JPH04122622A - Blank material and component molding method using same - Google Patents

Abstract

PURPOSE:To feed a blank material into a mold automatically and mechanically by forming recessed channels continuously on the surface of the blank material and fold laminating the blank material with its recessed channels used as the folding sections. CONSTITUTION:The resin component of a thermoplastic resin sheet 16 is melted in a heating section 3 and long fiber glass mats 13 are integrated into the thermoplastic resin sheet 16, and a number of recessed channels 19 provided with recesses and projections 8 formed on the surfaces of belts 7 and 11 are formed on the surface of said integrated raw sheet material. Said raw sheet material is fed into a cooling section 4, and the shape of recessed channels 19 are retained to form a raw sheet 20, which is fed out of an outlet 13. Said raw sheet 20 is wound into the coil shape as the recessed channels 19 as its bending sections. After that, the raw sheet 20 is unwound at an inlet of a heating oven 22, and specified number of pieces is sheared in group, and placed on a conveying section 25 as blank materials B and fed into a heating section 26 where the same is softened by heating and fed out of a carrying-out section. Said blank materials B are folded with the recessed channels 19 as folding lines and placed on a bearer 28.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention is directed to, for example, a glass fiber-reinforced thermoplastic resin blank material, and a bumper using this blank material.
This article relates to a method for molding parts such as seat frames and battery supports.

(Prior Art) As shown in FIG. 8, a conventional glass fiber reinforced thermoplastic resin sheet is produced by extruding two thermoplastic resin sheets 44 and a long fiber glass mat 45 into a thermoplastic resin 46 from an extruder 46.
a is melted and impregnated and the whole is heated in a heating section 47 to melt the thermoplastic resin and integrate the long fiber glass mat 45 into a thermoplastic resin sheet to obtain a material 48. This material 48 is carried into a cooling section 49, where its shape is retained by cooling, and the original plate 5
o, and is carried out from the exit section (Fig. 8 (1)).

This original plate 50 is cut into a predetermined length by a cutting device 51 to form a sheet (FIG. 8 (2>). This sheet-shaped original plate 52 is laminated on a bullet 53. After being transported, the blank material 54 is made by cutting it into the required dimensions (Fig. 8 (2), (3), (4))
.

The blank material 54 produced in this way is loaded into a bullet or container 55 and conveyed to the part molding machine (FIG. 8 (5)).

In this parts molding machine, a blank material 54 is supplied to the inlet side of a heating furnace 56, and is conveyed through the heating furnace 56 by a conveyor, heated, and melted. After the molten blank material 57 is carried out to the exit side of the heating furnace 56, it is laminated and put into the mold 59 of the molding press 8158, and a part 1, for example, a bumper is formed by press processing (see FIG. 8). 6), (7)).

(Problems to be Solved by the Invention) However, in the conventional example, the original plate 50 is cut into a sheet shape by a cutting device 51 to a predetermined length, and furthermore, the sheet-shaped standard length material 52 is pallet 53
After being stacked on top and transported, the blank material 54 is cut into required dimensions twice. For this reason, there was a problem that there was waste in the process and space was required to store each of the standard length materials and blank materials.

In addition, since the original plate 0 is cut into the standard length material 52 and the blank material 54, the glass fibers are exposed on the cut surfaces of the standard length material 52 and the blank material 54, and the glass fibers may come out or be cut. At times, the glass fibers are crushed into small pieces and powder, which can get stuck in the clothes or skin of workers during work, causing pain and itching and creating a poor working environment.

Furthermore, in the one-component molding machine, a blank material 54 is supplied to the inlet side of the heating furnace 55, and is conveyed by a conveyor inside the heating furnace 56 and heated and melted.
After the molten blank material 57 is carried out to the exit side of the heating furnace 56, it is stacked one by one and placed in a forming press l! 158 mold 5
This molten blank material 57 is fed into the molten blank material 57 and is then molded into a part, such as a bumper, by press working.
Because they are soft and stiff, it is extremely difficult to automate the process of stacking them up and feeding them into the mold 59, which means that it is difficult to automate the process and it has to be done manually.

The present invention has been made by paying attention to the above-mentioned problems, and its - objective is to fold the concave groove portions into folds, stack them, and then feed them into the mold of a molding press machine. The object of the present invention is to provide a blank material that can be used as a material for resin molded products.

Another object of the present invention is that the cutting process is reduced, the storage space for the blank material is not required as much, and the reinforcing fibers are exposed on the cut surface of the blank material, so that the reinforcing fibers are not pulled out. The problem is that the reinforcing fibers come out, or when cut, the reinforcing fibers are crushed into small pieces and powder, and the reinforcing fibers get stuck in the clothes or skin of the worker, causing pain and itching and worsening the working environment. Not only can this be solved, but there is no need to manually stack the molten blanks one by one after preheating, and the use of blanks makes it possible to automate and mechanize the feeding of the blanks into the mold. The object of the present invention is to provide a method for molding parts.

(Means for Solving the Problems) In order to achieve the above-mentioned object -5, the blank material according to the present invention has a structure in which at least one surface of the blank material made of reinforcing fiber-reinforced thermoplastic resin is folded. It has a structure in which a groove that becomes a crease is formed.

In order to achieve the other objects mentioned above, a part forming method using a blank material according to the present invention is a part forming method in which a plurality of heat-melted reinforcing fiber-reinforced thermoplastic resin blanks are laminated and press-molded. The method is characterized in that grooves are continuously formed on the surface of the blank material, and the blank materials are folded and stacked using the groove portions as bending portions.

(Function) By configuring the blank material as described above, 1. the blank material can be folded and stacked with the concave groove part as a crease, and then put into the mold of a molding press machine and used as a material for a resin molded product. obtain.

By the part forming method using the blank material as described above,
When carried into the mold of a molding press, the grooves are folded and stacked, and unlike conventional blank materials, they are not cut into required dimensions. Because of the concave grooves, it can be wound into a coil rather than a sheet, so it is possible to prepare the material in a coiled form up to the entrance of the preheating furnace without having to cut the material to a standard length or blank. Therefore, the number of cutting steps is reduced and the storage space for blanks is not required as much.

In addition, the blank material is folded and stacked with the concave groove part as a crease, and unlike conventional blank material, it is not cut to the required size, so the reinforcing fibers are exposed on the cut surface of the blank material. This prevents the reinforcing fibers from coming out, and when cutting, the reinforcing fibers are crushed and particles and powder get stuck in the clothes and skin of the workers, causing pain and itching. It is possible to solve the problem of deteriorating the environment.

Furthermore, since the blanks are folded and stacked with the concave grooves creased and placed into the mold of the forming press, it is necessary to stack the molten blanks one by one after preheating. This makes it possible to automate and mechanize the charging of blank materials into molds.

(Example) Hereinafter, a blank material according to the present invention and a component molding method using this blank material will be explained based on the drawings.

The blank material B according to the present invention has grooves 19 formed on at least one surface of the blank material made of glass fiber reinforced thermoplastic resin, which is the reinforcing 1a fiber thermoplastic resin, to form a crease when the blank material is folded. This is what I did. Then, the blank material B is folded and stacked with the concave groove 19 as a crease, and then put into the mold 29 of the molding press 32 to be used as a material for a resin molded product.

The reinforcing fiber materials include not only glass fiber materials but also carbon fiber materials, Kepra fiber materials, and the like.

The molding of this blank material B and the method of molding resin parts using this blank material B will be described below.

Figure 1 (1), (2), (3), (4), (5), (6
) is an explanatory diagram of the molding process of a resin molded article according to an embodiment of the present invention, and A in the figure is a long glass fiber reinforced thermoplastic f! This is a molding device for lubricant original plates (hereinafter referred to as original plates).

This forming apparatus A is a double belt press machine, and includes an upper belt part 1, a lower belt part 2, a heating part 3, and a cooling part 4. An endless belt 7 is hung between them, and the lower belt part 2 is
It consists of an endless belt 11 hung between pulleys 9 and 10,
The distance L2 between the pulleys 9.1o of this lower belt portion 2 is:
This is longer than the distance L1 between the pulleys 5.6 of the upper belt portion 1. The surface of these belts 7.11 has irregularities 8 along the width direction of the belts 7.11, as shown in FIG.
However, a large number of belts 7 and 11 are formed at a predetermined pitch in the running direction of the belt 7.11.

The upper and lower belt parts 1.2 are positioned vertically, the inlet pulley 5.9 is shifted back and forth to form the inlet part 12, and the outlet pulley 6.10 are aligned vertically to form an outlet portion 13. A molded part 14 is formed between the inlet part 12 and the outlet part 13. Note that the pulley 6.10 on the exit side is a drive pulley.

The heating section 3 and the cooling section 4 are arranged in the molding section 14. Further, an extruder 15 is arranged at the inlet portion 12.

Next, forming the original plate 20 using the above-described forming apparatus A will be explained.

By rotationally driving the pulley 6.10 on the exit side, which is a pulley on the drive side, the belt 7 is rotated to the left in FIG. 1, and the belt 11 is rotated to the right to operate the molded fA.

At the entrance part 12, two thermoplastic resin sheets 16 and two long fiber glass mats 17 are melted and impregnated with polypropylene resin 18 from the extruder 15 into the long fiber glass mats 17 to form a thermoplastic resin sheet. Insert between both belts 7° and 11 with 16 facing outside. Then, the thermoplastic resin sheet 16 sandwiching the long fiber glass mat 17 is carried into the heating section 3 by the movement of the belt 7.11. In this heating section 3, the thermoplastic resin sheet 16 is heated! The long fiber glass material 17 is integrated into the thermoplastic resin sheet 16 by melting the fat content, and the unevenness 8 formed on the surface of the belt 7. A large number of grooves 19 are formed.

In this way, the original plate material with a large number of grooves 19 formed on its surface is carried into the cooling section 4, where the grooves 19 are kept in shape by cooling to form an original plate 20. This original plate 20 is passed from the outlet section 13 It is carried out (Fig. 1 (1)).

This original plate 20 has a large number of grooves 19 formed on its surface, and can be wound into a coil shape using the grooves 19 as bending parts. Therefore, the original plate 20 carried out from the outlet section 13 is wound up into a coil (FIG. 1 (2)) and stored.

Alternatively, the original plate 20 carried out from the outlet section 13 is cut into a predetermined length to obtain a standard length material 20a, which is stacked and stored in a pallet 21 (FIG. 2).

Next, the process of forming a resin molded product using the original plate 20 formed as described above will be explained.

A heating furnace 22 and a molding press 23 are used for this molding process.

This heating furnace 22 is equipped with a conveyor belt 24 for conveyance, and a heating section 26 such as an infrared ray is arranged above a conveyance section 25 of this belt conveyor 24 for conveyance.

The original plate 20 wound into a coil shape as described above is placed in a heating furnace 22.
Bring it to the entrance side of the heating furnace 22 and unwind it, or bring the standard length material 20a made by cutting the original plate 20 to a predetermined length to the entrance side of the heating furnace 22, and cut it into groups of a specified number of sheets.
The blank material B is placed on the conveying section 25 of the conveyor 24 of the heating furnace 22 (Fig. 1 (3)) and sent to the heating section 266.Therefore, the blank material B is softened by heating and carried out from the discharging section. (Figure 1 (4)).

Then, the blank material B is folded with the concave groove 19 as a crease, and the receiver is placed on the stand 28 (Fig. 1 (5)).
.

The blank material B cut to a predetermined length and folded in this manner is carried into the mold 29 of the molding press 8123, and is press-worked to form a resin molded product, for example, a bumper (Fig. 1 (6)). .

Note that the original plate 20 is wound into a coil shape. Or standard length material 20a
may be cut after preheating.

In forming the grooves 19 on the front and back sides of the original plate 20, a large number of unevennesses 8 are formed on the surface of the belt 7.11 along the width direction of the belt 7.11 at a predetermined pitch in the running direction of the belt 7.11. The belt 7.
As shown in FIG. 4, a pair of groove-forming rollers 31 with unevenness 30 formed on the circumference are provided between the heating section 3 and the cooling section 4, without forming any unevenness 8 on the surface of the heating section. Pass the original sheet material coming out from groove forming roller 3 between groove forming rollers 3
The groove 19 may be formed by one unevenness 30.

Further, the grooves 19 formed on the original plate 20 may be formed on only one side. In this case, when using the belt 7.11 with the unevenness 8 formed thereon, the belt with the unevenness 8 formed thereon and the belt without the unevenness 8 formed thereon can be used. When a groove forming roller 31 is used, a roller with unevenness 30 and a roller without unevenness 30 are used.

Further, the groove 19 formed in the original plate 20 is
However, the groove 19 may extend along the longitudinal direction of the original plate 20 as shown in FIG.

To form such grooves 19, as shown in FIG. 6, a belt 7.11 is used in which unevenness 32 along the longitudinal direction of the belt 7.11 is formed on a molded 3fA of the original plate 20.

In forming the grooves 19, no unevenness 32 is formed on the surface of the belt 7.11, and as shown in FIG. A pair of groove-forming rollers 34 are provided with grooves 33 formed thereon, and the original sheet material coming out of the heating section 3 is passed between the groove-forming rollers 34 to form grooves 19 by the grooves 33 of the groove-forming rollers 34. .

The example describes the case where the grooves are formed during the production of the long glass fiber reinforced thermoplastic resin original plate, but in other examples, the grooves are formed not during the production of the original plate but as a preliminary step before press forming. It is also possible to form concave grooves in a regular length material during melting during heating.

(Effects of the Invention) As explained above, according to the present invention, grooves that become creases when the blank material is folded are formed on at least one surface of the reinforcing fiber-reinforced thermoplastic resin blank material. The concave grooves are folded and stacked, and the pieces are put into the mold of a molding press.
It can be used as a material for resin molded products.

Further, the present invention provides a part forming method in which a plurality of heat-melted reinforcing fiber-reinforced thermoplastic resin blanks are laminated and press-molded, in which grooves are continuously formed on the surface of the blank. Since the blank material is folded and stacked with the groove part as the fold, when the blank material is carried into the mold of the molding press, it is folded and stacked with the groove part as the crease. Therefore, unlike conventional blank materials, they are not cut into required dimensions, so the cutting process is reduced and the storage space for blank materials is not required as much.

In addition, the blank material is folded and stacked with the concave groove part as a crease, and unlike conventional blank material, it is not cut to the required size, so the reinforcing fibers are exposed on the cut surface of the blank material. In addition, when cutting, the reinforcing fibers are crushed into small pieces and powder, and the cutting does not come out, and the reinforcing fibers get stuck in the clothes or skin of the worker, causing pain and itching. It is possible to solve the problem of deteriorating the environment.

Furthermore, since the blanks are folded and stacked with the concave grooves creased and placed into the mold of the forming press, it is necessary to stack the molten blanks one by one after preheating. This makes it possible to automate and mechanize the charging of blank materials into molds.

In addition, since the blank material is not in the form of a sheet and has grooves that are easy to bend, it is possible to coil it into a coil and cut it in groups of a predetermined number of sheets just before the entrance of the heating furnace. Since it can be coiled and put into the line, it is extremely easy to automate, including cutting.

[Brief explanation of drawings]

Figure 1 (1), (2), (3), (4), (5) (6)
2 is an explanatory diagram of the molding process of a resin part according to an embodiment of the present invention, and FIG. 2 is a diagram showing the molding process of the resin part. An explanatory diagram showing a standard length material obtained by cutting an original plate to a predetermined length,
Figure 3 is a perspective view of the belt in the original plate forming device;
The figure is a side view of the groove forming mechanism that forms grooves on the original plate.
The figure is a perspective view of a part of the original plate with grooves in different directions, Figure 6 is a perspective view of a belt for forming the grooves along the longitudinal direction of the original plate, and Figure 7 is the direction of the grooves. A side view of a groove forming mechanism for forming grooves along the longitudinal direction of the original plate,
Figure 8 (1), (2), (3), (4), (5), (6
), , (7) are explanatory diagrams of the conventional molding process of resin parts. 9...concave groove. B...Blank material. b...Blank material. Figure Figure Figure Cause Figure Figure Figure Figure 1゜2゜ Procedural Amendment (Method) Date of December 1990

Claims (2)

[Claims] (1) A blank material made of reinforcing fiber-reinforced thermoplastic resin, which is characterized in that grooves are formed on at least one side of the blank material to form creases when the blank material is folded. (2) In a part forming method in which a plurality of heat-melted reinforcing fiber-reinforced thermoplastic resin blanks are laminated and press-molded, grooves are continuously formed on the surface of the blank,
A method for forming parts using blank materials, characterized in that the blank materials are folded and stacked with the groove portions being bent portions.