WO2009122735A1 - 発泡ブロー成形体及びその製造方法 - Google Patents
発泡ブロー成形体及びその製造方法 Download PDFInfo
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- WO2009122735A1 WO2009122735A1 PCT/JP2009/001519 JP2009001519W WO2009122735A1 WO 2009122735 A1 WO2009122735 A1 WO 2009122735A1 JP 2009001519 W JP2009001519 W JP 2009001519W WO 2009122735 A1 WO2009122735 A1 WO 2009122735A1
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- Prior art keywords
- molded article
- blow molded
- bubble
- cell
- wall portion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/3442—Mixing, kneading or conveying the foamable material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/3469—Cell or pore nucleation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/35—Component parts; Details or accessories
- B29C44/352—Means for giving the foam different characteristics in different directions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/0005—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor characterised by the material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/06905—Using combined techniques for making the preform
- B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
- B60H1/00557—Details of ducts or cables
- B60H1/00564—Details of ducts or cables of air ducts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/48—Moulds
- B29C49/4802—Moulds with means for locally compressing part(s) of the parison in the main blowing cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
- B29K2105/046—Condition, form or state of moulded material or of the material to be shaped cellular or porous with closed cells
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2022/00—Hollow articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/004—Bent tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
- Y10T428/1376—Foam or porous material containing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
Definitions
- the present invention relates to a foamed blow molded article and a method for producing the same.
- Foam blow molding is performed by extruding a thermoplastic resin to which a foaming agent has been added as a parison into the atmosphere and then sandwiching it with a split mold (see, for example, Patent Document 1).
- a foamed blow molded product obtained by such a method a product mainly composed of a polypropylene resin having predetermined physical properties is known (for example, see Patent Document 2).
- the present invention has been made in view of the above circumstances, and an object thereof is to provide a foamed blow molded article having a uniform cell size cell, lightweight, and having high surface smoothness, and a method for producing the same. To do.
- the inventors of the present invention have intensively studied to solve the above-mentioned problems. As a result, they have found that the above-described problems can be solved by using the following configuration, and have completed the present invention.
- the present invention provides (1) a foamed blow molded article comprising a wall portion formed by blow molding a thermoplastic resin mixed with a foaming agent, wherein the wall portion includes a plurality of closed cells.
- the structure has a foaming ratio of the wall portion of 2.0 times or more, the center line average roughness Ra of the outer surface of the wall portion is less than 9.0 ⁇ m, and the bubbles of the bubble cells in the thickness direction of the wall portion It exists in the foam blow molded object whose standard deviation of a diameter is less than 40 micrometers.
- the present invention resides in (2) the foamed blow molded article according to the above (1), wherein the thermoplastic resin is a polyolefin resin.
- the present invention resides in (3) the foamed blow molded article according to the above (2), wherein the polyolefin resin is a propylene homopolymer having a long-chain branched structure.
- the present invention resides in (4) the foamed blow molded article according to any one of (1) to (3) above, wherein the average cell diameter of the cell in the thickness direction of the wall is less than 300 ⁇ m.
- the average bubble diameter of the bubble cells in the thickness direction of the wall portion is less than 100 ⁇ m, and the standard deviation of the bubble diameters of the bubble cells in the thickness direction of the wall portion is less than 30 ⁇ m. It exists in the foaming blow-molding object as described in any one of (3).
- the present invention resides in (6) the foamed blow molded article according to any one of the above (1) to (5), which is an air conditioning duct for vehicles.
- the present invention relates to (7) the method for producing a foamed blow molded article according to any one of the above (1) to (6), wherein a thermoplastic resin is added to a foaming agent and mixed with an extruder.
- Mixing process to make mixed resin storing process to store mixed resin in cylindrical space between mandrel and die outer cylinder, extrusion process to extrude parison from die slit using ring-shaped piston, and parison divided into metal
- the present invention resides in (8) the method for producing a foamed blow molded article according to the above (7), wherein the thermoplastic resin is a polyolefin resin and the foaming agent is in a supercritical state.
- the present invention resides in (9) the method for producing a blow-molded foam according to (7) or (8), wherein the extrusion rate of the parison is 700 kg / hour or more in the extrusion step.
- the foamed blow molded article of the present invention has a closed cell structure including a plurality of bubble cells and a wall portion with a foaming ratio within a predetermined range, thereby reducing the weight, and in the thickness direction of the wall portion.
- a predetermined range By setting the standard deviation of the bubble diameter of the bubble cell within a predetermined range, it is possible to have a bubble cell having a uniform size, and the center line average roughness Ra of the outer surface of the wall portion is set to a predetermined value. By setting it as this range, it can be set as the thing whose surface smoothness is high. For this reason, when the said foaming blow molded object is used for the air conditioning duct for vehicles, for example, the frictional resistance with respect to distribution
- the foamed blow molded article is excellent in flexibility when the thermoplastic resin is made of a polyolefin resin, so that impact resistance is improved.
- the polyolefin resin is more preferably a propylene homopolymer having a long chain branched structure. In this case, it becomes easy to foam and a bubble cell is made more uniform.
- the surface of the foamed blow molded article is more excellent in surface smoothness.
- the average cell diameter is more preferably less than 100 ⁇ m.
- the size of the bubble cell is homogenized by storing the mixed resin at a predetermined position, and extruded at a predetermined extrusion speed using a ring-shaped piston.
- blow molding is performed in a state where the size of the bubble cell is maintained.
- the foam blow molding which has a cell with a uniform magnitude
- a bubble cell is refined
- the size of the bubble cells is further homogenized when the extrusion speed of the parison in the extrusion process is 700 kg / hour or more.
- FIG. 1 is a perspective view showing a first embodiment of a blow-molded foam according to the present invention.
- FIG. 2 is a flowchart of the method for producing a foamed blow molded article according to the present invention.
- FIG. 3 is a partial cross-sectional view showing an extrusion head used in the method for producing a blow-molded foam according to the present invention.
- FIG. 4 is a cross-sectional view showing a blow molding aspect in the method for producing a foamed blow molded article according to the present invention.
- FIG. 7 is an enlarged photograph of the wall surface cross section of the sample in Example 1 using a CCD camera.
- FIG. 8 is an enlarged photograph of the wall surface cross section of the sample in Comparative Example 1 using a CCD camera.
- FIG. 9 is a partial cross-sectional view showing a conventional extrusion head.
- FIG. 1 is a perspective view showing a first embodiment of a blow-molded foam according to the present invention.
- a foamed blow molded article (hereinafter also referred to as “air conditioning duct”) 1 is formed from a wall portion formed by blow molding a thermoplastic resin mixed with a foaming agent. It comprises a main body part 11, an air inflow part 13 provided at one end of the main body part 11, and an air outflow part 12 provided at the other end of the main body part 11.
- the blow molding will be described later.
- the air outflow part 12 cuts off the part closed by the post-process after blow molding, and is made into the open state.
- the air conditioning duct 1 has a hollow structure with a rectangular cross section. That is, the cross section of the main body 11 has a hollow structure surrounded by the wall. Therefore, the air-conditioning duct 1 can distribute the air-conditioned air through the hollow portion.
- the main body 11 is smoothly curved, and the air-conditioning air that has flowed in from the air inflow portion 13 is sent from the air outflow portion 12 that faces the L-shaped direction with respect to the direction in which the air-conditioning air has flowed. It performs the function of draining.
- the air inflow portion 13 is connected to an air conditioner unit, and air conditioned air supplied from the air conditioner unit is circulated through the hollow portion and discharged from the air outflow portion 12 disposed at a desired position. be able to.
- the wall portion has a closed cell structure including a plurality of bubble cells.
- the closed cell structure means a structure having a plurality of bubble cells, and at least a closed cell ratio of 70% or more.
- the wall portion has a closed cell structure, so that the surface smoothness is excellent, and the appearance, particularly in the air-conditioning duct, has the advantages of improving the blowing efficiency and reducing the occurrence of condensation.
- the bubble cell preferably has an average bubble diameter in the thickness direction of the wall portion of less than 300 ⁇ m, and more preferably less than 100 ⁇ m.
- the average bubble diameter means an average value of the maximum diameters of the respective bubbles in the thickness direction of the wall portion.
- the average wall thickness is preferably 3.5 mm or less.
- the average thickness exceeds 3.5 mm, the air flow path is reduced and the air blowing efficiency tends to be inferior as compared with the case where the average thickness is within the above range.
- the center line average roughness Ra of the outer surface of the wall portion is less than 9.0 ⁇ m, and preferably less than 6.0 ⁇ m.
- the center line average roughness Ra is a value measured according to JIS B0601.
- the standard deviation of the bubble diameter of the bubble cell in the thickness direction of the wall portion is less than 40 ⁇ m.
- the standard deviation of the bubble diameter indicates the homogeneity of the bubble cell diameter, and the smaller the standard deviation, the more uniform the cell diameter. If the standard deviation of the bubble diameter exceeds 40 ⁇ m, the variation in the bubble cell diameter tends to be large and the surface smoothness and appearance tend to be inferior.
- the standard deviation of the bubble diameter is more preferably less than 30 ⁇ m.
- the air conditioning duct 1 has a wall foaming ratio of 2.0 times or more.
- the expansion ratio is a value obtained by dividing the density of the thermoplastic resin used for foam blow molding by the apparent density of the wall surface of the foam blow molded article. If the expansion ratio is less than 2.0, a lightweight foamed blow molded product cannot be obtained.
- a foamed blow molded article (air conditioning duct) 1 is obtained by blow molding a thermoplastic resin mixed with a foaming agent.
- thermoplastic resins include polyolefin resins such as polyethylene resins and polypropylene resins. Since the polyolefin resin is excellent in flexibility, the impact resistance of the foamed blow body is improved.
- the thermoplastic resin preferably has a propylene unit, and specific examples include a propylene homopolymer, an ethylene-propylene block copolymer, an ethylene-propylene random copolymer, and the like. Further, among these, a propylene homopolymer having a long chain branched structure is particularly preferable. In this case, since melt tension becomes high, it becomes easy to foam and a bubble cell is made more uniform.
- the propylene homopolymer having a long-chain branched structure is preferably a propylene homopolymer having a weight average branching index of 0.9 or less.
- the weight average branching index g ′ is represented by V1 / V2, where V1 is the intrinsic viscosity of the branched polyolefin and V2 is the intrinsic viscosity of a linear polyolefin having the same weight average molecular weight as that of the branched polyolefin.
- thermoplastic resin it is preferable to use a polypropylene resin having a melt tension at 230 ° C. in the range of 30 to 350 mN.
- melt tension means melt tension.
- the foaming polypropylene resin exhibits strain-hardening properties, and a high foaming ratio can be obtained.
- the thermoplastic resin preferably has a melt flow rate (MFR) of 1 to 10 at 230 ° C.
- MFR is a value measured according to JIS K-7210. If the MFR is less than 1, it tends to be difficult to increase the extrusion speed as compared with the case where the MFR is in the above range. If the MFR exceeds 10, the MFR is in the above range. In comparison, blow molding tends to be difficult due to the occurrence of drawdown or the like.
- thermoplastic resin It is preferable to add a styrene elastomer and / or low density polyethylene to the thermoplastic resin.
- a styrene elastomer or low density polyethylene is added, the impact strength at low temperature of the foamed blow molded article is improved.
- styrene-type elastomer which has a styrene unit to which hydrogen was added in the molecule
- examples thereof include hydrogenated elastomers such as styrene-ethylene / butylene-styrene block copolymers, styrene-ethylene / propylene-styrene block copolymers, and styrene-butadiene random copolymers.
- the blending ratio of the styrene elastomer is preferably in the range of less than 40 wt% with respect to the thermoplastic resin.
- the content of styrene in the styrene-based elastomer is preferably less than 30 wt%, more preferably less than 20 wt%, from the viewpoint of impact strength at low temperatures.
- the low density polyethylene those having a density of 0.91 g / cm 3 or less are suitably used from the viewpoint of impact strength at low temperatures.
- the blending ratio of the low density polyethylene is preferably in the range of less than 40 wt% with respect to the thermoplastic resin.
- the thermoplastic resin is foamed using a foaming agent before blow molding.
- foaming agents include inorganic foaming agents such as air, carbon dioxide gas, nitrogen gas, and water, or organic foaming agents such as butane, pentane, hexane, dichloromethane, and dichloroethane.
- inorganic foaming agents such as air, carbon dioxide gas, nitrogen gas, and water
- organic foaming agents such as butane, pentane, hexane, dichloromethane, and dichloroethane.
- the mixed resin is foamed by setting the carbon dioxide gas or nitrogen gas to a supercritical state. In this case, air bubbles can be uniformly and reliably formed.
- thermoplastic resin In addition to the styrene-based elastomer, low-density polyethylene and foaming agent, a nucleating agent, a coloring agent, and the like may be added to the thermoplastic resin.
- the air-conditioning duct 1 (foamed blow molded article) according to the present embodiment has a closed cell structure including a plurality of bubble cells and a wall portion with a foaming ratio within a predetermined range, thereby reducing weight.
- a predetermined range By setting the standard deviation of the bubble diameter of the bubble cell in the thickness direction of the wall portion within a predetermined range, it is possible to have a bubble cell of a uniform size, and the center line of the outer surface of the wall portion By setting the average roughness Ra within a predetermined range, the surface can be highly smooth.
- the air conditioning duct 1 has a low frictional resistance against the circulating air, and the air blowing efficiency is improved. Thereby, the pressure loss of air-conditioning air is reduced, and the occurrence of condensation on the outside of the duct wall surface is reduced.
- FIG. 2 is a flowchart of the method for producing a foamed blow molded article according to the present invention.
- the manufacturing method of the foam blow molded body according to the present embodiment includes a mixing step S1 in which a thermoplastic resin is added to a foaming agent and mixed with an extruder to obtain a mixed resin, and the mandrel and the outside of the die.
- a storage step S2 for storing the mixed resin in a cylindrical space between the cylinder, an extrusion step S3 for extruding the parison from the die slit using a ring-shaped piston, and clamping the parison between the divided molds.
- a molding step S4 for performing blow molding by blowing air.
- blow molding is performed while maintaining the size of the bubble cell by extruding at a predetermined extrusion speed using a ring-shaped piston.
- the mixing step S1 is a step in which a thermoplastic resin is added to the foaming agent and mixed with an extruder to obtain a mixed resin.
- a well-known thing is used suitably for an extruder.
- the polyolefin resin mentioned above is used as a thermoplastic resin, and a foaming agent is used as a supercritical state. By using a foaming agent that is a supercritical fluid, the bubble cell is further refined.
- the foaming agent is preferably carbon dioxide gas or nitrogen gas. These can be brought into a supercritical state under relatively mild conditions. Specifically, the conditions for using carbon dioxide gas as a supercritical fluid are a critical temperature of 31 ° C. and a critical pressure of 7.4 MPa or higher, and the conditions for using nitrogen gas as a supercritical fluid are the critical temperature 149.1. The critical pressure is 3.4 MPa or higher.
- a mixed resin can be obtained by foaming the polyolefin resin using a supercritical fluid.
- a styrene elastomer and / or low density polyethylene may be added to the polyolefin.
- Storage process S2 is a process of storing mixed resin in the cylindrical space between the mandrel and the die outer cylinder. Such a storage process is performed using an extrusion head.
- FIG. 3 is a partial cross-sectional view showing an extrusion head used in the method for producing a blow-molded foam according to the present invention.
- the extrusion head 20 includes a die outer cylinder 28, a mandrel 27 disposed substantially at the center of the die outer cylinder 28, a cylindrical space 29 between the die outer cylinder 28 and the mandrel 27, A ring-shaped piston 22 for pushing the mixed resin stored in the cylindrical space 29 downward, and a die slit 21 for discharging the resin are provided.
- the mixed resin extruded by an extruder travels around the mandrel 27 and falls into the cylindrical space 29 between the mandrel 27 and the die outer cylinder 28 and is stored.
- the amount of resin to be stored is preferably 5 to 40 liters.
- the size of the bubble cells is homogenized while the mixed resin is stored. It will be.
- Extrusion process S3 is a process of extruding a parison from a die slit using a ring-shaped piston. That is, after a predetermined amount of resin is stored in the cylindrical space 29, the parison (not shown) is discharged from the die slit 21 by pushing the ring-shaped piston 22 downward.
- the distance of the die slit 21 can be shortened.
- the extrusion speed can also be increased. For this reason, the state of a bubble cell can be maintained.
- the conventional extrusion head shown in FIG. 9 is a method of extruding a parison with an accumulator 35 outside the die (external die accumulator method)
- the distance between the die slits becomes long and the extrusion speed cannot be increased.
- rate of the parison at this time is 700 kg / hour or more. In this case, a foamed blow molded article having higher surface smoothness can be obtained.
- the in-die accumulator used in the present invention has an injection rate of 200 cm 3 / sec or more, preferably 500 cm 3 / sec or more.
- the molding step S4 is a step of performing blow molding by clamping the parison between the divided molds and blowing air into the parison.
- FIG. 4 is a cross-sectional view showing a blow molding aspect in the method for producing a foam blow molded article according to the present invention.
- the cylindrical parison 32 is extruded between the split molds 33 from a die slit (not shown). Then, the mold is clamped by the split mold 33 so that the parison 32 is sandwiched from both sides.
- the pressure for blowing air is preferably 0.05 to 0.15 MPa from the viewpoint of maintaining the shape of the bubble cell.
- the size of the bubble cells is homogenized by storing the mixed resin at a predetermined position, and the ring-shaped piston is used at a predetermined extrusion speed. By extruding, blow molding is performed in a state where the size of the bubble cell is maintained. As a result, a foamed blow-molded article having a uniform size cell, light weight and high surface smoothness can be obtained.
- FIG. 5 is a perspective view showing a second embodiment of the blow-molded foam according to the present invention.
- the foamed blow molded article (hereinafter also referred to as “panel with skin”) 3 is a wall portion formed by blow molding a thermoplastic resin mixed with a foaming agent. It has a structure having a hollow double wall structure made of and having a skin material 4 adhered to one surface of a base body 2 made of a wall portion. The skin material 4 is integrally attached simultaneously with the blow molding of the wall in the molding process.
- the base body 2 made of a wall portion has a hollow double wall structure having a hollow portion 5, and a plurality of reinforcing ribs 6 are defined so as to partition the hollow portion 5. Is provided. Such reinforcing ribs 6 improve the strength in the vertical direction.
- the reinforcing rib 6 is formed so as to fold the wall portion of the parison by pressing against the side surface of the parison with a projecting slide core from one direction when the parison is clamped in the molding process. Therefore, in the manufacture of the panel with the skin, the skin material 4 is adhered and the reinforcing ribs 6 are simultaneously formed in the molding process.
- the said wall part is synonymous with the wall part in the foam blow molding which concerns on 1st Embodiment mentioned above, and a structure and a physical property are also the same, description is abbreviate
- the manufacturing method of the foam blow molded object which concerns on 2nd Embodiment is the same as the manufacturing method of the foam blow molded object which concerns on 1st Embodiment except a formation process differing as mentioned above.
- the panel with skin 3 (foamed blow molded article) according to the present embodiment has a closed cell structure including a plurality of bubble cells in the wall portion, and the wall portion has a foaming ratio within a predetermined range, thereby reducing weight.
- the standard deviation of the bubble diameter of the bubble cell in the thickness direction of the wall portion within a predetermined range, it is possible to have a bubble cell of a uniform size, and the center of the outer surface of the wall portion
- the line average roughness Ra within a predetermined range, the surface smoothness can be high.
- the welding strength of the reinforcing ribs formed on the inside of the panel wall surface and the welding strength of the skin adhered on the outside of the panel wall surface are improved, and the rigidity and appearance are also excellent.
- Example 1 70 wt% propylene homopolymer (thermoplastic resin, manufactured by Sun Allomer, trade name: PF814) having a long chain branched structure with an MFR of 3.0 g / min at 230 ° C. and an MFR of 0.5 g / min at 230 ° C. 30 wt% of a crystalline ethylene-propylene block copolymer (Novatec PP EC9, manufactured by Nippon Polychem Co., Ltd.) was mixed to prepare 96 parts by weight of this mixture and 3 parts of talc MB (masterbatch) as a nucleating agent. Part by weight and 1 part by weight of black MB (masterbatch) as a colorant were mixed.
- PF814 crystalline ethylene-propylene block copolymer
- the density of the mixed resin was 0.91 g / cm 3 .
- carbon dioxide in a supercritical state was added as a foaming agent and foamed to obtain a mixed resin.
- the mixed resin is stored in a cylindrical space between the mandrel and the die outer cylinder using the extrusion head shown in FIG. 3, and 1500 kg using a ring-shaped piston (in-die accumulator).
- a cylindrical parison is extruded between the split molds shown in FIG. 4 at a speed of / hour, and after mold clamping, blown air is blown into the parison at a pressure of 0.1 MPa after mold clamping.
- the MFR is measured with a test load of 2.16 kg according to JIS K-7210.
- Example 2 Sample B was obtained in the same manner as in Example 1 except that the extrusion speed was 750 kg / hour.
- Example 3 Sample C was obtained in the same manner as in Example 1 except that nitrogen gas was used instead of carbon dioxide gas.
- Example 4 Sample D was obtained in the same manner as in Example 1 except that nitrogen gas was used instead of carbon dioxide gas and the extrusion rate was 700 kg / hour.
- Example 5 Sample E was obtained in the same manner as in Example 1 except that nitrogen gas was used instead of carbon dioxide gas and the extrusion rate was 600 kg / hour.
- Example 6 Sample F was obtained in the same manner as in Example 1 except that the extrusion speed was 600 kg / hour.
- Example 1 Comparative Example 1
- a conventional extrusion head shown in FIG. 9 was used instead of the extrusion head shown in FIG. 3. That is, the mixed resin mixed by the extruder was supplied from a horizontal accumulator cylinder (external die accumulator) provided outside the die head to the crosshead using a plunger, and extruded as a cylindrical parison from the die slit. The extrusion speed was 450 kg / hour. A sample G was obtained in the same manner as Example 1 except for these.
- Comparative Example 2 Sample H was obtained in the same manner as in Comparative Example 1 except that nitrogen gas was used instead of carbon dioxide gas.
- Samples A to I obtained in Examples 1 to 6 and Comparative Examples 1 to 3 were evaluated as follows. Samples A to I were cut with a microtome (RM2145, manufactured by LEICA) at a relatively flat portion at both ends and the center in the longitudinal direction, and the cut cross section was photographed with a CCD camera (Keyence VH-630). 1. Average wall thickness (mm) The thickness of each of the three points A to I taken with a CCD camera was measured from the photograph, and the average value of each value was obtained by calculation. 2. Foaming ratio The foaming ratio was calculated by dividing the density of the mixed resin used in Samples A to I by the apparent density of the wall surfaces of the corresponding samples A to I. 3.
- Average bubble diameter For each of the three points A to I taken with a CCD camera, the size of the bubble diameter in the thickness direction at five equally spaced points from the outside in the thickness direction of the wall surface was measured from the photograph, and the average value was calculated. 4). Centerline average roughness (Ra) ( ⁇ m) The center average roughness of samples A to I was measured according to JIS B0601 using a surface roughness measuring instrument (Surfcom 470A manufactured by Tokyo Seimitsu Co., Ltd.). The measurement site
- part of the surface roughness of a foam blow molded object measured the outer five points of the wall surface of a foam blow molded object, and the inner five points of the wall surface, and made it the average value. 5). Standard deviation of bubble diameter ( ⁇ m) The standard deviation was obtained by calculation from the values of the bubble diameter in the thickness direction at a total of 15 points measured when calculating the average bubble diameter. The results obtained from these evaluations are shown in Table 1.
- Samples A to F of Examples 1 to 6 can be extruded as a parison in a short time by using an in-die accumulator having a high injection rate. As a result, the standard deviation of the bubble diameter of the bubble cell is small. A foamed blow molded article having a high surface smoothness (small variation in bubble diameter distribution) could be obtained. It was also found that the cell diameter can be made smaller by using supercritical nitrogen as the foaming agent.
- Samples G to I of Comparative Examples 1 to 3 had variations in the bubble diameter distribution of the bubble cells. This means that when an off-die accumulator is used, the molten thermoplastic resin stored in the cylinder is pushed out by changing the direction of flow by 90 degrees at the crosshead during extrusion, and is provided outside the die. This is probably because the pressure loss of the extruded thermoplastic resin increases because the distance from the cylinder to the die slit that is extruded as a parison is relatively long.
- Peel strength A non-woven fabric (hereinafter referred to as “packing”) (thickness 3 mm, width 10 mm) with double-sided tape attached to each test piece cut out from samples A to I, and one end face of the packing was adhered to the test piece. The tensile tester was attached to the other end face. Then, the other end face of the packing was pulled with a tensile tester so as to be folded back to the one end face side, and the peel strength at that time was measured.
- Samples A to F of Examples 1 to 6 of the present invention were superior in peel strength to Samples G to I of Comparative Examples 1 to 3. Thereby, it can be said that the foamed blow molded article of the present invention is excellent in smoothness. From these, according to the present invention, it was confirmed that a foamed blow-molded article having a uniform cell size, light weight and high surface smoothness can be obtained.
- the foamed blow molded article according to the present invention can be applied to vehicle interior materials and the like in addition to vehicle air conditioning ducts and skin panels.
- the foam blow molded article contributes to weight reduction of the vehicle without deteriorating various physical properties as a plastic part.
- Air conditioning duct (foamed blow molded product) 2 ... Base 3 ... Panel with skin (foamed blow molded product) DESCRIPTION OF SYMBOLS 4 ... Skin material 5 ... Hollow part 6 ... Reinforcement rib 11 ... Main-body part 12 ... Air outflow part 13 ... Air inflow part 20 ... Extrusion head 21 ... Die slit 22 ... Ring-shaped piston 27 ... Mandrel 28 ... Die outer cylinder 29 ... Cylindrical space 32 ... Parison 33 ... Split mold 35 ... Accumulator S1 ... Mixing process S2 ... Storage process S3 ... Extrusion process S4 ... Molding process
Abstract
Description
また、このような方法で得られる発泡ブロー成形品としては、所定の物性を有するポリプロピレン系樹脂を主成分としたものが知られている(例えば、特許文献2参照)。
このため、上記発泡ブロー成形体は、例えば、車両用空調ダクトに用いた場合、流通エアに対する摩擦抵抗が低く、送風効率も向上することになる。これにより、空調エアの圧力損失が低減され、ダクト壁面の外側への結露の発生が低減される。
また、表皮付きパネルに用いた場合、パネル壁面の内側に形成される補強リブの溶着強度及びパネル壁面の外側に貼着される表皮の溶着強度が向上し、且つ剛性、外観にも優れるものとなる。
これにより、上記発泡ブロー成形体の製造方法によれば、均質な大きさの気泡セルを有し、軽量で、表面の平滑性が高い発泡ブロー成形体が得られる。なお、超臨界流体である発泡剤を用いることにより、気泡セルがより微細化される。
第1実施形態として、本発明に係る発泡ブロー成形体を空調ダクトとして用いた場合について説明する。
図1は、本発明に係る発泡ブロー成形体の第1実施形態を示す斜視図である。
図1に示すように、本実施形態に係る発泡ブロー成形体(以下「空調ダクト」ともいう。)1は、発泡剤を混合させた熱可塑性樹脂をブロー成形することにより形成された壁部からなるものであり、本体部11と、本体部11の一端に設けられたエア流入部13と、本体部11の他端に設けられたエア流出部12とを備える。なお、ブロー成形については後述する。また、エア流出部12は、ブロー成形後の後加工により閉鎖された部分を切除して開口状態としたものである。
したがって、空調ダクト1は、中空の部分に空調エアを流通させることが可能である。
例えば、車両用空調ダクトにおいて、エア流入部13をエアコンユニットに連結し、エアコンユニットから供給される空調エアを、中空部分に流通させて、所望の位置に配置されたエア流出部12から排出させることができる。
空調ダクト1においては、壁部を独立気泡構造とすることにより、表面平滑性が優れ、外観性、特に空調ダクトにあっては送風効率の向上、結露発生が低減するという利点がある。
平均気泡径が300μm以上であると、平均気泡径が上記範囲内にある場合と比較して、表面粗さが大きくなり表面の平滑性が劣る傾向にある。
平均肉厚が3.5mmを超えると、平均肉厚が上記範囲内にある場合と比較して、エア流路が減少して送風効率が劣る傾向にある。
中心線平均粗さを9.0μm未満とすることにより、表面平滑性が優れ、外観性、特に空調ダクトにあっては送風効率の向上、結露発生が低減するという利点がある。
気泡径の標準偏差が、40μmを超えると、気泡セル径のバラツキが大きくなり、表面平滑性および外観性に劣る傾向にある。なお、気泡径の標準偏差は、30μm未満であることがより好ましい。
発泡倍率が2.0倍未満であると、軽量な発泡ブロー成形体を得ることができない。
かかる熱可塑性樹脂としては、ポリエチレン樹脂、ポリプロピレン樹脂等のポリオレフィン系樹脂が挙げられる。ポリオレフィン系樹脂は、柔軟性に優れるので、発泡ブロー体の耐衝撃性が向上する。
これらの中でも、熱可塑性樹脂は、プロピレン単位を有するものであることが好ましく、具体的には、プロピレン単独重合体、エチレン-プロピレンブロック共重合体、エチレン-プロピレンランダム共重合体等が挙げられる。
さらに、これらの中でも、長鎖分岐構造を有するプロピレン単独重合体であることが特に好ましい。この場合、溶融張力が高くなるので、発泡しやすくなり、気泡セルもより均一化される。
MFRが1未満であると、MFRが上記範囲内にある場合と比較して、押出速度を上げることが困難となる傾向にあり、MFRが10を超えると、MFRが上記範囲内にある場合と比較して、ドローダウン等の発生によりブロー成形が困難となる傾向にある。
スチレン系エラストマーの配合割合は、熱可塑性樹脂に対して、40wt%未満の範囲であることが好ましい。
また、スチレン系エラストマー中のスチレンの含有量は、低温時の衝撃強度の観点から、30wt%未満であることが好ましく、20wt%未満であることがより好ましい。
低密度のポリエチレンの配合割合は、熱可塑性樹脂に対して、40wt%未満の範囲であることが好ましい。
かかる発泡剤としては、空気、炭酸ガス、窒素ガス、水等の無機系発泡剤、又は、ブタン、ペンタン、ヘキサン、ジクロロメタン、ジクロロエタン等の有機系発泡剤が挙げられる。
これらの中でも、発泡剤は、空気、炭酸ガス又は窒素ガスを用いることが好ましい。この場合、有体物の混入が防げるので、耐久性等の低下が抑制される。
また、上記空調ダクト1は、流通エアに対する摩擦抵抗が低く、送風効率も向上することになる。これにより、空調エアの圧力損失が低減され、ダクト壁面の外側への結露の発生が低減される。
図2は、本発明に係る発泡ブロー成形体の製造方法のフローチャートである。
図2に示すように、本実施形態に係る発泡ブロー成形体の製造方法は、発泡剤に熱可塑性樹脂を添加し、押出機で混合して混合樹脂とする混合工程S1と、マンドレルとダイ外筒との間の円筒状空間に混合樹脂を貯留する貯留工程S2と、リング状ピストンを用いてダイスリットからパリソンを押し出す押出工程S3と、パリソンを分割金型間で型締めし、該パリソン内にエアを吹き込んでブロー成形を行う成形工程S4と、を備える。
これにより、上記発泡ブロー成形体の製造方法によれば、均質な大きさの気泡セルを有し、軽量で、表面の平滑性が高い発泡ブロー成形体が得られる。
(混合工程)
混合工程S1は、発泡剤に熱可塑性樹脂を添加し、押出機で混合して混合樹脂とする工程である。なお、押出機は公知のものが適宜用いられる。
また、本実施形態に係る発泡ブロー成形体の製造方法においては、熱可塑性樹脂として、上述したポリオレフィン系樹脂が用いられ、発泡剤は超臨界状態として用いられる。超臨界流体である発泡剤を用いることにより、気泡セルがより微細化される。
具体的には、炭酸ガスを超臨界流体とする場合の条件は、臨界温度31℃、臨界圧力7.4MPa以上であり、窒素ガスを超臨界流体とする場合の条件は、臨界温度149.1℃、臨界圧力3.4MPa以上である。
貯留工程S2は、マンドレルとダイ外筒との間の円筒状空間に混合樹脂を貯留する工程である。かかる貯留工程は、押出ヘッドを用いて行われる。
図3に示すように、押出ヘッド20は、ダイ外筒28と、ダイ外筒28の略中央に配置されたマンドレル27と、ダイ外筒28及びマンドレル27の間の円筒状空間29と、該円筒状空間29に貯留された混合樹脂を下方に押すためのリング状ピストン22と、樹脂を排出するダイスリット21と、を備える。
このとき、貯留させる樹脂量は、5~40リットルであることが好ましい。
押出工程S3は、リング状ピストンを用いてダイスリットからパリソンを押し出す工程である。すなわち、円筒状空間29に所定の樹脂量が貯留された後、リング状ピストン22を下方に押し下げることにより、ダイスリット21から図示しないパリソンが排出される。
ちなみに、図9に示す従来の押出ヘッドは、ダイ外のアキュムレーター35でパリソンを押し出す方式(ダイ外アキュムレーター方式)であるので、ダイスリットの距離が長くなり、押出速度も速くすることができない。
なお、このときのパリソンの押出速度は、700kg/時以上であることが好ましい。この場合、より表面の平滑性が高い発泡ブロー成形体が得られる。また、本発明に用いられるダイ内アキュムレーターは射出率が200cm3/sec以上、好ましくは500cm3/sec以上である。
成形工程S4は、パリソンを分割金型間で型締めし、該パリソン内にエアを吹き込んでブロー成形を行う工程である。
図4に示すように、円筒状のパリソン32は、図示しないダイスリットから、分割金型33の間に押出される。そして、パリソン32が両側から挟み込まれるように、分割金型33によって型締めされる。
このとき、エアを吹き込む圧力は、気泡セルの形状維持の観点から、0.05~0.15MPaの圧力であることが好ましい。
本実施形態に係る発泡ブロー成形体の製造方法によれば、混合樹脂を所定の位置で貯留させることにより、気泡セルのサイズの均質化が図られ、リング状ピストンを用いて所定の押出速度で押し出すことにより、気泡セルのサイズが維持させた状態で、ブロー成形されることになる。
これにより、均質な大きさの気泡セルを有し、軽量で、表面の平滑性が高い発泡ブロー成形体が得られる。
第2実施形態として、本発明に係る発泡ブロー成形体を表皮付きパネルとして用いた場合について説明する。
図5は、本発明に係る発泡ブロー成形体の第2実施形態を示す斜視図である。
図5に示すように、本実施形態に係る発泡ブロー成形体(以下「表皮付きパネル」ともいう。)3は、発泡剤を混合させた熱可塑性樹脂をブロー成形することにより形成された壁部からなる中空二重壁構造を有し、壁部からなる基体2の一方の面に表皮材4が貼着された構造となっている。なお、かかる表皮材4は、成形工程において、壁部のブロー成形と同時に一体に貼着される。
図6に示すように、表皮付きパネル3において、壁部からなる基体2は、中空部5を有する中空二重壁構造となっており、該中空部5を区画するように複数の補強リブ6が設けられている。かかる補強リブ6により、上下方向への強度が向上する。
したがって、上記表皮付きパネルの製造においては、成形工程において、表皮材4が貼着されると共に、補強リブ6も同時に形成される。
また、第2実施形態に係る発泡ブロー成形体の製造方法は、上述したように成形工程が異なる以外は、第1実施形態に係る発泡ブロー成形体の製造方法と同じである。
また、パネル壁面の内側に形成される補強リブの溶着強度及びパネル壁面の外側に貼着される表皮の溶着強度が向上し、且つ剛性、外観にも優れるものとなる。
230℃におけるMFRが3.0g/分の長鎖分岐構造を導入したプロピレン単独重合体(熱可塑性樹脂、サンアロマー社製、商品名:PF814)70wt%と、230℃におけるMFRが0.5g/分の結晶性のエチレン-プロピレンブロック共重合体(日本ポリケム社製、ノバテックPP EC9)30wt%と、を混合して混合物とし、この混合物96重量部と、核剤としてタルクMB(マスターバッチ)を3重量部と、着色剤として黒色MB(マスターバッチ)1重量部と、を混合した。混合樹脂の密度は0.91g/cm3であった。
そして、これに、発泡剤として超臨界状態の炭酸ガスを添加して発泡させ混合樹脂とした。これを、押出機で混合した後、図3に示す押出ヘッドを用い、マンドレルとダイ外筒の間の円筒状空間に混合樹脂を貯留し、リング状ピストン(ダイ内アキュムレーター)を用いて1500kg/時の速度で円筒状のパリソンを図4に示す分割金型の間に押出し、型締め後、型締め後パリソン内に0.1MPaの圧力でエアを吹き込むことにより、ブロー成形されたサンプルAを得た。なお、上記MFRはJIS K-7210に準じて試験荷重2.16kgで測定したものである。
押出し速度を750kg/時としたこと以外は、実施例1と同様にしてサンプルBを得た。
炭酸ガスの代わりに窒素ガスを用いたこと以外は、実施例1と同様にしてサンプルCを得た。
炭酸ガスの代わりに窒素ガスを用い、押出し速度を700kg/時としたこと以外は、実施例1と同様にしてサンプルDを得た。
炭酸ガスの代わりに窒素ガスを用い、押出し速度を600kg/時としたこと以外は、実施例1と同様にしてサンプルEを得た。
押出し速度を600kg/時としたこと以外は、実施例1と同様にしてサンプルFを得た。
図3に示す押出ヘッドの代わりに、図9に示す従来の押出しヘッドを用いた。すなわち、押出機で混合した混合樹脂をダイヘッド外部に設けた水平方向のアキュムレータシリンダ(ダイ外アキュムレーター)から、プランジャを用いてクロスヘッドに供給し、ダイスリットより円筒状のパリソンとして押出た。また、押出し速度は450kg/時とした。
これら以外は、実施例1と同様にしてサンプルGを得た。
炭酸ガスの代わりに窒素ガスを用いたこと以外は、比較例1と同様にしてサンプルHを得た。
押出し速度を300kg/時としたこと以外は、比較例1と同様にしてサンプルIを得た。
1.平均肉厚(mm)
サンプルA~IをCCDカメラで撮影した各3点について、写真より厚みを測定し、各値の平均値を計算により求めた。
2.発泡倍率
サンプルA~Iで用いた混合樹脂の密度を、対応するサンプルA~Iの壁面の見かけ密度で割ることにより、発泡倍率を算出した。
3.平均気泡径(μm)
サンプルA~IをCCDカメラで撮影した各3点について、写真より壁面の厚み方向外側から内側の等間隔5点における気泡径の厚み方向の大きさを測定し、平均値を計算により求めた。
4.中心線平均粗さ(Ra)(μm)
サンプルA~Iの中心平均粗さをJIS B0601に準じ、表面粗さ測定器(株式会社東京精密製サーフコム470A)を用いて測定した。発泡ブロー成形体の表面粗さの測定部位は、発泡ブロー成形体の壁面の外側5点と壁面の内側5点を測定し、その平均値とした。
5.気泡径の標準偏差(μm)
平均気泡径を計算する際に測定した計15点の厚み方向の気泡径の値から標準偏差を計算により求めた。
これらの評価により、得られた結果を表1に示す。
また、発泡剤として超臨界状態の窒素を用いることにより気泡セルの径をより小さくできることがわかった。
1.写真
実施例1及び比較例1により得られたサンプルA及びGの長手方向の中央において比較的平坦な部分をミクロトーム(LEICA社製 RM2145)で切り出し、切断断面をCCDカメラ(キーエンスVH-6300)で撮影した。
得られた実施例1のサンプルAの写真を図7に、比較例1のサンプルGの写真を図8に示す。
2.剥離強度(gf)
サンプルA~Iから切り出した試験片に、両面テープが貼着された不織布(以下「パッキン」という。)(厚さ3mm、幅10mm)をそれぞれ貼り付け、パッキンの一方の端面を試験片に粘着固定し、他方の端面に引張り試験機を取り付けた。
そして、パッキンの他方の端面を、一方の端面側に折り返すように、引張り試験機で引張り、そのときの剥離強度を測定した。なお、パッキンとしてJIS Z0237(180°引き剥がし法)による粘着力が18.6N/25mmの不織布/アクリル系粘着材(積水化学株式会社製 内装部材固定用両面テープ#5782)を用い、引張速度は、300mm/minとした。
得られた結果を表2に示す。
3.外観
サンプルA~Iの外観を以下の基準にしたがって、目視にて評価した。
○:表面が平滑で均質な外観を有している
△:表面は比較的に平滑であるが外観上均質さに劣る
×:表面の凹凸が目視ではっきりとわかり外観性に劣る
得られた結果を表2に示す。
これらのことにより、本発明によれば、均質な大きさの気泡セルを有し、軽量で、表面の平滑性が高い発泡ブロー成形体が得られることが確認された。
2・・・基体
3・・・表皮付きパネル(発泡ブロー成形体)
4・・・表皮材
5・・・中空部
6・・・補強リブ
11・・・本体部
12・・・エア流出部
13・・・エア流入部
20・・・押出ヘッド
21・・・ダイスリット
22・・・リング状ピストン
27・・・マンドレル
28・・・ダイ外筒
29・・・円筒状空間
32・・・パリソン
33・・・分割金型
35・・・アキュムレーター
S1・・・混合工程
S2・・・貯留工程
S3・・・押出工程
S4・・・成形工程
Claims (9)
- 発泡剤を混合させた熱可塑性樹脂をブロー成形することにより形成される壁部からなる発泡ブロー成形体において、
前記壁部が複数の気泡セルを複数含んだ独立気泡構造であり、
前記壁部の発泡倍率が2.0倍以上であり、
前記壁部の外側の面の中心線平均粗さRaが9.0μm未満であり、且つ
前記壁部の厚み方向における前記気泡セルの気泡径の標準偏差が40μm未満である発泡ブロー成形体。 - 前記熱可塑性樹脂がポリオレフィン系樹脂からなることを特徴とする請求項1記載の発泡ブロー成形体。
- 前記ポリオレフィン系樹脂が、長鎖分岐構造を有するプロピレン単独重合体である請求項2記載の発泡ブロー成形体。
- 前記壁部の厚み方向における前記気泡セルの平均気泡径が300μm未満である請求項1~3のいずれか一項に記載の発泡ブロー成形体。
- 前記壁部の厚み方向における前記気泡セルの平均気泡径が100μm未満であり、且つ前記壁部の厚み方向における前記気泡セルの気泡径の標準偏差が30μm未満である請求項1~3のいずれか一項に記載の発泡ブロー成形体。
- 車両用空調ダクトである請求項1~5のいずれか一項に記載の発泡ブロー成形体。
- 請求項1~6のいずれか一項に記載の発泡ブロー成形体の製造方法であって、
発泡剤に熱可塑性樹脂を添加し、押出機で混合して混合樹脂とする混合工程と、
マンドレルとダイ外筒との間の円筒状空間に前記混合樹脂を貯留する貯留工程と、
リング状ピストンを用いてダイスリットからパリソンを押し出す押出工程と、
前記パリソンを分割金型間で型締めし、該パリソン内にエアを吹き込んでブロー成形を行う成形工程と、
を備える発泡ブロー成形体の製造方法。 - 前記熱可塑性樹脂がポリオレフィン系樹脂であり、前記発泡剤が超臨界状態である請求項7記載の発泡ブロー成形体の製造方法。
- 前記押出工程において、前記パリソンの押出速度が700kg/時以上である請求項7又は8に記載の発泡ブロー成形体の製造方法。
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EP14188328.0A EP2842720B8 (en) | 2008-03-31 | 2009-03-31 | Process for producing blow-molded foam |
US12/935,520 US8517059B2 (en) | 2008-03-31 | 2009-03-31 | Blow-molded foam and process for producing the same |
CN200980119253.8A CN102046355B (zh) | 2008-03-31 | 2009-03-31 | 发泡吹塑成形体及其制造方法 |
EP09728880.7A EP2261004B1 (en) | 2008-03-31 | 2009-03-31 | A climate control duct and method of making it |
ES09728880.7T ES2527956T3 (es) | 2008-03-31 | 2009-03-31 | Un conducto de control climático y el método de realizarlo |
EP21172209.5A EP3878625A1 (en) | 2008-03-31 | 2009-03-31 | Blow-molded foam and process for producing the same |
US13/949,266 US9186955B2 (en) | 2008-03-31 | 2013-07-24 | Blow-molded foam and process for producing the same |
US13/950,248 US9340091B2 (en) | 2008-03-31 | 2013-07-24 | Blow-molded foam and process for producing the same |
US15/156,297 US10369727B2 (en) | 2008-03-31 | 2016-05-16 | Blow-molded foam and process for producing the same |
US16/457,846 US11045982B2 (en) | 2008-03-31 | 2019-06-28 | Blow-molded foam |
US17/326,645 US11833723B2 (en) | 2008-03-31 | 2021-05-21 | Blow-molded foam and process for producing the same |
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JP2012030498A (ja) * | 2010-07-30 | 2012-02-16 | Kyoraku Co Ltd | 発泡成形体の製造方法、及び発泡成形体 |
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EP2261004A4 (en) | 2013-01-09 |
US9186955B2 (en) | 2015-11-17 |
US20130313749A1 (en) | 2013-11-28 |
US10369727B2 (en) | 2019-08-06 |
JP2009241528A (ja) | 2009-10-22 |
ES2527956T3 (es) | 2015-02-02 |
EP3878625A1 (en) | 2021-09-15 |
EP2261004A1 (en) | 2010-12-15 |
US11045982B2 (en) | 2021-06-29 |
CN102046355B (zh) | 2014-08-27 |
US20160257040A1 (en) | 2016-09-08 |
US8517059B2 (en) | 2013-08-27 |
US9340091B2 (en) | 2016-05-17 |
JP5025549B2 (ja) | 2012-09-12 |
EP2842720B8 (en) | 2021-09-01 |
EP2261004B1 (en) | 2014-12-17 |
US20190322009A1 (en) | 2019-10-24 |
CN104015340A (zh) | 2014-09-03 |
EP2842720B1 (en) | 2021-06-16 |
CN102046355A (zh) | 2011-05-04 |
US20110048571A1 (en) | 2011-03-03 |
US20130323448A1 (en) | 2013-12-05 |
US20210276232A1 (en) | 2021-09-09 |
EP2842720A1 (en) | 2015-03-04 |
CN104015340B (zh) | 2019-03-08 |
US11833723B2 (en) | 2023-12-05 |
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