WO2009051027A1 - Appareil de moulage de résine - Google Patents

Appareil de moulage de résine Download PDF

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Publication number
WO2009051027A1
WO2009051027A1 PCT/JP2008/068133 JP2008068133W WO2009051027A1 WO 2009051027 A1 WO2009051027 A1 WO 2009051027A1 JP 2008068133 W JP2008068133 W JP 2008068133W WO 2009051027 A1 WO2009051027 A1 WO 2009051027A1
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WO
WIPO (PCT)
Prior art keywords
fiber
resin composition
resin
length
reinforced resin
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/JP2008/068133
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English (en)
Inventor
Kazunari Hatta
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.)
Yazaki Corp
Original Assignee
Yazaki Corp
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
Application filed by Yazaki Corp filed Critical Yazaki Corp
Priority to MX2010004266A priority Critical patent/MX2010004266A/es
Priority to CN200880118828.XA priority patent/CN101918185B/zh
Publication of WO2009051027A1 publication Critical patent/WO2009051027A1/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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
    • B29C48/83—Heating or cooling the cylinders
    • B29C48/832—Heating
    • 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
    • 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
    • B29C48/04—Particle-shaped
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/362—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using static mixing devices
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/793—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling upstream of the plasticising zone, e.g. heating in the hopper
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • B29C48/865—Heating
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/69—Filters or screens for the moulding material
    • B29C48/693—Substantially flat filters mounted at the end of an extruder screw perpendicular to the feed axis
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
    • B29C48/83—Heating or cooling the cylinders
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • 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
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • 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
    • B29K2105/25—Solid
    • B29K2105/251—Particles, powder or granules

Definitions

  • the present invention relates to a resin molding apparatus comprising a screw, a cylinder receiving the screw therein, an inlet disposed in a posterior portion of the cylinder, and an outlet disposed in a tip portion of the cylinder.
  • Thermoplastic resin-based composition is generally, for example, molded from molding material pellet into a molded article having a desired shape, by means of injection molding. At this point, a residual material such as a spool, runner, and so on are produced together with the molded article. Such residual material is separated from the final molded article, and is further subjected to grinding and extrusion molding so as to produce a recycled resin pellet. Thus obtained recycled resin pellet is combined with other virgin resin pellet in a predetermined amount, and are further subjected to injection molding.
  • the terms "thermoplastic resin-based composition” and "resin composition” are interchangeably used herein.
  • An exemplary resin molding apparatus generally used in such a extrusion molding process conventionally comprises a screw comprising a screw shaft and a plurality of flights extending from an outer circumferential face of the shaft, a cylinder receiving the screw therein, an inlet being configured to supply resin composition to inside the cylinder and being disposed in a posterior portion of the cylinder, an outlet being configured to discharge the resin composition that is melted and kneaded inside the cylinder and being disposed a tip portion of the cylinder, and a heater being configured to supply heat energy to the inside the cylinder.
  • Japanese Publication of Patent Application No. 2002-234063 discloses a conventional resin molding apparatus.
  • a screw is comprised of a resin feeding portion being disposed adjacent to the inlet in the cylinder and having a shaft with a substantially constant outer diameter, an extrusion portion communicating with the resin feeding portion and having a tapered shaft whose outer diameter is gradually reduced from one end thereof to the other end adjacent to the resin feeding portion, and a metering portion being disposed adjacent to the outlet in the cylinder, communicating with the extrusion portion, and having a shaft with a substantially constant outer diameter.
  • the distance (Dl) between the outer circumferential face of the shaft and the tip portion of the flight at the area of the resin feeding portion is made greater than the distance (D3) between the outer circumferential face of the shaft and the tip portion of the flight in the area of the metering portion.
  • the ratio of Dl to D3 is, for example, between 2.4 and 3.2.
  • the residual material is generally supplied via the inlet into the cylinder. Thereafter, the residual material is subjected to shear force exerted by the screw and is heated by means of the heater during the movement thereof from the inlet to the outlet within the cylinder. As a result, the residual material is fully melted and kneaded inside the cylinder. This melted resin is discharged via the outlet and is molded in a linear shape, and then is cut so as to result in a resin pellet. Thus obtained recycled resin pellet can be generally used in a next or further molding process.
  • the afore-mentioned resin composition is generally comprised of a base resin component mainly consisting of thermoplastic resin, and a fibrous filler component such as a glass fiber and a carbon filament.
  • a base resin component mainly consisting of thermoplastic resin
  • a fibrous filler component such as a glass fiber and a carbon filament.
  • above resin composition comprising such a fibrous filler component is referred to as a fiber-reinforced resin composition herein.
  • the fiber filler component generally is used for imparting enhanced mechanical properties to the base resin.
  • a resin molding apparatus capable of preventing the fibrous filler-containing residual material from being damaged and thus maintaining the high level of mechanical strength property of the fiber-reinforced resin composition.
  • a resin molding apparatus comprising: a screw having a screw shaft and a plurality of flights extending from an outer circumferential face of the screw shaft, a cylinder receiving the screw therein, an inlet being disposed in a posterior end portion of the cylinder and being configured to supply a fiber-reinforced resin composition into the cylinder, the fiber-reinforced resin composition comprising a base resin and a fibrous filler, and an outlet being disposed in a tip portion of the cylinder and being configured to discharge the fiber-reinforced resin composition therethrough, the fiber-reinforced resin composition being melted and kneaded inside the cylinder, wherein, (a) the screw comprises a resin feeding portion being disposed adjacent to the inlet, an extrusion portion communicating with the resin feeding portion, and a metering portion communicating with the extrusion portion; (b) an outer diameter of the screw shaft is kept constant throughout a length of the resin feeding portion, increases gradually toward the
  • both the resin feeding portion and the extrusion portion may be made longer than the metering portion.
  • a ratio of length of the extrusion portion to length of the metering portion may be between 2 and 4.
  • a ratio of length of the resin feeding portion to length of the metering portion may be between 1.33 and 5.
  • the afore-mentioned resin molding apparatus may further include a heater for supplying heat energy to the area of the resin feeding portion inside the cylinder, wherein the heater is maintained at a temperature of from 25°C below melting point of the base resin to the melting point.
  • FIG. 1 is a schematic view of one preferred embodiment of a resin molding apparatus in accordance with the present invention.
  • FIG. 2 is an enlarged side view of a screw as shown in FIG. 1.
  • FIG. 3 is a graph showing the relationship between the ratio of Dl to D3 and the length of the glass fiber included in the recycled pellet.
  • Dl is defined as a distance between the outer circumferential face of the screw shaft and the tip portion of the flight in the area of the resin feeding portion
  • D3 is defined as a distance between the outer circumferential face of the screw shaft and the tip portion of the flight in the area of the metering portion.
  • FIG. 4 is a graph showing the relationship between the ratio of L2 to L3 and the proportion (%) of the molten fiber-reinforced resin composition based on the total of the fiber-reinforced resin composition used (100%).
  • L2 is defined as the length of the extrusion portion
  • L3 is defined as the length of the metering portion.
  • FIG. 5 is a graph showing the relationship between the ratio of Ll to L3 and the temperature of the preheated fiber-reinforced resin composition.
  • the Ll is defined as the length of the resin feeding portion
  • the L3 is defined as the length of the metering portion.
  • FIG. 6 is a graph showing the relationship between the temperature of the heater for supplying heat energy to the resin feeding portion and the temperature of the preheated fiber-reinforced resin composition.
  • a resin molding apparatus 1 in accordance with a preferred embodiment of the present invention is provided for recycling a residual material such as a spool and a runner that is generally produced as a by-product during the injection molding process of fiber-reinforced resin composition.
  • the resin molding apparatus 1 is used for preparing a recycled pellet of fiber-reinforced resin composition.
  • the resin molding apparatus 1 comprises a screw 2, a cylinder 3, an inlet 4, an outlet 5, a screw-actuating member (now shown), and a heater 7.
  • a fiber-reinforced resin composition is generally comprised of a base resin and a fibrous filler.
  • the screw 2 is overall cylindrically formed.
  • the screw 2 is generally formed of metal material of high abrasive resistance for the purpose of decreasing the wear caused by use of the fibrous filler. As shown in FIG. 2, the outer diameter of the screw 2 is kept substantially constant throughout its overall length, hi this case, the outer diameter of the screw 2 is made twice as long as the distance between the shaft center and the tip portion 22a of the flight 22. In. a. preferred embodiment, the ratio of the length of the screw 2 to the outer diameter of the screw 2 is from 25 to 30. This is because the fiber-reinforced resin composition is preferably subjected to relatively less level of shear force.
  • the screw 2 is comprised of a screw shaft 21, a flight 22, and a groove 23.
  • the screw shaft 21 is generally cylindrically shaped.
  • the flight 22 extends from the outer circumferential face 21a of the screw shaft 21.
  • the flight 22 is spirally formed throughout the overall length of the screw shaft 21.
  • the groove 23 is defined by the outer circumferential face 21a of the screw shaft 21, and the outer faces of the flights 22. These flights are disposed apart from each other and extend approximately perpendicular to the outer circumferential face 21a of the screw shaft 21.
  • the groove 23 has an approximately U-shaped cross section.
  • the groove 23 is formed between spirally-formed flights 22, and is also spirally formed on the outer circumferential face of the screw 2 likewise the flight 22.
  • the fiber-reinforced resin composition moves along the groove 23 from the inlet 4 toward the outlet 5.
  • the screw 2 is shown to include a resin feeding portion 24 being disposed adjacent to the inlet 4, an extrusion portion 25 communicating with the resin feeding portion 24, and a metering portion 26 being disposed adjacent to the outlet 5 and communicating with the extrusion portion 25.
  • these three portions are basically designated for convenience of illustration of the screw 2.
  • the resin feeding portion 24, the extrusion portion 25, and the metering portion 26 are serially arranged along the longitudinal direction of the screw 2.
  • the resin feeding portion 24 moves the fiber-reinforced resin composition, which is supplied from the inlet 4 into the cylinder 4, toward the extrusion portion 25. During such a movement of the fiber-reinforced resin composition, the fiber-reinforced resin composition is preheated by means of a heater 7. The outer diameter of the screw shaft 21 of the resin feeding portion 24 is uniformly formed throughout its full length.
  • the ratio of Ll to L3 is generally from 1.33 to 5. If the ratio is less than the lower limit 1.33, the fiber-reinforced resin composition cannot be preheated sufficiently. To the contrary, if the ratio is greater than the upper limit 5, the metering portion 25 having a sufficient length cannot be ensured.
  • the extrusion portion 25 is configured to melt the fiber-reinforced resin composition delivered from the resin feeding portion 24 and to pass therethough by means of shear force generated between the extrusion portion 25 and the inner face of the cylinder 3, and heat energy supplied by the heater 7 during the movement of the fiber-reinforced resin composition 24 toward the metering portion 26.
  • the extrusion portion 25 has a gradually increasing outer diameter, as it approximates to the metering portion 26.
  • the outer diameter of the screw shaft has a value of minimum at a boundary with the resin feeding portion 24 and a value of maximum at a boundary with the metering portion 26.
  • the extrusion portion 25 has a length L2 longer than the length L3 of the metering portion 26.
  • the ratio of L2 to L3 is generally from 2 to 4. If the ratio is less than the lower limit value 2, the fiber-reinforced resin composition cannot be fully melted. To the contrary, if the ratio is greater than the upper limit value 4, the metering portion 26 having a sufficient length cannot be ensured.
  • the metering portion 26 is configured to move the molten the fiber-reinforced resin composition in a predetermined amount toward the outlet 5 for a predetermined period of time.
  • the outer diameter of the screw shaft 21 is designed to be substantially constant in its longitudinal direction and simultaneously greater than the outer diameter of the screw shaft 21 of in the area of the resin feeding portion 24.
  • Dl is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 in the area of the resin feeding portion 24, and D3 is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 in the area of the metering portion 26.
  • the ratio of Dl to D3 is generally from 1.2 to 1.95.
  • compression ratio of the screw 2 can be set at lower value in comparison with the conventional resin molding apparatus, m this case, the term compression ratio as used herein is defined as a ratio of the spatial volume of the groove 23 within the area of the resin feeding portion 24 to the spatial volume of the groove 23 within the area of the metering portion 26 in accordance with JIS B8650. If the ratio is less than the lower limit value 1.2, the fiber-reinforced resin composition cannot be melted sufficiently due to corresponding small amount of shear force. To the contrary, the ratio is greater than the upper limit value 1.95, the fibrous filler is easily damaged due to the corresponding large amount of shear force.
  • the metering portion 26 is made shorter in comparison with the metering portion of the conventional resin molding apparatus, there is a possibility that the molten fiber-reinforced resin composition in a desired amount cannot be moved toward the outlet 5 within a desired period of time, resulting in incompletely shaped final article.
  • the compression ratio is made lower in comparison with the conventional apparatus, the fiber-reinforced resin composition cannot be sufficiently melted and kneaded.
  • precise or rigid standard regarding the shape of the molded article is not required.
  • the cylinder 3 is cylindrically formed and is configured to receive the screw 2 therein.
  • the cylinder 3 is formed of metal material having a high level of abrasive resistance. This is because any friction caused by the use of the fibrous filler can be avoided or decreased.
  • the inner diameter of the cylinder 3 is generally formed constant and is slightly larger than the outer diameter of the screw 2.
  • the inlet 4 is formed in communication with the inside the cylinder 3.
  • the inlet 4 is formed in the posterior portion 3a of the cylinder 3.
  • the fiber-reinforced resin composition is supplied to the cylinder via the inlet 4.
  • the inlet 4 is provided with a hopper 41 disposed perpendicularly thereto or extending perpendicularly therefrom.
  • the hopper 41 is generally formed in a funnel shape.
  • the fiber-reinforced resin composition which is achieved by grinding the afore-mentioned residual material, is stored inside the hopper 41, and is in turn supplied to the inlet 4.
  • the outlet 5 is an opening in communication with the inside of the cylinder 3.
  • the outlet 5 is formed in the tip portion 3b of the cylinder 3.
  • the fiber-reinforced resin composition is sufficiently molted and kneaded in the cylinder 3, and then is discharged via the outlet 5 from the cylinder 3.
  • the outlet 5 is also provided with a breaker plate 51 and a die 54.
  • the breaker plate 51 is generally made of metal material, and is formed in a plane.
  • the breaker plate 51 is provided with a plurality of through-holes along the thickness of the breaker plate 51.
  • a wire-woven screen pack 53 is engaged to the breaker plate 51.
  • the fiber-reinforced resin composition which is melted in the metering portion 26 of the screw 2 is filtrated via the through holes disposed in the breaker plate 51 and via the screen pack 53, and is then extruded toward the die 54.
  • the afore-mentioned breaker plate 51 and the screen pack 53 are configured to remove foreign substance from the molten fiber-reinforced resin composition and are also configured to control the flow of the fiber-reinforced resin composition by elevating the back pressure inside the cylinder 3, resulting in fully melted fiber-reinforced resin composition.
  • the die 54 is made of metal material and is, for example, cylindrically formed.
  • the molten fiber-reinforced resin composition which has passed both the breaker plate 51 and the screen pack 53 is molded into a predetermined shape by means of the die 54.
  • the screw-actuating member includes, for example, a motor.
  • the screw-actuating member is configured to rotatably journal the screw 2 received within the cylinder 3 about the shaft center thereof, and is also configured to rotatably actuate or drive the screw 2 about the shaft center thereof.
  • the heater 7 is generally embedded in the outer wall of the cylinder 3, as shown in
  • the heater 7 may be made in a shape of band plates.
  • the heater 7 may be a plurality of heaters arranged in a shape of band.
  • the heater 7 is configured to provide the cylinder 3 with heat energy so as to melt the fiber-reinforced resin composition received in the cylinder 3.
  • a plurality of the heaters 7 may be serially arranged along the longitudinal direction of the cylinder 3.
  • the heater 7 is provided with a heater 71 for supplying heat energy to the area of the resin feeding portion 24 of the screw 2 inside the cylinder 3, a heater 72 for supplying heat energy to the area of the extrusion portion 25, and a heater 73 for supplying heat energy to the area of the metering portion 26, and a heater 74 for supplying heat energy to the area of the breaker-plate 51 and the die 54, which means
  • the heater 7 can supply different levels of heat energy to different areas of the resin molding apparatus 1, respectively.
  • the heater 71 for supplying heat energy to the area of the resin feeding portion 24 is maintained at a temperature lower than or equivalent to a melting point of the base resin used in the present invention, and is also maintained at a temperature higher than or equivalent to the temperature of 25°C below the melting point (Le., the melting point - 25°C) of the base resin so as to only preheat the fiber-reinforced resin composition without substantially melting the same resin composition. Furthermore, the heaters 72, 73, and 74 are respectively set at a temperature greater than the melting point of the base resin.
  • the heater 71 may be set at a temperature from about 200°C to about 225°C, and the heaters 72, 73 and 74 are respectively set at a temperature higher than about 225 °C.
  • the fiber-reinforced resin composition is generally comprised of the base resin and the fibrous filler, ha a preferred embodiment, unsaturated polyester resins may be used as the base resin.
  • unsaturated polyester resins polyethylene terephthalate, polybutylene terephthalate, polycyclohexane terephthalate, and so on can be utilized, hi addition to the afore-mentioned unsaturated polyester resins, the base resin includes epoxy resins, polyamide resins, phenol resins, and so on.
  • the base resin is not limited to the resin as mentioned previously, the resin other than the resin as mentioned above that is not against the objective of the present invention can apparently be used as the base resin in the implementation of the present invention.
  • the fibrous filler includes, for example, a glass fiber, a carbon filament, an aramid fiber, and so on.
  • the fibrous filler is generally added to the base resin so as to reinforce or enhance the mechanical strength properties of the base resin. If the fibrous filler having a relatively high level of hardness is used, the fibrous filler is easily damaged during a period of time when the fiber-reinforced resin composition is subjected to a relatively high level of shear force to produce the completely melted fiber-reinforced resin composition within the cylinder 3. In this case, enhanced mechanical strength properties of the fiber-reinforced resin composition cannot be maintained.
  • the fibrous filler is never limited to the material mentioned previously as a preferred embodiment, the fibrous filler other than the material as mentioned above that is not against the objective of the present invention can apparently be used as the fibrous filler in the implementation of the present invention.
  • the fiber-reinforced resin composition in accordance with the present invention for example, Toraycon 1010-G30 (trademark) available from Toray Industries, Inc. including a galss fiber as the fibrous filler in an amount of 30% in polybutylene terephthalate employed as the base resin may be employed.
  • Afore-mentioned fiber-reinforced resin composition is initially produced in the shape of a pellet.
  • the fiber-reinforced resin composition is not limited to such a resin composition as previously mentioned, the fiber-reinforced resin composition other than such a resin composition can be apparently used as the fiber-reinforced resin composition in accordance with the present invention, in somuch as it is not against the objective of the subject application.
  • the residual material as mentioned previously is fed into the hopper 41, and then is carried to the inside the cylinder 3 via the inlet 4.
  • the fiber-reinforced resin composition is fed into the groove 23 disposed in the area of the resin feeding portion 24 of the screw 2. Thereafter, as the screw rotates, the fiber-reinforced resin composition is carried to the groove 23 disposed in the area of the extrusion portion 25 of the screw 2, and then carried to the groove 23 disposed in the area of the metering portion 26 of the screw 2.
  • the fiber-reinforced resin composition is preheated sufficiently by the heater 71 which is set at a temperature equivalent or below the melting point of the base resin used. This predetermined range of temperature of the heater 71 ensures that the fiber-reinforced resin composition cannot be molted in this step.
  • the fiber-reinforced resin composition is melted by means of heat energy supplied from the heater 72 which is set at a temperature higher than the melting point of the base resin used, and also by means of the reduced level of shear force in comparison with the conventional apparatus.
  • the molten fiber-reinforced resin composition passes the area of the metering portion 26, which is made shorter in comparison with the resin feeding portion 24 and the extrusion portion 25, and is in turn carried to the breaker plate 51 , and then the screen pack 53 and the die 54.
  • the fiber-reinforced resin composition cools and hardens after passing through the die 54. After cooling, the fiber-reinforced resin composition is molded into a linear shape, is cut, and then is subjected to pelletization once more. In other words, the fiber-reinforced resin composition is finally produced into a recycled pellet.
  • the screw 2 is shown to include the resin feeding portion 24 disposed adjacent to the inlet 4, the extrusion portion 25 communicating with the resin feeding portion 24, and the metering portion 26 disposed adjacent to the outlet 5 and communicating with the extrusion portion 25.
  • the resin feeding portion 24 and the metering portion 26 are designed to be constant in their respective longitudinal direction, and the extrusion portion 25 is designed to increase gradually toward the metering portion 26.
  • the extrusion portion 25 of the screw 2 has a tapered shape whose outer diameter is gradually reduced from its one end adjacent to the metering portion 26 to the other end adjacent to the resin feeding portion 24.
  • Dl is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the resin feeding portion 24
  • D3 is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the metering portion 26.
  • the ratio of Dl to D3 is generally from 1.2 to 1.95.
  • both the resin feeding portion 24 and the extrusion portion 25 are respectively designed to have their length longer than the overall length of the metering portion 26, the fiber-reinforced resin composition is allowed to be preheated sufficiently at the area of the resin feeding portion 24 and then to be fully molted at the area of the extrusion portion 25 by means of heat energy supplied from the heater. Moreover, since the metering portion 26 is designed to be shorter, the molten fiber-reinforced resin composition is subjected to less shear force in the area of the metering portion 26.
  • the extrusion portion 25 generally has a length L2 longer than the length L3 of the metering portion 26.
  • the ratio of L2 to L3 is generally from 2 to 4.
  • the fiber-reinforced resin composition can be sufficiently melted in the area of the extrusion portion 25 by means of heat energy supplied from the heater.
  • the metering portion 26 is formed shorter, the molten fiber-reinforced resin composition is subjected to less shear force in the area of the metering portion 26.
  • the resin feeding portion 24 generally has the length Ll longer than the length L3 of the metering portion 26.
  • the ratio of Ll to L3 is generally from 1.33 to 5.
  • the fiber-reinforced resin composition can be sufficiently preheated in the area of the resin feeding portion 24.
  • the metering portion 26 is made shorter, the molten fiber-reinforced resin composition is thus subjected to less shear force in the area of the metering portion 26.
  • the heater 7 for supplying heat energy is disposed inside the cylinder 3.
  • the heater 7 for supplying heat energy is disposed inside the cylinder 3.
  • the fiber-reinforced resin composition is allowed to be sufficiently preheated at the area of the resin feeding portion 24, without being substantially melted. Accordingly, the fiber-reinforced resin composition will be subjected to less shear force at the area of the metering portion 26.
  • the inventor of the present invention prepared the afore-mentioned resin molding apparatus 1, and also carried out the following several experiments so as to test and evaluate the same.
  • Dl is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the resin feeding portion 24
  • D3 is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the metering portion 26.
  • the recycled pellet was prepared from the residual material of the fiber-reinforced resin composition, by means of the resin molding apparatus 1 in accordance with the present invention. Only base resin component of thus-obtained recycled pellet was solved in the specified solvent in order to collect only the glass fiber included in the recycled pellet. Microscopic analysis was carried out on the collected glass fiber, hi this microscopic analysis, the full length of the glass fiber was measured.
  • the screws 2 were prepared such that their ratios of Dl to D3 were set to different four values 1.5, 1.8, 3.0 and 3.8 respectively. All of the screws 2 were designed to have an outer diameter of 20 mm, IVD value of 25, Ll value (i.e., the length of the resin feeding portion 24) of 200 mm, L2 value (i.e., the length of the extrusion portion 25) of 240 mm, and L3 value (i.e., the length of the metering portion 26) of 80 mm, and a rotating speed at 150 rpm.
  • Ll value i.e., the length of the resin feeding portion 24
  • L2 value i.e., the length of the extrusion portion 25
  • L3 value i.e., the length of the metering portion 26
  • the resin molding apparatus 1 used in this example was D2025-type available from Toyo Seiki Seisaku-sho, Ltd.
  • the heater 71, 72 73, and 74 were respectively set at temperature of 200, 250, 260, and 270°C.
  • Toraycon 1010-G30 (trademark) available from Toray Industries, Inc. was employed as the fiber-reinforced resin composition in accordance with the present invention.
  • Example 1 The results of Example 1 were shown in FIG. 3.
  • the numerical values in FIG. 3 were the average of five specimens, respectively. More specifically, in FIG. 3, a lateral axis represents the ratio of Dl to D3, and a vertical axis represents the length ( ⁇ m) of the glass fiber included in the recycled pellet. With reference to FIG. 3, when the ratio of Dl to D3 is 1.5, the length of the glass fiber is 399 ⁇ m, which means that the length of the glass fiber included in the recycled pellet is substantially identical to the length (about 413 ⁇ m) of the glass fiber included in the virgin resin pellet.
  • the length of the glass fiber is 330 ⁇ m included in the recycled pellet, which means that the length of the glass fiber included in the recycled pellet corresponded to about 80% of the length of the virgin resin pellet.
  • the ratio of Dl to D3 is less than 1.2, the fiber-reinforced resin composition cannot be sufficiently melted, and therefore is not considered to be suited for further extrusion molding.
  • the ratio of Dl to D3 is greater than 1.95, the glass fiber in an amount of more than 25% is damaged. Conclusively, if the ratio of Dl to D3 is from 1.2 to 1.95, the glass fiber can be protected from such damage or breakage.
  • Each of screws 2 was prepared such that the ratio of Dl to D3 was 1.8.
  • Dl is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the resin feeding portion 24
  • D3 is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the metering portion 26.
  • Example 2 was carried out in the similar manner to Example 1, except for the length Ll of the resin feeding portion 24, the length L2 of the extrusion portion 25, the length L3 of the metering portion 26, and the ratio of L2 to L3.
  • the values Ll, L2, L3, and L2/L3 were set to 200 mm, 200 mm, 120 mm, and 1.7
  • the values Ll, L2, L3, and L2/L3 were set to 200 mm, 240 mm, 80 mm, and 3
  • the values Ll, L2, L3, and L2/L3 were set to 200 mm, 260 mm, 60 mm, and 4.3, respectively.
  • three different screws 2 were prepared as such.
  • Example 2 The results of Example 2 were shown in FIG. 4.
  • the numerical values in FIG. 4 were the average of five specimens, respectively.
  • a lateral axis represents the ratio of L2 to L3
  • a vertical axis represents the proportion (%) of the molten fiber-reinforced resin composition based on the total of the fiber-reinforced resin composition used (100%).
  • the ratio is from 2 to 4
  • the fiber-reinforced resin composition was melted in an amount of more than or equivalent to about 98%, which means that the fiber-reinforced resin composition is sufficiently melted.
  • Screws 2 were prepared such that their ratios of the length Ll of the resin feeding portion 24 to the length L3 of the metering portion 26 were different to each other.
  • the resin molding apparatus 1 each equipped with these different screws 2
  • the residual material of fiber-reinforced resin composition was subjected to pelletization.
  • a recycled pellet was prepared from the residual material of the fiber-reinforced resin composition.
  • the temperature of the fiber-reinforced resin composition preheated at the area of the resin feeding portion 24 was measured.
  • the screw 2 was prepared such that the ratio of Dl to D3 was 1.8.
  • Dl is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the resin feeding portion 24
  • D3 is defined as a distance between the outer circumferential face 21a of the screw shaft 21 and the tip portion 22a of the flight 22 at the area of the metering portion 26.
  • Example 3 was carried out in the similar manner to Example 1, except for the length Ll of the resin feeding portion 24, the length L2 of the extrusion portion 25, the length L3 of the metering portion 26, and the ratio of Ll to L3.
  • the values Ll, L2, L3, and L1/L3 were set to 240 mm, 200 mm, 80 mm, and 3, for another, the values Ll, L2, L3, and L1/L3 were set to 180 mm, 200 mm, 140 mm, and 1.29, and for the other, the values Ll, L2, L3, and L1/L3 were set to 170 mm, 200 mm, 150 mm, and 1.13, respectively. In other words, three different screws 2 were prepared as such.
  • Example 3 The results of Example 3 were shown in FIG. 5.
  • the numerical values in FIG. 5 were the average of five specimens, respectively.
  • a lateral axis represents the ratio of Ll to L3
  • a vertical axis represents the temperature of the fiber-reinforced resin composition.
  • the ratio (L1/L3) is less than 1.33, the fiber-reinforced resin composition is not sufficiently preheated.
  • the temperature of the fiber-reinforced resin composition is from about 198 ° C to about 200 ° C, which means that the fiber-reinforced resin composition is sufficiently preheated.
  • the recycled pellet was prepared from the residual material of the fiber-reinforced resin composition by varying the temperature of the heater 71, the heater 71 being configured to supply heat energy to the area of the resin feeding portion 24 inside the cylinder 3. During the pelletization, the temperature of the fiber-reinforced resin composition preheated in the area of the resin feeding portion 24 was measured. Further, the temperature of the heater 71 was respectively set to 200°C, 230°C, and 260°C. The screw 2 was prepared such that the ratio of Dl to D3 was 1.8.
  • Example 4 was carried out in a similar manner to Example 1.
  • Example 4 The results of Example 4 were shown in FIG. 6.
  • the numerical values in FIG. 6 were the average of five specimens, respectively.
  • a lateral axis represents the temperature of the heater 71
  • a vertical axis represents the temperature of the fiber-reinforced resin composition.
  • the temperature of the heater 71 is set to 200 ° C
  • the temperature of the fiber-reinforced resin composition is at about 195 ° C.
  • the temperature of the fiber-reinforced resin composition is at about 220 ° C .
  • FIG 6 shows that the heater 71 having a temperature lower than 200 ° C cannot preheat the fiber-reinforced resin composition sufficiently, and the heater 71 having a temperature higher than 225 ° C make the fiber-reinforced resin composition molten.
  • the heater 71 having a temperature of from about 200 ° C to about 225 ° C can preheat the fiber-reinforced resin composition sufficiently, without melting the same resin composition.
  • the resin molding apparatus 1 was equipped with one screw 2.
  • a resin molding apparatus 1 equipped with a plurality of screws 2 can be also utilized.
  • a plurality of the screws 2 may have their shafts parallel to each other. Otherwise, a plurality of the screws 2 may have their shafts being inclined to each other.
  • the screw comprises a resin feeding portion being disposed adjacent to the inlet, an extrusion portion communicating with the resin feeding portion, and a metering portion communicating with the extrusion portion; (b) an outer diameter of the screw shaft disposed in the screw is kept constant in the area of the resin feeding portion, is gradually reduced toward the metering portion in the area of the extrusion portion, and is kept constant in the area of the metering portion; and (c) a ratio of a distance between the outer circumferential face of the screw shaft and a tip portion of the flight in the area of the resin feeding portion to a distance between the outer circumferential face of the screw shaft and the tip portion of the flight in the area of the metering portion is set to value of from 1.2 to 1.95.
  • the fiber-reinforced resin composition can advantagelusly maintain its remarkably enhanced mechanical strength properties before and after its peptization.
  • the fiber-reinforced resin composition can be sufficiently preheated in the area of the resin feeding portion, can also be sufficiently molted in the area of the extrusion portion, and is subjected to less level of shear force in the area of the metering portion.
  • the fiber-reinforced resin composition can be sufficiently heated and melted in the area of the extrusion portion, and the molten fiber-reinforced resin composition is subjected to less level of shear force in the area of the metering portion.
  • the fiber-reinforced resin composition can be sufficiently preheated in the area of the resin feeding portion, and the molten fiber-reinforced resin composition is subjected to less level of shear force in the area of the metering portion.
  • the afore-mentioned resin molding apparatus further includes a heater for supplying heat energy to inside the cylinder, and the heater is maintained at a temperature of from 25°C below melting point of the base resin to the melting point, the fiber-reinforced resin composition can be sufficiently preheated without substantial melting, and is subjected to less level of shear force in the area of the resin feeding portion.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention porte sur un appareil de moulage de résine qui est capable d'empêcher la charge fibreuse comprise dans une composition de résine renforcée par des fibres d'être endommagée, ainsi que de maintenir des propriétés de résistance mécanique améliorées de celle-ci après la pelletisation. L'appareil de moulage de résine est caractérisé par un rapport d'une distance entre la face circonférentielle externe de la tige de vis et une partie de la pointe de la vis sans fin associée dans une zone de la partie d'alimentation de résine à une distance entre la face circonférentielle externe de la tige de vis et une partie de pointe de la vis sans fin associée dans une zone de la partie de dosage qui varie de 1,2 à 1,95.
PCT/JP2008/068133 2007-10-19 2008-09-30 Appareil de moulage de résine Ceased WO2009051027A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
MX2010004266A MX2010004266A (es) 2007-10-19 2008-09-30 Aparato de moldeo de resina.
CN200880118828.XA CN101918185B (zh) 2007-10-19 2008-09-30 树脂模制设备

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2007-272570 2007-10-19
JP2007272570A JP2009096150A (ja) 2007-10-19 2007-10-19 樹脂成形機

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WO2009051027A1 true WO2009051027A1 (fr) 2009-04-23

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JP5432477B2 (ja) * 2008-06-09 2014-03-05 矢崎総業株式会社 樹脂成形機
CN101920551B (zh) * 2010-08-10 2012-11-21 昆山科信橡塑机械有限公司 内外屏蔽电缆料专用螺杆
JP2015208916A (ja) * 2014-04-25 2015-11-24 株式会社星プラスチツク 合成樹脂の再ペレット化装置
ES2625736T3 (es) * 2014-09-10 2017-07-20 Starlinger & Co. Gesellschaft M.B.H. Dispositivo y procedimiento para la producción de un material compuesto polimérico relleno
CN114981062A (zh) * 2020-02-04 2022-08-30 株式会社日本制钢所 射出成形方法及射出成形装置

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5041258A (en) * 1989-04-28 1991-08-20 Polyplastics Co., Ltd. Injection process for long fiber-containing resin
EP0706873A2 (fr) * 1994-10-12 1996-04-17 Sumitomo Chemical Company Limited Appareil à vis et méthode d'utilisation de cet appareil pour distribuer de la résine fondue comprenant des fibres
JPH08318561A (ja) * 1995-05-26 1996-12-03 Mitsubishi Heavy Ind Ltd 樹脂の可塑化スクリュ
EP0920971A1 (fr) * 1997-05-22 1999-06-09 Kawasaki Steel Corporation Vis et dispositif servant a plastifier des resines thermoplastiques renforcees de fibres, procede et produit de moulage de ces resines

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5041258A (en) * 1989-04-28 1991-08-20 Polyplastics Co., Ltd. Injection process for long fiber-containing resin
EP0706873A2 (fr) * 1994-10-12 1996-04-17 Sumitomo Chemical Company Limited Appareil à vis et méthode d'utilisation de cet appareil pour distribuer de la résine fondue comprenant des fibres
JPH08318561A (ja) * 1995-05-26 1996-12-03 Mitsubishi Heavy Ind Ltd 樹脂の可塑化スクリュ
EP0920971A1 (fr) * 1997-05-22 1999-06-09 Kawasaki Steel Corporation Vis et dispositif servant a plastifier des resines thermoplastiques renforcees de fibres, procede et produit de moulage de ces resines

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CN101918185A (zh) 2010-12-15
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MX2010004266A (es) 2010-06-02

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