Forming device

Abstract

To mold a sheet-like molded product having protrusions with high precision. [Solution] Both the first processing roll 31 and the second processing roll 32 have recesses 311 and 321 formed in their outer peripheral walls. The first flow path section 51 is partitioned by the outer surface of the resin supply section 36 and the outer peripheral surface of the first processing roll 31, and extends along the outer peripheral surface of the first processing roll 31. The second flow path section 52 is partitioned by the outer surface of the resin supply section 36 and the outer peripheral surface of the second processing roll 32, and extends along the outer peripheral surface of the second processing roll 32. The confluence section 53 is partitioned by the outer surface of the resin supply section 36, the outer peripheral surface of the first processing roll 31, and the outer peripheral surface of the second processing roll 32, and constitutes the confluence portion of the first flow path section 51 and the second flow path section 52. The resin supply unit 36 ​​has a first passage 41 that opens at the first flow channel 51 and supplies molten resin material to the first flow channel 51, and a second passage 42 that opens at the second flow channel 52 and supplies molten resin material to the second flow channel 52.

Description

Technical Field

[0001] The present invention relates to a molding device.

Background Art

[0002] Patent Document 1 describes a molding device for molding a sheet-shaped molded product by extrusion molding. This molding device includes a pair of processing rolls and one die. Each processing roll has a cylindrical shape and is arranged such that the outer peripheral surfaces face each other. Each processing roll is rotationally driven in opposite directions. The die supplies a molten resin material between the pair of processing rolls. In the above molding device, the molten resin material supplied by the die is sent out in a direction away from the die by the pair of processing rolls, thereby forming a sheet-shaped molded product.

[0003] Conventionally, a laminated composite part including a base material and a sheet-shaped deformation member having a plurality of protrusions that protrude toward the base material and are bendable and deformable has been disclosed. In this composite part, when the deformation member is pushed into the base material, at least a part of the plurality of protrusions comes into contact with the base material and bends and deforms. Therefore, it is possible to present a feeling similar to that of a composite part in which a foaming material such as urethane foam is embedded to the user.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Here, it is conceivable to form a deformable member of a superimposed composite component, more specifically a sheet-like molded product having protrusions, using the above-mentioned molding apparatus. In this case, by providing recesses for forming protrusions on the outer circumferential wall of the processing roll, it becomes possible to form a sheet-like molded product having protrusions.

[0006] However, when molding a sheet-like molded product having protrusions using the above-described molding apparatus, it is necessary to fill the recesses with the molten resin material during the limited period (hereinafter referred to as the molding period) in which the molten resin material passes between a pair of processing rolls. If the molding period is insufficient, there is a risk of a phenomenon known as a short shot occurring, in which the recesses cannot be sufficiently filled with the molten resin material.

[0007] Furthermore, in the above case, it is necessary to sufficiently cool the molten resin material during the limited period from when it is supplied from the die until it passes through the pair of processing rolls and is sent out (hereinafter referred to as the cooling period). If the cooling period is insufficient, the temperature of the molten resin material will not drop sufficiently, which may cause the protrusions of the molded product to deform unnecessarily when the molded product is demolded. [Means for solving the problem]

[0008] A molding apparatus for solving the above problems comprises a cylindrical first processing roll, a cylindrical second processing roll arranged such that its central axis extends parallel to the first processing roll and its outer surfaces face each other, and a resin supply unit for supplying molten resin material between the first processing roll and the second processing roll, wherein the molten resin material supplied by the resin supply unit is fed away from the resin supply unit by the first processing roll and the second processing roll, which are rotated in opposite directions to each other, thereby forming a sheet-like molded product, wherein at least one of the first processing roll and the second processing roll has a recess formed in its outer wall, and the molding apparatus The resin supply unit comprises: a first flow path section formed by the outer surface of the resin supply unit and the outer surface of the first processing roll, extending along the outer surface of the first processing roll; a second flow path section formed by the outer surface of the resin supply unit and the outer surface of the second processing roll, extending along the outer surface of the second processing roll; and a junction section formed by the outer surface of the resin supply unit, the outer surface of the first processing roll, and the outer surface of the second processing roll, constituting a junction between the first flow path section and the second flow path section. The resin supply unit has a first passage that opens in the first flow path section and supplies the molten resin material to the first flow path section; and a second passage that opens in the second flow path section and supplies the molten resin material to the second flow path section. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a side cross-sectional view of a molding apparatus according to one embodiment. [Figure 2] Figure 2 is a side cross-sectional view of a superimposed composite component. [Figure 3] Figure 3 is a perspective view of the intermediate member. [Figure 4] Figure 4 is a plan view of the intermediate member. [Figure 5] Figure 5 is a perspective view of the molding apparatus of the same embodiment. [Figure 6] Figure 6 is a plan view of the molding apparatus of the same embodiment. [Figure 7] Figure 7 is an enlarged plan view showing the three types of protrusions. [Figure 8] Figure 8 is a diagram illustrating the process of how a molded product is formed. [Figure 9] Figure 9 is a diagram showing how molten resin material flows into the recess. [Figure 10] Figure 10 is a diagram illustrating how the extended wall portion suppresses leakage of the molten resin material. [Figure 11] Figure 11 is a diagram illustrating how the leakage of molten resin material is suppressed by the barrier wall. [Modes for carrying out the invention]

[0010] A molding apparatus of one embodiment will be described below with reference to Figures 1 to 11. The molding apparatus of this embodiment is used to mold sheet-like molded products having protrusions. First, we will explain the molded products formed by the molding apparatus, referring to Figures 2 to 4.

[0011] As shown in Figure 2, the molded intermediate member 20 constitutes a part of the overlapping composite part (hereinafter referred to as the interior part 10). The interior part 10 is, for example, a door trim for an automobile. The interior part 10 comprises a base material 11 and a thin, plate-like surface material 12 that covers the base material 11. The intermediate member 20 is provided between the base material 11 and the surface material 12. The interior part 10 is formed by overlapping the base material 11, the intermediate member 20, and the surface material 12. The intermediate member 20 is made of a soft resin material such as soft polyvinyl chloride.

[0012] <Intermediate member 20> As shown in FIGS. 2 and 3, the intermediate member 20 has a base portion 21 and projections 22. The base portion 21 and the projections 22 are integrally formed. The base portion 21 is in a sheet shape. A plurality of projections 22 are provided on both surfaces of the base portion 21 in the thickness direction, respectively. Specifically, a plurality of projections 22 are provided on the opposing surface of the base portion 21 facing the base material 11. Also, a plurality of projections 22 are provided on the opposing surface of the base portion 21 facing the skin material 12. In the present embodiment, the arrangement pattern of the projections 22 on each opposing surface is the same.

[0013] As shown in FIGS. 3 and 4, each projection 22 is a substantially quadrangular pyramid, and all corners are rounded. The protruding direction of each projection 22 is inclined by a predetermined angle with respect to the normal line of the base portion 21 (specifically, the above-mentioned opposing surface).

[0014] As shown in FIG. 4, in the present embodiment, virtual lines forming a polygonal lattice (hereinafter, virtual lattice 25) are set on each opposing surface of the base portion 21. In the present embodiment, as the polygonal lattice of the virtual lattice 25, a regular hexagonal lattice composed of a plurality of regular hexagons (hereinafter, hexagon 26) is adopted. The projections 22 are provided at positions corresponding to the sides (hereinafter, side 27) of the hexagon 26. Specifically, for one hexagon 26, a total of six projections 22 are provided, one on each of the six sides 27. Each projection 22 is provided such that its base end portion is located on the side 27 of the hexagon 26 on the opposing surface of the base portion 21. The projections 22 provided on two opposing sides 27 in the same hexagon 26 protrude in a state of being inclined in the same direction. Also, the projections 22 provided on adjacent sides 27 protrude in a state of being inclined in different directions from each other.

[0015] <Forming device 30> Hereinafter, the forming device 30 of the present embodiment will be described. As shown in FIGS. 1, 5, and 6, the forming device 30 includes a first processing roll 31 and a second processing roll 32.

[0016] <The first processing roll 31 and the second processing roll 32> The first processing roll 31 and the second processing roll 32 are formed of porous steel material and are cylindrical. The first processing roll 31 and the second processing roll 32 have a cylindrical outer peripheral surface. The first processing roll 31 and the second processing roll 32 are arranged such that their central axes extend parallel to each other and their outer peripheral surfaces face each other.

[0017] The forming device 30 includes a pair of columns 33. The pair of columns 33 are provided at intervals in the direction in which the central axis extends (hereinafter referred to as the central axis direction X) and extend in the arrangement direction Z (the vertical direction in FIG. 1) of the first processing roll 31 and the second processing roll 32. The first processing roll 31 and the second processing roll 32 are rotatably installed between the pair of columns 33. When the intermediate member 20 is formed by the forming device 30, the first processing roll 31 and the second processing roll 32 are rotationally driven in opposite directions about their respective central axes as the rotation centers.

[0018] <First recess 311> As shown in FIG. 1, a plurality of first recesses 311 are formed in the outer peripheral wall of the first processing roll 31. The first recesses 311 are recesses for forming the protrusions 22 (see FIG. 3). The first recesses 311 are arranged in the same manner as the arrangement pattern of the protrusions 22 on each opposing surface of the base portion 21. In FIGS. 1, 8 to 11, in order to facilitate the understanding of the first recesses 311 and the second recesses 321 to be described later, the recesses 311, 321 are schematically shown.

[0019] As shown in FIG. 7, three types of protrusions 22A, 22B, 22C having different protruding directions are formed on each opposing surface of the base portion 21. On the outer peripheral wall of the first processing roll 31 (see FIG. 1), three types of first recesses 311 for forming the three types of protrusions 22A, 22B, 22C are provided.

[0020] In the following, the direction from the opening of the first recess 311 toward the bottom on the outer peripheral wall of the first processing roll 31 will be referred to as the "first orientation," and the direction toward the front side in the rotational direction of the first processing roll 31 on the outer peripheral wall of the first processing roll 31 will be referred to as the "second orientation." Furthermore, the plane that is in contact with the portion of the outer peripheral surface of the first processing roll 31 where the first recess 311 opens will be referred to as the "first virtual plane."

[0021] The first recess 311 for forming the projection 22A is formed on the outer circumferential wall of the first processing roll 31 such that when the first orientation and the second orientation are projected onto the first virtual plane, the angle between the projected first orientation and the second orientation is "60 degrees". As a result, when viewed from the thickness direction of the base portion 21, the angle RA between the projection direction of the projection 22A (indicated by arrow A in Figure 7) and the feeding direction (indicated by arrow Y in Figure 7) in which the intermediate member 20 is fed out with the first processing roll 31 is "60 degrees". In this embodiment, the feeding direction Y is perpendicular to both the central axis direction X and the alignment direction Z.

[0022] Furthermore, the first recess 311 for forming the projection 22B is formed on the outer circumferential wall of the first processing roll 31 such that when the first orientation and the second orientation are projected onto the first virtual plane, the angle between the projected first orientation and the second orientation is "180 degrees". As a result, when viewed from the thickness direction of the base portion 21, the angle RB between the projection direction of the projection 22B (indicated by arrow B in Figure 7) and the feeding direction Y in which the intermediate member 20 is fed out with the first processing roll 31 is "180 degrees".

[0023] Furthermore, the first recess 311 for forming the protrusion 22C is formed on the outer circumferential wall of the first processing roll 31 such that when the first orientation and the second orientation are projected onto the first virtual plane, the angle between the projected first orientation and the second orientation is "300 degrees". As a result, when viewed from the thickness direction of the base portion 21, the angle RC between the protruding direction of the protrusion 22C (indicated by arrow C in Figure 7) and the feeding direction Y in which the intermediate member 20 is fed out with the first processing roll 31 becomes "300 degrees".

[0024] In this embodiment, each of the three types of first recesses 311 has a shape such that when the first orientation and the second orientation are projected onto the first virtual plane, the projected first orientation and the second orientation face different directions.

[0025] <Second recess 321> As shown in Figure 1, a plurality of second recesses 321 are formed on the outer peripheral wall of the second processing roll 32. The second recesses 321 are holes for forming the projections 22 (see Figure 3). The second recesses 321 are arranged in the same manner as the projections 22 on each opposing surface of the base portion 21.

[0026] In the following, the direction from the opening of the second recess 321 toward the bottom on the outer peripheral wall of the second processing roll 32 will be referred to as the "third direction," and the direction toward the front side in the rotational direction of the second processing roll 32 on the outer peripheral wall of the second processing roll 32 will be referred to as the "fourth direction." Furthermore, the plane that is in contact with the portion of the outer peripheral surface of the second processing roll 32 where the second recess 321 opens will be referred to as the "second virtual plane."

[0027] The outer circumferential wall of the second processing roll 32 is provided with three types of second recesses 321 for forming three types of protrusions 22A, 22B, and 22C (see Figure 7). The second recess 321 for forming the projection 22A is formed on the outer circumferential wall of the second processing roll 32 such that when the third orientation and the fourth orientation are projected onto the second virtual plane, the angle between the projected third orientation and the fourth orientation is "60 degrees". As a result, as shown in Figure 7, when viewed from the thickness direction of the base portion 21, the angle RA between the projection direction of the projection 22A (indicated by arrow A in Figure 7) and the feeding direction Y in which the intermediate member 20 is fed out with the second processing roll 32 is "60 degrees".

[0028] Furthermore, the second recess 321 for forming the projection 22B is formed on the outer circumferential wall of the second processing roll 32 such that when the third orientation and the fourth orientation are projected onto the second virtual plane, the angle between the projected third orientation and the fourth orientation is "180 degrees". As a result, when viewed from the thickness direction of the base portion 21, the angle RB between the projection direction of the projection 22B (indicated by arrow B in Figure 7) and the feeding direction Y in which the intermediate member 20 is fed out with the second processing roll 32 is "180 degrees".

[0029] Furthermore, the second recess 321 for forming the protrusion 22C is formed on the outer circumferential wall of the second processing roll 32 such that when the third and fourth orientations are projected onto the second virtual plane, the angle between the projected third and fourth orientations is "300 degrees". As a result, when viewed from the thickness direction of the base portion 21, the angle RC between the protruding direction of the protrusion 22C (indicated by arrow C in Figure 7) and the feeding direction Y in which the intermediate member 20 is fed out with the second processing roll 32 is "300 degrees".

[0030] In this embodiment, each of the three types of second recesses 321 has a shape such that when the third orientation and the fourth orientation are projected onto the second virtual plane, the projected third orientation and the fourth orientation face different directions.

[0031] As shown in Figures 1, 5, and 6, the molding apparatus 30 includes a resin supply device 34 that supplies molten resin material RM between the first processing roll 31 and the second processing roll 32. The resin supply device 34 has a dispensing device 35 and a resin supply section 36.

[0032] The dispensing device 35 heats and melts the resin material used for molding the intermediate member 20 and sends it to the resin supply unit 36. <Resin supply unit 36> As shown in Figures 1 and 5, the resin supply unit 36 ​​has a first passage 41 and a second passage 42. Molten resin material RM supplied from the dispensing device 35 flows into the first passage 41 and the second passage 42. The first passage 41 and the second passage 42 guide and supply the molten resin material RM between the first processing roll 31 and the second processing roll 32. In this embodiment, the temperature of the resin supply unit 36 ​​is set to a temperature high enough to maintain the molten resin material RM in a molten state.

[0033] As shown in Figure 1, in the molding apparatus 30, a first flow channel 51, a second flow channel 52, and a merging section 53 are provided between the pair of processing rolls 31 and 32 and the resin supply unit 36. The first flow channel 51, the second flow channel 52, and the merging section 53 all constitute a part of the flow channel for the molten resin material RM. In this embodiment, the first flow channel 51, the second flow channel 52, and the merging section 53 are all parts to which the molten resin material RM supplied from the delivery device 35 is supplied.

[0034] The first flow path section 51 is a flow path demarcated by the outer circumferential surface of the first processing roll 31 and the outer surface of the resin supply section 36, more specifically, the portion of the outer surface facing the first processing roll 31. The first flow path section 51 extends along the outer circumferential surface of the first processing roll 31. The first flow path section 51 has a circular arc cross-section and extends in the direction of the central axis X.

[0035] The second flow path section 52 is a flow path demarcated by the outer circumferential surface of the second processing roll 32 and the outer surface of the resin supply section 36, more specifically, the portion of the outer surface facing the second processing roll 32. The second flow path section 52 extends along the outer circumferential surface of the second processing roll 32. The second flow path section 52 has a circular arc cross-section and extends in the direction of the central axis X.

[0036] The confluence section 53 is a flow path partitioned by the outer surface of the resin supply section 36, the outer surface of the first processing roll 31, and the outer surface of the second processing roll 32. The confluence section 53 constitutes the confluence portion where the first flow path section 51 and the second flow path section 52 merge.

[0037] <1st aisle 41> The first passage 41 of the resin supply unit 36 ​​extends in a manner that connects the delivery device 35 and the first flow channel 51. The upstream end of the first passage 41 in the flow direction of the molten resin material RM (hereinafter simply referred to as the "upstream side") is connected to the outlet of the delivery device 35. The downstream end of the first passage 41 in the flow direction of the molten resin material RM (hereinafter simply referred to as the "downstream side") is open in the first flow channel 51. In this embodiment, the molten resin material RM delivered from the delivery device 35 is fed into the first flow channel 51 via the first passage 41.

[0038] The first passage 41 extends at an inclination with respect to the horizontal direction such that it is positioned lower as it approaches the first flow channel 51. In the first passage 41, the direction in which the molten resin material RM is fed into the first flow channel 51 (hereinafter referred to as the first feeding direction D1) is inclined with respect to the normal LN1 of the outer surface of the first processing roll 31 toward the portion toward which the molten resin material RM fed from the first passage 41 is directed. Specifically, in the first passage 41, the first feeding direction D1 is inclined with respect to the normal LN1 such that the molten resin material RM is fed toward the front side in the rotational direction of the first processing roll 31 toward the first flow channel 51. As a result, the molten resin material RM fed from the first passage 41 into the first flow channel 51 flows smoothly toward the downstream side in the first flow channel 51.

[0039] <Second aisle 42> The second passage 42 of the resin supply unit 36 ​​extends in a manner that connects the dispensing device 35 and the second flow path section 52. The upstream end of the second passage 42 is connected to the outlet of the dispensing device 35, and the downstream end of the second passage 42 opens in the second flow path section 52. In this embodiment, the molten resin material RM dispensed from the dispensing device 35 is fed into the second flow path section 52 via the second passage 42.

[0040] The second passage 42 extends at an inclination with respect to the horizontal direction such that it is positioned higher as it approaches the second flow channel 52. In the second passage 42, the direction in which the molten resin material RM is fed into the second flow channel 52 (hereinafter referred to as the second feeding direction D2) is inclined with respect to the normal LN2 of the outer surface of the second processing roll 32 toward the portion toward which the molten resin material RM fed from the second passage 42 is directed. Specifically, in the second passage 42, the second feeding direction D2 is inclined with respect to the normal LN2 such that the molten resin material RM is fed into the second flow channel 52 toward the front side in the rotational direction of the second processing roll 32. As a result, the molten resin material RM fed from the second passage 42 into the second flow channel 52 flows smoothly downstream in the second flow channel 52.

[0041] In this embodiment, the resin supply unit 36 ​​has a divided structure in which it is divided into a first divided section 361 and a second divided section 362 in the direction Z (vertical direction in Figure 1) of the alignment of the first processing roll 31 and the second processing roll 32. The first passage 41 is provided in the first divided section 361, and the second passage 42 is provided in the second divided section 362.

[0042] In this embodiment, the thickness of the base portion 21 of the intermediate member 20 formed by the molding apparatus 30 can be set by adjusting the distance between the first dividing portion 361 and the second dividing portion 362, as well as adjusting the distance between the first processing roll 31 and the second processing roll 32.

[0043] <Barrier wall section 363> The molding apparatus 30 includes a barrier wall portion 363. The barrier wall portion 363 is plate-shaped and extends in the direction of the central axis X, and is located between the first division portion 361 and the second division portion 362. Specifically, in the portion where the first division portion 361 and the second division portion 362 face each other, each of the first division portion 361 and the second division portion 362 is provided with a groove (hereinafter referred to as an engagement groove 364) extending in the direction of the central axis X. One end of the barrier wall portion 363 (upper end in Figure 1) engages with the engagement groove 364 of the first division portion 361, and the other end of the barrier wall portion 363 (lower end in Figure 1) engages with the engagement groove 364 of the second division portion 362. In this embodiment, the barrier wall portion 363 closes the gap between the first division portion 361 and the second division portion 362.

[0044] <Extended wall section 37> The molding apparatus 30 includes a pair of extending wall portions 37. Each extending wall portion 37 is plate-shaped and extends in the delivery direction Y and the alignment direction Z. The pair of extending wall portions 37 are positioned to sandwich the first processing roll 31, the second processing roll 32, and the resin supply portion 36 in the central axis direction X. The pair of extending wall portions 37 are integrally provided with the resin supply portion 36 so as to sandwich the resin supply portion 36 in the central axis direction X. In this embodiment, the pair of extending wall portions 37 extend to cover both ends of the first flow path portion 51, both ends of the second flow path portion 52, and both ends of the confluence portion 53 in the central axis direction X.

[0045] <Operation of this embodiment> The operation of this embodiment will now be described. As shown in Figure 8, in the molding apparatus 30, molten resin material RM is sent from the dispensing device 35 to the resin supply unit 36. This molten resin material RM is then sent to the first flow channel 51 via the first passage 41 of the resin supply unit 36, and also to the second flow channel 52 via the second passage 42 of the same resin supply unit 36.

[0046] The molten resin material RM fed into the first flow channel 51 flows downstream, specifically toward the confluence section 53. At this time, a sheet-like member is formed by the outer surface of the first processing roll 31 and the outer surface of the first dividing section 361 of the resin supply section 36. This member corresponds to the portion of the base section 21 on the side of the first processing roll 31. At this time, the molten resin material RM flows into the first recess 311 of the first processing roll 31, forming a projection 22. In this embodiment, as the molten resin material RM flows through the first flow channel 51, the portion of the intermediate member 20 corresponding to the first processing roll 31 side (hereinafter referred to as the first portion) is formed.

[0047] Meanwhile, the molten resin material RM fed into the second flow channel 52 flows downstream, specifically toward the confluence section 53. At this time, a sheet-like member is formed by the outer surface of the second processing roll 32 and the outer surface of the second dividing section 362 of the resin supply section 36. This member corresponds to the portion of the base section 21 on the second processing roll 32 side. At this time, the molten resin material RM flows into the second recess 321 of the second processing roll 32, forming a projection 22. In this embodiment, as the molten resin material RM flows through the second flow channel 52, the portion of the intermediate member 20 corresponding to the second processing roll 32 side (hereinafter referred to as the second portion) is formed.

[0048] In this embodiment, the resin supply unit 36 ​​is set to a high temperature to maintain the molten resin material RM in a molten state, while the first processing roll 31 and the second processing roll 32 are set to relatively low temperatures to cool the molten resin material RM. Therefore, in the first flow channel 51, the portion of the first part on the side of the first processing roll 31 is cooled by the relatively low temperature of the first processing roll 31, while the portion of the first part on the side of the resin supply unit 36 ​​is kept warm by the relatively high temperature of the resin supply unit 36. Similarly, in the second flow channel 52, the portion of the second part on the side of the second processing roll 32 is cooled by the relatively low temperature of the second processing roll 32, while the portion of the second part on the side of the resin supply unit 36 ​​is kept warm by the relatively high temperature of the resin supply unit 36.

[0049] At the junction 53, the first portion formed by the first flow channel 51 and the second portion formed by the second flow channel 52 are superimposed to form a single sheet, and in this state, they pass through the gap between the first processing roll 31 and the second processing roll 32. At this time, the first portion and the second portion are pressed against each other, so that the first portion and the second portion become one. Also at the junction 53, the first portion is cooled by the first processing roll 31 and the second portion is cooled by the second processing roll 32. In this embodiment, a sheet-like molded product MP having a plurality of protrusions 22 on both sides is formed in this way.

[0050] The molded product MP is fed away from the resin supply unit 36 ​​in a direction away from it (to the left in Figure 1) by the first processing roll 31 and the second processing roll 32, which are rotated in opposite directions. At this time, the projection 22 escapes from the first recess 311 of the first processing roll 31 and the projection 22 escapes from the second recess 321 of the second processing roll 32, and so on, and the molded product MP is released from the molding apparatus 30.

[0051] <Effects of this embodiment> The effects of this embodiment will now be explained. (1) The molding apparatus 30 comprises a first processing roll 31, a second processing roll 32, and a resin supply unit 36. The molding apparatus 30 forms a sheet-like molded product MP by feeding the molten resin material RM supplied by the resin supply unit 36 ​​in a direction away from the resin supply unit 36 ​​by the first processing roll 31 and the second processing roll 32, which are rotated in opposite directions to each other. Both the first processing roll 31 and the second processing roll 32 have recesses 311 and 321 formed in their outer peripheral walls. The molding apparatus 30 comprises a first flow path section 51, a second flow path section 52, and a confluence section 53. The first flow path section 51 is partitioned by the outer surface of the resin supply unit 36 ​​and the outer peripheral surface of the first processing roll 31 and extends along the outer peripheral surface of the first processing roll 31. The second flow path section 52 is partitioned by the outer surface of the resin supply unit 36 ​​and the outer peripheral surface of the second processing roll 32 and extends along the outer peripheral surface of the second processing roll 32. The confluence section 53 is formed by the outer surface of the resin supply section 36, the outer surface of the first processing roll 31, and the outer surface of the second processing roll 32, and constitutes the confluence of the first flow path section 51 and the second flow path section 52. The resin supply section 36 has a first passage 41 that opens at the first flow path section 51 and supplies molten resin material RM to the first flow path section 51, and a second passage 42 that opens at the second flow path section 52 and supplies molten resin material RM to the second flow path section 52.

[0052] According to the above configuration, a sheet-like molded product MP having a plurality of protrusions 22 on both sides can be formed by using a first processing roll 31 having a first recess 311 and a second processing roll 32 having a second recess 321.

[0053] Furthermore, the molten resin material RM can be supplied separately to the outer surfaces of the processing rolls 31 and 32 from just before the confluence section 53, which is the opposing section where the outer surfaces of the pair of processing rolls 31 and 32 face each other. This makes it possible to flow and fill the first recess 311 of the first processing roll 31 along the path from the point where the molten resin material RM is supplied in the first flow channel section 51 to the confluence section 53. Also, it makes it possible to flow and fill the second recess 321 of the second processing roll 32 along the path from the point where the molten resin material RM is supplied in the second flow channel section 52 to the confluence section 53. Therefore, compared to the case where the molten resin material RM is supplied directly to the opposing section, the period during which the molten resin material RM can be filled into the recesses 311 and 321 of the outer walls of each processing roll 31 and 32 can be extended. As a result, the occurrence of so-called short shots, where the recesses 311 and 321 of each processing roll 31 and 32 cannot be sufficiently filled with the molten resin material RM, can be suppressed.

[0054] Furthermore, in the path from the point where the molten resin material RM is supplied in the first flow channel 51 to the confluence section 53, the portion of the first section on the side of the first processing roll 31 is cooled by the relatively low temperature of the first processing roll 31. In the path from the point where the molten resin material RM is supplied in the second flow channel 52 to the confluence section 53, the portion of the second section on the side of the second processing roll 32 is cooled by the relatively low temperature of the second processing roll 32. Therefore, compared to the case where the molten resin material RM is supplied directly to the opposing portions, the period during which the molten resin material RM filling the recesses 311 and 321 can be cooled can be extended. As a result, the temperature of the molten resin material RM can be sufficiently reduced, thereby suppressing the breakage and deformation of the protrusions 22 during demolding of the molded product MP.

[0055] Therefore, according to the above configuration, an intermediate member 20, which is a sheet-like molded product MP having multiple protrusions 22 on both sides, can be molded with high precision. (2) The first feeding direction D1, which is the direction in which the molten resin material RM is fed from the first passage 41 to the first flow channel 51, is inclined with respect to the normal LN1 of the portion of the outer surface of the first processing roll 31 toward which the molten resin material RM fed from the first passage 41 is directed. The second feeding direction D2, which is the direction in which the molten resin material RM is fed from the second passage 42 to the second flow channel 52, is inclined with respect to the normal LN2 of the portion of the outer surface of the second processing roll 32 toward which the molten resin material RM fed from the second passage 42 is directed.

[0056] In this case, if the molten resin material RM is supplied from a direction directly opposite to the openings of the recesses 311 and 321, it is difficult for the molten resin material RM to flow into the recesses 311 and 321. Therefore, there is a risk that the openings of the recesses 311 and 321 may be blocked by the molten resin material RM before the recesses 311 and 321 are filled with the molten resin material RM.

[0057] With the above configuration, the molten resin material RM can be supplied to the openings of the recesses 311 and 321 in the outer peripheral walls of each processing roll 31 and 32 from an oblique direction, rather than from a direction directly facing the openings. As a result, as shown in Figure 9 as an example, the molten resin material RM can be supplied to the recesses 311 and 321 of each processing roll 31 and 32 by flowing it in from the side, allowing for smooth filling. Therefore, the occurrence of short shots can be effectively suppressed.

[0058] (3) A first orientation toward the bottom of the opening of the first recess 311 in the outer peripheral wall of the first processing roll 31, and a second orientation toward the front in the rotational direction of the first processing roll 31 are projected onto a first virtual plane that is in contact with the portion of the outer peripheral wall of the first processing roll 31 into which the first recess 311 opens. At this time, the first and second orientations projected onto the first virtual plane are facing in different directions. Also, a third orientation toward the bottom of the opening of the second recess 321 in the outer peripheral wall of the second processing roll 32, and a fourth orientation toward the front in the rotational direction of the second processing roll 32 are projected onto a second virtual plane that is in contact with the portion of the outer peripheral wall of the second processing roll 32 into which the second recess 321 opens. At this time, the third and fourth orientations projected onto the second virtual plane are facing in different directions.

[0059] When the first orientation and the second orientation projected onto the first virtual plane coincide, the projection 22 formed by the first recess 311 of the first processing roll 31 is tilted in the opposite direction to the first orientation, which is the orientation of the first recess 311, when the molded product MP is demolded. Therefore, stress tends to concentrate on the projection 22 when the molded product MP is demolded, which can easily lead to deformation of the projection 22. Also, when the third orientation and the fourth orientation projected onto the second virtual plane coincide, the projection 22 formed by the second recess 321 is tilted in the opposite direction to the third orientation, which is the orientation of the second recess 321, when the molded product MP is demolded. Therefore, stress tends to concentrate on the projection 22 when the molded product MP is demolded, which can easily lead to deformation of the projection 22.

[0060] According to the above configuration, the first orientation and the second orientation projected onto the first virtual plane do not coincide. Therefore, when demolding the molded product MP, the projection 22 formed by the first recess 311 can be released from the first recess 311 by twisting, releasing the force to the side in the direction of rotation of the first processing roll 31. Thus, deformation of the projection 22 formed by the first recess 311 during demolding can be suitably suppressed. Furthermore, the third orientation and the fourth orientation projected onto the second virtual plane do not coincide. Therefore, when demolding the molded product MP, the projection 22 formed by the second recess 321 can be released from the second recess 321 by twisting, releasing the force to the side in the direction of rotation of the second processing roll 32. Thus, deformation of the projection 22 formed by the second recess 321 during demolding can be suitably suppressed.

[0061] (4) The molding apparatus 30 includes an extending wall portion 37 that extends to cover both ends of the first flow channel portion 51, both ends of the second flow channel portion 52, and both ends of the confluence portion 53 in the direction of the central axis X. According to the above configuration, as shown in Figure 10 as an example, leakage of the molten resin material RM supplied by the resin supply unit 36 ​​to the outside of the molding apparatus 30 from both ends of the first flow channel 51, both ends of the second flow channel 52, and both ends of the confluence 53 in the central axis direction X is suppressed. As a result, unnecessary pressure drops of the molten resin material RM inside the molding apparatus 30 can be suppressed, and the molding apparatus 30 can mold a sheet-like molded product MP having multiple protrusions 22 on both sides with high precision.

[0062] (5) The resin supply unit 36 ​​has a divided structure in which it is divided into a first divided unit 361 and a second divided unit 362 in the alignment direction Z. The molding apparatus 30 is located between the first divided unit 361 and the second divided unit 362 and includes a barrier wall 363 that closes the gap between the first divided unit 361 and the second divided unit 362.

[0063] With the above configuration, as shown in Figure 11, leakage of the molten resin material RM supplied by the resin supply unit 36 ​​to the outside of the molding apparatus 30 through the gap between the first division unit 361 and the second division unit 362 is suppressed. This makes it possible to suppress an unnecessary pressure drop of the molten resin material RM inside the molding apparatus 30.

[0064] <Example of changes> The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0065] The material of the intermediate member 20 can be changed to a soft resin material other than soft polyvinyl chloride, such as styrene-based elastomer or olefin-based elastomer. The first processing roll 31 and the second processing roll 32 may be formed from a dense, non-porous metal material instead of from a porous steel material.

[0066] • The resin supply section 36 can be a single-piece structure in which the first divided section 361 and the second divided section 362 are integrally formed, rather than a divided structure. In this case, the barrier wall section 363 can be omitted.

[0067] One or both of the pair of extending wall portions 37 can be omitted. The first feeding direction D1, which is the direction in which the molten resin material RM is fed from the first passage 41 to the first flow channel 51, and the second feeding direction D2, which is the direction in which the molten resin material RM is fed from the second passage 42 to the second flow channel 52, can be arbitrarily changed. For example, the first feeding direction D1 may be inclined with respect to the normal LN1 so that the molten resin material RM is fed from the first passage 41 to the first flow channel 51 toward the rear in the direction of rotation of the first processing roll 31. Similarly, the second feeding direction D2 may be inclined with respect to the normal LN2 so that the molten resin material RM is fed from the second passage 42 to the second flow channel 52 toward the rear in the direction of rotation of the second processing roll 32. In addition, it is also possible to feed the molten resin material RM from a direction directly facing the openings of the recesses 311 and 321.

[0068] When the first orientation and the second orientation are projected onto the first virtual plane, the angle between the projected first orientation and the second orientation is not limited to "60 degrees," "180 degrees," or "300 degrees," but can be set to any angle. In this case, it is preferable that the first orientation and the second orientation projected onto the first virtual plane are different for all first recesses 311. With this configuration, deformation of the protrusion 22 formed by the first recess 311 during demolding can be suitably suppressed.

[0069] Furthermore, when the third and fourth orientations are projected onto the second virtual plane, the angle between the projected third and fourth orientations is not limited to "60 degrees," "180 degrees," or "300 degrees," but can be set to any angle. In this case, it is preferable that the third and fourth orientations projected onto the 12th virtual plane are different for all second recesses 321. This configuration allows for effective suppression of deformation of the protrusions 22 formed by the second recesses 321 during demolding.

[0070] - Either the first recess 311 of the first processing roll 31 or the second recess 321 of the second processing roll 32 can be omitted. <Note> The above embodiment includes the configuration described in the following appendix.

[0071] [Note 1] A molding apparatus comprising: a cylindrical first processing roll; a cylindrical second processing roll positioned so as to extend parallel to the first processing roll along its central axis and with its outer circumferential surfaces facing each other; and a resin supply unit for supplying molten resin material between the first and second processing rolls, wherein the molten resin material supplied by the resin supply unit is fed away from the resin supply unit by the first and second processing rolls, which are rotated in opposite directions, thereby forming a sheet-like molded product, wherein at least one of the first and second processing rolls has a recess formed in its outer circumferential wall, and the molding apparatus is located outside the resin supply unit. A molding apparatus comprising: a first flow path section formed by a surface and the outer circumferential surface of the first processing roll and extending along the outer circumferential surface of the first processing roll; a second flow path section formed by the outer surface of the resin supply section and the outer circumferential surface of the second processing roll and extending along the outer circumferential surface of the second processing roll; and a junction section formed by the outer surface of the resin supply section, the outer circumferential surface of the first processing roll and the outer circumferential surface of the second processing roll, constituting a confluence of the first flow path section and the second flow path section, wherein the resin supply section has a first passage that opens in the first flow path section and supplies the molten resin material to the first flow path section; and a second passage that opens in the second flow path section and supplies the molten resin material to the second flow path section.

[0072] [Note 2] The molding apparatus according to [Appendix 1], wherein the first processing roll has the recess, and the direction in which the molten resin material is fed from the first passage to the first flow channel is inclined with respect to the normal of the portion of the outer surface of the first processing roll toward which the molten resin material fed from the first passage is directed.

[0073] [Note 3] The molding apparatus according to [Appendix 1] or [Appendix 2], wherein the first processing roll has the recess, and when a first orientation toward the bottom of the recess in the outer peripheral wall and a second orientation toward the front in the rotational direction of the first processing roll in the outer peripheral wall are projected onto a virtual plane tangent to the portion of the outer peripheral wall in which the recess opens, the projected first orientation and second orientation are in different directions.

[0074] [Note 4] A molding apparatus according to any one of [Appendix 1] to [Appendix 3], comprising extending wall portions that extend to cover both ends of the first flow channel portion, both ends of the second flow channel portion, and both ends of the confluence portion in the direction of the central axis extending along the central axis.

[0075] [Note 5] The resin supply section has a divided structure in which it is divided into a first divided section and a second divided section in the direction in which the first processing roll and the second processing roll are aligned, and the molding apparatus is located between the first divided section and the second divided section and includes a barrier wall that closes the gap between the first divided section and the second divided section, as described in any one of [Appendix 1] to [Appendix 4]. [Explanation of Symbols]

[0076] 10…Interior parts 11...Base material 12…Skin material 20…Intermediate member 21...Base section 22,22A,22B,22C…Protrusion 25…Virtual Lattice 26…Hexagon 27... sides 30…Forming equipment 31…First processing roll 311...First recess 32...Second processing roll 321...Second recess 33…post 34…Resin supply device 35…Delivery device 36…Resin supply unit 361...1st division part 362…Second division part 363... Barrier wall section 364...Engagement groove 37...Extended wall part 41...1st aisle 42…Second aisle 51...First channel section 52...Second channel section 53... Confluence

Claims

1. A cylindrical first processing roll, A second processing roll is cylindrical in shape, and is positioned such that its central axis extends parallel to the first processing roll and its outer surfaces face each other. The system includes a resin supply unit that supplies molten resin material between the first processing roll and the second processing roll, A molding apparatus for forming a sheet-like molded product by feeding the molten resin material supplied by the resin supply unit in a direction away from the resin supply unit by the first processing roll and the second processing roll which are rotated in opposite directions to each other, At least one of the first processing roll and the second processing roll has a recess formed in its outer peripheral wall, The molding apparatus described above is A first flow path is formed by the outer surface of the resin supply section and the outer circumferential surface of the first processing roll, and extends along the outer circumferential surface of the first processing roll. A second flow path is formed by the outer surface of the resin supply section and the outer circumferential surface of the second processing roll, and extends along the outer circumferential surface of the second processing roll. The resin supply section is partitioned by the outer surface of the resin supply section, the outer surface of the first processing roll, and the outer surface of the second processing roll, and comprises a junction section that constitutes the confluence of the first flow path section and the second flow path section. The resin supply unit has a first passage that opens in the first flow channel and supplies the molten resin material to the first flow channel, and a second passage that opens in the second flow channel and supplies the molten resin material to the second flow channel. Molding equipment.

2. The first processing roll has the recess, The direction in which the molten resin material is fed from the first passage to the first flow channel is inclined with respect to the normal to the portion of the outer surface of the first processing roll toward which the molten resin material fed from the first passage is directed. The molding apparatus according to claim 1.

3. The first processing roll has the recess, When a first orientation toward the bottom of the recess in the outer peripheral wall and a second orientation toward the front in the rotational direction of the first processing roll in the outer peripheral wall are projected onto a virtual plane tangent to the portion of the outer peripheral wall where the recess opens, the projected first orientation and second orientation are in different directions. The molding apparatus according to claim 1 or 2.

4. The system includes extending wall portions that extend to cover both ends of the first flow channel, both ends of the second flow channel, and both ends of the confluence portion in the direction of the central axis extending along the central axis, The molding apparatus according to claim 1 or 2.

5. The resin supply unit has a divided structure in which it is divided into a first divided section and a second divided section in the direction in which the first processing roll and the second processing roll are aligned. The molding apparatus is located between the first divided portion and the second divided portion and includes a barrier wall that closes the gap between the first divided portion and the second divided portion. The molding apparatus according to claim 1 or 2.

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