WO2007026257A2 - Dispositif et procede pour le moulage evolue de mousse structuree - Google Patents

Dispositif et procede pour le moulage evolue de mousse structuree Download PDF

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Publication number
WO2007026257A2
WO2007026257A2 PCT/IB2006/003364 IB2006003364W WO2007026257A2 WO 2007026257 A2 WO2007026257 A2 WO 2007026257A2 IB 2006003364 W IB2006003364 W IB 2006003364W WO 2007026257 A2 WO2007026257 A2 WO 2007026257A2
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WO
WIPO (PCT)
Prior art keywords
accumulator
gas
advancing
extruder
polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2006/003364
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English (en)
Other versions
WO2007026257A3 (fr
Inventor
Chul B. Park
Xiang Xu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US11/219,309 external-priority patent/US20070052124A1/en
Application filed by Individual filed Critical Individual
Priority to EP06820982A priority Critical patent/EP1937455A2/fr
Priority to JP2008528600A priority patent/JP2009506909A/ja
Publication of WO2007026257A2 publication Critical patent/WO2007026257A2/fr
Publication of WO2007026257A3 publication Critical patent/WO2007026257A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • 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
    • B29C44/421—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 plastizising the material into a shot cavity and injecting using a plunger
    • 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
    • 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
    • B29C44/3442—Mixing, kneading or conveying the foamable material
    • 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
    • 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
    • B29C44/3469—Cell or pore nucleation

Definitions

  • Patent 4,548,776 issued in 1985 to J. Holdredge.
  • a valve-like mixing nozzle assembly including a rotating mixing turbine, mounted in the flow path of the plastic material can be selectively operated to control the flow of plastic material into an injection mold and thereby to improve the cellular structure of molded foams.
  • thermoplastic melt containing a blowing agent is first injected into a gas-pressurized mold cavity in a full shot, then releasing the gas pressure, and thereafter enlarging the volume in the molded cavity by movement of a mold wall.
  • a thermoplastic melt containing a blowing agent is first injected into a gas-pressurized mold cavity in a full shot, then releasing the gas pressure, and thereafter enlarging the volume in the molded cavity by movement of a mold wall.
  • Examples include, U.S. Patent 4,096,218 issued in 1978 to A, Yasuikc et al., U.S. Patent 4,133,858 issued in 1979 to A. Hayakawa et al.. and U.S. Patent 4,783,292 issued in 1988 to R. K. Rogers.
  • microcellular foams can be produced by inducing a thermodynamic instability through a rapid pressure drop, e.g., higher than 0.9 GPa/s in the nucleation device of an extrusion system.
  • Figure 1 shows a schematic illustration of system configuration Option 1.
  • Figure 2 shows a schematic illustration of system configuration Option 2.
  • Figure 3 shows a schematic illustration of system configuration Option 3.
  • Figure 4 shows a schematic illustration of system configuration Option 4.
  • Figure 5 shows a schematic illustration of system configuration Option 5.
  • Figure 6 shows a schematic illustration of system configuration Option 6.
  • Figure 7 shows a schematic illustration of system configuration Option 1
  • Figure 8 shows a schematic illustration of system configuration Option 8.
  • Figure 9 shows a schematic illustration of system configuration Option 9
  • Figure 10 shows a schematic illustration of system configuration Option 10.
  • Figure 11 shows a schematic illustration of system configuration Option 11.
  • Figure 12 shows a schematic illustration of system configuration Option 12.
  • Figure 13 shows the cell density of HDPE structural foams produced from this invention at various talc sizes, talc contents, and N 2 contents
  • shut- off valve or a non-returnable check valve
  • an additional accumulator needs to be installed before the shut-off valve (or non- returnable check valve).
  • the filial product may have non-uniform cell structures. But because of the additionally attached accumulator and the continuous rotation of the screw, the dispersion, of gas in the polymer melt is still better than that in the currently practiced structural foam molding technology, and consequently, lhe eel] structure is better than that of the current structural foams.
  • the injected gas (especially Nj with a low solubility) may not be dissolved completely in the polymer melt because of the low solubility of ga$ and/or the short residence time. Then the dispersed second-phased gas pockets will be most likely the nuclei of the cellular structure in the molded foams regardless of the added nucleating agent. Because of the consistency in the gas content in the polymer using the additional accumulator and the gear pump, the cellular structure will be uniform.
  • the cell-nuclei density will be governed by the distributed nucleating agent.
  • any commonly used nucleating agents such as talc, CaCO 3 , or a small amount of second phase polymer in blend
  • these nucleating agents can he added and distributed in the polymer matrix to produce a fine-cell structure.
  • a reasonably high cell density of 10 ⁇ 10 cells/cm 3 can be easily achieved from any conventionaj extrusion foam processing (CP. Park, Chap 8, Polyojef ⁇ n Foam, in: Polymeric Foams and Foam Technology, 2nd Ed , D.
  • the present invention is better than the currently practiced CBA based foam injection molding of wood fiber composites (A.IC. Blcdzki and O. Faruk, Blowing Agents and Foam Processing, Stuttgart, Germany, May 10-1 1 , 2005).
  • the polymer/WF composite should be heated to a high temperature and a significant amount of volatilcs will be generated as described in US Patent 6,936,200.
  • the present invention of making the injected N 2 be better dispersed atid play a proper role as the blowing agent can avoid the need to overheat the materials and therefore the generated volatilcs will be much less, indicating better wood fiber composite foams.
  • the main shut-off valve (9) is closed. But the plasticatmg screw (2) in the extrusion barrel (1) is continuously rotating at the same speed and the gas is also continuously injected into the melt.
  • the gear pump (7) is running at the same speed.
  • This continuously formed polymer/gas mixture is now accumulated in the secondary accumulator (15) driven by hydraulic system (16) during injection (or moid filling).
  • the nozzle shut-off valve (13) is closed and the main shut-off valve (9) is opened.
  • the main accumulator (10) start to receive the polymer/gas mixture from the gear pump (7).
  • the secondary accumulator (15) starts to discharge the stored polymer/gas mixture to the main accumulator (10) as well. This can be done by setting up a slightly higher pressure in the secondary accumulator (15). The higher pressure in the secondary accumulator (15) will not affect the barrel pressure much because of the gear pump (7).
  • the molded part (14) is cooled, it is ejected out to empty the mold and to be ready for the next cycle.
  • Figure 5 shows another variation of Option 1.
  • the differences arc tbatno secondary accumulator is added and a non-returnable check valve (S) is used between the main accumulator (10) and the gear pump (7) instead of a shut-off valve.
  • S non-returnable check valve
  • the non- returnable check valve (8) allows the melt flow only in one direction, i.e., from the gear pump (7)to the main accumulator (10), but not in the opposite direction, a continuous screw rotation with a constant barrel pressure can be realized. This will simplify the modification to the existing system.
  • the gear pump (7) may be broken down easily.
  • a lower injection pressure in the accumulator (10) may have to be used.
  • the shot-size control will be more difficult.
  • Figure 6 shows a variation pf Option 3. The difference is that a non-returnable check valve (8) is used between the secondary accumulator (15) and the main accumulator (10) instead of a shut-off valve. Due to the one-way flow feature of the non-returnable check valve (8), i t will be relatively easier to realize a continuous screw rotation without strict timing control of valve operations during injection and molding operations.
  • Figuie 7 shows another system configuration. Instead of utilizing two different accumulators after the gear pump, as shown in the other options, two compatible accumulators (10 and 18) and molding units (12 and 20) are attached after the gear pump (7) so that each accumulator-molding unit can be alternating.
  • the other lozzlc shut-off vcilve (21) is opened and the injection and molding operations aie onducted in the other molding system.
  • This alternating accumulation, and injection, will c continued.
  • the amount of polymer/gas mixture can be controlled by the rotational ..pee ⁇ oase ⁇ on rne snot sizes ot these two molding systems and the required cooling times.
  • more than two accumulators and molding units can be used.
  • Figure 12 shows a variation of Option 10. The difference is that no gear pump is added between tbe extrusion barrel (1) and line accumulators (10 and 18). Instead, an accumulator is attached. In this case, a continuous rotation of plasti eating sci evv and a consistent gas dosing can be still realized through close control of the shut-off valves (9 and 17). The modification for retrofitting to the existing system is simplified using this option.
  • the void fraction was varied by controlling the shot size of the polymer/gas mixture in the main accumulator for the fixed volume of mold cavity.
  • various void fractions in the range of 10% ⁇ 60% were successfully achieved without Formation of any large gas pockets or a non-uniform cell structure unlike the existing structural foams.
  • the cell size was greater with afi increase in the void fraction by using a reduced shot size, a very uniform cellular structure was achieved. This indicates that a very high void fraction up to 60% can be obtained from this tec nhology without forming any large gas pockets or a non-uniform cell structure. Therefore, even for a high void fraction, the rate of scrapping/recycling the defective structural-foam products due to the formation of large gas pockets will be completely removed using the present technology.

Landscapes

  • Injection Moulding Of Plastics Or The Like (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

Technologie évoluée de moulage de mousse structurée permettant d'améliorer la dispersion de l'agent gonflant dans la matrice polymère, ce qui permet d'améliorer l'état existant de la technique bien connue reposant sur une technologie de moulage de mousse structurée dont le fondement est la machine de moulage par injection du type à préplastification (en arrangement appelé « piggy-bag »). La mise en place d'un système de maintien du flux en fusion de matrice polymère, de préférence par le biais d'un accumulateur additionnel et d'une pompe à engrenages, permet de stabiliser les conditions de traitement pour disperser le gaz le gaz injecté de façon plus uniforme dans la matrice polymère. Une telle technologie permet de réduire la taille de cellule des mousses structurées, d'uniformiser la structure de cellule, d'augmenter la partie de vide (c'est-à-dire d'accentuer les économies de matériau), de réduire le tourbillon de surface et de réduire aussi le contraste de ligne de soudure.
PCT/IB2006/003364 2005-09-02 2006-08-30 Dispositif et procede pour le moulage evolue de mousse structuree Ceased WO2007026257A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP06820982A EP1937455A2 (fr) 2005-09-02 2006-08-30 Dispositif et procede pour le moulage evolue de mousse structuree
JP2008528600A JP2009506909A (ja) 2005-09-02 2006-08-30 最新構造物発泡成形装置および方法

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11/219,309 US20070052124A1 (en) 2005-09-02 2005-09-02 Apparatus and method for advanced structural foam molding
CA 2517995 CA2517995A1 (fr) 2005-09-02 2005-09-02 Dispositif et methode de moulage perfectionne de mousse structuree
CA2,517,995 2005-09-02
US11/219,309 2005-09-02

Publications (2)

Publication Number Publication Date
WO2007026257A2 true WO2007026257A2 (fr) 2007-03-08
WO2007026257A3 WO2007026257A3 (fr) 2007-08-02

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2006/003364 Ceased WO2007026257A2 (fr) 2005-09-02 2006-08-30 Dispositif et procede pour le moulage evolue de mousse structuree

Country Status (2)

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EP (1) EP1937455A2 (fr)
WO (1) WO2007026257A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020061535A1 (fr) * 2018-09-21 2020-03-26 Nike, Inc. Système et procédé de moulage

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110253824B (zh) * 2019-05-31 2021-01-08 界首市旭升塑胶制品有限公司 一种塑胶鞋吹气发泡注射机

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4124308A (en) * 1977-06-21 1978-11-07 Beloit Corporation Sequential co-injection unit adapted for structural foam molding
US5968429A (en) * 1997-03-20 1999-10-19 Eastman Chemical Company Apparatus and method for molding of polyester articles directly from a melt
US6322347B1 (en) * 1999-04-02 2001-11-27 Trexel, Inc. Methods for manufacturing foam material including systems with pressure restriction element

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020061535A1 (fr) * 2018-09-21 2020-03-26 Nike, Inc. Système et procédé de moulage
CN112805132A (zh) * 2018-09-21 2021-05-14 耐克创新有限合伙公司 模制系统和方法
US11370155B2 (en) 2018-09-21 2022-06-28 Nike, Inc Molding system and method
US20220258393A1 (en) * 2018-09-21 2022-08-18 Nike, Inc. Molding system and method
US11780134B2 (en) 2018-09-21 2023-10-10 Nike, Inc. Molding system and method

Also Published As

Publication number Publication date
EP1937455A2 (fr) 2008-07-02
WO2007026257A3 (fr) 2007-08-02

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