JP2007130982A - 超臨界流体を用いた熱可塑性樹脂の射出成形方法 - Google Patents
超臨界流体を用いた熱可塑性樹脂の射出成形方法 Download PDFInfo
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
【解決手段】 可塑化シリンダー内の溶融樹脂の充填量を計量することと、計量終了時のスクリューの位置から、スクリューを回転させることなく所定距離後退させるとともに、可塑化シリンダー内の溶融樹脂に超臨界流体を導入することと、溶融樹脂の圧力を検出することと、圧力に基づいてスクリューの射出開始位置を決定することとを含む射出成形方法により上記課題を解決する。
【選択図】 図5
Description
実施例1で用いたプラスチック射出成形装置の概略構成を図1に示した。この例で用いたプラスチック射出成形装置は、図1に示すように、射出成形機部201と、超臨界流体発生装置部202とから構成される。
まず、超臨界二酸化炭素の生成及び金属錯体の溶解方法について説明する。二酸化炭素ボンベ4に蓄えられた5〜7MPaの液化二酸化炭素が、フィルター20を介して連続フローシステム1に導入される。そして、連続フォローシステム1内のシリンジポンプの少なくとも1台では、導入された二酸化炭素に対して、所定圧力(10MPa)で常時昇圧および圧力保持がなされ、超臨界二酸化炭素が生成される。そして、連続フォローシステム1で生成された超臨界二酸化炭素は常時溶解槽2に導入される。40℃に昇温された溶解槽2には金属錯体であるヘキサフルオロアセチルアセトナトパラジウム(II)金属錯体が過飽和になるように仕込まれており、連続フローシステム1から導入された超臨界二酸化炭素に常時、金属錯体が飽和溶解している。この際、溶解槽2の圧力計16は10MPaに表示されている。
まず、この例で用いたプラスチック射出成形装置について説明する。この例で用いたプラスチック射出成形装置の概略構成を図9に示した。この例で用いたプラスチック射出成形装置は、図9に示すように、射出成形機部201と、超臨界流体発生装置部202と、カウンタープレッシャー導入装置部203とから構成される。
次に、この例の射出成形方法を説明する。最初に、次のようにして、カウンタープレッシャー用の二酸化炭素を生成した。なお、カウンタープレッシャー用のガスとしては、不活性ガスであれば任意のものを用いることができ、二酸化炭素以外では、窒素、空気等の不活性ガスが用い得る。まず、二酸化炭素ボンベ4からブースターポンプ36に二酸化炭素を供給し、ブースターポンプ36にて二酸化炭素を昇圧して、カウンタープレッシャー用の加圧二酸化炭素を生成した。次いで、減圧弁38を介して加圧二酸化炭素をバッファータンク35に貯蔵した。この際、圧力計37の表示が6MPaになるように二酸化炭素を減圧してバッファータンク35に貯蔵した。
この例の射出成形方法は次の通りである。ただし、この例では、実施例1と同様の装置(図1参照)を用いて、熱可塑性樹脂の表面改質及び射出成形を行った。
比較例1では、サックバック後、樹脂圧力センサー18によって計測される樹脂圧力をフィードバックせずに、可塑化完了位置の所定位置まで各ショット任意の圧力でスクリュー位置を戻す制御方法でスクリュー6の移動制御を行い、射出開始位置までスクリュー6を前進させて射出充填した。それ以外は、実施例1と同様にして射出成形を行いメッキ膜を形成した。その結果、比較例1で作製された成形品では、成形品の外周端部と一部表面とに気泡や樹脂の飛散した紛体が確認された。また、比較例1では、熱可塑性樹脂を多数成形し、全ての成形品に対して熱可塑性樹脂に浸透している機能性材料(金属微粒子)の密度を調べたところ、成形品に浸透している機能性材料の密度が成形品内の場所によりばらつき、また、成形品内における機能性材料に密度分布が成形品毎に異なっていた。すなわち、比較例1の方法では、所望の表面改質された成形品を安定して作製することができなかった。これは、比較例1では、樹脂圧力センサー18によって計測される樹脂圧力をフィードバックせずにスクリュー6の射出開始位置まで前進させたことにより、可塑性シリンダー内部の溶融樹脂圧力をスクリュー押し付け圧力によって均一化することができず、溶融樹脂から超臨界二酸化炭素が分離したためであると考えられる。
7 ガス注入機構
18 樹脂圧力センサー
19 キャビティ
22 金型
23 可塑化シリンダー
103 溶融樹脂
104 超臨界流体
105 超臨界流体及び機能性材料が浸透した溶融樹脂
Claims (12)
- 金型と、スクリューを有し且つ該スクリューにより熱可塑性樹脂の溶融樹脂を該金型内に射出する可塑化シリンダーとを備えた射出成形機を用いた射出成形方法であって、
上記可塑化シリンダー内の上記溶融樹脂の充填量を計量することと、
上記計量終了時の上記スクリューの位置から、上記スクリューを回転させることなく所定距離後退させるとともに、上記可塑化シリンダー内の上記溶融樹脂に超臨界流体を導入することと、
上記溶融樹脂の圧力を検出することと、
上記圧力に基づいて上記スクリューの射出開始位置を決定することとを含む射出成形方法。 - 上記スクリューの射出開始位置を決定することが、上記スクリューを前進させて上記溶融樹脂を加圧することを含むことを特徴とする請求項1に記載の射出成形方法。
- 上記スクリューの射出開始位置を決定することが、さらに、上記溶融樹脂を加圧した後、当該溶融樹脂を減圧することを含むことを特徴とする請求項2に記載の射出成形方法。
- 上記スクリューの上記射出開始位置が、上記計量終了時の上記スクリューの位置と異なることを特徴とする請求項1〜3のいずれか一項に記載の射出成形方法。
- さらに、上記スクリューを上記射出開始位置から前進させて上記溶融樹脂を上記金型内に射出することと含み、この際、上記スクリューの移動をストローク制御することを特徴とする請求項1〜4のいずれか一項に記載の射出成形方法。
- 上記溶融樹脂を上記金型内に射出する際に、所定のカウンタープレッシャー、保圧及び型締め圧のいずれかを上記金型内に与えることを含むことを特徴とする請求項5に記載の射出成形方法。
- さらに、上記溶融樹脂が上記金型内に充填された後、上記溶融樹脂に保圧を与えることを含む請求項5または6に記載の射出成形方法。
- 上記溶融樹脂を上記金型内に射出する際に、樹脂内圧を減圧して、成形品の少なくとも一部を発泡させることを特徴とする請求項5に記載の射出成形方法。
- 上記超臨界流体に機能性材料が含まれていることを特徴とする請求項1〜8のいずれか一項に記載の射出成形方法。
- 上記超臨界流体が上記可塑化シリンダー内の上記溶融樹脂のフローフロント部に導入されることを特徴とする請求項9に記載の射出成形方法。
- 上記機能性材料が金属微粒子であることを特徴とする請求項9または10に記載の射出成形方法。
- 熱可塑性樹脂上にメッキ膜を形成する方法であって、
上記請求項11に記載の射出成形方法により、表面に金属微粒子が偏析した熱可塑性樹脂を形成することと、
上記熱可塑性樹脂の金属微粒子が偏析した表面上に、無電解メッキ法によりメッキ膜を形成することとを含むメッキ膜の形成方法。
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WO2013129659A1 (ja) | 2012-03-02 | 2013-09-06 | 日立マクセル株式会社 | 成形体の製造方法、メッキ膜を有する成形体の製造方法、樹脂ペレットの製造方法、メッキ膜を有する発泡成形体、発泡射出成形方法、ノズルユニット及び射出成形装置 |
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