Sheet holding mechanism, molding system, method for manufacturing molded product, and method for manufacturing molded sheet

Abstract

To provide a seat holding mechanism with a form of opening that improves the function of the seat holding mechanism.SOLUTION: The sheet holding mechanism 31 holds the sheet 11 in the forming system 1 for forming the sheet 11, and it has as a frame section 33 having a frame shape with apertures 33a, a division section 34 provided in the frame section 33 that divides the apertures 33a into a plurality of aperture areas 33b, including at least a first aperture area 33b1 and a second aperture area 33b2, and a plurality of suction holes 31a including frame suction holes 31a1 provided in the frame section 33 and division suction holes 31a2 provided in the division section 34, and as sheet 11, a split sheet 111 facing the first opening area 33b1 and not facing the second opening area 33b2 is held by vacuum suction of the suction holes 31a, including at least the split section suction holes 31a2.SELECTED DRAWING: Figure 4a

Description

[Technical Field]

[0001] The present disclosure relates to a sheet holding mechanism, a molding system, a method for manufacturing a molded product, and a method for manufacturing a molded sheet. [Background technology]

[0002] Currently, methods for forming substrates using vacuum forming are widely known. For example, Patent Document 1 discloses forming a substrate by vacuum forming the substrate and then injection molding a resin onto the surface of the vacuum-formed substrate. Patent Document 1 also discloses using a holding mechanism that holds the substrate by adsorption, transporting the substrate to a mold having a recess connected to a gas flow path, and vacuum-forming the substrate to conform to the shape of the recess by drawing gas from the gas flow path with a suction pump. Patent Document 1 also discloses a holding mechanism having a frame-shaped main body with an opening. [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] With respect to a seat holding mechanism having a frame-shaped member with an opening, there has been a demand for devising a shape of the opening so as to improve the function of the seat holding mechanism.

[0005] The present disclosure has been made in consideration of these points, and has an object to provide a seat holding mechanism provided with an opening configured to improve the function of the seat holding mechanism. [Means for solving the problem]

[0006] A sheet holding mechanism according to one embodiment is a sheet holding mechanism that holds a sheet in a forming system that forms a sheet, the mechanism comprising: a frame portion having a frame-like shape with an opening; a dividing portion provided on the frame portion and dividing the opening into a plurality of opening regions including at least a first opening region and a second opening region; a plurality of suction holes including a frame suction hole provided in the frame portion and a division portion suction hole provided in the division portion, The sheet holding mechanism holds a divided sheet that faces the first opening region but does not face the second opening region as the sheet by vacuum suction of the suction holes including at least the divided portion suction holes.

[0007] In one embodiment, the sheet holding mechanism is configured to tightly contact the sheet with an opposing surface of a mold that is provided in the molding system and used for vacuum forming the sheet, the opposing surface facing the sheet during vacuum forming; The opposing surface has a plurality of forming areas capable of vacuum forming the sheet, including at least a first forming area and a second forming area, and a forming area dividing area located between the plurality of forming areas to separate the plurality of forming areas from each other, The sheet holding mechanism may also press the held divided sheet against an area surrounding the first molding area, including the molding area dividing area, of the opposing surface so that the divided sheet faces the first molding area of ​​the opposing surface but does not face the second molding area.

[0008] A molding system according to one embodiment includes the above-described sheet holding mechanism and a molding machine used for vacuum forming the sheet, the molding machine having a mold having an opposing surface that faces the sheet during vacuum forming; a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with the opposing surface, The opposing surface has a plurality of forming areas capable of vacuum forming the sheet, including at least a first forming area and a second forming area, and a forming area dividing area located between the plurality of forming areas to separate the plurality of forming areas from each other, The drive device is a molding system that drives the sheet holding mechanism to bring the divided sheet held by the sheet holding mechanism into close contact with an area surrounding the first molding area, including the molding area dividing area, of the opposing surface, so that the divided sheet faces the first molding area of ​​the opposing surface but does not face the second molding area.

[0009] In one embodiment, the molding system further includes a sheet supply device that feeds the divided sheet toward the sheet holding mechanism so that the divided sheet is held by the sheet holding mechanism, the molding region dividing region includes a first dividing region extending between the first molding region and the second molding region, The sheet feeding direction in which the sheet feeding device feeds the divided sheets may intersect with a dividing direction in which the dividing regions of the mold extend.

[0010] In one embodiment of the molding system, the molding machine may form a first storage space, a portion of which is partitioned by the first molding area and which stores at least a portion of the divided sheet, and may injection mold resin into the first storage space.

[0011] A method for manufacturing a molded product according to one embodiment is a method for manufacturing a molded product using the molding system described above, comprising: a step of bringing the divided sheet held by the sheet holding mechanism into close contact with an area surrounding the first molding area including the molding area dividing area on the opposing surface; a step of vacuum-forming, in the first molding area, the divided sheet that has been brought into close contact with the area surrounding the first molding area of ​​the opposing surface by the sheet holding mechanism; The method for manufacturing a molded product includes a step of forming the first storage space in which at least a portion of the divided sheet is stored in the molding machine, and injection molding a resin into the first storage space.

[0012] A method for manufacturing a molded product according to one embodiment includes the steps of: feeding the divided sheet to a sheet holding mechanism so that the divided sheet is held by the sheet holding mechanism; The method may further include a step of driving and rotating the sheet holding mechanism that holds the divided sheet so that the divided sheet rotates in a direction orbiting an axis perpendicular to a surface of the divided sheet.

[0013] A method for manufacturing a molded sheet according to one embodiment is a method for manufacturing a molded sheet using the molding system described above, a step of bringing the divided sheet held by the sheet holding mechanism into close contact with an area surrounding the first molding area including the molding area dividing area on the opposing surface; The method may further include a step of vacuum-forming, in the first molding area, the divided sheets that have been brought into close contact with the area surrounding the first molding area by the sheet holding mechanism.

[0014] A sheet holding mechanism according to one embodiment is a sheet holding mechanism that holds a sheet in a forming system that forms a sheet, the mechanism comprising: a frame portion having a frame-like shape with an opening; a plurality of suction holes including at least a frame suction hole provided in the frame, The sheet is held by vacuum suction through the suction holes, and is brought into close contact with an opposing surface of a mold that is provided in the molding system and used for vacuum forming of the sheet, the opposing surface facing the sheet during vacuum forming; The opposing surface has a forming area in which the sheet can be vacuum-formed and an outer peripheral area surrounding the forming area, The sheet holding mechanism adheres the held sheet to the area surrounding the molding area of ​​the opposing surface, facing the area surrounding the molding area of ​​the opposing surface, at multiple contact positions including at least a first position and a second position rotated from the first position by 5° or more in a direction orbiting an axis perpendicular to the surface of the held sheet.

[0015] The seat holding mechanism according to one embodiment may further include a dividing portion provided on the frame portion to divide the opening.

[0016] In the seat holding mechanism according to one embodiment, the frame portion may have a rectangular frame shape.

[0017] A molding system according to one embodiment includes the above-described sheet holding mechanism and a molding machine used for vacuum forming the sheet, the molding machine having a mold having an opposing surface that faces the sheet during vacuum forming; a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with the opposing surface, The opposing surface has a forming area in which the sheet can be vacuum-formed and an outer peripheral area surrounding the forming area, The drive device is a molding system that drives the sheet holding mechanism to face the area surrounding the molding area of ​​the opposing surface at the multiple contact positions, and to bring the sheet held by the sheet holding mechanism into close contact with the area surrounding the molding area of ​​the opposing surface.

[0018] In one embodiment of the molding system, the molding machine may form a storage space, a portion of which is partitioned by the molding area and which stores at least a portion of the sheet, and may injection-mold resin into the storage space.

[0019] A method for manufacturing a molded product according to one embodiment is a method for manufacturing a molded product using the molding system described above, comprising: a step of placing the sheet holding mechanism holding the sheet at any one of the plurality of contact positions and bringing the sheet into close contact with a region surrounding the molding region on the opposing surface; a step of vacuum-forming, in the molding area, the sheet that has been brought into close contact with the area surrounding the molding area of ​​the opposing surface by the sheet holding mechanism; a step of forming the storage space in which at least a portion of the sheet is stored in the molding machine, and injection-molding a resin into the storage space.

[0020] In one embodiment, a method for manufacturing a molded product includes the steps of: feeding the sheet to a sheet holding mechanism so that the sheet is held by the sheet holding mechanism; The method may further include a step of driving and rotating the sheet holding mechanism that holds the sheet so that the sheet rotates in a direction around an axis that is perpendicular to the surface of the sheet.

[0021] A method for manufacturing a molded sheet according to one embodiment is a method for manufacturing a molded sheet using the molding system described above, a step of placing the sheet holding mechanism holding the sheet at any one of the plurality of contact positions and bringing the sheet into close contact with a region surrounding the molding region on the opposing surface; and vacuum-forming the sheet, which has been brought into close contact with the area surrounding the molding area of ​​the opposing surface by the sheet holding mechanism, in the molding area. [Effects of the Invention]

[0022] According to the present disclosure, it is possible to provide a seat holding mechanism having an opening configured to improve the function of the seat holding mechanism. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a top view schematically showing the entire molding system according to the first embodiment. [Figure 2] FIG. 2 is a side view of the sheet feeding device according to the first embodiment, observed from a direction parallel to the sheet surface of the sheet fed by the sheet feeding device. [Figure 3] FIG. 3 is a front view schematically showing the head and the drive device according to the first embodiment. [Figure 4a]FIG. 4a is a perspective view of an example of a sheet holding mechanism according to the first embodiment. [Figure 4b] FIG. 4b is a perspective view of another example of the sheet holding mechanism according to the first embodiment. [Figure 5] FIG. 5 is a perspective view of the sheet holding mechanism holding the divided sheets according to the first embodiment. [Figure 6] FIG. 6 is a perspective view of the sheet holding mechanism holding the entire sheet according to the first embodiment. [Figure 7] FIG. 7 is a perspective view of the molded product holding mechanism according to the first embodiment. [Figure 8] FIG. 8 is a diagram schematically showing a molding machine according to the first embodiment and a head disposed between a mold and an opposing mold of the molding machine. [Figure 9] FIG. 9 is a plan view showing the mold according to the first embodiment as viewed from the opposing surface side. [Figure 10] FIG. 10 is a cross-sectional view taken along the line AA in FIG. [Figure 11] FIG. 11 is a diagram showing how the sheet is transferred from the sheet holding mechanism to the mold of the molding machine in the first embodiment. [Figure 12] FIG. 12 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the first embodiment. [Figure 13] FIG. 13 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the first embodiment. [Figure 14] FIG. 14 is a diagram showing a state in which the sheet is vacuum-formed in the first embodiment. [Figure 15] FIG. 15 is a diagram showing an example of how the counter mold is moved relative to the mold in the first embodiment. [Figure 16] FIG. 16 is a diagram showing a state in which an accommodation space is formed between a mold and an opposing mold in the first embodiment. [Figure 17]FIG. 17 is a diagram showing how the counter mold is separated from the mold in the first embodiment. [Figure 18] FIG. 18 is a diagram showing how a molded product is transferred from an opposing mold to a molded product holding mechanism in the first embodiment. [Figure 19] FIG. 19 is a diagram showing a state in which a molded product is transferred from an opposing mold to a molded product holding mechanism in the first embodiment. [Figure 20] FIG. 20 is a side view of a molded product manufactured by the method for manufacturing a molded product. [Figure 21] FIG. 21 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the first embodiment. [Figure 22] FIG. 22 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the first embodiment. [Figure 23] FIG. 23 is a diagram showing a state in which the sheet is vacuum-formed in the first embodiment. [Figure 24] FIG. 24 is a diagram showing a state in which an accommodation space is formed between a mold and an opposing mold in the first embodiment. [Figure 25] FIG. 25 is a side view of a molded product manufactured by the method for manufacturing a molded product according to the first embodiment. [Figure 26] FIG. 26 is a diagram showing a sheet holding mechanism according to a first comparative example. [Figure 27] FIG. 27 is a perspective view of a sheet holding mechanism according to the second embodiment. [Figure 28] FIG. 28 is a perspective view of a sheet holding mechanism holding a sheet according to the second embodiment. [Figure 29] FIG. 29 is a plan view showing the mold according to the second embodiment as viewed from the opposing surface side. [Figure 30] 30 is a cross-sectional view taken along line BB in FIG. [Figure 31]FIG. 31 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the second embodiment. [Figure 32] FIG. 32 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the second embodiment. [Figure 33] FIG. 33 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the second embodiment. [Figure 34] FIG. 34 is a diagram showing a state in which the sheet held by the sheet holding mechanism is brought into close contact with the opposing surface in the second embodiment. [Figure 35] FIG. 35 is a diagram showing a state in which a sheet is vacuum-formed in the second embodiment. [Figure 36] FIG. 36 is a diagram showing a state in which an accommodation space is formed between a mold and an opposing mold in the second embodiment. [Figure 37] FIG. 37 is a side view of a molded product manufactured by the method for manufacturing a molded product according to the second embodiment. [Figure 38] FIG. 38 is a plan view of a molded product manufactured by the method for manufacturing a molded product according to the second embodiment. [Figure 39] FIG. 39 is a plan view of a molded product manufactured by the method for manufacturing a molded product according to the second embodiment. [Figure 40] FIG. 40 is a diagram showing how a sheet is fed into a mold in Comparative Example 3. [Figure 41] FIG. 41 is a diagram showing a sheet holding mechanism according to the first modification. [Figure 42] FIG. 42 is a side view of a molded product manufactured by the method for manufacturing a molded product according to the second modification. [Figure 43] FIG. 43 is a side view of a molded product manufactured by a method for manufacturing a molded product according to the third modification. DETAILED DESCRIPTION OF THE INVENTION

[0024] Embodiments of the present disclosure will be described below with reference to the drawings. The figures shown below are schematic diagrams. Therefore, the size and shape of each part are appropriately exaggerated for ease of understanding. Furthermore, appropriate modifications can be made within the scope of the technical concept. In the figures shown below, identical parts are denoted by the same reference numerals, and some detailed descriptions may be omitted. Furthermore, the numerical values, such as dimensions, and material names of each component described in this specification are examples of embodiments, and are not limited thereto and may be appropriately selected and used. In this specification, terms specifying shapes or geometric conditions, such as parallel, perpendicular, and right angles, are interpreted not only to mean their strict meanings but also to include substantially the same state.

[0025] (First embodiment) First, a molding system 1 according to a first embodiment will be described. FIG. 1 is a schematic top view of the molding system 1 of the first embodiment. In the first embodiment, the molding system 1 produces a molded product 16 in which a resin-containing molded part 12 is provided on a sheet 11, as shown in FIG. 20 and described below. As shown in FIG. 1, the molding system 1 is covered by a clean booth 5. The clean booth 5 prevents unintended external objects from entering the molding system 1. The clean booth 5 has a first opening 6 on a first side s1 in the first direction d1 and a second opening 7 on a second side s2 in the first direction d1. In the clean booth 5, air flows in through the first opening 6 and out through the second opening 7. That is, an air flow occurs in the clean booth 5 from the first side s1 in the first direction d1 to the second side s2 in the first direction d1. This air flow prevents external foreign matter from adhering to the sheet 11 and other components in the devices and components of the molding system 1.

[0026] The molding system 1 includes a head 30, a molding machine 50, and a drive device 40. In the example shown in FIG. 1, the molding system 1 further includes a sheet supply device 20 and a trimming device 80. In the example shown in FIG. 1, the components of the molding system 1 are arranged in the above-described order from the first side s1 in the first direction d1 to the second side s2 in the first direction d1. The sheet supply device 20 supplies the sheet 11 cut to a predetermined size from the sheet 11 wound into a roll 10. The head 30 includes a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30. The head 30 receives the sheet 11 in the sheet holding mechanism 31 and holds the sheet 11. The head 30 is driven by the drive device 40 to transport the sheet 11 to the molding machine 50. The molding machine 50 receives the sheet 11. The molding machine 50 includes a mold 51 and an opposing mold 52. The molding machine 50 vacuum-forms the received sheet 11 using a mold 51. After vacuum-forming the sheet 11, the molding machine 50 brings the mold 51 and an opposing mold 52 closer together to form a storage space 55 that accommodates a portion of the sheet 11. The molding machine 50 then injects resin into the storage space 55 to provide the sheet 11 with a molded part 12 and form a molded product 13. The molded product 13 is held by the head 30. The head 30 holding the molded product 13 is driven by the drive device 40, and the molded product 13 is transported to the trimming device 80. The trimming device 80 trims the molded product 13 to produce a molded product 16. In this way, the molding system 1 can continuously supply the sheet 11, form the molded product 13, and trim the molded product 13 in a single system, thereby producing the molded product 16.

[0027] Each component of the molding system 1 will be described in detail below.

[0028] FIG. 2 shows a side view of the sheet supplying device 20. More specifically, FIG. 2 shows the sheet supplying device 20 as viewed from the side of the sheet 11 being supplied. Note that FIG. 2 does not show a dividing unit 34 of a sheet holding mechanism 31, which will be described later. The sheet supplying device 20 supplies the sheet 11, which is supplied from a roll 10 around which the sheet 11 is wound and cut to a predetermined size. The sheet 11 is made of a thermoplastic resin that softens when heated. Examples of materials for the sheet 11 include acrylic, polyethylene terephthalate (PET), ABS, polyethylene, polypropylene, and polycarbonate. The sheet 11 may bear a design such as a pattern or information such as text. The design or information is provided on the sheet 11, for example, by printing on the surface of the sheet 11. When a design or information is to be displayed on the sheet 11, the design or information is displayed appropriately on the sheet 11 supplied from the sheet supplying device 20 after the sheet 11 is deformed by a molding machine 50 or the like. 2, the sheet 11 supplied by the sheet supply device 20 is held by a sheet holding mechanism 31 of the head 30. As shown in FIG. 2, the sheet supply device 20 has a sheet cutting means 21, a first clamp 23a and a second clamp 23b, a plate member 25, and a sensor 27.

[0029] The sheet supply device 20 feeds the sheet 11 facing the sheet holding mechanism 31 so that the sheet 11 is held by the sheet holding mechanism 31. In the example shown in FIG. 2, the sheet 11 is fed from the roll 10 facing the sheet holding mechanism 31. The direction in which the sheet supply device feeds the sheet is also referred to as the feed direction d3. In the example shown in FIG. 2, the sheet 11 is fed from below to above in the vertical direction (the up-and-down direction in FIG. 2). That is, the feed direction d3 is a direction from below to above in the vertical direction. The sheet cutting means 21 cuts the sheet 11 fed from the roll 10 in a direction non-parallel to the feeding direction above the second clamp 23b, thereby adjusting the sheet 11 to a predetermined size. As described above, in the example shown in FIG. 2, the sheet 11 is fed from below to above in the vertical direction. Therefore, the sheet cutting means 21 cuts the vertically downward portion of the sheet 11 in a direction non-parallel to the vertical direction, for example, horizontally. As a result, a sheet 11 trimmed to a predetermined size is formed vertically upward. In particular, the sheet 11 is fed from below vertically upward and cut horizontally to form a rectangular sheet 11. The sheet cutting means 21 is, for example, a metal blade.

[0030] The first clamp 23a and the second clamp 23b clamp the sheet 11 fed from the roll 10. As shown in FIG. 2, the first clamp 23a can clamp the upper part of the sheet 11. The second clamp 23b can clamp the lower part of the sheet 11. After the first clamp 23a clamps the upper part of the sheet 11 and the sheet holding mechanism 31 holds the center of the sheet 11, the second clamp 23b clamps the sheet 11. Thereafter, the sheet cutting means 21 cuts the sheet 11, and the first clamp 23a releases the sheet 11, so that the sheet 11, which has been cut and trimmed to a predetermined size, can be smoothly held by the sheet holding mechanism 31. As an example, the first clamp 23a and the second clamp 23b are rod-shaped, but are not limited to this and may have any shape.

[0031] The plate member 25 moves the sheet 11 held by the first clamp 23a toward the sheet holding mechanism 31, for example by pushing it out. The plate member 25 is disposed on the side of the sheet feeder 20 opposite to the side from which the head 30 of the first clamp 23a approaches, in order to push the sheet 11 toward the sheet holding mechanism 31. In the example shown in FIG. 2, the sheet holding mechanism 31 approaches the sheet feeder 20 from the second side s2 in the first direction d1, so the plate member 25 is disposed on the first side s1 in the first direction d1 of the first clamp 23a. The plate member 25 also has a shape corresponding to the sheet holding mechanism 31. In other words, the plate member 25 has a shape complementary to that of the sheet holding mechanism 31. In the example shown in FIG. 2, the surface of the plate member 25 facing the sheet 11 is a plane parallel to the surface of the sheet 11 held by the first clamp 23a. The surface of the sheet holding mechanism 31 facing the sheet 11 is a plane parallel to the surface of the sheet 11 held by the first clamp 23a. As a result, the surface of the plate member 25 facing the sheet 11 and the surface of the sheet holding mechanism 31 facing the sheet 11 are parallel to each other. By pushing the sheet 11 out using the plate member 25, the sheet 11 comes into contact with the sheet holding mechanism 31 and is held by the sheet holding mechanism 31. The sheet 11 is then held by the second clamp 23b. The sheet 11 is cut by the sheet cutting means 21 and adjusted to a predetermined size. As a result, the sheet 11 is delivered from the sheet supply device 20 to the sheet holding mechanism 31 without bending.

[0032] The sensor 27 detects the sheet 11 in the sheet feeder 20. Based on this detection, the sheet 11 can be placed in the sheet feeder 20 at an appropriate position and orientation. The sensor 27 may also detect the length of the sheet 11 fed upward in the vertical direction. In the example shown in FIG. 2 , the sensor 27 is disposed on the same side as the plate member 25, i.e., the side opposite to the side to which the sheet holding mechanism 31 approaches. In other words, the sensor 27 is disposed on the first side s1 in the first direction d1 of the first clamp 23a and the second clamp 23b. The sensor 27 detects the position, orientation, etc. of the sheet 11 through a hole or the like (not shown) provided in the plate member 25. However, the illustrated example is not limiting, and the sensor 27 may be disposed on the same side to which the sheet holding mechanism 31 approaches in the sheet feeder 20 to hold the sheet 11. Such a sensor 27 is, for example, an imaging device such as a camera. As an example, although not shown, the sheet 11 may be provided with an alignment mark such as a cross symbol. In this case, the sensor can easily detect the position and orientation of the sheet 11 based on the alignment marks provided on the sheet 11.

[0033] FIG. 3 schematically shows the head 30 and the drive device 40. Note that in FIG. 3, a dividing section 34 of a sheet holding mechanism 31, which will be described later, is omitted from the illustration. The head 30 holds the sheet 11. The drive device 40 drives the head 30 to transport the sheet 11 to a mold 51 of a molding machine 50. In the example shown in FIG. 3, the drive device 40 transports the sheet 11 held by the head 30 from the sheet supply device 20 to the mold 51. Also, in the example shown in FIG. 3, the head 30 holds a molded product 13 to be molded in the molding machine 50. The drive device 40 drives the head 30 to transport the molded product 13 held by the head 30 from the molding machine 50 to a trimming device 80. The drive device 40 is, for example, an articulated robot.

[0034] As shown in Fig. 3, the head 30 has a sheet holding mechanism 31 and a heater 35. In the example shown in Fig. 3, the head 30 further has a molded product holding mechanism 32 and a molded product heater 36. The drive device 40 has a connection part 41 and a rotation part 43.

[0035] 4a shows an example of a perspective view of the sheet holding mechanism 31 and the heater 35. The sheet holding mechanism 31 is a part that holds the sheet 11 in the molding system 1 that molds the sheet 11. The sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20, transports the sheet 11 to a mold 51 of a molding machine 50, and delivers the sheet 11 to the mold 51.

[0036] As shown in Figure 4a, the sheet holding mechanism 31 of the first embodiment has a frame portion 33 having an opening 33a, a dividing portion 34 provided in the frame portion 33 to divide the opening 33a into multiple opening areas 33b, and multiple suction holes 31a.

[0037] The frame portion 33 has a frame-like shape. In the example shown in Fig. 4a, the frame portion 33 has a rectangular frame-like shape. That is, the frame portion 33 has a pair of first portions 33d extending in one direction (the up-down direction in Fig. 4a) and a pair of second portions 33e extending in a direction perpendicular to the direction in which the pair of first portions 33d extend (the left-right direction in Fig. 4a) and connecting the pair of first portions 33d to each other.

[0038] The dividing portion 34 is provided on the frame portion 33 and divides the opening 33a into a plurality of opening regions 33b, including at least a first opening region 33b1 and a second opening region 33b2. In the example shown in FIG. 4a, the dividing portion 34 extends in the direction in which the pair of first portions 33d extend (the vertical direction in FIG. 4a) and connects the pair of second portions 33e together. In this way, the dividing portion 34 divides the opening 33a into two opening regions 33b, the first opening region 33b1 and the second opening region 33b2. The dividing portion 34 may be integrated with the frame portion 33, or may be separable from the frame portion 33. If the dividing portion 34 is separable from the frame portion 33, the position at which the dividing portion 34 connects to the frame portion 33 may be adjustable.

[0039] Although not shown, the divider 34 may divide the opening 33a into three or more opening regions 33b. For example, the divider 34 may have a first divider portion that extends in the direction in which the pair of first portions 33d extend (the up-down direction in FIG. 4a) and connects the pair of second portions 33e together, and a second divider portion that extends in the direction in which the pair of second portions 33e extend (the left-right direction in FIG. 4a), intersects with the first divider portion, and connects the pair of first portions 33d together. In this case, the divider 34 divides the opening 33a into four opening regions 33b.

[0040] 4a, the sheet holding mechanism 31 has a second surface 31c located on the opposite side to the first surface 31b. The first surface 31b is formed by the surface of the frame portion 33 and the surface of the dividing portion 34. The second surface 31c is formed by the surface of the frame portion 33 and the surface of the dividing portion 34. The sheet holding mechanism 31 holds the sheet 11 on the first surface 31b side.

[0041] The sheet holding mechanism 31 has a shape that corresponds to the mold 51, in other words, a shape that is complementary to the mold 51, so that the sheet 11 can be properly transferred to the mold 51. The sheet holding mechanism 31 has a shape that is particularly complementary to a portion that forms an outer peripheral region 51e of an opposing surface 51a (described later) of the mold 51. As described above, the first surface 31b of the sheet holding mechanism 31 is a flat surface that is parallel to the surface of the sheet 11 clamped by the first clamp 23a.

[0042] As shown in FIG. 4a, the sheet holding mechanism 31 has a plurality of suction holes 31a. The plurality of suction holes 31a include frame suction holes 31a1 provided in the frame 33 and division portion suction holes 31a2 provided in the division portion 34. The suction holes 31a are provided in the first surface 31b of the sheet holding mechanism 31. The frame suction holes 31a1 are provided in a portion of the first surface 31b formed by the surface of the frame 33. The division portion suction holes 31a2 are provided in a portion of the first surface 31b formed by the surface of the division portion 34. The suction holes 31a hold the sheet 11 by vacuum suction. That is, by sucking air through the suction holes 31a, the sheet 11 can be sucked and held by the suction holes 31a. The suction holes 31a are, for example, circular, with a diameter of 2 mm to 5 mm. This makes the suction holes 31a sufficiently large to properly suck and hold the sheet 11. Furthermore, since the suction holes 31a are not too large, the possibility of problems such as foreign matter being sucked into the suction holes 31a is reduced.

[0043] As an example, the sheet holding mechanism 31 holds the sheet 11 so that when the sheet 11 held by the sheet holding mechanism 31 is observed from a direction perpendicular to the surface of the sheet 11, the sheet 11 protrudes only a small amount from the sheet holding mechanism 31. In particular, the sheet holding mechanism 31 holds the sheet 11 so that when the sheet 11 held by the sheet holding mechanism 31 is observed from a direction perpendicular to the surface of the sheet 11, the sheet 11 protrudes by 15 mm or less. The amount by which the sheet 11 protrudes from the sheet holding mechanism 31 is, for example, 5 mm or more and 10 mm or less. The sheet holding mechanism 31 may hold the sheet 11 so that when the sheet 11 held by the sheet holding mechanism 31 is observed from a direction perpendicular to the surface of the sheet 11, the sheet 11 does not protrude from the sheet holding mechanism 31. By making the width of the sheet 11 that protrudes from the sheet holding mechanism 31 small or by not making the sheet 11 protrude from the sheet holding mechanism 31 at all, it is possible to prevent the portion of the sheet 11 that protrudes from the sheet holding mechanism 31 from coming into contact with the heater 35 and causing a malfunction. It is also possible to prevent the portion of the sheet 11 that protrudes from the sheet holding mechanism 31 from being wasted, thereby preventing the cost of manufacturing the molded product 16 and the like from increasing.

[0044] Here, the sheet holding mechanism 31 holds, as the sheet 11, a divided sheet 111 that faces the first opening region 33b1 but not the second opening region 33b2, by vacuum suction of the suction holes 31a including at least the divided portion suction holes 31a2. The divided sheet 111 is sheet 11 whose dimensions are adjusted so that it can be placed on the first surface 31b of the sheet holding mechanism 31 so as to face the first opening region 33b1 but not face the second opening region 33b2.

[0045] In the sheet holding mechanism 31 shown in FIG. 4a, the plurality of division portion suction holes 31a2 are aligned in a row in the direction in which the division portion 34 extends (the vertical direction in FIG. 4a). However, the arrangement of the plurality of division portion suction holes 31a2 is not limited to this. FIG. 4b shows another example of a perspective view of the sheet holding mechanism 31 and heater 35 according to the first embodiment. In the example shown in FIG. 4b, the plurality of division portion suction holes 31a2 are aligned in two rows in the direction in which the division portion 34 extends (the vertical direction in FIG. 4b). In this case, the division portion suction holes 31a2 aligned in the row on the first opening region 33b1 side are referred to as first division portion suction holes 31a3. The division portion suction holes 31a2 aligned in the row on the second opening region 33b2 side are referred to as second division portion suction holes 31a4. In this specification, unless otherwise specified, a molding system 1 including a sheet holding mechanism 31 shown in FIG. 4a will be described as an example of the molding system 1 according to the first embodiment.

[0046] FIG. 5 is a perspective view showing the sheet holding mechanism 31 and heater 35 holding a divided sheet 111. Note that in FIG. 5, only the outline of the divided sheet 111 is shown by a dashed line. In the example shown in FIG. 5, the divided sheet 111 faces the first opening region 33b1, as well as the dividing portion 34 and a portion of the frame portion 33 closer to the first opening region 33b1 than the dividing portion 34 (the left side in FIG. 5). Therefore, the divided sheet 111 is held by the sheet holding mechanism 31 by vacuum suction of the dividing portion suction holes 31a2 provided in the dividing portion 34 and the frame portion suction holes 31a1 provided in the frame portion 33 closer to the first opening region 33b1 than the dividing portion 34.

[0047] The sheet holding mechanism 31 may have a circuit that switches on and off the vacuum suction of the sheet 11 by the suction holes 31a. The sheet holding mechanism 31 may have multiple such circuits. As an example, the sheet holding mechanism 31 shown in FIG. 4a has three circuits: a first circuit, a second circuit, and a third circuit. The division portion suction holes 31a2, the frame portion suction holes 31a1 provided closer to the first opening region 33b1 than the division portion 34 of the frame 33, and the frame portion suction holes 31a1 provided closer to the second opening region 33b2 than the division portion 34 of the frame 33 are not connected to each other. The first circuit switches on and off the vacuum suction of the division portion suction holes 31a2. The second circuit switches on and off the vacuum suction of the frame portion suction holes 31a1 provided closer to the first opening region 33b1 than the division portion 34 of the frame 33. The third circuit switches on and off the vacuum suction of the frame suction holes 31a1 provided closer to the second opening region 33b2 than the dividing portion 34 of the frame 33. In this case, when the sheet holding mechanism 31 holds the divided sheet 111 as shown in FIG. 5, the first circuit, the second circuit, and the third circuit may operate as follows: The first circuit turns on the vacuum suction of the dividing portion suction holes 31a2. The second circuit turns on the vacuum suction of the frame suction holes 31a1 provided closer to the first opening region 33b1 than the dividing portion 34 of the frame 33. The third circuit turns off the vacuum suction of the frame suction holes 31a1 provided closer to the second opening region 33b2 than the dividing portion 34 of the frame 33.

[0048] The sheet holding mechanism 31 has multiple circuits for switching on and off the vacuum suction of the sheet 11, which provides the following advantages when the sheet holding mechanism 31 holds the split sheet 111. The vacuum suction of the suction holes 31a facing the split sheet 111 and the vacuum suction of the suction holes 31a that are not connected to the suction holes 31a facing the split sheet 111 and do not face the split sheet 111 can be switched on and off independently. Therefore, when the vacuum suction of the suction holes 31a facing the split sheet 111 is turned on, air can be prevented from flowing from the suction holes 31a that do not face the split sheet 111 to the suction holes 31a facing the split sheet 111. For example, when the sheet holding mechanism 31 shown in FIG. 4a holds the split sheet 111 as shown in FIG. 5, air can be prevented from flowing from the frame suction holes 31a1 located closer to the second opening region 33b2 than the dividing portion 34 of the frame 33 to the other suction holes 31a. This prevents air from flowing into the suction holes 31a facing the split sheet 111, which would hinder vacuum suction, when the sheet holding mechanism 31 holds the split sheet 111 by vacuum suction of the suction holes 31a. Furthermore, because vacuum suction of the suction holes 31a that do not face the split sheet 111 can be turned off, the power consumption required for vacuum suction of the suction holes 31a can be reduced. Furthermore, because vacuum suction of the suction holes 31a that do not face the split sheet 111 can be turned off, it is possible to prevent the suction holes 31a that do not face the split sheet 111 from sucking in foreign matter and clogging the suction holes 31a.

[0049] Although not shown, when the dividing portion 34 divides the opening 33a into three or more opening regions 33b, the sheet holding mechanism 31 may hold a divided sheet 111 that faces at least one of the plurality of opening regions 33b but does not face at least one of the plurality of opening regions 33b. In this case, one of the plurality of opening regions 33b that faces the divided sheet 111 can be considered as a first opening region 33b1. Furthermore, one of the plurality of opening regions 33b that does not face the divided sheet 111 can be considered as a second opening region 33b2.

[0050] In addition, the sheet holding mechanism 31 may be capable of holding a divided sheet 111 as the sheet 11 that faces the first opening region 33b1 but not the second opening region 33b2, and may also be capable of holding a sheet 11 that faces the second opening region 33b2 but not the first opening region 33b1.

[0051] The sheet holding mechanism 31 according to the first embodiment can hold the entire sheet 112, which faces the entire opening 33a, as the sheet 11 by vacuum suction through the suction holes 31a. FIG. 6 is a perspective view showing the sheet holding mechanism 31 holding the entire sheet 112 and the heater 35. Note that in FIG. 6, only the outline of the entire sheet 112 is shown by a dashed line. In the example shown in FIG. 6, the entire sheet 112 faces the first opening region 33b1 and the second opening region 33b2. The entire sheet 112 also faces all of the multiple opening regions 33b.

[0052] 6, the whole sheet 112 faces the frame portion 33 around the entire periphery of the frame portion 33. The whole sheet 112 also faces the dividing portion 34. As an example, the whole sheet 112 is held by the sheet holding mechanism 31 by vacuum suction of dividing portion suction holes 31a2 provided in the dividing portion 34 and frame portion suction holes 31a1 provided in the frame portion 33. The whole sheet 112 is held by vacuum suction of the frame portion suction holes 31a1 provided in the frame portion 33, and does not necessarily have to be vacuum suctioned by the dividing portion suction holes 31a2 provided in the dividing portion 34.

[0053] In a case where the sheet holding mechanism 31 has the above-described first, second, and third circuits, when the whole sheet 112 is held by the sheet holding mechanism 31 by vacuum suction of the division portion suction holes 31a2 and the frame portion suction holes 31a1, the first, second, and third circuits operate as follows: The first circuit turns on vacuum suction of the division portion suction holes 31a2. The second and third circuits turn on vacuum suction of the frame portion suction holes 31a1. In a case where the sheet holding mechanism 31 has the above-described first, second, and third circuits, when the whole sheet 112 is held by the sheet holding mechanism 31 by vacuum suction of the frame portion suction holes 31a1 but not by vacuum suction of the division portion suction holes 31a2, the first, second, and third circuits operate as follows: The first circuit turns off vacuum suction of the division portion suction holes 31a2. The second and third circuits turn on vacuum suction of the frame portion suction holes 31a1.

[0054] If the molding system 1 includes the sheet holding mechanism 31 shown in FIG. 4b, the sheet holding mechanism 31 shown in FIG. 4b may have two circuits that switch on and off the vacuum suction of the sheet 11 through the suction holes 31a. For example, the sheet holding mechanism 31 shown in FIG. 4b has a first opening area circuit and a second opening area circuit as the multiple circuits. The first opening area circuit switches on and off the vacuum suction of the frame suction holes 31a1 and the first divided portion suction holes 31a3, which are located closer to the first opening area 33b1 than the divided portion 34 of the frame 33. The second opening area circuit switches on and off the vacuum suction of the frame suction holes 31a1 and the second divided portion suction holes 31a4, which are located closer to the second opening area 33b2 than the divided portion 34 of the frame 33. In this case, when the sheet holding mechanism 31 holds the divided sheet 111, the first opening area circuit and the second opening area circuit may operate as follows. The first opening area circuit turns on vacuum suction of frame suction holes 31a1 and first divided portion suction holes 31a3, which are provided closer to first opening area 33b1 than divided portion 34 of frame 33. The second opening area circuit turns off vacuum suction of frame suction holes 31a1 and second divided portion suction holes 31a4, which are provided closer to second opening area 33b2 than divided portion 34 of frame 33. When molding system 1 is equipped with sheet holding mechanism 31 shown in FIG. 4b, the operation of holding divided sheet 111 with sheet holding mechanism 31 while turning off vacuum suction of suction holes 31a that do not face divided sheet 111 can be performed by two circuits.

[0055] When the sheet holding mechanism 31 is made to hold divided sheets 111 as the sheets 11, the sheet supply device 20 described above feeds the divided sheets 111 so that they face the sheet holding mechanism 31 and are held by the sheet holding mechanism 31. When the sheet holding mechanism 31 is made to hold a whole sheet 112 as the sheets 11, the sheet supply device 20 described above feeds the whole sheet 112 so that they face the sheet holding mechanism 31 and are held by the sheet holding mechanism 31. Whether the sheet 11 fed by the sheet supply device 20 is the divided sheets 111 or the whole sheets 112 can be changed by adjusting the width of the roll 10. For example, the sheet supply device 20 can be made to feed the divided sheets 111 by setting the width of the roll 10 to the width w6 of the divided sheets 111 in the direction in which the pair of second portions 33e shown in FIG. 5 extend (the left-right direction in FIG. 5). In addition, by setting the width of the roll 10 to the width w7 of the whole sheet 112 in the direction in which the pair of second portions 33e shown in Figure 6 extend (the left-right direction in Figure 6), the sheet supply device 20 can be made to feed out the whole sheet 112.

[0056] The heater 35 is disposed on the second surface 31c side of the sheet holding mechanism 31. The heater 35 is provided overlapping the sheet holding mechanism 31. In the illustrated example, the heater 35 has a plate-like shape with a surface parallel to the second surface 31c of the sheet holding mechanism 31. However, the shape of the heater 35 is not limited to the illustrated example. The head 30 may also have multiple heaters 35. In the example shown in FIG. 4a, the second surface 31c of the sheet holding mechanism 31 and the surface of the heater 35 are in contact, and the positional relationship between the sheet holding mechanism 31 and the heater 35 is fixed.

[0057] The heater 35 heats the sheet 11 held by the sheet holding mechanism 31. The heater 35 heats the sheet 11 to, for example, a temperature between 100°C and 160°C. In particular, the heater 35 heats the sheet 11 for at least a period from when the sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20 until when the sheet 11 is transferred to the mold 51. The heater 35 may be larger in size than the sheet 11 held by the sheet holding mechanism 31 so as to heat the entire sheet 11 held by the sheet holding mechanism 31 uniformly. Note that if there is a portion where the heater 35 and the sheet 11 held by the sheet holding mechanism 31 are separated by a relatively large distance, the entire sheet 11 can be heated uniformly by increasing the temperature of the heater 35 in that portion. Furthermore, the entire sheet 11 can be heated more uniformly by covering the space between the sheet 11 held by the sheet holding mechanism 31 and the heater 35 from the sides with an inorganic plate or the like.

[0058] The heater 35 may generate heat in the entire portion facing the opening 33a. The heater 35 may be switchable between a state in which the entire portion facing the opening 33a generates heat and a state in which only the portion facing the first opening region 33b1 generates heat. As an example, the heater 35 shown in FIG. 4a includes a heating element, a first heater circuit that switches on / off the heating of the portion of the heating element facing the first opening region 33b1, and a second heater circuit that switches on / off the heating of the portion of the heating element facing the second opening region 33b2. In this case, when the sheet holding mechanism 31 holds the split sheet 111 as shown in FIG. 5, the first heater circuit and the second heater circuit may operate as follows: The first heater circuit turns on the heating of the portion of the heating element facing the first opening region 33b1. The second heater circuit turns on the heating of the portion of the heating element facing the second opening region 33b2. This turns off the heating of the heating element in the portion not facing the split sheet 111, thereby reducing power consumption.

[0059] FIG. 7 shows a perspective view of the molded product holding mechanism 32 and the molded product heater 36. The molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52 of the molding machine 50 and transports the molded product 13 to the trimming device 80. As will be described later, in the first embodiment, the molding machine 50 can mold multiple molded products 13, and the molded product holding mechanism 32 can hold multiple molded products 13 molded by the molding machine 50. In the example shown in FIG. 7, the molded product holding mechanism 32 has multiple suction pads 32a. The molded product holding mechanism 32 can suction and hold the molded product 13 by sucking air through the suction pads 32a. In the molded product holding mechanism 32, the multiple suction pads 32a are arranged along a shape corresponding to the opposing mold 52, in other words, a shape complementary to the opposing mold 52, so that the molded product 13 can be properly received from the opposing mold 52. The multiple suction pads 32a are positioned so that they can be pressed against and vacuum-sucked to the molded part 12. However, the molded product holding mechanism 32 is not limited to the illustrated example, and may hold the molded product 13 in any manner.

[0060] The molded product heater 36 is provided on top of the molded product holding mechanism 32. In the illustrated example, the molded product heater 36 is rectangular. The molded product heater 36 heats the molded product 13 held in the molded product holding mechanism 32. The molded product heater 36 heats the molded product 13 to, for example, a temperature of 40°C or higher and 70°C or lower. In particular, the molded product heater 36 heats the molded product 13 for at least a period from when the molded product holding mechanism 32 receives the molded product 13 from the molding machine 50 until when the molded product 13 is transported to the trimming device 80. The molded product heater 36 preferably has dimensions equal to or larger than the dimensions of the molded product 13 held in the molded product holding mechanism 32 so that the entire molded product 13 held in the molded product holding mechanism 32 can be uniformly heated.

[0061] The drive unit 40 is connected to the head 30 at a connection portion 41 and drives the connected head 30. The drive unit 40 drives the head 30, thereby driving a sheet holding mechanism 31, which is a part of the head 30. The drive unit 40 drives the sheet holding mechanism 31 so as to bring the sheet 11 held by the sheet holding mechanism 31 into close contact with a facing surface 51a (described later) of a mold 51. This allows the sheet holding mechanism 31 to bring the held sheet 11 into close contact with the facing surface 51a. When the sheet holding mechanism 31 holds a divided sheet 111 as shown in FIG. 7 , the drive unit 40 drives the sheet holding mechanism 31 so as to bring the divided sheet 111 into close contact with the facing surface 51a. The drive unit 40 drives the head 30, for example, by rotating a rotating unit 43. The drive unit 40 may have multiple rotating units 43. Such a drive unit 40 is, for example, a so-called multi-axis robot arm. The drive unit 40 is detachably connected to the head 30. Therefore, the head 30 connected to the drive unit 40 is replaceable.

[0062] The drive unit 40 drives the head 30 so that the sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20. The drive unit 40 also drives the head 30 so that the sheet 11 is transferred from the sheet holding mechanism 31 to a mold 51 of the molding machine 50. The drive unit 40 also drives the head 30 so that the molded product 13 is received by the molded product holding mechanism 32 from an opposing mold 52. The drive unit 40 also drives the head 30 so that the molded product 13 is transported from the molded product holding mechanism 32 to the trimming device 80. In the example shown in FIG. 8 , the sheet holding mechanism 31 transfers the sheet 11 to the mold 51 of the molding machine 50, and the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52. In this case, the drive unit 40 drives the head 30 so that at least a portion of the head 30 is positioned between the mold 51 and the counter mold 52 in the first direction d1, with the counter mold 52 of the molding machine 50 spaced apart from the mold 51. In particular, the drive unit 40 drives the head 30 so that the sheet holding mechanism 31 and the molded product holding mechanism 32 are positioned between the mold 51 and the counter mold 52 in the first direction d1. In the example shown in FIG. 8 , the entire head 30 is positioned between the mold 51 and the counter mold 52 in the first direction d1. The drive unit 40 drives the sheet holding mechanism 31 toward the first side s1 in the first direction d1. This transfers the sheet 11 from the sheet holding mechanism 31 to the mold 51. The sheet 11 held by the sheet holding mechanism 31 comes into close contact with a facing surface 51a (described later) of the mold 51. The drive unit 40 also drives the molded product holding mechanism 32 toward the second side s2 in the first direction d1. As a result, the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52. At this time, the drive device 40 may drive the entire head 30 to the first side s1 in the first direction d1 or the second side s2 in the first direction d1, or may drive only the sheet holding mechanism 31 in the head 30 to the first side s1 in the first direction d1 and only the molded product holding mechanism 32 to the second side s2 in the first direction d1. The drive device 40 can also rotate the sheet holding mechanism 31 holding the sheet 11 so that the sheet 11 rotates in a direction d5 orbiting an axis L1 perpendicular to the surface of the sheet 11.

[0063] The molding machine 50 has a mold 51 as described above. In the example shown in FIG. 8 , the molding machine 50 further has an opposing mold 52. As shown in FIG. 8 , the mold 51 of the molding machine 50 receives the sheet 11 held on the first side s1 in the first direction d1 of the sheet holding mechanism 31. The opposing mold 52 of the molding machine 50 also delivers the molded product 13 to the second side s2 in the first direction d1 of the molded product holding mechanism 32. More specifically, after the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52, the sheet holding mechanism 31 delivers the sheet 11 to the mold 51. Alternatively, the molded product holding mechanism 32 receives the molded product 13 from the opposing mold 52, and at the same time, the sheet holding mechanism 31 delivers the sheet 11 to the mold 51.

[0064] The molding machine 50 vacuum-forms the sheet 11 received from the sheet holding mechanism 31 using a mold 51. After vacuum-forming the sheet 11, the molding machine 50 forms a storage space 55 that accommodates a portion of the sheet 11 and then injection-moldes a resin into the storage space 55. The storage space 55 is defined by the surfaces of the mold 51 and the opposing mold 52 by bringing the mold 51 and the opposing mold 52 close to each other. In particular, the molding machine 50 injection-moldes a resin into the storage space 55 while the vacuum-formed portion of the sheet 11 is accommodated in the storage space 55. This allows the sheet 11 to be provided with a molded part 12 by resin injection molding, thereby forming a molded product 13 (described below). In particular, the molding machine 50 receives a divided sheet 111 as the sheet 11 from the sheet holding mechanism 31 and vacuum-forms the divided sheet 111 and injection-moldes a resin, thereby producing a first molded product 161 (described below) in a first molding region 51b1 (described below).

[0065] The mold 51 will be described. The mold 51 is provided in the molding system 1. As described above, the molding system 1 includes the molding machine 50, and the molding machine 50 has the mold 51, thereby providing the mold 51 in the molding system 1. The mold 51 is used for vacuum forming the sheet 11. In the example shown in FIG. 1 , the mold 51 is located between the sheet supply device 20 and the counter mold 52 in the first direction d1. In other words, the sheet supply device 20, the mold 51, and the counter mold 52 are arranged in this order in the first direction d1.

[0066] As shown in Fig. 8, mold 51 has opposing surface 51a. Opposing surface 51a is a surface that faces sheet 11 during vacuum forming of sheet 11. Fig. 9 is a plan view showing mold 51 as viewed from the opposing surface 51a side. Fig. 10 is a cross-sectional view showing a cross section taken along line AA in Fig. 9.

[0067] The opposing surface 51a will be described in detail. As shown in FIGS. 9 and 10, the opposing surface 51a has a forming region 51b in which the sheet 11 can be vacuum-formed. In the first embodiment, the opposing surface 51a has a plurality of forming regions 51b in which the sheet 11 can be vacuum-formed. The plurality of forming regions 51b includes at least a first forming region 51b1 and a second forming region 51b2. In the example shown in FIGS. 9 and 10, the opposing surface 51a has two forming regions 51b, the first forming region 51b1 and the second forming region 51b2. The plurality of forming regions 51b have shapes corresponding to the shape of the sheet 11 to be formed by vacuum forming in the forming region 51b. In the example shown in FIG. 10, the first forming region 51b1 and the second forming region 51b2 have curved surfaces.

[0068] When the molding machine 50 forms the storage space 55, a portion of the storage space 55 is defined by the molding region 51b. When the sheet 11 transferred from the sheet holding mechanism 31 to the mold 51 and brought into close contact with the opposing surface 51a of the mold 51 is a divided sheet 111, a first storage space 551, a portion of which is defined by the first molding region 51b1, is formed as the storage space 55.

[0069] 9 and 10, the opposing surface 51a further includes molding region dividing regions 51c located between the molding regions 51b to separate the molding regions 51b from one another. For this reason, the molding regions 51b are separated from one another. In the example shown in FIGS. 9 and 10, the molding region dividing region 51c includes a first dividing region 51c1 extending between the first molding region 51b1 and the second molding region 51b2.

[0070] 9 and 10, the opposing surface 51a further includes an outer peripheral region 51e that surrounds the molding region 51b. In the example shown in FIGS. 9 and 10, the outer peripheral region 51e surrounds the multiple molding regions 51b and the molding region dividing region 51c. In the example shown in FIGS. 9 and 10, the opposing surface 51a is flat in the molding region dividing region 51c and the outer peripheral region 51e. In particular, in the example shown in FIGS. 9 and 10, the molding region dividing region 51c and the outer peripheral region 51e are located on the same plane.

[0071] In the example shown in FIG. 9, the opposing surface 51a has a rectangular shape when observed from a direction perpendicular to the outer peripheral region 51e. The side of the opposing surface 51a having a rectangular shape shown in FIG. 9 that is located at the top of FIG. 9 is referred to as the upper side 511. The side that is located at the bottom of FIG. 9 and faces the upper side 511 is referred to as the lower side 512. The pair of sides that extend in the vertical direction of FIG. 9 between the upper side 511 and the lower side 512 are referred to as the side sides 513. In the first embodiment, the mold 51 is incorporated into the molding system 1 with the upper side 511 positioned at the top and the lower side 512 positioned at the bottom. In this case, in the mold 51 incorporated into the molding system 1, the first divided region 51c1 extends in the horizontal direction. The direction in which the first dividing region 51c1 extends is parallel to the outer peripheral region 51e when the outer peripheral region 51e is flat, and is perpendicular to the direction in which the first molding region 51b1 and the second molding region 51b2 are aligned. The direction in which the first dividing region 51c1 extends is also referred to as dividing direction d4.

[0072] The operation of the sheet holding mechanism 31 and the mold 51 when the sheet holding mechanism 31 holds the split sheet 111 and vacuum-forms the split sheet 111 will be specifically described with reference to FIGS. 11 to 14. FIG. 11 shows the sheet holding mechanism being driven by the drive device 40 to bring the split sheet 111 held by the sheet holding mechanism 31 into close contact with the opposing surface 51a of the mold 51. The arrow labeled A1 in FIG. 11 indicates the direction in which the sheet holding mechanism 31 is driven. In the example shown in FIG. 11, the mold 51 is fixed, and the sheet holding mechanism 31 moves to the first side s1 in the first direction d1 to approach the mold 51, bringing the split sheet 111 into close contact with the opposing surface 51a. More specifically, the sheet holding mechanism 31 holding the split sheet 111 is brought into close contact with the opposing surface 51a of the mold 51 with the first surface 31b facing the opposing surface 51a of the mold 51, thereby bringing the split sheet 111 into close contact with the opposing surface 51a.

[0073] FIG. 12 is a plan view showing the positional relationship between the sheet holding mechanism 31, the split sheet 111, and the mold 51 when the sheet holding mechanism 31 is driven to bring the split sheet 111 into close contact with the opposing surface 51a as shown in FIG. 11. In FIG. 12, only the outline of the split sheet 111 is shown by a dashed line. Also, in FIG. 12, only the outline of the sheet holding mechanism 31 is shown by a broken line. FIG. 13 is a cross-sectional view showing the cross section of the sheet holding mechanism 31, the split sheet 111, and the mold 51 when the sheet holding mechanism 31 is driven to bring the split sheet 111 into close contact with the opposing surface 51a as shown in FIG. 12 and FIG. 13, the sheet holding mechanism 31 brings the held split sheet 111 into close contact with the opposing surface 51a so that the split sheet 111 faces the first molding region 51b1 of the opposing surface 51a but does not face the second molding region 51b2. Furthermore, the sheet holding mechanism 31 brings the divided sheet 111 into close contact with the area surrounding the first molding region 51b1 including the molding region dividing region 51c of the facing surface 51a.

[0074] 12 and 13, the sheet holding mechanism 31 is driven by the driving device 40, thereby bringing the divided sheet 111 into close contact with the opposing surface 51a. That is, the driving device 40 drives the sheet holding mechanism 31 to bring the divided sheet 111 held by the sheet holding mechanism 31 into close contact with the region surrounding the first molding region 51b1, including the molding region dividing region 51c, of the opposing surface 51a, so that the divided sheet 111 faces the first molding region 51b1 of the opposing surface 51a but does not face the second molding region 51b2.

[0075] In the example shown in FIG. 13, the dividing portion 34 of the sheet holding mechanism 31 faces the molding region dividing region 51c on the opposing surface 51a of the mold 51. The dividing portion 34 is in contact with the divided sheet 111. As a result, the divided sheet 111 is pressed by the dividing portion 34 and is in close contact with the molding region dividing region 51c on the opposing surface 51a. In other words, the divided sheet 111 is sandwiched between the dividing portion 34 and the molding region dividing region 51c. In particular, in the example shown in FIG. 13, the dividing portion 34 that divides the opening 33a into the first opening region 33b1 and the second opening region 33b2 faces the first dividing region 51c1. The dividing portion 34 that divides the opening 33a into the first opening region 33b1 and the second opening region 33b2 is in contact with the divided sheet 111. As a result, divided sheet 111 is pressed by dividing portion 34 that divides opening 33a into first opening region 33b1 and second opening region 33b2, and is thereby in close contact with first dividing region 51c1 of opposing surface 51a. In other words, divided sheet 111 is sandwiched between dividing portion 34 that divides opening 33a into first opening region 33b1 and second opening region 33b2 and first dividing region 51c1.

[0076] 13, the frame 33 of the sheet holding mechanism 31 faces the outer peripheral region 51e of the opposing surface 51a of the mold 51. A portion of the frame 33 of the sheet holding mechanism 31 closer to the first opening region 33b1 than the dividing portion 34 contacts the divided sheet 111. As a result, the divided sheet 111 is pressed by the portion of the frame 33 of the sheet holding mechanism 31 closer to the first opening region 33b1 than the dividing portion 34, and is thereby in close contact with the portion of the outer peripheral region 51e of the opposing surface 51a closer to the first molding region 51b1 than the first dividing region 51c1. In other words, the divided sheet 111 is sandwiched between the portion of the frame 33 closer to the first opening region 33b1 than the dividing portion 34 and the portion of the outer peripheral region 51e closer to the first molding region 51b1 than the first dividing region 51c1.

[0077] When the sheet holding mechanism 31 is driven toward the facing surface 51a with the split sheet 111 in close contact with the first split region 51c1 and the portion of the outer peripheral region 51e closer to the first molding region 51b1 than the first split region 51c1, the split sheet 111 comes into close contact with the region of the facing surface 51a that surrounds the first molding region 51b1. Note that, as shown in Fig. 13, when the split sheet 111 is in close contact with the region of the facing surface 51a that surrounds the first molding region 51b1 and before vacuum forming of the split sheet 111, which will be described later, the split sheet 111 does not come into contact with the first molding region 51b1.

[0078] As an example, the number of molding regions 51b on the opposing surface 51a of the mold 51 is equal to the number of opening regions 33b on the sheet holding mechanism 31. In this case, as shown in FIGS. 12 and 13, when the sheet 11 held by the sheet holding mechanism 31 is in close contact with the opposing surface 51a, each of the molding regions 51b may face each of the opening regions 33b. In the example shown in FIGS. 12 and 13, the opposing surface 51a has two molding regions 51b, a first molding region 51b1 and a second molding region 51b2. The sheet holding mechanism 31 also has two opening regions 33b, a first opening region 33b1 and a second opening region 33b2. Then, when the sheet 11 held by the sheet holding mechanism 31 is in close contact with the opposing surface 51a as shown in Figures 12 and 13, the first molding area 51b1 faces the first opening area 33b1, and the second molding area 51b2 faces the second opening area 33b2.

[0079] 12 and 13, the opening region 33b of the sheet holding mechanism 31 faces the molding region 51b of the opposing surface 51a, while the frame portion 33 and the dividing portion 34 do not face the molding region 51b. In the example shown in FIGS. 12 and 13, the mold 51 has multiple molding regions 51b, and the frame portion 33 and the dividing portion 34 do not face any of the multiple molding regions 51b. The fact that the frame portion 33 and the dividing portion 34 do not face the molding region 51b provides the following advantages. The frame portion 33 and the dividing portion 34 may contain a highly insulating material to prevent damage from the heat of the heater 35. If the frame portion 33 and the dividing portion 34 contain a highly insulating material, the frame portion 33 and the dividing portion 34 may prevent the heat from the heater 35 from being transmitted to the sheet 11. In this case, heat from the heater 35 is more easily transmitted to portions of the sheet 11 that do not face the frame portion 33 and the dividing portion 34 than to portions of the sheet 11 that face the frame portion 33 and the dividing portion 34. Here, because the frame portion 33 and the dividing portion 34 do not face the forming region 51b, heat from the heater 35 is more easily transmitted to portions of the sheet 11 that face the forming region 51b and can be molded in the forming region 51b. In particular, because the frame portion 33 and the dividing portion 34 do not face any of the multiple forming regions 51b, heat from the heater 35 is more easily transmitted to portions of the sheet 11 that face any of the multiple forming regions 51b and can be molded in the forming region 51b.

[0080] In the molding system 1, the feed direction d3 in which the sheet supply device 20 feeds the divided sheet 111 intersects with the dividing direction d4 in which the first dividing region 51c1 of the mold 51 extends. In the first embodiment, the feed direction d3 is a vertical direction from bottom to top, and the dividing direction d4 is a horizontal direction. Therefore, in the molding system 1, the feed direction d3 and the dividing direction d4 are perpendicular to each other. When the feed direction d3 intersects with the dividing direction d4, it becomes necessary to rotate the sheet 11 and the sheet holding mechanism 31 to align the dividing section 34 with the molding region dividing region 51c. In particular, it becomes necessary to rotate the sheet 11 and the sheet holding mechanism 31 that holds the sheet 11 in the direction d5 orbiting the axis L1 perpendicular to the plane of the sheet 11 shown in FIG. 8. The operation of rotating the sheet 11 and the sheet holding mechanism 31 must be performed from the time the sheet holding mechanism 31 receives the sheet 11 from the sheet supply device 20 until the time the sheet holding mechanism 31 brings the sheet 11 into close contact with the opposing surface 51a of the mold 51. In the first embodiment, the sheet holding mechanism 31 is driven by the drive device 40. As described above, the drive device 40 rotates the sheet holding mechanism 31 holding the sheet 11 so that the sheet 11 rotates in the direction d5 around the axis L1 perpendicular to the surface of the sheet 11. As a result, even when the feed direction d3 intersects with the dividing direction d4, by rotating the sheet holding mechanism 31 by the drive device 40, the dividing section 34 and the molding region dividing area 51c can be opposed to each other, as shown in FIG. 13, and the sheet 11 can be brought into close contact with the opposing surface 51a. In particular, by rotating the sheet holding mechanism 31, the dividing portion 34 that divides the opening 33a into the first opening region 33b1 and the second opening region 33b2 faces the first dividing region 51c1, and the sheet 11 is brought into close contact with the opposing surface 51a.

[0081] With separate sheet 111 in close contact with the area surrounding first molding area 51b1 of opposing surface 51a, the space between separate sheet 111 and first molding area 51b1 of opposing surface 51a is evacuated, thereby vacuum-forming separate sheet 111 as shown in Fig. 14. The space between separate sheet 111 and first molding area 51b1 of opposing surface 51a can be evacuated by using, for example, suction holes (not shown) provided in opposing surface 51a of mold 51. In the example shown in Fig. 14, a portion bent along first molding area 51b1 is formed in separate sheet 111 by vacuum forming.

[0082] The opposing mold 52 moves relative to the mold 51 in the first direction d1 and forms an accommodation space 55 together with the mold 51. In the example shown in Fig. 1, the opposing mold 52 is located between the mold 51 and the trimming device 80 in the first direction d1. In other words, the mold 51, the opposing mold 52, and the trimming device 80 are lined up in this order along the first direction d1.

[0083] FIG. 15 shows an example of how the opposing mold 52 is moved relative to the mold 51. FIG. 15 shows how the opposing mold 52 is moved relative to the mold 51 after the divided sheet 111 is molded into the sheet 11 using the mold 51. The arrow labeled A2 in FIG. 15 indicates the direction in which the opposing mold 52 moves. In the example shown in FIG. 15, the mold 51 is fixed, and the opposing mold 52 moves toward the first side s1 in the first direction d1. Although not shown, the opposing mold 52 may be fixed, and the mold 51 may move toward the second side s2 in the first direction d1. Alternatively, the mold 51 and the opposing mold 52 may both move in the first direction d1, thereby bringing the mold 51 and the opposing mold 52 closer to each other. FIG. 16 shows a state in which the opposing mold 52 approaches the mold 51, thereby forming an accommodation space 55. After vacuum-forming the sheet 11 using the mold 51, the opposing mold 52 is moved relative to the mold 51 without moving the sheet 11 relative to the mold 51, thereby forming a state in which the vacuum-formed portion of the sheet 11 is accommodated in the accommodation space 55, as shown in Figure 16.

[0084] 16, after vacuum-forming divided sheet 111 as sheet 11, molding machine 50 moves opposing mold 52 relative to mold 51 to form first storage space 551 that accommodates at least a portion of divided sheet 111. In the example shown in FIG. 16, in particular, the vacuum-formed portion of divided sheet 111 is accommodated in storage space 55. As described above, a portion of first storage space 551 is defined by first molding region 51b1.

[0085] The opposing mold 52 has a shape that allows for the formation of an appropriate storage space 55 between it and the mold 51. In the example shown in FIG. 16, the surface of the opposing mold 52 has multiple opposing molding regions 52d, an opposing outer peripheral region 52e, and an opposing dividing region 52c. Each of the multiple opposing molding regions 52d faces the multiple molding regions 51b on the opposing surface 51a of the mold 51. In the example shown in FIG. 16, the opposing mold 52 has the multiple opposing molding regions 52d, including a first opposing molding region 52d1 facing the first molding region 51b1 and a second opposing molding region 52d2 facing the second molding region 51b2. In the example shown in FIG. 16, the opposing mold 52 is bent so as to be convex in each of the multiple opposing molding regions 52d. In the example shown in FIG. 16, the opposing mold 52 is bent so as to be convex in the first opposing molding region 52d1. Furthermore, the opposing mold 52 is bent so as to be convex in the second opposing molding region 52d2. 16, storage space 55 is defined by molding region 51b of mold 51 and opposing molding region 52d of opposing mold 52. In the example shown in Fig. 16, after dividing sheet 111 is vacuum-formed as sheet 11, opposing mold 52 is moved relative to mold 51, thereby forming first storage space 551 defined as storage space 55 by first molding region 51b1 and first opposing molding region 52d1.

[0086] The opposing outer peripheral region 52e of the opposing mold 52 faces the outer peripheral region 51e of the mold 51. The opposing outer peripheral region 52e has a shape complementary to that of the outer peripheral region 51e. In the example shown in FIG. 16, the opposing outer peripheral region 52e is flat. When the storage space 55 is formed, both the outer peripheral region 51e and the opposing outer peripheral region 52e are in close contact with the sheet 11. In other words, the sheet 11 is sandwiched between the outer peripheral region 51e and the opposing outer peripheral region 52e.

[0087] The opposing dividing region 52c of the opposing mold 52 faces the molding region dividing region 51c of the mold 51. The opposing dividing region 52c has a shape complementary to the molding region dividing region 51c. In the example shown in FIG. 16, the opposing dividing region 52c is flat. When the accommodation space 55 is formed, both the molding region dividing region 51c and the opposing dividing region 52c are in close contact with the sheet 11. In other words, the sheet 11 is sandwiched between the molding region dividing region 51c and the opposing dividing region 52c.

[0088] As described above, molding region 51b has a shape corresponding to sheet 11 included in molded product 13, which will be described later. Furthermore, opposing molding region 52d has a shape corresponding to the shape of molded part 12 included in molded product 13, which will be described later. As a result, storage space 55 defined by molding region 51b and opposing molding region 52d has a shape corresponding to the shape of molded product 13. After the vacuum-formed portion of sheet 11 is accommodated in storage space 55 as described above, resin is injected into storage space 55. This allows resin injection molding to be performed in the portion of storage space 55 where sheet 11 is not placed. Therefore, molded part 12 having a shape corresponding to the shape of opposing molding region 52d is provided in the vacuum-formed portion of sheet 11. In the example shown in FIG. 16 , after the vacuum-formed portion of divided sheet 111 is accommodated in first storage space 551, resin is injected into first storage space 551. As a result, a first molded part 121 having a shape corresponding to the shape of the first opposing molding region 52d1 is provided as the molded part 12 in the portion of the separate sheet 111 vacuum-formed in the first molding region 51b1. The resin injected into the storage space 55 is, for example, a thermoplastic resin such as ABS, PC-ABS, acrylic, polycarbonate, polyethylene, or polypropylene heated to a high temperature. In this case, the thermoplastic resin is injected and then cooled, thereby providing the molded part 12 on the sheet 11. As a result, as shown in FIG. 17, a molded product 13 including the sheet 11 and the molded part 12 and having a shape corresponding to the shape of the storage space 55 is formed. In the example shown in FIG. 17, a first molded product 131 is formed as the molded product 13, including the portion of the separate sheet 111 vacuum-formed in the first molding region 51b1 and the first molded part 121 having a shape corresponding to the shape of the first opposing molding region 52d1.

[0089] After the molded article 13 is molded, the opposing mold 52 moves to the second side s2 in the first direction d1 and separates from the mold 51, as shown in Fig. 17. The arrow labeled A3 in Fig. 17 indicates the direction in which the opposing mold 52 moves. The molded article 13 separates from the mold 51 together with the opposing mold 52. For example, because a portion of the molded part 12 is engaged with the opposing mold 52, the molded article 13 moves together with the opposing mold 52 to the second side s2 in the first direction d1.

[0090] The counter mold 52 delivers the molded product 13 molded by the molding machine 50 to the molded product holding mechanism 32 of the head 30. The arrow labeled A4 in FIG. 18 indicates the direction in which the molded product holding mechanism 32 moves. In the example shown in FIG. 18, the molded product holding mechanism 32, which is disposed between the mold 51 and the counter mold 52, moves relative to the counter mold 52 on which the molded product 13 is disposed. That is, it moves toward the second side s2 in the first direction d1. This causes the molded product holding mechanism 32 to approach the counter mold 52 and receive the molded product 13 from the counter mold 52. Thereafter, as shown in FIG. 19, the molded product holding mechanism 32 moves toward the first side s1 in the first direction d1 and moves away from the counter mold 52. The arrow labeled A5 in FIG. 19 indicates the direction in which the molded product holding mechanism 32 moves.

[0091] The trimming device 80 trims the molded product 13 molded by the molding machine 50. As shown in FIG. 19 , the molded product 13 held by the molded product holding mechanism 32 of the head 30 is transported to the trimming device 80 by the drive device 40 driving the head 30. The trimming device 80 receives the molded product 13 from the molded product holding mechanism 32 and trims it. The trimming device 80 trims the molded product 13 to remove portions unnecessary for the product from the molded product 13. This produces a molded product 16, as shown in FIG. 20 . In the example shown in FIG. 20 , the portions of the separate sheet 111 that were sandwiched between the outer peripheral region 51 e and the opposing outer peripheral region 52 e in FIG. 16 and the portions that were sandwiched between the molding region dividing region 51 c and the opposing dividing region 52 c of the separate sheet 111 have been trimmed from the first molded product 131 shown in FIG. 19 . In other words, trimming removes the portions of the separate sheet 111 other than the portion located between the first molding region 51b1 and the first opposing molding region 52d1 in Fig. 16. This produces a first molded product 161 as the molded product 16, which includes the portion of the sheet 11 molded in the first molding region 51b1 and the first molded part 121.

[0092] The trimming device 80 may have any configuration, as long as it can receive the transported molded product 13 and trim it to the desired shape. The trimming device 80 may have, for example, a support table on which the molded product 13 is placed and cutting means for cutting the molded product 13 placed on the support table. In this case, the support table receives the molded product 13 from the molded product holding mechanism 32, thereby placing the molded product 13 on the support table. The cutting means is, for example, a metal blade. The trimming device 80 can cut the molded product 13 by moving the cutting means while the cutting means is in contact with the molded product 13. This trims the molded product 13. The movement of the cutting means may be controlled by a control device or the like so that the molded product 13 is trimmed to the desired shape. By trimming the molded product 13 to the desired shape, a molded product 16 as shown in FIG. 20 is produced.

[0093] While the operation of the molding system 1 according to the first embodiment has been described above as the operation when the divided sheet 111 is held by the sheet holding mechanism 31 and the divided sheet 111 is molded, the molding system 1 according to the first embodiment can also be used to mold the whole sheet 112 by having the sheet holding mechanism 31 hold the whole sheet 112. Below, the operation of the molding system 1 according to the first embodiment when the whole sheet 112 is molded by having the sheet holding mechanism 31 hold the whole sheet 112 will be described. In the following explanation, the operation of the mold 51 when molding the whole sheet 112 will be described, focusing on differences from the operation of the mold 51 when molding the divided sheet 111. Furthermore, explanations of operations common to the operation of the mold 51 when molding the divided sheet 111 may be omitted.

[0094] As described above, the sheet holding mechanism 31 can hold the whole sheet 112 as shown in Fig. 6. Furthermore, the sheet supply device 20 can feed the whole sheet 112 by adjusting the width of the roll 10 as described above. Furthermore, when the sheet holding mechanism 31 holds the whole sheet 112 as shown in Fig. 6, the drive device 40 drives the sheet holding mechanism 31 so as to bring the whole sheet 112 into close contact with the opposing surface 51a.

[0095] The molding machine 50 receives a whole sheet 112 as the sheet 11 from the sheet holding mechanism 31, and performs vacuum forming and resin injection molding of the whole sheet 112, thereby producing a plurality of molded products 16 (described later) in a plurality of molding areas 51b (described later). In particular, by performing vacuum forming and resin injection molding of the whole sheet 112, a first molded product 161 can be produced in a first molding area 51b1 (described later), and a second molded product 162 can be produced in a second molding area 51b2 (described later).

[0096] When the molding machine 50 forms the storage space 55, if the sheet 11 transferred from the sheet holding mechanism 31 to the mold 51 and brought into close contact with the opposing surface 51a of the mold 51 is a whole sheet 112, a plurality of storage spaces 55 are formed according to the number of molding regions 51b included in the opposing surface 51a. In this case, each of the plurality of storage spaces 55 is partially defined by one of the plurality of molding regions 51b. For example, if the opposing surface 51a has two molding regions 51b, a first molding region 51b1 and a second molding region 51b2, as shown in FIGS. 9 and 10, two storage spaces 55 are formed: a first storage space 551 partially defined by the first molding region 51b1, and a second storage space 552 partially defined by the second molding region 51b2.

[0097] The operation of the mold 51 when the sheet holding mechanism 31 holds the whole sheet 112 and vacuum-forms the whole sheet 112 will be described with reference to FIGS. 21 to 24. FIG. 21 is a plan view showing the positional relationship between the sheet holding mechanism 31, the whole sheet 112, and the mold 51 when the sheet holding mechanism 31 is driven to bring the whole sheet 112 into close contact with the opposing surface 51a. In FIG. 21, only the outline of the whole sheet 112 is indicated by a dashed line. Also, in FIG. 21, only the outline of the sheet holding mechanism 31 is indicated by a broken line. FIG. 22 is a cross-sectional view showing the cross section of the sheet holding mechanism 31, the whole sheet 112, and the mold 51 when the sheet holding mechanism 31 is driven to bring the whole sheet 112 into close contact with the opposing surface 51a. As shown in FIGS. 21 and 22, the sheet holding mechanism 31 brings the held whole sheet 112 into close contact with the opposing surface 51a so as to face all of the multiple molding regions 51b of the opposing surface 51a. 21 and 22, the sheet holding mechanism 31 brings the whole sheet 112 into close contact with the opposing surface 51a so as to face both the first molding region 51b1 and the second molding region 51b2. The sheet holding mechanism 31 also brings the whole sheet 112 into close contact with the region of the opposing surface 51a that surrounds the first molding region 51b1 and the second molding region 51b2. The region of the opposing surface 51a to which the whole sheet 112 comes into close contact includes the molding region dividing region 51c.

[0098] 21, each of the multiple opening regions 33b of the sheet holding mechanism 31 faces each of the multiple molding regions 51b of the facing surface 51a of the mold 51. In this positional relationship, by driving the sheet holding mechanism 31 holding the whole sheet 112 toward the facing surface 51a, the whole sheet 112 comes into close contact with the areas of the facing surface 51a surrounding each of the multiple molding regions 51b. Specifically, the first opening region 33b1 faces the first molding region 51b1, and the second opening region 33b2 faces the second opening region 33b2. In this positional relationship, by driving the sheet holding mechanism 31 holding the whole sheet 112 toward the facing surface 51a, the whole sheet 112 comes into close contact with the areas of the facing surface 51a surrounding the first molding region 51b1 and the areas surrounding the second molding region 51b2.

[0099] With the whole sheet 112 in close contact with the areas of the opposing surface 51a surrounding each of the molding regions 51b, the space between each of the molding regions 51b and the whole sheet 112 is evacuated, thereby vacuum-forming the whole sheet 112, as shown in FIG. 23 . Specifically, with the whole sheet 112 in close contact with the areas of the opposing surface 51a surrounding the first molding region 51b1 and the area surrounding the second molding region 51b2, the space between the first molding region 51b1 and the whole sheet 112 and the space between the second molding region 51b2 and the whole sheet 112 are evacuated, thereby vacuum-forming the whole sheet 112. In the example shown in FIG. 23 , portions bent along each of the molding regions 51b are formed in the whole sheet 112 by vacuum forming. Specifically, portions bent along the first molding region 51b1 and the second molding region 51b2 are formed in the whole sheet 112 by vacuum forming.

[0100] Next, the function of the opposing mold 52 when molding the whole sheet 112 will be described. After vacuum-forming the whole sheet 112 into the sheet 11, the molding machine 50 moves the opposing mold 52 relative to the mold 51 to form multiple storage spaces 55, as shown in FIG. 24. In this case, a portion of each of the multiple storage spaces 55 is defined by one of the multiple molding regions 51b. In particular, a portion of each of the multiple storage spaces 55 is defined by one of the multiple molding regions 51b and one of the multiple opposing molding regions 52d. In the example shown in FIG. 24, the molding machine 50 forms two storage spaces 55: a first storage space 551 and a second storage space 552. The first storage space 551 is defined by a first molding region 51b1 and a first opposing molding region 52d1. The second storage space 552 is defined by a second molding region 51b2 and a second opposing molding region 52d2.

[0101] Each of the plurality of storage spaces 55 accommodates a portion of the whole sheet 112 vacuum-formed in the plurality of forming regions 51b. The first storage space 551 accommodates a portion of the whole sheet 112 vacuum-formed in the first forming region 51b1. The second storage space 552 accommodates a portion of the whole sheet 112 vacuum-formed in the second forming region 51b2.

[0102] After the multiple storage spaces 55 are formed, resin is injection-molded into the multiple storage spaces 55, thereby forming a molded part 12 having a shape corresponding to the shape of the opposing molding region 52d in each of the multiple storage spaces 55. In particular, as shown in FIG. 24 , after the first storage space 551 and the second storage space 552 are formed, a first molded part 121 having a shape corresponding to the shape of the first opposing molding region 52d1 is provided in the whole sheet 112 by injection-molding resin into the first storage space 551. Furthermore, a second molded part 122 having a shape corresponding to the shape of the second opposing molding region 52d2 is provided in the whole sheet 112 by injection-molding resin into the second storage space 552. In this way, a molded product 13 including the whole sheet 112 is formed.

[0103] Next, the operation of the trimming device 80 when molding the whole sheet 112 will be described. The trimming device 80 trims the molded product 13 molded by the molding machine 50 to remove portions of the molded product 13 that are not required for the product. The trimming device 80 may trim the molded product 13 to separate the portions of the whole sheet 112 where the molded parts 12 are provided. This produces a plurality of molded products 16 that include the portions molded in the molding region 51b of the sheet 11 and the molded parts 12. Specifically, the trimming device 80 trims the molded product 13 shown in FIG. 24 molded by the molding machine 50 to separate the portions of the whole sheet 112 where the first molded parts 121 are provided and the portions where the second molded parts 122 are provided, and also removes portions of the molded product 13 that are not required for the product. This produces a first molded product 161 shown in FIG. 20 and a second molded product 162 shown in FIG. 25 as the molded products 16. The first molded product 161 includes a portion molded in the first molding region 51b1 of the sheet 11 and a first molded part 121. The second molded product 162 includes a portion molded in the second molding region 51b2 of the sheet 11 and a second molded part 122.

[0104] Next, an example of a method for manufacturing a molded product 16 using the molding system 1 according to the first embodiment described above will be described. In particular, a case will be described in which a divided sheet 111 is used as the sheet 11 to manufacture a first molded product 161 as the molded product 16. In this case, the method for manufacturing the molded product 16 includes, in this order, a step of bringing the divided sheet 111 held by the sheet holding mechanism 31 into close contact with the opposing surface 51a, a step of vacuum-forming the divided sheet 111 brought into close contact with the opposing surface 51a, and a step of injection-molding a resin. The method for manufacturing the molded product 16 according to this embodiment includes, in this order, a step of supplying the divided sheet 111 to the sheet holding mechanism 31 before the divided sheet 111 comes into close contact with the opposing surface 51a in the step of bringing the divided sheet 111 held by the sheet holding mechanism 31 into close contact with the opposing surface 51a, and a step of driving and rotating the sheet holding mechanism 31 holding the divided sheet 111. The method for manufacturing the molded product 16 according to this embodiment further includes a step of trimming the molded product 13 molded by the molding machine 50 after the step of injection molding the resin.

[0105] In the process of supplying the divided sheet 111 to the sheet holding mechanism 31, the divided sheet 111 is supplied to the sheet holding mechanism 31 so that the divided sheet 111 is held by the sheet holding mechanism 31. In the process of supplying the divided sheet 111 to the sheet holding mechanism 31, first, as shown in FIG. 2, the sheet 11 wound into the roll 10 is clamped by the first clamp 23a. The width of the roll 10 is adjusted so that the sheet 11 fed by the sheet supply device 20 is the divided sheet 111. As described above, the width of the roll 10 is adjusted to the width w6 of the divided sheet 111 in the direction in which the pair of second portions 33e shown in FIG. 5 extend (the left-right direction in FIG. 5), thereby causing the sheet supply device 20 to feed out the divided sheet 111. As an example, the divided sheet 111 is fed upward in the vertical direction while the sensor 27 detects an alignment mark (not shown). Based on the detection of the alignment mark by sensor 27, the position, orientation, and size (length) of the separated sheet 111 to be fed correspond to the position, orientation, and predetermined size of the separated sheet 111 supplied from sheet supply device 20. Next, the separated sheet 111 is held by sheet holding mechanism 31. Then, second clamp 23b clamps the lower part of the separated sheet 111. The separated sheet 111 is cut vertically below and above second clamp 23b by sheet cutting means 21 in a direction non-parallel to the vertical direction, for example, horizontally, to form a separated sheet 111 of predetermined size. Finally, first clamp 23a releases the separated sheet 111. In this way, the separated sheet 111 of predetermined size is supplied from sheet supply device 20 to sheet holding mechanism 31. The sheet holding mechanism 31 holds the separated sheet 111 by suction to suction holes 31a.

[0106] After the step of supplying the split sheet 111 to the sheet holding mechanism 31, the split sheet 111 held by the sheet holding mechanism 31 is transported to the mold 51. Specifically, the head 30 is driven by the drive device 40 to transport the split sheet 111 held by the sheet holding mechanism 31 of the head 30 to the mold 51 of the molding machine 50. The split sheet 111 is heated by the heater 35 of the head 30 for at least a period from when it is held by the sheet holding mechanism 31 until it is transferred to the mold 51. Since it is preferable for the heater 35 to heat the split sheet 111 for a long period, it is preferable for the heater 35 to heat the split sheet 111 for the entire period from when it is held by the sheet holding mechanism 31 until it is transferred to the molding machine 50. The temperature of the heater 35 is determined depending on the time the sheet holding mechanism 31 holds the split sheet 111 so that the split sheet 111 is appropriately heated. For example, the longer the time the sheet holding mechanism 31 holds the sheet 111, the lower the temperature of the heater 35 is set. By heating the divided sheets 111 appropriately, the entire sheets are softened without causing problems such as the formation of blisters (air bubbles).

[0107] As described above, in the molding system 1 according to the first embodiment, the feed direction d3 in which the sheet supply device 20 feeds the split sheet 111 intersects with the split direction d4 in which the first split region 51c1 of the mold 51 extends. In this case, after the split sheet 111 is supplied to the sheet holding mechanism 31, the step of bringing the split sheet 111 held by the sheet holding mechanism 31 into close contact with the opposing surface 51a involves driving and rotating the sheet holding mechanism 31 before the split sheet 111 comes into close contact with the opposing surface 51a. In the step of driving and rotating the sheet holding mechanism 31, the sheet holding mechanism 31 is driven and rotated by the drive device 40. The sheet holding mechanism 31 is rotated so that the split sheet 111 held by the sheet holding mechanism 31 rotates in a direction d5 orbiting around the axis L1 perpendicular to the plane of the split sheet 111. This allows dividing portion 34 and molding region dividing region 51c to face each other when dividing sheet 111 is brought into close contact with opposing surface 51a, as shown in Fig. 11. In particular, dividing portion 34, which divides opening 33a into first opening region 33b1 and second opening region 33b2, and first dividing region 51c1 can be made to face each other.

[0108] In the step of adhering the split sheet 111 to the facing surface 51a, the split sheet 111 held by the sheet holding mechanism 31 is brought into close contact with the area of ​​the facing surface 51a that surrounds the first molding region 51b1. The area surrounding the first molding region 51b1 to which the split sheet 111 is brought into close contact includes the molding region dividing region 51c. In the step of adhering the split sheet 111 to the facing surface 51a, first, the head 30 holding the softened split sheet 111 in the sheet holding mechanism 31 is driven by the drive unit 40 to be positioned between the mold 51 and the counter mold 52 of the molding machine 50, as shown in FIG. 6. In the example shown in FIG. 6, the sheet holding mechanism 31 holding the split sheet 111 faces the mold 51. Furthermore, the molded product holding mechanism 32 of the head 30, which receives the first molded product 131 from the molding machine 50, faces the counter mold 52. In other words, as shown in Fig. 6, the sheet holding mechanism 31 faces the first side s1 in the first direction d1. The molded product holding mechanism 32 faces the second side s2 in the first direction d1. Thereafter, the drive device 40 moves the head 30 closer to the mold 51, as shown in Fig. 9. As a result, as shown in Figs. 10 and 11, the split sheet 111 held by the sheet holding mechanism 31 is pressed against the opposing surface 51a of the mold 51 by the sheet holding mechanism 31, and is brought into close contact with the opposing surface 51a. As a result, the split sheet 111 held by the sheet holding mechanism 31 is brought into close contact with the opposing surface 51a.

[0109] In the step of vacuum-forming the divided sheet 111 that has been brought into close contact with the opposing surface 51a, the divided sheet 111 that has been brought into close contact with the area surrounding the first molding area 51b1 of the opposing surface 51a by the sheet holding mechanism 31 is vacuum-formed in the first molding area 51b1. Specifically, a vacuum is drawn into the space between the first molding area 51b1 of the opposing surface 51a and the divided sheet 111, as shown in FIG. 11. As a result, the divided sheet 111 is vacuum-formed, as shown in FIG.

[0110] Next, suction of split sheet 111 by suction holes 31a is stopped, and sheet holding mechanism 31 is moved away from split sheet 111 by drive device 40. After this, the resin injection molding process is performed. In the resin injection molding process, first, molding machine 50 is caused to form first storage space 551 in which at least a portion of split sheet 111 is accommodated. Specifically, as shown in FIG. 13, opposing mold 52 is moved relative to mold 51, so that opposing mold 52 comes into contact with split sheet 111 located on opposing surface 51a of mold 51, thereby forming first storage space 551. As a result, the vacuum-formed portion of split sheet 111 is accommodated in first storage space 551, as shown in FIG. 14.

[0111] Next, resin is injection molded into the formed first accommodating space 551. Specifically, thermoplastic resin heated to a high temperature is injected into the first accommodating space 551. As a result, a first molded part 121 having a shape corresponding to the first accommodating space 551 is provided on the separate sheet 111, and a first molded product 131 including the separate sheet 111 and the first molded part 121 is molded.

[0112] The molded first molded product 131 is held by the head 30 and removed from the first storage space 551 by the following method. First, as shown in FIG. 15, the counter mold 52 is moved toward the second side s2 in the first direction d1 and separated from the mold 51. At this time, the first molded product 131 and the counter mold 52 are separated from the mold 51. Next, the drive unit 40 drives the head 30 to position it again between the mold 51 and the counter mold 52, as shown in FIG. 6. Next, as shown in FIG. 16, the drive unit 40 moves the molded product holding mechanism 32 of the head 30 toward the second side s2 in the first direction d1 to approach the counter mold 52. Then, the suction pad 32a of the molded product holding mechanism 32 is brought into contact with the first molded product 131, and the first molded product 131 is held by the molded product holding mechanism 32 by suction of the suction pad 32a. 17, the molded product holding mechanism 32 is moved by the drive device 40 to the first side s1 in the first direction d1, thereby separating the first molded product 131 from the opposing mold 52. As a result, the first molded product 131 is held by the head 30 and removed from the first storage space 551.

[0113] In the step of trimming the first molded product 131 molded by the molding machine 50, first, the head 30 is driven by the drive device 40 to transport the first molded product 131 held by the molded product holding mechanism 32 of the head 30 to the trimming device 80. Next, the first molded product 131 is trimmed into a desired shape by the trimming device 80.

[0114] The first molded product 131 is heated by the molded product heater 36 of the head 30 for at least a period from when it is held by the molded product holding mechanism 32 until it is transported to the trimming device 80. By being appropriately heated by the molded product heater 36, the first molded product 131 is less likely to undergo deformation such as shrinkage due to temperature changes.

[0115] The method of transporting the first molded product 131 to the trimming device 80 and the method of trimming the first molded product 131 by the trimming device 80 are determined appropriately depending on the configuration of the trimming device 80. For example, as described above, if the trimming device 80 has a support table on which the first molded product 131 is placed and cutting means for cutting the first molded product 131 placed on the support table, the first molded product 131 can be transported to the trimming device 80 and trimmed by the following method. First, the head 30 is driven by the drive device 40 to place the first molded product 131 held by the molded product holding mechanism 32 of the head 30 on the support table. Next, the suction pad 32a stops suctioning the divided sheet 111. Next, the head 30 is driven by the drive device 40 to move the molded product holding mechanism 32 away from the first molded product 131. Next, the cutting means is brought into contact with the first molded product 131 placed on the support table and the cutting means is moved. This allows the first molded product 131 to be cut and trimmed into a desired shape. By trimming the first molded product 131, a first molded product 161 as shown in Fig. 20 is produced as the molded product 16.

[0116] The manufacturing method of the molded product 16 does not have to include a step of trimming the first molded product 131 molded by the molding machine 50. For example, in the step of injection molding a resin, the first molded product 131 molded by injection molding the resin into the first accommodating space 551 may be made into the first molded product 161 without being trimmed.

[0117] As a method for manufacturing a molded product 16 using the molding system 1 according to the first embodiment, a method for manufacturing a first molded product 161 using a divided sheet 111 has been described above. However, multiple molded products 16 can also be manufactured using a whole sheet 112. Below, as a method for manufacturing a molded product 16 using the molding system 1 according to the first embodiment, a manufacturing method for manufacturing multiple molded products 16 using a whole sheet 112 will be described. In the following explanation, differences between the method for manufacturing multiple molded products 16 using a whole sheet 112 and the method for manufacturing the first molded product 161 using a divided sheet 111 will be mainly described. Furthermore, explanations of methods common to the method for manufacturing the first molded product 161 using a divided sheet 111 may be omitted.

[0118] When a plurality of molded products 16 are manufactured using the whole sheet 112, a step of supplying the whole sheet 112 to the sheet holding mechanism 31 is performed instead of the step of supplying the divided sheets 111 to the sheet holding mechanism 31. As a result, the whole sheet 112 is held by the sheet holding mechanism 31, as shown in Fig. 6. After the whole sheet 112 is supplied to the sheet holding mechanism 31, a step of driving and rotating the sheet holding mechanism 31 is performed before the whole sheet 112 held by the sheet holding mechanism 31 comes into close contact with the opposing surface 51a.

[0119] Then, the sheet holding mechanism 31 is driven by the drive device 40 to bring the whole sheet 112 held by the sheet holding mechanism 31 into close contact with the opposing surface 51a. As a result, the whole sheet 112 comes into close contact with the opposing surface 51a, as shown in FIGS. 21 and 22.

[0120] Next, a step of vacuum-forming the whole sheet 112 is performed. In the step of vacuum-forming the whole sheet 112, a vacuum is drawn into the space between each of the multiple forming zones 51b and the whole sheet 112. As a result, the whole sheet 112 is vacuum-formed in each of the multiple forming zones 51b, as shown in Fig. 23. In particular, by vacuuming the space between the first forming zone 51b1 and the whole sheet 112, and the space between the second forming zone 51b2 and the whole sheet 112, the whole sheet 112 can be vacuum-formed in the first forming zone 51b1 and the second forming zone 51b2, as shown in Fig. 23.

[0121] Next, the sheet holding mechanism 31 is moved away from the whole sheet 112. This is followed by a resin injection molding process. In the resin injection molding process, the opposing mold 52 is moved relative to the mold 51 and brought into contact with the whole sheet 112 positioned on the opposing surface 51a of the mold 51, thereby forming a plurality of accommodation spaces 55, as shown in FIG. 24 . In the example shown in FIG. 24 , a first accommodation space 551 and a second accommodation space 552 are formed as the plurality of accommodation spaces 55. Next, resin is injection molded into each of the formed plurality of accommodation spaces 55. This allows a molded part 12 to be formed in each of the plurality of accommodation spaces 55. In the example shown in FIG. 24 , a first molded part 121 is provided in the whole sheet 112 by injection molding resin into the first accommodation space 551. Furthermore, a second molded part 122 is provided in the whole sheet 112 by injection molding resin into the second accommodation space 552. This results in a molded product 13.

[0122] Next, the molded article 13 is transported to a trimming device 80, where a step of trimming the molded article 13 molded by the molding machine 50 is performed. In the step of trimming the molded article 13, the molded article 13 is trimmed using the trimming device 80 to remove portions of the molded article 13 that are not required as a product. In the step of trimming the molded article 13, portions of the entire sheet 112 where the molded parts 12 are provided may be separated from each other by trimming the molded article 13. This produces a plurality of molded products 16 including portions molded in the molding region 51b of the sheet 11 and the molded parts 12. As an example, in the trimming step, a first molded product 161 shown in FIG. 20 and a second molded product 162 shown in FIG. 25 are produced as molded products 16 by trimming the molded article 13 shown in FIG. 24.

[0123] The effects of the molding system 1 according to the first embodiment and the method for manufacturing a molded product 16 using the molding system 1 according to the first embodiment will be described. As Comparative Example 1, consider a molding system 1 that is similar to the molding system 1 according to the first embodiment except that the sheet holding mechanism 31 does not have a dividing section 34. The molding system 1 of Comparative Example 1 can also manufacture multiple molded products 16 by having the sheet holding mechanism 31 hold a whole sheet 112 and driving the sheet holding mechanism 31 to bring the whole sheet 112 into close contact with the mold 51.

[0124] FIG. 26 is a diagram showing the molding system 1 of Comparative Example 1, in which the sheet holding mechanism 31 holds the split sheet 111 and the sheet holding mechanism 31 is driven to bring the split sheet 111 into close contact with the mold 51. As shown in FIG. 26, in the molding system 1 of Comparative Example 1, the portion of the split sheet 111 facing the molding region dividing region 51c is not held by the sheet holding mechanism 31. Therefore, the molding system 1 of Comparative Example 1 is considered to lack the stability in holding the split sheet 111 compared to the molding system 1 of the first embodiment shown in FIG. 13. Also, in the molding system 1 of Comparative Example 1, as shown in FIG. 26, the split sheet 111 is not sandwiched between the dividing portion 34 and the molding region dividing region 51c. Therefore, compared to the molding system 1 of the first embodiment shown in FIG. 13, the molding system 1 of Comparative Example 1 cannot stably bring the split sheet 111 into close contact with the molding region dividing region 51c. Therefore, the molding system 1 of Comparative Example 1 cannot produce the first molded product 161 by using the split sheet 111. The molding system 1 of Comparative Example 1 cannot produce the first molded product 161 unless the whole sheet 112 is used, so even when it is desired to produce only the first molded product 161, the whole sheet 112 must be used, which may reduce the efficiency of use of the sheet 11.

[0125] In contrast, in the molding system 1 according to the first embodiment, the sheet holding mechanism 31 includes a dividing section 34, and can hold the divided sheet 111 by vacuum suction of the suction holes 31a, including at least the dividing section suction holes 31a2. The sheet holding mechanism 31 also tightly contacts the held divided sheet 111 with the area surrounding the first molding region 51b1, including the molding region dividing region 51c, on the opposing surface 51a of the mold 51, so that the divided sheet 111 faces the first molding region 51b1 but does not face the second molding region 51b2. Therefore, the molding system 1 according to the first embodiment can manufacture the first molded product 161 using the divided sheet 111. Therefore, the first molded product 161 can be manufactured while suppressing a decrease in the utilization efficiency of the sheet 11. Thus, the molding system 1 according to the first embodiment can provide an opening 33a shaped to improve the functionality of the sheet holding mechanism 31.

[0126] Furthermore, in the molding system 1 according to the first embodiment, the feed direction d3 in which the sheet supply device 20 feeds the divided sheet 111 as the sheet 11 intersects with the dividing direction d4 in which the first dividing region 51c1 of the mold 51 extends. Even in this case, according to the molding system 1 according to the first embodiment, the drive device 40 rotates the sheet holding mechanism 31 holding the sheet 11, so that the dividing section 34 and the molding region dividing region 51c face each other and the sheet 11 is brought into close contact with the opposing surface 51a. This improves the degree of freedom in the feed direction d3 of the sheet supply device 20 and the arrangement of the mold 51 in the molding system 1, while also making it possible to bring the dividing section 34 and the molding region dividing region 51c face each other and bring the sheet 11 into close contact with the opposing surface 51a.

[0127] In particular, when the feed direction d3 is vertical and the dividing direction d4 is a direction intersecting the vertical direction, the sheet holding mechanism 31 holding the divided sheet 111 is driven to rotate so that the divided sheet 111 rotates in a direction d5 that revolves around an axis perpendicular to the surface of the divided sheet 111. As a result, when the feed direction d3 is vertical and the dividing direction d4 is a direction intersecting the vertical direction, the dividing section 34 and the molding region dividing region 51c are opposed to each other, and the sheet 11 is brought into close contact with the opposing surface 51a.

[0128] (Second embodiment) Next, a molding system 1 according to a second embodiment will be described. In the second embodiment, the same parts as those in the first embodiment described above will be assigned the same reference numerals, and detailed description thereof will be omitted. In the following description, the molding system 1 according to the second embodiment will be described, focusing on the differences from the molding system 1 according to the first embodiment. Furthermore, if it is clear that the effects obtained in the first embodiment can also be obtained in this embodiment, the description thereof may be omitted.

[0129] Similar to the molding system 1 according to the first embodiment, the molding system 1 according to the second embodiment can also be represented by the top view shown in Fig. 1. That is, the molding system 1 according to the second embodiment includes a head 30, a molding machine 50, and a drive device 40. The molding system 1 according to the second embodiment further includes a sheet supply device 20 and a trimming device 80. The head 30 has a sheet holding mechanism 31. That is, the molding system 1 includes the sheet holding mechanism 31 as part of the head 30.

[0130] Fig. 27 is a perspective view showing an example of a sheet holding mechanism 31 and a heater 35 according to the second embodiment. As shown in Fig. 27, in the second embodiment, the sheet holding mechanism 31 of the head 30 includes a frame portion 33 having a frame-like shape with an opening 33a formed therein, and a plurality of suction holes 31a. The plurality of suction holes 31a includes at least a frame portion suction hole 31a1 formed in the frame portion 33. The frame portion 33 has a rectangular frame shape.

[0131] 27, the sheet holding mechanism 31 further includes a dividing portion 34 provided on the frame portion 33 to divide the opening 33a. In the example shown in FIG. 27, the dividing portion 34 has a first dividing portion 341 and a second dividing portion 342. The first dividing portion 341 is connected to one of the pair of first portions 33d of the frame portion 33 (the first portion 33d located on the left in FIG. 27) and one of the pair of second portions 33e of the frame portion 33 (the second portion 33e located on the bottom in FIG. 27). The second dividing portion 342 is connected to the other of the pair of first portions 33d of the frame portion 33 (the first portion 33d located on the right in FIG. 27) and the other of the pair of second portions 33e of the frame portion 33 (the second portion 33e located on the top in FIG. 27). The extending direction of the first dividing portion 341 and the extending direction of the second dividing portion 342 are parallel. The distance between the first dividing portion 341 and the second dividing portion 342 is adjusted so that the first dividing portion 341 and the second dividing portion 342 face the outer peripheral region 51e when the seat holding mechanism 31 is disposed in a second position described below. The dividing portion 34 includes the first dividing portion 341 and the second dividing portion 342, so that the opening 33a is divided into three opening regions 33b: a first opening region 33b1, a second opening region 33b2, and a third opening region 33b3. The first opening region 33b1 is in contact with a portion of the frame 33, the first dividing portion 341, and the second dividing portion 342. The second opening region 33b2 is in contact with a portion of the frame 33 and the first dividing portion 341. The third opening region 33b3 is in contact with a part of the frame portion 33 and the divided portion second part 342. In the second embodiment, as shown in Fig. 27, the divided portion 34 does not necessarily have to be provided with the divided portion suction holes 31a2.

[0132] Similar to the dividing section 34 according to the first embodiment, the dividing section 34 according to the second embodiment may be integrated with the frame section 33 or may be separable from the frame section 33. When the dividing section 34 is separable from the frame section 33, the position at which the dividing section 34 is connected to the frame section 33 may be adjustable.

[0133] The sheet holding mechanism 31 according to the second embodiment can hold the sheet 11 by vacuum suction of the suction holes 31a. FIG. 28 is a perspective view showing the sheet holding mechanism 31 according to the second embodiment holding the sheet 11, and the heater 35. In FIG. 28, the outline of the sheet 11 is indicated by a dashed line, and the position of the letter "A" printed on the sheet 11, which will be described later, is also shown. In the example shown in FIG. 28, the sheet holding mechanism 31 holds the sheet 11 by vacuum suction of the frame suction holes 31a1. In the example shown in FIG. 28, the sheet 11 faces the entire opening 33a. In other words, the sheet 11 faces all of the multiple opening regions 33b.

[0134] The sheet 11 shown in Fig. 28 can be supplied from the sheet supply device 20 to the sheet holding mechanism 31 by setting the width of the roll 10 used in the sheet supply device 20 to width w8 of the sheet 11 in the direction in which the pair of second portions 33e shown in Fig. 28 extend (the left-right direction in Fig. 28). Furthermore, the sheet 11 supplied from the sheet supply device 20 and held in the sheet holding mechanism 31 may be marked with a design such as a pattern or information such as letters. In the example shown in Fig. 28, the letter "A" is printed on the sheet 11.

[0135] Similar to the molding machine 50 of the molding system 1 of the first embodiment, the molding machine 50 of the second embodiment has a mold 51 and an opposing mold 52. The molding machine 50 molds the sheet 11 received from the sheet holding mechanism 31 by vacuum forming using the mold 51. After vacuum forming the sheet 11, the molding machine 50 forms a storage space 55 in which a portion of the sheet 11 is stored, and injection-moldes a resin into the storage space 55.

[0136] A mold 51 according to the second embodiment will be described. The mold 51 is provided in the molding system 1 and is used for vacuum forming the sheet 11. As described above, the molding system 1 is provided with the molding machine 50, and the molding machine 50 has the mold 51, so that the mold 51 is provided in the molding system 1. Fig. 29 is a plan view showing the mold 51 according to the second embodiment as viewed from the opposing surface 51a side. Fig. 30 is a cross-sectional view showing a cross section taken along line BB in Fig. 29. As shown in Figs. 29 and 30, the mold 51 has an opposing surface 51a that faces the sheet 11 during vacuum forming.

[0137] 29 and 30, the opposing surface 51a has a forming region 51b where the sheet 11 can be vacuum-formed, and an outer peripheral region 51e that surrounds the forming region 51b. In the example shown in Fig. 29 and 30, the opposing surface 51a has one forming region 51b.

[0138] The operation of the sheet holding mechanism 31 and the mold 51 when the sheet 11 is held by the sheet holding mechanism 31 and vacuum-formed will be specifically described with reference to FIGS. 31 to 35. FIG. 31 is a plan view showing an example of the positional relationship between the sheet holding mechanism 31, the sheet 11, and the mold 51 when the sheet holding mechanism 31 holding the sheet 11 is driven to bring the sheet 11 into close contact with the opposing surface 51a as shown in FIGS. 29 and 30. In FIG. 31, the outline of the sheet 11 is indicated by a dashed line, and the position of the letter "A" printed on the sheet 11 is also indicated. In FIG. 31, only the outline of the sheet holding mechanism 31 is indicated by a dashed line. FIG. 32 is a cross-sectional view showing the cross section of the sheet holding mechanism 31, the sheet 11, and the mold 51 when the sheet 11 held by the sheet holding mechanism 31 is brought into close contact with the opposing surface 51a as shown in FIG. 31. FIG. 32 corresponds to the cross section taken along line CC in FIG. 31.

[0139] 31 and 32, the sheet holding mechanism 31 faces the area surrounding the molding area 51b on the opposing surface 51a, and holds the held sheet 11 in close contact with the area surrounding the molding area 51b on the opposing surface 51a. The position of the sheet holding mechanism 31 relative to the mold 51 when the sheet 11 held by the sheet holding mechanism 31 is in close contact with the area surrounding the molding area 51b on the opposing surface 51a is referred to as the close contact position. One of the close contact positions is referred to as the first position. In the second embodiment, the close contact position shown in FIGS. 31 and 32 is considered to be the first position.

[0140] 31 and 32, when the sheet holding mechanism 31 is disposed in the first position, the sheet holding mechanism 31 and the mold 51 face each other so that the extension direction of the first portion 33d of the frame 33 is parallel to the extension direction of the upper side 511 and the lower side 512 of the facing surface 51a. Also, the sheet holding mechanism 31 and the mold 51 face each other so that the extension direction of the second portion 33e of the frame 33 is parallel to the extension direction of the side edge 513 of the facing surface 51a.

[0141] As shown in FIGS. 31 and 32 , when the sheet holding mechanism 31 is disposed in the first position, the sheet holding mechanism 31 faces the outer peripheral region 51e of the facing surface 51a of the mold 51. The frame portion 33 of the sheet holding mechanism 31 faces the outer peripheral region 51e over the entire periphery. The frame portion 33 of the sheet holding mechanism 31 contacts the sheet 11 over the entire periphery. Therefore, the sheet 11 is pressed by the frame portion 33 of the sheet holding mechanism 31 and is in close contact with the region of the outer peripheral region 51e that surrounds the molding region 51b. In other words, the sheet 11 is sandwiched between the frame portion 33 and the outer peripheral region 51e over the entire periphery of the frame portion 33. As shown in FIGS. 31 and 32 , when the sheet holding mechanism 31 is disposed in the first position, the dividing portion 34 of the sheet holding mechanism 31 faces the outer peripheral region 51e. The dividing portion 34 of the sheet holding mechanism 31 contacts the sheet 11. For this reason, the sheet 11 is pressed by the dividing portion 34 of the sheet holding mechanism 31, and is thereby in close contact with the outer peripheral region 51e. In other words, the sheet 11 is sandwiched between the dividing portion 34 and the outer peripheral region 51e.

[0142] As described above, by placing the sheet holding mechanism 31 in the first position, the sheet 11 comes into close contact with the area surrounding the forming area 51b of the facing surface 51a. With the sheet 11 in close contact with the area surrounding the forming area 51b of the facing surface 51a, the space between the sheet 11 and the forming area 51b is evacuated, whereby the sheet 11 is vacuum-formed, as shown in Fig. 35. Note that Fig. 35 shows the state in which the sheet holding mechanism 31 is moved away from the sheet 11 by the drive device 40 after the sheet 11 has been vacuum-formed.

[0143] Here, the sheet holding mechanism 31 according to the second embodiment faces the area surrounding the forming region 51b of the facing surface 51a at a plurality of contact positions, and holds the sheet 11 in close contact with the area surrounding the forming region 51b of the facing surface 51a. The plurality of contact positions include at least the first position described above and a second position obtained by rotating the sheet holding mechanism 31 from the first position. The second position is a position obtained by rotating the sheet holding mechanism 31 from the first position by 5° or more in a direction d5 orbiting the axis L1 perpendicular to the surface of the sheet 11 held by the sheet holding mechanism 31. The second position may be a position obtained by rotating the sheet holding mechanism 31 from the first position by 10° or more or by 20° or more in a direction d5 orbiting the axis L1 perpendicular to the surface of the sheet 11 held by the sheet holding mechanism 31. FIG. 33 is a plan view showing an example of the positional relationship between the sheet holding mechanism 31, the sheet 11, and the mold 51 when the sheet holding mechanism 31 holding the sheet 11 is placed in the second position as shown in FIGS. 29 and 30. In FIG. 33, the outline of the sheet 11 is shown by a dashed line, and the position of the letter "A" displayed on the sheet 11, which will be described later, is also shown. Also in FIG. 33, only the outline of the sheet holding mechanism 31 is shown by a dashed line. FIG. 34 is a cross-sectional view showing the cross section of the sheet holding mechanism 31, the sheet 11, and the mold 51 when the sheet holding mechanism 31 is placed in the second position as shown in FIG. 33. FIG. 34 corresponds to the cross section taken along line DD in FIG. 33.

[0144] 33 and 34, when the sheet holding mechanism 31 is disposed in the second position, the sheet holding mechanism 31 faces the area surrounding the forming region 51b of the facing surface 51a and holds the held sheet 11 in close contact with the area surrounding the forming region 51b of the facing surface 51a. In the second position shown in FIGS. 33 and 34, the sheet holding mechanism 31 is rotated by an angle θ from the first position in a direction d5. In the example shown in FIGS. 33 and 34, the extension directions of the first divided portion 341 and the second divided portion 342 are parallel to the upper side 511 and the lower side 512 of the facing surface 51a.

[0145] 33 and 34, when the sheet holding mechanism 31 is disposed in the second position, the sheet holding mechanism 31 faces the outer peripheral region 51e of the facing surface 51a of the mold 51. In particular, a portion of the sheet holding mechanism 31 that contacts the first opening region 33b1 of the frame portion 33, the divided portion first portion 341 and the divided portion second portion 342, faces the outer peripheral region 51e. The portion of the sheet holding mechanism 31 that contacts the first opening region 33b1 of the frame portion 33, the divided portion first portion 341 and the divided portion second portion 342, contact the sheet 11. For this reason, the sheet 11 is pressed by the portion of the sheet holding mechanism 31 that contacts the first opening region 33b1 of the frame portion 33, the divided portion first portion 341 and the divided portion second portion 342, and thereby adheres to the region of the outer peripheral region 51e that surrounds the molding region 51b. In other words, the sheet 11 is sandwiched between a part of the frame 33 that contacts the first opening region 33b1, the first divided portion 341 and the second divided portion 342, and the outer circumferential region 51e.

[0146] As described above, by placing the sheet holding mechanism 31 in the second position, the sheet 11 is brought into close contact with the area surrounding the forming zone 51b on the facing surface 51a, just as when the sheet holding mechanism 31 is placed in the first position. Therefore, by placing the sheet holding mechanism 31 in the second position and evacuating the space between the sheet 11 and the forming zone 51b, the sheet 11 can also be vacuum-formed as shown in FIG. 35. Although not shown, the sheet holding mechanism 31 may face the area surrounding the forming zone 51b on the facing surface 51a at three or more contact positions, thereby bringing the held sheet 11 into close contact with the area surrounding the forming zone 51b on the facing surface 51a. In this case, the sheet 11 can also be vacuum-formed by placing the sheet holding mechanism 31 in a contact position other than the first and second positions and evacuating the space between the sheet 11 and the forming zone 51b.

[0147] As an example, when the sheet holding mechanism 31 is positioned at the first position, the opening region 33b of the sheet holding mechanism 31 faces the molding region 51b of the opposing surface 51a, while the frame 33 and the dividing portion 34 do not face the molding region 51b. Also, when the sheet holding mechanism 31 is positioned at the second position, the opening region 33b of the sheet holding mechanism 31 faces the molding region 51b of the opposing surface 51a, while the frame 33 and the dividing portion 34 do not face the molding region 51b of the opposing surface 51a. The fact that the frame 33 and the dividing portion 34 do not face the molding region 51b when the sheet holding mechanism 31 is positioned at the first and second positions provides the following advantages: The frame 33 and the dividing portion 34 are less likely to interfere with the transfer of heat from the heater 35 to the portion of the sheet 11 that can be molded in the molding region 51b. The frame 33 and the dividing portion 34 do not need to face the molding region 51b at all of the contact positions where the sheet holding mechanism 31 can be positioned.

[0148] The drive unit 40 drives the sheet holding mechanism 31, thereby positioning the sheet holding mechanism 31 at a plurality of contact positions. That is, the drive unit 40 according to the second embodiment drives the sheet holding mechanism 31 so that the sheet holding mechanism 31 faces the area surrounding the forming area 51b of the facing surface 51a at a plurality of contact positions, and the sheet 11 is brought into close contact with the facing surface 51a. In this way, the drive unit 40 brings the sheet 11 held by the sheet holding mechanism 31 into close contact with the area surrounding the forming area 51b of the facing surface 51a.

[0149] After vacuum-forming the sheet 11, the molding machine 50 forms a storage space 55, a portion of which is partitioned by a molding region 51b and which stores at least a portion of the sheet 11, as shown in FIG. 36 , and then injection-moldes a resin into the storage space 55. The storage space 55 is formed by moving the opposing mold 52 relative to the mold 51. In the example shown in FIG. 36 , the opposing mold 52 has an opposing molding region 52d and an opposing outer peripheral region 52e that surrounds the opposing molding region 52d. In the example shown in FIG. 36 , the opposing mold 52 has one opposing molding region 52d. In the example shown in FIG. 36 , one storage space 55 is formed by one molding region 51b and one opposing molding region 52d. By injection molding using the molding machine 50, a molded part 12 is provided in the sheet 11, as shown in FIG. 36 , to form a molded product 13.

[0150] The trimming device 80 according to the second embodiment trims the molded product 13 molded by the molding machine 50 to remove portions of the molded product 13 that are not required for the product. This produces a molded product 16 including a sheet 11 and a molded part 12, as shown in FIG. 37. In particular, by positioning the sheet holding mechanism 31 at the first position and performing vacuum forming of the sheet 11 and resin injection molding, a molded product 16 is produced in which the letter "A" is visible when observed from the sheet 11 side, as shown in FIG. 38. Furthermore, by positioning the sheet holding mechanism 31 at the second position and performing vacuum forming of the sheet 11 and resin injection molding, a molded product 16 is produced in which the letter "A" is visible when observed from the sheet 11 side, as shown in FIG. 39.

[0151] Next, an example of a method for manufacturing a molded product 16 using the molding system 1 according to the second embodiment will be described. In the following explanation, the method for manufacturing a molded product 16 using the molding system 1 according to the second embodiment will be explained, focusing on the differences from the method for manufacturing a molded product 16 using the molding system 1 according to the first embodiment. Furthermore, if it is clear that the effects obtained in the first embodiment can also be obtained in this embodiment, the explanation may be omitted.

[0152] A method for manufacturing a molded product 16 using a molding system 1 according to the second embodiment includes, in this order, a step of closely adhering a sheet 11 to the opposing surface 51a, a step of vacuum-forming the sheet 11 that has been adhered to the opposing surface 51a, and a step of injection-molding a resin. The method for manufacturing a molded product 16 according to this embodiment includes, in this order, a step of supplying the sheet 11 to a sheet holding mechanism 31 before the sheet 11 adheres to the opposing surface 51a in the step of closely adhering the sheet 11 to the opposing surface 51a, and a step of driving and rotating the sheet holding mechanism 31 that holds the sheet 11. The method for manufacturing a molded product 16 according to this embodiment further includes, after the step of injection-molding a resin, a step of trimming the molded article 13 molded by the molding machine 50.

[0153] In the step of supplying the sheet 11 to the sheet holding mechanism 31, the sheet 11 is supplied to the sheet holding mechanism 31 so that the sheet 11 is held by the sheet holding mechanism 31. As a result, the sheet 11 is held by the sheet holding mechanism 31, as shown in FIG.

[0154] After the step of supplying the sheet 11 to the sheet holding mechanism 31, the sheet 11 held by the sheet holding mechanism 31 is conveyed to the mold 51 by the drive device 40. Here, after the sheet 11 is supplied to the sheet holding mechanism 31, but before the sheet 11 comes into close contact with the opposing surface 51a, a step of driving and rotating the sheet holding mechanism 31 holding the sheet 11 is performed. In the step of driving and rotating the sheet holding mechanism 31, the drive device 40 drives and rotates the sheet holding mechanism 31. The sheet holding mechanism 31 is rotated so that the sheet 11 held by the sheet holding mechanism 31 rotates in a direction d5 orbiting an axis L1 perpendicular to the surface of the sheet 11.

[0155] The step of driving and rotating the sheet holding mechanism 31 makes it possible to adjust which of a plurality of contact positions the sheet holding mechanism 31 is placed at in the step of bringing the sheet 11 into close contact with the opposing surface 51a. For example, by rotating the sheet holding mechanism 31 in the step of driving and rotating the sheet holding mechanism 31, it is possible to adjust whether the sheet holding mechanism 31 is placed at the first position or the second position.

[0156] In the step of bringing the sheet 11 into close contact with the opposing surface 51a, the sheet holding mechanism 31 holding the sheet 11 is placed at one of a plurality of contact positions. As an example, the sheet holding mechanism 31 holding the sheet 11 is placed at either the first position or the second position. This brings the sheet 11 held by the sheet holding mechanism 31 into close contact with the area surrounding the molding area 51b of the opposing surface 51a.

[0157] In the process of vacuum-forming the sheet 11 that has been brought into close contact with the opposing surface 51a, the sheet 11 that has been brought into close contact with the area surrounding the forming area 51b of the opposing surface 51a by the sheet holding mechanism 31 is vacuum-formed in the forming area 51b. Specifically, when the sheet holding mechanism 31 is placed in the first position, the space between the forming area 51b of the opposing surface 51a and the sheet 11, as shown in FIG. 32, is evacuated. When the sheet holding mechanism 31 is placed in the second position, the space between the forming area 51b of the opposing surface 51a and the sheet 11, as shown in FIG. 34, is evacuated. As a result, the sheet 11 is vacuum-formed, as shown in FIG. 35.

[0158] Next, as shown in FIG. 35, the sheet holding mechanism 31 is moved away from the sheet 11. This is followed by the step of injection molding the resin. In the step of injection molding the resin, a molding machine 50 is caused to form a storage space 55 in which at least a portion of the sheet 11 is stored, and the resin is injection molded into the storage space 55. Specifically, in the step of injection molding the resin, the opposing mold 52 is moved relative to the mold 51 and brought into contact with the sheet 11 located on the opposing surface 51a of the mold 51, thereby forming the storage space 55 as shown in FIG. 36. Next, the resin is injection molded into the formed storage space 55. As a result, a molded part 12 is formed in the storage space 55, and a molded product 13 having the sheet 11 and the molded part 12 is molded.

[0159] Next, the molded product 13 is transported to a trimming device 80, where the molded product 13 molded by the molding machine 50 is trimmed. In the trimming process, the molded product 13 is trimmed using the trimming device 80 to remove portions of the molded product 13 that are not required for the product. This results in a molded product 16, as shown in FIG. 37, that includes the portion molded in the molding region 51b of the sheet 11 and the molded part 12. In the process of driving and rotating the sheet holding mechanism 31, the orientation of the design, information, etc. displayed on the sheet 11 in the molded product 16 can be adjusted by adjusting which of multiple contact positions the sheet holding mechanism 31 is positioned at. For example, by adjusting the sheet holding mechanism 31 to be positioned at the first position, a molded product 16 can be manufactured in which the letter "A" is visible when viewed from the sheet 11 side, as shown in FIG. 37. By adjusting the sheet holding mechanism 31 so that it is positioned at the second position, it is possible to manufacture a molded product 16 in which the letter "A" is visible when observed from the sheet 11 side, as shown in FIG.

[0160] The effects of the molding system 1 according to the second embodiment and the method for manufacturing a molded product 16 using the molding system 1 according to the second embodiment will be described. As Comparative Example 2, consider a molding system 1 similar to the molding system 1 according to the first embodiment, except that the sheet holding mechanism 31 cannot be in close contact with the opposing surface 51a at multiple contact positions, including the first position and the second position. Specifically, as Comparative Example 2, consider a molding system 1 similar to the molding system 1 according to the first embodiment, except that the sheet holding mechanism 31 does not have a dividing section 34 and therefore cannot be in close contact with the opposing surface 51a at a position corresponding to the second position. The molding system 1 of Comparative Example 2 can also manufacture the molded product 16 shown in FIGS. 37 and 38 by placing the sheet holding mechanism 31 holding the sheet 11 at the first position and thereby bringing the sheet 11 into close contact with the mold 51. However, in Comparative Example 2, the sheet holding mechanism 31 cannot bring the held sheet 11 into close contact with the opposing surface 51a at multiple contact positions, including the second position. Therefore, when using the molding system 1 according to Comparative Example 2, it is not possible to adjust the orientation of the design, information, etc. displayed on the sheet 11 in the molded product 16 to be manufactured by adjusting which of the multiple contact positions the sheet holding mechanism 31 is placed at.

[0161] As a method for supplying the sheet 11 to the mold 51 in the molding system 1, it is also possible to directly feed the sheet 11 from the roll 10 to a position facing the facing surface 51a of the mold 51 without using the head 30 having the sheet holding mechanism 31 and the drive device 40. As Comparative Example 3, consider the molding system 1 in which the sheet 11 is directly fed from the roll 10 to a position facing the facing surface 51a, as described above. FIG. 40 is a diagram showing how the sheet 11 is fed to the mold 51 in the molding system 1 according to Comparative Example 3. In the example shown in FIG. 40, the sheet 11 is fed directly from the roll 10 to a position facing the facing surface 51a. The sheet 11 is fed from below to above in the vertical direction (the up-and-down direction in FIG. 40). In the case of Comparative Example 3, if the orientation of the design, information, etc. displayed on the sheet 11 in the molded product 16 to be manufactured is adjusted without changing the feeding direction of the sheet 11, the following adjustment method is possible. First, a plurality of rolls 10 are prepared, each having a different orientation of design, information, etc. relative to the direction in which the sheet 11 is fed. Then, a roll 10 to be used is selected from the plurality of rolls 10 in accordance with the orientation of the design, information, etc. to be displayed on the sheet 11 in the molded product 16. However, in this case, since a plurality of rolls 10 must be prepared, there is a risk that the initial cost for preparing the rolls 10 will be high.

[0162] In contrast, in the molding system 1 according to the second embodiment, the sheet holding mechanism 31 is in close contact with the opposing surface 51a at multiple contact positions, including a first position and a second position. Furthermore, in a method for manufacturing a molded product 16 using the molding system 1 according to the second embodiment, the sheet holding mechanism 31 holding the sheet 11 is positioned at one of the multiple contact positions, and the sheet 11 is brought into close contact with the area surrounding the molding area 51b on the opposing surface 51a. Therefore, by adjusting the contact position at which the sheet holding mechanism 31 is positioned, the orientation of the design, information, etc., displayed on the sheet 11 in the molded product 16 to be manufactured can be adjusted. For example, by adjusting the sheet holding mechanism 31 to be positioned at the first position, a molded product 16 can be manufactured in which the letter "A" is visible when observed from the side of the sheet 11, as shown in FIG. 37. By adjusting the sheet holding mechanism 31 to be positioned at the second position, a molded product 16 can be manufactured in which the letter "A" is visible when observed from the side of the sheet 11, as shown in FIG. 38. Furthermore, particularly compared to the molding system 1 according to Comparative Example 3, there is no need to prepare multiple rolls 10.

[0163] Furthermore, in the molding system 1 according to the second embodiment, the frame 33 has a rectangular frame-like shape. The effect of the frame 33 having a rectangular frame-like shape will be described. A sheet supplying device 20 that supplies a rectangular sheet 11 to the sheet holding mechanism 31 has a simpler structure than a sheet supplying device 20 that supplies a non-rectangular sheet 11 to the sheet holding mechanism 31. For example, when supplying a sheet 11 to the sheet holding mechanism 31 using a sheet supplying device 20 having a sheet cutting means 21 as shown in FIG. 2 , it becomes necessary to adjust the shape of the sheet cutting means 21, the angle at which the sheet cutting means 21 is disposed, and other factors when supplying a non-rectangular sheet 11. In contrast, when supplying a rectangular sheet 11, the linearly extending sheet cutting means 21 can be disposed perpendicular to the feed direction d3 of the sheet 11, thereby simplifying the structure of the sheet supplying device 20. Here, the rectangular frame-like shape of the frame 33 allows the rectangular sheet 11 to be held so that its width does not protrude too much from the sheet holding mechanism 31. This simplifies the structure of the sheet supply device 20, while holding the sheet 11 so that the width of the sheet 11 that protrudes from the sheet holding mechanism 31 does not become too large. In this way, the molding system 1 according to the second embodiment can provide the opening 33a having a configuration that improves the function of the sheet holding mechanism 31.

[0164] Furthermore, the manufacturing method of the molded product 16 using the molding system 1 according to the second embodiment includes a step of driving and rotating the sheet holding mechanism 31. This allows the orientation of the design, information, etc. displayed on the sheet 11 in the molded product 16 to be manufactured to be adjusted by adjusting which of the multiple contact positions the sheet holding mechanism 31 is to be placed at.

[0165] Although the first and second embodiments have been described using specific examples, these specific examples do not limit the first and second embodiments. The first and second embodiments described above can be implemented using various other specific examples, and various omissions, substitutions, changes, and additions can be made without departing from the spirit of the embodiments.

[0166] An example of the modification will be described below with reference to the drawings. In the following description and the drawings used in the following description, parts that can be configured similarly to the above-described example will be designated by the same reference numerals as those used for the corresponding parts in the above-described example, and duplicated descriptions will be omitted.

[0167] (Variation 1) In the second embodiment described above, the sheet holding mechanism 31 includes a dividing portion 34. However, the configuration of the sheet holding mechanism 31 is not limited to this. FIG. 41 is a perspective view showing the sheet holding mechanism 31 according to Modification 1 together with the heater 35. In the example shown in FIG. 41, the sheet holding mechanism 31 does not include a dividing portion 34. Therefore, the opening 33a of the sheet holding mechanism 31 is not divided into multiple opening regions 33b. In the example shown in FIG. 41, the widths of the pair of first portions 33d of the frame portion 33 vary. The sheet holding mechanism 31 shown in FIG. 41 has a shape corresponding to the shape of the sheet holding mechanism 31 shown in FIG. 27 in which the second opening region 33b2 and the third opening region 33b3 are blocked by members integrated with the frame portion 33 and the dividing portion 34.

[0168] 27, the seat holding mechanism 31 shown in FIG. 41 can be positioned at a first position and a second position rotated from the first position by an angle θ in the direction d5 shown in FIG. 33 to bring the held seat 11 into close contact with the opposing surface 51a. From the viewpoint of reducing the weight of the seat holding mechanism 31, it is preferable that the seat holding mechanism 31 include a dividing portion 34 as shown in FIG. 27. It is also preferable that the seat holding mechanism 31 include a dividing portion 34 from the following viewpoint. As described above, the dividing portion 34 can be designed to be separable from the frame portion 33. If the dividing portion 34 is separable from the frame portion 33, the angle θ by which the seat holding mechanism 31 is rotated when the seat holding mechanism 31 is positioned in the first position and moved to the second position can be changed by replacing the dividing portion 34 and adjusting the position at which the dividing portion 34 connects to the frame portion 33.

[0169] (Variation 2) In the above-described first embodiment, an example has been described in which the molding system 1 according to the first embodiment is used in a method for manufacturing a molded product 16 including a sheet 11 and a molded part 12. However, the use of the molding system 1 according to the first embodiment is not limited to this. The molding system 1 according to the first embodiment may also be used in a method for manufacturing a first molded sheet 171 and a second molded sheet 172 shown in FIG. 42. In this case, the molding machine 50 does not need to have an opposing mold 52. Furthermore, the sheet 11 vacuum-formed in the mold 51 may be transported to a trimming device 80.

[0170] The manufacturing method of molded sheet 17 according to Modification 2 is similar to the manufacturing method of molded product 16 using molding system 1 according to the first embodiment, except that it does not include the step of injection molding a resin. When a first molded sheet 171 is manufactured as molded sheet 17 using divided sheets 111 as sheet 11, the manufacturing method of molded sheet 17 according to Modification 2 includes the steps of adhering divided sheet 111 to opposing surface 51a and vacuum-forming divided sheet 111. In the step of adhering divided sheet 111 to opposing surface 51a, divided sheet 111 held by sheet holding mechanism 31 is brought into close contact with an area of ​​opposing surface 51a that surrounds first molding region 51b1, including molding region divided region 51c. In the step of vacuum-forming divided sheet 111, divided sheet 111 brought into close contact with the area that surrounds first molding region 51b1 by sheet holding mechanism 31 is vacuum-formed in first molding region 51b1. The manufacturing method of molded sheet 17 according to Modification 2 may further include a step of trimming vacuum-formed divided sheet 111. The step of trimming vacuum-formed divided sheet 111 may be performed by transporting divided sheet 111 vacuum-formed in mold 51 to trimming device 80, and using trimming device 80 similar to trimming device 80 of molding system 1 according to the first embodiment described above. This allows the manufacturing of first molded sheet 171 shown in FIG. 42.

[0171] In this way, in the manufacturing method of the molded sheet 17 according to the second modification, the first molded sheet 171 can be manufactured using the divided sheets 111. Therefore, the first molded sheet 171 can be manufactured while suppressing a decrease in the use efficiency of the sheet 11.

[0172] (Variation 3) In the above-described second embodiment, an example has been described in which the molding system 1 according to the second embodiment is used in a method for manufacturing a molded product 16 including a sheet 11 and a molded part 12. However, the use of the molding system 1 according to the second embodiment is not limited to this. The molding system 1 according to the second embodiment may also be used in a method for manufacturing a molded sheet 17 shown in FIG. 43. In this case, the molding machine 50 does not need to have an opposing mold 52. Furthermore, the sheet 11 vacuum-formed in the mold 51 may be transported to a trimming device 80.

[0173] The manufacturing method of molded sheet 17 according to Modification 3 is similar to the manufacturing method of molded product 16 using molding system 1 according to the second embodiment, except that it does not include the step of injection molding a resin. That is, the manufacturing method of molded sheet 17 according to Modification 3 includes the steps of closely adhering sheet 11 to opposing surface 51a and vacuum-forming sheet 11. In the step of closely adhering sheet 11 to opposing surface 51a, sheet holding mechanism 31 holding sheet 11 is positioned at one of a plurality of adhering positions, and sheet 11 is closely adhering to the area surrounding molding area 51b of opposing surface 51a. In the step of vacuum-forming sheet 11, sheet 11, which has been closely adhering to the area surrounding molding area 51b of opposing surface 51a by sheet holding mechanism 31, is vacuum-formed in molding area 51b. The manufacturing method of molded sheet 17 according to Modification 3 may further include the step of trimming the vacuum-formed sheet 11. The step of trimming the vacuum-formed sheet 11 can be performed by transporting the vacuum-formed sheet 11 in the mold 51 to a trimming device 80, and using the same trimming device 80 as the trimming device 80 of the molding system 1 according to the second embodiment described above. This allows the molded sheet 17 shown in FIG. 43 to be produced.

[0174] As described above, in the manufacturing method of molded sheet 17 according to the third modification, sheet holding mechanism 31 holding sheet 11 is placed at one of a plurality of contact positions, and sheet 11 is brought into close contact with the area surrounding molding area 51b on opposing surface 51a, and vacuum molding is performed. Therefore, by adjusting the contact position at which sheet holding mechanism 31 is placed, the orientation of the design, information, etc. displayed on sheet 11 in molded sheet 17 to be manufactured can be adjusted.

[0175] The components disclosed in the above-described embodiment and each modification may be combined as needed, or some components may be omitted from all the components shown in the above-described embodiment and each modification. [Explanation of symbols]

[0176] 1. Molding System 11 sheets 111 Split Sheet 112 Whole Sheet 12 Molded parts 13 Molded products 16 Molded products 17 Molded Sheet 20 Sheet feeding device 30 heads 31 Seat holding mechanism 31a Adsorption hole 31a1 Frame suction hole 31a2 Split suction hole 32 Molded product holding mechanism 33 Frame 33a aperture 33b Opening area 33b1 1st opening area 33b2 2nd opening area 40 Drive unit 50 Molding machine 51 Mold 51a Opposite side 51b Molding area 51b1 1st molding area 51b2 2nd molding area 51c Molding area division area 51c1 1st divided area 52 Opposing mold 55 Containment Space

Claims

1. A sheet holding mechanism for holding a sheet in a forming system for forming a sheet, comprising: a frame portion having a frame-like shape with an opening; a dividing portion provided on the frame portion and dividing the opening into a plurality of opening regions including at least a first opening region and a second opening region; a plurality of suction holes including a frame suction hole provided in the frame portion and a division portion suction hole provided in the division portion, a sheet holding mechanism that holds, as the sheet, a divided sheet that faces the first opening region but does not face the second opening region by vacuum suction of the suction holes including at least the divided portion suction holes;

2. the sheet holding mechanism brings the sheet into close contact with an opposing surface of a mold that is provided in the molding system and used for vacuum forming the sheet, the opposing surface facing the sheet during vacuum forming; The opposing surface has a plurality of forming areas capable of vacuum forming the sheet, including at least a first forming area and a second forming area, and a forming area dividing area located between the plurality of forming areas to separate the plurality of forming areas from each other, The sheet holding mechanism according to claim 1, wherein the sheet holding mechanism presses the held divided sheet against an area surrounding the first molding area, including the molding area dividing area, of the opposing surface so as to face the first molding area of ​​the opposing surface but not face the second molding area.

3. The seat holding mechanism according to claim 1 or 2; a molding machine used for vacuum forming the sheet, the molding machine having a mold having an opposing surface that faces the sheet during vacuum forming; a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with the opposing surface, The opposing surface has a plurality of forming areas capable of vacuum forming the sheet, including at least a first forming area and a second forming area, and a forming area dividing area located between the plurality of forming areas to separate the plurality of forming areas from each other, The drive device drives the sheet holding mechanism to bring the divided sheet held by the sheet holding mechanism into close contact with an area surrounding the first molding area, including the molding area dividing area, of the opposing surface, so that the divided sheet faces the first molding area of ​​the opposing surface but does not face the second molding area.

4. a sheet feeding device that feeds the divided sheets in a direction opposite to the sheet holding mechanism so that the divided sheets are held by the sheet holding mechanism; the molding region dividing region includes a first dividing region extending between the first molding region and the second molding region, The molding system according to claim 3 , wherein a feeding direction in which the sheet supply device feeds the divided sheets intersects with a dividing direction in which the divided molding regions of the mold extend.

5. The molding system according to claim 3 or 4, wherein the molding machine forms a first storage space, a portion of which is partitioned by the first molding area and in which at least a portion of the divided sheet is stored, and injection molding resin into the first storage space.

6. A method for manufacturing a molded product using the molding system according to claim 5, a step of bringing the divided sheet held by the sheet holding mechanism into close contact with an area surrounding the first molding area including the molding area dividing area on the opposing surface; a step of vacuum-forming, in the first molding area, the divided sheets that have been brought into close contact with the area surrounding the first molding area of ​​the opposing surface by the sheet holding mechanism; forming the first storage space in which at least a portion of the divided sheet is stored in the molding machine, and injection molding resin into the first storage space.

7. feeding the divided sheet to a sheet holding mechanism so that the divided sheet is held by the sheet holding mechanism; 7. The method for manufacturing a molded product according to claim 6, further comprising a step of driving and rotating the sheet holding mechanism that holds the divided sheet so that the divided sheet rotates in a direction orbiting an axis perpendicular to the plane of the divided sheet.

8. A method for producing a molded sheet using the molding system according to any one of claims 3 to 5, a step of bringing the divided sheet held by the sheet holding mechanism into close contact with an area surrounding the first molding area including the molding area dividing area on the opposing surface; a step of vacuum-forming, in the first molding area, the divided sheets that have been brought into close contact with the area surrounding the first molding area by the sheet holding mechanism.

9. A sheet holding mechanism for holding a sheet in a forming system for forming a sheet, comprising: a frame portion having a frame-like shape with an opening; a plurality of suction holes including at least a frame suction hole provided in the frame, The sheet is held by vacuum suction through the suction holes, and is brought into close contact with an opposing surface of a mold that is provided in the molding system and used for vacuum forming of the sheet, the opposing surface facing the sheet during vacuum forming; The opposing surface has a forming area in which the sheet can be vacuum-formed and an outer peripheral area surrounding the forming area, A sheet holding mechanism that adheres the held sheet to the area surrounding the molding area of ​​the opposing surface, facing the area surrounding the molding area of ​​the opposing surface, at multiple contact positions including at least a first position and a second position rotated from the first position by 5 degrees or more in a direction circumferential about an axis perpendicular to the surface of the held sheet.

10. The seat holding mechanism according to claim 9 , further comprising a dividing portion provided on the frame portion to divide the opening.

11. The seat holding mechanism according to claim 9 or 10, wherein the frame portion has a rectangular frame shape.

12. a seat holding mechanism according to any one of claims 9 to 11; a molding machine used for vacuum forming the sheet, the molding machine having a mold having an opposing surface that faces the sheet during vacuum forming; a drive device that drives the sheet holding mechanism so as to bring the sheet held by the sheet holding mechanism into close contact with the opposing surface, The opposing surface has a forming area in which the sheet can be vacuum-formed and an outer peripheral area surrounding the forming area, A molding system in which the drive device drives the sheet holding mechanism to face the area surrounding the molding area of ​​the opposing surface at the multiple contact positions, and to bring the sheet held by the sheet holding mechanism into close contact with the area surrounding the molding area of ​​the opposing surface.

13. The molding system according to claim 12 , wherein the molding machine forms a storage space, a portion of which is partitioned by the molding area and which stores at least a portion of the sheet, and injection-moldes a resin into the storage space.

14. A method for producing a molded product using the molding system according to claim 13, comprising: a step of placing the sheet holding mechanism holding the sheet at any one of the plurality of contact positions and bringing the sheet into close contact with a region surrounding the molding region on the opposing surface; a step of vacuum-forming, in the molding area, the sheet that has been brought into close contact with the area surrounding the molding area of ​​the opposing surface by the sheet holding mechanism; a step of forming the storage space in which at least a portion of the sheet is stored in the molding machine, and injection-molding a resin into the storage space.

15. feeding the sheet to a sheet holding mechanism so that the sheet is held by the sheet holding mechanism; The method for manufacturing a molded product according to claim 14, further comprising a step of driving and rotating the sheet holding mechanism that holds the sheet so that the sheet rotates in a direction around an axis perpendicular to the surface of the sheet.

16. A method for producing a molded sheet using the molding system according to claim 12 or 13, a step of placing the sheet holding mechanism holding the sheet at any one of the plurality of contact positions and bringing the sheet into close contact with a region surrounding the molding region on the opposing surface; a step of vacuum-forming, in the molding area, the sheet that has been brought into close contact with the area surrounding the molding area of ​​the opposing surface by the sheet holding mechanism.

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