PPS Molded Pipe Production for Long 3D Plumbing Shapes
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Solution Overview
Problem
Current methods for producing long, three-dimensionally complicated pipe-shaped plumbing components using thermoplastic resins face challenges such as complex bending processes, poor production efficiency, insufficient heat resistance, and chemical resistance, particularly with polyamide 66 resin compositions, and unsuitable melt tension for suction-type blow molding.
Innovation Solution
A method for producing a pipe-shaped integrally molded article using a polyphenylene sulfide resin composition with controlled melt tension, compounded with polyolefin-based resin and inorganic fillers, which allows for a single melt solidification cycle, achieving a length of 1000 mm or more with a high length-to-diameter ratio, and maintaining excellent heat and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a bending process is performed on a linear tube article obtained by extrusion molding to achieve a complicated three-dimensional shape, then the desired pipe shape is obtained, but the bending process becomes complicated and production efficiency decreases due to the need to join multiple molded articles
Solution Approach 1:
The invention combines multiple processes (extrusion molding and blow molding) into a single integrated production method. The linear tube article obtained by extrusion molding is directly subjected to blow molding to form the final complicated three-dimensional shape, eliminating the need for separate bending processes and joining operations. This merging of processes resolves the contradiction by maintaining shape complexity while dramatically improving production efficiency.
Solution Approach 2:
The invention performs preliminary extrusion molding to create a linear tube article with controlled dimensions and properties before applying blow molding. By pre-forming the tube with appropriate wall thickness and structural characteristics through extrusion, the subsequent blow molding process can efficiently achieve the complicated three-dimensional shape without requiring complex bending operations or multiple joining steps.
2Shape
If multiple molded articles are joined together after processing to achieve appropriate shape, then the desired pipe configuration is obtained, but the production efficiency becomes poor due to the joining process
Solution Approach 1:
The invention merges the shaping process into a single blow molding operation that forms the entire complicated three-dimensional shape from one linear tube article. This eliminates the need for joining multiple molded articles, thereby resolving the contradiction by maintaining shape appropriateness while significantly improving production efficiency through process integration.
3Productivity
If polyamide 66 resin composition is used for plumbing components, then production efficiency is improved, but heat resistance and chemical resistance are insufficient
Solution Approach 1:
The invention changes the material parameter by selecting polyphenylene sulfide resin instead of polyamide 66 resin. This material substitution fundamentally alters the thermal and chemical resistance properties while maintaining good blow moldability through optimized melt tension parameters. The parameter change resolves the contradiction by achieving both improved reliability (heat and chemical resistance) and maintained production efficiency.
Solution Approach 2:
The invention uses a composite resin composition comprising polyphenylene sulfide resin as the base material, potentially combined with other components to optimize both mechanical properties and moldability. This composite approach allows achieving the desired heat and chemical resistance while maintaining production efficiency through proper material formulation.
4Ease of manufacture
If melt tension of PPS resin composition is optimized to improve blow moldability, then drawdown property is improved, but followability may decrease causing irregular thickness and poor appearance
Solution Approach 1:
The invention optimizes the melt tension parameter to a specific range that balances drawdown property and followability. By carefully controlling the melt tension of the PPS resin composition, the invention achieves good blow moldability with adequate followability, preventing irregular thickness and poor appearance. This parameter optimization resolves the contradiction by finding the optimal balance point between the two competing requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the efficient production of long, complex-shaped pipe articles with uniform thickness and high mechanical strength, overcoming the limitations of existing technologies by providing excellent heat and chemical resistance and improved production efficiency.
Implementation Method 1
formed by molding a polyphenylene sulfide resin composition having a melt tension N (mN) at breakage of 10 or more and 50 or less within a single melt solidification cycle
Implementation Method 2
air is blown into a parison contained in a blow mold from a blow nozzle, and the parison is inflated to be integrated with a cylindrical component
Implementation Method 3
a production method of a long bent tube using a suction-type blow molding method
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 2D~2E
AI summary
Provided are: a pipe-shaped integrally molded article which is formed by molding a polyphenylene sulfide resin composition, and which has, at one or more portions thereof, at least one selected from different-shape sections, bent sections, and different-diameter sections, the pipe-shaped integrally molded article being characterized in that the total length L (mm) thereof is 1000 or more, and the ratio (L/D) of the total length L (mm) to the outer diameter D (mm) of the pipe-shaped integrally molded article is 20 or more: and a production method for the pipe-shaped integrally molded article. According to the present invention, it is possible to efficiently provide a pipe-shaped integrally molded article having a desired large length and including a three-dimensionally complicated shape, by using a PPS resin composition having excellent heat resistance and chemical resistance.