High transparent acrylic processing

The most important properties of acrylate resins are their transparency, good optical properties, surface hardness, chemical resistance, and good weather resistance. Its transparency is close to the crystal and its density is only half of the crystal. It can be processed into fibers, sheets, films, profiles, tubes, etc. The material is supplied in pellet form and can be extruded, calendered or injection molded.

Acrylic resin refers to a large family of resins that are tough and transparent. Acrylate resins can be used alone, in combination, or contain some other monomer, so that the properties of the polymer range from soft and flexible to hard or strong.

This polymer is formed by the polymerization of methacrylic acid monomer (MMA) with esters or amine, acrylic or methacrylic acid derivatives. Acrylates are free-radical polymers that are catalyzed by peroxides or nitrogen-containing compounds. The polymer can also be obtained by redox polymerization.

Polymethyl methacrylate (PMMA) is the most important homopolymer in the acrylate family and can be produced by bulk, suspension, emulsion or solution polymerization. The addition of pigments or dyes can produce transparent or translucent resins of various colors. Blending with vinyl, butadiene, acrylic, or polyester can improve the physical properties of the material.

Many PMMA resins used for injection molding have different molecular weights, resulting in different flow rates, heat resistance and toughness. PMMA resins rated 5, 6, and 8 by ASTM standards have a medium molecular weight. Changes in the formulation change the flow rate and heat resistance while exhibiting a certain degree of toughness. In addition to similar flow and heat resistance, high molecular weight grades of PMMA resins are also tougher. Due to their excellent resistance to fracture during assembly and transport, these grades of resins also become the first choice for extrusion molding. In injection molding, these grades not only exhibit good fracture resistance, but are also easily filled with complex molds.

The visible light transmittance reaches 92%, and the turbidity is less than 2%. The ordinary grade acrylic resin products are somewhat sensitive to notches, have low electrical conductivity, have good arc resistance, and have excellent dielectric strength. Sheet products are usually cast (by injecting MMA or the like between two smooth glass plates with a gasket or clip, ie, different thicknesses can be obtained). This is a batch process. Since this reaction is an exothermic reaction, it is necessary to control the reaction rate so as to avoid bubble generation.

Another method of producing sheets is to use continuous casting, which involves placing the polymer between two moving smooth stainless steel belts. In addition, sheets can also be produced using extrusion or calendering methods. Each of these methods has advantages and disadvantages. It cannot be said that one of the processing methods is necessarily better than the other. Typically, cast acrylate resin products have better optical properties and a smoother surface; sheets produced using the continuous process can achieve longer sheets with less variation in thickness than cast molding; extrusion or calendering methods are generally preferred Casting costs are low.

For fracture-resistant applications, impact-modified pellets are generally used to produce sheets by extrusion. This method generally requires the extruder screw to have a longer aspect ratio (L/D) so that the melt in the die can be better controlled. In order to improve the melt quality, static mixers are also installed between the screw and the die.

To ensure a high downstream downstream of the die, the reels require better polishing. Embossing the pattern on the roller can bring different surface polishing effects or other special effects to the sheet. Acrylic resin can be co-extruded with vinyl or ABS resin as the core layer of the sandwich structural panel, so that the panel has the function of UV resistance, heat insulation or protection of a smooth surface.

PMMA can be processed using a conventional injection molding machine. Since the resin is a hygroscopic material like nylon and polyester, the material must be dried prior to injection, otherwise the exhaust pipe must be installed on the injection machine. PMMA's viscosity is high. In order to produce high-quality products, the injection pressure of this material is generally selected higher than other thermoplastics. In the processing of some special products, such as car taillights, the molds usually need to be plated with chromium to obtain a smooth surface. At the same time, the mold exhaust function is also very important.

The elastic memory is very good, and the sheet can be produced using a universal thermoforming apparatus. Because of the low hot melt strength, PMMA is limited in blow molding, which means that extrusion blow molding of unmodified acrylate resin is very difficult. However, it can be processed by injection molding and then heated to complete blow molding.

Plexiglass is an important application of PMMA, especially for aircraft glare windows. Although it may be less than other applications in absolute usage, it plays a very important role in aircraft.

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