JP3881829B2 - Extrusion molding apparatus and method for producing molded body using the same - Google Patents

Extrusion molding apparatus and method for producing molded body using the same Download PDF

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Publication number
JP3881829B2
JP3881829B2 JP2000272340A JP2000272340A JP3881829B2 JP 3881829 B2 JP3881829 B2 JP 3881829B2 JP 2000272340 A JP2000272340 A JP 2000272340A JP 2000272340 A JP2000272340 A JP 2000272340A JP 3881829 B2 JP3881829 B2 JP 3881829B2
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extrusion
molded product
speed
extrusion hole
hole
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JP2002079568A (en
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諭 柴田
和也 土本
修 山西
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/92085—Velocity
    • B29C2948/92104—Flow or feed rate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92323—Location or phase of measurement
    • B29C2948/92361—Extrusion unit
    • B29C2948/92409—Die; Nozzle zone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/9258—Velocity
    • B29C2948/926—Flow or feed rate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
    • B29C2948/92857—Extrusion unit
    • B29C2948/92904—Die; Nozzle zone

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、成形品の切断長さのばらつきを最小限に抑えることができる押出成形装置とこれを用いる成形体の製造方法に関する。
【従来の技術】
【０００２】
一般に、触媒、触媒担体、吸着材、乾燥材、調湿材等は、直径２〜１０ｍｍ、長さ２〜２０ｍｍ程度の円柱形または円筒形の成形体に成形され、これを反応器に充填して種々の化学反応プロセスに使用される。このような触媒等の成形体を製造するために、従来から押出成形法が採用されている。
【０００３】
すなわち、アルミナ等の軟質な粘土状材料をダイから連続的に押し出した成形品を小さく切断して成形体を製造する。その際、成形品を刃物等で切断すると、成形体の切断された端部が変形して、反応器内に密に充填できなくなり、その結果、触媒等の充填量が少なくなって、化学反応プロセスに支障をきたすという問題が生じる。
【０００４】
そのため、従来より、ダイから押し出された直後の軟質な成形品を、２点間に張りわたしたピアノ線で切断することが行われている。すなわち、ピアノ線を２点間に張りわたした支持板を用いて、この支持板を押出方向と直交する方向に回転または往復動させて、ピアノ線を一定の時間間隔でダイの押出孔前面を横切らせることにより、押出直後の成形品を切断している。
【０００５】
この場合、ピアノ線による切断速度は一定値に設定して、成形品の切断が行われる。ところが、成形品の押出速度は、成形材料の粘度変化などによって変化しやすいため、成形品の押出速度がわずかでも変化すると、切断された成形体の長さに大きなばらつきが生じ、前記したように成形体を反応器内に密に充填できなくなるなどの問題が発生する。
【０００６】
【発明が解決しようとする課題】
本発明の目的は、成形品の切断長さのばらつきを小さくすることができ、寸法精度の高い成形品が得られる押出成形装置とこれを用いる成形体の製造方法を提供することである。
【０００７】
【課題を解決するための手段】
上記課題を解決するための本発明の押出成形装置は、成形品が連続的に押し出される押出孔を有するダイと、前記押出孔から押し出される成形品を切断するための切断装置と、前記押出孔の内方に設けられ押出孔から押し出される成形品の押出し速度を制御する流量制御弁と、前記押出孔から押し出される成形品の押出し速度を検出するためのセンサと、このセンサからの入力信号に基づいて前記流量制御弁の開閉操作を行わせるための制御手段とを備えたことを特徴とする。
【０００８】
すなわち、本発明によれば、センサにて成形品の押出し速度を検出しているので、成形品の押し出し速度が変化した場合には、センサからの入力信号に基づいて、制御手段が流量制御弁の開閉操作を行って成形品の押出し速度を制御し、これによって成形品の切断長さを調整するものである。
【０００９】
前記ダイは複数の押出孔を有するものであってもよい。この場合、押出成形装置は、成形品が連続的に押し出される複数の押出孔を有するダイと、前記押出孔から押し出される成形品を切断するための切断装置と、各押出孔の内方に設けられ各押出孔から押し出される成形品の押出し速度を制御する流量制御弁と、各押出孔から押し出される成形品の押出し速度を検出するためのセンサと、このセンサによって各押出孔ごとに検出された成形品の押出し速度に基づいて各流量制御弁の開閉操作を行わせるための制御手段とを備える。
【００１０】
前記センサはスポット光源式のセンサであるのが好ましく、成形品が押出孔からこのセンサの測定点に到達するまでの時間を測定することによって成形品の押出し速度を検出する。これによって、成形品の押出し速度を高精度で検出することができ、成形品の切断長さをより均一なものにすることができる。
【００１１】
前記制御手段による制御は、具体的には、各押出孔から押し出された各成形品の切断長さが成形品の切断長さの平均値に近づくように、押出孔ごとに流量制御弁の開閉操作を行って、成形品の押出し速度を調整するか、あるいは各押出孔から押し出された各成形品の切断長さが成形品の切断長さの設定値に近づくように、押出孔ごとに流量制御弁の開閉操作を行って、成形品の押出し速度を調整する。
【００１２】
また、本発明では、流量制御弁の制御と共に、切断装置の制御をも行うのが成形品の切断長さのばらつきをより小さくする上で好ましい。すなわち、本発明の他の押出成形装置は、成形品が連続的に押し出される押出孔を有するダイと、 ２点間に張りわたされた線材を有し前記成形品の押出方向と直交する方向に回転または往復動して前記線材を押出孔の前面を横切らせ押出直後の成形品を切断するための切断装置と、前記押出孔の内方に設けられ押出孔から押し出される成形品の押出し速度を制御する流量制御弁と、前記押出孔から押し出される成形品の押出し速度を検出するためのセンサと、このセンサからの入力信号に基づいて前記切断装置が回転または往復動する速度制御と前記流量制御弁の開閉操作とを行わせるための制御手段とを備える。
【００１３】
前記ダイは複数の押出孔を有するものであってもよい。この場合、本発明の押出成形装置は、成形品が連続的に押し出される複数の押出孔を有するダイと、２点間に張りわたされた線材を有し前記成形品の押出方向と直交する方向に回転または往復動して前記線材を各押出孔の前面を横切らせ押出直後の成形品を切断するための切断装置と、各押出孔の内方に設けられ押出孔から押し出される成形品の押出し速度を制御する流量制御弁と、各押出孔から押し出される成形品の押出し速度を検出するためのセンサと、このセンサからの入力信号に基づいて前記切断装置が回転または往復動する速度制御と前記各流量制御弁の開閉操作とを行わせるための制御手段とを備える。
【００１４】
具体的には、前記制御手段は、各押出孔から押し出された各成形品の切断長さの平均値が成形品の切断長さの設定値に近づくように、切断装置の回転または往復動する速度を制御すると共に、各押出孔から押し出された各成形品の切断長さが成形品の切断長さの平均値に近づくように、押出孔ごとに流量制御弁の開閉操作を行って、成形品の押出し速度を調整するのが好ましい。これにより、切断長さのばらつきが小さく、寸法精度の高い成形品を得ることが可能となる。
【００１５】
また、本発明は、前記した押出成形装置を用いて、ダイから連続的に押し出される成形品を切断装置で所定長さに順次切断することを特徴とする成形体の製造方法をも提供するものである。
【００１６】
【発明の実施の形態】
本発明の一実施形態を図１ないし図５に示す。図１はこの実施形態にかかる押出成形装置の概略を示しており、ダイ１の前面には切断装置２が設けられている。
【００１７】
ダイ１は、押出装置１０の前面に取り付けられ、成形品が連続的に押し出される複数の押出孔３を有する。また、切断装置２は、２つのガイドローラ４，５間に張りわたされたピアノ線６（線材）を有する。このピアノ線６は、押出孔３を設けた膨出部１５の頂面に接触しながら押出孔３の前面を移動して、ダイ１から押し出された成形品１１を所定長さで切断して成形体７を得るものである。
【００１８】
すなわち、前記切断装置２は、押出方向に平行に配置された回転軸８に該回転軸８に直交して一体に取り付けられた円板形の取付け板９を備え、この取付け板９をダイ１の外面と離隔対向させると共に、回転軸８を回転駆動部１６（モーター）にて回転させることにより成形品１１の押出方向に直交する方向に回転させるように構成されている。
【００１９】
前記回転軸８は、円板形のダイ１の中心軸と同軸上に設けられる。そして、図２に示すようにダイ１には複数の押出孔３が同心円状に配設されているので、回転軸８を回転させて、取付け板９を回転させることにより、その前面に張設したピアノ線６が各押出孔３の前面を横切りながら通過する。また、図２に示すように、取付け板９には回転軸８を介して互いに反対方向に２つのピアノ線６，６が張設されており、それぞれのピアノ線６，６にて成形品の切断が行われる。なお、使用するピアノ線６の直径は、成形体の材料、直径等を考慮して決定すればよいが、通常、３００μｍ以下が適当である。
【００２０】
一方、各押出孔３の内方には、それぞれ各押出孔３から押し出される成形品１１の押出し速度を制御するための流量制御弁１７が設けられる。この流量制御弁１７は、仕切り弁方式のゲートバルブであって、図１に示すように仕切り弁１８が押出装置１０の空隙１９内を出没自在に取付けられており、仕切り弁１８の空隙１９内への突出長さを調節することにより空隙１９内を通過する押出物の流量を制御することができる。仕切り弁１８の空隙１９内への出没には、例えば回転駆動部２０（モータ等)にてピニオンを回転させ、このピニオンと歯合したラックにて仕切り弁１８を移動させる、いわゆるラック・ピニオン方式等が採用可能である。
【００２１】
また、押出孔３の前面から離隔した位置には、スポット光源式のセンサ１２が設けられる。このセンサ１２には、例えば光源にレーザー光や発光ダイオード等を用いて距離測定等の目的で使用されるセンサが挙げられ、とくにスポット光を対象物に照射する照射部１３と対象物から反射した光を受ける受光部１４とを備えた反射型センサ１２（例えば反射型レーザーセンサ）を使用するのが装置全体のコンパクト化を図る上で好ましい。
【００２２】
センサ１２の取付け位置は、ダイ１から離隔した側方で、ダイ１から押し出された成形品１１が通過する経路にスポット光を照射できる部位である。このセンサ１２を使用して、成形品１１が押出孔３からセンサ１２の測定点に到達するまでの時間を測定する。すなわち、１回目の切断直後は、センサ１２の測定点（つまり光照射点）には成形品１１は存在しないので、センサ１２は成形品１１を検知しないが、１回目の切断後、新たに押し出された成形品１１の先端が測定点に到達したとき、センサ１２は成形品１１を検知するので、１回目の検知から２回目の検知までの時間ｔ1がわかる。押出孔３からセンサ１２の測定点までの距離Ｌはあらかじめ設定されているので、式：Ｌ／ｔ1から成形品１１の押し出し速度Ｖが求められる。なお、押出孔３からセンサ１２の測定点までの距離Ｌは、押出孔３からの切断長さと等しいか、それよりも小さい距離である。
【００２３】
一方、切断装置２の回転速度を測定することによってピアノ線６が押出孔３の前面を１回目に通過してから２回目に通過するまでの時間ｔ2は計算から求められるので、式：Ｖ×ｔ2から成形品１１の切断長さＸが検出される。
検出された切断長さＸは、センサ１２からの入力信号を受けた制御部１７にて設定値Ｘ0との比較が行われ、Ｘ＞Ｘ0である場合には弁棒１８を空隙１９内に進出させて流量を低減させ、逆にＸ＜Ｘ0である場合には弁棒１８を空隙１９内から退出させて、Ｘ＝Ｘ0となるように制御される。このとき、同時に、切断装置２の回転駆動部１６の制御も行うのが好ましい。すなわち、Ｘ＞Ｘ0の場合には回転駆動部１６の回転数を上げ、Ｘ＜Ｘ0の場合には回転駆動部１６の回転数を下げる。
【００２４】
センサ１２は、図３に示すように、全ての押出孔３について設置される。すなわち、センサ１２は、円盤形のダイ１に同心円状に配設された８つの押出孔３のそれぞれに設置される。
【００２５】
図３はこの実施形態における制御機構の詳細も示している。各センサ１２からの入力信号は入力切替装置１８を経て制御手段４０（シーケンサー）内の入力ユニット１９に送られる。一方、切断装置２の回転軸８の回転数(または回転速度)はロータリーエンコーダー２０にて検出され、ＣＰＵ２１（中央処理装置）に送られる。
【００２６】
ＣＰＵ２１では、図４に示すように、各押出孔３に配設したセンサ１２にて検出された各押出孔３での成形品１１の押出速度から切断長さＸnを求め、これから切断長さの平均値Ｘavが算出される。そして、各押出孔３での切断長さＸnと切断長さの平均値Ｘavとが比較され、Ｘn＞Ｘavである場合には流量制御弁１７の仕切り弁１８を空隙１９内に進出させて流量を抑え、押出速度を低下させＸ＝Ｘavとなるように制御する。逆にＸ＜Ｘavである場合には仕切り弁１８を空隙１９内から退出させて流量を増大させ、押出速度を上昇させ、Ｘ＝Ｘavとなるように制御する。Ｘ＝Ｘavの場合には流量制御弁１７は不変である。
【００２７】
これらの制御信号は、Ｄ／Ａ変換ユニット２２からインバーター２３を経て、各流量制御弁１７に設けられたそれぞれの回転駆動部２０ａ，２０ｂ，２０ｃ，……２０ｈへ送られ、各押出孔３ごとに流量制御（従って押出速度の制御）が行われる。このため、各押出孔３間での押出速度のばらつきが低減され、平均値Ｘavを中心とする切断長さＸｎのばらつきを非常に小さくすることができる。
なお、切断長さＸnは、平切断長さの平均値Ｘavに代えて、切断長さの設定値Ｘ0と比較してもよく、これにより各切断長さＸnの寸法精度が向上する。
【００２８】
また、前記平均値Ｘavと切断長さの初期設定値Ｘ0とが比較され、Ｘav＞Ｘ0である場合には回転駆動部１６の回転数を低減し、逆にＸav＜Ｘ0である場合には回転駆動部１６の回転数を増大させ、Ｘ＝Ｘ0となるように制御される。Ｘ＝Ｘ0である場合には回転駆動部１６の回転数は不変である。
【００２９】
回転駆動部１６への出力信号はＤ／Ａ変換ユニット２２からインバーター２３を経て回転駆動部１６へ送られ、回転数（従って回転速度）の調整が行われる。この結果、切断長さを設定値Ｘ0により近づけることができるようになり、成形品１１を切断して得られる成形体７の寸法精度が向上する。
【００３０】
一方、出力ユニット２４からＤ／Ａ変換器２５を経て記録計２６にデータが記録される。また、パソコンリンクユニット２７から長さ表示器２８に切断長さのデータを送り、表示させることもできる。
【００３１】
次にこの実施形態で使用のダイ１について説明する。ダイ１における押出孔３の内径は、約１ｍｍ〜１０ｍｍ、好ましくは約３ｍｍ〜６ｍｍである。押出孔の孔数はダイの外径、押出孔の内径等を考慮して決定すればよく、例えば１ケ、２ケ、４ケ、８ケ、１６ケ、３２ケ等が挙げられる。押出孔の形状は円形の他、例えばリング、ハニカム、クローバー状等が挙げられる。
【００３２】
成形物の具体例としては、例えば触媒、触媒担体、吸着材、乾燥材、調湿材等が挙げられる。また、成形体の材料は無機材料に限定されるものではなく、種々のプラスチック材料等に対して本発明の押出成形装置は適用可能である。
その際、使用する線材はピアノ線に限定されるものではなく、他の金属線であっても良く、プラスチック材、繊維材等から作られた線材であってもよいことは勿論である。
さらに、上記実施形態では、取付け板９は回転するように構成されたが、成形品の押出方向に対して直交する方向に往復動させてもよく、この場合には往復動する速度を制御すればよい。ピアノ線６はガイドローラー４、５間に固定されていてもよいが、連続的または断続的に巻き取られながらガイドローラー４、５間を移動させられることが好ましい。ピアノ線６を移動させることによってピアノ線の破断を防止し、成形体を連続して製造することができる。
【００３３】
本発明の他の実施形態を図５に基づいて説明する。図５に示す押出成形装置は、ゲート弁の一種であるバタフライ弁方式の流量制御弁３０を備えたものである。この流量制御弁３０は、ダイ１の各押出孔３の後方にそれぞれ設けられる。押出装置３１は、中央部にコーン３２が設けられ、押出物を各押出孔３に向かわせる（押出物の流れを矢印で示す）。
【００３４】
流量制御弁３０は、コーン３２とダイ１との間に介在した弁本体３２と、この弁本体３３と対向し押出物が通過する空隙１９内に位置する回転板３３と、この回転板３３を先端に保持し回転駆動部３５(モータ等)の駆動により歯車３６、３７を介して回転する弁棒３４とを備える。
【００３５】
回転駆動部３５は、制御手段からの信号を受けて、弁棒３４を介して回転板３３を回転させ、流量制御を行う。すなわち、回転板３３の板面が押出し方向に直交するとき流量は最小となり、逆に押出し方向と平行になると流量は最大となる。従って、回転板３３の向きを調節することにより流量制御が可能になる。その他は前述の実施形態と同じである。
【００３６】
本発明にかかる流量制御弁は、前記した仕切弁方式やバタフライ弁方式に限定されるものではなく、種々のゲート弁が採用可能である。例えば図６に示すようなスクリュー形式の流量制御弁３８等も採用可能である。このスクリュー形式の流量制御弁３８は押出孔３に対して前進または後退することにより流量制御を行うものである。
【００３７】
【実施例】
以下、実施例および比較例を挙げて本発明の押出成形装置を説明する。
【００３８】
実施例
図１〜図４に示す押出成形装置を用いて、粘土状のアルミナ触媒成形体を押出成形した。
使用したダイ１は、表面がクロムメッキされたもので、押出孔３を同心円状に８個配設した円盤形状を有する。押出孔３は内径が５ｍｍである。
切断装置２は、径が１５０μｍのピアノ線６を押出孔３が設けられた膨出部１５の頂面に接触させながら約９０回／秒で回転させた。
これらのダイ１および切断装置２を用いて、押出速度約１３００ｍｍ／分で上記アルミナ触媒成形体の押出成形を行った。その結果、成形体１１の切断長さは平均６．９８ｍｍ、標準偏差は０．４５ｍｍであった。
【００３９】
比較例
センサ１２を用いた制御を行わなかった他は、実施例と同様にしてアルミナ触媒成形体の押出成形を行った。その結果、成形体１１の切断長さは平均７．０２ｍｍ、標準偏差は０．５８ｍｍであった。
【００４０】
【発明の効果】
本発明によれば、成形品の切断長さのばらつきが小さくなり、寸法精度の高い成形体が得られるという効果がある。
【図面の簡単な説明】
【図１】本発明の一実施形態である押出成形装置を示す概略断面図である。
【図２】切断用の線材とダイの押出孔との関係を示す概略説明図である。
【図３】押出成形装置の制御機構を示す概略説明図である。
【図４】制御機構を示すブロック図である。
【図５】本発明の他の実施形態にかかる流量制御弁を含む押出装置を示す概略断面図である。
【図６】本発明のさらに他の実施形態にかかる流量制御弁を示す概略説明図である。
【符号の説明】
１ ダイ
２ 切断装置
３ 押出孔
６ ピアノ線（線材）
７ 成形体
８ 回転軸
１１ 成形品
１２ センサ
１６ 回転駆動部
１７ 流量制御弁
３０ 流量制御弁
４０ 制御手段[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an extrusion molding apparatus capable of minimizing variation in the cutting length of a molded product and a method for producing a molded body using the same.
[Prior art]
[0002]
In general, a catalyst, a catalyst carrier, an adsorbent, a desiccant, a humidity control material, etc. are formed into a cylindrical or cylindrical shaped body having a diameter of about 2 to 10 mm and a length of about 2 to 20 mm, and this is filled into a reactor. Used in various chemical reaction processes. In order to produce such a molded body such as a catalyst, an extrusion molding method has been conventionally employed.
[0003]
That is, a molded product is manufactured by cutting a molded product obtained by continuously extruding a soft clay-like material such as alumina from a die. At that time, if the molded product is cut with a blade or the like, the cut end portion of the molded body is deformed and cannot be filled in the reactor densely. The problem of disrupting the process arises.
[0004]
Therefore, conventionally, a soft molded product immediately after being extruded from a die is cut with a piano wire stretched between two points. That is, using a support plate with a piano wire stretched between two points, this support plate is rotated or reciprocated in a direction orthogonal to the extrusion direction, and the piano wire is moved over the front surface of the extrusion hole at regular intervals. By crossing, the molded product immediately after extrusion is cut.
[0005]
In this case, the cutting speed of the piano wire is set to a constant value, and the molded product is cut. However, since the extrusion speed of the molded product is likely to change due to changes in the viscosity of the molding material, etc., if the extrusion speed of the molded product changes even slightly, the length of the cut molded product varies greatly, as described above. There arises a problem that the compact cannot be packed in the reactor tightly.
[0006]
[Problems to be solved by the invention]
An object of the present invention is to provide an extrusion molding apparatus capable of reducing variation in the cutting length of a molded product and obtaining a molded product with high dimensional accuracy, and a method for producing a molded body using the same.
[0007]
[Means for Solving the Problems]
The extrusion molding apparatus of the present invention for solving the above problems includes a die having an extrusion hole through which a molded product is continuously extruded, a cutting device for cutting the molded product extruded from the extrusion hole, and the extrusion hole. A flow control valve for controlling the extrusion speed of the molded product extruded from the extrusion hole, a sensor for detecting the extrusion speed of the molded product extruded from the extrusion hole, and an input signal from this sensor And a control means for causing the flow control valve to open and close based on the control means.
[0008]
That is, according to the present invention, since the extrusion speed of the molded product is detected by the sensor, when the extrusion speed of the molded product changes, the control means controls the flow control valve based on the input signal from the sensor. The extrusion speed of the molded product is controlled by performing the opening / closing operation, and thereby the cutting length of the molded product is adjusted.
[0009]
The die may have a plurality of extrusion holes. In this case, the extrusion molding apparatus includes a die having a plurality of extrusion holes through which the molded product is continuously extruded, a cutting device for cutting the molded product extruded from the extrusion holes, and an inner side of each extrusion hole. A flow rate control valve for controlling the extrusion speed of the molded product extruded from each extrusion hole, a sensor for detecting the extrusion speed of the molded product extruded from each extrusion hole, and this sensor detects each extrusion hole. Control means for causing each flow control valve to open and close based on the extrusion speed of the molded product.
[0010]
The sensor is preferably a spot light source type sensor, and the extrusion speed of the molded product is detected by measuring the time required for the molded product to reach the measurement point of the sensor from the extrusion hole. Thereby, the extrusion speed of the molded product can be detected with high accuracy, and the cut length of the molded product can be made more uniform.
[0011]
Specifically, the control by the control means is to open and close the flow control valve for each extrusion hole so that the cutting length of each molded product extruded from each extrusion hole approaches the average value of the cutting length of the molded product. Adjust the extrusion speed of the molded product by performing the operation, or set the flow rate for each extrusion hole so that the cutting length of each molded product extruded from each extrusion hole approaches the set value of the cutting length of the molded product. The opening / closing operation of the control valve is performed to adjust the extrusion speed of the molded product.
[0012]
In the present invention, it is preferable to control the cutting device as well as the flow rate control valve in order to further reduce the variation in the cutting length of the molded product. That is, another extrusion molding apparatus according to the present invention includes a die having an extrusion hole through which a molded product is continuously extruded, and a wire stretched between two points, in a direction perpendicular to the extrusion direction of the molded product. A cutting device for rotating or reciprocating the wire to traverse the front surface of the extrusion hole to cut the molded product immediately after extrusion, and an extrusion speed of the molded product provided inside the extrusion hole and extruded from the extrusion hole. A flow control valve to be controlled, a sensor for detecting an extrusion speed of a molded product extruded from the extrusion hole, a speed control for rotating or reciprocating the cutting device based on an input signal from the sensor, and the flow control And a control means for causing the valve to open and close.
[0013]
The die may have a plurality of extrusion holes. In this case, the extrusion molding apparatus of the present invention has a die having a plurality of extrusion holes through which a molded product is continuously extruded and a wire rod stretched between two points, and a direction orthogonal to the extrusion direction of the molded product. And a cutting device for cutting the molded product immediately after extrusion by causing the wire to traverse the front surface of each extrusion hole and to extrude the molded product provided inside the extrusion hole and extruded from the extrusion hole. A flow rate control valve for controlling the speed, a sensor for detecting the extrusion speed of the molded product extruded from each extrusion hole, a speed control for rotating or reciprocating the cutting device based on an input signal from the sensor, And a control means for causing each flow control valve to open and close.
[0014]
Specifically, the control means rotates or reciprocates the cutting device so that the average value of the cutting length of each molded product extruded from each extrusion hole approaches the set value of the cutting length of the molded product. While controlling the speed, the flow control valve is opened and closed for each extrusion hole so that the cutting length of each molded product extruded from each extrusion hole approaches the average value of the cutting length of the molded product. It is preferable to adjust the extrusion speed of the product. Thereby, it is possible to obtain a molded product with small variation in cutting length and high dimensional accuracy.
[0015]
In addition, the present invention also provides a method for producing a molded body, wherein a molded product continuously extruded from a die is sequentially cut into a predetermined length by a cutting device using the above-described extrusion molding device. It is.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the present invention is shown in FIGS. FIG. 1 shows an outline of an extrusion molding apparatus according to this embodiment, and a cutting device 2 is provided on the front surface of a die 1.
[0017]
The die 1 is attached to the front surface of the extrusion apparatus 10 and has a plurality of extrusion holes 3 through which the molded product is continuously extruded. The cutting device 2 has a piano wire 6 (wire) stretched between two guide rollers 4 and 5. The piano wire 6 moves along the front surface of the extrusion hole 3 while being in contact with the top surface of the bulging portion 15 provided with the extrusion hole 3, and cuts the molded product 11 extruded from the die 1 by a predetermined length. The molded body 7 is obtained.
[0018]
In other words, the cutting device 2 includes a disk-shaped mounting plate 9 that is integrally mounted perpendicularly to the rotating shaft 8 on a rotating shaft 8 that is arranged in parallel with the extrusion direction. The rotating shaft 8 is rotated by a rotation drive unit 16 (motor) so as to rotate in a direction orthogonal to the extrusion direction of the molded product 11.
[0019]
The rotating shaft 8 is provided coaxially with the central axis of the disk-shaped die 1. As shown in FIG. 2, since the plurality of extrusion holes 3 are concentrically arranged in the die 1, the rotating shaft 8 is rotated and the mounting plate 9 is rotated, so that it is stretched on the front surface thereof. The piano wire 6 that has passed passes through the front surface of each extrusion hole 3. Further, as shown in FIG. 2, two piano wires 6 and 6 are stretched on the mounting plate 9 in opposite directions via the rotation shaft 8, and the molded product is formed on each piano wire 6 and 6. Cutting is done. The diameter of the piano wire 6 to be used may be determined in consideration of the material of the molded body, the diameter, etc., but usually 300 μm or less is appropriate.
[0020]
On the other hand, a flow rate control valve 17 for controlling the extrusion speed of the molded product 11 extruded from each extrusion hole 3 is provided inside each extrusion hole 3. This flow control valve 17 is a gate valve of a gate valve type, and as shown in FIG. 1, a gate valve 18 is attached so as to be able to move in and out of the gap 19 of the extrusion device 10. The flow rate of the extrudate passing through the gap 19 can be controlled by adjusting the protruding length of the protrusion. In order for the gate valve 18 to appear in and out of the gap 19, for example, a so-called rack and pinion system is used in which a pinion is rotated by a rotary drive unit 20 (motor or the like) and the gate valve 18 is moved by a rack meshed with the pinion. Etc. can be adopted.
[0021]
A spot light source type sensor 12 is provided at a position separated from the front surface of the extrusion hole 3. Examples of the sensor 12 include a sensor used for the purpose of distance measurement using a laser beam, a light emitting diode, or the like as a light source. It is preferable to use a reflection type sensor 12 (for example, a reflection type laser sensor) including a light receiving unit 14 that receives light in order to make the entire apparatus compact.
[0022]
The mounting position of the sensor 12 is a portion where the spot light can be irradiated to the path through which the molded article 11 extruded from the die 1 passes on the side away from the die 1. Using this sensor 12, the time until the molded article 11 reaches the measurement point of the sensor 12 from the extrusion hole 3 is measured. That is, immediately after the first cutting, since the molded product 11 does not exist at the measurement point (that is, the light irradiation point) of the sensor 12, the sensor 12 does not detect the molded product 11, but after the first cutting, a new extrusion is performed. When the tip of the molded product 11 reaches the measurement point, the sensor 12 detects the molded product 11, so that the time t 1 from the first detection to the second detection is known. Since the distance L from the extrusion hole 3 to the measurement point of the sensor 12 is set in advance, the extrusion speed V of the molded product 11 is obtained from the formula: L / t 1 . Note that the distance L from the extrusion hole 3 to the measurement point of the sensor 12 is equal to or smaller than the cutting length from the extrusion hole 3.
[0023]
On the other hand, the time t 2 from when the piano wire 6 passes the front surface of the extrusion hole 3 for the first time to the second time by measuring the rotational speed of the cutting device 2 can be obtained from the calculation. cut length X of the molded article 11 is detected from the × t 2.
The detected cutting length X is compared with the set value X 0 by the control unit 17 that has received an input signal from the sensor 12, and if X> X 0 , the valve stem 18 is placed in the gap 19. In order to reduce the flow rate, the valve rod 18 is retracted from the gap 19 when X <X 0 , and X = X 0 is controlled. At this time, it is preferable to simultaneously control the rotation drive unit 16 of the cutting device 2. That is, when X> X 0 , the rotational speed of the rotational drive unit 16 is increased, and when X <X 0 , the rotational speed of the rotational drive unit 16 is decreased.
[0024]
The sensor 12 is installed about all the extrusion holes 3 as shown in FIG. That is, the sensor 12 is installed in each of the eight extrusion holes 3 arranged concentrically on the disk-shaped die 1.
[0025]
FIG. 3 also shows details of the control mechanism in this embodiment. An input signal from each sensor 12 is sent to the input unit 19 in the control means 40 (sequencer) through the input switching device 18. On the other hand, the rotational speed (or rotational speed) of the rotary shaft 8 of the cutting device 2 is detected by the rotary encoder 20 and sent to the CPU 21 (central processing unit).
[0026]
As shown in FIG. 4, the CPU 21 obtains the cutting length X n from the extrusion speed of the molded product 11 in each extrusion hole 3 detected by the sensor 12 disposed in each extrusion hole 3, and from this, the cutting length is calculated. An average value X av is calculated. Then, the cutting length Xn at each extrusion hole 3 is compared with the average value Xav of the cutting length, and when Xn > Xav , the gate valve 18 of the flow control valve 17 is placed in the gap 19. The flow rate is controlled by advancing, and the extrusion speed is decreased to control X = X av . Conversely, when X <X av , the gate valve 18 is withdrawn from the gap 19 to increase the flow rate, the extrusion speed is increased, and X = X av is controlled. When X = X av , the flow control valve 17 remains unchanged.
[0027]
These control signals are sent from the D / A conversion unit 22 through the inverter 23 to the respective rotary drive units 20a, 20b, 20c,... The flow rate control (and hence the extrusion speed control) is performed. For this reason, the variation in extrusion speed between the respective extrusion holes 3 is reduced, and the variation in the cutting length Xn around the average value X av can be made extremely small.
Note that the cutting length X n may be compared with the set value X 0 of the cutting length instead of the average value X av of the flat cutting length, thereby improving the dimensional accuracy of each cutting length X n. To do.
[0028]
Further, the average value X av and cut length initialization value X 0 of the are compared, in the case of X av> X 0 reduces the rotational speed of the rotary drive unit 16, contrary to X av <X 0 In this case, the number of rotations of the rotation drive unit 16 is increased, and control is performed so that X = X 0 . When X = X 0 , the rotation speed of the rotation drive unit 16 remains unchanged.
[0029]
The output signal to the rotation drive unit 16 is sent from the D / A conversion unit 22 to the rotation drive unit 16 via the inverter 23, and the rotation speed (and hence the rotation speed) is adjusted. As a result, the cutting length can be made closer to the set value X 0 , and the dimensional accuracy of the molded body 7 obtained by cutting the molded product 11 is improved.
[0030]
On the other hand, data is recorded from the output unit 24 to the recorder 26 via the D / A converter 25. Further, the cutting length data can be sent from the personal computer link unit 27 to the length indicator 28 and displayed.
[0031]
Next, the die 1 used in this embodiment will be described. The inner diameter of the extrusion hole 3 in the die 1 is about 1 mm to 10 mm, preferably about 3 mm to 6 mm. The number of extrusion holes may be determined in consideration of the outer diameter of the die, the inner diameter of the extrusion hole, and the like, and examples include one, two, four, eight, sixteen, and thirty-two. The shape of the extrusion hole may be, for example, a ring, a honeycomb, or a clover shape in addition to a circle.
[0032]
Specific examples of the molded product include, for example, a catalyst, a catalyst carrier, an adsorbent, a desiccant, and a humidity control material. Further, the material of the molded body is not limited to the inorganic material, and the extrusion molding apparatus of the present invention can be applied to various plastic materials and the like.
In that case, the wire to be used is not limited to the piano wire, but may be another metal wire or a wire made of a plastic material, a fiber material, or the like.
Furthermore, in the above embodiment, the mounting plate 9 is configured to rotate. However, the mounting plate 9 may be reciprocated in a direction orthogonal to the extrusion direction of the molded product. In this case, the reciprocating speed is controlled. That's fine. The piano wire 6 may be fixed between the guide rollers 4 and 5, but is preferably moved between the guide rollers 4 and 5 while being wound continuously or intermittently. By moving the piano wire 6, it is possible to prevent the piano wire from being broken and to continuously manufacture the molded body.
[0033]
Another embodiment of the present invention will be described with reference to FIG. The extrusion molding apparatus shown in FIG. 5 includes a butterfly valve type flow control valve 30 which is a kind of gate valve. This flow control valve 30 is provided behind each extrusion hole 3 of the die 1. The extrusion device 31 is provided with a cone 32 at the center, and directs the extrudate to each extrusion hole 3 (the flow of the extrudate is indicated by an arrow).
[0034]
The flow control valve 30 includes a valve body 32 interposed between the cone 32 and the die 1, a rotating plate 33 facing the valve body 33 and positioned in the gap 19 through which the extrudate passes, and the rotating plate 33. And a valve rod 34 which is held at the tip and rotates via gears 36 and 37 by driving of a rotation driving unit 35 (motor or the like).
[0035]
The rotation drive unit 35 receives the signal from the control means, rotates the rotating plate 33 via the valve rod 34, and performs flow rate control. That is, the flow rate is minimized when the plate surface of the rotating plate 33 is orthogonal to the extrusion direction, and conversely, the flow rate is maximized when parallel to the extrusion direction. Accordingly, the flow rate can be controlled by adjusting the direction of the rotating plate 33. Others are the same as the above-mentioned embodiment.
[0036]
The flow control valve according to the present invention is not limited to the above-described gate valve method and butterfly valve method, and various gate valves can be employed. For example, a screw-type flow control valve 38 as shown in FIG. 6 may be employed. The screw-type flow rate control valve 38 controls the flow rate by moving forward or backward with respect to the extrusion hole 3.
[0037]
【Example】
Hereinafter, the extrusion molding apparatus of the present invention will be described with reference to Examples and Comparative Examples.
[0038]
EXAMPLE A clay-like alumina catalyst molded body was extruded using the extrusion molding apparatus shown in FIGS.
The die 1 used has a surface plated with chromium and has a disk shape in which eight extrusion holes 3 are arranged concentrically. The extrusion hole 3 has an inner diameter of 5 mm.
The cutting device 2 was rotated at about 90 times / second while bringing the piano wire 6 having a diameter of 150 μm into contact with the top surface of the bulging portion 15 provided with the extrusion hole 3.
Using the die 1 and the cutting device 2, the alumina catalyst molded body was extruded at an extrusion speed of about 1300 mm / min. As a result, the cut length of the molded body 11 was an average of 6.98 mm, and the standard deviation was 0.45 mm.
[0039]
Except that the control using the comparative example sensor 12 was not performed, the alumina catalyst molded body was extruded in the same manner as in the example. As a result, the cut length of the molded body 11 was 7.02 mm on average, and the standard deviation was 0.58 mm.
[0040]
【The invention's effect】
According to the present invention, the variation in the cutting length of the molded product is reduced, and there is an effect that a molded body with high dimensional accuracy can be obtained.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view showing an extrusion molding apparatus according to an embodiment of the present invention.
FIG. 2 is a schematic explanatory view showing a relationship between a cutting wire and an extrusion hole of a die.
FIG. 3 is a schematic explanatory view showing a control mechanism of the extrusion molding apparatus.
FIG. 4 is a block diagram showing a control mechanism.
FIG. 5 is a schematic sectional view showing an extrusion apparatus including a flow control valve according to another embodiment of the present invention.
FIG. 6 is a schematic explanatory view showing a flow control valve according to still another embodiment of the present invention.
[Explanation of symbols]
1 Die 2 Cutting device 3 Extrusion hole 6 Piano wire (wire)
7 Molded body 8 Rotating shaft 11 Molded product 12 Sensor 16 Rotation drive unit 17 Flow rate control valve 30 Flow rate control valve 40 Control means

Claims (5)

成形品が連続的に押し出される押出孔を有するダイと、
２点間に張りわたされた線材を有し、前記成形品の押出方向と直交する方向に回転または往復動して、前記線材を押出孔の前面を横切らせ、押出直後の成形品を切断するための切断装置と、
前記押出孔の内方に設けられ、押出孔から押し出される成形品の押出し速度を制御する流量制御弁と、
前記押出孔から押し出される成形品の押出し速度を検出するためのセンサと、
このセンサからの入力信号に基づいて前記切断装置が回転または往復動する速度制御と前記流量制御弁の開閉操作とを行わせるための制御手段とを備えた押出成形装置。A die having an extrusion hole through which a molded product is continuously extruded;
It has a wire stretched between two points, rotates or reciprocates in a direction perpendicular to the extrusion direction of the molded product, traverses the wire across the front surface of the extrusion hole, and cuts the molded product immediately after extrusion. A cutting device for,
A flow rate control valve that is provided inside the extrusion hole and controls the extrusion speed of a molded product extruded from the extrusion hole;
A sensor for detecting the extrusion speed of the molded product extruded from the extrusion hole;
An extrusion molding apparatus comprising: a speed control for rotating or reciprocating the cutting device based on an input signal from the sensor; and a control means for opening and closing the flow rate control valve. 成形品が連続的に押し出される複数の押出孔を有するダイと、
２点間に張りわたされた線材を有し、前記成形品の押出方向と直交する方向に回転または往復動して、前記線材を各押出孔の前面を横切らせ、押出直後の成形品を切断するための切断装置と、
各押出孔の内方に設けられ、押出孔から押し出される成形品の押出し速度を制御する流量制御弁と、
各押出孔から押し出される成形品の押出し速度を検出するためのセンサと、
このセンサからの入力信号に基づいて前記切断装置が回転または往復動する速度制御と前記各流量制御弁の開閉操作とを行わせるための制御手段とを備えた押出成形装置。A die having a plurality of extrusion holes through which a molded product is continuously extruded;
Having a wire stretched between two points, rotating or reciprocating in a direction perpendicular to the extrusion direction of the molded product, causing the wire to traverse the front of each extrusion hole and cutting the molded product immediately after extrusion A cutting device for
A flow rate control valve that is provided inside each extrusion hole and controls the extrusion speed of a molded product extruded from the extrusion hole;
A sensor for detecting the extrusion speed of the molded product extruded from each extrusion hole;
An extrusion molding apparatus comprising: a speed control for rotating or reciprocating the cutting device based on an input signal from the sensor; and a control means for opening and closing each flow control valve. 前記制御手段は、各押出孔から押し出された各成形品の切断長さの平均値が成形品の切断長さの設定値に近づくように、切断装置の回転または往復動する速度を制御すると共に、
各押出孔から押し出された各成形品の切断長さが成形品の切断長さの平均値に近づくように、押出孔ごとに流量制御弁の開閉操作を行って、成形品の押出し速度を調整する請求項２記載の押出成形装置。The control means controls the speed at which the cutting device rotates or reciprocates so that the average value of the cutting length of each molded product extruded from each extrusion hole approaches the set value of the cutting length of the molded product. ,
Adjust the extrusion speed of the molded product by opening and closing the flow control valve for each extrusion hole so that the cut length of each molded product extruded from each extrusion hole approaches the average value of the cut length of the molded product The extrusion molding apparatus according to claim 2 . ダイの押出孔から成形品を連続的に押し出しながら、前記押出孔から押し出される成形品の押出し速度をセンサで検出し、このセンサからの入力信号に基づいて、前記押出孔の前面を横切らせる２点間に張りわたされた線材の回転または往復動する速度を制御し、かつ前記押出孔の内方に設けた流量制御弁の開閉操作を行わせ、前記押出孔から押し出される成形品の押出し速度を制御して、押出直後の成形品を所定長さに順次切断することを特徴とする成形体の製造方法。  While the molded product is continuously extruded from the extrusion hole of the die, the extrusion speed of the molded product extruded from the extrusion hole is detected by a sensor, and based on the input signal from this sensor, the front surface of the extrusion hole is crossed 2 The speed at which the wire stretched between the points is rotated or reciprocated, and the flow rate control valve provided inside the extrusion hole is opened and closed. And the molded product immediately after extrusion is sequentially cut into a predetermined length. ダイに設けた複数の押出孔から成形品を連続的に押し出しながら、前記各押出孔から押し出される成形品の押出し速度をセンサで検出し、このセンサからの入力信号に基づいて、前記押出孔の前面を横切らせる２点間に張りわたされた線材の回転または往復動する速度を制御し、かつ前記各押出孔の内方に設けた流量制御弁の開閉操作を行わせ、各押出孔から押し出される成形品の押出し速度を制御して、押出直後の成形品を所定長さに順次切断することを特徴とする成形体の製造方法。  While continuously extruding the molded product from a plurality of extrusion holes provided in the die, the extrusion speed of the molded product extruded from each extrusion hole is detected by a sensor, and based on the input signal from the sensor, the extrusion hole The wire rod stretched between two points traversing the front is controlled to rotate or reciprocate, and the flow control valve provided inside each extrusion hole is opened and closed to be pushed out from each extrusion hole. A method for producing a molded product, comprising controlling the extrusion speed of a molded product to be cut into a predetermined length sequentially after the extrusion.
JP2000272340A 2000-09-07 2000-09-07 Extrusion molding apparatus and method for producing molded body using the same Expired - Fee Related JP3881829B2 (en)

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JP5335589B2 (en) * 2009-07-16 2013-11-06 住友化学株式会社 Manufacturing method of molded body
JP5493212B2 (en) * 2010-01-18 2014-05-14 住友化学株式会社 Extrusion molding apparatus and method for producing molded body using the same
JP6789085B2 (en) * 2016-11-30 2020-11-25 Ｔｏｙｏ Ｔｉｒｅ株式会社 Shape control device for molded members
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