JP5848443B2 - 薄肉部品の実質的に一定圧力の射出成形のための方法 - Google Patents
薄肉部品の実質的に一定圧力の射出成形のための方法 Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/18—Feeding the material into the injection moulding apparatus, i.e. feeding the non-plastified material into the injection unit
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
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- B29C2945/76026—Energy, power
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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
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Description
本出願は、それぞれ、2011年5月20日、2011年5月20日、2011年5月20日、2011年5月20日、2011年5月20日、2012年2月24日、2012年2月24日、2012年5月2日に出願された、米国仮特許出願第61/488,564号、同第61/488,547号、同第61/488,553号、同第61/488,555号、同第61/488,559号、同第61/602,650号、同第61/602,781号、及び同第61/641,349号の優先権を主張する非仮出願である。米国仮特許出願第61/488,564号、同第61/488,547号、同第61/488,553号、同第61/488,555号、同第61/488,559号、同第61/602,650号、同第61/602,781号、及び同第61/641,349号は、参照により本明細書に組み込まれる。
本発明は、射出成形のための装置及び方法に関し、より詳細には、実質的に一定の射出圧力で薄肉射出成形部品を製造するための装置及び方法に関する。
様々な熱可塑性材料を、本開示の実質的に一定圧力の射出成形法及び装置で使用することができる。一実施形態では、溶融熱可塑性材料は、ASTM D1238に準拠し、温度約230℃、2.16kg荷重で測定した場合、約0.1g/10分〜約500g/10分のメルトフローインデックスで定義された粘度を有する。例えば、ポリプロピレンでは、メルトフローインデックスは、約0.5g/10分〜約200g/10分の範囲であり得る。他の好適なメルトフローインデックスとしては、約1g/10分〜約400g/10分、約10g/10分〜約300g/10分、約20〜約200g/10分、約30g/10分〜約100g/10分、約50g/10分〜約75g/10分、約0.1g/10分〜約1g/10分、又は約1g/10分〜約25g/10分が挙げられる。材料のMFI(メルトフローインデックス)は、成形物品の用途及び使用に基づいて選択される。例えば、0.1g/10分〜約5g/10分のMFIを有する熱可塑性材料は、射出延伸吹込成形(ISBM)用途のプリフォームとして使用するのに適していてもよい。5g/10分〜約50g/10分のMFIを有する熱可塑性材料は、包装物品のキャップ及びクロージャとして使用するのに適していてもよい。50g/10分〜約150g/10分のMFIを有する熱可塑性材料は、バケツ又はタブの製造で使用するのに適していてもよい。150g/10分〜約500g/10分のMFIを有する熱可塑性材料は、薄板などの極めて高いL/T比を有する成形物品に適していてもよい。かかる熱可塑性材料の製造業者は、一般に、材料は、41.4MPa(6000psi)を超える、また多くの場合に41.4MPa(6000psi)を大幅に超える溶融圧力を用いて射出成形されるべきであると指導する。かかる熱可塑性材料の射出成形に関する従来の指導に反して、本開示の一定射出成形法及び装置の実施形態は、かかる熱可塑性材料を使用し、41.4MPa(6000psi)を下回る、また場合によっては、41.4MPa(6000psi)をはるかに下回る溶融圧力で加工して、良質の射出成形部品を形成するのを有利に可能にする。
Y=0.7218x+129.74
(式中、Y=ピーク電力流動係数、及び
X−L/T比である。)
力とL/Tとを対比させる上記チャートでデータを生成するために使用した試験金型の成形粘度試験を完了した。この試験は、最適な射出速度が15.2cm/s(6”/秒)であることを示した。射出速度と成形圧力との間の関係を説明するために、20.3cm/s(8”/秒)の追加速度で実施した。上述のように、現在の工業的手法は、成形プレスが達成することができる最大速度で射出することである。次のデータは、20.3cm/s(8”/秒)データランによって示されるように、射出速度を高めると、成形圧力の実質的な増加を招くことを説明している。例えば、25.4cm(10”/秒)、50.8cm/s(20”/秒)、又はそれ以上といった更に高速での射出は、圧力の実質的な増加を招く。試験データを次の表で要約する。
Claims (10)
- 実質的に一定に維持された圧力で薄肉部品を射出成形する方法であって、
溶融熱可塑性材料(図1の24)を金型キャビティ(図1の32)の中に前進させるように射出システム(図1の12)を操作する工程であって、前記金型キャビティは100以上のL/T比を有し、前記熱可塑性材料は50ccを超える射出能力(shot size)を有し、所定の射出圧力に達するまで電力を上昇させながら(当初明細書段落0070のチャートの充填開始時間0〜ピーク電力の時間tl)操作する工程、を含み、
ここで、前記L/T比は、流路の長さLを流路の厚みTで除した値であり、
前記射出能力は、射出直前の融液保持容器中のポリマーの温度及び圧力において、射出成形ラムの1ストロークで射出される溶融プラスチック材料の総体積をいい、
更に、
前記金型キャビティが最初に30%充填されるまでに、前記射出システムのピーク電力を生じさせるように、充填圧力プロファイルを調節する工程と、
前記所定の射出圧力に達してから前記金型キャビティが熱可塑性材料で少なくとも80%充填されるまで、前記射出システムの電力を低減して(当初明細書段落0070のチャートのピーク電力の時間t1〜充填終了時間t5)、前記所定の射出圧力を、実質的に一定に維持する工程と、を含み、
ここに実質的に一定に維持するとは、前記所定の射出圧力につき、上方または下方に30%未満の変動を許すことをいう、方法。 - 前記金型キャビティが20%充填される前に、前記ピーク電力が生じる、請求項1に記載の方法。
- 前記金型キャビティが10%充填される前に、前記ピーク電力が生じる、請求項1に記載の方法。
- 前記電力を低減する工程が、41.4MPa(1平方センチメートル当たり422重量キログラム)未満の、前記実質的に一定の射出応力を維持するように低減する工程を含む、請求項1〜3のいずれか一項に記載の方法。
- 前記操作する工程が、前記熱可塑性材料の流頭が連続して移動するように維持し、前記熱可塑性材料を前記金型キャビティを通って進むときに、ヘジテーションなしに移動するように操作することを含む、請求項1〜4のいずれか一項に記載の方法。
- 前記操作する工程が、前記熱可塑性材料の流頭が凝固し始める前に、少なくとも99%の充填するまで前記金型キャビティを充填することを含む、請求項1〜5のいずれか一項に記載の方法。
- 前記操作する工程が、溶融熱可塑性材料を、200以上の前記L/T比を有する前記金型キャビティの中に前進させるように操作することを含む、請求項1〜6のいずれか一項に記載の方法。
- 前記操作する工程が、溶融熱可塑性材料を、250以上の前記L/T比を有する前記金型キャビティの中に前進させるように操作することを含む、請求項1〜7のいずれか一項に記載の方法。
- 前記操作する工程が、前記熱可塑性材料が50ccを超える前記射出能力を有する前記射出システムを操作することを含む、請求項1〜8のいずれか一項に記載の方法。
- 前記操作する工程が、前記熱可塑性材料が100ccを超える前記射出能力を有する前記射出システムを操作することを含む、請求項1〜9のいずれか一項に記載の方法。
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JP2014518795A (ja) | 2014-08-07 |
EP2709817B1 (en) | 2018-10-24 |
CA2835961C (en) | 2016-07-12 |
US20130113131A1 (en) | 2013-05-09 |
US8828291B2 (en) | 2014-09-09 |
US20130069280A1 (en) | 2013-03-21 |
US20160176084A1 (en) | 2016-06-23 |
BR112013029234A2 (pt) | 2017-01-31 |
US9815233B2 (en) | 2017-11-14 |
CN103561935A (zh) | 2014-02-05 |
RU2013147760A (ru) | 2015-06-27 |
MX2013013583A (es) | 2014-01-16 |
CA2835961A1 (en) | 2012-11-29 |
WO2012162245A1 (en) | 2012-11-29 |
CN103561935B (zh) | 2017-08-29 |
KR20140001253A (ko) | 2014-01-06 |
EP2709817A1 (en) | 2014-03-26 |
CA2913161A1 (en) | 2012-11-29 |
US9272452B2 (en) | 2016-03-01 |
CA2913161C (en) | 2017-11-14 |
MX356268B (es) | 2018-05-21 |
AU2012258968A1 (en) | 2013-11-28 |
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