JP5674341B2 - POLYESTER THERMOFORMED ARTICLE AND METHOD FOR PRODUCING THE SAME - Google Patents
POLYESTER THERMOFORMED ARTICLE AND METHOD FOR PRODUCING THE SAME Download PDFInfo
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- JP5674341B2 JP5674341B2 JP2010118562A JP2010118562A JP5674341B2 JP 5674341 B2 JP5674341 B2 JP 5674341B2 JP 2010118562 A JP2010118562 A JP 2010118562A JP 2010118562 A JP2010118562 A JP 2010118562A JP 5674341 B2 JP5674341 B2 JP 5674341B2
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- Moulds For Moulding Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Description
本発明は延伸された熱可塑性ポリエステル系樹脂のシート又はフイルムを用いた熱成型品及びその製造方法に関る。本発明の製造方法は、賦形体を高速で加熱及びまたは冷却し、更には熱成形の過程において予熱温度以上の高温の熱処理を行うことにより耐熱等の向上した透明性等の高い熱成形品を高速で効率よく製造するものである。 The present invention relates to a thermoformed article using a stretched sheet or film of a thermoplastic polyester resin and a method for producing the same. In the production method of the present invention, a shaped article is heated and / or cooled at a high speed, and further, a heat-formed product having high transparency and the like having improved heat resistance is obtained by performing a heat treatment at a temperature higher than the preheating temperature in the thermoforming process. It is manufactured at high speed and efficiently.
ポリエチレンテレフタレート(ＰＥＴ)を代表とする熱可塑性ポリエステルは、成形品は強度が大きく、耐薬品性、耐光性、耐摩耗性等の耐久性にも優れており、シートや各種形態の容器等に成形し飲料、液体食品等の容器や食品トレーなどとして広く用いられている。しかしながら、用途によっては、なお耐熱性、耐衝撃性、ガスバリヤ性などが充分でなく、古くから種々の検討がなされてきた。この結果、熱成形の過程において高温の熱処理を行うことにより耐熱性等の増加し且つ透明性等の高い熱成形品を製造する種々の方法が開発されてきた。しかしながら、このような方法で高速で効率のよい製造方法はなく、特に延伸材料を使用した透明性のあるものは未だ商業的成功には至っていない。 Thermoplastic polyester, represented by polyethylene terephthalate (PET), has high strength and excellent durability such as chemical resistance, light resistance, and abrasion resistance, and is molded into sheets and containers of various forms. Widely used as containers for beverages and liquid foods, food trays, and the like. However, depending on the application, heat resistance, impact resistance, gas barrier properties, etc. are still insufficient, and various studies have been made for a long time. As a result, various methods have been developed for producing thermoformed articles having increased heat resistance and high transparency by performing high temperature heat treatment in the process of thermoforming. However, there is no high-speed and efficient production method by such a method, and a transparent material using a stretched material has not yet achieved commercial success.
例えば（１）特公昭４４−５１０８には、特定の結晶化度等を有するポリエチレンテレフタレートの板またはシートを輻射熱で予熱して真空成型に賦し、そのまま再び輻射熱にて加熱するなどして成形型内で熱処理する方法が開示されているが、この方法では熱処理に非常に長い時間がかかっており実用的ではない。また、（２）特公昭５６−７８５５にはポリエステルシートを一度１軸延伸配向させ次いでこれを加熱収縮させたシートを用いて熱成形する方法が開示されている。ここでは必要により成形時に熱風を用いる方法により熱固定する方法を例示しているが熱処理に非常に長い時間がかかり実用的ではなく、また冷却離型して良品を得る概念も含まれていない。また、（３）特公平５−４５４１２では、特定条件で２軸延伸し更に熱収縮させたシートを用いて熱成形と熱処理を行う方法が開示されている。ここでは、加熱型への移し替え、熱風、熱水、赤外線になどよる加熱法を例示しているが、その具体的な方法について触れておらず、また冷却して離型するプロセスは含まれていない。（４）特公昭６０−０３１６５１には特定の複屈折率を有するポリエステル延伸シートを熱成形し熱処理する方法が開示され、具体的には加熱された金型で成形し、冷却して成型品を得ることが示されているが、冷却方法は示されておらず、例えば金型ジャケットに熱媒を通じて加熱冷却しながらこのプロセスを行うとすれば時間がかかり実用的ではない。更にはまた、（５）特公昭５９−０５１４０７では、特定の複屈折率を有する２軸配向ポリエステルシートを熱盤に接触させ特定の温度に加熱し特定の圧力で圧空成形する方法が開示されているが、成形時の熱処理は実質的になされていない。また、特許３０５３２４５号は一軸延伸ポリエステルを用いた熱成形について開示しているが、熱成形方法についての開示はなく、また示された耐熱向上も微々たるもので実質的な効果はない。 For example, in (1) Japanese Examined Patent Publication No. 44-5108, a polyethylene terephthalate plate or sheet having a specific degree of crystallinity is preheated with radiant heat, subjected to vacuum forming, and then heated again with radiant heat. However, this method is not practical because it takes a very long time for the heat treatment. Also, (2) Japanese Examined Patent Publication No. 56-7855 discloses a method in which a polyester sheet is once uniaxially stretched and oriented, and then heat-shrinked using a heat-shrinked sheet. Here, a method of heat-fixing by a method using hot air at the time of molding is illustrated as necessary, but the heat treatment takes a very long time and is not practical, and the concept of obtaining good products by cooling and releasing is not included. Further, (3) Japanese Patent Publication No. 5-45412 discloses a method of performing thermoforming and heat treatment using a sheet biaxially stretched under specific conditions and further thermally contracted. Here, the transfer method to the heating mold, the heating method by hot air, hot water, infrared rays, etc. are illustrated, but the specific method is not mentioned, and the process of cooling and releasing is included. Not. (4) Japanese Examined Patent Publication No. 60-031651 discloses a method of thermoforming and heat-treating a stretched polyester sheet having a specific birefringence, specifically, molding with a heated mold and cooling to form a molded product. Although it is shown that it is obtained, the cooling method is not shown. For example, if this process is performed while heating and cooling the mold jacket through a heat medium, it takes time and is not practical. Furthermore, (5) Japanese Examined Patent Publication No. S59-051407 discloses a method in which a biaxially oriented polyester sheet having a specific birefringence is brought into contact with a heating plate, heated to a specific temperature, and subjected to pressure forming at a specific pressure. However, the heat treatment at the time of molding is not substantially performed. Japanese Patent No. 3053245 discloses thermoforming using a uniaxially stretched polyester, but there is no disclosure of a thermoforming method, and the heat resistance improvement shown is slight, so there is no substantial effect.
一方、特開２０００−３５５０９１、特開２０００−２９７１６２等のように 通常ＣＰＥＴと呼ばれる結晶化促進の為の核剤を含むポリエチレンテレフタレート樹脂を押出機よりシートに成形し、これを用いて熱成形と熱処理を行い結晶化を進める技術が知られており、球晶が発達し耐熱性については大幅に向上するものの白色不透明となり、耐衝撃性、特に低温における耐衝撃性が大きく低下する。しかし、これらのＣＰＥＴ成形では、熱処理すなわち結晶化に時間をかければ、熱処理温度以上の耐熱が得られ、材料が高温のまま離型しても変形が少なく冷却はあまり問題にならない．そして熱成形サイクル短縮とより安定な生産のために冷却型から加熱型へ、あるい加熱型から冷却型へ移して処理することも容易である。 On the other hand, a polyethylene terephthalate resin containing a nucleating agent for promoting crystallization, usually called CPET, as in JP-A-2000-355091 and JP-A-2000-297162 is formed into a sheet from an extruder, and this is used for thermoforming. A technique for performing crystallization by heat treatment is known, and although spherulites develop and heat resistance is greatly improved, it becomes white opaque, and impact resistance, particularly impact resistance at low temperatures is greatly reduced. However, in these CPET moldings, if heat treatment, that is, crystallization takes a long time, heat resistance equal to or higher than the heat treatment temperature can be obtained, and even if the material is released at a high temperature, deformation is small and cooling is not a problem. In order to shorten the thermoforming cycle and achieve more stable production, it is easy to transfer from the cooling mold to the heating mold or from the heating mold to the cooling mold for processing.
また、特許２６６８８４８号は、延伸された合成樹脂シートを成型する熱成形装置を開示し、その効果としては延伸により熱収縮性の材料となったポリスチレン等の材料を、加熱されたプラグと加熱された空気を用いて、深絞り等の成形ができることを述べている。この発明は熱収縮しやすくなった材料を定位置でクランプ固定して熱風で予熱しながら、延伸により成形しにくくなった材料をプラグで強制的に押し延ばしながら成形するもので、熱処理については何の記載もないが、こうした装置で予熱温度以上の熱処理はできない。また特許２６６８８４７号も前記同様の材料を同様にクランプ固定するようにし、加熱凹型に対して低温の凸型プラグを押し込み圧空成形する装置を開示している。この場合も延伸配向の熱固定を進める程の高温の熱処理については何の開示もしていないが、仮に高温の熱処理ができたとしても、シワの発生などが問題となり、またオフセットまたはアンダーカット形状のある成型品には適用しにくい。 Japanese Patent No. 2668848 discloses a thermoforming apparatus for molding a stretched synthetic resin sheet. As an effect thereof, a material such as polystyrene, which has become a heat-shrinkable material by stretching, is heated with a heated plug. It describes that deep drawing and other molding can be performed using fresh air. In this invention, a material that is easily heat-shrinkable is clamped in place and preheated with hot air, while a material that has become difficult to be formed by stretching is formed by forcibly stretching it with a plug. However, heat treatment above the preheating temperature cannot be performed with such an apparatus. Japanese Patent No. 2668847 also discloses a device that clamps and fixes the same material as described above, and presses a low-temperature convex plug into a heated concave mold to perform pressure forming. In this case as well, there is no disclosure of a heat treatment at a high temperature enough to advance the heat setting of the stretch orientation, but even if a heat treatment at a high temperature is possible, the occurrence of wrinkles becomes a problem, and the offset or undercut shape It is difficult to apply to certain molded products.
本発明はこのような従来技術の問題点に鑑みてなされたものである。その主な目的は、延伸されたポリエステル系樹脂シートの熱成形の賦形から離型までの過程において、賦形のためのシート予熱温度以上の高温の熱処理を行って離型する熱成形を高速で効率良く連続的に行う方法を提供することである。 The present invention has been made in view of such problems of the prior art. Its main purpose is high-speed thermoforming of mold release by heat treatment at a temperature higher than the sheet preheating temperature for shaping in the process from thermoforming to release of the stretched polyester resin sheet. It is to provide a method that performs efficiently and continuously.
（１）延伸されたポリエステル系樹脂シートを成形材料として熱成形するにあたり、成形型として、熱成型用表面層及びこれに隣接する背後層を有する熱成形型であって、該表面層は熱浸透率（ｋＪ／ｍ ２ ｓ １／２ Ｋ）が０.０１以上(望ましくは０.１以上、更に望ましくは０．３以上)でかつ２５以下(望ましくは２０以下、更に望ましくは１０以下)の材料により形成されると共に下式：
Ｆα １／２ ×１０ ３ ＞ｔ＞Ｇ ・・・・・・（１）
（式中、ｔ；表面層の厚み（ｍｍ）、α；温度伝達率 （ｍ ２ ／ｓ）、Ｆ；３０、Ｇ；０．０４）
で表される厚みを有し、かつ前記背後層の熱浸透率は前記表面層より大きい（望ましくは７以上）の材料により形成されている成形型を用い、賦形から離型までの過程において少なくとも一時的に該表面層の表面温度（又は賦形体との界面温度）を（当該成形材料樹脂のＴｇ＋５０℃）以上、望ましくは（Ｔｇ＋６０℃）以上、且つＴｍ（結晶融点）以下、望ましくは（Ｔｍ−３０）℃以下の温度にして行うことを特徴とする熱成形品の製造方法を提供するものである。また、本発明は下記（２）〜（９）の発明を提供するものである。なお、本発明は特に繰り返しの連続成形に適する方法である。
(1) In thermoforming a stretched polyester resin sheet as a molding material, a thermoforming die having a thermoforming surface layer and a back layer adjacent thereto as a forming die, the surface layer being heat-permeable The rate (kJ / m 2 s 1/2 K) is 0.01 or higher (preferably 0.1 or higher, more preferably 0.3 or higher) and 25 or lower (preferably 20 or lower, more preferably 10 or lower). Formed by the material and the following formula:
F α 1/2 × 10 3 >t> G (1)
(Where, t: thickness of the surface layer (mm), α: temperature transfer rate ( m 2 / s), F; 30, G; 0.04)
In the process from shaping to mold release, using a molding die that is formed of a material having a thickness represented by the above and a thermal permeability of the back layer larger than that of the surface layer (preferably 7 or more). At least temporarily, the surface temperature of the surface layer (or the interface temperature with the shaped body) is (Tg + 50 ° C. of the molding material resin) or more, desirably (Tg + 60 ° C.) or more and Tm (crystal melting point) or less, desirably ( Tm-30) The present invention provides a method for producing a thermoformed product, which is carried out at a temperature of not higher than C. The present invention also provides the following inventions (2) to (9). The present invention is a method particularly suitable for repeated continuous molding.
（２）前記成形工程中、成形サイクル（賦形待ちのインターバル含む）の中で、１）該背後層を経由する加熱、２）高温気体の該表面または賦形体裏面（成形型に接触していない面）への接触、３）赤外線の該表面または賦形体裏面（成形型に接触していない面）へ照射の中の少なくとも１つの手段を用いて、（成形材料樹脂のＴｇ＋５０℃）以上の表面温度を得る（１）の熱成形品の製造方法。
なお、本方法において用いられる高温気体は、強制的な気体流であることが望ましい。
(2) During the molding process, in the molding cycle (including the waiting interval for shaping), 1) heating through the back layer, 2) the surface of the hot gas or the back side of the shaped body (in contact with the molding die) 3) contact with the surface of the infrared rays or the back of the shaped body (surface not in contact with the mold) by using at least one of the means in the irradiation (Tg + 50 ° C. of the molding material resin) or more The method for producing a thermoformed product according to (1), wherein a surface temperature is obtained.
Note that the high-temperature gas used in the present method is preferably a forced gas flow.
（３）前記工程の成形サイクル中、１）該背後層を経由する冷却、２）冷却用流体流の賦形体裏面へ接触、３）揮発性液体の賦形体裏面への接触の中の少なくとも１つの手段を用いて、前記表面温度を降下させて離型を行う（１）〜（２）の方法。なお、この方法において、この温度降下は５℃以上でることが望ましく、また用いられる冷却用気体は強制を伴う気体流であることが望ましい。 (3) During the molding cycle of the above step, 1) Cooling via the back layer, 2) Contacting the cooling fluid stream to the back of the shaped body, 3) Contacting at least one of the volatile liquid to the back of the shaped body The method of (1)-(2) which performs mold release by lowering | hanging the said surface temperature using two means. In this method, the temperature drop is desirably 5 ° C. or more, and the cooling gas used is desirably a gas flow with forcing.
（４）該表面温度、または該表面下の浅層部または賦形体裏面の成形サイクルに伴い変化する温度（以下サイクル温度という）を計測し、賦形体の熱処理を伴うプロセスを管理または制御する（１）〜（３）の方法。 (4) Measure the surface temperature, or the temperature that changes with the molding cycle of the shallow layer portion or the back of the shaped body (hereinafter referred to as cycle temperature), and manage or control the process involving heat treatment of the shaped body ( The method of 1)-(3).
（５）賦形の方法として、１）真空成形法、２）圧空成形法、３）真空圧空成形法、４）プラグアシストを伴う前記成形法のいずれか、（５）嵌合ダイ成形法、のいずれかの方法を用いる（１）〜（４）の方法。
なおこれらの賦形方法の中で、真空圧空成形法または圧空成形法の方法が特に好ましく用いられる。
(5) As a forming method, 1) a vacuum forming method, 2) a pressure forming method, 3) a vacuum / pressure forming method, 4) any of the above forming methods with plug assist, (5) a fitting die forming method, The method of (1) to (4) using any one of the methods.
Among these shaping methods, the vacuum / pressure forming method or the pressure forming method is particularly preferably used.
（６）成形型の該背後層温度を、該表面温度の所定の最高温度と最低温度の間で制御し、賦形と同時あるいは賦形後に、高温気体の賦形体裏面への接触および又は同裏面への赤外線照射により所定の最高温度に到達させる工程と、冷却用気体流を成形体裏面に接触させ離型する工程を含む（１）〜（５）の方法（パターンＡ）。 (6) The temperature of the back layer of the mold is controlled between a predetermined maximum temperature and a minimum temperature of the surface temperature, and at the same time as shaping or after shaping, contact of the hot gas with the back of the shaped body and / or the same. A method (pattern A) of (1) to (5) including a step of reaching a predetermined maximum temperature by infrared irradiation on the back surface and a step of bringing the cooling gas flow into contact with the back surface of the molded body and releasing the mold.
（７）成形型の該背後層温度を該表面温度の所定の最低温度ないしこれを下回る温度に設定し、賦形と同時あるいは賦形後に、背後層温度以上の高温気体の賦形体裏面への接触および又は同裏面への赤外線照射により加熱する工程と、次いで所定の離型温度に達するまで待って離型する工程を含む（１）〜（５）の方法（パターンＢ）。 (7) The temperature of the back layer of the molding die is set to a predetermined minimum temperature of the surface temperature or a temperature lower than the predetermined temperature, and at the same time as or after the shaping, a hot gas having a temperature higher than the back layer temperature is applied to the back of the shaped body. The method of (1)-(5) (pattern B) including the process of heating by contact and / or the infrared irradiation to the back surface, and the process of waiting until it reaches a predetermined mold release temperature.
（８） 該成形型の該背後層温度を該表面温度の所定の最高温度のないしこれを上回る温度に設定しておき、賦形を行って該表面温度の所定の最高温度への到達を待って冷却用気体流を賦形体裏面に接触させる工程、または該最高温度への到達後に賦形と同時あるいは賦形後に冷却用気体流を賦形体裏面に接触させる工程により該表面温度を所定の離型温度に到達せしめて離型することを特徴とする（１）〜（５）の方法（パターンＣ）。 (8) The temperature of the back layer of the mold is set to a temperature that is equal to or higher than a predetermined maximum temperature of the surface temperature, and shaping is performed to wait for the surface temperature to reach a predetermined maximum temperature. The surface temperature is set at a predetermined separation by contacting the cooling gas flow with the back surface of the shaped body, or contacting the cooling gas flow with the back surface of the shaped body simultaneously with or after shaping after reaching the maximum temperature. The method of (1) to (5) (pattern C), wherein the mold is released after reaching the mold temperature.
（９）ポリエステル系の同樹脂の非延伸シートを用いた通常の熱成形品に比べ、耐熱性が少なくとも１０℃向上した熱成型品を得ることを特徴とする（１）〜（８）の何れかの方法。 (9) Any one of (1) to (8), wherein a thermoformed product having an improved heat resistance of at least 10 ° C. is obtained as compared with a normal thermoformed product using a polyester-based non-stretched sheet of the same resin. That way.
（１０）上記（１）〜（８）の何れかの方法を用いることにより得られたものが、ポリエステル系の同樹脂の非延伸シートを用いた通常の熱成形品に比べ、耐熱性が少なくとも１０℃向上した熱成型品 (10) What was obtained by using any one of the above methods (1) to (8) has at least heat resistance as compared with a normal thermoformed product using a polyester-based non-stretched sheet of the same resin. Thermoformed product improved by 10 ℃
以下本発明の内容をさらに詳細に説明する．
ポリエステル樹脂
本発明の延伸されたシートに用いられポリエステル系樹脂は、ポリエチレンテレフタレート系樹脂、ポリ乳酸系等の結晶性熱可塑ポリエステル系樹脂であり、ポリエチレンテレフタレート系樹脂が好ましく、ポリエチレンテレフタレートのホモポリマーは勿論のこと、エチレンテレフタレート単位を６５モル％以上、より好ましくは９０％以上含む実質的に線状のコポリエステルを含有する。このコポリエステルを構成する成分として例えば、イソフタル酸、ナフタレン−２，６−ジカルボン酸、ジフェニルジカルボン酸、ジフェノキシエタンジカルボン酸、ジフェニルエーテルジカルボン酸、ジフェニルスルホンジカルボン酸、ヘキサヒドロテレフタル酸、ヘキサヒドロイソフタル酸、アジピン酸、セバチン酸、アゼライン酸、ｐ−β−ヒドロキシエトキシ安息香酸、ε−オキシカプロン酸の如き芳香族、脂環族、脂肪族の二官能性カルボン酸、トリメチレングリコール、テトラメチレングリコール、ネオペンチルグリコール、ヘキサメチレングリコール、デカメチレングリコール、ジエチレングリコール、トリエチレングリコール、１，１−シクロヘキサンジメチロール、１，４−シクロヘキサンジメチロール、２，２−ビス（４’−β−ヒドロキシエトキシフェニル）スルホン酸のようなグリコール等が挙げられる。ここに挙げた化合物の１種または２種以上を含んでいてもよい。
The contents of the present invention will be described in more detail below.
Polyester resin The polyester resin used in the stretched sheet of the present invention is a crystalline thermoplastic polyester resin such as polyethylene terephthalate resin or polylactic acid, preferably polyethylene terephthalate resin, and polyethylene terephthalate homopolymer is Of course, it contains a substantially linear copolyester containing ethylene terephthalate units of 65 mol% or more, more preferably 90% or more. Examples of components constituting this copolyester include isophthalic acid, naphthalene-2,6-dicarboxylic acid, diphenyldicarboxylic acid, diphenoxyethanedicarboxylic acid, diphenyletherdicarboxylic acid, diphenylsulfonedicarboxylic acid, hexahydroterephthalic acid, hexahydroisophthalic acid Aromatic, alicyclic, and aliphatic bifunctional carboxylic acids such as adipic acid, sebacic acid, azelaic acid, p-β-hydroxyethoxybenzoic acid, and ε-oxycaproic acid, trimethylene glycol, tetramethylene glycol, Neopentyl glycol, hexamethylene glycol, decamethylene glycol, diethylene glycol, triethylene glycol, 1,1-cyclohexane dimethylol, 1,4-cyclohexane dimethylol, 2,2-bis (4 And glycols such as' -β-hydroxyethoxyphenyl) sulfonic acid. One or more of the compounds listed here may be included.
ポリエステルは、実質的に線状である範囲で少量の３官能以上の他官能化合物を共重合成分として含んでいるものであってもよい。 The polyester may contain a small amount of a trifunctional or higher functional compound as a copolymerization component within a substantially linear range.
またポリエステルの極限粘度（試料１．０ｇをフェノール／テトラクロロエタン５０／５０（重量比）の混合溶媒１００ｍｌ中に溶解した溶媒について３０℃で測定した値）は０．５以上〜１．３ｄｌ／ｇ、好ましくは０．６〜１．１ｄｌ／ｇの範囲にあることが好ましい。 またガラス転移点（Ｔｇ）（シートより５ｍｇ採取して、それを窒素中にて２８５℃で５分間溶融後急冷し、急冷物をＤＳＣにて昇温速度２０℃／分の条件下で測定した値）は、４０〜１１０℃の範囲のものが好ましく、５０〜１００℃の範囲のもは更に好ましく、６０〜１００℃の範囲のものが特に好ましい。Ｔｇがこれより小さい場合も大きい場合も、延伸シートの面配向度（ΔＰ）を適正な範囲に制御すめることが困難になり好ましくない。 The intrinsic viscosity of the polyester (value measured at 30 ° C. for a solvent obtained by dissolving 1.0 g of a sample in 100 ml of a mixed solvent of phenol / tetrachloroethane 50/50 (weight ratio)) is 0.5 to 1.3 dl / g. , Preferably in the range of 0.6 to 1.1 dl / g. Glass transition point (Tg) (5 mg was taken from the sheet, melted in nitrogen at 285 ° C. for 5 minutes and then rapidly cooled, and the rapidly cooled product was measured by DSC under a temperature rising rate of 20 ° C./min. The value) is preferably in the range of 40 to 110 ° C, more preferably in the range of 50 to 100 ° C, and particularly preferably in the range of 60 to 100 ° C. Whether Tg is smaller or larger than this, it is difficult to control the degree of plane orientation (ΔP) of the stretched sheet within an appropriate range, which is not preferable.
更に融点（Ｔｍ）（上記Ｔｇと同条件で測定した値）は１５０〜３００℃の範囲が好ましく、２００〜２８０℃の範囲が更に好ましく、２３０〜２７０℃の範囲が特に好ましい。 Further, the melting point (Tm) (value measured under the same conditions as the above Tg) is preferably in the range of 150 to 300 ° C, more preferably in the range of 200 to 280 ° C, and particularly preferably in the range of 230 to 270 ° C.
またポリエステルに添加剤、たとえば核剤、滑剤、紫外線吸収剤、熱安定剤、酸化防止剤、着色剤、帯電防止剤等を添加してもよい．さらに、ポリメチルペンタンや、ポリカーボネート、ポリメチルメタクリレート等の強化材も場合によっては添加してもよい。 Additives such as nucleating agents, lubricants, ultraviolet absorbers, heat stabilizers, antioxidants, colorants, antistatic agents and the like may be added to the polyester. Further, reinforcing materials such as polymethylpentane, polycarbonate, and polymethyl methacrylate may be added depending on circumstances.
延伸シート
前記のポリエステル樹脂からなるシートは実質的に延伸配向したものが用いられる。延伸方法は特に限定されるものではなく公知の延伸方法がいずれも用い得る。
ポリエステルシート（未延伸）を製造するには、例えば、原料樹脂を押出機に供給し、樹脂温度２６０〜３２０℃程度で溶融押出し、押出機に接続したフラツトダイを通じて押出されたシート状溶融物をキャスティングロールで引取り冷却固化して製造する。また、押出機にサーキュラーダイを接続してインフレーション成型したものを使用してもよく、またカレンダー機によりシーテイング成形したものを使用してもよい。
Stretched sheet A substantially stretched and oriented sheet is used for the above-mentioned polyester resin sheet. The stretching method is not particularly limited, and any known stretching method can be used.
In order to produce a polyester sheet (unstretched), for example, a raw material resin is supplied to an extruder, melt-extruded at a resin temperature of about 260 to 320 ° C., and a sheet-like melt extruded through a flat die connected to the extruder is cast. It is produced by taking a roll and solidifying by cooling. In addition, a product formed by inflation molding with a circular die connected to an extruder may be used, or a product formed by sheeting using a calender may be used.
このようにして得られたシートは通常は有効な延伸処理はなされておらず、これをインラインあるいはアウトラインで延伸処理する。延伸装置は特に限定されず、物理的に延伸可能な方法であれば適宜の装置を採用することができ、１軸延伸、２軸延伸のいずれも採用することができる。 The sheet thus obtained is usually not subjected to an effective stretching process, and is stretched inline or in outline. The stretching apparatus is not particularly limited, and any suitable apparatus can be adopted as long as it is a physically stretchable method, and both uniaxial stretching and biaxial stretching can be employed.
これらの内で、１軸延伸方式は温度調整したシートを１方向にのみ延伸する方法であり、通常は、複数のローラーを組合わせた装置あるいは拡幅用のテンターと呼ばれる装置が用いられる。また、２軸延伸は予熱したシートを縦横２方向に延伸するものであり、通常は上記の１軸延伸に続いて、更に拡幅用のテンターにて幅方向の延伸が行われる。２軸延伸方式では、縦横交互に延伸する逐次法と、縦横ほぼ同時に延伸する同時法があるが何れの方法を用いてもよい。又上記した１軸延伸方式あるいは２軸延伸方式以外の方法として、例えば円筒状フイルムのバルーンを高い空気圧により膨張させることによって延伸してもよく、また温度調整したシートをローラーにより圧延してもよい。このようして得られる市販の延伸シートには通常熱固定処理が施されているが、本発明ではこうした熱固定処理が施されたものも、施されていないものも使用できるが、施されていないものが特に好ましい。 また、こうした延伸方法の中では１軸延伸によるシートは、延伸装置も製造方法も比較的に簡易で低コストででき、熱成形性も良く残して調整することができ、連続成形機へのクランプも容易で、また本発明の熱処理構成により配向の異方性のも問題も解消することができ非常に好ましい。 Among these, the uniaxial stretching method is a method of stretching a temperature-adjusted sheet only in one direction, and an apparatus called a combination of a plurality of rollers or an apparatus called a widening tenter is usually used. Biaxial stretching is a method in which a preheated sheet is stretched in two directions in the vertical and horizontal directions. Usually, following the uniaxial stretching, stretching in the width direction is further performed by a tenter for widening. In the biaxial stretching method, there are a sequential method of stretching in the vertical and horizontal directions and a simultaneous method of stretching in the vertical and horizontal directions at the same time, and any method may be used. As a method other than the above-described uniaxial stretching method or biaxial stretching method, for example, a balloon of a cylindrical film may be stretched by inflating with high air pressure, or a temperature-adjusted sheet may be rolled with a roller. . The commercially available stretched sheet thus obtained is usually subjected to heat setting treatment. In the present invention, those subjected to such heat setting treatment and those not subjected to heat setting can be used. Particularly preferred are those without. Also, among these stretching methods, a uniaxially stretched sheet can be adjusted with a relatively simple and low cost stretching device and manufacturing method, with good thermoformability, and can be clamped to a continuous molding machine. In addition, the heat treatment structure of the present invention is very preferable because the problem of orientation anisotropy can be solved.
このような延伸は、通常、ポリエステル樹脂シートをその樹脂のガラス転移点以上、かつ結晶融点以下にして行われるが、延伸による配向効果をより発揮させるためには、ガラス転移点以上で、かつ結晶融点より６０℃以上低い温度に調整して行われる。また、延伸プロセスの最後に延伸状態を保持しつつ通常は延伸時よりも高い温度で短時間加熱する所謂熱固定(ヒートセット)処理を行い配向効果(配向結晶化度)の向上をはかることが行われる。本発明の成形法では、このような熱固定を行っていないシートも、熱固定を行ったシートも用いることができるが、熱固定を行っていないシートはより好ましく、より大きな絞り率の成形が、また細部の成型状態がより良い成形が可能である。 Such stretching is usually carried out with the polyester resin sheet having a glass transition point higher than the resin and not higher than the crystal melting point, but in order to exert the orientation effect by stretching more than the glass transition point and the crystal The temperature is adjusted to 60 ° C. or lower than the melting point. Further, at the end of the stretching process, the orientation effect (orientation crystallinity) can be improved by performing a so-called heat setting process in which the stretched state is maintained and usually heated for a short time at a temperature higher than that during stretching. Done. In the molding method of the present invention, a sheet that has not been heat-set as well as a sheet that has been heat-set can be used, but a sheet that has not been heat-set is more preferable, and molding with a larger drawing ratio is preferable. In addition, it is possible to perform molding with a finer molding state.
上記のようにして製造され本発明に使用される延伸シートは、その延伸配向効果を示す指標として面配向度（ΔＰ）が０．０１５〜０．１５であることが好ましく、０．０２〜０．１０であることは更に好ましく、０．０２〜０．０８であることが特に好ましい。また、かかるシートは流れ方向と幅方向のうち少なくとも一方向の延伸が１.２倍〜６倍に、より好ましくは１.８〜４倍に延伸して得られる。こうした中で１軸延伸で、延伸倍率が１．５〜３倍のもの、あるいはΔＰが０．０２〜０．０８のものが特に好ましく使用できる。 The stretched sheet produced as described above and used in the present invention preferably has a degree of plane orientation (ΔP) of 0.015 to 0.15 as an index indicating the stretch orientation effect, and is 0.02 to 0. 10 is more preferable, and 0.02 to 0.08 is particularly preferable. Further, such a sheet is obtained by stretching at least one of the flow direction and the width direction by 1.2 to 6 times, more preferably by 1.8 to 4 times. Among these, uniaxial stretching with a stretching ratio of 1.5 to 3 times or ΔP of 0.02 to 0.08 can be particularly preferably used.
また延伸したシートに熱をかけて収縮処理したシートも好ましく利用することができ、この場合は収縮処理した状態で上記の面配向度を有していることが好ましい。 Moreover, the sheet | seat which heat-processed the extended | stretched sheet | seat and can carry out the shrinkage | contraction process can also be utilized preferably.
面配向度（ΔＰ）がこれより小さい場合は、熱成型品の耐熱性をはじめ機械的特性等の改善が十分ではなく、また、これらを超えるものは熱成形性に劣り深絞りのものや、精密に成形ができない。あるいは圧空賦形に非常に高い圧力を必要とし、商業生産にとうてい適さない程の堅固で高価な圧空成型機が必要になってしまう。 If the degree of plane orientation (ΔP) is smaller than this, the improvement in mechanical properties such as heat resistance of the thermoformed product is not sufficient, and those exceeding these are inferior in thermoformability and deep drawn, It cannot be molded precisely. Alternatively, a very high pressure is required for pressure forming, and a pressure and pressure molding machine that is not so suitable for commercial production is required.
上記の面配向度（ΔＰ）は延伸による分子配向を示す指標であり、次式により求められたものである。
シートの面配向度（ΔＰ）＝（ｎ１−ｎ２）／２＋（ｎ２−ｎ３）・・（２）式シートの複屈折率（Δｎ）＝ｎ１−ｎ２ ・・・・・・・・・・・（３）式
ここで ｎ１；シート面方向の最大屈折率
ｎ２；ｎ１に直角する屈折率
ｎ３；シート厚さ方向屈折率
ただし、ｎ１、ｎ２、ｎ３ はアッベ屈折計を用い、ナトリウムＤ線を光源として２５℃の温度による測定値とする．
本発明にて用いられる延伸されたポリエステルシートの平均厚みは、通常０.００３〜１．５ｍｍであり、０.０６〜１ｍｍであるのが好ましく、０.１〜０.６ｍｍであることが更に好ましい。樹脂シートの厚みが前記の範囲より薄いと強度が不足するなど成形品として実用的でなく、一方、前記の範囲を超えると延伸シートの製作が難しくなる。
The degree of plane orientation (ΔP) is an index indicating molecular orientation by stretching, and is obtained from the following formula.
Sheet plane orientation (ΔP) = (n1−n2) / 2 + (n2−n3) (2) Birefringence of the sheet (Δn) = n1−n2 Formula (3) where n1 is the maximum refractive index in the sheet surface direction.
n2: Refractive index perpendicular to n1
n3: Refractive index in the sheet thickness direction However, n1, n2, and n3 are measured values at a temperature of 25 ° C. using an Abbe refractometer and a sodium D line as a light source.
The average thickness of the stretched polyester sheet used in the present invention is usually 0.003 to 1.5 mm, preferably 0.06 to 1 mm, and more preferably 0.1 to 0.6 mm. preferable. If the thickness of the resin sheet is thinner than the above range, the strength is insufficient and it is not practical as a molded product. On the other hand, if it exceeds the above range, it becomes difficult to produce a stretched sheet.
ポリエステル樹脂は上記延伸工程により、長鎖の分子配向と結晶化が進み、延伸に際して熱固定処理がなされると更に結晶化が進み配向が安定する。そして、その結晶化度は熱成形性や成形品の特性に影響する。本発明に用いられる延伸シートのポリエステル樹脂がポリエチレンテレフタレートホモ樹脂である場合、結晶化度は３〜３５％であることが好ましく、５〜２５％であるのが更に好ましい。結晶化度がこの範囲より低いと最終成形品の耐熱性向上効果が小さい。一方、この範囲を越えると熱成形が困難になり、また耐衝撃性が低下する傾向がある。なお、こうした配向結晶をしたものは着色剤等を配合したものでない限り高度に透明であるが、前記の熱固定処理に際して過剰に加熱したものなどは球晶が成長し透明度が低下したり、白化したりし熱成形性や耐衝撃性を低下させるので、これは避けることが好ましい。なお、結晶化度は密度勾配管を用いる常法によって求めることができる。 The polyester resin undergoes long-chain molecular orientation and crystallization through the above-described stretching process, and when heat-setting treatment is performed during stretching, crystallization proceeds and the orientation is stabilized. The crystallinity affects the thermoformability and the properties of the molded product. When the polyester resin of the stretched sheet used in the present invention is a polyethylene terephthalate homo resin, the crystallinity is preferably 3 to 35%, and more preferably 5 to 25%. When the crystallinity is lower than this range, the effect of improving the heat resistance of the final molded product is small. On the other hand, if it exceeds this range, thermoforming becomes difficult, and impact resistance tends to decrease. In addition, those having such oriented crystals are highly transparent unless a colorant or the like is blended. However, in the case of excessive heating during the heat setting treatment, spherulites grow and the transparency decreases, It is preferable to avoid this because it may reduce thermoformability and impact resistance. The crystallinity can be determined by a conventional method using a density gradient tube.
なお上記のシートは事前に製作しておいたものを熱成形すればよいが、本発明においては延伸と熱成形を一貫ラインでおこなうこともでき、その場合延伸時の熱をできるだけ逃がさないようにして熱成形に利用することもできる。なおその場合は成形前の延伸品をそのまま冷却したとして前記のシートの諸特性を考慮すればよい。 The above-mentioned sheet may be thermoformed from a sheet that has been produced in advance. However, in the present invention, stretching and thermoforming can be performed in an integrated line, and in that case, the heat during stretching should not be lost as much as possible. It can also be used for thermoforming. In this case, the various properties of the sheet may be taken into consideration, assuming that the stretched product before molding is cooled as it is.
賦形方法と熱成形装置
熱成形あるいは圧空成形という用語はプロセス全体を表すもので、賦形はその中の一つ工程として説明する。本発明において賦形の基本的な方法としては、１）真空成形法、２）圧空成形法、３）真空圧空成形法、４）プラグアシストを伴う前記成形法のいずれか、５）嵌合ダイを用いたプレス成形法など通常の熱成形に使われる方法は何れも利用することができる。そしてこれらの方法の中では、真空圧空による賦形または圧空による賦形の方法が特に好ましく用いられる。
なおこの賦形に先だっては、成形シートの予熱が行われるが、本発明で使用される前記の材料シートを過剰な高温にしたり、長い時間予熱すると成形性が低下するなど好ましくなない。材料の予熱温度は材料温度としてＴｇ〜（Ｔｇ＋５０℃）程度とすることが好ましく、また７５〜１２０℃程度とすることが好ましい。また迅速に予熱し予熱後は迅速に賦形することが好ましい。
Forming method and thermoforming apparatus The terms thermoforming or pressure forming represent the entire process, and shaping is described as one of the steps. In the present invention, the basic shaping method is as follows: 1) vacuum forming method, 2) pressure-air forming method, 3) vacuum-pressure forming method, 4) any of the above forming methods with plug assist, 5) fitting die Any of the methods used in normal thermoforming, such as a press molding method using, can be used. Among these methods, the shaping by vacuum pressure or the shaping method by pressure is particularly preferably used.
Prior to this shaping, the molded sheet is preheated. However, if the material sheet used in the present invention is heated to an excessively high temperature or preheated for a long time, the moldability is not preferable. The preheating temperature of the material is preferably about Tg to (Tg + 50 ° C.) as the material temperature, and preferably about 75 to 120 ° C. Moreover, it is preferable to preheat quickly and to shape rapidly after preheating.
本発明の製造法にて用いられる熱成形装置としては、圧空成型機、真空圧空成型機などの圧空を使用して成形を行う通常の熱成型機に高温高圧の気体を供給しあるいは冷却用気体をブロウする機構を付加することにより用いることができる。また、真空成型機、嵌合ダイのプレス成型機なども高温気体あるいは冷却用気体をブロウする機構などを付加して用いることができる。プラグアシストなど、公知の補助的方法も適宜組合せて使用してよい。 As a thermoforming apparatus used in the production method of the present invention, a high-temperature and high-pressure gas is supplied to a normal thermoforming machine that performs forming using compressed air such as a pressure forming machine or a vacuum / pressure forming machine, or a cooling gas. It can be used by adding a mechanism to blow. Further, a vacuum molding machine, a press molding machine for a fitting die, and the like can be used by adding a mechanism for blowing a high-temperature gas or a cooling gas. A known auxiliary method such as plug assist may be used in appropriate combination.
このような熱成形機には通常はシート予熱機構が備えられており、その予熱機構には遠赤外線ヒーター加熱などのオーブンによる間接加熱法か、あるいは加熱されたローラーや金属板等に接触させる直接加熱法が採用されているが何れも利用でき、シートの予熱と温度調整が可能な方法はどのような方法も利用できる。 Such a thermoforming machine is usually provided with a sheet preheating mechanism, which may be an indirect heating method using an oven such as far-infrared heater heating or a direct contact with a heated roller or metal plate. Although any heating method is employed, any method can be used, and any method that can preheat the sheet and adjust the temperature can be used.
なお、本発明の特別な対応として後述するようにこのような予熱機構を有しない熱成型機も利用できる。 In addition, as will be described later as a special measure of the present invention, a thermoforming machine having no such preheating mechanism can be used.
またこれらの熱成型機には、シートを一枚ずつ成形する枚葉成型機と、長尺のシートを連続的に順次成型する連続成形機がありいずれも利用できるが、本発明の方法は後者の連続成形機を用いて連続成形を行うことを本領とする方法である。
＜成形型の構造＞
本発明の型構成は、雄型、雌型、嵌合ダイ（マッチドダイ）など熱成形に通常使われているどのような成形型にも適用できる。なお、嵌合ダイの場合は雌雄何れかの型法が後述する構造と機構を備えておればよい。具体的な例として図１のような構造を示すことができる。図１において１は成形体本体、２は成形用表面層でｔはその厚み、３は真空孔、４は導気孔、５は熱媒通路を示す。
These thermoforming machines include a single-wafer forming machine that forms sheets one by one and a continuous forming machine that continuously forms long sheets successively. The main method is to perform continuous molding using a continuous molding machine.
<Structure of mold>
The mold configuration of the present invention can be applied to any mold normally used for thermoforming, such as a male mold, a female mold, and a fitting die (matched die). In the case of a fitting die, it is sufficient that either male or female mold method has a structure and mechanism described later. As a specific example, a structure as shown in FIG. 1 can be shown. In FIG. 1, 1 is a molded body, 2 is a molding surface layer, t is its thickness, 3 is a vacuum hole, 4 is an air introduction hole, and 5 is a heat medium passage.
＜熱浸透率について＞
本発明では特定の特性値すなわち熱浸透率を有する材料からなる表面層と背後層を組み合わせる。すなわち表面層は熱浸透率（ｋＪ／ｍ ２ ｓ １／２ Ｋ）が０．１〜２５の材料により形成され、これに隣接する背後層は表面層より大きな浸透率を有する。この熱浸透率は次式（２）にて得られる値である。
<About heat penetration rate>
In the present invention, a surface layer and a back layer made of a material having a specific characteristic value, that is, a heat permeability, are combined. That is, the surface layer is formed of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.1 to 25, and the back layer adjacent thereto has a larger permeability than the surface layer. This thermal permeability is a value obtained by the following equation (2).
熱浸透率（ｂ）＝（λρＣ） １／２ ・・・・・（２）
λ；熱伝導率（Ｊｓ −１ ｍ −１ Ｋ −１ ）
ρ；密度（ｋｇｍ −３ ）
Ｃ；非熱容量（Ｊｋｇ −１ Ｋ −１ ）
かかる熱浸透率は二つ物体の界面を通過して移動する熱量にかかわる特性値であり、この値が小さいと界面は少ない熱量しか流さない。特定の熱浸透率（ｂ値）を有する材料を組み合わせる技術的意義については後述する。
Thermal permeability (b) = (λρC) 1/2 (2)
λ: thermal conductivity (J s −1 m −1 K −1 )
ρ; density (kg m −3 )
C: Non-heat capacity (J kg −1 K −1 )
Such heat permeability is a characteristic value related to the amount of heat that moves through the interface between the two objects. When this value is small, the interface flows only a small amount of heat. The technical significance of combining materials having a specific heat permeability (b value) will be described later.
＜温度伝達率について＞
本発明の成形型は前記の材料を組み合わせると共に、その表面層は下式（１）
Ｆα １／２ ×１０ ３ ＞ｔ＞Ｇ ・・・・・・（１）
（式中、ｔ；表面層の厚み（ｍｍ）、α；温度伝達率（ｍ ２ ／ｓ）、Ｆ；３０、Ｇ；０．０４）
を満足する厚さ（ｔ）を有する。上記の式中、温度伝達率（α値）は次式にて得られる特性値である。
<Temperature transfer rate>
The mold of the present invention combines the above materials, and the surface layer has the following formula (1)
F α 1/2 × 10 3 >t> G (1)
(Where, t: thickness of the surface layer (mm), α: temperature transfer rate ( m 2 / s), F; 30, G; 0.04)
The thickness (t) satisfies the following. In the above formula, the temperature transfer rate (α value) is a characteristic value obtained by the following formula.
α＝λ／ρＣ（ｍ ２ ／ｓ）
（式中、λ、ρ、Ｃは前記式（２）の場合と同じものを意味する）
このα値は、温度拡散率等とも呼ばれ、物体内の任意の点の温度の時間的変化を示す指標となる。またこの式は温度の時間的変化は、温度の傾斜の位置的変化に比例することを意味している。
α = λ / ρC ( m 2 / s)
(In the formula, λ, ρ, and C mean the same as in the case of the formula (2)).
This α value is also called a temperature diffusivity or the like, and serves as an index indicating a temporal change in temperature at an arbitrary point in the object. This equation also means that the temporal change in temperature is proportional to the positional change in temperature gradient.
下記の表１に、いくつかの材料のｂ値とα値の参考値を示す。なおｂ値もα値も測定温度により若干違った値を示すが、本願においては、厳密には２０℃の値にて規定する。
また、使用温度範囲で相変化をする材料を含むなどにより、これらの値が直線的変化を示さない場合は、２０と１５０℃の時の値の平均値をもってこれに代えるものとする。
Table 1 below shows reference values of b values and α values of some materials. Although the b value and the α value are slightly different depending on the measurement temperature, in the present application, strictly, the value is defined as a value of 20 ° C.
Also, if these values do not show a linear change due to the inclusion of a material that undergoes a phase change in the operating temperature range, the average value of the values at 20 and 150 ° C. is substituted for this.
表面層の材料は、固体であって無害かつ強度や耐熱性等が熱成形に耐えられるものであり、ｂ値（熱浸透率）が０．１以上、望ましくは０．３以上であり、そして２５以下、望ましくは２０以下、更に望ましくは１０以下であれば何れの材料を用いてもよい。参考として身近な各種の材料の材料についてのｂ値とα値を表１に示すが、この表の中にあるものも、表以外のものも任意の材料を任意に選んで組み合わせ使用することができる。 The material of the surface layer is solid, harmless and has strength and heat resistance that can withstand thermoforming, and has a b value (thermal permeability) of 0.1 or more, preferably 0.3 or more, and Any material may be used as long as it is 25 or less, desirably 20 or less, and more desirably 10 or less. For reference, the b and α values for various familiar materials are shown in Table 1, but any material in the table or other than the table may be selected and used in combination. it can.
こうした材料の中で、表面層材料としては、 エポキシ樹脂、フェノール樹脂、ウレタン樹脂、熱硬化性ポリエステル樹脂、フォスファゼン樹脂、熱硬化性ポリイミド等の熱硬化性樹脂、あるいはポリアミドイミド、ＰＯＭ、ＰＥＥＫ、等の耐熱性のある熱可塑性樹脂、あるいはこれらの樹脂の発泡体または多孔体、あるいはまたこれらの樹脂にアルミニウム、鉄、酸化チタン、グラファイト、ガラス、各種セラミックス等の粉体あるいは繊維材料との複合体は、型の製作も容易で比較に安価であり特に好適に用いることができる。あるいはまた、アルミナ、ムライト、コージライト、イットリア、チタニア、炭化珪素、窒化珪素、窒化アルミ、ジルコニア、サーメット、あるいはこれらを含む複合物や琺瑯等のセラミックス材料は耐熱性、耐久性等が優れておの特に好適に用いられる。金属材料としては、ニッケル成分の多いニッケル鋼、ＳＵＳ、チタン系材料等が利用でき、ＳＵＳ材料等が好適に利用できる。こうした材料により前記（１）式に示した範囲内の厚みの成形用表層を形成させる。 Among these materials, surface layer materials include epoxy resins, phenol resins, urethane resins, thermosetting polyester resins, phosphazene resins, thermosetting polyimides, or polyamideimide, POM, PEEK, etc. Heat-resistant thermoplastic resins, foams or porous bodies of these resins, or composites of these resins with powders or fiber materials such as aluminum, iron, titanium oxide, graphite, glass, and various ceramics The mold is easy to manufacture and is comparatively inexpensive and can be used particularly suitably. Alternatively, ceramic materials such as alumina, mullite, cordierite, yttria, titania, silicon carbide, silicon nitride, aluminum nitride, zirconia, cermet, or composites and soot containing them have excellent heat resistance and durability. Are particularly preferably used. As the metal material, nickel steel, SUS, titanium-based material and the like with a large amount of nickel component can be used, and SUS material and the like can be suitably used. With such a material, a molding surface layer having a thickness within the range shown in the formula (1) is formed.
なお、このようなｂ値は物体としてその値を示しておれば良く、例えば内部に気泡等の空隙含んだもの、あるいは他の物体を含んだ複合体も好適に使用することができる。この複合体は例えば多層体あってもよく、その場合は表面層全厚みを考量したｂ値の測定値あるいは計算値が上記を満足しておればよい。従って本発明の表面層の表面に上記の限りおいてどのような層を形成させてもよく、例えばどのような材料でメッキ保護層を形成させてもよい。 Note that such a b value is only required to indicate the value of an object, and for example, an object including a void such as a bubble inside, or a complex including another object can also be suitably used. This composite may be, for example, a multilayer body. In that case, the measured value or calculated value of the b value considering the total thickness of the surface layer should satisfy the above. Therefore, any layer may be formed on the surface of the surface layer of the present invention as long as it is described above. For example, the plating protective layer may be formed of any material.
こうした材料により前記（１）式に示した範囲内の厚みの成形用表面層を形成させる。 With such a material, a molding surface layer having a thickness within the range shown in the formula (1) is formed.
Ｆα１／２×１０３＞ｔ ＞ Ｇ ・・・・・・（１）
（式中、ｔ；表面層の厚み(ｍｍ)、α；温度伝達率(ｍ２／ｓ)、Ｆ；３０
Ｇ；０．０４）
なおここに示す温度伝達率（α値）は次の式で求められる特性値である。
Fα1 / 2 × 103>t> G (1)
(Where, t: thickness of the surface layer (mm), α: temperature transfer rate (m2 / s), F; 30
G; 0.04)
The temperature transfer rate (α value) shown here is a characteristic value obtained by the following equation.
α＝ λ／ρＣ （ｍ２／ｓ）・・・・・（５）
なお、λ、ρ、Ｃは前述の熱浸透率の算出に用いた名称と同じ単位。
α = λ / ρC (m2 / s) (5)
Note that λ, ρ, and C are the same units as the names used in the above-described calculation of the thermal permeability.
（１）式においてＦの値は３０であること、望ましくは１５であること、更に望ましくは８であることが必要であり、またＧの値は０．０４であり、望ましくは０．０６、更に望ましくは０．０９、そして特段に望ましくは０．１３であることが必要である。 In the formula (1), the value of F needs to be 30, preferably 15 and more preferably 8, and the value of G is 0.04, preferably 0.06. More preferably 0.09, and particularly preferably 0.13.
本発明の範囲でｔを大きしていく、すなわちＦ値を大きくしていくと、成形サイクルに伴う該表面温度の頂点、低点の復帰に次第に時間がかかるようになり、また該表面温度の部位によるバラツキを補正する能力がなくなり、そしてまた条件の定常化に時間がかるようになり、Ｆ値が３０を超えると本発明の実用的な意義がなくなる。反対にＦ値を小さくしていくと、より高速サイクル、よりバラツキを小さく、より短時間に定常化できる可能性がでてくるが、成形材料厚み違いや種々の成形条件に対する汎用性が小さくなる。そして更にｔを小さく、すなわちＧ値を小さくしていくと背後層の熱量の影響がおおきくなり、熱容量の比較的ちいさな気体のブロウでは賦形体を加熱冷却することが次第に困難になり、Ｇ値が０．０４より小さい場合は本発明の意義がなくなる。 When t is increased within the scope of the present invention, that is, the F value is increased, it takes time to recover the apex and low points of the surface temperature accompanying the molding cycle. The ability to correct the variation due to the region is lost, and it takes time for the condition to stabilize. When the F value exceeds 30, the practical significance of the present invention is lost. On the other hand, if the F value is decreased, there is a possibility that it can be steady in a shorter time with faster cycles and smaller variations, but the versatility with respect to molding material thickness differences and various molding conditions decreases. . Further, when t is further reduced, that is, the G value is reduced, the influence of the heat amount of the back layer becomes large, and it becomes difficult to heat and cool the shaped body with a gas blow having a relatively small heat capacity. When it is smaller than 0.04, the significance of the present invention is lost.
なお、表面層材料としてα値が１０以上の材料を用いる場合は、ｔ値は比較的に大きくなり、それでも上記（１）式の上限以下であれば背後層の温度を必要な速度で伝える機能はあるのであるが、現実的には次の観点からはｔ値は更に小さくしてもよく、小さいことがより望ましい。 一方、通常の成形材料のｂ値は０．３〜１．０程度で、α値は０．０３〜０．１×１０−６程度であり、このような表面層材料（α値が１０以上の場合は特に）よりも大きく下回ってくるので、気体接触による加熱冷却に際しては、賦形体の厚み方向温度勾配が急激になる一方、成形型の表面および表面直下の温度の変化は小さく留まることになる。これらの温度変化が小さければ、背後層への温度影響は実質的になくなるのでｔ値は小さくてもよくなり、これをより小さくして、背後層と表面（界面）との間の熱量の授受をある程度までは速くすることは望ましく、Ｆ値を１５とすることが望ましく、８とすることが更に望ましい。 Note that when a material having an α value of 10 or more is used as the surface layer material, the t value becomes relatively large, and the function of transmitting the temperature of the back layer at a necessary speed if the value is still below the upper limit of the above formula (1). In reality, however, the t value may be further reduced from the following viewpoint, and is preferably smaller. On the other hand, the b value of a normal molding material is about 0.3 to 1.0, and the α value is about 0.03 to 0.1 × 10 −6. Such a surface layer material (α value is 10 or more). In particular, in the case of heating and cooling by gas contact, the temperature gradient in the thickness direction of the shaped body becomes abrupt while the temperature change of the mold and the temperature immediately below the surface remain small. Become. If these temperature changes are small, the temperature effect on the back layer is virtually eliminated, so the t value may be small, and this is reduced to transfer heat between the back layer and the surface (interface). It is desirable to increase the speed to a certain extent, and it is desirable to set the F value to 15, more desirably 8.
またこうした基準とは別に、表面層の厚を小さくし、重量を軽減し、表面層での蓄積熱量を小さくすることは、取り扱い上も、操作能率の点からも望ましく、ｔ値を３０ｍｍ以下とすることが望ましく、１５ｍｍ以下とすることが更に望ましい、６ｍｍ以下とすることは更に更に望ましい。 In addition to these standards, reducing the thickness of the surface layer, reducing the weight, and reducing the amount of heat stored in the surface layer are desirable from the viewpoint of handling and operational efficiency, and the t value is 30 mm or less. It is desirable to set it to 15 mm or less, and it is even more desirable to set it to 6 mm or less.
なお、一般的には表面層の厚みは均一にし、界面温度が各部分等しくなるように意図すれば良いが、それが問題にならない程度においては厚みの不均一は許容され、背後層との界面は概ね成形面形状に沿ったものであればよい。 In general, the thickness of the surface layer should be uniform and the interface temperature should be intended to be equal to each part. However, as long as it does not cause a problem, non-uniform thickness is allowed and the interface with the back layer is acceptable. May be generally along the shape of the molding surface.
しかしながら、成形品の形状と加熱気体あるいは冷却気体のブロウ方法や強さ等により、局部的に過剰な加熱や冷却がなされ大きな表面温度バラツキとなり障害が発生することがあり、これを緩和するためにこの局部の表面層の厚みを故意に加減することは望ましく、その加減程度は制約の限りではない。こうした部分を例示するならば、エッジや先端の部分は過熱あるいは過冷となりやすく、又狭い窪み部分などは十分な加熱冷却がなされないことになりやすい。また、分散性の悪い気体ブロウノズルの直下や、複雑形状の成形品でも同様に表面温度バラツキがおきやすい。 However, depending on the shape of the molded product and the blowing method or strength of the heating gas or cooling gas, excessive heating or cooling may occur locally, resulting in large surface temperature variations and failure. It is desirable to intentionally adjust the thickness of the local surface layer, and the degree of adjustment is not limited. If such a portion is illustrated, the edge and the tip portion are likely to be overheated or overcooled, and the narrow recessed portion is likely not to be sufficiently heated and cooled. Also, surface temperature variations are likely to occur in the same manner even under a gas blow nozzle having poor dispersibility or a molded product having a complicated shape.
なお、本発明では、該表面から背後層までの最短距離をその部分のｔ値と規定する。それは、成形品の形状は限定されるものではなく複雑ものもあり、また背後層との界面は必ずしも成形品の形状に相似しない部分もあり、必ずしも該表面の垂直下に背後層があるとは限らないからである。更に、本発明では、規定するｔ値の部分が該表面の面積の７０％以上、望ましくは８５％以上あればよく、他の部分はこの規定外の値であることも許容される。ｔ値が規定外の値の位置に該当する成形体の部分では適切な熱処理、あるいは冷却が行われてない可能性がある。しかし、成形品の形状にもよるが、適切な熱処理あるい冷却が行われて堅固な部分が、軟弱な部分を支持して全体形状保全してくれ、離型時、あるいは耐熱負荷時の収縮あるいは変形を防いでくれる。なお、表面層の厚さが成形品の高さを超えないようにすることが望ましい。 In the present invention, the shortest distance from the surface to the back layer is defined as the t value of that portion. The shape of the molded product is not limited and may be complicated, and the interface with the back layer does not necessarily resemble the shape of the molded product, and the back layer is not necessarily perpendicular to the surface. It is not limited. Further, in the present invention, the specified t value portion may be 70% or more of the surface area, preferably 85% or more, and other portions may be outside the specified value. There is a possibility that an appropriate heat treatment or cooling is not performed at the portion of the molded body corresponding to the position where the t value is outside the specified value. However, depending on the shape of the molded product, proper heat treatment or cooling is performed, and the solid part supports the soft part to maintain the overall shape, and shrinks at the time of mold release or heat load Or it prevents deformation. It is desirable that the thickness of the surface layer does not exceed the height of the molded product.
背後層は、熱浸透率（ｂ値）が該表面形成層以上であり、且つ望ましくは５以上、更に望ましく１０以上である材料により形成させる。さらには、背後層の熱浸透率は前記表面層のそれより１．２倍以上であることが望ましく、１．４倍以上にすることは更に好ましい。このようすることにより本発明の効果をより鮮明にすることができる。 The back layer is formed of a material having a thermal permeability (b value) equal to or higher than that of the surface forming layer, preferably 5 or higher, and more preferably 10 or higher. Furthermore, the thermal permeability of the back layer is desirably 1.2 times or more than that of the surface layer, and more preferably 1.4 times or more. By doing so, the effect of the present invention can be made clearer.
この背後層のｂ値をこのように大きくすることにより、ｂ値の小さな表面層との熱の出入りを容易にし、表面層の温度プロファイルを短時間に定常状態化し、また変化した表面温度を迅速に背後層温度Ｓ（後述）に対応する温度に引き戻す働きをする。背後層の厚みあるいは形状は特に規定するものではないが、その体積として表面層以上の熱容量を有することが望ましい。この背後層には必ずしも特別な温度調節を設けず、成形型の置かれた環境との熱の自由な出入りにまかせただけでも成形することもできる。すなわち成形材料、成形型の設計等に合わせ背後層定常温度（Ｓ値）の設定を変えて成形することができるからである。 By increasing the b value of the back layer in this way, heat can easily enter and exit from the surface layer having a small b value, the temperature profile of the surface layer can be made steady in a short time, and the changed surface temperature can be quickly increased. It works to return to a temperature corresponding to the back layer temperature S (described later). The thickness or shape of the back layer is not particularly specified, but it is desirable that the volume of the back layer has a heat capacity equal to or greater than that of the surface layer. The back layer is not necessarily provided with a special temperature control, and can be molded only by allowing heat to freely enter and exit from the environment in which the mold is placed. That is, it is possible to perform molding by changing the setting of the back layer steady-state temperature (S value) according to the molding material, the design of the mold, and the like.
具体的な成形型の材料構成としては、鉄、アルミニウム、亜鉛、銅、あるいはこれらをベースとした合金材料或いはグラフアイトが好適に利用できる。そうしてこれらの中から選ばれた材料を背後層とし、前述の材料を表面層として組み合わせればよいが、金属系材料と樹脂系材料、あるいはセラミックス系材料セラミックス系材料、セラミックス系材料と樹脂系材料の組み合わせは、性能、製作のし易さ、価格等から特に好ましい。 As a specific material configuration of the mold, iron, aluminum, zinc, copper, an alloy material based on these, or graphite can be suitably used. Then, a material selected from these may be used as a back layer, and the above-mentioned materials may be combined as a surface layer. However, a metal-based material and a resin-based material, or a ceramic-based material, a ceramic-based material, a ceramic-based material and a resin The combination of the system materials is particularly preferable from the viewpoint of performance, ease of manufacture, price, and the like.
このようにして表面層と背後層を組み合わせた成形型は単独で用いてもよいが、多くの場合は複数成形型を共通のボックスに収容するかあるいは共通のパネルに集積して、いわゆる多数個どりの成形が行われるが、このような多数個どりにも好適に用いることができる。 In this way, the mold that combines the surface layer and the back layer may be used alone. However, in many cases, a plurality of molds are accommodated in a common box or integrated in a common panel, so-called multiple pieces. Although molding is performed, it can be suitably used for such multiple molding.
一方、本発明の別の形態として、前記の表面層のみからなる成形型部品を複数個製作し、これらを共通のボックスに収容するかあるいは共通のパネルに集積し、このボックスあるいはパネルに後述の温度調節機構を内蔵あるいは外部付加することにより本成形型を構成することができ好ましく使用することができる。 On the other hand, as another embodiment of the present invention, a plurality of mold parts composed of only the surface layer are manufactured and stored in a common box or integrated in a common panel. By incorporating a temperature control mechanism inside or externally, the present mold can be configured and preferably used.
背後層の温度調節機構
この背後層には、温度調節機構を設けることが望ましい。この温度調節機構は、加熱手段、あるいは冷却手段いずれものでもよいが、両者を兼ねて行うことのできるものはより好ましい。例えば具体的な加熱の手段として、電気ヒーターを貼附あるいは内包させ、自然冷却とあわせて温度制御を行うことができる。あるいは又内部に設けたジャケットに適度な温度の熱媒を通ずる方法もあり、この方法は好ましい。冷却はを促進するためのフィンなど放熱手段を設けたりしてもよく、また、このフィン部に通風するようにしてもよい。加熱あるい冷却の手段は特に限定するものではなく、誘導加熱、誘電加熱、赤外線加熱、ペルチェ素子など公知の加熱冷却手段がいずれも採用できる。なお、補助的な方法として背後層を多孔体にしておき気体を通ずることにより背後層の冷却あるいは加熱を促進する方法、或いは背後層と表面層共に多孔体にしておき、成形の間歇時に背後層を通じて気体を表面層に送り表面層の加熱冷却を促進する方法などを用いてよい。
Temperature control mechanism of back layer It is desirable to provide a temperature control mechanism in this back layer. The temperature adjusting mechanism may be either a heating means or a cooling means, but a mechanism that can perform both functions is more preferable. For example, as a specific heating means, an electric heater can be attached or included, and temperature control can be performed together with natural cooling. Alternatively, there is a method of passing a heating medium at an appropriate temperature through a jacket provided inside, and this method is preferable. A heat dissipating means such as a fin for promoting cooling may be provided, or the fin portion may be ventilated. The heating or cooling means is not particularly limited, and any known heating and cooling means such as induction heating, dielectric heating, infrared heating, and Peltier element can be adopted. As a supplementary method, the back layer is made porous and the cooling or heating of the back layer is promoted by passing gas, or the back layer and the surface layer are both made porous, and the back layer is formed in the middle of molding. For example, a method may be used in which gas is sent to the surface layer through the surface to accelerate heating and cooling of the surface layer.
背後層に対する前記の加熱、冷却手段の熱源、冷却源は背後層の内部に設けてもよくまた内部に設けてもよい。この熱源あるいは冷却源は面状の広がりを有し均一な伝熱ができるかぎり該表面層との境界に近い程このましく、そのようでない場合は境界層に至るまでにこの境界温度ができる限り均一になるよう適当な距離を設けるのが好ましい。 The heating for the back layer, the heat source of the cooling means, and the cooling source may be provided inside or inside the back layer. This heat source or cooling source should have a planar spread and uniform heat transfer as close as possible to the boundary with the surface layer. Otherwise, the boundary temperature should be as high as possible before reaching the boundary layer. It is preferable to provide an appropriate distance so as to be uniform.
なお、この境界温度を均一にするには、別途の手段を取り入れることをしてもよく、例えばヒートパイプ等の高熱伝導材料の挿入やヒートパイプ構造を設けるなど種々の温度均一化手段を採用してよい。特別な構成として例えば、厚み方向に対して面方向の熱伝導率が極端に大きいグラファイトシート材料を挿入してもよい。 In order to make this boundary temperature uniform, another means may be incorporated. For example, various temperature equalization means such as insertion of a high heat conductive material such as a heat pipe or provision of a heat pipe structure are adopted. It's okay. As a special configuration, for example, a graphite sheet material having an extremely large thermal conductivity in the plane direction relative to the thickness direction may be inserted.
成形型の温度変化の計測
熱処理を伴う熱成形サイクルを管理あるいは制御するためには賦形体自体の温度変化を測定することが望ましいが、それは必ずしも容易ではない。本発明の方法では、成形型の該表面温度の変化、又はこれに代わる位置の温度変化あるいは賦形体裏面の温度変化を測定し、熱成形サイクルを管理あるいは制御を行ってもよい。具体的には賦形体裏面からの測定は赤外線測定してもよいが、測定には物理的障害もあり工夫を要する。該表面温度の測定は比較的に容易で、本出願においては、この表面温度（離型前は界面温度でもある）で説明することとし、後述の成形パターンと管理または制御について述べる。しかしこの測定は成型品上に痕跡を残すなどの障害もあるので、これを嫌う場合は代わるものとして該表面下の浅層部で成形サイクルに伴う変化がある位置で温度測定し利用してもよい。しかしこの浅層部温度の軌跡は該表面温度軌跡に比べ振幅が小さくなり、成形条件によっては振幅の中心位置等も変わるので、両者の違いを把握することが望ましい。 その具体的な位置は該表面下１２ｍｍ以内の位置で求めることもできる。しかし、この範囲内であっても深部は応答性が悪く成形条件によっては殆ど応答しないこともあるので、該表面下２ｍｍ以下であることが望ましく、更には該表面に可能な限り近いことが望ましい。
Measurement of mold temperature change
In order to manage or control a thermoforming cycle involving heat treatment, it is desirable to measure the temperature change of the shaped body itself, but this is not always easy. In the method of the present invention, a change in the surface temperature of the molding die, a temperature change at an alternative position, or a temperature change on the back surface of the shaped body may be measured, and the thermoforming cycle may be managed or controlled. Specifically, the measurement from the back of the shaped body may be carried out by infrared measurement, but the measurement requires physical measures because of physical obstacles. The measurement of the surface temperature is relatively easy. In this application, the surface temperature (which is also the interface temperature before mold release) will be described, and a molding pattern and management or control described later will be described. However, this measurement also has obstacles such as leaving traces on the molded product, so if you dislike it, you can use it by measuring the temperature at a position where there is a change with the molding cycle in the shallow layer below the surface as an alternative. Good. However, the amplitude of the shallow layer temperature trajectory is smaller than that of the surface temperature trajectory, and the center position of the amplitude changes depending on the molding conditions. Therefore, it is desirable to grasp the difference between the two. The specific position can also be determined at a position within 12 mm below the surface. However, even within this range, the deep part has poor responsiveness and may hardly respond depending on molding conditions. Therefore, it is desirable that the depth is 2 mm or less below the surface, and further as close as possible to the surface. .
なお、このような温度測定は成形品の形状に対応して複数部位で行うようにすることは望ましい。 It is desirable to perform such temperature measurement at a plurality of sites corresponding to the shape of the molded product.
まず、背後層を加熱して温度制御するためには、成形サイクルに直接追従せずに一定温度を示す温度を測定する必要があり、それは一定温度を示すならば加熱冷却源から該表面の下層に至るまでの間で任意に選べるが、通常は背後層の中で表面層に近いところがより好ましく。ここではこの位置の温度を深層又はＰ点の温度と称する。そしてこのＰ点の温度を背後層温度とし、成形サイクルの中で定常状態となった温度を定常温度Ｓと称することする。 First, in order to control the temperature by heating the back layer, it is necessary to measure a temperature indicating a constant temperature without directly following the molding cycle. However, it is usually more preferable that the back layer is closer to the surface layer. Here, the temperature at this position is referred to as a deep layer or P point temperature. The temperature at the point P is set as the back layer temperature, and the temperature that is in a steady state during the molding cycle is referred to as a steady temperature S.
一方、背後層の温度(成形サイクルに直接応答しない)を背後層の中で測定するこは望ましいが、これを行わずこれは付加されている温度制御に委ねることは可能で、例えば熱媒温度によって熱処理工程を制御あるいは管理することは可能である。 On the other hand, it is desirable to measure the temperature of the back layer (which does not respond directly to the molding cycle) in the back layer, but this is not done and this can be left to the added temperature control, e.g. the heating medium temperature. It is possible to control or manage the heat treatment process.
なお、このような温度測定を行う成形型は、成形型を集積した多数個どりのセットの中で少なくとも一個あればよいが、複数個あることは望ましい。 It should be noted that there is at least one mold for performing such temperature measurement, but it is desirable that there are a plurality of molds in a set of many molds in which the molds are integrated.
このようにして測定した結果をもとに、手動で成形条件の諸設定の修正を行ってもよいが、自動でこれを行うようにすることは望ましい。 Although various settings of the molding conditions may be manually corrected based on the measurement results in this way, it is desirable to do this automatically.
表面層表面（賦形体との界面）の昇温と降温手段
成形型の表面（賦形体との界面）の昇温または降温は、前記の背後層温度によって常時なされるが、間歇的な昇温手段としては該表面または賦形体裏面への高温気体の接触または赤外線照射による方法が用いられ、また間歇的な降温手段としては該表面または賦形体裏面へ冷却用気体を接触させる方法が用いられる。本発明では、背後層を経由する加熱または冷却効果の他に、上述の昇温手段と降温手段の少なくとも何れか、そして昇温手段を用いる場合は高温気体接触法と赤外線照射法の少なくとも何れかを用いることが必要である。高温気体あるいは冷却用気体等との接触は、賦形と同時に行ってもよく又賦形後に行って離型してもよく、賦形方法の特性に合わせ任意に行うことができる。高温気体あるいは冷却用気体は静止状態よりも気体流であることが、また気体流は高速であるほど熱伝達率が大きくなり加熱冷却が効果的である。用いる気体は空気、あるいは窒素など任意のものが利用できる。適用のタイミング及び温度等については後述する。
赤外線照射の方法は、高温気体接触法と同様で賦形と同時に行ってもよく又賦形後に行ってもよく、又高温気体接触法と併用してもよく単独で用いても良い。用いる赤外線は遠赤外線、近赤外線いずれも好適に利用できる。
The temperature rise of the surface layer surface (interface with the shaped body) and the temperature lowering means The temperature rise or fall of the surface of the mold (interface with the shaped body) is always done depending on the above-mentioned back layer temperature. As a means, a method of contacting a hot gas to the surface or the back of the shaped body or infrared irradiation is used, and as an intermittent temperature lowering means, a method of bringing a cooling gas into contact with the surface or the back of the shaped body is used. In the present invention, in addition to the heating or cooling effect via the back layer, at least one of the temperature raising means and the temperature lowering means described above, and when using the temperature raising means, at least one of the high temperature gas contact method and the infrared irradiation method Must be used. The contact with the high-temperature gas or the cooling gas may be performed simultaneously with the shaping, or may be performed after the shaping and may be released according to the characteristics of the shaping method. The high-temperature gas or the cooling gas is more gas flow than the stationary state, and the higher the gas flow, the higher the heat transfer rate and the more effective the heating and cooling. The gas used can be any air or nitrogen. Application timing and temperature will be described later.
The infrared irradiation method is the same as the high temperature gas contact method, may be performed simultaneously with shaping, may be performed after shaping, may be used in combination with the high temperature gas contact method, or may be used alone. As the infrared rays used, both far infrared rays and near infrared rays can be suitably used.
昇温手段として加熱気体を単独で用いる場合、の温度は、少なくとも１５０℃以上、望ましくは２００℃以上、更に望ましくは材料のＴｍ以上、更に更に望ましくは３００℃以上であることが望ましい。その上限は限定するものではなく、例えば１０００℃超える温度でも可能な場合もあるが、しかし鋭い角や先端部のある成形品では過剰に加熱され不都合を避けるためにた１０００℃以下が良い場合もある。加熱効果を良くするために加湿することも好ましく、また過熱蒸気も効果的に利用でき乾燥過熱蒸気、飽和過熱蒸気いずれも利用できる。 When a heated gas is used alone as the temperature raising means, the temperature is preferably at least 150 ° C. or higher, preferably 200 ° C. or higher, more preferably Tm of the material, and still more preferably 300 ° C. or higher. The upper limit is not limited and may be possible, for example, even at temperatures exceeding 1000 ° C. However, in the case of a molded product having sharp corners or tips, it may be less than 1000 ° C. in order to avoid overheating and inconvenience. is there. It is also preferable to humidify in order to improve the heating effect, and superheated steam can also be used effectively, and either dry superheated steam or saturated superheated steam can be used.
降温手段として用いられる冷却用気体流の温度は低いほど良く、又高速であるほど良いと云えるが、通常の手段で得られる圧縮空気や送風空気そのまま好適に利用することができる。しかし、場合個によっては、かなりの高温も許容され極端には加熱手段として用いた高圧気体を次の段階で周辺空気を巻き込みながらブロウして冷却をおこなうこともできる場合もある。
降温手段として 用いられる冷却用液体は水やアルコール、炭化水素、フッ化炭化水素など気化潜熱の大きいものが利用できるが、水が最もこのましい。具体的には１）水噴霧または水の微滴散布を行う、２）水噴霧と気体ブロウを順次行う、３）気体ブロウと平行して水噴霧を行うなどの方法がある。この２）の方法は特に好適に利用できる。
なお、予め加湿した冷却用気体の利用も熱容量が大きく能率的に冷却することができ好ましい。
Although it can be said that the lower the temperature of the cooling gas stream used as the temperature lowering means, and the higher the speed, the better. However, the compressed air and the blown air obtained by the usual means can be suitably used as they are. However, depending on the case, a considerably high temperature is allowed, and in some cases, the high-pressure gas used as a heating means may be blown while surrounding air is involved in the next stage to be cooled.
The cooling liquid used as the temperature lowering means can use water, alcohol, hydrocarbons, fluorinated hydrocarbons, etc. that have large latent heat of vaporization, but water is the best. Specifically, there are methods such as 1) spraying water or spraying fine droplets of water, 2) sequentially performing water spraying and gas blowing, and 3) spraying water in parallel with the gas blowing. The method 2) can be used particularly preferably.
Note that the use of a pre-humidified cooling gas is preferable because of its large heat capacity and efficient cooling.
このような、気体のブロウは先ずはブロウ面に対してできるだけ均一に行うことが必要であり、また、必要に応じ賦形体の特定位置に対し強弱をつけて行ってもよい。なお、均一にブロ−するためには、無数の孔あるいは多孔体から噴出させるようにした平板形状デバイスは好ましい。噴射ノズルは多数の孔を四方向けて開口するなどして、どの方向にも噴射するようにすることが好ましい。また単なる圧空ボックスの側面からの給気口であっても複数個にしたり、周囲を巡らすスリット状にするなどすることも好ましい。また、気体の排出についても同様に配慮することが好ましい
また、成形型を集積した多数個取りの場合も、どの賦形体に対してもできるだけ同一の処理がなされるように配慮することが必要であり、上記のような平板デバイスは好ましく、また単なる給排気口の場合ならばスリット状にしたりあるいは複数個を配置し、ノズルの場合ならば数多く用いることが好ましい。
Such a gas blow must first be performed as uniformly as possible on the blow surface, and may be performed with a certain level of strength of the shaped body as required. In order to blow uniformly, a plate-like device that is ejected from an infinite number of holes or porous bodies is preferable. The spray nozzle is preferably sprayed in any direction by opening a large number of holes in four directions. It is also preferable to use a plurality of air supply openings from the side of the compressed air box or to form a slit around the periphery. In addition, it is preferable to consider the gas discharge in the same way. Also, in the case of a large number of molds integrated with molds, it is necessary to consider that the same treatment should be applied to any shaped body as much as possible. The flat plate device as described above is preferable, and in the case of a simple air supply / exhaust port, it is preferable to use a slit shape or to arrange a plurality of devices, and in the case of a nozzle, it is preferable to use many.
なお、本発明においては、上記の加熱冷却気体は多くの場合、高速の気流が賦形体に接触し加熱冷却し、該表面（界面）は間接的に加熱冷却されることになる。秒単位でこの操作をおこなう一方成形材料の熱浸透率は一般的に小さいので該表面と賦形体裏面との間には大きな温度傾斜が生まれている。本願においては、熱処理温度あるいは離型温度は熱処理温度等は該表面温度で表すことするが、真の材料温度とは乖離し、該表面層材料、成形条件、材料厚みによりその適正温度が変わることに留意する必要がある。 In the present invention, in many cases, the heating / cooling gas is heated and cooled by a high-speed air current contacting the shaped body, and the surface (interface) is indirectly heated and cooled. While this operation is performed in units of seconds, since the heat permeability of the molding material is generally small, a large temperature gradient is created between the surface and the back of the shaped body. In the present application, the heat treatment temperature or mold release temperature is expressed by the surface temperature as the heat treatment temperature or the like, but deviates from the true material temperature, and the appropriate temperature changes depending on the surface layer material, molding conditions, and material thickness. It is necessary to pay attention to.
温度パーターンの制御
本発明では、上記の１）背後層の設定温度、２）賦形体裏面への加熱手段、３）賦形体裏面への冷却手段を主要な手段として、成形に必要とする該表面温度の温度サイクル（後述の温度パターン）を形成させ遂行する。そして、各手段の適用条件の組み合わせを最適にして最適最高速の成形サイクルを実現することができる。
Control of temperature pattern In the present invention, the above-mentioned surface required for molding with 1) the set temperature of the back layer, 2) heating means for the back of the shaped body, and 3) cooling means for the back of the shaped body A temperature cycle of temperature (a temperature pattern described later) is formed and executed. And the combination of the application conditions of each means can be optimized, and the optimal fastest molding cycle can be realized.
熱成形サイクルの該表面（賦形体との界面）の温度変化を制御する第１の手段は成形型に付加した温度調節機構により背後層温度を特定の定常温度（Ｓ）になるように調整または制御することである。通常は付加した前述の温度調節機構によってこれを行うが、該表面温度が所定の最高温度(頂点)及び最低温度(底点)を繰り返すように特定温度を選択する。しかしこの定常温度Ｓは該温度調節機構のみによって決らず、前記の加熱冷却の強弱条件とバランスして決まる。しかし、この定常温度の該表面温度への反映は表面層の厚みが小さいときは大きく、厚みが大きいときは小さい。またそれは表面層のα値が大きい時は大きく、α値が小さい時は小さい。またそれは背後層材料のｂ値が大きい時は大きく、ｂ値が小さい時は小さい。 The first means for controlling the temperature change of the surface of the thermoforming cycle (interface with the shaped body) is to adjust the back layer temperature to a specific steady-state temperature (S) by the temperature adjusting mechanism added to the mold or Is to control. Usually, this is performed by the added temperature control mechanism described above, but a specific temperature is selected so that the surface temperature repeats a predetermined maximum temperature (top) and minimum temperature (bottom point). However, the steady temperature S is not determined only by the temperature adjusting mechanism, but is determined in balance with the heating and cooling conditions. However, the reflection of the steady temperature on the surface temperature is large when the thickness of the surface layer is small, and small when the thickness is large. It is large when the α value of the surface layer is large, and small when the α value is small. It is large when the b value of the back layer material is large, and small when the b value is small.
第２の制御手段は該裏面への加熱手段の要素群の制御である。加熱気体についてはその温度、適用時間、流速、圧力、風量等、又赤外線照射についてはその強さ、適用時間、照射距離等の例を挙げることができる。なお、前者については湿度等も挙げることができ加湿や、過熱蒸気利用等も挙げることができる。表面温度のサイクルを観察し最高温度が低ければ加熱条件を強めた設定にすれば良い。なお、加熱を強めて頂点を上昇させると底点も上昇し、次のサイクルで更にある程度頂点が上昇していくことは留意して調整する必要がある。 The second control means is control of the element group of the heating means for the back surface. Examples of the heated gas include its temperature, application time, flow rate, pressure, air volume, etc., and infrared irradiation, its strength, application time, irradiation distance, and the like. In addition, about the former, humidity etc. can be mentioned, humidification, superheated steam utilization, etc. can be mentioned. Observe the surface temperature cycle, and if the maximum temperature is low, the heating conditions may be set to be stronger. It should be noted that if the heating is increased and the apex is raised, the bottom point is raised and the apex rises to some extent in the next cycle.
第３の制御手段は該裏面への冷却手段である冷却用気体の要素群の制御である。具体的には冷却用気体の温度、適用時間、流速、圧力等を挙げることができる。またこれに加えて加湿、水噴霧の併用なども挙げることができる。表面温度のサイクルを観察し最低温度が高ければ冷却条件を強めた設定にすれば良い。なお、冷却を強めて底点を降下させると、次のサイクルで頂点もある程度降下していくことは留意して調整する必要がある。 The third control means controls the element group of the cooling gas that is the cooling means for the back surface. Specifically, the temperature, application time, flow rate, pressure, etc. of the cooling gas can be mentioned. In addition to this, humidification and water spray can be used in combination. If the minimum temperature is observed by observing the surface temperature cycle, the cooling condition may be set to be stronger. It should be noted that if the bottom point is lowered by increasing the cooling, the apex will also drop to some extent in the next cycle.
以上三つのグループの手段（要素）を特定の条件の組み合わせとして選ぶことにより最適あるいは最速の成形サイクルを実行することができる。また、背後層の温度Ｓに注目して最適あるいは最速となる成形サイクルの設定条件を容易に発見することができる。端的に説明するならば、温度Ｓを高くすれば、加熱気体による温度、接触時間等の加熱条件は控えめでもよいが、冷却条件は強く設定しなければならず、この温度Ｓ設定を低くすればこれらは逆になる。また、加熱冷却の強さのバランスが適当でない場合は、成形サイクルの繰り返しと共に背後層温度は自動的に調整されて定常状態になる。そうして、このようにして発見された温度Ｓになるように予め背後層温度を調整して生産を開始すれば最短で定常状態となり、場合によっては最初から定常状態で操業ができる。 The optimum or fastest molding cycle can be executed by selecting means (elements) of the above three groups as a combination of specific conditions. Further, it is possible to easily find the setting condition of the molding cycle that is optimal or fastest by paying attention to the temperature S of the back layer. If it explains simply, if temperature S is made high, heating conditions, such as temperature by heating gas and contact time, may be moderate, but cooling conditions must be set up strongly, and if this temperature S setting is made low. These are reversed. Further, when the balance between the strengths of heating and cooling is not appropriate, the back layer temperature is automatically adjusted as the molding cycle is repeated, and a steady state is obtained. Then, if production is started by adjusting the back layer temperature in advance so as to reach the temperature S thus discovered, a steady state is reached in the shortest time, and in some cases, operation can be performed in a steady state from the beginning.
制御の方法は発見された各要素の条件を手動設定し、固定的なパターンとして操業運転してもよく、各要素の状態変動を手動で他に要素条件設定へ手動で反映させてもよい。しかし、何れかの要素の変動を自動的にフィードバックさせ他の要素の条件を自動的に調整すれば環境温度等不足の変動にも対応できて好ましい。 In the control method, the conditions of each discovered element may be manually set and operated as a fixed pattern, or the state variation of each element may be manually reflected in the element condition setting manually. However, it is preferable to automatically feed back the fluctuation of any element and automatically adjust the conditions of the other elements to cope with fluctuations such as an environmental temperature.
以上のようにして、背後層の温度Ｓの設定を調整し、次の（１）（２）、
（１）；賦形体裏面への高温気体の接触及び又は赤外線照射による加熱，
（２）；賦形体裏面への冷却用気体流の接触による冷却、
の少なくとも一つの手段を用い、その適用条件を調整することにより、成形型の表面温度を成形サイクル中において所定の最高温度（頂点温度）と所定の最低温度（底点温度）が得られるようにし、且つ両者を一定の値として繰り返すように制御し、この温度サイクルの中で所定のパターン（後述）の賦形から離型までのプロセスを繰り返す連続熱成形が行われる。
As described above, the setting of the temperature S of the back layer is adjusted, and the following (1), (2),
(1); heating by hot gas contact and / or infrared irradiation on the back of the shaped body,
(2); cooling by contact of the cooling gas flow to the back of the shaped body;
The surface temperature of the mold is adjusted so that a predetermined maximum temperature (apex temperature) and a predetermined minimum temperature (bottom temperature) are obtained during the molding cycle by adjusting the application conditions. In addition, continuous thermoforming is performed in such a manner that both are controlled to be repeated as a constant value, and the process from forming to releasing of a predetermined pattern (described later) is repeated in this temperature cycle.
熱成形の温度パターン
上記の加熱手段により、シートの予熱温度以上の温度の熱処理が行われるが、この熱処理（すなわち配向の熱固定）のためには、賦形体が接した成形型表面温度が（成形材料のＴｇ＋５０℃）以上、望ましくは（成形材料のＴｇ＋６０℃）以上である時間を経過する必要があり、この温度に達しない場合は熱処理効果がない。またこの表面温度は、成形材料のＴｍ以下で望ましくは（Ｔｍ−３０℃）以下の温度であることが必要であり、この温度を超える場合は、材料が白化あるいは溶融してしまう。このような熱処理を伴う繰り返し連続熱成形の典型的パターンとして図に３パターンを示し、これらについて順次説明する。なお、本発明に利用できる方法はこれらに限定するものではなく、本発明の温度サイクルの中で任意に賦形と離形を行うことができ、これらの変形、一部混合など様々なパターンが考えられる。
Thermoforming temperature pattern Heat treatment at a temperature equal to or higher than the preheating temperature of the sheet is performed by the heating means described above. For this heat treatment (that is, heat fixing of the orientation), the surface temperature of the molding die in contact with the shaped body is ( It is necessary to elapse a time that is not less than (Tg + 50 ° C. of the molding material), desirably (Tg + 60 ° C. of the molding material), and if this temperature is not reached, there is no heat treatment effect. Further, this surface temperature needs to be not higher than Tm of the molding material and desirably not higher than (Tm−30 ° C.), and if this temperature is exceeded, the material is whitened or melted. Three patterns are shown in the figure as typical patterns of repeated continuous thermoforming with such heat treatment, and these will be described in order. Note that the methods that can be used in the present invention are not limited to these, and can be arbitrarily shaped and released in the temperature cycle of the present invention. Conceivable.
図３に示す温度軌跡はパターンＡで、背後層温度を最高表面温度と最低表面温度との間となるように設定し、賦形体裏面から加熱に続いて冷却ブローを行う方法である。図４の温度軌跡はパターンＢで、背後層温度を最低表面温度ないしはそれ以下になるように設定し、賦形体裏面から加熱を行う方法である。図５の温度軌跡はパターンＣで、背後層温度を最高表面温度又はそれ以上になるように設定し、賦形体裏面から冷却を行う方法である。 The temperature trajectory shown in FIG. 3 is a pattern A, in which the back layer temperature is set to be between the maximum surface temperature and the minimum surface temperature, and cooling blow is performed from the back of the shaped body following heating. The temperature locus in FIG. 4 is pattern B , which is a method of setting the back layer temperature to be the lowest surface temperature or lower and heating from the back of the shaped body. The temperature trajectory in FIG. 5 is pattern C , which is a method of setting the back layer temperature to be the maximum surface temperature or higher and cooling from the back of the shaped body.
なお、パターンＡ、Ｂ、Ｃの各図は連続繰り返し成形中の表面温度（賦形体があるときは界面）の変化を概念的な模式図として示したものである。実際のプロセスではこのような滑らかな曲線ではなく、少なくとも賦形と離形に際してはかなりの跛行がある。パターンの軌跡では、太線部分が賦形体が成形型表面と接触した状態を、細線部分は賦形体が除去されている状態を示し、また太点線は賦形材料を密着させたまま放置されている状態を示す。Ｓ線は背後層Ｐ点の定常温度（背後層温度）を示している。 なお図においては表現されていないが、実質的な賦形作用は太線または点線の最初の部分で短時間に完了し、それに続く太線部分又は点線部分で賦形体の昇温または温度降下がなされる。 In addition, each figure of pattern A, B, and C shows the change of the surface temperature (interface when there is a shaping body) in continuous repetition shaping | molding as a conceptual schematic diagram. The actual process is not such a smooth curve, and there is considerable lameness at least during shaping and demolding. In the trace of the pattern, the thick line portion shows the state where the shaped body is in contact with the surface of the mold, the thin line portion shows the state where the shaped body has been removed, and the thick dotted line is left with the shaping material adhered. Indicates the state. The S line indicates the steady temperature (back layer temperature) at the back layer P point. Although not shown in the figure, the substantial shaping action is completed in a short time at the first part of the bold line or dotted line, and the temperature of the shaped object is increased or lowered at the subsequent thick line part or dotted line part. .
パターンＡは成形型の該背後層温度を、該表面温度の所定の最高温度と最低温度の間で制御し、賦形と同時あるいは賦形後に、高温気体の賦形体裏面への接触および又は同裏面への赤外線照射により所定の最高温度に到達させる工程と、冷却用気体を成形体裏面に接触させ離型する工程からなるパターンである。 The pattern A controls the temperature of the back layer of the mold between a predetermined maximum temperature and a minimum temperature of the surface temperature, and at the same time as or after the shaping, contact the hot gas with the back of the shaped body and / or the same. It is a pattern comprising a step of reaching a predetermined maximum temperature by infrared irradiation on the back surface and a step of bringing the cooling gas into contact with the back surface of the molded body and releasing the mold.
ａゾーンで賦形及び高温気体との接触が行われ、ｂゾーンでは冷却ブロウがおこなわれ、ｃゾーンでは賦形体の離型排出と新成形材料の配置が同時に行われる。なお、ａゾーンの賦形と高温気体接触は、両者を順次行ってもよいが高温気体により圧空賦形を行うかあるいは真空賦形を行いながら高温気体ブロウを行えばそれらを同時に始めることができ、又そのとき排気を行いながら圧空を行えばプロセスの効率は良い。
このパターンでは、最高温度への昇温は前出の加熱手段によりなされ、最低温度への
降下は前出の冷却手段によりなされ、背後層温度はこの両者をバランスさせる働きをする。
In the a zone, shaping and contact with a high-temperature gas are performed, in the b zone, cooling blow is performed, and in the c zone, release of the shaped body and placement of a new molding material are performed simultaneously. The a-zone shaping and the high-temperature gas contact may be carried out in sequence, but they can be started simultaneously by performing pressurized air shaping with a high-temperature gas or performing high-temperature gas blowing while performing vacuum shaping. If the compressed air is exhausted while exhausting, the process efficiency is good.
In this pattern, the temperature is raised to the maximum temperature by the above heating means, the temperature is lowered to the minimum temperature by the above cooling means, and the back layer temperature serves to balance the two.
このａからｃまでの１サイクルの更なる詳細は図中で1〜5のように区分して示しているが、1では、背後層の高温により表面温度の自然回復がなされ、2では背後層温度と高温気体の両者により、3では高温気体のみにより界面温度が上昇する。また、4背後層温度と冷却ブロウの両者により、5では冷却ブローによってのみ界面温度が冷却されて離型可能な状態になる。 Further details of one cycle from a to c are shown separately in the figure as 1 to 5, but in 1, the surface temperature is naturally recovered by the high temperature of the back layer, and in 2 the back layer Due to both the temperature and the hot gas, in 3 the interface temperature rises only with the hot gas. In addition, due to both the 4 back layer temperature and the cooling blow, in 5 the interface temperature is cooled only by cooling blow so that the mold can be released.
パターンＢは、成形型の該背後層温度を該表面温度の所定の最低温度ないしこれを下回る温度に設定し、賦形と同時あるいは賦形後に、背後層温度以上の高温気体の賦形体裏面への接触および又は同裏面への赤外線照射により加熱する工程と、次いで所定の離型温度に達するまで待って離型する工程からなるパターンである。このパターンでは、所定の最低温度への回帰が背後層からの冷却によって自動的になされる。
ａゾーンではパターンＡと同様に賦形と高温気体接触がなされるが、ｂゾーンでは放置するのみで背後層からの冷却を受け離型可能に達する。ｃゾーンではＡと同様に離型移動と新成形材料の配置が行われる。
In pattern B, the temperature of the back layer of the mold is set to a predetermined minimum temperature of the surface temperature or a temperature lower than this, and at the same time as shaping or after shaping, to the back side of the shaped body of a high-temperature gas higher than the back layer temperature. It is a pattern which consists of the process of heating by the contact of this and / or the infrared irradiation to the back surface, and the process of releasing after waiting until it reaches predetermined release temperature. In this pattern, the return to a predetermined minimum temperature is made automatically by cooling from the back layer.
In the a zone, shaping and hot gas contact are made in the same manner as in the pattern A. However, in the b zone, it is possible to release the mold by receiving cooling from the back layer only by leaving it to stand. In the c zone, as in the case of A, mold release movement and placement of a new molding material are performed.
パターンＣは、該成形型の該背後層温度を該表面温度の所定の最高温度ないしはこれを上回る温度に設定しておき、賦形を行って該表面温度の所定の最高温度への到達を待って冷却用気体流を賦形体裏面に接触させる工程、または該最高温度への到達後に賦形と同時あるいは賦形後に冷却用気体流を賦形体裏面に接触させる工程により該表面温度を所定の離型温度に到達せしめて離型するパターンである。 このパターンでは高温温度への回帰が該背後層から加熱によって自動的になされる。 In the pattern C, the temperature of the back layer of the mold is set to a predetermined maximum temperature of the surface temperature or a temperature exceeding the predetermined maximum temperature, and shaping is performed to wait for the surface temperature to reach the predetermined maximum temperature. The surface temperature is set at a predetermined separation by contacting the cooling gas flow with the back surface of the shaped body, or contacting the cooling gas flow with the back surface of the shaped body simultaneously with or after shaping after reaching the maximum temperature. It is a pattern in which the mold temperature is reached and released. In this pattern, the return to the high temperature is automatically performed by heating from the back layer.
ａゾーンでは、賦形を行って表面温度の所定の最高温度への上昇を待ち、ｂゾーンで冷却ブローが行われ、そしてｃゾーンで離型排出と新成形材料の配置が行われる。
なお、ａゾーンは極限まで短縮して行き、表面温度の最高温度への到達を待って賦形を行ってもよく、この場合は実質的にａゾーンはなくなる。そして、このとき通常の圧空賦形に続いて冷却ブロウする方法も望ましいが、一部の空気を排出しながら圧空賦形続ければ、賦形、熱処理、冷却一工程で進行しただちに離型でき非常に簡便で望ましい方法となる。
In zone a, shaping is performed to wait for the surface temperature to rise to a predetermined maximum temperature, cooling blow is performed in zone b, and mold release and placement of new molding materials are performed in zone c.
The a zone may be shortened to the limit, and shaping may be performed after the surface temperature reaches the maximum temperature. In this case, the a zone is substantially eliminated. At this time, the method of cooling blow is also desirable following normal pressure forming, but if you continue the pressure forming while discharging some air, the mold can be released immediately after the shaping, heat treatment, and cooling process. This is a simple and desirable method.
なお、上記の３パターンは典型的な態様を模式的に示したもので、これに限るものではなく、これパターンの境界型、混合型、変形型等は種々考えられる。たとえば、上記のパターンで、離型後の該表面に賦形体が存在しない期間に、該表面直接に気流を接触させて加熱冷却を補助支援すること行ったとしても、本発明を回避するものではない。 Note that the above three patterns schematically show typical aspects, and are not limited to these, and various boundary types, mixed types, modified types, and the like are conceivable. For example, in the above pattern, even if the airflow is brought into direct contact with the surface during the period when the shaped body is not present on the surface after release, the present invention is not avoided. Absent.
成形型の表面層材料として低いｂ値（０．１〜２）の材料を用いた場合は、賦形体との間で熱の授受が少ないことにより、（１）高温気体で容易に短時間で熱成型品を熱処理温度に昇温することができ、また（２）低温気体で容易に短時間で熱成型品の離型温度に冷却することができる。従って、Ａパターンの成形に適する。Ｂパターン、Ｃパターンを実行するときは背後層に大きなｂ値例えば７以上の材料を用い、表面層の厚さｔを小さくすれば望ましい設計となる。 When a material having a low b value (0.1 to 2) is used as the surface layer material of the molding die, (1) a high-temperature gas can be easily used in a short time because heat is transferred to and from the shaped body. The thermoformed product can be heated to the heat treatment temperature, and (2) it can be easily cooled to the mold release temperature of the thermoformed product in a short time with a low temperature gas. Therefore, it is suitable for forming the A pattern. When executing the B pattern and the C pattern, it is desirable to use a material having a large b value, for example, 7 or more for the back layer and to reduce the thickness t of the surface layer.
該表面層材料として中間的なｂ値（１〜１０）の材料を用いた場合は、Ａパターン、Ｂパターン、Ｃパターンいずれにも適し、Ａパターンではｔが比較的大きな場合でも比較的短時間に定常状態をつくり高速成形が可能である。また設計が適切であれば一つの成形型でこれらの成形パターンが自由に選択できる。 When a material having an intermediate b value (1 to 10) is used as the surface layer material, it is suitable for any of the A pattern, the B pattern, and the C pattern. In this way, a steady state can be created and high-speed molding is possible. If the design is appropriate, these molding patterns can be freely selected with a single mold.
また、該表面層材料として高いｂ値（８〜２５）の材料を用いた場合は、背後層温度を高く設定したＡパターンが好ましく、またＣパターンが好ましい。 In addition, when a material having a high b value (8 to 25) is used as the surface layer material, an A pattern in which the back layer temperature is set high is preferable, and a C pattern is preferable.
なお、上記のパターンで表面温度の軌跡をみるとき、最初の離型後次の賦形にいたるまでに成形表面温度が元の温度に完全戻るような状態であれば、定常状態として均一な成形品を連続生産できていることになる。完全に元に戻らない状態でも連続的に成形をすると最高温度と最低温度は共に次第に低下するか上昇するかして、時間の経過とともにいずれ定常状態に至る。 そして場合によっては適切な熱処理ができない状態になることもあるが、この場合は背後温度を変更し或いは加熱冷却の強弱を加減することによりこれを解消する。本発明では成形開始後実用的な短時間に定常状態を達成し、また成形開始と同時定常状態が得られる構成となっている。 When looking at the surface temperature trajectory with the above pattern, if the molding surface temperature completely returns to the original temperature after the first mold release until the next shaping, uniform molding as a steady state Products can be produced continuously. Even if it is not completely restored to its original state, if the molding is continuously performed, both the maximum temperature and the minimum temperature gradually decrease or increase, and eventually reach a steady state as time passes. In some cases, appropriate heat treatment may not be possible. In this case, this problem is solved by changing the backside temperature or adjusting heating / cooling strength. In the present invention, a steady state is achieved in a practical short time after the start of molding, and a steady state is obtained simultaneously with the start of molding.
＜各種の変形態様＞
高温気体による圧空成形を行う場合は完全密閉で行ってもよいが、圧空ボックスから高温気体を適度に漏洩するようにすれば、気体流が生まれ熱伝達率を大きくすることができ賦形体および該表面温度をよりより速くより高くすることができ好ましい。具体的には圧空ボックスにリークのためのスリットを設けたり、レギュレータ、フローバルブ、チェックバルブ、ニードルバルブ、開閉バルブ等を設けることにより実施でき任意に好ましく利用できる。 例えば、低温あるいは高温の圧空に引き続き、バルブを操作して低圧あるいは無圧で高温気体あるいは低温気体を吹き付ける方法も実施できる。このときも高速の気流である方が効率的であるが、加熱の場合は周囲の空気を巻き込むことが無いようにある程度閉鎖された空間でおこなうことが好ましい（熱圧空の漏洩又は高温気体ブロウ）。
<Various variants>
When performing pressure air molding with a high temperature gas, it may be completely sealed, but if a high temperature gas is appropriately leaked from the pressure air box, a gas flow is created and the heat transfer coefficient can be increased, and the shaped body and The surface temperature can be increased faster and more preferably. Specifically, it can be implemented preferably by providing a slit for leaking in the compressed air box, or by providing a regulator, a flow valve, a check valve, a needle valve, an on-off valve, or the like. For example, a method of blowing a high-temperature gas or a low-temperature gas at a low pressure or no pressure by operating a valve after a low-temperature or high-temperature compressed air can be performed. At this time, it is more efficient to use a high-speed air flow, but in the case of heating, it is preferable to carry out in a space closed to some extent so that surrounding air is not involved (leakage of hot and compressed air or high-temperature gas blow). .
冷却用気体の適用関しては、できるだけ低温の気体を用い、できるだけ高速の気体流を賦形体裏面に接するようにすることが好ましい。このような気体の吹きつけは略閉鎖された空間で行ってもよいが、開放空間で周囲の空気を引き込みながら吹き付ける方法も効率的で好ましい。 あるいはベンチュリー管の原理を利用し周囲の空気を吸い込みながらブロウすれば圧縮空気の消費も少なくなり効率的で好ましい(ベンチュリー管)。 Regarding the application of the cooling gas, it is preferable to use a gas as low as possible and to make the gas flow as fast as possible in contact with the back surface of the shaped body. Although such gas blowing may be performed in a substantially closed space, a method of blowing air while drawing ambient air in an open space is also efficient and preferable. Alternatively, if the air is blown while the surrounding air is sucked in using the principle of the Venturi tube, the consumption of compressed air is reduced, which is efficient and preferable (Venturi tube).
上記に説明した高速の高温あるいは低温の気体流を適用する手段として、成形型の面形状に略対応する形状の気体噴き出し（あるいは吸引）デバイスを賦形体に接近させて高速流を発生させる方法が好ましく採用できる。なお、このような気体流の高速化は、該表面層材料がｂ値１０以上の大きな値を有する場合、例えばアルミ、鋼、ＳＵＳ等の金属材料などの場合は特に必要性が高く望ましく利用できる（気体高速化デバイス）。 As a means for applying the high-speed high-temperature or low-temperature gas flow described above, there is a method of generating a high-speed flow by bringing a gas ejection (or suction) device having a shape substantially corresponding to the surface shape of the mold close to the shaped body. Preferably employed. Note that such high speed gas flow is highly necessary and desirable when the surface layer material has a large b value of 10 or more, for example, metal materials such as aluminum, steel, and SUS. (Gas acceleration device).
前述の成形パターンのＡ、Ｂ、Ｃにおいて、高温気体のかわりに、高温気体の適用と平行して遠赤外線あるいは近赤外線等の赤外線による加熱作用を利用することができ、具体的には、圧空ボックスの中に赤外線ラジエーターを設けておいて圧空と同時にあるいは、高温気体に吹き込み時に賦形体背面を加熱するようにしても良く好適に利用できる（赤外線照射）。 In the above-described molding patterns A, B, and C, a heating action by infrared rays such as far infrared rays or near infrared rays can be used in parallel with the application of the high temperature gas instead of the high temperature gas. An infrared radiator may be provided in the box, and the back of the shaped body may be heated at the same time as compressed air or when blown into a high-temperature gas (infrared irradiation).
熱成形法では通常、加熱オーブンあるいは熱盤接触等によりシートを熱成形適温に予熱するが、本発明の方法では予熱を行っていないシートを成形型の位置にセットして、高温気体、あるいは上記の赤外線ラジエーターを用いて予熱を行いながら賦形することができる。なお、高温気体を用いる場合は気体の温度に合わせて緩慢な速度で加圧する必要があり、また気体温度は高すぎないようにする必要がある。この方法も、仔細に観察すれば、シートの予熱がある程度先行して行われ、次いで賦形が同時進行し、次いでシート予熱温度以上の熱処理が行われるもので本発明の範囲を超えるものではない。これを例えば２８０℃の高圧空成形でおこなうこともできるが、ゆっくり且つ適正な速度で加圧する必要があり、急激に高温圧空を行えば材料は予熱不足のために破断してしまう。また加圧をゆっくりして高温に加熱しすぎたものは、伸びが失われまた成形不良となりまた白化などが発現してしまい、あるいは溶融してしまう。本発明に用いる材料は適正熱処理温度以上に予熱すると伸びが失われ成形不良となりまた白化などが発現してしまうので、成形材料は賦形中もある程度昇温してよいが厳密には賦形後に熱処理がなされなければならない。（予熱即賦形）
高温気体として過熱蒸気を通常の加熱空気の代わり用いることができ、乾燥過熱水蒸気、飽和過熱水蒸気いずれも熱容量が大きく効果的に該表面層あるいは賦形体を昇温させることができ好ましい。また条件設定により、その蒸発潜熱を利用できれば該表面層あるいは賦形体を効果的に冷却することができ好ましい。この冷却は、例えば過熱蒸気を用いて圧空を行い、途中でその圧力を下げ接触表面への結露を促し、次いで圧空を開放すれば、結露水は気化し効果的に冷却してくれる。さらにこの時、該表面層あるいは賦形体の冷却を１００℃まで終えるようにすれば、成形品に結露水をのこらないようにすることも容易で、優れた成形方法となる（過熱水蒸気の利用）。
In the thermoforming method, the sheet is usually preheated to a suitable temperature for thermoforming by contact with a heating oven or a hot platen or the like, but in the method of the present invention, a sheet that has not been preheated is set at the position of the forming die, and a high-temperature gas or the above-mentioned It can be shaped while preheating using an infrared radiator. When a high-temperature gas is used, it is necessary to pressurize at a slow rate in accordance with the gas temperature, and the gas temperature must not be too high. If this method is also closely observed, the sheet is preheated to some extent first, then the shaping is performed simultaneously, and then the heat treatment at the sheet preheat temperature or higher is performed, and does not exceed the scope of the present invention. . This can be done, for example, by high-pressure blank forming at 280 ° C., but it is necessary to pressurize slowly and at an appropriate speed. If high-temperature pressure is suddenly applied, the material breaks due to insufficient preheating. Further, when the pressure is slowly increased and the temperature is excessively heated, the elongation is lost, the molding becomes defective, whitening or the like occurs, or the material melts. If the material used in the present invention is preheated to a temperature equal to or higher than the appropriate heat treatment temperature, the elongation is lost and defective molding occurs and whitening or the like occurs. Therefore, the molding material may be heated to some extent during shaping, but strictly after shaping. Heat treatment must be done. (Preheating immediate form)
Superheated steam can be used as a high-temperature gas instead of ordinary heated air, and both dry superheated steam and saturated superheated steam are preferred because they have a large heat capacity and can effectively raise the temperature of the surface layer or shaped body. If the latent heat of vaporization can be used by setting conditions, the surface layer or shaped body can be effectively cooled, which is preferable. In this cooling, for example, if compressed air is used with superheated steam, the pressure is lowered in the middle to promote condensation on the contact surface, and then the pressurized air is released, the condensed water evaporates and cools effectively. Further, at this time, if the cooling of the surface layer or shaped body is finished up to 100 ° C., it is easy to prevent condensation from remaining on the molded product, which is an excellent molding method (use of superheated steam). ).
嵌合ダイあるいは雌雄型を用いて賦形し、賦形体を本発明の構造を有する雌雄いずれか片方の型（以下下型という）に残して他（以下上型という）を開けば、本文記載のとおり賦形体裏面に対して自由に加熱冷却を行うことができる。しかし特別な態様として、下型は本発明通りの構成とし、上型は気体ブロウのできる構造にし、両型を合わせるようにプレス賦形の後、上型を少し持ち上げるかあるいは取り去って、加熱気体あるいは冷却気体をブロウすることにより記述の自由な成形パターンを実行することができる。（雌雄型）
気体による加熱あるいは冷却の効率を高めるために、対象物表面でできるだけ高速の流れをつくり熱伝達率を高くすることは好ましい。そしてその手段の一つとして、
成形型の該表面と略相似形のガイドブロックとの間に狭い間隙をつくり、この間に気体を通すようにすれば容易に高速流をつくることができ、好ましい方法として用いることができる。そしてこの場合、ガイドブロックから気体を噴出させるようにしてもよく、またガイドブロックへ吸い込んで外部へ排出させるようにしてもよく、また両機構を併せ持つようにしてもよく、いずれも好ましい方法として用いることができる。
なお加熱あるいは冷却を均一に行うために、少なくとも気体を噴出させる場合は、噴出孔は複数であることが好ましく、又ガイドブロック材として多孔体を利用することも好ましい。 なお、このようなガイドブロックは、賦形後に賦形体裏面に近づけてもよいが、賦形の補助に用いるプラグアシストと兼ねてもよい。(気体流ガイド)
赤外線放射源の形状は、特に限定するものではなく、平面体にして賦形体の上空 に配置してもよい。しかし、赤外線照射の効率を高めて、あるいは均一に照射するために、成形型の該表面と略相似形の照射表面にして、賦形後に賦形体裏面表面への接近させまた離反するようにすることができ、好ましい方法として用いることができる。なお、このような照射体には気体のブロウあるいは排気機能を兼ね備えることもでき好ましい方法として用いることができる（ＩＲ接近ブロック）。
Forming with a fitting die or male and female mold, leaving the shaped body in one of the male and female molds having the structure of the present invention (hereinafter referred to as the lower mold) and opening the other (hereinafter referred to as the upper mold) As described above, heating and cooling can be freely performed on the rear surface of the shaped body. However, as a special embodiment, the lower mold is configured as in the present invention, the upper mold is made of a gas blowable structure, and after press forming so as to match both molds, the upper mold is lifted up or removed a little, and the heated gas Alternatively, a molding pattern having a free description can be executed by blowing a cooling gas. (Male and female type)
In order to increase the efficiency of heating or cooling with gas, it is preferable to create a flow as fast as possible on the surface of the object to increase the heat transfer coefficient. And as one of the means,
If a narrow gap is formed between the surface of the mold and a guide block having a substantially similar shape, and a gas is allowed to pass therethrough, a high-speed flow can be easily created, and this can be used as a preferred method. In this case, the gas may be ejected from the guide block, may be sucked into the guide block and discharged to the outside, or both mechanisms may be provided, both of which are used as preferred methods. be able to.
In order to perform heating or cooling uniformly, at least when a gas is ejected, it is preferable to have a plurality of ejection holes, and it is also preferable to use a porous body as a guide block material. In addition, although such a guide block may be brought close to the back of the shaped body after shaping, it may also serve as plug assist used for shaping assistance. (Gas flow guide)
The shape of the infrared radiation source is not particularly limited, and the infrared radiation source may be a flat body and disposed above the shaped body. However, in order to increase the efficiency of infrared irradiation or to irradiate uniformly, an irradiation surface that is substantially similar to the surface of the mold is made to approach and separate from the back surface of the shaped article after shaping. Can be used as a preferred method. Such an irradiator can also have a gas blowing or exhaust function, and can be used as a preferred method (IR approach block).
その他付記事項
上記のプロセスで得られた、本発明の成形品は、同材料シートの熱成形に比べ耐熱性が向上したものとなっており、少なくとも１０℃以上向上させることは容易であり、ホモのＰＥＴ材料の場合であれば耐熱８０℃以上にすることは容易であり、９０℃以上、あるいは１００℃以上、あるいは１２０℃以上、あるいは１４０℃以上とすることもでき、併せて透明性の高いものにすることができる。なお、ここでは耐熱性は、成形品を特定温度に加熱されたサラダオイル中に２分間浸漬して取り出し、肉眼判断で一見してわかる収縮変形の有無で耐熱性の判断とする。
Other Supplementary Notes The molded product of the present invention obtained by the above process has improved heat resistance compared to thermoforming of the same material sheet, and it is easy to improve at least 10 ° C. or more. In the case of the PET material, it is easy to make the heat resistance 80 ° C. or higher, and it can be 90 ° C. or higher, or 100 ° C. or higher, or 120 ° C. or higher, or 140 ° C. or higher. Can be a thing. Here, the heat resistance is determined based on the presence or absence of shrinkage deformation that can be seen at first glance by immersing the molded product in a salad oil heated to a specific temperature for 2 minutes and taking it out.
なお、本願に記載した表面温度については部位によるバラツキが想定されるが、成形型表面のうち成形品の有効部分が接する少なくとも１点の温度が記載の規定の範囲を満足させておればよい。また、複数の成形型を集積して成形を行う場合は必ずしも全ての成形型について管理あるいは制御する必要はなく少なくとも１つの成形型でこれを行えばよい。 Note that the surface temperature described in the present application may vary depending on the site, but it is sufficient that at least one point on the surface of the mold that is in contact with the effective portion of the molded product satisfies the specified range. Further, when molding is performed by accumulating a plurality of molding dies, it is not always necessary to manage or control all the molding dies, and this may be performed with at least one molding die.
（実施例１）
成形材料
共重合成分としてジエチレングリコール２モル％を含有し、エチレンテレフタレート単位が構成繰り返し単位の９８モル％を占めるポリエチレンテレフタレート樹脂を、ベント付き押出機にて樹脂温度２９０℃で溶融押出し、キャスティングロールで
引き取り冷却固化しシート成形した。得られた実質的に未延伸のシートを縦方向に２．５倍に１軸延伸し、厚さ０．２３ｍｍの延伸シートを得た。なお、このシートは延伸に際するヒートセット処理はおこなっていない。
Example 1
Polyethylene terephthalate resin containing 2 mol% of diethylene glycol as a molding material copolymerization component and ethylene terephthalate units occupying 98 mol% of constituent repeating units is melt extruded at a resin temperature of 290 ° C. with a vented extruder and taken up with a casting roll. Cooled and solidified to form a sheet. The obtained substantially unstretched sheet was uniaxially stretched 2.5 times in the longitudinal direction to obtain a stretched sheet having a thickness of 0.23 mm. In addition, this sheet | seat is not performing the heat set process in the case of extending | stretching.
このシートにおける樹脂の極限粘度は０．６９ｄｌ／ｇ、ガラス転移転（Ｔｇ）は７５℃、融点（Ｔｍ）は２５３℃、複屈折率（Δｎ）は０．０４９、面配向度（ΔＰ）は０．０３７であった。 The intrinsic viscosity of the resin in this sheet is 0.69 dl / g, the glass transition (Tg) is 75 ° C., the melting point (Tm) is 253 ° C., the birefringence (Δn) is 0.049, and the degree of plane orientation (ΔP) is It was 0.037.
成形型
円周に嵌合溝つきの大略半円球のカップ (内形１００ｍｍφ、深さ３５ｍｍ)のキャビテイ型(外寸１１０×１１０×高さ５３ｍｍ)で、成形時の真空孔（排気孔）を備えた図２の１に示す形状のものを製作して使用した（表２）。これは、ステンレス鋼（ＳＵＳ３０４）の表面層は平均厚みを５ｍｍとし切削加工によりで製作し、またアルミ材（Ａ５０５２）の背後層（本体）も切削加工にて製作しこれに前者を嵌め込んで密着一体化したものである。
It is a cavity type (outside dimension 110 x 110 x height 53 mm) with a semi-spherical cup (inner shape 100 mmφ, depth 35 mm) with a fitting groove on the circumference of the mold. The thing of the shape shown in 1 of the provided FIG. 2 was produced and used (Table 2). This is because the surface layer of stainless steel (SUS304) is manufactured by cutting with an average thickness of 5 mm, and the back layer (main body) of the aluminum material (A5052) is also manufactured by cutting, and the former is inserted into this. It is closely integrated.
そしてこのキャビテイを蛇管を内包したアルミニウム（Ａｌ５０５２）製の温調プレートに乗せ、蛇管には連続して熱媒を通す図２の構成とした。なお成形型にはカップ底部に近い側面の成形層表面と、同じ部分から内部へ１５ｍｍの位置にそれぞれ熱電対を配置し温度を計測した。また、温調プレートはカップ底部から１８ｍｍ下層に位置する構成とした。 Then, this cavity was placed on a temperature control plate made of aluminum (Al5052) containing a serpentine tube, and the configuration shown in FIG. In addition, the thermocouple was arrange | positioned to the position of 15 mm from the same part and the inside of the molding layer surface of the side surface close | similar to a cup bottom, and the temperature was measured, respectively. Moreover, the temperature control plate was configured to be positioned 18 mm below the cup bottom.
成形方法
この成形型装置を枚葉の真空圧空成形機（浅野研究所製）に装着し成形を行った。
上記成形材料をオーブンで８秒保留しシートを８５℃に予熱し、該表面を（Ｔｇ＋５０℃）以上である１８０℃に予熱しておいた成形型の上に移動させ、４秒間真空圧空賦形を行って離型した。圧空には約３０℃で元圧０．４ＭＰａの圧縮空気を用い、圧空ボックスは０．１５ＭＰａの排気弁を装着し、一定圧で圧空と同時に排気がなされるようにして、大きな気流により強力な冷却がなされるようにした。離型時の該位置の表面（賦形体との界面）温度は１６０℃まで低下していた。
Molding Method The molding tool was mounted on a single wafer vacuum / pressure forming machine (manufactured by Asano Laboratories) to perform molding.
The molding material is held in an oven for 8 seconds, the sheet is preheated to 85 ° C., and the surface is moved onto a mold preheated to 180 ° C. which is equal to or higher than (Tg + 50 ° C.). To release the mold. Compressed air is compressed air with an original pressure of 0.4 MPa at about 30 ° C., and the compressed air box is equipped with an exhaust valve of 0.15 MPa, and is exhausted at the same time as compressed air with a constant pressure, making it more powerful with a large air flow Cooling was made. The surface (interface with the shaped body) temperature at the position at the time of mold release was lowered to 160 ° C.
成形結果
成形品は透明で良好な形状をしており、加熱オイルに浸漬するテスト行った結果からは、少なくとも１２０℃では変形が無く耐熱性の高いものであった。ちなみに延伸を行っていない同樹脂のシートはこのような成形方法では成形品は得られないが、通常の熱成形法による成形品の耐熱性は約６５℃であった。
本方法では、材料シートの賦形と加熱と冷却が殆ど同時になされ、４秒間という驚異的な短時間に効果的な熱処理を伴う成形が可能であることを確認した。
Molding result The molded product was transparent and had a good shape. From the result of a test conducted by dipping in heated oil, it was found to be highly heat resistant with no deformation at least at 120 ° C. Incidentally, a sheet of the same resin that has not been stretched cannot be formed by such a molding method, but the heat resistance of the molded product by a normal thermoforming method was about 65 ° C.
In this method, it was confirmed that the material sheet was shaped, heated and cooled almost simultaneously, and that molding with effective heat treatment was possible in a surprisingly short time of 4 seconds.
連続成形性の確認
更に連続成形を近似的に模して、上記成形品を成形型に真空固定し、上記の条件の高温圧空と、表面（界面）温度回復待ちの繰り返しテストを行った結果、［４秒圧空１１秒待ち］のサイクルでは、約５分という短時間で定常状態となり表面頂上温度は１６５℃となり安定した。なお、実際の連続成形における材料交換は上記待ち時間の中で行うことができるので１サイクル１５秒となる。
Confirmation of continuous formability In addition to imitating continuous molding approximately, the above molded product was vacuum-fixed to the mold, and as a result of repeated tests of high temperature and pressure air under the above conditions and waiting for surface (interface) temperature recovery, In the cycle of [4 seconds pressure wait 11 seconds], the steady state was reached in a short time of about 5 minutes, and the surface top temperature was stabilized at 165 ° C. In addition, since material exchange in actual continuous molding can be performed during the waiting time, one cycle is 15 seconds.
この定常状態でも有効な熱処理を伴った熱成形が可能である。しかし上記の１８０℃設定で成形することを望むならば背後温度の設定を１５〜２０℃程度を上昇させて実現することができる。 本成形型はその設定調整も容易に迅速行うことができる。また、この材料を使う場合には、該層の厚みもっと小さくして、待ち時間、及び定常化時間をもっと短縮をはかることは可能である(パターンＣ）。 Even in this steady state, thermoforming with effective heat treatment is possible. However, if it is desired to mold at the above 180 ° C. setting, the setting of the back temperature can be realized by raising the temperature by about 15 to 20 ° C. The present mold can be easily adjusted quickly. When this material is used, it is possible to further reduce the waiting time and the stabilization time by reducing the thickness of the layer (pattern C).
（実施例２）
成形材料
実施例１に用いたものと同じものを用いた。
(Example 2)
Molding material The same material as used in Example 1 was used.
成形型
実施例１に用いたものを用い、この成形型を実施例と同じ温調プレートに乗せ、同じようにして温度計測を行うようにした。
The mold used in the mold example 1 was placed on the same temperature control plate as in the example, and the temperature was measured in the same manner.
成形装置
実施例１に使用した成形機に、高温の加熱空気を製造する装置を特別に付加してこの装置を経由して成型機の圧空用空気を圧空ボックス導入するようにし、更に圧空ボックス内の天井には電熱ヒーター内蔵のスチール製多孔板を設け、この多孔板を通じて加熱空気が賦形体裏面に向けて排出されるようにした。またこれとは別に外部から元圧０．７ＭＰａの圧縮空気を同ボックス内部に導き分散ノズルを通じて賦形体を裏面からブロウ冷却できる機構を付加した。なお、圧空ボックスには０．１５ＭＰａの排気弁を設置してあり一定圧を保ちながら排気がなされる。この冷却ブロウの機構は加熱気体導入のものとは全く別のものであり、圧空ボックスの閉鎖時も開放時も任意な時ブロウ冷却できるようにした。上記多孔板は導入気体の再加熱と同時に赤外線照射の働きもする。同板の赤外線放射率は約０．７５で成形型上面までの距離は約１００ｍｍである。 また成形型該表面の放射率は０．３程度と低く、ここで反射された赤外線は再度賦形体加熱に寄与しているものと思われる。
The molding machine used in Example 1 was specially added with a device for producing high-temperature heated air, and the compressed air of the molding machine was introduced into the compressed air box via this device. A steel perforated plate with a built-in electric heater was provided on the ceiling, and heated air was discharged through the perforated plate toward the back of the shaped body. Separately from this, a mechanism was added that allows compressed air with an original pressure of 0.7 MPa to be introduced into the box from the outside and blow-cooled the shaped body from the back side through a dispersion nozzle. Note that a 0.15 MPa exhaust valve is installed in the compressed air box, and exhaust is performed while maintaining a constant pressure. The cooling blow mechanism is completely different from that of the heated gas introduction, and blow cooling can be performed at any time, both when the compressed air box is closed and when it is opened. The perforated plate also serves to irradiate infrared rays simultaneously with reheating the introduced gas. The infrared emissivity of the plate is about 0.75, and the distance to the upper surface of the mold is about 100 mm. Further, the emissivity of the surface of the mold is as low as about 0.3, and the infrared ray reflected here seems to contribute to heating the shaped body again.
成形方法
上記成形材料をオーブンで８秒保持して８５℃に予熱し、該表面温度１６７℃の成形型の上に移動させ、加熱空気で３．５秒間真空圧空賦形を行い、次いで圧空ボックスを上昇させながらノズルから空気ブロウ冷却を４．５秒行い離型した。圧空中にボックス内は２９０℃に達した。また離型時の表面（界面）温度は１６３℃まで低下していた。なお、用いた加熱空気は、３５０℃設定の気体加熱装置を経由し、３５０℃の該多孔板を通じて圧空に供した。 なお、高温多孔盤からは赤外線照射がなされ、又賦形体の昇温には補助的に貢献しているものと思われる。
Molding method The above molding material is kept in an oven for 8 seconds, preheated to 85 ° C., transferred onto a molding die having a surface temperature of 167 ° C., and subjected to vacuum / pressure forming with heated air for 3.5 seconds, and then a compressed air box The mold was released from the nozzle by air blow cooling for 4.5 seconds. The inside of the box reached 290 ° C. in the compressed air. Further, the surface (interface) temperature at the time of mold release was lowered to 163 ° C. The heated air used was subjected to pressurized air through the perforated plate at 350 ° C. via a gas heating device set at 350 ° C. In addition, it is considered that infrared irradiation is performed from the high-temperature porous board, and that it contributes supplementarily to the temperature rise of the shaped body.
成形結果
成形品は透明で良好な形状をしており、実施例１と同様の耐熱テストの結果からは、少なくとも１２０℃の耐熱性があった。
本方法では、材料シートの賦形と兼ねた加熱を３．５秒、冷却を４．５秒という驚異的な短時間で効果的な熱処理を伴う成形が可能であることを確認した。
Molding Result The molded product was transparent and had a good shape. From the result of the heat test similar to that of Example 1, the molded product had a heat resistance of at least 120 ° C.
In this method, it was confirmed that molding with effective heat treatment was possible in a surprisingly short time of 3.5 seconds for heating combined with shaping of the material sheet and 4.5 seconds for cooling.
連続成形性の確認
実施例１と同様に、上記結果をもとに連続成形を近似的に模した繰り返し加熱冷却テストを行った結果、［３．５秒加熱、４秒冷却、２．５秒待ち］のサイクルでは頂上温度、冷却温度共に上昇する傾向があったので少し条件修正を行った。
その結果、［３秒加熱、４秒冷却、２秒待ち］という設定にしたところ１分以内に定常状態の温度曲線となった。定常状態の頂上温度は１８９℃、冷却温度は１５０℃であり熱処理と離型には十分な温度である。また待ち時間の２秒は、実際の連続成形における成形材料交換を想定したもので、１サイクルは９秒となる(パターンＡ)。
Confirmation of continuous formability As in Example 1, the results of a repeated heating / cooling test approximating continuous forming based on the above results were as follows: [3.5 seconds heating, 4 seconds cooling, 2.5 seconds In the “Waiting” cycle, both the top temperature and the cooling temperature tended to rise, so the conditions were slightly modified.
As a result, when the setting of [3 seconds heating, 4 seconds cooling, 2 seconds wait] was made, a steady state temperature curve was obtained within 1 minute. The top temperature in the steady state is 189 ° C. and the cooling temperature is 150 ° C., which is sufficient for heat treatment and mold release. The waiting time of 2 seconds assumes replacement of the molding material in actual continuous molding, and one cycle is 9 seconds (pattern A).
（実施例３）
成形材料
実施例１に用いたものと同じものを用いた。
Example 3
Molding material The same material as used in Example 1 was used.
成形型
表に示す構成のものを、実施例１と形状同寸のものを製作して使用した。アルミ粉含有エポキシ樹脂は日新樹脂製ＲＴ−４６１（表１に示す）を用い、これをアルミニウム本体にキャスティングする方法で一体化した。この成形型を実施例１と同じ温調プレートに乗せ、同じようにして温度計測を行うようにした。
The thing of the structure shown in a shaping | molding die table | surface and the shape same size as Example 1 were manufactured and used. As the aluminum powder-containing epoxy resin, Nisshin Resin RT-461 (shown in Table 1) was used, and this was integrated by a method of casting on an aluminum body. This mold was placed on the same temperature control plate as in Example 1, and the temperature was measured in the same manner.
成形装置
実施例２に用いた成型機を用い、同じ装置構成とした。
Molding apparatus The molding machine used in Example 2 was used to have the same apparatus configuration.
成形方法
実施例２と同じ方法で行った。上記成形材料をオーブンで８秒間保持して８５℃に予熱し、成形面を１４５℃に予熱しておいた成形型の上に移動させ、加熱空気で５秒間真空圧空賦形を行い、次いで圧空ボックスを上昇させながらノズルから空気ブロウ冷却を５秒行い離型した。圧空中にボックス内は３２８℃に達した。また表面（界面）温度は１８６℃に達した後１４６℃まで冷却され離型されている。なお用いた加熱空気は，４００℃設定の気体加熱装置を経由し、４００℃の該多孔板を通じて圧空に供した。
Molding method The same method as in Example 2 was used. The molding material is held in an oven for 8 seconds and preheated to 85 ° C., the molding surface is moved onto a mold that has been preheated to 145 ° C., vacuum-pressure forming is performed with heated air for 5 seconds, and then compressed air is used. While raising the box, air blow cooling from the nozzle was performed for 5 seconds to release the mold. The inside of the box reached 328 ° C. in the compressed air. Further, after the surface (interface) temperature reaches 186 ° C., it is cooled to 146 ° C. and released. The heated air used was supplied to compressed air through the perforated plate at 400 ° C. through a gas heating device set at 400 ° C.
成形結果
成形品は透明で良好な形状をしており、実施例１と同様の耐熱テストの結果からは、少なくとも１２０℃の耐熱性があった。
本方法では、材料シートの賦形と兼ねた加熱を５秒、冷却を５秒という驚異的な短時間で効果的な熱処理を伴う成形が可能であることを確認した。
Molding Result The molded product was transparent and had a good shape. From the result of the heat test similar to that of Example 1, the molded product had a heat resistance of at least 120 ° C.
In this method, it was confirmed that molding with effective heat treatment was possible in an astonishing short time of 5 seconds for heating combined with shaping of the material sheet and 5 seconds for cooling.
連続成形性の確認
実施例２と同様に、上記結果をもとに連続成形を近似的に模した繰り返し加熱冷却テストを行い、そして若干補正を行った結果、［３秒加熱、１秒待ち、５秒冷却、１秒待ち］というサイクル設定では１分半程度で温度曲線は安定な定常状態となった。このときの頂点温度（最高温度）は約１７８℃、底点温度（最高温度）は約１４２℃で安定しており、熱処理と離形を行うには十分な温度である。また待ち時間の２秒は、実際の連続成形における成形材料交換時間に想定できるので、１サイクルは１０秒となる。
（実施例４）
成形材料
実施例１に用いたものと同じものを用いた。
Confirmation of continuous formability As in Example 2, a repeated heating / cooling test that approximates continuous forming based on the above results was performed, and a slight correction was made. As a result, [3 seconds heating, 1 second waiting, In the cycle setting of “5 seconds cooling, 1 second waiting”, the temperature curve became a stable steady state in about 1 minute and a half. At this time, the peak temperature (maximum temperature) is stable at about 178 ° C., and the bottom temperature (maximum temperature) is stable at about 142 ° C., which is sufficient for heat treatment and mold release. Further, the waiting time of 2 seconds can be assumed as the molding material exchange time in actual continuous molding, so one cycle is 10 seconds.
Example 4
Molding material The same material as used in Example 1 was used.
成形型
実施例１と同形状、同寸法のも表に示す構成にて製作した。 先ず、成形表層より０．３ｍｍ削り込んだ寸法の背後層（本体）をアルミ材（Ａ５０５２）で切削加工により製作し、内面に強力な改質エポキシ系接着剤を薄く塗布し、これに対して結晶核剤作用物質を含んだ結晶性ポリエチレンテレフタレート樹脂シート、いわゆるＣＰＥＴ用シート（東洋紡製、厚み０．５ｍｍ）を真空圧空成形して一体化した。この表面層の厚み平均して０．３ｍｍに仕上がった。なお、真空圧空は１０分間続け、成形材料の結晶化と接着剤の固化を十分に行った。また当然ながら必要な場所には真空孔を設けた。この成形型を加熱プレートに乗せて真空圧空成型機に装着した。
Molds having the same shape and the same dimensions as those of the mold example 1 were manufactured as shown in the table. First, a back layer (main body) with a size of 0.3 mm cut from the molding surface layer is manufactured by cutting with aluminum material (A5052), and a strong modified epoxy adhesive is thinly applied to the inner surface. A crystalline polyethylene terephthalate resin sheet containing a crystal nucleating agent active substance, a so-called CPET sheet (manufactured by Toyobo Co., Ltd., thickness 0.5 mm) was integrated by vacuum / pressure forming. The average thickness of this surface layer was finished to 0.3 mm. Note that the vacuum / pressure air continued for 10 minutes to sufficiently crystallize the molding material and solidify the adhesive. Of course, a vacuum hole was provided in a necessary place. This mold was placed on a heating plate and mounted on a vacuum / pneumatic molding machine.
成形装置
実施例２に用いた成型機を用い、同じ装置構成とした。
Molding apparatus The molding machine used in Example 2 was used, and the same apparatus configuration was used.
成形方法
実施例２と同じ方法で行った。上記成形材料をオーブンで８秒間保持して８５℃に予熱し、成形用表面を１２８℃に予熱しておいた成形型の上に移動させ、加熱空気で６秒間真空圧空賦形を行い、次いで圧空ボックスを上昇させながらノズルから空気ブロウ冷却を９秒行い離型した。圧空中にボックス内は３３１℃に達した。また表面（界面）温度は１７５℃に達した後１１７℃まで冷却され離型されている。なお用いた加熱空気は，４００℃設定の気体加熱装置を経由し、４００℃の該多孔板を通じて圧空に供した。
Molding method The same method as in Example 2 was used. The molding material is held in an oven for 8 seconds and preheated to 85 ° C., the molding surface is moved onto a mold that has been preheated to 128 ° C., and vacuum-pressure forming is performed with heated air for 6 seconds, Air blow cooling from the nozzle was performed for 9 seconds while the compressed air box was raised, and the mold was released. The inside of the box reached 331 ° C. in the compressed air. Further, after the surface (interface) temperature reaches 175 ° C., it is cooled to 117 ° C. and released. The heated air used was supplied to compressed air through the perforated plate at 400 ° C. through a gas heating device set at 400 ° C.
成形結果
成形品は透明で良好な形状をしており、実施例１と同様の耐熱テストの結果からは、少なくとも１２０℃の耐熱性があった。
本方法では、材料シートの賦形と兼ねた加熱を６秒、冷却を９秒という驚異的な短時間で効果的な熱処理を伴う成形が可能であることを確認した。
Molding Result The molded product was transparent and had a good shape. From the result of the heat test similar to that of Example 1, the molded product had a heat resistance of at least 120 ° C.
In this method, it was confirmed that forming with effective heat treatment was possible in a surprisingly short time of 6 seconds for heating that was used for shaping the material sheet and 9 seconds for cooling.
連続成形性の確認
実施例２と同様に、上記結果をもとに連続成形を近似的に模した繰り返し加熱冷却テストを行い、そして若干補正を行った結果、［背後層温度１２４℃、５秒加熱、１秒待ち、８秒冷却、１秒待ち］というサイクル設定では４分程度で温度曲線は安定な定常状態となった。なおこの定常状態では背後層温度は５７℃、頂点温度は１９１℃、底点温度は１４１℃となりほぼ一定に安定しており一定温度のサイクルが続いた。また待ち時間の２秒は、実際の連続成形における成形材料交換時間に想定できるので、１サイクルは１５秒となる。
（実施例５）
成形材料
実施例１と同じものを用いた。
Confirmation of continuous formability As in Example 2, a repeated heating / cooling test approximating continuous forming was performed based on the above results, and a slight correction was made. In the cycle setting of “heating, waiting for 1 second, cooling for 8 seconds, waiting for 1 second”, the temperature curve became stable in about 4 minutes. In this steady state, the back layer temperature was 57 ° C., the apex temperature was 191 ° C., the bottom temperature was 141 ° C., and the cycle was constant and constant. In addition, the waiting time of 2 seconds can be assumed as the molding material exchange time in actual continuous molding, so one cycle is 15 seconds.
(Example 5)
The same molding material as in Example 1 was used.
成形型
表に示す構成のもので、実施例１と形状同寸のものを製作して使用した。純エポキシ樹脂は日新樹脂製ＣＥＰ−７を用い、実施例３と同様にして製作し、実施例１と同じ温調プレートに乗せ、同じようにして温度計測を行うようにした。
A product having the same configuration as that of Example 1 having the configuration shown in the mold table was used. The pure epoxy resin was CEP-7 manufactured by Nissin Resin Co., Ltd., manufactured in the same manner as in Example 3, placed on the same temperature control plate as in Example 1, and temperature measurement was performed in the same manner.
成形機及び関連装置
実施例３と同じものを用いた。ただし圧空ボックスの排気弁は０．３ＭＰａ設定のものとした。
The same molding machine and related apparatus as in Example 3 were used. However, the exhaust valve of the pneumatic box was set to 0.3 MPa.
成形方法および成形条件
材料シートをパターンＢで成形した。具体的には材料シートをオーブンで８秒間保持して８５℃予熱し、迅速に成形型上に移動させて圧空ボックスを閉鎖させるとほぼ同時に高温高圧の圧空気体をボックス内に導いた。この高温高圧気体は、０．４ＭＰａの圧縮空気を４００℃に設定した空気加熱装置と４００℃の該多孔板を通過させて供給した。圧空に際して高温気体の一部漏洩し、その内部は３３０℃、０．２５ＭＰａとなった。この操作で圧空と真空引きをほぼ同時に作動させ、次いで４秒間の圧空を行い、圧空ボックスを開放して１０秒間そのまま待って真空を解除して成形品を離型させた。 なお、温調プレートのジャケットには熱媒を常時通じ、表面層の表面が安定して１００℃となるようにして一連の操作を行った。該表面温度の最高温度は１７０／１６５℃（底面／側面）、離型時温度は１３０／１３０℃ （底面／側面）であった。
Molding method and molding conditions The material sheet was molded in pattern B. Specifically, the material sheet was held in an oven for 8 seconds, preheated to 85 ° C., quickly moved onto a mold and the compressed air box was closed, and at the same time, a high-temperature and high-pressure compressed air body was introduced into the box. This high-temperature high-pressure gas was supplied by passing 0.4 MPa compressed air through an air heating apparatus set at 400 ° C. and the 400 ° C. perforated plate. A part of the high temperature gas leaked during the compressed air, and the inside became 330 ° C. and 0.25 MPa. By this operation, compressed air and evacuation were operated almost simultaneously, then pressurized air was applied for 4 seconds, the compressed air box was opened, the vacuum was released as it was for 10 seconds, and the molded product was released. Note that a heat medium was always passed through the jacket of the temperature control plate, and a series of operations were performed so that the surface of the surface layer became stable at 100 ° C. The maximum surface temperature was 170/165 ° C. (bottom surface / side surface), and the temperature during mold release was 130/130 ° C. (bottom surface / side surface).
(成形結果)
得られた成形品はシワやタルミがなく嵌合溝等の細部まで精密に良く成形されていた。また、成形品には、くもり、乳白化が全くなく透明性に優れる。この成形品は、耐熱性が１１０℃であった。 圧空賦形と昇温加熱処理が殆ど同時に行われ、次いで時間待ちするだけで冷却され、合計１４秒という短時間で成形できることを確認した。
(Molding result)
The obtained molded product was fine and well molded with fine details such as fitting grooves, without wrinkles or tarmi. In addition, the molded product has no cloudiness or opacification and is excellent in transparency. This molded article had a heat resistance of 110 ° C. It was confirmed that the pressure forming and heating treatment were performed almost at the same time, and then cooled only by waiting for a time, and could be molded in a short time of 14 seconds in total.
連続成形性について
上記各実施例と同様にして連続成形性は確認でき、また実際の連続成形が可能であることは明らかである。
Regarding the continuous formability, it is clear that the continuous formability can be confirmed in the same manner as in the above-described embodiments, and that actual continuous forming is possible.
（比較例１）
先行技術である特公平５−４５４１２号公報の提案する方法を検証するために下記内容のテストを行った。
成形型をアルミニウム（Ａ５０５２）の単体構造とし、実施例１と同形状同寸法のカップ成形用キャビティ型を製作し、実施例１に使用し温調プレート上に乗せて固定しキャビティ型を温度制御できるようにした。成形材料は実施例１に用いたものと同じものを用いた。成形装置は、実施例２に使用にしたものを使用したが、圧空ボックスには必要により加熱気体を導入するようにし、また排気弁などないものとした。なお、またボックス閉鎖時に空気漏れ防止のシールを設けたもので、公知の方法どおり圧空成形するようにした。 次の各方法について調べてみた。
１）材料シートをオーブン中に８秒間置いて８５℃に予熱し、キャビテイ表面温度を１９０、２２０、２４０℃に調整してあるキャビテイ上に移動させ、およそ３０℃の圧縮空気を用い０．４Ｍｐａの圧力で１分間（非能率な時間であるが熱処理のための十分時間をかけて）の圧空賦形を行いそのまま離型する試みを行った。表面温度が１９０℃、２２０℃に調整したものはいずれも離型に際して収縮変形してしまった。また２４０℃に調整して行ったものは白化しそして破損してしまった。この結果から、少なくも用いた材料では良品が得られないことがわかった。
２）次いで、キャビテイ表面温度を低温３０及び６０℃に調整して、上記同様の条件で圧空賦形を行い、次いで圧空ボックスを開放しながら２２０℃の熱風を１分間吹き付けた後に離型する試みを行った。３０℃及び６０℃調整のものはいずれものも良好な成形品となっていたが、耐熱性試験の結果その向上は全くなかった。この熱処理可能温度の上限に近い高温度の熱風を用いても少なくとも短時間には熱処理がなされないことがわかった。なお、２２０℃の加熱空気は、元圧０．７ＭＰａの圧縮空気を２２℃設定の加熱装置を経由し２２０℃の該多孔盤を通じて放出するようにした。
３）上記公報には記載も示唆もないが、敷衍して表面温度をある程度高温にして２）と同じ条件で賦形し、同条件で熱風ブロウする試み行ってみた。
表面温度を８０℃、１００℃、１２０℃と高くした場合には離型に際して激しく収縮変形してしまった。 また、１４０、１６０、１８０℃とした場合は、離型に際して程度の成形形状は保持したものであったが、変形やシワなどの発生があり良品ではなかった。しかし、これら中で１６０℃、１８０℃設定の成形品は耐熱性試験では耐熱性は向上してるとみなすことはでき、特に１８０℃設定のものは１２０℃の試験でも成形時の状態以上には変形の悪化はしなかった。
(Comparative Example 1)
In order to verify the method proposed in Japanese Patent Publication No. 5-45412 which is the prior art, the following test was conducted.
The mold is made of aluminum (A5052) as a single unit, and a cavity mold for cup molding having the same shape and dimensions as in the first embodiment is manufactured. The mold is used on the first embodiment and fixed on the temperature control plate, and the cavity mold is temperature controlled. I was able to do it. The same molding material as that used in Example 1 was used. Although the molding apparatus used in Example 2 was used, a heated gas was introduced into the compressed air box as needed, and there was no exhaust valve. In addition, it was provided with a seal for preventing air leakage when the box was closed, and was compressed and formed according to a known method. I examined each of the following methods.
1) The material sheet is placed in an oven for 8 seconds, preheated to 85 ° C., moved onto a cavity whose cavities surface temperature is adjusted to 190, 220, 240 ° C. and 0.4 Mpa using compressed air of about 30 ° C. An attempt was made to perform pressure-air shaping at a pressure of 1 minute (inefficient time but sufficient time for heat treatment) and to release the mold as it was. In the case where the surface temperature was adjusted to 190 ° C. and 220 ° C., both of them were contracted and deformed upon release. Moreover, what was adjusted to 240 degreeC whitened and was damaged. From this result, it was found that a good product could not be obtained with at least the materials used.
2) Next, adjust the cavity surface temperature to a low temperature of 30 and 60 ° C, perform compressed air shaping under the same conditions as above, then try to release after blowing hot air of 220 ° C for 1 minute while opening the compressed air box Went. The ones adjusted at 30 ° C. and 60 ° C. were all good molded products, but as a result of the heat resistance test, there was no improvement. It has been found that even if hot air having a high temperature close to the upper limit of the heat treatment possible temperature is used, the heat treatment is not performed at least in a short time. The heated air at 220 ° C. was discharged through the perforated plate at 220 ° C. through a heating device set at 22 ° C. with compressed air having an original pressure of 0.7 MPa.
3) Although there is no description or suggestion in the above publication, an attempt was made to spread the surface temperature to a certain degree, shape under the same conditions as 2), and blow hot air under the same conditions.
When the surface temperature was increased to 80 ° C., 100 ° C., and 120 ° C., it was severely shrunk and deformed during release. Further, when the temperature was 140, 160, and 180 ° C., the molding shape was maintained to some extent at the time of mold release, but it was not a good product due to the occurrence of deformation and wrinkles. However, among these, the molded products set at 160 ° C. and 180 ° C. can be regarded as having improved heat resistance in the heat resistance test. In particular, the one set at 180 ° C. is more than the state at the time of molding even at 120 ° C. The deformation did not worsen.
以上３件の検証テストの結果からは、本公報の提案する熱処理の方法は、少なくともテストした延伸ポリエステル材料に適用できる方法ではない。
良好な良品を得るには本発明の如く少なくとも賦形体を冷却して離型するプロセスが必要である。
（比較例２）
先行技術である特公昭５９−０５１４０７号公報の方法及び敷衍して考えられる方法を検証するために下記内容のテストを行った。
From the results of the above three verification tests, the heat treatment method proposed in this publication is not a method that can be applied to at least the tested stretched polyester material.
In order to obtain a good non-defective product, at least a process of cooling and releasing the shaped body is necessary as in the present invention.
(Comparative Example 2)
In order to verify the method disclosed in Japanese Patent Publication No. 59-051407, which is the prior art, and the method that can be considered, the following tests were conducted.
熱成形の成形型として最も汎用されるアルミニウム材（Ａ５０５２）の単体構造とし、実施例１と同形状同寸法のカップ成形用キャビティ型を製作し、実施例１に使用し温調プレート上に乗せて固定しキャビティ型を温度制御できるようにした。
成形材料は実施例１に用いたものと同じものを用いた。
A single-piece structure of aluminum material (A5052), the most widely used mold for thermoforming, is manufactured, and a cup mold cavity mold having the same shape and dimensions as in Example 1 is manufactured and placed on the temperature control plate used in Example 1. The cavity mold was temperature controlled.
The same molding material as that used in Example 1 was used.
成形装置は、実施例１に使用にしたものを使用したが、シートの直接加熱方式の定法通りに、プレス天板下に熱盤をセットし熱盤からの空気により圧空賦形すると方式とした。従って上部の圧空ボックスはなく、また公知の定法に従い、キャビティ型を収納した下部ボックスの周縁にはシール材を取り付け、熱盤で封鎖して圧空を行う時に空気漏れがないようにして成形試験を行った。 The molding apparatus used was the one used in Example 1, but in accordance with the standard method for directly heating the sheet, a hot plate was set under the press top plate and compressed air was formed by air from the hot plate. . Therefore, there is no upper compressed air box, and according to a well-known standard method, a sealing material is attached to the periphery of the lower box containing the cavity mold and sealed with a hot platen so that there is no air leakage when compressed air is used. went.
材料シートを所定の各温度に調整してある熱盤と下部ボックスの間に挟み、この熱盤に真空圧接して予熱し、次いでこの熱盤を通じて通常の圧縮空気を送り表面温度を６５℃に調整にしてあるキャビテイ型で圧空賦形を行い離型した。
この時の熱盤温度は１００℃、１５０℃、１８０℃，２２０℃とし、真空圧接時間はいずれも１０秒間とした。なお、キャビティ表面温度の６５℃は、材料ＰＥＴのＴｇ（８０℃）以下の温度であり、離型時の収縮を回避できるように材料を十分冷却できる温度である。圧空賦形は、通常の圧縮空気を用い０．４ＭＰａの圧力で２秒間で、ほぼ参考公報に示されている条件どおり行った。
テストの結果、
ａ）熱盤温度１００℃のものは、良好な形状の成形品となったが、７５℃の温水浸漬で激しく収縮し耐熱性の向上は全くなかった。圧空に際して表面温度は瞬間的に７１℃に達したが圧空開放時（離型時）は約６６℃になっていた。この表面昇温は熱処理には不十分である。
ｂ）熱盤温度１５０℃と高くしたものは大きなネックインが入ってしまった。そこで追加試験として同樹脂で延伸倍率のみ低くした材料（延伸２．０倍）※を用い同様に成形しものは激しく白化してしまった。このものは 圧空に際して表面温度は瞬間的に９３℃に達したが圧空開放時（離型時）は約６９℃になっていた。この表面昇温は熱処理に不十分である。
The material sheet is sandwiched between a heating plate adjusted to each predetermined temperature and the lower box, vacuum-welded to this heating plate and preheated, and then normal compressed air is sent through this heating plate to bring the surface temperature to 65 ° C. Pneumatic forming was performed with the adjusted cavity type, and the mold was released.
The hot platen temperatures at this time were 100 ° C., 150 ° C., 180 ° C., and 220 ° C., and the vacuum welding time was 10 seconds. The cavity surface temperature of 65 ° C. is a temperature equal to or lower than the Tg (80 ° C.) of the material PET, and is a temperature at which the material can be sufficiently cooled so as to avoid shrinkage at the time of mold release. The compressed air shaping was carried out under normal compressed air at a pressure of 0.4 MPa for 2 seconds under almost the conditions shown in the reference publication.
Test results,
a) The one with a hot plate temperature of 100 ° C. was a molded product having a good shape, but it was shrunk violently when immersed in warm water at 75 ° C. and there was no improvement in heat resistance. The surface temperature instantaneously reached 71 ° C. during compressed air, but was about 66 ° C. when the compressed air was released (when released). This surface temperature rise is insufficient for heat treatment.
b) When the hot platen temperature was as high as 150 ° C., a large neck-in occurred. Therefore, as an additional test, a material molded in the same manner using a material (stretching 2.0 times) * made of the same resin and having only a low stretching ratio was severely whitened. In this case, the surface temperature instantaneously reached 93 ° C. during compressed air, but was about 69 ° C. when the compressed air was released (released). This surface temperature rise is insufficient for heat treatment.
ｃ）熱盤温度１８０℃と更に高くしたてテストが、２．５倍延伸品は大きなネックインが入ってしまった。そこで追加試験として、このもので熱盤への接触予熱時間を、３秒、１秒、０．５秒と順次短くしてみたが結果は同様であった。 c) A hot plate temperature of 180 ° C was further increased, and the 2.5-fold stretched product contained a large neck-in. Therefore, as an additional test, the contact preheating time to the hot platen was shortened to 3 seconds, 1 second, and 0.5 seconds in this order, but the results were the same.
また、同樹脂の延伸２．０倍延伸シートの成形品は激しく白化し、また厚みムラのあるものとなってしまった。 圧空に際して表面温度は瞬間的に９３℃に達したが圧空開放時（離型時）は約６９℃になっていた。この表面昇温はこれでも熱処理には不十分である。なお表面温度の変化は、昇温は主として予熱シートのも熱によるもので、この熱はただちに成形型に拡散し、圧空空気の運ぶ熱量は大きくなかったことを意味する。
＜※註、実施例１の材料シートに用いたものと同じ樹脂で、同様に溶融押出してシート成形し、同様に１軸延伸したもので、延伸倍率は２．０倍、厚み０．２３ｍｍのもので延伸に際するヒートセット処理の行っていないものである。なおこのシートの複屈折率（Δｎ）は０．０１３、面配向度（ΔＰ）は０．０１１であった。＞
ｄ）熱盤温度２２０℃のものは、成形品にネックイン状の大きな亀裂が入ってしまい製品となるようなものではなかった。 因みに、表面温度は９０℃に達したが直ちに低下し圧空開放時（離型時）は約７０℃となっていた。この表面温度の昇温は熱処理には不十分である。
In addition, the molded product of the stretched 2.0-fold sheet of the same resin was severely whitened and had uneven thickness. The surface temperature instantaneously reached 93.degree. C. during compressed air, but was about 69.degree. C. when the pressurized air was released (release). This surface temperature rise is still insufficient for heat treatment. The change in the surface temperature means that the temperature rise is mainly due to the heat of the preheating sheet, and this heat is immediately diffused into the mold, and the amount of heat carried by the compressed air is not large.
<*> The same resin as that used in the material sheet of Example 1, similarly melt-extruded and formed into a sheet, similarly uniaxially stretched, with a stretching ratio of 2.0 times and a thickness of 0.23 mm It is a thing which has not been subjected to heat setting treatment during stretching. The birefringence (Δn) of this sheet was 0.013, and the degree of plane orientation (ΔP) was 0.011. >
d) The one having a hot platen temperature of 220 ° C. was not such that a large neck-in crack was formed in the molded product, resulting in a product. Incidentally, although the surface temperature reached 90 ° C., it immediately decreased and was about 70 ° C. when the compressed air was released (when released). This increase in surface temperature is insufficient for heat treatment.
この結果からは、引用公報記載の方法は少なくともテストに用いた成形材料の熱処理成形には適切な方法ではないことは明かである。また、熱盤により材料シートを予熱し、そのままの位置で熱盤を通ずる空気により圧空成形を行う方法は公知の方法であり、この方法では空気は熱盤を通るとき期せずして加熱されて加熱空気による圧空が行われることになる。しかしながら、（１）表面温度の一時的昇温は予熱された材料によるもので、加熱気体による表面温度昇温の効果は殆どなく、また（２）圧空温度を高くすべく熱盤温度を高くすると適切な成形がなされなくなる。従って、こうした公知の方法では、本願の期待する熱処理を伴う成形は実現できず、またこれを敷衍して考えてもその実現は容易ではない。
（比較例３）
比較例２の公熱盤予熱圧空成形法を敷衍して下記の種々の方法を試みた。成形型の材料として硬質発泡ウレタンフォーム材（サンモジュール３３ 三洋化成製 熱浸透率ｂ値０．７）を用い、比較例２のものと同形同寸法の成形型を製作し同様に温調プレート上に設置し、比較例２に用いた成形装置をそのまま用いた。なおこの材料は機械加工が容易なことからテスト用あるいは小数成形の熱成形型に用いられているが、この熱浸透率ｂ値が０．７と小さく熱が蓄積しすやく高速の連続成形には向かないとされている。
１）比較例２に準じた成形試験
ａ）熱盤温度１００℃の試験結果は、比較例２と同様に、良好な形状の成形品となったが、同様に７５℃のサラダ油浸漬で激しく収縮し耐熱性の向上は全くなかった。
なお、１０秒間の圧空中に表面温度は主要部平均で７８℃に達し７１℃に低下したとき圧空が開放され、その４０秒後の離型時には全ての部位が７０℃以下になっていた。
From this result, it is clear that the method described in the cited publication is not an appropriate method at least for the heat treatment molding of the molding material used in the test. In addition, a method of preheating a material sheet with a hot platen and performing pressure air forming with air passing through the hot plate in the same position is a known method, and in this method, air is heated unexpectedly when passing through the hot platen. Thus, compressed air with heated air is performed. However, (1) the temporary temperature rise of the surface temperature is due to the preheated material, and there is almost no effect of the surface temperature rise by the heated gas, and (2) if the hot platen temperature is increased to increase the pressure air temperature Proper molding will not be performed. Therefore, with such a known method, molding with the heat treatment expected by the present application cannot be realized, and even if this is considered, it is not easy to realize it.
(Comparative Example 3)
The following various methods were tried by using the preheating / pressure forming method of the hot platen of Comparative Example 2. Using a rigid foamed urethane foam material (San module 33, Sanyo Chemical Co., Ltd., heat permeability b value 0.7) as the mold material, a mold having the same shape and dimensions as those of Comparative Example 2 was manufactured, and the temperature control plate was similarly used. The molding apparatus installed above and used in Comparative Example 2 was used as it was. Since this material is easy to machine, it is used for thermoforming molds for testing or decimal molding. However, the heat permeability b value is as small as 0.7, and heat accumulates quickly for high-speed continuous molding. It is said that it is not suitable.
1) Molding test according to Comparative Example 2 a) The test result at a hot platen temperature of 100 ° C. was a molded product having a good shape as in Comparative Example 2, but it was also severely shrunk when immersed in 75 ° C. salad oil. However, there was no improvement in heat resistance.
In 10 seconds of pressure air, the surface temperature reached an average of 78 ° C. on the average of the main part, and when the surface temperature dropped to 71 ° C., the pressure air was released, and all parts were at 70 ° C. or less at the time of release after 40 seconds.
ｂ）熱盤温度１５０℃の試験結果は、比較例２と同様にネックインキレツが発生したので、同様に成形材料を２．０倍延伸のものに変更して成形した。このものも同様に成形品の形状は保っているものの白化し製品としては不適であった。この後者の１０秒間の圧空中に表面温度は９２℃に達し８０℃に低下したとき圧空は開放され、そのご４０秒後の離型時には全ての部位が７０℃以下になっていた。 b) As for the test results at a hot platen temperature of 150 ° C., a neck ink was generated in the same manner as in Comparative Example 2. Therefore, the molding material was similarly changed to a 2.0-fold stretched molding. Similarly, although this product also maintained the shape of the molded product, it was whitened and unsuitable as a product. In the latter 10 seconds of pressurized air, when the surface temperature reached 92 ° C. and dropped to 80 ° C., the pressurized air was released, and all parts were at 70 ° C. or lower when released 40 seconds later.
ｃ）熱盤温度１８０℃の試験結果は、比較例２と同様にネックインキレツが発生したので、上記同様に成形材料を２．０倍延伸のものに変更して成形した。この後者の１０秒間の圧空中に表面温度は１０６℃に達１０２℃に低下したとき圧空は開放され、そのご４０秒後の離型時には全ての部位が７５℃以下になっていた。成形品は収縮変形し、また激しく白化したものであった。
ｄ）熱盤温度２２０℃試験結果は、比較例２と同様にネックインキレツが発生したので、上記同様に成形材料を２．０倍延伸のものに変更して成形した。しかしこのものは激しく白化しまた多数の孔があき成形状態にならなかった。
c) As a result of the test at a hot platen temperature of 180 ° C., a neck increment was generated in the same manner as in Comparative Example 2. Therefore, the molding material was changed to a 2.0-fold stretched material and molded as described above. In the latter 10 seconds of pressurized air, when the surface temperature reached 106 ° C. and dropped to 102 ° C., the pressurized air was released, and at the time of mold release 40 seconds later, all the sites were 75 ° C. or lower. The molded product was deformed by shrinkage and was severely whitened.
d) As for the test result of the hot platen temperature 220 ° C., neck increment was generated in the same manner as in Comparative Example 2. Therefore, the molding material was changed to 2.0-fold stretched material and molded as described above. However, this product was intensely whitened and did not become molded due to numerous holes.
この結果からは、本公報記載の方法は少なくともテストに用いた成形材料には適切な方法ではない。 なお、本成形型の表面温度調整に関しては、温度バラツキが大きく、また安定になりにくく、高温部位がおよそ６５℃程度の時を見計らって成形をおこなった。
２）この成形型の温度特性について調べてみた。
この成形型で表面温度を高温にして圧空賦形を行うこと狙いに、下記を試みた。
From this result, the method described in this publication is not appropriate for at least the molding material used in the test. In addition, regarding the surface temperature adjustment of the molding die, molding was performed in anticipation of a large temperature variation and difficulty in stabilization, and when the high temperature part was about 65 ° C.
2) The temperature characteristics of this mold were examined.
The following was attempted with the aim of carrying out compressed air shaping with this mold at a high surface temperature.
Ａ）１００及び１２５℃の温度に調整したプレートに常温の成形型を乗せて加熱したとき、それぞれ表面温度の昇温定常化には約６０、９０分と極めて長い時間を要した。 A) When a normal temperature mold was placed on a plate adjusted to a temperature of 100 and 125 ° C. and heated, it took an extremely long time of about 60 and 90 minutes to stabilize the surface temperature.
Ｂ）このときの表面温度の下部、中位、上部の平均はそれぞれ５０、６２℃で、部位による大小の温度差がいずれも２０〜２５℃と大きい値であった。そして加熱プレートとの温度差は非常に大きくなり、部位によっては７１℃にも達していた。 B) The averages of the lower, middle and upper surface temperatures at this time were 50 and 62 ° C., respectively, and the temperature difference depending on the site was as large as 20 to 25 ° C. And the temperature difference with a heating plate became very large, and it had reached 71 degreeC depending on the site | part.
Ｃ）上記は静止した空気での値であるが、環境の影響を調べてみたところ、空調機による気流、熱盤による放射熱等により変わり、また温度バラツキが更に大きくなった。 C) The above values are for still air, but when the influence of the environment was examined, it changed due to airflow by the air conditioner, radiant heat from the hot platen, etc., and the temperature variation further increased.
Ｄ）表面温度を平均１００℃以上の設定にする試みを行った。しかしプレート温度を型材の耐久耐熱温度（８０℃）を遙かに超える１８０℃以上の設定にしてもそれわ達成することはできず型を損傷してしまった。
この２）のテスト結果から、次の結論を導くことができる。
D) An attempt was made to set the surface temperature to an average of 100 ° C. or higher. However, even if the plate temperature is set to 180 ° C. or higher, which far exceeds the durable heat resistance temperature (80 ° C.) of the mold material, it cannot be achieved, and the mold is damaged.
The following conclusion can be drawn from the test result of 2).
このようなｂ値の小さな材料を用いた成形型では表面温度調整に関して；
ａ）自由な温度設定がしにくく、特に高温設定ができない。
In the mold using such a material having a small b value, the surface temperature is adjusted;
a) It is difficult to set a free temperature, and in particular, a high temperature cannot be set.
ｂ）昇温安定化に非常に長い時間を要する。 b) It takes a very long time to stabilize the temperature rise.
ｃ）部位による温度バラツキが大きい。 c) Large temperature variation due to the site.
ｄ）環境条件の影響を受けやすい。
以上１）２）のテスト結果からは次の結論を導くことができる。
d) It is susceptible to environmental conditions.
The following conclusions can be drawn from the test results of 1) and 2).
ａ）公知の圧空成形条件では熱処理を伴う成形が実現できない。 a) Molding with heat treatment cannot be realized under known pressure forming conditions.
ｂ）圧空時の熱処理温度到達を容易にするために、表面温度を高温に
設定しよとしても任意の高温設定ができない。
b) In order to make it easy to reach the heat treatment temperature at the time of compressed air, even if the surface temperature is set to a high temperature, an arbitrary high temperature cannot be set.
ｃ）仮に設定可能範囲で熱処理可能な材料を選ぶことができたとして
も、能率的連続成形には不都合である。
c) Even if a material that can be heat-treated within a settable range can be selected, it is inconvenient for efficient continuous molding.
ｄ）大きな温度バラツキは均一で欠陥のない製品づくりの障害となる。 d) Large temperature variations are an obstacle to making uniform and defect-free products.
（本発明の効用）
適度な延伸配向を行ったポリエステル系樹脂シートを熱成形過程において熱固定を行うことにより、耐熱性、透明性、剛性等の高い熱成形品が得られるが、その成型品を、
(１) 高温の熱処理を伴う熱成形が容易にできる。
(Utility of the present invention)
By heat-setting the polyester-based resin sheet that has been appropriately stretched and oriented in the thermoforming process, a thermoformed product with high heat resistance, transparency, rigidity, etc. can be obtained.
(1) Thermoforming with high temperature heat treatment can be easily performed.
(２) 容易に高速で安定した連続成形を実現できる。すなわち背後層温度の調整により最短サイクルを容易に実現でき、その調整が容易に短時間に行うことができる。すなわち、成形材料、高温気体の温度や接触の条件、冷却気体の温度や接触条件等により加熱プロセス、冷却プロセス等の時間が大きく変わるが、境界温度サイクル等をモニターしながら、背後層温度を上下させることにより加熱時間と冷却時間のバランスをとりサイクル時間を最短にすることができる。 (2) Easily achieves high-speed and stable continuous molding. That is, the shortest cycle can be easily realized by adjusting the back layer temperature, and the adjustment can be easily performed in a short time. In other words, the time of the heating process and cooling process varies greatly depending on the molding material, high-temperature gas temperature and contact conditions, cooling gas temperature and contact conditions, etc. Therefore, the cycle time can be minimized by balancing the heating time and the cooling time.
(３) 短時間にヒートアップして生産開始ができ、また連続成形開始後、も短時間に定常状態を実現し品質不良品を最少にすることができる。 (3) Production can be started by heating up in a short time, and a steady state can be realized in a short time after the start of continuous molding to minimize defective products.
(４) 一つの成形型で、ＡからＣパターン（混合パターン、変形バーン含む）まで任意の成形パターンを、装置や製品設計に合わせ選ぶことができる。 (4) With one mold, any molding pattern from A to C pattern (including mixed pattern and deformation burn) can be selected according to the device and product design.
(５) 均一な加熱冷却ができ 高品質な熱成型品が得られる。 (5) Uniform heating and cooling are possible, and high-quality thermoformed products can be obtained.
(６) 高温の火傷しやすい材料に対しも、火傷や曇りのないきれいな成形品が得られる（特に Ａパターン、Ｂパターン）。 (6) A clean molded product free from burns and fogging can be obtained even for materials that are easily burned at high temperatures (especially A pattern and B pattern).
(７) 気体加熱装置、あるいは気体冷却機構を有しないあるいは機構しか有しない成形機でも、高速の熱処理成形が実現できる（Ｃパターン）。 (7) High-speed heat treatment molding can be realized even with a gas heating device or a molding machine having no or only a gas cooling mechanism (C pattern).
(８) 成型機をシートの予熱オーブンを有しないコンパクトな装置にして利用することもできる。 (8) The molding machine can be used as a compact device without a sheet preheating oven.
１ 成形型本体 ２ 成形用表面層 ３ 真空孔
４ 導気孔 ５ 熱媒通路
1
4 Air conduction holes 5 Heat medium passage
Claims (8)
該表面層は熱浸透率（ｋＪ／ｍ２ｓ１／２Ｋ）が０．０１〜２５の材料により形成されると共に下式：
Ｆα１／２×１０３＞ｔ＞Ｇ ・・・・・・（１）
（式中、ｔ；表面層の厚み（ｍｍ）、α；温度伝達率（ｍ２／ｓ）、Ｆ；３０、Ｇ；０．０４）で表される厚みを有し、かつ前記背後層の熱浸透率は前記表面層より大きい材料により形成されている成形型を用い、賦形から離型までの過程において少なくとも一時的にその成形型表面層の表面温度又は賦形体との界面温度を（当該成形材料樹脂のＴｇ＋５０℃）以上の温度にして成形を行うことを特徴とする熱成形品の製造方法。 In thermoforming the stretched polyester resin sheet, as a mold, a thermoforming mold having a thermoforming surface layer and a back layer adjacent thereto,
The surface layer is formed of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.01 to 25 and has the following formula:
Fα 1/2 × 10 3 >t> G (1)
(Wherein, t: thickness of the surface layer (mm), α: temperature transfer rate (m 2 / s), F; 30, G; 0.04), and the back layer The heat permeability is a mold formed of a material larger than the surface layer, and the surface temperature of the mold surface layer or the interface temperature with the shaped body is at least temporarily in the process from shaping to mold release ( A method for producing a thermoformed product, wherein the molding is performed at a temperature equal to or higher than Tg + 50 ° C. of the molding material resin.
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