JP2016106050A - 圧力調整機構 - Google Patents
圧力調整機構 Download PDFInfo
- Publication number
- JP2016106050A JP2016106050A JP2016022613A JP2016022613A JP2016106050A JP 2016106050 A JP2016106050 A JP 2016106050A JP 2016022613 A JP2016022613 A JP 2016022613A JP 2016022613 A JP2016022613 A JP 2016022613A JP 2016106050 A JP2016106050 A JP 2016106050A
- Authority
- JP
- Japan
- Prior art keywords
- pressure
- zone
- molten resin
- pressurized fluid
- foaming agent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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Images
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Abstract
Description
本発明の第1の参考態様に従えば、熱可塑性樹脂の混練装置であって、可塑化シリンダであって、前記熱可塑性樹脂が可塑化溶融された溶融樹脂と加圧流体とを接触混練する高圧混練ゾーンと、前記加圧流体が接触混練された溶融樹脂からガス化した加圧流体を排気する減圧ゾーンとを有する可塑化シリンダと、前記可塑化シリンダ内に回転及び進退自在に配設されたスクリュと、前記高圧混練ゾーンと前記減圧ゾーンとの間に設けられ、前記高圧混練ゾーンと前記減圧ゾーンとの連通を遮断する下流側シール機構と、前記可塑化シリンダの前記減圧ゾーンに接続し、前記下流側シール機構が前記高圧混練ゾーンと前記減圧ゾーンとの連通を遮断したとき、前記減圧ゾーンの圧力を大気圧以上で且つ前記溶融樹脂に前記加圧流体を接触混練するときに到達する前記高圧混錬ゾーンの最高圧力以下に制御する減圧ゾーン圧力調整機構を有する混練装置を有する混練装置が提供される。
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。
本実施例では、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。本実施例では、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。
本実施例では、実施例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。本実施例では、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、実施例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、実施例1と同様の混練装置200及び成形機1000を用いて、実施例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、実施例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実施例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実施例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実施例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、実施例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 (8)
- 可塑化シリンダ内の圧力を調整する圧力調整機構であって、
前記可塑化シリンダは、熱可塑性樹脂が可塑化溶融された溶融樹脂と加圧流体とを接触混練する高圧混練ゾーンと、前記高圧混練ゾーンの下流に配置され、前記加圧流体が接触混練された溶融樹脂からガス化した加圧流体を排気する減圧ゾーンとを有し、
前記圧力調整機構は、前記減圧ゾーンに接続し、前記減圧ゾーンに不活性ガスを導入して、前記減圧ゾーンの圧力を大気圧以上に制御することを特徴とする圧力調整機構。 - 前記圧力調整機構は、前記減圧ゾーンの圧力を大気圧以上で且つ前記高圧混錬ゾーンの最高圧力以下に制御することを特徴とする請求項1に記載の圧力調整機構。
- 前記圧力調整機構は、前記減圧ゾーンを加圧する加圧機構を有することを特徴とする請求項1又は2に記載の圧力調整機構。
- 前記圧力調整機構は、前記減圧ゾーンから前記ガス化した加圧流体を排気する排気機構を更に有することを特徴とする請求項3に記載の圧力調整機構。
- 前記加圧機構は、不活性ガスボンベと、ポンプと、減圧弁とを有し、
前記不活性ガスボンベは、前記ポンプ、前記減圧弁をこの順に介在して、前記減圧ゾーンに接続されることを特徴とする請求項3又は4に記載の圧力調整機構。 - 前記排気機構は、バッファ容器と、背圧弁と、排気口とを有し、
前記バッファ容器は前記減圧ゾーンに接続し、前記バッファ容器は前記背圧弁を介して前記排気口へ接続することを特徴とする請求項4に記載の圧力調整機構。 - 前記可塑化シリンダ内には、前記高圧混練ゾーンと前記減圧ゾーンとの間に、前記高圧混練ゾーンと前記減圧ゾーンとの連通を遮断する下流側シール機構が設けられ、
前記下流側シール機構が前記高圧混練ゾーンと前記減圧ゾーンとの連通を遮断したとき、前記圧力調整機構は、前記減圧ゾーンの圧力を大気圧以上に制御することを特徴とする請求項1〜6のいずれか一項に記載の圧力調整機構。 - 前記圧力調整機構は、前記減圧ゾーンの圧力を大気圧以上で且つ前記溶融樹脂に前記加圧流体を接触混練するときに到達する前記高圧混錬ゾーンの最高圧力以下に制御することを特徴とする請求項7に記載の圧力調整機構。
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