PPS Blow-Molded Pipe for Long 3D Plumbing Shapes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing long, three-dimensionally complicated pipe-shaped plumbing components with polyphenylene sulfide resin (PPS) face challenges in heat resistance, chemical resistance, and production efficiency, particularly in achieving complex shapes and sufficient length without compromising mechanical properties.
Innovation Solution
A pipe-shaped integrally molded article using a PPS resin composition with specific properties, including a total length of 1000 mm or more, a length-to-diameter ratio of 20 or more, and a melt tension between 10 and 50 mN, compounded with polyolefin-based resin and inorganic fillers, is produced using a suction-type blow molding method within a single melt solidification cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a bending process is performed on a linear tube molded article to obtain a three-dimensional shape, then the pipe can be formed to fit limited space, but the production efficiency deteriorates due to complicated bending processes and the need to join multiple molded articles
Solution Approach 1:
The mold cavity is designed with a three-dimensional shape including bent sections in advance, allowing the pipe-shaped integrally molded article to be formed with the final shape directly during molding, eliminating the need for subsequent bending processes and joining operations
Solution Approach 2:
Multiple molded articles that would otherwise need to be bent and joined are merged into a single integrally molded article with total length of 1000 mm or more, forming all sections including bent portions in one continuous piece to eliminate joining processes
2Ease of manufacture
If the melt tension of PPS resin composition is increased to improve blow moldability, then the drawdown property improves, but the followability to mold shape decreases causing irregular thickness and poor appearance
Solution Approach 1:
The melt tension of the PPS resin composition is optimized to a specific range (10-50 mN) to achieve the right balance between drawdown property and followability, ensuring both good blow moldability and uniform wall thickness in the molded article
Solution Approach 2:
The resin composition is formulated with specific components (polyolefin-based resin and inorganic fillers in controlled amounts) to create local properties that enhance both moldability and dimensional accuracy during the blow molding process
3Productivity
If polyamide 66 resin composition is used to produce long bent tubes, then the production efficiency improves, but the heat resistance and chemical resistance are insufficient for automotive plumbing components
Solution Approach 1:
A composite resin composition is used consisting of PPS resin as the base material (providing heat and chemical resistance) combined with polyolefin-based resin and inorganic fillers (improving processability and moldability), achieving both high reliability and production efficiency
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 approach enables the efficient production of long, complex-shaped pipe components with enhanced heat resistance, chemical resistance, and mechanical strength, improving production efficiency and reducing the need for post-processing joining of multiple parts.
Implementation Method 1
a production method for a pipe-shaped integrally molded article using a suction-type blow molding method
Implementation Method 2
a pipe-shaped integrally molded article using a polyphenylene sulfide resin composition... within a single melt solidification cycle
Data Source
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.