Molding system, support arm, resin molding device and method of supporting a member to be supported, mold and method of manufacturing a molded body

Abstract

We provide a molding system capable of reducing molding defects. According to the present invention, a molding system comprises a first and second parison forming device, first and second molds configured to be openable and closable, and a control unit. The first parison forming device comprises a first extruder, a first accumulator, and a first injection head. It is configured to form a first parison by injecting a first molten resin from a first injection head after a first molten resin extruded from a first extruder is accumulated in a first accumulator. The second parison forming device comprises a second extruder, a second accumulator, and a second injection head. It is configured to form a second parison by injecting a second molten resin from a second injection head after a second molten resin extruded from a second extruder is accumulated in a second accumulator. The first and second parisons are injected between the first and second molds. The control unit, based on historical data from a past cycle, [manipulates] the first and second parison forming devices and the first and second molds in the next cycle. A molding system configured to determine the timing of the start of operation of at least one of the second molds is provided.

Description

Technology Field

[0001] The present invention relates to a molding system, a support arm, a resin molding device, a method for supporting a member to be supported, a mold, and a method for manufacturing a molded body. Background Technology

[0002] (First Perspective)

[0003] Patent Document 1 discloses an apparatus for manufacturing a sandwich panel by placing a core material between a pair of resin sheets extruded from each of a pair of T-dies and molding them using a pair of split molds.

[0004] (Second Perspective)

[0005] Conventionally, a technique is disclosed in which a pre-formed molded body is moved by a support arm to a molten resin sheet formed in a mold and welded to the molten resin sheet. For example, Patent Document 2 discloses a method for forming a sandwich panel having a thermoplastic resin core material interposed between two resin skin material sheets. In this method for forming a sandwich panel, a core material held by a suction plate of a manipulator (support arm) is inserted between thermoplastic resin sheets in the shape of a continuous sheet formed according to the cavity of a split mold, and the manipulator is moved horizontally toward the split mold to weld the core material to the thermoplastic resin sheets adsorbed in the cavity. The manipulator releases support for the core material and withdraws from between the split molds. Afterward, the split mold is mold clamped to weld the thermoplastic resin sheets from both sides of the core material. The molded sandwich panel is ejected by opening the split mold.

[0006] (Third Perspective)

[0007] Conventionally, a technique has been proposed to manufacture a resin molded body by placing a sheet-shaped thermoplastic resin between split molds and performing mold fastening. For example, Patent Document 3 discloses a method for manufacturing a resin molded body in which a molten thermoplastic resin sheet is suspended to the side of a cavity of a mold, and the thermoplastic resin sheet is vacuum-suctioned from the side of the cavity to adsorb it and form a shape that is almost consistent with the cavity, after which mold fastening is performed. After the above mold fastening, the thermoplastic resin sheet is pressed toward the cavity by a pressurized fluid blown from the mold facing the cavity, thereby forming the thermoplastic resin sheet into a shape consistent with the cavity. Prior art literature

[0008] Japanese Published Patent No. 2014-79901, Japanese Registered Patent No. 6551966, Japanese Published Patent No. 2018-52093 The problem to be solved

[0009] (First Perspective)

[0010] In a device such as Patent Document 1, the injection of a resin sheet or the opening and closing of a mold is generally hydraulically driven, but since the operating speed of hydraulic driving is affected by factors such as oil temperature, the timing of the injection of the resin sheet or the opening and closing of the mold is prone to deviating from a predetermined state. If the timing of the injection of the resin sheet or the opening and closing of the mold deviates from a predetermined state, molding defects are likely to occur.

[0011] The present invention has been implemented in consideration of these circumstances and provides a molding system capable of reducing molding defects.

[0012] (Second Perspective)

[0013] When the support beam of the support arm presses the core material toward the mold, it may bend at the free end side, making it impossible to sufficiently press the core material. If the bond between the core material and the thermoplastic resin sheet is weak, it is assumed that the core material may detach from the thermoplastic resin sheet or become misaligned. Additionally, although there is a method of adjusting the position or angle of the support arm every time, it is assumed that the work becomes cumbersome or that reproducibility is reduced due to changes in settings.

[0014] The present invention aims to provide a support arm capable of stably supplying a member to be supported, a resin molding device, and a method for supporting a member to be supported.

[0015] (Third Perspective)

[0016] After the resin molded body is cooled inside the mold, the mold is opened to release it. However, when a thermoplastic resin sheet is adsorbed into one mold and molded by applying pressure from another mold, a temperature difference may occur between the two sides of the thermoplastic resin sheet, which may cause warping in the molded body.

[0017] The present invention aims to provide a mold that can be formed well and a method for manufacturing a molded body. means of solving the problem

[0018] (First Perspective)

[0019] According to the present invention, a molding system comprises a first and second parison forming device, first and second molds configured to be openable and closable, and a control unit. The first parison forming device comprises a first extruder, a first accumulator, and a first injection head. It is configured to form a first parison by injecting a first molten resin from a first injection head after a first molten resin extruded from the first extruder is accumulated in the first accumulator. The second parison forming device comprises a second extruder, a second accumulator, and a second injection head. It is configured to form a second parison by injecting a second molten resin from a second injection head after a second molten resin extruded from the second extruder is accumulated in the second accumulator. The first and second parisons are injected between the first and second molds. The control unit, based on historical data from a past cycle, [manipulates] the first and second parison forming device and the first and second molds in the next cycle. A forming system configured to determine the timing of the initiation of at least one of the operations is provided.

[0020] In the present invention, a control unit is configured to determine the timing of the start of operation of at least one of the first and second parison forming devices and the first and second molds in the next cycle based on historical data from a past cycle. Therefore, even if a difference occurs in the timing of the start of operation of at least one of these devices, the difference is corrected in the next cycle, so the timing difference is suppressed and molding defects are reduced.

[0021] Various embodiments of the present invention are illustrated below.

[0022] Preferably, in the molding system, the control unit is configured to determine the injection start timing of the first and second molten resins in the next cycle based on historical data from a past cycle.

[0023] Preferably, in the molding system, the first and second molds are configured to be movable to a mold opening position, a standby position, and a mold closing position, wherein the standby position is a position in which the distance between the first and second molds is smaller than the mold opening position and the distance between the first and second molds is larger than the mold closing position, and the control unit is configured to determine the timing for the first and second molds to begin moving from the mold opening position toward the standby position in the next cycle based on historical data from a past cycle.

[0024] Preferably, in the molding system, the first molten resin is injected by hydraulic drive, and

[0025] The above control unit is a forming system configured to determine the hydraulic conditions of the hydraulic drive in the next cycle based on historical data from a past cycle.

[0026] Preferably, in the molding system, the first parison is a first resin sheet, the first resin sheet is fed by a roller disposed between a first injection head and first and second molds, and the molding system is configured such that the control unit determines the rotational speed of the roller in the next cycle based on historical data from a past cycle.

[0027] Preferably, in the molding system, the control unit is configured to determine the timing of the start of rotation of the screw of the first extruder in the next cycle based on historical data from a past cycle.

[0028] (Second Perspective)

[0029] The support arm of the present invention is characterized by comprising a support beam, a first support member supporting a member to be supported at the leading end of the support beam, and a second support member installed to be movable relative to the support beam and supporting the member to be supported at the base end of the support beam.

[0030] The resin molding device of the present invention is characterized by comprising: a support beam; a first support member supporting a member to be supported at the leading end of the support beam; a support arm having a second support member installed to be movable relative to the support beam at the lower end of the support beam and supporting the member to be supported; a mold including a first mold and a second mold; and a resin supply device for supplying a molten resin sheet to the first mold.

[0031] The method for supporting a member to be supported according to the present invention is a method for supporting a member to be supported in a resin molding apparatus, wherein the resin molding apparatus comprises a support beam, a first support member supporting a member to be supported at the leading end of the support beam, a support arm having a second support member installed to be movable relative to the support beam at the lower end of the support beam and supporting a member to be supported, and a mold adsorbing a molten resin sheet, and is characterized by including a process of moving the support arm so as to bring the member to be supported, which is supported by the first support member and the second support member, into contact with the molten resin sheet of the mold.

[0032] According to the present invention, a supporting arm capable of stably supplying a member to be supported, a resin molding device, and a method for supporting a member to be supported can be provided.

[0033] (Third Perspective)

[0034] The mold of the present invention comprises a first mold and a second mold for forming a molded body by inserting a molten resin sheet, wherein the first mold has a first contact surface capable of contacting the molten resin sheet and a protruding surface protruding from the first contact surface, and the second mold has a second contact surface corresponding to the first contact surface at a position opposite to the protruding surface.

[0035] The method for manufacturing a molded body according to the present invention is a method for manufacturing a molded body using a resin supply device, a first mold, and a second mold, characterized in that the resin supply device comprises a process of supplying a molten resin sheet between the first mold and the second mold, and a process of bringing the first mold and the second mold relatively close and bringing the first mold and the second mold into contact with the molten resin sheet to form a mold.

[0036] According to the present invention, a mold that can be formed well and a method for manufacturing a molded body can be provided. Brief explanation of the drawing

[0037] FIG. 1 shows the configuration of a molding system (601) according to the first aspect of the present invention and shows the state immediately before performing step C4 of the flowchart in FIG. 2. FIG. 2 is a flowchart showing a method for manufacturing a molded body using a molding system (601). Figure 3 shows the configuration of the molding system (601) and the state immediately after performing step C5 of the flowchart in Figure 2. FIG. 4 shows the configuration of the molding system (601) and the state immediately after the attachment of the core material (603) is completed in step D5 of the flowchart of FIG. 2. FIG. 5 is a perspective view of a sandwich member according to an embodiment of the second aspect of the present invention. FIG. 6 is a schematic diagram of a resin molding apparatus viewed from the side according to an embodiment of the second aspect of the present invention. FIG. 7 is a frontal perspective view of a support arm according to an embodiment of the second aspect of the present invention. FIG. 8 is a perspective view of the rear side of a support arm according to an embodiment of the second aspect of the present invention. FIG. 9 is a plan view of a support arm according to an embodiment of the second aspect of the present invention. In FIG. 10, FIG. 10A to FIG. 10B are cross-sectional views taken from the planar side of a repulsive member according to an embodiment of the second aspect of the present invention. FIG. 11 is a drawing showing a method for manufacturing a molded body according to an embodiment of the second aspect of the present invention, FIG. 11A shows a state in which a mold is brought into contact with a molten resin sheet, and FIG. 11B shows a state in which a molten resin sheet is formed within a mold. FIG. 12 is a drawing showing a method for manufacturing a molded body according to an embodiment of the second aspect of the present invention, FIG. 12A shows a state in which a core material is placed between molten resin sheets, and FIG. 12B shows a state in which the first mold and the second mold are joined together. FIG. 13 shows a planar schematic diagram of the state of FIG. 12A of a method for manufacturing a molded body according to an embodiment of the second aspect of the present invention. FIG. 14 is a schematic diagram of a resin molding apparatus according to an embodiment of the third aspect of the present invention. FIG. 15 is a perspective view showing a part of a first mold according to an embodiment of the third aspect of the present invention. FIG. 16 is an enlarged perspective view seen from the rear side of the first mold shown in FIG. 15 according to an embodiment of the third aspect of the present invention. FIG. 17 is a combined cross-sectional view in which the cross-section of the second regulating part is combined in the IV-IV cross-section of the first mold of FIG. 15 according to an embodiment of the third aspect of the present invention. FIG. 18 is a drawing showing a method for manufacturing a molded body according to an embodiment of the third aspect of the present invention, FIG. 18A shows a state in which a mold is brought into contact with a molten resin sheet, and FIG. 18B shows a state in which a molten resin sheet is formed within a mold. FIG. 19 is a drawing showing a method for manufacturing a molded body according to an embodiment of the third aspect of the present invention and shows the state in which the first mold and the second mold are joined together. FIG. 20 is an enlarged view of the first mold and the second mold in a state of being joined according to an embodiment of the third aspect of the present invention, FIG. 20A shows the initial state in which the molten resin sheet and the protrusion are in contact, FIG. 20B shows the state in which the molten resin sheet is in contact with the contact surface, and FIG. 20C shows the state in which the slide part is pressed in. FIG. 21 is a drawing showing a molded body manufactured by a resin molding device of an embodiment of the third aspect of the present invention. Specific details for implementing the invention

[0038] Embodiments of the present invention are described below. Among the embodiments shown below, the various features exemplified can be combined with one another. Furthermore, an invention is established independently for each feature.

[0039] (First Perspective)

[0040] 1. Components of the forming system

[0041] As shown in FIG. 1, a molding system (601) of one embodiment of the present invention comprises first and second parison forming devices (610, 620), first and second mold units (630, 640) configured to be openable and closable, a robot hand (650), and a control device (660).

[0042] The first and second parison forming apparatus (610, 620) is an apparatus for forming the first and second parisons (611, 621). The parisons (611, 621) are composed of molten resin. In the present embodiment, the parisons (611, 621) are first and second resin sheets (611a, 621a), but may have other shapes such as a cylindrical shape.

[0043] The parison forming device (610, 620) comprises first and second hoppers (612, 622), first and second extruders (613, 623), first and second accumulators (614, 624), first and second injection hydraulic mechanisms (615, 625), first and second injection heads (616, 626), and first and second roller units (617, 627). First and second raw resins (618, 628) fed from the hoppers (612, 622) into the extruders (613, 623) are melted and mixed in the extruders (613, 623) to become first and second molten resins (618a, 628a), which are then extruded and accumulated in the accumulators (614, 624). The accumulator (614, 624) is equipped with a cylinder (614a, 624a) and a piston (614b, 624b) capable of sliding inside it. In this embodiment, the injection head (616, 626) is composed of a T-die.

[0044] Molten resin (618a, 628a) in the accumulator (614, 624) is injected from the injection head (616, 626) by driving (i.e., hydraulically driving) the piston (614b, 624b) by the hydraulic mechanism (615, 625) to form a parison (611, 621) consisting of a resin sheet (611a, 621a). The hydraulic mechanism (615, 625) includes a cylinder (615a, 625a) and a piston (615b, 625b) capable of sliding within it. The piston (615b, 625b) is connected to the piston (614b, 624b). The piston (615b, 625b) is made to be driven by controlling the hydraulic pressure within the cylinder (615a, 625a).

[0045] The roller unit (617, 627) is positioned between the injection head (616, 626) and the first and second molds (631, 641). Each roller unit (617, 627) is equipped with a pair of rollers (617a, 627a), and the resin sheet (611a, 621a) is fitted into the pair of rollers (617a, 627a). Therefore, by changing the rotational speed of the rollers (617a, 627a), the speed at which the resin sheet (611a, 621a) passes through the roller unit (617, 627) can be adjusted.

[0046] The mold unit (630, 640) comprises first and second molds (631, 641), first and second mold frames (632, 642), and first and second platens (633, 643).

[0047] The mold (631, 641) is provided with a cavity surface (631a, 641a) having a shape corresponding to the outer shape of the desired molded body, and a pinch-off portion (631b, 641b) surrounding it. A vacuum suction hole not shown is installed in the cavity surface (631a, 641a), and a resin sheet (611a, 621a) is sucked in to form a shape according to the cavity surface (631a, 641a).

[0048] The mold (632, 642) is arranged along the circumference of the mold (631, 641) and is configured to be movable in the opening and closing direction of the mold (631, 641) relative to the mold (631, 641). The mold (632, 642) facilitates the suction of the resin sheet (611a, 621a) by the mold (631, 641) by applying pressure to the mold (631, 641) by suctioning the resin sheet (611a, 621a) under reduced pressure.

[0049] The platen (633, 643) is fixed to a mold opening / closing device not shown, and the mold (631, 641) is configured to be fixed to the mold opening / closing device through the platen (633, 643). The mold opening / closing device is configured to allow the platen (633, 643) to move symmetrically with respect to the surface passing through the center of the platen (633, 643).

[0050] The mold (631, 641) is configured to be openable and closable by a hydraulic mechanism (602) moving a platen (633) in the opening and closing direction of the mold (631, 641). The hydraulic mechanism (602) is equipped with a cylinder (602a) and a piston (602b) that can be articulated inside it. The piston (602b) is connected to the platen (633). The piston (602b) is configured to be driven by controlling the hydraulic pressure inside the cylinder (602a).

[0051] The robot hand (650) has the function of applying pressure to the core material (603) on the resin sheet (611a). The robot hand (650) is equipped with a base (650a) and an adsorption pad (650b) fixed thereto. The adsorption pad (650b) is configured to hold the core material (603) by suctioning it under reduced pressure. The base (650a) is mounted on a robot not shown and is configured to be movable in three dimensions. The core material (603) is composed of foamed resin and is configured to melt the core material (603) with the heat of the resin sheet (611a, 621a) so that the core material (603) can be welded to the resin sheet (611a, 621a).

[0052] The control unit (660) is equipped with a memory unit (661) and a control unit (662). The memory unit (661) stores historical data from past cycles and a program executed by the control unit (662). The control unit (662) controls the operation of the molding system (601). The function executed by the control unit (662) is realized by the arithmetic unit executing the program stored in the memory unit (661).

[0053] The control unit (662) is configured to determine the timing of the start of operation of at least one of the parison forming device (610, 620) and the mold (631, 641) in the next cycle based on historical data from a past cycle. As a result, even if a misalignment in the timing of the start of operation occurred in a past cycle, the misalignment is corrected in the next cycle, so the misalignment in timing is suppressed and molding defects are reduced. The historical data of the past cycle may be historical data from a past cycle (e.g., the previous cycle) or data obtained from historical data of multiple past cycles (e.g., an average value).

[0054] 2. Method for manufacturing a molded body

[0055] Referring to FIG. 2, a method for manufacturing a molded body using a molding system (601) is described. In the following description, it is assumed that the molded body is configured such that a core material (603) is sandwiched with resin sheets (611a, 621a) and has burrs around the sandwich panel (molded product), but it is also possible to manufacture a molded body with other configurations. Furthermore, in this manufacturing method, it is assumed that molded bodies are manufactured in succession by repeating a cycle for manufacturing molded bodies. FIG. 2 shows a process for one cycle, but it is assumed that steps A1, B1, C1, and D1 are executed after steps A7, B7, C8, and D6.

[0056] For convenience, the following state is considered the initial state. In the parison forming device (610, 620), the screw of the extruder (613, 623) rotates to fill the molten resin (618a, 628a) into the accumulator (614, 624). The mold (631, 641) is in the mold opening state. The robot hand (650) is outside the mold (631, 641) and holds the core material (603).

[0057] As time elapses from the initial state, the opening of the mold (631, 641) is completed in Step C1, and at the same time, the filling of resin into the accumulator (614, 624) is completed in Steps A1 and B1. After the opening of the mold is completed, the mold (631, 641) waits in the opening position.

[0058] When the opening of the molds (631, 641) in Step C1 is completed, in Step D1, the robot hand (650) begins to move so that the core material (603) is placed inside the molds (631, 641) (i.e., within the space between the molds (631, 641)), and completes the movement in Step D2. After the movement is completed, the robot hand (650) waits in that state.

[0059] When the resin filling in steps A1 and B1 is completed, in steps A2 and B2, the control unit (662) permits the injection of molten resin (618a, 628a) from the parison forming device (610, 620). At this time, injection start delay times T1 and T2 are set in steps A3 and B3. In steps A4 and B4, the injection of molten resin (618a, 628a) is started after the delay times T1 and T2 have elapsed. The molten resin (618a, 628a) is injected to form a resin sheet (611a, 621a). The resin sheet (611a, 621a) is held by a roller (617a, 627a) and sent downward according to the rotation of the roller (617a, 627a). Therefore, the downward movement speed of the resin sheet (611a, 621a) can be adjusted by changing the rotation speed of the rollers (617a, 627a).

[0060] Since it is assumed that the core material (603) is initially attached to the resin sheet (611a) and then attached to the resin sheet (621a), it is desirable to make the timing of the injection start of the molten resin (628a) later than the timing of the injection start of the molten resin (618a) so that the temperature of the resin sheet (621a) does not become too low at the time of attaching the core material (603) to the resin sheet (621a). Therefore, it is desirable that T2 > T1. In one example, T1 is 0.

[0061] When the injection of molten resin (618a) begins in Step A4, in Step C2, the control unit (662) allows the movement of the mold (631, 641) from the mold opening position shown in FIG. 1 to the standby position shown in FIG. 3. At this time, a standby position movement delay time T3 is set in Step C3. In Step C4, after the delay time T3 has elapsed, the movement of the mold (631, 641) to the standby position begins, and in Step C5, the movement of the mold (631, 641) to the standby position is completed.

[0062] The standby position is a position where the distance from the mold (631, 641) is shorter than the open position and the distance from the mold (631, 641) is longer than the closed position. In the open position, the mold (632, 642) does not come into contact with the resin sheet (611a, 621a), and in this state, the depressurization suction of the resin sheet (611a, 621a) by the mold (631, 641) cannot be performed. On the other hand, in the standby position, the mold (632, 642) can come into contact with the resin sheet (611a, 621a), so the depressurization suction of the resin sheet (611a, 621a) by the mold (631, 641) becomes possible. Meanwhile, instead of the mold (632, 642), the resin sheet (611a, 621a) may be held by another means (e.g., an expander) and the resin sheet (611a, 621a) may be brought into contact with the mold (631, 641).

[0063] If the mold (631, 641) is in a standby position while the bottom of the resin sheet (611a, 621a) is at a position higher than the top of the mold (631, 641), there is a risk that when the resin sheet (611a, 621a) shakes, the resin sheet (611a, 621a) will interfere with the mold (631, 641) (be placed on top of the mold (631, 641)). Therefore, in this embodiment, to prevent such problems from occurring, the movement of the mold (631, 641) to the standby position is completed when the bottom of the resin sheet (611a, 621a) reaches a position lower than the top of the mold (631, 641). In addition, to prevent the completion of the movement of the mold (631, 641) to the waiting position from happening too quickly, a delay time T3 is set, and the movement of the mold (631, 641) is started after the delay time T3 has elapsed.

[0064] After Step C5, in Step A5, the completion of injection of the molten resin (618a) is detected. The detection of injection completion may be performed by detecting that the bottom of the resin sheet (611a) has reached a reference position, by detecting that the remaining amount of molten resin (618a) in the accumulator (614) has reached a reference value, or by any other method. After Step A5, the resin sheet (611a) is vacuumed by the mold (632), and in that state, the resin sheet (611a) is brought into contact with the pinch-off portion (631b) by retracting the mold (632). In that state, the mold (631) vacuums the resin sheet (611a), thereby forming the resin sheet (611a) into a shape according to the cavity surface (631a).

[0065] Next, in steps D3 and D4, as shown in FIG. 4, a robot hand (650) holding the core material (603) between the molds (631, 641) moves toward the mold (631) to weld and attach the core material (603) to the resin sheet (611a). After that, the adsorption of the core material (603) by the adsorption pad (650b) is released, and the robot hand (650) begins to move away from the space between the molds (631, 641), and in step D5, the detachment of the robot hand (650) from the mold is completed. The core material (603) to be used in the next cycle is prepared in advance on the outside of the mold, and in step D6, the robot hand (650) adsorbs and holds the core material (603) to be used in the next cycle.

[0066] After Step A5, Step B5 detects the completion of the injection of the molten resin (628a). The method of detecting the completion of the injection is the same as in Step A5. Also, similar to Step A5, the mold (641) forms the resin sheet (621a) into a shape according to the cavity surface (641a) by suctioning the resin sheet (621a) under reduced pressure.

[0067] After steps A5, B5, and D5, movement to the mold closing position of the mold (631, 641) is initiated in step C6, and the movement is completed in step C7. At this time, the core material (603) is welded to the resin sheet (621a), and at the same time, the resin sheets (611a, 621a) are welded to each other at the periphery, thereby forming a molded body with a burr configuration around the sandwich panel (molded product).

[0068] Next, in step C8, the movement of the mold (631, 641) to the mold opening position is initiated, and the movement is completed in step C1. After the mold is opened, the molded body is ejected from the mold (631, 641). To prevent the molded body from falling unintentionally, the upper portion of the mold (631, 641) may be clamped with a clamping unit not shown before the mold is opened.

[0069] Subsequently, in steps A6 and B6, after the extruder screw rotation start delay times T4 and T5 set by the control unit (662) have elapsed, in steps A7 and B7, the screw of the extruder (613, 623) is rotated and the filling of molten resin (618a, 628a) into the accumulator (614, 624) is started. When the molding system (601) is operated alone, the delay times T4 and T5 are unnecessary, but in this embodiment, the molding system (601) is assumed to be operated in conjunction with a burr removal system (not shown) for removing burrs from the molded body, and in order to link the two, it is necessary to match the cycle time of the burr removal system with the cycle time of the molding system (601). Since the cycle time of the molding system (601) would be shorter than the cycle time of the burr removal system without the delay times T4 and T5, the cycle times of the two are matched by providing the delay times T4 and T5. In addition, providing delay times T4 and T5 before starting the rotation of the screw of the extruder (613, 623) is undesirable because if the delay time is provided after the completion of filling the molten resin (618a, 628a) into the accumulator (614, 624), the state (e.g., resin pressure) of the molten resin (618a, 628a) in the accumulator (614, 624) changes between the completion of filling and the start of injection.

[0070] 3. Correction Method

[0071] Ideally, the timing of each step described in "2. Method for Manufacturing a Molded Body" above should not vary from cycle to cycle, but in reality, there may be discrepancies in timing due to causes such as fluctuations in the hydraulic fluid temperature, fluctuations in the surrounding environment (temperature, humidity, etc.), and fluctuations in the material. Since discrepancies in timing are a cause of molding defects, the control unit (662) performs various corrections to reduce the timing discrepancies.

[0072] 3-1. Correction of Injection Start Timing

[0073] The time difference T6 between the completion of injection in Step A5 and the completion of injection in Step B5 is set so that the temperature of the resin sheet (611a, 621a) becomes optimal at the time when the core material (603) is welded to the resin sheet (611a, 621a), and if the time difference T6 becomes shorter or longer than the standard, molding defects are likely to occur.

[0074] Since the mold (631, 641) cannot be closed until the robot hand (650) exits the mold, if the time difference T6 is too short, the time between step B5 and step C6 becomes longer than expected, and as a result, the temperature of the resin sheet (621a) drops too low at the time when the core material (603) is welded to the resin sheet (621a), making it prone to welding defects. On the other hand, if the time difference T6 is too long, the time between step A5 and step C6 becomes longer than expected, and as a result, the temperature of the resin sheet (611a) drops too low at the time when the resin sheets (611a, 621a) are welded to each other, making it prone to welding defects between the resin sheets (611a, 621a).

[0075] Therefore, in order to reduce the deviation from the target value of the time difference T6, the control unit (662) is configured to determine the injection start timing of the first and second molten resins in the next cycle based on historical data from a past cycle. The historical data is, for example, the time difference T6 between the time of completion of the injection of the first molten resin (step A5) and the time of completion of the injection of the second molten resin (step B5). The adjustment of the injection start timing of the first and second molten resins can be performed, for example, by changing at least one of the delay times T1 and T2. For example, if the time difference T6 of the previous cycle is p seconds longer or shorter than the target value, the delay time T1 is not changed, and a correction is performed to make the delay time T2 shorter or longer by p seconds. As a result, it is expected that the time difference T6 in the next cycle will approach the target value.

[0076] 3-2. Correction of Timing for Moving the Mold to the Standby Position

[0077] If the movement of the mold (631, 641) from the opening position in Step C4~C5 to the waiting position is too fast, the problem of the resin sheet (611a, 621a) interfering with the mold (631, 641) is likely to occur, and if the movement is too slow, the problem of the mold (631) not reaching the waiting position at the time of injection completion in Step A5 and the molding defect of the resin sheet (611a) in the mold (631) is likely to occur.

[0078] Therefore, to suppress the occurrence of such problems, the control unit (662) is configured to determine the timing at which the mold (631, 641) begins to move from the mold opening position toward the waiting position in the next cycle based on historical data from a past cycle. The historical data is, for example, the time difference T7 between the time point of completion of the movement of the mold (631, 641) toward the waiting position (step C5) and the time point of completion of the injection of the first molten resin (step A5). The adjustment of the timing of the start of movement of the mold (631, 641) can be performed, for example, by changing the delay time T3. For example, if the time difference T7 of the previous cycle is q seconds longer or shorter than the target value, a correction is performed to make the delay time T3 longer or shorter by q seconds. As a result, it is expected that the time difference T7 in the next cycle will approach the target value.

[0079] 3-3. Correction of Extruder Screw Rotation Start Timing

[0080] As described above in relation to steps A6 and B6, in this embodiment, the molding system (601) is assumed to operate in conjunction with a burr removal system (not shown) for removing burrs from a molded body, and delay times T4 and T5 are provided to match the cycle times of both.

[0081] The cycle time of the molding system (601) depends on the filling time T8 from the start of screw rotation in steps A7 and B7 to the completion of resin filling in steps A1 and B1, but this filling time T8 is prone to becoming shorter, especially immediately after the start of the molding system (601), because the state of the resin in the extruder (613, 623) is not stable. If the filling time T8 becomes shorter than the target value, there is a problem that the cycle time of the molding system (601) and the burr removal system will be out of sync.

[0082] Therefore, to suppress the occurrence of such problems, the control unit (662) is configured to determine the timing of the start of rotation of the screw of the extruder (613, 623) in the next cycle based on historical data from past cycles. The historical data is, for example, the cycle time. The cycle time is, for example, the time from the start of injection of step A4 in the cycle before the previous one to the start of injection of step A4 in the cycle before that. The timing of the start of rotation of the screw of the extruder (613, 623) can be adjusted, for example, by changing the delay times T4 and T5. For example, if the cycle time in the previous cycle is r seconds longer or shorter than the target value, a correction is made by making the delay times T4 and T5 r seconds shorter or longer. As a result, it is expected that the cycle time in the next cycle will approach the target value.

[0083] 3-4. Correction of Injection Time

[0084] When injecting molten resin (618a, 628a) by hydraulic drive, the injection time (time from the start of injection to completion) may vary due to causes such as fluctuations in oil temperature, so it is desirable to stabilize the injection time.

[0085] Therefore, the control unit (662) is configured to determine the hydraulic pressure conditions for hydraulic drive in the next cycle based on historical data from past cycles. The historical data is, for example, injection time. In one example, if a state in which the deviation of injection time from the target value is greater than the threshold occurs for multiple cycles (e.g., 2 cycles) in succession, the control unit (662) performs a correction to increase or decrease the hydraulic pressure in the next cycle. In one example, if the injection time is longer than the target value, the hydraulic pressure in the next cycle is increased, and if the injection time is shorter than the target value, the hydraulic pressure in the next cycle is decreased. As a result, it is expected that the injection time in the next cycle will approach the target value.

[0086] 3-5. Correction of Sheet Length

[0087] It is preferable that the length of the resin sheet (611a, 621a) at the time of completion of injection of the molten resin (618a, 628a) be constant.

[0088] Accordingly, the control unit (662) is configured to determine the rotational speed of the rollers (617a, 627a) in the next cycle based on historical data from a past cycle. The historical data is, in one example, the length of the resin sheet (611a, 621a). In one example, if the deviation of the length of the resin sheet (611a, 621a) from the target value in the previous cycle is greater than or equal to a threshold, the control unit (662) performs a correction to increase or decrease the rotational speed of the rollers (617a, 627a) in the next cycle. In one example, if the length of the resin sheet (611a, 621a) is longer than the target value, the rotational speed of the rollers (617a, 627a) in the next cycle is reduced, and if the length of the resin sheet (611a, 621a) is shorter than the target value, the rotational speed of the rollers (617a, 627a) in the next cycle is increased. As a result, it is expected that the length of the resin sheet (611a, 621a) in the next cycle will approach the target value. It is preferable to perform this correction while the injection time described above is stable.

[0089] (Second Perspective)

[0090] Next, embodiments of the present invention will be described based on the drawings. The sandwich member (201) shown in FIG. 5 is formed in the shape of a nearly rectangular flat plate. The sandwich member (201) is a molded body formed by having a core material (202) (support member) inside and covering the outer surface of the core material (202) with a skin material (203). The sandwich member (201) is used as a structural member, for example, a bed panel or a board for a car trunk.

[0091] The core material (202) shown in FIG. 5 can be formed into a rectangular flat plate shape and can be formed by a resin to which a foaming agent has been added. As for the material forming the core material (202), examples include polyolefins which are homopolymers or copolymers of olefins such as ethylene, propylene, butene, isoprene pentene, methyl pentene, etc., polyolefins, polyamides, polystyrene, polyvinyl chloride, polyacrylonitrile, ethylene-ethyl acrylate copolymers, acrylic derivatives such as polycarbonates, vinyl acetate copolymers such as ethylene-vinyl acetate copolymers, ionomers, terpolymers such as ethylene-propylene-dienes, acrylonitrile-styrene copolymers, thermoplastic resins such as ABS resin, polyphenylene oxide, polyacetal, thermoplastic polyimide, etc., and thermosetting resins such as phenolic resin, melamine resin, epoxy resin, polyurethane, thermosetting polyimide, etc.

[0092] In addition, any of physical blowing agents, chemical blowing agents, and mixtures thereof may be used as the blowing agent. As the physical blowing agent, inorganic physical blowing agents such as air, carbon dioxide, nitrogen gas, and water, organic physical blowing agents such as butane, pentane, hexane, dichloromethane, and dichloroethane, and their supercritical fluids may be used.

[0093] The skin material (203) is formed from polyolefin resins such as polypropylene, engineering plastics, etc.

[0094] FIG. 6 is a drawing showing the configuration of a resin molding device (60). The sandwich member (201) of the present embodiment is formed by the resin molding device (60) shown in FIG. 6. The resin molding device (60) forms a first molten resin sheet (211) and a second molten resin sheet (212) respectively by two resin supply devices (61) (a first resin supply device (61A) and a second resin supply device (61B)) arranged opposite each other. A mold (80) (a first mold (81) and a second mold (82)) is arranged below the resin supply device (61).

[0095] The resin supply device (61) is equipped with a hopper (65) serving as a supply port for resin material, and an extruder (66) connected to a hydraulic motor (68) and configured to melt and mix the material supplied from the hopper (65) by means of a screw positioned inside. The extruder (66) is connected to an accumulator (70) equipped with a plunger (72). The melted and mixed resin material is sent to the accumulator (70) by the extruder (66). The resin material is subjected to high pressure in the accumulator (70) and sent to the T-die (71). Then, at an appropriate timing, the die slit of the T-die (71) is opened, and a first molten resin sheet (211) and a second molten resin sheet (212) sent by a roller (79) are formed. The first molten resin sheet (211) and the second molten resin sheet (212) are supplied to the first mold (81) and the second mold (82), respectively.

[0096] The first mold (81) and the second mold (82) are arranged facing each other. Molds (83, 84) are installed on the outer periphery of the first mold (81) and the second mold (82). A vacuum pump (not shown) is installed in the first mold (81) to reduce pressure in the space enclosed within the cavity (81a) of the first mold (81). Likewise, a vacuum pump (not shown) is installed in the second mold (82) to reduce pressure in the space enclosed within the cavity (82a) of the second mold (82).

[0097] FIGS. 7 and FIGS. 8 are perspective views of the front and rear sides of the support arm (4), respectively. The support arm (4) comprises a cantilever-shaped support beam (41), a substrate member (42) connected to the front side of the free end of the support beam (41), and a plurality of support members (44) connected to the front side of the substrate member (42) through a resilient member (5). In this embodiment, a core material (202) is supported by the plurality of support members (44), and the core material (202) is supplied to the mold (80).

[0098] The support beam (41) is cantilevered and supported by a driving unit, such as a robot, which is not shown, on the base side. Two substrate members (42) are installed so as to extend upward and downward, respectively, from the support beam (41). The substrate member (42A) on the upper side and the substrate member (42B) on the lower side are connected to a square frame-shaped frame member (43) on the front side (see FIG. 9). The frame member (43) can improve the overall rigidity of the substrate members (42A, 42B).

[0099] The support members (44) of the present embodiment are installed in a total of 4 rows and 2 columns in the up, down, left, and right directions, and are provided with support members (44A, 44B) (first support members) and support members (44C, 44D) (second support members) installed in parallel in the extension direction of the support beam (41) (i.e., the base side and free end side direction). The support members (44C, 44D) are installed on the base side of the support beam (41) rather than the support members (44A, 44B). Additionally, the support members (44A, 44C) are installed on the upper side of the support members (44B, 44D).

[0100] Each support member (44) is formed in the shape of a rectangular plate and is connected to and supported by a resilient member (5) at four corners. Each support member (44) is pressed by the resilient member (5) in a direction away from the support beam (41), and when pressed from the support surface (443) side shown in FIG. 7, each support member (44) can be independently moved toward the support beam (41) side by resisting the resilient force of the resilient member (5). Additionally, an opening (441) and an adsorption part (442) are formed in the support member (44). The adsorption part (442) has an adsorption surface including a suction port on the front side and can support the core material (202) placed on the support surface (443) side of the support member (44) by negative pressure. The adsorption part (442) is connected to a negative pressure source, such as a vacuum pump, through an air hose not shown. A plurality of adsorption parts (442) may be installed depending on the shape or weight of the supporting core material (202). In addition, in this embodiment, the plurality of adsorption parts (442) are formed such that the adsorption surface (first adsorption surface) of the support body (44A, 44B) (first support body) and the adsorption surface (second adsorption surface) of the support body (44C, 44D) (second support body) are on the same plane.

[0101] FIG. 10A is a cross-sectional view of a resilient member (5) viewed in the planar direction of FIG. 9. The resilient member (5) comprises a shaft holder (51) fixed to a support (44), an axial member (52) fixed to the shaft holder (51), a guide bush (53) that inserts the axial member (52) so as to allow sliding movement, and a coil spring (54) that resiliently pushes the support (44) away from the substrate member (42). The shaft holder (51) comprises a tubular portion (511) that accommodates one end of the axial member (52) and a flange portion (512) that bulges outward in the radial direction at the other end of the tubular portion (511). The shaft holder (51) is fixed to the support (44) by screwing through an opening installed in the flange portion (512) using a screw member. Additionally, the shaft holder (51) has an opening (511a) that penetrates in the axial direction through a tubular portion (511). The shaft member (52) is fixed to the shaft holder (51) by a screw member (55) inserted through the opening (511a) into a female screw portion (521) installed on one end.

[0102] The guide bush (53) is formed in a nearly cylindrical shape and is fixed to the substrate member (42) by screw fastening through a screw member inserted through the opening of the flange portion (531) installed on one side. The cylindrical portion (532) of the guide bush (53) is inserted into the opening (421) formed in the substrate member (42) and installed to protrude on the opposite side from the support (44).

[0103] Inside the guide bush (53), a bearing portion (533) corresponding to the outer circumference of the shaft member (52) is formed. The shaft member (52) is also provided with a female screw portion (522) on the other end side opposite to where the female screw portion (521) is installed. A screw member (58) with washer (56, 57) jointly fastened is inserted into this female screw portion (522). The washer (56, 57) is formed with a larger diameter than the bearing portion (533). Accordingly, the washer (56, 57) functions as a restraining portion to prevent the shaft member (52) from falling off the guide bush (53). Meanwhile, the washer (56) installed on the shaft member (52) side is formed with a larger diameter than the washer (57). In addition, since a direct-acting ball bearing (533a) is installed on the inner surface of the bearing portion (533), the shaft member (52) can reduce wear caused by sliding against the bearing portion (533).

[0104] A washer (59) is installed on the outer circumference of the shaft member (52) and on the side of the support body (44) of the flange portion (531). Additionally, the outer circumference diameter of the shaft member (52) is formed to be smaller than the outer circumference diameter of the tubular portion (511). One end of the coil spring (54) is in contact with the end (511b) of the tubular portion (511) of the shaft holder (51), and the other end is in contact with the washer (59). As shown in FIG. 10, the coil spring (54) is received in a compressed state while the movement toward the support surface (443) of the support body (44) is restricted by the washer (56, 57).

[0105] FIG. 10B shows a shape in which the support member (44) is pressed toward the substrate member (42) and the shaft member (52) slides within the bearing portion (533). The support member (44) can move relatively to the substrate member (42) together with the shaft member (52) by resisting the elastic force of the coil spring (54). When the pressure applied to the support member (44) toward the substrate member (42) is released, the support member (44) moves in a direction away from the substrate member (42) together with the shaft member (52), and the movement of the support member (44) is restricted when the washer (56) comes into contact with the end (532a) of the tubular portion (532). The washer (56) of this embodiment is formed of urethane and can function as a cushioning material.

[0106] Each elastic member (5) shown in FIGS. 7 and 8 can be set to have different elasticity depending on the plurality of support members (44A to 44D). For example, the elastic force of the elastic member (5) of the support member (44A, 44B) (first support member) installed on the front end side (free end side) of the support beam (41) is set to be stronger than the elastic force of the elastic member (5) of the support member (44C, 44D) (second support member) installed on the base side of the support beam (41). Meanwhile, the elastic force of the elastic member (5) may also be set to gradually increase from the base side to the front end side of the support beam (41) within each support member (44A to 44D). Additionally, the elastic force of the elastic member (5) may be set to be almost the same force for all of them, or varying strength may be provided for some parts.

[0107] Next, a method for manufacturing a sandwich member (201) is described. First, in the material supply process, the resin supply device (61) of FIG. 5 places the first molten resin sheet (211) and the second molten resin sheet (212) between the first mold (81) and the second mold (82).

[0108] In the molding process, the mold (83) is moved toward the first molten resin sheet (211) to come into contact with the sheet surface of the first molten resin sheet (211) (see FIG. 11A). Then, while bringing the mold (83) and the first mold (81) relatively close, the space formed by the first molten resin sheet (211), the cavity (81a), and the mold (83) is depressurized, and the first molten resin sheet (211) is molded along the cavity (81a) (see FIG. 11B).

[0109] Likewise, the second mold (82) facing the first mold (81) also moves the mold (84) toward the second molten resin sheet (212) and brings it into contact with the sheet surface of the second molten resin sheet (212) (see FIG. 11A). Then, while bringing the mold (84) and the second mold (82) closer together, the space formed by the second molten resin sheet (212), the cavity (82a), and the mold (83) is depressurized, and the second molten resin sheet (212) is molded along the cavity (82a) (see FIG. 11B).

[0110] In the process of moving the core material, between the material supply process and the molding process, the core material (202) supported by the support arm (4) is placed between the first mold (81) and the second mold (82) that mold the first molten resin sheet (211) and the second molten resin sheet (212) (see FIG. 12A). The core material (202) is supported by negative pressure received from each support surface (443) of the support body (44). Then, the support arm (4) is moved into the cavity (81a) of the first mold (81), which is a pair of molds, and the core material (202) is inserted (see the dashed line with two dots in FIG. 12A).

[0111] As a specific example of operation, the support arm (4) moves from the base side of the support beam (41) to the tip side (from the top to the bottom in FIG. 13) and moves between the first mold (81) and the second mold (82), and then moves in a direction nearly perpendicular to the sheet surface of the first molten resin sheet (211) formed according to the cavity (81a). At this time, even if the opposing surface (221) of the core material (202) supported by the support arm (4) with respect to the first molten resin sheet (211) or the cavity (81a) is tilted, the core material (202), which is the supported member, is corrected within the range of motion of the support body (44) by the elastic member (5) so that the opposing surface (221) of the first molten resin sheet (211) and the core material (202) can be reliably brought into contact.

[0112] The opposing surface (221) of the core material (202) in contact with the first molten resin sheet is melted at the high temperature of the first molten resin sheet (211), and the core material (202) and the first molten resin sheet (211) are welded together and connected. In this embodiment, the elastic force of the support body (44A, 44B) (first support body) installed on the leading end (free end) side of the support beam (41) against the support beam (41) and the substrate member (42) is set to be stronger than the elastic force of the support body (44C, 44D) (second support body) installed on the lower end side of the support beam (41) against the support beam (41) and the substrate member (42). Therefore, even if the support beam (41) is bent, the pressure applied to the core material (202) at the leading end of the support beam (41) is prevented from becoming relatively weak, and the welding defect of the core material (202) can be reduced.

[0113] After the core material (202) is welded to the first molten resin sheet (211), the negative pressure of each support member (44) is reduced, and the support arm (4) releases support of the core material (202). Then, the support arm (4), having finished moving the core material (202), moves back from between the first mold (81) and the second mold (82).

[0114] In the mold fastening process, the first molten resin sheet (211) is formed within the cavity (81a) of the first mold (81), and the first mold (81) with the core material (202) inserted and the second mold (82) are brought relatively close together, and the mold is fastened until the annular pinch-off portions (81b, 82b) come into contact with each other (see FIG. 12B). The first molten resin sheet (211) and the second molten resin sheet (212) are welded together along the pinch-off portions (81b, 82b) on the outer periphery by inserting the core material (202) to form a skin material (203). The portion where the core material (202) and the second molten resin sheet (212) come into contact is welded by the melting of the core material (202). Accordingly, a sandwich member (201) is formed in which the core material (202) is covered by the first molten resin sheet (211) and the second molten resin sheet (212).

[0115] Then, in the extraction process, the first mold (81) and the second mold (82) are opened to extract the sandwich member (201) formed within the first mold (81) and the second mold (82).

[0116] Meanwhile, in this embodiment, although a configuration has been described in which the support body (44) is supported by a resilient member (5) so as to be resilient to the support beam (41), other moving members may be provided instead of the resilient member (5) to support the support body (44) so ​​as to be movable by sliding, etc. The moving member can move the support body (44) relatively in a direction closer to the substrate member (42) when the support body (44) is pressed toward the substrate member (42), and move the support body (44) in a direction further away from the substrate member (42) when the pressure applied to the support body (44) toward the substrate member (42) is released or reduced. The moving member is not limited to a configuration that applies elastic pressure to the support body (44) in a direction that separates it from the support beam (41), but can be configured to actively or passively move some or all of the support bodies (44A~44D) to the support beam (41) side, where the pressure is higher than a predetermined amount. The amount of movement of each support body (44A~44D) is set according to the balance of the pressure, and the posture of the core material (202) can be corrected within the range of operation of the support bodies (44A~44D) by the moving member. Even in this case, the pressure (drag force) of the support body (44) on the leading end side of the support beam (41) toward the core material (202) can be set stronger than the pressure (drag force) of the support body (44) on the lower end side of the support beam (41) toward the core material (202).

[0117] Additionally, the support members (44A, 44B) (first support members) installed on the leading end (free end) of the support beam (41) may be fixed to the support beam (41) so as not to move, and the support members (44C, 44D) (second support members) installed on the lower end of the support beam (41) may be configured to be movable relative to the support beam (41).

[0118] In the above embodiment, a support arm (4) and a method of supporting a supported body have been described, comprising a support body (44A, 44B) (first support body) that supports a supported body at the leading end of the support beam (41), and a support body (44C, 44D) (second support body) that is installed to be movable relative to the support beam (41) at the lower end of the support beam (41) and supports a supported body. Accordingly, for parts of the supported body where the drag force received from the molten resin sheet is strong, the corresponding support body (44) moves flexibly in a direction away from the molten resin sheet, while for parts of the supported body where the drag force is relatively weak, the corresponding support body (44) does not move or the amount of movement is small, so the surface pressure between the molten resin sheet and the supported body is corrected to approach uniformly. Accordingly, the weldability between the supported body and the molten resin sheet is improved, and the supported member can be supplied stably.

[0119] Although embodiments of the present invention have been described above, the present invention is not limited to each embodiment and can be implemented with various modifications. For example, in this embodiment, the support members (44) are arranged in 2 rows and 2 columns in the direction of the extension of the support beam (41) and in a direction perpendicular to the extension direction, but multiple members may be arranged only in the direction of the extension of the support beam (41). Alternatively, the support members (44) may be arranged in 3 or more places in the direction of the extension of the support beam (41) or in 3 or more places in a direction perpendicular to the extension direction.

[0120] (Third Perspective)

[0121] Next, embodiments of the present invention will be described based on the drawings. FIG. 14 is a drawing showing a resin molding device (60) of the present embodiment. The resin molding device (60) forms a sheet-shaped resin material, a molten resin sheet (3), by means of a resin supply device (61). The molten resin sheet (3) can be formed from a polyolefin-based resin such as polypropylene, engineering plastic, etc. A mold (10) (first mold (1), second mold (2)) is disposed below the resin supply device (61).

[0122] The resin supply device (61) is equipped with a hopper (65) serving as a supply port for resin material, and an extruder (66) connected to a hydraulic motor (68) and configured to melt and mix the material supplied from the hopper (65) by means of a screw positioned inside. The extruder (66) is connected to an accumulator (70) equipped with a plunger (72). The melted and mixed resin material is sent to the accumulator (70) by the extruder (66). The resin material is subjected to high pressure in the accumulator (70) and sent to a T-die (71). Then, at an appropriate timing, the die slit of the T-die (71) opens, and a molten resin sheet (3) sent by a roller (79) is formed.

[0123] The first mold (1) and the second mold (2) are arranged facing each other. In this embodiment, the case where the first mold (1) and the second mold (2) are convex and concave, respectively, is exemplified. A core (1a) including a slide part (12) and a fixing part (13), which will be described later, is formed in the first mold (1). A cavity (2a) corresponding to the core (1a) is formed in the second mold (2), and a vacuum pump (not shown) is installed to reduce pressure by sucking air into the space enclosed within the cavity (2a) through an intake hole (2a1). Additionally, a mold (321) is installed on the outer circumference of the second mold (2).

[0124] FIG. 15 is a perspective view showing a part of the first mold (1). FIG. 16 is an enlarged perspective view of the first mold (1) of FIG. 15 seen from the rear side. FIG. 17 is a combined cross-sectional view of the first regulating part (16) in the IV-IV cross-section of the first mold (1) of FIG. 15. The first mold (1) is provided with a plurality of slide parts (12) that are movable relative to a flat base (11) and a fixed part (13) arranged to surround the outer circumference of the plurality of slide parts (12). The base (11) is fixed to the movable mold (14) of FIG. 14. In addition, the fixed part (13) of the present embodiment is configured as part of the movable mold (14) as shown in FIG. 14 (the dashed line in FIG. 17 is a virtual line of the boundary between the fixed part (13) and the movable mold (14), but it may be configured separately from the movable mold (14).

[0125] The slide portion (12) is formed in the shape of a rectangular flat plate and is arranged in multiple units in a matrix shape of 2 rows and 3 columns. The slide portion (12) has a nearly flat contact surface (121) (first contact surface) and a protrusion (122) formed on the contact surface (121). On the protrusion (122), a flat protrusion surface (123) is formed with a predetermined width and is nearly parallel to the contact surface (121). As shown in the enlarged view of section A of FIG. 15, the protrusion (122) includes a first protrusion (122a) that extends in a first direction in which three slide portions (12) are connected and installed, and a second protrusion (122b) that extends in a second direction in which two slide portions (12) are connected and installed. The first protrusion (122a) and the second protrusion (122b) are arranged in a linear fashion at nearly equal intervals and formed to be orthogonal (intersecting) each other. In this embodiment, the protrusions (122) are formed in a nearly grid pattern over the entire contact surface (121).

[0126] The width of the protruding surface (123) is formed to be smaller than the width of the contact surface (121). For example, the width of the plurality of protruding surfaces (123) shown in FIG. 15 can be 15 mm, and the pitch of the first direction and the second direction of the protruding surface (123) can be 80 mm or 40 mm (i.e., the width of each contact surface (121) is 65 mm or 25 mm).

[0127] The height of the protruding surface (123) (distance from the contact surface (121) to the protruding surface (123)) is smaller than the thickness of the molten resin sheet (3), and for example, the molten resin sheet (3) can be made about 2 to 3 mm and the height of the protruding surface (123) can be set to 0.5 mm. The height of the protruding surface (123) from the contact surface (121) is a height at which the molten resin sheet (3) does not come into contact with the contact surface (121) at the first timing when the first mold (1) comes into contact with the molten resin sheet (3) in the mold fastening process described later, depending on characteristics such as the fluidity (MFR, molten mass flow rate) of the molten resin sheet (3), and is set to a height at which the molten resin sheet (3) comes into contact with the contact surface (121) at the second timing after the first timing by the mold fastening force of the first mold (1) and the second mold (2). Therefore, cooling of the portion corresponding to the protruding surface (123) on the molten resin sheet (3) can be initiated quickly, and the cooling time of the entire molten resin sheet (3) can be shortened by subsequent contact of the contact surface (121).

[0128] As shown in the enlarged view of section B of FIG. 17, the side surface (125) surrounding each slide part (12) includes a parallel surface (125a) parallel to the direction of movement of the slide part (12) and an inclined surface (125b) connected in series with the parallel surface (125a). The parallel surface (125a) is installed on the contact surface (121) side, and the inclined surface (125b) is installed on the back surface (126) side (base part (11) side). The inclined surface (125b) is formed to be wider than the parallel surface (125a) in the direction of the plate thickness of the slide part (12). Accordingly, the slide part (12) is formed in the shape of a truncated pyramid of a thin plate so that it narrows overall as it faces the base part (11).

[0129] The slide portion (12) is supported by the resilient portion (15) and the first regulating portion (16) on the back side (126) where the base (11) is installed (see FIG. 16 and FIG. 17, etc.). The slide portion (12) is resiliently pressed from the base (11) side to the second mold (2) side, and the range of movement to the base (11) side and the second mold (2) side is regulated at a predetermined position by the first regulating portion (16).

[0130] The resilient member (15) is positioned at four locations corresponding to the four corners of the slide member (12) in a flat state. The resilient member (15) is equipped with an axis (151) that is installed from the slide member (12) toward the base (11), a bush (152) fixed toward the base (11), and a compression coil spring (153) that is wound around the outer circumference of the bush (152) into which the axis (151) is inserted. The axis (151) is inserted through the bush (152) so as to be able to move in contact with the bearing (111) of the base (11). The slide member (12) is pressed toward the contact surface (121) side (i.e., the second mold (2) side) by the compression coil spring (153) resiliently pushing in a direction that separates the slide member (12) and the base (11).

[0131] The first regulating part (16) restricts movement of the slide part (12) toward the contact surface (121). The first regulating part (16) is positioned to correspond to the nearly central position of the slide part (12) in a planar state. The first regulating part (16) has a cylindrical support shaft part (161) installed from the back surface (126) of the slide part (12), and a rectangular column-shaped enlarged part (162) formed at the end side of the support shaft part (161). The support shaft part (161) is inserted so as to be articulated with a bearing (112), which is a through hole installed in the base (11). The enlarged part (162) is formed with a larger diameter than the support shaft part (161) and the bearing (112) and is positioned in the articulated space (141) on the side of the moving mold (14) (see FIG. 17). Accordingly, the slide portion (12) is restricted from moving in the direction in which the expanded portion (162) comes into contact with the periphery of the bearing (112) and moves away from the base (11).

[0132] Additionally, a second rectifier (17) in the shape of a square column is installed facing toward the slide part (12) in the base (11). The second rectifier (17) is arranged in four places corresponding to the four sides of the slide part (12) in the planar view. As shown in the enlarged view of part B of FIG. 17, the cross-section (171) of each second rectifier (17) is spaced apart from the back surface (126) of the slide part (12) by a predetermined distance (G) when the slide part (12) is pressed toward the contact surface (121) (second mold (2) side). When the slide part (12) is pressed toward the base (11), the movement of the slide part (12) toward the base (11) is rectified by the cross-section (171) of the second rectifier (17) and the back surface (126) of the slide part (12) coming into contact. The movable width of the slide part (12) (maximum value of the gap (G)) is set to, for example, 1 mm.

[0133] Returning to FIG. 15, the fixed portion (13) is formed as a rectangular ring adjacent to the outer circumference of a plurality of slide portions (12). The fixed portion (13) has a contact surface (131) (third contact surface), which is a flat surface nearly parallel to the contact surface (121) of the slide portion (12), and a side surface (132), which is an inclined surface connected to the contact surface (131). From the side surface (132), a plurality of protruding wall portions (134) are installed at predetermined intervals. The protruding wall portions (134) protrude outward in a flat state, and the contact surface (131) also extends toward the protruding wall portions (134). The side surface (135) of the protruding wall portions (134) is formed at a steeper angle than the side surface (132). On the side (132) and the protruding wall (134), a third protrusion (133a) and a fourth protrusion (133b) are formed, which are extended in the direction of extension of the first protrusion (122a) or the second protrusion (122b) installed on the slide part (12). The height of the protruding surface of the third protrusion (133a) and the fourth protrusion (133b) from the contact surface (131) is approximately the same as the height of the protruding surface (123) of the first protrusion (122a) and the second protrusion (122b) from the contact surface (121). Additionally, the third protrusion (133a) and the fourth protrusion (133b) are formed with the same width as the first protrusion (122a) and the second protrusion (122b). In the state where the slide part (12) is pressed toward the second mold (2), the step difference between the contact surface (121) and the contact surface (131) can be set to be greater than the height from the contact surface (121, 131) of the protruding surface (123, 133c).

[0134] In the cavity (2a) of the second mold (2), a contact surface (322) (second contact surface) is formed with a shape corresponding to the contact surface (121) of the first mold (1) facing it. In this embodiment, the contact surface (322) is formed as a flat surface that is nearly parallel to the contact surface (121). For example, if the contact surface (121) of the first mold (1) has a curved surface or an inclined surface, the portion of the contact surface (322) of the second mold (2) facing it may be made curved or inclined to correspond to the contact surface (121).

[0135] Next, a method for manufacturing a molded body (305) will be described. The molded body (305) manufactured in this embodiment (see FIG. 18) is formed by a resin molding device (60) shown in FIG. 14, etc. First, in the material supply process, the resin supply device (61) supplies a molten resin sheet (3) by suspending it so that it is placed between the first mold (1) and the second mold (2) (see FIG. 14).

[0136] In the molding process, the mold (321) is moved toward the molten resin sheet (3) to come into contact with the sheet surface of the molten resin sheet (3) (see FIG. 18A). Then, while bringing the mold (321) and the second mold (2) relatively close, the space formed by the molten resin sheet (3), the cavity (2a), and the mold (321) is depressurized by suction from the suction port (2a1), and the molten resin sheet (3) is molded into the cavity (2a) (see FIG. 18B).

[0137] In the mold fastening process, the first mold (1) and the second mold (2) are brought relatively close together so that the annular pinch-off portions (1b, 2b) come into contact with each other (see FIG. 19). That is, the first mold (1) and the second mold (2) come into contact with the molten resin sheet (3) so as to be inserted directly from both sides. At the initial timing (first timing) when the slide portion (12) comes into contact with the molten resin sheet (3) by the mold fastening, as shown in the enlarged view of portion C1 of FIG. 20A, the molten resin sheet (3) initially comes into contact with the protrusion (122) (protrusion surface (123)) of the slide portion (12) and is pressed by this protrusion (122). Likewise, near the fixed portion (13), the molten resin sheet (3) initially comes into contact with the protrusion (133) (protrusion surface (133c)) of the fixed portion (13). Accordingly, cooling of the molten resin sheet (3) begins from the portion in contact with the lattice-shaped protrusions (122, 133).

[0138] After that, at a timing that has elapsed for a predetermined amount of time from the state of FIG. 20A (a second timing later than the first timing), as shown in the enlarged view of section C2 of FIG. 20B, the molten resin sheet (3) flows around the contact area with the protrusions (122, 133) and comes into contact with the contact surfaces (121, 131). On the side (132, 135) side of the fixed part (13), the molten resin sheet (3) also flows around the contact area with the protrusions (133) and comes into contact with the side (132, 135). Accordingly, cooling begins over almost the entire surface of the first mold (1) side of the molten resin sheet (3). Meanwhile, the portion corresponding to the protrusion (122, 133) of the molten resin sheet (3) comes into contact with the contact surface (121, 131) before the portion corresponding to the contact surface (121, 131) as described above, or has a thinner thickness compared to the portion corresponding to the surrounding contact surface (121, 131), so the grid-like region of the molten resin sheet (3) (the region corresponding to the concave portion (352) of the molded body (305) in FIG. 18) can be cooled preferentially.

[0139] When the drag force received from the molten resin sheet (3) by the mold clamping force of the first mold (1) and the second mold (2) becomes greater than the elastic force of the elastic part (15), the slide part (12) moves to the opposite side of the second mold (2) (opposite side of the molten resin sheet (3)) by resisting the elastic force of the elastic part (15). The movement of the slide part (12) is restricted by the back surface (126) coming into contact with the cross-section (171) of the second regulating part (17). When the slide part (12) is forcibly pressed in until it comes into contact with the second regulating part (17), the contact surface (121) and the contact surface (131) become almost the same surface, as shown in the enlarged view of section C3 of FIG. 20C.

[0140] Afterward, in the extraction process, the first mold (1) and the second mold (2) are opened to extract the molded body (305) formed inside the mold (10). Additionally, the molded body (305) is completely cooled and released before hardening, and the burrs on the outer edge are removed. Since the molded body (305) of this embodiment has a grid-like area (an area corresponding to the concave portion (352) in FIG. 18) where hardening has progressed more than the area in contact with the contact surface (121, 131), the overall strength of the molded body (305) can be increased even when extracted from the mold (10). Therefore, bending of the molded body (305) extracted from the mold (10) can be suppressed. The molded body (305) can be formed as a wall panel, for example, a toilet unit, a bathroom unit, a shower unit, or a prefabricated building.

[0141] The molten resin sheet (3) received from the T-die (71) of FIG. 14 may have different sheet thicknesses across corresponding ranges of the core (1a) and cavity (2a) of the first mold (1) and the second mold (2). For example, it is assumed that the molten resin sheet (3) is stretched on the T-die (71) side by its own weight, so that the thickness of the molten resin sheet (3) on the lower side is formed thinner than the T-die (71) side. In this case, when the mold is fastened in FIG. 19, the lower slide part (12C) among the plurality of slide parts (12A~12C) comes into contact with the molten resin sheet (3) before the other upper slide parts (12A, 12B), and then comes into contact with the molten resin sheet (3) in the order of the slide part (12B) and the slide part (12A). In addition, if the molten resin sheet (3) on the lower side corresponding to the slide portion (12C) is relatively thick, the slide portion (12C) has a larger amount of indentation compared to the slide portion (12A) and the slide portion (12B). Therefore, the amount of indentation of each slide portion (12A to 12C) (the same applies to the slide portions (12D to 12F) shown in FIG. 15) can be varied differently depending on the thickness of the molten resin sheet (3).

[0142] Therefore, even if a thin area occurs in the molten resin sheet (3), it is possible to prevent the first mold (1) from coming into contact with the molten resin sheet (3) and to reduce the uneven cooling of the molten resin sheet (3).

[0143] FIG. 21 is a drawing showing an example of a molded body (305) manufactured by a resin molding device. The molded body (305) is formed in a rectangular shape, almost flat. The surface (305a) of the molded body (305) shown in FIG. 21 is a molded surface formed by the second mold (2). Additionally, on the back surface (305b) opposite to the surface (305a) of the molded body (305), a contact surface (351) and a concave portion (352) (352a, 352b) formed by the contact surface (121) and protruding surface (123) of the first mold (1) are installed, as indicated by the dotted line. The concave portion (352a) corresponds to the first protruding portion (122a), and the concave portion (352b) corresponds to the second protruding portion (122b). The outer periphery (353) is an area formed by the fixed part (13). Meanwhile, although the surface (305a) of the molded body (305) is shown as an example configured as a nearly flat surface, irregularities can be provided arbitrarily. In this case, since the concave part (352) is installed thinner than the thickness of the molten resin sheet (3), the effect on the function or appearance of the surface (305a) of the molded body (305) can be reduced.

[0144] In addition, according to the present embodiment, one side of the molten resin sheet (3) is in contact with the second mold (2), and the other side of the molten resin sheet (3) is first in contact with the molten resin sheet (3) corresponding to the protrusions (122, 136). Therefore, the curing speed of the part corresponding to the protrusions (122, 136) of the molten resin sheet (3) is improved, and the overall cooling unevenness is reduced, thereby reducing the bending of the molded body (305). Furthermore, since the molded body (305) can be formed to be difficult to bend, the molded body (305) can be ejected with a short cooling time, thereby shortening the molding cycle and improving the productivity of the molded body (305).

[0145] Although embodiments of the present invention have been described above, the present invention is not limited to each embodiment and can be implemented with various modifications. For example, in this embodiment, a slide part (12) movable by drag force from the molten resin sheet (3) is installed in the first mold (1), but depending on the characteristics of the molten resin sheet (3), the configuration may be configured without installing the slide part (12). In this case, the first mold (1) can be configured simply.

[0146] In addition, although the present embodiment describes a configuration in which the first mold (1) is convex and the second mold (2) is concave, the first mold (1) equipped with the slide part (12) may be configured as a concave mold. Alternatively, the second mold (2) may be configured to have a slide part installed in it, just like the first mold (1).

[0147] Additionally, the protruding surface (123) in the protrusion (122) may be configured to extend over a portion of the contact surface (121), but it is preferable to install it so that it covers more than half, and more preferably more than 80%, of the entire contact surface (121) (the surface of the molded body (305). By increasing the ratio of the area of ​​the protruding surface (123) to the contact surface (121), the overall strength of the molded body (305) can be increased.

[0148] Additionally, when the protruding surface (123) is installed on a part of the contact surface (121), the protruding surface (123) can be installed in an area of ​​the contact surface (121) where the flat portion (including a curved portion with relatively small curvature) is large. For example, the protruding surface (123) can be installed in an area where the flat portion occupies more than 30% of the total area of ​​the contact surface (121). By partially installing the protruding surface (123), the configuration of the mold can be simplified. Explanation of the symbols

[0149] 1: First mold, 1a: Core, 1b: Pinch-off section, 2: Second mold, 2a: Cavity, 2a1: Intake hole, 2b: Pinch-off section, 3: Molten resin sheet, 4: Support arm, 5: Resilient member, 10: Mold, 11: Base, 12: Slide section, 12A: Slide section, 12B: Slide section, 12C: Slide section, 12D: Slide section, 12E: Slide section, 12F: Slide section, 13: Fixed section, 14: Moving mold, 15: Resilient section, 16: First restraining section, 17: Second restraining section, 41: Support beam, 42: Substrate member, 42A: Substrate member, 42B: Substrate member, 43: Frame member, 44: Support, 44A: Support, 44B: Support, 44C: Support, 44D: Support, 51: Shaft holder, 52: Shaft member, 53: Guide bush, 54: Coil spring, 55: Screw member, 56: Washer, 57: Washer, 58: Screw member, 59: Washer, 60: Resin molding device, 61: Resin supply device, 61A: First resin supply device, 61B: Second resin supply device, 65: Hopper, 66: Extruder, 68: Hydraulic motor, 70: Accumulator, 71: T-die, 72: Plunger, 79: Roller, 80: Mold, 81: First mold, 81a: Cavity, 81b: Pinch-off section, 82: Second mold, 82a: Cavity, 82b: Pinch-off section, 83: Mold, 84: Mold, 111: Bearing, 112: Bearing, 121: Contact surface, 122: Protrusion, 122a: First protrusion, 122b: Second protrusion, 123: Protruding surface, 125: Side, 125a: Parallel surface, 125b: Inclined surface, 126: Rear surface, 131: Contact surface, 132: Side, 133: Protrusion, 133a: Third protrusion, 133b: Fourth protrusion, 133c: Protruding surface, 134: Protruding wall, 135: Side, 136: Protrusion, 141: Sliding space, 151: Shaft center, 152: Bush, 153: Compression coil spring, 161: Support shaft part, 162: Enlarged part, 171: Cross-section, 201: Sandwich member, 202: Core material, 203: Skin material, 211: First molten resin sheet,212: Second molten resin sheet, 221: Opposing surface, 305: Molded body, 305a: Surface, 305b: Back surface, 321: Mold, 322: Contact surface, 351: Contacted surface, 352: Concave portion, 352a: Concave portion, 352b: Recess, 353: Peripheral portion, 421: Opening, 441: Opening, 442: Adsorption portion, 443: Support surface, 511: Tube-shaped portion, 511a: Opening, 511b: End portion, 512: Flange portion, 521: Female thread portion, 522: Female thread portion, 531: Flange portion, 532: Tube-shaped portion, 532a: End portion, 533: Bearing portion, 533a: Ball Bearing, 601: Molding system, 602: Hydraulic mechanism, 602a: Cylinder, 602b: Piston, 603: Core material, 610: First parison forming device, 611: First parison, 611a: First resin sheet, 612: First hopper, 613: First extruder, 614: First accumulator, 614a: Cylinder, 614b: Piston, 615: First injection hydraulic mechanism, 615a: Cylinder, 615b: Piston, 616: First injection head, 617: First roller unit, 617a: Roller, 618: First raw resin, 618a: First molten resin, 620: Second parison forming device, 621: Second parison, 621a: Second resin sheet, 622: Second hopper, 623: Second extruder, 624: Second accumulator, 624a: Cylinder, 624b: Piston, 625: Second injection hydraulic mechanism, 625a: Cylinder, 625b: Piston, 626: Second injection head, 627: Second roller unit, 627a: Roller, 628: Second raw resin, 628a: Second molten resin, 630: First mold unit, 631: First mold, 631a: Cavity surface, 631b: Pinch-off section, 632: First mold, 633: First platen, 640: Second mold unit, 641: Second mold, 641a: Cavity surface, 641b: Pinch-off section, 642: Second mold, 643: Second platen, 650: Robot hand, 650a: Base, 650b: Suction pad, 660: Control device, 661: Memory unit, 662: Control unit,

Claims

Claim 1 A molding system comprises a first and second parison forming device, first and second molds configured to be openable and closable, and a control unit. The first parison forming device comprises a first extruder, a first accumulator, and a first injection head. It is configured to form a first parison by injecting the first molten resin from the first injection head after the first molten resin extruded from the first extruder has accumulated in the first accumulator. The second parison forming device comprises a second extruder, a second accumulator, and a second injection head. It is configured to form a second parison by injecting the second molten resin from the second injection head after the second molten resin extruded from the second extruder has accumulated in the second accumulator. The first and second parisons are injected between the first and second molds. The control unit forms the first and second parisons in the next cycle based on historical data from a past cycle. A molding system configured to determine the timing of the start of operation of at least one of the device and the first and second molds, wherein the first molten resin is injected by hydraulic drive, and the control unit is configured to determine the hydraulic pressure conditions of the hydraulic drive in the next cycle based on historical data from past cycles, wherein the historical data is the injection time of the first and second molten resins, and when a state in which the deviation of the injection time from the target value is greater than a threshold occurs for multiple consecutive cycles, the control unit increases or decreases the hydraulic pressure in the next cycle. Claim 2 A molding system comprises a first and second parison forming device, first and second molds configured to be openable and closable, and a control unit. The first parison forming device comprises a first extruder, a first accumulator, and a first injection head. It is configured to form a first parison by injecting the first molten resin from the first injection head after the first molten resin extruded from the first extruder has accumulated in the first accumulator. The second parison forming device comprises a second extruder, a second accumulator, and a second injection head. It is configured to form a second parison by injecting the second molten resin from the second injection head after the second molten resin extruded from the second extruder has accumulated in the second accumulator. The first and second parisons are injected between the first and second molds. The control unit forms the first and second parisons in the next cycle based on historical data from a past cycle. A molding system configured to determine the timing of the start of operation of at least one of the device and the first and second molds, wherein the first parison is a first resin sheet, and the first resin sheet is delivered by a roller disposed between the first injection head and the first and second molds, and the control unit is configured to determine the rotational speed of the roller in the next cycle based on historical data from a past cycle, wherein the historical data is the lengths of the first and second parisons, and if the deviation of the lengths of the first and second parisons from the target value in the previous cycle is greater than or equal to a threshold, the control unit performs a correction to increase or decrease the rotational speed of the roller in the next cycle. Claim 3 delete Claim 4 delete Claim 5 delete Claim 6 A molding system according to claim 1 or 2, wherein the control unit is configured to determine the timing of the start of rotation of the screw of the first extruder in the next cycle based on historical data from a past cycle. Claim 7 A support arm comprising a cantilever-shaped support beam and a substrate member reinforced by a frame member at the front end, which is the free end of the support beam; a first support member provided so as to be fixed or elastically movable with respect to the front portion, which is the front end of the substrate member; a second support member provided so as to be movable with respect to the substrate member at the rear portion, which is the base end of the support beam, and supporting a member to be supported together with the first support member, wherein the elastic force of the first support member against the support beam is stronger than the elastic force of the second support member against the support beam. Claim 8 delete Claim 9 delete Claim 10 A support arm according to claim 7, wherein the first support member and the second support member each have a first suction surface and a second suction surface that support the member to be supported by negative pressure, and are pressed in a direction spaced apart from the support beam side by a coil spring. Claim 11 A resin molding device characterized by comprising a support arm according to claim 7 or 10, a mold including a first mold and a second mold, and a resin supply device for supplying a molten resin sheet to the first mold. Claim 12 A method for supporting a member to be supported in a resin molding apparatus, wherein the resin molding apparatus comprises a support arm according to claim 7 or 10 and a mold adsorbing a molten resin sheet, and a process of moving the support arm to bring the member to be supported by the first support body and the second support body into contact with the molten resin sheet of the mold. Claim 13 A first mold and a second mold are provided to form a molded body by fitting a molten resin sheet supplied by being suspended therein. The first mold has a first contact surface capable of contacting the molten resin sheet and a protruding surface protruding from the first contact surface. The first mold has a base, a plurality of slide parts that are movable relative to the base and include the first contact surface and the protruding surface, and are connected and installed in the direction in which the molten resin sheet is suspended therein, and a fixed part installed relatively fixed relative to the base so as to surround the outer periphery adjacent to the plurality of slide parts. The movement of the slide part toward the base side and the second mold side is restricted within a predetermined range. The fixed part has a third contact surface that is lower than the first contact surface of the slide part when positioned toward the second mold side. The step difference between the first contact surface and the third contact surface is set to be greater than the height of the protruding surface at the first contact surface. The second mold is positioned toward the protruding surface and is positioned toward the base side so as to be the same surface. A mold characterized by having a second contact surface corresponding to the first contact surface and the third contact surface of the slide portion in the state. Claim 14 A mold characterized in that, in Clause 13, the width of the protruding surface is formed in a plurality of lines such that it is smaller than the width of the first contact surface. Claim 15 A mold according to claim 14, characterized in that the protruding surface is formed over the entire first contact surface in a grid shape extended in mutually intersecting first and second directions. Claim 16 A mold characterized in that, in any one of claims 13 to 15, the height of the protruding surface from the first contact surface is set to be thinner than the thickness of the molten resin sheet. Claim 17 delete Claim 18 delete Claim 19 A method for manufacturing a molded body using a resin supply device, a first mold, and a second mold, comprising: a process in which the resin supply device supplies a molten resin sheet between the first mold and the second mold; and a process of bringing the first mold and the second mold relatively close and bringing the first mold and the second mold into contact with the molten resin sheet to form a mold, wherein the first mold has a first contact surface and a protruding surface protruding from the first contact surface, and the first mold has a base, a slide part movable relative to the base and including the first contact surface and the protruding surface, and a fixed part installed relatively fixed relative to the base to surround the outer periphery adjacent to the slide part, and the fixed part has a third contact surface lower than the first contact surface of the slide part when positioned on the side of the second mold, and the second mold has a position facing the protruding surface and a corresponding first contact surface and the third contact surface of the slide part when positioned on the side of the base so as to be the same surface. A method for manufacturing a molded body characterized by having a second contact surface, wherein in the mold fastening process, the protruding surface contacts the molten resin sheet and cools before the first contact surface, and after a predetermined time has elapsed, the first contact surface and the third contact surface become the same surface and contact the molten resin sheet and cool. Claim 20 delete

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