WO2013015169A1 - Thermoforming apparatus and forming method - Google Patents

Thermoforming apparatus and forming method Download PDF

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Publication number
WO2013015169A1
WO2013015169A1 PCT/JP2012/068191 JP2012068191W WO2013015169A1 WO 2013015169 A1 WO2013015169 A1 WO 2013015169A1 JP 2012068191 W JP2012068191 W JP 2012068191W WO 2013015169 A1 WO2013015169 A1 WO 2013015169A1
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WO
WIPO (PCT)
Prior art keywords
temperature
molding
compressed air
mold
air
Prior art date
Application number
PCT/JP2012/068191
Other languages
French (fr)
Japanese (ja)
Inventor
福村　三樹郎
Original Assignee
Fukumura Mikio
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2011165069A external-priority patent/JP5771794B2/en
Priority claimed from JP2011206514A external-priority patent/JP5807873B2/en
Priority claimed from JP2011206515A external-priority patent/JP5811339B2/en
Priority claimed from JP2011254641A external-priority patent/JP5971511B2/en
Application filed by Fukumura Mikio filed Critical Fukumura Mikio
Publication of WO2013015169A1 publication Critical patent/WO2013015169A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/428—Heating or cooling of moulds or mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7132—Bowls, Cups, Glasses

Definitions

  • the present invention relates to a method for producing a thermoformed article using a thermoplastic resin sheet or film, and relates to heating and / or cooling a shaped body during thermoforming at high speed, and further to a crystalline thermoplastic resin.
  • the heat treatment at a temperature higher than the preheating temperature of the sheet is performed, and regarding the high-speed and efficient production of thermoformed products with high mechanical properties such as heat resistance and transparency, the crystalline resin It relates to performing this thermoforming using a stretched sheet.
  • the thermoforming method is a method in which a preheated thermoplastic resin sheet or film is formed on a mold by pressing or evacuation and then released. Usually, the shaped body is released in a state of being cooled by a low-temperature mold.
  • a mold material a material such as aluminum or zinc alloy that is lightweight and has good workability and good thermal conductivity is used, and it is often continuously formed by natural heat dissipation.
  • the jacket provided inside the mold is cooled through a heat medium.
  • cheap and easy-to-process materials such as wood and plastic may be used, but these are not durable and difficult to control temperature, causing problems such as heat accumulation, making them suitable for continuous mass production.
  • its use is limited to sample trial production or small-scale production on a single-wafer molding machine.
  • Japanese Examined Patent Publication No. 56-7855 is a method of thermoforming a polyester sheet by uniaxially stretching and heat-shrinking the sheet, Although a method of heat setting by using hot air at the time of molding is disclosed, the heat treatment takes a very long time and is not practical.
  • Japanese Patent Publication No. 5-45412 discloses a method of performing thermoforming and heat treatment using a biaxially stretched and heat-shrinked sheet under specific conditions.
  • a method of transferring to a heating type, a heating method using hot air, hot water, infrared rays, etc. has been proposed, but it is not specifically described, and even if these are simply executed, there is no effect. And, if at all, it is not a fast, efficient and practical method.
  • Japanese Patent Publication No. 60-031651 also shows that a specific stretched polyester sheet is thermoformed and heat-treated, and it is shown that it is molded with a heated mold, but the mold or molded product is cooled and separated. There is no mention of typing. However, for heat treatment molding of such materials, it is desirable to cool the molded body to at least a temperature lower than the heat treatment temperature and release the mold. However, if this is done by a known method, the mold itself is electrically heated. And a method of cooling in advance by passing water through a mold jacket immediately after molding, or a method of alternately passing a high temperature heat medium and a low temperature heat medium through the mold manifold. However, such a method cannot perform continuous molding at high speed.
  • Patent 2532730 shows a method in which a non-stretched crystalline PET sheet is molded with a heated female mold, transferred to a low-temperature female mold, cooled, and released. At that time, deformation of the molded product, displacement, and generation of wrinkles become problems, and it is necessary to create a special dedicated molding apparatus capable of such operation.
  • Japanese Patent Publication No. 7-102608 shows a method of molding with a high-temperature female mold, taking it into a low-temperature male mold fitted to the mold, cooling it, and releasing the mold. It may be said that the method is the same as (4), and deformation and wrinkling of the molding become a problem as well, and it is difficult to apply to a molded product having an offset or undercut.
  • the molding of so-called CPET as in (4) and (5) if molding is performed with a high-temperature mold from the beginning, the molding material does not slide smoothly on the mold surface, and thus unevenness such as waves and unevenness is generated. There is also a problem that a pattern is likely to appear. To avoid this problem, a process of forming with a low temperature mold and then shifting to a high temperature mold is known, but this is also complicated.
  • a method disclosed in Japanese Patent No. 4057487 relates to thermoforming of a crystalline resin, and a sheet preheated in contact with a heating plate is compressed and shaped with hot air passing through the hot plate and a molding die. Then, cooling air jetting means prepared separately is carried in and cooled, but this heating plate is adjusted to an appropriate temperature for sheet preheating, and heated air is supplied from behind to produce heated and compressed air.
  • the heated gas is cooled in a conduit passing through the hot plate, and a very high temperature gas must be passed through the heat treatment, in which case the hot plate temperature is localized and non-uniform, and the material sheet is Local overheating tends to hinder good molding.
  • the disclosed cooling means cannot cool a large area uniformly and efficiently. Also, heat from the high temperature gas is easily dissipated into the mold, and the sheet cannot be easily heated to a high temperature in a short time, and high speed molding cannot be performed.
  • US Pat. No. 5,119,176 proposes a method in which a resin sheet once biaxially stretched is heated and thermally contracted onto a male mold. Although this method may improve the formability, a sufficient orientation effect cannot be used, and there are many molding restrictions such as a shape having an offset portion. There is no disclosure of rapid heat setting and cooling mold release.
  • JP2011-245463, JP2011-245644, JP2011-245650, and JP2011-245651 relate to a manufacturing method and a mold associated with the present application, and are the same as the present invention. It was made by a person. The present inventor has further invented 10 applications for a molding apparatus for carrying out these methods. This application gives priority to the application regarding these shaping
  • Non-Patent Documents 1 and 2 below show examples of known typical pneumatic boxes and heating plates to be compared with the pneumatic structure having a novel structure that forms part of the configuration of the present invention.
  • Japanese Patent Publication No.56-7855 Japanese Patent Publication No. 5-45412 Japanese Patent Publication No. 60-031651 Japanese Patent No. 2532730 Japanese Examined Patent Publication No. 7-102608 Japanese Patent No. 4057487 US Patent 519176 JP2011-245643 JP2011-245644 JP2011-245650 JP2011-245651
  • the present invention has been made in view of such problems of the prior art. Its main purpose is to heat the shaped body at high speed and cool it as necessary at high speed in the process from thermoforming to mold release, especially heat treatment at a temperature higher than the preheating sheet temperature before shaping. It is an object of the present invention to provide a thermoforming apparatus that can perform thermoforming for releasing at high speed and efficiently and obtain a molded product in a uniform and good state.
  • thermoforming apparatus capable of pressure forming of a resin sheet
  • a compressed gas is directed from the air supply opening to the upper part of the forming die as a pressure air plate or a pressure air box (both are also referred to as “pressure air means” hereinafter).
  • a second mechanism for sucking the gas sent to the compressed air space from the intake opening and exhausting it to the outside and the following 1) and 2), that is, 1) A structure in which the gas delivery of the first mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box, and 2) the second mechanism.
  • thermoplastic resin sheet molding apparatus using at least one of a structure in which intake air is accommodated in the air collecting space provided inside the compressed air plate or the inside of the compressed air box through a plurality of intake openings and guided to the outside.
  • said compressed air box is a housing
  • the shape does not necessarily need to be a square, and in particular, the shape of the open surface can be changed to any shape according to the shape of the mold.
  • the above-mentioned compressed air plate has a structure in which the mold facing surface is a flat plate or the like, and even if it cannot form a closed compressed air space by itself, it is combined with a mold having a peripheral wall or a mold storage box.
  • the shape object which can form a compressed air space, without passing through the process which contacts a resin sheet effective surface.
  • the compressed air means further comprising a mechanism for sending a separately introduced compressed gas from a separately provided delivery opening toward the upper part of the mold.
  • the high-temperature compressed gas in the third mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box.
  • the above-mentioned (1) to (5) are provided with a function of heating the compressed gas introduced inside any one of the above-mentioned air feeding mechanisms to a sufficient temperature of 200 ° C. or more and feeding it.
  • a molding apparatus according to any one of the above is provided.
  • the above-mentioned characterized in that at least the molding surface is formed of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.01 to 25 as the molding die ( The molding apparatus according to any one of 1) to (7) is provided.
  • the heat permeability is preferably 20 or less, more preferably 15 or less, and still more preferably 10 or less.
  • the definition of the mold material mentioned here excludes a coating agent or plating of about 50 ⁇ m or less for lubrication, mold release and the like applied to the molding surface, wear protection and scratch prevention. Shall be.
  • the mold is characterized by comprising a surface layer made of a material having a thermal permeability (b value) of 20 or less and a back body made of a material having a thermal permeability (b value) larger than that of the surface layer.
  • the molding apparatus according to any one of (1) to (8) above is provided.
  • the heat permeability is preferably 15 or less, and more preferably 10 or less.
  • it is preferable that such a mold has a configuration in which heating temperature adjusting means is further provided in close contact with the entire surface behind the surface layer, or heating temperature adjusting means is provided on the back body.
  • thermoforming or molding includes all steps from preheating to release of a resin sheet, and the step of forming a shape by vacuum or compressed air is called “shaping” or “shaping step”. .
  • shape body a molded product that has been shaped and is still held in the mold.
  • Thermoforming using the molding apparatus of the present invention has the following effects.
  • the apparatus of the present invention is a process at which the resin sheet is heat-treated at a temperature substantially exceeding the preheating temperature of the resin sheet in the process of preheating and releasing, and then cooled and released at a very high speed. It can be executed continuously, efficiently and stably.
  • the use of the above-described compressed air means in the configuration of the present invention facilitates the continuation and control of high-temperature gas injection.
  • the shaped body can be heated uniformly and powerfully, and the heat treatment time can be shortened.
  • the temperature setting of the mold can be lowered and the cooling time can be shortened.
  • a uniform and powerful heating temperature can be raised, so that the degree of freedom in designing the mold configuration is increased, and a low-cost mold can also be used.
  • the moving time of the cooling means can be saved and the molding cycle can be speeded up.
  • a stretched sheet of a crystalline thermoplastic resin that is difficult to be formed by stretching can be easily thermoformed.
  • Molding involving high-temperature heat treatment of a large number of molded products or small molded products can be performed on the entire surface uniformly, with a short molding cycle and with low energy consumption.
  • thermoformed product having excellent mechanical strength such as heat resistance, transparency and rigidity, and as a result of improved rigidity, It has become possible to reduce the wall thickness of general-purpose products such as food trays and greatly save molding materials.
  • the molding apparatus of the present invention constitutes a pressure forming machine or a vacuum / pressure forming machine that is a thermoforming machine.
  • the resin sheet that is a molding material may be preheated by a molding machine that employs any known method such as indirect heating using a heating oven or the like, or direct heating in contact with a heating plate. Further, it may be one without such a preheating mechanism, and in that case, the mechanism of the present invention can have the function. Further, if necessary, a heating / compressed gas generating device is attached.
  • Such a thermoforming machine is equipped with at least compressed air means having the following basic mechanism.
  • This compressed air means is integrated with a first mechanism for sending compressed gas from the air supply opening toward the upper part of the mold and a second mechanism for taking in the gas sent to the compressed air space from the intake opening and exhausting it outside.
  • These mechanisms are: 1) a structure in which the gas delivery of the first mechanism is distributed and sent through a plurality of air supply openings from a distribution space provided inside the compressed air plate or the inside of the compressed air box, or 2 ) At least one of the structures in which the intake air of the second mechanism is accommodated in the air collecting space provided inside the compressed air plate or the inside of the compressed air box through a plurality of intake openings and guided to the outside.
  • either the air supply opening or the air intake opening may be provided at a position closer to the mold surface, which is preferable.
  • the air supply opening or the air intake opening may be provided directly in the distribution space or the air collection space, respectively, or may be provided via a conduit.
  • the conduit leading to the air supply opening or the intake opening passes through the air collection space or the distribution space, or penetrates between the spaces.
  • a normal temperature compressed gas may be introduced into the compressed air means from the outside, or a high-temperature heated compressed gas may be introduced, and molding conditions can be set.
  • the former case it is possible to cool the shaped body efficiently by keeping the mold surface at a high temperature and evacuating while performing compressed air shaping or continuing air supply after shaping.
  • the shaped body can be efficiently heated and heated by performing the air pressure shaping with the high-temperature gas or performing the exhausting while continuing the air feeding after the shaping.
  • a cold compressed gas can be efficiently cooled by introducing a normal temperature compressed gas to the exhaust side if necessary and operating the valve so as to exhaust from the air supply side.
  • the preferable aspect of this compression means is mentioned later.
  • the above pneumatic means is fixed to the top plate of the press machine, the mold is fixed to the bottom plate directly below, and at least one of the top plate and the bottom plate is movable up and down, and the pressure separation means and the mold are joined and separated. enable.
  • the resin sheet for molding is preheated and brought into the upper part of the mold, and the sheet is sandwiched by lowering the compressed air means or raising the mold, and shaped and cooled by feeding the above-mentioned compressed air body. Is released.
  • the compressed air means starts to rise and returns to its original position at an arbitrary time after shaping or heat treatment.
  • the compressed gas used for compressed air can use arbitrary things, if it is harmless to a human body, a molded object, etc., such as air, nitrogen, a carbon dioxide. Further, in order to enhance the cooling effect as necessary, moisture may be mixed into these gases, or fine droplets of volatile substances such as volatile substances such as alcohol may be mixed.
  • FIGS. 2 An example of the overall configuration will be described with reference to FIGS. 2 is a plan view of the lower surface of the compressed air box in FIG.
  • the forming die 60 is fixed on the bottom plate of the press machine, and the compressed air box 30 is fixedly arranged.
  • the compressed air box is configured by integrating the first mechanism and the second mechanism, respectively.
  • An air port (air supply body) 31 and an exhaust port (exhaust body) 21 are provided.
  • Reference numeral 100 denotes a resin sheet of a molding material. The molding machine itself, the press machine, the preheating means, the compressed gas generating device, etc. are omitted from this figure.
  • This figure shows a state in which the preheated resin sheet 100 has been introduced into the upper part of the mold 60.
  • the compressed air box 30 descends and pressure forming with compressed gas and heat treatment with a heated mold are performed.
  • the temperature is raised successively, followed by cooling with compressed gas.
  • Compressed gas is sent out from the delivery port 31.
  • the exhaust valve of the exhaust port 21 is opened at the same time as shaping or immediately after shaping, the gas in the compressed air space is renewed and the shaped body can be cooled efficiently. it can.
  • the compressed air box is raised and the shaped body is released.
  • the molding die configuration 60 in FIG. 1 is a molding die composed of a surface layer 61 and a back layer (back body) 62 fixed to a collecting plate 66 through a high-temperature heating medium through a heating medium passage 65 and stored in a storage box 67. It is.
  • the surface layer 61 is made of a material having a low heat permeability
  • the back layer 62 is made of a material having a high heat permeability
  • the surface layer 61 is heated to a sufficiently high temperature via the back layer 62 to form a shaped body. Heat. Since the heat permeability of the surface layer 61 is small, the shaped body can be cooled efficiently by gas blowing.
  • the structure of the compressed air box shown in FIG. 1 can be left as it is, and the upper stage at the bottom can be used as an air supply port (that is, the first mechanism) and the lower stage can be used as an exhaust port (that is, the second mechanism).
  • an operation different from the above can be performed, and compressed air shaping with a high-temperature gas is performed by temporarily taking in a compressed gas heated to a high temperature externally and feeding it from an air-feeding port.
  • the shaped body can be heat-treated with a high-temperature gas, and if this is performed while exhausting from another port at the same time, efficient temperature rise can be continued.
  • a low temperature gas may be supplied from one of the ports, and if this is performed while exhausting from the other ports, the entire shaped surface can be uniformly and efficiently cooled.
  • the port is made of a material having a low thermal conductivity or has a structure that blocks heat.
  • the movement of the compressed air box or the mold does not necessarily have to be vertically moved up and down, and may be arbitrarily separated from each other by joining from an oblique direction, or may be separated by being joined by a specific track. .
  • the positional relationship between the shaping means and the molding die is relative, and raising the shaping means is synonymous with lowering the molding die, and the molding die may be lowered.
  • the shaping means may be inverted on the mold below.
  • the press machine may be rolled over, and a heavy mold or the like can be opened and closed easily and used as a preferred method. Instead of moving the cooling means to the upper part of the mold as described above, the mold may be moved to the lower part of the cooling means.
  • thermoforming machine constituting the present invention may be a single-wafer forming machine that forms short material sheets one by one, or may be a continuous molding machine that sequentially forms long material sheets. However, the latter is particularly preferable, and the characteristics of the present invention are exhibited to enable high-speed and efficient repetitive molding.
  • the inventor of the present invention Prior to the international application of the present invention (hereinafter referred to as “the present application”), the inventor of the present invention has disclosed, as inventions related to the molding apparatus of the present invention, Japanese Patent Application Nos. 2011-41294, 2011-165067, and 2011-165068.
  • Japanese patent applications No. 2011-165069, No. 2011-206514, No. 2011-206515, No. 2011-206516, No. 2011-254541, No. 2011-254640 and No. 2011-254640 have been filed in Japan.
  • This application is filed under the priority of Japanese Patent Application No. 2011-165069, Japanese Patent Application No. 2011-206515, Japanese Patent Application No. 2011-206514, and Japanese Patent Application No. 2011-2546410.
  • ⁇ Pressure plate or box> The concept of a well-known commonly used pressure plate or pressure box is to cover a mold or a group of molds sandwiched between resin sheets, create a closed space between the resin sheets, and send compressed gas into this closed space to form a compressed air It is a tool for performing.
  • compressed air molding is performed with a normal temperature compressed gas, and when air injection cooling is performed, air injection cooling is performed from the outside toward the space where the compressed air device is moved.
  • Japanese Patent No. 4057487 discloses a mechanism for moving the air injection means to the same space, but this mechanism cannot quickly start cooling, and can also provide a large shaping area uniformly. It cannot be cooled efficiently.
  • a compressed air plate or a compressed air box used in a thermoforming apparatus capable of pressure forming a resin sheet sends compressed gas from an air supply opening toward an upper part of a mold.
  • 1 mechanism and a second mechanism for sucking the gas sent to the compressed air space from the intake opening and exhausting it to the outside and the following 1) and 2), that is, 1) A structure in which the gas delivery of the first mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box, and 2) the second mechanism.
  • At least one of the structures in which the intake air is accommodated in the air collection space provided inside the compressed air plate or the inside of the compressed air box through a plurality of intake openings and guided to the outside is used.
  • the gas blown to the shaped body can be continuously updated in the compressed air space, and the entire area formed by a large shaped body or a large number of shaped bodies can be uniformly and efficiently cooled. It becomes. Furthermore, by introducing a gas heated to a high temperature at an arbitrary time and feeding it, the entire area formed by the resin sheet of the molding material or the large shaped body or a large number of shaped bodies is uniformly and efficiently heated. It becomes possible. In addition, the effect of sending a high-temperature gas will be described later in the column of the second invention.
  • FIG. 7 shows the simplest example of the above-described compressed air box of the present invention.
  • the compressed air box 30 in this figure has a structure in which an air supply port 31 includes a compressed gas introduction path 33, a distribution space 34, and a plurality of dispersed air supply openings 35 as the first mechanism.
  • the exhaust passage 23, the plurality of dispersed intake (collection) openings 25, and the exhaust conduit 28 have a structure having no air collection space. With this structure, air can be uniformly supplied to the entire surface of the shaping object, and gas can be collected and exhausted from the entire surface.
  • the temperature of the compressed gas can be arbitrarily selected. In the case of using room temperature gas, a hot mold can be used, and cooling with air supply gas can be performed following room temperature pressure shaping.
  • the temperature rising heat processing of a shaped object can be performed following a high temperature compressed air shaping.
  • the shaped body can be cooled depending on the temperature setting of a special mold described later, if necessary.
  • high temperature gas what is necessary is just to manufacture an air supply port with a material with small heat permeability, and to form a channel
  • FIG. 3 An example different from the above will be described with reference to FIG.
  • This example is a modification of the embodiment having both the distribution space and the air collection space, similar to the example shown in part of FIG. 1 and FIG.
  • the air supply port 31 (first mechanism) and the exhaust port 21 (second mechanism) are inserted alternately into the bottom inside of the compressed air box 30 (bottom of the compressed air space) instead of the vertical relationship.
  • the exhaust port 21 is from the exhaust path 23, the air collection space 24, the intake opening 25, and the operation valve 23v.
  • the air supply port 31 is the compressed gas introduction path 33, the distribution space 34, the air supply opening 35, the air supply surface. 36, a compressed air space 39, and an operation valve 33v.
  • the air supply / exhaust surface 36 is shifted up and down from the air supply / exhaust surface 29, but they may be arranged on the same plane.
  • the opening may be a simple hole, and may have any shape such as a slit shape.
  • Each opening may be provided at the end of a conduit having an arbitrary length connected to each port, or a known dispersion nozzle may be connected.
  • the gas introduced into the air supply port 31 is supplied to the compressed air space 39, and the supplied gas is collected into the exhaust port 21 and exhausted to the outside. It is possible to obtain the same effect by operating in the same manner as in FIG.
  • the structure of the compressed air box in FIG. 3 can be used as it is, and the exhaust port shown in the figure can be used as an air supply port, and the air supply port can be changed to an exhaust port.
  • the section between the air supply port 31 and the exhaust port 21 in the figure may be eliminated, and both may be formed of an integral material, or a gap may be partially provided between the two, or a heat insulating material may be provided. It may be inserted.
  • the functions of the air supply port 31 and the exhaust port 21 may be interchanged in the configuration of this figure, or gases having different temperatures and the like may be sent out sequentially from different ports by switching the operation valves 23v and 33v. Can be implemented.
  • FIG. 3 of this invention performs sending (injection) of the gas for cooling at least
  • a heating temperature adjusting means for example, any known method such as addition of a heater or circulation of a heat medium can be used.
  • compressed air shaping can be performed while preheating the resin sheet, and 3) the effect of facilitating the temperature rise of the shaped body by the high-temperature gas is obtained.
  • the function of pre-heating the resin sheet at the forming position and forming it almost simultaneously with pre-heating is particularly important when the molding material is a stretched sheet, which minimizes heat fixation before shaping. Enables fine detail molding.
  • FIGS. 4 includes an air supply port 31 and an exhaust port 21, and the air supply port 31 is heated by a built-in cartridge heater.
  • the compressed air plate alone cannot form a compressed air space
  • the mold is stored in a storage box having a side wall higher than that of the mold, and the preheated resin sheet 100 is evacuated from the mold side. Then, the compressed air box 30 is lowered and the compressed air space 39 is formed.
  • heated compressed gas is introduced from the outside through the introduction passage 33 and supplied from the air supply port 35 to perform compressed air shaping, and then non-heated compressed gas is introduced through the introduction passage 23 and injected from the intake port 25. Let the shaped body cool.
  • the shaped body With this operation, if the heated compressed gas is continuously supplied while exhausting the gas in the compressed air space through the intake port 25, the shaped body can be easily heated, and the exhaust gas is being exhausted through the air supply port 35. The shaped body can be easily cooled by continuing to feed the non-heated gas from the intake port 25. If the operation is performed as described above, the resin sheet does not substantially contact the compressed air plate, so that it can be set to any high temperature unrelated to the sheet preheating temperature.
  • the heat insulating material 28 is provided in order to prevent the partial high heat action on the resin sheet, another mechanism capable of blocking heat may be used such as passing water only through this portion.
  • FIG. 4 A heating means is added in the same manner as in FIG. 4, and a structure slightly different from this is shown in FIG. This figure shows the state in which pressure forming is performed by completely lowering the pressure box by introducing vacuum forming after the introduction of the preheating sheet.
  • the air supply mechanism 31 and the exhaust mechanism 21 are vertically stacked as in FIG. 1, a heater 32 is added to the air supply mechanism, and the air collection pipe is extended to form the exhaust opening 25.
  • the structure is close to the mold.
  • the exhaust mechanism 21 includes an exhaust path 23, an air collection space 24, an air collection pipe 26, an air collection surface 29, an intake opening 25, and an operation valve 23 v, and an air supply port 31 includes a heater 32 and a high-temperature compressed gas introduction path 33.
  • the apparatus in FIG. 4 can be operated in the same manner as in FIG. 3, and in the shaping process and heat treatment process in the first half of the process, the air supply mechanism 31 and the exhaust mechanism 21 are respectively the air supply mechanism and the exhaust mechanism as their names indicate. Operate as In the cooling process in the latter half of the process, the air supply mechanism 31 is operated as an exhaust mechanism and the exhaust mechanism 21 is operated as an air supply mechanism.
  • the heater 32 is for keeping or heating the introduced high-temperature gas. Switching between air supply and exhaust of each mechanism is performed by operation valves 23v and 33v.
  • the compressed air box is not necessarily in the lowered state, and the cooling gas may be injected while the pressure box is raised.
  • the height of the intake opening is adjusted to the depth of the depression of the mold, and in this way, the gas sent from the air supply opening 35 is sufficiently continuously applied to the surface of the shaped body. It can reach an effective and uniform heat treatment temperature increase.
  • the cooling step strong gas injection is performed from the intake opening 25 to the shaped body, and uniform and effective cooling of the entire shaped surface can be continued.
  • the air collection pipe 26 may be shortened (that is, the height of the air collection surface is lowered), and the air supply opening 35 may be brought closer to the forming die with a lead pipe.
  • the compressed die is provided with a separately introduced compressed gas from a delivery opening provided separately.
  • a more preferable device can be obtained by further providing a mechanism for feeding toward the upper part.
  • the position and type of the dedicated opening for each purpose can be determined, and powerful heating and cooling or cooling can be performed.
  • each mechanism It becomes possible for each mechanism to support each other without interfering with each other's action.
  • the high-temperature compressed gas in the third mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the compressed air box bottom.
  • a preferable molding apparatus can be obtained.
  • FIG. 6 shows an example in which the third invention and the fourth invention are embodied together.
  • a hot gas delivery mechanism 31 and an exhaust mechanism 21 are arranged in parallel at the bottom of the compressed air box 30, and openings 35 and 25 are directly provided in the mechanisms, respectively.
  • the gas delivery port 11 is arranged and an air feed opening 15 directed toward the mold is provided at the tip of the air feed pipe 16.
  • a heater 32 is added to the hot gas delivery mechanism 31.
  • the delivery of the high temperature gas by 31 is used for shaping and heat treatment of the resin sheet, the delivery of the low temperature gas by 11 is used for cooling the shaped body, and the exhaust by 21 continuously increases the temperature rise and cooling of the shaped body by heat treatment. Made to do efficiently.
  • Each operation of air supply and exhaust can be performed by the valves 11v, 22v, and 33v, and the timing of exhaust can be arbitrarily set as appropriate.
  • a heating temperature adjusting means to the third mechanism to deliver a high-temperature compressed gas from a delivery opening.
  • the gas temperature for pressure forming and the temperature for heating can be set separately, the degree of freedom in setting conditions according to the molding material and the like is increased, and (2) the heat loss is effectively reduced Heat treatment is possible, and operation of the apparatus is facilitated.
  • the compressed gas introduced inside the air feeding mechanism having any one of the heating temperature adjusting means of the apparatus of the present invention is 200 ° C or higher, and preferably 250 ° C or higher. More preferably, it can be preferably used by providing it with a function of 300 or more sufficiently heated and delivered. This can be done, for example, by sufficiently increasing the gas contact area of a heat medium such as metal heated inside the mechanism and sufficiently increasing the heating capacity of the heating means, and this method is preferable.
  • the inside of the mechanism may be constituted by a porous material or a granular solid heat medium. Note that a known hot plate or the like does not have this mechanism and cannot continue supplying gas at a sufficient temperature.
  • the fifth aspect of the invention has the advantage of eliminating the need for precision parts such as valves that require a high degree of heat resistance by eliminating the external gas heating device, making the entire device compact, eliminating heat loss due to the movement of hot gas. Bring me.
  • a molding apparatus in which the molding die facing surface of the compressed air plate or the compressed air box bottom can be heated and maintained at 200 ° C. or more and the infrared emissivity is 0.8 or more. It can be preferably used. Specifically, for example, an apparatus in which the high-temperature gas delivery surface 36 in FIGS. 4, 5, and 6 can be maintained at 200 ° C. or higher, further 250 ° C. or higher, and further 300 ° C. or higher can be preferably used. . Further, an apparatus having an infrared emissivity of 0.8 or more by applying a commercially available black paint for infrared radiation on this surface can be preferably used.
  • this sixth invention 1) it is possible to preheat the resin sheet at the shaping position, or to perform shaping immediately after finishing preheating (when preheated material is introduced), or to perform shaping while preheating. 2) The effect of reducing the deterioration of the shapeability due to the progress of heat setting of the stretched resin sheet and 2) heating the shaped body for heat setting or assisting the heating are brought about.
  • the compressed air means may further be configured as in the following 1) to 8), and these embodiments can be preferably used.
  • you may comprise so that sending gas can be changed into different gas, such as temperature, from the same air supply main body at the arbitrary time of 1 shaping
  • it is preferable to use a heat insulating material with a low thermal permeability for at least the inside of the air supply mechanism, and to make the air supply passage etc. appropriately between the two gas temperatures. That is preferred.
  • the heat treatment temperature of the shaped body may be raised with a heated gas, and then cooled with a low-temperature gas.
  • the compressed air shaping may be performed with a heated gas or a low temperature gas.
  • the basic structure shown in each of the above drawings may be left as it is, and the exhaust mechanism 21 may be changed to an air supply mechanism and the air supply mechanism 11 or 31 may be changed to an exhaust mechanism.
  • the resin sheet can be preheated by air supply from the compressed air means or infrared radiation from the same means. It is preferable to perform this in a configuration in which the resin sheet is heated immediately before shaping or during shaping and gas is gradually fed.
  • a volatile liquid such as water or alcohol
  • a nozzle for spraying or spraying the shaped object from the inside of the compressed air box or the like may be provided.
  • the cooling gas is preferably at a temperature lower than room temperature, and may be cooled by immersing the compressed gas in a dry ice granule, or the dry ice powder may be mixed and jetted with gas, Or you may cool using the means of adiabatic expansion.
  • Each of the above-described compressed air means has a further improved mechanism and more excellent utility than those disclosed in Japanese Patent Application Nos. 2011-165067 and 2011-41294, the inventors of which are the inventors.
  • the compressed air means used in the configuration of the present invention has the following effects. 1) The gas can be sent out continuously as desired, and the process can proceed to the cooling process quickly, and the molding cycle can be shortened. 2) The entire molding surface can be cooled uniformly and efficiently, and a uniform and highly accurate molded product can be obtained. 3) The entire molding apparatus can be simply configured. 4) Powerful cooling can be performed. As a result, the design flexibility of the mold configuration that can be used can be greatly expanded, and a simple and low-cost mold can be used.
  • the mold used as the apparatus constituent element of the present invention is not particularly limited as long as it includes necessary elements for known thermoforming such as a vacuum exhaust hole.
  • at least a molding surface is formed of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.01 to 25 as a molding die of the apparatus component of the eighth invention of the present invention. It is preferable to use one.
  • the heat permeability is preferably 20 or less, more preferably 15 or less, and still more preferably 10 or less.
  • the molding die is made of a single material having a heat permeability of 2 or more and 25 or less, it is preferable to adjust the temperature by adding a heater or the like directly to the material layer.
  • a temperature control means such as a heater, and molding is performed in a continuous molding cycle using heating gas and cooling gas.
  • the mold surface temperature can be controlled.
  • Examples of materials having a thermal permeability within this range include plastics, ceramics, and a small number of selected metal materials. These include aluminum materials and zinc alloys that are commonly used as thermoforming molds. You can also choose from materials. Examples of materials having a preferred range of heat permeability can be selected from Table 1. However, the notation is shown for reference to general substances or objects, and what can be used is not limited to these.
  • the molding die may have a single structure made of only the above-mentioned material, or may have an arbitrary composite structure having the above material as a surface layer.
  • a mold having a surface layer made of such a material may have a surface layer itself that generates heat, or a layer that heats and controls the surface layer in close contact with the entire back surface of the surface layer, or a heat storage layer.
  • the thing of the provided structure can be utilized preferably. In this case, the back layer or the back of the temperature control mechanism is not specified, and there may be no back layer.
  • the mold shown as a desirable mode for the configuration of the present invention is a prior application filed by the present inventor, Japanese Patent Application Nos. 2010-118555, 2010-118490, It is disclosed in Japanese Patent Application Nos. 2010-118489, 2010-118562, and 2011-0665069, and further describes that they can be suitably used in the four device configurations based on the priority application.
  • the above-described mold used for the apparatus configuration is composed of a surface layer made of a material having a thermal permeability (b value) of 20 or less and a thermal permeability (b value) of that of the surface layer.
  • the heat permeability is preferably 15 or less, and more preferably 10 or less.
  • the thickness of this surface layer needs to be 0.04 mm or more, it is preferable that it is 0.06 mm or more, and it is still more preferable that it is 0.1 mm or more.
  • the thickness is preferably 30 mm or less, more preferably 10 mm or less, and even more preferably 5 mm or less.
  • the surface layer preferably has a substantially uniform thickness.
  • the heat permeability of the back body is preferably 2 times or more, and more preferably 10 times or more that of the surface layer.
  • the thickness or shape of the back layer is not limited.
  • the back layer is not limited to a single material layer, and may be an arbitrary multilayer.
  • the thermal permeability of the back layer is preferably 3 or more, more preferably 6 or more, and even more preferably 10 or more.
  • the thermal permeability of the back layer is preferably 2 times or more, and more preferably 10 times or more than that of the surface layer.
  • the above-mentioned mold used for the apparatus configuration is constructed by adding a means for adjusting the temperature of the surface layer from the back to the mold used for the above eighth or ninth invention.
  • any known method such as a method using an electric heater or a method using a heat medium can be used.
  • the temperature control on the heating side is preferable.
  • temperature control means may be added anywhere in the back layer or back body, and it may be provided in the layer or externally.
  • the surface layer is constantly heated by the conduction heat from the back layer.
  • the back layer is not particularly limited in this case, and the back layer may not be provided.
  • a method of forming a planar high heat transfer layer over the entire surface behind the surface layer and conducting heat from a specific position is also included.
  • the molds 2), 3) and 4) are those disclosed in Japanese Patent Application No. 2011-165069.
  • the mold 60 includes a surface layer 61 and a back layer 62, 63 is a vacuum exhaust hole, 64 is an exhaust passage, and 65 is a heat medium passage for temperature control.
  • a 0.5 mm epoxy resin layer or a polyimide resin layer is formed on the back layer of the aluminum material 5052, and a fine thermocouple is exposed on the molding surface through the back layer and the surface layer.
  • the mold is high performance.
  • temperature control means such as this heat-medium channel
  • the heating means is provided in close contact with substantially the entire back surface of the surface layer having the predetermined heat permeability.
  • the structure of the surface layer in this case is the same as that in 1) above in terms of material and dimensions, and the desirable structure is also the same.
  • the formation of the heating means is not limited to the following. For example, there is a method in which a) a planar heating layer is formed behind the surface layer, and b) a planar high heat transfer layer is formed to conduct heat from a specific position. There is no particular restriction on the presence, material, or shape of the back layer.
  • the back layer 72 is not particularly limited as long as the surface layer or the layer of the heating unit can be held without hindering the function of the heating unit, and the shape of the surface layer can be maintained. It should be possible to fix it somewhere.
  • FIG. 9 shows an example of the structure 2) above.
  • the mold main body 60 includes a heat generating layer 65 behind the surface layer 61 having the predetermined heat permeability, and further includes a rear portion 62 behind the heat generating layer 65.
  • 63 denotes a vacuum exhaust hole
  • 64 denotes an exhaust passage
  • 66 denotes a lead wire.
  • ceramic or the like may be used as a back body, and a sheet heating element may be laid and pasted thereon, and a surface layer may be formed thereon with a material having the predetermined heat permeability.
  • a heating element layer may be formed by plating and etching a nickel-based resistor metal on the back body.
  • the surface layer material examples include heat-resistant resins such as epoxy resin, fluorine resin, polyimide, and PEEK.
  • heat-resistant resins such as epoxy resin, fluorine resin, polyimide, and PEEK.
  • thermoplastic resin comprising a resin sheet preheating step, a shaping step, a heat treatment step for heat treatment at a temperature higher than the preheating step, and, if necessary, a cooling step.
  • a resin sheet molding method can be carried out.
  • these steps can be performed at high speed, and efficient continuous molding can be performed using a long molding material resin sheet.
  • a method for heat-treating the shaped body at a high temperature 1) a method for injecting the high temperature gas onto the shaped body, 2) a method for irradiating the shaped body with infrared rays, or 3 This is done using at least one method of shaping by heating the mold surface to a high temperature.
  • these methods can be selected according to the characteristics of the mold used, and heat treatment can be performed efficiently at high speed.
  • the resin sheet is preheated with a preheating oven or a heating plate, and then guided to the upper part of the mold, and the compressed air box or the mold is moved up and down to sandwich the resin sheet. It is performed by cooling and separating the shaped body by separating the compressed air box and the mold.
  • the compressed air shaping is performed by sending compressed gas at normal temperature or a preheat suitable temperature of the resin sheet or a temperature lower than that, and the shaped body is heated from a mold that is heated and adjusted to a temperature higher than the preheat optimum temperature of the resin sheet.
  • the shaped body is cooled by continuously sending compressed gas to the compressed air space.
  • the continuous delivery of the compressed gas to the compressed air space is performed by starting the exhaust from the exhaust body while continuing the compressed air.
  • Exhaust from the exhaust body can be started at an arbitrary time, may be exhausted from the time of shaping, may be started immediately after shaping, or may be started after a short time immediately after shaping. Also good. These optimum times vary depending on the mold used and the set temperature conditions.
  • thermoforming may be changed in the following specific manner and can be preferably used.
  • 1) shaping may be performed by feeding a preheat temperature of a resin sheet or heated compressed gas close to this temperature, and then cooling may be performed by a gas at a lower temperature such as room temperature.
  • 2) shaping may be performed while preheating the resin sheet while slowly feeding the preheat temperature of the resin sheet or heated compressed gas close to this temperature at the molding position, and 3) in the compressed air box It may be shaped while preheating the resin sheet by means of infrared irradiation means. Note: To prevent deformation of the shaped body, it is desirable to fix the shaped body by vacuuming the mold until release.
  • the apparatus setting or the condition setting in the molding as described above can be roughly described in three patterns.
  • the molding process involving heat treatment can draw a sine curve-like continuous molding cycle when looking at changes in the surface temperature (T) of the mold and the internal temperature (S) of the mold.
  • T surface temperature
  • S internal temperature
  • T surface temperature
  • T maximum temperature
  • Tb minimum temperature
  • Pattern A is a pattern for adjusting S to a constant temperature between Tt and Tb of the surface temperature cycle.
  • Tt is a temperature reached by high-temperature gas or infrared irradiation
  • Tb is a temperature reached by the cooling means.
  • Direct temperature control of the back layer may or may not be performed. If the molding is continued continuously for a long time in a state where heat does not escape so much from the back side, the back layer temperature S settles at Tt and Tb of the surface temperature cycle. In this case, if the thermal permeability of the back layer is not so large, S is not linear in time in the vicinity of the surface layer, but draws a small temperature cycle following the surface layer. It is desirable to positively and arbitrarily adjust the temperature of the back layer, and the heating means and the cooling means can be set to the optimum shortest time depending on the temperature.
  • Pattern B is a pattern for adjusting S to a constant temperature equal to or lower than Tb.
  • Tb is reached mainly by heat transfer from the back layer, that is, the temperature of S.
  • the cooling means is not essential, but if used, the cycle can be shortened.
  • Tt is reached by the heating means.
  • Pattern C is a pattern for adjusting S to a constant temperature equal to or higher than Tt.
  • Tt is reached mainly by heat transfer from the back layer, that is, the temperature of S. Therefore, the heating temperature control of the back layer is essential.
  • the heating means is not essential, but the cycle can be shortened if used.
  • Tb is reached by the cooling means.
  • the patterns C and A can be molded particularly efficiently.
  • the molding method of the present invention is characterized by performing a heat treatment at a temperature higher than that at the time of shaping of the resin sheet between shaping and cooling, and is characterized by being able to be performed at high speed continuously. .
  • the method of the present invention makes it possible to produce various molded products that are easily heat-treated with a wide range of resins.
  • Specific applications include: a) molding involving heat setting of a stretched sheet of a crystalline resin such as PET, b) molding involving crystallization of a crystalline resin sheet such as a crystal nucleating agent-added PET (CPET), or
  • CPET crystal nucleating agent-added PET
  • c) heat treatment molding can be proposed in which the residual stress distortion associated with SPPF molding (solid phase high pressure molding) of polypropylene is relaxed.
  • stretched PET can efficiently produce a thermoformed product having excellent mechanical strength such as heat resistance, transparency, and rigidity.
  • a material-saving molded product can be obtained by utilizing rigidity.
  • the thermal permeation rate (b value) used as the specified value of the present invention is a characteristic value of an object related to the amount of heat moving through the interface and the contacting object, and is obtained by the following equation.
  • b ( ⁇ C) 1/2 (1) ⁇ ; thermal conductivity (Js ⁇ 1 m ⁇ 1 K ⁇ 1 ), ⁇ ; density (kgm ⁇ 3 ), C; specific heat (Jkg ⁇ 1 K ⁇ 1 )
  • An object having a small b value flows only a small amount of heat to the interface and does not give a large temperature change to the counterpart object, and is greatly influenced by the counterpart object near the interface. Therefore, when the material having a small b value is used as the mold surface material, the heat from the shaped body is not diffused, so that the shaped body can be easily heated and cooled by the high-temperature gas and the cooling gas. However, since the heat of the back layer is not easily transferred to the surface layer surface (interface with the shaped body), the surface temperature is highly uniform, and the surface layer thickness is reduced for fast and stable condition setting. Or by increasing this b value to some extent, it can be optimized in accordance with the molding material.
  • the b value is about 17 to 23 for an aluminum material, about 13 to 16 for an iron material, about 34 copper, 8.0 for a non-rust steel (SUS306), and 0.0 for many synthetic resins. About 2 to 0.8, many ceramics fall between 1 and 20.
  • Table 1 illustrates the b values of some materials.
  • the b value also shows a slightly different value depending on the measurement temperature, but in the present application, strictly, it is defined by a measurement value of 20 ° C.
  • a composite material with a material having no linearity in a change between 20 ° C. and 200 ° C. for example, a heat storage agent accompanied by a phase change, an average value of 100 ° C. and 150 ° C. should be adopted. To do. It should be noted that even if the same material is used, if the shape changes to a foam or a porous body, this value will change greatly.
  • the above mold has a structure of two or more layers, the back layer of the surface layer is controlled to a constant temperature, and the molding surface temperature of the surface layer that changes in temperature by the heating gas and the cooling gas through the shaped body is set to a desired level.
  • Quick return to the reference temperature if the thickness of the surface layer exceeds 30 mm, the control of the back layer takes too much time to reach a steady state in response to the surface temperature, which is not practically effective.
  • this thickness is less than 0.03 mm, the influence of the temperature of a back layer is received greatly, and the effect which accelerates
  • the coating thickness is usually as thin as 30 ⁇ m or less. There is no need to increase the thickness, and there is a difficulty, and no device that can achieve the effects of the present invention has been produced.
  • a single material may be used, but in this case, there may or may not be direct temperature control on the mold, and in either case, the desired surface temperature may be stabilized to some extent. If the time is taken, the desired molding is possible.
  • a material composed of a single material having a thermal permeability b value (kJ / m 2 s 1/2 K) of 0.01 to 3 preferably has no heating temperature control mechanism, As for those composed of three or more single materials, those equipped with a heating temperature control mechanism can be used more preferably.
  • the above-mentioned mold has a fine hole that enables vacuum forming or evacuation at the time of forming, and is housed in the above-mentioned mold storing box so that it can be evacuated.
  • thermocouple tip having a wire diameter of about 0.1 mm is projected on the molding surface of the mold, and this can be measured.
  • thermocouple tip having a wire diameter of about 0.1 mm is projected on the molding surface of the mold, and this can be measured.
  • thermocouple tip having a wire diameter of about 0.1 mm is projected on the molding surface of the mold, and this can be measured.
  • thermocouple tip having a wire diameter of about 0.1 mm is projected on the molding surface of the mold, and this can be measured.
  • the temperature of the S-line is actively controlled to control the temperature of the mold itself. However, depending on the distance from the molding surface or the distance from the heat source, the molding cycle is repeated with a temperature gradient. It is also a value that stabilizes at.
  • these temperatures are considerably different from the surface temperature or interface temperature shown here. This is because when heating and cooling are performed in units of seconds or less, a large temperature gradient occurs in the thickness direction of the shaped body.
  • temperature measurement from the back of the shaped body with infrared rays or the like does not accurately represent the material temperature. In the present invention, it is expressed by the surface temperature (interface temperature), but there is a difference from this temperature and it is necessary to consider it as a relative value.
  • the stretched PET sheet was molded with heat treatment.
  • Molding device A single-wafer vacuum / pressure forming machine having a pressure capacity of 10 tons was used.
  • a pressure air box made up of an air supply port 31 and an exhaust port 21 made of aluminum was mounted in a box body 67 made of aluminum and having an effective inner dimension of 330 ⁇ 550 mm.
  • the gas supply / discharge surface 36 was provided with a hot gas outlet 35 having a diameter of 1 mm at every intersection of a grid lattice with a spacing of 30 mm, and a gas collection tube 28 was provided in the arrangement shown in FIG.
  • the exhaust port 21 and the air collecting pipe 28 have a function of exhausting from the compressed air space.
  • the air supply port 31 and the delivery opening 35 have a function of delivering the compressed gas to the compressed air space.
  • Molding mold Surface layer / back layer system 60 shown in FIG. 1, with aluminum A5052 (b value 17.4) as the back layer, and PEEK resin (b value 0.35) 0.14 mm above What formed the surface layer by the coating baking method was used.
  • the molded product is a round dish shape with a diameter of 90 mm and a depth of 30 mm, and 15 molds with an outer dimension of 110 mm square are fixed to the fixing plate of the heater's inner package and stored in a storage box with an inner dimension of 332 x 552 mm. It was.
  • the upper surface of the mold was 5 mm lower than the side wall of the storage box, and a 1 mm gap was provided from the side wall.
  • Temperature measurement thin wire thermocouple tip exposed on the molding surface, and the molding surface temperature and The shape body interface temperature can be measured.
  • the exhaust from the exhaust port 21 is operated, and the normal temperature gas is continuously supplied from the air supply port 31 to cool the shaped body at a compressed air pressure of 0.1 MPa for 1.5 seconds, thereby releasing the mold. .
  • the surface (interface) temperature at the time of mold release again decreased to about 160 ° C.
  • Example 1 In the apparatus configuration shown in Example 1, a partial change of the compressed air box and a used stretched PET sheet were changed to perform molding with heat treatment. Here, compressed air shaping was performed so as not to cool the preheating temperature of the resin sheet.
  • Molding material A 2.7-fold uniaxially stretched sheet of homopolyethylene terephthalate resin (though not heat-set) and a thickness of 0.21 mm were used.
  • Molding apparatus The same molding machine as in Example 1 was used.
  • the compressed air box is the same as that of the first embodiment, that is, a heater is attached to the air supply port 31 of FIG. 1, the air supply port is heated slightly, and a slightly heated compressed gas is introduced into the resin sheet. The gas can be delivered at the same temperature as the preheating optimum temperature.
  • the same mold as in Example 1 was used.
  • the exhaust from the exhaust body 21 was operated, and the shaped body was cooled by continuing the same gas supply from the air supply body 31 for 4 seconds, and the mold was released.
  • the surface (interface) temperature was lowered to about 160 ° C.
  • Example 1 In the apparatus configuration shown in Example 1, the molding die and the operating conditions were changed, and the same stretched PET sheet as in Example 1 was molded with heat treatment.
  • 1) Molding material A 2.5 times uniaxially stretched sheet of homopolyethylene terephthalate resin (those not heat-fixed) having a thickness of 0.22 mm was used.
  • 2) Molding device The molding die has the same shape and dimensions as those of Example 1, except that S45C (b value 16.1) is used as a steel material as a molding material. It was configured using.
  • Molding result A good molded product was obtained.
  • the molded product was resistant to hot water at about 100 ° C., and heat treatment was effective.
  • the product was contracted and deformed at the time of mold release, and a molded product having a good shape could not be obtained. This indicates that cooling has not been performed by the time of mold release.
  • the same surface temperature is shown in the process of heat treatment and cooling. However, it can be considered that the temperature gradient in the thickness direction of the shaped body has a cooling effect and that good mold release is possible.
  • Example 1 In the apparatus configuration shown in Example 1, the molding die and the operating conditions were changed, and molding with heat treatment of the stretched PET sheet was performed. The same molding material as in Example 3 was used. 1) Molding material : The same material as in Example 3 was used.
  • Example 2 Molding apparatus The same molding machine as in Example 1 was used. Also, the same pneumatic box as in Example 1 was used. The mold is of the surface layer / back layer type shown in 60 of FIG. 1 and the like, with aluminum A5052 (b value 17.4) as the back layer and SUS304 (b value 8.0) of 5.0 mm on it. What formed the surface layer was used. The shape, size, number, and the like of the molded product were the same as those in Example 1, and the same fixed plate and storage box were used.
  • Molding result A good molded product was obtained.
  • the molded product was resistant to hot water at about 100 ° C., and heat treatment was effective.
  • Example 1 In the apparatus configuration shown in FIG. 5, the same stretched PET sheet as in Example 1 was used, and thermoforming with heat treatment was performed. 1) Molding material : The same material as in Example 1 was used.
  • Example 2 Molding apparatus The same molding machine as in Example 1 was used. The external dimensions of the compressed air box were the same as those in Example 1. The same mold as in Example 1 was used.
  • Example 3 Molding method and molding conditions
  • the resin sheet was preheated to 95 ° C.
  • the surface temperature of the mold was preheated to 165 ° C.
  • the air supply port of the compressed air box was heated to 275 ° C., and heated compressed gas of 275 ° C. (original pressure 0.4 MPa) was introduced from the outside to supply air.
  • the compressed air box was lowered and joined to the mold, and at the same time, heated air was supplied from the air supply port 31 to perform a compressed air vacuum forming process with a compressed air pressure of 0.4 MPa for 0.5 seconds.
  • the vacuum suction from the mold was activated with the start of the descent of the compressed air box.
  • the heat treatment step was performed by continuing the supply of heated air to the compressed air space for 2.3 seconds by opening the operation valve 29 and evacuating with a delay of 0.5 seconds after the compressed air shaping.
  • the mold surface (interface) temperature reached 185 ° C.
  • the operation valves 23v and 33v are switched, and the introduced normal temperature compressed air is continuously sent out from the exhaust port 21, and the sent air is collected in the air supply port 31 so that the exhaust continues, and the cooling process is performed for 0.8 seconds. , Released. During this time, the vacuum operation from the mold side was continued.
  • the mold surface (interface) temperature at the time of mold release dropped to about 160 ° C.
  • Example 2 In the apparatus configuration shown in Example 1, the molding die and the operating conditions were changed, and molding with heat treatment of the CPET sheet was performed. Here, no cooling means was used. 1) Molding material; A commercially available CPET sheet for molding containing a crystal nucleating agent (Toyobo, thickness 0.5 mm) was used. In addition, this thing does not have an extending
  • the resin sheet was preheated and moved for 18 seconds in a preheating oven set at 550 ° C. and placed on the upper part of the mold.
  • the sheet preheating temperature is about 100 ° C.
  • a back body whose temperature was adjusted to 80 ° C. with a heating medium oil and the surface temperature of the mold was about 70 ° C. was used.
  • Heated air having a pressure of about 300 ° C. and an original pressure of 0.4 MPa was introduced into the air introduced into the compressed air box, and the air supply / exhaust surface 36 was adjusted to substantially the same temperature as the introduced gas.
  • Exhaust from the low-temperature air supply / exhaust body 21 was activated, and high-temperature gas was supplied from the high-temperature air supply body 31 to perform vacuum / pneumatic shaping and heat treatment with a pneumatic pressure of 0.2 MPa for 12 seconds. ;
  • the compressed air temperature was about 250 ° C.
  • the heat treatment temperature (interface arrival temperature) was 195 ° C.
  • the cooling gas was not blown, and the mold was released immediately after the heat treatment. After mold release, the mold surface temperature dropped to the original set temperature in a short time, and the next molding was possible.
  • thermoforming A molding process involving heat treatment and cooling mold release for heating the shaped body above the preheating temperature for shaping can be carried out at a very high speed, continuously, efficiently and stably.
  • thermoforming that involves heat setting of a stretched crystalline resin sheet.
  • the material include stretched sheets such as PLA, thermoplastic resin such as PET, crystalline resin such as polypropylene, polyamide, and PEEK.
  • stretched sheets such as PLA, thermoplastic resin such as PET, crystalline resin such as polypropylene, polyamide, and PEEK.
  • thermoforming that performs the above heat treatment using a stretched PET sheet, it is possible to efficiently produce thermoformed products having excellent mechanical strength such as heat resistance, transparency, and rigidity. Can do.
  • a crystalline resin sheet that has not been subjected to stretching treatment for example, can be used for molding involving crystallization of PET (CPET) to which a crystal nucleating agent is added, and this can be performed at a higher speed than before. it can.
  • CPET crystallization of PET
  • a new method, etc. that can be applied to SPPF molding of polypropylene (solid phase high pressure molding) to solve the disadvantages of this molding method (reducing residual stress distortion and improving heat-resistant dimensional stability). Can do.
  • Molding with heat treatment can be performed precisely, uniformly, without variation, at high speed and with energy saving, and the improvement in strength and rigidity due to orientation and crystallization has been converted to a material with reduced thickness, It is possible to contribute to the social needs for resource conservation.
  • Air supply port (Third mechanism) 13 Compressed gas introduction path 13v Air supply valve 14 Air supply space 15 Air supply opening 16 minutes Delivery air pipe 21 Exhaust port (second mechanism) 23 Exhaust vent (sometimes also a supply passage) 23v Supply / exhaust switching valve 24 Air collection space (sometimes also a distribution space) 25 Intake opening (may also serve as air supply opening) 26 Air collection tube (In some cases, a distribution tube) 27 Heat insulating material 28 Exhaust pipe 29 Air supply / exhaust surface 31 Air supply port (first mechanism) 32 Heating heater 33 Compressed gas introduction path 33v Supply / exhaust switching valve 34 Distribution space (also a collection air space in some cases) 35 Air supply opening 36 Air supply / exhaust surface 37 Box outer wall 38 Air pipe 39 Air pressure space 40 Pressure plate 60 Mold (or Mold group configuration) 61 Surface layer 62 Back layer (back body) 63 Vacuum exhaust hole 64 Exhaust passage 65 Heating medium passage or heater 66 Mold Integration Plate 67 Mold Storage Box 68 Lead Wire 69 Surface (Molded surface) 100 The

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

Provided is a thermoforming apparatus with which a forming body is subject to a high-speed heating or heating and cooling process during a thermoforming process and a heat treatment may be performed at a high temperature higher than a preheating temperature for the forming body so that mold release forming may be performed rapidly, efficiently and continuously. An air compression unit comprises a first mechanism and a second mechanism integrated with each other, the first mechanism sending compressed air from an air supply opening toward an upper portion of a forming die and the second mechanism discharging the air sent to a compression space after absorbing the air from an air intake opening. At least one of the two following structures is used: 1) a structure in which the air of the first mechanism is distributed and sent from a distribution space disposed in the air compression unit through a plurality of air supply openings, and 2) a structure in which air intake of the second mechanism is led to an outer side through a plurality of air intake openings after being accommodated in an air collection space disposed in the air compression unit.

Description

熱成形用の装置と成形方法Apparatus and method for thermoforming
　本発明は熱可塑樹脂のシート又はフイルムを用いた熱成型品の製造方法に関るものであり、熱成形中の賦形体を高速で加熱及びまたは冷却することに関し、更には結晶性熱可塑性樹脂の熱成形の過程において、シートの予熱温度より高温の熱処理を行い、耐熱性、透明性等、機械強度等の特性の高い熱成形品を高速で効率よく製造することに関し、なかんずく結晶性樹脂の延伸シートを用いてこの熱成形を行うことに関する。 The present invention relates to a method for producing a thermoformed article using a thermoplastic resin sheet or film, and relates to heating and / or cooling a shaped body during thermoforming at high speed, and further to a crystalline thermoplastic resin. In the process of thermoforming, the heat treatment at a temperature higher than the preheating temperature of the sheet is performed, and regarding the high-speed and efficient production of thermoformed products with high mechanical properties such as heat resistance and transparency, the crystalline resin It relates to performing this thermoforming using a stretched sheet.
　熱成形法は予熱された熱可塑性樹脂シートまたはフイルムを成形型に押圧または真空引きにて賦形し離型する方法であり、通常は、賦形体は低温の金型で冷却された状態で離型される。金型材料としてはアルミニウム、亜鉛合金などの軽量で加工性がよく、かつ熱伝導率の良い材料が使われ自然放熱で連続成形されることが多い。しかしそれでも特に温度調節を行いたい場合は成形型内部に設けたジャケットに熱媒体を通じて冷却することも行われる。一方、木材、プラスチックのような安価で加工し易い材料が使用されることがあるがこうしたものは、耐久性がなく、また温度調節が難しく熱蓄積などが問題となるため連続大量生産には向かず、枚葉成形機でのサンプル試作あるいは少量生産などに使用が限られる。 The thermoforming method is a method in which a preheated thermoplastic resin sheet or film is formed on a mold by pressing or evacuation and then released. Usually, the shaped body is released in a state of being cooled by a low-temperature mold. Typed. As a mold material, a material such as aluminum or zinc alloy that is lightweight and has good workability and good thermal conductivity is used, and it is often continuously formed by natural heat dissipation. However, in particular, if it is desired to adjust the temperature, the jacket provided inside the mold is cooled through a heat medium. On the other hand, cheap and easy-to-process materials such as wood and plastic may be used, but these are not durable and difficult to control temperature, causing problems such as heat accumulation, making them suitable for continuous mass production. However, its use is limited to sample trial production or small-scale production on a single-wafer molding machine.
　そして、特殊な成形方法として成形サイクル中に賦形体を任意に加熱したり冷却しようとするときは、上記のジャケットに通す熱媒を途中で熱媒を変更したり、あるいは賦形体を別に温度調整した金型へ移しかえたりすることが行われる。しかしこのような方法では所望の熱処理を行った成形品を高速で連続的に効率よく製造することはできない。
　なお、延伸された結晶性樹脂シートは、熱成形性が低下するので、これを改善するための提案も数々なされてきたが、商業的に殆ど成功していない。 And as a special molding method, when you want to heat or cool the shaped body arbitrarily during the molding cycle, change the heating medium in the middle of the heating medium passed through the jacket, or adjust the temperature of the shaped body separately It is performed to move to the mold. However, with such a method, a molded product that has been subjected to a desired heat treatment cannot be produced continuously at high speed and efficiently.
In addition, since the stretched crystalline resin sheet has reduced thermoformability, many proposals have been made to improve it, but it has hardly been commercially successful.
　特別な加熱あるいは冷却を必要とする具体的な熱成形方法として、（１）特公昭５６－７８５５号はポリエステルシートを１軸延伸配向させて加熱収縮させたシートを用いて熱成形する方法で、成形時に熱風を用いるなどにより熱固定する方法が開示されているが、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）特公平５－４５４１２号では、特定条件で２軸延伸し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、加熱型へ移し替える方法、熱風、熱水、赤外線になどよる加熱法が提案されているが、具体的には記載されておらず、単純にこれらを実行してもその効果はなく、またあったとしても高速で効率のよい実用的な方法とはならない。 As a specific thermoforming method that requires special heating or cooling, (1) Japanese Examined Patent Publication No. 56-7855 is a method of thermoforming a polyester sheet by uniaxially stretching and heat-shrinking the sheet, Although a method of heat setting by using hot air at the time of molding is disclosed, the heat treatment takes a very long time and is not practical. Also, (2) Japanese Patent Publication No. 5-45412 discloses a method of performing thermoforming and heat treatment using a biaxially stretched and heat-shrinked sheet under specific conditions. Here, a method of transferring to a heating type, a heating method using hot air, hot water, infrared rays, etc. has been proposed, but it is not specifically described, and even if these are simply executed, there is no effect. And, if at all, it is not a fast, efficient and practical method.
（３）特公昭６０－０３１６５１号も特定のポリエステル延伸シートを熱成形し熱処理する方法で、加熱された金型で成形することは示されているが、金型あるいは成形品を冷却して離型することについては触れられていない。しかし、このような材料の熱処理成形には成形体を少なくとも熱処理温度より低い温度に冷却して離型することが望ましいが、知られた方法でこれを行うとすれば、金型自体を電熱ヒーターで予め加熱しておいて成形直後に金型のジャケットに通水して冷却する方法、あるいは金型マニホールドに高温熱媒、低温熱媒を交互に通ずる方法などが考えられる。しかしこうした方法では高速で連続成形を行うことはできない。また（４）特許２５３２７３０号では、非延伸の結晶性ＰＥＴシートを加熱された雌型で成形しこれを低温の雌型に移して冷却し離型する方法が示されているが、金型移行に際しては、成形品の変形、位置ずれ、シワの発生が問題となり、またそのような操作ができる特殊な専用成形装置をつくる必要がある。 (3) Japanese Patent Publication No. 60-031651 also shows that a specific stretched polyester sheet is thermoformed and heat-treated, and it is shown that it is molded with a heated mold, but the mold or molded product is cooled and separated. There is no mention of typing. However, for heat treatment molding of such materials, it is desirable to cool the molded body to at least a temperature lower than the heat treatment temperature and release the mold. However, if this is done by a known method, the mold itself is electrically heated. And a method of cooling in advance by passing water through a mold jacket immediately after molding, or a method of alternately passing a high temperature heat medium and a low temperature heat medium through the mold manifold. However, such a method cannot perform continuous molding at high speed. Also, (4) Patent 2532730 shows a method in which a non-stretched crystalline PET sheet is molded with a heated female mold, transferred to a low-temperature female mold, cooled, and released. At that time, deformation of the molded product, displacement, and generation of wrinkles become problems, and it is necessary to create a special dedicated molding apparatus capable of such operation.
　また（５）特公平７－１０２６０８号は、高温の雌型で成形し、これに嵌合する低温の雄型に引き取って冷却し離型する方法を示しているが、これも金型移行の方法と云ってよく（４）同様に成形の変形やシワが問題となり、又オフセットやアンダーカットのある成形品には適用し難い。またこうした例とは別に、（４）及び（５）のようないわゆるＣＰＥＴの成形では最初から高温の金型で成形すると、金型面で成形材料の滑りが悪いため波や凹凸などの不均一模様が出やすいというような問題もあり、これを避けるために最初低温金型で成形し高温金型に移行するプロセスも知られているが、これもやはり煩雑である。 In addition, (5) Japanese Patent Publication No. 7-102608 shows a method of molding with a high-temperature female mold, taking it into a low-temperature male mold fitted to the mold, cooling it, and releasing the mold. It may be said that the method is the same as (4), and deformation and wrinkling of the molding become a problem as well, and it is difficult to apply to a molded product having an offset or undercut. In addition to these examples, in the molding of so-called CPET as in (4) and (5), if molding is performed with a high-temperature mold from the beginning, the molding material does not slide smoothly on the mold surface, and thus unevenness such as waves and unevenness is generated. There is also a problem that a pattern is likely to appear. To avoid this problem, a process of forming with a low temperature mold and then shifting to a high temperature mold is known, but this is also complicated.
　また（６） 特許４０５７４８７号の開示する方法は、結晶性樹脂の熱成形に関し、加熱板に接触させて予熱されたシートを、熱板を通過する高温空気と成形金型にて圧空賦形し、次いで別に準備した冷却空気噴射の手段を運び込んで冷却するものであるが、この加熱板はシート予熱適温に調整されており、背後から加熱された空気が供給されて加熱圧空がなされる。この場合、加熱気体は加熱板中を通る導管内で冷やされ、また熱処理には非常な高温度気体を通す必要があの、その場合加熱板温度を局部的にして不均一にし、また材料シートを局部的に過熱し良好な成形に支障きたしやすい。また、開示された冷却手段では広い面積を均一に効率的に冷却できない。また高温気体からの熱は容易に金型に逸散して短時間に容易にシートを高温にできず、高速成形ができない。 Further, (6) A method disclosed in Japanese Patent No. 4057487 relates to thermoforming of a crystalline resin, and a sheet preheated in contact with a heating plate is compressed and shaped with hot air passing through the hot plate and a molding die. Then, cooling air jetting means prepared separately is carried in and cooled, but this heating plate is adjusted to an appropriate temperature for sheet preheating, and heated air is supplied from behind to produce heated and compressed air. In this case, the heated gas is cooled in a conduit passing through the hot plate, and a very high temperature gas must be passed through the heat treatment, in which case the hot plate temperature is localized and non-uniform, and the material sheet is Local overheating tends to hinder good molding. Further, the disclosed cooling means cannot cool a large area uniformly and efficiently. Also, heat from the high temperature gas is easily dissipated into the mold, and the sheet cannot be easily heated to a high temperature in a short time, and high speed molding cannot be performed.
　また、（７）米国特許５１９１７６は、一度２軸延伸処理した樹脂シートを加熱して雄型の上に熱収縮させて成形する方法を提案している。この方法では、賦形性は改善されるかもしれないが、十分な配向効果を利用することができず、また、オフセット部分のある形状など成形上の制約が多い。なお、迅速な熱固定と冷却離型について開示はない。 (7) US Pat. No. 5,119,176 proposes a method in which a resin sheet once biaxially stretched is heated and thermally contracted onto a male mold. Although this method may improve the formability, a sufficient orientation effect cannot be used, and there are many molding restrictions such as a shape having an offset portion. There is no disclosure of rapid heat setting and cooling mold release.
　なお、（８）特開２０１１－２４５６４３、 特開２０１１－２４５６４４、特開２０１１－２４５６５０、特開２０１１－２４５６５１は、本出願と関わりのある製造方法及び成形型に関するもので、本発明と同発明者によりなされたものである。本発明者は更にこれらの方法を実施するための成形装置等に関して発明をなし１０件の出願を行っている。本出願はこれらの成形装置に関する出願を優先権にして行うものである。
　なお、本発明の構成の一部をなす新規構造の圧空手段と比較される公知の代表的な圧空ボックスおよび加熱板の例は、下記の非特許文献１および２示されている。 Note that (8) JP2011-245463, JP2011-245644, JP2011-245650, and JP2011-245651 relate to a manufacturing method and a mold associated with the present application, and are the same as the present invention. It was made by a person. The present inventor has further invented 10 applications for a molding apparatus for carrying out these methods. This application gives priority to the application regarding these shaping | molding apparatuses.
Non-Patent Documents 1 and 2 below show examples of known typical pneumatic boxes and heating plates to be compared with the pneumatic structure having a novel structure that forms part of the configuration of the present invention.
特公昭５６－７８５５号公報Japanese Patent Publication No.56-7855 特公平５－４５４１２号公報Japanese Patent Publication No. 5-45412 特公昭６０－０３１６５１号公報Japanese Patent Publication No. 60-031651 特許２５３２７３０号公報Japanese Patent No. 2532730 特公平７－１０２６０８号公報Japanese Examined Patent Publication No. 7-102608 特許４０５７４８７号公報Japanese Patent No. 4057487 米国特許５１９１７６US Patent 519176 特開２０１１－２４５６４３JP2011-245643 特開２０１１－２４５６４４JP2011-245644 特開２０１１－２４５６５０JP2011-245650 特開２０１１－２４５６５１JP2011-245651
　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、熱成形の賦形から離型までの過程において、賦形体を高速で加熱しそして必要により高速で冷却し、特に賦形前の予熱シート温度以上の高温で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ことができ、また均一で良好な状態の成形品が得られる熱成形装置を提供するものである。 The present invention has been made in view of such problems of the prior art. Its main purpose is to heat the shaped body at high speed and cool it as necessary at high speed in the process from thermoforming to mold release, especially heat treatment at a temperature higher than the preheating sheet temperature before shaping. It is an object of the present invention to provide a thermoforming apparatus that can perform thermoforming for releasing at high speed and efficiently and obtain a molded product in a uniform and good state.
（１）樹脂シートの圧空成形の可能な熱成形装置において、圧空プレート又は圧空ボックス（両者合わせて以下「圧空手段」と称することもある）として、圧縮気体を送気開口から成形型上部に向けて送出する第１の機構と、圧空空間に送出された気体を吸気開口から吸気して外部に排気する第２の機構を一体として有し、次の１）及び２）、すなわち、
１）上記第１の機構の気体送出を、上記圧空プレート内部又は圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにした構造、及び
２）上記第２の機構の吸気を複数の吸気開口を通じて、上記圧空プレート内部又は圧空ボックス底内部に設けた集気空間に収容して外部に導くようにした構造のうち少なくとも１つを用いる熱可塑性樹脂シートの成形装置を提供するものである。
　なお、上記の圧空ボックスは、成形型を覆って圧空用空間を形成するための窪み空間を有する片面開放の筐体である。又その形状は必ずしも方形でなくてもよく、特に開放面の形は成形型形状に合わせ任意の形状にすることができる。
　なお、上記の圧空プレートは、成形型対向面が平板状等の構造物で、このもの単体では閉鎖圧空空間を形成できないものであっても、周壁のある成形型や成形型収納ボックス等と組み合わせたとき、樹脂シート有効面と接触する経過を経ずに圧空空間を形成できる形状物を指すものとする。 (1) In a thermoforming apparatus capable of pressure forming of a resin sheet, a compressed gas is directed from the air supply opening to the upper part of the forming die as a pressure air plate or a pressure air box (both are also referred to as “pressure air means” hereinafter). And a second mechanism for sucking the gas sent to the compressed air space from the intake opening and exhausting it to the outside, and the following 1) and 2), that is,
1) A structure in which the gas delivery of the first mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box, and 2) the second mechanism. Provided is a thermoplastic resin sheet molding apparatus using at least one of a structure in which intake air is accommodated in the air collecting space provided inside the compressed air plate or the inside of the compressed air box through a plurality of intake openings and guided to the outside. To do.
In addition, said compressed air box is a housing | casing of the single side | surface opening which has the hollow space for covering a shaping | molding die and forming the space for compressed air. Moreover, the shape does not necessarily need to be a square, and in particular, the shape of the open surface can be changed to any shape according to the shape of the mold.
Note that the above-mentioned compressed air plate has a structure in which the mold facing surface is a flat plate or the like, and even if it cannot form a closed compressed air space by itself, it is combined with a mold having a peripheral wall or a mold storage box. The shape object which can form a compressed air space, without passing through the process which contacts a resin sheet effective surface.
（２）上記第１の機構の送気機構に加熱温調手段を付加することを特徴とする上記（１）に記載の成形装置を提供するものである。 (2) A molding apparatus as described in (1) above, wherein a heating temperature adjusting means is added to the air supply mechanism of the first mechanism.
（３）上記第１の機構及とは別に、第３の機構として、別途導入した圧縮気体を別途設けた送出開口から上記成形型上部に向けて送出する機構を更に一体として備えた上記圧空手段を用いることを特徴とする上記（１）又は（２）に記載の成形装置を提供するものである。 (3) In addition to the first mechanism and the first mechanism, as a third mechanism, the compressed air means further comprising a mechanism for sending a separately introduced compressed gas from a separately provided delivery opening toward the upper part of the mold. The molding apparatus according to the above (1) or (2) is provided.
（４）上記の第３の機構における高温圧縮気体の送出を、上記圧空プレートの内部又は上記圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにしたことを特徴とする上記（１）から（３）の何れかに記載の成形装置を提供するものである。 (4) The high-temperature compressed gas in the third mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box. The molding apparatus according to any one of (1) to (3) above is provided.
（５）上記第３の機構に加熱温調手段を付与し高温の圧縮気体を送出開口から送出するようにした特徴とする上記（１）から（４）の何れかに記載の成形装置を提供するものである。 (5) The molding apparatus according to any one of (1) to (4) above, wherein a heating temperature adjusting means is provided to the third mechanism so that a high-temperature compressed gas is delivered from a delivery opening. To do.
（６）上記の何れかの送気機構の内部で導入した圧縮気体を２００℃以上の十分な温度に加熱して送出 する機能を備えていることを特徴とする上記（１）から（５）の何れかに記載の成形装置を提供するものである。 (6) The above-mentioned (1) to (5) are provided with a function of heating the compressed gas introduced inside any one of the above-mentioned air feeding mechanisms to a sufficient temperature of 200 ° C. or more and feeding it. A molding apparatus according to any one of the above is provided.
（７）上記圧空プレート又は圧空ボックス底の成形型対向面が２００℃以上に加熱保持が可能で、且つ赤外線放射率が０．８以上であるようにしたことを特徴とする（１）から（
６）の何れかに記載の成形装置を提供するものである。 (7) (1) to (1) characterized in that the molding die facing surface of the compressed air plate or the compressed air box can be heated and maintained at 200 ° C. or higher and the infrared emissivity is 0.8 or higher.
The molding apparatus according to any one of 6) is provided.
（８）成形型として、少なくともその成形用表面を熱浸透率（ｋＪ／ｍ２ｓ１／２Ｋ）が０．０１～２５である材料により形成させたものを用いることを特徴とする上記（１）から（７）の何れかに記載の成形装置を提供するものである。
なお、上記の熱浸透率は２０以下であることが好ましく、１５以下であることが更に好ましく、１０以下であることが更にまた好ましい。
　なお、ここでいう成形型材料の定義には、成形用表面に塗布される潤滑、離型等のための塗布剤、摩耗保護、傷防止等のための５０μ程度以下の塗料あるいはメッキは除外されるものとする。　　 (8) The above-mentioned, characterized in that at least the molding surface is formed of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.01 to 25 as the molding die ( The molding apparatus according to any one of 1) to (7) is provided.
The heat permeability is preferably 20 or less, more preferably 15 or less, and still more preferably 10 or less.
In addition, the definition of the mold material mentioned here excludes a coating agent or plating of about 50 μm or less for lubrication, mold release and the like applied to the molding surface, wear protection and scratch prevention. Shall be.
（９）成形型として、熱浸透率（ｂ値）が２０以下の材料によりなる表面層と熱浸透率（ｂ値）が表面層のそれより大きな材料からなる背後体からなることを特徴とする上記（１）から（８）の何れかに記載の成形装置を提供するものである。
なお、上記の熱浸透率は、１５以下であることが好ましく、１０以下であることが更に好ましい。
　なお、このような成形型には、更に表面層の背後に略全面に密接して加熱温調手段を設けるか又は上記の背後体に加熱温調手段を設けた構成であることが好ましい。 (9) The mold is characterized by comprising a surface layer made of a material having a thermal permeability (b value) of 20 or less and a back body made of a material having a thermal permeability (b value) larger than that of the surface layer. The molding apparatus according to any one of (1) to (8) above is provided.
The heat permeability is preferably 15 or less, and more preferably 10 or less.
In addition, it is preferable that such a mold has a configuration in which heating temperature adjusting means is further provided in close contact with the entire surface behind the surface layer, or heating temperature adjusting means is provided on the back body.
（１０）成形型として、上記の材料からなる表面層を背後から温度調整する手段を備えたものを用いる事を特徴とする上記（１）から（９）の何れかに記載の成形装置を提供するものである。 (10) The molding apparatus according to any one of (1) to (9) above, wherein a molding die having a means for adjusting the temperature of the surface layer made of the above material from behind is used. To do.
（１１）上記（１）から（１０）の何れかに記載の成形装置を用いた樹脂シートの成形方法であって、樹脂シートの予熱工程、賦形工程、賦形体を賦形時と予熱温度以上の高温で熱処理する工程、そして必要により賦形体の冷却工程を遂行する熱可塑性樹脂シートの熱成形方法を提供するものである。
　なお、本発明においては、熱成形又は成形は、樹脂シートの予熱から離型までの全工程を含み、真空或いは圧空等により形を形成する工程を「賦形」又は「賦形工程」と呼ぶ。また賦形されまだ成形型に保持された離型前の成形品を特に「賦形体」と呼ぶこととする。　 (11) A resin sheet molding method using the molding apparatus according to any one of (1) to (10) above, wherein the resin sheet preheating step, the shaping step, and the shaped body are shaped and preheated. The present invention provides a thermoplastic resin sheet thermoforming method that performs the above-described heat treatment step and, if necessary, the step of cooling the shaped body.
In the present invention, thermoforming or molding includes all steps from preheating to release of a resin sheet, and the step of forming a shape by vacuum or compressed air is called “shaping” or “shaping step”. . In addition, a molded product that has been shaped and is still held in the mold is referred to as a “shaped body”.
（１２）上記賦形体を高温で熱処理する方法として、１）上記高温気体を賦形体に噴射して行う方法、２）賦形体に赤外線照射して行う方法、若しくは３）上記成形型表面を高温に加熱しておいて賦形を行う方法の少なくとも1つを用いること特徴とする上記（１１）に記載の成形方法を提供するものである。 (12) As a method of heat-treating the shaped body at a high temperature, 1) a method in which the high-temperature gas is injected onto the shaped body, 2) a method in which the shaped body is irradiated with infrared rays, or 3) the surface of the mold is heated The molding method according to the above (11) is provided, wherein at least one of the methods of shaping by heating to a temperature is used.
　本発明の成形装置を用いる熱成形には下記のような効用がある。
１）本発明の装置は、樹脂シートを予熱賦形し離型するまでの過程において樹脂シートの予熱温度を大幅に上回る高温で熱処理し、次いで冷却して離型するプロセスを非常な高速で、連続的に、効率的にそして安定に実行することができる。 Thermoforming using the molding apparatus of the present invention has the following effects.
1) The apparatus of the present invention is a process at which the resin sheet is heat-treated at a temperature substantially exceeding the preheating temperature of the resin sheet in the process of preheating and releasing, and then cooled and released at a very high speed. It can be executed continuously, efficiently and stably.
２）特に本発明の構成に上記の圧空手段を用いることにより、高温気体の噴射の継続とその制御が容易になる。その結果、ａ）賦形体の均一で強力な加熱昇温ができ、熱処理時間の短縮ができる。ｂ）均一で強力な加熱昇温ができるので、成形型の温度設定を低くすることができ、冷却時間を短縮することができる。ｃ）均一で強力な加熱昇温ができるので成形型構成の設計自由度が大きくなり低価格成形型も利用できる。ｄ）圧空手段と冷却手段を一体化することにより、冷却手段の移動時間を省き成形サイクルを高速化することができる。 2) In particular, the use of the above-described compressed air means in the configuration of the present invention facilitates the continuation and control of high-temperature gas injection. As a result, a) the shaped body can be heated uniformly and powerfully, and the heat treatment time can be shortened. b) Since uniform and powerful heating can be performed, the temperature setting of the mold can be lowered and the cooling time can be shortened. c) A uniform and powerful heating temperature can be raised, so that the degree of freedom in designing the mold configuration is increased, and a low-cost mold can also be used. d) By integrating the compressed air means and the cooling means, the moving time of the cooling means can be saved and the molding cycle can be speeded up.
２） 延伸により成形が困難化する結晶性熱可塑性樹脂の延伸シートの熱成形
を容易に行うことができる。 2) A stretched sheet of a crystalline thermoplastic resin that is difficult to be formed by stretching can be easily thermoformed.
３）大型成形品あるいは小さな成形品多数個取りの高温の熱処理を伴う成形を、全面均一熱処理し、短い成形サイクルでそして少ないエネルギー消費で行うことができる。 3) Molding involving high-temperature heat treatment of a large number of molded products or small molded products can be performed on the entire surface uniformly, with a short molding cycle and with low energy consumption.
４）特に本発明の成形装置において上記のような成形型を組み合わせて用いることにより、賦形体の加熱冷却を伴う成形を更に高速で効率よく行うことができる。そして、応用できる成形材料対象を広げることができ、少ないエネルギーで生産を行うことができる。 4) In particular, by using a combination of the above-described molds in the molding apparatus of the present invention, molding involving heating and cooling of the shaped body can be performed at higher speed and efficiency. And the object of the molding material which can be applied can be expanded and it can produce with little energy.
５）本発明の成形装置を用いた結果、延伸ＰＥＴでは、耐熱性、透明性、剛性等の機械強度の優れた熱成形品を能率よく生産することができ、又、剛性が向上した結果、食品トレー等の汎用のを成形の肉厚を大木削減し、大幅に成形材料を節約することが可能となった。 5) As a result of using the molding apparatus of the present invention, with stretched PET, it is possible to efficiently produce a thermoformed product having excellent mechanical strength such as heat resistance, transparency and rigidity, and as a result of improved rigidity, It has become possible to reduce the wall thickness of general-purpose products such as food trays and greatly save molding materials.
６）本発明の成形装置を用いた結果、広範囲の樹脂で、種々の目的で容易に熱処理された成形品を製造することが可能となった。
具体的例を挙げると、ａ）ＰＥＴ等の結晶性樹脂の延伸シートの熱固定を伴う成形、ｂ）結晶核剤添加ＰＥＴ（ＣＰＥＴ）等の結晶性樹脂シートの結晶化を伴う成形、あるいはまたｃ）ポリプロピレンのＳＰＰＦ成形（固相高圧成形）に伴う残留応力歪緩和してする熱処理成形を提案することができる。ｄ）非結晶性（アモルファス）樹脂の熱成形でも残留歪みをなくし、寸法精度の高い製品をえることができる。 6) As a result of using the molding apparatus of the present invention, it has become possible to produce molded products that are easily heat-treated for various purposes with a wide range of resins.
Specific examples are: a) molding involving heat setting of a stretched sheet of crystalline resin such as PET, b) molding involving crystallization of a crystalline resin sheet such as crystal nucleating agent-added PET (CPET), or c) It is possible to propose heat treatment molding that relaxes residual stress strain associated with polypropylene SPPF molding (solid phase high pressure molding). d) Residual distortion is eliminated even by thermoforming of amorphous (amorphous) resin, and a product with high dimensional accuracy can be obtained.
本発明の圧空ボッスを用いた成形装置構成例の主要部を示す断面図である。It is sectional drawing which shows the principal part of the shaping | molding apparatus structural example using the compressed air box of this invention. 図１の圧空ボックスの下面を示す平面図である。It is a top view which shows the lower surface of the compressed air box of FIG. 本発明の装置構成に用いる最も簡素な圧空ボックスの例を示す断面図である。It is sectional drawing which shows the example of the simplest compressed air box used for the apparatus structure of this invention. 圧空ボックスの他の形態例を用いた本発明の装置構成を示す断面図である。It is sectional drawing which shows the apparatus structure of this invention using the other example of a compressed air box. 圧空プレートの一例を用いた本発明の装置構成の断面図である。It is sectional drawing of the apparatus structure of this invention using an example of a compressed air plate. 圧空ボックスの更に別の形態例を用いた成形装置構成の断面図である。It is sectional drawing of the shaping | molding apparatus structure using another example of a compressed air box. 圧空ボックスの更に別の形態例を用いた成形装置構成の断面図である。It is sectional drawing of the shaping | molding apparatus structure using another example of a compressed air box. 本発明の成形装置を構成する成形型の例を示す断面図である。It is sectional drawing which shows the example of the shaping | molding die which comprises the shaping | molding apparatus of this invention. 本発明の成形装置を構成する成形型の別の例を示す断面図である。It is sectional drawing which shows another example of the shaping | molding die which comprises the shaping | molding apparatus of this invention.
＜成形装置の全体構成＞　　
　本発明の成形装置は、熱成形機である圧空成形機若しくは真空圧空成形機を構成するものである。成形材料である樹脂シートの予熱は、加熱オーブン等を利用する間接加熱、あるいは加熱板に接触させる直接加熱など公知のどのような方式を採用する成形機であってもよい。そして又、こうした予熱機構のないものであってもよく、その場合は本発明の機構にその機能を持たせることもできる。そして又、必要により加熱圧縮気体の生成装置を装着する。 <Overall configuration of molding apparatus>
The molding apparatus of the present invention constitutes a pressure forming machine or a vacuum / pressure forming machine that is a thermoforming machine. The resin sheet that is a molding material may be preheated by a molding machine that employs any known method such as indirect heating using a heating oven or the like, or direct heating in contact with a heating plate. Further, it may be one without such a preheating mechanism, and in that case, the mechanism of the present invention can have the function. Further, if necessary, a heating / compressed gas generating device is attached.
　このような熱成形機に、少なくとも、下記の基本機構を有する圧空手段を装備する。この圧空手段は、圧縮気体を送気開口から成形型上部に向けて送出する第１の機構と、圧空空間に送出された気体を吸気開口から吸気して外部に排気する第２の機構を一体として構成した、圧空プレート又は圧空ボックスである。そして、これらの機構は、１）上記第１の機構の気体送出を、上記圧空プレート内部又は圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにした構造、又は２）上記第２の機構の吸気
を複数の吸気開口を通じて、上記圧空プレート内部又は圧空ボックス底内部に設けた集気空間に収容して外部に導くようにした構造のうち少なくとも１つを採用したものとする。 Such a thermoforming machine is equipped with at least compressed air means having the following basic mechanism. This compressed air means is integrated with a first mechanism for sending compressed gas from the air supply opening toward the upper part of the mold and a second mechanism for taking in the gas sent to the compressed air space from the intake opening and exhausting it outside. A compressed air plate or a compressed air box. These mechanisms are: 1) a structure in which the gas delivery of the first mechanism is distributed and sent through a plurality of air supply openings from a distribution space provided inside the compressed air plate or the inside of the compressed air box, or 2 ) At least one of the structures in which the intake air of the second mechanism is accommodated in the air collecting space provided inside the compressed air plate or the inside of the compressed air box through a plurality of intake openings and guided to the outside. And
　なお上記の圧空手段においては、上記送気開口と上記吸気開口の何れかが成形型表面により近い距離位置になるように設けてもよく、それは好ましい。上記送気開口又は吸気開口は、それぞれ分配空間又は集気空間に直接設けてもよく、また導管を介在させて設けてもよい。なお上記送気開口又は上記吸気開口に至る導管が、それぞれ上記集気空間又は分配空間を貫通するか又はそれぞれの上記空間の間を貫通して設けることは好ましい。 In the above-described compressed air means, either the air supply opening or the air intake opening may be provided at a position closer to the mold surface, which is preferable. The air supply opening or the air intake opening may be provided directly in the distribution space or the air collection space, respectively, or may be provided via a conduit. In addition, it is preferable that the conduit leading to the air supply opening or the intake opening passes through the air collection space or the distribution space, or penetrates between the spaces.
　上記の圧空手段には、外部から常温の圧縮気体を導入してもよく、又高温の加熱圧縮気体を導入してもよく、いずれ成形条件設定も可能である。前者の場合は、成形型表面を高温にしておいて、圧空賦形を行いながらあるいは賦形後も送気をつづけながら排気を行えば効率よく賦形体の冷却を行うことができる。また、後者の場合は、高温気体により圧空賦形を行いながらあるいは賦形後も送気をつづけながら排気を行えば効率良く賦形体を加熱昇温することができる。
　後者の場合、更に必要により排気側に常温圧縮気体を導入し、送気側から排気を行うようにバルブ操作すれば、効率よく冷却をおこなうことができる。なお、この圧縮手段の好ましい態様については後述する。 A normal temperature compressed gas may be introduced into the compressed air means from the outside, or a high-temperature heated compressed gas may be introduced, and molding conditions can be set. In the former case, it is possible to cool the shaped body efficiently by keeping the mold surface at a high temperature and evacuating while performing compressed air shaping or continuing air supply after shaping. In the latter case, the shaped body can be efficiently heated and heated by performing the air pressure shaping with the high-temperature gas or performing the exhausting while continuing the air feeding after the shaping.
In the latter case, if necessary, a cold compressed gas can be efficiently cooled by introducing a normal temperature compressed gas to the exhaust side if necessary and operating the valve so as to exhaust from the air supply side. In addition, the preferable aspect of this compression means is mentioned later.
　上記の圧空手段は、プレス機の天板に固定し、その直下の底板には成形型を固定し、天板と底板の少なくとも何れかを上下可動にして、圧空手段と成形型の接合離反を可能にする。成形用の樹脂シートは、予熱されて成形型上部に持ち込まれ、圧空手段の降下あるいは成形型の上昇によりこのシートを挟み込み、上記の圧空気体の送気により賦形及び冷却がなされ、賦形体の離型がなされる。圧空手段は、賦形後あるいは熱処理後の任意の時点で、上昇を始めて、元の位置に戻る。 The above pneumatic means is fixed to the top plate of the press machine, the mold is fixed to the bottom plate directly below, and at least one of the top plate and the bottom plate is movable up and down, and the pressure separation means and the mold are joined and separated. enable. The resin sheet for molding is preheated and brought into the upper part of the mold, and the sheet is sandwiched by lowering the compressed air means or raising the mold, and shaped and cooled by feeding the above-mentioned compressed air body. Is released. The compressed air means starts to rise and returns to its original position at an arbitrary time after shaping or heat treatment.
　なお、圧空に用いる圧縮気体は、空気、窒素、二酸化炭素など人体および成形物等に無害であれば任意のものを用いることができる。また必要により冷却効果を増強させるために、これらの気体に水分を混入させてもよく、また揮発性の物質、例えばアルコールなどの揮発性物質の微滴を混入させてもよい。　　　 In addition, the compressed gas used for compressed air can use arbitrary things, if it is harmless to a human body, a molded object, etc., such as air, nitrogen, a carbon dioxide. Further, in order to enhance the cooling effect as necessary, moisture may be mixed into these gases, or fine droplets of volatile substances such as volatile substances such as alcohol may be mixed. *
　上記の全体構成例を図１、及び図２について説明する。なお図２は図１の中の圧空ボックスの下面の平面図である。
この例は、プレス機底板上に成形型６０が、圧空ボックス３０が固定され配置された構成で、圧空ボックスは上記第１の機構及び上記第２の機構が一体となって構成され、それぞれ送気ポート（送気本体）３１及び排気ポート（排気本体）２１を有している。なお１００は成形材料の樹脂シートである。成形機そのもの及びプレス機、予熱手段、圧縮気体生成装置等は本図から省かれている。 An example of the overall configuration will be described with reference to FIGS. 2 is a plan view of the lower surface of the compressed air box in FIG.
In this example, the forming die 60 is fixed on the bottom plate of the press machine, and the compressed air box 30 is fixedly arranged. The compressed air box is configured by integrating the first mechanism and the second mechanism, respectively. An air port (air supply body) 31 and an exhaust port (exhaust body) 21 are provided. Reference numeral 100 denotes a resin sheet of a molding material. The molding machine itself, the press machine, the preheating means, the compressed gas generating device, etc. are omitted from this figure.
　本図では、予熱された樹脂シート１００が成形型６０の上部に導入された状態を示しているが、この後圧空ボックス３０が降下して圧縮気体による圧空賦形と加熱された成形型による熱処理昇温が相次いで行われ、続いて圧縮気体による冷却が行われる。送出ポート３１から圧縮気体が送出されるが、賦形と同時あるいは賦形直後のタイミングをはかり排気ポート２１の排気バルブを開くと圧空空間の気体は排気更新され効率よく賦形体を冷却することができる。冷却工程が終わって圧空ボックスが上昇するとともに賦形体の離型が行われる。 This figure shows a state in which the preheated resin sheet 100 has been introduced into the upper part of the mold 60. After this, the compressed air box 30 descends and pressure forming with compressed gas and heat treatment with a heated mold are performed. The temperature is raised successively, followed by cooling with compressed gas. Compressed gas is sent out from the delivery port 31. When the exhaust valve of the exhaust port 21 is opened at the same time as shaping or immediately after shaping, the gas in the compressed air space is renewed and the shaped body can be cooled efficiently. it can. After the cooling process is finished, the compressed air box is raised and the shaped body is released.
　図１における成形型構成６０は、表面層６１と背後層（背後体）６２からなる成形型を、熱媒通路６５に高温熱媒を通じた集積プレート６６に固定し、収納ボックス６７に収納したものである。なお、表面層６１は熱浸透率の小さな材料から、また背後層６２は熱浸透率の大きな材料からなるもので、表面層６１は背後層６２を介して十分に高温に加熱され、賦形体を加熱する。表面層６１の熱浸透率が小さいので、気体吹きつけによる賦形体の冷却を効率良く行うことができる。 The molding die configuration 60 in FIG. 1 is a molding die composed of a surface layer 61 and a back layer (back body) 62 fixed to a collecting plate 66 through a high-temperature heating medium through a heating medium passage 65 and stored in a storage box 67. It is. The surface layer 61 is made of a material having a low heat permeability, and the back layer 62 is made of a material having a high heat permeability, and the surface layer 61 is heated to a sufficiently high temperature via the back layer 62 to form a shaped body. Heat. Since the heat permeability of the surface layer 61 is small, the shaped body can be cooled efficiently by gas blowing.
　なお、図１の圧空ボックスの構造はそのままにして、底部の上段を送気ポート（すなわち第１の機構）とし下段を排気ポート（すなわち第２の機構）として利用することもできる。
　なお又、本図の装置構成において上記とは異なる操作を行うことができ、一時的に外部で高温に加熱された圧縮気体を取り入れ送気ポートから送気することにより、高温気体による圧空賦形あるいは高温気体による賦形体の熱処理を行うことができ、同時に他のポートから排気しながらこれを行うと効率良い昇温を続けることができる。熱処理後には、何れかのポートより低温の気体を送気すればよく、このとき他のポートから排気を行いながらこれを行えば全賦形面を均一で効率良く冷却することができる。このように高温気体を用いる場合には当然のことながらそのポートは、熱伝導率の小さな材料を用い、あるいは熱を遮断する構造にすることが望ましい。 The structure of the compressed air box shown in FIG. 1 can be left as it is, and the upper stage at the bottom can be used as an air supply port (that is, the first mechanism) and the lower stage can be used as an exhaust port (that is, the second mechanism).
In addition, in the apparatus configuration of this figure, an operation different from the above can be performed, and compressed air shaping with a high-temperature gas is performed by temporarily taking in a compressed gas heated to a high temperature externally and feeding it from an air-feeding port. Alternatively, the shaped body can be heat-treated with a high-temperature gas, and if this is performed while exhausting from another port at the same time, efficient temperature rise can be continued. After the heat treatment, a low temperature gas may be supplied from one of the ports, and if this is performed while exhausting from the other ports, the entire shaped surface can be uniformly and efficiently cooled. In the case of using a high-temperature gas in this way, as a matter of course, it is desirable that the port is made of a material having a low thermal conductivity or has a structure that blocks heat.
　なお、圧空ボックスあるいは成形型の移動は、必ずしも垂直な上下動でなくてもよく、それぞれ任意に斜め方向から接合して離反してもよく、また特定の軌道で接合して離反してもよい。なお、賦形手段と成形型の位置関係は相対的なものであり、賦形手段の上昇は成形型の降下と同義であって成形型を降下させてもよく、また両者を倒置して賦形手段を下に成形型上に倒置させてもよい。また、特異な態様として、プレス機を横転させてもよく、重量の大きい成形型等を、軽快に開閉でき好ましい方式として利用できる。
　なお、上記のように冷却手段を成形型上部に移動する代わりに、成形型を冷却手段の下部に移動させてもよい。その場合、賦形体を含む成形型を移動させてもよく、加熱板と成形型を保持したプレス機を移動させてもよい。
　なお、本発明を構成する熱成形機は、短尺の材料シートを一枚ずつ成形する枚葉成形機であってもよく、また長尺の材料シートを順次成形する連続成形機でもよい。しかし、後者であることが特に好ましく、本発明の特徴を発揮して高速で効率的な繰り返し成形を可能にする。 It should be noted that the movement of the compressed air box or the mold does not necessarily have to be vertically moved up and down, and may be arbitrarily separated from each other by joining from an oblique direction, or may be separated by being joined by a specific track. . Note that the positional relationship between the shaping means and the molding die is relative, and raising the shaping means is synonymous with lowering the molding die, and the molding die may be lowered. The shaping means may be inverted on the mold below. Further, as a unique aspect, the press machine may be rolled over, and a heavy mold or the like can be opened and closed easily and used as a preferred method.
Instead of moving the cooling means to the upper part of the mold as described above, the mold may be moved to the lower part of the cooling means. In that case, the shaping | molding die containing a shaping body may be moved, and the press machine holding the heating plate and the shaping | molding die may be moved.
The thermoforming machine constituting the present invention may be a single-wafer forming machine that forms short material sheets one by one, or may be a continuous molding machine that sequentially forms long material sheets. However, the latter is particularly preferable, and the characteristics of the present invention are exhibited to enable high-speed and efficient repetitive molding.
　本発明の発明者は、本発明の国際出願（以下本出願）に先立ち、本発明の成形装置に関連性のある発明として、特願２０１１－４１２９４、特願２０１１－１６５０６７、特願２０１１－１６５０６８、特願２０１１－１６５０６９、特願２０１１－２０６５１４、特願２０１１－２０６５１５、特願２０１１－２０６５１６、特願２０１１－２５４６４１、特願２０１１－２５４６４０の日本国出願を行っている。
　本出願は、上記の中の特願２０１１－１６５０６９、特願２０１１－２０６５１５、特願２０１１－２０６５１４、特願２０１１－２５４６４１０優先権のもとに行うものである。
　上記の圧空ボックスの具体的な形状及び変形態様等については、この後の＜圧空プレート及び圧空ボックスについて＞の欄で、又、使用する望ましい成形型については＜成形型についての欄＞で詳述する。 Prior to the international application of the present invention (hereinafter referred to as “the present application”), the inventor of the present invention has disclosed, as inventions related to the molding apparatus of the present invention, Japanese Patent Application Nos. 2011-41294, 2011-165067, and 2011-165068. Japanese patent applications No. 2011-165069, No. 2011-206514, No. 2011-206515, No. 2011-206516, No. 2011-254541, No. 2011-254640 and No. 2011-254640 have been filed in Japan.
This application is filed under the priority of Japanese Patent Application No. 2011-165069, Japanese Patent Application No. 2011-206515, Japanese Patent Application No. 2011-206514, and Japanese Patent Application No. 2011-2546410.
The specific shape and deformation mode of the above-mentioned compressed air box will be described in detail in the section <About the compressed air plate and compressed air box>, and the desirable mold to be used will be described in detail in the <Formed mold column>. To do.
＜圧空プレート又は圧空ボックスについて＞
　公知の通常用いられる圧空プレートあるいは圧空ボックスの概念は、樹脂シートと挟んで成形型または成形型群を覆い、樹脂シートとの間に閉鎖空間をつくり、この閉鎖空間に圧縮気体を送り込んで圧空成形をおこなうための道具である。通常は常温圧縮気体により圧空成形が行われ、空気噴射冷却を行う場合は圧空器具を移動させた空間に向けて外部から空気噴射冷却を行う。そして、同空間に、空気噴射手段を移動させてこれを行う機構は日本特許４０５７４８７号に開示されているが、この機構では迅速に冷却を開始できないばかりでなく、おおきな賦形面積を均一にかつ効率的に冷却することができない。 <Pressure plate or box>
The concept of a well-known commonly used pressure plate or pressure box is to cover a mold or a group of molds sandwiched between resin sheets, create a closed space between the resin sheets, and send compressed gas into this closed space to form a compressed air It is a tool for performing. Usually, compressed air molding is performed with a normal temperature compressed gas, and when air injection cooling is performed, air injection cooling is performed from the outside toward the space where the compressed air device is moved. Japanese Patent No. 4057487 discloses a mechanism for moving the air injection means to the same space, but this mechanism cannot quickly start cooling, and can also provide a large shaping area uniformly. It cannot be cooled efficiently.
　これに対して本発明の第１の基本発明として、樹脂シートの圧空成形の可能な熱成形装置に用いる圧空プレート又は圧空ボックスは、圧縮気体を送気開口から成形型上部に向けて送出する第１の機構と、圧空空間に送出された気体を吸気開口から吸気して外部に排気する第２の機構を一体として有し、次の１）及び２）、すなわち、
１）上記第１の機構の気体送出を、上記圧空プレート内部又は圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにした構造、及び
２）上記第２の機構の吸気を複数の吸気開口を通じて、上記圧空プレート内部又は圧空ボックス底内部に設けた集気空間に収容して外部に導くようにした構造のうち少なくとも１つを用いて構成する。 On the other hand, as a first basic invention of the present invention , a compressed air plate or a compressed air box used in a thermoforming apparatus capable of pressure forming a resin sheet sends compressed gas from an air supply opening toward an upper part of a mold. 1 mechanism and a second mechanism for sucking the gas sent to the compressed air space from the intake opening and exhausting it to the outside, and the following 1) and 2), that is,
1) A structure in which the gas delivery of the first mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box, and 2) the second mechanism. At least one of the structures in which the intake air is accommodated in the air collection space provided inside the compressed air plate or the inside of the compressed air box through a plurality of intake openings and guided to the outside is used.
　本発明のこの構成により、圧空空間で賦形体に吹き付ける気体を継続的に更新することができ、大きな賦形体あるいは多数個の賦形体がなす全面積を均一に且つ効率的に冷却することが可能となる。更に又任意の時点で高温に加熱された気体を導入して送気することにより、成形材料の樹脂シート又は大きな賦形体或いは多数個の賦形体がなす全面積を均一に且つ効率的に加熱することが可能となる。なお、高温の気体を送出する効用については後の第２の発明の欄述べる。 With this configuration of the present invention, the gas blown to the shaped body can be continuously updated in the compressed air space, and the entire area formed by a large shaped body or a large number of shaped bodies can be uniformly and efficiently cooled. It becomes. Furthermore, by introducing a gas heated to a high temperature at an arbitrary time and feeding it, the entire area formed by the resin sheet of the molding material or the large shaped body or a large number of shaped bodies is uniformly and efficiently heated. It becomes possible. In addition, the effect of sending a high-temperature gas will be described later in the column of the second invention.
　上記の本発明の圧空ボックスの最も簡素な例を図７に示す。この図の圧空ボックス３０は、上記第１の機構として送気ポート３１が圧縮気体導入路３３、分配空間３４、分散した複数の送気開口３５からなる構造を有し、上記第２の機構は、排気通路２３、分散した複数の吸気（集気）開口２５、排気導管２８からなり集気空間を有しない構造を有するものである。この構造により、賦形対象の全面に均一に送気し、同全面から気体を集めて排気することができる。圧縮気体の温度は任意に選ぶことができる。常温気体を用いる場合は、高温の成形型を用い、常温圧空賦形に続いて、送気気体による冷却を行うことができる。また高温圧縮気体を用いる場合は、高温圧空賦形に続いて賦形体の昇温熱処理を行うことができる。後者の場合、賦形体の冷却は必要により後述の特別な成形型の温度設定に依存して行うことができる。なお、高温気体を用いる場合は、送気ポートを熱浸透率の小さな材料で製作したり、通路を断熱材で形成したりすればよい。 FIG. 7 shows the simplest example of the above-described compressed air box of the present invention. The compressed air box 30 in this figure has a structure in which an air supply port 31 includes a compressed gas introduction path 33, a distribution space 34, and a plurality of dispersed air supply openings 35 as the first mechanism. The exhaust passage 23, the plurality of dispersed intake (collection) openings 25, and the exhaust conduit 28 have a structure having no air collection space. With this structure, air can be uniformly supplied to the entire surface of the shaping object, and gas can be collected and exhausted from the entire surface. The temperature of the compressed gas can be arbitrarily selected. In the case of using room temperature gas, a hot mold can be used, and cooling with air supply gas can be performed following room temperature pressure shaping. Moreover, when using high temperature compressed gas, the temperature rising heat processing of a shaped object can be performed following a high temperature compressed air shaping. In the latter case, the shaped body can be cooled depending on the temperature setting of a special mold described later, if necessary. In addition, when using high temperature gas, what is necessary is just to manufacture an air supply port with a material with small heat permeability, and to form a channel | path with a heat insulating material.
　上記とは別の例を図３に示して説明する。この例は、1図１及び図２の一部に示す例と同様に分配空間と集気空間の両者を有する態様を変形したものである。図３の形態は、圧空ボックス３０の底内部（圧空空間の底部）に、送気ポート３１（第１の機構）と排気ポート２１（第２の機構）を上下の関係ではなく、交互に差し込むようにして平面上に並べて配置したものである。排気ポート２１は、排気路２３、集気空間２４、吸気開口２５、操作バルブ２３ｖから、又、送気ポート３１は、圧縮気体の導入路３３、分配空間３４、送気開口３５、送気面３６、圧空空間３９、及び操作バルブ３３ｖから構成されている。 An example different from the above will be described with reference to FIG. This example is a modification of the embodiment having both the distribution space and the air collection space, similar to the example shown in part of FIG. 1 and FIG. In the embodiment of FIG. 3, the air supply port 31 (first mechanism) and the exhaust port 21 (second mechanism) are inserted alternately into the bottom inside of the compressed air box 30 (bottom of the compressed air space) instead of the vertical relationship. Thus, they are arranged side by side on a plane. The exhaust port 21 is from the exhaust path 23, the air collection space 24, the intake opening 25, and the operation valve 23v. The air supply port 31 is the compressed gas introduction path 33, the distribution space 34, the air supply opening 35, the air supply surface. 36, a compressed air space 39, and an operation valve 33v.
　図３では送排気面３６は送排気面２９とは上下にずらしているが同一平面上に並べてもよい。開口は単なる孔であってもよく、スリット状等任意の形にすることができる。又それぞれの開口は各ポートと接続した任意の長さの導管の先に設けてもよく、あるいは公知の分散ノズルを接続してもよい。図１の場合と同様に送気ポート３１に導入された気体は圧空空間３９に送気され、送気された気体は排気ポート２１に集気され外部に排気される。図１の場合と同様に操作し、同様の効果を得ることができる。 In FIG. 3, the air supply / exhaust surface 36 is shifted up and down from the air supply / exhaust surface 29, but they may be arranged on the same plane. The opening may be a simple hole, and may have any shape such as a slit shape. Each opening may be provided at the end of a conduit having an arbitrary length connected to each port, or a known dispersion nozzle may be connected. As in the case of FIG. 1, the gas introduced into the air supply port 31 is supplied to the compressed air space 39, and the supplied gas is collected into the exhaust port 21 and exhausted to the outside. It is possible to obtain the same effect by operating in the same manner as in FIG.
　なお、図３の圧空ボックスの構造はそのままにして、図に示す排気ポートを送気ポートとし、送気ポートを排気ポートに変更して利用することもできる。
なお、図中の送気ポート３１と排気ポート２１の間の区画をなくして両者を一体材料で構成してもよく、あるいは両者の間に部分的に間隙を設けてもよく、あるいは断熱材を挿入するなどしてもよい。
　なお、本図の構成で送気ポート３１と排気ポート２１の機能を入れ替えてもよく、又温度等の異なる気体を順次異なるポートから送出してもよく、それは操作バルブ２３ｖ、３３ｖの切り替え操作により実施できる。 The structure of the compressed air box in FIG. 3 can be used as it is, and the exhaust port shown in the figure can be used as an air supply port, and the air supply port can be changed to an exhaust port.
In addition, the section between the air supply port 31 and the exhaust port 21 in the figure may be eliminated, and both may be formed of an integral material, or a gap may be partially provided between the two, or a heat insulating material may be provided. It may be inserted.
It should be noted that the functions of the air supply port 31 and the exhaust port 21 may be interchanged in the configuration of this figure, or gases having different temperatures and the like may be sent out sequentially from different ports by switching the operation valves 23v and 33v. Can be implemented.
　なお、本発明の図３の構成は少なくとも冷却用気体の送出（噴射）を行うものであるが、必要な場合に応じて加熱気体の送出（噴射）を行ってもよい。その場合、この送気ポート３１あるいはその排気ポート２１等を、熱浸透率の低いセラミックス等で形成することが望ましく、これにより通過気体の熱ロスを減少させることができ好ましい。
　また必要により送気ポート３１等にヒーターを付設して加熱できるようにし送気気体温度な適切にものにすることは好ましく、それは本発明に属する第２の発明として後述する。 In addition, although the structure of FIG. 3 of this invention performs sending (injection) of the gas for cooling at least, you may perform sending (injection) of heated gas as needed. In that case, it is desirable to form the air supply port 31 or the exhaust port 21 thereof with ceramics having a low thermal permeability, and this can reduce the heat loss of the passing gas.
Further, if necessary, it is preferable to attach a heater to the air supply port 31 or the like so that the air supply port 31 can be heated so that the air supply gas temperature is appropriate, which will be described later as a second invention belonging to the present invention.
　本発明に属する第２の発明として、上記の圧空プレート又は圧空ボックスの第１の機構である送気機構に加熱温調手段を付加して好ましい成形装置とすることができる。このような加熱温調手段としては、例えば加熱ヒーターの付加、熱媒循環など公知の任意の方法を用いることができる。この第２の発明の構成により、先ず１）導入した気体を高温に保持あるいは加熱して圧空空間に送気することが容易になり、その結果２）圧空樹脂による樹脂シートの温度降下を防ぎ、あるいは樹脂シートを予熱しながら圧空賦形を行うことができるようになり、又３）高温気体による賦形体の昇温が容易になるという効果が得られる。　樹脂シートを賦形位置で予熱しながら、予熱と殆ど同時に賦形できるという機能は、成形材料が延伸シートである場合は特に重要であり、これにより、賦形前の熱固定を極力少なくして良好な細部成形が可能にする。 As a second invention belonging to the present invention, it is possible to obtain a preferable molding apparatus by adding a heating temperature adjusting means to the air supply mechanism which is the first mechanism of the compressed air plate or the compressed air box. As such heating temperature adjusting means, for example, any known method such as addition of a heater or circulation of a heat medium can be used. According to the configuration of the second invention, first, 1) it becomes easy to hold or heat the introduced gas and supply it to the compressed air space, and as a result 2) prevent the temperature drop of the resin sheet due to the compressed air resin, Alternatively, compressed air shaping can be performed while preheating the resin sheet, and 3) the effect of facilitating the temperature rise of the shaped body by the high-temperature gas is obtained. The function of pre-heating the resin sheet at the forming position and forming it almost simultaneously with pre-heating is particularly important when the molding material is a stretched sheet, which minimizes heat fixation before shaping. Enables fine detail molding.
　図４及び図５にその具体例を示す。図４の圧空プレート４０は、送気ポート３１と排気ポート２１から構成され、送気ポート３１は内蔵カートリッジヒーターで加熱されるようになっている。圧空プレートは単体では圧空空間を形成できないが、本図では、成形型を成形型より側壁の高い収納ボックスに収納し、予熱されて導入された樹脂シート１００に成形型側から真空引きを作動させ、その後に圧空ボックス３０を降下させ、圧空空間３９を形成させた状態を示している。この構成では、導入路３３を通じ外部から加熱圧縮気体を導入して送気口３５から送気して圧空賦形を行い、次いで導入路２３を通じて非加熱の圧縮気体を導入し吸気口２５から噴射させ賦形体を冷却する。この操作で、圧空空間内の気体を吸気口２５を通じて排気しながら加熱圧縮気体の送気を続ければ、賦形体の昇温を容易に行うことができ、又送気口３５を通じて排気を行いながら吸気口２５非加熱気体の送気を続ければ賦形体を容易に冷却することができる。なお、上述のように操作すれば、樹脂シートは実質的に圧空プレートに接触しないので、シート予熱温度とは無関係な任意の高温に設定することができる。樹脂シートへの部分的な高熱の作用を防ぐために断熱材２８を設けているが、この部分のみに通水するなど、熱遮断のできる別の機構を用いてもよい。 Specific examples are shown in FIGS. 4 includes an air supply port 31 and an exhaust port 21, and the air supply port 31 is heated by a built-in cartridge heater. Although the compressed air plate alone cannot form a compressed air space, in this figure, the mold is stored in a storage box having a side wall higher than that of the mold, and the preheated resin sheet 100 is evacuated from the mold side. Then, the compressed air box 30 is lowered and the compressed air space 39 is formed. In this configuration, heated compressed gas is introduced from the outside through the introduction passage 33 and supplied from the air supply port 35 to perform compressed air shaping, and then non-heated compressed gas is introduced through the introduction passage 23 and injected from the intake port 25. Let the shaped body cool. With this operation, if the heated compressed gas is continuously supplied while exhausting the gas in the compressed air space through the intake port 25, the shaped body can be easily heated, and the exhaust gas is being exhausted through the air supply port 35. The shaped body can be easily cooled by continuing to feed the non-heated gas from the intake port 25. If the operation is performed as described above, the resin sheet does not substantially contact the compressed air plate, so that it can be set to any high temperature unrelated to the sheet preheating temperature. Although the heat insulating material 28 is provided in order to prevent the partial high heat action on the resin sheet, another mechanism capable of blocking heat may be used such as passing water only through this portion.
　図４の場合と同様に加熱手段を付加したもので、これとは少し構造の異なるものを図５に示す。本図は、予熱シートの導入後に真空賦形を先行させ圧空ボックスを完全降下させ圧空賦形を行っている状態を示したものである。図５の圧空ボックス３０は、図１と同じように送気機構３１と排気機構２１を上下に重ね、送気機構に加熱ヒーター３２を付加し、更に集気管を延長して排気開口２５を成形型に近づけた構造にしたものである。
排気機構２１は、排気路２３、集気空間２４、集気管２６、集気面２９、吸気開口２５、操作バルブ２３ｖからなり、送気ポート３１は、加熱ヒーター３２、高温圧縮気体の導入路３３、分配空間３４、送気開口３５、送気面３６、断熱材３７、圧空空間３９、及び操作バルブ３３ｖから構成されている。 A heating means is added in the same manner as in FIG. 4, and a structure slightly different from this is shown in FIG. This figure shows the state in which pressure forming is performed by completely lowering the pressure box by introducing vacuum forming after the introduction of the preheating sheet. In the compressed air box 30 of FIG. 5, the air supply mechanism 31 and the exhaust mechanism 21 are vertically stacked as in FIG. 1, a heater 32 is added to the air supply mechanism, and the air collection pipe is extended to form the exhaust opening 25. The structure is close to the mold.
The exhaust mechanism 21 includes an exhaust path 23, an air collection space 24, an air collection pipe 26, an air collection surface 29, an intake opening 25, and an operation valve 23 v, and an air supply port 31 includes a heater 32 and a high-temperature compressed gas introduction path 33. , A distribution space 34, an air supply opening 35, an air supply surface 36, a heat insulating material 37, a compressed air space 39, and an operation valve 33v.
　図４の装置は、図３の場合と同様に操作することができ、工程の前半の賦形工程と熱処理工程では、送気機構３１及び排気機構２１はその名称どおりそれぞれ送気機構及び排気機構として作動させる。そして工程の後半の冷却工程では送気機構３１を排気機構、排気機構２１を送気機構として作動させる。加熱ヒーター３２は導入された高温気体を保温あるいは加熱するためのものである。各機構の送気、排気の切り替えは操作バルブ２３ｖ、３３ｖによって行われる。なお、冷却工程では、圧空ボックスは必ずしも降下状態ある必要はなく、これを上昇させながら冷却気体の噴射を行ってもよい。 The apparatus in FIG. 4 can be operated in the same manner as in FIG. 3, and in the shaping process and heat treatment process in the first half of the process, the air supply mechanism 31 and the exhaust mechanism 21 are respectively the air supply mechanism and the exhaust mechanism as their names indicate. Operate as In the cooling process in the latter half of the process, the air supply mechanism 31 is operated as an exhaust mechanism and the exhaust mechanism 21 is operated as an air supply mechanism. The heater 32 is for keeping or heating the introduced high-temperature gas. Switching between air supply and exhaust of each mechanism is performed by operation valves 23v and 33v. In the cooling process, the compressed air box is not necessarily in the lowered state, and the cooling gas may be injected while the pressure box is raised.
　図４の装置では、吸気開口の高さは成形型の窪みの深さに合わせたものであり、このようにすることにより送気開口３５から送られる気体が十分に継続的に賦形体表面に届き、効果的で均一な熱処理昇温ができる。そして冷却工程では、この吸気開口２５から賦形体に強い気体噴射を行い、全面賦形面の均一で効果的な冷却を継続することができる。
　本図の構造の変形として、集気管２６を短くして（すなわち集気面の高さを低くして）、送気開口３５をリード管で成形型に近づけるようにしてもよい。あるいは、別の変形として、図５における構造をそのままにして、３１の送気機構及び２１の排気機構を、それぞれ排気機構及び送気機構（但し加熱ヒータはこの送気機構に付加する）としてもよい。
　なお、この例では排気流入管の先端部は圧空ボックス壁よりも高く突出しているので、圧空ボックスを降下させたとき樹脂シートを突き刺してしまうことになる。しかし、圧空ボックスの降下に先だって真空賦形を先行させればこの事象は全く問題にならない。 In the apparatus of FIG. 4, the height of the intake opening is adjusted to the depth of the depression of the mold, and in this way, the gas sent from the air supply opening 35 is sufficiently continuously applied to the surface of the shaped body. It can reach an effective and uniform heat treatment temperature increase. In the cooling step, strong gas injection is performed from the intake opening 25 to the shaped body, and uniform and effective cooling of the entire shaped surface can be continued.
As a modification of the structure of this figure, the air collection pipe 26 may be shortened (that is, the height of the air collection surface is lowered), and the air supply opening 35 may be brought closer to the forming die with a lead pipe. Alternatively, as another modification, the structure in FIG. 5 is left as it is, and the 31 air supply mechanism and the 21 exhaust mechanism are replaced with an exhaust mechanism and an air supply mechanism (however, a heater is added to the air supply mechanism). Good.
In this example, since the tip of the exhaust inflow pipe protrudes higher than the pressure box wall, the resin sheet is pierced when the pressure box is lowered. However, this phenomenon is not a problem at all if the vacuum shaping is preceded by the descent of the compressed air box.
　更に、本発明に属する第３の発明として、圧空手段に、上記第１、第２の機構及とは別に、第３の機構として、別途導入した圧縮気体を別途設けた送出開口から上記成形型上部に向けて送出する機構を更に一体として備えることにより更に好ましい装置とすることができる。 Further, as a third invention belonging to the present invention, as a third mechanism, separately from the first and second mechanisms, the compressed die is provided with a separately introduced compressed gas from a delivery opening provided separately. A more preferable device can be obtained by further providing a mechanism for feeding toward the upper part.
　すなわち、この第３の発明の構成により、先ず１）各目的に合わせた専用の開口の位置及び形式（任意のノズルなじ）を決めることができ、強力な加熱昇温又は冷却が可能となり、又２）各機構が互いの作用を阻害することなく助成し合うことが可能になる。 That is, according to the configuration of the third aspect of the invention, first, 1) the position and type of the dedicated opening for each purpose (arbitrary nozzle alignment) can be determined, and powerful heating and cooling or cooling can be performed. 2) It becomes possible for each mechanism to support each other without interfering with each other's action.
　本発明に属する第４の発明として、上記の第３の機構における高温圧縮気体の送出を、上記圧空プレートの内部又は上記圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにし好ましい成形装置とすることができる。第３の機構を設けることの効用は既に記載しているが、この第５の発明により、圧空空間内で第１、２、３の機構の作用が、より効果的に互いを阻害することなくその機能を果たすことができる。 As a fourth invention belonging to the present invention, the high-temperature compressed gas in the third mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the compressed air box bottom. Thus, a preferable molding apparatus can be obtained. Although the utility of providing the third mechanism has already been described, according to the fifth invention, the actions of the first, second, and third mechanisms in the compressed air space are more effectively prevented from interfering with each other. It can fulfill its function.
　上記第３の発明、第４の発明を併せて具現化した例を図６に示す。本図の例は、圧空ボックス３０の底部に、高温気体の送出機構３１と排気機構２１を並列に配置しそれぞれに直接に開口３５及び２５を設け、更に両機構の背後に第３の機構の気体の送出ポート１１を配置して成形型方向に向けた送気開口１５を送気管１６の先端に設けた構造としている。高温気体の送出機構３１には加熱ヒーター３２を付加している。３１による高温気体の送出は樹脂シートの賦形、熱処理に利用され、１１による低温気体の送出は賦形体の冷却に利用され、２１による排気は賦形体の熱処理昇温及び冷却を継続的にかつ効率的行うためになされる。それぞれの送気及び排気の作動操作は、バルブ１１ｖ、２２ｖ、３３ｖによって行うことができ、排気のタイミングは適宜に任意に設定できる。 FIG. 6 shows an example in which the third invention and the fourth invention are embodied together. In the example of this figure, a hot gas delivery mechanism 31 and an exhaust mechanism 21 are arranged in parallel at the bottom of the compressed air box 30, and openings 35 and 25 are directly provided in the mechanisms, respectively. The gas delivery port 11 is arranged and an air feed opening 15 directed toward the mold is provided at the tip of the air feed pipe 16. A heater 32 is added to the hot gas delivery mechanism 31. The delivery of the high temperature gas by 31 is used for shaping and heat treatment of the resin sheet, the delivery of the low temperature gas by 11 is used for cooling the shaped body, and the exhaust by 21 continuously increases the temperature rise and cooling of the shaped body by heat treatment. Made to do efficiently. Each operation of air supply and exhaust can be performed by the valves 11v, 22v, and 33v, and the timing of exhaust can be arbitrarily set as appropriate.
　本発明に属する第５の発明として、上記第３の機構に加熱温調手段を付与し高温の圧縮気体を送出開口から送出するようすることにより、更に好ましい装置とすることができる。この第４の発明は、（１）圧空賦形用と加熱昇温用の気体温度を別々に設定でき、成形材料等に応じた条件設定の自由度が増し、（２）熱ロス少ない効果的な熱処理が可能にし、また装置操作を容易にする。　 As a fifth invention belonging to the present invention, it is possible to provide a more preferable device by providing a heating temperature adjusting means to the third mechanism to deliver a high-temperature compressed gas from a delivery opening. In the fourth aspect of the invention, (1) the gas temperature for pressure forming and the temperature for heating can be set separately, the degree of freedom in setting conditions according to the molding material and the like is increased, and (2) the heat loss is effectively reduced Heat treatment is possible, and operation of the apparatus is facilitated.
　本発明に属する第６の発明として、本発明の装置の上記の何れかの加熱温調手段を有する送気機構の内部で導入した圧縮気体を２００℃以上の、そして好ましくは２５０℃以上の、更に好ましくは３００以上の十分に加熱して送出する機能を備えたものにすることにより、これを好ましく用いることができる。これを行うには、例えば上記機構の内部で加熱された金属等の熱媒体の気体接触面積を十分大きくし、又加熱手段の加熱能力を十分大きくすることにより可能であり、この方法は好ましい。具体的には、上記機構の内部を多孔材料あるいは粒状の固体熱媒体で構成すればよい。なお、公知の熱板などでは、この機構はなく十分な温度の気体送気を続けることができない。又、機構内部に裸の加熱ヒーター（ジュール熱ヒーター）を設置する方法もあるが、急激な温度変化に耐えず問題になりやすい。
　上記第５の発明は、外部での気体加熱装置をなくして装置全体をコンパクトにし、又高熱気体の移動による熱損失をなくし、高度の耐熱を要するバルブ等精密部品の必要性をなくする利点をもたらしてくれる。 As a sixth invention belonging to the present invention, the compressed gas introduced inside the air feeding mechanism having any one of the heating temperature adjusting means of the apparatus of the present invention is 200 ° C or higher, and preferably 250 ° C or higher. More preferably, it can be preferably used by providing it with a function of 300 or more sufficiently heated and delivered. This can be done, for example, by sufficiently increasing the gas contact area of a heat medium such as metal heated inside the mechanism and sufficiently increasing the heating capacity of the heating means, and this method is preferable. Specifically, the inside of the mechanism may be constituted by a porous material or a granular solid heat medium. Note that a known hot plate or the like does not have this mechanism and cannot continue supplying gas at a sufficient temperature. In addition, there is a method of installing a bare heater (Joule heater) inside the mechanism, but it is not easy to withstand a rapid temperature change, which is problematic.
The fifth aspect of the invention has the advantage of eliminating the need for precision parts such as valves that require a high degree of heat resistance by eliminating the external gas heating device, making the entire device compact, eliminating heat loss due to the movement of hot gas. Bring me.
　本発明に属する第７の発明として、上記圧空プレート又は圧空ボックス底の成形型対向面を２００℃以上に加熱保持が可能で、且つ赤外線放射率が０．８以上であるようにした成形装置は好ましく用いることができる。具体的には、例えば図４、図５、図６における高温気体送出面３６を２００℃以上に、更に２５０℃以上に、更に又３００℃以上に保持できるようにした装置は好ましく用いることができる。又、この面に市販の赤外線放射用の黒色塗料の塗布により赤外線放射率が０．８以上にした装置は好ましく用いることができる。この第６の発明により、１）樹脂シートを賦形位置で予熱あるいは、仕上げ予熱（予熱された材料を導入した場合）直後に賦形を行い、あるいは予熱しながら賦形を行うことを可能にし、延伸樹脂シートの熱固定進行による賦形性の低下を少なくし、また２）熱固定のための賦形体の加熱あるいは加熱を助成する効用がもたらされる。 As a seventh invention belonging to the present invention, there is provided a molding apparatus in which the molding die facing surface of the compressed air plate or the compressed air box bottom can be heated and maintained at 200 ° C. or more and the infrared emissivity is 0.8 or more. It can be preferably used. Specifically, for example, an apparatus in which the high-temperature gas delivery surface 36 in FIGS. 4, 5, and 6 can be maintained at 200 ° C. or higher, further 250 ° C. or higher, and further 300 ° C. or higher can be preferably used. . Further, an apparatus having an infrared emissivity of 0.8 or more by applying a commercially available black paint for infrared radiation on this surface can be preferably used. According to this sixth invention, 1) it is possible to preheat the resin sheet at the shaping position, or to perform shaping immediately after finishing preheating (when preheated material is introduced), or to perform shaping while preheating. 2) The effect of reducing the deterioration of the shapeability due to the progress of heat setting of the stretched resin sheet and 2) heating the shaped body for heat setting or assisting the heating are brought about.
　上記圧空手段は、更に下記の１）～８）の様な態様してもよく、これらの態様は好ましく利用できる。
１）上記各図において、１成形サイクルの任意の時点で、同じ送気本体から、送出気体を温度等の異なる気体に変更して送出できるように構成してもよい。温度の大きく異なるものに変更する場合は、送気機構の少なくとも内部は熱浸透率の小さな断熱材料を用いることは好ましく、又その送気通路等を２つの気体温度の間の適正に温度にすることは好ましい。この構成により、加熱気体により賦形体の熱処理昇温を行い、次いで低温気体によりその冷却を行うようにしてもよい。なお、圧空賦形は加熱気体でおこなってもよく、又低温気体で行ってもよい。 The compressed air means may further be configured as in the following 1) to 8), and these embodiments can be preferably used.
1) In each said figure, you may comprise so that sending gas can be changed into different gas, such as temperature, from the same air supply main body at the arbitrary time of 1 shaping | molding cycle. In the case of changing to a greatly different temperature, it is preferable to use a heat insulating material with a low thermal permeability for at least the inside of the air supply mechanism, and to make the air supply passage etc. appropriately between the two gas temperatures. That is preferred. According to this configuration, the heat treatment temperature of the shaped body may be raised with a heated gas, and then cooled with a low-temperature gas. The compressed air shaping may be performed with a heated gas or a low temperature gas.
２）上記各図の基本構造をほぼそのままにして、排気機構２１を送気機構に、送気機構１１又は３１を排気機構に変更して構成してもよい。
３）樹脂シートの予熱を圧空手段からの送気又は同手段からの赤外線放射により行うことができるよう構成することができる。賦形直前又は賦形中の樹脂シートに加熱され気体を序々に送気する構成にしてこれを行うことは好ましい。 2) The basic structure shown in each of the above drawings may be left as it is, and the exhaust mechanism 21 may be changed to an air supply mechanism and the air supply mechanism 11 or 31 may be changed to an exhaust mechanism.
3) The resin sheet can be preheated by air supply from the compressed air means or infrared radiation from the same means. It is preferable to perform this in a configuration in which the resin sheet is heated immediately before shaping or during shaping and gas is gradually fed.
４）賦形体の冷却に、圧縮気体の送出と併せて水あるいはアルコール等の揮発性液体を噴射あるいは噴霧するようにすることも好ましい。この場合、圧空ボックス内等から賦形体に向けてその噴射又は噴霧するノズルを設ければよい。
５）冷却用気体は、常温より低温であることは好ましく、圧縮気体をドライアイス粒塊に潜らせて冷却してもよく、あるいはドライアイスの粉粒を混合して気体噴射してもよく、あるいは断熱膨張の手段を利用して冷却してもよい。 4) It is also preferable to spray or spray a volatile liquid such as water or alcohol in combination with the delivery of the compressed gas for cooling the shaped body. In this case, a nozzle for spraying or spraying the shaped object from the inside of the compressed air box or the like may be provided.
5) The cooling gas is preferably at a temperature lower than room temperature, and may be cooled by immersing the compressed gas in a dry ice granule, or the dry ice powder may be mixed and jetted with gas, Or you may cool using the means of adiabatic expansion.
６）上記圧空手段からの排気に際しては、吸気開口を通じて行う排気を、物理的矯正手段により促進するよう構成されることは好ましい。このような手段の具体例として、例えば吸引排気のブロウワーを付設してもよく、あるいは強力な直進噴射流を利用するアスピレーターの機構を利用してもよい。
７）上記圧空手段の排気に際して圧力弁を配置する事は好ましく、バルブ操作をしなくても一定圧で圧空賦形しながら賦形体の加熱昇温ができる。
８）上記圧空手段は、賦形後も必ずしも圧空間封鎖を継続する必要はなく、上記圧空手段を成形型から若干浮上させて高温気体あるいは冷却気体を継続してもよく、場合によってはこの方が好ましいこともある。 6) When exhausting from the compressed air means, it is preferable that exhaust performed through the intake opening is promoted by physical correction means. As a specific example of such means, for example, a suction exhaust blower may be provided, or an aspirator mechanism using a strong straight jet flow may be used.
7) It is preferable to dispose a pressure valve when evacuating the compressed air means, and it is possible to raise the temperature of the shaped body while heating with a constant pressure without operating the valve.
8) The compressed air means does not necessarily need to continue the sealed pressure space after shaping, and the pressurized air means may be slightly lifted from the mold and continued with the high-temperature gas or the cooling gas. It may be preferable.
　上記の各圧空手段は、本発明者を発明者とする特願２０１１－１６５０６７、出願２０１１－４１２９４に開示しているものより、更に改良された機構を有し、より優れた効用を有する。
　そして、本発明の構成に用いられる圧空手段には次のような効用がある。１）任意に継続して気体を送出することができ、迅速に冷却工程へ進むことができ、成形サイクルを短くすることができる。２）全成形面を均一にかつ効率的に冷却することができ、均一で精度の高い成形品を得ることができる。３）成形装置全体を簡易に構成することができる。４）強力な冷却を行うことができ、その結果利用できる成形型構成の設計自由度を大きく広げることができ、簡易で低価格成形型も利用できるようになるなどの効用がある。 Each of the above-described compressed air means has a further improved mechanism and more excellent utility than those disclosed in Japanese Patent Application Nos. 2011-165067 and 2011-41294, the inventors of which are the inventors.
The compressed air means used in the configuration of the present invention has the following effects. 1) The gas can be sent out continuously as desired, and the process can proceed to the cooling process quickly, and the molding cycle can be shortened. 2) The entire molding surface can be cooled uniformly and efficiently, and a uniform and highly accurate molded product can be obtained. 3) The entire molding apparatus can be simply configured. 4) Powerful cooling can be performed. As a result, the design flexibility of the mold configuration that can be used can be greatly expanded, and a simple and low-cost mold can be used.
＜成形型について＞　
　本発明の装置構成要素として用いられる成形型は、真空排気孔などの公知の熱成形としての必要要素を備えておればよく特に限定するものではない。
しかし、本発明の第８の発明の装置構成要素の成形型として、熱浸透率（ｋＪ／ｍ２ｓ１／２Ｋ）が０．０１～２５である材料により少なくとも成形用表面を形成させたものを用いることは好ましい。 <About molds>
The mold used as the apparatus constituent element of the present invention is not particularly limited as long as it includes necessary elements for known thermoforming such as a vacuum exhaust hole.
However, at least a molding surface is formed of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.01 to 25 as a molding die of the apparatus component of the eighth invention of the present invention. It is preferable to use one.
　なお、上記の熱浸透率は２０以下であることが好ましく、１５以下であることが更に好ましく、１０以下であることが更にまた好ましい。
なお、成形型を上記熱浸透率が２以上２５以下の材料で単一構成した場合は、はこの材料層直接にヒーター等を付加し温調することが好ましい。又上記熱浸透率が０．０１以上１５以下の材料で単一構成した場合はヒーター等の温調手段を付加は必ずしも必要でなく、加熱気体等と冷却気体を用いる連続成形のサイクル中で成形型表面の温度制御は可能である。　　
　上記熱浸透率とその数値限定の意義等については後に「本発明の内容についての補足説明」の欄で説明する。 The heat permeability is preferably 20 or less, more preferably 15 or less, and still more preferably 10 or less.
In the case where the molding die is made of a single material having a heat permeability of 2 or more and 25 or less, it is preferable to adjust the temperature by adding a heater or the like directly to the material layer. In addition, when a single material is formed with a material having a thermal permeability of 0.01 or more and 15 or less, it is not always necessary to add a temperature control means such as a heater, and molding is performed in a continuous molding cycle using heating gas and cooling gas. The mold surface temperature can be controlled.
The above-mentioned thermal permeation rate and the significance of limiting the numerical value will be described later in the section “Supplementary explanation about the contents of the present invention”.
　熱浸透率がこのような範囲にある材料として、プラスチックス、セラミックス、選ばれた小数の種類の金属材料等を挙げることができ、これらは熱成形の金型として通常使われるアルミニウム材、亜鉛合金材等の中からも選ぶことができる。好ましい範囲の熱浸透率を有する材料例は表１の中からも選ぶことができる。但し表記は一般的な物質あるいは物体を参考ため示したものであり、利用出来るものをこれらに限るものではない。 Examples of materials having a thermal permeability within this range include plastics, ceramics, and a small number of selected metal materials. These include aluminum materials and zinc alloys that are commonly used as thermoforming molds. You can also choose from materials. Examples of materials having a preferred range of heat permeability can be selected from Table 1. However, the notation is shown for reference to general substances or objects, and what can be used is not limited to these.
　成形型は、上記の材料のみによる単一構成であってもよく、又上記材料を表面層とする任意の複合構造であってもよい。あるいは又、このような材料の表面層を有する成形型は、表面層自体が発熱するようにしたもの、あるいは表面層の背後全面に密着して表面層を加熱温調する層、あるいは蓄熱層を設けた構成のものを好ましく利用できる。この場合、背後層あるいは温調機構の背後は特定されず、又背後層はなくてよい場合もある。 The molding die may have a single structure made of only the above-mentioned material, or may have an arbitrary composite structure having the above material as a surface layer. Alternatively, a mold having a surface layer made of such a material may have a surface layer itself that generates heat, or a layer that heats and controls the surface layer in close contact with the entire back surface of the surface layer, or a heat storage layer. The thing of the provided structure can be utilized preferably. In this case, the back layer or the back of the temperature control mechanism is not specified, and there may be no back layer.
　なお、本発明の構成に望ましい態様とし示す成形型は、本発明者を発明者とする先行出願、特願２０１０－１１８５５５、特願２０１０－１１８４９０、
特願２０１０－１１８４８９、特願２０１０－１１８５６２及び特願２０１１－０６５０６９に開示し、更に優先権出願の元にある前記４件の装置構成の中でそれらが好適に利用できることが記載されている。 Note that the mold shown as a desirable mode for the configuration of the present invention is a prior application filed by the present inventor, Japanese Patent Application Nos. 2010-118555, 2010-118490,
It is disclosed in Japanese Patent Application Nos. 2010-118489, 2010-118562, and 2011-0665069, and further describes that they can be suitably used in the four device configurations based on the priority application.
　本発明に属する第９の発明として、装置構成に用いる上記の成形型を、熱浸透率（ｂ値）が２０以下の材料によりなる表面層と熱浸透率（ｂ値）が表面層のそれより大きな材料からなる背後体からなるように構成したものは好適に用いることができる。　　
　なおこの場合、上記熱浸透率は、１５以下であることが好ましく、１０以下であることが更に好ましい。そして、この表面層の厚みは０．０４ｍｍ以上であることが必要であり、また０．０６ｍｍ以上であることが好ましく、０．１ｍｍ以上であることが更に好ましい。又同厚みは３０ｍｍ以下であることが好ましく、１０ｍｍ以下であることが更に好ましく、５ｍｍ以下であることが更に更に好ましい。なお、表面層の厚みは概ね均一であることが好ましい。 As a ninth invention belonging to the present invention, the above-described mold used for the apparatus configuration is composed of a surface layer made of a material having a thermal permeability (b value) of 20 or less and a thermal permeability (b value) of that of the surface layer. What was comprised so that it might consist of a back body which consists of a big material can be used suitably.
In this case, the heat permeability is preferably 15 or less, and more preferably 10 or less. And the thickness of this surface layer needs to be 0.04 mm or more, it is preferable that it is 0.06 mm or more, and it is still more preferable that it is 0.1 mm or more. The thickness is preferably 30 mm or less, more preferably 10 mm or less, and even more preferably 5 mm or less. The surface layer preferably has a substantially uniform thickness.
　また上記の背後体（背後層）の熱浸透率は、表面層のそれより２倍以上であることが好ましく、１０倍以上であることが特に好ましい。なお、背後層の厚みはあるいは形状は限定するものではない。またこの背後層を単一材料の層に限定するものではなく任意の多層にしてもよい。
　また、背後層の熱浸透率は、３以上であることが好ましく、６以上であることが更に好ましく、１０以上であることか更に更に好ましい。また背後層の熱浸透率は表面層のそれより２倍以上であることが好ましく、１０倍以上であることが特に好ましい。 Further, the heat permeability of the back body (back layer) is preferably 2 times or more, and more preferably 10 times or more that of the surface layer. The thickness or shape of the back layer is not limited. Further, the back layer is not limited to a single material layer, and may be an arbitrary multilayer.
Further, the thermal permeability of the back layer is preferably 3 or more, more preferably 6 or more, and even more preferably 10 or more. The thermal permeability of the back layer is preferably 2 times or more, and more preferably 10 times or more than that of the surface layer.
　本発明に属する第１０の発明として、装置構成に用いる上記の成形型を、上記の第８又は第９の発明に用いる成形型に、表面層を背後から温度調整する手段付加して構成したものは好適に用いることができる。
　このためのより具体的な好ましい方法として、１）表面層に密着し、より大きな熱浸透率を有する背後層に温調機構を付加する方法、２）表面層の背後に略全面に密接して均一温調手段を設ける方法、３）表面層自体を発熱させる方法。４）表面層の全背後に密着した蓄熱層を設ける方法などがある。この温調には、電熱ヒーターを用いる方法、熱媒を用いる方法等、公知のどのような方法も利用できる。しかし、本発明では加熱側の温調であることが好ましい。 As a tenth invention belonging to the present invention, the above-mentioned mold used for the apparatus configuration is constructed by adding a means for adjusting the temperature of the surface layer from the back to the mold used for the above eighth or ninth invention. Can be preferably used.
As a more specific and preferable method for this purpose, 1) a method of closely attaching to the surface layer and adding a temperature control mechanism to the back layer having a larger heat permeability, and 2) close to the entire surface behind the surface layer. A method of providing uniform temperature control means, 3) A method of generating heat on the surface layer itself. 4) There is a method of providing a heat storage layer in close contact behind the entire surface layer. For this temperature control, any known method such as a method using an electric heater or a method using a heat medium can be used. However, in the present invention, the temperature control on the heating side is preferable.
　上記１）の場合は、この背後層又背後体の何処に温調手段を付加してもよく、層中に設けてもよく、また外部に設けてもよい。背後層からの伝導熱により表面層が一定に加熱される。又上記２）および３）の場合は、この場合は背後層に特に限定はなく、又背後層がなくてもよい。なお、２）の場合は、表面層の背後全面に面状高伝熱層を形成し特定位置から熱伝導させる方法なども含まれる。この２）、３）、４）の成形型は特願２０１１－１６５０６９に開示しているものである。 In the case of 1) above, temperature control means may be added anywhere in the back layer or back body, and it may be provided in the layer or externally. The surface layer is constantly heated by the conduction heat from the back layer. In the above cases 2) and 3), the back layer is not particularly limited in this case, and the back layer may not be provided. In the case of 2), a method of forming a planar high heat transfer layer over the entire surface behind the surface layer and conducting heat from a specific position is also included. The molds 2), 3) and 4) are those disclosed in Japanese Patent Application No. 2011-165069.
　図４および図８に上記１）の構造の例を示す。成形型６０は、表面層６１と背後層６２から構成され、６３は真空排気孔、６４は排気通路、６５は温調用の熱媒通路を示している。この図の構成で、アルミニウム材５０５２の背後層の上に、０．５ｍｍのエポキシ樹脂層あるいはポリイミド樹脂層をつくり、背後層と表面層を通じ成形面に微細な熱電対を露出させて製作した成形型は高性能である。なお、この熱媒通路などの温調手段はここに設けず、成形型を固定する固定板を任意の加熱手段を設けるようにしてもよい。 4 and 8 show examples of the structure 1) above. The mold 60 includes a surface layer 61 and a back layer 62, 63 is a vacuum exhaust hole, 64 is an exhaust passage, and 65 is a heat medium passage for temperature control. With the structure shown in this figure, a 0.5 mm epoxy resin layer or a polyimide resin layer is formed on the back layer of the aluminum material 5052, and a fine thermocouple is exposed on the molding surface through the back layer and the surface layer. The mold is high performance. In addition, temperature control means, such as this heat-medium channel | path, are not provided here, You may make it provide arbitrary heating means for the fixing plate which fixes a shaping | molding die.
　上記２）の場合は、上記の所定の熱浸透率を有する表面層の背後の略全面に密接して加熱手段を設ける構成である。この場合の表面層の構成は材料、寸法形状ともに上記１）と同じであり、望ましい構成も同じである。加熱手段の形成は、次に限るものではないが、例えば表面層背後にａ）面状発熱層の形成、ｂ）面状高伝熱層を形成し特定位置から熱伝導させる方法などがある。背後層についてはその有無、あるいは材質、形状ともに特に制約するものではない。
　なお、この上記２）場合の構成においては、背後層７２は特に限定するものではなく、加熱手段の機能を阻害すことなく表面層あるいは加熱手段の層を保持できればよく、表面層の形状保持ができて何処かへ固定できればよい。 In the case of 2), the heating means is provided in close contact with substantially the entire back surface of the surface layer having the predetermined heat permeability. The structure of the surface layer in this case is the same as that in 1) above in terms of material and dimensions, and the desirable structure is also the same. The formation of the heating means is not limited to the following. For example, there is a method in which a) a planar heating layer is formed behind the surface layer, and b) a planar high heat transfer layer is formed to conduct heat from a specific position. There is no particular restriction on the presence, material, or shape of the back layer.
In the configuration of the above 2), the back layer 72 is not particularly limited as long as the surface layer or the layer of the heating unit can be held without hindering the function of the heating unit, and the shape of the surface layer can be maintained. It should be possible to fix it somewhere.
　図９に、上記２）の構造の例を示す。成形型本体６０は、上記の所定の熱浸透率を有する表面層６１の背後に発熱層６５を有し、さらにその背後の背後他６２からなる。６３は真空排気孔、６４は排気通路、６６はリード線を示す。より具体的には、例えばセラミックス等を背後体とし、その上に面状発熱体を敷き詰めて貼り、更にその上に前記所定の熱浸透率を有する材料により表面層を形成させればよい。面状発熱体を貼る代わりに、背後体の上にニッケル系抵抗体金属をメッキしてエッチングし発熱体層を形成させてもよい。表面層材料としてはエポキシ樹脂、弗素樹脂、ポリイミド、ＰＥＥＫ等の耐熱樹脂などを挙げることができる。なお図示はしていないが、背後体と表面層を通じ成形面に微細な熱電対先端を露出させて製作した成形型は、成形工程の管理に好都合である。 FIG. 9 shows an example of the structure 2) above. The mold main body 60 includes a heat generating layer 65 behind the surface layer 61 having the predetermined heat permeability, and further includes a rear portion 62 behind the heat generating layer 65. 63 denotes a vacuum exhaust hole, 64 denotes an exhaust passage, and 66 denotes a lead wire. More specifically, for example, ceramic or the like may be used as a back body, and a sheet heating element may be laid and pasted thereon, and a surface layer may be formed thereon with a material having the predetermined heat permeability. Instead of attaching the sheet heating element, a heating element layer may be formed by plating and etching a nickel-based resistor metal on the back body. Examples of the surface layer material include heat-resistant resins such as epoxy resin, fluorine resin, polyimide, and PEEK. Although not shown, a molding die manufactured by exposing a fine thermocouple tip to the molding surface through the back body and the surface layer is convenient for management of the molding process.
　＜成形方法について＞
　本発明に属する第１１として、前記した本発明の装置を用いて、樹脂シートの予熱工程、賦形工程、この予熱工程よりも高温で熱処理する熱処理工程と、そして必要により冷却工程を備える熱可塑性樹脂シートの成形方法を実施することができる。本発明の装置を用いた場合は、これらの工程を高速で進めることができ、長尺の成形材料樹脂シートを用いて効率的な連続成形を行うことができる。 <About molding method>
As an eleventh belonging to the present invention, using the above-described apparatus of the present invention, a thermoplastic resin comprising a resin sheet preheating step, a shaping step, a heat treatment step for heat treatment at a temperature higher than the preheating step, and, if necessary, a cooling step. A resin sheet molding method can be carried out. When the apparatus of the present invention is used, these steps can be performed at high speed, and efficient continuous molding can be performed using a long molding material resin sheet.
　本発明に属する第１２の発明として、上記賦形体を高温で熱処理する方法として、１）上記高温気体を賦形体に噴射して行う方法、２）賦形体に赤外線照射して行う方法、若しくは３）上記成形型表面を高温に加熱しておいて賦形を行う方法の少なくとも1つを用いてこれを行う。前記した本発明の装置では、用いる成形型の特性に合わせこれらの方法を選択し、熱処理を高速で能率よく行うことができる。 As a twelfth invention belonging to the present invention, as a method for heat-treating the shaped body at a high temperature, 1) a method for injecting the high temperature gas onto the shaped body, 2) a method for irradiating the shaped body with infrared rays, or 3 This is done using at least one method of shaping by heating the mold surface to a high temperature. In the apparatus of the present invention described above, these methods can be selected according to the characteristics of the mold used, and heat treatment can be performed efficiently at high speed.
　上記の成形工程は、樹脂シートを予熱オーブンあるいは加熱板等で予熱した後、成形型上部に導き、圧空ボックスまたは成形型をそれぞれ上下動させてこの樹脂シート挟み、圧空賦形と賦形体の加熱冷却を行い、圧空ボックスと成形型を離反させて賦形体を離型させることにより行われる。このとき、圧空賦形は、常温ないしは樹脂シートの予熱適温か又はそれ以下の温度の圧縮気体の送出によりなされ、賦形体の加熱は樹脂シートの予熱適温以上の温度に加熱調整された成形型からの伝熱によりなされ、賦形体の冷却は圧空空間への圧縮気体の継続的送出によりなされる。圧空空間への圧縮気体の継続的送出は、圧空を続けながら該排気本体から排気を開始することによりなされる。該排気本体からの排気開始は任意の時点で行うことができ、賦形時から排気してもよく、賦形直後に排気開始してもよく、賦形直後少し時間をおいて排気開始してもよい。これらの最適時間は、用いる成形型および設定温度条件により変わる。 In the above molding process, the resin sheet is preheated with a preheating oven or a heating plate, and then guided to the upper part of the mold, and the compressed air box or the mold is moved up and down to sandwich the resin sheet. It is performed by cooling and separating the shaped body by separating the compressed air box and the mold. At this time, the compressed air shaping is performed by sending compressed gas at normal temperature or a preheat suitable temperature of the resin sheet or a temperature lower than that, and the shaped body is heated from a mold that is heated and adjusted to a temperature higher than the preheat optimum temperature of the resin sheet. The shaped body is cooled by continuously sending compressed gas to the compressed air space. The continuous delivery of the compressed gas to the compressed air space is performed by starting the exhaust from the exhaust body while continuing the compressed air. Exhaust from the exhaust body can be started at an arbitrary time, may be exhausted from the time of shaping, may be started immediately after shaping, or may be started after a short time immediately after shaping. Also good. These optimum times vary depending on the mold used and the set temperature conditions.
　なお、上記の熱成形は次のような具体的な態様変更をおこなってもよく、好ましく利用できる。例えば、１）樹脂シートの予熱温度またはこの温度に近い加熱された圧縮気体の送出により賦形を行い、次いでそれより低い常温等の温度の気体により冷却を行ってもよい。あるいはまた、２）成形位置で、樹脂シートの予熱温度またはこの温度に近い加熱された圧縮気体をゆっくり送出しつつ樹脂シートの予熱を行いながら賦形を行ってもよく、また３）圧空ボックス内に設けたで赤外線照射手段により、樹脂シートの予熱を行いながら賦形を行ってもよい。　　　　　　　　　　　　　　　　　　　　　　　　　　なお、賦形体の変形を防ぐために、離型までは成形型の真空引きによる賦形体の固定を行うことが望ましい。 In addition, the above-mentioned thermoforming may be changed in the following specific manner and can be preferably used. For example, 1) shaping may be performed by feeding a preheat temperature of a resin sheet or heated compressed gas close to this temperature, and then cooling may be performed by a gas at a lower temperature such as room temperature. Alternatively, 2) shaping may be performed while preheating the resin sheet while slowly feeding the preheat temperature of the resin sheet or heated compressed gas close to this temperature at the molding position, and 3) in the compressed air box It may be shaped while preheating the resin sheet by means of infrared irradiation means. Note: To prevent deformation of the shaped body, it is desirable to fix the shaped body by vacuuming the mold until release.
　上記のような成形における装置設定あるいは条件設定は、大きく３つのパターンに分けて説明することができる。
　熱処理を伴う成形工程は、成形型の表面温度（Ｔ）と成形型の内部温度（Ｓ）の変化を見たとき、サインカーブ様の連続成形サイクルを描くことができる。例として、前記のような表面層と背後層からなる成形型を用いた場合を考えてみる。背後層温度をＳ、成形型表面温度をＴ、その最高温度をＴｔ　最低温度Ｔｂとする。 The apparatus setting or the condition setting in the molding as described above can be roughly described in three patterns.
The molding process involving heat treatment can draw a sine curve-like continuous molding cycle when looking at changes in the surface temperature (T) of the mold and the internal temperature (S) of the mold. As an example, consider the case of using a mold consisting of a surface layer and a back layer as described above. The back layer temperature is S, the mold surface temperature is T, and the maximum temperature is Tt and the minimum temperature Tb.
　パターンＡは、Ｓを、表面温度サイクルのＴｔとＴｂの間の一定温度に調整するパターンである。この場合、Ｔｔは高温気体か赤外線照射により到達する温度であり、Ｔｂは冷却手段により到達する温度である。背後層の直接的な温調は行う場合も、行う場合もある。背後そうからあまり熱が逃げない状態で、長時間連続的に成形を続ければ、背後層温度Ｓは表面温度サイクルのＴｔとＴｂに落ち着く。この場合、背後層の熱浸透率があまり大きくなければ、表面層の間近ではＳは時間的に直線ではなく、表面層に追従して小さな温度サイクル描く。背後層は積極的に任意に温調することは望ましく、その温度により加熱手段及び冷却手段を最適最短時間にすることができる。 Pattern A is a pattern for adjusting S to a constant temperature between Tt and Tb of the surface temperature cycle. In this case, Tt is a temperature reached by high-temperature gas or infrared irradiation, and Tb is a temperature reached by the cooling means. Direct temperature control of the back layer may or may not be performed. If the molding is continued continuously for a long time in a state where heat does not escape so much from the back side, the back layer temperature S settles at Tt and Tb of the surface temperature cycle. In this case, if the thermal permeability of the back layer is not so large, S is not linear in time in the vicinity of the surface layer, but draws a small temperature cycle following the surface layer. It is desirable to positively and arbitrarily adjust the temperature of the back layer, and the heating means and the cooling means can be set to the optimum shortest time depending on the temperature.
　パターンＢは、Ｓを、Ｔｂと同じかそれ以下の一定温度に調整するパターンである。この場合Ｔｂは、主として背後層からの伝熱すなわちＳの温度により到達する。冷却手段は必須ではないが使用すればサイクルを縮めることができる。なお、Ｔｔは加熱手段により到達する。 Pattern B is a pattern for adjusting S to a constant temperature equal to or lower than Tb. In this case, Tb is reached mainly by heat transfer from the back layer, that is, the temperature of S. The cooling means is not essential, but if used, the cycle can be shortened. Tt is reached by the heating means.
　パターンＣは、Ｓを、Ｔｔと同じかそれ以上の一定温度に調整するパターンである。この場合は、の場合Ｔｔは、主として背後層からの伝熱すなわちＳの温度により到達する。従って背後層の加熱温調は必須である。上記加熱手段は、必須ではないが使用すればサイクルを縮めることができる。なお、Ｔｂは冷却手段により到達する。
　本発明の成形装置の構成においては、パターンＣ及びＡの成形を特に効率的行うことができる。 Pattern C is a pattern for adjusting S to a constant temperature equal to or higher than Tt. In this case, Tt is reached mainly by heat transfer from the back layer, that is, the temperature of S. Therefore, the heating temperature control of the back layer is essential. The heating means is not essential, but the cycle can be shortened if used. Tb is reached by the cooling means.
In the configuration of the molding apparatus of the present invention, the patterns C and A can be molded particularly efficiently.
　通常の熱成形は、樹脂シートの予熱、賦形、冷却、離型の過程を経てなされる。これに対して本発明の成形方法では賦形から冷却までの間に、樹脂シートの賦形時以上の高温の熱処理を行うことが特徴であり、またこれを高速連続で実施できることが特徴である。 ¡Normal thermoforming is performed through the process of preheating, shaping, cooling and releasing the resin sheet. On the other hand, the molding method of the present invention is characterized by performing a heat treatment at a temperature higher than that at the time of shaping of the resin sheet between shaping and cooling, and is characterized by being able to be performed at high speed continuously. .
　本発明の方法により広範囲の樹脂で、容易に熱処理された各種成形品の製造が可能である。具体的な用途を挙げると、ａ）ＰＥＴ等の結晶性樹脂の延伸シートの熱固定を伴う成形、ｂ）結晶核剤添加ＰＥＴ（ＣＰＥＴ）等の結晶性樹脂シートの結晶化を伴う成形、あるいはまたｃ）ポリプロピレンのＳＰＰＦ成形（固相高圧成形）に伴う残留応力歪緩和してする熱処理成形を提案することができる。
　 特に、延伸ＰＥＴでは、耐熱性、透明性、剛性等の機械強度の優れた熱成形品を能率よく生産することができる。又、剛性を利用し省材料の成形品を得ることができる。
（本発明に用いる成形型についての補足説明） The method of the present invention makes it possible to produce various molded products that are easily heat-treated with a wide range of resins. Specific applications include: a) molding involving heat setting of a stretched sheet of a crystalline resin such as PET, b) molding involving crystallization of a crystalline resin sheet such as a crystal nucleating agent-added PET (CPET), or In addition, c) heat treatment molding can be proposed in which the residual stress distortion associated with SPPF molding (solid phase high pressure molding) of polypropylene is relaxed.
In particular, stretched PET can efficiently produce a thermoformed product having excellent mechanical strength such as heat resistance, transparency, and rigidity. Further, a material-saving molded product can be obtained by utilizing rigidity.
(Supplementary explanation about the mold used in the present invention)
（１）＜熱浸透率について＞
　本発明の規定値として用いた熱浸透率（ｂ値）は接触する物体と界面を通過して移動する熱量にかかわる物体の特性値であり、次の式で求められる。
ｂ＝　（λρＣ）１／２　・・・・・（１）　　　　　　　
λ；　熱伝導率（Ｊｓ－１ｍ－１Ｋ－１）、ρ； 密度（ｋｇｍ－３）、Ｃ；比熱（Ｊｋｇ－１Ｋ－１）　　 (1) <About heat penetration rate>
The thermal permeation rate (b value) used as the specified value of the present invention is a characteristic value of an object related to the amount of heat moving through the interface and the contacting object, and is obtained by the following equation.
b = (λρC) 1/2 (1)
λ; thermal conductivity (Js −1 m −1 K −1 ), ρ; density (kgm −3 ), C; specific heat (Jkg −1 K −1 )
　このｂ値が小さい物体は界面に少ない熱量しか流さず相手物体に大きな温度変化を与えず、また界面間近では相手物体から大きな温度影響をうける。
　従って、このｂ値が小さい材料を成形型表面材料として用いた場合は賦形体からの熱を拡散させないので、高温気体と冷却用気体により賦形体を容易に加熱冷却することができる。しかし背後層の熱を容易に表面層表面（賦形体体との界面）に伝えないので、表面温度の均一性が高く、高速で安定な条件設定のためには、表面層の厚みを小さくするか、あるいはこのｂ値をある程度大きくすることにより、成形材料に合わせて最適にすることができる。 An object having a small b value flows only a small amount of heat to the interface and does not give a large temperature change to the counterpart object, and is greatly influenced by the counterpart object near the interface.
Therefore, when the material having a small b value is used as the mold surface material, the heat from the shaped body is not diffused, so that the shaped body can be easily heated and cooled by the high-temperature gas and the cooling gas. However, since the heat of the back layer is not easily transferred to the surface layer surface (interface with the shaped body), the surface temperature is highly uniform, and the surface layer thickness is reduced for fast and stable condition setting. Or by increasing this b value to some extent, it can be optimized in accordance with the molding material.
　なお、ｂ値の参考例を示すと例えば、アルミニウム材は１７～２３程度、鉄材は１３～１６程度、銅３４程度、不錆鋼（ＳＵＳ３０６）は８．０で、多くの合成樹脂は０．２～０．８程度、多くのセラミックスは１～２０の間に入る。
　なお、表１にいくつかの材料のｂ値を例示する。なお、ｂ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℃の測定値にて規定することする。
ただし、２０℃から２００℃の間の変化に直線性を有しない材料、例えば相変化を伴う蓄熱剤などとの複合材料の場合は、１００℃、１５０℃の値の平均値を採用することとする。
なお、同じ材質でも、発泡体あるいは多孔体などに形状が変われば、この値が大きく変わることは留意を要する。
Figure JPOXMLDOC01-appb-T000001
 For example, the b value is about 17 to 23 for an aluminum material, about 13 to 16 for an iron material, about 34 copper, 8.0 for a non-rust steel (SUS306), and 0.0 for many synthetic resins. About 2 to 0.8, many ceramics fall between 1 and 20.
Table 1 illustrates the b values of some materials. The b value also shows a slightly different value depending on the measurement temperature, but in the present application, strictly, it is defined by a measurement value of 20 ° C.
However, in the case of a composite material with a material having no linearity in a change between 20 ° C. and 200 ° C., for example, a heat storage agent accompanied by a phase change, an average value of 100 ° C. and 150 ° C. should be adopted. To do.
It should be noted that even if the same material is used, if the shape changes to a foam or a porous body, this value will change greatly.
Figure JPOXMLDOC01-appb-T000001
（２）＜成形型構成の数値限定の意義について＞
　上記成形型の表面層として熱浸透率ｂ値の大きな表面材料を用いた場合は、賦形体から容易に熱を背後に分散させてしまうので、熱容量の比較的に熱容量の小さい加熱空気や冷却空気では容易に賦形体を加熱冷却できなくなり、この値が１０を超える材料である場合は、能率的に熱処理を行う成形を行うことができない。この値は小さいほうが好ましいが、０．０１より小さいものは強度など使用に耐える材料がない。 (2) <Significance of numerical limitation of mold configuration>
When a surface material having a large thermal permeability b value is used as the surface layer of the mold, heat is easily dispersed from the shaped body to the back, so that heated air or cooling air having a relatively small heat capacity is used. Then, it becomes impossible to heat and cool the shaped body easily, and when this value is a material exceeding 10, it is impossible to efficiently perform the heat treatment. This value is preferably small, but if it is smaller than 0.01, there is no material that can withstand use such as strength.
　上記の成形型において２層以上の構造とし、表面層の背面層を一定温度に制御して、賦形体を介して加熱気体および冷却気体により昇温降温変化する表面層の成形面温度を所望の基準温度へ迅速に回帰させることができる。
　この場合、表面層の厚みが３０ｍｍを超える場合は背後層の制御が、上記表面温度と呼応して定常状態に至る時間がかかりすぎ、実施的に効果がない。また、この厚みが０．０３ｍｍを下回る場合は背後層の温度の影響を大きく受けて、迅速な賦形体の昇温降温を促進する効果がなくなる。例えば、公知の成形方法において、潤滑離型のために金型に仮に弗素樹脂等のコートが成されることがあったしても、そのコート厚みは通常３０μ以下の薄いものであり、それを厚くする必要もなく又困難もあって、本発明の効果を発揮させるようなものは従来製作されていない。 The above mold has a structure of two or more layers, the back layer of the surface layer is controlled to a constant temperature, and the molding surface temperature of the surface layer that changes in temperature by the heating gas and the cooling gas through the shaped body is set to a desired level. Quick return to the reference temperature.
In this case, if the thickness of the surface layer exceeds 30 mm, the control of the back layer takes too much time to reach a steady state in response to the surface temperature, which is not practically effective. Moreover, when this thickness is less than 0.03 mm, the influence of the temperature of a back layer is received greatly, and the effect which accelerates | stimulates temperature rising / falling of a quick shaping body loses. For example, in a known molding method, even if a mold such as a fluorine resin is sometimes formed on a mold for lubrication and release, the coating thickness is usually as thin as 30 μm or less. There is no need to increase the thickness, and there is a difficulty, and no device that can achieve the effects of the present invention has been produced.
　なお、上記したように単体一材料のものでも良いが、この場合、成形型への直接の温度制御はあってもよく、またなくてよく、いずれであっても所望表面温度の定常化に多少の時間をかければ、所望の成形は可能である。しかし、この場合、熱浸透率ｂ値（ｋＪ／ｍ２ｓ１／２Ｋ）が０．０１～３の単一材料で構成してされたものでは加熱温調機構がないものが好ましく、またそれが３以上の単一材料で構成されたものは加熱温調機構を備えたものがより好ましく使用できる。
　なお、上記の成形型は、真空賦形又は賦形時の排気が可能にする微細孔を有し、真空引き可能なように先記成形型収納ボックスに収納されることが望ましい。 As described above, a single material may be used, but in this case, there may or may not be direct temperature control on the mold, and in either case, the desired surface temperature may be stabilized to some extent. If the time is taken, the desired molding is possible. However, in this case, a material composed of a single material having a thermal permeability b value (kJ / m 2 s 1/2 K) of 0.01 to 3 preferably has no heating temperature control mechanism, As for those composed of three or more single materials, those equipped with a heating temperature control mechanism can be used more preferably.
In addition, it is desirable that the above-mentioned mold has a fine hole that enables vacuum forming or evacuation at the time of forming, and is housed in the above-mentioned mold storing box so that it can be evacuated.
（３）＜賦形体の温度測定について＞ 
なお、本発明の装置においては、なんらかの方法で成型型表面温度あるいはと型と賦形体の界面温度の変化、または賦形体の温度変化を測定することは重要である。具体的には例えば、成形型の成形面上に、極めて繊細な測定プローブ、例えば線径０．１ｍｍ程度の熱電対先端を突出させておいてこれを測定することができる。別の方法としては賦形体を反対面から赤外線温度計非接触で測定する方法がある。しかし、これらには留意すべき点がある。 (3) <Temperature measurement of shaped body>
In the apparatus of the present invention, it is important to measure the change in the surface temperature of the mold or the interface temperature between the mold and the shaped body or the temperature change of the shaped body by some method. Specifically, for example, an extremely delicate measurement probe, for example, a thermocouple tip having a wire diameter of about 0.1 mm is projected on the molding surface of the mold, and this can be measured. As another method, there is a method of measuring the shaped body from the opposite surface without contact with an infrared thermometer. However, there are points to note.
　前記のＳ線の温度はパターンＡ、Ｃでは、成形型自体を積極的に温度調節制御を行うが、それでも成形表面からの距離、あるいは熱源からの距離によっては温度傾斜をもって、成形サイクルを繰り返す中で定常化する値でもある。
賦形材料の熱処理温度あるいは離型可能温度を厳密に考えるとき、これらの温度はここで示される表面温度あるいは界面温度とはかなり乖離があることは留意する必要がある。秒単位あるいはそれ以下の単位で加熱冷却を行う場合は、賦形体の厚み方向で大きな温度傾斜が発生するからである。また、赤外線等で賦形体裏面から温度測定も、材料温度を正確に表すものでなない。また本発明では表面温度（界面温度）で表現しているがこの温度とも乖離があり、相対的な値として考慮する必要がある。  In the patterns A and C, the temperature of the S-line is actively controlled to control the temperature of the mold itself. However, depending on the distance from the molding surface or the distance from the heat source, the molding cycle is repeated with a temperature gradient. It is also a value that stabilizes at.
When strictly considering the heat treatment temperature or mold release temperature of the shaping material, it should be noted that these temperatures are considerably different from the surface temperature or interface temperature shown here. This is because when heating and cooling are performed in units of seconds or less, a large temperature gradient occurs in the thickness direction of the shaped body. Also, temperature measurement from the back of the shaped body with infrared rays or the like does not accurately represent the material temperature. In the present invention, it is expressed by the surface temperature (interface temperature), but there is a difference from this temperature and it is necessary to consider it as a relative value.
　図１及び図２に示す装置構成で、延伸ＰＥＴシートの熱処理を伴う成形を行った。
１）成形材料；
ホモポリエチレンテレフタレート樹脂の２．３倍一軸延伸シート（但し熱固定を行っていないもの）、厚み０．２３ｍｍのものを使用した。 With the apparatus configuration shown in FIGS. 1 and 2, the stretched PET sheet was molded with heat treatment.
1) Molding material;
A 2.3 times uniaxially stretched sheet of homopolyethylene terephthalate resin (those not heat-fixed) having a thickness of 0.23 mm was used.
２）成形装置；　　
成形機；　枚葉真空圧空成形機、圧空能力１０ｔｏｎのものを使用した。
圧空ボックス；　図１及び２に示す構造で、アルミニウム製で有効内寸法３３０×５５０ｍｍのボックス体６７の中に、アルミニウム製の送気ポート３１と排気ポート２１からなる圧空ボックスを装着した。そして気体送排出面３６には間隔３０ｍｍの碁盤格子の交点毎に径１φｍｍの高温気体の送出口３５を穿ち、また図２に示す配置で集気管２８を設けた。排気ポート２１及び集気管２８は、圧空空間からの排気の機能を有する。送気ポート３１及び送出開口３５は圧縮気体を圧空空間に送出する機能を有する。
成形型；　図１の６０に示す表面層／背後層方式のもので、アルミニウムＡ５０５２（ｂ値１７．４）を背後層とし、その上にＰＥＥＫ樹脂（ｂ値０．３５）の０．１４ｍｍの表面層をコーティング焼成法で形成させたものを使用した。
成形物は深さ直径９０ｍｍ、深さ３０ｍｍの丸皿形状物で、成形型外寸を１１０ｍｍ角としたもの１５個をヒーター内包の固定板に固定し、内寸３３２×５５２ｍｍの収納ボックスに収めた。なお、成形型の上面は収納ボックス側壁より５ｍｍ低くなるようにし、又側壁とは１ｍｍ間隙を設けた。
温度測定;成形面には細線熱電対先端露出させて這わせ、成形面温度及び 
賦形体界面温度を測定できるようにした。 2) Molding device;
Molding machine : A single-wafer vacuum / pressure forming machine having a pressure capacity of 10 tons was used.
1 and 2 A pressure air box made up of an air supply port 31 and an exhaust port 21 made of aluminum was mounted in a box body 67 made of aluminum and having an effective inner dimension of 330 × 550 mm. The gas supply / discharge surface 36 was provided with a hot gas outlet 35 having a diameter of 1 mm at every intersection of a grid lattice with a spacing of 30 mm, and a gas collection tube 28 was provided in the arrangement shown in FIG. The exhaust port 21 and the air collecting pipe 28 have a function of exhausting from the compressed air space. The air supply port 31 and the delivery opening 35 have a function of delivering the compressed gas to the compressed air space.
Molding mold : Surface layer / back layer system 60 shown in FIG. 1, with aluminum A5052 (b value 17.4) as the back layer, and PEEK resin (b value 0.35) 0.14 mm above What formed the surface layer by the coating baking method was used.
The molded product is a round dish shape with a diameter of 90 mm and a depth of 30 mm, and 15 molds with an outer dimension of 110 mm square are fixed to the fixing plate of the heater's inner package and stored in a storage box with an inner dimension of 332 x 552 mm. It was. The upper surface of the mold was 5 mm lower than the side wall of the storage box, and a 1 mm gap was provided from the side wall.
Temperature measurement ; thin wire thermocouple tip exposed on the molding surface, and the molding surface temperature and
The shape body interface temperature can be measured.
３）成形方法と成形条件；
　樹脂シートを５５０℃設定の予熱オーブンで９秒間予熱して移動させ、成形型上部に乗せた。なお、シート予熱温度は９５℃であった。
成形型はその表面（成形面）を１８５℃に予熱しておいて使用した。次いで圧空ボックスへ約３０℃、元圧力０．４ＭＰａの空気を導入して送気し、３．０秒、圧空圧０．４ＭＰａで真空圧空賦形及び熱処理を行った。成形型表面温度は瞬間的に約１６０℃に低下したが、すぐに昇温して１８０℃（最高点）の熱処理ができた。
　この後、排気ポート２１からの排気を作動させ、送気ポート３１から常温気体の送気を続けることにより１．５秒間、圧空圧０．１ＭＰａで賦形体の冷却を行い、離型を行った。離型時の表面（界面）温度は再び約１６０℃に低下していた。 3) Molding method and molding conditions ;
The resin sheet was preheated and moved for 9 seconds in a preheating oven set at 550 ° C. and placed on the upper part of the mold. The sheet preheating temperature was 95 ° C.
The mold was used with its surface (molded surface) preheated to 185 ° C. Next, air of about 30 ° C. and an original pressure of 0.4 MPa was introduced into the compressed air box, and the air was fed, and vacuum compression molding and heat treatment were performed for 3.0 seconds at a compressed air pressure of 0.4 MPa. Although the mold surface temperature instantaneously decreased to about 160 ° C., the temperature was raised immediately and a heat treatment at 180 ° C. (the highest point) was achieved.
Thereafter, the exhaust from the exhaust port 21 is operated, and the normal temperature gas is continuously supplied from the air supply port 31 to cool the shaped body at a compressed air pressure of 0.1 MPa for 1.5 seconds, thereby releasing the mold. . The surface (interface) temperature at the time of mold release again decreased to about 160 ° C.
４）比較テスト
ａ）上記の条件で排気ポート２１からの排気を行わず、送気ポート３１からの送気（圧空）のみ続けるテストを行った。
ｂ）上記の条件で排気ポート２１からの排気を行わず、圧空ボックスを瞬間的に約２ｍｍ上昇さて送気ポート３１からの送気を続けるテストを行った。 4) Comparative test a) A test was conducted in which exhaust from the exhaust port 21 was not performed under the above conditions, and only air supply (compressed air) from the air supply port 31 was continued.
b) A test was conducted in which the exhaust from the exhaust port 21 was not performed under the above conditions, and the compressed air box was instantaneously raised by about 2 mm to continue air supply from the air supply port 31.
５）成形結果；
　得られた成形品は良好な形状、透明なものであった。１４０℃のシリコンオイルに２分間浸漬の耐熱試験を行い、変形、目立った収縮はなく、耐熱性の優れたものであった。使用した加熱板では、高温気体による熱処理昇温が容易であることがわかった。
　なお、比較テストのａ）では、冷却効果がなく、離型時に収縮変形し良好な形状の成形品とはならなかった。また比較テストのｂ）では、全成形面を均一に冷却することが出来ず、特に内部に特に位置する成形品の冷却不足による収縮変形が大きいことがわかった。 5) Molding result ;
The obtained molded product had a good shape and transparency. A heat resistance test was conducted by immersing in silicone oil at 140 ° C. for 2 minutes, and there was no deformation or noticeable shrinkage, and the heat resistance was excellent. It was found that the heating plate used was easy to heat-treat with a high-temperature gas.
In the comparative test a), there was no cooling effect, and the product was contracted and deformed at the time of mold release, so that a molded product having a good shape was not obtained. Further, in comparative test b), it was found that the entire molding surface could not be uniformly cooled, and in particular, the shrinkage deformation due to insufficient cooling of the molded product particularly located inside was found.
　実施例１に示す装置構成で、圧空ボックスの一部変更と使用延伸ＰＥＴシートを変更して、熱処理を伴う成形を行った。ここでは、樹脂シートの予熱温度を冷やさないように圧空賦形を行った。
１）成形材料；
ホモポリエチレンテレフタレート樹脂の２．７倍一軸延伸シート（但し熱固定を行っていないもの）、厚み０．２１ｍｍを使用した。
２）成形装置
　成型機は実施例１と同じものを用いた。圧空ボックスは、実施例１と同じものに、すなわち図１の送気ポート３１に加熱ヒーターを付設し、送気ポートを軽度に加熱し、軽度に加熱された圧縮気体を導入して、樹脂シート予熱適温と同温の気体送出ができるようにした。また、成形型は実施例１と同じものを用いた。 In the apparatus configuration shown in Example 1, a partial change of the compressed air box and a used stretched PET sheet were changed to perform molding with heat treatment. Here, compressed air shaping was performed so as not to cool the preheating temperature of the resin sheet.
1) Molding material ;
A 2.7-fold uniaxially stretched sheet of homopolyethylene terephthalate resin (though not heat-set) and a thickness of 0.21 mm were used.
2) Molding apparatus The same molding machine as in Example 1 was used. The compressed air box is the same as that of the first embodiment, that is, a heater is attached to the air supply port 31 of FIG. 1, the air supply port is heated slightly, and a slightly heated compressed gas is introduced into the resin sheet. The gas can be delivered at the same temperature as the preheating optimum temperature. The same mold as in Example 1 was used.
３）成形方法と成形条件；
実施例１同様にして樹脂シートを９５℃に予熱した。成形型は成形面を１９０℃に予熱しておいて使用した。次いで、送出ポートを９５℃に予熱した圧空ボックスに、約９５℃の加熱圧縮気を導入し、圧空空間へ送出して圧力０．４ＭＰａ、３．０秒間の真空圧空成形を行った。賦形時に上記表面温度（界面温度）は瞬間的に約１７０℃に低下したが、間もなく昇温して１８０℃の熱処理（最高温度）ができた。次いで、排気本体２１からの排気を作動させ、送気本体３１から同じ気体の送気４秒間続けることにより賦形体の冷却を行い、離型を行った。離型時に表面（界面）温度は約１６０℃に低下していた。 3) Molding method and molding conditions ;
The resin sheet was preheated to 95 ° C. in the same manner as in Example 1. The mold was used with the molding surface preheated to 190 ° C. Next, heated compressed air of about 95 ° C. was introduced into a compressed air box whose heating port was preheated to 95 ° C., and the compressed air was sent to the compressed air space to perform vacuum / pressure forming at a pressure of 0.4 MPa for 3.0 seconds. The surface temperature (interfacial temperature) instantaneously dropped to about 170 ° C. during shaping, but soon it was raised to 180 ° C. heat treatment (maximum temperature). Next, the exhaust from the exhaust body 21 was operated, and the shaped body was cooled by continuing the same gas supply from the air supply body 31 for 4 seconds, and the mold was released. At the time of mold release, the surface (interface) temperature was lowered to about 160 ° C.
４）比較テスト；
（ａ）排気ポート２１からの排気を止めたまま、送気本体３１から送気による圧空を行った。送気流がすぐに止まることになる。
（ｂ）圧空ボックスの加熱ヒーターを作動させず、常温の圧縮気体を導入送出した他は上記３）と同様にして成形を行った。
（ｃ）予熱オーブンによる予熱を１０秒（約１０６℃）にした他は上記３）と同様にして成形を行った。 4) Comparative test ;
(A) While the exhaust from the exhaust port 21 was stopped, compressed air was supplied from the air supply body 31 by air supply. The airflow will stop immediately.
(B) Molding was performed in the same manner as in the above 3) except that the heated heater of the compressed air box was not operated and compressed gas at normal temperature was introduced and sent.
(C) Molding was performed in the same manner as in the above 3) except that the preheating in the preheating oven was 10 seconds (about 106 ° C.).
５）成形結果；
　上記３）の条件で行った成形では、実施例１と同様に良好な成形品が得られた。賦形に適切な気体温度でも冷却が可能であることを示している。
　なお、比較テスト（ａ）では成形品は変形したものであり、冷却がなされていないこと示す。（ｂ）では、ほぼ良好なに見えるが細部の成形が悪く、コーナー部が丸くなったものであった。延伸倍率が大きく成形性の悪い材料の場合は、予熱シートを圧空空気により冷やすことなく賦形する方が良いことを示している。また（ｃ）でも、同様に細部の成形状態が劣るものであった。これは、また常温程度の気体圧空による冷却を見込んで、予熱を過剰に行うと、延伸シートの熱固定が進み成形に不都合であることを示している 5) Molding result ;
In the molding performed under the condition 3), a good molded product was obtained as in Example 1. It shows that cooling is possible even at a gas temperature suitable for shaping.
In comparison test (a), it is shown that the molded product is deformed and not cooled. In (b), although it looks almost good, the molding of details was bad and the corner portion was rounded. In the case of a material having a large stretch ratio and poor moldability, it is indicated that it is better to shape the preheated sheet without cooling it with compressed air. Moreover, also in (c), the detailed molding state was similarly inferior. This indicates that if the preheating is performed excessively in anticipation of cooling by gas pressure air at about room temperature, the heat setting of the stretched sheet proceeds and it is inconvenient for molding.
　実施例１に示す装置構成で成形型と操作条件を変更して、実施例１と同じ延伸ＰＥＴシートの熱処理を伴う成形を行った。
１）成形材料；
ホモポリエチレンテレフタレート樹脂の２．５倍一軸延伸シート（但し熱固定を行っていないもの）、厚み０．２２ｍｍのものを使用した。
２）成形装置；
　成形型は、型材料として鋼材としてＳ４５Ｃ（ｂ値１６．１）を用いた単体構成とした他は実施例１のものと同形状、同寸法とし、同数のものを、同じ固定板と収納ボックスを用いて構成した。 In the apparatus configuration shown in Example 1, the molding die and the operating conditions were changed, and the same stretched PET sheet as in Example 1 was molded with heat treatment.
1) Molding material ;
A 2.5 times uniaxially stretched sheet of homopolyethylene terephthalate resin (those not heat-fixed) having a thickness of 0.22 mm was used.
2) Molding device ;
The molding die has the same shape and dimensions as those of Example 1, except that S45C (b value 16.1) is used as a steel material as a molding material. It was configured using.
３）成形方法と成形条件；
　実施例１と同様にして樹脂シートを９５℃に予熱した。また成形型は表面温度を１９５℃に予熱しておいて使用した。圧空ボックスへは、常温、元圧力０．４ＭＰａの圧縮空気を導入し、排気本体２１からの排気を作動させながら、５秒間、圧空圧０．１５ＭＰａの送気を続けることにより、賦形、熱処理、冷却の各工程を続けて合わせて行った。なお、賦形時から成形型側からの真空作動を行い、排気は圧力調整バルブを通しておこなった。　成形型表面（界面）温度は、賦形時に瞬時に約１７５℃（各部位の平均）に達し、離型時までほぼ一定温度を示した。この方法では、賦形、熱処理、及び冷却の工程の明確な境界はわからない。 3) Molding method and molding conditions;
The resin sheet was preheated to 95 ° C. in the same manner as in Example 1. The mold was used with the surface temperature preheated to 195 ° C. Introducing compressed air at normal temperature and an original pressure of 0.4 MPa into the compressed air box, and continuing the air supply at a compressed air pressure of 0.15 MPa for 5 seconds while operating the exhaust from the exhaust body 21, shaping and heat treatment Each process of cooling was performed continuously. In addition, the vacuum operation from the mold side was performed from the time of shaping, and exhaust was performed through the pressure adjusting valve. The mold surface (interface) temperature instantaneously reached about 175 ° C. (average of each part) at the time of shaping, and showed a substantially constant temperature until the mold release. In this method, no clear boundaries between the shaping, heat treatment and cooling processes are known.
４）比較テスト；
　上記の条件で排気本体２１からの排気を停止して圧空を行った。 4) Comparative test;
Exhaust from the exhaust body 21 was stopped under the above conditions to perform compressed air.
５）成形結果；
　良好な成形品が得られた。成形品は約１００℃の熱水に耐え、熱処理は有効であった。なお、比較テストでは離型時に収縮変形し、良好な形状の成形品が得られなかった。これは、離型時までに冷却がなされていないことを示している。
　本実施例では、熱処理と冷却の過程で同一の表面温度を示しているが、賦形体厚み方向の温度勾配に冷却効果があり、良好な離型が可能になっているものと考えてよい。 5) Molding result;
A good molded product was obtained. The molded product was resistant to hot water at about 100 ° C., and heat treatment was effective. In the comparative test, the product was contracted and deformed at the time of mold release, and a molded product having a good shape could not be obtained. This indicates that cooling has not been performed by the time of mold release.
In this example, the same surface temperature is shown in the process of heat treatment and cooling. However, it can be considered that the temperature gradient in the thickness direction of the shaped body has a cooling effect and that good mold release is possible.
　実施例１に示す装置構成で成形型と操作条件を変更して、延伸ＰＥＴシートの熱処理を伴う成形を行った。なお成形材料は実施例３と同じものを用いた。
１）成形材料； 実施例３と同じものを用いた。 In the apparatus configuration shown in Example 1, the molding die and the operating conditions were changed, and molding with heat treatment of the stretched PET sheet was performed. The same molding material as in Example 3 was used.
1) Molding material : The same material as in Example 3 was used.
２）成形装置
　成型機は、実施例１と同じものを用いた。また、圧空ボックスも実施例１と同じものを用いた。
成形型は、図１等の６０に示す表面層／背後層方式のもので、アルミニウムＡ５０５２（ｂ値１７．４）を背後層とし、その上にＳＵＳ３０４（ｂ値８．０）５．０ｍｍの表面層を形成させたものを使用した。成形物形状、寸法、数等は実施例１同じにし、同じ固定板と収納ボックスを用いて構成した。 2) Molding apparatus The same molding machine as in Example 1 was used. Also, the same pneumatic box as in Example 1 was used.
The mold is of the surface layer / back layer type shown in 60 of FIG. 1 and the like, with aluminum A5052 (b value 17.4) as the back layer and SUS304 (b value 8.0) of 5.0 mm on it. What formed the surface layer was used. The shape, size, number, and the like of the molded product were the same as those in Example 1, and the same fixed plate and storage box were used.
３）成形方法と成形条件；
　実施例１と同様にして、樹脂シートを９５℃に予熱した。また、成形型はその表面温度を１８８℃に予熱して使用した。

圧空ボックスへは、常温、元圧力０．４ＭＰａの圧縮空気を導入し、排気本体２１からの排気を作動させながら、４秒間、圧空圧０．１５ＭＰａの送気を続けることにより、賦形、熱処理、冷却の各工程を続けて合わせて行った。なお、賦形時から成形型側からの真空作動を行い、排気は圧力調整バルブを通しておこなった。成形型の表面（界面）温度は、賦形時に瞬時に約１７１℃（各部位の平均）になり離型時までほぼ一定温度を示した。この方法では、賦形、熱処理、及び冷却の工程の明確な境界はわからない。 3) Molding method and molding conditions ;
In the same manner as in Example 1, the resin sheet was preheated to 95 ° C. The mold was used with its surface temperature preheated to 188 ° C.

Introducing compressed air at normal temperature and an original pressure of 0.4 MPa to the compressed air box, and continuing the air supply at a compressed air pressure of 0.15 MPa for 4 seconds while operating the exhaust from the exhaust body 21, shaping and heat treatment Each process of cooling was performed continuously. In addition, the vacuum operation from the mold side was performed from the time of shaping, and exhaust was performed through the pressure adjusting valve. The surface (interface) temperature of the mold was about 171 ° C. (average of each part) instantaneously at the time of shaping and showed a substantially constant temperature until the mold release. In this method, no clear boundaries between the shaping, heat treatment and cooling processes are known.
４）比較テスト；
　上記の条件で排気ポート２１からの排気を止めて圧空を行った。 4) Comparative test ;
Exhaust from the exhaust port 21 was stopped under the above conditions to perform compressed air.
５）成形結果；
　良好な成形品が得られた。成形品は約１００℃の熱水に耐え、熱処理は有効であった。比較テストでは、冷却効果がなく、離型時に収縮変形し、良好な形状の成形品とはならなかった。 5) Molding result ;
A good molded product was obtained. The molded product was resistant to hot water at about 100 ° C., and heat treatment was effective. In the comparative test, there was no cooling effect, shrinkage deformation at the time of mold release, and the molded product did not have a good shape.
　図５に示す装置構成で、実施例１と同じ延伸ＰＥＴシートを用い、熱処理を伴う熱成形を行った。
１）成形材料； 実施例１と同じものを用いた。 In the apparatus configuration shown in FIG. 5, the same stretched PET sheet as in Example 1 was used, and thermoforming with heat treatment was performed.
1) Molding material : The same material as in Example 1 was used.
２）成形装置
　成型機は、実施例１と同じものを用いた。圧空ボックスの外形寸法は実施例１と同じにした。成形型は、実施例１と同じものを用いた。 2) Molding apparatus The same molding machine as in Example 1 was used. The external dimensions of the compressed air box were the same as those in Example 1. The same mold as in Example 1 was used.
３）成形方法と成形条件　
　実施例１と同様にして、樹脂シートを９５℃に予熱した。また、成形型の表面温度を１６５℃に予熱して使用した。 圧空ボックスの送気ポートは２７５℃に加熱しておき、外部から２７５℃　（元圧力０．４ＭＰａ）の加熱圧縮気体を導入し送気するようにした。圧空ボックスを降下させ成形型と接合すると同時に送気ポート３１から加熱空気を送気し、０．５秒、　圧空圧０．４ＭＰａの圧空真空賦形工程を行った。なお、圧空ボックスの降下開始と共に成形型からの真空吸引を作動させた。
　次いで、圧空賦形に０．５秒遅れて操作バルブ２９を開き排気を行うことにより加熱空気の圧空空間への送気を２．３秒続けることにより、熱処理工程を実施した。成形型表面（界面）温度は１８５℃に達した。
次いで、操作バルブ２３ｖ及び３３ｖを切り替え、導入した常温圧縮空気を排気ポート２１から送出し続け、送出した空気を送気ポート３１に集め排気が続くようにして、冷却工程を０．８秒間実施し、離型した。この間、成形型側からの真空作動は続けて行った。離型時の成形型表面（界面）温度は約１６０℃まで降下していた。　 3) Molding method and molding conditions
In the same manner as in Example 1, the resin sheet was preheated to 95 ° C. The surface temperature of the mold was preheated to 165 ° C. The air supply port of the compressed air box was heated to 275 ° C., and heated compressed gas of 275 ° C. (original pressure 0.4 MPa) was introduced from the outside to supply air. The compressed air box was lowered and joined to the mold, and at the same time, heated air was supplied from the air supply port 31 to perform a compressed air vacuum forming process with a compressed air pressure of 0.4 MPa for 0.5 seconds. In addition, the vacuum suction from the mold was activated with the start of the descent of the compressed air box.
Next, the heat treatment step was performed by continuing the supply of heated air to the compressed air space for 2.3 seconds by opening the operation valve 29 and evacuating with a delay of 0.5 seconds after the compressed air shaping. The mold surface (interface) temperature reached 185 ° C.
Next, the operation valves 23v and 33v are switched, and the introduced normal temperature compressed air is continuously sent out from the exhaust port 21, and the sent air is collected in the air supply port 31 so that the exhaust continues, and the cooling process is performed for 0.8 seconds. , Released. During this time, the vacuum operation from the mold side was continued. The mold surface (interface) temperature at the time of mold release dropped to about 160 ° C.
４）結果
　収容ボックスに収容したどの部分の成型型でも変わりなくきれいな成形品が得られ、また1つの成型品のどの部位も変わらず均一に熱処理がなされ、しかも高速で熱処理を伴う成型を行うことができた。 4) As a result, a clean molded product can be obtained in any part of the mold contained in the storage box, and a uniform heat treatment can be performed without changing any part of one molded product, and the molding with heat treatment can be performed at high speed. I was able to.
　実施例１に示す装置構成で成形型と操作条件を変更して、ＣＰＥＴシートの熱処理を伴う成形を行った。なお、ここでは冷却手段は使用しなかった。
１）成形材料；
　結晶核剤入り処方の市販の成形用ＣＰＥＴシート（東洋紡製、厚み０．５ｍｍ）を使用した。なお、このものは延伸処理のないものである。
２）成形装置；
　成形型は実施例１と同材料、同形同構造で、表面層の厚みのみ０．３ｍｍに変更して使用した。 In the apparatus configuration shown in Example 1, the molding die and the operating conditions were changed, and molding with heat treatment of the CPET sheet was performed. Here, no cooling means was used.
1) Molding material;
A commercially available CPET sheet for molding containing a crystal nucleating agent (Toyobo, thickness 0.5 mm) was used. In addition, this thing does not have an extending | stretching process.
2) Molding device;
The mold was the same material and the same shape and structure as in Example 1, and only the thickness of the surface layer was changed to 0.3 mm.
２）成形方法と成形条件；
　樹脂シートを５５０℃設定の予熱オーブンで１８秒間予熱して移動させ、成形型上部に乗せた。なお、シート予熱温度は約１００℃である。成形型は、背後体を熱媒オイルで８０℃に温調し、成形型表面温度を約７０℃としたものを使用した。圧空ボックスへの導入空気へは、約３００℃、　元圧力０．４ＭＰａの加熱空気を導入するようにし、送排気面３６は、導入気体とほぼ同温度に調整した。低温送排気本体２１からの排気を作動させて、高温送気本体３１から高温気体の送気を行い、１２秒、圧空圧０．２ＭＰａの真空圧空賦形及び熱処理を行った。；
圧空温度は約２５０℃になった。熱処理温度（界面到達温度）は１９５℃となった。冷却用気体の送風は行わず、熱処理後即時に離型した。
離型後、成形型表面温度は短時間に元の設定温度に低下し、続けて次の成形が可能な状態となった。 2) Molding method and molding conditions;
The resin sheet was preheated and moved for 18 seconds in a preheating oven set at 550 ° C. and placed on the upper part of the mold. The sheet preheating temperature is about 100 ° C. As the mold, a back body whose temperature was adjusted to 80 ° C. with a heating medium oil and the surface temperature of the mold was about 70 ° C. was used. Heated air having a pressure of about 300 ° C. and an original pressure of 0.4 MPa was introduced into the air introduced into the compressed air box, and the air supply / exhaust surface 36 was adjusted to substantially the same temperature as the introduced gas. Exhaust from the low-temperature air supply / exhaust body 21 was activated, and high-temperature gas was supplied from the high-temperature air supply body 31 to perform vacuum / pneumatic shaping and heat treatment with a pneumatic pressure of 0.2 MPa for 12 seconds. ;
The compressed air temperature was about 250 ° C. The heat treatment temperature (interface arrival temperature) was 195 ° C. The cooling gas was not blown, and the mold was released immediately after the heat treatment.
After mold release, the mold surface temperature dropped to the original set temperature in a short time, and the next molding was possible.
３）参考テスト；
　熱処理昇温時間を短縮するために、成形型表面温度を熱処理温度に近ずけ１６０℃として、熱成形したところ、成形品に凹凸の激しいムラが発生した。ＣＰＥＴの成形にはその予熱温度程度以下の低温の成形型で賦形し、その後昇温して熱処理することが必要であった。 3) Reference test;
In order to shorten the heat treatment temperature increase time, when the mold surface temperature was set to 160 ° C. close to the heat treatment temperature, thermoforming was performed, and unevenness of unevenness occurred in the molded product. For the molding of CPET, it was necessary to shape it with a low-temperature mold less than its preheating temperature, and then heat it up by heating.
４）成形結果；
　精密かつ良好に成形された成形品を得た。有効に熱処理されたことは、賦形体がまだ１９５℃以上の高温であるにも関わらず、収縮変形することなく離型できたことからも理解される。
　公知のＣＰＥＴの熱成形では、低温の成形型で成形された成形品を高温の型に移して熱処理を行うなど、煩雑で時間のかかる方法が採用されているが、本方法では、簡略で短時間に、予熱温度以上の高温の熱処理を伴う成形を行うことができることがわかった。 4) Molding result;
A molded product that was precisely and satisfactorily molded was obtained. The fact that the heat treatment has been performed effectively is also understood from the fact that the molded body could be released from the mold without undergoing shrinkage deformation even though the shaped body was still at a high temperature of 195 ° C. or higher.
In the conventional thermoforming of CPET, a complicated and time-consuming method such as transferring a molded product molded with a low-temperature mold to a high-temperature mold and performing a heat treatment is adopted, but this method is simple and short. It has been found that it is possible to perform molding with heat treatment at a temperature higher than the preheating temperature over time.
　本発明による熱成形には下記のようなことが可能である。
（１）賦形のための予熱温度以上に賦形体の加熱する熱処理と冷却離型を伴う成形プロセスを、非常な高速で、連続的に、効率的にそして安定に実行することができる。
（２）このような熱処理を必要とする具体的な用途には、延伸された結晶性樹脂シートの熱固定を伴う熱成形である。材料してはＰＥＴ等の熱可塑性ポリエステルの他、ＰＬＡ樹脂、ポリプロピレン、ポリアミド、ＰＥＥＫ等の結晶性樹脂等の延伸シートを挙げることができる。
（３）その中でも特、延伸ＰＥＴシートを用いて上記のような熱処理を行う熱成形を行うことにより、耐熱性、透明性、剛性等の機械強度の優れた熱成形品を能率よく生産することができる。又、剛性を利用し省材料の成形品を得ることができ、省資源の社会的ニーズに対応することができる。
（４）延伸処理を行っていない結晶性樹脂シート、例えば結晶核剤の添加されたＰＥＴ（ＣＰＥＴ）の結晶化を伴う成形に利用することができ、これを従来よりも高速して行うことができる。
（５）また、ポリプロピレンのＳＰＰＦ成形（固相高圧成形）に応用し、この成形方法の欠点を解決（残留応力歪みを緩和して耐熱寸法安定性を向上）する新規の方法等を期待することができる。
（６）熱処理を伴う成形を、精密に、均一に、バラツキなく、高速で、省エネルギーで行うことができ、また、配向及び結晶化による強度剛性等の向上は薄肉化省材料に転換して、省資源の社会的ニーズに貢献することを可能にするものである。 The following is possible for thermoforming according to the present invention.
(1) A molding process involving heat treatment and cooling mold release for heating the shaped body above the preheating temperature for shaping can be carried out at a very high speed, continuously, efficiently and stably.
(2) A specific application that requires such heat treatment is thermoforming that involves heat setting of a stretched crystalline resin sheet. Examples of the material include stretched sheets such as PLA, thermoplastic resin such as PET, crystalline resin such as polypropylene, polyamide, and PEEK.
(3) Among them, in particular, by performing thermoforming that performs the above heat treatment using a stretched PET sheet, it is possible to efficiently produce thermoformed products having excellent mechanical strength such as heat resistance, transparency, and rigidity. Can do. Further, it is possible to obtain a material-saving molded product using rigidity, and to meet the social needs of resource saving.
(4) A crystalline resin sheet that has not been subjected to stretching treatment, for example, can be used for molding involving crystallization of PET (CPET) to which a crystal nucleating agent is added, and this can be performed at a higher speed than before. it can.
(5) In addition, expecting a new method, etc. that can be applied to SPPF molding of polypropylene (solid phase high pressure molding) to solve the disadvantages of this molding method (reducing residual stress distortion and improving heat-resistant dimensional stability). Can do.
(6) Molding with heat treatment can be performed precisely, uniformly, without variation, at high speed and with energy saving, and the improvement in strength and rigidity due to orientation and crystallization has been converted to a material with reduced thickness, It is possible to contribute to the social needs for resource conservation.
３０　圧空ボックス
　　　１１　　送気ポート (第３の機構)
　　　１３　　圧縮気体導入路
　　　１３ｖ　送気バルブ
　　　１４　　送気空間
　　　１５　　送気開口
　　　１６　　分配送気管
　　　２１　　排気ポート（第２の機構） 
　　　２３　　排気通気路（場合により兼給気通路）
　　　２３v 　給排気切り替えバルブ　　
　　　２４　　集気空間（場合により兼分配空間）
　　　２５　　吸気開口（場合により兼送気開口）
　　　２６　　集気管（場合により兼分配送気管）
　　　２７　　断熱材
　　　２８　　排気管
　　　２９　　送排気面
　　　３１　 送気ポート　（第１の機構）
　　　３２　 加熱ヒーター
　　　３３　 圧縮気体導入路
　　　３３v　 給排気切り替えバルブ
　　　３４　 分配空間（場合により兼集気空間）
　　　３５　　送気開口
　　　３６　　送排気面　　　
　　　３７　　ボックス外壁
　　　３８　　送気管　
　　　３９　　圧空空間　
４０　圧空プレート　
６０　成形型（又は成形型群構成）
　　　６１　表面層　　　　　　　　　　　　
　　　６２ 背後層（背後体）
　　　６３ 真空排気孔　　　　　　　　　　
　　　６４　排気通路
　　　６５　加熱熱媒通路または加熱ヒーター　　　　　　　　　
　　　６６　成形型集積プレート
　　　６７　成形型収納ボックス
　　　６８　リード電線　
　　　６９　表面（成形面）　　　　　
１００　熱可塑性樹脂シート（樹脂シート）　
　　１１０　熱可塑性樹脂シートの賦形体
Ａ 圧縮気体（冷却用気体）　
Ａ‘　排気
ＨＡ 高温圧縮気体（加熱用気体）
ＨＡ‘　高温気体の排気 30 Pneumatic box 11 Air supply port (Third mechanism)
13 Compressed gas introduction path 13v Air supply valve 14 Air supply space 15 Air supply opening 16 minutes Delivery air pipe 21 Exhaust port (second mechanism)
23 Exhaust vent (sometimes also a supply passage)
23v Supply / exhaust switching valve
24 Air collection space (sometimes also a distribution space)
25 Intake opening (may also serve as air supply opening)
26 Air collection tube (In some cases, a distribution tube)
27 Heat insulating material 28 Exhaust pipe 29 Air supply / exhaust surface 31 Air supply port (first mechanism)
32 Heating heater 33 Compressed gas introduction path 33v Supply / exhaust switching valve 34 Distribution space (also a collection air space in some cases)
35 Air supply opening 36 Air supply / exhaust surface
37 Box outer wall 38 Air pipe
39 Air pressure space
40 Pressure plate
60 Mold (or Mold group configuration)
61 Surface layer
62 Back layer (back body)
63 Vacuum exhaust hole
64 Exhaust passage 65 Heating medium passage or heater
66 Mold Integration Plate 67 Mold Storage Box 68 Lead Wire
69 Surface (Molded surface)
100 Thermoplastic resin sheet (resin sheet)
110 Shaped body A of thermoplastic resin sheet Compressed gas (gas for cooling)
A 'Exhaust HA High-temperature compressed gas (heating gas)
HA 'Exhaust of hot gas

Claims (12)

  1. 樹脂シートの圧空成形の可能な熱成形装置において、圧空プレート又は圧空ボックス（両者合わせて以下「圧空手段」と称する）として、圧縮気体を送気開口から成形型上部に向けて送出する第１の機構と、圧空空間に送出された気体を吸気開口から吸気して外部に排気する第２の機構を一体として有し、次の１）及び２）、すなわち、
    １）上記第１の機構の気体送出を、上記圧空プレートの内部又は上記圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにした構造、及び
    ２）上記第２の機構の吸気を複数の吸気開口を通じて、上記圧空プレートの内部又は上記圧空ボックス底内部に設けた集気空間に収容して外部に導くようにした構造のうち少なくとも１つを用いる熱可塑性樹脂シートの成形装置。     In a thermoforming apparatus capable of pressure forming of a resin sheet, as a compressed air plate or a compressed air box (both are hereinafter referred to as “compressed air means”), a compressed gas is sent from an air supply opening toward an upper part of a mold. The mechanism and the second mechanism for sucking the gas sent to the compressed air space from the intake opening and exhausting it to the outside are integrated, and the following 1) and 2), that is,
    1) A structure in which the gas delivery of the first mechanism is distributed and sent through a plurality of air supply openings from a distribution space provided in the compressed air plate or in the bottom of the compressed air box, and 2) the second A thermoplastic resin sheet using at least one of a structure in which intake air of a mechanism is accommodated in an air collecting space provided inside the compressed air plate or inside a compressed air box bottom through a plurality of intake openings and guided outside. Molding equipment.
  2. 上記第１の機構の送気機構に加熱温調手段を付加することを特徴とする請求項１に記載の成形装置。 The molding apparatus according to claim 1, wherein heating temperature adjusting means is added to the air supply mechanism of the first mechanism.
  3. 上記第１の機構及とは別に、第３の機構として、別途導入した圧縮気体を別途設けた送出開口から上記成形型上部に向けて送出する機構を更に一体として備えた圧空手段を用いることを特徴とする請求項１又は２に記載の成形装置。 In addition to the first mechanism and the first mechanism, as a third mechanism, a compressed air means provided with a mechanism for sending a separately introduced compressed gas from a separately provided delivery opening toward the upper part of the mold is further used. The molding apparatus according to claim 1, wherein the molding apparatus is characterized.
  4. 上記の第３の機構における高温圧縮気体の送出を、上記圧空プレートの内部又は上記圧空ボックス底内部に設けた分配空間から複数の送気開口を通じて分配送出するようにしたことを特徴とする請求項１から３の何れかに記載の成形装置。 The high-temperature compressed gas in the third mechanism is distributed and delivered through a plurality of air supply openings from a distribution space provided inside the compressed air plate or inside the compressed air box bottom. The molding apparatus according to any one of 1 to 3.
  5. 上記第３の機構に加熱温調手段を付与し高温の圧縮気体を送出開口から送出するようにした特徴とする請求項１から４の何れかに記載の成形装置。 The molding apparatus according to any one of claims 1 to 4, wherein a heating temperature adjusting means is provided to the third mechanism to deliver a high-temperature compressed gas from a delivery opening.
  6. 上記の何れかの送気機構の内部で導入した圧縮気体を２００℃以上の十分な温度に加熱して送出 する機能を備えていることを特徴とする請求項１から５の何れかに記載の成形装置。 The compressed gas introduced inside any one of the above air supply mechanisms is provided with a function of heating the compressed gas to a sufficient temperature of 200 ° C. or higher and sending it out. Molding equipment.
  7. 上記圧空プレート又は圧空ボックス底の成形型対向面が２００℃以上に加熱保持が可能で、且つ赤外線放射率が０．８以上であるようにしたことを特徴とする請求項１から６の何れかに記載の成形装置。 7. The molding die facing surface of the compressed air plate or the pressurized air box can be heated and maintained at 200 ° C. or higher, and the infrared emissivity is 0.8 or higher. The molding apparatus described in 1.
  8. 成形型として、少なくともその成形用表面を熱浸透率（ｋＪ／ｍ２ｓ１／２Ｋ）が０．０１～２５である材料により形成させたものを用いることを特徴とする請求項１から７の何れかに記載の成形装置。 8. The molding die, wherein at least the molding surface is made of a material having a thermal permeability (kJ / m 2 s 1/2 K) of 0.01 to 25, is used. The molding apparatus according to any one of the above.
  9. 成形型として、熱浸透率（ｂ値）が２０以下の材料によりなる表面層と熱浸透率（ｂ値）が表面層のそれより大きな材料からなる背後体からなることを特徴とする請求項１から８の何れかに記載の成形装置。 The molding die comprises a surface layer made of a material having a thermal permeability (b value) of 20 or less and a back body made of a material having a thermal permeability (b value) larger than that of the surface layer. To 8. The molding apparatus according to any one of 8 to 8.
  10. 成形型として、上記の材料からなる表面層を背後から温度調整する手段を備えたものを用いる事を特徴とする請求項１から９の何れかに記載の成形装置。 10. The molding apparatus according to claim 1, wherein a molding die having a means for adjusting the temperature of the surface layer made of the above material from behind is used.
  11. 　請求項１から１０の何れかに記載の成形装置を用いた樹脂シートの成形方法であって、樹脂シートの予熱工程、賦形工程、賦形体を賦形時と予熱温度以上の高温で熱処理する工程、そして必要により賦形体の冷却工程を遂行する熱可塑性樹脂シートの熱成形方法。 A resin sheet molding method using the molding apparatus according to any one of claims 1 to 10, wherein the resin sheet preheating step, the shaping step, and the shaped body are heat-treated at the time of shaping and at a temperature higher than the preheating temperature. A method of thermoforming a thermoplastic resin sheet, which performs a process and, if necessary, a cooling process of the shaped body.
  12. 上記賦形体を高温で熱処理する方法として、１）上記高温気体を賦形体に噴射して行う方
    法、２）賦形体に赤外線照射して行う方法、若しくは３）上記成形型表面を高温に加熱しておいて賦形を行う方法の少なくとも1つを用いること特徴とする請求項１１に記載の成形方法。     As a method of heat-treating the shaped body at a high temperature, 1) a method in which the high-temperature gas is injected onto the shaped body, 2) a method in which the shaped body is irradiated with infrared rays, or 3) the surface of the mold is heated to a high temperature. The molding method according to claim 11, wherein at least one of shaping methods is used.
PCT/JP2012/068191 2011-07-28 2012-07-18 Thermoforming apparatus and forming method WO2013015169A1 (en)

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
JP2011-165069 2011-07-28
JP2011165069A JP5771794B2 (en) 2011-07-28 2011-07-28 Apparatus and method for thermoforming
JP2011-206515 2011-09-21
JP2011206514A JP5807873B2 (en) 2011-09-21 2011-09-21 Apparatus and method for thermoforming
JP2011206515A JP5811339B2 (en) 2011-09-21 2011-09-21 Apparatus and method for thermoforming
JP2011-206514 2011-09-21
JP2011254641A JP5971511B2 (en) 2011-11-22 2011-11-22 Apparatus and method for thermoforming
JP2011-254641 2011-11-22

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CN115002947A (en) * 2022-08-04 2022-09-02 西安交通大学 Modularized heating device and method for aerospace plane thermal environment simulation
CN115782138A (en) * 2023-02-09 2023-03-14 广东誉佳兴科技有限公司 Thermal forming machine

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CN115782138A (en) * 2023-02-09 2023-03-14 广东誉佳兴科技有限公司 Thermal forming machine

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