JP2015044305A - Method for suppressing gas burning and outgas in injection molding of organic polymer material - Google Patents
Method for suppressing gas burning and outgas in injection molding of organic polymer material Download PDFInfo
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Abstract
Description
本発明は有機高分子材料の射出成形に用いる金型から成形時に、製品表面等に発生する表面炭化現象および充填不足の原因となる有機高分子材料分解ガス（アウトガス）の発生を抑制するための方法に関する。 The present invention is to suppress generation of organic polymer material decomposition gas (outgas) that causes surface carbonization phenomenon and insufficient filling that occurs on the product surface during molding from a mold used for injection molding of organic polymer material. Regarding the method.
（有機高分子材料の射出成形における現状と課題）
形状が複雑な有機高分子材料成形品の射出成形において、表面炭化による成形品の変色・変性現象の発現およびアウトガスが原因となる金型内部での充填不足といった成形不良が発生する場合がある。これらは、有機高分子材料のせん断発熱や、元々金型内に存在していた空気やアウトガスの断熱圧縮による発熱、およびそれに伴う空気中の酸素とアウトガスとの燃焼反応が主な要因と考えられている。これらの成形不良に関してはガスベントを設置する、金型のクリーニング頻度を高める、有機高分子材料を十分に乾燥させるなどの対策がなされてきたが、これらは現場技術者の経験、勘などの属人的、対症療法的な対応に過ぎない。
(Current status and issues in injection molding of organic polymer materials)
In injection molding of an organic polymer material molded product having a complicated shape, molding defects such as the occurrence of discoloration / denaturation phenomenon of the molded product due to surface carbonization and insufficient filling inside the mold due to outgassing may occur. These are thought to be mainly due to shear heat generation of organic polymer materials, heat generation due to adiabatic compression of air and outgas that originally existed in the mold, and the accompanying combustion reaction between oxygen and outgas in the air. ing. For these molding defects, measures such as installing gas vents, increasing the frequency of mold cleaning, and sufficiently drying organic polymer materials have been taken. It is merely a symptomatic treatment.
一方、海外製品と差別化し競争力の高い製品の創出を目的として、ブラシなどの植毛品、複数の部品から成る製品を一度の成形で製造することなどの形状複雑品の成形、メーカーを跨いだ部品の共通化などにともなう大量成形など、より高度な成形技術が求められている。形状複雑品の成形では射出圧力の増加、大量成形では一成形の時間短縮のため射出速度の増加など射出成形環境はますます厳しさを増している。 On the other hand, for the purpose of creating a highly competitive product that differentiates it from overseas products, it has crossed over manufacturers of shaped complex products such as flocking products such as brushes and products made of multiple parts in one molding. There is a need for more advanced molding technology, such as mass molding due to the common use of parts. The injection molding environment is becoming increasingly severe, such as increasing the injection pressure for molding complex shape products, and increasing the injection speed to shorten the molding time for large-scale molding.
（ガスを用いた成形不良改善の現状について）
有機高分子材料の射出成形における成形不良を防止する方法として、射出成形機のシリンダー内にガスを導入して加圧し、溶融した有機高分子材料の流動性を高めることにより成形不良を抑制する技術があるが、これは金型境界でのバリ、末端部での充填不足などを防止するものである（特許文献１）。
(Current status of improvement of molding defects using gas)
Technology to suppress molding defects by introducing gas into a cylinder of an injection molding machine and applying pressure to improve the fluidity of the molten organic polymer material as a method to prevent molding defects in the injection molding of organic polymer materials However, this prevents burrs at the mold boundary, insufficient filling at the end portion, and the like (Patent Document 1).
また、この他、金型内を真空にし、酸素などの支燃性ガスを除去した後に射出成形することで、有機高分子材料の燃焼を抑制し、結果的に上記成形不良を抑制する技術もある（特許文献２および３）。しかし、これらの技術では、金型内とシリンダー内との圧力差によって、金型内へ溶融した有機高分子材料がより急速に導入される。この場合、ラインやゲート付近における有機高分子材料のせん断発熱が増大しやすくなる他、成形加工性も低下するため、形状複雑品の成形には適さない。 In addition to this, there is also a technology that suppresses combustion of the organic polymer material and, as a result, suppresses the above-mentioned molding defects, by evacuating the inside of the mold and removing the combustion-supporting gas such as oxygen after injection molding. Yes (Patent Documents 2 and 3). However, in these techniques, the molten organic polymer material is more rapidly introduced into the mold due to the pressure difference between the mold and the cylinder. In this case, shear heat generation of the organic polymer material in the vicinity of the line and the gate is likely to increase, and the molding processability is also deteriorated.
（課題解決に向けた本発明の目的と本発明で解決しようとする具体的な技術課題）
そこで、金型内部の酸素濃度を低減し、燃焼反応による表面炭化の抑制に関して鋭意研究開発した結果、本発明者らは実成形金型内に不燃性ガスを導入する工程に続き常圧に戻す工程を経た後、有機高分子材料の射出成形を行うことで、アウトガス発生量が低減し、表面炭化および充填不足の抑制が可能であることを見出し、発明の完成に至った。
(Objective of the present invention for solving the problem and specific technical problem to be solved by the present invention)
Therefore, as a result of diligent research and development on the suppression of surface carbonization due to combustion reaction by reducing the oxygen concentration inside the mold, the present inventors returned to normal pressure following the process of introducing the nonflammable gas into the actual mold. After passing through the process, it was found that by performing injection molding of the organic polymer material, the amount of outgas generation was reduced, and it was possible to suppress surface carbonization and insufficient filling, thereby completing the invention.
すなわち本発明は（１）有機高分子材料の成形金型の任意箇所に成形不良を防止するための成形不良防止ガス導入ポートを設置する。不燃性ガスを圧力0.1kg/cm2,G以上10kg/cm2,G未満で成形不良防止ガス導入ポートから金型内に導入する工程に続いて、圧開放する工程を経て金型内圧力を常圧とした状態で、溶融した有機高分子材料を金型内に充填することを特徴とする表面炭化および充填不足の抑制方法であり、（２）不燃性ガスとして、周期表第１８族、二酸化炭素、および窒素から成る群から選ばれる少なくとも１種以上の成分を用いることを特徴とする請求項１記載のガス焼けおよび充填不足の抑制方法であり、（３）成形不良防止ガスとして、テトラクロロエチレン、トリクロロエチレン、テトラフルオロエチレン、トリフルオロエタンなどのハロゲン化炭化水素から成る群から少なくとも１種以上の成分を用いることを特徴とする請求項１記載の表面炭化および充填不足の抑制方法であり、（４）成形不良防止ガスとして、テトラクロロエチレン、トリクロロエチレン、テトラフルオロエチレン、トリフルオロエタンなどのハロゲン化炭化水素から成る群および周期表第１８族、二酸化炭素、および窒素から成る群から選ばれる２種以上の成分を用いることを特徴とする請求項１記載の表面炭化および充填不足の抑制方法であり、（５）シリンダー温度250℃以上270℃以下、射出速度50mm/sec以上300mm/sec以下で行われるポリブチレンテレフタレートの射出成形に関し、製品表面の色調に変化を認めないことを特徴とする（１）乃至（４）記載の表面炭化および充填不足の抑制方法であることを特徴とする。 That is, according to the present invention, (1) a molding defect prevention gas introduction port for preventing molding defects is installed at an arbitrary position of a molding die for organic polymer material. Following the process of introducing nonflammable gas into the mold from the molding failure prevention gas introduction port at a pressure of 0.1 kg / cm 2 , G to 10 kg / cm 2 , G, the pressure in the mold is reduced through the process of releasing the pressure. A method of suppressing surface carbonization and insufficient filling, characterized by filling a molten organic polymer material into a mold under normal pressure, (2) as a non-combustible gas, group 18 of the periodic table, The method according to claim 1, wherein at least one component selected from the group consisting of carbon dioxide and nitrogen is used. (3) Tetrachloroethylene as a molding defect prevention gas, 2. The surface carbonization and filling according to claim 1, wherein at least one component is used from the group consisting of halogenated hydrocarbons such as trichloroethylene, tetrafluoroethylene, and trifluoroethane. (4) A group consisting of halogenated hydrocarbons such as tetrachloroethylene, trichloroethylene, tetrafluoroethylene, trifluoroethane, etc. and periodic table group 18, carbon dioxide, and nitrogen as a molding defect prevention gas The method according to claim 1, wherein two or more components selected from the group are used. (5) Cylinder temperature 250 ° C to 270 ° C, injection speed 50mm / sec or more Regarding the injection molding of polybutylene terephthalate performed at 300 mm / sec or less, the method of suppressing surface carbonization and insufficient filling according to (1) to (4), wherein no change is observed in the color of the product surface Features.
以上のように、本発明では、有機高分子材料成形金型の任意箇所に設置された成形不良防止ガス導入ポートから上記の成形不良防止ガスを金型内へ導入する。これにより、金型内より酸素が除去されるため、有機高分子材料のせん断発熱や、空気や有機高分子材料分解ガスによる断熱圧縮に伴う燃焼反応を抑制することができる。また、燃焼反応によって生成する一酸化炭素および二酸化炭素といった燃焼生成ガスの発生も抑制できる。さらに、金型内とシリンダー内との圧力差も無いため、有機高分子材料は金型内へ急速に流入することもない。このため、成形品の表面炭化および充填不足などの成形不具合を、前述のような属人的、対症療法的な対応ではなく、より科学的、合理的に抑制することが可能となる。 As described above, in the present invention, the above-described molding defect prevention gas is introduced into the mold from the molding defect prevention gas introduction port installed at an arbitrary position of the organic polymer material molding mold. Thereby, since oxygen is removed from the inside of a metal mold | die, the shearing heat_generation | fever of organic polymer material and the combustion reaction accompanying the adiabatic compression by air or organic polymer material decomposition gas can be suppressed. Moreover, generation | occurrence | production of combustion product gas, such as carbon monoxide and a carbon dioxide produced | generated by a combustion reaction, can also be suppressed. Further, since there is no pressure difference between the mold and the cylinder, the organic polymer material does not flow into the mold rapidly. For this reason, molding defects such as carbonization of the surface of the molded product and insufficient filling can be suppressed more scientifically and rationally than the above-mentioned personal and symptomatic treatment.
本発明における好適な実施の形態について、添付図面を参照しながら詳細に説明する。なお、以下に説明する実施の形態は、特許請求の範囲に記載された本発明の内容を限定するものではない。また、以下に説明される構成の全てが、本発明の必須要件であるとは限らない。 Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The embodiments described below do not limit the contents of the present invention described in the claims. In addition, all of the configurations described below are not necessarily essential requirements of the present invention.
（有機高分子材料）
本発明に用いることが出来る有機高分子材料としては、ポリアセタール（POM）、ポリアミド（PA）、 ポリカーボネート（PC）、ポリフェニレンエーテル（PPE）、ポリブチレンテレフタレート（PBT）、ポリエチレンテレフタレート（PET）、ポリ乳酸(PLA)、ポリブチレンサクシネート(PBS)、ポリブチレンサクシネートアジペート(PBSA)、ポリエチレン（PE）、ポリプロピレン(PP)、ポリスチレン（PS）、アクリロニトリル-ブタジエン-スチレン共重合体（ABS）、ポリフェニレンサルファイド（PPS）、ポリ塩化ビニル(PVC)、ポリ塩化ビニリデン(PVDC) 、ポリテトラフルオロエチレン(PTFE) 、ポリメチルメタクリレート(PMMA)、エチレン−酢酸ビニル共重合体(EVA) などを挙げることができる。
これらの樹脂に関しては無着色、着色を問わない。また、金属微粉末の添加、ガラス繊維の添加を妨げない。上記樹脂の内、POM、PC、PBT、PET、PLA、PBS、PP、ABS、PMMA、EVAにおいてより発明の効果が得られ、PBT、PET、PLA、PBSといったポリエステル系有機高分子材料において発明の効果がより顕著になる。
(Organic polymer material)
Examples of organic polymer materials that can be used in the present invention include polyacetal (POM), polyamide (PA), polycarbonate (PC), polyphenylene ether (PPE), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), and polylactic acid. (PLA), polybutylene succinate (PBS), polybutylene succinate adipate (PBSA), polyethylene (PE), polypropylene (PP), polystyrene (PS), acrylonitrile-butadiene-styrene copolymer (ABS), polyphenylene sulfide (PPS), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polytetrafluoroethylene (PTFE), polymethyl methacrylate (PMMA), ethylene-vinyl acetate copolymer (EVA), and the like.
These resins may be uncolored or colored. Moreover, addition of a metal fine powder and addition of glass fiber are not prevented. Among the above resins, POM, PC, PBT, PET, PLA, PBS, PP, ABS, PMMA, EVA, the effect of the invention can be obtained more, and polyester organic polymer materials such as PBT, PET, PLA, PBS The effect becomes more remarkable.
（射出成形温度）
ポリブチレンテレフタレートの射出成形において、図１に示すシリンダーの加熱部１乃至３およびノズル部４の温度は250℃以上270℃以下、より望ましくは260℃以上270℃以下とする。これより低い温度条件では、ポリブチレンテレフタレートの溶融が不十分であり、スクリューやノズル部分の詰まりが生じやすくなる。一方、これより高い温度では、ポリブチレンテレフタレートの熱分解、酸化分解がより顕著になるためである。
(Injection molding temperature)
In the injection molding of polybutylene terephthalate, the temperatures of the heating parts 1 to 3 and the nozzle part 4 of the cylinder shown in FIG. 1 are 250 ° C. or higher and 270 ° C. or lower, more preferably 260 ° C. or higher and 270 ° C. or lower. Under lower temperature conditions, the polybutylene terephthalate is not sufficiently melted, and clogging of the screw and nozzle portion is likely to occur. On the other hand, at higher temperatures, the thermal decomposition and oxidative decomposition of polybutylene terephthalate become more prominent.
（射出速度）
本発明による成形不良防止ガスを導入した場合の射出速度は50mm/sec以上300mm/sec以下の範囲を選択でき、100mm/sec以上300mm/sec以下が好ましく、120mm/sec以上で300mm/sec以下がより好ましく、150mm/sec以上300mm/secがより好ましく、180mm/sec以上280mm/secが最も好ましい。これより遅い射出速度では、生産性を向上させる効果が減少し、成形不良防止ガスを導入する技術的な意味合いが希薄となる。一方、これより高い射出速度では、成形不良防止ガスの導入によって表面炭化は抑制されるものの、断熱圧縮やせん断発熱にともなう有機高分子材料の熱分解、ジェッティング等に伴う製品変形、熱分解ガスに起因する充填不足が見られやすくなる傾向がある。本発明では射出成形速度の上限値が高くなり生産性の向上が期待される。
(Injection speed)
When the molding defect prevention gas according to the present invention is introduced, the injection speed can be selected from the range of 50 mm / sec or more and 300 mm / sec or less, preferably 100 mm / sec or more and 300 mm / sec or less, 120 mm / sec or more and 300 mm / sec or less. More preferably, 150 mm / sec or more and 300 mm / sec are more preferable, and 180 mm / sec or more and 280 mm / sec are most preferable. If the injection speed is slower than this, the effect of improving the productivity is reduced, and the technical significance of introducing the molding defect prevention gas is diminished. On the other hand, at higher injection speeds, surface carbonization is suppressed by the introduction of molding defect prevention gas, but product deformation and pyrolysis gas due to thermal decomposition of organic polymer materials due to adiabatic compression and shear heating, jetting, etc. There is a tendency that insufficient filling due to the is easily observed. In the present invention, the upper limit of the injection molding speed is increased, and improvement in productivity is expected.
（金型内への成形不良防止ガス充填工程）
射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、成形不良防止ガスが充填されたボンベ７に取り付けられた調製弁８を開くことによって成形不良防止ガスが金型可動部５に設置した成形不良防止ガス導入ポート９から金型内部へ圧力が0.1kg/cm2,G以上10kg/cm2,G未満となるように導入することが望ましく、0.1kg/cm2,G以上1kg/cm2,G未満となるように導入することがより望ましく、0.1kg/cm2,G以上0.15kg/cm2,G未満となるように導入することが最も望ましい。なお、本工程において、成形不良防止ガス導入ポート９は金型固定部６に設置してもよい。さらに、射出により有機高分子材料が金型内へ導入される前に、金型内を常圧に戻すためのガスベント部１０の下方に設置されたコック１１を開け、金型内を常圧にする。この時、成形不良防止ガス充填時の金型内圧力が0.1kg/cm2,G未満である場合には、コック１１を解放した際に空気が金型内へ導入されるため、射出成形時に燃焼による表面炭化が起こりやすくなる。また、射出成形時に有機高分子材料が急激に金型内へ導入されるため、せん断発熱が大きくなり、それに伴う有機高分子材料の表面炭化も起こりやすくなる。一方、金型内の圧力が10kg/cm2,G以上である場合には、図１に示された付属装置の配管を耐圧性の高いものにする必要があるため、コスト面でのデメリットがある。
(Gas filling process to prevent molding defects in the mold)
After the injection mold movable part 5 moves and adheres to the mold fixing part 6 (clamping), the molding valve 8 attached to the cylinder 7 filled with a molding defect prevention gas is opened to prevent molding defects. It is desirable that gas is introduced from the molding defect prevention gas introduction port 9 installed in the mold movable part 5 into the mold so that the pressure is 0.1 kg / cm 2 , G or more and less than 10 kg / cm 2 , G, 0.1 It is more desirable to introduce it so that it is kg / cm 2 , G or more and less than 1 kg / cm 2 , G, and it is most preferable to introduce it so that it becomes 0.1 kg / cm 2 , G or more and less than 0.15 kg / cm 2 , G. desirable. In this step, the molding defect prevention gas introduction port 9 may be installed in the mold fixing part 6. Furthermore, before the organic polymer material is introduced into the mold by injection, the cock 11 installed below the gas vent 10 for returning the inside of the mold to normal pressure is opened, and the inside of the mold is brought to normal pressure. To do. At this time, if the pressure in the mold when filling the molding defect prevention gas is less than 0.1 kg / cm 2 , G, air is introduced into the mold when the cock 11 is released. Surface carbonization due to combustion tends to occur. In addition, since the organic polymer material is rapidly introduced into the mold at the time of injection molding, shear heat generation is increased, and the surface carbonization of the organic polymer material is likely to occur. On the other hand, if the pressure in the mold is 10kg / cm 2 , G or more, it is necessary to make the piping of the accessory device shown in FIG. is there.
（成形不良防止ガスについて）
また、成形不良防止ガスには、周期表第１８族、二酸化炭素、および窒素といった不燃性ガスから成る群から選ばれる少なくとも１種以上の成分、およびクロロジフルオロメタン、テトラフルオロエタン、ジフルオロエタン、ペンタフルオロエタン、トリフルオロエタンなどのハロゲン化炭化水素から成る群から選ばれる少なくとも１種以上の成分を好ましく用いることができる。なお、不燃性ガスとハロゲン化炭化水素を混合して用いることも好ましい。これらの成形不良防止ガスに関し、二酸化炭素がより好ましく、窒素がさらに好ましく、周期表第１８族が最も好ましい。この理由は、周期表第１８族は酸化物、塩化物などをはじめとする化合物を形成する可能性が最も小さく、成形不良防止ガスによる成形品の汚れ発生の可能性が最も小さい。窒素は置換後の酸素分圧が低い状況では窒素酸化物の発生の可能性は殆ど無く、周期表第１８族元素に次いで好ましい。二酸化炭素は成形時の圧縮で温度が約450℃以上に上昇し、有機高分子材料の脱水素反応が起こったような場合に、それ自身が還元される虞が僅かながらあるため窒素に次いで好ましい。ハロゲン化炭化水素は難燃性であるが、周期表第18族、二酸化炭素、窒素に比べ取扱い性が劣る面がある。一方で、沸点が高いため冷却などによる回収再利用が容易なメリットも有している。
(About molding defect prevention gas)
Further, the molding defect preventing gas includes at least one component selected from the group consisting of non-flammable gases such as Group 18 of the periodic table, carbon dioxide, and nitrogen, and chlorodifluoromethane, tetrafluoroethane, difluoroethane, and pentafluoro. At least one component selected from the group consisting of halogenated hydrocarbons such as ethane and trifluoroethane can be preferably used. It is also preferable to use a mixture of nonflammable gas and halogenated hydrocarbon. Regarding these molding failure prevention gases, carbon dioxide is more preferred, nitrogen is more preferred, and group 18 of the periodic table is most preferred. This is because group 18 of the periodic table has the lowest possibility of forming compounds such as oxides and chlorides, and the possibility of occurrence of contamination of molded products due to molding failure prevention gas is the lowest. Nitrogen has little possibility of the generation of nitrogen oxides in a situation where the oxygen partial pressure after substitution is low, and is preferred next to Group 18 elements of the periodic table. Carbon dioxide is preferable to nitrogen because the temperature rises to about 450 ° C or higher due to compression during molding, and there is a slight possibility that the organic polymer material itself may be reduced when dehydrogenation occurs. . Halogenated hydrocarbons are flame retardant, but have poor handling properties compared to Group 18 of the periodic table, carbon dioxide, and nitrogen. On the other hand, since it has a high boiling point, it has an advantage that it can be easily recovered and reused by cooling or the like.
（成形不良防止ガスの純度）
成形不良防止ガスの純度は、金型内において成形不良ガス単独および2種以上の混合ガスが80％以上を占めることが好ましく、85%以上を占めることがより好ましく、90％以上を占めることが最も好ましい。この範囲未満では、金型内の酸素分圧低減効果が不充分となり、成形不良防止効果が低減する可能性がある。上限値は特に限定されるものではないが、ボンベ等に充填された圧縮ガス純度が限値になる。なお、射出成形に先立って、熱伝導度型検出器付ガスクロマトグラフ（TCD-GC）により分析しておくことが望ましい。
(Purity of molding defect prevention gas)
The purity of the molding defect preventing gas is preferably 80% or more, more preferably 85% or more, more preferably 90% or more of the molding defect gas alone or two or more mixed gases in the mold. Most preferred. If it is less than this range, the effect of reducing the oxygen partial pressure in the mold becomes insufficient, and the effect of preventing molding defects may be reduced. The upper limit value is not particularly limited, but the purity of the compressed gas filled in the cylinder or the like becomes the limit value. Prior to injection molding, it is desirable to analyze by a gas chromatograph with a thermal conductivity detector (TCD-GC).
（成形機設置環境）
成形不良防止ガスを用いる際には、アウトガスを排気するための換気設備を設けることが望ましい。また、ハロゲン化炭化水素を成形不良防止ガスとして常に用いる際には、回収するための機構を設けることが、環境面への配慮から望ましい。
(Molding machine installation environment)
When the molding failure prevention gas is used, it is desirable to provide a ventilation facility for exhausting outgas. In addition, when a halogenated hydrocarbon is always used as a molding defect prevention gas, it is desirable to provide a mechanism for recovery from the viewpoint of environmental considerations.
以下に実施例を示し、本発明をより詳細に開示する。なお、開示する実施例等は本発明の本質を説明するためのものであり、これらによって本発明の範囲を限定的に解釈してはならない。 The following examples illustrate the present invention in more detail. Note that the disclosed embodiments and the like are for explaining the essence of the present invention, and the scope of the present invention should not be construed in a limited manner.
（射出成形条件）
本実施例では、射出成形機は住友重機械工業株式会社製SE-180DUZ-HP（シリンダー径：45mm）を用いた。図１に示すシリンダー内に設置されたスクリュー１３の回転数は65rpmとした。また、有機高分子材料を溶融するシリンダーの加熱部１、２および３の設定温度はそれぞれ270℃、270℃および265℃とし、ノズル部４の温度は260℃、金型温度は金型可動部５、金型固定部６ともに65℃とした。
(Injection molding conditions)
In this example, SE-180DUZ-HP (cylinder diameter: 45 mm) manufactured by Sumitomo Heavy Industries, Ltd. was used as the injection molding machine. The rotational speed of the screw 13 installed in the cylinder shown in FIG. 1 was 65 rpm. The set temperatures of the heating parts 1, 2 and 3 of the cylinder for melting the organic polymer material are 270 ° C., 270 ° C. and 265 ° C., the temperature of the nozzle part 4 is 260 ° C., and the mold temperature is the mold movable part. 5 and the mold fixing part 6 were both set to 65 ° C.
（有機高分子材料）
本実施例で用いた有機高分子材料はポリブチレンテレフタレート（PBT）で商品名Duranex natural #2000（日本ポリプラスチック株式会社製)を使用した。
(Organic polymer material)
The organic polymer material used in this example was polybutylene terephthalate (PBT) and the trade name Duranex natural # 2000 (manufactured by Nippon Polyplastics Co., Ltd.).
（射出成形工程の詳細）
射出成形の金型可動部５が移動して金型固定部６に密着（型締め）し、なおかつ溶融したPBTが金型内へ射出される前の時点において、窒素が充填されたボンベ７に取り付けられた調製弁８を開くことによって成形不良防止ガスのアルゴンガス（周期表第18族）を金型可動部５上部に設置した成形不良防止ガス導入ポート９から金型内部へ導入した。この時の金型内圧力は0.13kg/cm2,Gだった。さらに、コック１１を1秒間開けることにより、ガスベント部１０より金型内の窒素ガスを排出し、金型内圧力を常圧にした。一方、PBTはホッパー１２よりシリンダー内へ導入され、溶融しながらシリンダー内のスクリュー１３によりノズル部へ導入した。その後、射出速度300mm/secで図２に示すゲート１４より金型内へPBTを導入し、成形を行った。その際、金型内に存在するガスは先端部分１５より排出した。
(Details of injection molding process)
The injection mold movable part 5 moves and closely contacts (mold clamping) with the mold fixing part 6, and before the molten PBT is injected into the mold, the cylinder 7 filled with nitrogen is applied. By opening the prepared preparation valve 8, argon gas (group 18 of the periodic table) as a molding defect preventing gas was introduced into the mold from a molding defect preventing gas introduction port 9 installed on the upper part of the mold movable part 5. The pressure in the mold at this time was 0.13 kg / cm 2 , G. Further, by opening the cock 11 for 1 second, the nitrogen gas in the mold was discharged from the gas vent portion 10, and the pressure in the mold was made normal. On the other hand, PBT was introduced into the cylinder from the hopper 12 and introduced into the nozzle portion by the screw 13 in the cylinder while melting. Thereafter, PBT was introduced into the mold from the gate 14 shown in FIG. 2 at an injection speed of 300 mm / sec, and molding was performed. At that time, the gas present in the mold was discharged from the tip portion 15.
（表面炭化の評価）
本実施例において製造された成形品については、表１に示すような成形品のゲート付近における表面炭化の程度に関する指標を設定し、これを元に表面炭化の程度を評価し成形不良防止ガスの導入効果を評価した。
(Evaluation of surface carbonization)
For the molded product manufactured in this example, an index relating to the degree of surface carbonization in the vicinity of the gate of the molded product as shown in Table 1 is set, and based on this, the degree of surface carbonization is evaluated to determine the molding defect prevention gas. The introduction effect was evaluated.
実施例１の条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。 In the case of injection molding under the conditions of Example 1, no discoloration of the molded product in the vicinity of the gate was confirmed, and the surface carbonization index was 1.
成形不良防止ガスに窒素を用い、射出速度を280mm/secとした他は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。本条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。 The conditions were the same as those described in Example 1, except that nitrogen was used as a molding defect prevention gas and the injection speed was 280 mm / sec. Further, the same PBT as described in Example 1 was used for the material. In the molded product when injection molding was performed under these conditions, discoloration of the molded product in the vicinity of the gate was not confirmed, and the surface carbonization index was 1.
成形不良防止ガスに二酸化炭素を用い、射出速度を180mm/secとした他は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。本条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。 The conditions were the same as those described in Example 1, except that carbon dioxide was used as the molding defect prevention gas and the injection speed was 180 mm / sec. Further, the same PBT as described in Example 1 was used for the material. In the molded product when injection molding was performed under these conditions, discoloration of the molded product in the vicinity of the gate was not confirmed, and the surface carbonization index was 1.
成形不良防止ガスに窒素と二酸化炭素の混合気体（窒素30%、残部二酸化炭素）を用い、射出速度を150mm/secとした他は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。本条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。 The conditions were the same as those described in Example 1, except that a mixture gas of nitrogen and carbon dioxide (nitrogen 30%, balance carbon dioxide) was used as the molding defect prevention gas, and the injection speed was 150 mm / sec. Further, the same PBT as described in Example 1 was used for the material. In the molded product when injection molding was performed under these conditions, discoloration of the molded product in the vicinity of the gate was not confirmed, and the surface carbonization index was 1.
成形不良防止ガスにクロロジフルオロメタン(CHClF2) CAS No. 75-45-6を用い、射出速度を120mm/secとした他は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。本条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。 The same conditions as described in Example 1 were used except that chlorodifluoromethane (CHClF 2 ) CAS No. 75-45-6 was used as the molding defect prevention gas and the injection speed was 120 mm / sec. Further, the same PBT as described in Example 1 was used for the material. In the molded product when injection molding was performed under these conditions, discoloration of the molded product in the vicinity of the gate was not confirmed, and the surface carbonization index was 1.
成形不良防止ガスにテトラフルオロエタンとして1,1,1,2-テトラフルオロエタン（CF3-CH2F）CAS No. 811-97-2を用い、射出速度を100mm/secとした他は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。本条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。 Other than using 1,1,1,2-tetrafluoroethane (CF 3 -CH 2 F) CAS No. 811-97-2 as tetrafluoroethane as the molding defect prevention gas and setting the injection speed to 100 mm / sec. Same conditions as described in Example 1. Further, the same PBT as described in Example 1 was used for the material. In the molded product when injection molding was performed under these conditions, discoloration of the molded product in the vicinity of the gate was not confirmed, and the surface carbonization index was 1.
ペンタフルオロエタン（CF3-CHF2）Cas No.
354-33-6およびトリフルオロエタンとして1,1,1-トリフルオロエタン（CF3-CH3）Cas
No.420-46-2をそれぞれ44％および52%、残部をテトラフルオロエタンとして1,1,1,2-テトラフルオロエタンが占める3種混合ガスを用い、射出速度を50mm/secとした他は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。本条件で射出成形を行った場合における成形品ではゲート付近における成形品の変色は確認されず、表面炭化指標は１だった。なお、実施例１乃至実施例７の結果を表２にまとめて示す。
Pentafluoroethane (CF 3 -CHF 2 ) Cas No.
354-33-6 and 1,1,1-trifluoroethane (CF 3 -CH 3 ) Cas as trifluoroethane
Using No.420-46-2 with 44% and 52% respectively, and the remainder as tetrafluoroethane, using three kinds of mixed gas occupied by 1,1,1,2-tetrafluoroethane and setting the injection speed to 50mm / sec. Were the same as the conditions described in Example 1. Further, the same PBT as described in Example 1 was used for the material. In the molded product when injection molding was performed under these conditions, discoloration of the molded product in the vicinity of the gate was not confirmed, and the surface carbonization index was 1. The results of Examples 1 to 7 are summarized in Table 2.
使用した射出成形機、スクリュー回転数、シリンダー加熱部１乃至３の温度、ノズル温度、金型温度は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。一方、実施例１とは異なり、射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、かつ溶融したPBTが金型内へ射出される前の段階で金型内への成形不良防止ガスの導入は行わず、射出速度100mm/secで金型内へ溶融したPBTを導入した。このときの成形品の表面はゲート付近が淡黄色に変色し、表面炭化指標は２だった。 The injection molding machine used, the screw rotation speed, the temperature of the cylinder heating units 1 to 3, the nozzle temperature, and the mold temperature were the same as those described in Example 1. Further, the same PBT as described in Example 1 was used for the material. On the other hand, unlike the first embodiment, the stage after the injection mold movable part 5 is moved and is in close contact with the mold fixing part 6 (clamping), and before the molten PBT is injected into the mold. However, without introducing molding defect prevention gas into the mold, molten PBT was introduced into the mold at an injection speed of 100 mm / sec. At this time, the surface of the molded product turned pale yellow near the gate, and the surface carbonization index was 2.
使用した射出成形機、スクリュー回転数、シリンダー加熱部１乃至３の温度、ノズル温度、金型温度は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。一方、実施例１とは異なり、射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、かつ溶融したPBTが金型内へ射出される前の段階で金型内への成形不良防止ガスの導入は行わず、射出速度120mm/secで金型内へ溶融したPBTを導入した。このときの成形品の表面はゲート付近の一部が褐色〜黒変し、表面炭化指標は３だった。 The injection molding machine used, the screw rotation speed, the temperature of the cylinder heating units 1 to 3, the nozzle temperature, and the mold temperature were the same as those described in Example 1. Further, the same PBT as described in Example 1 was used for the material. On the other hand, unlike the first embodiment, the stage after the injection mold movable part 5 is moved and is in close contact with the mold fixing part 6 (clamping), and before the molten PBT is injected into the mold. However, without introducing molding defect prevention gas into the mold, molten PBT was introduced into the mold at an injection speed of 120 mm / sec. The surface of the molded product at this time was partially browned to black around the gate, and the surface carbonization index was 3.
使用した射出成形機、スクリュー回転数、シリンダー加熱部１乃至３の温度、ノズル温度、金型温度は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。一方、実施例１とは異なり、射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、かつ溶融したPBTが金型内へ射出される前の段階で金型内への成形不良防止ガスの導入は行わず、射出速度150mm/secで金型内へ溶融したPBTを導入した。このときの成形品の表面はゲート付近の一部が黒変し、表面炭化指標は３だった。 The injection molding machine used, the screw rotation speed, the temperature of the cylinder heating units 1 to 3, the nozzle temperature, and the mold temperature were the same as those described in Example 1. Further, the same PBT as described in Example 1 was used for the material. On the other hand, unlike the first embodiment, the stage after the injection mold movable part 5 moves and closely contacts the mold fixing part 6 and before the molten PBT is injected into the mold. However, without introducing molding defect prevention gas into the mold, molten PBT was introduced into the mold at an injection speed of 150 mm / sec. The surface of the molded product at this time was partially blackened near the gate, and the surface carbonization index was 3.
使用した射出成形機、スクリュー回転数、シリンダー加熱部１乃至３の温度、ノズル温度、金型温度は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。一方、実施例１とは異なり、射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、かつ溶融したPBTが金型内へ射出される前の段階で金型内への成形不良防止ガスの導入は行わず、射出速度180mm/secで金型内へ溶融したPBTを導入した。このときの成形品の表面はゲート付近が広く黒変し、表面炭化指標は４だった。 The injection molding machine used, the screw rotation speed, the temperature of the cylinder heating units 1 to 3, the nozzle temperature, and the mold temperature were the same as those described in Example 1. Further, the same PBT as described in Example 1 was used for the material. On the other hand, unlike the first embodiment, the stage after the injection mold movable part 5 is moved and is in close contact with the mold fixing part 6 (clamping), and before the molten PBT is injected into the mold. Therefore, the introduction of molten PBT into the mold was carried out at an injection speed of 180 mm / sec. At this time, the surface of the molded product was blackened widely near the gate, and the surface carbonization index was 4.
使用した射出成形機、スクリュー回転数、シリンダー加熱部１乃至３の温度、ノズル温度、金型温度は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。一方、実施例１とは異なり、射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、かつ溶融したPBTが金型内へ射出される前の段階で金型内への成形不良防止ガスの導入は行わず、射出速度280mm/secで金型内へ溶融したPBTを導入した。このときの成形品の表面は全体的に著しく黒変し、表面炭化指標は５だった。 The injection molding machine used, the screw rotation speed, the temperature of the cylinder heating units 1 to 3, the nozzle temperature, and the mold temperature were the same as those described in Example 1. Further, the same PBT as described in Example 1 was used for the material. On the other hand, unlike the first embodiment, the stage after the injection mold movable part 5 is moved and is in close contact with the mold fixing part 6 (clamping), and before the molten PBT is injected into the mold. However, without introducing molding defect prevention gas into the mold, molten PBT was introduced into the mold at an injection speed of 280 mm / sec. At this time, the surface of the molded product was significantly blackened as a whole, and the surface carbonization index was 5.
使用した射出成形機、スクリュー回転数、シリンダー加熱部１乃至３の温度、ノズル温度、金型温度は実施例１に記載した条件と同様とした。また、材料についても実施例１に記載したものと同様のPBTを使用した。一方、実施例１とは異なり、射出成形の金型可動部５が移動して金型固定部６に密着（型締め）した後、かつ溶融したPBTが金型内へ射出される前の段階で金型内への成形不良防止ガスの導入は行わず、射出速度300mm/secで金型内へ溶融したPBTを導入した。このときの成形品の表面は全体的に著しく黒変し、表面炭化指標は５だった。 The injection molding machine used, the screw rotation speed, the temperature of the cylinder heating units 1 to 3, the nozzle temperature, and the mold temperature were the same as those described in Example 1. Further, the same PBT as described in Example 1 was used for the material. On the other hand, unlike the first embodiment, the stage after the injection mold movable part 5 is moved and is in close contact with the mold fixing part 6 (clamping), and before the molten PBT is injected into the mold. However, without introducing a molding defect prevention gas into the mold, molten PBT was introduced into the mold at an injection speed of 300 mm / sec. At this time, the surface of the molded product was significantly blackened as a whole, and the surface carbonization index was 5.
比較例１乃至６の結果を表３にまとめて示す。 The results of Comparative Examples 1 to 6 are summarized in Table 3.
以上の結果から、金型内を成形不良防止ガスで充填することにより、射出成形の現場で問題となっている表面炭化および充填不足を効果的に抑制することができる。 From the above results, by filling the inside of the mold with a molding defect preventing gas, it is possible to effectively suppress surface carbonization and insufficient filling which are problems at the site of injection molding.
１．シリンダー加熱部
２．シリンダー加熱部
３．シリンダー加熱部
４．ノズル部
５．金型可動部
６．金型固定部
７．成形不良防止ガスが充填されたボンベ
８．調整弁
９．成形不良防止ガス導入ポート
１０．ガスベント部
１１．コック
１２．ホッパー
１３．スクリュー
１４．金型ゲート部、ここから有機高分子材料が金型内に流入する。
１５．金型内のガスベント部分
1. 1. Cylinder heating unit 2. Cylinder heating unit 3. Cylinder heating unit 4. Nozzle part 5. Mold movable part 6. Mold fixing part 7. A cylinder filled with a molding defect prevention gas. Regulating valve 9. Molding prevention gas introduction port 10. 10. Gas vent part Cock 12. Hopper 13. Screw 14. The organic polymer material flows into the mold from the mold gate portion.
15. Gas vent part in the mold
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62231715A (en) * | 1986-04-01 | 1987-10-12 | Eng Plast Kk | Method for injection molding non-compatible series polymer alloy resin molding |
| JP2004142104A (en) * | 2002-10-21 | 2004-05-20 | Fuji Electric Device Technology Co Ltd | Manufacturing method for substrate for data recording medium, substrate for data recording medium, and data recording medium |
| JP2009040023A (en) * | 2007-08-06 | 2009-02-26 | Fukuhara Co Ltd | Method and apparatus for feeding nitrogen gas to injection molding machine |
| US20120003101A1 (en) * | 2010-06-30 | 2012-01-05 | Karsten Schibsbye | Casting method for manufacturing a work piece |
| WO2012165148A1 (en) * | 2011-05-30 | 2012-12-06 | ウィンテックポリマー株式会社 | Insert-molded product |
-
2013
- 2013-08-27 JP JP2013175539A patent/JP6119020B2/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62231715A (en) * | 1986-04-01 | 1987-10-12 | Eng Plast Kk | Method for injection molding non-compatible series polymer alloy resin molding |
| JP2004142104A (en) * | 2002-10-21 | 2004-05-20 | Fuji Electric Device Technology Co Ltd | Manufacturing method for substrate for data recording medium, substrate for data recording medium, and data recording medium |
| JP2009040023A (en) * | 2007-08-06 | 2009-02-26 | Fukuhara Co Ltd | Method and apparatus for feeding nitrogen gas to injection molding machine |
| US20120003101A1 (en) * | 2010-06-30 | 2012-01-05 | Karsten Schibsbye | Casting method for manufacturing a work piece |
| JP2012011781A (en) * | 2010-06-30 | 2012-01-19 | Siemens Ag | Casting method for manufacturing work piece |
| WO2012165148A1 (en) * | 2011-05-30 | 2012-12-06 | ウィンテックポリマー株式会社 | Insert-molded product |
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