1、模垢的形成
1, the formation of scale

 
几乎所有热塑性塑料注塑成型时都会发生模垢。当最终产品的功能要求必须混入相关的添加物时(例如改质剂、防火剂等)，成型过程中，这些添加物非常可能残留在模穴表面，导致形成模垢。
Almost all thermoplastic injection molding mold can occur in a scale. When the final product function requirements must be mixed with additives (such as modification agent, fire prevention agent, etc.), molding process, these additives are very may remain in the cavity surface, lead to form scale.

 
图：模垢案例(模垢是指在模具表面上有附着物析出的一种现象)
Graph: die scale case with scale refers to the mold surface (die attachments to precipitate a phenomenon)

 
模垢的形成还有其他方面的原因，最常见的原因如下：
Die scale formation and other reasons, the most common reasons are as follows:

 
▶原料的热分解产物;
▶ raw material thermal decomposition products;

 
▶注射成型时，熔体流动极端的剪切力;
▶ injection molding, melt flow extreme shear force;

 
▶不适当的排气;
▶ inappropriate exhaust;

 
如上造成的模垢时常是不同因素的组合产物，并且寻求发现这些模垢究竟是什么原因造成及如何去预防，非常的麻烦，并且模垢在数日之后才会形成。
As above model scale is often caused by a combination of different factors, and seek to find these mould scale what causes and how to prevent, very trouble, and the model scale form in a few days before.

 
2、模垢的类别
2, model scale categories

 
1)各种添加剂产生特定类别的模垢。防火剂在高温时会起反应，形成分解并可能产生模垢产品。抗冲击剂在过度高温或极端剪切力的影响下，将从聚合物中分离并残留在模穴表面形成模垢。
1) all kinds of additives in a special category of scale. Fire retardant in the high temperature will react to form decomposition model and could produce scale products. Impact resistant agent in excessive heat or extreme under the influence of shear force, the separation from the polymer and residual scale formed in the cavity surface mould.

 
2)热塑性工程塑胶中的颜料在高温下熔化，将降低成型原料的热稳定性，结果造成降解的聚合物和分解的颜料组合形成模垢。
2) thermoplastic engineering plastic pigment in the heat of melting, will reduce the thermal stability of molding material, the result of biodegradable polymers and decomposition of pigment combination formed scale.

 
3)模具上特别热的零件(如模芯),改质剂/安定剂和其他添加剂可能黏附其表面并造成模垢。在此情形下,必须采取措施达成更好模具温度控制或使用特别的安定剂。
(3) the mold especially hot parts such as mold core), modification agent/stabilizer and other additives can stick the surface and cause model scale. In this case, measures must be taken to reach a better mold temperature control or use special stabilizer.

 
下列表格列出造成模垢的可能原因和预防发生措施：
The following table lists may cause of model scale and preventive measures:

 
3、突然发生的模垢对策
3, sudden die scale countermeasures

 
如果突然发生模垢，可能是由于成型条件的变更，或者因为更换不同批的成型原料。下列建议有助于改善模垢。
If a sudden die scale, may be due to the change in the molding conditions, change or because different batch of molding material. The following Suggestions will help improve the model scale.

 
首先，测量熔胶温度和目视检查熔胶是否有分解现象(如烧焦颗粒)。同时检查成型原料是否有外来物质污染，是否使用相同的清除原料。检查模具的排气状况。
First of all, melt temperature measurement and visual check for decomposition melt phenomenon (e.g., scorched particles). At the same time to check whether there is foreign material molding material pollution, whether or not to use the same clear material. Check the mold exhaust conditions.

 
再次，检查运作的机器：使用染料着色的成型原料(黑色除外)，约20分钟后关闭注塑机，拆除喷嘴、连接座，若可能同螺杆一起拆除，检查原料是否有烧焦的颗粒，进行原料颜色比较，迅速找出模垢来源。
Again, check the operation of the machine: using dye forming raw materials (except black), about 20 minutes after close the injection molding machine, demolition of nozzle, connection, and if possible with screw removed, check whether the raw material is burning in the grain, raw material color comparison, quickly find out the source of scale.

 
在许多案例中发现出令人惊讶的模垢缺陷原因。这项技术最适用于较小的注塑机，最大为40mm螺杆直径。模垢的消除还使成型其他原料时，制件的品质得到明确改善。上述对策也适用于有热流道系统的成型。
In many cases the current surprising model scale defects. The technology are best suited for small injection molding machine, screw diameter of 40 mm. Die scale remove also make molding other raw materials, improve the quality of the parts clearly. The above countermeasures is also applicable to forming of hot runner system.

 
模具模垢导致注塑制件外观缺陷，特别是有表面蚀纹的制件，可通过喷砂机喷砂处理进行制件表面修补。
Die scale lead to injection molding parts appearance defects, especially with etch the surface of the parts, by sandblasting sand blasting machine parts surface repair.

 
4、模具的保养
4, mold maintenance

 
使用上述所有措施无法消除模垢时，必须加强该模具保养和维护。
Using all of the above measures cannot eliminate mode scale, must strengthen the mold maintenance and maintenance.

 
模具表面模垢形成初期比较容易清除，因此模穴和排气通道必须定时清理和保养(例如在每批成型生产后)。长时间不进行模具保养和维护，模具形成较厚层模垢后清除非常困难和耗时。
Early model scale formation on the surface of mould is relatively easy to remove, so cavity and exhaust channel must be regularly cleaned and maintenance (e.g.) after each batch of molding production. Long time not to mold maintenance and maintenance, mold forming thicker layer model scale removal after very difficult and time-consuming.

 
注塑模具保养和维护所用的喷剂主要有：脱模剂、防锈剂、顶针油、胶渍清除剂、模具清洗剂等。
Injection mold spray are mainly used in the maintenance and maintenance: release agent, anti-rust agent, thimble oil, glue stains removal agent, mold cleaning agents, etc.

 
模垢的化学组成非常复杂，必须使用和尝试新的方法清除，如一般溶剂和各种特殊溶剂、烤炉喷剂、含咖啡因的柠檬水等。另类奇特方式有使用清洁模型轨道用橡胶。
Die scale chemical composition is very complicated, and must be used to try new methods to remove, such as general solvent and all kinds of special solvents, oven spray, caffeinated lemonade, etc. Strange alternative ways of using clean model orbit with a rubber.

 
5、预防模垢的建议
5, die scale prevention advice

 
使用热流道成型和热敏感原料时，熔体驻留时间将会变长，由此增加了原料分解形成模垢的风险。对注塑机螺杆进行清理。
Use of hot runner molding and heat sensitive material, melt dwell time will be longer, thus increase the risk of die material break down to form scale. For injection molding machine screw to clean up.

 
成型剪切力敏感的原料时使用尺寸较大的流道和浇口，多点浇口可减少流动距离，低射出速度，降低形成模垢的风险。
Forming shear force sensitive materials when the runner and gate with large size, more gate can reduce the flow distance, low speed, reduce the risk of scale forming die.

 
有效率的模具排气可减少形成模垢的可能，在模具设计阶段设置适当的模具排气。自动清除排气系统，或能轻易去除模垢的排气方式是最佳选择，排气系统的改善经常导致模具上模垢的减少。
Efficient mold exhaust can reduce the possibility of forming die scale, in the mold design stage set appropriate mold venting. Automatic removal of exhaust system, or can easily remove dirty way of exhaust is the best choice, and the improvement of the exhaust system often lead to a drop in the mold die scale.

 
在模穴表面覆盖特别的不粘涂层，可防止模垢的形成，应进行测试评估涂覆的效果。
In the cavity surface cover special non-stick coating, can prevent the formation of scale model, should be evaluated for testing the effect of the coating.

 
模具内表面进行钛氮化物处理可避免在模具上形成模垢。
Die surface of titanium nitride treatment can avoid scale on the mould forming die.