Microbubble creating method using a forming machine

Abstract

A microbubble creating method using a forming machine for creating microbubbles by: installed a microbubble generating member in a mold, feed screw or barrel for enabling a perforated tip of the microbubble generating member to be surrounded by the applied fluid polymer so that when a high pressure high temperature gas is delivered through the perforated tip of the microbubble generating member, microbubbles are created with well mixed with the fluid polymer, and the expected foamed polymer product is thus obtained after cooling.

Claims

1. A microbubble creating method for creating microbubbles in a polymer using a forming machine, said forming machine comprising a barrel, a feed screw and a microbubble generator, said barrel comprising an input end and an opposing output end, said feed screw being mounted in said barrel, said microbubble generator comprising a microbubble generating member mounted in said output end of said barrel, said microbubble generating member comprising a perforated tip which is extended through a peripheral wall of said barrel, the microbubble creating method comprising the steps of: a) driving said feed screw to propel a fluid polymer from said input end of said barrel toward said output end of said barrel, the fluid polymer being heated in said barrel, enabling said perforated tip of said microbubble generating member to be immersed in the fluid polymer and be surrounded by said fluid polymer; b) starting up said microbubble generator to fill a gas into an air passage of said barrel, enabling said gas to be heated when flowing through said air passage; and c) enabling the heated said gas to go through said air passage of said barrel into said microbubble generating member to create microbubbles for mixing with said fluid polymer by rotation of said feed screw.

2. The microbubble creating method as claimed in claim 1, wherein said microbubble generator further comprises a fluid delivery device installed near said input end of said barrel; said step a) further comprising a sub step of driving said fluid delivery device to inject a foaming fluid into said barrel for enabling the injected said foaming fluid to be mixed with said fluid polymer and heated to create microbubbles in said fluid polymer after evaporation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic drawing illustrating the flow of a microbubble creating method in accordance with a first embodiment of the present invention.

(2) FIG. 2 is a plain view of a microbubble generator in accordance with the first embodiment of the present invention.

(3) FIG. 3 is a schematic drawing illustrating the flow of a microbubble creating method in accordance with a second embodiment of the present invention.

(4) FIG. 4 is a schematic drawing illustrating a check ring stopped at a stop flange of a feed screw in accordance with a third embodiment of the present invention.

(5) FIG. 5 corresponds to FIG. 4, illustrating the check ring moved away from the stop flange of the feed screw.

(6) FIG. 6 is a schematic structural view of a fourth embodiment of the present invention.

(7) FIG. 7 is a schematic structural view of a fifth embodiment of the present invention.

(8) FIG. 8 is a schematic structural view of a sixth embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(9) Referring to FIG. 6, a microbubble creating method in accordance with a first embodiment of the invention is to be implemented using a foaming machine 10. The forming machine 10 in this first embodiment of the present invention is an extrusion molding machine, comprising a barrel 20, a heater 30 mounted around the periphery of the barrel 20 for melting a solid polymer into a fluid polymer 12, a feed screw 40 mounted in the barrel 20 for propelling the fluid polymer 12 toward a mold 14. As illustrated in FIG. 2, the forming machine 10 further comprises a microbubble generator 50. The microbubble generator 50 can be an air compressor or any other equivalent air compression device. In this embodiment, the microbubble generator 50 comprises a pressure cylinder 51, a accumulator 52, a plurality of electric heating components 53, and a plurality of microbubble generating members 54. The pressure cylinder 51 is adapted for increasing the pressure of air being filled from the outside. The accumulator 52 is connected to the pressure cylinder 51 for storing compressed air. The electric heating components 53 are mounted around the periphery of the accumulator 52 for heating compressed air in the accumulator 52. The microbubble generating members 54 are connected to the accumulator 52 for outputting high pressure high temperature gas into the accumulator 52. Further, each microbubble generating member 54 comprises a perforated tip 542 made from, but not limited to, metal, ceramics, or a composite of metal and ceramics. In this first embodiment, the microbubble generating members 54 are mounted in an input end 16 of the mold 14 with the perforated tip 542 thereof extended into the mold 14.

(10) Referring also to FIG. 1, the microbubble creating method in accordance with the first embodiment of the invention comprises the steps of:

(11) Step a): Drive the feed screw 40 to propel the fluid polymer 12 into the inside of the mold 14, enabling the perforated tips 542 of the microbubble generating members 54 to be immersed in the fluid polymer and is surrounded by the fluid polymer 12 in the mold 14.

(12) Step b): Start up the microbubble generator 50 to generate high pressure high temperature gas, forcing high pressure high temperature gas to go out of the perforated tips 542 of the microbubble generating members 54 and to further create microbubbles that are then mixed in the fluid polymer 12 inside the mold 14. After cooling, the expected foamed polymer product with smooth surface and foamed subcoat is thus obtained.

(13) Referring to FIG. 3, a microbubble creating method in accordance with a second embodiment of the invention can be implemented using an extrusion molding or injection molding machine. This second embodiment is substantially similar to the aforesaid first embodiment with the exception that each microbubble generating member 54 is obliquely mounted at a holder member 55 that defines a runner 552 in communication between the feed screw 40 and the mold 14 for enabling a fluid polymer 12 to pass; each microbubble generating member 54 comprises a perforated tip 542 with extended into the runner 552 so that microbubbles generated by each microbubble generating member 54 can be filled into the fluid polymer 12 at a low pressure; the microbubble generator 50 further comprises a static mixer 56 mounted in the runner 552 of the holder member 55 between the microbubble generating member 54 and the mold 14 for enabling generated microbubbles to be well mixed with the fluid polymer 12. Thus, the microbubble creating method in accordance with this second embodiment of the invention comprises the steps of:

(14) Step a): Drive the feed screw 40 to propel the feeding fluid polymer 12. When the fluid polymer 12 is being propelled into the runner 552 of the holder member 55, the perforated tips 542 of the microbubble generating members 54 will be to be immersed in the fluid polymer and surround the fluid polymer 12 and be propelled through the runner 552 of the holder member 55 into the mold 14.

(15) Step b): Start up the microbubble generator 50 to generate high pressure high temperature gas forcing high pressure high temperature gas to go out of the perforated tips 542 of the microbubble generating members 54 and to further create microbubbles that are then mixed in the fluid polymer 12 in the runner 552 subject to the functioning of the static mixer 56, and then delivered with the fluid polymer 12 toward the inside the mold 14. After cooling, the expected foamed polymer product with smooth surface and foamed subcoat is thus obtained.

(16) Referring to FIG. 4, a microbubble creating method in accordance with a third embodiment of the invention can be implemented using an injection molding machine. This third embodiment is substantially similar to the aforesaid first and second embodiments with the exception that each microbubble generating member 54 is mounted in a locating ring 57 that is mounted at a front end of the feed screw 40 in such a manner that the perforated tip 542 of each microbubble generating member 54 protrudes over the surface of the feed screw 40; the microbubble generator 50 further comprises an air compressor (not shown) adapted for providing high pressure gas to each microbubble generating member 54; a static mixer 56 is disposed at a front side relative to the feed screw 40. Thus, the microbubble creating method in accordance with this third embodiment of the invention comprises the steps of:

(17) Step a): Drive the feed screw 40 to propel the fluid polymer 12, enabling the fluid polymer 12 to surround the perforated tips 542 of the microbubble generating members 54 during delivery.

(18) Step b): Start up the air compressor of the microbubble generator 50 to provide high pressure gas into an air passage 42 in the feed screw 40, enabling high pressure gas to be heated by the heater 30 when flowing through the air passage 42.

(19) Step c): After heating, high pressure gas goes through the air passage 42 of the feed screw 40 into the microbubble generating members 54 to create microbubbles after passed through the perforated tips 542 of the microbubble generating members 54, enabling created microbubbles to be primarily mixed with the fluid polymer 12 subject to rotation of the feed screw 40 and then the static mixer 56 will mix the microbubbles with the fluid polymer 12 when injection again.

(20) Further, the feed screw 40 comprises a stop flange 44 disposed near a front end thereof and abutted against the locating ring 57. Further, a check ring 58 is attached to the front end of the feed screw 40, as shown in FIG. 5. When the feed screw 40 is being rotated to propel the feeding material, the check ring 58 will be forced to move away from the stop flange 44 of the feed screw 40, enabling the barrel 20 to accommodate sufficient high pressure high temperature gas and sufficient volume of the fluid polymer 12. When injecting the fluid polymer 12 into the mold 14, the check ring 58 will be stopped at the stop flange 44 of the feed screw 40 to prevent a reverse flow of the fluid polymer 12, avoiding clogging of the perforated tips 542 of the microbubble generating members 54 by micromolecules of the fluid polymer 12.

(21) Referring to FIG. 6, a microbubble creating method in accordance with a fourth embodiment of the invention can be implemented using an extrusion molding machine. This fourth embodiment is substantially similar to the aforesaid first embodiment with the exception that the microbubble generating members 54 are mounted in the output end 22 of the barrel 20 with the perforated tips 542 of the microbubble generating members 54 extended inside into the barrel 20; further, the microbubble generating members 54 are connected to an air compressor (not shown), constituting the microbubble generator 50. Thus, the microbubble creating method in accordance with this fourth embodiment of the invention comprises the steps of:

(22) Step a): Drive the feed screw 40 to propel the fluid polymer 12, enabling the fluid polymer 12 to be heated by the heater 30 and the perforated tips 542 of the microbubble generating members 54 immerse in the fluid polymer and to be surrounded by the fluid polymer 12 as the fluid polymer 12 is being propelled from the input end 21 of the barrel 20 toward the output end 22 of the barrel 20.

(23) Step b): Start up the microbubble generator 50 to provide high pressure gas into an air passage 23 in the barrel 20, enabling high pressure gas to be heated by the heater 30 when flowing through the air passage 23.

(24) Step c): After heating, high pressure gas goes from the air passage 23 of the barrel 20 through a pipeline 59 into the microbubble generating members 54 to create microbubbles after passed through the perforated tips 542 of the microbubble generating members 54, enabling created microbubbles to be mixed with the fluid polymer 12 during rotation of the feed screw 40.

(25) The microbubble generator 50 further comprises a fluid delivery device 60 mounted in the input end 21 of the barrel 20 and extend inside into the barrel 20. Thus, in the aforesaid Step a), the fluid delivery device 60 is controlled to inject a foaming fluid into the barrel 20, enabling the supplied foaming fluid to be mixed with the fluid polymer 12 and heated by the heater 30. When the foaming fluid is vaporized, microbubbles are created in the fluid polymer 12 to mate with the microbubbles generated by the microbubble generating members 54, achieving production that is well foamed polymer product.

(26) It is to be noted that, as shown in FIG. 7 and FIG. 8, it is not imperative to have the microbubble generating members 54 and the fluid delivery device 60 be concomitantly installed. In actual application, the microbubble generating members 54 and the fluid delivery device 60 can be selectively installed. For example, in the application example shown in FIG. 6, the microbubble generating members 54 and the fluid delivery device 60 are concomitantly installed; in the application example shown in FIG. 7, only the microbubble generating members 54 are installed; in the application example shown in FIG. 8, the fluid delivery device 60 is installed, and the aforesaid microbubble generating members 54 are eliminated. In any application example, sufficient microbubbles can be created to achieve excellent foaming. Of course, both the microbubble generating members 54 and the fluid delivery device 60 can be concomitantly installed to achieve optimal effects.

(27) In conclusion, the microbubble creating method of the invention is to insert microbubble generating members 54 into the applied fluid polymer 12. When compared to conventional techniques, the invention significantly increases the contact area between the microbubble generating members 54 and the fluid polymer 12, thereby increasing the amount of gas that enters the fluid polymer 12 and enabling generated microbubbles to be evenly distribute in the fluid polymer 12.

(28) Although particular embodiments of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.