A7 B7 424039 五、發明説明（1 ) 發明範噴 本發明一般係關於聚合物結構性泡綿處理，尤指微胞 孔結構性泡綿，及其製'造系統'和方法。 發明背景 結構性發泡材料已屬公知，其製法爲將物理發泡劑射 入熔化聚合物流內，將發泡劑在聚合物內分散，形成聚合 * 物內含有發泡劑晶胞的二相混合物，把混合物射入具有所 需形狀之模型，並令混合物在其內凝固，混合物內的壓力 降會造成聚合物內的晶胞成長。做爲物理發泡劑的另類， 可用化學發泡劑，在聚合物材料內進行化學反應，以形成 氣體。化學發泡劑一般爲低分支量有機化合物，會在臨界 溫度分解，釋出氮、二氧化碳或一氧化碳等氣體。在若干 條件下，胞孔可維持分離，得閉孔式發泡材料。在其他典 型上更激烈的發泡條件下，胞孔會破裂或相連，而得開孔 式材料，專利文獻上所述標準射出成型技術案例如下： 美國專利343 6446號（Angell)說明一種方法和裝置，利 用控制模型的壓力和溫度，成型具有固體外皮的發泡塑膠 物品。 美國專利4479914號（Baumoucker)記述一種發泡物品 形成方法，其中模型用氣體加壓，以防發泡氣體從射入腔 內的材料過早擴散。在待發泡材料射出之際，預加壓氣體 排放，最後到真空室產生真空，把材料抽經模腔。 微胞孔材料典型上由極小胞孔尺寸的聚合物泡綿形 成’年美國專利用5158986和4473665號內載有各種微胞 -1 - 本纸張尺度適用中國國家標準（CNS ) A4規格（2丨0X 297公釐} (锖先閧讀背面之注^*^項再填寫本頁) -5 鯉濟部中央標準局員工消費合作社印裂 A7 B7 五、發明説明（2 ) 孔材料。此等專利記載，令聚合物材料和物理發泡劑的單 相溶液’經熱力學不穩定性，產生棰髙密度的成核位置， 接著控制胞孔成長，製成微胞孔材料。美國專利4473 665 號（Martini-Vvedeusky)記述微胞孔組件的成型系統和製造 方法。聚合物粒以氣態發泡劑預加壓，並在習用壓出機內 熔化，形成發泡劑和熔化聚合物之溶液，再壓出進入加壓 模腔內。模型內的壓力在指定初始飽和的熔體溫度時，維 持在氣態發泡劑的溶解度壓力以上。若成型組件的溫度降 到適當臨界成核溫度，則模型上的壓力典型上降到周遭壓 力，容許該組件發泡。 經濟部中央標準局員工消費合作社印製 (請先W讀背面之注意事項再填舄本頁) 美國專利5 1 58986號（Cha等人）記載另類成型系統 和微胞孔組件之製法，將聚合物粒引進習知壓出機內加以 熔化。二氧化碳發泡劑在壓出筒內確立超臨界狀態，並混 合形成發泡劑和聚合物材料之均質溶液。將一部份壓出筒 加熱，使混合物流經筒，產生熱力學不穩定性，因而在熔 化聚合物料內產生成核位置。成核材料被壓入加壓模腔 內。利用空氣反壓維持模型內的壓力。當模腔膨脹，其內 壓力劇降，模腔內發生晶胞成長；模型膨脹提供成型和發 泡物，具有小胞孔尺寸和高晶胞密度。成核和晶胞成長是 分別按照技術發生；熱感應成核是發生在壓出機筒內，而 細晶胞長發生在模型內。 雖然上述和其他報告代表έ干技術，與微胞孔材料的 生產和藉射出成型的材料生產有關，但技術上仍亟需有改 進微胞孔射出成型製法。 -2 - 本紙張尺度適用中國國家標準（CNS) Α4規格（210><297公釐> 424039 A7 B7 _ 五、發明説明（3 ) 所以，本發明之目的，在於提供射出成型系統和方法， 有效製·成微胞It結構性泡綿，尤其是捶薄物品。另一目的 在於提供可用於微胞孔結構性泡綿之射出成型系統和方 法，亦可用於習知泡綿之射出成型，以及連續壓出微胞孔 或習知泡綿。 發明概要 本發明係針對可形成成型物之射出成型系統和方法， 以及形成各種發泡材料之系統和方法。在本發明所述各種 要旨中，在一組具體例內，材料爲習知發泡材料（胞孔尺 寸、密度等，不限定微胞孔材料），而另一組具體例內， 材料爲微胞孔材料》 經濟部中央標苹局貝工消費合作社印^ (請先閲讀背面之注^^項再填寫本可) 本發明一要旨涉及射出成型系統，構造成製造微胞孔 結構性發泡物。此系統包含壓出機，具有進口，在其進口 端設計成接受微胞孔材料之母質；成型室；以及封閉通道， 連接進口與成型室。成型室的構造和配置，在於接受聚合 物材料和發泡劑的非成核、均質、流體、單相溶液，於通 道內容納升壓時呈流體狀的聚合物材料和發泡劑的非成 核，均質流體單相溶液，並將溶液在通道內以流體按下游 方向，從進口端朝成垫室推進。封閉通道包含成核途徑， 以單相溶液通過的發泡劑在其內成核。成核途徑構成含有 聚合物承受端，承受聚合物和非成核發泡劑的均質流體單 相溶液；成核聚合物釋放端，構造和配置成釋放成核聚合 物材料；以及流體途徑，連接承受端至釋放端。聚合物釋 放端可視需要形成成塑室的噴嘴，或與成型室呈流體相 —3 — 本紙張尺>1適用中國國家標準{ C^IsTa4規格(ilOX 297公釐) 經濟部中央標準局貝工消費合作社印^ ^4039 a? B7 五、發明説明（4 ) 通，成核途徑構成具有長度和斷面尺寸，當與約6重量％ C02 均勻混合的流體聚合物以每小時約40磅流體通過途徑 時，在流體聚合物內產生壓力降速率至少約0.1 GPa/秒， 或至少約0.3 GP a/秒，或至少約1.0 GPa/sec，或至少約3 GPa/秒。成核途徑亦構成具有可變斷面尺寸，使流過途徑 的流體聚合物，受到可變壓力降速率和/或溫度上升。 按照本發明另_一要旨，提供一系統，具有成型室，構 造和配置成含有升壓的成核聚合物材料，以防在升壓下的 胞孔成長。加壓成型室可以流體或機械方式加壓，以便在 該升壓含有成核聚合物材料。在加壓成型室內減壓後，聚 合物材料會凝固成所需微胞孔聚合物品的形狀，因成型室 構造和配置成具有該項內部形狀。 按照本發明又一要旨，提供一系統，具有筒部，包括 進口設計成接受壓出材料的母質，出口設計成把發泡劑和 發泡聚合物品母質的流體非成核混合物，釋放至母質，孔 口可連接至發泡劑源，以及螺桿安裝在筒部內往復運動。 壓出系統亦可具有至少一孔口可連接至發泡劑源，而孔口 沿筒部軸線縱向配置，以便在螺桿往復運動中，依序引進 非成核混合物通過至少二孔口，進入筒部。系統亦可含有 第二壓出筒，與第一筒部串聯，第二筒部具有進口，設計 成接受流體非成核混合物，並有螺桿安裝成在筒部內往復 運動。 按照本發明另一要旨，提供一種方法，確定聚合物母 質和發泡劑的非成核、流體單相溶液連續流束，令流束成 — ^ 1 本紙張尺度適用中國國家標準（CNS ) Α4規格（210X297公釐） ----,--.----Ι------訂--^--^--^ 1 (請先閱讀背面之注意事項再填寫本頁) 04039 A7 ____B7 五、發明説明（5 ) 核產生混合物的成核流束，令成核流束通入容费內，並容 許混合物凝固成容器的形狀。流束可視需要連續成核，利 用其連續受到壓力降速率至少約0.1 GPa/秒，同時令流束 通入容器內，產生成核材料之連續流束。另外，此法涉及 流束斷續成核，令其受到壓力降速率至少約0.1 GPa/秒， 同時令流束通入容器內，使非成核材料先通入容器內，接 著才是成核材料。反之，成核流束可通入容器內，使成核 材料先通入容器內，接著才是非成核材料。此法亦涉及從 容器除去凝固的微胞孔物，並在約10分鐘內，在容器內提 供第二成核材料，容許第二混合物凝固成容器的形狀，並 從容器除去第二凝固微胞孔物。 本發明亦提供一方法，包括累積發泡聚合物材料和發 孢劑之母質加料，將限定於加料至少約2%的加料第一鄯 份，加熱到比加料平均溫度高至少約10 °C，並將加料射入 成型室內。 經濟部中央標隼局負工消費合作社印來 1— 1 I- - - J— I - : I I ΙΪ. - i· t {請先閲讀背面之注$項再填寫本頁} 另涉及一方法，包括在與成型室呈流體相連的累積器 內，累積加料，含有包括流體聚合物材料而基本上無發泡 劑的第一部份，以及包括流體聚合物材料與發泡劑混合的 第二部份，並將加料從累積器射入成型室內。 又提供一方法，涉及發泡聚合物材料母質和發泡劑的 流體單相溶液，從與壓出裝置呈流體相通的累積器射出進 入成型室，同時使溶液成核，產生成核混合物，並容許混 合物在成型室內凝固，成爲微胞孔聚合物品。 又提辦一方法，涉及將發泡劑射入聚合物壓出裝置的 —5 — 本纸張尺度適用中國國家榇準< CNS ) Λ4规格（210X297公釐) 經濟部中央標準局貝工消費合作社印製 424039 '__^__ 五、發明説明（6 ) 壓出機筒部內，同時壓出螺桿在筒部內軸向蓮動。 又提供一方法，涉及發泡劑從壓出螺桿射乂聚合物壓 出裝置之筒部內。 又提供一方法，涉及在壓出裝置的筒部內成立流體聚 合物品母質，從筒部排出一部份流體母質，將一部份流體 母質與發泡劑混合，形成發泡劑與部份流體母質的混合 物，把混合物引進筒部內。 又提供一方法，涉及將與超臨界流體添加剤相混的聚 合物材料，引入一部份內部尺寸約0.125吋以下的模型內， 容許聚合物材料在模型內凝固，引進和容許步驟需時在10 秒以內。 又提供一方法，涉及將與超臨界流體相混的聚合物材 料，引進一部份內部尺寸約0.125吋以下的模型，並容許 聚合物材料在模型內凝固。 又提供一方法，渉及成立至少二種不相似熔化聚合物 成份與超臨界流體發泡劑之混合物，將混合物壓出，形成 至少二種成份的不脫層泡綿。 又提供一方法，涉及將聚合物材料和發泡劑的單相溶 液，射入打開的模型內，合模並形成模型形狀之微胞孔物 品0 又提供一方法，涉及成立聚合物材料和發泡劑的單相 非成核溶液，艳溶液引進成塱室內，並使溶液成核，裂開 模型，因而容許晶胞成長，將形狀與成型室相似但比成型 室爲大的微胞孔聚合物品回收。 一 6 — 本紙張尺度適用中國國家標準{ CNS ) A4規格（210X297公釐） ----------/------訂------Ψ1 (請先閲讀背面之注^項再填寫本頁) 42 403 9 A7 ___B7_ 五'發明説明（7) 又提供一方法，涉及在壓出機內形成微胞孔聚合物材 料母質和發泡劑之非成核均質流體的單相溶液，以溶液充 填於成型室，並使溶液成核，在成型室內形成成核微胞孔 聚合物材料母質。 又提供一方法，涉及將聚合物/發泡劑混合物，在約 400 °F以下的熔點射入成型室內，在室內成型固體泡綿聚 合物品，其孔隙容積在約5%以下，長對厚比至少約50: 1。 本發明系統之一包含累積器，具有接受發泡聚合物材 料母質和發泡劑之進口，和出口；成型室，具有與累積器 出口呈流體相通的進口；以及與累積器相關的加熱裝置， 其構造和配置是在系統操作中，將靠近成型室的累積器第 一段加熱到較累積器平均溫度高至少約10 °C。 經濟部中央標準局負工消費合作社印製 (請先閲讀背面之注意事項再填寫本頁) 另提供一系統，包含壓出機，具有接受發泡聚合物材 料之進口，其構造和配置在於從母質製造流體聚合物材 料，位於從壓出機輸送流體聚合物材料的第一出口，在第 —出口下游可連接於物理發泡劑源之發泡劑進口，在發泡 劑進口下游，並構造和配置成製造流體聚合物母質和發泡 劑的混合物之混合物區，和在混合物區下游，位於輸送第 一聚合物母質和發泡劑的混合物之第二出口；以及累積 器，具有與壓出機的第一出口流體相連的第一進口，和與 壓出機的第二出口流體相連的第二進口。 又提供一系統，供製造射出成型的微胞孔材料，包含 壓出機，在其出口端具有出α，設計成釋出聚合物材料和 發泡劑的非成核均質流體單相溶液，以及成型室，具有與 —7 — 本紙張尺度適用中國國家標率（CNS ) Α4規格（2ΙΟΧ297公釐) ' 經濟部中央標率局員工消費合作社印製 4^4〇39 , A7 __B7_ 五、發明説明（8 ) 壓出機出口呈流體相通的進α。系統的構造和配置在於將 單相溶液從壓出機出α輸送至成型室，並在充填於成型室 之際，令單相溶液成核，在室內形成成核微胞孔聚合務材 料母質。 又提供一壓出系統，包含筒部，具有設計成接受壓出 材料母質的進口，.設計成釋放非成核發泡劑和母質之流體 混合物得出口，可連接至發泡劑源的孔口，和安裝在筒部 內往復運動的螺桿。 又提供一系統，供製造射出成型的微胞孔材料，包含 壓出機，在其出口端具有出口，設計成釋出微胞孔聚合物 材料母質和發泡劑，以及成型室，具有與壓出機出口流體 相通之進口。系統之構造和配置是可將微胞孔聚合物材料 母質和發泡劑循環射入成型室內。 本發明又提供一壓出系統，包含筒部，具有設計成接 受壓出材料母質的進口，和設計成釋出非成核發袍劑與母 質之流體混合物的出口，以及連接至發泡劑源之孔口。螺 桿安裝在筒部內往復運動。 另一要旨中，本發明提供一方法，渉及將發泡劑射入 聚合物壓出裝置的壓出機筒部內，同時壓出螺桿在筒部內 軸向運動。在一具體例中，方法涉及將發泡劑從壓出螺桿 射入聚合物壓出裝置的筒部內，此射出技術可用於各種各 樣的微胞孔和習知技術。另一要旨中，本發明涉及壓出螺 桿，其構造和配置可在聚合物壓出裝置的筒部內轉動，該 裝置在螺桿內含有腔口，與螺桿表面的孔口相通。此腔α —8 一 本紙張尺度適中國國家標準（CNS ) Α4規格（210 X 297公釐） <請先Μ讀背面之注項再填ΐ?本茛) .裝. *11 經潴部中央標隼局負工消費合作社印裝 424039 l] 五、發明説明（9 ) 可用來將發泡劑射入壓出筒部內。 在本發明另一要旨中，提供射出成型物品的製造系 統。系統包含壓出機、成型室、與壓出機和成型室呈流體 相連的流道*以及與流道通熱的溫度控制裝置。在另一要 旨中，本發明涉及在壓出機內成立發泡劑和射出成型材料 母質之流體混合物，令混合物通過流道進入成型室內，令 一部份流體混合物在室內凝固，同時維持流道內的一部份 混合物呈流體狀態，並將另外的流體混合物射入流道內， 因而將一部份流體和流道進入室內。 本發明又提供一方法，涉及從壓出筒部排出一部份流 體聚合物品母質，將部份流體母質與發泡劑混合形成混合 物，並將混合物再度引入筒部。 本發明又提供一系統，包含壓出機，具有壓出機筒部、 成型室，以及混合室、與筒部內上游第一孔口、筒部內下 游第二孔口，和發泡劑源流體相通。 在另一要旨中，本發明提供成型發泡物品，其形狀與 成型室基本上相符，至少一部份的斷面維度不超過約0.125 吋。 另一要旨涉及三維度微胞孔聚合物品，有三個交叉主 軸線，與三維度相對應，維度之一與第一軸線相關，以沿 第二垂直軸線的位置爲函數而變化，此物品至少一部份的 斷面積維度不超過約0.125吋。 另一要旨中，本發明提供射出成型聚合物組件，長/ 厚比至少約50 : 1，聚合物的熔體指數在約10以下。 -9 - 本紙乐尺度適用中國國家標準（CNS) A4规格（2丨0X297公釐） -----------/------訂------' (請先W讀背面之注意事項再填网本頁) 經滴部中央標丰局I工消费合作社印裒 4Z4039 't a? B7 五、發明説明（10) 另一要旨中，本發明提供射出成型聚合物組件，長/ 厚比至少約120 : 1，聚合物的熔體流量在約40以下。 另一要旨中，本發明提供射出成型聚合物泡綿，孔隙 容積至少約5%，表面並無肉眼可明顯看出的歪斜和旋渦。 另一要旨中，本發明提供一種物品，厚度在約0.125 吋以下，孔隙容積至少約20%，亦提供該物品之製法，涉 及將與超臨界流體相混的聚合物材料引進模型內，模型有 一部份內部維度在約0.125吋以下，容許聚合物材料在模 型內凝固，引進和容許步驟費時10秒以內。 本發明其他優點、新穎特點和目的，由本發明參照附 圓詳述如下即可明白，圓爲簡圓，無意照此比例尺。圖中 各相同或幾近相同的組件，以單一數字表示。爲清晰起見， 各組件未在各圖中——標示，本發明各具體例之每一組 件，亦不必逐一圖示才能使箇中技術專家明瞭。 圓式簡單說明 圖1爲本發明微胞孔射出或壓出成型系統，包含壓出 系統，具有成核途徑，形成成型室的孔口； 圖2爲含有累積器之本發明微胞孔射出成型系統； 圖3爲含有活動壁之成型系統的成型室具體例； 圓4爲成型室係氣體加壓模型之成型室另一具體例； 圖5爲系統操作之一階段，供微胞孔材料累積和射出 成型，形成具有實體壁和微胞孔內部（富發泡劑和寡發泡 劑），其中累積器是在射出之前充填； 圖6爲圖5系統在剛射出後的操作階段； •— 10" 本紙張尺度適和中固國家標率（CNS ) A4規格（210X297公漦） --------:---/------訂-------' — (請先M讀背面之注意事項再填寫本I ) 424039 A7 B7 _ 五、發明说明（η ) 圖7爲圖5系統在一射出循環後，於累積器充填之際 的操作階段； 圖8爲微胞孔射出成型系統，供形成熔化聚合物的富 發泡劑區和寡發泡劑區，系統包含熔體泵、氣體射出口和 混合器： 圖9爲射出成型系統或其他壓出系統所用螺形螺桿， 含有腔口，通過續桿旋溝，並與發泡劑源呈流體相通，以 便在壓出機的筒部內分佈發泡劑； 圓10爲使用本發明系統和方法所形成的射出成型品 之顯微照片； 圖11爲本發明微胞孔射出成型品之顯微照片； 亂1 2爲本免明另一微胞射出成型品之顯微照片； 圓13爲本發明另一微胞孔射出成型品之顯微照片： 圖14爲本發明另一微胞孔射出成型品之顯微照片； 圖15爲本發明另一微胞孔射出成型照片； 圖16爲前案對照的實體非發泡射出成型品表面之顯 微照片； 圖17爲本發明微胞孔射出成型品表面之顯微照片，具 有平滑表面，由肉眼看不出歪斜和旋渦； 圖18爲射出成型泡綿聚合物品表面之顯微照片，含有 肉眼可見的旋渦。 發明的詳細說明 本申請人於1996年12月20日提出的美國專利申請案 「微胞孔聚合物壓出方法和裝置」，以及1997年8月26 本紙張尺度適用中國國家標率（CNS ) Λ4規格（210X297公釐） (請先閲讀背面之注意事項再填寫本育) - 經濟部中央標牟局員工消费合作社印^ 經濟部中央標準局貝工消費合作社印焚 424039 A7 __B7_ 五、發明説明（12 ) 日提出的國際專利申請案PCT/US/97/15088號，於此列入 參考。 本發明各項具體例和要旨，由下述即可更爲明白。於 此「成核」指一種製法，即溶有在周遭條件下爲氣體的分 子之聚合物材料均質單相溶液，形成晶胞得以成長的「成 核位置」之分子群。即「成核」意指由均質單相溶液，變 化成至少有多種發泡劑分子形成的凝聚位置。成核界定爲 臨時狀態*在聚合物熔體內的溶液中之氣髌，從溶液逸出， 形成氣泡在聚合物熔內之懸浮物。一般而言，此項過渡狀 態是利用聚合物熔體的溶解度，由溶液內含有某一氣體量 的充分溶解度狀態，改變成溶液含有同量氣體的不充分溶 解度狀態，而強制發生，令均質單枏溶液付之快速熱力學 不穩定性，諸如快速溫度變化、快速降壓、或二者兼備， 而遂行成核，快速降壓可用下述成核途徑產生。快速溫度 變化可用壓出機的加熱部、熱甘油浴等產生。「成核劑」 爲分散劑，諸如滑石或其他填料顆粒，添加於聚合物，可 促進由單相均質瘠液形成成核位置。因此，「成份位置」 不限定聚合物內成核劑頼粒所在的地方。「成核」謂流體 聚合物材料含有在溶化周遭條件時爲氣體的分子之單相均 質溶液狀態，經事件（典型上爲熱力學不穩定性）導致形 成成核位置。「非成核」指聚合物材料和在周遭條件爲氣 體的溶化分子之均質單相溶液，無成核位置之狀態。「非 成核」材料可含有滑石等成核劑。「聚合物材料/發泡劑 痕合物」可爲至少二種的單相非成核溶液，至少二種的成 —12 — 本紙張尺度適用中國國家椋準（CNS ) A4規格（210X 297公釐） ---------d------IT (請先閲讀背面之注意事項再填寫本頁) 4 ；：： 4 Q 3 9_Βτ__ 五、發明说明（13 ) 核溶液，或內有發泡劑晶胞成長的混合物。「基本上密閉 晶胞」微胞孔材料指厚度約100微米，整個材料不含連接 晶胞途徑。「成核途徑」指限定彤成部份微胞孔聚合物泡 綿壓出裝置之途徑，且在裝置設計操作的條件下（典型上， 在成核器上游的壓力約1 500至約30,000 psi，流置爲每小 時約10磅聚合物材料以上），聚合物材料與發泡劑相混的 單相溶液壓力，以方便快速成核的速率，降到特定發海劑 濃度的飽和壓力以下。成核途徑（可視需要與其他成核途 徑）限定本發明裝置的成核區。「強化剤」指材料的補助 劑，基本上爲固體材料，其構造和配置在於增加維度穩定 性。凡精於此道之士均可試驗添加劑，以決定是否與特定 材料有關之強化劑。 經漓部中央標準局貝工消资合作社印繁 (锖先閲讀背面之注項再填寫本頁) 本發明提供聚合物材料（包含微胞孔聚合物材料）的 注入和射出成型系統和方法，以及可用於注入和射出成型 而且可用於與其他技術有關的系統和方法。例如，雖然主 要說明射出和注入成型，本發明亦可由精於此道之士釋易 修飾，用於其他成型方法，諸多但不限於低壓成型、共同 射出成型、層狀成型、射出壓縮等。在本發明中，橄胞孔 材料的定義是含晶胞直徑在約1 0 0微米以下的發泡材料， 或晶胞密度大於至少約106晶胞/立方厘米之材料，以二者 兼備爲佳。微胞孔材料的孔隙分率一般在5%至98%不等。 本發明內超徹胞孔材料的定義爲，晶胞大小在1 μιη以下， 而晶胞密度在每立方厘米1012晶胞以上。 在較隹具體例中，本發明微:胞孔材料是製成平均胞孔 -13 - 本紙張尺度適用中國國家標準（CNS)A4現格（210X297公釐） 4 2^ 039 a? B7 五、發明説明（1 4 ) 尺寸在約50微米以下。在若干具體例中，需特別小尺寸的 晶胞，而在此等具體例中，本發明材料的平均晶胞尺寸在 約20微米以下，以約10微米以下爲佳，而以約5微米以下 更好。微胞孔材料的最大晶胞尺寸約100微米。在需要特 別小晶胞尺寸的具體例內，材料的最大晶胞尺寸約50微 米，以約25微米爲佳，約IS微米更好，約8微米尤佳，而 以約5微米最好。一組具體例包含在此所指明平均晶胞尺 寸和最大晶胞尺寸的一切組合。例如，此組具體例中有一 具體例，包含微胞孔材料，平均晶胞尺寸在約30微米以下， 最大晶胞尺寸約50微米，而另一例爲平均晶胞尺寸約30 微米以下，最大晶胞尺寸約35微米。即爲各種目的設計的 微胞孔材料，可製成具有平均晶胞尺寸和較佳最大晶胞尺、 寸的特殊組合。晶胞尺寸的控制詳述於下。 在一具體例中，基本上密閉晶胞的微胞孔材料，是按 照本發明技術製造。於此，「基本上密閉晶胞」指厚度約 1〇〇微米，整個材料不含相連晶胞途徑之材料。 經濟部中央標準局負工消費合作社印繁 -----------Λ------,1τ (請先閲讀背面之注意事項再填寫本頁) 茲參見圓1，簡略表示的成型系統30可按本發明各種 具體例進行成型。圓1之系統30包含筒部32,具有上游第 —端34，和連接成型室37的下游第二端36。安裝在筒部 32內轉動的是螺桿38,在上游端與驅動馬達40操作連接。 雖然圖上未示，螺桿3 8含有進料、過渡、氣體射入、混合、 計量諸段。 可視需要沿筒部32位置的是溫度控制單元42。控制 單元42可爲電熱器，含有溫度控制流體用的通道等。單元 —14 一 本紙張尺度適用中國囤家標準（CNS ) A4規格（210 X 297公釐） 4 2· 4 Ο 3 这 A7 —_B7_ 五、發明説明（15) 42可用來對筒部內的粒化或流體聚合物材料流加熱，以方 便熔化和/或冷卻，控制粘度和有時候發泡劑溶解度。溫 度控制單元可在沿筒部不同位置做不同的操作，即在一或 以上位置加熱，和在一或以上不同位置冷卻。可設任何數 量的溫度控制單元。 經濟部中央標隼局負工消費合作社印製 C請先聞讀背面之汶意事項再填寫本頁) 筒部32的構造和配置在於接受聚合物材料的母質。於 此，「聚合物材料的母質」意指包含流體，或可形成流體， 且隨後可硬化形成微胞孔聚合物品之一切材料，典型上， 母質是限定熱塑性聚合物粒，但含其他種類。例如，在一 具體例中，母質可限定在各種條件下會反應形成微胞孔聚 合物材料之種類。本發明指包含由可以一同反應形成聚合 的種類，典型上爲發生反應時混合和發泡的單髖或低分子 量聚合物母質，任何組合製造微胞孔材料。一般而言，本 發明包括種類包含熱固性聚合物，反應和發泡時，由於聚 合物成份的交聯，發生聚合物分子量大增。例如縮合和加 成型聚醯胺類，包含脂族和芳族聚醯胺，諸如聚己二醯庚 二胺、聚（ε-己內醯胺）、多烯烴，諸如環芳族聚合物， 包含聚二環戊二烯、丙烯酸系聚合物，諸如聚丙烯醑胺、 聚丙烯酸醋、丙烯酸酯聚合物，諸如2 -氰基丙烯酸酯聚 合物、丙烯腈聚合物，及其組合物。 最好從非晶形、半晶形和結晶形材料中選用熱塑性聚 合物，或熱塑性聚合物之組合物，包含聚芳族，諸如苯乙 烯聚合物，包含聚苯乙烯、聚烯煙，諸如聚乙烯和聚丙烯、 含氟聚合物、交聯性聚烯烴、聚醯亞胺、聚芳族，諸如聚 —15 — 本紙張尺度適用中國國家標车{ CNS ) Λ4規格（210X297公釐） A7 B7 42厶 五、發明説明（16) 苯乙烯和聚氯乙烯。亦可用熱塑性彈料，尤其是二絡金屬 催化之聚乙烯。 (請先閲讀背面之注意事項再填寫本頁) 典型上引進預聚合性母質，是利甩標準漏斗44，容納 可經孔口 46加料入壓出機筒部內之粒化聚合物材料，雖然 母質可爲經孔口射入的流體聚合物材料，在筒邰內經由補 肋聚合劑聚合。關於本發明，只有在系統內要成立聚合物 材料的流體才是重要。 圖1內螺桿38下游端48的下游緊接著是區50，可爲 溫度調節和控制區、輔助混合區、輔助泵送區等。例如區 50內可含有溫度控制單元，在流體聚合物流成核之前調節 其溫度，詳後。區5〇可改含或另含其他標準混合軍元（圖 上未示），或流量控制單元，諸如齒輪泵（圖上未示> 。 在另一具體例內，區50可換成串聯的第二螓桿，含有冷卻 區。在一具體例內，螺桿38爲射出成型系統內之往復運動 螺桿，詳後，區50可限定累積區，聚合物材料和發泡劑的 單相非成核溶液，在射入模型37之前在此累積。 經濟部中央標隼局員工消費合作社印^ 本發明微胞孔材料之製造以使用物理發泡劑爲佳，在 周遭條件下爲氣體（詳後）。然而，化學發泡劑亦可用， 可與引進漏斗44內的聚合物料混配適當化學發泡劑包含 典型較低分子量有機化合物，在臨界溫度或壓出內可達成 的另一條件分解，並釋出氣體，諸如氮、二氧化碳或一氧 化碳。其例包含偶氮化合物，諸如偶氮甲醸胺。 如上所述，較佳具體例中使用物理發泡劑。使用物理 發泡劑而非化學發泡劑的具體例之一優點爲，產品的回收 —16 — 本紙張尺度適用中國國家標準（CMS ) A4規格（210X297公釐） 424039 a? _B7_ 五、發明説明（I7) 經潆部中失標準局員工消费合作社印繁 (請先閲讀背面之注意事項再填寫本頁) 性最大。使用化學發泡劑典型上減少聚合物回收的吸引 力，因爲殘餘化學發泡劑和發泡劑副產品，有助於整體不 均贫回收性材料庫。因爲以化學發泡劑發泡的泡綿，在製 成最後泡綿產昂後，本質上含有剩餘未反應化學發泡劑， 以及形成發泡劑的反應之化學副產品，在此組具雔例內的 本發明材料，包含剩餘化學發泡劑，或化學發泡劑之反應 副產品，其量低於0.1 %重量化學發泡劑或以上發泡之物品 基本上所見，而以0.05%重量化學發泡劑或以上發泡之物 品基本上所見爲佳。在特佳具體例內，材料之特徵爲基本 上不含殘餘化學發泡劑或化學發泡劑的反應副產品，即含 較少剩餘化學發泡劑或以任何化學發泡劑發泡的物品內基 本上所見副產品。在此具體例內，沿系統30的筒部32有 至少一通口 54，與物理發泡劑源56流體相通。一般技術 所知的任何各種物理發泡劑，諸如^類、含氯氟烴類、氮、 二氧化碳，或其混合物，均可用於本發明，按照較佳具體 例，發泡劑源56提供二氧化碳做發泡劑。超臨界流體發泡 劑特別好，尤其是超臨界二氧化碳。在一具體例中，只用 超臨界二氧化碳爲發泡劑，超臨界二氧化碳可引進壓出機 內，利用射入二氧化碳做爲超臨界流體，或射入二氧化碳 做爲氣體或液體，並容許壓出機內的條件使二氧化碳成爲 超臨界性，而與聚合物材料快速形成單相溶液。二氧化碳 以超臨界狀態射入壓出機內爲佳。超臨界二氧化碳和聚合 物材料以此方式形成的單相溶液，粘度極低，有利用在較 低溫度成型，茈快速充填於餘隙密切的模型內，形成極薄 ~ 17 - 本紙張尺度適用中國國家梯準（CNS ) A4規格（2!0X297公釐) 經漪部中央標準局員工消費合作社印聚 — A 7 ' B7五、發明説明（is ) 的成型組件，詳後。 典型上在發泡劑源56和至少一通〇 54間，設有加壓 和計量裝置58，可用來計最發泡劑，以便控制壓出機內聚 合物流所含發泡劑量，按照一組具雔例，維度發泡劑於聚 合物流和發泡劑重量的約1%至25%重量間的水準，以約6% 至20%重量間爲佳，而以約8%至15%重量間更好，尤以約 10%至12%重查間尤佳。所用特定發泡劑（二氧化碳、氮 等）及發泡劑用量，往往視聚合物密度降低、晶胞大小和 所需物理性能而定。 加壓和計量裝置可連接至控制器（圖上未示），後者 亦接驅動馬達40,以聚合物材料流量的關係控制計童發泡 劑，極其精密地控制發泡劑在流體聚合物混合物內的重量 百分比。 雖然通口 54可位於沿筒部的各種位置，惟按照較佳具 體例，係位於螺桿混合段60的正上游，或在螺桿含有未破 旋溝的螺桿位置62。 超臨界流體發泡劑亦具有方便不相似聚合物材料快速 密切混合之優點，因而提供不相似聚合物材料不會在模製 後脫層的混合和成型方法。不相似材料例如包含聚苯乙烯 和聚丙烯，或聚苯乙烯和聚乙烯。此等不相似材料典型上 具有大不相同的粘度、極性或化學功能，在大多數系統內 排除形成充分混合的均質組合物，導致脫層或其他物理性 能降低或物理性能劣化。在此具體例內，宜有至少二種不 相似成份存在，各含量至少約1 %重暈，以至少約5%爲佳， —18 一 (請先Μ讀背面之注意事項再填寫本瓦) 訂 本紙張尺度適用中國國家標準（CNS ) Α4规格（2Ι0Χ297公釐）A7 B7 424039 V. Description of the invention (1) Invention spray The present invention generally relates to the processing of polymer structural foams, especially the microcellular structural foams, and its manufacturing system and method. BACKGROUND OF THE INVENTION Structural foaming materials are well known. The method is to inject a physical foaming agent into a molten polymer stream and disperse the foaming agent in the polymer to form a two-phase polymer * containing a foaming agent unit cell. The mixture is injected into a model having a desired shape, and the mixture is solidified therein. The pressure drop in the mixture causes the unit cell in the polymer to grow. As an alternative to physical foaming agents, chemical foaming agents can be used to perform a chemical reaction in a polymer material to form a gas. Chemical blowing agents are generally low branching organic compounds that decompose at critical temperatures, releasing gases such as nitrogen, carbon dioxide or carbon monoxide. Under certain conditions, the cells can maintain separation, resulting in closed-cell foam material. Under other typically more intense foaming conditions, the cells will rupture or connect to form an open-cell material. The standard injection molding technology examples described in the patent literature are as follows: US Patent No. 343 6446 (Angell) describes a method and The device uses the pressure and temperature of the control model to form a foamed plastic article with a solid skin. U.S. Patent No. 4,479,914 (Baumoucker) describes a method for forming a foamed article in which the mold is pressurized with a gas to prevent the foamed gas from prematurely diffusing from the material injected into the cavity. When the foamed material is to be ejected, the pre-pressurized gas is discharged, and finally a vacuum is generated in the vacuum chamber, and the material is drawn through the mold cavity. Microcellular materials are typically formed of polymer foams with extremely small cell sizes. The annual US patents Nos. 5158986 and 4473665 contain a variety of cells-1-This paper size applies to Chinese National Standard (CNS) A4 specifications (2丨 0X 297mm} (锖 read the notes on the back ^ * ^, then fill out this page) -5 Lieji Central Standard Bureau Staff Consumer Cooperatives printed A7 B7 V. Description of the invention (2) Hole materials. These According to the patent, a single-phase solution of polymer material and physical blowing agent is caused by thermodynamic instability to generate a nucleation site of radon density, and then the cell growth is controlled to make a microcellular material. US Patent No. 4473 665 (Martini-Vvedeusky) describes the molding system and manufacturing method of microcellular components. The polymer particles are pre-pressurized with a gaseous foaming agent and melted in a conventional extruder to form a solution of the foaming agent and the molten polymer. Extruded into the pressurized cavity. The pressure in the model is maintained above the solubility pressure of the gaseous blowing agent when the initial saturated melt temperature is specified. If the temperature of the molded component drops to an appropriate critical nucleation temperature, the model is placed on the model pressure The model is reduced to the surrounding pressure, allowing the component to foam. Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs (please read the precautions on the back before filling out this page) US Patent 5 1 58986 (Cha et al.) An alternative molding system and microcellular assembly method, polymer particles are introduced into a conventional extruder and melted. The carbon dioxide blowing agent establishes a supercritical state in the extruder, and is mixed to form the blowing agent and the polymer material. Homogeneous solution. A part of the extruder is heated to cause the mixture to flow through the cylinder, resulting in thermodynamic instability, which creates a nucleation site in the molten polymer material. The nucleation material is pressed into the pressurized cavity. The pressure maintains the pressure in the model. When the cavity is expanded, the internal pressure drops sharply, and cell growth occurs in the cavity; the model expansion provides molding and foaming, with small cell size and high cell density. Nucleation and crystal Cell growth occurs separately in accordance with technology; thermal induction nucleation occurs in the extruder barrel, while fine crystal cell growth occurs in the model. Although the above and other reports represent the stem technology, and microcellular materials Production and materials produced by injection molding of related, but technically still desirable to have improved hole injection molding micelles Production Process 5-2 - This applies China National Standard Paper Scale (CNS) Α4 specifications (210 >.; < 297 mm > 424039 A7 B7 _ V. Description of the invention (3) Therefore, the object of the present invention is to provide an injection molding system and method for effectively manufacturing and forming micro-It structural foam, especially thin articles . Another object is to provide an injection molding system and method that can be used for microcellular structural foams, and can also be used for injection molding of conventional foams, and continuous extrusion of microcellular or conventional foams. SUMMARY OF THE INVENTION The present invention is directed to an injection molding system and method capable of forming a molded article, and a system and method for forming various foamed materials. In the various gist of the present invention, in one group of specific examples, the material is a conventional foaming material (cell size, density, etc., without limitation of the microcellular material), and in another group of specific examples, the material is microcellular Materials> Printed by the Central Bureau of Standards, the Ministry of Economic Affairs and the Shellfish Consumer Cooperatives ^ (please read the notes on the back ^^ before filling in this document) A gist of the present invention relates to an injection molding system, which is structured to produce microcellular structural foams. This system includes an extruder with an inlet that is designed to accept the parent material of the microporous material at its inlet; a molding chamber; and a closed channel connecting the inlet and the molding chamber. The structure and configuration of the molding chamber is to accept non-nucleating, homogeneous, fluid, single-phase solutions of polymer materials and foaming agents, and non-forming polymer materials and foaming agents that are fluid when the channel contains pressure. Nuclear, homogeneous fluid single-phase solution, and the solution in the channel with the fluid in the downstream direction, from the inlet end to the cushion chamber. The closed channel contains a nucleation pathway within which a foaming agent that passes through a single-phase solution nucleates. The nucleation pathway constitutes a homogeneous fluid single-phase solution containing a polymer bearing end, bearing the polymer and a non-nucleating blowing agent; a nucleating polymer release end, configured and configured to release a nucleating polymer material; and a fluid pathway, connecting the bearing End to release end. The polymer release end can be formed into a nozzle of a plastic chamber or a fluid phase with the molding chamber as required—3 — This paper ruler> 1 applies Chinese national standard {C ^ IsTa4 specification (ilOX 297 mm) Central Bureau of Standards, Ministry of Economic Affairs Printed by the Industrial and Consumer Cooperatives ^ ^ 4039 a? B7 V. Description of the invention (4) The nucleation pathway has a length and a cross-sectional size. When the fluid polymer is uniformly mixed with about 6% by weight of C02, about 40 pounds of fluid per hour When passing through the pathway, a pressure drop rate is generated in the fluid polymer of at least about 0.1 GPa / sec, or at least about 0.3 GP a / sec, or at least about 1.0 GPa / sec, or at least about 3 GPa / sec. The nucleation pathway also has a variable cross-sectional size, so that the fluid polymer flowing through the pathway is subjected to a variable pressure drop rate and / or temperature rise. According to another aspect of the present invention, there is provided a system having a molding chamber constructed and configured to contain a nucleated polymer material under pressure to prevent cell growth under pressure. The compression molding chamber may be pressurized fluidly or mechanically so that the pressurization contains a nucleating polymer material. After the pressure is reduced in the pressure molding chamber, the polymer material will solidify into the shape of the desired microcellular polymer product. The molding chamber is structured and configured to have the internal shape. According to yet another aspect of the present invention, a system is provided having a barrel portion, including an inlet designed to receive a matrix of extruded material, and an outlet designed to release a fluid non-nucleating mixture of a foaming agent and a matrix of a foamed polymer product to The parent material, the orifice can be connected to the foaming agent source, and the screw is reciprocated inside the barrel. The extrusion system can also have at least one orifice that can be connected to the foaming agent source, and the orifice is longitudinally arranged along the axis of the barrel, so that during the reciprocating movement of the screw, the non-nucleating mixture is sequentially introduced through at least two orifices and enters the barrel unit. The system may also include a second extruder tube, which is connected in series with the first tube portion. The second tube portion has an inlet and is designed to receive a fluid non-nucleating mixture. A screw is installed to reciprocate within the tube portion. According to another gist of the present invention, a method is provided for determining a continuous stream of a non-nucleated, fluid single-phase solution of a polymer matrix and a foaming agent, so that the stream is formed into a beam ^ 1 This paper size is applicable to the Chinese National Standard (CNS) Α4 Specifications (210X297 mm) ----, --.---- Ι ------ Order-^-^-^ 1 (Please read the precautions on the back before filling this page) 04039 A7 ____B7 V. Description of the invention (5) Nucleation produces a nucleation stream of the mixture, which allows the nucleation stream to pass into the container, and allows the mixture to solidify into the shape of a container. The stream can be continuously nucleated as required, and the continuous stream is subjected to a pressure drop rate of at least about 0.1 GPa / sec. At the same time, the stream is passed into the container to generate a continuous stream of nucleation material. In addition, this method involves intermittent nucleation of the stream beam, subjecting it to a pressure drop rate of at least about 0.1 GPa / sec. At the same time, the stream beam is passed into the container, and the non-nucleating material is first passed into the container, followed by nucleation. material. Conversely, the nucleation stream can pass into the container, so that the nucleating material passes into the container first, and then the non-nucleating material. This method also involves removing the solidified cellular pores from the container, and within about 10 minutes, providing a second nucleating material in the container, allowing the second mixture to solidify into the shape of the container, and removing the second solidified cells from the container. Holes. The present invention also provides a method, which comprises adding a parent material for accumulating the foamed polymer material and the spore-forming agent, heating the first portion of the feed limited to at least about 2%, and heating to at least about 10 ° C higher than the average temperature of the feed. And shoot the feed into the molding chamber. Printed on 1—1 I---J— I-: II ΙΪ.-I · t {Please read the note on the back before filling this page} Another method is involved Included in the accumulator fluidly connected to the molding chamber, accumulating feeds, containing a first portion comprising a fluid polymer material and substantially free of a blowing agent, and a second portion comprising a fluid polymer material mixed with a blowing agent Portion and shoot the feed from the accumulator into the molding chamber. A method is also provided, which involves a fluid single-phase solution of the foamed polymer material parent material and a foaming agent, which is injected into the molding chamber from an accumulator in fluid communication with the extrusion device, while nucleating the solution to generate a nucleation mixture. And allow the mixture to solidify in the molding chamber and become a microcellular polymer product. Another method is involved, which involves injecting foaming agent into the polymer extrusion device. < CNS) Λ4 specification (210X297mm) Printed by the Central Laboratories of the Ministry of Economic Affairs, Shelley Consumer Cooperative Co., Ltd. 424039 '__ ^ __ V. Description of the invention (6) Extruding in the barrel of the machine, and simultaneously pressing out the screw in the axial direction move. A method is also provided which involves blowing a foaming agent from the extruder screw into the barrel of the polymer extruder. A method is also provided, which involves setting up a fluid polymer matrix in the barrel of the extrusion device, discharging a portion of the fluid matrix from the barrel, mixing a portion of the fluid matrix with the foaming agent to form a foaming agent and the matrix. Part of the fluid parent material mixture, the mixture is introduced into the barrel. A method is also provided, which involves introducing a polymer material mixed with supercritical fluid into a part of a model having an internal size of about 0.125 inches or less, allowing the polymer material to solidify in the model, and introducing and allowing the steps to take Within 10 seconds. Another method is provided, which involves mixing a polymer material mixed with a supercritical fluid, introducing a part of a model having an internal size of about 0.125 inches or less, and allowing the polymer material to solidify in the model. A method is also provided for forming a mixture of at least two dissimilar melting polymer components and a supercritical fluid blowing agent, and extruding the mixture to form a non-delamination foam of at least two components. A method is also provided, which involves injecting a single-phase solution of a polymer material and a foaming agent into an opened mold, and closing the mold to form a microcellular article in the shape of a mold. The single-phase non-nucleating solution of the foaming agent, the brilliant solution is introduced into the tritium chamber, and the solution is nucleated to crack the model, thereby allowing the unit cell to grow, and polymerizing the micropores that are similar in shape but larger than the molding chamber. Item recycling. 6 — This paper size applies to Chinese National Standard {CNS) A4 specification (210X297 mm) ---------- / ------ Order ------ Ψ1 (Please read the back first Note ^, please fill in this page again) 42 403 9 A7 ___B7_ Five 'invention description (7) Another method is provided, which involves forming non-nucleation homogeneity of microcellular polymer material parent material and foaming agent in the extruder. The fluid single-phase solution is filled with the solution in the molding chamber, and the solution is nucleated to form a nucleated microcellular polymer material matrix in the molding chamber. Another method is provided, which involves injecting the polymer / foaming agent mixture into the molding chamber at a melting point below about 400 ° F, and molding the solid foam polymer product in the chamber, the pore volume of which is below 5%, and the length-to-thickness ratio At least about 50: 1. One of the systems of the present invention includes an accumulator having an inlet and an outlet for receiving a foamed polymer material matrix and a blowing agent; a molding chamber having an inlet in fluid communication with the accumulator outlet; and a heating device related to the accumulator. Its structure and configuration are to heat the first section of the accumulator close to the molding chamber to at least about 10 ° C higher than the average temperature of the accumulator during system operation. Printed by the Central Standards Bureau of the Ministry of Economic Affairs and Consumer Cooperatives (please read the notes on the back before filling out this page). Another system is provided, including an extruder, which has the ability to accept the import of foamed polymer materials. Its structure and configuration are from The parent polymer manufacturing fluid polymer material is located at the first outlet of the fluid polymer material conveyed from the extruder, downstream of the first outlet, the blowing agent inlet which can be connected to the source of the physical blowing agent, downstream of the blowing agent inlet, and Constructed and configured to produce a mixture zone of a mixture of a fluid polymer matrix and a blowing agent, and a second outlet downstream of the mixture zone, which transports the mixture of the first polymer matrix and the blowing agent; and an accumulator having A first inlet fluidly connected to the first outlet of the extruder and a second inlet fluidly connected to the second outlet of the extruder. There is also provided a system for manufacturing injection-molded microporous materials, including an extruder, having an α at an outlet end thereof, a non-nucleated homogeneous fluid single-phase solution designed to release a polymer material and a blowing agent, and Molding room with —7 — This paper size is applicable to China National Standards (CNS) A4 specifications (2IO × 297 mm) 'Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs 4 ^ 4〇39, A7 __B7_ V. Description of the invention (8) The outlet of the extruder is in fluid communication with α. The structure and configuration of the system consists in conveying the single-phase solution from the extruder α to the molding chamber, and when filling the molding chamber, the single-phase solution is nucleated to form the nucleated microporous polymerization material matrix in the room. . An extrusion system is also provided, including a barrel, with an inlet designed to receive the parent material of the extruded material, and an outlet designed to release the fluid mixture of the non-nucleating foaming agent and the parent material, which can be connected to the hole of the foaming agent source Port, and a reciprocating screw installed in the barrel. A system is also provided for manufacturing injection-molded microcellular materials, including an extruder, having an outlet at its exit end, designed to release the microcellular polymer material matrix and foaming agent, and a molding chamber with Extruder outlet with fluid communication inlet. The system is constructed and configured so that the microcellular polymer material matrix and foaming agent can be cyclically injected into the molding chamber. The invention also provides an extruding system, comprising a barrel, having an inlet designed to receive the parent material of the extruded material, an outlet designed to release a fluid mixture of the non-nucleating hair robe agent and the parent material, and a connection to a foaming agent Orifice of the Source. The screw is reciprocated inside the barrel. In another gist, the present invention provides a method for injecting a foaming agent into a barrel portion of an extruder of a polymer extrusion device, while simultaneously extruding the extrusion screw axially within the barrel portion. In a specific example, the method involves injecting a blowing agent from an extrusion screw into the barrel of a polymer extrusion device. This injection technique can be used for a variety of microcellular and conventional techniques. In another gist, the present invention relates to an extruder screw, the structure and arrangement of which can be rotated within the barrel of a polymer extruder device which contains a cavity in the screw and communicates with the orifice on the surface of the screw. This cavity α —8-This paper is suitable for Chinese National Standard (CNS) Α4 size (210 X 297 mm) < Please read the note on the back before filling in this book.) Packing. * 11 Printed by the Ministry of Economic Affairs, Central Bureau of Standards and Labor, Consumer Cooperatives 424039 l] 5. Description of the invention (9) can be used to foam The agent is injected into the cylinder. In another aspect of the present invention, a manufacturing system for an injection molded article is provided. The system consists of an extruder, a molding chamber, a flow channel * which is fluidly connected to the extruder and the molding chamber, and a temperature control device that passes heat to the flow channel. In another gist, the present invention relates to the establishment of a fluid mixture of foaming agent and injection molding material parent material in the extruder, so that the mixture enters the molding chamber through the flow channel, so that a part of the fluid mixture solidifies in the room while maintaining the flow. A part of the mixture in the channel is in a fluid state, and another fluid mixture is injected into the flow channel, so that a part of the fluid and the flow channel enter the room. The invention also provides a method, which involves discharging a part of the fluid polymer matrix from the extruded barrel, mixing a part of the fluid matrix with the foaming agent to form a mixture, and introducing the mixture into the barrel again. The invention also provides a system including an extruder, which has an extruder barrel, a molding chamber, and a mixing chamber, which are in fluid communication with the first upstream orifice in the barrel, the second downstream in the barrel, and the foaming agent source. . In another gist, the present invention provides a molded foam article whose shape substantially conforms to the molding chamber, and that the cross-sectional dimension of at least a portion does not exceed about 0.125 inches. Another gist relates to a three-dimensional microcellular polymer product, which has three intersecting major axes, corresponding to the three-dimensionality, one of the dimensions is related to the first axis, and changes as a function of the position along the second vertical axis. This item has at least one The section area dimension does not exceed about 0.125 inches. In another gist, the present invention provides an injection molded polymer component having a length / thickness ratio of at least about 50: 1 and a polymer melt index of about 10 or less. -9-This paper scale is applicable to China National Standard (CNS) A4 specification (2 丨 0X297mm) ----------- / ------ Order ------ '(Please Read the precautions on the back of the page before filling in this page.) By the Ministry of Standards and Standards Bureau, I Industrial Consumer Cooperatives 4Z4039 'ta? B7 V. Description of the invention (10) In another gist, the present invention provides injection molding polymers The component has a length / thickness ratio of at least about 120: 1 and a polymer melt flow below about 40. In another gist, the present invention provides an injection-molded polymer foam having a pore volume of at least about 5% and having no skew or vortex that can be clearly seen by the naked eye on the surface. In another gist, the present invention provides an article having a thickness of less than about 0.125 inches and a pore volume of at least about 20%. It also provides a method for manufacturing the article, which involves introducing a polymer material mixed with a supercritical fluid into a model. The model has a Some internal dimensions are below about 0.125 inches, allowing the polymer material to solidify in the model. The introduction and allowance steps take less than 10 seconds. Other advantages, novel features, and objectives of the present invention will be apparent from the following detailed description of the appended circle with reference to the present invention. The circle is a simple circle, and it is not intended to follow this scale. The same or nearly identical components in the figure are represented by a single number. For the sake of clarity, each component is not shown in each figure-each component of the specific examples of the present invention does not need to be illustrated one by one to make the technical experts in Langzhong clear. Brief description of the circle type Figure 1 is a microcellular injection or extrusion molding system of the present invention, including an extrusion system, with a nucleation path to form the orifice of the molding chamber; Figure 2 is a microcellular injection molding of the present invention containing an accumulator System; Figure 3 is a specific example of the molding chamber of the molding system with a movable wall; Circle 4 is another specific example of the molding chamber of the molding chamber gas pressure model; Figure 5 is a stage of system operation for the accumulation of microporous material And injection molding to form a solid wall and microcellular interior (rich foaming agent and oligofoaming agent), where the accumulator is filled before injection; Figure 6 is the operating stage of the system of Figure 5 immediately after injection; 10 " The size of this paper is in line with China Solid State Standards (CNS) A4 specifications (210X297 cm) --------: --- / ------ Order ------- ' — (Please read the notes on the back before filling in this I) 424039 A7 B7 _ V. Description of the invention (η) Figure 7 is the operation stage of the system of Figure 5 after the injection of the accumulator; Figure 8 Microcellular injection molding system for forming the foaming agent rich region and oligofoaming agent region of molten polymer. The system package Melt pump, gas injection port and mixer: Figure 9 shows the screw-shaped screw used in the injection molding system or other extrusion systems, which contains a cavity opening, passes through a continuous rod ditch, and is in fluid communication with the foaming agent source, so that The foaming agent is distributed in the barrel of the machine; circle 10 is a photomicrograph of the injection molded product formed by using the system and method of the present invention; FIG. 11 is a photomicrograph of the cell injection molded product of the present invention; This photomicrograph is a photomicrograph of another microcellular injection molded product; circle 13 is a photomicrograph of another microcellular injection molded product of the present invention: FIG. 14 is a photomicrograph of another microcellular injection molded product of the present invention Figure 15 is another microcellular injection molding photo of the present invention; Figure 16 is a microphotograph of the surface of a solid non-foamed injection molded product compared to the previous case; Figure 17 is a micrograph of the surface of the microcellular injection molded product of the present invention The photo has a smooth surface, and the skew and vortices are not visible to the naked eye. Figure 18 is a photomicrograph of the surface of the injection molded polymer product, which contains vortices visible to the naked eye. Detailed description of the invention The U.S. patent application "Method and Apparatus for Extruding Microcellular Polymers" filed by the applicant on December 20, 1996, and August 26, 1997 This paper standard applies China National Standards Rate (CNS) Λ4 specifications (210X297 mm) (Please read the notes on the back before filling in this education)-Printed by the Consumers' Cooperative of the Central Bureau of Standards of the Ministry of Economic Affairs ^ Printed by the Consumers Cooperative of the Central Standards Bureau of the Ministry of Economics 424039 A7 __B7_ V. Description of the Invention The international patent application PCT / US / 97/15088 filed on (12) date is hereby incorporated by reference. The specific examples and gist of the present invention will be clearer from the following. Here, “nucleation” refers to a manufacturing method, that is, a homogeneous single-phase solution of a polymer material in which molecules are gaseous under ambient conditions, forming a “nucleation site” molecular group in which a unit cell grows. That is, "nucleation" means a homogeneous single-phase solution that changes to an agglomeration site formed by at least a plurality of blowing agent molecules. Nucleation is defined as a temporary state of gas entrapment in the solution in the polymer melt, which escapes from the solution to form a suspension of bubbles in the polymer melt. Generally speaking, this transition state uses the solubility of the polymer melt to change from a sufficient solubility state containing a certain amount of gas in the solution to an inadequate solubility state containing the same amount of gas in the solution. The thorium solution is subject to rapid thermodynamic instability, such as rapid temperature changes, rapid decompression, or both, and then nucleation is performed. Rapid decompression can be generated by the nucleation pathway described below. Rapid temperature changes can be generated by the heating section of the extruder, a hot glycerin bath, and the like. A "nucleating agent" is a dispersant, such as talc or other filler particles, added to the polymer to promote the formation of nucleation sites from a single-phase homogeneous barren solution. Therefore, the "component position" does not limit the place where the nucleating agent particles in the polymer are located. “Nucleation” refers to the state of a single-phase homogeneous solution of a fluid polymer material containing molecules that are gases when the surrounding conditions are dissolved, and events (typically, thermodynamic instability) result in the formation of nucleation sites. "Non-nucleation" refers to a homogeneous single-phase solution of a polymer material and dissolved molecules that are gaseous in the surroundings, without a nucleation site. "Non-nucleating" materials may contain nucleating agents such as talc. "Polymer material / foaming agent trace compound" can be at least two kinds of single-phase non-nucleating solutions, and at least two kinds of compounds—12 — This paper size applies to China National Standard (CNS) A4 (210X 297) %) --------- d ------ IT (Please read the notes on the back before filling this page) 4;: 4 Q 3 9_Βτ__ V. Description of the invention (13) Nuclear solution, Or a mixture of cells with a foaming agent growing inside. A "substantially closed cell" cell pore material refers to a thickness of about 100 microns, and the entire material does not contain a unit cell pathway. "Nucleation pathway" means a pathway that defines a portion of the microcellular polymer foam that is pressed out of the device, and under the conditions in which the device is designed to operate (typically, the pressure upstream of the nucleator is about 1,500 to about 30,000 psi The flow rate is about 10 pounds of polymer material per hour or more). The pressure of the single-phase solution in which the polymer material and the foaming agent are mixed is lowered to the saturation pressure of the specific hair concentration at a convenient and rapid nucleation rate. The nucleation pathway (with other nucleation pathways as needed) defines the nucleation zone of the device of the invention. “Reinforced concrete” refers to a material supplement, which is basically a solid material. Its structure and configuration are to increase dimensional stability. Anyone who is proficient in this discipline can test additives to determine if they are related to specific materials. Printed by the Central Standards Bureau of the Ministry of Standards and Industry, Bengong Consumer Cooperatives (read the note on the back before filling this page) The present invention provides a system and method for injection and injection molding of polymer materials (including microcellular polymer materials). And systems and methods that can be used for injection and injection molding, and can be used in connection with other technologies. For example, although the injection and injection molding are mainly described, the present invention can also be modified by a person skilled in the art and used in other molding methods, many but not limited to low pressure molding, common injection molding, layered molding, injection compression, and the like. In the present invention, the definition of olive cell pore material is a foamed material containing a unit cell diameter of less than about 100 microns, or a material with a unit cell density greater than at least about 106 unit cells per cubic centimeter, preferably both. . The porosity of microporous materials generally ranges from 5% to 98%. In the present invention, the ultra-perforated cell material is defined as having a unit cell size of less than 1 μm and a unit cell density of more than 1012 unit cells per cubic centimeter. In a more specific example, the micro-cell material of the present invention is made of average cell -13-this paper size is applicable to China National Standard (CNS) A4 (210X297 mm) 4 2 ^ 039 a? B7 V. DESCRIPTION OF THE INVENTION (1 4) The size is below about 50 microns. In some specific examples, a unit cell of a particularly small size is required. In these specific examples, the average cell size of the material of the present invention is below about 20 microns, preferably below about 10 microns, and below about 5 microns. better. The maximum cell size of the microporous material is about 100 microns. In a specific example where a particular small cell size is required, the maximum cell size of the material is about 50 microns, preferably about 25 microns, more preferably about IS microns, more preferably about 8 microns, and most preferably about 5 microns. A specific set of examples includes all combinations of average cell size and maximum cell size indicated herein. For example, in this group of specific examples, there is a specific example, which contains microporous materials, with an average cell size of less than about 30 microns, a maximum cell size of about 50 microns, and another example with an average cell size of less than about 30 microns, The cell size is about 35 microns. That is, the microporous material designed for various purposes can be made into a special combination with an average cell size and a preferred maximum cell size, inch. Control of the unit cell size is detailed below. In a specific example, the microporous material of a substantially closed cell is manufactured according to the technology of the present invention. Here, "substantially closed cell" refers to a thickness of about 100 micrometers, and the entire material does not contain materials connected to the unit cell pathway. Central and Western Bureau of Work, Ministry of Economic Affairs, Consumer and Consumer Cooperatives, India ----------- Λ ------, 1τ (Please read the notes on the back before filling out this page) See circle 1, briefly The molding system 30 shown can be molded according to various specific examples of the present invention. The circle 30 system 30 includes a barrel portion 32 having an upstream first end 34 and a downstream second end 36 connected to the molding chamber 37. Mounted in the barrel portion 32 is a screw 38 that rotates and is operatively connected to the drive motor 40 at the upstream end. Although not shown in the figure, the screw 38 includes feeding, transition, gas injection, mixing, and metering sections. Where necessary, along the barrel portion 32 is a temperature control unit 42. The control unit 42 may be an electric heater, including a channel for temperature-controlling fluid, and the like. Unit—14 A paper size is applicable to China Standards (CNS) A4 specification (210 X 297 mm) 4 2 · 4 Ο 3 This A7 —_B7_ V. Description of the invention (15) 42 can be used to granulate the tube Or the fluid polymer material stream is heated to facilitate melting and / or cooling, to control viscosity and sometimes the solubility of the blowing agent. The temperature control unit can perform different operations at different positions along the barrel, that is, heating at one or more positions and cooling at one or more different positions. Any number of temperature control units can be set. Printed by the Central Bureau of Standards, Ministry of Economic Affairs and Consumer Cooperatives. C Please read the information on the back before filling out this page.) The structure and configuration of the tube section 32 is to accept the parent material of the polymer material. Here, the "parent material of a polymer material" means any material that contains a fluid, or can form a fluid, and then can be hardened to form a microcellular polymer product. Typically, the parent material is a defined thermoplastic polymer particle, but contains other kind. For example, in a specific example, the parent substance may be limited to a type that will react to form a microporous polymer material under various conditions. The present invention refers to the production of microcellular materials by including any kind that can be reacted together to form a polymer, typically a single hip or low molecular weight polymer matrix that is mixed and foamed when the reaction occurs. Generally speaking, the present invention includes a type that contains a thermosetting polymer. During reaction and foaming, a large increase in the molecular weight of the polymer occurs due to crosslinking of the polymer components. For example, condensation and addition polyamines, including aliphatic and aromatic polyamines, such as polyhexamethylene diamine, poly (ε-caprolactam), polyolefins, such as cycloaromatic polymers, containing Polydicyclopentadiene, acrylic polymers such as polyacrylamide, polyacrylic acid esters, acrylate polymers such as 2-cyanoacrylate polymers, acrylonitrile polymers, and combinations thereof. Thermoplastic polymers, or combinations of thermoplastic polymers, are preferred from amorphous, semi-crystalline, and crystalline materials, including polyaromatics, such as styrene polymers, and polystyrene, polyolefins, such as polyethylene and Polypropylene, fluoropolymer, cross-linkable polyolefin, polyimide, polyaromatic, such as poly-15 — This paper size is applicable to Chinese national standard car {CNS} 4 size (210X297 mm) A7 B7 42 厶V. Description of the invention (16) Styrene and polyvinyl chloride. It is also possible to use thermoplastic elastomers, especially di-metal catalyzed polyethylene. (Please read the precautions on the back before filling this page.) The pre-polymerized parent material is typically introduced. It is a standard funnel 44 that contains granulated polymer materials that can be fed into the barrel of the extruder through the orifice 46. Although The parent material can be a fluid polymer material injected through the orifice, and is polymerized in the cylinder via a rib-filling polymerizer. With regard to the present invention, it is only the fluid of the polymer material that is to be established within the system that is important. Downstream of the downstream end 48 of the inner screw 38 of Fig. 1 is a zone 50 immediately following, which may be a temperature regulation and control zone, an auxiliary mixing zone, an auxiliary pumping zone, and the like. For example, zone 50 may contain a temperature control unit that regulates the temperature of the fluid polymer stream prior to nucleation, as detailed below. Zone 50 can be changed or included with other standard hybrid military units (not shown in the figure), or flow control units such as gear pumps (not shown in the figure). In another specific example, zone 50 can be replaced by a series connection The second tappet contains a cooling zone. In a specific example, the screw 38 is a reciprocating screw in an injection molding system. In detail, the zone 50 can define a accumulation zone, a single-phase non-forming material of polymer material and foaming agent. The nuclear solution is accumulated here before being injected into the model 37. Printed by the Consumer Cooperative of the Central Bureau of Standards of the Ministry of Economic Affairs ^ The microporous material of the present invention is preferably manufactured using a physical foaming agent, and is a gas under ambient conditions (see details below) ). However, chemical foaming agents can also be used. They can be mixed with the polymer material introduced into the funnel 44. An appropriate chemical foaming agent contains typical lower molecular weight organic compounds and can be decomposed at a critical temperature or another condition of extrusion And release gas such as nitrogen, carbon dioxide or carbon monoxide. Examples include azo compounds such as azomethoxamine. As mentioned above, physical foaming agents are used in preferred embodiments. Physical foaming agents are used instead of chemical hair One of the specific examples of foaming agents has the advantage that the product is recycled—16— This paper size is in accordance with the Chinese National Standard (CMS) A4 specification (210X297 mm) 424039 a? _B7_ V. Description of the invention (I7) The standard in the economic department Bureau employee consumer cooperatives Yinfan (please read the precautions on the back before filling out this page). The use of chemical foaming agents typically reduces the attractiveness of polymer recycling, because residual chemical foaming agents and foaming agent by-products have Helps the overall uneven and poor recyclable material library. Because the foam foamed with chemical foaming agent, after the final foam is produced, it essentially contains the remaining unreacted chemical foaming agent, as well as the foaming agent. Reacted chemical by-products. The materials of the invention in this group of examples include residual chemical foaming agents, or reaction by-products of chemical foaming agents, the amount of which is less than 0.1% by weight of the chemical foaming agent or above. Basically seen, and articles that are foamed with 0.05% by weight of chemical foaming agent or above are basically better. In a particularly preferred embodiment, the material is characterized by being essentially free of residual chemical foaming agent or chemical hair. Reaction by-products of the agent, that is, by-products that are basically seen in articles containing less residual chemical foaming agent or foaming with any chemical foaming agent. In this specific example, there is at least one port 54 along the barrel 32 of the system 30, It is in fluid communication with the physical blowing agent source 56. Any of various physical blowing agents known in the art, such as ^, chlorofluorocarbons, nitrogen, carbon dioxide, or mixtures thereof, can be used in the present invention, and the preferred embodiment is as follows. For example, the blowing agent source 56 provides carbon dioxide as a blowing agent. Supercritical fluid blowing agents are particularly good, especially supercritical carbon dioxide. In a specific example, only supercritical carbon dioxide is used as a blowing agent, and supercritical carbon dioxide can be introduced In the extruder, the injection of carbon dioxide as a supercritical fluid, or the injection of carbon dioxide as a gas or liquid, allows the conditions in the extruder to make carbon dioxide supercritical, and quickly forms a single-phase solution with polymer materials. . Carbon dioxide is preferably injected into the extruder in a supercritical state. The single-phase solution formed by supercritical carbon dioxide and polymer materials in this way has extremely low viscosity. It can be formed at a lower temperature and quickly fill in a model with a close clearance to form an extremely thin ~ 17-This paper is applicable to China National Ladder Standard (CNS) A4 specification (2! 0X297 mm) Printed by the Consumers 'Cooperative of the Central Standards Bureau of the Ministry of Yiyi-A 7' B7 V. Molded components of the description of the invention (is), detailed later. Typically, a pressure and metering device 58 is provided between the blowing agent source 56 and at least one channel 54, which can be used to count the blowing agent in order to control the blowing amount contained in the polymer stream in the extruder. For example, the dimensional blowing agent is between about 1% and 25% by weight of the polymer stream and the weight of the blowing agent, preferably between about 6% and 20% by weight, and more preferably between about 8% and 15% by weight. OK, especially between 10% and 12%. The specific foaming agent (carbon dioxide, nitrogen, etc.) and the amount of foaming agent used will often depend on the decrease in polymer density, cell size, and required physical properties. The pressure and metering device can be connected to the controller (not shown in the figure), which is also connected to the drive motor 40, which controls the foaming agent based on the relationship of the polymer material flow rate, and extremely precisely controls the foaming agent in the fluid polymer mixture. Weight percent within. Although the port 54 may be located at various positions along the barrel, it is preferably located directly upstream of the screw mixing section 60 or at the screw position 62 where the screw contains an unbroken groove. Supercritical fluid foaming agents also have the advantage of facilitating rapid and close mixing of dissimilar polymer materials, thus providing a mixing and molding method that dissimilar polymer materials do not delaminate after molding. Dissimilar materials include, for example, polystyrene and polypropylene, or polystyrene and polyethylene. These dissimilar materials typically have widely differing viscosities, polarities, or chemical functions, which in most systems are excluded from forming a well-mixed homogeneous composition, resulting in delamination or other physical performance degradation or physical performance degradation. In this specific example, there should be at least two dissimilar ingredients, each containing at least about 1% heavy halo, preferably at least about 5%, -18 I (please read the precautions on the back before filling in this tile) The size of the paper is applicable to China National Standard (CNS) A4 (2Ι0 × 297 mm)
A7 B7__ 五、發明説明（丨9) 而以至少約1 0%更好，尤以至少約20%特佳。 形成不相似聚合物材料組合物之典型前案技術，涉及 將不相似聚合物材料壓出和製粒，再以顆粒提供於諸如圓 1所示系統之漏斗44內。按照本發明要旨*使用超臨界流 體發泡劑，即不必用到預混顆粒或混拌設備。於此要旨， 可在漏斗44內提供不同聚合物粒的混合物，例如聚苯乙烯 粒和聚丙烯粒之混合物，熔化，與超臨界流體發泡劑密切 混合，並壓出爲充分混合的均勻混合物。本發明在此要旨 中，可以下述流童和特定時間內，形成發泡劑和多成份聚 合物材料（包含不相似材料）之單相溶液。本發明此要旨 可用來形成由至少二種不相似聚合物料組成的聚合物品， 藉由壓出、上述成型，或其他技術坻抗脫層》 上述配置可方便按照本發明若干具體例實施之方法， 與射出或注入成型組合應用。此法涉及以約0.4至約1.4磅 /小時的流置，在流體聚合物材料內引進在周遭條件下爲 氣體的發泡劑，爲時在約1分鐘內，產生發泡劑流體在聚 合物內的單相溶液。發泡劑流體在溶液內的存在量，爲在 此配置內溶液重量的至少約2· 5%重量，在某些具體例內， 流體聚合物材料的流量爲約6至12磅/小時《在此等配置 中，添加發泡劑流體，在1分鐘內形成單相溶液，溶液內 的發泡劑存在量至少約3 %重量，以至少約5%重量爲佳， 而以至少約7%重量更好，又以至少約10%特佳（雖然上述 另一組較佳具體例中，使用發泡劑量降低）。在此等配置 中，每小時至少有約2.4磅發泡劑，以C02爲佳，引進流 —19 — 尺度適用中國國家標iicNS ) A4規格（210X297公釐） -----------.*衣------1T (請先閱讀背面之注意事項再填巧本頁〕 經濟部中央標準局員工消費合作社印掣 A1 λ〇39 A7 B7 五、發明説明（20 ) 體內相混形成單相溶液。發泡劑引進流量配合聚合物流 量，以達成最適發泡劑濃度。 經濟部中央標準局貝工消費合作社印聚 (請先閲讀背面之注意事項存填巧本頁> 在區50的下游是成核器66，其構造含有降壓成核途 徑67。此處在快速降壓文脈上所用「成核途徑」*指形成 微胞孔聚合物泡綿麽出裝置一部份的途徑，在裝置設計操 作的條件下（典型上在成核器上游的壓力約1 500至約 3 00 00PSi，每小#流量在約5磅聚合物材料以上），系統 內聚物材料與發泡劑相混的單相溶液壓力，以方便成核的 流量，降到特定發泡劑濃度的飽和壓力以下。成核途徑67 包含進口端69,以接受聚合物材料母質和發泡劑的單相溶 液，做爲流體聚合物流，以及成核聚合物釋出端70，以输 送成梭聚合物材料至成型室或邕型37。成极器66可位於 區50下游和模型37上游的各種位置。在較佳具體例中， 成核器66位於與模型37直接流體相通，使成核器形成噴 嘴，將壓出機與成型室連接，而成核聚合物釋放端70形成 成型室37的孔口。按照一組具體例，本發明在於把成核器 放在模型上游。雖然圖上未示，成核器66的另一具體例包 含成核途徑67,其構造和配置具有可變斷面積尺寸，亦即 途徑的斷面稹可以調節，可變斷面積成核途徑容許通過的 流體聚合物材料流內之降壓率可以變化，以便達成所需成 核密度。 在一具體例中，使用沿長度的斷面積尺寸變化之成核 途徑。具體而言，按下游方向降斷面積尺寸的成核途徑， 會大增降壓率，因而使用較低量的發泡劑，即可形成極高 —20 — 本紙張尺度適用中國國家標準（CNS ) A4規格（2丨0X297公釐） A7 B7 五、發明説明（21 ) 晶胞密度的微胞孔材料。上述和其他具體例之較佳成核 器，載於Anderson等人另案申請的美國専利申請案08/ 777,709號「微胞孔壓出方法和裝置」，以及國際專利申請 案PCT/US97/ 1 508 8號「微胞孔聚合物壓出方法和裝置」* 二者均列此參考。 雖然途徑67形成成核途徑，惟在模型充填之際，聚合 物材料以極快速¥降壓時，在模型本身內也會發生若千成 核。 圓1系統表示本發明一般具體例，其中藉由快速降壓， 使聚合物材料和發泡劑的單相未成核溶液成核，同時經由 螺桿38的轉動作用，逼入成型室37內。此具體例表示壓 出成型技術，在此具體例內，只需利用一發泡劑射入口 54。 在另一具體例內，系統30的螺桿38爲往復作動螺桿， 而系統限定射出成型系統。在此具體例中，螺桿38安裝成 在筒部32內往復作動，並含有複數發泡劑進口或射入口 54.5 5,57,5 9,61，沿筒部32軸向配置，各將筒部32流體相 連於加壓和計量裝置58及發泡劑源56 。各射入口 經濟部中央標率局貝工消費合作社印製 (請先W讀背面之注意事項再填湾本頁) 54.5 5,57,59,6 1可分別含有機械式關止閥1 54,1 55,1 5 7，159, 161，容許發泡劑以往復作動螺桿38在筒部內的軸向位置 爲函數，控制流入壓出機筒部38內。操作上，按照此具體 例，流體聚合物材料和發泡劑的加料（在若干具體例內可 爲擔相非成核加料）累積在螺桿38下游端48的下游區50 內。螺桿38在筒部32末梢（下游）被強制，造成區50內 加料射入模型37內。位於接近模型37孔口 70的機械式關 —21 - 本紙張尺度速用中國國家標準（CNS ) Λ4現格（210X297公釐） A7 B7 五、發明説明（22 ) 止閥64即可關閉，而模型37即可開啓放出射出成型件。 螺桿38轉動並收縮基端（朝向筒部的上游端34),而打 開關止閥161，同時關止閥155,15 7,15 4,159全關，容許發 泡劑僅經由最末梢通口 61射入筒部內。當筒部在轉動中收 縮時，關止閥161關，而關止閥159開，然後閥159關，而 閥154開等等。即控制發泡劑從發泡劑源射入筒部32內所 用關止閥，受到控‘制，使得螺桿38在基端收縮時，發泡劑 的射入位置沿筒部在基端（按上游方向）運動。結果是發 泡劑沿螺桿38射入位置基本上維持一定。因此，發泡劑添 加於流體聚合物材料，與聚合物材料混合程度和時間一 貫，無關螺桿38在筒部內的位置。爲此，可同時打開一以 上的關止閥155,157等，或至少部扮打開，以達成打鼯的 射入口間之平順過渡，並維持發泡劑沿筒部38射入的位置 基本上一定。 經濟部中央標隼局員工消費合作社印聚 (誚先閲讀背面之注意事項再填寫本頁) 一旦筒部38完全收縮（發泡劑最近只通過射入口 55 引入），全部發泡劑關止閥均關閉。此時，在筒部的末棺 區50內，爲基本上均勻的流體聚合物材料/發泡劑混合 物。再打開關止閥64，螺桿38末梢被逼將聚合物材料和 發泡劑加料射入模型37內。 本發明涉及往復作動螺桿的具體例，可用來製造習知 或微胞孔泡綿。若要製造習知泡綿，累積在末梢區50內的 加料，可爲多相混合物，包含在較低壓聚合物材料內的發 泡劑晶胞。此種混合物射入模型37內，會造成晶胞成長， 並製成習知泡綿。若要製造微胞孔材料，軍相非成核溶液 —2 2 — 本纸张尺度適用中國國家CNS ) Λ4規格~ΰΐ〇Χ297公釐> 經濟部中央榡準局貝工消費合作社印1ί ' ---- A 7 _B7_五、發明説明（23 ) 累積在50內，並射入模型37內，同時發生成核。 上述配置方便本發明方法，按照另一組具體例實施， 在筒部的末梢部50內累積加料內之不同位置，產生發泡劑 在流體聚合物材料內的不同濃度。此舉可由關止閥 1S5，1 57,1 54,1 59,1 6 1的控制達成，以便完成非均勻發泡劑 濃度。在此技術中，可製成不同密度的物品，例如實體外 表而發泡內部的物品。形成部份密度不同的物品之一技 術，參見圖5至圖7詳述如下。 雖然圖上未示，成型室37可含有排氣口，使模型內的 空氣在射出時逸出。排氣口的大小要在射出時提供充分反 壓，以控制晶胞成長，使發生均勻微胞孔發泡。在另一具 體例中，聚合物材料和發泡劑的單相非成核溶液，在引進 開口模型內時成核，再合模以造型微胞孔物品。 按照另一具體例，提供利用分開累積器之射出成型系 統。茲參見圖2，射出成型系統Η包含類似圓1所示的壓 出機。壓出機含有往復作動螺桿，一如圖1之系統，設有 至少一累積器78，先累積熔化聚合物材料，再射入成型室 37內，歷出機包含出口 51，藉由管道S3與累積器的進口 79流體相通，以供輸送聚合物材料和發泡劑的非成核單相 溶液至累積器。 累積器78在外殼內含有柱塞83，其構造和配置是 在累稹器外殼內軸向（基端和末梢端）活動。柱塞可在基 端收縮，使累積器可經進口 79充填聚合物材料/發泡劑， 再在末梢逼使強制聚合物材料/發泡劑混合物進入模型37 —23 - 本紙張尺度適用中國國家标準（〇^)六4规格（210';<297公釐) ' ' - - t- - - - —I— I - I—- - I Hi —11 ί - I II τ* (請先閲讀背面之注意事項再填寫本頁) 經濟部中央標率局負工消費合作社印繁 4 2 4 Ο 3 9_β7_五、發明説明（24 ) 內。在收縮位置時，容許熔化聚合物材料和發泡劑之單相 溶液形成的加料，累稹在累積器78內。當累積器78已裝 滿，此種系統即例如以液力控制的伸縮性射出汽紅（圖上 未示），強制加料通過成核器66以及所得成核混合物進入 成型室37內。此項配置表示另一具體例，其中聚合物材料 和發泡劑的非成核單相溶液，在成型室充填製程的結果而 成核。另外，降隳成核器可位在區50的下游和累積器78 的上游，使累積成核聚合物材料，而不是非成核材料，然 後射人模型37內。 在另一配置內，如圖1所示往復作動螺桿壓出機，可 用圖2之系統31，以接續射出聚合物材料和發泡劑加料（在 從壓出機逼入累積器時，可保留非成核或成核），同時柱 塞83上的壓力保持一定，以防在累積器內成核（或者，如 果在累積器內提供成核材料，可防止晶胞成長）。若在累 積器內引進複數加料，可打開關止閥64，在末梢驅動柱塞 83，把累積器內的加料轉移到模型37內。此對極大型組件 的生產有利。 球止回閥85位在累積器的進口 79附近，以謌節材料 流入累積器內，防止倒流入壓出機，並保持非成核發泡劑 和熔化聚合物材料之單相溶液所需系統壓力，或另外防止 引進其內的成核材料的晶胞成長。另外，射出成型系統31 可含一以上的累積器，與壓出機30和成型室37流體相通， 以便提高生產率。 系統31包含若干附加組件，詳後。 -24 - 本紙張尺度適用中國國家標準{ CNS ) Α4規格（210X297公釐） (請先閲讀背面之注意事項再填荇本頁) 經濟部中央標嗥局貝工消費合作社印製 424039 A7 B7 五、發明说明（25 ) 圖3和圖4表示使用本發明射出成型系統的另一具體 例之成型室，圖3簡略表示活動壁成行室71，含有模腔84、 溫度控制元件82、活動壁80、加壓機構（圓上未示）， 而在圖示較佳具體例中，至少有一成核器66,包含成核途 徑67,具有進U端69和釋放端70,形成模腔84的孔口。 在一具體例中》活動壁成型室71含有複數成核器66。活 動壁80可調節，以增加模型充填聚合物母質和發泡劑的成 核混合物時之模型容積，因而維持模型內壓力一定。如此 即可適當限制或控制晶胞成長。 圖4簡略表示氣體抗壓成型室73，含有模腔84、溫度 控制元件82、壓力控制器86、密封92，而在圖示較佳具 骽例中，至少有一成核器66，包含成核途徑67，形成.成 型室73的孔口。如前所述，成核途徑67具有進口端69和 釋放端70，後者形成室84之孔口。模型內壓力可藉壓力 控制器86維持，以限制或控制在引進模型內的成核混合物 內之晶胞成長。 活動壁模型，具有氣體壓力控制器的模型，和模型內 溫度控制元件的任何組合，可用於各種目的。如前所述， 可控制條件以限制或控制模型內的成核混合物內之晶胞成 長。溫度控制測量的另一用途是，一部份模型壁或整個模 型壁，可維持在較高或較低溫度，造成接近壁的區域（在 和接近微胞孔模型和產品外皮的區域），較模型內所形成 物品中心附近區域，有更多或更少晶胞成長。 在本發明一具體例中，成型較厚的微胞孔聚合物材 -25 - -----------^装-----—訂 (請先閲讀背面之注項再填寫本頁) 本紙張尺度適用中國國家標準（CNS ) Α4規格（2丨0Χ297公釐） 經濟部中央標準局員工消費合作社印^ ^2 4 0^9 A7 _B7 五、發明说明（26 ) 料，例如含有至少一部份的厚度至少爲0.5 00吋，是在模 型內建立成核微胞孔聚合物母質，並快速「裂開」，或打 開模型，以形成比模型本身內部更大的組件。當模型裂開 時，由於相對應降壓，發生晶胞成長。容許成核混合物部 份凝固爲锷型或容器的形狀，形成容器形狀的第一微胞孔 聚合物品，從容器取出，任其進一步膨脹，形成形狀較容 器形狀更大的第二微胞孔聚合物品。在某些方面，在模型 裂開後可繼續射出或吐出，以控制密度和晶胞結構。亦即 溶液可趁成核中引入模型內，同時模型可裂開，再進一步 打開，以控制模型內的反壓，並控制最後組件大小和晶胞 密度及結構。此亦可由所述類似活動壁模型完成。 本發明得以快速循環式聚合物泡綿成型。射出和成型 後，在約1 〇分鐘以內的時間，即可利用射入成型室內，容 許其發泡並凝固成容器形狀，而產生第二成型混合物，以 便取出。循環時間宜在約1分鐘內，以約20秒內更好。材 料引入模型內到凝固間的時間，典型上在約1 0秒內，由於 減少泡綿材料的重量，使循環時間少（要冷卻的質量少）， 藉降低超臨界流體發泡劑的粘度，可得低熔點。低熔點表 示射出所需吸熱少。 茲參見圖5至圖7，表示本發明使用系統31的另一具 體例，詳述系統31如下。系統31亦含有無發泡劑的管道 88，連接壓出口 90與累積器進口 91。累積器進口 91位於 累積器的柱塞83面。機械式關止閥99位於沿管道88，接 近出口 90爲佳。壓出機出口 90位於發泡劑進口 54上游的 -26 - 本紙張尺度適用中國國家標皁{ CNS ) Λ4規格（210X297公釐） ---------,袭------1Γ------,'J (請先閱讀背面之注意事項再填舄本I) 經濟部中央標隼局員工消費合作社印製 五、發明说明（27 ) 壓出機內（或多數發泡劑進口，如圖1所示壓出配置，該 配置用於圖5至圖7所述系統內），但在可輸送流骽聚合 物材料94的壓出機內夠違的下游。由管道88轅送的流體 聚合物材料94，爲寡發泡劑的材料，亦可基本上不含發泡 劑。因此，系統含有壓出機的第一出口 90，位於輸送基本 上不含發泡劑，或減少發泡剤濃度的流體聚合物材料，從 壓出機输送到累積器的第一進口 91，而壓出機混合區下游 的第二出口 51，位於輸送流體聚合物材料和發泡劑的混合 物（發泡劑濃度較從出口 90输送者爲高，即富發泡劑材 料），至累積器的第二進口 79;累積器可包含加熱單元96， 以控制其內的聚合物材料溫度。累積器包含出口，爲成核 器66的進口 69。形成成核途徑67的通道（或噴嘴），連 接累積器78至成型室37。 一系列閥*包含球止回閥98和85，位於累積器的第 一和第二進口，以及機械閥64和99，分別控制材料從壓 出機流至累積器，並視需要從累積器到模型，如下述若干 具體例。 本發明在所有具體例內涉及維持系統內壓力足以防止 不需成核處（成核器上游）過早成核，或已發生成核而不 需晶胞成長或需要控制晶胞成長處防止晶胞成長之能力。 實SS本發明一具體例之方法，涉及將寡發泡劑材料射 入模型內，以形成幾乎實體外皮，接著將富發泡劑材料射 入模型內，以形成赛泡芯部。可參見圓5至圓7加以說明。 雖然圓上未示，以適當同步可用此法來形成具有發泡外部 -27 - 本纸張尺度適用中囷國家標準（CNS > A4規格（2丨OX 297公釐） ----------- (請先閲讀背面之注意事項再填寫本頁) 丁 *-° -. 經濟部中央標準局員工消費合作社印製 五、發明説明（28) 和實體內部的物品。 圖5表示不含發泡劑的聚合物材料情況，或在累積器 末梢端和累積器基端含有限量的發泡劑（材料94)。即在 剛好柱塞83前方，成核途徑67內和剛好成核途徑67上游， 具有寡發泡劑材料94。在此等寡發泡劑94區間，累積器 內有富發泡劑材料101區，在此點，接至模型37的櫸械式 閥64打開，而柱塞83向下游驅動，逼使累積器78內的材 料進入模型37。此即圖6所示，寡發泡劑材料的第一段襯 於模型外部，形成基本上實體外壁，再將富發泡劑材料101 充填於模型中心 > 並在進入模型時成核。柱塞運動的末梢 限度，在近累積器末端時停止，而已位在剛好柱塞前方的 寡發泡劑材料區，如今位在巢積器末梢端，並充填累積器 的成核途徑。閥64即關閉，所得組件從模型37取出，機 械式閥99關時，當柱塞基端收縮，如圖7所示，壓出機被 驅動以引進富發泡劑材料*以聚合物材料和發泡劑的軍相 非成核溶液爲佳，進入累積器內。柱塞對累積器內的材料， 施加基本上一定的壓力，維持材料101在非成核狀態ρ當 柱塞幾乎到達其基端限度時，打開機械式閥99，令寡材料 .94，充填於剛好柱塞前方的累積器段，如圖5所示。圖5 代表在剛好在射入於模型之前，完成循環。 參見圓5至圓7，在本發明另一具體例中，可形成具 有寡發泡劑外壁和富發泡劑的微胞孔發泡內鄯之射出成型 微胞孔物品，不必充填累積器78，如圖示在寡發泡劑材料 間包夾富發泡劑材料&在此具體例中，富發準劑材料充填 —2 8 — 本纸張尺度適用中國國家標準（CNS) A4规格（2〗0X297公釐） (讀先W讀背面之注意事項再填寫本頁) d. 訂A7 B7__ 5. Description of the invention (丨 9) It is better to use at least about 10%, especially at least about 20%. A typical prior art technique for forming dissimilar polymer material compositions involves extruding and granulating dissimilar polymer materials, and providing the particles in a funnel 44 such as the system shown in circle 1. In accordance with the gist of the present invention * supercritical fluid blowing agents are used, i.e. no premixed particles or mixing equipment is required. For this purpose, a mixture of different polymer particles, such as a mixture of polystyrene particles and polypropylene particles, can be provided in the funnel 44, melted, closely mixed with the supercritical fluid blowing agent, and extruded into a well-mixed homogeneous mixture. . In this gist of the present invention, a single-phase solution of a foaming agent and a multi-component polymer material (including dissimilar materials) can be formed in the following flow children and within a specific time. The gist of the present invention can be used to form a polymer product composed of at least two dissimilar polymer materials. The above-mentioned configuration can be conveniently implemented according to several specific embodiments of the present invention through extrusion, the above-mentioned molding, or other techniques. Used in combination with injection or injection molding. This method involves introducing a foaming agent that is a gas under ambient conditions into the fluid polymer material at a flow rate of about 0.4 to about 1.4 pounds per hour, which produces a foaming agent fluid in the polymer in about 1 minute. Single-phase solution. The amount of blowing agent fluid present in the solution is at least about 2.5% by weight of the solution weight in this configuration. In some specific examples, the flow rate of the fluid polymer material is about 6 to 12 pounds per hour. In these configurations, a foaming agent fluid is added to form a single-phase solution within 1 minute. The foaming agent is present in the solution in an amount of at least about 3% by weight, preferably at least about 5% by weight, and at least about 7% by weight. Even better, at least about 10% is particularly preferred (although in the other set of preferred embodiments described above, the amount of foam used is reduced). In these configurations, there is at least about 2.4 pounds of foaming agent per hour, preferably C02, and the introduced stream — 19 — scale is applicable to the Chinese national standard iicNS) A4 specification (210X297 mm) --------- -. * 衣 ------ 1T (Please read the notes on the back before filling out this page) Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs A1 λ〇39 A7 B7 V. Description of the invention (20) Inside Mix to form a single-phase solution. The flow rate of the foaming agent is introduced in conjunction with the flow rate of the polymer to achieve the optimum concentration of the foaming agent. Downstream of zone 50 is a nucleator 66, the structure of which contains a step-down nucleation pathway 67. The "nucleation pathway" used in the context of the rapid pressure-reduction context * refers to the formation of a microcellular polymer foam device. Partial approach, under the conditions of the device design operation (typically the pressure upstream of the nucleator is about 1500 to about 3 00PSi, and the flow rate of each small # is above about 5 pounds of polymer material). The pressure of the single-phase solution mixed with the foaming agent to reduce the flow rate Below the saturation pressure of the blowing agent concentration. The nucleation pathway 67 includes an inlet 69 to accept a single-phase solution of the polymer material matrix and the blowing agent as a fluid polymer stream, and a nucleating polymer release 70, The shuttle polymer material is conveyed to the molding chamber or the mold 37. The pole generator 66 can be located in various positions downstream of the zone 50 and upstream of the model 37. In a preferred embodiment, the nucleator 66 is in direct fluid communication with the model 37 The nucleator is formed into a nozzle, the extruder is connected to the molding chamber, and the nucleated polymer release end 70 forms an orifice of the molding chamber 37. According to a set of specific examples, the present invention consists in placing the nucleator upstream of the model. Although not shown in the figure, another specific example of the nucleator 66 includes a nucleation pathway 67, whose structure and configuration has a variable cross-sectional area size, that is, the cross section of the pathway can be adjusted, and the variable cross-sectional nucleation pathway is adjustable. The depressurization rate in the fluid polymer material flow that is allowed to pass can be varied in order to achieve the desired nucleation density. In a specific example, a nucleation pathway with a change in size of the cross-sectional area along the length is used. Specifically, in the downstream direction Drop area The size of the nucleation pathway will greatly increase the pressure drop rate, so using a lower amount of foaming agent can form a very high —20 — This paper size applies to the Chinese National Standard (CNS) A4 specification (2 丨 0X297 mm) A7 B7 V. Description of the invention (21) Microcellular material with unit cell density. The preferred nucleator of the above and other specific examples is contained in US Patent Application No. 08 / 777,709, "Microcells," filed separately by Anderson et al. Extrusion method and device ", and international patent application PCT / US97 / 1 508 8" Microcellular Polymer Extrusion Method and Device "* Both are listed here for reference. Although pathway 67 forms a nucleation pathway, only When the model is filled, when the polymer material is depressurized at a very rapid ¥, nucleation will also occur in the model itself. The circle 1 system shows a general specific example of the present invention, in which a single-phase unnucleated solution of a polymer material and a foaming agent is nucleated by rapid depressurization, and simultaneously forced into a molding chamber 37 by the rotation of a screw 38. This specific example shows the extrusion molding technique. In this specific example, only a blowing agent injection port 54 is required. In another specific example, the screw 38 of the system 30 is a reciprocating screw, and the system defines an injection molding system. In this specific example, the screw 38 is mounted to reciprocate within the barrel portion 32 and contains a plurality of blowing agent inlets or injection inlets 54.5 5,57,5 9,61, which are arranged axially along the barrel portion 32, each of which 32 is fluidly connected to a pressurizing and metering device 58 and a foaming agent source 56. Printed by the Shell Standard Consumer Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs (please read the precautions on the back before filling in this page) 54.5 5,57,59,6 1 May contain mechanical shut-off valves 1 54, 1 55, 1 5 7, 159, 161, allowing the foaming agent to control the inflow into the extruder barrel 38 as a function of the axial position of the screw 38 in the barrel. In operation, in accordance with this specific example, the addition of fluid polymer material and blowing agent (which may be a non-nucleating phase charge in several specific examples) accumulates in the downstream region 50 of the downstream end 48 of the screw 38. The screw 38 is forced at the end (downstream) of the barrel portion 32, causing the feed in the zone 50 to be injected into the mold 37. The mechanical gate located near the opening 70 of the model 37—21-The national standard (CNS) of this paper standard Λ4 is present (210X297 mm) A7 B7 V. Description of the invention (22) The check valve 64 can be closed, and The mold 37 can be opened to eject the injection molded part. The screw 38 rotates and shrinks the base end (toward the upstream end 34 of the barrel), and the check valve 161 is opened and closed, and the valves 155, 15 7, 15 4,159 are all closed at the same time, allowing the foaming agent to shoot only through the most end port 61 Into the tube. When the barrel is retracted during rotation, the shut-off valve 161 is closed, the shut-off valve 159 is opened, then the valve 159 is closed, the valve 154 is opened, and so on. That is, the shut-off valve used to control the blowing agent from the blowing agent source into the barrel portion 32 is controlled so that when the screw 38 contracts at the base end, the injection position of the blowing agent is along the barrel portion at the base end (pressing Upstream direction). As a result, the injection position of the foaming agent along the screw 38 is maintained substantially constant. Therefore, the foaming agent is added to the fluid polymer material, and the degree and time of mixing with the polymer material are consistent regardless of the position of the screw 38 in the barrel. To this end, one or more closing valves 155, 157, etc. may be opened at the same time, or at least partially opened to achieve a smooth transition between the snoring injection ports, and to maintain the injection position of the foaming agent along the barrel portion 38 substantially constant. Employees' Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs of the People's Republic of China (read the precautions on the back before filling out this page) Once the barrel 38 has fully contracted (the foaming agent was recently introduced only through the injection port 55), all the foaming agent stop valves Both are closed. At this time, in the final coffin region 50 of the barrel, there is a substantially uniform fluid polymer material / foaming agent mixture. When the check valve 64 is opened and closed, the tip of the screw 38 is forced to inject the polymer material and the blowing agent into the mold 37. The present invention relates to a specific example of a reciprocating actuating screw, which can be used to make conventional or microcellular foam. If a conventional foam is to be made, the charge accumulated in the tip region 50 may be a multi-phase mixture containing the foaming unit cell contained in the lower pressure polymer material. This mixture is injected into the mold 37, which will cause the unit cell to grow and become a conventional foam. To make microporous materials, military-phase non-nucleating solution — 2 2 — This paper size is applicable to China's national CNS) Λ4 size ~ ΰΐ〇 × 297mm > Printed by the Bayou Consumer Cooperative of the Central Bureau of Standards, Ministry of Economic Affairs 1ί '- --- A 7 _B7_ V. Description of the invention (23) Accumulates in 50 and shoots into model 37, and nucleation occurs at the same time. The above configuration is convenient for the method of the present invention, and is implemented according to another group of specific examples. Different positions in the feed are accumulated in the tip portion 50 of the barrel portion, resulting in different concentrations of the foaming agent in the fluid polymer material. This can be achieved by the control of the shut-off valve 1S5, 1 57,1 54,1 59,1 6 1 in order to achieve a non-uniform foaming agent concentration. In this technique, items of different densities can be made, such as items that have a solid exterior and foam inside. One technique for forming articles with different partial densities is detailed below with reference to FIGS. 5 to 7. Although not shown in the figure, the molding chamber 37 may include an exhaust port to allow air in the mold to escape when being ejected. The size of the exhaust port should provide sufficient back pressure during injection to control the growth of the cell and cause uniform cell foaming. In another specific example, a single-phase non-nucleating solution of a polymer material and a blowing agent is nucleated when it is introduced into an open mold, and then the mold is closed to shape a microcellular article. According to another specific example, an injection molding system using a separate accumulator is provided. Referring now to Fig. 2, the injection molding system Η includes an extruder similar to that shown in circle 1. The extruder contains a reciprocating actuating screw. A system as shown in FIG. 1 is provided with at least one accumulator 78, which accumulates molten polymer material first, and then injects it into the molding chamber 37. The extruder includes an outlet 51. The inlet 79 of the accumulator is in fluid communication for the delivery of a non-nucleated single-phase solution of polymer material and blowing agent to the accumulator. The accumulator 78 contains a plunger 83 in the housing, and is constructed and arranged to move axially (base end and distal end) in the accumulator housing. The plunger can be contracted at the base end, so that the accumulator can be filled with the polymer material / foaming agent through the imported 79, and then forced to force the polymer material / foaming agent mixture into the model 37 —23-This paper size is applicable to China Standard (〇 ^) 6 4 specifications (210 '; < 297 mm)' '--t----—I— I-I—--I Hi —11 ί-I II τ * (Please read first Note on the back, please fill out this page again) Yin Fan 4 2 4 Ο 3 9_β7_ of the Central Standards Bureau of the Ministry of Economic Affairs, 5. Inventory (24). In the retracted position, the addition of a single-phase solution of molten polymer material and blowing agent is allowed to accumulate in the accumulator 78. When the accumulator 78 has been filled, such a system would, for example, inject steam red (not shown) with hydraulically controlled stretchability, forcing the feed through the nucleator 66 and the resulting nucleation mixture into the molding chamber 37. This configuration represents another specific example, in which a non-nucleating single-phase solution of a polymer material and a blowing agent is nucleated as a result of a filling process in a molding chamber. Alternatively, the tritium nucleator may be located downstream of the zone 50 and upstream of the accumulator 78, so that the accumulated nucleating polymer material, rather than the non-nucleating material, is shot into the model 37. In another configuration, as shown in Figure 1, the screw extruder can be reciprocated, and the system 31 of Figure 2 can be used to continuously inject polymer materials and blowing agent feeding (can be retained when forced from the extruder into the accumulator (Non-nucleation or nucleation), while the pressure on the plunger 83 is maintained to prevent nucleation in the accumulator (or, if a nucleation material is provided in the accumulator, the unit cell can be prevented from growing). If multiple feeds are introduced into the accumulator, the check valve 64 can be opened and closed, and the plunger 83 is driven at the tip to transfer the feed in the accumulator to the model 37. This is advantageous for the production of very large components. The ball check valve 85 is located near the inlet 79 of the accumulator, and flows into the accumulator with the joint material, preventing backflow into the extruder, and maintaining the system pressure required for the non-nucleating foaming agent and the single-phase solution of the molten polymer material. , Or otherwise prevent the cell growth of the nucleating material introduced therein. In addition, the injection molding system 31 may include more than one accumulator in fluid communication with the extruder 30 and the molding chamber 37 in order to increase productivity. The system 31 contains several additional components, as detailed below. -24-This paper size applies the Chinese National Standard {CNS) A4 size (210X297 mm) (Please read the notes on the back before filling out this page) Printed by the Central Standards Bureau of the Ministry of Economic Affairs, Shellfish Consumer Cooperative, 424039 A7 B7 5 3. Description of the invention (25) FIGS. 3 and 4 show a molding chamber using another specific example of the injection molding system of the present invention. FIG. 3 schematically shows a movable wall row chamber 71, which includes a cavity 84, a temperature control element 82, and a movable wall 80. Pressurizing mechanism (not shown on the circle), and in the illustrated preferred embodiment, there is at least one nucleator 66, which includes a nucleation path 67, has a U-end 69 and a release end 70, and forms a hole in the mold cavity 84. mouth. In a specific example, the movable wall forming chamber 71 includes a plurality of nucleators 66. The movable wall 80 can be adjusted to increase the model volume when the model is filled with the nucleation mixture of the polymer matrix and the foaming agent, thereby maintaining a constant pressure in the model. In this way, the cell growth can be appropriately restricted or controlled. FIG. 4 schematically shows a gas compression molding chamber 73, which includes a cavity 84, a temperature control element 82, a pressure controller 86, and a seal 92. In the preferred embodiment shown in the figure, at least one nucleator 66 includes a nucleator. Path 67 forms the orifice of the molding chamber 73. As previously mentioned, the nucleation pathway 67 has an inlet end 69 and a release end 70, the latter forming the orifice of the chamber 84. The pressure in the model can be maintained by the pressure controller 86 to limit or control the cell growth in the nucleation mixture introduced into the model. Any combination of movable wall models, models with gas pressure controllers, and temperature control elements within the model can be used for various purposes. As mentioned earlier, conditions can be controlled to limit or control the growth of unit cells in the nucleation mixture in the model. Another use of temperature control measurement is that a part of the model wall or the entire model wall can be maintained at a higher or lower temperature, resulting in areas close to the wall (in and near the cell model and the product skin). In the area near the center of the object formed in the model, more or less unit cells grow. In a specific example of the present invention, forming a thicker microcellular polymer material -25------------ ^ equipment ------- order (please read the note on the back before (Fill in this page) This paper size is applicable to Chinese National Standard (CNS) A4 specification (2 丨 0 × 297 mm) Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs ^ ^ 2 4 0 ^ 9 A7 _B7 V. Description of the invention (26) For example, it contains at least a part with a thickness of at least 0.5 00 inches. A nucleated microporous polymer matrix is established in the model and quickly "cracked", or the model is opened to form a larger component than the model itself. . When the model cracks, cell growth occurs due to the corresponding decompression. Allow the nucleation mixture to partly solidify into the shape of a cymbal or container to form the first microcellular polymer product in the shape of a container. Take it out of the container and allow it to expand further to form a second microcellular polymer with a larger shape than the shape of the container. article. In some aspects, injection or ejection can continue after the model has split to control density and cell structure. That is, the solution can be introduced into the model while nucleation, and the model can be cracked and then opened further to control the back pressure in the model and control the final component size and cell density and structure. This can also be done by the similar movable wall model. The invention enables rapid cycle polymer foam molding. After injection and molding, within about 10 minutes, the injection can be used into the molding chamber to allow it to foam and solidify into a container shape to produce a second molding mixture for removal. The cycle time is preferably within about 1 minute, and more preferably within about 20 seconds. The time between the introduction of the material into the mold and the solidification time is typically within about 10 seconds. Due to the reduced weight of the foam material, the cycle time is reduced (the mass to be cooled is less). By reducing the viscosity of the supercritical fluid foaming agent, A low melting point is obtained. A low melting point indicates that less heat is required for injection. 5-7, another specific example of the use system 31 of the present invention is shown. The system 31 is described in detail below. The system 31 also contains a blowing agent-free pipe 88 connecting the pressure outlet 90 to the accumulator inlet 91. The accumulator inlet 91 is located on the plunger 83 side of the accumulator. A mechanical shut-off valve 99 is preferably located along the pipe 88 and near the outlet 90. The extruder outlet 90 is located -26 upstream of the blowing agent inlet 54-This paper size is applicable to the Chinese national standard soap (CNS) Λ4 specification (210X297 mm) ---------, attack ----- -1Γ ------, 'J (Please read the notes on the back before filling in this I) Printed by the Consumer Cooperatives of the Central Bureau of Standards of the Ministry of Economic Affairs V. Invention Description (27) Extruder (or most The blowing agent inlet is shown in the extrusion configuration shown in FIG. 1, which is used in the system described in FIGS. 5 to 7), but downstream of the extruder that can transport the flow of polymer material 94. The fluid polymer material 94 carried by the pipe 88 is a material of an oligofoaming agent, and may also be substantially free of a foaming agent. Therefore, the system contains the first outlet 90 of the extruder, which is located to convey the fluid polymer material that contains substantially no foaming agent, or reduces the concentration of foaming radon, from the extruder to the first inlet 91 of the accumulator, and The second outlet 51 downstream of the extruder mixing zone is located to convey the mixture of the fluid polymer material and the blowing agent (the concentration of the blowing agent is higher than that conveyed from the outlet 90, that is, the rich blowing agent material), to the accumulator. The second inlet 79; the accumulator may include a heating unit 96 to control the temperature of the polymer material therein. The accumulator contains an outlet, which is the inlet 69 of the nucleator 66. A channel (or nozzle) forming a nucleation path 67 is connected to the accumulator 78 to the molding chamber 37. A series of valves * includes ball check valves 98 and 85, located at the first and second inlets of the accumulator, and mechanical valves 64 and 99, respectively, to control the flow of material from the extruder to the accumulator and, if necessary, from the accumulator to The model is as follows. The present invention involves maintaining the pressure in the system in all specific examples to prevent premature nucleation at the place where nucleation is not required (upstream of the nucleator), or nucleation has occurred without the need for cell growth or the need to control the growth of the unit to prevent crystal growth. Cell growth ability. The method for realizing a specific example of the present invention involves injecting an oligofoaming agent material into a mold to form an almost solid sheath, and then injecting a foaming agent-rich material into the mold to form a foam core. See circle 5 to circle 7 for explanation. Although it is not shown on the circle, this method can be used to form a foamed exterior -27 with proper synchronization-This paper size applies the China National Standard (CNS > A4 specification (2 丨 OX 297 mm) ------ ----- (Please read the notes on the back before filling out this page) Ding *-°-. Printed by the Consumer Cooperatives of the Central Standards Bureau of the Ministry of Economic Affairs 5. Description of the invention (28) and the items inside the entity. Figure 5 shows In the case of polymer materials that do not contain foaming agent, or contain a limited amount of foaming agent at the end of the accumulator and the base of the accumulator (material 94). That is, just in front of the plunger 83, within the nucleation pathway 67 and just nucleating Upstream of path 67, there is an oligofoaming agent material 94. In the region of these oligofoaming agents 94, there is a zone 101 of the foaming agent-rich material in the accumulator. At this point, the beech mechanical valve 64 connected to the model 37 opens, The plunger 83 is driven downstream, forcing the material in the accumulator 78 into the model 37. As shown in Figure 6, the first section of the oligofoaming agent material is lined to the outside of the model to form a substantially solid outer wall. Foaming agent material 101 fills the center of the model > and nucleates when entering the model. The end of the plunger movement It stops near the end of the accumulator, but is located in the area of the oligofoaming agent material just in front of the plunger. It is now at the end of the nest accumulator and fills the nucleation pathway of the accumulator. The valve 64 is closed, and the resulting component Take out from the model 37, when the mechanical valve 99 is closed, when the plunger base end is contracted, as shown in Fig. 7, the extruder is driven to introduce the foaming agent-rich material. The nucleation solution is better to enter the accumulator. The plunger exerts a certain pressure on the material in the accumulator to maintain the material 101 in a non-nucleating state. When the plunger almost reaches its base end limit, the mechanical type is opened. Valve 99, oligomaterial .94, is filled in the accumulator section just in front of the plunger, as shown in Figure 5. Figure 5 represents the cycle completed just before being injected into the model. See circle 5 to circle 7, in this section In another specific example of the invention, an injection molded microcellular article having an outer wall of an oligofoaming agent and a microcellular foam-rich inner foam can be formed without filling the accumulator 78. Encapsulating rich foaming material between materials & In this specific example, rich Quasi-agent material filling -28-- this paper scale applicable Chinese National Standard (CNS) A4 size (2〗 0X297 mm) (W read first read the back of the precautions to fill out this page) d set.
五、發明説明（29) 經濟部中央樣率局貝工消资合作社印製 於模型內，但成核途徑67限定的累棟器最末梢部份，加熱 到比累積器其他部份吏大的程度，此舉可用位於接近成核 器的加熱單元103完成◊如有需要，可設另外加熱器，對 成核途徑上游的累積器內轲料加熱。累積器最末梢部份的 材料加熱足夠程度，當累積器內加熱射入模型內時，在高 度受熱段內的發泡劑即很快從聚合物擴散，通過模型的排 氣口（圊上未示Γ。在最末梢更高度受熱的加料段上游之 聚合物材料內，發生晶胞成長，比發泡劑從俱全物擴散更 快形成微胞孔轲料。受熱加料的最末梢部，限定爲加料的 至少約2%，或至少約5%，或至少約1 0%，或至少約20%， 可在加料射入成Μ室之前，在比加料平均溫度高至少約10 aC的溫度加熱，或比加料苹均溫度髙至少約2〇0C、4〇t 或 SO 〇C。 在本發明另一具體例中，聚合物材料和發泡劑的單相 均質溶液，可射入模型內，同時維持模型內壓力髙到足以 防止成核。即發生射出而不成核，均質單相溶液即可在模 型內凍結成固體狀態，並打開模型$此時不發生成核和發 泡，成型品即可加熱造成成核和發泡，例如置於甘油浴內。 按照本發明可製成各種物品，例如消耗品和工業品， 像聚合物餐具、汽車零件，以及各種其他射闺成型組件。 圓8鲔略表示本發明另一具體例的射出成型系統 100。射出成型系統100包含類似圖1所示壓出機，含筒部 102，具有上游第一端104，和連接於成型室108的下游第 二端106 ό安裝在筒部102內往復運動和轉動的是螺桿 _ 29 - 本紙張尺度適用中國國家標準{ CNS ) Α4規格（210X297公釐） H ^1 - - J— n n n f— I I n T n I I ! ! n FT. "言 i^i ^ <請先閱讀背面之注意事項再填窍本頁) 經濟部中央標率局負工消費合作社印裝V. Description of the invention (29) The central sample rate bureau of the Ministry of Economic Affairs, Shellfish Consumer Cooperative, is printed in the model, but the last part of the accumulator that is limited by the nucleation path 67 is heated to be larger than other parts of the accumulator To this extent, this can be accomplished by the heating unit 103 located near the nucleator. If necessary, another heater can be provided to heat the material in the accumulator upstream of the nucleation pathway. The material at the end of the accumulator is heated enough. When the accumulator is heated and injected into the model, the foaming agent in the highly heated section quickly diffuses from the polymer and passes through the model's exhaust port (圊 上 未 未Shown Γ. In the polymer material upstream of the most highly heated feed section at the end, cell growth occurs, and the cell aggregate is formed faster than the foaming agent diffuses from the whole material. The end of the heated feed is limited to At least about 2%, or at least about 5%, or at least about 10%, or at least about 20% of the feed can be heated at a temperature at least about 10 aC higher than the average temperature of the feed before the feed is injected into the M chamber, Or it is at least about 2000C, 40t or SO ° C than the average temperature of the feed. In another embodiment of the present invention, a single-phase homogeneous solution of the polymer material and the blowing agent can be injected into the mold, and at the same time Maintain the pressure in the model sufficiently to prevent nucleation. That is, injection occurs without nucleation, the homogeneous single-phase solution can be frozen into a solid state in the model, and the model is opened. At this time, nucleation and foaming do not occur, and the molded product can be Nucleation and foaming caused by heating, for example In the bath, various articles such as consumables and industrial products, such as polymer tableware, automobile parts, and various other injection molding components can be made according to the present invention. The circle 8 shows an injection molding system of another specific example of the present invention. 100. The injection molding system 100 includes an extruder similar to that shown in FIG. 1, including a barrel portion 102, having an upstream first end 104, and a downstream second end 106 connected to the molding chamber 108. The reciprocating motion is installed in the barrel portion 102 and The screw is rotating _ 29-This paper size applies to the Chinese National Standard {CNS) A4 (210X297 mm) H ^ 1--J— nnnf— II n T n II!! N FT. &Quot; 言 i ^ i ^ < Please read the precautions on the back before filling out this page) Printed by the Consumer Standards Cooperative of Central Standards Bureau, Ministry of Economic Affairs
Oil A7 B7 五、發明説明（3〇) 110，在其上游端操作連接於驅動馬建（圖上來示）。達 接進口 113和筒部通口 115{進D下游的逋口）之側流114， 包倉依序流體連接的熔體泵116和混合器11S。熔體泵U6 可爲齒輪泵或小型壓出機，爲技藝上公知者。 上述本發明技術亦可用於借助氣慵的共同射岀6在此 技術中，將微胞孔材料母質在引進模型時壓出和成核，已 如上述，同時將氣體射入熔體流內，其方式是在非成核聚 合物材料靠近模壁形成外層，以及充填共同射出氣體的中 央孔隙，和其他具體例一樣發生晶胞成長。混合器118含 發泡劑射S 口 120，以供引進發泡劑，碍合器118可爲靜 態混合器或模腔轉移混合器，爲技藝上已知者。圓8的配 置方便本發明男一方法，可用來形成具有不同材料密度的 射出成型微胞孔組件，已如前述，此法渉及將預聚合材料 引入壓出機筒部102內，將預聚合材料熔化，把熔化聚合 物材料124向壓出機100的下游端1〇6推進。當熔化聚合物 材料124前進通遇壓出機筒部1〇2時，一部份利用熔體泵 116 (例如在螺桿110末梢端於側流114的進口 in基端收 縮後），轉道推進通過進口 113進入側流114內。當側流 II4內的熔化聚合物材料前進通過混合器U?時，即弓I進來 自氣體射入Ο 120的發泡劑，在其中徹底渥合，形成發泡 劑和熔化聚合物材料之單相非成梭溶液，從側流114經通 □ 115推進，進入壓出機筒部1〇2之下游端1〇6內，如圖8 所示，同時，往復作動螺桿110完全收縮。如此在筒部最 末梢端產生富發泡劑區122，和在富發泡劑區基端的寡發 一 30 _ 本紙張尺度剌中關料牌（CNS ) Λ4規格（210X 297公趁) "~ I - - I- - Jn I I (. - - I ^^1 ^^1-----J^i (請先閲讀背面之注意事項再填寫本頁> 經濟部中戎標準局員工消費合作社印策 ·<Η' ^ ^ ， Α7 Β7 五、發明説明（31 ) 泡劑區。富發泡劑材料和寡發泡劑材料的相對量，可利用 材料通過側流Η4增加發泡劑的流量加以控制。然後，使 用螺桿110的往復作動，將非成核發泡劑和熔化聚合物122 的富發泡劑單相溶液，接著是一部份寡發泡劑熔化聚合物 材料124，射入成型室108內。 在另一具體例中，本發明提供把發泡劑快速而有效引 進上述射出成型裝置中的流體聚合物母質內，以及基本上 按照任何配置的壓出裝置。此具體例包含圖9所示壓出螺 桿，在可位於壓出筒部（圖上未示）內的螺桿表面具有孔 口，可與發泡劑源呈流體相通。孔口形成從可連接於發泡 劑源的位置（諸如螺桿的基端位置）通過之腔口終端。在 較佳具髖例中，腔口沿螺桿的轉動軸線，從螺桿的基端在 縱向通過，並與螓桿表面的一或以上孔口連接。一或以上 孔口宜位在螺桿旋溝的外表面，從旋溝外表面稍微凹陷， 此項定位得以使發泡劑對筒部內表面進行剪力/擴散的方 式引進發泡劑。一或以上孔口可位於旋溝間之區域，亦可 使用孔口在各種位置的組合。參見圖9，壓出機螺桿130 包含旋溝132,以及與旋溝132外表面138上的孔口相通之 腔口 134。腔口 134的部位140從螺桿中心軸線上的腔口通 到孔口，經螺桿內孔口引進發泡劑之一優點是，在使用往 復作動螺桿的配置中，可提供發泡劑在聚合物母質內的均 勻性p 藉射出成型可製成物品，厚度或斷面尺寸低於0.100 吋，或不超過約0.075吋，以不超過約0.050吋爲佳，而以 -31 - 本紙張尺度適用中國國家標芈（CNS > Λ4规格（210X297公釐） ---------Λ------訂------Λ: (锖先閲讀背面之注意事項再填寫本！) 經满部中央標準局貝工消費合作社印繁 ,1° 4 039 A7 ' _B7_ 五、發明说明（32) 不超過約0.025吋更好，又以不超過約0.010吋尤隹，因爲 聚合物母質和超臨界流體的單相溶液粘度特低，以此方式 可射入楔型內，在其中形成物品。例如，超臨界流體和聚 合物母質的單相溶液可引進模型內，由此製成習知發泡或 微胞孔物品。射入模型內的流體低粘度可使上述射出成型 循環時間在10分鐘以下，以5分鐘以下爲佳，1分鐘以下 更好，30秒內尤佳，20秒內特佳，10秒以內進一步好， 5秒內最好。 本發明亦提供製造成型室形狀的成型微胞孔聚合物 品，包含至少一部份的斷面積尺寸不超過約0.125吋，或 在其他具體例中，有上述更小尺寸，物品的孔隙容積至少 約5%，以至少約1 0%爲佳，至少約1 5%更好，至少約20% 尤佳，至少約25%特佳，而以至少約3 0%最好。在其他具 體例中，物品的孔隙容積至少約50%，此項重大改進爲在 技術上挑戰提供極小型物品，藉泡綿孔隙容積，減輕聚合 物材料的重量。本發明物品包含在斷面積尺寸不超過約 0.125吋，或上述其他較小尺寸之段，具有上述孔隙容積。 本發明方法亦可製造厚度大於0.125吋，例如在0.200 吋和約0.5 00吋厚度間的射出成型組件，更加減重（如上 述）和更小晶胞。 本發明亦提供系統和方法，在於製造厚、薄泡綿成型 組件、表面復現實體組件。此等組件表面至少一部份，並 無肉眼可見的歪斜和旋渦。圖16至圓18配合實施例9(下 述），證明形成表面未有肉眼可見歪斜和旋渦之聚合物組 -32 - 本纸張尺度適用中國國家揉準（CNS ) A4规格（210X297公釐） I I - I ^^1 -I— i 1^1 H. 士良 -II ϋ« ^^1 /t XV 、-° (請先閲讀背面之注項再填寫本ϊ ) 4 k. 4 Ο 3 9 a7 _______B7 五、發明説明（33 ) 件。若熔點和成型溫度及發泡劑濃度最適於使發泡劑從組 件表面擴散，使表面含有基本上無晶胞之外皮層，即可製 成此等成型組件。此外皮層基本上爲實體聚合物，故以固 體聚合物組件呈現的組件，肉眼可見，發泡聚合物材料內 的歪斜和旋渦，係於表面向模壁逸散的氣泡所造成。利用 溫度控制，從表面除去氣泡，即可避免歪斜和旋渦。在此 等具體例中，製成成型組件的外皮，爲不含晶胞的基本上 實體聚合物材料，厚度爲泡綿材料平均晶胞尺寸的至少3 倍。外皮厚度以材料平均晶胞尺寸的至少約5倍爲佳。按 照本發明可製成無歪斜和旋渦的成型組件之另一理由是， 本發明人等深信超臨界流體發泡劑的擴散率，比典型發泡 劑更快，可在物品表面發生擴散，如上述，形成實體外皮。 經濟部中央標準局貝工消費合作社印1Ϊ 装-- (請先閱讀背面之注^^項再填寫本頁) 如上所述，本發明提供製造成型泡綿聚合物材料，以 具有薄段的微胞孔材料爲佳，尤指可製成長/厚比高的物 品。本發明提供射出成型聚合物材料的長/厚比至少約 50 : 1，其中聚合物的熔體指數約10以下，長/厚比以至 少約75: 1爲佳，至少約100: 1更好，而以至少150: 1 尤佳。熔體指數在約10以下的材料例爲聚苯乙烯。在另一 具體例中所提供物品的長/厚比至少約120: 1，聚合物的 熔體流量低於約40。在此具體例中，長/厚比至少約150 : 1，以至少175: 1爲佳，至少約2 00: 1更好，而以至少 250: 1尤佳。熔體流量低於約40的材料例，爲聚烯烴， 諸如聚乙烯。在本文內，長/厚比的定義爲，一部份聚合 物成型組件從模型內射出位置（噴嘴）延伸離開的延伸長 -33 - 本紙乐尺度適用中國國家標卒（CNS ) Α4規格（2丨ΟΧ^7公釐） Α7 Β7 424〇39 五、發明説明（34 ) 度，與橫跨距離的厚度之比。 本發明特別有利的組合特點是，孔隙容積較高的薄成 型組件。具體而言，本發明提供的泡綿聚合物品，一部份 厚度在約1.2 mm以下，孔隙容積至少30%。在聚合物品另 一具體例中，厚度低於約0.7mm，孔隙容積至少I5%。 在較佳具體例中提供的組件，具有於此限定的厚度， 於此限定的孔隙容’積，其中最大厚度存在於物品的至少約 2 5%，即薄成型組件面積至少約25%的厚度在所迪以下。 在其他具體例中，有更多組件的厚度低於最大限定，例如 5 0〇/〇或 1 00% 〇 本發明之特點爲，不用遮光劑，可製成不透明的物品。 蓋因聚合物泡緙會繞射光，因此基本上爲不透明，具有白 色外觀。本發明之特點爲*微胞孔泡綿比習用泡綿更爲不 透明，更爲均匀◊就構造和配置成含备材料，曝光會解構 的物品，諸如食品容器而言，此爲重大優點。此種材料涉 及可由人員等動物消耗的食物，含有曝光會破壞的維生 素。物品雖然典型上可#和顔料等遮光劑，但加顔料的材 料較不適於回收。本發明提供薄的不透明物品，含約1% 重量以下的輔助遮光劑，以約Q.05%以下爲佳，而以基本 上不含輔助遮光劑更好。本發明中「輔助遮光劑」指限定 顏料、染料、或特別設計來吸收光的其他品種、或滑石、 或可阻礙或繞射光之其他材料。精於此道之士均可測試添 加劑是否爲遮光劑。本發明微胞孔吹氣成型物品具有基本 上實體的白色塑膠品，具有重大的商業訴求。 -34 - 本紙張尺度適用中國國家標芈（CNS ) Λ4规格（210X297公嫠) ϋ I ----- (請先閱讀背面之注意事項再填寫本I) ,-β 經濟部中央標羋扃员工消資合作社印裝 經濟部中央標隼局員工消費合作社印絮 424 039 A7 _ _B7五、發明説明（35) 本發明系統可含有加熱流道（圖上未示）。「流道」 指形成流體途徑，使射出系統的出口端（在若干具體例中 爲成核器出口）與成型室流體相連，和/或將例如需要複 雜成型形狀的成型模腔各部份相連，流道爲技術上所公 知。在若干習知泡綿射出成型系統內，留在流道內的材料 會硬化，並隨成型組件取出。本發明提供的流道，由熱控 制單元定位，諸如供加熱流體流動用的通路。此可用於本 發明某些具體例，其中聚合物品母質材料在流道內宜維持 流體狀態，以免例如硬化材料取出時，在流道內發生材料 內有間隙，而造成壓力降。本發明配置涉及例如壓出機， 以供應聚合物材料和發泡劑的流體單相溶液；成核途徑； 以及途徑下游的流道，在途徑和成型室之間，流道包含在 下游端之閥，在模型充填時可打開，而模型開啓以取出物 品時可關閉。若用熔化聚合物材料，則流道加熱時，流道 內的成核材料可維持流體，適於射入模型內。本發明包含 溫度控制流道的具體例，可用於各種射出成型系統，涉及 各種組件間的任何流道數，而閥可視需要適當位在容許定 期充填模型段，不需從流道除去和丟棄硬化材料，流道可 用成核途徑。 本發明上述和其他具體例之功能和優點，由下述實施 例即可更爲明白。以下實施例旨在表示本發明之益處，但 不表示本發明的完全範圍。下述實施例證明聚合物材料和 超臨界流體發泡劑加料在射出成型的優點，其中形成的物 品表面相當於成型室的內部表面，即並無肉眼可見的歪斜 -35 - (請先閱婧背面之注意事項再填寫本頁) 本紙張尺度適用中囷國家榇率{ CNS ) A4規格（2IOX 297公釐） 424〇39 經濟部中央標準局貞工消费合作社印裝 五、發明説明（36) 和旋渦。 實施例1 二段式射出成型機（Engel公司製品）構成32 : 1 //d，40麵塑化單元，將熔化聚合物加料入40咖1柱塞內。 柱塞和塑化單元利用彈簧加載的球止回閥總成相連。柱塞 可通過典型上氣力驩動關止噴嘴射入模型內。超臨界C02 的射入，是將來自加料段大約16至20放入射出系統內， 後者含有一位於徑向之通口，含有176個直徑0.02吋的孔 口。射出系統含有受作動的控制閥，以計量發泡劑的質量 流量0.2至12磅/小時。 塑練機裝設有二段式螺桿，含有習知第一段進料、阻 礙過渡、和計量段，接著是多旋溝混合段，以供發泡劑勻 化。筒部裝設有加熱/冷卻帶。此設計容許聚合物和氣體 的均質單相溶液勻化和冷卻。 用來運動成型機所有組件的液力系統，可以修飾爲熔 體加壓至少1〇〇〇 Psi，但隨時不超過28,000 psi。此項技 術在塑性射入模型之前，可隨時控制和維持聚合物和氣體 的單相溶液。 實施例2 :射出成型微胞孔聚苯乙烯 使用實施例1所述成型機，成型微胞孔聚苯乙烯板。 取聚苯乙烯粒（N〇vac〇r 2282，llM.I.)加料於塑練機內， 大多數情況下，與發泡劑混合形成單相溶液，再射入注口 在中心的5 X 11 X 〇.〇5〇吋板模型內成核。射出是經由冷 澆口爲之。射出率可變化，以決定加工處理變數與晶胞尺 —3 6 — 本ίΛ張尺度適用中國固"家標率icNS) A4規格(_210X297公釐) " ' ---------Λ------訂-------' 1 (#‘先閱讀背面之注意事項再填艿本艽) 〇3^ A7 B7 五、發明説明（37) 寸和減重間的關係，晶胞尺寸控制在30微米以下，減重高 達2 0%。見表1和表2，相當於圖1〇至圖15。 表1 :射出速度對晶胞尺寸和減重的效應 射出速度 晶胞尺寸 發泡劑 減重 圖 (rt/ sec) (微米） (%) (點） 11 No Cells 11.9 11 10 5 1 00 11.9 11 11 4 10 11.9 19 12 2 10 11.9 1 8 13 1 30 11.9 12 _ 表2 :氣體濃度對晶胞尺寸和減重的效應 熔點：160 °C 模型溫度：66°C 射出速度：4_0"/sec 澆口 ： 0.375,直徑 (請先閲讀背面之注項再填窍本頁) 啤 經濟部中央標準局員工消费合作社印¾ 氣體濃度 晶胞尺寸 減重 發泡劑 圓 (磅/小時） (微米） (% ) (% ) 0.9 20 to 150 21 134 14 1.4 1 to 5 23 21 15 一 37 — 本纸張尺度適用中國國家標準（CNS ) A4规格（210X297公釐） ^24039 A7 B7 五、發明説明（38 ) 實施例3 :射出成型微胞孔聚對苯二甲酸乙二酯 使甩實施例1所述射出成型機，在350 T乾燥4小時 後，在5 X 1 1 X 0.200吋楔腔內成型PET(Eastman， 0.9 5IV)。熔體加工溫度爲550 T，模腔溫度151 °F，用 12%C02射出。熔體壓力保持3000 psi，射出速度爲5.0吋 /秒。 減重30%，‘胞尺寸爲直徑30至40微米。 實施例4 :射出成型聚丙烯至高度減重 使用貧施例1所述时出成型機，將聚丙烯（4熔體流 量（MFR)，共聚物，Montell 7523 > '聚丙嫌（20 MFR，共聚 物，Montell SD-3 76 )和充填滑石的聚丙烯（4 MFR，充填 40%滑石，Montell 65f4-4 )成型爲5 X 1 1 X「可變厚度」 板。使用下列條件完成高度減重。 表3 : "衣-- (請先閱讀背面之注意事項再填湾本筲)Oil A7 B7 5. Description of the invention (30) 110, which is operatively connected to drive Ma Jian at the upstream end (shown on the figure). It reaches the side flow 114 of the inlet 113 and the cylinder port 115 (the port downstream of D), the melt pump 116 and the mixer 11S are fluidly connected to the bunker in sequence. The melt pump U6 can be a gear pump or a small extruder, and is well known in the art. The above-mentioned technology of the present invention can also be used for the common injection of air radon6. In this technology, the parent material of the microporous material is pressed out and nucleated when the model is introduced, as described above, and the gas is injected into the melt stream at the same time. The method is to form an outer layer near the mold wall of the non-nucleated polymer material, and fill the central pores of the common ejected gas, and cell growth occurs as in other specific examples. The mixer 118 contains a blowing agent S-port 120 for introducing a blowing agent. The obstructor 118 may be a static mixer or a cavity transfer mixer, which is known in the art. The configuration of circle 8 is convenient for the male method of the present invention, which can be used to form injection-molded microcellular components with different material densities. As described above, this method involves introducing a pre-polymerized material into the barrel portion 102 of the extruder to pre-polymerize. The material melts and advances the molten polymer material 124 toward the downstream end 106 of the extruder 100. When the molten polymer material 124 advances through the extruder barrel portion 102, a part of the melt pump 116 is used (for example, after the end of the screw 110 is contracted at the base end of the inlet in the side flow 114), the lane advances It enters the side stream 114 through the inlet 113. When the molten polymer material in the side stream II4 advances through the mixer U ?, that is, the bower I enters the blowing agent from the gas injection 0 120, and it is fully mixed in it to form a single unit of the blowing agent and the molten polymer material. The phase non-shuttle solution is advanced from the side stream 114 through the through 115, and enters the downstream end 106 of the extruder barrel portion 102, as shown in FIG. 8, at the same time, the reciprocating screw 110 is completely contracted. In this way, the foaming agent-rich area 122 is generated at the extreme end of the tube, and the oligomer 30_ at the base end of the foaming agent-rich area is _4 size (210X 297) while quoting the paper size (210X 297) ~ I--I--Jn II (.--I ^^ 1 ^^ 1 ----- J ^ i (Please read the notes on the back before filling out this page > Staff Consumption of Zhongrong Standard Bureau, Ministry of Economic Affairs Cooperative printed policy < Η '^ ^, Α7 Β7 V. Description of the invention (31) Foaming agent area. The relative amount of foaming agent-rich material and oligofoaming agent material can be used to increase the foaming agent through the side flow 4 The flow rate is controlled. Then, using the reciprocating action of the screw 110, a non-nucleating foaming agent and a foaming agent-rich single-phase solution of the molten polymer 122, followed by a portion of the oligofoaming agent melted polymer material 124, shot Into the molding chamber 108. In another specific example, the present invention provides a rapid and effective introduction of a foaming agent into the fluid polymer matrix in the above-mentioned injection molding apparatus, and an extrusion apparatus substantially according to any configuration. This specific The example includes an extruder screw as shown in FIG. 9 on the surface of the screw that can be located in the extruder barrel (not shown). There are orifices that can be in fluid communication with the foaming agent source. The orifices form the end of a cavity opening that passes through a location that can be connected to the foaming agent source, such as the base end of the screw. In a preferred hip example, the cavity The mouth passes along the axis of rotation of the screw, passes longitudinally from the base end of the screw, and connects with one or more orifices on the surface of the stern shaft. One or more orifices should be located on the outer surface of the screw groove, slightly from the outer surface of the screw groove The depression, this positioning allows the blowing agent to introduce the blowing agent in a manner of shearing / diffusing the inner surface of the barrel. One or more orifices can be located in the area between the spiral grooves, or a combination of orifices can be used in various positions. Referring to Fig. 9, the extruder screw 130 includes a spiral groove 132 and a cavity opening 134 communicating with the orifice on the outer surface 138 of the spiral groove 132. A portion 140 of the cavity opening 134 passes from the cavity opening on the central axis of the screw to the orifice. One of the advantages of introducing foaming agent through the inner orifice of the screw is that in the configuration using a reciprocating actuating screw, it can provide the uniformity of the foaming agent in the polymer matrix. By injection molding, it can be made into articles, thickness or fracture. Face size below 0.100 inches, or no more than about 0.0 75 inches, preferably no more than about 0.050 inches, and -31-This paper size applies to the Chinese national standard (CNS > Λ4 size (210X297 mm) --------- Λ ---- --Order ------ Λ: (锖 Please read the notes on the back before filling in this!) Printed by the Central Bureau of Standards, Shellfish Consumer Cooperative, 1 ° 4 039 A7 '_B7_ V. Description of the invention (32 ) Is not more than about 0.025 inches, and especially not more than about 0.010 inches, because the single-phase solution of the polymer matrix and the supercritical fluid has a very low viscosity, which can be injected into the wedge in this way to form an article therein. . For example, a single-phase solution of a supercritical fluid and a polymer matrix can be introduced into a model, thereby making a conventional foamed or microcellular article. The low viscosity of the fluid injected into the mold can make the above injection molding cycle time less than 10 minutes, preferably less than 5 minutes, more preferably less than 1 minute, more preferably within 30 seconds, particularly good within 20 seconds, and further better within 10 seconds. , Best in 5 seconds. The present invention also provides a molded cell-shaped polymer product in the shape of a molding chamber, including at least a part of which has a cross-sectional area of not more than about 0.125 inches, or in other specific examples, the smaller size mentioned above, and the pore volume of the item is at least about It is preferably at least about 10%, more preferably at least about 15%, more preferably at least about 20%, particularly preferably at least about 25%, and most preferably at least about 30%. In other specific cases, the pore volume of the item is at least about 50%. This major improvement provides a technical challenge to provide very small items, which can reduce the weight of polymer materials through the pore volume of the foam. The article of the present invention includes the above-mentioned pore volume in a section having a cross-sectional area of not more than about 0.125 inches, or other smaller sizes mentioned above. The method of the present invention can also produce injection-molded components with a thickness greater than 0.125 inches, such as between 0.200 inches and about 0.5 00 inches, with a further reduction in weight (as described above) and smaller unit cells. The present invention also provides a system and method for manufacturing thick and thin foam molding components and surface restoration components. These components have at least a portion of the surface free of visible skew and vortices. Figures 16 to 18, in conjunction with Example 9 (described below), prove that a polymer group with no visible distortion or vortex on the surface is formed -32-This paper size is applicable to China National Standard (CNS) A4 (210X297 mm) II-I ^^ 1 -I— i 1 ^ 1 H. Shiliang-II ϋ «^^ 1 / t XV,-° (Please read the notes on the back before filling in this ϊ) 4 k. 4 Ο 3 9 a7 _______B7 V. Description of Invention (33). If the melting point, molding temperature, and blowing agent concentration are the most suitable for diffusing the blowing agent from the surface of the component, and the surface contains a substantially cell-free outer skin layer, such molded components can be produced. In addition, the skin layer is basically a solid polymer, so the components presented as solid polymer components can be seen by the naked eye. The skew and vortices in the foamed polymer material are caused by the bubbles that escape from the surface to the mold wall. With temperature control, air bubbles are removed from the surface to avoid skews and vortices. In these specific examples, the skin of the molded component is a substantially solid polymer material that does not contain a unit cell, and has a thickness that is at least three times the average unit cell size of the foam material. The skin thickness is preferably at least about 5 times the average cell size of the material. Another reason why a molded component without skew and vortex can be made according to the present invention is that the inventors are convinced that the diffusion rate of a supercritical fluid foaming agent is faster than a typical foaming agent and can diffuse on the surface of an article, such as As described above, a solid skin is formed. Printed by the Central Laboratories of the Ministry of Economic Affairs, Shellfish Consumer Cooperatives-(Please read the note ^^ on the back, and then fill out this page) As mentioned above, the present invention provides the manufacturing of foam polymer materials with thin sections. Cell materials are preferred, especially those that can be made into articles with a high length / thickness ratio. The invention provides an injection molded polymer material having a length / thickness ratio of at least about 50: 1, wherein the polymer has a melt index of about 10 or less, and the length / thickness ratio is preferably at least about 75: 1, and more preferably at least about 100: 1 And at least 150: 1 is preferred. An example of a material having a melt index of about 10 or less is polystyrene. In another embodiment, the article has a length / thickness ratio of at least about 120: 1, and the polymer has a melt flow rate of less than about 40. In this specific example, the length / thickness ratio is at least about 150: 1, preferably at least 175: 1, more preferably at least about 200: 1, and even more preferably at least 250: 1. Examples of materials with a melt flow below about 40 are polyolefins, such as polyethylene. In this paper, the length / thickness ratio is defined as the extension length of a part of the polymer molding component extending from the injection position (nozzle) in the model. -33-The paper scale is applicable to the Chinese National Standard (CNS) Α4 specification (2丨 〇Χ ^ 7mm) Α7 Β7 424〇39 5. Description of the invention (34) Degree, the ratio to the thickness across the distance. A particularly advantageous combination feature of the present invention is a thin molded component with a high pore volume. Specifically, the foam polymer product provided by the present invention has a thickness of at least about 1.2 mm and a pore volume of at least 30%. In another specific example of the polymer product, the thickness is less than about 0.7 mm and the pore volume is at least 15%. A component provided in a preferred embodiment has a thickness defined herein and a pore volume defined therein, wherein the maximum thickness is at least about 25% of the article, that is, a thickness of a thin molded component area of at least about 25% Below Sody. In other specific examples, there are more components whose thickness is below the maximum limit, such as 500/00 or 100%. The present invention is characterized in that it can be made into an opaque article without using a light-shielding agent. Gein polymer foams diffract light and are therefore essentially opaque and have a white appearance. The characteristics of the present invention are: * Microcellular foam is more opaque and more uniform than conventional foams. It is a major advantage in terms of construction and configuration of materials containing materials that are deconstructed by exposure, such as food containers. This material involves food that can be consumed by animals such as people and contains vitamins that can be destroyed by exposure. Although items are typically sunscreens such as # and pigments, pigmented materials are less suitable for recycling. The present invention provides a thin opaque article containing about 1% by weight of an auxiliary sunscreen agent, preferably about Q.05% or less, and more preferably substantially free of an auxiliary sunscreen agent. In the present invention, the "auxiliary opacifier" refers to pigments, dyes, or other materials specifically designed to absorb light, or talc, or other materials that can block or diffract light. Those skilled in the art can test whether an additive is a sunscreen. The microporous air-blowing molded article of the present invention has a substantially solid white plastic product and has significant commercial demands. -34-The size of this paper is applicable to China National Standard (CNS) Λ4 specification (210X297 cm) ϋ I ----- (Please read the notes on the back before filling in this I), -β Central Standard of the Ministry of Economic Affairs 芈 扃Employees' Consumer Cooperatives Printing and Printing Cooperative Prints 424 039 A7 _ _B7 of the Central Bureau of Standards of the Ministry of Economic Affairs V. Invention Description (35) The system of the present invention may include a heating runner (not shown in the figure). "Flow channel" means a fluid path that fluidly connects the exit end of the injection system (the nucleator outlet in some specific examples) with the molding chamber, and / or connects parts of the molding cavity that require complex molding shapes, for example Flow channels are well known in the art. In several conventional foam injection molding systems, the material remaining in the runner will harden and be removed with the molding assembly. The flow path provided by the present invention is positioned by a thermal control unit, such as a path for the heating fluid to flow. This can be used in some specific examples of the present invention, in which the polymer matrix material should be maintained in a fluid state in the flow path, so as to avoid a gap in the material in the flow path when the hardened material is taken out, for example, causing a pressure drop. The configuration of the present invention relates to, for example, an extruder to supply a fluid single-phase solution of a polymer material and a foaming agent; a nucleation pathway; and a flow path downstream of the path, between the path and the molding chamber, the flow path is included at the downstream end. The valve can be opened when the model is filled, and it can be closed when the model is opened to remove items. If a molten polymer material is used, the nucleating material in the flow channel can maintain the fluid when the flow channel is heated, which is suitable for shooting into the model. The present invention includes specific examples of temperature control runners, which can be used in various injection molding systems, involving any number of runners between various components, and the valve can be appropriately positioned to allow regular filling of model sections as required, without removing and discarding hardening from the runners. Materials, channels can be nucleated. The functions and advantages of the above and other specific examples of the present invention will be more apparent from the following examples. The following examples are intended to illustrate the benefits of the invention, but do not represent the full scope of the invention. The following examples demonstrate the advantages of injection molding of polymer materials and supercritical fluid blowing agents. The surface of the formed article is equivalent to the inner surface of the molding chamber, that is, there is no visible distortion -35-(Please read Jing Note on the back, please fill out this page again) This paper size is applicable to the Central China National Standard {CNS) A4 specification (2IOX 297 mm) 424〇39 Printed by Zhengong Consumer Cooperative, Central Bureau of Standards, Ministry of Economic Affairs 5. Description of invention (36) And vortex. Example 1 A two-stage injection molding machine (manufactured by Engel) constitutes a 32: 1 // d, 40-side plasticizing unit, and feeds a molten polymer into a 40-cab 1-plunger. The plunger and the plasticizing unit are connected by a spring-loaded ball check valve assembly. The plunger can be turned into the model by closing the nozzle with a typical upward force. The injection of supercritical C02 is about 16 to 20 from the feeding section into the system, the latter contains a radial port, containing 176 holes with a diameter of 0.02 inches. The injection system contains an actuated control valve to meter the mass flow rate of the blowing agent from 0.2 to 12 pounds per hour. The plastic training machine is equipped with a two-stage screw, which contains the conventional first-stage feeding, hindering transition, and metering section, followed by a multi-spindle mixing section for the foaming agent homogenization. The tube is equipped with a heating / cooling belt. This design allows homogeneous single-phase solutions of polymers and gases to homogenize and cool. The hydraulic system used to move all components of the molding machine can be modified to melt pressurize at least 1,000 Psi, but not exceed 28,000 psi at any time. This technology can control and maintain a single-phase solution of polymer and gas at any time before plastic injection into the model. Example 2: Injection molding of microcellular polystyrene Using the molding machine described in Example 1, a microcellular polystyrene plate was formed. Take polystyrene granules (Novavac 2282, llM.I.) and add them to the plastic scouring machine. In most cases, they are mixed with foaming agent to form a single-phase solution, and then injected into the center of the injection nozzle at 5 X Nucleation in a 11 X 0.05-inch plate model. The injection is done via a cold gate. The injection rate can be changed to determine the processing variables and cell size — 3 6 — This 张 Λ scale is applicable to China solid " house standard rate icNS) A4 specifications (_210X297 mm) " '-------- -Λ ------ Order ------- '1 (#' Read the notes on the back before filling in this book) 〇3 ^ A7 B7 V. Description of the invention (37) Inch and weight reduction The relationship is that the cell size is controlled below 30 microns and the weight loss is as high as 20%. See Tables 1 and 2, which correspond to Figures 10 to 15. Table 1: Effect of injection speed on cell size and weight reduction Injection speed Cell size foaming agent weight loss graph (rt / sec) (microns) (%) (points) 11 No Cells 11.9 11 10 5 1 00 11.9 11 11 4 10 11.9 19 12 2 10 11.9 1 8 13 1 30 11.9 12 _ Table 2: Effect of gas concentration on cell size and weight loss Melting point: 160 ° C Model temperature: 66 ° C Injection speed: 4_0 " / sec pouring Mouth: 0.375, diameter (please read the note on the back before filling this page) Printed by the Consumer Cooperative of the Central Standards Bureau of the Ministry of Beer Economy Gas concentration Cell size Weight reduction Foaming agent circle (lb / hr) (microns) ( %) (%) 0.9 20 to 150 21 134 14 1.4 1 to 5 23 21 15 I 37 — This paper size applies to China National Standard (CNS) A4 (210X297 mm) ^ 24039 A7 B7 V. Description of the invention (38 ) Example 3: Injection molding of microcellular polyethylene terephthalate. The injection molding machine described in Example 1 was shaken. After drying at 350 T for 4 hours, PET was formed in a 5 X 1 1 X 0.200 inch wedge cavity. (Eastman, 0.9 5IV). The melt processing temperature is 550 T, the cavity temperature is 151 ° F, and 12% C02 is injected. The melt pressure was maintained at 3000 psi and the injection speed was 5.0 inches / second. 30% weight loss, ' cell size is 30 to 40 microns in diameter. Example 4: Injection molding of polypropylene to a high degree of weight reduction Using the time-out molding machine described in Example 1, polypropylene (4 melt flow rate (MFR), copolymer, Montell 7523 > 'polypropylene (20 MFR, Copolymer, Montell SD-3 76) and talc-filled polypropylene (4 MFR, filled with 40% talc, Montell 65f4-4) were formed into 5 X 1 1 X "variable thickness" boards. Use the following conditions to achieve high weight reduction Table 3: " Clothing-(Please read the notes on the back before filling in this book)
、1T 經濟部中央標革局貝工消費合作社印裝 材料 組件厚度 (吋） 減重 (%) 熔點 (°F) 氣體百分 比(％ ) 模型溫 度fF) 7523 0.05 0 14.6 310 12.5 1 00 SD-376 0.100 30 320 12 150 65f4-4 0.100 15 330 15 200 -38 - 本紙張尺度適用中國囡家標牟（CNS ) A4規格（210X29?公釐） i B7 五、發明説明（39) 實施例5 ：射出成型密摩減少70%以上的聚苯乙燔組 使用實施例1所述射出成型機，在類似實施例2條件 下成型聚苯乙烯，但模型溫度在〗50 T至250 eF，而冷卻 時間3.2至22.8秒，可見密度大減。 表4 : 模型溫度 熔點 冷卻時間 實體組件 MuCell 密度 (°F) (°F) (秒） 密度 密度 減少 1 50 °F 250 3.2 0.88g/cc 0.37g/cc 58% 250 °F 250 22.8 0.8 S g/cc 0.16g/cc 8 2% 實施例6 :凝囲聚合物/超臨界流體組件之成型後成核 和晶胞成長 經濟部中央標率局負工消費合作社印裝 (讀先閲讀背面之注意事項再填寫本頁) 使用實施例1所述射出成型機，成型聚苯丙烯（No vacor 2282, 11 M.I.)，取聚苯乙烯粒加料於塑煉機內，按實施例 2所述射出。射入模型內的材料，在模型內冷卻到聚苯乙 烯凝固點以下的溫度。打開模型，組件以非發泡狀態取出， 組件再經外部熱源（甘油浴），因此成核，且晶胞成長， 得微胞孔物品。 實施例7 '·聚合物成型中證明粘度降低 此實施例證明使疳超臨界流體發泡劑的優點，在於降 低聚合物材料粘度以供在較低熔點引入模型內，並實現微 胞孔發泡的優點。 -39 - 本紙張尺度適用中国國家標準（CNS ) A4規格（21〇X297公釐） A7 039 _______ _B7 五、發明説明（4〇 ) (請先閲讀背面之注意事項再填舄本頁) 使用成型機，按實施例2所述成型聚苯乙烯，下述除 外。模型尺寸爲5X 11X 0.020吋。在實施例2同樣條件 下，以0%發泡劑射出聚苯乙烯，可得最大流動長度爲1吋， 造成長/厚比50，以〗5%超臨界二氧化碳發泡劑進行同樣 實驗，最大流動長度至少5.5吋，長/厚比270。 實施例8 ：在結晶熔點以下射出成型聚丙燔 使用實施例1所述射出成型機，在5X 11X 0.050模 型內成型聚丙烯（4 MFR,共聚物，Montell 7523 ) ，0%發 泡劑，充填該模型所需典型熔點大約43 0卞，以15%超臨 界二氧化碳發泡劑，可將通常爲325 °F的結晶熔點以下之 聚丙烯射出。實際熔點爲310卞。 經濟部中央標率局負工消资合作社印製 實施例9 ：證明微胞孔發泡品具有接近完美的表面 使用實施例2所述成型機，成型聚苯乙烯（Novacor 22 82, 11 Μ. I.)。將聚苯乙烯粒加料於塑煉機內，與（：02發 泡劑混合，形成超臨界〇02和聚苯乙烯的單相溶液，再藉 射入5 X 1 1 X 0.050吋板模型內成核。處理條件最適化以 鑑定適當條件獲得高度成核密度，以及看似實體外皮。提 供圓16至圖18之顯微照片，證明此技術之效果，圓16係 供比較用，表示實體非發泡聚苯乙烯，使用標準、非發泡 射出成型技術加以射出成型。 可見理想條件涉及熔點、模型溫度、和發泡劑濃度的 平衡。熔點必須高到足夠使熔體內的發泡劑擴散相當快， 而模型溫度必須高到足夠使發泡劑在表面以重大程度擴散 脫出熔體外，但模型溫度必須低到足夠避免產品翹曲和其 —4 0 _ 本紙張尺度適用中國國家標率（CNS ) Α4規格（210Χ297公釐） 經滴部中央標準局負工消費合作社印聚 424039 at _B7__ 五、發明说明Ui ) 他變形。發泡劑擴散率視熔點、發泡劑濃度、壓力差和熔 點而定。發泡劑從培體的擴散率，必須比聚合物表面冷卻 和凝固的速率爲大。 表5 : 表面特性 圖 熔點 (eF) 模型溫 度) 射出速度 (I.P.S.) 發泡劑 (%) 實體外觀 17 400 175 5.0 11.50 條紋 350 80 3.0 5.1 5 氣泡 350 80 4.4 23% 表面上曲折小泡 410 180 2.0 11.50 實體但裂開 385 160 3.5 9.75 旋渦 18 400 87° 10 13.25% 凡精於此道之士均知在此所列全部參變數均舉例用， 而實際參變數視本發明方法和裝置特定用途而定。所以， 須知前述具體例僅爲舉例之甩，而在所附申請專利範圍及 其等效範圍內，本發明也可以特定說明以外的方式實施。 —41 - 本紙張尺度適用中囷國家標準（CNS } A4規格（2丨0X29?公釐〉 -^------r ------^ (請先閱讀背面之注意事項再填苑本頁} A7 B7 五、發明說明（41*】） 元件符號說明 經濟郤智慧財產局具X消費合作社印製 30 成型系統 78 累積器 31,100 射出成型系統 79,91 累稹器進口，第二進口 32,102 筒部 80 活動壁 34,104 上游第一端 81 外殼 36,106 下游第二端 82 溫度控制元件 37,108 成型室 83 柱塞 38,110,130 螺桿 84 模腔 40 驅動馬達 85,98 球止回閥 42 溫度控制單元 86 壓力控制器 44 標準漏斗 88 無發泡劑管道 46 孔口 90 壓出口，第一出口 48,106 下游端 91 第一進口 50 ffi(溫度調節和控制 94,104,124 聚合物材料，寡發 區、輔助混合匾、 泡劑 辅助泵送區） 100 壓出機 51 壓出機出口 101,122 富發泡劑材料 53 管道 103 加熱單元 54 通口，發泡劑射入口 113 進口 56 發泡劑源 114 側流 58 加壓和計量裝置 115 通口 60 螺桿混合段 116 熔髖泵 61 末梢通口 118 混合器 62 螺桿位置 120 發泡劑射出口 64,99,154,155, 122 非成核發泡劑和 157,159,161 機械式關止閥 熔化聚合物 66 成核器 132 旋溝 67 降壓成核途徑 134 腔口 69 進口端 138 外表面 70 釋出端、孔口 140 腔口 134的部位 74 活動壁成行室 41-1 本纸張尺度適用中因囡家標準（CNS)A4規格（210 X 297公釐） (請先閱讀背面之注意事項再填寫本頁〕 裝 ----* 訂_-·--·-----線 —、 1T Thickness (in) of printed materials and components of the Central Standardization Bureau of the Ministry of Economic Affairs of Shellfish Consumer Cooperatives Weight loss (%) Melting point (° F) Gas percentage (%) Model temperature fF) 7523 0.05 0 14.6 310 12.5 1 00 SD-376 0.100 30 320 12 150 65f4-4 0.100 15 330 15 200 -38-The size of this paper is applicable to the Chinese family standard (CNS) A4 specification (210X29? Mm) i B7 V. Description of the invention (39) Example 5: Injection The polyphenylenesulfonate group whose molding density is reduced by more than 70% uses the injection molding machine described in Example 1 to mold polystyrene under similar conditions to Example 2, but the mold temperature is between 50 T and 250 eF, and the cooling time is 3.2 To 22.8 seconds, a significant decrease in density can be seen. Table 4: Model temperature, melting point, cooling time, solid cell MuCell Density (° F) (° F) (seconds) Density and density decrease 1 50 ° F 250 3.2 0.88g / cc 0.37g / cc 58% 250 ° F 250 22.8 0.8 S g / cc 0.16g / cc 8 2% Example 6: Nucleation and cell growth after formation of condensed polymer / supercritical fluid components Printed by the Consumers' Cooperative of the Central Standards Bureau of the Ministry of Economic Affairs (read the note on the back first) (Please fill in this page again for details.) Using the injection molding machine described in Example 1, polystyrene (No vacor 2282, 11 MI) was molded. Polystyrene pellets were added to the plasticizer and injected as described in Example 2. The material injected into the mold is cooled in the mold to a temperature below the freezing point of polystyrene. Open the model, the component is taken out in a non-foamed state, and the component is passed through an external heat source (glycerin bath), so it nucleates, and the unit cell grows to obtain a microcellular object. Example 7 '. Demonstration of reduced viscosity in polymer molding. This example demonstrates the advantage of making supercritical fluid foaming agents to reduce the viscosity of polymer materials for introduction into the model at a lower melting point and achieve microcellular foaming. The advantages. -39-This paper size applies to Chinese National Standard (CNS) A4 specification (21 × 297 mm) A7 039 _______ _B7 V. Description of the invention (4〇) (Please read the precautions on the back before filling this page) Use molding Machine, molding polystyrene as described in Example 2, except the following. The model size is 5X 11X 0.020 inches. Under the same conditions as in Example 2, injecting polystyrene with 0% blowing agent, the maximum flow length was 1 inch, resulting in a length / thickness ratio of 50. The same experiment was performed with 5% supercritical carbon dioxide blowing agent. The flow length is at least 5.5 inches and the length / thickness ratio is 270. Example 8: Polypropylene is injection molded below the crystalline melting point. Using the injection molding machine described in Example 1, polypropylene (4 MFR, copolymer, Montell 7523) is molded in a 5X 11X 0.050 model with 0% foaming agent. The model requires a typical melting point of about 43 ° F. With 15% supercritical carbon dioxide blowing agent, polypropylene with a crystalline melting point of usually 325 ° F or less can be injected. The actual melting point is 310 ° F. Printed in Example 9 by the Central Standards Bureau, Ministry of Economic Affairs, Consumer and Consumer Cooperatives: Prove that the microcellular foamed product has a nearly perfect surface. Using the molding machine described in Example 2, polystyrene (Novacor 22 82, 11 Μ. I.). Add polystyrene pellets into the plastic mixer, mix with (: 02 foaming agent to form a single-phase solution of supercritical 〇02 and polystyrene, and then inject it into a 5 X 1 1 X 0.050 inch plate model to form Nucleus. The processing conditions were optimized to identify the appropriate conditions to obtain a high nucleation density and look like a solid skin. Micrographs of circles 16 to 18 are provided to demonstrate the effectiveness of this technique. Circle 16 is for comparison purposes, indicating that the entity is non-developing. Expanded polystyrene is injection molded using standard, non-foaming injection molding techniques. It can be seen that the ideal conditions involve a balance of melting point, model temperature, and foaming agent concentration. The melting point must be high enough to allow the foaming agent in the melt to diffuse relatively quickly. The model temperature must be high enough to make the foaming agent diffuse out of the melt on the surface, but the model temperature must be low enough to avoid product warpage and its — 4 0 _ This paper scale is applicable to China ’s national standard ( CNS) Α4 specification (210 × 297 mm) Printed by the Central Standards Bureau of the Ministry of Work and Consumer Cooperatives, Printed Poly 424039 at _B7__ 5. Description of the invention Ui) He deformed. The foaming agent diffusivity depends on the melting point, foaming agent concentration, pressure difference, and melting point. The diffusion rate of the blowing agent from the culture body must be greater than the rate of cooling and solidification of the polymer surface. Table 5: Surface characteristics map Melting point (eF) Model temperature) Injection speed (IPS) Foaming agent (%) Solid appearance 17 400 175 5.0 11.50 Stripe 350 80 3.0 5.1 5 Bubbles 350 80 4.4 23% Zigzag small bubbles on the surface 410 180 2.0 11.50 solid but cracked 385 160 3.5 9.75 vortex 18 400 87 ° 10 13.25% Anyone skilled in this way knows that all the parameters listed here are examples, and the actual parameters depend on the specific use of the method and device of the present invention It depends. Therefore, it should be noted that the foregoing specific examples are merely examples, and within the scope of the attached patent application and its equivalent scope, the present invention may also be implemented in other ways than specifically described. —41-This paper's dimensions apply to the Chinese National Standard (CNS) A4 (2 丨 0X29? Mm)-^ ------ r ------ ^ (Please read the precautions on the back before filling Garden page} A7 B7 V. Description of the invention (41 *)) Component symbol description Economic but intellectual property bureau with X consumer cooperative printing 30 Molding system 78 Accumulator 31,100 Injection molding system 79,91 Accumulator import, second import 32, 102 tube 80 movable wall 34, 104 upstream first end 81 housing 36, 106 downstream second end 82 temperature control element 37, 108 molding chamber 83 plunger 38, 110, 130 screw 84 cavity 40 drive motor 85, 98 ball check valve 42 temperature control unit 86 pressure control 44 standard funnel 88 non-foaming agent pipeline 46 orifice 90 pressure outlet, first outlet 48,106 downstream end 91 first inlet 50 ffi (temperature adjustment and control 94,104,124 polymer material, oligogeneous zone, auxiliary mixing plaque, foam agent auxiliary Pumping zone) 100 Extruder 51 Extruder outlet 101, 122 Foaming agent-rich material 53 Pipe 103 Heating unit 54 port, blowing agent injection inlet 113 inlet 56 blowing agent source 114 side flow 58 plus And metering device 115 port 60 screw mixing section 116 melting hip pump 61 tip port 118 mixer 62 screw position 120 blowing agent injection port 64,99,154,155, 122 non-nucleating blowing agent and 157,159,161 mechanical shut-off valve to melt polymer 66 Nucleator 132 Rotary groove 67 Decompression nucleation pathway 134 Cavity opening 69 Inlet end 138 Outer surface 70 Release end, orifice 140 Portion of 134 74 Moving wall forming chamber 41-1 Family Standard (CNS) A4 Specification (210 X 297 mm) (Please read the precautions on the back before filling out this page) Packing ---- * Order _- ·-· ----- Line —