CN109382507A - 粉末射出成型喂料及其制备方法 - Google Patents
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Abstract
一种粉末射出成型喂料的制备方法,包括步骤:提供烧结粉末及高温骨架粘结剂并将该金属粉末及该高温骨架粘结剂进行第一次密炼,得到一混合物料;将该混合物料二次粉碎;及提供一主粘结剂并把该主粘结剂与粉碎后的该混合物料混合进行第二次密炼,以得到该喂料;该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度,微观上,该喂料的表层产生了“烧结粉末‑高温骨架粘结剂‑主粘结剂”的结合关系。本发明还涉及一种粉末射出成型喂料。
Description
技术领域
本发明涉及粉末射出成型领域,尤其涉及一种粉末射出成型喂料及其制备方法。
背景技术
随着手持式装置的轻薄化发展,为了改善微型化、薄形化后的零件强度,金属粉末射出成型(Metal Injection Molding,MIM)得以广泛使用。
但是,零件的微型化、薄形化也造成了烧结的困难。尤其机构设计者,常常为了降低机构件数,设计出具有高度复杂的特征。而MIM烧结过程中,主要靠热脱时期的棕胚的粘结剂及烧结的高温段的金属间互相扩散的结合力来维持自身外形。此复杂的外型,若烧结的刚性不足,其将受收缩力、重力等各种力量交互作用影响,并在过程中产生各式形变。
就目前的骨架粘结剂材料而言,以聚丙烯(polypropylene,PP)当骨架粘结剂,该PP在300~400℃左右即行裂解,此时金属粉的烧结效应不明显。因此在综合强度(综合强度=粘结剂强度+烧结强度)上,产生一强度低谷,若此低谷的强度过弱,即可能造成产品在烧结时的变型、扭曲甚至断裂。
以前习知方式是采用高玻璃化转变温度的高分子与塑基(例如聚甲醛(polyformaldehyde,POM))喂料或蜡基(石蜡)喂料同时进行密炼,但由于兼容性不佳,故现有市面上,并无此类成熟产品,多数是以PP或PE做骨架粘结剂。
发明内容
有鉴于此,有必要提供一种能够有效改善烧结时变形、扭曲及断裂的粉末射出成型喂料的制备方法及粉末射出成型方法。一种粉末射出成型喂料,该喂料包括烧结粉末、高温骨架粘结剂及主粘结剂,该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度,微观上,该喂料的表层产生了“烧结粉末-高温骨架粘结剂-主粘结剂”的结合关系。
进一步地,该高温骨架粘结剂为聚甲基丙烯酸甲酯或聚碳酸酯中的至少一种作为骨架剂的粘结剂。
进一步地,该主粘结剂为塑基粘结剂、蜡基粘结剂中的至少一种。
进一步地,该高温骨架粘结剂包覆该烧结粉末,该主粘结剂包覆该高温骨架粘结剂。
进一步地,该烧结粉末在该喂料中所占的体积百分比为55%~70%,该高温骨架粘结剂及该主粘结剂在该喂料中所占的体积百分比为30%~45%。
进一步地,该高温骨架粘结剂在该高温骨架粘结剂及该主粘结剂中所占的体积百分比为5%~20%。
进一步地,该喂料还包括辅剂。
进一步地,微观上,该喂料的表层还产生了“烧结粉末-高温骨架粘结剂-主粘结剂-辅剂”的结合关系。
一种粉末射出成型喂料的制备方法,包括步骤:提供烧结粉末及高温骨架粘结剂并将该金属粉末及该高温骨架粘结剂进行第一次密炼,得到一混合物料;将该混合物料二次粉碎;及提供主粘结剂并把该主粘结剂与粉碎后的该混合物料混合进行第二次密炼,以得到该喂料;该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度,微观上,该喂料的表层产生了“烧结粉末-高温骨架粘结剂-主粘结剂”的结合关系。
进一步地,该第一次密炼的密炼温度大于该高温骨架粘结剂的玻璃化转变温度,该第二次密炼的密炼温度大于该主粘结剂的玻璃化转变温度。
进一步地,在二次成粉的步骤之后,还包括步骤:添加辅剂,微观上,该喂料的表层还产生了“烧结粉末-高温骨架粘结剂-主粘结剂-辅剂”的结合关系。
与现有技术相比,本发明提供的粉末射出成型喂料的制备方法及粉末射出成型方法,采用了两种不同玻璃化转变温度的骨架粘结剂,且采用分段密炼模式(第一次密炼-二次粉碎-第二次密炼),1)当该喂料经由射出成型的高温高压时,两颗粉末表面的骨架粘结剂会重新再黏合,进而将烧结粉末再沾附一起,可以达成生胚成型效果。由于采用了高温,在烧结的前期,会保有较高的粘结剂强度,使烧结过程中会出现的综合强度的强度低谷的强度(刚性)值不会过低,可有效改善烧结时的变型、扭曲甚至断裂。2)由于先对该高温骨架粘结剂进行第一次密炼,二次粉碎之后再与主粘结剂进行第二次密炼,使得该高温骨架粘结剂及该主粘结剂具有较好的相容性。
具体实施方式
为能进一步阐述本发明达成预定发明目的所采取的技术手段及功效,以下结合较佳实施方式,对本发明提供的一种粉末射出成型喂料及其制备方法,作出如下详细说明。
本发明提供一种粉末射出成型喂料,该喂料包括烧结粉末、高温骨架粘结剂及主粘结剂。
其中,该高温骨架粘结剂包覆该烧结粉末,该主粘结剂包覆该高温骨架粘结剂。
微观上,该喂料的表层产生了“烧结粉末-高温骨架粘结剂-主粘结剂”的结合关系。
在该喂料中,该烧结粉末所占的体积百分比为55%~70%,该高温骨架粘结剂及该主粘结剂所占的体积百分比为30%~45%。该高温骨架粘结剂在该高温骨架粘结剂及该主粘结剂中所占的体积百分比为5%~20%。
其中,该烧结粉末为微米级金属粉末、陶瓷粉末等中的至少一种。
在本实施例中,该烧结粉末为金属粉末。
具体地,该金属粉末可以为铜、铁、硅、钨、镍、钴、铬、钼等常见烧结用烧结粉末中的至少一种。
其中,该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度。
其中,该高温骨架粘结剂为聚甲基丙烯酸甲酯(polymethyl methacrylate,PMMA)或聚碳酸酯(polycarbonate,PC)等高玻璃化转变温度的高分子聚合物。
在本实施例中,该高温骨架粘结剂为PC。
其中,该主粘结剂为塑基粘结剂、蜡基粘结剂等。在本实施例中,该主粘结剂为塑基粘结剂。
在本实施例中,该主粘结剂为聚甲醛(polyformaldehyde,POM)粘结剂。
当然,为了增加该主粘结剂与该高温骨架粘结剂之间的结合力,该喂料还包括辅剂,该辅剂分散于该喂料中。微观上,该喂料的表层还产生了“烧结粉末-高温骨架粘结剂-主粘结剂-辅剂”的结合关系。
其中,该辅剂可以是流动改性剂、增韧相容剂等。
具体地,流动改性剂品种有聚丙烯流动改性剂,PC.ABS流动改性剂,聚酯流动改性剂,高抗冲聚苯乙烯流动改性剂等。
具体地,增韧相容剂可以为环状酸酐型相容剂、羧酸型相容剂、环氧型相容剂、恶唑啉型相容剂、酰亚胺型相容剂、异氰酸酯型相容剂等。
本发明较佳实施方式提供一种粉末射出成型喂料的制备方法,该粉末射出成型喂料的制备方法包括如下步骤:
第一步,提供适量的烧结粉末及适量的高温骨架粘结剂,并将该烧结粉末及该高温骨架粘结剂加入到密炼机中进行密炼,得到一混合物料。
其中,该烧结粉末为微米级金属粉末、陶瓷粉末等中的至少一种。
其中,该金属粉末可以为铜、铁、硅、钨、镍、钴、铬、钼等常见烧结用烧结粉末中的至少一种。
其中,该烧结粉末在该喂料中所占的体积百分比为55%~70%。
其中,该高温骨架粘结剂为聚甲基丙烯酸甲酯(polymethyl methacrylate,PMMA)或聚碳酸酯(polycarbonate,PC)等高玻璃化转变温度的高分子聚合物。
在本实施例中,该高温骨架粘结剂为PC。
其中,该第一次密炼的密炼温度大于该高温骨架粘结剂的璃化转变温度。
在本实施例中,该第一次密炼的密炼温度大于250℃。
其中,该第一次密炼的密炼时间为20min~1h。
其中,该混合物料呈块状或团状,在该混合物料中,该高温骨架粘结剂包覆该烧结粉末。
第二步,将该混合物料冷却至室温并进行二次粉碎。
其中,该二次粉碎可以通过机械粉碎、高压粉碎等方式。在本实施例中,采用将混合物料冷却至室温之后,机械粉碎。
第三步,提供一主粘结剂并将该主粘结剂与冷却后的该混合物料加入到密炼机中进行密炼,得到该喂料。
其中,在该喂料中,该主粘结剂包覆该高温骨架粘结剂。该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度。
其中,该高温骨架粘结剂及该主粘结剂在该喂料中所占的体积百分比为30%~45%,该高温骨架粘结剂在该高温骨架粘结剂及该主粘结剂中所占的体积百分比为5%~20%。
其中,该主粘结剂为塑基粘结剂、蜡基粘结剂等。
在本实施例中,该主粘结剂为塑基粘结剂。优选地,该主粘结剂为聚甲醛(polyformaldehyde,POM)粘结剂。
其中,该第二次密炼的密炼温度大于该主粘结剂的玻璃化转变温度。
当然,为了增加该主粘结剂与该高温骨架粘结剂之间的结合力,在进行第二次密炼之前,还可以根据喂料的配方,提供适量的辅剂,并将该辅剂与该第二骨架粘结及该混合物料一起进行第二次密炼,以得到该喂料。
其中,该辅剂可以是流动改性剂、增韧相容剂等。
具体地,流动改性剂品种有聚丙烯流动改性剂,PC.ABS流动改性剂,聚酯流动改性剂,高抗冲聚苯乙烯流动改性剂等。
具体地,增韧相容剂可以为环状酸酐型相容剂、羧酸型相容剂、环氧型相容剂、恶唑啉型相容剂、酰亚胺型相容剂、异氰酸酯型相容剂等。
下面通过实施例对本发明进行具体说明。
实施例
提供体积百分比依次为60:35:5的金属粉末、PC骨架粘结剂及POM粘结剂,并将该金属粉末及该PC骨架粘结剂加入到密炼机中进行第一次密炼,得到一混合物料。该第一次密炼的密炼温度是265℃,密炼时间为40min;将混合物料冷却至室温并将之粉碎;其中,冷却时间是25min;将冷却后的该混合物料及该POM粘结剂加入到密炼机中进行第二次密炼,得到一喂料,其中,该第二次密炼的密炼温度是190℃,密炼时间为60min。
当该喂料经过射出成型机射出成型后,还需要经过催化脱脂及烧结。在催化脱脂阶段,该主粘结剂(POM粘结剂)在硝酸蒸汽下会变成甲醛气体挥发出去,从而使得成型后的该喂料的内部形成多孔的结构。此时,在成型后的该喂料中,不同的烧结粉末通过该高温骨架粘结剂(PC骨架粘结剂)粘结在一起。在烧结前期,由于该高温骨架粘结剂(PC骨架粘结剂)的玻璃化转变温度比较高,该高温骨架粘结剂(PC骨架粘结剂)主要对成型后的该喂料起到支撑作用,使其能够保持成型时的形状,而在烧结的后期,该高温骨架粘结剂(PC骨架粘结剂)才会从成型后的该喂料中去除。
与现有技术相比,本发明提供的粉末射出成型喂料的制备方法及粉末射出成型方法,采用了两种不同玻璃化转变温度的骨架粘结剂,且采用分段密炼模式(第一次密炼-二次粉碎-第二次密炼),1)当该喂料经由射出成型的高温高压时,两颗粉末表面的骨架粘结剂会重新再黏合,进而将烧结粉末再沾附一起,可以达成生胚成型效果。由于采用了高温,在烧结的前期,会保有较高的粘结剂强度,使烧结过程中会出现的综合强度的强度低谷的强度(刚性)值不会过低,可有效改善烧结时的变型、扭曲甚至断裂。2)由于先对该高温骨架粘结剂进行了第一次密炼,二次粉碎之后再与该主粘结剂进行第二次密炼,使得该高温骨架粘结剂及该主粘结剂主粘结剂具有较好的相容性。
另外,对于本领域的普通技术人员来说,可以根据本发明的技术构思做出其它各种相应的改变与变形,而所有这些改变与变形都应属于本发明权利要求的保护范围。
Claims (10)
1.一种粉末射出成型喂料,该喂料包括烧结粉末及主粘结剂,其特征在于,该喂料还包括高温骨架粘结剂,该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度;微观上,该喂料的表层产生了“烧结粉末-高温骨架粘结剂-主粘结剂”的结合关系。
2.如权利要求1所述的粉末射出成型喂料,其特征在于,该高温骨架粘结剂为聚甲基丙烯酸甲酯、聚碳酸酯中的至少一种作为骨架剂的粘结剂。
3.如权利要求1所述的粉末射出成型喂料,其特征在于,该主粘结剂为塑基粘结剂、蜡基粘结剂中的至少一种。
4.如权利要求1所述的粉末射出成型喂料,其特征在于,该高温骨架粘结剂包覆该烧结粉末,该主粘结剂包覆该高温骨架粘结剂。
5.如权利要求1所述的粉末射出成型喂料,其特征在于,该烧结粉末在该喂料中所占的体积百分比为55%~70%,该高温骨架粘结剂及该主粘结剂在该喂料中所占的体积百分比为30%~45%;该高温骨架粘结剂在该高温骨架粘结剂及该主粘结剂中所占的体积百分比为5%~20%。
6.如权利要求1所述的粉末射出成型喂料,其特征在于,该喂料还包括辅剂。
7.如权利要求6所述的粉末射出成型喂料,其特征在于,微观上,该喂料的表层还产生了“烧结粉末-高温骨架粘结剂-主粘结剂-辅剂”的结合关系。
8.一种粉末射出成型喂料的制备方法,包括步骤:
提供烧结粉末及高温骨架粘结剂并将该烧结粉末及该高温骨架粘结剂进行第一次密炼,得到一混合物料;
将该混合物料二次粉碎;及
提供一主粘结剂并把该主粘结剂与二次粉碎后的该物料混合物进行第二次密炼,以得到该喂料;
其中,该高温骨架粘结剂的玻璃化转变温度大于该主粘结剂的玻璃化转变温度,微观上,该喂料的表层产生了“烧结粉末-高温骨架粘结剂-主粘结剂”的结合关系。
9.如权利要求8所述的粉末射出成型喂料的制备方法,其特征在于,该第一次密炼的密炼温度大于该高温骨架粘结剂的玻璃化转变温度,该第二次密炼的密炼温度大于该主粘结剂的玻璃化转变温度。
10.如权利要求8所述的粉末射出成型喂料的制备方法,其特征在于,在二次成粉的步骤之后,还包括步骤:添加辅剂,以使得微观上,该喂料的表层还产生了“烧结粉末-高温骨架粘结剂-主粘结剂-辅剂”的结合关系。
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