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01 Eliminate the influence of injection molding machine and mold factors
It is necessary to choose an injection molding machine with the same capacity as the injection product. If the injection molding machine has problems such as material dead ends, it is best to replace the equipment. The chromatic aberration caused by the mold gating system and the exhaust groove can be solved by the maintenance mold of the corresponding part of the mold. The problem of injection molding machine and mold must be solved first before production can be organized to reduce the complexity of the problem.
02Eliminate the influence of raw resin and color masterbatch
Controlling raw materials is the key to completely solving chromatic aberration. Therefore, especially when producing light-colored products, the obvious influence of the different thermal stability of the raw material resin on the color fluctuation of the product cannot be ignored. In view of the fact that most injection molding manufacturers do not produce plastic masterbatch or color masterbatch themselves, the focus of attention can be placed on production management and raw material inspection. That is to strengthen the inspection of raw materials storage; the same product in the production is produced by the same manufacturer, the same brand of masterbatch, and color masterbatches; for color masterbatches, we must conduct random inspections before mass production. In this comparison, if the color difference is not large, it can be considered qualified. Just as the batch of color masterbatch has a slight color difference, the color masterbatch can be re-mixed and used to reduce the color difference caused by uneven mixing of the color masterbatch itself. At the same time, we also need to focus on testing the thermal stability of the raw resin and color masterbatch. For those with poor thermal stability, we recommend that the manufacturer replace them.
03Eliminate the influence of uneven mixing of masterbatch and masterbatch
Poor mixing of plastic masterbatch and color masterbatch will also make the product color change impermanent. After the masterbatch and color masterbatch are mechanically mixed and sent into the hopper through the lower suction material, the color masterbatch is separated from the masterbatch due to static electricity and is easily adsorbed on the hopper wall. This will inevitably cause the amount of color masterbatch in the injection cycle to change, resulting in Chromatic aberration. In this case, the raw material can be sucked into the hopper and then manually stirred. For the production of colored products by adding toner, the most effective way is to use a hot air dryer instead of a suction machine to prevent the color difference caused by separation of the toner from the master batch.
04Reduce the influence of barrel temperature on chromatic aberration
In the production, it is often encountered that a certain heating ring is damaged or failed or the heating control part is out of control and the temperature of the barrel changes drastically, resulting in a color difference. The chromatic aberration caused by this kind of reason is easy to determine. Generally, the chromatic aberration caused by the failure of the heating ring will be accompanied by uneven plasticization, and the out-of-control heating of the heating control part is often accompanied by product air spots, severe discoloration and even coking. Therefore, it is necessary to check the heating part frequently during production, and replace and repair it in time when the heating part is found to be damaged or out of control, so as to reduce the chance of this kind of color difference.
05Reduce the impact of injection molding process adjustment
When the injection molding process parameters need to be adjusted for non-chromatic aberration reasons, do not change the injection temperature, back pressure, injection cycle and the amount of masterbatch added as much as possible. The adjustment also needs to observe the effect of process parameter changes on the color and luster. If color aberration is found, it should be adjusted in time. Avoid the use of injection molding processes that cause strong shearing effects such as high injection speed and high back pressure as much as possible to prevent color difference caused by local overheating or thermal decomposition. Strictly control the temperature of each heating section of the barrel, especially the nozzle and the heating part close to the nozzle.
06 Grasp the influence of barrel temperature and color masterbatch volume on product color changes
Before adjusting the color difference, it is necessary to know the trend of the product color with the temperature and the amount of color masterbatch. With the change of the production temperature or the amount of color masterbatch, the color change law of the product is different. The color test process can be used to determine its changing law. Unless the color change law of this color masterbatch is known, it is impossible to adjust the color difference quickly, especially when using a new color masterbatch.