JP2013049234A - Facility for manufacturing molded sheet product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a facility for manufacturing a molded sheet product, capable of efficiently manufacturing favorable products in which misalignment of patterns is suppressed.SOLUTION: This facility includes: a sheet transfer means for transferring a strip of a thermoplastic resin sheet by intermittent feed in which the sheet is moved and stopped alternately in the longitudinal direction, and a molding die for thermally forming the thermoplastic resin sheet, in which the molding die is disposed to a path for transferring the thermoplastic resin sheet by the sheet transfer means, a means for controlling the transfer amount of the thermoplastic resin sheet based on the result of the detection of the position detection mark 21 by a position detection means to adjust the position for stopping a pattern 22 is provided as an adjusting means, at least two position detection means are provided as the position detection means, that is, a first position detection means provided upstream of the molding die in the transfer direction of the thermoplastic resin sheet and a second position detection means provided downstream of the molding die.

Description

  The present invention relates to a production facility for a sheet molded product, and more specifically, a sheet conveying unit that conveys a belt-shaped thermoplastic resin sheet by intermittent feeding that alternately moves and stops in the longitudinal direction, and the thermoplastic resin sheet A thermoplastic resin mold, and the thermoplastic resin sheet is provided at a predetermined interval in the longitudinal direction, and the thermoplastic resin sheet is arranged in a conveying path of the thermoplastic resin sheet by the sheet conveying means. Sheet molding further comprising adjusting means for adjusting a stop position of the design in the intermittent feeding to a predetermined position with respect to the molding die so that a sheet molded product with the design provided at a predetermined position can be manufactured using a sheet. Product manufacturing equipment.

Conventionally, it has been widely practiced to produce a sheet molded product such as a flat plate or a bowl container by thermoforming a thermoplastic resin sheet. As a thermoplastic resin sheet used for producing such a sheet molded product, a thermoplastic resin is used. A resin film using a resin, a resin foam sheet using a thermoplastic resin, or a laminated foam sheet in which the resin film is laminated on one side or both sides of the resin foam sheet are known.
In producing this type of sheet molded article, from the viewpoint of production efficiency, a wide belt-shaped thermoplastic resin sheet that is usually several tens of cm to over 1 m is used. A continuous production method using a wound sheet roll is employed.

For example, in a conventional method for producing a sheet molded article, a heating zone for heating a thermoplastic resin sheet and a molding zone adjacent to the heating zone via a shutter for blocking hot air in the heating zone are provided. A thermoforming machine configured to supply a thermoplastic resin sheet heated and softened in the heating zone to the molding zone and thermo-mold with a molding die provided in the molding zone is a sheet molding product. Widely used in continuous production.
In this type of thermoforming machine, usually, an operation of moving the strip-shaped thermoplastic resin sheet in the longitudinal direction by a length necessary for one-time thermoforming by the mold and the thermoplastic resin sheet in the mold are performed. The sheet forming apparatus further includes sheet conveying means for conveying the thermoplastic resin sheet by a conveying method called intermittent feeding that alternately performs an operation of stopping for a certain period for thermoforming, and the thermoforming machine includes the sheet The thermoplastic resin sheet is supplied to the molding zone by the conveying means, and the thermoplastic resin sheet after thermoforming can be discharged from the molding zone by the sheet conveying means.

By the way, when producing such a sheet molded article, a design such as a character or a pattern is provided for the purpose of imparting decorativeness.
At this time, a method of providing a design by performing curved surface printing etc. on a punched product obtained by punching a thermoplastic resin sheet after thermoforming with a Thomson blade mold or the like is generally adopted. Since curved surface printing requires a relatively advanced technique, the range of use is limited.
As a simpler method than the curved surface printing, there is widely known a method in which a thermoplastic resin sheet provided with a design is thermoformed and the design is provided in a sheet molded product.
On the other hand, in such a method, if the design is stopped at a predetermined position of the mold and thermoforming is not performed, the design may be shifted from the predetermined position of the sheet molded product.
For example, in such a method, if the amount of one-time movement of the thermoplastic resin sheet in intermittent feeding and the interval of the design of the thermoplastic resin sheet can be accurately matched, it is sufficient at the first thermoforming. By performing the alignment, the sheet molded product produced thereafter can be made equivalent to the one that was first thermoformed, but if the amount of movement in intermittent feeding is slightly different from the interval of the design, this The error is accumulated as the number of times of thermoforming is increased, and there is a possibility that the positional deviation between the forming die and the design becomes large and the sheet molded product becomes a defective product.

However, even if it is going to prevent such a problem, since the interval of the design actually introduced into the molding zone is influenced by the tension applied to the thermoplastic resin sheet in the intermittent feeding, the interval is accurately grasped in advance. It is difficult to keep the amount of movement of the thermoplastic resin sheet once and the interval between the designs.
In addition, conventionally, it is easy to cope with low-volume production of various products while reducing the storage space for raw materials, so a laminated foam sheet is produced by laminating a strip-shaped resin film with a design on the strip-shaped resin foam sheet. However, after the laminated foam sheet is thermoformed to obtain the required number of sheet molded articles, the resin foam sheet is left as it is, and only the resin film is switched to continuously produce sheet molded articles having different designs. However, in such a case, when the resin film is bonded to the resin foam sheet, the resin film may be stretched and the design interval may be different from the planned interval. Therefore, it is much more difficult to suppress the above problems.

  In order to solve such a problem, the following Patent Document 1 discloses that a design provided on a thermoplastic resin sheet can be imaged during a stop period of intermittent feeding, and the obtained image is analyzed and originally designed. Describes the manufacturing equipment for sheet molded products that can determine the amount of deviation between the position where the sheet should stop and the position where the design actually stopped not only in the longitudinal direction but also in the width direction of the thermoplastic resin sheet. A manufacturing facility is described which is configured so that the position of the mold can be corrected based on the amount of deviation when the analyzed region is introduced into the molding zone.

The manufacturing facility described in Patent Document 1 employs means for correcting the position of the mold as means for adjusting the stop position of the design to be a predetermined position with respect to the mold, and therefore, for the sheet molded product. Although it is possible to suppress the positional deviation of the design, the thermoplastic resin sheet is not largely displaced in the width direction after starting the production of the sheet molded product. Even performing the position adjustment not only makes the alignment excessively strict, but also increases the time required for thermoforming.
In addition, the manufacturing facility described in Patent Document 1 employs a means for correcting the position of the mold as a position adjusting means for adjusting the stop position of the design to a predetermined position. A large control mechanism is required, and a large amount of power may be required to move the mold.

  That is, it is difficult to efficiently manufacture a good product in which design deviation is suppressed with conventional sheet-formed product manufacturing equipment.

Japanese Patent Laying-Open No. 2005-081605

In order to solve the above problems, for example, as the thermoplastic resin sheet, a design is provided at a predetermined interval in the longitudinal direction, and a position detection mark is provided along the longitudinal direction by providing an interval corresponding to the interval of the design. Of the thermoplastic resin sheet in the intermittent feeding according to the interval of the position detection marks by providing the position detection means capable of detecting the position detection marks in the manufacturing equipment of the sheet molded product. By adjusting the amount of movement and adjusting the position of the design with respect to the mold, it is easy to create a good sheet molded product that does not require large-scale control such as correcting the position of the mold itself and suppresses the displacement of the design. Can get to.
For example, the amount of movement of the thermoplastic resin sheet is provided by providing the thermoplastic resin sheet with a position detection mark that has a difference from the surroundings depending on the shade of the color tone, and by providing position detection means such as a photoelectric tube in the manufacturing equipment for the sheet molded product. Can be adjusted according to the interval of the design, and a good sheet molded product in which the deviation of the design is suppressed can be easily obtained.

However, usually, in such a case, the position detection means is disposed in the middle of the path along which the position detection mark moves along with the movement of the thermoplastic resin sheet. If it is arranged on the upstream side, the information used for adjusting the amount of movement of the thermoplastic resin sheet after the end of the thermoplastic resin sheet has passed through the location where the position detecting means is arranged just before the end of production of the sheet molded product Is not obtained, and it becomes difficult to form a sheet molded product in which the displacement of the design is suppressed to the end portion of the thermoplastic resin sheet.
On the other hand, when the position detection means is arranged downstream of the mold, the thermoplastic resin is used until the thermoplastic resin sheet reaches the position where the position detection means is arranged after the start of the production of the sheet molded product. Information used for adjusting the amount of movement of the sheet cannot be obtained, and it may be difficult to form a good sheet molded product in which design deviation is suppressed.
Therefore, in the above cases, there is still a room for further improving the manufacturing efficiency of the sheet molded product.
This invention is made | formed in view of the above problems, and makes it a subject to provide the manufacturing apparatus of the sheet molded product which can manufacture efficiently the favorable product by which the shift | offset | difference of a design was suppressed.

  The present invention relating to a manufacturing facility for a sheet molded product for solving the above-described problems includes a sheet conveying unit that conveys a belt-shaped thermoplastic resin sheet by intermittent feeding that alternately moves and stops in the longitudinal direction, and the heat A molding die for thermoforming the thermoplastic resin sheet, and the molding die is arranged in a conveyance path of the thermoplastic resin sheet by the sheet conveying means, and a design is provided at predetermined intervals in the longitudinal direction. The apparatus further includes adjusting means for adjusting a stop position of the design in the intermittent feeding to a predetermined position with respect to the mold so that a sheet molded product having the design provided at a predetermined position can be manufactured using a thermoplastic resin sheet. A sheet-formed product manufacturing facility having a band-like shape provided with a position detection mark along a longitudinal direction with an interval corresponding to the interval of the design together with the design Position detection means for detecting the position detection mark to prepare the sheet molded product using a thermoplastic resin sheet is provided, and based on the detection result of the position detection mark by the position detection means, Means for adjusting the amount of movement to adjust the stop position of the design is provided as the adjusting means, and the first means disposed as the position detecting means on the upstream side in the moving direction of the thermoplastic resin sheet from the mold. It is characterized in that at least two position detecting means are provided, that is, a position detecting means and a second position detecting means arranged downstream of the mold.

Note that the “design interval” in the longitudinal direction of the strip-shaped thermoplastic resin sheet refers to this mold in the case of using a multi-cavity mold in which a plurality of products are formed by one-shot thermoforming. It does not mean the distance between the designs introduced into adjacent molding surfaces among the plurality of molding surfaces, and does not simply mean the distance between the designs adjacent in the longitudinal direction.
That is, the “design interval” in the longitudinal direction of the strip-shaped thermoplastic resin sheet in the present specification means the interval that the design to be introduced on the same molding surface of the mold is maintained in the longitudinal direction of the thermoplastic resin sheet. I mean.

  In the present invention, since the means for adjusting the stop position of the design by adjusting the moving amount of the thermoplastic resin sheet is provided as the adjusting means for adjusting the stop position of the design to a predetermined position with respect to the mold, Control can be simplified compared with conventional manufacturing equipment that corrects the position, and power required for position adjustment can be reduced.

Moreover, in the present invention, as the position detecting means, first position detecting means provided on the upstream side in the movement direction of the thermoplastic resin sheet from the mold and second position detecting provided on the downstream side of the mold. Since at least two position detection means are provided, the first position detection means provided on the upstream side of the mold is used immediately after the start of the production of the sheet molded product, thereby suppressing the deviation of the design. A sheet molded product in which the deviation of the design is suppressed by using the second position detecting means provided on the downstream side of the mold at the end of the production of the sheet molded product. Can be manufactured.
That is, according to the present invention, a sheet molded product in which design deviation is suppressed can be manufactured from the start to the end of manufacture, and a good product in which design deviation is suppressed can be efficiently manufactured. .

The schematic perspective view which shows the round dish container which is a sheet molded product manufactured by the manufacturing equipment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS Schematic which shows the equipment structure of the sheet molded product of this invention ((a) top view, (b) front view). The enlarged view of the area | region shown with the broken line X in FIG.

  In the following, a thermoplastic resin film with a design (hereinafter also simply referred to as “resin film”) is laminated on one side of a thermoplastic resin foam sheet (hereinafter also simply referred to as “resin foam sheet”) to obtain a laminated foam sheet. A round dish container having a laminating apparatus for manufacturing and a thermoforming machine for thermoforming the laminated foamed sheet formed by the laminating apparatus, wherein the inner surface of the container is formed of the resin film by the thermoforming machine. The production facility for the sheet molded product of the present invention will be described taking the production facility to be manufactured as an example.

FIG. 1 is a schematic perspective view showing the round dish container produced by the manufacturing equipment of this embodiment. As shown in this figure, in this embodiment, a checkered pattern is formed on the inner surface as a sheet molded product. The production equipment for sheet molded products will be described taking as an example the case of producing a round dish container 1 having the above design.
The round dish container 1 is formed by a laminated foamed sheet 4 obtained by laminating a resin film 2 with a design to be provided in the round dish container 1 on a white plain resin foamed sheet 3, and the inner surface side is the resin film. 2 and the outer surface side is formed of the resin foam sheet 3.
The round dish container 1 includes a bottom surface portion 11 having a circular shape in plan view, a side wall portion 12 rising outwardly from an outer edge 11e of the bottom surface portion 11, and a flange portion 13 extending short outward from the upper end edge 12e of the side wall portion 12. A circular opening is formed in the upper portion by the upper end edge 12e of the side wall portion 12.
The round dish container 1 is decorated with the checkered pattern only on the inner surface portion of the side wall portion 12 excluding the bottom surface portion 11 and the flange portion 13.

  In this embodiment, the long strip-shaped laminated foamed sheet 2 in which donut-shaped designs 22 for forming such a round container 1 are provided at predetermined intervals in the longitudinal direction is moved in the longitudinal direction. The design is supplied to the thermoforming machine 5 by intermittent feeding that repeats the stop and adjusted to a predetermined position with respect to the mold 51 provided in the thermoforming machine 5 by adjusting the amount of movement of the thermoplastic resin sheet in the intermittent feeding. The round plate container in which the design 22 for stopping the design 22 is adjusted, the molding die 51 is brought into contact with the laminated foamed sheet 2 at the time of the stop and thermoforming is performed, and the design 22 is provided at a predetermined position. 1 is manufactured.

In addition, in the present embodiment, the laminated foamed sheet 2 is provided with a laminated foamed sheet 2 provided with a plurality of position detection marks 21 along the longitudinal direction at intervals corresponding to the intervals of the design 22. Using a manufacturing facility provided with a position detection means 7 capable of detecting the detection mark 21, the position detection means 7 is arranged at a position which becomes a movement path of the position detection mark, and the position detection mark 21 by the position detection means 7 is used. Position detection is performed for each movement of the thermoplastic resin sheet, the movement amount of the thermoplastic resin sheet is adjusted so that the movement amount corresponds to the interval of the design, and the position adjustment of the design 22 is performed to adjust the roundness. The dish container 1 is produced.
In the figure, the moving direction of the laminated foam sheet 2 (position detection mark 21) is indicated by an arrow “D”.

  In the present embodiment, in each movement of the laminated foam sheet 2 in intermittent feeding, the position detection mark 21 is moved downstream and the position detecting means 7 detects the position of the laminated foam sheet 2. The movement distance is set to a constant distance less than the interval between the position detection marks, the next position detection mark is stopped on the upstream side of the position detection means, and the movement distance after the position detection is performed at a preset speed. The manufacturing equipment used to manufacture the round dish container 1 with a constant time required for the movement after the position detection will be described.

The manufacturing equipment and members of the round dish container 1 will be described with reference to FIGS.
FIG. 2 is a schematic diagram showing the configuration of the manufacturing facility according to the present embodiment used for manufacturing the round dish container, and the direction from the left side to the right side when viewed from the front is the flow direction of the manufacturing line.
2A is a plan view, and FIG. 2B is a front view.
3 is an enlarged view of the region indicated by the broken line X in FIG. 2, and the introduction of the thermoformed machine 5 and the laminated foamed sheet 2 immediately after the resin film 4 is laminated on the resin foamed sheet 3. It is the schematic plan view which showed the mode of the said laminated foam sheet 2 in the heating zone provided in the part.

In the sheet molded product manufacturing facility 100 used in the present embodiment, the long band-shaped resin foam sheet 3 and the long band-shaped resin film 4 having substantially the same width are sequentially laminated and integrated in the length direction. A laminating apparatus 6 for continuously producing the laminated foamed sheet 2 and a thermoforming machine 5 for thermoforming the laminated foamed sheet 2 produced by the laminating apparatus 6.
That is, the manufacturing equipment of the present embodiment is configured to produce the laminated foamed sheet 2 by laminating and integrating the resin foamed sheet 3 and the resin film 4 by thermal lamination, and the laminated foamed sheet 2 to the thermoforming machine 5. It is comprised so that it can supply to the said round dish container 1 and can be manufactured.

The laminating apparatus 6 is provided with a raw roll 30 in which the resin foam sheet 3 is wound at a position on the most upstream side, and a long belt-like resin is provided on the downstream side of the raw roll 30. A film roll 40 around which the film 4 is wound is disposed.
And the said laminating apparatus 6 with which the manufacturing equipment of this embodiment is equipped is comprised so that the resin foam sheet 3 paid out from the said original fabric roll 30 and the resin film 4 drawn out from the said film roll 40 may be heat-laminated. The resin film 4 is overlapped on the upper surface of the resin foam sheet 3 that is horizontally disposed, and the resin film 4 can be laminated and integrated by passing between a pair of upper and lower rollers 61 and 62. Has been.
That is, the pair of rollers 61 and 62 is a heating roller 61 in which the upper roller that is in contact with the resin film 4 can be set to a predetermined temperature, and the lower roller is simply a heating roller that does not normally perform heating. A backup roller 62 is provided.
Moreover, these rollers 61 and 62 are provided in the laminating device 6 so that the pressure at the time of laminating the resin film 4 on the resin foam sheet 3 can be adjusted by adjusting the clearance therebetween.

The laminating apparatus 6 is provided in the manufacturing facility so that the laminated sheet 2 can be supplied to the thermoforming machine 5 with the resin film side facing upward and substantially horizontally supported. The machine 5 is provided with a sheet conveying means so that the laminated foamed sheet 2 supplied from the laminating apparatus 6 can be passed through while being held substantially horizontally.
The thermoforming machine 5 includes heating zones 50a, 50b, and 50c for heating the laminated foam sheet 2 in a softened state that can be thermoformed in order from the upstream side in the moving direction of the laminated foam sheet 2 and the mold 51. The molding zone 52d is a multi-cavity mold capable of forming a plurality of product shapes on the laminated foamed sheet 2 at a time by vacuum molding as the molding die 51. Is provided.

The heating zones 50a, 50b, and 50c have a total space as large as about three surfaces of the mold 51, and the most upstream region (hereinafter also referred to as “first heating zone 50a”), It is formed so that the temperature of the three regions of the middle region (hereinafter also referred to as “second heating zone 50b”) and the most downstream region (hereinafter also referred to as “third heating zone 50c”) can be individually set. .
That is, the thermoforming machine 5 in the present embodiment is configured so that the first heating zone 50a is intermittently fed to the laminated foamed sheet 2 for one-time thermoforming by the molding die 51 arranged in the laminated foam sheet conveyance path. To the third heating zone 50c are formed so as to be sequentially retained and passed, and the laminated foam sheet 2 that has been softened and secondarily expanded through these regions is introduced into the molding zone 50d. The mold 51 is formed so that vacuum forming can be performed.

The thermoforming machine 5 in the present embodiment deforms the laminated foamed sheet 2 heated and softened in the heating zones 50a, 50b, and 50c along the molding surface of the mold 51 in the molding zone 50d, It is formed so that it can be cured while imparting a product shape and being cooled by the mold and maintaining the product shape.
The thermoforming machine 5 and the third heating zone 50d and the third heating zone 5d are prevented from being heated by the hot air entering from the third heating zone 50c adjacent to the molding zone 50d. A shutter 55 for partitioning the zone 50c is provided. The shutter 55 is closed when the laminated foam sheet 2 is stopped and thermoformed, and when the laminated foam sheet 2 after molding is moved. It is provided in an open state.
That is, the shutter 55 is provided so that it can be opened and closed in conjunction with the movement of the sheet conveying means (intermittent feeding of the laminated sheets).

In the molding zone 50d, the shape of the round dish container 1 is such that four product shapes in the width direction of the laminated foam sheet 2 and three products in the longitudinal direction can be formed by a single thermoforming. The molding die 51 in which twelve concave portions 51a having a molding surface corresponding to the above are arranged is provided. The molding die 51 in this embodiment opens the concave portion 51a upward, and the laminated foam sheet 2 Are arranged in the thermoforming machine 5 so as to be vertically movable so that they can be brought into contact with each other.
In other words, the molding die 51 is provided in the thermoforming machine 5 so as to move up and down in conjunction with the intermittent feeding of the laminated foamed sheet 2, and when the laminated foamed sheet 2 is moved, the molding die 51 stands by below the laminated foamed sheet 2. It is prepared to be in the state.
The mold 51 rises as the laminated foamed sheet 2 stops, and when the laminated foamed sheet 2 stops, the mold 51 is brought into contact with the lower surface side of the laminated foamed sheet 2 almost simultaneously. Settings are made in conjunction with the movement of the transport means.

Further, the thermoforming machine 5 in the present embodiment is provided with a plug assist mechanism 52 for assisting vacuum forming by the forming die 51, and the plug assist mechanism 52 is provided above the forming die 51. , A substrate 52a provided so as to face the molding die 51, and a projecting portion 52b projecting so as to correspond to the concave portion 51a of the molding die 51 on the lower surface side of the substrate 52a.
The plug assist mechanism 52 is configured to be able to move the substrate 52a up and down. The protrusion 52b provided on the lower surface of the substrate 52a by the vertical movement is moved with respect to the recess 51a of the mold 51. It can be made to move forward and backward.
That is, the plug assist mechanism 52 is also provided in the thermoforming machine 5 so as to move up and down in conjunction with the intermittent feed of the laminated foam sheet 2 in the same manner as the mold 51, and when the laminated foam sheet 2 moves. It is provided so that it may be in a standby state above the laminated foam sheet 2.
The plug assist mechanism 52 descends as the laminated foam sheet 2 stops. When the laminated foam sheet 2 stops, the tip of the projecting portion 52b is substantially simultaneously on the upper surface side of the laminated foam sheet 2. Settings are made in conjunction with the movement of the sheet conveying means so as to be in contact with each other.
The plug assist mechanism 52 continues to descend even after the laminated foam sheet 2 is stopped, and further causes the protrusion 52b brought into contact with the upper surface side of the laminated foam sheet 2 to further enter the recess 51a of the mold 51, It is formed so that vacuum forming of the laminated foam sheet 2 can be assisted.

The sheet conveying means includes a pair of left and right metal chains 54 that circulate on the side of the laminated foam sheet 2 from the heating zones 50a, 50b, and 50c to the forming zone 50d, and a predetermined amount for the metal chains 54. A gripping tool (clamp) 54a attached with a gap and protruding inward from the metal chain 54, a motor and a control device (not shown) for causing the metal chain 54 to perform a predetermined operation, and the like. ing.
That is, the sheet conveying means grips both ends (both side edge portions) of the laminated foamed sheet 2 in the width direction by the clamps 54a so that the laminated foamed sheet 2 is heated from the heating zones 50a, 50b, 50c to the forming zone 50d. It is comprised so that it can convey.

  The sheet conveying means conveys the laminated foam sheet 2 having a length necessary for one-time thermoforming in the molding zone 50d to the molding zone 50d, and then completes thermoforming in the molding zone 50d. The interlaminar foam sheet 2 is stopped, and after the completion of the thermoforming, the laminated foam sheet 2 for one side of the mold is moved downstream and thermoformed in the molding zone 50d. The laminated foam sheet 2 is configured to be introduced into the thermoforming machine by intermittent feeding that alternately and repeatedly stops.

In the laminated foam sheet 2 used in the present embodiment, a donut-shaped design 22 is arranged corresponding to the arrangement of the concave portions 51 a of the molding die 51 by a checkered pattern to be provided on the side wall portion 12. In order to determine the distance of each movement in the intermittent feed, the design 22 is provided in the longitudinal direction of the laminated foam sheet 2 at a predetermined interval. The position detection mark 21 is provided on the edge).
A plurality of the position detection marks 21 are provided along the side edge of the laminated foam sheet 2 at an interval corresponding to the interval in the longitudinal direction of the laminated foam sheet 2 ("P1" in FIG. 2). .
This position detection mark 21 is provided in a shape that makes the contrast with the surroundings stand out by printing a rectangular black solid that is horizontally long with respect to the moving direction of the laminated foamed sheet 2, and along the longitudinal direction of the laminated foamed sheet 2. The same interval (P2 in FIG. 2) as the interval (P1) of the design 22 is maintained.

In the manufacturing facility of the present embodiment, the amount of movement of the laminated foam sheet 2 in intermittent feeding is adjusted based on the position detection mark 21, and the stop position of the design 22 is set to a predetermined position with respect to the mold 51. Adjustment means for adjusting is provided.
In the present embodiment, the position detecting means 7 for detecting the position of the position detecting mark 21 (one edge on the long side of the rectangle) is provided as the adjusting means. Two photoelectric tubes 70 a and 70 b are provided in the movement path of the position detection mark 21.
One of the photoelectric tubes 70a and 70b is arranged upstream of the mold 51 and is provided in front of the entrance to the first heating zone 50a (upstream).
The remaining one is arranged on the downstream side of the mold 51 and is provided at the rear (downstream side) of the outlet from the molding zone 50d.
More specifically, photoelectric tubes 70a and 70b are arranged at positions slightly downstream from the stop position of the position detection mark 21 when the laminated foam sheet 2 is stopped.
In the following, the upstream side of the first heating zone 50a is also referred to as a first photoelectric tube 70a, and the position detection means 7 by the first photoelectric tube 70a is also referred to as a first position detection means 7a.
In the following, the downstream side of the molding zone 50d is also referred to as a second photoelectric tube 70b, and the position detection means 7 using the second photoelectric tube 70b is also referred to as a second position detection means 7b.
The photoelectric tubes 70a and 70b are provided above the laminated foam sheet 2 so as to irradiate light on the upper surface of the laminated foam sheet 2 and receive reflected light from the upper surface, and pass through the lower side thereof. The position detection mark 21 to be detected is provided.

  Note that the thermoforming machine 5 in this embodiment is configured such that the movement amount and movement speed of the laminated foam sheet 2 after the first position detection means 7a or the second position detection means 7b detects the passage of the position detection mark 21. These values can be set in advance so as to be reflected in the intermittent feeding of the sheet conveying means, and the stop time of the laminated foamed sheet 2 can also be set in advance.

A method of manufacturing the round dish container 1 using such a manufacturing facility will be described below. First, the resin foam sheet 3 is unwound from the raw roll 30, and the heating roller 61 and the backup roller 62 of the laminating apparatus 6 are used. The resin film 21 is also fed out from the film roll 2 and passed through the laminating apparatus 6 in the same manner as the resin foam sheet 3.
At this time, the heating roller 61 and the backup roller 62 of the laminating apparatus 6 are kept in a state of being opened, and the heater provided in the heating zone of the thermoforming machine 5 is set so that the heating roller 61 does not contact the resin film 21. The power supply and the heating roller 61 are turned on, and wait for each to reach a predetermined temperature.

Thereafter, when the heating zone of the thermoforming machine 5 and the heating roller 61 are stabilized at a predetermined temperature, the laminating device 6 is started, and the space between the heating roller 61 and the backup roller 62 is narrowed to a predetermined interval. The resin foam sheet 3 and the resin film 4 are brought into pressure contact with each other, and the heating roller 61 and the backup roller 62 are rotated at a predetermined peripheral speed.
As a result, the resin foam sheet 3 and the resin film 4 are taken up, and the laminated foam sheet 2 can be continuously supplied to the downstream side of the heating roller 61 at a constant speed.

  And when the laminated foam sheet 2 in which the operation state of the laminating apparatus 6 is stable and good is supplied stably, the laminated foam sheet 2 is passed through the thermoforming machine 5 using the sheet conveying means, The mold 51 of the thermoforming machine 5 and the design 22 of the laminated foamed sheet 2 are aligned, and the round dish container 1 in which the design 22 is not displaced with respect to the round dish container 1 is produced by trial molding.

When the design value of the interval of the design 22 is set to “P0”, if the actual design interval (P1) completely matches the design value (P0), the design is not misaligned. When the position of the laminated foam sheet 2 on which the round dish container 1 is formed is specified, the subsequent production of the round dish container 1 is started by setting the movement amount of the laminated foam sheet 2 as the design value. Usually, the interval (P1) of the design is slightly deviated from the design value (P0) due to the tension applied to the resin film 4 in the laminating apparatus 6 or the like.
When the amount of deviation between the actual design interval and the design value is “ΔP”, when the laminated foam sheet is intermittently fed and thermoforming is repeated n times, the cumulative value of the amount of deviation is “ΔP × n”. It becomes.
Then, when this cumulative value (ΔP × n) becomes an unacceptable value as a product, the product becomes a defective product.
For example, even if the deviation amount from the design value is 0.1 mm and the design deviation in the round dish container does not cause a substantial problem, the position as shown in this embodiment Without carrying out the adjustment, if the round foam container is formed by intermittently feeding the laminated foam sheet at a fixed pitch, a deviation of 1 mm occurs when the thermoforming is performed 10 times. There is a risk that a defective product such as a checkered pattern may be formed.

In this embodiment, a checkered pattern is applied to the entire surface of the side wall portion 12 of the round dish container 1, and a bent portion such as a boundary between the side wall portion 12 and the bottom surface portion 11 or a boundary between the side wall portion 12 and the flange portion 13. Since the outline of the design is located along the center of the side wall, the design is easily noticeable, unlike the case where a one-point design is provided in the central portion of the side wall. There is a risk of it.
In order to prevent this, it may be possible to stop the production line and correct the position at a rate of once every several times. It will stay in the heating zone for the time required for correction, and this portion may not be used for the product.
In other words, it is difficult to efficiently produce a product by correcting the position while stopping such a line.

  On the other hand, in this embodiment, an intermittent feed condition to be implemented in the production is set based on the position detection of the position detection mark 21 by the photoelectric tubes 70a and 70b, and then the laminated foam sheet 2 is stopped after the position detection. The amount of movement of the laminated foamed sheet 2 until it is set is set to a constant value less than the interval of the design 22 and the main production is started, so that a non-defective product with suppressed positional deviation can be produced efficiently.

For example, when the round dish container 1 having a design at a predetermined position is obtained, the distance from the photoelectric tubes 70a, 70b to the position detection mark 21 is measured, and the laminated foam sheet 2 before being introduced into the heating zone. By setting the value subtracted from the actual interval (P1 ′) of the design in FIG. 4 as the movement distance after position detection and starting the main production, a non-defective product with suppressed positional deviation can be produced.
At this time, if the distance from the phototubes 70a and 70b to the position detection mark 21 is “D1”, a value obtained by subtracting the distance (D1) from the actual interval (P1 ′) (P1′−D1) after position detection. Set the travel distance and start production.

And after this thermoforming, a sheet molded product is manufactured by the following process.
(First move)
In the movement after the thermoforming, the next position detection mark 21 is detected by the photoelectric tubes 70a and 70b when the laminated foam sheet 2 moves the distance “D1”.
Since the movement amount after position detection is set to be “P1′−D1” as described above, the total movement amount is “P1 ′” (“D1” + “P1′−D1”). At that time, the laminated foam sheet 2 stops and the first movement is completed.
(First stop)
Since the amount of movement after position detection is set to be “P1′−D1” as described above, the stop position of the position detection mark 21 in the stop after the first movement (first stop) is the photoelectric tube. The distance “D1” is upstream from 70a and 70b.
In addition, for each subsequent movement, the total movement amount is “P1 ′”, and intermittent feeding is always performed with a movement amount corresponding to the actual interval of the design, so that the design shift with respect to the round dish container 1 is prevented. It will be.

Next, when the laminated foam sheet 2 was produced, the tension applied to the resin film 4 changed, and the actual interval of the design changed to a value larger by “ΔP ′” than before (“P1 ′” → “ P1 ′ + ΔP ′ ”)) Considering the case, after this change, the position of the design is automatically adjusted by the following process.
(First move)
As described above, in the movement after thermoforming, the next position detection mark 21 is detected by the photoelectric tubes 70a and 70b when the laminated foam sheet 2 moves the distance “D1”, and the movement amount after the position detection is “P1 ′”. -D1 "is set, the laminated foam sheet 2 stops when the total movement amount becomes" P1 '".
(First stop)
At this time, since the actual interval of the design is increased by “ΔP ′”, the stop position of the position detection mark 21 in the first stop is not “D1” but a distance “D1 + ΔP ′” from the photoelectric tubes 70a and 70b. It becomes the position.
(Second move)
In the movement after the first stop, unlike the first movement, the next position detection mark 21 is detected by the photoelectric tubes 70a and 70b when the laminated foamed sheet 2 moves the distance “D1 + ΔP ′”.
Since the movement amount after the position detection is set to be “P1′−D1” as described above, the total movement amount is “P1 ′ + ΔP ′” (“D1 + ΔP ′” + “P1′−D1”). ), The laminated foamed sheet 2 stops and the second movement is completed.
That is, in the second movement, the laminated foam sheet 2 is moved by a movement amount corresponding to the interval of the design after the change.
(Second stop)
As described above, since the actual interval of the design is “P1 ′ + ΔP ′” and the movement amount after the position detection is set to “P1′−D1”, the position detection after the second movement is completed. The distance between the stop position of the mark 21 and the photoelectric tubes 70a and 70b is “D1 + ΔP ′” (“P1 ′ + ΔP ′” − “P1′−D1”) as in the first stop.
Therefore, after that, intermittent feed is performed with a movement amount corresponding to the actual interval of the design after the change, and the position adjustment of the design with respect to the mold is automatically performed.

In the above case, only the first movement after the actual interval of the design is changed, the movement amount is not “P1 ′ + ΔP ′” but “P1 ′” before the change.
For this reason, after the actual interval of the design is changed, there is a possibility that the design deviation of “ΔP ′” may occur in the round dish container.
However, since the intermittent feed is immediately performed so that the movement amount becomes “P1 ′ + ΔP ′”, the deviation is not accumulated every time the number of thermoforming is repeated, and the round dish container manufactured thereafter The positional deviation that occurs in the above will remain at the magnitude of “ΔP ′”.
In general, since the interval between the designs does not change greatly during the production of the sheet molded product, this misalignment is likely to be of a level that does not cause a substantial problem. The possibility that the container becomes a defective product can be suppressed.

If the design interval changes greatly during the manufacture of the round dish container and the amount of deviation of “ΔP ′” exceeds the allowable range, position of the position detection means is arranged according to the design positional deviation amount. The shift may be corrected by moving back and forth along the movement path of the detection mark.
For example, the laminated foam sheet 2 should be moved by the movement amount of “P1 ′ + ΔP ′” even in the first movement, but the laminated foam sheet 2 is moved only by the movement amount of “P1 ′”. If the stop position of the design is shifted by “ΔP ′” to the upstream side with respect to the concave portion 51 a of the mold 51, the photoelectric tubes 70 a and 70 b are moved “ΔP ′” to the downstream side, and the next movement At this time, it is possible to perform correction such that the design is returned to a predetermined position to be originally stopped with respect to the mold 51 by moving the laminated foam sheet 2 by “ΔP ′”.

  In this way, even if there is a change in the amount of deviation after the start of production, it is possible to perform intermittent feeding by adjusting according to this change, so it is necessary to correct the position by stopping the line. In addition, the material loss can be reduced, the occurrence of defective products can be prevented, and a round dish container can be manufactured with a high yield.

  In the present embodiment, the movement distance after the position detection is set constant as described above, and the movement speed in the movement is set in advance, so that the movement time after the position detection is constant, and the position Based on the detected time, the operation timings of the shutter 55, the mold 51, and the plug assist mechanism 52 are set, and a round dish container can be efficiently manufactured.

For example, if the movement distance after the position detection is “D2” (= (P1′−D1)) and the movement speed after the position detection is “V2”, the laminated foaming is performed after the time “D2 / V2” has elapsed after the position detection. Since the sheet 2 can be predicted to stop, it is possible to operate the shutter 55 so as to be closed immediately after stopping the laminated foamed sheet 2 without contacting the moving laminated foamed sheet 2 and the plug assist mechanism. As for 52, the protrusion part 52b can be made to contact a resin film surface immediately after the lamination | stacking foam sheet 2 stops.
Therefore, the tact time can be shortened, and the manufacturing efficiency of the round dish container 1 can be further improved.

When manufacturing similar products using similar equipment, the amount of deviation of the actual interval with respect to the design value of the design does not vary greatly depending on the manufacturing lot, so the movement distance after position detection is once required. For example, in the subsequent manufacturing, the main production can be started without performing trial molding or the like.
Temporarily, if the movement of the design after the position detection is set based on the past results and the manufacturing of the sheet molded product starts and the position of the design shifts in the sheet molded product, the movement after the position detection will occur. The amount of movement after the position detection is left as it is, and the position detection means is moved back and forth along the movement path of the position detection mark in accordance with the amount of positional deviation of the design. May be.

The photoelectric tubes 70a and 70b can obtain the above-described effects even when only the first photoelectric tube 70a on the upstream side of the first heating zone 50a or the second photoelectric tube 701b on the downstream side.
In other words, the above-described manufacturing method can be carried out as long as the photoelectric tube is arranged at least along the path along which the position detection mark 21 moves by intermittent feeding.
However, if the position of the position detection mark is detected only by the first photoelectric tube 70a (first position detection means) upstream of the first heating zone 50a, the laminated foam sheet 2 for three shots is placed in the heating zone. The production of the round dish container 1 must be finished while leaving it.

Further, if the position detection mark is detected only by the second photoelectric tube 70b (second position detecting means) on the downstream side of the molding zone 50d, the laminated foam sheet 2 for at least four shots of the heating zone and the molding zone is used. Since the main production cannot be started until after is supplied to the thermoforming machine 5 in advance, material loss occurs as in the case of using only the first photoelectric tube 70a.
From this, in this embodiment, in order to use the produced laminated foam sheet 2 as much as possible, and to manufacture the round dish container 1 efficiently, the manufacturing which provided the phototube in both the upstream and downstream of the shaping zone 50d Equipment is used.
That is, in the present embodiment, in order to further improve the manufacturing efficiency of the round dish container, the position detection means arranged on the upstream side and the downstream side of the molding zone are used to detect the position of the position detection mark, and At the start, the position of the design is adjusted by detecting the position of the position detection mark by the first position detecting means, and after the start of production, the second position detecting means is adjusted so that the position of the design is adjusted. We are manufacturing.

  In order to shorten the tact time, it is preferable not only to shorten the time required to complete the molding after the laminated foam sheet 2 is stopped in the molding zone, but also to shorten the moving time of the laminated foam sheet 2. .

In each movement of the laminated foam sheet in this embodiment, the position detection mark 21 is moved downstream to detect the position by the photoelectric tubes 70a and 70b, and the movement distance of the laminated foam sheet after the position detection is determined. The position detection mark 21 to be detected next after being less than the interval between the position detection marks 21 is stopped on the upstream side of the photoelectric tubes 70a and 70b, and the movement amount after the position detection is set to a predetermined movement distance. In addition, the movement after the position detection is performed at a preset speed.
Then, after the start of the movement of the laminated foam sheet 2 and until the position detection mark 21 is detected, it is difficult to accurately detect the position if the sheet is moved at an excessively high speed.
Therefore, in order to shorten the movement time of the laminated foamed sheet 2, it is preferable to increase the moving speed of the laminated foamed sheet 2 after the position detection in the intermittent feeding compared to the moving speed before the position detection.
For example, the moving speed of the laminated foamed sheet 2 until the detection of the position detection mark 21 is 10 m / sec to 20 m / sec, and the moving speed of the laminated foamed sheet 2 after detecting the position detecting mark 21 is 100 m / sec to It can be 120 m / sec.

Moreover, it is preferable to perform intermittent feeding so that the movement of the laminated foam sheet 2 after position detection, which can be moved at a high speed, is a long distance movement compared to the movement before position detection.
That is, when the laminated foam sheet is stopped, it is preferable to stop the position detection mark 21 at a position as close as possible to the upstream side of the photoelectric tubes 70a and 70b.
However, if the position detection mark 21 and the photoelectric tubes 70a and 70b are excessively brought close to each other, for example, when contraction occurs such that the interval between the designs in the longitudinal direction of the laminated foam sheet is shorter than the design value, the photoelectric tube 70a and 70b may not be able to detect the position detection mark 21.
For this reason, the distance between the position detection mark and the phototube when the laminated foam sheet 2 is stopped (the moving distance of the laminated foam sheet before position detection) is preferably more than 0 mm and 50 mm or less.

In the above description, the manufacturing equipment in which the phototubes 70a and 70b are fixedly arranged on the upstream side of the heating zone and the downstream side of the molding zone is illustrated. However, for example, it can be moved along the movement path of the position detection mark 21. It is also possible to use a manufacturing facility in which the phototubes 70a and 70b are arranged on the movement path in such a state.
That is, while the laminated foam sheet 2 is stopped in intermittent feeding, the photoelectric tubes 70a and 70b are moved along the movement path to detect the position of the position detection mark 21, and the position detection obtained by the position detection is performed. It is also possible to carry out the position adjustment of the design by adjusting the movement amount of the laminated foamed sheet 2 in the next movement to be a movement amount corresponding to the interval of the design 22 based on the position information of the mark 21. .

  For example, when the stop position of the laminated foam sheet 2 suitable for obtaining the round dish container 1 in which the design 22 is not misaligned by trial molding is found, the origin positions of the photoelectric tubes 70a and 70b are set as position detection marks. 21 is set slightly downstream (for example, 5 mm to 10 mm downstream), and the distance between the position detection mark 21 and the positions of the photoelectric tubes 70a and 70b is defined as a variable movement amount (Px). A movement amount (P1′−Px) obtained by subtracting the fluctuation movement amount (Px) from P1 ′) is set as a fixed movement amount (Py), and the position detection mark 21 is detected from the origin at each stop in intermittent feeding. The movement distance (fluctuation movement amount (Px)) of the phototubes 70a and 70b up to this point is measured, and the total movement amount (Py + Px = P1 ′) with the fixed movement amount (Py) is set as the movement amount in the movement after the stop. It may be set intermittent feed conditions in the production as.

The origin positions of the photoelectric tubes 70a and 70b are set slightly upstream of the position detection mark 21. When the laminated foam sheet 2 is stopped, the photoelectric tubes 70a and 70b are located downstream along the movement path of the position detection mark 21. The position of the position detection mark 21 may be detected by moving the position detection mark 21.
In this case, a moving amount (P1 ′ + Px ′) obtained by adding the moving distance (variable moving amount (Px ′)) of the photoelectric tubes 70a and 70b from the origin to the detection of the position detection mark 21 to the interval (P1) of the design. Is set as the fixed movement amount (Py ′), and the variable movement amount (Px ′) obtained by each position detection is subtracted from the fixed movement amount (Py ′) to obtain the movement amount in the next movement.

  Alternatively, when a stop position of the laminated foam sheet 2 suitable for obtaining the round dish container 1 in which the design 22 is not displaced by trial molding is found, the stop position of the position detection mark 21 at this time is set as the photoelectric tube. The origin positions of 70a and 70b are set, the photoelectric tubes 70a and 70b are moved back and forth along the movement path of the position detection mark 21 at each stop, and the stop position of the position detection mark 21 at each stop is the photoelectric tube 70a and 70b. It may be detected whether the position is shifted upstream or downstream with respect to the origin position.

  Even in such a case, the position of the design is adjusted by the first position detecting means (photoelectric tube 70a) at the start of the main production, and after the start of the main production, the position is adjusted by the second position detecting means (photoelectric tube 70b). The point that the round dish container 1 can be efficiently produced by producing the round dish container 1 is the same as the case of using a fixedly arranged phototube.

In the present embodiment, the photoelectric tube is used as the position detection unit, and the edge detection of the position detection mark provided by the black solid printing is performed. However, the position detection unit for detecting the position detection mark is limited to the photoelectric tube. First, various sensors can be employed.
For example, a resin film in which position detection marks are drawn with a magnetic material may be used, and a magnetic sensor may be employed as the position detection means.
In addition, the method of providing the position detection mark is not limited to printing or the like. For example, a notch is provided on the side edge of the laminated foam sheet, or a through hole is provided slightly on the side edge. May be used as a position detection mark.
Further, in the present embodiment, the position detection mark is provided in the region gripped by the clamp 54a so as to secure a wider range that can be used for forming the sheet molded product. For example, the position detection mark is gripped by the clamp 54a. A position detection mark may be provided on the inner side of the area.
In this case, since the position detection mark is not hidden by the clamp, for example, a position sensor is used to detect the position immediately before the molding zone 50d using a heat-resistant sensor that can be installed in the third heating zone 50c. You may make it make it.

Further, in the present embodiment, the position detection mark 21 is provided together with the design in that the interval in the longitudinal direction of the design is likely to change with changes in manufacturing conditions and the effects of the present invention can be exhibited more remarkably. In the present invention, the laminated foam sheet 20 in which the resin film 4 and the resin foam sheet 3 are laminated is used for forming the round dish container. In the present invention, the thermoplastic resin sheet to be used is laminated as described above. It is not limited to foam sheets.
That is, a case where a sheet molded product such as a round dish container is manufactured using a thermoplastic resin sheet provided with a design on a resin foam sheet or a resin film alone is also within the intended scope of the present invention.
Moreover, in this invention, the sheet molded product to manufacture is not limited to the above round dish containers.
Furthermore, it goes without saying that conventionally well-known technical matters regarding the manufacturing equipment for sheet molded products can be appropriately adopted in the manufacturing equipment for sheet molded products of the present invention.

1: round dish container (sheet molded product), 2: laminated foam sheet, 3: thermoplastic resin film, 4: thermoplastic resin foam sheet, 5: thermoforming machine, 7: position detection means, 21: position detection mark, 22: Design, 51: Mold, 100: Production equipment for sheet molding

Claims (2)

A sheet conveying means for conveying the belt-shaped thermoplastic resin sheet by intermittent feeding that alternately moves and stops in the longitudinal direction; and a molding die for thermoforming the thermoplastic resin sheet, the sheet conveying means A sheet molded product in which the molding die is arranged in the conveyance path of the thermoplastic resin sheet and the design is provided at a predetermined position using a thermoplastic resin sheet provided with the design at predetermined intervals in the longitudinal direction. A sheet molding product manufacturing facility further comprising an adjusting means for adjusting a stop position of the design in the intermittent feeding to a predetermined position with respect to the molding die so as to be able to produce
Detection of the position detection mark to produce the sheet molded article using a strip-shaped thermoplastic resin sheet provided with a position detection mark along the longitudinal direction with an interval corresponding to the interval of the design along with the design Position detecting means is provided, and means for adjusting the stop position of the design by adjusting the amount of movement of the thermoplastic resin sheet based on the detection result of the position detection mark by the position detecting means is provided as the adjusting means. A first position detecting means disposed upstream of the molding die in the moving direction of the thermoplastic resin sheet as the position detecting means, and a second position detecting means disposed downstream of the molding die. An apparatus for manufacturing a sheet molded product, comprising at least two position detecting means.   The first position detection means and the second position detection means are arranged at a position downstream of the stop position of the position detection mark when the thermoplastic resin sheet is stopped. The sheet molded product according to claim 1, wherein the movement amount and movement speed of the thermoplastic resin sheet after the first position detection means and the second position detection means detect the passage of the position detection mark can be set. Facility.

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