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JP4740028B2 - 中空体成形装置 - Google Patents

中空体成形装置 Download PDF

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Publication number
JP4740028B2
JP4740028B2 JP2006125730A JP2006125730A JP4740028B2 JP 4740028 B2 JP4740028 B2 JP 4740028B2 JP 2006125730 A JP2006125730 A JP 2006125730A JP 2006125730 A JP2006125730 A JP 2006125730A JP 4740028 B2 JP4740028 B2 JP 4740028B2
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Japan
Prior art keywords
hollow
infrared
semi
mold
hollow member
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JP2007296700A (ja
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将史 湯下
健志 谷垣
正三 西田
孝志 上村
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Japan Steel Works Ltd
Aisin Corp
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Aisin Seiki Co Ltd
Japan Steel Works Ltd
Aisin Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006—Joining parts moulded in separate cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1412—Infrared [IR] radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface direct heating of the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
    • B29C65/1467—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous welding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being non-straight, e.g. forming non-closed contours
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/841—Machines or tools adaptable for making articles of different dimensions or shapes or for making joints of different dimensions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • B29C66/91423—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools using joining tools having different temperature zones or using several joining tools with different temperatures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91651—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006—Joining parts moulded in separate cavities
    • B29C2045/0063—Joining parts moulded in separate cavities facing before assembling, i.e. bringing the parts opposite to each other before assembling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006—Joining parts moulded in separate cavities
    • B29C2045/0074—Joining parts moulded in separate cavities inserting a heating tool inside the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/91653—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating by controlling or regulating the voltage, i.e. the electric potential difference or electric tension

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

本発明は、射出成型した半中空部材同士を加熱溶着して中空体を成形する中空体成形装置に関する。さらに詳しくは、接合面が三次元曲面形状を有する樹脂部材の中空体成形装置に関する。
ポリタンク、ブレーキ液タンク、スプレータンク、ブイなどの剛性樹脂製の中空体製品の製造方法としては、射出成形機による成形方法が知られている。射出成形機により中空体製品を製造する場合は、一次形成において中空体を二つ割りの半中空体あるいは分割体として形成し、二次形成においてその分割面を突き合わせ、そして突き合わせた部分を加熱あるいは溶着して一個の中空体製品を製造している。この射出成形機を用いた成形方法によると、完全に密封された中空体製品を作ることができるとともに、均一な肉厚の中空体製品を得ることもでき、また、複雑な形状にも対処できるので多用されており、中空体成形装置や中空成形体の製造方法に関しては従来から多くの提案がなされている。
例えば、特許文献１には、一次成形で半中空部材をセット成形した後、これらの半中空体をその接合部が対向するように重ね、各々の接合部の内面側を加熱して加圧溶着して中空体製品を得る成形方法が開示されている。ここでは、電熱コイルや抵抗ヒータなどの電気発熱体を接合部内部に埋設して溶着する、あるいは接合部の内面側を熱風で加熱して溶着することを特徴としている。
しかし、接合部に電熱コイルを埋設したり、熱風を送通する流路を形成する必要があり、複雑な構成となり、中空体の量産には適当ではない。特に、接合面が三次元曲面形状を有する中空体には不向きである。
また、特許文献１と同様の方法で半中空部材を成形し、対向配置した半中空部材同士の空間部に熱板を挿入するとともに、この熱板を半中空部材に押し付けてその接合面を加熱溶融させる中空体の成形装置が提案されている（特許文献２、３参照）。
しかし、この成形装置では、熱板を樹脂からなる半中空部材の接合面に直接押し付けるため、例えばＰＡ６のようなエンジニアプラスティック材料によっては、熱板に加熱溶融された樹脂が焦げ付いて付着したり、糸引きするなどの不具合を生じて良好な溶着接合部を確保できない虞がある。つまり、熱板を直接接合部に押し付けて加熱するという接合面の溶融方法は、生産に使用できる樹脂材料の種類が制約されるという問題がある。
また、提案されている熱板は平板形状であるので、溶着面が二次元平面の場合には接合面の全面に密着させて接合部を加熱溶融させることが可能であり、製品毎に異なる形状の熱板を準備する必要がなく共通性を持たせることができる。しかし、接合面が三次元曲面形状で製品毎に接合面形状が異なる場合には、熱板を三次元曲面化する必要があると同時に製品毎に異なる形状の熱板を準備する必要がある。このためコスト高となる。
上記のように熱板を直接接合面に押し付けることなく、熱板を接合面と適切な隙間を設けて配置して輻射熱で接合面を溶融させることも可能である。しかし、この場合には、熱板と接合面との隙間を１〜２ｍｍ程度に制御する必要がある。このため成形寸法バラツキや熱源位置のバラツキを考慮すると、接合面が三次元曲面形状を有する製品では、接合面全体にわたって熱板との隙間を１〜２ｍｍ程度に制御して、接合面の全面に均一に熱量を与えて溶融させることは困難である。
以上のように、特に、接合面が三次元曲面形状を有する中空体において、接合面を適切に加熱できる加熱体を備えた中空体成形装置の開発が望まれていた。
特開平７−１６９４５号公報 実用新案第３００７１６６号公報 特開平１０−１６６４４９号公報
本発明は、上記の問題を解決するためになされたもので、三次元曲面形状の接合面を有する樹脂部材の接合面を均一に加熱溶融可能な加熱体を備えた中空体成形装置を提供することを課題とする。
本発明の中空体成形装置は、所定の間隔を隔てて第１凸部と第２凹部とを有する第１金型と、所定の間隔を隔てて第１凹部と第２凸部とを有する第２金型とを備え、第１金型と第２金型とを対向して当接することで、第１凸部と第１凹部とにより第１キャビティを、また第２凹部と第２凸部とにより第２キャビティを形成し、この第１キャビティと第２キャビティに溶融樹脂を注入して各々三次元曲面形状の接合面を有する第１半中空部材と第２半中空部材とを形成し、第１凹部に保持された第１中空部材と、記第２凹部に保持された第２中空部材とを隙間を持って対向配置するとともに、加熱手段により各々の接合面を加熱溶融して圧接することで第１半中空部材と第２半中空部材とを溶着する中空体成形装置であって、前記加熱手段は、所定形状の基板の両面に複数の赤外線照射体を隣接して配置した加熱体を備えるとともに、接合面に対向する赤外線照射体の接合面までの照射距離に応じて、赤外線照射体の出力を個別に制御する制御装置を有することを特徴とする。
また、本発明の中空体成形装置において、赤外線照射体は、通電により赤外線を発生する赤外線ランプと、この赤外線ランプを支持し発生した赤外線を反射する反射面を有する支持部材と、照射する赤外線を収斂するレンズとを備えることが望ましく、赤外線ランプはハロゲンランプを用いることができる。
本発明の中空体成形装置は、接合（以後、溶着ともいう）面を加熱溶融する加熱手段の加熱体（熱板ともいう）に赤外線照射体（赤外線発熱体ともいう）を用いているので、接合部が数十ｍｍ離れた位置でも接合面を溶融することが可能である。このため、加熱体に樹脂材料が付着したり糸引きの心配がないため、中空体の適切な溶着状態を確保できる。
また、加熱体に設けられた複数の赤外線照射体の出力をそれぞれ個別に制御することができるので、溶着曲面形状と赤外線の照射距離に合わせて赤外線出力を赤外線照射体毎に変化可能である。これ故、三次元曲面形状を有する中空品を容易に且つ高品質で製造できる。
さらに、加熱体は、平板治具へ赤外線照射体を隣接して多数埋め込んだ構成であるから、溶着形状毎に品番切り替えすることでその形状に見合った赤外線照射体が点灯し、溶着面形状が異なる製品でも加熱体の共通化が可能でありコストを低減できる。
以下、本発明の実施の形態について図を参照しながら説明する。
図１は、本発明の実施の一形態を示す主要部概略構成図であり、型締め前の状態を示している。
本態様の中空体成形装置１は、可動金型（第１金型）１０と、固定金型（第２金型）２０とを備えており、固定金型２０はシリンダ３０により基盤４０に沿って上下方向にスライド可能なスライド金型である。可動金型１０には所定の間隔を隔てて第１凸部１２と第２凹部１４とが形成されている。また、固定金型２０には所定の間隔を隔てて第２凸部２２と第１凹部２４とが形成されている。
上記の構成を有する中空体成形装置１の動作を中空体の製造手順に沿って説明する。
まず、可動金型１０を固定金型２０に対して型締めすることで、第１凸部１２は第１凹部２４と協働して第１キャビティを形成し、第２凸部２２は第２凹部１４と協働して第２キャビティを形成する。
そして、このようにして形成された第１キャビティと第２キャビティに、スライド金型２０の略中央部に設けられたスプール２６を介して射出機のノズル（図示しない）から射出される溶融樹脂を充填することで第１半中空部材Ａと第２半中空部材Ｂとを形成する。
図２は、キャビティに樹脂を充填した状態を示している。
次いで、可動金型１０を後退させ、続いてスライド金型２０を第１半中空部材Ａが保持されている状態で上方にスライドさせる。この時、第１半中空部材Ａの接合部（溶着面）が、第２半中空部材Ｂの接合部（溶着面）に対向するまでスライドさせる。
第１半中空部材Ａの接合部と第２半中空部材Ｂの接合部とは隙間を持って対向しているので、この隙間に加熱体Ｈを配置して各接合部表面が溶融するまで加熱する。接合部表面が均一に溶融されたら加熱体Ｈを金型外部へ後退させて、可動金型１０を固定金型２０に対して型締めし、第１半中空部材Ａの接合部（溶着面）と第２半中空部材Ｂの接合部（溶着面）とを当接させて圧接する。図３は半中空部材Ａ、Ｂの接合面Ａ１、Ｂ１を加熱体Ｈで加熱している状態を示している。
半中空部材Ａ、Ｂを溶着して接合部が冷却したら可動金型１０を後退させて成形された中空体を取り出し、スライド金型２０を下方にスライドさせて図１の状態に戻す。これにより中空体成形の１サイクルが完了する。
次に、本発明の中空体成形装置１における加熱手段２について説明する。
図４に示すように、加熱手段２は、多数の赤外線照射体Ｒを有する加熱体Ｈと、加熱体Ｈを金型に対して進退可能な油圧シリンダなどの駆動手段Ｓと、加熱体Ｈの電源Ｅと、赤外線照射体Ｒの出力を個別に制御する制御装置Ｃとで構成されている。
図５に加熱体Ｈの一例を斜視図で示す。加熱体Ｈは対向している半中空部材Ａと半中空部材Ｂとの間に進出して配置されている。そして基板５０に埋設された赤外線照射体Ｒにより接合面Ａ１と接合面Ｂ１とを加熱することができる。なお、図５では金型を省略して示している。
また、図６には図３の円Ｉの部分を拡大して加熱体Ｈの断面を模式的に示す。赤外線照射体Ｒは基板５０の両面にそれぞれ隣接して埋設されており、赤外線Ｌを発生する赤外線ランプ５２と、赤外線ランプ５２を支持し赤外線Ｌを反射する反射面５４ａを有する支持部材５４と、照射する赤外線Ｌを収斂するレンズ５６とを備えている。
この赤外線照射体Ｒの出力は制御装置Ｃによって個別に制御することができる。制御方法について図７及び図８を用いて説明する。
図７は加熱体Ｈの正面概念図であり、多数の赤外線照射体Ｒが碁盤目状に配置されている。図７で曲線ａと曲線ｂとで囲まれた範囲は、例えば、半中空部材Ａの接合面Ａ１の投影面Ａ１´である。このような形状の半中空部材Ａを加熱する場合には、投影面Ａ１´が領有する図７の斜線で示す赤外線照射体Ｒ１を通電して点灯する。しかし、その他の赤外線照射体Ｒ０は通電しないので点灯しない。つまり、加熱手段は、第１半中空部材及び第２半中空部材の接合面に対応する投影面に配置された赤外線照射体を通電させることができる。
図８は図７のＸ−Ｘ´断面を示す模式図である。接合面Ａ１は三次元曲面であるので対向する各々の赤外線照射体Ｒの接合面Ａ１までの照射距離ｄが異なる。このため、各赤外線照射体Ｒから照射した赤外線の受熱量が接合面Ａ１でほぼ均一になるように、各赤外線照射体ｒ１〜ｒ１２の出力を個別に制御する。
まず、半中空部材Ａの投影面Ａ１´が領有しない範囲の赤外線照射体ｒ１、ｒ２、ｒ９〜ｒ１２は通電しない。そして半中空部材Ａの接合面Ａ１に対向する赤外線照射体ｒ３〜ｒ８は照射距離ｄによって出力を変化させる。例えば、赤外線照射体ｒ３とｒ８とに負荷する電圧をＶ１、赤外線照射体ｒ４とｒ７とに負荷する電圧をＶ２、赤外線照射体ｒ５とｒ６とに負荷する電圧をＶ３とし多場合には、Ｖ１＜Ｖ２＜Ｖ３となるようにするとよい。ここで赤外線照射体ｒ３〜ｒ８の出力をそれぞれの照射距離に従って全く個別に制御してよいことは勿論である。
なお、照射距離ｄは数ｍｍ〜数十ｍｍとすることができるが、５〜３０ｍｍ程度とすることが好ましい。また、加熱時間は半中空部材の樹脂材料にもよるが、概ね５〜２５秒程度が好ましい。赤外線ランプ５２は赤外線（赤外線波長：０．８〜１０００μｍ）を発生できるものであれば特に制約はないが、ハロゲンランプ、カーボンランプ、あるいは半導体やＹＡＧなどのレーザ光線などを好適に用いることができる。
以上のように、本態様の加熱体Ｈを用いることにより赤外線Ｌの接合面Ａ１における受熱量を均一にすることができるので、樹脂部材である中空体の変形や溶着不足による接合部の強度低下といった不具合を生じることがない。また、接合面に対応する部位の赤外線照射体のみを通電して加熱することができるので、加熱体のエネルギ効率を向上することができる。
本態様の加熱手段によれば、形状や樹脂材料の異なる中空体製品毎に好適な赤外線照射体の出力を制御装置にマトリックスとして設定することができる。すなわち、異なる三次元曲面形状を有する半中空部材についても加熱体を変更することなく同一の加熱体Ｈを用いて適切な加熱溶融を施し、良好な溶着中空体を得ることができる。
本発明の中空体成形装置は、分割した半中空樹脂部材を金型中で溶着する中空体の成形装置として好適である。特に溶着部が三次元曲面形状を有する中空体の成形装置として有用である。
中空体成形装置の主要部構成を示す概略断面図である。 型締めしてキャビティに溶融樹脂を充填した状態を示す概略断面図である。 対向配置した半中空部材の接合部を加熱する状態を示す概略断面図である。 加熱手段の構成を説明する説明図である。 加熱体の一例を示す斜視図である。 加熱体の断面を示す部分模式図である。 接合面と赤外線照射体との関係を説明する説明図である。 図７のＸ−Ｘ´断面模式図である。
符号の説明
１０：可動金型 ２０：固定（スライド）金型 １４：第１凹部 ２４：第２凹部 ２６：スプール ５０：基板 ５２：赤外線ランプ ５４：支持部材 ５６：レンズ
Ａ、Ｂ：半中空部材 Ｃ：制御装置 Ｈ：加熱体 Ｌ：赤外線 Ｒ：赤外線照射体

Claims (3)

  1. 所定の間隔を隔てて第１凸部と第２凹部とを有する第１金型と、所定の間隔を隔てて第１凹部と第２凸部とを有する第２金型とを備え、
    前記第１金型と前記第２金型とを対向して当接することで、前記第１凸部と第１凹部とにより第１キャビティを、また前記第２凹部と前記第２凸部とにより第２キャビティを形成し、
    前記第１キャビティと前記第２キャビティとに溶融樹脂を注入して各々三次元曲面形状の接合面を有する第１半中空部材と第２半中空部材とを形成し、
    前記第１凹部に保持された前記第１中空部材と、前記第２凹部に保持された前記第２中空部材とを隙間を持って対向配置するとともに、加熱手段により各々の前記接合面を加熱溶融して圧接することで前記第１半中空部材と前記第２半中空部材とを溶着する中空体成形装置であって、
    前記加熱手段は、所定形状の基板の両面に複数の赤外線照射体を隣接して配置した加熱体を備えるとともに、該接合面に対向する該赤外線照射体の該接合面までの照射距離に応じて、該赤外線照射体の出力を個別に制御する制御装置を有することを特徴とする中空体成形装置。
  2. 前記赤外線照射体は、赤外線を発生する赤外線ランプと、該赤外線ランプを支持し発生した前記赤外線を反射する反射面を有する支持部材と、照射する赤外線を収斂するレンズとを備える請求項１に記載の中空体成形装置。
  3. 前記赤外線ランプはハロゲンランプである請求項２に記載の中空体成形装置。
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JPH10166449A (ja) * 1996-12-09 1998-06-23 Nissan Motor Co Ltd 樹脂成形品の溶着接合装置および同溶着接合方法

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* Cited by examiner, † Cited by third party
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JPH08309919A (ja) * 1995-05-22 1996-11-26 Nippon Carbide Ind Co Inc 真空積層装置
JPH10166449A (ja) * 1996-12-09 1998-06-23 Nissan Motor Co Ltd 樹脂成形品の溶着接合装置および同溶着接合方法

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