JP2015160393A - Decorative molding apparatus for thermoplastic frp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an FRP molded article in which an exterior design surface is decorated by a decorative sheet and is decorated without impairing appearance quality, while permitting a convex shape formation, such as boss and rib, by using a thermoplastic FRP.SOLUTION: A decorative molding apparatus includes a mold made up of a first mold (1) and a second mold (2). A decorative sheet (4) and a thermoplastic FRP (5) composed of reinforced fiber and thermoplastic matrix resin are disposed in the order named from the first mold (1) side in the mold. The mold includes a heating circuit (6), a cooling circuit (7), and a control section (50) to heat, press, and cool the thermosetting FRP (5) in a state in which temperature of the second mold (2) is higher than temperature of the first mold (1) by controlling the heating circuit (6) and the cooling circuit (7). An FRP flow on the second mold (2) is made more active than an FRP flow on the first mold (1) having the exterior design surface (3).

Description

  The present invention relates to a decorative molding apparatus for thermoplastic FRP molded products.

  FRP containing reinforced fiber and matrix resin has high specific strength, high specific modulus, and excellent mechanical properties. Therefore, it is possible to reduce the thickness and weight while maintaining the strength of the product and maintaining the strength. Adoption has progressed in the field of equipment and sports. Here, FRP is an abbreviation for Fiber Reinforced Plastics, which is a fiber reinforced resin.

  FRP is also used for exterior molded products, and there is a need for improvement in design as well as strength. The SMC base material and BMC base material are press-molded together with the decorative sheet, and the decorative sheet is heated and pressed. The design can be transferred to the FRP, and a special design such as embossing can be expressed on the surface of the FRP molded product. Here, SMC is an abbreviation for Sheet Molding Compounds, which is a sheet-like material in which a mixture of resin, filler, and other additives is impregnated into reinforcing fibers. BMC is an abbreviation for Bulk Molding Compounds. It is a lump material in which resin, filler and reinforcing material are kneaded.

FIG. 14 shows the molding method described in Patent Document 1.
In this conventional molding method, a mold is formed of an upper mold 40 having a molded product surface on the design surface side, and a lower mold 41 that makes a pair with the upper mold 40. After heating this metal mold | die, it arrange | positions in a metal mold | die in order of the decorating sheet 42, SMC, or BMC43 from the upper mold | type 40 side, and pressurizes by press operation.

  As a result, the SMC or BMC 43 is heated by the mold. Since SMC or BMC43 is impregnated with a thermosetting resin, it is possible to obtain a molded product that is solidified by heating to transfer the mold shape. The decorative sheet 42 is also heated by the mold, and the printed part of the decorative sheet 42 is transferred to the molded product by heat, whereby the molded product can be decorated.

JP 2004-98343 A

  However, the thermosetting resin impregnated with SMC or BMC43 has a low melt viscosity, for example, 3 Pa · s or less in the case of polyurethane. Therefore, even if pressure is applied during molding, the pressure propagation to the reinforcing fibers is small, and the reinforcing fibers do not flow. Therefore, a sheet-like shape can be formed by bending the shape with a uniform thickness, but a new convex shape is raised from a sheet-like material such as a boss or rib, resulting in a change in thickness. Cannot be formed. Therefore, it is difficult to apply FRP to a molded product used for a digital device or a home appliance that requires a complicated shape such as a boss or a rib.

  In order to form convex shapes such as bosses and ribs on the sheet-like FRP, it is possible to use FRP impregnated with a thermoplastic resin. For example, when the resin is a nylon resin, the viscosity is 100 Pa · s or more, and pressure is propagated to the reinforcing fiber by pressurization during molding, and the reinforcing fiber flows along with the flow of the resin. Boss and rib can be formed by raising the shape.

  However, when the decorative sheet 42 is placed in the mold and pressed by the press operation as in the prior art document 1, a load is applied to the decorative sheet 42 along with the convex protrusion of the FRP, and the decorative sheet 42 is decorated. Since the printed part of the sheet 42 and the base material sheet are torn and cracked and transferred to the molded product, the appearance quality as an exterior molded product is impaired.

  The present invention solves the above-mentioned conventional problems, and uses a thermoplastic FRP to decorate the exterior design surface with a decorative sheet while enabling the convex shape of bosses and ribs to deteriorate the appearance quality. The object is to provide a decorated FRP molded product.

  The thermoplastic FRP decorative molding apparatus according to the present invention includes a decorative sheet, a reinforcing fiber, and a thermoplastic matrix in a mold constituted by a first mold and a second mold, from the first mold side. A thermoplastic FRP made of resin is disposed, and the mold controls the heating circuit and the cooling circuit, and the heating circuit and the cooling circuit to make the temperature of the second mold higher than the temperature of the first mold. And a controller that heats, pressurizes, and cools the thermoplastic FRP.

  According to this configuration, the FRP flow on the second mold side can be made more active than the FRP flow on the first mold side having the exterior design surface, and a new convexity can be added to the FRP without deteriorating the appearance quality. Because it is possible to decorate the exterior surface of molded products with convex shapes such as bosses and ribs that raise the shape and cause changes in thickness, on the configuration of products such as digital equipment and home appliances, It becomes possible to replace exterior molded products that require complex shapes with thermoplastic FRP.

  And by using thermoplastic FRP which is excellent in specific strength, the strength of the member can be increased, the thickness can be reduced while maintaining the strength and the number of parts can be reduced, and the product can be made thinner and lighter.

  Compared with thermosetting FRP, thermoplastic FRP is excellent in productivity because the molding time is short and the equipment such as a press is small, and by utilizing the property of being melted by heat, Recycling becomes easy.

Configuration diagram of the decorative molding apparatus of the present invention Configuration diagram of decorative sheet in the same embodiment (A) (b) (c) Clamping process diagram in embodiment 1 of the present invention Sectional drawing of the mold opening process in the same embodiment Sectional drawing of the protrusion process in the same embodiment The flowchart which shows the structure of the control part in the embodiment Sectional drawing which shows another decoration molding apparatus in the embodiment (A) Cross-sectional view of decorative molded product and (b) Cross-sectional view of decorative molding apparatus in Embodiment 2 of the present invention Sectional drawing of another decoration molding apparatus in the embodiment The expanded sectional view of the principal part of the exterior molded article in the embodiment Sectional drawing of another decoration molding apparatus in Embodiment 3 of this invention The expanded sectional view which showed the transfer state of the minute unevenness | corrugation 27 in the embodiment 4A is a sectional view of a decorative molding apparatus in a pressurized state at the initial stage of mold clamping in Embodiment 4 of the present invention, and FIG. (A) Cross-sectional view of a decorative molding apparatus in a clamped state in Embodiment 5 of the present invention and (b) an enlarged view of the main part thereof Sectional view of the main part of a conventional decorative molding device

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
(Embodiment 1)
1 to 6 show Embodiment 1 of the present invention.

FIG. 1 shows a decorative molding apparatus according to the first embodiment.
The mold is composed of a first mold 1 having an exterior design surface 3 of a molded product and another second mold 2. Each of the first mold 1 and the second mold 2 has a cartridge heater 6 in the vicinity of the cavity space, and a cooling circuit 7 at a position farther from the cavity space than the cartridge heater 6. Reference numeral 50 denotes a control unit which controls the temperature of the first mold 1 and the temperature of the second mold 2 by controlling the mold clamping, the mold opening protrusion operation, and the cartridge heater 6 and the cooling circuit 7 as heating circuits. The temperature is adjusted to each set temperature.

The state of FIG. 1 shows a process in the middle of arranging the decorative sheet 4 and the thermoplastic FRP 5 in order from the vicinity of the exterior design surface 3 between the first mold 1 and the second mold 2.
FIG. 6 is an overall flowchart showing an example of a molding method using this decorative molding apparatus. The temperature control of the first mold 1 and the temperature of the second mold 2 by the control unit 50 will be specifically described in accordance with the steps S1 to S8.

In step S1, the controller 50 controls the temperature of the cartridge heaters 6 of the first mold 1 and the second mold 2 to heat the first mold 1 and the second mold 2 to their respective set temperatures.
In step S2, the decorative sheet 4 and the thermoplastic FRP 5 are conveyed to a mold and arranged as shown in FIG. Here, the decorative sheet 4 is disposed so as to contact the surface of the pad 14, and the thermoplastic FPR sheet 5 is disposed so as to contact the surface of the second mold 2.

In step S3, the thermoplastic FRP 5 is heated by the second mold 2 and the thermoplastic matrix resin is melted, so that the thermoplastic FRP 5 can be molded.
The positional relationship between the layer structure of the decorative sheet 4 and the thermoplastic FRP 5 is shown in FIG.

  The decorative sheet 4 includes a base sheet 8, a release layer 9, and a transfer layer 10 that is attached to the base sheet 8 through the release layer 9. The transfer layer 10 is formed of a hard coat layer 11, a pattern layer 12, and an adhesive layer 13 from the base material sheet 8 side.

The thermoplastic FRP 5 is made of, for example, continuous carbon reinforcing fiber and thermoplastic polyurethane.
In this case, in step S1, the control unit 50 controls the temperatures of the first mold 1 and the second mold 2 as follows.

  The melting point of the thermoplastic polyurethane of the thermoplastic FRP5 is 190 ° C., and it is necessary to heat the mold above that temperature. However, when polyethylene terephthalate is used as the material of the base sheet 8 of the decorative sheet 4, the heat resistance temperature is 210 ° C., so if the mold is heated further, the decorative sheet The appearance quality of the molded product is deteriorated due to tearing due to a decrease in mechanical properties of 4 and discoloration due to deterioration of the transfer layer 10.

  Therefore, the second mold 2 is set to 200 ° C. which is lower than the heat resistance temperature (210 ° C.) of polyethylene terephthalate and higher than the melting point (190 ° C.) of the thermoplastic polyurethane, and as shown in FIG. The thermoplastic FRP5 is disposed on the upper surface of the substrate and heated to form a molten state that can be molded. Further, when the thermoplastic FRP 5 in the vicinity of the exterior design surface 3 of the first mold 1 flows during molding, due to the frictional resistance, the transfer layer 10 may flow and partly thin, which may impair the appearance quality. It is desirable that the temperature of the deflection point of the thermoplastic polyurethane be 185 ° C. or lower. In the present embodiment, the mold temperature of the first mold 1 is set to 170 ° C. That is, the temperature of the first mold 1 is set to the first temperature. Control below the temperature of the two molds 2.

  In step S4, when the mold clamping is started as shown in FIG. 3A, the pad 14 is pressed against the first mold 1 by the spring 15, and the decoration sheet 4 is pressed by the force with the first mold 1 and the pad 14. It is in a state of being sandwiched between.

The force of clamping the decorative sheet 4 is generated by the repulsive force of the spring 15, but if the grip is completely gripped, the first decorative sheet 4 is moved by the second mold 2 and the thermoplastic FRP 5 during the press described later. When drawing into the mold 1, tensile stress is generated, and the elongation of the decorative sheet 4 causes thinning of the sheet or tearing due to elongation exceeding the limit. On the contrary, if there is no clamping by the pad 14, wrinkles are generated in the decorative sheet 4 at the time of pull-in by the press operation and are transferred to the molded product as they are, which may impair the appearance quality. Therefore, in this embodiment, the pressing force by the spring 15 is set to 0.2 kgf / cm ² . In addition, as shown to Fig.3 (a), after the pre-clamp of the decorating sheet 4, the decorating sheet 4 was made to follow the 1st metal mold | die 1 by attracting | sucking the cavity inside of a metal mold | die with the air circuit 16. Thereafter, the operation may be shifted to a press operation.

  In step S5, as shown in FIGS. 3B and 3C, the first mold 1 and the second mold 2 are pressurized by a press operation, and the decorative sheet 4 and the thermoplastic FRP 5 are sandwiched. Then, the thermoplastic FRP 5 is transferred to the same shape as the cavity space, and the transfer layer 10 of the decorative sheet 4 comes into contact with the molten thermoplastic matrix resin, and is transferred to the thermoplastic FRP 5 by melting and solidifying the adhesive layer 13. , Decorated. Further, sufficient pressure is applied to the thermoplastic FRP inside the mold, and the exterior design surface 3 is transferred to a high quality.

3 (b) and 3 (c) will be described in detail.
FIG. 3B shows a state in which the outline of the thermoplastic FRP 5 is bent by the pressing operation. The end of the molten thermoplastic FRP 5 and the first mold 1 are in contact with each other, and the outline of the thermoplastic FRP 5 is bent. By bending the outer shell, the contact area between the thermoplastic FRP 5 and the second mold 2 is gradually increased, the softening range of the thermoplastic FRP 5 is further increased, and the contact area is further increased. The press operation is continued while accelerating the melting of the thermoplastic FRP 5 by repeating the process until the shape of the cavity space becomes the same.

FIG. 3C shows a state where the bottom dead center of the pressing operation has been reached. In this state of FIG. 3C, the first mold 1 and the second mold 2 are pressurized and pressure is applied to the inside of the cavity, so that the mold surface is sufficiently transferred to the thermoplastic FRP 5 and the high-quality exterior The design surface 3 can be obtained. In this embodiment, the pressing force for applying pressure inside the cavity was set to 600 kgf / cm ² . Further, in the state of FIG. 3C, the resin sealing surfaces 17 of the first mold 1 and the second mold 2 are grounded without any gap, and the outflow of the thermoplastic matrix resin is prevented and the burr of the molded product is suppressed. can do. Here, the resin sealing surface 17 has an angle of, for example, 3 °, and the resin sealing surface clearance 18 is large until the first mold 1 and the second mold 2 are joined together by a press operation, and galling or baking is performed. The sticking does not occur, and when the first mold 1 reaches the bottom dead center, the slopes come together and the resin can be reliably sealed.

  The resin sealing surface clearance 18 is desirably about 0.03 mm, the decorative sheet 4 is sandwiched between the resin sealing surfaces 17, and the thickness of the decorative sheet 4 is 0.05 mm. Is broken when the thickness exceeds the limit of elongation of 0.02 mm, and the transfer layer 10 is scraped off due to rubbing of the decorative sheet 4 and part of the second mold 2, resulting in a molded product. Will cause a problem that is not decorated in part. However, if the resin sealing surface clearance 18 is too large, resin burrs will enter, so the resin sealing surface clearance 18 is set to about 0.03 mm. Further, as described above, since the controller 50 sets the temperature of the first mold 1 to 170 ° C. and the temperature of the second mold 2 to 200 ° C., the resin sealing surface clearance 18 is the thermal expansion of the mold. Fluctuates before and after heating. Therefore, it is necessary to set the resin sealing surface clearance 18 in the normal temperature state in consideration of the thermal expansion after the heating process.

  In step S6 at the time when the pressurization is finished, the cartridge heater 6 is turned off, and the first mold 1 and the second mold 2 are cooled by circulating the cooling water through the cooling circuit 7, whereby the thermoplastic FRP 5 Is cooled and the thermoplastic matrix resin is cooled and solidified to solidify the thermoplastic FRP 5 so that it can be removed from the mold.

  The cartridge heater 6 may be turned off after the cooling water is circulated through the cooling circuit 7. Moreover, the timing which turns off the cartridge heater 6 of the 1st metal mold | die 1 and the 2nd metal mold | die 2 is changed in each position, and cooling of the 1st metal mold | die 1, the 2nd metal mold | die 2, and the thermoplastic FRP5 is carried out. The speed can be partially controlled. Therefore, by cooling the part that is thick and difficult to cool as the shape of the molded product first, and cooling the other parts later, the cooling and solidification state of the entire molded product is made uniform, and the density difference is alleviated. Thus, it is possible to suppress the internal stress of the molded product and reduce warping and distortion after molding.

  In step S7, the first mold 1 and the second mold 2 are opened as shown in FIG. Here, the decorative sheet 4 and the decorative molded product 19 are separated from the first mold 1. Further, since the decorative molded product 19 is held by the second mold 2, the decorative sheet 4 is separated into the base sheet 8 and the transfer layer 10 with the release layer 9 in FIG. Only the base material sheet 8 is left on the sheet 4.

  In step S <b> 8, as shown in FIG. 5, the decorative molded product 19 is extruded and released from the second mold 2 by protruding the protruding pin 20 by the protruding mechanism of the press. By this step, the decorative molded product 19 is separated from the second mold 2 and can be taken out, thereby completing the molding step.

  In addition, even if arrangement | positioning of the 1st metal mold | die 1 and the 2nd metal mold | die 2 of FIG. 1 is reversed, it can implement similarly. Specifically, as shown in FIG. 7, molding is performed with the second mold 2 having the exterior design surface 3 of the molded product and the other first mold 1. The thermoplastic FRP 5 and the decorative sheet 4 are arranged in order from the vicinity of the exterior design surface 3, and the thermoplastic FRP 5 is transferred in the same shape as the cavity space formed by the first mold 1 and the second mold 2 by a press operation. The surface of the decorative molded product 19 opposite to the exterior design surface 3 is decorated with the decorative sheet 4. Similarly to the above, the temperature of the first mold 1 is set lower than the temperature of the second mold 2.

  Although the 2nd metal mold | die 2 has the exterior design surface 3, when a transparent material is selected for thermoplastic FRP5, for example, when the decorative molded product 19 is seen from the exterior design surface 3, the back side, that is, the first The mold 1 side can be seen. Therefore, by decorating the back side with the decorative sheet 4 and allowing the pattern layer to be seen through the decorative molded product 19, it is possible to mold a decorative molded product with higher design and a high-quality appearance. Moreover, if a circuit-like pattern is formed on the transfer layer 10 on the back surface using a conductive material such as silver paste, an electric circuit can be formed on the molded product. A molded product can be formed.

(Embodiment 2)
In the decorative molded product 19 molded by the decorative molding apparatus of the first embodiment, the cavity forming portion of the second mold 3 is flat, but in this second embodiment, it is shown in FIG. 8A (a). Thus, the case where convex parts, such as a boss | hub and a rib, and the rib 19b in this Example are shape | molded on the back surface side of the decorative molded product 19 is demonstrated.

  In the decorative molding apparatus in this case, as shown in FIG. 8A (b), a rib space 21 necessary for forming the rib 19b on the surface of the second mold 2 is formed. The rest is the same as in the first embodiment.

  In order to mold the ribs 19b, the area and thickness of the thermoplastic FRP 5 are determined so that “the cavity volume including the ribs 19b” ≦ “the volume of the thermoplastic FRP 5”, and are arranged in the mold. Alternatively, as in another specific example shown in FIG. 8B, the second thermoplastic FRP 5 b is superposed on the thermoplastic FRP 5 and placed in the mold to replenish the volume of the rib space 21 of the second mold 2. It can also be realized by supplementing the second thermoplastic FRP 5b. The rest is the same as in the first embodiment.

  When the second thermoplastic FRP 5b is arranged so as to overlap as shown in FIG. 8B, so that “the cavity volume including the rib 19b” ≦ “the total layer volume of the thermoplastic FRP 5 and the second thermoplastic FRP 5b”. The areas and thicknesses of the thermoplastic FRP5 and the thermoplastic FRP5b are determined.

  FIG. 9 shows that a single thermoplastic FRP 5 is placed in the mold as shown in FIG. 8A (b) and pressed, or a plurality of thermoplastic FRPs 5 and 5b are placed in the mold as shown in FIG. 8B. Shows the state of pressing. That is, the first matrix resin range 23 in the vicinity of the first mold 1 and the decorative sheet 4 and the second matrix resin range 24 in the vicinity of the second mold 2 and the rib 19b are configured.

  In addition, the thermoplastic matrix resin of the thermoplastic FRP 5 and the second thermoplastic FRP 5b is melted by heating the mold. As described above, the first mold 1 is not more than the deflection temperature under load of the thermoplastic matrix resin. Since the mold 2 is set to be equal to or higher than the melting point of the thermoplastic matrix resin, “temperature of the first mold 1” <“temperature of the second mold 2”.

  As shown in FIG. 9, the first matrix resin range 23 in the vicinity of the first mold 1 is in a state where the temperature is lower than the deflection temperature under load, no significant decrease in viscosity occurs, and the thermoplastic matrix resin hardly flows. It has become.

  Therefore, the flow of the thermoplastic FRP 5 and the second thermoplastic FRP 5b in the vicinity of the decorative sheet 4 is suppressed, and even when molded and pressed, the force of pulling the decorative sheet 4 and the friction due to the friction of the transfer layer are reduced. The influence of the appearance on the decorative molded product can be reduced.

  Further, since the temperature of the second matrix resin range 24 in the vicinity of the second mold 2 is set to be equal to or higher than the melting point, the viscosity is lowered and the thermoplastic matrix resin is easy to flow. Therefore, when the resin flows into the rib 19b located in the second mold 2, the flow of the thermoplastic FRP5 and the second thermoplastic FRP5b in the second matrix resin range 24 becomes active, and the rib 19b is easily formed. Can be formed. Further, as described above, since the flow of the thermoplastic FRP 5 and the second thermoplastic FRP 5b in the vicinity of the first mold 1 is suppressed, the appearance is affected even if the rib 19b is formed. Therefore, the rib 19b can be formed without impairing the appearance quality as a decorative molded product.

  In addition, if the rib thickness 25 of the rib 19b is thicker than the thickness 26 of the decorative molded product 19 after the completion of molding, the rib 19b becomes thick at the intersection of the rib 19b and the decorative molded product thickness 26 and is pressed by a press. In this case, it is difficult to propagate the pressure, and the thermoplastic matrix resin is not sufficiently cooled, and a minute sink-like dent is generated, which deteriorates the appearance quality of the decorative molded product 19. Therefore, it is desirable that the thickness 25 of the rib 19b is set to 26 or less.

  In the present embodiment, the shape of the second mold 2 is referred to as a rib. However, the same effect can be obtained with a shape in which a convex shape is newly raised from the thermoplastic FRP 5 having a uniform thickness, such as a boss. It is possible to form a convex shape on the second mold 2 without affecting the appearance and without deteriorating the appearance quality as an exterior molded product.

(Embodiment 3)
10 and 11 show the third embodiment.
In the decorative molding apparatus according to the third embodiment, as shown in FIG. 10, minute irregularities 27 are formed on the exterior design surface 3 of the first mold 1. Others are the same as the first embodiment and the second embodiment.

  Since it comprised in this way, as shown in FIG. 11 at the time of shaping | molding, the micro unevenness | corrugation 27 of the 1st metal mold | die 1 is thermoplastic FRP5 via the base film 8, the peeling layer 9, and the transfer layer 10 of the decorating sheet 4. Has been transcribed.

  In this embodiment, the fine unevenness 27 of the first mold 1 is formed into an uneven shape having a depth of about 20 μm by embossing by etching. However, the surface area of the exterior design surface 3 increases due to the uneven shape. When the thermoplastic matrix resin of the thermoplastic FRP5 is a thermoplastic polyurethane, the temperature of the first mold 1 is 170 ° C. with respect to the resin having a melting point of 190 ° C., so that the thermoplastic FRP 5 is the first mold. The cooling and solidification of the thermoplastic FRP 5 starts from the moment when the outer exterior design surface 3 is touched. In the cooling and solidification, since the minute unevenness 27 is formed on the exterior design surface 3, the surface area is large and the efficiency of cooling and solidification is improved as compared with the case where the exterior design surface 3 is a smooth mirror surface. Can do. If cooling and solidification are promoted, a decrease in the viscosity of the first thermoplastic matrix resin range 23 shown in FIG. 9 can be suppressed, the load on the decorative sheet 4 can be reduced, and the appearance quality can be further improved.

  For example, when polyethylene terephthalate is used for the base material sheet 8 of the decorative sheet 4, the thermal expansion coefficient is 20.0 × E-6 (1 / K), and cold die steel ( If SKD11) is used, its thermal expansion coefficient is 11.7 × E-6 (1 / K). In this case, once the mold is heated to 170 ° C. and the decorative sheet 4 and the thermoplastic FRP 5 are molded, the decorative sheet 4 is also heated to about 170 ° C. in a clamped state. The decorative sheet 4 is held by the resin sealing surface 17 as shown in FIG. 3 (c), but if it enters the cooling step as it is, the decorative sheet 4 is further contracted due to a difference in thermal contraction with the mold. Load is applied in the direction. Therefore, the thickness is partially reduced, and fine unevenness occurs in the transfer layer 10 of the decorative sheet 4, thereby deteriorating the appearance quality.

  However, if the first mold 1 has the minute unevenness 27 as in the third embodiment, the minute unevenness is transferred to the decorative sheet 4 after pressing by molding as shown in FIG. The unevenness 27 improves the frictional resistance between the first mold 1 and the decorative sheet 4, and the entire exterior design surface 3 holds the decorative sheet 4 and plays a role of relaxing the heat shrinkage difference. Therefore, the tensile stress generated when the decorative sheet 4 contracts is reduced, the occurrence of fine unevenness on the transfer layer 10 of the decorative sheet 4 is suppressed, and the decorative molded product 19 is not impaired without deteriorating the appearance quality. Can be obtained.

  Furthermore, as shown in FIG. 11, the minute irregularities 27 are also transferred to the interface between the transfer layer 10 and the thermoplastic FRP 5, and the thermoplastic matrix resin of the thermoplastic FRP 5 is solidified in the state where the minute irregularities 27b are entered. Therefore, when the resin is solidified and held by countless uneven surfaces, that is, the anchor effect is expected, the adhesion between the thermoplastic FRP 5 and the transfer layer 10 is improved, and the transfer layer 10 is used as an exterior molded product. Can be made difficult to peel off.

(Embodiment 4)
In this Embodiment 4, the thermal expansion coefficient of the 1st metal mold | die 1 and the 2nd metal mold | die 2 in said each embodiment is demonstrated in detail.

  FIG. 12A shows a pressurization state of the first mold 1 and the second mold 2 in the initial stage of clamping. FIG. 12B shows a pressure holding state in which the first mold 1 has reached the bottom dead center and the cooling of the first mold 1 and the second mold 2 has progressed a little.

  The characteristics of the materials of the first mold 1 and the second mold 2 in the first to third embodiments are as follows: “thermal expansion coefficient of the first mold 1” <“thermal expansion coefficient of the second mold 2” It has become. For this reason, the second mold 2 in the state of FIG. 12B is smaller than the second mold 2 in the state of FIG. Therefore, although the resin sealing surface clearance 18 is increased, the first mold 1 and the second mold 2 are always fastened by the press operation, and the second mold 2 is gradually moved to the first mold. Pressed against the mold 1 side. As a result, the cavity space 28 is also gradually reduced, the pressure inside the cavity gradually increases, and sufficient transfer is possible when the thermoplastic FRP 5 is inside the cavity.

  With this configuration, it is possible to gradually increase the cavity internal pressure while the resin sealing surface 17 is sealed. By suppressing the resin burr and increasing the sufficient pressure, there is less burr and high quality. Can be obtained.

(Embodiment 5)
In the fifth embodiment, the angle of the first sealing surface of the first mold 1 and the angle of the second sealing surface of the second mold 2 in the resin sealing surface 17 in each of the above embodiments are described in detail. explain.

  In the molding process, the transfer layer of the decorative sheet 4 and the second mold 2 come into contact with each other due to the rubbing of the transfer layer, the tearing by sandwiching the base sheet of the decorative sheet 4, etc. There is a concern that the quality of appearance deteriorates. However, if the resin-sealed surface clearance 18 (FIG. 12) is widened, secondary processing operations such as deterioration of appearance quality and deburring due to burrs become necessary.

  Therefore, in the fifth embodiment, the resin sealing surface clearance 18 is set to 0.03 mm in the vicinity of the cavity space 28 as described in the first embodiment, and the resin sealing surface clearance 18 increases as the distance from the cavity space 28 increases. By setting so as not to spread and sandwich the decorative sheet 4, the rubbing of the transfer layer and the tearing of the base sheet of the decorative sheet 4 were alleviated, and the molding in a state in which the appearance quality was not impaired was made possible.

FIG.13 (b) has shown the expansion of the resin sealing surface 17 in Fig.13 (a).
The resin sealing surface 17 that is grounded when the first mold 1 and the second mold 2 are clamped and prevents the thermoplastic matrix resin from flowing out of the thermoplastic FRP 5 is provided with the first sealing of the first mold 1. It consists of a stop surface 1 b and a second sealing surface 2 b of the second mold 2.

  The angle between the mold clamping and mold opening direction and the first sealing surface 1b is the first sealing surface angle 29, and the angle between the mold clamping and mold opening direction and the second sealing surface 2b is the second sealing surface. The stop surface angle is 30. The first sealing surface angle 29 is larger than the second sealing surface angle 30, and is positioned from the vicinity of the cavity space 28 to the first sealing surface clearance 31 and the second sealing surface clearance 32, and is sealed with resin. The clearance of the surface 17 gradually increases as the distance from the vicinity of the thermoplastic FRP 5 increases.

  In this way, “first sealing surface angle 29”> “second sealing surface angle 30” is set, and the sandwiching of the decorative sheet 4 due to clamping of the first mold 1 and the second mold 2 is alleviated. Thus, it is possible to suppress burrs due to molding while suppressing rubbing of the transfer layer and tearing of the base sheet of the decorative sheet 4, and high-quality decorative molding without impairing the appearance quality as an exterior molded product. Goods can be obtained.

  Each of the above-described embodiments is merely an example, and various modifications can be made. By applying the molding die according to the present invention and its molding method, it is possible to produce a variety of decorative molded products without deteriorating the appearance quality in exterior molded products using thermoplastic FRP. For example, according to the mold configuration shown in the first to fifth embodiments, it is possible to form a decorative molded product of thermoplastic FRP with good productivity and good appearance quality, and it is possible to form a complicated shape such as a rib. Therefore, it can be expected to be used for various products.

Further, Embodiments 1 to 5 can be performed simultaneously.
As described above, the present invention relates to a thermoplastic FRP decorative molded product in which a decorative sheet is disposed on one side, and the flow of the thermoplastic matrix resin of the thermoplastic FRP on the side on which the decorative sheet is disposed during molding, Is smaller than the flow of the thermoplastic matrix resin of the thermoplastic FRP on the side where the resin is not disposed. Specifically, the temperature of the cavity of the first mold close to the decorative sheet is set lower than the deflection temperature under load of the thermoplastic matrix resin and lower than the temperature of the cavity of the second mold. As a result, it is possible to decorate the exterior surface of a molded product having a convex shape such as a boss or a rib, which raises a new convex shape on the FRP and causes a change in thickness without deteriorating the appearance quality. realizable.

  The present invention contributes to the realization of a molded product that requires a reduction in thickness and weight, particularly among exterior parts in transportation equipment, mobile equipment, wearable equipment, and the like.

DESCRIPTION OF SYMBOLS 1 1st metal mold | die 1b 1st sealing surface of the 1st metal mold | die 2 2nd metal mold | die 2b 2nd sealing surface of the 2nd metal mold | die 3 Exterior design surface 4 Decorating sheet 5 Thermoplastic FRP
5b Second thermoplastic FRP
6 Cartridge heater 7 Cooling circuit 8 Substrate sheet 9 Release layer 10 Transfer layer 11 Hard coat layer 12 Picture layer 13 Adhesive layer 14 Pad 15 Spring 16 Air circuit 17 Resin sealing surface 18 Resin sealing surface clearance 19 Decorative molded product 19b Rib 20 Extrusion pin 21 Rib space 23 First matrix resin range 24 Second matrix resin range 25 Rib thickness 26 Decorative molded product thickness 27 Small unevenness 28 Cavity space 29 First sealing surface angle 30 Second sealing surface angle 31 One sealing surface clearance 32 Second sealing surface clearance 50 Control unit

Claims (6)

In the mold composed of the first mold and the second mold, from the first mold side, a decorative sheet, and a thermoplastic FRP made of a reinforcing fiber and a thermoplastic matrix resin are arranged,
The mold includes a heating circuit and a cooling circuit,
A controller that controls the heating circuit and the cooling circuit to heat, pressurize, and cool the thermoplastic FRP in a state where the temperature of the second mold is higher than the temperature of the first mold. Yes,
Decorative molding equipment for thermoplastic FRP. A concave portion is provided in the cavity forming portion of the second mold, and a convex shape by the thermoplastic FRP is raised to form a boss or a rib shape.
A decorative molding apparatus for thermoplastic FRP according to claim 1. In the first mold having the exterior design surface of the decorative molded product, minute irregularities are formed,
A decorative molding apparatus for thermoplastic FRP according to claim 1 or 2. “Thermal expansion coefficient of the material of the first mold” <“Thermal expansion coefficient of the material of the second mold”
The decorative molding apparatus for thermoplastic FRP according to any one of claims 1 to 3. A resin sealing surface that is grounded when the first mold and the second mold are clamped and prevents the thermoplastic matrix resin from flowing out of the thermoplastic FRP is “the first sealing of the first mold”. The angle of the stop surface is ">" the angle of the second sealing surface of the second mold ", and the clearance between the first mold and the second mold of the resin sealing surface is from the vicinity of the thermoplastic FRP. Grows with distance
The decorative molding apparatus for thermoplastic FRP according to any one of claims 1 to 4.   A decorative molding method for thermoplastic FRP, which is molded by the decorative molding apparatus according to any one of claims 1 to 5.