Head, molding system, sheet arrangement method, and molding product manufacturing method

Abstract

To control sheet elongation.SOLUTION: A head 30 is driven to transport a sheet 11. The head 30 has a holding section 31 and a protruding section 32. The holding section 31 holds the sheet 11. The protrusion 32 is movable relative to the holding section 31 so as to pass through a holding surface 31m defined by the holding section 31.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present disclosure relates to a head driven to transport a sheet, a forming system having the head, and a method for positioning the sheet. [Background technology]

[0002] For example, a molding system such as that described in Patent Document 1 is known, which uses an injection molding machine to provide molded parts on a sheet to produce a molded product. Such a molding system makes it possible to easily provide molded parts with complex shapes on a sheet. The sheet is provided with a design. The design on the sheet allows the molded product to have a desired design. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2018 / 186414 Summary of the Invention [Problem to be solved by the invention]

[0004] A sheet is placed in a mold of an injection molding machine. When placed in the mold, the sheet deforms to conform to the shape of the mold. The shape of the mold is determined by the shape of the molded product to be formed. The mold may include a concave shape. In such a mold, the sheet may be deformed so as to be stretched when placed in the mold. When the sheet is stretched, a design provided on the sheet is also stretched. As a result, the design provided on the molded product becomes unintended. The present disclosure aims to suppress sheet stretching. [Means for solving the problem]

[0005] The head of the present disclosure is a head that is driven to transport a sheet, a holding portion that holds the sheet; The holding portion has a protrusion that is movable relative to the holding portion so as to pass through a holding surface defined by the holding portion.

[0006] The head of the present disclosure may further include an elastic member connected to the holding portion.

[0007] The head of the present disclosure comprises: a link mechanism connecting the holding portion and the protruding portion; The link mechanism may have a first movable part connected to the protrusion, a second movable part connected to the holding part, a rotation interlocking part provided between the first movable part and the second movable part, a first movable shaft connecting the first movable part and the rotation interlocking part, and a second movable shaft connecting the second movable part and the rotation interlocking part.

[0008] In the head of the present disclosure, the edge of the protrusion may be chamfered.

[0009] In the head of the present disclosure, the holding portion may include a first suction hole.

[0010] In the head of the present disclosure, the protrusion may have an uneven shape.

[0011] The head of the present disclosure may further include a second protrusion movable relative to the holding portion so as to pass through the holding surface.

[0012] The molding system of the present disclosure comprises: Any of the heads described above; a sheet feeding device for feeding the sheet; a drive unit that drives the head; and an injection molding machine that molds a molded product in a storage space that stores the sheet.

[0013] In the molding system of the present disclosure, the injection molding machine has a first mold including a concave shape; The first mold has a second suction hole, The protrusion may cause the sheet to protrude relative to the first mold.

[0014] The seat arrangement method of the present disclosure includes: a step of holding the sheet by a holding portion; moving the head having the holding portion to an injection molding machine; placing the sheet in a first mold of the injection molding machine; The process of placing the sheet on the first mold includes a process of deforming the sheet so that a portion of the sheet protrudes from the holding surface defined by the holding portion toward the first mold, and a process of the first mold adsorbing the sheet.

[0015] The method for producing a molded article of the present disclosure includes: placing the sheet in the first mold by the sheet placement method described above; a step of bringing a second mold into contact with the first mold; and injecting a thermoplastic resin into a storage space formed between the first mold and the second mold so that the thermoplastic resin contacts at least a portion of the sheet. [Effects of the Invention]

[0016] According to the present disclosure, stretching of the sheet can be suppressed. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a top view schematically showing the entire molding system. [Figure 2] FIG. 2 is a side view of the sheet feeding device observed from a direction parallel to the sheet surface of the sheet. [Figure 3] FIG. 3 is a front view of the sheet feeding device observed from the normal direction of the sheet surface of the sheet. [Figure 4] FIG. 4 is a front view schematically showing the head and the drive unit. [Figure 5] FIG. 5 is a perspective view of the holding portion and protrusion of the head. [Figure 6]FIG. 6 is a diagram schematically showing an injection molding machine and a head disposed between a first mold and a second mold of the injection molding machine. [Figure 7] FIG. 7 is a diagram showing a state in which the head holds the sheet from the sheet supply device. [Figure 8] FIG. 8 is a diagram showing a process of placing a sheet in a first mold. [Figure 9] FIG. 9 is a diagram showing a state in which a sheet is placed on the first mold. [Figure 10] FIG. 10 is a perspective view showing a first modified example of the head. [Figure 11] FIG. 11 is a side view showing a first modified example of the head. [Figure 12] FIG. 12 is a side view showing a first modified example of the head. [Figure 13] FIG. 13 is a side view showing a second modified example of the head. [Figure 14] FIG. 14 is a side view showing a second modified example of the head. [Figure 15] FIG. 15 is a perspective view showing a third modified example of the head. [Figure 16] FIG. 16 is a side view showing a third modified example of the head. [Figure 17] FIG. 17 is a side view showing a third modified example of the head. DETAILED DESCRIPTION OF THE INVENTION

[0018] An embodiment of the present invention will now be described with reference to the drawings. The scale and aspect ratios of the drawings attached to this specification have been changed and exaggerated from those of the actual objects for ease of illustration and understanding.

[0019] The term "sheet surface" refers to a surface that coincides with the planar direction of the target sheet-like member when the target sheet-like member is viewed overall and from a global perspective.

[0020] Terms used in this specification that specify shapes and geometric conditions and their degrees, such as "parallel," "orthogonal," and "identical," as well as values ​​of lengths and angles, are not limited to strict meanings and are interpreted to include a range of degrees within which similar functions can be expected.

[0021] FIG. 1 is a schematic top view of a molding system according to the present embodiment. The molding system 1 produces a molded product 13, which includes a sheet 11 and a molded part 12. As shown in FIG. 1, the molding system 1 is enclosed in a clean booth 5, preventing unintended foreign matter from entering the molding system 1 from the outside. The clean booth 5 is provided with a first opening 6 and a second opening 7. The first opening 6 is located on a first side s1 of the flow direction dF. The second opening 7 is located on a second side s2 of the flow direction dF. In the clean booth 5, air flows in through the first opening 6 and out through the second opening 7. In the clean booth 5, an air flow occurs from the first side s1 to the second side s2 of the flow direction dF. This air flow prevents foreign matter from adhering to the sheet 11 and other components of the molding system 1. In the illustrated example, the flow direction dF is shown as a straight line, but it may also be a curved or broken line. For example, the flow direction dF may be an L-shaped direction.

[0022] As shown in FIG. 1, the molding system 1 includes a sheet supply device 20, a head 30, a drive device 40, an injection molding machine 50, and a collection position 90. In the example particularly shown in FIG. 1, the components of the molding system 1 are arranged in the following order from a first side s1 to a second side s2 in the flow direction dF: the sheet supply device 20, the injection molding machine 50, and the collection position 90. The sheet supply device 20 supplies a sheet 11 by cutting a film 10 to a predetermined size. The head 30 receives the sheet 11 from the sheet supply device 20 and holds the sheet 11. The head 30 is driven by the drive device 40, and the sheet 11 is transported to the injection molding machine 50. The injection molding machine 50 receives the sheet 11 from the head 30. The injection molding machine 50 provides a molding part 12 on the sheet 11 to produce a molded product 13. The molded product 13 is held by the head 30. The head 30 is driven by the drive unit 40 to transport the molded product 13 to the collection position 90. In this manner, the molding system 1 can manufacture the molded product 13.

[0023] The sheet 11 is formed by cutting the film 10. The film 10 is in a roll shape and is appropriately fed out by the sheet feeder 20. The dimensions of the sheet 11 may be, for example, a rectangular shape with a roll feed length of 15 cm to 150 cm and a roll width of 15 cm to 100 cm. The thickness of the sheet 11 may be, for example, 50 μm to 1000 μm. The sheet 11 may have any shape and dimensions. The sheet 11 is made of a thermoplastic resin that softens when heated. The material of the sheet 11 may be, for example, acrylic, PET, ABS, polyethylene, polypropylene, or polycarbonate. The sheet 11 may have a design such as a pattern, lettering, or picture. The design on the sheet 11 is preferably appropriately displayed when the sheet 11 undergoes an intended deformation, such as when held by the head 30. The design on the sheet 11 is preferably designed taking into account the intended deformation, such as when the sheet 11 is held by the head 30.

[0024] Each component of the molding system 1 will be described in detail below.

[0025] FIG. 2 shows a side view of the sheet feeding apparatus 20 of the first embodiment. More specifically, FIG. 2 shows the sheet feeding apparatus 20 observed from a direction parallel to the sheet surface of the sheet 11 being fed. The sheet feeding apparatus 20 feeds sheets 11 of predetermined dimensions. A film 10 forming the sheet 11 is fed into the sheet feeding apparatus 20. In the sheet feeding apparatus 20, the film 10 is preferably fed vertically from the bottom to the top. In this case, the installation area of ​​the sheet feeding apparatus 20 can be made smaller than when the film 10 is fed horizontally. As shown in FIG. 2, the sheet feeding apparatus 20 includes a tensioning means 21, a clamp 22, a plate member 23, a cutting means 27, and a sensor 28.

[0026] In the illustrated example, the clamps 22 consist of a first clamp 22a and a second clamp 22b. The first clamp 22a and the second clamp 22b clamp the film 10. FIG. 3 shows the sheet feeding device 20 as viewed from the normal direction of the sheet surface of the sheet 11 being fed. As shown in FIGS. 2 and 3, the first clamp 22a clamps the second side s4 of the film 10 in the first direction d1, and the second clamp 22b clamps the first side s3 of the film 10 in the first direction d1. In the example shown in FIG. 3, the first clamp 22a and the second clamp 22b are shown as rod-shaped, but they may have any shape.

[0027] With the film 10 held between the clamps 22, the tensioning means 21 applies tension to the film 10 from the first side s3 in the first direction d1. In the example shown in FIG. 2, the tensioning means 21 is a roll around which the film 10 is partially wound. By rotating the roll, the tension applied to the film 10 held between the clamps 22 can be kept substantially constant. The tensioning means 21 is not limited to a roll and may be any member.

[0028] The first direction d1 is preferably a vertical direction, and the first side s3 of the first direction d1 is preferably a lower side in the vertical direction.

[0029] Plate member 23 moves film 10 clamped by first clamp 22a toward head 30, for example, by pushing it. Plate member 23 is positioned on the side of first clamp 22a opposite to the side from which head 30 approaches in sheet supply device 20, in order to push film 10 toward head 30. In the example shown in FIG. 2 , head 30 approaches sheet supply device 20 from second side s6 in second direction d2. Plate member 23 is positioned on first side s5 in second direction d2 of first clamp 22a. Plate member 23 pushes film 10 toward second side s6 in second direction d2. As plate member 23 pushes film 10, film 10 is supported by plate member 23.

[0030] The second direction d2 is a direction non-parallel to the first direction d1, and is preferably a direction perpendicular to the first direction d1. When the first direction d1 is a vertical direction, the second direction d2 is a horizontal direction.

[0031] The plate member 23 has a smaller dimension than the sheet 11 formed by cutting the film 10 in the unwinding direction of the roll of film 10, i.e., the first direction d1, so that the film 10 can be appropriately cut into sheets 11. The length of the plate member 23 in the unwinding direction of the roll of film 10, i.e., the first direction d1, may be, for example, 18 cm or more and 148 cm or less. On the other hand, the plate member 23 has a larger dimension than the sheet 11 formed by cutting the film 10 in the direction along the width of the roll, so that the film 10 can be appropriately deformed. The length of the plate member 23 along the width of the roll of film 10 may be, for example, 20 cm or more and 120 cm or less.

[0032] Plate member 23 is made of a material that is resistant to deformation so as to properly support film 10. Because film 10 is held by holding portion 31 while being heated by heater 34 (described later) of head 30, plate member 23 is preferably made of a material that is resistant to thermal deformation. Plate member 23 is made of, for example, aluminum, stainless steel, galvanized iron plate, or the like.

[0033] The cutting means 27 cuts the film 10 at predetermined positions to form sheets 11 of predetermined dimensions. The cutting means 27 cuts the rolled film 10 in a direction non-parallel to the unwound direction on the second side s4 of the second clamp 22b in the first direction d1. When the first direction d1 is vertical, the cutting means 27 cuts the lower vertical side of the film 10 in a direction non-parallel to the vertical direction, for example, horizontally. This forms a sheet 11 on the upper vertical side. The cutting means 27 is, for example, a metal blade.

[0034] The sensor 28 detects the film 10 in the sheet supply device 20. Based on this detection, the film 10 can be placed in the sheet supply device 20 at an appropriate position and orientation. The sensor 28 may also detect the length of the film 10 unwound in the first direction d1. In the example shown in FIG. 2, the sensor 28 is located on the same side as the plate member 23. This same side as the plate member 23 is the side opposite to the side to which the head 30 approaches to hold the sheet 11 in the sheet supply device 20; in other words, it is the first side s5 of the clamp 22 in the second direction d2. The sensor 28 detects the position, orientation, etc. of the film 10 through a hole or the like (not shown) provided in the plate member 23. The sensor 28 is not limited to the illustrated example and may be located at any position. The sensor 28 is, for example, an imaging device such as a camera.

[0035] As shown in FIG. 3, alignment marks 10a are provided on the film 10. The sensor 28 can easily detect the position and orientation of the film 10 based on the alignment marks 10a. In the example shown in FIG. 3, the alignment marks 10a are cross-shaped symbols provided on the film 10. The alignment marks 10a are not limited to the illustrated example and may have any shape. The alignment marks 10a may be part of a design provided on the film 10. In other words, the design provided on the film 10 may include the alignment marks 10a. The alignment marks 10a allow the film 10 to be positioned and oriented appropriately in accordance with the design provided on the film 10.

[0036] 4 schematically shows the head 30 and the drive device 40. The head 30 holds the sheet 11. The head 30 may also hold the molded product 13. The head 30 is driven by the drive device 40. In the example shown in FIG. 4, the head 30 has a holder 31, a protrusion 32, a heater 34, an elastic member 35, and a second holder 39.

[0037] The holding unit 31 receives the sheet 11 from the sheet supply device 20 and holds the sheet 11. As shown in FIG. 2, the holding unit 31 approaches the sheet supply device 20 from the second side s6 in the second direction d2. The holding unit 31 receives and holds the sheet 11 from the sheet supply device 20. With the holding unit 31 holding the sheet 11, the head 30 is driven and moves to the injection molding machine 50. The holding unit 31 delivers the sheet 11 to a first mold 51 of the injection molding machine 50, which will be described later.

[0038] FIG. 5 shows a perspective view of the holding portion 31 and the protrusion 32. In the example shown in FIG. 5, the holding portion 31 has a rectangular frame shape. The holding portion 31 defines a holding surface 31m on the side that holds the sheet 11. The holding portion 31 holds the sheet 11 along the holding surface 31m. The holding surface 31m is defined as a surface that is continuous with the surface of the holding portion 31 that is surrounded by the holding portion 31. In the example shown, the holding surface 31m is defined by the surface of the holding portion 31 that has the holding means described below and the frame-shaped opening. The holding surface 31m is a substantially flat surface.

[0039] The holder 31 has a holding means for holding the sheet 11 along the holding surface 31m. In the example shown in FIG. 5, the holding means is a first suction hole 31a that holds the sheet 11 by suction. When the holder 31 is in contact with the sheet 11, air is sucked through the first suction hole 31a using a pump (not shown) or the like, allowing the holder 31 to suction and hold the sheet 11 at the first suction hole 31a. The first suction hole 31a is, for example, circular, with a diameter of 2 mm to 5 mm. Because the first suction hole 31a is sufficiently large, it can properly suction and hold the sheet 11. Because the first suction hole 31a is not too large, the possibility of foreign matter being sucked into the first suction hole 31a and causing problems is reduced. The holder 31 may have any holding means, not limited to the example shown.

[0040] The holding portion 31 has dimensions smaller than the sheet 11 so as to properly hold the sheet 11. The dimensions of the holding portion 31 may be, for example, a length in one direction of 18 cm or more and 148 cm or less, and a length in another direction perpendicular to the one direction of 15 cm or more and 100 cm or less.

[0041] Because the sheet 11 held by the holding part 31 is heated by the heater 34, the holding part 31 is preferably made of a material that is resistant to thermal deformation. The holding part 31 is made of, for example, aluminum or stainless steel. To protect the first die 51, the holding part 31 may be provided with a protective member such as a silicone pad on its surface.

[0042] The protrusion 32 causes the sheet 11 held by the holding unit 31 to protrude toward a first die 51 (described later) of the injection molding machine 50. The protrusion 32 is movable relative to the holding unit 31 so as to pass over a holding surface 31m. The protrusion 32 may move relative to the holding unit 31, the holding unit 31 may move relative to the protrusion 32, or both the holding unit 31 and the protrusion 32 may move relative to each other. When the protrusion 32 passes over the holding surface 31m, the sheet 11 held by the holding unit 31 protrudes and deforms toward the first die 51 of the injection molding machine 50. In the example shown, the protrusion 32 is fixed to the heater 34.

[0043] The protrusion 32 has a shape corresponding to the first die 51. The protrusion 32 deforms the sheet 11 so that the sheet 11 has a shape corresponding to the shape of the first die 51.

[0044] 5, the protrusion 32 is disposed in an opening of the frame-shaped holding portion 31. In the illustrated example, the protrusion 32 has a rectangular frame shape. The protrusion 32 may have any shape.

[0045] 4, the edge 32e of the protrusion 32 has a chamfered shape. In other words, the edge 32e of the protrusion 32 is rounded. In other words, the edge 32e of the protrusion 32 has an R-shape.

[0046] The heater 34 heats the sheet 11 held by the holding unit 31. The heater 34 is provided near the holding unit 31. In the example shown in Fig. 4, the heater 34 is provided on the opposite side of the holding unit 31 from the side that holds the sheet 11.

[0047] The heater 34 heats the sheet 11 held in the holding unit 31 to, for example, 100°C or higher and 160°C or lower. The heater 34 heats the sheet 11 for at least a period from when the holding unit 31 receives the sheet 11 from the sheet supply device 20 until when the holding unit 31 delivers the sheet 11 to the injection molding machine 50. The heater 34 preferably has dimensions equal to or larger than the sheet 11 held in the holding unit 31 so that the entire sheet 11 held in the holding unit 31 can be uniformly heated. The head 30 can be rotated by the drive unit 40, for example, to change the vertical positional relationship between the sheet 11 held in the holding unit 31 and the heater 34. If there is a portion where the heater 34 and the sheet 11 held in the holding unit 31 are relatively far apart, the entire sheet 11 can be uniformly heated by increasing the temperature of the heater 34 in that portion. The entire sheet 11 can be heated more uniformly by covering the space between the sheet 11 held in the holding unit 31 and the heater 34 from the sides with an inorganic plate or the like.

[0048] The elastic member 35 connects the heater 34 to the holder 31. The elastic member 35 changes the distance between the holder 31 and the heater 34. As a result, the elastic member 35 moves the protrusion 32 relative to the holder 31. The elastic member 35 may be, for example, a spring. The elastic member 35 may connect a component of the head 30 other than the heater 34 to the holder 31, as long as it can move the protrusion 32 relative to the holder 31.

[0049] The second holding unit 39 receives the molded article 13 from a second mold 52 (described later) of the injection molding machine 50 and holds the molded article 13. The head 30 is driven while the second holding unit 39 is holding the molded article 13. The second holding unit 39 releases the molded article 13 at the collection position 90.

[0050] The second holding section 39 has holding means for holding the molded article 13. In the example shown in Fig. 4, the holding means is a plurality of suction pads 39a that adsorb the molded article 13. By sucking air from the suction pads 39a while the second holding section 39 is in contact with the molded article 13, the second holding section 39 can adsorb and hold the molded article 13 on the suction pads 39a. The second holding section 39 is not limited to the example shown in the figure, and may have any holding means.

[0051] The drive unit 40 drives the head 30 to transport the sheet 11 held in the holding unit 31 of the head 30 from the sheet supply device 20 to the injection molding machine 50. More specifically, the drive unit 40 drives the head 30 so that the holding unit 31 of the head 30 receives the sheet 11 from the sheet supply device 20 and transfers the sheet 11 from the holding unit 31 to a first mold 51 of the injection molding machine 50. The drive unit 40 may also drive the head 30 to transport the molded article 13 held in the second holding unit 39 of the head 30 from the injection molding machine 50 to a collection position 90. More specifically, the drive unit 40 may drive the head 30 so that the second holding unit 39 receives the molded article 13 from the second mold 52 and transports the molded article 13 from the second holding unit 39 to the collection position 90.

[0052] The driving device 40 is, for example, a so-called multi-axis robot arm. The driving device 40 is detachably connected to the head 30. The head 30 connected to the driving device 40 may be replaceable. By replacing the head 30, the shapes of the holding unit 31 and the second holding unit 39 can be adjusted to match the shape of the molded product 13 to be molded by the molding system 1.

[0053] The injection molding machine 50 provides a molded part 12 on the sheet 11 while deforming the sheet 11, thereby forming a molded article 13. The injection molding machine 50 has a first mold 51 and a second mold 52. The injection molding machine 50 accommodates the sheet 11 in a storage space formed by the first mold 51 and the second mold 52. The sheet 11 deforms to conform to the shape of the storage space, particularly the shape of the first mold 51. The injection molding machine 50 provides the molded part 12 on the sheet 11, conforming to the shape of the storage space. FIG. 6 shows a state in which the head 30 is driven to be positioned between the first mold 51 and the second mold 52 of the injection molding machine 50. As shown in FIGS. 1 and 6, the first mold 51 is located on a first side s1 in the flow direction dF, and the second mold 52 is located on a second side s2 in the flow direction dF. In the injection molding machine 50, after receiving the sheet 11 held by the holding portion 31 of the head 30 in the first mold 51, the injection molding machine 50 delivers the molded article 13 to the second holding portion 39 of the head 30 in the second mold 52. Alternatively, the injection molding machine 50 delivers the molded article 13 to the second holding portion 39 of the head 30 in the second mold 52 at the same time as receiving the sheet 11 held by the holding portion 31 of the head 30 in the first mold 51.

[0054] The first die 51 receives the sheet 11 from the holding section 31. The first die 51 has a shape that mainly corresponds to the shape of the sheet 11 in the molded product 13. The shape of the first die 51 is a shape that forms an appropriate storage space between it and the second die 52. The first die 51 includes a concave shape. The concave shape is a shape that is recessed in a direction away from the second die 52. The first die 51 shapes the sheet 11 to the shape of the sheet 11 in the molded product 13.

[0055] The first mold 51 has a positioning means for positioning the sheet 11 along its shape. In the example shown in FIG. 6 , the positioning means is a second suction hole 51a that adsorbs the sheet 11. The first mold 51 sucks air through the second suction hole 51a using a pump (not shown), allowing the first mold 51 to adsorb the sheet 11 at the second suction hole 51a and position the sheet 11 along its shape. The second suction hole 51a is, for example, circular, with a diameter of 1.5 mm to 10 mm. Because the second suction hole 51a is sufficiently large, the sheet 11 can be properly adsorbed and positioned. Because the second suction hole 51a is not too large, the possibility of foreign matter being sucked into the second suction hole 51a and causing problems is reduced. The second suction hole 51a may be formed in a mesh shape to prevent foreign matter from being sucked in. The first mold 51 may have any holding means, not limited to the example shown.

[0056] The second die 52 delivers the molded product 13 to the second holding section 39. The second die 52 has a shape that mainly corresponds to the shape of the molded part 12 in the molded product 13. The shape of the second die 52 is such that an appropriate storage space is formed between the second die 52 and the first die 51.

[0057] As shown in FIG. 1 , the first die 51 is located between the sheet supply device 20 and the second die 52 in the flow direction dF. The second die 52 is located between the first die 51 and the collection position 90 in the flow direction dF. In other words, the sheet supply device 20, the first die 51, the second die 52, and the collection position 90 are arranged in this order along the flow direction dF. In this case, the head 30 handles the sheet 11 only on the first side s1 in the flow direction dF, so that the holding unit 31 of the head 30 can smoothly receive the sheet 11 from the sheet supply device 20 and transfer it to the first die 51. Because the head 30 handles the molded product 13 only on the second side s2 in the flow direction dF, the second holding unit 39 of the head 30 can smoothly receive the molded product 13 from the second die 52 and release it at the collection position 90.

[0058] The second die 52 moves relative to the first die 51 in the flow direction dF and forms a storage space together with the first die 51. The first die 51 is fixed, in other words, it is preferable that the first die 51 does not move, and the holding unit 31 moves to the first side s1 in the flow direction dF to approach the first die 51, thereby delivering the sheet 11 to the first die 51. When the first die 51 is fixed, unintended deformation of the sheet 11 is less likely to occur due to the movement of the first die 51 before the molded part 12 is provided. The first die 51 may be unfixed and move to the second side s2 in the flow direction dF. Alternatively, both the first die 51 and the second die 52 may move in the flow direction dF.

[0059] The storage space formed between the first die 51 and the second die 52 has a shape corresponding to the molded product 13 to be molded by the injection molding machine 50. The sheet 11 is shaped into a desired shape by vacuuming through the second suction holes 51a from the first die 51 side. A thermoplastic resin such as ABS, PC-ABS, acrylic, polycarbonate, polyethylene, or polypropylene heated to a high temperature is injected from the second die 52 side, and then the thermoplastic resin is cooled to form the molded part 12. The molded part 12 is formed in the shaped sheet 11, thereby forming the molded product 13.

[0060] The collection position 90 is a position for collecting the manufactured molded articles 13. The molded articles 13 collected at the collection position 90 are transported, for example, by a belt conveyor or the like.

[0061] An example of a method for manufacturing the molded product 13 using the molding system 1 will be described with reference to FIG. 2 and FIGS. 6 to 9. FIG.

[0062] As shown in FIG. 2, in the sheet supply device 20, a roll of film 10 is clamped by the first clamp 22a. The film 10 is unwound from the first side s3 in the first direction d1 to the second side s4. While the film 10 is unwound in the first direction d1, tension is applied to the film 10 from the first side in the first direction d1 by the tensioning means 21. If the first direction d1 is vertical, the film 10 is unwound from the lower side to the upper side in the vertical direction. The alignment mark 10a on the film 10 is detected by the sensor 28. The position, orientation, and unwound length of the film 10 are determined based on the detection of the alignment mark 10a by the sensor 28. The plate member 23 contacts the film 10 clamped by the first clamp 22a from the first side s5 in the second direction d2. The second clamp 22b clamps the first side s3 of the film 10 in the first direction d1. Thereafter, the holding portion 31 of the head 30 approaches the sheet supplying device 20 from the second side s6 in the second direction d2.

[0063] Next, holding unit 31 comes into contact with film 10. By sucking air through first suction holes 31a of holding unit 31, holding unit 31 adsorbs and holds film 10 at first suction holes 31a. Then, cutting means 27 cuts first side s3 of film 10 in the first direction d1, which is the second side s4 of second clamp 22b. Film 10 held by holding unit 31 becomes sheet 11 of the specified dimensions. Clamp 22 releases sheet 11.

[0064] The sheet 11 supplied from the sheet supply device 20 is held along the holding surface 31m of the holding unit 31 of the head 30. The head 30 is driven by the drive device 40 to move away from the sheet supply device 20, as shown in FIG. 7 . The head 30 is driven by the drive device 40 to move from the sheet supply device 20 to the injection molding machine 50. The sheet 11 held in the holding unit 31 is transported from the sheet supply device 20 to the injection molding machine 50. The sheet 11 is heated by the heater 34 of the head 30 for at least a period from when the sheet 11 is held in the holding unit 31 to when the sheet 11 is delivered to the injection molding machine 50. It is preferable that the heater 34 heat the sheet 11 for a long period of time. Therefore, it is preferable that the sheet 11 be heated by the heater 34 throughout the entire period from when the sheet 11 is held in the holding unit 31 to when the sheet 11 is delivered to the injection molding machine 50. The temperature of the heater 34 is determined depending on the time the holding unit 31 holds the sheet 11. For example, the temperature of the heater 34 is lowered as the holding unit 31 holds the sheet 11 for a longer period of time. The head 30 is driven by the drive device 40 to adjust the vertical positional relationship between the heater 34 and the sheet 11 held by the holding unit 31. For example, if it is desired to heat the sheet 11 more, the heater 34 is changed to a positional relationship such that it is vertically below the sheet 11. By adjusting the heating time by the heater 34 and the positional relationship between the heater 34 and the sheet 11, the sheet 11 can be appropriately heated. This allows the entire sheet 11 to be softened without causing problems such as blisters. Adjusting the vertical positional relationship of the sheet 11 can prevent the heated and softened sheet 11 from deforming due to its own weight.

[0065] As shown in FIG. 6, the head 30, which holds the softened sheet 11 in the holding portion 31, is positioned between the first mold 51 and the second mold 52 of the injection molding machine 50. In the example shown in FIG. 6, the entire head 30 is positioned between the first mold 51 and the second mold 52 in the flow direction dF. The holding portion 31 holding the sheet 11 faces the first mold 51, and the second holding portion 39, which receives the molded product 13, faces the second mold 52. In the example shown in FIG. 6, the holding portion 31 faces the first side s1 in the flow direction dF, and the second holding portion 39 faces the second side s2 in the flow direction dF. The head 30 then approaches the first mold 51.

[0066] FIG. 8 shows a state in which the sheet 11 held by the holding portion 31 of the head 30 approaches the first mold 51. The holding portion 31 contacts the first mold 51 via the sheet 11. After the sheet 11 approaches the first mold 51, the protruding portion 32 moves relative to the holding portion 31, for example, due to contraction of the elastic member 35. This causes the protruding portion 32 to pass through the holding surface 31m. Having passed through the holding surface 31m, the protruding portion 32 deforms a portion of the sheet 11 so that it protrudes from the holding surface 31m toward the first mold 51. The protruding portion 32 does not contact the first mold 51. In other words, the protruding portion 32 is separated from the first mold 51.

[0067] Thereafter, air is sucked through the second suction holes 51a of the first die 51, causing the first die 51 to begin suctioning the sheet 11 at the second suction holes 51a. This causes the sheet 11 to deform to fit the shape of the first die 51. The suction of air through the first suction holes 31a of the holder 31 is stopped, and the holder 31 no longer holds the sheet 11. This causes the sheet 11 to leave the holder 31 and be placed on the first die 51, as shown in FIG. 9. The sheet 11 is suctioned through the second suction holes 51a, causing the sheet 11 to be shaped to fit the shape of the first die 51. Through the above process, the sheet 11 is placed from the holder 31 onto the first die 51.

[0068] After placing the sheet 11 in the first mold 51, the head 30 moves away from the injection molding machine 50. Then, the second mold 52 moves closer to the first mold 51. This forms a storage space between the first mold 51 and the second mold 52. Thermoplastic resin heated to a high temperature is injected into the storage space so that it comes into contact with at least a portion of the sheet 11. As the thermoplastic resin cools and hardens, a molded part 12 having a shape corresponding to the storage space is provided on the sheet 11. Through these steps, a molded product 13 is manufactured.

[0069] The second mold 52 then moves away from the first mold 51. The molded article 13 is disposed in the second mold 52 and moves away from the first mold 51 together with the second mold 52. For example, if a portion of the molded part 12 is engaged with the second mold 52, the molded article 13 moves away from the first mold 51 together with the second mold 52. The head 30 is again positioned between the first mold 51 and the second mold 52 of the injection molding machine 50. The second holding portion 39 of the head 30 approaches the second mold 52, and the molded article 13 is transferred to the second holding portion 39. The second holding portion 39 holds the molded article 13 by suction. After receiving the molded article 13, the second holding portion 39 moves away from the injection molding machine 50. The head 30 is driven by the drive unit 40 to transport the molded article 13 to the collection position 90. At the collection position 90, the second holding portion 39 releases the molded article 13.

[0070] Through the above steps, molded articles 13 each having molded parts 12 provided on a sheet 11 are manufactured and collected. By repeating this process, molded articles 13 can be manufactured continuously. In the above-described process, after the sheet 11 held by the holding unit 31 is placed in the first mold 51, the molded article 13 may be delivered from the second mold 52 to the second holding unit 39 before the head 30 leaves the injection molding machine 50.

[0071] When a sheet is placed in a mold of an injection molding machine, it deforms to conform to the shape of the mold. The mold of an injection molding machine may include convex or concave shapes depending on the shape of the molded product to be formed. When a sheet is placed in a mold with a convex shape, the sheet is pressed against the convex shape and deforms. In this case, the sheet is difficult to stretch. On the other hand, when a sheet is placed in a mold that includes a concave shape, the sheet is drawn into the concave shape and deforms. In this case, the sheet is easy to stretch. When the sheet is stretched, the design on the sheet is also stretched. As a result, the design imparted to the molded product becomes unintended.

[0072] In this embodiment, the protrusion 32 is movable relative to the holding unit 31 so as to pass through the holding surface 31m. The protrusion 32 moves relative to the holding unit 31, causing it to protrude from the holding surface 31m. A portion of the sheet 11 is pressed against the protrusion 32 protruding from the holding surface 31m and deformed. At this time, the sheet 11 is not easily stretched. In particular, the portion of the sheet 11 protruding from the holding surface 31m by the protrusion 32 is not easily stretched. This portion is where the molded part 12 is provided, and where a design for the molded product 13 is provided. The protrusion 32 has a shape corresponding to the first mold 51 of the injection molding machine 50. The protrusion 32 deforms the sheet 11 to a shape corresponding to the shape of the first mold 51. Even if the first mold 51 includes a concave shape, the sheet 11 is prevented from being caught in the concave shape and deformed when placed in the first mold 51. Stretching of the sheet 11 can be suppressed. The design provided on the sheet 11 is not easily stretched. The molded product 13 can be easily provided with the intended design.

[0073] The head 30 further has an elastic member 35 connected to the holding portion 31. When the elastic member 35 contracts, the protrusion 32 can easily move relative to the holding portion 31. When the holding portion 31 places the sheet 11 on the first mold 51, the elastic member 35 contracts, preventing excessive pressure from being applied to the sheet 11. This makes it possible to suppress unintended deformation of the sheet 11.

[0074] The edge 32e of the protruding portion 32 is chamfered. Even if the protruding portion 32 moves relative to the holding portion 31 and is pressed against the sheet 11 held by the holding portion 31, the edge 32e of the protruding portion 32 prevents the sheet 11 from being damaged.

[0075] The holding portion 31 includes first suction holes 31a. By sucking air through the first suction holes 31a, the holding portion 31 can easily hold the sheet 11.

[0076] The protrusion 32 causes the sheet 11 to protrude relative to the first mold 51 of the injection molding machine 50. The sheet 11 deforms so as to protrude relative to the first mold 51. At this time, the sheet 11 is unlikely to be stretched. Even if the first mold 51 has a concave shape, the sheet 11 is prevented from being deformed when placed in the first mold 51. The sheet 11 can be prevented from being deformed so as to be stretched.

[0077] The head 30 of this embodiment is a head that is driven to transport the sheet 11, and includes a holding portion 31 that holds the sheet 11, and a protruding portion 32 that is movable relative to the holding portion 31 so as to pass through a holding surface 31m defined by the holding portion 31. With this head 30, a portion of the sheet 11 held by the holding portion 31 is deformed so as to protrude from the holding surface 31m. The portion of the sheet 11 is deformed by being pressed against the protruding portion 32. At this time, the sheet 11 is unlikely to be stretched. This makes it possible to prevent the sheet 11 from stretching when it is deformed.

[0078] It should be noted that various modifications can be made to the above-described embodiment. Modifications of the head 30 will now be described with reference to the drawings.

[0079] FIG. 10 shows a perspective view of a first modified example of the head 30. FIG. 11 shows a side view of the modified head 30 of FIG. 10. In the modified example shown in FIGS. 10 and 11, the protrusion 32 has an uneven shape 32a. In other words, as shown in FIG. 11, the length of the protrusion 32 passing through a certain point A on the holding surface 31m may differ from the length of the protrusion 32 passing through another certain point B on the holding surface 31m. As shown in FIG. 12, a portion of the sheet 11 held by the holding portion 31 is pressed against the protrusion 32 and deforms along the uneven shape 32a. At this time, the sheet 11 is not easily stretched. The uneven shape 32a is not limited to the shape shown in FIG. 10 and may be any shape. The uneven shape 32a corresponds to the shape of the first mold 51 of the injection molding machine 50.

[0080] The sheet 11 may have an uneven shape in the molded product 13 to be formed. The first mold 51 of the injection molding machine 50 also has a shape corresponding to the uneven shape of the sheet 11 in the molded product 13. The uneven shape 32a of the protrusion 32 allows the sheet 11 to be deformed to a shape that corresponds to the shape of the first mold 51, even if the first mold 51 has an uneven shape. Even if the first mold 51 includes a concave shape, deformation of the sheet 11 by the first mold 51 when the sheet 11 is placed in the first mold 51 is more effectively suppressed. Stretching of the sheet 11 can be more effectively suppressed. A design provided on the sheet 11 is less likely to be stretched. The intended design is more easily provided on the molded product 13.

[0081] FIG. 13 shows a side view of a second modified example of the head 30. In the modified example shown in FIG. 13, the head 30 further includes a second protrusion 33. Like the protrusion 32, the second protrusion 33 is movable relative to the holder 31 so as to pass through the holding surface 31m. The length over which the second protrusion 33 passes through the holding surface 31m may be the same as or different from the length over which the protrusion 32 passes through the holding surface 31m. In the example shown in FIG. 13, the second protrusion 33 is provided adjacent to the protrusion 32. The second protrusion 33 may be provided at any position. For example, the second protrusion 33 may be provided at an opening of the frame-shaped protrusion 32. The protrusion 32 and the second protrusion 33 work together to form a shape corresponding to the first mold 51. The protrusion 32 and the second protrusion 33 work together to deform the sheet 11 into a shape corresponding to the shape of the first mold 51.

[0082] The sheet 11 may have a complex shape in the molded product 13 to be formed. The first mold 51 of the injection molding machine 50 also has a shape corresponding to the shape of the sheet 11 in the molded product 13. The protrusion 32 and the second protrusion 33 allow the sheet 11 to be deformed to a shape that corresponds to the shape of the first mold 51, even if the first mold 51 has a complex shape. Even if the first mold 51 includes a concave shape, deformation of the sheet 11 by the first mold 51 is more effectively suppressed when the sheet 11 is placed in the first mold 51. Stretching of the sheet 11 can be more effectively suppressed. A design provided on the sheet 11 is less likely to be stretched. The intended design is more easily provided on the molded product 13.

[0083] FIG. 15 shows a perspective view of a third modified example of the head 30. In the modified example shown in FIG. 15, the head 30 further includes a link mechanism 36 connecting the holding portion 31 and the protrusion 32. The link mechanism 36 moves the protrusion 32 relative to the holding portion 31 so that the protrusion 32 passes through the holding surface 31m. In the example shown in FIG. 15, the holding portion 31 and the protrusion 32 are connected by four link mechanisms 36. The number of link mechanisms 36 may be any number as long as the protrusion 32 can be appropriately moved relative to the holding portion 31. The link mechanisms 36 may be connected to other components of the head 30.

[0084] The link mechanism 36 has multiple movable parts, movable shafts, and a rotation interlocking part. FIG. 16 shows a side view of a third modified example of the head 30. In the example shown in FIG. 16, each link mechanism 36 has a first movable part 37a, a second movable part 37b, a rotation interlocking part 37c, a first movable shaft 38a, and a second movable shaft 38b. The first movable part 37a is connected to the protruding part 32. The second movable part 37b is connected to the holding part 31. The rotation interlocking part 37c is provided between the first movable part 37a and the second movable part 37b. The first movable shaft 38a is connected to the rotation interlocking part 37c at the first movable part 37a. The second movable shaft 38b is connected to the rotation interlocking part 37c at the second movable part 37b. The rotation interlocking part 37c is rotatable around a rotation center shaft 38c. As shown clearly in FIG. 16, a closed circuit is formed by the holding portion 31, the protruding portion 32 and a plurality of link mechanisms .

[0085] When the holding part 31 is pressed against the first die 51, the rotation interlocking part 37c rotates, driving the link mechanism 36. FIG. 17 shows a side view of the head 30 after the rotation interlocking part 37c has rotated. In the example shown in FIG. 17, the rotation center axis 38c of the rotation interlocking part 37c is fixed. When the holding part 31 is pressed against the first die 51, the second movable axis 38b moves in the opposite direction to the first die 51, and the rotation interlocking part 37c rotates around the rotation center axis 38c. This causes the first movable axis 38a to move toward the first die 51. As a result, the protrusion 32 to which the first movable part 37a is connected moves relative to the holding part 31 to which the second movable part 37b is connected. The protrusion 32 moves to pass through the holding surface 31m.

[0086] The length that the protrusion 32 passes through the holding surface 31m may be regulated, for example, by restricting the length over which the first movable shaft 38a can move using the length of the elliptical hole shown in Figures 16 and 17, or by providing a stopper (not shown) on the first movable part 37a, the second movable part 37b or the rotation interlocking part 37c.

[0087] The link mechanism 36 has a simple structure and can move the protrusion 32 relative to the holder 31 without delay. In addition, the link mechanism 36 is lightweight, so that the weight of the head 30 does not increase and the drive of the head 30 is prevented from being hindered.

[0088] Naturally, it is also possible to combine the various modifications as appropriate. [Explanation of symbols]

[0089] 1. Molding System 5 Clean Booth 10 Film 10a Alignment Mark 11 sheets 12 Molded parts 13 Molded products 20 Sheet feeding device 21 Pulling means 22 Clamp 22a First clamp 22b Second clamp 23 Plate member 27 Cutting means 28 Sensors 30 heads 31 Holding part 31a 1st suction hole 31m holding surface 32 Protrusion 32a Uneven shape 32e Edge 33 Second protrusion 34 Heater 35 Elastic member 36 Link mechanism 37a 1st moving part 37b 2nd moving part 37c Rotation linkage part 38a 1st movable axis 38b 2nd movable axis 38c Rotational axis 39 Second holding part 40 Drive unit 50 injection molding machine 51 Type 1 51a 2nd suction hole 52 Type 2 90 Collection Location

Claims

1. a head driven to transport a sheet, a holding portion that holds the sheet; a protrusion movable relative to the holding portion so as to pass through a holding surface defined by the holding portion; A head, wherein the sheet is deformed by the protrusion passing through the holding surface.

2. The head according to claim 1 , further comprising an elastic member connected to the holding portion.

3. A head driven to transport a sheet, a holding portion that holds the sheet; a protrusion movable relative to the holding portion so as to pass through a holding surface defined by the holding portion; a link mechanism connecting the holding portion and the protruding portion; The link mechanism includes a first movable part connected to the protrusion, a second movable part connected to the holding part, a rotation interlocking part provided between the first movable part and the second movable part, a first movable shaft connecting the first movable part and the rotation interlocking part, and a second movable shaft connecting the second movable part and the rotation interlocking part.

4. The head according to claim 1 , wherein the edge of the protrusion is chamfered.

5. The head according to claim 1 , wherein the holding portion includes a first suction hole.

6. A head driven to transport a sheet, comprising: a holding portion that holds the sheet; a protrusion movable relative to the holding portion so as to pass through a holding surface defined by the holding portion; The head, wherein the protrusion has an uneven shape.

7. The head according to claim 1 , further comprising a second protrusion movable relative to the holding portion so as to pass through the holding surface.

8. A head according to any one of claims 1 to 7; a sheet feeding device for feeding the sheet; a drive unit that drives the head; an injection molding machine that molds a molded product in a storage space that stores the sheet.

9. the injection molding machine has a first mold including a concave shape; The first mold has a second suction hole, The molding system of claim 8 , wherein the protrusion causes the sheet to protrude relative to the first mold.

10. a step of holding the sheet by a holding portion; moving the head having the holding portion to an injection molding machine; placing the sheet in a first mold of the injection molding machine; the head includes a protrusion movable relative to the holding portion so as to pass through a holding surface defined by the holding portion; A method for placing a sheet, wherein the step of placing the sheet on the first mold includes a step of deforming the sheet so that a portion of the sheet protrudes from the holding surface toward the first mold by the protrusion that has passed through the holding surface, and a step of the first mold adsorbing the sheet.

11. placing the sheet on the first mold by the sheet placement method of claim 10; a second mold approaching the first mold; a step of injecting a thermoplastic resin into a storage space formed between the first mold and the second mold so that the thermoplastic resin contacts at least a portion of the sheet.

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