JP3896666B2

JP3896666B2 - Film member molding method and assembly method thereof

Info

Publication number: JP3896666B2
Application number: JP00423198A
Authority: JP
Inventors: 俊之横井; 英尚大澤; 浩伊藤
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 1998-01-12
Filing date: 1998-01-12
Publication date: 2007-03-22
Anticipated expiration: 2018-01-12
Also published as: JPH11198224A

Description

【０００１】
【発明の属する技術分野】
本発明はフィルム部材の成形方法およびその組付方法に関するもので、具体的には、車両用空調装置における空気通路の切替作用を果たすフィルム式ロータリドアにおけるフィルム部材の成形方法およびその組付方法として好適なものである。
【０００２】
【従来の技術】
本出願人は先に、特願平８−１７０１６５号等の特許出願において、フィルム式のロータリドア部にて複数の吹出空気通路開口部を切替える空気通路切替装置を提案している。まず、この先願の装置の概要を図２５〜図２７により説明すると、円弧状の外周面を有する樹脂製ドア基板部材１００を、ケース１１０内に複数の吹出空気通路開口部１１１、１１２、１１３と対向するようにして回動可能に設け、このドア基板部材１００の外周部に樹脂製フィルム部材１２０を配設するとともに、このフィルム部材１２０に風圧を加えるためのドア通風口１０１をドア基板部材１００の円周壁１０２に開けている。
【０００３】
また、フィルム部材１２０には、吹出空気通路開口部１１１〜１１３と連通し得るフィルム開口部１２１を設けている。なお、吹出空気通路開口部１１１は具体的には、車室内の乗員頭部への吹出用のフェイス吹出口に連通し、吹出空気通路開口部１１２は具体的には、車室内の乗員足元への吹出用のフット吹出口に連通し、吹出空気通路開口部１１３は具体的には、車室内の窓ガラス内側への吹出用のデフロスタ吹出口に連通するものである。
【０００４】
そして、ドア基板部材１００を回転軸１０５を中心として矢印Ｘ、Ｙ方向に回動操作して、その回動位置を選択することにより、複数の吹出空気通路開口部１１１〜１１３を選択的に開閉する。すなわち、フィルム部材１２０のうちフィルム開口部１２１のない部分がケース側の吹出空気通路開口部１１１〜１１３のいずれかの周縁部に風圧により圧接することにより、フィルム部材１２０にて吹出空気通路開口部を閉塞し、一方、フィルム部材１２０の開口部１２１と吹出空気通路開口部とが重畳して、この両者が連通することにより、空気通路を開放するようにしている。
【０００５】
ところで、上記のごとき空気通路切替装置において、フィルム部材１２０とドア基板部材１００との組立構造は次のごとくなっている。
すなわち、図２６、図２７に示すように、ドア基板部材１００の円周壁１０２の円周方向の両端部にそれぞれ複数本のピン１０３およびピン１０４を一体に成形する。一方、フィルム部材１２０の両端部にそれぞれ、ピン１０３、ピン１０４が挿通可能な複数個の長孔状の取付孔部１２２、１２３を形成するとともに、取付孔部１２３側の端部１２６を円弧形状の内方へ折り曲げて折り曲げ部１２４を形成しておく。
【０００６】
そして、フィルム部材１２０の両端の取付孔部１２２、１２３をそれぞぞれピン１０３、１０４に挿通するようにして、フィルム部材１２０をドア基板部材１００の外周側に被せた後に、ピン１０３、１０４の先端部を熱かしめして、ピン部材１０３、１０４の先端部をリベット状に拡大する。これにより、フィルム部材１２０がドア基板部材１００から外れるのを防止して、フィルム部材１２０とドア基板部材１００との組立を終えることができる。
【０００７】
【発明が解決しようとする課題】
本発明者らは、上記のごとき空気通路切替装置の具体的組立方法および組立装置の開発に際して、まず、次の方法を検討してみた。フィルム部材１２０をヒータ内蔵の加熱成形型に装着して、フィルム部材１２０を構成する樹脂材料（ＰＥＴ：ポリエチレンテレフタレート）のガラス転移温度（８１°Ｃ）より高い所定温度（例えば、１３０°Ｃ）に加熱して、所定の円弧形状に成形することを検討してみた。ここで、樹脂材料のガラス転移温度以上の温度にフィルム部材１２０を加熱するのは成形後のスプリングバックによる変形を抑制するためである。
【０００８】
ところで、ガラス転移温度以上に加熱したフィルム部材１２０を所定形状に成形するためには、フィルム部材１２０を所定形状に維持したままで常温近傍まで冷却する必要があるが、加熱成形型は熱容量が大きな装置であるので、常温近傍まで冷却しようとすると、冷却時間が非常に長くかかるという問題を生じる。また、熱容量の大きい加熱成形型を一旦常温近傍まで冷却すると、次のフィルム部材１２０の成形のために、加熱成形型を再び樹脂材料のガラス転移温度以上に温度上昇させるのに時間が非常に長くかかってしまう。従って、同一装置を用いて、フィルム部材１２０を繰り返し成形する際に、フィルム部材１２０の成形作業の生産性を著しく低下させることになる。
【０００９】
そこで、加熱成形型とは別に冷却成形型を用意して、フィルム部材１２０を加熱成形型においてガラス転移温度以上の温度に加熱して成形した後に、フィルム部材１２０を加熱成形型から取り外して、常温に維持されている冷却成形型にフィルム部材１２０を装着し、この冷却成形型にてフィルム部材１２０を常温近傍まで冷却することを検討したが、この場合は、加熱成形型と冷却成形型の２つの型を用意する必要があり、設備費が高くつく。また、加熱成形型と冷却成形型の２つの型の間でフィルム部材１２０を脱着して移動させる作業が必要となり、加工工数の増加を招く。
【００１０】
さらには、フィルム部材１２０が板厚１８８μｍ程度の薄膜状部材であり、熱容量が非常に小さい部材であるので、フィルム部材１２０を加熱成形型から取り外して、冷却成形型に装着するまでの移動の間にフィルム部材１２０の温度がガラス転移温度以下の温度に急速に低下してしまい、その結果、フィルム部材１２０を所期の設計通りの形状に成形できない場合が生じる。
【００１１】
すなわち、フィルム部材１２０の一端部に円弧形状の内方への折り曲げ部１２４を形成する場合は、この折り曲げ部１２４が成形型にとって型抜きの妨げとなるアンダーカット形状となるので、フィルム部材１２０を加熱成形型から取り外す際には、このアンダーカット形状となる折り曲げ部１２４を一時的に外方へ押し広げてフィルム部材１２０を加熱成形型から取り外す必要がある。その結果、この折り曲げ部１２４を押し広げた状態のときにフィルム部材１２０の温度がガラス転移温度以下の温度に低下してしまう事態が発生し、フィルム部材１２０を所期の設計通りの形状に成形できないという不具合が生じる。
【００１２】
本発明は上記点に鑑みてなされたもので、第１には、フィルム部材の所定形状への曲げ成形を高い生産性で効率よく行うことができる成形方法を提供することを目的とする。
また、第２には、ロボット装置の１つのハンド部を用いて、フィルム部材の所定形状への曲げ成形と、フィルム部材と基板部材との組立を高い生産性で効率よく行うことができるようにすることをを目的とする。
【００１３】
【課題を解決するための手段】
上記目的を達成するため、請求項１〜６記載の発明では、薄膜状の樹脂製フィルム部材（１２０）を加熱成形型（１１）により所定の曲げ形状に曲げ成形する成形方法であって、
加熱成形型（１１）の外周成形面（１１ａ）を円弧状に形成し、円弧状の外周成形面（１１ａ）には略矩形の凹形状からなる多数の溝部（１１ｂ）と多数の溝部（１１ｂ）間に位置する仕切り部（１１ｂ’）とを外周成形面（１１ａ）の円周方向に交互に形成し、
仕切り部（１１ｂ’）の頂面は円弧状の平滑面とし、
フィルム部材（１２０）の両端部（１２５、１２６）を組付用ツール（１７）により把持して、フィルム部材（１２０）を加熱成形型（１１）の仕切り部（１１ｂ’）の頂面に沿うように押し当て、これにより、フィルム部材（１２０）を加熱成形型（１１）に対して円弧状に装着して、加熱成形型（１１）によりフィルム部材（１２０）を所定温度に加熱した後に、加熱成形型（１１）の外周成形面（１１ａ）の多数の溝部（１１ｂ）に空気供給手段（１３、１４）により冷却空気を供給するとともに、外周成形面（１１ａ）とフィルム部材（１２０）との間に多数の溝部（１１ｂ）により空気層（１２）を形成することによりフィルム部材（１２０）を冷却することを特徴としている。
【００１４】
これよると、フィルム部材（１２０）が薄膜状の形態であって熱容量が非常に小さいことと、空気層（１２）の形成とにより、フィルム部材（１２０）を加熱成形型（１１）に装着したままでも、フィルム部材（１２０）を短時間で良好に冷却できる。
従って、１つの加熱成形型の使用で、フィルム部材の所定形状への曲げ成形を高い生産性で効率よく行うことができる。
また、加熱成形型１１の外周成形面（１１ａ）に溝部（１１ｂ）を形成することにより、空気層（１２）を簡単に形成できる。
また、フィルム部材をアンダーカット形状の部分（例えば、請求項３の折り曲げ部（１２４））を持つ形状に曲げ成形する場合でも、フィルム部材（１２０）を加熱成形型（１１）に装着したまま冷却するから、フィルム部材の曲げ成形性を損なうことが全くない。
【００１５】
請求項２記載の発明のように、フィルム部材（１２０）の加熱工程において、フィルム部材（１２０）の樹脂材料のガラス転移温度以上にフィルム部材を加熱するようにすれば、フィルム部材の成形後のスプリングバックによる変形を抑制できる。
請求項４記載の発明では、請求項３に記載のフィルム部材の成形方法において、空気供給手段は、加熱成形型（１１）において円弧状の外周成形面（１１ａ）の軸方向の両側の側方に配置されたエアブロー用ノズル装置（１３、１４）で構成され、
前記冷却工程において、前記両側のエアブロー用ノズル装置（１３、１４）のうち一方側のノズル装置（１３）により多数の溝部（１１ｂ）全体に冷却空気を供給し、他方側のノズル装置（１４）により折り曲げ部（１２４）に冷却空気を供給することを特徴とする。
これによると、フィルム部材（１２０）の折り曲げ部（１２４）を他方側のノズル装置（１４）により集中的に良好に冷却できる。
【００１６】
特に、請求項５記載の発明では、フィルム部材（１２０）が所定曲げ形状の途中に開口部（１２１）を有する形状であり、加熱成形型（１１）に対してフィルム部材（１２０）を装着する工程において、フィルム部材（１２０）のうち、開口部（１２１）のある部位の周辺を押さえプレート（１７２）により外周成形面（１１ａ）側に押圧することを特徴としている。
【００１７】
フィルム部材（１２０）の加熱工程時には、フィルム部材が急激な温度上昇により熱収縮を発生して歪みを発生しようとする。特に、フィルム部材のうち、多数の開口部（１２１）が形成されている部位では、開口部同志の間に細い仕切り部があるので、熱収縮による歪みが発生しやすい。しかるに、請求項５記載の発明によると、押さえプレート（１７２）によって、フィルム部材の開口部（１２１）周辺の部位を加熱成形型（１１）の外周成形面（１１ａ）側に押圧することにより、フィルム部材の熱収縮による歪みを良好に抑制できる。
【００１８】
また、請求項７〜９記載の発明では、薄膜状の樹脂製フィルム部材（１２０）を加熱成形型（１１）により所定の曲げ形状に曲げ成形した後に、このフィルム部材（１２０）を基板部材（１００）に組み付ける組付方法であって、
加熱成形型（１１）の外周成形面（１１ａ）を円弧状に形成し、円弧状の外周成形面（１１ａ）には略矩形の凹形状からなる多数の溝部（１１ｂ）と多数の溝部（１１ｂ）間に位置する仕切り部（１１ｂ’）とを外周成形面（１１ａ）の円周方向に交互に形成し、
仕切り部（１１ｂ’）の頂面は円弧状の平滑面とし、
ロボット装置（１５）のハンド部（１６）に備えられた組付用ツール（１７）によりフィルム部材（１２０）の両端部（１２５、１２６）を把持して、フィルム部材（１２０）を加熱成形型（１１）の仕切り部（１１ｂ’）の頂面に沿うように押し当て、これにより、フィルム部材（１２０）を加熱成形型（１１）に円弧状に装着して、加熱成形型（１１）によりフィルム部材（１２０）を所定温度に加熱し、
この加熱工程の後に、外周成形面（１１ａ）の多数の溝部（１１ｂ）に空気供給手段（１３、１４）により冷却空気を供給するとともに、外周成形面（１１ａ）とフィルム部材（１２０）との間に多数の溝部（１１ｂ）により空気層（１２）を形成することによりフィルム部材（１２０）を冷却し、
この冷却工程の後に、組付用ツール（１７）によりフィルム部材（１２０）を加熱成形型（１１）から取り外して基板部材（１００）のセット部位まで移動させ、フィルム部材（１２０）を基板部材（１００）に組み付けることを特徴としている。
【００１９】
これによると、請求項１記載の発明によるフィルム部材の曲げ成形の効果を発揮できると同時に、フィルム部材の曲げ成形からフィルム部材と基板部材との組付に至る一連の工程を１つのロボット装置（１５）のハンド部（１６）の動作により効率よく実施できる。
なお、上記各手段の括弧内の符号は、後述する実施形態記載の具体的手段との対応関係を示すものである。
【００２０】
【発明の実施の形態】
以下、本発明の実施の形態を図に基づいて説明する。
最初に、本実施形態におけるフィルム部材１２０の成形方法および組付方法を実施するための成形、組付装置を図１〜図８に基づいて説明する。なお、ドア基板部材１００およびフィルム部材１２０は前述の図２５〜２７に示す通りであるので、説明は省略する。
【００２１】
図１、２は成形、組付装置の全体構成の概要を示すもので、略矩形状の基台１０の上面の中央部に加熱成形型１１が配置されている。この加熱成形型１１は図３に示すように金属製の円弧状の外周成形面１１ａを有し、そして、この円弧状の外周成形面１１ａには、その軸方向に略矩形の凹形状からなる多数の溝部１１ｂ（図４参照）が形成してある。
【００２２】
この溝部１１ｂは、後述のフィルム冷却工程においてフィルム部材１２０と外周成形面１１ａとの間に空気層１２を形成するためのものである。ここで、空気層１２（溝部１１ｂ）の幅Ｗ₁は、溝部１１ｂ間の仕切り部１１ｂ′の幅Ｗ₂より十分大きく（２倍程度）して、フィルム冷却工程での冷却効果を高めるようにしてある。
【００２３】
また、図５に示すように、加熱成形型１１において、円弧状の外周成形面１１ａの内側には複数本（図５の例では９本）の電気ヒータ１１ｃが軸方向に平行に配設されている。さらに、円弧状の外周成形面１１ａの内側には熱電対からなる温度検出器１１ｄを複数箇所配置し、この温度検出器１１ｄの検出温度に応じて電気ヒータ１１ｂの通電を断続制御することにより、外周成形面１１ａの温度を所定温度に制御し、維持するようになっている。
【００２４】
本例では、具体的には、フィルム部材１２０を構成する樹脂材料（ＰＥＴ：ポリエチレンテレフタレート）のガラス転移温度（８１°Ｃ）より高くて、溶融温度（２６４°Ｃ）より低い所定温度（例えば、１３０°Ｃ±５°Ｃ）に外周成形面１１ａの温度を維持する。
また、加熱成形型１１において、円弧状の外周成形面１１ａの軸方向の両側の側方には、空気供給手段としてのエアブロー用ノズル装置１３、１４が配置されている。左側のノズル装置１３は、円弧状の外周成形面１１ａの溝部１１ｂの全体に冷却空気を供給できるように、溝部１１ｂに沿って円弧状に配置された複数（例えば、９個）のノズル１３ａを有している。
【００２５】
右側のノズル装置１４は、フィルム部材１２０の端面曲げ側（９０°曲げ側、後述の図１０参照）の端部１２６に集中的に冷却空気を供給して、この端部１２６の冷却効果を高めるためのものである。そのため、右側のノズル装置１４はこの端部１２６に対向する部位に配置したノズル１４ａを１個のみ有している。
次に、基台１０の上面の中央部で、加熱成形型１１より奥まった位置に産業用ロボット装置１５のハンド部１６が配置されている。このハンド部１６は、水平方向に移動可能な水平多関節型のものであって、図１の円弧線１６ａはハンド部１６の最大可動エリアを示している。ハンド部１６の先端には組付用ツール１７が取付られている。
【００２６】
図６は、この組付用ツール１７の全体の概要を示し、図７はその主要要素の具体的な配置レイアウトを例示する図である。なお、図７は図６の長手方向中間部位での断面配置図である。１７０は組付用ツール１７のフレーム本体であり、このフレーム本体１７０の全体形状は概略半円筒状になっている。このフレーム本体１７０は、その上面部に配置された、ハンド部１６の軸部１７１に連結されている。
【００２７】
フレーム本体１７０の上方寄りの部位には略円弧状の金属薄板（例えば、ＳＵＳ３０４、板厚ｔ＝０．５ｍｍ）からなる押さえプレート１７２が備えられている。この押さえプレート１７２は、図１０、図２５〜図２７に示すフィルム部材１２０のうち、開口部１２１のある部位の周辺を加熱成形型１１の円弧状外周成形面１１ａ側に押圧するためのものである。この押さえプレート１７２の円周方向の両端部には、押さえプレート１７２の両端部を図７の上下方向に変位させるエアシリンダ（操作手段）１７３、１７４が配置されている。
【００２８】
一方、フレーム本体１７０の半円筒状の一端側に、フィルム部材１２０の円弧曲げ（後述の図１０参照）用の第１アーム１７５が支点軸１７６により回動可能に配置されている。また、フレーム本体１７０の半円筒状の他端側に、フィルム部材１２０の９０°曲げ（後述の図１０参照）用の第２アーム１７７が支点軸１７８により回転可能に配置されている。
【００２９】
ここで、第１アーム１７５と支点軸１７６は図示しないロータリエアシリンダ（操作手段）により、所定回転角（例えば、９８°）の範囲で回転するようになっている。同様に、第２アーム１７７と支点軸１７８も図示しないロータリエアシリンダ（操作手段）により、所定回転角（例えば、９０°）の範囲で回転するようになっている。
【００３０】
また、フレーム本体１７０において、第１アーム１７５の支点軸１７６より下方側の部位にカム溝１７９が形成されており、このカム溝１７９内には溝形状に沿って摺動可能な円形のカム従動体１８０が配置されている。このカム従動体１８０は支点軸１８１により２つのサブアーム１８２、１８３の一端部と回転可能に連結されている。サブアーム１８３の他端部は支点軸１８４により第１アーム１７５に回転可能に連結されている。また、サブアーム１８２の先端にはフィルム部材１２０の円弧曲げ側の端部１２５を把持するためのチャック用爪部１８５が一体に設けられている。
【００３１】
本例では、円弧曲げ用の第１アーム１７５が支点軸１７６を中心として９８°回転すると、支点軸１８４の変位によりサブアーム１８３を介してカム従動体１８０がカム溝１７９の溝形状に沿ってインボリュート曲線を描きながらチャック用爪部１８５を移動させる。
また、サブアーム１８２の他端部は支点軸１８６により駆動ロッド１８７に回転可能に連結されている。この駆動ロッド１８７はエアシリンダ（操作手段）１８８により図示の矢印のように前進後退する。なお、エアシリンダ１８８のボディ部は、支点軸１８９により支持プレート１９０に対して回転可能に支持され、この支持プレート１９０は第１アーム１７５に一体に保持されている。
【００３２】
次に、第２アーム１７７には２つの支持プレート１９１、１９２が一体に備えられており、支持プレート１９２の先端部にはエアシリンダ（操作手段）１９３が支点軸１９４により回転可能に支持されている。このエアシリンダ１９３により駆動ロッド１９５が図示の矢印のように前進後退する。駆動ロッド１９５の先端部には支点軸１９６によりサブアーム１９７の一端部が回転可能に連結されている。
【００３３】
また、サブアーム１９７の他端部は上記支持プレート１９１の先端部に支点軸１９８により回転可能に連結されている。さらに、サブアーム１９７の先端にはフィルム部材１２０の９０°曲げ側の端部１２６を把持するためのチャック用爪部１９９が一体に設けられている。
一方、基台１０の上面において、加熱成形型１１の一方の側方にフィルム部材１２０のセット装置２０が配置されている。このセット装置２０の基板２００は、基台１０の上面に固定された２本の第１レール２０１の上に図１の矢印Ａ方向に前進後退できるように配置されている。このセット装置２０の前進後退は、図示しないエアシリンダ（操作手段）の操作力により行う。
【００３４】
基板２００の上面には図８に示すように２本の第２レール２０２が配置され、この第２レール２０２の上に移動支持台２０３が前進後退できるように配置されている。この移動支持台２０３の前進後退はエアシリンダ（操作手段）２０４により行う。移動支持台２０３の上面には、ロータリエアシリンダ（操作手段）２０５により回転可能な第１ロータリチャック２０６が配置されている。
【００３５】
この第１ロータリチャック２０６には、フィルム部材１２０の円弧曲げ側の端部１２５の長孔状取付孔部１２２に挿入される位置決めピン２０６ａおよびフィルム部材１２０の円弧曲げ側の端部１２５を挟み込み固定するチャック片２０６ｂが備えられている。
また、基板２００の上面には２本の第２レール２０２から所定間隔開けて、固定支持台２０７が位置不動に固定されている。この固定支持台２０７の上面には、ロータリエアシリンダ（操作手段）２０８により回転可能な第２ロータリチャック２０９が配置されている。この第２ロータリチャック２０９も、第１ロータリチャック２０６と同様な構成のものであって、フィルム部材１２０の９０°曲げ側の端部１２６の長孔状取付孔部１２３に挿入される位置決めピン２０９ａおよびフィルム部材１２０の９０°曲げ側の端部１２６を挟み込み固定するチャック片２０９ｂが備えられている。
【００３６】
次に、図１、２に示すように、基台１０の上面において、加熱成形型１１の他方の側方にドア基板部材１００のセット装置３０が配置されている。このセット装置３０の基板３００は、基台１０の上面に固定されたレール３０１の上に図１の矢印Ｂ方向に前進後退できるように配置されている。このセット装置３０の前進後退は、図示しないエアシリンダ（操作手段）の操作力により行う。
【００３７】
基板３００の上面にはドア基板部材１００の軸方向両端部から外側へ突出する回転軸１０５を支持するＶ状凹部を持つ支持台３０２が備えられている。また、基板３００のうち、ドア基板部材１００の径方向の上下両側には、貫通穴部３０３、３０４が設けられている。この貫通穴部３０３、３０４は熱かしめ装置３０５の熱かしめ用溶着ヘッド３０６、３０７を通過させるために開けてある。
【００３８】
ここで、熱かしめ装置３０５は加熱成形型１１の直ぐ側方に配置され、一方の溶着ヘッド３０６は、ドア基板部材１００の円周方向の一端側（フィルム部材１２０の円弧曲げ側の端部１２５に対応）の３本のピン１０３の先端部を熱かしめするように、３本設けられている。また、他方の溶着ヘッド３０７は、ドア基板部材１００の円周方向の他端側（フィルム部材１２０の円弧曲げ側の端部１２６に対応）の５本のピン１０４の先端部を熱かしめするように、５本設けられている。
【００３９】
この２組の溶着ヘッド３０６、３０７は、それぞれ図２の矢印Ｃ、Ｄ方向に移動可能になっている。また、熱かしめ装置３０５には、図示しないエアブロー用のノズル（空気供給手段）が溶着ヘッド３０６、３０７に隣接して設けられており、このエアブロー用のノズルによりピン１０３、１０４を熱かしめ後に強制冷却するようになっている。
【００４０】
次に、本実施形態におけるフィルム部材１２０の成形方法およびフィルム部材１２０とドア基板部材１００と組付方法を説明する。図９は本実施形態による成形、組付方法の工程の流れの説明図であり、図１０はフィルム部材１２０の形状の変化の推移を示す。
以下、本実施形態による成形、組付方法の各工程を具体的に説明する。
（１）フィルム部材１２０およびドア基板部材１００のセット工程
フィルム部材１２０は図１０の上部に示す外形抜き加工された平坦形状の状態で、負圧チャック機構または作業者Ｍの手動操作にてセット装置２０上方に供給（図１の矢印Ｅ方向）される。そして、フィルム部材１２０の両端部１２５、１２６の取付孔部１２２、１２３を第１ロータリチャック２０６、第２ロータリチャック２０９の位置決めピン２０６ａ、２０９ａに嵌合して、セット装置２０に対するフィルム部材１２０の位置決めを行うとともに、第１ロータリチャック２０６、第２ロータリチャック２０９のチャック片２０６ｂ、２０９ｂにてフィルム部材１２０の両端部１２５、１２６を把持（チャック）する。
【００４１】
一方、ドア基板部材１００は予め図１０に示す半円筒状の形状に樹脂成形されており、このドア基板部材１００を自動チャック機構または作業者Ｍの手動操作にて矢印Ｈ方向からセット装置３０の上方に供給し、ドア基板部材１００の軸方向両端部の回転軸１０５を基板３００の支持台３０２のＶ状凹部上に載せ、図示しないエアシリンダにより回転軸１０５部分を保持し、ドア基板部材１００を固定する。
【００４２】
この後、基板３００を図示しないエアシリンダの操作力によりレール３０１の上で前進（図１の上方へ移動）させて、セット装置３０とともにドア基板部材１００を図１の上側位置（ロボット装置１５のハンド部１６の移動範囲）に待機させておく。
（２）フィルム部材１２０の仮曲げ工程
上記フィルム部材１２０のセット後に、フィルム部材１２０のセット装置２０の全体を図示しないエアシリンダの操作力により図８の矢印Ａ方向に移動させて、図８の右側位置（ロボット装置１５のハンド部１６の移動範囲）にセット装置２０を移動させる。これと同時に、移動支持台２０３を第２レール２０２上でエアシリンダ（操作手段）２０４により前進させて、フィルム部材１２０の縮み動作を行うとともに、ロータリエアシリンダ２０５、２０８により第１、第２ロータリチャック２０６、２０９をそれぞれ図８の矢印Ｆ、Ｇ方向に回転して、フィルム部材１２０の全体を円弧状に仮曲げする。この仮曲げは、後述の組付用ツール１７によるフィルム部材１２０の把持を可能にするために行う。
（３）フィルム部材１２０の加熱成形型１１への装着、曲げ工程
上記のごとく第１、第２ロータリチャック２０６、２０９にて円弧状に仮曲げしたフィルム部材１２０の位置にハンド部１６を移動させて、ハンド部１６の組付用ツール１７によりフィルム部材１２０の両端部１２５、１２６を把持する。この際に、組付用ツール１７は図１１に示す原位置（フィルム受け取り位置）にあって、チャック用爪部１８５、１９９が開いた位置にある。
【００４３】
そして、この状態において、組付用ツール１７のエアシリンダ１８８、１９３を作動させて、その駆動用ロッド１８７、１９５を前進（図１１の下方へ移動）させると、支点軸１８６、１９６の位置が下方へ移動するので、チャック用爪部１８５、１９９が上記原位置から支点軸１８１、１９８を中心として回転し、図１２の位置に移動する。この図１２の状態になった後にセット装置２０においては、第１、第２ロータリチャック２０６、２０９のチャック片２０６ｂ、２０９ｂがフィルム部材１２０の両端部１２５、１２６を解放する状態に復帰する。
【００４４】
図１２はフィルム部材１２０の両端部１２５、１２６を把持する状態（フィルムチャック状態）を示す。この状態では、フィルム部材１２０の円弧曲げ側端部１２５は、サブアーム１８３の側面部とチャック用爪部１８５とにより挟持され、また、フィルム部材１２０の９０°曲げ側端部１２６は、支持プレート１９１の側面部とチャック用爪部１９９とにより挟持される。なお、このチャック用爪部１８５、１９９による挟持部分は、フィルム部材１２０の円弧曲げ側端部１２５および９０°曲げ側端部１２６においてそれぞれ２か所づつ設定してある。
【００４５】
上記のようにして、フィルム部材１２０の両端部１２５、１２６を組付用ツール１７により把持した後に、ハンド部１６を加熱成形型１１の位置に向かって回転させて、フィルム部材１２０を加熱成形型１１の位置に搬送する。そして、フィルム部材１２０の円周方向の中央部を加熱成形型１１の円弧状外周成形面１１ａ（より具体的には、仕切り部１１ｂ’の頂面）に押し当てる。
【００４６】
図１３はこのフィルム押し当て状態を示すもので、図１３では加熱成形型１１の円弧状外周成形面１１ａにフィルム部材１２０の中央部を押し当てた後に、フィルム部材１２０の９０°曲げ側端部１２６における９０°曲げを完了した状態を示している。この９０°曲げ加工は、図１２の状態から、組付用ツール１７の第２アーム１７７を時計方向に９０°回転することにより行うことができる。
【００４７】
次に、組付用ツール１７の第１アーム１７５を図１４に示すように、図１２、図１３の状態から反時計方向に９８°回転することにより、フィルム部材１２０の円弧曲げ側端部１２５を加熱成形型１１の円弧状外周成形面１１ａに沿った円弧状に曲げることができる。以上により、加熱成形型１１へのフィルム部材１２０の装着と曲げ加工を完了できる。
（３）フィルム部材１２０の加熱工程
加熱成形型１１の外周成形面１１ａはその内蔵電気ヒータ１１ｃにより所定温度（フィルム部材１２０の樹脂材料のガラス転移温度より高い１３０°Ｃ±５°Ｃ）に維持されているので、加熱成形型１１へのフィルム部材１２０の装着（巻き付け）が完了すると、直ちに、フィルム部材１２０の加熱が開始される。
【００４８】
このとき、フィルム部材１２０が急激な温度上昇により熱収縮を発生して歪みを発生することがある。特に、フィルム部材１２０のうち、多数の開口部１２１が形成されている部位では開口部１２１同志の間に細い仕切り部があるので、熱収縮による歪みが発生しやすい。そこで、図１５に示すように、エアシリンダ１７３、１７４の駆動ロッド１７３ａ、１７４ａを下降させて、金属薄板からなる押さえプレート１７２を下降させ、この押さえプレート１７２によって、フィルム部材１２０のうち、開口部１２１周辺の部位を加熱成形型１１の円弧状外周成形面１１ａ側に押圧する。これにより、フィルム部材１２０の熱収縮による歪みを良好に抑制できる。
【００４９】
このように、押さえプレート１７２によって、フィルム部材１２０の開口部１２１周辺の部位を加熱成形型１１の円弧状外周成形面１１ａ側に押圧した状態で、フィルム部材１２０を所定時間（例えば、数秒程度）加熱する。
（４）フィルム部材１２０の冷却工程
上記加熱開始後の時間がタイマー手段による所定時間経過すると、フィルム部材１２０がその樹脂材料のガラス転移温度より高い温度まで上昇して加熱が完了するので、フィルム部材１２０の冷却を開始する。この冷却工程においては、まず、図１６に示すように、エアシリンダ１７３、１７４の駆動ロッド１７３ａ、１７４ａを上昇させて、押さえプレート１７２を上方へ戻す。この後に、エアブロー用ノズル装置１３、１４のノズル１３ａ、１４ａから冷却空気（周囲の常温の空気）を噴出して、フィルム部材１２０を冷却する。
【００５０】
このとき、左側のノズル装置１３のノズル１３ａは、加熱成形型１１の円弧状外周成形面１１ａの溝部１１ｂの全体に冷却空気を供給するので、外周成形面１１ａとフィルム部材１２０との間に空気層１２（図４参照）を形成することができる。この空気層１２の形成と、フィルム部材１２０の熱容量が小さいこととが相まって、フィルム部材１２０を加熱成形型１１の円弧状外周成形面１１ａに装着したままの状態でも、フィルム部材１２０を急速に冷却できる。右側のノズル装置１４は、フィルム部材１２０の９０°曲げ側端部１２６に集中的に冷却空気を供給して、この端部１２６の冷却効果を高める。
【００５１】
ここで、フィルム部材１２０の形状を設計通りの形状に成形するためには、樹脂材料のガラス転移温度以下までフィルム部材１２０を冷却する必要があるが、上記のごとく、空気層１２を形成して熱容量の小さいフィルム部材１２０を強制空冷することにより、加熱成形型１１の内蔵電気ヒータ１１ｃの通電（発熱）を維持したままでも、フィルム部材１２０の冷却を極く短時間（例えば、数秒程度）で完了できる。
【００５２】
また、上記エアブロー用ノズル装置１３、１４からの冷却空気供給により、加熱成形型１１の円弧状外周成形面１１ａの表面温度は一時的に上記所定温度より２０°Ｃ程度低下するが、この程度の温度低下は冷却空気の供給停止後、短時間で上記所定温度に復帰させることができるので、次のフィルム部材１２０の加熱を遅延させる恐れはない。
【００５３】
また、フィルム部材１２０は、その一端部１２６側に円弧形状の内方へ９０°曲げした折り曲げ部１２４を有する形状であって、この折り曲げ部１２４は成形型にとって型抜きの妨げとなるアンダーカット形状となるが、上記のようにフィルム部材１２０を加熱成形型１１に装着したままで、フィルム部材１２０の冷却を行うから、９０°曲げした折り曲げ部１２４を有するフィルム部材１２０の成形性を損なうことが全くない。
【００５４】
上記した冷却工程は、タイマー手段にて上記エアブロー用ノズル装置１３、１４からの冷却空気の供給を所定時間で停止することにより完了し、以上によりフィルム部材１２０の成形が完了する。
（４）フィルム部材１２０とドア基板部材（１００）との組付工程
上記冷却工程の完了後に、まず最初に、フィルム部材１２０搬送のための準備を行う。すなわち、図１７に示すように、最初に、組付用ツール１７の第１アーム１７５を図１６の状態から時計方向に９８°回転することにより、フィルム部材１２０の円弧曲げ側端部１２５を加熱成形型１１の円弧状外周成形面１１ａから離す。この図１７の状態は前述の図１３と同じ状態である。
【００５５】
次に、図１８に示すように、組付用ツール１７の第２アーム１７７を図１６の状態から反時計方向に９０°回転することにより、フィルム部材１２０の９０°曲げ側端部１２６を加熱成形型１１の円弧状外周成形面１１ａから離す。この図１８の状態は前述の図１２と同じ状態である。なお、フィルム部材１２０の９０°曲げ側端部１２６を強制的に広げることにより、フィルム部材１２０の全体が加熱成形型１１の円弧状外周成形面１１ａから離れる。
【００５６】
これにより、フィルム部材１２０が搬送可能な状態になるので、次に、ハンド部１６を図１において反時計方向に回転させて、セット装置３０上のドア基板部材１００の位置に向かって移動させ、フィルム部材１２０を、円弧状の円周壁１０２を有するドア基板部材１００の位置に搬送する。そして、図１９に示すように、組付用ツール１７の第２アーム１７７を前述の図１８の状態から時計方向に９０°回転することにより、フィルム部材１２０の９０°曲げ側端部１２６をドア基板部材１００に組付ける。このとき、フィルム部材１２０の９０°曲げ側端部１２６の折り曲げ部１２４に設けられている取付孔部１２３をドア基板部材１００の円周壁１０２の一端側のピン１０４に挿通する。
【００５７】
次に、図２０に示すように、組付用ツール１７の第１アーム１７５を前述の図１８の状態から反時計方向に９８°回転することにより、フィルム部材１２０の円弧曲げ側端部１２５をドア基板部材１００に組付ける。このとき、フィルム部材１２０の円弧曲げ側端部１２５に設けられている取付孔部１２２をドア基板部材１００の円周壁１０２の他端側のピン１０３に挿通する。
【００５８】
次に、図２１に示すように、組付用ツール１７において、エアシリンダの駆動ロッド１８７、１９５をそれぞれ後退させて、チャック用爪部１８５、１９９をそれぞれフィルム部材１２０の両端部１２５、１２６から離れた位置（フィルムアンチャック位置）に操作する。
次に、図２２に示すように、組付用ツール１７において、第１アーム１７５を図２１の状態から時計方向に９８°回転することにより、第１アーム１７５を原位置に戻し、同様に、図２３に示すように、第２アーム１７７を図２１の状態から反時計方向に９０°回転することにより、第２アーム１７７を原位置に戻すことができ、チャック用爪部１８５、１９９をフィルム部材１２０とドア基板部材１００との組付ブロック体から十分離れた位置に移動できる。
【００５９】
上記のように、組付ブロック体の位置から組付用ツール１７を離した後に、フィルム部材１２０の円弧曲げ側端部１２５と９０°曲げ側端部１２６を、熱かしめ装置３０５に備えられた保持手段（図示せず、）によりドア基板部材１００に保持してフィルム部材１２０を固定する。なお、この保持手段は、具体的には、例えば、円弧曲げ側端部１２５では負圧チャック機構であり、また、９０°曲げ側端部１２６では押さえピンである。
【００６０】
しかるのち、上記ピン１０３およびピン１０４の先端部を同時に熱かしめする。この熱かしめは、ドア基板部材１００のセット装置３０の基板３００に設けられた貫通穴部３０３、３０４を通して、熱かしめ装置３０５の熱かしめ用溶着ヘッド３０６、３０７をピン１０３およびピン１０４の先端部に圧着することにより行うことができる。
【００６１】
この熱かしめ工程をさらに具体的に説明すると、図２４はドア基板部材１００のピン１０４を熱かしめする溶着ヘッド３０７を示しているが、ピン１０３を熱かしめする溶着ヘッド３０６も同様の構成で、熱かしめ方法も同様である。図２４において、溶着ヘッド３０７（３０６）はピン１０４（１０３）の拡大頭部１０４ａ（１０３ａ）を形成するための円形凹部３０７ａ（３０６ａ）を先端部に有している。
【００６２】
また、ピン１０４（１０３）の根元部と拡大頭部１０４（１０３ａ）との間に所定間隔を形成するため、熱かしめ装置３０５には、金属薄板（例えば、板厚＝０．５ｍｍ）からなるスペーサ３０８が図示しないエアシリンダ（操作手段）にてピン１０４（１０３）の外周側に前進後退できるように備えられている。
溶着ヘッド３０６、３０７はドア基板部材１００の樹脂材料（例えば、ポリプロピレン）の溶融温度（１６５°Ｃ）より高い温度（例えば、３００°Ｃ）に加熱される。
【００６３】
熱かしめの実施は、まず、スペーサ３０８をフィルム部材１２０の外面側においてピン１０３、１０４の外周側に前進させた後、溶着ヘッド３０６、３０７をピン１０３、１０４の先端部に圧着することにより、ピン１０３、１０４の先端部が樹脂の軟化温度以上に加熱されると同時に加圧されて、溶着ヘッド３０６、３０７の先端部の円形凹部３０６ａ、３０７ａに沿った形状に変形し、拡大頭部１０３ａ、１０４ａが形成される。
【００６４】
この拡大頭部の形成後に、溶着ヘッド３０６、３０７に隣接して設けられているエアブロー用のノズル（図示せず）からピン１０３、１０４に対して冷却空気を供給して、ピン１０３、１０４を強制冷却することにより、ピン１０３、１０４の熱かしめ形状を確定する。以上により、ピン１０３、１０４の熱かしめを終了することができ、これによって、フィルム部材１２０がドア基板部材１００から外れるのを防止できる。
【００６５】
この後、組付用ツール１７をハンド部１６とともに上記組付ブロック体から離れる方向に移動させた後に、セット装置３０を図１の下方側（作業者Ｍ側）へ移動させて、上記組付ブロック体をセット装置３０から矢印Ｉ方向へ取り出す。
以上により、本実施形態による、フィルム部材の成形、組付方法をすべて終了する。
【００６６】
（他の実施形態）
なお、上記の一実施形態では、フィルム部材１２０の成形に際して、加熱成形型１１の円弧状の外周成形面１１ａに溝部１１ｂを形成して、空気層１２を形成することにより、フィルム部材１２０の冷却を行っているが、本発明はこれに限定されるものではなく、例えば、加熱成形型１１の円弧状の外周成形面１１ａにに冷却空気の噴出穴を設けて、この噴出穴から冷却空気をフィルム部材１２０の内側面に向けて噴出することにより、外周成形面１１ａとフィルム部材１２０との間に空気層１２を形成するようにしてもよい。
【００６７】
また、上記の一実施形態では、フィルム部材１２０を円弧状に曲げ成形する場合について説明したが、円弧状以外の他の形状（例えば、多角形状等）にフィルム部材１２０を曲げ成形する場合にも本発明は適用できる。
また、上記の一実施形態では、車両用空調装置における空気通路の切替作用を果たすフィルム式ロータリドアにおけるフィルム部材１２０の成形、組付方法に本発明を適用する場合について説明したが、本発明はこれに限定されるものではなく、種々な用途におけるフィルム部材１２０の成形、組付方法に広く適用できる。
【図面の簡単な説明】
【図１】本発明の一実施形態による成形、組付方法を実施するための装置の概略平面図である。
【図２】図１の装置の側面図である。
【図３】図１、２の装置における加熱成形型部分の斜視図である。
【図４】図３の加熱成形型にフィルム部材を装着した状態での拡大断面図である。
【図５】図３の加熱成形型の断面構造図である。
【図６】図１、２に示すロボット装置のハンド部の組付用ツールの概略斜視図である。
【図７】図６の組付用ツールの具体的構造図である。
【図８】図１に示すフィルム部材用セット装置の概略斜視図である。
【図９】本発明方法の一実施形態における工程の全体説明図である。
【図１０】本発明方法の一実施形態におけるフィルム部材の成形、組付工程の流れ説明図である。
【図１１】組付用ツールの作動説明図である。
【図１２】組付用ツールの作動説明図である。
【図１３】組付用ツールの作動説明図である。
【図１４】組付用ツールの作動説明図である。
【図１５】組付用ツールの作動説明図である。
【図１６】組付用ツールの作動説明図である。
【図１７】組付用ツールの作動説明図である。
【図１８】組付用ツールの作動説明図である。
【図１９】組付用ツールの作動説明図である。
【図２０】組付用ツールの作動説明図である。
【図２１】組付用ツールの作動説明図である。
【図２２】組付用ツールの作動説明図である。
【図２３】組付用ツールの作動説明図である。
【図２４】熱かしめ工程の説明図である。
【図２５】先願のフィルム式のロータリドアを用いた空気通路切替装置を示す断面図である。
【図２６】図２５のフィルム式のロータリドアの断面図である。
【図２７】図２５、２６におけるフィルム部材およびドア基板部材の分解斜視図である。
【符号の説明】
１１…加熱成形型、１１ａ…外周成形面、１１ｂ…溝部、１２…空気層、
１３、１４…エアブロー用ノズル装置（空気供給手段）、１５…ロボット装置、
１６…ハンド部、１７…組付用ツール、１００…基板部材、
１２０…フィルム部材。[0001]
BACKGROUND OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a film member forming method and an assembling method thereof, and specifically, as a film member forming method and an assembling method thereof in a film type rotary door that performs an air passage switching action in a vehicle air conditioner. Is preferred.
[0002]
[Prior art]
The present applicant has previously proposed an air passage switching device for switching a plurality of blowing air passage openings in a film-type rotary door portion in a patent application such as Japanese Patent Application No. 8-170165. First, the outline of the apparatus of the prior application will be described with reference to FIGS. 25 to 27. A resin door substrate member 100 having an arcuate outer peripheral surface is connected to a plurality of blowing air passage openings 111, 112, 113 in a case 110. The resin film member 120 is disposed on the outer periphery of the door substrate member 100 so as to be able to rotate, and a door vent 101 for applying wind pressure to the film member 120 is provided in the door substrate member 100. The circumferential wall 102 is open.
[0003]
The film member 120 is provided with a film opening 121 that can communicate with the blown air passage openings 111 to 113. Specifically, the blowout air passage opening 111 communicates with a face blowout opening for blowing out to the passenger's head in the passenger compartment, and the blowout air passage opening 112 specifically to the passenger's feet in the passenger compartment. Specifically, the blowout air passage opening 113 communicates with a defroster blowout port for blowing into the window glass inside the vehicle interior.
[0004]
Then, the door substrate member 100 is rotated in the directions of the arrows X and Y about the rotation axis 105, and the rotation position is selected to selectively open and close the plurality of blowing air passage openings 111 to 113. To do. That is, the part without the film opening 121 of the film member 120 is brought into pressure contact with the peripheral edge of any of the blowing air passage openings 111 to 113 on the case side by wind pressure, so that the blowing air passage opening at the film member 120 is obtained. On the other hand, the opening 121 of the film member 120 and the blown air passage opening overlap each other and communicate with each other, thereby opening the air passage.
[0005]
Incidentally, in the air passage switching device as described above, the assembly structure of the film member 120 and the door substrate member 100 is as follows.
That is, as shown in FIGS. 26 and 27, a plurality of pins 103 and pins 104 are integrally formed at both ends in the circumferential direction of the circumferential wall 102 of the door substrate member 100. On the other hand, a plurality of elongate attachment holes 122 and 123 into which the pins 103 and 104 can be inserted are formed at both ends of the film member 120, and the end 126 on the attachment hole 123 side is formed in an arc shape. The bent portion 124 is formed by bending inward.
[0006]
And after attaching the film member 120 to the outer peripheral side of the door board | substrate member 100 so that the attachment hole parts 122 and 123 of the both ends of the film member 120 may be penetrated to the pins 103 and 104, respectively, The tip portions of the pin members 103 and 104 are enlarged in a rivet shape by caulking the tip portions. Accordingly, the film member 120 can be prevented from being detached from the door substrate member 100, and the assembly of the film member 120 and the door substrate member 100 can be completed.
[0007]
[Problems to be solved by the invention]
The inventors of the present invention first examined the following method in developing a specific assembling method and an assembling device for the air passage switching device as described above. The film member 120 is mounted on a thermoforming die with a built-in heater, and is set to a predetermined temperature (eg, 130 ° C.) higher than the glass transition temperature (81 ° C.) of the resin material (PET: polyethylene terephthalate) constituting the film member 120. It was considered to heat and form into a predetermined arc shape. Here, the reason why the film member 120 is heated to a temperature equal to or higher than the glass transition temperature of the resin material is to suppress deformation due to springback after molding.
[0008]
By the way, in order to form the film member 120 heated to the glass transition temperature or higher into a predetermined shape, it is necessary to cool the film member 120 to near the normal temperature while maintaining the predetermined shape, but the thermoforming mold has a large heat capacity. Since it is an apparatus, when it is going to cool to near normal temperature, the problem that cooling time takes very long will arise. Moreover, once the thermoforming mold having a large heat capacity is cooled to near normal temperature, it takes a very long time to raise the thermoforming mold again to a temperature higher than the glass transition temperature of the resin material in order to form the next film member 120. It will take. Therefore, when the film member 120 is repeatedly formed using the same apparatus, the productivity of the forming operation of the film member 120 is significantly reduced.
[0009]
Therefore, a cooling mold is prepared separately from the heat mold, and after the film member 120 is heated to a temperature equal to or higher than the glass transition temperature in the heat mold, the film member 120 is removed from the heat mold and is In this case, the film member 120 was mounted on a cooling mold maintained at the same temperature, and the film member 120 was cooled to near room temperature with the cooling mold. In this case, the heating mold and the cooling mold 2 were used. It is necessary to prepare two molds and the equipment cost is high. Moreover, the operation | work which remove | desorbs and moves the film member 120 between two type | molds, a heating shaping | molding die and a cooling shaping | molding die, is needed, and causes an increase in a process man-hour.
[0010]
Furthermore, since the film member 120 is a thin film-like member having a plate thickness of about 188 μm and has a very small heat capacity, the film member 120 is removed from the heating mold and is moved to the cooling mold. In addition, the temperature of the film member 120 rapidly decreases to a temperature not higher than the glass transition temperature, and as a result, the film member 120 may not be formed into a shape as designed.
[0011]
That is, when the arc-shaped inwardly bent portion 124 is formed at one end portion of the film member 120, the bent portion 124 has an undercut shape that prevents the mold from being removed. When removing from the thermoforming mold, it is necessary to remove the film member 120 from the thermoforming mold by temporarily spreading the bent portion 124 having an undercut shape outward. As a result, there is a situation in which the temperature of the film member 120 is lowered to a temperature lower than the glass transition temperature when the folded portion 124 is pushed and spread, and the film member 120 is formed into a desired shape. There is a problem that it cannot be done.
[0012]
The present invention has been made in view of the above points. First, an object of the present invention is to provide a molding method capable of efficiently bending a film member into a predetermined shape with high productivity.
Second, using one hand part of the robot apparatus, the film member can be bent into a predetermined shape and the assembly of the film member and the substrate member can be efficiently performed with high productivity. The purpose is to do.
[0013]
[Means for Solving the Problems]
  In order to achieve the above object, the invention according to claims 1 to 6 is a molding method in which a thin film-like resin film member (120) is bent into a predetermined bent shape by a thermoforming die (11),
  The outer peripheral molding surface (11a) of the heating mold (11) is formed in an arc shape, and the arc-shaped outer peripheral molding surface (11a) has a large number of groove portions (11b) and a large number of groove portions (11b) having a substantially rectangular concave shape. ) Partitioning portions (11b ′) located between them are alternately formed in the circumferential direction of the outer peripheral molding surface (11a),
  The top surface of the partition portion (11b ') is an arc-shaped smooth surface,
  Holding both ends (125, 126) of the film member (120) with the assembling tool (17), the film member (120) isAlong the top surface of the partition part (11b ') of the thermoforming mold (11)Against the film member (120)For thermoforming mold (11)In an arcAfter mounting and heating the film member (120) to a predetermined temperature by the thermoforming die (11), air supply means (13) are provided to the numerous grooves (11b) of the outer peripheral molding surface (11a) of the thermoforming die (11). 14), cooling air is supplied, and an air layer (12) is formed by a large number of grooves (11b) between the outer peripheral molding surface (11a) and the film member (120), thereby forming the film member (120). It is characterized by cooling.
[0014]
  According to this, the film member (120) is attached to the thermoforming die (11) due to the fact that the film member (120) is in the form of a thin film and has a very small heat capacity and the formation of the air layer (12). Even if it remains, the film member (120) can be satisfactorily cooled in a short time.
  Therefore, it is possible to efficiently perform the bending of the film member into a predetermined shape with high productivity by using one heating mold.
  Moreover, an air layer (12) can be easily formed by forming a groove part (11b) in the outer peripheral shaping | molding surface (11a) of the thermoforming mold 11. FIG.
  Further, even when the film member is bent and formed into a shape having an undercut-shaped portion (for example, the bent portion (124) of claim 3), the film member (120) is cooled while mounted on the thermoforming die (11). Therefore, there is no loss of the bend formability of the film member.
[0015]
  If the film member is heated to a temperature higher than the glass transition temperature of the resin material of the film member (120) in the heating step of the film member (120) as in the invention described in claim 2, after the film member is molded Deformation due to springback can be suppressed.
  According to a fourth aspect of the present invention, in the method for forming a film member according to the third aspect, the air supply means is lateral to both sides in the axial direction of the arc-shaped outer peripheral molding surface (11a) in the heating mold (11). The air blow nozzle device (13, 14) arranged in the
  In the cooling step, cooling air is supplied to the whole of the plurality of grooves (11b) by the nozzle device (13) on one side of the air blowing nozzle devices (13, 14) on both sides, and the nozzle device (14) on the other side. Thus, cooling air is supplied to the bent portion (124).
According to this, the bending part (124) of a film member (120) can be cooled intensively and favorably by the nozzle device (14) on the other side.
[0016]
Particularly, in the invention according to claim 5, the film member (120) has a shape having an opening (121) in the middle of a predetermined bending shape, and the film member (120) is mounted on the thermoforming mold (11). In the process, the film member (120) is characterized in that the periphery of the portion having the opening (121) is pressed to the outer peripheral molding surface (11a) side by the pressing plate (172).
[0017]
During the heating process of the film member (120), the film member tries to generate distortion due to thermal contraction due to a rapid temperature rise. In particular, in a part where a large number of openings (121) are formed in the film member, since there is a thin partition between the openings, distortion due to thermal contraction is likely to occur. However, according to the invention described in claim 5, by pressing the portion around the opening (121) of the film member to the outer peripheral molding surface (11a) side of the thermoforming die (11) by the pressing plate (172), Distortion due to thermal shrinkage of the film member can be satisfactorily suppressed.
[0018]
  Moreover, in invention of Claims 7-9, after carrying out the bending shaping | molding of the thin film-form resin-made film member (120) to a predetermined bending shape with a thermoforming die (11), this film member (120) is made into a board | substrate member ( 100), and an assembly method
  The outer peripheral molding surface (11a) of the heating mold (11) is formed in an arc shape, and the arc-shaped outer peripheral molding surface (11a) has a large number of groove portions (11b) and a large number of groove portions (11b) having a substantially rectangular concave shape. ) Partitioning portions (11b ′) located between them are alternately formed in the circumferential direction of the outer peripheral molding surface (11a),
  The top surface of the partition portion (11b ') is an arc-shaped smooth surface,
  The film member (120) by the assembling tool (17) provided in the hand portion (16) of the robot apparatus (15).Both ends (125, 126)HoldFilm member (120)Along the top surface of the partition part (11b ') of the thermoforming mold (11)Against the film member (120)For thermoforming mold (11)In an arcAttaching and heating the film member (120) to a predetermined temperature by the thermoforming mold (11),
  After this heating step, cooling air is supplied to the multiple grooves (11b) of the outer peripheral molding surface (11a) by the air supply means (13, 14), and the outer peripheral molding surface (11a) and the film member (120) The film member (120) is cooled by forming an air layer (12) with a large number of grooves (11b) in between,
  After this cooling step, the film member (120) is removed from the thermoforming mold (11) by the assembly tool (17) and moved to the set part of the substrate member (100), and the film member (120) is moved to the substrate member ( 100).
[0019]
According to this, the effect of the bending of the film member according to the invention of claim 1 can be exhibited, and at the same time, a series of processes from the bending of the film member to the assembly of the film member and the substrate member can be performed by one robot apparatus ( The operation can be efficiently performed by the operation of the hand portion (16) of 15).
In addition, the code | symbol in the bracket | parenthesis of each said means shows a corresponding relationship with the specific means of embodiment description later mentioned.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Initially, the shaping | molding and assembly apparatus for enforcing the shaping | molding method and the assembling method of the film member 120 in this embodiment are demonstrated based on FIGS. The door substrate member 100 and the film member 120 are as shown in FIGS.
[0021]
1 and 2 show an outline of the entire configuration of the molding and assembling apparatus. A heating mold 11 is arranged at the center of the upper surface of a substantially rectangular base 10. As shown in FIG. 3, the heating mold 11 has a metal arc-shaped outer peripheral molding surface 11a, and the arc-shaped outer peripheral molding surface 11a has a substantially rectangular concave shape in its axial direction. A large number of grooves 11b (see FIG. 4) are formed.
[0022]
This groove part 11b is for forming the air layer 12 between the film member 120 and the outer periphery shaping | molding surface 11a in the below-mentioned film cooling process. Here, the width W of the air layer 12 (groove 11b)₁Is the width W of the partition 11b 'between the grooves 11b.₂It is made sufficiently large (about twice) to enhance the cooling effect in the film cooling step.
[0023]
As shown in FIG. 5, in the heating mold 11, a plurality of (9 in the example of FIG. 5) electric heaters 11c are arranged in parallel to the axial direction inside the arc-shaped outer peripheral molding surface 11a. ing. Further, a plurality of temperature detectors 11d made of thermocouples are arranged inside the arc-shaped outer peripheral molding surface 11a, and the energization of the electric heater 11b is intermittently controlled according to the detected temperature of the temperature detector 11d. The temperature of the outer peripheral molding surface 11a is controlled to be maintained at a predetermined temperature.
[0024]
In this example, specifically, a predetermined temperature (for example, higher than the glass transition temperature (81 ° C.) of the resin material (PET: polyethylene terephthalate) constituting the film member 120 and lower than the melting temperature (264 ° C.) (for example, The temperature of the outer peripheral molding surface 11a is maintained at 130 ° C ± 5 ° C).
In the thermoforming mold 11, air blow nozzle devices 13 and 14 as air supply means are disposed on both sides in the axial direction of the arc-shaped outer peripheral molding surface 11 a. The left nozzle device 13 includes a plurality of (for example, nine) nozzles 13a arranged in an arc shape along the groove portion 11b so that cooling air can be supplied to the entire groove portion 11b of the arc-shaped outer peripheral molding surface 11a. Have.
[0025]
The nozzle device 14 on the right side supplies cooling air intensively to the end portion 126 on the end face bending side (90 ° bending side, see FIG. 10 described later) of the film member 120 to enhance the cooling effect of the end portion 126. Is for. Therefore, the nozzle device 14 on the right side has only one nozzle 14 a arranged at a portion facing this end portion 126.
Next, the hand portion 16 of the industrial robot apparatus 15 is disposed at a position deeper than the heating mold 11 at the center of the upper surface of the base 10. The hand portion 16 is of a horizontal articulated type that can move in the horizontal direction, and the arc 16 a in FIG. 1 indicates the maximum movable area of the hand portion 16. An assembly tool 17 is attached to the tip of the hand portion 16.
[0026]
FIG. 6 shows an overview of the entire assembly tool 17, and FIG. 7 is a diagram illustrating a specific layout of the main elements. FIG. 7 is a cross-sectional arrangement view at an intermediate portion in the longitudinal direction of FIG. Reference numeral 170 denotes a frame main body of the assembling tool 17, and the overall shape of the frame main body 170 is substantially semi-cylindrical. The frame main body 170 is connected to a shaft portion 171 of the hand portion 16 disposed on the upper surface portion thereof.
[0027]
A pressing plate 172 made of a substantially arc-shaped metal thin plate (for example, SUS304, plate thickness t = 0.5 mm) is provided at a position near the upper side of the frame main body 170. This pressing plate 172 is for pressing the periphery of the part having the opening 121 in the film member 120 shown in FIGS. 10 and 25 to 27 toward the arcuate outer peripheral molding surface 11 a side of the heating mold 11. is there. Air cylinders (operation means) 173 and 174 for displacing the both end portions of the pressing plate 172 in the vertical direction of FIG. 7 are arranged at both ends of the pressing plate 172 in the circumferential direction.
[0028]
On the other hand, a first arm 175 for arc bending (see FIG. 10 described later) of the film member 120 is rotatably disposed on one end side of the semi-cylindrical shape of the frame body 170 by a fulcrum shaft 176. Further, a second arm 177 for bending the film member 120 by 90 ° (see FIG. 10 described later) is rotatably disposed on the other end side of the semi-cylindrical shape of the frame body 170 by a fulcrum shaft 178.
[0029]
Here, the first arm 175 and the fulcrum shaft 176 are rotated within a predetermined rotation angle (for example, 98 °) by a rotary air cylinder (operation means) (not shown). Similarly, the second arm 177 and the fulcrum shaft 178 are also rotated in a range of a predetermined rotation angle (for example, 90 °) by a rotary air cylinder (operation means) (not shown).
[0030]
In the frame body 170, a cam groove 179 is formed in a portion below the fulcrum shaft 176 of the first arm 175, and a circular cam driven in the cam groove 179 is slidable along the groove shape. A body 180 is arranged. The cam follower 180 is rotatably connected to one end portions of the two sub arms 182 and 183 by a fulcrum shaft 181. The other end of the sub arm 183 is rotatably connected to the first arm 175 by a fulcrum shaft 184. Further, a chuck claw portion 185 for gripping the end portion 125 on the arc bending side of the film member 120 is integrally provided at the tip of the sub arm 182.
[0031]
In this example, when the first arm 175 for arc bending rotates 98 ° about the fulcrum shaft 176, the cam follower 180 moves along the groove shape of the cam groove 179 via the sub arm 183 due to the displacement of the fulcrum shaft 184. The chuck claw 185 is moved while drawing a curve.
The other end of the sub arm 182 is rotatably connected to the drive rod 187 by a fulcrum shaft 186. The drive rod 187 is moved forward and backward by an air cylinder (operation means) 188 as shown by the arrow in the figure. The body portion of the air cylinder 188 is rotatably supported with respect to the support plate 190 by a fulcrum shaft 189, and the support plate 190 is integrally held by the first arm 175.
[0032]
Next, the second arm 177 is integrally provided with two support plates 191 and 192, and an air cylinder (operation means) 193 is rotatably supported by a fulcrum shaft 194 at the tip of the support plate 192. Yes. The air cylinder 193 causes the drive rod 195 to move forward and backward as shown by the arrows in the figure. One end of a sub arm 197 is rotatably connected to the tip of the drive rod 195 by a fulcrum shaft 196.
[0033]
The other end of the sub arm 197 is rotatably connected to the tip of the support plate 191 by a fulcrum shaft 198. Further, a chuck claw portion 199 for gripping the end portion 126 on the 90 ° bending side of the film member 120 is integrally provided at the tip of the sub arm 197.
On the other hand, a set device 20 for the film member 120 is disposed on one side of the thermoforming mold 11 on the upper surface of the base 10. The substrate 200 of the set device 20 is disposed on the two first rails 201 fixed to the upper surface of the base 10 so as to be able to advance and retreat in the direction of arrow A in FIG. The set device 20 is moved forward and backward by operating force of an air cylinder (operating means) (not shown).
[0034]
As shown in FIG. 8, two second rails 202 are disposed on the upper surface of the substrate 200, and the movable support base 203 is disposed on the second rail 202 so as to be able to advance and retreat. The movement support table 203 is moved forward and backward by an air cylinder (operation means) 204. A first rotary chuck 206 that can be rotated by a rotary air cylinder (operation means) 205 is disposed on the upper surface of the movable support base 203.
[0035]
The first rotary chuck 206 sandwiches and fixes the positioning pin 206a inserted into the long hole-like attachment hole 122 of the end portion 125 on the arc bending side of the film member 120 and the end portion 125 on the arc bending side of the film member 120. A chuck piece 206b is provided.
In addition, a fixed support base 207 is fixed to the upper surface of the substrate 200 at a predetermined distance from the two second rails 202 so as not to move. A second rotary chuck 209 that can be rotated by a rotary air cylinder (operation means) 208 is disposed on the upper surface of the fixed support base 207. The second rotary chuck 209 has the same configuration as the first rotary chuck 206, and is a positioning pin 209a to be inserted into the long hole-like mounting hole 123 of the end portion 126 on the 90 ° bending side of the film member 120. And a chuck piece 209b for sandwiching and fixing the end portion 126 on the 90 ° bending side of the film member 120.
[0036]
Next, as shown in FIGS. 1 and 2, a set device 30 for the door substrate member 100 is disposed on the other side of the thermoforming mold 11 on the upper surface of the base 10. The substrate 300 of the set device 30 is arranged on the rail 301 fixed to the upper surface of the base 10 so as to be able to advance and retreat in the direction of arrow B in FIG. The set device 30 is moved forward and backward by operating force of an air cylinder (operating means) (not shown).
[0037]
On the upper surface of the substrate 300, a support base 302 having a V-shaped recess for supporting the rotating shaft 105 protruding outward from both axial end portions of the door substrate member 100 is provided. In addition, through holes 303 and 304 are provided on both upper and lower sides in the radial direction of the door substrate member 100 in the substrate 300. The through holes 303 and 304 are opened to allow the heat caulking welding heads 306 and 307 of the heat caulking device 305 to pass therethrough.
[0038]
Here, the heat caulking device 305 is arranged immediately on the side of the thermoforming mold 11, and one welding head 306 is arranged at one end side in the circumferential direction of the door substrate member 100 (the end 125 of the film member 120 on the arc bending side). 3 pins are provided so that the tips of the three pins 103 can be heat caulked. Further, the other welding head 307 heats the tip of the five pins 104 on the other end side in the circumferential direction of the door substrate member 100 (corresponding to the end 126 on the arc bending side of the film member 120). Five are provided.
[0039]
The two sets of welding heads 306 and 307 are movable in the directions of arrows C and D in FIG. In addition, the heat caulking device 305 is provided with an air blow nozzle (air supply means) (not shown) adjacent to the welding heads 306 and 307, and the pins 103 and 104 are forcibly forced after heat caulking by the air blow nozzle. It is designed to cool.
[0040]
Next, a method for forming the film member 120 and a method for assembling the film member 120, the door substrate member 100, and the like will be described. FIG. 9 is an explanatory diagram of the process flow of the molding and assembling method according to the present embodiment, and FIG. 10 shows the transition of the change in the shape of the film member 120.
Hereinafter, each process of the shaping | molding by this embodiment and the assembly | attachment method is demonstrated concretely.
(1) Setting process of film member 120 and door substrate member 100
The film member 120 is supplied to the upper side of the set device 20 (in the direction of arrow E in FIG. 1) by a negative pressure chuck mechanism or a manual operation of the operator M in a flat shape with an outer shape cut out shown in the upper part of FIG. . Then, the mounting holes 122 and 123 of the both end portions 125 and 126 of the film member 120 are fitted to the positioning pins 206a and 209a of the first rotary chuck 206 and the second rotary chuck 209, and the film member 120 with respect to the set device 20 is fitted. In addition to positioning, both end portions 125 and 126 of the film member 120 are gripped (chucked) by the chuck pieces 206b and 209b of the first rotary chuck 206 and the second rotary chuck 209.
[0041]
On the other hand, the door substrate member 100 is preliminarily molded into a semicylindrical shape as shown in FIG. 10, and the door substrate member 100 is moved from the direction of the arrow H by the automatic chuck mechanism or the manual operation of the operator M. The rotating shaft 105 at both ends in the axial direction of the door substrate member 100 is placed on the V-shaped concave portion of the support base 302 of the substrate 300, and the rotating shaft 105 portion is held by an air cylinder (not shown). To fix.
[0042]
Thereafter, the substrate 300 is moved forward (moved upward in FIG. 1) on the rail 301 by an operating force of an air cylinder (not shown), and the door substrate member 100 is moved together with the set device 30 to the upper position (of the robot device 15 of FIG. 1). The hand unit 16 is kept in a standby state).
(2) Temporary bending process of the film member 120
After the film member 120 is set, the entire setting device 20 for the film member 120 is moved in the direction of arrow A in FIG. 8 by an operating force of an air cylinder (not shown), and the right side position in FIG. To the moving range). At the same time, the moving support base 203 is advanced on the second rail 202 by the air cylinder (operation means) 204 to perform the shrinking operation of the film member 120, and the first and second rotary cylinders are rotated by the rotary air cylinders 205 and 208. The chucks 206 and 209 are rotated in the directions of arrows F and G in FIG. 8 respectively, and the entire film member 120 is temporarily bent into an arc shape. This temporary bending is performed in order to enable the film member 120 to be gripped by an assembly tool 17 described later.
(3) Mounting and bending process of film member 120 on thermoforming mold 11
As described above, the hand portion 16 is moved to the position of the film member 120 temporarily bent into an arc shape by the first and second rotary chucks 206 and 209, and both ends of the film member 120 are moved by the assembly tool 17 of the hand portion 16. The parts 125 and 126 are gripped. At this time, the assembling tool 17 is in the original position (film receiving position) shown in FIG. 11, and the chucking claws 185 and 199 are open.
[0043]
In this state, when the air cylinders 188 and 193 of the assembly tool 17 are operated and the drive rods 187 and 195 are moved forward (moved downward in FIG. 11), the positions of the fulcrum shafts 186 and 196 are changed. Since it moves downward, the chuck claws 185 and 199 rotate around the fulcrum shafts 181 and 198 from the original position and move to the position shown in FIG. After the state shown in FIG. 12 is reached, in the setting device 20, the chuck pieces 206 b and 209 b of the first and second rotary chucks 206 and 209 return to a state in which both end portions 125 and 126 of the film member 120 are released.
[0044]
FIG. 12 shows a state in which both end portions 125 and 126 of the film member 120 are gripped (film chuck state). In this state, the arc bending side end portion 125 of the film member 120 is sandwiched between the side surface portion of the sub arm 183 and the chucking claw portion 185, and the 90 ° bending side end portion 126 of the film member 120 is supported by the support plate 191. And the chuck claw 199. It is to be noted that the clamping portions by the chuck claws 185 and 199 are set at two positions respectively at the arc bending side end portion 125 and the 90 ° bending side end portion 126 of the film member 120.
[0045]
  As described above, after the both end portions 125 and 126 of the film member 120 are gripped by the assembling tool 17, the hand portion 16 is rotated toward the position of the heating mold 11, and the film member 120 is heated. 11 to the position. And the center part of the circumferential direction of the film member 120 is made into the circular arc-shaped outer periphery shaping | molding surface 11a of the thermoforming die 11.(More specifically, the top surface of the partition portion 11b ')Press against.
[0046]
FIG. 13 shows this film pressing state. In FIG. 13, after the central portion of the film member 120 is pressed against the arc-shaped outer peripheral molding surface 11 a of the thermoforming mold 11, the end portion of the film member 120 on the 90 ° bending side is shown. The state where the 90 ° bending at 126 is completed is shown. This 90 ° bending process can be performed by rotating the second arm 177 of the assembling tool 17 by 90 ° in the clockwise direction from the state of FIG.
[0047]
Next, as shown in FIG. 14, the first arm 175 of the assembling tool 17 is rotated 98 ° counterclockwise from the state shown in FIGS. Can be bent into an arc shape along the arc-shaped outer peripheral molding surface 11a of the heating mold 11. As described above, the mounting and bending of the film member 120 on the thermoforming mold 11 can be completed.
(3) Heating process of film member 120
The outer peripheral molding surface 11a of the heating mold 11 is maintained at a predetermined temperature (130 ° C ± 5 ° C higher than the glass transition temperature of the resin material of the film member 120) by the built-in electric heater 11c. As soon as the mounting (winding) of the film member 120 is completed, heating of the film member 120 is started.
[0048]
At this time, the film member 120 may be distorted due to thermal contraction due to a rapid temperature rise. In particular, in the portion of the film member 120 where a large number of openings 121 are formed, since there is a thin partition between the openings 121, distortion due to thermal contraction is likely to occur. Therefore, as shown in FIG. 15, the drive rods 173 a and 174 a of the air cylinders 173 and 174 are lowered to lower the pressing plate 172 made of a thin metal plate, and the pressing plate 172 opens the opening portion of the film member 120. The region around 121 is pressed toward the arcuate outer peripheral molding surface 11 a side of the thermoforming mold 11. Thereby, the distortion by the heat shrink of the film member 120 can be suppressed favorably.
[0049]
As described above, the film member 120 is held for a predetermined time (for example, about several seconds) in a state in which the portion around the opening 121 of the film member 120 is pressed against the arc-shaped outer peripheral molding surface 11a side of the thermoforming mold 11 by the pressing plate 172. Heat.
(4) Cooling process of film member 120
When the time after the start of heating elapses a predetermined time by the timer means, the film member 120 rises to a temperature higher than the glass transition temperature of the resin material and the heating is completed, so the cooling of the film member 120 is started. In this cooling step, first, as shown in FIG. 16, the drive rods 173a and 174a of the air cylinders 173 and 174 are raised, and the pressing plate 172 is returned upward. Thereafter, cooling air (air at ambient ambient temperature) is ejected from the nozzles 13 a and 14 a of the air blowing nozzle devices 13 and 14 to cool the film member 120.
[0050]
At this time, the nozzle 13a of the left nozzle device 13 supplies cooling air to the entire groove 11b of the arc-shaped outer peripheral molding surface 11a of the heating mold 11, so that air is interposed between the outer peripheral molding surface 11a and the film member 120. Layer 12 (see FIG. 4) can be formed. In combination with the formation of the air layer 12 and the small heat capacity of the film member 120, the film member 120 is rapidly cooled even when the film member 120 is still mounted on the arcuate outer peripheral molding surface 11a of the heating mold 11. it can. The nozzle device 14 on the right side supplies cooling air intensively to the 90 ° bending side end portion 126 of the film member 120 to enhance the cooling effect of the end portion 126.
[0051]
Here, in order to form the shape of the film member 120 into the shape as designed, it is necessary to cool the film member 120 to below the glass transition temperature of the resin material, but as described above, the air layer 12 is formed. By forcibly air-cooling the film member 120 having a small heat capacity, the film member 120 can be cooled in a very short time (for example, about several seconds) while the energization (heat generation) of the built-in electric heater 11c of the heating mold 11 is maintained. Can be completed.
[0052]
In addition, due to the supply of cooling air from the air blow nozzle devices 13 and 14, the surface temperature of the arc-shaped outer peripheral molding surface 11a of the heating mold 11 temporarily decreases by about 20 ° C. from the predetermined temperature. Since the temperature can be restored to the predetermined temperature in a short time after the supply of cooling air is stopped, there is no possibility of delaying the heating of the next film member 120.
[0053]
The film member 120 has a bent portion 124 bent 90 ° inward in an arc shape on one end portion 126 side, and the bent portion 124 is an undercut shape that prevents the mold from being removed from the mold. However, since the film member 120 is cooled with the film member 120 mounted on the thermoforming mold 11 as described above, the moldability of the film member 120 having the bent portion 124 bent by 90 ° may be impaired. Not at all.
[0054]
The cooling process described above is completed by stopping the supply of the cooling air from the air blowing nozzle devices 13 and 14 by a timer means for a predetermined time, and the formation of the film member 120 is completed as described above.
(4) Assembly process of film member 120 and door substrate member (100)
After completion of the cooling process, first, preparation for conveying the film member 120 is performed. That is, as shown in FIG. 17, first, the first arm 175 of the assembly tool 17 is rotated 98 ° clockwise from the state shown in FIG. The mold 11 is separated from the arcuate outer peripheral molding surface 11a. The state shown in FIG. 17 is the same as that shown in FIG.
[0055]
Next, as shown in FIG. 18, the second arm 177 of the assembly tool 17 is rotated 90 ° counterclockwise from the state shown in FIG. The mold 11 is separated from the arcuate outer peripheral molding surface 11a. The state shown in FIG. 18 is the same as that shown in FIG. The entire film member 120 is separated from the arcuate outer peripheral molding surface 11 a of the thermoforming mold 11 by forcibly expanding the 90 ° bending side end 126 of the film member 120.
[0056]
As a result, the film member 120 can be transported. Next, the hand unit 16 is rotated counterclockwise in FIG. 1 and moved toward the position of the door substrate member 100 on the setting device 30. The film member 120 is conveyed to the position of the door substrate member 100 having the arcuate circumferential wall 102. Then, as shown in FIG. 19, the second arm 177 of the assembly tool 17 is rotated 90 ° clockwise from the state shown in FIG. The substrate member 100 is assembled. At this time, the attachment hole 123 provided in the bent portion 124 of the 90 ° bent side end portion 126 of the film member 120 is inserted into the pin 104 on one end side of the circumferential wall 102 of the door substrate member 100.
[0057]
Next, as shown in FIG. 20, the first arm 175 of the assembly tool 17 is rotated 98 ° counterclockwise from the state shown in FIG. The door board member 100 is assembled. At this time, the mounting hole 122 provided in the arc bending side end portion 125 of the film member 120 is inserted into the pin 103 on the other end side of the circumferential wall 102 of the door substrate member 100.
[0058]
Next, as shown in FIG. 21, in the assembly tool 17, the air cylinder drive rods 187 and 195 are respectively retracted, and the chuck claws 185 and 199 are respectively moved from both ends 125 and 126 of the film member 120. Operate to a distant position (film unchuck position).
Next, as shown in FIG. 22, in the assembly tool 17, the first arm 175 is rotated 98 ° clockwise from the state of FIG. 21 to return the first arm 175 to the original position. As shown in FIG. 23, the second arm 177 can be returned to the original position by rotating the second arm 177 counterclockwise by 90 ° from the state shown in FIG. 21, and the chuck claws 185 and 199 are attached to the film. The member 120 and the door substrate member 100 can be moved to a position sufficiently away from the assembly block body.
[0059]
As described above, after the assembly tool 17 is separated from the position of the assembly block body, the arc bending side end portion 125 and the 90 ° bending side end portion 126 of the film member 120 are provided in the heat caulking device 305. The film member 120 is fixed by being held on the door substrate member 100 by holding means (not shown). Specifically, this holding means is, for example, a negative pressure chuck mechanism at the arc bending side end portion 125, and a holding pin at the 90 ° bending side end portion 126.
[0060]
Thereafter, the tip portions of the pins 103 and 104 are heat squeezed simultaneously. The heat caulking is performed by passing the welding heads 306 and 307 for thermal caulking of the thermal caulking device 305 through the through holes 303 and 304 provided in the substrate 300 of the setting device 30 of the door substrate member 100 and the tips of the pins 103 and 104. It can be performed by pressure bonding to.
[0061]
This heat caulking process will be described more specifically. FIG. 24 shows a welding head 307 for caulking the pins 104 of the door substrate member 100, but the welding head 306 for caulking the pins 103 has the same configuration. The heat caulking method is the same. In FIG. 24, the welding head 307 (306) has a circular recess 307a (306a) at the tip for forming the enlarged head 104a (103a) of the pin 104 (103).
[0062]
Further, in order to form a predetermined interval between the root portion of the pin 104 (103) and the enlarged head portion 104 (103a), the heat caulking device 305 is made of a thin metal plate (for example, plate thickness = 0.5 mm). A spacer 308 is provided so as to be able to advance and retreat to the outer peripheral side of the pin 104 (103) by an air cylinder (operation means) (not shown).
The welding heads 306 and 307 are heated to a temperature (for example, 300 ° C.) higher than the melting temperature (165 ° C.) of the resin material (for example, polypropylene) of the door substrate member 100.
[0063]
In the heat caulking, first, the spacer 308 is advanced to the outer peripheral side of the pins 103 and 104 on the outer surface side of the film member 120, and then the welding heads 306 and 307 are pressure-bonded to the tips of the pins 103 and 104, The tip portions of the pins 103 and 104 are heated and pressurized at the same time as the softening temperature of the resin, and deformed into a shape along the circular recesses 306a and 307a at the tip portions of the welding heads 306 and 307, and the enlarged head 103a. , 104a are formed.
[0064]
After the formation of the enlarged head, cooling air is supplied to the pins 103 and 104 from an air blow nozzle (not shown) provided adjacent to the welding heads 306 and 307 so that the pins 103 and 104 are By performing forced cooling, the heat caulking shape of the pins 103 and 104 is determined. As described above, the heat caulking of the pins 103 and 104 can be completed, thereby preventing the film member 120 from being detached from the door substrate member 100.
[0065]
Thereafter, the assembling tool 17 is moved together with the hand portion 16 in a direction away from the assembling block body, and then the setting device 30 is moved to the lower side (worker M side) in FIG. The block body is taken out from the setting device 30 in the direction of arrow I.
With the above, all the film member forming and assembling methods according to the present embodiment are completed.
[0066]
(Other embodiments)
In the above embodiment, when the film member 120 is formed, the groove portion 11b is formed on the arc-shaped outer peripheral molding surface 11a of the thermoforming mold 11 to form the air layer 12, thereby cooling the film member 120. However, the present invention is not limited to this. For example, a cooling air injection hole is provided in the arc-shaped outer peripheral molding surface 11a of the heating mold 11, and the cooling air is supplied from the injection hole. You may make it form the air layer 12 between the outer peripheral shaping | molding surface 11a and the film member 120 by ejecting toward the inner surface of the film member 120. FIG.
[0067]
In the above-described embodiment, the case where the film member 120 is bent into an arc shape has been described. However, the film member 120 may be bent into a shape other than the arc shape (for example, a polygonal shape). The present invention is applicable.
In the above embodiment, the case where the present invention is applied to the forming and assembling method of the film member 120 in the film type rotary door that performs the switching action of the air passage in the vehicle air conditioner has been described. However, the present invention is not limited to this, and can be widely applied to the forming and assembling methods of the film member 120 in various uses.
[Brief description of the drawings]
FIG. 1 is a schematic plan view of an apparatus for carrying out a forming and assembling method according to an embodiment of the present invention.
FIG. 2 is a side view of the apparatus of FIG.
FIG. 3 is a perspective view of a thermoforming mold part in the apparatus of FIGS.
4 is an enlarged cross-sectional view in a state where a film member is mounted on the thermoforming mold of FIG. 3;
FIG. 5 is a cross-sectional structure diagram of the thermoforming mold of FIG. 3;
6 is a schematic perspective view of a tool for assembling a hand part of the robot apparatus shown in FIGS.
7 is a specific structural diagram of the assembling tool of FIG. 6;
8 is a schematic perspective view of the film member setting device shown in FIG. 1. FIG.
FIG. 9 is an overall explanatory view of steps in an embodiment of the method of the present invention.
FIG. 10 is a flow explanatory diagram of a film member forming and assembling step in an embodiment of the method of the present invention.
FIG. 11 is an operation explanatory diagram of the assembling tool.
FIG. 12 is an operation explanatory diagram of the assembling tool.
FIG. 13 is an operation explanatory view of the assembly tool.
FIG. 14 is an operation explanatory diagram of the assembling tool.
FIG. 15 is an operation explanatory view of the assembling tool.
FIG. 16 is an operation explanatory view of the assembling tool.
FIG. 17 is an operation explanatory diagram of the assembling tool.
FIG. 18 is an operation explanatory diagram of the assembling tool.
FIG. 19 is an operation explanatory view of the assembling tool.
FIG. 20 is an operation explanatory diagram of the assembling tool.
FIG. 21 is an operation explanatory diagram of the assembling tool.
FIG. 22 is an operation explanatory diagram of the assembling tool.
FIG. 23 is an operation explanatory diagram of the assembling tool.
FIG. 24 is an explanatory diagram of a heat caulking step.
FIG. 25 is a sectional view showing an air passage switching device using a film-type rotary door of a prior application.
26 is a sectional view of the film-type rotary door of FIG. 25. FIG.
27 is an exploded perspective view of the film member and door substrate member in FIGS. 25 and 26. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 ... Heat-molding die, 11a ... Outer peripheral molding surface, 11b ... Groove part, 12 ... Air layer,
13, 14 ... Air blow nozzle device (air supply means), 15 ... Robot device,
16 ... Hand part, 17 ... Assembly tool, 100 ... Substrate member,
120: Film member.

Claims

A molding method in which a thin film-shaped resin film member (120) is bent into a predetermined bent shape by a thermoforming mold (11),
The outer peripheral molding surface (11a) of the thermoforming mold (11) is formed in an arc shape, and the arc-shaped outer peripheral molding surface (11a) has a large number of grooves (11b) having a substantially rectangular concave shape and the Partition portions (11b ′) located between a plurality of groove portions (11b) are alternately formed in the circumferential direction of the outer peripheral molding surface (11a),
The top surface of the partition part (11b ′) is a smooth surface along the arc shape,
Both ends (125, 126) of the film member (120) are gripped by the assembling tool (17), and the film member (120) is attached to the partition portion (11b ′) of the thermoforming die (11). A pressing step along the top surface , thereby mounting the film member (120) in an arc shape with respect to the thermoforming mold (11);
After this mounting step, a heating step of heating the film member (120) to a predetermined temperature by the thermoforming mold (11),
After this heating step, cooling air is supplied to the multiple grooves (11b) of the outer peripheral molding surface (11a) by air supply means (13, 14), and the outer peripheral molding surface (11a) and the film member ( 120) and a cooling step of cooling the film member (120) by forming an air layer (12) with the plurality of grooves (11b).

The said film member (120) is heated in the said heating process more than the glass transition temperature of the resin material, The shaping | molding method of the film member of Claim 1 characterized by the above-mentioned.

3. The film member according to claim 1, wherein in the mounting step, an inwardly bent portion (124) of the predetermined bent shape is formed at one end (125) of the film member (120). Molding method.

The air supply means is composed of air blow nozzle devices (13, 14) arranged on both sides in the axial direction of the arc-shaped outer peripheral molding surface (11a) in the thermoforming mold (11),
In the cooling step, cooling air is supplied to the whole of the plurality of grooves (11b) by the nozzle device (13) on one side of the air blow nozzle devices (13, 14) on both sides, and the nozzle device (14 on the other side). 4. The method for forming a film member according to claim 3, wherein cooling air is supplied to the bent portion (124).

The film member (120) has a shape having an opening (121) in the middle of the predetermined bending shape,
The mounting step includes pressing a periphery of a portion of the film member (120) having the opening (121) toward the outer peripheral molding surface (11a) by a pressing plate (172). The method for forming a film member according to any one of 1 to 4.

The groove width (W ₁₎ of the film member according to any one of claims 1 to 5, characterized in that larger than the width (W ₂₎ of the partition section (11b ') of (11b) Molding method.

An assembly method for assembling the film member (120) to the substrate member (100) after bending the thin film-shaped resin film member (120) into a predetermined bending shape by the thermoforming mold (11),
The outer peripheral molding surface (11a) of the thermoforming mold (11) is formed in an arc shape, and the arc-shaped outer peripheral molding surface (11a) has a large number of grooves (11b) having a substantially rectangular concave shape and the Partition portions (11b ′) located between a plurality of groove portions (11b) are alternately formed in the circumferential direction of the outer peripheral molding surface (11a),
The top surface of the partition part (11b ′) is a smooth surface along the arc shape,
The both ends (125, 126) of the film member ( 120) are held by the assembly tool (17) provided in the hand portion (16) of the robot apparatus (15), and the film member (120) is moved to the A mounting step of pressing the film member (120) on the thermoforming die (11) in an arcuate shape by pressing along the top surface of the partition portion (11b ′) of the thermoforming die (11); ,
After this mounting step, a heating step of heating the film member (120) to a predetermined temperature by the thermoforming mold (11),
After this heating step, cooling air is supplied to the multiple grooves (11b) of the outer peripheral molding surface (11a) by air supply means (13, 14), and the outer peripheral molding surface (11a) and the film member ( 120) and cooling the film member (120) by forming an air layer (12) with the multiple grooves (11b),
After this cooling step, the film member (120) is removed from the thermoforming mold (11) by the assembly tool (17) and moved to the set site of the substrate member (100), and the film member (120 And an assembling step for assembling the film member on the substrate member (100).

Prior to said mounting step, said film member (120) in advance into an arc shape provisional bend, the arcuate film member (120) at both ends (125, 126) the use with assembly tool (17) of The method for assembling a film member according to claim 7, wherein the mounting step is performed by gripping with a film.

The film member (120) has mounting hole portions (122, 123) at both ends (125, 126) in the circular arc-shaped circumferential direction, and the substrate member (100) has the mounting hole portion (122). , 123), and pins (103, 104) that can be inserted into the resin are integrally formed of resin,
In the assembling step, after inserting the mounting hole portions (122, 123) of the film member (120) into the pins (103, 104), the tip portions of the pins (103, 104) are heat-caulked. The method for assembling a film member according to claim 8.