WO2010137531A1 - 積層成形装置及び積層成形方法 - Google Patents
積層成形装置及び積層成形方法 Download PDFInfo
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- WO2010137531A1 WO2010137531A1 PCT/JP2010/058649 JP2010058649W WO2010137531A1 WO 2010137531 A1 WO2010137531 A1 WO 2010137531A1 JP 2010058649 W JP2010058649 W JP 2010058649W WO 2010137531 A1 WO2010137531 A1 WO 2010137531A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/03—Injection moulding apparatus
- B29C45/04—Injection moulding apparatus using movable moulds or mould halves
- B29C45/0441—Injection moulding apparatus using movable moulds or mould halves involving a rotational movement
- B29C45/045—Injection moulding apparatus using movable moulds or mould halves involving a rotational movement mounted on the circumference of a rotating support having a rotating axis perpendicular to the mould opening, closing or clamping direction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/03—Injection moulding apparatus
- B29C45/10—Injection moulding apparatus using moulds or injection units usable in different arrangements or combinations to each other
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/34—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1675—Making multilayered or multicoloured articles using exchangeable mould halves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C2045/167—Making multilayered or multicoloured articles injecting the second layer through the first layer
Definitions
- the present invention relates to a laminate molding apparatus and a laminate molding method used for molding a laminate molded product in which a plurality of materials or a plurality of colors of resins are superimposed.
- a fixed mold having two sets of cavity molds having different shapes, a fixed plate on which the fixed mold is mounted in the horizontal direction, and a parallel arrangement in the longitudinal direction of the apparatus, Two molders arranged in a cavity mold for injection filling, a movable mold with a core mold that forms different product cavities in combination with two cavity molds with different fixed mold shapes, and moves the movable mold
- a mold holder that is slidably guided in a lateral direction perpendicular to the mold opening / closing direction by a cylinder for use, and a movable plate that is attached to the mold holder and that is movable in the mold opening / closing direction with respect to the fixed platen.
- the lamination molding apparatus of Patent Document 2 has a structure in which a movable mold is guided by a mold holder of a movable board and is slid in a horizontal direction within the entire width of the movable board, and a fixed mold attached to the fixed board is movable. Since it has a form having a plurality of product cavities in the lateral direction according to the mold, the size of the mold is reduced with respect to the entire apparatus, and is about the same as a laminated molded product that can be molded with the laminated molding apparatus of Patent Document 1. In the case of molding a laminated molded article having a size of 1 mm, there is a problem that the entire apparatus must be made large. Increasing the size of such an apparatus causes an increase in weight, and there is a problem that the precision of the movement operation in the mold opening / closing direction at the time of mold clamping and mold opening is reduced.
- an object of the present invention is to provide a lamination molding apparatus and a lamination molding method in which the precision of the moving operation in the mold opening / closing direction is improved.
- one laminated molding apparatus includes a stationary platen to which a product core mold is attached, a dummy plate attached to a surface facing the product core die, and the stationary platen.
- a movable platen that is movable in the mold opening and closing direction, and is disposed between the fixed platen and the movable platen, and is movable in the mold opening and closing direction with respect to the fixed platen and the movable platen.
- a rotation axis orthogonal to the direction is provided so as to be rotatable, and has at least a surface facing the product core mold at a first rotation position and a surface facing the product core mold at a second rotation position.
- a first product cavity mold is attached to a surface facing the product core mold at the first rotation position, and a second product cavity mold is mounted on the surface facing the product core mold at the second rotation position.
- 1 injection unit and a second cavity which is disposed on the fixed platen side so as to be connectable to the product core mold, and is formed by clamping the product core mold and the second product cavity mold.
- a second injection unit for injecting and filling resin and a mold clamping mechanism for moving the movable plate relative to the fixed plate in a mold opening / closing direction are provided.
- the rotating disk and the movable disk are integrally configured to be movable in a mold opening / closing direction.
- the mold clamping mechanism is a toggle type mold clamping mechanism.
- the rotating disk and the second injection unit are detachable separate members.
- another lamination molding apparatus has a fixed plate having a surface on which a product core mold can be mounted, and a dummy plate mounted on a surface of the fixed plate facing the surface on which the product core mold can be mounted.
- a movable platen that is movable with respect to the fixed platen and movable in a mold opening / closing direction, and is disposed between the fixed platen and the movable platen, and is opened and closed with respect to the fixed platen and the movable platen.
- the laminate molding method according to the present invention is a laminate molding method performed using the one laminate molding apparatus according to the present invention, wherein the product core mold and the first product cavity mold are clamped.
- a primary mold clamping step for forming the first cavity a primary molding step for molding the primary molded body by filling the first cavity with resin from the first injection unit, and the primary molding after the primary molding step.
- the second injection unit fills the second cavity with resin.
- the primary molding step includes a primary injection filling step of filling the first cavity from the first injection unit with the foamable molten resin, and the movable plate after the primary injection filling step.
- a micro mold opening step in which the rotating disk is integrally opened by a predetermined amount and the foamable molten resin filled in the primary injection filling step is expanded and expanded in the first cavity.
- the secondary molding step includes a secondary injection filling step of filling the second cavity with the foamable molten resin from the second injection unit, and after the secondary injection filling step.
- a micro mold opening step in which the movable plate and the rotary plate are integrally opened by a predetermined amount by a small amount, and the foamable molten resin filled in the secondary injection filling step is expanded and expanded in the second cavity. You may prepare.
- the movable plate and the rotary plate are slightly opened by a predetermined amount between the product core mold and the first product cavity mold.
- the product core mold and the first product cavity mold are clamped together with the mold closing process for closing the mold to a position and forming the first cavity, in conjunction with the primary molding process or after the primary molding process.
- a primary injection filling step of filling the first cavity with the resin from the first injection unit after the mold closing step. May be provided.
- the secondary mold clamping step includes the step of moving the movable plate and the rotating plate by a predetermined amount between the product core mold and the second product cavity mold.
- the product core mold and the second product cavity mold are closed to the opened position to form the second cavity, and in conjunction with the secondary molding process or after the secondary molding process.
- An injection press process for clamping the mold and compressing the resin in the second cavity, and the secondary molding process fills the second cavity from the second injection unit after the mold closing process.
- a secondary injection filling step may be provided.
- FIG.1 (a) is a top view which shows the whole schematic structure of the lamination molding apparatus which concerns on one Embodiment of this invention
- FIG.1 (b) is a front view which shows the whole schematic structure of the same lamination molding apparatus. It is a top view which shows the process of the 1st shaping
- FIG. 1A is a plan view in which a part of the lamination molding apparatus 1 according to this embodiment is omitted
- FIG. 1B is a front view in which a part of the lamination molding apparatus 1 is omitted.
- the lamination molding apparatus 1 has a fixed platen 3 fixed to the bed 2 and a movable plate provided so as to be movable in the mold opening / closing direction with respect to the fixed platen 3.
- a rotary plate 4 that is movable in the mold opening / closing direction and is rotatable between the fixed plate 3 and the movable platen 5, and a first injection unit 17 and a second injection unit 17 provided on the fixed platen 3 side, respectively.
- An injection unit 18 and a mold clamping mechanism driving device 7 for moving the movable platen 5 in the mold opening / closing direction with respect to the fixed platen 3 are provided.
- a product core mold 21 is attached to the fixed platen 3 at the center of the surface on the front side (the side facing the movable platen 5), and the first injection unit 17 is placed from the back side to the front side.
- a through hole 3 a for advancing and retreating toward 21 is formed.
- the product core mold 21 was injected from the second injection unit 18 and the resin flow path 21 a for introducing the resin injected from the first injection unit 17 into the first cavity formed by the product core mold 21.
- Resin flow paths 21b for introducing the resin into the second cavities formed by the product core mold 21 are formed.
- the resin flow paths 21a and 21b of the product core mold 21 each have a resin cutoff opening switching valve (not shown).
- Tie bars 9 are provided so as to protrude from the four corners of the fixed platen 3, and each tie bar 9 penetrates the movable platen 5.
- the movable platen 5 is guided by a tie bar 9 and is provided so as to be movable forward and backward with respect to the fixed platen 3 by a toggle type mold clamping mechanism 14 driven by a mold clamping mechanism driving device 7.
- a plate-shaped dummy plate 6 is attached to the movable platen 5 at the center of the surface of the fixed platen 3 facing the product core mold 21, and the movable platen 5 and the rotating plate 4 are connected and integrated.
- a turntable coupling mechanism 15 is provided.
- the turntable coupling mechanism 15 includes a knock pin or the like in which the tip 15a is advanced and retracted by hydraulic pressure, a servo motor, or the like.
- the dummy plate 6 of the movable plate 5 and the first product cavity mold 19 or the second product cavity of the turntable 4 are provided.
- the connecting mechanism 15 a is advanced from the upper or side surface of the movable platen 5 to be connected to the upper or side surface of the rotating platen 4, so that the movable platen 5 and the rotary platen 4 are integrated. It is to make it.
- the turntable coupling mechanism 15 may be provided on either the movable platen 5 or the turntable 4, or the dummy plate 6 of the movable platen 5, or the first product cavity mold 19 and the second product of the turntable 4.
- the cavity mold 20 may be provided with a coupling mechanism such as a clamping mechanism driven by hydraulic pressure or a magnet clamping mechanism coupled by magnetic force.
- the turntable 4 is formed in a plate shape having surfaces facing the fixed platen 3 and the movable platen 5, respectively, via a turntable rotation mechanism 11 that rotates the turntable 4 about the vertical axis about the rotation shaft 13. It is installed on the turntable moving mechanism 12.
- the turntable 4 has a first product cavity mold 19 attached to the center of one surface and a second product cavity mold 20 attached to the center of the other surface.
- the turntable 4, the turntable rotating mechanism 11, and the turntable moving mechanism 12 may be separate members that can be attached to a forming apparatus for single layer forming.
- the rotating disk rotating mechanism 11 supports a load formed on a rotating disk 4 including a first product cavity mold 19 and a second product cavity mold 20 and is configured by a circumferential guide that can be rotated. It has a mechanism and is configured to rotate the rotating disk 4 around the rotating shaft 13 at an arbitrary movement position by an independent driving device such as a servo motor.
- the turntable moving mechanism 12 has a linear guide mechanism constituted by a combination of a ball screw, a ball screw nut, and a linear guide, and a driving device such as a servo motor combined with these.
- the rotating plate moving mechanism 12 rotates in conjunction with the mold opening / closing operation of the movable platen 5 when the movable platen 5 and the rotating plate 4 are connected by the rotating plate connecting mechanism 15 provided on the movable platen 5.
- the panel 4 is configured to be movable in the mold opening / closing direction within the mold opening / closing stroke range.
- the turntable moving mechanism 12 is configured to stop the turntable 4 at an arbitrary moving position and maintain the position.
- the driving device of the turntable moving mechanism 12 is configured so that the stroke end is set to the stop position when the mold is opened.
- a cylinder or the like can be used, whereby the configuration of the rotating disk moving mechanism 12 can be simplified.
- the first product cavity mold 19 and the second product cavity mold 20 of the turntable 4 are formed in different shapes, and the first product cavity mold 19 is the same as the product core mold 21 of the stationary platen 3.
- the second product cavity mold 20 is formed with the product core mold 21 of the stationary platen 3 and the mold so as to form a first cavity capable of forming the primary molded body when the mold is clamped. When fastened, it is formed in such a shape that a second cavity capable of molding the secondary molded body is formed on the surface of the primary molded body left in the product core mold 21.
- the first injection unit 17 is detachably provided on the back side of the fixed platen 3, and a nozzle 17 a for injecting resin is provided on the back side of the product core mold 21 through the through hole 3 a of the fixed platen 3 (FIG. 1A).
- the first cavity is filled with resin via the resin flow path 21a of the product core mold 21.
- the first injection unit 17 may be fixed and provided with the nozzle 17a connected to the back surface of the product core mold 21.
- the first injection unit 17 can be moved back and forth with respect to the product core mold 21 by a moving mechanism (not shown). It may be provided.
- the first injection unit 17 may be a separate member that can be attached to a molding apparatus for single layer molding.
- the second injection unit 18 has a front side of the stationary platen 3 so that the nozzle 18a for injecting the resin is connected to the side surface (upper side in FIG. 1A) of the product core mold 21 from the direction orthogonal to the mold opening / closing direction. It is provided to be removable.
- the second injection unit 18 is configured such that the nozzle 18 a is connected to the side surface of the product core mold 21, and the resin is filled into the second cavity via the resin flow path 21 b of the product core mold 21. .
- the second injection unit 18 may be fixedly provided with the nozzle 18a connected to the side surface of the product core mold 21.
- the second injection unit 18 can be moved back and forth with respect to the product core mold 21 by a moving mechanism (not shown). May be provided.
- the second injection unit 18 is provided substantially parallel to the first injection unit 17 or at a predetermined angle, and the nozzle 18a has a through hole 3a of the stationary platen 3 or another through hole (not shown) provided in the vicinity.
- the second cavity may be filled with resin via a resin flow path 21 b of the product core mold 21.
- the second injection unit 18 may be a separate member that can be attached to a molding apparatus for single layer molding.
- the movable platen 5 In the fully open state of FIG. 1 (a), the movable platen 5 is in the mold opening limit position corresponding to the mold thickness to be used.
- the turntable 4 is rotatable with the turntable 4 mounted with the first product cavity mold 19 and the second product cavity mold 20, and the product core mold 21 of the fixed plate 3 and the second of the turntable 4.
- Product cavity mold 20 When the molding of the laminated molded product is completed, the second product cavity mold 20 of the turntable 4 is positioned on the product core mold 21 side of the stationary platen 3. See FIG. 2 (f).
- a product take-out device (not shown) is inserted, and the laminated molded product extruded by the product push-out mechanism (not shown) from the product core mold 21 of the stationary platen 3 is in a “predetermined position”.
- the “predetermined position” at which the rotating disk 4 is stopped is appropriately set at an appropriate position according to the thickness of the mold used.
- a well-known thermoplastic resin having a melt-bonding property can be used for molding a multilayer molded product.
- the primary molded body molded in the first layer (base layer, product core mold side) of the laminated molded product has a function of ensuring the shape, strength and rigidity of the laminated molded product.
- the secondary molded body molded in the second layer (surface layer, product cavity mold side) of the laminated molded product is a cover of poor appearance of the primary molded body, coloring expression, and decorative expression of the whole or part, etc.
- the design of the laminated molded product is improved, and a soft feeling is imparted to the design surface, and in the case of an unfoamed layer, a non-slip property is imparted to the design surface.
- thermoplastic resins primary molded products are easily available and stable in price, such as polypropylene (PP), polyethylene (PE), acrylonitrile, butadiene, styrene copolymer synthetic resin (ABS resin), etc.
- PP polypropylene
- PE polyethylene
- ABS resin styrene copolymer synthetic resin
- a thermoplastic resin of a different material from the primary molded body or the same material as the primary molded body can be used as the secondary molded body.
- Resin having different colors elastomeric resins such as thermoplastic elastomer (TPO), styrene elastomer (SBC), and urethane elastomer (TPU) can be used.
- TPO thermoplastic elastomer
- SBC styrene elastomer
- TPU urethane elastomer
- thermoplastic resins By mixing these thermoplastic resins with fiber reinforced resins such as glass fibers, carbon fibers and natural fibers, the strength and rigidity of the secondary molded body can be improved, and various flame retardants and conductive agents can be used. By adding these additives, functions such as flame retardancy and antistatic properties can be imparted.
- the foamed layer in the laminated molded article is well known, such as a method in which a foaming agent is mixed in a thermoplastic resin in advance (chemical foam molding method) or a method in which a foaming gas is injected during injection filling of a thermoplastic resin (gas foam molding method). It can shape
- FIG. 2 is a plan view showing a process of a first molding example of the lamination molding apparatus according to the present embodiment.
- a primary molded body is molded from an unfoamed resin
- a secondary molded body is molded from a foamable molten resin.
- the movable platen 5 and the rotary platen 4 are closed in the direction of the fixed platen 3 by the toggle type mold clamping mechanism 14 of the mold clamping mechanism driving device 7. Specifically, first, the movable platen 5 is closed to the rotating plate 4 held at the “predetermined position” by the rotary plate moving mechanism 12 by the toggle type mold clamping mechanism 14, and the dummy of the movable platen 5 is used. The plate 6 is matched with the second product cavity mold 20. After mold matching, the movable disk 5 and the rotating disk 4 are integrated by the rotating disk coupling mechanism 15, and then the holding of the rotating disk 4 by the rotating disk moving mechanism 12 is released.
- the integrated movable platen 5 and rotating platen 4 are closed by a toggle type mold clamping mechanism 14, and the first product cavity die 19 of the rotating platen 4 is formed on the product core die 21 of the fixed platen 3. Let them match.
- the toggle mold clamping mechanism 14 uses the first product cavity mold 19 of the turntable 4 and the product core mold 21 of the fixed plate 3 and the dummy plate 6 and the turntable 4 of the movable plate 5.
- the second product cavity mold 20 is clamped (primary mold clamping step).
- the primary material 41 is subjected to primary injection filling in accordance with a preset injection filling pattern from the first injection unit 17 to form the primary molded body 41 (primary molding step).
- the movable platen 5 and the rotary platen 4 are separated from the fixed platen 3 with the primary molded body 41 adhered to the product core mold 21 of the fixed platen 3 as shown in FIG. Open the mold in the direction you want. Specifically, first, the movable platen 5 and the turntable 4 that are integrated are opened by the toggle type mold clamping mechanism 14 until the turntable 4 reaches the “predetermined position”. Next, when the turntable 4 reaches the “predetermined position”, the turntable moving mechanism 12 stops the turntable 4 and simultaneously releases the turntable connection mechanism 15. Then, the movable platen 5 is opened as it is by the toggle type clamping mechanism 14 to the mold opening limit position (mold opening process).
- the rotating disk 4 is rotated 180 degrees by the rotating disk rotating mechanism 11 at the “predetermined position”, and the second product cavity mold 20 of the rotating disk 4 is fixed.
- the panel 3 is switched to a position facing the product core mold 21 (rotation process).
- the movable platen 5 and the rotary platen 4 are again closed, and the second product cavity mold 20 of the rotary platen 4 is left with the primary molded body 41.
- the mold is matched with the product core mold 21 of the fixed platen 3 in the state. Since the mold closing operation of the movable platen 5 and the rotary platen 4 is the same as the above-described operation, the description thereof is omitted.
- the toggle mold clamping mechanism 14 causes the second product cavity mold 20 of the turntable 4 and the product core mold 21 of the fixed plate 3, and the dummy plate 6 and the turntable 4 of the movable plate 5.
- the first product cavity mold 19 is clamped (secondary clamping process).
- the product core is formed in the second cavity C2 formed by the second product cavity mold 20 of the turntable 4 and the surface of the primary molded body 41 attached to the product core mold 21 of the stationary platen 3.
- Secondary injection filling of a secondary material which is a foamable molten resin, is performed from the second injection unit 18 in accordance with an injection filling pattern set in advance from the resin flow path 21b of the mold 21 (secondary injection filling step). .
- the movable platen 5 and the rotary platen 4 are integrally opened by a predetermined amount ⁇ by the toggle type mold clamping mechanism 14, and foamed in the second cavity C2.
- the secondary molded body 44 having fine foam cells in the interior covered with the non-foamed skin layer is formed on a part or the entire surface of the primary molded body 41 by foaming and expanding the functional molten resin (micro mold opening step) ).
- the movable platen 5 and the rotary platen 4 are opened (mold opening process). Since the mold opening operation of the movable platen 5 and the rotary platen 4 is the same as the above-described operation, the description thereof is omitted.
- a laminated molded product 40 composed of a primary molded body 41 and a secondary molded body 44 attached to the product core mold 21 of the stationary platen 3 is a product (not shown).
- the turntable 4 is rotated by the turntable rotating mechanism 11 so that the first product cavity mold 19 of the turntable 4 is opposed to the product core mold 21 of the fixed plate 3. (Rotation process).
- the laminated molded product 40 is continuously formed by repeating the molding cycle from the state of FIG. 2A to the state of FIG. 2G.
- the rigidity of the laminated molded product 40 can be secured, and the secondary molded body 44 is expanded.
- the rigidity of the laminated molded product 40 can be secured, and the secondary molded body 44 is expanded.
- a molten resin By molding with a molten resin, it is possible to give a soft feeling to the design surface of the product and to reduce the weight of the laminated molded product 40 and to improve the heat insulation and sound insulation.
- automotive interior parts such as instrument panels, door trims, glove box covers, housing equipment such as flooring, miscellaneous goods and toys, etc. need to produce cushioning and high-quality feeling.
- the laminated molded product 40 can be molded.
- FIG. 3 is a plan view showing a process of a second molding example of the lamination molding apparatus according to the present embodiment.
- a primary molded body and a secondary molded body are molded from a foamable molten resin.
- the molding process of the secondary molded body 44 is the same as in the first molding example, and therefore only the molding process of the primary molded body 43 will be described.
- the toggle mold clamping mechanism 14 of the mold clamping mechanism driving device 7 causes the first product cavity mold 19 of the turntable 4, the product core mold 21 of the stationary platen 3, and the movable platen 5.
- the dummy plate 6 and the second product cavity mold 20 of the turntable 4 are clamped (primary mold clamping step).
- the product core mold is formed in the first cavity C1 formed by the first product cavity mold 19 of the turntable 4 and the product core mold 21 of the stationary platen 3, as shown in FIG.
- a primary material that is a foamable molten resin is primarily injected and filled from the first injection unit 17 through a resin flow path 21a of the mold 21 in accordance with an injection filling pattern set in advance (primary injection filling step).
- the movable platen 5 and the rotary platen 4 are integrally opened by a predetermined amount ⁇ by the toggle type mold clamping mechanism 14, and foamability is formed in the first cavity C1.
- the molten resin is foamed and expanded to form a primary molded body 43 having fine foam cells inside covered with a non-foamed skin layer (micro mold opening step).
- the movable platen 5 and the rotary platen 4 are fixed to the fixed platen 3 with the primary molded body 43 attached to the product core mold 21 of the fixed platen 3 as in the mold opening process of the first molding example.
- the mold is opened in a direction away from (see FIG. 3C).
- a secondary molded body 44 having fine foamed cells inside covered with a non-foamed skin layer is molded on a part or the entire surface of the primary molded body 43.
- the foamed laminated molded product 40 ′ composed of the primary molded body 43 and the secondary molded body 44 is taken out by a product take-out device (not shown) (see FIGS. 3D to 3H).
- a product take-out device not shown
- the primary molded body 43 and the secondary molded body 44 are molded from the foamable molten resin, thereby ensuring the rigidity of the foamed laminated molded product 40 'and performing foam molding. It is possible to reduce weight and improve heat insulation and sound insulation. Further, according to the second molding example, it is possible to mold an automobile interior part or the like that is further reduced in weight than the first molding example, thereby realizing reduction in fuel consumption of the automobile.
- FIG. 4 is a plan view showing a process of a third molding example of the lamination molding apparatus according to the present embodiment.
- a primary molded body and a secondary molded body are molded from an unfoamed resin.
- the molding process of the primary molded body 41 is the same as that of the first molding example, and therefore only the molding process of the secondary molded body 42 will be described.
- the primary molded body 41 is formed in the first cavity C1 formed by the first product cavity mold 19 of the turntable 4 and the product core mold 21 of the stationary platen 3 by a molding process similar to the first molding example. Molding is performed (see FIG. 4A).
- the movable platen 5 and the rotating platen 4 are fixed to the fixed platen 3 with the primary molded body 41 attached to the product core mold 21 of the fixed platen 3 as in the mold opening process of the first molding example.
- the mold is opened in a direction away from (see FIG. 4B).
- the turntable 4 is rotated 180 degrees by the turntable rotation mechanism 11, and the second product cavity mold 20 of the turntable 4 is turned into the product core mold 21 of the fixed plate 3.
- the position is switched to the opposite position (see FIG. 4C).
- the toggle mold clamping mechanism 14 allows the second product cavity mold 20 of the rotating disk 4, the product core mold 21 of the stationary disk 3, and the movable disk 5 to be moved.
- the dummy plate 6 and the first product cavity mold 19 of the turntable 4 are clamped.
- the second product cavity mold 20 of the turntable 4 and the surface of the primary molded body 41 attached to the product core mold 21 of the stationary platen 3 are formed.
- the secondary material is secondarily injected and filled in the second cavity C2 through the resin flow path 21b of the product core mold 21 in accordance with the injection filling pattern set in advance from the second injection unit 18.
- the secondary molded body 42 is molded on a part or the entire surface of the molded body 41 (secondary molding step).
- the movable platen 5 and the rotating platen 4 are opened (see FIG. 4 (e)), and the primary molded body 41 and the secondary molded body, as in the mold opening process of the first molding example.
- the laminated molded product 40 ′′ comprising 42 is taken out by a product take-out device (not shown) (see FIG. 4 (f)). In this way, thereafter, by repeating the molding cycle from the state of FIG. 4A to the state of FIG. 4F, the laminated molded product 40 ′′ is continuously molded.
- the primary molded body 41 and the secondary molded body 42 are molded from the unfoamed resin, thereby ensuring the rigidity of the laminated molded product 40 ′′ and the secondary molded body.
- functionality such as design property and non-slip property, can be imparted to the laminated molded product 40 ′′.
- automobile interior parts such as console boxes, assist grips and airbag covers, sundries, miscellaneous goods such as toothbrushes, stationery such as mechanical pencils, tools, sports, medical
- a laminated molded product 40 ′′ such as a grip of equipment can be molded.
- the primary molded body 41 may be molded from a container recycled resin or a recycled resin from waste products such as automobile parts and home appliances.
- a container recycled resin or a recycled resin from waste products such as automobile parts and home appliances.
- the primary molded body 41 is made of a recycled resin, for example, a transportation pallet for logistics, an automobile part such as a bumper, or a laminated molded product 40 ′′ such as a home appliance can be formed.
- a fourth molding example of the laminate molding apparatus 1 according to the present embodiment is injection press molding (compression molding).
- the primary molded body 43 ′ is made of, for example, a transparent polycarbonate resin as a glass substitute material.
- a glass resin molded product 40 ′′ is molded by molding with a resin and molding the secondary molded body 42 with a resin such as a colored polycarbonate resin as a support member.
- FIG. 5 is a plan view showing a process of a fourth molding example of the lamination molding apparatus according to the present embodiment.
- the molding process of the secondary molded body 42 is the same as in the third molding example, and therefore only the molding process of the primary molded body 43 'will be described.
- the movable platen 5 and the rotating plate 4 are moved by the toggle type mold clamping mechanism 14 to the product core die 21 of the fixed platen 3 and the first product cavity die 19 of the rotating plate 4.
- the mold is closed to a position where the mold is slightly opened by a predetermined amount ⁇ to form the first cavity C1 (mold closing process).
- the resin flow path 21a of the product core mold 21 is provided in the first cavity C1 formed by the first product cavity mold 19 and the product core mold 21.
- the primary material is subjected to primary injection filling in accordance with a preset injection filling pattern from the first injection unit 17 (primary injection filling step).
- the movable platen 5 and the rotary platen 4 are moved together in the mold closing direction by the toggle type mold clamping mechanism 14. Then, the first product cavity mold 19, the product core mold 21, the dummy plate 6 of the movable platen 5, and the second product cavity mold 20 of the rotating plate 4 are clamped (injection press process). As a result, the primary material is compressed in the first cavity C1 to form the primary molded body 43 ′.
- the movable platen 5 and the rotating platen 4 are fixed to the fixed platen with the primary molded body 43 ′ attached to the product core mold 21 of the fixed platen 3 in the same manner as the mold opening process of the first forming example.
- the mold is opened in a direction away from 3 (see FIG. 5C).
- the secondary molded body 42 is molded on a part or the entire surface of the primary molded body 43 ′ by the molding process similar to that of the third molding example, and from the primary molded body 43 ′ and the secondary molded body 42.
- the formed glass resin molded product 40 ''' is taken out by a product take-out device (not shown) (see FIGS. 5 (d) to 5 (g)).
- the glass resin molded product 40 ′′ ′′ is continuously molded by repeating the molding cycle from the state of FIG. 5A to the state of FIG. 5G.
- high-precision injection press molding can be performed, so that a high distortion suppressing effect at the time of injection filling can be obtained, and the mold clamping side (first product cavity mold 19 Since the holding pressure is uniformly applied from the side), a high product deformation suppressing effect can be obtained.
- glass-resin-formed molded articles 40 "" such as a resin-made glass of a motor vehicle exterior, and the design panel of a household appliance and OA apparatus, can be shape
- the fifth molding example of the laminate molding apparatus 1 according to the present embodiment is the same injection press molding (compression molding) as the fourth molding example.
- the primary molded body 42 ′ is used as a support member, for example.
- Glass resin molded article 40 "" is formed by molding the secondary molded body 43 "with a resin such as transparent polycarbonate resin as a glass substitute material.
- FIG. 6 is a plan view showing a process of a fifth molding example of the lamination molding apparatus according to the present embodiment.
- a glass resin molded product is molded by changing the molding order of the molding process of the primary molded body 43 ′ and the molding process of the secondary molded body 42 in the fourth molding example. Therefore, detailed description of the same steps as in the fourth molding example is omitted, and only different steps are described.
- a second product cavity mold 20 and a product core mold 21 are formed by a molding process similar to the molding of the secondary molded body 42 in the fourth molding example, as shown in FIG.
- a primary molded body 42 'made of a resin such as a colored polyalloy resin is molded in the two cavities C2.
- the movable platen 5 and the rotating platen 4 are opened in a direction away from the fixed platen 3 while the primary molded body 42 ′ is attached to the product core mold 21 of the fixed platen 3.
- the turntable 4 is rotated to switch the first product cavity mold 19 of the turntable 4 to a position facing the product core mold 21 of the fixed plate 3 (see FIG. 6B).
- the movable platen 5 and the rotary platen 4 are fixed by the toggle type mold clamping mechanism 14, as shown in FIG. 6C, by the same molding process as the molding of the primary molded body 43 ′ in the fourth molding example.
- the mold is closed to a position where the space between the product core mold 21 of the board 3 and the first product cavity mold 19 of the rotating board 4 is slightly opened by a predetermined amount ⁇ to form the first cavity C1 (mold closing process).
- a resin such as transparent polycarbonate resin is injected and filled from the first injection unit 17 into the first cavity C1 formed by the first product cavity mold 19 and the product core mold 21 (secondary injection). Filling step).
- the movable platen 5 and the rotating platen 4 are integrated in the mold closing direction by the toggle type mold clamping mechanism 14.
- the first product cavity mold 19 and the product core mold 21, the dummy plate 6 of the movable platen 5, and the second product cavity mold 20 of the rotating plate 4 are clamped (injection press process).
- the secondary material resin such as transparent polycarbonate resin
- the glass resin molded product 40 ′′ ′′ is molded. it can.
- the primary molded body 42 ′ as the surface layer is normally molded, and then the secondary molded body 43 ′′ as the base layer is molded by injection press molding, A glass resin molded product having the same structure as the molding example can be molded.
- the primary molded body 42 ′ is used as a base layer, and the secondary molded body 43 ′′ is formed as a surface layer, so that the base layer of the glass resin molded product 40 ′′ of the fourth molding example can be obtained.
- a glass resin molded product having a structure in which the surface layer is replaced can be formed.
- the movable platen 5 and the rotary platen 4 are integrated by the rotary plate coupling mechanism 15, and the integrated movable platen 5 and rotary platen 4 are integrated.
- the toggle type clamping mechanism 14 is moved in the mold opening / closing direction.
- the present invention is not limited to this, and the rotary plate 4 and the movable platen can be moved by independent drive sources, for example, the rotary plate moving mechanism 12 and the toggle type clamping mechanism 14.
- the board 5 may be controlled so as to move in the mold opening / closing direction.
- the movement of the rotating plate 4 and the movable platen 5 in the mold opening / closing direction is preferably controlled so as to be integrally performed by the rotating plate moving mechanism 12 and the toggle type clamping mechanism 14.
- the integrated control by the toggle type mold clamping mechanism 14 and the connection by the rotating disk connecting mechanism 15 may be used in combination, or the movable disk 5 and the rotating disk 4 are connected by the rotating disk connecting mechanism 15. You may not.
- the primary mold clamping (secondary mold clamping) process includes the dummy plate 6 of the movable platen 5 and the second product cavity mold 20 (the first product cavity mold 19 of the rotating plate 4). ),
- the first product cavity mold 19 (second product cavity mold 20) of the turntable 4 and the product core mold 21 of the stationary platen 3 are matched to each other.
- the rotating plate 4 is closed to the fixed plate 3 by the rotating plate moving mechanism 12, and the first product cavity die 19 (second product cavity die 20) is matched to the product core die 21.
- the movable platen 5 is closed to the rotating platen 4 by the toggle type mold clamping mechanism 14 so that the dummy plate 6 and the second product cavity die 20 (first product cavity die 19) are matched.
- turntable coupling mechanism 5 by are integrated with the movable plate 5 and the rotating disk 4, or is controlled integrally by the turntable moving mechanism 12 and a toggle type mold clamping mechanism 14 may be step causes tightening type.
- the rotating plate coupling mechanism 15 is released.
- the present invention is not limited to this, and the movable platen 5 can be moved after the connection between the movable platen 5 and the rotary platen 4 is released by the rotating plate coupling mechanism 15. Only the panel 5 may be opened by the toggle type clamping mechanism 14, and at the same time or later, the rotating disk 4 may be opened by the rotating disk moving mechanism 12.
- the movable platen 5 and the rotating disc 4 are moved by a toggle type mold clamping mechanism 14 with a predetermined amount ⁇ , ⁇ .
- the mold closing is performed, the present invention is not limited to this, and the movement of the rotating disk 4 and the movable disk 5 in the mold opening / closing direction by the rotating disk moving mechanism 12 and the toggle type mold clamping mechanism 14 is controlled so as to be integrally performed. By doing so, it may be possible to open and close the molds by predetermined amounts ⁇ and ⁇ .
- the lamination molding method according to the present invention is not limited to the first to fifth molding examples, and various combinations of operations that can be performed with the apparatus configuration of the present invention are possible depending on the constraints of the mold and the multilayer molded product. You may control.
- the multilayer molding apparatus 1 according to the present embodiment can mold a multilayer molded product having a base layer made of a foam layer and a surface layer made of an unfoamed layer.
- the primary molded body is molded from a foamable molten resin
- the secondary molded body is molded from an unfoamed resin, or is molded in the first cavity C1 of the first molding example.
- the layer can be formed by using the layer as a base layer and the foam layer formed in the second cavity C2 as a surface layer.
- the lamination molding apparatus 1 according to the present embodiment may mold the primary molded body and the secondary molded body by injection press molding, or may form the primary molded body and the secondary molded body. Either one of the molded bodies may be molded by foam molding and the other may be molded by injection press molding.
- the lamination molding apparatus 1 according to the present embodiment can also perform single layer molding by integrating the rotating disk 4 and the movable disk 5 using the rotating disk coupling mechanism 15 or a fastening member.
- the primary injection machine moves in the mold opening / closing direction in conjunction with the mold opening / closing operation of the movable platen. Since it moves forward and backward in the longitudinal direction of the apparatus, there is a problem that the entire length of the apparatus is longer than that of a conventional single-layer molding apparatus when the area of the mold mounting surface of the movable platen is substantially the same. Further, in order to form one type of laminated molded product, it is necessary to attach the same mold to each of the surfaces of the rotating plate facing the movable platen and the fixed platen.
- the lamination molding apparatus of patent document 2 arranges a plurality of injection devices in parallel to the fixed platen side, when the area of the mold mounting surface of the movable plate is substantially the same area, the lamination molding apparatus of patent document 1 Compared to the overall length of the device. Further, since the movable mold corresponding to the fixed mold having a plurality of cavity molds is shared, it is not necessary to attach a plurality of the same molds to the movable platen side. Furthermore, single layer or single color molding is also possible, and the problem of the lamination molding apparatus of Patent Document 1 is solved. However, this lamination molding apparatus has the following new problems.
- the lamination molding apparatus of Patent Document 2 has a structure in which a movable mold is guided by a mold holder of a movable board and is slid in a lateral direction within the entire width of the movable board. Only small molds considering sliding can be attached. Since the fixed mold attached to the fixed plate also has a plurality of product cavities in the horizontal direction that match the movable mold, when the area of the mold mounting surface of the movable plate is substantially the same area, the laminated molding of Patent Document 1 Only a small-sized laminated molded product can be molded as compared with a laminated molded product that can be molded by an apparatus.
- the movable mold having a projection area smaller than the area of the mold mounting surface of the movable plate is clamped to the fixed mold at a position deviated from the center of the mold mounting surface of the movable plate. You cannot add power in a well-balanced manner. For this reason, the mold may be damaged, or the molten resin may leak from the mold mating surface during injection filling.
- the lamination molding apparatus and the lamination molding method according to the present embodiment the following effects can be obtained.
- the movable platen and the rotating plate are configured to be movable in the mold opening / closing direction as a whole by being integrated by a mechanism capable of connecting the movable platen and the rotating plate, or by being controlled integrally by independent drive sources. ing. Accordingly, foam molding can be performed in which the product cavity mold of the rotating disk is opened with a predetermined amount integrally with the movable disk, and the foamable molten resin injected and filled in the product cavity is expanded and expanded.
- the molten resin is injected and filled into the product cavity in a state where the mold is opened, and in conjunction therewith, after that, the product cavity mold of the turntable is clamped integrally with the movable platen, and the molten resin Can be injection press-molded.
- the mold clamping mechanism is a toggle type, highly accurate mold opening amount control can be performed in foam molding and injection press molding that require high precision mold opening amount control.
- the drive device is an electric servo motor, more precise mold opening amount control is possible.
- a conventional single-layer molding apparatus that moves the movable plate forward and backward with respect to the fixed plate by a mold clamping mechanism by adding an injection unit and a rotating plate, and has a multi-function that provides the effects (1) to (9). It can be easily remodeled to the laminated molding apparatus.
- the product core mold 21 of the stationary platen 3 is used as the common mold corresponding to the first product cavity mold 19 and the second product cavity mold 20 of the turntable 4.
- the product cavity is switched on the product cavity mold side of the turntable 4, and the primary molded body and the laminated molded product adhere to the product core mold 21 side of the stationary platen 3 instead of the turntable 4 side.
- the same male mold is attached to both sides of the rotating disk, and the rotating mold is rotated with the primary molded body attached to the male mold side of the rotating disk, and the female mold side having different shapes attached to the movable disk and the stationary disk.
- One type of product cavity mold to be attached to one surface of the mold and the point attached to the approximate center of the rotating disk 4 is the side of the mold having a plurality of molds attached to the same surface of the fixed platen or a plurality of product cavity molds.
- the product cavity is switched at this point, which is a big difference from the laminate molding apparatus of Patent Document 2, and when the area of the mold mounting surface of the movable plate is substantially the same area, molding is possible with the laminate molding apparatus of Patent Document 2.
- a laminate molded product having a size larger than that of the laminate molded product can be formed, and a mold clamping force can be applied to the mold in a balanced manner during mold clamping.
- the lamination molding apparatus according to the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the technical idea of the present invention.
- the rotating disk 4 is rotated around the vertical axis, but is not limited thereto, and the rotating disk 4 is rotated around the horizontal axis perpendicular to the apparatus longitudinal direction. It may be rotated.
- the “predetermined position” for stopping the turntable 4 in the mold opening operation is such that the turntable 4 has the first product cavity mold 19 and the second product cavity mold 20.
- the product core mold 21 of the fixed platen 3 and the second product cavity mold 20 of the rotary platen 4 (when the molding of the laminated molded product is completed, the second product cavity mold of the rotary platen 4 is rotatable. 20 is located on the product core mold 21 side of the stationary platen 3. Refer to FIG. 2 (f).) A product take-out device (not shown) is inserted between the product core die 21 of the stationary platen 3 and illustrated.
- the present invention is not limited to this, and it is not limited to this, and when rotating the rotating disk 4 and between the stationary disk 3 and the rotating disk 4 with a product extracting device (not shown).
- the rotating disk 4 may be a position different stopping "predetermined position". In the latter case, by setting the turntable 4 to a position in the direction of the movable platen 5 from the “predetermined position” in the former case, the second product cavity mold 20 and the fixed platen 3 of the turntable 4 when the mold is opened.
- the space between the product core molds 21 can be made larger, and the design restrictions on the product take-out device side can be further reduced.
- the rotating disk 4 is formed in a plate shape having surfaces facing the fixed platen 3 and the movable platen 5, respectively, and a first product cavity mold is formed at the center of one surface. 19 is attached, and the second product cavity mold 20 is attached to the center of the other surface.
- the shape of the rotating disk is a polyhedron having three or more surfaces. It is good also as a structure which attaches a product cavity metal mold to.
- the product core mold 21, the first product cavity mold 19, the second product cavity mold 20, and the dummy plate 6 have already been fixed to the fixed plate 3 and the rotating plate 4.
- the present invention is not limited to this.
- the present invention is not limited to this, and the product core mold is provided on the stationary platen, at least two product cavity molds are provided on the rotary platen, and the dummy plate is provided on the movable platen. Any lamination molding apparatus that can be attached may be used.
- the lamination molding apparatus 1 includes the turntable coupling mechanism 15, the present invention is not limited to this, and the turntable coupling mechanism 15 may not be provided.
- the present invention solves the problems of the conventional laminate molding apparatus, and as a result, the effects described in the above-mentioned “Effects of the Invention” can be achieved and the industrial applicability is great.
- the addition of an injection unit and a turntable makes it possible to easily modify a conventional single-layer forming device that moves the movable plate forward and backward with respect to the fixed plate using a mold-clamping mechanism to a multi-function layered forming device.
- the availability of is very large.
- the laminating apparatus and the laminating method of the present invention can be easily changed to a multi-functional layered molding device by remodeling.
- the lamination molding apparatus and the lamination molding method in addition to single layer, single color molding, normal multilayer, and multicolor molding, a wide variety of multilayer molded products such as foam molding and in-mold coating molding methods can be molded. In recent years, it is possible to improve the operation rate of each lamination molding apparatus in response to the lamination molding products that are required to be produced in various small quantities.
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- Engineering & Computer Science (AREA)
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- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
製品コア金型21には、第1射出ユニット17から射出された樹脂を製品コア金型21によって形成される第1キャビティ内に導入する樹脂流路21aと、第2射出ユニット18から射出された樹脂を製品コア金型21によって形成される第2キャビティ内に導入する樹脂流路21bとがそれぞれ形成されている。製品コア金型21の樹脂流路21a、21bは、それぞれ樹脂遮断開放切替弁(図示せず)を有している。
固定盤3の四隅からはタイバー9が突出して設けられ、このタイバー9は、それぞれ可動盤5を貫通している。
可動盤5には、固定盤3の製品コア金型21と対向する側の面の中央に板状のダミープレート6が取付けられると共に、可動盤5と回転盤4とを連結し、一体化させることが可能な回転盤連結機構15が設けられている。
この回転盤連結機構15は、可動盤5と回転盤4とのいずれに設けても良いし、可動盤5のダミープレート6、もしくは、回転盤4の第1製品キャビティ金型19と第2製品キャビティ金型20とに、油圧で駆動されるクランプ機構や、磁力で連結させるマグネットクランプ機構等の連結機構を設ける形態でも良い。
回転盤4には、一方の面の中央に第1製品キャビティ金型19が取付けられ、他方の面の中央に第2製品キャビティ金型20が取付けられている。
ここで、回転盤4、回転盤回転機構11及び回転盤移動機構12は、単層成形用の成形装置に取付可能な別部材であるとしても良い。
回転盤移動機構12は、ボールネジとボールネジナットと直動ガイドとの組合せ等で構成される直線状のガイド機構及びこれらと組み合わされるサーボモータ等の駆動装置を有している。この回転盤移動機構12は、可動盤5に設けられた回転盤連結機構15により可動盤5と回転盤4とが連結された状態においては、可動盤5の型開閉動作に連動させて、回転盤4を型開閉ストローク範囲内において型開閉方向に移動可能に構成されている。また、回転盤移動機構12は、回転盤4を任意の移動位置で停止させ、その位置を維持するように構成されている。
ここで、回転盤移動機構12の駆動装置は、回転盤4の型開き時の停止位置が一定である場合には、そのストロークエンドを型開き時の停止位置とする形態にすることにより、油圧シリンダ等を用いることができ、これにより、回転盤移動機構12の構成を簡素化することができる。
この第1射出ユニット17は、ノズル17aが製品コア金型21の背面に接続した状態で固定して設けられても良いし、図示しない移動機構等により製品コア金型21に対して進退可能に設けられても良い。
ここで、第1射出ユニット17は、単層成形用の成形装置に取付可能な別部材であるとしても良い。
また、第2射出ユニット18は、ノズル18aが製品コア金型21の側面に接続した状態で固定して設けられても良いし、図示しない移動機構等により製品コア金型21に対して進退可能に設けられても良い。さらに、第2射出ユニット18は、第1射出ユニット17と略平行、あるいは所定の角度をもって設けられ、ノズル18aが固定盤3の貫通孔3a、あるいは近隣に設けられた図示しない別の貫通孔を介して製品コア金型21と接続し、製品コア金型21の樹脂流路21bを介して第2キャビティ内に樹脂を充填するように構成されても良い。
ここで、第2射出ユニット18は、単層成形用の成形装置に取付可能な別部材であるとしても良い。
まず、図2を用いて、本実施形態に係る積層成形装置1の第1成形例について説明する。図2は、本実施形態に係る積層成形装置の第1成形例の工程を示す平面図である。第1成形例は、一次成形体を未発泡樹脂により成形し、二次成形体を発泡性溶融樹脂により成形するものである。
すべての型合わせが完了した後、トグル式型締機構14で回転盤4の第1製品キャビティ金型19と固定盤3の製品コア金型21、及び可動盤5のダミープレート6と回転盤4の第2製品キャビティ金型20とを型締めする(一次型締め工程)。
このようにして、以後、図2(a)の状態から図2(g)の状態に至る成形サイクルを繰り返すことにより、積層成形品40が連続的に成形される。
次に、図3を用いて、本実施形態に係る積層成形装置1の第2成形例について説明する。図3は、本実施形態に係る積層成形装置の第2成形例の工程を示す平面図である。第2成形例は、一次成形体及び二次成形体を発泡性溶融樹脂により成形したものである。なお、第2成形例において、二次成形体44の成形工程は、第1成形例と同様であるため、一次成形体43の成形工程についてのみ説明する。
このようにして、以後、図3(a)の状態から図3(h)の状態に至る成形サイクルを繰り返すことにより、発泡積層成形品40´が連続的に成形される。
次に、図4を用いて、本実施形態に係る積層成形装置1の第3成形例について説明する。図4は、本実施形態に係る積層成形装置の第3成形例の工程を示す平面図である。第3成形例は、一次成形体及び二次成形体を未発泡樹脂により成形したものである。なお、第3成形例において、一次成形体41の成形工程は、第1成形例と同様であるため、二次成形体42の成形工程についてのみ説明する。
このようにして、以後、図4(a)の状態から図4(f)の状態に至る成形サイクルを繰り返すことにより、積層成形品40´´が連続的に成形される。
次に、本実施形態に係る積層成形装置1の第4成形例について説明する。本実施形態に係る積層成形装置1の第4成形例は、射出プレス成形(圧縮成形)であり、図5に示すように、一次成形体43´を例えばガラス代替材としての透明ポリカ樹脂等の樹脂により成形し、二次成形体42を例えば支持部材としての有色ポリカアロイ樹脂等の樹脂により成形することにより、ガラス樹脂化成形品40´´´を成形するものである。図5は、本実施形態に係る積層成形装置の第4成形例の工程を示す平面図である。なお、第4成形例において、二次成形体42の成形工程は、第3成形例と同様であるため、一次成形体43´の成形工程についてのみ説明する。
このようにして、以後、図5(a)の状態から図5(g)の状態に至る成形サイクルを繰り返すことにより、ガラス樹脂化成形品40´´´が連続的に成形される。
次に、本実施形態に係る積層成形装置1の第5成形例について説明する。本実施形態に係る積層成形装置1の第5成形例は、第4成形例と同様の射出プレス成形(圧縮成形)であり、図6に示すように、一次成形体42´を例えば支持部材としての有色ポリカアロイ樹脂等の樹脂により成形し、二次成形体43´´を例えばガラス代替材としての透明ポリカ樹脂等の樹脂により成形することにより、ガラス樹脂化成形品40´´´´を成形するものである。図6は、本実施形態に係る積層成形装置の第5成形例の工程を示す平面図である。なお、第5成形例は、第4成形例における一次成形体43´の成形工程と二次成形体42の成形工程との成形順序を変更して、ガラス樹脂化成形品を成形するものであるため、第4成形例と同様の工程についての詳細な説明は省略し、異なる工程についてのみ説明する。
(1)可動盤に金型及び射出ユニットが取付けられておらず、可動盤側の重量を軽くすることができるため、型開閉方向の移動動作の精密さを向上させることができる。
(2)少なくとも2個の射出ユニットを固定盤側に配設するため、可動盤の金型取付面の面積が略同面積の場合、2個の対向する射出ユニットを有する従来の引用文献1の積層成形装置と比較して装置全長を短くすることができる。
(3)異なる形状を有したそれぞれの製品キャビティ金型に対応する製品コア金型を共通化しているため、1種類の積層成形品を成形するのに同じ金型が不要になり、使用する金型数を少なくすることができる。
(4)一次成形体と積層成形品とが固定盤の製品コア金型に残る積層成形法のため、回転盤に製品押出し機構を内蔵させる必要がなく、これらを駆動させる油圧、空圧、電気などの接続も不要となり、回転盤の構造を単純にすることができる。
(5)単層あるいは単色成形が可能である。
(6)回転盤の両面に、異なる形状を有した製品キャビティ金型をそれぞれ取り付けるため、可動盤の金型取付面の面積が略同面積の場合、固定盤に複数の金型を同一面上に取り付ける従来の引用文献2の積層成形装置と比較して、回転盤の1面に取り付ける製品キャビティ金型の大きさを大きくすることができ、より大きなサイズの積層成形品を成形することができる。
(7)固定盤と可動盤との金型取付面の略中央に金型を取り付けるため、型締時に金型にバランスよく型締力を加えることができる。
(8)可動盤及び回転盤は、可動盤と回転盤とを連結可能な機構により一体化、又はそれぞれ独立した駆動源により一体として制御することで、一体として型開閉方向に移動可能に構成されている。これにより、回転盤の製品キャビティ金型を可動盤と一体で所定量だけ型開きさせて、製品キャビティ内に射出充填された発泡性溶融樹脂を発泡膨張させる発泡成形が可能である。また、所定量だけ型開きされた状態で製品キャビティ内に溶融樹脂を射出充填させ、それに連動して、またその後に、回転盤の製品キャビティ金型を可動盤と一体で型締めさせ、溶融樹脂を圧縮させる射出プレス成形が可能である。更に、型締機構がトグル式であれば、高精度の型開き量の制御が必要とされる発泡成形及び射出プレス成形において、高精度の型開き量制御が可能となる。加えて、その駆動装置が電動サーボモータである形態のものであれば、より高精度の型開き量制御が可能となる。
(9)型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置の機能に基づいており、また、可動盤と回転盤とを連結可能な機構、又はそれぞれ独立した駆動源により一体で型開閉動作させることが可能なため、単層、単色成形や通常の多層、多色成形に加えて、前記(8)の発泡成形や型内被覆成形方法等、型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置で実施されている種々の成形方法が実施可能であり、更に、それらを組み合わせた積層成形品の成形も可能である。
(10)射出ユニット及び回転盤の追加により、型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置を、前記(1)から(9)の効果を奏する、多機能を有する積層成形装置に容易に改造することができる。
本発明は、前記従来の積層成形装置の課題を解決するものであり、その結果、前記”発明の効果”に記載した効果を奏することができ、産業上の利用可能性は大きい。特に、射出ユニットと回転盤との追加で、型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置を、多機能を有する積層成形装置に容易に改造できる点は産業上の利用可能性が非常に大きい。なぜなら、型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置の機能に基づいていることから、単層、単色成形や通常の多層、多色成形に加えて、発泡成形や型内被覆成形方法等、型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置で実施されている種々の成形方法が実施可能であり、更に、それらを組み合わせた積層成形品の成形も可能になるからである。すなわち、装置の設置スペースあるいは装置の設置費用の制約のため、専用の積層成形装置を設置することが困難であった企業、特に中小規模の企業においても、本発明の積層成形装置と積層成形方法により、既に設置している、型締機構で可動盤を固定盤に対して進退させる従来の単層成形装置を、改造によって多機能を有する積層成形装置へと容易に変更することができ、この積層成形装置と積層成形方法により、単層、単色成形や通常の多層、多色成形に加えて、発泡成形や型内被覆成形方法等、多種多様な積層成形品が成形可能になる。そして、近年、多種少量生産が求められる積層成形品に対応して、各積層成形装置の稼動率を向上させることができる。
Claims (10)
- 製品コア金型が取り付けられた固定盤と、
前記製品コア金型と対向する面にダミープレートが取り付けられ、前記固定盤に対して型開閉方向に移動可能に設けられた可動盤と、
前記固定盤と前記可動盤との間に配置され、前記固定盤及び可動盤に対して型開閉方向に移動可能でかつ型開閉方向と直交する回転軸を中心として回転可能に設けられ、少なくとも第1の回転位置で前記製品コア金型と対向する面及び第2の回転位置で前記製品コア金型と対向する面を有し、前記第1の回転位置で前記製品コア金型と対向する面に第1製品キャビティ金型が取付けられ、前記第2の回転位置で前記製品コア金型と対向する面に第2製品キャビティ金型が取付けられた回転盤と、
前記製品コア金型に接続可能な状態で前記固定盤側に配置され、前記製品コア金型と前記第1製品キャビティ金型とが型締めされて形成される第1キャビティに樹脂を射出充填する第1射出ユニットと、
前記製品コア金型に接続可能な状態で前記固定盤側に配置され、前記製品コア金型と前記第2製品キャビティ金型とが型締めされて形成される第2キャビティに樹脂を射出充填する第2射出ユニットと、
前記可動盤を前記固定盤に対して型開閉方向に移動させる型締め機構と
を備えることを特徴とする積層成形装置。 - 前記回転盤及び前記可動盤は、一体として型開閉方向に移動可能に構成されていることを特徴とする請求項1記載の積層成形装置。
- 前記型締め機構は、トグル式の型締め機構であることを特徴とする請求項1又は2記載の積層成形装置。
- 前記回転盤及び前記第2射出ユニットは、脱着可能な別部材であることを特徴とする請求項1乃至3いずれか1項記載の積層成形装置。
- 製品コア金型を取付可能な面を有する固定盤と、
前記固定盤の製品コア金型を取付可能な面と対向する面にダミープレートを取付可能で、かつ前記固定盤に対して型開閉方向に移動可能に設けられた可動盤と、
前記固定盤と前記可動盤との間に配置され、前記固定盤及び前記可動盤に対して型開閉方向に移動可能でかつ型開閉方向と直交する回転軸を中心として回転可能に設けられ、少なくとも第1の回転位置で前記固定盤の製品コア金型を取付可能な面と対向する面及び第2の回転位置で前記固定盤の製品コア金型を取付可能な面と対向する面を有し、これらの面にそれぞれ製品キャビティ金型を取付可能な回転盤と、
前記固定盤側に配置され、前記固定盤の製品コア金型を取付可能な面と前記回転盤の第1の回転位置で前記固定盤の製品コア金型を取付可能な面と対向する面との間に形成される第1キャビティに樹脂を射出充填する第1射出ユニットと、
前記固定盤側に配置され、前記固定盤の製品コア金型を取付可能な面と前記回転盤の第2の回転位置で前記固定盤の製品コア金型を取付可能な面と対向する面との間に形成される第2キャビティに樹脂を射出充填する第2射出ユニットと、
前記可動盤を前記固定盤に対して型開閉方向に移動させる型締め機構と
を備えることを特徴とする積層成形装置。 - 請求項1乃至4いずれか1項に記載の積層成形装置を用いて行なう積層成形方法であって、
前記製品コア金型と前記第1製品キャビティ金型とを型締めし、前記第1キャビティを形成する一次型締め工程と、
前記第1射出ユニットから前記第1キャビティに樹脂を充填して一次成形体を成形する一次成形工程と、
前記一次成形工程後に、前記一次成形体を前記製品コア金型に残した状態で、前記回転盤を回転させて前記第2製品キャビティ金型を前記製品コア金型と対向させる回転工程と、
前記回転工程後に、前記製品コア金型と前記第2製品キャビティ金型とを型締めし、前記第2キャビティを形成する二次型締め工程と、
前記二次型締め工程後に、前記第2射出ユニットから前記第2キャビティに樹脂を充填して二次成形体を成形する二次成形工程と
を備えることを特徴とする積層成形方法。 - 前記一次成形工程は、
前記第1射出ユニットから前記第1キャビティに発泡性溶融樹脂を充填する一次射出充填工程と、
前記一次射出充填工程後に、前記可動盤と前記回転盤とを一体で所定量だけ微少型開きさせて、前記一次射出充填工程により充填された発泡性溶融樹脂を第1キャビティ内で発泡膨張させる微少型開き工程と
を備えることを特徴とする請求項6記載の積層成形方法。 - 前記二次成形工程は、
前記第2射出ユニットから前記第2キャビティに発泡性溶融樹脂を充填する二次射出充填工程と、
前記二次射出充填工程後に、前記可動盤と前記回転盤とを一体で所定量だけ微少型開きさせて、前記二次射出充填工程により充填された発泡性溶融樹脂を第2キャビティ内で発泡膨張させる微少型開き工程と
を備えることを特徴とする請求項6又は7記載の積層成形方法。 - 前記一次型締め工程は、
前記可動盤及び前記回転盤を、前記製品コア金型及び前記第1製品キャビティ金型の間が所定量だけ微少型開きされる位置まで型閉じさせ、前記第1キャビティを形成する型閉じ工程と、
前記一次成形工程と連動して又は前記一次成形工程後に、前記製品コア金型及び前記第1製品キャビティ金型を型締めし、前記第1キャビティ内の樹脂を圧縮する射出プレス工程とを備え、
前記一次成形工程は、前記型閉じ工程後に、前記第1射出ユニットから前記第1キャビティに樹脂を充填する一次射出充填工程を備える
ことを特徴とする請求項6記載の積層成形方法。 - 前記二次型締め工程は、
前記可動盤及び前記回転盤を、前記製品コア金型及び前記第2製品キャビティ金型の間が所定量だけ微少型開きされる位置まで型閉じさせ、前記第2キャビティを形成する型閉じ工程と、
前記二次成形工程と連動して又は前記二次成形工程後に、前記製品コア金型及び前記第2製品キャビティ金型を型締めし、前記第2キャビティ内の樹脂を圧縮する射出プレス工程とを備え、
前記二次成形工程は、前記型閉じ工程後に、前記第2射出ユニットから前記第2キャビティに樹脂を充填する二次射出充填工程を備える
ことを特徴とする請求項6記載の積層成形方法。
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KR101355419B1 (ko) | 2014-01-27 |
CN102448697A (zh) | 2012-05-09 |
US20120049408A1 (en) | 2012-03-01 |
KR20120027373A (ko) | 2012-03-21 |
JP4623241B1 (ja) | 2011-02-02 |
CN102448697B (zh) | 2014-11-05 |
JPWO2010137531A1 (ja) | 2012-11-15 |
US8899966B2 (en) | 2014-12-02 |
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