JP2021091824A - Resin block, resin block production device, resin block production method, and resin molding - Google Patents

Abstract

To provide a resin block in which, for example, a granular resin material of a different color exists in a resin substrate of another color while kept in a granular state.SOLUTION: To a resin block formation space, the peripheral sides of which are surrounded by a plurality of mold plates, supplied is a raw material comprising a plurality of kinds of granular resin materials. While removing bubbles among the granular resin materials constituting the raw material, the granular resin materials are brought into intimate contact with each other. In order that in the resin block formation space formed is a resin layer having a portion in which the granular resin materials exist while kept in a granular state, the raw material in the resin block formation space is first subjected to a predetermined compression and then heated under predetermined conditions.SELECTED DRAWING: Figure 1

Description

The present invention comprises a highly decorative resin block in which a granular resin material is present in the block, a resin block manufacturing apparatus and a resin block manufacturing method for manufacturing such a resin block, and processing such a resin block. Regarding molded resin molded products.

So-called plastics are generally lightweight, durable, easy to mold, and have properties such as heat insulation and insulation, so they are highly convenient and are indispensable molding materials in modern society. Usually, the resin material has a desired shape by solidifying the molten resin to produce a resin block having a certain size and cutting the resin block, or by pouring a liquid resin into a mold and solidifying the resin block. It is said to be a molded product of.

The resin material is excellent in colorability, and there are materials of various colors. However, when a resin block or the like is formed by mixing a plurality of materials having different colors, the resins of different colors are mixed to form a monochromatic resin block, and the resin block whose color pattern is three-dimensionally expressed to the inside is Cannot be manufactured. Further, if the number of colors is large, the whole becomes a muddy color of gray or black, which is not preferable. However, it is possible to form a marble-patterned resin block by utilizing the intermediate stage in which the colors flow and mix. A resin molded body having such a pattern imitates marble and is used in, for example, a system kitchen (Patent Document 1).

By the way, in recent years, pollution of the natural environment such as the ocean by plastic waste has become a serious problem, and urgent measures are required. As one of the measures, it is recommended to collect and reuse plastic waste. One of the methods for reusing plastic waste is to dissolve the plastic waste and recycle it into a plastic raw material or a plastic product.

Many of the wastes that can be collected and recycled into plastic raw materials and plastic products are colorful and highly decorative, such as PET bottle caps. Effective use of such waste can be expected to be commercially successful, accelerate the recovery of plastic waste, and significantly improve the environment.

Japanese Unexamined Patent Publication No. 2019-43993

However, although the caps of PET bottles are individually colorful and highly decorative, when they are dissolved together, the resin material produced by mixing becomes dark gray or black as described above. As a result, the recycled resin material is more difficult to color and less decorative, thus limiting its use and limiting the reusable resin products.

The present invention has been made in view of such a problem, and an object of the present invention is that it can be manufactured by reusing an originally colorful resin material such as a cap of a PET bottle, and is highly decorative. An object of the present invention is to provide a resin block having excellent workability. Another object of the present invention is a resin block manufacturing apparatus for manufacturing such a highly decorative resin block, a resin block manufacturing method for manufacturing such a highly decorative resin block, and a resin block manufacturing method. An object of the present invention is to provide a resin molded product obtained by processing and molding such a resin block.

The resin block of the present invention is characterized in that the granular resin material has a portion existing in a state of maintaining the grain state.

Preferably, the resin block of the present invention is characterized by containing, as the granular resin material, a granular resin material having a color different from that of other resin materials forming the resin block. Here, the "other resin material" is a concept including a resin base material and other granular resin materials when focusing on a specific granular resin material. Since such a resin block exists independently in the block without mixing the granular resin materials, the user or the like observes (visually recognizes) particles of different colors in the resin block. Can be done. As a result, the resin block of the present invention enables a rich expression in which grains of a desired color are present at a desired density, which is rich in color and gives the viewer various senses of color. .. As described above, the resin block of the present invention is a resin block having extremely high decorativeness, and can be widely used in various resin products.

Further, in the resin block of the present invention, most of the granular resin material <grain material main body portion> is likely to remain in a shape close to the original shape even if it is slightly deformed. Therefore, the resin block according to the present invention can exert expressive power not only in color but also in the grain shape of the resin block by using resin materials having various grain shapes, and is also decorative in that respect. Can be a high resin block.

As a specific example, the granular resin material is a member obtained by crushing a cap of a PET bottle. Since PET bottle caps are very colorful, that is, colorful, if resin materials of various colors produced by crushing PET bottle caps are used as the granular resin material of the present invention, they are very colorful and highly decorative resins. Blocks can be manufactured. Therefore, the resin block of the present invention provides a commercially successful method of reusing the recovered plastic waste, which can accelerate the recovery of the plastic waste and thus contribute to a significant improvement in the environment. It is a thing.

The type of the granular resin material contained in the resin block may be one type or a plurality of types. Here, the type of granular resin material refers to a granular resin material having different visually recognizable characteristics such as color, hue, gloss, and saturation. Further, the color of the granular resin material may be one color or may include a large number of two or more colors.

In the present invention, the resin block is a resin material formed as one block having a certain size. The state in which the grain state is maintained means that the granular resin material does not melt with other surrounding materials or does not become a so-called flowing state during melting, and is maintained in a size and shape that can be visually recognized as one grain. It is in a state of being. Further, "including a portion existing in a state where the grain state is maintained" means that there may be as much as possible a portion in the resin block in which the granular resin material exists in a state where the granular state is maintained, and the other part is granular. It is meant to include cases where the resin material has melted or has flowed.

Further, in the case of forming the resin block of the present invention by mixing the granular resin materials and heating and pressurizing, the shape of the grains of the resin material as a raw material before blocking and the granular resin after blocking. The shape of the grain of the material does not have to be the same. The granular resin material that has been softened by heating and cooled and solidified in a state of being pressurized and deformed may be present in the resin block in a shape different from the original shape. Even in such a case, as long as the resin material is visually recognizable in the grain state, it is still a granular resin material that exists in the state of maintaining the grain state.

Conventionally, such a resin block does not exist. Methods for molding a resin block from a thermoplastic resin include injection molding and casting, in which a melt of a powdered resin material is poured into a mold to cool and solidify it, and granular resin is heated and melted in the mold. Powder molding that cools and solidifies is known. However, in either method, when the different resin materials were melted in one mold, the resin materials flowed and mixed in a liquid state, and the color pattern of the molded product was completely mixed without forming a pattern. It becomes a color, or a pattern called a flowing pattern or a marble pattern.

However, in the resin block of the present invention, it does not mean that the granular resin material is not dissolved at all at the manufacturing stage and is not mixed with the surrounding resin material at all. The range of melting (boundary melting part) is limited to the range of the extremely thin layer on the surface of the granular resin material, and at least at first glance, the part that is not mixed with the surrounding material, that is, the initial characteristics. It means that the part that continues to be exhibited (the main body part of the grain material) exists in the granular resin material, and this remains in the resin block in a visually recognizable state.

As a specific example, the resin block according to the present invention has a configuration in which a portion in which a granular resin material exists in a state in which a granular resin material is maintained in a grain state is arranged in a melt-molded resin base material, and the grain state is maintained. The granular resin material exists in a form of being embedded in the resin base material.

Further, as a specific example, the granular resin material is a linear resin material having a predetermined length, and in the resin block according to the present invention, the linear resin material holding a linear state is contained in the resin base material. In addition, it exists in a buried form.

Further, as another specific example, the resin block according to the present invention does not have a structure called a base material, and a plurality of types of the granular resin materials are formed in close contact with each other while maintaining the grain state. It is a configured configuration.

In the resin block of the present invention, the size of the granular resin material existing in the resin block may be any size as long as the granular resin material can be visually recognized as grains. Specifically, the size of the main body portion of the granular material may be visually recognizable as grains, as long as it is distinguished from the melted portion (boundary molten portion) on the surface of the granular resin material. Specifically, when the granular resin material existing in the resin block is cut in an arbitrary direction, the cross section may have a size that may expose a surface larger than a circle having a diameter of 0.2 mm.

As a result of the experiment, the inventor of the present invention visually recognizes the surface of an object held in his hand (on a plane at a distance of about 40 cm from the eye) as a part different from the surroundings due to, for example, a different color. It has been found that the minimum size of the possible portion is a rectangle having a length and a width of about 0.2 mm or a circle having a diameter of about 0.2 mm. When the length is sufficiently long (specifically, for example, the length is 3 mm or more, preferably 5 mm or more, more preferably 1 cm or more), the width is about 0.05 mm or more (about the size of fine human hair). It was found that if there is a width), it can be visually recognized as a part different from the surroundings.

Further, if the size is a rectangle of about 0.3 mm in length and width or a circle or more with a diameter of about 0.3 mm, or if the length is 5 mm or more, the width remains about 0.05 mm, but a human. Found that it can be easily visually recognized as a single object without the need to stare at it. Further, if the size is a rectangle of about 0.5 mm in length and width or a circle or more with a diameter of about 0.5 mm, or if the length is 1 cm or more and the width is about 0.08 mm or more, it is in the field of view. It was found that it can attract human consciousness to the extent that the viewpoint stops.

From the above experimental results and observation results, as described above, the inventor of the present invention relates to the present invention that a solid having a surface capable of including a circle having a diameter of 0.2 mm may be exposed as a cross section. We found that it was the smallest size that could be effective.

Further, the resin block manufacturing apparatus according to the present invention is
A slide unit having a plurality of molded plates that can slide and move in a horizontal plane, and when the molded plates are closed, a resin block forming space surrounded by the side surfaces of the molded plates is formed.
An elevating unit having a bottom plate that defines the bottom surface of the resin block forming space and an elevating mechanism that elevates and elevates the bottom plate.
A heater unit having a heating plate forming the upper surface of the resin block forming space, a heater for heating the heating plate, and an elevating mechanism for raising and lowering the heating plate.
A material supply unit that supplies raw materials containing a plurality of types of granular resin materials to the resin block forming space, and
It has a control unit that controls the slide unit, the heater unit, and the elevating unit, and heats, pressurizes, cools, and solidifies the raw material supplied to the resin block forming space under predetermined conditions.
The control unit removes air bubbles between the granular resin materials constituting the raw material by heating the raw material in the resin block forming space under predetermined conditions after preceding a predetermined pressurization. The slide unit, said, so that the granular resin materials are brought into close contact with each other while forming a resin layer having a portion in which the granular resin material exists in a state in which the granular resin material is held in a granular state. It is characterized by controlling a heater unit and the elevating unit.

Preferably, the resin block manufacturing apparatus according to the present invention repeats the formation of the resin layer in the resin block forming space, lowers the bottom plate for each formation of the resin layer, and repeats the formation in the resin block forming space. The formed resin layers are sequentially laminated on the bottom plate to produce a resin block having a desired height.

Further, preferably, the slide unit has a plurality of slide mechanisms having a base, a heat insulating material, and the molded plate, and the upper edge portion of each of the molded plates projects substantially horizontally toward the resin block forming space side. , A return portion that can be brought into contact with the side surface of the heating plate is installed.

Further, the resin block manufacturing method according to the present invention is:
Raw materials containing multiple types of granular resin materials are supplied to the resin block forming space surrounded by multiple molding plates around the side surfaces.
The granular resin materials are brought into close contact with each other while removing air bubbles between the granular resin materials constituting the raw material, and the granular resin material has a portion existing in the resin block forming space in a state where the granular state is maintained. The raw material in the resin block forming space is heated under predetermined conditions after being preceded by a predetermined pressurization so that a resin layer is formed.

Preferably, in the resin block manufacturing method according to the present invention, the formation of the resin layer in the resin block forming space is repeated, and the repeatedly formed resin layers are sequentially laminated to obtain a resin block having a desired height. To manufacture.

Further, preferably, in the resin block manufacturing method according to the present invention, the surface of the granular resin material constituting the raw material is melted into a thin layer, while the inside of the granular resin material is maintained in a softened state. The raw material is pressurized and heated under the predetermined conditions.

Further, the resin block according to the present invention includes any of the resin block manufacturing devices or resin block manufacturing methods described above.
Further, the resin molded product according to the present invention is a resin molded product formed by cutting any of the above-mentioned resin blocks according to the present invention, and any of the above-mentioned resin blocks according to the present invention having a desired shape. It is a resin molded product formed as a molded product of.

FIG. 1A is a perspective view showing a resin block according to the present invention, and FIG. 1B is a view showing the surface of an example of the resin block according to the present invention. FIG. 2 is a diagram showing the surface of another example of the resin block according to the present invention. FIG. 3 is a diagram showing the surface of still another example of the resin block according to the present invention. FIG. 4 is a perspective view showing a resin block manufacturing apparatus according to an embodiment of the present invention. FIG. 5 is a perspective view showing a moving unit of the resin block manufacturing apparatus shown in FIG. FIG. 6 is a perspective view showing a slide unit of the resin block manufacturing apparatus shown in FIG. FIG. 7 is a diagram schematically showing a resin block forming space of the resin block manufacturing apparatus shown in FIG. FIG. 8 is a first flowchart showing the operation of the resin block manufacturing apparatus shown in FIG. FIG. 9 is a second flowchart showing the operation of the resin block manufacturing apparatus following FIG. 10 (A) and 10 (B) are a first diagram and a second diagram showing the operation of the resin block manufacturing apparatus, and schematically a process of putting a resin material into a resin block forming space and starting molding. It is a figure which shows. 11 (A) and 11 (B) are third and fourth views showing the operation of the resin block manufacturing apparatus, and schematically show a step of heating and pressurizing the resin material in the resin block forming space. It is a figure. 12 (A) to 12 (F) are 5th to 10th views showing the operation of the resin block manufacturing apparatus, and is a diagram schematically showing a step of releasing the formed resin block layer. Is. FIG. 13 is a diagram for explaining a problem of a resin block manufacturing apparatus having a molded plate having no return portion.

First, the resin block according to the present invention will be described with reference to FIGS. 1 to 3.
FIG. 1A is a perspective view schematically showing a resin block according to the present invention, and FIG. 1B is a surface of a first example of the resin block according to the present invention (for example, FIG. 1A). It is a figure which shows the state of the region z) of).

As shown in FIG. 1A, the resin block 8 according to the present invention is _{configured by sequentially laminating resin layers 8 i} (i = 1, 2, 3, ...) Of a predetermined height. In the example shown in FIG. 1 (A), constitute the first resin block 8 is the resin layer 8 _{1-8 5} five layers are laminated. In the present embodiment, the thickness of one resin layer 8 _i, is about 5 mm. When the resin block is manufactured by the manufacturing apparatus and manufacturing method according to the present invention described later, the laminated thickness of the resin layer is preferably 5 mm or less in order to prevent bubbles from remaining in the resin block.

The resin block 8a shown in FIG. 1 (B) is a resin block having a portion in which a granular resin material exists in a melt-molded resin base material in a state of maintaining a grain state. That is, it is a resin block in which a granular resin material that retains a grain state exists in a form embedded in a resin base material.

The portion t shown in black in FIG. 1 (B) is the granular resin existing in the resin block in a state where the granular resin material maintains the granular state, and is the portion described above as the “granular material main body portion”. Is. In the resin block 8 of the present embodiment, the granular resin material is a material obtained by crushing the cap of a PET bottle, and FIG. 1 (B) is a black-and-white diagram, so it is shown in black. Each grain t is a granular resin of various colors.

The portion h that is white between the granular resins in FIG. 1B is the resin portion used as the base material in this resin block. The base material portion h is formed by melting and solidifying new white pellets (those formed into granules of about 3 to 5 mm so that the resin material can be easily processed as an industrial raw material).

Further, in FIG. 1B, a gray blurred region g is observed around the black granular resin. This is because the granular resin t is arranged in a state of being buried in the depth direction from the surface of the resin block being observed, so that the color is faded (blurred) by the base material portion h covering the surface side. In the black-and-white diagram, it looks gray, and it is not the part where the granular resin is melted and mixed with the resin of the base material, or the granular resin material is poured.

In the resin block 8a, on the surface of the granular resin t, there is a boundary melting portion m in which the surface of the granular resin material is melted into a thin layer and fused with the resin of the base material. In FIG. 1B, the surface of the granular resin t is indicated by the reference numeral m, but the boundary melted portion is very thin and cannot be actually observed with the naked eye. Therefore, when the surface of the resin block 8a shown in FIG. 1B is viewed with the naked eye, the granular resins t of various colors are clearly distinguished on the white base material h while maintaining the grain state. It can be observed as if it were buried. Therefore, the resin block 8a is a very colorful and decorative resin block that has never existed before.

FIG. 2 is a diagram showing a state of the surface (corresponding to the region z in FIG. 1A) of the second example of the resin block according to the present invention. The resin block 8b shown in FIG. 2 is a resin block using a linear resin material having a predetermined length as the granular resin material. That is, it is a resin block in which a linear resin material that retains a linear state exists in a form embedded in a base material.

The portion t shown in black in FIG. 2 is a granular resin existing in the resin block in a state where the linear resin material maintains the linear state (grain state). Also in the resin block 8b shown in FIG. 2, the linear resin material is a material obtained by crushing the cap of the PET bottle, and since FIG. 2 is a black and white diagram, it is shown in black, but in reality, each line is shown. The shaped portion t exhibits various colors.

In FIG. 2, the base material portion h that is white between the granular resins, the region g that is gray-blurred around the linear resin, and the boundary melting portion m on the surface of the linear resin t. The configuration and meaning are the same as those of the resin block 8a described above with reference to FIG. 1 (B).

When such a resin block 8b is viewed, it can be observed that the linear resins t of various colors are clearly distinguished and embedded in the white base material h while maintaining the linear state. .. Therefore, the resin block 8b is an unprecedented resin block that is rich in decoration and has a high-class feeling in which a colorful linear material is present as an accent while being based on white.

FIG. 3 is a diagram showing a state of the surface (corresponding to the region z in FIG. 1A) of the third example of the resin block according to the present invention. The resin block 8b shown in FIG. 3 does not have a resin portion called a base material, and a plurality of types of granular resin materials are in close contact with each other while maintaining the grain state to form one mass. It is a resin block.

All of the respective portions t shown separately in shades of black or gray in FIG. 3 indicate individual granular resin materials. Also in the resin block 8c of the present embodiment, the granular resin material is a material obtained by crushing the cap of a PET bottle, and in reality, each grain t is a granular resin of various colors.

Also in the resin block 8c shown in FIG. 3, a part of the observed resin block is arranged so as to be buried in the depth direction from the surface, and another granular resin is formed on the surface side of the granular resin. By covering and arranging, there is a possibility that a portion (g) to be observed as a color different from the resin main body portion exists around the granular resin. However, in the resin block 8c, since the base resin on a white background is not used and all the constituent resins are colored, such a portion is not conspicuous.

In the resin block 8c of FIG. 3, the configuration and meaning of the boundary melting portion m on the surface of the granular resin t are the same as those of the resin block 8a described above with reference to FIG. 1 (B).

When such a resin block 8c is viewed, it can be observed that the granular resins t of various colors are clearly distinguished, adhered to each other, and integrally molded while maintaining the grain state. Therefore, the resin block 8c is a highly-designed, colorful, and therefore highly decorative, unprecedented resin block in which grains of a large number of colors are arranged in a mosaic pattern.
The resin blocks according to the present invention are, for example, such resin blocks 8a to 8c.

Next, the resin block manufacturing apparatus according to the present invention will be described with reference to FIGS. 4 to 7.
FIG. 4 is a perspective view showing the configuration of the resin block manufacturing apparatus 1 according to the embodiment of the present invention. As shown in FIG. 4, the resin block manufacturing apparatus 1 has a main body 10 and a moving unit 20. FIG. 5 is a perspective view showing the moving unit 20.

As shown in FIG. 4, the main body 10 has a supply stage 11, a molding stage 12, and a take-out stage 13. The moving unit 20 is movably housed in the main body 10, and a rail 15 for moving the moving unit 20 in the width direction of the main body 10 (X direction in FIG. 4) is installed at the bottom portion of the main body 10. Has been done. A heater unit 300 is installed near the center of the upper part of the main body 10 in the width direction. Further, a material supply unit 400 including a hopper 410 is installed on one end side in the width direction of the upper part of the main body 10.

As described above, the moving unit 20 is housed in the main body 10 so as to be movable between the supply stage 11, the forming stage 12, and the take-out stage 13 along the rail 15. The movement unit 20 is moved by a drive device (not shown) such as an actuator mechanism using a ball screw using a servo. As shown in FIG. 5, the slide unit 100 is installed at the upper part of the moving unit 20, and the elevating unit 200 is installed inside.

The slide unit 100 provided in the moving unit 20 has a configuration that defines the position of the horizontal plane (XY plane) of the resin block forming space for forming the resin block.
FIG. 6 is a perspective view showing the configuration of the slide unit 100, and FIG. 7 is a diagram schematically showing a resin block forming space.
The resin block is formed by putting a solid resin material, which is a raw material of the resin block, into the resin block forming space 150 of the slide unit 100, and heating and cooling and solidifying the resin block.

As shown in FIG. 6, the slide unit 100 includes a flat plate-shaped stage 110 and four first to fourth slide mechanisms 120a to 120d. Each of the four slide mechanisms 120a to 120d is movably installed on the stage 110 in a horizontal plane.

The first and second slide mechanisms 120a and 120b have a resin block forming position which is a predetermined center side position and a resin block release type which is a predetermined outer position in the Y direction (depth direction of the resin block manufacturing apparatus 1). It is configured so that it can be slid to and from the position. Further, the third and fourth slide mechanisms 120c and 120d have a resin block forming position which is a predetermined central side position and a predetermined outer position in the X direction (width direction of the resin block manufacturing apparatus 1, see FIG. 4). It is installed on the stage 110 so that it can be slidably moved between the resin block mold release position and the resin block. The movement of the slide mechanisms 120a to 120d is performed by a drive device (not shown) and a control device thereof.

The central surface of the slide mechanisms 120a to 120d, that is, the facing surfaces of the first and second slide mechanisms 120a and 120b, and the facing surfaces of the third and fourth slide mechanisms 120c and 120d Molded plates 125a to 125d that define the side surfaces of the resin block to be manufactured are installed. The central portion of the slide unit 100 surrounded by the molded plates 125a to 125d serves as the resin block forming space 150. When all the slide mechanisms 120a to 120d are arranged at the resin block forming positions, the molded plates 125a to 125d of the slide mechanisms 120a to 120d are sequentially in contact with each other, and are in a state of being rotated and closed.

The first and second slide mechanisms 120a and 120b are wider than the third and fourth slide mechanisms 120c and 120d. The third and fourth slide mechanisms 120c and 120d are housed between the facing surfaces of the first and second slide mechanisms 120a and 120b, and X is provided between the facing surfaces of the first and second slide mechanisms 120a and 120b. It is configured to slide in the axial direction.

At the upper edges of each of the molding plates 125a to 125d, return portions 126a to 126d projecting substantially horizontally on the resin block forming space 150 side are installed. As shown in FIG. 7, the return portions 126a to 126d have rod-shaped members having a rectangular cross section and a predetermined length formed on the upper edges of the molding plates 125a to 125d along the width direction of the molding plates 125a to 125d. It was installed with the width of.

Each of the return portions 126a to 126d has a length substantially equal to a piece of the side surface 317 of the heating plate 315 of the heating portion 310. Further, when each of the slide mechanisms 120a to 120d and the heating portion 310 is arranged at the resin block forming position, the inner side surfaces 127 of the return portions 126a to 126d each come into contact with the side surface 317 of the heating plate 315 of the heating portion 310. , The return portions 126a to 126d are arranged. With such a length and arrangement, when the slide mechanisms 120a to 120d are arranged at the resin block forming positions, it is possible to prevent the return portions 126a to 126d of the adjacent slide mechanisms from interfering with each other.

The return portions 126a to 126d are preferably metal members, but any heat-resistant member may be used. The molded plates 125a to 125d and the return portions 126a to 126d may be bonded by any bonding means, or may be integrally formed as one member.

By providing the molding plates 125a to 125d with such return portions 126a to 126d, it is possible to prevent unnecessary resin material from flowing into the resin block forming space 150 and to facilitate mold release. That is, when there are no return portions 126a to 126d, as shown in FIG. 13, the resin flows into a slight gap between the heating plate 315b and the molding plates 125a to 125d, and the heating plate 315 rises. There is a possibility that defects such as defects, defective sliding operation of the molded plates 125a to 125d, and breakage of the resin block at the time of mold opening may occur. On the other hand, if the return portions 126a to 126d are installed, it is possible to prevent the resin from flowing in the slight gap between the heating plate 315b and the molding plates 125a to 125d, and the heating plate 315 and the molding plate can be prevented from flowing. 125a to 125d can be appropriately moved, damage to the resin block can be prevented, and demolding of the resin block can be easily and appropriately performed.

As shown in FIG. 6, the molding plates 125a to 125d are installed on the bases 123a to 123d via the heat insulating materials 124a to 124. The heat insulating materials 124a to 124 prevent the heat from escaping from the resin block forming space 150 when the resin block forming space 150 is heated by the heater unit 300 described later, and prevent the bases 123a to 123d from becoming extremely hot. I'm out.

An opening 112 is formed in the central portion of the molding stage 121. The opening 128 is formed in the XY plane of the resin block forming space 150 when the slide mechanisms 120a to 120d are arranged at the resin block forming positions and the periphery of the resin block forming space 150 is closed by the molding plates 125a to 125d. It is formed in a range substantially the same as the range or slightly larger than the resin block forming space 150. The bottom surface 210 of the elevating unit 200, which will be described later, can pass through the opening 128 of the molding stage 121. The bottom surface portion 210 has a configuration that defines the bottom surface of the resin block forming space 150.

Further, as shown in FIG. 7, a metal plate 160 for blocking heat from the molding plate 125 (125a to 125d) is installed under each slide mechanism 120 (120a to 120d). By providing the metal plate 160, even if a part of the molten resin leaks downward from the gap around the bottom plate 215, it is cooled and hardened by the plate 160, so that the leakage of the high-temperature molten resin is suppressed. be able to. The metal plate 160 is not shown in other drawings of the present application.

The elevating unit 200 (see FIG. 5) provided in the moving unit 20 defines the bottom surface of the resin block forming space 150, and is configured to sequentially stack resin materials to form a large-volume resin block. The elevating unit 200 has a bottom surface portion 210 (see FIG. 7) and an elevating mechanism 230 (see FIG. 5) that elevates (moves) the bottom surface portion 210 in the vertical direction (Z direction).

The bottom surface portion 210 is installed at the upper end portion of the elevating mechanism 230. When starting the production of the resin block, the bottom surface 210 of the elevating unit 200 passes through the opening 112 formed in the stage 110 of the slide unit 100 and is arranged at a predetermined resin block formation start position above the stage 110. .. In the subsequent step, in order to pressurize the resin in the resin block forming space 150, the bottom surface portion 210 moves slightly further upward from the resin block forming start position. The resin block formation start position is set slightly below the uppermost position where the bottom surface 210 can move up and down in order to enable this pressurization operation.

Further, the bottom surface portion 210 is arranged at a position below the resin block formation start position when the manufactured resin block is taken out from the resin block manufacturing apparatus 1, and at a predetermined release position determined by the size of the resin block to be manufactured. Will be done.

As shown in FIG. 7, a bottom plate 215, which serves as the bottom surface of the resin block forming space 150 and defines the lower surface of the resin block to be manufactured, is installed on the uppermost surface of the bottom surface portion 210. When all the slide mechanisms 120a to 120d of the slide unit 100 are arranged at the resin block forming positions, the periphery of the resin block forming space 150 is closed, and the bottom surface 210 is arranged at the resin block forming start position, the bottom plate The four sides of the 215 are arranged in close contact with the lower portion of the molded plates 125a to 125d of the slide mechanisms 120a to 120d (see FIG. 10A).

The bottom plate 215 is installed on the base 213 via a heat insulating material 214. The heat insulating material 214 prevents the base 213 from becoming extremely hot due to the heat of the resin block forming space 150 or the high temperature resin block immediately after solidification.

Engagement screws 218 are installed on the bottom surface 210 so as to project upward from the bottom plate 215 and can be rotatably pulled out from the bottom surface of the bottom surface 210. The engaging screws 218 are installed at four corners of the bottom plate 215 or at two diagonal positions, for example, but the number and arrangement thereof may be arbitrary.

The engaging screw 218 is a member for releasing the resin block laminated and formed on the bottom plate 215. When forming the resin block on the bottom plate 215, the engaging screw 218 is installed. As a result, the engaging screw 218 engages (bites) with the resin block, and the resin block does not release from the bottom plate 215. When the formed resin block is released from the bottom plate 215, the engaging screw 218 is loosened and pulled out. As a result, the engagement state between the engaging screw 218 and the resin block is released, and the resin block can be easily released from the bottom plate 215.

The elevating mechanism 230 moves the bottom surface portion 210 up and down within the predetermined range described above. When starting the formation of the resin block, the elevating mechanism 230 moves the bottom surface portion 210 to the resin block formation start position. During the formation of the resin block, the elevating mechanism 230 pushes the bottom surface 210 upward with a predetermined force in order to pressurize the pellets, the molten resin, the resin softened by heating, or the resin in the process of solidification in the resin block forming space 150. ..

Further, the elevating mechanism 230 lowers the bottom surface portion 210 by a height corresponding to the thickness of the resin layer formed immediately before each time the resin layers are sequentially formed and laminated. Then, when a resin block of a desired size can be formed, the engaging screw 218 is pulled out at that position, or at a position where the bottom surface 210 is further lowered, that is, at the above-mentioned mold release position, and the resin block is pulled out. The bottom surface 210 is further pulled down to release the shape. Such movement of the bottom surface portion 210 by the elevating mechanism 230 may be automatically performed by a drive device (not shown), a control device thereof, or the like, or may be manually operated by an operator.

The heater unit 300 provided in the main body 10 of the resin block manufacturing apparatus 1 is configured to heat the resin material put into the resin block forming space 150 and pressurize the resin material to form a block. The heater unit 300 includes a heating unit 310 (see FIG. 7), an elevating mechanism 330 (see FIG. 4) that elevates (moves) the heating unit 310 in the vertical direction (Z direction), and a cooling device (not shown). The heating unit 310 is installed at the lower end of the elevating mechanism 330. Further, in the present embodiment, the cooling device cools the heating plate 315 with the antifreeze liquid. However, the refrigerant for cooling the heating plate 315 is not limited to the antifreeze liquid, and any refrigerant may be used.

In the heater unit 300, the heating unit 310 is configured to be movable up and down between the retracted position and the heating position. The retracted position is a predetermined uppermost position, and the heating position is a predetermined position defined within the height range of the molding plates 125a to 125d of the slide unit 100.

As shown in FIG. 7, on the lowermost surface of the heating unit 310, a heating plate 315 that serves as the upper surface of the resin block forming space 150 and defines the upper surface of the resin block to be manufactured is installed. The heating plate 315 is formed in a trapezoidal state in which the area is slightly narrowed downward (resin block forming space 150), and as a result, the side surface 317 of the heating plate 315 is slightly inclined with respect to the vertical direction. It is formed on the surface. When the heating portion 310 is in the heating position, the return portions 126a to 126d of the molding plates 125a to 125d of the slide mechanisms 120a to 120d are in close contact with the side surface 317 as described above. As a result, the resin block forming space 150 is defined below the heating unit 310.

A heater 312 is embedded in the heating plate 315. The heating plate 315 is heated by the heater 312 to heat the granular resin material charged into the resin block forming space 150. The heating plate 315 is installed on the base 313 via a heat insulating material 314. The heat insulating material 314 insulates between the base 313 and the heating plate 315 so that the heat generated by the heater 312 does not escape toward the base 313 and the base 313 does not become extremely hot.

The elevating mechanism 330 moves the heating unit 310 up and down within the predetermined range described above. When the newly introduced granular resin material is heated, the elevating mechanism 330 moves the heating unit 310 from the retracted position, which is the uppermost position, to the heating position in the resin block forming space 150. In this state, the bottom surface 210 of the elevating unit 200 moves upward by the operation of the elevating mechanism 230, so that the heating plate 315 of the heater unit 300 and the bottom plate of the elevating unit 200 are melted while the granular resin material is melted. It is sandwiched between 215 or a resin block laminated on it and pressed. When the heated and adhered granular resin material is layered on the bottom plate 215 of the elevating unit 200 or on the resin layer already laminated, the elevating mechanism 330 raises the heating unit 310 and retracts the position. Return to. Such movement of the heating unit 310 by the elevating mechanism 330 may be automatically performed by a drive device (not shown), a control device thereof, or the like, or may be manually operated by an operator.

The material supply unit 400 is configured to supply the granular resin material to the resin block forming space 150. As shown in FIG. 4, the material supply unit 400 has one hopper 410 installed above the supply stage 11 of the main body 10. A granular resin material is stored in the hopper 410. Although not shown, the material supply unit 400 includes a screw for charging an appropriate amount of resin material into the resin block forming space 150, a servo or motor for driving the screw, and a control unit (included in the servo) for controlling these. In some cases). In the material supply unit 400, an appropriate amount of resin material is supplied to the resin block forming space 150 while being electrically controlled by these configurations.

In order to manufacture the resin block according to the present invention, a plurality of types of granular resin materials are mixed, heated, brought into close contact with each other, and integrated. Specifically, for example, in the case of producing the resin block 8a shown in FIG. 1, the white pellets and the crushed resin material of the caps of PET bottles of various colors are mixed in advance to prepare raw materials. , This is supplied to the resin block forming space 150 via the material supply unit 400.

Specifically, in the resin block manufacturing apparatus 1, when a new resin layer is laminated on the molded plate 125 of the slide unit 100, or when the resin layer is further laminated on the already laminated resin layer. , The moving unit 20 is moved to the supply stage 11 of the main body 10. At this time, since the heater unit 300 covering the upper part of the resin block forming space 150 is installed on the molding stage 12 of the main body 10 and does not move to the supply stage 11, the upper part of the resin block forming space 150 of the slide unit 100 is in an open state. It has become. The material supply unit 400 puts the resin material to be laminated next into the resin block forming space 150 of the slide unit 100 through this opening.

In the resin block manufacturing apparatus 1 having such a configuration, the moving unit 20 is appropriately moved to the supply stage 11, the molding stage 12, and the take-out stage 13 shown in FIG. Laminate to form a resin block of the desired size. The resin block manufacturing apparatus 1 may further include a take-out mechanism or the like for automatically taking out the completed resin block from the moving unit 20 moved to the take-out stage 13 of the main body 10.

Next, a method of manufacturing a resin block using the resin block manufacturing apparatus 1 having such a configuration will be described with reference to FIGS. 8 to 12.
When manufacturing a resin block in the resin block manufacturing apparatus 1, first, the elevating unit 200 of the moving unit 20 is warmed up at a warm temperature of 240 to 270 ° C. (step S1). This is to improve the weldability of the resin material when molding the first resin layer.

Next, the moving unit 20 is moved to the supply stage 11 (step S2), and the raw material is supplied to the resin block forming space 150 as shown in FIG. 10 (A) (step S3). As described above, for example, when the resin block 8a shown in FIG. 1 is manufactured, the white pellet h as the base resin and the granular resin material t of various colors prepared by crushing the cap of the PET bottle are used. The raw material containing the above is supplied to the resin block forming space 150 via the material supply unit 400. At this time, the slide mechanisms 120a to 120d are closed, and the bottom surface 210 of the elevating unit 200 is arranged at the resin block formation start position.

After the raw material resin material is put into the resin block forming space 150, the moving unit 20 is moved to the molding stage 12, and as shown in FIG. 10B, the resin block forming space 150 is placed under the heating unit 310 of the heater unit 300. (Step S4). Then, the heating plate 315 of the heater unit 300 is lowered to the heating position in the resin block forming space 150 (step S5), and the heating of the heating plate 315 is started by the heater 312 (step S6).

At about the same time, the elevating mechanism 230 of the elevating unit 200 is driven to raise the bottom plate 215 (step S7), and as shown in FIG. 11A, pressure is applied to the raw material in the resin block forming space 150. The raw material in the resin block forming space 150 is compressed at a predetermined pressure (step S8).

That is, pressure is applied to the raw material in the resin block forming space 150 before the temperature of the heating plate 315 becomes sufficiently high, and the temperature is gradually raised toward a predetermined set temperature while applying pressure. The pressurizing pressure at this time is adjusted in the normal range of 50 to 100%. That is, for example, ^{when pressurizing with a surface pressure of 14.25 (kg / cm 2} ) or an axial pressure of 3200 (kgf), the pressure is lower than that, which is 50% of 7.13 (kg / cm ^2). ) Or a desired pressure greater than the axial pressure of 1600 (kgf).

Further, the heating temperature at this time is set to a temperature (about 270 ° C.) that is about 10% higher than, for example, when the same raw material is molded by ordinary injection molding (for example, when this is 250 ° C.). By operating the resin block manufacturing apparatus 1 under such temperature conditions, pressurizing conditions, and operating conditions, as shown in FIG. 11B, the raw materials (resin materials) can be appropriately bonded to each other without bubbles inside. Along with welding, the granular resin material can be present in the resin block while maintaining the granular state.

After holding the temperature of the resin block forming space 150 at a predetermined set temperature for a predetermined time (for example, about 1 to 10 minutes) (step S9), the temperature of the heating plate 315 is brought to room temperature by a cooling device (not shown) in the heater unit 300. Cool (step S10).

When the heating plate 315 is cooled to room temperature, first, as shown in FIG. 12A, the heating plate 315 is raised once and the heating plate 315 is peeled off from the molded resin layer (step S11), and the heating plate 315 is released. After separating from the resin layer, as shown in FIG. 12B, the heating plate 315 is lowered again to hold the resin layer between the heating plate and the elevating unit (step S12).

Next, as shown in FIG. 12C, each of the four slide mechanisms 120a to 120d of the slide unit 100 is slid outward to open the side surface of the resin block forming space 150, and the molded plate 125 is once placed in the resin layer. Peel off from (step S13). When the molding plate 125 is peeled off from the resin layer, the molding plate 125 is returned to a position close to the side surface of the resin layer as shown in FIG. 12 (D) (step S14). When lowering the resin block downward, the molding plate 125 is closed until the resin block slides on the molding plate 125 so that the position of the resin block does not shift or tilt.

When such a state is reached, as shown in FIG. 12 (E), the elevating unit is lowered while holding the resin block with the heating plate 315 (step S15). That is, while the resin layer is held between the heating plate 315 and the bottom plate 215 of the elevating unit 200, the entire resin layer is lowered downward.

Next, when the elevating unit 200 is lowered by the amount of the next resin laminate, the heating unit including the heating plate 315 is raised to the retracted position (step S12), and the moving unit 20 is moved, as shown in FIG. 12 (F). to enable. Then, it is determined whether or not the resin block on the bottom plate 215 of the bottom surface portion 210 has reached a desired height (whether or not the resin layers are laminated a predetermined number of times) (step S18), and if not, step S2. Return, the process of steps S2 to S18 is repeated, and the next resin layer is laminated on the resin layer laminated this time.

When it is determined in step S18 that the resin block has reached a desired height, the moving unit 20 is taken out and moved to the stage 13 to take out the completed resin block. That is, the engaging screw 218 installed on the bottom surface 210 of the elevating unit 200 is loosened, and the resin block 8 is released from the bottom plate 215 (step S19).
In the resin block manufacturing apparatus 1 of the present embodiment, the desired resin block 8 is manufactured in this way.

The present invention is not limited to the above-described embodiment, and various suitable modifications can be made.

1 ... Resin block manufacturing equipment 10 ... Main body 11 ... Supply stage 12 ... Molding stage 13 ... Extraction stage 20 ... Moving unit 100 ... Slide unit 110 ... Stage
112 ... Opening 120 ... Slide mechanism
123 ... Base
124 ... Insulation material
125 ... Molded plate
126 ... Return part 150 ... Resin block forming space 160 ... Metal plate 200 ... Elevating unit 210 ... Bottom part
213 ... Base
214 ... Insulation material
215 ... Bottom plate
218 ... Engagement screw 230 ... Elevating mechanism 300 ... Heater unit 310 ... Heating unit
312 ... heater
313 ... Base
314 ... Insulation material
315 ... Heating plate
317 ... Heating plate side surface 330 ... Elevating mechanism 400 ... Material supply unit 410 ... Hopper 7 ... Pellet 8 ... Resin block

Claims (16)

A resin block characterized in that the granular resin material has a portion that exists in a state where the grain state is maintained. The resin block according to claim 1, wherein the granular resin material contains a granular resin material having a color different from that of other resin materials forming the resin block. The resin block according to claim 1 or 2, wherein the granular resin material is a member obtained by crushing a cap of a PET bottle. A claim characterized in that the portion is arranged on a melt-molded resin base material, and the granular resin material holding the grain state is present in a form embedded in the resin base material. Item 2. The resin block according to any one of Items 1 to 3. The granular resin material is a linear resin material having a predetermined length, and is characterized in that the linear resin material holding a linear state exists in a form embedded in the resin base material. The resin block according to claim 4. The resin block according to any one of claims 1 to 3, wherein a plurality of types of the granular resin materials are formed in close contact with each other while maintaining the grain state. A slide unit having a plurality of molded plates that can slide and move in a horizontal plane, and when the molded plates are closed, a resin block forming space surrounded by the side surfaces of the molded plates is formed.
An elevating unit having a bottom plate that defines the bottom surface of the resin block forming space and an elevating mechanism that elevates and elevates the bottom plate.
A heater unit having a heating plate forming the upper surface of the resin block forming space, a heater for heating the heating plate, and an elevating mechanism for raising and lowering the heating plate.
A material supply unit that supplies raw materials containing a plurality of types of granular resin materials to the resin block forming space, and
It has a control unit that controls the slide unit, the heater unit, and the elevating unit, and heats, pressurizes, cools, and solidifies the raw material supplied to the resin block forming space under predetermined conditions.
The control unit removes air bubbles between the granular resin materials constituting the raw material by heating the raw material in the resin block forming space under predetermined conditions after preceding a predetermined pressurization. The slide unit, said, so that the granular resin materials are brought into close contact with each other while forming a resin layer having a portion in which the granular resin material exists in a state in which the granular resin material is held in a granular state. A resin block manufacturing apparatus characterized by controlling a heater unit and the elevating unit. The formation of the resin layer in the resin block forming space is repeated, the bottom plate is lowered each time the resin layer is formed, and the resin layer repeatedly formed in the resin block forming space is sequentially laminated on the bottom plate. The resin block manufacturing apparatus according to claim 7, wherein a resin block having a desired height is manufactured. The slide unit has a plurality of slide mechanisms having a base, a heat insulating material, and the molded plate, and the upper edge portion of each of the molded plates projects substantially horizontally toward the resin block forming space side of the heating plate. The resin block manufacturing apparatus according to claim 7 or 8, wherein a return portion that can be brought into contact with the side surface is provided. A resin block manufactured by the resin block manufacturing apparatus according to any one of claims 7 to 9. Raw materials containing multiple types of granular resin materials are supplied to the resin block forming space surrounded by multiple molding plates around the side surfaces.
The granular resin materials are brought into close contact with each other while removing air bubbles between the granular resin materials constituting the raw material, and the granular resin material has a portion existing in the resin block forming space in a state where the granular state is maintained. A method for producing a resin block, which comprises heating the raw material in the resin block forming space under predetermined conditions after preceding a predetermined pressurization so that a resin layer is formed. The resin according to claim 11, wherein the resin layer is repeatedly formed in the resin block forming space, and the repeatedly formed resin layers are sequentially laminated to produce a resin block having a desired height. Block manufacturing method. Pressurizing and heating the raw material under the predetermined conditions so that the surface of the granular resin material constituting the raw material melts into a thin layer while the inside of the granular resin material is maintained in a softened state. The resin block manufacturing method according to claim 11 or 12. A resin block manufactured by the resin block manufacturing method according to any one of claims 11 to 13. A resin molded product formed by cutting the resin block according to any one of claims 1 to 6, 10 or 14. A resin molded product obtained by forming the resin block according to any one of claims 1 to 6, 10 or 14 as a molded product having a desired shape.

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