The mold shrinkage of polycarbonate (PC) was studied with disks, 4in. in diameter by 1/8 in. in thickness, gated radially at a single point in the edge, 5.2 mm in width by 2.6 mm in depth and 2.2mm in land length, molded with the injection molding machines of plunger or reciprocating screw type. The following results were obtained.
i) The initial shrinkage observed within 30 min after ejection was ascribed to the temperature change of PC from mold temperature to room temperature. The after shrinkage was apparently small as it was diminished by the expansion of PC caused by the absorption of humidity in air. Hence it was possible to estimate the final dimensions of disks from their initial dimensions immediately after ejection. ii) The statistically treated data indicated that PC was moldable within ±0.02% precision in diameter, provided the shape was simple with a uniform thickness. iii) The mold shrinkage varied between 46×10
-4 (mm/mm) and 114×10
-4 (mm/mm) with change in molding conditions. iv) The relationships of mold shrinkage
S (mm/mm) with nominal holding pressure
Ph, (kg/cm
2), stock temperature
TS (°C) or mold temperature
Tm (°C) were summarized in the following equations,
S×10
4=
A1-0.04
Ph (1)
S×10
4=
A2-0.51
TS (2)
S×10
4=
A3 A3-0.20
Tm (3)
where
A1 was a constant which was characteristic of pressure drop of holding pressure along the flow channel, and
A2 and
A3 were constants. The equation (3) meaned that the disk diameter became larger with increase in
Tm. This tendency resulted from the following phenomenon that the cavity dimension expanded to became larger with increase in
Tm. v) The effects of both
TS and molecular weight
Mv on
S were summed up in one single equation as a function of melt viscosity η(poise), i. e.
S×10
4=
A4+3.8×10
-3η, where
A4 was a constant. This result sugested that the change in
TS or
Mv gave rise to the change in effective holding pressure. vi) The effect of holding time or feed cushion on
S was striking, however the type of nozzle, injection pressure or injection rate did not influence
S. vii) Also the mold shrinkage of polyacetal was measured and the distinctions between PC and polyacetal were discussed.
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