CN103946009B - 具有中空部的热塑性树脂成型体及其制造方法 - Google Patents

具有中空部的热塑性树脂成型体及其制造方法 Download PDF

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Publication number
CN103946009B
CN103946009B CN201280056509.7A CN201280056509A CN103946009B CN 103946009 B CN103946009 B CN 103946009B CN 201280056509 A CN201280056509 A CN 201280056509A CN 103946009 B CN103946009 B CN 103946009B
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China
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thermoplastic resin
mould
manufacture method
resin forming
forming body
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Expired - Fee Related
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CN201280056509.7A
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CN103946009A (zh
Inventor
馆山胜
越政之
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Toray Industries Inc
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Toray Industries Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B29C51/105—Twin sheet thermoforming, i.e. deforming two parallel opposing sheets or foils at the same time by using one common mould cavity and without welding them together during thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/261—Handling means, e.g. transfer means, feeding means
    • B29C51/262—Clamping means for the sheets, e.g. clamping frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
    • B29C51/365—Porous moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/428—Heating or cooling of moulds or mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
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    • B29C66/72141—Fibres of continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
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Abstract

提供一种具有中空部的热塑性树脂成型体的制造方法、及通过该方法制造的具有1m2以上的上表面的表面积的热塑性树脂成型体，该方法的特征在于，将预先成型的由热塑性树脂形成的成型体A放置于第1模具上，通过利用真空压力使熔融了的热塑性树脂板B吸附在与第1模具相对的第2模具的内表面上而将该热塑性树脂板B赋形为沿着该第2模具的内表面的形状，通过将第1模具和第2模具合模，而仅在预先确定的区域将热塑性树脂板B和成型体A熔接，并且使非熔接区域的至少一部分形成为中空部。在薄壁大面积的树脂成型体结构、并且要求在一部分上形成中空结构的情况下，也能够容易地高效率且高精度地制造作为目标的结构的热塑性树脂成型体。

Description

具有中空部的热塑性树脂成型体及其制造方法
技术领域
本发明涉及具有中空部的热塑性树脂成型体及其制造方法，尤其涉及适合薄壁大面积且在一部分上具有中空结构部的大型成型体的、具有中空部的热塑性树脂成型体及其制造方法。
背景技术
作为将在至少一部分中具有中空结构部的树脂中空成型体一体成型的方法，公知有吹塑成型和气体辅助成型、模具滑动注射成型(dieslideinjection)等成型方法，但在任一种成型方法中，均难以将薄壁大面积且在一部分上具有中空结构部的成型体成型。另一方面，作为具有薄壁大面积的成型体的成型方法，公知有冲压成型或其他成型方法(例如，专利文献1～5)，但在这些以往的成型方法中，制作中空结构部极为困难。
因此，在薄壁大面积且在一部分上具有中空结构部的树脂成型体的成型中，将最终要成型的成型体的结构分割，首先成型被分割了的各部件，将经成型的各部件粘接或熔接，由此制造规定结构的成型体。但是，在这样的制造方法中，随着成型体的增大，在粘接的情况下需要大量时间，在熔接的情况下熔接设备成为不现实的规模，因此，强烈要求能够更容易地制造薄壁大面积且在一部分上具有中空结构部的成型体的技术。
专利文献1：日本特开平05－117411号公报
专利文献2：日本特开2004－142165号公报
专利文献3：日本特开平05－309724号公报
专利文献4：日本特开平05－185466号公报
专利文献5：国际公开2007/013385号公报
发明内容
因此，本发明的课题在于，为了满足上述这样的期望，提供一种即使是薄壁大面积的树脂成型体结构、并且要求在一部分中形成中空结构的情况下，也能够容易地高效率地且高精度地制造作为目标的结构的热塑性树脂成型体的技术。
为了解决上述课题，本发明的具有中空部的热塑性树脂成型体的制造方法由具有如下特征的方法构成，所述特征为，将预先成型的由热塑性树脂形成的成型体A放置于第1模具上，通过利用真空压力使熔融了的热塑性树脂板B吸附在与上述第1模具相对的第2模具的内表面上而将上述热塑性树脂板B赋形为沿着该第2模具的内表面的形状，通过将上述第1模具和上述第2模具合模，而仅在预先确定的区域将上述热塑性树脂板B和上述成型体A熔接，并且使非熔接区域的至少一部分形成为中空部。在此，在成型模具由上模和下模构成的情况下，只要作为上述第1模具而使用上模和下模中的任一方的模具、作为上述第2模具而使用另一方的模具即可。
在这样的本发明的具有中空部的热塑性树脂成型体的制造方法中，由热塑性树脂形成的成型体A预先成型为规定形状且放置于第1模具上，使热塑性树脂板B与该成型体A熔接。热塑性树脂板B在熔融了的状态下通过真空压力而被吸附在第2模具的内表面上，并通过该吸附而被赋形为沿着该第2模具的内表面的形状，并且，即使是薄壁大面积的热塑性树脂板B，也能够以紧贴第2模具的内表面的状态牢固且良好地被保持。与该赋形同时地或在赋形后，通过将第1模具和第2模具合模，而仅在预先确定的区域将热塑性树脂板B和成型体A熔接，并且使未熔接的非熔接区域的至少一部分形成为中空部。关于中空部，吸附在第2模具的内表面上而被赋形为沿着第2模具的内表面的形状且牢固地保持在第2模具的内表面上的热塑性树脂板B部分，相对于放置于第1模具上的成型体A部分具有间隔地被定位，两部分之间形成中空部。放置于第1模具上的成型体A、和吸附在第2模具的内表面上而被赋形为沿着第2模具的内表面的形状且牢固地保持在第2模具的内表面上的热塑性树脂板B，通过合模而在整体范围内被暂时高精度地定位，因此即使在要形成的中空部具有大面积的情况下、具有长尺寸的情况下、具有复杂的平面形状的情况下、在彼此不同的部位形成多个的情况下等，也能够高精度地容易地且在极短时间内高效率地形成所期望的中空部。另外，由于成型体A通过冲压成型等而预先成型，所以能够容易地高精度地成型为规定的薄壁形状，由于热塑性树脂板B在熔融了的状态下通过真空压力吸附在第2模具的内表面上，且通过该吸附而被赋形为沿着该第2模具的内表面的形状，所以能够容易地成型为薄壁形状，并且能够高精度地维持该薄壁形状直至合模完成。高精度地维持了规定的薄壁形状的热塑性树脂板B通过合模而与成型体A熔接，因此所形成的中空部也能够容易地形成为规定形状，能够在短时间内高效率且容易地制造以高精度实现了作为目标的形态的热塑性树脂成型体。
上述本发明的热塑性树脂成型体的制造方法也能够适用于成型体A及热塑性树脂板B均仅由树脂形成的情况，但为特别适合上述成型体A及热塑性树脂板B中、至少热塑性树脂板B由纤维增强热塑性树脂形成的情况的方法。当然，也适合于成型体A及热塑性树脂板B双方由纤维增强热塑性树脂形成的情况。在至少热塑性树脂板B由纤维增强热塑性树脂形成的情况下，在热塑性树脂板B以熔融了的状态通过真空压力被吸附在第2模具的内表面上时，通过增强纤维的存在而防止或抑制熔融且变为低粘度的树脂的变形或流下，即使是薄壁大面积的热塑性树脂板B，也能够更容易地边保持规定的吸附形态边进行合模。其结果是，能够使具有规定的中空部的热塑性树脂成型体的成型进一步容易化。即，能够容易地制造具有中空部的纤维增强热塑性树脂成型体。
在至少热塑性树脂板B由纤维增强热塑性树脂形成的情况下，作为该纤维增强热塑性树脂的增强纤维没有特别限定，例如可以使用选自碳纤维、玻璃纤维、芳族聚酰胺纤维中的至少一种增强纤维。也可以是这些增强纤维的、或者也包含其他增强纤维将两种以上的增强纤维共同使用的混合结构。
另外，作为纤维增强热塑性树脂的增强纤维的形态，例如可以采用不连续纤维。通过将不连续纤维用于增强纤维，能够容易地使熔融状态的热塑性树脂板B中的增强纤维的分散维持均匀状态，并且能够提高通过吸附使其沿着第2模具的内表面时的赋形性(悬垂性)，其结果是，能够有助于提高最终成型体的机械特性的均匀性和表面质量。
作为上述不连续纤维的重量平均纤维长度，优选10mm以上。若不足10mm，则存在作为增强纤维本来目的的提高成型体的机械特性的效果不充分的可能。另外，作为上述纤维增强热塑性树脂中的上述不连续纤维的含量，优选处于5～50重量％的范围。若含量比该范围少，则存在成型体的机械特性的提高效果变得过小的可能，若含量超过该范围，则存在难以进行向上模的内表面的高精度吸附的情况。
另一方面，作为上述纤维增强热塑性树脂的增强纤维，也可以使用连续纤维。当然，也可以采用上述这样的不连续纤维和连续纤维的组合形态。通过将连续纤维用作增强纤维，能够使增强纤维本身具有所期望的各向异性(例如特定方向的规定的机械特性)和形态保持性。另外，使用了由连续纤维形成的增强纤维的纤维增强树脂成型体在连续纤维的排列方向上能够体现高的机械特性，因此能够提高成型后的成型体的机械特性。
作为上述连续纤维，例如可以采用增强纤维由单向排列的连续纤维形成的形态。通过像这样使由连续纤维形成的增强纤维单向排列，能够特别提高该方向上的机械特性，能够实现与成型体的用途相应的更合适的设计。
另外，作为上述纤维增强热塑性树脂中的上述连续纤维的含量，优选处于1～80重量％的范围。若含量比该范围少，则存在成型体的机械特性的提高效果变得过小的可能，关于超过该范围的含量，即使在增强纤维由连续纤维形成的情况下，在现实中树脂量也变得过少，因此难以实现。
另外，作为上述纤维增强热塑性树脂的增强纤维，也可以采用织物的形态。作为织物的形态，可以使用利用辅助纱线将上述那样的单向排列的连续纤维编织而成的单向织物、或将连续增强纤维作为经纱、纬纱的织物等。通过形成织物的形态，能够使增强纤维本身具有形态保持性，因此能够更容易地将纤维增强热塑性树脂中的增强纤维的形态维持为目标形态。其结果是，能够更可靠地实现热塑性树脂板B的熔融前和熔融时的热塑性树脂板B的形态维持性能的提高、最终热塑性树脂成型体中的目标机械特性的达成。
另外，在上述热塑性树脂板B包含上述那样的由连续纤维形成的增强纤维的情况下，例如，作为该热塑性树脂板B，可以采用由预先通过热压将单向排列的增强纤维和热塑性树脂一体化而成的带状纤维增强热塑性树脂形成的形态。在这种由带状纤维增强热塑性树脂形成的热塑性树脂板B中，通过包含提高了操作性且单向排列的增强纤维，能够高效率地提高特定方向的机械特性，能够更容易地进行与成型体的用途相应的最优的设计。
在使用这种由带状纤维增强热塑性树脂形成的热塑性树脂板B的情况下，若考虑操作性和吸附于第2模具的内表面时的保持性、赋形性，则其带宽优选处于6～50mm的范围。
另外，在本发明的方法中，作为上述第2模具，优选使用具有用于从模腔内抽吸空气的微细孔的模具。特别是通过将多个微细孔配置在适当位置，即使是薄壁大面积的热塑性树脂板B，也能够更容易、且更可靠地使热塑性树脂板B吸附在第2模具的内表面上，从而使合模、进而使整体的成型变得容易。
另外，作为上述第1模具，也可以使用具有用于保持上述成型体A的抽吸微细孔的模具。这样的形态在使用上下模中的上模作为第1模具、且使成型体A保持于该上模的下表面侧的情况下尤其有效。
另外，在使热塑性树脂板B沿着上述第2模具的内表面而对其赋形、并将该热塑性树脂板B和成型体A熔接时，也可以在热塑性树脂板B的与上述第2模具的非接触面上层合热塑性树脂膜而对热塑性树脂板B赋形。特别是在如上述那样通过从微细孔抽吸而使热塑性树脂板B吸附在第2模具的内表面上的情况下，热塑性树脂板B的一部分成为多孔状而供抽吸用空气穿过，该部位的吸附有时可能会变得不充分，因此通过上述结构，能够容易地防止这样的不良情况的产生。
另外，在本发明的方法中，作为构成成型体A及热塑性树脂板B的树脂，没有特别限定，但作为优选的热塑性树脂，可以例示聚苯硫醚树脂、聚酰胺树脂、聚烯烃树脂、聚酯树脂、ABS树脂、聚碳酸酯树脂、聚缩醛树脂中的至少一种以上。
另外，在本发明的方法中，也可以边按压热塑性树脂板B的外周部边对热塑性树脂板B赋形。由此，能够高效率地防止在赋形时热塑性树脂板B产生不期望的错位，能够在相对于第2模具为相对期望的位置进行所希望的赋形。
另外，在本发明的方法中，也可以至少在上述第2模具的与上述熔接区域的至少一部分相对应的部位设置加热机构(例如埋设加热器)，利用基于该加热机构的加热进行上述熔接。当然，也可以在第1模具和第2模具双方上设置加热机构。若预先设置这样的加热机构，则热塑性树脂板B与成型体A的规定熔接容易化。另外，若将加热机构预先设于热塑性树脂板B的整个赋形区域范围内，则也能够在用于热塑性树脂板B的熔融的加热中使用，从而与赋形相关的一系列操作更加容易化。
本发明也提供通过上述这样的方法制造的、具有1m2以上的上表面的表面积的、具有中空部的热塑性树脂成型体。即，上述本发明的方法尤其适合薄壁大面积的热塑性树脂成型体的制造，尤其适合由热塑性树脂板B形成的上表面的表面积为1m2以上的大型的成型体的制造，本发明也提供这样的大型的、具有中空部的热塑性树脂成型体。作为这样的大型的、具有中空部的热塑性树脂成型体，例如可以例示车辆、尤其是汽车的无骨架式车身(monocoquebody)、大型的发动机罩(bonnet)、以及各种大型结构体的面板等。
根据本发明的具有中空部的热塑性树脂成型体及其制造方法，能够容易地在短时间内高效率、且高精度地制造薄壁大面积且在一部分上具有中空结构部的大型的热塑性树脂成型体。特别是，能够容易地制造至少热塑性树脂板B由纤维增强热塑性树脂形成的、薄壁大面积且在一部分上具有中空结构部的大型的热塑性树脂成型体。
附图说明
图1是表示本发明的一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图2是表示本发明的另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图3是表示本发明再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图4是表示本发明再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图5是表示本发明再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图6是表示本发明再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图7是表示本发明再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图8是表示本发明再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图9是表示本发明中的成型体A的保持方法的例子的概略结构图。
图10是表示本发明的再另一实施方式的热塑性树脂成型体的制造方法的工序流程图。
图11是表示本发明的再另一实施方式的热塑性树脂成型体的制造方法的模具的纵剖视图。
具体实施方式
以下，参照附图来说明用于实施本发明的具体方式。
需要说明的是，在图1～图8所示的实施方式中，例示了使用下模作为本发明中的第1模具、使用上模作为第2模具的方式，但也可以使用上模作为本发明中的第1模具、使用下模作为第2模具。图1示出了本发明的一实施方式的热塑性树脂成型体的制造方法的各工序。图1所示的工序(A)示出了预先成型的由热塑性树脂或纤维增强热塑性树脂形成的成型体A(1)的成型例。在该例中，成型体A(1)通过使用了预成型用的下模2和上模3的压力成型而预先成型。
将上述预先成型的成型体A(1)在工序(B)中放置于本发明的具有中空部的热塑性树脂成型体的制造方法中的作为第1模具的下模11上。该下模11也可以兼用作上述预成型用的下模2。对于在该具有中空部的热塑性树脂成型体的成型中使用的作为第2模具的上模12，使用具有用于从模腔内抽吸空气的多个微细孔13的模具，通过经由与各微细孔13连通的抽吸通路14、各微细孔13的抽吸，利用真空压力将熔融了的热塑性树脂板B(15)吸附在上模12的内表面上(工序(Ｃ))，通过该吸附而将熔融了的热塑性树脂板B(15)赋形为沿着上模12的内表面的形状。该热塑性树脂板B(15)可以仅由热塑性树脂构成，也可以由包含增强纤维的纤维增强热塑性树脂构成。
在进行上述热塑性树脂板B(15)的吸附、赋形的同时，或者在热塑性树脂板B(15)的吸附、赋形完成后，边维持该吸附状态边将上模12相对于下模11合模(工序(Ｄ))。通过该合模，处于熔融状态的热塑性树脂板B(15)和处于成型固化状态的成型体A(1)仅在预先确定的区域(仅在应接合的区域)被压接而被熔接，并且，非熔接区域的至少一部分形成为中空部16。之后，通过使处于熔融状态的热塑性树脂板B(15)冷却固化，具有中空部16的热塑性树脂成型体17的成型完成。
在这样的具有中空部的热塑性树脂成型体的制造方法中，熔融了的热塑性树脂板B(15)通过真空压力而吸附在上模12的内表面上，并通过该吸附而被赋形为沿着该上模12的内表面的形状，因此，能够容易地成型为薄壁的规定形状，并且，能够高精度地维持该薄壁的规定形状直至合模完成，因此也能够容易地形成作为目标的中空部，即使是薄壁大面积，也能够在短时间内高效率地容易地制造期望的具有中空部的热塑性树脂成型体。
上述本发明的具有中空部的热塑性树脂成型体的制造方法除上述图1所示的方式外，还可以采用例如图2～图8所示的各种方式。在图2所示的方式中，与图1所示的方式相比较，为了制造具有更多中空部、尤其是在中央部也具有中空部21的热塑性树脂成型体22，在预先成型的成型体A(23)的中央部预先形成有凹部24，将该成型体A(23)放置于下模25上(工序(A))，与图1所示相同地，通过真空压力将熔融了的热塑性树脂板B(15)吸附在上模12的内表面上而将该热塑性树脂板B(15)赋形为沿着上模12的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(15)仅在规定区域与成型体A(23)熔接(工序(Ｃ))。通过这样的成型，能够制造除中空部16外还具有中空部21的热塑性树脂成型体22。
另外，在图3所示的方式中，与图1所示的方式相比较，制造与图2所示的方式相同地在中央部也具有中空部31的热塑性树脂成型体32，但在本实施方式中，对于预先成型的成型体A(1)使用与图1所示相同的部件，将该成型体A(1)放置于下模11上(工序(A))。使用在内表面中央部具有凹部33的上模34，通过真空压力将熔融了的热塑性树脂板B(35)吸附在上模34的内表面上而将该热塑性树脂板B(35)赋形为沿着上模34的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(35)仅在规定区域与成型体A(1)熔接(工序(Ｃ))。为了通过真空压力使热塑性树脂板B(35)相对于上模34的内表面中央部的凹部33也良好地吸附，对于该部位，也适当配置用于从模腔内抽吸空气的微细孔36。通过这样的成型，能够制造除中空部16外在成型体上表面还具有凸状的中空部31的热塑性树脂成型体32。
另外，在图4所示的方式中，与图1所示的方式相比较，制造具有中空部41的热塑性树脂成型体42，该中空部41形成于成型体周边部，且在成型体上表面呈凸状地还向上方伸出。在本实施方式中，对于预先成型的成型体A(1)使用与图1所示相同的部件，将该成型体A(1)放置于下模11上(工序(A))。对于上模43，与图1所示的方式相比较，使用在与微细孔44相对应的模具内表面部位具有凹部45的部件，通过真空压力将熔融了的热塑性树脂板B(46)吸附在上模43的内表面上而将该热塑性树脂板B(46)赋形为沿着上模43的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(46)仅在规定区域与成型体A(1)熔接(工序(Ｃ))。通过这样的成型，能够制造具有更大的、且在成型体上表面侧呈凸状地伸出的中空部41的热塑性树脂成型体42。
另外，在图5所示的方式中，与图1所示的方式相比较，制造具有更大面积的中空部51的热塑性树脂成型体52。在本实施方式中，对于预先成型的成型体A(1)使用与图1所示相同的部件，将该成型体A(1)放置于下模11上(工序(A))。对于上模53，与图1所示的方式相比较，使用在模具内表面部位具有面积更大的凹部54、且对于该凹部54具有比图1所示的方式数量更多的微细孔55的部件，通过真空压力将熔融了的热塑性树脂板B(56)吸附在上模53的内表面上而将该热塑性树脂板B(56)赋形为沿着上模53的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(56)仅在规定区域(在图示例中仅在周边区域)与成型体A(1)熔接(工序(Ｃ))。通过这样的成型，能够制造具有更大面积的中空部51的热塑性树脂成型体52。
另外在图6所示的方式中，与图5所示的方式相比较，制造将大面积的图5的中空部51分割为中空部61a和中空部61b的形态的热塑性树脂成型体62。在本实施方式中，在预先成型的成型体A(63)的中央部上表面预先形成有凸部64，在具有与该凸部64相对应的形状的上表面凸部65的下模66上放置成型体A(63)(工序(A))。对于上模53，使用与图5所示的方式相同的部件，通过真空压力将熔融了的热塑性树脂板B(56)吸附在上模53的内表面上而将该热塑性树脂板B(56)赋形为沿着上模53的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(56)仅在规定区域(在图示例中仅在周边区域和中央部的区域)与成型体A(63)熔接(工序(Ｃ))。通过这样的成型，能够制造具有大面积的被分割的中空部61a、61b的热塑性树脂成型体62。
另外，在图7所示的方式中，与图2所示的方式相比较，制造将中央部的中空部71更大面积地形成的热塑性树脂成型体72。在本实施方式中，在预先成型的成型体A(73)的中央部上表面预先形成有与图2所示的相比为更大面积的凹部74，在具有与该凹部74相对应的形状的上表面凹部的下模75上放置成型体A(73)(工序(A))。对于上模53，使用与图5所示的方式相同的部件，通过真空压力将熔融了的热塑性树脂板B(56)吸附在上模53的内表面上而将该热塑性树脂板B(56)赋形为沿着上模53的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(56)仅在规定区域(在图示例中仅在外边区域和中央部的周边区域)与成型体A(73)熔接(工序(Ｃ))。通过这样的成型，能够制造具有中央部的中空部71和周边部的中空部76的热塑性树脂成型体72。
在图8所示的方式中，与图1所示的方式相比较，将预先成型的成型体A(81)预先形成为平板状，将该成型体A(81)放置于上表面为平面的下模82上(工序(A))，与图1所示相同地，通过真空压力将熔融了的热塑性树脂板B(15)吸附在上模12的内表面上而将该热塑性树脂板B(15)赋形为沿着上模12的内表面的形状(工序(B))，通过合模使该热塑性树脂板B(15)仅在规定区域(在图示例中仅在周边区域)与成型体A(81)熔接(工序(Ｃ))。通过这样的成型，能够制造在中央部形成有大面积的中空部83的热塑性树脂成型体84。
像这样，本发明的具有中空部的热塑性树脂成型体及其制造方法可以采用各种方式，也可以采用上述图示例以外的方式。
需要说明的是，在本发明中，作为将上述成型体A保持于第1模具上的方法，可以适当地适用各种方法。例如，在图9中例示了使用上模91作为第1模具的情况，如图9(A)所示，设置用于通过真空抽吸将成型体A(92)吸附保持于上模91的下表面上的抽吸孔93，利用真空泵96从各抽吸孔93通过抽吸通路94、真空线路95而进行抽吸，由此能够将成型体A(92)可靠地保持为规定形态。另外，如图9(B)所示，也可以为，在上模91的下表面的适当部位粘贴胶带97，经由胶带97将成型体A(92)可靠地保持为规定形态。另外，如图9(Ｃ)所示，也可以为，例如在上模91的两内侧面上适当地预先设置小的根切(undercut)部98，通过该根切部98将成型体A(92)相对于上模91保持为规定形态。另外，也可以采用除这些图示例以外的保持方法。
另外，也可以为，例如如图10所示，使用上模101作为第1模具，使用下模102作为第2模具，设置用于通过真空抽吸将成型体A(103)吸附保持在上模101的下表面上的微细孔104，从各微细孔104通过抽吸通路105、真空线路106进行抽吸，从而将成型体A(103)保持为规定形态，在下模102上预先设置用于通过真空压力将熔融了的热塑性树脂板B(107)吸附在下模102的表面上的微细孔108、抽吸通路109(工序(A))。对相对于下模102配置在规定位置的热塑性树脂板B(107)，设置按压其外周部的按压机构110，边利用该按压机构110按压热塑性树脂板B(107)的外周部(工序(B))边通过微细孔108、抽吸通路109、真空线路111进行抽吸，从而对热塑性树脂板B(107)进行抽吸，由此使热塑性树脂板B(107)沿着下模102的表面而对其赋形(工序(Ｃ))。通过合模使被赋形后的热塑性树脂板B(107)仅在规定区域(在图示例中为仅周边区域)与成型体A(103)熔接(工序(Ｄ))，能够制造形成有中空部112的热塑性树脂成型体113。
另外可以为，例如如图11所示，在通过作为第1模具的上模121与作为第2模具的下模122的合模，使成型体A(123)和热塑性树脂板B(124)在规定区域熔接，从而制造具有中空部125的热塑性树脂成型体126时，可以特别地在下模122的与上述熔接区域的至少一部分相对应的部位设置作为加热机构的加热器127，利用基于该加热器127的加热而进行上述熔接。如前所述，由于加热器127还用于热塑性树脂成型体126的熔融，所以该加热器127可以设置在下模122的更大的区域、例如实质上为整个区域的范围内。同样地，也可以在上模121的与上述熔接区域的至少一部分相对应的部位、进而在更大的区域、例如实质上为整个区域的范围内，设置作为加热机构的加热器128。
工业实用性
本发明的具有中空部的热塑性树脂成型体及其制造方法尤其适合薄壁大面积且在一部分上具有中空结构部的大型的成型体，例如适合汽车的无骨架式车身、大型的发动机罩、以及各种大型结构体的面板等。
附图标记说明
1、23、63、73、81、103、123成型体A
2、11、25、66、75、82作为第1模具的下模
3、12、34、43、53作为第2模具的上模
13、36、44、55、104、108微细孔
14、105、109抽吸通路
15、35、46、56、107、124热塑性树脂板B
16、21、31、41、51、61a、61b、71、76、83、112、125中空部
17、22、32、42、52、62、72、84、113、126热塑性树脂成型体
24、33、45、54、74凹部
64凸部
65上表面凸部
91、101、121作为第1模具的上模
92成型体A
93抽吸孔
94抽吸通路
95、106、111真空线路
96真空泵
97胶带
98根切部
102、122作为第2模具的下模
110按压机构
127、128作为加热机构的加热器

Claims (19)

1.一种具有中空部的热塑性树脂成型体的制造方法，其特征在于，将预先成型的由热塑性树脂形成的成型体A放置于第1模具上，通过利用真空压力使熔融了的热塑性树脂板B吸附在与所述第1模具相对的第2模具的内表面上而将所述热塑性树脂板B赋形为沿着所述第2模具的内表面的形状，通过将所述第1模具和所述第2模具合模，而仅在预先确定的区域将所述热塑性树脂板B和所述成型体A熔接，并且使非熔接区域的至少一部分形成为中空部。
2.如权利要求1所述的热塑性树脂成型体的制造方法，其中，所述成型体A及热塑性树脂板B中的至少热塑性树脂板B由纤维增强热塑性树脂形成。
3.如权利要求2所述的热塑性树脂成型体的制造方法，其中，所述纤维增强热塑性树脂的增强纤维是选自碳纤维、玻璃纤维、芳族聚酰胺纤维中的至少一种。
4.如权利要求2或3所述的热塑性树脂成型体的制造方法，其中，所述纤维增强热塑性树脂的增强纤维由不连续纤维形成。
5.如权利要求4所述的热塑性树脂成型体的制造方法，其中，所述不连续纤维的重量平均纤维长度为10mm以上。
6.如权利要求4所述的热塑性树脂成型体的制造方法，其中，所述纤维增强热塑性树脂中的所述不连续纤维的含量处于5～50重量％的范围。
7.如权利要求2或3所述的热塑性树脂成型体的制造方法，其中，所述纤维增强热塑性树脂的增强纤维由连续纤维形成。
8.如权利要求7所述的热塑性树脂成型体的制造方法，其中，所述增强纤维由单向排列的连续纤维形成。
9.如权利要求7所述的热塑性树脂成型体的制造方法，其中，所述纤维增强热塑性树脂中的所述连续纤维的含量处于1～80重量％的范围。
10.如权利要求7所述的热塑性树脂成型体的制造方法，其中，所述纤维增强热塑性树脂的增强纤维由织物形成。
11.如权利要求7所述的热塑性树脂成型体的制造方法，其中，所述热塑性树脂板B由预先通过热压将单向排列的增强纤维和热塑性树脂一体化而成的带状纤维增强热塑性树脂形成。
12.如权利要求11所述的热塑性树脂成型体的制造方法，其中，所述带状纤维增强热塑性树脂的带宽处于6～50mm的范围。
13.如权利要求1所述的热塑性树脂成型体的制造方法，其中，作为所述第2模具，使用具有用于从模腔内抽吸空气的微细孔的模具。
14.如权利要求1所述的热塑性树脂成型体的制造方法，其中，作为所述第1模具，使用具有用于保持所述成型体A的抽吸微细孔的模具。
15.如权利要求13或14所述的热塑性树脂成型体的制造方法，其中，在热塑性树脂板B的与所述第2模具的非接触面上层合热塑性树脂膜而对热塑性树脂板B赋形。
16.如权利要求1所述的热塑性树脂成型体的制造方法，其中，构成成型体A及热塑性树脂板B的热塑性树脂由聚苯硫醚树脂、聚酰胺树脂、聚烯烃树脂、聚酯树脂、ABS树脂、聚碳酸酯树脂、聚缩醛树脂中的至少一种以上形成。
17.如权利要求1所述的热塑性树脂成型体的制造方法，其中，边按压热塑性树脂板B的外周部边对热塑性树脂板B赋形。
18.如权利要求1所述的热塑性树脂成型体的制造方法，其中，至少在所述第2模具的与所述熔接区域的至少一部分相对应的部位设置加热机构，利用基于所述加热机构的加热而进行所述熔接。
19.一种具有中空部的热塑性树脂成型体，其通过权利要求1～18中任一项所述的方法而制造，且具有1m2以上的上表面的表面积。
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