TWI708671B - Multi-stage foaming method - Google Patents
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Abstract
本發明所提供多段成型之方法,其主要之技術特徵係令高分子原料之發泡結構係經由兩階段的發泡製程所產生,其中,在第一階段的發泡製程中,係將高分子原料與發泡劑混合後,經由射出機或押出機等供料裝置之輔助,使混合後的材料進入一第一模具中,經發泡並受該第一模具模製成型為具有一第一發泡倍率之發泡胚,再將該發泡胚自該第一模具中取出;在第二階段之發泡製程中,則係以超臨界流體為發泡劑,對被置入於一密閉空間中之該發泡胚在預設之溫度及壓力下進行第二次發泡,使之成為具有一第二發泡倍率之發泡物,並使該第一發泡倍率小於該第二發泡倍率。The main technical feature of the multi-stage molding method provided by the present invention is that the foamed structure of the polymer material is produced through a two-stage foaming process. In the first stage of the foaming process, the polymer After the raw material is mixed with the foaming agent, with the aid of a feeding device such as an injection machine or an extruder, the mixed material enters a first mold, and is foamed and molded by the first mold to have a first mold. A foamed embryo with a foaming ratio is then taken out from the first mold; in the second stage of the foaming process, supercritical fluid is used as the foaming agent, and the pair is placed in a The foamed embryo in the closed space is foamed for the second time at a preset temperature and pressure, so that it becomes a foam with a second foaming ratio, and the first foaming ratio is smaller than the second foaming ratio Foaming ratio.
Description
本發明係與高分子加工技術有關,特別是關於一種多段發泡之方法。The present invention is related to polymer processing technology, especially a multi-stage foaming method.
按,高分子之發泡成型技術,乃係利用適當之發泡劑在高分子成型加工的製程中,使成型物具有多孔性之結構,以達到降低密度、減輕重量或者提高彈性等物性的改變,而在進行中、低倍率之發泡時,通常係採用化學發泡劑,相對的,在進行中、高倍率之發泡時,通常採用的則是物理發泡劑。According to the polymer foam molding technology, the use of appropriate foaming agents in the polymer molding process to make the molded product have a porous structure to achieve changes in physical properties such as reducing density, reducing weight, or improving elasticity , And when foaming at medium and low magnification, usually use chemical foaming agent, on the contrary, when foaming at medium and high magnification, usually use physical foaming agent.
但在進行高倍率之發泡時,由於激烈的氣泡成長容易導致氣泡壁的破裂,使小氣泡相互地結合成為大的氣泡,造成機械強度的降低,甚至於形成為開放性之發泡結構(opened-cell foam),是等技術上的限制導致了以密閉性發泡結構(closed-cell foam)為必要條件的發泡物、例如海上飄浮設備、輪胎、鞋底等物品,在進行高倍率發泡成型加工時,不易獲得品質良好及穩定的成品。However, during high-rate foaming, the fierce bubble growth will easily lead to the rupture of the bubble wall, which will combine small bubbles to form large bubbles, resulting in a decrease in mechanical strength, and even an open foam structure ( opened-cell foam), it is due to technical restrictions that have caused foams that require a closed-cell foam structure (closed-cell foam) as a necessary condition, such as floating equipment, tires, shoe soles and other items to undergo high magnification. During the bubble forming process, it is not easy to obtain good quality and stable finished products.
因此,本發明之主要目的即係在提供一種多段發泡之方法,其係可使進行高倍率發泡加工之高分子發泡成型物獲得穩定及良好品質的高倍率發泡結構。Therefore, the main purpose of the present invention is to provide a multi-stage foaming method, which can obtain a stable and good-quality high-rate foamed structure for high-rate foamed polymer molded products.
緣是,為達成上述目的,本發明所提供多段成型之方法,其主要之技術特徵係令高分子原料之發泡結構係經由兩階段的發泡製程所產生,其中,在第一階段的發泡製程中,係將高分子原料與發泡劑混合後,經由射出機或押出機等供料裝置之輔助,使混合後的材料進入一第一模具中,經發泡並受該第一模具模製成型為具有一第一發泡倍率之發泡胚,再將該發泡胚自該第一模具中取出。The reason is that, in order to achieve the above object, the multi-stage molding method provided by the present invention has the main technical feature that the foamed structure of the polymer material is produced through a two-stage foaming process. Among them, the first stage In the foaming process, after the polymer raw material is mixed with the foaming agent, the mixed material enters a first mold with the aid of a feeding device such as an injection machine or an extruder, and is foamed and subjected to the first mold. The molded shape is a foamed embryo with a first foaming ratio, and the foamed embryo is taken out of the first mold.
在第二階段之發泡製程中,則係以超臨界流體為發泡劑,對被置入於一密閉空間中之該發泡胚在預設之溫度及壓力下進行第二次發泡,使之成為具有一第二發泡倍率之發泡物,並使該第一發泡倍率小於該第二發泡倍率。In the second stage of the foaming process, supercritical fluid is used as the foaming agent, and the foamed embryo placed in a closed space is foamed a second time at a preset temperature and pressure. It is made into a foam with a second expansion ratio, and the first expansion ratio is made smaller than the second expansion ratio.
其中,第一階段發泡係可為習知應用物理性發泡劑或化學性發泡劑所進行之發泡,而其發泡結構除為密閉性外亦可為開放性者。Among them, the first-stage foaming system can be a conventional foaming using a physical foaming agent or a chemical foaming agent, and its foaming structure can also be open in addition to being airtight.
本發明之另一目的則在提供一種多段發泡之方法,其係可增加高發泡倍率發泡物之強度。Another object of the present invention is to provide a method of multi-stage foaming, which can increase the strength of high foaming ratio foams.
而為達成是一目的,在本發明所提供的多段發泡之方法中,係使藉由一第一發泡劑進行發泡的高分子原料,在所進入之一第一模具的模室中,預先置入一固態之補強元件,從而使該高分子原料與該第一發泡劑之混合物在進入該第一模具之模室後,包覆該補強元件,同時使該高分子原料在該第一模具之模室中進行發泡時,該補強元件不隨之發泡。In order to achieve one goal, in the multi-stage foaming method provided by the present invention, the polymer material foamed by a first foaming agent is placed in the cavity of a first mold. , Pre-place a solid reinforcing element, so that the mixture of the polymer raw material and the first foaming agent enters the cavity of the first mold to cover the reinforcing element, and at the same time make the polymer raw material in the When foaming is carried out in the cavity of the first mold, the reinforcing element does not foam with it.
進一步地,該高分子原料於該第一模具中以該第一發泡劑完成上述的第一階段發泡並將該補強件包裹於內部所形成的發泡胚,係被移置至一密閉空間中,以超臨界流體含浸之,而在預設的壓力及溫度下進行第二階段發泡,使該發泡胚與該補強元件各自進行發泡,而獲得一發泡物。Further, the polymer material is used in the first mold to complete the first stage of foaming with the first foaming agent, and the foaming embryo formed by wrapping the reinforcing member in the interior is transferred to a closed The space is impregnated with supercritical fluid, and the second stage of foaming is performed at a preset pressure and temperature, so that the foamed embryo and the reinforcing element are foamed separately to obtain a foam.
其中,該高分子原料於該第一階段發泡後係具有一第一發泡倍率之發泡程度,並於該第二階段發泡後則具有一第二發泡倍率之發泡程度,且使該第一發泡倍率小於該第二發泡倍率。Wherein, the polymer material has a foaming degree of a first foaming ratio after foaming in the first stage, and a foaming degree of a second foaming ratio after foaming in the second stage, and Make the first expansion ratio smaller than the second expansion ratio.
其中,該補強元件於該第二階段發泡時,係以該超臨界流體為發泡劑地以一第三發泡倍率進行發泡,並使該第三發泡倍率小於該第二發泡倍率。Wherein, when the reinforcing element is foamed in the second stage, the supercritical fluid is used as the foaming agent to foam at a third expansion ratio, and the third expansion ratio is made smaller than the second expansion ratio. Magnification.
茲即舉以本發明二較佳實施例加以詳細說明如后。Hereinafter, two preferred embodiments of the present invention are described in detail as follows.
在本發明第一較佳實施例中所提供的多段發泡之方法,其係令所預設的高發泡倍率係經由至少兩階段的發泡製程來達成,以克服習知技術以單一發泡製程進行高倍率發泡時所易產生之缺失,具體上來說,該多段發泡之方法係至少包含了有在實施的時間上有先後順序的一第一階段發泡製程及一第二階段發泡製程。In the multi-stage foaming method provided in the first preferred embodiment of the present invention, the preset high foaming ratio is achieved through at least two-stage foaming process, so as to overcome the conventional technology to use a single foaming process. The process is easy to produce defects during high-rate foaming. Specifically, the multi-stage foaming method at least includes a first-stage foaming process and a second-stage foaming process that are sequential in the implementation time. Bubble process.
在該第一階段發泡製程中,係將高分子原料與一第一發泡劑之混合物,利用射出機或押出機等習知的適當供料技術,定量地供給至一第一模具內的模室空間中,從而使該高分子原料得藉由該第一發泡劑進行第一階段之發泡並藉由該第一模具賦予其與該模室空間相同之形狀,製得一具有第一發泡倍率的發泡胚。In the first-stage foaming process, a mixture of polymer raw materials and a first foaming agent is quantitatively supplied to a first mold by using conventional appropriate feeding techniques such as injection machines or extruders. In the mold chamber space, the polymer material is foamed in the first stage by the first foaming agent and given the same shape as the mold chamber space by the first mold, so as to produce a A foaming embryo with a foaming ratio.
繼之,該第二階段發泡製程即以該發泡胚所具有的第一發泡倍率為基礎,進一步地提高該發泡胚的發泡倍率,來達到所需的預設高發泡倍率者,在實施上,係將該發泡胚自該第一模具移出後,再移入一不同於該模室空間的密閉空間中,並以超臨界流體為一第二發泡劑地灌注至該密閉空間內,使該發泡胚在該密閉空間中受到該第二發泡劑所含浸,據以令該發泡胚在該第二發泡劑的作用下發泡為一具有第二發泡倍率之發泡物,而由於發泡程度的累積,該第二發泡倍率乃大於該第一發泡倍率。Subsequently, the second-stage foaming process is based on the first foaming ratio of the foamed embryo to further increase the foaming ratio of the foamed embryo to achieve the desired preset high foaming ratio In practice, after removing the foaming embryo from the first mold, it is moved into a closed space different from the space of the mold chamber, and supercritical fluid is used as a second foaming agent to pour into the closed space. In the space, the foaming embryo is impregnated by the second foaming agent in the enclosed space, so that the foaming embryo is foamed under the action of the second foaming agent to have a second foaming ratio Due to the accumulation of foaming degree, the second foaming ratio is greater than the first foaming ratio.
藉由使該高分子原料先以相對較低的第一發泡倍率進行發泡,使發泡胚的內部因為發泡所形成的多孔構造具有相對較小空間或較低密度的氣孔,以此為基礎所進行的該第二階段發泡製程,乃可在提高發泡倍率之同時,保持多孔構造的完整性,以確保該發泡物在相對較高的第二發泡倍率狀態下,仍能保持其結構的完整性,來穩定產品的品質。By first foaming the polymer material at a relatively low first expansion ratio, the foamed embryo has a relatively small space or low-density pores in the porous structure formed by foaming. The second-stage foaming process based on this can increase the expansion ratio while maintaining the integrity of the porous structure to ensure that the foam is still at a relatively high second expansion ratio. It can maintain its structural integrity to stabilize product quality.
由於該第一階段發泡製程係以提供較低發泡倍率之發泡胚為目的,因此關於其具體之技術內容並不存在需加以特別進行限制之必要,換言之,該發泡胚之取得係可採用本發明所屬技術領域中之通常知識者所已周知的發泡技術來達成,例如採用化學性發泡劑或物理性發泡劑、採用模內發泡之方法或模外發泡之方法等,均無礙於其提供發泡胚之目的,亦即並無加以限制之必要性存在;Since the first-stage foaming process is aimed at providing foamed embryos with a lower foaming ratio, there is no need to specifically limit the specific technical content. In other words, the foaming embryo is obtained by the system It can be achieved by using foaming techniques known to those skilled in the art to which the present invention belongs, such as using chemical or physical foaming agents, using in-mold foaming methods or out-of-mold foaming methods Etc., it does not hinder its purpose of providing foamed embryos, that is, there is no need to restrict it;
另外,該第一模具所提供的模室空間形狀,對於本發明所屬技術領域具有通常知識者而言,其變化及選擇並無需再特別加以說明之必要,舉凡如鞋底、實心輪胎或自行車座墊墊體等需求發泡結構來提供彈性者,或其他以減重為目的者,均可被選用,並無特別需加以限制之必要。In addition, the shape of the mold chamber space provided by the first mold, for those with ordinary knowledge in the technical field of the present invention, its changes and selections do not need to be specifically explained, such as shoe soles, solid tires or bicycle seat cushions. Those who require foamed structures such as cushions to provide flexibility, or those whose purpose is to reduce weight, can be selected, and there is no need to restrict them.
再者,在該第二階段發泡製程中,該密閉空間乃係可被開啟呈開放狀並可被關閉呈與大氣隔絕的密閉狀態,例如習知的壓力釜等,以便於該發泡胚移入該密閉空間中,以及將該發泡物自該密閉空間移出,是等容納技術應屬本發明所屬技術中具有通常知識者所周知,於此即無再加贅言之必要;Furthermore, in the second-stage foaming process, the enclosed space can be opened to an open shape and can be closed to a sealed state isolated from the atmosphere, such as a conventional autoclave, etc., to facilitate the foaming embryo Moving into the confined space and removing the foam from the confined space, etc. containment technology should be well known by those with ordinary knowledge in the technology to which the present invention belongs, so there is no need to add any more details here;
另外,構成該第二發泡劑之超臨界流體係可視該高分子原料之組成而選擇適當的氣體,例如氮、二氧化碳或惰性氣體等均得以被作為該第二發泡劑之組成成分;In addition, the supercritical flow system that constitutes the second blowing agent can select an appropriate gas depending on the composition of the polymer raw material, such as nitrogen, carbon dioxide, or inert gas, etc., can be used as the component of the second blowing agent;
至於以超臨界流體進行高分子發泡之發泡技術,係屬已經公開之習知技術內容,且就本發明而言,如何以超臨界流體進行發泡之技術本身,並非本發明之技術特徵所在,因而關其發泡技術之本身即予以略之。As for the foaming technology of polymer foaming with supercritical fluid, it belongs to the known technical content that has been disclosed, and as far as the present invention is concerned, the technology itself how to foam with supercritical fluid is not the technical feature of the present invention Therefore, the foaming technology itself is ignored.
更有進者,該發泡物在完成該第二發泡倍率之發泡後,係可再被移置至一第二模具內進行再加熱加壓之塑形後,將之冷卻以定型成為成品。Even more advanced, after the foam is foamed at the second expansion ratio, it can be moved into a second mold for reheating and pressing, and then cooled to shape it into Finished product.
藉由上述技術,該多段發泡之方法所獲得之高發泡倍率之發泡物,除可使其產品之品質穩定外,更能獲得較於習知單一程序所能完成發泡倍率更高的發泡倍率,以擴大產品之應用範圍,提昇經濟效益。With the above-mentioned technology, the high expansion ratio foam obtained by the multi-stage foaming method can not only stabilize the quality of the product, but also obtain a higher expansion ratio than the conventional single process can complete. The expansion ratio is used to expand the application range of the product and improve economic efficiency.
惟由於發泡物的發泡倍率與其機械強度二者間,通常係呈反比的狀態,因此,藉由上述第一實施例所揭多段發泡之方法所製成之發泡物成品,在機械強度上可能會因此而有不足,為此,本發明即再舉以一第二較佳實施例來增加高倍率發泡物之機械強度。However, since the expansion ratio of the foam and its mechanical strength are usually inversely proportional to each other, the foam product made by the multi-stage foaming method disclosed in the first embodiment above is mechanically The strength may be insufficient because of this. Therefore, the present invention uses a second preferred embodiment to increase the mechanical strength of the high-rate foam.
具體而言,該第二較佳實施例之技術內容,除了包含該第一較佳實施例所揭之全部技術內容外,其係更進一步地在第一階段發泡製程中,在高分子原料與第一發泡劑之混合物尚未進入該第一模具前,預先將具有固定形狀之一補強元件固體置入該第一模具之模室空間中,並使該混合物進入該模室空間後將該補強元件之全部或一部進行包覆,以及使該補強元件在該第一階段發泡製程中不進行發泡,藉此,所製成的具有第一發泡倍率之發泡胚即與該補強元件固結成一體。Specifically, the technical content of the second preferred embodiment, in addition to including all the technical content disclosed in the first preferred embodiment, is a further step in the first-stage foaming process in the polymer raw material Before the mixture with the first foaming agent enters the first mold, a solid reinforcement element with a fixed shape is placed in the mold chamber space of the first mold in advance, and the mixture enters the mold chamber space. All or part of the reinforcing element is covered, and the reinforcing element is not foamed in the first-stage foaming process, so that the foamed embryo with the first foaming ratio is made with the The reinforcing elements are consolidated into one body.
而在後續之第二階段製程中,該發泡胚與所固接的該補強元件係同時地被置入密閉空間中,但接續所灌注之第二發泡劑則使該發泡胚與該補強元件同時浸於該第二發泡劑中,是等狀態下,該發泡胚固可如前述第一較佳實施例所揭般地利用該第二發泡劑進行再發泡至第二發泡倍率之狀態,惟該補強元件則視其本身之成分組成而有不同,舉例而言,如該補強元件係為金屬元素或金屬化合物為組成成分時,超臨界流體並不會在其內部進行發泡反應,但如其組成成分為可進行發泡之高分子物時,則超臨界流體即可於其內部進行發泡,從而使該補強元件在該第二階段製程中亦進行發泡而具有一第三發泡倍率,且由於該補強元件僅在第二階段製程中進行發泡,相較於該發泡物係經由第一發泡倍率的發泡胚所再發泡的第二發泡倍率而言,該第三發泡倍率自會小於該第二發泡倍率,從而使得該發泡物可以藉由較低發泡配率的補強元件來強化其整體的機械強度,以補足第一較佳實施例之不足。In the subsequent second stage of the manufacturing process, the foamed embryo and the fixed reinforcing element are simultaneously placed in the enclosed space, but the second foaming agent is continuously poured to make the foamed embryo and the The reinforcing element is immersed in the second foaming agent at the same time. In a constant state, the foaming embryo can be re-foamed to the second foaming agent using the second foaming agent as disclosed in the first preferred embodiment. The state of foaming rate, but the reinforcing element is different depending on its own composition. For example, if the reinforcing element is made of metal elements or metal compounds, the supercritical fluid will not be inside. Carry out the foaming reaction, but if the composition is a foamable polymer, the supercritical fluid can be foamed inside, so that the reinforcing element can also be foamed during the second stage of the process. It has a third foaming ratio, and because the reinforcing element is only foamed in the second stage of the process, it is compared with the second foam that is re-foamed by the foaming embryo of the first foaming ratio. In terms of foaming ratio, the third foaming ratio will naturally be smaller than the second foaming ratio, so that the foam can be strengthened by a reinforcing element with a lower foaming ratio to enhance its overall mechanical strength to complement the first Disadvantages of a preferred embodiment.
更進一步來說,在該補強元件係為高分子材料時,為確保其與該發泡物間的結合性,係可選用與該高分子原料相同的成分,來確保兩者間良好的結合程度,惟此乃屬最佳之實施例,不應限縮本發明應受保護的範圍。Furthermore, when the reinforcing element is a polymer material, in order to ensure its bond with the foam, the same components as the polymer material can be selected to ensure a good degree of bonding between the two However, this is the best embodiment and should not limit the scope of protection of the present invention.
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