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Effect of Scale-Dependent Viscosity and Transesterification on Filling Behavior of Polycarbonate/Poly(ethylene terephthalate) Blends in Micro-Injection Molding

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Abstract

This study introduces a new scale-dependent viscosity model, in which transesterification reaction of polycarbonate/poly(ethylene terephthalate) (PC/PET) blends with various phase morphologies and micro-scale effects have been taken into account. It is found that a Power-law model can be used to quantitatively describe the relationship between the degree of transesterification and shear rate employed during compounding of PC and PET. A micro-scale viscosity model, which incorporates the micro-scale effects, has been developed by characterizing the flow using a double-barrel capillary rheometer with different microscale channels. For both neat PC and PC/PET blends, under the conditions of the constant shear rate and melt temperature, the shear viscosity dropped with decreasing capillary diameter because of the wall-slip effect. The proposed viscosity model based on the Cross equation can describe the variation of shear viscosity for PC/PET blends under both macro- and micro-scale conditions. Less than 7% average error is obtained between the model predictions and rheological experimental data. Filling simulation and micro-injection molding (µIM) short-shot experiments were conducted to validate the accuracy of the proposed viscosity model. For all the L9(34) design of experiment (DOE) molding trials, the average relative error under the micro-scale condition was 4.5±1.1%, which is much smaller than that of the average relative error under the macro-scale condition at 11.4±2.7%.

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Acknowledgment

The authors would like to acknowledge the financial support received from the technological research project of Henan Province (No.202102210028), and the National Science Fund (No. U1909219 and 11372286). The technical support from the Wisconsin Institute for Discovery by hosting the visit of the corresponding author is also acknowledged.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Zhengzhou University, Zhengzhou, 450001, P. R. China

    Bozhi Cai, Yongjun Cao, Ning Zhang & Qian Li

  2. School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou, 450001, P. R. China

    Jing Jiang

  3. National Center for International Joint Research of Micro-Nano Molding Technology, Zhengzhou University, Zhengzhou, 450001, P. R. China

    Bozhi Cai, Jing Jiang, Yongjun Cao, Junwei Sun, Ning Zhang & Qian Li

Authors
  1. Bozhi Cai
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  2. Jing Jiang
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  3. Yongjun Cao
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  4. Junwei Sun
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  5. Ning Zhang
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  6. Qian Li
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Corresponding author

Correspondence to Jing Jiang.

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Supporting information

Information are available regarding the coefficients in Power-Law model for PC/PET blends (Table S1), the schematic of mesh size (Figure S2), and coefficients in presented micro-scale viscosity model (Table S2). The materials are available via the Internet at www.springer.com/13233.

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Cai, B., Jiang, J., Cao, Y. et al. Effect of Scale-Dependent Viscosity and Transesterification on Filling Behavior of Polycarbonate/Poly(ethylene terephthalate) Blends in Micro-Injection Molding. Macromol. Res. 30, 163–171 (2022). https://doi.org/10.1007/s13233-022-0023-y

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  • DOI: https://doi.org/10.1007/s13233-022-0023-y

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