JPH08238671A - Method and apparatus for manufacturing molding - Google Patents

Abstract

PURPOSE: To suppress the generation of a strain upon molding and to manufacture a molding of high quality by causing a sheetlike molding material to follow the inner surface of a cavity to be transferred with the molding shape of the molding, and gradually plastically deforming the opening edge of the cavity toward the inner bottom. CONSTITUTION: When a molding 1 is manufactured by using a molding manufacturing apparatus 7, first a composite material sheet 4 is mounted in the cavity 8 of a mold 9, and fixed by a fastening plate 10a. In this case, the mold 9 is previously heated by mold heating means 12. Then, a roller 11a is pressurized to the opening edge of the cavity 8 to be slidably brought into contact with the roller driving means 11b of pressure molding means 11 via the sheet 4, and rolled in the direction 13 of an arrow. Then, after the roller 11a arrives at the side edge of the inner bottom 8b of the cavity 8, the roller 11a is lifted. Thus, the sheet 4 is plastically deformed along the inner surface 8a of the cavity 8, the bottom 8b is brought into close contact, and the shape of the cavity 8 is transferred to the sheet 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a molded part made of a composite material of plastic and metal, for example.

[0002]

2. Description of the Related Art Conventionally, a vacuum forming method or a press forming method has been applied as a method for producing a molded part made of a sheet-shaped composite material having a thickness of 0.5 mm or less. In the former vacuum forming method, as shown in FIG. 8, a minute suction hole B is provided in a mold A, and a sheet-shaped member D fixed by a jig C by pressing a peripheral portion through the suction hole B is used. Cavity E formed in the mold A in a tray mold by suction
The shape of is transferred. On the other hand, in the latter press-molding method, as shown in FIG. 9, the male mold H is fitted to the female mold G having the cavity F formed in the tray mold, so that the female mold G is pressed to the peripheral portion of the female mold G. The shape of the cavity F is transferred by pressing the sheet-like member K fixed via the jig J.

Here, the sheet-like members D and K are, for example, PET (polyethylene terephthalate) or P on both sides of an Al (aluminum) sheet having a thickness of 7 μm.
It is made of a composite material obtained by thermocompression bonding a plastic sheet such as AN (polyacrylonitrile).

However, in the molded part formed by the vacuum forming method, the central part comes into contact with the mold A before the other parts, so that the central part has the smallest distortion and the corner part has the largest distortion. For example, assuming that the plastic member D in contact with the mold A does not slip at all, the distortion at the corner is about 18%.

Further, in the molded part formed by the press molding method, the strain on the bottom surface is 0%, but the strain on the side surface is as large as about 41%. If the above distortion is unevenly distributed in the molded part, cracks or deformations may occur during use, which is a quality control problem.

[0006]

As described above, the composite material of plastic and metal, for example, has a thickness of 0.5 m.
In a vacuum forming method or a press forming method as a method for producing a sheet-shaped molded part having a size of m or less, distortion is unevenly distributed in each molded part, and cracks or deformations occur during use due to the distortion. It is causing quality control problems. The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method and apparatus for manufacturing a molded part that enables low distortion molding.

[0007]

According to a first aspect of the present invention, there is provided a method for producing a molded part, which comprises a side plate and a bottom plate from a sheet-shaped material, and a metal having a cavity for transferring the molded shape of the molded part. The sheet material fixing step of fixing the sheet material to the mold so as to cover the opening of the cavity, and the sheet material fixed in the sheet material fixing step correspond to the side plate of the molded part of the cavity. And a molding step of molding the molded part by rotating a molded plate having a shape corresponding to the side plate of the molded part with the opening side of the part to be rotated as a rotation axis.

A second aspect of the present invention is characterized in that the mold is heated in the molding step of the first aspect.
According to a third aspect of the present invention, in a molded part manufacturing apparatus for molding a molded part in which a side plate and a bottom plate are flat from a sheet-shaped material, a mold having a cavity for transferring the molded shape of the molded part, and the sheet-shaped material. A sheet-like material having a holding means for fixing the above-mentioned opening part of the cavity and a roller provided for each part of the cavity corresponding to the side plate of the molded part, and fixing the roller by the holding means. Forming means for rolling along a plane portion corresponding to the side plate of the above-mentioned formed part via the above.

According to a fourth aspect of the present invention, in the third aspect,
The mold is characterized in that the heating means is embedded therein. According to a fifth aspect of the present invention, in the method of manufacturing a molded part, which comprises molding a side plate and a bottom plate from a sheet-shaped material, the sheet-shaped material is provided in a mold having a cavity for transferring the molding shape of the molded part. A sheet-shaped material fixing step of covering and fixing the opening of
A molding plate having a shape corresponding to the side plate of the molded part is formed by using the sheet-shaped material fixed in the sheet-shaped material fixing step with the opening side of the portion of the cavity corresponding to the side plate of the molded part as a rotation axis. And a molding step of rotating to mold the molded part.

According to claim 6 of the present invention,
It is characterized in that the mold is heated in the molding plate rotation molding step. According to a seventh aspect of the present invention, in a molded component manufacturing apparatus that molds a molded component including a side plate and a bottom plate from a sheet-shaped material, the mold having a cavity for transferring the molded shape of the molded component and the sheet-shaped material are A sheet-like material having a holding means for covering and fixing the opening of the cavity, and a forming plate provided for each portion of the cavity corresponding to the side plate of the formed part, wherein the forming plate is fixed by the holding means. Molding means for rotating the opening side of the cavity corresponding to the side plate of the molded part through the cavity as a rotation axis. An eighth aspect of the present invention is characterized in that, in the seventh aspect, a heating means is embedded in the mold.

[0011]

According to the first to eighth aspects of the present invention, the sheet-shaped material is moved from the opening edge side of the cavity toward the inner bottom portion along the inner side surface of the cavity for transferring the molding shape of the molded part. Since it is gradually plastically deformed, it is possible to suppress the occurrence of distortion due to molding to a minimum, the shape accuracy after mold release is improved, and cracks and deformation do not occur during use. It greatly contributes to the improvement of reliability.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described in detail below with reference to the drawings. 1 and 2 show a tray-shaped molded part 1 manufactured in this embodiment. As shown in FIG. 3, this molded part 1 is made of, for example, Al having a thickness of 7 μm.
The composite material sheet 4 is obtained by thermocompression bonding plastic sheets 3 and 3 such as PET or PAN on both sides of the (aluminum) sheet 2. The composite material sheet 4 has a square shape at the material stage. Then, the molded part 1 is composed of a recess 5 having a shape of a regular square pyramid having a depth of, for example, 20 mm, and a collar portion 6 extending on the peripheral edge of the recess 5. Thus, the inner bottom surface of the recess 5 has a square shape with one side of 260 mm, for example. Further, the peripheral edge of the recess 5 has a square shape with one side of 300 mm, for example. The side plates 5a of the recess 5 are
It is inclined at 45 degrees with respect to the collar portion 6 and the bottom plate 5b.

On the other hand, FIGS. 4 and 5 (the composite material sheet 4 is not shown in this figure) show a molded part manufacturing apparatus 7 used for manufacturing the molded part 1 of this embodiment. This molding component manufacturing apparatus 7 covers a die 8 made of, for example, steel having a cavity 8 for transferring a molding shape to the molding component 1 and a composite material sheet 4 which is a raw material of the molding component 1 so as to cover an opening of the cavity 8. In the cavity 8 of the mold 9
For example, the pressing means 10 fixed to the peripheral portion, the pressure molding means 11 pressing the composite material sheet 4 fixed by the pressing means 10, and the mold 9 are 120 ° C. to 130 ° C.
It comprises a mold heating means 12 for heating to ° C. Thus, the cavity 8 has an inner surface 8a for molding the side plates 5a, and an inner bottom surface 8b for molding the bottom plate 5b.
It consists of The pressing means 10 is composed of a rectangular frame-shaped compression plate 10a for clamping and fixing the composite material sheet 4 together with the upper end surface of the mold 9, and a pressing control mechanism 10b for raising and lowering the compression plate 10a. Further, the press-molding means 11 is made of, for example, four copper-based metals that are in sliding contact with the inner side surfaces 8a of the cavities 8 through the composite material sheet 4 under pressure and roll toward the inner bottom surface 8b. .. and roller driving means 11b for holding the rollers 11a .. Further, the mold heating means 12 is used for the mold 9
It comprises a heating wire 12a provided inside and a power feeding means 12b for feeding power to this heating wire.

Next, a method of manufacturing the molded part 1 using the molded part manufacturing apparatus 7 having the above configuration will be described. First, the composite material sheet 4 is placed in the cavity 8 of the mold 9 and fixed by the compression plate 10a so as not to shift. At this time, the mold 9 is preheated from the mold heating means 12 at 120 ° C.
Heat to 130 ° C. Next, the roller driving means 1
1b to start the rollers 11a ...
While slidingly contacting the opening edge of the cavity 8 while pressing, it rolls in the direction of arrow 13. And
When the rollers 11a reach the side edge of the inner bottom surface 8b, they are pulled up. As a result, the composite material sheet 4 has a cavity 8
While being plastically deformed following the inner side surfaces 8a of the above, the shape of the cavity 8 is transferred to the composite material sheet 4 by being in close contact with the inner bottom surface 8b. Then, the fixation of the composite material sheet 4 to the mold 9 by the pressing means 10 is released, the molded part 1 is removed, and the next composite material sheet 4 is newly fixed to the mold 9.

As described above, according to this embodiment, the shape of the cavity 8 is gradually transferred to the composite material sheet 4 by rolling the rollers 11a ... With respect to the cavity 8. It is possible to minimize the occurrence of strain due to plastic deformation. Incidentally, according to this embodiment, the rollers 11a ...
Since the composite material sheet 4 is gradually squeezed and shaped in accordance with, the distortion of the corner portion and the bottom portion of the molded component 1 is
It was about 6% and could be reduced to 1/3 or less of the strain generated by the vacuum forming method or the press forming method. As a result, the shape accuracy after releasing the mold is improved, and cracks and deformations are not generated during use, which greatly contributes to the improvement of product reliability.

In the above embodiment, the roller 11
The number of a is four, but two may be provided and rolled at different timings so as not to interfere in directions orthogonal to each other. Further, as the mold heating means 12, infrared radiation or a heating furnace may be used instead of the heating wire.

Next, FIGS. 6 and 7 (the composite material sheet 4 is not shown in this figure) show a molded part manufacturing apparatus 20 of another embodiment. The molding part manufacturing apparatus 20 includes, for example, a steel mold 9 having a cavity 8 for transferring a molding shape to the molding part 1, and a composite material sheet 4 as a raw material of the molding part 1 at a peripheral portion of the cavity 8 of the mold 9. The pressing means 10 for fixing to, the pressure molding means 21 for press-molding the composite material sheet 4 fixed by the pressing means 10, and the mold 9 are, for example, 120 ° C to 130 °.
It comprises a die heating means 12 for heating to C. The cavity 8 is composed of an inner side surface 8a for molding the side plates 5a, and an inner bottom surface 8b for molding the bottom plate 5b. The pressing means 10 is composed of a rectangular frame-shaped compression plate 10a for clamping and fixing the composite material sheet 4 together with the upper end surface of the mold 9, and a pressing control mechanism 10b for raising and lowering the compression plate 10a. Further, the pressure forming means 21 includes four forming plates 21a made of, for example, a copper-based metal, which are rotatably attached to the inner end edge of the compression plate 10a with the inner end edge as a rotation axis. , And a forming plate drive mechanism 21b for driving these forming plates 21a. Further, the mold heating means 12 is composed of a heating wire 12a provided inside the mold 9 and a power feeding means 12b for supplying power to this heating wire.

Next, the molded part manufacturing apparatus 20 having the above structure
A method of manufacturing the molded part 1 using the will be described. First,
The composite material sheet 4 is placed in the cavity 8 of the mold 9 and fixed by the compression plate 10a so as not to shift. At this time, the mold 9 is 120 ° C. in advance from the mold heating means 12.
Heat to ~ 130 ° C. Next, the forming plate drive mechanism 21b is activated, and the forming plates 21a are rotated in the direction of the arrow 23a until they come into close contact with the inner side surfaces 8a. As a result, the composite material sheet 4 is plastically deformed following the inner side surfaces 8a of the cavities 8 and is in close contact with the inner bottom surface 8b, so that the shape of the cavities 8 is transferred to the composite material sheet 4. Then, the fixation of the composite material sheet 4 to the mold 9 by the pressing means 10 is released, the molded part 1 is removed, and the next composite material sheet 4 is newly fixed to the mold 9.

As described above, according to this embodiment, the shapes of the cavities 8 are gradually transferred to the composite material sheet 4 by rotating the molding plates 21a ... Until they come into close contact with the inner side surfaces 8a. Therefore, the occurrence of strain due to plastic deformation can be suppressed to a minimum. By the way, since the distortion of the corner portion of the molded part 1 is about 7% and the side surfaces of the molded plate 21a are only in contact with each other, the distortion due to the molding is almost 0%. It was possible to reduce the strain caused by 1/3 or less. As a result, the shape accuracy after releasing the mold is improved, and cracks and deformations are not generated during use, which greatly contributes to the improvement of product reliability.

In the above embodiment, the forming plate 21
a is attached to the compression plate 10a, which is attached to the compression plate 1a.
0a may be provided independently, and the mold 9 may be appropriately brought into contact with or separated from the mold.

Further, in the above-mentioned embodiment, the composite material is exemplified as the material of the molded part, but the invention is not particularly limited to this, and it can be applied to the molding of a sheet of metal alone or plastic alone.

Furthermore, in the above-mentioned two embodiments, the molded part is exemplified by the recess having the shape of a regular square pyramid, but the invention is not limited to this, and the side plate and the bottom plate are flat. If so, there is no restriction on the shape. Further, in the latter embodiment, even if the side plate has a curved surface or a complicated flat surface, molding can be performed by making the shape of the molding plate correspond to it.

[0023]

The present invention has the following special effects. That is, it is possible to suppress the occurrence of strain due to plastic deformation to a minimum. By the way, the strain at the corner and bottom of the molded part could be reduced to 1/3 or less of the strain generated by the vacuum molding method or the press molding method. As a result, the shape accuracy after releasing the mold is improved, and cracks and deformations are not generated during use, which greatly contributes to the improvement of product reliability.

[Brief description of drawings]

FIG. 1 is a front view of a molded part.

FIG. 2 is a plan view of FIG.

FIG. 3 is an enlarged cross-sectional view of a main part of a composite material sheet.

FIG. 4 is a configuration diagram of a molded part manufacturing apparatus according to an embodiment of the present invention.

FIG. 5 is a plan view of FIG.

FIG. 6 is a configuration diagram of a molded part manufacturing apparatus according to another embodiment of the present invention.

FIG. 7 is a plan view of FIG. 6;

FIG. 8 is an explanatory diagram of a conventional technique.

FIG. 9 is an explanatory diagram of a conventional technique.

[Explanation of symbols]

1: molded part, 4: composite material sheet, 8: cavity,
9: mold, 10: pressing means, 11: pressure molding means, 1
2: heating means, 11a: roller, 21a: forming plate.

Claims (8)

[Claims] 1. A method for manufacturing a molded part, which comprises molding a side plate and a bottom plate from a sheet-shaped material, wherein the sheet-shaped material is placed in a mold having a cavity for transferring the molding shape of the molded part. A sheet-like material fixing step of covering and fixing the sheet-like material fixed in the sheet-like material fixing step from the opening side of the cavity of the portion corresponding to the side plate of the molded component to the roller of the molded component. And a pressure molding step of molding the molded part by rolling toward a portion corresponding to the bottom plate. 2. The method of manufacturing a molded part according to claim 1, wherein the mold is heated in the pressure molding step. 3. A molding part manufacturing apparatus for molding a molding part having a flat side plate and a bottom plate from a sheet-shaped material, and a mold having a cavity for transferring the molding shape of the molding part, and the sheet-shaped material as the cavity. Via a sheet-like material having a holding means for covering and fixing the opening and a roller provided for each part of the cavity corresponding to the side plate of the molded part, and fixing the roller by the holding means. A molded component manufacturing apparatus, comprising: a pressure molding unit that rolls along a plane portion corresponding to a side plate of the molded component. 4. The molding part manufacturing apparatus according to claim 3, wherein the mold has a heating means embedded therein. 5. A molded part manufacturing method for molding a molded part composed of a side plate and a bottom plate from a sheet-shaped material, wherein the sheet-shaped material is placed in a mold having a cavity for transferring the molded shape of the molded part. A sheet-shaped material fixing step of covering and fixing the sheet-shaped material, and the sheet-shaped material fixed in the sheet-shaped material fixing step is formed by using the opening side of a portion corresponding to the side plate of the formed part of the cavity as a rotation axis And a pressure molding step of rotating a molding plate having a shape corresponding to a side plate of the component to mold the molded component. 6. The method of manufacturing a molded part according to claim 5, wherein the mold is heated in the pressure molding step. 7. A molded part manufacturing apparatus for molding a molded part composed of a side plate and a bottom plate from a sheet-shaped material, and a mold having a cavity for transferring the molding shape of the molded part, and the sheet-shaped material for opening the cavity. Via a sheet-like material having a pressing means for covering and fixing the portion and a molding plate provided for each part of the cavity corresponding to the side plate of the molded part, and fixing the molding plate by the pressing means; A molded component manufacturing apparatus comprising: a pressure molding unit configured to rotate about an opening side of a portion of the cavity corresponding to a side plate of the molded component as a rotation axis. 8. The molding part manufacturing apparatus according to claim 7, wherein the mold has a heating means embedded therein.