas. The agreement obtained is satisfactory considering the broad range of processing parameters used.     

Processing of polyurethane–polyester interpenetrating polymer network (IPN)

The kinetics and heat transfer during the curing of a polyurethane–polyester interpenetrating polymer network (IPN) were investigated experimentally and theoretically. A model based on the additivity rule of constituent ingredients was used to predict the IPNs reaction kinetics and heat transfer. Compared with the adiabatic temperature rise measured during reaction injection molding and the temperature profiles measured during a casting process, the model prediction is close to the experimental data. Deviations of model prediction from experimental results were found in the comparison of reaction rate profiles measured by differential scanning calorimetry. This suggests that reaction interactions may exist in the polymerization system.     

基于计算机仿真的注塑成型工艺优化研究

为了优化注塑成型工艺,研究了注塑成型的数学模型,以及产生翘曲形变的原因,在此基础上利用Moldflow软件对薄壁件塑料注塑成型过程中的宽浇口平板进行了仿真实验,并采用了无定型塑料丙烯腈-丁二烯-苯乙烯共聚物+聚碳酸酯(ABS+PC)对其进行注射、保压、冷却等流程模拟,选定了保压压力、熔体温度、冷却时间、模具温度、注射时间、保压时间等主要工艺参数,并通过方差比较的方法对这些工艺参数进行了评价,最终确定了注塑成型的优化方案。通过实验得出了ABS+PC的最优工艺参数组合,有效降低薄壳制件的翘曲量并优化了其制品性能。     

Adiabatic reactive viscometry for polyurethane reaction injection molding

Adiabatic reactive rheometry involves the simultaneous measurement of viscosity and temperature changes during adiabatic polymerization. Using the adiabatic reactor method to relate temperature to fractional conversion results in a useful rheokinetic tool ideally suited for fastreacting reaction injection molding (RIM) systems for which the mold-filling step is nearly adiabatic. In this work, a small laboratory RIM machine is used to mix the reactants and deliver them to a constant stress rheometer retrofitted with a wide-gap Couette geometry and two thermocouples. Measurements on two polyurethane systems are reported. A simple cross-linking system is used to verify the adiabatic rheokinetic method through comparison to a known gel conversion. Subsequent measurements on a phase-separating RIM system show that increases in catalyst level, hard segment content, and initial reactant temperature result in a decreased gel time and an increased gel conversion. The viscosity rise profiles aid our understanding of the onset and development of phase separation. They are also essential for mold-filling models and establishing moldability criteria for these RIM systems.     

基于数学模型的微细发泡注塑成型工艺与微泡关系的研究

研究了微细发泡注塑成型工艺中微泡长大的数学模型，建立了成型工艺和微泡尺寸之间的数学关系。在对该数学模型进行数值分析的基础上，着重研究了熔体温度、注塑时间、模具温度、初始填充量对微泡尺寸的影响。     

Effect of dual-initiator on low temperature curing of unsaturated polyester resins

In low temperature composite manufacturing processes, a major concern is how to control the resin gel time and cure time and how to achieve a high resin conversion with low residual volatile organic chemicals. In this study, a cobalt promoter catalyzed dual-initiator system was used to control the reaction rate and resin conversion of unsaturated polyester resins. A mechanistic kinetic model was developed to predict the reaction kinetics with dual initiators. This model can be used to simulate the isothermal and dynamic reaction rate and conversion profiles. It can also be utilized to predict the effect of promoter concentration on UP resin cured at low temperatures. The dual-initiator system was applied in the vacuum-assisted resin transfer molding process at room temperature. The kinetic model, in conjunction with the heat transfer analysis, was able to successfully predict the temperature profiles during the molding processes.