WO2013073405A1 - プリフォームの射出成形装置、射出成形方法、及びプリフォーム - Google Patents
プリフォームの射出成形装置、射出成形方法、及びプリフォーム Download PDFInfo
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- WO2013073405A1 WO2013073405A1 PCT/JP2012/078662 JP2012078662W WO2013073405A1 WO 2013073405 A1 WO2013073405 A1 WO 2013073405A1 JP 2012078662 W JP2012078662 W JP 2012078662W WO 2013073405 A1 WO2013073405 A1 WO 2013073405A1
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Images
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Definitions
- the present invention relates to an injection molding apparatus, an injection molding method, and a preform for a test tubular preform for molding a synthetic resin casing in which an intermediate layer is laminated in a main material layer forming a main body by biaxial stretch blow molding. Regarding reform.
- PET resin casings made from biaxially stretched blow-molded test tubular preforms by injection molding have properties such as excellent transparency, mechanical strength, and gas barrier properties. It is used in various fields such as food, food and cosmetics.
- gas barrier properties such as oxygen are required to suppress degradation of the quality of the content liquid
- an intermediate layer made of nylon resin with high gas barrier properties is laminated in the main material layer made of PET resin that forms the main body
- the PET bottle which has this kind of laminated structure can be obtained by biaxially stretching blow-molding a test tubular preform having a laminated structure of two kinds and three layers by injection molding.
- Patent Document 1 describes an invention relating to a molding apparatus having a multi-layer nozzle for injection molding the above-described two types and three layers of preforms.
- FIG. 10A shows a conventional example of this type of preform 101
- FIG. 11 is a cross-sectional view schematically showing an example of the nozzle portion 11 of a molding apparatus for molding the preform 101.
- FIG. 12, FIG. 12 is an explanatory view showing an example of an injection pattern for molding the preform 101 using this apparatus
- FIG. 13 shows a filling process of the molten resin into the mold cavity in this injection pattern. It is explanatory drawing.
- the preform 101 in FIG. 10A is formed by laminating a barrier resin layer 101b formed of a resin having a high gas barrier property as an intermediate layer, and the preform 101 is subjected to biaxial stretch blow molding, for example, oxygen from the outside.
- a barrier resin layer 101b formed of a resin having a high gas barrier property as an intermediate layer
- biaxial stretch blow molding for example, oxygen from the outside.
- the preform 101 having such a laminated structure is molded by an injection pattern as shown in FIG. 12 by a molding apparatus having the multilayer nozzle portion 11 shown in FIG. That is, the PET resin supplied from the first supply unit Sa in the apparatus of FIG. 11 flows from the outer channel 15a and the inner channel 15c to the combined channel 19, and the barrier resin supplied from the second supply unit Sb is the middle channel. 15b flows into the combined flow path 19 and flows between the outer flow path 15a and the inner flow path 15c. In the combined flow path 19, a combined resin body in which the barrier resin Rb is laminated in a cylindrical shape in the main material resin Ra is formed. The joined resin body is injected and filled into the cavity 4 of the mold 1.
- FIG. 13A shows a state immediately before time E of the injection pattern shown in FIG. 12, and shows a state in which only the PET resin Ra is filled.
- injection of the barrier resin Rb starts.
- the mold cavity is filled with the barrier resin Rb sandwiched between the PET resins Ra (see FIG. 13B).
- the injection of the barrier resin is stopped and only the PET resin Ra is filled again, the injection process is finished (see FIG. 13C), and the preform 101 shown in FIG. 10A can be obtained.
- the barrier resin layer 101b is not necessarily laminated on all of the peripheral walls forming the preform 101, as can be seen from FIG. 10 (a).
- the upper end portion and the bottom portion 106 of the mouth tube portion 102 are configured such that the barrier resin layer 101b is not laminated.
- the barrier layer 101b formed of a different kind of resin is laminated to the upper end in combination with the open end, molding shrinkage or thermal crystallization treatment of the mouth tube portion 102 is performed. Therefore, the barrier layer 101b is not laminated on the upper end portion.
- the front edge LE of the barrier resin layer 101b is formed at a substantially central height of the mouthpiece portion 102 in consideration of the above-described deformation, gas barrier property, and material cost of the gas barrier resin. It is required to control the position of the leading edge LE of the barrier resin layer 101b with high accuracy.
- the mouth tube portion 102 is relatively thick without undergoing stretching deformation even after biaxial stretch blow molding to the housing, and even if the limited portion of the upper end portion is the PET resin layer 101a alone, The decrease in gas barrier properties can be kept relatively small.
- the bottom portion 106 is a portion that is stretched and thinned unlike the mouth tube portion 102, as shown in FIG. 10B, from the viewpoint of suppressing a decrease in gas barrier properties of the entire casing.
- the barrier resin layer 101b is laminated in a non-uniform state, such as the barrier resin layer 101b is laminated in a plurality of layers, or a piece of the barrier resin layer 101b, so-called scale is laminated, the bottom portion of the housing is deformed unevenly As a result, the grounding state is not stable, and the mechanical strength is reduced. There is also a problem that a fragment of the barrier resin Rb remains at the tip of the multi-layer nozzle portion 11, and this fragment is mixed into the PET resin Ra in the next shot.
- the barrier resin layer 101b can be continuously laminated without being divided into capsules at the bottom 106.
- the size of the gate mark located in the center of the bottom portion 106 of the preform is not stable, the moldability is not stable, and the PET resin layer 101a on the inner surface side is pierced during longitudinal stretching by the stretching rod. is there.
- the present invention is for solving the problems in the prior art related to the injection molding of a preform in which the second resin layer is laminated as an intermediate layer in the main material layer, and the technical problem is By controlling the lamination of the intermediate layer at the bottom of the preform with high productivity and high accuracy, biaxial stretch molding can be realized with high productivity, and functions such as gas barrier properties by the intermediate layer are highly demonstrated.
- the purpose is to provide a housing to be made.
- the present invention relates to a preform injection molding apparatus, an injection molding method using the apparatus, and a preform that can be molded by the injection molding method.
- an injection molding apparatus, an injection molding method, and a preform will be described in this order.
- the main configuration related to the injection molding apparatus of the present invention is: In an injection molding apparatus for injection molding a test tube preform for biaxial stretch blow molding in which a second resin layer is laminated as an intermediate layer in a main material layer forming a main body, A nozzle part for forming a joined resin body by joining the second resin for forming the second resin layer into the main material resin for forming the main material layer, and a mold disposed at the tip of the nozzle part.
- the nozzle portion includes an outer flow channel, an intermediate flow channel, an inner flow channel, and a combined flow channel that extends to the tip of the nozzle portion and communicates with these three flow channels in order from the outside.
- the main material resin is supplied to the road, and the second resin is supplied to the middle flow path.
- the other structure of this invention is the said main structure, A first supply unit for supplying a main resin and a second supply unit for supplying a second resin;
- the nozzle portion includes a cylindrical outer flow channel, an intermediate flow channel, an inner flow channel, and a column-shaped combined flow channel that extends to the tip of the nozzle portion and communicates with these three flow channels.
- the opening of the inner flow path to the combined flow path is controlled by controlling the position of the tip of the cylindrical shut-off pin that is slidably inserted and disposed inside the inner flow path.
- the resin is supplied from the outer channel, the middle channel, and the inner channel to the combined channel while continuing to supply the resin from the first supply unit and the second supply unit.
- the second resin supplied via the middle flow path in the combined flow path can be obtained by completely opening the inner flow path by positioning the tip upstream of the opening end of the inner flow path to the combined flow path.
- the structure of the merged resin body formed by the flow path between the outer flow path and the main flow path resin from the inner flow path is formed into a cylindrical main material resin with the second resin in a cylindrical shape. It can be laminated. 2)
- the tip is positioned at a predetermined position in the vicinity of the opening end of the inner flow path, the opening degree of the opening end is reduced, and the supply speed of the main material resin from the inner flow path is reduced, thereby forming a cylindrical shape.
- the lamination mode of the second resin in the main material resin can be made into a finer cylindrical shape.
- the main resin in the merged resin body 2 can be controlled with high accuracy to a cylindrical shape having a predetermined diameter, and in particular, the intermediate layer at the bottom of the preform, which has been difficult with the prior art, can be controlled with high accuracy. It becomes possible to control.
- the opening degree of the opening end of the inner flow path is adjusted with high accuracy at a predetermined timing because of a simple mechanism called linear sliding of the shut-off pin. Is possible.
- Still another configuration relating to the injection molding apparatus of the present invention is such that, in the above configuration, the inner flow path has a reduced diameter flow path that tapers toward the combined flow path at the tip of the cylindrical flow path. It is said.
- Still another configuration relating to the injection molding apparatus of the present invention is a configuration in which the sliding operation of the shut-off pin is controlled by a servo mechanism in the main configuration described above.
- the inner flow path can be shut off and opened with high precision at a predetermined timing, and the position of the tip of the shut-off pin can be set with high precision. Since it can be controlled, it is possible to adjust the opening degree of the opening end portion of the inner flow path by the tip of the shutoff pin with higher accuracy.
- the main configuration relating to the preform injection molding method of the present invention is: In the injection molding method of a test tubular preform for biaxial stretch blow molding in which a second resin layer is laminated as an intermediate layer in a main material layer forming a main body,
- the above-described injection molding apparatus of the present invention is used, Supply the main material resin from the outer channel and the inner channel to the combined channel for a predetermined time at a predetermined supply speed, Supplying a second resin from the middle flow path to the combined flow path at a predetermined supply speed for a fixed time within a predetermined time range in which the main material resin is supplied; Before the second resin is supplied, or after a predetermined time from the start of supply, until at least the supply of the second resin ends, the shut-off pin is slid so that the tip of the shut-off pin flows inward.
- Another configuration relating to the injection molding method of the preform of the present invention is the main configuration described above, First, the main material resin is supplied from the first supply part to the combined flow path through the outer flow path and the inner flow path as a state where the opening end of the inner flow path is completely opened by controlling the sliding position of the shut-off pin, Next, after a predetermined time from the start of supply of the main material resin, the second resin is supplied from the second supply unit to the combined flow path through the middle flow path for a certain time, and the main resin from the outer flow path and the inner flow path is supplied.
- the tip of the shut-off pin is disposed at a predetermined position near the opening end to the combined flow path of the inner flow path, and the main material from the inner flow path Decrease the resin supply speed to the specified speed,
- a predetermined time after completion of the supply of the second resin the inner flow path is completely opened by the sliding of the shut-off pin, and the pressure is maintained for a predetermined time.
- Still another configuration relating to the injection molding method of the preform of the present invention is the above main configuration,
- the merged resin body formed from the main resin and the second resin in the merge channel is sequentially placed in the cavity via a pin gate disposed at a position corresponding to the center of the bottom bottom wall of the mold cavity.
- the sliding speed of the shut-off pin related to the adjustment of the opening rate of the opening end of the inner flow path, including the main material resin supply speed, the second resin supply start time, the end time, the injection pattern including the supply speed
- the end edge of the second resin layer laminated as an intermediate layer in the main material layer in the preform is located within a predetermined range of the bottom portion excluding a gate mark formed at the center of the bottom portion formed in a hemispherical arc shell shape. It is said that.
- cylindrical joining resin bodies are sequentially formed in the joining flow path in the following process.
- a merged resin body laminated in a cylindrical shape is formed.
- (3) is a process for highly controlling the lamination mode of the second resin layer in the vicinity of the bottom of the preform.
- the molding method since the supply of the main material resin from the inner flow path is continued until a small amount of the second resin is supplied, the second resin is cylindrical up to its end edge. Encapsulation is maintained and encapsulation of the entire region including the gate traces at the bottom of the preform can be prevented from being continuously laminated, resulting in poor moldability due to encapsulation, deformation of the bottom of the housing, etc. It becomes possible to solve the problem.
- the second resin can be formed into a cylindrical laminated form having a predetermined diameter at least in the vicinity of the terminal edge thereof, whereby the main material in the preform
- the termination edge of the second resin layer laminated as an intermediate layer in the layer is positioned in a predetermined range in the vicinity of the bottom excluding the circular pin gate mark formed at the center of the bottom bottom wall. Control becomes possible.
- the timing for adjusting the opening degree of the opening end of the inner flow path at the tip of the shutoff pin can be before the supply start time of the second resin, or in the middle of the supply time period.
- the thin cylindrical stacking mode is maintained in the vicinity of the terminal edge of the second resin layer in the merged resin body. It is necessary to adjust the opening degree of the opening end portion of the inner flow path at least until the supply of the second resin layer is completed.
- Still another configuration relating to the injection molding method of the invention is the main configuration described above,
- the second resin is a synthetic resin having excellent gas barrier properties, and the second resin layer is a gas barrier layer.
- the main configuration relating to the preform of the present invention is as follows.
- a test tubular preform for biaxial stretch blow molding in which a second resin layer is laminated as an intermediate layer in a main material layer forming a main body, At the bottom surface of the preform, the terminal edge of the second resin layer is within a range from the outer periphery of the circular gate mark formed at the center of the bottom surface to the periphery corresponding to the inner peripheral surface of the trunk portion. It is said that it is set as the position structure.
- the second resin By adjusting the opening degree of the opening end portion of the inner flow path, the second resin can be made into a cylindrical laminated form having a predetermined diameter at least in the vicinity of the terminal edge thereof, whereby in the main material layer in the preform Advanced control of the lamination mode is performed such that the end edge of the second resin layer laminated as an intermediate layer is positioned in a predetermined range near the bottom excluding the circular pin gate mark formed in the center of the bottom bottom wall.
- the second resin layer has sufficient functions such as gas barrier properties while solving problems such as poor moldability due to the second resin layer being stacked on the gate mark and deformation of the bottom of the casing. Can be demonstrated.
- (A) of the preform of this invention is a partial longitudinal cross-sectional view
- (b) is a bottom view.
- FIG. 1 shows an example of a preform 101 of the present invention molded by an injection molding method of the present invention, which will be described later.
- the overall shape is a test tube, and a PET resin which is a main material layer forming a main body.
- the layer 101a has a laminated structure having a barrier resin layer 101b as a second resin layer as an intermediate layer.
- MXD6 nylon is used as the barrier resin.
- the total height of the preform 101 is 100 mm
- the outer diameter of the body 105 is 20 mm
- the average wall thickness of the peripheral wall of the body 105 is 2.5 mm
- the weight is 22 g.
- a circular gate mark 107 having a diameter of 5 mm remains in the center of the outer peripheral surface of the bottom portion 106 (see FIG. 1B).
- the leading edge LE referred to as the leading edge of the barrier resin layer 101b is located at a distance La of 19.3 mm from the top surface of the mouthpiece portion 102, and the trailing edge of the barrier resin layer 101b.
- the terminal edge TE referred to is located at a position where the distance Lb from the center of the bottom surface of the bottom portion 106 is 5 mm, that is, approximately 2.5 mm outside the outer periphery of the gate mark 107, and is located circumferentially in FIG.
- the circular gate mark 107 formed at the center of the bottom surface of the bottom portion 106 is located within the range from the outer periphery to the periphery corresponding to the inner peripheral surface 105p of the body portion 105. I understand.
- the distances La and Lb are average values.
- FIGS. 2, 3 and 4 schematically show an example of the injection molding apparatus of the present invention.
- FIG. 2 is a longitudinal sectional view in the vicinity of the nozzle portion 11 and shows a state where the mold 1 is attached to the downstream side.
- 3 is an explanatory view for explaining the position of the tip 20p of the shut-off pin 20 in the apparatus of FIG. 2
- FIG. 4 is a longitudinal sectional view showing a schematic structure of the mold 1. As shown in FIG.
- the nozzle portion 11 includes a cylindrical first mandrel 21, a second mandrel 22, and a third mandrel 23 that are arranged in the same central axis in order from the inside, and a columnar shut inside the first mandrel 21.
- An off pin 20 is slidably inserted and disposed.
- the tip of each mandrel has a tapered cylindrical shape with a diameter reduced toward the downstream side.
- a cylindrical outer flow path 15 a in which the main material resin Ra flows is formed between the third mandrel 23 and the second mandrel 22, and the second resin Rb is interposed between the second mandrel 22 and the first mandrel 21.
- a flowing cylindrical middle flow path 15b is formed, and a cylindrical inner flow path 15c through which the main material resin Ra flows is formed between the first mandrel 21 and the shut-off pin 20 similarly to the outer flow path 15a.
- the main material resin Ra is supplied from a first supply portion Sa such as a screw-type extruder or an accumulator having a plunger attached to the tip of the extruder, and passes through the introduction path 12a and is connected to the outside via the manifolds 14a1 and 14a2. It is introduced into the flow path 15a and the inner flow path 15c. Further, the second resin Rb is supplied from the second supply part Sb, and is introduced into the middle flow path 15b through the introduction path 12b and the manifold 14b.
- a first supply portion Sa such as a screw-type extruder or an accumulator having a plunger attached to the tip of the extruder
- the main material resin Ra is obtained from the reduced diameter flow path 15as disposed at the front end portion of the outer flow path 15a and the reduced diameter flow path 15cs disposed at the front end portion of the inner flow path 15c, and the second resin Rb is The reduced diameter flow path 15bs disposed at the tip of the middle flow path 15b is supplied to the cylindrical merged flow path 19, and the main resin Ra and the second resin Rb merge in the merged flow path 19 to form a merged resin body.
- this merged resin body is arranged at a position corresponding to the center of the bottom wall of the bottom portion 106 of the preform 101 in the cavity 4 formed by the core mold 2 and the cavity mold 3 of the mold 1. Inject and fill into the cavity 4 via
- the shut-off pin 20 is configured to slide on the inner peripheral surface of the reduced diameter tip portion of the first mandrel 21 that forms the inner flow path 15c together with the shut-off pin 20.
- the shut-off pin 20 moves the tip 20p at a predetermined position in the vicinity of the open end 17c to the combined channel 19 of the inner channel 15c.
- the opening degree of the open end portion 17c is adjusted between the fully open state and the shut-off state, and the supply amount of the main material resin Ra from the inner flow path 15c to the combined flow path 19 is adjusted.
- the sliding operation (in the vertical direction in FIG. 2) of the shut-off pin 20 is controlled by a servo mechanism using a servo motor (not shown) so that the advanced flow path adjustment function as described above is exhibited.
- a servo mechanism using a servo motor (not shown)
- the adjustment of the supply speed of the main material resin Ra supplied from the inner flow path 15c by the shut-off pin 20 is performed at the portion in contact with the combined flow path 19 called the open end 17c of the inner flow path 15c. Therefore, as compared with the conventional flow rate adjustment function using a check valve or a spool valve disposed at a position distant from the combined flow path 19 on the upstream side of the nozzle portion 11, the viscoelastic property of the molten resin. Time delays can be avoided, and control related to shut-off, supply, and flow rate adjustment can be performed with higher accuracy.
- FIG. 3 is a view for explaining the position of the tip 20p of the shut-off pin 20 in the apparatus of FIG. 2.
- the distance from the position Ls0 that is the tip is indicated.
- the position Ls1 is a position corresponding to the upstream end of the reduced diameter flow path 15cs, and in the apparatus of this embodiment, the distance from the position Ls0 is 18 mm.
- FIG. 5 schematically shows an injection pattern when the preform 101 shown in FIG. 1 is injection-molded by the injection molding apparatus shown in FIG. 2, with the horizontal axis representing the time axis and the vertical axis representing the molten resin supply speed.
- the solid line indicates the injection pattern of the main resin resin PET resin Ra
- the broken line indicates the injection pattern of the barrier resin Rb.
- the supply rate Va of the PET resin Ra from the first supply unit Sa is 7.1 g / sec
- the supply rate Vb of the barrier resin from the second supply unit Sb is 0.53 g / sec.
- the position of the tip 20p of the shut-off pin 20 along the passage of time is shown by a two-dot chain line.
- the tip 20p is Ls1 shown in FIG.
- the tip 20p is at a position of 14.55 mm in the case of this embodiment, and the opening degree of the open end portion 17c of the inner flow path 15c is reduced to supply the PET resin Ra. Is controlled to be small.
- the injection start time ta1 of the PET resin Ra is used as a reference, the injection end time ta2 of the PET resin Ra is 4.5 seconds.
- the injection start time tb1 of the barrier resin Rb is 1.6 seconds
- the end time tb2 is 3.4 seconds
- the tip 20p of the shut-off pin 20 is disposed at a position of 14.55 mm from time ts1 (2.1 seconds) to ts2 (3.9 seconds).
- the injection molding process of the injection pattern in FIG. 5 along with the passage of time is as follows.
- the position of the tip 20p of the shut-off pin 20 is set to Ls1 (see FIG. 3), the open end 17c of the inner flow path 15c is completely opened, and the PET resin Ra is removed from the first supply part Sa to the outside. It is supplied to the combined channel 19 through the channel 15a and the inner channel 15c.
- the barrier resin Rb is supplied from the second supply section Sb to the combined flow path 19 via the intermediate flow path 15b, and is caused to flow between the PET resin Ra from the outer flow path 15a and the inner flow path 15c.
- the position of the tip 20p of the shut-off pin 20 is set to Ls (see FIG.
- FIG. 6 is a schematic explanatory diagram for explaining the filling process of the PET resin Ra and the barrier resin Rb into the cavity 4 of the mold 1 in the process as described above by the injection pattern of FIG. Filling into the cavity 4 proceeds in the order of (a) ⁇ (b) ⁇ (c). Note that, on the right side of each of the drawings (a), (b), and (c), cross-sectional views along lines J1-J1, J2-J2, and J3-J3 are shown, respectively.
- the PET resin supplied from the outer flow path 15a is indicated as Ra1
- the PET resin supplied from the inner flow path 15c is indicated as Ra2.
- the barrier resin Rb when the barrier resin Rb is supplied from the middle flow path 15b, the supply amount of the PET resin Ra2 from the inner flow path 15c is reduced.
- the barrier resin Rb is laminated in the pin gate 5 in a thin cylindrical shape having a small diameter in the PET resins Ra1 and Ra2.
- the distance Lb from the center of the bottom 106 of the terminal edge TE of the barrier resin layer 101b was 5 mm, and could be close to the vicinity of the outer periphery of the gate mark 107.
- FIG. 7 shows the PET resin Ra and the barrier when injection molding is performed in the injection pattern of FIG. 5 while holding the tip 20p of the shut-off pin 20 at the position of Ls1, ie, 18 mm.
- FIG. 7 shows the PET resin Ra and the barrier when injection molding is performed in the injection pattern of FIG. 5 while holding the tip 20p of the shut-off pin 20 at the position of Ls1, ie, 18 mm.
- the injection molding with the injection pattern in which the position of the tip 20p is held at Ls1, that is, the position of 18 mm is the same as the conventional molding method shown in FIGS. 11 to 13 described above, and the amount of PET resin Ra2 supplied from the inner flow path 15c. Since the barrier resin Rb is supplied from the middle flow path 15b without changing the size, As shown in FIG. 7A, in the pin gate 5, the barrier resin Rb is laminated in a cylindrical shape having a large diameter among the PET resins Ra1 and Ra2. When the filling in the state of FIG. 7C is completed through the state of FIG. 7B, the terminal edge TE of the barrier resin layer 101b is considerably downstream as in the preform 101 of FIG. The distance Lb from the center of the bottom portion 106 is 19.4 mm.
- the barrier resin layer 101b formed of the barrier resin Rb is located close to the inner peripheral surface of the preform 101 as shown in FIG. I understand that.
- FIG. 8 shows the position Ls of the tip 20p of the shut-off pin 20 shown in FIG. 3 at the time ts1 to ts2 in the injection pattern shown in FIG. 5 at 14.00 mm, 14.55 mm, and 14.60 mm. , 15.10 mm, 18.00 mm and the preforms of Examples 1 to 5 molded at five positions, 6 is a table summarizing the distance La of the leading edge LE, the distance Lb of the terminal edge TE, and the oxygen transmission rate (OTR (cc / day)) measured with a biaxially stretched blow-molded housing.
- OTR oxygen transmission rate
- the housing 201 has a mouth tube portion 202, a neck ring 203, a tapered tubular shoulder portion 204, a cylindrical body portion 205 and a bottom portion 206.
- the overall height is 160 mm, and the outer diameter of the body portion 205 is 70 mm.
- the oxygen permeation rate of the casing 201 was measured using a device called OX-TRAN 10/50 manufactured by Modern Controls under the conditions of 23 ° C. and oxygen partial pressure of 21%.
- Example 1 where Ls is 14.00 mm, the supply of the PET resin Ra2 from the inner flow path 15c is cut off after the time ts1 when the tip 20p is set to the position Ls.
- the thin cylindrical stacking mode shown in FIG. 6A becomes a thin cylindrical shape.
- the terminal edge TE is continuous at the bottom portion 106 of the reform 101 and becomes a so-called encapsulated state.
- the OTR has an excellent oxygen barrier property of 0.0026 cc / day, but as described above, the PET inside the stretched rod caused by the gas barrier resin layer 101b being laminated on the gate trace 107 as well.
- the terminal edge TE of the gas barrier resin layer 101b is It is necessary to be located outside the outer peripheral edge of the gate mark 107.
- Example 2 in which Ls is 14.55 is the same as that described in the above-described embodiment, and the average value of the position of the terminal edge TE is 5.0 mm. As shown in FIG. It is located between the outer peripheral edge 107 and the peripheral edge corresponding to the inner peripheral surface 105 p of the body 105.
- the OTR was approximately the same as the 14.00 mm example with an encapsulated structure described above at 0.0028 cc / day.
- Example 3 in which Ls was 14.60 mm, the distance Lb of the terminal edge TE was 11.5 mm, and the OTR was 0.0075 cc / day.
- Example 4 where Ls was 15.10, the distance Lb of the terminal edge TE was 15.9 mm.
- Example 5 in which Ls is 18.00 mm is the comparative example described in FIG. 7.
- the distance Lb of the terminal edge TE is 19.4 mm
- the OTR is 0.0236 cc / day. Is about 8.5 times larger than that of the 14.55 mm example, indicating that the oxygen barrier properties are greatly reduced.
- the OTR is about three times larger than the example of 14.60 mm, and conversely, even when Ls is 14.60 mm and the distance Lb of the end edge TE is 11.5 mm, It can be seen that a considerably good oxygen barrier property can be obtained as compared with the conventional molding method.
- the distance La of the tip edge LE gradually decreases from 21.7 mm to 17.6 mm.
- the distance Lb of the end edge TE greatly changes due to a slight displacement of the tip 20p position of the shut-off pin 20, and molding is performed according to this change. It can be seen that the oxygen barrier property of the casing 201 is greatly changed.
- the position of the tip 20p of the shut-off pin 20 can be controlled with high accuracy by the servo mechanism only by sliding the shut-off pin 20 slightly.
- the flow rate can be adjusted to a high degree in a very short time, and the position of the terminal edge TE of the barrier resin layer 101b can be controlled with high accuracy.
- the apparatus shown in FIG. 2 is merely an example, and various variations of the detailed configuration can be used.
- the injection pattern shown in FIG. 5 is merely an example.
- the tip 20p of the shut-off pin 20 is moved to the arrangement position Ls after the supply start time tb1 of the barrier resin Rb, but is moved before the supply start time tb1 of the barrier resin Rb. You can also.
- the main resin for forming the preform is not limited to the PET resin, but a resin such as a polypropylene resin that has been conventionally used for a biaxially stretched blow molded casing can be used.
- the second resin In addition to the barrier resin, a resin having other functions or a resin for decoration can be used.
- the barrier resin in addition to MXD6 nylon resin, other nylon resins, ethylene- Other barrier resins such as vinyl alcohol copolymer (EVOH) can also be used.
- the preform using the injection molding apparatus of the present invention can provide a casing in which the lamination mode of the intermediate layer such as the barrier resin layer is highly controlled, particularly near the bottom, and is expected to be widely used.
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Abstract
Description
内容液の品質の低下を抑制するため、さらに酸素等のガスバリア性が必要な用途では、主体を形成するPET樹脂からなる主材層の中にガスバリア性の高いナイロン樹脂等からなる中間層を積層した2種3層の積層構造とする場合が多い。
そして、この種の積層構造を有するペットボトルは、射出成形による2種3層の積層構造を有する試験管状のプリフォームを2軸延伸ブロー成形して得ることができる。
ここで、図10(a)はこの種のプリフォーム101の従来例を示すものであり、図11はこのプリフォーム101を成形するための成形装置のノズル部11の一例を概略的に示す断面図、図12はこの装置を使用して上記プリフォーム101を成形するための射出パターンの一例を示す説明図、そして図13はこの射出パターンにおける、金型キャビティへの溶融樹脂の充填過程を示す説明図である。
すなわち、図11の装置で第1供給部Saから供給されるPET樹脂は外側流路15aと内側流路15cから合流路19に流動し、第2供給部Sbから供給されるバリア樹脂は中流路15bから合流路19に流動し、外側流路15aと内側流路15cの間に流入し、合流路19では主材樹脂Raの中にバリア樹脂Rbが円筒状に積層した合流樹脂体が形成され、この合流樹脂体が金型1のキャビティ4内に射出、充填される。
E時点でバリア樹脂Rbの射出が開始し、E~F時点間ではPET樹脂Raの間にバリア樹脂Rbが挟まれた積層状態で金型キャビティに充填され(図13(b)参照)、F時点でバリア樹脂の射出が停止され再びPET樹脂Raのみの充填となり、射出工程を終了(図13(c)参照)、図10(a)に示されるプリフォーム101を得ることができる。
図10(a)のプリフォーム101の例ではバリア樹脂層101bの先端縁LEを、上記した変形、ガスバリア性、さらにはガスバリア樹脂の材料コスト等を考慮し、口筒部102の略中央高さに位置させており、バリア樹脂層101bの先端縁LEの位置を高精度に制御することが求められている。
ただ、口筒部102は壜体への2軸延伸ブロー成形後も延伸変形することなく比較的肉厚で、上端部の限られた部分がPET樹脂層101a単独であっても壜体全体のガスバリア性の低下は比較的小さく抑えることができる。
しかし、図12の射出パターンのF時点、すなわちバリア樹脂の射出終了時点で、バリア樹脂のキャビティ4への流動が瞬時に止まらないと、所謂、切れが悪い状態となって、底部106の底面壁部分に、バリア樹脂層101bが、複数の層に積層する、バリア樹脂層101bの断片、所謂、スケールが積層する等、不均一な状態で積層されるため、壜体において底部が不均一に変形して接地状態が安定しない、さらには機械的強度が低下する等の問題も発生する。
また、多層ノズル部11の先端部にバリア樹脂Rbの断片が残留し、次のショットではこの断片がPET樹脂Raに混入してしまうと云う問題もある。
まず、本発明のうち射出成形装置に係る主たる構成は、
主体を形成する主材層中に中間層として第2の樹脂層を積層した2軸延伸ブロー成形用の試験管状のプリフォームを射出成形する射出成形装置において、
主材層を形成する主材樹脂中に第2の樹脂層を形成する第2の樹脂を合流させて合流樹脂体を形成するノズル部と、このノズル部の先端に配設される金型を有し、
ノズル部は、外側から順に外側流路、中流路、内側流路、そしてこれら3つの流路に連通してノズル部の先端にまで延設される合流路を配設し
外側流路と内側流路に主材樹脂を、中流路に第2の樹脂を供給する構成とし、
内側流路の内側に摺動可能に挿入、配設される円柱状のシャットオフピンの先端の配置位置の制御により、内側流路の合流路への開口端部の遮断あるいは開放、さらには開度の調整が可能な構成とする、と云うものである。
主材樹脂を供給する第1供給部及び第2の樹脂を供給する第2供給部を有し、
ノズル部は、外側から順にそれぞれ円筒状の、外側流路、中流路、内側流路、そしてこれら3つの流路に連通してノズル部の先端にまで延設される円柱状の合流路を配設し、
第1供給部から主材樹脂を外側流路と内側流路に、また第2供給部から第2の樹脂を中流路に供給する構成とし、
合流路で円柱状に合流した合流樹脂体を、金型のキャビティの、プリフォームの底部底壁の中央に相当する位置に配設されるピンゲートを介してキャビティ内に射出、充填する構成とする、と云うものである。
このシャットオフピンの先端の配置位置の制御により、第1供給部および第2供給部からの樹脂の供給を継続しながら、外側流路、中流路、内側流路から合流路への樹脂の供給を次のように制御することができる。
1)先端を内側流路の合流路への開口端部より上流側に位置させて、内側流路を完全に開放することにより、合流路で、中流路を経て供給される第2の樹脂を、外側流路と内側流路からの主材樹脂の間に流動させて、合流路で形成される合流樹脂体の構成を、円柱状の主材樹脂の中に第2の樹脂を円筒状に積層したものとすることができる。
2)先端を内側流路の開口端部近傍の所定位置に位置させて、この開口端部の開度を小さくし、内側流路からの主材樹脂の供給速度を小さくすることにより、円柱状の主材樹脂の中での第2の樹脂の積層態様を、1)の場合に比較してより細円筒状とすることができる。
3)先端を内側流路の合流端部より下流側に位置させて、内側流路を完全に遮断することにより、内側流路からの主材樹脂の供給が完全に遮断されるため、中流路を経て供給される第2の樹脂を、外側流路だけから供給される主材樹脂中に流動させて、合流路で形成される合流樹脂体の構成を円柱状の主材樹脂の中心に第2の樹脂を細円筒状に積層したものとすることができる。
主体を形成する主材層中に中間層として第2の樹脂層を積層した2軸延伸ブロー成形用の試験管状のプリフォームの射出成形方法において、
上述した本発明の射出成形装置を使用するものとし、
主材樹脂を外側流路と内側流路から合流路に所定の供給速度で所定時間供給し、
主材樹脂が供給される所定時間範囲内の一定時間、同時に第2の樹脂を中流路から合流路に所定の供給速度で供給し、
第2の樹脂が供給される前から、あるいは供給開始から所定時間後から少なくとも第2の樹脂の供給が終了するまでの間、シャットオフピンを摺動させてこのシャットオフピンの先端を内側流路の合流路への開口端部近傍の所定位置に配置させて、この開口端部の開度を調整し、内側流路から合流路への主材樹脂の供給速度を所定の速度まで小さくする、
と云うものである。
まず、シャットオフピンの摺動位置の制御により内側流路の開口端部を完全に開放した状態として第1供給部から主材樹脂を外側流路と内側流路を経て合流路に供給し、
次に、主材樹脂の供給開始の所定時間後に、第2の樹脂を一定時間、第2供給部から中流路を経て合流路に供給し、外側流路と内側流路からの主材樹脂の間に流動させ、
次に、第2の樹脂の供給の開始後から所定時間後に、シャットオフピンの先端を内側流路の合流路への開口端部近傍の所定位置に配置させて、内側流路からの主材樹脂の供給速度を所定の速度まで小さくし、
次に、第2の樹脂の供給の終了から所定時間後にシャットオフピンの摺動により内側流路を完全に開放して所定時間保圧する、と云うものである。
合流路内で主材樹脂と第2の樹脂から形成される合流樹脂体を順次金型のキャビティの、プリフォームの底部底壁の中央に相当する位置に配設されるピンゲートを介してキャビティ内に射出、充填し、
主材樹脂の供給速度、第2の樹脂の供給の開始時間、終了時間、供給速度を含めた射出パターン、さらには内側流路の開口端部の開度の調整に係るシャットオフピンの摺動時期および先端の配置位置の設定により、
プリフォームにおいて主材層中に中間層として積層する第2の樹脂層の終端縁を、半球弧殻状に形成される底部の中央に形成されるゲート痕を除く、底部の所定範囲内に位置させる、と云うものである。
(1)まず、合流路で外側流路と内側流路からの主材樹脂が合流して、主材樹脂からなる円柱状の合流樹脂体が形成される。
(2)次に、合流路で、中流路から第2の樹脂が外側流路と内側流路からの主材樹脂の間に流動し、円柱状の主材樹脂の中に第2の樹脂を円筒状に積層した合流樹脂体が形成される。
(3)ここで、シャットオフピンの先端による内側流路の開口端部の開度の調整により、内側流路からの主材樹脂の供給速度を所定の速度まで小さくし、第2の樹脂が所定の径を有する細円筒状に積層した合流樹脂体が形成される。
(4)中流路からの第2の樹脂の供給が停止し、最後には外側流路と内側流路からの主材樹脂が合流して主材樹脂からなる円柱状の合流樹脂体が再び形成される。
上記成形方法によれば、第2の樹脂の供給が停止するまで内側流路からの主材樹脂の供給が少量であっても継続されるので、第2の樹脂はその終端縁まで円筒状の積層態様が保持され、プリフォームの底部でゲート痕も含む全領域が連続的な積層状態になるカプセル化を防ぐことができ、カプセル化に伴う成形性の不良や、壜体における底部の変形等の問題を解消することが可能となる。
上記したように、底部近傍での第2の樹脂層の積層態様を高度に制御するためには、合流樹脂体中で第2の樹脂層の終端縁近傍で細円筒状の積層態様が保持されていることが必要であり、少なくとも第2の樹脂層の供給が終了するまで、内側流路の開口端部の開度を調整することが必要である。
第2の樹脂をガスバリア性に優れた合成樹脂とし、第2の樹脂層をガスバリア層とする、と云うものである。
主体を形成する主材層中に中間層として第2の樹脂層を積層した2軸延伸ブロー成形用の試験管状のプリフォームにおいて、
プリフォームの底面で、第2の樹脂層の終端縁が、底部の底面の中央に形成される円形のゲート痕の外周縁の外側から胴部の内周面に相当する周縁までの範囲内に位置する構成とする、と云うものである。
第2の樹脂層の終端縁を、ゲート痕を除く底部の限定された領域に位置させることにより、第2の樹脂層がゲート痕に積層することに起因する成形性の不良や、壜体の底部の変形等の問題を解消しながら、第2の樹脂層によるガスバリア性等の機能を十分に発揮させることが可能となる。
内側流路の開口端部の開度の調整により第2の樹脂を、少なくともその終端縁近傍で所定の径を有する円筒状の積層態様とすることができ、これによりプリフォームにおいて主材層中に中間層として積層する第2の樹脂層の終端縁を、底部底壁の中央に形成される円形のピンゲート痕を除く底部近傍の所定の範囲に位置させると云う、積層態様の高度な制御ができ、第2の樹脂層がゲート痕に積層することに起因する成形性の不良や、壜体の底部の変形等の問題を解消しながら、第2の樹脂層によるガスバリア性等の機能を十分に発揮させることができる。
図1は、後述する本発明の射出成形方法により成形される本発明のプリフォーム101の一例を示すもので、全体的な形状は試験管状であり、主体を形成する主材層であるPET樹脂層101a中に中間層として第2樹脂層であるバリア樹脂層101bを有する積層構造を有するものである。
なお、本実施例ではバリア樹脂としてMXD6ナイロンを使用している。
このプリフォーム101の全高さは100mm、胴部105の外径は20mm、胴部105の周壁の平均肉厚は2.5mm、重量は22gである。
また、底部106の外周面の中央に直径が5mmの円形のゲート痕107が残存形成されている(図1(b)参照)。
また、バリア樹脂層101bのトレーリングエッジと称される終端縁TEは底部106の底面の中心からの距離Lbが5mmの位置、すなわちゲート痕107の外周縁の略2.5mm外側に周状に位置しており、図1(b)の底面図で見ると、底部106の底面の中央に形成される円形のゲート痕107の外周縁の外側から胴部105の内周面105pに相当する周縁までの範囲内に位置していることが分かる。
なお、距離La、Lb等はいずれも平均値である。
また、各マンドレルの先端部は下流側に向かって縮径したテーパー筒状となっている。
そして、第3マンドレル23と第2マンドレル22の間に主材樹脂Raが流動する円筒状の外側流路15aが形成され、第2マンドレル22と第1マンドレル21の間に第2の樹脂Rbが流動する円筒状の中流路15bが形成され、さらに第1マンドレル21とシャットオフピン20の間に外側流路15aと同様に主材樹脂Raが流動する円筒状の内側流路15cが形成されている。
また、第2の樹脂Rbは第2供給部Sbから供給され、導入路12bを経てマニホールド14bを介して中流路15bに導入される。
そして、この合流樹脂体を、金型1のコア金型2とキャビティ金型3で形成されるキャビティ4の、プリフォーム101の底部106底壁の中央に相当する位置に配設されるピンゲート5を介してキャビティ4内に射出、充填する。
このシャットオフピン20は、ノズル部11の先端部を遮断あるいは開放すると云う通常の機能の他に、その先端20pの位置を内側流路15cの合流路19への開口端部17c近傍の所定の位置に制御、位置させることにより、この開口端部17cの開度を全開状態と遮断状態の間で調整し、内側流路15cから合流路19への主材樹脂Raの供給量を調整すると云う機能を発揮する。
そして、上記のような高度な流路の調整機能が発揮されるように、シャットオフピン20の(図2では上下方向の)摺動動作はサーボモーターを使用したサーボ機構により(図示省略)制御するようにしている。
ここで位置Ls1は縮径流路15csの上流端に相当する位置であり、本実施例の装置では位置Ls0からの距離は18mmである。
図5は、図2に示した射出成形装置で図1に示したプリフォーム101を射出成形する際の射出パターンを、横軸を時間軸、縦軸を溶融樹脂の供給速度として概略的に示した説明図で、実線で主材樹脂であるPET樹脂Raの、破線でバリア樹脂Rbの射出パターンを示している。
なお、第1供給部SaからのPET樹脂Raの供給速度Vaは7.1g/sec、第2供給部Sbからのバリア樹脂の供給速度Vbは0.53g/secである。
また、時間軸について云うと、PET樹脂Raの射出開始時間ta1を基準にすると、PET樹脂Raの射出終了時間ta2は4.5秒、
バリア樹脂Rbの射出開始時間tb1は1.6秒、終了時間tb2は3.4秒、
そしてシャトオフピン20の先端20pは、時間ts1(2.1秒)からts2(3.9秒)の間、14.55mmの位置に配置される。
(1)シャットオフピン20の先端20pの位置をLs1として(図3参照)、内側流路15cの開口端部17cを完全に開放した状態とし、第1供給部SaからPET樹脂Raを、外側流路15aと内側流路15cを経て合流路19に供給する。
(2)時間tb1にバリア樹脂Rbを第2供給部Sbから中流路15bを経て合流路19に供給し、外側流路15aと内側流路15cからのPET樹脂Raの間に流動させる。
(3)時間ts1にシャットオフピン20の先端20pの位置をLsとして(図3参照)、内側流路15cからのPET樹脂Raの供給速度を所定の量まで小さくする。
(4)時間tb2に第2供給部Sbからのバリア樹脂Rbの供給を停止する。
(5)時間ts2にシャットオフピン20の先端20pの位置をLs1に戻し、内側流路15cからのPET樹脂Raの供給速度を元の速度に戻す。
(6)時間ta2に金型圧力を所定圧力まで低下させて(この結果として第1供給部Saからの供給速度が低下する。)、時間ta3までを保圧工程とする。
なお、(a)、(b)、(c)各図の右側にはそれぞれJ1-J1、J2-J2、J3―J3線に沿った断面図を示している。
またここでは、外側流路15aから供給されるPET樹脂をRa1、内側流路15cから供給されるPET樹脂をRa2とし、区別して示している。
図6(a)に見られるように、ピンゲート5でバリア樹脂Rbは、PET樹脂Ra1、Ra2の中で、径の小さな細円筒状に積層される。
このようにバリア樹脂Rbを細円筒状の積層状態とすることにより、図6(b)の状態を経て、図6(c)の状態で充填を完了すると、
図1のプリフォーム101のように、バリア樹脂層101bの終端縁TEの底部106の中心からの距離Lbは5mmとなり、ゲート痕107の外周縁の近傍にまで近づけることができた。
この例は上記したLsを14.55mmとした実施例の比較例に相当するものであるが、図7(a)→(b)→(c)の順にキャビティ4への充填が進行している。
なお、図7でも図6と同様に(a)、(b)、(c)各図の右側にはそれぞれK1-K1、K2-K2、K3―K3線に沿った断面図を示している。
図7(a)に見られるように、ピンゲート5ではバリア樹脂RbはPET樹脂Ra1、Ra2の中で、径の大きな円筒状に積層される。
そして、図7(b)の状態を経て、図7(c)の状態で充填を完了すると、図10(a)のプリフォーム101のように、バリア樹脂層101bの終端縁TEはかなり下流側(図10では上方に)に位置し、底部106の中心からの距離Lbは19.4mmとなった。
先端縁LEの距離La、終端縁TEの距離Lb、そして2軸延伸ブロー成形した壜体で測定した酸素透過速度(OTR(cc/day))をまとめた表である。
ここで、例2~例4の場合は、図5に示されるパターンで、位置Lsだけを変えたものであるが、例1の場合は図5に示されるパターンで先端20pを位置Ls(14.00mm)にする時間ts1をバリア樹脂Rbが供給される時間帯であるtb1とtb2の中間にしたパターンとして成形したものである。
なお、図9に2軸延伸ブロー成形した壜体の正面図を示す。この壜体201は口筒部202、ネックリング203、テーパー筒状の肩部204、円筒状の胴部205そして底部206を有し、全高さは160mm、胴部205の外径は70mmである。
また、壜体201の酸素透過速度はモダンコントロールズ社製のOX-TRAN10/50という装置を用いて、23℃、酸素分圧21%という条件で測定した。
バリア樹脂Rbの終端縁近傍では、図6(a)に示される細円筒状の積層態様が細円柱状になってしまい、その結果、図10(b)のプリフォームに示されるように、プリフォーム101の底部106で終端縁TEが連続化し、所謂、カプセル化した状態となってしまう。
この場合、OTRは0.0026cc/dayと優れた酸素バリア性を有するが前述したように、特にゲート跡107にもガスバリア樹脂層101bが積層されていることに起因する、延伸ロッドによる内側のPET樹脂層101aの突き破れや、壜体201の底部206の変形により、歩留まりが低くなり、生産性が低下すると云う問題が発生する。
なお、プリフォーム101の底部106で終端縁TEが連続化していない場合でも、ゲート跡107にガスバリア樹脂層101bが積層されていると同様な問題が生じるので、ガスバリア樹脂層101bの終端縁TEはゲート跡107の外周縁の外側に位置させる必要がある。
次に、Lsを14.60mmとした例3では、終端縁TEの距離Lbは11.5mmで、OTRは0.0075cc/dayであった。
また、Lsを15.10とした例4では、終端縁TEの距離Lbは15.9mmであった。
また、14.60mmの例と比較してもOTRは3倍程度大きくなっており、このことは逆にみると、Lsが14.60mmで、終端縁TEの距離Lbが11.5mmの場合でも、従来の成形方法によるものと比較すればかなり良好な酸素バリア性が得られることが判る。
このことは、逆にみると本発明の装置によれば、シャットオフピン20を僅かに摺動させるだけで、サーボ機構によりシャットオフピン20の先端20pの位置を高精度に制御することができることも相俟って、極く、短時間で流量の調整を高度に達成することができ、バリア樹脂層101bの終端縁TEの位置を高精度に制御できることを示している。
上記実施例では、PET樹脂からなる主材層の中にバリア樹脂からなる第2の樹脂層を積層した2種3層の積層構造を有するプリフォーム、その射出成形方法及び成形装置について説明したが、本発明は2種3層の積層構造に限定されることなく、主材層と第2の樹脂層の積層態様を高い生産性で高精度に制御すると云う本発明の技術思想の範疇のなかで、たとえば、加飾のための着色樹脂層を中間層としてさらに積層する等、さまざまな積層構造とすることができる。
また射出成形方法についても、例えば図5に示した射出パターンは一例にすぎない。たとえば、図5のパターンではバリア樹脂Rbの供給開始時間tb1の後にシャットオフピン20の先端20pを、配置位置Lsに移動しているが、バリア樹脂Rbの供給開始時間tb1の前に移動することもできる。
2 ;コア金型
3 ;キャビティ金型
4 ;キャビティ
5 ;ピンゲート
11;ノズル部
12a、12b;導入路
14a1、14a2、14b;マニホールド
15a;外側流路
15b;中流路
15c;内側流路
15as、15bs、15cs;縮径流路
17c;開口端部
19;合流路
20;シャットオフピン
20p;先端
21;第1マンドレル
22;第2マンドレル
23;第3マンドレル
Ls0、Ls、Ls1;(シャットオフピンの先端の)位置
Ra;主材樹脂(PET樹脂)
Rb;第2の樹脂(バリア樹脂)
Sa;第1供給部
Sb;第2供給部;
101;プリフォーム
101a;主材層(PET樹脂層)
101b;第2の樹脂層(バリア樹脂層)
102;口筒部
103;ネックリング
105;胴部
105p;内周面
106;底部
107;ゲート痕
LE;先端縁
TE;終端縁
La;(先端縁までの)距離
Lb;(終端縁までの)距離
201;壜体
202;口筒部
203;ネックリング
204;肩部
205;胴部
206;底部
Claims (9)
- 主体を形成する主材層(101a)中に中間層として第2の樹脂層(101b)を積層した2軸延伸ブロー成形用の試験管状のプリフォーム(101) を射出成形する射出成形装置であって、前記主材層(101a)を形成する主材樹脂(Ra)中に第2の樹脂層(101b)を形成する第2の樹脂(Rb)を合流させて合流樹脂体を形成するノズル部(11)と、該ノズル部(11)の先端に配設される金型(1)を有し、前記ノズル部(11)は、外側から順に外側流路(15a)、中流路(15b)、内側流路(15c)、そして該3つの流路に連通してノズル部(11)の先端にまで延設される合流路(19)を配設し、前記外側流路(15a)と内側流路(15c)に主材樹脂(Ra)を、中流路(15b)に第2の樹脂(Rb)を供給する構成とし、内側流路(15c)の内側に摺動可能に挿入、配設される円柱状のシャットオフピン(20)の先端(20p)の配置位置の制御により、内側流路(15c)の合流路(19)への開口端部(17c)の遮断あるいは開放、さらには開度の調整が可能な構成としたことを特徴とする射出成形装置。
- 主材樹脂(Ra)を供給する第1供給部(Sa)及び第2の樹脂(Rb)を供給する第2供給部(Sb)を有し、ノズル部(11)は、外側から順にそれぞれ円筒状の、外側流路(15a)、中流路(15b)、内側流路(15c)、そして該3つの流路に連通してノズル部(11)の先端にまで延設される円柱状の合流路(19)を配設し、前記第1供給部(Sa)から主材樹脂(Ra)を外側流路(15a)と内側流路(15c)に、また第2供給部(Sb)から第2の樹脂(Rb)を中流路(15b)に供給する構成とし、前記合流路(19)に円柱状に合流した合流樹脂体を、前記金型(1)のキャビティ(4)の、プリフォーム(101)の底部底壁の中央に相当する位置に配設されるピンゲート(5)を介して前記キャビティ(4)内に射出、充填する構成とした請求項1記載の射出成形装置。
- 内側流路(15c)は、円筒状流路の先端部に合流路に向けてテーパー状に縮径する縮径流路(15cs)を有する構成とした請求項2記載の射出成形装置。
- サーボ機構により、シャットオフピン(20)の摺動動作を制御する構成とした請求項1、2または3記載の射出成形装置。
- 主体を形成する主材層(101a)中に中間層として第2の樹脂層(101b)を積層した2軸延伸ブロー成形用の試験管状のプリフォーム(101) の射出成形方法であって、請求項1、2、3または4に記載のある射出成形装置を使用し、主材樹脂(Ra)を外側流路(15a)と内側流路(15c)から合流路(19)に所定の供給速度で所定時間供給し、前記、主材樹脂(Ra)が供給される所定時間範囲内の一定時間、同時に第2の樹脂(Rb)を中流路(15b)から合流路(19)に所定の供給速度で供給し、前記、第2の樹脂(Rb)が供給される前から、あるいは供給開始から所定時間後から少なくとも該第2の樹脂(Rb)の供給が終了するまでの間、シャットオフピン(20)を摺動させて該シャットオフピン(20)の先端(20p)を、内側流路(15c)の合流路(19)への開口端部(17c)近傍の所定位置に配置させて、該開口端部(17c)の開度を調整し、内側流路(15c)から合流路(19)への主材樹脂(Ra)の供給速度を所定の速度まで小さくすることを特徴とする射出成形方法。
- 初めに、シャットオフピン(20)の摺動位置の制御により内側流路(15c)の開口端部(17c)を完全に開放した状態として第1供給部(Sa)から主材樹脂(Ra)を外側流路(15a)と内側流路(15c)を経て合流路(19)に供給し、前記主材樹脂(Ra)の供給開始の所定時間後に、第2の樹脂(Rb)を一定時間、第2供給部(Sb)から中流路(15b)を経て合流路(19)に供給し、外側流路(15a)と内側流路(15c)からの主材樹脂(Ra)の間に流動させ、前記第2の樹脂(Rb)の供給の開始後から所定時間後に、シャットオフピン(20)の先端(20p)を内側流路(15c)の合流路(19)への開口端部(17c)近傍の所定位置に配置させて、内側流路(15c)からの主材樹脂(Ra)の供給速度を所定の速度まで小さくし、前記第2の樹脂(Rb)の供給の終了から所定時間後にシャットオフピン(20)の摺動により内側流路(15c)を完全に開放して所定時間保圧することを特徴とする請求項5記載の射出成形方法。
- 合流路(19)内で主材樹脂(Ra)と第2の樹脂(Rb)から形成される合流樹脂体を順次金型(1)のキャビティ(4)の、プリフォーム(101)の底部底壁の中央に相当する位置に配設されるピンゲート(5)を介して前記キャビティ(4)内に射出、充填し、主材樹脂(Ra)の供給速度、第2の樹脂(Rb)の供給の開始時間、終了時間、供給速度を含めた射出パターン、さらには内側流路(15c)の開口端部(17c)の開度の調整に係るシャットオフピン(20)の摺動時期および先端(20p)の配置位置の設定により、前記プリフォーム(101)において主材層(101a)中に中間層として積層する第2の樹脂層(101b)の終端縁(TE)を、半球弧殻状に形成される底部(106)の中央に形成されるゲート痕(107)を除く、該底部(106)の所定範囲内に位置させることを特徴とする請求項5または6記載の射出成形方法。
- 第2の樹脂(Rb)をガスバリア性に優れた合成樹脂とし、第2の樹脂層(101b)をガスバリア層とした請求項5、6または7記載の射出成形方法。
- 主体を形成する主材層(101a)中に中間層として第2の樹脂層(101b)を積層した2軸延伸ブロー成形用の試験管状のプリフォームであって、
該プリフォームの底面で、前記第2の樹脂層(101b)の終端縁(TE)が、底部(106)の底面の中央に形成される円形のゲート痕(107)の外周縁の外側から胴部(105)の内周面(105p)に相当する周縁までの範囲内に位置することを特徴とするプリフォーム。
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JP2013107212A (ja) | 2013-06-06 |
KR20140095091A (ko) | 2014-07-31 |
EP3222400B1 (en) | 2021-03-03 |
CN105965770A (zh) | 2016-09-28 |
CN105965770B (zh) | 2020-10-20 |
US20190381752A1 (en) | 2019-12-19 |
CA3093219C (en) | 2023-06-27 |
US10870245B2 (en) | 2020-12-22 |
CN103998203B (zh) | 2016-06-29 |
EP2781330A1 (en) | 2014-09-24 |
CA2855760C (en) | 2021-02-16 |
KR102042520B1 (ko) | 2019-11-08 |
AU2017204219B2 (en) | 2019-11-21 |
US9956707B2 (en) | 2018-05-01 |
CN103998203A (zh) | 2014-08-20 |
US10723093B2 (en) | 2020-07-28 |
AU2019264547B2 (en) | 2021-05-20 |
US20180178465A1 (en) | 2018-06-28 |
CA3093219A1 (en) | 2013-05-23 |
EP3222400A1 (en) | 2017-09-27 |
CA2855760A1 (en) | 2013-05-23 |
KR20190086572A (ko) | 2019-07-22 |
AU2012337975B2 (en) | 2017-07-06 |
EP2781330B1 (en) | 2018-09-12 |
JP5817077B2 (ja) | 2015-11-18 |
EP2781330A4 (en) | 2015-09-09 |
US20140327176A1 (en) | 2014-11-06 |
AU2017204219A1 (en) | 2017-07-13 |
AU2019264547A1 (en) | 2019-12-05 |
KR102088729B1 (ko) | 2020-03-16 |
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