JP2011140218A - Method for molding thermoplastic resin molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for molding a thermoplastic resin molded article capable of effectively melting thermoplastic resin by electromagnetic waves in a narrow radiation range so as to mold the thermoplastic resin molded article even when the thermoplastic resin molded article is large or of the complicated-shape. <P>SOLUTION: In a placement step, a first thermoplastic resin 3A is placed in a part of a cavity 22 of a rubber mold 2, the first thermoplastic resin 3A being a solid shaped along the shape of the part of the cavity 22, and a second thermoplastic resin 3B being granular is placed in the rest of the cavity 22. Next, in a heating step, the first thermoplastic resin 3A and the second thermoplastic resin 3B within the cavity 22 are irradiated with electromagnetic waves X including a wavelength region of 0.78 to 2 μm via the rubber mold 2 to be heated and melted to make a molten resin. In a cooling step, the molten resin within the cavity 22 is cooled to obtain the thermoplastic resin molded article composed of the first thermoplastic resin 3A and the second thermoplastic resin 3B integrated together. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for forming a thermoplastic resin molded article in a rubber mold cavity by irradiating electromagnetic waves.

In general, there are various molding methods such as injection molding, blow molding, extrusion molding, and press molding as methods for obtaining a resin molded product having a predetermined shape using a thermoplastic resin.
On the other hand, in Patent Document 1, when a resin molded product made of a thermoplastic resin is molded by a vacuum casting method using a rubber mold, the thermoplastic resin is selectively used with respect to the mold. A resin molding method that can be heated is disclosed. In this resin molding method, when the molten thermoplastic resin is filled in the cavity of the mold, the thermoplastic resin is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the mold, Due to the difference in physical properties between the rubber constituting the mold and the thermoplastic resin, the thermoplastic resin can be positively heated as compared with the rubber mold.

JP 2007-216447 A

  However, in the case of molding a large thermoplastic resin molded article, there is a problem that the electromagnetic wave does not spread over the entire thermoplastic resin in the cavity because there is a limitation on the irradiation range of the electromagnetic wave. In addition, when molding a thermoplastic resin molded product having a complicated shape, the thermoplastic resin filled in a specific part of the cavity becomes a shadow of the thermoplastic resin filled in the other part, and the electromagnetic wave is sufficient. There is a problem of not reaching.

  The present invention has been made in view of such conventional problems. Even in a thermoplastic resin molded product having a large or complicated shape, the thermoplastic resin is efficiently melted by electromagnetic waves in a narrow irradiation range. An object of the present invention is to provide a method for molding a thermoplastic resin molded product that can mold a resin molded product.

In the first invention, a first thermoplastic resin in a solid state along a part of the cavity is disposed in a part of a cavity of a rubber mold made of a rubber material, and a solid state is disposed in the remaining part of the cavity. Arranging the second thermoplastic resin in a particle state or in a molten state;
The first thermoplastic resin and the second thermoplastic resin in the cavity are irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold, and the first thermoplastic resin and the second thermoplastic resin are irradiated. A heating step in which the thermoplastic resin is heated to melt as a molten resin;
A cooling step of cooling the molten resin in the cavity to obtain a thermoplastic resin molded product in which the first thermoplastic resin and the second thermoplastic resin are integrated. The method is a method of molding a product (claim 1).

In a second invention, an arrangement step of arranging a particulate thermoplastic resin in a rubber mold cavity made of a rubber material;
A part of the cavity is arranged at an electromagnetic wave irradiation position, and the thermoplastic resin in the part of the cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the rubber mold, and the thermoplastic resin is irradiated. A first molding step of melting the molten resin as a molten resin and replenishing a molten thermoplastic resin from a first injection gate provided in a part of the cavity;
The other part of the cavity is disposed at the irradiation position, and the thermoplastic resin in the other part of the cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the rubber mold, A second molding step of heating and melting the thermoplastic resin as a molten resin and replenishing the molten thermoplastic resin from a second injection gate provided in another part of the cavity;
And a cooling step of obtaining a thermoplastic resin molded product by cooling the molten resin in the cavity. (Claim 4)

According to a third aspect of the present invention, a rubber mold made of a rubber material is used, and a cavity of the rubber mold is connected to a main body cavity connected to a thermoplastic resin injection gate, and a first intersecting cavity connected to the main body cavity. Forming a second intersecting cavity that communicates with the main body cavity around the first intersecting cavity;
A core made of a rubber material is inserted into the first intersecting cavity, or the first intersecting cavity is closed with respect to the main body cavity, and the main body cavity and the second intersecting cavity are in a particle state or melted. The thermoplastic resin in a state is placed, and the thermoplastic resin is irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold to heat the thermoplastic resin, and then the heat A first preforming step of cooling the plastic resin to obtain a first molded body;
A core made of a rubber material is inserted into the second intersecting cavity, or the second intersecting cavity is closed with respect to the main body cavity, and the main body cavity and the first intersecting cavity are in a particle state or melted. The thermoplastic resin in a state is placed, and the thermoplastic resin is irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold to heat the thermoplastic resin, and then the heat A second preforming step of cooling the plastic resin to obtain a second molded body;
From the first molded body taken out from the cavity, a first molded body cut portion molded in the second cross cavity is cut out, and the first molded body cut portion is cut into the second cross cavity of the rubber mold. The second molded body cut out part molded in the first intersecting cavity is cut out from the second molded body taken out from the cavity, and the second molded body cut out part is cut into the rubber mold. The thermoplastic resin in the particle state or the molten state is disposed in the main body cavity of the rubber mold, and the first molding in the cavity is interposed through the rubber mold. The body cut portion, the second molded body cut portion, and the thermoplastic resin are irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm, and the first molded body cut portion and the second molded body cut. Protruding portion and the The thermoplastic resin is heated and melted as a molten resin, and then the molten resin is cooled, and the first molded body cut portion, the second molded body cut portion, and the thermoplastic resin are integrated. And a main molding step for obtaining a resin molded product. (5) A method for molding a thermoplastic resin molded product.

According to a fourth aspect of the present invention, a rubber mold made of a rubber material and having a cavity along the shape of a thermoplastic resin molded product to be molded is divided into a plurality of divided mold portions so that the cavity is divided into a plurality of divided cavities. Formed,
A thermoplastic resin in a solid state, a particle state, or a molten state is disposed in the split cavity of the end split mold portion located at an end of the plurality of split mold portions, and the above-described through the end split mold portion. A first molding step of irradiating the thermoplastic resin in the divided cavity with an electromagnetic wave including a wavelength region of 0.78 to 2 μm, heating the thermoplastic resin, and then cooling the thermoplastic resin;
The adjacent split mold part adjacent to the end split mold part among the plurality of split mold parts is connected to the end split mold part in a state where the thermoplastic resin is disposed in the split cavity, and the adjacent split mold part A solid state, a particle state, or a molten thermoplastic resin is disposed in the divided cavity, and a wavelength region of 0.78 to 2 μm is applied to the thermoplastic resin in the divided cavity via the adjacent divided mold portion. Performing a second molding step of heating the thermoplastic resin, welding the thermoplastic resin with the thermoplastic resin in the split cavity of the end split mold part, and cooling the thermoplastic resin,
The second molding step is repeated in the same manner for all the divided cavities of the plurality of divided mold parts, and a thermoplastic resin molded product is obtained by the cavities in which all the divided cavities are connected. The method is for molding a resin molded product (Claim 7).

  According to a fifth aspect of the present invention, there is provided a thermoplastic resin molded product obtained by performing the above-described method for molding a thermoplastic resin molded product.

In the molding method of the thermoplastic resin molded article of the first invention, molding is performed by irradiating the thermoplastic resin in the cavity with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through a rubber mold. Depending on the size, shape, etc. of the thermoplastic resin molded product, measures are taken when electromagnetic wave irradiation becomes insufficient.
Specifically, in the present invention, first, as the arranging step, the solid first thermoplastic resin is arranged in a part of the cavity of the rubber mold made of the rubber material, and the solid state is formed in the remaining part of the cavity. A second thermoplastic resin in a particle state or a molten state is disposed. At this time, the first thermoplastic resin in a solid state is formed along the shape of a part of the cavity.
By disposing the first thermoplastic resin in a solid state in a part of the cavity, the thermoplastic resin can be quickly disposed in a part of the cavity without shortage.

  Next, as a heating step, the first thermoplastic resin and the second thermoplastic resin in the cavity are irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold, and the first thermoplastic resin and the second thermoplastic resin are irradiated. The thermoplastic resin is heated and melted as a molten resin. At this time, the thermoplastic resin can be selectively heated compared to the rubber mold due to the difference in physical properties between the rubber material and the thermoplastic resin constituting the rubber mold (increasing the heating amount of the thermoplastic resin). Can do). Thereby, the temperature rise of a rubber mold | type can be suppressed and the 1st thermoplastic resin and 2nd thermoplastic resin in a cavity can be fuse | melted.

In addition, when performing the above melting, if the second thermoplastic resin is in a solid state, only the periphery of the joint portion between the first thermoplastic resin and the second thermoplastic resin is heated and melted. It can be melted as a resin.
Further, when the second thermoplastic resin is in a particle state, the joining portion of the first thermoplastic resin with the second thermoplastic resin and the entire second thermoplastic resin are melted as a molten resin. be able to. Furthermore, when the melted state (paste state, liquid state) is used for the second thermoplastic resin, the joining portion with the second thermoplastic resin in the first thermoplastic resin is melted as a molten resin, A state where the entire second thermoplastic resin is melted can be maintained as a molten resin.

  When the second thermoplastic resin in a solid state or a particle state is used, an unfilled cavity portion may be formed in the cavity when the second thermoplastic resin filled in the cavity is melted. Therefore, this unfilled cavity can be replenished with a molten thermoplastic resin. In addition, the first thermoplastic resin and the second thermoplastic resin are arranged in a cavity having a volume equal to or larger than the volume of the thermoplastic resin to be molded so that an unfilled cavity portion does not occur, and the cavity is reduced. Thus, a thermoplastic resin molded product can be molded.

Thereafter, when the molten resin in the cavity is cooled as a cooling step, a thermoplastic resin molded product in which the first thermoplastic resin and the second thermoplastic resin are integrated can be obtained.
Thereby, for example, when molding a large thermoplastic resin molded article, even when there is a limitation in the irradiation range of electromagnetic waves, the joining portion of the first thermoplastic resin and the second thermoplastic resin, or the first thermoplastic By irradiating electromagnetic waves through the rubber mold to the joint portion of the resin with the second thermoplastic resin and the entire second thermoplastic resin, the thermoplastic resin can be efficiently melted by electromagnetic waves in a narrow irradiation range. .
For example, when molding a thermoplastic resin molded product having a complicated shape, the thermoplastic resin filled in a specific part of the cavity becomes a shadow of the thermoplastic resin filled in the other part, and electromagnetic waves are generated. Even when it is considered that it does not reach sufficiently, the joined portion of the first thermoplastic resin and the second thermoplastic resin, or the joined portion of the first thermoplastic resin with the second thermoplastic resin and the entire second thermoplastic resin Furthermore, by irradiating electromagnetic waves through a rubber mold, the thermoplastic resin can be efficiently melted by electromagnetic waves in a narrow irradiation range.

  Therefore, according to the method for molding a thermoplastic resin molded article of the present invention, even a thermoplastic resin molded article having a large or complicated shape can be efficiently melted by electromagnetic waves in a narrow irradiation range and melted. A plastic resin molded product can be molded.

Also in the molding method of the thermoplastic resin molded product of the second invention, molding is performed when the thermoplastic resin in the cavity is irradiated with an electromagnetic wave containing a wavelength region of 0.78 to 2 μm through a rubber mold. Depending on the size, shape, etc. of the thermoplastic resin molded product, measures are taken when electromagnetic wave irradiation becomes insufficient.
Specifically, in the present invention, first, as an arranging step, a particulate thermoplastic resin is arranged in a cavity of a rubber mold made of a rubber material.

Next, as a first molding step, a part of the cavity is arranged at an electromagnetic wave irradiation position, and the thermoplastic resin in a part of the cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the rubber mold. Then, the thermoplastic resin in a part of the cavity is heated and melted as a molten resin.
At this time, the thermoplastic resin can be selectively heated compared to the rubber mold due to the difference in physical properties between the rubber material and the thermoplastic resin constituting the rubber mold (increasing the heating amount of the thermoplastic resin). Is possible). Thereby, the temperature rise of the rubber mold can be suppressed and the thermoplastic resin in a part of the cavity can be melted.

  Further, when the thermoplastic resin in a part of the cavity is melted, an unfilled cavity part that is not filled with the thermoplastic resin is formed in a part of the cavity. In the first molding step, molten thermoplastic resin is replenished from a first injection gate provided in a part of the cavity. As a result, the unfilled cavity portion can be filled with the molten thermoplastic resin, and the thermoplastic resin can be spread over the entire portion of the cavity.

Next, as the second molding step, another part of the cavity is arranged at the electromagnetic wave irradiation position, and a wavelength region of 0.78 to 2 μm is formed on the thermoplastic resin in the other part of the cavity through the rubber mold. The electromagnetic wave containing it is irradiated and the thermoplastic resin in the other part of the cavity is heated and melted as a molten resin.
At this time, the thermoplastic resin can be selectively heated compared to the rubber mold due to the difference in physical properties between the rubber material and the thermoplastic resin constituting the rubber mold (increasing the heating amount of the thermoplastic resin). Is possible). Thereby, the temperature rise of the rubber mold can be suppressed and the thermoplastic resin in the other part of the cavity can be melted.
In addition, the change of the arrangement relationship between the part of the cavity or the other part and the irradiation position of the electromagnetic wave can be performed by moving, rotating, or changing the direction of the rubber mold with respect to the irradiation position of the electromagnetic wave. It can also be performed by moving, rotating, changing the direction of the electromagnetic wave irradiation relative to the mold.

  Further, even when the thermoplastic resin in the other part of the cavity is melted, an unfilled cavity part not filled with the thermoplastic resin is formed in the other part of the cavity. In the second molding step, molten thermoplastic resin is replenished from a second injection gate provided in another part of the cavity. As a result, the unfilled cavity portion can be filled with the molten thermoplastic resin, and the thermoplastic resin can be spread throughout the other part of the cavity.

Thereafter, when the molten resin in the cavity is cooled as a cooling step, a thermoplastic resin molded product can be obtained by the entire cavity.
The cooling step can be air cooling (natural cooling), and when the first molding step is finished, the thermoplastic resin in a part of the cavity is cooled.
Further, when the molding process is performed twice, the other part of the cavity can be the remainder of the cavity, and when the molding process is performed three or more times, the second molding process includes: It can be repeated twice or more.

Also in the present invention, for example, when molding a large thermoplastic resin molded article, even when there is a limit to the electromagnetic wave irradiation range, by sequentially arranging each part of the cavity at the electromagnetic wave irradiation position, the electromagnetic wave is Each part can be easily spread, and the thermoplastic resin can be efficiently melted by the electromagnetic waves in a narrow irradiation range.
For example, when molding a thermoplastic resin molded product having a complicated shape, the thermoplastic resin filled in a specific part of the cavity becomes a shadow of the thermoplastic resin filled in the other part, and electromagnetic waves are generated. Even when it is thought that it does not reach sufficiently, each part of the cavity is sequentially arranged at the irradiation position of the electromagnetic wave, so that the electromagnetic wave can be easily spread to each part of the cavity, and the thermoplastic resin is efficiently used by the electromagnetic wave in a narrow irradiation range. Can be melted.

  Therefore, the thermoplastic resin can be efficiently melted by electromagnetic waves in a narrow irradiation range, regardless of whether the thermoplastic resin molded product of the present invention is a molding method or a thermoplastic resin molded product having a large or complicated shape. A resin molded product can be molded.

Also in the molding method of the thermoplastic resin molded product of the third invention, molding is performed when the thermoplastic resin in the cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through a rubber mold. Depending on the size, shape, etc. of the thermoplastic resin molded product, measures are taken when electromagnetic wave irradiation becomes insufficient.
In the present invention, a portion of a molded body is formed for each portion where the thermoplastic resin molded product is molded, and a thermoplastic resin molded product is molded using the portion of each molded body. According to the molding method of the present invention, in particular, due to the shape of the thermoplastic resin molded product, the thermoplastic resin filled in a specific part of the cavity becomes a shadow of the thermoplastic resin filled in the other part, and the electromagnetic wave is sufficient. It is an effective method when it is considered that it does not reach.

Specifically, the rubber mold cavity of the present invention is formed by intersecting the main body cavity with a first intersecting cavity and a second intersecting cavity.
First, in the first preforming step, a core made of a rubber material is inserted into the first intersecting cavity, or the first intersecting cavity is closed with respect to the body cavity, and the body cavity and the second intersecting cavity are separated. A thermoplastic resin in a particle state or a molten state is disposed. Then, the thermoplastic resin is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the rubber mold to heat the thermoplastic resin, and then the thermoplastic resin is cooled, and the main body cavity and the second A first molded body having a shape along the intersecting cavity is obtained.
Also, in the second preforming step, similarly to the first preforming step, placement of the thermoplastic resin and irradiation of electromagnetic waves are performed, and a second molded body having a shape along the main body cavity and the first intersecting cavity is obtained. obtain.

Thereafter, in the main molding step, the first molded body cut-out portion molded in the second intersecting cavity is cut out from the first molded body taken out from the cavity, and the first molded body cut-out portion is used as the rubber mold first portion. Reposition in 2 intersecting cavities. In addition, the second molded body cut out part molded in the first cross cavity is cut out from the second molded body taken out from the cavity, and the second molded body cut out part is rearranged in the first cross cavity of the rubber mold. To do. And the thermoplastic resin of a particle state or a molten state is arrange | positioned in a rubber-type main body cavity.
The rubber mold used in the first preforming process, the rubber mold used in the second preforming process, and the rubber mold used in the main molding process can be the same or different. .

In this molding process, the first molded body cutout part, the second molded body cutout part and the thermoplastic resin in the cavity are irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold. To do. Then, the first molded body cut portion, the second molded body cut portion and the thermoplastic resin in the cavity are heated and melted as a molten resin, and then the molten resin is cooled to cut the first molded body cut out. A thermoplastic resin molded product in which the portion, the second molded body cut-out portion, and the thermoplastic resin are integrated is obtained.
As a result, in the present invention, the second intersecting cavity is formed around the first intersecting cavity, and when the electromagnetic wave irradiation is performed, the thermoplastic resin filled in the first intersecting cavity and the second intersecting cavity are filled. Even when any one of the thermoplastic resins becomes a shadow of the other, and it is considered that electromagnetic waves do not sufficiently reach either one of them, the first molded body cut portion and the second molded body cut in advance are formed. By using the protruding portion, the portion where the first molded body cutout portion is bonded to the thermoplastic resin in the main body cavity and the portion where the second molded body cutout portion is bonded to the thermoplastic resin in the main body cavity are narrowed. It can be efficiently melted by the electromagnetic waves in the irradiation range.

  In each step, when a particulate thermoplastic resin is used, an unfilled cavity may be formed in the cavity when the thermoplastic resin filled in the cavity is melted. Therefore, this unfilled cavity can be replenished with a molten thermoplastic resin. Also, in order to prevent unfilled cavities from occurring, each molded body or thermoplastic is arranged so that the cavity is reduced by disposing the thermoplastic resin in the cavity having a volume equal to or larger than the volume of the thermoplastic resin to be molded. A resin molded product can also be molded.

  Therefore, even if the thermoplastic resin molded product of the present invention is used, or even a thermoplastic resin molded product having a complicated shape, the thermoplastic resin is efficiently melted by electromagnetic waves in a narrow irradiation range. The product can be molded.

Also in the molding method of the thermoplastic resin molded product of the fourth invention, molding is performed by irradiating the thermoplastic resin in the cavity with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through a rubber mold. Depending on the size, shape, etc. of the thermoplastic resin molded product, measures are taken when electromagnetic wave irradiation becomes insufficient.
In the present invention, the rubber mold is divided into a plurality of divided mold parts, each part of the thermoplastic resin molded product is molded for each divided mold part, and each part of the thermoplastic resin molded product is connected to form a thermoplastic resin Mold the product. The molding method of the present invention is an effective method especially when the thermoplastic resin molded product is large and the irradiation range of electromagnetic waves is limited.

Specifically, the rubber mold of the present invention is formed by dividing into a plurality of divided mold parts so that the cavity is divided into a plurality of divided cavities.
First, in a 1st shaping | molding process, the thermoplastic resin of a solid state, a particle | grain state, or a molten state is arrange | positioned to the division | segmentation cavity of the end division type | mold part located in the edge among several division | segmentation type | mold parts. Then, the thermoplastic resin in the split cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the end split mold part to heat the thermoplastic resin, and then cool the thermoplastic resin. Thus, the portion of the thermoplastic resin molded product is molded.
The end split mold part does not necessarily mean the end of the entire split mold part, but refers to the split mold part that heats the thermoplastic resin first.

In the second molding step, the adjacent split mold part adjacent to the end split mold part among the plurality of split mold parts is connected to the end split mold part in which the thermoplastic resin is disposed in the split cavity. And the thermoplastic resin of a solid state, a particle | grain state, or a molten state is arrange | positioned to the division | segmentation cavity of an adjacent division | segmentation type | mold part. In addition, the thermoplastic resin in the divided cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the adjacent divided mold part to heat the thermoplastic resin.
At this time, the thermoplastic resin in the split cavity of the adjacent split mold part is heated, and the joining portion of the thermoplastic resin in the split cavity of the end split mold part is also heated. Thereby, the thermoplastic resin in the split cavity of the adjacent split mold part and the joining portion of the thermoplastic resin in the split cavity of the end split mold part are melted and welded.

Thereafter, the second molding step is repeated in the same manner for all the divided cavities of the plurality of divided mold parts, and a thermoplastic resin molded product can be obtained by the cavity in which all the divided cavities are connected.
Thereby, when molding a large thermoplastic resin molded article, even if there is a limit to the irradiation range of electromagnetic waves, it is only necessary to heat the thermoplastic resin in the divided cavities of each divided mold part. It can be narrowed.

  In addition, when a thermoplastic resin in a solid state or a particle state is used, an unfilled cavity portion may be formed in the divided cavity when the second thermoplastic resin filled in the divided cavity is melted. Therefore, this unfilled cavity can be replenished with a molten thermoplastic resin. Further, in order to prevent an unfilled hollow portion from being formed, the thermoplastic resin is disposed in a divided cavity having a volume equal to or larger than the volume of the thermoplastic resin molded article to be molded, and the divided cavity is reduced so as to be thermoplastic. A resin molded product can also be molded.

  Therefore, according to the method for molding a thermoplastic resin molded article of the present invention, even a large thermoplastic resin molded article is obtained by efficiently melting a thermoplastic resin by electromagnetic waves in a narrow irradiation range. Can be molded.

  The thermoplastic resin molded article of the fifth invention is obtained by performing the molding method of the thermoplastic resin molded article, and can easily produce a thermoplastic resin molded article having a large or complicated shape. .

Sectional explanatory drawing which shows the state which has arrange | positioned the solid state 1st thermoplastic resin in the rubber-type cavity in Example 1. FIG. Sectional explanatory drawing which shows the state which arrange | positions the 2nd thermoplastic resin of a particle state in the rubber-type cavity in Example 1, and heat-melts. Sectional explanatory drawing which shows the state which shape | molded the thermoplastic resin molded product in the rubber-type cavity in Example 1. FIG. In Example 1, the wavelength (nm) is taken on a horizontal axis | shaft and the light transmittance (%) is taken on the vertical axis | shaft, and the graph which shows the light transmittance about transparent silicone rubber and translucent silicone rubber. Sectional explanatory drawing which shows the state which fills the cavity of a rubber mold with small thermoplastic resin particles and large thermoplastic resin particles in Example 1. FIG. Sectional explanatory drawing which shows the cavity of a rubber mold in Example 2. FIG. Sectional explanatory drawing which shows the state which heat-melts the thermoplastic resin in some cavities arrange | positioned in the irradiation position of the electromagnetic wave in Example 2. FIG. Sectional explanatory drawing which shows the state which solidifies the thermoplastic resin in a part of cavity in Example 2. FIG. Sectional explanatory drawing which shows the state which moves the rubber type | mold in Example 2, and heat-melts the thermoplastic resin in the remainder of the cavity arrange | positioned in the irradiation position of electromagnetic waves. Sectional explanatory drawing which shows the state which shape | molded the thermoplastic resin molded product in the rubber-type cavity in Example 2. FIG. Cross-sectional explanatory drawing which shows the state which heat-melts the thermoplastic resin in a main body cavity and a 2nd cross | intersection cavity in Example 3, and shape | molds a 1st molded object. Sectional explanatory drawing which shows the state which shape | molded the 1st molded object which has a shape in alignment with a main body cavity and a 2nd cross | intersection cavity in Example 3. FIG. Sectional explanatory drawing which shows the state which heat-melts the thermoplastic resin in a main body cavity and a 1st cross | intersection cavity in Example 3, and shape | molds a 2nd molded object. Sectional explanatory drawing which shows the state which shape | molded the 2nd molded object which has a shape in alignment with the main body cavity and the 1st intersection cavity in Example 3. FIG. Sectional explanatory drawing which shows the state which cut out the 1st molded object cutout part from the 1st molded object in Example 3. FIG. Sectional explanatory drawing which shows the state which cut out the 2nd molded object cutout part from the 2nd molded object in Example 3. FIG. Sectional explanatory drawing which shows the state which rearranges the 1st molded object cutting part and 2nd molded object cutting part in Example 3, and heat-melts it with the newly filled thermoplastic resin. Sectional explanatory drawing which shows the state which shape | molded the thermoplastic resin molded product in the rubber-type cavity in Example 3. FIG. Sectional explanatory drawing which shows the rubber die divided | segmented into the some division | segmentation type | mold part in Example 4. FIG. Sectional explanatory drawing which shows the state which heat-melts the thermoplastic resin in the division | segmentation cavity of an edge division | segmentation type | mold part in Example 4. FIG. Sectional explanatory drawing which shows the state which heat-melts the thermoplastic resin in the division | segmentation cavity of an adjacent division | segmentation type | mold part in Example 4. FIG. Sectional explanatory drawing which shows the state which cools and solidifies the molten resin in the division | segmentation cavity of an end division | segmentation type | mold part and an adjacent division | segmentation mold part in Example 4. FIG. Sectional explanatory drawing which shows the state which shape | molded the thermoplastic resin molded product in the rubber-type cavity in Example 4. FIG. Sectional explanatory drawing which shows a pair of rubber mold part in Example 5 before approaching mutually. Sectional explanatory drawing which shows a pair of rubber mold part in Example 5 after approaching mutually.

A preferred embodiment in the first to fourth inventions described above will be described.
1st invention WHEREIN: The thermoplastic resin of the same composition can be used for the 1st thermoplastic resin of the said solid state, and the 2nd thermoplastic resin of the said solid state, particle | grain state, or a molten state, A different composition These thermoplastic resins can also be used. Moreover, also about the thermoplastic resin used in 2nd-4th invention, the thermoplastic resin of the same composition can be used, and the thermoplastic resin of a different composition can also be used. When using thermoplastic resins having different compositions, it is preferable to use highly compatible thermoplastic resins in order to increase the mechanical strength.

Moreover, in the 1st-4th invention, the laminated body of a thermoplastic resin molded product can be easily shape | molded by using together the thermoplastic resin of a different composition.
In the first to fourth inventions, the rubber mold can be formed from a transparent or translucent silicone rubber as a rubber material. The hardness of this silicone rubber can be set to 25-80 in the JIS-A standard measurement.

Moreover, as a thermoplastic resin used for electromagnetic wave irradiation shaping | molding in the 1st-4th invention, what absorbs electromagnetic waves and a heating is accelerated | stimulated can be used.
The thermoplastic resin is not particularly limited as long as it contains a polymer having thermoplasticity, ABS resin (acrylonitrile / butadiene / styrene resin), ASA resin (acrylate / styrene / acrylonitrile resin), AES resin (acrylonitrile).・ Ethylene-propylene-diene / styrene resin) rubber reinforced styrene resin, polystyrene, styrene / acrylonitrile copolymer, styrene / maleic anhydride copolymer, styrene such as (meth) acrylic acid ester / styrene copolymer Resins, olefin resins such as polyethylene and polypropylene, cyclic olefin resins, acrylic resins, polycarbonate resins, polyester resins, polyamide resins, vinyl chloride resins, polyarylate resins, polyacetal resins, polyphenylene ethers Tellurium resin, polyphenylene sulfide resin, fluorine resin, imide resin, ketone resin, sulfone resin, urethane resin, polyvinyl acetate, polyethylene oxide, polyvinyl alcohol, polyvinyl ether, polyvinyl butyral, phenoxy resin, photosensitive resin, liquid crystal Examples thereof include polymers and biodegradable plastics. These can be used alone or in combination of two or more.

  Among the above thermoplastic resins, rubber-reinforced styrene resins, olefin resins, acrylic resins, polyester resins, polyamide resins, polyester resins and polycarbonate resins are suitable as thermoplastic resins used for electromagnetic wave irradiation molding. Examples include alloys of alloys, rubber-reinforced styrene resins and polycarbonate resins, alloys of rubber-reinforced styrene resins and polyester resins.

In addition, the first thermoplastic resin in the solid state uses a preformed rubber mold having a preforming cavity having the same shape as a part of the cavity, and 0% of the thermoplastic resin filled in the preforming cavity. It is preferable that it is obtained by irradiating an electromagnetic wave including a wavelength region of .78 to 2 μm, heating the thermoplastic resin, and then cooling it.
In this case, the first thermoplastic resin in a solid state having a shape along a part of the cavity can be easily molded by using a rubber mold for preforming.

In the first invention, in the arranging step, the second thermoplastic resin in the particle state is arranged in the remaining portion of the cavity, and in the heating step, the molten thermoplastic resin is replenished in the remaining portion of the cavity. (Claim 3).
In the third invention, in the main molding step, it is preferable that the thermoplastic resin in a particle state is placed in the main body cavity and heated and melted, and the main body cavity is replenished with the molten thermoplastic resin. Item 6).

  In this case, the entire cavity can be filled with the thermoplastic resin without increasing the filling pressure so much that the deformation and opening of the rubber mold can be effectively suppressed. Therefore, it is possible to prevent resin leakage from the divided surface (parting surface) in the rubber mold, and to effectively improve the quality, mechanical strength, and the like of the molded thermoplastic resin molded product. be able to.

1st-4th invention WHEREIN: The thermoplastic resin of the said particle state contains 0.1-20 mass% of small thermoplastic resin particles with a particle diameter of 1-100 micrometers, and the remainder is from this small thermoplastic resin particle. It is preferable that the thermoplastic resin particle composition is composed of large thermoplastic resin particles having a large size.
In this case, by using a thermoplastic resin particle composition containing small thermoplastic resin particles having a particle diameter of 1 to 100 μm and large thermoplastic resin particles larger than that, a particulate thermoplastic resin is obtained. When filling the rubber mold cavity, the small thermoplastic resin particles adhere to the inner wall surface of the cavity, and the large thermoplastic resin particles pass between the small thermoplastic resin particles in the cavity. Can do. Therefore, the filling of the thermoplastic resin in the particle state into the cavity can be performed smoothly.

Here, the rubber mold is made of a rubber material, and the small thermoplastic resin particles can be adhered to the inner wall surface of the cavity made of the rubber material when the particle diameter is in the range of 1 to 100 μm. it can.
In addition, when the thermoplastic resin in the particle state is disposed in a rubber-type cavity (including a main body cavity, a first intersecting cavity, a second intersecting cavity, and a divided cavity), small thermoplastic resin particles are disposed first. Thereafter, large thermoplastic resin particles can be arranged. Thereby, small thermoplastic resin particles can be easily attached to the inner wall surface of the cavity.

  The content ratio of the small thermoplastic resin particles to the large thermoplastic resin particles is 0.1 to 20% by mass for the former and 80 to 99.9% by mass for the latter. As a result, the ratio of large thermoplastic resin particles is increased, and when the thermoplastic resin particle composition is heated and melted by irradiating the electromagnetic wave through a rubber mold, the thermoplastic resin particle composition is burned or the like. It is possible to prevent problems from occurring.

  In addition, it is difficult to produce a small thermoplastic resin particle having a particle diameter of less than 1 μm. When the small thermoplastic resin particle has a particle diameter of less than 1 μm, the thermoplastic resin molded product may be molded. Handling becomes difficult. On the other hand, when the particle size of the small thermoplastic resin particles is more than 100 μm, it is difficult to exert an effect of adhering the small thermoplastic resin particles to the inner wall surface of the cavity.

  Further, when the content ratio of the small thermoplastic resin particles is less than 0.1% by mass, the amount of the small thermoplastic resin particles attached to the inner wall surface of the cavity is small, and the small thermoplastic resin particles in the cavity are small. It becomes difficult to exert the effect of passing large thermoplastic resin particles between each other. On the other hand, when the content ratio of the small thermoplastic resin particles exceeds 20% by mass, when the thermoplastic resin particle composition is heated and melted, the small thermoplastic resin particles attached to the inner wall surface of the cavity are burned. May cause problems.

The particle size of the small thermoplastic resin particles is more preferably 3 to 90 μm. Moreover, the particle diameter of the said large thermoplastic resin particle can be made into the range of 200-3000 micrometers, for example. The particle size of the large thermoplastic resin particles is more preferably 300 to 2000 μm, and further preferably 350 to 1500 μm.
In addition, the content ratio of the small thermoplastic resin particles in the thermoplastic resin particle composition is preferably 10% by mass or less, and more preferably 7% by mass or less.
The melt flow rate (220 ° C., 10 kg load) of the thermoplastic resin used for the small thermoplastic resin particles and the large thermoplastic resin particles is preferably 1 to 100 g / 10 min, and is preferably 5 to 80 g / 10 min. More preferably, it is more preferably 15 to 65 g / 10 min.

  In the first invention, in the arranging step, the second thermoplastic resin in a solid state or a particle state is arranged in the remaining portion of the cavity, and in the heating step, the pressure in the cavity is set by the vacuum means. Lowering the pressure outside the rubber mold part and generating a suction force between the pair of rubber mold parts, while melting the first thermoplastic resin and the second thermoplastic resin, A pair of rubber mold parts are brought close to each other, and in the cooling step, the thermoplastic resin molded product can be obtained by the cavity having a reduced volume.

  In this case, a cavity having a larger volume than the molded product to be molded is formed between the pair of rubber mold parts, and the volume of the cavity is melted when the first thermoplastic resin and the second thermoplastic resin are melted. Can be reduced to obtain a molded product. Further, in this case, the melted thermoplastic resin is easily spread over the entire cavity by bringing the pair of rubber mold portions closer to each other using the suction force (clamping force) generated by the vacuum means. be able to.

Further, the rubber mold is formed by combining a pair of rubber mold parts, and the cavity is formed between facing surfaces where the pair of rubber mold parts are combined with each other, and either one of the pair of rubber mold parts The rubber mold part is formed with a frame-like or annular fitting recess in the entire circumference of the cavity, and the other rubber mold part of the pair of rubber mold parts is fitted into the fitting recess. An annular or convex insertion convex portion is formed, and the entire circumference of the cavity can be closed by inserting the insertion convex portion into the insertion concave portion (claim 10).
In this case, it is possible to easily prevent the thermoplastic resin from leaking out from the gap formed on the opposing surface in order to bring the pair of rubber mold portions closer to each other.

Hereinafter, embodiments of the method for molding a thermoplastic resin molded article of the present invention will be described with reference to the drawings.
Example 1
In the molding method of the thermoplastic resin molded product 6 of this example, the thermoplastic resin molded product 6 is molded by performing the following arrangement process, heating process and cooling process.
In the arrangement step, as shown in FIG. 1, the solid first thermoplastic resin 3 </ b> A having a shape along the part 221 of the cavity 22 is arranged in the part 221 of the cavity 22 of the rubber mold 2 made of a rubber material. In addition, as shown in FIG. 2, the second thermoplastic resin 3 </ b> B in the particle state is disposed in the remaining part 222 of the cavity 22. Next, in the heating step, the first thermoplastic resin 3A and the second thermoplastic resin 3B in the cavity 22 are irradiated with an electromagnetic wave X including a wavelength region of 0.78 to 2 μm through the rubber mold 2 to obtain the first The thermoplastic resin 3A and the second thermoplastic resin 3B are heated and melted as a molten resin. In the cooling step, as shown in FIG. 3, the molten resin in the cavity 22 is cooled to obtain a thermoplastic resin molded product 6 in which the first thermoplastic resin 3A and the second thermoplastic resin 3B are integrated. .

Below, it explains in full detail with reference to FIGS. 1-5 about the shaping | molding method of the thermoplastic resin molded product 6 of this example.
In this example, an ABS resin that is an amorphous resin and a rubber-reinforced styrene resin is used as the thermoplastic resin.
The rubber mold 2 of this example is made of a transparent or translucent silicone rubber. This rubber mold 2 has a master model (manufactured product, etc.) of a thermoplastic resin molded product 6 to be molded placed in a liquid silicone rubber, the silicone rubber is cured, and the cured silicone rubber is cut open. It can be produced by taking out the master model from silicone rubber.

  Further, as shown in FIG. 1, the rubber mold 2 can be formed by forming one separation surface and combining two separation mold portions 21, and forming two or more separation surfaces to form three or more The separation mold part 21 can also be formed in combination. At the time of molding, the plurality of separation mold portions 21 hold the combined state by means for preventing mold opening. In addition, the separation surfaces 21 can be easily aligned with each other by forming the separation surface in an irregular wave shape or the like.

As shown in FIG. 2, the electromagnetic wave irradiation device 1 includes a generation source 11 of an electromagnetic wave (light) X and a reflector (reflecting plate) 12 that guides the electromagnetic wave X from the generation source 11 toward the rubber mold 2. . As the electromagnetic wave irradiation device 1 of this example, a near infrared halogen heater having a light intensity peak in the vicinity of about 1.2 μm in the near infrared region is used. This near-infrared halogen heater is configured to emit an electromagnetic wave X including a wavelength region of 0.78 to 2 μm.
In this example, when filling the molten thermoplastic resin into the cavity 22 of the rubber mold 2, it can be filled with an injection pressure of 0.5 to 5 MPa. Further, when the molten thermoplastic resin is filled into the cavity 22 of the rubber mold 2, the inside of the cavity 22 can be evacuated.

  Further, in the step of solidifying the thermoplastic resin by heating and melting, it is preferable to clamp the mold so that each separation mold portion 21 in the rubber mold 2 does not open. Specifically, mold clamping using a metal plate or the like by a hydraulic or electric device, mold clamping using a clamp, a screw, or the like, and the inside of the rubber mold 2 (between the separation mold parts 21) are evacuated to a large size. For example, mold clamping using the difference from atmospheric pressure. Among these, it is preferable to perform mold clamping using a vacuum state from the viewpoint that the irradiation of the electromagnetic wave X is not prevented when the thermoplastic resin is heated and melted.

  In addition, the absorbance to electromagnetic waves (light) X including a wavelength region of 0.78 to 2 μm (a measure indicating the absorption intensity with respect to light of a specific wavelength) is the rubber rubber mold of the ABS resin used as the thermoplastic resin. It is larger than the silicone rubber used as 2. The absorbance can be measured using, for example, Shimadzu UV3100.

  FIG. 4 shows the light transmittance of each silicone rubber, with wavelength (nm) on the horizontal axis and light transmittance (%) on the vertical axis for transparent silicone rubber and translucent silicone rubber. It is a graph. In the figure, it can be seen that each silicone rubber transmits light having a wavelength between 200 and 2200 (nm). For this reason, when the surface of the rubber mold 2 made of silicone rubber is irradiated with near-infrared rays (light having a wavelength range of 0.78 to 2 μm) that is in this wavelength region, most of the near-infrared rays are transmitted through the rubber die 2. It can be absorbed by a thermoplastic resin. It can be seen that the thermoplastic resin can be selectively heated as compared with the rubber mold 2.

In the molding method of the thermoplastic resin molded article 6 of this example, when the thermoplastic resin in the cavity 22 is irradiated with the electromagnetic wave X including the wavelength region of 0.78 to 2 μm through the rubber mold 2, Depending on the size, shape, etc. of the thermoplastic resin molded product 6 to be molded, measures are taken when the irradiation with the electromagnetic wave X becomes insufficient.
Next, a method for molding the thermoplastic resin molded product 6 using the electromagnetic wave irradiation device 1 and the rubber mold 2 and the effects thereof will be described in detail.

  As shown in FIG. 1, the cavity 22 of the rubber mold 2 of this example includes a main body cavity 222 in which a thermoplastic resin injection gate 23 is communicated with the main body cavity 222 according to the shape of the thermoplastic resin molded product 6 to be molded. And a plurality of intersecting cavities 221 communicating with each other. In this example, as shown in FIG. 2, the first thermoplastic resin 3 </ b> A in a solid state is used for the portion of the thermoplastic resin molded product 6 that is molded into a plurality of intersecting cavities 221 as a part 221 of the cavity 22. The portion of the thermoplastic resin molded product 6 to be molded into the remaining main body cavity 222 is molded using the second thermoplastic resin 3B in the particle state.

First, as a preforming step, a preforming rubber mold having a preforming cavity having the same shape as the intersecting cavity 221 is used, and the thermoplastic resin filled in the preforming cavity includes a wavelength region of 0.78 to 2 μm. The electromagnetic wave X is irradiated, the thermoplastic resin is heated, and then cooled to mold the solid first thermoplastic resin 3A.
Next, as shown in FIG. 1, as an arranging step, the first thermoplastic resin 3 </ b> A in a solid state is arranged in the intersecting cavity (a part of the cavity 22) 221 of the rubber mold 2 made of a rubber material, and shown in FIG. 2. As described above, the second thermoplastic resin 3 </ b> B in a particle state is disposed in the main body cavity (the remaining part of the cavity 22) 222. By disposing the first thermoplastic resin 3 </ b> A in the solid state in the intersecting cavity 221, it is possible to quickly dispose the thermoplastic resin in a part 221 of the cavity 22 without shortage.

  As shown in FIG. 5, the second thermoplastic resin 3 </ b> B of this example contains 0.1 to 20% by mass of small thermoplastic resin particles 32 having a particle diameter of 1 to 100 μm, and the remainder is smaller than the small thermoplastic resin particles 32. This is a thermoplastic resin particle composition comprising large thermoplastic resin particles 31 having a large size. When the second thermoplastic resin 3B is filled into the cavity 22 of the rubber mold 2, the small thermoplastic resin particles 32 adhere to the inner wall surface 220 of the cavity 22, and the large thermoplastic resin particles 31 It is possible to pass between the small thermoplastic resin particles 32 in 22. Therefore, it is possible to smoothly fill the cavity 22 with the particulate thermoplastic resin.

Here, the rubber mold 2 is made of a rubber material, and the small thermoplastic resin particles 32 are formed on the inner wall surface 220 of the cavity 22 made of a rubber material by the particle diameter being in the range of 1 to 100 μm. Can be attached.
Further, in the arranging step, the small thermoplastic resin particles 32 are arranged (sprinkled) in the cavity 22 with the rubber mold 2 opened, and the thermoplastic resin for the cavity 22 is closed with the rubber mold 2 closed. The large thermoplastic resin particles 31 can be filled from the injection gate 23.

  And as for the content ratio of the small thermoplastic resin particle 32 and the large thermoplastic resin particle 31, the former is 0.1-20 mass% and the latter is 80-99.9 mass%. Thus, when the ratio of the large thermoplastic resin particles 31 is increased and the electromagnetic wave X is irradiated through the rubber mold 2 to melt the thermoplastic resin particle composition, the thermoplastic resin particle composition is added to the thermoplastic resin particle composition. It is possible to prevent problems such as burning.

Next, as shown in FIG. 2, as a heating process, an electromagnetic wave X including a wavelength region of 0.78 to 2 μm is applied to the first thermoplastic resin 3 </ b> A and the second thermoplastic resin 3 </ b> B in the cavity 22 through the rubber mold 2. Irradiate and heat the first thermoplastic resin 3A and the second thermoplastic resin 3B to melt as a molten resin. At this time, the thermoplastic resin can be selectively heated as compared with the rubber mold 2 due to the difference in physical properties between the rubber material and the thermoplastic resin constituting the rubber mold 2 (the heating amount of the thermoplastic resin is increased). can do). Thereby, the temperature rise of the rubber mold 2 can be suppressed, and the first thermoplastic resin 3A and the second thermoplastic resin 3B in the cavity 22 can be melted.
In addition, when the melting is performed, the joining portion 31A of the first thermoplastic resin 3A with the second thermoplastic resin 3B is remelted as a molten resin, and the entire second thermoplastic resin 3B is melted as a molten resin. Can do.

  When the thermoplastic resin particle composition (thermoplastic resin in a particle state) in the main body cavity 222 is melted, an unfilled cavity portion that is not filled with the thermoplastic resin is formed in the main body cavity 222. In the heating step, molten thermoplastic resin is replenished from the injection gate 23 provided in the main body cavity 222. Thereby, the unfilled cavity portion can be filled with the molten thermoplastic resin, and the thermoplastic resin can be spread throughout the cavity 22.

Thereafter, as shown in FIG. 3, when the molten resin in the cavity 22 is cooled as a cooling step, the thermoplastic resin molded product 6 in which the first thermoplastic resin 3A and the second thermoplastic resin 3B are integrated is obtained. Can do.
Thereby, when molding the large thermoplastic resin molded product 6, even when the irradiation range of the electromagnetic wave X is limited, the joining portion 31 </ b> A and the second thermoplastic resin 3 </ b> A in the first thermoplastic resin 3 </ b> A are second and second. By irradiating the entire thermoplastic resin 3B with the electromagnetic wave X through the rubber mold 2, the thermoplastic resin can be efficiently melted by the electromagnetic wave X in a narrow irradiation range.

  Further, when molding the thermoplastic resin molded product 6 having a complicated shape, the heat filled in the intersecting cavity 221 as the other portion of the thermoplastic resin filled in the intersecting cavity 221 as the specific portion in the cavity 22 is obtained. Even when it is considered that the electromagnetic wave X does not reach the shadow in the shadow of the plastic resin, the joint portion 31A of the first thermoplastic resin 3A with the second thermoplastic resin 3B and the entire second thermoplastic resin 3B By irradiating the electromagnetic wave X through the rubber mold 2, the thermoplastic resin can be efficiently melted by the electromagnetic wave X in a narrow irradiation range.

  Further, in this example, by using the second thermoplastic resin 3B in the particle state, the entire cavity 22 can be filled with the thermoplastic resin without excessively increasing the filling pressure. Opening can be effectively suppressed. Therefore, resin leakage from the separation surface (parting surface) in the rubber mold 2 can be prevented, and the quality, mechanical strength, and the like of the molded thermoplastic resin molded product 6 can be effectively improved. Can be improved.

  Therefore, according to the molding method of the thermoplastic resin molded product 6 of this example, the thermoplastic resin is efficiently melted by the electromagnetic wave X in a narrow irradiation range even in the thermoplastic resin molded product 6 having a large or complicated shape. Thus, the thermoplastic resin molded product 6 can be molded.

(Example 2)
In this example, as shown in FIGS. 6 to 10, as a countermeasure when the irradiation of the electromagnetic wave X is insufficient depending on the size, shape, etc. of the thermoplastic resin molded product 6 to be molded, the electromagnetic wave irradiation device 1 is used. In this example, the thermoplastic resin molded product 6 is molded by sequentially moving the positions where the respective portions of the cavity 22 of the rubber mold 2 face each other.
As shown in FIG. 6, the rubber mold 2 used in this example has thermoplastic resin injection gates 23 at a plurality of locations of the cavity 22. Specifically, the rubber mold 2 of this example has a first injection gate 23 </ b> A on one side of the cavity 22 and a second injection gate 23 </ b> B on the other side of the cavity 22.
The rubber mold 2 is arranged on the moving means, and the part to be irradiated with the electromagnetic wave X can be changed by facing the electromagnetic wave irradiation device 1. The moving means of this example is configured to rotate the rubber mold 2 so that a part 221 of the cavity 22 in the rubber mold 2 and the remaining part 222 are sequentially opposed to the electromagnetic wave irradiation device 1.

In this example, as shown in FIG. 7, first, as a disposing step, the particle-shaped thermoplastic resin 3C is filled into the cavity 22 of the rubber mold 2 made of a rubber material. As the particulate thermoplastic resin 3C, the same thermoplastic resin composition as in Example 1 is used.
Next, as shown in the figure, as a first molding step, a part 221 of the cavity 22 is placed at the irradiation position P of the electromagnetic wave X by the moving means (focusing on the electromagnetic wave irradiation apparatus 1), and the rubber mold 2 is interposed. Then, the thermoplastic resin in the part 221 of the cavity 22 is irradiated with an electromagnetic wave X including a wavelength region of 0.78 to 2 μm, and the thermoplastic resin in the part 221 of the cavity 22 is heated and melted as a molten resin.

  At this time, the thermoplastic resin can be selectively heated as compared with the rubber mold 2 due to the difference in physical properties between the rubber material and the thermoplastic resin constituting the rubber mold 2 (the heating amount of the thermoplastic resin is increased). can do). Thereby, the temperature rise of the rubber mold 2 can be suppressed, and the thermoplastic resin in the part 221 of the cavity 22 can be melted.

Further, when the thermoplastic resin in the part 221 of the cavity 22 is melted, an unfilled cavity part that is not filled with the thermoplastic resin is formed in the part 221 of the cavity 22. In the first molding step, the molten thermoplastic resin is replenished from the first injection gate 23 </ b> A provided in the part 221 of the cavity 22. Thereby, the unfilled cavity portion can be filled with the molten thermoplastic resin, and the thermoplastic resin can be spread over the entire part 221 of the cavity 22.
Thereafter, as shown in FIG. 8, the thermoplastic resin in the part 221 of the cavity 22 is cooled.

Next, as shown in FIG. 9, as a second molding step, the remaining portion 222 of the cavity 22 is placed at the irradiation position P of the electromagnetic wave X by the moving means (focusing on the electromagnetic wave irradiation device 1), and the rubber mold 2 is interposed. The thermoplastic resin in the remaining part 222 of the cavity 22 is irradiated with an electromagnetic wave X including a wavelength region of 0.78 to 2 μm, and the thermoplastic resin in the remaining part 222 of the cavity 22 is heated and melted as a molten resin.
At this time, the thermoplastic resin can be selectively heated as compared with the rubber mold 2 due to the difference in physical properties between the rubber material and the thermoplastic resin constituting the rubber mold 2 (the heating amount of the thermoplastic resin is increased). can do). Thereby, the temperature rise of the rubber mold 2 can be suppressed and the thermoplastic resin in the remaining portion 222 of the cavity 22 can be melted.

  Further, even when the thermoplastic resin in the remaining portion 222 of the cavity 22 is melted, an unfilled hollow portion that is not filled with the thermoplastic resin is formed in the remaining portion 222 of the cavity 22. In the second molding step, molten thermoplastic resin is replenished from the second injection gate 23 </ b> B provided in the remaining portion 222 of the cavity 22. Thereby, the unfilled cavity portion can be filled with the molten thermoplastic resin, and the thermoplastic resin can be spread over the entire remaining portion 222 of the cavity 22.

Thereafter, as shown in FIG. 10, when the molten resin in the cavity 22 is cooled as a cooling step, the thermoplastic resin molded product 6 can be obtained by the entire cavity 22.
The cooling step can be air cooling (natural cooling), and when the heating by the electromagnetic wave X is finished, cooling of the thermoplastic resin in the cavity 22 is started.

Also in this example, when molding a large thermoplastic resin molded product 6, even when the irradiation range of the electromagnetic wave X is limited, each part of the cavity 22 is sequentially disposed at the irradiation position P of the electromagnetic wave X, thereby X can be easily distributed to each part of the cavity 22, and the thermoplastic resin can be efficiently melted by the electromagnetic wave X in a narrow irradiation range.
Further, when molding a thermoplastic resin molded product 6 having a complicated shape, the thermoplastic resin filled in a specific portion of the cavity 22 becomes a shadow of the thermoplastic resin filled in the other portion, and the electromagnetic wave X Even when it is considered that the electromagnetic wave X is not sufficiently reached, the electromagnetic wave X can be easily distributed to the respective parts of the cavity 22 by sequentially arranging the respective parts of the cavity 22 at the irradiation position P of the electromagnetic wave X. The thermoplastic resin can be efficiently melted by X.

Therefore, the thermoplastic resin is efficiently melted by the electromagnetic wave X in a narrow irradiation range, regardless of the molding method of the thermoplastic resin molded product 6 of this example or the thermoplastic resin molded product 6 having a large or complicated shape. Thus, the thermoplastic resin molded product 6 can be molded.
Also in this example, other configurations are the same as those of the first embodiment, and the same effects as those of the first embodiment can be obtained.

(Example 3)
In this example, as shown in FIGS. 11 to 18, depending on the size, shape, etc. of the thermoplastic resin molded product 6 to be molded, as a countermeasure when the irradiation of the electromagnetic wave X becomes insufficient, a part of the cavity 22 is used. This is an example in which molded bodies 41A and 41B having shapes corresponding to the shapes are molded in advance, and molding by electromagnetic wave irradiation heating is performed using the molded bodies 41A and 41B.
In this example, moldings 41A and 41B are molded for each portion where the thermoplastic resin molded product 6 is molded, and the thermoplastic resin molded product 6 is molded using the molded products 41A and 41B. According to the molding method of this example, the thermoplastic resin filled in a specific part of the cavity 22 becomes a shadow of the thermoplastic resin filled in the other part due to the shape of the thermoplastic resin molded product 6 in particular. This is an effective method when X is considered not to reach sufficiently.

In this example, as shown in FIG. 11, the cavity 22 of the rubber mold 2 is divided into a main body cavity 22A in which a thermoplastic resin injection gate 23 is connected, and a first intersecting cavity 22B in communication with the main body cavity 22A. A second intersecting cavity 22C communicating with the main body cavity 22A is formed around the first intersecting cavity 22B.
The first intersecting cavity 22B and the second intersecting cavity 22C are formed on the same side in the thickness direction of the main body cavity 22A, and when irradiating the electromagnetic wave X, one of the intersecting cavities 22B or 22C is filled. The thermoplastic resin becomes a shadow of the thermoplastic resin filled in the other intersecting cavity 22C or 22B, and a state where the electromagnetic wave X does not reach sufficiently is formed.

Therefore, in this example, the thermoplastic resin molded product 6 is molded by performing the following first preforming step, second preforming step, and main molding step.
First, as shown in FIG. 11, in the first preforming step, a core 25 made of a rubber material is inserted into the first intersecting cavity 22B, and the particle-like heat is introduced into the main body cavity 22A and the second intersecting cavity 22C. A plastic resin 3C is disposed. The thermoplastic resin is irradiated with an electromagnetic wave X including a wavelength region of 0.78 to 2 μm through the rubber mold 2, and the thermoplastic resin 3C is heated and melted as a molten resin. As the particulate thermoplastic resin 3C, the same thermoplastic resin composition as in Example 1 is used.

Next, when the thermoplastic resin in the main body cavity 22A and the second intersecting cavity 22C is melted, an unfilled cavity portion not filled with the thermoplastic resin is formed in the main body cavity 22A and the second intersecting cavity 22C. In the first preforming step, molten thermoplastic resin is replenished from an injection gate 23 provided in the main body cavity 22A. Thereby, the unfilled cavity portion can be filled with the molten thermoplastic resin, and the thermoplastic resin can be spread over the main body cavity 22A and the second intersecting cavity 22C.
Thereafter, as shown in FIG. 12, the molten resin in the cavity 22 is cooled to obtain a first molded body 4A having a shape along the main body cavity 22A and the second intersecting cavity 22C.

  Further, as shown in FIG. 13, in the second preforming step, a core 25 made of a rubber material is inserted into the second intersecting cavity 22C, and the particle-like heat is introduced into the main body cavity 22A and the first intersecting cavity 22B. A plastic resin 3C is disposed. The thermoplastic resin is irradiated with an electromagnetic wave X including a wavelength region of 0.78 to 2 μm through the rubber mold 2, and the thermoplastic resin 3C is heated and melted as a molten resin. As the particulate thermoplastic resin 3C, the same thermoplastic resin composition as in Example 1 is used.

Next, as in the case of the first preforming step, an injection gate 23 provided in the main body cavity 22A is formed in an unfilled hollow portion formed when the thermoplastic resin in the main body cavity 22A and the first intersecting cavity 22B is melted. To refill the molten thermoplastic resin. Thus, the unfilled cavity is filled with the molten thermoplastic resin.
Thereafter, as shown in FIG. 14, the molten resin in the cavity 22 is cooled to obtain a second molded body 4B having a shape along the main body cavity 22A and the first intersecting cavity 22B.

  Thereafter, in the main molding step, as shown in FIG. 15, the first molded body cut portion 41A molded in the second intersecting cavity 22C is cut out from the first molded body 4A taken out from the cavity 22, and FIG. As shown, the first molded body cut portion 41A is rearranged in the second intersecting cavity 22C of the rubber mold 2. Further, as shown in FIG. 16, a second molded body cut portion 41B molded in the first intersecting cavity 22B is cut out from the second molded body 4B taken out from the cavity 22, and the second molded body 41B is cut as shown in FIG. The molded body cut portion 41B is rearranged in the first intersecting cavity 22B of the rubber mold 2. Then, the thermoplastic resin 3 </ b> C in a particle state is disposed in the main body cavity 22 </ b> A of the rubber mold 2. As the particulate thermoplastic resin 3C, the same thermoplastic resin composition as in Example 1 is used.

The rubber mold 2 used in the first preforming process, the rubber mold 2 used in the second preforming process, and the rubber mold 2 used in the main molding process can be the same or different. You can also
Further, instead of using the core 25, the first intersecting cavity 22B or the second intersecting cavity 22C may be closed with a material such as a rubber film or sheet.

  As shown in FIG. 17, in the main molding step, the first molded body cut portion 41 </ b> A, the second molded body cut portion 41 </ b> B and the thermoplastic resin 3 </ b> C in the cavity 22 through the rubber mold 2 are set to 0. An electromagnetic wave X including a wavelength region of 78 to 2 μm is irradiated. Then, the first molded body cut portion 41A, the second molded body cut portion 41B, and the thermoplastic resin 3C in the cavity 22 are heated and melted as a molten resin.

At this time, the first molded body cut portion 41A may remelt the joint portion 411A with respect to the thermoplastic resin 3C, and the second molded body cut portion 41B may remelt the joint portion 411B with respect to the thermoplastic resin 3C. it can.
The unfilled hollow portion formed when the thermoplastic resin 3C in the main body cavity 22A is melted is replenished with molten thermoplastic resin from the injection gate 23 provided in the main body cavity 22A. Thus, the unfilled cavity is filled with the molten thermoplastic resin.

Thereafter, as shown in FIG. 18, the molten resin in the cavity 22 is cooled, and the first molded body cut portion 41A, the second molded body cut portion 41B, and the thermoplastic resin 3C are integrated. 6 is obtained.
Thereby, in this example, the second intersecting cavity 22C is formed around the first intersecting cavity 22B, and when the electromagnetic wave X is irradiated, the thermoplastic resin filled in the first intersecting cavity 22B and the second intersecting cavity 22B. Even when one of the thermoplastic resins filled in the cavity 22C becomes a shadow of the other, and the electromagnetic wave X is considered not to sufficiently reach either one, the first molded body cut-out portion molded in advance By using 41A and the second molded body cut portion 41B, the first molded body cut portion 41A is joined to the molten resin in the main body cavity 22A, and the second molded body cut portion 41B is the main body cavity 22A. The portion 411B joined to the molten resin can be efficiently melted by the electromagnetic wave X in a narrow irradiation range.

Therefore, even with the molding method of the thermoplastic resin molded product 6 of this example and the thermoplastic resin molded product 6 having a complicated shape, the thermoplastic resin is efficiently melted by the electromagnetic wave X in a narrow irradiation range and heated. The plastic resin molded product 6 can be molded.
Also in this example, other configurations are the same as those of the first embodiment, and the same effects as those of the first embodiment can be obtained.

Example 4
In this example, as shown in FIGS. 19 to 23, depending on the size, shape, etc. of the thermoplastic resin molded product 6 to be molded, a plurality of rubber molds 2 are used as a countermeasure when electromagnetic wave X irradiation is insufficient. Dividing into split mold parts 26A and 26B, molding each part of the thermoplastic resin molded product 6 for each split mold part 26, and connecting each part of the thermoplastic resin molded product 6 to mold the thermoplastic resin molded product 6 This is an example. The molding method of this example is an effective method especially when the irradiation range of the electromagnetic wave X is limited because the thermoplastic resin molded product 6 is large.

  In this example, as shown in FIG. 19, a plurality of divided mold parts are formed so that the rubber mold 2 having the cavity 22 along the shape of the thermoplastic resin molded product 6 to be molded is divided into a plurality of divided cavities 27. It is divided into 26A and 26B. A gate mold portion 26C in which a thermoplastic resin injection gate 23 is formed is connected to the end portions of the plurality of divided mold portions 26A and 26B.

First, as shown in FIG. 20, in the first molding step, the gate mold part 26C is connected to the split cavity 27 of the end split mold part 26A located at the end of the plurality of split mold parts 26A, 26B, and the gate The particulate thermoplastic resin 3C is disposed from the injection gate 23 in the mold part 26C. As the particulate thermoplastic resin 3C, the same thermoplastic resin composition as in Example 1 is used.
Then, the thermoplastic resin 3C in the split cavity 27 is irradiated with the electromagnetic wave X including the wavelength region of 0.78 to 2 μm through the end split mold part 26A, and the thermoplastic resin 3C is heated to form a molten resin. Melt.

At this time, the unfilled hollow portion formed when the thermoplastic resin 3C in the divided cavity 27 is melted is replenished with the molten thermoplastic resin from the injection gate 23 provided in the gate mold portion 26C. Thus, the unfilled cavity is filled with the molten thermoplastic resin.
Then, as shown in FIG. 21, the portion 61 of the thermoplastic resin molded product 6 is formed by cooling the molten resin in the divided cavity 27.

  Next, as shown in the figure, in the second molding step, among the plurality of split mold parts 26A, 26B, the adjacent split mold part 26B adjacent to the end split mold part 26A is replaced by the thermoplastic resin portion 61 of the split cavity 27. It is connected to the end-split mold part 26A in the state of being disposed at the position. Then, the thermoplastic resin 3C in a particle state is disposed in the divided cavity 27 of the adjacent divided mold part 26B. Further, the thermoplastic resin 3C in the divided cavity 27 is irradiated with an electromagnetic wave X including a wavelength region of 0.78 to 2 μm through the adjacent divided mold part 26B to heat the thermoplastic resin 3C.

At this time, the thermoplastic resin 3C in the split cavity 27 of the adjacent split mold portion 26B is heated, and the joining portion 611 of the thermoplastic resin portion 61 in the split cavity 27 of the end split mold portion 26A is also heated. As a result, the thermoplastic resin 3C in the split cavity 27 of the adjacent split mold portion 26B is melted as a molten resin, and the joining portion 611 of the thermoplastic resin portion 61 in the split cavity 27 of the end split mold portion 26A is the molten resin. Remelt as. Then, an unfilled hollow portion formed when the thermoplastic resin 3C in the divided cavity 27 of the adjacent divided mold portion 26B is melted is replenished with molten thermoplastic resin.
Thereafter, as shown in FIG. 22, the molten resin in the split cavities 27 of the end split mold part 26A and the adjacent split mold part 26B is cooled, so that the thermoplastic resin in each split cavity 27 is welded, and the thermoplastic resin is welded. A portion 62 of the molded product 6 is molded.

Thereafter, as shown in FIG. 23, the second molding step is repeated in the same manner for the remaining divided cavities 27 of the adjacent divided mold part 26B, and the thermoplastic resin molded product 6 is obtained by the cavities 22 in which all the divided cavities 27 are connected. be able to.
Thereby, when the large thermoplastic resin molded article 6 is molded, even if the irradiation range of the electromagnetic wave X is limited, it is only necessary to heat the thermoplastic resin in the divided cavities 27 of each divided mold part 26. The irradiation range of X can be narrowed.

Therefore, according to the molding method of the thermoplastic resin molded product 6 of the present example, even for a large thermoplastic resin molded product 6, the thermoplastic resin is efficiently melted by the electromagnetic wave X in a narrow irradiation range and is thermoplastic. The resin molded product 6 can be molded.
Also in this example, other configurations are the same as those of the first embodiment, and the same effects as those of the first embodiment can be obtained.

(Example 5)
In this example, as shown in FIGS. 24 and 25, a cavity 22 having a volume larger than that of the thermoplastic resin molded product 6 to be molded is formed between a pair of rubber mold portions 2A and 2B formed by dividing the rubber mold 2. In this example, the thermoplastic resin molded product 6 is obtained by reducing the volume of the cavity 22 when the first thermoplastic resin 3A and the second thermoplastic resin 3B are melted.
In this example, the cavity 22 is formed between the opposing surfaces 201 where the pair of rubber mold portions 2A and 2B are joined together, and one side rubber mold portion which is one of the pair of rubber mold portions 2A and 2B. 2A is formed with annular insertion recesses 282 and 283 around the entire circumference of the cavity 22, and the other rubber mold portion 2B of the pair of rubber mold portions 2A and 2B has an insertion recess 282 and 283. An annular fitting convex portion 284 is formed to be fitted into the.

As shown in FIG. 24, the one-side rubber mold portion 2A of this example includes a cavity forming convex portion 281 for molding the back surface 602 of the thermoplastic resin molded product 6, and an annular fitting concave portion 282 on the entire circumference of the cavity forming convex portion 281. An annular outer peripheral convex portion 283 that is formed and protruded is provided. The other rubber mold portion 2B has a cavity forming concave portion 285 for forming the design surface 601 of the thermoplastic resin molded product 6 by disposing the cavity forming convex portion 281 on the inside, and protrudes at the entire peripheral edge portion of the cavity forming concave portion 285 and protrudes annularly. An annular inner circumferential convex portion 284 that is fitted into the inner circumferential surface 283A of the convex portion 283 and is disposed in the annular fitting concave portion 282 is provided.
The insertion recesses 282 and 283 in the rubber mold parts 2A and 2B of this example are formed by the annular insertion recess part 282 and the annular outer peripheral protrusion part 283 in the one-side rubber mold part 2A, and the rubber mold parts 2A and 2B of this example. The insertion convex portion 284 is formed by an annular inner peripheral convex portion 284 in the other rubber mold portion 2B.

As shown in the figure, the outer peripheral surface 284A of the annular inner circumferential convex portion 284 in the other rubber mold portion 2B is the inner circumferential surface of the annular outer circumferential convex portion 283 at the original position before the pair of rubber mold portions 2A, 2B are brought close to each other. It is inserted into 283A. The pair of rubber mold parts 2A, 2B is formed between the pair of rubber mold parts 2A, 2B by the outer peripheral surface 284A of the annular inner peripheral convex part 284 and the inner peripheral surface 283A of the annular outer peripheral convex part 283 before and after being brought close to each other. The entire circumference of the cavity 22 and the opposing surface (divided surface) 201 is closed.
By fitting the outer peripheral surface 284A of the annular inner peripheral convex portion 284 in the other rubber mold portion 2B into the inner peripheral surface 283A of the annular outer peripheral convex portion 283 in the one side rubber mold portion 2A, the pair of rubber mold portions 2A, 2B are brought closer to each other. Therefore, it is possible to easily prevent the molten thermoplastic resins 3A and 3B from leaking from the gap 29 formed in the facing surface 201.

As shown in FIGS. 24 and 25, in this example, in addition to the pair of rubber mold portions 2 </ b> A and 2 </ b> B and the electromagnetic wave irradiation device 1, a vacuum means 51 that evacuates the cavity 22 is used. The vacuum means 51 is a pump connected to the pair of rubber mold portions 2A, 2B, and is configured to evacuate the cavity 22 in which the thermoplastic resins 3A, 3B are arranged, and to make the cavity 22 in a vacuum state. Has been.
Further, a backup plate 2C is disposed opposite to the one-side rubber mold portion 2A, and a vacuum for vacuuming by the vacuum means 51 is provided between the one-side rubber mold portion 2A and the backup plate 2C. A pulling path 286 is formed.

In the arrangement step of this example, the second thermoplastic resin 3B in the particle state is arranged in the remaining part of the cavity 22 formed by arranging the first thermoplastic resin 3A in the solid state.
Next, in the heating step, the pressure in the cavity 22 is made lower than the pressure outside the pair of rubber mold parts 2A, 2B by the vacuum means 51, and a suction force (mold) is formed between the pair of rubber mold parts 2A, 2B. By generating the fastening force F, the pair of rubber mold parts 2A and 2B are brought close to each other while melting the first thermoplastic resin 3A and the second thermoplastic resin 3B.
Thereafter, in the cooling step, the thermoplastic resin molded product 6 is obtained by the cavity 22 having a reduced volume.

In this example, since the volume of the cavity 22 is reduced and the thermoplastic resin molded product 6 is molded, there is no need to separately fill the cavity 22 with a molten thermoplastic resin. Further, a device such as a resin injection nozzle that melts the thermoplastic resin in advance and injects it into the cavity 22 becomes unnecessary. In addition, almost all of the thermoplastic resins 3 </ b> A and 3 </ b> B disposed in the cavity 22 can be used for molding the thermoplastic resin molded product 6.
Also in this example, other configurations are the same as those of the first embodiment, and the same effects as those of the first embodiment can be obtained.

DESCRIPTION OF SYMBOLS 1 Electromagnetic wave irradiation apparatus 2 Rubber mold 22 Cavity 221 Crossing cavity 222 Main body cavity 23 Injection gate 25 Core 3A 1st thermoplastic resin 3B 2nd thermoplastic resin 3C Thermoplastic resin of a particle state 31 Large thermoplastic resin particle 32 Small heat Plastic resin particles 4A First molded body 4B Second molded body 6 Thermoplastic resin molded product X Electromagnetic wave

Claims (11)

A solid state first thermoplastic resin having a shape along a part of the cavity is disposed in a part of a cavity of a rubber mold made of a rubber material, and a solid state, a particle state, or a molten state is disposed in the remaining part of the cavity. An arrangement step of arranging the second thermoplastic resin;
The first thermoplastic resin and the second thermoplastic resin in the cavity are irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold, and the first thermoplastic resin and the second thermoplastic resin are irradiated. A heating step in which the thermoplastic resin is heated to melt as a molten resin;
A cooling step of cooling the molten resin in the cavity to obtain a thermoplastic resin molded product in which the first thermoplastic resin and the second thermoplastic resin are integrated. Molding method.   2. The thermoplastic resin according to claim 1, wherein the first thermoplastic resin in the solid state uses a preforming rubber mold having a preforming cavity having the same shape as a part of the cavity, and is filled in the preforming cavity. A method for molding a thermoplastic resin molded article, which is obtained by irradiating a resin with an electromagnetic wave containing a wavelength region of 0.78 to 2 μm, heating the thermoplastic resin, and then cooling. In Claim 1 or 2, in the arrangement step, the second thermoplastic resin in a particle state is arranged in the remainder of the cavity,
In the heating step, a molten thermoplastic resin is replenished to the remainder of the cavity, and a method for molding a thermoplastic resin molded product is provided. An arrangement step of arranging a particulate thermoplastic resin in a rubber mold cavity made of a rubber material;
A part of the cavity is arranged at an electromagnetic wave irradiation position, and the thermoplastic resin in the part of the cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the rubber mold, and the thermoplastic resin is irradiated. A first molding step of melting the molten resin as a molten resin and replenishing a molten thermoplastic resin from a first injection gate provided in a part of the cavity;
The other part of the cavity is disposed at the irradiation position, and the thermoplastic resin in the other part of the cavity is irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm through the rubber mold, A second molding step of heating and melting the thermoplastic resin as a molten resin and replenishing the molten thermoplastic resin from a second injection gate provided in another part of the cavity;
And a cooling step for cooling the molten resin in the cavity to obtain a thermoplastic resin molded product. A rubber mold made of a rubber material is used, and a cavity of the rubber mold is connected to a main body cavity connected to a thermoplastic resin injection gate, a first cross cavity connected to the main body cavity, and the first cross cavity. And forming a second intersecting cavity communicating with the main body cavity in the periphery of
A core made of a rubber material is inserted into the first intersecting cavity, or the first intersecting cavity is closed with respect to the main body cavity, and the main body cavity and the second intersecting cavity are in a particle state or melted. The thermoplastic resin in a state is placed, and the thermoplastic resin is irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold to heat the thermoplastic resin, and then the heat A first preforming step of cooling the plastic resin to obtain a first molded body;
A core made of a rubber material is inserted into the second intersecting cavity, or the second intersecting cavity is closed with respect to the main body cavity, and the main body cavity and the first intersecting cavity are in a particle state or melted. The thermoplastic resin in a state is placed, and the thermoplastic resin is irradiated with electromagnetic waves including a wavelength region of 0.78 to 2 μm through the rubber mold to heat the thermoplastic resin, and then the heat A second preforming step of cooling the plastic resin to obtain a second molded body;
From the first molded body taken out from the cavity, a first molded body cut portion molded in the second cross cavity is cut out, and the first molded body cut portion is cut into the second cross cavity of the rubber mold. The second molded body cut out part molded in the first intersecting cavity is cut out from the second molded body taken out from the cavity, and the second molded body cut out part is cut into the rubber mold. The thermoplastic resin in the particle state or the molten state is disposed in the main body cavity of the rubber mold, and the first molding in the cavity is interposed through the rubber mold. The body cut portion, the second molded body cut portion, and the thermoplastic resin are irradiated with an electromagnetic wave including a wavelength region of 0.78 to 2 μm, and the first molded body cut portion and the second molded body cut. Protruding portion and the The thermoplastic resin is heated and melted as a molten resin, and then the molten resin is cooled, and the first molded body cut portion, the second molded body cut portion, and the thermoplastic resin are integrated. A molding method for a thermoplastic resin molded product comprising a main molding step of obtaining a resin molded product.   6. The heat forming method according to claim 5, wherein, in the main molding step, the thermoplastic resin in a particle state is placed in the main body cavity and heated and melted, and the main body cavity is replenished with the molten thermoplastic resin. Molding method of plastic resin molded product. A rubber mold made of a rubber material and having a cavity along the shape of a thermoplastic resin molded product to be molded is divided into a plurality of divided mold parts so as to divide the cavity into a plurality of divided cavities,
A thermoplastic resin in a solid state, a particle state, or a molten state is disposed in the split cavity of the end split mold portion located at an end of the plurality of split mold portions, and the above-described through the end split mold portion. A first molding step of irradiating the thermoplastic resin in the divided cavity with an electromagnetic wave including a wavelength region of 0.78 to 2 μm, heating the thermoplastic resin, and then cooling the thermoplastic resin;
The adjacent split mold part adjacent to the end split mold part among the plurality of split mold parts is connected to the end split mold part in a state where the thermoplastic resin is disposed in the split cavity, and the adjacent split mold part A solid state, a particle state, or a molten thermoplastic resin is disposed in the divided cavity, and a wavelength region of 0.78 to 2 μm is applied to the thermoplastic resin in the divided cavity via the adjacent divided mold portion. Performing a second molding step of heating the thermoplastic resin, welding the thermoplastic resin with the thermoplastic resin in the split cavity of the end split mold part, and cooling the thermoplastic resin,
The second molding step is repeated in the same manner for all the divided cavities of the plurality of divided mold parts, and a thermoplastic resin molded product is obtained by the cavities in which all the divided cavities are connected. Molding method for resin molded products.   The thermoplastic resin according to any one of claims 1 to 7, wherein the particulate thermoplastic resin contains 0.1 to 20% by mass of small thermoplastic resin particles having a particle diameter of 1 to 100 µm, and the balance is the small thermoplastic resin. A method for molding a thermoplastic resin molded article, which is a thermoplastic resin particle composition comprising large thermoplastic resin particles larger than resin particles. In Claim 1 or 2, in the arrangement step, the second thermoplastic resin in a solid state or a particle state is arranged in the remaining part of the cavity,
In the heating step, the pressure in the cavity is made lower than the pressure outside the pair of rubber mold parts by vacuum means, and a suction force is generated between the pair of rubber mold parts, whereby the first While melting one thermoplastic resin and the second thermoplastic resin, the pair of rubber mold parts are brought close to each other,
In the cooling step, the thermoplastic resin molded product is obtained by the cavity having a reduced volume. The rubber mold according to claim 9, wherein the rubber mold is formed by combining a pair of rubber mold portions, and the cavity is formed between opposing surfaces where the pair of rubber mold portions are combined with each other,
One of the pair of rubber mold parts is formed with a frame-like or annular insertion recess on the entire circumference of the cavity, and the other rubber mold of the pair of rubber mold parts The part is formed with a frame-like or annular fitting convex part that fits into the fitting concave part,
A method for molding a thermoplastic resin molded article, wherein the entire circumference of the cavity is closed by inserting the insertion convex portion into the insertion concave portion.   A thermoplastic resin molded article obtained by performing the method for molding a thermoplastic resin molded article according to any one of claims 1 to 10.

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