CN111556803A - 发泡成型体的制造方法 - Google Patents

发泡成型体的制造方法 Download PDF

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CN111556803A
CN111556803A CN201980007481.XA CN201980007481A CN111556803A CN 111556803 A CN111556803 A CN 111556803A CN 201980007481 A CN201980007481 A CN 201980007481A CN 111556803 A CN111556803 A CN 111556803A
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大野庆词
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Kyoraku Co Ltd
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Abstract

提供一种能够使气泡形状接近正圆的发泡成型体的制造方法。根据本发明，提供一种发泡成型体的制造方法，具备利用将原料树脂和发泡气体在挤出机的料缸内熔融混炼而构成的熔融混炼树脂形成发泡型坯，将上述发泡型坯成型而得到发泡成型体的工序，上述发泡气体包含0.1～1.0％的氩气。

Description

发泡成型体的制造方法
【技术领域】
本发明涉及发泡成型体的制造方法。
【背景技术】
例如，汽车等的空调装置中，使用使空气流通的管状的空调用管道。
作为空调用管道，利用通过发泡气体使热塑性树脂发泡的发泡树脂的发泡成型体已被知晓。发泡成型体由于能够同时实现高隔热性和轻量化而其需求在扩大。
作为这种发泡成型体的制造方法，利用组合模具对熔融状态的发泡树脂进行闭模，向内部吹入空气使其膨胀的吹塑成型方法被广泛知晓(参照专利文献1)。
【现有技术文献】
【专利文献】
【专利文献1】日本专利特开2012－030498号公报
【发明内容】
【发明要解决的问题】
然而，气泡越接近正圆形状的发泡成型体其隔热性越高而优选，但气泡形状有沿着树脂流动方向变长的倾向，不容易使气泡形状接近正圆。
本发明是鉴于这样的情况而完成的，提供一种能够使气泡形状接近正圆的发泡成型体的制造方法。
【用于解决问题的手段】
根据本发明，提供一种发泡成型体的制造方法，具备利用在挤出机的料缸内熔融混炼原料树脂和发泡气体而构成的熔融混炼树脂形成发泡型坯，将上述发泡型坯成型而得到发泡成型体的工序，上述发泡气体包含0.1～1.0％的氩气。
本发明人等进行了认真研究发现，发泡气体包含0.1～1.0％的氩气时，气泡形状接近正圆，完成了本发明。
以下，例示本发明的各种实施方式。以下示出的实施方式可以相互组合。
优选，在上述的方法中，上述发泡气体包含98.0～99.9％的氮气。
优选，在上述的方法中，上述发泡气体是利用吸附剂从大气中去除氧气而得到的气体。
根据本发明的其他观点，提供一种发泡成型体的制造方法，具备利用在挤出机的料缸内熔融混炼原料树脂和发泡气体而构成的熔融混炼树脂形成发泡型坯，将上述发泡型坯成型而得到发泡成型体的工序，上述发泡气体是利用吸附剂从大气中去除氧气而得到的气体。
【附图说明】
图1表示能够在本发明的一个实施方式的制造方法中使用的发泡吹塑成型机1的一个例子。
图2表示图1中的氮气产生单元15的具体结构。
图3中，图3A是实施例1的发泡成型体的剖面照片，图3B是比较例1的发泡成型体的剖面照片。
【具体实施方式】
以下，对本发明的实施方式进行说明。以下示出的实施方式中所示的各种特征事项可以互相组合。并且，各特征事项独立地使发明成立。
本发明的一个实施方式的发泡成型体的制造方法具备以下工序：在挤出机的料缸内熔融混炼原料树脂和发泡气体而构成的熔融混炼树脂，利用该熔融混炼树脂形成发泡型坯，使上述发泡型坯成型而得到发泡成型体，上述发泡气体包含0.1～1.0％的氩气。
本实施方式的方法可利用图1所示的发泡吹塑成型机1实施。发泡吹塑成型机1具备料斗12、挤出机13、喷射器16、积存器17、模头18、组合模具19。挤出机13与积存器17通过连接管25连接。积存器17与模头18通过连接管27连接。
以下，对各构成进行说明。
＜料斗12，挤出机13＞
料斗12用于将原料树脂11投入挤出机13的料缸13a内。原料树脂11的形态没有特别限定，通常为颗粒状。原料树脂11是在由料斗12投入料缸13a内之后，在料缸13a中被加热而被熔融，从而成为熔融树脂。并且，通过配置于料缸13a内的螺旋桨的旋转，向料缸13a的前端进行搬送。螺旋桨配置于料缸13a内，通过其旋转来混炼熔融树脂的同时进行搬送。在螺旋桨的基端设置有齿轮装置，通过齿轮装置使螺旋桨旋转驱动。
＜喷射器16、气体供给装置14、氮气产生单元15、发泡气体＞
料缸13a设置有用于向料缸13a内注入发泡材料的喷射器16。喷射器16通过配管2连接气体供给装置14。
在气体供给装置14中对压力及流量进行调整的状态下，发泡气体通过喷射器16注入于料缸13a内。发泡气体优选以超临界流体的状态注入于料缸13a内。
气体供给装置14是供给发泡气体的装置，可以是将来自1个或多个储气瓶的气体作为发泡气体供给的装置，也可以是将从大气中取出期望成分的气体作为发泡气体供给的装置。
发泡气体包含0.1～1.0％的氩气即可，作为剩余的成分，可列举氮气、氧气、二氧化碳等大气中包含的气体。通过利用这种发泡气体进行发泡成型，从而提高发泡成型的气泡的正圆度。
发泡气体中的氩气浓度具体而言例如为0.1、0.2、0.3、0.4、0.5、0.6、0.7、0.8、0.9、1.0％，也可以在这里例示的任意2个数值之间的范围内。发泡气体优选包含98.0～99.9％(优选为99.0～99.9％)的氮气。发泡气体中的氮气浓度具体而言例如为98.0、98.1、98.2、98.3、98.4、98.5、98.6、98.7、98.8、98.9、99.0、99.1、99.2、99.3、99.4、99.5、99.6、99.7、99.8、99.9％，也可以在这里例示的任意2个数值之间的范围内。发泡气体中的氮气和氩气的总浓度例如为99～100％，具体而言例如为99、99.9、99.99、99.999、99.9999、100％，也可以在这里例示的任意2个数值之间的范围内。
气体供给装置14优选为利用吸附剂从大气中去除氧气的方式的氮气产生单元15。通过这种方式能够有效地去除氧气，但是无法去除大部分或所有氩气，因此在得到的发泡气体中会残留有大气中包含的氩气中的至少一部分。因此，无须另外添加氩气，即可得到包含0.1～1.0％的氩气的发泡气体。作为吸附剂，可列举活性碳或沸石等微多孔的吸附剂。
如图2所示，在一个例子中，氮气产生单元15具备：压缩机15a、罐15b、氮气产生装置15c、缓冲罐15d、压缩机15e、以及缓冲罐15f。
压缩机15a是压缩大气的设备，在制造工厂用于获得高压空气。罐15b是用于储存由压缩机15a制造的压缩空气，当配备氮气产生单元15的工厂已具备相当于压缩机15a及罐15b的设备时，无须另外准备压缩机15a和罐15b。
储存在罐15b的压缩空气用于运行氮气产生装置15c。氮气产生装置15c是利用吸附剂从压缩空气去除氧气的设备，在此，提高纯度的氮气被蓄积到缓冲罐15d。压缩机15e用于对储存在缓冲罐15d气体加压，缓冲罐15f是用于储存在压缩机15e加压的气体的设备。
应予说明，为了在制造开始时消耗大流量的发泡气体(消耗总量少)，对配管2进行分支而与氮气储气瓶连接，从而能够实现整体的小型化的同时，也能够确保设备的稳定性。
氮气产生装置15c是用于从大气中去除氧气的设备，因此无法得到运行原料用空气压以上的排出压。由压缩机15a压缩的空气为0.7MPa左右，氮气产生装置15c的排出压为0.6MPa左右的实际值。并且，在日本国内，若加压至1.0MPa以上则会被归类为“高压气体制造设备”而会变得难以销售的同时，由于没有将氮气加压至1.0MPa以上而消耗的需求，因此几乎不存在对应于加压的氮气产生装置。
另一方面，喷射器16以从储气瓶供给气体作为前提，因此以确认储气瓶残量和确保加压的稳定性为目的，需要1.5MPa以上的气压。于是，在氮气产生装置15c的紧后、即喷射器16的紧前，需要加压用的压缩机15e。若压缩机15e过大则缓冲罐15d立即变空而无法稳定地运行，若压缩机15e过小则需要一些时间来充满缓冲罐15f，因此需要选择适当大小的压缩机15e。
＜积存器17、模头18＞
从料缸13a的树脂挤出口挤出原料树脂和发泡气体熔融混炼而构成的熔融混炼树脂，通过连接管25注入积存器17内。积存器17具备料缸17a和可以在其内部滑动的活塞17b，可以在料缸17a内积存熔融树脂11a。另外，在料缸17a内积存规定量的熔融树脂11a之后使活塞17b移动，从而通过连接管27将熔融混炼树脂11a从设置于模头18内的模缝挤出而形成发泡型坯23。发泡型坯23的形状没有特别限定，可以为筒状，也可以为片状。
＜组合模具19＞
发泡型坯23被引导至一对组合模具19之间。利用组合模具19进行发泡型坯23的成型，从而得到发泡成型体。利用组合模具19的成型方法没有特别限定，可以是向组合模具19的型腔内吹入空气而进行成型的吹塑成型，也可以是从组合模具19的型腔的内表面对型腔内减压而进行发泡型坯23的成型的真空成型，也可以是其组合。
【实施例】
1.发泡成型体的制作
＜实施例1＞
利用图1所示的发泡吹塑成型机1，制作发泡成型体，进行发泡成型性的评价。挤出机13的料缸13a的内径为50mm，L/D＝34。作为原料树脂使用了以质量比30：70混合丙烯均聚物(Borealis社(Borealis AG)制造、商品名“Daploy WB140”)、长链分支聚丙烯(日本Polypro株式会社制造、商品名“EX6000K”)，相对于树脂100质量份，作为成核剂添加包含20wt％的碳酸氢钠系发泡剂的以LDPE为基础的母料(大日精化工业株式会社制造、商品名“FinecellMaster P0217K”)1.0质量份、以及作为着色剂添加包含40wt％的碳黑的以LLDPE为基础的母料1.0质量份的原料。对各个部位进行温度控制，以使发泡型坯23的温度为190～200℃。使螺旋桨的旋转数为60rmm，挤出量为20kg/hr。
作为发泡气体，通过喷射器16将由图2所示的氮气产生单元15产生的气体注入料缸13a内。作为氮气产生装置15c，使用了利用微多孔的吸附剂吸附氧气的PSA方式的装置。氮气和氩气的总浓度为99.990％。由于利用吸附剂无法去除大部分或所有氩气，实施例1的发泡气体中的氩气浓度为0.1～1.0％。
利用由以上的条件形成的发泡型坯，将圆筒状的成型体配置在用于成型的组合模具之间。接着，对其组合模具进行闭模之后，以0.1MPa的压力将空气吹入发泡型坯内，从而进行吹塑成型，制作了φ50mm、高度100mm且厚度5mm的圆筒状的发泡成型体。
＜比较例1＞
在比较例1中，作为发泡气体，使用了填充有通过深冷分离法生成的氮气的氮气储气瓶的气体，除此之外，以与实施例1同样的方法制作了发泡成型体。
发泡气体中的氮气和氩气的总浓度为99.995％。可通过深冷分离法去除氩气，因此发泡气体中几乎或完全不会残留有氩气，其浓度小于0.1％。
2.评价
将实施例1及比较例1的发泡成型体的剖面照片示于图3A～图3B。如图3A～图3B所示，与比较例1的发泡成型体相比，实施例1的发泡成型体的气泡的正圆度明显更高。
并且，测定了实施例1及比较例1的发泡成型体的表面粗度(Ra)，结果分别为8.5μm及9.6μm。该结果表示，与比较例1的发泡成型体相比，实施例1的发泡成型体的表面光滑。
【符号的说明】
1：发泡吹塑成型机、2：配管、11：原料树脂、11a：熔融混炼树脂、12：料斗、13：挤出机、13a：料缸、14：气体供给装置、15：氮气产生单元、15a：压缩机、15b：罐、15c：氮气产生装置、15d：缓冲罐、15e：压缩机、15f：缓冲罐、16：喷射器、17：积存器、17a：料缸、17b：活塞、18：模头、19：组合模具、23：发泡型坯、25：连接管、27：连接管

Claims (4)

1.一种发泡成型体的制造方法，具备：
利用在挤出机的料缸内熔融混炼原料树脂和发泡气体而构成的熔融混炼树脂形成发泡型坯，将所述发泡型坯成型而得到发泡成型体的工序，
所述发泡气体包含0.1～1.0％的氩气。
2.根据权利要求1所述的制造方法，其特征在于，
所述发泡气体包含98.0～99.9％的氮气。
3.根据权利要求1或2所述的制造方法，其特征在于，
所述发泡气体是利用吸附剂从大气中去除氧气而得到的气体。
4.一种发泡成型体的制造方法，具备：
利用在挤出机的料缸内熔融混炼原料树脂和发泡气体而构成的熔融混炼树脂形成发泡型坯，将所述发泡型坯成型而得到发泡成型体的工序，
所述发泡气体是利用吸附剂从大气中去除氧气而得到的气体。
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