WO2010125896A1 - 成形体の製造方法及びブリスター発生を抑制する方法 - Google Patents
成形体の製造方法及びブリスター発生を抑制する方法 Download PDFInfo
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- WO2010125896A1 WO2010125896A1 PCT/JP2010/056238 JP2010056238W WO2010125896A1 WO 2010125896 A1 WO2010125896 A1 WO 2010125896A1 JP 2010056238 W JP2010056238 W JP 2010056238W WO 2010125896 A1 WO2010125896 A1 WO 2010125896A1
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- WO
- WIPO (PCT)
- Prior art keywords
- crystalline resin
- outlet diameter
- resin composition
- max
- liquid crystalline
- Prior art date
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- 238000000034 method Methods 0.000 title claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000002347 injection Methods 0.000 claims abstract description 110
- 239000007924 injection Substances 0.000 claims abstract description 110
- 229920006038 crystalline resin Polymers 0.000 claims abstract description 85
- 239000011342 resin composition Substances 0.000 claims abstract description 78
- 238000000465 moulding Methods 0.000 claims abstract description 43
- 239000007788 liquid Substances 0.000 claims description 81
- 238000001746 injection moulding Methods 0.000 claims description 18
- 239000003365 glass fiber Substances 0.000 claims description 11
- -1 aromatic hydroxycarboxylic acids Chemical class 0.000 description 18
- 238000005259 measurement Methods 0.000 description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 10
- 125000003118 aryl group Chemical group 0.000 description 10
- 230000008569 process Effects 0.000 description 10
- 229920005989 resin Polymers 0.000 description 10
- 239000011347 resin Substances 0.000 description 10
- 239000000835 fiber Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- 239000011256 inorganic filler Substances 0.000 description 8
- 229910003475 inorganic filler Inorganic materials 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 8
- 239000002184 metal Substances 0.000 description 8
- 229920000728 polyester Polymers 0.000 description 8
- 239000004973 liquid crystal related substance Substances 0.000 description 6
- 238000002844 melting Methods 0.000 description 6
- 230000008018 melting Effects 0.000 description 6
- 229920006149 polyester-amide block copolymer Polymers 0.000 description 6
- 239000011521 glass Substances 0.000 description 5
- 230000000704 physical effect Effects 0.000 description 5
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- 238000009795 derivation Methods 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 239000000377 silicon dioxide Substances 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 150000004984 aromatic diamines Chemical class 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000004898 kneading Methods 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000000454 talc Substances 0.000 description 3
- 229910052623 talc Inorganic materials 0.000 description 3
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 2
- PLIKAWJENQZMHA-UHFFFAOYSA-N 4-aminophenol Chemical compound NC1=CC=C(O)C=C1 PLIKAWJENQZMHA-UHFFFAOYSA-N 0.000 description 2
- FJKROLUGYXJWQN-UHFFFAOYSA-N 4-hydroxybenzoic acid Chemical compound OC(=O)C1=CC=C(O)C=C1 FJKROLUGYXJWQN-UHFFFAOYSA-N 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- QIGBRXMKCJKVMJ-UHFFFAOYSA-N Hydroquinone Chemical compound OC1=CC=C(O)C=C1 QIGBRXMKCJKVMJ-UHFFFAOYSA-N 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 125000002723 alicyclic group Chemical group 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 239000002657 fibrous material Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 238000012886 linear function Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 239000010445 mica Substances 0.000 description 2
- 229910052618 mica group Inorganic materials 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- CBCKQZAAMUWICA-UHFFFAOYSA-N 1,4-phenylenediamine Chemical compound NC1=CC=C(N)C=C1 CBCKQZAAMUWICA-UHFFFAOYSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- XBNGYFFABRKICK-UHFFFAOYSA-N 2,3,4,5,6-pentafluorophenol Chemical compound OC1=C(F)C(F)=C(F)C(F)=C1F XBNGYFFABRKICK-UHFFFAOYSA-N 0.000 description 1
- NEQFBGHQPUXOFH-UHFFFAOYSA-N 4-(4-carboxyphenyl)benzoic acid Chemical compound C1=CC(C(=O)O)=CC=C1C1=CC=C(C(O)=O)C=C1 NEQFBGHQPUXOFH-UHFFFAOYSA-N 0.000 description 1
- 229940090248 4-hydroxybenzoic acid Drugs 0.000 description 1
- KAUQJMHLAFIZDU-UHFFFAOYSA-N 6-Hydroxy-2-naphthoic acid Chemical compound C1=C(O)C=CC2=CC(C(=O)O)=CC=C21 KAUQJMHLAFIZDU-UHFFFAOYSA-N 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910001369 Brass Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- 206010039101 Rhinorrhoea Diseases 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000004840 adhesive resin Substances 0.000 description 1
- 229920006223 adhesive resin Polymers 0.000 description 1
- 125000002947 alkylene group Chemical group 0.000 description 1
- 125000001118 alkylidene group Chemical group 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 150000004982 aromatic amines Chemical class 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- VCCBEIPGXKNHFW-UHFFFAOYSA-N biphenyl-4,4'-diol Chemical group C1=CC(O)=CC=C1C1=CC=C(O)C=C1 VCCBEIPGXKNHFW-UHFFFAOYSA-N 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920006351 engineering plastic Polymers 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000012765 fibrous filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- PCILLCXFKWDRMK-UHFFFAOYSA-N naphthalene-1,4-diol Chemical compound C1=CC=C2C(O)=CC=C(O)C2=C1 PCILLCXFKWDRMK-UHFFFAOYSA-N 0.000 description 1
- RXOHFPCZGPKIRD-UHFFFAOYSA-N naphthalene-2,6-dicarboxylic acid Chemical compound C1=C(C(O)=O)C=CC2=CC(C(=O)O)=CC=C21 RXOHFPCZGPKIRD-UHFFFAOYSA-N 0.000 description 1
- MNZMMCVIXORAQL-UHFFFAOYSA-N naphthalene-2,6-diol Chemical compound C1=C(O)C=CC2=CC(O)=CC=C21 MNZMMCVIXORAQL-UHFFFAOYSA-N 0.000 description 1
- 208000010753 nasal discharge Diseases 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- IZUPBVBPLAPZRR-UHFFFAOYSA-N pentachloro-phenol Natural products OC1=C(Cl)C(Cl)=C(Cl)C(Cl)=C1Cl IZUPBVBPLAPZRR-UHFFFAOYSA-N 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 230000010287 polarization Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 1
- 229960001755 resorcinol Drugs 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 239000010456 wollastonite Substances 0.000 description 1
- 229910052882 wollastonite Inorganic materials 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Images
Classifications
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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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/766—Measuring, controlling or regulating the setting or resetting of moulding conditions, e.g. before starting a cycle
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/761—Dimensions, e.g. thickness
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/76163—Errors, malfunctioning
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76177—Location of measurement
- B29C2945/76254—Mould
- B29C2945/76274—Mould runners, nozzles
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76177—Location of measurement
- B29C2945/7629—Moulded articles
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76545—Flow rate
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76655—Location of control
- B29C2945/76765—Moulding material
-
- 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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76822—Phase or stage of control
- B29C2945/76859—Injection
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0025—Preventing defects on the moulded article, e.g. weld lines, shrinkage marks
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
-
- 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
- B29K2105/0079—Liquid crystals
Definitions
- the present invention relates to a method for producing a molded body obtained by injection molding a liquid crystalline resin composition, and a method for suppressing blister generation when the liquid crystalline resin composition is injection molded.
- a group of plastics called engineering plastics has high strength and is being replaced by metal parts.
- a group of plastics called liquid crystalline resins melts while maintaining the crystal structure, so the volume changes between melting and solidification due to the high strength based on the crystal structure and the fact that the crystal structure does not change significantly during solidification. Is small and molding shrinkage is small.
- the liquid crystalline resin as described above is excellent in moldability and heat resistance and is preferably used as a constituent material of small electronic parts.
- a liquid crystalline resin composition with improved heat resistance and the like can be obtained by appropriately melting and kneading the liquid crystalline resin and the inorganic filler.
- the liquid crystalline resin composition as described above is used for sealing parts such as relay parts, coil bobbins, connectors, volume parts, motor parts such as commutators and separators, or elements such as coils, crystal resonators and IC chips. ing.
- the liquid crystalline resin composition is a very excellent material and can be used for various purposes.
- the liquid crystalline resin composition has a problem to be improved upon molding.
- the problem in molding this liquid crystalline resin composition is that the liquid crystalline resin composition that is in a molten state at the time of molding entrains gas generated from air or material, so that bubbles are contained inside the molded product. is there.
- the molded product is exposed to a high temperature by heat treatment or the like, whereby air or gas in the bubbles expands and the surface of the molded product expands. This swelling of the surface of the molded product is called a blister.
- Measures for suppressing the occurrence of blisters as described above include sufficiently degassing from the vent hole during melt extrusion of the resin composition, and not allowing the resin composition to stay in the molding machine for a long time during molding. .
- the occurrence of blisters cannot be sufficiently suppressed only by changing the conditions during molding.
- Patent Document 1 discloses a specific liquid crystalline resin composition containing a specific amount of an inorganic filler in a kneading machine having an open port for removing volatile components from a material to be kneaded and a pair of two screws.
- a method for producing a liquid crystal polyester composition having a deflection temperature under load of 230 ° C. or higher obtained by melting and kneading the above a method for producing a liquid crystalline resin composition is disclosed in which the screw engagement rate of the kneader is adjusted to 1.60 or more. Yes.
- a liquid crystalline resin composition having excellent blister resistance can be provided while maintaining basic heat resistance such as melting point and deflection temperature under load of the liquid crystalline resin composition. .
- the liquid crystalline resin composition when the liquid crystalline resin composition is injection molded, if the injection speed is lowered, the generation of blisters can be suppressed. However, from the viewpoint of improving the productivity of molded products, it is strongly demanded to increase the injection speed.
- the present invention has been made in order to solve the above-mentioned problems, and the object thereof is to suppress the generation of blisters and to improve the productivity of the molded product regardless of the type of liquid crystalline resin composition to be used. It is providing the manufacturing method of the molded object which can be raised to the limit, and the method of suppressing generation
- the present inventors paid attention to the point that the liquid crystalline resin composition in the molten state at the time of molding embraced air, and conducted intensive studies to solve the above problems. As a result, it has been found that the main air entrainment that causes blistering occurs at the sprue, and further, the maximum injection capacity (Vc max ) at which blistering does not occur, the sprue outlet diameter and the nozzle outlet diameter.
- the injection capacity (Vc max ) 2 of the above, the relationship between the step of measuring the maximum injection capacity (Vc max ) where no blister occurs and the ratio ( ⁇ s / ⁇ n) of the sprue outlet diameter to the nozzle outlet diameter And a step of deriving with a function of a predetermined form (Vc max f ( ⁇ s / ⁇ n)), and a liquid crystalline resin composition under a condition satisfying Vc max (cm 3 / sec) ⁇ f ( ⁇ s / ⁇ n) Characterized by injection molding Method for producing a molded body.
- the present invention it is possible to easily derive a condition with as much injection volume as possible. As the injection capacity increases, the productivity of the resulting molded product increases. For this reason, when shape
- the first injection volume measuring step is a step of measuring the maximum injection volume (Vc max ) 1 at which no blister is generated on the surface of the molded body when the liquid crystalline resin composition is injection molded under predetermined molding conditions.
- the method for measuring the maximum injection capacity at which no blister is generated is not particularly limited. For example, until the ratio ( ⁇ s / ⁇ n) between the sprue outlet diameter and the nozzle outlet diameter is fixed to a predetermined value, the blister is generated. By gradually increasing the injection capacity condition, the injection capacity condition that is one step lower than the injection capacity condition in which the blister is generated can be determined as the “maximum injection capacity (Vc max ) at which no blister is generated”.
- the present invention is characterized in that the relationship between the maximum injection capacity (Vc max ) at which no blister is generated and the ratio ( ⁇ s / ⁇ n) between the outlet diameter of the sprue and the outlet diameter of the nozzle is obtained.
- the maximum injection capacity (Vc max ) at a predetermined ratio ( ⁇ s / ⁇ n) necessary for obtaining the above relationship is obtained.
- the above ratio and injection capacity obtained in this step are ( ⁇ s / ⁇ n) 1 and (Vc max ) 1 .
- Fig. 1 shows the state where the runner, sprue and nozzle are connected.
- the sprue outlet diameter is the sprue diameter of the connection portion between the sprue and the runner.
- the nozzle outlet diameter is the nozzle inner diameter of the nozzle tip outlet.
- the blister occurs on the surface of the molded body
- how to determine whether or not the blister occurs is not particularly limited.
- five or more molded bodies are molded by injection molding under predetermined molding conditions, and a reflow process with a peak temperature of 280 ° C. is performed on all molded bodies (for example, a reflow process performed under the conditions described in the examples).
- a determination method of evaluating that “a blister occurs” is preferable.
- the ratio between the maximum injection capacity (Vc max ) at which no blisters are generated and the outlet diameter of the sprue and the outlet diameter of the nozzle ( ⁇ s / ⁇ n) can be expressed by a more accurate relational expression.
- the predetermined molding conditions are conditions at the time of injection molding such as the type of molding machine, mold temperature, injection speed, screw rotation speed, and the like. These conditions are appropriately changed to preferable conditions according to the type of the liquid crystalline resin composition to be used. In this step, only the injection capacity condition is changed and injection molding is repeated to measure the maximum injection capacity at which blisters are not generated on the surface of the molded body.
- the relationship between the maximum injection capacity (Vc max ) at which no blister is generated and the ratio ( ⁇ s / ⁇ n) between the outlet diameter of the sprue and the outlet diameter of the nozzle is obtained. Therefore, in the present invention, the maximum injection capacity at which blisters are not generated on the surface of the molded body is measured. Any method that obtains the above relationship by measuring the injection capacity rather than the injection speed or the like has the advantage of being applicable to molding machines having various screw diameters.
- the ratio of the sprue outlet diameter to the nozzle outlet diameter ( ⁇ s / ⁇ n) is preferably 4.5 or less, as will be described later.
- the present invention can derive conditions under which blisters are not generated on the surface of a molded product when injection molding a liquid crystalline resin composition.
- the blisters on the surface of the molded body tend to be generated when the nozzle outlet diameter is less than 3 mm. Therefore, it is useful to use the method for producing a molded body of the present invention in the case of predetermined molding conditions in which the nozzle outlet diameter is less than 3 mm. If the nozzle outlet diameter is 3 mm or more, problems such as “nose dripping” occur. As a result, in many liquid crystalline resin compositions, it is necessary to set the nozzle diameter to less than 3 mm. Therefore, the present invention is useful for a large number of liquid crystal resin compositions.
- “nose sag” is a phenomenon in which the molten resin flows out from the nozzle.
- the nozzle outlet diameter is 2 mm or less, other problems such as blistering and nasal discharge do not occur, and the liquid crystalline resin composition has high productivity.
- a molded body formed by molding can be obtained.
- the exit diameter of a nozzle is 1 mm or more from a viewpoint of ensuring fluidity
- the liquid crystalline resin used in the present invention refers to a melt processable polymer having a property capable of forming an optically anisotropic molten phase.
- the property of the anisotropic molten phase can be confirmed by a conventional polarization inspection method using an orthogonal polarizer. More specifically, the anisotropic molten phase can be confirmed by using a Leitz polarizing microscope and observing a molten sample placed on a Leitz hot stage under a nitrogen atmosphere at a magnification of 40 times.
- polarized light is normally transmitted even in a molten stationary state, and optically anisotropic.
- the liquid crystalline resin as described above is not particularly limited, but is preferably an aromatic polyester or an aromatic polyester amide, and a polyester partially including an aromatic polyester or an aromatic polyester amide in the same molecular chain is also within the range. It is in. They preferably have a logarithmic viscosity (IV) of at least about 2.0 dl / g, more preferably 2.0-10.0 dl / g when dissolved in pentafluorophenol at 60 ° C. at a concentration of 0.1% by weight. .) Are used.
- IV logarithmic viscosity
- the aromatic polyester or aromatic polyester amide as the liquid crystalline resin applicable to the present invention is particularly preferably at least one compound selected from the group of aromatic hydroxycarboxylic acids, aromatic hydroxyamines, and aromatic diamines. Aromatic polyesters and aromatic polyester amides as constituent components.
- a polyester amide comprising one or more of aromatic dicarboxylic acid, alicyclic dicarboxylic acid and derivatives thereof; (4) mainly (a) one or more of aromatic hydroxycarboxylic acids and derivatives thereof; (b) one or more of aromatic hydroxyamines, aromatic diamines and derivatives thereof; and (c). One or more of aromatic dicarboxylic acid, alicyclic dicarboxylic acid and derivatives thereof, and (d) at least one or more of aromatic diol, alicyclic diol, aliphatic diol and derivatives thereof, and And polyester amides composed of Furthermore, you may use a molecular weight modifier together with said structural component as needed.
- Specific examples of the specific compound constituting the liquid crystalline resin applicable to the present invention include aromatic hydroxycarboxylic acids such as p-hydroxybenzoic acid and 6-hydroxy-2-naphthoic acid, 2,6-dihydroxynaphthalene, 1,4-dihydroxynaphthalene, 4,4′-dihydroxybiphenyl, hydroquinone, resorcin, aromatic diols such as compounds represented by the following general formula (I) and the following general formula (II); terephthalic acid, isophthalic acid, 4 , 4′-diphenyldicarboxylic acid, 2,6-naphthalenedicarboxylic acid and aromatic dicarboxylic acids such as compounds represented by the following general formula (III); aromatic amines such as p-aminophenol and p-phenylenediamine Can be mentioned.
- aromatic hydroxycarboxylic acids such as p-hydroxybenzoic acid and 6-hydroxy-2-naphthoic acid, 2,6-d
- X is a group selected from alkylene (C1 to C4), alkylidene, —O—, —SO—, —SO 2 —, —S—, and —CO—.
- the liquid crystalline resin composition used in the present invention may contain two or more types of liquid crystalline resins or may contain a resin other than the liquid crystalline resin.
- a composition imparted with desired characteristics by adding additives such as a nucleating agent, carbon black, a pigment such as an inorganic fired pigment, an antioxidant, a stabilizer, a plasticizer, a lubricant, a release agent, and a flame retardant Is also included.
- the method for producing a molded article of the present invention is suitable when a liquid crystalline resin composition containing an inorganic filler is used.
- the inorganic filler which can be used is not specifically limited, A conventionally well-known thing can be used.
- conventionally known inorganic fillers include, as fibrous fillers, asbestos fibers, silica fibers, silica / alumina fibers, alumina fibers, zirconia fibers, boron nitride fibers, silicon nitride fibers, boron fibers, potassium titanate fibers,
- inorganic fibrous materials such as metal fibrous materials, such as stainless steel, aluminum, titanium, copper, and brass, are mentioned.
- the granular fillers include carbon black, graphite, silica, quartz powder, glass beads, milled glass fiber, glass balloon, glass powder, calcium silicate, aluminum silicate, kaolin, talc, clay, diatomaceous earth, wollastonite, etc. Salts, iron oxide, titanium oxide, zinc oxide, antimony trioxide, oxides of metals such as alumina, carbonates of metals such as calcium carbonate and magnesium carbonate, sulfates of metals such as calcium sulfate and barium sulfate, other ferrites, Examples thereof include silicon carbide, silicon nitride, boron nitride, and various metal powders.
- Those containing a plurality of these inorganic fillers are also included in the liquid crystalline resin composition usable in the present invention.
- the plate-like filler include mica, glass flakes, various metal foils and the like.
- glass fiber and talc are preferably used as described later.
- the second injection volume measuring step is to change the ratio ( ⁇ s / ⁇ n) between the sprue outlet diameter ( ⁇ s) and the nozzle outlet diameter ( ⁇ n) among the predetermined molding conditions in the first injection volume measuring step.
- This is a step of measuring the maximum injection capacity (Vc max ) at which blisters are not generated on the surface of the molded product when the liquid crystalline resin composition is injection molded.
- the ratio ( ⁇ s / ⁇ n) set in this step and the injection capacity (Vc max ) obtained in this step are ( ⁇ s / ⁇ n) 2 and (Vc max ) 2 , respectively.
- the present invention obtains the relationship between the maximum injection capacity (Vc max ) at which no blister is generated and the ratio ( ⁇ s / ⁇ n) between the sprue outlet diameter and the nozzle outlet diameter.
- Vc max maximum injection capacity
- the relationship between ( ⁇ s / ⁇ n) and the injection capacity (Vc max ) can be obtained.
- the method for measuring the maximum injection volume at which no blister is generated is not particularly limited as in the case of the first injection volume measurement step.
- the injection capacity (Vc max ) is preferably 30 (cm 3 / s) or more.
- the injection capacity is lower than 30 (cm 3 / s), it is a region that is not usually molded when handling a liquid crystalline resin from the viewpoint of productivity.
- the ratio ( ⁇ s / ⁇ n) is further changed to perform the third injection volume measuring step, and the maximum injection volume (Vc max ) 3 at which no blister is generated on the surface of the molded body is measured.
- Vc max the maximum injection volume
- the injection volume (Vc max) in measurement performed after said second injection volume measurement step is preferably 30 (cm 3 / s) or more. This is because the relational expression described later can be obtained more accurately.
- a specific relational derivation method is ( ⁇ s / ⁇ n) 1 , (Vc max ) 1 obtained in the first injection volume measurement step, and ( ⁇ s / ⁇ n) 2 obtained in the second injection volume measurement step.
- the form of the approximation function is not particularly limited, and examples include power approximation, logarithmic approximation, linear approximation, polynomial approximation, and exponential approximation.
- the approximate function can be obtained by a conventionally known method. For example, it can be obtained by a method using Microsoft Excel spreadsheet software.
- the relationship between the ratio ( ⁇ s / ⁇ n) and the injection capacity (Vc max ) is as shown in FIG. 2B, at what ratio ( ⁇ s / ⁇ n) when the injection capacity becomes lower than a certain value. Even if it exists, it will be in the state which does not generate blister.
- the “certain constant value” is 30 (cm 3 / s). For this reason, a part important for examination of molding conditions is a part of 30 (cm 3 / s) or more.
- the invention is intended to increase the productivity of the molded body by producing the molded body under conditions where the injection capacity is as large as possible, and there is a risk of blisters occurring under conditions of a high injection capacity of 30 (cm 3 / s) or more. Because there is. Therefore, the above relational expression is preferably obtained from data of an injection capacity (usually 30 (cm 3 / s)) or more at which no blister is generated at any ratio ( ⁇ s / ⁇ n). In particular, as shown in FIG. 2 (b), the ratio ( ⁇ s / ⁇ n) and the injection capacity (by the linear approximation only from the data (data less than the predetermined ratio) before the injection capacity (Vc max ) becomes constant. By deriving the relationship with Vc max ), an accurate relational expression can be easily obtained (a and b in FIG. 2B are constants).
- the liquid crystalline resin composition can contain an inorganic filler as described above. Glass fiber is often blended to improve physical properties, but the present invention can be preferably applied to a liquid crystalline resin composition containing glass fiber.
- Vc max the injection capacity
- a more accurate relational expression can be obtained by obtaining an approximate function from more data of the ratio ( ⁇ s / ⁇ n) and the injection capacity (Vc max ).
- the relational expression can be obtained more accurately by using data of three or more points.
- the data of the ratio ( ⁇ s / ⁇ n) and the injection capacity (Vc max ) is equal to or greater than the injection capacity (usually 30 (cm 3 / s)) where no blister is generated at any ratio ( ⁇ s / ⁇ n). It is preferable that the data is.
- the ratio ( ⁇ s / ⁇ n) between the sprue diameter and the nozzle diameter it is preferable that the ratio ( ⁇ s / ⁇ n) is 1.2 or more for the reason of maintaining fluidity.
- the injection molding step is a step of injection molding the liquid crystalline resin composition under conditions that satisfy Vc max (cm 3 / sec) ⁇ f ( ⁇ s / ⁇ n).
- a step of producing a molded body by adjusting the sprue outlet diameter, nozzle outlet diameter, and injection volume so as to satisfy Vc max (cm 3 / sec) ⁇ f ( ⁇ s / ⁇ n) It is. That is, the conditions of the outlet diameter of the sprue, the outlet diameter of the nozzle, and the injection capacity are set from the shaded area in FIGS. 2 (a) and 2 (b).
- the desired molding conditions are the mold temperature, screw rotation speed, etc. as described in the above “predetermined molding conditions”, and the desired molding conditions are usually set in the first injection volume measuring step.
- the predetermined molding conditions are determined from the liquid crystalline resin composition to be used.
- the sprue outlet diameter, nozzle outlet diameter, and injection volume conditions are set from the shaded area in FIGS. 2 (a) and 2 (b).
- the above-mentioned conditions are set within a range in which an excellent molded product can be obtained without causing a problem.
- the ratio of the outlet diameter of the sprue to the outlet diameter of the nozzle ( ⁇ s / ⁇ n) is selected to be 4.5 or less, blisters tend not to occur even at a high injection capacity. Therefore, it is preferable to perform injection molding under the condition that the ratio ( ⁇ s / ⁇ n) is 4.5 or less.
- the ratio ( ⁇ s / ⁇ n) between the outlet diameter (mm) of the sprue and the outlet diameter (mm) of the nozzle to a predetermined value or less, the liquid crystalline resin composition can be obtained under the conditions of the highest injection capacity.
- the generation of blisters when an object is injection-molded can be suppressed. Blisters tend to occur when the nozzle outlet diameter is less than 3 mm.
- the method for suppressing the generation of blisters of the present invention is particularly useful when the nozzle outlet diameter is less than 3 mm.
- the nozzle outlet diameter is preferably 1.0 mm or more and less than 3 mm.
- a more preferable range of the nozzle diameter is 1.2 mm to 1.5 mm.
- the ratio ( ⁇ s / ⁇ n) between the outlet diameter of the sprue and the outlet diameter of the nozzle is preferably 1.2 to 4.5.
- the outlet diameter of the nozzle is 1.2 mm
- the outlet diameter of the sprue is preferably 1.44 mm to 5.4 mm.
- the sprue outlet diameter is preferably 1.8 mm to 6.75 mm.
- the sprue outlet diameter is preferably 1.44 mm to 6.75 mm.
- the outlet diameter of the sprue used when molding the liquid crystalline resin composition is about 7.0 mm.
- the liquid crystalline resin composition in a molten state has high fluidity. For this reason, it is possible to set the outlet diameter of the sprue small.
- the sprue outlet diameter has been set with a sufficient margin so as not to hinder the flow of the molten resin.
- molding can be performed under conditions where the injection capacity is as high as possible without impairing the flow of the molten resin and without causing problems such as blistering.
- a high-quality molded product can be obtained with high productivity.
- the liquid crystalline resin composition remaining in the sprue portion after molding and solidified in this portion is reused.
- the sprue outlet diameter can be made smaller than that of the conventional one, so the volume of the resin remaining in the sprue portion is also reduced, and the amount of the liquid crystalline resin composition that must be reused Can be suppressed. As a result, the labor of reuse is reduced, and the productivity of high-quality molded products is increased.
- Such an effect can be obtained by adjusting the ratio ( ⁇ s / ⁇ n) of the sprue outlet diameter to the nozzle outlet diameter so that the molten resin discharged from the nozzle is applied to the inner wall surface of the sprue near the sprue inlet. It is considered that sticking and the molten resin proceeds to the sprue outlet along the inner wall surface, so that it is difficult to entrap air in the sprue and prevent bubbles from being mixed into the molded product.
- Liquid crystalline resin composition 1 Liquid crystalline resin (manufactured by Polyplastics, “Vectra E950i”), melting point 336 ° C., melt viscosity 30 Pa ⁇ s (measured at 350 ° C., shear rate 1000 / s) and glass fiber 30% by mass Liquid crystalline resin composition in which liquid crystal resin composition 2: Liquid crystalline resin (manufactured by Polyplastics, “Vectra E950i”), melting point 336 ° C., melt viscosity 30 Pa ⁇ s (350 ° C., shear rate 1000 / s) Liquid crystalline resin composition containing 20% by mass of glass fiber and 15% by mass of talc
- Example 1 [First injection volume measurement process] Using the liquid crystalline resin compositions 1 and 2, the nozzle outlet diameter was fixed to 1.5 mm, the ratio ( ⁇ s / ⁇ n) 1 was 2, and the other molding conditions were as shown below. (“ ⁇ -50-C” manufactured by FANUC) was used for injection molding.
- the injection volume 26.5 (cm 3 /sec),39.8(cm 3 /sec),53.1(cm 3 /sec),66.3(cm 3 / sec) 79.6 ( cm 3 /sec),92.9(cm 3 /sec),106.1(cm 3 /sec),119.4(cm 3 /sec),132.7(cm 3 /sec)145.9(cm 3 / sec), 159.2 (cm 3 / sec), and after molding five shots for each injection capacity in order from the lowest, reflow treatment at a peak temperature of 280 ° C.
- the maximum injection capacity at which blisters are not generated at the ratio ( ⁇ s / ⁇ n) as shown below was obtained.
- the ratio ( ⁇ s / ⁇ n) was changed to 4.7, and the maximum injection volume at which no blisters were generated was determined in the same manner as in the first injection volume measurement step.
- the ratio ( ⁇ s / ⁇ n) was changed to 6, and the maximum injection volume at which no blisters were generated was determined in the same manner as in the first injection volume measurement step.
- the ratio ( ⁇ s / ⁇ n) was changed to 7.3, the maximum injection volume at which no blisters were generated was determined in the same manner as in the first injection volume measurement step.
- the injection capacity condition can be increased as much as possible by using the manufacturing method of the present invention.
- the manufacturing method of this invention is applicable regardless of the kind of liquid crystalline resin composition to be used. As a result, it is possible to suppress the generation of blisters without improving the material change or the like, and it is possible to easily increase the productivity of the molded body to the limit.
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Abstract
Description
Vcmax(cm3/sec)<-45(φs/φn)+240・・・(I)
φn<3mm・・・(II)
第一射出容量測定工程とは、所定の成形条件で液晶性樹脂組成物を射出成形した場合に、成形体表面にブリスターが発生しない最大の射出容量(Vcmax)1を測定する工程である。ブリスターが発生しない最大の射出容量を測定する方法は特に限定されず、例えば、スプルーの出口径とノズルの出口径との比(φs/φn)を所定の値に固定し、ブリスターが発生するまで射出容量の条件を段階的に上昇させていき、ブリスターが発生した射出容量の条件より一段階低い射出容量の条件を「ブリスターが発生しない最大の射出容量(Vcmax)」と決めることができる。段階的に射出容量の条件を上昇させる際に、射出容量をどの程度の間隔で上げて、最大の射出容量を測定するかは、使用する液晶性樹脂組成物等により適宜変更される。本発明では、後述する通り、ブリスターが発生しない最大の射出容量(Vcmax)とスプルーの出口径とノズルの出口径との比(φs/φn)との関係を求めることに特徴がある。本工程では、上記関係を求めるために必要となる所定の比(φs/φn)での最大の射出容量(Vcmax)を求める。本工程で求めた上記比と射出容量を、(φs/φn)1、(Vcmax)1とする。
所定の成形条件とは、成形機の種類、金型温度、射出速度、スクリュー回転数等の射出成形の際の条件である。これらの条件は、使用する液晶性樹脂組成物の種類に応じて適宜好ましい条件に変更される。本工程では、射出容量の条件のみを変更して射出成形を繰り返すことで、成形体表面にブリスターが発生しない最大の射出容量を測定する。
本発明で使用する液晶性樹脂とは、光学異方性溶融相を形成し得る性質を有する溶融加工性ポリマーを指す。異方性溶融相の性質は、直交偏光子を利用した慣用の偏光検査法により確認することが出来る。より具体的には、異方性溶融相の確認は、Leitz偏光顕微鏡を使用し、Leitzホットステージに載せた溶融試料を窒素雰囲気下で40倍の倍率で観察することにより実施できる。本発明に適用できる液晶性樹脂は直交偏光子の間で検査したときに、たとえ溶融静止状態であっても偏光は通常透過し、光学的に異方性を示す。
(1)主として芳香族ヒドロキシカルボン酸及びその誘導体の1種又は2種以上からなるポリエステル;
(2)主として(a)芳香族ヒドロキシカルボン酸及びその誘導体の1種又は2種以上と、(b)芳香族ジカルボン酸、脂環族ジカルボン酸及びその誘導体の1種又は2種以上と、(c)芳香族ジオール、脂環族ジオール、脂肪族ジオール及びその誘導体の少なくとも1種又は2種以上、とからなるポリエステル;
(3)主として(a)芳香族ヒドロキシカルボン酸及びその誘導体の1種又は2種以上と、(b)芳香族ヒドロキシアミン、芳香族ジアミン及びその誘導体の1種又は2種以上と、(c)芳香族ジカルボン酸、脂環族ジカルボン酸及びその誘導体の1種又は2種以上、とからなるポリエステルアミド;
(4)主として(a)芳香族ヒドロキシカルボン酸及びその誘導体の1種又は2種以上と、(b)芳香族ヒドロキシアミン、芳香族ジアミン及びその誘導体の1種又は2種以上と、(c)芳香族ジカルボン酸、脂環族ジカルボン酸及びその誘導体の1種又は2種以上と、(d)芳香族ジオール、脂環族ジオール、脂肪族ジオール及びその誘導体の少なくとも1種又は2種以上、とからなるポリエステルアミド等が挙げられる。さらに上記の構成成分に必要に応じ分子量調整剤を併用してもよい。
第二射出容量測定工程とは、上記第一射出容量測定工程での所定の成形条件のうちスプルーの出口径(φs)とノズルの出口径(φn)との比(φs/φn)を変更して、上記液晶性樹脂組成物を射出成形した場合に、成形体表面にブリスターが発生しない最大の射出容量(Vcmax)を測定する工程である。本工程で設定した上記比(φs/φn)と本工程で求まる上記射出容量(Vcmax)とを、それぞれ(φs/φn)2、(Vcmax)2とする。本発明は、後述する通り、ブリスターが発生しない最大の射出容量(Vcmax)と、スプルーの出口径とノズルの出口径との比(φs/φn)と、の関係を求める。上記第一射出容量測定工程で得られる、(φs/φn)1、(Vcmax)1に加えて、本工程で得られる(φs/φn)2、(Vcmax)2を求めることで、比(φs/φn)と射出容量(Vcmax)との関係を求めることができる。ブリスターが発生しない最大の射出容量の測定方法は、第一射出容量測定工程の場合と同様に特に限定されない。
関係式導出工程とは、ブリスターが発生しない最大の射出容量(Vcmax)と、スプルーの出口径とノズルの出口径との比(φs/φn)と、の関係を所定の形式の関数(Vcmax=f(φs/φn))で導出する工程である。本発明の特徴の一つは、上記比(φs/φn)と、ブリスターが発生しない最大の射出容量(Vcmax)との間に相関関係があることを見出し、さらにこの関係式が多くの液晶性樹脂組成物の適用できることを見出したことにある。
射出成形工程とは、Vcmax(cm3/sec)<f(φs/φn)を満たす条件で液晶性樹脂組成物を射出成形する工程である。所望の成形条件に加えて、Vcmax(cm3/sec)<f(φs/φn)を満たすようなスプルーの出口径、ノズルの出口径、射出容量に調整して成形体の製造を行う工程である。即ち、図2(a)、(b)の斜線部分の領域からスプルーの出口径、ノズルの出口径、射出容量の条件を設定する。なお、所望の成形条件とは、上記「所定の成形条件」で説明したものと同様に金型温度、スクリュー回転数等であり、所望の成形条件は、通常、第一射出容量測定工程で設定した、用いる液晶性樹脂組成物等から決められる所定の成形条件である。
液晶性樹脂組成物1:液晶性樹脂(ポリプラスチックス社製、「ベクトラE950i」)、融点336℃、溶融粘度30Pa・s(350℃、せん断速度1000/sで測定)にガラス繊維30質量%を配合した液晶性樹脂組成物
液晶性樹脂組成物2:液晶性樹脂(ポリプラスチックス社製、「ベクトラE950i」)、融点336℃、溶融粘度30Pa・s(350℃、せん断速度1000/sで測定)にガラス繊維20質量%及びタルク15質量%を配合した液晶性樹脂組成物
[第一射出容量測定工程]
液晶性樹脂組成物1、2を使用して、ノズルの出口径を1.5mmに固定し、比(φs/φn)1を2、その他の成形条件は下記に示す成形条件で、射出成形機(「α-50-C」ファナック社製)を用いて射出成形を行った。また、射出容量については、26.5(cm3/sec)、39.8(cm3/sec)、53.1(cm3/sec)、66.3(cm3/sec)79.6(cm3/sec)、92.9(cm3/sec)、106.1(cm3/sec)、119.4(cm3/sec)、132.7(cm3/sec)145.9(cm3/sec)、159.2(cm3/sec)で、低いものから順に各射出容量の条件について5ショットの成形を行った後、ピーク温度280℃のリフロー処理(詳細な条件は後述する)を施し、5個の成形品の中で、目視観察にてブリスターが発生するものが確認できなければ、さらに高い射出容量の条件で5ショットの成形を行い、同様のリフロー処理を施し、ブリスターが発生するまで目視にて評価して、ブリスターが発生しない(目視にて全く観察されない)最大の射出容量(Vcmax)を求めた。第一射出容量測定工程の結果を表1に示した。
スクリュー径:φ26mm
スクリュー回転数:100rpm
背圧:3MPa
保圧力:50MPa
保圧時間:1秒
冷却時間:5秒
サックバック:3mm
サイクル時間:15秒
シリンダー温度:340℃-340℃-330℃-320℃
金型温度:80℃
装置:赤外線リフロー炉(「RE-300」、日本パルス技術研究所製)
プレヒートゾーン温度設定:150℃×3分
ヒートゾーン温度設定:218℃×2分
加熱炉通過時間:5分
成形品表面ピーク温度:280℃
(成形品表面ピーク温度は、リフロー加熱条件で成形品表面に熱伝対を取り付けて測定した最も高い温度である)
比(φs/φn)を2から3.3に変更した以外は、第一射出容量測定工程と同様の方法で、ブリスターが発生しない最大の射出容量を求めた。第二射出容量測定工程の結果を表1に示した。
液晶性樹脂組成物1、2ともに比(φs/φn)と射出容量(Vcmax)との関係は、同じ挙動を示した。そこで、比(φs/φn)の値が2、3.3、4.7の液晶性樹脂組成物1、2のデータを用い、比(φs/φn)と射出容量(Vcmax)との関係を表す近似式を、マイクロソフト・エクセル表計算ソフトを用いる方法で、線形関数として求めた。得られた線形関数は、Vcmax=-45(φs/φn)+240(図3中の破線)であった。
Claims (7)
- 所定の成形条件で液晶性樹脂組成物を射出成形した場合に、成形体表面にブリスターが発生しない最大の射出容量(Vcmax)1を測定する工程と、
前記所定の成形条件のうちスプルーの出口径(φs)とノズルの出口径(φn)との比(φs/φn)を変更して、前記液晶性樹脂組成物を射出成形した場合に、成形体表面にブリスターが発生しない最大の射出容量(Vcmax)2を測定する工程と、
ブリスターが発生しない最大の射出容量(Vcmax)と、スプルーの出口径とノズルの出口径との比(φs/φn)と、の関係を所定の形式の関数(Vcmax=f(φs/φn))で導出する工程と、を備え、
Vcmax(cm3/sec)<f(φs/φn)を満たす条件で液晶性樹脂組成物を射出成形することを特徴とする成形体の製造方法。 - 前記所定の形式の関数が、下記の式(I)で表され、
さらに下記式(II)を満たす成形条件で液晶性樹脂組成物を射出成形することを特徴とする請求項1に記載の成形体の製造方法。
Vcmax(cm3/sec)<-45(φs/φn)+240・・・(I)
φn<3mm・・・(II) - 前記ノズルの出口径(φn)が2mm以下であることを特徴とする請求項1又は2に記載の成形体の製造方法。
- 前記液晶性樹脂組成物は、ガラス繊維を含むことを特徴とする請求項1から3のいずれかに記載の成形体の製造方法。
- 前記スプルーの出口径と前記ノズルの出口径との比(φs/φn)が、4.5以下である請求項1から4のいずれかに記載の成形体の製造方法。
- スプルーの出口径(mm)とノズルの出口径(mm)との比(φs/φn)を所定の値以下とすることで、液晶性樹脂組成物を射出成形する際のブリスター発生を抑制する方法。
- 前記所定の値が4.5以下であり、前記ノズルの出口径(φn)が3mm以下である請求項6記載のブリスター発生を抑制する方法。
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JPH1148278A (ja) * | 1997-07-31 | 1999-02-23 | Polyplastics Co | 液晶ポリマーの射出成形方法並びに射出成形品 |
JP2003062854A (ja) * | 2001-08-29 | 2003-03-05 | Polyplastics Co | 再生樹脂含有射出成形体及びその成形方法 |
JP2004009462A (ja) * | 2002-06-05 | 2004-01-15 | Polyplastics Co | 射出成形装置及び射出成形方法 |
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JPH1148278A (ja) * | 1997-07-31 | 1999-02-23 | Polyplastics Co | 液晶ポリマーの射出成形方法並びに射出成形品 |
JP2003062854A (ja) * | 2001-08-29 | 2003-03-05 | Polyplastics Co | 再生樹脂含有射出成形体及びその成形方法 |
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