JP4402114B2 - Transfer molding die, transfer molding device, method for manufacturing transfer molded product, and transfer molded product - Google Patents

Description

The present invention relates to a transfer molding die, a transfer molding apparatus, and a method for manufacturing a transfer molded product for molding a transfer molding material that is a thermoplastic resin. The present invention also relates to a transfer molded product obtained by molding a transfer molding material that is a thermoplastic resin.

  A conventional stamping molded product manufacturing method will be described. 19A to 19C are cross-sectional process diagrams illustrating a conventional method of manufacturing a stamped molded product. Moreover, FIG. 19D is sectional drawing which shows the molded article shape | molded with the manufacturing method of the conventional stamping molded article. As shown in FIG. 19A, a conventional stamping molded product manufacturing method first uses a stamping molding material 104 (hereinafter referred to as molding material 104) as a molding die 101 composed of an upper mold 102 and a lower mold 103. Then, it is put on the molding surface 103 a of the lower mold 103. Specifically, the molding material 104 is heated and melted in a far-infrared heating furnace, and is installed so as to occupy an area of about 70% to 80% of the molding surface 103a. Next, as shown in FIG. 19B, the upper mold 102 is installed from above the lower mold 103, and the molding material 104 is sandwiched between the lower mold 103 and the upper mold 102. Next, as shown in FIG. 19C, the molding material 104 is crushed by closing both molds (the upper mold 102 and the lower mold 103) by pressing. The molding material 104 flows into the remaining 20-30% of the molding surface 103a of the lower mold 103 where the molding material 104 is not installed. In this way, a stamping molded product 105 (hereinafter referred to as a molded product 105) as shown in FIG. 19D is manufactured. Thus, the conventional stamping molded product manufacturing method is a so-called compression molding manufacturing method. As the stamping molding material, a long fiber reinforced thermoplastic resin stampable sheet is used. A long fiber reinforced thermoplastic resin stampable sheet is a sheet-like composite material in which a mat generally composed of long fibers such as glass fibers is impregnated with a thermoplastic resin. The long fiber refers to an inorganic fiber such as glass fiber or carbon fiber, an organic fiber such as aramid fiber or nylon, or a natural fiber such as kenaf having an average fiber length of 8 mm or more. Hereinafter, the long fiber reinforced thermoplastic resin stampable sheet is simply referred to as a stampable sheet. Such a stamping molding material (stampable sheet) is disclosed in, for example, Patent Document 1 and Patent Document 2. Further, a conventional stamping molded product manufacturing method is disclosed in Patent Document 1, for example.

  Since the conventional stamping molded product manufacturing method requires lower molding pressure than the manufacturing method using injection molding, the equipment cost including the mold cost is relatively low. In addition, a large molded product that is considered to be relatively difficult to manufacture by other molded products can be easily molded. Furthermore, since there is no shearing process by the screw in the plasticizing process of the molding material as in the case of injection molding using fiber-reinforced pellets as a molding material, the residual fiber length of the fiber is very long and a molded product with high strength is required. Obtainable.

  However, the conventional stamping molded product manufacturing method has the following drawbacks. First, the appearance of the molded product is poor. The reason for this will be described with reference to FIGS. 20A to 20D. FIG. 20A is a view for explaining the reason why the appearance deteriorates in the stamped molded product manufacturing method, and is a side sectional view showing a molding material heated and melted. FIG. 20B is a view for explaining the reason why the appearance deteriorates in the stamped molded product manufacturing method, and is a side sectional view showing a state where the molding material is put into the molding die. FIG. 20C is a view for explaining the reason why the appearance deteriorates in the stamping molded product manufacturing method, and is a side sectional view showing a state in which the molding material is clamped. FIG. 20D is a view for explaining the reason why the appearance deteriorates in the stamped molded product manufacturing method, and is a side sectional view showing the molded product.

  As shown in FIG. 20A, countless fibers 113 restrained by the resin 112 appear on the surface of the molding material 104 that is a stampable sheet heated and melted in a far-infrared heating furnace or the like. This is because the fiber 113 is restored by a phenomenon called springback due to melt softening and expands to 2 to 3 times the original.

  When the molding material 104 that has been heated and melted is taken out of the far infrared heating furnace, the temperature rapidly decreases due to heat radiation. As shown in FIG. 20B, when the molding material 104 is put into the molding die 101, cooling and solidification starts from a portion in contact with the die (lower die 103). Furthermore, as shown in FIG. 20C, by clamping the mold, the molding material 104 comes into contact with the lower mold 103 and the upper mold 102 and is rapidly cooled. Therefore, the temperature of the surface portion of the molding material 104 is lowered to the vicinity of the crystallization temperature of the resin 112, and a part of the exposed fiber 113 appears on the surface without being covered with the resin 112 again. Therefore, the appearance of the molding material 104 is greatly impaired.

  As shown in FIG. 20D, the obtained molded product 105 after clamping has many fibers 113 appearing on the surface and has poor appearance.

  For this reason, when producing a molded product 105 that requires appearance, the mold temperatures of the upper mold 102 and the lower mold 103 are increased in order to delay cooling due to contact with the molding mold 101, and the upper mold 102 and the lower mold 103 are deeply embossed. Thereby, the quantity of the fiber 113 which appears on the surface decreases. However, since this method requires a long cooling time, the manufacturing time becomes long. Furthermore, it is necessary to take measures against deformation due to post-shrinkage.

  Further, in the conventional method for manufacturing a stamped molded product, when the molding material 104 is charged into the molding die 101, there is a problem that it is necessary to always pay attention to the balance between the installation position and the charging amount. FIG. 21A to FIG. 21C are cross-sectional views illustrating each process for explaining a case where the balance between the placement position of the molding material and the input amount is poor in the conventional stamping molded product manufacturing method. FIG. 21D is a cross-sectional view showing a molded product in a case where the balance between the installation position of the molding material and the input amount is poor in the conventional stamping molded product manufacturing method. As shown in FIG. 21A, when the molding material 104 is placed on the lower mold 103, if the molding material 104 is disposed not at the center of the molding surface 103a but at the periphery, as shown in FIG. The clearance of the molding die 101 is affected. The clearance is the distance in the thickness direction of the space inside the molding die 101 corresponding to the plate thickness of the molded product 105. That is, as shown in FIG. 21C, the lower mold 103 and the upper mold 102 are pressed in a tilted state. Accordingly, the fluidity of the molding material 104 and the dispersibility of the fibers may vary, and a lack of thickness may occur, so that a poor molded product 105a is produced as shown in FIG. 21D. In order to prevent this, the molding die 101 must be closed after a predetermined amount of the molding material 104 is placed at a predetermined location on the molding surface 103a. For this reason, it is difficult to automate the installation of the molding material 104, and the skill level of the operator is also required.

  In addition, if a plurality of molding materials 104 are laminated at one place and installed in the lower mold 103, the plurality of molding materials 104 are collapsed when the mold is closed, and the flow state of the glass fibers of the molding material 104 is disturbed. In some cases, the material protrudes from the molding die 101 to cause a lack of thickness, or sometimes the molding die 101 is damaged.

  In addition, the conventional stamping molded product manufacturing method cannot produce a product having a small shape or a small product. The reason is as follows. In the stamped molded product manufacturing method, a space in which a stampable sheet, which is the molding material 104, can be installed in the molding die 101 is required. For this reason, it is not possible to use a molding die for a product having a small shape or a small product that cannot install a stampable sheet. Therefore, the conventional stamping molded product manufacturing method cannot produce a product having a small shape or a small product.

  Further, in the conventional method for producing a stamped molded product, it is difficult to produce a thin molded product, and there is a limit to the thickness of the molded product. This is because when a thin molded article is produced, the molding material 104 can be reduced, and therefore, the molding material 104 is generally put in without being laminated. In this case, the molding material 104 is rapidly dissipated. This is because the temperature decreases and a large molding pressure is required. FIG. 22 is a diagram showing a change in the temperature of the molding material over time after the molding material is taken out from the heating furnace. FIG. 22 shows the temperature change with time of the internal temperature of the molding material 104 and the temperature change with time of the surface temperature of the molding material 104 when the molding material 104 is five layers, two layers and one layer. Is shown. The change in the surface temperature of the molding material 104 is the same regardless of the number of laminated sheets. In FIG. 22, a range 114 is a range of time taken to fix the upper mold 102 and the lower mold 103 after pressing the molding die 101, and a range 115 starts to crystallize the molding material 104. The temperature range. As shown in FIG. 22, the temperature drop is more remarkable as the number of laminated layers of the molding material 104 decreases. In particular, when the molded product 105 is a thin molded product, the ratio of the remaining area (the area buried by the flow) is higher than the area where the molding material 104 is placed on the molding surface 103a, and the molding material 104 is laminated. It is often installed without using. In such a case, the temperature of the molding material 104 is greatly reduced by heat dissipation, and the molding material 104 is molded in a so-called semi-molten and semi-solid state, and the fluidity of the molding material 104 is low. Therefore, the molding pressure is excessively large, and it is particularly difficult to produce a thin molded product having a thickness of 1.5 mm or less.

  Further, in the conventional stamping molded product manufacturing method, the dimension in the thickness direction of the molded product 105 to be obtained is likely to vary depending on the volume of the molding material 104 installed in the lower mold 103 as in general compression molding. There is a drawback. In other words, when the molding material 104 is installed in the lower mold 104, it is rapidly cooled and the fluidity becomes low. Therefore, in the location where the molding material 104 is installed and the location where the molding material 104 flows and spreads by the press, There arises a problem that the thickness of the molded product 105 is different.

  In addition, it is difficult to produce a molded product 105 having a hole shape by a conventional stamping molded product manufacturing method. The reason is as follows. If the molding material 104 is placed in the hole-shaped portion and the mold is clamped, the material is sandwiched between the fitting portions corresponding to the hole shapes of the upper mold 102 and the lower mold 103, so that the molding die 101 is closed. There is a possibility that the molding die 101 may be obstructed or damaged. Further, when a plurality of positions avoiding the hole-shaped portion are selected and the molding material 104 is installed, the number of the molding materials 104 to be installed increases and the charging position becomes complicated. As a result, the above-described balance abnormality at the time of mold closing occurs, resulting in a malfunction. Therefore, in the conventional stamping molded product manufacturing method, the hole shape is manufactured by punching after the molded product is manufactured. Therefore, a punching loss due to the secondary processing occurs, and a punching die must be separately manufactured, resulting in an increase in manufacturing cost.

  Further, in the conventional stamping molded product manufacturing method, in order to reduce the manufacturing cost, a plurality of molded products are manufactured by a single press with the molding die 101 having a mold having a structure for obtaining a plurality of molded products. Was. However, this method tends to cause variations in the amount and arrangement of the molding material 104, makes it difficult for the molding die 101 to be uniformly closed, and tends to cause a lack of thickness and a defective product thickness.

  On the other hand, a transfer molding method is generally known as a method for manufacturing a molded product in which molding is performed without directly feeding a material into a molding section (for example, Patent Document 3, Patent Document 4, Patent Document 5, and Patent Document). 6). However, this molding method is applied exclusively to thermosetting resins. Further, this molding method has the following drawbacks.

Since the thermosetting resin is used as a molding material, the remaining molding material filled in the mold cannot be reused, which results in material loss. Therefore, there is a problem that a large amount of material loss occurs when a large amount of material to be filled in the mold is required as in a large product.
JP-A-10-193350 JP 2003-80519 A JP 2003-286328 A JP 2001-205622 A JP 2000-334766 A JP 2000-037746 A

The present invention was made in view of the above problems, good appearance quality and transfer molding die can be manufactured with high dimensional precision moldings, to provide a method of manufacturing a transfer molding apparatus and transfer moldings Objective. Another object of the present invention is to provide a transfer molded product with good appearance quality and high dimensional accuracy.

Transfer molding die of the present invention is filled in a state where the mold portion for molding a long-fiber-reinforced thermoplastic resin molding material has therein sheet made from the long fiber-reinforced thermoplastic resin molding material is overlapped plural A molding part provided with a feeding part, a connecting hole for connecting the mold part and the feeding part, and an injection part having a convex part to be inserted into the feeding part, the molding part inside the mold part And a pin that can be inserted and removed to fix the reinforcing material, and the convex portion applies pressure to the long-fiber reinforced thermoplastic resin molding material filled in the input portion, and passes through the connection hole. A long fiber reinforced thermoplastic resin molding material is injected into the mold part.

The transfer molding apparatus of the present invention includes the transfer molding die of the present invention.

Further, the method for producing a transfer molded product of the present invention comprises the above-mentioned long fiber reinforced thermoplastic resin which is heated and melted in a feeding part connected by a connecting hole and a mold for molding a long fiber reinforced thermoplastic resin molding material. the sheet made of the molding material filled in the plurality overlapped state, through the connecting hole, and injecting the long fiber-reinforced thermoplastic resin molding material into the mold portion from the feeding section, the long fiber-reinforced thermoplastic A method of manufacturing a transfer molded product for molding a resin molding material , wherein a convex portion is inserted into the input portion, and a pressure is applied to a plurality of sheets made of the long fiber reinforced thermoplastic resin molding material by the convex portion. When the long fiber reinforced thermoplastic resin molding material is injected into the mold part from the input part through the connecting hole and molded, the long fiber reinforced thermoplastic resin molding material remaining in the input part And wherein it is sheet-like.

Moreover, the transfer molded product of the present invention is molded by the transfer molding die of the present invention.

By using the transfer molding die, the transfer molding apparatus, and the method for manufacturing a transfer molded product of the present invention, it is possible to manufacture a molded product with good appearance quality and high dimensional accuracy. Further, the transfer molded product of the present invention has good appearance quality and high dimensional accuracy.

The transfer molding die of the present invention has a structure in which a molded part is molded by fluidly filling a molding material, which is closed in advance, with a molding material. Therefore, a molded product with high dimensional accuracy can be manufactured, and thin molding is also possible. Further, it is possible to produce a molded product with very little appearance of fibers in the molding material and excellent appearance quality. In addition, it is possible to easily manufacture a molded product having a high strength and incorporating a reinforcing material. Moreover, the molded article in which the pattern etc. were formed can be manufactured by using the reinforcing material which has a predetermined shape or a predetermined pattern.

Preferably, in the transfer mold according to the present invention, the convex portion and the insertion portion into which the convex portion is inserted constitute a mold portion different from the mold portion. Thereby, a molded product can be manufactured also in the input part.

Preferably, in the transfer molding die of the present invention, one mold part and a plurality of input parts are connected by a plurality of connection holes. Thereby, the molding material is uniformly injected into the mold part. Accordingly, defects and the like are unlikely to occur. Further, even when the molded product is large, a highly accurate molded product can be easily manufactured.

Preferably, in the transfer molding die of the present invention, the one input portion and the plurality of mold portions are connected by the plurality of connection holes. Thereby, a some molded article can be manufactured at once.

Preferably, in the transfer molding die of the present invention, the molding part is composed of a plurality of members, and has a fastening part for fixing the members to each other. Thereby, the mold part does not open when the molding material is injected into the mold part, and the mold can be opened easily .

Also, transfer molding apparatus of the present invention includes a transfer molding die of the present invention. Therefore, a molded product with high dimensional accuracy can be manufactured, and thin molding is also possible. Further, it is possible to produce a molded product with very little appearance of fibers in the molding material and excellent appearance quality.

Moreover, the manufacturing method of the transfer molded product of this invention manufactures a molded product by inject | pouring a long fiber reinforced thermoplastic resin molding material into the mold part closed previously. Therefore, a molded product with high dimensional accuracy can be manufactured, and thin molding is also possible. Further, it is possible to produce a molded product with very little appearance of fibers in the molding material and excellent appearance quality. Further, the remaining molding material introduction part upon producing formed molded article, it is easy to use in the next molding. Therefore, the molding material can be used without waste.

Preferably, in the method for manufacturing a transfer molded product of the present invention, the length of the long fiber reinforced thermoplastic resin molding material remaining in the input portion is the same as the thickness of one of the sheets. As a result, the molding material remaining in the input portion can be handled in the same manner as a new transfer molding material, so that it can be easily reused .

Also, the manufacturing method of transfer molding article of the present invention, preferably, after installing a pre reinforcement to the mold portion, injecting the long fiber-reinforced thermoplastic resin molding material into the mold portion. Thereby, a high-strength molded product with a built-in reinforcing material can be easily manufactured. Moreover, the molded article in which the pattern etc. were formed can be manufactured by using the reinforcing material which has a predetermined shape or a predetermined pattern.

The transfer molded product of the present invention is molded by the transfer molding die of the present invention. Thereby, the appearance quality is good and the dimensional accuracy is high.

  Hereinafter, specific embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
A transfer molding die (hereinafter referred to as a molding die) according to Embodiment 1 of the present invention and a transfer molding apparatus (hereinafter referred to as a molding device) including the same will be described. 1 is a perspective view showing a configuration of an upper mold of a molding die according to Embodiment 1. FIG. FIG. 2 is a perspective view showing a configuration of an intermediate mold of the molding die according to the first embodiment. FIG. 3 is a perspective view showing the configuration of the lower mold of the molding die according to the first embodiment. The molding die of Embodiment 1 is composed of an upper die 1, an intermediate die 2 and a lower die 3 shown in FIGS.

  As shown in FIG. 1, the upper mold (injection part) 1 has a convex part 4. As shown in FIG. 2, the intermediate mold 2 has a concave mold portion 8, an intermediate mold through hole 10, and a groove 9 formed so as to connect the concave mold portion 8 and the intermediate mold through hole 10. ing. As shown in FIG. 3, the lower mold 3 includes a convex mold part 13, a convex part 14 connected to the convex mold part 13, and a lower mold input part 15.

  The lower mold 3, the intermediate mold 2 and the upper mold 1 are clamped by being sequentially stacked. With these installed, the intermediate mold through hole 10 and the lower mold insertion portion 15 are integrated to form an insertion portion, and the convex portion 4 is fitted into this insertion portion. Further, the concave mold portion 8 is fitted with the convex mold portion 13 to form a mold portion. Moreover, as shown in FIGS. 1-3, the upper mold | type 1, the intermediate mold | type 2, and the lower mold | type 3 are provided with the fastening parts 6, 11, and 16, respectively. Furthermore, the fastening part 11 has a movable slide bar 11a.

A method of manufacturing a molded product for producing a transfer molded product (hereinafter referred to as a molded product) using the molding die composed of the upper mold 1, the intermediate mold 2 and the lower mold 3 will be described with reference to the drawings. 4A to 4E are cross-sectional process diagrams for explaining the method of manufacturing the molded product according to the first embodiment. FIG. 4F is a cross-sectional view showing a molded product molded by the method for manufacturing a molded product of the first embodiment. 4A to 4E are cross-sectional views, the fastening portions 6, 11, and 16 should not appear on the drawings, but are illustrated in view of ease of viewing.

  As shown in FIG. 4A, the intermediate mold 2 is installed on the lower mold 3. The intermediate mold 2 shown in FIG. 2 is turned upside down when installed on the lower mold 3. That is, the concave mold portion 8 faces downward and is fitted to the convex mold portion 13. In addition, what the intermediate mold | type 2 was installed in the lower mold | type 3 is a shaping | molding part. A mold part 12 which is a space is formed between the convex mold part 13 and the concave mold part 8, and the mold part 12 is filled with a molding material and molded into a desired shape. By installing the intermediate mold 2 on the lower mold 3, the convex portion 14 of the lower mold 3 fits into the groove 9 of the intermediate mold 2. A connecting hole 17 that is a space is formed between the convex portion 14 and the groove 9. The connection hole 17 is connected to the mold part 12 formed between the convex mold part 13 and the concave mold part 8. Further, by placing the intermediate mold 2 on the lower mold 3, the lower mold insertion portion 15 and the intermediate mold through-hole 10 are connected and integrated to form the insertion portion 19. The insertion part 19 and the mold part 12 are connected by a connection hole 17.

  After the intermediate mold 2 is installed on the lower mold 3, the intermediate mold 2 and the lower mold 3 are fastened and fixed using the fastening portions 11 and 16 (clamping). Although not shown in FIG. 3, it is preferable that the lower mold 3 is provided with an ejector pin 18. The ejector pin 18 can protrude from the convex mold part 13 and the lower mold input part 15, and is used for removing the molded product.

Next, as shown in FIG. 4B, the molding material 20 is charged into the charging unit 19 so as to be stacked. As the molding material 20, with the aid of a long fiber-reinforced thermoplastic trees Aburashi over preparative. The long fiber-reinforced thermoplastic trees Aburashi over preparative, a composite material in sheet form impregnated with a thermoplastic resin to the mat constituted by long fibers such as typically glass fibers. The long fibers are, for example, inorganic fibers such as glass fibers and carbon fibers, organic fibers such as aramid fibers and nylon, or natural fibers such as kenaf, and have an average fiber length of 8 mm or more. That of the long fiber-reinforced thermoplastic trees Aburashi over preparative, also referred to as a sheet over bets on the single in the following.

  The insertion portion 19 has a function of guiding the convex portion 4 as described below. It also has a role to prevent the laminated molding material 20 from falling down. Therefore, the input part 19 has a sufficient depth so that the upper part of the laminated molding material 20 does not come out above the input part 19. The molding die 7 of the first embodiment includes an upper die 1, an intermediate die 2, and a lower die 3.

  Furthermore, as shown in FIG. 4C, the upper mold 1 is installed on the lower mold 3 and the intermediate mold 2. The upper mold 1 shown in FIG. 1 is used upside down when installed on the lower mold 3 and the intermediate mold 2. That is, the convex portion 4 of the upper mold 1 is fitted into the insertion portion 19. In this state, pressure is applied to both the upper mold 1 and the lower mold 3 and the intermediate mold 2 so as to approach each other. As a result, the molding material 20 installed in the input part 19 is pushed by the convex part 4 and fluidly filled into the mold part 12 through the connecting hole 17. In this case, the speed at which the upper mold 1 approaches the lower mold 3 and the intermediate mold 2 (clamping speed) is preferably 10 mm / s or more. If the speed is lower than this, the fluidity of the molding material 20 flowing from the charging portion 19 is significantly lowered, and problems such as lack of thickness may occur.

  As shown in FIG. 4D, the upper die 1 and the intermediate die 2 are fixed by the fastening portion 6 and the fastening portion 11 (see FIG. 2) in a state where the molding material 20 is completely filled in the die portion 12. Thereby, the upper mold 1 and the intermediate mold 2 are integrated.

  Next, as shown in FIG. 4E, the integrated upper mold 1 and intermediate mold 2 are removed from the lower mold 3 (open mold). At this time, the fastening part 11 (see FIG. 2) and the fastening part 16 are opened, and the intermediate mold 2 and the lower mold 3 are separated. The molded product 21 remains on the convex mold part 13, the convex part 14, and the input part 15 of the lower mold 3 after removing the integrated upper mold 1 and intermediate mold 2. Here, the molded product 21 can be easily released from the lower mold 3 by pushing the ejector pin 18 upward.

  FIG. 4F shows the molded product 21. Of the molded product 21, an unnecessary molded product 22 formed by the input portion 19 and the connecting hole 17 is cut at the cutting point 24, and the product 23 is completed.

  As described above, in the molding die 7 of the first embodiment, the molding material 20 is charged into the feeding portion 19 and then pressure is applied by the convex portion 4 of the upper die 1 so that the mold portion 12 is closed in advance. It is fluidly filled. A plurality of the molding materials 20 are filled in the charging unit 19 in a state where a plurality of the molding materials 20 are overlapped. Therefore, when the molding material 20 is pressurized by the convex part 4 and fluidly filled into the mold part 12, the internal temperature of the molding material 20 hardly flows down and is fluidly filled into the mold part 12 in a high temperature state. Is done. Thereby, after the surface of the mold part 12 is covered with the resin of the molding material 20, the fiber is filled into the mold part 12. Therefore, the fiber which has been a problem in the past hardly appears on the outer surface of the molded product 21, and the molded product 21 having a beautiful appearance can be obtained.

  Moreover, since the molding material 20 is reliably filled in the mold part 12, the molded product 21 is not damaged. Moreover, the mold part 12 into which the molding material 20 is poured is formed by the intermediate mold 2 and the lower mold 3, and the molding material 20 is poured in a state in which these are clamped. That is, the molding material 20 is poured in a state where the concave molding portion 8 and the convex molding portion 13 are correctly arranged. Therefore, the shape of the mold part 12 does not shift, and the possibility of producing a defective product is low. Therefore, the volume of the molded product 21 is always constant, and the dimensional accuracy in the thickness direction is also good.

  Here, FIG. 5 is a side sectional view showing the configuration of a molded product formed using the molding die of the first embodiment. As can be seen from FIG. 5, in the molded product 27 composed of the resin 28 and the fiber 29, the fiber 29 exists inside the resin 28 and is hardly exposed to the outside. That is, the surface layer (skin layer) of the molded product 27 is rich in resin. Therefore, the appearance quality of the molded product 27 is good. Also, the dimensional accuracy in the thickness direction is good.

  Furthermore, the molded product 21 is molded by charging the molding material 20 into the feeding portion 19, which is a place different from the mold portion 12, and fluidly filling the molding material 20 into the molding portion 12. The molding material 20 is uniformly filled in the portion 12, and a molded product having a hole shape, a thin molded product, a small molded product, or the like can be easily molded.

  Moreover, it is preferable that the input portion 19 has such a size that it cannot be input unless the molding material 20 is laminated. Thereby, the molding material 20 is stacked and charged, and the temperature drop of the molding material 20 is small (see FIG. 22). Therefore, the fluidity of the molding material 20 is high. Therefore, molding is possible even with a small pressing pressure. The press pressure is a force applied in the pressing direction when molding the molding material. Moreover, what divided | segmented this press pressure by the area which a press pressure applies is called surface pressure.

  Here, the surface pressure in the molding die 20 of the first embodiment is a value obtained by dividing the pressing pressure at the time of molding by the area of the bottom surface of the feeding portion 19. Further, the surface pressure of the conventional stamping molding is a value obtained by dividing the pressing pressure at the time of molding by the area of the surface perpendicular to the pressing direction among the portions that contact the molding material 104 of the upper mold 102 in FIG. 19C. It is. In the first embodiment, the area of the bottom surface of the charging portion 19 is designed to be smaller than the area of the die portion 12, and therefore, in the first embodiment and the conventional molding, the same press is formed when molding the same die. When pressure is applied, the surface pressure in the first embodiment is higher. That is, the molding die 7 of Embodiment 1 can realize a large surface pressure with a small pressing pressure. Therefore, the fluidity of the molding material 20 is high during molding.

  In thin molding, a large surface pressure is required. In the conventional molding, for example, generally, the minimum thickness of the stamping material before molding is 2.0 mm, and the thickness of the molded product is only as thin as 1.8 mm. However, in Embodiment 1, since the flowability of the molding material 20 is high because the temperature drop of the molding material 20 is small and the surface pressure is high, even a thin article can be easily molded. . Specifically, it has been confirmed by experiments that the thickness of the molded product can be reduced to 1.2 mm.

  Moreover, when manufacturing the molded product which has a hole shape, the hole for forming a hole shape should just be formed in the type | mold part 12, and it may be set as the structure where the injection | throwing-in part 19 is arrange | positioned in the hole. Thereby, the whole size of the molding die 7 can be reduced, and the material cost of the molding die 7 can be reduced.

  In addition, since the input portion of the molding material 20 is specified in the input unit 19, the operation of inputting the molding material 20 is simplified, the skill level of the operator is unnecessary, and automation is possible.

Further, a closing portion 19, the convex portions unnecessary moldings 22 formed by 4, the molding material 20 Der Resid over preparative similar flat plate loading portion 19 so that the (sheet) and the convex portion 4 Is preferably designed. The thickness of the flat plate T (see FIG. 4D) is, it is more preferably designed to be the same as the sheet over bets before the original heating. In other words, as shown in FIG. 4D, the upper mold 1 and the intermediate mold 2 are fixed and surrounded by the surface (the bottom surface and the side surface of the charging portion 19) and the convex portion 4. It is preferable that the area | region currently made into flat plate shape (sheet shape). Further, the thickness of this region, it is more preferable that the same as the sheet over preparative before the original heating.

Thereby, it is easy to use the unnecessary molded product 22 again as the next molding material 20. That is, the unnecessary molded article 22 again, the far-infrared heating furnace, and heated and melted together with sheet over preparative virgin, installed in the insertion portion 19 may be a molded article 21. Since unnecessary size of the molded article 22 and sheet over bets Virgin are identical, it can be handled unwanted moldings 22 similarly to the sheet over preparative virgin. Thus, since the loss of the molding material which arises in the case of shaping | molding can be used again for shaping | molding, it can shape | mold efficiently. In addition, what is necessary is just to remove and use the part formed by the connection hole 17 among the unnecessary molded articles 22. FIG.

FIG. 6 is a diagram showing the relationship between the tensile property change rate and the number of heating times of the molding material used in the first embodiment. The tensile property change rate is an index indicating the tensile strength of the molding material after heating, based on the tensile strength of the molding material not subjected to heat treatment. As shown in FIG. 6, the molding material 20 Der Cie over bets are used in the first embodiment, a reduction in tensile properties due to repeated heating it is not observed. That is, as described above, even if the unnecessary molded product 22 generated after molding is used again as a molding material, the quality of the molded product 21 does not deteriorate. Moreover, unnecessary moldings 22, because of the same thickness as the virgin sheet over bets a molding material 20, it is possible to heat and melt at the same heating conditions, easy to handle.

  Next, the fastening portions 6, 11 and 16 for fixing the upper mold 1 and the intermediate mold 2, and the intermediate mold 2 and the lower mold 3 will be described. Considering mass productivity, it is preferable to use a slide lock mechanism as the fastening portions 6, 11 and 16. Any mechanism other than the slide lock mechanism may be used as long as it can fix the upper mold 1 and the intermediate mold 2 and the intermediate mold 2 and the lower mold 3 by using a bolt or a lock mechanism using a spring.

  FIG. 7A is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die when the lower die and the intermediate die are fixed. As shown in FIG. 7A, the intermediate mold 2 is installed on the lower mold 3. The fastening portion 11 of the intermediate mold 2 includes a slide bar 11a that can move to the left and right. The fastening portion 16 of the lower die 3 has a through hole at the same height as the slide rod 11a in a state where the intermediate die 2 is installed on the lower die 3, and the slide rod 11a is placed on the fastening portion 16 side. Slide to penetrate the through hole of the fastening portion 16. Thereby, the intermediate mold 2 and the lower mold 3 are fixed and integrated. In FIG. 7A, only one surface of the intermediate die 2 and the lower die 3 is visible, but the fastening portions 11 and 16 are also installed on the surface opposite to this surface, so that the intermediate die 2 and the lower die 3 are 2 Fixed in place.

  FIG. 7B is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die in a state where molding is performed. That is, the upper die 1 is placed on the intermediate die 2 and the lower die 3 and pressure is applied. At this time, since the intermediate mold 2 and the lower mold 3 only need to be fixed, the fastening portions 11 and 16 are in the state shown in FIG. 7A. In addition, when the upper mold | type 1 is completely installed on the intermediate mold | type 2, the fastening part 6 of the upper mold | type 1 has a through-hole in the same height position as the slide rod 11a.

  FIG. 7C is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die immediately before performing the mold opening. At this time, the slide bar 11 a that is passed through the through hole of the fastening part 16 is slid toward the fastening part 6 so that the slide bar 11 a passes through the through hole of the fastening part 6. As a result, the upper mold 1 and the intermediate mold 2 are fixed and integrated. At the same time, the intermediate mold 2 and the lower mold 3 are not fixed.

  FIG. 7D is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die in a state where the mold is opened. Since the slide bar 11a passes through the through hole of the fastening portion 6, the upper mold 1 and the intermediate mold 2 are integrated, so that they can be easily separated from the lower mold 3.

  Next, another molding die according to Embodiment 1 having a structure in which a fastening portion is different from that of the molding die shown in FIGS. 7A to 7D will be described. FIG. 8A is a diagram for explaining a fastening portion of another molding die according to the first embodiment, and is a front sectional view of the molding die showing a state where each die is separated. FIG. 8B is a diagram for explaining a fastening portion of another molding die according to Embodiment 1, in which a lower die and an upper die are closed, and a molding die showing a state in which they are fixed by the fastening portion. FIG. 8A and 8B, only the upper die 41, the intermediate die 42, and the lower die 43 are cross-sectional views, and the other is a front view for ease of viewing.

  As shown in FIGS. 8A and 8B, the molding die 47 includes an upper die 41, an intermediate die 42, and a lower die 43. The lower mold 43 is provided with a fastening portion 44 having a movable rod 44a. The movable rod 44a can move left and right with respect to FIG. 8A and has a wedge-shaped tip. The movable rod 44a has a notch 44b.

  A recess 42 a is formed in the intermediate mold 42. The recess 42 a is formed at a position where the tip of the movable rod 44 a fits in a state where the intermediate mold 42 is installed on the lower mold 43. Further, the intermediate die 42 is connected to a connecting rod 45 protruding upward, and the upper end of the connecting rod 45 is disposed in a space 46 formed in the upper die 41. The upper end of the connecting rod 45 is caught at the bottom of the space 46 so that the connecting rod 45 does not come out of the space 46.

  The upper die 41 includes a fixture 41b for fixing the movable rod 44a so as not to move left and right by being inserted into the notch 44a of the movable rod 44a, and an elastic body 41a disposed at the upper end of the fixture 41b. ing.

  The movement of the molding die 47 will be described. As shown in FIG. 8A, in a state where the intermediate mold 42 and the lower mold 43 are not closed, the intermediate mold 42 is suspended from the upper mold 41 via the connecting rod 45. The upper mold 41 gradually descends, and the intermediate mold 42 is installed on the lower mold 43. In this state, the movable rod 44 a is accommodated inside the lower mold 43 so as not to prevent the intermediate mold 42 from being installed on the lower mold 43.

  As shown in FIG. 8B, after the intermediate mold 42 is installed on the lower mold 43, the upper mold 41 is further lowered by about 30 mm. Thereby, the upper end of the connecting rod 45 is not near the bottom of the space 46 but near the middle. In this way, the movable rod 44 a moves with the intermediate mold 42 installed on the lower mold 43, and the tip of the movable rod 44 a fits into the recess 42 a formed in the intermediate mold 42. As a result, the lower mold 43 and the intermediate mold 42 are fixed (closed mold) by the movable rod 44a. Further, the fixture 41b is fitted into the notch 44b of the movable rod 44a so that the movable rod 44a does not come out of the recess 42a. The fixing tool 41b is not easily pulled out from the notch 44b because a force is applied downward by the elastic body 41a. The movable rod 44a may be moved by, for example, hydraulic pressure.

  As described above, in the other molding die 47 according to the first embodiment, the intermediate die 42 and the lower die 43 are fixed. In addition, although the integration of the intermediate mold 42 and the lower mold 43 has been described, for example, the upper mold 41 and the intermediate mold 42 can be integrated by a similar mechanism.

  In the above, the molding die of Embodiment 1 and the manufacturing method of the molded article using the same were demonstrated. Next, a molding apparatus according to Embodiment 1 for realizing molding using a molding die will be described. FIG. 9 is a side sectional view showing the configuration of the molding apparatus according to the first embodiment. The molding apparatus 30 according to the first embodiment includes a main body pedestal 31, a lower mold plate 32, a movable pedestal 33, an upper mold plate 34, a press main body 35, and the molding die 7 according to the first embodiment. In the press main body 35, a main body base 31, a lower mold plate 32, a movable base 33, and an upper mold plate 34 are installed. A lower mold plate 32 is installed on the main body base 31, and the lower mold 3 is installed thereon.

  The movable pedestal 33 is movable up and down and is installed in the press body 35. An upper mold plate 34 is installed at the lower part of the press body 35. The upper mold 1 is installed on the upper mold plate 34. The molding apparatus 30 according to the first embodiment moves the upper mold 1 up and down by moving the movable base 33 up and down. As shown in FIG. 9, the intermediate mold 2 is installed on the lower mold 3 and closed, and the molding material 20 is charged into the charging unit 19. In this state, the movable pedestal 33 is moved downward to bring the upper die 1 into close contact with the intermediate die 2 as shown in FIG. . Thereby, the molded article mentioned above is produced.

  Since the molding apparatus 30 according to the first embodiment includes the molding die 7 according to the first embodiment, it is possible to produce a molded product with high appearance quality and high accuracy.

(Embodiment 2)
A molding die according to Embodiment 2 of the present invention will be described with reference to the drawings. FIG. 10A is a perspective view showing the configuration of the upper mold of the molding die according to the second embodiment. FIG. 10B is a perspective view showing the configuration of the intermediate mold of the molding die according to the second embodiment. FIG. 10C is a perspective view showing the configuration of the lower mold of the molding die according to the second embodiment. The molding die according to the second embodiment can mold a molded product, which is a product, also in the input parts (intermediate mold through hole 10a and lower mold input part 15a) for extruding the molding material.

  As shown in FIG. 10A, the upper mold (injection part) 1a has a convex part 4a. During the production of the molded product, pressure is applied to the molding material by the convex portion 4a.

  As shown in FIG. 10B, the intermediate mold 2a has a concave mold portion 8a, an intermediate mold through hole 10a, and a groove 9a formed so as to connect the concave mold portion 8a and the intermediate mold through hole 10a. ing.

  As shown in FIG. 10C, the lower mold 3a has a convex mold part 13a and a lower mold charging part 15a.

  Note that the lower mold 3a, the intermediate mold 2a, and the upper mold 1a are clamped by being sequentially stacked. With these installed, the intermediate die through-hole 10a and the lower die throwing portion 15a are integrated to form a throwing portion. The convex part 4a fits in this insertion part. Further, the concave mold portion 8a is fitted with the convex mold portion 13a so as to form the first mold portion. Further, in a state where the convex portion 4a is fitted in the charging portion, the charging portion and the convex portion 4a form a second mold portion.

A method of manufacturing a molded product using the molding die including the upper mold 1a, the intermediate mold 2a, and the lower mold 3a will be described. The intermediate mold 2a is placed on the lower mold 3a and clamped so that the convex mold part 13a fits into the concave mold part 8a. As in the first embodiment, a fastening part for clamping the lower mold 3a and the intermediate mold 2a is actually installed, but illustration and description thereof are omitted. Similarly, a fastening portion for integrating the upper mold 1a and the intermediate mold 2a is actually installed, but illustration and description thereof are omitted. The closing portion formed at an intermediate type through hole 10a and the lower die insertion portion 15a, a stacked installation molding material is a sheet over bets heated and melted. Next, the upper mold 1a is placed on the intermediate mold 2a and the lower mold 3a so that the convex part 4a fits in the charging part, and pressure is applied to the molding material in the charging part by the convex part 4a. The molding material is filled into the first mold part formed by the concave mold part 8a and the convex mold part 13a through the connecting hole formed by the groove 9a, and a molded product is formed. At the same time, a molded product is formed by the second mold part formed by the convex part 4a and the input part (intermediate mold input part and lower mold input part 15a). FIG. 11 is a perspective view showing a configuration of a molded product formed using the molding die of the second embodiment. The molded product 21a shown in FIG. 11 is cut at a cutting point 24a to complete two products 23a. The appearance quality of the molded product 21a is good, and the dimensional accuracy in the thickness direction is also good.

  In addition to the same effect as the molding die of the first embodiment, the molding die of the second embodiment has an effect that two products 23a can be simultaneously produced.

  In the molding apparatus of the first embodiment, the molding die of the second embodiment may be installed instead of the molding die of the first embodiment.

(Embodiment 3)
A molding die according to Embodiment 3 of the present invention will be described with reference to the drawings. FIG. 12A is a perspective view showing the configuration of the upper mold of the molding die according to the third embodiment. FIG. 12B is a perspective view showing a configuration of an intermediate mold of the molding die according to the third embodiment. FIG. 12C is a perspective view showing the configuration of the lower mold of the molding die according to the third embodiment. In the molding die of Embodiment 3, two mold parts are connected to one input part.

  As shown in FIG. 12A, the upper mold (injection part) 1b has a convex part 4b. At the time of molding, pressure is applied to the molding material by the convex portions 4b.

  As shown in FIG. 12B, the intermediate mold 2b includes two concave mold parts 8b, an intermediate mold through hole 10b, and two grooves formed so as to connect each concave mold part 8b and the intermediate mold through hole 10b. 9b.

  As shown in FIG. 12C, the lower mold 3b has two convex mold parts 13b and a lower mold input part 15b.

  Note that the lower mold 3b, the intermediate mold 2b, and the upper mold 1b are clamped by being sequentially stacked. In a state where these are installed, the intermediate die through hole 10b and the lower die insertion portion 15b are integrated to form an insertion portion, and the convex portion 4b is fitted into this insertion portion. Further, the two concave mold parts 8b are respectively fitted with the two convex mold parts 13b, and each of them forms two mold parts.

A method for manufacturing a molded product using the molding die including the upper die 1b, the intermediate die 2b, and the lower die 3b will be described. The intermediate mold 2b is placed on the lower mold 3b and clamped so that each convex mold part 13b fits into each concave mold part 8b. As in the first embodiment, a fastening part for clamping the lower mold 3b and the intermediate mold 2b is actually installed, but illustration and description thereof are omitted. Similarly, a fastening portion for integrating the upper die 1b and the intermediate die 2b is actually installed, but illustration and description thereof are omitted. The closing portion formed at an intermediate type through hole 10b and the lower mold insertion portion 15b, the stacked installation molding material is a sheet over bets heated and melted. Next, the upper mold 1b is placed on the intermediate mold 2b and the lower mold 3b so that the convex part 4b fits in the charging part, and pressure is applied to the molding material in the charging part by the convex part 4b. The molding material is filled into the two mold parts formed by the respective concave molding parts 8b and the respective convex molding parts 13b through the connecting holes formed by the respective grooves 9b, thereby forming a molded product. FIG. 13 is a perspective view showing a configuration of a molded product formed using the molding die of the third embodiment. The molded product 21b shown in FIG. 13 is cut at the cutting point 24b to complete two products 23b. The appearance quality of the molded product 21b is good, and the dimensional accuracy in the thickness direction is also good.

  In addition to the same effect as the molding die of the first embodiment, the molding die of the third embodiment has an effect that two products 23b can be simultaneously produced. Two or more concave mold parts 8b and two convex mold parts 13b may be provided. Thereby, a plurality of products can be created at a time in a single molding process.

  In the molding apparatus of the first embodiment, the molding die of the third embodiment may be installed instead of the molding die of the first embodiment.

(Embodiment 4)
A molding die according to Embodiment 4 of the present invention will be described with reference to the drawings. FIG. 14A is a perspective view showing the configuration of the upper mold of the molding die according to the fourth embodiment. FIG. 14B is a perspective view showing a configuration of an intermediate mold of the molding die according to the fourth embodiment. FIG. 14C is a perspective view showing the configuration of the lower mold of the molding die according to the fourth embodiment. In the molding die of the fourth embodiment, three input parts are connected to one mold part.

  As shown in FIG. 14A, the upper mold 1c has three convex portions 4c. During molding, pressure is applied to the molding material by the convex portions 4c.

  As shown in FIG. 14B, the intermediate mold 2c includes a concave mold portion 8c, three intermediate mold through holes 10c, and three grooves formed so as to connect each intermediate mold through hole 10c and the concave mold portion 8c. 9c.

  As shown in FIG. 14C, the lower mold 3c has a convex mold part 13c, three convex parts 14c connecting the convex mold part 13c, and three lower mold input parts 15c.

  Note that the lower mold 3c, the intermediate mold 2c, and the upper mold 1c are clamped by being sequentially stacked. With these installed, each intermediate mold through hole 10c and each lower mold insertion portion 15c are integrated to form three insertion portions, and each projection 4c fits into this insertion portion. Further, the concave mold portion 8c is arranged so that the convex mold portion 13c is fitted therein to form a mold portion.

A method of manufacturing a molded product using the molding die including the upper die 1c, the intermediate die 2c, and the lower die 3c will be described. The intermediate mold 2c is placed on the lower mold 3c and clamped so that the convex mold part 13c fits into the concave mold part 8c. In addition, each convex part 14c fits in each groove | channel 9c at this time. As in the first embodiment, a fastening part for clamping the lower mold 3c and the intermediate mold 2c is actually installed, but illustration and description thereof are omitted. Similarly, a fastening portion for integrating the upper mold 1c and the intermediate mold 2c is actually installed, but illustration and description thereof are omitted. Three-on portion formed at each intermediate-type through-hole 10c and the lower mold insertion portion 15c, respectively laminated installing a molding material is a sheet over bets heated and melted. Next, the upper mold 1c is placed on the intermediate mold 2c and the lower mold 3c so that the projections 4c are fitted to the input parts, and pressure is applied to the molding material in the input parts by the convex parts 4c. The molding material is filled into the mold part formed by the concave mold part 8c and the convex mold part 13c through the connecting hole formed by each groove 9c and each convex part 14c, and a molded product is formed. . The appearance quality of this molded product is good, and the dimensional accuracy in the thickness direction is also good. Further, since the molding material is filled into the mold part from a plurality of locations, the mold material is filled evenly. Accordingly, defects and the like are unlikely to occur.

  Since the molding die of the fourth embodiment has a structure in which the molding material is filled from a plurality of locations, in addition to the same effects as the molding die of the first embodiment, the molded product is large. In this case, it is possible to produce a molded product with particularly high accuracy. Note that the number of the input portions and the convex portions 4c is not limited to three, and other numbers may be used.

  In the molding apparatus of the first embodiment, the molding die of the fourth embodiment may be installed instead of the molding die of the first embodiment.

(Embodiment 5)
A method for manufacturing a molding die and a molded product according to Embodiment 5 of the present invention will be described. FIG. 15 is a cross-sectional view showing a configuration of a molding die according to the fifth embodiment. 16A to 16D are cross-sectional process diagrams illustrating a method for manufacturing a molded product according to Embodiment 5. FIG. FIG. 16E is a cross-sectional view showing a molded product molded by the method of manufacturing a molded product according to Embodiment 5. The molding die according to Embodiment 5 is a molding die for producing a molded product having a reinforcing material therein.

  The molding die 7d according to the fifth embodiment has a configuration in which a pin 26 for fixing the fiber cloth 25 is added to the molding die according to the first embodiment shown in FIGS. Therefore, in FIG. 15, the same members as those in the molding die of Embodiment 1 shown in FIGS. 1, 2, and 3 are denoted by the same reference numerals, and description thereof is omitted.

  As shown in FIG. 15, among the molding dies 7 d of the fifth embodiment, the intermediate mold 2 includes pins 26 for fixing the fiber cloth (reinforcing material) 25. The pin 26 is normally housed in the intermediate mold 2, but can protrude from the concave mold portion 8 by a mechanism such as hydraulic pressure.

  As shown in FIG. 16A, the intermediate mold 2 is placed on the lower mold 3 so that the concave mold portion 8 fits into the convex mold portion 13. A molding material is filled in the mold part 12 which is a space formed between the convex molding part 13 and the concave molding part 8, and the molding material is molded into a desired shape. Furthermore, a fiber cloth 25 is installed in the mold part 12 in advance. The fiber cloth 25 is, for example, a nonwoven fabric or a cloth cloth. Further, the form of the fiber may be glass fiber, carbon fiber, aramid fiber or the like. As the pin 26 protrudes, the fiber cloth 25 is fixed in place. In this state, the intermediate mold 2 and the lower mold 3 are fastened and fixed using the fastening portions 11 and 16 (clamping). Further, the molding material 20 is laminated and installed on the input unit 19.

  Next, as shown in FIG. 16B, the upper mold 1 is installed on the lower mold 3 and the intermediate mold 2 so that the convex part 4 of the upper mold 1 fits into the insertion part 19. In this state, pressure is applied to the lower mold 3, the intermediate mold 2, and the upper mold 1 so that the convex portion 4 presses the molding material 20. As a result, the molding material 20 installed in the feeding part 19 is pushed by the convex part 4 and flows into the mold part 12 through the connecting hole 17 which is a space formed between the convex part 14 and the groove 9. Filled.

  As shown in FIG. 16C, pressure is applied until the mold part 12 is completely filled with the molding material 20. The pin 26 may be stored in the intermediate mold 2 (not shown) when the molding material 20 is filled in the mold part 12. Thereby, the fiber cloth 25 is fixed at a predetermined position, and the chip 26 is not damaged.

  Next, as shown in FIG. 16D, the integrated upper mold 1 and intermediate mold 2 are removed from the lower mold 3 (open mold). On the lower side 3 after removing the integrated upper mold 1 and intermediate mold 2, a molded product 21 d containing the fiber cloth 25 remains.

  FIG. 16E shows a molded product 21d. Of the molded product 21d, the unnecessary molded product 22 formed by the input portion 19 and the convex portion 4 is cut at a cutting point 24, and a product 23d incorporating the fiber cloth 25 is completed.

  Thus, the fiber cloth 25 is installed in the mold part 12 in advance, and the fiber cloth 25 is built in by injecting the molding material 20 into the mold part 12 through the connecting hole 17 from the input part 19. The molded product 21d can be easily manufactured. The appearance quality of the molded product 21d is good, and the dimensional accuracy in the thickness direction is also good.

  In addition, although the fiber cloth 25 was installed in the product 23d for reinforcement, the fiber cloth 25 may be incorporated in the product 23d for design.

In the fifth embodiment, the fiber cloth 25 such as a nonwoven fabric or a cloth cloth is used as a reinforcing material. Instead of the fiber cloth 25, a sheet obtained by impregnating a thermoplastic resin with a metal, resin, or fiber cloth is heated and melted. A long fiber-reinforced thermoplastic resin sheet material and the like that are heated and melted may be used. Thereby, a high-strength molded product incorporating the reinforcing material can be easily manufactured. Moreover, the molded article in which the pattern etc. were formed can be manufactured by using the reinforcing material which has a predetermined shape or a predetermined pattern.

  In addition to the same effect as the molding die of the first embodiment, the molding die of the fifth embodiment has an effect that a molded product incorporating the fiber cloth can be molded as described above.

  In the molding apparatus of the first embodiment, the molding die of the fifth embodiment may be installed instead of the molding die of the first embodiment.

Although the first to fifth embodiments have been described above, the specific structure of the component is merely an example, and the present invention is not limited to only these specific examples. For example, as a molding material, but using a long fiber-reinforced thermoplastic trees Aburashi over preparative may be used a sheet-like thermoplastic resin molding material long fibers uncomplexed.

  The results of comparing the products actually produced using the molding dies according to the present invention (Examples 1 and 2) and the products produced using conventional molding dies (Comparative Examples 1 and 2) Summarized.

Example 1
FIG. 17A is a perspective view showing the configuration of the lower mold of the molding die used in Examples 1 and 2. FIG. FIG. 17B is a perspective view showing the configuration of the intermediate mold of the molding die used in Examples 1 and 2. FIG. 17C is a perspective view showing the configuration of the upper mold of the molding die used in Examples 1 and 2.

The product of Example 1 was produced using the molding dies (upper mold 1e, intermediate mold 2e, and lower mold 3e) shown in FIGS. 17A to 17C. Long fiber reinforced thermoplastic trees Aburashi over bets are molding materials, L (longitudinal): 126mm × W (horizontal): 60mm × T (thickness): 3.8 mm in the size of those were used five. After heating these in a far-infrared heating furnace, using the mold shown in FIGS. 17A to 17C, the clamping speed was 25 mm / s, and the press pressure (clamping force) was 196 × 10 ⁴ N. The product of Example 1 was produced.

(Example 2)
The product of Example 2 was produced using the molding dies (upper mold 1e, intermediate mold 2e, and lower mold 3e) shown in FIGS. 17A to 17C. Long fiber reinforced thermoplastic trees Aburashi over bets are molding materials, L: 126mm × W: 60mm × T: using four size of those of 3.8 mm. After heating these in a far-infrared heating furnace, using the mold shown in FIGS. 17A to 17C, the clamping speed was 25 mm / s, and the press pressure (clamping force) was 196 × 10 ⁴ N. The product of Example 2 was produced.

(Comparative Example 1)
18A is a perspective view showing the configuration of the lower mold of the molding die used in Comparative Examples 1 and 2. FIG. FIG. 18B is a perspective view showing the configuration of the upper mold of the molding die used in Comparative Examples 1 and 2.

The product of Comparative Example 1 was produced using the molding dies (upper mold 103e and lower mold 102e) shown in FIGS. 18A and 18B. Two long fiber reinforced thermoplastic resin stampable sheets as molding materials having a size of L: 150 mm × W: 100 mm × T: 3.8 mm were used. After heating these in a far-infrared heating furnace, using the mold shown in FIGS. 18A and 18B, the clamping speed was 25 mm / s, and the press pressure (clamping force) was 196 × 10 ⁴ N. A product of Comparative Example 1 was produced.

(Comparative Example 2)
The product of Comparative Example 2 was produced using the molding die shown in FIGS. 18A and 18B. Two long fiber reinforced thermoplastic resin stampable sheets as molding materials having a size of L: 125 mm × W: 100 mm × T: 3.8 mm were used. After heating these in a far-infrared heating furnace, using the mold shown in FIGS. 18A and 18B, the clamping speed was 25 mm / s, and the press pressure (clamping force) was 196 × 10 ⁴ N. A product of Comparative Example 2 was produced.

  The evaluation results for the products of Examples 1 and 2 and Comparative Examples 1 and 2 are summarized in Table 1 above.

  Table 1 shows the following. In both Example 1 and Comparative Example 1, a product having a plate thickness of 1.8 mm was obtained. In contrast, the product of Example 1 was good in appearance with no fiber protrusion, whereas the product of Comparative Example 1 had fiber protrusion. Is remarkably inferior in appearance. In addition, Example 2 obtained a product with a plate thickness of 1.3 mm in spite of the same pressing pressure as Comparative Example 2, and the product of Example 2 was good with no appearance of fibers in appearance. On the other hand, the product of Comparative Example 2 has significantly raised fibers and is poor in appearance. In addition, the product of Comparative Example 2 showed a significant lack of thickness.

  Such a difference in the formability between the products of Examples 1 and 2 and the products of Comparative Examples 1 and 2 is considered to be due to the great difference in surface pressure. The surface pressure is obtained by dividing the pressing pressure by the area where the pressing pressure is applied, as described above. As shown in Table 1, the surface pressure in Examples 1 and 2 reached 3.8 times that in Comparative Examples 1 and 2.

  Further, the difference in appearance between the products of Examples 1 and 2 and the products of Comparative Examples 1 and 2 is that the molding material is fluidly filled into the mold and molded in the products of Examples 1 and 2. Nevertheless, the products of Comparative Examples 1 and 2 are considered to be caused by the molding material being molded without flowing. That is, the appearance of the products of Comparative Examples 1 and 2 is impaired because the fibers appearing on the surface of the molding material are not re-coated and appear on the surface of the molded part as they are.

Transfer molding die according to the present invention, by using the manufacturing method of the transfer molding apparatus and a transfer molded product, good appearance quality and therefore dimensional precision can be performed with high transfer molding, utilizing a transfer molded product in wider fields Can do. In addition, the transfer molded product according to the present invention has good appearance quality and high dimensional accuracy, and therefore can be used in a wide range of fields.

1 is a perspective view showing a configuration of an upper mold of a molding die according to Embodiment 1. FIG. FIG. 2 is a perspective view showing a configuration of an intermediate mold of the molding die according to the first embodiment. FIG. 3 is a perspective view showing the configuration of the lower mold of the molding die according to the first embodiment. FIG. 4A is a sectional process diagram for describing the method for manufacturing the molded article according to the first embodiment. FIG. 4B is a cross-sectional process diagram for describing the method for manufacturing the molded article according to the first embodiment. FIG. 4C is a cross-sectional process diagram for describing the method for manufacturing the molded article of the first embodiment. FIG. 4D is a cross-sectional process diagram for illustrating the method of manufacturing the molded article according to the first embodiment. FIG. 4E is a cross-sectional process diagram for describing the method of manufacturing the molded article according to the first embodiment. FIG. 4F is a cross-sectional view showing a molded product molded by the method of manufacturing the molded product of the first embodiment. FIG. 5 is a side sectional view showing a configuration of a molded product formed using the molding die of the first embodiment. FIG. 6 is a graph showing the relationship between the tensile property change rate and the number of heating times of the molding material used in the first embodiment. FIG. 7A is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die when the lower die and the intermediate die are fixed. FIG. 7B is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die in a state where molding is performed. FIG. 7C is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die immediately before performing the mold opening. FIG. 7D is a view for explaining the slide mechanism that is the fastening portion of the first embodiment, and is a side view showing the configuration of the molding die in a state where the mold is opened. FIG. 8A is a diagram for explaining a fastening portion of another molding die according to the first embodiment, and is a front sectional view of the molding die showing a state where each die is separated. FIG. 8B is a diagram for explaining a fastening portion of another molding die according to Embodiment 1, in which a lower die and an upper die are closed, and a molding die showing a state in which they are fixed by the fastening portion. FIG. FIG. 9 is a side sectional view showing the configuration of the molding apparatus according to the first embodiment. FIG. 10A is a perspective view showing the configuration of the upper mold of the molding die according to the second embodiment. FIG. 10B is a perspective view showing a configuration of an intermediate mold of the molding die according to the second embodiment. FIG. 10C is a perspective view showing the configuration of the lower mold of the molding die according to Embodiment 2. FIG. 11 is a perspective view showing the configuration of a molded product formed using the molding die of the second embodiment. FIG. 12A is a perspective view showing the configuration of the upper mold of the molding die according to the third embodiment. 12B is a perspective view showing a configuration of an intermediate mold of the molding die according to Embodiment 3. FIG. FIG. 12C is a perspective view showing the configuration of the lower mold of the molding die according to the third embodiment. FIG. 13 is a perspective view showing a configuration of a molded product formed using the molding die of the third embodiment. FIG. 14A is a perspective view showing the configuration of the upper mold of the molding die according to the fourth embodiment. FIG. 14B is a perspective view showing a configuration of an intermediate mold of the molding die according to the fourth embodiment. FIG. 14C is a perspective view showing the configuration of the lower mold of the molding die according to Embodiment 4. FIG. 15 is a cross-sectional view showing a configuration of a molding die according to the fifth embodiment. FIG. 16A is a cross-sectional process diagram for describing the method of manufacturing the molded article according to the fifth embodiment. FIG. 16B is a cross-sectional process diagram for describing the method of manufacturing the molded article according to the fifth embodiment. FIG. 16C is a cross-sectional process diagram for describing the method of manufacturing the molded article according to the fifth embodiment. FIG. 16D is a cross-sectional process diagram for describing the method of manufacturing the molded article according to the fifth embodiment. FIG. 16E is a cross-sectional view showing a molded product molded by the method of manufacturing the molded product of Embodiment 5. FIG. 17A is a perspective view showing the configuration of the lower mold of the molding die used in Examples 1 and 2. FIG. FIG. 17B is a perspective view showing a configuration of an intermediate mold of the molding die used in Examples 1 and 2. FIG. 17C is a perspective view showing the configuration of the upper mold of the molding die used in Examples 1 and 2. 18A is a perspective view showing the configuration of the lower mold of the molding die used in Comparative Examples 1 and 2. FIG. 18B is a perspective view showing the configuration of the upper mold of the molding die used in Comparative Examples 1 and 2. FIG. FIG. 19A is a cross-sectional process diagram illustrating a method of manufacturing a conventional stamped molded product. FIG. 19B is a cross-sectional process diagram illustrating a method for manufacturing a conventional stamped molded product. FIG. 19C is a cross-sectional process diagram illustrating a conventional method of manufacturing a stamped molded product. FIG. 19D is a cross-sectional view showing a molded product molded by a conventional stamping molded product manufacturing method. FIG. 20A is a view for explaining the reason why the appearance deteriorates in the stamped molded product manufacturing method, and is a side sectional view showing a molding material heated and melted. FIG. 20B is a view for explaining the reason why the appearance is deteriorated in the manufacturing method of the stamped molded product, and is a side sectional view showing a state where the molding material is put into the molding die. FIG. 20C is a diagram for explaining the reason why the appearance deteriorates in the stamped molded product manufacturing method, and is a side sectional view showing a state in which the molding material is clamped. FIG. 20D is a view for explaining the reason why the appearance deteriorates in the stamping molded product manufacturing method, and is a side sectional view showing the molded product. FIG. 21A is a cross-sectional process diagram for explaining a case where the installation position of the molding material and the balance of the input amounts are poor in the conventional stamping molded product manufacturing method. FIG. 21B is a cross-sectional process diagram for explaining a case where the balance between the installation position of the molding material and the input amount is poor in the conventional stamping molded product manufacturing method. FIG. 21C is a cross-sectional process diagram for explaining a case where the balance between the installation position of the molding material and the input amount is poor in the conventional stamping molded product manufacturing method. FIG. 21D is a cross-sectional view showing a molded product in a case where the balance between the installation position of the molding material and the input amount is poor in the conventional stamping molded product manufacturing method. FIG. 22 is a view showing a change in the temperature of the molding material over time after the molding material is taken out from the heating furnace.

Claims (10)

Has a mold part for molding the long-fiber-reinforced thermoplastic resin molding material therein, the sheet made from the long fiber-reinforced thermoplastic resin molding material and a feeding section which is filled with a plurality overlapping state, and the mold portion A molded part having a connecting hole for connecting the input part;
An injection part having a convex part to be inserted into the charging part,
The molding part comprises a pin that can be taken in and out for fixing the reinforcing material in the mold part,
The convex portion, the under pressure in the long fiber-reinforced thermoplastic resin molding material filled in the insertion portion, a transfer that makes injecting the long fiber-reinforced thermoplastic resin molding material through the connecting hole in the mold part Molding mold. The transfer mold according to claim 1, wherein the convex portion and the insertion portion into which the convex portion is inserted constitute a mold portion different from the mold portion. The transfer mold according to claim 1, wherein one mold part and a plurality of the input parts are connected by a plurality of the connection holes. The transfer molding die according to claim 1, wherein the one input part and the plurality of mold parts are connected by the plurality of connection holes. The transfer molding die according to claim 1, wherein the molding part includes a plurality of members and has a fastening part for fixing the members. Transfer molding apparatus having a transfer molding die according to any one of claims 1 to 5. The mold part and the introduction part which is connected by a connecting hole for forming the long fiber-reinforced thermoplastic resin molding material, filling a sheet containing the heat melted the long fiber-reinforced thermoplastic resin molding material in a plurality overlapped state And
Through the connecting hole, the long fiber-reinforced thermoplastic resin molding material is injected into the mold portion from the insertion portion, a manufacturing method of a transfer molded article for molding the long-fiber-reinforced thermoplastic resin molding material ,
A convex portion is inserted into the charging portion, and a pressure is applied to the plurality of sheets made of the long fiber reinforced thermoplastic resin molding material by the convex portion, and the long fiber reinforced thermoplastic resin molding material is connected through the connection hole. Is injected into the mold part from the charging part and molded,
The method for producing a transfer molded product, wherein the long fiber reinforced thermoplastic resin molding material remaining in the charging portion is in the form of a sheet . The method of manufacturing a transfer molded product according to claim 7 , wherein a thickness of the long fiber reinforced thermoplastic resin molding material remaining in the input portion is the same as one thickness of the sheet. The method for manufacturing a transfer molded article according to claim 7 , wherein a reinforcing material is previously installed in the mold part, and then the long fiber reinforced thermoplastic resin molding material is injected into the mold part. By transfer molding die according to any one of claims 1 to 5, shaped transfer molded article.

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