JP2017140822A - モジュール式熱成形システム - Google Patents
モジュール式熱成形システム Download PDFInfo
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- JP2017140822A JP2017140822A JP2016225136A JP2016225136A JP2017140822A JP 2017140822 A JP2017140822 A JP 2017140822A JP 2016225136 A JP2016225136 A JP 2016225136A JP 2016225136 A JP2016225136 A JP 2016225136A JP 2017140822 A JP2017140822 A JP 2017140822A
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
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Abstract
【解決手段】航空機の内装パネルなどの熱可塑性部品を製造する熱成形システム及び関連する方法が、ロールツーロール工程及び少なくとも1つの選択的に回転可能なツールを有する成形プレスを含み得る。モールド及び/又はダイを含み得る回転可能なツールが、多面であり、ツールの異なる面が、異なる成形特徴のための異なるモールド配置を有し得る。
【選択図】なし
Description
回転式の多面モールドツーリングを有する熱成形システムの様々な例、及び関連する方法が、以下に記載され、対応する図面に示される。別段の定めがない限り、熱成形システム及び/又はその種々の構成要素は、必須ではないが、本書に記載され、図解され、及び/又は組み込まれた構造、構成要素、機能、及び/又は変形例のうちの少なくとも1つを含み得る。更に、本教示に関連して本書に記載され、図解され、及び/又は組み込まれたプロセスステップ、構造、構成要素、機能、及び/又は変形例は、必須ではないが、他の類似の熱成形システムに含まれ得る。種々の例についての以下の説明は、本質的に単なる例示であり、本開示、その応用又は用途を限定することを意図するものでは決してない。加えて、下記のような、例によって提供される利益は、本質的に例示であり、全ての例が、同じ利益又は同じ程度の利益を提供するとは限らない。
「熱可塑性材料(Thermoplastic)」又は「熱可塑性材料(thermoplastics)」は、ガラス転移温度より高く加熱されると、軟化し、新たな形状に成形されることができ、その後、冷却すると硬化して、新たな形状を実質的に保持するプラスチック材料(又はポリマー)のタイプを指す。このプロセスは、通常、可逆的且つ繰り返し可能であるので、熱可塑性材料はリサイクル(例えば、再成形)され得る。成形は、圧縮成形、真空成形、押出成形、射出成形等、又はこれらの任意の組み合わせなどの任意の適当な方法により達成され得る。熱可塑性材料の例は、アクリル、アクリロ二トリル・ブタジエン・スチレン(ABS)、ナイロン、ポリエチレン、ポリエーテルエーテルケトン(PEEK)、ポリプロピレン、ポリスチレン、及びポリ塩化ビニル(PVC)、等を含む。他の例は、PEI,PPS,PPSU,PEKKなどの、高温システムに適した材料並びにポリカーボネート及びポリウレタンなどの、低温システムに適した材料を含み得る。
以下の節は、例示的な熱成形システム並びに関連するシステム及び/又は方法の選択された態様を記載する。これらの節中の例は、例示用に意図されており、本開示の範囲全体を限定するものと解釈されるべきでない。各節は、1つ以上の別個の発明、及び/又は文脈上の若しくは関連する情報、機能、及び/又は構造を含み得る。
図1に示されるように、この節は、熱成形方法10の選択された工程を説明する。図1は、1つの例によって実施される工程を示すフローチャートであり、完全なプロセス又は本方法の全てのステップを列挙しているわけではない。図1は、本開示の態様による熱成形システムと共に実施され得る、全体として10で示される方法の複数のステップを描く。方法10の様々なステップが、以下に記載され、また図1に描かれているけれども、ステップは、必ずしも全て実施される必要はなく、場合によっては、示されている順序と異なる順序で実施されてもよい。
図2〜図4に示されるように、この節は、とりわけ方法10を実施するのに適し得る熱成形システム100を記載する。
この節は、熱成形システム及び方法の追加の態様及び特徴を記載し、限定なしに一連のパラグラフとして提示されており、その一部又は全部が、明快さ及び効率のために、アルファベットと数字を組み合わせて指定され得る。これらのパラグラフの各々が、1つ以上の他のパラグラフ及び/又は、相互参照において参照によって組み入れられた内容を含む、本出願の他の部分からの開示と、任意の適当な仕方で組み合わせることができる。以下のパラグラフの幾つかは、他のパラグラフを明確に参照し、更に限定し、限定なしに、適当な組合せの幾つかについての例を提供する。
上記の開示は、独立した効用を有する複数の別個の例を包含し得る。これらの各々が、好適な形態(複数可)で開示されているけれども、本書に開示され説明された特定の例は、限定の意味で考えられるべきでなく、多くの変形例が可能である。節の表題は、本開示内で用いられる限りにおいて、構成上の目的にすぎない。本発明(複数可)の内容は、本書に開示された様々な要素、特徴、機能、及び/又は性質の、全ての新規で非自明なコンビネーション及びサブコンビネーションを含む。以下の請求項は、新規且つ非自明と考えられる幾つかのコンビネーション及びサブコンビネーションを特に示している。特徴、機能、要素、及び/又は性質の他のコンビネーション及びサブコンビネーションが、本出願又は関連出願に基づく優先権を主張する出願において請求され得る。そのような請求項もまた、元の請求項に対して範囲が広くても、狭くても、等しくても、又は異なっていても、本開示の内容の範囲内に含まれるものと見なされる。
Claims (17)
- 熱可塑性部品を成形する方法であって、
予熱オーブンの中に熱可塑性材料を供給して、予熱された熱可塑性材料を形成するステップ(12)と、
前記予熱された熱可塑性材料を成形プレスの中に供給して、プレスされた熱可塑性部品を成形するステップであって、前記成形プレスは、第一のツール及び第二のツールを備え、少なくとも前記第一のツールが、複数の面を有する回転式ツールを含む、ステップ(16)と、
前記プレスされた熱可塑性部品を仕上げるステップ(18)と
を含む方法。 - 前記回転式ツールの各面が、異なるモールド形状を有し、
前記回転式ツールを回転させて、どの面が前記第二のツールの方に向けられるかを変更するステップを更に含む、請求項1に記載の方法。 - 前記第一のツールがプレスツールであり、前記第二のツールがモールドツールであり、好ましくは、前記プレスツール及び前記モールドツールが、互いと嵌合するように構成されており、好ましくは、前記成形プレスの前記第一のツール及び前記第二のツールの各々が、複数の面を有する回転式ツールを含む、請求項1又は2に記載の方法。
- 前記回転式ツールの各面が、交換可能なインサートを固定するための受け取り構造を有し、各インサートが、異なるモールド形状を有し、
前記回転式ツールの受け取り構造から第一のインサートを取り外し、それを第二のインサートと取り替えるステップを更に含む、請求項1から3のいずれか一項に記載の方法。 - 熱可塑性材料のウェブを、前記予熱オーブンの上流のロールから連続的な処理経路を通って移動させるステップを更に含む、請求項1から4のいずれか一項に記載の方法。
- 前記面のうちの1つ以上の面を前記回転式ツールの内部から加熱するステップを更に含む、請求項1から5のいずれか一項に記載の方法。
- 前記成形プレスを用いて前記熱可塑性材料に付帯的な構成要素を埋め込み、及び/又は前記成形プレス内で前記熱可塑性材料にテクスチャーのあるツール表面をプレスするステップを更に含む、請求項1から6のいずれか一項に記載の方法。
- 前記プレスツールの面上の特定のインサートパネルに対応するモールド部品を、前記モールドツール上にロボットで置くステップを更に含む、請求項1から7のいずれか一項に記載の方法。
- 前記回転式ツールが、ほぼ水平な軸の周りに回転して、前記回転式ツールの種々の面の適用を変更し、好ましくは、前記回転式ツールが、前記処理経路の方向に対して横方向の軸の周りに回転して、前記回転式ツールの種々の面の適用を変更する、請求項1に記載の方法。
- 連続的な処理経路が、前記予熱オーブンの上流の熱可塑性材料のロールから前記成形プレスを通って仕上げステーションへと定められる、請求項1に記載の方法。
- 特定の航空機設計における組立て用に構成された一組の内装パネルに対応する一組のインサートを前記回転式ツールにロードするステップを更に含み、好ましくは、あらかじめ作られた装飾用デザインを前記熱可塑性材料に与えるステップを更に含む、請求項1から10のいずれか一項に記載の方法。
- プレスステップの間、前記ウェブの供給を止め、同時に、仕上げられた部品を切断し、前記成形プレスの下流の前記処理経路から取り除くステップを更に含む、請求項1から11のいずれか一項に記載の方法。
- モールドツール(124)及びプレスツール(126)を備える成形プレスであって、
前記モールドツール及びプレスツールのうちの少なくとも1つが、複数の面(128)を有する回転式ツールを含み、各面が、熱可塑性材料に異なる部品を成形するように構成された異なるモールドを有し、好ましくは、前記回転式ツールが、加熱機構(132)を有する、成形プレス。 - 前記回転式ツールの各面(128)が、交換可能なインサート(134)を固定する受け取り構造を有し、各インサートが、異なるモールド形状を有し、好ましくは、前記回転式ツールが、特定の航空機設計における組立て用に構成された一組の熱可塑性内装パネルに対応する一組のインサートを保持する、請求項13に記載の成形プレス。
- 熱可塑性源ステーション(104)、プレスステーション(118)、及び仕上げステーション(142)を備える、熱可塑性部品を成形するシステムであって、連続的な処理経路が、前記熱可塑性源ステーションにおける熱可塑性ウェブ材料のロールから、前記プレスステーションを通って前記仕上げステーションへと定められ、好ましくは、前記プレスステーションが、内部加熱機構を有するツールを含む、システム。
- 前記プレスステーション(118)が、異なる部品を成形するための複数の面(128)を有する回転式ツールを含み、好ましくは、
前記プレスステーション(118)が、モールドツール(124)及びプレスツール(126)を含み、各ツールが、異なる部品を成形するための複数の面(128)を有する回転式ツールを含む、請求項15に記載のシステム。 - 前記プレスステーションの上流に予熱ステーション(112)を更に備える、請求項15又は16に記載のシステム。
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