JP2006181910A - Plastic laminate and its manufacturing method - Google Patents

Plastic laminate and its manufacturing method Download PDF

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JP2006181910A
JP2006181910A JP2004379069A JP2004379069A JP2006181910A JP 2006181910 A JP2006181910 A JP 2006181910A JP 2004379069 A JP2004379069 A JP 2004379069A JP 2004379069 A JP2004379069 A JP 2004379069A JP 2006181910 A JP2006181910 A JP 2006181910A
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plastic
pressing
base material
shape
layer sheet
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Jun Watabe
順 渡部
Yasuki Sugimoto
泰規 杉本
Yasutomo Aman
康知 阿萬
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Ricoh Co Ltd
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Ricoh Co Ltd
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<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a plastic laminate of high precision such as a large-sized plastic mirror or the like, and the plastic laminate. <P>SOLUTION: In a plastic laminate manufacturing apparatus 1, a plastic base material 10 preliminarily processed into an almost final shape and a surface layer sheet 12 are arranged between a transfer piece 6 having a transfer surface 8 processed into a final shape and a pressure member 7 so as to hold an intermediate member 11 comprising a thermoplastic resin to move the pressure member 7 not only to press the surface layer sheet 12 to the transfer surface 8 of the transfer piece 6 by the plastic base material 10 pressed by the pressure member 7 but also to soften the intermediate member 11. The plastic base material 10, the intermediate member 11 and the surface layer sheet 12 are closely and integrally bonded to be formed into the shape of the transfer surface 8 by correction processing but a pressurizing protruded part 13 is formed on the back 10b on the pressure side of the plastic base material 10 and the pressure member 7 is brought into contact only with the pressurizing protruded part 13 to press the plastic base material 10. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、プラスチック積層体の製造方法及びプラスチック積層体に関し、詳細には、大型プラスチックミラー等の高精度なプラスチック積層体の製造方法及びプラスチック積層体に関する。   The present invention relates to a method for producing a plastic laminate and a plastic laminate, and more particularly to a method for producing a highly accurate plastic laminate such as a large plastic mirror and a plastic laminate.

複写機、レーザプリンタ等の光走査に用いられるfθミラー、プロジェクションテレビ等の光路屈曲用の大型ミラー、フライトシュミレータやアミューズメント用途の画像表示に用いられる大型ミラーには、軽量化、低コスト化、多品種少量生産に対応するため等の理由により、プラスチック製のミラーが多用されてきている。   The fθ mirror used for optical scanning of copying machines, laser printers, etc., large mirrors for bending optical paths such as projection televisions, and large mirrors used for image display for flight simulators and amusement applications are light weight, low cost, and many Plastic mirrors have been frequently used for reasons such as low-mix production.

また、大型ミラーは、その形状精度を維持するために剛性が必要であり、一般的な外装部品と比較して、肉厚となっている。   Further, the large mirror needs rigidity in order to maintain its shape accuracy, and is thicker than a general exterior part.

このようなプラスチック製のミラーの製造方法としては、従来、製造コストが低く、大量生産に適した射出成形方法が用いられ、成形後に真空蒸着によって金属反射膜が形成されることで、製造されている。   As a manufacturing method of such a plastic mirror, conventionally, an injection molding method that is low in manufacturing cost and suitable for mass production is used, and is manufactured by forming a metal reflective film by vacuum deposition after molding. Yes.

そして、射出成形法においては、加熱溶融した樹脂材料を金型内に射出充填した後、冷却固化させるが、この冷却工程において、金型内の樹脂圧力や樹脂温度を均一に保つことで、所望の形状精度を確保することができる。   In the injection molding method, the heat-melted resin material is injected and filled into the mold, and then cooled and solidified. In this cooling step, the resin pressure and the resin temperature in the mold are kept uniform, and desired. The shape accuracy can be ensured.

ところが、プロジェクションテレビ等の光路屈曲用のミラー、フライトシュミレータやアミューズメント用途の画像表示に用いられる大型ミラーのように、製造対象のミラーの形状が厚肉で、大型になると、ミラーの中心部と周辺部で冷却速度が異なり、体積収縮量が異なったものとなって、ひけが生じたり、形状精度が悪化するという問題があった。   However, if the shape of the mirror to be manufactured is thick and large, such as a mirror for bending an optical path such as a projection TV, a large mirror used for image display for a flight simulator or amusement, the center and the periphery of the mirror There are problems that the cooling rate is different at each part and the volume shrinkage is different, which causes sink marks and the shape accuracy deteriorates.

また、ミラーを製造する場合、従来、射出成形したプラスチック成形体に、金属反射膜を形成することで、ミラーを製造している。そして、この金属反射膜の形成は、通常、成形後に、真空蒸着によるバッチ処理で行われているため、プラスチック成形体の加工設備に加えて、さらに、別に、金属反射膜を形成するための蒸着設備が必要になるだけでなく、金属反射膜を形成する対象の形状が大きくなると、1バッチあたりの取り数が少なくなり、蒸着コストが大きくなるとう問題も生じる。   When manufacturing a mirror, conventionally, a mirror is manufactured by forming a metal reflective film on an injection molded plastic molded body. And since the formation of this metal reflective film is usually performed by batch processing by vacuum deposition after molding, in addition to the processing equipment for plastic molded bodies, vapor deposition for forming a metal reflective film is also separately provided. In addition to the need for equipment, if the shape of the object on which the metal reflective film is to be formed increases, the number of batches per batch decreases and the deposition cost increases.

そこで、本出願人は、先に、予め略最終形状に加工されたプラスチック母材と、反射膜の形成されたプラスチックフィルムとを金型キャビティ内に挿入した後、金型をプラスチック母材のガラス転移温度以上に加熱し、樹脂内圧を発生させてフィルム表面に金型鏡面を転写させ、金型を徐冷してプラスチック母材が熱変形温度以下になった後に取り出すプラスチックミラーの製造方法及びその製造装置及びプラスチック成形品の製造方法を提案している(特許文献1参照)。   Therefore, the applicant first inserts a plastic base material, which has been processed into a substantially final shape in advance, and a plastic film on which a reflective film is formed into the mold cavity, and then inserts the mold into the glass of the plastic base material. A method of manufacturing a plastic mirror that is heated to a temperature higher than the transition temperature, generates an internal pressure of the resin, transfers the mold mirror surface to the film surface, slowly cools the mold, and is taken out after the plastic base material is lower than the thermal deformation temperature, and its The manufacturing apparatus and the manufacturing method of a plastic molded product are proposed (refer patent document 1).

特開平6−182783号公報Japanese Patent Laid-Open No. 6-182783

しかしながら、上記従来技術にあっては、プラスチック母材をガラス転移温度以上から熱変形温度までゆっくりさせることで加工時の温度分布や圧力分布が生じることなく高精度な面転写を実現するとともに、プラスチックフィルムに予め金属反射膜を形成しておくことで蒸着コストを低減しているが、熱容量の大きいプラスチック母材自体をガラス転移温度以上に加熱し、その後、熱変形温度以下までゆっくりと冷却するといった工程が必要であるため、加工時間が長くなり、生産性を向上させる上で改良の必要があった。   However, in the above prior art, by making the plastic base material slowly from the glass transition temperature to the heat distortion temperature, high-accuracy surface transfer can be realized without causing temperature distribution or pressure distribution during processing. Although the deposition cost is reduced by forming a metal reflective film on the film in advance, the plastic base material itself having a large heat capacity is heated to the glass transition temperature or higher, and then slowly cooled to the heat deformation temperature or lower. Since the process is necessary, the processing time becomes long, and it is necessary to improve the productivity.

そこで、本発明は、均一な圧力をプラスチック基材全域に付加できるようにして、プラスチック積層体を高精度に製造することのできるプラスチック積層体の製造方法及び当該製造方法で製造するプラスチック積層体を提供することを目的としている。   Therefore, the present invention provides a method for producing a plastic laminate capable of producing a plastic laminate with high accuracy by applying a uniform pressure to the entire plastic substrate, and a plastic laminate produced by the production method. It is intended to provide.

請求項1記載の発明のプラスチック積層体の製造方法は、最終形状に加工された転写面の形成されている型部材と当該型部材に対して相対向する状態で配設されている加圧部材との間に、予め略最終形状に加工されたプラスチック基材と予め所望の機能膜の形成されている表層シートを、熱可塑性樹脂からなる中間部材を間に挟んで当該表層シートが前記型部材側に位置する状態で配設して、前記型部材と前記加圧部材を相対移動させて、当該加圧部材で押圧される前記プラスチック基材が前記表層シートを前記型部材の前記転写面に押圧するとともに、少なくとも前記中間部材を当該中間部材の軟化温度以上に加熱して軟化させて、前記プラスチック基材、前記中間部材及び前記表層シートを密着一体化させるとともに、前記転写面形状に補正加工するプラスチック積層体の製造方法であって、前記加圧部材と前記プラスチック基材は、少なくとも一方が他方側に突出した凸面形状であって、当該他方側が当該凸面形状と対応する凹面形状であり、当該凸面形状の頂点部分と当該凹面形状の底部分とが所定の当接面積を有する所定の部分押圧端部で当接して、前記加圧部材が前記プラスチック基材を押圧することにより、上記目的を達成している。   The method for producing a plastic laminate according to the first aspect of the present invention includes a mold member having a transfer surface formed into a final shape and a pressure member disposed in a state of being opposed to the mold member. Between the intermediate member made of a thermoplastic resin and the surface layer sheet in which a desired functional film is formed in advance, and the surface layer sheet is the mold member The plastic substrate pressed by the pressure member is disposed on the transfer surface of the mold member by being relatively moved between the mold member and the pressure member. While pressing, at least the intermediate member is heated and softened to a temperature equal to or higher than the softening temperature of the intermediate member, and the plastic base material, the intermediate member, and the surface layer sheet are brought into close contact and integrated into the transfer surface shape. A method of manufacturing a plastic laminate to be processed normally, wherein the pressure member and the plastic substrate have a convex shape in which at least one protrudes to the other side, and the other side has a concave shape corresponding to the convex shape. Yes, the convex shape apex portion and the concave bottom portion are in contact at a predetermined partial pressing end portion having a predetermined contact area, and the pressure member presses the plastic substrate, The above objective has been achieved.

この場合、例えば、請求項2に記載するように、前記部分押圧端部は、前記プラスチック基材の前記加圧部材側の面に前記加圧部材方向に所定量突出して形成された押圧凸部であってもよい。   In this case, for example, as described in claim 2, the partial pressing end portion is a pressing convex portion formed by protruding a predetermined amount in the pressing member direction on the surface of the plastic substrate on the pressing member side. It may be.

また、例えば、請求項3に記載するように、前記部分押圧端部は、前記加圧部材の前記プラスチック基材側の面に前記プラスチック基材方向に所定量突出して形成された押圧凸部であってもよい。   For example, as described in claim 3, the partial pressing end portion is a pressing convex portion formed by protruding a predetermined amount in the direction of the plastic substrate on the surface of the pressing member on the plastic substrate side. There may be.

さらに、例えば、請求項4に記載するように、前記押圧凸部は、その先端部が所定の曲率を有した曲面に形成されていてもよい。   Further, for example, as described in claim 4, the pressing convex portion may be formed in a curved surface having a predetermined curvature at a tip portion thereof.

また、例えば、請求項5に記載するように、前記加圧部材または前記プラスチック基材は、前記加圧時に前記押圧凸部の進入する凹部が形成されていてもよい。   For example, as described in claim 5, the pressurizing member or the plastic base material may be formed with a recess into which the pressing convex portion enters during the pressurization.

さらに、例えば、請求項6に記載するように、前記押圧凸部は、その高さが前記凹部の深さよりも所定量だけ高く形成されていてもよい。   Further, for example, as described in claim 6, the pressing convex portion may be formed such that the height thereof is higher by a predetermined amount than the depth of the concave portion.

また、例えば、請求項7に記載するように、前記押圧凸部と前記凹部は、当該押圧凸部の先端部に先端ほどその先端方向に対して直交する方向の断面面積が小さくなる傾斜面と当該凹部の開口側端部に開口側ほどその開口面積が大きくなる傾斜面のうち、少なくとも一方が形成されていてもよい。   For example, as described in claim 7, the pressing convex portion and the concave portion are inclined surfaces in which a cross-sectional area in a direction orthogonal to the distal end direction becomes smaller toward the distal end portion of the pressing convex portion. At least one of the inclined surfaces whose opening area increases toward the opening side may be formed at the opening side end of the concave portion.

さらに、例えば、請求項8に記載するように、前記プラスチック基材は、射出成形法で作製されていてもよい。   Further, for example, as described in claim 8, the plastic substrate may be produced by an injection molding method.

また、例えば、請求項9に記載するように、前記プラスチック基材は、繊維等の強化充填材を含む非プラスチック複合材料で作製されていてもよい。   For example, as described in claim 9, the plastic substrate may be made of a non-plastic composite material including a reinforcing filler such as a fiber.

請求項10記載の発明のプラスチック積層体は、最終形状に加工された転写面の形成されている型部材と当該型部材に対して相対向する状態で配設されている加圧部材との間に、予め略最終形状に加工されたプラスチック基材と予め所望の機能膜の形成されている表層シートが、熱可塑性樹脂からなる中間部材を間に挟んで当該表層シートが前記型部材側に位置する状態で配設され、前記型部材と前記加圧部材が相対移動されて、当該加圧部材によって押圧される前記プラスチック基材が前記表層シートを前記型部材の前記転写面に押圧するとともに、少なくとも前記中間部材が当該中間部材の軟化温度以上に加熱されて軟化して、前記プラスチック基材、前記中間部材及び前記表層シートが密着一体化されるとともに、前記転写面形状に補正加工されて製造されるプラスチック積層体であって、請求項1から請求項9のいずれかに記載のプラスチック積層体の製造方法で製造されていることにより、上記目的を達成している。   According to a tenth aspect of the present invention, there is provided a plastic laminate between a mold member formed with a transfer surface processed into a final shape and a pressure member disposed in a state of facing the mold member. In addition, a surface layer sheet on which a plastic base material previously processed into a substantially final shape and a desired functional film are formed is positioned on the mold member side with an intermediate member made of a thermoplastic resin in between. The mold member and the pressure member are relatively moved, and the plastic substrate pressed by the pressure member presses the surface sheet against the transfer surface of the mold member. At least the intermediate member is heated and softened to a temperature equal to or higher than the softening temperature of the intermediate member, and the plastic base material, the intermediate member, and the surface layer sheet are closely integrated with each other, and the shape of the transfer surface is compensated. A plastic laminate produced are processed, by being manufactured by the manufacturing method for a plastic laminate according to any one of claims 1 to 9, have achieved the above objects.

この場合、例えば、請求項11に記載するように、前記表層シートは、前記機能膜として、予め金属反射膜が形成されていてもよい。   In this case, for example, as described in claim 11, a metal reflective film may be formed in advance on the surface layer sheet as the functional film.

本発明のプラスチック積層体の製造方法によれば、最終形状に加工された転写面の形成されている型部材と当該型部材に対して相対向する状態で配設されている加圧部材との間に、予め略最終形状に加工されたプラスチック基材と予め所望の機能膜の形成されている表層シートを、熱可塑性樹脂からなる中間部材を間に挟んで当該表層シートが型部材側に位置する状態で配設して、型部材と加圧部材を相対移動させて、当該加圧部材によって押圧されるプラスチック基材が表層シートを型部材の転写面に押圧するとともに、少なくとも中間部材を当該中間部材の軟化温度以上に加熱して軟化させて、プラスチック基材、中間部材及び表層シートを密着一体化させるとともに、転写面形状に補正加工するに際して、加圧部材とプラスチック基材を、少なくとも一方が他方側に突出した凸面形状であって、当該他方側が当該凸面形状と対応する凹面形状とし、当該凸面形状の頂点部分と当該凹面形状の底部分とを、所定の当接面積を有する所定の部分押圧端部で当接させて、加圧部材でプラスチック基材を押圧させているので、均一な圧力をプラスチック基材全域に付加することができ、プラスチック積層体を高精度に製造することができる。   According to the method for producing a plastic laminate of the present invention, a mold member on which a transfer surface processed into a final shape is formed and a pressure member disposed in a state of facing the mold member. A surface layer sheet, which is previously formed into a substantially final shape and a surface layer sheet on which a desired functional film is formed, is positioned on the mold member side with an intermediate member made of a thermoplastic resin in between. The plastic member pressed by the pressure member presses the surface layer sheet against the transfer surface of the mold member, and at least the intermediate member is moved. When the softening temperature is raised above the softening temperature of the intermediate member to soften the plastic base material, the intermediate member and the surface layer sheet, and the correction processing to the transfer surface shape, the pressure member and the plastic base material And at least one is a convex shape protruding to the other side, and the other side is a concave shape corresponding to the convex shape, and the apex portion of the convex shape and the bottom portion of the concave shape have a predetermined contact area. Since the plastic base material is pressed by the pressure member by contacting with the predetermined partial pressing end, it is possible to apply uniform pressure to the entire area of the plastic base material and manufacture the plastic laminate with high accuracy. can do.

本発明のプラスチック積層体によれば、最終形状に加工された転写面の形成されている型部材と当該型部材に対して相対向する状態で配設されている加圧部材との間に、予め略最終形状に加工されたプラスチック基材と予め所望の機能膜の形成されている表層シートが、熱可塑性樹脂からなる中間部材を間に挟んで当該表層シートが前記型部材側に位置する状態で配設され、前記型部材と前記加圧部材が相対移動されて、当該加圧部材によって押圧される前記プラスチック基材が前記表層シートを前記型部材の前記転写面に押圧するとともに、少なくとも前記中間部材が当該中間部材の軟化温度以上に加熱されて軟化して、前記プラスチック基材、前記中間部材及び前記表層シートが密着一体化されるとともに、前記転写面形状に補正加工されて製造されるプラスチック積層体を、請求項1から請求項9のいずれかに記載のプラスチック積層体の製造方法で製造しているため、高精度なものとすることができる。   According to the plastic laminate of the present invention, between the mold member on which the transfer surface processed into the final shape is formed and the pressure member disposed in a state facing the mold member, A state in which a surface layer sheet on which a plastic base material previously processed into a substantially final shape and a desired functional film are formed is positioned on the mold member side with an intermediate member made of a thermoplastic resin interposed therebetween The mold member and the pressure member are relatively moved, and the plastic substrate pressed by the pressure member presses the surface sheet against the transfer surface of the mold member, and at least the The intermediate member is heated and softened above the softening temperature of the intermediate member, and the plastic base material, the intermediate member, and the surface layer sheet are intimately integrated and corrected to the transfer surface shape. The plastic laminate produced Te, because it produced by the production process of the plastic laminate according to any one of claims 1 to 9, can be made highly accurate.

以下、本発明の好適な実施例を添付図面に基づいて詳細に説明する。なお、以下に述べる実施例は、本発明の好適な実施例であるから、技術的に好ましい種々の限定が付されているが、本発明の範囲は、以下の説明において特に本発明を限定する旨の記載がない限り、これらの態様に限られるものではない。   Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In addition, since the Example described below is a suitable Example of this invention, various technically preferable restrictions are attached | subjected, However, The scope of the present invention limits this invention especially in the following description. As long as there is no description of the effect, it is not restricted to these aspects.

図1〜図15は、本発明のプラスチック積層体の製造方法及びプラスチック積層体の第1実施例を示す図であり、図1は、本発明のプラスチック積層体の製造方法及びプラスチック積層体の第1実施例を適用したプラスチック積層体製造装置1の正面概略構成図である。   1 to 15 are views showing a plastic laminate manufacturing method and a plastic laminate according to a first embodiment of the present invention. FIG. 1 shows a plastic laminate manufacturing method and a plastic laminate of the present invention. It is a front schematic block diagram of the plastic laminated body manufacturing apparatus 1 to which one Example is applied.

図1において、プラスチック積層体製造装置1は、下側ダイプレート2、上側ダイプレート3及びタイバー4を有したプレス機5を備えており、プレス機5は、下側ダイプレート2に対して鉛直方向に延在する状態でタイバー4が設置されていて、上側ダイプレート3が、タイバー4に沿って上下方向に移動可能となっていて、下側ダイプレート2との間に所定の圧力を付加することができる構造となっている。なお、プレス機5は、上側ダイプレート3が移動する場合だけでなく、下側ダイプレート2が移動してもよく、また、下側ダイプレート2と上側ダイプレート3の双方が移動するようになっていてもい。   In FIG. 1, the plastic laminate manufacturing apparatus 1 includes a press machine 5 having a lower die plate 2, an upper die plate 3 and a tie bar 4, and the press machine 5 is perpendicular to the lower die plate 2. The tie bar 4 is installed in a state extending in the direction, and the upper die plate 3 is movable in the vertical direction along the tie bar 4, and a predetermined pressure is applied to the lower die plate 2. It has a structure that can do. Note that the press machine 5 may move not only when the upper die plate 3 moves but also when the lower die plate 2 moves, and so that both the lower die plate 2 and the upper die plate 3 move. It does not matter.

そして、下側ダイプレート2には、転写駒(型部材)6が固定されており、上側ダイプレート3には、加圧部材7が固定されている。加圧部材7の転写駒6に対向する側の面は、所望の最終形状の凸面形状に形成されており、転写駒6の加圧部材7に対向する側の面は、所望の最終形状に凹面形状に加工された転写面8が形成されている。   A transfer piece (mold member) 6 is fixed to the lower die plate 2, and a pressure member 7 is fixed to the upper die plate 3. The surface of the pressure member 7 facing the transfer piece 6 is formed in a convex shape having a desired final shape, and the surface of the transfer piece 6 facing the pressure member 7 is formed in a desired final shape. A transfer surface 8 processed into a concave shape is formed.

また、転写駒6には、転写駒6を加熱するヒータ9が設けられており、転写駒6を加熱する加熱手段としては、ヒータ9に限るものではなく、例えば、高周波加熱、赤外線ヒーター加熱、温風加熱等の非接触な加熱手段を用いてもよい。   Further, the transfer piece 6 is provided with a heater 9 for heating the transfer piece 6, and the heating means for heating the transfer piece 6 is not limited to the heater 9, for example, high-frequency heating, infrared heater heating, Non-contact heating means such as warm air heating may be used.

プラスチック積層体製造装置1は、上記転写駒6と加圧部材7との間に、プラスチック基材10、中間部材11及び表層シート12が、配置される。この場合、プラスチック基材10が加圧部材7側に位置し、表層シート12が転写駒6側に位置して、それらの間に、熱可塑性樹脂からなる中間部材11が位置する状態で配置される。   In the plastic laminate manufacturing apparatus 1, a plastic base material 10, an intermediate member 11, and a surface layer sheet 12 are disposed between the transfer piece 6 and the pressure member 7. In this case, the plastic substrate 10 is positioned on the pressure member 7 side, the surface layer sheet 12 is positioned on the transfer piece 6 side, and the intermediate member 11 made of thermoplastic resin is positioned between them. The

このプラスチック基材10は、例えば、軟化温度150℃のポリカーボネイト樹脂を使用して、上記転写駒6と加圧部材7との間に配置されたときに、転写駒6の転写面8側となる基材転写面10aの形状が当該基材転写面10a側が突出した凸面形状である略最終形状に予め加工されており、プラスチック基材10には、図2に示すように、その基材転写面10aとは反対側の裏面10bの中央部、すなわち、凸面形状の基材転写面10aの頂点部に対応する位置に、所定量だけ略柱状に突出した押圧凸部(部分押圧端部)13が形成されている。プラスチック基材10の作製方法は、限定されるものではないが、射出成形を用いることで、押圧凸部13を含めて、プラスチック基材10の外形が複雑な形状であっても、容易にかつ短時間で作製することができる。また、プラスチック基材10は、繊維等の強化充填材を含む非プラスチック複合材料で作製されていてもよい。   This plastic base material 10 becomes the transfer surface 8 side of the transfer piece 6 when, for example, a polycarbonate resin having a softening temperature of 150 ° C. is used and disposed between the transfer piece 6 and the pressure member 7. The shape of the base material transfer surface 10a is processed in advance into a substantially final shape which is a convex shape protruding from the base material transfer surface 10a side, and the plastic base material 10 has its base material transfer surface as shown in FIG. A pressing convex portion (partial pressing end portion) 13 protruding in a substantially columnar shape by a predetermined amount is provided at a position corresponding to the central portion of the back surface 10b opposite to 10a, that is, the apex portion of the convex substrate transfer surface 10a. Is formed. Although the manufacturing method of the plastic base material 10 is not limited, even if the external shape of the plastic base material 10 including the pressing convex part 13 is complicated by using injection molding, It can be produced in a short time. The plastic substrate 10 may be made of a non-plastic composite material including a reinforcing filler such as fiber.

そして、このプラスチック基材10の押圧凸部13は、その先端部が、図3に示すように、所定の曲率半径R0を有した曲面に形成されており、この押圧凸部13の曲率半径R0は、当該押圧凸部13の当接する相手方である加圧部材7が、上述のように、プラスチック基材10方向にその中央部が突出した凸面形状となっているため、この加圧部材7の凸面形状の曲率半径をR1としたとき、R0>R1となる曲率半径となっている。プラスチック基材10の押圧凸部13の先端部の曲面形状の曲率半径R0を、このような条件を満たした曲率半径とすることで、凸面形状の加圧部材7と押圧凸部13とが接触した際に、片当たりが発生することを適切に防止することができる。   And as for the press convex part 13 of this plastic base material 10, the front-end | tip part is formed in the curved surface which has the predetermined curvature radius R0, as shown in FIG. 3, and the curvature radius R0 of this press convex part 13 is shown. Since the pressing member 7 which is the other party with which the pressing convex portion 13 abuts has a convex shape with its central portion protruding in the direction of the plastic substrate 10 as described above, When the curvature radius of the convex shape is R1, the curvature radius is R0> R1. By making the curvature radius R0 of the curved surface shape at the tip of the pressing convex portion 13 of the plastic base material 10 into a curvature radius satisfying such conditions, the convex pressing member 7 and the pressing convex portion 13 are in contact with each other. When this occurs, it is possible to appropriately prevent the occurrence of contact with each other.

すなわち、例えば、図4に示すように、押圧凸部13の先端部が平面形状に形成されていて、当接する相手の加圧部材7が、当該押圧凸部13に対して凹面形状であると、押圧凸部13が当該加圧部材7に対して型当たりが発生するおそれがあり、このような型当たりが発生すると、加工安定性が悪化する。   That is, for example, as shown in FIG. 4, the tip portion of the pressing convex portion 13 is formed in a planar shape, and the pressing member 7 that is in contact with the pressing convex portion 13 has a concave shape with respect to the pressing convex portion 13. In addition, there is a possibility that the pressing convex portion 13 may be subjected to die contact with respect to the pressing member 7, and when such die contact occurs, the processing stability is deteriorated.

そこで、図3に示したように、加圧部材7が押圧凸部13に対して凸面形状であるときには、上記条件の曲率半径R0の曲面を押圧凸部13に形成することで、上述のような型当たりの発生を防止することができ、加工安定性を向上させることができる。   Therefore, as shown in FIG. 3, when the pressing member 7 has a convex shape with respect to the pressing convex portion 13, a curved surface having the curvature radius R0 of the above condition is formed on the pressing convex portion 13, as described above. Therefore, it is possible to prevent the occurrence of per unit mold and improve the processing stability.

また、図5に示すように、加圧部材7が押圧凸部13に対して凹面形状であるときには、当該加圧部材7の凹面形状の曲率半径をR2としたとき、押圧凸部13の凸面形状の曲率半径R0を、R0<R2となる曲率半径とすることで、凹面形状の加圧部材7と押圧凸部13とが接触した際に、片当たりが発生することを適切に防止することができる。   As shown in FIG. 5, when the pressing member 7 has a concave shape with respect to the pressing convex portion 13, when the radius of curvature of the concave shape of the pressing member 7 is R2, the convex surface of the pressing convex portion 13 By setting the curvature radius R0 of the shape to a curvature radius satisfying R0 <R2, it is possible to appropriately prevent occurrence of one-side contact when the concave-shaped pressure member 7 and the pressing convex portion 13 come into contact with each other. Can do.

中間部材11は、加圧時のプラスチック基材10と転写面8との間の形状誤差によって生じる空隙の最大幅以上の厚さを有している。   The intermediate member 11 has a thickness that is equal to or greater than the maximum width of the air gap caused by the shape error between the plastic substrate 10 and the transfer surface 8 during pressurization.

次に、本実施例の作用を説明する。本実施例のプラスチック積層体製造装置1は、加圧部材7が当接して加圧するプラスチック基材10の加圧側の裏面10bに押圧凸部13を形成して、加圧部材7がこの押圧凸部13のみと接触してプラスチック基材10を押圧することで、プラスチック基材10の基材転写面10aを、転写駒6の転写面8方向に均一に押圧する。   Next, the operation of this embodiment will be described. The plastic laminate manufacturing apparatus 1 according to the present embodiment forms the pressing convex portion 13 on the back surface 10b on the pressing side of the plastic substrate 10 to which the pressing member 7 comes into contact and pressurizes, and the pressing member 7 is pressed against the pressing convex portion. By pressing the plastic substrate 10 in contact with only the portion 13, the substrate transfer surface 10 a of the plastic substrate 10 is uniformly pressed in the direction of the transfer surface 8 of the transfer piece 6.

すなわち、プラスチック積層体の製造方法として、例えば、図6に示すように、転写面側が凸面形状で裏面側が平坦なプラスチック基材101を用いて押圧側が平面の加圧部材102で押圧することで、成型する場合、例えば、図7に示すように、転写駒103と加圧部材102との間に、プラスチック基材101と中間部材104を挟んで表層シート105を、転写面103aの形成されている転写駒103側に表層シート105が位置するように配置して、図8に矢印で示すように、中間部材104を加熱・軟化させて、加圧部材102を転写駒103方向に移動させて、加圧一体化する方法で成形すると、加圧時に軟化した中間部材104を変形させることで、プラスチック基材101の形状誤差を補正して転写駒103の転写面103aの形状を忠実に表層シート105の面に転写することができる。また、この場合、軟化させる中間部材104の厚みは転写駒103の転写面103aの形状に対するプラスチック基材101の形状誤差分だけあれば良い。すなわち、非常に薄い中間部材104のみを加熱・冷却すればよいため、加工時間を非常に短くかつ高精度なミラーを作製することができ、また、表層シート105に予め金属反射膜が形成されているため、蒸着コストも低減することができる。   That is, as a method for producing a plastic laminate, for example, as shown in FIG. 6, by using a plastic substrate 101 having a convex shape on the transfer surface side and a flat back surface side, and pressing with a pressing member 102 having a flat pressure side, In the case of molding, for example, as shown in FIG. 7, a transfer sheet 103 is formed with a surface layer sheet 105 between a transfer piece 103 and a pressure member 102 with a plastic substrate 101 and an intermediate member 104 interposed therebetween. Arranged so that the surface layer sheet 105 is positioned on the transfer piece 103 side, as shown by the arrow in FIG. 8, the intermediate member 104 is heated and softened, and the pressure member 102 is moved toward the transfer piece 103, When the molding is performed by the pressure-integrating method, the intermediate member 104 that has been softened at the time of pressing is deformed to correct the shape error of the plastic substrate 101 and to transfer the surface 10 of the transfer piece 103. The a shape faithfully may be transferred to the surface of the surface layer sheet 105. Further, in this case, the thickness of the intermediate member 104 to be softened may be as much as the shape error of the plastic substrate 101 with respect to the shape of the transfer surface 103a of the transfer piece 103. In other words, since only the very thin intermediate member 104 needs to be heated and cooled, it is possible to manufacture a mirror with a very short processing time and high accuracy, and a metal reflective film is formed on the surface layer sheet 105 in advance. Therefore, the vapor deposition cost can be reduced.

ところが、上述のように、プラスチック基材101が軟化していないため、プラスチック基材101は、その裏面と加圧部材102とが剛体同士で接触して押圧されることとなるとともに、プラスチック基材101の裏面形状を加圧部材102の形状と同一形状に加工することが困難でことから、プラスチック基材101の裏面と加圧部材101との間に空隙106が発生し、成形品質を悪化させる。特に、プラスチック基材101が、図6及び図7に示したように、転写面側が凸面形状で裏面側が平坦な偏肉形状のプラスチック基材101であると、プラスチック基材101の中央部がヒケ気味となり、裏面が凹形状となる。このような状態で、図8に示すように、加圧部材102を転写駒103方向に移動させて加圧力を付与すると、プラスチック基材101が、図8に丸印で示す部分で、部分的に加圧されることとなり、プラスチック基材101の転写駒103側の面を中間部材104及び表層シート105を介して転写面103aに密着させたときに、プラスチック基材101自体が、図8に黒矢印で示すように変形する。また、図9に示すように、プラスチック基材101を転写駒103の転写面103aから離型する際に、プラスチック基材101が軟化していないため、変形状態からの弾性回復によって、図9に丸印で示すように、部分的に加圧された部分のみが先に転写面103aから剥離して、形状精度が大きく崩れて悪化する。   However, as described above, since the plastic base material 101 is not softened, the plastic base material 101 is pressed while the back surface thereof and the pressing member 102 are in contact with each other between rigid bodies, and the plastic base material 101 is pressed. Since it is difficult to process the back surface shape of 101 to the same shape as that of the pressure member 102, a gap 106 is generated between the back surface of the plastic substrate 101 and the pressure member 101, thereby deteriorating the molding quality. . In particular, as shown in FIGS. 6 and 7, when the plastic substrate 101 is an uneven plastic substrate 101 having a convex shape on the transfer surface side and a flat back surface side, the central portion of the plastic substrate 101 has a sink mark. It feels a bit and the back side is concave. In this state, as shown in FIG. 8, when the pressing member 102 is moved in the direction of the transfer piece 103 and pressure is applied, the plastic substrate 101 is partly shown by a circle in FIG. 8. When the surface on the transfer piece 103 side of the plastic substrate 101 is brought into close contact with the transfer surface 103a via the intermediate member 104 and the surface layer sheet 105, the plastic substrate 101 itself is shown in FIG. Deforms as shown by the black arrow. Further, as shown in FIG. 9, when the plastic substrate 101 is released from the transfer surface 103a of the transfer piece 103, since the plastic substrate 101 is not softened, the elastic recovery from the deformed state results in FIG. As indicated by the circles, only the partially pressurized portion is peeled off from the transfer surface 103a first, and the shape accuracy is greatly degraded and deteriorated.

そして、プラスチック積層体(成形品)が曲面ミラーである場合には、通常、成形性、軽量化を考慮して、図10に示すように、プラスチック基材110が略筋肉形状の曲面形状として、加圧部材111が転写駒方向に突出した球面形状に形成されるが、このような筋肉曲面形状のプラスチック基材110では、球面形状の加圧部材111とプラスチック基材110との形状を一致させることが難しく、プラスチック基材110と加圧部材111との間に図10に示すような空隙112が発生して、上記問題と同様の問題が発生する。また、たとえ加圧部材111とプラスチック基材110の裏面形状が一致している場合であっても、加圧部材111とプラスチック基材110との位置が少しでもずれると、プラスチック基材110と加圧部材111との間に図10に示すような空隙112が発生して、上記問題と同様の問題が発生する。   And, when the plastic laminate (molded product) is a curved mirror, in consideration of moldability and weight reduction, as shown in FIG. 10, the plastic substrate 110 has a generally muscular curved shape, The pressure member 111 is formed in a spherical shape protruding in the transfer frame direction. In such a muscle curved plastic base material 110, the spherical pressure member 111 and the plastic base material 110 have the same shape. This is difficult, and a gap 112 as shown in FIG. 10 is generated between the plastic substrate 110 and the pressure member 111, and the same problem as the above problem occurs. Further, even if the back surface shapes of the pressure member 111 and the plastic base material 110 are the same, if the positions of the pressure member 111 and the plastic base material 110 are slightly shifted, the plastic base material 110 and the plastic base material 110 may be added. A gap 112 as shown in FIG. 10 is generated between the pressure member 111 and the same problem as described above.

そこで、本実施例のプラスチック積層体製造装置1は、加圧部材7が当接して加圧するプラスチック基材10の加圧側の裏面10bに押圧凸部13を形成して、加圧部材7がこの押圧凸部13のみと接触してプラスチック基材10を押圧することで、プラスチック基材10の基材転写面10aを、転写駒6の転写面8方向に均一に押圧する。   Therefore, the plastic laminate manufacturing apparatus 1 according to the present embodiment forms the pressing convex portion 13 on the back surface 10b on the pressing side of the plastic substrate 10 to which the pressing member 7 contacts and pressurizes, and the pressing member 7 By pressing the plastic substrate 10 in contact with only the pressing protrusion 13, the substrate transfer surface 10 a of the plastic substrate 10 is uniformly pressed in the direction of the transfer surface 8 of the transfer piece 6.

以下、製造工程順に、製造方法を説明する。なお、以下の説明では、プラスチック基材10として、軟化温度が150℃のポリカーボネート樹脂を用い、表層シート12として、軟化温度が260℃のポリエチレンテレフタレートフィルムを用い、中間部材11として、軟化温度が100℃のウレタンフィルムを用いた場合を例として、説明する。   Hereinafter, a manufacturing method is demonstrated in order of a manufacturing process. In the following description, a polycarbonate resin having a softening temperature of 150 ° C. is used as the plastic substrate 10, a polyethylene terephthalate film having a softening temperature of 260 ° C. is used as the surface layer sheet 12, and a softening temperature is 100 as the intermediate member 11. A case where a urethane film of ° C. is used will be described as an example.

まず、図1に示したうに、中間部材11と表層シート12を、表層シート12が転写面8側に位置する状態にして、転写面8の形成されている転写駒6上に配置して、ヒータ9で転写駒6を介して中間部材11の軟化温度以上の所定温度、例えば、ウレタンフィルムである中間部材11の軟化温度100℃以上の130℃に中間部材11を加熱して、中間部材11のみを軟化させる。すなわち、上述のように、プラスチック基材10として、軟化温度が150℃のポリカーボネート樹脂を用い、表層シート12として、軟化温度が260℃のポリエチレンテレフタレートフィルムを用い、中間部材11として、軟化温度が100℃のウレタンフィルムを用いて、赤外線ヒータ12で中間部材11を130℃に加熱することで、中間部材11のみを軟化させることができる。   First, as shown in FIG. 1, the intermediate member 11 and the surface layer sheet 12 are placed on the transfer piece 6 on which the transfer surface 8 is formed, with the surface layer sheet 12 positioned on the transfer surface 8 side. The intermediate member 11 is heated by the heater 9 through the transfer piece 6 to a predetermined temperature equal to or higher than the softening temperature of the intermediate member 11, for example, 130 ° C. higher than the softening temperature of the intermediate member 11, which is a urethane film, 100 ° C. Only softens. That is, as described above, a polycarbonate resin having a softening temperature of 150 ° C. is used as the plastic substrate 10, a polyethylene terephthalate film having a softening temperature of 260 ° C. is used as the surface layer sheet 12, and a softening temperature is 100 as the intermediate member 11. Only the intermediate member 11 can be softened by heating the intermediate member 11 to 130 ° C. with the infrared heater 12 using a urethane film at 0 ° C.

次に、プラスチック積層体製造装置1は、図11に矢印で示すように、上側ダイプレート3を下側ダイプレート2方向に移動させて、上側ダイプレート3に取り付けられている加圧部材7をプラスチック基材10の押圧凸部13のみに接触させ、加圧する。このとき、中間部材11が軟化されているため、プラスチック基材10で中間部材11を転写駒6方向に加圧することで、中間部材11が、プラスチック基材10の転写面8側(中間部材11側)の形状と転写駒6の転写面8の形状の誤差を補完するように、軟化変形する。   Next, the plastic laminate manufacturing apparatus 1 moves the upper die plate 3 in the direction of the lower die plate 2 as shown by arrows in FIG. Only the pressing convex portion 13 of the plastic substrate 10 is brought into contact with and pressed. At this time, since the intermediate member 11 is softened, by pressing the intermediate member 11 in the direction of the transfer piece 6 with the plastic base material 10, the intermediate member 11 becomes the transfer surface 8 side (intermediate member 11) of the plastic base material 10. Side) and the shape of the transfer surface 8 of the transfer piece 6 are softened and deformed so as to complement the error.

次に、プラスチック積層体製造装置1は、加圧部材16でプラスチック基材10を加圧した状態のまま、中間部材11が軟化温度以下になるまで冷却した後、図12に示すように、上側ダイプレート3を上方に移動させ、プラスチック基材10、中間部材11及び表層シート12から構成される一体化されたプラスチック積層体(積層プラスチック成形品)20を、図示しない搬送装置等で離型して取り出す。   Next, the plastic laminate manufacturing apparatus 1 is cooled until the intermediate member 11 is not higher than the softening temperature in a state where the plastic base material 10 is pressurized with the pressure member 16, and then the upper side as shown in FIG. The die plate 3 is moved upward, and the integrated plastic laminate (laminated plastic molded product) 20 composed of the plastic base material 10, the intermediate member 11, and the surface layer sheet 12 is released with a conveying device (not shown). And take it out.

なお、本実施例では、中間部材11と表層シート12をプラスチック基材10による押圧によって変形させているが、例えば、転写駒6に、転写面8の有効範囲外の位置で当該転写面8に開口する連通孔を形成するとともに、当該連通孔を、転写駒6の外部に設置されている真空吸引装置に連通して、中間部材11と表層シート12を、表層シート12が転写面8側に位置する状態にして、転写面8の形成されている転写駒6上に固定配置して、中間部材11及び表層シート12でその開口部が覆われた転写面8内の空気を連通孔を介して真空吸引装置によって吸引することで、転写駒6に固定されている表層シート12及び中間部材11を、転写面8に沿うように変形させてもよい。   In this embodiment, the intermediate member 11 and the surface layer sheet 12 are deformed by pressing with the plastic base material 10, but for example, the transfer piece 6 is placed on the transfer surface 8 at a position outside the effective range of the transfer surface 8. In addition to forming a communication hole that opens, the communication hole is communicated with a vacuum suction device installed outside the transfer piece 6, and the intermediate member 11 and the surface layer sheet 12 are connected to the transfer surface 8 side. In a positioned state, it is fixedly arranged on the transfer piece 6 on which the transfer surface 8 is formed, and the air in the transfer surface 8 whose opening is covered with the intermediate member 11 and the surface layer sheet 12 is passed through the communication hole. Then, the surface layer sheet 12 and the intermediate member 11 fixed to the transfer piece 6 may be deformed along the transfer surface 8 by being sucked by a vacuum suction device.

このように、本実施例のプラスチック積層体製造装置1は、加圧部材7が当接して加圧するプラスチック基材10の加圧側の裏面10bに押圧凸部13を形成して、加圧部材7がこの押圧凸部13のみと接触してプラスチック基材10を押圧している。   As described above, the plastic laminate manufacturing apparatus 1 according to the present embodiment forms the pressing convex portion 13 on the back surface 10b on the pressing side of the plastic substrate 10 to which the pressing member 7 contacts and pressurizes, and the pressing member 7 However, the plastic substrate 10 is pressed only in contact with the pressing projection 13.

すなわち、図13に示すように、プラスチック基材10に押圧凸部13を設けない場合、プラスチック基材10の裏面と加圧部材7の形状が異なると、加圧時に、プラスチック基材10と加圧部材7との間に隙間30が生じ、プラスチック基材10が転写駒6の転写面8と接する位置と加圧部材7がプラスチック基材10を押す位置が異なり、プラスチック基材10が、図13に黒矢印で示す方向に変形して、成形精度が悪化する。なお、図13では、説明の便宜上、中間部材11と表層シート12を省いた状態で示している。   That is, as shown in FIG. 13, when the pressing protrusion 13 is not provided on the plastic base material 10, if the back surface of the plastic base material 10 and the shape of the pressing member 7 are different, the plastic base material 10 and the pressurizing member 7 are added during pressing. A gap 30 is formed between the pressure member 7 and the position where the plastic substrate 10 contacts the transfer surface 8 of the transfer piece 6 and the position where the pressure member 7 presses the plastic substrate 10 are different. 13 is deformed in the direction indicated by the black arrow, and the molding accuracy deteriorates. In FIG. 13, for convenience of explanation, the intermediate member 11 and the surface layer sheet 12 are omitted.

ところが、本実施例のプラスチック積層体製造装置1は、図14に示すように、加圧部材7が当接して加圧するプラスチック基材10の加圧側の裏面10bに押圧凸部13を形成しているので、たとえプラスチック基材10の裏面と加圧部材7の形状が異なっていることで、図13と同様の隙間30が発生する状態であっても、プラスチック基材10が転写面8と接する位置と加圧部材7がプラスチック基材10を押す位置が一致しているため、図13の場合のようなプラスチック基材10の変形が発生せず、離型時の弾性回復による形状変形の発生を防止することができる。そして、図14に丸印で示した空隙31には、実際には、軟化変形した中間部材11で補完される。   However, the plastic laminate manufacturing apparatus 1 according to the present embodiment, as shown in FIG. 14, forms the pressing convex portion 13 on the back surface 10 b on the pressing side of the plastic substrate 10 to which the pressing member 7 contacts and pressurizes. Therefore, even if the back surface of the plastic substrate 10 and the shape of the pressure member 7 are different, the plastic substrate 10 is in contact with the transfer surface 8 even in a state where a gap 30 similar to that in FIG. 13 is generated. Since the position and the position where the pressing member 7 pushes the plastic base material 10 coincide with each other, the plastic base material 10 is not deformed as in the case of FIG. Can be prevented. The gap 31 indicated by a circle in FIG. 14 is actually supplemented by the softened and deformed intermediate member 11.

また、本実施例のプラスチック積層体製造装置1は、加圧時には中間部材11が軟化しているため、プラスチック基材10を変形させない。   Moreover, since the intermediate member 11 is softened when the plastic laminated body manufacturing apparatus 1 of a present Example pressurizes, the plastic base material 10 is not deformed.

なお、プラスチック基材10として、例えば、ガラス繊維、炭素繊維、または、マイカ等を強化充填材としたプラスチック複合材料を用いて作製すると、プラスチック基材10の剛性が向上し、空隙30のような加圧力が直接付与されない部分でも、プラスチック基材10の剛性で、軟化した中間部材11を空隙31の形状に確実に変形させることができる。   In addition, when the plastic base material 10 is manufactured using, for example, a plastic composite material using glass fiber, carbon fiber, mica, or the like as a reinforcing filler, the rigidity of the plastic base material 10 is improved, Even in the portion where the pressure is not directly applied, the softened intermediate member 11 can be reliably deformed into the shape of the gap 31 by the rigidity of the plastic substrate 10.

また、本実施例のプラスチック積層体製造装置1は、図15に示されるように、転写駒40の転写面40aが凹面である場合にも、プラスチック基材41の裏面側の頂点部に押圧凸部42を形成することで、その押圧面が凹面形状を有する加圧部材43がプラスチック基材41を付勢する場合に、押圧凸部42のみと接触して、均一にプラスチック基材41を押圧するように、することができ、成形品であるプラスチック積層体の品質を向上させることができる。   Further, as shown in FIG. 15, the plastic laminate manufacturing apparatus 1 of the present embodiment has a pressing protrusion on the apex portion on the back surface side of the plastic substrate 41 even when the transfer surface 40 a of the transfer piece 40 is a concave surface. By forming the portion 42, when the pressing member 43 whose pressing surface has a concave shape urges the plastic base material 41, it contacts only the pressing convex portion 42 and uniformly presses the plastic base material 41. As a result, the quality of the plastic laminate as a molded product can be improved.

図16〜図18は、本発明のプラスチック積層体の製造方法及びプラスチック積層体の第2実施例を示す図であり、図16は、本発明のプラスチック積層体の製造方法及びプラスチック積層体の第2実施例を適用したプラスチック積層体製造装置50の正面概略構成図である。   16 to 18 are views showing a method for producing a plastic laminate and a second embodiment of the plastic laminate of the present invention, and FIG. 16 shows a method for producing a plastic laminate and a plastic laminate of the present invention. It is a front schematic block diagram of the plastic laminated body manufacturing apparatus 50 to which 2 Example is applied.

なお、本実施例は、上記第1実施例のプラスチック積層体製造装置1と同様のプラスチック積層体製造装置に適用したものであり、本実施例の説明において、上記第1実施例のプラスチック積層体製造装置1と同様の構成部分には、同一の符号を付して、その詳細な説明を省略する。   The present embodiment is applied to a plastic laminate manufacturing apparatus similar to the plastic laminate manufacturing apparatus 1 of the first embodiment. In the description of this embodiment, the plastic laminate of the first embodiment is used. The same components as those of the manufacturing apparatus 1 are denoted by the same reference numerals, and detailed description thereof is omitted.

図16において、プラスチック積層体製造装置50は、下側ダイプレート2、上側ダイプレート3及びタイバー4を有したプレス機5を備えており、下側ダイプレート2には、転写駒(型部材)6が固定されており、上側ダイプレート3には、加圧部材51が固定されている。   In FIG. 16, the plastic laminate manufacturing apparatus 50 includes a press machine 5 having a lower die plate 2, an upper die plate 3, and a tie bar 4, and a transfer piece (a mold member) is provided on the lower die plate 2. 6 is fixed, and a pressure member 51 is fixed to the upper die plate 3.

プラスチック積層体製造装置50は、転写駒6と加圧部材51との間に、プラスチック基材52、中間部材11及び表層シート12が、配置される。この場合、プラスチック基材52が加圧部材7側に位置し、表層シート12が転写駒6側に位置して、それらの間に、熱可塑性樹脂からなる中間部材11が位置する状態で配置される。   In the plastic laminate manufacturing apparatus 50, the plastic substrate 52, the intermediate member 11, and the surface layer sheet 12 are disposed between the transfer piece 6 and the pressure member 51. In this case, the plastic substrate 52 is positioned on the pressing member 7 side, the surface layer sheet 12 is positioned on the transfer piece 6 side, and the intermediate member 11 made of thermoplastic resin is positioned between them. The

このプラスチック基材52は、例えば、軟化温度150℃のポリカーボネイト樹脂を使用して、上記転写駒6と加圧部材7との間に配置されたときに、転写駒6の転写面8側となる基材転写面52aの形状が当該基材転写面52a側が突出した凸面形状である略最終形状に予め加工されているとともに、略筋肉形状に形成されている。プラスチック基材52の作製方法は、限定されるものではないが、射出成形を用いることで、プラスチック基材52の外形が複雑な形状であっても、容易にかつ短時間で作製することができる。   The plastic substrate 52 becomes the transfer surface 8 side of the transfer piece 6 when, for example, a polycarbonate resin having a softening temperature of 150 ° C. is used and disposed between the transfer piece 6 and the pressure member 7. The shape of the base material transfer surface 52a is processed in advance into a substantially final shape which is a convex shape protruding from the base material transfer surface 52a side, and is formed into a substantially muscular shape. The method for producing the plastic substrate 52 is not limited, but by using injection molding, even if the outer shape of the plastic substrate 52 is complicated, it can be produced easily and in a short time. .

そして、上記加圧部材51は、その転写駒6側の面が、中央部ほど転写駒6方向に突出した凸面形状に形成されており、当該凸面形状の頂点部に、加圧時に上記プラスチック基材52に当接する押圧凸部(部分押圧端部)53が形成されており、この押圧凸部53は、第1実施例の押圧凸部13と同様に、所定の曲率半径を有した曲面に形成されている。   The pressing member 51 is formed in a convex shape in which the surface on the transfer piece 6 side protrudes in the direction of the transfer piece 6 toward the center, and the plastic base is applied to the apex of the convex shape at the time of pressurization. A pressing convex portion (partial pressing end portion) 53 that abuts the material 52 is formed, and the pressing convex portion 53 has a curved surface having a predetermined radius of curvature, like the pressing convex portion 13 of the first embodiment. Is formed.

このような加圧部材51の押圧凸部53とその加圧部材51側の裏面が凹面形状のプラスチック基材52の裏面52bとが接触した際に、片当たりが発生することを適切に防止することができる。   When the pressing convex portion 53 of the pressure member 51 and the back surface 52b of the plastic substrate 52 having the concave surface on the pressure member 51 side come into contact with each other, it is possible to appropriately prevent occurrence of one-side contact. be able to.

次に、本実施例の作用を説明する。本実施例のプラスチック積層体製造装置50は、凸面形状の加圧部材51の頂点部分に押圧凸部53を形成して、その裏面が凹面形状となっているプラスチック基材52の裏面に当該加圧部材51の押圧凸部53のみを接触させてプラスチック基材52を押圧することで、プラスチック基材52の基材転写面52aを、転写駒6の転写面8方向に均一に押圧する。   Next, the operation of this embodiment will be described. The plastic laminate manufacturing apparatus 50 according to the present embodiment forms the pressing convex portion 53 at the apex portion of the convex-shaped pressing member 51, and applies the applied pressure to the back surface of the plastic base material 52 whose concave surface is a concave shape. By pressing only the pressing base 53 of the pressure member 51 and pressing the plastic substrate 52, the substrate transfer surface 52 a of the plastic substrate 52 is pressed uniformly in the direction of the transfer surface 8 of the transfer piece 6.

以下、製造工程順に、製造方法を説明する。なお、以下の説明では、プラスチック基材52として、軟化温度が150℃のポリカーボネート樹脂を用い、表層シート12として、軟化温度が260℃のポリエチレンテレフタレートフィルムを用い、中間部材11として、軟化温度が100℃のウレタンフィルムを用いた場合を例として、説明する。   Hereinafter, a manufacturing method is demonstrated in order of a manufacturing process. In the following description, a polycarbonate resin having a softening temperature of 150 ° C. is used as the plastic substrate 52, a polyethylene terephthalate film having a softening temperature of 260 ° C. is used as the surface layer sheet 12, and a softening temperature is 100 as the intermediate member 11. A case where a urethane film of ° C. is used will be described as an example.

まず、図16に示したように、中間部材11と表層シート12を、表層シート12が転写面8側に位置する状態にして、転写面8の形成されている転写駒6上に配置して、ヒータ9で転写駒6を介して中間部材11の軟化温度以上の所定温度、例えば、ウレタンフィルムである中間部材11の軟化温度100℃以上の130℃に中間部材11を加熱して、中間部材11のみを軟化させる。   First, as shown in FIG. 16, the intermediate member 11 and the surface layer sheet 12 are arranged on the transfer piece 6 on which the transfer surface 8 is formed, with the surface layer sheet 12 positioned on the transfer surface 8 side. The intermediate member 11 is heated by the heater 9 through the transfer piece 6 to a predetermined temperature equal to or higher than the softening temperature of the intermediate member 11, for example, 130 ° C., which is equal to or higher than the softening temperature of the intermediate member 11, which is a urethane film. Only 11 is softened.

次に、プラスチック積層体製造装置50は、図17に矢印で示すように、上側ダイプレート3を下側ダイプレート2方向に移動させて、上側ダイプレート3に取り付けられている加圧部材51をその押圧凸部53のみを、プラスチック基材52の裏面に接触させ、加圧する。このとき、中間部材11が軟化されているため、プラスチック基材52で中間部材11を転写駒6方向に加圧することで、中間部材11が、プラスチック基材52の転写面8側(中間部材11側)の形状と転写駒6の転写面8の形状の誤差を補完するように、軟化変形する。   Next, the plastic laminate manufacturing apparatus 50 moves the upper die plate 3 in the direction of the lower die plate 2 and moves the pressure member 51 attached to the upper die plate 3 as indicated by an arrow in FIG. Only the pressing convex portion 53 is brought into contact with the back surface of the plastic substrate 52 and pressed. At this time, since the intermediate member 11 is softened, the intermediate member 11 is pressed in the direction of the transfer piece 6 with the plastic substrate 52, so that the intermediate member 11 is moved to the transfer surface 8 side (intermediate member 11) of the plastic substrate 52. Side) and the shape of the transfer surface 8 of the transfer piece 6 are softened and deformed so as to complement the error.

次に、プラスチック積層体製造装置50は、加圧部材51でプラスチック基材52を加圧した状態のまま、中間部材11が軟化温度以下になるまで冷却した後、図18に示すように、上側ダイプレート3を上方に移動させ、プラスチック基材52、中間部材11及び表層シート12から構成される一体化されたプラスチック積層体(積層プラスチック成形品)60を、図示しない搬送装置等で離型して取り出す。   Next, the plastic laminate manufacturing apparatus 50 is cooled until the intermediate member 11 becomes the softening temperature or lower while the plastic base material 52 is pressurized with the pressure member 51, and then the upper side as shown in FIG. The die plate 3 is moved upward, and the integrated plastic laminate (laminated plastic molded product) 60 composed of the plastic base material 52, the intermediate member 11 and the surface layer sheet 12 is released by a conveying device or the like (not shown). And take it out.

なお、本実施例では、中間部材11と表層シート12をプラスチック基材52による押圧によって変形させているが、例えば、転写駒6に、転写面8の有効範囲外の位置で当該転写面8に開口する連通孔を形成するとともに、当該連通孔を、転写駒6の外部に設置されている真空吸引装置に連通して、中間部材11と表層シート12を、表層シート12が転写面8側に位置する状態にして、転写面8の形成されている転写駒6上に固定配置して、中間部材11及び表層シート12でその開口部が覆われた転写面8内の空気を連通孔を介して真空吸引装置によって吸引することで、転写駒6に固定されている表層シート12及び中間部材11を、転写面8に沿うように変形させてもよい。   In the present embodiment, the intermediate member 11 and the surface layer sheet 12 are deformed by pressing with the plastic base material 52. However, for example, the transfer piece 6 is placed on the transfer surface 8 at a position outside the effective range of the transfer surface 8. In addition to forming a communication hole that opens, the communication hole communicates with a vacuum suction device installed outside the transfer piece 6 so that the intermediate member 11 and the surface layer sheet 12 are connected to the transfer surface 8 side. In a positioned state, it is fixedly arranged on the transfer piece 6 on which the transfer surface 8 is formed, and the air in the transfer surface 8 whose opening is covered with the intermediate member 11 and the surface layer sheet 12 is passed through the communication hole. Then, the surface layer sheet 12 and the intermediate member 11 fixed to the transfer piece 6 may be deformed along the transfer surface 8 by being sucked by a vacuum suction device.

このように、押圧凸部53が加圧部材51に設けられている場合にも、第1実施例と同様に、たとえプラスチック基材52の裏面と加圧部材51の加圧面側の形状が異なって隙間が発生する状態であっても、プラスチック基材52が転写面8と接する位置と加圧部材51がプラスチック基材52を押す位置が一致しているため、プラスチック基材52の変形が発生せず、離型時の弾性回復による形状変形の発生を防止することができ、プラスチック積層体60の品質を向上させることができる。   As described above, even when the pressing convex portion 53 is provided on the pressing member 51, the shapes of the back surface of the plastic substrate 52 and the pressing surface side of the pressing member 51 are different as in the first embodiment. Even when a gap is generated, the plastic substrate 52 is deformed because the position where the plastic substrate 52 contacts the transfer surface 8 and the position where the pressing member 51 presses the plastic substrate 52 are the same. Therefore, the occurrence of shape deformation due to elastic recovery at the time of mold release can be prevented, and the quality of the plastic laminate 60 can be improved.

また、本実施例のプラスチック積層体製造装置50は、加圧部材51に押圧凸部53を設けているので、プラスチック基材52の形状の自由度が増え、筋肉に形状として、容易に作製することができる。   In addition, since the plastic laminate manufacturing apparatus 50 according to the present embodiment is provided with the pressing convex portion 53 on the pressing member 51, the degree of freedom of the shape of the plastic base material 52 is increased, and it is easily manufactured as a shape on the muscle. be able to.

さらに、本実施例のプラスチック積層体製造装置50は、加圧部材51に押圧凸部53を設けて、当該押圧凸部53のみをプラスチック基材52の裏面に接触させて押圧しているので、プラスチック基材52の加工バラツキが発生しても、加工毎に押圧位置が変わることを防止することができ、安定してプラスチック積層体60を作製することができる。   Furthermore, since the plastic laminate manufacturing apparatus 50 of the present embodiment is provided with the pressing convex portion 53 on the pressing member 51 and presses only the pressing convex portion 53 in contact with the back surface of the plastic substrate 52, Even if processing variations of the plastic substrate 52 occur, it is possible to prevent the pressing position from being changed for each processing, and the plastic laminate 60 can be stably manufactured.

さらに、本実施例のプラスチック積層体製造装置50は、転写駒の転写面が凹面である場合にも、同様に適用することができる。   Furthermore, the plastic laminate manufacturing apparatus 50 of the present embodiment can be similarly applied when the transfer surface of the transfer piece is a concave surface.

図19〜図22は、本発明のプラスチック積層体の製造方法及びプラスチック積層体の第3実施例を示す図であり、図19は、本発明のプラスチック積層体の製造方法及びプラスチック積層体の第3実施例を適用したプラスチック積層体製造装置70の正面概略構成図である。   19 to 22 are views showing a method for producing a plastic laminate and a third embodiment of the plastic laminate of the present invention, and FIG. 19 shows a method for producing a plastic laminate and a plastic laminate of the present invention. It is a front schematic block diagram of the plastic laminated body manufacturing apparatus 70 to which 3 Example is applied.

なお、本実施例は、上記第1実施例のプラスチック積層体製造装置1と同様のプラスチック積層体製造装置に適用したものであり、本実施例の説明において、上記第1実施例のプラスチック積層体製造装置1と同様の構成部分には、同一の符号を付して、その詳細な説明を省略する。   The present embodiment is applied to a plastic laminate manufacturing apparatus similar to the plastic laminate manufacturing apparatus 1 of the first embodiment. In the description of this embodiment, the plastic laminate of the first embodiment is used. The same components as those of the manufacturing apparatus 1 are denoted by the same reference numerals, and detailed description thereof is omitted.

図19において、プラスチック積層体製造装置70は、下側ダイプレート2、上側ダイプレート3及びタイバー4を有したプレス機5を備えており、下側ダイプレート2には、転写駒(型部材)6が固定されており、上側ダイプレート3には、加圧部材71が固定されている。   In FIG. 19, the plastic laminate manufacturing apparatus 70 includes a press machine 5 having a lower die plate 2, an upper die plate 3 and a tie bar 4, and a transfer piece (mold member) is provided on the lower die plate 2. 6 is fixed, and a pressure member 71 is fixed to the upper die plate 3.

プラスチック積層体製造装置70は、転写駒6と加圧部材71との間に、プラスチック基材72、中間部材11及び表層シート12が、配置される。この場合、プラスチック基材72が加圧部材7側に位置し、表層シート12が転写駒6側に位置して、それらの間に、熱可塑性樹脂からなる中間部材11が位置する状態で配置される。   In the plastic laminate manufacturing apparatus 70, the plastic substrate 72, the intermediate member 11, and the surface layer sheet 12 are disposed between the transfer piece 6 and the pressure member 71. In this case, the plastic substrate 72 is positioned on the pressure member 7 side, the surface layer sheet 12 is positioned on the transfer piece 6 side, and the intermediate member 11 made of thermoplastic resin is positioned between them. The

このプラスチック基材72は、例えば、軟化温度150℃のポリカーボネイト樹脂を使用して、上記転写駒6と加圧部材7との間に配置されたときに、転写駒6の転写面8側となる基材転写面72aの形状が当該基材転写面72a側が突出した凸面形状である略最終形状に予め加工されているとともに、略筋肉形状に形成されている。   This plastic base material 72 becomes the transfer surface 8 side of the transfer piece 6 when it is disposed between the transfer piece 6 and the pressure member 7 using, for example, a polycarbonate resin having a softening temperature of 150 ° C. The shape of the base material transfer surface 72a is processed in advance into a substantially final shape which is a convex shape protruding from the base material transfer surface 72a side, and is formed into a substantially muscular shape.

上記加圧部材71は、その転写駒6側の面が、中央部ほど転写駒6方向に突出した凸面形状に形成されており、当該凸面形状の頂点部に、加圧時に上記プラスチック基材72に当接する押圧凸部73が形成されており、この押圧凸部73は、第1実施例の押圧凸部13と同様に、所定の曲率半径を有した曲面に形成されている。   The pressing member 71 has a surface on the transfer piece 6 side formed in a convex shape protruding toward the transfer piece 6 toward the center, and the plastic base material 72 is applied to the apex of the convex shape at the time of pressurization. The pressing projection 73 is formed in a curved surface having a predetermined radius of curvature, like the pressing projection 13 of the first embodiment.

一方、プラスチック基材72の加圧部材71側の面である裏面72bの中央部には、加圧部材71の押圧凸部73が進入する所定量窪んだ凹部74が形成されている。   On the other hand, a concave portion 74 that is depressed by a predetermined amount into which the pressing convex portion 73 of the pressurizing member 71 enters is formed in the central portion of the back surface 72b that is the surface of the plastic base material 72 on the pressurizing member 71 side.

そして、部分押圧端部として機能する加圧部材71の押圧凸部73とプラスチック基材72の凹部74は、加圧部材71の押圧凸部73の突出高さL1とプラスチック基材72の凹部74の深さL2とが、突出隆SAL1>深さL2の関係となるように形成されている。   The pressing convex portion 73 of the pressing member 71 and the concave portion 74 of the plastic base material 72 functioning as a partial pressing end are the projection height L1 of the pressing convex portion 73 of the pressing member 71 and the concave portion 74 of the plastic base material 72. The depth L2 is formed such that the protruding ridge SAL1> depth L2.

また、加圧部材71の押圧凸部73とプラスチック基材72の凹部74は、図20に示すように押圧凸部73の先端部と凹部74の開口側端部のうち、少なくとも一方が所定の傾斜面形状(テーパー形状)に形成されている。すなわち、図20(a)に示すように、加圧部材71の押圧凸部73の先端部にその先端方向に対して直交する方向の断面積が先端側ほど小さくなる傾斜面73aが形成されていても良いし、図20(b)に示すように、プラスチック基材72の凹部74の開口側端部に開口側ほど開口面積が広くなる傾斜面74aが形成されていても良いし、あるいは、図20(c)に示すように、加圧部材71の押圧凸部73の先端部に傾斜面73aが形成され、かつ、プラスチック基材72の凹部74の開口側端部に傾斜面74aが形成されていても良い。   Further, as shown in FIG. 20, the pressing convex portion 73 of the pressing member 71 and the concave portion 74 of the plastic base material 72 have at least one of the tip end portion of the pressing convex portion 73 and the opening side end portion of the concave portion 74 being predetermined. It is formed in an inclined surface shape (taper shape). That is, as shown in FIG. 20 (a), an inclined surface 73a is formed at the distal end portion of the pressing convex portion 73 of the pressing member 71 so that the sectional area in the direction orthogonal to the distal end direction becomes smaller toward the distal end side. Alternatively, as shown in FIG. 20B, an inclined surface 74a whose opening area becomes wider toward the opening side may be formed at the opening side end portion of the recess 74 of the plastic substrate 72, or As shown in FIG. 20 (c), an inclined surface 73 a is formed at the distal end portion of the pressing convex portion 73 of the pressing member 71, and an inclined surface 74 a is formed at the opening side end portion of the concave portion 74 of the plastic base material 72. May be.

次に、本実施例の作用を説明する。本実施例のプラスチック積層体製造装置70は、凸面形状の加圧部材71の頂点部分に押圧凸部73を形成し、その裏面が凹面形状となっているプラスチック基材72の裏面に当該加圧部材71の押圧凸部73の進入する凹部74を形成して、加圧部材71の押圧凸部73をプラスチック基材72の凹部74内に進入させ、加圧部材71の押圧凸部73をプラスチック基材72の凹部のみに接触させてプラスチック基材72を押圧することで、加圧部材72のプラスチック基材72に対する位置決めを適切に行いつつ、プラスチック基材72の基材転写面72aを、転写駒6の転写面8方向に均一に押圧する。   Next, the operation of this embodiment will be described. The plastic laminate manufacturing apparatus 70 of the present embodiment forms a pressing convex portion 73 at the apex portion of the convex-shaped pressing member 71, and the pressing is applied to the back surface of the plastic substrate 72 whose concave surface is a concave shape. A concave portion 74 into which the pressing convex portion 73 of the member 71 enters is formed so that the pressing convex portion 73 of the pressing member 71 enters the concave portion 74 of the plastic base material 72, and the pressing convex portion 73 of the pressing member 71 is plastic. By pressing the plastic substrate 72 in contact with only the concave portion of the substrate 72, the substrate transfer surface 72a of the plastic substrate 72 is transferred while appropriately positioning the pressing member 72 with respect to the plastic substrate 72. Press uniformly in the direction of the transfer surface 8 of the piece 6.

以下、製造工程順に、製造方法を説明する。なお、以下の説明では、プラスチック基材72として、軟化温度が150℃のポリカーボネート樹脂を用い、表層シート12として、軟化温度が260℃のポリエチレンテレフタレートフィルムを用い、中間部材11として、軟化温度が100℃のウレタンフィルムを用いた場合を例として、説明する。   Hereinafter, a manufacturing method is demonstrated in order of a manufacturing process. In the following description, a polycarbonate resin having a softening temperature of 150 ° C. is used as the plastic substrate 72, a polyethylene terephthalate film having a softening temperature of 260 ° C. is used as the surface layer sheet 12, and the softening temperature is 100 as the intermediate member 11. A case where a urethane film of ° C. is used will be described as an example.

まず、図19に示したように、中間部材11と表層シート12を、表層シート12が転写面8側に位置する状態にして、転写面8の形成されている転写駒6上に配置して、ヒータ9で転写駒6を介して中間部材11の軟化温度以上の所定温度、例えば、ウレタンフィルムである中間部材11の軟化温度100℃以上の130℃に中間部材11を加熱して、中間部材11のみを軟化させる。   First, as shown in FIG. 19, the intermediate member 11 and the surface layer sheet 12 are arranged on the transfer piece 6 on which the transfer surface 8 is formed with the surface layer sheet 12 positioned on the transfer surface 8 side. The intermediate member 11 is heated by the heater 9 through the transfer piece 6 to a predetermined temperature equal to or higher than the softening temperature of the intermediate member 11, for example, 130 ° C., which is equal to or higher than the softening temperature of the intermediate member 11, which is a urethane film. Only 11 is softened.

次に、プラスチック積層体製造装置70は、図21に矢印で示すように、上側ダイプレート3を下側ダイプレート2方向に移動させて、上側ダイプレート3に取り付けられている加圧部材71の押圧凸部73をプラスチック基材72の裏面72bに形成されている凹部74内に進入させる。このとき、加圧部材71の押圧凸部73とプラスチック基材72の凹部74は、加圧部材71の押圧凸部73の突出高さL1とプラスチック基材72の凹部74の深さL2とが、突出高さL1>深さL2の関係となるように形成されているので、加圧部材71の押圧凸部73が、プラスチック基材72の凹部74の底面に確実に当接して、当該凹部74の底面のみを加圧する。また、加圧部材71の押圧凸部73がプラスチック基材72の凹部74内に進入することで、加圧部材71とプラスチック基材72の位置決めを適切に行い、加圧したい場所を確実に加圧することができるとともに、プラスチック基材72をプレス機5の上側ダイプレート3と下側ダイプレート2の間に挿入する場合に常に同じ場所に安定して挿入することができる。   Next, the plastic laminate manufacturing apparatus 70 moves the upper die plate 3 in the direction of the lower die plate 2 and moves the upper die plate 3 to the pressure member 71 attached to the upper die plate 3 as indicated by an arrow in FIG. The pressing convex portion 73 is caused to enter the concave portion 74 formed on the back surface 72 b of the plastic base material 72. At this time, the pressing convex portion 73 of the pressing member 71 and the concave portion 74 of the plastic base material 72 have a protrusion height L1 of the pressing convex portion 73 of the pressing member 71 and a depth L2 of the concave portion 74 of the plastic base material 72. Since the projecting height L1> the depth L2, the pressing convex portion 73 of the pressing member 71 is surely brought into contact with the bottom surface of the concave portion 74 of the plastic substrate 72, and the concave portion Only the bottom surface of 74 is pressurized. Further, when the pressing convex portion 73 of the pressing member 71 enters the concave portion 74 of the plastic base material 72, the pressing member 71 and the plastic base material 72 are properly positioned, and the place to be pressurized is surely added. In addition, when the plastic substrate 72 is inserted between the upper die plate 3 and the lower die plate 2 of the press machine 5, it can be stably inserted at the same place.

そして、加圧部材71がプラスチック基材72を押圧するとき、中間部材11が軟化されているため、プラスチック基材72で中間部材11を転写駒6方向に加圧することで、中間部材11が、プラスチック基材72の転写面8側(中間部材11側)の形状と転写駒6の転写面8の形状の誤差を補完するように、軟化変形する。   When the pressing member 71 presses the plastic substrate 72, the intermediate member 11 is softened. By pressing the intermediate member 11 in the direction of the transfer piece 6 with the plastic substrate 72, the intermediate member 11 becomes The plastic substrate 72 is softened and deformed so as to compensate for the error between the shape of the transfer surface 8 side (intermediate member 11 side) of the plastic substrate 72 and the shape of the transfer surface 8 of the transfer piece 6.

次に、プラスチック積層体製造装置70は、加圧部材71でプラスチック基材72を加圧した状態のまま、中間部材11が軟化温度以下になるまで冷却した後、図22に示すように、上側ダイプレート3を上方に移動させ、プラスチック基材72、中間部材11及び表層シート12から構成される一体化されたプラスチック積層体(積層プラスチック成形品)80を、図示しない搬送装置等で離型して取り出す。   Next, the plastic laminate manufacturing apparatus 70 is cooled until the intermediate member 11 is not higher than the softening temperature in a state where the plastic base material 72 is pressurized with the pressure member 71, and then the upper side as shown in FIG. The die plate 3 is moved upward, and the integrated plastic laminate (laminated plastic molded product) 80 composed of the plastic base material 72, the intermediate member 11, and the surface layer sheet 12 is released by a conveying device or the like (not shown). And take it out.

なお、本実施例においても、中間部材11と表層シート12をプラスチック基材72による押圧によって変形させているが、例えば、転写駒6に、転写面8の有効範囲外の位置で当該転写面8に開口する連通孔を形成するとともに、当該連通孔を、転写駒6の外部に設置されている真空吸引装置に連通して、中間部材11と表層シート12を、表層シート12が転写面8側に位置する状態にして、転写面8の形成されている転写駒6上に固定配置して、中間部材11及び表層シート12でその開口部が覆われた転写面8内の空気を連通孔を介して真空吸引装置によって吸引することで、転写駒6に固定されている表層シート12及び中間部材11を、転写面8に沿うように変形させてもよい。   Also in this embodiment, the intermediate member 11 and the surface layer sheet 12 are deformed by pressing with the plastic base material 72. For example, the transfer surface 8 is placed on the transfer piece 6 at a position outside the effective range of the transfer surface 8. The communication hole is communicated with a vacuum suction device installed outside the transfer piece 6 to connect the intermediate member 11 and the surface layer sheet 12 to each other, and the surface layer sheet 12 is on the transfer surface 8 side. In a state where the transfer surface 8 is fixed, it is fixedly placed on the transfer piece 6 on which the transfer surface 8 is formed, and air in the transfer surface 8 whose opening is covered with the intermediate member 11 and the surface layer sheet 12 is communicated through the communication hole. The surface layer sheet 12 and the intermediate member 11 fixed to the transfer piece 6 may be deformed along the transfer surface 8 by being sucked by a vacuum suction device.

このように、本実施例のプラスチック積層体製造装置70においては、凸面形状の加圧部材71の頂点部分に押圧凸部73を形成し、その裏面が凹面形状となっているプラスチック基材72の裏面に当該加圧部材71の押圧凸部73の進入する凹部74を形成して、加圧部材71の押圧凸部73をプラスチック基材72の凹部74内に進入させ、加圧部材71の押圧凸部73をプラスチック基材72の凹部のみに接触させてプラスチック基材72を押圧している。   Thus, in the plastic laminated body manufacturing apparatus 70 of a present Example, the press convex part 73 is formed in the vertex part of the convex-shaped pressurization member 71, and the back surface of the plastic base material 72 used as the concave shape A concave portion 74 into which the pressing convex portion 73 of the pressing member 71 enters is formed on the back surface, and the pressing convex portion 73 of the pressing member 71 enters the concave portion 74 of the plastic base material 72 to press the pressing member 71. The convex portion 73 is brought into contact with only the concave portion of the plastic substrate 72 to press the plastic substrate 72.

したがって、加圧部材72のプラスチック基材72に対する位置決めを適切に行いつつ、プラスチック基材72の基材転写面72aを、転写駒6の転写面8方向に均一に押圧することができる。   Therefore, the base material transfer surface 72 a of the plastic base material 72 can be uniformly pressed in the direction of the transfer surface 8 of the transfer piece 6 while appropriately positioning the pressing member 72 with respect to the plastic base material 72.

また、本実施例のプラスチック積層体製造装置70は、加圧部材71の押圧凸部73をプラスチック基材72の凹部74内に進入させ、加圧部材71とプラスチック基材72の位置決めを適切に行うとともに、加圧部材71の押圧凸部73をプラスチック基材72の凹部のみに接触させてプラスチック基材72を押圧している。   Further, the plastic laminate manufacturing apparatus 70 of the present embodiment allows the pressing convex portion 73 of the pressing member 71 to enter the concave portion 74 of the plastic base material 72 so that the pressing member 71 and the plastic base material 72 are properly positioned. At the same time, the pressing projection 73 of the pressing member 71 is brought into contact only with the recess of the plastic substrate 72 to press the plastic substrate 72.

したがって、プラスチック基材72の加工バラツキが発生しても、加工毎に押圧位置が変わることを防止することができ、また、加圧したい場所を確実に加圧することができるとともに、プラスチック基材72をプレス機5の上側ダイプレート3と下側ダイプレート2の間に挿入する場合に常に同じ場所に安定して挿入することができる。   Therefore, even if processing variations of the plastic base material 72 occur, it is possible to prevent the pressing position from being changed for each processing, and it is possible to pressurize the place where the press is desired, and the plastic base material 72. Can be inserted stably between the upper die plate 3 and the lower die plate 2 of the press 5 at the same place.

なお、本実施例においては、加圧部材71に押圧凸部73を形成し、プラスチック基材72に凹部74を形成しているが、逆に、プラスチック基材72に押圧凸部を形成し、加圧部材71に当該プラスチック基材72の押圧凸部の進入する凹部を形成しても良い。この場合にも、押圧凸部の高さを凹部の深さよりも高くする。   In this embodiment, the pressing protrusion 73 is formed on the pressing member 71 and the recess 74 is formed on the plastic substrate 72. Conversely, the pressing protrusion is formed on the plastic substrate 72, A concave portion into which the pressing convex portion of the plastic substrate 72 enters may be formed in the pressing member 71. Also in this case, the height of the pressing convex portion is made higher than the depth of the concave portion.

また、図23に示すように、加圧部材71の中央部に2つの押圧凸部75を形成し、プラスチック基材72の裏面72bに、加圧部材71の押圧凸部75に対応する位置に、2箇所の凹部76を形成しても良い。この場合も、押圧凸部75の高さを凹部76の深さよりも高くする。   Further, as shown in FIG. 23, two pressing convex portions 75 are formed in the center portion of the pressing member 71, and the back surface 72 b of the plastic substrate 72 is positioned at a position corresponding to the pressing convex portion 75 of the pressing member 71. Two concave portions 76 may be formed. Also in this case, the height of the pressing convex portion 75 is made higher than the depth of the concave portion 76.

このように、押圧凸部75を2つ形成し、対応する凹部76をプラスチック基材72に2つ形成すると、プラスチック基材72と加圧部材71の位置関係を回転方向においても位置決めすることができ、より一層形状精度を向上させることができる。   As described above, when two pressing convex portions 75 are formed and two corresponding concave portions 76 are formed on the plastic base material 72, the positional relationship between the plastic base material 72 and the pressing member 71 can be positioned even in the rotation direction. The shape accuracy can be further improved.

なお、図23では、2つの押圧凸部75と2つの凹部76を形成している場合を示しているが、回転方向をも位置づけする場合には、押圧凸部75と凹部76の数は、2つ以上であれば、その数は限定されない。   FIG. 23 shows a case where two pressing convex portions 75 and two concave portions 76 are formed. However, when positioning the rotational direction, the number of pressing convex portions 75 and concave portions 76 is as follows. The number is not limited as long as it is two or more.

以上、本発明者によってなされた発明を好適な実施例に基づき具体的に説明したが、本発明は上記のものに限定されるものではなく、その要旨を逸脱しない範囲で種々変更可能であることはいうまでもない。   The invention made by the present inventor has been specifically described based on the preferred embodiments. However, the present invention is not limited to the above, and various modifications can be made without departing from the scope of the invention. Needless to say.

大型プラスチックミラー等の高精度なプラスチック積層体を製造する製造方法及びプラスチック積層体に適用することができる。   The present invention can be applied to a manufacturing method for manufacturing a highly accurate plastic laminate such as a large plastic mirror and a plastic laminate.

本発明のプラスチック積層体の製造方法及びプラスチック積層体の第1実施例を適用したプラスチック積層体製造装置の正面概略構成図。BRIEF DESCRIPTION OF THE DRAWINGS The front schematic block diagram of the plastic laminated body manufacturing apparatus to which the manufacturing method of the plastic laminated body of this invention and 1st Example of a plastic laminated body are applied. 図1のプラスチック基材の拡大正面図。The enlarged front view of the plastic base material of FIG. 図1のプラスチック基材の押圧凸部と凸面形状の加圧部材の当接状態の拡大正面図。The enlarged front view of the contact state of the press convex part of the plastic base material of FIG. 1, and a convex-shaped pressurization member. 図1のプラスチック基材の押圧凸部の先端部が平面形状としたときに凹面形状の加圧部材に片当たりする状態の説明図。Explanatory drawing of the state which strikes a concave-shaped pressurization member when the front-end | tip part of the press convex part of the plastic base material of FIG. 図4の押圧凸部の先端部を所定の曲率半径の曲面として型当たりが防止できている状態の説明図。Explanatory drawing of the state which has prevented the die | dye contact | abutting by making the front-end | tip part of the press convex part of FIG. 平面状の加圧部材で裏面が平面で転写面側が凸面のプラスチック基材を押圧する場合の正面図。The front view in the case of pressing a plastic base material with a flat pressing member with a flat back surface and a convex transfer surface side. 図6の加圧部材とプラスチック基材を用いたプラスチック積層体製造装置の正面図。The front view of the plastic laminated body manufacturing apparatus using the pressurization member and plastic base material of FIG. 図7のプラスチック積層体製造装置の加圧時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of the pressurization of the plastic laminated body manufacturing apparatus of FIG. 図7のプラスチック積層体製造装置の離型時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of mold release of the plastic laminated body manufacturing apparatus of FIG. 凸面形状の加圧部材で略筋肉の凸面形状のプラスチック基材を押圧する場合の正面図。The front view in the case of pressing a substantially muscle convex-shaped plastic base material with a convex-shaped pressurization member. 図1のプラスチック積層体製造装置の加圧時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of the pressurization of the plastic laminated body manufacturing apparatus of FIG. 図1のプラスチック積層体製造装置の離型時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of mold release of the plastic laminated body manufacturing apparatus of FIG. 図1のプラスチック積層体製造装置のプラスチック基材に押圧凸部を形成しない場合の押圧状態の説明図。Explanatory drawing of the press state when not forming a press convex part in the plastic base material of the plastic laminated body manufacturing apparatus of FIG. 図13のプラスチック積層体製造装置のプラスチック基材に押圧凸部を形成した場合の押圧状態の説明図。Explanatory drawing of a press state at the time of forming a press convex part in the plastic base material of the plastic laminated body manufacturing apparatus of FIG. 図14のプラスチック積層体製造装置の筋肉の凹面形状の裏面に押圧凸部が形成され凹面形状の加圧部材で押圧する場合の押圧状態の説明図。Explanatory drawing of a press state in case a pressing convex part is formed in the concave back surface of the muscle of the plastic laminated body manufacturing apparatus of FIG. 14, and it presses with a concave pressing member. 本発明のプラスチック積層体の製造方法及びプラスチック積層体の第2実施例を適用したプラスチック積層体製造装置の正面概略構成図。The front schematic block diagram of the plastic laminated body manufacturing apparatus to which the manufacturing method of the plastic laminated body of this invention and the 2nd Example of a plastic laminated body are applied. 図16のプラスチック積層体製造装置の加圧時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of the pressurization of the plastic laminated body manufacturing apparatus of FIG. 図16のプラスチック積層体製造装置の離型時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of mold release of the plastic laminated body manufacturing apparatus of FIG. 本発明のプラスチック積層体の製造方法及びプラスチック積層体の第3実施例を適用したプラスチック積層体製造装置の正面概略構成図。The front schematic block diagram of the plastic laminated body manufacturing apparatus to which the manufacturing method of the plastic laminated body of this invention and the 3rd Example of a plastic laminated body are applied. 図19の加圧部材の先端部に傾斜面の形成されている押圧凸部とプラスチック基材の凹部部分(a)、加圧部材の押圧凸部とプラスチック基材の開口端部に傾斜面の形成されている凹部部分(b)及び加圧部材の先端部に傾斜面の形成されている押圧凸部とプラスチック基材の開口端部に傾斜面の形成されている凹部部分(c)の拡大正面断面図。The pressing convex part and the concave part (a) of the plastic substrate on which the inclined surface is formed at the tip part of the pressing member in FIG. 19, and the inclined surface on the pressing convex part of the pressing member and the opening end part of the plastic substrate. Expansion of the recessed part (c) in which the recessed part (b) currently formed and the press convex part by which the inclined surface is formed in the front-end | tip part of a pressurization member, and the inclined surface are formed in the opening edge part of a plastic base material Front sectional drawing. 図19のプラスチック積層体製造装置の加圧時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of the pressurization of the plastic laminated body manufacturing apparatus of FIG. 図19のプラスチック積層体製造装置の離型時の状態を示す正面概略構成図。The front schematic block diagram which shows the state at the time of mold release of the plastic laminated body manufacturing apparatus of FIG. 2つの押圧凸部の形成されているプラスチック基材と2つの凹部の形成されているプラスチック基材の拡大正面断面図。The expanded front sectional view of the plastic base material in which two press convex parts are formed, and the plastic base material in which two concave parts are formed.

符号の説明Explanation of symbols

1 プラスチック積層体製造装置
2 下側ダイプレート
3 上側ダイプレート
4 タイバー
5 プレス機
6 転写駒
7 加圧部材
8 転写面
9 ヒータ
10 プラスチック基材
10a 基材転写面
10b 裏面
11 中間部材
12 表層シート
13 押圧凸部
20 プラスチック積層体
30 隙間
31 空隙
40 転写駒
40a 転写面
41 プラスチック基材
42 押圧凸部
43 加圧部材
50 プラスチック積層体製造装置
51 加圧部材
52 プラスチック基材
52a 基材転写面
52b 裏面
53 押圧凸部
70 プラスチック積層体製造装置
71 加圧部材
72 プラスチック基材
72a 基材転写面
72b 裏面
73 押圧凸部
74 凹部
80 プラスチック積層体
DESCRIPTION OF SYMBOLS 1 Plastic laminated body manufacturing apparatus 2 Lower die plate 3 Upper die plate 4 Tie bar 5 Press machine 6 Transfer piece 7 Pressure member 8 Transfer surface 9 Heater 10 Plastic base material 10a Base material transfer surface 10b Back surface 11 Intermediate member 12 Surface layer sheet 13 Press convex portion 20 Plastic laminate 30 Clearance 31 Space 40 Transfer piece 40a Transfer surface 41 Plastic base material 42 Press convex portion 43 Pressure member 50 Plastic laminate manufacturing apparatus 51 Pressure member 52 Plastic base material 52a Base material transfer surface 52b Back surface DESCRIPTION OF SYMBOLS 53 Pressing convex part 70 Plastic laminated body manufacturing apparatus 71 Pressurizing member 72 Plastic base material 72a Base material transfer surface 72b Back surface 73 Pressing convex part 74 Recessed part 80 Plastic laminated body

Claims (11)

最終形状に加工された転写面の形成されている型部材と当該型部材に対して相対向する状態で配設されている加圧部材との間に、予め略最終形状に加工されたプラスチック基材と予め所望の機能膜の形成されている表層シートを、熱可塑性樹脂からなる中間部材を間に挟んで当該表層シートが前記型部材側に位置する状態で配設して、前記型部材と前記加圧部材を相対移動させて、当該加圧部材で押圧される前記プラスチック基材が前記表層シートを前記型部材の前記転写面に押圧するとともに、少なくとも前記中間部材を当該中間部材の軟化温度以上に加熱して軟化させて、前記プラスチック基材、前記中間部材及び前記表層シートを密着一体化させるとともに、前記転写面形状に補正加工するプラスチック積層体の製造方法であって、前記加圧部材と前記プラスチック基材は、少なくとも一方が他方側に突出した凸面形状であって、当該他方側が当該凸面形状と対応する凹面形状であり、当該凸面形状の頂点部分と当該凹面形状の底部分とが所定の当接面積を有する所定の部分押圧端部で当接して、前記加圧部材が前記プラスチック基材を押圧することを特徴とするプラスチック積層体の製造方法。   A plastic substrate that has been processed into a substantially final shape in advance between a mold member having a transfer surface that has been processed into a final shape and a pressure member that is disposed in a state of facing the mold member. A material and a surface layer sheet in which a desired functional film is formed in advance are disposed in a state where the surface layer sheet is located on the mold member side with an intermediate member made of a thermoplastic resin interposed therebetween, and the mold member and The pressure member is moved relative to each other, and the plastic substrate pressed by the pressure member presses the surface sheet against the transfer surface of the mold member, and at least the intermediate member is softened by the intermediate member. A method for producing a plastic laminate, wherein the plastic base material, the intermediate member, and the surface layer sheet are tightly integrated by heating and softening as described above, and the transfer surface shape is corrected. The pressure member and the plastic base material have a convex shape in which at least one protrudes to the other side, and the other side has a concave shape corresponding to the convex shape, the apex portion of the convex shape and the bottom of the concave shape A method of manufacturing a plastic laminate, wherein the portion is brought into contact with a predetermined partial pressing end portion having a predetermined contact area, and the pressure member presses the plastic substrate. 前記部分押圧端部は、前記プラスチック基材の前記加圧部材側の面に前記加圧部材方向に所定量突出して形成された押圧凸部であることを特徴とする請求項1記載のプラスチック積層体の製造方法。   2. The plastic laminate according to claim 1, wherein the partial pressing end portion is a pressing convex portion formed by protruding a predetermined amount in the pressing member direction on a surface of the plastic substrate on the pressing member side. Body manufacturing method. 前記部分押圧端部は、前記加圧部材の前記プラスチック基材側の面に前記プラスチック基材方向に所定量突出して形成された押圧凸部であることを特徴とする請求項1記載のプラスチック積層体の製造方法。   2. The plastic laminate according to claim 1, wherein the partial pressing end portion is a pressing convex portion formed by protruding a predetermined amount in the direction of the plastic substrate on the surface of the pressing member on the plastic substrate side. Body manufacturing method. 前記押圧凸部は、その先端部が所定の曲率を有した曲面に形成されていることを特徴とする請求項2または請求項3記載のプラスチック積層体の製造方法。   4. The method for manufacturing a plastic laminate according to claim 2, wherein the pressing convex portion is formed in a curved surface having a predetermined curvature at a tip portion thereof. 前記加圧部材または前記プラスチック基材は、前記加圧時に前記押圧凸部の進入する凹部が形成されていることを特徴とする請求項2から請求項4のいずれかに記載のプラスチック積層体の製造方法。   5. The plastic laminate according to claim 2, wherein the pressurizing member or the plastic base material is formed with a concave portion into which the pressing convex portion enters during the pressurization. Production method. 前記押圧凸部は、その高さが前記凹部の深さよりも所定量だけ高く形成されていることを特徴とする請求項5記載のプラスチック積層体の製造方法。   6. The method for manufacturing a plastic laminate according to claim 5, wherein the pressing convex portion is formed with a height higher than a depth of the concave portion by a predetermined amount. 前記押圧凸部と前記凹部は、当該押圧凸部の先端部に先端ほどその先端方向に対して直交する方向の断面面積が小さくなる傾斜面と当該凹部の開口側端部に開口側ほどその開口面積が大きくなる傾斜面のうち、少なくとも一方が形成されていることを特徴とする請求項5または請求項6記載のプラスチック積層体の製造方法。   The pressing convex part and the concave part have an inclined surface whose sectional area in the direction orthogonal to the tip direction becomes smaller toward the tip part of the pressing convex part and the opening side end part of the concave part toward the opening side. The method for producing a plastic laminate according to claim 5 or 6, wherein at least one of the inclined surfaces having an increased area is formed. 前記プラスチック基材は、射出成形法で作製されていることを特徴とする請求項1から請求項7のいずれかに記載のプラスチック積層体の製造方法。   The method for producing a plastic laminate according to any one of claims 1 to 7, wherein the plastic substrate is produced by an injection molding method. 前記プラスチック基材は、繊維等の強化充填材を含む非プラスチック複合材料で作製されていることを特徴とする請求項1から請求項8のいずれかに記載のプラスチック積層体の製造方法。   The method for producing a plastic laminate according to any one of claims 1 to 8, wherein the plastic substrate is made of a non-plastic composite material including a reinforcing filler such as a fiber. 最終形状に加工された転写面の形成されている型部材と当該型部材に対して相対向する状態で配設されている加圧部材との間に、予め略最終形状に加工されたプラスチック基材と予め所望の機能膜の形成されている表層シートが、熱可塑性樹脂からなる中間部材を間に挟んで当該表層シートが前記型部材側に位置する状態で配設され、前記型部材と前記加圧部材が相対移動されて、当該加圧部材によって押圧される前記プラスチック基材が前記表層シートを前記型部材の前記転写面に押圧するとともに、少なくとも前記中間部材が当該中間部材の軟化温度以上に加熱されて軟化して、前記プラスチック基材、前記中間部材及び前記表層シートが密着一体化されるとともに、前記転写面形状に補正加工されて製造されるプラスチック積層体であって、請求項1から請求項9のいずれかに記載のプラスチック積層体の製造方法で製造されていることを特徴とするプラスチック積層体。   A plastic base that has been processed into a substantially final shape in advance between a mold member having a transfer surface that has been processed into a final shape and a pressure member that is disposed opposite to the mold member. A surface layer sheet on which a material and a desired functional film are previously formed is disposed in a state where the surface layer sheet is located on the mold member side with an intermediate member made of a thermoplastic resin interposed therebetween, and the mold member and the The pressure member is relatively moved, and the plastic substrate pressed by the pressure member presses the surface layer sheet against the transfer surface of the mold member, and at least the intermediate member is equal to or higher than the softening temperature of the intermediate member. And the plastic base material, the intermediate member, and the surface layer sheet are closely integrated with each other and softened to the shape of the transfer surface. Te, plastic laminate, characterized in that it is manufactured by the manufacturing method for a plastic laminate according to any one of claims 1 to 9. 前記表層シートは、前記機能膜として、予め金属反射膜が形成されていることを特徴とする請求項10記載のプラスチック積層体。
The plastic laminate according to claim 10, wherein a metal reflective film is formed in advance on the surface layer sheet as the functional film.
JP2004379069A 2004-12-28 2004-12-28 Plastic laminate and its manufacturing method Pending JP2006181910A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105500730A (en) * 2015-12-24 2016-04-20 中航复合材料有限责任公司 High-precision forming mold and method for thickly-laid composite material boxes

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105500730A (en) * 2015-12-24 2016-04-20 中航复合材料有限责任公司 High-precision forming mold and method for thickly-laid composite material boxes
CN105500730B (en) * 2015-12-24 2020-06-09 中航复合材料有限责任公司 High-precision forming die and method for thick-layer composite material box

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