可视化滚塑设备的研究以及滚塑工艺的开发
|
摘要
滚塑成型工艺在国内尚属于一种新型塑料成型工艺。本文首先对滚塑工艺的概况做了较全面的介绍，包括滚塑的工作原理、特点、应用、材料、设备、工艺性能要求以及在国内外的发展历史与现状。滚塑工业的兴起，已经使其成为了塑料加工工艺中一股不可忽视的力量。
为了更好的研究滚塑工艺，本课题中设计了一台可视化、远红外以及微波加热的摇摆式滚塑设备。滚塑工艺与可视化工艺研究，红外线加热，微波加热的结合，在国内都属于空白。可视窗的设计，远红外加热、微波加热都将为滚塑工艺研究提供了新的方法。新型的滚塑设备，也将为滚塑工艺研究提供有力的保证。
滚塑发泡工艺在国外已经日趋成熟，同样在国内研究却非常少。采用自制的滚塑发泡小装置，对滚塑发泡工艺进行了多次实验。实验过程就是将LLDPE和AC发泡剂按照一定量的配比量放入自制装置，加热到一定温度，使其发泡，然后取出制品。实验研究对滚塑工艺条件的控制有了一定的了解。实验研究显示，影响滚塑发泡工艺的因素除了发泡剂种类以及加入量，还有加热冷却温度、速度等等。同时，脱模剂在滚塑发泡工艺中也是值得注意的环节。
微波加热塑料的研究，主要是为日后滚塑工艺微波加热研究提供理论依据。实验过程是按一定的配比称量在HDPE或者LLDPE中加热敏化剂(分别加入N_(234)、HG-1P、Al_2O_3))，混合后经双螺杆挤出机熔融共混，造粒，再将共混料均匀分散在微波场中进行加热实验，确定其升温曲线。实验证明，塑料的微波加热成型中，塑料和敏化剂的种类以及其加入量比的改变，都在极大程度上影响着塑料塑化效果。塑料和敏化剂的配比也是影响塑化效果的一个重要作用。微波加热的加热温度和加热时间在微波加热工艺也具有着重要的作用。
Rotational molding is a new polymer processing. It is introduced relatively comprehensively about the general situation in rotation molding, such as the principle, the advantages and disadvantages, the application, the materials, the machines and the process performance of plastics and the development in past time and now days in home and abroad.. It is noticeable that with the development of rotational molding technology it has been an important force in polymer processing.
To comprehend more about the rotational molding process, a new visual rotational molding machine was designed in this subject. It could be heated by far-infrared or micro-wave. And it was vacant that the process was combined with visualization, far-infrared heating or microwave heating. Some new way was supplied in the process study in rotational molding such as applying visualization, heating by far-infrared or microwave. And at the same time, the new machine could be a strong guarantee for the process study.
The rotational molding has been developed perfectly abroad, but rarely in China. Many experiments has been done by using the home-made rotational foaming molding machine. LLDPE and AC blowing agent was set into the home-made machine respectively according to a certain weight in advance. Then the polymer would be foamed when the mould was heated up to a certain temperature. After the polymer was foamed completely, cool the mould and take out the part. The operation conditions of rotational foam molding was exposed in the experiments. It showed that the heating and cooling temperature and rate was the factor effecting the process except for the blowing agent variety and the loading weigh. And the demoulding agent should be also noticed in the rotational foam molding.
The base theory would be found though the study of plastic heated by microwave for the succedent rotational micro-wave heating molding. The sensitizing agent such as N_(234)、HG-1P、Al_2O_3, was set into the HDPE or LLDPE respectively according to a certain weight in advance. After the mixture was melt, compounded and prilled by twin screw extruder, the blender was dispersed uniformly and heated in the micro-wave area. The heating-up curve was drawed after the experiment. It showed that the variety of plastic and sensitizing agent and the vary of the weigh had a serious effect on the plastication in the rotational micro-wave heating molding. The mixture radio of plastic and sensitizing agent also played an important role in the plastication. The heating and cooling temperature and time were important in the rotational micro-wave heating molding.
为了更好的研究滚塑工艺，本课题中设计了一台可视化、远红外以及微波加热的摇摆式滚塑设备。滚塑工艺与可视化工艺研究，红外线加热，微波加热的结合，在国内都属于空白。可视窗的设计，远红外加热、微波加热都将为滚塑工艺研究提供了新的方法。新型的滚塑设备，也将为滚塑工艺研究提供有力的保证。
滚塑发泡工艺在国外已经日趋成熟，同样在国内研究却非常少。采用自制的滚塑发泡小装置，对滚塑发泡工艺进行了多次实验。实验过程就是将LLDPE和AC发泡剂按照一定量的配比量放入自制装置，加热到一定温度，使其发泡，然后取出制品。实验研究对滚塑工艺条件的控制有了一定的了解。实验研究显示，影响滚塑发泡工艺的因素除了发泡剂种类以及加入量，还有加热冷却温度、速度等等。同时，脱模剂在滚塑发泡工艺中也是值得注意的环节。
微波加热塑料的研究，主要是为日后滚塑工艺微波加热研究提供理论依据。实验过程是按一定的配比称量在HDPE或者LLDPE中加热敏化剂(分别加入N_(234)、HG-1P、Al_2O_3))，混合后经双螺杆挤出机熔融共混，造粒，再将共混料均匀分散在微波场中进行加热实验，确定其升温曲线。实验证明，塑料的微波加热成型中，塑料和敏化剂的种类以及其加入量比的改变，都在极大程度上影响着塑料塑化效果。塑料和敏化剂的配比也是影响塑化效果的一个重要作用。微波加热的加热温度和加热时间在微波加热工艺也具有着重要的作用。
Rotational molding is a new polymer processing. It is introduced relatively comprehensively about the general situation in rotation molding, such as the principle, the advantages and disadvantages, the application, the materials, the machines and the process performance of plastics and the development in past time and now days in home and abroad.. It is noticeable that with the development of rotational molding technology it has been an important force in polymer processing.
To comprehend more about the rotational molding process, a new visual rotational molding machine was designed in this subject. It could be heated by far-infrared or micro-wave. And it was vacant that the process was combined with visualization, far-infrared heating or microwave heating. Some new way was supplied in the process study in rotational molding such as applying visualization, heating by far-infrared or microwave. And at the same time, the new machine could be a strong guarantee for the process study.
The rotational molding has been developed perfectly abroad, but rarely in China. Many experiments has been done by using the home-made rotational foaming molding machine. LLDPE and AC blowing agent was set into the home-made machine respectively according to a certain weight in advance. Then the polymer would be foamed when the mould was heated up to a certain temperature. After the polymer was foamed completely, cool the mould and take out the part. The operation conditions of rotational foam molding was exposed in the experiments. It showed that the heating and cooling temperature and rate was the factor effecting the process except for the blowing agent variety and the loading weigh. And the demoulding agent should be also noticed in the rotational foam molding.
The base theory would be found though the study of plastic heated by microwave for the succedent rotational micro-wave heating molding. The sensitizing agent such as N_(234)、HG-1P、Al_2O_3, was set into the HDPE or LLDPE respectively according to a certain weight in advance. After the mixture was melt, compounded and prilled by twin screw extruder, the blender was dispersed uniformly and heated in the micro-wave area. The heating-up curve was drawed after the experiment. It showed that the variety of plastic and sensitizing agent and the vary of the weigh had a serious effect on the plastication in the rotational micro-wave heating molding. The mixture radio of plastic and sensitizing agent also played an important role in the plastication. The heating and cooling temperature and time were important in the rotational micro-wave heating molding.
引文
[1] 王政，杨荆泉，陈世谦．塑料旋转模塑制造技术[M]．化学工业出版社，2003，9：9
[2] 马秀清译．旋转模塑：设计、材料、模具及工艺／(美)格伦 L．比尔(Glenn L．Beall)著[M]：北京：化学工业出版社，2005：6
[3] 臧群传，张威，王剑．国内外滚塑设备的现状及发展[J]．中国塑料．1999，11(13)：19-27
[4] 孙彤彤译，刘国海校．滚塑成型的现状与未来[J]．国外塑料，1998，16(4)：11
[5] 刘国海，孙彤彤．滚塑成型加工技术的发展概况[J]．中国包装工业 1999，59(5)：30
[6] 张惠曦，滚塑制品的应用与开发，中国包装[J]，1998，18(1)：70-71
[7] 张惠敏，塑料旋转成型的特点与研究[J]．工程塑料应用．2002，30(4)：23-27
[8] 姚勤．大型聚乙烯中空制品的滚塑成型技术[J]．上海大学学报．1999，5(5)：467-470
[9] C.T. Bellehumeur, M. K. Bisaria, J. Vlachopoulos An Experimental Study and Model Assessment of Polymer Sinte ring[J]. Polymer Engineering and Science, 199s,. 36 (17)
[10] 臧群传，勒凤林，高岩，张桂荣，许萍．聚乙烯滚塑专用料地研制[J]．中国塑料．1999，13(12)：16-20
[11] 李百顺，滚塑成型工艺参数对制品性能的影响[J]．现代塑料加工应用．1998，10(6)：36-38
[12] 刘善本．滚塑树脂的性能要求与选择[J]．国外塑料．1999，17(3)：24-26
[13] 聂群莲，王晓，许家瑞．塑料旋转成型用原料的特点、品种和发展[J]．广州化工．2003，31(4)：55-60
[14] 李祝，刘春阳．滚塑成型聚乙烯制品的冲击强度[J]．国外塑料．199917(4)：28-35
[15] Louise Therese Pick and Eileen Harkin-Jones. An Investigation Into the Relationship Between the Impact Performance of Rotationally Molded Poly et hyiene Productsand Their Dynamic Mechanical Properties[J]. Polymer Engineering and Science, 2003,43 (4): 905-918
[16] 李百顺．聚乙烯滚塑工艺及设备[J]．中国塑料．1999，13(4)：45-47
[17] 孔繁兴，王爱阳．滚塑成型技术及发展趋势[J]．塑料科技．1998，166(4)：58
[18] 杨慧娟．气压传动及控制在可控震源上的应用[J]．物探装备．2005，13(1)
[19] 《气动技术》编写组编．气动技术[M]北京：北京出版社，1981：120
[20] 李百顺．滚塑成型模具设计[J]．塑料．1997，26(6)：43-46
[21] 李百顺．220 L塑料桶滚塑成型技术[J]．兰化科技．1998 16(4)：224-227
[22] 杨晓东．塑料注射成型数值模拟计算结果的可视化方法[J]．塑料工业．2003，31(12)：24-27
[23] 李月军．塑料加工过程中的红外技术简介[J]．塑料工业．2004，32(6)：56
[24] 高洁，朱复华．远红外加热技术应用于塑料土工格栅生产[J]．工程塑料应用．2000，28(4)：16-17
[25] 南景宇，杨富，杨景发，徐景智，田野．红外定向强辐射器结构和性能特点分析[J]．激光与红外．2005，35(7)：466-468
[26] A. Greco, A. Maffezzoli. Simulation of Heat Transfer During Rotational Molding[J] Advances in Polymer Technology, 2003,22(4):71-279
[27] Bharat Indu Chaudhary .Processing Enhancers for Rotational Molding of Polyethylene[J]. Polymer Engineering and Science. 2001, 41 (10): 1731-1742
[28] 王剑，刘春阳，黄玉强．交联聚乙烯滚塑技术[J]．中国塑料2000，14(1)：2-55
[29] A.G. Spence and R. J. Crawford. The Effect of Processing Variables on the Formation and Removal of Bubbles in Rotationally Molded Products[J] Polymer Engineering And Science, 19M,36(7): 993-1009
[30] 刘圣军，田丰，杨荆泉，高万玉，陈世谦，共混改性聚乙烯滚塑专用树脂的研制[J]，塑料，2002，6：22-24
[31] 董桂梅．滚塑用PE粉料[J]．齐鲁石油化工．1989(3)：45-48
[32] 林瑞华．LLDPE旋转成型技术及其在防腐蚀工程中的应用[J]．腐蚀与防护．2000，21(8)：362-367
[33] SFUDHAR K. SIDDHAMALLI and VICTOR W. LEE The Influence of Rotational Molding Cycle on the Morphology and Physical Properties of FR-LLDPE[J]. Journal of Vinyl &Additive Technology. 1998, 4(4):222～228
[34] Shih-Jung Liu, Ching-Hsiung Yang. An Experimental Study of Foamed Polyethylene in Rotational Molding[J]. Polymer Engineering And Science, 1999, 39(9): 1776-1786
[35] Guobin Liu. Polymer Engineering And Science[J], Polymer Engineering And Science, 1998, 38(12): 1997-2007
[36] D.D.agostino, E. Takacs, J. Vlachopoulos. Foaming with Polymer Microspheres in Rotational Molding: The Effect of Coupling Agent[J]. Journal of Cellular Plastics 2004,40(1):64-75
[37] Remon Pop-Iliev. Manufacturability of Fine-celled Cellular Structures in Rotational Foam Molding[J]. Journal of Cellular Plastics 2004,40(1): 13-25
[38] E. archer, E. Harkin-Jones, M. P. Kearns. Processing Characteristics and Mechanical Properties of Metallocene Catalyzed Linear Low-Density Polyethylene Foams for Rotational Molding[J] Polymer Engineering And Science, 2004,44(4):638-647
[39] Remon Pop-Iliev, Chul B. Park. Single-step Rotational Foam Molding of Skin-surrounded Polyethylene Foams[J]. Journal of Cellular Plastics 2004,39 (1):49-58
[40] 彭响方，张凤岭，兰庆贵，周南桥．滚塑发泡成型技术及其发展方向[J]．塑料．2004，33(5)：16-21
[41] Shih-Jung Liu, Ching-Hsiung Yang. Rotational Molding of Two-Layered Polyethylene Foams[J]. Advances in Polymer Technology. 2001,20(2): 108-115
[42] 马东卫．塑料浇铸成型和旋转成型[M]．北京：化学工业出版社，2005：132
[43] 黄艳，彭强，谢明贵．微波在高分子中的应用[J]．化学研究与应用，2002，1：84-89
[44] 戈明亮．微波在聚合物科学中的应用[J]．合成材料老化与应用，2004，33(2)：37-40：21
[45] 卢凯．微波的原理及特点[J]．农业机械化与电气化．2007，1：61
[46] 苏洁．微波塑化塑料[J]．福建建材，1997，2：37-39
[47] 苏洁．微波敏化剂[J]．塑料科技，1998，4：5-7
[48] 王孝军，杨杰，李光宪，陈广玲．微波敏化剂传热模型[J]．塑料工业，2005，3：36-38
[2] 马秀清译．旋转模塑：设计、材料、模具及工艺／(美)格伦 L．比尔(Glenn L．Beall)著[M]：北京：化学工业出版社，2005：6
[3] 臧群传，张威，王剑．国内外滚塑设备的现状及发展[J]．中国塑料．1999，11(13)：19-27
[4] 孙彤彤译，刘国海校．滚塑成型的现状与未来[J]．国外塑料，1998，16(4)：11
[5] 刘国海，孙彤彤．滚塑成型加工技术的发展概况[J]．中国包装工业 1999，59(5)：30
[6] 张惠曦，滚塑制品的应用与开发，中国包装[J]，1998，18(1)：70-71
[7] 张惠敏，塑料旋转成型的特点与研究[J]．工程塑料应用．2002，30(4)：23-27
[8] 姚勤．大型聚乙烯中空制品的滚塑成型技术[J]．上海大学学报．1999，5(5)：467-470
[9] C.T. Bellehumeur, M. K. Bisaria, J. Vlachopoulos An Experimental Study and Model Assessment of Polymer Sinte ring[J]. Polymer Engineering and Science, 199s,. 36 (17)
[10] 臧群传，勒凤林，高岩，张桂荣，许萍．聚乙烯滚塑专用料地研制[J]．中国塑料．1999，13(12)：16-20
[11] 李百顺，滚塑成型工艺参数对制品性能的影响[J]．现代塑料加工应用．1998，10(6)：36-38
[12] 刘善本．滚塑树脂的性能要求与选择[J]．国外塑料．1999，17(3)：24-26
[13] 聂群莲，王晓，许家瑞．塑料旋转成型用原料的特点、品种和发展[J]．广州化工．2003，31(4)：55-60
[14] 李祝，刘春阳．滚塑成型聚乙烯制品的冲击强度[J]．国外塑料．199917(4)：28-35
[15] Louise Therese Pick and Eileen Harkin-Jones. An Investigation Into the Relationship Between the Impact Performance of Rotationally Molded Poly et hyiene Productsand Their Dynamic Mechanical Properties[J]. Polymer Engineering and Science, 2003,43 (4): 905-918
[16] 李百顺．聚乙烯滚塑工艺及设备[J]．中国塑料．1999，13(4)：45-47
[17] 孔繁兴，王爱阳．滚塑成型技术及发展趋势[J]．塑料科技．1998，166(4)：58
[18] 杨慧娟．气压传动及控制在可控震源上的应用[J]．物探装备．2005，13(1)
[19] 《气动技术》编写组编．气动技术[M]北京：北京出版社，1981：120
[20] 李百顺．滚塑成型模具设计[J]．塑料．1997，26(6)：43-46
[21] 李百顺．220 L塑料桶滚塑成型技术[J]．兰化科技．1998 16(4)：224-227
[22] 杨晓东．塑料注射成型数值模拟计算结果的可视化方法[J]．塑料工业．2003，31(12)：24-27
[23] 李月军．塑料加工过程中的红外技术简介[J]．塑料工业．2004，32(6)：56
[24] 高洁，朱复华．远红外加热技术应用于塑料土工格栅生产[J]．工程塑料应用．2000，28(4)：16-17
[25] 南景宇，杨富，杨景发，徐景智，田野．红外定向强辐射器结构和性能特点分析[J]．激光与红外．2005，35(7)：466-468
[26] A. Greco, A. Maffezzoli. Simulation of Heat Transfer During Rotational Molding[J] Advances in Polymer Technology, 2003,22(4):71-279
[27] Bharat Indu Chaudhary .Processing Enhancers for Rotational Molding of Polyethylene[J]. Polymer Engineering and Science. 2001, 41 (10): 1731-1742
[28] 王剑，刘春阳，黄玉强．交联聚乙烯滚塑技术[J]．中国塑料2000，14(1)：2-55
[29] A.G. Spence and R. J. Crawford. The Effect of Processing Variables on the Formation and Removal of Bubbles in Rotationally Molded Products[J] Polymer Engineering And Science, 19M,36(7): 993-1009
[30] 刘圣军，田丰，杨荆泉，高万玉，陈世谦，共混改性聚乙烯滚塑专用树脂的研制[J]，塑料，2002，6：22-24
[31] 董桂梅．滚塑用PE粉料[J]．齐鲁石油化工．1989(3)：45-48
[32] 林瑞华．LLDPE旋转成型技术及其在防腐蚀工程中的应用[J]．腐蚀与防护．2000，21(8)：362-367
[33] SFUDHAR K. SIDDHAMALLI and VICTOR W. LEE The Influence of Rotational Molding Cycle on the Morphology and Physical Properties of FR-LLDPE[J]. Journal of Vinyl &Additive Technology. 1998, 4(4):222～228
[34] Shih-Jung Liu, Ching-Hsiung Yang. An Experimental Study of Foamed Polyethylene in Rotational Molding[J]. Polymer Engineering And Science, 1999, 39(9): 1776-1786
[35] Guobin Liu. Polymer Engineering And Science[J], Polymer Engineering And Science, 1998, 38(12): 1997-2007
[36] D.D.agostino, E. Takacs, J. Vlachopoulos. Foaming with Polymer Microspheres in Rotational Molding: The Effect of Coupling Agent[J]. Journal of Cellular Plastics 2004,40(1):64-75
[37] Remon Pop-Iliev. Manufacturability of Fine-celled Cellular Structures in Rotational Foam Molding[J]. Journal of Cellular Plastics 2004,40(1): 13-25
[38] E. archer, E. Harkin-Jones, M. P. Kearns. Processing Characteristics and Mechanical Properties of Metallocene Catalyzed Linear Low-Density Polyethylene Foams for Rotational Molding[J] Polymer Engineering And Science, 2004,44(4):638-647
[39] Remon Pop-Iliev, Chul B. Park. Single-step Rotational Foam Molding of Skin-surrounded Polyethylene Foams[J]. Journal of Cellular Plastics 2004,39 (1):49-58
[40] 彭响方，张凤岭，兰庆贵，周南桥．滚塑发泡成型技术及其发展方向[J]．塑料．2004，33(5)：16-21
[41] Shih-Jung Liu, Ching-Hsiung Yang. Rotational Molding of Two-Layered Polyethylene Foams[J]. Advances in Polymer Technology. 2001,20(2): 108-115
[42] 马东卫．塑料浇铸成型和旋转成型[M]．北京：化学工业出版社，2005：132
[43] 黄艳，彭强，谢明贵．微波在高分子中的应用[J]．化学研究与应用，2002，1：84-89
[44] 戈明亮．微波在聚合物科学中的应用[J]．合成材料老化与应用，2004，33(2)：37-40：21
[45] 卢凯．微波的原理及特点[J]．农业机械化与电气化．2007，1：61
[46] 苏洁．微波塑化塑料[J]．福建建材，1997，2：37-39
[47] 苏洁．微波敏化剂[J]．塑料科技，1998，4：5-7
[48] 王孝军，杨杰，李光宪，陈广玲．微波敏化剂传热模型[J]．塑料工业，2005，3：36-38