JP7430176B2 - 生分解性で産業的に堆肥化可能な射出成形の微細軟質発泡体およびその製造方法 - Google Patents
生分解性で産業的に堆肥化可能な射出成形の微細軟質発泡体およびその製造方法 Download PDFInfo
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- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/10—Applying counter-pressure during expanding
- B29C44/105—Applying counter-pressure during expanding the counterpressure being exerted by a fluid
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- 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
- B29C44/36—Feeding the material to be shaped
- B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
- B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
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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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- 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
- B29C44/36—Feeding the material to be shaped
- B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
- B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
- B29C44/422—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum by injecting by forward movement of the plastizising screw
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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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- 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
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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
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
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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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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0046—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
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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
- B29C45/03—Injection moulding apparatus
- B29C45/12—Injection moulding apparatus using two or more fixed moulds, e.g. in tandem
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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
- B29C45/1781—Aligning injection nozzles with the mould sprue bush
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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
- B29C45/26—Moulds
- B29C45/263—Moulds with mould wall parts provided with fine grooves or impressions, e.g. for record discs
- B29C45/2642—Heating or cooling means therefor
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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
- B29C45/76—Measuring, controlling or regulating
- B29C45/78—Measuring, controlling or regulating of temperature
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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
- B29C2045/1784—Component parts, details or accessories not otherwise provided for; Auxiliary operations not otherwise provided for
- B29C2045/1787—Mould parts driven by pressure of injected material
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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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- B29C2791/00—Shaping characteristics in general
- B29C2791/002—Making articles of definite length, i.e. discrete articles
-
- 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
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
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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
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/007—Using fluid under pressure
-
- 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
- B29C2945/76003—Measured parameter
- B29C2945/76006—Pressure
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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
- B29C2945/76003—Measured parameter
- B29C2945/7604—Temperature
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- 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
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
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- 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
- B29K2003/00—Use of starch or derivatives as moulding material
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- 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
- B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
- B29K2067/04—Polyesters derived from hydroxycarboxylic acids
- B29K2067/046—PLA, i.e. polylactic acid or polylactide
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- 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
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
- B29K2105/041—Microporous
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Toxicology (AREA)
- Environmental & Geological Engineering (AREA)
- Environmental Sciences (AREA)
- Biodiversity & Conservation Biology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Health & Medical Sciences (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Biological Depolymerization Polymers (AREA)
- Molding Of Porous Articles (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Description
[0001]本出願は、2018年5月21日出願の「BIODEGRADABLE AND INDUSTRIALLY COMPOSTABLE INJECTION MOULDED MICROCELLULAR FLEXIBLE FOAMS, AND A METHOD OF MANUFACTURING THE SAME」という名称の米国特許仮出願第62/674,544号の優先権および利益を主張するものであり、これらの開示はあらゆる目的で全体として参照により本明細書に組み込まれる。
[0040]上記その他の態様について、以下の図面を参照して次に詳細に説明する。
[0045]本明細書は、生分解性で産業的に堆肥化可能な微細軟質発泡体およびその製造方法について記載する。発泡体は、好ましくは独立気泡発泡体であるが、場合により連続気泡発泡体として形成することもできる。様々な実装形態では、生分解性で産業的に堆肥化可能な軟質発泡体は、従来の石油化学エチレン酢酸ビニル(EVA)発泡体などと同一の特性および特徴を有しながら、高い割合のバイオマス炭素含有量を含むようにすることができる。
Claims (15)
- 生分解性で産業的に堆肥化可能な軟質発泡体成形製品を製造する方法であって、
発泡のために熱可塑性バイオポリマー混合マスタバッチを成形装置のバレルに導入するステップであって、前記熱可塑性バイオポリマー混合マスタバッチが、ポリ乳酸(PLA)、ポリ(L-乳酸)(PLLA)、ポリ(ブチレンアジペート-co-テレフタレート)(PBAT)、ポリカプロラクトン(PCL)、ポリヒドロキシアルカノエート(PHA)、ポリブチレンサクシネート(PBS)、ポリブチレンサクシネートアジペート(PBSA)、ポリブチレンアジペート(PBA)、アセチルセルロース(CA)、または、熱可塑性デンプン(TPS)のうちの1つまたは複数を含む、ステップと、
超臨界流体を生じさせるための温度および圧力条件下で前記バレルに流体を導入するステップであり、前記超臨界流体が、前記熱可塑性バイオポリマー混合マスタバッチに接触すると、熱可塑性発泡溶融物を生じさせる、流体を導入するステップと、
前記熱可塑性発泡溶融物を好適な金型形状の空洞に射出するステップと、
前記空洞にガス逆圧を印加するステップと、
前記空洞を冷却して、架橋されていない成形製品である生分解性で産業的に堆肥化可能な軟質発泡体成形製品を作製するステップとを含む、方法。 - 前記熱可塑性バイオポリマーマスタバッチの1つまたは複数の前記導入が、スプルーブッシングを介して行われる、請求項1に記載の方法。
- 前記熱可塑性バイオポリマー混合マスタバッチが、二軸スクリュー押出機を介して作製される、請求項2に記載の方法。
- 前記熱可塑性バイオポリマー混合マスタバッチが、ポリ(ブチレンアジペート-co-テレフタレート)(PBAT)を含む、請求項1に記載の方法。
- 前記流体が、計測ユニットを介して前記バレルに導入される、請求項1に記載の方法。
- 前記超臨界流体が、窒素および二酸化炭素のうちの1つまたは複数を含む、請求項1に記載の方法。
- 前記超臨界流体が、圧力が約150×105パスカル(150バール)~約300×105パスカル(300バール)の範囲であり、温度が約150℃~約350℃の範囲である、圧力および温度で導入される、請求項6に記載の方法。
- 前記温度が、動的成形温度制御を介して制御される、請求項7に記載の方法。
- 前記ガス逆圧が、約5×105パスカル(5バール)~約50×105パスカル(50バール)の範囲であり、1秒~25秒の時間の長さにわたって印加される、請求項8に記載の方法。
- 前記成形製品が、ソール、ミッドソール、およびインソールのうちの1つまたは複数を含むシューズ構成要素である、請求項1に記載の方法。
- 架橋されていない成形製品である生分解性で産業的に堆肥化可能な軟質発泡体成形製品を作製する射出成形装置であって、
複数の熱可塑性バイオポリマーが入れられ、当該複数の熱可塑性バイオポリマーを前記成形装置に導入するように構成されたホッパーであり、前記熱可塑性バイオポリマーが、混合されるマスタバッチを形成し、前記熱可塑性バイオポリマーが、ポリ乳酸(PLA)、ポリ(L-乳酸)(PLLA)、ポリ(ブチレンアジペート-co-テレフタレート)(PBAT)、ポリカプロラクトン(PCL)、ポリヒドロキシアルカノエート(PHA)、ポリブチレンサクシネート(PBS)、ポリブチレンサクシネートアジペート(PBSA)、ポリブチレンアジペート(PBA)、アセチルセルロース(CA)、または、熱可塑性デンプン(TPS)のうちの1つまたは複数を含む、ホッパーと、
窒素および二酸化炭素のうちの1つまたは複数を含む流体を受け取り、導入時に超臨界流体を生じさせるための条件下で、前記受け取った流体を前記成形装置に導入するように構成された計測ユニットと、
バイオポリマー前記超臨界流体が第1の空洞内で前記混合熱可塑性バイオポリマーマスタバッチに接触すると、熱可塑性発泡溶融物が生じるように、前記成形装置に導入されたとき、前記混合熱可塑性バイオポリマーマスタバッチおよび前記流体を受け取るように構成された前記第1の空洞を有するバレルと、
前記バレルの前記第1の空洞と流体連通している第2の空洞を有する金型であり、前記第2の空洞が、前記発泡溶融物を受け取り、前記溶融物が冷却されると、前記軟質発泡体成形製品を作製するように構成される、金型と、
前記第2の空洞へガス逆圧を送達して前記発泡溶融物の膨張を制御するように構成されたガス逆圧送達ユニットと、
を備える射出成形装置。 - 前記第1の空洞内で前記発泡溶融物を圧縮し、前記圧縮された発泡溶融物を前記金型の前記第2の空洞内へ運搬するように構成された往復スクリューをさらに備える、請求項11に記載の射出成形装置。
- 前記バレルの前記第1の空洞と前記金型の前記第2の空洞との間に導管をさらに備え、前記導管がノズルを含み、前記ノズルが、前記バレルと前記金型との間に封止を形成するために、スプルーブッシングをさらに含む、請求項12に記載の射出成形装置。
- 前記熱可塑性バイオポリマーが、ポリ(ブチレンアジペート-co-テレフタレート)(PBAT)を含む、請求項11に記載の射出成形装置。
- 前記金型が、ソール、ミッドソール、およびインソールのうちの1つまたは複数を含むシューズ構成要素の成形製品を作製するための形状を有する、請求項11に記載の射出成形装置。
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