Molding system, support arm, resin molding device, and support method for supported member, mold, and manufacturing method for molded body

Abstract

Provided is a molding system capable of reducing molding defects. According to the present invention, a molding system is provided with a first and a second parison forming device, openable and closable first and second molds, and a control unit. The first parison forming device is provided with a first extruder, a first accumulator, and a first nozzle. First molten resin extruded from the first extruder is accumulated in the first accumulator, and a first parison is formed by extruding the first molten resin from the first nozzle. The second parison forming device is provided with a second extruder, a second accumulator, and a second nozzle. Second molten resin extruded from the second extruder is accumulated in the second accumulator, and a second parison is formed by extruding the second molten resin from the second nozzle. The first and second parisons are extruded between the first and second molds. The control unit determines the timing at which the first and second parison forming devices and at least one of the first and second molds start to operate based on historical data from past cycles.

Description

Technical Field

[0001] This invention relates to molding systems, support arms, resin molding apparatuses, methods for supporting supported components, molds, and methods for manufacturing molded bodies. Background Technology

[0002] (First viewpoint) Patent document 1 discloses an apparatus in which a core material is disposed between a pair of resin sheets extruded from a pair of T-die and formed using a pair of combined dies, thereby manufacturing a sandwich panel.

[0003] (Second viewpoint) Traditional techniques involve using a support arm to move a pre-made molded body to a molten resin sheet already shaped in a mold, whereby the body is fused to the molten resin sheet. For example, Patent Document 2 discloses a method for molding a sandwich panel having a thermoplastic resin core material between two resin skin sheets. In this method, the core material, held by an adsorption plate of a robotic arm (support arm), is inserted between the thermoplastic resin sheets. The robotic arm moves horizontally toward the assembly mold, fusing the core material to the thermoplastic resin sheets adsorbed in the cavity. The thermoplastic resin sheets are shaped as continuous sheets following the shape of the cavity of the assembly mold. The robotic arm releases the support of the core material and retracts from between the assembly molds. The assembly mold is then closed, and the thermoplastic resin sheets are fused from both sides of the core material. The assembly mold is then opened to remove the molded sandwich panel.

[0004] (Third viewpoint) Traditional techniques involve placing sheet-like thermoplastic resin between combined molds and then closing the molds to manufacture resin molded articles. For example, Patent Document 3 discloses a method for manufacturing a resin molded article: a sheet of molten thermoplastic resin is lowered toward the cavity side of a mold, and the sheet is vacuum-attracted and adsorbed from the cavity side, shaping it approximately along the shape of the cavity before closing the mold. After closing the mold, pressurized fluid blown into the mold opposite the cavity is used to pressurize the thermoplastic resin sheet toward the cavity side, shaping it into the shape along the cavity. Existing technical documents Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2014-79901 Patent Document 2: Japanese Patent No. 6551966 Patent Document 3: Japanese Patent Application Publication No. 2018-52093 Summary of the Invention (The problem the invention aims to solve)

[0006] (First viewpoint) In the device described in Patent Document 1, the injection of the resin sheet or the opening and closing of the mold is typically driven by hydraulic pressure. However, in hydraulic actuation, the speed of action is affected by factors such as oil temperature, which can easily cause the timing of the resin sheet injection or the mold opening and closing to deviate from the specified state. If the timing of the resin sheet injection or the mold opening and closing deviates from the specified state, it will lead to poor molding.

[0007] The present invention was made in view of the following circumstances, and provides a molding system capable of reducing molding defects.

[0008] (Second viewpoint) When pressing the core material towards the mold side, the support beam of the support arm may bend at its free end, preventing sufficient pressure on the core material. If the bond between the core material and the thermoplastic sheet is weak, the core material may detach from or become misaligned. Furthermore, while there are methods to adjust the position or angle of the support arm each time, this complicates the operation or reduces repeatability due to settings changes.

[0009] The purpose of this invention is to provide a support arm, a resin molding device, and a support method for the supported component that can stably supply the supported component.

[0010] (Third viewpoint) After the resin molded body is cooled inside the mold, it is demolded by opening the mold. However, when a thermoplastic resin sheet is adsorbed into one mold and pressed from another mold to form a mold, a temperature difference may occur on both sides of the thermoplastic resin sheet, causing the molded body to warp.

[0011] The purpose of this invention is to provide a mold capable of good molding and a method for manufacturing the molded body. (Technical solution used to solve the problem)

[0012] (First viewpoint) According to the present invention, a molding system is provided, comprising first and second preform forming apparatuses, openable and closable first and second dies, and a control unit. The first preform forming apparatus comprises a first extruder, a first reservoir, and a first injection head. After first molten resin extruded by the first extruder is stored in the first reservoir, a first preform is formed by injecting the first molten resin through the first injection head. The second preform forming apparatus comprises a second extruder, a second reservoir, and a second injection head. After second molten resin extruded by the second extruder is stored in the second reservoir, a second preform is formed by injecting the second molten resin through the second injection head. The first and second preforms are injected between the first and second dies. The control unit determines the start time of at least one operation of the first and second preform forming apparatuses and the first and second dies in the next cycle based on historical data from past cycles.

[0013] In this invention, the control unit is configured to determine the start timing of at least one operation of the first and second preform forming apparatuses and the first and second dies in the next cycle based on historical data from past cycles. Therefore, even if there is a deviation in the start timing of at least one operation of these apparatuses, the deviation can be corrected in the next cycle, suppressing the deviation and reducing molding defects.

[0014] The following examples illustrate various embodiments of the present invention. Preferably, in the molding system described above, the control unit determines the injection start timing of the first and second molten resins in the next cycle based on historical data from past cycles. Preferably, in the molding system described above, the first and second molds can be moved to an open mold position, a standby position, and a closed mold position. The standby position is a position where the distance between the first and second molds is less than the open mold position and the distance between the first and second molds is greater than the closed mold position. The control unit determines the timing for the first and second molds to start moving from the open mold position toward the standby position in the next cycle based on historical data from past cycles. Preferably, in the molding system described above, the first molten resin is injected by hydraulic drive, and the control unit determines the hydraulic conditions of the hydraulic drive for the next cycle based on historical data from previous cycles. Preferably, in the above-described molding system, the first preform is a first resin sheet, which is fed out by a roller disposed between the first injection head and the first and second molds. The control unit determines the rotation speed of the roller for the next cycle based on historical data from previous cycles. Preferably, in the above-described molding system, the control unit determines the timing for starting the rotation of the screw of the first extruder in the next cycle based on historical data from past cycles.

[0015] (Second viewpoint) The support arm of the present invention comprises: a support beam; a first support body supporting a supported component at the front end of the support beam; and a second support body configured to be movable relative to the support beam at the base end of the support beam and supporting the supported component.

[0016] The resin molding apparatus of the present invention comprises: a support arm having a support beam, a first support body supporting a supported component at the front end of the support beam, and a second support body movable relative to the support beam at the base end of the support beam to support the supported component; a mold including a first mold and a second mold; and a resin supply device for supplying molten resin sheets to the first mold.

[0017] The method for supporting a supported component according to the present invention is a method for supporting a supported component of a resin molding apparatus, the resin molding apparatus comprising: a support arm having a support beam, a first support body supporting the supported component at the front end of the support beam, and a second support body movable relative to the support beam at the base end of the support beam to support the supported component; and a mold for adsorbing molten resin sheets, thereby moving the support arm in a manner that causes the supported component supported by the first support body and the second support body to abut against the molten resin sheet of the mold.

[0018] According to the present invention, a support arm capable of stably supplying a supported component, a resin molding apparatus, and a method for supporting the supported component are provided.

[0019] (Third viewpoint) The mold of the present invention includes a first mold and a second mold for forming a molded body by clamping a sheet of molten resin. The first mold has a first abutting surface that can abut against the sheet of molten resin and a protruding surface that protrudes from the first abutting surface. The second mold has a second abutting surface that corresponds to the first abutting surface at a position opposite to the protruding surface.

[0020] The method for manufacturing a molded body according to the present invention is a method for manufacturing a molded body using a resin supply device, a first mold, and a second mold, comprising: a step of supplying molten resin sheets to the space between the first mold and the second mold by the resin supply device; and a step of bringing the first mold and the second mold closer together, so that the first mold and the second mold abut against the molten resin sheets and perform mold closing.

[0021] According to the present invention, a mold capable of good molding and a method for manufacturing a molded body can be provided. Attached Figure Description

[0022] Figure 1 The structure of the molding system 601, representing the first aspect of the present invention, is about to be implemented. Figure 2 The state before step C4 in the flowchart. Figure 2 This is a flowchart illustrating a method for manufacturing a molded body using the molding system 601. Figure 3 This indicates the structure of molding system 601, and indicates that it has just been implemented. Figure 2 The state after step C5 in the flowchart. Figure 4 This indicates the structure of molding system 601, and shows the part that has just been completed in... Figure 2 The state of the core material 603 after pasting in step D5 of the flowchart. Figure 5This is a perspective view of a sandwich component according to an embodiment of the second aspect of the present invention. Figure 6 This is a schematic diagram viewed from the side of a resin molding apparatus according to a second aspect of the present invention. Figure 7 This is a perspective view of the support arm from the front of an embodiment of the second viewpoint of the present invention. Figure 8 This is a perspective view of the support arm viewed from the rear side of an embodiment of the second aspect of the present invention. Figure 9 This is a top view of the support arm according to the second aspect of the present invention. Figure 10 middle, Figure 10 A~ Figure 10 B is a top view of a cross-sectional view of the elastic component of the second aspect of the present invention. Figure 11 This is a diagram illustrating a method for manufacturing a molded article according to an embodiment of the second aspect of the present invention, wherein, Figure 11 A indicates the state where the mold frame is in contact with the molten resin sheet. Figure 11 B indicates the state in which the molten resin sheet is shaped within the mold. Figure 12 A method for manufacturing a molded article according to an embodiment of the second aspect of the present invention, wherein, Figure 12 A indicates the arrangement of core material between molten resin sheets. Figure 12 B indicates the state where the first mold and the second mold are closed. Figure 13 The method for manufacturing a molded body according to an embodiment of the second aspect of the present invention Figure 12 A top-down view of state A. Figure 14 This is a schematic diagram of a resin molding apparatus according to an embodiment of the third aspect of the present invention. Figure 15 This is a perspective view of a portion of the first mold representing an embodiment of the third viewpoint of the present invention. Figure 16 This is an embodiment from the third viewpoint of the present invention. Figure 15 An enlarged perspective view of the back side of the first mold shown. Figure 17 This is an embodiment of the third aspect of the present invention. Figure 15 The first mold has a cross-section IV-IV, and the second limiting part has a combined cross-section. Figure 18 A method for manufacturing a molded article according to an embodiment of the third aspect of the present invention, wherein, Figure 18 A indicates the state where the mold frame is in contact with the molten resin sheet. Figure 18 B indicates the state in which the molten resin sheet is shaped within the mold. Figure 19 The method for manufacturing a molded body according to an embodiment of the third aspect of the present invention shows the state in which the first mold and the second mold are closed. Figure 20 This is an enlarged view of the first mold and the second mold in the closed state according to the third aspect of the present invention, wherein, Figure 20 A represents the initial state in which the molten resin sheet contacts the protrusion. Figure 20 B indicates the shape of the molten resin sheet abutting the contact surface. Figure 20 C indicates the shape of the sliding part being pressed in. Figure 21 This refers to a molded body manufactured using a resin molding apparatus according to an embodiment of the third aspect of the present invention. Detailed Implementation

[0023] The following describes embodiments of the present invention. The various features illustrated in the embodiments shown below can be combined with each other. Furthermore, each feature independently enables the invention to succeed.

[0024] (First viewpoint) 1. Structure of the molding system like Figure 1 As shown, a molding system 601 according to one embodiment of the present invention includes first and second preform forming apparatuses 610 and 620, first and second mold units 630 and 640 that can be opened and closed, a robot 650, and a control device 660.

[0025] The first and second preform forming apparatuses 610 and 620 are for forming the first and second preforms 611 and 621. The preforms 611 and 621 are made of molten resin. In this embodiment, the preforms 611 and 621 are the first and second resin sheets 611a and 621a, but they can also be other shapes such as cylindrical.

[0026] The preform forming apparatuses 610 and 620 include first and second hoppers 612 and 622, first and second extruders 613 and 623, first and second storage tanks 614 and 624, first and second injection hydraulic mechanisms 615 and 625, first and second injection heads 616 and 626, and first and second roller units 617 and 627. First and second raw material resins 618 and 628 fed from hoppers 612 and 622 into extruders 613 and 623 are melt-blended by extruders 613 and 623 to form first and second molten resins 618a and 628a, which are then extruded and stored in storage tanks 614 and 624. Storage tanks 614 and 624 include barrels 614a and 624a and pistons 614b and 624b that can slide inside them. In this embodiment, the injection heads 616 and 626 are composed of T-shaped molds.

[0027] Molten resin 618a and 628a from reservoirs 614 and 624 are ejected from injection heads 616 and 626 by pistons 614b and 624b driven by hydraulic mechanisms 615 and 625 (i.e., hydraulically driven), forming preforms 611 and 621 composed of resin sheets 611a and 621a. Hydraulic mechanisms 615 and 625 include barrels 615a and 625a, and pistons 615b and 625b that can slide within them. Pistons 615b and 625b are connected to pistons 614b and 624b. Pistons 615b and 625b can be driven by controlling the hydraulic pressure within the barrels 615a and 625a.

[0028] Roller units 617 and 627 are disposed between injection heads 616 and 626 and the first and second molds 631 and 641, respectively. Roller units 617 and 627 each have a pair of rollers 617a and 627a, and resin sheets 611a and 621a are clamped by the pair of rollers 617 and 627a. Therefore, by changing the rotational speed of rollers 617a and 627a, the speed at which resin sheets 611a and 621a pass through roller units 617 and 627 can be adjusted.

[0029] The mold units 630 and 640 include first and second molds 631 and 641, first and second mold frames 632 and 642, and first and second pressure plates 633 and 643.

[0030] Molds 631 and 641 have cavity surfaces 631a and 641a with shapes corresponding to the desired molded body shape, and clamping portions 631b and 641b surrounding the cavity surfaces. Cavity surfaces 631a and 641a are provided with pressure-reducing suction holes (not shown) that can attract resin sheets 611a and 621a and shape them along the shape of the cavity surfaces 631a and 641a.

[0031] Mold frames 632 and 642 are arranged along the circumferential surfaces of molds 631 and 641, and are configured to slide relative to molds 631 and 641 in the opening and closing directions of molds 631 and 641. Mold frames 632 and 642 attract resin sheets 611a and 621a by depressurization and press them against molds 631 and 641, thereby facilitating the attraction of resin sheets 611a and 621a through molds 631 and 641.

[0032] Pressure plates 633 and 643 are fixed to a mold opening and closing device (not shown), and molds 631 and 641 can be fixed to the mold opening and closing device via pressure plates 633 and 643. The mold opening and closing device is capable of moving pressure plates 633 and 643 symmetrically relative to a plane passing through the center of pressure plates 633 and 643.

[0033] The hydraulic mechanism 602 moves the pressure plate 633 along the opening and closing directions of the molds 631 and 641, thereby enabling the molds 631 and 641 to open and close. The hydraulic mechanism 602 includes a barrel 602a and a piston 602b that can slide inside it. The piston 602b is connected to the pressure plate 633. The piston 602b can be driven by controlling the hydraulic pressure within the barrel 602a.

[0034] The robotic arm 650 has the function of pressing the core material 603 onto the resin sheet 611a. The robotic arm 650 includes a base 650a and a suction cup 650b fixed to the base. The suction cup 650b can hold the core material 603 by depressurization and suction. The base 650a is mounted on a robot (not shown) and is capable of three-dimensional movement. The core material 603 is made of foamed resin, and the core material 603 can be fused to the resin sheets 611a and 621a by utilizing the heat from the resin sheets 611a and 621a.

[0035] The control device 660 includes a storage unit 661 and a control unit 662. The storage unit 661 stores historical data from past cycles and programs executed by the control unit 662. The control unit 662 controls the operation of the molding system 601. The functions executed by the control unit 662 are realized by a computing device executing the programs stored in the storage unit 661.

[0036] The control unit 662 is configured to determine the timing of the start of at least one operation of the preform forming apparatus 610, 620 and the molds 631, 641 in the next cycle based on historical data from past cycles. Therefore, even if a deviation in the timing of the operation occurred in a past cycle, it can be corrected in the next cycle, thus suppressing timing deviations and reducing molding defects. The historical data from past cycles can be historical data from one past cycle (e.g., the previous cycle) or data derived from historical data from multiple past cycles (e.g., the average value).

[0037] 2. Molding manufacturing method Reference Figure 2 This describes a method for manufacturing a molded body using molding system 601. In the following description, the molded body is a sandwich panel (molded article) formed by sandwiching core material 603 between resin sheets 611a and 621a, with a burr-like structure around it; however, other structures can also be manufactured. Furthermore, in this manufacturing method, molded bodies are manufactured one after another by repeating the cycle used to manufacture the molded bodies. Figure 2 This indicates a cycle of operations, but steps A1, B1, C1, and D1 are executed after steps A7, B7, C8, and D6.

[0038] For ease of explanation, the following state is taken as the initial state. In the preform forming apparatus 610, 620, the screws of the extruders 613, 623 are rotating and filling the reservoirs 614, 624 with molten resin 618a, 628a. The molds 631, 641 are in the open state. The robot 650 holds the core material 603 outside the molds 631, 641.

[0039] If a certain amount of time has elapsed from the initial state, then while the molds 631 and 641 are being opened in step C1, the resin is being filled into the reservoirs 614 and 624 in steps A1 and B1. After the molds 631 and 641 are opened, the system remains in standby position.

[0040] If the molds 631 and 641 are opened in step C1, then in step D1, the robot 650 begins to move to place the core material 603 within the molds 631 and 641 (i.e., within the space between the molds 631 and 641), and the movement is completed in step D2. After the movement is completed, the robot 650 is in standby mode.

[0041] If resin filling is completed in steps A1 and B1, then in steps A2 and B2, control unit 662 allows the injection of molten resin 618a and 628a from preform forming apparatuses 610 and 620. At this time, injection start delay times T1 and T2 are set in steps A3 and B3. In steps A4 and B4, after the delay times T1 and T2, the injection of molten resin 618a and 628a begins. The injected molten resin 618a and 628a form resin sheets 611a and 621a. The resin sheets 611a and 621a are clamped by rollers 617a and 627a and moved downwards as the rollers 617a and 627a rotate. Therefore, by changing the rotation speed of the rollers 617a and 627a, the downward movement speed of the resin sheets 611a and 621a can be adjusted.

[0042] The core material 603 is first bonded to resin sheet 611a, and then to resin sheet 621a. Therefore, in order to prevent the temperature of resin sheet 621a from becoming too low when bonding the core material 603 to resin sheet 621a, it is preferable that the injection of molten resin 628a begins later than the injection of molten resin 618a. Thus, it is preferable that T2 > T1. In one example, T1 is 0.

[0043] If the injection of molten resin 618a begins in step A4, then in step C2, the control unit 662 allows the molds 631 and 641 to... Figure 1 The mold opening position shown is moved to Figure 3 The standby position is shown. At this time, the standby position movement delay time T3 is set in step C3. In step C4, after the delay time T3, the movement of molds 631 and 641 to the standby position begins. In step C5, the movement of molds 631 and 641 to the standby position is completed.

[0044] The standby position is a position where the distance between the mold frames 631 and 641 is less than that of the mold-opening position, and greater than that of the mold-closed position. In the mold-opening position, the mold frames 632 and 642 are not in contact with the resin sheets 611a and 621a, and in this state, decompression suction of the resin sheets 611a and 621a through the molds 631 and 641 is not possible. On the other hand, in the standby position, the mold frames 632 and 642 can be in contact with the resin sheets 611a and 621a, thus enabling decompression suction of the resin sheets 611a and 621a through the molds 631 and 641. It should be noted that other means (e.g., an expander) can be used to hold the resin sheets 611a and 621a in place of the mold frames 632 and 642, allowing the resin sheets 611a and 621a to abut against the molds 631 and 641.

[0045] When the lower ends of resin sheets 611a and 621a are higher than the upper ends of molds 631 and 641, if molds 631 and 641 are in the standby position, the resin sheets 611a and 621a may interfere with molds 631 and 641 (by resting on top of them) when the resin sheets 611a and 621a are shaken. Therefore, in this embodiment, to prevent this problem, the movement of molds 631 and 641 to the standby position is completed at the point when the lower ends of resin sheets 611a and 621a reach a position lower than the upper ends of molds 631 and 641. Furthermore, to prevent the movement of molds 631 and 641 to the standby position from being completed prematurely, a delay time T3 is set, and the movement of molds 631 and 641 begins after the delay time T3 has elapsed.

[0046] After step C5, in step A5, the completion of injection of molten resin 618a is detected. The detection of completion can be performed by checking whether the lower end of the resin sheet 611a has reached a reference position, or by checking whether the remaining amount of molten resin 618a in the reservoir 614 has reached a reference value, or by other methods. After step A5, the resin sheet 611a is drawn in by depressurizing the mold frame 632. In this state, the mold frame 632 is retracted, causing the resin sheet 611a to abut against the clamping portion 631b. In this state, the resin sheet 611a is drawn in by depressurizing the mold 631, thereby shaping the resin sheet 611a into a shape along the cavity surface 631a.

[0047] Next, in steps D3 to D4, as follows Figure 4 As shown, a robotic arm 650, holding the core material 603 between molds 631 and 641, moves toward mold 631, thereby adhering the core material 603 to the resin sheet 611a. Next, the core material 603 is released from the suction cup 650b, and the robotic arm 650 begins to detach from the space between molds 631 and 641. In step D5, the robotic arm 650 is detached from the mold. Outside the mold, the core material 603 for the next cycle is prepared in advance. In step D6, the robotic arm 650 adsorbs and holds the core material 603 for the next cycle.

[0048] Following step A5, in step B5, the completion of injection of molten resin 628a is detected. The method for detecting completion of injection is the same as in step A5. Furthermore, similarly to step A5, the mold 641 depressurizes and draws the resin sheet 621a, thereby shaping the resin sheet 621a into a shape along the cavity surface 641a.

[0049] After steps A5, B5, and D5, the movement of molds 631 and 641 towards the closed position begins in step C6 and is completed in step C7. At this time, the core material 603 is fused to the resin sheet 621a, while the resin sheets 611a and 621a are fused to each other at their periphery, thereby forming a molded body with a rough edge structure around the sandwich panel (molded article).

[0050] Next, in step C8, molds 631 and 641 begin to move towards the mold opening position, and the movement is completed in step C1. After the mold opens, the molded body is removed from molds 631 and 641. To prevent the molded body from accidentally falling, the upper part of molds 631 and 641 can also be clamped using a clamping unit (not shown) before the mold opens.

[0051] Next, in steps A6 and B6, after the extruder screw rotation start delay time T4 and T5 set by the control unit 662, in steps A7 and B7, the screws of extruders 613 and 623 begin to rotate, and the molten resin 618a and 628a begin to fill the reservoirs 614 and 624. When the molding system 601 operates alone, the delay time T4 and T5 are not required. However, in this embodiment, the molding system 601 operates in conjunction with a deburring system (not shown) for removing burrs from the molded body. For this linkage, the cycle time of the deburring system needs to be consistent with the cycle time of the molding system 601. Without the delay time T4 and T5, the cycle time of the molding system 601 would be shorter than the cycle time of the deburring system. Therefore, by setting the delay time T4 and T5, the cycle times of the two are made consistent. Furthermore, the delay time T4 and T5 are set before the screws of the extruders 613 and 623 begin to rotate because if the delay time is set after the molten resins 618a and 628a are filled into the reservoirs 614 and 624, the state (e.g., resin pressure) of the molten resins 618a and 628a in the reservoirs 614 and 624 will change between the completion of filling and the start of injection, which is therefore not preferred.

[0052] 3. Correction Method Ideally, the timing of each step described in "2. Method for Manufacturing Molded Articles" above should not change with each cycle. However, in reality, time deviations can sometimes occur due to variations in the oil temperature of the hydraulic mechanism, changes in the surrounding environment (temperature, humidity, etc.), and changes in the material. Time deviations can lead to molding defects, and the control unit 662 performs various corrections to reduce time deviations.

[0053] 3-1. Correction of the timing of the start of firing The time difference T6 between the completion of injection in step A5 and the completion of injection in step B5 is set to ensure that the temperature of resin sheets 611a and 621a is optimal at the time when the core material 603 is fused to the resin sheets 611a and 621a. If the time difference T6 is shorter or longer than the reference, poor molding may easily occur.

[0054] Since molds 631 and 641 cannot be closed until the robot arm 650 disengages from the mold, if the time difference T6 is too short, the time between steps B5 and C6 will be longer than expected. As a result, when the core material 603 is fused to the resin sheet 621a, the temperature of the resin sheet 621a drops too much, easily leading to poor fusion. On the other hand, if the time difference T6 is too long, the time between steps A5 and C6 will be longer than expected. As a result, at the point when the resin sheets 611a and 621a are fused together, the temperature of the resin sheet 611a drops too much, easily leading to poor fusion between the resin sheets 611a and 621a.

[0055] Therefore, to reduce the deviation between the time difference T6 and the target value, the control unit 662 is configured to determine the injection start timing of the first and second molten resins in the next cycle based on historical data from past cycles. In one example, the historical data is the time difference T6 between the injection completion time of the first molten resin (step A5) and the injection completion time of the second molten resin (step B5). For example, the injection start timing of the first and second molten resins can be adjusted by changing at least one of the delay times T1 and T2. In one example, when the time difference T6 of the previous cycle is longer or shorter than the target value by p seconds, the delay time T1 is not changed, but the delay time T2 is shortened or extended by p seconds. As a result, it is expected that the time difference T6 in the next cycle will be close to the target value.

[0056] 3-2. Correction of the timing of mold movement to the standby position If the molds 631 and 641 move too quickly from the mold opening position to the standby position in steps C4 to C5, the resin sheets 611a and 621a may interfere with the molds 631 and 641. If the movement is too slow, the mold 631 may not reach the standby position at the injection completion time in step A5, which may result in poor shaping of the resin sheets 611a in the mold 631.

[0057] Therefore, to suppress such problems, the control unit 662 is configured to determine the timing when the molds 631 and 641 begin to move from the mold opening position to the standby position in the next cycle, based on historical data from past cycles. In one example, the historical data is the time difference T7 between the completion time of the movement of the molds 631 and 641 to the standby position (step C5) and the completion time of the injection of the first molten resin (step A5). For example, the starting timing of the movement of the molds 631 and 641 can be adjusted by changing the delay time T3. In one example, when the time difference T7 of the previous cycle is longer or shorter than the target value by q seconds, a correction is made by extending or shortening the delay time T3 by q seconds. As a result, the time difference T7 of the next cycle is expected to be close to the target value.

[0058] 3-3. Correction of the timing of the screw rotation start in the extruder As described above regarding steps A6 and B6, in this embodiment, the molding system 601 operates in conjunction with a burr removal system (not shown) for removing burrs from the molded body. To ensure that the cycle times of the two are consistent, delay times T4 and T5 are set.

[0059] The cycle time of molding system 601 depends on the filling time T8 from the start of screw rotation in steps A7 and B7 to the completion of resin filling in steps A1 and B1. However, this filling time T8 is prone to shortening, especially after molding system 601 has just started, due to the unstable state of the resin in extruders 613 and 623. If the filling time T8 is shorter than the target value, it will cause a deviation between the cycle time of molding system 601 and the deburring system.

[0060] Therefore, to suppress such problems, the control unit 662 is configured to determine the timing of the screw rotation start of the extruders 613 and 623 in the next cycle based on historical data from past cycles. In one example, the historical data is the cycle time. The cycle time is, for example, the time from the start of injection at step A4 of the previous cycle to the start of injection at step A4 of the previous cycle. For example, the timing of the screw rotation start of the extruders 613 and 623 can be adjusted by changing the delay times T4 and T5. In one example, when the cycle time of the previous cycle is r seconds longer or shorter than the target value, a correction is made by shortening or extending the delay times T4 and T5 by r seconds. As a result, the cycle time of the next cycle is expected to be close to the target value.

[0061] 3-4. Correction of ejection time When injecting molten resins 618a and 628a using hydraulic drive, the injection time (the time from the start of injection to completion) may sometimes change due to variations in oil temperature and other factors. It is best to stabilize the injection time.

[0062] Therefore, the control unit 662 is configured to determine the hydraulic conditions for the hydraulic drive in the next cycle based on historical data from past cycles. In one example, the historical data is the injection time. In another example, when the deviation between the target value and the injection time exceeds a threshold value for multiple consecutive cycles (e.g., 2 cycles), the control unit 662 performs corrections by increasing or decreasing the hydraulic pressure in the next cycle. In one example, when the injection time is longer than the target value, the hydraulic pressure in the next cycle is increased; when the injection time is shorter than the target value, the hydraulic pressure in the next cycle is decreased. Thus, the injection time in the next cycle is expected to be close to the target value.

[0063] 3-5. Sheet length correction Preferably, the lengths of the resin sheets 611a and 621a are constant at the injection completion time points of the molten resins 618a and 628a.

[0064] Therefore, the control unit 662 is configured to determine the rotational speed of the rollers 617a and 627a for the next cycle based on historical data from past cycles. In one example, the historical data is the length of the resin sheets 611a and 621a. In one example, if the deviation between the length of the resin sheets 611a and 621a and the target value in the previous cycle is above a threshold, the control unit 662 corrects by increasing or decreasing the rotational speed of the rollers 617a and 627a for the next cycle. In one example, when the length of the resin sheets 611a and 621a is longer than the target value, the rotational speed of the rollers 617a and 627a for the next cycle is decreased; when the length of the resin sheets 611a and 621a is shorter than the target value, the rotational speed of the rollers 617a and 627a for the next cycle is increased. Thus, it is expected that the length of the resin sheets 611a and 621a for the next cycle will be close to the target value. This correction is preferably performed when the injection time is stable as described above.

[0065] (Second viewpoint) Next, embodiments of the present invention will be described with reference to the accompanying drawings. Figure 5 The sandwich component 201 shown is generally formed into a rectangular flat plate shape. The sandwich component 201 has a core material 202 (supported component) inside, which is a molded body formed by covering the outer peripheral surface of the core material 202 with a skin material 203. The sandwich component 201 can be used, for example, as a structural component such as a bed board or a car trunk partition.

[0066] Figure 5 The core material 202 shown is formed into a rectangular flat plate and can be formed from a resin with added foaming agent. Examples of materials forming the core material 202 include homopolymers of olefins such as ethylene, propylene, butene, isoprene, and methylpentene, or copolymers such as polyolefins, polyamides, polystyrene, polyvinyl chloride, polyacrylonitrile, acrylic acid derivatives such as ethylene-ethyl acrylate copolymers, polycarbonate, vinyl acetate copolymers such as ethylene-vinyl acetate copolymers, ionomers, trimers such as ethylene-propylene-diene derivatives, acrylonitrile-styrene copolymers, ABS resin, polyphenylene ether, polyacetal, thermoplastic polyimide, and thermosetting resins such as phenolic resin, melamine resin, epoxy resin, polyurethane, and thermosetting polyimide.

[0067] Furthermore, as a foaming agent, any of physical foaming agents, chemical foaming agents, and mixtures thereof can be used. As a physical foaming agent, inorganic physical foaming agents such as air, carbon dioxide gas, nitrogen, and water, organic physical foaming agents such as butane, pentane, hexane, dichloromethane, and dichloroethane, and supercritical fluids thereof can be used.

[0068] The skin material 203 is formed from polyolefin resins such as polypropylene and processed plastics.

[0069] Figure 6 This illustrates the structure of the resin molding apparatus 60. The sandwich component 201 in this embodiment is constructed via… Figure 6 The resin molding apparatus 60 shown is formed. The resin molding apparatus 60 forms the first molten resin sheet 211 and the second molten resin sheet 212 by two resin supply devices 61 arranged opposite each other (first resin supply device 61A and second resin supply device 61B). Molds 80 (first mold 81 and second mold 82) are arranged below the resin supply devices 61.

[0070] The resin supply device 61 includes a hopper 65 serving as a resin material supply port, and an extruder 66 that melts and mixes the material supplied from the hopper 65 via a screw configured inside a hydraulic motor 68. The extruder 66 is connected to a storage tank 70 equipped with a plunger 72. The molten and mixed resin material is fed from the extruder 66 to the storage tank 70. The resin material is fed to a T-die 71 under high pressure in the storage tank 70. At an appropriate time, the die slit of the T-die 71 is opened to form a first molten resin sheet 211 and a second molten resin sheet 212 fed out by a roller 79. The first molten resin sheet 211 and the second molten resin sheet 212 are respectively supplied to a first die 81 and a second die 82.

[0071] First mold 81 and second mold 82 are arranged opposite each other. Mold frames 83 and 84 are provided on the outer periphery of first mold 81 and second mold 82. First mold 81 is provided with a vacuum pump (not shown) for depressurizing the space inside cavity 81a of first mold 81. Similarly, second mold 82 is also provided with a vacuum pump (not shown) for depressurizing the space inside cavity 82a of second mold 82.

[0072] Figure 7 as well as Figure 8 These are perspective views taken from the front and rear sides of the support arm 4. The support arm 4 includes a cantilevered support beam 41, a base plate component 42 connected to the front of the free end of the support beam 41, and multiple support bodies 44 connected to the base plate component 42 forward via elastic members 5. In this embodiment, a core material 202 is supported by the multiple support bodies 44, and the core material 202 is supplied to the mold 80.

[0073] The support beam 41 is cantilevered at its base end by a drive unit (not shown) such as a robot. Two base plate components 42 extend to the upper and lower sides of the support beam 41, respectively. The upper base plate component 42A and the lower base plate component 42B are connected to (see also...) on the front side... Figure 9 The four corner frame components 43 are connected. The frame components 43 can improve the overall rigidity of the substrate components 42A and 42B.

[0074] In this embodiment, four supports 44 are arranged in two rows and two columns along the vertical and horizontal directions. Each support 44 has supports 44A and 44B (first supports) and supports 44C and 44D (second supports) arranged parallel to each other along the extension direction of the support beam 41 (in other words, the direction of the base end and the free end). Supports 44C and 44D are positioned closer to the base end of the support beam 41 than supports 44A and 44B. Furthermore, supports 44A and 44C are positioned above supports 44B and 44D.

[0075] Each support 44 is formed as a rectangular flat plate and is supported by connecting to the elastic members 5 at four angles. Each support 44 applies force to the elastic members 5 in a direction away from the support beam 41. Figure 7 When the support surface 443 side is pressed, it resists the elastic force of the elastic member 5, allowing each support 44 to move independently toward the support beam 41 side. Furthermore, the support 44 has an opening 441 and an adsorption portion 442. The adsorption portion 442 has an adsorption surface including an adsorption port on its front side, and can support the core material 202 disposed on the support surface 443 side of the support 44 through negative pressure. The adsorption portion 442 is connected to a negative pressure source such as a vacuum pump via an air pipe (not shown). Multiple adsorption portions 442 can be provided depending on the shape or weight of the supported core material 202. In this embodiment, the multiple adsorption portions 442 are formed such that the adsorption surfaces (first adsorption surfaces) of the supports 44A and 44B (first supports) and the adsorption surfaces (second adsorption surfaces) of the supports 44C and 44D (second supports) are on the same plane.

[0076] Figure 10 A is from Figure 9 The elastic member 5 is shown in cross-sectional view from a top-down perspective. The elastic member 5 includes a shaft bracket 51 fixed to the support body 44, a shaft member 52 fixed relative to the shaft bracket 51, a guide sleeve 53 slidably inserted into the shaft member 52, and a helical spring 54 resisting the support body 44 in a direction away from the base plate member 42. The shaft bracket 51 has a cylindrical portion 511 that houses one end of the shaft member 52, and a flange portion 512 that bulges radially outward at the other end of the cylindrical portion 511. The shaft bracket 51 is fastened to the support body 44 via an opening in the flange portion 512 by screws from a screw member. Furthermore, the shaft bracket 51 has an opening 511a extending through the cylindrical portion 511 along the axial direction. The shaft member 52 is fixed to the shaft bracket 51 by a screw member 55 inserted through the opening into an internally threaded portion 521 at one end.

[0077] The guide sleeve 53 is formed in a generally cylindrical shape and is fastened to the base plate component 42 by a screw inserted through the opening of the flange portion 531 provided at one end. The cylindrical portion 532 of the guide sleeve 53 is inserted through the opening 421 formed in the base plate component 42 and protrudes along the side opposite to the support body 44.

[0078] The guide sleeve 53 has a bearing portion 533 formed inside, corresponding to the outer circumference of the shaft member 52. The shaft member 52 also has an internal thread portion 522 on the opposite end side to the side where the internal thread portion 521 is provided. A screw member 58 is inserted into this internal thread portion 522 to fasten washers 56 and 57 together. Washers 56 and 57 have a larger diameter than the bearing portion 533. Therefore, washers 56 and 57 can act as restraints to prevent the shaft member 52 from falling off the guide sleeve 53. It should be noted that washer 56 on the shaft member 52 side has a larger diameter than washer 57. Furthermore, a linear motion ball bearing 533a is provided on the inner circumferential surface of the bearing portion 533, thus reducing wear caused by sliding of the shaft member 52 relative to the bearing portion 533.

[0079] A washer 59 is provided on the support body 44 side of the flange portion 531 and around the outer periphery of the shaft member 52. Furthermore, the outer circumference of the shaft member 52 is smaller than the outer circumference of the cylindrical portion 511. One end of the helical spring 54 abuts against the end 511b of the cylindrical portion 511 of the shaft bracket 51, and the other end abuts against the washer 59. Figure 10 As shown, with the movement of the support body 44 toward the support surface 443 restricted by the washers 56 and 57, the coil spring 54 is contained in a compressed state.

[0080] Figure 10 B indicates that the support 44 is pressed against the substrate member 42, and the shaft member 52 slides within the bearing portion 533. The support 44 can move relative to the substrate member 42 together with the shaft member 52 against the elastic force of the coil spring 54. If the pressure of the support 44 against the substrate member 42 is released, the support 44 and the shaft member 52 move together in a direction away from the substrate member 42. If the washer 56 abuts against the end 532a of the cylindrical portion 532, the movement of the support 44 is restricted. In this embodiment, the washer 56 is formed of polyurethane and can be used as a cushioning material.

[0081] Figure 7 as well as Figure 8 The elastic members 5 shown can be configured with different elastic forces depending on the multiple supports 44A to 44D. For example, the elastic force of the elastic members 5 of supports 44A and 44B (first supports) located at the front end (free end) of the support beam 41 can be configured to be greater than the elastic force of the elastic members 5 of supports 44C and 44D (second supports) located at the base end of the support beam 41. It should be noted that the elastic force of the elastic members 5 can also be configured to gradually increase from the base end to the front end of the support beam 41, even within each support 44A to 44D. Furthermore, the elastic force of the elastic members 5 can be configured to be approximately the same, or different magnitudes of elastic force can be configured in certain locations.

[0082] Next, the manufacturing method of the sandwich component 201 will be described. First, in the material supply process, Figure 5 The resin supply device 61 suspends the first molten resin sheet 211 and the second molten resin sheet 212 and arranges them between the first mold 81 and the second mold 82.

[0083] In the shaping process, the mold frame 83 is moved toward the first molten resin sheet 211 so that it abuts against the surface of the first molten resin sheet 211. Figure 11 (Ref. A). Furthermore, while bringing the mold frame 83 closer to the first mold 81, depressurization is applied to the space formed by the first molten resin sheet 211, the cavity 81a, and the mold frame 83, causing the first molten resin sheet 211 to be shaped by the cavity 81a (Ref. A). Figure 11 B).

[0084] The mold frame 84, facing the first mold 81, is also moved toward the second molten resin sheet 212 so that it abuts against the sheet surface of the second molten resin sheet 212 (see reference). Figure 11 A). Furthermore, while bringing the mold frame 84 closer to the second mold 82, depressurization is applied to the space formed by the second molten resin sheet 212, the cavity 82a, and the mold frame 83, causing the second molten resin sheet 212 to be shaped by the cavity 82a (see reference). Figure 11 B).

[0085] In the core material moving process, between the material supply process and the shaping process, the core material 202 supported by the support arm 4 is positioned between the first mold 81 and the second mold 82 that shape the first molten resin sheet 211 and the second molten resin sheet 212 (see reference). Figure 12 A). The core material 202 is supported by negative pressure from each support surface 443 of the support body 44. Furthermore, the support arm 4 is moved, and the core material 202 is inserted into the cavity 81a of a mold, namely the first mold 81 (see reference). Figure 12 (A is a double-dotted line).

[0086] As a specific example of the action, the support arm 4 extends from the base end side of the support beam 41 along the front end side (from... Figure 13 The core material 202 (from top to bottom) moves between the first mold 81 and the second mold 82, and then moves in a generally vertical direction relative to the surface of the first molten resin sheet 211 shaped by the cavity 81a. At this time, even if the opposing surface 221 of the core material 202 supported by the support arm 4 is tilted relative to the first molten resin sheet 211 or the cavity 81a, the core material 202, as the supported component, is corrected within the movable range of the support body 44 by the elastic member 5, so that the first molten resin sheet 211 and the opposing surface 221 of the core material 202 can reliably abut against the ground.

[0087] In the opposing surface 221 of the core material 202 that abuts against the first molten resin sheet, the portion in contact with the first molten resin sheet 211, which is in a high-temperature state, melts, thereby fusing the core material 202 with the first molten resin sheet 211 and connecting them. In this embodiment, it is configured such that the elastic force of the supports 44A and 44B (first supports) provided on the front end side (free end side) of the support beam 41 on the support beam 41 and the substrate component 42 is stronger than the elastic force of the supports 44C and 44D (second supports) provided on the base end side of the support beam 41 on the support beam 41 and the substrate component 42. Therefore, even when the support beam 41 is bent, it is possible to prevent the pressing pressure of the core material 202 on the front end side of the support beam 41 from relatively weakening, thereby reducing the possibility of poor welding of the core material 202.

[0088] After the core material 202 is fused to the first molten resin sheet 211, the negative pressure of each support 44 is reduced, and the support arm 4 releases the support of the core material 202. In addition, the support arm 4, which has completed the movement of the core material 202, retracts from between the first mold 81 and the second mold 82.

[0089] In the mold closing process, with the first molten resin sheet 211 shaped within the cavity 81a of the first mold 81, the first mold 81 with the core material 202 inserted is brought closer together with the second mold 82, and the molds are closed until the annular clamping portions 81b and 82b abut against each other (see reference). Figure 12 B). The first molten resin sheet 211 and the second molten resin sheet 212 are fused together along the clamping portions 81b and 82b of their outer periphery to form a skin material 203, sandwiching the core material 202. The core material 202 is molten and fused together at the portion where it contacts the second molten resin sheet 212. Thus, a sandwich component 201 is formed in which the core material 202 is covered by the first molten resin sheet 211 and the second molten resin sheet 212.

[0090] In addition, during the removal process, the first mold 81 and the second mold 82 are opened, and the formed sandwich component 201 is removed from the first mold 81 and the second mold 82.

[0091] It should be noted that in this embodiment, a structure is described in which the support body 44 is elastically supported on the support beam 41 by the elastic member 5. However, other moving members that allow the support body 44 to be movably supported on the support beam 41 by sliding or other means may be used instead of the elastic member 5. If the support body 44 is pressed against the substrate member 42, the moving member moves the support body 44 relative to the substrate member 42. If the pressing force of the support body 44 on the substrate member 42 is released or reduced, the support body 44 moves away from the substrate member 42. The moving member is not limited to a structure that elastically applies force to the support body 44 in a direction away from the support beam 41. It may also be a configuration in which part or all of the support bodies 44A to 44D with a pressing force higher than a certain value are actively or passively moved towards the support beam 41. The amount of movement of each support body 44A to 44D is set according to the balance of the pressing force, and the posture of the core material 202 can be corrected by the moving member within the movable range of the support bodies 44A to 44D. Even under these circumstances, it can be set such that the pressing force (resistance) of the support body 44 on the front end side of the support beam 41 toward the core material 202 is stronger than the pressing force (resistance) of the support body 44 on the base end side of the support beam 41 toward the core material 202.

[0092] Furthermore, it can also be configured such that the supports 44A and 44B (first supports) provided on the front end side (free end side) of the support beam 41 are fixed relative to the support beam 41 and do not move, while the supports 44C and 44D (second supports) provided on the base end side of the support beam 41 can move relative to the support beam 41.

[0093] The above description, in this embodiment, illustrates a support arm 4 comprising support bodies 44A and 44B (first support bodies), and support bodies 44C and 44D (second support bodies), as well as a method for supporting the supported body. Support bodies 44A and 44B support the supported body at the front end of the support beam 41, while support bodies 44C and 44D are movable relative to the support beam 41 at their base ends. Therefore, for the supported body portion experiencing greater resistance from the molten resin sheet, the corresponding support body 44 moves flexibly in a direction away from the molten resin sheet, while for the supported body portion experiencing weaker resistance, the corresponding support body 44 does not move or moves only slightly. Thus, the surface pressure between the molten resin sheet and the supported body is corrected to be more uniform. Therefore, the weldability between the supported body and the molten resin sheet can be improved, and the supported component can be stably supplied.

[0094] The embodiments of the present invention have been described above, but the present invention is not limited to each embodiment and can be implemented with various modifications. For example, in this embodiment, two rows and two columns of support bodies 44 are arranged along the extension direction of the support beam 41 and in a direction perpendicular to the extension direction, but multiple support bodies 44 may be arranged only in the extension direction of the support beam 41. Alternatively, three or more support bodies 44 may be arranged along the extension direction of the support beam 41, and three or more support bodies 44 may be arranged in a direction perpendicular to the extension direction.

[0095] (Third viewpoint) The embodiments of the present invention will now be described based on the accompanying drawings. Figure 14 This describes the resin molding apparatus 60 of this embodiment. The resin molding apparatus 60 molds molten resin sheets 3, which are sheet-like resin materials, using a resin supply device 61. The molten resin sheets 3 can be formed from polyolefin resins such as polypropylene, engineering plastics, etc. Molds 10 (first mold 1 and second mold 2) are disposed below the resin supply device 61.

[0096] The resin supply device 61 includes a hopper 65 serving as a resin material supply port, and an extruder 66 connected to a hydraulic motor 68, which melts and mixes the material supplied from the hopper 65 via a screw disposed inside the extruder. The extruder 66 is connected to a storage tank 70 equipped with a plunger 72. The melted and mixed resin material is fed from the extruder 66 to the storage tank 70. The resin material is subjected to high pressure in the storage tank 70 and fed to a T-die 71. Furthermore, the die slit of the T-die 71 is opened at an appropriate time to form a molten resin sheet 3 fed out by a roller 79.

[0097] The first mold 1 and the second mold 2 are arranged opposite each other. In this embodiment, the first mold 1 and the second mold 2 are respectively convex and concave. The first mold 1 is formed with a core member 1a including a sliding part 12 and a fixing part 13, which will be described later. The second mold 2 is formed with a cavity 2a corresponding to the core member 1a, and is provided with a vacuum pump (not shown) that draws air into and depresses the space inside the cavity 2a through a suction hole 2a1. Furthermore, a mold frame 321 is provided on the outer periphery of the second mold 2.

[0098] Figure 15 This is a three-dimensional view showing a portion of the first mold 1. Figure 16 From Figure 15 An enlarged perspective view of the back side of mold 1. Furthermore, Figure 17 Is Figure 15 The first mold 1 is shown in cross-section IV-IV, which is a combined cross-sectional view of the first limiting part 16. The first mold 1 has a plurality of sliding parts 12 movable relative to a flat base 11, and a fixing part 13 configured to surround the outer periphery of the plurality of sliding parts 12. The base 11 is fixed to... Figure 14The movable mold 14. Furthermore, the fixing part 13 in this embodiment is configured as follows: Figure 14 A portion of the movable mold 14 shown ( Figure 17 The dotted line shown is an imaginary line representing the boundary between the fixed part 13 and the movable mold 14, but it can also be a structure formed separately from the movable mold 14.

[0099] The sliding portion 12 is formed in the shape of a rectangular plate, and multiple sliding portions are arranged in a matrix of 2 rows and 3 columns. The sliding portion 12 has a generally flat abutment surface 121 (first abutment surface) and a protrusion 122 formed on the abutment surface 121. The protrusion 122 has a protruding surface 123 with a predetermined width that is generally parallel to and flat with the abutment surface 121. Figure 15 As shown in the enlarged view of part A, the protrusion 122 includes a first protrusion 122a extending along a first direction (i.e., a direction in which three sliding portions 12 are continuously arranged), and a second protrusion 122b extending along a second direction (a direction in which two sliding portions 12 are continuously arranged). A plurality of first protrusions 122a and second protrusions 122b are arranged in a straight line at approximately equal intervals, forming an intersecting arrangement. In this embodiment, the protrusion 122 is formed in a generally grid-like shape covering the entire contact surface 121.

[0100] The width of the protruding surface 123 is narrower than the width of the abutting surface 121. For example, it can be made... Figure 15 The width of the plurality of protruding surfaces 123 shown is 15 mm, and the spacing between the protruding surfaces 123 in the first and second directions is 80 mm or 40 mm (i.e., the width of each abutting surface 121 is 65 mm or 25 mm).

[0101] The height of the protruding surface 123 (the distance from the abutting surface 121 to the protruding surface 123) is less than the wall thickness of the molten resin sheet 3, and thus protrudes. For example, the molten resin sheet 3 can be set to approximately 2-3 mm thick, and the height of the protruding surface 123 to be 0.5 mm. The height of the abutting surface 121 of the protruding surface 123 is set according to the characteristics of the molten resin sheet 3, such as its flowability (MFR, melt flow rate), as follows: at the first moment of contact between the first mold 1 and the molten resin sheet 3 in the mold closing process described later, the height at which the molten resin sheet 3 does not contact the abutting surface 121, and at the second moment after the first moment, the height at which it contacts the abutting surface 121 due to the closing force of the first mold 1 and the second mold 2. Thus, the cooling of the molten resin sheet 3 at the position corresponding to the protruding surface 123 can be started quickly, and the overall cooling time of the molten resin sheet 3 can be shortened by the subsequent contact of the abutting surface 121.

[0102] Figure 17As shown in the enlarged view of part B, the four sides 125 surrounding each sliding part 12 include a parallel surface 125a parallel to the moving direction of the sliding part 12, and an inclined surface 125b continuously connected to the parallel surface 125a. The parallel surface 125a is provided on the abutment surface 121, and the inclined surface 125b is provided on the back surface 126 side (base 11 side). The inclined surface 125b is formed such that its width is greater than that of the parallel surface 125a in the thickness direction of the sliding part 12. Therefore, the sliding part 12 is formed into a truncated pyramid shape of a thin plate, which narrows as it approaches the base 11.

[0103] The sliding part 12 is supported by the elastic part 15 and the first limiting part 16 on the back side 126 where the base 11 is provided (see reference). Figure 16 as well as Figure 17 (etc.). The sliding part 12 applies elastic force from the base 11 side to the second mold 2 side, and the first limiting part 16 restricts the range of movement to the base 11 side and the second mold 2 side to a predetermined position.

[0104] When viewed from above, the elastic portion 15 is positioned at four locations corresponding to the four corners of the sliding portion 12. The elastic portion 15 includes a shaft core 151 erected along the base 11 side from the sliding portion 12, a bushing 152 fixed to the base 11 side, and a compression coil spring 153 wound around the outer periphery of the bushing 152 into which the shaft core 151 is inserted. The shaft core 151 is slidably inserted through the bearing 111 of the base 11 via the bushing 152. An elastic force is applied along the compression coil spring 153 in a direction away from the sliding portion 12 and the base 11, causing the sliding portion 12 to be pushed towards the contact surface 121 side (in other words, the second mold 2 side).

[0105] The first limiting part 16 restricts the movement of the sliding part 12 toward the contact surface 121. Viewed from above, the first limiting part 16 is positioned approximately at the center of the sliding part 12. The first limiting part 16 has a cylindrical support shaft 161 erected from the back surface 126 of the sliding part 12, and a quadrangular prism-shaped enlarged diameter part 162 formed at the end of the support shaft 161. The support shaft 161 is slidably inserted into a bearing 112, which serves as a through hole in the base 11. The diameter of the enlarged diameter part 162 is larger than the diameters of the support shaft 161 and the bearing 112, and it is located in the sliding space 141 (see reference 141) on the moving mold 14 side. Figure 17 Therefore, the enlarged diameter portion 162 abuts against the periphery of the bearing 112, restricting the movement of the sliding portion 12 in a direction away from the base 11.

[0106] Furthermore, the base 11 is provided with a second, four-cornered, columnar limiting part 17 erected towards the sliding part 12. When viewed from above, the second limiting part 17 is positioned at four locations corresponding to the four sides of the sliding part 12. For example... Figure 17As shown in the enlarged view of part B, with the sliding part 12 pressed against the contact surface 121 (second mold 2 side), the end face 171 of each second restricting part 17 is separated from the back surface 126 of the sliding part 12 by a predetermined gap G. When the sliding part 12 is pressed against the base 11, the end face 171 of the second restricting part 17 abuts against the back surface 126 of the sliding part 12, thus restricting the movement of the sliding part 12 towards the base 11. The movable width of the sliding part 12 (the maximum value of the gap G) is set, for example, to 1 mm.

[0107] Back Figure 15 The fixing portion 13 is formed as a rectangular ring arranged adjacent to each other on the outer periphery of a plurality of sliding portions 12. The fixing portion 13 has an abutment surface 131 (third abutment surface) that is a flat surface substantially parallel to the abutment surface 121 of the sliding portion 12, and a side surface 132 that is an inclined surface continuously provided from the abutment surface 131. A plurality of protruding wall portions 134 are provided that protrude from the side surface 132 at predetermined intervals. When viewed from above, the protruding wall portions 134 protrude outward, and the abutment surface 131 also extends along the side of the protruding wall portions 134. The side surface 135 of the protruding wall portions 134 is formed at a steeper angle than the side surface 132. The side surface 132 and the protruding wall portions 134 are formed with a third protrusion 133a and a fourth protrusion 133b that are continuously provided along the extending direction of the first protrusion 122a or the second protrusion 122b provided on the sliding portion 12. The height of the protruding surfaces on the third protrusion 133a and the fourth protrusion 133b from the abutting surface 131 is approximately the same as the height of the protruding surfaces 123 on the first protrusion 122a and the second protrusion 122b from the abutting surface 121. Furthermore, the third protrusion 133a and the fourth protrusion 133b are formed with the same width as the first protrusion 122a and the second protrusion 122b. The step difference between the abutting surface 121 and the abutting surface 131 when the sliding part 12 is pressed against the second mold 2 side can be set to be greater than the height of the protruding surfaces 123 and 133c from the abutting surfaces 121 and 131.

[0108] The cavity 2a of the second mold 2 has an abutment surface 322 (second abutment surface) with a shape corresponding to the abutment surface 121 of the opposing first mold 1. In this embodiment, the abutment surface 322 is formed as a flat surface that is substantially parallel to the abutment surface 121. For example, when the abutment surface 121 of the first mold 1 has a curved surface or an inclined surface, the position of the abutment surface 322 of the opposing second mold 2 can be a curved surface or an inclined surface corresponding to the abutment surface 121.

[0109] Next, the manufacturing method of the molded body 305 will be described. The molded body 305 manufactured in this embodiment (see reference) Figure 18 )pass Figure 14The resin molding apparatus 60 shown is formed. First, in the material supply process, the resin supply device 61 supplies molten resin sheets 3 by hanging them down in a manner disposed between the first mold 1 and the second mold 2 (see reference). Figure 14 ).

[0110] In the shaping process, the mold frame 321 is moved toward the molten resin sheet 3 and brought into contact with the surface of the molten resin sheet 3 (see reference). Figure 18 A). Additionally, while bringing the mold frame 321 closer to the second mold 2, the space formed by the molten resin sheet 3, the cavity 2a, and the mold frame 321 is depressurized by suction through the suction hole 2a1, causing the molten resin sheet 3 to be shaped by the cavity 2a (see reference). Figure 18 B).

[0111] In the mold closing process, the first mold 1 and the second mold 2 are brought close together so that the annular clamping portions 1b and 2b abut against each other to close the mold (see reference). Figure 19 That is, the first mold 1 and the second mold 2 abut against the molten resin sheet 3 by directly clamping in from both sides. At the initial moment (first moment) when the sliding part 12 abuts against the molten resin sheet 3 by mold closing, such as... Figure 20 As shown in the enlarged view of part C1 of A, the molten resin sheet 3 first abuts against the protrusion 122 (protruding surface 123) of the sliding part 12 and is pressed through the protrusion 122. Near the fixing part 13, the molten resin sheet 3 similarly abuts against the protrusion 133 (protruding surface 133c) of the fixing part 13 for the first time. Therefore, the molten resin sheet 3 begins to cool from the position where it abuts against the protrusions 122 and 133, which are formed in a grid pattern.

[0112] Next, from Figure 20 State A after a specified time (the second time after the first time mentioned above), such as Figure 20 As shown in the enlarged view of section C2 of B, the molten resin sheet 3 flows to the vicinity of the contact positions with the protrusions 122 and 133 and abuts against the contact surfaces 121 and 131. On the sides 132 and 135 of the fixing portion 13, the molten resin sheet 3 also flows to the vicinity of the contact position with the protrusion 133 and abuts against the sides 132 and 135. Thus, the surface of the molten resin sheet 3 on the first mold 1 side begins to cool approximately the entire surface. It should be noted that, as described above, the positions of the molten resin sheet 3 corresponding to the protrusions 122 and 133 abut against the contact surfaces 121 and 131 before, or have a thinner wall thickness than the positions corresponding to the surrounding contact surfaces 121 and 131, thus allowing preferential cooling of the grid-like areas in the molten resin sheet 3. Figure 18 (The area of ​​the molded body 305 corresponding to the recess 352).

[0113] If the resistance force from the molten resin sheet 3 due to the clamping force of the first mold 1 and the second mold 2 is greater than the elastic force of the elastic part 15, then the sliding part 12 moves against the elastic force of the elastic part 15 along the side opposite to the second mold 2 (opposite to the molten resin sheet 3). The back surface 126 abuts against the end face 171 of the second limiting part 17, thus restricting the movement of the sliding part 12. When the sliding part 12 is pressed in until the second limiting part 17 abuts against it, as... Figure 20 As shown in the enlarged view of C3 of C, the abutting surface 121 and the abutting surface 131 will become approximately the same plane.

[0114] Next, in the removal process, the first mold 1 and the second mold 2 are opened, and the molded body 305 is removed from the mold 10. Furthermore, the molded body 305 is demolded before it has completely cooled and solidified, and the burrs on the outer periphery are removed. The molded body 305 of this embodiment has a grid-like region (with) where the solidification progresses faster than the area abutting the contact surfaces 121 and 131. Figure 18 The area corresponding to the recess 352 is such that the overall strength of the molded body 305 is improved even after it is removed from the mold 10. Therefore, warping of the molded body 305 after being removed from the mold 10 can be suppressed. The molded body 305 is formed, for example, as a wall panel for a toilet unit, bathroom unit, shower unit, or prefabricated building.

[0115] from Figure 14 Sometimes, the thickness of the molten resin sheet 3 hanging from the T-mold 71 differs in the corresponding ranges of the core 1a and cavity 2a in the first mold 1 and the second mold 2. For example, the molten resin sheet 3 extends to the T-mold 71 side due to its own weight, resulting in a thinner molten resin sheet 3 at the lower end of the T-mold 71 side. In this case, Figure 19 During mold closing, the lower sliding portion 12C of the plurality of sliding portions 12A to 12C contacts the molten resin sheet 3 before the other upper sliding portions 12A and 12B, and then the sliding portions 12B and 12A abut against the molten resin sheet 3 in that order. Furthermore, when the molten resin sheet 3 on the lower side corresponding to the sliding portion 12C is thicker, the indentation amount of the sliding portion 12C is greater than that of the sliding portions 12A and 12B. Therefore, each sliding portion 12A to 12C ( Figure 15 The amount of pressure applied to the sliding parts 12D to 12F shown can vary depending on the thickness of the molten resin sheet 3.

[0116] Therefore, even if a thinner portion appears on the molten resin sheet 3, it can prevent the first mold 1 from failing to contact the molten resin sheet 3, and can reduce uneven cooling of the molten resin sheet 3.

[0117] Figure 21 This illustrates an example of a molded body 305 manufactured using a resin molding apparatus. The molded body 305 is formed into a generally rectangular flat plate shape. The molded body 305's... Figure 21 The surface 305a shown is a molded surface formed by the second mold 2. Furthermore, as shown by the dashed lines, the back surface 305b, opposite to the surface 305a of the molded body 305, has a contact surface 351 formed by the contact surface 121 and the protruding surface 123 of the first mold 1, and recesses 352 (352a, 352b). The recess 352a corresponds to the first protruding part 122a, and the recess 352b corresponds to the second protruding part 122b. The outer peripheral portion 353 is the area formed by the fixing part 13. It should be noted that the surface 305a of the molded body 305 is shown as a generally flat surface, but irregularities can be arbitrarily provided. Even in this case, since the wall thickness of the recess 352 is thinner than the wall thickness of the molten resin sheet 3, the impact on the function or appearance of the surface 305a side of the molded body 305 can be reduced.

[0118] According to this embodiment, one side of the molten resin sheet 3 abuts against the second mold 2, and the molten resin sheet 3 corresponding to the protrusions 122 and 136 preferentially abuts against the other side of the molten resin sheet 3. Therefore, the curing speed at the positions corresponding to the protrusions 122 and 136 of the molten resin sheet 3 can be increased, overall cooling unevenness can be reduced, and warping of the molded body 305 can be reduced. Furthermore, since the molded body 305 is less prone to warping, the molded body 305 can be removed in a shorter cooling time, thus shortening the molding cycle and improving the productivity of the molded body 305.

[0119] The embodiments of the present invention have been described above, but the present invention is not limited to each embodiment and various modifications can be made. For example, in this embodiment, the first mold 1 is provided with a sliding part 12 that can be moved by resistance from the molten resin sheet 3, but the sliding part 12 may not be provided depending on the characteristics of the molten resin sheet 3. In this case, the structure of the first mold 1 can be simplified.

[0120] Furthermore, in this embodiment, the structure of the first mold 1 being convex and the second mold 2 being concave is described, but the first mold 1 having the sliding part 12 may also be concave. Alternatively, the second mold 2 may also be provided with a sliding part, similar to the first mold 1.

[0121] Furthermore, the protruding surface 123 of the protrusion 122 can also be provided in a portion of the abutment surface 121, preferably in more than half of the entire abutment surface 121 (the surface of the molded body 305), and more preferably in more than 80% of the area. By increasing the area ratio of the protruding surface 123 relative to the abutment surface 121, the overall strength of the molded body 305 can be improved.

[0122] Furthermore, when the protruding surface 123 is provided on a portion of the abutment surface 121, the protruding surface 123 can be provided in a region of the abutment surface 121 where the flat portion (including the curved surface portion with a small curvature) is larger. For example, the protruding surface 123 can be provided in a region where the flat portion occupies more than 30% of the total area of ​​the abutment surface 121. By providing the protruding surface 123 on a portion, the structure of the mold can be simplified. (Symbol Explanation)

[0123] 1: First mold; 1a: Core component; 1b: Clamping part; 2: Second mold; 2a: Cavity; 2a1: Suction hole; 2b: Clamping part; 3: Molten resin sheet; 4: Support arm; 5: Elastic component; 10: Mold; 11: Base; 12: Sliding part; 12A: Sliding part; 12B: Sliding part; 12C: Sliding part; 12D: Sliding part; 12E: Sliding part; 12F: Sliding part; 13: Fixed part; 14: Moving mold; 15: Elastic part; 16: First limiting part; 17: Second limiting part; 41: Support beam; 42: Substrate component; 42A: Substrate component; 42B: Substrate component; 43: Frame component; 44: Support body; 44A: Support body; 44B: Support body; 44C: Support body; 44 D: Support body; 51: Shaft bracket; 52: Shaft component; 53: Guide sleeve; 54: Helical spring; 55: Screw component; 56: Washer; 57: Washer; 58: Screw component; 59: Washer; 60: Resin molding device; 61: Resin supply device; 61A: First resin supply device; 61B: Second resin supply device; 65: Hopper; 66: Extruder; 68: Hydraulic motor; 70: Storage container; 71: T-die; 72: Piston; 79: Roller; 80: Die; 81: First die; 81a: Cavity; 81b: Clamping part; 82: Second die; 82a: Cavity; 82b: Clamping part; 83: Die frame; 84: Die frame; 111: Bearing; 112: Bearing; 121: Abutment surface; 12 2: Protrusion, 122a: First Protrusion, 122b: Second Protrusion, 123: Protruding Surface, 125: Side Surface, 125a: Parallel Surface, 125b: Inclined Surface, 126: Back Side, 131: Abutting Surface, 132: Side Surface, 133: Protrusion, 133a: Third Protrusion, 133b: Fourth Protrusion, 133c: Protruding Surface, 134: Protruding Wall, 135: Side Surface, 136: Protrusion, 141: Sliding Space, 151: Shaft Core, 152: Bushing, 153: Compression Coil Spring, 161: Support Shaft, 162: Expanded Diameter, 171: End Face, 201: Sandwich Component, 202: Core Material, 203: Sheath Material, 211: First Molten Resin Sheet, 212: Second Molten Resin Sheet Grease sheet, 221: Opposing surface, 305: Molded body, 305a: Surface, 305b: Back side, 321: Mold frame, 322: Abutting surface, 351: Abutted surface, 352: Recess, 352a: Recess, 352b: Recess, 353: Outer periphery, 421: Opening, 441: Opening, 442: Adsorption part, 443: Support surface, 511: Cylindrical part, 511a: Opening, 511b: End, 512: Flange, 521: Internal thread, 522: Internal thread, 531: Flange, 532: Cylindrical part, 532a: End, 533: Bearing part, 533a: Ball bearing, 601: Molding system, 602: Hydraulic mechanism, 602a: Barrel, 602b: Piston,603: Core material; 610: First preform forming apparatus; 611: First preform; 611a: First resin sheet; 612: First hopper; 613: First extruder; 614: First storage tank; 614a: Barrel; 614b: Piston; 615: First injection hydraulic mechanism; 615a: Barrel; 615b: Piston; 616: First injection head; 617: First roller unit; 617a: Roller; 618: First raw material resin; 618a: First molten resin; 620: Second preform forming apparatus; 621: Second preform; 621a: Second resin sheet; 622: Second hopper; 623: Second extruder; 624: Second storage tank; 624a: Barrel; 624b: Piston 625: Second injection hydraulic mechanism; 625a: Barrel; 625b: Piston; 626: Second injection head; 627: Second roller unit; 627a: Roller; 628: Second raw material resin; 628a: Second molten resin; 630: First mold unit; 631: First mold; 631a: Cavity surface; 631b: Clamping part; 632: First mold frame; 633: First pressure plate; 640: Second mold unit; 641: Second mold; 641a: Cavity surface; 641b: Clamping part; 642: Second mold frame; 643: Second pressure plate; 650: Robotic arm; 650a: Base; 650b: Suction cup; 660: Control device; 661: Storage unit; 662: Control unit.

Claims

1. A molding system for manufacturing a sandwich panel with a core material sandwiched between a first preform and a second preform, comprising first and second preform forming apparatuses, openable and closable first and second molds, and a control unit. The first type of preform forming apparatus includes a first extruder, a first feed tank, and a first injection head. After the first molten resin extruded from the first extruder is stored in the first reservoir, the first preform is formed by injecting the first molten resin through the first injection head. The second type of preform forming apparatus includes a second extruder, a second feed tank, and a second injection head. After the second molten resin extruded from the second extruder is stored in the second reservoir, the second preform is formed by injecting the second molten resin through the second injection head. The first and second preforms are injected between the first and second molds. Based on historical data from past cycles, the control unit determines the start timing of at least one operation of the first and second blank forming devices and the first and second dies in the next cycle. The first preform is the first resin sheet. The first resin sheet is fed out through rollers positioned between the first injection head and the first and second molds. The control unit determines the rotational speed of the roller for the next cycle based on the length of the first resin sheet from the previous cycle. In the previous cycle, if the deviation of the length of the first resin sheet from the target value is above a threshold, the control unit adjusts the rotational speed of the roller for the next cycle by increasing or decreasing the speed. The injection of the second type of billet was completed later than the injection of the first type of billet. After the injection of the first preform is completed and before the injection of the second preform is completed, the core material is bonded to the first preform. The control unit determines the start timing of screw rotation for the first extruder in the next cycle based on the cycle time of previous cycles. The cycle time is adjusted by setting a delay time before the screw begins to rotate, without setting a delay time between the completion of filling of the first reservoir and the start of injection.

2. The molding system according to claim 1, wherein, The first molten resin is injected via hydraulic drive. The control unit is configured to determine the hydraulic conditions of the hydraulic drive and the rotational speed of the roller for the next cycle based on historical data from past cycles. The historical data includes the injection time of the first molten resin and the length of the first resin sheet. When the deviation between the target value and the injection time exceeds a threshold value in multiple consecutive cycles, the control unit stabilizes the injection time by increasing or decreasing the hydraulic pressure in the next cycle. Once the injection time has been stabilized, if the deviation between the length of the first resin sheet and the target value is above a threshold in the previous cycle, the control unit corrects the rotation speed of the roller for the next cycle by increasing or decreasing it.

3. The molding system according to claim 1 or 2, wherein, The control unit determines the injection start timing of the first and second molten resins in the next cycle based on the time difference between the completion of injection of the first preform and the completion of injection of the second preform in the previous cycle.

4. The molding system according to claim 1 or 2, wherein, The first and second molds can be moved to the mold opening position, the standby position, and the mold closing position. The standby position is a position where the distance between it and the first and second molds is less than the mold opening position, and the distance between it and the first and second molds is greater than the mold closing position. Based on historical data from past cycles, the control unit determines when the first and second molds will begin to move from the mold opening position toward the standby position in the next cycle.

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