JP2013107402A - 発泡射出成形方法 - Google Patents
発泡射出成形方法 Download PDFInfo
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- JP2013107402A JP2013107402A JP2013047805A JP2013047805A JP2013107402A JP 2013107402 A JP2013107402 A JP 2013107402A JP 2013047805 A JP2013047805 A JP 2013047805A JP 2013047805 A JP2013047805 A JP 2013047805A JP 2013107402 A JP2013107402 A JP 2013107402A
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Abstract
【解決手段】熱可塑性樹脂の発泡射出成形方法であって、前記熱可塑性樹脂を可塑化して溶融樹脂とすることと、前記溶融樹脂と、物理発泡剤とを接触混練することと、前記溶融樹脂中の前記物理発泡剤の濃度が、飽和溶解度に近づくように、前記物理発泡剤が接触混練された溶融樹脂の圧力を前記溶融樹脂に前記物理発泡剤を接触混練するときに到達する最高圧力以下に、前記溶融樹脂の雰囲気の圧力を調整することによって制御することと、圧力を制御した前記溶融樹脂を発泡させ、且つ、所望の形状に成形することを含む。
【選択図】 図13
Description
第1の実施形態では、加圧流体として加圧二酸化炭素を用い、更に、加圧二酸化炭素に機能性材料を含ませる。可塑化シリンダ内で加圧二酸化炭素と共に機能性材料を溶融樹脂に混錬させ、更に、二酸化炭素のみを排気する混練装置及び該混練装置を用いた熱可塑性樹脂成形体の製造方法について説明する。
図1に示すように、混練装置200は成形機1000に備えられる。成形機1000は、混練装置200と、加圧流体を混練装置200に供給する加圧流体供給装置100と、金型が設けられた型締めユニット250と、加圧流体供給装置100、混練装置200、及び型締めユニット250を動作制御する制御装置(不図示)を備える。
上流側シール機構S1及び下流側シール機構S2は、ゾーン21、22、23の連通を遮断することができれば、種々のものを利用できるが、本実形態では、以下に説明するスクリュ20の回転状態に応じてこれらのゾーンを連通/遮断する機構を用いた。
次に、図9に示すフローチャートに従い、本実施形態の混練装置200を用いた熱可塑性樹脂成形体の製造方法について説明する。本実施形態の熱可塑性樹脂成形体の製造方法においては、まず、熱可塑性樹脂を可塑化シリンダ210に供給し、スクリュ20を回転させることにより、可塑化ゾーン21で熱可塑性樹脂を可塑化して溶融樹脂とする(ステップS1)。
第2の実施形態では、可塑化シリンダ内で物理発泡剤を溶融樹脂に混錬させ、更に、一部の物理発泡剤を排気する混練装置及び該混練装置を用いた発泡セルを有する成形体(発泡成形体)の製造方法、即ち、発泡射出成形方法について説明する。
本実施形態では、第1の実施形態と同一の構造の混練装置200を用いる。図10に示すように、混練装置200は、成形機2000に設けられる。成形機2000は、加圧流体供給装置100の代わりに物理発泡剤供給装置300を備える以外は、第1の実施形態で用いた図1に示す成形機1000と同一の構造である。第1の実施形態と同様に、図10における可塑化シリンダ210の内部においては、右手を「上流」又は「後方」、左手を「下流」又は「前方」と定義する。
図13に示すフローチャートに従い、図10に示す成形機2000を用いた発泡射出成形方法について説明する。まず、熱可塑性樹脂を可塑化シリンダ210に供給し、スクリュ20を回転させることにより、可塑化ゾーン21で熱可塑性樹脂を可塑化して溶融樹脂とする(ステップS11)。熱可塑性樹脂としては、第1の実施形態で用いるものと同様の熱可塑性樹脂を用いることができる。
本参考例では、図1に示す混練装置200を備える成形機1000を用いて、機能性材料が分散した熱可塑性樹脂成形体を射出成形により製造した。加圧流体としては、加圧二酸化炭素を用いた。熱可塑性樹脂としては、ガラス繊維を30%含有する6ナイロンを、機能性材料としては、有機金属錯体であるヘキサフルオロアセチルアセトナパラジウム(II)を、機能性材料を溶解する溶媒としてはフッ素系有機溶媒であるパーフルオロペンチルアミンを用いた。尚、1ショットごとの溶融樹脂に対し、二酸化炭素の濃度が2.5wt%、有機金属錯体の濃度が約100ppmとなるように混合加圧流体の導入量を調整した。
上述したように、図1に示す成形機1000は、加圧流体供給装置100と、混練装置200と、型締めユニット250と、加圧流体供給装置100、混練装置200、及び型締めユニット250を動作制御する制御装置(不図示)を備える。加圧流体供給装置100は、加圧二酸化炭素と、機能性材料を溶媒に溶解させた溶液Cとを混合して混合加圧流体を調製し、該調製された混合加圧流体を可塑化シリンダ210に供給する。また、混練装置200には、ノズル先端29にエアーシリンダ12の駆動により開閉するシャットオフバルブ36が設けられ、可塑化シリンダ210の内部を高圧に保持できる。ノズル先端29には、金型が密着し、金型が形成するキャビティ253内に、ノズル先端29から溶融樹脂が射出充填される。
まず、吸引用エアオペレートバルブ104を開放して、液体二酸化炭素ボンベ101から液体二酸化炭素を吸引する。次に、二酸化炭素用シリンジポンプ102の圧力制御により所定圧力まで液体二酸化炭素を加圧する。本参考例では、二酸化炭素用シリンジポンプ102のヘッドと途中の経路を10℃に冷却し、圧力が10MPa、温度が10℃の加圧二酸化炭素を調製した。
本参考例では、参考例1と同様の混練装置200を備えた成形機1000を用いて、機能性材料を分散させた熱可塑性樹脂成形体を射出成形により製造した。本参考例では、高圧混練ゾーン22に溶融樹脂を滞留させた状態で、高圧混練ゾーン22と減圧ゾーン23との連通と遮断を複数回繰り返えした。加圧流体としては、参考例1と同様に加圧二酸化炭素を用いた。熱可塑性樹脂としてはポリプロピレンを、機能性材料としては抗菌剤である銀錯体、ヘプタフルオロ酪酸銀塩(I)を、機能性材料を溶解する溶媒としてはエタノールを用いた。尚、1ショットごとの溶融樹脂に対し、二酸化炭素の濃度が20wt%、銀錯体の濃度が0.5wt%となるように混合加圧流体の導入量を調整した。
本実施例では、参考例1と同様の混練装置200及び成形機1000を用いて、参考例1よりも減圧ゾーン23の圧力を高くすることで、発泡セルを有する成形体(発泡成形体)を発泡射出成形により製造した。加圧流体、熱可塑性樹脂、機能性材料及び溶媒としては、それぞれ、参考例1と同様の物質を用いた。本実施例は、発泡射出成形を行ったので、加圧流体は物理発泡剤として機能した。また、金型に導入する溶融樹脂の充填重量は参考例1と比較して30wt%減とし、樹脂に対する混合加圧流体の導入量は参考例1と同等にした。
本比較例においては、混練装置200が減圧ゾーン圧力調整機構219を有していないこと以外は参考例1と同様の形態の成形機を用いて、機能性材料が分散した熱可塑性樹脂成形体を射出成形により製造した。したがって、本比較例では、減圧ゾーン23の圧力は制御されず、ほぼ大気圧の状態で二酸化炭素の排気を行った。それ以外は、参考例1と同様の方法により、連続して100ショットの射出成形を行った。
本実施例では、先に説明した図10に示す成形機2000を用いて、発泡セルを有する成形体(発泡成形体)を発泡射出成形により製造した。熱可塑性樹脂としては、ガラス繊維を30%含有する6ナイロンを、物理発泡剤としては、常温(25℃)、圧力10MPaの加圧流体である液体二酸化炭素を用いた。本実施例では、1ショット(100g)ごとの溶融樹脂に対し、物理発泡剤の濃度が2wt%となるように物理発泡剤の導入量を調整し、スクリュ背圧は5.5MPaに設定した。尚、本実施例では、機能性材料は用いなかった。
本実施例では、実施例2と同様の図10に示す成形機2000を用いて、成形体(発泡成形体)を発泡射出成形により製造した。熱可塑性樹脂及び物理発泡剤は、実施例2と同様のものを用い、物理発泡剤の導入量を1ショット(100g)ごとの溶融樹脂に対し、物理発泡剤の濃度が15wt%と、実施例2より高濃度となるように調整した。また、本実施例では、減圧ゾーン23の圧力を8MPaと実施例2よりも高く設定した。尚、スクリュ背圧は8.5MPaに設定した。尚、本実施例では、機能性材料は用いなかった。
本実施例では、図11に示す成形機3000を用いて、成形体(発泡成形体)を発泡射出成形により製造した。成形機3000は、シリンジポンプを有さない物理発泡剤供給装置400を用い可塑化シリンダ210へ物理発泡剤を供給する以外は、図10に示す成形機2000と同様の構成である。本実施例では、物理発泡剤として加圧窒素を用い、熱可塑性樹脂は実施例2と同様のものを用いた。本実施例においては、物理発泡剤の導入量を計測して可塑化シリンダ210へ供給することは行なわなかった。また、本実施例では、減圧ゾーン23の圧力を6MPaとした。尚、スクリュ背圧は6.5MPaに設定した。また、本実施例では、機能性材料は用いなかった。
本比較例では、物理発泡剤を接触混練した溶融樹脂の圧力を制御せずに、発泡射出成形方法により発泡成形体を製造した。成形機としては、減圧ゾーン圧力調整機構219を有していないこと、ベント203のような余剰な物理発泡剤を排出する排出口を有さないこと、及びスクリュ20の代わりに、フラット部20Bを有さずに全体にフライトが設けられている通常のスクリュを有すること以外は実施例2で用いた成形機2000と同様の形態の成形機を用いた。熱可塑性樹脂、物理発泡剤及び物理発泡剤の導入量は、実施例2と同様としたが、本比較例では、高圧混練ゾーン23と減圧ゾーン22の連通は遮断せず、また、減圧ゾーン23の圧力制御及び可塑化シリンダ210からの物理発泡剤の排気も行わなかった。また、減圧ゾーンの冷却も行わず、冷却ゾーンの温度制御は他のゾーンと同様とした。つまり従来の発泡成形と同様な形態にて射出成形を行なった。
210 可塑化シリンダ
20 スクリュ
S1 上流側シール機構
S2 下流側シール機構
219 減圧ゾーン圧力調整機構
1 排気機構
2 加圧機構
3 背圧弁
4 圧力計
5 バッファ容器、
5a、5b 接続口
7 不活性ガスボンベ
8 ブースターポンプ
10 減圧弁
11 排気口
1000、2000、3000 成形機
100 加圧流体供給装置
300、400 物理発泡剤供給装置
250 型締めユニット
Claims (2)
- 熱可塑性樹脂の発泡射出成形方法であって、
前記熱可塑性樹脂を可塑化して溶融樹脂とすることと、
前記溶融樹脂と、物理発泡剤とを接触混練することと、
前記溶融樹脂中の前記物理発泡剤の濃度が飽和溶解度に近づくように、前記物理発泡剤が接触混練された溶融樹脂の圧力を前記溶融樹脂に前記物理発泡剤を接触混練するときに到達する最高圧力以下に、前記溶融樹脂の周囲のガスの圧力を調整することによって制御することと、
圧力を制御した前記溶融樹脂を発泡させ、且つ、所望の形状に成形することを含む発泡射出成形方法。 - 前記物理発泡剤が接触混練された溶融樹脂の圧力の制御は、
前記溶融樹脂からガス化した物理発泡剤を分離することを含む請求項1に記載の発泡射出成形方法。
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US20150103615A1 (en) | 2015-04-16 |
JP2016106050A (ja) | 2016-06-16 |
WO2013027615A1 (ja) | 2013-02-28 |
EP2746025A4 (en) | 2015-02-25 |
JPWO2013027615A1 (ja) | 2015-03-19 |
EP2746025A1 (en) | 2014-06-25 |
US8980147B2 (en) | 2015-03-17 |
EP2746025B1 (en) | 2017-01-11 |
JP6109360B2 (ja) | 2017-04-05 |
US20160039116A1 (en) | 2016-02-11 |
JP5226904B1 (ja) | 2013-07-03 |
US9186634B2 (en) | 2015-11-17 |
JP5956369B2 (ja) | 2016-07-27 |
US20130285273A1 (en) | 2013-10-31 |
US9718217B2 (en) | 2017-08-01 |
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