Purging Resin Composition for Clean Molding Machine Changeovers
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Solution Overview
Problem
Existing purging agents for molding machines have insufficient cleaning performance, require large amounts of resin replacement, cause metering failures at high temperatures, and pose risks of burns and fume emissions during cleaning, especially when cleaning engineering plastics and highly heat-resistant materials.
Innovation Solution
A resin composition comprising a thermoplastic resin, a synthetic wax, and a polyolefin-based resin, with specific solubility parameter differences and compounding amounts, enhances cleaning power, facilitates easy replacement, and suppresses fume emissions and metering failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional purging agents are used to clean molding machines, then cleaning power is improved, but the amount of resin replacement increases and metering failures occur at high temperatures
Solution Approach 1:
The patent modifies the chemical composition parameters of the purging agent by incorporating specific lubricants and surfactants in controlled amounts. This changes the melt flow characteristics and thermal stability parameters, allowing the purging agent to maintain cleaning effectiveness while preventing metering failures at high temperatures through optimized rheological properties
Solution Approach 2:
The patent creates a composite purging agent formulation combining multiple components including thermoplastic resin, lubricants, and surfactants. This composite structure integrates the cleaning power of traditional purging agents with the metering stability provided by lubricant-surfactant complexes, resolving the contradiction between cleaning effectiveness and metering reliability
2Object-affected harmful factors
If lubricants or surfactants are added to enhance cleaning power, then cleaning capability is improved, but workability deteriorates due to spurt and fume emissions
Solution Approach 1:
The patent carefully controls the concentration parameters of lubricants and surfactants within specific ranges. This parameter optimization ensures sufficient cleaning capability while preventing excessive spurt and fume emissions by maintaining the formulation within safe operational thresholds
Solution Approach 2:
The patent introduces a balanced formulation system where lubricants and surfactants act as intermediaries between the purging agent and the molding machine surfaces. These intermediaries provide necessary cleaning action while their controlled presence prevents harmful spurt and fume emissions through moderated chemical interaction
3Object-affected harmful factors
If manual disassembly and cleaning is performed, then complete residue removal is achieved, but productivity decreases and machine damage risk increases
Solution Approach 1:
The patent creates a self-acting purging system where the purging agent automatically flows through the molding machine, dissolves residues, and is ejected without manual intervention. This self-service mechanism achieves complete residue removal while maintaining high productivity by eliminating manual disassembly and reducing cleaning time
Solution Approach 2:
The patent replaces manual mechanical cleaning operations with a chemical-mechanical purging system. The purging agent chemically acts on residues while being mechanically pumped through the system, substituting labor-intensive manual disassembly and cleaning with an automated chemical process that achieves equivalent or superior cleaning results
4Object-affected harmful factors
If large amounts of molding material are used for residue removal, then cleaning effectiveness is improved, but loss of substance increases and time consumption increases
Solution Approach 1:
The patent extracts the essential cleaning function from large quantities of molding material by concentrating cleaning agents (lubricants and surfactants) in a small-volume purging agent formulation. This extraction allows residue removal effectiveness to be achieved with minimal material consumption by using highly concentrated active cleaning components
Solution Approach 2:
The patent changes the concentration parameters of cleaning components in the purging agent formulation, creating a highly concentrated product that delivers equivalent cleaning effectiveness to large amounts of conventional molding material but with significantly reduced material consumption and waste generation
Data Source
AI summary
A resin composition for cleaning molding machines that achieves both high cleaning power for the material mold-processed before cleaning and easy replacement to the material to be mold-processed after cleaning, improves stable raw material feedability, has metered purging suitability, and has improved workability by suppressing spurt and emission of fume from a molding machine during the cleaning process is provided. To achieve the object, the present disclosure is a resin composition for cleaning molding machines including a thermoplastic resin (A), a synthetic wax (B), and a polyolefin-based resin (C), wherein an absolute value of a difference between solubility parameters of (A) and (B) is 2.0 (cal/cm3)1/2 or more and 7.0 (cal/cm3)1/2 or less, a compounding amount of (C) is more than 0.1 mass % and less than 10 mass %, and a glass transition temperature of (C) is higher than −150° C. and lower than 40° C.