JP2019044011A - 発泡成形用樹脂、発泡成形体、発泡成形体の製造方法 - Google Patents
発泡成形用樹脂、発泡成形体、発泡成形体の製造方法 Download PDFInfo
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Abstract
【解決手段】低密度ポリエチレンを含有する発泡成形用樹脂であって、前記低密度ポリエチレンは、ひずみ硬化度が0.40以上である。発泡成形用樹脂は、高密度ポリエチレンをさらに含有し、前記低密度ポリエチレンと前記高密度ポリエチレンの質量比は、2:8〜8:2である。
【選択図】なし
Description
好ましくは、発泡成形用樹脂は、高密度ポリエチレンをさらに含有する。
好ましくは、前記低密度ポリエチレンと前記高密度ポリエチレンの質量比は、2:8〜8:2である。
好ましくは、前記低密度ポリエチレンのメルトテンションが、250mN以上である。
好ましくは、前記低密度ポリエチレンのせん断粘度が、450Pa・s以上である。
本発明の一実施形態の発泡成形用樹脂は、LDPEを含有する発泡成形用樹脂であって、前記LDPEは、ひずみ硬化度が0.40以上である。
λn=ηE(t、εnon−liner)/ηE(t、εliner) ・・・式(1)
式(1)において、ηE(t、εnon−liner)はひずみ硬化中の伸張粘度の測定値であり、ηE(t、εliner)ひずみ硬化しない場合の伸張粘度の測定値である。
MFR:0.2〜0.4g/10分
せん断粘度:550〜650Pa・s
密度:0.94〜0.96g/cm3
MT:70〜200mN
本発明の一実施形態の発泡成形体の製造方法では、上述した発泡成形用樹脂と発泡剤を発泡押出機内で溶融混練してなる溶融混練樹脂を前記発泡押出機から押し出して発泡パリソンを形成し、前記発泡パリソンを成形して発泡成形体を得る工程を備える。
得られた発泡成形体は、例えば、車両用空調ダクト等に用いることができる。
樹脂投入口5は、いわゆるホッパーであり、ここから、原料樹脂を投入する。原料樹脂の形態は、特に限定されないが、通常は、ペレット状である。原料樹脂は、上述した本発明の一実施形態の発泡成形用樹脂である。原料樹脂は、樹脂投入口5からシリンダ3内に投入された後、シリンダ3内で加熱されることによって溶融されて溶融樹脂になる。また、シリンダ3内に配置されたスクリュー7の回転によってシリンダ3の一端に設けられた樹脂押出口11に向けて搬送される。
スクリュー7は、シリンダ3内に配置され、その回転によって溶融樹脂を混練しながら樹脂押出口11に向けて搬送する。スクリュー7の一端にはギア装置15が設けられており、ギア装置15によってスクリュー7が回転駆動される。シリンダ3内に配置されるスクリュー7の数は、1本でもよく、2本以上であってもよい。
シリンダ3には、シリンダ3内に発泡剤を注入するための発泡剤注入口Pが設けられる。発泡剤注入口Pを設ける位置は特に限定されないが、シリンダ3の樹脂投入口5側の端部の位置を0、樹脂押出口11側の端部の位置をLとした場合、発泡剤注入口Pは、0.3L〜0.7L(好ましくは0.4〜0.6L)の位置に設けることが好ましい。発泡剤注入口Pが0.3Lよりも樹脂投入口5側に設けられると、溶融樹脂の混練が不十分な状態で発泡剤が注入されてしまって発泡剤の分散が不十分になる場合がある。また、溶融樹脂の温度は通常樹脂押出口11に向かって徐々に低下するように制御されるので、発泡剤注入口P0.7Lよりも樹脂押出口11側に設けられると、発泡剤を注入する部位での溶融樹脂の温度が低すぎて発泡剤の注入量が減少してしまう場合がある。
温度制御部9は、シリンダ3に沿って設けられた複数の温調ユニットを個別に制御して、シリンダ3の各部分の温度を制御するように構成されている。また、温度制御部9は、パリソンを形成するためのダイヘッド12の温度、及びシリンダ3とダイヘッド12の間の連結部10の温度も制御可能である。
原料樹脂と発泡剤が溶融混練されてなる溶融混練樹脂は、樹脂押出口11から押し出され、連結部10を通じてダイヘッド12内に注入される。ダイヘッド12は、図4に示すように、円筒状のダイ外筒41と、その内部に収容されるマンドレル43を備え、その間の空間47にシリンダ3から押し出された溶融混練樹脂を貯留する。そして、空間47に溶融混練樹脂が所定量貯留された後にリング状ピストン45を鉛直方向に押し下げることによって溶融混練樹脂をダイスリット49から押し出して円筒状の発泡パリソン13を形成する。なお、ここでは、円筒状の発泡パリソン13を形成するためのダイヘッド12を示しているが、ダイヘッド12は、シート状の発泡パリソンを形成するためのものであってもよい。
発泡パリソン13は、一対の分割金型14間に導かれる。分割金型14を用いて発泡パリソン13の成形を行うことによって発泡成形体が得られる。分割金型14を用いた成形の方法は特に限定されず、分割金型14のキャビティ内にエアーを吹き込んで成形を行うブロー成形であってもよく、分割金型14のキャビティの内面からキャビティ内を減圧して発泡パリソン13の成形を行う真空成形であってもよく、その組み合わせであってもよい。
図3に示す発泡押出機1及び分割金型14を用いて、発泡成形品を作製し、発泡成形性の評価を行った。発泡押出機1のシリンダ3の内径は50mmであり、L/D=34であった。原料樹脂には、表1に示すLDPEと、HDPE(グレード:B470,旭化成ケミカルズ製)とを質量比1:1で混合したものを用いた。発泡パリソン13の温度が190〜200℃になるように温度制御部9の設定を行った。スクリュー7の回転数は、60rmmとし、押出量は、20kg/hrとした。発泡剤にはN2ガスを用い、0.5Lの位置に設けられた発泡剤注入口Pから注入した。注入ガス量を変化させることによって発泡倍率の調整を行った。
実験例2では、実施例2のLDPE(グレード:1005FY20、Reliance製)を用い、LDPEとHDPEの質量比を7:3に変更した実施例3と、LDPEとHDPEの質量比を3:7に変更した実施例4を作製し、成形可能な発泡倍率を測定した。その結果、成形可能な発泡倍率は、実施例3では3.5倍、実施例4では2.4倍であった。この結果は、LDPEとHDPEの質量比が1:1である場合以外であっても、ひずみ硬化度が0.40以上であるLDPEを用いることによって発泡成形体の発泡倍率を高めることができることを示している。
Claims (7)
- 低密度ポリエチレンを含有する発泡成形用樹脂であって、
前記低密度ポリエチレンは、ひずみ硬化度が0.40以上である、発泡成形用樹脂。 - 前記発泡成形用樹脂は、高密度ポリエチレンをさらに含有する、請求項1に記載の発泡成形用樹脂。
- 前記低密度ポリエチレンと前記高密度ポリエチレンの質量比は、2:8〜8:2である、請求項2に記載の発泡成形用樹脂。
- 前記低密度ポリエチレンのメルトテンションが、250mN以上である、請求項1〜請求項3のいずれか1つに記載の発泡成形用樹脂。
- 前記低密度ポリエチレンのせん断粘度が、450Pa・s以上である、請求項1〜請求項4のいずれか1つに記載の発泡成形用樹脂。
- 請求項1〜請求項5のいずれか1つに記載の発泡成形用樹脂を成形してなる発泡成形体。
- 請求項1〜請求項5のいずれか1つに記載の発泡成形用樹脂と発泡剤を発泡押出機内で溶融混練してなる溶融混練樹脂を前記発泡押出機から押し出して発泡パリソンを形成し、前記発泡パリソンを成形して発泡成形体を得る工程を備える、発泡成形体の製造方法。
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