JP7446337B2 - 構造用発泡剤、着色剤、他の添加剤の射出のリアルタイム制御のための方法および装置 - Google Patents
構造用発泡剤、着色剤、他の添加剤の射出のリアルタイム制御のための方法および装置 Download PDFInfo
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- JP7446337B2 JP7446337B2 JP2021569388A JP2021569388A JP7446337B2 JP 7446337 B2 JP7446337 B2 JP 7446337B2 JP 2021569388 A JP2021569388 A JP 2021569388A JP 2021569388 A JP2021569388 A JP 2021569388A JP 7446337 B2 JP7446337 B2 JP 7446337B2
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Description
本非仮特許出願は、2019年5月23日に出願された米国仮特許出願第62/852,106号の出願日の利益を主張し、その全体が参照により本明細書に組み込まれる。
添加剤射出システム150はまた、材料を成形型空洞122に射出し得る。添加剤射出システム150は、添加剤材料154の供給物を収容する添加剤タンク152の形態であり得る、添加剤材料の供給源と、その各々が添加剤タンク152から添加剤材料154を受容し、かつ添加剤材料154を成形型空洞122に射出する、添加剤射出器156と、を含む。添加剤射出器156は、共通マニホルド158、または添加剤材料154が添加剤タンク152から添加剤射出器156に進行するためのチャネルを提供する、添加剤供給チャネルによって、添加剤タンク152に接続され得る。添加剤ポンプ160は、添加剤タンク152および/または共通マニホルド158に接続され、添加剤材料154を添加剤タンク152および/または共通マニホルド158から添加剤射出器156にポンプ圧送し得る。
前述のように、射出成形サイクル中に、センサ128および129は、添加剤射出器156からのフィードバックを送信することに加えて、添加剤射出デバイス150の動作に関連する少なくとも1つの変数を示す信号データを提供する。動作中、コントローラ170は、ソフトウェア171に記憶され得る添加剤射出プロファイルを開始する。いくつかの例では、添加剤射出プロファイルは、測定された変数が閾値に達したときに開始され得る。これらの例では、変数または特性は、時間以外のもの(例えば、サイクル、工程、または他の時間)である可能性があり、それゆえ、時間は直接測定されず、かつ添加剤射出プロファイルの開始または長さを判定するために使用され得ない、したがって、時間は、直接測定されず、かつ添加剤射出プロファイルがいつ完了したかを判定するために使用されない。むしろ、変数または特性は、添加剤射出プロファイルの完了に関する判定係数として、別の値または指標に依存する。1つ以上の非時間依存変数の使用は、連続する実行中に、ペレット108の同じ供給がある状態でも、ペレット品質、添加剤材料154の量、触媒安定性、周囲条件、または他の係数における変動が、成形型空洞122内の添加剤材料154の場所および密度の精度に影響を及ぼし得るので有利である。時間依存プロセスは、ほとんどの時間満足のいく部品を提供し得るが、1つ以上の非時間依存変数に基づいて、射出サイクルにおける添加剤射出プロファイルの進行を判定するシステムが、成形システム100および添加剤射出デバイス150の個々のサイクルごとの添加剤材料の準備状況のより正確な評価を提供するため、より望ましい。
Claims (18)
- 射出成形装置であって、
第1の成形型側面および第2の成形型側面により形成される複数の成形型空洞を有する成形型と、
射出ユニットであって、前記成形型空洞と流体連通する1以上のゲートを介して、溶融された材料を前記成形型空洞に射出するノズルに向かって、前記溶融された材料を先進させるように構成されたホッパー、バレルおよび往復ねじを含む射出ユニットと、
添加剤射出成形システムであって、
1つ以上の添加剤タンクであって、各々が、前記溶融された材料と異なる添加剤流体材料の供給を有する、添加剤タンクと、
前記1つ以上の添加剤タンクと流体連通している1つ以上の添加剤射出器であって、その各々の添加剤射出器が、前記添加剤流体材料を受容し、かつ前記成形型空洞の各々に射出し、前記1つ以上の添加物射出器が前記ノズルとは異なり、前記成形型空洞のそれぞれ一つに配置される、添加剤射出器と、
前記1つ以上の添加剤タンクおよび前記1つ以上の添加剤射出器の各々を接続する、共通のマニホルドと、
前記1つ以上の添加剤射出器を通して前記添加剤流体材料をポンプ圧送する、1つ以上の添加剤ポンプと、を含む添加剤射出成形システムと、
前記成形型、前記射出ユニット、および前記添加剤射出器の操作を制御するように構成されたコントローラと、を含み、
前記添加剤流体材料が、膨張性架橋ポリマー、非膨張性ポリマー、着色剤、ガス、液体、超臨界流体、粉末、界面活性剤、触媒、乳化剤、またはこれらの任意の組み合わせを含む、射出成形装置。 - 前記添加剤射出成形システムに結合され、前記コントローラと通信する1つまたは複数のセンサであって、前記1つまたは複数のセンサの少なくとも1つが、射出成形サイクル中の少なくとも1つの非時間依存変数を測定するように構成される、1つまたは複数のセンサをさらに有する、請求項1に記載の射出成形装置。
- 前記1つ以上のセンサの少なくとも1つは、射出成形サイクル中の少なくとも1つの非時間依存変数を測定し、(a)前記添加剤流体材料の投入開始、(b)前記添加剤流体材料の投入停止、および/または(c)前記添加剤流体材料の投入速度の変更、を保証する状態を表示する、請求項2に記載の射出成形装置。
- 前記1つ以上の添加剤射出器のうちの少なくとも1つが、前記複数の成形型空洞のそれぞれの入口端から離れる方向で、前記入口端と反対の端部に向かって、下向きに前記添加剤流体材料を射出するように構成された出口ノズルを有する、請求項1に記載の射出成形装置。
- 前記成形型空洞の少なくとも1つにおいて、前記1つ以上の添加剤射出器により射出された添加剤流体材料を溶融された材料中に混合するために提供された混合要素をさらに含む、請求項4に記載の射出成形装置。
- 前記混合要素が、前記成形型空洞の入口端と前記出口ノズルのそれぞれとの間に配置されている、請求項5に記載の射出成形装置。
- 前記出口ノズルのそれぞれが、前記混合要素と前記成形型空洞の入口端との間に配置されている、請求項5に記載の射出成形装置。
- 前記1つ以上の添加剤射出器のうちの少なくとも1つが、前記複数の成形型空洞のそれぞれの入口端から離れる方向で、前記入口端と反対の端部に向かって、上向きに前記添加剤流体材料を射出するように構成された出口ノズルを有する、請求項1に記載の射出成形装置。
- 前記成形型空洞の少なくとも1つにおいて、前記1つ以上の添加剤射出器により射出された添加剤流体材料を溶融された材料中に混合するために提供された混合要素をさらに含む、請求項8に記載の射出成形装置。
- 前記混合要素が、前記成形型空洞の入口端と前記出口ノズルのそれぞれとの間に配置されている、請求項9に記載の射出成形装置。
- 前記出口ノズルのそれぞれが、前記混合要素と前記成形型空洞の入口端との間に配置されている、請求項9に記載の射出成形装置。
- 前記1つ以上の添加剤射出器が、6,000psi以下の圧力の添加剤流体を射出する、請求項1に記載の射出成形装置。
- 前記1つ以上の添加剤タンクが、複数の添加剤タンクを備え、前記複数の添加剤タンクの少なくとも1つが前記複数の添加剤タンクの他の前記添加剤流体材料と異なる添加剤流体材料の供給を含む、請求項1に記載の射出成形装置。
- 前記少なくとも1つの非時間依存変数は前記添加剤流体材料の投入開始、前記添加剤流体材料の投入停止、および前記添加剤流体材料の投入速度の変更を含む群の一つを保証する状態を表示する、請求項2に記載の射出成形装置。
- 前記1つ以上の添加剤射出器が、前記コントローラにフィードバック情報を提供する、請求項1に記載の射出成形装置。
- 前記コントローラが、前記添加剤射出成形システムの開ループ制御を提供する、請求項1に記載の射出成形装置。
- 前記コントローラが、前記1つ以上のセンサからの少なくとも1つの測定からのフィードバック情報および/または前記1つ以上の添加剤射出器からのフィードバック情報を用いて、前記添加剤射出成形システムの閉ループ制御を提供する、請求項1に記載の射出成形装置。
- 前記コントローラが、前記添加剤射出器に、パルス方式で前記添加剤流体材料のそれぞれを射出することを制御するように構成される、請求項1に記載の射出成形装置。
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