JP7132487B2 - 発泡成形体の製造方法 - Google Patents
発泡成形体の製造方法 Download PDFInfo
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- 239000006260 foam Substances 0.000 title description 16
- 238000004519 manufacturing process Methods 0.000 title description 10
- 239000007789 gas Substances 0.000 claims description 52
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 34
- 238000005187 foaming Methods 0.000 claims description 29
- 229920005989 resin Polymers 0.000 claims description 25
- 239000011347 resin Substances 0.000 claims description 25
- 229910052786 argon Inorganic materials 0.000 claims description 17
- 239000002994 raw material Substances 0.000 claims description 11
- 239000003463 adsorbent Substances 0.000 claims description 9
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 9
- 239000001301 oxygen Substances 0.000 claims description 9
- 229910052760 oxygen Inorganic materials 0.000 claims description 9
- 238000004898 kneading Methods 0.000 claims description 6
- 238000007664 blowing Methods 0.000 claims description 2
- 238000007666 vacuum forming Methods 0.000 claims description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 34
- 229910001873 dinitrogen Inorganic materials 0.000 description 18
- 239000000872 buffer Substances 0.000 description 9
- 238000000071 blow moulding Methods 0.000 description 8
- 229910052757 nitrogen Inorganic materials 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 230000005587 bubbling Effects 0.000 description 6
- 238000000465 moulding Methods 0.000 description 6
- 238000000034 method Methods 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 239000004594 Masterbatch (MB) Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 2
- 238000004378 air conditioning Methods 0.000 description 2
- 238000010097 foam moulding Methods 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 229920001384 propylene homopolymer Polymers 0.000 description 1
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 1
- 235000017557 sodium bicarbonate Nutrition 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
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- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/122—Hydrogen, oxygen, CO2, nitrogen or noble gases
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/06—Making preforms by moulding the material
- B29B11/10—Extrusion moulding
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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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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- B29C44/3446—Feeding the blowing agent
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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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/36—Feeding the material to be shaped
- B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
- B29C44/50—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
- B29C44/507—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying extruding the compound through an annular die
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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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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- B29C44/56—After-treatment of articles, e.g. for altering the shape
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
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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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/024—Preparation or use of a blowing agent concentrate, i.e. masterbatch in a foamable composition
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/06—CO2, N2 or noble gases
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J2423/10—Homopolymers or copolymers of propene
- C08J2423/12—Polypropene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
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- C08J9/0066—Use of inorganic compounding ingredients
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
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- Chemical & Material Sciences (AREA)
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- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Molding Of Porous Articles (AREA)
Description
好ましくは、前記記載の方法であって、前記発泡ガスは、98.0~99.9%の窒素を含む、方法である。
好ましくは、前記記載の方法であって、前記発泡ガスは、吸着剤を用いて大気から酸素を除去することによって得られるガスである、方法である。
本発明の別の観点によれば、原料樹脂と発泡ガスを押出機のシリンダ内で溶融混練してなる溶融混練樹脂を用い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、前記発泡ガスは、吸着剤を用いて大気から酸素を除去することによって得られるガスである、発泡成形体の製造方法が提供される。
以下、各構成について詳細に説明する。
ホッパー12は、原料樹脂11を押出機13のシリンダ13a内に投入するために用いられる。原料樹脂11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11は、ホッパー12からシリンダ13a内に投入された後、シリンダ13a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13a内に配置されたスクリューの回転によってシリンダ13aの先端に向けて搬送される。スクリューは、シリンダ13a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搬送する。スクリューの基端にはギア装置が設けられており、ギア装置によってスクリューが回転駆動される。
シリンダ13aには、シリンダ13a内に発泡ガスを注入するためのインジェクタ16が設けられる。インジェクタ16には、配管2を介して、ガス供給装置14が連結される。
原料樹脂と発泡ガスが溶融混練されてなる溶融混練樹脂は、シリンダ13aの樹脂押出口から押し出され、連結管25を通じてアキュームレータ17内に注入される。アキュームレータ17は、シリンダ17aとその内部で摺動可能なピストン17bを備えており、シリンダ17a内に溶融混練樹脂11aが貯留可能になっている。そして、シリンダ17a内に溶融混練樹脂11aが所定量貯留された後にピストン17bを移動させてことによって、連結管27を通じて溶融混練樹脂11aをヘッド18内に設けられたダイスリットから押し出して発泡パリソン23を形成する。発泡パリソン23の形状は、特に限定されず、円筒状であってもよく、シート状であってもよい。
発泡パリソン23は、一対の分割金型19間に導かれる。分割金型19を用いて発泡パリソン23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19を用いた成形の方法は特に限定されず、分割金型19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19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23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。
<実施例1>
図1に示す発泡ブロー成形機1を用いて、発泡成形体を作製し、発泡成形性の評価を行った。押出機13のシリンダ13aの内径は50mmであり、L/D=34であった。原料樹脂には、プロピレン単独重合体(ポレアリス社(Borealis AG)製、商品名「Daploy WB140」)と、長鎖分岐ポリプロピレン(日本ポリプロ株式会社製、商品名「EX6000K」)を質量比30:70で混合し、樹脂100質量部に対して、核剤として20wt%の炭酸水素ナトリウム系発泡剤を含むLDPEベースマスターバッチ(大日精化工業株式会社製、商品名「ファインセルマスターP0217K」)を1.0重量部、および着色剤として40wt%のカーボンブラックを含むLLDPEベースマスターバッチ1.0重量部を添加したものを用いた。発泡パリソン23の温度が190~200℃になるように各部位の温度制御を行った。スクリューの回転数は、60rmmとし、押出量は、20kg/hrとした。
比較例1では、発泡ガスとして、深冷分離法によって生成した窒素ガスを充填させた窒素ガスボンベのガスを用いた以外は、実施例1と同様の方法で発泡成形体を作製した。
実施例1及び比較例1の発泡成形体の断面写真を図3A~図3Bに示す。図3A~図3Bに示すように、実施例1の発泡成形体は、比較例1の発泡成形体に比べて、気泡の真円度が大幅に高いことが分かる。
2 :配管
11 :原料樹脂
11a:溶融混練樹脂
12 :ホッパー
13 :押出機
13a:シリンダ
14 :ガス供給装置
15 :窒素ガス発生ユニット
15a:コンプレッサ
15b:タンク
15c:窒素ガス発生装置
15d:バッファタンク
15e:コンプレッサ
15f:バッファタンク
16 :インジェクタ
17 :アキュームレータ
17a:シリンダ
17b:ピストン
18 :ヘッド
19 :分割金型
23 :発泡パリソン
25 :連結管
27 :連結管
Claims (1)
- 原料樹脂と発泡ガスを押出機のシリンダ内で溶融混練してなる溶融混練樹脂を用いて発泡パリソンを形成し、前記発泡パリソンをブロー又は真空成形して発泡成形体を得る工程を備え、
前記発泡ガスは、吸着剤を用いて大気から酸素を除去することによって得られ且つ0.1%以上のアルゴンを含むガスである、発泡成形体の製造方法。
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2018065785A JP7132487B2 (ja) | 2018-03-29 | 2018-03-29 | 発泡成形体の製造方法 |
CN201980007481.XA CN111556803A (zh) | 2018-03-29 | 2019-03-22 | 发泡成型体的制造方法 |
US16/976,817 US11679537B2 (en) | 2018-03-29 | 2019-03-22 | Method for manufacturing foam molded body |
KR1020207018715A KR20200132839A (ko) | 2018-03-29 | 2019-03-22 | 발포 성형체의 제조 방법 |
EP19778168.5A EP3778175A4 (en) | 2018-03-29 | 2019-03-22 | METHOD OF MANUFACTURING A FOAM SHAPED BODY |
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WO2017007032A1 (ja) | 2015-07-08 | 2017-01-12 | 日立マクセル株式会社 | 発泡成形体の製造方法及び製造装置 |
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WO2008038639A1 (fr) * | 2006-09-29 | 2008-04-03 | Asahi Kasei Chemicals Corporation | Feuille de mousse d'une composition de résine thermoplastique et son procédé de production |
CN101959942B (zh) * | 2007-12-28 | 2013-05-08 | 陶氏环球技术有限责任公司 | 用于制备吸振垫的具有高填充量的基于pe的交联弹性泡沫体以及用于鞋用制品和地面材料应用的制品 |
JP5602468B2 (ja) * | 2010-03-24 | 2014-10-08 | 株式会社ジェイエスピー | ポリプロピレン系樹脂発泡ブロー成形体の製造方法 |
JP5589651B2 (ja) | 2010-07-30 | 2014-09-17 | キョーラク株式会社 | 発泡成形体の製造方法、及び発泡成形体 |
CN102321309B (zh) * | 2011-06-09 | 2012-10-31 | 四川大学 | 具有梯度结构的聚合物泡沫复合材料及其制备方法 |
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WO2016147883A1 (ja) | 2015-03-18 | 2016-09-22 | バンドー化学株式会社 | 発泡用樹脂組成物及び発泡成形体 |
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