You don't necessarily know all these LCP injection molding knowledge!
Time:2022-04-30 08:47:34 / Popularity: / Source:
1. Processing technology of LCP material (liquid crystal polymer)
Important: LCP material should be dried before use, temperature is about 150 ℃, and time is about 4 to 6 hours. Residual moisture content of dehumidified LCP material should be below 0.02%, and dew point should be kept at -35 ℃.
Note: It is recommended to use a vacuum dehumidifying dryer instead of a general dryer. Because vacuum dehumidification dryer can extract moisture in LCP material, and general dryer cannot completely extract moisture in material, it is difficult to achieve required quality of product.
Note: It is recommended to use a vacuum dehumidifying dryer instead of a general dryer. Because vacuum dehumidification dryer can extract moisture in LCP material, and general dryer cannot completely extract moisture in material, it is difficult to achieve required quality of product.
2. LCP injection molding process
Resin drying conditions | Temperature | Around 150° |
Time | 4-6 hours | |
Tube temperature (℃) | Section 3rd | 290 |
Section 2nd | 330 | |
Section 1st | 325 | |
Nozzle | 325 | |
Suitable resin temperature (℃) | 380 | |
Mold temperature (℃) | 40-160 | |
Injection pressure (MPa) | 120-160 | |
Holding pressure (MPa) | 40-50 | |
Screw back pressure (MPa) | 0-5 | |
Injection speed | Medium to high speed | |
Screw revolutions (rpm) | 100-150 |
When molding, following issues should be paid attention to:
① Proportional back pressure makes feeding more accurate and stable;
② Large products can use large back pressure, and small products can use small back pressure;
③ If back pressure of large products is small, density will be relatively small, and surface gloss will be poor;
④ High-sensitivity injection system and automatic V-P (V injection pressure, P holding pressure) conversion function, so that product is precise and stable. In the case of need (such as product is very precise), it is recommended to install a pressure sensor at the gate of cavity to make V-P switching closer to reality;
⑥ Holding time of beer plane products should not be too long in general, otherwise it will easily cause warping and deformation of products, generate stress;
⑦ If LCP material stays in material tube for a long time or residual amount is too large, LCP material will be overheated, and there will be bubbles on the surface of product. Generally, mold is opened within 3 seconds after melting of material pipe, and residual amount is guaranteed to be within 5mm;
⑧ If machine is shut down and restarted, waste needs to be ejected;
⑨ Molding cycle depends on size, shape, thickness, mold structure and molding conditions of product. LCP material has good fluidity, so filling time is relatively short, and crystallization molding speed is relatively fast, so molding cycle is relatively short.
① Proportional back pressure makes feeding more accurate and stable;
② Large products can use large back pressure, and small products can use small back pressure;
③ If back pressure of large products is small, density will be relatively small, and surface gloss will be poor;
④ High-sensitivity injection system and automatic V-P (V injection pressure, P holding pressure) conversion function, so that product is precise and stable. In the case of need (such as product is very precise), it is recommended to install a pressure sensor at the gate of cavity to make V-P switching closer to reality;
⑥ Holding time of beer plane products should not be too long in general, otherwise it will easily cause warping and deformation of products, generate stress;
⑦ If LCP material stays in material tube for a long time or residual amount is too large, LCP material will be overheated, and there will be bubbles on the surface of product. Generally, mold is opened within 3 seconds after melting of material pipe, and residual amount is guaranteed to be within 5mm;
⑧ If machine is shut down and restarted, waste needs to be ejected;
⑨ Molding cycle depends on size, shape, thickness, mold structure and molding conditions of product. LCP material has good fluidity, so filling time is relatively short, and crystallization molding speed is relatively fast, so molding cycle is relatively short.
3. Overview of selection of special injection molding machine for LCP material
A special injection molding machine for LCP material must be selected;
Screw needs to be made of materials with better wear resistance;
Screw head uses a structure that can prevent backflow;
Requires a more precise temperature control system;
Nozzle part needs special design;
Feeding and injection system should be sensitive;
Capacity of injection tube should pay attention to weight of product, not too much or too little.
Screw needs to be made of materials with better wear resistance;
Screw head uses a structure that can prevent backflow;
Requires a more precise temperature control system;
Nozzle part needs special design;
Feeding and injection system should be sensitive;
Capacity of injection tube should pay attention to weight of product, not too much or too little.
4. Key points of special mold for LCP material
① Mold design of LCP products is very important. Plastic inlet of mold should be an ordinary open mouth instead of a hot mouth. If hot mouth product is used, it is easy to foam, that is, if temperature is too high, product may be overheated.
② Generally, mold temperature is about 140℃, upper (front) mold temperature should be higher than the lower (rear) mold temperature, because upper (front) mold temperature is high, fluidity of molten glue is good and it is not easy to cause cold glue. Low temperature products are easy to crystallize and form, temperature difference between upper (front) and lower (back) molds does not exceed 15 ℃.
③ In terms of mold temperature selection, a lower mold temperature should be selected in order to shorten molding cycle and prevent protruding; if product is required to have high dimensional stability, reduce occurrence of seams and insufficient filling, a higher mold temperature should be selected.
② Generally, mold temperature is about 140℃, upper (front) mold temperature should be higher than the lower (rear) mold temperature, because upper (front) mold temperature is high, fluidity of molten glue is good and it is not easy to cause cold glue. Low temperature products are easy to crystallize and form, temperature difference between upper (front) and lower (back) molds does not exceed 15 ℃.
③ In terms of mold temperature selection, a lower mold temperature should be selected in order to shorten molding cycle and prevent protruding; if product is required to have high dimensional stability, reduce occurrence of seams and insufficient filling, a higher mold temperature should be selected.
5. Pressure and speed
The most suitable pressure must depend on material, product shape, mold design (especially sprue, runner, gate) and other molding conditions. However, melt viscosity of LCP without any grade is very low, so pressure is lower than that of general thermoplastic resins.
It is a good method to use low pressure at the beginning of molding and then gradually increase pressure. Most molded products can be molded under pressure of 15MPa-45MPa. In addition, curing time of LCP is relatively fast, so it is easy to obtain good results if speed is fast.
It is a good method to use low pressure at the beginning of molding and then gradually increase pressure. Most molded products can be molded under pressure of 15MPa-45MPa. In addition, curing time of LCP is relatively fast, so it is easy to obtain good results if speed is fast.
6. Molding cycle
Molding cycle depends on size, shape, thickness, mold structure and molding conditions of molded product. As mentioned above, LCP has good fluidity, so its filling time is relatively short, and curing speed is relatively fast, so we can get a short molding cycle. A typical molding cycle is 10 seconds to 30 seconds.
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