JP2015104886A - Decorative molding method, decorative molding metallic component by decorative sheet, decorative molding metallic mold having the metallic mold component, and decorative molding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative molding method and device capable of attaining the improvement of a yield of a molding material without spoiling the aesthetic appearance of a molded product.SOLUTION: A decorative molding method includes: a step of arranging thermoplastic resin sheets P1 and P2 in a molten state at the lateral side of cavities so as to protrude to the surrounding of the cavities in a state of being separated from the cavities 116A and 116B of metallic molds 32A and 32B; a step of surface-adhering a decorative sheet D facing the thermoplastic resin sheet and held so as to protrude to the surrounding of the cavities in a state of being separated from the cavities of the metallic molds, to the thermoplastic resin sheet P to be laminated in a first closed space 230 formed in cooperation with the arranged thermoplastic resin sheet and the cavities; and pushing the surface-adhered thermoplastic resin sheet P and decorative sheet D to the cavities by vacuum suctioning the first closed space from a cavity side followed by contouring.

Description

  The present invention relates to a decorative molding method, a decorative molding mold part using a decorative sheet, a decorative molding mold having the part, and a decorative molding device, and more specifically, an aesthetic appearance of a molded product. Decorative molding method that can achieve improved yield of molding materials without loss, yield of molding materials without sacrificing aesthetic appearance of molded products without requiring major remodeling of existing molds Mold component for decorative molding with a decorative sheet capable of performing vacuum molding of a decorative resin sheet capable of achieving improvement of the decorative mold, a mold for decorative molding having the component, and a decorative molding device About.

Conventionally, from the viewpoint of improving the aesthetic appearance, a decorative sheet is applied to both surfaces or one surface of a resin molded product having a solid structure, a hollow structure, or a sandwich structure.
When such a resin molded product is molded using a mold, particularly in the case of a solid structure, it is possible to perform injection molding by forming a sealed space with the mold. Because of this characteristic, there is a restriction that the molten resin to be injected under pressure in the sealed space must be pressed against the entire cavity surface where the molten resin is in contact, and a part of the molten resin is shaped and applied only to that part. It is unsuitable for welding a decorative sheet.
In this regard, in the case of a solid structure, it is advantageous to vacuum-suck a single resin sheet from the single mold side, and in the case of a hollow structure or a sandwich structure, two resin sheets are used. By using the mold clamp, the peripheral edges of the two resin sheets are welded together to form a hollow part inside the sealed mold formed inside the mold. In general, blow molding is performed by blowing air.
In such a molding method, when a decorative sheet is pasted on both sides or one side of a resin molded product, it is not an additional pasting step after molding of the resin molded product, but before or during molding of the resin molded product. It is desirable to apply a decorative sheet.
Patent Document 1 discloses the former example, and Patent Document 2 discloses the latter example.
More specifically, in Patent Document 1, when decorating a resin molded product with a pattern or the like on the surface, a decorative film is held in the mold cavity by vacuum suction or the like, A method of obtaining a decorated product surface simultaneously with product molding by hanging a resin parison and blow molding is disclosed.
On the other hand, in Patent Document 2, a sheet-like parison is formed by primary molding, and when the sheet-like parison is suspended in a mold, a pressure roller is used to crimp the sheet-like parison and the decorative film, and the inside is a sheet. A method is disclosed in which a parison is formed, and a parison having a decorative film on the outside is formed and placed in a mold cavity.

However, in Patent Document 1, it is necessary to provide fine through holes in the decorative film in order to prevent air from remaining between the parison and the decorative film during blow molding. If this through-hole becomes large, the escape of residual air will be good, but it will affect the appearance of the product.If the through-hole is small, an air pool will occur between the molded product and the decorative film due to the effect of residual air. It becomes a molding defect.
Alternatively, if vacuum suction is performed from the cavity side, the decorative film covers the cavity. Therefore, it is necessary to use a breathable decorative film, which causes a similar technical problem.
On the other hand, in the method of Patent Document 2, when placing the decorative sheet and the crimped parison in the mold, decoration is performed in the burr part from the pressure roller to the upper part of the mold and the burr part at the lower part of the mold. Since the film and the parison are in a completely pressure-bonded state, there is a problem that recycling is extremely difficult depending on the material and color of the decorative film.

On the other hand, it is easy to recycle the molding material without compromising the aesthetic appearance of the decorative sheet itself, without having to make major modifications to existing molds that are decorated with a decorative sheet. There is a demand in the industry for a molding apparatus for a decorative sheet capable of improving the yield.
In particular, when the decorative sheet is welded to the resin sheet using blow molding of the resin sheet, the resin sheet is pressed against the cavity while the decorative sheet is held in the cavity. For example, it is necessary to insert a blow pin into a molten resin sheet and blow air into the sealed space through the blow pin, and an extra step is required and the pin is attached to the resin sheet. Traces remain and the aesthetic appearance is impaired.

JP 2000-177063 JP 2000-218682 A

In view of the above technical problems, an object of the present invention is to provide a decorative molding method capable of achieving an improvement in the yield of a molding material without impairing the aesthetic appearance of a molded product.
In view of the above technical problems, the object of the present invention is to achieve an improvement in the yield of molding material without impairing the aesthetic appearance of the molded product without requiring extensive modification of the existing mold itself. An object of the present invention is to provide a decorative mold component using a decorative sheet capable of performing vacuum forming of a decorative resin sheet, a decorative mold having the component, and a decorative molding apparatus.

In order to achieve the above object, the decorative molding method according to the present invention comprises:
Placing the molten thermoplastic resin sheet on the side of the cavity so that it protrudes around the cavity in a spaced state from the mold cavity;
In the first sealed space formed by the cooperation of the disposed thermoplastic resin sheet and the cavity, the thermoplastic resin sheet faces the thermoplastic resin sheet and protrudes from the mold cavity around the cavity. The step of adhering the decorative sheet held on the surface to the thermoplastic resin sheet so as to be laminated,
Vacuuming the inside of the first sealed space from the cavity side, pressing the surface-bonded thermoplastic resin sheet and the decorative sheet against the cavity, and shaping,
It has composition.

According to the decorative molding method having the above-described configuration, the decorative sheet is once bonded to the surface of the thermoplastic resin sheet so as to be laminated, and then the surface-bonded thermoplastic resin sheet and the decorative sheet are decorated. By pressing the sheet against the cavity and shaping, the sheet made of thermoplastic resin is placed against the cavity through vacuum suction from the cavity side with the decorative sheet previously placed in the cavity as in the past. By pressing, it is possible to perform decorative molding using a non-breathable decorative sheet without having to weld the decorative sheet with breathability to the thermoplastic resin sheet at the same time. Yes, the appearance of the surface of the decorative sheet is not impaired.
On the other hand, in the first sealed space formed by the cooperation of the thermoplastic resin sheet and the cavity disposed on the side of the cavity, the thermoplastic resin sheet faces the thermoplastic resin sheet and is separated from the mold cavity. The surface of the decorative sheet held so as to protrude from the periphery of the cavity is bonded to the thermoplastic resin sheet, so that the decorative sheet having a predetermined length that can be accommodated in the first sealed space is made of the thermoplastic resin. It is possible to bond the surface to the sheet made of the sheet, for example, unlike the conventional method, in which the decorative sheet and the thermoplastic resin sheet are pressure-bonded by the pressure roller and sent to the mold cavity. The burr portion of the molding material on the outer periphery of the pinch-off portion of the mold can be made only of a thermoplastic resin sheet on which the decorative sheet is not welded. Cycle is facilitated, can be achieved to improve the yield of the molding material.

Further, the step of arranging the thermoplastic resin sheet to the side of the cavity preferably includes a step of extruding the molten thermoplastic resin sheet.
Further, the molten thermoplastic resin sheet may be formed by cutting a molten cylindrical parison in the longitudinal direction.
Furthermore, the thermoplastic resin sheet in the molten state may be once molded and then reheated to be in a molten state.
In addition, the surface bonding step may include a step of forming a first sealed space in cooperation with the thermoplastic resin sheet and the cavity after the decorative sheet is held by the mold.

In the aspect of the surface adhesion step, the second sealed space is formed between the two sheets in a form in which the first sealed space is partitioned by the decorative sheet in cooperation with the thermoplastic resin sheet and the decorative sheet. And a step of adhering the decorative sheet to the thermoplastic resin sheet by vacuum suction of the second sealed space.
Further, the decorative sheet may be a non-breathable sheet.

In order to achieve the above object, a mold part for decorative molding with a decorative sheet according to the present invention is:
A frame body having a through portion that can be externally fitted to the outer peripheral surface of the mold, and on its annular end surface, a contact surface capable of contacting the molten molding material sheet is formed,
The contact surface has an annular contact surface for a thermoplastic resin sheet that can contact the thermoplastic resin sheet on the outer peripheral side and an outer peripheral portion of the decorative sheet on the inner peripheral side. An annular contact surface for the decorative sheet that can be contacted, and the annular contact surface for the thermoplastic resin sheet protrudes from the annular contact surface for the decorative sheet.
Furthermore, the mold part for decorative molding is an annular integrated product, the annular contact surface for the thermoplastic resin sheet extends to the outer peripheral edge of the annular end surface, and the annular contact surface for the decorative sheet is It is preferable that a step is formed up to the inner peripheral edge of the annular end surface and between the annular contact surface for the thermoplastic resin sheet and the annular contact surface for the decorative sheet.
Still further, the decorative mold part has an outer frame and an inner frame, and the outer frame has an annular contact surface for the thermoplastic resin sheet, and the inner frame Has an annular contact surface for the decorative sheet, and the outer frame body and the inner frame body are slidable with respect to the outer peripheral surface of the inner frame body. It is preferable that they can move relative to each other.
In addition, the decorative molding die part may have an air discharge through hole in the outer frame body or the inner frame body.

In order to achieve the above object, a decorative mold using the decorative sheet according to the present invention is:
A mold having an annular pinch-off part and a cavity formed inside the annular pinch-off part on one side,
12. The mold part for decorative molding using the decorative sheet according to claim 8, wherein an outer peripheral side surface of the mold is positioned so that the contact surface is located on the cavity side. Provided to fit outside,
The annular contact surface for the thermoplastic resin sheet is brought into contact with the thermoplastic resin sheet disposed on the side of the cavity of the mold, so that the outer surface of the thermoplastic resin sheet, the decoration A vacuum suction hole is provided for vacuum suction of the first sealed space formed by the inner peripheral surface of the molding die part and the cavity.

In order to achieve the above object, a decorative molding apparatus using a decorative sheet according to the present invention,
A thermoplastic resin is shaped by extrusion molding, and a primary molded portion is extruded in a form in which the primary molded thermoplastic resin is suspended, and a thermoplastic resin extruded by the primary molded portion is subjected to secondary molding by blow molding or vacuum molding. In a thermoplastic resin molding device having a secondary molding part,
The primary molding part is:
A melt-kneading means for melt-kneading the thermoplastic resin;
Storage means for storing a predetermined amount of melt-kneaded thermoplastic resin;
An extrusion slit that extrudes intermittently so as to hang down the stored thermoplastic resin into a molten sheet,
The secondary molded part is
It is set as the structure which has the metal mold | die for decoration shaping | molding by the said decorating sheet of Claim 12.

    Further, the first sealed space, the surface of the thermoplastic resin sheet, the inner peripheral surface of the vacuum mold part, and the second sealed space formed by the surface of the decorative sheet are vacuum-suctioned. One common vacuum pump and a suction pipe connected to the vacuum pump may be provided at the distal end portion, with a branch portion communicating with each of the first sealed space and the second sealed space.

In order to achieve the above object, the decorative molding method according to the present invention comprises:
Preparing a mold part for decorative molding by the decorative sheet according to claim 9 so as to be fitted on the outer peripheral side surface of the mold so that the contact surface is located on the cavity side;
Holding the decorative sheet by the step, and
The surface of the thermoplastic resin sheet is moved by moving the decorative mold part in the mold clamping direction until the annular contact surface for the thermoplastic resin sheet contacts the thermoplastic resin sheet, The first sealed space is formed by the inner peripheral surface of the vacuum mold component and the surface of the cavity, and the surface of the thermoplastic resin sheet, the inner peripheral surface of the vacuum mold component and the decoration Forming the second sealed space by the surface of the sheet.

In order to achieve the above object, the decorative molding method according to the present invention comprises:
Preparing a mold part for decorative molding by the decorative sheet according to claim 10 so as to be fitted on the outer peripheral side surface of the mold so that the contact surface is located on the cavity side;
Moving the inner frame body in the mold clamping direction to a position where the annular contact surface for the decorative sheet projects at least from the top of the pinch-off portion;
Holding the decorative sheet by the annular contact surface for the decorative sheet so as not to protrude from the outer peripheral edge of the annular contact surface for the decorative sheet;
By moving the outer frame body in the mold clamping direction until the annular contact surface for the thermoplastic resin sheet contacts the thermoplastic resin sheet, the surface of the thermoplastic resin sheet, the vacuum forming gold The first sealed space is formed by the inner peripheral surface of the mold part and the surface of the cavity, and the surface of the thermoplastic resin sheet, the inner peripheral surface for the decorative molding, and the surface of the decorative sheet, Forming a second sealed space;
It has composition.

Furthermore, the vacuum suction step includes a step of inserting a pin into a portion of the thermoplastic resin sheet or decorative sheet outside the pinch-off portion,
It is preferable to vacuum the inside of the second sealed space through a pin.
Further, the vacuum suction step includes a step of providing a through hole in the frame,
And a step of vacuum-sucking the inside of the second sealed space through the through hole.
In addition, a step of providing the through hole in the extending direction of the through hole of the decorative mold part may be provided.

Furthermore, you may have the step which provides the said through hole in the thickness direction with respect to the protrusion part from the said inner frame of the said outer frame.
Furthermore, the surface bonding step of the decorative sheet is formed by vacuum suction in the second sealed space, and is formed by the surface of the decorative sheet, the inner peripheral surface of the decorative mold part, and the cavity. A step of blowing air into the third sealed space may be included.
In addition, the step of holding the decorative sheet has a step of vacuum-sucking the surface of the decorative sheet, the inner peripheral surface of the mold part for decorative molding, and the inside of the third sealed space formed by the cavity. But you can.

Further, the decorative sheet is made of the same material as the resin sheet, and the decorative sheet may be surface-bonded to the molten resin sheet. The resin sheet, a resin sheet portion made of a different material, and a non-woven sheet portion are laminated, and the decorative sheet is a non-woven sheet portion with respect to the molten resin sheet. By facing and pressing, surface bonding may be performed based on the anchor effect.

Further, when the second sealed space is formed between the decorative sheet and the resin sheet, the second sealed space is formed so as not to form an air pocket between the decorative sheet and the resin sheet. It is preferable to have a step of surface-bonding the decorative sheet and the resin sheet while exhausting the air to the outside.
Furthermore, by vacuum-sucking the second sealed space between the decorative sheet and the resin sheet through a through hole provided in the frame of the mold, the decorative sheet and the resin sheet There may be a step of surface bonding.
In addition, by pressing the inside of the third sealed space between the decorative sheet and the corresponding cavity, the decorative sheet is provided on the frame of the mold while pressing the decorative sheet against the resin sheet. The surface of the decorative sheet and the resin sheet may be bonded to each other by exhausting the air in the second sealed space to the outside through the through holes.

Moreover, when vacuum-sucking the second sealed space, the method may further include a step of moving the inner frame body in the mold clamping direction while bringing the decorative sheet close to the resin sheet.

Further, the mold part for decorative molding using the decorative sheet according to claim 10 is fitted on at least one outer peripheral side surface of the pair of split molds so that the contact surface is located on the cavity side. The stage to prepare for,
Positioning a pair of molten thermoplastic resin sheets spaced apart from each other between the pair of split molds in a form protruding around the cavities of the pair of split molds;
Moving the inner frame body in the mold clamping direction to a position where the annular contact surface for the decorative sheet projects at least from the top of the pinch-off portion;
Holding the decorative sheet by the annular contact surface for the decorative sheet so as not to protrude from the outer peripheral edge of the annular contact surface for the decorative sheet;
By moving the outer frame body in the mold clamping direction until the annular contact surface for thermoplastic resin sheet contacts the corresponding thermoplastic resin sheet, the surface of the corresponding thermoplastic resin sheet, The step of forming the second sealed space by the inner peripheral surface of the decorative mold part and the surface of the decorative sheet;
A step of adhering the decorative sheet to the thermoplastic resin sheet by vacuum suction of the second sealed space;
Vacuum suction is performed from the cavity side in the first sealed space formed by the surface of the decorative sheet surface-bonded to the thermoplastic resin sheet, the inner peripheral surface of the decorative mold part, and the surface of the cavity. By pressing the surface-bonded thermoplastic resin sheet and the decorative sheet against the cavity and shaping, the pair of split molds are clamped to form a pair of split molds. Forming a sealed space inside, thereby welding the peripheral edges of the two thermoplastic resin sheets,
Further, by pressing from the inside of the sealed space, or by sucking the inside of the sealed space through the other divided mold, the thermoplasticity facing the cavity of the other divided mold in the sealed space And a step of shaping the resin sheet.
Furthermore, in the mold clamping step of the divided mold, the inside of the first sealed space is vacuum-sucked from the cavity side to press the surface-bonded thermoplastic resin sheet and the decorative sheet against the cavity. It may be performed after the shaping step is completed.

A first embodiment of a molding apparatus for a resin molded product according to the present invention will be described below in detail with reference to the drawings.
In the present embodiment, as a resin molded product, a double wall structure molded product using two strips of thermoplastic resin sheet P is targeted, and two strips of thermoplastic resin sheet P are simultaneously molded. About the thermoplastic resin sheet P, the molten thermoplastic resin is extruded in a form that hangs downward from the extrusion slit of the T-die into a sheet shape, and in the secondary molding, the two strips of thermoplastic resin sheet P extruded downward A resin molded product is molded by vacuum molding through mold clamping of a split mold.

As shown in FIG. 1, a molding apparatus 10 for a resin molded product is formed by extruding a thermoplastic resin by extrusion molding, and extruding the primary molded thermoplastic resin in a form that hangs down and a primary molding part. And a secondary molding part that performs secondary molding by blow molding or vacuum molding, the primary molding part has an extrusion device 12, and the extrusion device 12 melts and kneads the thermoplastic resin. Kneading means, storage means for storing a predetermined amount of the melted and kneaded thermoplastic resin, and an extrusion slit for extruding the stored thermoplastic resin intermittently so as to hang down into a molten sheet.
On the other hand, the secondary molding unit has a mold clamping device 14 disposed below the extrusion device 12, and sends a molten thermoplastic resin sheet extruded from the extrusion device 12 to the mold clamping device 14. The apparatus 14 forms a molten thermoplastic resin sheet.

The extrusion device 12 is a conventionally known type, and detailed description thereof is omitted.
, A screw (not shown) provided in the cylinder 18, a hydraulic motor 20 connected to the screw, an accumulator 24 communicating with the cylinder 18, and an accumulator 24. The resin pellets introduced from the hopper 16 are melted and kneaded in the cylinder 18 by the rotation of the screw by the hydraulic motor 20, and the molten resin is transferred to the accumulator 24 chamber to a certain amount. The molten resin is stored and fed toward the T-die 28 by driving the plunger 26, the thermoplastic resin sheet is pushed out through the extrusion slit 34, and pressed downward by a pair of rollers 30 arranged at intervals. And is suspended between the divided molds 32. Thereby, as will be described in detail later, the thermoplastic resin sheet is disposed between the split molds 32 in a state of having a uniform thickness in the vertical direction (extrusion direction).

The extrusion capability of the extrusion device 12 is appropriately selected from the viewpoints of the size of the resin molded product to be molded, the drawdown of the thermoplastic resin sheet, or the prevention of neck-in occurrence. More specifically, from a practical point of view, the extrusion amount of one shot in intermittent extrusion is preferably 1 to 10 kg, and the extrusion rate of the resin from the extrusion slit 34 is several hundred kg / hour or more, more preferably 700 kg / hour or more. Further, from the viewpoint of preventing the draw-down or neck-in of the thermoplastic resin sheet P, the extrusion process of the thermoplastic resin sheet is preferably as short as possible, depending on the type of resin, the MFR value, and the melt tension value. Generally, the extrusion process should be completed within 40 seconds, more preferably within 10-20 seconds. For this reason, the unit area from the extrusion slit 34 of thermoplastic resin, the amount of extrusion per unit time is 50 kg / hour cm.
² or more, more preferably 150 kg / hour cm ² or more. For example, the density is 0.9 g / cm from the extrusion slit 34 of the T die 28 having a slit interval of 0.5 mm and a length in the width direction of the slit of 1000 mm.
^When extruding in 15 seconds as a thermoplastic resin sheet having a thickness of 1.0 mm, a width of 1000 mm, and a length of 2000 mm in the extrusion direction using the thermoplastic resin of ³ in 1.8 seconds, 1.8 kg of thermoplastic resin is shot in 15 seconds for one shot. The extrusion speed was 432 kg / hour, and the extrusion speed per unit area was about 86 kg / hour cm.
² can be calculated.

As will be described later, the thermoplastic resin sheet P can be stretched and thinned by feeding downward the thermoplastic resin sheet P sandwiched between the pair of rollers 30 by the rotation of the pair of rollers 30. Yes, by adjusting the relationship between the extrusion speed of the extruded thermoplastic resin sheet P and the delivery speed of the thermoplastic resin sheet P by the pair of rollers 30, it is possible to prevent the occurrence of drawdown or neck-in. Therefore, it is possible to reduce the restrictions on the type of resin, particularly the MFR value and melt tension value, or the extrusion amount per unit time.

As shown in FIG. 1, the extrusion slit 34 provided in the T die 28 is arranged vertically downward, and the thermoplastic resin sheet extruded from the extrusion slit 34 hangs down from the extrusion slit 34 as it is. To be sent to.

  The sheet extruded from the T-die 28 is preferably adjusted so that the thickness in the extrusion direction is uniform when it is suspended between the divided molds 32, that is, when the mold is clamped. In this case, the slit gap A is gradually widened from the start of extrusion and is varied so as to become maximum at the end of extrusion. As a result, the thickness of the sheet extruded from the T die 28 gradually increases from the start of extrusion, but the sheet extruded in the molten state is stretched by its own weight and gradually decreases from the bottom to the top of the sheet. The portion of the sheet that has been spread and thickened and the portion that has been stretched and thinned by the drawdown phenomenon cancel each other out, and the sheet can be adjusted to a uniform thickness from above to below.

The pair of rollers 30 will be described with reference to FIGS. 2 and 3. The pair of rollers 30 are arranged below the extrusion slit 34 so that their respective rotation axes are arranged substantially in parallel with each other and one of them is rotationally driven. It is a roller 30A, and the other is a driven roller 30B. More specifically, as shown in FIG. 1, the pair of rollers 30 are arranged so as to be line-symmetric with respect to the thermoplastic resin sheet P extruded in a form that hangs downward from the extrusion slit 34. The diameter of each roller and the axial length of the roller may be appropriately set according to the extrusion speed of the thermoplastic resin sheet P to be molded, the length and width of the sheet in the extrusion direction, the type of resin, and the like. As will be described later, from the viewpoint of smoothly feeding the thermoplastic resin sheet P downward by rotation of the roller with the thermoplastic resin sheet P sandwiched between the pair of rollers 30, the diameter of the rotational drive roller 30A Is preferably slightly larger than the diameter of the driven roller 30B. The diameter of the roller is preferably in the range of 50 to 300 mm. If the roller curvature is too large or too small in contact with the thermoplastic resin sheet, the thermoplastic resin sheet is wound around the roller. Cause.

The rotation driving roller 30A is provided with a roller rotation driving means 94 and a roller moving means 96. The roller rotation driving means 94 enables the rotation driving roller 30A to rotate around its axial direction, while the roller moving means 96 Thus, the rotation driving roller 30A approaches the rotation driving roller 30B or holds the rotation driving roller 30B while maintaining a parallel positional relationship with the rotation driving roller 30B in a plane including the pair of rollers 30. It is moved away from.

More specifically, the roller rotation drive means 94 is a rotation drive motor 98 connected to the rotation drive roller 30A, and the rotation torque of the rotation drive motor 98 is rotated via, for example, a gear reduction mechanism (not shown). To communicate. The rotation drive motor 98 is a conventionally known one, and a rotation speed adjusting device 100 is attached so that the rotation speed can be adjusted. The rotation speed adjusting device 100 may adjust, for example, the current value for the electric motor. As will be described later, the extrusion speed at which the thermoplastic resin sheet P is extruded from the extrusion slit 34 and the rotation of the pair of rollers 30. Thus, the relative speed difference with the feed speed at which the thermoplastic resin sheet P is sent downward is adjusted according to the extrusion speed of the thermoplastic resin sheet P.
For example, when a thermoplastic resin sheet having a length of 2000 mm is fed in the feeding direction in 15 seconds using a pair of rollers having a diameter of 100 mm, the feeding speed of the thermoplastic resin sheet by the roller is about 6. Four rotations are required, and the rotation speed of the roller can be calculated to be about 25.5 rpm. The feeding speed of the thermoplastic resin sheet P can be easily adjusted by increasing or decreasing the rotation speed of the roller.

As shown in FIG. 2, the rotation driven roller 30 </ b> B rotates around the rotation axis of the roller over the end circumferential surface 102 so that the rotation driven roller 30 </ b> B rotates in synchronization with the rotation driving roller 30 </ b> A. The rotary drive roller 30 </ b> A has a second gear 108 that meshes with the first gear 104 and that can rotate about the rotation axis of the roller over the end surface 107.

As shown in FIG. 3, the roller moving means 96 is composed of a piston-cylinder mechanism, and the tip of the piston rod 109 is connected to a cover 117 that rotatably supports the rotational driving roller 30A in its axial direction. By adjusting, the piston 113 is slid with respect to the cylinder 115, whereby the rotational driving roller 30A is moved in the horizontal direction, so that the interval between the pair of rollers 30 can be adjusted. In this case, as will be described later, before the lowermost portion of the sheet-shaped resin is supplied between the pair of rollers 30, the distance between the pair of rollers 30 is expanded from the thickness of the supplied sheet-shaped resin (see FIG. 3 (A), an open position that constitutes the interval D1), the sheet-like resin is smoothly supplied between the pair of rollers 30, and then the interval between the pair of rollers 30 is narrowed so that the pair of rollers 30 Thus, the sheet-like resin is sandwiched (closed position constituting the interval D2 in FIG. 3A), and the sheet-like resin is sent downward by the rotation of the roller. The stroke of the piston 113 may be set so as to be the distance between the open position and the closed position. Further, by adjusting the air pressure, it is possible to adjust the pressing force that acts on the sheet-shaped resin from the rollers when the sheet-shaped resin passes between the pair of rollers 30. The range of the pressing force is that the pair of rollers 30 is rotated so that no slip occurs between the surface of the pair of rollers 30 and the surface of the sheet-like resin, while the sheet-like resin is torn off by the pair of rollers 30. In order to prevent this, it is determined that the sheet-like resin is surely sent out downward, and is, for example, 0.05 MPA to 6 MPA, depending on the type of resin.

When the sheet-shaped resin is sent downward by the rotation of the pair of rollers 30, the rotation-driven roller 30 </ b> A has a helical shape that is oriented so as to guide the sheet-shaped resin toward each end of the rotation drive roller 30 </ b> A. A pair of shallow grooves 112 is provided over the outer peripheral surface. Thereby, it can be set as the state stretched | stretched in the direction which expands the width | variety of sheet-like resin because sheet-like resin passes a pair of roller 30. FIG. The pitch and depth of the shallow grooves 112 may be appropriately set according to the material of the sheet-like resin, the rotation speed of the set roller, and the like. Incidentally, the pitch of the shallow grooves in FIG. 2 is exaggerated for easy understanding.
The rotational driving roller 30A may be provided with a surface temperature adjusting means for adjusting the surface temperature of the roller according to the temperature of the sheet-like resin. By circulating the refrigerant, heat exchange may be performed so that the surface of the roller is not excessively heated by the molten sheet-shaped resin sandwiched between the pair of rollers 30. The outer peripheral surface of the roller is preferably heat-resistant.

On the other hand, the mold clamping device 14 is also a conventionally known type like the extrusion device 12, and detailed description thereof will be omitted, but the two divided molds 32A and 32B and the molds 32A and 32B are melted. A mold driving device that moves between an open position and a closed position in a direction substantially orthogonal to the supply direction of the sheet-like thermoplastic resin sheet P.

As shown in FIG. 1, the two divided molds 32 </ b> A and 32 </ b> B are arranged with the cavities 116 facing each other, and the cavities 116 are arranged so as to face substantially vertically. The surface of each cavity 116 is provided with an uneven portion according to the outer shape and surface shape of a molded product molded based on a molten thermoplastic resin sheet. In each of the two divided molds 32A and 32B, a pinch-off part 118 is formed around the cavity 116. The pinch-off part 118 is formed in an annular shape around the cavity 116, and the opposing molds 32A and 32B are formed. Protrusively toward. As a result, when the two divided molds 32A and 32B are clamped, the tip portions of the respective pinch-off portions 118 come into contact with each other, and a parting line PL is formed at the periphery of the molten thermoplastic resin sheet P. I try to do it.

As shown in FIG. 4, the molds 32 </ b> A and 32 </ b> B have substantially the same structure, and both have an annular pinch-off part 118 and a cavity 116 formed inside the annular pinch-off part 118 on one side.
One mold 32A is provided with a decorative molding die component 200 by a decorative sheet D so as to be fitted on the outer peripheral side surface of the mold 32 so that the contact surface is located on the cavity 116 side. In the cavity 116, a vacuum suction hole 122 (for vacuum suction of the first sealed space 230 formed by the outer surface of the thermoplastic resin sheet P, the inner peripheral surface of the decorative mold part 200, and the cavity 116). FIG. 5) is provided.
A mold part 200 for decorative molding using the decorative sheet D is a frame having a through-hole 203 that can be fitted to the outer peripheral surface 204 of the mold 32, and a molten molding material sheet is provided on the annular end surface of the frame. A contact surface that can contact the thermoplastic resin sheet P is formed on the outer peripheral side of the contact surface. On the inner peripheral side, there is a decorative sheet annular contact surface 206 that can contact the outer peripheral portion 260 of the decorative sheet D, and the thermoplastic resin sheet annular contact surface 202 is decorated. It can project with respect to the annular contact surface 206 for the sheet.

More specifically, the annular contact surface 202 for the thermoplastic resin sheet is configured to contact the thermoplastic resin sheet P disposed on the side of the cavity 116 of the mold 32, and for this reason, the decoration is performed. The molding die part 200 has an outer frame body 208 and an inner frame body 210 that are in a fitting relationship with each other, and the outer frame body 208 has an annular contact surface 202 for a thermoplastic resin sheet, The frame 210 has a decorative sheet annular contact surface 206, and the outer frame 208 and the inner frame 210 are arranged on the inner peripheral surface of the outer frame 208 by a formwork moving device (not shown). 252 are slidable relative to the outer peripheral surface 204 of the inner frame body 210 and can move relative to each other. The outer frame body 208 has an air discharge through hole 212. For example, a plurality of air discharge through holes 212 may be provided at intervals in the annular direction of the outer frame body 208.
More specifically, as shown in FIG. 12, the outer frame 208 has a holding position (FIG. 12B) and a contact position (FIG. 12A) that contacts the thermoplastic resin sheet P. When the outer frame body 208 is located at the contact position, the outer frame body 208 protrudes in the mold clamping direction with respect to the inner frame body 210, so that the outer frame body 208 moves in the thickness direction. The provided air discharge through hole 212 can be exposed.
Similarly, as shown in FIG. 13, the inner frame 210 is movable between a holding position (FIG. 13B) and a contact position that contacts the decorative sheet D (FIG. 13A). When the inner frame body 210 is located at the contact position, the inner frame body 210 protrudes at least from the pinch-off portion 118 of the mold 32 described later in the mold clamping direction, whereby the mold of the inner frame body 210 is The decorative sheet D that contacts the decorative sheet annular contact surface 206 of the inner frame 210 is held by vacuum suction through the air discharge through hole 219 provided in the tightening direction. For example, a plurality of air discharge through holes 219 may be provided at intervals in the annular direction of the inner frame body 210.
Accordingly, as shown in FIG. 7, the outer frame body 208 is positioned at the contact position, and the inner frame body 210 is positioned at the contact position, whereby the inner surface 248 of the thermoplastic resin sheet P, the outer frame A second sealed space 232 is formed by the inner peripheral surface 250 of the body 208 and the outer surface 258 of the decorative sheet D so that the second sealed space 232 can be vacuum-sucked through the air discharge through hole 212. .
The widths W1 and W2 of the annular contact surface 202 for the thermoplastic resin sheet and the annular contact surface 206 for the decorative sheet are the same as that of the annular contact surface 202 for the thermoplastic resin sheet. When the first sealed space 230 is vacuum-sucked in contact with the plastic resin sheet, the contact state can be maintained, while the decorative sheet annular contact surface 206 is in contact with the decorative sheet D. What is necessary is just to determine from a viewpoint which can maintain a contact state, when vacuum-sucking the 2nd sealed space 232 in the state which contact | connected.
Unlike the mold 32A, the other mold 32B is not subjected to the decorative molding by the decorative sheet D. Therefore, the mold part 200 for decorative molding by the decorative sheet D is not installed, and the mold 32B is not installed. A mold 33B is slidably fitted on the outer periphery of the mold 33, and the mold 33B can be moved relative to the mold 32B by a mold moving device (not shown). More specifically, the mold frame 33B protrudes toward the mold 32A with respect to the mold 32B, so that it can come into contact with the side surface of the thermoplastic resin sheet P1 disposed between the molds 32A and 32B. Yes.

  As shown in FIG. 17, the decorative molding mold part 200 is provided so as to surround the divided mold 32 </ b> A with a square, and in the outer frame body 208, a thermoplastic resin that comes into contact with the thermoplastic resin sheet P is provided. The inner ring body 210 has a suction opening 271 on the decorative sheet annular contact surface 206 that contacts the decorative sheet D, and has the suction opening 271 on the annular contact surface 202 for sheet making. doing. A plurality of suction openings 270 and 271 are provided at predetermined intervals in the annular direction of the annular contact surface 202 for the thermoplastic resin sheet and the annular contact surface 206 for the decorative sheet, both forming an annular body, Air is sucked, and the decorative sheet D and the thermoplastic resin sheet P are drawn into the decorative sheet annular contact surface 206 and the thermoplastic resin sheet annular contact surface 202 by suction of the suction openings 270 and 271, respectively. The decorative sheet D and the thermoplastic resin sheet P are brought into close contact with the corresponding contact surfaces. Note that the suction opening 270 can be formed in various shapes (for example, a circle, an ellipse, and a polygon), but it is formed in a groove shape (linear shape) as shown in FIG. Is preferred. For example, when the suction openings 270 and 271 are formed into holes (dots), the decorative sheet D and the thermoplastic resin sheet P are partially adsorbed to the corresponding contact surfaces, and the suction opening 270 , 271 of the part of the decorative sheet D and the thermoplastic resin sheet P that are not adsorbed may float from the corresponding contact surfaces. For this reason, by forming the suction openings 270 and 271 in a groove shape (linear shape), the decorative sheet D and the thermoplastic resin sheet P can be adsorbed in a groove shape on the corresponding contact surfaces. The decorative sheet D and the thermoplastic resin sheet P that are not adsorbed by the openings 270 and 271 can be made difficult to float from the corresponding contact surfaces.

The mold driving device is the same as the conventional one, and the description thereof is omitted. However, the two divided molds 32A and 32B are respectively driven by the mold driving device and are divided into two in the open position. A molten thermoplastic resin sheet P can be placed between the molds 32A and 32B, and in the closed position, the pinch-off portions 118 of the two divided molds 32A and 32B come into contact with each other, and an annular pinch-off is formed. When the portions 118 are in contact with each other, a sealed space is formed in the two divided molds 32A and 32B. In addition, about the movement of each metal mold | die 32A, B from an open position to a closed position, a closed position is made into the position of the centerline of the thermoplastic resin sheet P of a molten state, and each metal mold | die 32 is set.
32A and B are driven by the mold driving device so as to move toward the position.

As shown in FIG. 5, the vacuum suction chamber 120A inside one split mold 32A communicates with the cavity 116A through the suction hole 122A, and is sucked from the vacuum suction chamber 120A through the suction hole 122A. The thermoplastic resin sheet P integrated with the decorative sheet D / film is adsorbed toward the cavity 116A and shaped into a shape along the outer surface of the cavity 116A.
A vacuum suction chamber 120B is also provided inside one of the divided molds 32B. The vacuum suction chamber 120B communicates with the cavity 116B through the suction hole 122B, and is sucked from the vacuum suction chamber 120B through the suction hole 122B. The thermoplastic resin sheet P is adsorbed toward the cavity 116B and shaped into a shape along the outer surface of the cavity 116B.

The thermoplastic resin sheet P is made of a sheet formed from polypropylene, engineering plastics, olefin resin, or the like. More specifically, the thermoplastic resin sheet P is preferably made of a resin material having a high melt tension from the viewpoint of preventing the occurrence of thickness variation due to drawdown, neck-in, or the like, while the mold 32 is used. It is preferable to use a resin material with high fluidity in order to improve the transferability to and the followability to.

Specifically, it is a polyolefin (for example, polypropylene, high density polyethylene) which is a homopolymer or copolymer of olefins such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., and has an MFR (JIS K) at 230 ° C. Measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to −7210) of 3.0 g / 10 min or less, more preferably from 0.3 to 1.5 g / 10 min, or acrylonitrile butadiene styrene Amorphous resin such as copolymer, polystyrene, high impact polystyrene (HIPS resin), acrylonitrile / styrene copolymer (AS resin), MFR at 200 ° C. (test temperature 200 ° C. according to JIS K-7210) , Measured at a test load of 2.16 kg) is 3.0-60 g / 10 min. More preferably, the melt tension at 30 to 50 g / 10 min and at 230 ° C. (using a melt tension tester manufactured by Toyo Seiki Co., Ltd., preheating temperature 230 ° C., extrusion speed 5.7 mm / min, diameter 2.095 mm, A strand is extruded from an orifice having a length of 8 mm, and a tension when the strand is wound around a roller having a diameter of 50 mm at a winding speed of 100 rpm) is 50 mN or more, preferably 120 mN or more.

Further, in order to prevent the thermoplastic resin sheet P from being cracked by impact, it is preferable that a hydrogenated styrene thermoplastic elastomer is added in a range of less than 30 wt%, preferably less than 15 wt%. Specifically, a styrene-ethylene / butylene-styrene block copolymer, a styrene-ethylene / propylene-styrene block copolymer, a hydrogenated styrene-butadiene rubber and a mixture thereof are suitable as the hydrogenated styrene-based thermoplastic elastomer. The styrene content is less than 30 wt%, preferably less than 20 wt%, and the MFR at 230 ° C. (measured at a test temperature of 230 ° C. and a test load of 2.16 kg according to JIS K-7210) is 1.0 to 10 g / 10. Minute, preferably 5.0 g / 10 min or less and 1.0 g / 10 min or more.

Furthermore, the thermoplastic resin sheet P may contain an additive. Examples of the additive include inorganic fillers such as silica, mica, talc, calcium carbonate, glass fiber, and carbon fiber, plasticizer, and stabilizer. , Colorants, antistatic agents, flame retardants, foaming agents and the like.
Specifically, silica, mica, glass fiber or the like is added in an amount of 50 wt% or less, preferably 30 to 40 wt%, based on the molding resin.

The decorative sheet D is made of the same material as the resin sheet, and the decorative sheet D is surface-bonded to the molten resin sheet. As a modification, the decorative sheet D includes a resin sheet, a resin sheet portion made of a different material, and a non-woven sheet portion, and the decorative sheet D is in a molten resin sheet. Surface bonding is performed on the basis of the anchor effect by pressing the non-woven sheet portion so as to face each other. In any case, even if the decorative sheet D is a non-breathable sheet, the decorative sheet D can be decoratively molded. It is possible to avoid the deterioration of the aesthetic appearance of the decorative sheet D by providing fine through holes in D.
When the decorative sheet D is made of the same material as the resin sheet, surface welding can be performed on the molten resin sheet. However, the decorative sheet D is a resin sheet. When the sheet portion made of a different material and the sheet portion made of a non-woven fabric are laminated, the surface is bonded to the molten resin sheet instead of surface welding.

As shown in FIG. 14, a single vacuum pump 240 is used for vacuum suction of each of the first sealed space 230, the second sealed space 232, the third sealed space 234, and the fourth sealed space 262, and is shared. We are trying to make it. More specifically, a single vacuum pump 240 and suction pipes 244A to 244D that connect the first sealed space 230, the second sealed space 232, the third sealed space 234, and the fourth sealed space 262, respectively, are provided for suction. By installing the gate valves 245A to D in the pipes 244A to 244D, for example, when the first sealed space 230 is vacuumed by the single vacuum pump 240, the gate valve 245A is opened and the gate valves 245B to 245D are used. Should be closed. As a result, cost reduction is achieved through the common use of vacuum pumps.

The operation of the resin molded product molding apparatus 10 having the above configuration will be described below with reference to the drawings.
First, as shown in FIG. 18, in each of the divided molds 32A and 32B, a predetermined amount of the melted and kneaded thermoplastic resin is stored in the accumulator 24, and from the extrusion slits 34 provided at predetermined intervals on the T die 28, By intermittently extruding the stored thermoplastic resin at a predetermined extrusion rate per unit time, the thermoplastic resin swells and is extruded at a predetermined extrusion speed with a predetermined thickness so as to hang downward into a molten sheet. It is.

Next, by driving the piston / cylinder mechanism 96, as shown in FIG. 3A, the pair of rollers 30 is moved to the open position, and the distance between the pair of rollers 30 disposed below the extrusion slit 34. Is made wider than the thickness of the thermoplastic resin sheet P, so that the lowermost portion of the molten thermoplastic resin sheet P extruded downward is smoothly supplied between the pair of rollers 30. In addition, the timing which expands the space | interval of the rollers 30 from the thickness of the sheet | seat P made from a thermoplastic resin may be performed at the time of the completion | finish of secondary shaping | molding for every one shot not after an extrusion start.
Next, by driving the piston-cylinder mechanism 96, as shown in FIG. 3B, the pair of rollers 30 are moved close to each other and moved to the closed position, and the gap between the pair of rollers 30 is reduced. The plastic resin sheet P is sandwiched, and the thermoplastic resin sheet P is sent downward by the rotation of the roller. At that time, while the thermoplastic resin sheet P in a swelled state due to the rotation of the roller 30 is being sent to the pair of rollers 30, the feed rate of the thermoplastic resin sheet P downward by the pair of rollers 30 is The rotation speed of the roller is adjusted so as to be equal to or higher than the extrusion speed of the plastic resin sheet P.
More specifically, as the swelled thermoplastic resin sheet P is fed downward to the pair of rollers 30, the length of the thermoplastic resin sheet P that hangs down in the vertical direction becomes longer, resulting in drooping. The upper part of the thermoplastic resin sheet P is thinned by the weight of the thermoplastic resin sheet P (drawdown or neck-in), while the feeding speed by the pair of rollers 30 is higher than the extrusion speed. By adjusting the rotation speed of the roller, the thermoplastic resin sheet P is pulled downward by the pair of rollers 30, and the thermoplastic resin sheet P is stretched and thinned.
At this time, the rotational speed of the roller is reduced with the passage of time, and the feed speed is adjusted to approach the extrusion speed of the thermoplastic resin sheet.

For example, as shown in FIG. 6 (A), the extrusion speed of the thermoplastic resin sheet P may be kept constant, while the rotational speed of the roller may be decreased stepwise over time, or FIG. 6 (B). As shown in Fig. 6, while the rotation speed of the roller is made constant, the extrusion speed of the thermoplastic resin sheet P may be decreased stepwise with time. Within the range where the rotational speed is larger, both the rotational speed of the roller and the extrusion speed of the thermoplastic resin sheet P may be changed stepwise over time.
In any case, as time elapses, the relative speed difference between the downward feeding speed of the thermoplastic resin sheet P due to the rotation of the pair of rollers 30 and the extrusion speed of the thermoplastic resin sheet P is reduced. Accordingly, the downward pulling force by the pair of rollers 30 decreases toward the upper part of the thermoplastic resin sheet P, and the thinning due to the pulling force is relatively reduced, and the thinning due to drawdown or neck-in is reduced. It is possible to counteract the formation, effectively prevent drawdown or neck-in, and thereby form a uniform thickness in the extrusion direction.

In this case, as a modification, adjustment of the interval between the extrusion slits 34 and adjustment of the rotation speed of the roller may be linked. More specifically, the speed at which the thermoplastic resin sheet P is fed downward by the pair of rollers 30 is reduced by decreasing the rotational speed of the rollers with time, and the slit gap adjusting device is used for extrusion. The interval between the slits 34 may be increased. Thereby, at the stage of primary molding, the thickness of the thermoplastic resin sheet P extruded downward from the extrusion slit 34 increases with time, and at the same time, the stretched thin wall of the thermoplastic resin sheet P by the pair of rollers 30. Since the effect is reduced, the upper part of the thermoplastic resin sheet P is more effectively drawn down by the synergistic effect of increasing the thickness of the thermoplastic resin sheet P and reducing the stretched thin wall effect of the thermoplastic resin sheet P. Or it becomes possible to prevent a neck-in.

In particular, as shown in FIGS. 6B and 6C, when the extrusion speed of the thermoplastic resin sheet P is changed during the molding of the thermoplastic resin sheet P, the plunger 26 is usually used. Since it is necessary to change the extrusion amount of the molten resin per unit time, if the extrusion amount of the molten resin is changed, the swell of the molten resin immediately after being extruded from the extrusion slit 34 is affected. In order to prevent the influence of the increase in the thickness of the thermoplastic resin sheet P, it is preferable to adjust the interval between the extrusion slits 34 together with the adjustment of the rotation speed of the roller.
More specifically, as the amount of extrusion per unit time increases, the molding time from the start of primary molding to the end of secondary molding is shortened, thereby improving molding efficiency and thermoplastic resin before secondary molding. It is possible to reduce the possibility of drawdown or neck-in by shortening the time during which the manufactured sheet P hangs down. On the other hand, as the amount of extrusion per unit time increases, from the extrusion slit 34 The swell of the extruded thermoplastic resin sheet P is promoted, and it may be necessary to adjust the distance between the pair of rollers 30 according to the thickening accompanying the swell. In this respect, it is technically advantageous to adjust the thickness of the thermoplastic resin sheet P by the swell itself by adjusting the interval between the extrusion slits 34.

In this case, it is possible to adjust the thickness of the extruded thermoplastic resin sheet P by only adjusting the distance between the extrusion slits 34, but the thermoplasticity can be adjusted by adjusting the rotation speed of the pair of rollers 30. It is technically advantageous to adjust the thickness of the resin sheet P in the following points.

First, the adjustment of the rotational speed of the pair of rollers 30 is that the thickness of the thermoplastic resin sheet P can be adjusted more easily than the adjustment of the interval between the extrusion slits 34. More specifically, when the extrusion amount of the molten resin per unit time is constant, the swell of the thermoplastic resin sheet P is reduced as the interval between the extrusion slits 34 is narrow, but on the other hand, the extrusion pressure is increased. Since the swell of the plastic resin sheet P is promoted, it is difficult to adjust the thickness of the thermoplastic resin sheet P immediately after being extruded from the extrusion slit 34 to a desired value. It is difficult to adjust the thickness after swell by changing the interval of the extrusion slit 34 during molding.

Secondly, the adjustment of the rotation speed of the pair of rollers 30 is superior in the responsiveness to the thickness of the thermoplastic resin sheet P than the adjustment of the interval between the extrusion slits 34. More specifically, when the interval between the extrusion slits 34 is changed, it takes time for the thickness of the thermoplastic resin sheet P immediately after being extruded from the extrusion slit 34 to reach a steady state. The portion of the sheet P made of the plastic resin cannot be used for the secondary molding, and the yield is reduced. On the other hand, in the case of adjusting the rotational speed of the pair of rollers 30, the downward feed speed of the thermoplastic resin sheet P sandwiched between the pair of rollers varies with the fluctuation of the rotational speed. Since the tensile force of the thermoplastic resin sheet P by the roller of the roller fluctuates and the thermoplastic resin sheet P is stretched and thinned, the response to the thickness of the thermoplastic resin sheet P is excellent, and the yield is reduced. It is possible to suppress.

Thirdly, the adjustment of the rotation speed of the pair of rollers 30 is that the thickness of the thermoplastic resin sheet P immediately before the mold clamping by the secondary molding can be adjusted by adjusting the distance between the extrusion slits 34. More specifically, if the thickness of the thermoplastic resin sheet P before mold clamping is non-uniform in the extrusion direction due to drawdown or neck-in, the mold forming effect by blow molding or vacuum molding is adversely affected. It is more preferable to ensure the uniformity of the thickness of the thermoplastic resin sheet P immediately before the mold clamping of 32, and in this respect, the thickness between the primary molding by extrusion and the secondary molding by blow molding or vacuum molding. It is advantageous to adjust.

  Fourthly, the surface adhesion of the decorative sheet D to the thermoplastic resin sheet P can be performed smoothly and reliably. More specifically, since the thickness of the thermoplastic resin sheet P can be uniformly adjusted in the extrusion direction immediately before the secondary molding by the pair of rollers 30, the surface of the thermoplastic resin sheet P facing the decorative sheet; Without adhering to the surface of the decorative sheet, it is possible to adhere and adhere to the surface without forming an air pocket.

Regarding secondary molding, as shown in FIG. 18, two thermoplastic resin sheets P having a uniform thickness in the extrusion direction are disposed between the split molds 32 disposed below the pair of rollers 30. . More specifically, in a form that protrudes around the cavity 116 of the pair of split molds 32, two molten thermoplastic resin sheets P spaced apart from each other are formed into a pair of split molds 32. Place between.
Next, as shown in FIG. 1, the inner frame 210 is moved in the mold clamping direction to a position where the decorative sheet annular contact surface 206 of the inner frame 210 protrudes at least from the top of the pinch-off portion 118. More specifically, the outer frame 208 is stationary and moves the inner frame 210 in the mold clamping direction with respect to the outer frame 208 by the frame moving device.

Next, as shown in FIG. 1, the decorative sheet D is held by the decorative sheet annular contact surface 206 so as not to protrude from the outer peripheral edge 220 of the decorative sheet annular contact surface 206. More specifically, the decorative sheet D adjusted to a size that does not protrude from the outer peripheral edge 220 of the decorative sheet annular contact surface 206 is, for example, the decorative sheet annular contact surface by the common vacuum pump 240. Holding is performed by vacuum suction from 206 through the suction opening 270.
In this case, when the decorative sheet D has a charging property, it may be held by the decorative sheet annular contact surface 206 using static electricity, or alternatively, the decorative sheet annular contact surface A pin may be provided at 206 and hooked there.
Next, as shown in FIG. 7, the outer frame body 208 is moved in the mold clamping direction until the annular contact surface 202 for the thermoplastic resin sheet contacts the corresponding thermoplastic resin sheet P <b> 2. A second sealed space 232 is formed by the inner surface 248 of the thermoplastic resin sheet P2, the inner peripheral surface 250 of the outer frame 208, and the outer surface 258 of the decorative sheet D. More specifically, the inner frame 210 is stationary while holding the decorative sheet D, and the frame moving device moves the outer frame 208 in the mold clamping direction with respect to the inner frame 210. The first sealed space 230 formed by the thermoplastic resin sheet P2, the inner peripheral surface 250 of the decorative molding die part 200, and the surface of the cavity 116. The sheet is partitioned by the decorative sheet D held by the inner frame 210, and specifically, protrudes in the mold clamping direction from the inner surface 248 of the corresponding thermoplastic resin sheet P2 and the inner frame 210 of the outer frame 208. A second sealed space 232 is formed by the inner peripheral surface 250 and the outer surface 258 of the decorative sheet D, while the inner surface 261 of the decorative sheet D, the inner peripheral surface 254 of the inner frame 210 and the cavity 1 The 6 surface, the third closed space 234 is formed.

Next, as shown in FIG. 8, the decorative sheet D is surface-bonded to the thermoplastic resin sheet P <b> 2 by vacuum suction of the second sealed space 232. More specifically, the decorative sheet D and the thermoplastic resin sheet P2 are operated by operating the common vacuum pump 240 and vacuuming the air in the second sealed space 232 through the air discharge through hole 212. In between, the decorative sheet D and the thermoplastic resin sheet P2 are in close contact with each other and are integrally laminated without forming an air pocket.
In this case, if the decorative sheet D is a resin of the same material as the thermoplastic resin sheet P2, the decorative sheet D can be welded by being pressed against the molten thermoplastic resin sheet P2. On the other hand, when the decorative sheet D is a laminate of a thermoplastic resin sheet P2, a different resin sheet portion, and a non-woven sheet portion, the decorative sheet D is in a molten state. Surface bonding is performed on the basis of the anchor effect by pressing the non-woven sheet portion against the thermoplastic resin sheet P2. At that time, it is preferable to continue the vacuum suction through the suction opening 270 of the decorative sheet D.

Next, as shown in FIG. 9, the surface 256 of the decorative sheet D that is surface-bonded to the thermoplastic resin sheet P2, the inner peripheral surface 250 of the decorative molding die part 200, and the surface of the cavity 116 are formed. By vacuuming the inside of the first sealed space 230 from the cavity 116 side, the surface-bonded thermoplastic resin sheet P2 and the decorative sheet D are pressed against the cavity 116 and shaped. More specifically, by operating the common vacuum pump 240 and vacuuming the air in the first sealed space 230 through the air discharge through hole 212, the thermoplastic resin sheet P2 and the decorative sheet D are drawn. Is formed in one piece. In this case, when the thermoplastic sheet P2 is pressed against the cavity 116 by vacuum suction from the cavity 116 side with the decorative sheet D held on the surface of the cavity 116 as in the prior art, The decorative sheet D needs to be breathable, and accordingly, the aesthetic appearance of the decorative sheet D has been impaired. Without such restrictions, the thermoplastic resin sheet P2 and the decorative sheet D It is possible to shape in one piece.
The other thermoplastic resin sheet P1 is similarly shaped by the mold 32B.

Next, as shown in FIG. 10, the pair of split molds 32 are clamped to form a sealed space in the pair of split molds 32. More specifically, the outer frame body 208 remains in contact with the corresponding thermoplastic resin sheet P, while the inner frame body 210 holds the outer peripheral portion of the decorative sheet D, while both are stationary and are added. The split mold 32 is moved in the mold clamping direction with respect to the decorative mold part 200 until the respective pinch-off portions 118 come into contact with each other, whereby the two peripheral edges of the thermoplastic resin sheets P1, 2 are welded together. In addition, a parting line is formed, and a sealed hollow portion is formed inside the two thermoplastic resin sheets P1 and P2.

Next, as shown in FIG. 11, the split mold 32 is opened, the molded resin molded product is taken out, and burrs formed around the parting line are removed. This completes the secondary molding. In this case, the vacuum suction is stopped.
By repeating the above steps each time the molten resin is intermittently extruded in the primary molding, a sheet-like resin molded product can be molded one after another.
As described above, the thermoplastic resin is intermittently extruded as a thermoplastic resin sheet P in a molten state by primary molding (extrusion molding), and the sheet-like resin extruded by secondary molding (blow molding or vacuum molding) is divided. It is possible to mold using the mold 32. In this case, since the vertical thickness of the two sheets of thermoplastic resin sheet P before suction is uniform, the shaping process is not satisfactorily performed due to the thickness distribution caused by the blow ratio. It is possible to prevent unexpected situations.

As a modification of the extruding step, the molten thermoplastic resin sheet P is not extruded from the extrusion slit 34, but the molten thermoplastic resin sheet P is a longitudinal direction of the molten cylindrical thermoplastic resin sheet. The thermoplastic resin sheet P in a molten state may be formed once and then reheated to be in a molten state.

As a modified example of the holding stage of the decorative sheet D, the inside of the third sealed space 234 formed by the surface 256 of the decorative sheet D, the inner peripheral surface 250 of the mold part 200 for decorative molding, and the cavity 116 is vacuum-sucked. By doing this, the decorative sheet D may be held by the decorative sheet annular contact surface 206, or the decorative sheet D may be attached by vacuum suction or static electricity through the decorative sheet annular contact surface 206. As a backup, the inside of the third sealed space 234 may be vacuumed.

  About the order of the holding | maintenance stage of the decorating sheet | seat D, and the formation stage of the 1st sealed space 230, after holding the decorating sheet | seat D with the metal mold | die 32 as above-mentioned, with the sheet | seat P and the cavity 116 made from a thermoplastic resin. In addition to forming the first sealed space 230 by cooperation, the decorative sheet D is added to the inner frame 210 after the outer frame 208 is moved in the mold clamping direction to form the first sealed space 230. The decorative sheet annular contact surface 206 may be used, or the decorative sheet D may be held and the first sealed space 230 may be formed simultaneously.

  As a modified example of the vacuum suction stage of the second sealed space 232, as an alternative to vacuum suction through the air discharge through hole 212 provided in the outer frame body 208 of the mold 32, a thermoplastic resin sheet outside the pinch-off portion 118 is provided. You may have the step which stabs a pin in the part of P or the decoration sheet | seat D, and the step which vacuum-sucks the inside of the 2nd sealed space 232 through a pin. In addition, the outer frame 208 may include a step of providing the air discharge through hole 212 and a step of vacuuming the inside of the second sealed space 232 through the air discharge through hole 212. A step of providing the through hole 212 for the air discharge in the extending direction of the air discharge through hole 212 of the decorative molding die part 200, or the protruding part of the outer frame 208 from the inner frame 210 of the outer frame 208 On the other hand, you may have the step provided in the thickness direction. In this case, it is possible to shorten the length of the air discharge through hole 212 by providing the air discharge through hole 212 in the thickness direction, thereby reducing the possibility of the air discharge through hole 212 being blocked. It is possible to simplify the processing at this time.

    As a modified example of the step of welding the decorative sheet D to the thermoplastic resin sheet, when the second sealed space 232 is vacuum-sucked, the decorative sheet D is made of resin by moving the inner frame 210 in the mold clamping direction. It may further include a step performed while approaching the sheet, or vacuum suction is performed in the second sealed space 232, and the surface 256 of the decorative sheet D, the inner peripheral surface 250 of the decorative molding die part 200, and the cavity A step of blowing air into the third sealed space 234 formed by 116 may be provided. Thereby, it is possible to more reliably achieve the welding of the decorative sheet D to the thermoplastic resin sheet.

The order of the mold clamping stage of the divided mold 32 and the shaping stage by vacuum suction of the first sealed space 230 is integrally laminated by vacuum suction of the first sealed space 230 as described above. After the decorative sheet D and the thermoplastic resin sheet P are pressed against the cavity 116 and shaped, it is not limited to the mold clamping of the split mold 32, but two molds of thermoplasticity by mold clamping As long as the resin sheet P is not welded at a portion other than the peripheral portion, the shaping step by vacuum suction may extend to the clamping step of the divided mold 32 in terms of time.
In this case, when a complicated shape is formed on the decorative sheet D and the thermoplastic resin sheet P that are integrally laminated, the sealing formed in the divided mold 32 by clamping the divided mold 32. By vacuuming from the cavity 116 side while pressurizing the space, it is possible to shape a desired shape as compared to vacuum suction alone.

As a modification, instead of a resin molded product having a hollow structure as in the present embodiment, a resin molded product having a sandwich structure may be molded by inserting a resin core or metal insert into the hollow portion. .
In the case of the resin-made core, the arrangement timing may be before the mold 32 is clamped after the mold is opened, and before the divided mold 32 is clamped, any of the two thermoplastic thermoplastic resin sheets P is placed. In the case of a metal insert, any one of the two thermoplastic thermoplastic resin sheets P is vacuum-sucked from the cavity 116 of the corresponding split mold 32 so that a part of the hollow portion is obtained. What is necessary is just to hold | maintain metal insert in a recessed part, after forming the recessed part to comprise.
As another modified example, two decorative sheets D may be applied to each side of two thermoplastic resin sheets for a resin molded product having a hollow structure or a resin molded product having a sandwich structure. Good. In this case, in each of the pair of split molds 32, the decorative molding mold part 200 is fitted on the outer peripheral side surface of each of the split molds 32. What is necessary is just to shape | mold by vacuum-sucking the decorative sheet D and the corresponding thermoplastic resin sheet which were integrally laminated, after making it weld to a corresponding thermoplastic resin sheet.

As described above, when a resin molded product having a hollow portion is formed using a tubular thermoplastic resin sheet as in the conventional case, a molded product having a uniform thickness is formed in relation to the blow ratio. Where technically difficult, according to the present embodiment, the peripheral portion of the two thermoplastic resin sheet P is formed by secondary molding using the two thermoplastic resin sheet P having a uniform thickness. By welding together, it is possible to mold a molded product having a hollow portion with a uniform thickness.
More specifically, according to the present embodiment, when a resin molded product having a hollow portion is formed using two sheets of thermoplastic resin sheet P, each of the pair of rollers 30 is adjusted by adjusting the number of rotations. By making the thickness uniform in the extrusion direction before the secondary molding of the sheet-like resin, the secondary molding can form a sheet having a desired thickness without adversely affecting the shaping of the secondary molding. Since it is possible to mold, using such two strips of thermoplastic resin sheet P, the peripheral edges of the thermoplastic resin sheet P are welded to each other by clamping the mold 32, and a hollow portion is formed inside. In order to form a resin molded product having the above, the peripheral edges of the thermoplastic resin sheet P are reliably welded together, thereby obtaining a resin molded product having sufficient strength despite having a hollow portion inside. Is possible.

In particular, according to the decorative molding method having the above-described configuration, the decorative sheet D is once bonded to the surface of the thermoplastic resin sheet P so as to be laminated, and then the surface-bonded thermoplastic resin is manufactured. By pressing and shaping the sheet P and the decorative sheet D against the cavity 116, the vacuum sheet from the cavity 116 side is passed through in a state where the decorative sheet D is arranged in the cavity 116 in the conventional manner. By pressing the thermoplastic resin sheet P against the cavity 116, the decorative sheet D having air permeability is welded to the thermoplastic resin sheet P, and at the same time, there is no need to form the air. The decorative sheet D can be used for decorative molding, and the appearance of the surface 256 of the decorative sheet D is not impaired.

On the other hand, in the first sealed space 230 formed in cooperation with the thermoplastic resin sheet P disposed on the side of the cavity 116 and the cavity 116, the thermoplastic resin sheet P is opposed to the mold. The decorative sheet D held so as to protrude from around the cavity 116 in a state of being separated from the 32 cavities 116 is surface-adhered to the thermoplastic resin sheet P, so that it can be accommodated in the first sealed space 230. The decorative sheet D having a predetermined length can be surface-bonded to the thermoplastic resin sheet P. For example, the decorative sheet D and the thermoplastic resin sheet P can be bonded to the thermoplastic resin sheet P by a pressure roller as in the past. Unlike the case where the sheet is pressed and fed into the cavity 116 of the mold 32, the decorative sheet is formed on the burr portion of the molding material on the outer periphery of the pinch-off portion 118 of the mold 32. There it is possible to only a thermoplastic resin sheet P which is not welded, whereby it becomes easy to recycle, can be achieved to improve the yield of the molding material.

  Further, for example, not only when vacuum forming is performed as secondary forming as in the present embodiment, but also when performing press molding or blow molding using the mold 32, the decorative mold component 200 is used. Is simply fitted on the outer peripheral side surface of the existing mold 32, so that it is possible to perform decorative molding using the decorative sheet D without having to make extensive modifications or corrections to the existing mold 32 itself. It becomes.

Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. In the following description, the same reference numerals are given to the same components as those in the first embodiment, the description thereof will be omitted, and the features of the present embodiment will be described in detail.
In the first embodiment, a resin molded product having a hollow structure, or a resin molded product having a sandwich panel structure in which a core or an insert is disposed, and a decorative sheet D is attached to one side or both sides. In contrast to molding with a split mold 32 using a decorative sheet D and two resin sheets, the feature of this embodiment is a resin molding having a solid structure It is the point which is shape | molded by the single metal mold | die 32 using the decoration sheet D and the resin sheet of 1 item | strip | row for the resin molded product which has stuck the decoration sheet D on the single side | surface. .
Furthermore, in the first embodiment, the decorative mold part 200 employs a structure having an outer frame body 208 and an inner frame body 210 that are relatively movable with respect to each other. Is the point which employ | adopts the cyclic | annular integrated product which has the level | step-difference part 211 as the metal mold | die part 200 for decoration molding.

More specifically, as shown in FIG. 16, the single mold 32 is disposed so that the cavity 116 faces substantially vertically, and a pinch-off portion 118 is formed in an annular shape around the cavity 116. The decorative molding mold component 200 is attached so as to be fitted onto the outer peripheral surface 204 of the mold 32.
As shown in FIG. 17, the decorative mold component 200 is an annular integrated product, and the annular contact surface 202 for the thermoplastic resin sheet extends to the outer peripheral edge 220 of the annular end surface 205 and for the decorative sheet. The annular contact surface 206 extends to the inner peripheral edge 222 of the annular end surface 205, and a step 211 is formed between the annular contact surface 202 for the thermoplastic resin sheet and the annular contact surface 206 for the decorative sheet.
The height of the stepped portion 211 is such that the decorative sheet D is in contact with the annular contact surface 206 for the decorative sheet while the thermoplastic resin sheet P is in contact with the annular contact surface 202 for the thermoplastic resin sheet. If it is set in such a manner that the second sealed space 232 is formed by the inner surface 248 of the thermoplastic resin sheet P, the outer surface 258 of the decorative sheet D, and the inner peripheral surface of the step 211 portion in the contact state. Good.
Unlike the first embodiment, the mold moving means 200 can be omitted by adopting the decorative molding mold part 200 provided with the stepped portion 211. On the other hand, as in the first embodiment, the mold can be omitted. Since the relative movement between the outer frame body 208 and the inner frame body 210 cannot be performed by the frame moving means, the degree of protrusion of the outer frame body 208 with respect to the inner frame body 210 is fixed by the step portion 211, but the decorative sheet Depending on the thickness of D and the like, various decorative mold parts 200 having different stepped portions 211 may be prepared.

In this case, the decorative molding method includes a step of preparing the decorative molding mold part 200 so as to fit the outer peripheral side surface of the mold 32 so that the contact surface is located on the cavity 116 side, The decorative molding die part 200 is moved in the mold clamping direction until the decorative sheet D is held by the step 211 and the annular contact surface 202 for the thermoplastic resin sheet abuts on the thermoplastic resin sheet P. And forming a second sealed space 232 by the surface of the thermoplastic resin sheet P, the inner peripheral surface 250 of the decorative molding die part 200 and the surface 256 of the decorative sheet D, and The subsequent steps are the same as those in the first embodiment, and a description thereof will be omitted.

As a modification, a pressurization chamber (not shown) is provided on the side of the single mold 32 like the split mold 32B with respect to the split mold 32A in the first embodiment, and is formed by the pressurization chamber. After the decorative sheet D is welded to the thermoplastic resin sheet P by vacuum suction of the second sealed space 232, the decorative decoration integrally laminated by vacuum suction of the first sealed space 230 When the sheet D and the thermoplastic resin sheet P are pressed against the cavity 116 and shaped, the decorative chamber D and the thermoplastic resin sheet P that are integrally laminated are sandwiched between the pressure chamber and the split mold 32A. By making contact, a fourth sealed space 262 is formed between the outer surface 246 of the thermoplastic resin sheet P and the pressurizing chamber, and the second sealed space 232 is formed while pressurizing the fourth sealed space 262. By forming a complex shape on the decorative sheet D and the thermoplastic resin sheet P integrally laminated by the cavity 116 by empty suction, a desired shape along the unevenness of the cavity 116 is obtained. It is easy to shape.

The embodiments of the present invention have been described in detail above, but various modifications or changes can be made by those skilled in the art without departing from the scope of the present invention.
For example, in the first embodiment, using the decorative molding mold part 200, the thermoplastic resin sheet, the inner peripheral surface 250 of the decorative molding mold part 200, and the surface of the cavity 116 of the mold 32 are used. The decorative sheet D is held by the inner frame body 210 of the decorative molding die part 200 in such a manner as to partition the first sealed space 230 configured by the above, whereby the thermoplastic resin sheet and the decorative molding gold A second sealed space 232 is formed by the inner peripheral surface 250 of the mold part 200 and the decorative sheet D, and the second sealed space 232 is vacuum-sucked to weld the decorative sheet D to the thermoplastic resin sheet. However, the present invention is not limited thereto. As long as the decorative sheet D and the thermoplastic resin sheet integrally laminated can be shaped by vacuum suction of the first sealed space 230, The second sealed space 232 may not be formed by the decorative sheet D. In that case, for example, if the decorative sheet D is held by a manipulator and pressed against the thermoplastic resin sheet, the second sealed space 232 may be welded. Good.

For example, in the first embodiment, using the decorative molding mold part 200, the thermoplastic resin sheet, the inner peripheral surface 250 of the decorative molding mold part 200, and the surface of the cavity 116 of the mold 32 are used. The decorative sheet D is held by the inner frame body 210 of the decorative molding die part 200 in such a manner as to partition the first sealed space 230 configured by the above, whereby the thermoplastic resin sheet and the decorative molding gold A second sealed space 232 is formed by the inner peripheral surface 250 of the mold part 200 and the decorative sheet D, and the second sealed space 232 is vacuum-sucked to weld the decorative sheet D to the thermoplastic resin sheet. However, the present invention is not limited thereto. As long as the decorative sheet D and the thermoplastic resin sheet integrally laminated can be shaped by vacuum suction of the first sealed space 230, The second sealed space 232 may not be vacuumed by the decorative sheet D. In that case, when the second sealed space 232 is formed between the decorative sheet D and the resin sheet, the decorative sheet D and The decorative sheet D is used for surface-bonding the decorative sheet D and the resin sheet while exhausting the air in the second sealed space 232 to the outside so as not to form an air pocket between the resin sheet and the resin sheet. 212 is provided in the outer frame body 208 of the mold 32 while pressing the decorative sheet D against the resin sheet by pressurizing the inside of the third sealed space 234 between the cavity 116 and the corresponding cavity 116. The decorative sheet D and the resin sheet may be surface-bonded by exhausting the air in the second sealed space 232 to the outside through the through hole for use.

For example, in the first embodiment, as the decorative molding mold part 200, the outer frame body 208 is moved in the mold clamping direction with respect to the inner frame body 210, thereby making the outer frame body 208 a corresponding thermoplastic resin. Although the case where the first sealed space 230 is formed in contact with the sheet has been described, the positional relationship between the tip of the inner frame 210 and the tip of the pinch-off portion 118 of the mold 32 is not limited thereto. Conversely, the inner frame 210 may be moved relative to the outer frame 208 in the mold clamping direction or in the opposite direction.

Moreover, as a use of the molded product in the first embodiment, as a sandwich panel 10 used for a cargo floor board, there is a case where a decorative sheet is bonded to a front side skin material sheet exhibiting an appearance. Without being limited to sandwich panels used for cargo floor boards, automotive interior materials such as footrests, side door trims, seat backs, rear parcel shelves, door panels, seat seats, carrying cases for machinery and equipment, parts for light electrical products, It is suitably used for applications such as wall materials, architectural interior materials such as partitions, furniture such as chairs, and tanks, dust, cases, housings, trays, containers and the like.

  For example, in the first embodiment, after the thermoplastic resin sheet P2 and the decorative sheet D are bonded to each other to form a laminated body, the first sealed space 230 is vacuum-sucked from the mold 32A side to obtain the laminated body. Although described as what is shaped, it is not limited thereto, and after forming the laminate, the outer frame 208 and the inner frame 210 are integrated, and the inner surface 261 of the decorative sheet D is the mold 32A. It moves to the mold 32A side until it comes into contact with the pinch-off part 118, and a sealed space is formed by the inner surface 261 of the decorative sheet D, the inner peripheral surface of the pinch-off part 118, and the cavity 116 of the mold 32A. May be vacuum-sucked from the mold 32A side to shape the laminate.

It is a schematic side view of the shaping | molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention. It is a schematic plan view which shows the circumference | surroundings of a pair of roller of the shaping | molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention. It is a schematic side view which shows the circumference | surroundings of a pair of roller of the shaping | molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention. It is a schematic side view which shows the mold component for decorative molding of the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention. It is a schematic side view which shows the vacuum suction mechanism of the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a schematic graph which shows the change with time of the extrusion speed of the sheet | seat P made from a thermoplastic resin, and the rotational speed of a roller. FIG. 2 is a schematic side view showing a state in which a thermoplastic resin sheet P is disposed between split molds 32 in the resin molded product molding apparatus according to the first embodiment of the present invention. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a schematic side view which shows the state in which a decorating sheet surface-bonds with respect to the sheet | seat P made from a thermoplastic resin. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a schematic side view which shows the state by which the decorative sheet and thermoplastic resin sheet P of a lamination | stacking state are shape | molded by vacuum suction. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a schematic side view which shows the state by which a division mold is clamped. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a schematic side view which shows the state by which a split mold is opened. About the outer frame of the mold part for decorative molding of the molding apparatus for resin molded products according to the first embodiment of the present invention, the contact position (FIG. 12 (A)) and the holding position (FIG. 12 (B)). It is the schematic which shows the state which exists in. About the inner frame of the mold part for decorative molding of the molding apparatus of the resin molded product according to the first embodiment of the present invention, the contact position (FIG. 13A) and the holding position (FIG. 13B) It is the schematic which shows the state which exists in. It is the schematic shown about the vacuum suction mechanism of the shaping | molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention. It is a figure similar to FIG. 4 about the metal mold | die for decoration molding of the molding apparatus of the resin molded product which concerns on 2nd Embodiment of this invention. It is the schematic which shows the state which exists in a contact position and a reservation position about the frame of the metal mold | die part for decorative molding of the shaping | molding apparatus of the resin molded product which concerns on 2nd Embodiment of this invention. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a front view which shows the frame of the mold component for decoration molding. In the molding apparatus of the resin molded product which concerns on 1st Embodiment of this invention, it is a front view which shows the frame of the mold component for decoration molding.

P Sheet made of thermoplastic resin PL Parting line D Decoration sheet
S1 Stroke of outer frame
S2 Stroke of inner frame 10 Molding device 12 Extruding device 14 Clamping device 16 Hopper 18 Cylinder 22 Hydraulic motor 24 Accumulator 26 Plunger 28 T die 30 Roller 32 Dividing die 34 Extrusion slit 36 Die lip 38 Die 94 Roller rotation drive means 96 Roller moving means 98 Rotation drive motor 100 Rotational speed adjusting device 102 End surface 104 First gear 107 End surface 108 Second gear 109 Piston rod 112 Shallow groove 113 Piston 114 Roller surface temperature adjusting means 115 Cylinder 116 Cavity 117 Cover 118 Pinch off Portion 120 Vacuum suction chamber 122 Suction hole 124 Pressure fluid introduction hole 126 Mold frame 128 Frame member 130 Opening 200 Mold part for decorative molding 202 Annular contact surface for sheet made of thermoplastic resin 203 Through portion 204 Outer peripheral surface 205 annular end surface 206 annular contact surface 208 for decorative sheet outer frame body 210 inner frame body 211 step 212 air discharge through hole 220 outer peripheral edge 222 inner peripheral edge 230 first sealed space 232 second sealed space 234 third sealed space 240 Common vacuum pump 244 Suction pipe 245 Gate valve 246 Outer surface 248 Inner surface 250 Inner surface 252 Inner surface 254 Inner surface 256 Surface 258 Outer surface 260 Outer portion 261 Inner surface 262 Fourth sealed space 270 Suction opening 271 Suction opening

Claims (30)

Placing the molten thermoplastic resin sheet on the side of the cavity so that it protrudes around the cavity in a spaced state from the mold cavity;
In the first sealed space formed by the cooperation of the disposed thermoplastic resin sheet and the cavity, the thermoplastic resin sheet faces the thermoplastic resin sheet and protrudes from the mold cavity around the cavity. The step of adhering the decorative sheet held on the surface to the thermoplastic resin sheet so as to be laminated,
Vacuuming the inside of the first sealed space from the cavity side, pressing the surface-bonded thermoplastic resin sheet and the decorative sheet against the cavity, and shaping,
A decorative molding method characterized by comprising: The decorative molding method according to claim 1, wherein the step of arranging the thermoplastic resin sheet to the side of the cavity includes a step of extruding a molten thermoplastic resin sheet. The decorative molding method according to claim 2, wherein the molten thermoplastic resin sheet is formed by cutting a molten cylindrical parison in a longitudinal direction. The decorative molding method according to claim 2, wherein the molten thermoplastic resin sheet is once molded and then reheated to be in a molten state. 2. The decorative molding according to claim 1, wherein the surface bonding step includes a step of forming a first sealed space in cooperation with the thermoplastic resin sheet and the cavity after the decorative sheet is held by a mold. Method. The surface bonding step is a step of forming a second sealed space between both sheets in a mode in which the first sealed space is partitioned by the decorative sheet in cooperation with the thermoplastic resin sheet and the decorative sheet. And a step of adhering the decorative sheet to the thermoplastic resin sheet by vacuum suction of the second sealed space.     The decorative molding method according to any one of claims 1 to 6, wherein the decorative sheet is a non-breathable sheet. A frame body having a through portion that can be externally fitted to the outer peripheral surface of the mold, and on its annular end surface, a contact surface capable of contacting the molten molding material sheet is formed,
The contact surface has an annular contact surface for a thermoplastic resin sheet that can contact the thermoplastic resin sheet on the outer peripheral side and an outer peripheral portion of the decorative sheet on the inner peripheral side. An annular contact surface for the decorative sheet that can be contacted, and the annular contact surface for the thermoplastic resin sheet protrudes from the annular contact surface for the decorative sheet, Mold parts for decorative molding with decorative sheets.       The decorative molding mold part is an annular integrated product, the annular contact surface for the thermoplastic resin sheet extends to the outer peripheral edge of the annular end surface, and the annular contact surface for the decorative sheet is The step with the decorative sheet according to claim 8, wherein a step is formed up to an inner peripheral edge of the annular end surface and between the annular contact surface for the thermoplastic resin sheet and the annular contact surface for the decorative sheet. Mold parts for decorative molding.     The decorative mold part has an outer frame and an inner frame, the outer frame has an annular contact surface for the thermoplastic resin sheet, and the inner frame The decorative frame has an annular contact surface, and the outer frame body and the inner frame body are relative to each other such that the inner peripheral surface of the outer frame body is slidable with respect to the outer peripheral surface of the inner frame body. A mold part for decorative molding by the decorative sheet according to claim 8, which is movable.     The decorative molding mold part according to claim 10, wherein the decorative molding mold part has an air discharge through hole in the outer frame body or the inner frame body. A mold having an annular pinch-off part and a cavity formed inside the annular pinch-off part on one side,
12. The mold part for decorative molding using the decorative sheet according to claim 8, wherein an outer peripheral side surface of the mold is positioned so that the contact surface is located on the cavity side. Provided to fit outside,
The annular contact surface for the thermoplastic resin sheet is brought into contact with the thermoplastic resin sheet disposed on the side of the cavity of the mold, so that the outer surface of the thermoplastic resin sheet, the decoration A vacuum suction hole is provided for vacuum suction of the first sealed space formed by the inner peripheral surface of the molding die part and the cavity.
A mold for decorative molding using a decorative sheet. A thermoplastic resin is shaped by extrusion molding, and a primary molded portion is extruded in a form in which the primary molded thermoplastic resin is suspended, and a thermoplastic resin extruded by the primary molded portion is subjected to secondary molding by blow molding or vacuum molding. In a thermoplastic resin molding device having a secondary molding part,
The primary molding part is:
A melt-kneading means for melt-kneading the thermoplastic resin;
Storage means for storing a predetermined amount of melt-kneaded thermoplastic resin;
An extrusion slit that extrudes intermittently so as to hang down the stored thermoplastic resin into a molten sheet,
The secondary molded part is
It has a metal mold | die for the decoration shaping | molding by the said decoration sheet of Claim 12, The decoration shaping | molding apparatus by the decoration sheet characterized by the above-mentioned.     Further, the first sealed space, the surface of the thermoplastic resin sheet, the inner peripheral surface of the vacuum mold part, and the second sealed space formed by the surface of the decorative sheet are vacuum-suctioned. The common vacuum pump, and a distal end portion is provided with a branch portion that communicates with each of the first sealed space and the second sealed space, and a suction pipe connected to the vacuum pump is provided. A decorative molding apparatus using the decorative sheet as described. Preparing a mold part for decorative molding by the decorative sheet according to claim 9 so as to be fitted on the outer peripheral side surface of the mold so that the contact surface is located on the cavity side;
Holding the decorative sheet by the step, and
The surface of the thermoplastic resin sheet is moved by moving the decorative mold part in the mold clamping direction until the annular contact surface for the thermoplastic resin sheet contacts the thermoplastic resin sheet, The first sealed space is formed by the inner peripheral surface of the vacuum mold component and the surface of the cavity, and the surface of the thermoplastic resin sheet, the inner peripheral surface of the vacuum mold component and the decoration Forming the second sealed space by the surface of the sheet;
The decorative molding method according to claim 6, comprising: Preparing a mold part for decorative molding by the decorative sheet according to claim 10 so as to be fitted on the outer peripheral side surface of the mold so that the contact surface is located on the cavity side;
Moving the inner frame body in the mold clamping direction to a position where the annular contact surface for the decorative sheet projects at least from the top of the pinch-off portion;
Holding the decorative sheet by the annular contact surface for the decorative sheet so as not to protrude from the outer peripheral edge of the annular contact surface for the decorative sheet;
By moving the outer frame body in the mold clamping direction until the annular contact surface for the thermoplastic resin sheet contacts the thermoplastic resin sheet, the surface of the thermoplastic resin sheet, the vacuum forming gold The first sealed space is formed by the inner peripheral surface of the mold part and the surface of the cavity, and the surface of the thermoplastic resin sheet, the inner peripheral surface for the decorative molding, and the surface of the decorative sheet, Forming a second sealed space;
The decorative molding method according to claim 6, comprising: The vacuum suction step is a step of inserting a pin into a thermoplastic resin sheet or a decorative sheet portion outside the pinch-off portion;
The decorative molding method according to claim 15 or 16, further comprising: vacuuming the second sealed space through a pin. The vacuum suction step includes providing a through hole in the frame;
The decorative molding method according to claim 15 or 16, further comprising: vacuuming the inside of the second sealed space through the through hole.         The decorative molding method according to claim 18, comprising a step of providing the through hole in an extending direction of the through hole of the decorative molding die part.         The decorative molding method according to claim 18, further comprising a step of providing the through hole in a thickness direction with respect to a protruding portion of the outer frame body from the inner frame body. In the surface bonding step of the decorative sheet, the inside of the second sealed space is vacuum-sucked, and a third sealed space is formed by the surface of the decorative sheet, the inner peripheral surface of the decorative mold part, and the cavity. The decorative molding method according to claim 15 or 16, comprising a step of blowing air into the space. The step of holding the decorative sheet includes a step of vacuum-sucking the inside of a third sealed space formed by the surface of the decorative sheet, the inner peripheral surface of the mold part for decorative molding, and the cavity. Or the decoration shaping | molding method of Claim 16.         The decorative molding according to claim 1, wherein the decorative sheet is made of the same material as the resin sheet, and the decorative sheet is surface-bonded to the molten resin sheet. Method. The decorative sheet is a laminate of a resin sheet portion made of a different material from the resin sheet, and a non-woven sheet portion,
The decoration of Claim 1 by which the said decorating sheet is surface-bonded based on an anchor effect by making the sheet | seat part made from a nonwoven fabric face and press with respect to the said resin-made sheet | seat of a molten state. Molding method.         When forming the second sealed space between the decorative sheet and the resin sheet, air in the second sealed space is formed so as not to form an air pocket between the decorative sheet and the resin sheet. The decorative molding method according to claim 6, comprising a step of surface-bonding the decorative sheet and the resin sheet while exhausting the air to the outside.         The second sealing space between the decorative sheet and the resin sheet is vacuum-suctioned through a through-hole provided in the frame of the mold, so that the decorative sheet and the resin sheet are surface bonded. 26. The decorative molding method according to claim 25, comprising the step of:         A through hole provided in the frame of the mold while pressing the decorative sheet against the resin sheet by pressurizing the inside of the third sealed space between the decorative sheet and the corresponding cavity. The decorative molding method according to claim 25, further comprising a step of surface-bonding the decorative sheet and the resin sheet by exhausting air in the second sealed space to the outside.         The process according to claim 16, further comprising the step of moving the inner frame body in a mold clamping direction while bringing the decorative sheet closer to the resin sheet when vacuum sucking the second sealed space. Decoration molding method. A mold part for decorative molding using the decorative sheet according to claim 10 is prepared so as to be externally fitted to at least one outer peripheral side surface of a pair of split molds so that the contact surface is located on the cavity side. And the stage of
Positioning a pair of molten thermoplastic resin sheets spaced apart from each other between the pair of split molds in a form protruding around the cavities of the pair of split molds;
Moving the inner frame body in the mold clamping direction to a position where the annular contact surface for the decorative sheet projects at least from the top of the pinch-off portion;
Holding the decorative sheet by the annular contact surface for the decorative sheet so as not to protrude from the outer peripheral edge of the annular contact surface for the decorative sheet;
By moving the outer frame body in the mold clamping direction until the annular contact surface for thermoplastic resin sheet contacts the corresponding thermoplastic resin sheet, the surface of the corresponding thermoplastic resin sheet, The step of forming the second sealed space by the inner peripheral surface of the decorative mold part and the surface of the decorative sheet;
A step of adhering the decorative sheet to the thermoplastic resin sheet by vacuum suction of the second sealed space;
Vacuum suction is performed from the cavity side in the first sealed space formed by the surface of the decorative sheet surface-bonded to the thermoplastic resin sheet, the inner peripheral surface of the decorative mold part, and the surface of the cavity. By pressing the surface-bonded thermoplastic resin sheet and the decorative sheet against the cavity and shaping, the pair of split molds are clamped to form a pair of split molds. Forming a sealed space inside, thereby welding the peripheral edges of the two thermoplastic resin sheets,
Further, by pressing from the inside of the sealed space, or by sucking the inside of the sealed space through the other divided mold, the thermoplasticity facing the cavity of the other divided mold in the sealed space And a step of shaping a resin sheet.         The mold clamping step of the divided mold is formed by pressing the surface-bonded thermoplastic resin sheet and the decorative sheet against the cavity by vacuum suction from the cavity side in the first sealed space. 30. The decorative molding method according to claim 29, which is performed after the step of performing is completed.

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