JP2023505919A - 粒子発泡体から成形部品を製造する方法 - Google Patents
粒子発泡体から成形部品を製造する方法 Download PDFInfo
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- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/3461—Making or treating expandable particles
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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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
- B29C67/205—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored comprising surface fusion, and bonding of particles to form voids, e.g. sintering
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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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
- B29C67/207—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored comprising impregnating expanded particles or fragments with a binder
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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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
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
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- C08J2451/08—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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- C—CHEMISTRY; METALLURGY
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- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Thermal Sciences (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Toxicology (AREA)
- Electromagnetism (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Molding Of Porous Articles (AREA)
Abstract
Description
a)粒子発泡体粒子を提供するステップと、
b)粒子発泡体粒子を少なくとも1種のポリオレフィンの水性エマルションで湿潤し、それによって官能化可能な粒子発泡体粒子を得るステップと、
c)湿潤された官能化可能な粒子発泡体粒子を乾燥するステップと、
d)官能化可能な粒子発泡体の粒子を賦形するステップと、
e)賦形された官能化可能な粒子発泡体粒子を、粒子発泡体粒子の溶融範囲よりも低い温度に加熱し、それによって、賦形された官能化可能な粒子発泡体粒子を官能化するステップであって、粒子発泡体粒子が接合される、ステップと、
f)冷却し、それによって、賦形された粒子発泡体粒子を得るステップと、
を含み、上記少なくとも1種のポリオレフィンの水性エマルションは、不飽和カルボン酸の無水物で液体状態に変換され、かつメタクリル酸エステルコポリマーで変性された、少なくとも1種のポリオレフィンを含む水性エマルションであることを特徴とする。
iii)下記のシランのアクリル酸エステル基への結合及びその後の加水分解
市販の粒子発泡体を使用する。PPベースの粒子発泡体、例えば、JSP社のARPRO、BASF社のNeopolen PまたはKaneka社のEperan Pの商標名のものを、例として挙げることができる。PSをベースとする粒子発泡体は、とりわけ、BASFからのStyroporの名称で知られる。他の加工可能な粒子発泡体は、ほんの少しを選択すると、例えば、SekisuiのPiocelan、 BASFの Infinergy、ArmacellのArmaShapeである。
官能化可能な粒子発泡体粒子を、更なる加工の前に、短時間保管することが推奨される。後の加工のために粒子発泡体粒子を準備する場合、活性化剤が完全に乾燥されていれば、保管はプロセスに有害ではない。最大保管時間は、現在の開発段階では、まだ決定されていない。
経済的製造のため、間接加熱される金型を作製することが賢明である。全般的な基本設計は、射出成形金型に非常に似ている。意図する金型は、広い温度範囲にわたって高速且つ絶対的な乾燥サイクルを再現できることが重要であり、ここで温度範囲は、使用する粒子発泡体に応じて、60℃~220℃となり得る。従来の射出成形で使用されているもののような、外部温度制御ユニットの使用は、非常に有効であることが判明している。変温(variothermic)制御も有利に使用できる。
2つの半金型を閉じた後、官能化可能な粒子発泡体粒子を、粒子発泡体の標準的な充填デバイスを用いて、圧力ホース及び充填物注入機を介して、金型に充填する。充填デバイスは、官能化可能な粒子発泡体粒子を金型内で圧縮する(油圧で、機械的に、または併用して)ことができ、それによる圧縮比は最大で当初のかさ密度の50%までとなり得る。金型内での圧縮は、その後の成形部品密度に大きく影響する。
官能化可能な粒子発泡体粒子が充填された金型を、上記の温度制御デバイスによって必要なプロセス温度にする。加熱の持続時間は、使用する粒子発泡体及び成形部品の最大肉厚に大きく依存する。必要なコア温度に達すると(コア温度は必要に応じて温度プローブを使用して成形部品の内側で測定できる)、金型を、約40℃~80℃の離型温度まで冷却する。
離型温度に達した後、金型を開放する。成形部品は通常、金型のいわゆるボンネット部分に残っている。次いで、成形部品を、手作業で、またはハンドリングロボット等の吸引及び除去デバイスを補助的に用いて、取り除く。充填物注入機の特殊なイジェクタ機能による機械的な離型も可能である。成形部品は、直ちに加工することができる。更なる加工ステップは必要ではない。
Claims (15)
- 粒子発泡体から成形部品を製造する方法であって、
a)粒子発泡体粒子を提供するステップと、
b)前記粒子発泡体粒子を少なくとも1種のポリオレフィンの水性エマルションで湿潤し、それによって官能化可能な粒子発泡体粒子を得るステップと、
c)前記湿潤された官能化可能な粒子発泡体粒子を乾燥するステップと、
d)前記官能化可能な粒子発泡体の粒子を賦形するステップと、
e)前記賦形された官能化可能な粒子発泡体粒子を、前記粒子発泡体粒子の溶融範囲よりも低い温度に加熱し、それによって、前記賦形された官能化可能な粒子発泡体粒子を官能化するステップであって、前記粒子発泡体粒子が接合される、ステップと、
f)冷却し、それによって、前記賦形された粒子発泡体粒子を得るステップと、
を含み、前記少なくとも1種のポリオレフィンの前記水性エマルションは、不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、少なくとも1種のポリオレフィンを含む水性エマルションである
ことを特徴とする方法。 - 前記水性エマルションが、無水マレイン酸で液体状態に変換され、且つアクリレート樹脂で変性された、少なくとも1種のポリオレフィンの塩素フリー水性エマルションである
請求項1に記載の方法。 - 不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、前記少なくとも1種のポリオレフィンの前記水性エマルションに、少なくとも1種のエポキシ末端シランが添加されてもよい
請求項1または2に記載の方法。 - 不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、前記少なくとも1種のポリオレフィンの前記水性エマルションへの前記少なくとも1種のエポキシ末端シランの前記添加は、前記ステップb)の直前に起こる
請求項3に記載の方法。 - 不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、前記少なくとも1種のポリオレフィンの前記水性エマルションに、少なくとも1種のエポキシ樹脂が添加される
請求項1または2に記載の方法。 - 前記ステップa)で提供された前記粒子発泡体粒子は、2種以上の異なる粒子発泡体材料を含む
請求項1ないし5のいずれかに記載の方法。 - 前記ステップd)の前に、
d0)前記粒子発泡体粒子と共に複合材成形部品を形成する異種材料を提供するステップ
を更に含み、前記ステップd)において、前記官能化可能な粒子発泡体粒子の成形が、前記異種材料と直接接触して実施される
請求項1ないし6のいずれかに記載の方法。 - 前記ステップf)の後、既に完成した粒子発泡体成形部品が、更なる粒子発泡体成形体と継ぎ合わされる、または異種材料が提供され、それに対して、前記ステップb)と同様に、不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、前記少なくとも1種のポリオレフィンの前記水性エマルションを、継ぎ合わせようとする部品の関連する表面に適用し、それを前記ステップc)に従って乾燥し、次いで、前記ステップd)と同様に継ぎ合せた後、前記ステップe)に従って、製造しようとする複合材を継ぎ合わせのため加熱し、前記ステップf)に従って冷却する
請求項1ないし6のいずれかに記載の方法。 - 前記ステップd)における前記賦形が、少なくとも一時的に機械的圧力下で実施される、
及び/または
前記ステップf)における前記加熱が無加圧で起こる
請求項1ないし8のいずれかに記載の方法。 - -改良ステップd)において、前記賦形は、官能化可能な粒子発泡体粒子の個別の層及び/または構造で実施され、且つ
-改良ステップe)において、加熱は、局所集中可能なエネルギー源を用いて実施され、その結果、前記個別の層または構造内の前記官能化可能な粒子発泡体粒子が接合され、且つ
-改良ステップf)において、冷却は、局所集中可能なエネルギー源を不活化し、部分的な粒子発泡体成形部品を最初に得ることで実施され、
ここで、前記改良ステップf)に続いて、ステップg)において、官能化可能な粒子発泡体粒子の少なくとも1つの更なる層及び/または1つの更なる構造が、前記部分的な粒子発泡体成形部品と接触して提供され、
前記改良ステップd)、前記改良ステップe)及びf)並びに前記ステップg)が、最終的な粒子発泡体成形部品が達成されるまで繰り返される、
請求項1ないし6のいずれかに記載の方法。 - 請求項1ないし10のいずれかに記載の方法によって得られる
ことを特徴とする粒子発泡体成形部品。 - 不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、少なくとも1種のポリオレフィンを含む、少なくとも1種のポリオレフィンの塩素フリー水性エマルションの、粒子発泡体成形部品の製造のための使用であって、前記粒子発泡体が熱可塑性材料から選択される
ことを特徴とする使用。 - 不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、少なくとも1種のポリオレフィンを含む、少なくとも1種のポリオレフィンの塩素フリー水性エマルションの、粒子発泡体成形部品の製造のための使用であって、前記粒子発泡体が天然の再生可能原料から選択される
ことを特徴とする使用。 - 不飽和カルボン酸の無水物で液体状態に変換され、且つメタクリル酸エステルコポリマーで変性された、少なくとも1種のポリオレフィンを含む、少なくとも1種のポリオレフィンの塩素フリー水性エマルションの、金属表面の永久接合のための使用。
- 前記塩素フリー水性エマルションは、無水マレイン酸で液体状態に変換され、且つアクリレート樹脂で変性された、少なくとも1種のポリオレフィンの水性エマルションである
請求項12ないし14のいずれかに記載の少なくとも1種のポリオレフィンの塩素フリー水性エマルションの使用。
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