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1、一 寸 光 阴 不 可 轻Chapter 3第三篇Mixing and Casting Polyurethane搅拌和聚氨酯的浇注This chapter is divided into two parts:Basic mixing and castingBackground to mixing and casting这一篇分为两部分：搅拌和浇注的基本知识；搅拌和浇注的背景。The first part covers the steps and equipment required for making a polyurethane part; the second covers more d
2、etailed aspects of the process.第一部分涵盖了制造聚氨酯件的步骤和设备要求，第二部分涵盖了聚氨酯工艺的更多的细节方面的内容。3.1 Basic Mixing and Casting 搅拌和浇注的基本知识There are two basic ways to mix polyurethane:Machine processingManually这里有两个基本的搅拌聚氨酯的方法：机器搅拌工艺和人工操作。Note: Before any handling of polyurethane chemicals or equipment, all staff and make
3、rs must be familiar with the occupational Health and Safety requirements for the use of chemicals and machinery as well as all local rules and regulations. Copies of the relevant Material Safety Data Sheets(MSDSs)must be studied and adhered to. Chapter 14 discusses the subject of health and safety i
4、n more detail.注意：在进行聚氨酯的化学试剂或设备的使用前，所有的员工及生产商必须对使用这些化学制品及设备像了解本地政策及习俗一样的熟悉。相关的材料的安全成分表的复印件必须拿来学习并坚持遵守。第14篇就是对健康和安全这一课题的详细讨论。3.1.1 Machining Processing机械制造工艺Machine processing should be carried out using the initial setting given by the raw material and the machine manufacturers. Both the machine and
5、 the machine system must be compatible with each other and capable of allowing fine adjustments. 机械的制造工艺应该通过采用聚氨酯原材料商和设备制造商提供的最初设置来进行实施。这些设备和设备系统必须彼此互相兼容且有很周密的调整适应功能。The machine must be large enough for the production to be completed without a full shutdown and recharge of the system.这个机器设备必须足够大，使得产
6、品在生产过程中不能没有一个完整的断电再充电系统。Machine casting is ideal for one-shot processes where all the ingredients are mixed in a multi-input machine. Some of the ingredients may be preblended, such as the polyols, catalysts, and extenders.机械浇注对于一次浇注成型的工艺来说是可行的，所有的配料都被混合在一个多端输入的机器中。有些配料需要被预混合，像聚氨酯，催化剂以及填充剂。3.1.2 Man
7、ually人工操作Basic equipment基础设施-Safety gloves, mask, and goggles安全手套，防毒面具以及护目镜-Molds模具-Ovens烤箱-Microwave oven微波炉-Scales电子称-Devacuuming system抽真空系统-Dry nitrogen supply干氮气供应-Mixing container搅拌锅-Stirring paddles搅拌桨-Melting pots for solid curatives(if required)加热固体激活剂的加热罐-Bonding agents 粘结力测试工具-Butane burn
8、er丁烷燃烧炉-Trimming knives修整用的刀具-Machining equipment(if required)机器设备（如果需要）-Measuring and test equipment(as required)测量及检测设备（如果需要）Basic Materials 基本原料-Prepolymers预聚物-Curatives激活剂-Alternative quasiprepolymer system可供选择的预聚化物系统-Mold release 脱模剂-Pigments颜料-Fillers填充剂-Plasticizers增塑剂（塑料桶？）-Cleaning solvents
9、干净的清洁试剂3.1.2.1 Method 方法The molding procedure is a multistep process with several steps running in parallel.这个注模过程是一个有多种步骤同时进行的复合工艺。1. Preparation准备a. Clean and bring molds to temperature清理模具并预热模具到一定温度Make any repairs修理完毕Clean surface dirt清理掉表面的灰尘Remove old mold buildup if necessaryHeat to curing te
10、mperature加热到固化温度b. Thaw prepolymers 已溶解的聚氨酯Keep in warm parts of shop 在工厂中保持它的温度Under oven 置于烤箱中Polytetramethylene glycol( PTMEG) based prone to solidify聚丁二醇倾向于固化No center milkiness中心没有乳状浑浊Roll mix to eliminate temperature variations摇晃搅拌时减少温度变化c. Melt curative if necessary加热激活剂使融化如果需要的话Do not overhe
11、at不要过热Only sufficient for day仅够1天足量的即可d. Weigh out prepolymer and curative称量预聚物和激活剂Into clean dry container彻底清理干净装的容器Maximum depth 25% of height最大深度是总深度的25%Can we use more than one container for large pours大的浇注可以使用1个以上的容器e. Bring to correct temperature调到合适的温度Bring to suppliers recommended temperatur
12、e调到供应商建议的温度Use microwave for smaller amount 可使用微波炉来加热较小的量f. Degas脱气Use vacuum pot使用真空罐Approximately 6KPa(28”Hg)vacuum真空压强在6Kpa(28”Hg)Break vacuum if too foamy如果太多的气泡需要停止抽真空2. Mixing 搅拌a. Add pigment to prepolymer 将颜料添加到聚氨酯中Some pigments need to be predispersed into the prepolymer 有些颜料需要提前加到聚氨酯中分散开b.
13、 Add curative to prepolymer in gentle stream将激活剂缓缓加入到聚氨酯中Add to mixing container in a stream连续不断的将激活剂加到搅拌的容器Pour along one edge沿着一个边倾倒c. Mix using zigzag motion or cross-blending使用曲折的动作曲线来交错双向搅拌Do not whip in air不要在空气中搅拌Clean prepolymer from edges and corners into mix聚氨酯的边边角角都要进行搅拌Clear mixes must b
14、e streak free搅拌器要清理干净Pigments must be completely dispersed颜料必须完全地在聚氨酯中扩散开d. Degas again再次脱气If required degas again provided there is sufficient pot life倘若在有效的适用期内要求再次脱气3. Pouring浇注a. Add to mold in thin stream将原料成细股状浇入模具中Rate of pouring must not block inlet in mold浇注时不能大股地注入到模具中Increase height to pr
15、event blockage during pouring在浇注过程中逐渐地增加高度来防止浇注过程中的中断b. Polyurethane must flow down mold and displace air upward聚氨酯必须流入模具中并使得空气往上排出Mold fill should be from bottom up.模具的浇注需从底部往上面来浇满All surfaces must be wetted with no adhering air bubbles.所有的覆膜面都不能有气泡附着在表面。c. Air must not be trapped in mold 空气绝对不能残留在模具中Mold must be titled and/or rotated for undercuts to be completely filledd. Polyurethane should not fold on itself聚氨酯不能靠自己来混合Polyurethane that is gelling can fold over on itself and cause fault linese. Pouring must be completed in time for air bubbles to escape b
