JP4657780B2 - Molding method of resin sheet - Google Patents
Molding method of resin sheet Download PDFInfo
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- JP4657780B2 JP4657780B2 JP2005107835A JP2005107835A JP4657780B2 JP 4657780 B2 JP4657780 B2 JP 4657780B2 JP 2005107835 A JP2005107835 A JP 2005107835A JP 2005107835 A JP2005107835 A JP 2005107835A JP 4657780 B2 JP4657780 B2 JP 4657780B2
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Description
本発明は、熱可塑性樹脂シートを加熱軟化させて成形型で成形する成形技術に関する。 The present invention relates to a molding technique in which a thermoplastic resin sheet is softened by heating and molded with a molding die.
一般的に、熱可塑性樹脂シートを所望形状に成形する際、加熱軟化させたシートを成形型の上方から降下させてゆき、シートを成形型の成形面上に載置して真空引きまたは型締め等により成形面に密着させ、所望の形状に成形するようにしている。この成形時に、シートが伸ばされる率が大きい箇所では、シートが薄くなる等の不具合が発生し、また、シートとしてシボ模様や梨地模様等で加飾されたシートを使用するときは、伸長率の大きい部位のシボの残存深さが浅くなったり、シボパターンが大きくなったり、シートの表面艶が他の部位に較べて光沢が生じたりする等の不具合が生じ易くなる。 Generally, when a thermoplastic resin sheet is formed into a desired shape, the heat-softened sheet is lowered from above the mold, and the sheet is placed on the molding surface of the mold and vacuumed or clamped. For example, they are brought into close contact with the molding surface and molded into a desired shape. At the time of molding, problems such as thinning of the sheet occur at locations where the sheet is stretched, and when using a sheet decorated with a texture pattern or satin pattern as the sheet, Problems such as a small remaining depth of the grain at the large part, a large grain pattern, and a glossy surface gloss of the sheet as compared with other parts are likely to occur.
このため、加熱軟化させたシートを成形型に当接する過程において、シートが最も伸長しやすい部分が過度に伸長しないようにするため、シートの周縁部に対応する成形型に肩部を設ける一方、シートの周縁部を肩部に向けて押圧することのできる押圧部材を設け、成形型の成形面にシートを当接させる際、押圧部材によってシートを肩部に向けて押圧することにより、押圧部位より内側の成形部側のシートの伸長を阻止するような技術(例えば、特許文献1参照。)が知られている。なお、この技術では、シートに対する押圧部材の接触部が左右側方にずれないよう、押圧部材はリンク機構として構成されている。
ところが、上記技術では成形型にシートを当接させる段階で、シートの端部を押圧部材によって肩部に押圧し、それより内側の成形部側の伸長を阻止するようにしているが、押圧部材の押圧位置が固定されているため、その後、真空引き等によってシートを成形面に密着させる段階では、押圧部材より内側のシートの伸長を阻止することはできず、シートの伸長率防止に限界がある。 However, in the above technique, at the stage where the sheet is brought into contact with the molding die, the end of the sheet is pressed against the shoulder by the pressing member, and the inner side of the molding unit is prevented from being extended. Therefore, at the stage where the sheet is brought into close contact with the molding surface by vacuuming or the like after that, it is not possible to prevent the extension of the sheet inside the pressing member, and there is a limit to the prevention of the sheet extension rate. is there.
そこで本発明は、シートの局部的な伸びを一層抑制し、厚みが不均一になるのを防止するとともに、加飾が施されているシートの場合は、見栄えが低下する等の不具合を防止することを目的とする。 Therefore, the present invention further suppresses local elongation of the sheet, prevents the thickness from becoming non-uniform, and prevents problems such as deterioration in appearance in the case of a sheet that has been decorated. For the purpose.
上記目的を達成するため本発明は、加熱軟化させた熱可塑性樹脂シートを成形型の上方から降下させ、成形型の成形面上に密着させて成形する樹脂シートの成形方法において、前記熱可塑性樹脂シートを降下させ、前記成形面の突出部にシートの一部が接触した段階で、シートの突出部近傍の少なくとも一部を成形面に対して非接触状態にすることで該突出部近傍の一部のシートを張った状態にして型締めし、次いで、前記非接触状態のシート端部を、成形型に設けたシート保持部材で保持しつつ該シート保持材を前記突出部側に移動させ、非接触状態のシートを成形面に接触させるようにした。 In order to achieve the above object, the present invention provides a method for molding a resin sheet in which a heat-softened thermoplastic resin sheet is lowered from above a molding die and is brought into close contact with the molding surface of the molding die. When the sheet is lowered and a part of the sheet comes into contact with the protruding portion of the molding surface, at least a part of the vicinity of the protruding portion of the sheet is brought into a non-contact state with respect to the molding surface. The sheet is clamped in a stretched state, and then the sheet holding member is moved to the protruding portion side while holding the non-contact sheet end with a sheet holding member provided in the mold, The non-contact sheet was brought into contact with the molding surface.
すなわち、シートの伸長率が最も大きくなる部位は、一般的に、成形面のうち、急激に突出する突出部近傍でシートに対して大きな角度で交差する側壁部分である。そこで、このような大きな角度で交差する側壁部分に対しては、シートを非接触にして張った状態で型締めし、その後、非接触のシート端部を保持するシート保持部材を突出部側に移動させれば、同部のシートにゆとりができ(成形に必要な量のシートを補充するようなイメージ)、局部的な伸びが緩和される。
なお、この際、シート保持部材で保持されるシートの保持部より外側部分(突出部とは反対側部分)は伸ばされるため、この部分が非製品部(意匠外部分)になるようにしておけば好ましい。
That is, the portion where the sheet elongation rate is the largest is generally the side wall portion that intersects the sheet at a large angle in the vicinity of the projecting portion that projects rapidly on the molding surface. Therefore, the side wall portions intersecting at such a large angle are clamped in a state where the sheet is stretched in a non-contact state, and then the sheet holding member that holds the non-contact sheet end is moved to the protruding portion side. If moved, the sheet of the same part can be relaxed (image such as replenishing the amount of sheets necessary for molding), and the local elongation is alleviated.
At this time, since the outer portion (the portion opposite to the protruding portion) of the sheet holding portion held by the sheet holding member is extended, this portion should be a non-product portion (outside design portion). It is preferable.
加熱軟化させた熱可塑性樹脂シートを成形型で成形するにあたり、成形型の突出部にシートが接触した段階で、シートの突出部近傍の一部を成形面に対して非接触状態にし、その後、この非接触状態のシート端部を保持するシート保持部材を突出部側に移動させれば、最初に非接触であったシート部分にゆとりが生じ、伸び率を抑えることができて、局所的な伸びによる成形不良が抑制される。 In molding the heat-softened thermoplastic resin sheet with a molding die, when the sheet contacts the projection of the molding die, a part of the vicinity of the projection of the sheet is brought into a non-contact state with respect to the molding surface. If the sheet holding member that holds the sheet end portion in the non-contact state is moved to the protruding portion side, a space is generated in the sheet portion that was initially non-contact, and the elongation rate can be suppressed. Molding defects due to elongation are suppressed.
本発明の実施の形態について添付した図面に基づき説明する。
ここで図1は本発明に係る成形方法が適用される成形型の一部を示す説明図、図2は本成形方法の説明図である。
Embodiments of the present invention will be described with reference to the accompanying drawings.
Here, FIG. 1 is an explanatory view showing a part of a forming die to which the forming method according to the present invention is applied, and FIG. 2 is an explanatory view of the forming method.
本発明に係る樹脂シートの成形方法は、熱可塑性樹脂シートを加熱軟化させ、成形型の成形面に倣って成形するにあたり、成形形状が複雑で局部的な伸びが生じ易い場合でも、それを抑制して見栄えの低下が生じないようになれており、特にシートが伸び易い箇所のシートにゆとりを持たせて成形することを特徴としている。 The method for molding a resin sheet according to the present invention suppresses the heat-softening of a thermoplastic resin sheet and suppresses even when the molding shape is complicated and local elongation tends to occur when molding is performed following the molding surface of the mold. Thus, the appearance is not deteriorated, and the sheet is particularly characterized in that it is formed with a space in the sheet where the sheet is easily stretched.
そこで、まず、本成形方法が採用される成形型の概要について図1に基づき説明する。
本成形型は、加熱軟化される熱可塑性樹脂シートを真空成形するための真空成形型として構成され、図1に示すように、表面に突出部1tを有する成形面を備え且つ成形面に多数の真空引き孔が形成される第1成形型1と、第1成形型1の上方で上下動自在な第2成形型2と、シートWの周縁部を把持する把持枠3を備えており、この把持枠3は、第1、第2成形型1、2の間に配置されるとともに、第1成形型1に対して上下動自在にされている。
Therefore, first, an outline of a mold in which the present molding method is adopted will be described with reference to FIG.
This molding die is configured as a vacuum molding die for vacuum molding a thermoplastic resin sheet to be heat-softened. As shown in FIG. 1, the molding die is provided with a molding surface having a protruding portion 1t on the surface and a large number of molding surfaces. A first mold 1 in which a vacuum hole is formed; a second mold 2 that is movable up and down above the first mold 1; and a gripping frame 3 that grips the peripheral edge of the sheet W. The grip frame 3 is disposed between the first and second molds 1 and 2 and is movable up and down with respect to the first mold 1.
前記第1成形型1には、第1コア4が設けられ、この第1コア4は、ガイド部材5に沿って水平方向にスライド自在にされるとともに、通常時は、不図示の復元機構により、図1に示す左方の位置に移動し待機している。 The first mold 1 is provided with a first core 4, which is slidable in the horizontal direction along the guide member 5, and normally, by a restoring mechanism (not shown). 1 is moved to the left position shown in FIG.
前記第2成形型2には、型本体に対して水平方向にスライド自在な第2コア6が設けられ、第2成形型2が降下すると、第2コア6が第1コア4の外側近傍に降下し、第2コア6が成形面側に向けて水平内側にスライドすると、第1コア4を押圧して第1コア4と一緒にスライドするようにされている。 The second mold 2 is provided with a second core 6 that is slidable in the horizontal direction with respect to the mold body. When the second mold 2 is lowered, the second core 6 is located near the outside of the first core 4. When the second core 6 descends and slides horizontally inward toward the molding surface side, the first core 4 is pressed to slide together with the first core 4.
以上のような成形型を使用した本成形方法について、図2に基づき説明する。
把持枠3で把持するTPO、PPシート等の熱可塑性シートWで、凹凸模様や、皮模様や、幾何学模様等のシボ模様や、梨地仕上げ等で加飾されたものを約180℃程度の成形可能な温度に加温した後、第2成形型2と把持枠3を降下させることにより、シートWを第1成形型1に当接させる。すると、図2(a)に示すように、シートWは最初に成形面の突出部1tに当接する。なお、この時の第1成形型1の金型温度は約70℃程度のシートが固化可能な温度である。
The present molding method using the above mold will be described with reference to FIG.
A thermoplastic sheet W such as TPO or PP sheet gripped by the gripping frame 3, which is decorated with a concavo-convex pattern, leather pattern, texture pattern such as a geometric pattern, or satin finish, etc. at about 180 ° C. After heating to a temperature at which molding is possible, the sheet W is brought into contact with the first molding die 1 by lowering the second molding die 2 and the grip frame 3. Then, as shown in FIG. 2A, the sheet W first comes into contact with the protruding portion 1t of the molding surface. The mold temperature of the first mold 1 at this time is a temperature at which a sheet of about 70 ° C. can be solidified.
そして、第2成形型2と把持枠3を更に降下させると、図2(b)に示すように、シートWの一部が第1成形型1の第1コア4と、第2成形型2の第2コア6により挟み込まれた状態で保持され、型締めが終了した段階では、突出部1tの頂点と、第1、第2コア4、6の保持部との間のシートWが、成形面とは非接触で引張られた状態になる。なお、この箇所は、通常であればシートWの伸長率が最も大きい箇所である。 Then, when the second mold 2 and the gripping frame 3 are further lowered, as shown in FIG. 2B, a part of the sheet W becomes the first core 4 of the first mold 1 and the second mold 2. The sheet W between the apex of the projecting portion 1t and the holding portions of the first and second cores 4 and 6 is formed at the stage where the clamping is finished and is held between the second core 6 The surface is pulled without contact. In addition, this location is usually a location where the expansion rate of the sheet W is the largest.
次いで、図2(c)に示すように、第2コア6を前進させると、シートWの一部を挟んで第1コア4も押されて、突出部1tの頂点と、第1、第2コア4、6の保持部との間のシートWが成形面に近づくようになる。そして、第1成形型1の真空引き孔から真空引きすれば、突出部1tの頂点と、第1、第2コア4、6の保持部との間のシートWが大きく伸ばされることなく、同部の薄肉化が防止されるとともに、シボ模様等のシボ深さやパターンが変化したり、光沢に差が生じたりするような不具合を防止できる。 Next, as shown in FIG. 2C, when the second core 6 is advanced, the first core 4 is also pushed across a part of the sheet W, and the apex of the protruding portion 1t and the first and second portions The sheet W between the holding parts of the cores 4 and 6 comes close to the molding surface. If the vacuum is pulled from the vacuum pulling hole of the first mold 1, the sheet W between the apex of the projecting portion 1 t and the holding portions of the first and second cores 4 and 6 is not greatly stretched. In addition to preventing the thickness of the portion from being reduced, it is possible to prevent problems such as changes in the texture depth and pattern such as a texture pattern, and differences in gloss.
一方、第1、第2コア4、6の保持部より外側部分(図の左方部分)のシートWは、伸びが大きくなり、薄肉化や品質低下が生じ易くなるが、本実施例では、この部分は製品面部外の非製品部であり、後からトリミングで除去するため、外観品質の悪化はない。
以上のような要領により、製品面部のうちシートWが一番伸び易い部分の伸びが抑制され、薄肉化が防止されるとともに、シボ模様の変化のなくなり、成形品質を高めることができる。
On the other hand, the sheet W of the outer portion (the left portion in the figure) of the holding portions of the first and second cores 4 and 6 is increased in elongation and is likely to be thinned and deteriorated in quality. This portion is a non-product portion outside the product surface portion and is removed by trimming later, so that the appearance quality is not deteriorated.
By the above procedure, the elongation of the portion of the product surface portion where the sheet W is most likely to be stretched is suppressed, the thinning is prevented, the texture pattern is not changed, and the molding quality can be improved.
なお、本発明は以上のような実施形態に限定されるものではない。本発明の特許請求の範囲に記載した事項と実質的に同一の構成を有し、同一の作用効果を奏するものは本発明の技術的範囲に属する。
例えば、熱可塑性樹脂シートWの素材等は任意であり、また、第1成形型1の成形面の形状等は例示である。
更に、本成形方法は真空成形に限られるものではない。
In addition, this invention is not limited to the above embodiments. What has substantially the same configuration as the matters described in the claims of the present invention and exhibits the same operational effects belongs to the technical scope of the present invention.
For example, the raw material of the thermoplastic resin sheet W is arbitrary, and the shape of the molding surface of the first mold 1 is an example.
Furthermore, this forming method is not limited to vacuum forming.
加熱軟化させた熱可塑性樹脂シートを成形型で成形する際、局部的な伸びを抑制して、薄肉化が生じるのを防止するとともに、シボ模様の変化等の成形不良を防止して品質のよい成形品を成形することができる。 When molding a heat-softened thermoplastic resin sheet with a molding die, it suppresses local elongation, prevents thinning, and prevents quality defects such as changes in wrinkle patterns. A molded product can be formed.
1…第1成形型、1t…突出部、2…第2成形型、4…第1コア、6…第2コア、W…樹脂シート。 DESCRIPTION OF SYMBOLS 1 ... 1st shaping | molding die, 1t ... Projection part, 2 ... 2nd shaping | molding die, 4 ... 1st core, 6 ... 2nd core, W ... Resin sheet.
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JP2005107835A JP4657780B2 (en) | 2005-04-04 | 2005-04-04 | Molding method of resin sheet |
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JP2005107835A JP4657780B2 (en) | 2005-04-04 | 2005-04-04 | Molding method of resin sheet |
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JP4657780B2 true JP4657780B2 (en) | 2011-03-23 |
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Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS6382537U (en) * | 1986-11-18 | 1988-05-31 | ||
JPH06198730A (en) * | 1992-12-28 | 1994-07-19 | Tokyo Seat Kk | Method for molding laminate by vacuum drawing |
JP2001138389A (en) * | 1999-11-11 | 2001-05-22 | Kojima Press Co Ltd | Method for vacuum forming |
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Publication number | Priority date | Publication date | Assignee | Title |
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JPS6382537U (en) * | 1986-11-18 | 1988-05-31 | ||
JPH06198730A (en) * | 1992-12-28 | 1994-07-19 | Tokyo Seat Kk | Method for molding laminate by vacuum drawing |
JP2001138389A (en) * | 1999-11-11 | 2001-05-22 | Kojima Press Co Ltd | Method for vacuum forming |
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