JP2024066267A - SHEET HOLDING MECHANISM, MOLD, FORMING MACHINE, FORMING SYSTEM, METHOD FOR PRODUCING FORMED PRODUCT, AND METHOD FOR PRODUCING FORMED SHEET - Google Patents

Abstract

[Problem] To provide a sheet holding mechanism that prevents a sheet from falling off a member that holds the sheet. [Solution] The sheet holding mechanism is a sheet holding mechanism for holding a sheet in a forming system that forms a sheet, and includes a frame 33 having a frame-like shape with an opening, a frame suction hole provided in the frame, and a frame expandable member having a first end where the suction opening is provided and a second end located on the opposite side to the first end, the second end being accommodated in the frame suction hole and the first end protruding from the frame suction hole, and the frame expandable member contracts when pressed so that the first end is accommodated in the frame suction hole, and holds the sheet by vacuum suction of the suction opening. [Selected Figure] Figure 6

Description

The present disclosure relates to a sheet holding mechanism, a mold, a molding machine, a molding system, a manufacturing method for a molded product, and a manufacturing method for a molded sheet.

Currently, methods of forming substrates using vacuum forming are widely known. For example, Patent Document 1 discloses forming a substrate by vacuum forming the substrate and then performing injection molding of resin on the surface of the vacuum formed substrate. Patent Document 1 also discloses transporting the substrate to a mold having a recess to which a gas flow path is connected using a holding mechanism that holds the substrate by adsorbing it, and vacuum forming the substrate to conform to the shape of the recess by drawing gas from the gas flow path with a suction pump.

International Publication No. 2018/186414

In a method of transporting a sheet to a mold and using the mold to mold a substrate, there has been a need to prevent the sheet from falling off the member that holds the sheet. For example, when a sheet is transported to the mold using a sheet holding mechanism, there has been a need to prevent the sheet from falling off the sheet holding mechanism. Also, when a substrate is molded using the mold, there has been a need to prevent the sheet from falling off the mold.

This disclosure has been made in consideration of these points, and aims to prevent the sheet from falling off the member that holds it.

A first aspect of the present disclosure is a sheet holding mechanism for holding a sheet in a forming system for forming a sheet, the mechanism comprising:
A frame portion having a frame-like shape with an opening provided therein;
A frame suction hole provided in the frame;
a frame expandable member having a first end provided with a suction opening and a second end located opposite the first end, the second end being accommodated in the frame suction hole and the first end protruding from the frame suction hole, and the frame expandable member contracts when pressed so that the first end is accommodated in the frame suction hole,
A sheet holding mechanism holds the sheet by vacuum suction of the suction opening.

A second aspect of the present disclosure is a sheet holding mechanism for holding a sheet in a forming system for forming a sheet, the mechanism comprising:
A frame portion having a frame-like shape with an opening provided therein;
A frame suction hole provided in the frame;
a frame heater that heats the frame and is attached to at least one of an inner surface that forms the opening of the frame and an outer surface that is located opposite to the inner surface;
The sheet holding mechanism holds the sheet by vacuum suction of the frame suction holes.

A third aspect of the present disclosure is a sheet holding mechanism for holding a sheet in a forming system for forming a sheet, comprising:
A frame portion having a frame-like shape with an opening provided therein;
a frame suction hole provided in the frame and opening in a frame first surface of the frame facing the sheet;
an elastic body that is more easily elastically deformed than the frame and is attached to an area of the first surface of the frame where the frame suction holes are not provided so as to surround the opening,
The sheet holding mechanism holds the sheet by vacuum suction of the frame suction holes.

A fourth aspect of the present disclosure is a mold for use in vacuum forming a sheet, comprising:
A mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area;
a suction hole provided in the mold body and opening in the outer circumferential region;
an elastic body that is more easily elastically deformed than the mold body and is attached to the outer circumferential region so as to surround a region in which the suction holes are provided,
The mold holds the sheet by vacuum suction through the suction holes.

A fifth aspect of the present disclosure is a mold for use in vacuum forming a sheet, comprising:
A mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area;
a suction hole provided in the mold body and opening in the outer circumferential region;
an expandable member having a first end provided with a suction opening and a second end located opposite the first end, the second end being accommodated in the suction hole and the first end protruding from the suction hole, and the expandable member being compressed to contract so that the first end is accommodated in the suction hole;
A mold that holds the sheet by vacuum suction of the suction openings.

A sixth aspect of the present disclosure is a mold according to the fifth aspect described above, further comprising a linear groove provided on the first surface and surrounding at least a portion of the molding region;
and a linear groove suction hole having an opening at least partially provided on a wall surface of the linear groove, the linear groove suction hole drawing the sheet into the linear groove by vacuum suction.
The suction hole may be open outside the area surrounded by the linear groove.

A seventh aspect of the present disclosure is a mold according to the fourth aspect described above,
and an opposing mold that, together with the molding area of the mold, forms an accommodation space into which a portion of the sheet is accommodated and into which a resin is injection molded;
The opposing mold is a molding machine having a recess that accommodates at least a portion of the elastic body when the mold and the opposing mold form the accommodation space.

An eighth aspect of the present disclosure is a molding system for molding a sheet, comprising:
a sheet holding mechanism for holding the sheet;
a molding machine including a mold used for vacuum forming the sheet;
the sheet holding mechanism has a frame having a frame-like shape with an opening, frame suction holes provided in the frame and opening in a frame first surface of the frame facing the sheet, and a linear protrusion provided in an area of the frame first surface where the frame suction holes are not provided and surrounding the opening, and holds the sheet by vacuum suction of the frame suction holes;
The mold comprises a mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area, a linear suction groove provided in the outer peripheral area and surrounding the forming area, and a suction hole provided in the mold body, at least a portion of which has an opening provided in a wall surface of the linear suction groove,
the sheet holding mechanism brings the held sheet into close contact with a region surrounding the molding region of the mold;
This is a molding system, wherein when the sheet holding mechanism presses the sheet against an area surrounding the molding area on the first surface, at least a portion of the linear protrusion is inserted into the suction linear groove.

A ninth aspect of the present disclosure is a sheet holding mechanism according to each of the first to third aspects described above;
a molding machine including a mold used for vacuum forming the sheet, the mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area;
A molding system comprising: a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with an area surrounding the molding area of the first surface.

A tenth aspect of the present disclosure is a molding machine including a mold according to each of the fourth to sixth aspects described above;
a sheet holding mechanism for holding the sheet;
A molding system comprising: a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with an area surrounding the molding area of the mold.

An eleventh aspect of the present disclosure is a molding machine according to the seventh aspect described above;
a sheet holding mechanism for holding the sheet;
A molding system comprising: a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with an area surrounding the molding area of the mold.

A twelfth aspect of the present disclosure is a molding system according to the eighth aspect described above, wherein the molding machine forms a storage space, a portion of which is partitioned by the molding area and in which a portion of the sheet is stored, and injection molds resin into the storage space.

A thirteenth aspect of the present disclosure is a molding system according to the ninth aspect described above, in which the molding machine forms a storage space, a portion of which is partitioned by the molding area and in which a portion of the sheet is stored, and injection molding of resin into the storage space.

A fourteenth aspect of the present disclosure is a molding system according to the tenth aspect described above, in which the molding machine forms a storage space, a portion of which is partitioned by the molding area and in which a portion of the sheet is stored, and injection molding of resin into the storage space.

A fifteenth aspect of the present disclosure is a method for producing a molded product using a molding system according to the eleventh aspect or the twelfth aspect, comprising:
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
A method for manufacturing a molded product comprising the steps of: causing the molding machine to form the storage space in which a portion of the sheet is stored, and injection molding a resin into the storage space.

A sixteenth aspect of the present disclosure is a method for producing a molded product using the molding system according to the thirteenth aspect described above,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
A method for manufacturing a molded product comprising the steps of: causing the molding machine to form the storage space in which a portion of the sheet is stored, and injection molding a resin into the storage space.

A seventeenth aspect of the present disclosure is a method for producing a molded product using the molding system according to the fourteenth aspect described above,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
A method for manufacturing a molded product comprising the steps of: causing the molding machine to form the storage space in which a portion of the sheet is stored, and injection molding a resin into the storage space.

An eighteenth aspect of the present disclosure is a method for producing a molded product using the molding system according to the eighth aspect described above,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
A method for manufacturing a molded product comprising the steps of: causing the molding machine to form the storage space in which a portion of the sheet is stored, and injection molding a resin into the storage space.

A nineteenth aspect of the present disclosure is a method for producing a molded product using the molding system according to the ninth aspect described above,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
A method for manufacturing a molded product comprising the steps of: causing the molding machine to form the storage space in which a portion of the sheet is stored, and injection molding a resin into the storage space.

A twentieth aspect of the present disclosure is a method for producing a molded product using the molding system according to the tenth aspect described above,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
A method for manufacturing a molded product comprising the steps of: causing the molding machine to form the storage space in which a portion of the sheet is stored, and injection molding a resin into the storage space.

This disclosure makes it possible to prevent the sheet from falling off the member that holds the sheet.

FIG. 1 is a top view that shows a schematic view of the entire molding system according to the first embodiment. FIG. 2 is a side view of the sheet feeding apparatus according to the first embodiment, observed from a direction parallel to the sheet surface of the sheet fed by the sheet feeding apparatus. FIG. 3 is a front view showing the head and the drive device according to the first embodiment. FIG. 4 is a perspective view of the sheet holding mechanism according to the first embodiment. 5 is an enlarged cross-sectional view taken along line VV in FIG. 4, showing an enlarged view of the periphery of one frame suction hole. FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. FIG. 7 is a perspective view of the molded product holding mechanism according to the first embodiment. FIG. 8 is a schematic diagram showing a molding machine according to the first embodiment and a head disposed between a mold and an opposing mold of the molding machine. FIG. 9 is a plan view showing the mold according to the first embodiment as viewed from the first surface side of the mold body. FIG. 10 is a cross-sectional view taken along line XX in FIG. FIG. 11 is a diagram showing how the sheet is transferred from the sheet holding mechanism to the mold of the molding machine in the first embodiment. FIG. 12 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the mold in the first embodiment. FIG. 13 is a diagram showing a state in which the sheet is vacuum-formed in the first embodiment. FIG. 14 is a diagram showing an example of a state in which the counter mold is moved relative to the mold in the first embodiment. FIG. 15 is a diagram showing a state in which an accommodation space is formed between a die and an opposing die in the first embodiment. FIG. 16 is a diagram showing a state in which the counter mold is separated from the mold in the first embodiment. FIG. 17 is a diagram showing how a molded product is transferred from an opposing mold to a molded product holding mechanism in the first embodiment. FIG. 18 is a diagram showing a state in which a molded product is transferred from an opposing mold to a molded product holding mechanism in the first embodiment. FIG. 19 is a side view of a molded product manufactured by the manufacturing method of a molded product. FIG. 20 is a perspective view of a sheet holding mechanism according to the second embodiment. 21 is a cross-sectional view taken along line XXI-XXI of FIG. 20. As shown in FIG. FIG. 22 is a plan view showing the sheet holding mechanism according to the third embodiment as viewed from the frame first surface side. 23 is a cross-sectional view taken along line XXIII-XXIII in FIG. 22. As shown in FIG. FIG. 24 is a plan view showing the mold according to the fourth embodiment as viewed from the first surface side of the mold body. 25 is a cross-sectional view taken along line XXV-XXV of FIG. 24. As shown in FIG. FIG. 26 is a cross-sectional view showing a cross section of a mold according to the fourth embodiment. FIG. 27 is a diagram showing a state in which an accommodation space is formed between a die and an opposing die in the fourth embodiment. FIG. 28 is a plan view showing the mold according to the fifth embodiment as viewed from the first surface side of the mold body. FIG. 29 is a cross-sectional view taken along line XXIV-XXIV in FIG. FIG. 30 is a plan view showing the sheet holding mechanism according to the sixth embodiment as viewed from the frame first surface side. FIG. 31 is a cross-sectional view taken along line XXXI-XXXI in FIG. FIG. 32 is a plan view showing the mold according to the sixth embodiment as viewed from the first surface side of the mold body. FIG. 33 is a side view of a molded sheet manufactured by a molded sheet manufacturing method according to a modified example.

The following describes the embodiments of the present disclosure with reference to the drawings. Each of the figures shown below is a schematic diagram. Therefore, the size and shape of each part are appropriately exaggerated to facilitate understanding. In addition, the embodiments of the present disclosure can be modified as appropriate within the scope of the technical concept. In each of the figures shown below, the same parts are given the same reference numerals, and some detailed explanations may be omitted. In addition, the numerical values such as dimensions of each member and the material names described in this specification are examples of embodiments, and can be appropriately selected and used without being limited thereto. In this specification, terms that specify shapes or geometric conditions, such as parallel, vertical, and right angles, are interpreted to include substantially the same state in addition to their strict meaning.

(First embodiment)
First, a molding system 1 according to a first embodiment will be described. FIG. 1 is a schematic top view of the molding system 1 according to the first embodiment. In the first embodiment, the molding system 1 manufactures a molded product 16 in which a molded part 12 containing resin is provided on a sheet 11, as shown in FIG. 19 and described later. As shown in FIG. 1, the molding system 1 is covered by a clean booth 5. The clean booth 5 prevents an object from entering the molding system 1 from the outside unintentionally. The clean booth 5 has a first opening 6 on a first side s1 of the first direction d1, and a second opening 7 on a second side s2 of the first direction d1. In the clean booth 5, air flows in from the first opening 6, and air flows out from the second opening 7. That is, in the clean booth 5, an air flow is generated from the first side s1 of the first direction d1 to the second side s2 of the first direction d1. This air flow prevents foreign matter from adhering to the sheet 11 from the outside in each device of the molding system 1.

The molding system 1 includes a head 30, a molding machine 50, and a drive device 40. In the example shown in FIG. 1, the molding system 1 further includes a sheet supply device 20 and a trimming device 80. In the example shown in FIG. 1, the components are arranged in the above-mentioned order from the first side s1 in the first direction d1 to the second side s2 in the first direction d1 in the molding system 1. The sheet supply device 20 supplies the sheet 11 cut to a predetermined size from the sheet 11 wound to form a roll 10. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes a sheet holding mechanism 31 described later as a part of the head 30. The head 30 receives the sheet 11 at the sheet holding mechanism 31 and holds the sheet 11. The head 30 is driven by the drive device 40 to transport the sheet 11 to the molding machine 50. The molding machine 50 receives the sheet 11 from the head 30. The molding machine 50 includes a mold 51 and an opposing mold 52. The molding machine 50 vacuum-forms the received sheet 11 using a metal mold 51. After vacuum-forming the sheet 11, the molding machine 50 brings the metal mold 51 and the opposing metal mold 52 closer to each other to form a storage space 55 in which a part of the sheet 11 is stored. The molding machine 50 injects resin into the storage space 55 to provide the molded part 12 on the sheet 11 and mold the molded product 13. The molded product 13 is held by the head 30. The head 30 holding the molded product 13 is driven by the drive device 40 to transport the molded product 13 to the trimming device 80. The trimming device 80 trims the molded product 13 to produce the molded product 16. In this way, the molding system 1 can continuously supply the sheet 11, mold the molded product 13, and trim the molded product 13 in a single system to manufacture the molded product 16.

Each component of the molding system 1 is explained in detail below.

2 shows a side view of the sheet supplying device 20. More specifically, FIG. 2 shows the sheet supplying device 20 observed from the side direction of the sheet 11 being supplied. The sheet supplying device 20 supplies the sheet 11, which is supplied from the roll 10 on which the sheet 11 is wound and cut to a predetermined size. The sheet 11 is made of a thermoplastic resin that is softened by heating. Examples of materials for the sheet 11 include acrylic, polyethylene terephthalate (PET), ABS, polyethylene, polypropylene, and polycarbonate. The sheet 11 may be provided with a design such as a pattern or information such as letters. The design, information, etc. are provided on the sheet 11 by, for example, printing on the surface of the sheet 11. When the design, information, etc. are provided on the sheet 11, the design, information, etc. are provided on the sheet 11 supplied from the sheet supplying device 20 so that they are appropriately displayed after the sheet 11 is deformed by the molding machine 50 or the like. The sheet 11 supplied by the sheet supplying device 20 is held by the sheet holding mechanism 31 of the head 30, as shown in FIG. 2. As shown in FIG. 2, the sheet feeder 20 includes a sheet cutting means 21, a first clamp 23a and a second clamp 23b, a plate member 25, and a sensor 27.

The sheet supply device 20 sends out the sheet 11 so as to face the sheet holding mechanism 31 so that the sheet 11 is held by the sheet holding mechanism 31. In the example shown in FIG. 2, the sheet 11 is sent out from the roll 10 so as to face the sheet holding mechanism 31. The direction in which the sheet supply device sends out the sheet is also referred to as the sending direction d2. In the example shown in FIG. 2, the sheet 11 is sent out from below to above in the vertical direction (the up-down direction in FIG. 2). That is, the sending direction d2 is a direction from below to above in the vertical direction. The sheet cutting means 21 cuts the sheet 11 sent out from the roll 10 in a direction non-parallel to the sending direction above the second clamp 23b, and adjusts the sheet 11 to a predetermined dimension. As described above, in the example shown in FIG. 2, the sheet 11 is sent out from below to above in the vertical direction. Therefore, the sheet cutting means 21 cuts the lower part of the sheet 11 in the vertical direction in a direction non-parallel to the vertical direction, for example, in the horizontal direction. As a result, a sheet 11 trimmed to a predetermined dimension is formed vertically upward. In particular, the sheet 11 is fed vertically from below to above and cut horizontally to form a rectangular sheet 11. The sheet cutting means 21 is, for example, a blade made of metal.

The first clamp 23a and the second clamp 23b clamp the sheet 11 sent out from the roll 10. As shown in FIG. 2, the first clamp 23a can clamp the top of the sheet 11. The second clamp 23b can clamp the bottom of the sheet 11. After the first clamp 23a clamps the top of the sheet 11 and the sheet holding mechanism 31 holds the center of the sheet 11, the second clamp 23b clamps the sheet 11. The sheet cutting means 21 then cuts the sheet 11, and the first clamp 23a releases the sheet 11, so that the sheet 11 cut to a predetermined size can be smoothly held by the sheet holding mechanism 31. As an example, the first clamp 23a and the second clamp 23b are rod-shaped, but are not limited to this and may be any shape.

The plate member 25 moves the sheet 11 held by the first clamp 23a toward the sheet holding mechanism 31, for example by pushing it out. The plate member 25 is arranged on the opposite side to the side where the head 30 of the first clamp 23a approaches in the sheet supply device 20 in order to push the sheet 11 toward the sheet holding mechanism 31. In the example shown in FIG. 2, the sheet holding mechanism 31 approaches the sheet supply device 20 from the second side s2 of the first direction d1, so the plate member 25 is arranged on the first side s1 of the first clamp 23a in the first direction d1. The plate member 25 also has a shape corresponding to the sheet holding mechanism 31. In other words, the plate member 25 has a shape complementary to the sheet holding mechanism 31. In the example shown in FIG. 2, the surface of the plate member 25 facing the sheet 11 is a plane parallel to the surface of the sheet 11 held by the first clamp 23a. The surface of the sheet holding mechanism 31 facing the sheet 11 is a plane parallel to the surface of the sheet 11 held by the first clamp 23a. As a result, the surface of the plate member 25 facing the sheet 11 and the surface of the sheet holding mechanism 31 facing the sheet 11 are parallel to each other. By pushing out the sheet 11 with the plate member 25, the sheet 11 is brought into contact with the sheet holding mechanism 31 and is held by the sheet holding mechanism 31. The sheet 11 is then held by the second clamp 23b. The sheet 11 is cut by the sheet cutting means 21 and adjusted to a predetermined dimension. As a result, the sheet 11 is delivered from the sheet supply device 20 to the sheet holding mechanism 31 without bending.

The sensor 27 detects the sheet 11 in the sheet supply device 20. Based on this detection, the sheet 11 can be placed in the sheet supply device 20 at an appropriate position and orientation. The sensor 27 may also detect the length of the sheet 11 sent upward in the vertical direction. In the example shown in FIG. 2, the sensor 27 is arranged on the same side as the plate member 25, that is, the opposite side to the side to which the sheet holding mechanism 31 approaches. In other words, the sensor 27 is arranged on the first side s1 in the first direction d1 of the first clamp 23a and the second clamp 23b. The sensor 27 detects the position, orientation, etc. of the sheet 11 through a hole or the like (not shown) provided in the plate member 25. However, the sensor 27 is not limited to the example shown in the figure, and may be arranged on the same side as the side to which the sheet holding mechanism 31 approaches in order to hold the sheet 11 in the sheet supply device 20. Such a sensor 27 is, for example, an imaging device such as a camera. As an example, although not shown, an alignment mark such as a cross-shaped symbol is provided on the sheet 11. In this case, the sensor can easily detect the position and orientation of sheet 11 based on the alignment marks provided on sheet 11.

In FIG. 3, the head 30 and the drive unit 40 are shown in schematic form. The head 30 holds the sheet 11. The drive unit 40 drives the head 30 to transport the sheet 11 to the mold 51 of the molding machine 50. In the example shown in FIG. 3, the drive unit 40 drives the sheet holding mechanism 31 to transport the sheet 11 held by the sheet holding mechanism 31 from the sheet supply device 20 to the mold 51. In the example shown in FIG. 3, the head 30 holds the molded product 13 to be molded in the molding machine 50. The drive unit 40 drives the head 30 to transport the molded product 13 held by the head 30 from the molding machine 50 to the trimming device 80. The drive unit 40 is, for example, an articulated robot.

As shown in FIG. 3, the head 30 has a sheet holding mechanism 31 and a heater 35. In the example shown in FIG. 3, the head 30 further has a molded product holding mechanism 32 and a molded product heater 36. The drive device 40 has a connection portion 41 and a rotation portion 43.

Figure 4 shows an example of a perspective view of the sheet holding mechanism 31 and heater 35. The sheet holding mechanism 31 is a part that holds the sheet 11 in the molding system 1 that molds the sheet 11. The sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20, transports the sheet 11 to the mold 51 of the molding machine 50, and delivers the sheet 11 to the mold 51.

As shown in FIG. 4, the sheet holding mechanism 31 according to the first embodiment has a frame 33 with an opening 33a and a frame suction hole 31a provided in the frame 33. The sheet holding mechanism 31 according to the first embodiment further includes a frame expansion member 34.

The frame portion 33 has a frame-like shape. In the example shown in FIG. 4, the frame portion 33 has a rectangular frame-like shape. That is, the frame portion 33 has a pair of first portions 33d extending in one direction (the up-down direction in FIG. 4) and a pair of second portions 33e extending in a direction perpendicular to the direction in which the pair of first portions 33d extend (the left-right direction in FIG. 4) and connecting the pair of first portions 33d.

In the example shown in FIG. 4, the frame portion 33 has a frame first surface 31b which is the surface facing the sheet 11 held by the sheet holding mechanism 31. The frame portion 33 also has a frame second surface 31c located on the opposite side to the frame first surface 31b. The sheet holding mechanism 31 holds the sheet 11 on the frame first surface 31b side of the frame portion 33.

The sheet holding mechanism 31 has a shape that corresponds to the mold 51, in other words, a shape that is complementary to the mold 51, so that the sheet 11 can be appropriately transferred to the mold 51. The sheet holding mechanism 31 has a shape that is particularly complementary to the portion that forms the outer peripheral region 51c of the first surface 51a of the mold body 511 of the mold 51, which will be described later. Also, as described above, the frame first surface 31b is a plane that is parallel to the surface of the sheet 11 clamped by the first clamp 23a.

As shown in FIG. 4, the sheet holding mechanism 31 has a frame suction hole 31a provided in the frame 33. In the example shown in FIG. 4, the sheet holding mechanism 31 has a plurality of frame suction holes 31a. The plurality of frame suction holes 31a are aligned along the direction in which the pair of first parts 33d and the pair of second parts 33e extend. The frame suction holes 31a are open in the frame first surface 31b of the frame 33 facing the sheet 11. The sheet holding mechanism 31 holds the sheet 11 by vacuum suction of the frame suction holes 31a. That is, the sheet 11 is held by sucking air in the frame suction holes 31a from the frame second surface 31c side. The frame suction holes 31a have a circular cross section with a diameter of, for example, 2 mm to 10 mm. This makes the frame suction holes 31a sufficiently large, and the sheet 11 can be appropriately suctioned and held. In addition, because the frame suction holes 31a are not too large, the possibility of problems such as foreign objects being sucked into the frame suction holes 31a is reduced.

Figure 5 is an enlarged cross-sectional view of the periphery of one frame suction hole 31a along the V-V line in Figure 4. In particular, Figure 5 shows a cross section passing through the axis L1 of the frame suction hole 31a, which is a virtual straight line passing through the center of one frame suction hole 31a. As shown in Figure 5, the sheet holding mechanism 31 includes a frame expansion member 34 having a first end 34b where the suction opening 34a is provided and a second end 34c located on the opposite side to the first end 34b. In Figure 5, the frame expansion member 34 is in an unpressed state. At this time, the second end 34c is accommodated in the frame suction hole 31a. Also, the first end 34b protrudes from the frame suction hole 31a. In other words, the first end 34b is located on the opposite side of the frame first surface 31b to the side where the frame second surface 31c is located.

In the first embodiment, the sheet holding mechanism 31 includes a plurality of frame extension members 34. The number of frame extension members 34 is the same as the number of frame suction holes 31a. The second end 34c of each of the plurality of frame extension members 34 is accommodated in each of the frame suction holes 31a. The first end 34b of each of the plurality of frame extension members 34 protrudes from each of the frame suction holes 31a.

In the example shown in FIG. 5, the frame expandable member 34 has a cylindrical shape extending in the extension direction of the frame suction hole 31a. The frame expandable member 34 has a through hole 34d extending from the first end 34b to the second end 34c. The through hole 34d forms the suction opening 34a at the first end 34b. The minimum width w1 of the through hole 34d in the direction perpendicular to the axis L1 is, for example, 1 mm or more and 5 mm or less.

The sheet holding mechanism 31 of the first embodiment holds the sheet 11 by vacuum suction of the suction opening 34a. In the example shown in FIG. 5, the outer wall 34e of the frame expansion and contraction member 34 and the inner wall 31d of the frame suction hole 31a are sealed at the second end 34c side of the frame expansion and contraction member 34. The sheet holding mechanism 31 further includes a sealing member 31f arranged between the outer wall 34e of the frame expansion and contraction member 34 and the inner wall 31d of the frame suction hole 31a. The sealing member 31f seals the outer wall 34e of the frame expansion and contraction member 34 and the inner wall 31d of the frame suction hole 31a. As a result, the air in the frame suction hole 31a is sucked from the frame second surface 31c side, and the air in the through hole 34d is sucked, and the sheet 11 can be held by vacuum suction of the suction opening 34a. Because the suction opening 34a can be vacuum-sucked by sucking the air in the frame suction hole 31a, holding the sheet 11 by vacuum suction of the frame suction hole 31a can be said to include holding the sheet 11 by vacuum suction of the suction opening 34a. In the example shown in FIG. 5, the first end 34b protrudes from the frame suction hole 31a. This allows the sheet holding mechanism 31 to hold the sheet 11 so that the sheet 11 is separated from the frame first surface 31b.

When pressed, the frame expandable member 34 contracts so that the first end 34b is accommodated in the frame suction hole 31a. When the first end 34b is pressed toward the second end 34c, the frame expandable member 34 contracts so that the distance between the first end 34b and the second end 34c becomes smaller. When pressed by the pressing force received by the frame expandable member 34 in the process of adhering the sheet 11 held by the sheet holding mechanism 31 to the area surrounding the molding area 51b of the mold 51, the frame expandable member 34 is easily deformed to such an extent that the first end 34b contracts so that it is accommodated in the frame suction hole 31a. When released from the pressure, the frame expandable member 34 expands so that the first end 34b returns to the position where it protrudes from the frame suction hole 31a.

The means for ensuring the ease of deformation of the frame expansion and contraction member 34 is not particularly limited as long as the sheet 11 can be held by vacuum suction of the suction opening 34a. The frame expansion and contraction member 34 of the first embodiment has a bellows-like shape in a cross section passing through the axis L1 of the frame suction hole 31a. That is, the frame expansion and contraction member 34 has a shape in which mountain folds and valley folds are alternately repeated in a cross section passing through the axis L1 of the frame suction hole 31a. Each of the mountain folds and valley folds goes around the axis L1. In this case, the frame expansion and contraction member 34 expands and contracts as the folding angles of the mountain folds and valley folds change. For example, when the first end 34b is pressed toward the second end 34c, the folding angles of the mountain folds and valley folds change, and the frame expansion and contraction member 34 shrinks so that the distance between the first end 34b and the second end 34c becomes smaller. The frame elastic member 34 may be made elastic by selecting a material that is easily elastically deformed as the material for the frame elastic member 34, for example, a material that is more easily elastically deformed than the material for the frame 33. In this case, the material for the frame elastic member 34 is, for example, rubber.

The dashed line in FIG. 4 shows an example of the contour of the sheet 11 when the sheet holding mechanism 31 holds the sheet 11. FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. 4, along with the sheet 11 held by the sheet holding mechanism 31. In the example shown in FIGS. 4 and 6, the sheet 11 faces the opening 33a and also faces the portion of the frame 33 where the frame suction holes 31a are provided. Therefore, the sheet 11 is held by the sheet holding mechanism 31 by vacuum suction of the frame suction holes 31a. In the first embodiment, the sheet 11 is held by the sheet holding mechanism 31 by vacuum suction of the suction openings 34a.

The effect of the sheet holding mechanism 31 having a frame expansion and contraction member 34 and the sheet 11 being held by the sheet holding mechanism 31 through vacuum suction of the suction opening 34a will be described. When the sheet holding mechanism 31 is holding the sheet 11, the sheet 11 may be deformed. For example, when the sheet holding mechanism 31 is holding the sheet 11, the sheet 11 may be deformed by sagging due to the weight of the sheet 11 itself. Also, the sheet 11 may be deformed by being heated by the heater 35 as described later. More specifically, the sheet 11 may be deformed by being heated by the heater 35 and softening, becoming more likely to sag. Also, the sheet 11 may be stretched during manufacturing, and in this case, stress is generated inside the sheet 11. In this case, when the sheet 11 is heated by the heater 35, the stress inside the sheet 11 is reduced and the sheet 11 shrinks. That is, when the sheet 11 is heated by the heater 35, the sheet 11 may be deformed so that it shrinks due to stress relaxation. Here, in the first embodiment, the sheet holding mechanism 31 holds the sheet 11 by vacuum suction of the suction opening 34a of the frame expansion member 34. As a result, when the sheet 11 is deformed, the frame expansion member 34 deforms, and the suction opening 34a can be moved to follow the deformation of the sheet 11. This makes it possible to prevent the sheet 11 from falling off the sheet holding mechanism 31 due to the sheet 11 being misaligned with the suction opening 34a. In this way, according to the first embodiment, it is possible to prevent the sheet 11 from falling off the sheet holding mechanism 31, which is a member that holds the sheet 11.

The sheet holding mechanism 31 may have a circuit that switches on and off the vacuum suction of the sheet 11 by the frame suction holes 31a. This allows the vacuum suction of the sheet 11 by the suction openings 34a to be switched on and off.

The heater 35 is disposed on the second frame surface 31c side of the sheet holding mechanism 31. The heater 35 is provided overlapping the sheet holding mechanism 31. In the illustrated example, the heater 35 has a plate shape with a surface parallel to the second frame surface 31c of the sheet holding mechanism 31. However, the shape of the heater 35 is not limited to the illustrated example. The head 30 may also have multiple heaters 35. In the example shown in FIG. 4, the second frame surface 31c of the sheet holding mechanism 31 and the surface of the heater 35 are in contact with each other, and the positional relationship between the sheet holding mechanism 31 and the heater 35 is fixed.

The heater 35 heats the sheet 11 held by the sheet holding mechanism 31. The heater 35 can generate heat in the entire portion facing the opening 33a. The heater 35 heats the sheet 11, for example, to 100°C or higher and 160°C or lower. In particular, the heater 35 heats the sheet 11 for at least a period from when the sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20 until when the sheet 11 is transferred to the mold 51. The heater 35 may have a size equal to or larger than the size of the sheet 11 held by the sheet holding mechanism 31 so that the entire sheet 11 held by the sheet holding mechanism 31 can be heated uniformly. In addition, when there is a portion where the distance between the heater 35 and the sheet 11 held by the sheet holding mechanism 31 is relatively large, the entire sheet 11 can be heated uniformly by increasing the temperature of the heater 35 in that portion. In addition, by covering the space between the sheet 11 held by the sheet holding mechanism 31 and the heater 35 from the side with an inorganic plate or the like, the entire sheet 11 can be heated more uniformly.

7 shows a perspective view of the molded product holding mechanism 32 and the molded product heater 36. The molded product holding mechanism 32 receives the molded product 13 from the opposing die 52 of the molding machine 50 and transports the molded product 13 to the trimming device 80. In the example shown in FIG. 7, the molded product holding mechanism 32 has multiple suction pads 32a. The molded product holding mechanism 32 can suck air from the suction pads 32a to suction and hold the molded product 13. In the molded product holding mechanism 32, the multiple suction pads 32a are arranged along a shape corresponding to the opposing die 52, in other words, a shape complementary to the opposing die 52, so that the molded product 13 can be appropriately received from the opposing die 52, and the multiple suction pads 32a are arranged at positions where they can be pressed and vacuum-adsorbed to the molded part 12. However, the molded product holding mechanism 32 is not limited to the example shown in the figure, and may hold the molded product 13 in any manner.

The molded product heater 36 is provided on top of the molded product holding mechanism 32. In the illustrated example, the molded product heater 36 is rectangular. The molded product heater 36 heats the molded product 13 held by the molded product holding mechanism 32. The molded product heater 36 heats the molded product 13, for example, to a temperature of 40°C or higher and 70°C or lower. In particular, the molded product heater 36 heats the molded product 13 for at least a period from when the molded product holding mechanism 32 receives the molded product 13 from the molding machine 50 until when the molded product 13 is transported to the trimming device 80. It is preferable that the molded product heater 36 has dimensions equal to or larger than the dimensions of the molded product 13 held by the molded product holding mechanism 32 so that the entire molded product 13 held by the molded product holding mechanism 32 can be uniformly heated.

The driving device 40 is connected to the head 30 at the connection portion 41, and drives the connected head 30. The driving device 40 drives the sheet holding mechanism 31, which is a part of the head 30, by driving the head 30. The driving device 40 drives the sheet holding mechanism 31 so as to bring the sheet 11 held by the sheet holding mechanism 31 into close contact with the area surrounding the molding area 51b of the mold 51. This allows the sheet holding mechanism 31 to bring the held sheet 11 into close contact with the mold 51. The driving device 40 drives the head 30, for example, by rotating the rotating portion 43. The driving device 40 may have multiple rotating portions 43. Such a driving device 40 is, for example, a so-called multi-axis robot arm. The driving device 40 is removably connected to the head 30. Therefore, the head 30 connected to the driving device 40 is replaceable.

The drive unit 40 drives the head 30 so that the sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20. The drive unit 40 also drives the head 30 so that the sheet 11 is transferred from the sheet holding mechanism 31 to the mold 51 of the molding machine 50. The drive unit 40 also drives the head 30 so that the molded product 13 is received from the opposing mold 52 by the molded product holding mechanism 32. The drive unit 40 also drives the head 30 so that the molded product 13 is transported from the molded product holding mechanism 32 to the trimming device 80. In the example shown in FIG. 8, the sheet holding mechanism 31 transfers the sheet 11 to the mold 51 of the molding machine 50, and the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52. At this time, the drive unit 40 drives the head 30 so that at least a part of the head 30 is disposed between the mold 51 and the opposing mold 52 in the first direction d1 with the opposing mold 52 of the molding machine 50 separated from the mold 51. In particular, the drive device 40 drives the head 30 so as to dispose the sheet holding mechanism 31 and the molded product holding mechanism 32 between the mold 51 and the opposing mold 52 in the first direction d1. In the example shown in FIG. 8, the entire head 30 is disposed between the mold 51 and the opposing mold 52 in the first direction d1. The drive device 40 drives the sheet holding mechanism 31 to the first side s1 in the first direction d1. As a result, the sheet 11 is transferred from the sheet holding mechanism 31 to the mold 51. In addition, the sheet 11 held by the sheet holding mechanism 31 is in close contact with the mold 51. In addition, the drive device 40 drives the molded product holding mechanism 32 to the second side s2 in the first direction d1. As a result, the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52. At this time, the drive device 40 may drive the entire head 30 to the first side s1 in the first direction d1 or to the second side s2 in the first direction d1, or may drive only the sheet holding mechanism 31 in the head 30 to the first side s1 in the first direction d1 and only the molded product holding mechanism 32 to the second side s2 in the first direction d1.

The molding machine 50 includes the mold 51 as described above. In the example shown in FIG. 8, the molding machine 50 further includes an opposing mold 52. As shown in FIG. 8, the mold 51 of the molding machine 50 receives the sheet 11 held on the first side s1 of the sheet holding mechanism 31 in the first direction d1. The opposing mold 52 of the molding machine 50 also delivers the molded product 13 to the second side s2 of the molded product holding mechanism 32 in the first direction d1. More specifically, after the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52, the sheet holding mechanism 31 delivers the sheet 11 to the mold 51. Alternatively, the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52, and at the same time, the sheet holding mechanism 31 delivers the sheet 11 to the mold 51.

The molding machine 50 molds the sheet 11 received from the sheet holding mechanism 31 by vacuum molding using a mold 51. After vacuum molding the sheet 11, the molding machine 50 forms a storage space 55 in which a portion of the sheet 11 is housed, and injection molds resin into the storage space 55. The storage space 55 is defined by the surface of the mold 51 and the surface of the opposing mold 52 by bringing the mold 51 and the opposing mold 52 close to each other. In particular, the molding machine 50 injection molds resin into the storage space 55 with the vacuum-formed portion of the sheet 11 housed in the storage space 55. This allows the sheet 11 to be provided with a molded part 12 by injection molding the resin, and a molded product 13, which will be described later, to be molded.

The mold 51 will now be described. The mold 51 is provided in the molding system 1. As described above, the molding system 1 includes the molding machine 50, and the molding machine 50 includes the mold 51, thereby providing the mold 51 in the molding system 1. The mold 51 is used for vacuum forming the sheet 11. In the example shown in FIG. 1, the mold 51 is located between the sheet supply device 20 and the opposing mold 52 in the first direction d1. In other words, the sheet supply device 20, the mold 51, and the opposing mold 52 are arranged in this order in the first direction d1.

As shown in FIG. 8, the mold 51 has a mold body 511. The mold body 511 has a first surface 51a. The first surface 51a is the surface that faces the sheet 11 during vacuum forming of the sheet 11. The mold body 511 also has a second surface 51g located on the opposite side to the first surface 51a. FIG. 9 is a plan view showing the mold 51 as viewed from the first surface 51a side. FIG. 10 is a cross-sectional view showing a cross section along line X-X in FIG. 9.

The details of the first surface 51a will be described. As shown in Figures 9 and 10, the first surface 51a has a forming region 51b in which the sheet 11 is vacuum-formed, and an outer peripheral region 51c that surrounds the forming region 51b. The forming region 51b has a shape that corresponds to the shape of the sheet 11 to be formed by vacuum forming in the forming region 51b. In the example shown in Figure 10, the forming region 51b has a curved surface.

As described above, the molding machine 50 forms a storage space 55 in which a portion of the sheet 11 is stored, and then injection molds resin into the storage space 55. Here, a portion of the storage space 55 is partitioned by a molding region 51b. In the example shown in Figures 9 and 10, the first surface 51a is flat in the outer peripheral region 51c.

The area of the molding area 51b that defines a portion of the storage space 55 is referred to as the storage space area 51d. In the example shown in FIG. 9, the storage space area 51d is located in the center of the molding area 51b. In the example shown in FIG. 9, the molding area 51b has the storage space area 51d and a suction hole area 51e that surrounds the storage space area 51d. The suction hole area 51e is an area in which the suction holes 516 described below are provided. In the example shown in FIG. 9, the suction hole area 51e is located on the periphery of the approximately rectangular molding area 51b.

In the example shown in FIG. 10, the suction hole region 51e protrudes further from the storage space region 51d toward the side where the sheet 11 is located during vacuum forming. In the example shown in FIG. 10, a recess is formed in the storage space region 51d that is recessed toward the second surface 51g of the mold body 511 relative to the suction hole region 51e. For this reason, the suction hole region 51e is located closer to the first surface 51a of the mold body 511 than the storage space region 51d.

In the example shown in Figures 9 and 10, the storage space region 51d has a shape corresponding to the shape of the sheet 11 included in the molded product 13 described below. In the example shown in Figure 18 described below, the surface of the sheet 11 of the molded product 13 that comes into contact with the suction hole region 51e is a flat surface. Also, in the sheet 11 of the molded product 13 shown in Figure 18, the surface that comes into contact with the suction hole region 51e and the surface that comes into contact with the outer peripheral region 51c are parallel. In this case, as shown in Figure 10, the suction hole region 51e is a flat surface parallel to the outer peripheral region 51c.

In the example shown in FIG. 9, the first surface 51a has a rectangular shape when observed from a direction perpendicular to the outer peripheral region 51c. The side of the first surface 51a having a rectangular shape shown in FIG. 9 that is located at the top of FIG. 9 is referred to as the upper side 514. The side that is located at the bottom of FIG. 9 and faces the upper side 514 is referred to as the lower side 512. The pair of sides that extend in the vertical direction of FIG. 9 between the upper side 514 and the lower side 512 are referred to as the side sides 513. In the first embodiment, the mold 51 is incorporated into the molding system 1 with the upper side 514 located at the top and the lower side 512 located at the bottom.

The mold 51 further includes suction holes 515 that are provided in the mold body 511 and open in the outer peripheral region 51c. The mold 51 holds the sheet 11 by vacuum suction of the suction holes 515. In the example shown in FIG. 9, the mold 51 includes a plurality of suction holes 515. The plurality of suction holes 515 are aligned along the upper edge 514, the lower edge 512, and the side edge 513 of the mold 51.

The suction holes 515 have a circular cross section with a diameter of, for example, 1.5 mm or more and 10 mm or less. More preferably, the suction holes 515 have a circular cross section with a diameter of 1.5 mm or more and 5 mm or less. This makes the suction holes 515 sufficiently large so that the sheet 11 can be properly suctioned and held by the mold 51. In addition, since the suction holes 515 are not too large, the possibility of problems such as foreign matter being sucked into the suction holes 515 is reduced. Note that, from the viewpoint of preventing the overall size of the mold 51 from becoming large, which would require the size of the sheet 11 supplied to the mold 51 to be increased in order to be held by the mold 51, it is preferable that the size of the suction holes 515 is small.

The mold 51 further includes suction holes 516 that open in the molding region 51b. The suction holes 516 vacuum-suck the sheet 11 held in the mold 51 to vacuum-form it. The suction holes 516 are provided in the mold body 511. The suction holes 516 are provided in the molding region 51b of the first surface 51a of the mold body 511. In particular, the suction holes 516 are provided in the suction hole region 51e. In the example shown in FIG. 9, the mold 51 includes multiple suction holes 516.

The shape, number, and arrangement of the suction holes 516 are not particularly limited as long as the sheet 11 can be vacuum-formed by the vacuum suction of the suction holes 516. The suction holes 516 have a circular cross section with a diameter of, for example, 1.5 mm to 10 mm. This makes the suction holes 516 sufficiently large, and the sheet 11 can be vacuum-suctioned with a suction force sufficient to vacuum-form the sheet 11. In addition, because the suction holes 516 are not too large, the possibility of problems such as foreign matter being sucked into the suction holes 516 is reduced. In the example shown in FIG. 9, the multiple suction holes 516 are aligned along the boundary 51f between the storage space area 51d and the suction hole area 51e.

The operation of the sheet holding mechanism 31 and the mold 51 when the sheet 11 is held by the sheet holding mechanism 31 and vacuum-formed is specifically described with reference to Figs. 11 to 13. Fig. 11 shows the state in which the sheet holding mechanism 31 is driven by the drive device 40 to bring the sheet 11 held by the sheet holding mechanism 31 into close contact with the mold 51. The arrow with the symbol A1 in Fig. 11 indicates the direction in which the sheet holding mechanism 31 is driven. Fig. 12 is a cross-sectional view showing the cross section of the sheet holding mechanism 31, the sheet 11, and the mold 51 when the sheet holding mechanism 31 is driven to bring the sheet 11 into close contact with the mold 51 as shown in Fig. 11. After fixing the mold 51, the sheet holding mechanism 31 is moved to the first side s1 in the first direction d1 to approach the mold 51, and the sheet 11 is brought into close contact with the mold 51 as shown in Fig. 12. More specifically, the sheet holding mechanism 31 holding the sheet 11 is brought close to the first surface 51a of the mold body 511 with the frame first surface 31b facing the first surface 51a of the mold body 511, so that the sheet 11 is in close contact with the area surrounding the molding area 51b of the mold 51, facing the first surface 51a of the mold body 511.

Here, in the first embodiment, the frame expansion and contraction member 34 is pressed so that the first end 34b is accommodated in the frame suction hole 31a. As a result, in a state in which the sheet 11 is in close contact with the mold 51, the frame first surface 31b of the frame 33 of the sheet holding mechanism 31 can be brought into contact with the sheet 11 held by vacuum suction of the suction opening 34a. In the example shown in FIG. 12, the frame first surface 31b of the frame 33 of the sheet holding mechanism 31 and the outer peripheral region 51c of the first surface 51a of the mold body 511 face each other. Then, by moving the sheet holding mechanism 31 to the first side s1 in the first direction d1 to approach the mold 51, the frame expansion and contraction member 34 is pressed between the frame 33 and the mold 51, although this is not shown in FIG. 12. For this reason, the frame first surface 31b of the frame 33 of the sheet holding mechanism 31 is in contact with the sheet 11. As a result, the sheet 11 can be pressed by the first frame surface 31b of the frame portion 33 of the sheet holding mechanism 31, and can be firmly attached to the outer peripheral region 51c of the first surface 51a. In other words, the sheet 11 can be sandwiched between the first frame surface 31b of the frame portion 33 and the outer peripheral region 51c of the first surface 51a, and can be firmly attached to the outer peripheral region 51c of the first surface 51a. In this way, according to the first embodiment, the sheet 11 can be firmly attached to the region surrounding the molding region 51b of the mold 51. Note that, in a state in which the sheet 11 is in close contact with the region surrounding the molding region 51b of the mold 51, and before the vacuum molding of the sheet 11 described below is performed, the sheet 11 does not contact the molding region 51b.

With the sheet 11 in close contact with the area surrounding the molding area 51b of the mold 51, the space between the molding area 51b of the first surface 51a and the sheet 11 is suctioned by the suction holes 516, whereby the sheet 11 is vacuum-formed as shown in FIG. 14. In the example shown in FIG. 14, a portion of the sheet 11 is formed that is bent along the molding area 51b by the vacuum forming.

The opposing die 52, together with the molding region 51b of the die 51, forms an accommodation space 55 in which a portion of the sheet 11 is accommodated and resin is injection molded. The opposing die 52 moves relative to the die 51 in the first direction d1 to form the accommodation space 55 together with the die 51. In the example shown in FIG. 1, the opposing die 52 is positioned between the die 51 and the trimming device 80 in the first direction d1. In other words, the die 51, the opposing die 52, and the trimming device 80 are arranged in this order along the first direction d1.

14 shows an example of the manner in which the opposing die 52 is moved relative to the die 51. The arrow with the symbol A2 in FIG. 14 indicates the direction in which the opposing die 52 moves. In the example shown in FIG. 14, the die 51 is fixed, and the opposing die 52 moves to the first side s1 in the first direction d1. Although not shown, the opposing die 52 may be fixed, and the die 51 may move to the second side s2 in the first direction d1. Alternatively, the die 51 and the opposing die 52 may move in the first direction d1 to bring the die 51 and the opposing die 52 closer to each other. FIG. 15 shows a state in which the opposing die 52 approaches the die 51 to form a storage space 55. After the sheet 11 is vacuum-formed using the die 51, the opposing die 52 is moved relative to the die 51 without moving the sheet 11 relative to the die 51, so that the vacuum-formed portion of the sheet 11 is stored in the storage space 55, as shown in FIG. 15.

The opposing mold 52 has a shape that can form an appropriate storage space 55 between the mold 51. In the example shown in FIG. 15, the surface of the opposing mold 52 has an opposing storage space area 52d, an opposing suction hole area 52e, and an opposing outer peripheral area 52c. The opposing storage space area 52d faces the storage space area 51d of the molding area 51b of the mold 51. In the example shown in the figure, the opposing mold 52 is bent so as to be convex in the opposing storage space area 52d. In the example shown in FIG. 15, the storage space 55 is defined by the storage space area 51d of the molding area 51b of the mold 51 and the opposing storage space area 52d of the opposing mold 52. The opposing suction hole area 52e faces the suction hole area 51e of the molding area 51b of the mold 51. In the example shown in FIG. 15, the opposing suction hole area 52e has a shape complementary to the suction hole area 51e. In the example shown in FIG. 15, the opposing suction hole area 52e is a plane. When the storage space 55 is formed, both the suction hole region 51e and the opposing suction hole region 52e are in close contact with the sheet 11. In other words, the sheet 11 is sandwiched between the suction hole region 51e and the opposing suction hole region 52e. The opposing outer peripheral region 52c faces the outer peripheral region 51c of the mold 51. The opposing outer peripheral region 52c has a shape complementary to the outer peripheral region 51c. In the example shown in FIG. 15, the opposing outer peripheral region 52c is flat. When the storage space 55 is formed, both the outer peripheral region 51c and the opposing outer peripheral region 52c are in close contact with the sheet 11. In other words, the sheet 11 is sandwiched between the outer peripheral region 51c and the opposing outer peripheral region 52c.

As described above, the storage space area 51d has a shape corresponding to the sheet 11 included in the molded product 13 described later. The opposing storage space area 52d has a shape corresponding to the shape of the molded part 12 included in the molded product 13 described later. As a result, the storage space 55 partitioned by the storage space area 51d and the opposing storage space area 52d has a shape corresponding to the shape of the molded product 13. As described above, after the vacuum-formed part of the sheet 11 is stored in the storage space 55, resin is injected into the storage space 55. As a result, resin injection molding is performed in the part of the storage space 55 where the sheet 11 is not placed. Therefore, the molded part 12 having a shape corresponding to the shape of the opposing storage space area 52d is provided in the vacuum-formed part of the sheet 11. The resin injected into the storage space 55 is, for example, a thermoplastic resin such as ABS, PC-ABS, acrylic, polycarbonate, polyethylene, or polypropylene heated to a high temperature. In this case, the thermoplastic resin is injected and then cooled, so that the molded part 12 is provided in the sheet 11. As a result of the above, a molded product 13 is formed that includes the sheet 11 and the molded part 12 and has a shape that corresponds to the shape of the storage space 55, as shown in FIG. 16.

After the molded product 13 is molded, the opposing die 52 moves to the second side s2 in the first direction d1 and separates from the die 51, as shown in FIG. 16. The arrow with the symbol A3 in FIG. 16 indicates the direction in which the opposing die 52 moves. The molded product 13 separates from the die 51 together with the opposing die 52. For example, because a part of the molded part 12 is engaged with the opposing die 52, the molded product 13 moves to the second side s2 in the first direction d1 together with the opposing die 52.

The opposing die 52 delivers the molded product 13 molded by the molding machine 50 to the molded product holding mechanism 32 of the head 30. The arrow with the symbol A4 in FIG. 17 indicates the direction in which the molded product holding mechanism 32 moves. In the example shown in FIG. 17, the molded product holding mechanism 32 arranged between the die 51 and the opposing die 52 moves relative to the opposing die 52 on which the molded product 13 is arranged. That is, it moves to the second side s2 in the first direction d1. As a result, the molded product holding mechanism 32 approaches the opposing die 52 and receives the molded product 13 from the opposing die 52. Then, as shown in FIG. 18, the molded product holding mechanism 32 moves to the first side s1 in the first direction d1 and moves away from the opposing die 52. The arrow with the symbol A5 in FIG. 18 indicates the direction in which the molded product holding mechanism 32 moves.

The trimming device 80 is a device that trims the molded product 13 molded by the molding machine 50. As shown in FIG. 18, the molded product 13 held by the molded product holding mechanism 32 of the head 30 is transported to the trimming device 80 by the drive device 40 driving the head 30. The trimming device 80 receives the molded product 13 from the molded product holding mechanism 32 and trims it. The trimming device 80 removes unnecessary parts from the molded product 13 by trimming. As a result, a molded product 16 is manufactured as shown in FIG. 19. In the example shown in FIG. 19, the parts located between the outer peripheral region 51c and the opposing outer peripheral region 52c of the sheet 11 in FIG. 15 and the parts located between the suction hole region 51e and the opposing suction hole region 52e of the sheet 11 are removed by trimming. In other words, the parts other than the parts located between the storage space region 51d and the opposing storage space region 52d of the sheet 11 in FIG. 15 are removed by trimming.

The form of the trimming device 80 is not particularly limited as long as it can receive the molded product 13 being transported and trim it to a desired shape. The trimming device 80 may have, for example, a support table on which the molded product 13 is placed, and a cutting means for cutting the molded product 13 placed on the support table. In this case, the support table receives the molded product 13 from the molded product holding mechanism 32, and the molded product 13 is placed on the support table. The cutting means is, for example, a blade made of metal. The trimming device 80 can cut the molded product 13 by moving the cutting means while the cutting means is in contact with the molded product 13. This trims the molded product 13. The movement of the cutting means may be controlled by a control device or the like so that the molded product 13 is trimmed to a desired shape. By trimming the molded product 13 to a desired shape, a molded product 16 as shown in FIG. 19 is manufactured. Although not shown, multiple molded products 16 may be manufactured from one molded product 13.

Next, an example of a method for manufacturing a molded product 16 using the molding system 1 of the first embodiment described above will be described. The method for manufacturing a molded product 16 includes, in this order, a step of bringing the sheet 11 held by the sheet holding mechanism 31 into close contact with a molding region 51b of a mold 51, a step of vacuum molding the sheet 11 using the mold 51, and a step of injection molding a resin. The method for manufacturing a molded product 16 of the first embodiment further includes a step of supplying the sheet 11 to the sheet holding mechanism 31 before the sheet 11 comes into close contact with the mold 51 in the step of bringing the sheet 11 held by the sheet holding mechanism 31 into close contact with the mold 51.
The manufacturing method of molded product 16 of the first embodiment further includes a step of holding sheet 11 in mold 51 after the step of closely contacting sheet 11 held by sheet holding mechanism 31 with mold 51. The manufacturing method of molded product 16 of the first embodiment further includes a step of trimming molded article 13 molded by molding machine 50 after the step of injection molding resin.

In the process of supplying the sheet 11 to the sheet holding mechanism 31, the sheet 11 is supplied to the sheet holding mechanism 31 so that the sheet 11 is held by the sheet holding mechanism 31. In the process of supplying the sheet 11 to the sheet holding mechanism 31, first, as shown in FIG. 2, the sheet 11 wound to form a roll 10 is clamped by the first clamp 23a. As an example, the sheet 11 is sent upward in the vertical direction while an alignment mark (not shown) is detected by the sensor 27. By detecting the alignment mark by the sensor 27, the sheet 11 can be supplied from the sheet supply device 20 to the sheet holding mechanism 31 at the desired position, in the desired orientation, and with the desired sent dimension (length). Next, the sheet 11 is held by the sheet holding mechanism 31. After that, the second clamp 23b clamps the lower part of the sheet 11. The sheet 11 is cut vertically below and above the second clamp 23b in a direction non-parallel to the vertical direction, for example, horizontally, by the sheet cutting means 21, to form a sheet 11 of a predetermined size. Finally, the first clamp 23a releases the sheet 11. In this manner, the sheet 11 of a predetermined size is supplied from the sheet supply device 20 to the sheet holding mechanism 31. The sheet holding mechanism 31 holds the sheet 11 by vacuum suction of the frame suction holes 31a. In the method for manufacturing a molded product 16 using the molding system 1 of the first embodiment, the sheet holding mechanism 31 holds the sheet 11 by vacuum suction of the suction openings 34a.

After the process of supplying the sheet 11 to the sheet holding mechanism 31, the sheet 11 held by the sheet holding mechanism 31 is transported to the mold 51. Specifically, the head 30 is driven by the drive device 40 to transport the sheet 11 held by the sheet holding mechanism 31 of the head 30 to the mold 51 of the molding machine 50. The sheet 11 is heated by the heater 35 of the head 30 for at least a period from when it is held by the sheet holding mechanism 31 to when it is transferred to the mold 51. Since it is preferable that the heater 35 heats the sheet 11 for a long period, it is preferable that the sheet 11 is heated by the heater 35 for the entire period from when it is held by the sheet holding mechanism 31 to when it is transferred to the molding machine 50. The temperature of the heater 35 is determined according to the time that the sheet holding mechanism 31 holds the sheet 11 so as to heat the sheet 11 appropriately. For example, the longer the time that the sheet holding mechanism 31 holds the sheet 11, the lower the temperature of the heater 35. By heating the sheet 11 appropriately, the entire sheet softens without causing problems such as blisters (air bubbles).

In the process of adhering the sheet 11 to the mold 51, the sheet 11 held by the sheet holding mechanism 31 is adhered to the area surrounding the molding area 51b of the mold 51. As an example, the sheet 11 held by the sheet holding mechanism 31 is adhered to the outer peripheral area 51c of the first surface 51a. In the process of adhering the sheet 11 to the mold 51, first, the head 30 holding the softened sheet 11 in the sheet holding mechanism 31 is driven by the drive device 40 to be placed between the mold 51 and the opposing mold 52 of the molding machine 50 as shown in FIG. 8. In the example shown in FIG. 8, the sheet holding mechanism 31 holding the sheet 11 faces the mold 51. Also, the molded product holding mechanism 32 of the head 30 that receives the molded product 13 from the molding machine 50 faces the opposing mold 52. In other words, as shown in FIG. 8, the sheet holding mechanism 31 faces the first side s1 of the first direction d1. Also, the molded product holding mechanism 32 faces the second side s2 of the first direction d1. Thereafter, the head 30 is brought close to the mold 51 by the driving device 40, as shown in FIG. 11. As a result, as shown in FIG. 12, the sheet 11 held by the sheet holding mechanism 31 can be pressed against the first surface 51a of the mold body 511 by the sheet holding mechanism 31, so that the sheet 11 is brought into close contact with the mold 51.

Here, in the first embodiment, the frame expandable member 34 is compressed so that the first end 34b is accommodated in the frame suction hole 31a by being pressed. As described above, the frame expandable member 34 is easily deformed to such an extent that the first end 34b is compressed so that the first end 34b is accommodated in the frame suction hole 31a by being pressed by the pressing force received by the frame expandable member 34 in the process of adhering the sheet 11 to the mold 51. As a result, in the process of adhering the sheet 11 to the mold 51, the frame expandable member 34 shrinks, and the frame first surface 31b of the frame 33 of the sheet holding mechanism 31 comes into contact with the sheet 11. Therefore, the sheet 11 can be sandwiched between the frame first surface 31b of the frame 33 and the outer peripheral region 51c of the first surface 51a of the mold body 511 and firmly adhered to the outer peripheral region 51c of the first surface 51a. As a result, the sheet 11 held by the sheet holding mechanism 31 can be adhered to the mold 51.

In the process of holding the sheet 11 on the mold 51, the sheet 11 is held on the mold 51 by vacuum suction through the suction holes 515. When the sheet 11 is in close contact with the mold 51 by the sheet holding mechanism 31, the suction holes 515 vacuum-suck the sheet 11, thereby holding the sheet 11 on the mold 51.

In the process of vacuum forming the sheet 11, the sheet 11, which is in close contact with the area surrounding the forming area 51b of the mold 51, is vacuum formed using the mold 51. Specifically, the space between the forming area 51b of the first surface 51a shown in FIG. 12 and the sheet 11 is evacuated by the suction holes 516. This results in the sheet 11 being vacuum formed as shown in FIG. 14.

In the process of vacuum forming the sheet 11, the sheet 11 that has been brought into close contact with the region surrounding the forming region 51b of the die 51 by the sheet holding mechanism 31 can be vacuum formed using the die 51. In the process of vacuum forming the sheet 11, the sheet 11 may be vacuum formed while the sheet holding mechanism 31 presses the sheet 11 toward the outer peripheral region 51c. Specifically, after the process of holding the sheet 11 in the die 51, as shown in FIG. 14, the sheet 11 may be vacuum formed while maintaining the pressing of the sheet 11 by the sheet holding mechanism 31. Note that the vacuum suction of the sheet 11 by the suction holes 515 and the vacuum suction by the suction holes 516 may be started simultaneously. This allows the sheet 11 to be firmly attached to the outer peripheral region 51c of the first surface 51a by utilizing both the effect of the suction of the sheet 11 by the suction holes 515 and the effect of the pressing of the sheet 11 by the sheet holding mechanism 31. This allows the sheet 11 to be efficiently vacuum formed by the vacuum suction of the suction holes 516.

Although not shown, in the process of vacuum forming the sheet 11, the sheet 11 may be vacuum formed in a state where the sheet holding mechanism 31 is not pressing the sheet 11 toward the outer peripheral region 51c. Specifically, after the process of holding the sheet 11 in the mold 51, the suction of the sheet 11 by the frame suction holes 31a may be stopped, the sheet holding mechanism 31 may be moved away from the sheet 11 by the drive device 40, and the sheet 11 may be vacuum formed thereafter. Even in this case, the sheet 11 may be firmly attached to the outer peripheral region 51c of the first surface 51a by the suction effect of the suction holes 515, and the sheet 11 may be vacuum formed. Note that the process of stopping the suction of the sheet 11 by the frame suction holes 31a and moving the sheet holding mechanism 31 away from the sheet 11 by the drive device 40 is performed at least before the process of injection molding the resin into the storage space 55. As an example of a method for manufacturing the molded product 16, the sheet 11 may first be brought into close contact with the mold 51, then the suction of the sheet 11 by the frame suction holes 31a may be stopped, and then the sheet 11 may be held by the mold 51 by vacuum suction of the suction holes 515.

The suction of the sheet 11 by the frame suction holes 31a is stopped, and the sheet holding mechanism 31 is moved away from the sheet 11 by the drive device 40, and then the resin is injection molded. In the resin injection molding process, the molding machine 50 forms a storage space 55 in which a part of the sheet 11 is stored, and the resin is injection molded into the storage space 55. Specifically, first, as shown in FIG. 14, the opposing mold 52 is moved relative to the mold 51. As a result, the opposing mold 52 comes into contact with the sheet 11 held by the mold 51, and the storage space 55 is formed. As a result, as shown in FIG. 15, the vacuum-formed part of the sheet 11 is stored in the storage space 55.

Next, resin is injection molded into the formed storage space 55. Specifically, thermoplastic resin heated to a high temperature is injected into the storage space 55. As a result, a molded part 12 having a shape corresponding to the storage space 55 is provided on the sheet 11, and a molded product 13 including the sheet 11 and the molded part 12 is formed.

As an example, the process of injection molding resin into the storage space 55 includes a process of stopping suction through the suction holes 515 of the sheet 11. As an example, suction through the suction holes 515 is stopped after the storage space 55 is formed and before the opposing mold 52 and the molded product 13 are separated from the mold 51, as described below. When injection molding resin into the storage space 55, the suction holes 515 may or may not be suctioning the sheet 11.

The molded product 13 is held by the head 30 and taken out of the storage space 55 by the following method. First, as shown in FIG. 16, the opposing die 52 is moved to the second side s2 in the first direction d1 to separate it from the die 51. At this time, the molded product 13 separates from the die 51 together with the opposing die 52. Next, the head 30 is driven by the drive unit 40, and the head 30 is again positioned between the die 51 and the opposing die 52 as shown in FIG. 8. Next, the drive unit 40 moves the molded product holding mechanism 32 of the head 30 to the second side s2 in the first direction d1 to approach the opposing die 52 as shown in FIG. 17. Then, the suction pad 32a of the molded product holding mechanism 32 is brought into contact with the molded product 13, and the molded product 13 is held by the molded product holding mechanism 32 by suction of the suction pad 32a. After that, as shown in FIG. 18, the molded product holding mechanism 32 is moved to the first side s1 in the first direction d1 by the drive device 40, so that the molded product 13 is separated from the opposing mold 52. As a result, the molded product 13 is held by the head 30 and removed from the storage space 55.

In the process of trimming the molded product 13 molded by the molding machine 50, the head 30 is first driven by the drive device 40 to transport the molded product 13 held by the molded product holding mechanism 32 of the head 30 to the trimming device 80. Next, the molded product 13 is trimmed to the desired shape by the trimming device 80.

The molded product 13 is heated by the molded product heater 36 of the head 30 for at least a period from when it is held by the molded product holding mechanism 32 until it is transported to the trimming device 80. By being appropriately heated by the molded product heater 36, the molded product 13 is less likely to undergo deformation such as shrinkage due to temperature changes.

The method of transporting the molded product 13 to the trimming device 80 and the method of trimming the molded product 13 by the trimming device 80 are appropriately determined according to the form of the trimming device 80. For example, as described above, when the trimming device 80 has a support table on which the molded product 13 is placed and a cutting means for cutting the molded product 13 placed on the support table, the molded product 13 can be transported to the trimming device 80 and trimmed by the following method. First, the head 30 is driven by the drive device 40 to place the molded product 13 held by the molded product holding mechanism 32 of the head 30 on the support table. Next, the suction of the sheet 11 by the suction pad 32a is stopped. Next, the head 30 is driven by the drive device 40 to separate the molded product holding mechanism 32 from the molded product 13. Next, the cutting means is brought into contact with the molded product 13 placed on the support table and the cutting means is moved. This allows the molded product 13 to be cut and trimmed into a desired shape. By trimming the molded part 13, a molded product 16 as shown in Figure 19 is produced.

The manufacturing method of the molded product 16 does not have to include a step of trimming the molded product 13 molded by the molding machine 50. For example, in the resin injection molding step, the molded product 13 molded by injecting resin into the storage space 55 may be made into the molded product 16 without being trimmed.

In the first embodiment, the sheet holding mechanism 31 includes a frame expansion and contraction member 34, and the sheet 11 is held by the sheet holding mechanism 31 by vacuum suction of the suction opening 34a. According to the sheet holding mechanism 31 of the first embodiment, the molding system 1, and the manufacturing method of the molded product 16 using the molding system 1 of the first embodiment, as described above, it is possible to prevent the sheet 11 from falling off the sheet holding mechanism 31. In particular, even when the sheet 11 is deformed due to the weight of the sheet 11 itself or heating by the heater 35, it is possible to prevent the sheet 11 from falling off the sheet holding mechanism 31.

Second Embodiment
Next, a molding system 1 according to a second embodiment will be described. In the second embodiment, the same parts as those in the first embodiment described above are given the same reference numerals, and detailed description will be omitted. In the following description, the molding system 1 according to the second embodiment will be described with a focus on the differences from the molding system 1 according to the first embodiment. Also, if it is clear that the effects obtained in the first embodiment can also be obtained in this embodiment, the description may be omitted.

The molding system 1 according to the second embodiment can also be represented by the top view shown in FIG. 1, similar to the molding system 1 according to the first embodiment. That is, the molding system 1 according to the second embodiment includes a head 30, a molding machine 50, and a drive device 40. The molding system 1 according to the second embodiment further includes a sheet supply device 20 and a trimming device 80. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30.

Figure 20 is a perspective view showing an example of a sheet holding mechanism 31 and heater 35 according to the second embodiment. Figure 21 is a cross-sectional view taken along line XXI-XXI in Figure 20, showing the sheet 11 held by the sheet holding mechanism 31 and the mold 51 to which the sheet 11 is in close contact. As shown in Figure 20, in the second embodiment, the sheet holding mechanism 31 includes a frame portion 33 having a frame-like shape with an opening portion 33a, and a frame portion suction hole 31a provided in the frame portion 33.

The frame 33 of the sheet holding mechanism 31 has an inner surface 33b that forms the opening 33a of the frame 33, and an outer surface 33c located on the opposite side to the inner surface 33b. In the example shown in Figures 20 and 21, the inner surface 33b and the outer surface 33c are surfaces that connect the frame first surface 31b and the frame second surface 31c. Furthermore, the inner surface 33b and the outer surface 33c are surfaces that are perpendicular to the frame first surface 31b and the frame second surface 31c.

In the second embodiment, the sheet holding mechanism 31 further includes a frame heater 37 that heats the frame 33. In the second embodiment, the frame heater 37 is attached to at least one of the inner surface 33b that forms the opening 33a of the frame 33 and the outer surface 33c that is located opposite the inner surface 33b. In the example shown in Figures 20 and 21, the frame heater 37 is attached to the inner surface 33b. Although not shown, the frame heater 37 may also be attached to the outer surface 33c.

The type of frame heater 37 is not particularly limited as long as it can heat the first frame surface 31b of the frame 33. The frame heater 37 is, for example, a plate-shaped heater known as a plate heater.

The sheet holding mechanism 31 further includes a frame heater 37, which provides the following effects. In the second embodiment, a heater 35 is disposed on the frame second surface 31c side of the sheet holding mechanism 31. The heater 35 heats the sheet 11 for at least a period from when the sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20 until when the sheet holding mechanism 31 transfers the sheet 11 to the mold 51. Here, the frame 33 may prevent the transfer of heat from the heater 35 to the sheet 11. In this case, the heat from the heater 35 is less likely to be transferred to the portion of the sheet 11 facing the frame first surface 31b of the frame 33. The portion of the sheet 11 facing the frame first surface 31b of the frame 33 is referred to as the frame facing portion 111. In this case, since the frame 33 is located between the heater 35 and the frame facing portion 111, the heat from the heater 35 is less likely to be transferred to the frame facing portion 111. In this case, by providing the sheet holding mechanism 31 with a frame heater 37, the frame heater 37 can heat the frame 33, and the heat of the frame heater 37 can be transferred to the frame facing portion 111 via the frame 33.

Here, when the sheet holding mechanism 31 delivers the sheet 11 to the mold 51, the sheet 11 in close contact with the mold 51 may lose heat to the mold 51 and be cooled. As an example, the temperature of the sheet 11 held by the sheet holding mechanism 31 and heated by the heater 35 or the frame heater 37 is 120°C or higher and 170°C or lower. As another example, the temperature of the mold 51 is 40°C or higher and 70°C or lower. When the sheet 11 loses heat to the mold 51 and is cooled, the sheet 11 may shrink. In this case, the sheet 11 may shrink particularly rapidly in the frame facing portion 111, which is difficult to heat by the heater 35. Here, by heating the frame facing portion 111 with the frame heater 37, the rapid shrinkage of the sheet 11 at the frame facing portion 111 can be suppressed. This prevents the sheet 11 from falling off the mold 51 due to sudden contraction of the sheet 11 at the frame facing portion 111 when the sheet holding mechanism 31 transfers the sheet 11 to the mold 51 and the mold 51 holds the sheet 11 by vacuum suction through the suction holes 515.

Furthermore, it may be required to increase the dimensions of the molded product 16 and the molded sheet 17, which will be described later, manufactured using the molding system 1 relative to the dimensions of the sheet 11 supplied from the sheet supply device 20 to the sheet holding mechanism 31, thereby increasing the utilization efficiency of the sheet 11. In this case, it is required to reduce the dimensions of the sheet 11 that can be held by the sheet holding mechanism 31 and the mold 51, while sufficiently increasing the dimensions of the molded product 16 and the molded sheet 17, which will be described later, manufactured using the molding system 1. In this case, as shown in FIG. 21, it may be required to design the sheet holding mechanism 31 and the mold 51 so that the frame 33 overlaps the suction hole 515 when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51. In the example shown in FIG. 21, the sheet holding mechanism 31 and the mold 51 are designed so that the frame suction hole 31a overlaps the suction hole 515 when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51. In this case, the mold 51 holds the sheet 11 by vacuum adsorbing the frame opposing portion 111 through the suction hole 515. Here, as described above, the transfer of heat from the heater 35 to the frame facing portion 111 may be hindered by the frame 33. Even in this case, the frame heater 37 provided in the sheet holding mechanism 31 allows the frame heater 37 to heat and soften the frame facing portion 111. Therefore, when the mold 51 vacuum-adsorbs the frame facing portion 111 through the suction holes 515, the frame facing portion 111 is drawn into the suction holes 515, and the sheet 11 can be stably held by the mold 51. In addition, by heating the frame facing portion 111 with the frame heater 37, sudden contraction of the sheet 11 at the frame facing portion 111 can be suppressed. As a result, even when the mold 51 holds the sheet 11 by vacuum-adsorbing the frame facing portion 111 through the suction holes 515, it is possible to suppress the sheet 11 from falling off the mold 51 due to sudden contraction of the sheet 11 at the frame facing portion 111.

As described above, by further providing the frame heater 37 to the sheet holding mechanism 31, it is possible to prevent the sheet 11 from falling off from the mold 51, which is the member that holds the sheet 11. In particular, in the method for manufacturing a molded product 16 using the molding system 1, it is possible to prevent the sheet 11 from falling off from the mold 51 during the period from when the sheet holding mechanism 31 separates from the sheet 11 held by the mold 51 until when the opposing mold 52 comes into contact with the sheet 11 held by the mold 51.

21, if the frame suction holes 31a overlap the suction holes 515 when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51, in the method for manufacturing the molded product 16 using the molding system 1, the sheet 11 is brought into close contact with the mold 51, the suction of the sheet 11 by the frame suction holes 31a is stopped, and the sheet 11 is held by the mold 51 in the following procedure. First, the sheet 11 is brought into close contact with the mold 51, then the suction of the sheet 11 by the frame suction holes 31a is stopped, and the sheet 11 is held by the mold 51 by vacuum suction of the suction holes 515.

The sheet holding mechanism 31 shown in Figures 20 and 21 does not include the frame expansion and contraction member 34 described above in the first embodiment. The sheet holding mechanism 31 shown in Figures 20 and 21 holds the sheet 11 by vacuum suction of the frame suction holes 31a by sucking air through the frame suction holes 31a. Although not shown, the sheet holding mechanism 31 of the second embodiment may further include the frame expansion and contraction member 34 described above in the first embodiment.

Third Embodiment
Next, a molding system 1 according to a third embodiment will be described. In the third embodiment, the same parts as those in the above-mentioned embodiments are given the same reference numerals, and detailed description will be omitted. In the following description, the molding system 1 according to the third embodiment will be described with a focus on the differences from the molding system 1 according to the above-mentioned embodiments. In addition, if it is clear that the effects obtained in the above-mentioned embodiments can also be obtained in this embodiment, the description may be omitted.

The molding system 1 according to the third embodiment can also be represented by the top view shown in FIG. 1, similar to the molding system 1 according to the first embodiment. That is, the molding system 1 according to the third embodiment includes a head 30, a molding machine 50, and a drive device 40. The molding system 1 according to the third embodiment further includes a sheet supply device 20 and a trimming device 80. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30.

Figure 22 is a plan view showing an example of a sheet holding mechanism 31 and heater 35 according to the third embodiment, as viewed from the frame first surface 31b side of the frame 33 of the sheet holding mechanism 31. Figure 23 is a cross-sectional view taken along line XXIII-XXIII in Figure 22, showing the sheet 11 held by the sheet holding mechanism 31 and the mold 51 to which the sheet 11 is in close contact. As shown in Figure 22, in the third embodiment, the sheet holding mechanism 31 includes a frame 33 having a frame-like shape with an opening 33a, and a frame suction hole 31a provided in the frame 33.

In the third embodiment, the sheet holding mechanism 31 further includes an elastic body 381 that is more easily elastically deformed than the frame 33 and is attached to an area of the frame first surface 31b where the frame suction holes 31a are not provided, so as to surround the opening 33a. As an example, the elastic body 381 is more easily elastically deformed than the mold body 511 of the mold 51. Durometer hardness can be used as an index of ease of elastic deformation. That is, a test piece is prepared for the materials of the frame 33, the mold body 511, and the elastic body 381, and a value obtained from the depth to which the indenter is pressed when a specified indenter is pressed into the test piece under specified conditions can be used as an index of ease of elastic deformation. Durometer hardness can be measured by the following method. A test machine having an indenter is prepared in accordance with JIS K6253-3:2012, and test pieces of the same shape are created for the materials of the frame 33, the mold body 511, and the elastic body 381. A type A durometer is prepared as the test machine. Next, the tester is used to press the indenter into the test piece under specified conditions. The durometer hardness is calculated from the depth to which the indenter is pressed into the test piece. The measured elongation of the test piece is compared for the frame 33, the mold body 511, and the elastic body 381. The durometer hardness of the elastic body 381 measured by a type A durometer hardness test in accordance with JIS K6253-3:2012 is, for example, less than 60. This makes the elastic body 381 more susceptible to elastic deformation than a typical mold body 511. The elastic body 381 is preferably soft rubber having a durometer hardness of 20 or less measured by a type A durometer hardness test in accordance with JIS K6253-3:2012.

The elastic body 381 has a frame-like shape having a portion extending along the extension direction of the first portion 33d of the frame portion 33 and a portion extending along the extension direction of the second portion 33e and connected to the portion extending along the extension direction of the first portion 33d. In the example shown in FIG. 22, the elastic body 381 is attached so as to surround the area in which the frame suction holes 31a are provided on the frame first surface 31b. Although not shown, the elastic body 381 may be attached between the area in which the frame suction holes 31a are provided on the frame first surface 31b and the opening 33a. As shown in FIG. 23, when the sheet holding mechanism 31 is in close contact with the mold 51, the elastic body 381 overlaps the area surrounding the area in which the suction holes 515 are provided on the outer peripheral area 51c of the mold 51.

23, the frame first surface 31b of the frame 33 is provided with a storage groove 382 that stores a part of the elastic body 381. The storage groove 382 is provided to surround the opening 33a so as to overlap the elastic body 381. The elastic body 381 is attached to the frame first surface 31b by fitting a part of the elastic body 381 into the storage groove 382. Although not shown, the elastic body 381 may cover the entire area of the frame first surface 31b other than the area where the frame suction holes 31a are provided. In this case, the storage groove 382 may not be provided in the frame first surface 31b of the frame 33.

The sheet holding mechanism 31 further includes an elastic body 381, which provides the following effects. As shown in FIG. 23, when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51, the sheet 11 can be sandwiched between the elastic body 381 and the mold 51, and the sheet 11 can be firmly attached to the mold 51. This allows the sheet 11 to be vacuum-attached by the suction holes 515 after the space between the mold 51 and the sheet 11 is tightly sealed. This makes it possible to more firmly vacuum-attach the sheet 11 by the suction holes 515 and prevent the sheet 11 from falling off the mold 51. In particular, even when the sheet 11 is deformed, it is possible to prevent the sheet 11 from falling off the mold 51. In addition, after the space between the mold 51 and the sheet 11 is tightly sealed, the sheet 11 can be vacuum-formed by vacuum suction through the suction holes 516. This makes it possible to efficiently vacuum-form the sheet 11 by vacuum suction through the suction holes 516.

In the example shown in FIG. 23, the elastic body 381 protrudes from the frame first surface 31b by a width w2 in a direction perpendicular to the frame first surface 31b. The protruding width w2 of the elastic body 381 is, for example, 2 mm or more and 5 mm or less. By making the width w2 2 mm or more, the sheet 11 can be more stably sandwiched between the elastic body 381 and the mold 51. By making the width w2 5 mm or less, the following effects can be obtained. When the sheet 11 is held by the sheet holding mechanism 31 having the frame 33 and the elastic body 381 as shown in FIG. 23, it is necessary to deform the sheet 11 so as to contact the elastic body 381 and the portion of the frame suction hole 31a of the frame 33. In the example shown in FIG. 23, the sheet 11 is deformed so as to be bent so as to contact the surface of the elastic body 381 facing the mold 51 and the portion of the frame 33 where the frame suction hole 31a is provided. Here, by setting the width w2 to 5 mm or less, it becomes easy to deform the sheet 11 so that it comes into contact with the surface of the elastic body 381 facing the mold 51 and the portion of the frame 33 where the frame suction holes 31a are provided. This allows the sheet 11 to be held by vacuum suction of the frame suction holes 31a while being sandwiched between the elastic body 381 and the mold 51 and the sheet 11 coming into contact with the portion of the frame 33 where the frame suction holes 31a are provided.

The material of the elastic body 381 is not particularly limited as long as it is more elastically deformable than the frame portion 33 and the space between the mold 51 and the sheet 11 can be sealed by sandwiching the sheet 11 between the elastic body 381 and the mold 51. The material of the elastic body 381 is, for example, a silicone sponge.

The sheet holding mechanism 31 shown in Figures 22 and 23 does not include the frame expansion and contraction member 34 described above in the first embodiment. Although not shown, the sheet holding mechanism 31 of the third embodiment may further include the frame expansion and contraction member 34 described above in the first embodiment. Furthermore, the sheet holding mechanism 31 shown in Figures 22 and 23 does not include the frame heater 37 described above in the second embodiment. Although not shown, the sheet holding mechanism 31 of the third embodiment may further include the frame heater 37 described above in the second embodiment.

(Fourth embodiment)
Next, a molding system 1 according to a fourth embodiment will be described. In the fourth embodiment, the same parts as those in the above-mentioned embodiments are given the same reference numerals, and detailed description will be omitted. In the following description, the molding system 1 according to the fourth embodiment will be described with a focus on the differences from the molding system 1 according to the above-mentioned embodiments. In addition, if it is clear that the effects obtained in the above-mentioned embodiments can also be obtained in this embodiment, the description may be omitted.

The molding system 1 according to the fourth embodiment can also be represented by the top view shown in FIG. 1, similar to the molding system 1 according to the first embodiment. That is, the molding system 1 according to the fourth embodiment includes a head 30, a molding machine 50, and a drive device 40. The molding system 1 according to the fourth embodiment further includes a sheet supply device 20 and a trimming device 80. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30.

Figure 24 is a plan view showing an example of a mold 51 according to the fourth embodiment as viewed from the first surface 51a side of the mold body 511. Figure 25 is a cross-sectional view showing a cross section along line XXV-XXV in Figure 24, together with the sheet holding mechanism 31 and the sheet 11 held by the sheet holding mechanism 31 and in close contact with the mold 51. As shown in Figure 24, in the fourth embodiment, the mold 51 has a mold body 511 having a first surface 51a. The first surface 51a has a molding region 51b for vacuum-forming the sheet 11, and an outer peripheral region 51c surrounding the molding region 51b. The mold 51 further has a suction hole 515 provided in the mold body 511 and opening in the outer peripheral region 51c.

In the fourth embodiment, the mold 51 further includes an elastic body 518 that is more easily elastically deformed than the mold body 511 and is attached to the outer peripheral region 51c so as to surround the region in which the suction holes 515 are provided. As an example, the elastic body 518 is more easily elastically deformed than the frame portion 33 of the sheet holding mechanism 31. The index of ease of elastic deformation of the elastic body 518 of the mold 51 in the fourth embodiment is the same as the index of ease of elastic deformation of the elastic body 381 of the sheet holding mechanism 31 described above in the third embodiment.

The elastic body 518 has a frame-like shape having a portion extending along the upper side 514 and the lower side 512 of the mold 51 and a portion extending along the side 513 and connected to the portion extending along the upper side 514 and the lower side 512. The elastic body 518 is attached to the first surface 51a of the mold body 511 so as to surround the molding area 51b. As a result, the elastic body 518 forms an area surrounding the molding area 51b of the mold 51. As an example, when the sheet holding mechanism 31 is in close contact with the sheet 11 to the mold 51, the elastic body 518 overlaps an area of the frame first surface 31b where the frame suction holes 31a are not provided. As an example, the elastic body 518 overlaps an area surrounding an area of the frame first surface 31b where the frame suction holes 31a are provided.

In the example shown in FIG. 25, a storage groove 519 that stores a portion of the elastic body 518 is provided on the first surface 51a of the mold body 511. The storage groove 519 is provided so as to surround the area of the outer peripheral region 51c in which the suction holes 515 are provided, so as to overlap the elastic body 518. The elastic body 518 is attached to the first surface 51a by fitting a portion of the elastic body 518 into the storage groove 519.

The mold 51 further includes an elastic body 518, which provides the following effects. As shown in FIG. 25, when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51, the sheet 11 can be sandwiched between the frame 33 of the sheet holding mechanism 31 and the elastic body 518 to firmly adhere the sheet 11 to the elastic body of the mold 51. In the example shown in FIG. 25, the elastic body 518 forms a region surrounding the molding region 51b of the mold 51. Therefore, by sandwiching the sheet 11 between the frame 33 of the sheet holding mechanism 31 and the elastic body 518, the sheet 11 can be firmly adhered to the region surrounding the molding region 51b of the mold 51. This allows the space between the mold 51 and the sheet 11 to be firmly sealed, and then the sheet 11 can be vacuum-adsorbed by the suction holes 515. Therefore, the vacuum adsorption of the sheet 11 by the suction holes 515 can be more firmly performed, thereby preventing the sheet 11 from falling off the mold 51. In particular, even if the sheet 11 is deformed, it is possible to prevent the sheet 11 from falling off the mold 51. Furthermore, the space between the mold 51 and the sheet 11 can be tightly sealed, and then the vacuum forming of the sheet 11 can be performed by vacuum suction through the suction holes 516. Therefore, the vacuum forming of the sheet 11 can be efficiently performed by vacuum suction through the suction holes 516.

In the example shown in FIG. 25, the elastic body 518 protrudes from the outer peripheral region 51c by a width w3 in a direction perpendicular to the outer peripheral region 51c of the first surface 51a. The protruding width w3 of the elastic body 518 is, for example, 2 mm or more and 5 mm or less. By making the width w3 2 mm or more, the sheet 11 can be more stably sandwiched between the frame portion 33 and the elastic body 518. By making the width w3 5 mm or less, the following effects can be obtained. When the sheet 11 is held by the mold 51 having the mold body 511 and the elastic body 518 as shown in FIG. 25, it is necessary to deform the sheet 11 so as to contact the elastic body 518 and the part of the mold body 511 where the suction holes 515 are provided, as shown in FIG. 26. In the example shown in FIG. 26, the sheet 11 is deformed so as to be bent so as to contact the surface of the elastic body 518 facing the sheet holding mechanism 31 and the part of the mold body 511 where the suction holes 515 are provided. Here, by setting the width w3 to 5 mm or less, it becomes easy to deform the sheet 11 so that it comes into contact with the surface of the elastic body 518 facing the sheet holding mechanism 31 and the portion of the mold body 511 where the suction holes 515 are provided. This makes it possible to suppress the occurrence of gaps between the sheet 11 and the surface of the elastic body 518 facing the sheet holding mechanism 31, or between the sheet 11 and the portion of the mold body 511 where the suction holes 515 are provided, causing vacuum leakage. In particular, it is possible to suppress the occurrence of gaps between the sheet 11 and the surface of the elastic body 518 facing the sheet holding mechanism 31, or between the sheet 11 and the portion of the mold body 511 where the suction holes 515 are provided, caused by the sheet 11 deforming in a wavy manner without deforming along the shapes of the elastic body 518 and the mold body 511. As described above, while sandwiching the sheet 11 between the frame portion 33 and the elastic body 518, the sheet 11 can be brought into contact with the portion of the mold body 511 where the suction holes 515 are provided, and the sheet 11 can be held by vacuum suction of the suction holes 515. Furthermore, by setting w3 to 5 mm or less, the maximum distance w4 between the sheet 11 and the molding region 51b in the direction perpendicular to the surface of the sheet 11 when the sheet 11 held by the sheet holding mechanism 31 is in close contact with the mold 51 as shown in FIG. 25 is kept small. This keeps the amount of stretching of the sheet 11 small when vacuum forming the sheet 11 by vacuum suction through the suction holes 516. By keeping the amount of stretching of the sheet 11 small, it is possible to more stably prevent cracks and pattern stretching from occurring in the sheet 11. Pattern stretching refers to the display of the design, information, etc. printed on the surface of the sheet 11 becoming different from the desired display due to the sheet 11 being stretched more than expected. It is also possible to prevent the sheet 11 from becoming see-through due to the sheet 11 being stretched too much.

The material of the elastic body 518 is not particularly limited as long as it is more elastically deformable than the mold body 511 and the space between the mold 51 and the sheet 11 can be sealed by sandwiching the sheet 11 between the frame portion 33 and the elastic body 518. As an example, the material of the elastic body 518 of the mold 51 is the same as the material of the elastic body 381 of the sheet holding mechanism 31 described above in the third embodiment. The material of the elastic body 518 is, for example, a silicone sponge.

Figure 27 is a diagram showing a state in which, after vacuum forming the sheet 11, the opposing die 52 approaches the die 51 to form the storage space 55 in the molding system 1 according to the fourth embodiment. In the fourth embodiment, the molding machine 50 includes the above-mentioned die 51 and the opposing die 52. The opposing die 52 has a recess 521 that accommodates at least a portion of the elastic body 518 when the die 51 and the opposing die 52 form the storage space 55. The recess 521 is provided in the opposing outer peripheral region 52c of the opposing die 52 so as to surround the opposing storage space region 52d and the opposing suction hole region 52e.

As an example, the recess 521 accommodates at least a portion of the elastic body 518 and a portion of the sheet 11 in contact with the elastic body 518 when the mold 51 and the opposing mold 52 form the accommodation space 55. As a result, when the mold 51 and the opposing mold 52 form the accommodation space 55, the portion of the outer peripheral region 51c of the mold body 511 to which the elastic body 518 is not attached can be in close contact with the sheet 11. Also, the region of the opposing outer peripheral region 52c of the opposing mold 52 to which the recess 521 is not provided can be in close contact with the sheet 11. Therefore, by having the recess 521 in the opposing mold 52, while attaching the elastic body 518 to the mold body 511, when the mold 51 and the opposing mold 52 form the accommodation space 55, the outer peripheral region 51c of the mold body 511 and the opposing outer peripheral region 52c of the opposing mold 52 can be in close contact with the sheet 11 without being hindered by the elastic body 518. This allows the sheet 11 to be sandwiched between the outer peripheral region 51c and the opposing outer peripheral region 52c, tightly sealing the storage space 55.

In the molding system 1 shown in Figures 24 to 27, the sheet holding mechanism 31 does not include the frame expansion and contraction member 34 described above in the first embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the fourth embodiment may further include the frame expansion and contraction member 34 described above in the first embodiment. In addition, in the molding system 1 shown in Figures 24 to 27, the sheet holding mechanism 31 does not include the frame heater 37 described above in the second embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the fourth embodiment may further include the frame heater 37 described above in the second embodiment.

Fifth embodiment
Next, a molding system 1 according to a fifth embodiment will be described. In the fifth embodiment, the same parts as those in the above-mentioned embodiments are given the same reference numerals, and detailed description will be omitted. In the following description, the molding system 1 according to the fifth embodiment will be described with a focus on the differences from the molding system 1 according to the above-mentioned embodiments. In addition, if it is clear that the effects obtained in the above-mentioned embodiments can also be obtained in this embodiment, the description may be omitted.

The molding system 1 according to the fifth embodiment can also be represented by the top view shown in FIG. 1, similar to the molding system 1 according to the first embodiment. That is, the molding system 1 according to the fifth embodiment includes a head 30, a molding machine 50, and a drive device 40. The molding system 1 according to the fifth embodiment further includes a sheet supply device 20 and a trimming device 80. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30.

Figure 28 is a plan view showing an example of a mold 51 according to the fifth embodiment as viewed from the first surface 51a side. Figure 29 is a cross-sectional view taken along line XXIV-XXIV in Figure 28. As shown in Figure 29, in the fifth embodiment, the mold 51 includes a mold body 511 having a first surface 51a. The first surface 51a includes a molding region 51b for vacuum-forming the sheet 11, and an outer peripheral region 51c surrounding the molding region 51b. The mold 51 further includes a suction hole 515 provided in the mold body 511 and opening in the outer peripheral region 51c.

In the fifth embodiment, the mold 51 further includes an expandable member 56 having a first end 56b with a suction opening 56a and a second end 56c located opposite the first end 56b. In FIG. 28, the expandable member 56 is in an unpressurized state. At this time, the second end 56c is accommodated in the suction hole 515. Also, the first end 56b protrudes from the suction hole 515. In other words, the first end 56b is located on the side of the first surface 51a opposite the side on which the second surface 51g is located.

In the fifth embodiment, the mold 51 includes a plurality of elastic members 56. The number of the elastic members 56 is the same as the number of the suction holes 515. The second end 56c of each of the plurality of elastic members 56 is accommodated in each of the suction holes 515. The first end 56b of each of the plurality of elastic members 56 protrudes from each of the suction holes 515.

In the example shown in FIG. 28, the elastic member 56 has a cylindrical shape that extends in the direction in which the suction hole 515 extends. The elastic member 56 has a through hole 56d that extends from the first end 56b to the second end 56c. The through hole 56d forms the suction opening 56a at the first end 56b.

The mold 51 of the fifth embodiment holds the sheet 11 by vacuum suction of the suction opening 56a. In the example shown in FIG. 28, the outer wall of the elastic member 56 and the inner wall of the suction hole 515 are sealed at the second end 56c side of the elastic member 56. The mold 51 further includes a sealing member 57 arranged between the outer wall of the elastic member 56 and the inner wall of the suction hole 515. The sealing member 57 seals the outer wall of the elastic member 56 and the inner wall of the suction hole 515. As a result, by sucking the air in the suction hole 515 from the second surface 51g side, the air in the through hole 56d can be sucked, and the sheet 11 can be held by vacuum suction of the suction opening 56a. Since the vacuum suction of the suction opening 56a can be performed by sucking the air in the suction hole 515, it can be said that holding the sheet 11 by vacuum suction of the suction hole 515 includes holding the sheet 11 by vacuum suction of the suction opening 56a. In the example shown in FIG. 28, the first end 56b protrudes from the suction hole 515. This allows the mold 51 to hold the sheet 11 so that the sheet 11 is spaced apart from the first surface 51a.

When the elastic member 56 is pressed, the first end 56b contracts so that it is accommodated in the suction hole 515. When the first end 56b is pressed toward the second end 56c, the elastic member 56 contracts so that the distance between the first end 56b and the second end 56c becomes smaller. When the elastic member 56 is pressed by the pressing force received by the elastic member 56 in the process of adhering the sheet 11 held by the sheet holding mechanism 31 to the area surrounding the molding area 51b of the mold 51, the elastic member 56 is easily deformed to such an extent that the first end 56b contracts so that it is accommodated in the suction hole 515. When the elastic member 56 is released from the pressure, the first end 56b expands so that it returns to the position where it protrudes from the suction hole 515.

The means for ensuring the ease of deformation of the elastic member 56 through expansion and contraction is not particularly limited as long as the sheet 11 can be held by vacuum suction of the suction opening 56a. The elastic member 56 may be a member similar to the frame elastic member 34 described above in the first embodiment. The elastic member 56 may have a bellows-like shape in a cross section passing through the axis of the suction hole 515.

The effect of the mold 51 having the elastic member 56 and the sheet 11 being held by the mold 51 by vacuum suction of the suction opening 56a will be described. As described above, when the mold 51 is holding the sheet 11, the sheet 11 may be deformed. Here, in the fifth embodiment, the mold 51 holds the sheet 11 by vacuum suction of the suction opening 56a of the elastic member 56. As a result, when the sheet 11 is deformed, the elastic member 56 deforms, and the suction opening 56a can be moved to follow the deformation of the sheet 11. Therefore, it is possible to prevent the sheet 11 from falling off the mold 51 due to the sheet 11 being misaligned with the suction opening 56a. In this way, according to the fifth embodiment, it is possible to prevent the sheet 11 from falling off the mold 51, which is a member that holds the sheet 11.

In addition, the elastic member 56 is compressed so that the first end 56b is accommodated in the suction hole 515 by being pressed. As described above, the elastic member 56 is easily deformed to such an extent that the first end 56b is compressed so that the first end 56b is accommodated in the suction hole 515 by being pressed by the pressing force received by the elastic member 56 in the process of adhering the sheet 11 to the mold 51. As a result, in the process of adhering the sheet 11 to the mold 51, the elastic member 56 is compressed, and the outer peripheral region 51c of the first surface 51a of the mold body 511 comes into contact with the sheet 11. Therefore, the sheet 11 can be sandwiched between the frame first surface 31b of the frame 33 and the outer peripheral region 51c of the first surface 51a of the mold body 511 and firmly adhered to the outer peripheral region 51c of the first surface 51a. As a result, the sheet 11 held by the sheet holding mechanism 31 can be adhered to the outer peripheral region 51c of the first surface 51a of the mold body 511.

28 and 29, the mold 51 further includes a linear groove 58 provided on the first surface 51a and surrounding at least a portion of the molding region 51b. The mold 51 further includes a linear groove suction hole 517 that draws the sheet 11 into the linear groove 58 by vacuum suction. The linear groove suction hole 517 is provided in the mold body 511. The linear groove suction hole 517 has an opening. At least a portion of the opening of the linear groove suction hole 517 is provided in the wall surface 58a of the linear groove 58. In the example shown in FIG. 28 and FIG. 29, the linear groove 58 is provided in the suction hole region 51e of the first surface 51a of the mold body 511. The linear groove 58 is provided so as to surround the storage space region 51d of the first surface 51a of the mold body 511. In the example shown in FIG. 28 and FIG. 29, the mold 51 includes a plurality of linear groove suction holes 517. The multiple linear groove suction holes 517 are aligned along the direction in which the linear groove 58 extends. In the example shown in Figures 28 and 29, the entire openings of the multiple linear groove suction holes 517 are provided on the wall surface 58a of the linear groove 58.

At least a portion of the opening of the linear groove suction hole 517 is provided on the wall surface 58a of the linear groove 58, so that by sucking in the air inside the linear groove suction hole 517, a portion of the sheet 11 arranged near the linear groove 58 can be drawn into the linear groove 58.

28 and 29, the suction holes 516 used in the vacuum forming of the sheet 11 described above also serve as the linear groove suction holes 517. In other words, at least a portion of the opening of the suction holes 516 is provided in the wall surface 58a of the linear groove 58. Although not shown, the linear groove suction holes 517 may be a hole separate from the suction holes 516. When the linear groove suction holes 517 are a hole separate from the suction holes 516, the linear groove 58 and the linear groove suction holes 517 may be provided in the suction hole region 51e or in the outer peripheral region 51c.

In the fifth embodiment, the suction holes 515 open outside the area surrounded by the linear grooves 58. In the example shown in Figures 28 and 29, the mold 51 has multiple suction holes 515. All of the multiple suction holes 515 open outside the area surrounded by the linear grooves 58.

By providing the mold 51 with the linear grooves 58 and the linear groove suction holes 517, when the mold 51 holds the sheet 11, a portion of the sheet 11 can be drawn into the linear grooves 58, and the sheet 11 can be held by the linear grooves 58. Therefore, the sheet 11 can be held by vacuum suction of the suction holes 515, and also by the linear grooves 58. This makes it possible to more stably prevent the sheet 11 from falling off the mold 51. In particular, even if the sheet 11 is deformed, it is possible to prevent the sheet 11 from falling off the mold 51.

When the suction holes 516 used for vacuum forming the sheet 11 also serve as the linear groove suction holes 517, a portion of the sheet 11 may be drawn into the linear groove 58 at the same time that the sheet 11 is vacuum formed by the vacuum suction of the suction holes 516.

28 and 29, the sheet holding mechanism 31 does not include the frame expandable member 34 described above in the first embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the fifth embodiment may further include the frame expandable member 34 described above in the first embodiment. In this case, the frame expandable member 34 and the expandable member 56 are arranged so that the frame expandable member 34 and the expandable member 56 do not come into contact with each other when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51. As an example, the frame suction hole 31a and the suction hole 515 are arranged so that the opening of the frame suction hole 31a does not overlap with the opening of the suction hole 515 when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the mold 51. This allows the frame expandable member 34 and the expandable member 56 to be arranged so that they do not come into contact with each other. Also, in the molding system 1 shown in FIG. 28 and FIG. 29, the sheet holding mechanism 31 does not include the frame heater 37 described above in the second embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the fifth embodiment may further include the frame heater 37 described above in the second embodiment. In addition, in the molding system 1 shown in Figures 28 and 29, the sheet holding mechanism 31 does not include the elastic body 381 described above in the third embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the fifth embodiment may further include the elastic body 381 described above in the third embodiment. In addition, in the molding system 1 shown in Figures 28 and 29, the mold 51 does not include the elastic body 518 described above in the fourth embodiment. Although not shown, the mold 51 of the molding system 1 of the fifth embodiment may further include the elastic body 518 described above in the fourth embodiment.

Sixth embodiment
Next, a molding system 1 according to a sixth embodiment will be described. In the sixth embodiment, the same parts as those in the above-mentioned embodiments are given the same reference numerals, and detailed description will be omitted. In the following description, the molding system 1 according to the sixth embodiment will be described with a focus on the differences from the molding system 1 according to the above-mentioned embodiments. In addition, if it is clear that the effects obtained in the above-mentioned embodiments can also be obtained in this embodiment, the description may be omitted.

The molding system 1 according to the sixth embodiment can also be represented by the top view shown in FIG. 1, similar to the molding system 1 according to the first embodiment. That is, the molding system 1 according to the sixth embodiment includes a head 30, a molding machine 50, and a drive device 40. The molding system 1 according to the sixth embodiment further includes a sheet supply device 20 and a trimming device 80. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30.

Figure 30 is a plan view showing an example of the sheet holding mechanism 31 and heater 35 according to the sixth embodiment, as viewed from the frame first surface 31b side of the frame 33 of the sheet holding mechanism 31. Figure 31 is a cross-sectional view showing a cross section along line XXXI-XXXI in Figure 30, together with the sheet 11 held by the sheet holding mechanism 31 and the mold 51 to which the sheet 11 is in close contact. As shown in Figure 31, in the sixth embodiment, the sheet holding mechanism 31 has a frame 33 having a frame-like shape with an opening 33a, and a frame suction hole 31a provided in the frame 33. Also, as shown in Figure 31, the mold 51 has a mold body 511 having a first surface 51a. The first surface 51a has a forming region 51b for vacuum forming the sheet 11, and an outer peripheral region 51c surrounding the forming region 51b.

In the sixth embodiment, the sheet holding mechanism 31 further has a linear protrusion 33f that is provided in an area of the frame first surface 31b where the frame suction holes 31a are not provided and surrounds the opening 33a. In the example shown in Figures 30 and 31, the linear protrusion 33f is integral with the frame 33. The linear protrusion 33f also has a portion that extends along the extension direction of the first part 33d of the frame 33 and a portion that extends along the extension direction of the second part 33e and is connected to the portion that extends along the extension direction of the first part 33d. In the example shown in Figure 30, the linear protrusion 33f is provided between the area of the frame first surface 31b where the frame suction holes 31a are provided and the opening 33a. Although not shown, the linear protrusion 33f may be provided so as to surround the area of the frame first surface 31b where the frame suction holes 31a are provided. As shown in FIG. 31, when the sheet holding mechanism 31 is in close contact with the sheet 11 against the mold 51, the linear protrusion 33f overlaps with an area of the outer peripheral region 51c of the mold body 511 where the suction linear groove 59 described below is provided. When the sheet holding mechanism 31 is holding the sheet 11 as shown in FIG. 31, a part of the sheet 11 overlaps the linear protrusion 33f.

In the sixth embodiment, the mold 51 further has an adsorption linear groove 59 provided in the outer peripheral region 51c. FIG. 32 is a plan view showing the mold 51 shown in FIG. 31 as viewed from the first surface 51a side. As shown in FIG. 32, the adsorption linear groove 59 surrounds the molding region 51b. The mold 51 also has an adsorption hole 515 provided in the mold body 511. The adsorption hole 515 has an opening. At least a part of the opening of the adsorption hole 515 is provided in the wall surface 59a of the adsorption linear groove 59. In the example shown in FIG. 31, the adsorption linear groove 59 is provided in the outer peripheral region 51c of the first surface 51a of the mold body 511. In the example shown in FIG. 31, the mold 51 has a plurality of adsorption holes 515. The plurality of adsorption holes 515 are arranged along the extension direction of the adsorption linear groove 59. In the example shown in FIG. 31, the entire openings of the multiple suction holes 515 are provided on the wall surface 59a of the suction linear groove 59. Because at least a portion of the openings of the suction holes 515 are provided on the wall surface 59a of the suction linear groove 59, a portion of the sheet 11 arranged near the suction linear groove 59 can be drawn into the suction linear groove 59 by sucking in the air inside the suction holes 515.

As shown in FIG. 31, when the sheet holding mechanism 31 presses the sheet 11 against the region surrounding the molding region 51b of the first surface 51a, at least a portion of the linear convex portion 33f is inserted into the suction linear groove 59. By inserting at least a portion of the linear convex portion 33f into the suction linear groove 59, the portion of the sheet 11 that overlaps the linear convex portion 33f is pushed into the suction linear groove 59. In the sixth embodiment, the entire tip 33g of the linear convex portion 33f is inserted into the suction linear groove 59. In this case, the entire portion of the sheet 11 that overlaps the tip 33g of the linear convex portion 33f is pushed into the suction linear groove 59.

When the sheet holding mechanism 31 adheres the sheet 11 to the region surrounding the molding region 51b of the first surface 51a, at least a part of the linear protrusion 33f is inserted into the suction linear groove 59, which provides the following effects. When the sheet holding mechanism 31 adheres the sheet 11 to the region surrounding the molding region 51b of the first surface 51a, the linear protrusion 33f can push a part of the sheet 11 into the suction linear groove 59. By pushing a part of the sheet 11 into the suction linear groove 59, the vacuum suction of the sheet 11 by the suction holes 515 opening in the wall surface 59a of the suction linear groove 59 can be more stably generated. In addition, by pushing a part of the sheet 11 into the suction linear groove 59, the movement of the sheet 11 relative to the mold 51 is suppressed. As a result, the sheet 11 can be more stably held by the mold 51, and the sheet 11 can be prevented from falling off the mold 51.

30 and 31, the sheet holding mechanism 31 does not include the frame expansion and contraction member 34 described above in the first embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the sixth embodiment may further include the frame expansion and contraction member 34 described above in the first embodiment. Also, in the molding system 1 shown in FIG. 30 and FIG. 31, the sheet holding mechanism 31 does not include the frame heater 37 described above in the second embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the sixth embodiment may further include the frame heater 37 described above in the second embodiment. Also, in the molding system 1 shown in FIG. 30 and FIG. 31, the sheet holding mechanism 31 does not include the elastic body 381 described above in the third embodiment. Although not shown, the sheet holding mechanism 31 of the molding system 1 of the sixth embodiment may further include the elastic body 381 described above in the third embodiment. In addition, in the molding system 1 shown in Figures 30 and 31, the mold 51 does not include the elastic body 518 described above in the fourth embodiment. Although not shown, the mold 51 of the molding system 1 of the sixth embodiment may further include the elastic body 518 described above in the fourth embodiment.

Although the first to sixth embodiments have been described using specific examples, these specific examples do not limit the first to sixth embodiments. The first to sixth embodiments described above can be implemented using various other specific examples, and various omissions, substitutions, changes, and additions can be made without departing from the spirit of the invention.

Below, an example of a modification will be described with reference to the drawings. In the following description and the drawings used in the following description, parts that can be configured similarly to the specific example described above will be designated by the same reference numerals as those used for the corresponding parts in the specific example described above, and duplicate descriptions will be omitted.

(Modification)
In the above-mentioned first to sixth embodiments, an example has been described in which the molding system 1 according to the first to sixth embodiments is used in a manufacturing method of a molded product 16 including a sheet 11 and a molded part 12. However, the use of the molding system 1 according to the first to sixth embodiments is not limited to this. The molding system 1 according to the first to sixth embodiments may be used in a manufacturing method of a molded sheet 17 shown in FIG. 33. In this case, the molding machine 50 does not need to have an opposing mold 52. Also, the sheet 11 vacuum-formed in the mold 51 may be transported to a trimming device 80.

The manufacturing method of the molded sheet 17 according to this modification is the same as the manufacturing method of the molded product 16 using any one of the molding systems 1 according to the first to sixth embodiments, except that it does not include a step of injection molding a resin. That is, the manufacturing method of the molded sheet 17 according to this modification includes a step of adhering the sheet 11 held by the sheet holding mechanism 31 to the area surrounding the molding area 51b of the first surface 51a, and a step of vacuum-forming the sheet 11 adhered to the area surrounding the molding area 51b of the first surface 51a using a mold 51. The manufacturing method of the molded sheet 17 according to this modification may further include a step of trimming the vacuum-formed sheet 11. The step of trimming the vacuum-formed sheet 11 can be performed by conveying the sheet 11 vacuum-formed in the mold 51 to a trimming device 80 and using the same trimming device 80 as the trimming device 80 of the molding system 1 according to the first to sixth embodiments described above. This allows the molded sheet 17 shown in FIG. 33 to be manufactured.

The multiple components disclosed in the above embodiments and modifications may be combined as needed. Alternatively, some components may be deleted from all the components shown in the above embodiments and modifications.

1 Molding system 11 Sheet 16 Molded product 17 Molded sheet 31 Sheet holding mechanism 31a Frame suction hole 33 Frame 33a Opening 33f Linear convex portion 34 Frame expandable member 34a Suction opening 37 Frame heater 381 Elastic body 40 Drive device 50 Molding machine 51 Mold 51b Molding region 51c Outer periphery region 511 Mold body 515 Suction hole 516 Suction hole 517 Linear groove suction hole 518 Elastic body 52 Counter mold 521 Recess 55 Storage space 56 Expandable member 56a Suction opening 58 Linear groove 59 Suction linear groove

Claims (20)

A sheet holding mechanism for holding a sheet in a forming system for forming a sheet, comprising:
A frame portion having a frame-like shape with an opening provided therein;
A frame suction hole provided in the frame;
a frame expandable member having a first end provided with a suction opening and a second end located opposite the first end, the second end being accommodated in the frame suction hole and the first end protruding from the frame suction hole, and the frame expandable member contracts when pressed so that the first end is accommodated in the frame suction hole,
A sheet holding mechanism that holds the sheet by vacuum suction of the suction opening. A sheet holding mechanism for holding a sheet in a forming system for forming a sheet, comprising:
A frame portion having a frame-like shape with an opening provided therein;
A frame suction hole provided in the frame;
a frame heater that heats the frame and is attached to at least one of an inner surface that forms the opening of the frame and an outer surface that is located opposite to the inner surface;
a sheet holding mechanism that holds the sheet by vacuum suction of the frame suction holes; A sheet holding mechanism for holding a sheet in a forming system for forming a sheet, comprising:
A frame portion having a frame-like shape with an opening provided therein;
a frame suction hole provided in the frame and opening in a frame first surface of the frame facing the sheet;
an elastic body that is more easily elastically deformed than the frame and is attached to an area of the first surface of the frame where the frame suction holes are not provided so as to surround the opening,
a sheet holding mechanism that holds the sheet by vacuum suction of the frame suction holes; A mold used for vacuum forming a sheet, comprising:
A mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area;
a suction hole provided in the mold body and opening in the outer circumferential region;
an elastic body that is more easily elastically deformed than the mold body and is attached to the outer circumferential region so as to surround a region in which the suction holes are provided,
A mold that holds the sheet by vacuum suction of the suction holes. A mold used for vacuum forming a sheet, comprising:
A mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area;
a suction hole provided in the mold body and opening in the outer circumferential region;
an expandable member having a first end provided with a suction opening and a second end located opposite the first end, the second end being accommodated in the suction hole and the first end protruding from the suction hole, and the expandable member being compressed to contract so that the first end is accommodated in the suction hole;
A mold that holds the sheet by vacuum suction of the suction openings. A linear groove provided on the first surface and surrounding at least a portion of the molding region;
and a linear groove suction hole having an opening at least partially provided on a wall surface of the linear groove, the linear groove suction hole drawing the sheet into the linear groove by vacuum suction.
The mold according to claim 5 , wherein the suction holes are open outside the area surrounded by the linear grooves. A mold according to claim 4;
and an opposing mold that, together with the molding area of the mold, forms an accommodation space into which a portion of the sheet is accommodated and into which a resin is injection molded;
a molding machine, wherein the opposing mold has a recess that accommodates at least a portion of the elastic body when the mold and the opposing mold form the accommodation space. 1. A forming system for forming a sheet, comprising:
a sheet holding mechanism for holding the sheet;
a molding machine including a mold used for vacuum forming the sheet;
the sheet holding mechanism has a frame having a frame-like shape with an opening, frame suction holes provided in the frame and opening in a frame first surface of the frame facing the sheet, and a linear protrusion provided in an area of the frame first surface where the frame suction holes are not provided and surrounding the opening, and holds the sheet by vacuum suction of the frame suction holes;
The mold comprises a mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area, a linear suction groove provided in the outer peripheral area and surrounding the forming area, and a suction hole provided in the mold body, at least a portion of which has an opening provided in a wall surface of the linear suction groove,
the sheet holding mechanism brings the held sheet into close contact with a region surrounding the molding region of the mold;
A molding system, wherein at least a portion of the linear protrusion is inserted into the suction linear groove when the sheet holding mechanism is bringing the sheet into close contact with the area surrounding the molding area on the first surface. A seat holding mechanism according to any one of claims 1 to 3;
a molding machine including a mold used for vacuum forming the sheet, the mold body having a first surface facing the sheet during vacuum forming, the first surface having a forming area for vacuum forming the sheet and an outer peripheral area surrounding the forming area;
A molding system comprising: a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with an area surrounding the molding area of the first surface. A molding machine including the mold according to any one of claims 4 to 6;
a sheet holding mechanism for holding the sheet;
A molding system comprising: a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with an area surrounding the molding area of the mold. A molding machine according to claim 7;
a sheet holding mechanism for holding the sheet;
A molding system comprising: a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with an area surrounding the molding area of the mold. The molding system according to claim 8, wherein the molding machine forms a storage space, a portion of which is partitioned by the molding area and in which a portion of the sheet is stored, and injection molds resin into the storage space. The molding system according to claim 9, wherein the molding machine forms a storage space, a portion of which is partitioned by the molding area and in which a portion of the sheet is stored, and injection molds resin into the storage space. The molding system according to claim 10, wherein the molding machine forms a storage space, a portion of which is partitioned by the molding area and in which a portion of the sheet is stored, and injection molds resin into the storage space. A method for producing a molded product using the molding system according to claim 11 or 12, comprising the steps of:
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
causing the molding machine to form the storage space in which a portion of the sheet is stored, and then injection molding a resin into the storage space. A method for producing a molded product using the molding system according to claim 13, comprising the steps of:
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
causing the molding machine to form the storage space in which a portion of the sheet is stored, and then injection molding a resin into the storage space. A method for producing a molded product using the molding system according to claim 14, comprising the steps of:
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
a step of vacuum-molding the sheet, which is in close contact with a region of the mold surrounding the molding region, by using the mold;
causing the molding machine to form the storage space in which a portion of the sheet is stored, and then injection molding a resin into the storage space. A method for producing a molded sheet using the molding system according to claim 8,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
and vacuum-molding the sheet, which has been brought into close contact with an area surrounding the molding area of the mold, using the mold. A method for producing a molded sheet using the molding system according to claim 9,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
and vacuum-molding the sheet, which has been brought into close contact with an area surrounding the molding area of the mold, using the mold. A method for producing a molded sheet using the molding system according to claim 10,
a step of closely contacting the sheet held by the sheet holding mechanism with a region surrounding the molding region of the mold;
and vacuum-molding the sheet, which has been brought into close contact with an area surrounding the molding area of the mold, using the mold.