JP2017154409A - Hot press molding method and hot press molding apparatus - Google Patents
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Abstract
Description
本発明は、樹脂シートの被加工材を目的の形状に熱プレス成形する方法に関するものである。 The present invention relates to a method for hot press molding a work piece of a resin sheet into a target shape.
形状が転写された成形品を得る方法として、熱プレス成形方法や、射出成形方法が知られている。
図11は特許文献1などに記載されている熱プレス成形装置である。これは、被加工材14を事前に加熱し、この加熱された被加工材14を、第1金型1と第2金型2の間に設置する。次に、第1金型1を押し込みながら、第2金型2に沿うように被加工材14を変形させ、第1金型1が第2金型2と密着し被加工材14を加圧する。次に、第1金型1と第2金型2で挟んでいる被加工材14を、第1金型1と第2金型2で冷却する。この冷却の後に、第2金型2の表面形状が転写された被加工材14の成形品を、型開きして取り出す。
As a method for obtaining a molded product having a transferred shape, a hot press molding method and an injection molding method are known.
FIG. 11 shows a hot press molding apparatus described in Patent Document 1 and the like. In this process, the workpiece 14 is heated in advance, and the heated workpiece 14 is placed between the first mold 1 and the second mold 2. Next, while pushing the first mold 1, the workpiece 14 is deformed along the second mold 2, and the first mold 1 comes into close contact with the second mold 2 and pressurizes the workpiece 14. . Next, the workpiece 14 sandwiched between the first mold 1 and the second mold 2 is cooled by the first mold 1 and the second mold 2. After this cooling, the molded product of the workpiece 14 to which the surface shape of the second mold 2 is transferred is opened and taken out.
図12は特許文献2などに記載されている射出成形装置である。従来の射出成形方法は、第1金型1と、第2金型2を加熱し、第2金型2を移動させ、第1金型1と密着させてキャビティを形成し、溶融した樹脂を前記キャビティに射出し、その後に第1金型1と第2金型2を冷却する。この冷却の後、キャビティの形状が転写された成形品を取り出す。 FIG. 12 shows an injection molding apparatus described in Patent Document 2 and the like. In the conventional injection molding method, the first mold 1 and the second mold 2 are heated, the second mold 2 is moved, and the cavity is formed in close contact with the first mold 1, and the molten resin The first mold 1 and the second mold 2 are cooled after injection into the cavity. After this cooling, the molded product having the cavity shape transferred thereon is taken out.
しかし、従来の熱プレス成形方法では、事前に加熱された被加工材14を金型内に搬送する際に、自然冷却してしまい、形状を維持することができない。そのため特許文献1では、第1金型1と第2金型2を個別に加熱できるヒータ16と、第1金型1と第2金型2を個別に冷却できる冷却水管18を設け、成形時は、樹脂が軟化する温度まで金型を加熱し、成形後は金型を冷却し、樹脂を固化させ、成形品を取り出すことができるようにしている。 However, in the conventional hot press molding method, when the workpiece 14 heated in advance is transported into the mold, it naturally cools and the shape cannot be maintained. Therefore, in Patent Document 1, a heater 16 capable of individually heating the first mold 1 and the second mold 2 and a cooling water pipe 18 capable of individually cooling the first mold 1 and the second mold 2 are provided, The mold is heated to a temperature at which the resin softens, and after the molding, the mold is cooled, the resin is solidified, and the molded product can be taken out.
また、従来の射出成形方法では、溶融した樹脂を射出し、金型形状に追従させるが、射出した瞬間に、金型に熱が奪われるため、樹脂の流動が悪くなり、ヒケ、ウェルドといった成形不良や、成形品表面の光沢がなくなるという外観品位が悪くなってしまう。そのため特許文献2では、金型を加熱し、樹脂を射出時には金型を高温にし、射出充填後、冷却し、成形している。 In addition, in the conventional injection molding method, molten resin is injected and allowed to follow the mold shape, but at the moment of injection, heat is lost to the mold, so that the resin flow deteriorates and molding such as sink marks and welds is formed. Deterioration and appearance quality such as loss of gloss on the surface of the molded product will be deteriorated. Therefore, in Patent Document 2, the mold is heated, the mold is heated to a high temperature when the resin is injected, and after injection filling, the mold is cooled and molded.
成形品が、深絞り形状などの場合、特許文献1では、被加工材14と金型が接触するタイミングが場所によって変わるため、被加工材14に金型から熱伝導で供給される熱量してくる時間が場所によって変わり、被加工材14表面の軟化度合いにバラツキが生じる。冷却についても、被加工材14の表裏の温度状態により、冷却後の被加工材14の応力状態にバラツキが生じ、成形後のフィルムに反り等が発生することがある。 In the case where the molded product has a deep drawing shape or the like, in Patent Document 1, since the timing at which the workpiece 14 and the mold come into contact varies depending on the location, the amount of heat supplied from the mold to the workpiece 14 by heat conduction is calculated. The coming time varies depending on the location, and the degree of softening of the surface of the workpiece 14 varies. As for cooling, the stress state of the workpiece 14 after cooling varies depending on the temperature state of the front and back surfaces of the workpiece 14, and the film after molding may be warped.
特許文献2では、ヒータ16間のピッチや、ヒータと金型表面方向の距離が金型形状により均等に配置できなかったり、金型材料の熱伝達ばらつきなどのため、金型表面温度は不均一になってしまい、さらに、同様に金型冷却時にも、冷却水管18間のピッチや、金型材料の熱伝達ばらつきなどのため、熱伝達バラツキにより金型表面温度が不均一になってしまうことにより、成形品表面の面内の温度分布にばらつきが生じ、外観品位が悪くなってしまう。 In Patent Document 2, the mold surface temperature is not uniform because the pitch between the heaters 16 and the distance between the heater and the mold surface cannot be evenly arranged due to the mold shape, or the heat transfer variation of the mold material. Furthermore, when the mold is cooled, the mold surface temperature becomes non-uniform due to variations in heat transfer due to the pitch between the cooling water pipes 18 and the heat transfer variation of the mold material. As a result, the temperature distribution within the surface of the molded product varies and the appearance quality deteriorates.
本発明は、熱プレス成形方法において、形状が安定した成形品を得ることができ、成形品の表面の高品質外観を得ることができる、熱プレス成形方法および装置を提供することを目的とする。 An object of the present invention is to provide a hot press molding method and apparatus capable of obtaining a molded product having a stable shape and obtaining a high-quality appearance of the surface of the molded product in the hot press molding method. .
本発明の熱プレス成形方法は、凸形状を有する第1金型と凹形状を有する第2金型との間に被加工材を配置する配置工程と、前記第1,第2金型と接近させて、前記第1金型の凸形状の頂点と前記被加工材接触する接触工程と、加熱した前記被加工材を、加熱した第2金型に対して下死点まで接近させて、前記被加工材を変形および加熱する変形加熱工程と、前記第1金型と前記第2金型とを冷却して、前記被加工材を冷却する冷却工程と、前記第1金型と前記第2金型とを離間させて成形が完了した前記被加工材の成形が完了した成形品を取り出す取り出し工程とを有し、前記変形加熱工程での前記第1金型の前記被加工材との接触面の温度は、前記第2金型の前記被加工材との接触面の温度より低いことを特徴とする。 The hot press molding method of the present invention includes an arrangement step of arranging a workpiece between a first mold having a convex shape and a second mold having a concave shape, and approaching the first and second molds. Letting the convex top of the first mold come into contact with the workpiece, and bringing the heated workpiece closer to the bottom dead center with respect to the heated second mold, A deformation heating process for deforming and heating the workpiece, a cooling process for cooling the first mold and the second mold to cool the workpiece, the first mold and the second mold A step of taking out a molded product that has been molded by separating the mold from the workpiece, and contacting the workpiece of the first mold in the deformation heating step. The temperature of the surface is lower than the temperature of the contact surface of the second mold with the workpiece.
また、本発明の熱プレス成形装置は、凸形状を有する第1金型と凹形状を有する第2金型と、前記第1金型を加熱した前記第2金型に対して下死点まで接近させて被加工材を変形および加熱する際に、前記第1金型の前記被加工材との接触面の温度を、前記第2金型の前記被加工材の接触面の温度より低くなるように温度制御する温度制御装置と
を有することを特徴とする。
Moreover, the hot press molding apparatus of the present invention includes a first mold having a convex shape, a second mold having a concave shape, and a bottom dead center with respect to the second mold that has heated the first mold. When the workpiece is deformed and heated close, the temperature of the contact surface of the first mold with the workpiece becomes lower than the temperature of the contact surface of the workpiece of the second mold. And a temperature control device for controlling the temperature as described above.
この構成によると、変形加熱工程での第1金型の被加工材との接触面の温度は、第2金型の被加工材との接触面の温度より低いので、樹脂シートの被加工材の形状が安定した成形品を得ることができ、表面の外観高品位を得ることができる。 According to this configuration, since the temperature of the contact surface with the workpiece of the first mold in the deformation heating step is lower than the temperature of the contact surface with the workpiece of the second mold, the workpiece of the resin sheet A molded product having a stable shape can be obtained, and a high-quality surface appearance can be obtained.
以下、本発明の熱プレス成形方法を実現する熱プレス成形装置を図1〜図10に基づいて説明する。
図1は、本発明の実施の形態1の熱プレス成形装置を示す。
Hereinafter, the hot press molding apparatus which implement | achieves the hot press molding method of this invention is demonstrated based on FIGS.
FIG. 1 shows a hot press molding apparatus according to Embodiment 1 of the present invention.
本装置は、凸型を有した第1金型1と、凹型を有した第2金型2を有している。
第1金型1には、ヒータ16aと温度センサ17aと冷却水管18aが内蔵されている。この第1金型1は複数の温度制御ゾーン、この実施の形態では第1,第2,第3温度制御ゾーン6,7,8に分割され、ヒータ16aは、各温度制御ゾーン毎に複数本内蔵されている。第1,第2,第3温度制御ゾーン6,7,8毎に温度センサ17aを内蔵している。第1,第2,第3温度制御ゾーン6,7,8毎の温度センサ17aは、温度制御装置4によって読み込まれ、加熱期間おける第1,第2,第3温度制御ゾーン6,7,8毎の温度が目標値に近付くようにヒータ16aへの通電が温度制御装置4によって制御されている。更に、冷却期間には、第1,第2,第3温度制御ゾーン6,7,8毎の温度が目標値に近付くように冷水制御装置5と冷却水バルブ19を介して温度制御装置4によって、冷却水管18aへの通水が制御されている。
This apparatus has a first mold 1 having a convex mold and a second mold 2 having a concave mold.
The first mold 1 includes a heater 16a, a temperature sensor 17a, and a cooling water pipe 18a. The first mold 1 is divided into a plurality of temperature control zones, in this embodiment, first, second, and third temperature control zones 6, 7, and 8. A plurality of heaters 16a are provided for each temperature control zone. Built in. A temperature sensor 17a is incorporated in each of the first, second, and third temperature control zones 6, 7, and 8. The temperature sensor 17a for each of the first, second, and third temperature control zones 6, 7, and 8 is read by the temperature control device 4, and the first, second, and third temperature control zones 6, 7, and 8 during the heating period. Energization of the heater 16a is controlled by the temperature control device 4 so that each temperature approaches the target value. Further, during the cooling period, the temperature control device 4 via the chilled water control device 5 and the cooling water valve 19 so that the temperature of each of the first, second, third temperature control zones 6, 7, 8 approaches the target value. The water flow to the cooling water pipe 18a is controlled.
同様に、第2金型2には、ヒータ16bと温度センサ17bと冷却水管18bが内蔵されている。この第2金型2は複数の温度制御ゾーン、この実施の形態では
第4,第5,第6,第7,第8温度制御ゾーン9,10,11,12,13に分割され、ヒータ16bは、各温度制御ゾーン毎に複数本内蔵されている。第4〜第8温度制御ゾーン9〜13毎に温度センサ17bを内蔵している。第4〜第8温度制御ゾーン9〜13毎の温度センサ17bは、温度制御装置4によって読み込まれ、加熱期間おける第4〜第8温度制御ゾーン9〜13毎の温度が目標値に近付くようにヒータ16bへの通電が制御されている。更に、冷却期間には、第4〜第8温度制御ゾーン9〜13毎の温度が目標値に近付くように冷水制御装置5と冷却水バルブ19を介して温度制御装置4によって、冷却水管18bへの通水が制御されている。
Similarly, the second mold 2 includes a heater 16b, a temperature sensor 17b, and a cooling water pipe 18b. The second mold 2 is divided into a plurality of temperature control zones, which are the fourth, fifth, sixth, seventh and eighth temperature control zones 9, 10, 11, 12, 13 in this embodiment, and the heater 16b. Are incorporated in each temperature control zone. A temperature sensor 17b is incorporated in each of the fourth to eighth temperature control zones 9 to 13. The temperature sensor 17b for each of the fourth to eighth temperature control zones 9 to 13 is read by the temperature control device 4 so that the temperature for each of the fourth to eighth temperature control zones 9 to 13 in the heating period approaches the target value. Energization to the heater 16b is controlled. Further, during the cooling period, the temperature control device 4 and the cooling water valve 19 pass the cooling water pipe 18b through the cooling water control device 5 and the cooling water valve 19 so that the temperatures of the fourth to eighth temperature control zones 9 to 13 approach the target value. The water flow is controlled.
なお、第1金型1には3個の温度制御ゾーン設定し、第2金型2には5個の温度制御ゾーンを設定しているが、これに限るものではない。第1金型1の温度制御ゾーン数は、第2金型2の温度制御ゾーン数より少なくしている。 Although three temperature control zones are set for the first mold 1 and five temperature control zones are set for the second mold 2, the present invention is not limited to this. The number of temperature control zones of the first mold 1 is smaller than the number of temperature control zones of the second mold 2.
ヒータ16a,16bには、本文中では棒状のカートリッジヒータで記載しているが、これに限るものではない。
この熱プレス成形装置のシーケンスは、図2(a)〜図2(h)を1サイクルとして実行されている。
The heaters 16a and 16b are described as rod-shaped cartridge heaters in the text, but are not limited thereto.
The sequence of this hot press molding apparatus is executed with one cycle from FIG. 2 (a) to FIG. 2 (h).
図2(a)に示した配置工程では、凸形状を有する第1金型1と凹形状を有する第2金型2との間に樹脂シートの被加工材14を配置する。被加工材14の具体例としては、図6のように繊維層21を中央にしてその両面に樹脂層20,22を積層したシートや、複数の樹脂シートの積層されたシートや、繊維層を含んだシートを例に挙げることができる。 In the arrangement step shown in FIG. 2A, a work piece 14 of a resin sheet is arranged between the first mold 1 having a convex shape and the second mold 2 having a concave shape. Specific examples of the workpiece 14 include a sheet in which the fiber layer 21 is centered as shown in FIG. 6 and the resin layers 20 and 22 are laminated on both sides, a sheet in which a plurality of resin sheets are laminated, and a fiber layer. An example is a sheet that contains it.
図2(b)に示した接触工程では、第1金型1を第2金型2に接近させて、第1金型1の頂点が被加工材14に接触する。
図2(c)〜図2(f)の変形加熱工程では、加熱した第1金型1を、加熱した第2金型2に対して下死点まで接近させて、被加工材14を変形および加熱する。図2(c)は変形開始工程、図2(d)は第1金型側変形工程、図2(e)は第2金型側変形工程、図2(f)は熱プレス工程の詳細は、追って説明する。
In the contact step shown in FIG. 2 (b), the first mold 1 is brought close to the second mold 2, and the apex of the first mold 1 contacts the workpiece 14.
2 (c) to 2 (f), the heated first mold 1 is brought close to the bottom dead center with respect to the heated second mold 2 to deform the workpiece 14. And heat. 2 (c) shows a deformation start process, FIG. 2 (d) shows a first mold side deformation process, FIG. 2 (e) shows a second mold side deformation process, and FIG. 2 (f) shows a hot press process in detail. I will explain later.
図2(g)の冷却工程では、第1金型1と第2金型2を冷却して、加工中の被加工材14を冷却する。
図2(h)の取り出し工程では、第1金型1と第2金型2とを離間させて、被加工材14が成形されて目的の形状に仕上がった成形品を取り出す。
In the cooling step of FIG. 2G, the first mold 1 and the second mold 2 are cooled to cool the workpiece 14 being processed.
2 (h), the first mold 1 and the second mold 2 are separated from each other, and a molded product in which the workpiece 14 is molded and finished into a target shape is taken out.
図2(c)〜図2(f)の変形加熱工程での第1金型1と第2金型2の加熱および冷却は、第1〜第8温度制御ゾーン6〜13に分けて個別に行い、この変形加熱工程での第1金型1の被加工材14の接触面の温度は、第2金型2の被加工材14との接触面の温度より低い温度にすることにより熱プレス成形している。 The heating and cooling of the first mold 1 and the second mold 2 in the deformation heating process of FIGS. 2C to 2F are divided into first to eighth temperature control zones 6 to 13 individually. The temperature of the contact surface of the workpiece 14 of the first mold 1 in this deformation heating step is set to a temperature lower than the temperature of the contact surface of the second mold 2 with the workpiece 14. Molding.
熱プレス成形時の動作について詳しく述べる。
図2(a)の配置工程は、被加工材14が第2金型2に所定の位置に供給される。この時、第1金型1、第2金型2は被加工材14の樹脂材料の融点より高い所定の温度に制御されている。
The operation during hot press molding will be described in detail.
2A, the workpiece 14 is supplied to the second mold 2 at a predetermined position. At this time, the first mold 1 and the second mold 2 are controlled to a predetermined temperature higher than the melting point of the resin material of the workpiece 14.
図2(b)の接触工程は、移動を開始した第1金型1の凸部の頂点と被加工材14が接触する。
図2(c)の変形開始の変形加熱工程は、更に第1金型1と第2金型2を近づけて、型閉めすることにより、被加工材14を曲げ始める。
In the contact step of FIG. 2B, the workpiece 14 comes into contact with the apex of the convex portion of the first mold 1 that has started moving.
In the deformation heating process at the start of deformation in FIG. 2C, the workpiece 14 is started to bend by further bringing the first mold 1 and the second mold 2 closer to each other and closing the mold.
図2(d)の第1金型側変形の変形加熱工程は、第1金型1を第2金型2に更に押し込んでいくことにより、図2(e)のように第2金型2に沿うように被加工材14が更に変形する。 In the deformation heating process of the first mold side deformation in FIG. 2D, the first mold 1 is further pushed into the second mold 2 so that the second mold 2 as shown in FIG. The workpiece 14 further deforms along
図2(f)の熱プレスの変形加熱工程は、第1金型1が下死点、または行き限に達した状態で被加工材14の樹脂材料の融点より高い金型温度になっている状態を一定時間保持する。 The deformation heating process of the hot press in FIG. 2 (f) has a mold temperature higher than the melting point of the resin material of the workpiece 14 in a state where the first mold 1 reaches the bottom dead center or the limit. Hold the state for a certain time.
図2(g)の冷却工程は、第1金型1が下死点、または行き限に達した状態で冷却温度に一定時間保持する。なお、第1金型1を第2金型2よりも先に冷却を開始することで、変形した被加工材14の反りを安定させている。 In the cooling process of FIG. 2G, the first mold 1 is held at the cooling temperature for a certain time in a state where the first die 1 has reached the bottom dead center or the limit. Note that the warping of the deformed workpiece 14 is stabilized by starting the cooling of the first mold 1 before the second mold 2.
図2(h)の取り出し工程は、第1金型1を元に戻すことにより、被加工材14が成形された成形品15を取り出す。
次に、図2(a)〜図2(h)に示した成形工程の第1金型1と第2金型2の成形動作中の温度プロファイルを図3に基づいて詳しく説明する。
2 (h), the molded product 15 in which the workpiece 14 is molded is taken out by returning the first mold 1 to the original state.
Next, the temperature profile during the molding operation of the first mold 1 and the second mold 2 in the molding process shown in FIGS. 2A to 2H will be described in detail with reference to FIG.
Aは第4,第8温度制御ゾーン9,13の温度プロファイル、Bは第5,第7温度制御ゾーン10,12の温度プロファイル、Cは第1,第2,第3温度制御ゾーン6,7,8の温度プロファイル、Dは第6温度制御ゾーン11の温度プロファイルを示している。 A is the temperature profile of the fourth and eighth temperature control zones 9 and 13, B is the temperature profile of the fifth and seventh temperature control zones 10 and 12, and C is the first, second and third temperature control zones 6 and 7. , 8, D indicates the temperature profile of the sixth temperature control zone 11.
第1金型1と第2金型2が開いた状態から図2(f)の熱プレス工程にかけて、第1金型1、および第2金型2の第1〜第8温度制御ゾーン6〜13毎にそれぞれ加熱し、温度を上昇させる。 From the state in which the first mold 1 and the second mold 2 are opened to the hot pressing step of FIG. 2 (f), the first to eighth temperature control zones 6 to 6 of the first mold 1 and the second mold 2. Each 13 is heated to increase the temperature.
図2(a)で被加工材14を供給して所定の時間経過後、または第1金型1および第2金型2のぞれぞれのゾーンが所定の温度到達後に、図2(b)の接触工程を開始し、第1金型1を第2金型2に向けて移動させ、型閉動作に入る。なお、ここで言っている所定の温度到達後とは、被加工材14の樹脂材料の融点より高い金型温度であり、金型表面全体を融点近傍にしたいため、温度センサ地点としては、融点より高い温度になる。また、あわせて、金型中央部分は、熱が集中しやすく、一般的に、設定温度は、低めでもよい。また、図1の通り、一方では、温度センサの設置場所により、温度検出感度にも差があるため、第6温度制御ゾーン11は、温度設定が低くても金型表面温度は、融点近傍に上げることができ、一方、両サイドの第4,第8温度制御ゾーン9,13は、中央部に比べて、温度上昇が遅いため、温度測定点では、高い温度にしないと、金型表面では、融点に達しない。 2 (a), the workpiece 14 is supplied and after a predetermined time has elapsed, or after each zone of the first mold 1 and the second mold 2 reaches a predetermined temperature, FIG. ) Is started, the first mold 1 is moved toward the second mold 2, and the mold closing operation is started. Note that after the predetermined temperature is reached, the temperature of the mold is higher than the melting point of the resin material of the workpiece 14, and the entire mold surface is desired to be close to the melting point. Higher temperature. At the same time, heat tends to concentrate in the central portion of the mold, and generally the set temperature may be lower. In addition, as shown in FIG. 1, on the other hand, since there is a difference in temperature detection sensitivity depending on the installation location of the temperature sensor, in the sixth temperature control zone 11, the mold surface temperature is in the vicinity of the melting point even if the temperature setting is low. On the other hand, since the temperature rise of the fourth and eighth temperature control zones 9 and 13 on both sides is slower than that of the central portion, if the temperature is not high at the temperature measurement point, Does not reach the melting point.
図2(c)の変形加熱工程,図2(d),(e)の第1金型側変形の変形加熱工程を経て、第1金型1が図2(f)の熱プレス工程で下死点、または行き限に到達すると、図2(g)の冷却工程において、加熱を停止し、第1金型1,第2金型2に冷却水を通水し、金型を冷却させる。この第1金型1が下死点、または行き限に到達した際に、第1金型1,第2金型2の表面が温度制御ゾーン毎に、所定の温度設定になるように、温度制御装置4が第1〜第8温度制御ゾーン6〜13に配置されたヒータ16a,16bを加熱制御する。 After the deformation heating process of FIG. 2 (c) and the deformation heating process of the first mold side deformation of FIGS. 2 (d) and 2 (e), the first mold 1 is lowered in the hot press process of FIG. 2 (f). When the dead point or the limit is reached, in the cooling step of FIG. 2 (g), heating is stopped, cooling water is passed through the first mold 1 and the second mold 2, and the mold is cooled. When the first mold 1 reaches the bottom dead center or the limit, the temperature of the surfaces of the first mold 1 and the second mold 2 is set to a predetermined temperature for each temperature control zone. The control device 4 controls the heating of the heaters 16a and 16b disposed in the first to eighth temperature control zones 6 to 13.
この時、成形品の形状に左右されるが、本実施例の形状の場合、凸形状を有する第1金型1の被加工材14との接触面の温度を、凹形状を有する第2金型2のシート接触面の温度よりも温度を低めに設定することで、成形品15の状態では、第1金型1側の方が凹形状になり、第2金型2側の方が凸形状となり、温度の高い第2金型2の方が、成形品表面の熱膨張が大きくでき、成形品の表裏の熱膨張差をつけることで、凹型の形状の安定性を図ることができる。 At this time, although it depends on the shape of the molded product, in the case of the shape of the present embodiment, the temperature of the contact surface with the workpiece 14 of the first mold 1 having the convex shape is set to the second metal having the concave shape. By setting the temperature lower than the temperature of the sheet contact surface of the mold 2, in the state of the molded product 15, the first mold 1 side becomes concave and the second mold 2 side protrudes. The shape of the second mold 2 having a higher temperature can increase the thermal expansion of the surface of the molded product, and the stability of the concave shape can be improved by providing a difference in thermal expansion between the front and back of the molded product.
また、被加工材14が第1金型1により曲げられて変形し、第2金型2に接触するタイミングが、周辺部の第4,第8温度制御ゾーン9,13と中央部の第5,第6,第7温度制御ゾーン10,11,12では異なるため、温度制御装置4が、温度制御ゾーン毎で温度設定を変える。特に、被加工材14への供給熱量を等しくするためには、第6温度制御ゾーン11を、周辺部の第4,第8温度制御ゾーン9,13よりも低めにするとよい。形状によっては、全面を均一な温度にする。第1金型1と第2金型2の温度を同じにすることもある。 Further, the timing at which the workpiece 14 is bent and deformed by the first mold 1 and contacts the second mold 2 is the fourth and eighth temperature control zones 9 and 13 in the peripheral portion and the fifth in the central portion. The sixth and seventh temperature control zones 10, 11, and 12 are different, and the temperature control device 4 changes the temperature setting for each temperature control zone. In particular, in order to equalize the amount of heat supplied to the workpiece 14, the sixth temperature control zone 11 may be set lower than the fourth and eighth temperature control zones 9 and 13 in the peripheral portion. Depending on the shape, the entire surface is set to a uniform temperature. The temperature of the 1st metal mold | die 1 and the 2nd metal mold | die 2 may be made the same.
なお、第1金型1の加熱は、被加工材14が第1金型1に接した後に加熱を停止し、接する順に各温度制御ゾーン毎に加熱を停止し、第2金型2については、先に接触する端部から順に各温度制御ゾーン毎に加熱を停止し、シート表面に投入される加熱エネルギーを均等にしている。 The heating of the first mold 1 is stopped after the workpiece 14 comes into contact with the first mold 1, the heating is stopped for each temperature control zone in the order of contact, and the second mold 2 is The heating is stopped for each temperature control zone in order from the end portion that comes into contact with the tip, and the heating energy supplied to the sheet surface is made uniform.
ここで、第1金型1の場合を例に挙げて温度を均一にする場合を説明する。第2金型2の場合も同様である。
図4に、第1温度制御ゾーン6、第2温度制御ゾーン7、第3温度制御ゾーン8の温度を均一にする場合の実施例を記す。この図4は、3つのゾーンでの事例を示すが、この数や組み合わせに限るものではない。第1〜第8温度制御ゾーン6〜13においては、ヒータと金型の接触度合い、金型の材料による熱伝導率のばらつきのため、ヒータの加熱に対しての金型表面の昇温速度が場所によって異なったり、また、ヒータの昇温よりも実際の金型表面温度が遅れて昇温することがある。そのため、図4では、第1温度制御ゾーン6の昇温が早く、第3温度制御ゾーン8がヒータ加熱よりも遅れて昇温する場合、第1温度制御ゾーン6はヒータ加熱を、第2温度制御ゾーン7よりも早くヒータ加熱を停止して冷却に入り、第3温度制御ゾーン8は、ヒータ停止後、放置時間を設定し、ヒータから金型表面に熱が伝導するのを待つことで、金型表面の温度を所定の温度に制御するようにしている。一方、冷却時も同様に、第1温度制御ゾーン6,第2温度制御ゾーン7は、冷却動作に入った後、所定の温度まで下がるように冷却水を通水するが、第1温度制御ゾーン6の方が昇温が早い場合は、冷却終了後、第2温度制御ゾーン7を先に加熱開始し、第1温度制御ゾーン6は所定の放置時間終了後、加熱し、成形時に所定の温度になるように温度制御する。一方、第3温度制御ゾーン8については、金型表面温度がヒータ温度よりも遅く変化する場合、冷却動作と加熱動作を同時に行うことにより、加熱時の時間ロスを吸収している。
Here, the case where the temperature is made uniform will be described by taking the case of the first mold 1 as an example. The same applies to the second mold 2.
FIG. 4 shows an embodiment in which the temperatures of the first temperature control zone 6, the second temperature control zone 7, and the third temperature control zone 8 are made uniform. Although FIG. 4 shows an example in three zones, the number and combinations are not limited to this. In the first to eighth temperature control zones 6 to 13, due to the degree of contact between the heater and the mold and the variation in the thermal conductivity depending on the material of the mold, the heating rate of the mold surface with respect to the heating of the heater is Depending on the location, the actual mold surface temperature may rise later than the heater temperature. Therefore, in FIG. 4, when the temperature rise of the first temperature control zone 6 is fast and the temperature rise of the third temperature control zone 8 is delayed from the heater heating, the first temperature control zone 6 performs the heater heating and the second temperature. The heater heating is stopped earlier than the control zone 7 to enter cooling, and the third temperature control zone 8 sets the leaving time after stopping the heater, and waits for the heat to be transferred from the heater to the mold surface. The temperature of the mold surface is controlled to a predetermined temperature. On the other hand, similarly during cooling, the first temperature control zone 6 and the second temperature control zone 7 allow cooling water to flow down to a predetermined temperature after entering the cooling operation. When the temperature rises faster in 6, the second temperature control zone 7 is first heated after the cooling is finished, and the first temperature control zone 6 is heated after the predetermined standing time is finished. Control the temperature so that On the other hand, for the third temperature control zone 8, when the mold surface temperature changes later than the heater temperature, the time loss during heating is absorbed by simultaneously performing the cooling operation and the heating operation.
さらに、図5では、冷却時に、過冷却による温度低下で加熱時の昇温不足を防ぐために、さらに、または、加熱時の過昇温を防ぐために、ヒータ加熱と冷却を同時に実施するタイムチャートを示す。ここでも、図4と同様に、3つのゾーンでの事例を示すが、この数や組み合わせに限るものではない。第3温度制御ゾーン8の金型表面昇温がヒータの昇温に比べ遅い場合、過昇温を防ぐために、加熱終了前に冷却水を循環させることで、昇温を抑える効果がある。一方、冷却回路に比べ、温度制御ゾーン数が多い場合、冷却回路の冷却の影響が複数の温度制御ゾーンに及ぶことがある。そのため、過冷却により、次の成形サイクルに入ったときに、昇温が間に合わないことがある。そのため、冷却を故意に遅くするため、冷却終了前に第3温度制御ゾーン8のヒータをONにし、所定の温度以下にならないように加熱する。これにより、冷却による温度ばらつきを抑制し、加熱前の金型温度状態を一定に保つ効果がある。 Further, in FIG. 5, a time chart for simultaneously performing heating and cooling of the heater at the time of cooling in order to prevent an insufficient temperature rise at the time of heating due to a temperature drop due to overcooling or to prevent an excessive temperature rise at the time of heating. Show. Here, as in FIG. 4, examples in three zones are shown, but the number and combination are not limited thereto. In the case where the mold surface temperature rise in the third temperature control zone 8 is slower than the heater temperature rise, in order to prevent an excessive temperature rise, there is an effect of suppressing the temperature rise by circulating the cooling water before the end of heating. On the other hand, when the number of temperature control zones is larger than that of the cooling circuit, the cooling effect of the cooling circuit may reach a plurality of temperature control zones. Therefore, due to overcooling, the temperature rise may not be in time when entering the next molding cycle. Therefore, in order to intentionally slow down the cooling, the heater of the third temperature control zone 8 is turned on before the cooling is finished, and heating is performed so that the temperature does not fall below a predetermined temperature. This has the effect of suppressing temperature variations due to cooling and keeping the mold temperature state before heating constant.
図7と図8は、成形品形状が扇状の場合の温度制御ゾーンの実施例である。
図7(a)は第1金型1におけるヒータの配置を示す平面図、図7(b)は図7(a)の断面図である。第1金型1は凸部一端の幅W1が凸部の他端の幅W2よりも狭い扇状である。第1金型1の第1,第2,第3温度制御ゾーン6,7,8には、それぞれ複数本のヒータ16aが扇状の凸部に沿って埋め込まれている。複数本のヒータ16aの一端の幅W3は他端の幅W4よりも狭い。
7 and 8 show examples of temperature control zones when the shape of the molded product is a fan shape.
FIG. 7A is a plan view showing the arrangement of heaters in the first mold 1, and FIG. 7B is a cross-sectional view of FIG. 7A. The first mold 1 has a fan shape in which the width W1 at one end of the convex portion is narrower than the width W2 at the other end of the convex portion. In the first, second, and third temperature control zones 6, 7, and 8 of the first mold 1, a plurality of heaters 16 a are embedded along fan-shaped convex portions. The width W3 at one end of the plurality of heaters 16a is narrower than the width W4 at the other end.
図8(a)は第2金型2におけるヒータの配置を示す平面図、図8(b)は図8(a)の断面図である。図8(a)では金型形状が仮想線で示されており、第2金型2は凹部一端の幅W5が凹部の他端の幅W6よりも狭い扇状である。第2金型2の第4〜第8温度制御ゾーン9〜13には、それぞれ複数本のヒータ16bが扇状の凹部に沿って埋め込まれている。複数本のヒータ16bの一端の幅W7は他端の幅W8よりも狭い。 FIG. 8A is a plan view showing the arrangement of heaters in the second mold 2, and FIG. 8B is a cross-sectional view of FIG. 8A. In FIG. 8A, the mold shape is indicated by a virtual line, and the second mold 2 has a fan shape in which the width W5 at one end of the recess is narrower than the width W6 at the other end of the recess. In the fourth to eighth temperature control zones 9 to 13 of the second mold 2, a plurality of heaters 16 b are embedded along the fan-shaped recesses. The width W7 at one end of the plurality of heaters 16b is narrower than the width W8 at the other end.
このように、ヒータ16a,16b間の幅が図中上下で違う場合、温度制御ゾーン毎で温度制御しても、温度制御ゾーン内で温度ばらつきが発生する。すなわち、複数本のヒータ16a,16bで同時に加熱した場合、ヒータ間の幅が狭いところは、温度上昇が早く、広いところは、温度上昇が遅い。 Thus, when the width between the heaters 16a and 16b is different between the upper and lower sides in the figure, even if the temperature control is performed for each temperature control zone, temperature variation occurs in the temperature control zone. That is, when heating is simultaneously performed by a plurality of heaters 16a and 16b, the temperature rise is fast when the width between the heaters is narrow, and the temperature rise is slow when the width is wide.
この実施例では、図9(a)(b)のように、1本のヒータ内でヒータ線の巻きピッチを変えることで、そのヒータの電力[W]をヒータ表面積[cm2]で除した単位表面あたりの電力値であるワット密度[W/cm2]を変えて、温度上昇度を所定の範囲に制御している。つまり、図9(a)に示した第1金型1の凸部の場合のように、第1金型1に埋め込まれている各ヒータ16bは、図9(b)のように扇状の凸部に対応して、凸部の最も幅広の部分のヒータ16bのワット密度P1、凸部の最も幅狭の部分のヒータ16bのワット密度P4、凸部の最も幅広の部分から最も幅狭の部分に次第に狭くなる区間のヒータ16bのワット密度P2,P3とした場合、 P1> P2> P3> P4で、凸部の最も幅広の部分に対応する区間のワット密度が最も大きい。 In this embodiment, as shown in FIGS. 9A and 9B, by changing the winding pitch of the heater wire in one heater, the heater power [W] is divided by the heater surface area [cm2]. The watt density [W / cm 2], which is the power value per surface, is changed to control the temperature rise within a predetermined range. That is, as in the case of the convex portion of the first mold 1 shown in FIG. 9A, each heater 16b embedded in the first mold 1 has a fan-like convex shape as shown in FIG. The watt density P1 of the heater 16b in the widest part of the convex part, the watt density P4 of the heater 16b in the narrowest part of the convex part, and the narrowest part from the widest part of the convex part. When the watt density P2 and P3 of the heater 16b in the gradually narrowing section is set, P1> P2> P3> P4, and the watt density in the section corresponding to the widest portion of the convex portion is the largest.
さらに、ヒータ16bと金型表面までの距離が違う場合も図10(a)(b)に示すように、1本のヒータ16b内でワット密度を変えることで金型表面の温度上昇度を所定の範囲に制御している。つまり、図10(a)に示した第2金型2の凹部の場合のように、埋め込まれている各ヒータ16bは、ヒータ16bから凹部の表面までの距離z1 > z2 > z3 > z4に対応して、最も距離が長い部分のヒータ16bのワット密度P1、最も距離の短い部分のヒータ16bのワット密度P4、その間の区間のヒータ16bのワット密度P2,P3とした場合、P1 > P2 > P3 > P4で、最も距離の長い部分に対応する区間のワット密度が最も大きい。ヒータ16aの場合も同様である。 Further, even when the distance between the heater 16b and the mold surface is different, as shown in FIGS. 10 (a) and 10 (b), the degree of temperature rise on the mold surface is predetermined by changing the watt density in one heater 16b. The range is controlled. In other words, each embedded heater 16b corresponds to a distance z1> z2> z3> z4 from the heater 16b to the surface of the recess, as in the case of the recess of the second mold 2 shown in FIG. When the watt density P1 of the heater 16b at the longest distance, the watt density P4 of the heater 16b at the shortest distance, and the watt densities P2 and P3 of the heater 16b in the interval, P1> P2> P3 > At P4, the watt density in the section corresponding to the longest distance portion is the largest. The same applies to the heater 16a.
このように構成することにより、シートを金型内に配置し、金型を加熱して加圧して変形させる熱プレス成形方法において、成形品の形状が安定し、かつ、または、成形品の表面の外観高品位の成形品を得ることができる。 With such a configuration, in a hot press molding method in which a sheet is placed in a mold and the mold is heated and pressed to be deformed, the shape of the molded article is stable and / or the surface of the molded article A high-quality molded product can be obtained.
被加工材14の具体例として図6のように繊維層21を中央にしてその両面に樹脂層20,22を積層したシートを説明したが、複数の樹脂シートの積層されたシートや、繊維層を含んだシートを例に挙げることもできる。表面側の樹脂層に対して、溶融点を越えて加熱し、成形後に急冷することにより、表面に光沢を出すことができ、成形品の品位を向上させることができる。また、表裏の樹脂シートに対して、成形時に温度差を設けることにより、膨張収縮差を利用し、成形品の反りを制御することが可能になる。 Although the sheet | seat which laminated | stacked the resin layers 20 and 22 on the both surfaces was demonstrated as a specific example of the workpiece 14 like FIG. 6 at the center, the sheet | seat on which the several resin sheet was laminated | stacked, or a fiber layer As an example, a sheet including By heating the resin layer on the surface side beyond the melting point and quenching after molding, the surface can be glossed and the quality of the molded product can be improved. Further, by providing a temperature difference at the time of molding with respect to the front and back resin sheets, it becomes possible to control the warpage of the molded product by utilizing the expansion / contraction difference.
本発明の熱プレス成形方法は、シートの熱曲げ成形の成形に適用することにより、成形品の形状が安定し、外観高品位の成形品を得ることができ、各種の成形品の品質向上に寄与する。 By applying the hot press molding method of the present invention to the hot bending molding of a sheet, the shape of the molded product can be stabilized and a high-quality molded product can be obtained, and the quality of various molded products can be improved. Contribute.
1 第1金型
2 第2金型
4 温度制御装置
5 冷却水制御装置
6 第1温度制御ゾーン
7 第2温度制御ゾーン
8 第3温度制御ゾーン
9 第4温度制御ゾーン
10 第5温度制御ゾーン
11 第6温度制御ゾーン
12 第7温度制御ゾーン
13 第8温度制御ゾーン
14 被加工材
15 成形品
16a,16b ヒータ
17a,17b 温度センサ
18a,18b 冷却水管
19 冷却水バルブ
20 樹脂層
21 繊維層
22 樹脂層
DESCRIPTION OF SYMBOLS 1 1st metal mold 2 2nd metal mold 4 Temperature control device 5 Cooling water control device 6 1st temperature control zone 7 2nd temperature control zone 8 3rd temperature control zone 9 4th temperature control zone 10 5th temperature control zone 11 6th temperature control zone 12 7th temperature control zone 13 8th temperature control zone 14 Work material 15 Molded products 16a and 16b Heaters 17a and 17b Temperature sensors 18a and 18b Cooling water pipe 19 Cooling water valve 20 Resin layer 21 Fiber layer 22 Resin layer
Claims (10)
前記第1,第2金型と接近させて、前記第1金型の凸形状の頂点と前記被加工材が接触する接触工程と、
加熱した前記被加工材を、加熱した第2金型に対して下死点まで接近させて、前記被加工材を変形および加熱する変形加熱工程と、
前記第1金型と前記第2金型とを冷却して、前記被加工材を冷却する冷却工程と、
前記第1金型と前記第2金型とを離間させて成形が完了した前記被加工材の成形が完了した成形品を取り出す取り出し工程と
を有し、
前記変形加熱工程での前記第1金型の前記被加工材との接触面の温度は、前記第2金型の前記被加工材との接触面の温度より低い、熱プレス成形方法。 An arrangement step of arranging a workpiece between a first mold having a convex shape and a second mold having a concave shape;
Contacting the first and second molds so that the convex apex of the first mold and the workpiece are in contact with each other;
A deformation heating step of deforming and heating the workpiece by bringing the heated workpiece toward the bottom dead center with respect to the heated second mold;
A cooling step of cooling the first mold and the second mold to cool the workpiece;
A step of taking out a molded product in which molding of the workpiece, which has been molded by separating the first mold and the second mold, is completed,
The hot press molding method, wherein a temperature of a contact surface of the first mold with the workpiece in the deformation heating step is lower than a temperature of a contact surface of the second mold with the workpiece.
前記第1金型の加熱は、前記被加工材が第1金型に接した後に加熱を停止し、接する順に前記各温度制御ゾーン毎に加熱を停止し、第2金型については、先に接触する端部から順に前記各温度制御ゾーン毎に加熱を停止し、シート表面に投入される加熱エネルギーを均等にすることを特徴とする、請求項2に記載の熱プレス成形方法。 The contact step includes
The heating of the first mold is stopped after the workpiece is in contact with the first mold, and the heating is stopped for each temperature control zone in the order of contact. The hot press molding method according to claim 2, wherein heating is stopped for each of the temperature control zones in order from the contacting end portion, and the heating energy input to the sheet surface is made uniform.
加圧圧縮開始時に前記各温度制御ゾーン毎に所定の温度に制御され、前記第2金型または前記第1金型を、前記被加工材の融点以上に加熱し、加熱圧縮後に、冷却させることを特徴とする、請求項2に記載の熱プレス成形方法。 The deformation heating step includes
The temperature is controlled to a predetermined temperature for each temperature control zone at the start of pressure compression, and the second mold or the first mold is heated to the melting point of the workpiece or cooled after being heated and compressed. The hot press molding method according to claim 2, wherein:
前記第1金型および前記第2金型内で、それぞれ金型毎に冷却しながら、あわせて前記ゾーン毎で同時に加熱を入り切りすることにより、冷却時に所定の温度を維持し、一定の冷却速度で冷却することを特徴とする、請求項6に記載の熱プレス成形方法。 The cooling step includes
In the first mold and the second mold, while cooling each mold, heating is turned on and off at the same time for each zone, thereby maintaining a predetermined temperature during cooling and a constant cooling rate. The hot press molding method according to claim 6, wherein the hot press molding method is performed by cooling.
前記第1金型を加熱した前記第2金型に対して下死点まで接近させて被加工材を変形および加熱する際に、前記第1金型の前記被加工材との接触面の温度を、前記第2金型の前記被加工材の接触面の温度より低くなるように温度制御する温度制御装置とを有する、
熱プレス成形装置。 A first mold having a convex shape and a second mold having a concave shape;
The temperature of the contact surface of the first mold with the workpiece when the workpiece is deformed and heated with the second mold heated to approach the bottom dead center. A temperature control device for controlling the temperature so as to be lower than the temperature of the contact surface of the workpiece of the second mold,
Hot press molding equipment.
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