Method for manufacturing resin sheet joined body

Abstract

To manufacture a plurality of resin sheet joined bodies by one injection molding while suppressing an increase in the size of a mold.SOLUTION: A method for manufacturing a resin sheet joined body according to one embodiment of the present disclosure includes the steps of: stacking pairs of resin sheets and spacer plates alternately; injecting resin between the resin sheets of each pair in a mold and bonding the resin sheets of each pair together with the injected resin to mold a plurality of resin sheet joined bodies; and separating the molded plurality of resin sheet joined bodies from the spacer plates.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a method for producing a resin sheet joined body. [Background technology]

[0002] Patent Document 1 discloses a method in which a resin part is placed in a metal mold for injection molding, resin is injected into the metal mold, and the resin part and the injected resin are integrally molded. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-001740 A Summary of the Invention [Problem to be solved by the invention]

[0004] Meanwhile, the inventor has developed a technology in which a pair of resin sheets is placed side by side in a mold for injection molding, resin is injected between the pair of resin sheets in the mold, and the injected resin joins the pair of resin sheets together.

[0005] The inventors have found the following problems with respect to such a technique for manufacturing a resin sheet joined body by joining a pair of resin sheets together. The inventors have been considering producing a plurality of resin sheet joined bodies by one injection molding in order to improve productivity. However, there is a problem in that the size of the injection molding die increases when a plurality of pairs of resin sheets are arranged side by side in the die.

[0006] The present disclosure has been made in consideration of such circumstances, and provides a method for producing a plurality of resin sheet joined bodies by a single injection molding while suppressing an increase in the size of a mold. [Means for solving the problem]

[0007] A method for producing a resin sheet joined body according to one embodiment of the present disclosure includes: A step of stacking a pair of resin sheets and spacer plates alternately in a mold for injection molding; a step of injecting a resin between each pair of resin sheets in the mold and bonding each pair of resin sheets together with the injected resin to form a plurality of resin sheet bonded bodies; and separating the molded resin sheet assembly from the spacer plate.

[0008] In a method for producing a resin sheet joined body according to one aspect of the present disclosure, a pair of resin sheets and a spacer plate are alternately stacked and arranged in a mold for injection molding. Therefore, the size of the mold can be suppressed compared to a case where a plurality of pairs of resin sheets are arranged side by side in the horizontal direction. Then, resin is injected between each pair of resin sheets in the mold, and each pair of resin sheets is joined together by the injected resin to form a plurality of resin sheet joined bodies. Therefore, a plurality of resin sheet joined bodies can be produced by a single injection molding. That is, a plurality of resin sheet joined bodies can be produced by a single injection molding while suppressing an increase in the size of the mold.

[0009] The spacer plate may be made of metal. With this configuration, the spacer plate and the resin sheet joined body can be easily separated.

[0010] In the separation step, the spacer plates may be connected to each other by a connecting member. By pulling out all the spacer plates connected by the connecting members from the molded resin sheet assembly, the two can be easily separated from each other.

[0011] The connecting members may be bolts, and the spacer plates may be connected to each other by inserting the bolts into through holes provided in the respective spacer plates. This makes it possible to connect the spacer plates with each other using a simple structure.

[0012] The resin injected into the mold may be the same type of thermoplastic resin as the resin sheets, and the resin sheet joined body can be entirely made of the same type of resin. Effect of the Invention

[0013] According to the present disclosure, it is possible to produce a plurality of resin sheet joined bodies by a single injection molding while suppressing an increase in the size of a mold. [Brief description of the drawings]

[0014] [Figure 1] 3 is a flowchart showing a method for producing a resin sheet joined body according to the first embodiment. [Diagram 2] FIG. 2 is a schematic plan view illustrating a method for producing a resin sheet joined body according to the first embodiment. [Diagram 3] 1A to 1D are schematic cross-sectional views illustrating a method for producing a resin sheet joined body according to a first embodiment. [Figure 4] 1A to 1D are schematic cross-sectional views illustrating a method for producing a resin sheet joined body according to a first embodiment. [Diagram 5] 1A to 1D are schematic cross-sectional views illustrating a method for producing a resin sheet joined body according to a first embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, specific embodiments of the present disclosure will be described in detail with reference to the drawings. However, the present disclosure is not limited to the following embodiments. In addition, the following description and drawings are appropriately simplified for clarity of explanation.

[0016] (First embodiment) <Method for producing resin sheet joined body according to the first embodiment> First, a method for producing a resin sheet joined body according to a first embodiment will be described with reference to Figs. 1 to 5. Fig. 1 is a flow chart showing a method for producing a resin sheet joined body according to the first embodiment. Fig. 2 is a schematic plan view showing a method for producing a resin sheet joined body according to the first embodiment. Figs. 3 to 5 are schematic cross-sectional views showing a method for producing a resin sheet joined body according to the first embodiment. The resin sheet joined body produced is not limited in any way and is used, for example, for a heat-sealed portion of an exterior material of a laminate-type lithium ion battery.

[0017] Naturally, the right-handed XYZ Cartesian coordinate system shown in Fig. 1 and other drawings is for the convenience of explaining the positional relationship of the components. In Fig. 1 etc., the positive direction of the Z axis is vertically upward, and the XY plane is a horizontal plane, which is common to all drawings. 3 to 5 correspond to the cross-sectional view taken along line III-III in FIG. 2, and correspond to steps ST1 to ST3 shown in FIG. 1, respectively.

[0018] 1 to 3, a pair of resin sheets RS and a spacer plate SP are alternately stacked inside an injection molding die (lower die LD) (step ST1). Therefore, the die can be prevented from becoming large in size, compared to the case where multiple pairs of resin sheets RS are arranged side by side in the horizontal direction.

[0019] More specifically, a pair of resin sheets RS is first placed in a lower die LD, which is a metal mold for injection molding, and a spacer plate SP is placed thereon, as shown in the upper part of Fig. 3. Thereafter, the pair of resin sheets RS and the spacer plate SP are alternately stacked in the lower die LD, as shown in the lower part of Fig. 3.

[0020] 3, after the resin sheets RS and the spacer plates SP are stacked to a depth greater than that of the lower mold LD, the upper mold UD is pressed against the lower mold LD. As a result, the upper mold UD presses the multiple pairs of resin sheets RS and the multiple spacer plates SP stacked in the lower mold LD from above. That is, the multiple pairs of resin sheets RS and the multiple spacer plates SP are stacked without any gaps.

[0021] In the example shown in Fig. 3, four pairs of resin sheets RS and three spacer plates SP are stacked, but the number of stacked resin sheets RS and spacer plates SP is determined appropriately. As shown in the lower part of Fig. 3, by arranging the resin sheets RS at the lowest level that contacts the lower mold LD and at the lowest level that contacts the lower surface of the upper mold UD, the number of spacer plates SP used can be reduced.

[0022] In the illustrated example, the lower mold LD has a rectangular parallelepiped housing portion (i.e., a hollow portion) as shown in Fig. 2. A spacer plate SP having a rectangular shape in a plan view is housed in the housing portion of the lower mold LD. Here, the length of the spacer plate SP in the Y-axis direction is equal to the length of the housing portion of the lower mold LD in the Y-axis direction.

[0023] The spacer plate SP is made of, for example, metal, and is preferably made of the same metal material as the mold. By making the spacer plate SP out of metal, it is possible to easily separate the spacer plate SP from the resin sheet joined body 10, which will be described later. In addition, the spacer plate SP can be made thin, and a large number of resin sheet joined bodies 10 can be manufactured by one injection molding.

[0024] The thickness of the spacer plate SP is, for example, about 0.2 to 0.4 mm. The thinner the spacer plate SP is, the more resin sheet joined bodies 10 can be manufactured by one injection molding. On the other hand, if the spacer plate SP is too thin, there is a risk of deformation during injection molding. The resin sheet has a thickness of, for example, about 0.2 to 0.5 mm.

[0025] 2, through holes TH for connecting the spacer plates SP to each other are provided at the ends of the spacer plates SP on the negative side of the X-axis. As shown in FIG 2, the through holes TH are provided at positions that do not overlap with the resin sheets RS in a plan view. The through holes TH are not essential.

[0026] 2, a pair of resin sheets RS having a rectangular shape in plan view are accommodated in the accommodation portion of the lower mold LD, side by side in the X-axis direction at a predetermined interval. In other words, the pair of resin sheets RS are arranged opposite each other with a resin flow path interposed therebetween. Here, the length of the resin sheet RS in the Y-axis direction is also equal to the length of the accommodation portion of the lower mold LD in the Y-axis direction.

[0027] At least one of the two resin sheets RS may extend beyond the lower mold LD in the positive direction of the Y axis. Also, the resin sheet RS disposed on the X axis positive side may extend beyond the lower mold LD in the positive direction of the X axis.

[0028] Next, as shown in Fig. 1 and Fig. 4, a resin IR is injected between each pair of resin sheets RS inside the mold (lower mold LD and upper mold UD), and each pair of resin sheets RS is bonded together by the injected resin IR to form a plurality of resin sheet joined bodies 10 (step ST2). In this manner, a plurality of resin sheet joined bodies 10 can be manufactured by a single injection molding. In the example shown in Fig. 4, four resin sheet joined bodies 10 are manufactured. The upper part of FIG. 4 is the same as the lower part of FIG.

[0029] In detail, as shown in Fig. 2, in a plan view, the injected resin IR fills the gaps between each pair of resin sheets RS through a resin flow path provided in the lower mold LD. Also, as shown in the lower part of Fig. 4, in a cross-sectional view, the injected resin IR simultaneously fills the gaps between each pair of resin sheets RS sandwiched between the spacer plates SP. Therefore, even if the spacer plates SP are as thin as, for example, about 0.3 mm, deformation of the spacer plates SP can be suppressed.

[0030] The resin IR injected into the molds (lower mold LD and upper mold UD) is the same type of thermoplastic resin as the resin sheet RS, such as polyethylene, polypropylene, etc. With this configuration, the entire resin sheet joined body 10 can be made of the same type of resin. As shown in the lower part of FIG. 4, the injected resin IR fills only the gaps between each pair of resin sheets RS, and does not fill other spaces inside the molds (lower mold LD and upper mold UD).

[0031] 1 and 5, the molded resin sheet assembly 10 and the spacer plates SP are removed from the molds (lower mold LD and upper mold UD) and separated (step ST3). In detail, as shown in the upper side of Fig. 5, bolts BL, which are connecting members, are inserted into the through holes TH of the spacer plates SP to connect the spacer plates SP. Thereafter, all the spacer plates SP connected by the bolts BL are pulled out from the molded resin sheet assembly 10, whereby the two are separated.

[0032] Here, in the cross section shown in the lower part of Fig. 5, the multiple resin sheet assembled bodies 10 are spaced apart, but all of the resin sheet assembled bodies 10 are integrated together by excess resin filled in the resin flow paths (gates, etc.) shown in Fig. 2, for example. Therefore, all of the spacer plates SP and all of the resin sheet assembled bodies 10 connected by the bolts BL can be easily separated from each other. Thereafter, the excess resin is removed from all of the integrated resin sheet assembled bodies 10, thereby obtaining individual resin sheet assembled bodies 10.

[0033] In FIG. 5, nuts (not shown) may be screwed into the lower ends of the bolts BL, and all the spacer plates SP may be fastened and fixed by the bolts BL and the nuts. Also, a plurality of through holes TH may be provided in each spacer plate SP, and the spacer plates SP may be connected together by a plurality of bolts BL.

[0034] Furthermore, before injection molding, a plurality of spacer plates SP may be previously connected by bolts BL inside the mold (lower mold LD and upper mold UD). Furthermore, instead of using the through holes TH and bolts BL as the connecting members, connecting members that clamp the ends of a plurality of spacer plates SP from above and below may be used.

[0035] As described above, in the method for producing a resin sheet joined body according to the first embodiment, pairs of resin sheets RS and spacer plates SP are alternately stacked in a metal mold for injection molding (step ST1). Therefore, the size of the metal mold can be suppressed compared to the case where a plurality of pairs of resin sheets RS are arranged side by side in the horizontal direction.

[0036] Then, a resin IR is injected between each pair of resin sheets RS in the mold, and each pair of resin sheets RS is joined together by the injected resin IR to form a plurality of resin sheet joined bodies 10 (step ST2). Therefore, a plurality of resin sheet joined bodies can be manufactured by a single injection molding.

[0037] That is, the method for producing a resin sheet joined body according to the first embodiment makes it possible to produce a plurality of resin sheet joined bodies by one injection molding while suppressing an increase in the size of a mold.

[0038] The present disclosure is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the present disclosure. [Explanation of symbols]

[0039] 10 Resin sheet joint BL Bolt IR Resin LD lower mold RS Resin Sheet SP spacer plate TH through hole UD upper mold

Claims

1. A step of stacking a pair of resin sheets and spacer plates alternately in a mold for injection molding; a step of injecting a resin between each pair of resin sheets in the mold and bonding each pair of resin sheets together with the injected resin to form a plurality of resin sheet bonded bodies; and separating the molded resin sheet bonded body from the spacer plate. A method for producing a resin sheet joined body.

2. The spacer plate is made of metal. A method for producing the resin sheet joined body according to claim 1 .

3. In the separating step, Each of the spacer plates is connected by a connecting member. The method for producing the resin sheet joined body according to claim 1 or 2.

4. the connecting member is a bolt, The spacer plates are connected to each other by inserting the bolts into through holes provided in the spacer plates. The method for producing the resin sheet joined body according to claim 3 .

5. The resin injected into the mold is the same type of thermoplastic resin as the resin sheet. The method for producing the resin sheet joined body according to claim 1 or 2.

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