JP2018503546A - 射出成形システムおよび部品製造方法 - Google Patents
射出成形システムおよび部品製造方法 Download PDFInfo
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/47—Means for plasticising or homogenising the moulding material or forcing it into the mould using screws
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C48/92—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
- B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
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Abstract
Description
本特許出願は、米国特許法第119条(e)項に従い、米国仮特許出願第62/087,414号の優先権の利益を主張しており、その出願は、2014年12月4日に出願され、かつ、発明の名称が「押出充填型(Extrude-to-Fill、エクストルード・ツゥー・フィル、押出によってモールド内への材料充填を行う方式、スクリュー回転による押出によってモールド内への材料充填を行う方式)の射出成形方法および押出スクリュー」であり、本特許出願は、さらに、米国仮特許出願第62/087,449号の優先権の利益を主張しており、その出願は、2014年12月4日に出願され、かつ、発明の名称が「押出充填型(Extrude-to-Fill)の射出成形システムのためのノズル・シャットオフ方法(Shut-off、遮断方法、閉塞方法)」であり、本特許出願は、さらに、米国仮特許出願第62/087,480号の優先権の利益を主張しており、その出願は、2014年12月4日に出願され、かつ、発明の名称が「押出充填型(Extrude-to-Fill)の射出成形方法のための制御システム」であり、それら出願の各々は、引用により全体的に本特許出願に合体する。
この書類の開示事項は、理解を助けるために提供されており、当業者の一人であれば、この開示事項の様々な側面および特徴の各々が、いくつかの事例において互いに分離して用いられることが有利であるか、または、他のいくつかの事例において、この開示事項の他のいくつかの側面および特徴と組み合わせて用いられることが有利であるかもしれないということが理解されることになる。したがって、この開示事項は、実施態様という観点で提示されるが、理解されるべきことは、いずれの実施態様の個々の側面であっても、互いに分離して特許請求の対象になるか、または、同じ実施態様のうちの側面および特徴、もしくは、他のいずれかの実施態様の側面および特徴と組み合わせて特許請求の対象になることが可能であるということである。
この書類で説明される押出充填式(ETF)の射出成形システムは、必要な射出圧が、従来の射出成形システムより一層低い。例えば、この押出充填式(ETF)の射出成形システムは、モールド・キャビティ内の圧力と等圧の圧力を発生させるか、または、モールド・キャビティ内の圧力が取り得る500psiから1,500psiまでの範囲より、例えば5%−10%高いというように、わずかに高い射出圧を発生させるかもしれない。これに対し、来の射出成形システムが500psiから1,500psiまでの範囲というモールド・キャビティ内の圧力と等圧の圧力を発生させるために、20,000psiから30,000psiまでの範囲内の射出圧が必要であるかもしれない。このことは、今回の押出充填式の射出成形システムに必要な総電力(power、電力量)が、110Vまたは208Vの単相電源で0.5kWhから3kWhまでの範囲であることを可能にする。従来の射出成形システムは、220Vまたは440Vの三相電源で6kWhから12kWhまでの範囲の電力量を必要とする。
このETF射出システムに用いられる静的な(static、動きを伴わない)熱発生および静的な熱伝導は、樹脂材料にも樹脂特性にも影響されず、その樹脂特性は、とりわけ、樹脂グレード、樹脂純度、樹脂均一性およびメルトフローインデックス(melt flow index、溶融指数)を含むがそれらに限定されない。
Claims (25)
- 装置であって、
第1セクションと第2セクションと温度遷移セクションとを有するバレルであって、前記第1セクションは、ノズルまたはゲート・インサートを経由してモールドと関連付けられる端部を有し、前記第2セクションは、材料を前記バレル内に充填するように構成されるホッパに連結され、前記温度遷移セクションは、前記第1セクションと前記第2セクションとの間に存在するものと、
そのバレル内に配置されるとともにそのバレルに対して相対的に回転可能である押出スクリューと、
前記バレル内の前記材料を加熱するために前記バレルの前記第1セクションと関連付けられる1または複数のヒータと
を含み、
前記押出スクリューが前記バレルに対して相対的に回転することにより、前記材料が前記モールド内へ連続的に押し出される装置。 - 前記材料は、アモルファス熱可塑性プラスチック(amorphous thermoplastics)、結晶性または半結晶性の熱可塑性プラスチック(crystalline or semi-crystalline thermoplastics)、未使用樹脂、ガラス繊維、カーボン繊維またはセルロース繊維によって強化されたプラスチック、再生された熱可塑性プラスチック、混合された(mixed、ミックスされた)および混合された(comingled、コミングルされた)熱可塑性樹脂、天然樹脂(organic resins)、有機食品化合物(organic food compounds)、炭水化物系樹脂(carbohydrate based resins)、糖系化合物(sugar-based compounds)、ゼラチン(gelatin)、プロピレン・グリコール化合物(propylene glycol compounds)、でんぷん系化合物(starch based compounds)、ならびに金属射出成形(metal injection molding)(MIM)フィードストック(feedstocks)より成るグループから選択される請求項1に記載の装置。
- 前記押出スクリューは、伝導性(conductive、熱伝導性)を有する材料であって、銅、銅合金、真鍮、黄銅合金(brass alloy)、炭素鋼およびステンレス鋼であって、それら材料のうちのいずれかはクロムまたは他の特殊めっきで処理されてもよいものより成るグループから選択される請求項1または2に記載の装置。
- 前記バレルまたは前記押出スクリューは、誘導加熱のための磁性材料の一部を含む請求項1ないし3のいずれかに記載の装置。
- 前記ホッパは、冷却流体を循環させるように構成されている請求項1ないし4のいずれかに記載の装置。
- 前記バレルの前記温度遷移セクションは、溶融した材料を効果的に(effectively、シール領域がない場合より効果的に)押し込むために前記材料がシール領域を形成することを可能にする長さを有する請求項1ないし5のいずれかに記載の装置。
- 前記押出スクリューおよび前記バレルは、それぞれ段付き状を成す外径部および内径部を有する請求項1ないし6のいずれかに記載の装置。
- 前記押出スクリューは、軸方向位置に関して固定されている請求項1ないし7のいずれかに記載の装置。
- 前記材料は、主に(primalily、実質的に)前記1または複数のヒータによって加熱される請求項1ないし8のいずれかに記載の装置。
- 各々、請求項1ないし9のいずれかに記載されている複数の装置を含む装置体であって、
当該装置体は、1つのモールド・キャビティを、複数のゲートから1つのモールド・キャビティに向けて充填するように構成されているか、または1つのモールド内において複数のモールド・キャビティを充填するように構成されている装置体。 - 前記複数の装置の各々は、目標圧力が達成されると、材料の流れを停止させるように他の装置から独立して制御される請求項10に記載の装置体。
- 前記複数の装置の各々は、それぞれの圧力データを、対応するコントローラに提供する請求項10または11に記載の装置体。
- 押出充填式(extrude-to-fill、スクリューの押出によってモールド内への材料充填を行う方式)の射出成形装置であって、
時計回りおよび反時計回りに回転するように構成される押出スクリューと、
その押出スクリューの外側に配置されるバレルに連結されるホッパであって、材料を前記バレル内に充填するとともに冷却流体を循環させるように構成されたものと、
前記押出スクリューが回転すると、溶融した材料がノズルを経由してモールド内へ押し込まれるように前記材料を加熱するために、前記ホッパから距離を隔てた位置において、前記バレルに関連付けられる1または複数のヒータと
を含む押出充填式の射出成形装置。 - 前記押出スクリューは、自身の長さ方向に沿って一定である谷径を有する請求項13に記載の射出成形装置。
- 前記押出スクリューは、一定のフライト高さを有する請求項13または14に記載の射出成形装置。
- 前記押出スクリューは、前記ノズルの近傍において材料を効果的に(effectively、第2の部分より効果的に)混合させるように構成されたジトメトリを有する第1部分と、前記ホッパから材料を効果的に(effectively、第1の部分より効果的に)供給するように構成されたジトメトリを有する第2部分とを含む請求項13ないし15のいずれかに記載の射出成形装置。
- 前記押出スクリューは、第1フライト高さを有する第1部分と、その第1部分より大きな第2フライト高さを有する第2部分とを含み、前記第1部分は、溶融した材料を前記モールド内に流入させるために、前記バレルと関連付けられる前記ノズルに適合する端部を有する請求項13または14に記載の射出成形装置。
- 前記第1部分は、溶融材料を効果的に効果的に(effectively、第2の部分より効果的に)押し込むように構成されており、前記第2部分は、効果的に(effectively、第1の部分より効果的に)材料を供給するとともに混合させるように構成されており、前記第2部分は、前記第1部分より前記ホッパに近い位置に存在する請求項17に記載の射出成形装置。
- 前記押出スクリューと前記バレルとの間の空隙は、スクリュー回転によって前記材料内に発生するせん断熱を減少させるために十分な大きさである請求項13ないし18のいずれかに記載の射出成形装置。
- 各々、請求項13ないし19のいずれかに記載されている複数の射出成形装置を含む装置体であって、
当該装置体は、1つのモールド・キャビティを、複数のゲートから1つのモールド・キャビティに向けて充填するように構成されているか、または1つのモールド内において複数のモールド・キャビティを充填するように構成されている装置体。 - 前記複数の射出成形装置の各々は、目標圧力が達成されると、材料の流れを停止させるように他の射出成形装置から独立して制御される請求項20に記載の装置体。
- 前記複数の射出成形装置の各々は、それぞれの圧力データを、対応するコントローラに提供する請求項20または21に記載の装置体。
- 装置であって、
中空である押出スクリューであって、当該押出スクリュー内にヒータを収容するように構成されるものと、
前記押出スクリューの外側に存在するバレルであって、ノズルまたはゲート・インサートを経由してモールドと関連付けられる一端部を有するものと、
そのバレルの他端部に連結されるとともに材料を前記バレル内に供給するように構成されるホッパであって、冷却流体を循環させるように構成されるものと、
前記押出スクリューが、溶融した材料を前記ノズルの開口部を経由して前記モールド内へ押し込むように前記材料を加熱するために、前記ホッパから距離を隔てた位置において、前記バレルの外側に配置される1または複数のヒータと
を含む装置。 - 部品を製造する方法であって、
バレル内の材料を溶融させるために1または複数のヒータを起動させる工程と、
モールドが充填されるまで、溶融した材料を前記モールド内に押し込むように押出スクリューを回転させる(rotate、正回転させる)工程と、
前記バレルを減圧するという目的と、前記材料の非ニュートン挙動を停止させるという目的とのために前記押出スクリューを逆回転させる工程と
を含む方法。 - 前記材料は、アモルファス熱可塑性プラスチック(amorphous thermoplastics)、結晶性または半結晶性の熱可塑性プラスチック(crystalline or semi-crystalline thermoplastics)、未使用樹脂、強化プラスチック、再生された熱可塑性プラスチック(recycled thermoplastics)、工業目的で使用された後に再生された樹脂(post-industrial recycled resins)、消費者によって消費された後に再生された樹脂(post-consumer recycled resins)、混合された(mixed、ミックスされた)および混合された(comingled、コミングルされた)熱可塑性樹脂、天然樹脂(organic resins)、有機食品化合物(organic food compounds)、炭水化物系樹脂(carbohydrate based resins)、糖系化合物(sugar-based compounds)、ゼラチン(gelatin)、プロピレン・グリコール化合物(propylene glycol compounds)、でんぷん系化合物(starch based compounds)、および金属射出成形(metal injection molding)(MIM)フィードストック(feedstocks)より成るグループから選択される請求項24に記載の方法。
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