JPH0132051B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a method for producing a synthetic resin laminate and a synthetic resin laminate molded using this method, and its purpose is to produce one or two types of synthetic resin laminates. Efficiently produce large and thick (15 mm or more thick) synthetic resin laminates made of the same material, or synthetic resin laminates having a core material and laminated with one or two types of synthetic resins, The object of the present invention is to provide a method for molding a mold device used in this method, which is free from distortion and has little residual stress, and a synthetic resin laminate. (Prior art) Conventionally, methods for forming large and thick (thickness 15 mm or more) synthetic resin molded bodies made of one type of material are described below. The following is a method for producing a thick synthetic resin laminate.
There has been a method for producing a synthetic resin molded body having a core material and laminated with synthetic resins made of one or two types of materials. A method of molding large and thick synthetic resin moldings by extrusion molding. One or two types of large and thin items (thickness 5
A method to obtain large and thick synthetic resin laminates by bonding synthetic resin molded bodies (about 2 mm) to each other with adhesive. A method of obtaining a synthetic resin laminate by bonding two types of synthetic resin molded bodies and a core material of different materials together with an adhesive. (Problems to be Solved by the Invention) The conventional methods described above have corresponding problems (1) to (3) below. (1) If a synthetic resin molded object with a thickness exceeding 15 mm is molded using the method described above, the synthetic resin molded object may become distorted, warped, or
In addition to surface irregularities and excessive residual stress, productivity is extremely poor as it must be extruded slowly.On the other hand, if the extrusion speed is increased to increase productivity, the synthetic resin molded product often breaks midway, which is not practical. There is a problem in that there are synthetic resin molded articles that cannot be subjected to extrusion molding, and contain things that cannot be done by extrusion molding, that is, fillers, pigments, or metal powders. In method (2), bonding with an adhesive requires adhesive, man-hours, time, and skilled techniques, and the hardened layer of the adhesive and the synthetic resin have different physical properties, making it difficult to synthesize a uniform material. There were problems in that not only a resin laminate could not be obtained, but also the end faces of the synthetic resin molded bodies to be bonded became irregular, making them unusable in some cases. Method (3) not only requires adhesive, man-hours, time, and skilled techniques to bond with adhesive, but also causes the edges of the synthetic resin molded objects to be bonded to be uneven, making it impossible to use them. The problem was that there were cases where it was not available. This invention was completed in order to solve the above-mentioned problems. (Means for solving the problem) At least one of the upper mold and the lower mold is made of a main mold, a sliding mold that can freely slide up and down along the main mold, and a sliding mold that can freely slide up and down along the main mold. A synthetic resin comprising a telescoping device for sliding a sliding mold, using a vertically separated synthetic resin molding mold consisting of the upper mold and the lower mold, and having at least the following steps a to c: The above-mentioned problems are solved by providing a method for manufacturing a laminate and a synthetic resin laminate molded using this method. a. A core material is supported by the sliding mold between the upper mold and the lower mold, and the core material defines a cavity of the synthetic resin mold, and b. Then, from within the lower mold. Supply the molten synthetic resin into the lower mold cavity and into the upper mold cavity from above the core material in random order or at the same time, c. Immediately thereafter, clamp the synthetic resin mold. (Example) An example according to the present invention will be described in detail below based on the drawings. FIG. 1 is an explanatory side view of the device according to this embodiment;
Figure 2 is a view taken along the line A-A in Figure 1, and Figure 3 is a view of Figure 1.
It is a sectional view taken along the line BB in the figure. 4 to 11 are a partially omitted vertical cross-sectional view of FIG. 1 and a 12th
The figure is a side view of a synthetic resin laminate manufactured by the method of this invention. In the drawings, 1 is an upper mold, 2 is a lower mold, 3 is a main mold, 4 is a sliding mold, 5 is a telescopic device for sliding the sliding mold 4, and 6 is an upper mold 1 and a lower mold. This is a synthetic resin molding mold consisting of a mold 2 and a top and bottom separated type. The lower mold 2 includes a main mold 3, a sliding mold 4, and an expansion/contraction device 5.
It consists of. In all the embodiments and modifications described below, the sliding mold 4 is provided in the lower mold 2 , but the same operation and effect can be achieved even if the sliding mold 4 is provided in the upper mold 1. . The upper mold 1 and the lower mold 2 each have a molten plastic passage 7 therein, and a flexible tube 8 is connected to a joint 8a on the molten plastic supply side of the molten plastic passage 7.
Upper mold 1 and lower mold 2 have a pressure-resistant structure through
connected to. The distal end portion 7a of the molten plastic passageway 7 has a molten plastic resin supply cutoff part (not shown) such as a needle valve. The flexible tube 8 has pressure resistance and heat resistance, and has a reinforcing layer of stainless steel wire on the outer periphery of the fluorine-based synthetic resin tube (not shown; manufactured by Yokohama Go Co., Ltd.), etc., with a heat insulating material and heat retention mechanism. It is preferable to use a device equipped with In addition, the molten synthetic resin passage 7 and the tip part 7 of the lower mold 2
a, the flexible tube 8 and the joint 8a are shown only in FIG. 1, and these are not limited to this configuration and may be configured according to a conventional method. The sliding mold 4 is vertically slidable along the entire circumference of the main mold 3. As the expansion/contraction device 5, in addition to a known hydraulic press cushion, a steel spring, a urethane spring, a hydraulic cylinder, a pneumatic spring, etc. can be used. The sliding mold 4 is provided with a support 9 as shown in the drawing. The support portion 9 is provided at a portion near the approximate center of each inner surface 4a of the sliding mold 4, and has a very small jagged surface shape. The jagged convex apex 9a (see FIG. 4) and the inner surface 4a are substantially on the same plane. In this invention, the shape and position of the support portion 9 are not necessarily limited to this embodiment. A synthetic resin laminate is manufactured by the following steps (1) to (7) using the synthetic resin molding die 6 of this embodiment having such a configuration. (1) The molten synthetic resin 10 is transferred from the flexible tube 8 and molten plastic passageway 7 of either the upper mold 1 or the lower mold 2 or both molds 1 and 2 to the synthetic resin molding mold 6 cavity 6a. (See Figure 4). (2) Then, when the synthetic resin molding mold 6 is immediately clamped in the required manner and with the required force, the upper mold 1 slides onto the sliding mold 4 and then comes into contact with the sliding mold 4. (See Figure 5). (3) When the synthetic resin molding mold 6 is further clamped, the sliding mold 4 slides on the main mold 3 and the synthetic resin molding mold 6 meshes with each other (see FIG. 6). (4) After the molten synthetic resin 10 has hardened, when the clamping force of the synthetic resin molding mold 6 is removed, the upper mold 1 separates from the lower mold 2 , and at the same time the sliding mold 4 expands and contracts. Due to the reaction force of the device 5, it automatically slides onto the main mold 3, and the core material 11 (also a synthetic resin molded body).
The core material 10 (having a thickness of approximately 5 to 6 mm) is supported by the serrations of the support portion 9 and moves upward together with the sliding mold 4, and the core material 10 defines a cavity 6a of the synthetic resin molding mold 6 (Fig. 7). reference). It goes without saying that the reaction force of the expansion and contraction device 5 is smaller than the mold clamping force, and that the clamping direction of the synthetic resin mold 6 and the sliding direction of the sliding mold 4 are the same. (5) Next, melt the synthetic resin 10 from inside the lower mold 2 into the lower mold 2 cavity 6a and from inside the upper mold 1 into the upper mold 1 cavity 6a in random order or simultaneously according to the step (1). supply (8th
(see figure). (6) Immediately after that, the synthetic resin molding mold 6 is clamped in the required manner and with the required force, and the upper mold 1 slides onto the sliding mold 4, and the upper mold 1 slides into the sliding mold. 4, the sliding mold 4 slides on the main mold 3, and the synthetic resin molding mold 6 meshes with it (Figs. 9 and 10).
(see figure). At the same time, the core material 11 is pressed downward by the mold clamping force via the molten synthetic resin 10 above the core material 11, and the jagged portion 11a of the core material 11 is scraped off by the support section 9, while the core material 11 is pushed downward. Moving. It goes without saying that the supporting force of the core material 11 of the support portion 9 is at least greater than the weight of the core material 11 and smaller than the mold clamping force. (7) After the molten synthetic resin 10 has hardened, when the clamping force of the synthetic resin molding die 6 is removed, the upper die 1 is separated from the lower die 2 , and at the same time the sliding die 4 is separated from the expansion device 5. The reaction force automatically slides onto the main mold 3, and the core material 11 and the synthetic resin layer 12 (thickness 5,
The synthetic resin laminate 13 (about 15 to 18 mm thick), which is integrally formed with the sliding mold 4 (about 6 mm), is supported by the serrations of the support part 9 and moves upward together with the sliding mold 4 (see FIG. 11). Incidentally, when further laminating a synthetic resin on the synthetic resin laminate 13 , the steps shown in FIGS. 8 to 11, that is, steps (5) to (7) are repeated. Thereafter, this synthetic resin laminate 13 is taken out from the synthetic resin molding die 6 . Synthetic resin laminate 13 manufactured in this way
As shown in FIG.
The jagged portion 11a is smoothed if necessary. The synthetic resin laminate 13 according to this embodiment is then subjected to necessary processing and used as a pallet. (Effects of Example) The inventive method according to this example simultaneously exhibits the following excellent effects. (1) Since the flexible tube 8 is connected to the upper mold 1, mold clamping and
The vertical movement of the upper mold 1 during separation can be easily handled, and the molten synthetic resin can be smoothly supplied. (2) The lower mold 2 is composed of a main mold 3, a sliding mold 4, and an expansion/contraction device 5, and the supporting part 9 of the sliding mold 4 is jagged, so that it can be made continuously with a simple device. Synthetic resin layers 12 can be laminated. (3) Since extrusion molding is not used, a synthetic resin laminate 6 containing an extender, pigment, or metal powder can be molded. (4) By changing the material, color, etc. of the molten synthetic resin supplied to the upper and lower molds 1 and 2 , it is also possible to manufacture a synthetic resin laminate 13 having different required functions on the front and back sides. (5) An ultra-thick synthetic resin laminate 13 exceeding 15 mm in thickness can be produced. (6) Melt synthetic resin 10 on both sides of core material 11 almost simultaneously.
Since the synthetic resin layer 12 is supplied, two synthetic resin layers 12 can be laminated at once, which is efficient, and since no adhesive is used, no skilled technique is required. (7) Since the synthetic resin layer 12 is molded without regard to warpage, distortion, and surface irregularities of the core material 11, these warpage, distortion, and surface irregularities do not accumulate in the synthetic resin laminate 13 . In addition, the synthetic resin laminate 13 molded using the invention method according to this embodiment exhibits the following excellent effects at the same time. (1) Molten synthetic resin 10 is applied approximately equally to both sides of the core material 11.
In other words, since heat is applied to both sides of the core material 11 at the same time, warpage, distortion, and surface irregularities do not accumulate, so there is no distortion, warpage, surface irregularity, excessive residual stress, and unevenness of the end surface. (2) There is no hardened adhesive layer; in other words, it is made of laminated synthetic resin layers with uniform material properties (chemical properties, mechanical properties), so it can be used for a wide range of purposes. (Modification example) In the present invention, the method of supplying the molten synthetic resin 10 into the cavity 6a of the upper mold 1 from above the core material is not limited to the above-mentioned embodiment, but for example, the method of supplying the molten synthetic resin 10 into the cavity 6a of the upper mold 1 from above the core material is not limited to the above-mentioned embodiment, but for example, the method of supplying the molten synthetic resin 10 into the cavity 6a of the upper mold 1 from above the core material is not limited to the above-mentioned embodiment. You can also do it. Hereinafter, a modification example according to the present invention will be explained in detail based on FIG. 13. In FIG. 13, 14 is a molten synthetic resin passage device, and 15 is a movable device. As the core material 11, a synthetic resin plate, an iron plate, a copper plate, a stainless steel plate, or any other plate as required is used to partition the cavity 6a of the synthetic resin molding die 6. The molten plastic passage device 14 has a molten plastic passage 7 therein, and a flexible tube 8 is connected to the molten plastic supply side of the molten plastic passage 7 via a joint 8a with a pressure-resistant structure. Ru. The distal end portion 7a of the molten plastic passageway 7 has a molten plastic resin supply cutoff part (not shown) such as a needle valve. As the movable device 15 , a robot whose technology has recently been developed and is mass-produced is suitably used, and the movable device 15 is movable in and out of at least a space 16 formed by the upper and lower molds 1 and 2 . The fused synthetic resin passage device 14 is supported by a hand 15a of a movable device 15 , and the flexible tube 8 is inserted into a ring 15b fixed to the movable device 15. In this modification, the molten plastic resin supplied from above the core material 11 into the cavity 6a of the upper mold 1 is supplied via the flexible tube 8 and then via the molten plastic passage device 14 . In this modified example, a synthetic resin laminate is manufactured in accordance with steps (5) to (7) of the previous embodiment, ie, the steps shown in FIGS. 8 to 11. (Effects of Modification) The invention method according to this modification does not require a molten plastic passageway in the upper mold 1, that is, a single molten plastic resin supply device 14 can be used for upper molds of various shapes. Therefore, the number of man-hours and manufacturing time for the upper mold can be reduced.
This has the effect of being able to provide synthetic resin laminates at low cost and in a short delivery time. In this invention, the shape of the sliding mold 4 is not limited to that shown in FIGS. 1 to 3,
The sliding mold 4 may be discontinuous as shown in FIGS. 14 to 16. In the present invention, the support portion 9 of the sliding mold 4 is not limited to the above-described embodiments and modified examples, but may have a shape as shown in FIGS. 17 to 18 or 19, for example. In FIGS. 17 to 18, the sliding mold 4 has a supporting body 9a on which the supporting portion 9 is carved, and a sliding mold main body 4.
b with bolt 9b. After molding the synthetic resin laminate, the sliding mold 4 having such a configuration warms up the bolts 9b and attaches them to the support 9.
This has the effect that the synthetic resin laminate can be easily taken out from the synthetic resin molding die by shifting a to the outside of the synthetic resin molding die. In FIG. 19, the sliding mold 4 includes a sliding mold body 4b, a support portion 9, a hydraulic cylinder device 17, and bolts 9b for fixing the hydraulic cylinder device 17 to the sliding mold body 4b. The hydraulic cylinder device 17 includes a cylinder 17a, a piston 17b, and an oil chamber 17c formed by these.
It consists of. The support portion 9 is arbitrarily slid within the sliding mold body 4b by a hydraulic control device (not shown). After molding the synthetic resin laminate, the sliding mold 4 having such a configuration lowers the pressure in the oil chamber 17c and slides the support part 9 toward the outside of the synthetic resin molding mold. This has the effect that the synthetic resin laminate can be easily taken out from the synthetic resin molding die. (Effects of the Invention) As detailed above, the method for producing a synthetic resin laminate according to the present invention simultaneously exhibits the following excellent effects. (1) At least one of the upper mold and the lower mold is composed of a main mold, a sliding mold, and an expansion/contraction device, and the sliding mold is provided with a supporting part, so that it is continuous. Synthetic resin layers can be laminated using the same method. (2) Since the molten synthetic resin is supplied almost simultaneously to both sides of the core material, two synthetic resin layers can be laminated at once, which is efficient, and since no adhesive is used, no skilled technique is required. (3) Since the synthetic resin layer is shaped without regard to warpage, distortion, and surface irregularities of the core material, these warpage, distortion, and surface irregularities do not accumulate in the synthetic resin laminate 13 . The mold apparatus used in this method produces excellent effects when used in the method for producing the above-mentioned excellent synthetic resin laminate.

[Brief explanation of drawings]

1 to 16 are diagrams for explaining the method or synthetic resin laminate according to the present invention.
Fig. 1 is a side view of the device according to the embodiment, Fig. 2 is a view taken along line A-A in Fig. 1, and Fig. 3 is a view taken along line B-B in Fig. 1.
FIG. 4 to 11 are views explaining the steps of the example, and are partially omitted vertical cross-sectional views of FIG. 1. FIG. 4 is a cross-sectional view of the step (1), and FIG. Figure 6 is a sectional view of step (2), Figure 6 is a sectional view of step (3), Figure 7 is a sectional view of step (4), Figure 8 is a sectional view of step (5), Figure 9 is a sectional view of step (5), The figure is a cross-sectional view of step (6), Figure 10 is a cross-sectional view of step (6), and Figure 11 is a cross-sectional view of step (7).
FIG. FIG. 12 is a side view of the synthetic resin laminate, FIG. 13 is a side view of a device according to a modified example, FIG. 14 is a side view of a device according to a further modified example, and FIG. 15 is A-A in FIG. 14. Line sectional view, 1st
6 is a sectional view taken along the line B-B in FIG. 14, FIG. 17 is a vertical sectional view of a modified example of the sliding mold, FIG. 18 is a view taken along the line A-A in FIG. 17, and FIG. It is a longitudinal cross-sectional view of a further modification of the dynamic mold. 1... Upper mold, 2 ... Lower mold, 3... Main mold,
4... Sliding mold, 5... Expanding device, 6 ... Synthetic resin molding mold, 7... Molten synthetic resin passage, 8...
Flexible tube, 9... Support part, 10... Molten synthetic resin,
11...core material, 13 ...synthetic resin laminate, 14 ...
... Molten synthetic resin passageway, 15 ... Movable device.

Claims (1)

[Scope of Claims] 1. At least one of the upper mold and the lower mold is a main mold, a sliding mold that can freely slide up and down along the main mold, and this sliding mold. The method is characterized in that it comprises a telescopic device for sliding the mold, uses a top and bottom separated synthetic resin molding mold consisting of the upper mold and the lower mold, and has at least the following steps a to c. A method for producing a synthetic resin laminate. a. A core material is supported by the sliding mold between the upper mold and the lower mold, and the core material defines a cavity of the synthetic resin mold, and b. Then, from within the lower mold. Supply the molten synthetic resin into the lower mold cavity and into the upper mold cavity from above the core material in random order or at the same time, c. Immediately thereafter, clamp the synthetic resin mold. 2. A synthetic resin molded article whose core material is formed by molding a molten synthetic resin supplied into the cavity of the synthetic resin molding die by clamping the synthetic resin molding die, the step before the step a. 2. A method for producing a synthetic resin laminate according to claim 1, wherein the synthetic resin laminate is molded as a synthetic resin laminate. 3 The molten synthetic resin is supplied into the upper mold cavity from above the core material, passes through the pressure-resistant and heat-resistant flexible material connected to the upper mold with a pressure-resistant structure, and then 2. The method for producing a synthetic resin laminate according to claim 1, wherein the molten synthetic resin is supplied via a molten synthetic resin passage in the upper mold. 4. The molten synthetic resin that is supplied into the upper mold cavity from above the core material passes through a pressure-resistant and heat-resistant flexible tube, and then the flexible tube has a pressure-resistant structure at the tip. The molten synthetic resin is supplied via a molten synthetic resin passage device connected to the molten resin, and at least this molten synthetic resin passage device is supported by a movable device that can freely move in and out of the space formed by the upper and lower molds. A method for producing a synthetic resin laminate according to claim 1. 5 At least one of the upper mold and the lower mold is a main mold, a sliding mold that can freely slide up and down along this main mold, and an expansion and contraction that allows this sliding mold to slide. This sliding mold has a support part that supports a core material between the upper mold and the lower mold, and this core material together with the synthetic resin molding mold forms a cavity. A mold device comprising a molten plastic resin supply device that partitions the molten plastic resin into the lower mold cavity from the lower mold cavity and from above the core material into the upper mold cavity in random order or at the same time. .