JP4445634B2

JP4445634B2 - Press molding method and apparatus

Info

Publication number: JP4445634B2
Application number: JP2000055700A
Authority: JP
Inventors: 静明岡崎; 孝一樋口
Original assignee: Kitagawa Seiki KK
Current assignee: Kitagawa Seiki KK
Priority date: 2000-03-01
Filing date: 2000-03-01
Publication date: 2010-04-07
Anticipated expiration: 2020-03-01
Also published as: JP2001239536A

Description

【０００１】
【産業上の利用分野】
本発明は、たとえばプラスティック製のＩＣカードなどの被加工物を加熱しながら圧縮して成型するプレス成型方法および装置に関する。
【０００２】
【従来技術】
従来、プラスティク成型品、たとえばＩＣカード（インテグレーテド・サーキット）を製造するには、コアシートの貫通孔にＩＣとコイルを挿入し、このコアシートとインナシートを表面、裏面の双方からオーバーシートで挟んだ状態でプレス装置にて加熱・圧縮して成型した後、冷却することで、これらのシートを一体成型していた。（たとえば、１９８９年７月１０日、株式会社電気書院発行、玉田丈夫、穐山晴臣、桑原正幸共著の「ＩＣカード
しくみと広がる世界」第４１頁図５・４）
この場合、プラスティックとしてはＰＶＣ（ポリ塩化ビニル）を用い、ＩＣカードを多数枚重ねてプレス装置で加熱・圧縮して同時成型することで、多量生産していた。
【０００３】
【発明が解決しようとする課題】
しかしながら、ＰＶＣは廃棄処分時に燃焼すると塩化水素ガスを発生するなど環境上問題がある。また、ＩＣカード等は厚さが約０．７６ｍｍ（ＩＳＯ規格）と薄いのでカードがひずみ変形しやすく、カードリーダ・ライタへの出し入れ不能といったケースが発生することがある。特に、接触型のＩＣカードに比べ非接触型ＩＣカードや磁気カードの場合には、内部に配置する要素が増える結果、シート間の接合面積が減少することから、ＩＣカードがＰＶＣでは剛性不足で変形しやすくなる。
そこで、ＰＶＣの代わりに環境に優しく剛性も高いＰＥＴ（ポリエチレンテレフタレート）を用いることが考えられる。ところが、ＰＥＴを用いて成型する場合、加熱時にＰＥＴはひずみが大きくなりやすく、また、ＰＥＴは冷却方法によって剛性等も大きく異なってくる。したがって、ＰＥＴ製のＩＣカード等の成型では、加熱、冷却方法が難しく、同時成型できる枚数はＰＶＣに比べて少なくならざるをえず生産効率がよくない。
【０００４】
【発明の目的】
本発明の目的は、上記ＰＥＴのよう加熱圧縮して成型する材料を所望の形状にひずみなく成型する際、時間あたりの生産性を向上できるようにしたプレス成型方法および装置を提供することにある。
【０００５】
【課題を解決するための手段】
本発明のプレス成型方法では、被加工物の成型をホットプレスのプレスサイクルとコールドプレスのプレスサイクルに分けて行うようにしている。すなわち、まずホットプレス装置にて被加工物を徐々に加熱していき成型温度で加熱加圧した後、結晶化温度まで徐冷していくホットプレス工程を実行し、このホットプレスした被加工物を搬送手段によりコールドプレス装置へ受け渡し、次にこの結晶化温度の被加工物をこれにほぼ等しい温度で受け取った後、冷却しながら加圧する工程を実行する。このプレスサイクルの分離により、プレス装置の温度調整幅が小さくて済み、１台で全プレスサイクルを実行する場合に比べ短時間で生産が可能となる。また、温度調整によるエネルギロスも小さい。この方法は、特にＰＥＴでＩＣカード等を成型するときに最適である。
【０００６】
上記プレス成型方法にあっては、望ましくは、上記ホットプレスのプレスサイクルと上記コールドプレスのプレスサイクルとを同期させ、新規な被加工物のホットプレスとこれに先行する被加工物のコールドプレスを同時に実行する。この結果、無駄な時間を省き流れ作業による生産性の向上を図れると同時に、これら両プレス装置への被加工物の搬入を１台の搬送手段だけで可能にできる。
【０００７】
上記ホットプレスのプレスサイクル工程では、望ましくは、ホットプレス装置の熱盤を結晶化温度から成型温度まで温度を上昇させて、被加工物の温度を上昇させる。この間たとえば０．１〜０．２Ｋｇといった低圧のタッチ圧で熱盤を被加工物に接触させておく。熱盤の温度を成型温度に保っていると、被加工物の温度も成型温度に達し、成型可能な状態となる。この状態を保ちながら、たとえば２０トンといった高圧で加圧して所定時間経過したら、熱盤の温度を下げて被加工物を結晶温度付近まで徐冷していく。この間、被加工物の厚みとこれに作用する全圧力を同時コントロールすることで所望の形状に成型可能となる。
【０００８】
上記ホットプレスのプレスサイクル工程では、望ましくは、ホットプレス装置の遮蔽板で被加工物を密閉し脱気する。したがって被加工物の中に残留している空気を取り除くことで良好な成型性を確保できる。
【０００９】
上記コールドプレスのコールドプレス工程では、望ましくは、コールドプレス装置の冷却盤が、ホットプレス装置から搬入された被加工物を急冷させて結晶化を阻害しないように、受け渡し時に結晶温度まで加熱されており、被加工物の結晶化を促進する。この後、冷却盤の温度を低温まで下げ、低温を保つことで高圧、たとえば２５トンの加圧と相まって、結晶化した被加工物にひずみやそりが発生するのを防ぐとともに被加工物に光沢を出させる。したがって、被加工物に高い剛性を持たせ、かつ精度よい成型が可能となる。
【００１０】
上記ホットプレスのプレスサイクル工程と上記コールドプレスのプレスサイクル工程では、望ましくは、リフタで被加工物を支持しながら被加工物と熱盤間の隙間、被加工物と冷却盤間の隙間がほぼ等しくなるように、これらの間隔を変えていくよう制御する。したがって、被加工物の局部あるいは一方の面が他の部分より加熱されてひずみが生じる、といった不具合が解消される。ここで、被加工物と熱盤間の隙間、被加工物と冷却盤間の隙間がほぼ等しくなるとは、これらの隙間がまったく同じである必要はなく、また両熱盤が被加工物にまったく同時に接触する必要もないのであって、実質的に被加工物の両面からの加熱で一方面側が他方面より温度が高くなってひずみが生じるような不具合が起こらなければよい程度の隙間の関係を意味する。
【００１１】
また、本発明のプレス成型方法および装置では、望ましくは、搬入された新規な被加工物をホットプレス装置の上方定盤の熱盤と下方定盤の熱盤で挟み込み、成型可能な温度まで加熱・圧縮して成型すると同時に、ホットプレス装置での成型が終了した先行の被加工物を下流に配置したコールドプレス装置の上方定盤の冷却盤と下方定盤の冷却盤とで挟み込み、結晶化温度で冷却・圧縮する。
したがって、ＰＥＴのように加熱、冷却が難しい素材であっても、ホットプレスの工程とコールドプレスの工程を分けてこれらを連続して成型することが可能なので、１台のプレス装置で加熱・圧縮した後さらに冷却圧縮する場合に比べ熱盤や冷却盤への加熱、冷却時間が短くて済み、時間あたりの生産枚数を多くすることが可能になる。したがって、このプレス装置システムは、特にＰＥＴでＩＣカード等を成型するのに最適である。
【００１２】
上記リフタは、望ましくは、被加工物を支持し、昇降機構によりこの被加工物を上方定盤の熱調整盤（熱盤あるいは冷却盤）、下方定盤の熱調整盤（熱盤あるいは冷却盤）がこれらと被加工物との隙間をほぼ等しく保ちながら被加工物の上下面から近づいていくように構成する。したがって、被加工物は、この上下面の一方側のみが熱盤（あるいは冷却盤）に急に接触したり、あるいは一面側のみが熱盤（あるいは冷却盤）により偏って加熱されたりするおそれがない。この結果、被加工物にひずみが発生するのを抑えることができる。また、リフタが無い場合は、プレス装置内に被加工物が入ったときに高温となった一方の熱盤等に直接ふれることになり、熱でひずみを生じてしまう。この不具合を避けるには、あらかじめ熱盤等の温度をひずみが生じない温度まで下げておき、両熱盤が被加工物に接触してから温度を上げる必要があり、逆に被加工物が搬出されたら次の被加工物が入ってくるまでに冷却しておかねばならない。これでは成型に時間がかかってしまうことになるが、本願のリフタがあれば搬入の当初から被加工物を両熱盤等から離しておけるので、熱盤等の最低温度を高くしておくことが可能となり、成型時間の短縮、エネルギロスの低減が可能となる。
【００１３】
また上記リフタの昇降機構は、望ましくは、ロータリアクチュエータに一体のピニオンと、これと噛み合い昇降プレートを取り付けたラックにて構成し、ロータリアクチュエータを回転制御してピニオン、ラックにより昇降プレートを上下動する。したがって、この昇降プレートにて搬送ベルト等との被加工物の受け渡しが可能となるとともに、被加工物と前記両熱盤との間隔制御が可能となる。
【００１４】
好ましくは、上記下方定盤を固定定盤とし、上方定盤と荷重が小さいリフタとを下方定盤に向けて下降制御するようにすると、すべてが可動するものより構造をシンプルにでき修理補修が簡単になる。また、場合によっては、リフタが上方定盤により押圧されながら一体的に下降するようにしてもよい。この場合も上記同様、実質的に隙間関係が同じ（被加工物の一面側のみの加熱によりひずみが生じない程度）となるようにすることが可能である。
【００１５】
好ましくは、上記熱盤と被加工物とを遮蔽壁内に密封して真空ユニットにて脱気するように構成する。この結果、被加工物の加工穴など隙間に存在していた空気を取り除くことができ、良好な成型性を得ることが可能となる。
【００１６】
上記ホットプレス装置とコールドプレス装置は、望ましくは、ベルト等の搬送要素で被加工物を移動させる搬送手段を有しており、この搬送手段により、新規の被加工物をホットプレス装置に搬入すると同時に、このホットプレス装置で先行してホットプレスした被加工物をホットプレス装置からコールドプレス装置へ搬入する。この場合、ホットプレス装置までの搬入距離とコールドプレス装置への搬入距離を同じにするのが望ましい。したがって、これらの搬入によりホットプレス装置によるホットプレスとコールドプレス装置によるコールドプレスとは同期して実行することが可能となり、時間あたりの生産性を向上できる。また、両搬入には搬送装置１台だけで済む。
【００１７】
この場合、搬送手段は、望ましくは、被加工物を移動可能な搬送要素間の間隔を狭めた搬送位置と、搬送要素間の間隔を広げた待機位置とに変更可能な移動機構を有する。搬送位置にて搬送要素が被加工物をプレス装置まで運び、上記リフタの上昇にて被加工物を受け渡す。この後、搬送要素が待機位置に拡幅することで、一方の定盤が他方の定盤に近づき熱盤同士または冷却盤同士による被加工物の加圧時、熱盤等と搬送要素とが干渉しないようにしている。
【００１８】
また、この場合、望ましくは、搬送要素がベルトであり、上記移動機構がロータリアクチュエータと、このアクチュエータと一体回転する回転リンクと、回転リンクの回動によりベルトのローラを支持する支持部材を被加工物の移動方向及び厚さ方向に略直交する幅方向に移動させるロッドとを有する。プレス装置への被加工物の搬入時には、ベルト間距離が前記被加工物の幅より狭くかつ前記リフタを内側に挟む搬送位置にくるようにしてある。搬入後、ロータリアクチュエータを回転駆動してこれと一体の回転リンクを一方向に回転させる。この結果、回転リンクの両端側に連結され幅方向に伸ばされたロッドが、幅方向に移動してベルトのローラ支持部材をベルトとともにこれら間の間隔が大きくなる待機位置まで移動させる。この結果、熱盤等による加圧時に両ベルトを前記ホットプレス装置の前記遮蔽壁より外側になる位置に移動させ、これらの遮蔽壁との干渉を防ぐ。加圧後は、定盤同士を離間し、ロータリアクチュエータを逆転させ、ロッドを逆方向に移動させることでベルトのローラ支持部材をベルトとともにこれら間の間隔が小さくなる搬送位置まで移動させる。この状態でリフタを下降させれば、プレス装置から被加工物を搬出できる。
【００１９】
【実施の形態】
以下、本発明の実施形態を図１に基づき説明する。まず、プレス装置システムの全体を図１に示す。同図において、被加工物の流れ順に装置類を説明していくと、１は被加工物を最初にセットする挿入セットコンベアであり、この後流に挿入バッファコンベア２を設置する。この挿入バッファコンベアの後にはプレス内コンベア３を設置して、このプレス内コンベアをホットプレス装置４、コールドプレス装置５内をそれぞれ貫通させ、これらのプレス装置で順次成型加工できるようにしている。ホットプレス装置４，コールドプレス装置５には、それぞれパイプ８６、８７、８８、８９を介してホットプレス用加熱冷却ユニット６、コールドプレス用加熱冷却ユニット７を接続し、それぞれ高温油、低温油を循環供給可能にする。プレス内コンベア３の下流には搬出クロスコンベア１０を設けることで、被加工物をプレス内コンベア３から受け入れた後９０度方向変換し、これに続く搬出横送りコンベア１１に受け渡す。この搬出横送りコンベア１１の下流には被加工物の移動方向を再度９０度変える回流クロスコンベア１２を設置し、この後、回流コンベア１３を介してクロスコンベア１４へと受け渡し、ここで９０度方向変換させて操作者の方へ向ける。クロスコンベア１４は、操作者の手前にあるコンベア１５へと続く。なお、挿入バッファコンベア２での被加工物受け入れ位置からホットプレス装置４での成型位置までのピッチＬ１と、このホットプレス装置の成型位置からコールドプレス装置５の成型位置までのピッチＬ２とは同一に設定しておく。
【００２０】
次に、図２に基づき、ホットプレス装置４の詳細につき説明する。
ホットプレス装置４は、幅方向に離間配置した両支柱１６ａ、１６ｂ間の上下をアーチ１７、ベース１８によりそれぞれ連結して構成したフレーム１９を有する。このアーチ１７には上方位置からみて方形位置にそれぞれシリンダ２０、２１、２２、２３を合計４本固定配置する。これらのシリンダ内にはねじ軸２４、２５、２６、２７を貫通させ、ねじ軸の外周面とシリンダ２０〜２３内に配置した固定シリンダ２０ａ〜２３ａの内周面とに螺旋のボール溝を形成してボールを介在させて、ボールねじを構成することでねじ軸がシリンダ２０〜２３に対し回転しながら上下動可能とする。ねじ軸２４〜２７は、これらの上方部分を軸受で上台２８に支持するとともに、その上端部分に歯付きベルト車２９、３０、３１、３３を連結する。各ベルト車２９〜３３は歯付きベルト３４にかみ合わせる。上記ベルト車２９〜３３のうちの１個を上台２８に取り付けた電気モータ３５にて回転駆動可能とし、このベルト車を回転駆動することによりベルト３４を介して全ベルト車、したがってねじ軸２４〜２７を同じ回転方向・同じ回転量だけ同時駆動するようにしている。なお、電気モータ３５にはエンコーダ１０３を取り付けてある。ねじ軸２４〜２７の下側部分は、上方定盤としての可動定盤３６に軸受で回転可能かつ軸方向一体に取り付ける。
可動定盤３６の下方には断熱材３７を介して熱盤３８を取り付けて、この熱盤にパイプ８６を介してホットプレス用加熱冷却システム６から温度調節した高温油を循環供給可能とする。ベース１８側には下方定盤としての固定定盤３９を配置し、この上方に断熱材４０を介して熱盤４１を取り付け、この熱盤にパイプ８６を介して同じくホットプレス用加熱冷却システム６から温度調節した高温油を循環供給可能とする。これらの熱盤３８、４１の表面には、セラミックコーティングを施してある。
【００２１】
上記固定定盤３９には、被加工物を上下動可能にするリフタ４２を設ける。このリフタ４２は、図３（ａ）、（ｂ）に拡大して示すように被加工物を支持する２枚の昇降プレート４３、４４を有し、この中央部分からそれぞれ下方に伸ばしたラック４５、４６にピニオン４７、４８をかみ合わせる。これら両ピニオン４７、４８は、固定定盤３９を貫通するシャフト５０の両端に取り付け、一方のピニオン４６をロータリアクチュエータ４９で駆動制御することで昇降プレート４３、４４の上下動を可能とする。このロータリアクチュエータ４９は、コントローラ１０４にて制御する。昇降プレート同士４３、４４の離間幅を熱盤３８、４１より大きく設定するとともに、それぞれの昇降プレート４３、４４の前後端に上方に突出する突出部４３ａ、４３ｂ、４４ａ、４４ｂを形成する。昇降プレート４３、４４は、これらの突出部間４３ａ〜４３ｂ、４４ａ〜４４ｂの溝部４３ｃ、４４にてＩＣカード等の被加工物を支持可能である。
【００２２】
図２に戻って、可動定盤３６、固定定盤３９側のベース１８には、それぞれ遮蔽壁５５、５６を設けてこれらの下端開口縁、上端開口縁にシール５８、５９を取り付け、可動定盤３６が固定定盤３９に所定距離まで近づくと遮蔽壁５５、５６のシール５８、５９同士が圧接して遮蔽壁５５、５６内をこの室外から遮断することにより空気の出入りを不能とする。この遮蔽壁５５、５６内は、エアホース６０に連結してあり、密閉した遮蔽壁内の空気を真空ユニット１０５にて吸引し脱気することが可能である。なお、遮蔽壁５５、５６の大きさは、リフタ４２の昇降プレート４３、４４や熱盤３８、３９を収納でき、かつプレス内コンベア３のベルト位置が後述する拡幅する待機位置にあるとき両ベルト６１、６２間に収まるように設定してある。
【００２３】
また、固定定盤３９は、この下面の前後方向２カ所でベース１８に設けたピン１０１、１０２にて位置決めするとともに、下面の４カ所とベース１８との間にロードセル９７、９８、９９、１００を配置し、これらのロードセルが受ける荷重を検出する。これらの検出信号はコントローラ１０４に入力する。
【００２４】
コールドプレス装置５の構成は、図４に示すように基本的にはホットプレス装置４とほぼ同じである。ただ、ホットプレス装置４と構成上異なるのは、コールドプレス装置５では真空室が不要なので遮蔽壁およびシールを備えていない点、また熱盤の代わりに冷却盤８、９を用いこれをパイプ８７を介してコールドプレス用の加熱冷却ユニット７に接続して低い温度の油を供給する点である。他は、ホットプレス装置と実質的に同一なので、その説明を省略する。なお、図３ではホットプレス装置に実質的に対応する構成要素にはこれと同一の番号の後にＡを付けて示してある。
【００２５】
本プレス装置システムに使われている搬送装置としてのコンベアは通常のベルトコンベアであるのでその詳細な説明を省略する。ただプレス内コンベアは、本願プレス装置との関係で重要なので、図５〜図７に基づき説明する。図５はコンベアを上方から見た図、図６はこのコンベアに設けた上流側のリンク機構、図７は同じくこのコンベアに設けた下流側のリンク機構をそれぞれ示す。
同図において、６１と６２は被加工物を上に載せて搬送する搬送要素としてのベルトであり、それぞれコンベアの前後方向両端に設けたプーリ６３、６４、６５、６６に巻き掛けしてある。これらプーリのうち下流側のプーリ６４、６６同士はシャフト６７で連結し、サーボ６８にて回転・停止制御する。
またプーリの各支持部材６９、７０、７１、７２は、それぞれコンベアフレーム７３に対し幅方向にスライド可能であり、リンク機構７４，７５により幅方向へ移動可能である。すなわち、下流側のリンク機構７５にあっては、図７に示すように幅方向に位置する一方の支持部材７０が、この下端部に回動可能に一端部をジョイント結合したロッド７６、このロッドの他端部がジョイント結合する回転リンク７７、この回転リンクに一端部がジョイント結合したロッド７８を介して他方の支持部材７２に連結される。上記回転リンク７７は、図５に示すようにコンベアフレーム７３にベルト方向に沿って配置、かつ軸支したシャフト７９の下流端に連結する。このシャフト７９の上流端は、ロータリアクチュエータ８０により駆動される。このロータリアクチュエータの上流側にもシャフト７９と同軸位置の別のシャフト８１を配置して、このシャフト８１の下流側端にクランク８２を介して上記ロータリアクチュエータ８０を連結する。したがって、ロータリアクチュエータ８０は、シャフト７９とともにシャフト８１も回転駆動し、リンク機構７４を介して上流側支持部材６９、７１をスライド可能である。この上流側のリンク機構７４の構成も、図６に示すように上記下流側のリンク機構７５と同様に一方の支持部材６９側のロッド８３、回転リンク８４、他方の支持部材７１側のロッド８５にて構成する。
この結果、ロータリアクチュエータ８０の回転駆動によりシャフト７９、８１、回転リンク７７、８４、各ロッド７６、７８、８３、８５を介して各支持部材６９〜７２を幅方向へ移動させ、両ベルト６１、６２の間幅を狭くした搬送位置（図６（ｂ）に、また図２、図４に実線にて示す）と、広くした待機位置（図６（ａ）に、また図２、図４に点線にて示す）と変更できる。このベルト間のすきま幅は、狭くした搬送位置ではリフタ４２の昇降プレート４３、４４がベルト６１、６２間にあって上下動可能な幅に、また広くした待機位置ではホットプレス装置４の可動定盤３６が降下してきたとき遮蔽壁５６、５７が入ることができる大きさに設定する。なお、上記リンク機構７４、７５やロータリアクチュエータ８０等は、ベルトの移動機構を構成する。
【００２６】
上記プレス成型方法および上記プレス装置による被加工物の成型工程につき、以下に説明する。まず、操作者は図外の操作制御盤を操作してシステム稼働の状態にする。図８に示すように、下からクッション紙９１ａ、片鏡面板９２ａ、組み立て前のＩＣカード９３ａ、両鏡面板９４ａ、ＩＣカード９３ｂ、…、ＩＣカード９３ｅ、片鏡面板９２ｂ、クッション紙９１ｂと重ね合わせた被加工物９６を、図１に示す挿入セットクロスコンベア１に乗せ、挿入バッファコンベア２へ受け渡す。プレス内コンベア３は、挿入バッファコンベア２の受け渡し位置からベルト６１、６２でＬ１だけ移動してホットプレス装置４の固定定盤３９上でに停止させる。この間、プレス内コンベア３のベルト６１、６２は、これらのすきま幅が最小となる搬送位置にある。
【００２７】
この後、リフタ４２を上昇させ被加工物をベルト６１，６２から持ち上げる。すなわち、ロータリアクチュエータ４９によりピニオン４７、４８を回転させ、これらとかみ合うラック４５、４６によりこれらと一体の昇降プレート４３、４４上昇させるが、このときリフタの昇降プレート４３、４４の溝部４３ｃ、４４ｃにて被加工物のを支え、ベルト６１、６２よりも所定量高い位置まで上昇してその位置を保持する。リフタへ４２による被加工物の受け取り後、プレス内コンベア３のロータリアクチュエータ８０を作動させ、回転リンク７７、８３を回転してロッド７６、７８、８２、８４の押し引きにより支持部材６９、７１と支持部材７０、７２とを離間させてベルト６１、６２の間幅を広げて待機位置に移動する。この結果、ベルト６１、６２の隙間幅は、遮蔽壁５６、５７が収納可能な大きさとなる。
【００２８】
この状態でコントローラ１０４にて電気モータ３５を回転させると、歯付きベルト３４により４つのベルト車２９〜３３が同じ回転方向、同じ回転量だけ回転する。このベルト車の回転により、これらと一体のねじ軸２４〜２７も回転しボールねじ５５により上台２８、電気モータ３５ともども下方へ移動していく。ねじ軸２４〜２７の下降にしたがって、これに軸受で連結した可動定盤３６も下降していき、遮蔽壁５６を遮蔽壁５７に押しつけ、これら間のシール５８、５９を圧着する。この密閉後、遮蔽壁内の空気を真空ユニット１０５でエアホース６０を介して吸引し始め、被加工物９６の隙間等に存在する空気を抜き取る。
【００２９】
一方、上記可動定盤３６の下降に伴ってリフタ４２も、ロータリアクチュエータ４９によりピニオン４７、４８、ラック４５、４６を介して下降していく。このリフタ４２の下降は、下降中、被加工物９６および可動定盤３６側の熱盤３８間の隙間と、被加工物９６および固定定盤３９側の熱盤４１間の隙間とがほぼ等しくなるように制御する。この結果、被加工物９６の上下面が両熱盤３８、４１から受ける熱がほぼ同じになる。また、この下降中、熱盤３８、４１の表面がセラミックコーティングされているので、遠赤外線による輻射熱で被加工物９６が熱盤３８、４１と接触する前から徐々に全体が加熱されていき、局所的に高温となってひずみが生じるといった不具合を回避しながら素早く被加工物を加熱できる。
下降の最終段階では、可動定盤３６側の熱盤３８と固定定盤３９側の熱盤４１とが被加工物９６の上下面に同時に接触する。熱盤３８、４１により後述するホットプレスのプレスサイクルにて被加工物９６を加熱・圧縮して成型する。このときの圧縮は、エンコーダ１０３で位置を検出することにより被加工物の厚み制御を行うとともに、ロードセル９７〜１００によりプレスの全荷重を検出して荷重制御を行う。すなわち、これらプレス全荷重とモータ回転位置の検出値にしたがって、コントローラ１０４が電気モータ３５を目標値になるように制御する。
【００３０】
上記ホットプレス工程が終了したら、可動定盤３６とリフタ４２を上記下降制御とは逆に上昇させる。すなわち、電気モータ３５で可動定盤３６を上昇させ、ロータリアクチュエータ４９を駆動させて被加工物９６をリフタ４２で持ち上げ所定位置で停止させる。この上昇後、サーボ６８を駆動してリンク機構７４、７５によりベルト６１、６２の間隔を搬送位置まで狭め、これらのベルトを被加工物９６の下方に位置させる。次いでリフタ４２を下降させてベルト６１、６２上へホットプレスした被加工物９６を受け渡す。
【００３１】
上記受け渡しが終了したら、プレス内コンベア３のベルト６１、６２を回転駆動する。このベルト搬送により、上記ホットプレスが終了した被加工物９６をコールドプレス装置５の固定定盤３９Ａ上（コールドプレス位置）まで移動すると同時に、上流側の挿入バッファコンベア２に待機していたホットプレス予定の次の被加工物をホットプレス装置４の固定定盤３９上（ホットプレス位置）まで移動させる。これらの両移動が同期した同一ピッチＬ１、Ｌ２にて実行されることは前述のとおりである。この移動後、ホットプレス装置４は上記で説明した作動を再度繰り返し続ける。
一方、コールドプレス装置５も、ベルト６１、６２の待機位置での拡幅後、ホットプレス装置と同様にリフタ４２Ａが上記ホットプレス済みの被加工物を持ち上げ、続いて可動定盤３６Ａとリフタ４２Ａが稼働定盤３６Ａ側の冷却盤８および被加工物間の隙間と、固定定盤３９Ａ側の冷却盤９および被加工物間の隙間とがほぼ等しくなるように、その位置と速度の制御をしながら下降する。ただし、コールドプレス装置においては、遮蔽壁による密閉、真空引きは行われない。可動定盤３６Ａと固定定盤３９Ａとの冷却盤８、９同士が被加工物に接すると、後述するコールドプレスのプレスサイクルにて冷却・圧縮する。
上記ホットプレス工程とコールドプレス工程とは、タンデム配置したホットプレス装置４とコールドプレス装置５とで、同じサイクルかつ同期して次々と実行される。
これらのプレスが終了したら、両プレス装置４、５の可動定盤３６、３６Ａとリフタ４２、４２Ａが上昇し、ベルト６１、６２が幅を狭めた搬送位置へ移動した後、リフタ４２、４２Ａが下降してコールドプレス済みの被加工物とこれに続くホットプレス済みの被加工物をベルト６１、６２へ受け渡す。続いて前者を搬出クロスコンベア１０へ、また後者をコールドプレス位置へ、また新しい被加工物を搬入バッファコンベア２からホットプレス位置へと同時に移動させる。
以後、これらの工程が繰り返される。
【００３２】
次に、ホットプレスとコールドプレスの各プレスサイクルの内容につき、図９に基づきより詳細に説明する。
同図は、上半部がホットプレスのプレスサイクルを、下半部がコールドプレスのプレスサイクルを示す。図では縦軸に温度、横軸に時間をとっており、上半部に３つの連続するホットプレスの各サイクルＡ１、Ａ２、Ａ３を、また下半部に３つの連続するコールドプレスの各サイクルＢ０、Ｂ１、Ｂ２を記載している。被加工物９６は、まずホットプレス装置４で加熱・圧縮した後、プレス内コンベアにてコールドプレス装置５へ移動させ、ここで冷却・圧縮するので、図ではＡ１でホットプレスした被加工物は次工程のコールドプレスＢ１へと進み、このコールドプレスの終了後、搬出クロスコンベアへ受け渡されることになる。
Ａ１→Ｂ１と被加工物が進行するのと同様に、次の被加工物もＡ２→Ｂ２、…と進んでいくが、Ａ１とＢ０、Ａ２とＢ１、Ａ３とＢ２、…とこれらのホットプレスとコールドプレスとは、ホットプレス装置４とコールドプレス装置５とにより同期したサイクルで実行される。
【００３３】
上記ホットプレス装置４内にホットプレスでのプレスサイクルは、Ａ１に示すように、被加工物から離間された位置にある可動定盤３６の熱盤３８と固定定盤３９の熱盤４１との温度Ｔａは、プレスサイクル中、最低の温度である約８０℃に保っておく。ホットプレス装置４に時点ｔ０に搬入完了された被加工物の温度Ｔｂは、雰囲気温度（図では約３０℃）である。時点ｔ０から時点ｔ１の間、可動定盤３６を降下させていくと、遮蔽壁５６と遮蔽壁５７とがシール５８、５９を圧着する。この状態で密閉室内をエアホース６０で真空引きする。この真空圧力を図中Ｐａで示す。ただし、シール５８、５９同士が接触するまでは、被加工物は加圧しないようにしておく。
一方、熱盤３８、４１の温度Ｔａも搬入完了のｔ０の時点になったら約８０℃から約１４０℃に向けて上げていく。上記時点ｔ１の少し後の時点ｔ２から電気モータ３５を駆動してプレス圧力Ｐｂが軽くさわる程度のタッチ圧（０．１〜０．２Kg程度）となるようにしてこの圧を保つ。このタッチ圧と上記熱盤温度Ｔａにより被加工物の温度Ｔｂも上昇していき、柔らかくなってくる。
熱盤温度Ｔａをそのまま約１４０℃に保っておき、被加工物の温度Ｔｂが成型に最適な約１４０℃になる時点（ｔ３）から電気モータ３５をさらに駆動して被加工物に高圧（２０トン程度）をかけ、この加熱・加圧を下記の要領で制御する。時間ｔ３から所定時間経過した時間ｔ４になったら、熱盤３８、４１の温度を約８０℃に向けて下げ始める。この熱板温度Ｔａの温度降下制御は、途中の時間ｔ５まではやや緩やかに、その後はこれよりやや急に温度降下させていく。この結果、被加工物の温度Ｔｂもやや遅れて温度低下していく。そして、被加工物が約１００℃程度になる時点ｔ６にて被加工物のホットプレス成型完了と見なし、電気モータ３５を逆転して可動定盤３６を上昇させプレス圧を解除するとともに、遮蔽壁内も大気解放する。可動定盤３６の上昇が終了した時点ｔ７でホットプレス完了信号が出力される。
時点ｔ７後の所定時間Δｔ１では、さらに電気モータ３５を回し続け上方熱盤３８を上昇させ、被加工物から離す。この後の期間Δｔ２は、プレス内コンベア３を稼働し被加工物を移動させる。
以上が、ホットプレスのプレスサイクルだが、上記ｔ０〜ｔ７、Δｔ１、Δｔ２、Ｐｂ等は、あらかじめ実験により最適値を決めておく。
なお、上記加圧制御はロードセル９７〜１００での検出値をフィードバックして、またＩＣカードの厚みはエンコーダ１０３からの信号によりコントローラ１０４にて制御する。
【００３４】
次に、コールドサイクルのプレスサイクルにつき、図９の下半部に基づき説明する。
ホットプレス装置４からの受け渡し時にあっては、受け渡される被加工物の温度Ｔｂは約１００℃程度である。この温度付近まで低下させないと、被加工物であるＩＣカードの結晶化を進行できず剥がれてしまい、また急激に低下しすぎると十分な結晶化ができず剛性も低下してしまう。そこで、この受け渡し時にあっては、冷却盤８、９の温度Ｔｃを最高の約８０℃に上げておく。この結果、被加工物の温度Ｔｂは結晶化温度を所定時間保たれる。次いで、電気モータ３５Ａを駆動して可動定盤３６Ａの冷却盤８と冷却盤９とで被加工物に高圧Ｐｃ（たとえば２５トン）をかけるとともに冷却盤８、９の温度Ｔｃを約８０℃から２０℃程度まで低下させ、この温度と上記高圧を所定時間続ける。被加工物は、冷却盤８、９の温度降下制御後もしばらくは結晶化温度を保ち、その後、徐々に温度が低下していく。上記ｔ３の時点になったら、電気モータ３５Ａを逆転させプレス圧を解除する。この後のコールドプレス装置５からの排出時にあっても、被加工物温度Ｔｂは、５０℃程度あり、以後はコンベア搬送時に冷却させていく。なお、図中ΔＴは、被加工物の移載時間である。以上がコールドプレスのプレスサイクルであり、このプレスサイクルは上記ホットプレスのプレスサイクルと同期させて実行する。
【００３５】
上記実施態様においては、ＩＣカードなどの被加工物の成型にあってこの成型加工の工程を二分し、被加工物を成型可能な高温まで加熱加圧した後、結晶化温度まで徐冷するホットプレス装置４と、この結晶化温度の被加工物をホットプレス装置４から受け渡され、冷却加熱して結晶化していくコールドプレス装置５とをタンデム配置して、被加工物をこの順に流し相次いで搬入される被加工物を上記ホットプレス装置４とコールドプレス装置５とで同期させて成型するようにしたので、ホットプレス装置４の熱盤３８、４１の温度調整範囲を約８０℃から約１４０℃の間で、またコールドプレス装置４の冷却盤８、９の温度調整を約８０℃から約２０℃の間で調整すればよくこの温度上昇下降に要する時間が短縮できる結果、時間あたりの生産量を増やすことができる。また、１台のプレス装置で上記ホットプレスとコールドプレスの両サイクルを実行する場合、約１４０℃から２０℃まで各被加工物ごとに調整する必要があり、途中で大量の熱を捨てねばならず生産コスト高となるのに対し、本実施態様のものでは、途中で捨てる熱量が少なくて済み、経済的である。また、本実施態様にあっては、リフタ４２、４２Ａにて被加工物を支持し、可動定盤３６、３６Ａとともに下降させるが、これらの下降を被加工物９６および可動定盤３６、３６Ａの熱盤３８（あるいは冷却盤８）間の隙間と、被加工物９６および固定定盤３９、３９Ａの熱盤４１８あるいは冷却盤９）と間の隙間とがほぼ等しくなるように制御しているので、被加工物が局所的に加熱されてひずむといった不具合を解消できる。さらにホットプレス装置４では、遮蔽壁５６、５７にて被加工物を密閉して真空引きするようにしたので、被加工物の隙間に存在していた空気を取り除くことができ、良好な成型性を確保できる。
【００３６】
なお、上記実施態様にあっては、上方定盤を可動定盤、下方定盤を固定定盤とし、リフタが被加工物を上下動可能な構成としている。この構成が安価で制御も簡単であるが、本発明はこれに限られるものではなく、上方定盤を固定定盤、下方定盤を可動定盤とし、下方定盤が固定の上方定盤近づくにしたがってリフタを上昇させていくように構成することも可能である。あるいは、リフタをプレス内コンベアから被加工物を受け取った後に所定位置に固定し、上方定盤、下方定盤がともに可動定盤としてリフタに向かって同時に近づくように制御することも可能である。また、図３に示すように、昇降プレート４３、４４の各突出部４３、４３ａ、４４、４４ａに上下方向に突出量を調整可能なストップピン５１、５２、５３、５４を取り付け、上方定盤の下降時、この下方定盤を上記ストップピン５１、５２、５３、５４にあてて一体的になってリフタを押し下げるようにしてもよい。この場合、被加工物および上方熱盤の隙間、被加工物と下方熱盤の隙間は全く同じとはならず、また被加工物と上記両熱盤との接触も上下面で同時とはならないものの、被加工物の一方の面のみ加熱が強すぎてひずみが生じるといった不具合が生じることがない隙間関係（実質的に同じ隙間関係）、下降速度関係にしてあるので、素早くひずみない成型が可能になる。
【図面の簡単な説明】
【図１】本実施態様のプレス装置システム全体を示す図である。
【図２】本実施態様によるホットプレス装置を示す図である。
【図３】（ａ）、（ｂ）とも図２のホットプレス装置のリフタを拡大して示す図であり、（ａ）はリフタの側面図、（ｂ）はリフタの正面図である。
【図４】本実施態様によるコールドプレス装置を示す図である。
【図５】本実施態様による搬入装置としてのコンベアを上方からみた図である。
【図６】図５のコンベアに設けた上流側のリンク機構を示す図である。（ａ）は待機位置の状態、（ｂ）は搬送位置の状態を示す。
【図７】図５のコンベアに設けた下流側のリンク機構を示す図である。
【図８】上記ホットプレス装置及び上記コールドプレス装置に搬入する際の被加工物を示す図である。
【図９】ホットプレスとコールドプレスとのプレスサイクルを示す図である。
【符号の説明】
３プレス内コンベア
４ホットプレス装置
５コールドプレス装置
６ホットプレス用加熱冷却システム
７コールドプレス用加熱冷却システム
８、９冷却盤（熱調整盤）
１９、１９Ａフレーム
３５、３５Ａ電気モータ
３６、３６Ａ可動定盤（上方定盤）
３８、４１熱盤(熱調整盤)
３９、３９Ａ固定定盤（下方定盤）
４２、４２Ａリフタ
４３、４３Ａ、４４、４４Ａ昇降プレート
４５、４５Ａ、４６、４６Ａラック
４７、４７Ａ、４８、４８Ａピニオン
４９、４９Ａロータリアクチュエータ
６１、６２ベルト（搬送要素）
７４、７５リンク機構（移動機構）
８０ロータリアクチュエータ（移動機構）
９３ａ〜９３ｅＩＣカード
９６被加工物
９７〜１００ロードセル
１０３エンコーダ
１０４コントローラ[0001]
[Industrial application fields]
The present invention relates to a press molding method and apparatus for compressing and molding a workpiece such as a plastic IC card while heating.
[0002]
[Prior art]
Conventionally, in order to manufacture a plastic molded product, for example, an IC card (integrated circuit), an IC and a coil are inserted into a through hole of the core sheet, and the core sheet and the inner sheet are oversheeted from both the front surface and the back surface. These sheets were integrally molded by heating and compressing them with a press apparatus while being sandwiched between them and then cooling them. (For example, July 10, 1989, published by Denki Shoin Co., Ltd., Takeo Tamada, Haruomi Hiyama, Masayuki Kuwahara, “IC Card”
The Structure and the Expanding World ”(page 41, Fig. 5.4)
In this case, PVC (polyvinyl chloride) is used as the plastic, and a large number of IC cards are stacked, heated and compressed by a press device, and simultaneously formed by mass production.
[0003]
[Problems to be solved by the invention]
However, PVC has environmental problems such as generation of hydrogen chloride gas when burned at the time of disposal. Further, since the thickness of an IC card or the like is as thin as about 0.76 mm (ISO standard), the card is likely to be distorted and deformed, and there are cases in which it cannot be inserted into and removed from the card reader / writer. In particular, in the case of a non-contact type IC card or a magnetic card compared to a contact type IC card, the number of elements arranged inside increases, resulting in a decrease in the bonding area between sheets. It becomes easy to deform.
Therefore, it is conceivable to use PET (polyethylene terephthalate) that is environmentally friendly and highly rigid instead of PVC. However, when molding using PET, the strain of PET tends to increase during heating, and the rigidity of PET varies greatly depending on the cooling method. Therefore, in the molding of an IC card made of PET or the like, the heating and cooling methods are difficult, and the number of sheets that can be molded simultaneously must be smaller than that of PVC, and the production efficiency is not good.
[0004]
OBJECT OF THE INVENTION
An object of the present invention is to provide a press molding method and apparatus capable of improving productivity per time when a material to be molded by heating and compression such as PET is molded without distortion into a desired shape. .
[0005]
[Means for Solving the Problems]
In the press molding method of the present invention, the workpiece is molded separately into a hot press press cycle and a cold press press cycle. That is, first, a hot press process is performed in which a workpiece is gradually heated by a hot press apparatus, heated and pressed at a molding temperature, and then gradually cooled to a crystallization temperature. Is transferred to the cold press apparatus by the conveying means, and after receiving the workpiece of this crystallization temperature at a temperature substantially equal to this, a step of pressurizing while cooling is executed. By separating the press cycles, the temperature adjustment range of the press device can be reduced, and production can be performed in a shorter time than when the entire press cycle is executed by a single machine. In addition, energy loss due to temperature adjustment is small. This method is particularly suitable when an IC card or the like is molded from PET.
[0006]
In the press molding method, preferably, the hot press press cycle and the cold press press cycle are synchronized, and a new workpiece hot press and a preceding workpiece cold press are performed. Run at the same time. As a result, it is possible to save wasted time and improve productivity by the flow work, and at the same time, it is possible to carry the workpiece into both the press devices with only one conveying means.
[0007]
In the press cycle process of the hot press, preferably, the temperature of the workpiece is increased by raising the temperature of the hot platen of the hot press apparatus from the crystallization temperature to the molding temperature. During this time, the hot platen is kept in contact with the workpiece with a low touch pressure such as 0.1 to 0.2 kg. If the temperature of the hot platen is kept at the molding temperature, the temperature of the workpiece also reaches the molding temperature, and the molding becomes possible. While maintaining this state, when a predetermined time elapses after pressurizing at a high pressure of 20 tons, for example, the temperature of the hot platen is lowered to gradually cool the workpiece to near the crystal temperature. During this time, it is possible to mold the workpiece into a desired shape by simultaneously controlling the thickness of the workpiece and the total pressure acting on the workpiece.
[0008]
In the hot press press cycle process, the workpiece is desirably sealed and degassed by a shielding plate of a hot press apparatus. Therefore, good moldability can be ensured by removing the air remaining in the workpiece.
[0009]
In the cold press process of the cold press, desirably, the cooling plate of the cold press apparatus is heated to the crystal temperature at the time of delivery so as not to disturb the crystallization by rapidly cooling the workpiece carried from the hot press apparatus. And promote crystallization of the workpiece. After this, the temperature of the cooling plate is lowered to a low temperature and kept at a low temperature, combined with a high pressure, for example, 25 tons of pressure, to prevent the crystallized workpiece from being distorted or warped, and the workpiece to be glossy. To give out. Accordingly, it is possible to give a high rigidity to the workpiece and to perform accurate molding.
[0010]
In the press cycle process of the hot press and the press cycle process of the cold press, preferably, the gap between the work and the hot platen, and the gap between the work and the cooling plate are approximately while supporting the work with the lifter. These intervals are controlled so as to be equal. Therefore, the problem that the local part or one surface of the workpiece is heated from the other part to cause distortion is eliminated. Here, the gap between the workpiece and the hot platen, and the gap between the workpiece and the cooling plate are almost equal. These gaps do not have to be exactly the same, and both the hot plates are completely on the workpiece. There is no need to make contact at the same time, and the relationship between the gaps is sufficient so long as heating from both sides of the workpiece does not cause a problem such that the temperature on one side becomes higher than that on the other side and distortion occurs. means.
[0011]
In the press molding method and apparatus of the present invention, preferably, a new workpiece to be loaded is sandwiched between the hot platen of the upper platen and the hot platen of the lower platen of the hot press device, and heated to a moldable temperature.・ At the same time as compression and molding, the preceding workpiece that has been molded in the hot press device is sandwiched between the cooling plate of the upper platen and the cooling plate of the lower platen, which is arranged downstream, and crystallizes. Cool and compress at temperature.
Therefore, even a material that is difficult to heat and cool, such as PET, can be molded continuously by dividing the hot press process and the cold press process. Then, compared with the case of further cooling and compression, the heating and cooling time for the heating plate and the cooling plate can be shortened, and the number of sheets produced per hour can be increased. Therefore, this press apparatus system is optimal for molding an IC card or the like using PET.
[0012]
Preferably, the lifter supports a workpiece, and the workpiece is moved by an elevating mechanism to the upper surface plate thermal adjustment panel (hot plate or cooling plate) and lower surface plate heat adjustment plate (hot plate or cooling plate). ) Are configured to approach from the upper and lower surfaces of the workpiece while keeping the gap between them and the workpiece substantially equal. Therefore, there is a possibility that only one side of the upper and lower surfaces of the workpiece suddenly comes into contact with the heating plate (or cooling plate), or only one surface side is heated unevenly by the heating plate (or cooling plate). Absent. As a result, it is possible to prevent the workpiece from being distorted. In addition, when there is no lifter, when the work piece enters the press device, it directly touches one hot platen or the like that becomes high temperature, and heat causes distortion. In order to avoid this problem, it is necessary to lower the temperature of the hot platen in advance to a temperature that does not cause distortion, and then raise the temperature after both hot plates touch the work piece. Once it is done, it must be cooled before the next workpiece enters. This will take time to mold, but with the lifter of this application, the work piece can be separated from both hot plates from the beginning of loading, so keep the minimum temperature of the hot plate etc. high. Thus, the molding time can be shortened and energy loss can be reduced.
[0013]
Further, the lifter lifting mechanism is preferably composed of a pinion integrated with the rotary actuator and a rack fitted with the pinion and attached to the lifting plate, and the rotary actuator is rotationally controlled to move the lifting plate up and down by the pinion and rack. . Therefore, it is possible to transfer the workpiece to and from the conveyor belt or the like with this elevating plate, and to control the distance between the workpiece and the two heating plates.
[0014]
Preferably, if the lower surface plate is a fixed surface plate and the upper surface plate and the lifter with a small load are controlled to move downward toward the lower surface plate, the structure can be simplified and repair repairs can be made than anything that is movable. It will be easy. In some cases, the lifter may be integrally lowered while being pressed by the upper surface plate. In this case as well, as described above, it is possible to make the gap relationship substantially the same (a degree in which distortion is not caused by heating only on one surface side of the workpiece).
[0015]
Preferably, the heating plate and the workpiece are sealed in a shielding wall and deaerated by a vacuum unit. As a result, it is possible to remove air that has been present in the gaps such as the machining holes of the workpiece, and it is possible to obtain good moldability.
[0016]
Preferably, the hot press apparatus and the cold press apparatus have a conveying means for moving a workpiece by a conveying element such as a belt, and when the new workpiece is carried into the hot press apparatus by the conveying means. At the same time, the workpiece that has been hot-pressed in advance by this hot-pressing device is carried from the hot-pressing device to the cold-pressing device. In this case, it is desirable that the carry-in distance to the hot press apparatus and the carry-in distance to the cold press apparatus are the same. Therefore, by carrying in them, the hot press by the hot press apparatus and the cold press by the cold press apparatus can be executed synchronously, and the productivity per hour can be improved. In addition, only one transfer device is required for both loading.
[0017]
In this case, the conveying means preferably has a moving mechanism that can be changed to a conveying position in which the interval between the conveying elements capable of moving the workpiece is narrowed and a standby position in which the interval between the conveying elements is widened. The conveying element carries the workpiece to the press device at the conveying position, and delivers the workpiece by raising the lifter. After that, when the conveying element is widened to the standby position, one of the surface plates approaches the other surface plate, and the heated platen and the conveying element interfere with each other when the workpieces are pressed by the heating plates or the cooling plates. I try not to.
[0018]
In this case, preferably, the conveying element is a belt, and the moving mechanism is a rotary actuator, a rotating link that rotates integrally with the actuator, and a support member that supports the roller of the belt by rotating the rotating link. And a rod that moves in the width direction substantially orthogonal to the moving direction and thickness direction of the object. When the workpiece is carried into the press apparatus, the distance between the belts is narrower than the width of the workpiece, and the carrier is located at a conveying position where the lifter is sandwiched inside. After carrying in, the rotary actuator is rotationally driven to rotate the rotary link integral therewith in one direction. As a result, the rods connected to both ends of the rotary link and extended in the width direction move in the width direction to move the roller support members of the belt together with the belt to a standby position where the distance between them increases. As a result, both belts are moved to a position outside the shielding wall of the hot press device when pressed by a hot platen or the like, thereby preventing interference with these shielding walls. After pressurization, the surface plates are separated from each other, the rotary actuator is rotated in the reverse direction, and the rod is moved in the reverse direction, thereby moving the roller support member of the belt together with the belt to the conveyance position where the distance between them becomes small. If the lifter is lowered in this state, the workpiece can be carried out from the press device.
[0019]
Embodiment
Hereinafter, an embodiment of the present invention will be described with reference to FIG. First, the whole press apparatus system is shown in FIG. In the figure, the apparatus will be described in the order of the flow of the workpiece. Reference numeral 1 denotes an insertion set conveyor for first setting the workpiece, and an insertion buffer conveyor 2 is installed in the downstream. An in-press conveyor 3 is installed after the insertion buffer conveyor, and the in-press conveyor passes through the hot press device 4 and the cold press device 5, respectively, so that these press devices can be sequentially molded. A hot press heating / cooling unit 6 and a cold press heating / cooling unit 7 are connected to the hot press device 4 and the cold press device 5 through pipes 86, 87, 88, 89, respectively. Enable circulation supply. By providing a carry-out cross conveyor 10 downstream of the in-press conveyor 3, the workpiece is received from the in-press conveyor 3, changed in direction by 90 degrees, and transferred to the subsequent carry-out conveyor 11. A circulating cross conveyor 12 that changes the moving direction of the workpiece again by 90 degrees is installed downstream of the carry-out conveyor 11 and then transferred to the cross conveyor 14 via the circulating conveyor 13, where the direction is 90 degrees. Convert it and direct it to the operator. The cross conveyor 14 continues to the conveyor 15 in front of the operator. The pitch L1 from the workpiece receiving position on the insertion buffer conveyor 2 to the molding position on the hot press device 4 is the same as the pitch L2 from the molding position on the hot press device to the molding position on the cold press device 5. Set to.
[0020]
Next, the details of the hot press apparatus 4 will be described with reference to FIG.
The hot press apparatus 4 has a frame 19 configured by connecting the upper and lower columns 16 a and 16 b spaced apart in the width direction with an arch 17 and a base 18. A total of four cylinders 20, 21, 22, and 23 are fixedly arranged on the arch 17 at square positions as viewed from the upper position. Screw shafts 24, 25, 26, and 27 are passed through these cylinders to form spiral ball grooves on the outer peripheral surface of the screw shaft and the inner peripheral surfaces of the fixed cylinders 20a to 23a disposed in the cylinders 20 to 23. Thus, a ball screw is formed by interposing a ball so that the screw shaft can move up and down while rotating with respect to the cylinders 20 to 23. The screw shafts 24 to 27 support these upper portions on the upper base 28 with bearings, and connect the toothed belt wheels 29, 30, 31, and 33 to their upper end portions. Each belt wheel 29-33 meshes with the toothed belt 34. One of the belt wheels 29 to 33 can be rotationally driven by an electric motor 35 attached to the upper base 28, and the belt wheel is rotationally driven to drive all belt vehicles, and hence the screw shafts 24 to 24 via the belt 34. 27 is simultaneously driven by the same rotation direction and the same rotation amount. The electric motor 35 has an encoder 103 attached thereto. Lower portions of the screw shafts 24 to 27 are attached to a movable surface plate 36 serving as an upper surface plate so as to be rotatable with a bearing and integrally in the axial direction.
A hot platen 38 is attached to the lower side of the movable surface plate 36 via a heat insulating material 37, and high temperature oil whose temperature is adjusted from the hot press heating / cooling system 6 can be circulated and supplied to the hot platen via a pipe 86. A fixed surface plate 39 as a lower surface plate is disposed on the base 18 side, a heat platen 41 is attached to the upper side via a heat insulating material 40, and the heating and cooling system 6 for hot press is also connected to the heat plate via a pipe 86. It is possible to circulate and supply high-temperature oil whose temperature is controlled from A ceramic coating is applied to the surfaces of the hot plates 38 and 41.
[0021]
The fixed surface plate 39 is provided with a lifter 42 that allows the workpiece to move up and down. The lifter 42 has two lifting plates 43 and 44 for supporting a workpiece as shown in enlarged views in FIGS. 3A and 3B, and a rack 45 extending downward from the central portion. , 46 are engaged with pinions 47 and 48. Both the pinions 47 and 48 are attached to both ends of the shaft 50 penetrating the fixed surface plate 39, and one of the pinions 46 is driven and controlled by the rotary actuator 49, so that the elevating plates 43 and 44 can be moved up and down. The rotary actuator 49 is controlled by the controller 104. The spacing between the elevating plates 43 and 44 is set larger than that of the heating plates 38 and 41, and projecting portions 43a, 43b, 44a and 44b projecting upward are formed at the front and rear ends of the elevating plates 43 and 44, respectively. The elevating plates 43 and 44 can support a workpiece such as an IC card in the groove portions 43c and 44 between the protruding portions 43a to 43b and 44a to 44b.
[0022]
Returning to FIG. 2, the base 18 on the movable surface plate 36 and the fixed surface plate 39 side is provided with shielding walls 55 and 56, respectively, and seals 58 and 59 are attached to the lower opening edge and the upper opening edge, respectively. When the panel 36 approaches the fixed surface plate 39 to a predetermined distance, the seals 58 and 59 of the shielding walls 55 and 56 are brought into pressure contact with each other to block the inside of the shielding walls 55 and 56 from the outside, thereby making it impossible for air to enter and exit. The inside of the shielding walls 55 and 56 is connected to the air hose 60, and the air inside the sealed shielding wall can be sucked and deaerated by the vacuum unit 105. The size of the shielding walls 55 and 56 is such that both the belts can be accommodated when the lifting plates 43 and 44 of the lifter 42 and the heating plates 38 and 39 can be accommodated and the belt position of the in-press conveyor 3 is at a widening standby position described later. 61 and 62 are set so as to fit.
[0023]
The fixed surface plate 39 is positioned by pins 101 and 102 provided on the base 18 at two places on the lower surface in the front-rear direction, and the load cells 97, 98, 99 and 100 are provided between the four places on the lower surface and the base 18. , And the load received by these load cells is detected. These detection signals are input to the controller 104.
[0024]
The configuration of the cold press apparatus 5 is basically the same as that of the hot press apparatus 4 as shown in FIG. However, the hot press device 4 is different from the hot press device 4 in that the cold press device 5 does not require a vacuum chamber and thus does not include a shielding wall and a seal. It connects to the heating-cooling unit 7 for cold press via, and is a point which supplies low temperature oil. Others are substantially the same as the hot press apparatus, and the description thereof is omitted. In FIG. 3, components substantially corresponding to the hot press apparatus are denoted by the same reference numerals with “A” appended thereto.
[0025]
Since the conveyor as a conveying device used in this press apparatus system is a normal belt conveyor, its detailed description is omitted. However, since the in-press conveyor is important in relation to the press device of the present application, it will be described with reference to FIGS. 5 is a view of the conveyor as viewed from above, FIG. 6 is an upstream link mechanism provided on the conveyor, and FIG. 7 is a downstream link mechanism provided on the conveyor.
In the figure, reference numerals 61 and 62 denote belts as conveying elements that convey a workpiece on top, and are respectively wound around pulleys 63, 64, 65, 66 provided at both ends of the conveyor in the front-rear direction. Of these pulleys, the pulleys 64 and 66 on the downstream side are connected by a shaft 67, and rotation / stop control is performed by a servo 68.
The pulley support members 69, 70, 71, 72 can slide in the width direction relative to the conveyor frame 73, and can be moved in the width direction by the link mechanisms 74, 75. That is, in the link mechanism 75 on the downstream side, as shown in FIG. 7, one support member 70 positioned in the width direction has a rod 76 jointed at one end to the lower end, and this rod The other end of the rotary link 77 is connected to the other support member 72 via a rotary link 77 joint-joined and a rod 78 jointed to the rotary link at one end. As shown in FIG. 5, the rotating link 77 is arranged along the belt direction on the conveyor frame 73 and is connected to the downstream end of the shaft 79 that is pivotally supported. The upstream end of the shaft 79 is driven by a rotary actuator 80. Another shaft 81 coaxial with the shaft 79 is also arranged on the upstream side of the rotary actuator, and the rotary actuator 80 is connected to the downstream end of the shaft 81 via a crank 82. Accordingly, the rotary actuator 80 can also drive the shaft 81 together with the shaft 79 to slide the upstream support members 69 and 71 via the link mechanism 74. As shown in FIG. 6, the upstream link mechanism 74 has the same structure as that of the downstream link mechanism 75, such as the rod 83 on the one support member 69 side, the rotary link 84, and the rod 85 on the other support member 71 side. It consists of.
As a result, by rotating the rotary actuator 80, the support members 69 to 72 are moved in the width direction via the shafts 79 and 81, the rotation links 77 and 84, and the rods 76, 78, 83, and 85, and both belts 61, 62, the conveyance position with a narrow width (shown in FIG. 6 (b) and in FIG. 2 and FIG. 4 by a solid line) and the widened standby position (FIG. 6 (a), and FIG. 2 and FIG. 4). It can be changed as shown by the dotted line). The gap width between the belts is such that the lift plates 43 and 44 of the lifter 42 are vertically movable between the belts 61 and 62 at the conveying position where the belt is narrowed, and the movable platen 36 of the hot press device 4 at the widened standby position. Is set to a size that allows the shielding walls 56 and 57 to enter when the lowering has come down. The link mechanisms 74 and 75, the rotary actuator 80, and the like constitute a belt moving mechanism.
[0026]
The molding process of the workpiece by the press molding method and the press apparatus will be described below. First, the operator operates the operation control panel (not shown) to bring the system into operation. As shown in FIG. 8, the cushion paper 91a, the single mirror plate 92a, the pre-assembled IC card 93a, the two mirror plates 94a, the IC card 93b,..., The IC card 93e, the single mirror plate 92b, and the cushion paper 91b are overlapped from below. The combined workpieces 96 are placed on the insertion set cross conveyor 1 shown in FIG. 1 and delivered to the insertion buffer conveyor 2. The in-press conveyor 3 moves from the delivery position of the insertion buffer conveyor 2 by L1 by the belts 61 and 62 and stops on the fixed surface plate 39 of the hot press apparatus 4. In the meantime, the belts 61 and 62 of the in-press conveyor 3 are at the transport position where the clearance width is minimized.
[0027]
Thereafter, the lifter 42 is raised to lift the workpiece from the belts 61 and 62. That is, the pinions 47 and 48 are rotated by the rotary actuator 49, and the lifting plates 43 and 44 integral therewith are raised by the racks 45 and 46 meshing with these, but at this time, the grooves 43c and 44c of the lifting plates 43 and 44 of the lifter are moved. Thus, the workpiece is supported and raised to a position higher than the belts 61 and 62 by a predetermined amount to hold the position. After the workpiece is received by the lifter 42, the rotary actuator 80 of the in-press conveyor 3 is actuated to rotate the rotary links 77, 83 and push the rods 76, 78, 82, 84 to pull the support members 69, 71. The support members 70 and 72 are separated from each other, and the width between the belts 61 and 62 is increased to move to the standby position. As a result, the gap width between the belts 61 and 62 is large enough to accommodate the shielding walls 56 and 57.
[0028]
When the electric motor 35 is rotated by the controller 104 in this state, the four belt wheels 29 to 33 are rotated by the toothed belt 34 by the same rotation direction and the same rotation amount. With the rotation of the belt wheel, the screw shafts 24 to 27 integrated therewith are also rotated, and the upper base 28 and the electric motor 35 are moved downward by the ball screw 55. As the screw shafts 24 to 27 are lowered, the movable surface plate 36 coupled to the screw shafts 24 is also lowered, the shielding wall 56 is pressed against the shielding wall 57, and the seals 58 and 59 between them are pressure-bonded. After this sealing, the air in the shielding wall starts to be sucked by the vacuum unit 105 through the air hose 60, and the air existing in the gap of the workpiece 96 is extracted.
[0029]
On the other hand, as the movable surface plate 36 is lowered, the lifter 42 is also lowered by the rotary actuator 49 via the pinions 47 and 48 and the racks 45 and 46. When the lifter 42 is lowered, the clearance between the workpiece 96 and the heating platen 38 on the movable surface plate 36 side and the clearance between the workpiece 96 and the heating platen 41 side of the fixed surface plate 39 are substantially equal. Control to be. As a result, the heat received by the upper and lower surfaces of the workpiece 96 from the two heating plates 38 and 41 is substantially the same. Further, since the surfaces of the heating plates 38 and 41 are ceramic coated during the descending, the whole work 96 is gradually heated before the workpiece 96 comes into contact with the heating plates 38 and 41 by the radiant heat generated by the far infrared rays. The work piece can be quickly heated while avoiding the problem that distortion occurs due to high temperature locally.
At the final stage of lowering, the hot platen 38 on the movable platen 36 side and the hot platen 41 on the fixed platen 39 side simultaneously contact the upper and lower surfaces of the workpiece 96. The workpiece 96 is heated and compressed by a hot press press cycle, which will be described later, by the hot plates 38 and 41 and molded. At this time, the thickness of the workpiece is controlled by detecting the position by the encoder 103, and the load control is performed by detecting the total load of the press by the load cells 97 to 100. That is, the controller 104 controls the electric motor 35 to be a target value in accordance with the detected value of the total press load and the motor rotational position.
[0030]
When the hot pressing step is completed, the movable surface plate 36 and the lifter 42 are raised in the reverse of the lowering control. That is, the movable platen 36 is raised by the electric motor 35 and the rotary actuator 49 is driven to lift the workpiece 96 by the lifter 42 and stop it at a predetermined position. After this ascent, the servo 68 is driven to reduce the distance between the belts 61 and 62 to the conveying position by the link mechanisms 74 and 75, and these belts are positioned below the workpiece 96. Next, the lifter 42 is lowered and the workpiece 96 hot-pressed onto the belts 61 and 62 is delivered.
[0031]
When the delivery is completed, the belts 61 and 62 of the in-press conveyor 3 are rotationally driven. By this belt conveyance, the workpiece 96 that has been hot-pressed is moved to the fixed surface plate 39A (cold press position) of the cold press device 5 and at the same time, the hot press that has been waiting on the insertion buffer conveyor 2 on the upstream side. The next workpiece to be scheduled is moved to the fixed surface plate 39 (hot press position) of the hot press apparatus 4. As described above, these two movements are executed at the same pitches L1 and L2 which are synchronized. After this movement, the hot press apparatus 4 keeps repeating the operation described above again.
On the other hand, in the cold press apparatus 5, after the belts 61 and 62 are widened at the standby position, the lifter 42A lifts the hot-pressed workpiece as in the hot press apparatus, and then the movable surface plate 36A and the lifter 42A The position and speed are controlled so that the clearance between the cooling plate 8 and the workpiece on the operating surface plate 36A side and the clearance between the cooling plate 9 and the workpiece on the fixed surface plate 39A side are substantially equal. While descending. However, in a cold press apparatus, sealing and vacuuming by a shielding wall are not performed. When the cooling plates 8 and 9 of the movable platen 36A and the fixed platen 39A come into contact with the workpiece, they are cooled and compressed by a cold press press cycle described later.
The hot press process and the cold press process are executed one after another in the same cycle and in synchronism with the hot press apparatus 4 and the cold press apparatus 5 arranged in tandem.
When these presses are completed, the movable surface plates 36, 36A and the lifters 42, 42A of both press devices 4, 5 are lifted, and the belts 61, 62 are moved to the transport position where the width is narrowed. The workpiece is lowered and delivered to the belts 61 and 62 after the cold-pressed workpiece and the subsequent hot-pressed workpiece. Subsequently, the former is moved to the carry-out cross conveyor 10, the latter is moved to the cold press position, and the new workpiece is simultaneously moved from the carry-in buffer conveyor 2 to the hot press position.
Thereafter, these steps are repeated.
[0032]
Next, the contents of each press cycle of hot press and cold press will be described in more detail with reference to FIG.
The upper half shows a hot press press cycle, and the lower half shows a cold press press cycle. In the figure, temperature is plotted on the vertical axis and time is plotted on the horizontal axis. Three consecutive hot press cycles A1, A2, A3 are shown in the upper half, and three consecutive cold press cycles are shown in the lower half. B0, B1, and B2 are described. The workpiece 96 is first heated and compressed by the hot press device 4 and then moved to the cold press device 5 by an in-press conveyor, where it is cooled and compressed, so that the workpiece hot pressed in A1 in the figure is The process proceeds to the cold press B1 of the next process, and after the cold press is completed, the cold cross is transferred to the carry-out cross conveyor.
Just as A1 → B1 and the workpiece proceed, the next workpiece also proceeds as A2 → B2,..., A1 and B0, A2 and B1, A3 and B2,. The cold press is executed in a cycle synchronized by the hot press device 4 and the cold press device 5.
[0033]
The press cycle in the hot press in the hot press apparatus 4 is as shown in A1 between the hot platen 38 of the movable platen 36 and the hot platen 41 of the fixed platen 39 located at a position separated from the workpiece. The temperature Ta is kept at a minimum temperature of about 80 ° C. during the press cycle. The temperature Tb of the workpiece that has been brought into the hot press device 4 at time t0 is the ambient temperature (about 30 ° C. in the figure). When the movable surface plate 36 is lowered from time t0 to time t1, the shielding wall 56 and the shielding wall 57 press the seals 58 and 59 together. In this state, the sealed chamber is evacuated by the air hose 60. This vacuum pressure is indicated by Pa in the figure. However, the workpiece is not pressurized until the seals 58 and 59 come into contact with each other.
On the other hand, the temperature Ta of the heating plates 38 and 41 is also increased from about 80 ° C. to about 140 ° C. at the time t0 when the loading is completed. The electric motor 35 is driven from a time point t2 slightly after the time point t1, and the pressure is maintained so that the touch pressure (about 0.1 to 0.2 kg) can be lightly touched. Due to the touch pressure and the hot platen temperature Ta, the temperature Tb of the workpiece also rises and becomes softer.
The hot platen temperature Ta is kept as it is at about 140 ° C., and the electric motor 35 is further driven from the time (t 3) when the temperature Tb of the workpiece reaches about 140 ° C. which is optimal for molding. The heating and pressurization are controlled as follows. At time t4 when a predetermined time has elapsed from time t3, the temperature of the hot plates 38 and 41 starts to decrease toward about 80 ° C. In the temperature drop control of the hot plate temperature Ta, the temperature is gradually lowered until a time t5, and thereafter, the temperature is lowered slightly more rapidly. As a result, the temperature Tb of the workpiece also decreases with a slight delay. At time t6 when the workpiece reaches about 100 ° C., it is regarded that the hot press molding of the workpiece is completed, the electric motor 35 is reversed to raise the movable surface plate 36 to release the press pressure, and the shielding wall The inside is also released to the atmosphere. A hot press completion signal is output at time t7 when the rising of the movable surface plate 36 is completed.
At a predetermined time Δt1 after time t7, the electric motor 35 is further rotated and the upper heating platen 38 is raised and separated from the workpiece. In the subsequent period Δt2, the in-press conveyor 3 is operated to move the workpiece.
The above is the press cycle of the hot press, and the optimum values of t0 to t7, Δt1, Δt2, Pb, etc. are previously determined by experiment.
The pressurization control feeds back the detection values of the load cells 97 to 100, and the thickness of the IC card is controlled by the controller 104 by a signal from the encoder 103.
[0034]
Next, a cold cycle press cycle will be described with reference to the lower half of FIG.
At the time of delivery from the hot press device 4, the temperature Tb of the workpiece to be delivered is about 100 ° C. If the temperature is not lowered to near this temperature, the crystallization of the IC card as a workpiece cannot be progressed and peeled off. If the temperature is too rapidly lowered, sufficient crystallization cannot be achieved and the rigidity is also lowered. Therefore, at the time of this delivery, the temperature Tc of the cooling boards 8 and 9 is raised to the maximum of about 80 ° C. As a result, the temperature Tb of the workpiece is maintained at the crystallization temperature for a predetermined time. Next, the electric motor 35A is driven to apply a high pressure Pc (for example, 25 tons) to the workpiece by the cooling plate 8 and the cooling plate 9 of the movable surface plate 36A, and the temperature Tc of the cooling plates 8 and 9 is about 80 ° C. The temperature is lowered to about 20 ° C., and this temperature and the high pressure are continued for a predetermined time. The workpiece maintains the crystallization temperature for a while even after the temperature drop control of the cooling boards 8 and 9, and thereafter the temperature gradually decreases. When the time t3 is reached, the electric motor 35A is reversely rotated to release the press pressure. Even at the time of discharging from the cold press device 5 thereafter, the workpiece temperature Tb is about 50 ° C., and thereafter, the workpiece is cooled during conveyance. In the figure, ΔT is the transfer time of the workpiece. The above is the press cycle of the cold press, and this press cycle is executed in synchronization with the hot press press cycle.
[0035]
In the above-described embodiment, in the molding of a workpiece such as an IC card, the molding process is divided in half, and the workpiece is heated and pressurized to a moldable high temperature and then slowly cooled to the crystallization temperature. The press apparatus 4 and the cold press apparatus 5 that is transferred from the hot press apparatus 4 and is cooled and heated to be crystallized are delivered in tandem, and the workpieces are flowed in this order and successively Since the workpieces carried in are molded in synchronism with the hot press device 4 and the cold press device 5, the temperature adjustment range of the hot plates 38 and 41 of the hot press device 4 is about 80 ° C to about 80 ° C. It is only necessary to adjust the temperature adjustment of the cooling plates 8 and 9 of the cold press device 4 between about 80 ° C. and about 20 ° C. between 140 ° C. As a result, the time required for the temperature rise and fall can be shortened. It is possible to increase the production amount. In addition, when both the hot press and cold press cycles described above are performed with a single press device, it is necessary to adjust each work piece from about 140 ° C. to 20 ° C., and a large amount of heat must be thrown away. In contrast, the production cost is high, but in the case of the present embodiment, the amount of heat to be discarded in the middle is small, which is economical. In the present embodiment, the workpiece is supported by the lifters 42 and 42A and is lowered together with the movable surface plates 36 and 36A. These lowerings are caused by the workpiece 96 and the movable surface plates 36 and 36A. Since the gap between the hot platen 38 (or the cooling plate 8) and the gap between the workpiece 96 and the fixed platen 39, 39A and the hot platen 418 or the cooling plate 9) are controlled to be substantially equal. The problem that the workpiece is locally heated and distorted can be solved. Furthermore, in the hot press apparatus 4, since the workpieces are hermetically sealed by the shielding walls 56 and 57, the air existing in the gaps between the workpieces can be removed, and the moldability is excellent. Can be secured.
[0036]
In the above embodiment, the upper surface plate is a movable surface plate, the lower surface plate is a fixed surface plate, and the lifter can move the workpiece up and down. Although this configuration is inexpensive and easy to control, the present invention is not limited to this, and the upper surface plate is a fixed surface plate, the lower surface plate is a movable surface plate, and the lower surface plate approaches the fixed upper surface plate. It is also possible to configure so that the lifter is raised according to the above. Alternatively, the lifter can be fixed at a predetermined position after receiving the workpiece from the in-press conveyor, and both the upper surface plate and the lower surface plate can be controlled to move toward the lifter simultaneously as a movable surface plate. Further, as shown in FIG. 3, stop pins 51, 52, 53, and 54 that can adjust the amount of protrusion in the vertical direction are attached to the protrusions 43, 43a, 44, and 44a of the elevating plates 43 and 44, respectively. The lower surface plate may be applied to the stop pins 51, 52, 53, and 54 so as to integrally push down the lifter. In this case, the gap between the workpiece and the upper heating plate, the gap between the workpiece and the lower heating plate are not exactly the same, and the contact between the workpiece and the two heating plates is not simultaneous on the upper and lower surfaces. However, because only one side of the work piece has a gap relationship (substantially the same gap relationship) and a descending velocity relationship that does not cause problems such as heating that is too strong and distortion occurs, it is possible to quickly mold without distortion. become.
[Brief description of the drawings]
FIG. 1 is a diagram illustrating an entire press apparatus system according to an embodiment.
FIG. 2 is a diagram showing a hot press apparatus according to the present embodiment.
3 (a) and 3 (b) are enlarged views of the lifter of the hot press apparatus of FIG. 2, (a) is a side view of the lifter, and (b) is a front view of the lifter.
FIG. 4 is a diagram showing a cold press apparatus according to the present embodiment.
FIG. 5 is a view of a conveyor as a carry-in device according to the present embodiment as viewed from above.
6 is a view showing an upstream link mechanism provided on the conveyor of FIG. 5; FIG. (A) shows the state of the standby position, and (b) shows the state of the transport position.
7 is a view showing a downstream link mechanism provided on the conveyor of FIG. 5. FIG.
FIG. 8 is a diagram showing a workpiece to be carried into the hot press apparatus and the cold press apparatus.
FIG. 9 is a diagram showing a press cycle between a hot press and a cold press.
[Explanation of symbols]
3 Conveyor in press
4 Hot press equipment
5 Cold press equipment
6 Heating / cooling system for hot press
7 Heating and cooling system for cold press
8, 9 Cooling panel (heat control panel)
19, 19A frame
35, 35A Electric motor
36, 36A Movable surface plate (upper surface plate)
38, 41 Heating board (heat adjustment board)
39, 39A Fixed surface plate (lower surface plate)
42, 42A Lifter
43, 43A, 44, 44A Lift plate
45, 45A, 46, 46A rack
47, 47A, 48, 48A Pinion
49, 49A Rotary actuator
61, 62 Belt (conveying element)
74, 75 Link mechanism (moving mechanism)
80 Rotary actuator (movement mechanism)
93a-93e IC card
96 Workpiece
97-100 load cell
103 Encoder
104 controller

Claims

A hot press press cycle process in which a workpiece is gradually heated with a hot press apparatus, heated and pressurized at a molding temperature, and then gradually cooled and pressurized to a crystallization temperature;
A transfer step of transferring the workpiece at the crystallization temperature to the cold press device by a transfer device;
A press molding method including a cold press press cycle step in which the workpiece is pressurized while being cooled from a crystallization temperature by a cold press apparatus.

The press molding method according to claim 1, wherein a press cycle process of the hot press and a press cycle process of the cold press are synchronized.

The heating in the hot press apparatus is to raise the temperature of the hot platen of the hot press apparatus from the crystallization temperature to the molding temperature, hold this temperature for a predetermined time, and then gradually cool to the crystallization temperature.
The pressurization of the workpiece by the hot press apparatus is maintained at a low pressure until the temperature of the workpiece reaches the molding temperature, and after the molding temperature is reached, the high pressure is maintained until the hot press molding of the workpiece is completed. The press molding method according to claim 1, wherein the press molding method is maintained.

The press molding method according to any one of claims 1 to 3, wherein the press cycle process of the hot press is performed in a deaerated state.

In the cold press press cycle step, the cooling disk of the cold press apparatus is heated to a crystallization temperature when the workpiece is delivered, and then kept at a low temperature. The press molding method according to any one of 4.

In the hot press press cycle step and the cold press press cycle step, the workpiece is supported by lifters provided in the hot press device and the cold press device, respectively, and the workpiece is placed between the hot plates or the The press molding method according to any one of claims 1 to 5, further comprising a step of narrowing the gap while maintaining a substantially equal gap with respect to the cooling plates.

A hot press device comprising an upper surface plate and a lower surface plate each having a hot platen, and compressing a new workpiece to be carried in while being heated by the both hot plates by relatively bringing the two platens relatively close together. When,
Workpieces that are located downstream of the hot press device, each provided with an upper surface plate and a lower surface plate each having a cooling plate, are sent from the hot press device by relatively bringing both surface plates closer together. A cold press device that compresses while cooling with both the cooling plates,
The temperature of the hot platen of the hot press apparatus and the pressure of the surface plate are controlled so that the workpiece is gradually heated and heated and pressurized at the molding temperature and then gradually cooled and pressurized to the crystallization temperature. A press molding apparatus comprising a controller.

The hot press device and the cold press device each include a lifter for supporting the workpiece,
At least two of the lifter, the upper surface plate, and the lower surface plate hold the work piece at a position that is equidistant from the other heat plate or the cooling plate with respect to the remaining one. The press molding apparatus according to claim 7, wherein the press molding apparatus approaches.

The lifter includes a lift plate positioned on both sides of the heating plate, a rack provided on the lift plate, a pinion that meshes with the rack, and a rotary actuator that controls the rotation of the pinion. The press molding apparatus according to claim 8.

The press molding apparatus according to any one of claims 7 to 9, wherein the lower surface plate is a fixed surface plate.

The hot press device and the cold press device each include a lifter for supporting the workpiece,
The press molding apparatus according to claim 7, wherein the lifter is pressed by the upper surface plate and is lowered together with the upper surface plate.

12. The hot press apparatus according to claim 7, further comprising a shielding wall capable of accommodating the hot platen and the workpiece and keeping the inside in a deaerated state. The press molding apparatus according to item.

The introduction of a new workpiece into the hot press apparatus and the introduction of the preceding workpiece heated and pressurized by the hot press apparatus prior to the new workpiece into the cold press apparatus at the same pitch are synchronized. The press molding apparatus according to any one of claims 7 to 12, further comprising conveying means that is executed by movement.

The conveying means is configured to move the workpiece while moving the workpiece while being spaced apart from each other in the width direction substantially orthogonal to the moving direction and the thickness direction of the workpiece;
Between the conveyance position where the interval between the conveyance elements becomes narrower than the width of the workpiece and the lifter enters inside the conveyance elements, and the standby position outside the shielding wall of the hot press device The press molding apparatus according to claim 13, further comprising a moving mechanism that moves the conveying element apart and approaches in the width direction.

The conveying element is a belt;
The moving mechanism includes a rotary actuator, a rotary link that rotates integrally with the rotary actuator, and an end portion of the rotary link that extends in the separation direction and a roller support member of both belts. The press molding apparatus according to claim 14, further comprising a rod that changes a distance in a width direction of the support member.

Frame,
An upper surface plate having a heat adjustment plate supported by the frame and capable of being heated or cooled;
A lower surface plate having a heat adjustment plate supported by the frame and capable of heating or cooling;
A lifter capable of supporting a workpiece at a position between the two heating plates;
An actuator capable of pressurizing the workpiece between the two heat adjustment panels by displacing at least two of the lifter, the upper surface plate, and the lower surface plate in the vertical direction toward the remaining one. When,
Of the lifter, the upper surface plate, and the lower surface plate, the one to be displaced is changed to a gap between the workpiece supported by the lifter and the one heat adjustment plate, and the workpiece and the other heat. A controller that controls the actuator so that the gap between the adjustment panels is substantially the same;
And
The conveying means
A pair of transport elements that move away from each other while supporting the workpiece;
The conveyance element is narrower than the separation direction dimension of the conveyance element of the workpiece and the lifter is located inside the conveyance element between the conveyance elements, and wider than the separation direction dimension of the conveyance element of the workpiece. A pressing apparatus comprising: a moving mechanism that moves to and away from a standby position in a width direction substantially orthogonal to a moving direction and a thickness direction of the workpiece.

The lower surface plate is a fixed surface plate,
The lifter includes a lift plate that is positioned on both sides of the lower surface plate to support the workpiece, and a lift mechanism that moves the lift plate up and down relative to the lower surface plate. Press equipment.

18. The press apparatus according to claim 17, wherein the elevating mechanism is a pinion driven by a rotary actuator, and a rack that meshes with the pinion and has the elevating plate attached thereto.

The press device according to claim 16, wherein the lifter is pressed by the upper surface plate and lowered together with the upper surface plate.

The press apparatus according to any one of claims 16 to 19, wherein the surface plate is provided with a shielding wall surrounding the workpiece in a sealed state, and the inside of the shielding wall is connected to a vacuum unit. .

The moving mechanism includes a support member that supports each transport element at a position in the width direction, a rotary actuator, a rotary link that is integral with the rotary actuator, and a rod that is connected to both the support members. The press device according to any one of claims 16 to 19, wherein the width direction interval between the two support members is changed by rotation of a rotary actuator.