Method for manufacturing a sealing material, filling device, and manufacturing apparatus for a sealing material

Abstract

To provide a seal material manufacturing method which can suppress leakage of an ultraviolet curable seal material composition between an upper mold and a lower mold, in a method for manufacturing a seal material by an ultraviolet curing method, a filling device and a seal material manufacturing apparatus.SOLUTION: A seal material manufacturing method includes a filling step of filling a mold with an ultraviolet curable seal material composition using a filling machine, wherein the mold is composed of an upper mold and a lower mold, and in the filling step, a presser plate is arranged above the upper mold, and the mold is filled with the ultraviolet curable seal material composition while pressing the upper mold against the lower mold by the presser plate.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a sealing material, a filling device, and a manufacturing device for a sealing material.

Background Art

[0002] Patent Document 1 discloses a method for manufacturing a sealing material by filling a thermosetting rubber composition into a mold and performing hot press molding.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As a method for manufacturing a sealing material, an ultraviolet curing method in which an ultraviolet curable sealing material composition is filled into a mold and cured by ultraviolet irradiation has been studied. Since the ultraviolet curing method cures the ultraviolet curable sealing material composition by ultraviolet irradiation, the manufacturing time of the sealing material is shorter and heat is less likely to be generated compared to the heat crosslinking method for thermosetting rubber compositions. Molds used for manufacturing sealing materials are often composed of a plurality of mold parts in order to facilitate removal of the cured sealing material from the mold.

[0005] An object of the present invention is to provide a method for manufacturing a sealing material, a filling device, and a manufacturing device for a sealing material that can suppress leakage of an ultraviolet curable sealing material composition between an upper mold and a lower mold in a method for manufacturing a sealing material by an ultraviolet curing method.

Means for Solving the Problems

[0006] The present invention provides the following method for manufacturing a sealing material, a filling device, and a manufacturing device for a sealing material. [1] A method for manufacturing a sealing material, comprising: a filling step of filling an ultraviolet curable sealing material composition into a mold using a filling machine; wherein, the mold is composed of an upper mold and a lower mold, and in the filling step, a pressing plate is disposed above the upper mold, and the upper mold is pressed against the lower mold by the pressing plate. [2] The method for manufacturing a sealing material according to [1], wherein a load is applied to the pressing plate by the filling machine. [3] The method for manufacturing a sealing material according to [2], wherein a spring is disposed between the filling machine and the pressing plate. [4] Further comprising a mold preparation step of preparing the mold before the filling step, and after the filling step, further comprising an irradiation step of irradiating ultraviolet rays to the ultraviolet curable sealing material composition and a demolding step of taking out the sealing material from the mold, wherein the mold filled with the ultraviolet curable sealing material composition in the filling step is conveyed to the irradiation step, and the mold from which the sealing material is taken out in the demolding step is returned to the mold preparation step. The method for manufacturing a sealing material according to any one of [1] to [3]. [5] The method for manufacturing a sealing material according to any one of [1] to [4], wherein the mold is formed of at least one selected from the group consisting of glass, quartz, polyester resin, polycarbonate resin, acrylic resin, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polyvinylidene fluoride, polyvinyl fluoride, tetrafluoroethylene-ethylene copolymer, polychlorotrifluoroethylene, and cycloolefin polymer. [6] A filling device for filling an ultraviolet curable sealing material composition into a mold, wherein the mold is composed of an upper mold and a lower mold, and the filling device is provided with means for pressing the upper mold against the lower mold by a pressing plate. [7] Further comprising a filling machine, A filling device according to [6], wherein a spring is disposed between the filling machine and the pressing plate, and the filling machine is lowered to apply a load to the pressing plate via the spring. [8] A sealing material manufacturing apparatus comprising the filling device according to [6] or [7]. [9] A mold used in the method for manufacturing a sealing material according to any one of [1] to [5], the mold being formed of at least one selected from the group consisting of glass, quartz, polyester resin, polycarbonate resin, acrylic resin, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polyvinylidene fluoride, polyvinyl fluoride, tetrafluoroethylene-ethylene copolymer, polychlorotrifluoroethylene, and cycloolefin polymer.

Advantages of the Invention

[0007] According to the present invention, there are provided a method for manufacturing a sealing material, a filling device, and a sealing material manufacturing apparatus capable of suppressing leakage of an ultraviolet curable sealing material composition between an upper mold and a lower mold in a method for manufacturing a sealing material by an ultraviolet curing method.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to the following embodiments. In all the following drawings, the scale is appropriately adjusted for easy understanding of each component, and the scale of each component shown in the drawings does not necessarily match the scale of the actual component.

[0010] <Method for manufacturing a sealing material> The method for manufacturing a sealing material of the present invention includes a filling step of filling an ultraviolet curable sealing material composition into a mold using a filling machine. The mold is composed of an upper mold and a lower mold. In the filling step, a pressing plate is arranged above the upper mold, and the upper mold is pressed against the lower mold by the pressing plate.

[0011] In the method for manufacturing a sealing material, a sealing material can be manufactured by curing an ultraviolet curable sealing material composition in a mold. The method for manufacturing a sealing material can further include a mold preparation step of preparing a mold, an irradiation step of irradiating ultraviolet rays onto the ultraviolet curable sealing material composition filled in the mold, and a demolding step of taking out the sealing material from the mold. When the mold is transportable, a plurality of molds can be used, and the molds can be transported between processes, so that a plurality of processes can be performed independently and continuously, and the productivity of the sealing material can be increased.

[0012] The filling step can be performed using a filling device. The filling step will be described with reference to the drawings. FIG. 1 is a cross-sectional view for explaining the filling step. The filling device 100 includes a filling machine 10 and a pressing plate 12.

[0013] In the filling process, as shown in Fig. 1, first, a pressing plate 12 and a mold 13 are arranged under the filling machine 10. The mold 13 is composed of an upper mold 13a and a lower mold 13b. In Fig. 1, the upper mold 13a and the lower mold 13b are arranged in a separated state from each other, but they may also be arranged in a combined state. The mold 13 is removable from the filling device 100. The mold 13 can be transported, for example, from a process before the filling process (such as a mold preparation process), installed in the filling device 100, filled with an ultraviolet curable sealant composition, and then transported to the next process after the filling process.

[0014] In the filling process, the ultraviolet curable sealant composition can be filled into the mold 13 using the filling machine 10. The filling machine 10 is provided with a filling nozzle 11. The filling machine 10 can be provided with one or more filling nozzles. The filling machine 10 can be provided with a material filling port 14. The ultraviolet curable sealant composition can be fed from the material filling port 14 into the filling nozzle 11. The tip shape of the filling nozzle 11 may be cylindrical (without a tapered portion described later), or may be frustum-shaped (shown as a trapezoidal cross-sectional shape in Fig. 1). When the tip shape is cylindrical, the sealing performance between the filling nozzle 11 and the mold 13 tends to be improved.

[0015] When the tip shape of the filling nozzle 11 is frustum-shaped, the filling nozzle 11 may have a tapered portion 11a. When the filling nozzle 11 has a tapered portion 11a, it becomes easier to bring the filling nozzle insertion portion 18 into which the filling nozzle 11 is inserted closer to the cavity portion 17, so that the runner portion can be shortened. By pressing the upper mold 13a with the filling machine 10 and sealing with the tapered portion 11a of the filling nozzle 11 and the tapered portion 18a of the filling nozzle insertion portion 18, the ultraviolet curable sealant composition can be filled without leakage between the filling nozzle 11 and the upper mold 13a.

[0016] The filling nozzle 11 can be arranged according to the position of the filling nozzle insertion portion 18 so that it can be inserted into the filling nozzle insertion portion 18 described later.

[0017] The tip 11b of the filling nozzle 11 may be provided with a sealing mechanism. As the sealing mechanism, for example, a sealing material (such as an O-ring or the like) can be arranged.

[0018] When the diameter of the filling nozzle 11 is the distance D shown in FIG. 1, the diameter D of the filling nozzle 11 may be, for example, 0.5 to 50 mm, preferably 1 to 20 mm, and more preferably 1 to 10 mm.

[0019] The pressing plate 12 may be made of, for example, metal. Examples of the metal include iron, stainless steel (SUS), etc. The pressing plate 12 may be in a flat plate shape. The thickness of the pressing plate 12 can be, for example, 5 to 10 mm. If the thickness of the pressing plate 12 is within the above range, it is easy to suppress the leakage of the ultraviolet curable sealant composition to the outside of the cavity of the mold 13.

[0020] The pressing plate 12 may have a nozzle through hole 15 for inserting the filling nozzle 11 into the mold 13. The filling nozzle 11 can be inserted into the filling nozzle insertion portion 18 described later through the nozzle through hole 15.

[0021] The upper mold 13a is pressed against the lower mold 13b by the pressing plate 12. While the upper mold 13a is pressed against the lower mold 13b by the pressing plate 12, the ultraviolet curable sealant composition can be filled into the mold 13. Also, with the upper mold 13a pressed against the lower mold 13b by the pressing plate 12, the upper mold 13a and the lower mold 13b can be fixed by a clamping jig described later, and the ultraviolet curable sealant composition can be filled into the mold 13. By filling the ultraviolet curable sealant composition into the mold 13 with the upper mold 13a pressed against the lower mold 13b, it is easy to suppress the leakage of the ultraviolet curable sealant composition outside the cavity of the mold 13.

[0022] The pressure (filling pressure) when the ultraviolet curable sealant composition is filled into the mold may be, for example, 0.05 to 15 MPa, preferably 0.1 to 1 MPa.

[0023] As a method of pressing the upper mold 13a against the lower mold 13b with the pressing plate 12, for example, an interlocking mechanism 24 for simultaneously lowering the filling machine 10 and the pressing plate 12 is arranged, and a method of applying a load to the pressing plate 12 by lowering the filling machine 10, or a mechanism for lowering the pressing plate 12 (hereinafter also referred to as the second mechanism) different from the mechanism for lowering the filling machine 10 (hereinafter also referred to as the first mechanism) is used to lower the pressing plate 12.

[0024] When applying a load to the pressing plate 12, the pressing plate 12 and the mold 13 can be detached from the conveying system and performed on a stage having greater load-bearing capacity. Thereby, it becomes possible to increase the load applied to the pressing plate 12, and the ultraviolet curable sealant composition can be filled with a large force such as hydraulic pressure.

[0025] FIG. 2 shows a state in which the upper mold 13a is pressed against the lower mold 13b while applying a load to the pressing plate 12 by lowering the filling machine 10 from the state of FIG. 1. A spring can be arranged between the filling machine 10 and the pressing plate 12. By arranging the spring, the load applied to the pressing plate 12 by lowering the filling machine 10 can be made appropriate.

[0026] FIG. 3 shows a state in which the pressing plate 12 is lowered in the direction of the arrow by the second mechanism 27 to press the upper mold 13a against the lower mold 13b.

[0027] After the upper mold 13a is pressed against the lower mold 13b while applying a load to the pressing plate 12 by the filling machine 10 or the second mechanism 27, the ultraviolet curable sealant composition can be filled into the mold 13. In order to make the ultraviolet curable sealant composition flow easily, the inside of the mold 13 can be evacuated from the exhaust port 25 while or before filling the ultraviolet curable sealant composition into the mold 13 from the filling nozzle 11. A mold sealant 26 may be arranged to facilitate evacuation, and a sealant (for example, an O-ring etc.) may be arranged at the tip of the filling nozzle. The mold sealant 26 may be, for example, an O-ring etc.

[0028] The load applied to the pressing plate 12 can be a force greater than the filling pressure of the ultraviolet curable sealant composition. When the mold sealant 26 is disposed on the lower mold 13b, the load applied to the pressing plate 12 can be a force greater than the sum of the filling pressure of the ultraviolet curable sealant composition and the repulsive force of the mold sealant 26. The load (MPa) applied to the pressing plate 12 may be, for example, a load higher than 0.05 MPa than the filling pressure of the ultraviolet curable sealant composition. When the load applied to the pressing plate 12 is within the above range, it tends to be easier to suppress the ultraviolet curable sealant composition from leaking out of the cavity 17 from the joint of the upper mold 13a and the lower mold 13b.

[0029] While applying a load to the pressing plate 12 by the filling machine 10 or the second mechanism 27, after the upper mold 13a is pressed against the lower mold 13b, the upper mold 13a and the lower mold 13b can be fixed in that state by clamping with a clamping jig (not shown). The mold in which the upper mold 13a and the lower mold 13b are clamped and fixed by the clamping jig maintains the state where the upper mold 13a is pressed against the lower mold 13b even after removing the load by the pressing plate 12 after filling the ultraviolet curable sealant composition. Therefore, it is possible to transport the mold to the subsequent irradiation step while suppressing the ultraviolet curable sealant composition from leaking out of the cavity 17. The clamping jig may be, for example, a clamp or a screw. The clamping force by the clamping jig may be the same as or greater than the load applied to the pressing plate 12.

[0030] In order to irradiate and cure the ultraviolet curable sealant composition filled in the mold 13 with ultraviolet rays, the upper mold 13a can usually have ultraviolet transmittance. The ultraviolet transmittance of the upper mold 13a may be, for example, a light transmittance of 80% or more at a wavelength of 365 nm, preferably 90% or more, more preferably 95% or more, and usually 100% or less, from the viewpoint of the curability of the ultraviolet curable sealant composition. The entire mold 13 may have ultraviolet transmittance, or only the portions necessary for curing the ultraviolet curable sealant composition may have ultraviolet transmittance.

[0031] The upper mold 13a is formed of a material having ultraviolet transmittance. The upper mold 13a may be formed of a material having ultraviolet transmittance for the portions that need to have ultraviolet transmittance, and the other portions may be composed of a material having no ultraviolet transmittance. Examples of the material having ultraviolet transmittance include glass, quartz, polyester resin, polycarbonate resin, acrylic resin, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), tetrafluoroethylene-ethylene copolymer (ETFE), polychlorotrifluoroethylene (ECTFE), cycloolefin polymer (COP), and the like. Among them, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) and acrylic resin are preferable from the viewpoints of handleability and transparency, and acrylic resin is more preferable. The material having ultraviolet transmittance can be used alone or in combination of two or more. The material constituting the upper mold 13a is preferably acrylic resin or tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), and more preferably acrylic resin.

[0032] The thickness of the upper mold 13a can be, for example, 20 mm or less. When the thickness of the upper mold 13a is within the above range, it is easy to enhance the ultraviolet transmittance, and it is easy to reduce the distance between the ultraviolet curable sealant composition filled in the mold and the light source of the irradiated ultraviolet rays. Therefore, the ultraviolet curable sealant composition can be efficiently cured. When the thickness of the upper mold 13a is 20 mm or less, usually, warping occurs due to the filling pressure of the ultraviolet curable sealant composition, and a gap tends to be formed between the upper mold 13a and the lower mold 13b. However, according to the present invention, even when the thickness of the upper mold 13a is 20 mm or less, since filling is performed with the upper mold 13a pressed against the lower mold 13b, warping of the upper mold 13a is suppressed, and it is possible to easily suppress the leakage of the ultraviolet curable sealant composition outside the cavity of the mold 13. The thickness of the upper mold 13a is preferably 15 mm or less, more preferably 10 mm or less, still more preferably 5 mm or less, and may be, for example, 1 mm or more. When the upper surface of the upper mold 13a is flat, it tends to be easily pressed by the pressing plate 12. In this specification, the thicknesses of the upper mold and the lower mold are respectively the thicknesses of the thickest portions of the upper mold 13a and the lower mold 13b in the direction of being pressed by the pressing plate 12.

[0033] As an example of the material forming the lower mold 13b, those exemplified as the material of the upper mold 13a are applicable. The materials forming the upper mold 13a and the lower mold 13b may be of the same type or different types. The thickness of the lower mold 13b may be a thickness that can withstand the load by the pressing plate 12 and the filling pressure of the ultraviolet curable sealant composition.

[0034] As shown in FIG. 1, when arranging the pressing plate 12 and the mold 13 under the filling machine 10, a substrate 16 for forming a sealant may be arranged between the upper mold 13a and the lower mold 13b. The substrate 16 may be, for example, one selected from the group consisting of a film, a plate material, and a molded product. The substrate 16 may be, for example, a metal plate or the like, and may preferably be composed of SUS or the like. The substrate 16 may be included in the product together with the sealant.

[0035] The mold 13 can have a cavity 17. The cavity 17 can be formed from the upper mold 13a and the lower mold 13b. When the substrate 16 is arranged as shown in FIG. 1, the cavity 17 is formed from the upper mold 13a and the substrate 16.

[0036] The cavity 17 can have a shape corresponding to the shape of the sealing material to be manufactured. The sealing material can be formed by curing the ultraviolet curable sealant composition filled in the cavity 17.

[0037] The mold 13 can be provided with a filling nozzle insertion portion 18 for inserting a filling nozzle 11 for filling the ultraviolet curable sealing material composition. The shape of the filling nozzle insertion portion 18 is preferably a shape that can be fitted with the filling nozzle 11. As described above, when the filling nozzle 11 has a tapered portion 11a, the filling nozzle insertion portion 18 can have a tapered portion 18a. When the filling nozzle 11 is cylindrical without a tapered portion 11a, the shape of the filling nozzle insertion portion 18 can be cylindrical without a tapered portion.

[0038] The tapered portion 18a can have the same taper angle as the tapered portion 11a from the viewpoint of the sealing property between the filling nozzle 11 and the mold 13. Thereby, when the filling nozzle 11 is pressed against the mold 13 to apply a load, the contact surface between the filling nozzle 11 and the mold 13 becomes wider. As a result, the sealing property between the filling nozzle 11 and the mold 13 is enhanced, and leakage of the ultraviolet curable sealing material composition between the filling nozzle 11 and the mold 13 tends to be suppressed. The taper angle of the tapered portion 18a (the smaller angle among the angles formed by the horizontal direction and the tapered portion 18a in FIG. 1) can be, for example, 0° or more and less than 90°, preferably 30° or more and 60° or less. The taper angle of the tapered portion 18a can be adjusted, for example, according to the location where the cavity 17 is arranged.

[0039] The mold 13 may further have a runner portion 19. The filling nozzle insertion portion 18 is connected to the runner portion 19, and the runner portion 19 may be connected to the cavity 17.

[0040] The mold 13 may have one or more filling nozzle insertion parts 18, cavity parts 17, and runner parts 19 respectively. When there are a plurality of filling nozzle insertion parts 18, it becomes possible to fill the ultraviolet curable sealant composition from a plurality of locations, and the time of the filling process can be shortened. The filling nozzle insertion part 18 may be arranged so as to be directly connected to the cavity part 17, or may be arranged so as to be connected to the cavity part 17 via the runner part 19. The runner part 19 can be a path through which the ultraviolet curable sealant composition flows to the cavity part 17.

[0041] When the ultraviolet curable sealant composition remains in the runner part, the remaining ultraviolet curable sealant composition is cured by ultraviolet irradiation, and the cured product cannot be taken out from the runner part. As a result, it may become difficult to continuously mold the sealant. Therefore, it is preferable to arrange the filling nozzle insertion part 18 and the cavity part 17 so that the runner part 19 becomes as short as possible.

[0042] The lower mold 13b may be provided with a protrusion 21 for fixing the pressing plate 12 and the upper mold 13a. By inserting the protrusion 21 into the through hole 22 of the pressing plate 12 and the through hole 23 of the upper mold 13a, the lower mold 13b, the pressing plate 12, and the upper mold 13a can be fixed.

[0043] The ultraviolet curable sealant composition filled in the mold 13 is a composition having the property of being cured by receiving ultraviolet irradiation. The ultraviolet curable sealant composition can contain an ultraviolet curable resin component and a photoinitiator.

[0044] Examples of the ultraviolet curable resin component include rubber-based resins, polyolefin-based resins, acrylic resins, epoxy resins, silicone-based resins, urethane-based resins, vinyl alkyl ether-based resins, polyvinyl pyrrolidone-based resins, polyacrylamide-based resins, cellulose-based resins, and the like. The ultraviolet curable resin component may contain a polyolefin-based resin, an acrylic resin, or an epoxy resin. These cured products can have crosslinking points and exhibit rubber elasticity.

[0045] Examples of the rubber-based resin include isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, ethylene-propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, urethane rubber, silicone rubber, and the like. Examples of the polyolefin-based resin include polyisobutylene and the like. Commercially available products of the ultraviolet curable sealant composition containing a polyolefin-based resin include, for example, ThreeBond 3178 (manufactured by ThreeBond Co., Ltd.) and the like.

[0046] The content of the ultraviolet curable resin component may be, for example, 50% by mass or more, preferably 50% by mass or more, more preferably 60% by mass or more, still more preferably 70% by mass or more, particularly preferably 80% by mass or more, and extremely preferably 90% by mass or more in the solid content of the ultraviolet curable sealant composition. The content of the ultraviolet curable resin component may be, for example, 99% by mass or less, or 98% by mass or less in the solid content of the ultraviolet curable sealant composition.

[0047] Examples of the photopolymerization initiator include photo cationic polymerization initiators, photo radical polymerization initiators, and the like.

[0048] The content of the photopolymerization initiator may be, for example, 0.001 part by mass or more and 10 parts by mass or less, preferably 0.005 part by mass or more and 10 parts by mass or less, and more preferably 0.01 part by mass or more and 10 parts by mass or less with respect to 100 parts by mass of the ultraviolet curable resin component.

[0049] The ultraviolet curable sealing material composition can further contain a crosslinking agent, other resin components, additives, fillers, etc.

[0050] The viscosity of the ultraviolet curable sealing material composition may be, for example, 500 Pa·s or less, preferably 300 Pa·s or less, more preferably 200 Pa·s or less from the viewpoint of filling property. The viscosity of the ultraviolet curable sealing material composition is measured using, for example, a B-type viscometer. In order to facilitate filling, the viscosity of the ultraviolet curable sealing material composition may be lowered by heat.

[0051] The manufacturing method of the sealing material may be a method for continuously manufacturing the sealing material. As shown in FIG. 4, the manufacturing method of the sealing material can include a mold preparation step (S10), a filling step (S20), an irradiation step (S30), and a mold release step (S40). In the filling step (S20), the mold filled with the ultraviolet curable sealing material composition can be conveyed to the irradiation step (S30), and the mold from which the sealing material is taken out in the mold release step can be returned to the mold preparation step. The manufacturing method of the sealing material shown in FIG. 4 can further include an inspection step (S50) for inspecting the taken-out sealing material, a packaging step (S60) for packaging the sealing material, a cleaning step (S70) for cleaning the mold returned to the mold preparation step (S10), a mold release agent application step (S80) for applying a mold release agent to the cleaned mold, etc. The manufacturing method of the sealing material can continuously perform the steps from the mold preparation step (S10) to the mold release agent application step (S80). After the mold release step (S40), by returning the mold to the mold preparation step (S10), the above steps can be repeatedly and continuously performed.

[0052] The method for continuously manufacturing the sealing material is not particularly limited. For example, a method of performing the above steps in series while linearly conveying the mold (hereinafter also referred to as the linear method), a method of arranging a plurality of the above linear methods side by side (hereinafter also referred to as the multi-line method), a method of performing the above steps while conveying the mold concentrically (hereinafter also referred to as the rotation method), etc. can be mentioned. Also, a plurality of steps may be integrated and performed as one step, or a plurality of steps may be performed in parallel.

[0053] FIG. 5 is a diagram for explaining a method of continuously manufacturing a sealing material, with the conveyance direction of the mold indicated by an arrow. The method shown in FIG. 5(a) is a linear method in which steps a1, a2, a3, and a4 are continuously performed in this order, the mold is recovered in step a4 (for example, a mold release step), and the mold is returned to step a1 (for example, a mold preparation step). The method shown in FIG. 5(b) is a linear method in which steps a1, a2, a3, and a4 are continuously performed in this order, while a plurality of steps a2 are performed in parallel, the mold is recovered in step a4 (for example, a mold release step), and the mold is returned to step a1 (for example, a mold preparation step). The method shown in FIG. 5(c) is a rotational method in which steps a1, a2, a3, and a4 are continuously performed in this order, and in step a2, the mold is conveyed concentrically in the order of 1 to 8 while being processed. As shown in FIG. 5(c), for example, in step a3 (for example, a mold release step), the product can be taken out from the mold, the mold can be returned to step a1 (for example, a mold preparation step), and the product can be conveyed to a subsequent step a4 (for example, an inspection step or the like).

[0054] In the method for manufacturing a sealing material, for example, the time (tact time) from the mold preparation step, through the filling step and the irradiation step, until the sealing material is removed in the mold release step may be, for example, 60 seconds or less, preferably 50 seconds or less, more preferably 40 seconds or less, still more preferably 30 seconds or less, particularly preferably 20 seconds or less, and extremely preferably 10 seconds or less.

[0055] The type of the sealing material manufactured by the method for manufacturing a sealing material is not particularly limited. The use of the sealing material manufactured by the method for manufacturing a sealing material is not particularly limited, and may be, for example, for applications such as vehicles, aircraft, ships, internal combustion engines, manufacturing equipment, plants, medical products, buildings, semiconductors, foods, and batteries. Further, the sealing material of the present invention can also be made into an integrally molded product, a composite product, etc. in combination with a mold, a resin part, various sheets, etc.

[0056] <Filling device> A filling device according to another aspect of the present invention is a filling device for filling an ultraviolet curable sealing material composition into a mold. The mold is composed of an upper mold and a lower mold, and includes means for pressing the upper mold against the lower mold with a pressing plate. The above description applies to the filling device, the ultraviolet curable sealing material composition, the mold, the upper mold, the lower mold, and the pressing plate. The filling device can include the above-described filling machine.

[0057] As the means for pressing the upper mold against the lower mold with the pressing plate, for example, it may be means for lowering the filling machine, and in addition to lowering the filling machine, it may also be means for directly applying a load to the pressing plate.

[0058] When the means for pressing the upper mold against the lower mold with the pressing plate is means for lowering the filling machine, a spring can be arranged between the filling machine and the pressing plate, and the filling machine can be lowered to apply a load to the pressing plate via the spring.

[0059] <Sealing material manufacturing device> A method for manufacturing a sealing material can use a manufacturing device for the sealing material. The manufacturing device for the sealing material can include the above-described filling device. The manufacturing device for the sealing material may have a plurality of devices used for performing the above-described steps arranged linearly, any one or all of the plurality of devices may be arranged in parallel, the plurality of devices may be arranged concentrically, or these arrangements may be combined.

[0060] FIG. 6 shows a manufacturing apparatus for a sealing material in a linear system. While referring to the manufacturing apparatus 200 for the sealing material shown in FIG. 6, the manufacturing apparatus for the sealing material of the present invention will be described. In the manufacturing apparatus 200 for the sealing material, a conveying device 201, a mold supply device 202, a mold 13, a filling device 100, an ultraviolet irradiation device 203, and a mold release device 204 are linearly arranged. The mold 13 is supplied by the mold supply device 202, the mold 13 is conveyed to the filling device 100 by the conveying device 201, the ultraviolet curable sealing material composition is filled into the mold 13 by the filling device 100, then ultraviolet rays are irradiated in the ultraviolet irradiation device 203, and after curing, the sealing material 205 is removed from the mold 13 in the mold release device 204. In the mold supply device 202, a substrate 16 is disposed between the upper mold 13a and the lower mold 13b. The mold 13 is returned to the mold supply device 202 according to the arrow from the mold release device 204.

[0061] As the conveying device 201, for example, a belt conveyor, a free flow conveyor, a linear conveyor module, a conveying roll, a conveying arm, or the like can be used.

[0062] The ultraviolet irradiation device 203 can be provided with a light source such as a metal halide lamp, an LED, or the like. According to the present invention, since it is possible to reduce the thickness of the upper mold, it is easy to reduce the distance between the light source and the ultraviolet curable sealing material composition filled in the mold. When the distance between the ultraviolet curable sealing material composition filled in the mold is short, for example, even if ultraviolet rays are not irradiated at a high illuminance, the ultraviolet curable sealing material composition filled in the mold tends to be easily cured in a short time. The distance between the light source and the ultraviolet curable sealing material composition filled in the mold may be, for example, 30 mm or less, preferably 20 mm or less, more preferably 15 mm or less, still more preferably 10 mm or less, and particularly preferably 6 mm or less from the viewpoint of efficient curing of the ultraviolet curable sealing material composition.

Examples

[0063] Hereinafter, the present invention will be described in more detail with reference to examples. In the examples, “%” and “parts” are mass % and parts by mass, respectively, unless otherwise specified.

[0064] [Preparation of Ultraviolet-Curable Sealant Composition] An ultraviolet-curable sealant composition was prepared by mixing polyisobutylene and a photoinitiator and stirring them.

[0065] [Example 1] In the mold preparation step, an SUS plate was placed between the upper mold and the lower mold made of an acrylic resin to prepare the mold. The upper mold had a filling nozzle insertion part, a runner part, and a gate part. The thickness of the upper mold was 5 mm. A pressing plate made of SUS was placed on the upper mold of the mold conveyed to the filling step by a belt conveyor. By lowering the filling machine of the filling device, a load was applied to the pressing plate via a spring disposed between the filling machine and the pressing plate, the upper mold was pressed against the lower mold, and the filling nozzle of the filling device was inserted into the filling nozzle insertion part. With the upper mold pressed against the lower mold, the upper mold and the lower mold were fixed by clamping, and the ultraviolet-curable sealant composition was filled into the cavity of the mold from the filling nozzle. Next, the filling nozzle was removed from the mold. Thereafter, the mold filled with the ultraviolet-curable sealant composition was conveyed to the irradiation step, irradiated with ultraviolet rays from an ultraviolet irradiation device having an LED as a light source for ultraviolet rays, and the ultraviolet-curable sealant composition was cured. Thereafter, it was conveyed to the mold release step, the clamp was removed, and the sealant was removed from the mold together with the SUS plate. No leakage of the ultraviolet-curable sealant composition was confirmed between the mold used as the upper mold. [Explanation of Signs]

[0066] 10 Filling machine, 11 Filling nozzle, 11a Taper part, 11b Tip, 12 Pressing plate, 13 Mold, 13a Upper mold, 13b Lower mold, 14 Material filling port, 15 Nozzle through hole, 16 Substrate, 17 Cavity, 18 Filling nozzle insertion part, 18a Taper part, 19 Runner part, 21 Protrusion, 22, 23 Through holes, 24 Interlocking mechanism, 25 Exhaust port, 26 Mold sealant, 27 Second mechanism, 100 Filling device, 200 Sealant manufacturing device, 201 Conveying device, 202 Mold supply device, 203 Ultraviolet irradiation device, 204 Mold release device, 205 Sealant.

Claims

1. A method for manufacturing a sealing material, comprising: a mold preparation step of preparing a mold; a filling step of filling the mold with an ultraviolet curable sealing material composition using a filling machine; an irradiation step of irradiating the ultraviolet curable sealing material composition with ultraviolet rays; and a demolding step of removing the sealing material from the mold, wherein in the filling step, the mold filled with the ultraviolet curable sealing material composition is conveyed to the irradiation step, in the demolding step, the mold from which the sealing material has been removed is returned to the mold preparation step, the mold is composed of an upper mold and a lower mold, and in the filling step, a pressing plate is disposed above the upper mold, and the pressing plate is lowered to press the mold from above the upper mold toward the lower mold side. A method for manufacturing a sealing material.

2. The method for manufacturing a sealing material according to claim 1, wherein the filling machine is lowered to further press the mold from above the upper mold toward the lower mold side through the pressing plate by the filling machine.

3. The method for manufacturing a sealing material according to claim 2, wherein a spring is disposed between the filling machine and the pressing plate.

4. The mold is formed of at least one selected from the group consisting of glass, quartz, polyester resin, polycarbonate resin, acrylic resin, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polyvinylidene fluoride, polyvinyl fluoride, tetrafluoroethylene-ethylene copolymer, polychlorotrifluoroethylene, and cycloolefin polymer. The method for manufacturing a sealing material according to claim 1.

5. A manufacturing apparatus for a sealing material, comprising: a mold supply device for supplying a mold; a filling device for filling the mold with an ultraviolet curable sealing material composition; an ultraviolet irradiation device for irradiating the ultraviolet curable sealing material composition with ultraviolet rays to cure the ultraviolet curable sealing material composition; a demolding device for removing the sealing material from the mold; and a conveying device for conveying the mold between processes wherein the mold is composed of an upper mold and a lower mold, the filling device includes a pressing plate disposed above the upper mold, and the filling device further includes means for lowering the pressing plate to press the mold from above the upper mold toward the lower mold side. A manufacturing apparatus for a sealing material.

6. The filling device further includes a filling machine above the pressing plate, and a spring is disposed between the filling machine and the pressing plate. The sealing material manufacturing apparatus according to claim 5, further comprising means for lowering the filling machine to further press the mold from above the upper mold toward the lower mold side through the spring and the pressing plate by the filling machine.

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