WO2022163339A1 - 成形体の製造方法 - Google Patents
成形体の製造方法 Download PDFInfo
- Publication number
- WO2022163339A1 WO2022163339A1 PCT/JP2022/000529 JP2022000529W WO2022163339A1 WO 2022163339 A1 WO2022163339 A1 WO 2022163339A1 JP 2022000529 W JP2022000529 W JP 2022000529W WO 2022163339 A1 WO2022163339 A1 WO 2022163339A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cavity
- mold
- heating element
- raw material
- suppressor
- Prior art date
Links
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Images
Classifications
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
- B29C33/08—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means for dielectric heating
-
- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/52—Heating or cooling
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/56—Compression moulding under special conditions, e.g. vacuum
-
- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
- B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
-
- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
- B29C2035/0855—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using microwave
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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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/56—Compression moulding under special conditions, e.g. vacuum
- B29C2043/568—Compression moulding under special conditions, e.g. vacuum in a magnetic or electric field
-
- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/10—Thermosetting resins
-
- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
-
- 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
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
-
- 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
- B29K2507/00—Use of elements other than metals as filler
- B29K2507/04—Carbon
Definitions
- the present invention relates to a method for manufacturing a molded body.
- Patent Document 1 discloses a mold made of an insulating material and electromagnetic wave irradiation means for irradiating a specific electromagnetic wave including a wavelength range of 0.01 to 100 m, and the mold is divided into a plurality of mold parts. A cavity for filling a thermoplastic resin and molding a molded product is formed between the mold parts, and at least a part of the inner wall surface of the cavity absorbs the specific electromagnetic wave.
- a method of molding using an electromagnetic irradiation molding apparatus characterized in that a surface layer having a performance to be formed is formed, comprising: placing a thermoplastic resin in the cavity; a heating step of irradiating the thermoplastic resin with a specific electromagnetic wave including a wavelength range of 0.01 to 100 m from the electromagnetic wave irradiation means through the mold; and a cooling step of cooling the thermoplastic resin to obtain a molded product.
- An electromagnetic wave irradiation molding method is described, which includes: In such a method, the thermoplastic resin itself generates heat, the entire thermoplastic resin is heated more effectively, and the entire thermoplastic resin can be melted in a short time, so that the thickness of each part changes. It is described that it is possible to stably mold a molded product with a large deformation, a molded product with a complicated shape, etc. with excellent appearance and dimensional accuracy (see paragraphs 0007 and 0008).
- the purpose of the present invention is to solve the above problems. That is, it is an object of the present invention to provide a method for producing a molded article that can be applied to a wide range of types of raw materials.
- the present invention provides the following (1) to (10). (1) After putting the raw material into the cavity of the mold, at least part of the mold is irradiated with electromagnetic waves, or at least part of the mold is placed in an alternating electric field, and molding is performed in the cavity.
- a method for producing a molded body for molding a body The mold is having a heating element outside the cavity that generates heat by absorbing the electromagnetic wave or generates heat by being placed in an alternating electric field; At least a portion between the heating element and the cavity has a transmission amount suppressor that suppresses an amount of transmission of the electromagnetic wave or the alternating electric field into the cavity, or at least a portion of the cavity is the Consisting of a permeation amount suppressor, The heating element generates heat, and the heat is conducted to the raw material to perform molding.
- a method for producing a molded article (2) The method for producing a molded article according to (1) above, wherein the heating element entirely covers the cavity.
- the transmission suppressor blocks transmission of the electromagnetic wave or the alternating electric field into the cavity.
- the cavity comprises the permeation suppressor;
- the heating element is a mold in which the cavity fits; at least a portion of the outer surface of the cavity is in contact with the inner surface of the heating element;
- the raw material contains at least one selected from the group consisting of thermoplastic resins, thermosetting resins, low-melting metals, and low-melting non-metals. 3.
- the heating element contains silicone rubber and/or fluororubber, and at least one selected from the group consisting of silicon carbide, ferrite, barium titanate, carbon black and graphite as a dielectric property-imparting substance.
- the permeation suppressor contains a metal and/or a non-metal.
- FIG. 4 is a schematic cross-sectional view illustrating a preferred embodiment of a cavity
- FIG. FIG. 4 is a schematic cross-sectional view showing a mold in which a permeation amount suppressor is present between a heating element and a cavity
- FIG. 4 is a schematic cross-sectional view showing a mold in which a permeation amount suppressor is present between the heating element and the cavity so as to cover the entire cavity
- FIG. 4 is a schematic cross-sectional view showing a mold in which a heating element covers a cavity made up of a permeation amount suppressor
- FIG. 5 is a schematic cross-sectional view showing a case where the mold described with reference to FIG. 4 is irradiated with electromagnetic waves;
- FIG. 5 is a schematic cross-sectional view showing a case where the mold described with reference to FIG. 4 is placed in an alternating electric field; It is a schematic perspective view of a cavity used in Examples.
- 1 is a schematic cross-sectional view of a cavity used in Examples;
- FIG. It is an appearance photograph of the cavity used in the example.
- It is a schematic sectional view about the state which put the raw material into the cavity used in the Example.
- FIG. 4 is a schematic cross-sectional view showing a state in which the cavity is fitted in the rubber mold; It is an appearance photograph which shows the state which fitted the cavity in the center part of the rubber mold.
- FIG. 3 is a schematic perspective view of another mold used in Examples.
- FIG. 3 is a schematic cross-sectional view of another mold used in Examples. It is a schematic sectional drawing of a permeation
- the present invention will be described.
- the molding die has a heating element outside the cavity that generates heat by absorbing the electromagnetic wave or by being placed in an alternating electric field. and, at least partly between the heating element and the cavity, there is a transmission amount suppressing body for suppressing the amount of transmission of the electromagnetic wave or the alternating electric field into the cavity, or at least part of the cavity. is the permeation amount suppressor, the heating element generates heat, and the heat is transferred to the raw material to perform molding.
- the production method of the present invention is hereinafter also referred to as "the production method of the present invention”.
- the mold in the manufacturing method of the present invention has a heating element.
- the heating element may be one that generates heat by absorbing electromagnetic waves as described later, or one that generates heat by being placed in an alternating electric field as described later.
- the heating element is preferably made of rubber, resin, or ceramics to which a dielectric-imparting substance is added.
- a dielectric-imparting substance for example, it may be a sintered body obtained by adding a dielectric imparting substance to ceramics.
- the heating element is preferably made of silicone rubber and/or fluororubber containing a dielectric-imparting substance.
- the dielectric property-imparting substance is a substance capable of imparting dielectric properties, and preferably has a dielectric power factor (dielectric loss tangent, tan ⁇ ) of 0.01 or more.
- the dielectric-imparting substance is preferably at least one selected from the group consisting of silicon carbide, ferrite, barium titanate, carbon black and graphite.
- the content of the dielectric property-imparting substance in the heating element is preferably 5 to 90% by volume.
- the heating element contains silicone rubber and/or fluororubber, and at least one selected from the group consisting of silicon carbide, ferrite, barium titanate, carbon black and graphite as a dielectric property-imparting substance. It is preferable to contain 90% by volume.
- the content of the dielectric property-imparting substance in the heating element is more preferably 10 to 70% by volume, more preferably 13 to 50% by volume, even more preferably 15 to 35% by volume.
- the heating element When the content of the dielectric property-imparting substance in the heating element is within such a range, heat is easily generated by absorbing an electromagnetic wave as described later, or heat is easily generated by being placed in an alternating electric field as described later. Because it becomes In addition, it becomes difficult for the heating element to generate heat locally. Also, when the raw material is heated, there is a tendency that sparks (for example, a phenomenon of electric discharge) are less likely to occur. Furthermore, this is because the heating element can easily exhibit the necessary strength.
- the dielectric property-imparting substance is powder
- its average particle diameter (D 50 ) is preferably 3 to 800 ⁇ m, more preferably 4 to 500 ⁇ m, more preferably 5 to 300 ⁇ m. It is more preferably ⁇ 100 ⁇ m, further preferably 7 to 50 ⁇ m.
- the average particle size of the powdery dielectric property-imparting substance is within such a range, heat is easily generated by absorbing an electromagnetic wave as described later, or heat is generated by being placed in an alternating electric field as described later. This is because it becomes easier. In addition, this is because the heating element is likely to exhibit the necessary strength.
- the mold has such a heating element outside the cavity.
- the mold in the manufacturing method of the present invention has a cavity.
- a cavity is a mold into which a raw material is put, and in principle, a molded body having the same shape as the inner space of the cavity can be obtained.
- FIG. 1 is a schematic cross-sectional view of a preferred embodiment cavity.
- the cavity in the manufacturing method of the present invention is not limited to the mode shown in FIG.
- the cavity 10 may be divided into a plurality (two in FIG. 1) and configured by a combination of the first mold section 11 and the second mold section 12.
- an internal space 15 for filling raw material is formed between the pair of first mold portion 11 and second mold portion 12 .
- the internal space 15 in the cavity can be formed, for example, by transferring a master model of the molding to be molded.
- a vacuum hole is formed in the first mold part 11 or the second mold part 12 to which a vacuum pump is connected to make the internal space 15 have a lower pressure than the atmospheric pressure (for example, a vacuum state). good too.
- the first mold portion 11 and the second mold portion 12 are configured to be slidable relative to each other. Sliding closer together reduces the volume of the interior space 15 .
- the second mold portion 12 has a guide portion 121 for allowing the first mold portion 11 and the second mold portion 12 to slide relative to each other.
- the internal space 15 is a space surrounded by the inner surfaces of the first mold portion 11 and the second mold portion forming the cavity.
- the space may be partially surrounded by the inner surface of the member forming the cavity.
- the space may be surrounded by the inner surface of the portion forming the cavity and the inner surface of the permeation suppressor.
- the mold in the manufacturing method of the present invention has a permeation amount suppressor at least partly between the heating element and the cavity as described above, or at least part of the cavity is composed of the permeation amount suppressor.
- the transmission amount suppressor may be made of a substance capable of suppressing the amount of electromagnetic waves or alternating electric fields transmitted into the cavity. Specifically, any material may be used as long as it can suppress the amount of electromagnetic waves or alternating electric fields that penetrate into the cavity to the extent that the raw material in the cavity does not spark or undergo thermal runaway. Note that thermal runaway means a phenomenon in which the temperature rises in a short time and temperature control becomes difficult.
- the transmission amount suppressor is preferably made of a material capable of blocking the amount of electromagnetic waves or alternating electric fields transmitted into the cavity.
- the permeation amount suppressor preferably contains a metal and/or a non-metal.
- the content of metal and/or nonmetal in the permeation amount suppressor is preferably 50% by mass or more, more preferably 65% by mass or more, more preferably 80% by mass or more, and 95% by mass. It is more preferably equal to or greater than, and more preferably substantially 100%.
- substantially means that only unavoidable impurities that can be mixed from raw materials and manufacturing processes are allowed to be included. Specifically, among metals, at least one selected from the group consisting of aluminum, iron, copper and alloys containing these is preferable.
- the alloy containing aluminum, iron, and copper may be an alloy containing at least one of aluminum, iron, and copper, such as brass (copper-zinc alloy).
- brass copper-zinc alloy
- shielding glass is preferable. These can reduce or block the amount of electromagnetic waves or alternating electric fields that penetrate into the interior of the cavity.
- FIG. 2 is a schematic cross-sectional view showing the mold 1a in which a permeation suppressor 30a is present between the heating element 20a and the cavity 10.
- FIG. 3 is a schematic cross-sectional view showing the mold 1b in which a permeation suppressor 30b exists between the heating element 20b and the cavity 10 so as to cover the entire cavity 10.
- the embodiments shown in FIGS. 2 and 3 are preferred examples, and the mold used in the manufacturing method of the present invention is not limited thereto.
- the mold 1a shown in FIG. 2 has a heating element 20a outside the cavity 10 and a permeation suppressor 30a between them.
- a heating element 20a When at least a portion of such a mold 1a (a portion including at least a portion of the heating element 20a) is irradiated with an electromagnetic wave, or at least a portion of the molding die 1a (a portion including at least a portion of the heating element 20a) is placed in an alternating electric field, the heating element 20a generates heat. Even when at least part of the heating element 20a in the mold 1a is irradiated with electromagnetic waves, or even when only at least part of the heating element 20a in the molding die 1a is placed in an alternating electric field, the heating element 20a Fever.
- the heat is conducted to the raw material existing in the internal space 15 of the cavity 10 through the permeation amount suppressing member 30a and the like, and the raw material is melted or hardened by the heat, thereby performing molding. Since the transmission amount suppressor 30a is present between the heating element 20a and the cavity 10, the transmission amount of the electromagnetic wave or alternating electric field in the direction from the heating element 20a to the cavity 10 to the cavity 10 is suppressed or blocked.
- a mold 1b shown in FIG. 3 has a heating element 20b on the outside of the cavity 10, and a permeation suppressor 30b between them.
- the permeation amount suppressor 30b covers the entire cavity 10, and the entire permeation amount suppressor 30b is further covered by the heating element 20b (on the front side and the back side in FIG. 3). is also the same). That is, the heating element 20b covers the entire cavity 10.
- the permeation amount suppressor 30b may be a mold in which the cavity 10 is fitted.
- the permeation amount suppressor 30b may be made of a plate (for example, a mesh plate) or the like.
- the heating element 20b may be of a type in which the permeation amount suppressor 30b is fitted.
- the heating element 20b When at least part of the mold 1b is irradiated with electromagnetic waves, or when at least part of the mold 1b is placed in an alternating electric field, the heating element 20b generates heat. Then, the heat is conducted to the raw material existing in the internal space 15 of the cavity 10 through the permeation amount suppressing body 30b and the like, and the raw material is melted or hardened by the heat, and molding is performed. Since the transmission amount suppressor 30b is present between the heating element 20b and the cavity 10, the amount of electromagnetic waves or alternating electric fields transmitted to the internal space 15 of the cavity 10 is suppressed or blocked.
- the molds (1a, 1b) are positioned between the cavity 10 and the permeation suppressors (30a, 30b), or between the permeation suppressors (30a, 30b) and the heating element (20a). , 20b).
- the material of the cavity 10 may be any material that does not soften under conditions where the raw material in the internal space 15 melts or hardens.
- it may be a curable resin material (thermosetting resin material, photo-curable resin material, etc.), cement material, gypsum material, various heat-resistant non-metallic materials, etc., preferably made of rubber material.
- the rubber material silicone rubber, fluororubber, and various other rubbers can be used.
- the following aspects of the manufacturing method of the present invention can be carried out. i.e. After the raw material is placed in the cavity of the mold, at least part of the mold is irradiated with electromagnetic waves, or at least part of the mold is placed in an alternating electric field to form a compact in the cavity.
- a method for manufacturing a molded body The mold is having a heating element outside the cavity that generates heat by absorbing the electromagnetic wave or generates heat by being placed in an alternating electric field; At least a part between the heating element and the cavity has a transmission amount suppressor that suppresses (preferably blocks) the amount of transmission of the electromagnetic wave or the alternating electric field into the cavity,
- a method for producing a molded body, in which the heating element generates heat and the heat is conducted to the raw material to perform molding; can be implemented.
- FIG. 4 is a schematic cross-sectional view showing the molding die 1c when the heating element 20c covers the cavity 10 made of the permeation amount suppressor.
- the embodiment shown in FIG. 4 is a preferred example, and the mold in the manufacturing method of the present invention is not limited to this. For example, only part of the cavity may be made of the permeation suppressor.
- the cavity 10 is made of a permeation suppressor.
- the heating element 20c covers the cavity 10 entirely.
- heating element 20c is a mold in which cavity 10 fits.
- the heating element 20c shown in FIG. 4 has one mold portion 201c and the other mold portion 202c, which are configured to be slidable relative to each other.
- the one mold part 201c and the other mold part 202c slide and approach each other, the first mold part 11 and the second mold part 12 in the cavity 10 inside them approach each other.
- at least part of the outer surface of the cavity 10 is in contact with the inner surface of the heating element 20c.
- the other mold portion 202c has a vacuum hole 25 to which is connected a vacuum pump for making the inside of the heating element 20c into a state (for example, a vacuum state) that is lower than the atmospheric pressure. ing.
- a state for example, a vacuum state
- the one mold portion 201c and the other mold portion 202c approach each other, and the first mold portion 11 and the second mold portion 11 in the cavity 10 inside the mold portion 201c and the other mold portion 202c approach each other.
- the mold part 12 approaches each other.
- the heating element 20c When at least part of the mold 1c as shown in FIG. 4 is irradiated with electromagnetic waves, or when at least part of the mold 1c is placed in an alternating electric field, the heating element 20c generates heat.
- the heating element 20c generates heat even when only part of the heating element in the molding die 1c is irradiated with electromagnetic waves, or even when only a part of the heating element in the molding die 1c is placed in the alternating electric field. It is preferable to irradiate the entire outer surface of the heating element in the mold 1c with electromagnetic waves.
- the heat is conducted to the raw material existing in the internal space 15 of the cavity 10 composed of the permeation amount suppressing body, and the raw material is melted or hardened by the heat to perform molding.
- the cavity 10 is made of a transmission amount suppressor, the amount of electromagnetic waves or alternating electric fields transmitted to the internal space 15 of the cavity 10 is suppressed or blocked.
- the mold 1c may have another portion between the cavity 10 and the heating element 20c.
- the heating element may be present outside the cavity, and as shown in FIG. may Also, the heating element does not have to be a mold in which the cavity is fitted.
- the cavity is made of a permeation amount suppressor, and the permeation amount suppressor contains a substance with a high melting point such as a metal and / or a non-metal (preferably 50% by mass or more, more preferably 65% by mass or more, more preferably 80% by mass or more, more preferably 95% by mass or more, more preferably substantially 100%), using a raw material that needs to be treated at a higher temperature,
- a substance with a high melting point such as a metal and / or a non-metal (preferably 50% by mass or more, more preferably 65% by mass or more, more preferably 80% by mass or more, more preferably 95% by mass or more, more preferably substantially 100%)
- the cavity may soften when the cavity is exposed to high temperatures (eg, about 250° C. or higher).
- high temperatures eg, about 250° C. or higher.
- a raw material with a high melting point for example, a raw material with a melting point of about 250° C. or higher. This is because the cavity softens at the temperature at which the raw material melts or hardens.
- Materials with high molding temperatures include PA66, PET, and PBT.
- the permeation amount suppressor constituting the cavity is at least one metal and/or nonmetal selected from the group consisting of aluminum, iron, copper, alloys containing these, and shielding glass. (preferably 50% by mass or more, more preferably 65% by mass or more, more preferably 80% by mass or more, more preferably 95% by mass or more, more preferably substantially 100%), a molded product can be produced using a raw material with a high molding temperature.
- the material of the remaining part of the cavity 10 does not soften under conditions where the raw material in the internal space 15 melts or hardens. Anything is fine.
- it may be a curable resin material (thermosetting resin material, photo-curable resin material, etc.), cement material, gypsum material, various heat-resistant non-metallic materials, etc., preferably made of rubber material.
- the rubber material silicone rubber, fluororubber, and various other rubbers can be used.
- the following aspects of the manufacturing method of the present invention can be carried out. i.e. After the raw material is placed in the cavity of the mold, at least part of the mold is irradiated with electromagnetic waves, or at least part of the mold is placed in an alternating electric field to form a compact in the cavity.
- a method for manufacturing a molded body The mold is having a heating element outside the cavity that generates heat by absorbing the electromagnetic wave or generates heat by being placed in an alternating electric field; At least part of the cavity comprises a transmission amount suppressor that suppresses (preferably blocks) the amount of transmission of the electromagnetic wave or the alternating electric field into the cavity,
- a method for producing a molded body, in which the heating element generates heat and the heat is conducted to the raw material to perform molding; can be implemented.
- the raw material is not particularly limited as long as the main component is a substance that melts or hardens due to the heat generated by the heating element and transferred into the cavity via the permeation amount suppressor or the like.
- the raw material preferably contains at least one selected from the group consisting of thermoplastic resins, thermosetting resins, low-melting metals and low-melting non-metals as a main component.
- main component means that the content is 50% by mass or more.
- the content is preferably 65% by mass or more, more preferably 80% by mass or more, more preferably 95% by mass or more, and even more preferably substantially 100%.
- substantially means that only unavoidable impurities that can be mixed from raw materials and manufacturing processes are allowed to be included.
- the “main component” in the production method of the present invention means the above.
- thermoplastic resins examples include ABS resin (acrylonitrile-butadiene-styrene resin), ASA resin (acrylate-styrene-acrylonitrile resin), AES resin (acrylonitrile-ethylene-propylene-diene-styrene resin), and the like.
- ABS resin acrylonitrile-butadiene-styrene resin
- ASA resin acrylate-styrene-acrylonitrile resin
- AES resin acrylonitrile-ethylene-propylene-diene-styrene resin
- rubber-reinforced styrene resins polystyrene, styrene/acrylonitrile copolymer, styrene/maleic anhydride copolymer, (meth)acrylic acid ester/styrene copolymer, etc.
- olefin resins such as polyethylene, polypropylene, etc.
- thermoplastic resin may be a thermoplastic elastomer (styrene, olefin, vinyl chloride, vinyl acetate, urethane, polyester, etc.).
- the heat generated by the heating element melts the raw material in the cavity.
- the amount of transmission of electromagnetic waves or alternating electric fields to the internal space of the cavity is suppressed or blocked, in principle, no self-heating occurs.
- a raw material with strong self-heating behavior such as a nylon-based resin
- thermal runaway may occur when self-heating occurs.
- the raw material in principle, does not generate heat by itself, so that a molded article can be produced using a nylon-based resin or the like as the raw material.
- thermoplastic resin When a thermoplastic resin is used as a raw material, a granular or flaky thermoplastic resin may be used.
- the average particle diameter is preferably 0.2 to 5 mm, more preferably 0.5 to 3 mm.
- the average particle size means D50 obtained from the weight-based particle size distribution determined by sieving.
- a preform made of thermoplastic resin can be used as a raw material.
- a preform is formed in a three-dimensional shape by some method using a thermoplastic resin, and examples thereof include those laminated in a three-dimensional shape by a lamination molding method.
- the additive manufacturing method is a method using various 3D printers (AM: additive manufacturing) that stacks thermoplastic resin discharged in a thread shape (linear shape) or granular shape from a nozzle in a three-dimensional shape, and a method using hot melt lamination Method (Material Extrusion Deposition Method): FDM (Fused Deposition Modeling), extrusion molding method, ink jet method, granule bonding method and the like.
- Thermosetting resins that can be used as raw materials include, for example, phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, and thermosetting polyimides.
- phenol resins epoxy resins
- melamine resins urea resins
- unsaturated polyester resins alkyd resins
- polyurethanes polyurethanes
- thermosetting polyimides thermosetting polyimides
- low-melting-point metals that can be used as raw materials include alloys mainly composed of zinc, indium, gallium, tin, bismuth, lead, and the like.
- a low-melting-point metal is used as a raw material, the raw material is melted by the heat generated by the heating element in the manufacturing method of the present invention.
- low-melting-point nonmetals examples include glass.
- the raw material is melted by the heat generated by the heating element in the manufacturing method of the present invention.
- the raw material is at least one selected from the group consisting of thermoplastic resins, thermosetting resins, low-melting-point metals, and low-melting-point nonmetals.
- Other components include high melting point metals, high melting point nonmetals (ceramics, etc.), UV curable resins, fiber materials (CF (carbon fiber), GF (glass fiber), metal fiber (SUS fiber, etc.), glass fiber, etc.), softener (plasticizer, oil, etc.), colorant (pigment, etc.), impact modifier (rubber component, etc.), antistatic agent, conductive material, filler (thermally conductive filler, metallic filler, etc.), flame retardant, heat resistant resin, low heat storage resin, slidability improver, and the like.
- the method is not particularly limited. It suffices if the electromagnetic waves that can generate heat in the heating element of the molding die can be applied. At least all or part of the surface of the heating element may be irradiated with electromagnetic waves.
- FIG. 5 is a schematic cross-sectional view illustrating a case where the mold 1c described with reference to FIG. 4 is irradiated with electromagnetic waves.
- the raw material is placed in the internal space 15 existing between the pair of the first mold portion 11 and the second mold portion 12 in the cavity 10 .
- the vacuum hole 25 formed in the other mold portion 202c is connected to the vacuum pump 40, and by driving the vacuum pump 40, the pressure inside the heating element 20c is reduced to a state lower than the atmospheric pressure (for example, a vacuum state).
- an electromagnetic wave can be generated from the electromagnetic wave generator 42 to irradiate the mold 1c with the electromagnetic wave.
- the electromagnetic wave generator 42 is preferably capable of generating electromagnetic waves including a wavelength range of 0.78 ⁇ m to 100 m. In other words, it is preferable that the wavelength region of the generated electromagnetic wave is included in the range of 0.78 ⁇ m to 100 m. Further, the electromagnetic wave generator 42 generates an electromagnetic wave (near infrared rays) including a wavelength range of 0.78 to 2 ⁇ m, an electromagnetic wave (microwave) including a wavelength range of 0.01 to 1 m, or an electromagnetic wave including a wavelength range of 1 to 100 m. (high frequency) can be generated. When generating near-infrared rays, the electromagnetic wave generator 42 may be a halogen lamp. When generating microwaves, the electromagnetic wave generator 42 may be a microwave oscillator. When generating high frequency, the electromagnetic wave generator 42 may be a high frequency oscillator.
- the method is not particularly limited when placing at least part of the mold in an alternating electric field after putting the raw material as described above into the cavity of the mold. It is sufficient that the heating element of the mold can be heated by placing the mold in the alternating electric field. At least all or part of the heating element may be placed within the alternating electric field.
- FIG. 6 is a schematic cross-sectional view illustrating a case where the mold 1c described with reference to FIG. 4 is placed in an alternating electric field.
- an internal space 15 existing between a pair of first mold portion 11 and second mold portion 12 in mold 1c is filled with raw material.
- the vacuum hole 25 formed in the other mold portion 202c is connected to the vacuum pump 40, and by driving the vacuum pump 40, the pressure inside the heating element 20c is reduced to a state lower than the atmospheric pressure (for example, a vacuum state). ).
- the frequency of the AC voltage generated by the dielectric heater 44 is preferably a high frequency electromagnetic wave including a wavelength range of 1 m to 100 m.
- Such a production method of the present invention has a wide range of applicable raw materials. Also, conventionally known pellets can be used as the raw material. In addition, the dimensional accuracy of the molded body is higher than that of the conventional one. Also, the cooling time can be shortened compared to the conventional art.
- a mold was prepared.
- the molding die has a mode similar to that shown in FIG. 4, in which the cavity is composed of a permeation amount suppressor, and the cavity is fitted inside the rubber mold, which is a heating element.
- FIG. 7 shows a schematic perspective view of the cavity
- FIG. 8 shows a schematic sectional view of the cavity
- FIG. 9 shows a photograph of the appearance of the cavity.
- the cavity 50 has a structure in which three parts, an upper part 51, a central part 52 and a lower part 53 are combined.
- FIG. 8 shows a cross section of the cavity 50 formed by fitting parts of the upper portion 51 and the lower portion 53 shown in FIG. 7 into the central portion 52 .
- the dimensions of each part in the cavity 50 are as shown in FIG. That is, each of the upper portion 51, the central portion 52, and the lower portion 53 forms a square having a side of approximately 30 mm when viewed from above.
- the thickness (maximum thickness) of the upper portion 51 and the lower portion 53 is 10 mm.
- the thickness is 5 mm.
- the thickness of the central portion 52 (the length of the upper portion 51 and the lower portion 53 in the direction parallel to the thickness direction) is 12 mm. Therefore, when the upper portion 51 and the lower portion 53 are fitted into the central portion 52, a substantially rectangular internal space 55 having a thickness of 2 mm and a side of 26 mm and a substantially square bottom surface 55 appears.
- the raw material 57 is put into the inner space 55, the raw material 57 is completely covered with the upper portion 51, the central portion 52 and the lower portion 53.
- FIG. 10 when the raw material 57 is put into the inner space 55, the raw material 57 is completely covered with the upper portion 51, the central portion 52 and the lower portion 53.
- FIG. 10 is a schematic cross-sectional view showing the state immediately after the raw material 57 is put into the internal space 55.
- the void in the raw material 57 is reduced, and accordingly, the upper portion 51 and the lower portion 52 are separated. becomes smaller (that is, the upper portion 51 and the lower portion 52 become closer), and the internal space 55 shrinks.
- the rubber mold has a mode in which a cavity is fitted inside, as shown in the exterior photograph shown in FIG. 11 also shows the same cavity as that shown in FIG. 9 together with the rubber mold.
- 12 is a schematic sectional view showing a state in which the cavity 50 shown in FIG. 8 is fitted in the rubber mold 59.
- FIG. 13 is an external photograph showing a state in which the cavity shown in FIG. 11 is fitted in the central portion of the rubber mold.
- the rubber mold is made by adding silicon carbide as a dielectric-imparting substance to silicone, kneading, curing, and then hollowing out the center so that the cavity fits.
- the rubber mold as a heating element covers the entire cavity, and the cavity fits inside the rubber mold. It is in the form of being in contact with the surface.
- two holes were formed in the rubber mold to connect the outside of the rubber mold and the cavity arranged therein.
- an alumina sheath tube was inserted into one of the holes.
- the sheath tube is placed in contact with the outer surface of the internal cavity, and is constructed so that the temperature of the outer surface of the cavity can be continuously measured by inserting an optical fiber thermometer into the sheath tube.
- the other hole is connected to a tube connected to a vacuum pump, and is configured to reduce the pressure in the cavity by driving the vacuum pump. This hole corresponds to the vacuum hole 25 shown in FIG.
- the raw material was filled so as to fill the internal space in the cavity.
- micropellets of nylon resin Amilan CM1011G-30 manufactured by Toray Industries, Inc.
- the particle size of the micropellets is about 0.8 to 1 mm.
- the cavity was fitted inside the rubber mold, the rubber mold was closed, and a heat-resistant tape was attached to tightly seal the rubber mold so that it would not open.
- thermometer was inserted into the sheath tube so that the temperature of the outer surface of the cavity could be measured continuously.
- a tube connected to a vacuum pump was connected to the other hole formed in the rubber mold.
- the molding die was placed in a microwave molding device, and the molding was performed by irradiating the molding die with electromagnetic waves while evacuating with a vacuum pump so that the pressure inside the rubber mold was -95 kPa.
- Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- the molding temperature and heating rate were adjusted while measuring with an optical fiber thermometer inserted in the sheath tube.
- Example 2 As a raw material, NS0031 (manufactured by SABIC Japan LLC), which is a PC/ABS resin, was used. This raw material contains 15% by mass of filler made of SUS. Other than that, molding was carried out in the same manner as in Example 1. However, the molding temperature, heating rate, and holding time at the molding temperature during molding were changed according to the characteristics of the raw material. Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- Example 3 PA6CF30 (manufactured by Toray Industries, Inc.), which is a nylon resin, was used as a raw material. In addition, it contains 30% by mass of carbon fiber. Other than that, molding was carried out in the same manner as in Example 1. However, the molding temperature, heating rate, and holding time at the molding temperature during molding were changed according to the characteristics of the raw material. Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- Example 4 As a raw material, pellets of 1101G-30 (manufactured by Toray Industries, Inc.), which is a polyester resin (PBT resin), were used. The grain size of the pellets is about 0.8 to 1 mm. Other than that, molding was carried out in the same manner as in Example 1. However, the molding temperature, heating rate, and holding time at the molding temperature during molding were changed according to the characteristics of the raw material. Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- Example 5 Meta-xylylenediamine polyamide resin (MXD6 C-408 long carbon fiber grade) was used as a raw material. This raw material is in the form of pellets containing 40% by mass of carbon filler. Other than that, molding was carried out in the same manner as in Example 1. However, the molding temperature, heating rate, and holding time at the molding temperature during molding were changed according to the characteristics of the raw material. Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- Example 6 As a raw material, A630T-30V (manufactured by Toray Industries, Inc.), which is a carbon fiber reinforced PPS resin, was used. In addition, it contains 30% by mass of carbon fiber. Other than that, molding was carried out in the same manner as in Example 1. However, the molding temperature, heating rate, and holding time at the molding temperature during molding were changed according to the characteristics of the raw material. Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- Example 7 As a raw material, micropellets of PEEK resin (thermoplastic super engineering plastic) VESTAKEEP 2000P (EVONIK) were used. The particle size of the micropellets is about 0.8 to 1.0 mm. Other than that, molding was carried out in the same manner as in Example 1. However, the molding temperature, heating rate, and holding time at the molding temperature during molding were changed according to the characteristics of the raw material. Table 1 shows the molding temperature, heating rate, and holding time at the molding temperature during molding.
- PEEK resin thermoplastic super engineering plastic
- VESTAKEEP 2000P EVONIK
- Example 8 Molds different from those of Examples 1-7 were prepared.
- the mold used in Example 8 had a rubber heating element outside the rubber cavity and a permeation suppressor between them. Also, the permeation amount suppressor forms a mold in which the cavity can be present in close contact, and can cover the entire cavity. Furthermore, the heating element has a mold in which the permeation amount suppressor is fitted, so that the entire permeation amount suppressor can be covered.
- This mold is similar to the embodiment shown in FIG. 3, but differs therefrom in the structure of the cavity and the permeation amount suppressor.
- FIG. 14 is a schematic perspective view of a mold used in Example 8
- FIG. 15 is a schematic cross-sectional view thereof
- FIG. 16 is a schematic cross-sectional view of a permeation amount suppressor
- FIG. It is a photograph showing that a permeation amount suppressor is fitted in a part and a cavity is formed inside the permeation amount suppressor.
- the heating element 64 is composed of two parts, inside of which a permeation amount suppressor 66 is fitted.
- the heating element 64 is a rubber mold formed by adding silicon carbide as a dielectric-imparting substance to silicone, kneading and curing the silicone, and hollowing out the center of the rubber mold so that the permeation amount suppressor 66 is fitted therein.
- the entire outer surface of the permeation amount suppressor 66 is in contact with the inner surface of the rubber mold as the heating element 64 .
- the permeation amount suppressor 66 consists of two parts, each of which has a rectangular main surface, and when they are fitted together, a space is created inside.
- the permeation amount suppressor 66 used in Example 8 is formed by processing an extruded aluminum material (5052 material).
- the cavity 62 is present in close contact with the inside of the permeation amount suppressor 66 .
- an internal space 68 for containing raw material is partly in contact with the inner surface of the permeation amount suppressor 66 .
- the cavity 62 was formed inside the permeation amount suppressor 66 using a heat-resistant liquid rubber made of silicone rubber.
- two holes are formed in the rubber mold as the heating element 64 to connect the outside of the rubber mold with the outer surface of the permeation amount suppressor 66 disposed inside the rubber mold.
- a sheath tube made of alumina is inserted so that the temperature of the outer surface of the permeation amount suppressor 66 can be continuously measured by inserting an optical fiber thermometer into the sheath tube, and the other hole is a vacuum.
- the inside of the cavity 62 can be reduced in pressure. This hole corresponds to the vacuum hole 25 shown in FIG.
- Kraft Alloy manufactured by Nisshin Resin Co., Ltd., which is a low-melting-point alloy mainly containing tin and bismuth and having a melting point of 150° C., was used as a raw material.
- the permeation amount suppressor 66 After filling 20.5 g of this raw material into the cavity 62 and closing the permeation amount suppressor 66, the permeation amount suppressor 66 is fitted inside a rubber mold as a heating element 64, the rubber mold is closed, and heat-resistant tape is pasted. By attaching it, the rubber mold was firmly sealed so that it would not open.
- an optical fiber thermometer was inserted into the sheath tube so that the temperature of the outer surface of the permeation amount suppressor 66 could be continuously measured.
- a tube connected to a vacuum pump was connected to the other hole formed in the rubber mold.
- the molding die was placed in a microwave molding apparatus, and the molding was performed by irradiating the molding die with an electromagnetic wave while drawing a vacuum with a vacuum pump so that the pressure inside the rubber mold was -95 kPa.
- the molding temperature during molding was 150° C.
- the heating rate was 10° C./min
- the holding time at the molding temperature was 60 seconds.
- the molding temperature and heating rate were adjusted while measuring with an optical fiber thermometer inserted in the sheath tube.
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Abstract
Description
特許文献1には、絶縁性材料からなる成形型と、0.01~100mの波長領域を含む特定電磁波を照射する電磁波照射手段とを備え、上記成形型は、複数の成形型部に分割されており、該成形型部の間には、熱可塑性樹脂を充填して成形品を成形するためのキャビティが形成されており、該キャビティの内壁面の少なくとも一部には、上記特定電磁波を吸収する性能を有する表面層が形成されていることを特徴とする電磁波照射成形装置を用いて成形を行う方法であって、上記キャビティ内に熱可塑性樹脂を配置する配置工程と、上記キャビティ内に配置した熱可塑性樹脂に、上記電磁波照射手段から上記成形型を介して0.01~100mの波長領域を含む特定電磁波を照射する加熱工程と、上記熱可塑性樹脂を冷却して成形品を得る冷却工程とを含むことを特徴とする電磁波照射成形方法が記載されている(請求項1、請求項5参照)。そして、このような方法では熱可塑性樹脂が自ら発熱し、熱可塑性樹脂の全体がより効果的に加熱され、熱可塑性樹脂の全体を短時間で溶融させることができるため、各部の肉厚の変化が大きい成形品、複雑な形状の成形品等を、優れた外観および寸法精度で安定して成形することができることが記載されている(0007、0008段落参照)。
本発明は、以下の(1)~(10)である。
(1)原料を成形型のキャビティ内に入れた後、前記成形型の少なくとも一部に電磁波を照射し、または前記成形型の少なくとも一部を交番電界内に配置して、前記キャビティ内で成形体を成形する、成形体の製造方法であって、
前記成形型は、
前記電磁波を吸収して発熱する、または交番電界内に配置されることで発熱する発熱体を前記キャビティの外側に有し、
前記発熱体と前記キャビティとの間の少なくとも一部に、前記電磁波または前記交番電界の前記キャビティの内部への透過量を抑制する透過量抑制体を有するか、または前記キャビティの少なくとも一部が前記透過量抑制体からなり、
前記発熱体が発熱し、その熱が前記原料に伝導して成形が行われる、
成形体の製造方法。
(2)前記発熱体が前記キャビティの全体を覆っている、上記(1)に記載の成形体の製造方法。
(3)前記透過量抑制体が、前記電磁波または前記交番電界の前記キャビティの内部への透過を遮断するものである、上記(1)または(2)に記載の成形体の製造方法。
(4)前記キャビティは前記透過量抑制体からなり、
前記発熱体は前記キャビティがその内部に嵌る型であり、
前記キャビティの外表面の少なくとも一部が、前記発熱体の内表面と接している、
上記(1)~(3)のいずれかに記載の成形体の製造方法。
(5)前記原料が、熱可塑性樹脂、熱硬化性樹脂、低融点金属および低融点非金属からなる群から選ばれる少なくとも1つを主成分とする、上記(1)~(4)のいずれかに記載の成形体の製造方法。
(6)前記原料が繊維材および/またはフィラーを含む、上記(1)~(5)のいずれかに記載の成形体の製造方法。
(7)前記発熱体が、シリコーンゴムおよび/またはフッ素ゴムを含有し、さらに、誘電性付与物質としての炭化珪素、フェライト、チタン酸バリウム、カーボンブラックおよび黒鉛からなる群から選ばれる少なくとも1つを5~90体積%含有している、上記(1)~(6)のいずれかに記載の成形体の製造方法。
(8)前記透過量抑制体が金属および/または非金属を含む、上記(1)~(7)のいずれかに記載の成形体の製造方法。
(9)前記金属および/または前記非金属がアルミニウム、鉄、銅、これらを含む合金および遮蔽ガラスからなる群から選ばれる少なくとも1つである、上記(8)に記載の成形体の製造方法。
(10)前記電磁波の波長領域が0.78μm~100mの範囲に含まれる、上記(1)~(9)のいずれかに記載の成形体の製造方法。
本発明は、原料を成形型のキャビティ内に入れた後、前記成形型の少なくとも一部に電磁波を照射し、または前記成形型の少なくとも一部を交番電界内に配置して、前記キャビティ内で成形体を成形する、成形体の製造方法であって、前記成形型は、前記電磁波を吸収して発熱する、または交番電界内に配置されることで発熱する発熱体を前記キャビティの外側に有し、前記発熱体と前記キャビティとの間の少なくとも一部に、前記電磁波または前記交番電界の前記キャビティの内部への透過量を抑制する透過量抑制体を有するか、または前記キャビティの少なくとも一部が前記透過量抑制体からなり、前記発熱体が発熱し、その熱が前記原料に伝導して成形が行われる、成形体の製造方法である。
このような成形体の製造方法を、以下では「本発明の製造方法」ともいう。
本発明の製造方法において用いる成形型について説明する。
本発明の製造方法における成形型は発熱体を有する。
発熱体は、後述するような電磁波を吸収して発熱するものか、または、後述するような交番電界内に配置されることで発熱するものであればよい。
また、発熱体が、シリコーンゴムおよび/またはフッ素ゴムを含有し、さらに、誘電性付与物質としての炭化珪素、フェライト、チタン酸バリウム、カーボンブラックおよび黒鉛からなる群から選ばれる少なくとも1つを5~90体積%含有していることが好ましい。
発熱体における誘電性付与物質の含有率は10~70体積%であることがより好ましく、13~50体積%であることがより好ましく、15~35体積%であることがさらに好ましい。発熱体における誘電性付与物質の含有率がこのような範囲であると、後述するような電磁波を吸収して発熱しやすくなり、または後述するような交番電界内に配置されることで発熱しやすくなるからである。また、発熱体が局所的に発熱するようなことが生じ難くなるからである。また、原料が加熱された際にスパーク(例えば放電する現象)が発生し難くなる傾向がある。さらに、発熱体が必要な強度を発現しやすくなるからである。
なお、この平均粒子径は、ふるいわけで求めた重量基準の粒度分布から求められるD50を意味するものとする。
本発明の製造方法における成形型はキャビティを有する。
キャビティは成形型において原料を入れる型であり、原則、キャビティの内部空間と同一形状の成形体が得られる。
ここで、第2型部12が、第1型部11と第2型部12とが相対的にスライドするためのガイド部121を有することが好ましい。第1型部11と第2型部12とが互いに接近すると、内部空間15の容積が減少し、内部空間15内の原料が内部空間15の内壁に押し当てられる。
本発明の製造方法における成形型は、上記のような発熱体とキャビティとの間の少なくとも一部に透過量抑制体を有するか、または、キャビティの少なくとも一部が透過量抑制体からなる。
透過量抑制体は、電磁波または交番電界のキャビティの内部への透過量を遮断することができる物質からなることが好ましい。
透過量抑制体における金属および/または非金属の含有率は50質量%以上であることが好ましく、65質量%以上であることがより好ましく、80質量%以上であることがより好ましく、95質量%以上であることがより好ましく、実質的に100%であることがさらに好ましい。なお、「実質的に」とは原料や製造過程から混入し得る不可避的不純物が含まれることのみを許容することを意味する。
具体的には金属の中でもアルミニウム、鉄、銅およびこれらを含む合金からなる群から選ばれる少なくとも1つであることが好ましい。アルミニウム、鉄、銅を含む合金は、アルミニウム、鉄、銅のいずれか1つ以上を含んでいる合金であればよく、例えば真鍮(銅亜鉛合金)が挙げられる。
また、非金属の中でも遮蔽ガラスであることが好ましい。
これらは電磁波または交番電界のキャビティの内部への透過量を抑制または遮断することができる。
成形型が上記のような発熱体とキャビティとの間の少なくとも一部に透過量抑制体を有する場合について、図2および図3を用いて説明する。
図2は発熱体20aとキャビティ10との間に透過量抑制体30aが存在する場合の成形型1aを示す概略断面図である。また、図3は発熱体20bとキャビティ10との間に、キャビティ10全体を覆うように透過量抑制体30bが存在する場合の成形型1bを示す概略断面図である。
図2および図3に示す態様は好適例であり、本発明の製造方法における成形型はこれに限定されない。
そして、その熱が透過量抑制体30a等を介して、キャビティ10の内部空間15に存する原料に伝導し、その熱によって原料が溶融または硬化することで成形がなされる。ここで発熱体20aとキャビティ10との間に透過量抑制体30aが存在するため、発熱体20aからキャビティ10へ向かう方向の電磁波または交番電界のキャビティ10への透過量は抑制または遮断される。
このような成形型1bの少なくとも一部に電磁波を照射した場合、または、成形型1bの少なくとも一部を交番電界内に配置した場合、発熱体20bは発熱する。そして、その熱が透過量抑制体30b等を介して、キャビティ10の内部空間15に存する原料に伝導し、その熱によって原料が溶融または硬化することで成形がなされる。ここで発熱体20bとキャビティ10との間に透過量抑制体30bが存在するため、電磁波または交番電界のキャビティ10の内部空間15への透過量は抑制または遮断される。
ゴム材料として、シリコーンゴム、フッ素ゴムの他、種々のゴムを用いることができる。
すなわち、
原料を成形型のキャビティ内に入れた後、前記成形型の少なくとも一部に電磁波を照射し、または前記成形型の少なくとも一部を交番電界内に配置して、前記キャビティ内で成形体を成形する、成形体の製造方法であって、
前記成形型は、
前記電磁波を吸収して発熱する、または交番電界内に配置されることで発熱する発熱体を前記キャビティの外側に有し、
前記発熱体と前記キャビティとの間の少なくとも一部に、前記電磁波または前記交番電界の前記キャビティの内部への透過量を抑制(好ましくは遮断)する透過量抑制体を有し、
前記発熱体が発熱し、その熱が前記原料に伝導して成形が行われる、成形体の製造方法、
を実施することができる。
図4は発熱体20cが透過量抑制体からなるキャビティ10を覆っている場合の成形型1cを示す概略断面図である。
図4に示す態様は好適例であり、本発明の製造方法における成形型はこれに限定されない。例えば、キャビティの一部のみが透過量抑制体からなっていてもよい。
図4に示す好適態様において発熱体20cは、その内部にキャビティ10が嵌る型である。具体的には図4に示す発熱体20cは一方型部201cおよび他方型部202cを有しており、これらは互いにスライド可能に構成されている。スライドして一方型部201cと他方型部202cとが互いに接近すると、その内部のキャビティ10における第1型部11と第2型部12とが互いに接近する。ここで、キャビティ10の外表面の少なくとも一部(原則、外表面の全て)が、発熱体20cの内表面と接している。
成形型1cにおける発熱体の外表面全体に電磁波を照射することが好ましい。
そして、その熱が透過量抑制体からなるキャビティ10の内部空間15に存する原料に伝導し、その熱によって原料が溶融または硬化することで成形がなされる。ここでキャビティ10が透過量抑制体からなるため、電磁波または交番電界のキャビティ10の内部空間15への透過量は抑制または遮断される。
従来、例えばシリコーンゴムまたはフッ素ゴムからなるキャビティや、シリコーンゴムまたはフッ素ゴムに誘電性付与物質(炭化珪素、フェライト、チタン酸バリウム、カーボンブラック、黒鉛など)を添加した混合物からなるキャビティを用いた場合、キャビティが高温(例えば約250℃以上)になるとキャビティが軟化する場合がある。このような場合、融点が高い原料(例えば融点が約250℃以上の原料)を用いて成形体を製造することは困難であった。原料が溶融または硬化する温度においてキャビティが軟化してしまうからである。成形温度が高い原料としてはPA66、PET、PBTが挙げられる。
これに対して、本発明の製造方法においてキャビティを構成する透過量抑制体がアルミニウム、鉄、銅、これらを含む合金および遮蔽ガラスからなる群から選ばれる少なくとも1つのような金属および/または非金属のような融点が高い物質を含む(好ましくは50質量%以上含む、より好ましくは65質量%以上含む、より好ましくは80質量%以上含む、より好ましくは95質量%以上含む、さらに好ましくは実質的に100%である)場合、成形温度が高い原料を用いて、成形体を製造することができる。
ゴム材料として、シリコーンゴム、フッ素ゴムの他、種々のゴムを用いることができる。
すなわち、
原料を成形型のキャビティ内に入れた後、前記成形型の少なくとも一部に電磁波を照射し、または前記成形型の少なくとも一部を交番電界内に配置して、前記キャビティ内で成形体を成形する、成形体の製造方法であって、
前記成形型は、
前記電磁波を吸収して発熱する、または交番電界内に配置されることで発熱する発熱体を前記キャビティの外側に有し、
前記キャビティの少なくとも一部が、前記電磁波または前記交番電界の前記キャビティの内部への透過量を抑制(好ましくは遮断)する透過量抑制体からなり、
前記発熱体が発熱し、その熱が前記原料に伝導して成形が行われる、成形体の製造方法、
を実施することができる。
また、このような態様において、前記発熱体が前記キャビティの全体を覆っていることが好ましい。
本発明の製造方法では、初めに、上記のような成形型のキャビティ内に原料を入れる。
特に断りがない限り、本発明の製造方法において「主成分」は、上記を意味するものとする。
また、熱可塑性樹脂は熱可塑性エラストマー(スチレン系、オレフィン系、塩化ビニル系、酢酸ビニル系、ウレタン系、ポリエステル系等)であってもよい。
原料として熱硬化性樹脂を用いる場合、本発明の製造方法において原料は発熱体が発する熱によって硬化し、成形体となる。
原料として低融点金属を用いる場合、本発明の製造方法において原料は発熱体が発する熱によって溶融する。
原料として低融点非金属を用いる場合、本発明の製造方法において原料は発熱体が発する熱によって溶融する。
上記のような原料を成形型のキャビティ内に入れた後、成形型の少なくとも一部に電磁波を照射する場合、その方法は特に限定されない。照射することで、成形型が有する発熱体を発熱させることができる電磁波を照射することができればよい。電磁波は少なくとも発熱体の表面の全部または一部に照射すればよい。
図5において、キャビティ10における一対の第1型部11および第2型部12の間に存在する内部空間15には、原料が入れられている。
また、他方型部202cに形成されている真空孔25は真空ポンプ40に接続されており、真空ポンプ40を駆動することで、発熱体20c内を大気圧よりも圧力が低い状態(例えば真空状態)とすることができる。
そして、電磁波発生器42から電磁波を発生させ、電磁波を成形型1cに照射することができる。
また、電磁波発生器42は、0.78~2μmの波長領域を含む電磁波(近赤外線)、0.01~1mの波長領域を含む電磁波(マイクロ波)、または1~100mの波長領域を含む電磁波(高周波)を発生することができることが好ましい。
近赤外線を発生させる場合、電磁波発生器42はハロゲンランプであってよい。
マイクロ波を発生させる場合、電磁波発生器42はマイクロ波発振器であってよい。
高周波を発生させる場合、電磁波発生器42は高周波発振器であってよい。
上記のような原料を成形型のキャビティ内に入れた後、成形型の少なくとも一部を交番電界内に配置する場合、その方法は特に限定されない。交番電界内に成形型を配置することで、成形型が有する発熱体を発熱させることができればよい。少なくとも発熱体の全部または一部を交番電界内に配置すればよい。
図6において、成形型1cにおける一対の第1型部11および第2型部12の間に存在する内部空間15には、原料が充填されている。
また、他方型部202cに形成されている真空孔25は真空ポンプ40に接続されており、真空ポンプ40を駆動することで、発熱体20c内を大気圧よりも圧力が低い状態(例えば真空状態)とすることができる。
そして、誘電加熱器44を用い、一対の電極441、442に印加される高周波の交流電圧によって成形型1cに交番電界を印加することできる。誘電加熱器44による交流電圧の周波数は、1m~100mの波長領域を含む電磁波としての高周波とすることが好ましい。
また、原料として従来公知のペレットを用いることができる。また、従来と比べて成形体の寸法精度が高い。また、従来と比べて冷却時間を短くすることができる。
初めに成形型を用意した。成形型はキャビティが透過量抑制体からなり、発熱体であるゴム型の内部にキャビティが嵌る、図4に示したものと同様の態様である。
図7にキャビティの概略斜視図、図8にキャビティの概略断面図、図9にキャビティの外観写真を示す。
図7に示すように、キャビティ50は上部51、中央部52および下部53の3つの部位を組み合わせてなる構造を備える。また、図7に示した上部51および下部53の一部を中央部52に嵌合させてなるキャビティ50の断面は、図8のようになる。
キャビティ50における各部の寸法は図8に示す通りである。すなわち、上部51、中央部52および下部53の各々は、上から見た場合に、おおむね一辺が30mmの正方形をなしている。また、上部51および下部53の厚さ(最大厚さ)は10mmであり、そのうち、上部51および下部53を中央部52に嵌合したときに中央部52内に嵌合(進入)する部分の厚さは5mmである。また、中央部52の厚さ(上部51および下部53における厚さ方向と平行方向の長さ)は12mmである。したがって、上部51および下部53を中央部52に嵌合すると、中央部52内に、厚さが2mm、一辺が26mmの略正方形を底面とする略直方体の内部空間55が現れる。
ここで図10に示すように、内部空間55に原料57を入れたときに、原料57が上部51、中央部52および下部53によって完全に覆われるようにする。そうすることで、電磁波や交番電界のキャビティの内部への透過は遮断される。
なお、図10は内部空間55に原料57を入れた直後の状態を示す概略断面図であり、原料57が加熱されると原料57内の空隙が減少し、それに合わせて上部51と下部52との間隔が小さくなり(つまり上部51と下部52とが近づいていき)、内部空間55が縮小する。
そして、一方の孔にアルミナ製のさや管を装入した。さや管は内部のキャビティの外表面に接するように配置されていて、さや管に光ファイバー温度計を挿入することでキャビティの外表面の温度を継続的に測定することができるように構成されている。
また、他方の孔は、真空ポンプに繋がるチューブと接続し、真空ポンプを駆動することで、キャビティ内を減圧状態とすることができるように構成されている。この孔は、図4に示した真空孔25に相当する。
ここで原料として、ナイロン樹脂であるアミランCM1011G-30(東レ社製)のマイクロペレットを用いた。マイクロペレットの粒径は0.8~1mm程度である。
原料として、PC/ABS樹脂であるNS0031(SABICジャパン合同会社製)を用いた。なお、この原料はSUS製のフィラーを15質量%含有している。
そして、それ以外は、実施例1と同様として成形を行った。
ただし、原料の特性に合わせ、成形時の成形温度、昇温速度、成形温度での保持時間は変更した。成形時の成形温度、昇温速度、成形温度での保持時間を表1に示す。
原料として、ナイロン樹脂であるPA6CF30(東レ社製)を用いた。なお、これは炭素繊維を30質量%含有する。
そして、それ以外は、実施例1と同様として成形を行った。
ただし、原料の特性に合わせ、成形時の成形温度、昇温速度、成形温度での保持時間は変更した。成形時の成形温度、昇温速度、成形温度での保持時間を表1に示す。
原料として、ポリエステル樹脂(PBT樹脂)である1101G-30(東レ社製)のペレットを用いた。ペレットの粒径は0.8~1mm程度である。
そして、それ以外は、実施例1と同様として成形を行った。
ただし、原料の特性に合わせ、成形時の成形温度、昇温速度、成形温度での保持時間は変更した。成形時の成形温度、昇温速度、成形温度での保持時間を表1に示す。
原料として、メタキシリレンジアミンポリアミド樹脂(MXD6 C-408 カーボン長繊維グレード)を用いた。なお、この原料はカーボン製のフィラーを40質量%含有したペレット状のものである。
そして、それ以外は、実施例1と同様として成形を行った。
ただし、原料の特性に合わせ、成形時の成形温度、昇温速度、成形温度での保持時間は変更した。成形時の成形温度、昇温速度、成形温度での保持時間を表1に示す。
原料として、炭素繊維強化PPS樹脂であるA630T-30V(東レ社製)を用いた。なお、これは炭素繊維を30質量%含有する。
そして、それ以外は、実施例1と同様として成形を行った。
ただし、原料の特性に合わせ、成形時の成形温度、昇温速度、成形温度での保持時間は変更した。成形時の成形温度、昇温速度、成形温度での保持時間を表1に示す。
原料として、PEEK樹脂(熱可塑性スーパーエンプラ)であるベスタキープ2000P(EVONIK社)のマイクロペレットを用いた。マイクロペレットの粒径は0.8~1.0mm程度である。
そして、それ以外は、実施例1と同様として成形を行った。
ただし、原料の特性に合わせ、成形時の成形温度、昇温速度、成形温度での保持時間は変更した。成形時の成形温度、昇温速度、成形温度での保持時間を表1に示す。
その結果、実施例1~7の全てにおいて成形体を得ることができた。なお、製造過程において原料の自己発熱による熱暴走やスパークは発生しなかった。
実施例1~7とは異なる成形型を用意した。
実施例8において用いた成形型は、ゴム製のキャビティの外側にゴム製の発熱体が存在し、それらの間に透過量抑制体が存在する態様のものである。また、透過量抑制体は、その内部にキャビティが密着して存在し得る型をなしていて、キャビティの全体を覆うことができる。さらに、発熱体は、その内部に透過量抑制体が嵌る型をなしていて、透過量抑制体の全体を覆うことができる。
この成形型は、図3に示した態様と類似するが、これとはキャビティおよび透過量抑制体の構造等が異なる。
ここで発熱体64は、シリコーンに誘電付与物質として炭化珪素を含有させ、混錬し、硬化させた後、その内部に透過量抑制体66が嵌るように中心付近をくり貫いたゴム型である。原則、透過量抑制体66の外表面の全てが発熱体64としてのゴム型の内表面と接している。
このような成形型60のキャビティ62において、原料を入れる内部空間68は、その一部が透過量抑制体66の内面に接している。
ここで原料として、融点が150℃であり、錫およびビスマスを主として含む低融点合金であるクラフトアロイ(日新レジン株式会社製)を用いた。
ここで成形時の成形温度を150℃、昇温速度を10℃/min、成形温度での保持時間を60秒とした。なお、成形温度、昇温速度は、さや管に挿入された光ファイバー温度計によって測定しながら調整した。
その結果、図18に示すように成形体を得ることができた。なお、製造過程において原料のスパークは発生しなかった。
10 キャビティ
11 第1型部
12 第2型部
121 ガイド部
15 内部空間
20a、20b、20c 発熱体
201c 一方型部
202c 他方型部
25 真空孔
30a、30b、 透過量抑制体
40 真空ポンプ
42 電磁波発生器
44 誘電加熱器
441、442 電極
50 キャビティ
51 上部
52 中央部
53 下部
55 内部空間
57 原料
59 ゴム型
60 成形型
62 キャビティ
64 発熱体
66 透過量抑制体
68 内部空間
Claims (10)
- 原料を成形型のキャビティ内に入れた後、前記成形型の少なくとも一部に電磁波を照射し、または前記成形型の少なくとも一部を交番電界内に配置して、前記キャビティ内で成形体を成形する、成形体の製造方法であって、
前記成形型は、
前記電磁波を吸収して発熱する、または交番電界内に配置されることで発熱する発熱体を前記キャビティの外側に有し、
前記発熱体と前記キャビティとの間の少なくとも一部に、前記電磁波または前記交番電界の前記キャビティの内部への透過量を抑制する透過量抑制体を有するか、または前記キャビティの少なくとも一部が前記透過量抑制体からなり、
前記発熱体が発熱し、その熱が前記原料に伝導して成形が行われる、
成形体の製造方法。 - 前記発熱体が前記キャビティの全体を覆っている、請求項1に記載の成形体の製造方法。
- 前記透過量抑制体が、前記電磁波または前記交番電界の前記キャビティの内部への透過を遮断するものである、請求項1または2に記載の成形体の製造方法。
- 前記キャビティは前記透過量抑制体からなり、
前記発熱体は前記キャビティがその内部に嵌る型であり、
前記キャビティの外表面の少なくとも一部が、前記発熱体の内表面と接している、
請求項1~3のいずれかに記載の成形体の製造方法。 - 前記原料が、熱可塑性樹脂、熱硬化性樹脂、低融点金属および低融点非金属からなる群から選ばれる少なくとも1つを主成分とする、請求項1~4のいずれかに記載の成形体の製造方法。
- 前記原料が繊維材および/またはフィラーを含む、請求項1~5のいずれかに記載の成形体の製造方法。
- 前記発熱体が、シリコーンゴムおよび/またはフッ素ゴムを含有し、さらに、誘電性付与物質としての炭化珪素、フェライト、チタン酸バリウム、カーボンブラックおよび黒鉛からなる群から選ばれる少なくとも1つを5~90体積%含有している、
請求項1~6のいずれかに記載の成形体の製造方法。 - 前記透過量抑制体が金属および/または非金属を含む、請求項1~7のいずれかに記載の成形体の製造方法。
- 前記金属および/または前記非金属がアルミニウム、鉄、銅、これらを含む合金および遮蔽ガラスからなる群から選ばれる少なくとも1つである、請求項8に記載の成形体の製造方法。
- 前記電磁波の波長領域が0.78μm~100mの範囲に含まれる、請求項1~9のいずれかに記載の成形体の製造方法。
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WO2012173053A1 (ja) | 2011-06-17 | 2012-12-20 | テクノポリマー株式会社 | 電磁波照射成形装置及び電磁波照射成形方法 |
JP2013119219A (ja) * | 2011-12-07 | 2013-06-17 | Kyodo Printing Co Ltd | 樹脂部材の製造方法、転写用型及び転写装置 |
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JP2019192724A (ja) * | 2018-04-23 | 2019-10-31 | 四国化成工業株式会社 | ナノインプリント用硬化性組成物、及びこれを用いたパターン基板 |
WO2020203472A1 (ja) * | 2019-03-29 | 2020-10-08 | 大日本印刷株式会社 | インプリント用光硬化性樹脂組成物、インプリント用光硬化性樹脂組成物の製造方法、およびパターン形成体の製造方法 |
JP2021012024A (ja) | 2019-07-03 | 2021-02-04 | 日本電産コパル電子株式会社 | トルクセンサの取り付け構造 |
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- 2022-01-11 WO PCT/JP2022/000529 patent/WO2022163339A1/ja active Application Filing
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WO2012173053A1 (ja) | 2011-06-17 | 2012-12-20 | テクノポリマー株式会社 | 電磁波照射成形装置及び電磁波照射成形方法 |
JP2013119219A (ja) * | 2011-12-07 | 2013-06-17 | Kyodo Printing Co Ltd | 樹脂部材の製造方法、転写用型及び転写装置 |
JP2018114723A (ja) * | 2017-01-20 | 2018-07-26 | Jsr株式会社 | 樹脂ブロック及びその製造方法 |
JP2019192724A (ja) * | 2018-04-23 | 2019-10-31 | 四国化成工業株式会社 | ナノインプリント用硬化性組成物、及びこれを用いたパターン基板 |
WO2020203472A1 (ja) * | 2019-03-29 | 2020-10-08 | 大日本印刷株式会社 | インプリント用光硬化性樹脂組成物、インプリント用光硬化性樹脂組成物の製造方法、およびパターン形成体の製造方法 |
JP2021012024A (ja) | 2019-07-03 | 2021-02-04 | 日本電産コパル電子株式会社 | トルクセンサの取り付け構造 |
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