WO2022163561A1 - Method for producing molded body - Google Patents

Method for producing molded body Download PDF

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Publication number
WO2022163561A1
WO2022163561A1 PCT/JP2022/002344 JP2022002344W WO2022163561A1 WO 2022163561 A1 WO2022163561 A1 WO 2022163561A1 JP 2022002344 W JP2022002344 W JP 2022002344W WO 2022163561 A1 WO2022163561 A1 WO 2022163561A1
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WO
WIPO (PCT)
Prior art keywords
mold
resin sheet
molten resin
split
clamping
Prior art date
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PCT/JP2022/002344
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French (fr)
Japanese (ja)
Inventor
太一 中嶋
健一 村尾
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キョーラク株式会社
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Publication of WO2022163561A1 publication Critical patent/WO2022163561A1/en

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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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete 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
    • B29C51/00—Shaping 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
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only

Definitions

  • the present invention relates to a method for manufacturing a molded body.
  • Patent Literature 1 discloses a method of press-molding a molten resin sheet extruded from a resin sheet forming apparatus (extrusion apparatus) by suspending it between molds. According to such a manufacturing method, it is possible to efficiently mold a resin panel by directly molding a resin sheet in a molten state with a mold.
  • the present invention has been made in view of such circumstances, and provides a method for manufacturing a molded body that can efficiently use a mold and improve molding efficiency.
  • the second split mold is arranged on the side of the first resin sheet forming device, and the second split mold is arranged on the side of the second resin sheet forming device. and a step of clamping with the second split mold and a step of extruding the second molten resin sheet from the second resin sheet forming device and clamping the mold with the first and second split molds alternately. is provided.
  • a set of molds (first and second split molds) sequentially clamp the molten resin sheets alternately extruded from the first and second resin sheet forming devices, thereby can be used efficiently to improve molding efficiency.
  • the first and second resin sheet forming devices each include an accumulator capable of storing molten resin and a T die for extruding the molten resin in a sheet form, and the T die of one of the resin sheet forming devices While the extruded molten resin sheet is forming the molded body, the molten resin is stored in the accumulator of the other resin sheet forming apparatus.
  • a first mold frame is provided on the outer periphery of the first split mold
  • a second mold frame is provided on the outer periphery of the second split mold
  • the first mold frame is the first mold frame.
  • the second formwork is configured to be capable of adsorbing the second molten resin sheet
  • the first formwork or the second formwork is configured to adsorb the corresponding molten resin sheet. In this state, the first and second split molds are clamped.
  • the first mold and the second mold are configured to move forward and backward in a mold closing direction and a mold opening direction, respectively, and the first mold and the second mold are arranged in the mold closing direction. Adsorbs the corresponding molten resin sheet in the state of advancing to.
  • the first split mold is a convex mold
  • the second split mold is a concave mold
  • the first or second molten resin is melted by clamping the first and second split molds. Shape the sheet.
  • FIG. 1 is a schematic diagram showing an example of a molding machine 1 that can be used in a method for manufacturing a molded article according to one embodiment of the present invention
  • FIG. 1 is a flow chart showing a method for manufacturing a molded body according to an embodiment of the present invention
  • 3 is a schematic diagram showing a state in which a first molten resin sheet 5A is suspended from a first resin sheet forming device 2A in the molding machine 1 of FIG. 2.
  • FIG. 6 is a schematic diagram showing a state in which the first molten resin sheet 5A is cut off by the first split mold 3A and the second split mold 3B after the state of FIG. 5; It is a schematic diagram which shows a mode that the 1st split metal mold 3A and the 2nd split metal mold 3B were clamped after the state of FIG. 2 is a schematic diagram showing a state in which a second molten resin sheet 5B is suspended from a second resin sheet forming device 2B in the molding machine 1 of FIG. 1.
  • FIG. 8 After the state of FIG. 8, it is a schematic diagram which shows a mode that the 2nd mold 4B was advanced and it was made to contact
  • FIG. 9 After the state of FIG. 9, clamping of the first split mold 3A and the second split mold 3B was started, and the second molten resin sheet 5B was brought into contact with the cutout portion 31 of the second split mold 3B.
  • FIG. 11 is a schematic diagram showing how the second molten resin sheet 5B is cut off by the first split mold 3A and the second split mold 3B after the state of FIG. 10 ; 11.
  • the molding machine 1 includes first and second resin sheet forming devices 2A and 2B, first and second split molds 3A and 3B that can be opened and closed, and first and second molds 4A and 4B.
  • a resin panel can be given as a molded body manufactured by the molding machine 1 of the present embodiment.
  • the molding machine 1 of the present embodiment is particularly suitable for manufacturing large panels such as wall materials for temporary toilets. Each configuration will be described in detail below.
  • the first and second resin sheet forming apparatuses 2A and 2B have the same configuration, and include a hopper 21, an extruder 22, a hydraulic motor 23, an accumulator 24, a plunger 25, a T-die 26, and rollers 27, respectively. and
  • the extruder 22 and the accumulator 24 are connected via a connecting pipe 28 .
  • the accumulator 24 and the T-die 26 are connected via a connecting pipe 29 .
  • the hopper 21 is used to charge raw material resin into the extruder 22 .
  • the form of the raw material resin is not particularly limited, it is usually in the form of pellets.
  • the raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymers and mixtures thereof.
  • the extruder 22 heats the raw material resin to form a molten resin, rotates a screw (not shown) arranged inside by the hydraulic motor 23, and conveys the raw material resin toward the tip while kneading it.
  • the conveyed molten resin is extruded from the resin extrusion port and injected into the accumulator 24 through the connecting pipe 28 .
  • the accumulator 24 stores and cools a predetermined amount of molten resin.
  • the plunger 25 raises the pressure of the molten resin in the accumulator 24 and pushes it out through the connecting pipe 29 to the T-die 26 .
  • the T-die 26 has a slit, and by opening the slit at an appropriate timing, the molten resin sheets 5A and 5B in a molten state are extruded in a sheet form.
  • the extruded molten resin sheets 5A and 5B are sent out by rollers 27 and suspended between the split molds 3A and 3B.
  • the first and second split molds 3A, 3B are arranged facing each other and configured to be openable and closable.
  • the first and second split molds 3A and 3B respectively form a first molten resin sheet 5A suspended from the first resin sheet forming device 2A and a second molten resin sheet 5B suspended from the second resin sheet forming device 2B. It is arranged so that mold clamping is possible.
  • the first split mold 3A is arranged on the side of the first resin sheet forming device 2A
  • the second split mold 3B is arranged on the side of the second resin sheet forming device 2B.
  • the first split mold 3A is a convex mold
  • the second split mold 3B is a concave mold.
  • a cut portion 31 is formed in the second split mold 3B.
  • the first mold 4A is provided over the entire circumference of the first split mold 3A
  • the second mold 4B is provided over the outer periphery of the second split mold 3B.
  • the first and second molds 4A and 4B are provided with groove-shaped vacuum suction holes 41 for vacuum suction.
  • the vacuum suction holes 41 are connected to a vacuum device (not shown).
  • the suction hole 41 is configured to be able to suck the second molten resin sheet 5B.
  • the first and second forms 4A and 4B are configured to be able to advance and retreat (advance and retreat) in the mold closing direction and the mold opening direction, respectively.
  • FIG. 1 The method of the present embodiment includes a first molding step of extruding a first molten resin sheet 5A (see FIG. 3) from a first resin sheet forming apparatus 2A and clamping the first and second split molds 3A and 3B; A second molding step in which a second molten resin sheet 5B (see FIG. 4) is extruded from a second resin sheet forming device 2B and clamped by first and second split molds 3A and 3B is alternately performed.
  • a first molding step of extruding a first molten resin sheet 5A see FIG. 3
  • a second molding step in which a second molten resin sheet 5B (see FIG. 4) is extruded from a second resin sheet forming device 2B and clamped by first and second split molds 3A and 3B is alternately performed.
  • a first hanging step S1 a first adsorption step S2, a first mold clamping step S3, and a first mold opening step S4 are sequentially performed.
  • the first formwork 4A is advanced in the clamping direction to adsorb the first molten resin sheet 5A.
  • the first molten resin is The sheet 5A is adsorbed to the first formwork 4A.
  • the first molten resin sheet 5A is gripped by the first molding frame 4A, and the curtain phenomenon (occurrence of slack and wrinkles) due to drawdown of the first molten resin sheet 5A during mold clamping is suppressed.
  • first mold clamping step S3 Next, in the first mold clamping step S3, as shown in FIGS. 4 to 7, the first and second split molds 3A and 3B are clamped. At this time, first, the first split mold 3A and the first mold frame 4A, and the second split mold 3B and the second mold frame 4B are moved integrally in the mold clamping direction, and the first molten resin sheet 5A is moved. abuts on the cutout portion 31 of the second split mold 3B (see FIG. 5). Further, by moving the first split mold 3A relative to the first mold 4A in the clamping direction, the first molten resin sheet 5A comes into contact with the convex first split mold 3A. (See Figure 6).
  • the molds are clamped by moving the first and second split molds 3A and 3B in the mold clamping direction.
  • the first split mold 3A advances further until the molds are clamped.
  • the first formwork 4A retreats. This is to prevent the first mold 4A and the second split mold 3B from approaching each other and biting the first molten resin sheet 5A between them.
  • the first molten resin sheet 5A is shaped by clamping the first and second split molds 3A and 3B.
  • the first molten resin sheet 5A of the present embodiment is shaped by mold clamping, and the first split mold 3A performs vacuum suction (cavity vacuum suction) before mold clamping. It is not shaped.
  • vacuum suction cavity vacuum suction
  • the pressure is reduced prior to mold clamping.
  • Suction is effective. In this case, vacuum suction is preferably performed immediately before closing the mold.
  • the first molten resin sheet 5A of the present embodiment is out of contact with the first and second split molds 3A and 3B until immediately before the molds are clamped. It is designed not to be cooled by the split molds 3A and 3B. Also, in the first mold clamping step S3, the second mold 4B is always at a position retreating from the cutting edge 31 so as not to interfere with the first mold 4A.
  • Second Forming Step After completing the first forming step, when continuing to form the molded body, the second forming step is performed.
  • a second hanging process S6, a second adsorption process S7, a second mold clamping process S8, and a second mold opening process S9 are sequentially performed.
  • the second molten resin sheet 5B is also shaped by mold clamping, and the second split mold 3B performs vacuum suction (cavity vacuum suction) before mold clamping. It is not shaped. However, even if shaping is not performed, in order to release the air in the space surrounded by the cavity of the second split mold 3B, the second mold 4B, and the second molten resin sheet 5B, the pressure is reduced prior to mold clamping. Suction is effective. In this case, vacuum suction is preferably performed immediately before closing the mold.
  • the second molten resin sheet 5B of the present embodiment is out of contact with the first and second split molds 3A and 3B until immediately before the molds are clamped. It is designed not to be cooled by the split molds 3A and 3B.
  • the first mold 4A is always in a retracted position so as not to interfere with the second mold 4B.
  • the molded body is continuously molded by repeating the above-described first molding step and second molding step. It is a way to Specifically, as shown in the flowchart of FIG. 2, after the first mold opening step S4 of the first molding step is completed, and after the second mold opening step S9 of the second molding step is completed, predetermined It is determined whether or not a number of molded bodies have been molded (steps S5 and S10), and the first molding process and the second molding process are repeated until a predetermined number of molded bodies are molded.
  • the first resin sheet forming device 2A and the second resin sheet forming device 2B alternately form and hang down the first and second molten resin sheets 5A and 5B. While one resin sheet forming apparatus 2A, 2B is forming the molten resin sheets 5A, 5B, the molten resin is stored and cooled in the accumulator 24 of the other resin sheet forming apparatus 2B, 2A.
  • the mold clamping position L is not changed for each of the resin sheet forming apparatuses 2A and 2B, and the mold clamping position L by the first and second split molds 3A and 3B (Fig. 7 and FIG. 12) are the same in the first molding process and the second molding process. In other words, even if the positions at which the molten resin sheets 5A and 5B are suspended are different, the first and second split molds 3A and 3B are opened and closed at the same position for mold clamping.
  • the mold clamping position L is between the hanging position of the first molten resin sheet 5A by the first resin sheet forming device 2A and the hanging position of the second molten resin sheet 5B by the second resin sheet forming device 2B. , substantially midway between the two drooping positions of the molten resin sheets 5A and 5B.
  • the first and second split molds 3A and 3B are alternately fed from the first and second resin sheet forming devices 2A and 2B.
  • the molten resin is stored in the accumulator 24 of the other resin sheet forming apparatus 2B, 2A.
  • ⁇ Since cooling time can be taken, it is possible to improve molding efficiency with only one set of molds without a complicated structure. In this respect, for example, when molding a large molded product such as a wall material for a temporary toilet, cooling in the accumulator 24 takes a particularly long time. , 3B do not have to wait, and the molding efficiency can be improved.
  • first mold clamping step S3 and the second mold clamping step S8 of the present embodiment shaping by cavity vacuum suction is not performed, and the first molten resin sheet 5A or the second molten resin sheet 5B is shaped by clamping. shape.
  • first and second molten resin sheets 5A and 5B are first separated from the cutout portion 31 of the second split mold 3B which is a concave mold. , and immediately after contacting the convex first split mold 3A, the mold is clamped.
  • both the first mold clamping step S3 and the second mold clamping step S8 the first and second split molds 3A, 3B are applied in the same order to the first and second molten resin sheets 5A, 5B. Therefore, the cooling time of both sides of the first and second molten resin sheets 5A and 5B in the first molding process and the second molding process becomes equal, and the quality of the molded product can be made uniform. can. Furthermore, in the first mold clamping step S3 and the second mold clamping step S8 of the present embodiment, both surfaces of the first and second molten resin sheets 5A, 5B are cooled substantially simultaneously by the first and second split molds 3A, 3B. Therefore, it is possible to suppress the warpage of the molded product.
  • the present invention can also be implemented in the following modes. - In the above-described embodiment, the first and second molds 4A, 4B are provided over the entire circumferences of the first and second split molds 3A, 3B. However, in the method for manufacturing a molded body of the present invention, since shaping by cavity vacuum suction is not performed, the first and second molds 4A and 4B are placed on the outer periphery of the first and second split molds 3A and 3B. It is also possible to set it as the structure provided only in one part. Even with such a configuration, the first and second molds 4A, 4B grip the first and second molten resin sheets 5A, 5B, and the first and second molten resin sheets 5A, 5B during mold clamping.
  • first and second forms 4A and 4B are used to suppress the curtain phenomenon caused by the drawdown of the first and second molten resin sheets 5A and 5B during mold clamping.
  • a gripping mechanism expander
  • the first and second molten resin sheets 5A and 5B are pulled by the gripping mechanism, and the first and second molten resin sheets 5A and 5B are moved to the mold clamping position in a state where the wrinkles are smoothed out to clamp the molds. , the drawdown can be suppressed.

Abstract

Provided is a method for producing a molded body that enables molding efficiency to be improved by using a mold efficiently.　According to the present invention, provided is a method for producing a molded body that uses first and second resin sheet forming devices and first and second split molds that can be opened and closed. The first split mold is disposed on the first resin sheet forming device side and the second split mold is disposed on the second resin sheet forming device side. The method includes, executed alternately, a step for extruding a first molten resin sheet from the first resin sheet forming device and performing mold clamping using the first and second split molds, and a step for extruding a second molten resin sheet from the second resin sheet forming device and performing mold clamping using the first and second split molds.

Description

成形体の製造方法Molded body manufacturing method
　本発明は、成形体の製造方法に関する。 The present invention relates to a method for manufacturing a molded body.
　従来、樹脂シートを一対の金型により型締めして成形する成形体の製造方法がある。例えば、特許文献１には、樹脂シート形成装置（押出装置）から押し出された溶融状態の樹脂シートを金型の間に垂下し、その樹脂シートをプレス成形する方法が開示されている。このような製造方法によれば、溶融状態の樹脂シートをそのまま金型で成形することで、効率的に樹脂製パネルを成形することが可能である。 Conventionally, there is a method of manufacturing a molded product in which a resin sheet is molded by clamping it with a pair of molds. For example, Patent Literature 1 discloses a method of press-molding a molten resin sheet extruded from a resin sheet forming apparatus (extrusion apparatus) by suspending it between molds. According to such a manufacturing method, it is possible to efficiently mold a resin panel by directly molding a resin sheet in a molten state with a mold.
実開平６－２８４８８８号公報Japanese Utility Model Laid-Open No. 6-284888
　しかしながら、上記のような製造方法において、樹脂シート形成装置が一度樹脂シートを押し出した後には、アキュームレータに次に押し出すための溶融樹脂を貯留するための時間が必要である。そして、特に大型のパネルを成形する場合には必要な溶融樹脂の貯留量が多いため、金型を型開きして樹脂製パネルを取り出した後も、次の樹脂シートが押し出し可能になるまでに待ち時間が生じることがあった。 However, in the manufacturing method as described above, after the resin sheet forming apparatus once extrudes the resin sheet, it takes time for the accumulator to store the molten resin for the next extrusion. Especially when molding a large panel, a large amount of molten resin is required to be stored. Sometimes there was waiting time.
　本発明はこのような事情に鑑みてなされたものであり、金型を効率的に使用し、成形効率を向上させることが可能な成形体の製造方法を提供するものである。 The present invention has been made in view of such circumstances, and provides a method for manufacturing a molded body that can efficiently use a mold and improve molding efficiency.
　本発明によれば、第１及び第２樹脂シート形成装置と、開閉可能な第１及び第２分割金型とを用いた成形体の製造方法であって、前記第１分割金型は前記第１樹脂シート形成装置側に配置され、前記第２分割金型は前記第２樹脂シート形成装置側に配置されており、前記第１樹脂シート形成装置から第１溶融樹脂シートを押し出して前記第１及び第２分割金型により型締めする工程と、前記第２樹脂シート形成装置から第２溶融樹脂シートを押し出して前記第１及び第２分割金型により型締めする工程とを交互に行う、方法が提供される。 According to the present invention, there is provided a method for manufacturing a molded body using first and second resin sheet forming apparatuses and first and second split molds that can be opened and closed, wherein the first split mold is the second split mold. The second split mold is arranged on the side of the first resin sheet forming device, and the second split mold is arranged on the side of the second resin sheet forming device. and a step of clamping with the second split mold and a step of extruding the second molten resin sheet from the second resin sheet forming device and clamping the mold with the first and second split molds alternately. is provided.
　本発明によれば、一組の金型（第１及び第２分割金型）が第１及び第２樹脂シート形成装置から交互に押し出された溶融樹脂シートを順次型締めすることで、金型を効率的に使用し、成形効率を向上させることが可能となっている。 According to the present invention, a set of molds (first and second split molds) sequentially clamp the molten resin sheets alternately extruded from the first and second resin sheet forming devices, thereby can be used efficiently to improve molding efficiency.
　以下、本発明の種々の実施形態を例示する。以下に示す実施形態は互いに組み合わせ可能である。 Various embodiments of the present invention are exemplified below. The embodiments shown below can be combined with each other.
　好ましくは、前記第１及び第２樹脂シート形成装置はそれぞれ、溶融樹脂を貯留可能なアキュームレータと、前記溶融樹脂をシート状にして押し出すＴダイとを備え、一方の樹脂シート形成装置のＴダイから押し出された溶融樹脂シートによって前記成形体を成形している間に、他方の樹脂シート形成装置のアキュームレータに前記溶融樹脂を貯留する。 Preferably, the first and second resin sheet forming devices each include an accumulator capable of storing molten resin and a T die for extruding the molten resin in a sheet form, and the T die of one of the resin sheet forming devices While the extruded molten resin sheet is forming the molded body, the molten resin is stored in the accumulator of the other resin sheet forming apparatus.
　好ましくは、前記第１分割金型の外周には第１型枠が設けられ、前記第２分割金型の外周には第２型枠が設けられており、前記第１型枠は前記第１溶融樹脂シートを吸着可能に構成され、前記第２型枠は前記第２溶融樹脂シートを吸着可能に構成されており、前記第１型枠又は前記第２型枠が対応する溶融樹脂シートを吸着した状態で前記第１及び第２分割金型を型締めする。 Preferably, a first mold frame is provided on the outer periphery of the first split mold, and a second mold frame is provided on the outer periphery of the second split mold, and the first mold frame is the first mold frame. The second formwork is configured to be capable of adsorbing the second molten resin sheet, and the first formwork or the second formwork is configured to adsorb the corresponding molten resin sheet. In this state, the first and second split molds are clamped.
　好ましくは、前記第１型枠及び前記第２型枠は、それぞれ型締め方向及び型開き方向に進退可能に構成されており、前記第１型枠及び前記第２型枠は、前記型締め方向に前進した状態で対応する溶融樹脂シートを吸着する。 Preferably, the first mold and the second mold are configured to move forward and backward in a mold closing direction and a mold opening direction, respectively, and the first mold and the second mold are arranged in the mold closing direction. Adsorbs the corresponding molten resin sheet in the state of advancing to.
　好ましくは、前記第１分割金型は凸型であり、前記第２分割金型は凹型であって、前記第１及び第２分割金型を型締めすることによって前記第１又は第２溶融樹脂シートを賦形する。 Preferably, the first split mold is a convex mold, the second split mold is a concave mold, and the first or second molten resin is melted by clamping the first and second split molds. Shape the sheet.
本発明の一実施形態に係る成形体の製造方法に利用可能な成形機１の一例を示す模式図である。1 is a schematic diagram showing an example of a molding machine 1 that can be used in a method for manufacturing a molded article according to one embodiment of the present invention; FIG. 本発明の一実施形態に係る成形体の製造方法を示すフローチャートである。1 is a flow chart showing a method for manufacturing a molded body according to an embodiment of the present invention; 図２の成形機１において、第１樹脂シート形成装置２Ａから第１溶融樹脂シート５Ａを垂下させている状態を示す模式図である。3 is a schematic diagram showing a state in which a first molten resin sheet 5A is suspended from a first resin sheet forming device 2A in the molding machine 1 of FIG. 2. FIG. 図３の状態の後、第１型枠４Ａを前進させて第１溶融樹脂シート５Ａに当接させた様子を示す模式図である。After the state of FIG. 3, it is a schematic diagram which shows a mode that 4 A of 1st molds were advanced and it was made to contact|abut on 5 A of 1st molten resin sheets. 図４の状態の後、第１分割金型３Ａ及び第２分割金型３Ｂの型締めを開始し、第１溶融樹脂シート５Ａを第２分割金型３Ｂの食切り部３１に当接させた様子を示す模式図である。After the state of FIG. 4, clamping of the first split mold 3A and the second split mold 3B was started, and the first molten resin sheet 5A was brought into contact with the cutout portion 31 of the second split mold 3B. It is a schematic diagram which shows a state. 図５の状態の後、第１分割金型３Ａ及び第２分割金型３Ｂにより第１溶融樹脂シート５Ａを食い切った様子を示す模式図である。FIG. 6 is a schematic diagram showing a state in which the first molten resin sheet 5A is cut off by the first split mold 3A and the second split mold 3B after the state of FIG. 5; 図６の状態の後、第１分割金型３Ａ及び第２分割金型３Ｂを型締めした様子を示す模式図である。It is a schematic diagram which shows a mode that the 1st split metal mold 3A and the 2nd split metal mold 3B were clamped after the state of FIG. 図１の成形機１において、第２樹脂シート形成装置２Ｂから第２溶融樹脂シート５Ｂを垂下させている状態を示す模式図である。2 is a schematic diagram showing a state in which a second molten resin sheet 5B is suspended from a second resin sheet forming device 2B in the molding machine 1 of FIG. 1. FIG. 図８の状態の後、第２型枠４Ｂを前進させて第２溶融樹脂シート５Ｂに当接させた様子を示す模式図である。After the state of FIG. 8, it is a schematic diagram which shows a mode that the 2nd mold 4B was advanced and it was made to contact|abut the 2nd molten resin sheet 5B. 図９の状態の後、第１分割金型３Ａ及び第２分割金型３Ｂの型締めを開始し、第２溶融樹脂シート５Ｂを第２分割金型３Ｂの食切り部３１に当接させた様子を示す模式図である。After the state of FIG. 9, clamping of the first split mold 3A and the second split mold 3B was started, and the second molten resin sheet 5B was brought into contact with the cutout portion 31 of the second split mold 3B. It is a schematic diagram which shows a state. 図１０の状態の後、第１分割金型３Ａ及び第２分割金型３Ｂにより第２溶融樹脂シート５Ｂを食い切った様子を示す模式図である。FIG. 11 is a schematic diagram showing how the second molten resin sheet 5B is cut off by the first split mold 3A and the second split mold 3B after the state of FIG. 10 ; 図１１の状態の後、第１分割金型３Ａ及び第２分割金型３Ｂを型締めした様子を示す模式図である。11. It is a schematic diagram which shows a mode that the 1st split metal mold 3A and the 2nd split metal mold 3B were clamped after the state of FIG.
　以下、本発明の実施形態について説明する。以下に示す実施形態中で示した各種特徴事項は、互いに組み合わせ可能である。また、各特徴について独立して発明が成立する。 Embodiments of the present invention will be described below. Various features shown in the embodiments shown below can be combined with each other. In addition, the invention is established independently for each feature.
１．成形機１の構成
　まず、図１を用いて、本発明の一実施形態に係る成形体の製造方法の実施に利用可能な成形機１について説明する。成形機１は、第１及び第２樹脂シート形成装置２Ａ，２Ｂと、開閉可能な第１及び第２分割金型３Ａ，３Ｂと、第１及び第２型枠４Ａ，４Ｂとを備える。なお、本実施形態の成形機１によって製造される成形体としては、例えば、樹脂製パネルが挙げられる。また、本実施形態の成形機１は、特に、仮設トイレの壁材等の大型パネルを製造するのに好適に利用される。以下、各構成について詳細に説明する。 1. Configuration of Molding Machine 1 First, a molding machine 1 that can be used for carrying out a method for manufacturing a molded article according to an embodiment of the present invention will be described with reference to FIG. The molding machine 1 includes first and second resin sheet forming devices 2A and 2B, first and second split molds 3A and 3B that can be opened and closed, and first and second molds 4A and 4B. For example, a resin panel can be given as a molded body manufactured by the molding machine 1 of the present embodiment. In addition, the molding machine 1 of the present embodiment is particularly suitable for manufacturing large panels such as wall materials for temporary toilets. Each configuration will be described in detail below.
＜第１及び第２樹脂シート形成装置２Ａ，２Ｂ＞
　第１及び第２樹脂シート形成装置２Ａ，２Ｂは、同一の構成であり、それぞれホッパー２１と、押出機２２と、油圧モータ２３と、アキュームレータ２４と、プランジャ２５と、Ｔダイ２６と、ローラ２７とを備える。押出機２２とアキュームレータ２４は、連結管２８を介して連結される。アキュームレータ２４とＴダイ２６は、連結管２９を介して連結される。 <First and second resin sheet forming devices 2A, 2B>
The first and second resin sheet forming apparatuses 2A and 2B have the same configuration, and include a hopper 21, an extruder 22, a hydraulic motor 23, an accumulator 24, a plunger 25, a T-die 26, and rollers 27, respectively. and The extruder 22 and the accumulator 24 are connected via a connecting pipe 28 . The accumulator 24 and the T-die 26 are connected via a connecting pipe 29 .
　ホッパー２１は、原料樹脂を押出機２２内に投入するために用いられる。原料樹脂の形態は、特に限定されないが、通常は、ペレット状である。原料樹脂は、例えばポリオレフィンなどの熱可塑性樹脂であり、ポリオレフィンとしては、低密度ポリエチレン、直鎖状低密度ポリエチレン、高密度ポリエチレン、ポリプロピレン、エチレン－プロピレン共重合体及びその混合物などが挙げられる。 The hopper 21 is used to charge raw material resin into the extruder 22 . Although the form of the raw material resin is not particularly limited, it is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymers and mixtures thereof.
　押出機２２は、原料樹脂を加熱して溶融樹脂とするとともに、油圧モータ２３により内部に配置されたスクリュー（図示せず）を回転駆動させ、原料樹脂を混練しながら先端に向けて搬送する。搬送された溶融樹脂は、樹脂押出口から押し出され、連結管２８を通じてアキュームレータ２４内に注入される。 The extruder 22 heats the raw material resin to form a molten resin, rotates a screw (not shown) arranged inside by the hydraulic motor 23, and conveys the raw material resin toward the tip while kneading it. The conveyed molten resin is extruded from the resin extrusion port and injected into the accumulator 24 through the connecting pipe 28 .
　アキュームレータ２４は、所定量の溶融樹脂を貯留・冷却する。プランジャ２５は、アキュームレータ２４内の溶融樹脂を高圧にして、連結管２９を通じてＴダイ２６に押し出す。また、Ｔダイ２６は、スリットを備えており、適宜のタイミングでスリットを開くことで、溶融状態の溶融樹脂シート５Ａ，５Ｂをシート状にして押し出す。押し出された溶融樹脂シート５Ａ，５Ｂは、ローラ２７によって送り出され、分割金型３Ａ，３Ｂ間に垂下される。 The accumulator 24 stores and cools a predetermined amount of molten resin. The plunger 25 raises the pressure of the molten resin in the accumulator 24 and pushes it out through the connecting pipe 29 to the T-die 26 . Further, the T-die 26 has a slit, and by opening the slit at an appropriate timing, the molten resin sheets 5A and 5B in a molten state are extruded in a sheet form. The extruded molten resin sheets 5A and 5B are sent out by rollers 27 and suspended between the split molds 3A and 3B.
＜第１及び第２分割金型３Ａ，３Ｂ＞
　第１及び第２分割金型３Ａ，３Ｂは、対向して配置され、開閉可能に構成される。第１及び第２分割金型３Ａ，３Ｂは、第１樹脂シート形成装置２Ａから垂下された第１溶融樹脂シート５Ａ及び第２樹脂シート形成装置２Ｂから垂下された第２溶融樹脂シート５Ｂをそれぞれ型締め可能に配置される。本実施形態において、第１分割金型３Ａは第１樹脂シート形成装置２Ａ側に配置され、第２分割金型３Ｂは第２樹脂シート形成装置２Ｂ側に配置される。また、第１分割金型３Ａは凸型であり、第２分割金型３Ｂは凹型である。そして、第２分割金型３Ｂには、食切り部３１が形成される。 <First and Second Split Molds 3A, 3B>
The first and second split molds 3A, 3B are arranged facing each other and configured to be openable and closable. The first and second split molds 3A and 3B respectively form a first molten resin sheet 5A suspended from the first resin sheet forming device 2A and a second molten resin sheet 5B suspended from the second resin sheet forming device 2B. It is arranged so that mold clamping is possible. In this embodiment, the first split mold 3A is arranged on the side of the first resin sheet forming device 2A, and the second split mold 3B is arranged on the side of the second resin sheet forming device 2B. Also, the first split mold 3A is a convex mold, and the second split mold 3B is a concave mold. A cut portion 31 is formed in the second split mold 3B.
＜第１及び第２型枠４Ａ，４Ｂ＞
　第１型枠４Ａは、第１分割金型３Ａの全周に亘って設けられ、第２型枠４Ｂは、第２分割金型３Ｂの外周に亘って設けられる。第１及び第２型枠４Ａ，４Ｂには、減圧吸引のための溝状の減圧吸引孔４１が設けられている。減圧吸引孔４１は、減圧装置（図示せず）に接続されており、第１型枠４Ａの減圧吸引孔４１は第１溶融樹脂シート５Ａを吸着可能に構成され、第２型枠４Ｂの減圧吸引孔４１は第２溶融樹脂シート５Ｂを吸着可能に構成されている。また、第１及び第２型枠４Ａ，４Ｂは、それぞれ型締め方向及び型開き方向に進退可能（前進及び後退可能）に構成されている。 <First and second forms 4A, 4B>
The first mold 4A is provided over the entire circumference of the first split mold 3A, and the second mold 4B is provided over the outer periphery of the second split mold 3B. The first and second molds 4A and 4B are provided with groove-shaped vacuum suction holes 41 for vacuum suction. The vacuum suction holes 41 are connected to a vacuum device (not shown). The suction hole 41 is configured to be able to suck the second molten resin sheet 5B. In addition, the first and second forms 4A and 4B are configured to be able to advance and retreat (advance and retreat) in the mold closing direction and the mold opening direction, respectively.
２．成形体の製造方法
　次に、図１～図１２を用いて、本発明の一実施形態の成形体の製造方法について説明する。本実施形態の方法は、第１樹脂シート形成装置２Ａから第１溶融樹脂シート５Ａ（図３参照）を押し出して第１及び第２分割金型３Ａ，３Ｂにより型締めする第１成形工程と、第２樹脂シート形成装置２Ｂから第２溶融樹脂シート５Ｂ（図４参照）を押し出して第１及び第２分割金型３Ａ，３Ｂにより型締めする第２成形工程とを交互に行う。以下、各工程を詳細に説明する。 2. Method for Manufacturing Molded Body Next, a method for manufacturing a molded body according to an embodiment of the present invention will be described with reference to FIGS. 1 to 12. FIG. The method of the present embodiment includes a first molding step of extruding a first molten resin sheet 5A (see FIG. 3) from a first resin sheet forming apparatus 2A and clamping the first and second split molds 3A and 3B; A second molding step in which a second molten resin sheet 5B (see FIG. 4) is extruded from a second resin sheet forming device 2B and clamped by first and second split molds 3A and 3B is alternately performed. Each step will be described in detail below.
２．１　第１成形工程
　第１成形工程では、第１垂下工程Ｓ１と、第１吸着工程Ｓ２と、第１型締め工程Ｓ３と、第１型開き工程Ｓ４を順次実行する。 2.1 First Forming Step In the first forming step, a first hanging step S1, a first adsorption step S2, a first mold clamping step S3, and a first mold opening step S4 are sequentially performed.
＜第１垂下工程Ｓ１＞
　まず、第１垂下工程Ｓ１では、図３に示すように、第１樹脂シート形成装置２Ａから第１分割金型３Ａの前面側に第１溶融樹脂シート５Ａを垂下させる。図３に示すように、第１溶融樹脂シート５Ａが垂下される間、第１型枠４Ａは、第１溶融樹脂シート５Ａから離れた位置に後退している。 <First hanging step S1>
First, in the first hanging step S1, as shown in FIG. 3, the first molten resin sheet 5A is hung from the first resin sheet forming apparatus 2A to the front side of the first split mold 3A. As shown in FIG. 3, while the first molten resin sheet 5A is suspended, the first formwork 4A is retracted to a position away from the first molten resin sheet 5A.
＜第１吸着工程Ｓ２＞
　次に、第１吸着工程Ｓ２では、図４に示すように、第１型枠４Ａを型締め方向に前進させ、第１溶融樹脂シート５Ａを吸着する。具体的には、第１型枠４Ａを第１溶融樹脂シート５Ａに当接させた状態で第１型枠４Ａの減圧吸引孔４１に接続された減圧装置を作動させることによって、第１溶融樹脂シート５Ａを第１型枠４Ａに吸着させる。これによって、第１溶融樹脂シート５Ａは第１型枠４Ａに把持されることになり、型締めの際の第１溶融樹脂シート５Ａのドローダウンによるカーテン現象（たるみやシワの発生）が抑制される。 <First Adsorption Step S2>
Next, in the first adsorption step S2, as shown in FIG. 4, the first formwork 4A is advanced in the clamping direction to adsorb the first molten resin sheet 5A. Specifically, in a state in which the first mold 4A is in contact with the first molten resin sheet 5A, the first molten resin is The sheet 5A is adsorbed to the first formwork 4A. As a result, the first molten resin sheet 5A is gripped by the first molding frame 4A, and the curtain phenomenon (occurrence of slack and wrinkles) due to drawdown of the first molten resin sheet 5A during mold clamping is suppressed. be.
＜第１型締め工程Ｓ３＞
　次に、第１型締め工程Ｓ３では、図４～図７に示すように、第１及び第２分割金型３Ａ，３Ｂの型締めを行う。この際には、まず、第１分割金型３Ａと第１型枠４Ａ、第２分割金型３Ｂと第２型枠４Ｂがそれぞれ一体的に型締め方向に移動し、第１溶融樹脂シート５Ａが第２分割金型３Ｂの食切り部３１に当接する（図５参照）。そして、さらに第１型枠４Ａに対して第１分割金型３Ａが相対的に型締め方向に移動することで、第１溶融樹脂シート５Ａが凸型である第１分割金型３Ａに当接する（図６参照）。その後は、第１及び第２分割金型３Ａ，３Ｂが型締め方向に移動することで型締めがなされる。なお、図６～図７に示すように、第１溶融樹脂シート５Ａが第１分割金型３Ａに当接した後、型締めされるまでは、第１分割金型３Ａはさらに前進する一方、第１型枠４Ａは後退する。これは、第１型枠４Ａと第２分割金型３Ｂが接近してこれらの間で第１溶融樹脂シート５Ａを噛んでしまうことを防止するためである。 <First mold clamping step S3>
Next, in the first mold clamping step S3, as shown in FIGS. 4 to 7, the first and second split molds 3A and 3B are clamped. At this time, first, the first split mold 3A and the first mold frame 4A, and the second split mold 3B and the second mold frame 4B are moved integrally in the mold clamping direction, and the first molten resin sheet 5A is moved. abuts on the cutout portion 31 of the second split mold 3B (see FIG. 5). Further, by moving the first split mold 3A relative to the first mold 4A in the clamping direction, the first molten resin sheet 5A comes into contact with the convex first split mold 3A. (See Figure 6). Thereafter, the molds are clamped by moving the first and second split molds 3A and 3B in the mold clamping direction. As shown in FIGS. 6 and 7, after the first molten resin sheet 5A comes into contact with the first split mold 3A, the first split mold 3A advances further until the molds are clamped. The first formwork 4A retreats. This is to prevent the first mold 4A and the second split mold 3B from approaching each other and biting the first molten resin sheet 5A between them.
　第１及び第２分割金型３Ａ，３Ｂを型締めすることによって、第１溶融樹脂シート５Ａは賦形される。このように、本実施形態の第１溶融樹脂シート５Ａは、型締めによって賦形されるようになっており、型締め前に第１分割金型３Ａが減圧吸引（キャビティ真空吸引）を行って賦形することはない。ただし、賦形を行わなくても、第１分割金型３Ａのキャビティ、第１型枠４Ａ及び第１溶融樹脂シート５Ａで囲まれる空間の空気を逃がすために、型締め前に補助的に減圧吸引することは有効である。この場合、減圧吸引は型締めの直前に行うことが好ましい。
The first molten resin sheet 5A is shaped by clamping the first and second split molds 3A and 3B. In this way, the first molten resin sheet 5A of the present embodiment is shaped by mold clamping, and the first split mold 3A performs vacuum suction (cavity vacuum suction) before mold clamping. It is not shaped. However, even if shaping is not performed, in order to release the air in the space surrounded by the cavity of the first split mold 3A, the first mold 4A, and the first molten resin sheet 5A, the pressure is reduced prior to mold clamping. Suction is effective. In this case, vacuum suction is preferably performed immediately before closing the mold.
　なお、このような工程であるため、本実施形態の第１溶融樹脂シート５Ａは、型締めされる直前まで第１及び第２分割金型３Ａ，３Ｂと非接触となり、これら第１及び第２分割金型３Ａ，３Ｂによって冷却されないようになっている。また、第１型締め工程Ｓ３において、第２型枠４Ｂは常に食切り部３１よりも後退した位置にあり、第１型枠４Ａと干渉しないようになっている。 Note that, due to such a process, the first molten resin sheet 5A of the present embodiment is out of contact with the first and second split molds 3A and 3B until immediately before the molds are clamped. It is designed not to be cooled by the split molds 3A and 3B. Also, in the first mold clamping step S3, the second mold 4B is always at a position retreating from the cutting edge 31 so as not to interfere with the first mold 4A.
＜第１型開き工程Ｓ４＞
　第１型締め工程Ｓ３の後は、第１及び第２分割金型３Ａ，３Ｂを開いて成形体を取り出し、バリを除去する。これにより、所望の成形体を得ることができる。 <First mold opening step S4>
After the first mold clamping step S3, the first and second split molds 3A and 3B are opened to take out the compact and remove burrs. Thereby, a desired compact can be obtained.
２．２　第２成形工程
　第１成形工程が終了した後、成形体の成形を継続する場合は、第２成形工程を行う。第２成形工程では、第２垂下工程Ｓ６と、第２吸着工程Ｓ７と、第２型締め工程Ｓ８と、第２型開き工程Ｓ９を順次実行する。 2.2 Second Forming Step After completing the first forming step, when continuing to form the molded body, the second forming step is performed. In the second molding process, a second hanging process S6, a second adsorption process S7, a second mold clamping process S8, and a second mold opening process S9 are sequentially performed.
＜第２垂下工程Ｓ６＞
　まず、第２垂下工程Ｓ６では、図８に示すように、第２樹脂シート形成装置２Ｂから第２分割金型３Ｂの前面側に第２溶融樹脂シート５Ｂを垂下させる。図８に示すように、第２溶融樹脂シート５Ｂが垂下される間、第２型枠４Ｂは、第２溶融樹脂シート５Ｂから離れた位置に後退している。 <Second Hanging Step S6>
First, in the second hanging step S6, as shown in FIG. 8, the second molten resin sheet 5B is hung from the second resin sheet forming device 2B to the front side of the second split mold 3B. As shown in FIG. 8, while the second molten resin sheet 5B is suspended, the second mold 4B is retreated to a position away from the second molten resin sheet 5B.
＜第２吸着工程Ｓ７＞
　次に、第２吸着工程Ｓ７では、図９に示すように、第２型枠４Ｂを型締め方向に前進させ、第２溶融樹脂シート５Ｂを吸着する。具体的には、第２型枠４Ｂを第２溶融樹脂シート５Ｂに当接させた状態で第２型枠４Ｂの減圧吸引孔４１に接続された減圧装置を作動させることによって、第２溶融樹脂シート５Ｂを第２型枠４Ｂに吸着させる。これによって、第２溶融樹脂シート５Ｂは第２型枠４Ｂに把持されることになり、型締めの際の第２溶融樹脂シート５Ｂのドローダウンによるカーテン現象（たるみやシワの発生）が抑制される。 <Second Adsorption Step S7>
Next, in the second adsorption step S7, as shown in FIG. 9, the second formwork 4B is advanced in the mold clamping direction to adsorb the second molten resin sheet 5B. Specifically, in a state in which the second mold 4B is in contact with the second molten resin sheet 5B, the second molten resin is The sheet 5B is attracted to the second formwork 4B. As a result, the second molten resin sheet 5B is held by the second mold frame 4B, and the curtain phenomenon (occurrence of slack and wrinkles) due to the drawdown of the second molten resin sheet 5B during mold clamping is suppressed. be.
＜第２型締め工程Ｓ８＞
　次に、第２型締め工程Ｓ８では、図９～図１２に示すように、第１及び第２分割金型３Ａ，３Ｂの型締めを行う。この際には、まず、第１分割金型３Ａと第１型枠４Ａが一体的に型締め方向に移動し、第２分割金型３Ｂと第２型枠４Ｂも型締め方向に移動する。ただし、第１分割金型３Ａが第２分割金型３Ｂに近づいた後は、第２型枠４Ｂのみが後退するか、又は、第２型枠４Ｂよりも第２分割金型３Ｂのほうが相対的に早く型締め方向に移動することで、型締め前に、第２溶融樹脂シート５Ｂが第２分割金型３Ｂの食切り部３１に当接する（図１０参照）。そして、第２分割金型３Ｂの食切り部３１と第２型枠４Ｂがともに第２溶融樹脂シート５Ｂに当接した後は、第２分割金型３Ｂと第２型枠４Ｂは一体的に型締め方向に移動する。そして、第２溶融樹脂シート５Ｂが凸型である第１分割金型３Ａに当接し（図１１参照）、さらに第１及び第２分割金型３Ａ，３Ｂが型締め方向に移動することで型締めがなされる（図１２参照）。第１及び第２分割金型３Ａ，３Ｂを型締めすることによって、第２溶融樹脂シート５Ｂは賦形される。このように、本実施形態では、第２溶融樹脂シート５Ｂも型締めによって賦形されるようになっており、型締め前に第２分割金型３Ｂが減圧吸引（キャビティ真空吸引）を行って賦形することはない。ただし、賦形を行わなくても、第２分割金型３Ｂのキャビティ、第２型枠４Ｂ及び第２溶融樹脂シート５Ｂで囲まれる空間の空気を逃がすために、型締め前に補助的に減圧吸引することは有効である。この場合、減圧吸引は型締めの直前に行うことが好ましい。 <Second mold clamping step S8>
Next, in the second mold clamping step S8, as shown in FIGS. 9 to 12, the first and second split molds 3A and 3B are clamped. At this time, first, the first split mold 3A and the first mold frame 4A move integrally in the mold clamping direction, and the second split mold 3B and the second mold frame 4B also move in the mold clamping direction. However, after the first split mold 3A approaches the second split mold 3B, only the second split mold 4B retreats, or the second split mold 3B moves closer to the second split mold 4B than the second split mold 4B. The second molten resin sheet 5B comes into contact with the cutting edge 31 of the second split mold 3B (see FIG. 10) by moving in the mold clamping direction relatively quickly. After both the cutout portion 31 of the second split mold 3B and the second mold frame 4B abut against the second molten resin sheet 5B, the second split mold 3B and the second mold frame 4B are integrated together. Move in the clamping direction. Then, the second molten resin sheet 5B comes into contact with the convex first split mold 3A (see FIG. 11), and the first and second split molds 3A and 3B move in the mold clamping direction, thereby Tightening is performed (see FIG. 12). The second molten resin sheet 5B is shaped by clamping the first and second split molds 3A and 3B. As described above, in the present embodiment, the second molten resin sheet 5B is also shaped by mold clamping, and the second split mold 3B performs vacuum suction (cavity vacuum suction) before mold clamping. It is not shaped. However, even if shaping is not performed, in order to release the air in the space surrounded by the cavity of the second split mold 3B, the second mold 4B, and the second molten resin sheet 5B, the pressure is reduced prior to mold clamping. Suction is effective. In this case, vacuum suction is preferably performed immediately before closing the mold.
　なお、このような工程であるため、本実施形態の第２溶融樹脂シート５Ｂは、型締めされる直前まで第１及び第２分割金型３Ａ，３Ｂと非接触となり、これら第１及び第２分割金型３Ａ，３Ｂによって冷却されないようになっている。なお、第１型締め工程Ｓ３において、第１型枠４Ａは常に後退した位置にあり、第２型枠４Ｂと干渉しないようになっている。 Due to such a process, the second molten resin sheet 5B of the present embodiment is out of contact with the first and second split molds 3A and 3B until immediately before the molds are clamped. It is designed not to be cooled by the split molds 3A and 3B. In the first mold clamping step S3, the first mold 4A is always in a retracted position so as not to interfere with the second mold 4B.
＜第２型開き工程Ｓ９＞
　第２型締め工程Ｓ８の後は、第１及び第２分割金型３Ａ，３Ｂを開いて成形体を取り出し、バリを除去する。これにより、所望の成形体を得ることができる。 <Second Mold Opening Step S9>
After the second mold clamping step S8, the first and second split molds 3A and 3B are opened, the compact is taken out, and burrs are removed. Thereby, a desired compact can be obtained.
２．３　第１成形工程と第２成形工程の繰り返し
　本実施形態の成形体の製造方法は、上述した第１成形工程と第２成形工程とを繰り返し行うことで、成形体を連続的に成形する方法である。具体的には、図２のフローチャートに示すように、第１成形工程の第１型開き工程Ｓ４が終了した後と、第２成形工程の第２型開き工程Ｓ９が終了した後には、それぞれ所定数の成形体が成形されたかどうかの判定を行い（ステップＳ５及びステップＳ１０）、所定数の成形体が成形されるまで、第１成形工程と第２成形工程とを繰り返し行う。この間、第１樹脂シート形成装置２Ａと第２樹脂シート形成装置２Ｂは交互に第１及び第２溶融樹脂シート５Ａ，５Ｂを形成・垂下する。一方の樹脂シート形成装置２Ａ，２Ｂが溶融樹脂シート５Ａ，５Ｂを形成している間、他方の樹脂シート形成装置２Ｂ，２Ａのアキュームレータ２４においては、溶融樹脂の貯留・冷却が行われる。 2.3 Repetition of first molding step and second molding step In the method for manufacturing a molded body of the present embodiment, the molded body is continuously molded by repeating the above-described first molding step and second molding step. It is a way to Specifically, as shown in the flowchart of FIG. 2, after the first mold opening step S4 of the first molding step is completed, and after the second mold opening step S9 of the second molding step is completed, predetermined It is determined whether or not a number of molded bodies have been molded (steps S5 and S10), and the first molding process and the second molding process are repeated until a predetermined number of molded bodies are molded. During this time, the first resin sheet forming device 2A and the second resin sheet forming device 2B alternately form and hang down the first and second molten resin sheets 5A and 5B. While one resin sheet forming apparatus 2A, 2B is forming the molten resin sheets 5A, 5B, the molten resin is stored and cooled in the accumulator 24 of the other resin sheet forming apparatus 2B, 2A.
　なお、本実施形態の成形体の製造方法では、樹脂シート形成装置２Ａ，２Ｂごとに型締め位置Ｌは変えておらず、第１及び第２分割金型３Ａ，３Ｂによる型締め位置Ｌ（図７及び図１２参照）は、第１成形工程と第２成形工程で一致するようになっている。つまり、溶融樹脂シート５Ａ，５Ｂを垂下する位置が異なっても、第１及び第２分割金型３Ａ，３Ｂを同じ位置で開閉して型締めを行うようになっている。型締め位置Ｌは、具体的には、第１樹脂シート形成装置２Ａによる第１溶融樹脂シート５Ａの垂下位置と第２樹脂シート形成装置２Ｂによる第２溶融樹脂シート５Ｂの垂下位置の間であり、溶融樹脂シート５Ａ，５Ｂの２つの垂下位置の略中間地点であることが好ましい。本実施形態の成形機１は、このような構成とすることで、装置が大掛かりになることを抑制することが可能となっている。 In addition, in the manufacturing method of the molded article of the present embodiment, the mold clamping position L is not changed for each of the resin sheet forming apparatuses 2A and 2B, and the mold clamping position L by the first and second split molds 3A and 3B (Fig. 7 and FIG. 12) are the same in the first molding process and the second molding process. In other words, even if the positions at which the molten resin sheets 5A and 5B are suspended are different, the first and second split molds 3A and 3B are opened and closed at the same position for mold clamping. Specifically, the mold clamping position L is between the hanging position of the first molten resin sheet 5A by the first resin sheet forming device 2A and the hanging position of the second molten resin sheet 5B by the second resin sheet forming device 2B. , substantially midway between the two drooping positions of the molten resin sheets 5A and 5B. By configuring the molding machine 1 of the present embodiment as described above, it is possible to prevent the apparatus from becoming large-scale.
３．作用効果
　以上のような本発明の一実施形態に係る成形体の製造方法によれば、第１及び第２分割金型３Ａ，３Ｂが第１及び第２樹脂シート形成装置２Ａ，２Ｂから交互に押し出された第１及び第２溶融樹脂シート５Ａ，５Ｂを順次型締めすることで、金型を効率的に使用し、成形効率を向上させることが可能となっている。具体的には、一方の樹脂シート形成装置２Ａ，２Ｂでの溶融樹脂シート５Ａ，５Ｂの形成及びこれの型締めの間に、他方の樹脂シート形成装置２Ｂ，２Ａのアキュームレータ２４において溶融樹脂の貯留・冷却時間が取れることから、複雑な構成にすることなく、１組の金型のみで成形効率を向上させることができるようになっている。この点、例えば仮設トイレの壁材等の大型成形品を成形する場合には、アキュームレータ２４における冷却に特に時間がかかるが、このような場合であっても、第１及び第２分割金型３Ａ，３Ｂに待ち時間を生じさせず、成形効率を向上させることが可能となる。 3. Effect According to the method for manufacturing a molded article according to the embodiment of the present invention as described above, the first and second split molds 3A and 3B are alternately fed from the first and second resin sheet forming devices 2A and 2B. By successively clamping the extruded first and second molten resin sheets 5A and 5B, it is possible to use the mold efficiently and improve molding efficiency. Specifically, during the formation of the molten resin sheets 5A, 5B in one resin sheet forming apparatus 2A, 2B and mold clamping thereof, the molten resin is stored in the accumulator 24 of the other resin sheet forming apparatus 2B, 2A.・Since cooling time can be taken, it is possible to improve molding efficiency with only one set of molds without a complicated structure. In this respect, for example, when molding a large molded product such as a wall material for a temporary toilet, cooling in the accumulator 24 takes a particularly long time. , 3B do not have to wait, and the molding efficiency can be improved.
　また、本実施形態の第１型締め工程Ｓ３及び第２型締め工程Ｓ８においては、キャビティ真空吸引による賦形を行わず、型締めによって第１溶融樹脂シート５Ａ又は第２溶融樹脂シート５Ｂを賦形する。そしてこの際、第１型締め工程Ｓ３と第２型締め工程Ｓ８のいずれにおいても、第１及び第２溶融樹脂シート５Ａ，５Ｂは、まず凹型である第２分割金型３Ｂの食切り部３１と当接し、続いて凸型の第１分割金型３Ａに当接した直後に型締めがなされる。このように、第１型締め工程Ｓ３及び第２型締め工程Ｓ８のいずれにおいても、第１及び第２溶融樹脂シート５Ａ，５Ｂに対し同様の順番で第１及び第２分割金型３Ａ，３Ｂが当接することになるため、第１成形工程及び第２成形工程での第１及び第２溶融樹脂シート５Ａ，５Ｂの両面の冷却時間が均等になり、成形品の品質を均一にすることができる。さらに、本実施形態の第１型締め工程Ｓ３及び第２型締め工程Ｓ８では第１及び第２溶融樹脂シート５Ａ，５Ｂの両面が第１及び第２分割金型３Ａ，３Ｂによりほぼ同時に冷却されるため、成形品の反りを抑制することも可能となっている。 Further, in the first mold clamping step S3 and the second mold clamping step S8 of the present embodiment, shaping by cavity vacuum suction is not performed, and the first molten resin sheet 5A or the second molten resin sheet 5B is shaped by clamping. shape. At this time, in both the first mold clamping step S3 and the second mold clamping step S8, the first and second molten resin sheets 5A and 5B are first separated from the cutout portion 31 of the second split mold 3B which is a concave mold. , and immediately after contacting the convex first split mold 3A, the mold is clamped. Thus, in both the first mold clamping step S3 and the second mold clamping step S8, the first and second split molds 3A, 3B are applied in the same order to the first and second molten resin sheets 5A, 5B. Therefore, the cooling time of both sides of the first and second molten resin sheets 5A and 5B in the first molding process and the second molding process becomes equal, and the quality of the molded product can be made uniform. can. Furthermore, in the first mold clamping step S3 and the second mold clamping step S8 of the present embodiment, both surfaces of the first and second molten resin sheets 5A, 5B are cooled substantially simultaneously by the first and second split molds 3A, 3B. Therefore, it is possible to suppress the warpage of the molded product.
４．変形例
　なお、本発明は、以下の態様でも実施可能である。
・上述した実施形態において、第１及び第２型枠４Ａ，４Ｂは、第１及び第２分割金型３Ａ，３Ｂの全周に亘って設けられていた。しかしながら、本発明の成形体の製造方法であれば、キャビティ真空吸引による賦形を行わないため、第１及び第２型枠４Ａ，４Ｂを第１及び第２分割金型３Ａ，３Ｂの外周のうち一部だけに設ける構成とすることも可能である。このような構成であっても、第１及び第２型枠４Ａ，４Ｂが第１及び第２溶融樹脂シート５Ａ，５Ｂを把持し、型締めの際の第１及び第２溶融樹脂シート５Ａ，５Ｂのドローダウンによるカーテン現象を抑制することが可能である。また、第１及び第２溶融樹脂シート５Ａ，５Ｂの性質によっては、第１及び第２型枠４Ａ，４Ｂを設けない構成とすることも可能である。
・上述した実施形態では、型締めの際の第１及び第２溶融樹脂シート５Ａ，５Ｂのドローダウンによるカーテン現象を抑制するために第１及び第２型枠４Ａ，４Ｂを用いていた。しかしながら、第１及び第２型枠４Ａ，４Ｂの代わりに、第１及び第２溶融樹脂シート５Ａ，５Ｂを各垂下位置において把持して引っ張る把持機構（エキスパンダー）を設けることも可能である。この場合、把持機構によって第１及び第２溶融樹脂シート５Ａ，５Ｂ引っ張り、シワを伸ばした状態で第１及び第２溶融樹脂シート５Ａ，５Ｂを型締め位置に移動させ、型締めを行うことで、ドローダウンを抑制することができる。 4. Modifications The present invention can also be implemented in the following modes.
- In the above-described embodiment, the first and second molds 4A, 4B are provided over the entire circumferences of the first and second split molds 3A, 3B. However, in the method for manufacturing a molded body of the present invention, since shaping by cavity vacuum suction is not performed, the first and second molds 4A and 4B are placed on the outer periphery of the first and second split molds 3A and 3B. It is also possible to set it as the structure provided only in one part. Even with such a configuration, the first and second molds 4A, 4B grip the first and second molten resin sheets 5A, 5B, and the first and second molten resin sheets 5A, 5B during mold clamping. It is possible to suppress the curtain phenomenon due to the drawdown of 5B. Further, depending on the properties of the first and second molten resin sheets 5A, 5B, it is possible to adopt a configuration in which the first and second molds 4A, 4B are not provided.
- In the above-described embodiment, the first and second forms 4A and 4B are used to suppress the curtain phenomenon caused by the drawdown of the first and second molten resin sheets 5A and 5B during mold clamping. However, instead of the first and second forms 4A, 4B, it is also possible to provide a gripping mechanism (expander) that grips and pulls the first and second molten resin sheets 5A, 5B at their hanging positions. In this case, the first and second molten resin sheets 5A and 5B are pulled by the gripping mechanism, and the first and second molten resin sheets 5A and 5B are moved to the mold clamping position in a state where the wrinkles are smoothed out to clamp the molds. , the drawdown can be suppressed.
１：成形機、２Ａ：第１樹脂シート形成装置、２Ｂ：第２樹脂シート形成装置、３Ａ：第１分割金型、３Ｂ：第２分割金型、４Ａ：第１型枠、４Ｂ：第２型枠、５Ａ：第１溶融樹脂シート、５Ｂ：第２溶融樹脂シート、２１：ホッパー、２２：押出機、２３：油圧モータ、２４：アキュームレータ、２５：プランジャ、２６：Ｔダイ、２７：ローラ、２８：連結管、２９：連結管、３１：食切り部、４１：減圧吸引孔 1: molding machine, 2A: first resin sheet forming device, 2B: second resin sheet forming device, 3A: first split mold, 3B: second split mold, 4A: first mold, 4B: second Formwork, 5A: first molten resin sheet, 5B: second molten resin sheet, 21: hopper, 22: extruder, 23: hydraulic motor, 24: accumulator, 25: plunger, 26: T die, 27: roller, 28: connecting pipe, 29: connecting pipe, 31: cutting portion, 41: vacuum suction hole

Claims (5)

  1. 　第１及び第２樹脂シート形成装置と、開閉可能な第１及び第２分割金型とを用いた成形体の製造方法であって、
    　前記第１分割金型は前記第１樹脂シート形成装置側に配置され、前記第２分割金型は前記第２樹脂シート形成装置側に配置されており、
    　前記第１樹脂シート形成装置から第１溶融樹脂シートを押し出して前記第１及び第２分割金型により型締めする工程と、前記第２樹脂シート形成装置から第２溶融樹脂シートを押し出して前記第１及び第２分割金型により型締めする工程とを交互に行う、方法。     A method for manufacturing a molded body using first and second resin sheet forming apparatuses and openable and closable first and second split molds,
    The first split mold is arranged on the first resin sheet forming device side, and the second split mold is arranged on the second resin sheet forming device side,
    A step of extruding a first molten resin sheet from the first resin sheet forming device and clamping it with the first and second split molds; extruding a second molten resin sheet from the second resin sheet forming device and A method of alternately performing a step of clamping with the first and second split molds.
  2. 　請求項１に記載の成形体の製造方法であって、
    　前記第１及び第２樹脂シート形成装置はそれぞれ、溶融樹脂を貯留可能なアキュームレータと、前記溶融樹脂をシート状にして押し出すＴダイとを備え、
    　一方の樹脂シート形成装置のＴダイから押し出された溶融樹脂シートによって前記成形体を成形している間に、他方の樹脂シート形成装置のアキュームレータに前記溶融樹脂を貯留する、方法。     A method for producing a molded article according to claim 1,
    Each of the first and second resin sheet forming devices includes an accumulator capable of storing molten resin, and a T die for extruding the molten resin into a sheet,
    A method of accumulating the molten resin in an accumulator of the other resin sheet forming device while the molded body is formed by the molten resin sheet extruded from the T-die of one of the resin sheet forming devices.
  3. 　請求項１又は請求項２に記載の成形体の製造方法であって、
    　前記第１分割金型の外周には第１型枠が設けられ、前記第２分割金型の外周には第２型枠が設けられており、
    　前記第１型枠は前記第１溶融樹脂シートを吸着可能に構成され、前記第２型枠は前記第２溶融樹脂シートを吸着可能に構成されており、
    　前記第１型枠又は前記第２型枠が対応する溶融樹脂シートを吸着した状態で前記第１及び第２分割金型を型締めする、方法。     A method for producing a molded article according to claim 1 or 2,
    A first mold frame is provided on the outer periphery of the first split mold, and a second mold frame is provided on the outer periphery of the second split mold,
    The first formwork is configured to be capable of adsorbing the first molten resin sheet, and the second formwork is configured to be capable of adsorbing the second molten resin sheet,
    A method of clamping the first and second split molds in a state in which the first mold or the second mold has attracted the corresponding molten resin sheet.
  4. 　請求項３に記載の成形体の製造方法であって、
    　前記第１型枠及び前記第２型枠は、それぞれ型締め方向及び型開き方向に進退可能に構成されており、
    　前記第１型枠及び前記第２型枠は、前記型締め方向に前進した状態で対応する溶融樹脂シートを吸着する、方法。     A method for producing a molded article according to claim 3,
    The first mold and the second mold are configured to move forward and backward in a mold clamping direction and a mold opening direction, respectively,
    The method, wherein the first mold frame and the second mold frame adsorb the corresponding molten resin sheets while advancing in the mold clamping direction.
  5. 　請求項３又は請求項４に記載の成形体の製造方法であって、
    　前記第１分割金型は凸型であり、前記第２分割金型は凹型であって、
    　前記第１及び第２分割金型を型締めすることによって前記第１又は第２溶融樹脂シートを賦形する、方法。     A method for producing a molded article according to claim 3 or 4,
    The first split mold is a convex mold, and the second split mold is a concave mold,
    A method of shaping the first or second molten resin sheet by clamping the first and second split molds.
PCT/JP2022/002344 2021-01-29 2022-01-24 Method for producing molded body WO2022163561A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59101322A (en) * 1982-12-02 1984-06-11 Sumitomo Chem Co Ltd Method of press molding thermoplastic resin
JP2011031500A (en) * 2009-07-31 2011-02-17 Kyoraku Co Ltd Method for molding thermoplastic resin-made single wall structure
JP2013028031A (en) * 2011-07-27 2013-02-07 Kyoraku Co Ltd Method of manufacturing resin molded product
JP2018140575A (en) * 2017-02-28 2018-09-13 キョーラク株式会社 Method for producing molded article
JP2018202620A (en) * 2017-05-30 2018-12-27 キョーラク株式会社 Structure and production method

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59101322A (en) * 1982-12-02 1984-06-11 Sumitomo Chem Co Ltd Method of press molding thermoplastic resin
JP2011031500A (en) * 2009-07-31 2011-02-17 Kyoraku Co Ltd Method for molding thermoplastic resin-made single wall structure
JP2013028031A (en) * 2011-07-27 2013-02-07 Kyoraku Co Ltd Method of manufacturing resin molded product
JP2018140575A (en) * 2017-02-28 2018-09-13 キョーラク株式会社 Method for producing molded article
JP2018202620A (en) * 2017-05-30 2018-12-27 キョーラク株式会社 Structure and production method

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