JP5171309B2 - Sandwich molding method for resin handles - Google Patents
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Description
本発明は、樹脂製取っ手の成形方法に関する。詳しくは、結晶性エンジニアリング樹脂（Ａ）の表層部分、補強材を含有した該結晶性エンジニアリング樹脂（Ａ）と同系の結晶性樹脂からなる樹脂組成物（Ｂ）の内側部分及び金属インサート物（Ｃ）からなる樹脂製取っ手のサンドイッチ成形方法に関する。 The present invention relates to a method for molding a resin handle. Specifically, the surface layer portion of the crystalline engineering resin (A), the inner portion of the resin composition (B) made of the same crystalline resin as the crystalline engineering resin (A) containing the reinforcing material, and the metal insert (C And a resin mold sandwich molding method.
運輸機関および建物に設置される窓や扉の開閉用および水周り等の流体開放用、水周り周辺の取っ手は、作動および長期信頼性から、充分な製品強度が必要とされる。またＱＣ活動に代表される日本の品質規格は、当然ながら表面外観性に優れた製品を求めている。 Sufficient product strength is required for the opening and closing of windows and doors installed in transportation facilities and buildings, and for the opening of fluids such as around water, and handles around the water because of operation and long-term reliability. In addition, Japanese quality standards represented by QC activities naturally require products with excellent surface appearance.
一般にＰＥやＰＰに代表される汎用の結晶性樹脂は、補強材を添加しても充分な補強効果が得られない上、製品のヒケにより良外観品が得られにくく、かつ固化スピードが遅いため量産性に問題がある。一方、ＰＳやＡＢＳに代表される汎用の非晶性樹脂では、補強材を添加した場合でも、良外観品が得られず、かつ耐薬品性に問題があるため、使用環境下における長期信頼性に不安があり、さらには汎用の結晶性樹脂と同様に固化スピードが遅いため、量産性に問題がある。 In general, general-purpose crystalline resins represented by PE and PP do not provide a sufficient reinforcing effect even when a reinforcing material is added, and it is difficult to obtain a good appearance product due to the sink of the product, and the solidification speed is slow. There is a problem with mass productivity. On the other hand, general-purpose amorphous resins typified by PS and ABS cannot obtain good-quality products even when reinforcing materials are added, and have problems with chemical resistance. In addition, there is a problem in mass productivity because the solidification speed is slow like a general-purpose crystalline resin.
これら補強材で補強していない汎用樹脂を単独で用いて射出成形された取っ手は、充分な製品強度を持たすためには肉厚化する必要が有り、これにより固化スピードが遅くなり量産性に問題がある。また、充分な製品強度を持たせるために金属を内側部分にインサートし補強することが行われているが、工程等がかかり生産量の低下およびコスト高になるという問題がある。一方、充分な製品強度がある補強材を添加した汎用樹脂を単独で用いて射出成形された取っ手は、強度は問題無いが、表面外観性が、補強材無添加の樹脂を単独で用いた場合と比較すると劣るため、表面外観を上げるために金型温度を上げると成形サイクルが延び量産性に問題が生じる。さらに近年、顧客ニーズの多様化により、製品の表面装飾も求められている。 Handles injection-molded using a general-purpose resin that is not reinforced with these reinforcing materials need to be thickened to have sufficient product strength, which slows down the solidification speed and causes problems in mass productivity. There is. Further, in order to give sufficient product strength, metal is inserted into the inner portion and reinforced, but there is a problem that a process or the like is required and the production amount is reduced and the cost is increased. On the other hand, the handle that is injection-molded using a general-purpose resin alone with the addition of a reinforcing material with sufficient product strength has no problem with strength, but the surface appearance is when a resin without a reinforcing material is used alone. Therefore, if the mold temperature is raised in order to improve the surface appearance, the molding cycle is extended and a problem arises in mass productivity. In recent years, surface decoration of products has been demanded due to diversification of customer needs.
これらの問題点を解決する方法の一つとして、射出成形機や金型に機構を取り入れたサンドイッチ成形により、表層部分に表面性の優れた樹脂、内部部分に強度の優れた樹脂を同時に射出成形する事が考えられている。しかしながら、これらの従来の技術で用いる樹脂は、固化スピードが遅い汎用の結晶性樹脂や耐薬品性に問題がある汎用の非晶性樹脂のみで、量産性と長期信頼性に問題点が残ったままであった。 As one of the methods to solve these problems, sandwich molding that incorporates a mechanism in an injection molding machine or a mold enables simultaneous injection molding of a resin with excellent surface properties on the surface layer and a resin with excellent strength on the inner part. It is thought to do. However, the resins used in these conventional technologies are only general-purpose crystalline resins that have a slow solidification speed and general-purpose amorphous resins that have problems with chemical resistance, and problems remain in mass productivity and long-term reliability. It was up to.
サンドイッチ成形に関しては、汎用樹脂を使用した射出成形により、金型のスライドコアの開閉等により、捨てキャビティーへ樹脂を排出する方法が提案されている（例えば特許文献１，２）。しかし、特許文献１，２では、保圧工程ではなく充填工程で内部樹脂を充填して表層部分の樹脂を捨てキャビティーに排出する方法であり、また、使用している樹脂が固化スピードの遅い汎用樹脂であり、上記問題を解決し得るものではない。 With respect to sandwich molding, a method has been proposed in which resin is discharged into a waste cavity by injection molding using a general-purpose resin, such as opening and closing of a mold slide core (for example, Patent Documents 1 and 2). However, in Patent Documents 1 and 2, it is a method of filling the internal resin in the filling process instead of the pressure-holding process and discarding the resin in the surface layer portion and discharging it to the cavity, and the resin used is slow in solidification speed It is a general-purpose resin and cannot solve the above problems.
さらに、特許文献３には、保圧工程時に窒素ガス等を使用したガスアシスト成形により樹脂製取っ手を成形することが開示されているが、保圧工程に使用ガスを使用しており、本発明とは異なるものである。 Further, Patent Document 3 discloses that a resin handle is formed by gas assist molding using nitrogen gas or the like during the pressure holding process, but the gas used is used in the pressure holding process, and the present invention is disclosed. Is different.
本発明は、製品強度が高くて、長期信頼性が高く、表面外観性が優れ、かつ量産性に優れた樹脂製取っ手の成形方法を提供する事を目的とする。 An object of the present invention is to provide a method for molding a resin handle having high product strength, high long-term reliability, excellent surface appearance, and excellent mass productivity.
本発明は上記の問題点を解決するために、結晶性エンジニアリング樹脂、特に耐薬品性が良く、結晶性材料の固化スピードは速いが、補強材による補強効果が大きいポリアミド樹脂に着目し、情熱と信念を持って日夜鋭意検討した結果、製品強度が高くて、長期信頼性が高く、良外観と量産性を満足する樹脂製取っ手の成形に有効なサンドイッチ成形を用いた射出成形方法を見出し、本発明に到達した。 In order to solve the above problems, the present invention focuses on a crystalline engineering resin, particularly a polyamide resin having good chemical resistance and a fast solidification speed of the crystalline material, but having a large reinforcing effect by the reinforcing material. As a result of intensive study day and night with the belief, we found an injection molding method using sandwich molding that is effective for molding resin handles that have high product strength, high long-term reliability, and satisfactory appearance and mass productivity. The invention has been reached.
即ち、本発明の樹脂製取っ手のサンドイッチ成形方法は、
結晶性エンジニアリング樹脂（Ａ）の表層部分、補強材を含有した該結晶性エンジニアリング樹脂（Ａ）と同系の結晶性エンジニアリング樹脂からなる樹脂組成物（Ｂ）の内側部分及び金属インサート物（Ｃ）からなる樹脂製取っ手のサンドイッチ成形方法であって、
前記金属インサート物（Ｃ）が入ったキャビティー（Ｄ）、該キャビティー（Ｄ）の流動末端部分とつながった捨てキャビティー（Ｆ）、及び該キャビティー（Ｄ）と該捨てキャビティー（Ｆ）との間に設置された流路開閉機構（Ｅ）、前記金属インサート物（Ｃ）の近くに設けられたゲート（Ｇ）から構成される金型を用い、
前記流路開閉機構（Ｅ）を閉じた状態で、前記ゲート（Ｇ）から、前記結晶性エンジニアリング樹脂（Ａ）及び前記樹脂組成物（Ｂ）を前記キャビティー（Ｄ）に充填し、該キャビティー（Ｄ）を該結晶性エンジニアリング樹脂（Ａ）及び該樹脂組成物（Ｂ）で完全に満たして保圧状態とし、次いで、閉じていた前記流路開閉機構（Ｅ）を開き、前記捨てキャビティー（Ｆ）に、前記結晶性エンジニアリング樹脂（Ａ）と前記樹脂組成物（Ｂ）、或いは前記結晶性エンジニアリング樹脂（Ａ）を排出することを特徴とする。
That is, the sandwich molding method of the resin handle of the present invention is:
From the surface layer portion of the crystalline engineering resin (A), the inner portion of the resin composition (B) composed of a crystalline engineering resin similar to the crystalline engineering resin (A) containing the reinforcing material, and the metal insert (C) A resin mold sandwich molding method comprising:
A cavity (D) containing the metal insert (C), a waste cavity (F) connected to the flow end portion of the cavity (D), and the cavity (D) and the waste cavity (F) A flow path opening / closing mechanism (E) installed between the metal insert (C) and a gate (G) provided near the metal insert (C),
With the flow path opening / closing mechanism (E) closed, the cavity (D) is filled with the crystalline engineering resin (A) and the resin composition (B) from the gate (G). The tee (D) is completely filled with the crystalline engineering resin (A) and the resin composition (B) to obtain a pressure-holding state, then the closed channel opening / closing mechanism (E) is opened, and the waste mold The crystalline engineering resin (A) and the resin composition (B) or the crystalline engineering resin (A) are discharged into a tee (F).
本発明によれば、結晶性エンジニアリング樹脂、特に補強材による補強効果が大きいポリアミド樹脂と、射出成形のサンドイッチ成形方法、特に、充填・保圧工程の状態、すなわち、キャビティーに樹脂を完全に満たし転写させ良外観を出した後、保圧工程で内側部分の樹脂または再度射出する表層部部分の樹脂により捨てキャビティーへ樹脂を排出する方法を組み合わせる事により、製品強度が高くて、長期信頼性が高く、表面外観性が優れ、かつ量産性に優れた樹脂製取っ手を提供する事が可能である。 According to the present invention, a crystalline engineering resin, particularly a polyamide resin having a large reinforcing effect by a reinforcing material, and a sandwich molding method of injection molding, in particular, a filling / holding process state, that is, a cavity is completely filled with the resin. After transferring and showing good appearance, by combining the method of discarding the resin with the resin of the inner part or the resin of the surface layer part to be injected again in the pressure holding process, the product strength is high and long-term reliability Therefore, it is possible to provide a resin handle having a high surface appearance and an excellent mass productivity.
以下、本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail.
本発明で成形される樹脂製取っ手は、表層部分、内側部分及び金属インサート物（Ｃ）からなり、特に、金属インサート物（Ｃ）を回転軸の中心として少なくとも３０°以上、好ましくは６０°以上回転させる用途に用いられる取っ手として好適に用いられる。具体的には、運輸機関や建物に設置される窓や扉開閉用、水周り等の流体開放用の握り、水周り周辺の手摺り、ハンドル、ノブ、クレセントおよびコック等に使用される取っ手等が挙げられる。その形状、肉厚等は特に制限するものではないが、手との触感および見た目の高級感を出す為、製品の表面に俗称シボの加工するものもある。 The resin handle molded in the present invention comprises a surface layer portion, an inner portion and a metal insert (C), and in particular, at least 30 ° or more, preferably 60 ° or more with the metal insert (C) as the center of the rotation axis. It is suitably used as a handle used for rotating purposes. Specifically, handles used to open and close windows and doors installed in transport organizations and buildings, fluid release grips around water, handrails around water, handles, knobs, crescents, cocks, etc. Is mentioned. There are no particular restrictions on the shape, thickness, etc., but there are also products that are commonly called wrinkled on the surface of the product in order to give a touch to the hand and a high-quality appearance.
本発明においては、表層部分に結晶性エンジニアリング樹脂（Ａ）を、内側部分に補強材を含有した該結晶性エンジニアリング樹脂（Ａ）と同系の結晶性樹脂からなる樹脂組成物（Ｂ）を用いる。 In the present invention, a crystalline engineering resin (A) is used for the surface layer portion, and a resin composition (B) made of a crystalline resin similar to the crystalline engineering resin (A) containing a reinforcing material for the inner portion is used.
結晶性エンジニアリング樹脂（Ａ）及び、樹脂組成物（Ｂ）に用いる結晶性エンジニアリング樹脂（Ａ）と同系の結晶性エンジニアリング樹脂としては、例えばポリアセタール樹脂、ポリアミド系樹脂、ＰＢＴ樹脂、ＰＥＴ樹脂、およびこれらを一構成成分とするアロイ樹脂やエラストマーをブレンドした樹脂が挙げられる。特に補強材を含有した際の補強効果が大きいポリアミド系の樹脂およびこれらを一構成成分とするアロイ樹脂やエラストマーをブレンドした樹脂が好ましい。 Examples of the crystalline engineering resin (A) and the crystalline engineering resin similar to the crystalline engineering resin (A) used for the resin composition (B) include polyacetal resins, polyamide resins, PBT resins, PET resins, and the like. And resin blended with an alloy resin or an elastomer. In particular, a polyamide-based resin having a large reinforcing effect when a reinforcing material is contained and a resin blended with an alloy resin or an elastomer containing these as one constituent component are preferable.
ポリアミド系の樹脂としては、主としてＰＡ６、ＰＡ６６、ＰＡ６１０、６Ｉ、６Ｔ樹脂およびこれらのコーポリマー、またはこれらを一構成成分とするアロイ樹脂やエラストマーをブレンドした樹脂を示す。また、６Ｃ、１２Ｃ、ＰＡ１２およびＰＡ６１２樹脂も使用できるが、これらを使用する場合は、表層部分と内側部分の界面での接着力の観点から、ＰＡ６、ＰＡ６６、ＰＡ６１０、６Ｉ、６Ｔと混合して使用する、または結晶性エンジニアリング樹脂（Ａ）、樹脂組成物（Ｂ）の結晶性エンジニアリング樹脂共に６Ｃ、１２Ｃ、ＰＡ１２、ＰＡ６１２を使用することが好ましい。 As the polyamide-based resin, PA6, PA66, PA610, 6I, and 6T resins and their copolymers, or resins obtained by blending alloy resins and elastomers containing these as one constituent component are mainly shown. 6C, 12C, PA12 and PA612 resins can also be used, but when these are used, they are mixed with PA6, PA66, PA610, 6I, and 6T from the viewpoint of the adhesive strength at the interface between the surface layer portion and the inner portion. It is preferable to use 6C, 12C, PA12, PA612 for both the crystalline engineering resin (A) and the crystalline engineering resin of the resin composition (B).
樹脂組成物（Ｂ）に含有する補強材としては、無機または有機の繊維状、板状、粉粒状の充填剤等の１種または２種以上が挙げられ、その中でも特に補強効果が大きい無機のガラス繊維が好ましい。 Examples of the reinforcing material contained in the resin composition (B) include one or more of inorganic or organic fiber-like, plate-like, and powder-like fillers. Glass fiber is preferred.
更に、必要に応じて、熱可塑性樹脂に対する一般的な添加剤、例えば染料、顔料等の着色剤、滑剤、核剤、離型剤、帯電防止剤、界面活性剤、結晶遅延剤、耐候性向上のための紫外線吸収剤、或いは有機高分子材料を結晶性エンジニアリング樹脂（Ａ）と樹脂組成物（Ｂ）の良好な界面接着力を阻害しない範囲で添加することが出来る。 Furthermore, if necessary, general additives for thermoplastic resins, such as colorants such as dyes and pigments, lubricants, nucleating agents, mold release agents, antistatic agents, surfactants, crystal retarders, and weather resistance improvement UV absorbers or organic polymer materials can be added within a range that does not impair the good interfacial adhesive force between the crystalline engineering resin (A) and the resin composition (B).
本発明で用いる金型の一例を図１に示す。図１（ａ）は全体構成図、図１（ｂ）は上面図である。図１に示すように、本発明で用いる金型は、金属インサート物（Ｃ）が入ったキャビティー（Ｄ）、キャビティー（Ｄ）の流動末端部分とつながった捨てキャビティー（Ｆ）を有し、キャビティー（Ｄ）と捨てキャビティー（Ｆ）との間に、流路開閉機構としてシャットオフピン（Ｅ）が設置されている。捨てキャビティー（Ｆ）の容積は大きいほど好ましいが、経済的な観念から、スプルー、ランナー、キャビティー（Ｄ）の全容積の３０％を目処に設けることが好ましい。また、ゲート（Ｇ）は、射出充填する樹脂の直進性を妨げることにより、ゲート（Ｇ）周辺のジェッティングやフローマークを防止し、製品の良外観化が図れる様に、金属インサート物（Ｃ）の近くに設けられている。 An example of a mold used in the present invention is shown in FIG. FIG. 1A is an overall configuration diagram, and FIG. 1B is a top view. As shown in FIG. 1, the mold used in the present invention has a cavity (D) containing a metal insert (C) and a waste cavity (F) connected to the flow end portion of the cavity (D). In addition, a shut-off pin (E) is installed as a flow path opening / closing mechanism between the cavity (D) and the disposal cavity (F). The volume of the discarded cavity (F) is preferably as large as possible, but it is preferable to provide 30% of the total volume of the sprue, the runner, and the cavity (D) as a target from an economic point of view. In addition, the gate (G) prevents metal jetting and flow marks around the gate (G) by preventing the straightness of the resin to be injected and filled, so that the appearance of the product can be improved. ).
また、図１に示すように、キャビティー（Ｄ）とシャットオフピン（Ｅ）との間にエアーベント（Ｈ）を設けることが好ましい。エアーベント（Ｈ）の形状については、深さは０．０１〜０．１ｍｍの範囲で、幅は２．０〜５０ｍｍの範囲、かつ長さは３．０〜２０．０ｍｍの範囲が好ましい。特に前記の長さの範囲を越えた場合の深さは、０．５〜１．０ｍｍの範囲でパーティングラインまで伸ばすのが、離型剤やモールドデポジットが溜らずメンテナンス時間が延び好ましい。 Moreover, as shown in FIG. 1, it is preferable to provide an air vent (H) between the cavity (D) and the shut-off pin (E). Regarding the shape of the air vent (H), the depth is preferably in the range of 0.01 to 0.1 mm, the width is in the range of 2.0 to 50 mm, and the length is preferably in the range of 3.0 to 20.0 mm. In particular, when the depth exceeds the above-mentioned range of length, it is preferable that the depth is extended to the parting line in the range of 0.5 to 1.0 mm because the release agent and mold deposit do not accumulate and maintenance time is extended.
さらに、金型には、ゲートおよび捨てキャビティー（Ｆ）部分をカットするために、射出成形機の突き出し機構や金型内のスプリング等を利用した型内ゲートカット機構を組み合わせてもよい。 Further, the mold may be combined with an in-mold gate cutting mechanism using an ejection mechanism of an injection molding machine or a spring in the mold in order to cut the gate and the discarded cavity (F) portion.
本発明で用いるサンドイッチ成形装置は、例えば、射出成形機メーカーが工程シーケンスを組み、射出成形機に２本以上のＡ、Ｂ、Ｃ等のスクリューおよびシリンダーを有する物であり、別々のスクリューおよびシリンダーで溶融、計量された結晶性エンジニアリング樹脂（Ａ）と樹脂組成物（Ｂ）を切替え部で切替えて充填できるものである。 The sandwich molding apparatus used in the present invention is, for example, a product in which an injection molding machine manufacturer sets up a process sequence, and the injection molding machine has two or more A, B, C, etc. screws and cylinders. The crystalline engineering resin (A) and the resin composition (B) that have been melted and weighed in (1) can be switched and filled in the switching section.
以下、本発明の具体的手順について、２本のスクリューおよびシリンダー（Ａシリンダー、Ｂシリンダー）を有するサンドイッチ成形装置を用いた場合を例にとり、図２を用いて説明する。 Hereinafter, the specific procedure of the present invention will be described with reference to FIG. 2, taking as an example the case of using a sandwich molding apparatus having two screws and cylinders (A cylinder, B cylinder).
まず、シャットオフピン（Ｅ）を閉じた状態で、Ａシリンダーで溶融された結晶性エンジニアリング樹脂（Ａ）を、スプルー、ランナー、キャビティー（Ｄ）の全容積の半分以上を目処に計量し、スプルー、ランナー、キャビティー（Ｄ）の全容積の１／３を目処に射出する。次に、Ｂシリンダーで溶融された樹脂組成物（Ｂ）をスプルー、ランナー、キャビティー（Ｄ）の全容積の残りの容積分以上計量し射出すると、図２（ａ）に示す様に、スプルー、ランナー内にある結晶性エンジニアリング樹脂（Ａ）をキャビティー（Ｄ）内に入れながら、樹脂組成物（Ｂ）もキャビティー（Ｄ）に充填される。 First, with the shut-off pin (E) closed, the crystalline engineering resin (A) melted in the A cylinder is weighed over about half of the total volume of the sprue, runner and cavity (D). Inject 1/3 of the total volume of the sprue, runner, and cavity (D). Next, when the resin composition (B) melted in the B cylinder is weighed and injected over the remaining volume of the total volume of the sprue, runner, and cavity (D), as shown in FIG. While the crystalline engineering resin (A) in the runner is put into the cavity (D), the resin composition (B) is also filled into the cavity (D).
そして、充填工程が進むと、図２（ｂ）に示す様に、やがてキャビティー（Ｄ）が完全に満たされ、保圧状態となる。保圧状態となったかどうかは、最新の射出成形機では充填圧力の波形から見る事が出来、この充填圧力が階段状の２段目で急激に上がる付近で判断する事も出来る。 Then, as the filling process proceeds, as shown in FIG. 2B, the cavity (D) is eventually completely filled and a pressure holding state is obtained. Whether or not the pressure holding state has been reached can be seen from the waveform of the filling pressure in the latest injection molding machine, and it can also be judged in the vicinity where this filling pressure suddenly increases in the second step.
その後、図２（ｃ）に示す様に、シャットオフピン（Ｅ）を後退させて流路を開き、Ａシリンダーで溶融された残りの結晶性エンジニアリング樹脂（Ａ）を保圧充填し、キャビティー（Ｄ）内にある結晶性エンジニアリング樹脂（Ａ）および樹脂組成物（Ｂ）を捨てキャビティー（Ｆ）に排出する。シャットオフピン（Ｅ）を開くタイミングはキャビティー（Ｄ）容量および成形品取り数により異なり特に限定されないが、金型表面を転写するのに必要な時間であることが好ましく、０．５秒〜５．０秒の範囲が好ましい。 Thereafter, as shown in FIG. 2 (c), the shut-off pin (E) is retracted to open the flow path, and the remaining crystalline engineering resin (A) melted in the A cylinder is pressure-filled, and the cavity The crystalline engineering resin (A) and the resin composition (B) in (D) are discarded and discharged into the cavity (F). The timing for opening the shut-off pin (E) varies depending on the capacity of the cavity (D) and the number of molded products, and is not particularly limited. However, it is preferably a time required to transfer the mold surface, from 0.5 seconds to A range of 5.0 seconds is preferred.
樹脂を充填する順番は限定されないが、上述の例のように、結晶性エンジニアリング樹脂（Ａ）、樹脂組成物（Ｂ）の順で充填して保圧状態とし、次いで結晶性エンジニアリング樹脂（Ａ）を充填すると、ゲート（Ｇ）周辺部の外観が向上し、ゲート（Ｇ）跡が良好な状態になり、また次のショット時に前の材料が残らず、好ましい。 The order in which the resin is filled is not limited, but as in the above example, the crystalline engineering resin (A) and the resin composition (B) are filled in this order to obtain a pressure holding state, and then the crystalline engineering resin (A). Is preferable because the appearance of the periphery of the gate (G) is improved, the trace of the gate (G) becomes good, and the previous material does not remain at the next shot.
また、捨てキャビティー（Ｆ）に排出する樹脂も特に限定されず、捨てキャビティーへの流路処理跡を残さないようにする場合は結晶性エンジニアリング樹脂（Ａ）のみ、製品強度を重視する場合は、上述の例のように、結晶性エンジニアリング樹脂（Ａ）と樹脂組成物（Ｂ）とすればよい。特に、後者の場合には、捨てキャビティーを目視で観察することにより、強度上に問題無いか判断出来るため、製品強度を考慮する場合に好適である。捨てキャビティー（Ｆ）に排出する樹脂は、捨てキャビティー（Ｆ）への樹脂排出状態を確認しながら、結晶性エンジニアリング樹脂（Ａ）と樹脂組成物（Ｂ）の充填容量や樹脂組成物（Ｂ）の充填圧力を調整し、決定することができる。 Also, the resin discharged into the disposal cavity (F) is not particularly limited. When not leaving a trace of the flow path to the disposal cavity, only the crystalline engineering resin (A) is important for product strength. The crystalline engineering resin (A) and the resin composition (B) may be used as in the above example. In particular, in the latter case, it is possible to determine whether there is no problem in strength by visually observing the discarded cavity, which is preferable when considering the product strength. The resin discharged into the waste cavity (F) is checked with the resin discharge state into the waste cavity (F), while the filling capacity of the crystalline engineering resin (A) and the resin composition (B) and the resin composition ( The filling pressure of B) can be adjusted and determined.
以下、本発明を実施例により更に具体的に説明する。尚、実施例において使用した樹脂、評価方法は以下の通りである。 Hereinafter, the present invention will be described more specifically with reference to examples. In addition, resin used in the Example and the evaluation method are as follows.
［使用樹脂］
（Ａ）表層部分
Ｘ１．ＰＰ樹脂 密度＝９００ｋｇ／ｍ3 （株）プライムポリマー製
（商品名）プライムポリプロ Ｊ−７８６ＨＶ
Ｘ２．ＡＢＳ樹脂 密度＝１０５０ｋｇ／ｍ3 旭化成ケミカルズ（株）製
（商品名）スタイラック １２１
Ｘ３．ＰＡ６６樹脂 密度＝１１４０ｋｇ／ｍ3 旭化成ケミカルズ（株）製
（商品名）レオナ １３００Ｓ
Ｘ４．ＰＡ６６樹脂 ナノコンポジット材料 密度＝１１７０ｋｇ／ｍ3
旭化成ケミカルズ（株）製 （商品名）レオナ ９４Ｎ０５
Ｘ５．ＰＡ１２樹脂 密度＝１０７０ｋｇ／ｍ3 ダイセル・テグサ（株）製
（商品名）ベスタミド Ｘ７０９４
（Ｂ）内側部分
Ｙ１．ＰＰ樹脂 ＧＦ＝３０％品 密度＝１１２０ｋｇ／ｍ3
（株）プライムポリマー製 （商品名）プライムポリプロ Ｅ７０００
Ｙ２．ＡＢＳ樹脂 ＧＦ＝３０％品 密度＝１２９０ｋｇ／ｍ3
旭化成ケミカルズ（株）製、（商品名）スタイラック Ｒ２６０Ａ
Ｙ３．ＰＡ６６樹脂 ＧＦ＝３３％品 密度＝１３９０ｋｇ／ｍ3
旭化成ケミカルズ（株）製 （商品名）レオナ ９３Ｇ３３
Ｙ４．ＰＡ６６樹脂 ＧＦ＝５０％品 密度＝１５８０ｋｇ／ｍ3
旭化成ケミカルズ（株）製 （商品名）レオナ ９０Ｇ５０
[Resin used]
(A) Surface layer portion X1. PP resin Density = 900kg / m 3 Made by Prime Polymer Co., Ltd. (Product Name) Prime Polypro J-786HV
X2. ABS resin Density = 1050 kg / m 3 Asahi Kasei Chemicals Co., Ltd. (trade name) Stylac 121
X3. PA66 resin Density = 1140kg / m 3 Asahi Kasei Chemicals Co., Ltd. (trade name) Leona 1300S
X4. PA66 resin Nanocomposite material Density = 1170kg / m 3
Asahi Kasei Chemicals Corporation (trade name) Leona 94N05
X5. PA12 resin Density = 1070 kg / m 3 Daicel Tegusa Co., Ltd. (trade name) Vestamide X7094
(B) Inner part Y1. PP resin GF = 30% product Density = 1120kg / m 3
Made by Prime Polymer Co., Ltd. (Product Name) Prime Polypro E7000
Y2. ABS resin GF = 30% product density = 1290kg / m 3
Asahi Kasei Chemicals Co., Ltd. (trade name) Stylac R260A
Y3. PA66 resin GF = 33% product Density = 1390kg / m 3
Asahi Kasei Chemicals Corporation (trade name) Leona 93G33
Y4. PA66 resin GF = 50% product Density = 1580kg / m 3
Asahi Kasei Chemicals Corporation (trade name) Leona 90G50
［評価方法］
１．生産性
射出成形工程において、製品を取り出し後放置し、表面に付いているシボが残る冷却時間で比較。製品表面についているシボＮｏ．は、ベアロン（株）製ＢＫ−１００５を使用。
[Evaluation method]
1. Productivity In the injection molding process, the product is taken out and allowed to stand, and compared with the cooling time during which the wrinkles on the surface remain. No. on the product surface. Uses BK-1005 manufactured by BEARON Co., Ltd.
２．ゲート跡
製品のゲート周辺の状態を肉眼で確認し、違和感が無いかまたは良好な状態か確認する。
2. Gate traces Check the condition of the product's gate area with the naked eye to make sure that there is no sense of incongruity or that it is in good condition.
３．剥離性
取っ手成形品の長手方向をＸ軸、Ｙ軸方向に切削して四等分し、表層部分と内側部分の樹脂を親指で押して剥離するか確認する。
3. Peelability The longitudinal direction of the handle molded product is cut in the X-axis and Y-axis directions and divided into four equal parts, and it is confirmed whether the resin on the surface layer portion and the inner portion is pushed with the thumb to peel.
４．製品外観
製品の外観状態を肉眼で確認し、シボ面が良好に転写されているか、または部分的転写不良等の状態が無いか確認する。
4). Product appearance Check the appearance of the product with the naked eye, and confirm that the textured surface is well transferred or that there is no partial transfer failure.
５．製品強度
製品をＳ５５Ｃの冶具に取付け、金属インサート物の中心から、取っ手の末端方向に向かって１００ｍｍの位置にドリルでφ３．５ｍｍの穴を垂直方向に開けて、耐荷重３００ｋｇの市販ワイヤーを通し、ロードセルに取付け、万能引張り試験機のクロスヘッドを１００ｍｍ／ｍｉｍｓで下方に移動させて、その時の荷重をロードセルで測定した。
5. Product strength Install the product on a jig of S55C, drill a φ3.5mm hole vertically from the center of the metal insert to the end of the handle with a diameter of 100mm, and pass a commercial wire with a load capacity of 300kg. Then, it was attached to the load cell, the crosshead of the universal tensile tester was moved downward at 100 mm / mims, and the load at that time was measured with the load cell.
＜実施例１＞
２本のスクリューおよびシリンダー（Ａシリンダー、Ｂシリンダー）を有するサンドイッチ成形機のＡシリンダーに表層部分用樹脂、Ｂシリンダーに内側部分用樹脂を入れ、図１に示す金型（エアーベントの（Ｈ）の深さ０．０８ｍｍ、幅６．０ｍｍ、長さ１２．０ｍｍ）を使用して、全長１２０ｍｍ、幅１８ｍｍ、高さ２０ｍｍの取っ手を成形した。
<Example 1>
In the sandwich molding machine with two screws and cylinders (A cylinder, B cylinder), put the resin for the surface layer in the A cylinder and the resin for the inner part in the B cylinder. The handle having a total length of 120 mm, a width of 18 mm, and a height of 20 mm was formed using a depth of 0.08 mm, a width of 6.0 mm, and a length of 12.0 mm.
Ａシリンダーにポリアミド樹脂（Ｘ３）、Ｂシリンダーにポリアミド樹脂（Ｙ３）を入れ、樹脂温度それぞれ２８０℃で溶融させ、金属インサート物を金型にセットし、金型温度設定を８０℃とした。 The polyamide resin (X3) was put in the A cylinder, and the polyamide resin (Y3) was put in the B cylinder, and the resin temperature was melted at 280 ° C., and the metal insert was set in the mold, and the mold temperature was set at 80 ° C.
シャットオフピン（Ｅ）を閉じた状態で、ポリアミド樹脂（Ｘ３）を、スプルー、ランナー、キャビティーの全容積の半分以上を目処に計量し、スプルー、ランナー、キャビティーの全容積の１／３を目処に射出した。次に、ポリアミド樹脂（Ｙ３）をスプルー、ランナー、キャビティー全容積の残りの容積分計量して射出し、キャビティーを完全に満たし、保圧した。 With the shut-off pin (E) closed, measure the polyamide resin (X3) to more than half of the total volume of the sprue, runner and cavity, and 1/3 of the total volume of the sprue, runner and cavity. Was fired at the target. Next, polyamide resin (Y3) was weighed and injected for the remaining volume of the sprue, runner and cavity total volume, and the cavity was completely filled and pressure-retained.
約１．２秒経過後、シャットオフピン（Ｅ）を開き、前記残りのポリアミド樹脂（Ｘ３）を射出して、捨てキャビティー（Ｆ）へポリアミド樹脂（Ｘ３）とポリアミド樹脂（Ｙ３）を排出しながら充填し、取っ手を得た。評価結果を表１に示す。 After about 1.2 seconds, the shut-off pin (E) is opened, the remaining polyamide resin (X3) is injected, and the polyamide resin (X3) and the polyamide resin (Y3) are discharged into the disposal cavity (F). While filling, a handle was obtained. The evaluation results are shown in Table 1.
＜実施例２＞
耐候性付与として、Ａシリンダーに耐候性の優れたポリアミド樹脂（Ｘ４）、Ｂシリンダーに強度の優れたポリアミド樹脂（Ｙ４）を入れ、樹脂温度それぞれ２９０℃で溶融させ、金型温度設定を９０℃とした以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Example 2>
To provide weather resistance, polyamide resin (X4) with excellent weather resistance is put into the A cylinder, and polyamide resin (Y4) with excellent strength is put into the B cylinder, and the resin temperature is melted at 290 ° C., and the mold temperature is set to 90 ° C. A handle was obtained in the same manner as in Example 1 except that. The evaluation results are shown in Table 1.
＜実施例３＞
表面装飾用として、アルミ金属紛を１％添加したポリアミド樹脂（Ｘ３）をＡシリンダーに入れて、Ｂシリンダーに強度の優れたポリアミド樹脂（Ｙ４）を入れ、樹脂温度それぞれ２９０℃で溶融させ、金型温度設定を９０℃とした以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Example 3>
For surface decoration, put polyamide resin (X3) added with 1% aluminum metal powder into A cylinder, put polyamide resin (Y4) with excellent strength into B cylinder, melt at 290 ° C each resin temperature, A handle was obtained in the same manner as in Example 1 except that the mold temperature was set to 90 ° C. The evaluation results are shown in Table 1.
＜実施例４＞
ポリアミド樹脂（Ｘ３）とポリアミド樹脂（Ｘ５）を重量比１：１でドライブレンドした樹脂をＡシリンダーに入れ、Ｂシリンダーにポリアミド樹脂（Ｙ３）を入れ、樹脂温度それぞれ２８０℃で溶融させ、金型温度設定を９０℃とした以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Example 4>
A resin obtained by dry blending polyamide resin (X3) and polyamide resin (X5) at a weight ratio of 1: 1 is placed in the A cylinder, the polyamide resin (Y3) is placed in the B cylinder, and the resin temperature is melted at 280 ° C. respectively. A handle was obtained in the same manner as in Example 1 except that the temperature was set to 90 ° C. The evaluation results are shown in Table 1.
＜実施例５＞
ゲート跡を実施例１と比較するため、キャビティー（Ｄ）を完全に満たし保圧した後、シャットオフピン（Ｅ）を開き、結晶性エンジニアリング樹脂（Ａ）を充填せずに、捨てキャビティー（Ｆ）へ結晶性エンジニアリング樹脂（Ａ）のみを排出した以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Example 5>
In order to compare the gate trace with that of Example 1, the cavity (D) was completely filled and held, then the shut-off pin (E) was opened, and the cavity was discarded without being filled with the crystalline engineering resin (A). A handle was obtained in the same manner as in Example 1 except that only the crystalline engineering resin (A) was discharged to (F). The evaluation results are shown in Table 1.
＜実施例６＞
エアーベント（Ｈ）の有効性を把握するため、実施例１の条件で連続成形し、エアーベント（Ｈ）を設けた場合と設けない場合を比較した。
<Example 6>
In order to grasp the effectiveness of the air vent (H), continuous molding was performed under the conditions of Example 1, and the case where the air vent (H) was not provided was compared with the case where the air vent (H) was not provided.
その結果、エアーベント（Ｈ）を設けない場合には、約１万ショットでシャットオフピン（Ｅ）にモールドデポジットや離型剤が溜り、作動不良の状態を引き起こし、捨てキャビティー（Ｆ）への樹脂の排出が困難になった。一方、エアーベント（Ｈ）を設けた金型では、約３万ショットでもシャットオフピン（Ｅ）の作動不良は認められなかった。補足ではあるが、この両条件のトータル成形サイクルは約５０ｓｅｃである。 As a result, when the air vent (H) is not provided, mold deposits and release agents accumulate on the shut-off pin (E) after about 10,000 shots, causing a malfunction, and returning to the waste cavity (F). It became difficult to discharge the resin. On the other hand, in the mold provided with the air vent (H), the malfunction of the shut-off pin (E) was not recognized even with about 30,000 shots. As a supplement, the total molding cycle for both conditions is about 50 sec.
＜比較例１＞
生産性と製品強度を実施例と比較するため、汎用結晶性樹脂を用いた。即ち、ＡシリンダーにＰＰ樹脂（Ｘ１）、ＢシリンダーにＰＰ樹脂（Ｙ１）を入れ、樹脂温度それぞれ２２０℃で溶融させ、金型温度設定４０℃とした以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Comparative Example 1>
A general crystalline resin was used to compare productivity and product strength with the examples. That is, the handle is the same as in Example 1 except that PP resin (X1) is put into the A cylinder, PP resin (Y1) is put into the B cylinder, the resin temperature is melted at 220 ° C., and the mold temperature is set to 40 ° C. Got. The evaluation results are shown in Table 1.
＜比較例２＞
生産性と製品強度を実施例と比較するため、汎用非晶性樹脂を用いた。即ち、ＡシリンダーにＡＢＳ樹脂（Ｘ２）、ＢシリンダーにＡＢＳ樹脂（Ｙ２）を入れ、樹脂温度それぞれ２４０℃、２５０℃で溶融させ、金型温度設定を４０℃とした以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Comparative example 2>
In order to compare the productivity and product strength with the examples, a general-purpose amorphous resin was used. That is, Example 1 except that ABS resin (X2) was put in the A cylinder and ABS resin (Y2) was put in the B cylinder and melted at 240 ° C. and 250 ° C. respectively, and the mold temperature was set to 40 ° C. A handle was obtained in the same manner. The evaluation results are shown in Table 1.
＜比較例３＞
剥離性を実施例と比較するため、ＡシリンダーにＰＰ樹脂（Ｘ１）、Ｂシリンダーにポリアミド樹脂（Ｙ３）を入れ、樹脂温度それぞれ２２０℃、２８０℃で溶融させ、金型温度設定を４０℃とした以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Comparative Example 3>
In order to compare the peelability with the examples, PP resin (X1) is put in the A cylinder and polyamide resin (Y3) is put in the B cylinder, and the resin temperature is melted at 220 ° C. and 280 ° C., respectively, and the mold temperature setting is 40 ° C. A handle was obtained in the same manner as in Example 1 except that. The evaluation results are shown in Table 1.
＜比較例４＞
製品の外観を実施例１と比較するため、樹脂組成物（Ｂ）をスプルー、ランナー、キャビティー（Ｄ）の全容積の残りの容積分より少ない量射出し、キャビティー（Ｄ）を完全には満たさなかった以外は、実施例１と同様にして取っ手を得た。評価結果を表１に示す。
<Comparative example 4>
In order to compare the appearance of the product with that of Example 1, the resin composition (B) was injected in an amount smaller than the remaining volume of the total volume of the sprue, runner and cavity (D), and the cavity (D) was completely discharged. A handle was obtained in the same manner as in Example 1 except that it was not satisfied. The evaluation results are shown in Table 1.
本発明により、結晶性エンジニアリング樹脂（Ａ）、特に補強材による補強効果が大きいポリアミド樹脂と射出成形のサンドイッチ成形方法を組み合わせる事により、製品強度が高くて、長期信頼性が高く、表面外観性が優れ、かつ量産性に優れた樹脂製取っ手を提供する事が可能となった。 According to the present invention, by combining the crystalline engineering resin (A), in particular, the polyamide resin having a large reinforcing effect by the reinforcing material and the sandwich molding method of injection molding, the product strength is high, the long-term reliability is high, and the surface appearance is high. It has become possible to provide an excellent resin handle with excellent mass productivity.
（Ａ）結晶性エンジニアリング樹脂
（Ｂ）樹脂組成物
（Ｃ）金属インサート物
（Ｄ）キャビティー
（Ｅ）流路開閉機構（シャットオフピン）
（Ｆ）捨てキャビティー
（Ｇ）ゲート
（Ｈ）エアーベント
(A) Crystalline engineering resin (B) Resin composition (C) Metal insert (D) Cavity (E) Channel opening / closing mechanism (shutoff pin)
(F) Waste cavity (G) Gate (H) Air vent
Claims (3)
前記金属インサート物（Ｃ）が入ったキャビティー（Ｄ）、該キャビティー（Ｄ）の流動末端部分とつながった捨てキャビティー（Ｆ）、及び該キャビティー（Ｄ）と該捨てキャビティー（Ｆ）との間に設置された流路開閉機構（Ｅ）、前記キャビティー（Ｄ）と前記流路開閉機構（Ｅ）との間に設けられたエアーベント（Ｈ）、前記金属インサート物（Ｃ）の近くに設けられたゲート（Ｇ）から構成される金型を用い、
前記流路開閉機構（Ｅ）を閉じた状態で、前記ゲート（Ｇ）から、前記結晶性エンジニアリング樹脂（Ａ）及び前記樹脂組成物（Ｂ）を前記キャビティー（Ｄ）に充填し、該キャビティー（Ｄ）を該結晶性エンジニアリング樹脂（Ａ）及び該樹脂組成物（Ｂ）で完全に満たして保圧状態とし、次いで、閉じていた前記流路開閉機構（Ｅ）を開き、前記捨てキャビティー（Ｆ）に、前記結晶性エンジニアリング樹脂（Ａ）と前記樹脂組成物（Ｂ）、或いは前記結晶性エンジニアリング樹脂（Ａ）を排出することを特徴とする樹脂製取っ手のサンドイッチ成形方法。 From the surface layer portion of the crystalline engineering resin (A), the inner portion of the resin composition (B) composed of a crystalline engineering resin similar to the crystalline engineering resin (A) containing the reinforcing material, and the metal insert (C) A resin mold sandwich molding method comprising:
A cavity (D) containing the metal insert (C), a waste cavity (F) connected to the flow end portion of the cavity (D), and the cavity (D) and the waste cavity (F) ), The air vent (H) provided between the cavity (D) and the channel opening / closing mechanism (E), and the metal insert (C). ) Using a mold composed of a gate (G) provided near
With the flow path opening / closing mechanism (E) closed, the cavity (D) is filled with the crystalline engineering resin (A) and the resin composition (B) from the gate (G). The tee (D) is completely filled with the crystalline engineering resin (A) and the resin composition (B) to obtain a pressure-holding state, then the closed channel opening / closing mechanism (E) is opened, and the waste mold A sandwich molding method for a resin handle, wherein the crystalline engineering resin (A) and the resin composition (B) or the crystalline engineering resin (A) is discharged to a tee (F).
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| JP2008043102A JP5171309B2 (en) | 2007-08-30 | 2008-02-25 | Sandwich molding method for resin handles |
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