KR100617857B1 - Powder slush molding device and powder slush molding method - Google Patents

Abstract

Provided are a powder slash molding machine and a powder slash molding method capable of continuously performing a powder slash molding step of a sheet-like product and a surface treatment step, and efficiently producing a sheet-shaped article excellent in adhesion.

Therefore, in the powder slash molding machine provided with a powder slash part, a metal mold | die cooling part, and a surface treatment part, and the powder slash shaping | molding method using the same, it is shape | molded by a powder slash part in a surface treatment part, It is characterized by including the surface treatment apparatus for forming a surface treatment layer on the surface of the sheet-like thing cooled by temperature.

Powder slush molding machine, mold heating part, powder slush part, mold cooling part

Description

Powder slush molding device and powder slush molding method

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a powder slash molding machine and a powder slash molding method. In particular, the powder slash molding process and the surface treatment process can be carried out continuously. The present invention relates to a powder slash molding machine and a powder slash molding method.

Conventionally, a powder slicing method for slicing powders (powder resins) using powder slush having a powder slashing part and a mold cooling part when manufacturing a large-sized, complicated shape sheet-like material such as an automobile interior material. This is widely practiced.

For example, Japanese Patent Application Laid-Open No. 2000-334843 or 2001-219433 discloses a method for producing automotive interior parts from a powder-slash molded skin, an adhesive layer, and a core material. More specifically, the manufacturing method characterized by sticking the said skin with an adhesive agent to the core material which carried out the flame-processing etc. after creating a skin by the powder slash shaping | molding method is disclosed.

However, no method of manufacturing automotive interior parts could directly apply surface treatment to the powder slash molded skin. Therefore, a problem that time and effort are required for surface treatment of the core material, or surface treatment becomes insufficient, is easily peeled off at the interface between the skin and the adhesive.

Accordingly, the inventors of the present invention have conducted a thorough investigation and, as a result of performing surface treatment immediately on the surface of the sheet-like article immediately after powder slash molding, subsequent primer processing or the like can be eliminated or reduced as much as possible. It was found that this easy sheet-like article can be provided efficiently.

That is, an object of the present invention is to provide a powder slash molding machine and a powder slash molding method capable of continuously performing a powder slash molding process and a surface treatment process of a sheet-like product and efficiently producing a sheet-like article having excellent adhesion. Doing.

Disclosure of the Invention

[1] According to the present invention, there is provided a powder slash molding machine having a powder slash unit, a mold cooling unit, and a surface treatment unit, wherein the sheet is molded in the powder slash unit and cooled in the mold cooling unit. A powder slush molding machine having a surface treatment apparatus for forming a surface treatment layer on the surface of a shaped article is provided, which can solve the above-mentioned problems.

That is, by constructing the powder slush molding machine in this way, since the surface treatment part enters inside, the powder slush molding process and the surface treatment process can be performed continuously, and between the powder slush molding machine and the surface treatment apparatus This eliminates the need for transportation equipment and can provide a compact powder slash molding machine as a whole.

In addition, immediately after powder slash molding, the sheet-like article can be surface-treated quickly and uniformly, so that subsequent primer processing and the like are unnecessary, and the powder slab which can efficiently manufacture a sheet-like article which is easily adhered to, etc. A shee molding machine can be provided.

In addition, when a predetermined mold change part is provided, the mold change can be performed while the powder slash molding machine is in operation, so that the powder slash molding machine can be provided more efficiently and at a lower cost.

[2] Another aspect of the present invention is a powder slash molding method using a powder slash molding machine having a powder slash portion, a mold cooling portion, and a surface treatment portion, wherein a sheet-like article is molded in the powder slash portion. And a step of cooling the sheet-like article in the mold cooling section, and a step of forming a surface treatment layer on the surface of the sheet-like article cooled in the surface treatment section.

That is, by performing a powder slash part shaping | molding method in this way, it can surface-treat quickly and uniformly with respect to a sheet-like thing immediately after powder slash part shaping | molding. Therefore, the powder slash molding method which can manufacture efficiently the sheet-like thing which does not need subsequent primer processing etc. and is easy for adhesive processing etc. can be provided. In addition, since the powder slash molding step and the surface treatment step of the sheet-like article can be carried out continuously, a compact and inexpensive powder slash molding method can be provided as a whole.

BRIEF DESCRIPTION OF THE DRAWINGS It is a side view provided in order to demonstrate the powder slash molding machine of this invention.

2 is a plan view provided to explain the powder slush molding machine of the present invention.

It is a figure provided in order to demonstrate a metal mold | die heating part.

It is a figure provided in order to demonstrate the relationship with a hot air blowing part and an energy recovery part in the bottom surface of the heating furnace in a metal mold | die heating part.

It is a figure provided in order to demonstrate the lateral hot air blowing part of a metal mold | die heating part.

It is a figure provided in order to demonstrate arrangement | positioning of the shaping | molding surface in a metal mold | die.

It is a figure provided in order to demonstrate the powder slash shaping | molding method of this invention (first).

It is a figure provided in order to demonstrate the powder slash shaping | molding method of this invention (second).

It is a figure provided in order to demonstrate the function of the pressure adjusting device at the time of powder slash shaping.

It is a figure provided in order to demonstrate a metal mold | die cooling part.

11 is a perspective view showing an example of a sheet-like article (first).

12 is a perspective view illustrating an example of a sheet-like article (second).

It is a figure provided in order to demonstrate the lamination | stacking method of the decorative member at the time of creating a three-dimensional decoration (first).

It is a figure provided in order to demonstrate the lamination | stacking method of the decorative member at the time of creating a three-dimensional decoration (2nd).

Best mode for carrying out the invention

EMBODIMENT OF THE INVENTION Hereinafter, with reference to drawings, the highly suitable embodiment regarding the powder slash molding machine and powder slash shaping | molding method of this invention is demonstrated concretely.

[First Embodiment]

As illustrated in FIGS. 1 and 2, the first embodiment includes a powder slab having a powder slash part (part A), a mold heating part (B part), a mold cooling part (C part), and a surface treatment part (D part). Shear molding machine (10). Then, the powder slash molding machine 10 is provided with a surface treatment apparatus 68 for forming a surface treatment layer on the surface of the sheet-like object cooled at the same time as being molded at the powder slash portion in the surface treatment portion. to be.

In addition, FIG. 1 has shown the side view of the powder slush molding machine, and FIG. 2 has shown the top view which looked at the powder slush molding machine from the top, respectively.

Hereinafter, the suitable example of the powder slash molding machine 10 is demonstrated concretely.

1. Mold heating part

(1) hot air blower

The structure of the hot air blowing unit for directly heating the mold in the mold heating unit is not particularly limited, but is, for example, hot air obtained by a hot air generating device (not shown), as shown in FIG. It is preferable that the configuration is supplied to the hot air blower outlet 16 through the main pipe 43 by an air supply fan 46 provided below or below the hot air blower outlet 16. That is, in the mixing chamber 44, the hot wind obtained from the hot wind generating device and the hot air recovered from the inside of the heating furnace through the energy recovery unit 24 and transferred to the mixing chamber 44 by the air circulation fan 42 in the mixing chamber 44. After mixing suitably, it is preferable that it is the structure which supplies to the hot air blower outlet 16 through the main piping 43 as a large amount of hot air which has a predetermined wind speed by the air supply fan 46. FIG.

The reason for this is that when the hot air 14 flows along the inner surface of the metal mold 12 with respect to the heating mode of the metal mold 12 of the heating furnace 28, the heat of the hot air 14 is This is because heat is transferred to the mold 12. That is, since heat is mainly transmitted in the heat transfer mode, the heat supplied into the heating furnace 28 is less dissipated out of the heating furnace 28. Therefore, even if the heating furnace 28 and the hot wind generation circulation apparatus 40 are small, compared with the conventional large heating furnace, it will have more than equivalent productivity. In addition, by mixing the hot air from the hot air generating device (not shown) supplied through the hot air blower outlet 16 with the hot air recovered from the inside of the heating furnace through the energy recovery unit 24, the amount of air flows to increase. Since the furnace 28 etc. are pressurized, the heating effect to the metal mold | die 12 will increase. Furthermore, since the energy recovery part 24 is installed in the circumference | surroundings or lower part of the heating furnace 28, and since it is in a reduced pressure state compared with the heating furnace 28 in relation to the quantity of air, the hot air after heating the metal mold | die 12 Can be recovered more effectively.

In addition, it is preferable to install the hot air storage chamber 39 in the middle of the main pipe 43, and to install a baffle plate 49 in the outlet portion of the main pipe 43 in the hot air storage chamber 39.

The reason for this is that by configuring in this way, the hot air conveyed by the air supply fan 46 can be dispersed by the baffle plate 49, even if a plurality of hot air blower outlets 16 are provided. This is because the hot air can be blown uniformly from the hot air blower outlet.

In addition, the shape of the opening part in the hot-air blowing part is round, elliptical, and square (including a square, a rectangle, a strip | belt shape, etc.) so that the hot air which has predetermined wind speed may be blown in a controlled state, It is preferable to have a structure having a polygon or other shape.

Also, the number of hot air jets is preferably set to one or more numbers as shown in Figs. 3A and 3B. For example, as shown in Fig. 3 (a), even when the number of hot air blower outlets 16 is substantially one, even if the mold is relatively large, the energy recovery unit 24 is appropriately provided. Can be heated. In addition, as shown in FIG. 3 (b), the number of hot air jet openings 16 is substantially two or more, even if a plurality of metal molds are simultaneously heated at different heating conditions. have.

(2) energy recovery

It is preferable to provide an energy recovery section for recovering hot air (heat energy) having a large amount of energy and still having a large amount of energy after heating the mold. That is, as shown in FIG. 3 (a), it is preferable to excrete such energy recovery part 24 using the bottom surface 18 of the heating furnace 28 or the periphery of the heating furnace 28. Do.

Here, the structure itself of the energy recovery unit 24 is not particularly limited, but for example, as shown in Fig. 3 (a), it has an opening to the bottom surface 18 of the heating furnace 28 in the heating furnace. At the same time, it is preferable to have a duct structure having branch pipes 47 connected to the hot air generating circulation device 40. And as mentioned above, it is preferable to arrange the damper 47a in the middle of the branch piping 47 which follows the energy recovery part 24. As shown in FIG.

Moreover, the energy recovery part 24 arrange | positioned at the heating furnace bottom surface 18 of the heating furnace 28 has the bottom surface 18 in a heating furnace, as the opening part is shown to FIG. 4 (a) and (b). It is preferable to be provided along the corner part or edge part of ().

The reason for this is that the flow of hot air 14 moving from the hot air jetting port 16 toward the energy recovery unit 24 along the inner surface of the metal mold 12 becomes easy, so that the residence time This is further longer, and as a result, the hot air 14 can be effectively heated in the heat transfer mode to every corner of the mold 12. In addition, 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 rate velocity.

In addition, it is preferable to make the shape of the opening part of an energy recovery part into substantially V shape or C shape as shown in FIG.4 (b).

The reason for this is that the hot air 14 blowing from the hot air jetting port 16 moves easily and quickly toward the energy recovery portion 24 having such a predetermined shape, and a moderate flow of hot air is generated between the molds 12. It is because it can heat effectively.

In addition, regarding the shape of the opening part of the energy recovery part 24, although it is also possible to combine shapes, as shown to FIG. 4 (a) and FIG. 4 (b), even if it is, the flow of a suitable hot air is further increased. It is preferable to construct easily to produce easily. For example, as shown in Fig. 4A, the upper portion of the rectangular energy recovery unit (sub recovery unit) 24 is substantially covered with a predetermined space, and is shown in Fig. 4B. As shown in FIG. 4 (a), after the heat energy is recovered through the V-shaped or U-shaped energy recovery unit (circular recovery unit), the rectangular energy recovery unit (sub-recovery unit) 24 shown in FIG. It is more preferable to recover thermal energy finally.

(3) heating furnace

① Basic structure

The heating furnace 28 is arrange | positioned above the hot air generation circulation apparatus 40, as shown in FIG.3 (a), and it is preferable that it is comprised by one compact heating apparatus as a whole. In this way, the supply of the thermal energy to the heating furnace 28 becomes easy, and the energy recovery part 24 can also be used for the recovery of the thermal energy from the heating furnace 28 easily.

Moreover, the heating furnace main body contained in the heating furnace 28 is formed in the flat rectangular box-shaped body which has an opening part which can be opened and closed on an upper surface, for example, and the metal mold | die 12 is opened with the opening part of an upper surface open. And after bringing the frame member 13 into the heating furnace, the opening is closed, and the hot air 14 is blown by the hot wind generating circulation device 40 to heat the mold 12. It is preferable.

In addition, it is possible to change suitably as a form of the furnace main body contained in the furnace 28. For example, it is also preferable to make a heating furnace main body correspond to the shape of a metal mold, and to make cylindrical shape, a cube, or another shape.

② Side hot air blower

In addition, the heating furnace 28 is comprised by branching to the exit part of the main piping 43, as shown in FIG. 3 and FIG. 5, and has a predetermined | prescribed height, and the metal mold | die 12 in the heating furnace 28 is moved from a lateral direction. It is preferable to provide the duct structure extended in the vertical direction, that is, the side hot air outlet 50 so that it can be heated also.

Moreover, it is preferable that such a side hot air blower outlet 50 is arrange | positioned along the inside of the heating furnace 28, and also it is the branch pipe 41 and main pipe 43 which are connected to the hot air generating circulation apparatus 40. It is preferable to adjust the quantity of air by the damper 48 or the like.

The reason for this is that the mold 12 can be heated by blowing hot air not only in the downward direction but also in the transverse direction, and thus the mold 12 can be heated more effectively. .

In addition, although it is preferable to change the shape of the side hot air blower (duct) 50 according to the shape of a metal mold | die, for example, it is made into snorkel shape, and the side hot air blower 50 and the metal mold | die 12 are the same. Since the distance can be easily controlled in a certain range and the direction of the hot air blower is constant, the heating efficiency for the mold 12 can be further increased, which is a preferable structure.

(4) mold

① Composition

As shown in FIG. 3 (a), the mold 12 is disposed on the tongue bottom surface 18 in the heating furnace 28 with the frame member 13 for movement and manipulation of the mold 12 attached thereto. It is preferable to put on the metal mold | die support member (not shown).

In addition, as shown to Fig.10 (a) and (b), the metal mold | die is the part which becomes the joint of the frame member 13 and the shaping | molding surface 85 of the metal mold 84, for example, a seal material. It is preferable to be waterproofed by (87). This is because it is comprised in this way and it can prevent excessive moisture from adhering to the surface of a sheet-like thing in a metal mold | die cooling process. Therefore, in a surface treatment process, formation of the surface treatment layer by a silicic acid flame treatment becomes easy, for example.

In addition, such a mold 84 moves the frame member 13 in a robot arm (not shown), or moves it in a suspended state. For example, the mold 84 is located in the mold heating unit, and the frame member 13 is moved by the robot arm. It is preferable that it is a structure which can move to the upper surface part, and can carry in in the heating furnace 28 from the opening part provided in the surface part there. It is because such a structure makes it easy to convey a metal mold | die, and also arrange | positions each component part in a powder slash molding machine.

Moreover, it is preferable that the metal mold | die support member covers the surface by the heat insulating material (not shown) which has a sealing effect, for example, a combination of silicone rubber / fluorine resin film. This is because the gap between the mold 84 and the bottom surface 18 of the heating furnace can be effectively filled by the mold supporting member to prevent hot air from running out. Furthermore, such a mold support member includes the positioning of the mold 12 accommodated in the heating furnace for heating and the hot air 14 from the hot air blower outlet 16 of the bottom surface 18 of the heating furnace. It is preferable to have the function of adjusting the height from the hot air blower outlet 16 so that it may fit to the inner surface of the inside efficiently.

② Molding surface

Although the metal mold | die 12 may be isolate | separated independently as shown to FIG. 3 (b), it is preferable to have substantially two or more shaping | molding surfaces 83 and 85 of a sheet-like thing.

This is because, according to such a mold, two or more sheet-like objects can be molded at the same time with one mold.

Here, two or more molding surfaces are provided or one molding surface is heated, but when heating a plurality of molds, as shown in Figs. 6 (a) and 6 (b), the rotation axis direction X of the metal mold 12 is shown. In addition, it is preferable to arrange | position each shaping | molding surface 83 and 85 apart, and to provide a channel | path (not shown) so that powder may easily come and go.

The reason for this is that, when the mold 12 is rotated in the powder slash process, powder easily enters each of the molding surfaces, and thus a sheet-like article having a uniform thickness can be easily obtained. to be.

2. Powder Slash Part

(1) basic composition

As shown in FIG. 7 (b), the powder slash portion reserves a reservoir containing a mold 84 including the frame member 82 heated in FIG. 7 (a) and a powder 92 having a flow shape. To carry out the process of connecting the tank 88 up and down integrally with the molding surface 85 of the mold 84 facing downward, and the opening surface of the reservoir tank 88 facing upward. It is a site for.

Therefore, in order to improve the dispersibility of the powder 92 in the reserve tank 88, and to form the resin film (sheet-shaped object) 94 of uniform thickness, the stirring chamber provided below the reservoir tank 88 ( 88a) It is preferable to introduce air and bring the powder 92 into the flow state. Although the introduction direction of air is shown to FIG. 9 (a) concretely, the upper part of the stirring chamber 88a is comprised by the perforated member (mesh member), and the powder 92 is wound up by the introduced air. It is preferable that it is a structure.

(2) square frame

Moreover, when rotating the metal mold | die 84 containing the frame member 82 reversely, the metal mold | die 84 and the reservoir tank (so that a resin film may be formed only in the shaping | molding surface 85 made into the objective of the metal mold 84) It is preferable to provide the square frames 84a and 84b having a predetermined thickness (height) between the 88 and the substrate. Here, the lower portion 84b of the rectangular frame is made of aluminum, for example, and the upper portion 84a of the rectangular frame is made of a combination of a silicone rubber / fluorine resin film, whereby the mold 84 and the reserve tank 88 are formed. It can play a role in filling the gap between and.

3. Mold Cooling Part

(1) composition

As shown in FIG. 8B, the mold cooling unit cools the mold 84 including the frame member 82 by a cooling device 98 such as water cooling or air cooling to cool the resin film 94. It is a part for curing to a predetermined degree.

Therefore, as shown in FIG.10 (a), it is preferable to equip the metal mold | die cooling part with the shower device 98 as shown in FIG.10 (a) and FIG.8 (b). The reason for this is that, by configuring in this way, occurrence of thermal damage or cracking of the mold can be effectively prevented.

In addition, the shower device and the spray device are connected to one water supply tank, and it is also preferable to determine the spray amount and the shower amount by converters such as control valves provided in the jet port.

(2) temperature

It is preferable to cool a sheet-like thing and to make the surface temperature of the said sheet-like thing into the value within the range of 30-100 degreeC.

The reason for this is that when the surface temperature of such a sheet-like article is less than 30 ° C, it is difficult to adjust the lower limit temperature in the surface treatment section, which is the next step. This is because the formation may be difficult. On the other hand, when the surface temperature of such a sheet-like thing exceeds 100 degreeC, rigidity of the sheet-like thing in a surface treatment part which is a next process will become inadequate, and on the contrary, formation of a surface treatment layer may become difficult.

Therefore, it is more preferable to make the surface temperature at the time of cooling a sheet-like thing in a metal mold | die cooling part into the value within the range of 35-80 degreeC, and it is still more preferable to set it as the value within the range which is 40-60 degreeC.

In addition, the surface temperature of the sheet-like thing in a metal mold | die cooling part is the surface temperature of the sheet-like thing measured using a surface thermometer etc. immediately after cooling process.

4. Mold Exchange

(1) composition

It is preferable that the powder slash part molding machine of this invention further has a metal mold | die exchange part. That is, a mold change part may be used to change a mold for forming a sheet-like material having a different type during the powder slash part molding, or a mold damage may occur during the powder slash part molding. This is because the mold can be changed while the sheet forming machine is operated.

Thus, as shown in Figs. 1 and 2, at least two or more supports 66, 66a, 66b for installing the mold 60 are provided, and the respective supports 66, 66a are provided. It is preferable that 66b is movable by external control.

Here, with reference to FIG. 2, the structure which replaces with the new metal mold | die 60f on the assumption that the one metal mold | die 60d is damaged among the some metal mold | die 60b, 60c, 60d is demonstrated concretely.

For example, the 1st metal mold | die 60c is put in the powder slush part process in the powder slash part A part, and the 2nd metal mold 60c is put in the heating process in the metal mold | die heating part B part. And it is said that the 3rd metal mold | die 60d is put in the cooling process in the metal mold | die cooling part (C part). And when a crack is found in 60 d of 3rd metal mold | die of a metal mold | die cooling part (C part), the 3rd metal mold | die 60d is a surface treatment part (D part) normally after a metal mold cooling part (C part). Instead of being surface-treated at), it is stopped at a predetermined position of the mold exchange part (E part) in common with the surface treatment part (D part), and is lowered on the first support base 66a. Then, the damaged third mold 60d on the first support base 66a is moved laterally toward one end of the exchange table 69 including the roller, while the 60 f of new metal mold | die on the 2nd support stand 66b previously installed in one end is moved to a reverse transverse direction, and it is installed in the position of metal mold | die exchange part E part.

In this way, the mold 60d which is damaged can be replaced by the new mold 60f in the mold exchange part E part, but the tact time is the surface treatment time or the powder slash molding time or the mold. By shortening the heating time there is less impact on other processes.

(2) placement

It is preferable to arrange | position a metal mold | die exchange part so that it may become the next process of a metal mold | die cooling part.

This is because, in this configuration, since the mold is replaced at the stage where the mold is cooled, it is not necessary to heat the newly used mold in advance or immediately after the replacement, and thus can be transferred to the next step more smoothly. to be. In addition, it is because the work after replacement can also be made safe if it is a mold of a cooled state.

4. Surface Treatment

(1) surface treatment device

Although the kind of surface treatment apparatus is not specifically limited, For example, as shown below, applying at least one surface treatment of ozone treatment, plasma treatment, corona treatment, high pressure discharge treatment, ultraviolet treatment, and silicate treatment. It is preferable that it is a surface treatment apparatus for.

This is because such a surface treatment apparatus has a relatively small size of the surface treatment apparatus and the treatment portion, so that even a conventional powder slush molding machine can be inserted relatively easily. This is because, in such a surface treatment apparatus, the sheet-like article is cooled to a predetermined temperature and thus surface treatment in a shorter time is possible.

Moreover, it is more preferable that it is a surface treatment apparatus for adding a silicate salt treatment among such surface treatment apparatuses. The reason for this is that if the silicate treatment is used, the effect of the surface modification layer is less likely to be extinguished by external moisture or dust. Because it can.

① Ozone treatment

The ozone treatment is a surface treatment in which the surface is oxidized by irradiating ozone substance (O ₃ ) to the surface of the sheet-like article to form a surface modification layer.

② Plasma treatment

The plasma treatment is performed by irradiating the surface of the sheet-like material with plasma materials (excited materials, radical materials, ionic materials, etc.) generated by plasma discharge and etching the surfaces. It is the surface treatment which forms a layer.

③ Corona treatment

Corona treatment is surface treatment which forms a surface modification layer, performing a corona discharge process on the surface of a sheet-like thing, and generating a polar group etc.

④ high pressure discharge treatment

The high pressure discharge treatment is a surface treatment for forming a surface modification layer by repeatedly performing high pressure discharge on a surface of a sheet-like article and insulating and destroying a part of the surface.

⑤UV treatment

Ultraviolet treatment is surface treatment which forms a surface modification layer, irradiating a predetermined amount of ultraviolet-ray of a predetermined wavelength with respect to the surface of a sheet-like thing, and activating a part of surface.

⑥ Silicate treatment

The silicate treatment is a surface treatment in which a flame of a fuel gas containing a silane compound is blown all or partly to the surface of a sheet-like object to form a silica layer from a flame decomposition product of the silane compound.

Here, it is preferable that the boiling point (under atmospheric pressure) of a silane compound is called the value within the range of 10-100 degreeC, It is more preferable to call it the value within the range of 15-80 degreeC, It is a value within the range of 20-60 degreeC More preferably. This reason is because when the boiling point of such a silane compound is less than 10 degreeC, volatility may be violent and handling may become difficult. On the other hand, when the boiling point of such a silane compound exceeds 100 degreeC, the mixing property with flammable gases, such as air, and a flame retardant will remarkably fall, and an silane compound will be incompletely burned easily, and the surface modification effect will become nonuniform or for a long time It is because it may become difficult to maintain a modification effect over time.

Moreover, although it does not restrict | limit especially about the kind of silane compound, For example, an alkyl silane compound, an alkoxy silane compound, or its modified substance is mentioned. In addition, among these compounds, alkylsilane compounds generally have a low boiling point, and are preferably preferred silane compounds because they can be easily vaporized by heating and uniformly mixed with air or the like.

More specifically, tetramethyl silane and tetraethyl silane are particularly preferable silane compounds because they have a low boiling point and are easily mixed with air and the like, and halogenated silane compounds such as 1 and 2-dichlorotetramethyl silane are Since the surface modification effect is especially excellent, it is a preferable silane compound.

Moreover, when the addition amount of the silane compound in fuel gas is 100 mol% when the total amount of combustion gas is called, it is preferable to call it the value in the range of 1 * 10 <^{-10> -10} mol%, and it is 1 * 10 <^-9>. It is more preferable that it is a value in the range of -5 mol%, and it is still more preferable that it is a value in the range of 1 * 10 <^-8> -1 mol%.

This reason is because when the addition amount of such a silane compound becomes a value less than 1x10 <^-10> mol%, a modification effect may not express. On the other hand, when the addition amount of such a silane compound exceeds 10 mol%, the mixing property of a silane compound, air, etc. will fall, and a silane compound may incompletely burn accordingly.

In addition, since the control of the flame temperature is facilitated in carrying out the silicate treatment, it is usually preferable to add a flammable gas to the combustion gas. As such flammable gas, propane gas, natural gas, oxygen, air, hydrogen, etc. are mentioned. In addition, when using combustion gas in an aerosol can, it is preferable to use propane gas, compressed air, etc. as such flammable gas.

Moreover, when content of such flammable gas is 100 mol%, it is preferable that it is a value in the range of 80-99.9 mol%, and it is more preferable that it is a value in the range of 85-99 mol%. It is preferable to call it a value within the range of 90-99 mol%. This is because when the content of such flammable gas is less than 80 mol%, the mixing property between the silane compound and air is lowered, and the silane compound may be incompletely burned accordingly. On the other hand, when the addition amount of such a silane compound exceeds 99.9 mol%, it is because the modifying effect may not express.

(2) placement

It is preferable to arrange | position the surface treatment part so that it may become the next process of a metal mold | die cooling part so that the surface of a sheet-like thing may be processed correctly.

This is because, when the surface treatment part becomes a step before the mold cooling part, the surface of the sheet-like object may not be cured to a predetermined degree, and surface treatment effects such as silicate treatment may not be expressed.

In addition, the surface treatment unit and the mold exchange unit. That is, as shown in FIG. 1, it is preferable to provide the surface treatment apparatus 68 in the lower part of the support stand 66 in a metal mold | die exchange part.

The reason for this is that the mold 60 cooled by the mold cooling unit of the mold exchange unit is once installed on the support 66, so that the surface treatment is performed on the sheet-shaped object using this state, and at the same time, space saving can be achieved. It is because the sheet-like thing excellent in adhesiveness can be obtained more efficiently.

5. Sheet Shape

(1) form

As for the form of the sheet-like article, the constituent material is not particularly limited, and for example, from at least one resin of epoxy resin, vinyl chloride resin, acrylic resin, olefin resin, urethane resin, polycarbonate resin, or polyester resin. It is preferable that it is comprised.

The reason for this is that a sheet-like article having high versatility, low cost, and excellent decorativeness can be used in this manner.

Moreover, it is preferable to make the thickness of a sheet-like thing into the value within the range of 10-500 micrometers. This is because, when the thickness of such a sheet-like article is less than 10 µm, the mechanical strength and durability of the sheet-like article may be significantly reduced. On the other hand, when the thickness of such a sheet-like thing exceeds 500 micrometers, handling and adhesion | attachment may become difficult. Therefore, it is more preferable to make the thickness of a sheet-like thing into the value within 25-300 micrometers range.

Moreover, although the form of a sheet-like thing is a flat film, since adhesiveness and handling are easy, it is preferable, but since it is more decorative, it is also preferable that an embossing process and an opening part (including a slit) are provided in the surface. Moreover, it is also preferable that predetermined | prescribed printing and coloring exist in the surface and inside of a sheet-like thing. In addition, it is preferable that a sheet-like thing has an external shape suitable for an automotive component, as shown to FIG. 11 (a)-(c) and FIG. 12 (a)-(b).

(2) surface treatment layer

In addition, although the surface treatment layer formed on a sheet-like thing changes with kinds of surface treatment, a silica layer corresponds, for example when performing a silicate salt treatment.

In addition, the thickness of a surface treatment layer is not specifically limited, For example, it is preferable to set it as the value within the range of 0.01-100 micrometers. This is because when the thickness of such a surface treatment layer is less than 0.01 µm, the surface treatment effect may not be expressed or may be scattered. On the other hand, when the thickness of such a surface treatment layer exceeds 100 micrometers, the thickness of a sheet-like thing may become excessively thick or it may become easy to peel from the surface of a sheet-like thing.

Therefore, it is more preferable to make the thickness of the surface treatment layer formed on a sheet-like thing into the value within the range of 0.05-20 micrometers, and it is still more preferable to set it as the value within the range which is 0.1-5 micrometers.

In addition, the surface treatment layer formed on a sheet-like thing does not necessarily need to be a continuous layer, and may be a discontinuous layer or a spot form.

Second Embodiment

As shown to FIG. 7 (a)-(c) and FIG. 8 (a)-(c), 2nd Embodiment uses the powder slash molding machine provided with the powder slash part, the metal mold | die cooling part, and the surface treatment part. It is a powder slash shaping | molding method, The powder slash shaping | molding method containing the following processes (1)-(3).

(1) A step of molding the sheet-like object 94 in the powder slash portion (hereinafter, may be referred to as a powder slash process).

(2) The process of cooling the sheet-like object 94 in a metal mold | die cooling part (henceforth a mold cooling process may be called.)

(3) The step of forming the surface treatment layer 53 on the surface of the sheet-shaped object 94 that is not in contact with the mold in the state where the cooled sheet-like object 94 is held in the mold (hereinafter, referred to as a surface treatment part). May be called a surface treatment process.)

1. Powder Slash Process

When performing a powder slash process, as shown in FIG.7 (c), it rotates in the state which connected the metal mold | die 84 containing the frame member 82, and the reservoir tank 88, and shaping | molding the metal mold 84. It is preferable to form the resin film 94 of a predetermined thickness on the surface 85.

That is, it is preferable to reverse the mold 84 including the frame member 82 and the reservoir tank 88 in the combined state in the vertical direction. The reason for this is that, in this way, the powder 92 in the reserve tank 88 falls to the molding surface 85 of the mold 84 by its own weight and is in contact with the molding surface 85 of the mold 84. Only the powder 92 and the powder 92 in the vicinity thereof are adhered in the dissolved state by the heat of the mold 84, so that the resin film 94 can be formed on the molding surface 85 of the mold 84 in one instant. Because there is a number.

In addition, when the die 84 including the frame member 82 is rotated halfway, only the molding surface 85 for the purpose of the die 84, so that the powder 92 does not scatter outside the predetermined place, As shown in FIG. 9 (b), the resin film 94 is preferably sucked through the stirring chamber 88a to lower the pressure in the mold 84. That is, in order to lower the internal pressure of the mold 84, the air is sucked into the powder 92 of the reservoir tank 88 before the powder slash molding. It is preferable that a pressure regulator (not shown) for blowing is provided.

In addition, as shown in Fig. 3B, it is preferable to perform powder slash molding using a mold having a plurality of molding surfaces 83 and 85. This is because, in this way, a plurality of sheet-like articles can be formed at the same time in one step, and a sheet-like article excellent in adhesiveness can be obtained more efficiently.

2. mold cooling process

When performing a die cooling process, it can also be set as a single cooling process, or it can also be set as a multistage cooling process.

For example, in the case of a single cooling process, as shown in FIG. 10 (a), the spray device 121 sprays water or hot water, and the mold 84 is relatively unstimulated to about 100 ° C. It is desirable to cool.

The reason for this is as described above. Even if the mold is enlarged and complicated, even if the mold is heated unevenly, the mold can be cooled without relatively irritating and the occurrence of thermal damage or cracking of the mold can be effectively prevented. Because.

On the other hand, in the case of the two-stage cooling step, as shown in FIG. 10 (a) as the first cooling step, the spray device 121 sprays water or hot water, and the mold 84 is relatively lightly heated to about 150 ° C. ) Is preferably cooled. Next, as shown in FIG. 8 (b), as the second cooling step, the shower film 98 allows the resin film 94 to peel off using a relatively large amount of water or hot water, using evaporation enthalpy. It is preferable to efficiently cool a metal mold | die to the temperature of about 100 degreeC, for example.

This is because by performing in this way, it is possible to effectively prevent the occurrence of thermal damage or cracking of the mold and to shorten the time required for cooling.

3. Surface treatment process

(1) interaction

When performing a surface treatment process, as shown to FIG. 1 and 2, the metal mold | die exchange part (E part) and the surface treatment part (D part) are integrally provided, and the metal mold | die exchange apparatus (shown in this mold exchange part) is shown. And the surface treatment apparatus 68 mutually operate in an externally controlled state, respectively.

That is, it is preferable to save space by integrating a mold exchange part and a surface treatment part, and mutually operating the metal mold | die exchange apparatus (not shown) and the surface treatment apparatus 68 including the support base 66 installed there. In addition, the microcomputer or the like controls the operations of the mold exchanger (not shown) including the support 66 and the surface treatment apparatus 68 from the outside, even in a narrow space, the mold exchange process and the surface treatment process. It is desirable to carry out mold replacement and surface treatment continuously or sparsely, and in part repeatedly.

Therefore, the mold replacement can be performed smoothly with the powder slash molding machine running, while the surface treatment process can be performed using the state where the mold is once installed on the support.

(2) surface treatment conditions

① Processing direction

It is preferable to surface-treat from the lower surface with the surface treatment apparatus 68 of the surface treatment part, maintaining the sheet-like thing cooled in the metal mold | die cooling part substantially in a horizontal state, as shown to FIG. 8 (c). .

The reason for this is that by surface treatment in this way, even if the sheet-like article is in an excessively moist state, it is possible to easily form a surface treatment layer such as silica over the entire sheet-like article by, for example, silicate salt treatment. Because there is a number.

Moreover, by surface treatment in this way, even if a recess etc. are formed in the inside of a metal mold | die, the surface treatment layer, such as a silica, is made along the internal shape of a metal mold | die by the silicate salt treatment, for example, It is because it can form easily.

② flame temperature

Moreover, when performing a silicate salt treatment as surface treatment, it is preferable to make the flame temperature into the value within the range of 500-1500 degreeC.

This reason is because when such flame temperature becomes a value below 500 degreeC, it may become difficult to effectively prevent incomplete combustion of a silane compound. On the other hand, when the temperature of such a flame exceeds 1500 degreeC, it is because a sheet-like thing may thermally deform or thermally deteriorate.

Therefore, it is preferable to make such flame temperature into the value within the range of 550-1200 degreeC, and it is more preferable to set it as the value within the range which is less than 600-900 degreeC.

③ Processing time

Moreover, when performing a silicate salt treatment as surface treatment, it is preferable to make the processing time (injection time) of the flame per unit area (1 m <^2> ) into the value within the range of 0.1 second-100 second.

This reason is because when the treatment time of a flame reaches a value of less than 0.1 second, the modification effect by a silane compound may not be expressed uniformly. On the other hand, when the processing time of a flame exceeds 100 second, a sheet-like thing may thermally deform or thermally deteriorate.

Therefore, it is preferable to make the processing time of a flame into the value within the range of 0.3-30 second, and it is more preferable to set it as the value within the range of 0.5-20 second.

4. Other

(1) leaving process

After performing the powder slash molding method, it is preferable that the surface-treated sheet-like object is detached from the mold.

However, it is also preferable to remove from a metal mold | die in the step conveyed to the next process, without leaving on the spot.

(2) lamination process

Moreover, it is preferable to laminate | stack the obtained sheet-like thing and base material after performing powder slash shaping | molding or as a part. For example, as illustrated in FIG. 13, it is preferable to stack the surface-treated sheet-like object 54 on the substrate 58 through the intermediate layer 56. In addition, as the intermediate layer 56, it is preferable to provide a foam layer, for example.

However, since the process can be simplified and speeded up, as shown in Fig. 14, the foamed material 56 ', which is a raw material of the intermediate layer 56, is combined on the substrate 58, and then the surface-treated sheet-like material 54 is further layered. Furthermore, it is also preferable to carry out the adhesive fixation of the sheet | seat 54 and the formation of the intermediate | middle layer 56 simultaneously by heating or irradiating an ultraviolet-ray in the state laminated | stacked on it.

Example 1

1. Creation of Sheet Shape

Using a powder slash molding machine as shown in FIG. 1, a three-dimensional sheet-like article as shown in FIG. 11 (a) was powder-slash molded with B-stage epoxy resin powder.

Next, after shower-cooling the surface temperature of a sheet-like object to 100 degreeC in the metal mold | die cooling part, further, the surface treatment part processed the silicate salt on condition of the following, and formed the silica layer on the surface of the sheet-like object. .

Fuel gas value: Propane gas

Silane Compound: Each 50 mol% mixture of tetramethylsilane / tetraethylsilane

Flame temperature: 1,000 ° C (flame tip)

Flame Treatment Time: 5 seconds / m ²

Surface temperature: 45 ℃

2. Preparation of three-dimensional decoration and evaluation of adhesion

(1) create

On the base material made of propylene resin, the foamed urethane material was used, and the three-dimensional sheet-like thing was heated in the state laminated | stacked, and the three-dimensional decoration as an interior material for automobiles was created.

(2) adhesive evaluation

The three-dimensional decorative body was peeled and destroyed, the peeling state was observed, and the adhesiveness was evaluated based on the following criteria.

(Double-circle): 95% or more of peeling area is the cohesive failure of foamable urethane material.

(Circle): 70% or more of peeling area is a cohesive failure of a foamable urethane material, but it is partly an interface peeling.

(Triangle | delta): Although 50% or more of peeling area is cohesive failure of a foamable urethane material, it is a part and interface peeling.

X: 50% or more of the peeling area is interfacial peeling.

Example 2

In Example 1, the sheet-like object was created like Example 1 except having performed the normal flame treatment (it does not contain a silane compound) instead of the silicate treatment, and a three-dimensional decoration body is created using it. In addition, adhesiveness was evaluated.

Example 3

In Example 1, the sheet-like object was created like Example 1 except having corona-treated instead of the silicate treatment, the three-dimensional decoration was created using it, and adhesiveness was evaluated.

Comparative Example 1

In Example 1, the sheet-like object was created like Example 1 except not having performed the silicate salt process, the three-dimensional decoration was created using it, and adhesiveness was evaluated.

Surface treatment Surface temperature (℃) Adhesive Example 1 Silicate treatment 45 ◎ Example 2 Flame treatment 45 △ Example 3 Corona treatment 45 △ Comparative Example 4 none － ×

According to the powder slush molding machine and the powder slush molding method of the present invention, the powder slash molding process and the surface treatment process can be performed continuously in the form of a powder slush, so that the powder slash molding machine can Immediately after the shaping, it was possible to perform the surface treatment. Therefore, since the surface treatment layer is effectively formed, subsequent primer processing and the like are unnecessary, and the sheet-like article which is easy to be bonded and the like can be efficiently provided.

Claims (12)

A powder slush molding machine having a powder slash unit, a mold cooling unit, and a surface treatment unit, wherein the surface treatment unit is formed on the surface of the sheet-like article which is molded in the powder slash unit and cooled by the mold cooling unit. Powder slush molding machine characterized by having a surface treatment device for forming. The powder slush molding machine according to claim 1, further comprising a metal mold exchange part capable of continuously exchanging metal molds during the manufacturing process of the sheet-like article. The surface treatment apparatus according to claim 1 or 2, wherein the surface treatment apparatus is a surface treatment apparatus for applying at least one surface treatment of ozone treatment, plasma treatment, corona treatment, high pressure discharge treatment, ultraviolet treatment, and silicate treatment. Powder slash molding machine characterized by the above-mentioned. The powder slush molding machine according to claim 1 or 2, wherein the sheet-like article is subjected to surface treatment by a surface treatment apparatus of the surface treatment portion while keeping the sheet-like article substantially in a horizontal state. The powder slush molding machine according to claim 1 or 2, wherein the mold cooling unit includes a spray device and a shower device. The said surface treatment part and the said metal mold | die exchange part are provided integrally, and the metal mold | die exchange apparatus and the said surface treatment apparatus in the said metal mold | die exchange part operate | move in a respectively controlled state, It is characterized by the above-mentioned. Powder slash molding machine. The powder slicing molding machine according to claim 2, wherein the mold exchanger includes a plurality of supports for installing a mold, and each support is movable by external control. The powder slush molding machine according to claim 1 or 2, further comprising a mold having a plurality of molding surfaces. Powder slash molding method using a powder slash molding machine having a powder slash part, a mold cooling part and a surface treatment part, Forming a sheet-like article in the powder slash section; Cooling the sheet-like article in the die cooling unit; And in the surface treatment portion, a step of forming a surface treatment layer on the surface of the sheet-shaped object 94 that is not in contact with the mold in a state where the cooled sheet-like article is held in the mold. Slash molding method. 10. The powder slicing molding method according to claim 9, wherein the sheet-like article is subjected to surface treatment by a surface treatment apparatus of the surface treatment portion while keeping the sheet-shaped article substantially in a horizontal state. The powder slicing molding method according to claim 9 or 10, wherein, in the mold cooling unit, the mold is cooled by a spray device. The powder slicing molding method according to claim 9 or 10, wherein a plurality of sheet-like articles are simultaneously formed by using a mold having a plurality of molding surfaces.

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