JPWO2004060630A1 - Powder slush molding machine and powder slush molding method - Google Patents

Abstract

Provided are a powder slush molding machine and a powder slush molding method capable of uniformly adhering powder to a powder slush molding die. Therefore, in a powder slush molding machine including a mold heating unit, a powder slush unit, and a mold cooling unit, and a powder slush molding method using the same, a flow rate from the lower side of the mold to the mold heating unit Energy for recovering hot air after heating the mold, provided along the hot air blowing part for blowing hot air of 15 m / sec or more and the corner or side of the bottom surface in the furnace of the mold heating part And a recovery part, and a heat reflecting plate is provided on the bottom surface of the furnace.

Description

  The present invention relates to a powder slush molding machine and a powder slush molding method, and in particular, a powder slush molding machine and powder slush molding capable of uniformly adhering powder (powder resin) to a large-sized and complicated mold. Regarding the method.

2. Description of the Related Art Conventionally, a powder slush molding method in which slush molding is performed using powder (powder resin) has been widely practiced in manufacturing large and complex shaped sheet materials such as automobile interior materials.
Here, in order to make the thickness of the interior material made of powder uniform, it is desired to heat the mold to a uniform temperature.
For example, JP-A-3-202329 includes a temporary heating step and a preliminary heating step controlled to a predetermined temperature, respectively, to heat the mold to a uniform temperature, and after using the mold, A method for forming leather, characterized by being immersed in water and slowly cooled, is disclosed.
Japanese Patent Laid-Open No. 4-191018 discloses a slush molding die as a porous die, the opening of a hot air supply duct is brought into contact with the material inlet of the die, and hot air is blown from the duct into the die. A method for heating a slush molding die, characterized by being pumped inward, is disclosed.
Furthermore, in Japanese Patent Application Laid-Open No. 2002-210761 and Japanese Patent Application Laid-Open No. 2002-210762, a heating chamber and a hot air control chamber are provided in a heating furnace, and an openable / closable blade is pivotally supported in the hot air control chamber. Heating device for resin powder molding die provided with air volume adjusting damper and wind direction adjusting nozzle having cylindrical nozzle body, and further for resin powder molding provided with primary main hot air outlet and plural primary auxiliary hot air outlets A mold heating apparatus is disclosed.
However, none of the heating devices is provided with an outlet for hot air after heating the mold, energy recovery is insufficient, and high-speed heating and uniform heating of the mold are still insufficient. There was a problem.
Therefore, in the Japanese Patent Application Laid-Open No. 9-248832, the applicant carries in and out a mold for resin powder molding into and out of the furnace from the upper opening that can be opened and closed, and opens the upper opening as shown in FIG. In a powder slush molding machine having a furnace structure that heats a mold in a closed furnace, a hot air blowing unit having a hot air control mechanism for blowing hot air onto the mold from below is disposed on the bottom surface of the furnace, A powder slush molding machine is proposed in which an energy recovery unit for recovering thermal energy in the furnace is disposed in the furnace.
However, even in such a powder slush molding machine, further high-speed heating and uniform heating of the mold have been desired in order to cope with molds that are becoming larger and more complicated. Moreover, since the air velocity control of the hot air in the hot air blowing part was insufficient, the film thickness of the obtained sheet-like material varies, or a post-heating step is provided to cause thermal damage when the mold is reheated. A case was seen.
Therefore, as a result of intensive studies, the inventor of the present invention blows hot air at a specific flow velocity to the mold and devise the arrangement of the energy recovery unit to increase the size and complexity of the mold. Another object of the present invention is to provide a powder slush molding machine and a powder slush molding method capable of uniformly and quickly depositing powder and generating less heat damage when the mold is reheated.

According to the present invention, there is provided a powder slush molding machine including a mold heating unit, a powder slush unit, and a mold cooling unit, and a flow rate of 15 m / sec from below the mold to the mold heating unit. A hot air blowing part for blowing the above hot air, and an energy recovery part for collecting hot air after heating the mold, provided along the corner or side of the bottom surface in the furnace of the mold heating part , A powder slush molding machine is provided.
By comprising in this way, it becomes easy to produce the swirl by a hot air in a metallic mold heating part, and it can improve greatly the thermal efficiency at the time of heating a metallic mold for that, As a result, a metallic mold enlarges, Even if it is complicated, the powder can be adhered uniformly and rapidly. In addition, because the mold is heated at a predetermined wind speed in the mold heating section, conditions such as reheating of the mold are relaxed, and thermal damage occurs, particularly thermal damage during cooling in the mold cooling section. Can be reduced.
Moreover, according to another aspect of the present invention, a powder slush is used to form a sheet-like material from powder using a powder slush molding machine provided with a mold heating unit, a powder slush unit, and a mold cooling unit. A hot air blowing part and an energy recovery part that is provided along a corner or a side part of the bottom surface in the furnace of the mold heating part and recovers hot air after heating the mold. In the provided mold heating unit, hot air having a flow velocity of 15 m / sec or more is blown from below the mold.
And after powder slush molding of the sheet-like material in the powder slush portion, the obtained sheet-like material is re-heated in the mold heating unit, and in the mold cooling unit, the spray-type device and the shower device sequentially It is preferable to cool the mold having the sheet-like material attached thereto.

FIG. 1 is a diagram provided for explaining the overall arrangement of the powder slush molding machine of the present invention.
FIG. 2 is a diagram for explaining the relationship among the bottom surface in the furnace, the hot air blowing section, and the energy recovery section in the mold heating section (part 1).
FIG. 3 is a diagram for explaining another relationship among the bottom surface in the furnace, the hot air blowing unit, and the energy recovery unit in the mold heating unit (part 2).
FIG. 4 is a diagram provided to explain the outline of the hot air control mechanism in the mold heating unit.
FIG. 5 is a diagram provided for explaining the relationship between the hot air blowing section of the mold heating section and the hot air generating and circulating apparatus.
Drawing 6 is a figure offered in order to explain a side hot air blowing part of a mold heating part.
Drawing 7 is a figure offered in order to explain a powder slush molding method (the 1).
FIG. 8 is a diagram for explaining the powder slush molding method (part 2).
FIG. 9 is a diagram for explaining the function of the pressure adjusting device during powder slush molding.
FIG. 10 is a diagram for explaining the hammering apparatus.
FIG. 11 is a diagram for explaining the mold cooling unit.
FIG. 12 is a diagram provided for explaining the relationship between the conventional hot air blowing section and the hot air generating and circulating apparatus.

▲４▼熱風制御板
また、熱風吹出口１６に、図４（ａ）〜（ｃ）に示すように、熱風制御板３０を設けることが好ましい。この理由は、これらの熱風制御板３０によって、金型１２の内面の下方から吹き上げられる熱風１４の方向性、広がり性、送風量等を容易に制御することができるためである。例えば、図４（ａ）では、熱風制御板３０が、向かって左側を向いているため、熱風１４も、金型１２の左方向の内面を集中的に加熱することができる。また、同様に、図４（ｂ）では、熱風制御板３０が、真っ直ぐ上方を向いているため、熱風１４も、金型１２の中央付近の内面を集中的に加熱することができ、図４（ｃ）では、熱風制御板３０が、向かって右側を向いているため、熱風１４により、金型１２の右方向の内面を集中的に加熱することができる。
ここで、熱風制御板３０の長さを、熱風吹出口１６の長手方向の長さと、実質的に等しくしてあることが好ましい。この理由は、このように構成することにより、大型の金型や、複雑化した金型を加熱する場合であっても、多量の熱風の方向を制御しながら、熱風吹出口１６の長手方向の全般から吹き上げることができるためである。
また、熱風制御板３０は、駆動装置（図示せず）によって、支点３１を中心に回動して、独自の所定の開き角度に制御できる構成であることが好ましい。この理由は、このように構成することにより、加熱温度、加熱時間、金型の大きさや形状等を考慮して、多量の熱風を、均一に吹き付けることができるためである。
さらに、熱風制御板３０は、耐熱性材料から形成してあることが好ましいが、例えば、金属、セラミックス（鋳物、焼物を含む。）、ガラス等が好適例として挙げられ、特に、軽量性（動作性）、加工性および耐久性に優れていることから、長尺状の鋳物製プレートであることがより好ましい。
▲５▼熱風発生循環装置
また、熱風発生循環装置４０は、図５に示すように、熱風発生装置（図示せず）により得られた所定風速を有する熱風を、熱風循環ファン４２により、主配管４３を通じて、熱風吹出口１６に供給する構成であることが好ましい。
また、空気供給ファン４６から供給された空気と、エネルギー回収部２４を通じて炉内から回収された熱風とを、混合室４４において適宜混合した後、熱風発生装置により得られた熱風をさらに混合して、所定風速を有する大量の熱風として、熱風循環ファン４２により、主配管４３を通じて、熱風吹出口１６に供給する構成であることが好ましい。
この理由は、このように構成することにより、加熱炉２８における金型１２の加熱モードに関して、熱風１４が金型１２の内面に沿って流れる際に、かかる熱風１４が有する熱が、金型１２へ伝熱されることによって行われるためである。すなわち、主として伝熱モードで、熱が伝わるため、加熱炉２８の内部に供給された熱が、加熱炉２８の外へ放散することが少なくなるためである。したがって、加熱炉２８及び熱風発生循環装置４０が小型であっても、従来の大型加熱炉と比較して、同等以上の生産性を有することになる。また、加熱炉２８において、熱風発生循環装置４０を含めた全体を著しく小型化することができるので、図１に示すように、特定の熱風発生循環装置を備えた金型加熱部（Ａ部）と、パウダリング装置と、金型冷却装置（Ｃ部）と、を地表に一列に並べた場合であっても、コンパクトなパウダースラッシュ成形機１０を構成することが可能となる。
なお、エネルギー回収部２４に連なる分岐配管４７の途中に、ダンパー４７ａを配設することが好ましい。この理由は、このように構成することにより、炉内底面１８の熱風吹出口１６と、図６に示すような炉側面２８ａの分岐配管４７に設けられた側面熱風吹出口５０とから吹き出す熱風の量的比率を、かかるダンパー４７ａによって、容易に制御することができるためである。
（２）エネルギー回収部
▲１▼基本的構造
加熱炉２８の炉内底面１８に配設されたエネルギー回収部２４の構造は、特に制限されるものではないが、例えば、図５に示すように、加熱炉２８の炉内底面１８に通じる開口部を有するとともに、熱風発生循環装置４０に連なる分岐配管４７を備えたダクト構造を有することが好ましい。そして、既に上述したように、エネルギー回収部２４に連なる分岐配管４７の途中に、ダンパー４７ａを配設することが好ましい。
▲２▼配置
また、加熱炉２８の炉内底面１８に配設するエネルギー回収部２４は、図２および図３にその開口部を示すように、炉内底面１８の角部または辺部に沿って設けられていることを特徴とする。
したがって、熱風吹出口１６から吹き出された熱風１４は、金型１２を加熱した後、かかる金型１２の内面に沿って、炉内底面１８の角部または辺部に沿って形成してあるエネルギー回収部２４に向かって移動し、その間に、金型１２内に所定時間滞留することができる。すなわち、金型１２内で、かかる金型１２の内面に沿って、熱風吹出口１６からエネルギー回収部２４に向かって移動する熱風１４の流れができやすくなる。よって、滞留時間がさらに長くなり、その結果、金型１２内の隅々まで、熱風１４によって効果的に伝熱モードで加熱することができるようになる。また、熱風１４の風速が速いために、伝熱モードが拡散律束になることを有効に防止することができる。
なお、上述した熱風吹出口１６のみならず、熱エネルギー回収部２４が、炉内底面１８と、フレーム部材１３と、金型１２と、によって形成される空間内であって、炉内底面１８の角部または辺部に沿って配設されていることから、加熱炉２８内に導入された熱エネルギーを容易かつ有効に回収することができる。
また、また、かかるエネルギー回収部の開口部の形状を、図３に示すように、実質的にＶ字状またはコの字状にすることが好ましい。この理由は、熱風吹出口１６から吹き出された熱風１４が、このような所定形状のエネルギー回収部２４に向かって容易かつ迅速に移動し、その間に、適度な熱風の流れが生じて、金型１２を効果的に加熱することができるためである。
また、エネルギー回収部２４の開口部の形状を、図３に示すように、実質的にＶ字状またはコの字状にした場合、適度な熱風の流れがさらに容易に生成しやすいように構成することが好ましい。すなわち、かかるエネルギー回収部が、連通する主回収部および副回収部から構成されており、当該主回収部において、金型を加熱した後の熱風を回収し、次いで、副回収部を介して、回収した熱風を、熱風発生循環装置に循環させることが好ましい。例えば、図２に示すような小さいエネルギー回収部（副回収部）２４の上方については塞いでしまい、Ｖ字状またはコの字状のエネルギー回収部（主回収部）のみを介して回収し、それを副回収部２４の側方から、当該副回収部２４の開口部に導入して、熱風を循環させることがより好ましい。なお、図４等において、熱風が側方からエネルギー回収部２４の開口部に導入されているのは、この方式を具体的に示すものである。
（３）加熱炉
▲１▼基本的構造
加熱炉２８は、図５に示すように、熱風発生循環装置４０の上方に配置されており、全体として一つのコンパクトな加熱装置として構成されていることが好ましい。このように構成することにより、加熱炉２８への熱エネルギーの供給が容易になるばかりか、エネルギー回収部２４を利用して、加熱炉２８からの熱エネルギーの回収についても容易に実施することができる。
また、加熱炉２８の炉本体は、例えば、上面に、開閉可能な開口部を有する平面長方形の箱状体に形成されており、上面の開口部を開口した状態で、金型１２およびそのフレーム部材１３を炉内に搬入した後、開口部を閉じて、熱風発生循環装置４０によって熱風１４を吹き込むことにより、金型１２に対する加熱が行われるように構成されていることが好ましい。
なお、加熱炉２８に含まれる炉本体の形態としては、適宜変更することが可能である。例えば、炉本体を、金型の形状に対応させて、円筒状や立方体、あるいは異形とすることも好ましい。
▲２▼熱反射板
また、図４に示すように、加熱炉２８の炉内底面１８に、熱反射板２６を設けることが好ましい。すなわち、熱風発生循環装置４０から吹き出された熱風１４は、熱風吹出口１６を介して、金型１２に対して、直接的に吹き付けられるが、熱反射板２６が炉内底面１８に、全面的または部分的に設けてあることにより、金型１２で反射された熱風１４を、かかる熱反射板２６によって、さらに反射できる構造とすることが好ましい。
ここで、熱反射板２６は、耐熱無機材料からなる板状物、例えば、ステンレス、白金、金、銀等からなる金属板、酸化アルミニウム、酸化チタン、酸化ジルコニウム等からなるセラミック板、ソーダガラス、石英等からなるガラス板等を、炉内底面１８に積層して構成することもできるし、あるいは、これらの耐熱無機材料を、炉内底面１８を構成する板状物としてそのまま利用し、熱反射板２６からなる炉内底面１８として構成することもできる。すなわち、このような鏡面構造を容易に達成できる耐熱無機材料であれば、炉内底面１８の表面に積層しても、あるいはそのまま炉内底面１８を構成しても、優れた熱反射性を示すことができる。
▲３▼傾斜
また、図４および図５に示すように、加熱炉２８の炉内底面１８に、傾斜部１９を設けることが好ましい。この理由は、傾斜した炉内底面１８の最深部に熱風吹出部１６を設けることができ、熱風１４の整流性が良好になるとともに、熱風１４の滞留空間の大きさ（デッドスペース）が狭まって、より効果的に、金型１２を加熱することができるためである。また、炉内底面１８に、このような傾斜部１９を設けることにより、かかる傾斜部１９によって、金型１２で一旦反射された熱風１４をさらに効率的に反射して、例えば、渦巻きを生成させ、それを用いて、再び金型１２を効果的に加熱することができるためである。
ここで、炉内底面１８における傾斜部１９の角度は、金型１２の大きさ、形状、あるいは加熱効率を考慮して定めることができるが、例えば、１〜６０°の範囲内の値とすることが好ましい。
この理由は、かかる傾斜部１９の角度が１°未満となると、金型１２へ再反射できる熱風量が著しく低下する場合があるためであり、一方、かかる傾斜部１９の角度が６０°を超えると、熱風１４による渦巻きの生成が困難になって、金型１２の加熱効率が低下する場合があるためである。
したがって、炉内底面１８における傾斜部１９の角度を５〜５０°の範囲内の値とすることがより好ましく、１０〜４５°の範囲内の値とすることがさらに好ましい。
▲４▼側方熱風吹出部
また、加熱炉２８においては、図６に示すように、側方熱風吹出口５０が、加熱炉２８に対して所定高さであって、金型１２を側方からも加熱できるように設けられていることが好ましい。
例えば、かかる側方熱風吹出口５０は、加熱炉２８の内側に沿って配置したダクト構造であって、熱風発生循環装置４０に連なる分岐配管４７や、主配管４３に連結してあり、その風量をダンパ等によって調節することが好ましい。
この理由は、このように構成することにより、金型１２を、下方向のみならず、横方向からも熱風を吹き付けて加熱することにより、金型１２をさらに効果的に加熱することができるためである。
また、かかる側方熱風吹出口５０は、図６に示すように、直径０．１〜１０ｍｍの穴列から構成してあることが好ましい。この理由は、このように構成することにより、圧力の関係で、分岐配管４７から吹き出された後に、熱風が広範に広がることができるためである。したがって、整流板がなくとも、大面積の金型を加熱することが可能となる。
（４）金型
金型１２は、図５に示すように、かかる金型１２の移動及び操作のためのフレーム部材１３が取りつけられた状態で、加熱炉２８内の炉内底面１８に配設された金型支持部材（図示せず）上に、載置されていることが好ましい。
また、かかる金型１２は、ロボットアーム（図示せず）にフレーム部材１３を把持または懸架した状態で動かし、例えば、金型加熱部においては、ロボットアームによりフレーム部材１３を上面部まで移動させ、そこで上面部に設けられた開口部より加熱炉２８内に搬入できる構造であることが好ましい。
なお、金型支持部材は、その表面を、シーリング効果を有する断熱材（図示せず）、例えば、シリコーンゴム／フッ素樹脂フィルムの組合せによって、覆うことが好ましい。この理由は、金型支持部材によって、金型１２と、炉内底面１８との間の隙間を埋めて、熱風が外部に逃げることを有効に防止することができるためである。さらに、かかる金型支持部材は、加熱のために炉内に収容する金型１２の位置決めと、炉内底面１８の熱風吹出口１６からの熱風１４が、金型１２の内面に効率良くあたるように、熱風吹出口１６からの高さを調節する機能をそれぞれ有していることが好ましい。
２．パウダースラッシュ部
パウダースラッシュ部は、図７（ｂ）に示すように、図７（ａ）で加熱されたフレーム部材８２を含む金型８４と、流動状を有するパウダー９２を収容したリザーバタンク８８とを、金型（成形型）８４の成形面８５を下向きにするとともに、リザーバタンク８８の開口面を上向きにした状態で、上下に一体的に連結する工程を実施するための部位である。
その際、リザーバタンク８８内のパウダー９２の分散性を向上させ、均一な厚さの樹脂膜（シート状物）９４を形成するために、リザーバタンク８８の下方に設けた攪拌室８８ａに空気を導入して、パウダー９２を流動状態とすることが好ましい。図９（ａ）に空気の導入方向を具体的に示すが、攪拌室８８ａの上方は、穴開き部材（メッシュ部材）から構成してあり、導入された空気によって、パウダー９２を巻き上げる構造であることが好ましい。
また、パウダースラッシュ部は、図７（ｃ）に示すように、フレーム部材８２を含む金型８４と、リザーバタンク８８とを連結した状態で回転させて、金型８４の成形面８５に所定の厚さの樹脂膜９４を形成する工程を実施するための部位でもある。
すなわち、フレーム部材８２を含む金型８４と、リザーバタンク８８とを組み合わせた状態で、上下方向に反転させることが好ましい。この理由は、このように実施すると、リザーバタンク８８内のパウダー９２は自重で成形型８４の成形面８５に落下し、かかる金型８４の成形面８５に接するパウダー９２およびその近傍のパウダー９２のみが、金型８４の熱によって溶融状態となって付着し、金型８４の成形面８５に対して、樹脂膜９４を一瞬にして形成することができるためである。
また、フレーム部材８２を含む金型８４を反転させる際、かかる金型８４における所望の成形面８５のみに、樹脂膜９４を形成できるように、金型８４と、リザーバタンク８８との間に、所定の厚さ（高さ）を有する方枠８４ａ、８４ｂを設けることが好ましい。ここで、かかる方枠の下部８４ｂを、例えば、アルミニウムから構成し、方枠の上部８４ａをシリコーンゴム／フッ素樹脂フィルムの組合せから構成することにより、金型８４と、リザーバタンク８８との間の隙間を充填する役目を果たすこともできる。
また、フレーム部材８２を含む金型８４を反転させる際、パウダー９２が所定箇所以外に飛散しないように、かかる金型８４における所望の成形面８５のみに、樹脂膜９４を形成できるように、図９（ｂ）に示すように、攪拌室８８ａを介して吸引し、金型８４内の圧力を低下させることが好ましい。すなわち、金型８４を回転させてパウダースラッシュ成形している最中には、金型８４の内圧を低下させるために吸引し、パウダースラッシュ成形前には、リザーバタンク８８のパウダー９２内に空気を吹き込むための圧力調整装置（図示せず）が設けてあることが好ましい。
また、金型８４を反転させる際、かかる金型８４のフレーム部材８２に設けた突起部８２ａを、図１０に示すような一つまたは複数のハンマリング装置によって、両側から交互に殴打することが好ましい。この理由は、金型８４を回転する際に、ハンマリング装置１００によって殴打して、所定の振動を付与することにより、金型８４の所定箇所に、パウダー９２が均一に行きわたるためである。
また、パウダースラッシュ部は、図８（ａ）に示すように、金型８４に、所定厚さの樹脂膜９４が形成された状態で、リザーバタンク８８を、金型８４から取り外す工程を実施するための部位である。
３．金型冷却部
金型冷却部は、図８（ｂ）に示すように、フレーム部材８２を含む金型８４を、水冷あるいは空冷等の冷却手段９８により冷却して、樹脂膜９４を硬化させる工程を実施するための部位である。また、金型冷却部は、図８（ｃ）に示すように、金型冷却部の最終工程として、金型８４から樹脂膜９４を剥離、すなわち脱型する工程を実施するための部位でもある。
ここで、金型の熱損傷を有効に防止するためには、金型冷却部に、図１０に示すように噴霧装置と、図８（ｂ）に示すようにシャワー装置とを備えることが好ましい。すなわち、第一冷却段階として、噴霧装置によって、水または温水を噴霧して、５０〜１００℃程度まで、比較的マイルドに金型を冷却することが好ましい。次いで、第二冷却段階として、シャワー装置によって、水または温水を比較的多量に吹き付け、蒸発エンタルピーを利用して、樹脂膜９４が剥離できる程度、例えば、５０℃未満の温度にまで、金型を効率的に冷却することが好ましい。この理由は、このように実施することにより、大型化かつ複雑化した金型が不均一に加熱されている場合であっても、金型の熱損傷や割れ等の発生を有効に防止することができるためである。なお、シャワー装置および噴霧装置は、一つの給水タンクに連結されてあって、吹き出し口に設けた制御弁等の切替によって、噴霧量やシャワー量を決定するように構成してあることも好ましい。
４．全体配置および後加熱工程
（１）全体配置
図１に例示するように、パウダースラッシュ成形装置１０は、加熱炉２８を含む各工程の装置を地表に一列に並べて配置した場合、向かって左側から、パウダースラッシュ部（Ａ部）、金型加熱部（Ｂ部）、金型冷却部（Ｃ部）の順に配置することが好ましい。また、金型加熱部を二つ設けて、パウダースラッシュ部、第１の金型加熱部、第２の金型加熱部、および金型冷却部の順に配置することも好ましい。さらに、金型待機部、後加熱部、金型交換部、脱型部等を、適宜設けて、本発明のパウダースラッシュ成形機に組み込むことも好ましい。
いずれにしても、本発明のパウダースラッシュ成形機１０は、各部を、地表に隣接して列状に並べて配置するとともに、移動ロボットおよびロボットアームにより金型を各部に移動させるだけで、パウダースラッシュ成形を効率的に実施することができる。
（２）後加熱工程
また、後加熱工程を設け、前述した金型加熱部を、その後加熱工程における加熱部として使用することも好ましい。すなわち、パウダースラッシュ成形部において得られる樹脂膜（樹脂溶融物層）が付着した金型を、ロボットアームにより加熱炉の真上に位置に搬送し、そのまま下方に向けた状態で、静止させることが好ましい。その間、加熱炉２８の開口部（スライドドア）は、開いた状態になっていて、炉内底面１８の熱風吹出口１６から吹き上がる熱風によって、後加熱することが好ましい。この理由は、このように後加熱することにより、樹脂膜が再加熱されて、適度にフローすることにより、かかる厚さを均質なものとすることができるためである。また、金型加熱部を、後加熱工程を実施するための加熱部として併用することにより、パウダースラッシュ成形機を、全体として、コンパクトに設計することができるためである。Hereinafter, with reference to the drawings, preferred embodiments of the powder slush molding machine and the powder slush molding method of the present invention will be described in detail.
[First Embodiment]
As illustrated in FIG. 1, the first embodiment is a powder slash provided with a powder slash part (A part), a mold heating part (B part), and a mold cooling part (C part). This is a molding machine 10. And as illustrated in FIG. 3A, a hot air blowing section 16 for blowing hot air 14 having a flow velocity of 15 m / second or more from below the mold 12 to the mold heating section (B section), An energy recovery unit 24 provided along the corners or sides of the bottom 18 of the furnace of the mold heating unit (B) and for recovering hot air 14 after heating the mold 12; This is a featured powder slush molding machine 10.
Hereinafter, the suitable example of the powder slush molding machine 10 is demonstrated concretely. 7 and 8 illustrate a powder slush molding method using the powder slush molding machine 10, and the powder slush molding method will be described as appropriate with reference to the drawings.
1. Mold heating part (1) Hot air blowing part (1) Basic structure The structure of the hot air blowing part is connected to a hot air generating and circulating device to be described later and has a function of blowing hot air having a predetermined wind speed. Although not particularly limited, for example, the shape of the opening in the hot air blowing portion is preferably a circle, an ellipse, a quadrangle (including a square, a rectangle, a belt, etc.), a polygon, and an irregular shape.
Moreover, it is also preferable to arrange the openings having such a shape in one or more rows or in a circular shape in the length direction or the lateral direction of the bottom surface in the furnace. For example, in FIG. 2 and FIG. 3, the hot air blowing part 16 which has a comparatively short strip | belt-shaped opening part is provided in parallel with the length direction, and the hot air blowing of the bottom face 26 in a furnace is carried out from a total of two hot air blowing parts. Part 16 is configured.
(2) Arrangement Regarding the arrangement of the hot air blowing section, the hot air blowing section is not particularly limited as long as it is arranged so as to be blown from below the mold. It is preferable to arrange | position.
More specifically, as shown in FIGS. 4A to 4C, the gold suspended on the frame member 13 disposed at a predetermined distance above the inner bottom surface 18 of the heating furnace 28. The arrangement is preferably such that the inner surface of the mold 12 can be effectively heated by the hot air 14 blown from the hot air outlet 16 on the bottom surface 18 in the furnace.
As will be described later, when the inclined portion 19 is provided on the bottom surface 18 in the furnace of the mold heating portion, one or more hot air blowing portions 16 are provided at the deepest portion of the bottom surface 18 in the furnace and in the vicinity thereof. It is preferable to provide it. The reason for this is that even if the hot air 14 blown from the hot air blowing portion 16 located at the deepest portion of the bottom surface 18 in the furnace spreads in an oblique direction unexpectedly, along the inclined portion 18 of the bottom surface 18 in the furnace, This is because the mold 12 can be reached efficiently.
(3) Velocity The flow velocity (wind velocity) of hot air measured using an anemometer or the like at the hot air outlet is 15 m / sec. It is characterized by the above values.
This is because the flow velocity of the hot air is 15 m / sec. When the value is less than the value, it may be difficult to quickly and uniformly heat a large-sized mold or a complex-shaped mold, for example, a large-sized mold having an inner area of about 1 to 10 m ^2. Because there is. However, if the flow rate of the hot air is excessively high, the mold may be heated unevenly or the mold may be thermally fatigued.
Therefore, the flow rate of hot air is 18-100 m / sec. Is more preferably in the range of 20 to 50 m / sec. It is more preferable to set the value within the range.
Here, in Table 1 below, the flow velocity of hot air is 1 to 100 m / sec. Shows the variation (maximum value of variation from the average value (%)) in the measured value (20 locations) of the thickness of the resin film obtained using the automobile interior material creation mold in the range of . In addition, in a cycle where a post-heating step is provided and hot air is further blown by changing the flow rate of hot air to the mold after powder slush molding, and it is cooled to room temperature by showering, until the mold is thermally damaged The number of cycles was measured. As is apparent from the results, the flow velocity of hot air is 15 m / sec. By setting it as the above, the dispersion | variation in the thickness of a resin film decreases, and the number of cycles until a thermal damage arises to a metal mold | die can be remarkably increased in the reheating in a post-heating process.

(4) Hot air control plate It is preferable to provide a hot air control plate 30 at the hot air outlet 16 as shown in FIGS. The reason for this is that these hot air control plates 30 can easily control the direction of the hot air 14 blown from the lower side of the inner surface of the mold 12, the spreadability, the air flow rate, and the like. For example, in FIG. 4A, since the hot air control plate 30 faces leftward, the hot air 14 can also intensively heat the left inner surface of the mold 12. Similarly, in FIG. 4B, since the hot air control plate 30 faces straight upward, the hot air 14 can also intensively heat the inner surface near the center of the mold 12, and FIG. In (c), since the hot air control plate 30 faces the right side, the right inner surface of the mold 12 can be intensively heated by the hot air 14.
Here, it is preferable that the length of the hot air control plate 30 is substantially equal to the length of the hot air outlet 16 in the longitudinal direction. The reason for this is that, even when a large mold or a complicated mold is heated, the longitudinal direction of the hot air outlet 16 is controlled while controlling the direction of a large amount of hot air. It is because it can be blown up from the whole.
Moreover, it is preferable that the hot air control board 30 is the structure which can be rotated centering on the fulcrum 31 and controlled to an original predetermined opening angle by a drive device (not shown). The reason for this is that a large amount of hot air can be uniformly blown in consideration of the heating temperature, the heating time, the size and shape of the mold, and the like.
Further, the hot air control plate 30 is preferably formed from a heat-resistant material. For example, metals, ceramics (including castings and ceramics), glass, and the like are preferable examples. ), Workability, and durability, it is more preferably a long cast plate.
(5) Hot air generating / circulating device As shown in FIG. 5, the hot air generating / circulating device 40 is configured to supply hot air having a predetermined wind speed obtained by a hot air generating device (not shown) by a hot air circulating fan 42 to the main pipe. A configuration in which the hot air blowing outlet 16 is supplied through 43 is preferable.
Further, the air supplied from the air supply fan 46 and hot air recovered from the furnace through the energy recovery unit 24 are appropriately mixed in the mixing chamber 44, and then the hot air obtained by the hot air generator is further mixed. It is preferable that the hot air circulation fan 42 supplies a large amount of hot air having a predetermined air speed to the hot air outlet 16 through the main pipe 43.
The reason for this is that, with respect to the heating mode of the mold 12 in the heating furnace 28, when the hot air 14 flows along the inner surface of the mold 12, the heat of the hot air 14 is transferred to the mold 12. This is because it is performed by being transferred to the heat. That is, since heat is transmitted mainly in the heat transfer mode, the heat supplied to the inside of the heating furnace 28 is less likely to be dissipated out of the heating furnace 28. Therefore, even if the heating furnace 28 and the hot air generator / circulator 40 are small, the productivity is equal to or higher than that of the conventional large heating furnace. Further, in the heating furnace 28, since the whole including the hot air generating and circulating device 40 can be remarkably reduced in size, as shown in FIG. 1, a mold heating unit (part A) provided with a specific hot air generating and circulating device. Even when the powdering device and the mold cooling device (C section) are arranged in a line on the ground surface, a compact powder slush molding machine 10 can be configured.
In addition, it is preferable to arrange a damper 47 a in the middle of the branch pipe 47 connected to the energy recovery unit 24. This is because the hot air blown out from the hot air outlet 16 on the bottom surface 18 in the furnace and the side hot air outlet 50 provided in the branch pipe 47 of the furnace side surface 28a as shown in FIG. This is because the quantitative ratio can be easily controlled by the damper 47a.
(2) Energy Recovery Unit {circle around (1)} Basic Structure The structure of the energy recovery unit 24 arranged on the bottom surface 18 in the furnace 28 is not particularly limited. For example, as shown in FIG. It is preferable to have a duct structure having an opening that leads to the furnace bottom surface 18 of the heating furnace 28 and a branch pipe 47 that is connected to the hot-air generating and circulating device 40. And as already mentioned above, it is preferable to arrange the damper 47a in the middle of the branch pipe 47 connected to the energy recovery unit 24.
(2) Arrangement In addition, the energy recovery section 24 disposed on the bottom surface 18 of the heating furnace 28 extends along the corners or sides of the bottom surface 18 of the furnace as shown in FIGS. 2 and 3. It is characterized by being provided.
Therefore, the hot air 14 blown out from the hot air outlet 16 heats the mold 12 and then forms energy along the inner surface of the mold 12 along the corner or side of the bottom surface 18 in the furnace. It moves toward the collection unit 24 and can stay in the mold 12 for a predetermined time. In other words, the flow of the hot air 14 moving from the hot air outlet 16 toward the energy recovery unit 24 along the inner surface of the mold 12 is easily generated in the mold 12. Therefore, the residence time is further increased, and as a result, every corner of the mold 12 can be effectively heated by the hot air 14 in the heat transfer mode. Further, since the wind speed of the hot air 14 is high, it is possible to effectively prevent the heat transfer mode from becoming a diffusion law.
In addition to the hot air outlet 16 described above, the thermal energy recovery unit 24 is in a space formed by the furnace bottom surface 18, the frame member 13, and the mold 12, and Since it is disposed along the corner or side, the thermal energy introduced into the heating furnace 28 can be recovered easily and effectively.
Moreover, it is preferable that the shape of the opening of the energy recovery unit is substantially V-shaped or U-shaped as shown in FIG. The reason for this is that the hot air 14 blown out from the hot air outlet 16 moves easily and quickly toward the energy recovery unit 24 having such a predetermined shape, and an appropriate flow of hot air is generated in the meantime. This is because 12 can be effectively heated.
Further, when the shape of the opening of the energy recovery unit 24 is substantially V-shaped or U-shaped as shown in FIG. 3, a configuration in which an appropriate flow of hot air is more easily generated is obtained. It is preferable to do. That is, the energy recovery unit is composed of a main recovery unit and a sub-recovery unit that communicate with each other. In the main recovery unit, hot air after heating the mold is recovered, and then, via the sub-recovery unit, The recovered hot air is preferably circulated through the hot air generating and circulating device. For example, the upper part of the small energy recovery part (sub-recovery part) 24 as shown in FIG. 2 is blocked and recovered only through the V-shaped or U-shaped energy recovery part (main recovery part), More preferably, it is introduced from the side of the sub-recovery unit 24 into the opening of the sub-recovery unit 24 to circulate hot air. In addition, in FIG. 4 etc., the hot air is introduced into the opening part of the energy recovery part 24 from the side specifically shows this system.
(3) Heating furnace (1) Basic structure As shown in FIG. 5, the heating furnace 28 is disposed above the hot-air generating and circulating device 40, and is configured as a single compact heating device as a whole. Is preferred. Such a configuration not only facilitates the supply of thermal energy to the heating furnace 28, but also facilitates the recovery of thermal energy from the heating furnace 28 using the energy recovery unit 24. it can.
Further, the furnace body of the heating furnace 28 is formed, for example, in a flat rectangular box-like body having an openable and closable opening on the upper surface, and the mold 12 and its frame are opened with the upper opening opened. After the member 13 is carried into the furnace, the opening is closed, and hot air 14 is blown by the hot air generator / circulator 40 so that the mold 12 is heated.
Note that the form of the furnace body included in the heating furnace 28 can be changed as appropriate. For example, it is also preferable that the furnace body has a cylindrical shape, a cubic shape, or an irregular shape corresponding to the shape of the mold.
(2) Heat Reflecting Plate As shown in FIG. 4, it is preferable to provide a heat reflecting plate 26 on the bottom surface 18 in the furnace 28. That is, the hot air 14 blown out from the hot air generator / circulator 40 is directly blown against the mold 12 through the hot air outlet 16, but the heat reflector 26 is entirely applied to the bottom surface 18 in the furnace. Alternatively, it is preferable that the hot air 14 reflected by the mold 12 can be further reflected by the heat reflecting plate 26 by being partially provided.
Here, the heat reflecting plate 26 is a plate-like material made of a heat-resistant inorganic material, for example, a metal plate made of stainless steel, platinum, gold, silver, etc., a ceramic plate made of aluminum oxide, titanium oxide, zirconium oxide, etc., soda glass, A glass plate or the like made of quartz or the like can be laminated on the bottom surface 18 in the furnace, or these heat-resistant inorganic materials can be used as they are as a plate-like material constituting the bottom surface 18 in the furnace to reflect heat. It can also be configured as an in-furnace bottom surface 18 made of a plate 26. That is, if it is a heat-resistant inorganic material that can easily achieve such a mirror surface structure, even if it is laminated on the surface of the bottom surface 18 in the furnace or the bottom surface 18 of the furnace is configured as it is, it exhibits excellent heat reflectivity. be able to.
(3) Inclination As shown in FIGS. 4 and 5, it is preferable to provide an inclined portion 19 on the bottom surface 18 in the furnace 28 of the heating furnace 28. This is because the hot air blowing portion 16 can be provided at the deepest portion of the inclined bottom surface 18 of the furnace, the rectifying property of the hot air 14 is improved, and the size (dead space) of the hot air 14 is reduced. This is because the mold 12 can be heated more effectively. Further, by providing such an inclined portion 19 on the bottom surface 18 in the furnace, the inclined portion 19 further reflects the hot air 14 once reflected by the mold 12 more efficiently, for example, to generate a spiral. This is because the mold 12 can be effectively heated again by using it.
Here, the angle of the inclined portion 19 on the bottom surface 18 in the furnace can be determined in consideration of the size, shape, or heating efficiency of the mold 12, for example, a value in the range of 1 to 60 °. It is preferable.
The reason for this is that when the angle of the inclined portion 19 is less than 1 °, the amount of hot air that can be re-reflected to the mold 12 may be significantly reduced, while the angle of the inclined portion 19 exceeds 60 °. This is because it may be difficult to generate a spiral by the hot air 14 and the heating efficiency of the mold 12 may be reduced.
Therefore, it is more preferable to set the angle of the inclined portion 19 on the bottom surface 18 in the furnace to a value within the range of 5 to 50 °, and even more preferable to set the value within the range of 10 to 45 °.
(4) Side hot air blowing section In the heating furnace 28, as shown in FIG. 6, the side hot air outlet 50 has a predetermined height with respect to the heating furnace 28, and the mold 12 is moved sideways. It is preferable that it is provided so that it can be heated.
For example, the side hot air outlet 50 has a duct structure arranged along the inside of the heating furnace 28, and is connected to the branch pipe 47 connected to the hot air generating and circulating device 40 and the main pipe 43. Is preferably adjusted by a damper or the like.
The reason for this is that by configuring in this way, the mold 12 can be heated more effectively by blowing hot air not only in the downward direction but also in the lateral direction. It is.
Moreover, as shown in FIG. 6, it is preferable that this side hot-air blower outlet 50 is comprised from the row | line | column of diameters 0.1-10 mm. The reason for this is that the hot air can spread widely after being blown out from the branch pipe 47 due to the pressure due to such a configuration. Therefore, even if there is no current plate, it is possible to heat a large-area mold.
(4) Mold As shown in FIG. 5, the mold 12 is disposed on the bottom surface 18 in the furnace 28 with the frame member 13 for moving and operating the mold 12 attached thereto. It is preferable to be placed on a mold support member (not shown).
Further, the mold 12 is moved while holding or suspending the frame member 13 on a robot arm (not shown). For example, in the mold heating unit, the frame member 13 is moved to the upper surface by the robot arm, Therefore, it is preferable to have a structure that can be carried into the heating furnace 28 through an opening provided on the upper surface.
In addition, it is preferable to cover the surface of the mold support member with a heat insulating material (not shown) having a sealing effect, for example, a combination of a silicone rubber / fluororesin film. This is because the mold support member can effectively prevent hot air from escaping to the outside by filling the gap between the mold 12 and the bottom surface 18 in the furnace. Further, such a mold support member allows the positioning of the mold 12 accommodated in the furnace for heating and the hot air 14 from the hot air outlet 16 on the bottom surface 18 in the furnace to efficiently hit the inner surface of the mold 12. In addition, it is preferable to have a function of adjusting the height from the hot air outlet 16.
2. As shown in FIG. 7B, the powder slash part includes a mold 84 including the frame member 82 heated in FIG. 7A, and a reservoir tank 88 containing a powder 92 having a fluid state. Is a part for carrying out a step of integrally connecting the upper side and the lower side with the molding surface 85 of the mold (molding die) 84 facing downward and the opening surface of the reservoir tank 88 facing upward.
At this time, in order to improve the dispersibility of the powder 92 in the reservoir tank 88 and form a resin film (sheet-like material) 94 having a uniform thickness, air is supplied to the stirring chamber 88a provided below the reservoir tank 88. It is preferable to introduce the powder 92 into a fluid state. FIG. 9 (a) specifically shows the direction of air introduction, and the upper part of the stirring chamber 88a is composed of a perforated member (mesh member) and has a structure in which the powder 92 is wound up by the introduced air. It is preferable.
Further, as shown in FIG. 7C, the powder slash portion is rotated on the molding surface 85 of the mold 84 by rotating the mold 84 including the frame member 82 and the reservoir tank 88 in a connected state. It is also a part for performing the process of forming the resin film 94 having a thickness.
That is, it is preferable that the mold 84 including the frame member 82 and the reservoir tank 88 are combined and inverted in the vertical direction. This is because, when implemented in this manner, the powder 92 in the reservoir tank 88 falls by its own weight onto the molding surface 85 of the molding die 84, and only the powder 92 in contact with the molding surface 85 of the die 84 and the powder 92 in the vicinity thereof. However, this is because the resin film 94 can be instantaneously formed on the molding surface 85 of the mold 84 by adhering in a molten state due to the heat of the mold 84.
Further, when the metal mold 84 including the frame member 82 is reversed, the resin film 94 can be formed only on the desired molding surface 85 of the metal mold 84 so that the resin film 94 can be formed between the metal mold 84 and the reservoir tank 88. It is preferable to provide the frames 84a and 84b having a predetermined thickness (height). Here, the lower portion 84b of the frame is made of, for example, aluminum, and the upper portion 84a of the frame is made of a combination of a silicone rubber / fluororesin film, so that the mold 84 and the reservoir tank 88 are separated. It can also serve to fill the gap.
Further, when the metal mold 84 including the frame member 82 is reversed, the resin film 94 can be formed only on a desired molding surface 85 of the metal mold 84 so that the powder 92 is not scattered except at a predetermined position. As shown in FIG. 9B, it is preferable to suck through the stirring chamber 88a to reduce the pressure in the mold 84. That is, during the powder slush molding by rotating the mold 84, suction is performed to reduce the internal pressure of the mold 84, and before the powder slush molding, air is introduced into the powder 92 of the reservoir tank 88. It is preferable that a pressure adjusting device (not shown) for blowing is provided.
Further, when the mold 84 is reversed, the protrusions 82a provided on the frame member 82 of the mold 84 can be alternately beaten from both sides by one or a plurality of hammering devices as shown in FIG. preferable. This is because when the mold 84 is rotated, the hammer 92 is beaten by the hammering device 100 to apply a predetermined vibration so that the powder 92 uniformly reaches a predetermined portion of the mold 84.
8A, the powder slash portion performs a process of removing the reservoir tank 88 from the mold 84 in a state where the resin film 94 having a predetermined thickness is formed on the mold 84. As shown in FIG. It is a part for.
3. Mold Cooling Unit The mold cooling unit is a process of curing the resin film 94 by cooling the mold 84 including the frame member 82 by cooling means 98 such as water cooling or air cooling as shown in FIG. It is a part for carrying out. Further, as shown in FIG. 8C, the mold cooling unit is also a part for performing a step of peeling the resin film 94 from the mold 84, that is, demolding as a final process of the mold cooling unit. .
Here, in order to effectively prevent the thermal damage of the mold, it is preferable to provide the mold cooling unit with a spray device as shown in FIG. 10 and a shower device as shown in FIG. . That is, as the first cooling stage, it is preferable to spray the water or warm water with a spraying device to cool the mold relatively mildly to about 50 to 100 ° C. Next, as a second cooling stage, a relatively large amount of water or warm water is sprayed by a shower device, and the mold is moved to a temperature at which the resin film 94 can be peeled off using the enthalpy of evaporation, for example, to a temperature below 50 ° C. It is preferable to cool efficiently. The reason for this is to effectively prevent the occurrence of thermal damage and cracking of the mold even when the large and complicated mold is heated unevenly. It is because it can do. In addition, it is also preferable that the shower device and the spray device are connected to one water supply tank and are configured to determine the spray amount and the shower amount by switching a control valve or the like provided at the outlet.
4). Overall Arrangement and Post-heating Step (1) Overall Arrangement As illustrated in FIG. 1, when the powder slush molding device 10 is arranged in a row on the ground, the devices of each process including the heating furnace 28 are arranged from the left side. It is preferable to arrange the powder slash part (A part), the mold heating part (B part), and the mold cooling part (C part) in this order. It is also preferable to provide two mold heating parts and arrange them in the order of the powder slush part, the first mold heating part, the second mold heating part, and the mold cooling part. Furthermore, it is also preferable that a mold standby part, a post-heating part, a mold exchange part, a demolding part, etc. are appropriately provided and incorporated in the powder slush molding machine of the present invention.
In any case, the powder slush molding machine 10 of the present invention arranges each part in a row adjacent to the ground surface, and moves the mold to each part by a mobile robot and a robot arm. Can be implemented efficiently.
(2) Post-heating step It is also preferable to provide a post-heating step and use the mold heating unit described above as the heating unit in the subsequent heating step. In other words, the mold to which the resin film (resin melt layer) obtained in the powder slush molding part is attached can be transported to a position directly above the heating furnace by the robot arm and kept still in a state of being directed downward. preferable. Meanwhile, the opening (sliding door) of the heating furnace 28 is in an open state, and it is preferable to perform post-heating by hot air blowing from the hot air outlet 16 on the bottom surface 18 in the furnace. This is because the resin film is reheated by post-heating in this way, and the thickness can be made uniform by appropriately flowing. Moreover, it is because a powder slush molding machine can be designed compactly as a whole by using a metal mold | die heating part together as a heating part for implementing a post-heating process.

According to the powder slush molding machine and the powder slush molding method of the present invention, when the mold is heated by blowing hot air at a specific flow rate against the mold and devising the arrangement of the energy recovery unit, for example, Therefore, it becomes easy to generate a swirl due to a large amount of hot air, and for this reason, the thermal efficiency can be greatly improved.
Therefore, even when the mold is enlarged and complicated, the powder can be uniformly applied in a short time.
Further, in the powder slush molding machine and the powder slush molding method of the present invention, an inclined part is provided on the bottom surface of the furnace, a specific hot air control mechanism is provided on the mold heating part, or powder slush molding is being performed. In addition, a specific hammering device is used to strike a specific part, and furthermore, a mold heating unit is used for a post-heating process, thereby causing variations in the thickness of the resin film (actual thickness measurement). The maximum variation (%) from the average value (20 locations) can be easily controlled to a value within 50%, for example.

DETAILED DESCRIPTION OF THE INVENTION
TECHNICAL FIELD The present invention relates to a powder slush molding machine and a powder slush molding method, and in particular, a powder slush molding machine and powder capable of uniformly adhering powder (powder resin) to a large and complicated mold. The present invention relates to a slush molding method.
BACKGROUND ART Conventionally, a powder slush molding method in which slush molding is performed using powder (powder resin) has been widely practiced in manufacturing large and complex sheet-like materials such as automobile interior materials.
Here, in order to make the thickness of the interior material made of powder uniform, it is desired to heat the mold to a uniform temperature.
For example, JP-A-3-202329 includes a temporary heating step and a preliminary heating step controlled to a predetermined temperature, respectively, to heat the mold to a uniform temperature, and after using the mold, A method for forming leather, characterized by being immersed in water and slowly cooled, is disclosed.
Japanese Patent Laid-Open No. 4-191018 discloses a slush molding die as a porous die, the opening of a hot air supply duct is brought into contact with the material inlet of the die, and hot air is blown from the duct into the die. A method for heating a slush molding die, characterized by being pumped inward, is disclosed.
Furthermore, in Japanese Patent Application Laid-Open No. 2002-210761 and Japanese Patent Application Laid-Open No. 2002-210762, a heating chamber and a hot air control chamber are provided in a heating furnace, and an openable / closable blade is pivotally supported in the hot air control chamber. Heating device for resin powder molding die provided with air volume adjusting damper and wind direction adjusting nozzle having cylindrical nozzle body, and further for resin powder molding provided with primary main hot air outlet and plural primary auxiliary hot air outlets A mold heating apparatus is disclosed.
However, none of the heating devices is provided with an outlet for hot air after heating the mold, energy recovery is insufficient, and high-speed heating and uniform heating of the mold are still insufficient. There was a problem.
Therefore, in the Japanese Patent Application Laid-Open No. 9-248832, the applicant carries in and out a mold for resin powder molding into and out of the furnace from the upper opening that can be opened and closed, and opens the upper opening as shown in FIG. In a powder slush molding machine having a furnace structure that heats a mold in a closed furnace, a hot air blowing unit having a hot air control mechanism for blowing hot air onto the mold from below is disposed on the bottom surface of the furnace, A powder slush molding machine is proposed in which an energy recovery unit for recovering thermal energy in the furnace is disposed in the furnace.
However, even in such a powder slush molding machine, further high-speed heating and uniform heating of the mold have been desired in order to cope with molds that are becoming larger and more complicated. Moreover, since the air velocity control of the hot air in the hot air blowing part was insufficient, the film thickness of the obtained sheet-like material varies, or a post-heating step is provided to cause thermal damage when the mold is reheated. A case was seen.
Therefore, as a result of intensive studies, the inventor of the present invention blows hot air at a specific flow velocity to the mold and devise the arrangement of the energy recovery unit to increase the size and complexity of the mold. Another object of the present invention is to provide a powder slush molding machine and a powder slush molding method capable of uniformly and quickly depositing powder and generating less heat damage when the mold is reheated.

DISCLOSURE OF THE INVENTION According to the present invention, there is provided a powder slush molding machine comprising a mold heating part, a powder slush part, and a mold cooling part, wherein the blower is blown into the mold heating part from below the mold. A hot air blowing part for blowing hot air whose flow rate measured at the outlet is a value within the range of 15 to 50 m / sec, and a corner or side part of the bottom face in the furnace of the mold heating part are provided, An energy recovery unit for recovering hot air after heating the mold, a hot air control mechanism for blowing hot air while rectifying the hot air, and an inclined part on the bottom surface in the furnace of the mold heating unit, There is provided a powder slush molding machine characterized in that a hot air blowing part is provided at the deepest part of the bottom face in the furnace .
By comprising in this way, it becomes easy to produce the swirl by a hot air in a metallic mold heating part, and it can improve greatly the thermal efficiency at the time of heating a metallic mold for that, As a result, a metallic mold enlarges, Even if it is complicated, the powder can be adhered uniformly and rapidly. In addition, because the mold is heated at a predetermined wind speed in the mold heating section, conditions such as reheating of the mold are relaxed, and thermal damage occurs, particularly thermal damage during cooling in the mold cooling section. Can be reduced.
Further, another aspect of the present invention is a powder slush molding machine including a mold heating unit, a powder slush unit, and a mold cooling unit, and the mold heating unit, from below the mold, A hot air blowing part for blowing hot air whose flow velocity measured at the blow outlet is a value within a range of 15 to 50 m / sec, and a corner or side part of the bottom face in the furnace of the mold heating part are provided, To provide an energy recovery unit for recovering hot air after heating the mold and a hot air control mechanism for blowing hot air while rectifying the hot air, and to perform the first cooling stage in the mold cooling unit A powder slush molding machine characterized by comprising a spraying device and a shower device for carrying out the second cooling stage.
By comprising in this way, the thermal efficiency at the time of heating a metal mold | die can be improved, while powder can be uniformly and rapidly attached to a metal mold | die, and a metal mold | die is cooled rapidly. The occurrence of thermal damage can be further reduced.
Yet another aspect of the present invention is a powder slush molding method for molding a sheet-like material using the above-described powder slush molding machine.
And after powder slush molding of the sheet-like material in the powder slush portion, the obtained sheet-like material is re-heated in the mold heating unit, and in the mold cooling unit, the spray-type device and the shower device sequentially It is preferable to cool the mold having the sheet-like material attached thereto.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram for explaining the overall arrangement of a powder slush molding machine of the present invention.
FIG. 2 is a diagram for explaining the relationship among the bottom surface in the furnace, the hot air blowing section, and the energy recovery section in the mold heating section (part 1).
FIG. 3 is a diagram for explaining another relationship among the bottom surface in the furnace, the hot air blowing unit, and the energy recovery unit in the mold heating unit (part 2).
FIG. 4 is a diagram provided to explain the outline of the hot air control mechanism in the mold heating unit.
FIG. 5 is a diagram provided for explaining the relationship between the hot air blowing section of the mold heating section and the hot air generating and circulating apparatus.
Drawing 6 is a figure offered in order to explain a side hot air blowing part of a mold heating part.
Drawing 7 is a figure offered in order to explain a powder slush molding method (the 1).
FIG. 8 is a diagram for explaining the powder slush molding method (part 2).
FIG. 9 is a diagram for explaining the function of the pressure adjusting device during powder slush molding.
FIG. 10 is a diagram for explaining the hammering apparatus.
FIG. 11 is a diagram for explaining the mold cooling unit.
FIG. 12 is a diagram provided for explaining the relationship between the conventional hot air blowing section and the hot air generating and circulating apparatus.

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments relating to a powder slush molding machine and a powder slush molding method of the present invention will be specifically described below with reference to the drawings.

[First embodiment]
As illustrated in FIG. 1, the first embodiment is a powder slash provided with a powder slash part (A part), a mold heating part (B part), and a mold cooling part (C part). This is a molding machine 10. Then, as illustrated in FIG. 3A, the flow rate measured at the outlet from the lower side of the mold 12 is a value within a range of 15 to 50 m / second in the mold heating section (B section). A hot air blowing part 16 for blowing a certain hot air 14 and a hot air 14 after heating the mold 12 are provided along the corners or sides of the furnace bottom surface 18 of the mold heating part (B part). An energy recovery unit 24 for recovery and a hot air control mechanism 30 for blowing hot air while rectifying the hot air are provided.
In addition, an inclined part 19 is provided on the bottom surface 18 in the furnace of the mold heating part (B part), and a hot air blowing part 16 is provided at the deepest part of the bottom surface 18 in the furnace, or a mold cooling part. (Part C) is provided with a spraying device for carrying out the first cooling stage and a shower device for carrying out the second cooling stage .
Hereinafter, the suitable example of the powder slush molding machine 10 is demonstrated concretely. 7 and 8 illustrate a powder slush molding method using the powder slush molding machine 10, and the powder slush molding method will be described as appropriate with reference to the drawings.

1. Mold heating part (1) Hot air blowing part (1) -1 Basic structure The structure of the hot air blowing part is connected to a hot air generating and circulating device described later and has a function of blowing hot air having a predetermined wind speed. If it is not particularly limited, for example, the shape of the opening in the hot air blowing portion is preferably a circle, an ellipse, a quadrangle (including a square, a rectangle, a belt, etc.), a polygon, and an irregular shape. .
Moreover, it is also preferable to arrange the openings having such a shape in one or more rows or in a circular shape in the length direction or the lateral direction of the bottom surface in the furnace. For example, in FIG. 2 and FIG. 3, the hot air blowing part 16 which has a comparatively short strip | belt-shaped opening part is provided in parallel with the length direction, and the hot air blowing of the bottom face 26 in a furnace is carried out from a total of two hot air blowing parts. Part 16 is configured.

(1) -2 Arrangement
With regard to the arrangement of the hot air blowing section, the hot air blowing section is not particularly limited as long as it is arranged so as to be sprayed from below the mold. For example, it is arranged at the center of the bottom surface in the furnace in the heating furnace. Preferably it is.
More specifically, as shown in FIGS. 4A to 4C, the gold suspended on the frame member 13 disposed at a predetermined distance above the inner bottom surface 18 of the heating furnace 28. The arrangement is preferably such that the inner surface of the mold 12 can be effectively heated by the hot air 14 blown from the hot air outlet 16 on the bottom surface 18 in the furnace.
Moreover, it is preferable to provide the inclined part 19 on the bottom surface 18 in the furnace of the mold heating part, and to provide one or more hot air blowing parts 16 in the deepest part of the bottom surface 18 in the furnace and the vicinity thereof. The reason for this is that even if the hot air 14 blown from the hot air blowing portion 16 located at the deepest portion of the bottom surface 18 in the furnace spreads in an oblique direction unexpectedly, along the inclined portion 18 of the bottom surface 18 in the furnace, This is because the mold 12 can be reached efficiently.

(1) -3 Flow velocity The flow velocity (wind velocity) of hot air measured using an anemometer or the like at the outlet of the hot air blowing section is set to a value in the range of 15 to 50 m / sec .
The reason for this is that when the flow velocity of the hot air is less than 15 m / second, for a large mold or a complex mold, for example, a large mold having an inner area of about 1 to 10 m ² , This is because it may be difficult to heat quickly and uniformly. On the other hand, if the flow rate of hot air exceeds 50 m / sec, uneven heating of the mold or thermal fatigue of the mold may occur.
Here, in the case where the flow velocity of hot air measured at the outlet is changed in the range of 1 to 100 m / sec in Table 1 below, the thickness of the resin film obtained using the automobile interior material creation mold is shown. The variation (maximum value (%) of variation from the average value) in the actual measurement value (20 locations) is shown. In addition, in a cycle where a post-heating step is provided and hot air is further blown by changing the flow rate of hot air to the mold after powder slush molding, and it is cooled to room temperature by showering, until the mold is thermally damaged The number of cycles was measured. As is clear from the results, by setting the flow velocity of the hot air to a value within the range of 15 to 50 m / sec, variation in the thickness of the resin film is reduced, and in the reheating in the post-heating process, The number of cycles until thermal damage occurs can be significantly increased.
Table 1
Hot air flow rate Thickness variation Number of cycles (m / sec) (%) (Number of times)
1 500 500
10 300 2000
15 50 10,000 or more 20 20 10,000 or more 50 10 10,000 or more 70 40 10,000 or more 100 60 7000

(1) -4 Hot air control board
Moreover, the hot air blower outlet 16 is provided with the hot air control board 30 as shown to Fig.4 (a)-(c). The reason for this is that these hot air control plates 30 can easily control the direction of the hot air 14 blown from the lower side of the inner surface of the mold 12, the spreadability, the air flow rate, and the like. For example, in FIG. 4A, since the hot air control plate 30 faces leftward, the hot air 14 can also intensively heat the left inner surface of the mold 12. Similarly, in FIG. 4B, since the hot air control plate 30 faces straight upward, the hot air 14 can also intensively heat the inner surface near the center of the mold 12, and FIG. In (c), since the hot air control plate 30 faces the right side, the right inner surface of the mold 12 can be intensively heated by the hot air 14.
Here, it is preferable that the length of the hot air control plate 30 is substantially equal to the length of the hot air outlet 16 in the longitudinal direction. The reason for this is that, even when a large mold or a complicated mold is heated, the longitudinal direction of the hot air outlet 16 is controlled while controlling the direction of a large amount of hot air. It is because it can be blown up from the whole.
Moreover, it is preferable that the hot air control board 30 is the structure which can be rotated centering on the fulcrum 31 and controlled to an original predetermined opening angle by a drive device (not shown). The reason for this is that a large amount of hot air can be uniformly blown in consideration of the heating temperature, the heating time, the size and shape of the mold, and the like.
Further, the hot air control plate 30 is preferably formed from a heat-resistant material. For example, metals, ceramics (including castings and ceramics), glass, and the like are preferable examples. ), Workability, and durability, it is more preferably a long cast plate.

(1) -5 Hot Air Generating / Circulating Device Further, as shown in FIG. 5, the hot air generating / circulating device 40 uses a hot air circulating fan 42 to convert hot air having a predetermined air speed obtained by a hot air generating device (not shown). A configuration in which the hot air outlet 16 is supplied through the main pipe 43 is preferable.
Further, the air supplied from the air supply fan 46 and hot air recovered from the furnace through the energy recovery unit 24 are appropriately mixed in the mixing chamber 44, and then the hot air obtained by the hot air generator is further mixed. It is preferable that the hot air circulation fan 42 supplies a large amount of hot air having a predetermined air speed to the hot air outlet 16 through the main pipe 43.
The reason for this is that, with respect to the heating mode of the mold 12 in the heating furnace 28, when the hot air 14 flows along the inner surface of the mold 12, the heat of the hot air 14 is transferred to the mold 12. This is because it is performed by being transferred to the heat. That is, since heat is transmitted mainly in the heat transfer mode, the heat supplied to the inside of the heating furnace 28 is less likely to be dissipated out of the heating furnace 28. Therefore, even if the heating furnace 28 and the hot air generator / circulator 40 are small, the productivity is equal to or higher than that of the conventional large heating furnace. Further, in the heating furnace 28, since the whole including the hot air generating and circulating device 40 can be remarkably reduced in size, as shown in FIG. 1, a mold heating unit (part A) provided with a specific hot air generating and circulating device. Even when the powdering device and the mold cooling device (C section) are arranged in a line on the ground surface, a compact powder slush molding machine 10 can be configured.
In addition, it is preferable to arrange a damper 47 a in the middle of the branch pipe 47 connected to the energy recovery unit 24. This is because the hot air blown out from the hot air outlet 16 on the bottom surface 18 in the furnace and the side hot air outlet 50 provided in the branch pipe 47 of the furnace side surface 28a as shown in FIG. This is because the quantitative ratio can be easily controlled by the damper 47a.

(2) Energy Recovery Unit (2) -1 Basic Structure The structure of the energy recovery unit 24 disposed on the bottom surface 18 of the heating furnace 28 is not particularly limited. For example, as shown in FIG. As described above, it is preferable to have a duct structure including an opening that leads to the furnace bottom surface 18 of the heating furnace 28 and a branch pipe 47 that is connected to the hot air generating and circulating device 40. And as already mentioned above, it is preferable to arrange the damper 47a in the middle of the branch pipe 47 connected to the energy recovery unit 24.

(2) -2 Arrangement In addition, the energy recovery unit 24 disposed on the bottom surface 18 of the heating furnace 28 has corners or sides of the bottom surface 18 of the furnace as shown in FIGS. 2 and 3. It is characterized by being provided along.
Therefore, the hot air 14 blown out from the hot air outlet 16 heats the mold 12 and then forms energy along the inner surface of the mold 12 along the corner or side of the bottom surface 18 in the furnace. It moves toward the collection unit 24 and can stay in the mold 12 for a predetermined time. In other words, the flow of the hot air 14 moving from the hot air outlet 16 toward the energy recovery unit 24 along the inner surface of the mold 12 is easily generated in the mold 12. Therefore, the residence time is further increased, and as a result, every corner of the mold 12 can be effectively heated by the hot air 14 in the heat transfer mode. Further, since the wind speed of the hot air 14 is high, it is possible to effectively prevent the heat transfer mode from becoming a diffusion law.
In addition to the hot air outlet 16 described above, the thermal energy recovery unit 24 is in a space formed by the furnace bottom surface 18, the frame member 13, and the mold 12, and Since it is disposed along the corner or side, the thermal energy introduced into the heating furnace 28 can be recovered easily and effectively.
Moreover, it is preferable that the shape of the opening of the energy recovery unit is substantially V-shaped or U-shaped as shown in FIG. The reason for this is that the hot air 14 blown out from the hot air outlet 16 moves easily and quickly toward the energy recovery unit 24 having such a predetermined shape, and an appropriate flow of hot air is generated in the meantime. This is because 12 can be effectively heated.
Further, when the shape of the opening of the energy recovery unit 24 is substantially V-shaped or U-shaped as shown in FIG. 3, a configuration in which an appropriate flow of hot air is more easily generated is obtained. It is preferable to do. That is, the energy recovery unit is composed of a main recovery unit and a sub-recovery unit that communicate with each other. In the main recovery unit, hot air after heating the mold is recovered, and then, via the sub-recovery unit, The recovered hot air is preferably circulated through the hot air generating and circulating device. For example, the upper part of the small energy recovery part (sub-recovery part) 24 as shown in FIG. 2 is blocked and recovered only through the V-shaped or U-shaped energy recovery part (main recovery part), More preferably, it is introduced from the side of the sub-recovery unit 24 into the opening of the sub-recovery unit 24 to circulate hot air. In addition, in FIG. 4 etc., the hot air is introduced into the opening part of the energy recovery part 24 from the side specifically shows this system.

(3) Heating furnace (3) -1 Basic structure As shown in FIG. 5, the heating furnace 28 is arranged above the hot-air generating and circulating device 40, and is configured as one compact heating device as a whole. Preferably it is. Such a configuration not only facilitates the supply of thermal energy to the heating furnace 28, but also facilitates the recovery of thermal energy from the heating furnace 28 using the energy recovery unit 24. it can.
Further, the furnace body of the heating furnace 28 is formed, for example, in a flat rectangular box-like body having an openable and closable opening on the upper surface, and the mold 12 and its frame are opened with the upper opening opened. After the member 13 is carried into the furnace, the opening is closed, and hot air 14 is blown by the hot air generator / circulator 40 so that the mold 12 is heated.
Note that the form of the furnace body included in the heating furnace 28 can be changed as appropriate. For example, it is also preferable that the furnace body has a cylindrical shape, a cubic shape, or an irregular shape corresponding to the shape of the mold.
(3) -2 Heat Reflector As shown in FIG. 4, it is preferable to provide a heat reflector 26 on the bottom surface 18 in the furnace 28. That is, the hot air 14 blown out from the hot air generator / circulator 40 is directly blown against the mold 12 through the hot air outlet 16, but the heat reflector 26 is entirely applied to the bottom surface 18 in the furnace. Alternatively, it is preferable that the hot air 14 reflected by the mold 12 can be further reflected by the heat reflecting plate 26 by being partially provided.
Here, the heat reflecting plate 26 is a plate-like material made of a heat-resistant inorganic material, for example, a metal plate made of stainless steel, platinum, gold, silver, etc., a ceramic plate made of aluminum oxide, titanium oxide, zirconium oxide, etc., soda glass, A glass plate or the like made of quartz or the like can be laminated on the bottom surface 18 in the furnace, or these heat-resistant inorganic materials can be used as they are as a plate-like material constituting the bottom surface 18 in the furnace to reflect heat. It can also be configured as an in-furnace bottom surface 18 made of a plate 26. That is, if it is a heat-resistant inorganic material that can easily achieve such a mirror surface structure, even if it is laminated on the surface of the bottom surface 18 in the furnace or the bottom surface 18 of the furnace is configured as it is, it exhibits excellent heat reflectivity. be able to.

(3) -3 Inclination As shown in FIGS. 4 and 5, it is preferable to provide an inclined portion 19 on the bottom surface 18 of the heating furnace 28. This is because the hot air blowing portion 16 can be provided at the deepest portion of the inclined bottom surface 18 of the furnace, the rectifying property of the hot air 14 is improved, and the size (dead space) of the hot air 14 is reduced. This is because the mold 12 can be heated more effectively. Further, by providing such an inclined portion 19 on the bottom surface 18 in the furnace, the inclined portion 19 further reflects the hot air 14 once reflected by the mold 12 more efficiently, for example, to generate a spiral. This is because the mold 12 can be effectively heated again by using it.
Here, the angle of the inclined portion 19 on the bottom surface 18 in the furnace can be determined in consideration of the size, shape, or heating efficiency of the mold 12, for example, a value in the range of 1 to 60 °. It is preferable.
The reason for this is that when the angle of the inclined portion 19 is less than 1 °, the amount of hot air that can be re-reflected to the mold 12 may be significantly reduced, while the angle of the inclined portion 19 exceeds 60 °. This is because it may be difficult to generate a spiral by the hot air 14 and the heating efficiency of the mold 12 may be reduced.
Therefore, it is more preferable to set the angle of the inclined portion 19 on the bottom surface 18 in the furnace to a value within the range of 5 to 50 °, and even more preferable to set the value within the range of 10 to 45 °.

(3) -4 Side Hot Air Blowing Unit Further, in the heating furnace 28, as shown in FIG. 6, the side hot air outlet 50 has a predetermined height with respect to the heating furnace 28, and the mold 12 is It is preferable to be provided so that it can also be heated from the side.
For example, the side hot air outlet 50 has a duct structure arranged along the inside of the heating furnace 28, and is connected to the branch pipe 47 connected to the hot air generating and circulating device 40 and the main pipe 43. Is preferably adjusted by a damper or the like.
The reason for this is that by configuring in this way, the mold 12 can be heated more effectively by blowing hot air not only in the downward direction but also in the lateral direction. It is.
Moreover, as shown in FIG. 6, it is preferable that this side hot-air blower outlet 50 is comprised from the row | line | column of diameters 0.1-10 mm. The reason for this is that the hot air can spread widely after being blown out from the branch pipe 47 due to the pressure due to such a configuration. Therefore, even if there is no current plate, it is possible to heat a large-area mold.

(4) Mold As shown in FIG. 5, the mold 12 is disposed on the bottom surface 18 in the furnace 28 with the frame member 13 for moving and operating the mold 12 attached thereto. It is preferable to be placed on a mold support member (not shown).
Further, the mold 12 moves while holding or suspending the frame member 13 on a robot arm (not shown). For example, in the mold heating unit, the frame member 13 is moved to the upper surface by the robot arm. It is preferable that the structure be able to be carried into the heating furnace 28 through an opening provided in the upper surface portion.
In addition, it is preferable to cover the surface of the mold support member with a heat insulating material (not shown) having a sealing effect, for example, a combination of a silicone rubber / fluororesin film. This is because the mold support member can effectively prevent hot air from escaping to the outside by filling the gap between the mold 12 and the bottom surface 18 in the furnace. Further, such a mold support member allows the positioning of the mold 12 accommodated in the furnace for heating and the hot air 14 from the hot air outlet 16 on the bottom surface 18 in the furnace to efficiently hit the inner surface of the mold 12. In addition, it is preferable to have a function of adjusting the height from the hot air outlet 16.

2. As shown in FIG. 7B, the powder slash part includes a mold 84 including the frame member 82 heated in FIG. 7A, and a reservoir tank 88 containing a powder 92 having a fluid state. Is a part for carrying out a step of integrally connecting the upper side and the lower side with the molding surface 85 of the mold (molding die) 84 facing downward and the opening surface of the reservoir tank 88 facing upward.
At this time, in order to improve the dispersibility of the powder 92 in the reservoir tank 88 and form a resin film (sheet-like material) 94 having a uniform thickness, air is supplied to the stirring chamber 88a provided below the reservoir tank 88. It is preferable to introduce the powder 92 into a fluid state. FIG. 9 (a) specifically shows the direction of air introduction, and the upper part of the stirring chamber 88a is composed of a perforated member (mesh member) and has a structure in which the powder 92 is wound up by the introduced air. It is preferable.
Further, as shown in FIG. 7C, the powder slash portion is rotated on the molding surface 85 of the mold 84 by rotating the mold 84 including the frame member 82 and the reservoir tank 88 in a connected state. It is also a part for performing the process of forming the resin film 94 having a thickness.
That is, it is preferable that the mold 84 including the frame member 82 and the reservoir tank 88 are combined and inverted in the vertical direction. This is because, when implemented in this manner, the powder 92 in the reservoir tank 88 falls by its own weight onto the molding surface 85 of the molding die 84, and only the powder 92 in contact with the molding surface 85 of the die 84 and the powder 92 in the vicinity thereof. However, this is because the resin film 94 can be instantaneously formed on the molding surface 85 of the mold 84 by adhering in a molten state due to the heat of the mold 84.
Further, when the metal mold 84 including the frame member 82 is reversed, the resin film 94 can be formed only on the desired molding surface 85 of the metal mold 84 so that the resin film 94 can be formed between the metal mold 84 and the reservoir tank 88. It is preferable to provide the frames 84a and 84b having a predetermined thickness (height). Here, the lower portion 84b of the frame is made of, for example, aluminum, and the upper portion 84a of the frame is made of a combination of a silicone rubber / fluororesin film, so that the mold 84 and the reservoir tank 88 are separated. It can also serve to fill the gap.
Further, when the metal mold 84 including the frame member 82 is reversed, the resin film 94 can be formed only on a desired molding surface 85 of the metal mold 84 so that the powder 92 is not scattered except at a predetermined position. As shown in FIG. 9B, it is preferable to suck through the stirring chamber 88a to reduce the pressure in the mold 84. That is, during the powder slush molding by rotating the mold 84, suction is performed to reduce the internal pressure of the mold 84, and before the powder slush molding, air is introduced into the powder 92 of the reservoir tank 88. It is preferable that a pressure adjusting device (not shown) for blowing is provided.
Further, when the mold 84 is reversed, the protrusions 82a provided on the frame member 82 of the mold 84 can be alternately beaten from both sides by one or a plurality of hammering devices as shown in FIG. preferable. This is because when the mold 84 is rotated, the hammer 92 is beaten by the hammering device 100 to apply a predetermined vibration so that the powder 92 uniformly reaches a predetermined portion of the mold 84.
8A, the powder slash portion performs a process of removing the reservoir tank 88 from the mold 84 in a state where the resin film 94 having a predetermined thickness is formed on the mold 84. As shown in FIG. It is a part for.

3. Mold Cooling Unit The mold cooling unit is a process of curing the resin film 94 by cooling the mold 84 including the frame member 82 by cooling means 98 such as water cooling or air cooling as shown in FIG. It is a part for carrying out. Further, as shown in FIG. 8C, the mold cooling unit is also a part for performing a step of peeling the resin film 94 from the mold 84, that is, demolding as a final process of the mold cooling unit. .
Here, in order to effectively prevent the thermal damage of the mold, it is preferable to provide the mold cooling unit with a spray device as shown in FIG. 10 and a shower device as shown in FIG. . That is, as the first cooling stage, it is preferable to spray the water or warm water with a spraying device to cool the mold relatively mildly to about 50 to 100 ° C. Next, as a second cooling stage, a relatively large amount of water or warm water is sprayed by a shower device, and the mold is moved to a temperature at which the resin film 94 can be peeled off using the enthalpy of evaporation, for example, to a temperature below 50 ° C. It is preferable to cool efficiently. The reason for this is to effectively prevent the occurrence of thermal damage and cracking of the mold even when the large and complicated mold is heated unevenly. It is because it can do. In addition, it is also preferable that the shower device and the spray device are connected to one water supply tank and are configured to determine the spray amount and the shower amount by switching a control valve or the like provided at the outlet.

4). Overall Arrangement and Post-heating Step (1) Overall Arrangement As illustrated in FIG. 1, when the powder slush molding device 10 is arranged in a row on the ground, the devices of each process including the heating furnace 28 are arranged from the left side. It is preferable to arrange the powder slash part (A part), the mold heating part (B part), and the mold cooling part (C part) in this order. It is also preferable to provide two mold heating parts and arrange them in the order of the powder slush part, the first mold heating part, the second mold heating part, and the mold cooling part. Furthermore, it is also preferable that a mold standby part, a post-heating part, a mold exchange part, a demolding part, etc. are appropriately provided and incorporated in the powder slush molding machine of the present invention.
In any case, the powder slush molding machine 10 of the present invention arranges each part in a row adjacent to the ground surface, and moves the mold to each part by a mobile robot and a robot arm. Can be implemented efficiently.
(2) Post-heating step It is also preferable to provide a post-heating step and use the mold heating unit described above as the heating unit in the subsequent heating step. In other words, the mold to which the resin film (resin melt layer) obtained in the powder slush molding part is attached can be transported to a position directly above the heating furnace by the robot arm and kept still in a state of being directed downward. preferable. Meanwhile, the opening (sliding door) of the heating furnace 28 is in an open state, and it is preferable to perform post-heating by hot air blowing from the hot air outlet 16 on the bottom surface 18 in the furnace. This is because the resin film is reheated by post-heating in this way, and the thickness can be made uniform by appropriately flowing. Moreover, it is because a powder slush molding machine can be designed compactly as a whole by using a metal mold | die heating part together as a heating part for implementing a post-heating process.

INDUSTRIAL APPLICABILITY According to the powder slush molding machine and the powder slush molding method of the present invention, hot air having a specific flow velocity is blown against the mold, and the mold is removed by devising the arrangement of the energy recovery unit. When heating, for example, it becomes easy to generate a swirl due to a large amount of hot air, and thus thermal efficiency can be greatly improved.
Therefore, even when the mold is enlarged and complicated, the powder can be uniformly applied in a short time.
Further, in the powder slush molding machine and the powder slush molding method of the present invention, an inclined part is provided on the bottom surface of the furnace, a specific hot air control mechanism is provided on the mold heating part, or powder slush molding is being performed. In addition, a specific hammering device is used to strike a specific part, and furthermore, a mold heating unit is used for a post-heating process, thereby causing variations in the thickness of the resin film (actual thickness measurement). The maximum variation (%) from the average value (20 locations) can be easily controlled to a value within 50%, for example.

Claims (10)

A powder slush molding machine including a mold heating unit, a powder slush unit, and a mold cooling unit,
A hot air blowing part for blowing hot air with a flow velocity of 15 m / sec or more to the mold heating part from below the mold, and a corner or a side part on the bottom surface in the furnace of the mold heating part, An energy recovery unit for recovering hot air after heating the mold, and a powder slush molding machine. The powder slush molding machine according to claim 1, wherein the shape of the opening of the energy recovery unit is substantially V-shaped or U-shaped. The energy recovery unit includes a main recovery unit and a sub-recovery unit that communicate with each other. In the main recovery unit, hot air after heating the mold is recovered, and then the hot air is passed through the sub-recovery unit. The powder slush molding machine according to claim 1 or 2, wherein the powder slush molding machine is circulated through a generator / circulator. The inclined portion is provided on the bottom surface in the furnace of the mold heating portion, and the hot air blowing portion is provided in the deepest portion of the bottom surface in the furnace. Powder slush molding machine. The hot air control mechanism for blowing hot air while rectifying the hot air is provided in the mold heating unit, and the hot air control mechanism is a long cast plate and its driving device. The powder slush molding machine as described in any one of 1-4. A plurality of hammering devices for alternately striking the protrusions provided on the frame member of the mold from both sides during the powder slush molding by rotating the mold on the powder slash part The powder slush molding machine according to any one of claims 1 to 5, wherein the powder slush molding machine is provided. During powder slush molding by rotating the mold into the powder slash part, suction is performed to reduce the internal pressure of the mold, and before powder slush molding, air is blown into the powder. A powder slush molding machine according to any one of claims 1 to 6, wherein a pressure adjusting device is provided. The powder slush molding machine according to any one of claims 1 to 7, wherein the mold cooling unit includes a spraying device and a shower device. A powder slush molding method for molding a sheet from powder using a powder slush molding machine including a mold heating unit, a powder slush unit, and a mold cooling unit,
A mold heating unit provided with a hot air blowing unit and an energy recovery unit that is provided along the corner or side of the bottom surface in the furnace of the mold heating unit and collects hot air after heating the mold In this method, hot blast with a flow velocity of 15 m / sec or more is blown from below the mold. After powder slush molding of the sheet-like material in the powder slush portion, the obtained sheet-like material is reheated in the mold heating unit, and in the mold cooling unit, the spray device and the shower device sequentially 10. The powder slush molding method according to claim 9, wherein the mold having the sheet-like material attached thereto is cooled.

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