JP4910265B2 - 熱可塑性樹脂製中空容器およびその製造方法 - Google Patents
熱可塑性樹脂製中空容器およびその製造方法 Download PDFInfo
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- JP4910265B2 JP4910265B2 JP2004026493A JP2004026493A JP4910265B2 JP 4910265 B2 JP4910265 B2 JP 4910265B2 JP 2004026493 A JP2004026493 A JP 2004026493A JP 2004026493 A JP2004026493 A JP 2004026493A JP 4910265 B2 JP4910265 B2 JP 4910265B2
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
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- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
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- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1648—Laser beams characterised by the way of heating the interface radiating the edges of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
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- B29C65/1677—Laser beams making use of an absorber or impact modifier
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/169—Laser beams making use of light guides being a part of the joined article
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- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
- B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
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- B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
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- B29C65/5071—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and being composed by one single element
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- B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
- B29C65/5085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and comprising grooves, e.g. being E-shaped, H-shaped
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
- B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
- B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
- B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/65—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles with a relative motion between the article and the welding tool
- B29C66/652—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles with a relative motion between the article and the welding tool moving the welding tool around the fixed article
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- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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Description
前記帯状成形体の溶着前の断面形状が、三角形、四角形、半円形およびコの字形から選ばれたいずれかであること、
前記帯状成形体が、未架橋ポリフェニレンスルフィド樹脂を含むレーザー透過性熱可塑性樹脂からなること
前記未架橋ポリフェニレンスルフィド樹脂材料のクロロホルムで5時間全還流抽出するソックスレー抽出法による抽出量が3.0重量%以下であること、
前記帯状成形体が、未架橋ポリフェニレンスルフィド樹脂と非晶性樹脂との熱可塑性樹脂組成物からなること、および
前記帯状成形体が、さらにシラン化合物および/または酸化防止剤を配合してなる熱可塑性樹脂組成物からなること
が、いずれも好ましい条件として挙げられる。
PPS−1の製造
攪拌機付きオートクレーブに、硫化ナトリウム9水塩6.005kg(25モル)、酢酸ナトリウム0.656kg(8モル)およびN−メチル−2−ピロリドン(以下NMPと略す)5kgを仕込み、窒素を通じながら徐々に205℃まで昇温し、水3.6リットルを留出した。次に、反応容器を180℃に冷却後、1,4−ジクロロベンゼン3.756kg(25.55モル)ならびにNMP2.4kgを加えて、窒素下に密閉し、270℃まで昇温後、270℃で2.5時間反応した。次に、100℃に加熱されたNMP10kg中に投入して、約1時間攪拌し続けたのち、濾過し、さらに80℃の熱水で30分の洗浄を3回繰り返した。これを90℃に加熱されたpH4の酢酸水溶液25リットル中に投入し、約1時間攪拌し続けたのち、濾過し、濾液のpHが7になるまで約90℃のイオン交換水で洗浄後、80℃で24時間減圧乾燥し、MFR300g/10分、クロロホルム抽出量0.5重量%のPPS−1を得た。
攪拌機付きオートクレーブに、硫化ナトリウム9水塩6.005kg(25モル)、酢酸ナトリウム0.656kg(8モル)およびNMP5kgを仕込み、窒素を通じながら徐々に205℃まで昇温し、水3.6リットルを留出した。次に、反応容器を180℃に冷却後、1,4−ジクロロベンゼン3.675kg(25.0モル)ならびにNMP2.4kgを加えて、窒素下に密閉し、274℃まで昇温後、274℃で0.8時間反応した。次いで、230〜250℃、5〜10kPaの高温高圧下でNMPを除去したのち、50〜70℃の熱水で洗浄した。これを濾過し、90℃に加熱されたpH4の酢酸水溶液25リットル中に投入し、約1時間攪拌し続けたのち、濾過し、濾液のpHが7になるまで約90℃のイオン交換水で洗浄後、80℃で24時間減圧乾燥し、MFR300g/10分、クロロホルム抽出量3.8重量%のPPS−2を得た。
N,N−ジメチルアセトアミドを、重合溶媒とする酸クロリド法低温溶液重合法にて合成した。以下に詳細を示す。N,N−ジメチルアセトアミド(DMAC)65リットルにジアミノジフェニルエーテル(DDE)12kgおよびメタフェニレンジアミン(MPDA)2.0kgを溶解し、氷浴で冷却しながら、粉末状の無水トリメリット酸モノクロリド(TMAC)15kgを内温が30℃を超えないような速度で添加した。TMACを全て添加した後、無水トリメリット酸(TMA)1.7kgを添加し、30℃で2時間撹拌保持した。粘調となった重合液をカッターミキサーに張った100リットルの水中に投入し、高速撹拌することによりスラリー状にポリマを析出させた。得られたスラリーを遠心分離機で脱水処理した。脱水後のケークを60℃の水200リットルを用いて洗浄し、再度遠心分離機で脱水処理した。得られたケークを熱風乾燥機を用いて、220℃/5時間の条件で乾燥し、ガラス転移温度(Tg)=275℃の粉末状ポリマを得た。
高密度ポリエチレン(PE):“ハイゼックス”7000F(三井化学(株)製)
ナイロン6,6(PA):“アミラン”CM3001−N(東レ(株)製)
ポリカーボネート(PC):“タフロン”A2200(出光石油化学(株)製)
参考例4 シラン化合物:β−(3,4−エポキシシクロヘキシル)エチルトリメトキシシラン、KBM303(信越化学工業(株)製)
参考例5 酸化防止剤:“次亜リン酸カルシウム”(太平科学産業(株)製)
参考例6 着色剤(レーザー光吸収剤)、カーボンブラック:“三菱カーボンブラック”MA100B(三菱化学(株)製)
実施例1〜14、比較例1〜8
中空容器用熱可塑性樹脂材料の上下両部材、帯状成形体用ならびに物性評価用試験片を、参考例1のPPS樹脂、参考例2のPAI樹脂、参考例3のPPS樹脂、PAI樹脂以外の熱可塑性樹脂、参考例4のシラン化合物、参考例5の酸化防止剤、参考例6の着色剤を、リボンブレンダーで表1および2に示す量でブレンドし、4ホールストランドダイヘッド付きTEX44(2軸押出機;日本製鋼所(株)製)にて溶融混練を行うことにより得られたペレットを用いて成形した。
なお、帯状成形体の寸法は、
図4(A):長さL76mm、高さH4mm、幅D2mm、
図4(B):長さL76mm、高さH4mm、幅D4mm、
図4(C):長さL76mm、高さH4mm、幅D2mm、
図4(D):長さL76mm、高さH4mm、幅D2mm、中央最小幅d1mm
図4(E):長さL76mm、高さH4mm、中央部高さh2mm、
幅D2mm、中央部幅d1mm
とした。
上部材〜外形L1:80mm、内径L2:76ミリ、高さH:30ミリ、
あし部分長さa1:7mm、あし部分幅a2:2mm、
フランジ部厚みb1:2mm、フランジ部幅b2:3mm
下部材〜外形L1:80mm、内径L2:76ミリ、高さH:30ミリ、
フランジ部厚みb1:2mm、フランジ部幅b2:3mm
とした。
(1)溶着強度
(1−1)レーザー溶着強度
溶着強度測定の試験片としては、熱可塑性樹脂製中空容器から溶着部が中心となるように15mm×50mmに切り出した角状成形品を用いた。試験装置には(AG−500C)を用い、該試験片の両端を固定し、引張試験を行った。強度測定時の引張速度は1mm/min、スパンは20mmである。溶着強度は溶着部位が破断したときの応力とした。一方、非溶着部の強度測定の試験片としては、溶着部のない熱可塑性樹脂製中空容器の下面中心部を15mm×50mmに切り出した角状成形品を用いた。引張試験の方法は上述する溶着部の試験方法と同様に行った。
(1−2)振動溶着強度
溶着部、非溶着部の試験片ならびに引張試験方法は、レーザー溶着強度と同様に行った。
(2)耐薬品性
ASTM1号ダンベルを試験片として、耐圧容器中で80℃×500hrのガソリン浸漬処理を行った後、ASTM−D638に準拠する引張試験による引張強度を測定した。ガソリン浸漬後の引張強度を未処理の引張強度で除した値(強度保持率)を耐薬品性の評価結果とした。
(3)バリア性
レーザーまたは振動溶着後、図5に示す中空容器上面に直径3mmの開口部を設け、50ccのモデルガソリン(トルエン//イソオクタン=50//50体積%)とエタノールを90対10重量比に混合したアルコールガソリン混合物を当該開口部から入れ、開口部を封じて50℃×500hr処理した際の重量減量挙動からそのバリア性を評価した。燃料減少量が0.1g/day未満を二重丸、0.1g/day以上0.4g/day未満を丸、0.4g/day以上をバツと評価した。
(4)衝撃強度 ASTM−D256に準拠して測定した。
2 熱可塑性樹脂製中空容器下部部材
3 帯状成形体
4 レーザー溶着部
5 あし部分
6 接合面
Claims (7)
- 予め複数に分割して成形されたポリフェニレンスルフィド樹脂またはポリフェニレンスルフィド樹脂を含む樹脂組成物製中空分割部品の周縁接合面をレーザー溶着により接合してなる熱可塑性樹脂製中空容器であって、該周縁接合面の一部にポリフェニレンスルフィド樹脂を含むレーザー透過性熱可塑性樹脂またはその樹脂組成物の帯状成形体が介在されており、該中空分割部品と該帯状成形体の両方が接触面において溶融してレーザー溶着され、かつ残りの接合面は帯状成形体が介在しない状態で接していることを特徴とする熱可塑性樹脂製中空容器。
- 前記帯状成形体の溶着前の断面形状が、三角形、四角形、半円形およびコの字形から選ばれたいずれかであることを特徴とする請求項1記載の熱可塑性樹脂製中空容器。
- 前記帯状成形体が、未架橋ポリフェニレンスルフィド樹脂を含むレーザー透過性熱可塑性樹脂からなることを特徴とする請求項1または2記載の熱可塑性樹脂製中空容器。
- 前記未架橋ポリフェニレンスルフィド樹脂材料のクロロホルムで5時間全還流抽出するソックスレー抽出法による抽出量が3.0重量%以下であることを特徴とする請求項3記載の熱可塑性樹脂製中空容器。
- 前記帯状成形体が、未架橋ポリフェニレンスルフィド樹脂と非晶性樹脂との熱可塑性樹脂組成物からなることを特徴とする請求項1〜4のいずれか1項記載の熱可塑性樹脂製中空容器。
- 前記帯状成形体が、さらにシラン化合物および/または酸化防止剤を配合してなる熱可塑性樹脂組成物からなることを特徴とする請求項1〜5のいずれか1項記載の熱可塑性樹脂製中空容器。
- 予め複数に分割して成形されたポリフェニレンスルフィド樹脂またはポリフェニレンスルフィド樹脂を含む樹脂組成物製中空分割部品の周縁接合面の一部に、ポリフェニレンスルフィド樹脂を含むレーザー透過性熱可塑性樹脂またはその樹脂組成物の帯状成形体を介在させ、該帯状成形体側からレーザー光を照射することにより、該中空分割部品と該帯状成形体の接触面を溶着させ、残りの接合面は帯状成形体を介在せずに接した状態で保持することを特徴とする熱可塑性樹脂製中空容器の製造方法。
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