TWI734076B - 以連續式拉擠成型生產ｌｆｔ押出件及其使用的押出機 - Google Patents

以連續式拉擠成型生產ｌｆｔ押出件及其使用的押出機 Download PDF

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TWI734076B
TWI734076B TW108103609A TW108103609A TWI734076B TW I734076 B TWI734076 B TW I734076B TW 108103609 A TW108103609 A TW 108103609A TW 108103609 A TW108103609 A TW 108103609A TW I734076 B TWI734076 B TW I734076B
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lft
length
screw
section
item
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TW202027958A (zh
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廖德超
許漢卿
陳春來
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南亞塑膠工業股份有限公司
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Priority to TW108103609A priority Critical patent/TWI734076B/zh
Priority to CN201910463164.0A priority patent/CN111497168A/zh
Priority to US16/679,452 priority patent/US20200238641A1/en
Publication of TW202027958A publication Critical patent/TW202027958A/zh
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Publication of TWI734076B publication Critical patent/TWI734076B/zh
Priority to US18/119,933 priority patent/US20230211537A1/en

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    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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Abstract

一種LFT押出件，使用長纖維熱塑性塑膠(LFT)為原料，以連續式押出成型製程生產LFT片材、管材與異型材，尤其是，製程中所使用的押出機的螺桿，需要提出結構改良，包括所述螺桿的桿身，區分為三個螺紋溝深區段，依序包括一進料段(F)、一壓縮段(C)及一計量段(M)，使得所生產的LFT片材、管材與異型材具有高強度、高剛度、高尺寸穩定性、低翹曲度、耐潛變等特點。

Description

以連續式拉擠成型生產LFT押出件及其使用的押出機
本發明涉及一種長纖複合材料的押出件，特別是以連續式拉擠成型製法生產長纖複合材料(LFT)及其使用的押出機。
長纖維熱塑性塑膠(long fiber thermoplastics，LFT)，也稱長纖複合材料，是將包含玻纖與碳纖且長度介於6-25mm的纖維與熱塑性樹脂基材經過造粒而製成的熱塑性樹脂，適用於聚丙烯(PP)、聚醯胺(PA6、PA66)，聚對苯二甲酸丁二酯(PBT)或聚苯硫醚(PPS)等熱塑型樹脂。
長纖維複合材料(LFT)具有輕量化、高強度、高剛度、高尺寸穩定性、低翹曲度、耐潛變等顯著特點，其中，以拉伸及衝擊強度更能凸顯長纖維複合材料(LFT)的強度，可以彌補短纖複合材料(short fiber thermoplastics，SFT)強度上的不足。
長纖維複合材料(LFT)的加工方式，習知技藝是以射出成型(injection molding)與模壓成型(sheet molding compound)加工LFT片材、管材或異型材產品，即使也採用以連續式拉擠成型(continuous pultrusion)加工LFT產品，但單螺桿押出機的螺桿則需要提出結構改良。
有鑑於此，本發明的主要目的在於提供一種單螺桿押出機的螺桿結構改良，使得長纖維複合材料(LFT)的加工方式，適用以連續式拉擠成型(continuous pultrusion)加工法生產LFT片材、管材或異型材產品；所 述螺桿的結構特徵，包括：1. 螺桿長度(L)與螺桿直徑(D)的L/D比值介於20~26；2. 螺桿的桿身，按桿身的螺紋溝深的深淺，區分為三個區段，包括進料段(F)、壓縮段(C)及計量段(M)，其中，進料段(F)的長度為L1、壓縮段(C)的長度為L2、以及，計量段(M)的長度為L3，且滿足下列條件：1)L1+L2+L3=L；2)進料段(F)的長度(L1)為0.40~0.50倍的螺桿長度(L)，優選為0.40倍的螺桿長度(L)，進料段(F)的螺紋溝深為d1，且4mm≦d1≦7mm；3)計量段(M)的長度(L3)為0.10~0.20倍的螺桿長度(L)，優選為0.20倍的螺桿長度(L)，且計量段(M)的螺紋溝深為d3；4)螺桿的壓縮比(CR)為進料段(F)的螺紋溝深(d1)與計量段(M)的螺紋溝深(d3)的d1/d3比值介於2.0~4.0；優選為2.0~2.5；5)壓縮段(C)的長度(L2)為0.30~0.40倍的螺桿長度(L)，優選為0.40倍的螺桿長度(L)，壓縮段(C)的螺紋溝深為d2，且d3≦d2≦d1，優選為d3<d2<d1；本發明所使用連續式押出成型製程之押出機將長纖複合材料加熱成熔融狀態，再將此熔融塑料自模頭(Die Head)連續不斷地押出，經真空定型冷卻，由牽引機拉取，使其形成連續的製品。
單螺桿押出機工藝條件為：一區溫度為180-260℃，二區溫度為200-260℃，三區溫度為210-285℃，四區溫度為220-290℃，模頭溫度為240~310℃，螺桿轉速5~50rpm。
上述牽引機引取速度控制在0.3~2.0米/分鐘。
本發明的另一主要目的在於提供一種以連續式拉擠成型生 產LFT押出件，所使用的長纖維複合材料(LFT)原料，依據產品需求以及製造方法的參數加以調整，包含1-90重量%的熱可塑性樹脂及99-10重量%的長纖維熱可塑性母粒，優選為包含33.3-75重量%的熱可塑性樹脂及25-66.7重量%的長纖維熱可塑性母粒；其中，所述熱可塑性樹脂選自聚丙烯樹脂、聚醯胺(PA6或PA66)、或聚苯硫醚(PPS)中的一種以上；所述長纖維熱可塑性母粒為具有長度6-25mm的玻璃纖維或碳纖維材料。
本發明使用的長纖維複合材料(LFT)原料，依據本領域中具有通常知識者的常識，可以選用添加其他功能性的添加劑，使得以連續式拉擠成型生產的LFT押出件產品具有額外的功能性；所述添加劑選自抗氧化劑、滑劑、耐候劑或色料中的一種以上。
本發明的有益效果，是以連續式押出成型製程生產的LFT異型押出件，具有輕量化、高強度、高剛度及高尺寸穩定性的優點。
10‧‧‧LFT異型押出件生產設備
20‧‧‧單螺桿押出機
25‧‧‧螺桿
30‧‧‧押出模頭
40‧‧‧真空定型模
50‧‧‧冷卻水槽
60‧‧‧牽引機
70‧‧‧裁切機
L‧‧‧螺桿長度
D‧‧‧螺桿直徑
F‧‧‧進料段
C‧‧‧壓縮段
M‧‧‧計量段
L1‧‧‧進料段的長度
L2‧‧‧壓縮段的長度
L3‧‧‧計量段的長度
d1‧‧‧進料段的螺紋溝深
d2‧‧‧壓縮段的螺紋溝深
d3‧‧‧計量段的螺紋溝深
圖1為本發明使用的LFT異型押出件生產設備示意圖。
圖2為圖1的LFT異型押出件生產設備中的連續式拉擠成型押出機的螺桿結構改良放大圖。
習知技藝是以射出成型或模壓成型加工長纖維複合材料(LFT)。本發明是教導以連續式押出成型製程生產LFT異型押出件，包括LFT片材、管材與異型材等產品。
如圖1所示，本發明使用的LFT異型押出件生產設備10，包括一單螺桿押出機20、一押出模頭30、一真空定型模40、一冷卻水槽50、一牽引機60及一裁切機70。LFT異型押出件的生產製程，包括：長纖 維複合材料(LFT)通過單螺桿押出機20加熱成熔融狀態，再將熔融的LFT塑料自押出模頭30連續不斷地押出，經真空定型模40(可以是圓形、平板、方形或是異型)定型冷卻，經冷卻水槽50以水冷或氣冷完全冷卻後，再由牽引機60連續拉取形成的製品，最後以裁切機70裁切成尺寸。
如圖2所示，為實現長纖維複合材料(LFT)適用以連續式拉擠成型加工法生產LFT異型押出件，本發明的單螺桿押出機20的螺桿25結構，具備以下結構特徵，包括：1. 螺桿25的長度(L)與螺桿25的直徑(D)的L/D比值介於20~26；2. 螺桿25的桿身，按其桿身的螺紋溝深的深淺，區分為三個區段，包括進料段(F)、壓縮段(C)及計量段(M)，其中，進料段(F)的長度為L1、壓縮段(C)的長度為L2、以及，計量段(M)的長度為L3，且滿足下列條件：1)L1+L2+L3=L；2)進料段(F)的長度(L1)為0.40~0.50倍的螺桿長度(L)，優選為0.40倍的螺桿長度(L)，進料段(F)的螺紋溝深為d1，且4mm≦d1≦7mm；3)計量段(M)的長度(L3)為0.10~0.20倍的螺桿長度(L)，優選為0.20倍的螺桿長度(L)，且計量段(M)的螺紋溝深為d3；4)螺桿的壓縮比(CR)為進料段(F)的螺紋溝深(d1)與計量段(M)的螺紋溝深(d3)的d1/d3比值介於2.0~4.0；優選為2.0~2.5；5)壓縮段(C)的長度(L2)為0.30~0.40倍的螺桿長度(L)，優選為0.40倍的螺桿長度(L)，壓縮段(C)的螺紋溝深為d2，且d3≦d2≦d1，優選為d3<d2<d1。
本發明使用的長纖維複合材料(LFT)原料，依據產品需求以及製造方法的參數加以調整，包含1-90重量%的熱可塑性樹脂及99-10重 量%的長纖維熱可塑性母粒，優選為包含33.3-75重量%的熱可塑性樹脂及25-66.7重量%的長纖維熱可塑性母粒；其中，所述熱可塑性樹脂選自聚丙烯樹脂、聚醯胺(PA6或PA66)、或聚苯硫醚(PPS)中的一種以上；所述長纖維熱可塑性母粒為具有長度6-25mm的玻璃纖維或碳纖維材料。
本發明的單螺桿押出機20的押出條件，分為五個加熱溫度區，逐漸將長纖維複合材料(LFT)加熱成熔融狀態，第一區溫度為180-260℃，第二區溫度為200-260℃，第三區溫度為210-285℃，第四區溫度為220-290℃，第五區溫度為押出模頭30的溫度為240~310℃；而本發明的單螺桿押出機20的螺桿25轉速為5~50rpm；所述牽引機50的引取速度控制在0.3~2.0米/分鐘。
本發明使用的長纖維複合材料(LFT)原料，依據本領域中具有通常知識者的常識，可以選用添加其他功能性的添加劑，使得以連續式拉擠成型生產的LFT押出件產品具有額外的功能性；所述添加劑選自抗氧化劑、滑劑、耐候劑或色料中的一種以上。
以下列舉實施例具體說明本發明的內容及可達成的功效，但本發明並不僅局限於此等實施例。實施例及比較例的各項物性評估，係採行下列方法加以進行：
1. 比重：
使用ASTM-D792測定。
2. 抗拉強度(MPa)：
依據ASTM D638測試標準。
3. 彎曲強度(MPa)：
依據ASTM D 790測試標準
4. 彎曲模數(MPa)：
依據ASTM D 790測試標準。
5. Izod衝擊強度(kg-cm/cm)：
依據ASTM D 256測試標準。
6. 耐荷重試驗(kgf)：
以跨距70cm進行彎曲破壞載重。
【實施例1】
長纖維複合材料(LFT)取包含33.3重量%的熱可塑性樹脂及66.7重量%的長纖維熱可塑性母粒(內含60%玻纖)。如圖1及圖2所示，使用押出量為25~50kg/hr的LFT異型押出件生產設備10，以連續式拉擠成型加工法生產LFT平板材。
單螺桿押出機20的螺桿25結構，具備以下結構特徵，包括：1)螺桿25的長度(L)為1，690mm；螺桿25的直徑(D)為65mm；L/D的比值為26；2)螺桿25的桿身區分為三個區段，包括進料段(F)的長度(L1)為0.40倍的螺桿25的長度(L)、壓縮段(C)的長度(L2)為0.40倍的螺桿25的長度(L)及計量段(M)的長度(L3)為0.20倍的螺桿25的長度(L)，3)進料段(F)的螺紋溝深(d1)為7mm；計量段(M)的螺紋溝深(d3)為3mm；螺桿的壓縮比(d1/d3)為2.33。
單螺桿押出機20的押出條件，設定為五個加熱溫度區，第一區溫度及第二區溫度設定為210℃，第三區溫度及第四區溫度設定為220℃，第五 區溫度為平板材模頭的溫度，設定為220℃，螺桿轉速8rpm，引取速度控制在0.71米/分鐘
測試所製得的LFT平板材的物性，測試結果如表1所示。
【實施例2】
除了單螺桿押出機20的押出模頭30改為使用圓形模頭，同實施例1的原料配方及其製法，以製得尺寸外徑
Figure 108103609-A0101-12-0007-6
34mm x厚度2.0mm的LFT圓形管。
測試所製得的LFT圓形管的物性，測試結果如表2所示。
【實施例3】
除了單螺桿押出機20的押出模頭30改為使用方形管模頭，以及，單螺桿押出機20的押出條件，設定為五個加熱溫度區，第一區溫度設定為190℃，第二區溫度設定為210℃，第三區溫度設定為220℃，第四區溫度設定為225℃，第五區溫度為方形管模頭的溫度，設定為240℃，螺桿轉速8rpm，引取速度控制在0.56米/分鐘。
同實施例1的原料配方及其製法，以製得尺寸長30mm x寬30mm x厚度2.0mm LFT方形管
測試所製得的LFT方形管的物性，測試結果如表2所示。
【比較例1】
樣品為一般市售的硬質PVC平板，測試樣品的物性如表2所示。
【比較例2】
同實施例1的原料配方，但以射出成型加工法生產寬50mm x厚度3.0mm的LFT平板材。
測試所製得的LFT平板材的物性，測試結果如表2所示。
【比較例3】
1. 樣品為一般市售的外徑
Figure 108103609-A0101-12-0008-7
34mm x厚度2.0mm的硬質PVC圓管，測試樣品的物性如表2所示。
【結果】
2. 實施例1製得的LFT平板材的物性，與比較例1的市售硬質PVC平板及比較例2以射出成型加工的LFT平板材(簡稱射出平板材)相較，在衝擊強度上，分別為PVC板的3倍及射出平板材的1.2倍，其抗拉及彎曲強度也優於PVC板，加上密度上也較PVC板小，具有輕量化、高強度、高剛度，可以取代PVC板材及射出平板材的。
3. 由表2數據可得知，本發明以連續式押出成型製程生產LFT片材、管材與異型材等產品，不但有效提升LFT異型押出件的耐荷重強度，且具備輕量化的競爭力。
Figure 108103609-A0101-12-0008-1
Figure 108103609-A0101-12-0009-2
Figure 108103609-A0101-12-0009-3
25‧‧‧螺桿
L‧‧‧螺桿長度
D‧‧‧螺桿直徑
F‧‧‧進料段
C‧‧‧壓縮段
M‧‧‧計量段
L1‧‧‧進料段的長度
L2‧‧‧壓縮段的長度
L3‧‧‧計量段的長度
d1‧‧‧進料段的螺紋溝深
d2‧‧‧壓縮段的螺紋溝深
d3‧‧‧計量段的螺紋溝深

Claims (9)

  1. 一種以連續式拉擠成型生產LFT押出件的單螺桿押出機，其特徵在於，所述單螺桿押出機具有一螺桿，且滿足以下條件：1)所述螺桿長度(L)與其螺桿直徑(D)的L/D比值介於20~26，並且螺桿直徑(D)為65mm；2)所述螺桿的桿身，區分為三個螺紋溝深區段，依序包括一進料段(F)、一壓縮段(C)及一計量段(M)，其中，所述進料段(F)的長度為L1、所述壓縮段(C)的長度為L2，所述計量段(M)的長度為L3，且滿足L1+L2+L3=L；3)所述進料段(F)的長度(L1)為0.40~0.50倍的螺桿長度(L)，且所述進料段(F)的螺紋溝深為d1，且4mm≦d1≦7mm；4)所述計量段(M)的長度(L3)為0.10~0.20倍的螺桿長度(L)，且計量段(M)的螺紋溝深為d3；5)所述螺桿的壓縮比(CR)，為所述進料段(F)的螺紋溝深(d1)與所述計量段(M)的螺紋溝深(d3)的d1/d3比值介於2.0~4.0；6)所述壓縮段(C)的長度(L2)為0.30~0.40倍的螺桿長度(L)，且所述壓縮段(C)的螺紋溝深為d2，且d3≦d2≦d1；7)所述進料段(F)、所述壓縮段(C)、及所述計量段(M)之間的長度關係為L1≧L2>L3。
  2. 如申請專利範圍第1項所述之單螺桿押出機，其中，所述進料段(F)的長度(L1)為0.40倍的螺桿長度(L)，所述壓縮段(C)的長度(L2)為0.40倍的螺桿長度(L)，且所述計量段(M)的長度(L3)為0.20倍的螺桿長度(L)。
  3. 如申請專利範圍第1項所述之單螺桿押出機，其中，所述螺桿的壓縮比(CR)介於2.0~2.5。
  4. 如申請專利範圍第1項所述之單螺桿押出機，其中，d3<d2<d1。
  5. 一種使用申請專利範圍第1項的單螺桿押出機製得的LFT押出件，其特徵在於，所述LFT押出件的原料，選自1-90重量%的熱可塑性樹脂及99-10重量%的長纖維熱可塑性母粒。
  6. 如申請專利範圍第5項所述的LFT押出件，其中，所述LFT押出件的原料，選自33.3-75重量%的熱可塑性樹脂及25-66.7重量%的長纖維熱可塑性母粒。
  7. 如申請專利範圍第5項或第6項所述的LFT押出件，其中，所述熱可塑性樹脂選自聚丙烯樹脂、聚醯胺或聚苯硫醚(PPS)中的一種以上；所述長纖維熱可塑性母粒具有長度6-25mm的玻璃纖維或碳纖維。
  8. 如申請專利範圍第5項或第6項所述的LFT押出件，其中，所述熱可塑性樹脂進一步包含添加劑，且所述添加劑選自抗氧化劑、滑劑、耐候劑或色料中的一種以上。
  9. 一種生產LFT押出件的方法，其包含：提供如申請專利範圍第1項的一單螺桿押出機； 利用所述單螺桿押出機將一長纖維複合材料(LFT)加熱成熔融狀態；其中，所述單螺桿押出機的押出條件，分為五個加熱溫度區，逐漸將所述長纖維複合材料加熱成熔融狀態，第一區溫度為180-260℃，第二區溫度為200-260℃，第三區溫度為210-285℃，第四區溫度為220-290℃，第五區溫度為240~310℃；其中，所述單螺桿押出機的所述螺桿的一轉速為5~50rpm；其中，所述LFT押出件為LFT平板材、LFT圓形管或LFT方形管，並且所述LFT圓形管的彎曲破壞載重介於41.92~42.55kgf之間，所述LFT方形管的彎曲破壞載重介於152.65~158.62kgf之間。
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