Method for producing molded article
View Patent ↗The present invention provides a method for producing a molded article which enables dissolution of a desired amount of a subject material in a molten resin without any limitation by the solubility of a high-pressure carbon dioxide in the molten resin and which is therefore suitable for commercial production of molded articles. The present invention pertains to a method for producing a molded article by molding a molten resin, and this method is characterized by including steps of supplying a high-pressure carbon dioxide and a subject material dissolved therein, into the molten resin; kneading the molten resin into which the high-pressure carbon dioxide and the subject material have been supplied; and exhausting the high-pressure carbon dioxide from the kneaded molten resin.
1. A method for producing a molded article by molding a molten resin, characterized in that said method includes the steps of
supplying a high-pressure carbon dioxide at 7 MPa or higher and a subject material dissolved therein, into said molten resin,
kneading said molten resin into which said high-pressure carbon dioxide and said subject material have been supplied, and
exhausting said high-pressure carbon dioxide from said kneaded molten resin,
said method further including the following steps before said supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin;
supplying a high-pressure carbon dioxide at 7 MPa or higher having a metal complex and said subject material dissolved therein, into said molten resin, and
kneading said molten resin having said metal complex, said subject material and said high-pressure carbon dioxide supplied thereinto,
wherein, after the start of said exhaustion of said high-pressure carbon dioxide from said kneaded molten resin, said supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin is started.
2. The method of claim 1 , wherein said exhaustion of said high-pressure carbon dioxide from said kneaded molten resin is performed concurrently with said supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin, so that said high-pressure carbon dioxide is supplied into said molten resin at a higher concentration than a saturation solubility of said high-pressure carbon dioxide in said molten resin.
3. The method of claim 1 or 2 , wherein said kneading of said molten resin includes
charging said molten resin into a cylinder equipped with a screw, and kneading the molten resin by rotating the screw within the cylinder, and
rotating the screw normally and reversely, during said supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin.
4. The method of claim 1 , further including the following steps before said supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin:
supplying a high-pressure carbon dioxide having a metal complex dissolved therein, into said molten resin, and
kneading said molten resin into which said high-pressure carbon dioxide and said metal complex have been supplied,
wherein, after the start of said exhaustion of said high-pressure carbon dioxide from said kneaded molten resin, said supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin is started.
5. The method of claim 1 , wherein, in the supply of said high-pressure carbon dioxide and said subject material dissolved therein, into said molten resin, said subject material is dissolved in said high-pressure carbon dioxide at a unsaturation concentration.
6. The method of claim 1 , further including the steps of
molding said molten resin kneaded with said high-pressure carbon dioxide and said subject material, to form a molded article, and
subjecting said molded article to electroless plating to form a metal film on said molded article.
7. The method of claim 1 , wherein the concentration of said subject material in said kneaded molten resin is increased, while the concentration of said high-pressure carbon dioxide in said molten resin is being controlled.
8. The method of claim 1 , wherein said subject material is a metal alkoxide.
9. The method of claim 1 , wherein said subject material is a silicone oil.
10. The method of claim 1 , wherein said subject material is a fluorine compound.
11. The method of claim 4 , wherein said subject material is a fluorine compound, and said metal complex is a fluorine-containing metal complex.
12. The method of claim 1 , wherein said subject material is a reactive monomer, and said reactive monomer is polymerized in said kneaded molten resin to disperse the resulting polymer in said molten resin.
13. The method of claim 12 , wherein said reactive monomer is ε-caprolactam, and said polymer is 6-Nylon.