Molding method

Abstract

Provided is a molding method with which it is possible to efficiently mold a high-quality molded article using a regenerated resin material. Provided is a molding method using a regenerated resin material, in which the type and content of foreign matter contained in the regenerated resin material are grasped, a correction coefficient is calculated on the basis of the type and content of foreign matter, and a preset molding condition is corrected using the correction coefficient.

Description

Technical Field

[0001] This invention relates to a molding method. Background Technology

[0002] like Figure 4 As shown, in injection molding, in which resin material is melted by an injection molding machine and injected into a mold to form a resin product, molding conditions C1 to C5 are set, including the temperature of the heating cylinder and mold C1, the metering of the resin material C2, the injection speed C3, the holding pressure when the mold is locked C4, and the injection time C5. Molding M is performed under these molding conditions C1 to C5.

[0003] In pursuit of a circular economy (CE) and carbon neutrality (CN), it is necessary to replace petroleum-based resins used in injection molding with recycled resins from scrap vehicles and other industries. However, when replacing resins with recycled ones, the presence of foreign matter in these recycled resins frequently leads to quality defects in injection-molded products, such as dimensional deviations and poor appearance.

[0004] Patent Document 1 describes how data accumulated based on the correlation between the material properties of the resin, injection molding conditions, and molding quality parameters is used to generate injection molding conditions according to a prescribed formula. Furthermore, examples of the generated injection molding conditions include injection speed, temperature, and holding pressure.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2022-141495 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] The aforementioned formulas are, for example, created at the delivery unit of recycled resin material supplied by the material supplier. Therefore, if various data are correlated and accumulated to create formulas to generate molding conditions for each delivery of recycled resin material, a considerable number of trials are required for each delivery, resulting in low production efficiency.

[0010] The present invention was made in view of the above-mentioned actual situation, and its purpose is to provide a molding method that can efficiently mold high-quality molded articles using recycled resin materials.

[0011] Methods for solving problems

[0012] To achieve the above objectives, the molding method of the present invention uses a molding method for recycled resin materials, which involves determining the types and contents of foreign matter contained in the recycled resin material, calculating a correction coefficient based on the types and contents of the foreign matter, and using the correction coefficient to correct the pre-set molding conditions.

[0013] According to this molding method, by using a correction coefficient calculated based on the type and content of foreign matter contained in the recycled resin material, the pre-set molding conditions under specified conditions are corrected, thereby eliminating the need to try molding for each recycled resin material and enabling the efficient molding of high-quality molded products under appropriate molding conditions.

[0014] Invention Effects

[0015] According to the present invention, a molding method is provided that can use recycled resin materials to efficiently mold high-quality molded articles. Attached Figure Description

[0016] Figure 1 An explanatory diagram illustrating the molding method involved in this embodiment.

[0017] Figure 2 A graph showing the types and amounts of foreign substances and the correction coefficients for each type of foreign substance.

[0018] Figure 3 A graph showing the correction factors for various foreign substances and their contents.

[0019] Figure 4 An explanatory diagram illustrating a general molding method.

[0020] Explanation of reference numerals in the attached figures

[0021] Content of A, B, C, D, and E

[0022] Molding conditions for C1, C2, C3, C4, and C5

[0023] P1 Foreign Object Analysis Process

[0024] Calculation process of P2 correction coefficient

[0025] Z, Y, X, W, V correction coefficients Detailed Implementation

[0026] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0027] Figure 1 An explanatory diagram illustrating the molding method involved in this embodiment.

[0028] like Figure 1As shown, the molding method involved in this embodiment is a method of molding resin articles using an injection molding machine. In injection molding, in which resin material is melted in an injection molding machine, injected into a mold, and molded into a resin article, predetermined molding conditions C1 to C5 are set in advance, and molding is performed under these molding conditions C1 to C5.

[0029] As described above, when the resin material is replaced with recycled resin material, defects such as dimensional deviations and poor appearance frequently occur in the molded products due to the influence of foreign matter contained in the recycled resin material.

[0030] Therefore, in this embodiment, molding conditions C1 to C5 are modified according to the foreign matter contained in the recycled resin material used. This allows for molding using recycled resin material under appropriate molding conditions. Consequently, quality defects such as dimensional deviations and poor appearance are suppressed, enabling the molding of high-quality molded articles equivalent to those molded from petroleum-derived resin materials.

[0031] The molding method involved in this embodiment will be described below.

[0032] (Setting molding conditions)

[0033] First, set the molding conditions C1 to C5 for injection molding. Molding conditions C1 to C5 include, for example, the temperature of the heating cylinder and mold C1, the metering of resin material C2, the injection speed C3, the holding pressure when locking the mold C4, and the injection time C5.

[0034] (Analysis of recycled resin materials)

[0035] Next, a foreign matter analysis process P1 is performed on the recycled resin material being used. This process involves analyzing the foreign matter in recycled resin materials found in scrap vehicles and other industrial materials. For example, recycled resin materials sometimes contain foreign matter such as iron (Fe), copper (Cu), sodium (Na), chlorine (Cl), and zinc (Zn). In this foreign matter analysis process P1, to understand the impact of these foreign matter on molding, the types and amounts of foreign matter are identified, and their physical properties (thermal conductivity, melting point, hardness, chemical reactivity, etc.) are determined.

[0036] Figure 2 A graph showing the types and amounts of foreign substances, and the correction coefficient for each type of foreign substance. (e.g.) Figure 2 As shown, in the foreign matter analysis process P1, the types of foreign matter (iron, copper, sodium, chlorine, zinc) and the content of each foreign matter A, B, C, D, E contained in the recycled resin material are calculated.

[0037] (Calculation of correction factor)

[0038] Next, the correction coefficient calculation process P2 is performed. In this correction coefficient calculation process P2, based on the types and contents of foreign matter A, B, C, D, and E as determined through analysis process P1, the correction coefficients Z, Y, X, W, and V for each foreign matter are calculated (refer to...). Figure 2 ).

[0039] (Injection molding)

[0040] As described above, based on the correction coefficients Z, Y, X, W, and V calculated according to the type and content of each foreign object, the molding conditions C1 to C5 are corrected, and molding M is performed using these corrected molding conditions C1 to C5 (refer to...). Figure 1 This suppresses the impact of foreign matter contained in recycled resin materials on injection molding.

[0041] Secondly, the specific correction coefficients for each type of foreign matter contained in the recycled resin material are explained.

[0042] Figure 3 A graph showing the correction factors for various foreign substances and their contents.

[0043] For each correction factor Z, Y, X, W, and V, there are temperature correction factors (°C) for molding condition C1 (temperature), metering correction factors (g) for molding condition C2 (metering), speed correction factors (%) for molding condition C3 (speed), holding pressure correction factors (%) for molding condition C4 (holding pressure), and time correction factors (seconds) for molding condition C5 (time). These temperature correction factors (°C), metering correction factors (g), speed correction factors (%), holding pressure correction factors (%), and time correction factors (seconds) are obtained based on molding tests conducted under the actual set molding conditions C1 to C5.

[0044] That is, such as Figure 3 As shown, the correction coefficients Z, Y, X, W, and V are configured for each type of foreign object as described below.

[0045] The correction factor Z for iron includes temperature correction factor Z1, metering correction factor Z2, speed correction factor Z3, pressure holding correction factor Z4, and time correction factor Z5.

[0046] The correction factor Y for copper includes temperature correction factor Y1, metering correction factor Y2, speed correction factor Y3, pressure holding correction factor Y4, and time correction factor Y5.

[0047] The correction factor X for sodium includes temperature correction factor X1, metering correction factor X2, speed correction factor X3, pressure holding correction factor X4, and time correction factor X5.

[0048] The correction factor W for chlorine includes temperature correction factor W1, metering correction factor W2, rate correction factor W3, pressure holding correction factor W4, and time correction factor W5.

[0049] The correction factor V for zinc includes temperature correction factor V1, metering correction factor V2, speed correction factor V3, pressure holding correction factor V4, and time correction factor V5.

[0050] The correction coefficients Z1-Z5 for iron, Y1-Y5 for copper, X1-X5 for sodium, W1-W5 for chlorine, and V1-V5 for zinc are used to adjust the molding conditions C1-C5 according to the content of each foreign substance. These coefficients are calculated based on the reference values ​​in each molding condition C1-C5. The reference values ​​are those when each foreign substance contains 1%, and correspond to the reference temperature, reference metering, reference speed, reference holding pressure, and reference time for molding conditions C1-C5.

[0051] Secondly, the reasons for correction and the calculation formulas for correction coefficients for iron, copper, sodium, chlorine and zinc, which are foreign substances, will be explained.

[0052] (1) Iron (Fe)

[0053] (temperature)

[0054] Reason for correction: For iron, due to its high thermal conductivity, the molding temperature needs to be lowered.

[0055] Temperature correction factor (°C): Z1 = Reference temperature - A% × 0.5

[0056] (Measurement)

[0057] Reason for correction: For iron, due to its weight, it is necessary to improve the measurement accuracy of the material.

[0058] Measurement correction factor (g): Z2 = reference measurement + A% × 0.1

[0059] (speed)

[0060] Reason for correction: Due to the hardness of iron, the fluidity of the material decreases, therefore the injection speed should be reduced.

[0061] Speed ​​correction factor (%): Z3 = Reference speed - A% × 0.2

[0062] (Pressure holding)

[0063] Reason for correction: By appropriately increasing the holding pressure, dimensional stability is ensured.

[0064] Pressure holding correction factor (%): Z4 = Reference pressure holding + A% × 0.3

[0065] (time)

[0066] Reason for revision: Extend the cooldown time.

[0067] Time correction factor (seconds): Z5 = Reference time + A% × 0.2

[0068] (2) Copper (Cu)

[0069] (temperature)

[0070] Reason for correction: For copper, due to its high thermal conductivity, the molding temperature needs to be lowered.

[0071] Temperature correction factor (°C): Y1 = Reference temperature - B% × 0.4

[0072] (Measurement)

[0073] Reason for revision: Considering the weight of copper, it is necessary to improve the measurement accuracy.

[0074] Measurement correction factor (g): Y2 = reference measurement + B% × 0.1

[0075] (speed)

[0076] Reason for revision: Considering the impact of fluidity, the injection speed was reduced.

[0077] Speed ​​correction factor (%): Y3 = Base speed - B% × 0.15

[0078] (Pressure holding)

[0079] Reason for correction: By appropriately increasing the holding pressure, dimensional stability is ensured.

[0080] Pressure holding correction factor (%): Y4 = Reference pressure + B% × 0.25

[0081] (time)

[0082] Reason for revision: Extend the cooldown time.

[0083] Time correction factor (seconds): Y5 = Base time + B% × 0.15

[0084] (3)Sodium (Na)

[0085] (temperature)

[0086] Reason for correction: For sodium, due to its low melting point, the molding temperature needs to be lowered.

[0087] Temperature correction factor (°C): X1 = Reference temperature - C% × 0.2

[0088] (Measurement)

[0089] Reason for correction: Considering the weight of sodium, it is necessary to improve the measurement accuracy.

[0090] Measurement correction factor (g): X2 = reference measurement + C% × 0.05

[0091] (speed)

[0092] Reason for correction: The injection speed was adjusted because it affected the flowability.

[0093] Speed ​​correction factor (%): X3 = Base speed - C% × 0.1

[0094] (Pressure holding)

[0095] Reason for correction: Adjust the pressure holding time appropriately.

[0096] Pressure holding correction factor (%): X4 = Reference pressure + C% × 0.2

[0097] (time)

[0098] Reason for correction: Adjusted cooldown time.

[0099] Time correction factor (seconds): X5 = base time + C% × 0.1 (4) Chlorine (Cl)

[0100] (temperature)

[0101] Reason for correction: The molding temperature is adjusted to account for the chemical reactivity of chlorine. Temperature correction factor (°C): W1 = Reference temperature - D% × 0.3 (measurement)

[0102] Reason for correction: To improve measurement accuracy.

[0103] Measurement correction factor (g): W2 = Reference measurement + D% × 0.05 (speed)

[0104] Reason for correction: Correct the injection speed.

[0105] Speed ​​correction factor (%): W3 = Reference speed - D% × 0.1 (holding pressure)

[0106] Reason for correction: Correction of pressure holding.

[0107] Pressure holding correction factor (%): W4 = reference pressure + D% × 0.2 (time)

[0108] Reason for correction: Adjusted cooldown time.

[0109] Time correction factor (seconds): W5 = base time + D% × 0.1 (5) Zinc (Zn)

[0110] (temperature)

[0111] Reason for correction: The molding temperature has been adjusted to take into account the influence of zinc.

[0112] Temperature correction factor (°C): V1 = Reference temperature - E% × 0.4 (measurement)

[0113] Reason for correction: To improve measurement accuracy.

[0114] Measurement correction factor (g): V2 = reference measurement + E% × 0.1 (speed)

[0115] Reason for correction: Correct the injection speed.

[0116] Speed ​​correction factor (%): V3 = Base speed - E% × 0.15

[0117] (Pressure holding)

[0118] Reason for correction: Correction of pressure holding.

[0119] Pressure holding correction factor (%): V4 = reference pressure + E% × 0.25

[0120] (time)

[0121] Reason for correction: Adjusted cooldown time.

[0122] Time correction factor (seconds): V5 = Base time + E% × 0.15

[0123] Using the correction coefficients obtained in this way, the molding conditions C1 to C5 can be finely modified according to various foreign substances (iron, copper, sodium, chlorine, zinc).

[0124] As explained above, according to the molding method of this embodiment, by correcting the molding conditions C1 to C5 based on the correction coefficients calculated from the types and contents of foreign matter contained in the recycled resin material, it is not necessary to try molding for each recycled resin material. Molding can be carried out under appropriate molding conditions, and high-quality molded articles with suppressed dimensional deviations and poor appearance can be efficiently molded.

Claims

1. A molding method which is a molding method using a recycled resin material, wherein, The kind and content of foreign matters contained in the regenerated resin material are grasped, a correction coefficient is calculated based on the kind and content of the foreign matters, and the correction coefficient is used to correct the molding conditions set in advance.

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