WO2013099828A1 - 中空部を有する熱可塑性樹脂成形体およびその製造方法 - Google Patents

中空部を有する熱可塑性樹脂成形体およびその製造方法 Download PDF

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Publication number
WO2013099828A1
WO2013099828A1 PCT/JP2012/083383 JP2012083383W WO2013099828A1 WO 2013099828 A1 WO2013099828 A1 WO 2013099828A1 JP 2012083383 W JP2012083383 W JP 2012083383W WO 2013099828 A1 WO2013099828 A1 WO 2013099828A1
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Prior art keywords
thermoplastic resin
mold
molded body
producing
molded article
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PCT/JP2012/083383
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English (en)
French (fr)
Inventor
舘山勝
越政之
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東レ株式会社
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Application filed by 東レ株式会社 filed Critical 東レ株式会社
Priority to CN201280056509.7A priority Critical patent/CN103946009B/zh
Priority to EP12862555.5A priority patent/EP2799213A4/en
Priority to KR1020147014044A priority patent/KR20140108634A/ko
Priority to JP2012558107A priority patent/JP5991590B2/ja
Priority to US14/364,385 priority patent/US9855700B2/en
Publication of WO2013099828A1 publication Critical patent/WO2013099828A1/ja

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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00Producing articles with hollow walls
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B29C51/267Two sheets being thermoformed in separate mould parts and joined together while still in the mould
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/78Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04Polymers of esters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2055/00Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
    • B29K2055/02ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00Use of polyesters or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2081/00Use of polymers having sulfur, with or without nitrogen, oxygen or carbon only, in the main chain, as moulding material
    • B29K2081/04Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • B29K2105/101Oriented
    • B29K2105/105Oriented uni directionally
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles

Definitions

  • the present invention relates to a thermoplastic resin molded body having a hollow portion and a method for producing the same, and in particular, a thermoplastic resin molded body having a hollow portion, which is suitable for a large-sized molded body having a thin-walled large area and a partial hollow structure portion. And a manufacturing method thereof.
  • the structure of the molded body to be finally molded is divided, and each divided part is first molded and molded.
  • a molded body having a predetermined structure has been manufactured by bonding or welding the parts.
  • the compact becomes larger, it takes a lot of time in the case of bonding, and in the case of welding, the welding machine becomes an unrealistic scale.
  • the object of the present invention is to satisfy the above-mentioned demands even when a thin-walled and large-area resin molded body structure is required and a hollow structure is partially formed. It is an object of the present invention to provide a technology capable of easily and efficiently producing a thermoplastic resin molded body having a structure to achieve this.
  • a method for producing a thermoplastic resin molded article having a hollow portion is a method in which a molded article A made of a thermoplastic resin molded in advance is set in a first mold and melted.
  • the resin plate B is shaped to a shape along the inner surface of the second mold by adsorbing the resin plate B to the inner surface of the second mold facing the first mold with a vacuum pressure, and the first mold and the second mold.
  • the mold is clamped to weld the thermoplastic resin plate B and the molded body A only in a predetermined area, and at least a part of the non-welded area is formed as a hollow part. Consists of.
  • the molding die is composed of an upper die and a lower die, if either the upper die or the lower die is used as the first die and the other die is used as the second die, Good.
  • thermoplastic resin molded body having a hollow portion In such a method for producing a thermoplastic resin molded body having a hollow portion according to the present invention, a molded body A made of a thermoplastic resin is previously molded into a predetermined shape and set in a first mold, and the molded body A The thermoplastic resin plate B is welded to the surface.
  • the thermoplastic resin plate B is adsorbed on the inner surface of the second mold by a vacuum pressure in a molten state, shaped into a shape along the inner surface of the second mold by the adsorption, and has a thin and large area heat. Even the plastic resin plate B is firmly and satisfactorily held in close contact with the inner surface of the second mold.
  • the first mold and the second mold are clamped, so that the thermoplastic resin plate B and the molded body A are welded only in a predetermined region and are not welded. At least a part of the welding region is formed as a hollow portion.
  • the portion of the molded body A set on the first mold is adsorbed on the inner surface of the second mold and shaped into a shape along the inner surface of the second mold.
  • the portion of the thermoplastic resin plate B firmly held on the inner surface is positioned with a gap, and both portions are formed in the hollow portion.
  • the plate B is accurately positioned at a time by clamping, so when the hollow part to be formed has a large area, when it has a long dimension, when it has a complicated planar shape, it is in a different place from each other. Even in the case where a plurality of layers are formed, the desired hollow portion can be formed accurately, easily, and efficiently in a very short time.
  • the molded body A is preliminarily molded by stamping molding or the like, it can be easily and accurately molded into a predetermined thin shape, and the thermoplastic resin plate B is melted in a vacuum state with the second mold. Since it is adsorbed on the inner surface and shaped into a shape along the inner surface of the second mold by the adsorption, it is easily formed into a thin wall shape, and the thin wall shape is accurately maintained until the mold clamping is completed. . Since the thermoplastic resin plate B, which is accurately maintained in a predetermined thin shape, is welded to the molded body A by clamping, the formed hollow portion is also easily formed into a predetermined shape, and the target form is highly accurate. The realized thermoplastic resin molding can be manufactured efficiently and easily in a short time.
  • thermoplastic resin molded body can also be applied to the case where both the molded body A and the thermoplastic resin plate B are made only of a resin.
  • the molded body A and the thermoplastic resin plate B Of these, it is a suitable method when at least the thermoplastic resin plate B is made of a fiber-reinforced thermoplastic resin.
  • both the molded object A and the thermoplastic resin board B consist of a fiber reinforced thermoplastic resin.
  • thermoplastic resin plate B When at least the thermoplastic resin plate B is made of a fiber reinforced thermoplastic resin, when the thermoplastic resin plate B is adsorbed to the inner surface of the second mold by a vacuum pressure in a molten state, the thermoplastic resin plate B melts due to the presence of the reinforcing fibers. The deformation and flow down of the resin having a low viscosity is prevented or suppressed, and even the thin-walled large-area thermoplastic resin plate B is more easily clamped while being held in a predetermined adsorption form. As a result, the molding of the thermoplastic resin molded body having a predetermined hollow portion is further facilitated. That is, a fiber-reinforced thermoplastic resin molded body having a hollow portion is easily produced.
  • the reinforcing fiber of the fiber-reinforced thermoplastic resin is not particularly limited.
  • at least one type of reinforcement selected from carbon fiber, glass fiber, and aramid fiber Fiber can be used.
  • a hybrid configuration in which two or more kinds of reinforcing fibers including these reinforcing fibers or other reinforcing fibers are used is also possible.
  • the form of the reinforcing fiber of the fiber reinforced thermoplastic resin for example, a discontinuous fiber can be adopted.
  • discontinuous fibers are used as the reinforcing fibers, the dispersion of the reinforcing fibers in the thermoplastic resin plate B in the molten state can be easily maintained in a uniform state, and at the same time along the inner surface of the second mold by adsorption. As a result, it is possible to improve the uniformity of mechanical properties and the surface quality of the final molded body.
  • the weight average fiber length of the discontinuous fibers is preferably 10 mm or more. If it is less than 10 mm, there is a possibility that the effect of improving the mechanical properties of the molded article, which is the original purpose of the reinforcing fiber, is insufficient.
  • the content of the discontinuous fibers in the fiber reinforced thermoplastic resin is preferably in the range of 5 to 50% by weight. If the content is less than this range, the effect of improving the mechanical properties of the molded product may be too small, and if it exceeds this range, high-precision adsorption to the inner surface of the upper mold may be difficult.
  • continuous fibers can also be used as the reinforcing fibers of the fiber-reinforced thermoplastic resin.
  • the combination form of the above discontinuous fibers and continuous fibers can also be employed.
  • the reinforcing fibers themselves can have desired anisotropy (for example, predetermined mechanical properties in a specific direction) and form retention.
  • the fiber reinforced resin molding using the reinforced fiber composed of continuous fibers can exhibit high mechanical properties in the orientation direction of the continuous fibers, it is possible to improve the mechanical properties of the molded product after molding.
  • the continuous fiber for example, a form made of continuous fibers in which reinforcing fibers are aligned in one direction can be adopted.
  • reinforced fibers consisting of continuous fibers are aligned in one direction, which makes it possible to specifically improve the mechanical properties in that direction, enabling a more optimal design according to the application of the molded body.
  • the content of the continuous fiber in the fiber reinforced thermoplastic resin is preferably in the range of 1 to 80% by weight. If the content is less than this range, the effect of improving the mechanical properties of the molded product may be too small, and the content exceeding this range is realistic even when the reinforcing fiber is composed of continuous fibers. Since the amount of resin becomes too small, it is difficult to realize.
  • a woven fabric as the reinforcing fiber of the fiber reinforced thermoplastic resin.
  • the form of the woven fabric there can be used a unidirectional woven fabric in which continuous fibers arranged in one direction as described above are woven with auxiliary yarns, or a woven fabric using continuous reinforcing fibers as warp yarns and weft yarns.
  • the reinforcing fibers themselves can be provided with a form-retaining property, so that the reinforcing fiber forms in the fiber-reinforced thermoplastic resin can be more easily maintained at the target form.
  • thermoplastic resin plate B includes reinforcing fibers made of continuous fibers as described above, for example, as the thermoplastic resin plate B, reinforcing fibers and thermoplastic resin aligned in one direction are preliminarily hot pressed.
  • the form which consists of a tape-like fiber reinforced thermoplastic resin integrated by this can be employ
  • the handleability is improved, and the mechanical properties in a specific direction are efficiently enhanced by including the reinforced fibers aligned in one direction. It becomes possible, and it becomes possible to perform the optimal design according to the use of a molded object more easily.
  • the tape width is 6 in consideration of handling property, retention property when adsorbed to the inner surface of the second mold, and formability. It is preferably in the range of ⁇ 50 mm.
  • thermoplastic resin plate B can be more easily and more reliably attached to the inner surface of the second mold, even if the thermoplastic resin plate B is thin and large. It becomes possible to adsorb, and mold clamping and, as a result, overall molding is facilitated.
  • a mold having suction fine holes for holding the molded body A can be used as the first mold.
  • Such a configuration is particularly effective when the upper mold of the upper and lower molds is used as the first mold and the molded body A is held on the lower surface side of the upper mold.
  • thermoplastic resin plate B when the thermoplastic resin plate B is shaped along the inner surface of the second mold and the thermoplastic resin plate B and the molded body A are welded, the second of the thermoplastic resin plate B is used.
  • a thermoplastic resin film can be formed by laminating a thermoplastic resin film on the non-contact surface to the mold. In this way, in particular, when the thermoplastic resin plate B is adsorbed to the inner surface of the second mold through suction from the fine holes as described above, a part of the thermoplastic resin plate B becomes porous. Since the suction air may pass through and there is a possibility that the suction of the portion may be insufficient, such a problem can be easily prevented.
  • the resin constituting the molded product A and the thermoplastic resin plate B is not particularly limited, but preferred thermoplastic resins include polyphenylene sulfide resin, polyamide resin, polyolefin resin, polyester resin, ABS. Examples include at least one of resin, polycarbonate resin, and polyacetal resin.
  • thermoplastic resin plate B can be shaped while pressing the outer peripheral portion of the thermoplastic resin plate B. In this way, it is possible to efficiently prevent an undesirable displacement in the thermoplastic resin plate B during shaping, and to perform the desired shaping at a relatively desirable position with respect to the second mold. it can.
  • a heating means is installed at a portion corresponding to at least a part of the welding region of the second type (for example, a heater is embedded), and heating by the heating means is used.
  • a heating means in both a 1st type
  • a heating means is provided over the shaping area
  • the present invention also provides a thermoplastic resin molded article having a hollow part, having a surface area of the upper surface of 1 m 2 or more, produced by the method as described above. That is, the method according to the present invention is particularly suitable for the production of a thin-walled large-area thermoplastic resin molded body, and particularly a large-sized molding having a surface area of 1 m 2 or more on the upper surface formed of the thermoplastic resin plate B.
  • the present invention also provides such a large thermoplastic resin molded body having a hollow portion. Examples of such a large thermoplastic resin molded body having a hollow portion include a monocoque body of a vehicle, particularly an automobile, a large bonnet, and panels of various large structures.
  • thermoplastic resin molded body having a hollow portion and a method for producing the same According to the thermoplastic resin molded body having a hollow portion and a method for producing the same according to the present invention, a large-sized thermoplastic resin molded body having a thin large area and a part of a hollow structure portion can be easily and efficiently produced in a short time. It can be manufactured with good accuracy.
  • thermoplastic resin plate B can be easily manufactured in a large-sized thermoplastic resin molded body having a thin and large area made of fiber-reinforced thermoplastic resin and partially having a hollow structure.
  • thermoplastic resin fabrication object It is a process flow figure showing a manufacturing method of a thermoplastic resin fabrication object concerning one embodiment of the present invention. It is a process flow figure showing a manufacturing method of a thermoplastic resin fabrication object concerning another embodiment of the present invention. It is a process flowchart which shows the manufacturing method of the thermoplastic resin molding which concerns on another embodiment of this invention. It is a process flowchart which shows the manufacturing method of the thermoplastic resin molding which concerns on another embodiment of this invention. It is a process flowchart which shows the manufacturing method of the thermoplastic resin molding which concerns on another embodiment of this invention. It is a process flowchart which shows the manufacturing method of the thermoplastic resin molding which concerns on another embodiment of this invention.
  • thermoplastic resin molding which concerns on another embodiment of this invention. It is a process flowchart which shows the manufacturing method of the thermoplastic resin molding which concerns on another embodiment of this invention. It is a schematic block diagram which shows the example of the holding method of the molded object A in this invention. It is a process flowchart which shows the manufacturing method of the thermoplastic resin molding which concerns on another embodiment of this invention. It is a longitudinal cross-sectional view of the metal mold
  • FIG. 1 shows each process of a manufacturing method of a thermoplastic resin fabrication object concerning one embodiment of the present invention.
  • the process (A) shown in FIG. 1 shows a molding example of a molded body A (1) made of a preformed thermoplastic resin or fiber reinforced thermoplastic resin.
  • the molded body A (1) is molded in advance by press molding using the lower mold 2 and the upper mold 3 for preforming.
  • the preformed molded body A (1) is set on the lower mold 11 as the first mold in the method for producing a thermoplastic resin molded body having a hollow portion according to the present invention in the step (B). .
  • the lower mold 11 can also be used as the lower mold 2 for preforming.
  • a mold having a plurality of micro holes 13 for sucking air from the cavity is used for the upper mold 12 as the second mold used for molding the thermoplastic resin molded body having the hollow portion.
  • thermoplastic resin plate B By the suction path 14 communicating with the hole 13 and suction through each fine hole 13, the molten thermoplastic resin plate B (15) is adsorbed to the inner surface of the upper mold 12 by a vacuum pressure (step (C)), The thermoplastic resin plate B (15) melted by adsorption is shaped into a shape along the inner surface of the upper mold 12.
  • This thermoplastic resin board B (15) may be comprised only from a thermoplastic resin, and may be comprised from the fiber reinforced thermoplastic resin containing a reinforced fiber.
  • thermoplastic resin plate B While adsorbing and shaping the thermoplastic resin plate B (15), or after completion of the adsorption and shaping of the thermoplastic resin plate B (15), the adsorbed state is maintained and the lower mold 11 is maintained.
  • the upper mold 12 is clamped (step (D)).
  • the thermoplastic resin plate B (15) in a molten state and the molded body A (1) in a molded and solidified state are brought into contact pressure only in a predetermined region (only in a region to be joined). While being welded, at least a part of the non-welded region is formed as the hollow portion 16. Thereafter, the thermoplastic resin plate B (15) in a molten state is cooled and solidified, whereby the molding of the thermoplastic resin molded body 17 having the hollow portion 16 is completed.
  • thermoplastic resin molded body having such a hollow portion In the method for producing a thermoplastic resin molded body having such a hollow portion, the molten thermoplastic resin plate B (15) is adsorbed on the inner surface of the upper mold 12 by vacuum pressure, and the inner surface of the upper mold 12 is obtained by the adsorption. Therefore, the target hollow part can be easily formed. Even with a thin large area, a thermoplastic resin molded body having a desired hollow portion can be easily and efficiently produced in a short time.
  • the method for producing a thermoplastic resin molded body having a hollow portion according to the present invention may take various forms as shown in FIGS. 2 to 8 in addition to the form shown in FIG.
  • a plurality of hollow parts in particular, a thermoplastic resin molded body 22 having a hollow part 21 at the center part is formed in advance.
  • a concave portion 24 is formed at the center of the molded body A (23), and the molded body A (23) is set on the lower mold 25 (step (A)), as shown in FIG.
  • thermoplastic resin plate B is adsorbed on the inner surface of the upper die 12 by vacuum pressure and shaped into a shape along the inner surface of the upper die 12 (step (B)), and the thermoplastic resin plate B ( 15) is welded only to a predetermined region to the molded body A (23) by clamping (step (C)).
  • a thermoplastic resin molded body 22 having a hollow portion 21 in addition to the hollow portion 16 can be manufactured.
  • thermoplastic resin molded body 32 having a hollow portion 31 at the center is manufactured as in the embodiment shown in FIG. 2.
  • the molded body A (1) molded in advance is the same as that shown in FIG. 1, and the molded body A (1) is set on the lower mold 11 (step (A)).
  • the molten thermoplastic resin plate B (35) is adsorbed to the inner surface of the upper die 34 by vacuum pressure and shaped into a shape along the inner surface of the upper die 34.
  • thermoplastic resin plate B (35) is welded only to a predetermined region to the molded body A (1) by clamping (step (C)).
  • this portion is also fine for sucking air from inside the cavity.
  • the holes 36 are appropriately arranged.
  • thermoplastic resin molded body having a hollow portion 41 that is formed in the periphery of the molded body and protrudes upward in a convex shape on the upper surface of the molded body. 42 is manufactured.
  • the molded body A (1) previously molded is the same as that shown in FIG. 1, and the molded body A (1) is set on the lower mold 11 (step (A )).
  • the upper mold 43 is one having a recess 45 in the inner surface portion of the mold corresponding to the fine hole 44, and the molten thermoplastic resin plate B (46) is vacuum-pressed on the upper mold 43.
  • thermoplastic resin plate B Adsorbed to the inner surface of the upper mold 43 and shaped into a shape along the inner surface of the upper mold 43 (step (B)), and the thermoplastic resin plate B (46) is welded only to a predetermined region to the molded body A (1) by clamping. (Step (C)).
  • thermoplastic resin molded body 42 having a hollow portion 41 that is larger and protrudes in a convex shape on the upper surface side of the molded body.
  • thermoplastic resin molded body 52 having a hollow portion 51 having a larger area is manufactured as compared with the form shown in FIG.
  • the molded body A (1) previously molded is the same as that shown in FIG. 1, and the molded body A (1) is set on the lower mold 11 (step (A )).
  • the upper mold 53 has a concave portion 54 having a larger area than the form shown in FIG. 1, and has a larger number of fine holes 55 than the form shown in FIG.
  • thermoplastic resin plate B (56) is adsorbed to the inner surface of the upper mold 53 by vacuum pressure and shaped into a shape along the inner surface of the upper mold 53 (step (B)), and the thermoplastic resin The plate B (56) is welded to the molded body A (1) only in a predetermined region (only the peripheral region in the illustrated example) by clamping (step (C)).
  • a thermoplastic resin molded body 52 having a hollow portion 51 with a larger area can be manufactured.
  • segmented into the hollow part 61a and the hollow part 61b is manufactured.
  • a convex portion 64 is formed on the upper surface of the central portion of the molded body A (63) that is molded in advance, and is molded on the lower mold 66 having the upper surface convex portion 65 having a shape corresponding to the convex portion 64.
  • the body A (63) is set (step (A)).
  • the upper mold 53 is the same as that shown in FIG.
  • thermoplastic resin plate B is adsorbed to the inner surface of the upper mold 53 by a vacuum pressure and is along the inner surface of the upper mold 53. It is shaped into a shape (step (B)), and the thermoplastic resin plate B (56) is welded to the molded body A (63) only by a predetermined region (in the illustrated example, only the peripheral region and the central region). (Step (C)).
  • a thermoplastic resin molded body 62 having large-area divided hollow portions 61a and 61b can be manufactured.
  • thermoplastic resin molded body 72 in which the hollow part 71 in the central part is formed in a larger area is manufactured as compared with the form shown in FIG.
  • a concave portion 74 having a larger area than that shown in FIG. 2 is formed on the upper surface of the central portion of the molded body A (73) molded in advance, and an upper surface concave portion having a shape corresponding to the concave portion 74 is formed.
  • the molded product A (73) is set on the lower mold 75 (step (A)).
  • the upper mold 53 is the same as that shown in FIG.
  • thermoplastic resin plate B having a hollow portion 71 in the central portion and a hollow portion 76 in the peripheral portion can be manufactured.
  • thermoplastic resin molded body 84 having a large-area hollow portion 83 formed at the center can be manufactured.
  • thermoplastic resin molded body having a hollow portion according to the present invention and the manufacturing method thereof can take various forms, and can also take forms other than the illustrated examples.
  • various methods can be appropriately applied as a method for holding the molded body A in the first mold.
  • the compact A (92) is sucked and held on the lower surface of the upper die 91 by vacuum suction.
  • the suction holes 93 for performing the suction and suctioning from each suction hole 93 through the suction path 94 and the vacuum line 95 by the vacuum pump 96 the molded body A (92) can be reliably held in a predetermined form. Further, as shown in FIG.
  • an adhesive tape 97 is attached to an appropriate location on the lower surface of the upper die 91, and the molded product A (92) is securely held in a predetermined form via the adhesive tape 97.
  • the upper mold 101 is used as the first mold
  • the lower mold 102 is used as the second mold
  • the molded body A (103) is sucked and held on the lower surface of the upper mold 101 by vacuum suction.
  • the suction passage 105 and the vacuum line 106 are provided through the suction passage 105 and the vacuum line 106 to hold the molded body A (103) in a predetermined form
  • the lower mold 102 has a molten thermoplastic.
  • a fine hole 108 and a suction path 109 for adsorbing the resin plate B (107) to the surface of the lower mold 102 with a vacuum pressure can be provided (step (A)).
  • thermoplastic resin plate B (107) disposed at a predetermined position with respect to the lower mold 102 is provided with a pressing means 110 that presses the outer peripheral portion thereof, and the pressing means 110 moves the outer peripheral portion of the thermoplastic resin plate B (107).
  • step (B) the thermoplastic resin plate B (107) is sucked by sucking through the fine holes 108, the suction path 109, and the vacuum line 111, and shaped along the surface of the lower mold 102.
  • Step (C) The formed thermoplastic resin plate B (107) was welded to the molded body A (103) only in a predetermined region (only the peripheral region in the illustrated example) by clamping (step (D)), and the hollow portion 112 was formed.
  • the thermoplastic resin molded body 113 can be manufactured.
  • the molded body A (123) and the thermoplastic resin plate B (124) are fixed by clamping the upper mold 121 as the first mold and the lower mold 122 as the second mold.
  • a heater 127 as a heating unit is installed particularly at a portion corresponding to at least a part of the welding region of the lower mold 122, The welding can be performed using heating by the heater 127. Since the heater 127 is also used for melting the thermoplastic resin molded body 126 as described above, the heater 127 may be provided over a wider area, for example, substantially the entire area of the lower mold 122. Similarly, a heater 128 as a heating unit may be installed in a portion corresponding to at least a part of the welding region of the upper mold 121, or in a wider region, for example, substantially the entire region.
  • thermoplastic resin molded body having a hollow portion according to the present invention and the method for producing the same are particularly suitable for a large-sized molded body having a thin-walled large area and a part of a hollow structure portion, for example, a monocoque body of an automobile, It is suitable for large bonnets and panels of various large structures.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

 予め成形した熱可塑性樹脂からなる成形体Aを第1の型にセットし、溶融した熱可塑性樹脂板Bを真空圧で第1の型に対向する第2の型の内面に吸着させることにより該第2の型の内面に沿う形状に賦形し、第1の型と第2の型を型締めすることにより、熱可塑性樹脂板Bと成形体Aを予め定めた領域のみで溶着するとともに、非溶着領域の少なくとも一部を中空部として形成することを特徴とする、中空部を有する熱可塑性樹脂成形体の製造方法、およびその方法により製造された1m以上の上面の表面積を有する熱可塑性樹脂成形体が提供される。薄肉大面積の樹脂成形体構造で、かつ、一部に中空構造を形成することが要求される場合にあっても、目標とする構造の熱可塑性樹脂成形体を容易に効率よくしかも精度よく製造できる。

Description

中空部を有する熱可塑性樹脂成形体およびその製造方法
 本発明は、中空部を有する熱可塑性樹脂成形体およびその製造方法に関し、とくに、薄肉大面積で一部に中空構造部を有する大型の成形体に好適な、中空部を有する熱可塑性樹脂成形体およびその製造方法に関する。
 少なくとも一部に中空構造部を有する樹脂中空成形体を一体成形する方法としては、ブロー成形やガスアシスト成形、ダイスライドインジェクションなどの成形方法が知られているが、いずれの成形方法においても、薄肉大面積で一部に中空構造部を有する成形体を成形することは困難である。一方、薄肉大面積を有する成形体の成形方法として、スタンピング成形やその他の成形方法が知られているが(例えば、特許文献1~5)、これらの従来の成形方法では、中空構造部を作ることが極めて困難である。
 そのため、薄肉大面積で一部に中空構造部を有する樹脂成形体の成形では、最終的に成形しようとする成形体の構造を分割し、分割された各部品をまず成形し、成形された各部品を接着や溶着することにより所定構造の成形体を製造していた。しかしこのような製造方法では、成形体が大きくなるにつれて、接着の場合には多大な時間を要することから、溶着の場合には溶着機械が非現実的な規模になることから、薄肉大面積で一部に中空構造部を有する成形体をより容易に製造できる技術が強く求められている。
特開平05-117411号公報 特開2004-142165号公報 特開平05-309724号公報 特開平05-185466号公報 国際公開2007/013385号公報
 そこで本発明の課題は、上記のような要望を満たすために、薄肉大面積の樹脂成形体構造で、かつ、一部に中空構造を形成することが要求される場合にあっても、目標とする構造の熱可塑性樹脂成形体を容易に効率よくしかも精度よく製造できる技術を提供することにある。
 上記課題を解決するために、本発明に係る中空部を有する熱可塑性樹脂成形体の製造方法は、予め成形した熱可塑性樹脂からなる成形体Aを第1の型にセットし、溶融した熱可塑性樹脂板Bを真空圧で前記第1の型に対向する第2の型の内面に吸着させることにより該第2の型の内面に沿う形状に賦形し、前記第1の型と前記第2の型を型締めすることにより、前記熱可塑性樹脂板Bと前記成形体Aを予め定めた領域のみで溶着するとともに、非溶着領域の少なくとも一部を中空部として形成することを特徴とする方法からなる。ここで、成形型が上型と下型からなる場合には、上記第1の型としては上型と下型のいずれか一方の型、上記第2の型としては他方の型を使用すればよい。
 このような本発明に係る中空部を有する熱可塑性樹脂成形体の製造方法においては、熱可塑性樹脂からなる成形体Aは予め所定形状に成形されて第1の型にセットされ、その成形体Aに対して熱可塑性樹脂板Bが溶着される。熱可塑性樹脂板Bは、溶融した状態にて真空圧で第2の型の内面に吸着され、該吸着により該第2の型の内面に沿う形状に賦形され、かつ、薄肉大面積の熱可塑性樹脂板Bであっても第2の型の内面に密着した状態で強固にかつ良好に保持される。この賦形と同時にあるいは賦形後に、第1の型と第2の型を型締めすることにより、熱可塑性樹脂板Bと成形体Aは予め定めた領域のみで溶着されるとともに、溶着されない非溶着領域の少なくとも一部が中空部として形成される。中空部に関してみれば、第1の型上にセットされた成形体A部分に対して、第2の型の内面に吸着され第2の型の内面に沿う形状に賦形され第2の型の内面に強固に保持された熱可塑性樹脂板B部分が間隔をもって位置決めされることになり、両部分間が中空部に形成される。第1の型上にセットされた成形体Aと第2の型の内面に吸着され第2の型の内面に沿う形状に賦形され第2の型の内面に強固に保持された熱可塑性樹脂板Bとは、型締めによって全体にわたって一時に精度よく位置決めされるので、形成されるべき中空部が大きな面積を有する場合、長い寸法を有する場合、複雑な平面形状を有する場合、互いに異なる箇所に複数形成される場合等にあっても、所望の中空部が精度よく、容易に、しかもごく短時間のうちに効率よく形成されることになる。また、成形体Aはスタンピング成形等により予め成形されるので、容易に精度よく所定の薄肉形状に成形することができ、熱可塑性樹脂板Bは溶融した状態にて真空圧で第2の型の内面に吸着され、該吸着により該第2の型の内面に沿う形状に賦形されるので、容易に薄肉形状に成形されるとともに、型締め完了に至るまでその薄肉形状に精度よく維持される。所定の薄肉形状に精度よく維持された熱可塑性樹脂板Bが型締めにより成形体Aに溶着されるので、形成される中空部も容易に所定形状に形成され、目標とする形態が高精度で実現された熱可塑性樹脂成形体が短時間のうちに効率よく容易に製造される。
 上記本発明に係る熱可塑性樹脂成形体の製造方法は、成形体Aおよび熱可塑性樹脂板Bがともに樹脂のみからなる場合にも適用できるが、とくに、上記成形体Aおよび熱可塑性樹脂板Bのうち少なくとも熱可塑性樹脂板Bが繊維強化熱可塑性樹脂からなる場合に好適な方法である。もちろん、成形体Aおよび熱可塑性樹脂板Bの両方が繊維強化熱可塑性樹脂からなる場合にも好適である。少なくとも熱可塑性樹脂板Bが繊維強化熱可塑性樹脂からなる場合、熱可塑性樹脂板Bが溶融した状態にて真空圧で第2の型の内面に吸着されるとき、強化繊維の存在によって溶融して低粘度となった樹脂の変形や流下が防止ないし抑制され、薄肉大面積の熱可塑性樹脂板Bであっても、より容易に、所定の吸着形態に保持されつつ型締めが行われる。その結果、所定の中空部を有する熱可塑性樹脂成形体の成形がより容易化される。すなわち、中空部を有する繊維強化熱可塑性樹脂成形体が容易に製造される。
 少なくとも熱可塑性樹脂板Bが繊維強化熱可塑性樹脂からなる場合、その繊維強化熱可塑性樹脂の強化繊維としては特に限定されず、例えば、炭素繊維、ガラス繊維、アラミド繊維から選ばれる少なくとも1種の強化繊維を使用できる。これらの強化繊維の、あるいは他の強化繊維も含めて、2種以上の強化繊維をともに使用するハイブリッド構成も可能である。
 また、繊維強化熱可塑性樹脂の強化繊維の形態としては、例えば不連続繊維を採用できる。強化繊維に不連続繊維を用いることにより、溶融状態の熱可塑性樹脂板B中の強化繊維の分散を容易に均一状態に維持できるようになるとともに、吸着により第2の型の内面に沿わせる際の賦形性(ドレープ性)を向上でき、結果的に最終成形体の機械特性の均一性や表面品位の向上に貢献できる。
 上記不連続繊維の重量平均繊維長としては10mm以上であることが好ましい。10mm未満であれば、強化繊維本来の目的である成形体の機械特性の向上効果が不足するおそれがある。また、上記繊維強化熱可塑性樹脂中の上記不連続繊維の含有量としては、5~50重量%の範囲にあることが好ましい。含有量がこの範囲よりも少ないと、成形体の機械特性の向上効果が小さくなりすぎるおそれがあり、この範囲を超えると、上型の内面への高精度の吸着が難しくなる場合がある。
 他方、上記繊維強化熱可塑性樹脂の強化繊維として連続繊維を使用することもできる。もちろん、上記のような不連続繊維と連続繊維の組み合わせ形態も採用可能である。強化繊維として連続繊維を使用することにより、強化繊維自体に、所望の異方性(例えば、特定方向の所定の機械特性)や形態保持性を持たせることが可能になる。また、連続繊維からなる強化繊維を使用した繊維強化樹脂成形体は、連続繊維の配向方向に高い機械特性を発現できるので、成形後の成形体の機械特性の向上が可能になる。
 上記連続繊維としては、例えば、強化繊維が一方向に引き揃えられた連続繊維からなる形態を採用できる。このように連続繊維からなる強化繊維が一方向に引き揃えられていることにより、その方向における機械特性を特異的に高めることが可能になり、成形体の用途に応じたより最適な設計が可能になる。
 また、上記維強化熱可塑性樹脂中の上記連続繊維の含有量としては、1~80重量%の範囲にあることが好ましい。含有量がこの範囲よりも少ないと、成形体の機械特性の向上効果が小さくなりすぎるおそれがあり、この範囲を超える含有量は、強化繊維が連続繊維からなる場合にあっても現実的には樹脂量が少なくなりすぎるため、実現困難である。
 さらに、上記繊維強化熱可塑性樹脂の強化繊維として織物の形態を採ることも可能である。織物の形態としては、上記のような一方向に引き揃えられた連続繊維を補助糸で織成した一方向織物や、連続強化繊維をたて糸、よこ糸とする織物等を使用できる。織物の形態とすることにより、強化繊維自体に形態保持性を持たせることができるので、繊維強化熱可塑性樹脂中の強化繊維の形態をより容易に目標形態に維持することが可能になる。その結果、熱可塑性樹脂板Bの溶融前や溶融時における熱可塑性樹脂板Bの形態維持性能の向上、最終熱可塑性樹脂成形体における目標機械特性の達成が、より確実に実現可能となる。
 また、上記熱可塑性樹脂板Bが上記のような連続繊維からなる強化繊維を含む場合、例えば、該熱可塑性樹脂板Bとして、一方向に引き揃えられた強化繊維と熱可塑性樹脂が予め熱プレスにより一体化されたテープ状繊維強化熱可塑性樹脂からなる形態を採用できる。このようなテープ状繊維強化熱可塑性樹脂からなる熱可塑性樹脂板Bでは、取扱い性が向上され、一方向に引き揃えられた強化繊維を含むことで、特定の方向の機械特性を効率よく高めることが可能になり、より容易に、成形体の用途に応じた最適な設計を行うことが可能になる。
 このようなテープ状繊維強化熱可塑性樹脂からなる熱可塑性樹脂板Bを用いる場合、取扱い性や第2の型の内面に吸着させる際の保持性、賦形性を考慮すると、そのテープ幅は6~50mmの範囲にあることが好ましい。
 また、本発明に係る方法においては、上記第2の型として、キャビティ内から空気を吸引するための微細孔を有する金型を使用することが好ましい。とくに複数の微細孔を適切な位置に配置することにより、薄肉大面積の熱可塑性樹脂板Bであっても、より容易に、かつより確実に熱可塑性樹脂板Bを第2の型の内面に吸着させることが可能になり、型締め、ひいては全体の成形が容易化される。
 また、上記第1の型としても、上記成形体Aを保持するための吸引微細孔を有する金型を使用するができる。このような形態は、第1の型として上下型の上型を使用し、成形体Aをその上型の下面側に保持させる場合にとくに有効である。
 また、熱可塑性樹脂板Bを上記第2の型の内面に沿わせて賦形し、該熱可塑性樹脂板Bと成形体Aとを溶着するに際しては、熱可塑性樹脂板Bの上記第2の型への非接触面に熱可塑性樹脂フイルムを積層して熱可塑性樹脂板Bを賦形するようにすることもできる。このようにすれば、とくに熱可塑性樹脂板Bを上記のように微細孔からの吸引を介して第2の型の内面に吸着させる場合、熱可塑性樹脂板Bの一部がポーラス状になって吸引用空気が通り抜け、その部位の吸着が不十分となるおそれが生じることがあるので、このような不具合の発生を容易に防止できるようになる。
 また、本発明に係る方法においては、成形体Aおよび熱可塑性樹脂板Bを構成する樹脂としてはとくに限定されないが、好ましい熱可塑性樹脂として、ポリフェニレンスルフィド樹脂、ポリアミド樹脂、ポリオレフィン樹脂、ポリエステル樹脂、ABS樹脂、ポリカーボネート樹脂、ポリアセタール樹脂の少なくとも1種以上を例示することができる。
 また、本発明に係る方法においては、熱可塑性樹脂板Bの外周部を押さえながら熱可塑性樹脂板Bを賦形することもできる。このようにすれば、賦形時に熱可塑性樹脂板Bに望ましくない位置ずれが生じることを効率よく防止でき、第2の型に対して相対的に望ましい位置にて所望の賦形を行うことができる。
 さらに、本発明に係る方法においては、少なくとも上記第2の型の上記溶着領域の少なくとも一部に対応する部位に加熱手段を設置し(例えば、ヒーターを埋設し)、該加熱手段による加熱を利用して上記溶着を行うようにすることもできる。もちろん、第1の型と第2の型の両方に加熱手段を設けてもよい。このような加熱手段を設けておくと、熱可塑性樹脂板Bと成形体Aとの所定の溶着が容易化される。また、加熱手段を熱可塑性樹脂板Bの賦形領域にわたって設けておくと、熱可塑性樹脂板Bの溶融のための加熱にも使用でき、賦形に関する一連の操作がより容易化される。
 本発明は、上記のような方法により製造された、1m以上の上面の表面積を有する、中空部を有する熱可塑性樹脂成形体についても提供する。すなわち、上記本発明に係る方法は、とくに薄肉大面積の熱可塑性樹脂成形体の製造に好適なものであり、とくに熱可塑性樹脂板Bで形成される上面の表面積が1m以上の大型の成形体の製造に好適なものであり、本発明はこのような大型の、中空部を有する熱可塑性樹脂成形体も提供する。このような大型の、中空部を有する熱可塑性樹脂成形体として、例えば、車両、とくに自動車のモノコックボディや、大型のボンネット、さらに、各種大型構造体のパネル等を例示できる。
 本発明に係る中空部を有する熱可塑性樹脂成形体およびその製造方法によれば、薄肉大面積で一部に中空構造部を有する大型の熱可塑性樹脂成形体を、容易に短時間のうちに効率よく、しかも精度よく製造することができる。とくに、少なくとも熱可塑性樹脂板Bが繊維強化熱可塑性樹脂からなる薄肉大面積で一部に中空構造部を有する大型の熱可塑性樹脂成形体を容易に製造できるようになる。
本発明の一実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明の別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明における成形体Aの保持方法の例を示す概略構成図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す工程フロー図である。 本発明のさらに別の実施態様に係る熱可塑性樹脂成形体の製造方法を示す金型の縦断面図である。
 以下に、本発明を実施するための具体的な形態について、図面を参照して説明する。
 なお、図1~図8に示す実施態様では、本発明における第1の型として下型を、第2の型として上型を使用した形態を例示しているが、本発明における第1の型として上型を、第2の型として下型を使用することもできる。図1は、本発明の一実施態様に係る熱可塑性樹脂成形体の製造方法の各工程を示している。図1に示す工程(A)は、予め成形される熱可塑性樹脂あるいは繊維強化熱可塑性樹脂からなる成形体A(1)の成形例を示している。この例では、成形体A(1)が、予備成形用の下型2と上型3を用いたプレス成形によって、予め成形される。
 上記予め成形された成形体A(1)は、工程(B)において、本発明に係る中空部を有する熱可塑性樹脂成形体の製造方法における第1の型としての下型11上にセットされる。この下型11は、上記予備成形用の下型2と兼用することも可能である。この中空部を有する熱可塑性樹脂成形体の成形に用いる第2の型としての上型12には、キャビティ内から空気を吸引するための複数の微細孔13を有する金型が使用され、各微細孔13に連通する吸引路14、各微細孔13を介しての吸引により、溶融した熱可塑性樹脂板B(15)が真空圧で上型12の内面に吸着され(工程(C))、該吸着により溶融した熱可塑性樹脂板B(15)が上型12の内面に沿う形状に賦形される。この熱可塑性樹脂板B(15)は、熱可塑性樹脂のみから構成されてもよく、強化繊維を含む繊維強化熱可塑性樹脂から構成されてもよい。
 上記熱可塑性樹脂板B(15)の吸着、賦形を行いつつ、あるいは熱可塑性樹脂板B(15)の吸着、賦形が完了した後に、その吸着状態が維持されつつ、下型11に対し上型12が型締めされる(工程(D))。この型締めにより、溶融状態にある熱可塑性樹脂板B(15)と成形固化状態にある成形体A(1)が、予め定められた領域のみで(接合すべき領域のみで)接圧されて溶着されるとともに、非溶着領域の少なくとも一部が中空部16として形成される。しかる後に、溶融状態にあった熱可塑性樹脂板B(15)が冷却固化されることにより、中空部16を有する熱可塑性樹脂成形体17の成形が完了する。
 このような中空部を有する熱可塑性樹脂成形体の製造方法においては、溶融した熱可塑性樹脂板B(15)は真空圧で上型12の内面に吸着され、該吸着により該上型12の内面に沿う形状に賦形されるので、容易に薄肉の所定形状に成形されるとともに、型締め完了に至るまでその薄肉の所定形状に精度よく維持されるので、目標とする中空部も容易に形成され、薄肉大面積であっても、所望の中空部を有する熱可塑性樹脂成形体が短時間のうちに効率よく容易に製造されることになる。
 上記本発明に係る中空部を有する熱可塑性樹脂成形体の製造方法は、上記図1に示した形態以外にも、例えば図2~図8に示すような各種形態を採り得る。図2に示す形態においては、図1に示した形態に比べ、より多くの複数の中空部、とくに中央部にも中空部21を有する熱可塑性樹脂成形体22を製造するために、予め成形される成形体A(23)の中央部に凹部24を形成しておき、この成形体A(23)を下型25上にセットし(工程(A))、図1に示したのと同様に、溶融した熱可塑性樹脂板B(15)を真空圧で上型12の内面に吸着して上型12の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(15)を型締めにより成形体A(23)に所定領域のみ溶着させる(工程(C))。このような成形により、中空部16に加え中空部21を有する熱可塑性樹脂成形体22を製造できる。
 また、図3に示す形態においては、図1に示した形態に比べ、図2に示した形態と同様に中央部にも中空部31を有する熱可塑性樹脂成形体32を製造するが、本実施態様では、予め成形される成形体A(1)には図1に示したのと同様のものを使用し、その成形体A(1)を下型11上にセットする(工程(A))。内面中央部に凹部33を有する上型34を使用し、溶融した熱可塑性樹脂板B(35)を真空圧で上型34の内面に吸着して上型34の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(35)を型締めにより成形体A(1)に所定領域のみ溶着させる(工程(C))。上型34の内面中央部の凹部33に対しても熱可塑性樹脂板B(35)を真空圧で良好に吸着させるために、この部位に対しても、キャビティ内から空気を吸引するための微細孔36が適宜配設されている。このような成形により、中空部16に加え、成形体上面にて凸状の中空部31を有する熱可塑性樹脂成形体32を製造できる。
 また、図4に示す形態においては、図1に示した形態に比べ、成形体周辺部に形成され、成形体上面にて凸状に上方にも張り出す中空部41を有する熱可塑性樹脂成形体42を製造する。本実施態様では、予め成形される成形体A(1)には図1に示したのと同様のものを使用し、その成形体A(1)を下型11上にセットする(工程(A))。上型43には、図1に示した形態に比べ、微細孔44に対応する型内面部位に凹部45を有するものを使用し、溶融した熱可塑性樹脂板B(46)を真空圧で上型43の内面に吸着して上型43の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(46)を型締めにより成形体A(1)に所定領域のみ溶着させる(工程(C))。このような成形により、より大きく、成形体上面側に凸状に張り出した中空部41を有する熱可塑性樹脂成形体42を製造できる。
 また、図5に示す形態においては、図1に示した形態に比べ、より大きな面積の中空部51を有する熱可塑性樹脂成形体52を製造する。本実施態様では、予め成形される成形体A(1)には図1に示したのと同様のものを使用し、その成形体A(1)を下型11上にセットする(工程(A))。上型53には、図1に示した形態に比べ、型内面部位により面積の大きな凹部54を有し、その凹部54に対して図1に示した形態よりも数多くの微細孔55を有するものを使用し、溶融した熱可塑性樹脂板B(56)を真空圧で上型53の内面に吸着して上型53の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(56)を型締めにより成形体A(1)に所定領域のみ(図示例では周辺領域のみ)溶着させる(工程(C))。このような成形により、より大面積の中空部51を有する熱可塑性樹脂成形体52を製造できる。
 また、図6に示す形態においては、図5に示した形態に比べ、大きな面積の図5の中空部51が中空部61aと中空部61bに分割された形態の熱可塑性樹脂成形体62を製造する。本実施態様では、予め成形される成形体A(63)の中央部上面に凸部64を形成しておき、この凸部64に対応する形状の上面凸部65を有する下型66上に成形体A(63)をセットする(工程(A))。上型53には、図5に示した形態と同様のものを使用し、溶融した熱可塑性樹脂板B(56)を真空圧で上型53の内面に吸着して上型53の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(56)を型締めにより成形体A(63)に所定領域のみ(図示例では周辺領域と中央部の領域のみ)溶着させる(工程(C))。このような成形により、大面積の分割された中空部61a、61bを有する熱可塑性樹脂成形体62を製造できる。
 また、図7に示す形態においては、図2に示した形態に比べ、中央部の中空部71をより大面積に形成した熱可塑性樹脂成形体72を製造する。本実施態様では、予め成形される成形体A(73)の中央部上面に図2に示したのよりも大面積の凹部74を形成しておき、この凹部74に対応する形状の上面凹部を有する下型75上に成形体A(73)をセットする(工程(A))。上型53には、図5に示した形態と同様のものを使用し、溶融した熱可塑性樹脂板B(56)を真空圧で上型53の内面に吸着して上型53の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(56)を型締めにより成形体A(73)に所定領域のみ(図示例では外辺領域と中央部の周辺領域のみ)溶着させる(工程(C))。このような成形により、中央部の中空部71と周辺部の中空部76を有する熱可塑性樹脂成形体72を製造できる。
 図8に示す形態においては、図1に示した形態に比べ、予め成形される成形体A(81)を平板状に形成しておき、この成形体A(81)を上面が平面の下型82上にセットし(工程(A))、図1に示したのと同様に、溶融した熱可塑性樹脂板B(15)を真空圧で上型12の内面に吸着して上型12の内面に沿う形状に賦形し(工程(B))、その熱可塑性樹脂板B(15)を型締めにより成形体A(81)に所定領域のみ(図示例では周辺領域のみ)溶着させる(工程(C))。このような成形により、中央部に大面積の中空部83が形成された熱可塑性樹脂成形体84を製造できる。
 このように、本発明に係る中空部を有する熱可塑性樹脂成形体およびその製造方法は種々の形態を採り得、上記図示例以外の形態も採り得る。
 なお、本発明において、上記成形体Aを第1の型に保持する方法としては、適宜各種の方法を適用し得る。例えば、図9に第1の型として上型91を使用した場合について例示するに、図9(A)に示すように、成形体A(92)を真空吸引により上型91の下面に吸着保持するための吸引孔93を設け、各吸引孔93から吸引路94、真空ライン95を通して真空ポンプ96によって吸引することにより、成形体A(92)を確実に所定形態に保持することができる。また、図9(B)に示すように、上型91の下面の適切な箇所に粘着テープ97を貼着し、粘着テープ97を介して成形体A(92)を確実に所定形態に保持することもできる。さらに、図9(C)に示すように、例えば上型91の両内側面に適当に小さなアンダーカット部98を設けておき、このアンダーカット部98により成形体A(92)を上型91に対し所定形態に保持することもできる。さらに、これら図示例以外の保持方法も採用可能である。
 また、例えば図10に示すように、第1の型として上型101を、第2の型として下型102を使用し、成形体A(103)を真空吸引により上型101の下面に吸着保持するための微細孔104を設け、各微細孔104から吸引路105、真空ライン106を通して吸引することにより、成形体A(103)を所定形態に保持し、下型102には、溶融した熱可塑性樹脂板B(107)を真空圧で下型102の表面に吸着するための微細孔108、吸引路109を設けておくことができる(工程(A))。下型102に対し所定位置に配置された熱可塑性樹脂板B(107)に対し、その外周部を押さえる押さえ手段110を設け、該押さえ手段110で熱可塑性樹脂板B(107)の外周部を押さえながら(工程(B))、微細孔108、吸引路109、真空ライン111を通して吸引することにより熱可塑性樹脂板B(107)を吸引することにより、下型102の表面に沿わせて賦形する(工程(C))。賦形された熱可塑性樹脂板B(107)を型締めにより成形体A(103)に所定領域のみ(図示例では周辺領域のみ)溶着させ(工程(D))、中空部112が形成された熱可塑性樹脂成形体113を製造できる。
 さらに、例えば図11に示すように、第1の型としての上型121と第2の型としての下型122の型締めにより、成形体A(123)と熱可塑性樹脂板B(124)を所定領域で溶着させて、中空部125を有する熱可塑性樹脂成形体126を製造するに際し、とくに下型122の前記溶着領域の少なくとも一部に対応する部位に加熱手段としてのヒーター127を設置し、該ヒーター127による加熱を利用して前記溶着を行うようにすることができる。ヒーター127は、前述の如く、熱可塑性樹脂成形体126の溶融にも供するため、下型122のより広い領域、例えば実質的に全域にわたって設けておいてもよい。同様に、上型121の前記溶着領域の少なくとも一部に対応する部位、さらにはより広い領域、例えば実質的に全域にわたって、加熱手段としてのヒーター128を設置しておいてもよい。
 本発明に係る中空部を有する熱可塑性樹脂成形体およびその製造方法は、とくに、薄肉大面積で一部に中空構造部を有する大型の成形体に好適であり、例えば、自動車のモノコックボディや、大型のボンネット、さらに、各種大型構造体のパネル等に好適なものである。
1、23、63、73、81、103、123 成形体A
2、11、25、66、75、82 第1の型としての下型
3、12,34、43、53 第2の型としての上型
13、36、44、55,104、108 微細孔
14、105、109 吸引路
15、35、46、56、107、124 熱可塑性樹脂板B
16、21、31、41、51、61a、61b、71、76、83,112,125 中空部
17、22、32、42、52、62、72、84、113、126 熱可塑性樹脂成形体
24,33、45、54、74 凹部
64 凸部
65 上面凸部
91、101、121 第1の型として上型
92 成形体A
93 吸引孔
94 吸引路
95,106、111 真空ライン
96 真空ポンプ
97 粘着テープ
98 アンダーカット部
102、122 第2の型としての下型
110 押さえ手段
127、128 加熱手段としてのヒーター

Claims (19)

  1.  予め成形した熱可塑性樹脂からなる成形体Aを第1の型にセットし、溶融した熱可塑性樹脂板Bを真空圧で前記第1の型に対向する第2の型の内面に吸着させることにより該第2の型の内面に沿う形状に賦形し、前記第1の型と前記第2の型を型締めすることにより、前記熱可塑性樹脂板Bと前記成形体Aを予め定めた領域のみで溶着するとともに、非溶着領域の少なくとも一部を中空部として形成することを特徴とする、中空部を有する熱可塑性樹脂成形体の製造方法。
  2.  前記成形体Aおよび熱可塑性樹脂板Bのうち少なくとも熱可塑性樹脂板Bが繊維強化熱可塑性樹脂からなる、請求項1に記載の熱可塑性樹脂成形体の製造方法。
  3.  前記繊維強化熱可塑性樹脂の強化繊維が炭素繊維、ガラス繊維、アラミド繊維から選ばれる少なくとも1種である、請求項2に記載の熱可塑性樹脂成形体の製造方法。
  4.  前記繊維強化熱可塑性樹脂の強化繊維が不連続繊維からなる、請求項2または3に記載の熱可塑性樹脂成形体の製造方法。                                            
  5.  前記不連続繊維の重量平均繊維長が10mm以上である、請求項4に記載の熱可塑性樹脂成形体の製造方法。
  6.  前記繊維強化熱可塑性樹脂中の前記不連続繊維の含有量が5~50重量%の範囲にある、請求項4または5に記載の熱可塑性樹脂成形体の製造方法。
  7.  前記繊維強化熱可塑性樹脂の強化繊維が連続繊維からなる、請求項2または3に記載の熱可塑性樹脂成形体の製造方法
  8.  前記強化繊維が一方向に引き揃えられた連続繊維からなる、請求項7に記載の熱可塑性樹脂成形体の製造方法。
  9.  前記繊維強化熱可塑性樹脂中の前記連続繊維の含有量が1~80重量%の範囲にある、請求項7または8に記載の熱可塑性樹脂成形体の製造方法。
  10.  前記繊維強化熱可塑性樹脂の強化繊維が織物からなる、請求項7~9のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  11.  前記熱可塑性樹脂板Bが、一方向に引き揃えられた強化繊維と熱可塑性樹脂が予め熱プレスにより一体化されたテープ状繊維強化熱可塑性樹脂からなる、請求項7~10のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  12.  前記テープ状繊維強化熱可塑性樹脂のテープ幅が6~50mmの範囲にある、請求項11に記載の熱可塑性樹脂成形体の製造方法。
  13.  前記第2の型として、キャビティ内から空気を吸引するための微細孔を有する金型を使用する、請求項1~12のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  14.  前記第1の型として、前記成形体Aを保持するための吸引微細孔を有する金型を使用する、請求項1~13のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  15.  熱可塑性樹脂板Bの前記第2の型への非接触面に熱可塑性樹脂フイルムを積層して熱可塑性樹脂板Bを賦形する、請求項13または14に記載の熱可塑性樹脂成形体の製造方法。
  16.  成形体Aおよび熱可塑性樹脂板Bを構成する熱可塑性樹脂がポリフェニレンスルフィド樹脂、ポリアミド樹脂、ポリオレフィン樹脂、ポリエステル樹脂、ABS樹脂、ポリカーボネート樹脂、ポリアセタール樹脂の少なくとも1種以上からなる、請求項1~15のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  17.  熱可塑性樹脂板Bの外周部を押さえながら熱可塑性樹脂板Bを賦形する、請求項1~16のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  18.  少なくとも前記第2の型の前記溶着領域の少なくとも一部に対応する部位に加熱手段を設置し、該加熱手段による加熱を利用して前記溶着を行う、請求項1~17のいずれかに記載の熱可塑性樹脂成形体の製造方法。
  19.  請求項1~18のいずれかに記載の方法により製造された、1m以上の上面の表面積を有する、中空部を有する熱可塑性樹脂成形体。
PCT/JP2012/083383 2011-12-28 2012-12-25 中空部を有する熱可塑性樹脂成形体およびその製造方法 WO2013099828A1 (ja)

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CN103946009A (zh) 2014-07-23
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