JP6640431B1 - 連続プレス成形方法及びその実施のための加熱装置 - Google Patents
連続プレス成形方法及びその実施のための加熱装置 Download PDFInfo
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Abstract
Description
溶融樹脂をダイスより押出すことにより帯状軟化樹脂シートに形成する工程と、
帯状軟化樹脂シートを幅方向に切断することにより所定長さの一連の単位樹脂シートとする切断工程と、
一連の単位樹脂シートを加熱することによりプレス成形に適した温度まで加熱する単位樹脂シート加熱工程と、
加熱された単位樹脂シートのプレス型への搬入、プレス型によるプレス成形物へのプレス成形、プレス成形品の次工程への搬出からなる単位樹脂シートのプレス成形品へのプレス加工を一連の単位樹脂シートについてサイクルタイムにおいて繰返的に行うプレス成形工程と、
を具備して成り、前記単位樹脂シート加熱工程は、単位樹脂シートのプレス成形に適した単位樹脂シート温度より幾分低い第1の温度までサイクルタイムにおいて徐々に加熱する第1の加熱工程と、前記第1の加熱工程後に、単位樹脂シートをプレス成形に適した第2の温度にサイクルタイムにおいて急速加熱する第2の加熱工程とから成る。
14…切断装置
16…加熱装置
20…プレス成形機
20-1…雄型2
20-2…雌型
24…後処理ライン
26…樹脂ペレット投入用ホッパ
34…ダイス
44…切断装置
44-1…固定刃
44-2…可動刃
50…スリット形成装置
52…切刃
54…エアシリンダ
54-1…下部空気圧ポート
54-2…上部空気圧ポート
55…ピストン
60…エアシリンダの水平駆動部材
62…エアシリンダの支持部材
64, 66…スプロケットホイール
68…無端チェーン
68-1…チェーン駒
70, 72…ブラケット
76…サーボモータ(A, B, C)
84…一次加熱炉
84-1…一次加熱炉の加熱室
84-2…一次加熱炉のコンベヤ
84-3, 84-4…一次加熱炉の赤外線加熱ヒータ
84-5…一次加熱炉のコンベヤの駆動モータ
86…二次加熱炉
86-1…二次加熱炉の加熱室
86-2…二次加熱炉のコンベヤ
86-3, 86-4…二次加熱炉の赤外線加熱ヒータ
86-5…二次加熱炉のコンベヤの駆動モータ
C1, C2, C3, C4, C5…スリット(切込み)
P…プレス成形物
P1, P2…プレス成形物のプロテクターフェンダーとなる部位
P3…プレス成形物のスクラップとなる部位
W…プレス成形物の縦壁部分
E…プレス成形物のエンボス部分
S…帯状軟化樹脂シート
ST…サイクルタイム
U…単位樹脂シート
Claims (7)
- 溶融樹脂をダイスより押出すことにより帯状軟化樹脂シートに形成する工程と、
帯状軟化樹脂シートを幅方向に切断することにより所定長さの一連の単位樹脂シートとする切断工程と、
一連の単位樹脂シートを加熱することによりプレス成形に適した温度まで加熱する単位樹脂シート加熱工程と、
加熱された単位樹脂シートのプレス型への搬入、プレス型によるプレス成形物へのプレス成形、プレス成形品の次工程への搬出からなる単位樹脂シートのプレス成形品へのプレス加工を一連の単位樹脂シートについてサイクルタイムにおいて繰返的に行うプレス成形工程と、
を具備して成り、前記単位樹脂シート加熱工程は、単位樹脂シートのプレス成形に適した単位樹脂シート温度より幾分低い第1の温度までサイクルタイムにおいて徐々に加熱する第1の加熱工程と、前記第1の加熱工程後に、単位樹脂シートをプレス成形に適した第2の温度にサイクルタイムにおいて急速加熱する第2の加熱工程とから成る連続プレス成形方法。 - 請求項1に記載のプレス成形方法において、溶融樹脂の素材として40〜60%のポリプロピレン樹脂と60〜40%のポリエチレン樹脂との混合樹脂を使用し、押出時の混合樹脂温度が190〜220℃であり、単位シートに切断時の樹脂シートの温度は115〜135℃でありかつ樹脂シートの大きさは、700〜1550mm×1000〜2300mmであり、第1の加熱工程で加熱された樹脂の温度は125〜135℃であり、第2の加熱工程で加熱された樹脂の温度は130〜160℃のとき、単位樹脂シートへの切断からプレス成形までの工程のサイクルタイムは15〜25秒であるプレス成形方法。
- 請求項1若しくは2に記載のプレス成形方法において、第1の加熱工程における単位樹脂シートの加熱は単位樹脂シートを0.02〜1.0m/sの速度で連続送りしながら行い、第2の加熱工程における単位樹脂シートの加熱は単位樹脂シートを停止させて行うプレス成形方法。
- 請求項3に記載のプレス成形方法において、第1の加熱工程における単位樹脂シートの連続加熱のため波長10〜20μmの遠赤外領域の赤外線を放射する熱源を使用し、第2の加熱工程における単位樹脂シートの急速加熱のため波長5〜10μmの中赤外領域の赤外線を放射する熱源を使用するプレス成形方法。
- 請求項1から4のいずれか一項に記載のプレス成形方法の実施のための単位樹脂シートの加熱装置であって、第1の加熱工程の加熱を行うための第1の加熱炉と、第2の加熱工程を行うための第2の加熱炉とから成り、第1の加熱炉及び第2の加熱炉は、夫々、加熱室と、加熱室内に配置され、単位樹脂シートの搬送を行うコンベヤと、単位樹脂シートの搬送経路に沿って加熱室に配置された赤外線ヒータとからなり、第1の加熱炉における赤外線ヒータは波長10〜20μmの遠赤外領域の赤外線を放射し、第2の加熱炉における赤外線ヒータは波長5〜10μmの中赤外領域の赤外線を放射する加熱装置。
- 請求項5に記載の加熱装置において、第1の加熱炉のコンベヤは、単位樹脂シートを徐々に加熱するための単位樹脂シートの低速移動を行うと共に第1の加熱炉での加熱のための単位樹脂シートの急速受入れ及び加熱後の第2の加熱炉への単位樹脂シートの排出を行う第1のコンベヤ駆動機構を備え、第2の加熱炉のコンベヤは、加熱中の単位樹脂シートの停止、及び第1の加熱炉からの単位樹脂シートの急速受入れ及び加熱後の単位樹脂シートのプレス成形機側への急速送り出しを行う第2のコンベヤ駆動機構を備えた加熱装置。
- プレス成形物の連続成形装置であって、
溶融樹脂を帯状軟化樹脂シートに押出し形成する押出機と、
押出機により押出された帯状軟化樹脂シートを幅方向に切断することにより所定長さの一連の単位樹脂シートとする切断装置と、
単位樹脂シートを加熱することによりプレス成形に適した温度まで加熱する単位樹脂シート加熱装置と、
加熱された単位樹脂シートをプレス成形することによりプレス成形物とするプレス成形機と、
を具備してなり、
前記単位樹脂シート加熱装置は、第1の加熱工程の加熱を行うための第1の加熱炉と、第2の加熱工程を行うための第2の加熱炉とから成り、第1の加熱炉及び第2の加熱炉は、夫々、加熱室と、加熱室内に配置され、単位樹脂シートの搬送を行うコンベヤと、単位樹脂シートの搬送経路に沿って加熱室に配置された赤外線ヒータとからなり、第1の加熱炉における赤外線ヒータは波長10〜20μmの遠赤外領域の赤外線を放射し、第2の加熱炉における赤外線ヒータは波長5〜10μmの中赤外領域の赤外線を放射するようにされるプレス成形物の連続成形装置。
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