Injection molding process with reactive gas treatment

Abstract

A process for making shaped articles by injecting a thermoplastic or thermoset polymer into a mold cavity in which is maintained a reactive atmosphere containing between 0.1 mole % and 50 mole % F.sub.2 and at least 20 ppm O.sub.2 while the polymer is being injected into the mold, such that any portion of the polymer contacts the reactive atmosphere for a time not greater than 0.5 sec.

Description

TECHNICAL FIELD OF THE INVENTION

The present invention relates to injection molding processes for making shaped articles having improved physical and chemical properties.

BACKGROUND OF THE INVENTION

Injection molding has become a major method for producing articles from a wide variety of thermoplastic polymers. Typical injection molding processes involve several basic steps. The first step is to plasticize the thermoplastic polymer to a point where it will flow under pressure. This is usually done by masticating with a reciprocating screw while simultaneously heating until it forms a melt at elevated and uniform temperature and uniform viscosity. The liquid is then injected into the mold where it is shaped into the desired object by the confines of the mold cavity. The liquid is allowed to solidify under pressure within the mold after which the mold is opened and the article is recovered.

U.S. Pat. No. 4,435,453 discloses a method of increasing the barrier properties of containers manufactured by conventional injection molding techniques. A controlled amount of saturated gas is added under pressure into a molten polymer stream residing in the screw channels of a screw type plasticizer employed in a preform injection molding machine. The gas is added in an amount to saturate the plastic walls of the container so that when a beverage containing that gas is sealed in the container, gas from the beverage will not be absorbed into the container walls.

U.S. Pat. No. 4,550,043 discloses preforms formed by injection molding thermoplastic materials wherein the preform comprises inner and outer rst layers of a thermoplastic resin, inner and outer second layers of a barrier material and a second layer of thermoplastic material between the barrier layers. The preform is subsequently used to form articles in blow molding operations.

G.B. Pat. No. 1,169,394 discloses an injection molding process in which a gas, such as air, is introduced into the mold prior to injecting the plastic. The gas is introduced under a pressure higher than atmospheric but lower than the injection pressure of the plastic material.

Japanese patent application 6 1152-421A discloses an injection molding device comprising a vacuum chamber and evacuating device which provides for evacuation of the mold in a short time.

Most other attempts at altering the physical and/or chemical properties of thermoplastic polymeric articles have been directed toward blow-molding operations or involved post-treatment techniques.

U.S. Pat. No. 3,862,284 discloses a process whereby the barrier properties of blow molded thermoplastic articles are improved by employing a blowing gas containing about 0.1 to about 20% by volume fluorine during the expansion stage of the blow-molding operation.

Joffe, U.S. Pat. No. 2,811,468 teaches improving the barrier properties of polyethylene film toward atmospheric gases by fluorinating at least one surface of the film to contain not more than about 3.5% by weight fluorine.

U.S. Pat. No. 3.255,099 discloses a process for modifying and improving the surface characteristics of polymeric shaped structures by subjecting the surface of the structure to the action of an electrical discharge between positive and negative electrodes in a gaseous atmosphere consisting essentially of the vapor of an inorganic agent having an affinity for electrons.

U.S. Pat. No. 3,988,491 discloses a process for improving dye receptivity and soil and stain release properties of fiber form materials such as polyesters and polyamides. The improved properties are achieved by subjecting the fibers to fluorine treatment in the presence of little or no oxygen for brief periods of time.

U.S. Pat. No. 4,009,304 teaches a process for improving adhesion of polyester yarn, tire cord or fabric in polyester reinforced rubber goods, such as tires. Improved adhesion is achieved by fluorinating the polyester yarn, tire cord or fabric prior to incorporation into the tire or rubber goods.

BRIEF SUMMARY OF THE INVENTION

The present invention is an injection molding process for making thermoplastic polymeric shaped articles having improved physical and chemical properties. The process comprises injecting the thermoplastic polymer, in a plasticized state, into a mold cavity in which is maintained a reactive atmosphere containing between 0.1 mole % and 50 mole % F.sub.2 and at least 20 ppm and preferably at least 100 ppm O.sub.2. The thermoplastic polymer is injected into the mold cavity at a rate such that any portion of said polymer contacts the reactive atmosphere for a time not greater than 0.5 sec. Provisions are made to allow the gas to exhaust from the mold cavity as the plasticized polymer is being injected into the cavity.

The thermoplastic polymer is allowed to cool and harden before being recovered from the mold. The resulting thermoplastic shaped articles exhibit improved properties such as improved coating adhesion (e.g. paints, inks, etc.), improved substrate bonding and the ability to form a clean break at weld lines formed at points where two interfaces of the plasticized polymer join in the mold.

In addition to exhibiting altered physical and chemical properties, the polymeric shaped articles are treated in-situ in a very short period of time, and optionally with a high fluorine concentration (e.g. up to 50 mole %), while they are being molded which allows for an efficient, continuous on-line process.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is an improvement in conventional injection molding processes to produce thermoplastic polymeric shaped articles having improved physical and chemical properties such as improved coating adhesion and substrate bonding.

Conventional injection molding processes comprise injecting a plasticized thermoplastic or thermoset polymer material into a mold cavity contoured in accordance with the desired shape of the article to be formed. The polymeric material is confined under pressure in the mold while heat is removed to solidify the plastic and freeze it permanently into the desired shape, after which it is ejected from the mold.

It has now been found that improvements in the physical and/or chemical characteristics of injection molded thermoplastic articles can be attained by maintaining in the mold cavity a reactive atmosphere containing between 0.1 mole % and 50 mole % F.sub.2 and at least 20 ppm and preferably at least 100 ppm O.sub.2 while the polymeric material is being injected into the mold. The polymeric material is injected into the mold cavity at a rate such that any porton of the material contacts the reactive atmosphere for a period of time not exceeding 0.5 sec, and preferably not exceeding 0.1 sec. It has been found that the desired property improvements in the materials can be achieved at these short contact times, even at low F.sub.2 concentrations, although an additional advantage of the present process is that high levels of F.sub.2 ; i.e. greater than 10 mole %, can be used to achieve even greater levels of fluorination without charring or burning the materials as was shown to occur in in-situ blow molding treating processes. The reactive atmosphere may be introduced and maintained in the mold cavity in any suitable fashion, such as by pulling a vacuum to evacuate the mold cavity and subsequently adding the reactive gas, or alternatively by a one-step flush process whereby the gas is introduced through one set of vents displacing the gas in the mold which is discharged through another set of vents. As with conventional injection molding processes using air filled mold cavities, a means must be provided for exhausting the reactive gas from the mold cavity while the polymeric material is being injected into said cavity.

While a fluorine concentration of between 0.1 mole % and 50 mole % can be employed, it is preferred that the concentration be maintained above 2 mole % and in many instances at or above 10 mole %. In addition to the fluorine and at least 20 ppm O.sub.2, the balance of the reactive atmosphere can comprise any components which do not adversely interfere with the interaction between the polymeric material and the O.sub.2 /F.sub.2 atmosphere; with typical examples being nitrogen or air. Other examples of suitable gaseous atmospheres include: F.sub.2 /Cl.sub.2, F.sub.2 /Cl.sub.2 /N.sub.2, F.sub.2 /SO.sub.2 /N.sub.2, F.sub.2 /SO.sub.3 /N.sub.2, F.sub.2 /SO.sub.3 /N.sub.2, F.sub.2 /SO.sub.2 Cl.sub.2 /N.sub.2, F.sub.2 SO.sub.2 Cl/N.sub.2 and similar gaseous mixtures all containing at least 20 ppm of oxygen. The source of oxygen may be as a separate entity added to the gas mixture, as part of one of the components of the gas mixture (e.g. SO.sub.2), as an impurity in the fluorine source, or even as residual gas present in the mold. While the source of fluorine is typically gaseous F.sub.2, other examples of fluorine sources include PF.sub.5, CF.sub.4, NF.sub.3, CH.sub.3 COF and the like.

It is also believed that, in at least some instances, SO.sub.3 may be substituted for the fluorine in the mold atmosphere without adversely effecting the desired results. In such instances the SO.sub.3 may be used in combination with a fluorine source, or may be used alone or with other gaseous components. If the SO.sub.3 is used without fluorine, the SO.sub.3 concentrating preferably should be at least 0.1 mole %.

The present process has been found to be capable of improving various chemical and/or physical characteristics of a wide range of thermoplastic polymeric substrates. For example, injection molded articles produced in accordance with this invention exhibit increased surface bond strength with the same or other polymer materials, increased coating adhesion, and the ability to form a clean break at weld lines formed at points where two interfaces of the plasticized polymer join in the mold.

The present process can be operated as a continuous on-line process, with the contact time between the polymeric material and the reactive atmosphere being extremely short; i.e. less than 0.5 sec. and preferably less than 0.1 sec. The injection molding technique is such that, when the plasticized material flows into the mold, a front of molten material is set up such that a layer forms against the side of the mold and a new material continues to fill the cavity by flowing through the center of the part; i.e., parabolic flow. This type of flow results in fresh material continuously coming into contact with the remaining gas in the cavity and then forming the surface of the article, thereby insuring nearly uniform treatment across the entire surface of the article.

Any polymeric thermoplastic or thermoset material which is capable of being plasticized and injected into a mold can be used in this invention. Specific examples of materials well suited for this process include polyolefins such as low-density polyethylene, high-density polyethylene (HDPE), and polypropylene(PP); polyesters; polyamides; polyimides; polycarbonates; sulfones, and the like. The temperature of the process will vary depending upon the polymeric material used, with the initial temperature being sufficient to plasticize the polymer and allow it to flow into the mold cavity. The mold pressure can be maintained at atmospheric, although it has been found, at least in some instances, that higher pressures, such as 25 psig and above, can result in further improvements in the surface characteristics of the formed articles, and also may result in greater changes in the surface chemistry.

The changes in the physical and/or chemical characteristics of the injection molded parts which result from this process are believed to be the result of alterations in the chemical make-up of the surface of the parts. The present process achieves such property improvements at extremely short contact times between the polymeric material and the reactive gas, in fact at significantly shorter times than taught in any of the prior art fluorination literature.

EXAMPLE 1

Several polypropylene (PP) plaques were injection molded using various reactive atmospheres within the mold cavity at atmospheric pressure (in-situ). Several plaques were also molded using air in the mold cavity and a number of these plaques were post treated with a fluorine containing gas while an untreated plaque was used as a control. The results from photoelectron spectroscopy (ESCA) for the control and treated plaques are reported in Table 1 below.

TABLE 1__________________________________________________________________________ Treatment Treatment Gas Mold Pressure Elemental Surface Composition %Material Method Composition (PSIG) C F O__________________________________________________________________________PP CONTROL AIR 0 95.4 0.0 3.1PP IN-SITU 1% F.sub.2 /AIR* 0 78.2 2.0 12.6PP IN-SITU 4% F.sub.2 /AIR** 0 88.3 3.6 6.9PP IN-SITU 10% F.sub.2 /N.sub.2 0 55.8 39.0 5.0PP IN-SITU 10% F.sub.2 /N.sub.2 54 43.5 53.4 2.9PP POST-TREAT 1% F.sub.2 /AIR 0 69.2 16.0 14.8PP POST-TREAT 2% F.sub.2 /AIR 0 69.4 16.6 14.0PP POST-TREAT 4% F.sub.2 /AIR 0 65.0 19.4 15.5HDPE CONTROL AIR 0 100.0 0.0 0.0HDPE IN-SITU 1% F.sub.2 /AIR 50 69.7 16.0 14.2HDPE IN-SITU 8% F.sub.2 /AIR 0 67.0 17.0 15.6HDPE IN-SITU 8% F.sub.2 /AIR 52 65.5 19.0 15.6HDPE IN-SITU 10% F.sub.2 /N.sub.2 0 65.4 31.8 2.8HDPE IN-SITU 10% F.sub.2 /N.sub.2 50 50.0 46.5 3.5HDPE POST-TREAT 10% F.sub.2 /N.sub.2 0 58.2 33.6 8.0__________________________________________________________________________ *Blending 1 part (10% F.sub.2 /N.sub.2) with 9 parts air. **Blending 2 parts (10% F.sub.2 /N.sub.2) with 3 parts air.

As can be seen from the ESCA results reported above, the injection molding process of the present invention results in alteration of the surface composition of the injection molded part. Surface alteration is observed for parts molded at 0 psig as well as for parts molded at increased pressures. Additionally, the concentration of oxygen on the surface indicates the presence of oxygen in the mold cavity even for runs using only an F.sub.2 /N.sub.2 treatment gas.

EXAMPLE 2

A high density polyethylene (HDPE) plaque was formed by injection molding plasticized HDPE into a mold cavity containing a reactive gas mixture containing about 4% by volume F.sub.2 and at least 20 ppm O.sub.2 at atmospheric mold pressure. The mold cavity was designed such that the flowing HDPE formed a weld line in the center of the plaque. Two other HDPE plaques were injection molded using the same mold and same resin, but with the cavity filled with air. One of these plaques was subsequently post treated with a gas stream containing 4% by volume F.sub.2. The injection rate in all instances was about 18 cm.sup.3 /sec and the HDPE used had a Melt Index of 30.

The plaques were tested for weld line strength and failure mode using Instron tenile test equipment, and the results are reported in Table 2 below.

TABLE 2______________________________________ Treat- Reactive Average StandardMa- ment Gas Failure Failure De-terial Method Concentration Mode Stress viation______________________________________HDPE None 0% Yield 4825 psi 50 psiHDPE in-situ 4% Break 3875 psi 175 psiHDPE Post- 4% Yield 4875 psi 25 psi treatment______________________________________

The results reported above indicate that the part which was injection molded in accordance with the present invention exhibited a clean, smooth break at the weld line interface, whereas both the untreated and post treated parts initially yielded at the weld line and exhibited a rough and irregular surface when they broke.

EXAMPLE 3

A second test was carried out to determine the failure mode and average failure stress of weld lines present in injected molded HDPE and also PP parts. The parts were injection molded into mold cavities having various reactive atmospheres as set out below. Additionally, a HDPE and a PP part were both injection molded using an air filled mold as controls. The HDPE had a melt index of 0.5 and the PP had a melt index of 12. The injection rate in all cases was about 18 cm.sup.3 /sec. The results are reported in Table 3 below.

TABLE 3______________________________________ Standard Average Deviation Failure Failure FailureMaterial Mold Gas Mode Stress Stress______________________________________HDPE Control (AIR) Yield 3582 psi 75 psiHDPE 4% F.sub.2 /Air Break 3006 95PP Control (Air) Yield 5104 46PP 1% F.sub.2 /Air Break 3281 627PP 2% F.sub.2 /Air Break 3047 644PP 4% F.sub.2 /Air Break Broke in Mold______________________________________

The results reported above are consistent with the results of Example 2 and indicate that the parts which were injection molded in accordance with the present invention showed a clean smooth break at the weld line, and did not exhibit yielding and stretching of the part close to the weld line as was observed with the controls.

EXAMPLE 4

Tests were carried out to compare the Lap Shear strength of bonded polypropylene plaques made in accordance with the present invention versus post-treated parts and a control part. Identically treated plaques were bonded together over one square inch of surface using a polyurethane adhesive and the force needed to separate the parts was measured. The results of this test, along with the specific treatment conditions employed are reported in Table 4 below.

TABLE 4__________________________________________________________________________ Sample 1 Sample 2Substrate Plaque Treatment Gas Gas Adhesive Shear.sup.(1) Failure.sup.(2) Shear.sup.(1) Failure.sup.(2) 7Material Dimensions Method Composition Pressure Type Strength Mode Strength Mode__________________________________________________________________________ PP.sup.(4) 1" .times. 2" .times. 1/4" IN-SITU AIR 0 PSIG PU.sup.(3) 0 A 12 APP 1" .times. 2" .times. 1/4" IN-SITU 1% F.sub.2 /AIR 0 PSIG PU 309 A 360 APP 1" .times. 2" .times. 1/4" IN-SITU 1% F.sub.2 /AIR 54 PSIG PU 679 S 568 APP 1" .times. 2" .times. 1/4" IN-SITU 2% F.sub.2 /AIR 0 PSIG PU 310 A 390 APP 1" .times. 2" .times. 1/4" IN-SITU 4% F.sub.2 /AIR 0 PSIG PU 369 A 315 APP 1" .times. 2" .times. 1/4" IN-SITU 1% F.sub.2 /N.sub.2 0 PSIG PU 260 A 288 APP 1" .times. 2" .times. 1/4" IN-SITU 1% F.sub.2 /N.sub.2 54 PSIG PU 842 S 468 APP 1" .times. 2" .times. 1/4" POST TREAT 1% F.sub.2 /AIR 0 PSIG PU 702 S 698 SPP 1" .times. 2" .times. 1/4" POST TREAT 2% F.sub.2 /AIR 0 PSIG PU 890 S 825 SPP 1" .times. 2" .times. 1/4" POST TREAT 4% F.sub.2 /AIR 0 PSIG PU 870 C 940 S PE.sup.(5) 1" .times. 2" .times. 1/8" IN-SITU AIR 0 PSIG PU 88 A 55 APE 1" .times. 2" .times. 1/8" IN-SITU 8% F.sub.2 /AIR 0 PSIG PU 359 S UnavailablePE 1" .times. 2" .times. 1/8" IN-SITU 8% F.sub.2 /AIR 52 PSIG PU 428 S 446 SPE 1" .times. 2" .times. 1/8" IN-SITU 10% F.sub.2 /N.sub.2 0 PSIG PU 474 S UnavailablePE 1" .times. 2" .times. 1/8" IN-SITU 10% F.sub.2 /N.sub.2 54 PSIG PU 450 S 443 SPE 1" .times. 2" .times. 1/8" IN-SITU AIR 0 PSIG EPOXY 85 A UnavailablePE 1" .times. 2" .times. 1/8" IN-SITU 8% F.sub.2 /AIR 52 PSIG EPOXY 132 S 148 SPE 1" .times. 2" .times. 1/8" IN-SITU 10% F.sub.2 /N.sub.2 0 PSIG EPOXY 117 S UnavailablePE 1" .times. 2" .times. 1/8" IN-SITU 10% F.sub.2 /N.sub.2 54 PSIG EPOXY 167 S 127 SPE 1" .times. 2" .times. 1/8" POST TREAT 8% F.sub.2 /AIR 0 PSIG EPOXY 115 S UnavailablePE 1" .times. 2" .times. 1/8" POST TREAT 10% F.sub.2 /N.sub.2 0 PSIG EPOXY 129 S Unavailable__________________________________________________________________________ .sup.(1) Shear strength reported as pounds per linear inch. .sup.(2) Failure Type A = Adhesive; C = Cohesive; S = Substrate .sup.(3) PU = Polyurethane .sup.(4) PP = Polypropylene .sup.(5) PE = Polyethylene

The results reported above indicate that in-situ treated polypropylene plaques bonded together with polyurethane exhibit improved shear strength over conventional injection molded parts. The in-situ treated polyethylene plaques bonded with either polyurethane or epoxy, exhibited a significant increase in shear strength to the extent that the failure mode exhibited was substrate failure rather than adhesive failure which was exhibited by conventional (untreated) injection molded parts. In some instances, such as polypropylene bonded with polyurethane, bonding strength improved significantly with increased mold pressure, even to the extent of improving the failure mode from adhesive failure to substrate failure.

EXAMPLE 5

Runs were carried out to compare the extent of fluorination of an injection molded high density polyethylene (HDPE) plaque treated in accordance with the present invention, with similar injection molded plaques which were post treated. The amount of fluorination was determined by ESCA analysis. The reaction conditions and results are reported in Table 5 below.

TABLE 5______________________________________ Treatment Contact Elemental AnalysisTreatment Conditions Time (ESCA)Method (% F.sub.2 /air) (SEC) C O F F/C______________________________________Control 0 0 100 0 0 0In-Situ 1 0.01 69.7 14.2 16.0 0.230Post 1 1 82.0 11.0 7.0 0.085Post 1 60 71.0 14.0 15.0 0.211______________________________________

The results reported above clearly show that in-situ treatment significantly increases the rate of fluorination over post treatment at a given fluorine concentration. In fact. the in-situ run (0.01 sec. contact time) showed a greater degree of fluorination than even the 60 sec post-treatment run; an increase of 6000 X the contact time. These results clearly demonstrate the superior performance of the present process.

EXAMPLE 6

A comparison was made between the performance of an in-situ fluorination blow molding process with the in-situ fluorination injection molding process of the present invention using a high concentration (i.e., 10%) of fluorine in the treatment gas.

Two blow molding runs were carried out as follows: polyethylene pellets having a density of 0.92 gm/cc were fed into a three-zone extruder having temperatures of 380.degree. F., 390.degree. F. and 400.degree. F. for the three zones, respectively. The resulting molten thermoplastic material was extruded through the parison extrusion die maintained at 410.degree. F. to form a parison. The parison was then enclosed within a mold and the bottom ends of the parison were sealed. The still molten parison was then expanded into the shape (a bottle) of the mold with a reactive gas mixture having a concentration of 10% fluorine in air for one run and 10% fluorine in nitrogen for a second run. The blowing time was six seconds. Air was passed through the bottle encased in the mold for approximately 15 seconds to cool the resulting bottle. It was observe that both bottles showed charring and were borderline between burning and non-burning, indicating that high fluorine concentrations are not desirable for such operations.

In-situ fluorination of injection molded parts was carried out under the same reactive gas compositions and at the same or even higher temperatures than the blow molding runs. No evidence of charring or burning was observed for any of the injection molding runs, thereby clearly indicating that, unlike in-situ fluorination blow molding, a high o fluorine concentration can be used, thereby assuring adequate fluorination over a relatively short period of time.

In summary, the results of the above Examples clearly show the unique and advantageous properties exhibited by injection molded thermoplastic parts made in accordance with the present invention. The parts exhibit smooth clean breaking at weld lines which is a useful property for ampules containing medicines, bottles with break-away caps, and for model parts connected to a common runner which must be separated from the runner when used. Additionally, the present process imparts improved bonding strength to the parts for substrate and coating adhesion.

Having thus described the present invention, what is now deemed appropriate for Letters Patent is set out in the following appended claims.

Claims

1. In a process for making shaped articles by injecting a thermoplastic or thermoset polymer into a mold cavity, the improvement for increasing coating adhesion and substrate bonding properties of the shaped articles which comprises:

maintaining in said mold cavity a reactive atmosphere containing between 0.1 mole % and 50 mole % F.sub.2 and at least 20 ppm O.sub.2 while said polymer is being injected into the mold cavity and injecting said polymer into the mold cavity at a rate such that any portion of the polymer contacts the reactive atmosphere for a period of time not exceeding 0.5 seconds.

2. A process in accordance with claim 1 wherein said atmosphere in the mold cavity contains at least 2 mole F.sub.2 %.

3. A process in accordance with claim 1 wherein the balance of the atmosphere in the mold cavity is inert gaseous components.

4. A process in accordance with claim 1 wherein the balance of the atmosphere in the mold cavity is air.

5. A process in accordance with claim 1 wherein the thermoplastic or thermoset polymer is a polyolefin.

6. A process in accordance with claim 1 wherein the pressure within the mold cavity is maintained between 20 and 60 psig.

7. A process in accordance with claim 1 wherein said atmosphere in the mold cavity contains at least 10 mole % F.sub.2.

8. A process for injection molding an article from a thermoplastic or thermoset polymer such that the resulting article has improved coating adhesion and substrate bonding properties, said process comprising:

(a) evacuating or displacing air or other gas from the cavity of a mold;

(b) introducing a reactive gas containing between 0.1 mole % and 50 mole % F.sub.2 into the mold cavity;

(c) plasticizing the thermoplastic polymer or blending the thermoset polymer; and

(d) injecting the resultant polymer into the mold cavity containing the reactive gas at a rate such that any portion of the polymer contacts the reactive gas for a period of time not exceeding 0.5 seconds.

9. A process in accordance with claim 8 wherein said polymer is plasticized by use of a reciprocating screw in conjunction with a source of heat.

10. A process in accordance with claim 8 wherein said reactive gas contains at least 2 mole % F.sub.2 in air.

11. A process in accordance with claim 8 wherein said polymer is a polyolefin.

12. A process in accordance with claim 8 wherein said mold cavity is pressurized to between 20 psig and 60 psig.

13. A process in accordance with claim 8 wherein said reactive gas contains at least 10 mole % F.sub.2 in air.

14. A process in accordance with claim 8 wherein the surface of said article has increased surface energy relative to an untreated article.

15. A process in accordance with claim 8 wherein said reactive gas also contains at least 20 ppm of O.sub.2.