Forming system and forming method

Abstract

To solve the above problems, a molding system includes a trimming blade 7 that cuts a sheet material 2 disposed between a lower mold 60 and an upper mold 66, a first lower plate 81 that is disposed at a position further outward than a first lower mold end 60a in a side view of the lower mold 60 and extends toward the upper mold 66, and a first upper plate 85 that is disposed at a position further outward than a first upper mold end 66a in a side view of the upper mold 66 in a manner that advances and retreats together with the upper mold 66 and extends toward the first lower plate 81. A cut surface formed by the trimming blade 7 intersects a first remaining rim portion 25 that is a portion of the sheet material 2 further outward than the lower mold end 60a, and at least a portion of the remaining rim portion 25 is sandwiched between the first lower plate 81 and the first upper plate 85 in a state in which the lower mold 60 and the upper mold 66 are clamped.

Description

TECHNICAL FIELD

[0001] The present application relates to a molding system and a molding method. More specifically, the present application relates to a molding system and a molding method in which a lower mold provided with a clamped sheet material is closed with an upper mold, and the sheet material is cut by a trimming blade to mold a product. BACKGROUND

[0002] In the past, as a method of molding a sheet material made of resin to form a skin of a dashboard of an automobile, a method is known in which the sheet material is further extended after being heated, and a base material of the dashboard is bonded to the sheet material while being vacuum molded (for example, refer to Patent Literature 1 of the present applicant).

[0003] In the method described in Patent Literature 1, the sheet material is gripped by a gripping frame, and the sheet material is heated by a heating device, and the sheet material is disposed between a lower mold and an upper mold in which the base material is previously disposed, and then the lower mold and the upper mold are closed, whereby the sheet material is bonded to the base material.

[0004] [Prior Art Documents]

[0005] (Patent Literature)

[0006] Patent Literature 1: International Publication No. 2020 / 138340 SUMMARY

[0007] [Problems to be Solved by the Invention]

[0008] Incidentally, in the molding method described in Patent Literature 1, two products of the same shape are manufactured from one sheet material by forming two lower mold surfaces of the same shape on one lower mold. However, in this Patent Literature 1, the process of cutting the sheet material after the lower mold and the upper mold are closed, and dividing the two products, is not sufficiently studied. In this case, if the reduction of the cycle time required for the manufacture of the product and the simplification of the equipment are considered, it is preferable that the sheet material be cut by a trimming blade provided on the same equipment at the time of molding by closing the lower mold and the upper mold.

[0009] Figure 17 is a diagram schematically illustrating a molding device 100 in which a trimming blade 104 for cutting the sheet material 103 after the lower mold 101 and the upper mold 102 are closed is provided in the molding device 100 described in Patent Literature 1.

[0010] As described above, in the molding apparatus described in Patent Document 1, it is necessary to grip the end portion of the sheet material 103 with the gripping frame before the lower mold 101 and the upper mold 102 are closed, and therefore, there is a remaining edge portion 103a that protrudes from the mold end 105 when viewed from the side of the lower mold 101 and the upper mold 102 in the sheet material 103. Therefore, when the trimming blade 104 provided to the lower mold 101 is lowered, as shown in FIG. 6, the remaining edge portion 103a sometimes retreats downward, and thus, cutting failure occurs. Figure 17

[0011] An object of the present application is to provide a molding system and a molding method that can properly cut a sheet material including a remaining edge portion that protrudes from a mold end.

[0012] [Means of Solving the Problem]

[0013] (1) The molding system (for example, the molding system 1 described later) of the present application is characterized by including: a lower mold (for example, the lower mold 60 described later); an upper mold (for example, the upper mold 66 described later) that is provided so as to be able to advance and retreat with respect to the lower mold; a trimming blade (for example, the trimming blade 7 described later) that cuts a sheet material (for example, the sheet material 2 described later) provided between the lower mold and the upper mold; a lower plate (for example, the first lower plate 81 and the second lower plate 91 described later) that is provided at a position that is more outward than a lower mold end (for example, the first lower mold end 60a and the second lower mold end 60b described later) when viewed from the side of the lower mold, and that extends toward the upper mold; and an upper plate (for example, the first upper plate 85 and the second upper plate 95 described later) that is provided at a position that is more outward than an upper mold end (for example, the first upper mold end 66a described later) when viewed from the side of the upper mold, in a manner that advances and retreats together with the upper mold, and that extends toward the lower plate; and a cut surface (for example, the cut surface 71 described later) formed by the trimming blade intersects with a remaining edge portion (for example, the first remaining edge portion 25 and the second remaining edge portion 26 described later) that is a portion of the sheet material that is more outward than the lower mold end, and at least a portion of the remaining edge portion is pinched between the lower plate and the upper plate in a state in which the lower mold and the upper mold are closed.

[0014] (2) At this time, it is preferable that a lower guide portion (for example, the first lower guide portion 83 described later) and an upper guide portion (for example, the first upper guide portion 87 described later) that are slit-shaped along the cut surface be formed on the lower plate and the upper plate, respectively, and the trimming blade cuts the remaining edge portion by moving the lower guide portion and the upper guide portion.

[0015] ​(3) At this time, it is preferable that the aforementioned lower mold have a first lower mold surface (e.g., the aforementioned first lower mold surface 61a) that sets a first base material (e.g., the aforementioned first base material 63) and a second lower mold surface (e.g., the aforementioned second lower mold surface 62a) that sets a second base material (e.g., the aforementioned second base material 64), the aforementioned first base material and second base material are attached to the aforementioned sheet material by closing the aforementioned lower mold and the aforementioned upper mold, the aforementioned trimming blade cuts the aforementioned sheet material between the aforementioned first lower mold surface and the aforementioned second lower mold surface in plan view, thereby cutting the aforementioned sheet material into a first product portion to which the aforementioned first base material is attached and a second product portion to which the aforementioned second base material is attached.

[0016] (4) At this time, it is preferable that there be a frame (e.g., the aforementioned gripping frame 30) that grips at least a portion of the aforementioned end edge (e.g., the aforementioned end edges 25a, 26a) of the aforementioned sheet material between the aforementioned lower mold and the aforementioned upper mold in a manner in which the aforementioned lower plate and the aforementioned upper plate are disposed further inward than the aforementioned end edge in plan view.

[0017] (5) A molding method of the present application that molds a product by closing a lower mold (e.g., the aforementioned lower mold 60) and an upper mold (e.g., the aforementioned upper mold 66) that sandwich a sheet material (e.g., the aforementioned sheet material 2) and cutting the aforementioned sheet material with a trimming blade (e.g., the aforementioned trimming blade 7), the molding method characterized by comprising: a molding step (e.g., the step S3 of the aforementioned molding method 1), in which the aforementioned sheet material is disposed between the aforementioned lower mold and the aforementioned upper mold, and the aforementioned lower mold and the aforementioned upper mold are closed; and a cutting step (e.g., the step S4 of the aforementioned molding method 1), in which the aforementioned trimming blade is moved after the aforementioned lower mold and the aforementioned upper mold are closed, thereby cutting the aforementioned sheet material; and in the aforementioned cutting step, the aforementioned sheet material is cut in a manner in which a cut surface formed by the aforementioned trimming blade intersects a remaining edge portion (e.g., the aforementioned first remaining edge portion 25 and the aforementioned second remaining edge portion 26) that is a portion of the aforementioned sheet material that is further outward than a lower mold end (e.g., the aforementioned first lower mold end 60a and the aforementioned second lower mold end 60b) of the aforementioned lower mold in plan view, and in a state in which at least a portion of the aforementioned remaining edge portion is positioned. Figure 12 Figure 12

[0018] ​​(6) At this time, it is preferable that, in the cutting step, the remaining edge portion is positioned by sandwiching at least a part of the remaining edge portion between a lower plate (for example, the first lower plate 81 and the second lower plate 91 described later) disposed at a position further outward than the lower mold end in a side view of the lower mold and extending toward the upper mold side and an upper plate (for example, the first upper plate 85 and the second upper plate 95 described later) disposed at a position further outward than the upper mold end in a side view of the upper mold and extending toward the lower plate side in a manner that advances and retreats in conjunction with the upper mold.

[0019] (7) At this time, it is preferable that, in the forming step, the first base material (for example, the first base material 63 described later) and the second base material (for example, the second base material 64 described later) are attached to the sheet material by closing the lower mold and the upper mold in a state in which the first base material and the second base material are disposed on a first lower mold surface (for example, the first lower mold surface 61a described later) and a second lower mold surface (for example, the second lower mold surface 62a described later) formed on the lower mold, respectively, and, in the cutting step, the sheet material is divided into a first product portion to which the first base material is attached and a second product portion to which the second base material is attached by cutting the sheet material between the first lower mold surface and the second lower mold surface in a plan view.

[0020] (8) At this time, it is preferable that, in the forming step, the end edge of the sheet material is gripped by a frame (for example, the gripping frame 30 described later) in a manner that the lower plate and the upper plate in a plan view are disposed at positions further inward than the end edge of the sheet material between the lower mold and the upper mold, and the lower mold and the upper mold are closed in this state.

[0021] (EFFECTS OF THE INVENTION)

[0022] (1) The forming system of the present application includes a trimming blade that cuts a sheet material, a lower plate disposed at a position further outward than a lower mold end in a side view of the lower mold and extending toward an upper mold side, and an upper plate disposed at a position further outward than an upper mold end in a side view of the upper mold in a manner that advances and retreats in conjunction with the upper mold and extending toward the lower plate side. In addition, in the forming system of the present application, a cut surface (that is, a surface formed by a cutting edge of the trimming blade when the trimming blade is moved within a movable range) formed by the trimming blade intersects with a remaining edge portion of the sheet material, and at least a part of the remaining edge portion is positioned by being sandwiched between the lower plate and the upper plate in a state in which the lower mold and the upper mold are closed. Thus, according to the present application, it is possible to prevent the remaining edge portion of the sheet material from retreating outside the cut surface of the trimming blade when the trimming blade is moved within its movable range, so it is possible to prevent cutting failure of the sheet material.

[0023] (2) In the forming system of the present application, by positioning the remaining edge portion of the sheet material by using the lower plate and the upper plate that form the slit-like lower guide portion and the upper guide portion along the cutting surface of the trimming blade, it is possible to more reliably prevent the remaining edge portion from retreating outside the cutting surface when the trimming blade is moved, so it is possible to more reliably prevent cutting failure of the sheet material.

[0024] (3) According to the forming system of the present application, on the basis that at least a part of the remaining edge portion of the sheet material is positioned by the lower plate and the upper plate, by cutting the portion including the remaining edge portion among the sheet material by the trimming blade, it is possible to divide into the first product portion attached to the first base material and the second product portion attached to the second base material.

[0025] (4) According to the forming system of the present application, by gripping at least a part of the end edge of the sheet material by the frame body in a manner that the lower plate and the upper plate are arranged at a position more inward than the end edge of the sheet material in plan view between the lower mold and the upper mold, it is possible to more reliably sandwich a part of the remaining edge portion of the sheet material between the lower plate and the upper plate when the lower mold and the upper mold are closed, so it is possible to more reliably prevent the remaining edge portion of the sheet material from retreating outside the cutting surface of the trimming blade when the trimming blade is moved within the movable range, so it is possible to more reliably prevent cutting failure of the sheet material.

[0026] (5) The forming method of the present application includes: a forming step of arranging the sheet material between the lower mold and the upper mold, and closing the lower mold and the upper mold; and a cutting step of moving the trimming blade after closing the lower mold and the upper mold, thereby cutting the sheet material. In the present application, in the cutting step, the sheet material is cut in a state that the remaining edge portion is positioned in a manner that the cutting surface formed by the trimming blade intersects with the remaining edge portion. Thus, according to the present application, it is possible to prevent the remaining edge portion of the sheet material from retreating outside the cutting surface of the trimming blade when the trimming blade is moved within the movable range thereof, so it is possible to prevent cutting failure of the sheet material.

[0027] (6) In the forming method of the present application, by positioning the remaining edge portion of the sheet material by being sandwiched between the lower plate and the upper plate that extend along the advancing and retreating direction of the upper mold, it is possible to more reliably prevent the remaining edge portion from retreating outside the cutting surface when the trimming blade is moved, so it is possible to more reliably prevent cutting failure of the sheet material.

[0028] (7) According to the forming method of the present application, on the basis that at least a part of the remaining edge portion of the sheet material is positioned, by cutting the portion including the remaining edge portion among the sheet material by the trimming blade, it is possible to divide into the first product portion attached to the first base material and the second product portion attached to the second base material.

[0029] (8) According to the molding method of the present application, by holding at least a part of the end edge of the sheet material by the frame from the inside of the end edge of the sheet material in plan view, when the lower mold and the upper mold are closed, a part of the remaining edge portion of the sheet material is surely sandwiched between the lower plate and the upper plate, so the cutting failure of the sheet material can be surely prevented when the trimming blade is moved in the movable range, and the remaining edge portion of the sheet material is retreated from the cutting surface of the trimming blade, so the cutting failure of the sheet material can be surely prevented. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 Fig. 1 is a diagram schematically illustrating a configuration of a molding system to which a molding method according to an embodiment of the present application is applied.

[0031] Figure 2 Fig. 2 is a diagram illustrating a configuration of a holding device.

[0032] Figure 3 Fig. 3 is a sectional view of a first curved portion of a first edge member.

[0033] Figure 4A Fig. 4 is a partial sectional view of a first X-end right clamp unit of the first edge member.

[0034] Figure 4B Fig. 5 is a partial sectional view of a first X-end right clamp unit of the first edge member.

[0035] Figure 5A Fig. 6 is a diagram schematically illustrating a side view of the holding device as viewed in the Y direction from the first X edge member side.

[0036] Figure 5B Fig. 7 is a diagram schematically illustrating a side view of the holding device as viewed in the Y direction from the first X edge member side.

[0037] Figure 6A Fig. 8 is a diagram schematically illustrating a side view of the holding device as viewed in the X direction from the first Y edge member side.

[0038] Figure 6B Fig. 9 is a diagram schematically illustrating a side view of the holding device as viewed in the X direction from the first Y edge member side.

[0039] Figure 7 Fig. 10 is a diagram schematically illustrating a side view of the molding device as viewed in the Y direction from the first X edge member side of the holding device.

[0040] Figure 8 Fig. 11 is a diagram schematically illustrating a plan view of the molding device as viewed in the Z direction from the upper side.

[0041] Figure 9 Fig. 12 is a diagram illustrating a perspective view of the lower mold and the holding device.

[0042] Figure 10 Is Figure 7 The side view shows a portion of the forming device disconnected.

[0043] Figure 11A This is a side view of the first positioning part.

[0044] Figure 11B This is a side view of the first positioning part when the lower mold and the upper mold are closed.

[0045] Figure 12 This is a flowchart illustrating the specific process of the forming method of this embodiment.

[0046] Figure 13 This is a diagram illustrating the process of lowering the gripping device during the forming process (one of the diagrams).

[0047] Figure 14 This is a diagram illustrating the process of lowering the gripping device during the forming process (Part Two).

[0048] Figure 15 It is along Figure 11A A cross-sectional view of the first positioning part of line AA.

[0049] Figure 16 It is along Figure 11B A cross-sectional view of the first positioning part of line BB.

[0050] Figure 17 This is a schematic diagram of a forming apparatus consisting of a trimming blade in an existing forming apparatus, the trimming blade being used to cut sheet material after the lower and upper molds are closed. Detailed Implementation

[0051] Hereinafter, the structure of a molding system to which a molding method according to an embodiment of the present invention is applied will be described with reference to the accompanying drawings. Molding system 1 and molding method using molding system 1 are apparatuses and methods for manufacturing a product (automotive dashboard) by molding a sheet material (e.g., made of resin) and attaching the sheet material to a substrate of an automotive dashboard as its skin.

[0052] Figure 1 This is a schematic diagram illustrating the structure of the molding system 1 using the molding method of this embodiment. (See below for reference.) Figures 2-7 As described above, the forming system 1 includes: a gripping device 3 that grips the sheet material 2 and causes the sheet material 2 to extend or bend; a sheet supply unit 4 that supplies new sheet material 2 to the gripping device 3; a heating device 5 that heats the sheet material 2 gripped by the gripping device 3 to soften it; and a forming device 6 that vacuum-forms the sheet material 2 softened by the heating device 5.

[0053] The gripping device 3 grips the sheet material 2 supplied from the sheet supply section 4, and moves to the heating device 5 and the forming device 6 in order while gripping the sheet material 2. In the forming device 6, the sheet material 2 gripped by the gripping device 3 is vacuum formed, whereby the sheet material 2 is attached to the base material 61 as a skin. The gripping device 3 returns to the sheet supply section 4 after the processing in the forming device 6 is completed.

[0054] As the sheet material 2, a material suitable for the material of the skin of the base material 61 of the instrument panel, for example, a material in which a foamed layer of a polypropylene foam is joined to a thin film of a thermoplastic olefin, can be used. The sheet material 2 corresponds to the skin of the instrument panel, and is rectangular in plan view.

[0055] The sheet material 2 is obtained by cutting a resin sheet raw material that is wound into a roll shape while being pulled in a winding direction in accordance with the size of each long side direction of the sheet material 2, and further cutting in the center in the width direction. Thus, the sheet material 2 is already extended in the long side direction at the time when the resin sheet raw material is wound into a roll shape. That is, the device that winds the above-described resin sheet raw material into a roll shape while pulling it in the winding direction and the device that cuts the resin sheet raw material function as means for obtaining the sheet material 2 in an extended state in the long side direction.

[0056] The sheet supply section 4 has a sheet transfer mechanism 41 that grips one of the sheet materials 2 overlapped on the lower portion of the sheet supply section 4 and transfers it to the gripping device 3.

[0057] Figure 2 is a perspective view illustrating the configuration of the gripping device 3. As shown in Figure 2 , the gripping device 3 is a rectangular frame in plan view. Hereinafter, the direction along the short side direction of the gripping device 3 is set as the X-axis direction, the direction orthogonal to the X-axis direction and along the long side direction of the gripping device 3 is set as the Y-axis direction, and the direction orthogonal to these X-axis direction and Y-axis direction is set as the Z-axis direction.

[0058] The gripping device 3 includes a fixed frame 39 that is a rectangular frame in plan view, and a gripping frame 30 that is a rectangular frame smaller than the fixed frame 39 in plan view, and grips the sheet material 2.

[0059] The gripping frame 30 includes first and second X edge members 31 and 32 extending along the first and second X edge ends 21X and 22X of the sheet material 2 on both sides in the Y direction, and first and second Y edge members 33 and 34 extending along the first and second Y edge ends 23Y and 24Y of the sheet material 2 on both sides in the X direction. The first X edge member 31 grips the first X edge end 21X of the sheet material 2, the second X edge member 32 grips the second X edge end 22X of the sheet material 2, the first Y edge member 33 grips the first Y edge end 23Y of the sheet material 2, and the second Y edge member 34 grips the second Y edge end 24Y of the sheet material 2. Thus, the four edge ends of the sheet material 2, which is rectangular when viewed from above, are gripped by the gripping frame 30.

[0060] The fixing frame 39 includes a first X frame member 391 extending along the first X edge end 21X of the sheet material 2, a second X frame member 392 extending along the second X edge end 22X of the sheet material 2, a first Y frame member 393 extending along the first Y edge end 23Y of the sheet material 2 and connecting the end of the first X frame member 391 on the negative side in the X direction with the end of the second X frame member 392 on the negative side in the X direction, and a second Y frame member 394 extending along the second Y edge end 24Y of the sheet material 2 and connecting the end of the first X frame member 391 on the positive side in the X direction with the end of the second X frame member 392 on the positive side in the X direction.

[0061] The first X edge member 31 includes a first curved portion 310 for abutting against the front end of the first curved upright column 67 described later, a first X end right clamp unit 311 provided on the negative side in the X direction with respect to the first curved portion 310 and gripping the first X edge end 21X, a first X end left clamp unit 312 provided on the positive side in the X direction with respect to the first curved portion 310 and gripping the first X edge end 21X, a first right shaft 313 connecting the end of the first curved portion 310 on the positive side in the X direction with the first X end right clamp unit 311, and a first left shaft 314 connecting the end of the first curved portion 310 on the negative side in the X direction with the first X end left clamp unit 312.

[0062] Figure 3 is a sectional view of the first curved portion 310. The first curved portion 310 is a columnar shape extending in the X direction. The lower surface of the first curved portion 310 in the Z direction becomes a column abutting surface 310a for abutting against the front end of the first curved upright column 67 described later, and the upper surface thereof in the Z direction becomes a sheet abutting surface 310b for abutting against the sheet material 2. In addition, a guide hole 310c, which is a through hole extending in the Z direction from the column abutting surface 310a toward the sheet abutting surface 310b, is formed in the central portion of the first curved portion 310. In addition, a tapered surface 310d is formed on the column abutting surface 310a side in the guide hole 310c.

[0063] First right and left turning shafts 310e and 310f extending along the Y direction are provided at both ends of the first curved portion 310 in the X direction. The first right turning shaft 310e rotatably supports the front end portion 313a of the first right shaft 313, and the first left turning shaft 310f rotatably supports the front end portion 314a of the first left shaft 314. Thus, the first X end portion 31 is bendable at both ends of the first curved portion 310 about the first right and left turning shafts 310e and 310f.

[0064] Returning to Figure 2 , the first X end right jig unit 311 is rectangular in plan view extending along the X direction. A first right shaft support portion 311a is provided at the X direction positive side end portion of the first X end right jig unit 311, and rotatably supports the base end portion of the first right shaft 313. Thus, the interval between the first X end right jig unit 311 and the first curved portion 310 in the X direction can be adjusted by sliding the first X end right jig unit 311 along the first right shaft 313.

[0065] Further, the X direction negative side end portion of the first X end right jig unit 311 is connected to the first support shaft 331 via a first X end jig support portion 333 of the first Y end portion member 33. Thus, the X direction negative side end portion of the first X end right jig unit 311 is rotatable about the first support shaft 331.

[0066] Figure 4A and Figure 4B is a partial sectional view of the first X end right jig unit 311 along the Y direction. The first X end right jig unit 311 includes a jig base portion 315, a jig arm 316, a jig lever 317, and a link 318.

[0067] The jig base portion 315 extends along the Y direction on the lower surface side of the sheet material 2. A contact surface 315a for the lower surface of the sheet material 2 is formed at the front end portion of the jig base portion 315. The jig arm 316 extends along the Y direction on the upper surface side of the sheet material 2. A claw portion 316a for the upper surface of the sheet material 2 is provided at the front end portion of the jig arm 316. Further, the base end portion of the jig arm 316 is connected to the jig base portion 315 via an opening and closing shaft 315b extending along the X direction. Further, an arm shaft 316b extending along the X direction is provided between the claw portion 316a and the opening and closing shaft 315b in the jig arm 316.

[0068] The clamp lever 317 extends in the Y direction. The front end portion of the clamp lever 317 is coupled to the clamp arm 316 via the arm shaft 316b described above. First and second link shafts 318a and 318b extending in the X direction are provided at both end portions of the link 318, respectively. The first link shaft 318a couples the base end portion of the link 318 to a position in the clamp base 315 more toward the base end side than the opening and closing shaft 315b. The second link shaft 318b couples the front end portion of the link 318 to a position between the arm shaft 316b and the base end portion 317a in the clamp lever 317.

[0069] According to the first X-end right clamp unit 311 as described above, when the base end portion 317a of the clamp lever 317 is pressed downward along the Z direction by the clamp cylinder 42 provided in the sheet supply section 4, the edge portion of the sheet material 2 is gripped by the claw portion 316a of the clamp arm 316 and the contact surface 315a of the clamp base 315 (refer to FIG. 6A). Figure 4B That is, when the base end portion 317a of the clamp lever 317 is pressed downward, the clamp lever 317 moves toward the claw portion 316a while being rotated counterclockwise at the second link shaft 318b. In addition, when the clamp lever 317 moves toward the claw portion 316a, the clamp arm 316 is rotated clockwise at the opening and closing shaft 315b, and the claw portion 316a approaches the contact surface 315a. Thus, the end portion of the sheet material 2 is gripped by the first X-end right clamp unit 311.

[0070] In addition, according to the first X-end right clamp unit 311 as described above, when the base end portion 317a of the clamp lever 317 is lifted upward along the Z direction by the first right unclamping unit 691 described later, the claw portion 316a of the clamp arm 316 is separated from the contact surface 315a of the clamp base 315, and the grip of the sheet material 2 is released (refer to FIG. 6B). Figure 4A That is, when the base end portion 317a of the clamp lever 317 is lifted upward, the clamp lever 317 moves toward the base end portion 317a while being rotated clockwise at the second link shaft 318b. In addition, when the clamp lever 317 moves toward the base end portion 317a, the clamp arm 316 is rotated counterclockwise at the opening and closing shaft 315b, and the claw portion 316a is separated from the contact surface 315a. Thus, the grip of the sheet material 2 by the first X-end right clamp unit 311 is released.

[0071] Returning to Figure 2, the first X-end left clamp unit 312 is a rectangle extending in the X direction in plan view. A first left shaft support portion 312a is provided at the end on the negative side of the X direction of the first X-end left clamp unit 312, and the first left shaft support portion 312a supports the proximal end portion of the first left shaft 314 so as to be slidable in the X direction. Therefore, the interval in the X direction between the first X-end left clamp unit 312 and the first curved portion 310 can be adjusted by sliding the first X-end left clamp unit 312 along the first left shaft 314.

[0072] In addition, the end on the positive side of the X direction of the first X-end left clamp unit 312 is connected to the second support shaft 341 via the first X-end clamp support portion 343 of the second Y-edge portion 34 described later. Therefore, the end on the positive side of the X direction of the first X-end left clamp unit 312 is rotatable about the second support shaft 341. Furthermore, the first X-end left clamp unit 312 includes a clamp base, a clamp arm, a clamp lever, and a link rod having the same configuration as the first X-end right clamp unit 311 described with reference to Figure 4A and Figure 4B Thus, the detailed configuration and description of the first X-end left clamp unit 312 are omitted below.

[0073] The second X-edge portion 32 includes a second curved portion 320, against which the proximal end portion of the second curved column 68 described later abuts; a second X-end left clamp unit 321 provided on the positive side of the X direction with respect to the second curved portion 320 and gripping the second X-edge end portion 22X; a second X-end right clamp unit 322 provided on the negative side of the X direction with respect to the second curved portion 320 and gripping the second X-edge end portion 22X; a second left shaft 323 connecting the end on the positive side of the X direction of the second curved portion 320 and the second X-end left clamp unit 321; and a second right shaft 324 connecting the end on the negative side of the X direction of the second curved portion 320 and the second X-end right clamp unit 322.

[0074] Furthermore, the configurations of the second curved portion 320, the second X-end left clamp unit 321, the second X-end right clamp unit 322, the second left shaft 323, and the second right shaft 324 are the same as those of the first curved portion 310, the first X-end right clamp unit 311, the first X-end left clamp unit 312, the first right shaft 313, and the first left shaft 314 of the first X-edge portion 31, respectively, so detailed description is omitted.

[0075] The first Y-edge portion 33 includes a first base portion 330 extending in the Y direction; a first support shaft 331 extending in the Y direction and supported by the first base portion 330; a plurality of (in the present embodiment, two) first Y-end left clamp units 332 provided on the positive side of the Y direction with respect to the first support shaft 331 and gripping the first Y-edge end portion 23Y; a plurality of (in the present embodiment, two) first Y-end right clamp units 333 provided on the negative side of the Y direction with respect to the first support shaft 331 and gripping the first Y-edge end portion 23Y; a first left shaft 334 connecting the end on the positive side of the Y direction of the first support shaft 331 and the first Y-end left clamp units 332; and a first right shaft 335 connecting the end on the negative side of the Y direction of the first support shaft 331 and the first Y-end right clamp units 333. Figure 2A first X end clamp support portion 333 is provided to an end portion on the positive side in the Y direction in the first support shaft 331. A second X end clamp support portion 334 is provided to an end portion on the negative side in the Y direction in the first support shaft 331.

[0076] The Y end clamp 332 has a pair of clamps that are opened and closed with the first support shaft 331 as a rotation axis, and grips the first Y edge end portion 23Y of the sheet material 2 by the pair of clamps.

[0077] The first base 330 extends in parallel with the first Y frame member 393 on the lower side in the Z direction of the fixed frame 39. An end portion on the positive side in the Y direction in the first base 330 is connected to an X axis guide rail (not shown) provided to the lower surface side of the first X frame member 391, and an end portion on the negative side in the Y direction in the first base 330 is connected to an X axis guide rail (not shown) provided to the lower surface side of the second X frame member 392. Therefore, the first base 330 is slidable in the X direction with respect to the fixed frame 39 by the X axis guide rails provided to the X frame members 391, 392.

[0078] The first X end clamp support portion 333 rotatably supports an end portion on the negative side in the X direction of the first X end right clamp unit 311 of the first X edge member 31 about the first support shaft 331. In addition, the first X end clamp support portion 333 is connected to a Y axis guide rail (not shown) provided to the first base 330. Therefore, the first X edge member 31 is slidable in the Y direction with respect to the fixed frame 39 by the Y axis guide rail provided to the first base 330.

[0079] The second X end clamp support portion 334 rotatably supports an end portion on the negative side in the X direction of the second X end left clamp unit 321 of the second X edge member 32 about the first support shaft 331. In addition, the second X end clamp support portion 334 is connected to a Y axis guide rail (not shown) provided to the first base 330. Therefore, the second X edge member 32 is slidable in the Y direction with respect to the fixed frame 39 by the Y axis guide rail provided to the first base 330.

[0080] The second Y edge member 34 includes a second base 340 that extends in the Y direction, a second support shaft 341 that extends in the Y direction and is supported to the second base 340, a plurality of Y end clamps (not shown) provided to the second support shaft 341, a first X end clamp support portion 343 provided to an end portion on the positive side in the Y direction in the second support shaft 341, and a second X end clamp support portion 344 provided to an end portion on the negative side in the Y direction in the second support shaft 341.

[0081] The plurality of Y-end clamps provided on the second support shaft 341 have pairs of clamps that can be opened and closed with the second support shaft 341 as the axis of rotation, and these pairs of clamps grip the second Y-edge end portion 24Y of the sheet material 2.

[0082] The second base 340 extends parallel to the second Y-frame member 394 on the lower side in the Z direction of the fixed frame 39. The end portion on the positive side in the Y direction in the second base 340 is connected to an X-axis guide rail (not shown) provided on the lower surface side of the first X-frame member 391, and the end portion on the negative side in the Y direction in the second base 340 is connected to an X-axis guide rail (not shown) provided on the lower surface side of the second X-frame member 392. Thus, the second base 340 is slidable in the X direction with respect to the fixed frame 39 by the X-axis guide rails provided on the X-frame members 391, 392.

[0083] The first X-end clamp support portion 343 rotatably supports the end portion on the positive side in the X direction of the first X-end left clamp unit 312 of the first X-edge member 31 about the second support shaft 341, and is connected to a Y-axis guide rail (not shown) provided on the second base 340. Thus, the first X-edge member 31 is slidable in the Y direction with respect to the fixed frame 39 by the Y-axis guide rail provided on the second base 340.

[0084] The second X-end clamp support portion 344 rotatably supports the end portion on the positive side in the X direction of the second X-end right clamp unit 322 of the second X-edge member 32 about the second support shaft 341. In addition, the second X-end clamp support portion 344 is connected to a Y-axis guide rail (not shown) provided on the second base 340. Thus, the second X-edge member 32 is slidable in the Y direction with respect to the fixed frame 39 by the Y-axis guide rail provided on the second base 340.

[0085] Figure 5A and Figure 5B is a side view schematically illustrating the gripper device 3 as viewed in the Y direction from the side of the first X-edge member 31. As described above, the end portion on the negative side in the X direction of the first X-end right clamp unit 311 of the first X-edge member 31 is connected to the first base 330 via the first X-end clamp support portion 333 of the first Y-edge member 33. In addition, the end portion on the positive side in the X direction of the first X-end left clamp unit 312 of the first X-edge member 31 is connected to the second base 340 via the first X-end clamp support portion 343 of the second Y-edge member 34. In addition, the first base 330 and the second base 340 are each connected to an X-axis guide rail provided on the first X-frame member 391 of the fixed frame 39, and are slidable in the X direction with respect to the fixed frame 39.

[0086] Furthermore, a first X-axis actuator 395 that allows the first base 330 to slide along the X-axis guide rail, and a second X-axis actuator 396 that allows the second base 340 to slide along the X-axis guide rail are provided on the fixed frame 39. Therefore, in the gripping device 3, by driving these X-axis actuators 395 and 396, the first base 330 slides to the negative side in the X direction and the second base 340 slides to the positive side in the X direction, as... Figure 5B As shown, the sheet material 2, gripped by the first X-end right clamping unit 311 and the first X-end left clamping unit 312, can extend along the X direction. Furthermore, the structure of the second X-side component 32 in the gripping device 3 is also similar to... Figure 5A and Figure 5B Since they are the same, illustrations and detailed explanations are omitted.

[0087] Figure 6A and Figure 6B This is a schematic side view of the gripping device 3 as seen from the side of the first Y-side component 33 along the X direction. Furthermore, in Figure 6A and Figure 6B For ease of understanding, the illustration of the first support shaft 331 is omitted. As described above, the first X-end clamp support portion 333 of the first Y-side member 33 is connected to the Y-axis guide rail provided on the first base 330. Therefore, the first X-end clamp support portion 333 can slide freely relative to the fixed frame 39 in the Y direction using the Y-axis guide rail of the first base 330. Furthermore, the second X-end clamp support portion 334 of the first Y-side member 33 is connected to the Y-axis guide rail provided on the first base 330. Therefore, the second X-end clamp support portion 334 can slide freely relative to the fixed frame 39 in the Y direction using the Y-axis guide rail of the first base 330.

[0088] Furthermore, a first Y-axis actuator 397 that allows the first X-end clamp support 333 to slide along the Y-axis guide rail, and a second Y-axis actuator 398 that allows the second X-end clamp support 334 to slide along the Y-axis guide rail are provided on the fixed frame 39. Therefore, in the gripping device 3, by driving these Y-axis actuators 397 and 398, the first X-end clamp support 333 slides towards the positive Y direction and the second X-end clamp support 334 slides towards the negative Y direction, as... Figure 6B As shown, the sheet material 2, gripped by the first X-side member 31 and the second X-side member 32, can extend along the Y direction. Furthermore, the structure of the second Y-side member 34 side of the gripping device 3 is also similar to... Figure 6A and Figure 6B Since they are the same, illustrations and detailed explanations are omitted.

[0089] Next, refer to Figures 7-11B The structure of the forming device 6 will be explained.

[0090] Figure 7is a diagram schematically illustrating a side view of the molding device 6 as viewed in the Y direction from the first X edge member 31 side of the gripping device 3.

[0091] Figure 8 is a diagram schematically illustrating a plan view of the molding device 6 as viewed in the Z direction from the upper side. Further, in Figure 8 , the sheet material 2 gripped by the gripping frame in the gripping device 3, the curved portions 310, 320 as constituent parts of the gripping frame, and the first X-end right clamp unit 311, 321 and the first X-end left clamp unit 312, 322 gripping the sheet material 2 are indicated by broken lines.

[0092] The molding device 6 includes a lower mold 60, an upper mold 66 provided on the Z direction positive side (vertically upper side) of the lower mold 60 to sandwich the sheet material 2, a lowering device 65 to lower the gripping device 3 along the Z direction between the lower mold 60 and the upper mold 66 to bring the sheet material 2 gripped by the gripping device 3 close to the lower mold 60, the upper mold 66 provided separately from the lower mold 60 on the vertically upper side of the lower mold 60 to sandwich the sheet material 2, first and second curved columns 67, 68 provided on both sides in the Y direction with respect to the lower mold surfaces 61a, 62a of the lower mold 60, first right and left unclamping units 691, 692 provided on the Y direction positive side with respect to the lower mold surfaces 61a, 62a, and second right and left unclamping units 693, 694 provided on the Y direction negative side with respect to the lower mold surfaces 61a, 62a.

[0093] As shown in Figure 8 , the lower mold 60 is rectangular in plan view with the Y direction as the long side direction and the X direction as the width direction, and is divided into the first and second lower molds 61, 62 at the center in the width direction. On these first and second lower molds 61, 62, first and second lower mold surfaces 61a, 62a of the same shape are formed, respectively. Further, on these first and second lower mold surfaces 61a, 62a, first and second base materials 63, 64 of the same shape are provided, respectively.

[0094] As shown in Figure 8 , these first and second lower mold surfaces 61a, 62a are of the same shape and are provided back-to-back with each other in plan view. Therefore, the entire lower mold 60 after the first and second lower molds 61, 62 are brought together is convex upward in side view along the Y direction. A suction device not shown is connected to these lower mold surfaces 61a, 62a, so that gas can be sucked from these lower mold surfaces 61a, 62a.

[0095] Furthermore, the first substrate 63 disposed on the first lower mold surface 61a and the second substrate 64 disposed on the second lower mold surface 62a are of the same shape and are arranged back-to-back in plan view. Therefore, in the forming apparatus 6, sheet material 2 can be attached to both substrates 63 and 64 simultaneously. Thus, according to this forming apparatus 6, by closing the lower mold 60 and the upper mold 66 which hold the sheet material 2, a first product part formed by the first lower mold surface 61a and a second product part formed by the second lower mold surface 62a can be manufactured simultaneously.

[0096] The upper mold 66 is concave upwards in a side view along the Y direction. In a top view, the upper mold 66 is a rectangle with the Y direction as its longer side and the X direction as its width, divided in the middle of its width direction into a first upper mold 661 and a second upper mold 662. The first upper mold 661 includes a first upper mold surface 661a facing the first lower mold surface 61a when the mold is closed, and a second upper mold surface 662a facing the second lower mold surface 62a. The upper mold 66 can move freely forward and backward relative to the lower mold 60 along the Z direction using a lifting mechanism (not shown). Furthermore, a suction device (not shown) is connected to these upper mold surfaces 661a and 662a, allowing gas to be drawn from them.

[0097] In addition, the following, such as Figure 8 As shown, the portion of the sheet material 2 held by the gripping device 3 that is further outward than the first lower die end 60a on the positive side of the Y direction when viewed from the side along the X direction is called the first residual edge portion 25, and the portion that is further outward than the second lower die end 60b on the negative side of the Y direction is called the second residual edge portion 26.

[0098] The gripping frame 30 of the gripping device 3 is located between the lower mold 60 and the upper mold 66, with the first positioning part 8 and the second positioning part 9 (described later in top view) positioned further inside the end edges on both positive and negative sides of the sheet material 2 in the Y direction. At least a portion of these end edges are gripped by the clamping units 311, 312, 321, and 322.

[0099] A lowering device 65 is disposed between the lower mold 60 and the upper mold 66. The lowering device 65 uses a driving force generated by a hydraulic cylinder or electromagnetic actuator to lower the gripping device 3 along the Z-direction, bringing the sheet material 2 gripped by the gripping frame 30 closer to the lower mold 60. Furthermore, at this time, the lowering device 65 preferably grips only the fixed frame 39 in the gripping device 3. Thus, the gripping device 3 can be lowered while the gripping frame 30 is deformed.

[0100] The first curved column 67 includes a first column member 671 erected near the lower mold 60 and extending along the Z direction, and a first curved column pin 672 disposed at the front end of the first column member 671. Additionally, as... Figure 3As shown, the outer diameter of the first bent post pin 672 is slightly smaller than the inner diameter of the guide hole 310c of the first bent portion 310. Furthermore, the front end of the first bent post pin 672 forms a tapered surface 673 that tapers from the base end side towards the front end side. Therefore, by bringing the first bent portion 310 close to the front end of the first bent post 67, the first bent post pin 672 can be inserted into the guide hole 310c of the first bent portion 310, thereby aligning the first bent portion 310 with the first bent post 67 while the post abutment surface 310a of the first bent portion 310 abuts against the front end face 671a of the first post member 671. Additionally, as... Figure 7 As shown, the height of the front end face 671a of the first curved column 67 along the Z direction is higher than the highest portion of the lower die 60 along the Z direction. Here, the highest portion of the lower die 60 along the Z direction refers to the portion at the center of the width direction parallel to the X direction in the side view viewed along the Y direction, and is the lower die ridge 60t extending along the Y direction between the first lower die 61 and the second lower die 62 (see reference). Figure 8 That is, the front end face 671a of the first curved column 67 is located on the upper side in the vertical direction, which is further above the lower die line 60t. In addition, although the illustrations and detailed descriptions are omitted, the second curved column 68 includes a second column member 681 and a second curved column pin 682 with the same structure as the first column member 671 and the first curved column pin 672 described above.

[0101] like Figure 8 As shown, the first curved column 67 is positioned further outward than the first lower die end 60a of the lower die 60, and the second curved column 68 is positioned further outward than the second lower die end 60b of the lower die 60. These first curved columns 67 and second curved columns 68, when viewed from above, are positioned to clamp the lower die 60 and face each other along the X direction. Furthermore, these first curved columns 67 and second curved columns 68 are positioned at the center of the width direction of the lower die 60 in a side view along the Y direction, i.e., on the extension line of the lower die ridge line 60t. Additionally, the first curved column 67 is positioned below the first curved portion 310, which is part of the gripping frame of the gripping piece material 2, in the Z direction, and the second curved column 68 is positioned below the second curved portion 320, which is part of the gripping frame, in the Z direction. Therefore, by using the lowering device 65 to lower the gripping device 3 along the Z direction, the bent portions 310 and 320 can abut against the bent posts 67 and 68 respectively before the sheet material 2 contacts the lower mold surfaces 61a and 62a. Furthermore, after these bent portions 310 and 320 abut against the bent posts 67 and 68, by using the lowering device 65 to further lower the fixing frame 39 of the gripping device 3, the gripping frame 30 can be bent into an upwardly convex shape when viewed from the side along the Y direction using these bent posts 67 and 68.

[0102] Figure 9 is a perspective view of the lower mold 60 and the gripping device 3. Furthermore, in Figure 9 , the illustration of the second lower mold 62 among the lower molds 60 is omitted for easy understanding.

[0103] As shown in Figure 9 and Figure 8 , the first right unclamping unit 691 and the first left unclamping unit 692 are respectively provided at positions further outward than the first lower mold end 60a of the lower mold 60, and the second left unclamping unit 693 and the second right unclamping unit 694 are respectively provided at positions further outward than the second lower mold end 60b of the lower mold 60. The first right unclamping unit 691 is provided at a position further to the X direction negative side than the first curved upright 67, and the first left unclamping unit 692 is provided at a position further to the X direction positive side than the first curved upright 67. The second left unclamping unit 693 is provided at a position further to the X direction negative side than the second curved upright 68, and the second right unclamping unit 694 is provided at a position further to the X direction positive side than the second curved upright 68.

[0104] As shown in Figure 8 , the first right unclamping unit 691 is provided at the Z direction lower side relative to the first X end right clamp unit 311 of the gripping frame when viewed from above, and faces the first X end right clamp unit 311 when the gripping device 3 is lowered as described later. The first left unclamping unit 692 is provided at the Z direction lower side relative to the first X end left clamp unit 312 of the gripping frame when viewed from above, and faces the first X end left clamp unit 312 when the gripping device 3 is lowered. The second left unclamping unit 693 is provided at the Z direction lower side relative to the second X end left clamp unit 321 of the gripping frame when viewed from above, and faces the second X end left clamp unit 321 when the gripping device 3 is lowered as described later. The second right unclamping unit 694 is provided at the Z direction lower side relative to the second X end right clamp unit 322 of the gripping frame when viewed from above, and faces the second X end right clamp unit 322 when the gripping device 3 is lowered. These unclamping units 691, 692, 693, 694 release the gripping of the sheet material 2 by the clamp units 311, 312, 321, 322 facing each other by lifting the base end portions of the clamp levers of the respective clamp units 311, 312, 321, 322 upward along the Z direction when the gripping device 3 is lowered (refer to the above description of the operation of the gripping device 3). Figure 4A .

[0105] Figure 10 is a diagram schematically illustrating a side view of the molding device 6 as viewed in the same orientation as Figure 7 . Furthermore, in Figure 10 , for easy understanding, a case where a portion of the first curved upright 67 in the molding device 6 is broken away is shown.

[0106] As Figure 8 and Figure 10 shown in FIGS. 1 and 2, the shaping device 6 includes a trimming blade 7 that cuts the sheet material 2 provided between the lower mold 60 and the upper mold 66, and a first positioning portion 8 and a second positioning portion 9 that align a portion of the first remaining edge portion 25 and a portion of the second remaining edge portion 26 of the sheet material 2, respectively, when the sheet material 2 is cut by the trimming blade 7.

[0107] The trimming blade 7 is plate-shaped having a cutting edge extending in the Y direction, and is provided to the upper mold 66. More specifically, the trimming blade 7 is provided between the first upper mold 661 and the second upper mold 662, and is movable in the Z direction with respect to these upper molds 661, 662 by a not-shown drive device. In Figure 8 a cutting surface 71 formed by the trimming blade 7 (i.e., a surface formed by the cutting edge of the trimming blade 7 when the trimming blade 7 has been moved in the movable range in the Z direction) is shown in FIG. 2 by a thick broken line. As Figure 8 shown in FIG. 2, the cutting surface 71 of the trimming blade 7 extends on the lower mold ridge 60t in the Y direction from between the first lower mold end 60a and the first curved column 67 to between the second lower mold end 60b and the second curved column 68 in plan view. Thus, the cutting surface 71 of the trimming blade 7 intersects the first remaining edge portion 25 on the positive side in the Y direction and the second remaining edge portion 26 on the negative side in the Y direction in the sheet material 2.

[0108] As Figure 8 and Figure 10 shown in FIGS. 1 and 2, the first positioning portion 8 has a first lower plate 81 and a first upper plate 85 provided to clamp the first remaining edge portion 25 of the sheet material 2 at a position further outward than the first lower mold end 60a of the lower mold 60 (i.e., further toward the first curved column 67 than the first lower mold end 60a). When the lower mold 60 and the upper mold 66 are clamped, the first positioning portion 8 performs positioning of the first remaining edge portion 25 by clamping the portion of the first remaining edge portion 25 intersecting the cutting surface 71 of the trimming blade 7 between the first lower plate 81 and the first upper plate 85.

[0109] Figure 11A is a side view of the first positioning portion 8.

[0110] Figure 11B is a side view of the first positioning portion 8 when the lower mold 60 and the upper mold 66 are clamped.

[0111] As Figure 10 and Figure 11AAs shown in FIG. 1, the first lower plate 81 is a plate shape extending toward the upper die 66, and is disposed at a position more outward than the first lower die end 60a in a substantially parallel manner to the first lower die end 60a of the lower die 60. The first lower plate 81 is fixed to the first lower die end 60a of the lower die 60 in a manner that the upper end portion 82 thereof on the upper die 66 side is disposed at a position higher in the Z direction than the lower die ridge line 60t of the lower die 60. Thus, hereinafter, the case where the first lower plate 81 is fixed to the lower die 60 will be described, but the present application is not limited thereto. The first lower plate 81 can also be erected near the first lower die end 60a of the lower die 60 in the same manner as the first curved column 67. Further, a first lower guide portion 83 in the form of a slit along the cut surface 71 of the dressing blade 7 is formed in the first lower plate 81.

[0112] The first upper plate 85 is a plate shape extending toward the lower die 60 and the aforementioned first lower plate 81, and is disposed at a position more outward than the first upper die end 66a on the Y direction positive side in a side view along the X direction of the upper die 66 in a substantially parallel manner to the first lower plate 81. Further, the first upper plate 85 is fixed to the first upper die end 66a of the upper die 66 in a manner that advances and retreats together with the upper die 66. Furthermore, hereinafter, the case where the first upper plate 85 is disposed at a position more outward than the first lower plate 81 will be described, but the present application is not limited thereto. The first upper plate 85 can also be disposed at a position more inward than the first lower plate 81.

[0113] Further, as shown in FIG. 1, the first upper plate 85 is fixed to the upper die 66 in a manner that the lower end portion 86 thereof on the lower die 60 side is lower in the Z direction than the upper end portion 82 of the first lower plate 81 when the lower die 60 and the upper die 66 are clamped. Thus, when the lower die 60 and the upper die 66 are clamped, at least a portion of the first lower plate 81 and the first upper plate 85 overlap in a side view, and thus a portion including the upper end portion 82 of the first lower plate 81 is hidden inside the first upper plate 85. Figure 11B Further, a first upper guide portion 87 in the form of a slit along the cut surface 71 of the dressing blade 7 is formed in the first upper plate 85. As shown in FIG. 1, the first upper guide portion 87 and the first lower guide portion 83 formed in the first lower plate 81 overlap in a side view along the Y direction when the lower die 60 and the upper die 66 are clamped. Thus, the dressing blade 7 can cut the first remaining edge portion 25 positioned by the first lower plate 81 and the first upper plate 85 by moving along the first lower guide portion 83 and the first upper guide portion 87 after the lower die 60 and the upper die 66 are clamped.

[0114] Figure 11B Returning to FIG. 1, the first upper plate 85 is fixed to the first upper die end 66a of the upper die 66 in a manner that the lower end portion 86 thereof on the lower die 60 side is lower in the Z direction than the upper end portion 82 of the first lower plate 81 when the lower die 60 and the upper die 66 are clamped. Thus, when the lower die 60 and the upper die 66 are clamped, at least a portion of the first lower plate 81 and the first upper plate 85 overlap in a side view, and thus a portion including the upper end portion 82 of the first lower plate 81 is hidden inside the first upper plate 85.

[0115] Returning to FIG. 1, the first upper plate 85 is fixed to the first upper die end 66a of the upper die 66 in a manner that the lower end portion 86 thereof on the lower die 60 side is lower in the Z direction than the upper end portion 82 of the first lower plate 81 when the lower die 60 and the upper die 66 are clamped. Thus, when the lower die 60 and the upper die 66 are clamped, at least a portion of the first lower plate 81 and the first upper plate 85 overlap in a side view, and thus a portion including the upper end portion 82 of the first lower plate 81 is hidden inside the first upper plate 85. Figure 8 ​The second positioning section 9 has a second lower plate 91 and a second upper plate 95 provided for clamping the second remaining edge portion 26 of the sheet material 2 at a position further outward than the second lower die end 60b of the lower die 60, i.e., further toward the second curved column 68 side than the second lower die end 60b. When the lower die 60 and the upper die 66 are closed, the second positioning section 9 positions the second remaining edge portion 26 by clamping the portion of the second remaining edge portion 26 intersecting the cut surface 71 of the trimming blade 7 between the lower plate 91 and the upper plate 95. Further, the second lower plate 91 and the second upper plate 95 have almost the same configuration as the first lower plate 81 and the first upper plate 85 described above, so the illustration and detailed description thereof are omitted.

[0116] Next, the flow of the molding method using the molding system 1 described above will be described.

[0117] Figure 12 is a flowchart illustrating the detailed flow of the resin molding method.

[0118] First, in the gripping process S1, the sheet feeding section 4, after causing the gripping frame 30 of the gripping device 3 to grip a new sheet material 2 by using the sheet transfer mechanism 41, transports the gripping device 3 to the heating device 5. More specifically, the Y edge ends 23Y, 24Y of the sheet material 2 are gripped by the Y end clamps of the Y edge members 33, 34 of the gripping frame 30, and the X edge ends 21X, 22X of the sheet material 2 are gripped by the clamp units 311, 312 of the first X edge member 31 and the clamp units 321, 322 of the second X edge member 32 of the gripping frame 30. As described with reference to Figure 4B The clamp cylinder 42 is provided on the sheet feeding section 4. Therefore, in the gripping process S1, the gripping device 3 is transported to the heating device 5 after the sheet material 2 is gripped by the clamp units 311, 312, 321, 322 by pressing the base end portions of the clamp operating rods of the respective clamp units 311, 312, 321, 322 downward along the Z direction by the clamp cylinder 42.

[0119] Next, in the heating / stretching process S2, the heating device 5 heats the sheet material 2 gripped by the gripping frame 30 of the gripping device 3 to soften it. Further, in the heating / stretching process S2, after the sheet material 2 softened by the heating of the heating device 5 is stretched in the X direction or the Y direction by the gripping device 3 by driving the X-axis actuators 395, 396 or the Y-axis actuators 397, 398 (see Figure 5A ,5B and Figure 6A ,6B), the gripping device 3 is transported to the molding device 6. Further, in the heating / stretching process S2, the sheet material 2 can be stretched in both the X direction and the Y direction, can be stretched in only one of the X direction and the Y direction, or can not be stretched in either the X direction or the Y direction. That is, the stretching process is not necessarily provided.

[0120] Next, in the molding step S3, the sheet material 2 that has passed through the heating / stretching step S2 is arranged between the lower mold 60 and the upper mold 66, and these lower mold 60 and upper mold 66 are closed, and the sheet material 2 is attached to the base materials 63, 64 as a skin, thereby manufacturing a product. More specifically, in the molding step S3, after the gripping device 3 that has passed through the heating / stretching step S2 is lowered to the lower side in the Z direction by the lowering device 65, and the sheet material 2 gripped by the gripping frame 30 is brought close to the lower mold 60, these lower mold 60 and upper mold 66 are closed, and further, gas is sucked from the lower mold surfaces 61a, 62a and the upper mold surfaces 661a, 662a by a not-shown suction device, thereby attaching the sheet material 2 to the base materials 63, 64.

[0121] Next, referring to Figures 8-9 and Figures 13-14 , the procedure of lowering the gripping device 3 in the molding step S3 is described in detail.

[0122] Figures 13-14 is a view illustrating the procedure of lowering the gripping device 3. Further, in these Figures 13-14 , the illustration of the second lower mold 62 is omitted for easy understanding.

[0123] First, in the molding step S3, as shown in Figure 9 , the gripping device 3 that grips the sheet material 2 is carried to between the lower mold 60 and the upper mold 66 by a not-shown carrying device. More specifically, as shown in Figure 8 , the gripping device 3 is carried to between the lower mold 60 and the upper mold 66 in such a manner that the first lower plate 81 and the first upper plate 85 and the second lower plate 91 and the second upper plate 95 are arranged at positions more inward than the end edges of the sheet material 2 gripped by the gripping frame 30 in plan view.

[0124] Next, as shown in Figure 13 , the lowering device 65 lowers the fixed frame 39 of the gripping device 3 downward along the Z direction until the curved portions 310, 320 of the gripping frame 30 abut against the front end portions of the curved columns 67, 68. More specifically, the lowering device 65 lowers the fixed frame 39 along the Z direction until the curved column pins 672, 682 provided at the front end portions of the curved columns 67, 68 are inserted into the guide holes formed in the curved portions 310, 320, and the column abutment faces of the curved portions 310, 320 abut against the front end faces of the curved columns 67, 68.

[0125] Further, as referred to Figure 3As explained, conical surfaces are formed on the guide holes of the bent portions 310 and 320 and on the bent column pins 672 and 682, respectively. Therefore, even if the position of the gripping device 3 relative to the bent columns 67 and 68 and the lower dies 61 and 62 deviates from its normal position, the bent portions 310 and 320 can be inserted into the bent column pins 672 and 682 while the gripping device 3 is aligned in its normal position. Furthermore, by aligning the gripping device 3 relative to the bent columns 67 and 68 and the lower dies 61 and 62 in this way, the sheet material 2 gripped by the gripping frame 30 of the gripping device 3 can always be attached to the same position relative to the substrates 63 and 64 provided on the lower dies 61 and 62, thus improving product quality.

[0126] Next, as Figure 14 As shown, the lowering device 65 causes the fixing frame 39 of the gripping device 3 to descend further downward along the Z direction. (See reference...) Figure 3 As explained, the first X-side component 31 and the second X-side component 32 of the gripping frame 30 can bend freely at both ends of the curved portions 310 and 320 in the X direction. Therefore, when these curved portions 310 and 320 abut against the front ends of the curved columns 67 and 68, and the fixing frame 39 is further lowered, as... Figure 14 As shown, the first X-side component 31 and the second X-side component 32 are bent at both ends of the curved portion 310, 320.

[0127] Additionally, as referenced Figure 5A and Figure 5B As explained, the first base 330 and the second base 340, which connect the two ends of the first X-side component 31 and the second X-side component 32, can slide freely relative to the fixed frame 39 along the X direction. Therefore, when the fixed frame 39 of the gripping device 3 is lowered using the lowering device 65, the first base 330 and the second base 340 slide closer to each other along the X direction due to the tension of the sheet material 2. Therefore, as Figure 14 As shown, the first X-side component 31 and the second X-side component 32 are bent on both sides of the curved portion 310, 320, and are upwardly convex when viewed along the Y direction.

[0128] Furthermore, when the fixing frame 39 is lowered in this manner, the central portion of the X-side ends 21X, 22X of the sheet material 2 held by these side members 31, 32 along the X direction will abut against the sheet contact surface of the curved portions 310, 320. Therefore, the sheet material 2 will also bend at both ends of the curved portions 310, 320 and will bulge upward when viewed along the Y direction. Based on the above, in the forming process S3, by simply lowering the fixing frame 39 of the gripping device 3 using the lowering device 65, the sheet material 2 can be bent in a manner that follows the convex shape of the lower mold surfaces 61a, 62a.

[0129] Thus, in this embodiment, by bending the gripping frames 30 at the four ends 21X, 22X, 23Y, and 24Y of the gripping sheet material 2 to make the sheet material 2 bend upward in a convex shape, the extension of each part of the sheet material 2 in the surface direction can be made uniform, and the thickness of each part of the sheet material 2 can also be made uniform, so the quality of the product can be further improved.

[0130] Figure 15 It is along Figure 11A A cross-sectional view of the first positioning part 8 of line AA. More specifically, Figure 15 Is it like this? Figure 14 The diagram shows a cross-sectional view of the first positioning part 8 when the gripping device 3 is lowered to the lower mold 60.

[0131] As described above, in forming process S3, the sheet material 2 is positioned between the lower mold 60 and the upper mold 66 such that, when viewed from above, the first lower plate 81 and the first upper plate 85 are positioned further inward than the end edge 25a of the first remaining edge portion 25. Therefore, when the gripping device 3 is lowered to the lower mold 60, as... Figure 15 As shown, the sheet material 2 is in a state where the first remaining edge 25 is engaged with the upper end 82 of the first lower plate 81. Furthermore, in this state, the end edge 25a of the first remaining edge 25 is outside the cutting surface 71 of the trimming blade 7.

[0132] In addition, in the forming process S3, after the sheet material 2 is brought close to the lower mold 60 by the above operation, the lower mold 60 and the upper mold 66 are closed, and then the gas is drawn from these lower mold surfaces 61a, 62a and upper mold surfaces 661a, 662a by a suction device (not shown), thereby attaching the sheet material 2 to the substrate 63, 64.

[0133] Figure 16 It is along Figure 11B A cross-sectional view of the first positioning part 8 of line BB. More specifically, Figure 16 From Figure 15 The state shown is a cross-sectional view of the first positioning part 8 when the lower mold 60 and the upper mold 66 are closed.

[0134] like Figure 16 As shown, when from Figure 15 In the state shown, when the upper mold 66 approaches the lower mold 60 and the first upper plate 85 descends along the Z direction toward the first lower plate 81, the lower end 86 of the first upper plate 85 abuts against the first remaining edge 25 of the sheet material 2. Furthermore, when the upper mold 66 is brought closer to the lower mold 60, the first remaining edge 25 is folded in such a way that the end edge 25a is pulled between the first lower plate 81 and the first upper plate 85. Thus, in the closed state of the lower mold 60 and the upper mold 66, as... Figure 16As shown in FIG. 6, the portion of the first remaining edge portion 25 that intersects the cut surface 71 of the trimming blade 7, including the end edge 25a, is sandwiched between the first lower plate 81 and the first upper plate 85. Thus, the first remaining edge portion 25 is positioned by the first lower plate 81 and the first upper plate 85 in a state in which the end edge 25a thereof is controlled within the range of the cut surface 71 of the trimming blade 7.

[0135] Further, although not shown or described in detail, by closing the lower mold 60 and the upper mold 66 using the above-described procedure, the second remaining edge portion 26 of the sheet material 2 is positioned by the second lower plate 91 and the second upper plate 95 of the second positioning portion 9 using the same procedure as the first remaining edge portion 25.

[0136] Further, as shown in FIG. 6, the second remaining edge portion 26 of the sheet material 2 is positioned by the second lower plate 91 and the second upper plate 95 of the second positioning portion 9. Figure 14 As shown in FIG. 6, when the fixed frame 39 is lowered using the lowering device 65, the clamp units 311, 312 that grip the first X edge end portion 21X of the sheet material 2 and the clamp units 321, 322 that grip the second X edge end portion 22X are respectively opposed to the unclamping units 691, 692, 693, 694. Thus, in the forming process S3, after the sheet material 2 is attached to the base materials 63, 64 using the above-described procedure, the grips of the clamp units 311, 312, 321, 322 are lifted upward along the Z direction by the unclamping units 691, 692, 693, 694 to release the grip of the sheet material 2 by the clamp units 311, 312, 321, 322.

[0137] Thus, in the present embodiment, by making the unclamping units 691 to 694 that release the grip of the sheet material 2 by the gripping device 3 independent of the gripping device 3 and disposing them in the vicinity of the lower molds 61, 62, it is possible to always keep the unclamping units 691 to 694 at room temperature. That is, it is also possible to consider disposing the unclamping units in the gripping device 3, but as described above, the gripping device 3 is heated by the heating device 5 together with the sheet material 2. In contrast, according to the present embodiment, as described above, it is possible to always keep the unclamping units 691 to 694 at room temperature, so it is possible to prevent the unclamping units 691 to 694 from malfunctioning or deforming due to heat.

[0138] Returning to Figure 12In the cutting step S4, the trimming blade 7 is moved downward along the Z direction toward the lower mold 60 side in a state where the lower mold 60 and the upper mold 66 are closed as described above, and the first and second remaining edge portions 25, 26 are positioned by the first and second positioning portions 8, 9, and the sheet material 2 is cut. As described above, when the lower mold 60 and the upper mold 66 are closed, the first remaining edge portion 25 is sandwiched between the first lower plate 81 and the first upper plate 85, and the second remaining edge portion 26 is sandwiched between the second lower plate 91 and the second upper plate 95. In addition, at this time, the end edge 25a of the first remaining edge portion 25 and the end edge 26a of the second remaining edge portion 26 are both drawn into the range of the cutting surface 71 of the trimming blade 7. Therefore, in the cutting step S4, by moving the trimming blade 7 along the cutting surface 71, the sheet material 2 can be divided into two portions of the first product portion attached to the first base material 63 and the second product portion attached to the second base material 64.

[0139] In the carrying step S5, an unillustrated carrying device carries the gripping device 3 after the release of the grip of the sheet material 2 from the forming device 6 to the sheet supply portion 4. More specifically, in this carrying step S5, the carrying device carries the gripping device 3 to the sheet supply portion 4 while restoring the gripping frame 30 extended in the X and Y directions in the heating / elongation step S2 to the origin.

[0140] Further, in the above-described embodiment, a case where a pair of curved supports 67, 68 erected in the vicinity of the lower molds 61, 62 are used as a pair of curved support portions for the first and second curved portions 310, 320 of the gripping frame 30 of the gripping device 3 to abut against is described, but the present application is not limited to this. As for the pair of curved support portions for the pair of curved portions 310, 320 of the gripping frame 30 to abut against and bend the gripping frame 30, for example, a part of the lower mold or a part of a device different from the forming device can be used.

[0141] According to the forming system 1 and the forming method of the present embodiment, the following effects are exerted.

[0142] (1) The molding system 1 includes the trimming blade 7 that cuts the sheet material 2, the lower plates 81, 91 that are provided at positions further outward than the lower mold ends 60a, 60b in a side view along the X direction of the lower mold 60 and extend toward the upper mold 66, and the upper plates 85, 95 that are provided at positions further outward than the upper mold ends in a side view along the X direction of the upper mold 66 in a manner that advances and retreats in conjunction with the upper mold 66 and extend toward the lower plates 81, 91. In addition, in the molding system 1, the cut surface 71 (i.e., a surface formed by the tip of the trimming blade 7 when the trimming blade 7 has been moved within the movable range) formed by the trimming blade 7 intersects the remaining edge portions 25, 26 of the sheet material 2, and at least a portion of these remaining edge portions 25, 26 is positioned by being sandwiched between the lower plates 81, 91 and the upper plates 85, 95 in a state in which the lower mold 60 and the upper mold 66 are clamped. Thus, according to the molding system 1, it is possible to prevent the remaining edge portions 25, 26 of the sheet material 2 from retreating outside the cut surface 71 of the trimming blade 7 when the trimming blade 7 has been moved within the movable range thereof, and thus it is possible to prevent cutting failure of the sheet material 2.

[0143] (2) In the molding system 1, by positioning the remaining edge portions 25 of the sheet material 2 by the lower plates 81 and the upper plates 85 using the slit-like lower guide portions 83 and the upper guide portions 87 that form the cut surface 71 along the trimming blade 7, it is possible to more reliably prevent the remaining edge portions 25 from retreating outside the cut surface 71 when the trimming blade 7 has been moved, and thus it is possible to more reliably prevent cutting failure of the sheet material 2.

[0144] (3) According to the molding system 1, on the basis of the remaining edge portions 25 of the sheet material 2 being positioned by the lower plates 81 and the upper plates 85 with respect to the cut surface 71 of the trimming blade 7, by cutting the portion of the sheet material 2 including the remaining edge portions 25 using the trimming blade 7, it is possible to divide into a first product portion attached to the first base material 63 and a second product portion attached to the second base material 64.

[0145] (4) According to the molding system 1, by gripping at least a portion of the end edge 25a of the sheet material 2 using the gripping frame 30 in a manner in which the lower plates 81 and the upper plates 85 are disposed further inward than the end edge 25a of the remaining edge portions 25 of the sheet material 2 in a plan view between the lower mold 60 and the upper mold 66, it is possible to reliably sandwich the portion of the remaining edge portions 25 of the sheet material 2 that intersects the cut surface 71 between the lower plates 81 and the upper plates 85 when the lower mold 60 and the upper mold 66 are clamped, and thus it is possible to more reliably prevent the remaining edge portions 25 of the sheet material 2 from retreating outside the cut surface 71 of the trimming blade 7 when the trimming blade 7 has been moved within the movable range thereof, and thus it is possible to more reliably prevent cutting failure of the sheet material 2.

[0146] (5) The molding method of this embodiment includes a molding step of arranging the sheet material 2 between the lower mold 60 and the upper mold 66 and closing the lower mold 60 and the upper mold 66, and a cutting step of moving the trimming blade 7 after closing the lower mold 60 and the upper mold 66, thereby cutting the sheet material 2. In addition, in the cutting step, the sheet material 2 is cut in a state where the remaining edge portions 25, 26 are positioned so as to cross the cutting surface 71 formed by the trimming blade 7. Thus, according to this molding method, it is possible to prevent the remaining edge portions 25, 26 of the sheet material 2 from retreating outside the cutting surface 71 of the trimming blade 7 when the trimming blade 7 is moved within the movable range thereof, and thus it is possible to prevent cutting failure of the sheet material 2.

[0147] (6) In the molding method of this embodiment, the remaining edge portions 25, 26 of the sheet material 2 are positioned by being sandwiched between the lower plate 81, 91 and the upper plate 85, 95 extending in the advancing and retreating direction of the upper mold 66, and thus it is possible to more surely prevent the remaining edge portions 25, 26 from retreating outside the cutting surface 71 when the trimming blade 7 is moved, and thus it is possible to more surely prevent cutting failure of the sheet material 2.

[0148] (7) According to the molding method of this embodiment, on the basis of the remaining edge portions 25, 26 of the sheet material 2 being positioned by the positioning portions 8, 9 so as to cross the cutting surface 71 of the trimming blade 7, the portion of the sheet material 2 including the remaining edge portions 25, 26 is cut by the trimming blade 7, and thus it is possible to divide into a first product portion attached to the first base material 63 and a second product portion attached to the second base material 64.

[0149] (8) According to the molding method of this embodiment, by gripping at least a portion of the end edge 25a, 25b of the sheet material 2 by the gripping frame 30 in a manner such that the lower plate 81, 91 and the upper plate 85, 95 are arranged at a position further inward than the end edge 25a, 25b of the sheet material 2 in plan view, when the lower mold 60 and the upper mold 66 are closed, it is possible to more surely sandwich a portion of the remaining edge portions 25, 26 of the sheet material 2 between the lower plate 81, 91 and the upper plate 85, 95, and thus it is possible to more surely prevent the remaining edge portions 25, 26 of the sheet material 2 from retreating outside the cutting surface 71 of the trimming blade 7 when the trimming blade 7 is moved within the movable range thereof, and thus it is possible to more surely prevent cutting failure of the sheet material 2.

[0150] The above describes one embodiment of the present application, but the present application is not limited thereto. The detailed configuration can be appropriately changed within the scope of the gist of the present application.

[0151] Reference Signs

[0152] 1 Molding system

[0153] 2 sheet material

[0154] 25 first remaining edge portion (remaining edge portion)

[0155] 25a end edge

[0156] 26 second remaining edge portion (remaining edge portion)

[0157] 26a end edge

[0158] 3 gripping device

[0159] 30 gripping frame (frame body)

[0160] 4 sheet supply portion

[0161] 5 heating device

[0162] 6 forming device

[0163] 60 lower mold

[0164] 60a, 60b lower mold end

[0165] 60t lower mold ridge

[0166] 61 first lower mold

[0167] 61a first lower mold face

[0168] 62 second lower mold

[0169] 62a second lower mold face

[0170] 63 first base material

[0171] 64 second base material

[0172] 65 lowering device

[0173] 66 upper mold

[0174] 66a first upper mold end

[0175] 67 first curved column

[0176] 68 second curved column

[0177] 7 trimming blade

[0178] 8 first positioning portion

[0179] 81 first lower plate (lower plate)

[0180] 82 upper end portion

[0181] 83 first lower guide portion (lower guide portion)

[0182] 85 first upper plate (upper plate)

[0183] 86 lower end portion

[0184] 87 first upper guide portion (guide portion)

[0185] 9 second positioning portion

[0186] 91 second lower plate (lower plate)

[0187] 95 second upper plate (upper plate).

Claims

1. A forming system, comprising: Lower mold; The upper mold is configured to move freely forward and backward relative to the lower mold along the vertical direction; and, Trim the blade to cut the sheet material positioned between the lower die and the upper die; The forming system is characterized in that it includes: The lower plate is located further outward than the lower mold end in the side view of the aforementioned lower mold, and extends towards the aforementioned upper mold side; and, The upper plate is positioned further outward than the upper mold end in the side view, and extends towards the lower plate, in a manner that moves forward and backward together with the aforementioned upper mold; and, The cut surface formed by the aforementioned trimming blade intersects with the remaining edge portion of the aforementioned sheet material, which is located further outward than the aforementioned lower die end. When the aforementioned lower mold and the aforementioned upper mold are closed, the lower end of the aforementioned upper plate is lower in height along the aforementioned vertical direction than the upper end of the aforementioned lower plate, and at least a portion of the aforementioned lower plate and the aforementioned upper plate are repeated in side view. With the lower mold and the upper mold closed, at least a portion of the remaining edge portion is clamped between the lower plate and the upper plate.

2. The forming system according to claim 1, wherein, A slit-shaped lower guide portion and an upper guide portion along the aforementioned cut surface are respectively formed on the aforementioned lower plate and the aforementioned upper plate. After the lower mold and the upper mold are closed, the trimming blade cuts off the remaining edge portion positioned by the lower plate and the upper plate by moving along the lower guide portion and the upper guide portion.

3. The forming system according to claim 1 or 2, wherein, The aforementioned lower mold has a first lower mold surface for setting the first substrate and a second lower mold surface for setting the second substrate. The aforementioned first substrate and second substrate are respectively attached to the aforementioned sheet material by closing the aforementioned lower mold and the aforementioned upper mold. The aforementioned trimming blade cuts the aforementioned sheet material between the aforementioned first lower die surface and the aforementioned second lower die surface when viewed from above, thereby dividing the aforementioned sheet material into a first product portion attached to the aforementioned first substrate and a second product portion attached to the aforementioned second substrate.

4. The forming system according to claim 1 or 2, further comprising a frame body, the frame body being positioned between the lower mold and the upper mold, such that, in a top view, the lower plate and the upper plate are positioned further inward than the end edge of the sheet material, gripping at least a portion of the end edge.

5. A forming method for forming a product using the forming system according to claim 1, characterized in that the forming method comprises: In the forming process, the aforementioned sheet material is placed between the aforementioned lower mold and the aforementioned upper mold, and the aforementioned lower mold and the aforementioned upper mold are closed; and, In the cutting process, after the lower mold and the upper mold are closed, the trimming blade is moved to cut the sheet material; and... In the aforementioned cutting process, the sheet material is cut while at least a portion of the remaining edge is positioned such that the cutting surface formed by the aforementioned trimming blade intersects with the aforementioned remaining edge.

6. The forming method according to claim 5, wherein, In the aforementioned cutting process, the aforementioned remaining edge portion is positioned by clamping at least a portion of the aforementioned remaining edge portion between the aforementioned lower plate and the aforementioned upper plate.

7. The forming method according to claim 5 or 6, wherein, In the aforementioned forming process, by closing the lower mold and the upper mold with the first substrate and the second substrate respectively disposed on the first lower mold surface and the second lower mold surface formed on the lower mold, the first substrate and the second substrate are attached to the sheet material. In the aforementioned cutting process, the aforementioned sheet material is cut between the aforementioned first lower die surface and the aforementioned second lower die surface when viewed from above, thereby dividing the aforementioned sheet material into a first product portion attached to the aforementioned first substrate and a second product portion attached to the aforementioned second substrate.

8. The forming method according to claim 6, wherein, In the aforementioned forming process, between the aforementioned lower mold and the aforementioned upper mold, the frame holds the aforementioned end edge in a manner in which the aforementioned lower plate and the aforementioned upper plate are positioned further inside than the aforementioned end edge of the sheet material when viewed from above, and in this state the aforementioned lower mold and the aforementioned upper mold are closed.

Images