Continuous press forming apparatus, mold, and molded article

Abstract

To provide a press apparatus or the like that enables suppression of damage to a press-forming target sheet material at the time of press forming.SOLUTION: A continuous press forming apparatus comprises: a forming die 20 including an upper forming die having a first upper press surface including one of a concave shape and a convex shape entering the concave shape, and a lower forming die having a first lower press surface including the other of the concave shape and the convex shape; a transport device that transports a press-forming target sheet material; and a positioning die 30 including an upper positioning die having a second upper press surface corresponding to the first upper press surface, and a lower positioning die having a second lower press surface corresponding to the first lower press surface. The convex shape is a convex shape extending while spreading in a fan shape from an inner diameter side toward an outer diameter side, and the concave shape is a concave shape into which the convex shape enters.SELECTED DRAWING: Figure 20

Description

[Technical Field]

[0001] The present disclosure relates to a continuous press molding apparatus, a mold, and a molded product. [Background technology]

[0002] A press device is known that places a preheated sheet material to be press-molded (e.g., a thermoplastic resin sheet) between an upper mold having a press surface including a concave-convex shape and a lower mold having a press surface including a convex shape that fits into the concave shape and a concave shape that the convex shape fits into, and performs press molding in which the press surface of the upper mold and the press surface of the lower mold sandwich and pressurize the sheet material to be press-molded placed between them (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-156012 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in Patent Document 1, when an FRP sheet material (e.g., prepreg, laminate, stampable sheet) is used as the sheet material to be press-molded, the FRP sheet material reinforced with reinforcing fibers hardly stretches, so when the convex shapes on the press surface of the upper mold are pressed simultaneously into the concave shapes on the press surface of the lower mold (i.e., when the molds are closed), the FRP sheet material between the concave shapes on the press surface of the lower mold (between the convex shapes on the press surface of the upper mold) is pulled, posing a problem of concern that the FRP sheet material may be damaged.

[0005] Other objects and novel features will become apparent from the description of this specification and the accompanying drawings. [Means for solving the problem]

[0006] A continuous press-forming apparatus according to one embodiment comprises a shaping mold including an upper shaping mold having a first upper press surface including one of a concave shape and a convex shape that fits into the concave shape, and a lower shaping mold having a first lower press surface including the other of the concave shape and the convex shape; a positioning mold including an upper positioning mold having a second upper press surface corresponding to the first upper press surface, and a lower positioning mold having a second lower press surface corresponding to the first lower press surface; and a conveying device that conveys a sheet material to be press-formed, wherein clamping of the shaping mold is performed by the first upper press surface of the upper shaping mold and the first lower press surface of the lower shaping mold sandwiching and applying pressure to a preheated portion of the sheet material to be press-formed that is placed between them, and clamping of the positioning mold is performed by the second upper press surface of the upper positioning mold and the second lower press surface of the lower positioning mold sandwiching a shaped portion of the sheet material to be press-formed that is placed between them, which has been shaped by the shaping mold. The pressing is carried out by pressing and pressurizing the sheet material to be press-molded, and the conveying device conveys the sheet material to be press-molded so that, each time the shaping die and the positioning die are opened, a preheated portion of the sheet material to be press-molded is positioned between the first upper press surface of the upper shaping die and the first lower press surface of the lower shaping die, and the shaped portion of the sheet material to be press-molded is positioned between the second upper press surface of the upper positioning die and the second lower press surface of the lower positioning die, the convex shape is a convex shape that extends while spreading out in a fan shape from the inner diameter side to the outer diameter side, and the concave shape is a concave shape that extends while spreading out in a fan shape from the inner diameter side to the outer diameter side, into which the convex shape fits, the shaping die and the positioning die are arranged in an arc shape in this order along the conveying direction of the sheet material to be press-molded, and clamping of the positioning die, clamping of the shaping die, and opening of the shaping die and the positioning die are carried out repeatedly and continuously in this order. [Effects of the Invention]

[0007] According to the embodiment, it is possible to provide a continuous press-forming apparatus, a mold, and a molded product that can suppress damage to a sheet material to be press-formed during press-forming. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a diagram showing the overall configuration of a continuous press-forming apparatus 1 according to a first embodiment. [Figure 2] 1 is a perspective view of a molded product molded (manufactured) by the continuous press molding device 1. FIG. [Figure 3] 2 is a cross-sectional view taken along the line AA in FIG. 1. [Figure 4] 2 is a cross-sectional view of FIG. 1 taken along line B-B. [Figure 5] 1 shows an example of the configuration of a mold clamping mechanism 100. [Figure 6] FIG. 2 is a top view of the transport device 50. [Figure 7] FIG. 2 is a system configuration diagram of a control device 60. [Figure 8] 4 is a flowchart of an example of the operation of the continuous press-forming device 1. [Figure 9] This figure shows how a molded product (see Figure 2) with a continuous alternating pattern of concave and convex shapes is produced by press-molding the sheet material M to be press-molded using each of the molds 10, 20, 30, and 40 each time the sheet material M to be press-molded is transported a predetermined distance (for example, one pitch). [Figure 10] These are modified examples of the convex shapes of the upper shaping mold, upper positioning mold, and upper cooling mold, and the concave shapes of the lower shaping mold, lower positioning mold, and lower cooling mold. [Figure 11] FIG. 10 is a diagram showing the overall configuration of a continuous press-forming apparatus 1A according to a second embodiment. [Figure 12] FIG. 10 is a system configuration diagram of a control device 60 according to a second embodiment. [Figure 13] 10 is a flowchart of an example of mold clamping processing. [Figure 14]This figure shows how a molded product (see Figure 2) with a continuous alternating pattern of concave and convex shapes is produced by press-molding the sheet material M to be press-molded using each mold 10, 20A, 30 each time the sheet material M to be press-molded is transported a predetermined distance (e.g., one pitch). [Figure 15] 4 is a flowchart of an example of the operation of the continuous press-forming apparatus 1A. [Figure 16] (a) An example of the upper surface (flat surface) of the movable gripping portion 51b provided on the downstream side where the sheet material M to be press-molded (a molded product having a series of alternating concave and convex shapes) is placed, and (b) another example (variant) of the upper surface of the movable gripping portion 51b provided on the downstream side where the sheet material M to be press-molded (a molded product having a series of alternating concave and convex shapes) is placed. [Figure 17] 10 is a modified example of the sheet material M to be press-molded. [Figure 18] FIG. 1 is a perspective view of a molded product having an arc shape (fan shape) on which alternately continuous concave and convex shapes are molded. [Figure 19] 1 is a top view (schematic diagram) of a continuous press-molding apparatus 1A. [Figure 20] FIG. 2 is a perspective view of each mold (shaping mold 20, positioning mold 30, cooling mold 40) of the continuous press molding apparatus 1A. [Figure 21] FIG. 2 is a top view (schematic view) of a continuous press-molding apparatus 1B. [Figure 22] FIG. 1 is a perspective view of a molded product having an arc shape (fan shape) on which alternately continuous concave and convex shapes are molded. [Figure 23] FIG. 2 is a top view (schematic diagram) of a continuous press-forming apparatus 1C. [Figure 24] FIG. 2 is a perspective view of each mold (shaping mold 20, positioning mold 30, cooling mold 40) of the continuous press-molding apparatus 1C. [Figure 25] FIG. 1 is a top view (schematic diagram) of a continuous press-forming apparatus 1D. DETAILED DESCRIPTION OF THE INVENTION

[0009] <First Embodiment> Hereinafter, the first embodiment will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiment. In addition, the following description and drawings have been simplified as appropriate for clarity of explanation.

[0010] <Overall configuration of the press device> First, the overall configuration of a press apparatus according to embodiment 1 will be described with reference to Fig. 1. Fig. 1 is a diagram showing the overall configuration of a continuous press-molding apparatus 1 according to embodiment 1. Fig. 2 is a perspective view of a molded product molded (manufactured) by the continuous press-molding apparatus 1.

[0011] The continuous press-molding apparatus 1 is an apparatus for producing a molded product (see FIG. 2) having a series of alternating concave and convex shapes by press-molding the sheet material M to be press-molded using each of the molds 10, 20, 30, and 40 each time the sheet material M to be press-molded is transferred (transported) a predetermined distance (e.g., one pitch). The distance P1 (see FIG. 2) between the concave shapes of the molded product corresponds to the distance P2 (see FIG. 1) in the X-axis direction between the convex shapes of each mold. Hereinafter, these distances P1 and P2 will be referred to as one pitch. One pitch is, for example, 50 mm.

[0012] The press-molding target sheet material M is, for example, an FRP sheet material. FPR stands for fiber-reinforced plastics. This plastic may be a thermoplastic resin or a thermosetting resin. That is, the press-molding target sheet material M may be an FRP sheet material made of a thermoplastic resin or an FRP sheet material made of a thermosetting resin. Examples of FRP sheet materials include prepregs, laminated plates, and stampable sheets. The press-molding target sheet material M may be cut to a predetermined length, or may be unwound from a roll of the press-molding target sheet material M. Furthermore, the press-molding target sheet material M may be a single sheet, or multiple sheets may be stacked together.

[0013] As shown in Figure 1, the continuous press molding device 1 includes a preheating mold 10, a shaping mold 20, a positioning mold 30, a cooling mold 40, a conveying device 50, a control device 60 (omitted in Figure 1), and a mold clamping mechanism 100 (omitted in Figure 1).

[0014] For ease of explanation, the X, Y, and Z axes are defined below as shown in Fig. 1 etc. The X axis extends in the conveying direction (horizontal direction) of the sheet material M to be press-formed. The Y axis extends in a direction (horizontal direction) perpendicular to the X axis. The Z axis extends in a direction (vertical direction) perpendicular to the XY plane.

[0015] The preheating mold 10 includes an upper preheating mold 11 and a lower preheating mold 12. Similarly, the shaping mold 20 includes an upper shaping mold 21 and a lower shaping mold 22. Similarly, the positioning mold 30 includes an upper positioning mold 31 and a lower positioning mold 32. Similarly, the cooling mold 40 includes an upper cooling mold 41 and a lower cooling mold 42.

[0016] The upper molds (upper shaping mold 21, upper positioning mold 31, upper cooling mold 41) are attached to the underside of the upper mold platen 70A (movable platen). Similarly, the lower molds (lower shaping mold 22, lower positioning mold 32, lower cooling mold 42) are attached to the upper side of the lower mold platen 70B (fixed platen). Specific examples of the attachment structure of the upper and lower molds will be described later.

[0017] A gap (clearance) G1 (see FIG. 1) exists between the shaping mold 20 (upper shaping mold 21 and lower shaping mold 22) and the positioning mold 30 (upper positioning mold 31 and lower positioning mold 32). Similarly, a gap (clearance) G2 (see FIG. 1) exists between the positioning mold 30 (upper positioning mold 31 and lower positioning mold 32) and the cooling mold 40 (upper cooling mold 41 and lower cooling mold 42). It is preferable that the gaps G1 and G2 are as short as possible, for example, 1 mm.

[0018] Length L of the positioning die 30 in the X-axis direction 30_X is the length L of the shaping mold 20 in the X-axis direction 20_X The length L of the cooling mold 40 in the X-axis direction is shorter than40_X is the length L of the shaping mold 20 in the X-axis direction 20_X is the same as

[0019] In this way, by making the lengths of the dies 20, 30, 40 in the X-axis direction different, it becomes possible to pressurize the portions of the sheet material M to be press-molded that correspond to the gaps G1, G2 in one of the steps (see Figures 9(a) to 9(d)). The lengths of the dies 10, 20, 30, 40 in the Y-axis direction correspond to the width of the sheet material M to be press-molded.

[0020] Length L of the preheating mold 10 in the X-axis direction 10_X is the length L of the shaping mold 20 in the X-axis direction 20_X Therefore, as will be described later, when the press-molding target sheet material M is transferred (transported) at one pitch at a time (see FIGS. 9(a) to 9(d)), the preheating mold 10 heats and presses a portion (the same portion) of the press-molding target sheet material M multiple times, allowing for a longer heating time for the press-molding target sheet material M. Furthermore, because the portion of the press-molding target sheet material M is heated during preheating without dropping below the intended molding temperature, molding defects such as wrinkles and voids that tend to occur due to insufficient molding temperature can be suppressed. As a result, the internal quality of the press-molding target sheet material M is improved. For example, defects such as voids inside the press-molding target sheet material M can be eliminated or reduced.

[0021] <Configuration of preheating mold 10> As shown in FIG. 1, the preheating mold 10 includes an upper preheating mold 11 and a lower preheating mold 12. The preheating mold 10 is placed on a lower mold platen 70B (fixed platen). The upper press surface 11a of the upper preheating mold 11 is a plane parallel to the XY plane. Similarly, the lower press surface 11b of the lower preheating mold 12 is a plane parallel to the XY plane. At least one of the upper preheating mold 11 and the lower preheating mold 12 is heated to a predetermined temperature by a heating device (e.g., an electric heater 13; see FIG. 7). The heating device may be built into the preheating mold 10 or may be provided external to the preheating mold 10.

[0022] <Example of clamping operation of preheating mold 10> The preheating mold 10 is clamped by the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12, which sandwich and press the portion of the sheet material M to be press-molded located therebetween. This is achieved by the control device 60 controlling the air cylinder 14 (a solenoid valve for adjusting the air supply amount provided midway through the air supply line connected to the air cylinder; see FIG. 7 ) connected to the upper preheating mold 11 to lower the upper preheating mold 11. At this time, since the preheating mold 10 is heated to a predetermined temperature by the heating device, the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwich and heat and press the portion of the sheet material M to be press-molded located therebetween at a predetermined pressure. Hereinafter, the portion of the sheet material M to be press-molded that has been preheated in this manner will be referred to as the preheated portion of the sheet material M to be press-molded.

[0023] On the other hand, the preheating mold 10 is opened by the control device 60 controlling the air cylinder 14 (an electromagnetic valve for adjusting the amount of air supply provided midway in the air supply path connected to the air cylinder; see FIG. 7) connected to the upper preheating mold 11, thereby lifting the upper preheating mold 11.

[0024] <Configuration of the shaping mold 20> As shown in FIG. 1, the shaping mold 20 includes an upper shaping mold 21 having an upper press surface (an example of a first upper press surface of the present disclosure) including a convex shape 21c that is convex in the -Z direction, and a lower shaping mold 22 having a lower press surface (an example of a first lower press surface of the present disclosure) including a concave shape 22c into which the convex shape 21c fits. The upper press surface of the upper shaping mold 21 includes planes 21a and 21b parallel to the XY plane and the convex shape 21c that is convex in the -Z direction. The convex shape 21c has, for example, a convex shape whose cross-sectional shape (cross-sectional shape taken along a plane parallel to the XZ plane) is an inverted trapezoid (see FIG. 1). The planes 21a and 21b and the convex shape 21c extend in the Y-axis direction. On the other hand, the press surface of the lower shaping mold 22 includes planes 22a and 22b parallel to the XY plane and the concave shape 22c into which the convex shape 21c fits. The flat surfaces 22a, 22b and the recessed shape 22c extend in the Y-axis direction. At least one of the upper shaping mold 21 and the lower shaping mold 22 is heated to a predetermined temperature by a heating device (e.g., an electric heater 23; see FIG. 7). The predetermined temperature is lower than that of the upper pre-heating mold 11. The heating device may be built into the shaping mold 20 or may be provided outside the shaping mold 20.

[0025] <Mounting structure of the shaping mold 20> The upper shaping die 21 is attached in a fixed state to the lower surface side of the upper die platen 70A. Specifically, it is attached as follows.

[0026] FIG. 3 is a cross-sectional view taken along the line AA in FIG.

[0027] As shown in FIG. 3, a mounting plate 82A and a heat insulating plate 83A are arranged in this order from top to bottom between the upper shaping mold 21 and the upper mold platen 70A.

[0028] As will be described later, the upper platen 70A is raised and lowered in the vertical direction (Z-axis direction) by a clamping mechanism 100. The mounting plate 82A is fixed to the upper platen 70A with its upper surface in surface contact with the lower surface of the upper platen 70A. The two are fixed together by, for example, bolts (not shown).

[0029] On the other hand, the upper shaping mold 21 is fixed to the mounting plate 82A with a heat insulating plate 83A sandwiched between its upper surface and the lower surface of the mounting plate 82A. The two are fixed by, for example, bolts B2. Reference numeral 84 denotes a knock pin for accurately fixing the upper shaping mold 21 to the mounting plate 82A.

[0030] As described above, the upper shaping mold 21 is attached in a fixed state to the upper mold platen 70A side.

[0031] On the other hand, the lower shaping mold 22 is attached in a fixed state to the upper surface side of the lower mold platen 70B. Specifically, it is attached as follows.

[0032] As shown in FIG. 3, a mounting plate 82B and a heat insulating plate 83B are arranged in this order from bottom to top between the lower shaping mold 22 and the lower mold platen 70B.

[0033] The mounting plate 82B is fixed to the lower platen 70B with its lower surface in surface contact with the upper surface of the lower platen 70B, and the two are fixed together by, for example, bolts (not shown).

[0034] On the other hand, the lower shaping mold 22 is fixed to the mounting plate 82B with a heat insulating plate 83B sandwiched between its lower surface and the upper surface of the mounting plate 82B. Both are fixed by, for example, bolts B4. Reference numeral 85 denotes a knock pin for accurately fixing the lower shaping mold 22 to the mounting plate 82B.

[0035] <Example of clamping operation of the shaping mold 20> The shaping mold 20 is clamped by the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22 clamping and applying pressure to the preheated portion (portion preheated by the preheating mold 10) of the sheet material M to be press-molded, which is placed between them. As will be described later, this is realized by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lowering the upper platen 70A on which the upper shaping mold 21 is attached.

[0036] At this time, since the shaping mold 20 is heated to a predetermined temperature by a heating device, the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22 sandwich the preheated portion of the sheet material M to be press-molded, which is placed between them, and heat and press it with a predetermined pressure. The predetermined pressure is higher than that of the preheating mold 10.

[0037] At this time, the preheated portion of the press-molded sheet material M is pressed into the concave shape 22c of the lower press surface of the lower shaping die 22 by the convex shape 21c of the upper press surface of the upper shaping die 21. As a result, a shape (concave shape) corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22 is formed in the preheated portion of the press-molded sheet material M. Hereinafter, the portion of the press-molded sheet material M that has been shaped in this way will be referred to as the shaped portion of the press-molded sheet material M.

[0038] On the other hand, the opening of the shaping mold 20 is realized by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and raise the upper platen 70A on which the upper shaping mold 21 is attached.

[0039] <Configuration of positioning mold 30> As shown in FIG. 1, the positioning die 30 includes an upper positioning die 31 having an upper press surface (an example of the second upper press surface of the present disclosure) corresponding to the upper press surface of the upper shaping die 21, and a lower positioning die 32 having a lower press surface (an example of the second lower press surface of the present disclosure) corresponding to the lower press surface of the lower shaping die 22. The upper press surface of the upper positioning die 31 has the same shape as the upper press surface of the upper shaping die 21, and includes planes 31a and 31b parallel to the XY plane and a convex shape 31c convex in the -Z direction. The convex shape 31c has the same shape as the convex shape 21c, and is, for example, a convex shape whose cross-sectional shape (cross-sectional shape taken along a plane parallel to the XZ plane) is an inverted trapezoid (see FIG. 1). The planes 31a and 31b and the convex shape 31c extend in the Y-axis direction. On the other hand, the lower press surface of the lower positioning die 32 has the same shape as the lower press surface of the lower shaping die 22, and includes flat surfaces 32a and 32b parallel to the XY plane and a concave shape 32c into which the convex shape 31c fits. The flat surfaces 32a and 32b and the concave shape 32c extend in the Y-axis direction. The positioning die 30 has a lower temperature than the shaping die 20. <Mounting structure of the positioning mold 30> The upper positioning die 31 is attached to the lower surface side of the upper die platen 70A so as to be movable in a direction (Z-axis direction) in which it approaches and moves away from the upper die platen 70A. Specifically, it is attached as follows.

[0040] Fig. 4 is a cross-sectional view taken along line BB in Fig. 1. The cross-sectional view taken along line CC in Fig. 1 is the same as Fig. 4.

[0041] As shown in FIG. 4, a mounting plate 82A and a heat insulating plate 83A are arranged in this order from top to bottom between the upper positioning die 31 and the upper die platen 70A.

[0042] As will be described later, the upper platen 70A is raised and lowered in the vertical direction (Z-axis direction) by a clamping mechanism 100. The mounting plate 82A is fixed to the upper platen 70A with its upper surface in surface contact with the lower surface of the upper platen 70A. The two are fixed together by, for example, bolts (not shown).

[0043] The upper positioning mold 31 is attached to the underside of the upper mold plate 70A so as to be movable in the direction of approaching and moving away from the upper mold plate 70A (Z-axis direction) by screwing a bolt 94 inserted into a through hole H1 formed in the mounting plate 82A and a through hole H2 formed in the insulating plate 83A at its top (see the enlarged view within the rectangle C1 in Figure 4).

[0044] The through-hole H1 formed in the mounting plate 82A includes a large-diameter hole H1a formed in the upper part in the thickness direction of the mounting plate 82A and a small-diameter hole H1b formed in the lower part in the thickness direction of the mounting plate 82A. A step portion 95 is formed between the large-diameter hole H1a and the small-diameter hole H1b.

[0045] A head portion 94a of the bolt 94 is inserted into the large diameter hole H1a, while a shaft portion 94b of the bolt 94 is inserted into the small diameter hole H1b and the through hole H2.

[0046] The diameter of the large diameter hole H1a is slightly larger than the diameter of the head 94a of the bolt 94. Similarly, the diameters of the small diameter hole H1b and the through hole H2 are slightly larger than the diameter of the shaft 94b of the bolt 94. Therefore, the upper positioning die 31 is movable in the direction (Z-axis direction) toward and away from the upper die platen 70A.

[0047] The upper positioning die 31 moves downward (in the -Z direction) relative to the upper platen 70A due to its own weight, etc., but further downward movement is restricted when the heads 94a of the bolts 94 engage with the stepped portions 95. In this state, a gap G3 (see FIG. 4) is formed between the heat insulating plate 83A and the upper positioning die 31. The upper positioning die 31 can move in the direction toward and away from the upper platen 70A (in the Z-axis direction) within the range of this gap G3.

[0048] As described above, the upper positioning die 31 is attached to the lower surface side of the upper die platen 70A so as to be movable in the direction (Z-axis direction) in which it approaches and moves away from the upper die platen 70A.

[0049] An elastic body 96 is provided between the upper positioning die 31 and the upper platen 70A (see FIGS. 1 and 4). The elastic body 96 is elastically deformed when the upper positioning die 31 moves in a direction (+Z direction) approaching the upper platen 70A, and biases the upper positioning die 31 toward the lower positioning die 32. The elastic body 96 is, for example, a coil spring.

[0050] On the other hand, the lower positioning die 32 is attached in a fixed state to the upper surface side of the lower die platen 70B. Specifically, it is attached as follows.

[0051] As shown in FIG. 4, a mounting plate 82B and a heat insulating plate 83B are arranged in this order from bottom to top between the lower positioning die 32 and the lower die platen 70B.

[0052] The mounting plate 82B is fixed to the lower platen 70B with its lower surface in surface contact with the upper surface of the lower platen 70B, and the two are fixed together by, for example, bolts (not shown).

[0053] On the other hand, the lower positioning mold 32 is fixed to the mounting plate 82B with a heat insulating plate 83B sandwiched between the lower surface of the lower positioning mold 32 and the upper surface of the mounting plate 82B. Both are fixed together by, for example, bolts (not shown).

[0054] <Example of clamping operation of positioning mold 30> The clamping of the positioning die 30 is performed by the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31 and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning die 32 clamping and applying pressure to the shaped portion of the sheet material M to be press-molded (the portion shaped by the shaping die 20) placed between them. As will be described later, this is achieved by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lowering the upper platen 70A on which the upper positioning die 31 is attached.

[0055] At this time, the lower positioning die 32 pushes up the upper positioning die 31 in the +Z direction. This causes the upper positioning die 31 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96 (elastic body 96 (see FIG. 1) arranged between the upper positioning die 31 and the upper platen 70A; hereinafter also referred to as elastic body 96A) to elastically deform, and the upper positioning die 31 is urged toward the lower positioning die 32 by this elastically deformed elastic body 96A. The elastic body 96A is an example of a first elastic body of the present disclosure.

[0056] Therefore, clamping of the positioning mold 30 is carried out between the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31, which is urged toward the lower positioning mold 32 by the elastic body 96A, and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32.

[0057] At this time, since the positioning die 30 is at a lower temperature than the shaping die 20, the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31 and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning die 32, which are urged toward the lower positioning die 32 by the elastic body 96A, sandwich the shaping portion of the sheet material M to be press-molded that is placed between them, and cool and pressurize them at a predetermined pressure. Note that this predetermined pressure can be changed to any pressure by using an elastic body with a different spring constant as the elastic body 96A.

[0058] At this time, the shaped portion (concave shape) of the press-molded sheet material M is pressed into the concave shape 32c on the lower press surface of the lower positioning die 32, and the convex shape 31c on the upper press surface of the upper positioning die 31 is pressed into the shaped portion (concave shape) of the press-molded sheet material M. This positions the press-molded sheet material M. This positioning allows concave shapes to be accurately formed in the press-molded sheet material M at one pitch at a time. In addition, the shaped portion of the press-molded sheet material M is cooled and pressurized. Then, by lowering the shaped portion of the press-molded sheet material M to below the resin solidification temperature while pressurizing it, molding defects such as wrinkles and voids that tend to occur due to insufficient pressure can be suppressed. This prevents a decrease in the quality of the molded product.

[0059] On the other hand, the positioning die 30 is opened by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and raise the upper die platen 70A to which the upper positioning die 31 is attached.

[0060] <Configuration of cooling mold 40> As shown in FIG. 1, the cooling mold 40 includes an upper cooling mold 41 having an upper press surface (an example of the third upper press surface of the present disclosure) corresponding to the upper press surface of the upper shaping mold 21, and a lower cooling mold 42 having a lower press surface (an example of the third lower press surface of the present disclosure) corresponding to the lower press surface of the lower shaping mold 22. The upper press surface of the upper cooling mold 41 has the same shape as the upper press surface of the upper shaping mold 21, and includes planes 41a and 41b parallel to the XY plane and a convex shape 41c convex in the -Z direction. The convex shape 41c has the same shape as the convex shape 21c, and is, for example, a convex shape having an inverted trapezoidal cross section (cross section taken along a plane parallel to the XZ plane) (see FIG. 1). The planes 41a and 41b and the convex shape 41c extend in the Y-axis direction. On the other hand, the press surface of the lower cooling mold 42 has the same shape as the press surface of the lower shaping mold 22, and includes flat surfaces 42a and 42b parallel to the XY plane and a concave shape 42c into which the convex shape 41c fits. The flat surfaces 42a and 42b and the concave shape 42c extend in the Y-axis direction. Unlike the shaping mold 20, the cooling mold 40 is not heated by a heating device and is at room temperature.

[0061] <Mounting structure of cooling mold 40> The upper cooling mold 41, like the upper positioning mold 31, is attached to the underside of the upper mold platen 70A so as to be movable in a direction (Z-axis direction) toward and away from the upper mold platen 70A. This attachment structure is similar to that of the upper positioning mold 31, and therefore its description will be omitted. On the other hand, the lower cooling mold 42, like the lower positioning mold 32, is attached in a fixed state to the upper surface of the lower mold platen 70B. This attachment structure is similar to that of the lower positioning mold 32, and therefore its description will be omitted.

[0062] <Example of clamping operation of cooling mold 40> The cooling mold 40 is clamped by the upper press surface of the upper cooling mold 41 and the lower press surface of the lower cooling mold 42 sandwiching and applying pressure to the shaped portion of the sheet material M to be press-molded (the shaped portion pressurized by the positioning mold 30) that is placed between them. As will be described later, this is achieved by the control device 60 controlling the electric motor 102 to rotate the ball screw 101, and lowering the upper mold platen 70A on which the upper cooling mold 41 is attached.

[0063] At that time, the lower cooling mold 42 pushes up the upper cooling mold 41 in the +Z direction. This causes the upper cooling mold 41 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96 (elastic body 96 (see FIG. 1) arranged between the upper cooling mold 41 and the upper platen 70A; hereinafter, also referred to as elastic body 96B) to elastically deform, and the upper cooling mold 41 is urged toward the lower cooling mold 42 by this elastically deformed elastic body 96B. The elastic body 96B is elastically deformed by the movement of the upper cooling mold 41 in a direction (+Z direction) approaching the upper platen 70A, and urges the upper cooling mold 41 toward the lower cooling mold 42.

[0064] Therefore, the clamping of the cooling mold 40 is carried out between the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41, which is biased toward the lower cooling mold 42 by the elastic body 96B, and the lower press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling mold 42.

[0065] At this time, because the cooling die 40 is at room temperature, the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling die 41 and the lower press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling die 42, which are urged toward the lower cooling die 42 by the elastic body 96B, sandwich the shaped portion of the sheet material M to be press-molded (the shaped portion pressurized by the positioning die 30) placed between them, and cool and pressurize it at a predetermined pressure. Note that this predetermined pressure can be changed to any pressure by using an elastic body with a different spring constant as the elastic body 96B.

[0066] At this time, the shaped portion of the press-molding target sheet material M (the shaped portion pressed by the positioning die 30) (concave shape) is pressed into the concave shape 42c on the lower press surface of the lower cooling die 42, and the convex shape 41c on the upper press surface of the upper cooling die 41 is pressed into the shaped portion of the press-molding target sheet material M (the shaped portion pressed by the positioning die 30) (concave shape). As a result, the shaped portion of the press-molding target sheet material M (the shaped portion pressed by the positioning die 30) is cooled and pressurized. As a result, it is further cooled and pressurized compared to immediately after being pressed by the positioning die 30. Therefore, by reliably pressing the shaped portion of the press-molding target sheet material M down to below the solidification temperature of the resin, molding defects such as wrinkles and voids that tend to occur due to insufficient pressurization can be suppressed, and a decrease in the quality of the molded product can be suppressed.

[0067] On the other hand, the cooling mold 40 is opened by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and raise the upper mold platen 70A on which the upper cooling mold 41 is attached.

[0068] <Configuration of mold clamping mechanism> The mold clamping mechanism 100 is a mechanism that moves the upper platen 70A, to which the upper dies (upper shaping die 21, upper positioning die 31, upper cooling die 41) are attached, in a direction (Z-axis direction) toward and away from the lower platen 70B, i.e., a mechanism that raises and lowers the upper platen 70A in the vertical direction (Z-axis direction). The mold clamping mechanism 100 may have any configuration as long as it is a mechanism that raises and lowers the upper platen 70A in the vertical direction (Z-axis direction). For example, the mold clamping mechanism 100 may be a mechanism that uses an electric motor as a drive source, a mechanism that uses a hydraulic cylinder as a drive source, or some other mechanism.

[0069] Hereinafter, as an example, a mold clamping mechanism 100 using an electric motor as a drive source will be described. Fig. 5 shows an example of the configuration of the mold clamping mechanism 100. Note that the transport device 50 is omitted from Fig. 5.

[0070] 5, the mold clamping mechanism 100 includes a ball screw 101 connected to the upper platen 70A, and an electric motor 102 connected to the ball screw 101. The electric motor 102 is attached to an upper fixed platen 104, which is fixed to the tip end of support columns 103, the base ends of which are fixed to the four corners of the lower platen 70B and extend in the +Z direction.

[0071] <Example of mold clamping mechanism operation> The upper platen 70A moves up and down (in the Z-axis direction) by the control device 60 controlling the electric motor 102 to rotate (forward and reverse) the ball screw 101. At this time, the upper platen 70A moves up and down while remaining parallel to the lower platen 70B. For example, the control device 60 controls the electric motor 102 to rotate the ball screw 101 forward, thereby lowering the upper platen 70A. As a result, the upper dies (upper shaping die 21, upper positioning die 31, upper cooling die 41) attached to the upper platen 70A also move down, and clamping is performed between the upper dies and the lower dies (lower shaping die 22, lower positioning die 32, lower cooling die 42).

[0072] 1, the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31 is located below the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21 before the clamping of each die (clamping of the shaping die 20, clamping of the positioning die 30 and clamping of the cooling die 40) is performed. This is realized, for example, by adjusting the gap G3 (see FIG. 4) of the upper positioning die 31 so that the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31 is located below the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21. Furthermore, before the clamping of each mold (clamping of the shaping mold 20, clamping of the positioning mold 30, and clamping of the cooling mold 40) is performed, the upper press surface (flat surfaces 41a, 41b and convex shape 31c) of the upper cooling mold 41 is located below the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper shaping mold 21. This is achieved, for example, by adjusting the gap G3 (see FIG. 4) of the upper cooling mold 41 so that the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41 is located below the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper shaping mold 21.

[0073] Therefore, by lowering the upper mold platen 70A as described above, the clamping of the positioning mold 30, the clamping of the cooling mold 40, and the clamping of the shaping mold 20 are carried out in this order. In other words, the clamping of the positioning mold 30, the clamping of the cooling mold 40, and the clamping of the shaping mold 20 are not carried out simultaneously, but at different times.

[0074] By clamping the positioning mold 30, the cooling mold 40, and the shaping mold 20 at different times in this manner, the following advantages are obtained.

[0075] That is, when the positioning die 30, the cooling die 40, and the shaping die 20 are clamped simultaneously, the sheet material M to be press-molded (for example, an FRP sheet material reinforced with reinforcing fibers) hardly stretches, and therefore, as in the above-mentioned prior art document, the convex shapes (plural) on the press surfaces of the upper dies (upper shaping die 21, upper positioning die 31, upper cooling die 41) "simultaneously" press the sheet material M to be press-molded into the concave shapes (plural) on the press surfaces of the lower dies (lower shaping die 22, lower positioning die 32, lower cooling die 42). As a result, the sheet material M to be press-molded that is present between the concave shapes on the press surface of the lower die (between the convex shapes on the press surface of the upper die) is pulled, which poses a problem of concern that the sheet material M to be press-molded (molded product) may be damaged.

[0076] In contrast, by clamping the positioning die 30, the cooling die 40, and the shaping die 20 in this order, that is, by clamping them at different times, the convex shapes (plural) on the press surfaces of the upper dies (upper shaping die 21, upper positioning die 31, upper cooling die 41) will press the press-molded sheet material M into the concave shapes (plural) on the press surfaces of the lower dies (lower shaping die 22, lower positioning die 32, lower cooling die 42) at "different times." This prevents the press-molded sheet material M present between the concave shapes on the press surface of the lower die (between the convex shapes on the press surface of the upper die) from being pulled, which has the advantage of preventing damage to the press-molded sheet material M (molded product).

[0077] Conversely, the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper shaping mold 21 may be located below the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41 before the mold clamping of each mold (clamping of the shaping mold 20, clamping of the positioning mold 30 and clamping of the cooling mold 40) is performed. This also has the advantage of preventing damage to the sheet material M (molded product) to be press-molded, as described above.

[0078] Furthermore, the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41 may be located at the same height as the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper shaping mold 21 before the mold clamping of each mold (clamping of the shaping mold 20, clamping of the positioning mold 30 and clamping of the cooling mold 40) is performed. This also has the advantage of preventing damage to the sheet material M (molded product) to be press-molded, as described above.

[0079] Meanwhile, the upper platen 70A rises as a result of the control device 60 controlling the electric motor 102 to reversely rotate the ball screw 101. This also causes the upper dies (upper shaping die 21, upper positioning die 31, upper cooling die 41) attached to the upper platen 70A to rise, thereby clamping the positioning die 30, clamping the cooling die 40, and opening the shaping die 20.

[0080] <Conveyor device configuration> As shown in FIG. 1, the conveying device (transfer mechanism) 50 is a device that conveys (transfers) the press-molded sheet material M. The conveying device 50 is installed on a lower mold platen 70B (fixed platen). The conveying devices 50 are provided at two locations, one upstream (upstream in the conveying direction of the press-molded sheet material M) and one downstream (downstream in the conveying direction of the press-molded sheet material M) with respect to the mold group (preheating mold 10, shaping mold 20, positioning mold 30, cooling mold 40). Hereinafter, the conveying device 50 provided on the upstream side will be referred to as conveying device 50A, and the conveying device 50 provided on the downstream side will be referred to as conveying device 50B.

[0081] The conveying device 50 (50A, 50B) includes a gripping mechanism 51 that grips and releases the sheet material M to be press-molded, and a moving mechanism 52 that moves the gripping mechanism 51 in the X direction.

[0082] FIG. 6 is a top view of the transport device 50. As shown in FIG.

[0083] As shown in Fig. 6, the gripping mechanisms 51 are provided on both sides in the width direction of the sheet material M to be press-molded. As shown in Fig. 1, the gripping mechanism 51 includes a pair of upper and lower fixed grippers 51a and movable grippers 51b, and an air cylinder 51c (an example of a movable gripper drive mechanism of the present disclosure) connected to the movable gripper 51b. An air supply path (not shown) that supplies air to the air cylinder 51c is connected to the air cylinder 51c, and an electromagnetic valve for adjusting the amount of air supplied is provided midway along the air supply path.

[0084] The moving mechanism 52 includes a slider 52a on which the gripping mechanism 51 is placed. The slider 52a is slidably attached to a guide rail (not shown) extending in the X-axis direction. The moving mechanism 52 also includes a ball screw (not shown) extending in the X-axis direction and connected to the slider 52a, and an electric motor 53 (e.g., a servo motor; see FIG. 7) connected to the ball screw. The ball screw and the electric motor 53 are an example of a slider drive mechanism of the present disclosure.

[0085] <Operation example of the transport device 50> The following mainly describes an example of the operation of the transport device 50A provided on the upstream side.

[0086] First, the gripping mechanism 51 grips the press-molding target sheet material M. Specifically, the movable gripping portion 51b rises, and the movable gripping portion 51b lifts both widthwise ends of the press-molding target sheet material M in the +Z direction and presses both widthwise ends of the lifted press-molding target sheet material M against the upper fixed gripping portion 51a. In this way, the gripping mechanism 51 grips both widthwise ends of the press-molding target sheet material M by sandwiching them from above and below. This is achieved by the control device 60 controlling the air cylinder 51c connected to the movable gripping portion 51b (an electromagnetic valve for adjusting the air supply amount provided midway in an air supply path connected to the air cylinder 51c).

[0087] Next, the movement mechanism 52 slides the slider 52a, on which the gripping mechanism 51 gripping the press-molded sheet material M as described above, a predetermined distance in the +X direction. This is achieved by the control device 60 controlling an electric motor (e.g., a servo motor) connected to a ball screw connected to the slider 52a so that it rotates in the positive direction. The predetermined distance is, for example, the distance P2 (see FIG. 1) in the X-axis direction between the convex shapes of each mold, i.e., one pitch.

[0088] Next, the gripping mechanism 51 releases the grip on the sheet material M to be press-molded. Specifically, the movable gripping part 51b descends. This is achieved by the control device 60 controlling the air cylinder 51c connected to the movable gripping part 51b (the electromagnetic valve for adjusting the amount of air supply provided midway in the air supply path connected to the air cylinder 51c).

[0089] Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 that has released its grip on the sheet material M to be press-molded as described above, in the -X direction, and returns it to the initial position before conveyance. This is achieved by the control device 60 controlling the electric motor (for example, a servo motor) connected to the ball screw connected to the slider 52a so that it rotates in the reverse direction, for example.

[0090] In each of the above steps, both widthwise ends of the press-molding target sheet material M are disposed between the movable gripping part 51b and the fixed gripping part 51a.

[0091] The above has mainly explained an example of the operation of the conveying device 50A provided on the upstream side, but the conveying device 50B provided on the downstream side is also controlled to perform the same operation at the same timing as the conveying device 50A provided on the upstream side.

[0092] <Control device 60> Fig. 7 is a system configuration diagram of the control device 60. The control device 60 includes a processor, RAM, ROM, etc., which are not shown. As shown in Fig. 7, the control device 60 is electrically connected to an electric heater 13 for heating the preheating mold 10, an air cylinder 14 for raising and lowering the upper preheating mold 11 (an electromagnetic valve for adjusting the amount of air supplied provided in the air supply path connected to the air cylinder 14), an electric heater 23 for heating the shaping mold 20, an air cylinder 51c for driving the gripping mechanism 51 (movable gripping portion 51b) (an electromagnetic valve for adjusting the amount of air supplied provided in the air supply path connected to the air cylinder 51c), an electric motor 53 for driving the moving mechanism 52 (slider 52a), and an electric motor 102 for driving the mold clamping mechanism 100.

[0093] The processor is, for example, a CPU. The processor may be one or more. For example, the processor executes a program read from ROM to RAM to function as a control means for controlling the electric heater 13 for heating the preheating mold 10, the air cylinder 14 for raising and lowering the upper preheating mold 11 (an electromagnetic valve for adjusting the amount of air supplied provided in the air supply path connected to the air cylinder 14), the electric heater 23 for heating the shaping mold 20, the air cylinder 51c for driving the gripping mechanism 51 (movable gripping portion 51b) (an electromagnetic valve for adjusting the amount of air supplied provided in the air supply path connected to the air cylinder 51c), the electric motor 53 for driving the moving mechanism 52 (slider 52a), the electric motor 102 for driving the mold clamping mechanism 100, etc.

[0094] <Operation example of continuous press forming device 1> An example of the operation of the continuous press-forming apparatus 1 will be described with reference to Figures 8 and 9. Note that the conveying device 50 is omitted in Figure 9.

[0095] Fig. 8 is a flowchart of an example of the operation of the continuous press-molding apparatus 1. Fig. 9(a) to Fig. 9(d) are diagrams showing how a molded product having a continuous alternating pattern of concave and convex shapes (see Fig. 2) is produced by press-molding the sheet material M to be press-molded by each of the dies 10, 20, 30, and 40 every time the sheet material M to be press-molded is conveyed a predetermined distance (for example, one pitch).

[0096] First, a portion of the press-molding target sheet material M is placed between the upper preheating mold 11 and the lower preheating mold 12 (step S10). This is achieved by a conveying device 50A provided upstream. Specifically, first, the gripping mechanism 51 grips the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 that has gripped the press-molding target sheet material M as described above, a predetermined distance in the +X direction. Next, the gripping mechanism 51 releases its grip on the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 that has released its grip on the press-molding target sheet material M as described above, in the -X direction to return it to its initial position before conveyance. In this way, the portion p1 of the press-molding target sheet material M is placed between the upper preheating mold 11 and the lower preheating mold 12 (see FIG. 9(a)).

[0097] Next, the preheating mold 10 is clamped (step S11). The preheating mold 10 is clamped by the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwiching and pressuring the portion p1 of the sheet material M to be press-molded placed therebetween. At this time, since the preheating mold 10 has been heated to a predetermined temperature by a heating device, the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwich and heat and press the portion p1 of the sheet material M to be press-molded placed therebetween with a predetermined pressure.

[0098] Next, the preheating mold 10 is opened (step S12). This is achieved by the control device 60 controlling the air cylinder connected to the upper preheating mold 11 (the electromagnetic valve for adjusting the air supply amount provided midway in the air supply path connected to the air cylinder) to raise the upper preheating mold 11.

[0099] Next, the press-molding target sheet material M is conveyed by one pitch (step S13). This is achieved by the conveying device 50A provided upstream. Specifically, first, the gripping mechanism 51 grips the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 gripping the press-molding target sheet material M as described above, by one pitch P2 (see FIG. 1) in the +X direction. Next, the gripping mechanism 51 releases its grip on the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51, which has released its grip on the press-molding target sheet material M as described above, in the -X direction, returning it to its initial position before conveyance. In this way, the portion p1 (preheated portion) of the press-molding target sheet material M is positioned between the upper shaping mold 21 and the lower shaping mold 22 (see FIG. 9(b)). Furthermore, a portion p2 of the sheet material M to be press-molded is placed between the upper preheating mold 11 and the lower preheating mold 12 (see FIG. 9(b)).

[0100] Next, the molds are clamped (step S14). That is, the preheating mold 10 and the shaping mold 20 are clamped.

[0101] The preheating mold 10 is clamped by sandwiching and pressurizing the portion p2 of the sheet material M to be press-molded placed between the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12. At this time, since the preheating mold 10 is heated to a predetermined temperature by a heating device, the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwich and heat and press the portion p2 of the sheet material M to be press-molded placed between them with a predetermined pressure.

[0102] On the other hand, clamping of the shaping mold 20 is performed by the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22 clamping and pressing the portion p1 (preheated portion) of the sheet material M to be press-molded, which is placed between them. This is performed by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lowering the upper platen 70A on which the upper shaping mold 21 is attached (for example, by executing the clamping process (see FIG. 13) described below). At this time, since the shaping mold 20 is heated to a predetermined temperature by a heating device, the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22 sandwich the portion p1 (preheated portion) of the sheet material M to be press-molded, which is placed between them, and heat and press it at a predetermined pressure.

[0103] At this time, the portion p1 (preheated portion) of the sheet material M to be press-molded is pressed into the concave shape 22c of the lower press surface of the lower shaping die 22 by the convex shape 21c of the upper press surface of the upper shaping die 21. As a result, a shape (concave shape) corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22 is formed in the portion p1 (preheated portion) of the sheet material M to be press-molded.

[0104] Next, the molds are opened (step S15). That is, the preheating mold 10 and the shaping mold 20 are opened.

[0105] The preheating mold 10 is opened by the control device 60 controlling the air cylinder connected to the upper preheating mold 11 (the electromagnetic valve for adjusting the air supply amount provided midway in the air supply path connected to the air cylinder) and lifting the upper preheating mold 11.

[0106] On the other hand, the shaping mold 20 is opened by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and raise the upper platen 70A on which the upper shaping mold 21 is attached.

[0107] Next, the press-molding target sheet material M is conveyed by one pitch (step S16). This is achieved by the conveying device 50A provided upstream. Specifically, first, the gripping mechanism 51 grips the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 gripping the press-molding target sheet material M as described above, by one pitch P2 (see FIG. 1), in the +X direction. Next, the gripping mechanism 51 releases its grip on the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51, which has released its grip on the press-molding target sheet material M as described above, in the -X direction, returning it to its initial position before conveyance. In this way, the portion p1 (shape portion) of the press-molding target sheet material M is positioned between the upper positioning die 31 and the lower positioning die 32 (see FIG. 9(c)). Furthermore, a portion p2 (preheated portion) of the sheet material M to be press-molded is disposed between the upper shaping die 21 and the lower shaping die 22 (see FIG. 9(c)). Furthermore, a portion p3 of the sheet material M to be press-molded is disposed between the upper preheating die 11 and the lower preheating die 12 (see FIG. 9(c)).

[0108] Next, the molds are clamped (step S17). That is, the preheating mold 10, the shaping mold 20, and the positioning mold 30 are clamped.

[0109] The preheating mold 10 is clamped by sandwiching and pressurizing the portion p3 of the sheet material M to be press-molded placed between the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12. At this time, since the preheating mold 10 is heated to a predetermined temperature by a heating device, the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwich and heat and press the portion p3 of the sheet material M to be press-molded placed between them with a predetermined pressure.

[0110] On the other hand, the clamping of the positioning mold 30 and the clamping of the shaping mold 20 are performed in this order by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lowering the upper mold platen 70A on which the upper positioning mold 31 and the upper shaping mold 21 are attached (for example, by executing the clamping process described below (see Figure 13)).

[0111] Specifically, the clamping of the positioning mold 30 is performed by clamping and applying pressure to the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31 and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32, which sandwich and pressurize the portion p1 (shaped portion) of the sheet material M to be press-molded that is placed between them.

[0112] At this time, the lower positioning die 32 pushes up the upper positioning die 31 in the +Z direction. This causes the upper positioning die 31 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96A arranged between the upper positioning die 31 and the upper platen 70A to elastically deform, and the upper positioning die 31 is urged toward the lower positioning die 32 by this elastically deformed elastic body 96A.

[0113] Therefore, clamping of the positioning mold 30 is carried out between the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31, which is urged toward the lower positioning mold 32 by the elastic body 96A, and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32.

[0114] At this time, since the positioning mold 30 is at a lower temperature than the shaping mold 20, the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31, which is biased toward the lower positioning mold 32 by the elastic body 96A, and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32 sandwich the portion p1 (shaping portion) of the sheet material M to be press-molded, which is placed between them, and cool and pressurize it at a predetermined pressure.

[0115] At this time, portion p1 (shaping portion) (concave shape) of the press-molded sheet material M is pressed into the concave shape 32c of the lower press surface of the lower positioning die 32, and the convex shape 31c of the upper press surface of the upper positioning die 31 is pressed into portion p1 (shaping portion) (concave shape) of the press-molded sheet material M. This positions the press-molded sheet material M. This positioning allows concave shapes to be accurately formed in the press-molded sheet material M at one pitch at a time. In addition, portion p1 (shaping portion) of the press-molded sheet material M is cooled and pressurized. This, as described above, makes it possible to prevent a decrease in the quality of the molded product.

[0116] On the other hand, the clamping of the shaping mold 20 is performed by sandwiching and pressurizing the portion p2 (preheated portion) of the sheet material M to be press-molded placed between the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22. At this time, since the shaping mold 20 is heated to a predetermined temperature by a heating device, the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22 sandwich and heat and pressurize the portion p2 (preheated portion) of the sheet material M to be press-molded placed between them with a predetermined pressure.

[0117] At this time, the portion p2 (preheated portion) of the sheet material M to be press-molded is pressed into the concave shape 22c of the lower press surface of the lower shaping die 22 by the convex shape 21c of the upper press surface of the upper shaping die 21. As a result, a shape (concave shape) corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22 is formed in the portion p2 (preheated portion) of the sheet material M to be press-molded.

[0118] Next, the molds are opened (step S18). That is, the preheating mold 10 is opened, the shaping mold 20 is opened, and the positioning mold 30 is opened. This is the same as step S15, so the explanation will be omitted.

[0119] Next, the press-molding target sheet material M is conveyed by one pitch (step S19). This is achieved by the conveying device 50A provided upstream. Specifically, first, the gripping mechanism 51 grips the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 gripping the press-molding target sheet material M as described above, by one pitch P2 (see FIG. 1) in the +X direction. Next, the gripping mechanism 51 releases its grip on the press-molding target sheet material M. Next, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51, which has released its grip on the press-molding target sheet material M as described above, in the -X direction, returning it to its initial position before conveyance. In this way, the portion p1 of the press-molding target sheet material M (the shaped portion pressurized by the positioning die 30) is positioned between the upper cooling die 41 and the lower cooling die 42 (see FIG. 9(d)). Furthermore, a portion p2 (shaping portion) of the sheet material M to be press-molded is disposed between the upper positioning die 31 and the lower positioning die 32 (see FIG. 9(d)). Further, a portion p3 (preheating portion) of the sheet material M to be press-molded is disposed between the upper shaping die 21 and the lower shaping die 22 (see FIG. 9(d)). Furthermore, a portion p4 of the sheet material M to be press-molded is disposed between the upper preheating die 11 and the lower preheating die 12 (see FIG. 9(d)).

[0120] Next, the molds are clamped (step S20). That is, the preheating mold 10, the shaping mold 20, the positioning mold 30, and the cooling mold 40 are clamped.

[0121] The preheating mold 10 is clamped by sandwiching and pressurizing the portion p4 of the sheet material M to be press-molded placed between the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12. At this time, since the preheating mold 10 is heated to a predetermined temperature by a heating device, the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwich and heat and press the portion p4 of the sheet material M to be press-molded placed between them with a predetermined pressure.

[0122] On the other hand, the clamping of the positioning mold 30, the positioning of the cooling mold 40, and the clamping of the shaping mold 20 are performed in this order by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lowering the upper mold platen 70A on which the upper positioning mold 31, the upper cooling mold 41, and the upper shaping mold 21 are attached (for example, by executing the clamping process described below (see Figure 13)).

[0123] Specifically, the clamping of the positioning mold 30 is performed by clamping and applying pressure to the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31 and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32, which sandwich and pressurize the portion p2 (shaped portion) of the sheet material M to be press-molded, which is placed between them.

[0124] At this time, the lower positioning die 32 pushes up the upper positioning die 31 in the +Z direction. This causes the upper positioning die 31 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96A arranged between the upper positioning die 31 and the upper platen 70A to elastically deform, and the upper positioning die 31 is urged toward the lower positioning die 32 by this elastically deformed elastic body 96A.

[0125] Therefore, clamping of the positioning mold 30 is carried out between the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31, which is urged toward the lower positioning mold 32 by the elastic body 96A, and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32.

[0126] At this time, since the positioning mold 30 is at a lower temperature than the shaping mold 20, the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31, which is biased toward the lower positioning mold 32 by the elastic body 96A, and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning mold 32 sandwich the portion p2 (shaping portion) of the sheet material M to be press-molded, which is placed between them, and cool and pressurize it at a predetermined pressure.

[0127] At this time, portion p2 (shaping portion) (concave shape) of the press-molded sheet material M is pressed into the concave shape 32c of the lower press surface of the lower positioning die 32, and the convex shape 31c of the upper press surface of the upper positioning die 31 is pressed into portion p2 (shaping portion) (concave shape) of the press-molded sheet material M. This positions the press-molded sheet material M. This positioning allows concave shapes to be accurately formed in the press-molded sheet material M at one pitch at a time. In addition, portion p2 (shaping portion) of the press-molded sheet material M is cooled and pressurized. This, as described above, makes it possible to prevent a decrease in the quality of the molded product.

[0128] On the other hand, the clamping of the cooling mold 40 is performed by clamping and applying pressure to the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41 and the lower press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling mold 42, which sandwich and pressurize the portion p1 (the shaped portion pressurized by the positioning mold 30) of the sheet material M to be press-molded that is placed between them.

[0129] At that time, the lower cooling mold 42 pushes up the upper cooling mold 41 in the +Z direction. This causes the upper cooling mold 41 to move in a direction (+Z direction) approaching the upper mold platen 70A, which causes the elastic body 96B (see FIG. 1) arranged between the upper cooling mold 41 and the upper mold platen 70A to elastically deform, and the upper cooling mold 41 is urged toward the lower cooling mold 42 by this elastically deformed elastic body 96B.

[0130] Therefore, the clamping of the cooling mold 40 is carried out between the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41, which is biased toward the lower cooling mold 42 by the elastic body 96B, and the lower press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling mold 42.

[0131] At this time, since the cooling mold 40 is at room temperature, the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the lower cooling mold 42 and the lower press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling mold 42, which are urged toward the lower cooling mold 42 by the elastic body 96B, sandwich the portion p1 (the shaped portion pressurized by the positioning mold 30) of the sheet material M to be press-molded that is placed between them and cool and pressurize it at a predetermined pressure.

[0132] At this time, portion p1 (the shaped portion pressurized by the positioning die 30) (concave shape) of the press-molding target sheet material M is pressed into the concave shape 42c of the lower press surface of the lower cooling die 42, and the convex shape 41c of the upper press surface of the upper cooling die 41 is pressed into portion p1 (the shaped portion pressurized by the positioning die 30) (concave shape) of the press-molding target sheet material M. As a result, portion p1 (the shaped portion pressurized by the positioning die 30) of the press-molding target sheet material M is cooled and pressurized. As a result, as described above, deterioration in the quality of the molded product can be suppressed.

[0133] On the other hand, the clamping of the shaping mold 20 is performed by sandwiching and pressurizing the portion p3 (preheated portion) of the sheet material M to be press-molded placed between the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22. At this time, since the shaping mold 20 is heated to a predetermined temperature by a heating device, the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping mold 21 and the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping mold 22 sandwich and heat and pressurize the portion p3 (preheated portion) of the sheet material M to be press-molded placed between them with a predetermined pressure.

[0134] At this time, the portion p3 (preheated portion) of the sheet material M to be press-molded is pressed into the concave shape 22c of the lower press surface of the lower shaping die 22 by the convex shape 21c of the upper press surface of the upper shaping die 21. As a result, a shape (concave shape) corresponding to the upper press surface of the upper shaping die 21 (flat surfaces 21a, 21b and convex shape 21c) and the lower press surface of the lower shaping die 22 (flat surfaces 22a, 22b and concave shape 22c) is formed in the portion p3 (preheated portion) of the sheet material M to be press-molded.

[0135] Next, each mold is opened (step S21). That is, the preheating mold 10 is opened, the shaping mold 20 is opened, the positioning mold 30 is opened, and the cooling mold 40 is opened. This is the same as step S15, so a description thereof will be omitted.

[0136] Thereafter, the processes of steps S19 to S21 are repeatedly executed. At that time, each time the molds (preheating mold 10, shaping mold 20, positioning mold 30, and cooling mold 40) are opened (step S21), the conveying device 50 conveys the press-molding target sheet material M so that the preheated portion of the press-molding target sheet material M is disposed between the upper press surface of the upper shaping mold 21 and the lower press surface of the lower shaping mold 22, the shaped portion of the press-molding target sheet material M is disposed between the upper press surface of the upper positioning mold 31 and the lower press surface of the lower positioning mold 32, and the shaped portion of the press-molding target sheet material M (the shaped portion pressurized by the positioning mold 30) is disposed between the upper press surface of the upper cooling mold 41 and the lower press surface of the lower cooling mold 42 (step S19).

[0137] In this manner, the clamping of the positioning mold 30, the clamping of the cooling mold 40, the clamping of the shaping mold 20 (step S20), and the opening of each mold (positioning mold 30, cooling mold 40, and shaping mold 20) (step S21) are carried out repeatedly and continuously in this order.

[0138] This makes it possible to manufacture a molded product having a series of alternating concave and convex shapes (see FIG. 2). The press-molding target sheet material M manufactured as described above (a molded product having a series of alternating concave and convex shapes) is then placed between the movable gripping unit 51b and the fixed gripping unit 51a of the conveying device 50B provided downstream (see FIG. 1). The conveying device 50B performs the same operation as the conveying device 50A provided upstream, at the same timing, on the press-molding target sheet material M (a molded product having a series of alternating concave and convex shapes) placed between the movable gripping unit 51b and the fixed gripping unit 51a.

[0139] As described above, according to the first embodiment, it is possible to provide a press device that can suppress damage to a sheet to be formed during press forming.

[0140] This is because the clamping of the positioning mold 30, the clamping of the cooling mold 40, and the clamping of the shaping mold 20 are performed in this order, that is, at different timings.

[0141] The invention made by the present inventor has been specifically described above based on embodiment 1, but it goes without saying that the present invention is not limited to the embodiment already described, and various modifications are possible within the scope of the gist of the invention.

[0142] For example, in the above-mentioned first embodiment, an example has been described in which the upper shaping die 21 having an upper press surface including the convex shape 21c is used as the upper shaping die, and the lower shaping die 22 having a lower press surface including the concave shape 22c into which the convex shape 21c fits is used as the lower shaping die, but this is not limiting. Conversely, it is also possible to use the upper shaping die 21 having an upper press surface including the concave shape 22c into which the convex shape 21c fits as the upper shaping die, and the lower shaping die 22 having a lower press surface including the convex shape 21c as the lower shaping die. The same applies to the upper positioning die and the lower positioning die, and the upper cooling die and the lower cooling die.

[0143] In the first embodiment, the conveying device 50 including the gripping mechanism 51 and the moving mechanism 52 is used as the conveying device, but the present invention is not limited to this. For example, other mechanisms (e.g., a robot arm) may be used as the conveying device. Furthermore, the conveying device may be omitted, and the sheet material M to be press-molded may be conveyed manually by an operator.

[0144] Furthermore, in the first embodiment, an example in which the cooling mold 40 is used has been described, but the present invention is not limited to this. For example, the cooling mold 40 may be omitted.

[0145] In addition, in the above embodiment 1, an example was described in which the upper platen 70A to which each upper mold (upper shaping mold 21, upper positioning mold 31, upper cooling mold 41) is attached is a movable platen, and the lower platen 70B to which each lower mold (lower shaping mold 22, lower positioning mold 32, lower cooling mold 42) is attached is a fixed platen, and the mold clamping mechanism 100 is a mechanism that moves the upper platen 70A (movable platen) in a direction toward and away from the lower platen 70B (Z-axis direction), i.e., a mechanism that raises and lowers the upper platen 70A in the vertical direction (Z-axis direction), but this is not limited to this. Conversely, the upper platen 70A to which each upper mold (upper shaping mold 21, upper positioning mold 31, upper cooling mold 41) is attached may be used as a fixed platen, and the lower platen 70B to which each lower mold (lower shaping mold 22, lower positioning mold 32, lower cooling mold 42) is attached may be used as a movable platen, and the mold clamping mechanism 100 may be a mechanism that moves the lower platen 70B (movable platen) in a direction toward and away from the upper platen 70A (Z-axis direction), i.e., a mechanism that raises and lowers the lower platen 70B in the vertical direction (Z-axis direction).

[0146] FIG. 10 shows modified examples of the convex shapes of the upper shaping mold, upper positioning mold, and upper cooling mold, and the concave shapes of the lower shaping mold, lower positioning mold, and lower cooling mold.

[0147] In the first embodiment described above, an example has been described in which the convex shapes of the upper shaping mold 21, the upper positioning mold 31, and the upper cooling mold 41 have a cross-sectional shape (cross-sectional shape taken along a plane parallel to the XZ plane) that is an inverted trapezoid (see FIG. 1), but this is not limitative. For example, as shown in FIG. 10, the convex shapes of the upper shaping mold 21, the upper positioning mold 31, and the upper cooling mold 41 may have a cross-sectional shape (cross-sectional shape taken along a plane parallel to the XZ plane) that is a quadratic curve convex downward, or other cross-sectional shapes.

[0148] Similarly, although an example has been described in which the concave shapes of the lower shaping mold 22, the lower positioning mold 32, and the lower cooling mold 42 are each formed in a cross-sectional shape (cross-sectional shape taken along a plane parallel to the XZ plane) that corresponds to a convex shape of an inverted trapezoid (see FIG. 1), the present invention is not limited to this. For example, as shown in FIG. 10, the concave shapes of the lower shaping mold 22, the lower positioning mold 32, and the lower cooling mold 42 may each be formed in a cross-sectional shape (cross-sectional shape taken along a plane parallel to the XZ plane) that corresponds to a convex shape of a quadratic curve that is convex downward, or other concave cross-sectional shapes.

[0149] Furthermore, in the above-mentioned first embodiment, an example has been described in which the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41 is located below the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper shaping mold 21 before the shaping mold 20, the positioning mold 30 and the cooling mold 40 are clamped, but this is not limiting. Conversely, the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper shaping mold 21 may be located below the upper press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling mold 41 before the shaping mold 20, the positioning mold 30 and the cooling mold 40 are clamped. In this way, by lowering the upper mold plate 70A on which each upper mold (upper shaping mold 21, upper positioning mold 31, upper cooling mold 41) is attached, the clamping of the positioning mold 30, the clamping of the shaping mold 20, and the clamping of the cooling mold 40 can be performed in that order.

[0150] <Embodiment 2> The second embodiment will be described in detail below with reference to the drawings.

[0151] <Overall configuration of the press device> First, the overall configuration of a press-forming apparatus 1A according to the second embodiment will be described with reference to Fig. 11. Fig. 11 is a diagram showing the overall configuration of a continuous press-forming apparatus 1A according to the second embodiment.

[0152] As shown in Fig. 11, the continuous press molding apparatus 1A differs from the continuous press molding apparatus 1 of embodiment 1 in the configuration of the upper shaping die 21 and in the omission of the cooling die 40. Hereinafter, the shaping die 20 of embodiment 2 will be referred to as shaping die 20A, and the upper shaping die 21 of embodiment 2 will be referred to as upper shaping die 21A. Otherwise, the continuous press molding apparatus 1A has the same configuration as the continuous press molding apparatus 1 of embodiment 1. Below, the differences from embodiment 1 will be mainly described, and the same configurations as embodiment 1 will be assigned the same reference numerals and will not be described as appropriate.

[0153] <Configuration of upper shaping mold 21A> 11, the upper shaping mold 21A includes a first upper half shaping mold 21A1 and a second upper half shaping mold 21A2 split in half in the horizontal direction. The first upper half shaping mold 21A1 and the second upper half shaping mold 21A2 correspond to two molds that are separated by cutting the upper shaping mold 21 of embodiment 1 along a plane (the AA cross section in FIG. 1) that is parallel to the YZ plane and passes through the center in the X-axis direction.

[0154] The first upper half shaping die 21A1 has a half press surface (flat surface 21a and half convex shape 21c1). Similarly, the second upper half shaping die 21A2 has a half press surface (flat surface 21b and half convex shape 21c2). The first upper half shaping die 21A1, the second upper half shaping die 21A2, and the positioning die 30 are arranged in this order along the conveying direction of the sheet material M to be press-molded.

[0155] At least one of the upper shaping mold 21A (first half upper shaping mold 21A1 and second half upper shaping mold 21A2) and the lower shaping mold 22 is heated to a predetermined temperature by a heating device (for example, an electric heater 23; see FIG. 12). The heating device may be built into the shaping mold 20A or may be provided outside the shaping mold 20A.

[0156] A protrusion 21A2a is provided at the lower end of the second upper half shaping mold 21A2 (see the enlarged view in the circle C2 in Figure 11). The protrusion length B1 in the -X direction of the protrusion 21A2a is, for example, 0.1 mm. The length B2 in the Z-axis direction of the protrusion 21A2a is, for example, 1 mm. When the mold is closed, the second upper half shaping mold 21A2 moves in a direction approaching the upper mold platen 70A (+Z direction), and the protrusion 21A2a is inserted into the gap S1 (see the enlarged view in the circle C2 in Figure 11) between the lower end of the first upper half shaping mold 21A1 and the lower end of the second upper half shaping mold 21A2, widening the gap S1 in the X-axis direction.

[0157] At this time, in order to make it easier to insert the protrusions 21A2a, an inclined surface 21A2b is provided on the upper part of the protrusions 21A2a. Also, in order to ensure the wear resistance of the protrusions 21A2a, the hardness of the protrusions 21A2a is higher than the hardness of the portions other than the protrusions 21A2a (portions of the upper shaping die 21A other than the protrusions 21A2a). This is achieved, for example, by subjecting the protrusions 21A2a to a heat treatment.

[0158] <Mounting structure of first half-split upper shaping mold 21A1 and second half-split upper shaping mold 21A2> The first half-split upper shaping die 21A1 is attached in a fixed state to the underside of the upper platen 70A. This attachment structure is similar to the attachment structure of the upper shaping die 21 in embodiment 1 (see FIG. 3), and therefore its description will be omitted. On the other hand, the second half-split upper shaping die 21A2 is attached to the underside of the upper platen 70A so as to be movable in a direction (Z-axis direction) toward and away from the upper platen 70A. This attachment structure is similar to the attachment structure of the upper positioning die 31 (see FIG. 4), and therefore its description will be omitted.

[0159] <Example of clamping operation of first half-split upper shaping mold 21A1 and second half-split upper shaping mold 21A2> The first half-split upper shaping mold 21A1 is clamped by the half-split press surface (flat surface 21a and half-split convex shape 21c1) of the first half-split upper shaping mold 21A1 and the lower press surface (flat surface 22a and concave shape 22c) of the lower shaping mold sandwiching the preheated portion (portion preheated by the preheating mold 10) of the sheet material M to be press-molded, which is placed between them, and applying pressure (heating and pressurizing) at a predetermined pressure.

[0160] The second upper half shaping mold 21A2 is clamped by the half press surface (flat surface 21b and half convex shape 21c2) of the second upper half shaping mold 21A2 and the lower press surface (flat surface 22b and concave shape 22c) of the lower shaping mold sandwiching the preheated portion (portion preheated by the preheating mold 10) of the sheet material M to be press-molded, which is placed between them, and applying a predetermined pressure (heating and pressurizing). Note that this predetermined pressure can be changed to any pressure by using an elastic body with a different spring constant as the elastic body 96C.

[0161] The clamping of the first half-split upper shaping mold 21A1 and the clamping of the second half-split upper shaping mold 21A2 are carried out by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lowering the upper positioning mold 31 and the upper mold platen 70A to which the upper shaping mold 21 is attached.

[0162] At that time, the lower shaping die 22 pushes up the second half upper shaping die 21A2 in the +Z direction. This causes the second half upper shaping die 21A2 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96 (an elastic body (see FIG. 11) arranged between the second half upper shaping die 21A2 and the upper platen 70A; hereinafter, also referred to as elastic body 96C) to elastically deform, and the second half upper shaping die 21A2 is urged toward the lower shaping die 22 by this elastically deformed elastic body 96C. The elastic body 96C is an example of the second elastic body of the present disclosure.

[0163] Therefore, the clamping of the second half-split upper shaping mold 21A2 is carried out between the half-split press surface (flat surface 21b and half-split convex shape 21c2) of the second half-split upper shaping mold 21A2, which is biased toward the lower shaping mold 22 by the elastic body 96C, and the lower press surface (flat surface 22b and concave shape 22c) of the lower shaping mold 22.

[0164] Here, as shown in Figure 11, before the clamping of each mold (clamping of the first half upper shaping mold 21A1, clamping of the second half upper shaping mold 21A2, and clamping of the positioning mold 30) is performed, the upper press surface (plane 21a and half convex shape 21c1) of the first half upper shaping mold 21A1 and the half press surface (plane 21b and half convex shape 21c2) of the second half upper shaping mold 21A2. This is realized, for example, by adjusting the gap G3 (see FIG. 4) of the upper positioning mold 31 so that the upper press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning mold 31 is positioned below the half press surface (flat surface 21a and half convex shape 21c1) of the first upper half shaping mold 21A1 and the half press surface (flat surface 21b and half convex shape 21c2) of the second upper half shaping mold 21A2. Also, the half press surface (flat surface 21b and half convex shape 21c2) of the second upper half shaping mold 21A2 is positioned below the half press surface (flat surface 21a and half convex shape 21c1) of the first upper half shaping mold 21A1 before the mold clamping of each mold (mold clamping of the first upper half shaping mold 21A1 and mold clamping of the second upper half shaping mold 21A2) is performed. This is achieved, for example, by adjusting the gap G3 (see Figure 4) of the second half-split upper shaping mold 21A2 so that the half-split press surface (plane 21b and half-split convex shape 21c2) of the second half-split upper shaping mold 21A2 is positioned lower than the half-split press surface (plane 21a and half-split convex shape 21c1) of the first half-split upper shaping mold 21A1.

[0165] Therefore, by lowering the upper mold platen 70A as described above, the clamping of the positioning mold 30, the clamping of the second half upper shaping mold 21A2, and the clamping of the first half upper shaping mold 21A1 are performed in this order. In other words, the clamping of the positioning mold 30, the clamping of the second half upper shaping mold 21A2, and the clamping of the first half upper shaping mold 21A1 are not performed simultaneously, but at different times.

[0166] By clamping the second half-split upper shaping mold 21A2 and the first half-split upper shaping mold 21A1 at different timings in this way, the following advantages are obtained.

[0167] In other words, when mold clamping is performed using a single upper shaping mold 21 that is not split in half as in embodiment 1, the sheet material M to be press-molded (e.g., an FRP sheet material reinforced with reinforcing fibers) hardly stretches, and therefore, as in the above prior art document, when the convex shape 21c of the upper shaping mold 21 presses the sheet material M to be press-molded into the concave shape 22c of the press surface of the lower shaping mold 22, the pressed sheet material M to be press-molded is pulled, which poses a problem of concern that the sheet material M to be press-molded (molded product) may be damaged.

[0168] In contrast, by clamping the second upper half shaping die 21A2 and the first upper half shaping die 21A1 in this order, that is, by clamping them at different times, the half-split convex shape 21c1 of the half press surface of the first upper half shaping die 21A1 and the half-split convex shape 21c2 of the half press surface of the second upper half shaping die 21A2 will press the press-molded sheet material M into the concave shape 22c of the press surface of the lower shaping die 22 "at different times." This prevents the pressed press-molded sheet material M from being pulled when the press-molded sheet material M is pressed into the concave shape 22c of the press surface of the lower shaping die 22, which has the advantage of preventing damage to the press-molded sheet material M (molded product).

[0169] Conversely, the half press surface (flat surface 21a and half convex shape 21c1) of the first half upper shaping mold 21A1 may be located below the half press surface (flat surface 21b and half convex shape 21c2) of the second half upper shaping mold 21A2 before the molds are closed (the mold closing of the first half upper shaping mold 21A1 and the mold closing of the second half upper shaping mold 21A2). This also has the advantage of preventing damage to the sheet material M (molded product) to be press-molded, as described above.

[0170] During the above mold clamping, the second half-split upper shaping mold 21A2 moves in a direction approaching the upper mold platen 70A (+Z direction), and the protrusion 21A2a (see enlarged view in circle C2 in Figure 11) provided at the lower end of the second half-split upper shaping mold 21A2 is inserted into the gap S1 (see enlarged view in circle C2 in Figure 11) between the lower end of the first half-split upper shaping mold 21A1 and the lower end of the second half-split upper shaping mold 21A2, widening the gap S1 in the X-axis direction.

[0171] This further pressurizes the half press surface (inclined surface 21A1a of half convex shape 21c1) of the first half upper shaping die 21A1, the half press surface (inclined surface 21A2c of half convex shape 21c2) of the second half upper shaping die 21A2, and the lower press surface (inclined surfaces 22c1, 22c2 of concave shape 22c) of the lower shaping die 22. This further pressurizes the sheet material M to be press-formed compared to when the protrusion 21A2a is not provided. This improves the internal quality of the sheet material M to be press-formed. For example, defects such as voids inside the sheet material M to be press-formed can be eliminated or reduced.

[0172] <Control device 60> 12 is a system configuration diagram of a control device 60 according to the second embodiment. The control device 60 includes a processor, RAM, ROM, etc., which are not shown. FIG. 12 corresponds to FIG. 7 in which a distance sensor 110 and a pressure sensor 120 (e.g., a load cell) are added. The distance sensor 110 and the pressure sensor 120 are electrically connected to the control device 60.

[0173] The distance sensor 110 detects the movement distance (amount of change from the initial position) of the upper platen 70A. The pressure sensor 120 detects the clamping pressure (molding pressure) of the molds (shaping mold 20A, positioning mold 30) during mold clamping. The distance sensor 110 and the pressure sensor 120 are provided at appropriate locations.

[0174] <Example of mold clamping process> FIG. 13 is a flowchart of an example of mold clamping processing.

[0175] 13 is realized by, for example, the control device 60 (processor) executing a program read from the ROM to the RAM. Note that this process may be applied to the continuous press forming device 1 of the first embodiment or other continuous press forming devices.

[0176] When clamping the dies (upper positioning die 31, second half upper shaping die 21A2, first half upper shaping die 21A1), the upper platen 70A moves (descends) at a first speed in a direction (-Z direction) approaching the lower platen 70B (step S30). This is performed by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lower the upper platen 70A so that the upper platen 70A descends at the first speed (set speed). It is desirable to make the first speed as fast as possible.

[0177] Next, it is determined whether the press-molding target sheet material M is about to be pressed (several mm before) (step S31). This is achieved, for example, by comparing the distance detected by the distance sensor 110 with a first threshold value. If the comparison result shows that the distance detected by the distance sensor 110 is greater than the first threshold value, it is determined that the press-molding target sheet material M is about to be pressed (several mm before) (step S31: YES).

[0178] In this case, the upper platen 70A (first speed) is decelerated to protect the mold (step S32). On the other hand, if the distance detected by the distance sensor 110 is smaller than the first threshold value, it is determined that the press-molding target sheet material M is not about to be pressed (several mm before) (step S31: NO). In this case, the processing of step S30 is repeatedly executed until it is determined that the press-molding target sheet material M is about to be pressed (several mm before).

[0179] Next, it is determined whether it is time to apply pressure to the press-molding target sheet material M (step S33). This is achieved by comparing the pressure detected by the pressure sensor 120 with a second threshold value. If the comparison shows that the pressure detected by the pressure sensor 120 is greater than the second threshold value, it is determined that it is time to apply pressure to the press-molding target sheet material M (step S33: YES). In this case, the upper platen 70A moves (descends) in a direction approaching the lower platen 70B (-Z direction) at a second speed slower than the first speed (step S34).

[0180] This is performed by the control device 60 controlling the electric motor 102 to rotate the ball screw 101 and lower the upper platen 70A so that the upper platen 70A descends at a second speed (set speed). On the other hand, if the pressure detected by the pressure sensor 120 is smaller than the second threshold value, it is determined that it is not the timing to apply pressure to the press-molding target sheet material M (step S33: NO). In this case, the processing of step S32 is repeatedly executed until it is determined that it is the timing to apply pressure to the press-molding target sheet material M.

[0181] Next, it is determined whether the target pressure has been reached (step S35). This is achieved by comparing the pressure detected by the pressure sensor 120 with a third threshold value. If the comparison shows that the pressure detected by the pressure sensor 120 is greater than the third threshold value, it is determined that the target pressure has been reached (step S35: YES). In this case, the mold clamping process of FIG. 13 is terminated. On the other hand, if the pressure detected by the pressure sensor 120 is less than the third threshold value, it is determined that the target pressure has not been reached (step S35: NO). In this case, the process of step S34 is repeatedly executed until it is determined that the target pressure has been reached.

[0182] As described above, when the press-molding target sheet material M is pressed under pressure control by the mold clamping process (see FIG. 13), the press-molding target sheet material M is gradually cooled and thermally contracted in each mold, so that the thickness of the press-molding target sheet material M differs for each portion corresponding to each mold.

[0183] Even if the thickness of the sheet material M to be press-molded differs for each part corresponding to each mold, when the mold is closed, the upper positioning mold 31 is urged toward the lower positioning mold 32 by the elastic body 96A, and the second half-split upper shaping mold 21A2 is urged toward the lower shaping mold 22 by the elastic body 96C, so that each part of the sheet material M to be press-molded can be pressurized in accordance with the change in thickness.

[0184] <Operation example of continuous press forming device 1A> An example of the operation of the continuous press-forming apparatus 1A will be described with reference to Figures 14 and 15. Figures 14(a) to 14(h) are diagrams showing how the sheet material M to be press-formed is press-formed by each of the dies 10, 20A, and 30 every time the sheet material M to be press-formed is conveyed a predetermined distance (for example, one pitch), thereby producing a molded product having a series of alternating concave and convex shapes (see Figure 2). Figure 15 is a flowchart of an example of the operation of the continuous press-forming apparatus 1A. For ease of explanation, the positioning die 30 is omitted from Figure 14.

[0185] First, the sheet material M to be press-molded is conveyed a predetermined distance in the +X direction to place a portion p1 of the sheet material M to be press-molded between the upper preheating die 11 and the lower preheating die 12 (see FIG. 14(a)). This is achieved as follows: First, as shown in FIG. 15, the gripping mechanism 51 grips the sheet material M to be press-molded (step S40).

[0186] Next, the movement mechanism 52 moves (slides) the slider 52a, on which the gripping mechanism 51 gripping the press-molding target sheet material M as described above, a predetermined distance in the +X direction (step S41). Next, the gripping mechanism 51 releases the grip on the press-molding target sheet material M (step S42). As a result, the press-molding target sheet material M is transported a predetermined distance in the +X direction, and the portion p1 of the press-molding target sheet material M is positioned between the upper preheating mold 11 and the lower preheating mold 12 (see FIG. 14(a)).

[0187] Next, at the timing when the gripping mechanism 51 releases its grip on the press-molding target sheet material M (see grip release timing TM1 in FIG. 15), the preheating mold 10 is clamped (step S60) to the portion p1 of the press-molding target sheet material M arranged as described above (see FIG. 14(b)). The preheating mold 10 is clamped (step S60) by the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwiching the portion p1 of the press-molding target sheet material M arranged therebetween and heating and pressurizing it at a predetermined pressure.

[0188] At the same time, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 that has released its grip on the sheet material M to be press-molded as described above, in the -X direction, and returns it to its initial position before conveyance (step S43, see FIG. 14(b)). In this way, the return of the moving mechanism 52 (slider 52a) to its initial position (step S43) is performed in parallel with the clamping of the preheating mold 10 (step S60) (see FIG. 15).

[0189] Next, the preheating mold 10 is opened (step S61) (see FIG. 14(c)). At the same time, at the timing of opening the preheating mold 10 (see intermediate mold opening timing TM2 in FIG. 15), the press-molding target sheet material M is transported one pitch in the +X direction (see FIG. 14(d)). This is achieved as follows. First, as shown in FIG. 14(c), the gripping mechanism 51 grips the press-molding target sheet material M (step S44). Next, as shown in FIG. 14(d), the moving mechanism 52 moves (slides) the slider 52a, on which the gripping mechanism 51 gripping the press-molding target sheet material M as described above, one pitch in the +X direction (step S45). Next, the gripping mechanism 51 releases its grip on the press-molding target sheet material M (step S46).

[0190] As a result, the press-molding target sheet material M is transported one pitch in the +X direction, and a portion p1 (preheated portion) of the press-molding target sheet material M is positioned between the upper shaping mold 21A and the lower shaping mold 22 (see FIG. 14(d)). Also, a portion p2 of the press-molding target sheet material M is positioned between the upper preheating mold 11 and the lower preheating mold 12 (see FIG. 14(d)). In this way, the gripping of the press-molding target sheet material M (step S44), the one-pitch movement of the press-molding target sheet material M (step S45), and the release of the gripping of the press-molding target sheet material M (step S46) are carried out in parallel with the mold opening of the preheating mold 10 (step S61) (see FIG. 15).

[0191] Next, when the gripping mechanism 51 releases its grip on the press-molding target sheet material M (see grip release timing TM3 in FIG. 15), each mold is clamped (step S62) (see FIG. 14(e)). Specifically, as described above, the shaping mold 20A (clamping of the first half upper shaping mold 21A1 and the second half upper shaping mold 21A2) is performed on the portion p1 (preheated portion) of the press-molding target sheet material M arranged between the upper shaping mold 21A (the first half upper shaping mold 21A1 and the second half upper shaping mold 21A2) and the lower shaping mold 22 (see FIGS. 14(e) and 14(f)). In addition, the preheating mold 10 is clamped on the portion p2 of the press-molding target sheet material M arranged between the upper preheating mold 11 and the lower preheating mold 12 (see FIGS. 14(e) and 14(f)).

[0192] The second upper half shaping mold 21A2 and the first upper half shaping mold 21A1 are clamped in this order by performing the clamping process (see FIG. 13) and lowering the upper mold platen 70A. By clamping the second upper half shaping mold 21A2 and the first upper half shaping mold 21A1 at different times, the convex shape 21c1 on the press surface of the first upper half shaping mold 21A1 and the convex shape 21c2 on the press surface of the second upper half shaping mold 21A2 press the press-molded sheet material M into the concave shape 22c on the press surface of the lower shaping mold 22 at different times. This prevents the press-molded sheet material M from being pulled when the press-molded sheet material M is pressed into the concave shape 22c on the press surface of the lower shaping mold 22, which has the advantage of preventing damage to the press-molded sheet material M (molded product).

[0193] At this time, the lower shaping die 22 attached to the lower platen 70B pushes up the second half upper shaping die 21A2 in the +Z direction. This causes the second half upper shaping die 21A2 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96C arranged between the second half upper shaping die 21A2 and the upper platen 70A to elastically deform, and the second half upper shaping die 21A2 is urged toward the lower shaping die 22 by the elastically deformed elastic body 96C.

[0194] Therefore, the clamping of the second half-split upper shaping mold 21A2 is carried out by the half-split press surface (flat surface 21b and half-split convex shape 21c2) of the second half-split upper shaping mold 21A2, which is biased toward the lower shaping mold 22 by the elastic body 96C, and the lower press surface (flat surface 22b and concave shape 22c) of the lower shaping mold sandwiching and pressurizing (heating and pressurizing) the portion p1 (pre-heated portion) of the sheet material M to be press-molded, which is placed between them.

[0195] On the other hand, the clamping of the first half-split upper shaping mold 21A1 is carried out by sandwiching and applying pressure (heating and pressing) to the half-split press surface (flat surface 21a and half-split convex shape 21c1) of the first half-split upper shaping mold 21A1 and the lower press surface (flat surface 22a and concave shape 22c) of the lower shaping mold, and the portion p1 (pre-heated portion) of the sheet material M to be press-molded that is placed between them.

[0196] At this time, as the second half-split upper shaping mold 21A2 moves in a direction approaching the upper mold plate 70A (+Z direction), the protrusion 21A2a (see enlarged view in circle C2 in Figure 11) provided at the lower end of the second half-split upper shaping mold 21A2 is inserted into the gap S1 (see enlarged view in circle C2 in Figure 11) between the lower end of the first half-split upper shaping mold 21A1 and the lower end of the second half-split upper shaping mold 21A2, widening the gap S1 in the X-axis direction.

[0197] This further pressurizes the half press surface (inclined surface 21A1a of half convex shape 21c1) of the first half upper shaping die 21A1, the half press surface (inclined surface 21A2c of half convex shape 21c2) of the second half upper shaping die 21A2, and the lower press surface (inclined surfaces 22c1, 22c2 of concave shape 22c) of the lower shaping die 22. This further pressurizes portion p1 of the press-molded sheet material M compared to when the protrusion 21A2a is not provided. This improves the internal quality of the press-molded sheet material M. For example, defects such as voids inside the press-molded sheet material M can be eliminated or reduced.

[0198] In addition, the preheating mold 10 is clamped by the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwiching the portion p2 of the sheet material M to be press-molded between them and heating and pressing it at a predetermined pressure.

[0199] Simultaneously with the clamping of each mold (step S62), the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 that has released its grip on the sheet material M to be press-molded as described above, in the -X direction, and returns it to its initial position before conveyance (step S47; see FIG. 14(f)). In this way, the return of the moving mechanism 52 (slider 52a) to its initial position (step S47) is performed in parallel with the clamping of each mold (step S62) (see FIG. 15).

[0200] Next, each mold is opened (step S63) (see FIG. 14(g)). At the same time, at the timing of opening each mold (see middle mold opening timing TM4 in FIG. 15), for example, at the timing when the mold clamping process (see FIG. 13) is completed, the press-molding target sheet material M is conveyed one pitch in the +X direction (see FIG. 14(h)). This is achieved as follows. First, as shown in FIG. 14(g), the gripping mechanism 51 grips the press-molding target sheet material M (step S48). Next, as shown in FIG. 14(h), the moving mechanism 52 moves (slides) the slider 52a, on which the gripping mechanism 51 gripping the press-molding target sheet material M as described above is placed, one pitch in the +X direction (step S49).

[0201] Next, the gripping mechanism 51 releases the grip on the press-molding target sheet material M (step S50). As a result, the press-molding target sheet material M is transported one pitch in the +X direction, and a portion p1 (shaping portion) of the press-molding target sheet material M is disposed between the upper positioning die 31 (not shown in FIG. 14) and the lower positioning die 32 (not shown in FIG. 14) (see FIG. 14(h)). In addition, a portion p2 (preheating portion) of the press-molding target sheet material M is disposed between the upper shaping die 21A and the lower shaping die 22 (see FIG. 14(h)).

[0202] Furthermore, a portion p3 of the press-molding target sheet material M is disposed between the upper preheating mold 11 and the lower preheating mold 12 (see FIG. 14(h)). In this manner, the gripping of the press-molding target sheet material M (step S48), the one-pitch movement of the press-molding target sheet material M (step S49), and the release of the gripping of the press-molding target sheet material M (step S50) are carried out in parallel with the mold opening of each mold (step S63) (see FIG. 15).

[0203] Next, when the gripping mechanism 51 releases its grip on the press-molding target sheet material M (see grip release timing TM5 in FIG. 15), each mold is clamped (step S64) (not shown). Specifically, the positioning mold 30 is clamped to the portion p1 (shaping portion) of the press-molding target sheet material M arranged between the upper positioning mold 31 and the lower positioning mold 32 as described above. Also, the shaping mold 20A (clamping of the first half upper shaping mold 21A1 and the second half upper shaping mold 21A2) is clamped to the portion p2 (preheated portion) of the press-molding target sheet material M arranged between the upper shaping mold 21A (first half upper shaping mold 21A1 and second half upper shaping mold 21A2) and the lower shaping mold 22. Also, the preheating mold 10 is clamped to the portion p3 of the press-molding target sheet material M arranged between the upper preheating mold 11 and the lower preheating mold 12.

[0204] The clamping of the positioning die 30, the clamping of the second upper half shaping die 21A2, and the clamping of the first upper half shaping die 21A1 are performed in this order by executing the clamping process (see FIG. 13) and lowering the upper mold platen 70A. By clamping the positioning die 30, the clamping of the second upper half shaping die 21A2, and the clamping of the first upper half shaping die 21A1 at different times in this way, the convex shapes (plural) on the press surfaces of the upper dies (upper positioning die 31, second upper half shaping die 21A2, first upper half shaping die 21A1) press the sheet material M to be press-molded into the concave shapes (plural) on the press surfaces of the lower dies (lower positioning die 32, lower shaping die 22) at "different times." This prevents the sheet material M to be press-molded that is located between the concave shapes on the press surface of the lower mold (between the convex shapes on the press surface of the upper mold) from being pulled, which has the advantage of preventing damage to the sheet material M to be press-molded (molded product).

[0205] At this time, the lower positioning die 32 attached to the lower platen 70B pushes up the upper positioning die 31 in the +Z direction. This causes the upper positioning die 31 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96A arranged between the upper positioning die 31 and the upper platen 70A to elastically deform, and the upper positioning die 31 is urged toward the lower positioning die 32 by this elastically deformed elastic body 96A.

[0206] Therefore, the clamping of the positioning die 30 is carried out by the press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31, which is biased toward the lower positioning die 32 by the elastic body 96A, and the lower press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning die 32, clamping and applying pressure to the portion p1 (shaped portion) of the sheet material M to be press-molded, which is placed between them.

[0207] At the same time, the lower shaping die 22 attached to the lower platen 70B pushes up the second half upper shaping die 21A2 in the +Z direction. This causes the second half upper shaping die 21A2 to move in a direction (+Z direction) approaching the upper platen 70A, which causes the elastic body 96C arranged between the second half upper shaping die 21A2 and the upper platen 70A to elastically deform, and the second half upper shaping die 21A2 is urged toward the lower shaping die 22 by the elastically deformed elastic body 96C.

[0208] Therefore, the clamping of the second half-split upper shaping mold 21A2 is carried out by the half-split press surface (flat surface 21b and half-split convex shape 21c2) of the second half-split upper shaping mold 21A2, which is biased toward the lower shaping mold 22 by the elastic body 96C, and the lower press surface (flat surface 22b and concave shape 22c) of the lower shaping mold clamping and pressurizing (heating and pressurizing) the portion p2 (pre-heated portion) of the sheet material M to be press-molded, which is placed between them.

[0209] On the other hand, the clamping of the first half-split upper shaping mold 21A1 is carried out by sandwiching and pressurizing (heating and pressurizing) the portion p2 (pre-heated portion) of the sheet material M to be press-molded between the half-split press surface (flat surface 21a and half-split convex shape 21c1) of the first half-split upper shaping mold 21A1 and the lower press surface (flat surface 22a and concave shape 22c) of the lower shaping mold.

[0210] At this time, as the second half-split upper shaping mold 21A2 moves in a direction approaching the upper mold plate 70A (+Z direction), the protrusion 21A2a (see enlarged view in circle C2 in Figure 11) provided at the lower end of the second half-split upper shaping mold 21A2 is inserted into the gap S1 (see enlarged view in circle C2 in Figure 11) between the lower end of the first half-split upper shaping mold 21A1 and the lower end of the second half-split upper shaping mold 21A2, widening the gap S1 in the X-axis direction.

[0211] This further pressurizes the half press surface (inclined surface 21A1a of half convex shape 21c1) of the first half upper shaping die 21A1, the half press surface (inclined surface 21A2c of half convex shape 21c2) of the second half upper shaping die 21A2, and the lower press surface (inclined surfaces 22c1, 22c2 of concave shape 22c) of the lower shaping die 22. This further pressurizes portion p2 of the press-molded sheet material M compared to when no protrusion 21A2a is provided. This improves the internal quality of the press-molded sheet material M. For example, defects such as voids inside the press-molded sheet material M can be eliminated or reduced.

[0212] In addition, the preheating mold 10 is clamped by the upper press surface 11a of the upper preheating mold 11 and the lower press surface 11b of the lower preheating mold 12 sandwiching the portion p3 of the sheet material M to be press-molded between them and heating and pressurizing it at a predetermined pressure.

[0213] At the same time, the moving mechanism 52 slides the slider 52a, on which the gripping mechanism 51 that has released the grip of the sheet material M to be press-molded as described above, in the -X direction, and returns it to its initial position before conveyance (step S51). In this way, the return of the moving mechanism 52 (slider 52a) to its initial position (step S51) is performed in parallel with the clamping of each mold (step S64) (see FIG. 15).

[0214] Thereafter, the same processes as steps S48 to S51, S63, and S64 are repeatedly executed. At this time, the clamping of the positioning mold 30, the clamping of the second half upper shaping mold 21A2, the clamping of the first half upper shaping mold 21A1, and the opening of each mold are repeatedly and continuously executed in this order.

[0215] This makes it possible to manufacture a molded product having a series of alternating concave and convex shapes (see FIG. 2). The press-molding target sheet material M manufactured as described above (a molded product having a series of alternating concave and convex shapes) is then placed between the movable gripper 51b and the fixed gripper 51a of the conveying device 50B provided downstream, in a state in which it is placed on the upper surface (flat surface) of the movable gripper 51b (see FIG. 16(a)). The conveying device 50B provided downstream performs the same operation as the conveying device 50A provided upstream at the same timing with respect to the press-molding target sheet material M (a molded product having a series of alternating concave and convex shapes) that is placed between the movable gripper 51b and the fixed gripper 51a.

[0216] As described above, the conveying device 50 conveys the sheet material M to be press-molded so that each time each mold opening is performed for each mold (preheating mold 10, shaping mold 20A and positioning mold 30), a portion (preheated portion) of the sheet material M to be press-molded is positioned between the upper press surface of the upper shaping mold 21A (first half-split upper shaping mold 21A1 and second half-split upper shaping mold 21A2) and the lower press surface of the lower shaping mold 22, and a portion (shaped portion) of the sheet material M to be press-molded is positioned between the upper press surface of the upper positioning mold 31 and the lower press surface of the lower positioning mold 32.

[0217] Each operation of the conveying device 50 (gripping the sheet material M to be press-molded, moving the sheet material M to be press-molded by one pitch, releasing the grip of the sheet material M to be press-molded, and returning the moving mechanism 52 (slider 52a) to the initial position) is performed in parallel with the mold closing and mold opening (see FIG. 15). This allows the mold closing and mold opening to be performed continuously, making it possible to prevent the temperature of the sheet material M to be press-molded from decreasing during each operation of the conveying device 50.

[0218] As described above, according to the second embodiment, it is possible to provide a press device that can suppress damage to the sheet to be formed during press forming.

[0219] This is because the clamping of the positioning mold 30, the clamping of the second half-split upper shaping mold 21A2, and the clamping of the first half-split upper shaping mold 21A1 are performed in this order, i.e., at different times.

[0220] The invention made by the present inventor has been specifically described above based on embodiment 2, but it goes without saying that the present invention is not limited to the embodiment already described, and various modifications are possible within the scope of the gist of the invention.

[0221] For example, in the above-mentioned second embodiment, an example was described in which a first half-split upper shaping mold 21A1 having an upper press surface including half-split convex shape 21c1 is used as the first half-split upper shaping mold, a second half-split upper shaping mold 21A2 having an upper press surface including half-split convex shape 21c2 is used as the second half-split upper shaping mold, and a lower shaping mold 22 having a lower press surface including concave shape 22c into which convex shape 21c (half-split convex shapes 21c1, 21c2) fits is used as the lower shaping mold, but this is not limited to this.

[0222] Conversely, a first half-split upper shaping mold 21A1 having an upper press surface including a half-split concave shape may be used as the first half-split upper shaping mold, a second half-split upper shaping mold 21A2 having an upper press surface including a half-split concave shape may be used as the second half-split upper shaping mold, and a lower shaping mold 22 having a lower press surface including a convex shape 21c that fits into the half-split concave shape may be used as the lower shaping mold.

[0223] In the second embodiment, the protrusion 21A2a is provided at the lower end of the second upper half shaping mold 21A2, but this is not limiting. For example, the protrusion 21A2a may be provided at the lower end of the first upper half shaping mold 21A1.

[0224] Furthermore, in the second embodiment, an example in which the cooling mold 40 is omitted has been described, but the present invention is not limited to this. For example, the cooling mold 40 may be used as in the first embodiment.

[0225] Furthermore, in the above-described first and second embodiments, an example has been described in which a press-molding target sheet material M having nothing attached to its front and back surfaces is used, but this is not limiting. The same applies to the following third to sixth embodiments. For example, as shown in FIG. 17, a press-molding target sheet material M having a metal foil F attached to at least one of its front and back surfaces may be used. The metal foil F may be, for example, copper foil, but may also be another metal foil. In this way, the sheet material can be easily peeled from the mold without using a release agent. Furthermore, a molded product having a continuous alternating concave and convex shape with the metal foil F attached to its front and back surfaces can be produced. Furthermore, the surface is electrically conductive via the metal foil F, fulfilling functions such as connecting a ground wire. Furthermore, thermal conductivity is improved.

[0226] Furthermore, in the above-mentioned first and second embodiments, an example has been described in which the upper surface of the movable gripper 51b provided on the downstream side where the press-molded sheet material M (a molded product having a series of alternating concave and convex shapes) is flat (see, for example, FIG. 16(a)), but this is not limiting. FIG. 16(a) shows an example of the upper surface (flat surface) of the movable gripper 51b provided on the downstream side where the press-molded sheet material M (a molded product having a series of alternating concave and convex shapes) is placed.

[0227] For example, as shown in Fig. 16(b), the upper surface of the movable gripping part 51b provided on the downstream side may be formed with an uneven shape 51b1 that fits into the uneven shape formed in the press-molding target sheet material M. Fig. 16(b) shows another example (modified example) of the upper surface of the movable gripping part 51b provided on the downstream side on which the press-molding target sheet material M (a molded product having a series of alternating uneven shapes) is placed. The press-molding target sheet material M (a molded product having a series of alternating uneven shapes) may be placed on the upper surface of the movable gripping part 51b provided on the downstream side with the uneven shape 51b1 fitting into the uneven shape formed in the press-molding target sheet material M (see Fig. 16(b)).

[0228] In this way, when the gripping mechanism 51 grips the sheet material M to be press-molded, that is, when the movable gripping portion 51b rises and the movable gripping portion 51b lifts both widthwise ends of the sheet material M to be press-molded in the +Z direction and presses both widthwise ends of the lifted sheet material M to be press-molded against the upper fixed gripping portion 51a, the uneven shape formed in the sheet material M to be press-molded can be prevented from being crushed.

[0229] Furthermore, in the above-mentioned first and second embodiments, an example has been described in which the upper positioning mold 31, the upper cooling mold 41, and the second upper half shaping mold 21A2 are clamped in the above-mentioned order by being biased by the elastic body 96, but this is not limiting. For example, a mechanism including an actuator (e.g., an air cylinder) that clamps each mold (the shaping mold 20, the positioning mold 30, and the cooling mold 40) individually may be provided, and the clamping of each mold may be performed in the above-mentioned order by this mechanism.

[0230] Furthermore, in the above-mentioned first and second embodiments, an example has been described in which the preheating mold 10 is provided upstream (upstream in the conveying direction of the sheet material M to be press-molded) of the mold group (preheating mold 10, shaping mold 20, positioning mold 30, cooling mold 40) and a portion of the sheet material M to be press-molded is heated (preheated) by this preheating mold 10, but this is not limitative. For example, a heating device (e.g., an electric heater) may be provided upstream of the mold group (preheating mold 10, shaping mold 20, positioning mold 30, cooling mold 40) instead of the preheating mold 10, and a portion of the sheet material M to be press-molded may be heated (preheated) by this heating device.

[0231] <Third Embodiment> Hereinafter, as the third embodiment, a first example will be described in which an arc-shaped (fan-shaped) molded product (see FIG. 18) having alternating continuous concave and convex shapes is manufactured.

[0232] FIG. 18 is a perspective view of a molded product having an arc shape (fan shape) on which alternately continuous concave and convex shapes are molded.

[0233] This molded product (see FIG. 18) includes concave shapes Ma (plural) and convex shapes Mb (plural) arranged alternately in the circumferential direction. The concave shapes Ma extend from the inner diameter side toward the outer diameter side and are concave shapes with an inverted trapezoidal cross section. On the other hand, the convex shapes Mb extend from the inner diameter side toward the outer diameter side while spreading out in a fan shape and are convex shapes with a trapezoidal cross section. The depth H of the concave shapes Ma Ma is the same between the inner diameter side and the outer diameter side. Similarly, the height H of the convex shape Mb Mb is the same between the inner diameter side and the outer diameter side.

[0234] <Configuration example for manufacturing molded products (see Figure 18)> FIG. 19 is a top view (schematic diagram) of the continuous press-molding apparatus 1A.

[0235] The molded product (see FIG. 18) can be manufactured by a continuous press molding apparatus 1A shown in FIG.

[0236] The continuous press-forming apparatus 1A will be described below, focusing on the differences from the continuous press-forming apparatus 1 of the first embodiment.

[0237] 19, the continuous press molding apparatus 1A has the same configuration as the continuous press molding apparatus 1 of embodiment 1, and includes each mold (a shaping mold 20, a positioning mold 30, and a cooling mold 40). Note that the cooling mold 40 may be omitted.

[0238] Unlike the continuous press molding apparatus 1 of embodiment 1, the shaping dies 20 (upper shaping die 21, lower shaping die 22) are configured to have a trapezoidal (or arc-shaped) shape when viewed from above. That is, the upper shaping die 21 has an upper press surface that is trapezoidal (or arc-shaped) when viewed from above. Similarly, the lower shaping die 22 has a lower press surface that is trapezoidal (or arc-shaped) when viewed from above.

[0239] FIG. 20 is a perspective view of each mold (shaping mold 20, positioning mold 30, cooling mold 40) of the continuous press-molding apparatus 1A.

[0240] As shown in FIG. 20, the upper press surface of the upper shaping die 21 includes a convex shape 21c and flat surfaces 21a and 21b arranged on both sides thereof.

[0241] The convex shape 21c is, for example, a convex shape having an inverted trapezoidal cross section. The convex shape 21c extends linearly from the inner diameter side to the outer diameter side in correspondence with the concave shape Ma of the molded product (see FIG. 18). The height H of the convex shape 21c 21c The planes 21a and 21b correspond to the convex shape Mb and extend from the inner diameter side to the outer diameter side while widening in a fan shape.

[0242] On the other hand, the press surface of the lower shaping die 22 includes a concave shape 22c and flat surfaces 22a and 22b arranged on both sides thereof.

[0243] The recessed shape 22c is a recessed shape 22c into which the protruding shape 21c fits. The recessed shape 22c extends linearly from the inner diameter side to the outer diameter side in correspondence with the protruding shape 21c. The depth H of the recessed shape 22c 22c The planes 22a and 22b correspond to the planes 21a and 21b and extend from the inner diameter side to the outer diameter side while widening in a fan shape.

[0244] The press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31 is configured in a shape corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21, i.e., in a shape similar to the upper press surface of the upper shaping die 21. Similarly, the press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning die 32 is configured in a shape corresponding to the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22, i.e., in a shape similar to the lower press surface of the lower shaping die 22.

[0245] Similarly, the press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling die 41 is configured in a shape corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21, i.e., in a shape similar to the upper press surface of the upper shaping die 21. Similarly, the press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling die 42 is configured in a shape corresponding to the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22, i.e., in a shape similar to the lower press surface of the lower shaping die 22.

[0246] As shown in Fig. 19, the shaping die 20, positioning die 30, and cooling die 40 are arranged in this order in an arc shape along the conveying direction of the sheet material M to be press-molded. The gap (clearance) G1 between the shaping die 20 (upper shaping die 21 and lower shaping die 22) and the positioning die 30 (upper positioning die 31 and lower positioning die 32) is preferably as short as possible, for example, 1 mm. The same is true for the gap (clearance) G2 between the positioning die 30 (upper positioning die 31 and lower positioning die 32) and the cooling die 40 (upper cooling die 41 and lower cooling die 42).

[0247] In the third embodiment, unlike the first embodiment, the conveying device 50 (gripping mechanism 51) moves in an arc direction. Specifically, although not shown, the slider 52a of the conveying device 50 (gripping mechanism 51) is slidably attached to a guide rail extending in the arc direction. Therefore, the gripping mechanism 51 placed on the slider 52a moves in the arc direction along the guide rail extending in the arc direction. In FIG. 19, the symbol Ar1 indicates the movement direction of the conveying device 50A (gripping mechanism 51) provided on the upstream side. On the other hand, the symbol Ar2 in FIG. 19 indicates the movement direction of the conveying device 50B (gripping mechanism 51) provided on the downstream side.

[0248] Moreover, in the third embodiment, unlike the first embodiment, an arc-shaped sheet material M to be press-molded is used as shown in FIG.

[0249] Other than the above, the continuous press-forming apparatus 1A has the same configuration as the continuous press-forming apparatus 1 of the first embodiment.

[0250] <Operation example of continuous press forming device 1A> An example of the operation of the continuous press-molding apparatus 1A is similar to the example of the operation of the continuous press-molding apparatus 1 described in the first embodiment (see FIGS. 8 and 9), and therefore a description thereof will be omitted.

[0251] The continuous press-molding apparatus 1A having the above-described configuration can produce an arc-shaped molded product (see FIG. 18) having alternating, continuous concave and convex shapes formed therein.

[0252] As described above, according to the third embodiment, it is possible to provide a press device that can suppress damage to a sheet to be formed during press forming.

[0253] <Fourth Embodiment> Hereinafter, as the fourth embodiment, a second example will be described in which an arc-shaped (fan-shaped) molded product (see FIG. 18) having alternating continuous concave and convex shapes is manufactured.

[0254] FIG. 21 is a top view (schematic diagram) of the continuous press-molding apparatus 1B.

[0255] The molded product (see FIG. 18) can be manufactured by a continuous press molding apparatus 1B shown in FIG.

[0256] The continuous press-forming apparatus 1B will be described below, focusing on the differences from the continuous press-forming apparatus 1A of the third embodiment.

[0257] The continuous press molding apparatus 1B is equipped with an upper shaping die 21A instead of the upper shaping die 21 of the continuous press molding apparatus 1A of embodiment 3. Other than that, the continuous press molding apparatus 1B has the same configuration as the continuous press molding apparatus 1A of embodiment 3. Note that the cooling die 40 may be omitted.

[0258] 21, the upper shaping mold 21A includes a first half upper shaping mold 21A1 and a second half upper shaping mold 21A2 that are split in half in the horizontal direction. The first half upper shaping mold 21A1 and the second half upper shaping mold 21A2 correspond to two molds that are split roughly symmetrically by cutting the upper shaping mold 21 of embodiment 3 along a plane (DD cross section in FIG. 19).

[0259] Other than the above, the continuous press-forming apparatus 1B has the same configuration as the continuous press-forming apparatus 1A of the third embodiment.

[0260] <Operation example of continuous press forming device 1B> An example of the operation of the continuous press-molding apparatus 1B is similar to the example of the operation of the continuous press-molding apparatus 1 described in the second embodiment (see FIGS. 14 and 15), and therefore a description thereof will be omitted.

[0261] The continuous press-molding apparatus 1B having the above-described configuration can produce an arc-shaped molded product (see FIG. 18) in which alternating, continuous concave and convex shapes are formed.

[0262] As described above, according to the fourth embodiment, it is possible to provide a press device that can suppress damage to a sheet to be formed during press forming.

[0263] <Fifth Embodiment> Hereinafter, as the fifth embodiment, a first example of manufacturing an arc-shaped (fan-shaped) molded product (see FIG. 22) having alternating continuous concave and convex shapes will be described.

[0264] FIG. 22 is a perspective view of a molded product having an arc shape (fan shape) on which alternately continuous concave and convex shapes are molded.

[0265] This molded product (see FIG. 22) includes concave shapes Mc (plural) and convex shapes Md (plural) arranged alternately in the circumferential direction. The concave shapes Mc extend from the inner diameter side toward the outer diameter side and are concave shapes with an inverted trapezoidal cross section. On the other hand, the convex shapes Mb extend from the inner diameter side toward the outer diameter side while spreading out in a fan shape and are convex shapes with a trapezoidal cross section. The depth H of the concave shapes McMc The height H of the convex shape Mb is gradually reduced from the inner diameter side to the outer diameter side. Md becomes gradually lower from the inner diameter side to the outer diameter side.

[0266] <Configuration example for manufacturing molded products (see Figure 22)> FIG. 23 is a top view (schematic diagram) of the continuous press-molding apparatus 1C.

[0267] The molded product (see FIG. 22) can be manufactured by a continuous press molding apparatus 1C shown in FIG.

[0268] The continuous press-forming apparatus 1C will be described below, focusing on the differences from the continuous press-forming apparatus 1A of the third embodiment.

[0269] 23, the continuous press molding apparatus 1C has the same configuration as the continuous press molding apparatus 1A of embodiment 3, and includes each mold (shaping mold 20, positioning mold 30, cooling mold 40). Note that the cooling mold 40 may be omitted.

[0270] Unlike the continuous press molding apparatus 1 of embodiment 1, the shaping dies 20 (upper shaping die 21, lower shaping die 22) are configured to have a trapezoidal (or arc-shaped) shape when viewed from above. That is, the upper shaping die 21 has an upper press surface that is trapezoidal (or arc-shaped) when viewed from above. Similarly, the lower shaping die 22 has a lower press surface that is trapezoidal (or arc-shaped) when viewed from above.

[0271] FIG. 24 is a perspective view of each mold (shaping mold 20, positioning mold 30, cooling mold 40) of the continuous press-molding apparatus 1C.

[0272] As shown in FIG. 24, the upper press surface of the upper shaping die 21 includes a convex shape 21c and flat surfaces 21a and 21b arranged on both sides thereof.

[0273] The convex shape 21c is, for example, a convex shape having an inverted trapezoidal cross section. The convex shape 21c extends linearly from the inner diameter side to the outer diameter side in correspondence with the concave shape Mc of the molded product (see FIG. 22). The height H of the convex shape 21c 21c The flat surfaces 21a and 21b correspond to the convex shape Md and extend from the inner diameter side to the outer diameter side while widening in a fan shape.

[0274] On the other hand, the press surface of the lower shaping die 22 includes a concave shape 22c and flat surfaces 22a and 22b arranged on both sides thereof.

[0275] The recessed shape 22c is a recessed shape 22c into which the protruding shape 21c fits. The recessed shape 22c extends linearly from the inner diameter side to the outer diameter side in correspondence with the protruding shape 21c. The depth H of the recessed shape 22c 22c The flat surfaces 22a and 22b correspond to the flat surfaces 21a and 21b and extend from the inner diameter side to the outer diameter side while widening in a fan shape.

[0276] The press surface (flat surfaces 31a, 31b and convex shape 31c) of the upper positioning die 31 is configured in a shape corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21, i.e., in a shape similar to the upper press surface of the upper shaping die 21. Similarly, the press surface (flat surfaces 32a, 32b and concave shape 32c) of the lower positioning die 32 is configured in a shape corresponding to the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22, i.e., in a shape similar to the lower press surface of the lower shaping die 22.

[0277] Similarly, the press surface (flat surfaces 41a, 41b and convex shape 41c) of the upper cooling die 41 is configured in a shape corresponding to the upper press surface (flat surfaces 21a, 21b and convex shape 21c) of the upper shaping die 21, i.e., in a shape similar to the upper press surface of the upper shaping die 21. Similarly, the press surface (flat surfaces 42a, 42b and concave shape 42c) of the lower cooling die 42 is configured in a shape corresponding to the lower press surface (flat surfaces 22a, 22b and concave shape 22c) of the lower shaping die 22, i.e., in a shape similar to the lower press surface of the lower shaping die 22.

[0278] As shown in Figure 23, the shaping die 20, positioning die 30, and cooling die 40 are arranged in this order in an arc shape along the conveying direction of the sheet material M to be press-molded. The gap (clearance) G1 between the shaping die 20 (upper shaping die 21 and lower shaping die 22) and the positioning die 30 (upper positioning die 31 and lower positioning die 32) is preferably as short as possible, for example, 1 mm. The same is true for the gap (clearance) G2 between the positioning die 30 (upper positioning die 31 and lower positioning die 32) and the cooling die 40 (upper cooling die 41 and lower cooling die 42).

[0279] In the fifth embodiment, unlike the third embodiment, the conveying device 50 (gripping mechanism 51) is provided only on the upstream side (upstream side in the conveying direction of the press-molded sheet material M) of the die group (preheating die 10, shaping die 20, positioning die 30, cooling die 40). On the other hand, on the downstream side (downstream side in the conveying direction of the press-molded sheet material M) of the die group (preheating die 10, shaping die 20, positioning die 30, cooling die 40), a placing table 130 is provided on which a molded product (see FIG. 22) manufactured by passing through the die group (preheating die 10, shaping die 20, positioning die 30, cooling die 40) is placed. In FIG. 23, the symbol Ar3 indicates the moving direction of the conveying device 50A (gripping mechanism 51) provided on the upstream side. On the other hand, the symbol Ar4 in FIG. 23 indicates the conveying direction of the molded product (see FIG. 22).

[0280] In the fifth embodiment, similarly to the first and second embodiments, a linear sheet material M to be press-molded is used as shown in FIG.

[0281] Other than the above, the continuous press-forming apparatus 1C has the same configuration as the continuous press-forming apparatus 1A of the third embodiment.

[0282] <Operation example of continuous press forming device 1C> An example of the operation of the continuous press-molding apparatus 1C is similar to the example of the operation of the continuous press-molding apparatus 1A described in the third embodiment (see FIGS. 8 and 9), and therefore a description thereof will be omitted.

[0283] According to the continuous press-molding apparatus 1C having the above-described configuration, it is possible to manufacture a circular-arc shaped molded product (see FIG. 22) in which alternating continuous concave and convex shapes are formed.

[0284] As described above, according to the fifth embodiment, it is possible to provide a press device that can suppress damage to the sheet to be formed during press forming.

[0285] <Sixth Embodiment> Hereinafter, as the sixth embodiment, a second example will be described in which a molded product having an arc shape (fan shape) with alternating continuous concave and convex shapes (see FIG. 22) is manufactured.

[0286] FIG. 25 is a top view (schematic diagram) of the continuous press-molding apparatus 1D.

[0287] The molded product (see FIG. 22) can be manufactured by a continuous press molding apparatus 1D shown in FIG.

[0288] The continuous press-forming apparatus 1D will be described below, focusing on the differences from the continuous press-forming apparatus 1C of the fifth embodiment.

[0289] The continuous press molding apparatus 1D is equipped with an upper shaping die 21A instead of the upper shaping die 21 of the continuous press molding apparatus 1C of embodiment 5. Other than that, the continuous press molding apparatus 1D has the same configuration as the continuous press molding apparatus 1C of embodiment 5. Note that the cooling die 40 may be omitted.

[0290] As shown in Fig. 25, the upper shaping mold 21A includes a first half upper shaping mold 21A1 and a second half upper shaping mold 21A2 that are split in half in the horizontal direction. The first half upper shaping mold 21A1 and the second half upper shaping mold 21A2 correspond to two molds that are split roughly symmetrically by cutting the upper shaping mold 21 of embodiment 5 along a plane (EE cross section in Fig. 23).

[0291] Other than the above, the continuous press-forming apparatus 1D has the same configuration as the continuous press-forming apparatus 1C of the fifth embodiment.

[0292] <Example of operation of continuous press forming device 1D> An example of the operation of the continuous press-forming apparatus 1D is similar to the example of the operation of the continuous press-forming apparatus 1C described in the fifth embodiment (see FIGS. 14 and 15), and therefore a description thereof will be omitted.

[0293] The continuous press-molding apparatus 1D having the above-described configuration can produce an arc-shaped molded product (see FIG. 22) in which alternating, continuous concave and convex shapes are formed.

[0294] As described above, according to the sixth embodiment, it is possible to provide a press device that can suppress damage to the sheet to be formed during press forming. [Explanation of symbols]

[0295] 1...Pressing device 10...Preheating mold 11...Upper preheating mold 11a, 11b...pressed surface 12...Lower preheating mold 13...Electric heater 14...Air cylinder 20, 20A...Forming mold 21, 20A...Upper forming mold 21A1...First half-split upper forming mold 21A2...Second half-split upper forming mold 21A2a…Protrusion 21a, 21b...plane 21c…Convex shape 22...Lower forming mold 22a, 22b...plane 22c…Concave shape 23...Electric heater 30... Positioning mold 31...Upper positioning die 31a, 31b...plane 31c…Convex shape 32...Lower positioning die 32a, 32b...plane 32c…concave shape 40...Cooling mold 41...Upper cooling mold 41a, 41b...plane 41c…Convex shape 42...Lower cooling mold 42a, 42b...plane 42c…Concave shape 50, 50A, 50B...Transport device 51...Gripping mechanism 51a...Fixed grip part 51b...Movable grip part 51c...Air cylinder 52...Movement mechanism 52a...Slider 53...Electric motor 60...Control device 70A…Upper mold board 70B…Lower mold board 82A...Mounting plate 82B...Mounting plate 83A, 83B...heat insulating board 94...Bolt 94a...Head 94b...Shaft part 95...Step 96, 96A, 96B...Elastic body 100...Mold clamping mechanism 101...Ball screw 102...Electric motor 103…post 104…Upper fixed plate 110...Distance sensor 120...Pressure sensor B1~B7...Bolts G1~G3...Gap H1...Through hole H1a...Large diameter hole H1b…Small diameter hole H2…Through hole M: Sheet material for press molding p1~p4…part F...Metal foil

Claims

1. a shaping mold including an upper shaping mold having a first upper press surface that is trapezoidal in top view and includes one of a concave shape and a convex shape that fits into the concave shape, and a lower shaping mold having a first lower press surface that is trapezoidal in top view and includes the other of the concave shape and the convex shape; a positioning die including an upper positioning die having a second upper press surface that is trapezoidal in top view and corresponds to the first upper press surface, and a lower positioning die having a second lower press surface that is trapezoidal in top view and corresponds to the first lower press surface; a conveying device that conveys a sheet material to be press-molded, The clamping of the shaping mold is carried out by the first upper press surface of the upper shaping mold and the first lower press surface of the lower shaping mold sandwiching and pressing the preheated preheated portion of the press-molded sheet material arranged between them, The clamping of the positioning mold is carried out by sandwiching and applying pressure to the second upper press surface of the upper positioning mold and the second lower press surface of the lower positioning mold, the shaped portion of the press-molded sheet material arranged between them, which has been shaped by the shaping mold; The conveying device conveys the press-molded sheet material so that each time each mold is opened, a preheated portion of the press-molded sheet material is disposed between the first upper press surface of the upper shaping mold and the first lower press surface of the lower shaping mold, and the shaped portion of the press-molded sheet material is disposed between the second upper press surface of the upper positioning mold and the second lower press surface of the lower positioning mold; the shaping die and the positioning die are arranged in this order in an arc shape along a conveying direction of the press-molded sheet material, A continuous press molding device in which the clamping of the positioning mold and the clamping of the shaping mold are performed continuously in this order.

2. The first upper press surface of the upper shaping mold extends from the inner diameter side to the outer diameter side, and includes a convex shape having an inverted trapezoidal cross section and flat surfaces arranged on both sides thereof, The first lower press surface of the lower shaping mold extends from the inner diameter side to the outer diameter side, and includes a concave shape into which the convex shape of the inverted trapezoid shape of the first upper press surface fits, and flat surfaces arranged on both sides thereof, the second upper press surface of the upper positioning die extends from an inner diameter side toward an outer diameter side, and includes a convex shape having an inverted trapezoidal cross section and flat surfaces disposed on both sides thereof; The continuous press molding apparatus described in claim 1, wherein the second lower press surface of the lower positioning mold extends from the inner diameter side toward the outer diameter side and includes a concave shape into which the inverted trapezoidal convex shape of the second upper press surface fits, and flat surfaces arranged on both sides of the concave shape.

3. The height of the convex shape of the first upper press surface of the upper shaping mold is the same between the inner diameter side and the outer diameter side, The depth of the concave shape of the first lower press surface of the lower shaping mold is the same between the inner diameter side and the outer diameter side, the height of the convex shape of the second upper press surface of the upper positioning die is the same between the inner diameter side and the outer diameter side, a depth of the concave shape of the second lower press surface of the lower positioning die is the same between an inner diameter side and an outer diameter side; The continuous press-forming apparatus according to claim 2 , wherein the sheet material to be press-formed has an arc shape.

4. The height of the convex shape of the first upper press surface of the upper shaping mold gradually decreases from the inner diameter side toward the outer diameter side, The depth of the concave shape of the first lower press surface of the lower shaping die gradually becomes shallower from the inner diameter side toward the outer diameter side, a height of the convex shape of the second upper press surface of the upper positioning die gradually decreases from an inner diameter side toward an outer diameter side, a depth of the concave shape of the second lower press surface of the lower positioning die gradually decreases from an inner diameter side toward an outer diameter side, The continuous press-forming apparatus according to claim 2 , wherein the sheet material to be press-formed has a linear shape.

5. The upper shaping mold includes a first half upper shaping mold and a second half upper shaping mold that are split in half horizontally, The first half upper shaping mold has one half press surface of the first upper press surface, The second half upper shaping mold has the other half press surface that is half of the first upper press surface, The first half-split upper shaping die, the second half-split upper shaping die, and the positioning die are arranged in this order in an arc shape along the conveying direction of the press-molded sheet material, The clamping of the first half upper shaping mold is carried out by sandwiching and pressurizing the preheated preheated portion of the press-molded sheet material arranged between the one half press surface of the first half upper shaping mold and the first lower press surface of the lower shaping mold, The clamping of the second half upper shaping mold is carried out by the other half press surface of the second half upper shaping mold and the first lower press surface of the lower shaping mold sandwiching and pressing the preheated preheated portion of the press-molded sheet material arranged between them, The clamping of the positioning mold is carried out by sandwiching and applying pressure to the second upper press surface of the upper positioning mold and the second lower press surface of the lower positioning mold, the shaped portion of the press-molded sheet material arranged between them, which has been shaped by the shaping mold; A continuous press molding apparatus as described in claim 1, in which the clamping of the positioning mold, the clamping of the second half-split upper shaping mold, the clamping of the first half-split upper shaping mold, and the opening of each mold are repeatedly performed in this order.

6. an upper die having an upper press surface that is trapezoidal in top view and includes one of a concave shape and a convex shape that fits into the concave shape; a lower die having a lower press surface that is trapezoidal in top view and includes the other of the concave shape and the convex shape; the upper press surface extends from the inner diameter side toward the outer diameter side, and includes a convex shape having an inverted trapezoidal cross section and flat surfaces disposed on both sides of the convex shape; The lower press surface extends from the inner diameter side toward the outer diameter side, and includes a concave shape into which the inverted trapezoidal convex shape of the upper press surface fits, and flat surfaces arranged on both sides of the concave shape.

7. the height of the convex shape of the upper press surface is the same between the inner diameter side and the outer diameter side, The mold according to claim 6 , wherein the depth of the concave shape of the lower press surface is the same on the inner diameter side and the outer diameter side.

8. the height of the convex shape of the upper press surface gradually decreases from the inner diameter side toward the outer diameter side, The mold according to claim 6 , wherein the depth of the concave shape of the lower press surface gradually decreases from the inner diameter side toward the outer diameter side.

9. The upper mold includes a first half mold and a second half mold that are split in half in the horizontal direction, The first half mold has one half press surface of the upper press surface, The mold according to any one of claims 6 to 8, wherein the second half mold has the other half press surface that is the other half of the upper press surface.

10. A molded product having an arc shape in which alternating continuous concave and convex shapes are formed by performing press molding on a press-molded sheet material, the concave shape extends from an inner diameter side toward an outer diameter side and has a cross-sectional shape of an inverted trapezoid, The convex shape extends from the inner diameter side toward the outer diameter side, widening like a fan, and has a trapezoidal cross-sectional shape.

11. The molded product according to claim 10, wherein the depth of the recessed shape is the same on the inner diameter side and the outer diameter side.

12. The molded product according to claim 10, wherein the depth of the recessed shape gradually decreases from the inner diameter side toward the outer diameter side.

13. The molded article according to any one of claims 10 to 12, wherein a metal foil is attached to at least one of the front and back surfaces of the molded article.

Images