JP4043638B2 - Method and apparatus for forming irregular gasket - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for forming an amorphous gasket by discharging a high viscosity material and an apparatus for carrying out the method.
[0002]
[Prior art]
Conventionally, as a method for forming a gasket on the surface of an article, there is a technique described in JP-A-3-121375. According to the technique described in the publication, a gasket material is first applied on the surface of an article to form an elongated bead. Next, a mold having an elongated cavity having substantially the same cross-sectional area as the bead over its entire length is applied to the article surface and the bead. Then, after the bead has hardened, it is demolded to form a gasket having the required bead height on the article.
[0003]
[Problems to be solved by the invention]
However, the above conventional technique requires a step of applying the mold to the bead, which complicates the procedure for forming the gasket, and there is a problem that the formation time and cost are required accordingly. Moreover, in accordance with the shape, cross-sectional area and length of the gasket to be formed on the article, a matching mold must be prepared each time, and a wide variety of gaskets that can be formed in arbitrary shapes and dimensions. There was a problem that it could not respond quickly to various applications.
[0004]
In order to solve this problem, a forming method may be considered in which a bead is formed while directly applying the gasket material discharged from the discharge nozzle to the surface to be coated without using a mold, but there is a problem shown in FIG. . That is, as shown in the upper diagram of the figure, when a discharge nozzle having a normal discharge diameter is used, it is difficult to control the application position of the gasket material if the distance between the workpiece (surface to be applied) and the nozzle is large. It becomes. For this reason, the coating height is limited (for example, a maximum of 5 mm), and the bead diameter cannot be formed more than this coating height (Problem (1)). Of course, even if the nozzle discharge diameter is simply increased, a sufficient discharge pressure cannot be obtained and application becomes difficult.
[0005]
Further, as shown in the lower diagram of FIG. 10, the applied bead flows at the top of the convex portion during the curing process, sagging into a flat cross-sectional shape, and the ratio of the bead vertical diameter to the bead horizontal diameter (aspect ratio). Becomes smaller. For this reason, the gasket function of the formed beads is lowered, that is, the sealing performance and the buffering performance are deteriorated (Problem (2)).
[0006]
The present invention has been made in view of the above-mentioned facts. An amorphous gasket having a better aspect ratio and an excellent sealing property and buffering property can be used for various uses, shapes and dimensions without using a mold. It is an object of the present invention to provide a gasket forming method and apparatus that can be easily and quickly formed.
[0007]
In addition, the present invention provides a gasket that can be easily and quickly formed into a gasket having a sufficiently large bead diameter in addition to excellent sealing performance and cushioning performance at a larger aspect ratio, and corresponding to various applications, shapes, and dimensions. It is an object to provide a forming method and apparatus.
[0008]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, the invention of claim 1 is a method of forming an irregular gasket, comprising a supply step of supplying a high-viscosity material, and the high-viscosity material supplied in the supply step on the surface to be coated. A discharge step of discharging, and a curing step of curing the high-viscosity material discharged in the discharge step and applied to the surface to be coated with the high-viscosity material cured in a state where the top portion is directed substantially vertically downward. It is composed of
[0009]
In the invention of claim 1, since the high-viscosity material ejected in the ejection process and applied to the surface to be coated is cured with the top portion thereof facing substantially vertically downward, the material is The dripping of the high-viscosity material is prevented by the action of gravity downward in the vertical direction before being completely cured, or the material that has been dripped during the discharging process is also elongated in the vertical direction. Thereby, the high-viscosity material after curing does not become flat, and a good aspect ratio can be obtained. Further, since the material is cured in a state where the top of the high-viscosity material faces vertically downward, it is possible to prevent asymmetric deformation of the cross section of the irregular gasket.
[0010]
In the first aspect of the invention, in the discharging step, the high-viscosity material may be discharged onto the surface to be coated so that the top of the applied high-viscosity material is already vertically downward. For example, this case includes a case where a high-viscosity material is discharged from the bottom to the top with the surface to be coated facing downward. Conversely, the high-viscosity material may be discharged from the top to the bottom with the surface to be coated facing upward.
[0011]
In the latter case, as in the invention of claim 2, in the discharge step of claim 1, the high-viscosity material supplied in the supply step is discharged downward onto the surface to be coated, and next to the discharge step. It is most preferable that the method further includes a reversing step in which the surface to be coated is turned upside down so that the top of the high-viscosity material applied to the surface to be coated is substantially vertically downward. The invention of claim 2 is advantageous in that the material can reach the application surface without increasing the discharge pressure of the high-viscosity material, and can be applied to a method of use in which the applied high-viscosity material is not adhered to the application surface. There is.
[0012]
In the inversion step of claim 2, when a part of the surface of the member having the surface to be coated is formed, as an example, the member is gripped by a robot hand or the like, and inverted in this state, A method of reversing the conveyance path of the member can be considered. It is also possible for the operator to perform the reversal through manual operation.
[0013]
According to a third aspect of the present invention, in the discharge step according to the first or second aspect, the high-viscosity material is discharged to a surface to be coated through a nozzle, and the nozzle is a material passage provided in the nozzle. The inner diameter is formed so as to gradually decrease to a predetermined position in the direction toward the nozzle tip and gradually increase from the position to the nozzle tip.
[0014]
In the invention of claim 3, when the high-viscosity material passes through the region where the diameter is gradually reduced, the internal pressure gradually increases, and when the high-viscosity material reaches the gradually expanded region, the large internal pressure is rapidly released, The material flow is expanded and discharged from the nozzle tip. As described above, in the present invention, a sufficient discharge pressure can be ensured even when the inner diameter of the nozzle tip is increased, so that it is possible to form an indeterminate gasket having an outer diameter larger than that of a conventional nozzle. In particular, it is useful when a foam material in which fine bubbles of gas are dispersed and mixed in the material is used as the high viscosity material.
[0015]
The high-viscosity material supplied in the supply step according to any one of claims 1 to 3 is a hot melt composition that is solid at room temperature, as in the inventions of claims 4 to 6. You may select from a thermosetting composition and a moisture-curable composition. In this case, in the curing step, holding at normal temperature, heat treatment, and moisture treatment are applied according to the selected composition. In the present invention, the high-viscosity material after application is not immediately cured immediately after the top portion is directed substantially vertically downward, and if it has a certain degree of fluidity, the material that is dripped when it is discharged will extend downward. Therefore, it is preferable to use a thermosetting composition or a moisture curable composition. However, even a room-temperature solid hot melt composition can be sufficiently applied when it takes a long time to cure, or when the discharge process is shorter than the curing time. Alternatively, the discharge process may be performed at a temperature lower than room temperature.
[0016]
Further, as in the invention of claim 7, the high-viscosity material supplied in the supply step according to any one of claims 1 to 3 is dispersed and mixed with fine gas bubbles in the material. It may be a foamed material.
[0017]
In the invention of claim 7, since the amorphous gasket is formed of a foam containing fine bubbles, it is lighter than a simple high-viscosity material bead, and less stress is required when compressing. A seal portion having hardness can be provided.
[0018]
According to a seventh aspect of the present invention, the supply step of supplying a foam material provides a piston pump in which a suction step and a discharge step are performed by reciprocating a piston in a cylinder. A high-viscosity material that is in a fluidized state in the piston pump containing the gas after the gas is introduced into the piston pump when the cylinder has negative pressure in the process and the suction process is completed. The gas and the high-viscosity material mixed in the cylinder are discharged from the discharge port of the cylinder, and the pumped mixture is elongated. By passing through the dispersion line, the gas bubbles are further sheared and finely dispersed in the high viscosity material. Preferred.
[0019]
In the invention of claim 8, since a good foam in which fine gas is uniformly dispersed and mixed can be supplied by a simple foaming system, the advantages specific to the present invention can be sufficiently exhibited.
[0020]
Furthermore, in the invention of claim 8, as in the invention of claim 9, the gas and high viscosity material mixture pumped from the piston pump is passed through a premixer to finely cut the gas bubbles. At the same time, these gas bubbles are preferably dispersed in the high viscosity material. As a result, the gas bubbles can be dispersed more finely and more uniformly, so that a good foam can be obtained.
[0021]
Further, in the invention of claim 8 or claim 9, as in the inventions of claim 11 and claim 12, the high-viscosity materials to be pump-filled into the piston pump are respectively a thermosetting composition and a moisture-curable composition. It is most preferable for the reasons described above. Of course, a hot melt composition that is solid at room temperature as in the invention of claim 10 can also be applied.
[0022]
The inventions of claims 13 to 24 relate to an apparatus for carrying out the methods of claims 1 to 11 and have the same operational effects.
A twenty-fifth aspect of the invention is the invention according to any one of the thirteenth to twenty-fourth aspects, wherein a manipulator capable of moving the discharge nozzle to an arbitrary position within a predetermined range, and an indeterminate gasket from the discharge nozzle. And a control means for automatically controlling the manipulator so that the discharge nozzle moves along the part to be coated of the article.
[0023]
Thus, in the invention of claim 25, since the discharge of the irregular gasket and the control of the ejection position are automated, the irregular gasket having a good aspect ratio can be mass-produced.
[0024]
The invention of claim 26 is a discharge nozzle for discharging the supplied high-viscosity material onto the surface to be coated, wherein the inner diameter of the material passage provided in the nozzle is a predetermined position in the direction toward the nozzle tip. It is characterized in that the diameter is gradually reduced to a point and gradually increased from the position to the tip of the nozzle.
[0025]
The discharge nozzle according to claim 26 can be applied to any method and apparatus for forming an irregular gasket, and can form an irregular gasket having an outer diameter larger than that of a conventional nozzle.
[0026]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
In the first embodiment, the method for forming an irregular gasket according to the present invention is applied to a mass production method for automatically applying beads of an irregular gasket along an edge of a cover plate of a control panel as an example. An example is shown.
[0027]
FIG. 1 shows a schematic configuration of an irregular gasket forming application system 1. As shown in the figure, the irregular gasket forming and coating system 1 includes a delivery device 10 that discharges the supplied high-viscosity material from the nozzle 12 at the tip to form a bead of the irregular gasket, and a shape-preserving in a fluid state. A high-viscosity material supply unit 16 that supplies a high-viscosity material of a thermosetting composition that has high formability and is cured by heating to the delivery device 10, and supplies air or the like to the delivery device 10, and controls the pressure of the air And a valve control unit 18 for controlling opening and closing of a discharge valve (not shown) provided inside the delivery device. It should be noted that valve opening / closing control may be electrically driven based on a command signal instead of air.
[0028]
In addition, since the delivery device 10 is used for automatic molding and coating for mass production, the delivery device 10 can move the tip portion of the manipulator 60 that can move the tip portion to an arbitrary position within a predetermined region in accordance with a command signal. It is attached to the tip. Further, the irregular gasket forming and coating system 1 includes a transport device 65 that sequentially transports the plurality of cover plates 23 arranged on the work table 67 to a position where the cover plate 23 can be applied, and the cover plate 23 on the transport device 65 is a predetermined plate. A detection sensor 25 for detecting that the sheet has been transported to the application position, an image sensor 26 for imaging a bead of a lid plate 23 and an amorphous gasket molded and applied on the cover plate, and a cover plate 23 after bead application. Control and manage the entire system 1, a reversing device 70 having a function of reversing up and down, a heating furnace 90 for heating the coating bead of the cover plate reversed up and down to a predetermined temperature, and the bead. A controller 22, a storage device 24 storing data necessary for bead molding application, and an input / output port for controlling an input / output interface between the controller 22 and other components. Is provided with a door 20, a.
[0029]
These constituent elements can be realized by a known technique. For example, the detection sensor 25 may be composed of a combination of a light emitting diode that emits light at the predetermined position and a phototransistor arranged to detect the light of the diode. In this case, the cover plate 23 is a light emitting diode. It can be considered that the cover plate 23 has come to the predetermined position at this time. The image sensor 26 can also be constituted by a so-called CCD (charge coupled device). The controller 22 can be realized by a microprocessor or a personal computer that performs various processes such as image analysis based on a CCD image and so-called PI (proportional integration) control according to a predetermined program.
[0030]
Next, specific configuration examples of the reversing device 70 and the heating furnace 90 will be described with reference to FIG. According to the example shown in the figure, the reversing device 70 is composed of a robot arm as a whole, and the structure is described as a motor car that can move freely along the rail 71 in accordance with a control signal from the controller 22. 72, a pair of arms 73 rotatably supported by rotating shafts 75 respectively extending from both side surfaces of the motor car 72, and attached to the distal end portion of the arms 73 so as to grip an object A pair of configured robot hands 76 and a hand drive unit 74 that is interposed between the arm 73 and the robot hand 76 and electrically drives the robot hand 76 in accordance with a control signal from the controller 22 are provided.
[0031]
Of these, the hand drive unit 74 not only grips and separates the object by opening and closing the robot hand 76, but also rotates the robot hand 76 itself at an arbitrary angle around the rotation axis 77 extending substantially horizontally. An electric motor (not shown) is built in.
[0032]
The arm 73 is composed of an upper arm portion 73a and a lower arm portion 73b, and the robot arm 76 can move up and down by the lower arm portion 73b sliding in the upper arm portion 73a by driving means (not shown). You may do it. In addition, although not shown, a distance between the left and right robot hands 76 may be freely adjusted by providing a drive mechanism in which the pair of arms 73 move in parallel along the axial direction of the rotation shaft 75.
[0033]
In addition, the heating furnace 90 includes a cavity portion 91, an opening 96 above the cavity portion 91, a mounting table 95 for placing the application surface of the cover plate 23 facing the opening 96, and an opening 96. A temperature sensor 94 disposed in the vicinity of the heater, and a heater 92 that is disposed at the bottom of the cavity 91 and includes a temperature adjusting means (not shown) for keeping the temperature detected by the temperature sensor constant. ing.
[0034]
Among them, the heater 92 and the temperature sensor 94 may be electrically connected to the controller 22 so that the heaters can be turned on / off and the temperature can be adjusted by commands from the controller 22. Moreover, the structure which controls heating independently from the controller 22 may be sufficient. The heating furnace 90 may be provided with an enclosure for preventing heat diffusion at the top of the placed lid plate 23. Moreover, you may comprise the heating furnace 90 from a microwave oven etc.
[0035]
Next, the configuration of the internal cross section of the nozzle 12 will be briefly described with reference to FIG. As shown in the figure, the nozzle 12 gradually decreases in diameter in the direction toward the nozzle tip 100 in a region 102 where the inner diameter of the material passage provided in the nozzle is a predetermined distance V or more away from the nozzle tip 100. It is formed to have an inner diameter φ1 at a predetermined distance V. In the region 104 from this position to the nozzle tip 100, the inner diameter gradually increases in a trumpet shape, and is formed so as to be φ2 (> φ1) at the nozzle tip 100. The specific dimensions of φ1, φ2, and V, and the three-dimensional shape of the inner walls of the regions 102 and 104 (the truncated cone in the example of FIG. 3A) depend on, for example, a desired discharge amount and discharge speed. Furthermore, it can be set as appropriate according to the shape of the discharge bead. In addition, when a foam material is used as the high viscosity material as in the second embodiment described later, this also depends on the foaming condition of the foam material.
[0036]
The high-viscosity material supply unit 16 in FIG. 1 can be realized by a very simple configuration shown in FIG. 4 when a high-viscosity material that is not a foam material is used. As shown in the figure, the high-viscosity material supply unit 16 was discharged with a storage can 47 for storing the high-viscosity material, a pump 48 for discharging the high-viscosity material stored in the storage can at a constant flow rate, and the like. A valve 49 that opens and closes a flow path of the high-viscosity material, a check valve 50 for preventing a backflow, and a conduit 51 connected to the material supply port 11a of the delivery device 10 are configured. As the pump 48, for example, a follower plate type plunger pump can be used. The pump 48 and the valve 49 are controlled by the controller 22.
[0037]
Here, as the high-viscosity material stored in the storage can 47, a thermosetting composition that cures at a relatively low temperature of about 60 to 80 ° C. in a short curing time is preferable. In addition, it is preferable to select a material that exhibits low dynamic viscosity in a flow in a high speed region and fluidity, and that exhibits a high static viscosity in a flow in a low speed region and high shape retention. Accordingly, the delivery pressure of the pump 48 is selected so that the high-viscosity material supplied to the delivery device 10 is discharged in a high speed region.
[0038]
As in this embodiment, when a bead is to be attached or adhered to the cover plate 23 of the control panel, the high-viscosity material has adhesiveness or adhesiveness on the contact surface with the cover plate 23 when cured. The material is selected so that it does not have adhesiveness or adhesion on the non-contact surface. However, in the case where an adhesive is applied in advance to the application site of the lid plate 23 and a high-viscosity material is discharged thereon, a high-viscosity material having no adhesiveness may be selected.
[0039]
Next, the operation of the first embodiment will be described.
The lid 23 of the control panel arranged on the work table 67 at a predetermined interval is sequentially conveyed by the conveying device 65 into the movable region of the manipulator 60 (the conveying direction is a direction perpendicular to the paper surface of FIG. 1). ). Here, a top view of the cover plate 23 is shown in FIG. The application site is a portion 56 along the edge of the lid plate 23.
[0040]
When the detection sensor 25 detects that the lid plate 23 has been transported to a predetermined position, the transport device 65 temporarily stops. Then, the controller 22 moves the delivery device 10 to control the manipulator 60 so that the nozzle 12 faces vertically downward just above a predetermined start position of the cover plate 23, and supplies the valve control unit 18 and the high-viscosity material. The part 16 is controlled to discharge the high-viscosity material from the nozzle 12 in a high-speed flow state.
[0041]
The flow velocity of the high-viscosity material discharged vertically downward from the nozzle 12 is in a high-speed range due to the supply pressure, and thus its dynamic viscosity is low, so that it can be flexibly formed by moving the nozzle. Then, when the flow of the high-viscosity material in the high speed region hits the portion to be coated of the lid plate 23, the flow speed decreases to the low speed region. For this reason, static viscosity becomes high and it apply | coats to a to-be-coated site, maintaining the shape at that time. Since the nozzle 12 is controlled to move along the application site 56 in this state, the high-viscosity material is shaped and applied in a shape along the application site of the lid plate 23. Even if the part to be coated has another arbitrary shape, the bead can be freely formed along the part.
[0042]
At this time, since the high-viscosity material passes through the region 102 where the diameter is gradually reduced in the nozzle 12, the internal pressure gradually increases, and when the diameter reaches the gradually expanded region 104, the large internal pressure is rapidly released. The flow of the high-viscosity material is discharged from the nozzle tip 100 while spreading in a trumpet shape along the inner wall of the region 104. Thus, in this embodiment, even if the diameter of the nozzle tip 100 is increased, a sufficient discharge pressure can be secured. Therefore, as shown in FIG. 56 can easily generate fluidized beads, resulting in a larger outer diameter φ compared to conventional nozzles. _Three Bead can be formed. In addition, the cross-sectional shape of a bead can be arbitrarily changed suitably by changing the cross-sectional shape of the area | region 104 of the nozzle 12 arbitrarily.
[0043]
With the procedure as described above, the controller 22 controls the manipulator 60 so that the beads are formed and applied along the entire circumference of the application site 56 (FIG. 5A). During the molding application, the CCD sensor 25 images the applied bead and constantly transmits the image data to the controller 22 via the input / output port 20. The controller 22 analyzes the received image data in real time, extracts the contour of the tip portion of the bead actually applied, and calculates the actual application position at the present time. Then, a target application position that is a target at that time stored in advance in the storage device 24 is read, a deviation between the calculated actual application position and the read target application position is calculated, and a predetermined control algorithm ( In accordance with, for example, PI control, the manipulator 60 is controlled so that the deviation is substantially equal to zero, and the discharge position of the nozzle 12 is accurately adjusted.
[0044]
Here, when the bead 57 has been applied to one cover plate 23, it may be automatically determined whether or not this molding application has been performed satisfactorily. For example, the entire image of the bead 57 that has been applied by the CCD sensor 26 is captured, and the image data is transmitted to the controller 22. The controller 22 analyzes the received image data, detects the entire contour of the bead 57, and extracts the feature pattern. In addition, the reference feature pattern of the accurately applied bead stored in advance in the storage device 24 is read, the actual bead feature pattern is compared with the read reference feature pattern, and the distance value representing the degree of dissimilarity between the two. Is calculated. When the calculated distance value exceeds a certain value, the applied bead is considered to be defective. Otherwise, it is determined that the applied bead is good and the determination result is displayed on a display device (not shown). You may make it make it. The operator can quickly take subsequent actions according to the displayed determination result.
[0045]
As a result, finally, as shown in FIG. 5B, the bead 57 is accurately formed and applied over the entire circumference in the vicinity of the edge of the lid plate 23. Then, the discharge of the delivery device 10 is stopped, the conveying device 65 is started again, the prepared lid plate 23 is then transported to a predetermined position, and the same steps are repeated again in order.
[0046]
On the other hand, the cover plate 23 on which the bead application has been completed is automatically gripped by a pair of robot hands 76 extending from a motor car 72 moving along a rail 71 via an arm 73, as shown in FIG. (Step {circle around (1)}) is moved to a position away from the transfer device 65 (Step {circle around (2)}). Then, the robot hand 76 rotates about 180 degrees around the rotation shaft 77 while holding the cover plate 23 (steps (2) and (3)). At this time, the surface to be coated of the lid plate 23 is turned upside down, and the top of the bead is directed substantially vertically downward (step (3)). Next, the motor car 72 moves to the heating furnace 90, where the robot hand 76 keeps the cover plate 23 of the mounting table 95 of the heating furnace 90 so that its application surface faces the opening 96 while being inverted upside down. Place on top. At this time, the top of the bead 57 is substantially vertically downward. Next, the heating furnace 90 heats the bead 57 of the placed cover plate 23 at the curing temperature (for example, 60 ° C. to 80 ° C.) of the bead thermosetting composition (step (4)). During this heating, the arm 73 may be rotated around the rotating shaft 75 and the robot hand 76 may be retracted above the heating furnace 90.
[0047]
After the curing time of the thermosetting composition of the bead 57 has elapsed, the robot arm 57 grips the cover plate 23 again, moves away from the heating furnace 90, and again rotates about 180 degrees around the rotation shaft 77. Rotate to bring the coated surface back upward again (step (5)). Thereafter, the motor car 72 moves while gripping the completed cover plate 23, for example, for distribution to a product sorting process. In addition, the rail 71 may form a closed curve as a whole so that the motor car 72 can return and circulate again from the place of the product sorting process to the place of the conveying device 65. Needless to say, the above-described curing step of the bead 57 may be systematically continuous or batch-type.
[0048]
As described above, in the present embodiment, the applied bead 57 is cured in a state where the top portion thereof is directed substantially vertically downward, so that the material does not sag and become flat, and the line SS ′ in FIG. A very good aspect ratio is obtained, as shown in the bead cross section taken along the line. For example, conventionally, the bead height: width ratio was 1: 2, but in this embodiment, the bead height: width ratio can be approximately 1: 1. Further, since the top of the bead does not become flat, the sealing performance and the buffering performance can be remarkably improved.
[0049]
As described above, the present embodiment can be easily applied to a portion requiring a seal height such as a car lamp body seal or a door seal, and can be applied to various applications by arbitrarily changing the application position. Yes. In addition, as described above, there is an advantage that a bead having a larger diameter can be easily formed by using the nozzle 12 having the gradually reduced diameter and the gradually expanded inner diameter.
(Second Embodiment)
In the second embodiment, an irregular gasket bead made of a foam material is formed. For this reason, the structure of 2nd Embodiment becomes what replaced the high-viscosity material supply part 16 with the mechanical foaming system 17 in FIG. Since the other constituent elements are the same as those in the first embodiment, the same reference numerals are given and detailed description thereof is omitted.
[0050]
As the mechanical foaming system 17 according to the present embodiment, the most preferable configuration is shown in FIG. As shown in the figure, the mechanical foaming system 17 includes a gas supply unit 37A, a high-viscosity material supply unit 37B, a mixing unit 37C that supplies gas and high-viscosity material, and gas bubbles more finely dispersed in the high-viscosity material. And a dispersion unit 37D.
[0051]
The gas supply unit 37A has a predetermined pressure (0.1 to 5 kg / cm ² Within a range, preferably 0.1 to 3 Kg / cm ² Gas) at a low pressure adjusted by a degree). In this embodiment, a known nitrogen gas generator configured to separate and take out nitrogen gas by a membrane separation type by supplying compressed air is used. Such a gas supply unit 37A includes a port 31 that receives compressed air from a compressor (not shown), a filter 32, a membrane separation module 33, a pressure regulating valve 34, a gas flow meter 35, and separated nitrogen gas. It can comprise from the conduit 39A for supplying.
[0052]
The high-viscosity material supply unit 37B includes a plunger pump 42A that discharges the high-viscosity material stored in the storage can at a constant flow rate, an air motor 30 that drives the pump 42A, and a conduit 39B through which the discharged high-viscosity material flows. And. The high-viscosity material stored in the storage can is preferably a thermosetting composition that cures at a relatively low temperature of 60 to 80 ° C. in a short time.
[0053]
The mixing unit 37C includes two piston pumps 45A and 45B. The piston rods of the piston pumps 45A and 45B are connected to air motors or hydraulic motors 36A and 36B for reciprocating linear drive of the respective pistons. The piston pumps 45A and 45B are configured such that the dead space in the cylinder becomes substantially zero when the discharge process is completed.
[0054]
Further, the gas supply part 37A has a pipe 39A that branches into two, one pipe connected to the vicinity of the top dead center of the piston pump 45A via the control valve V1, and the other pipe connected to the control valve V4. Is connected to the vicinity of the top dead center of the piston pump 45B. Further, the pipe line 39B of the high-viscosity material supply unit 37B branches into two, one pipe line is connected to the vicinity of the bottom dead center of the piston pump 45A via the control valve V1, and the other pipe line is controlled. It is connected to the vicinity of the bottom dead center of the piston pump 45B via the valve V2. That is, the piston pumps 45A and 45B can introduce the high-viscosity material pumped from the high-viscosity material supply unit 37B and the gas sent from the gas supply unit 37A in a batch manner at a predetermined ratio. Yes. Here, the bottom dead center of the piston pump refers to the stroke end of the discharge process, and the top dead center refers to the stroke end of the suction process.
[0055]
Furthermore, the piston pumps 45A and 45B are extended with discharge pipes for discharging the mixture of the gas mixed in the cylinder and the high-viscosity material from the stroke end of the discharge process. Are connected to the valves V5 and V6 and the check valves CV5 and CV6, and are integrated into the conduit 39C.
[0056]
The pipe line 39c is connected to the discharge pipe line 44 and the discharge nozzle 12 via the dispersion part 37D. The dispersion part 37D has two constant flow piston pumps 41A and 41B and a dispersion pipe 43 made of an elongated hose or the like. Moreover, it is preferable to provide the premixer 120 in the front | former stage of a constant flow piston pump in the dispersion | distribution part 37D.
[0057]
As shown in FIGS. 8A, 8B, and 8C, the premixer 120 includes a housing 130 having an inlet 136 connected to the conduit 39C and an outlet 137 connected to the conduit 39D. And a shaft 132 for rotational driving extending along the central axis 140 in the housing, and the shaft has a cross-shaped stirring blade 133 whose blade tip extends to the vicinity of the inner wall 144 of the housing. A plurality of stages are attached at predetermined intervals along the length direction of the shaft, and the housing 130 is formed with bar-like protruding blades 135 protruding so as to enter between adjacent stirring blades from a plurality of locations on the inner wall 144 of the housing. Yes. Referring to FIG. 8C, the cross-shaped stirring blade 133 is formed with a recess 148 between adjacent blade tips 146, and there is a wide gap between the recess and the housing inner wall 144. It is formed.
[0058]
Next, the operation of the second embodiment will be described.
In the second embodiment, a foam is supplied from the mechanical foaming system 17 to the delivery device 10, and the foam is discharged from the nozzle 12. Then, a bead of foamed amorphous gasket is applied to the cover plate 23. And like 1st Embodiment, as shown in FIG. 2, the foam bead which was hardened | cured through the upside down and heating process, and was excellent in the aspect-ratio can be provided.
[0059]
In addition, since this foam bead has many fine bubbles, it is lighter than a bead of a simple high viscosity material, and less stress is required when compressing, thus providing a seal cushioning part with appropriate hardness. can do. As a result, the sealing performance when the control panel is closed with the lid 23 is further improved, and there is an advantage that the lid can be opened and closed easily because it is lighter.
[0060]
Next, the operation of the mechanical foaming system 17 will be described below.
As shown in the timing chart of FIG. 7, in the piston pump (45A, 45B), during the suction process in which the piston moves from the discharge end (bottom dead center) to the suction end (top dead center) in the cylinder. A gas having a predetermined pressure is introduced into the cylinder. At this time, since the inside of the cylinder is in a negative pressure state lower than the atmospheric pressure, it can be introduced with a relatively low pressure gas. This facilitates handling and maintenance of the gas, and can improve safety. In addition, since the piston pumps (45A, 45B) that can be ignored with dead space being substantially zero are used, the volume of the introduced gas can be adjusted with high accuracy.
[0061]
Next, after the gas suction step is completed, the fluidized high-viscosity material is pumped and filled at a relatively high pressure into the piston pumps (45A, 45B) containing the gas with the piston stopped (FIG. 7). Since the high-pressure high-viscosity material is filled in this way, the low-pressure gas previously filled in the cylinder is compressed at a ratio equal to the pressure ratio, and as a result, the volume becomes almost negligible. As described above, in this embodiment, a constant volume piston pump with a negligible dead space is first filled with a gas that undergoes a volume change due to pressure at a low pressure, and then a high-viscosity material that hardly undergoes a volume change due to pressure is added to the above-described high viscosity material. Since the filling is performed at a pressure higher than the gas pressure, the mixing ratio R of the gas and the high-viscosity material can be easily determined according to the pressure ratio, and the foaming ratio can be adjusted. Conversely, the filling pressure of the high-viscosity material is kept constant at a pressure sufficiently higher than the pressure of the gas, and only the pressure of the gas causing the volume change is adjusted, so that the gas when converted to atmospheric pressure and the high-viscosity material The mixing ratio R, that is, the expansion ratio can be easily adjusted with high accuracy.
[0062]
Next, by executing a discharge process for moving the piston from the top dead center to the bottom dead center, the mixture of the gas and the high-viscosity material in the piston pump (45A, 45B) is discharged from the cylinder discharge port. 7). At this time, the gas exists as gas bubbles having a substantially uniform size in the high viscosity material.
[0063]
Next, the mixture of the gas and the high-viscosity material discharged from the piston pump is passed through the premixer 120 in which the shaft 132 is driven to rotate. At this time, the gas bubbles in the high-viscosity material are successively cut when passing through the gap between the rotating cross-shaped stirring blades 133. Further, the flow including the gas bubbles is blocked by the area portion of the stirring blade 133 and the rod-shaped protrusion blade 135 and diffuses in a random direction. Thus, the gas bubbles are more finely dispersed in the high-viscosity material by sequentially repeating the cutting and diffusion of the gas bubbles.
[0064]
Next, the dispersed mixture of the gas and the high-viscosity material that has passed through the premixer 120 is pumped in a pressurized state at a constant flow rate by constant flow piston pumps (41A, 41B). When the discharge of one of the two constant flow piston pumps is completed and the bottom dead center is reached, the mixture is automatically filled into the constant flow piston pump moved to the bottom dead center. On the other hand, while the other constant flow piston pump is discharging, preparations for the next discharge are made. That is, similarly to the behavior of the piston pump, the discharge operation is continuously performed by alternately operating two constant flow piston pumps in a batch manner.
[0065]
Next, the gas / pressure-dispersed mixture of the gas and the high-viscosity material is passed through the dispersion conduit 43. The flow field of the mixture in the dispersion pipe 43 shows a flow velocity distribution in which the flow velocity becomes slow near the pipe wall due to friction with the wall, and the flow velocity becomes high in the center of the pipe line where there is no contact with the wall. A relative speed difference occurs in the radial direction. Therefore, the gas bubbles existing in such a flow field are stretched by a shearing action caused by the radial relative velocity difference, and are shredded into smaller gas bubbles.
[0066]
In addition, since the gas bubble has a specific gravity significantly smaller and a lower viscosity than a high-viscosity material as the diameter increases, the gas bubble tends to move toward a tube wall having a slower flow rate. In the region closer to the tube wall, the relative velocity difference between the flow velocities is larger, so that the gas bubble having a larger diameter is finely cut by a larger shearing force.
[0067]
In this way, when the bubble diameter is ultrafine and mixed in the high viscosity material, the specific gravity difference and the viscosity difference with only the high viscosity material are reduced. A return phenomenon occurs. Here, when the pressure in the pipe line decreases, the volume of the bubble increases and the bubble moves to the pipe wall where it is cut again. Such a phenomenon is repeated, and the gas bubbles are gradually finely and uniformly dispersed in the flow of the high viscosity material. In addition, since there is no member to be driven in the dispersion pipe, heat generation can be suppressed.
[0068]
Finally, a finely dispersed mixture of gas and high viscosity material is discharged from the nozzle 12 into the atmosphere. By depressurizing the finely dispersed mixture to atmospheric pressure, the gas bubbles rapidly expand and a foam of high viscosity material is formed.
[0069]
As described above, the mechanical foaming system 17 having a simple configuration shown in FIG. 6 can easily form a good foam in which the foaming ratio is accurate and the gas bubbles are uniformly finely dispersed in the high viscosity material. . Therefore, each of the above effects according to the present invention can be fully enjoyed.
(Third embodiment)
The third embodiment is not an automatic application system for mass production of each of the above embodiments, but relates to an irregular-shaped gasket forming apparatus capable of manually applying a bead or foam bead to a desired site. The configuration is shown in FIG. In addition, about the structure similar to 1st and 2nd embodiment, the same code | symbol is attached | subjected and detailed description is abbreviate | omitted.
[0070]
As shown in FIG. 9, the irregular gasket forming device 160 is installed on a cart 161 with casters 162, and supplies a supply device 163 that supplies a foam or a high-viscosity material, and a housing side surface of the supply device 163. An extended mounting base 164, a delivery device 10c that is detachably attached to the mounting base 164 via a grip portion 167, and discharges a foam or a high-viscosity material supplied from the supply device, and the delivery device 10c. And a supply hose bundle 168 for connecting the supply device 163 to each other.
[0071]
Of these, the supply device 163 preferably has the configuration shown in FIG. 4 when supplying a high-viscosity material, and the configuration shown in FIG. 6 when supplying a foam.
Further, the delivery device 10c has a grip portion 167 having a discharge switch 167, and is configured to be able to control opening and closing of a valve (not shown) by turning on and off the discharge switch 167. The nozzle 12 has the configuration shown in FIG.
[0072]
By using such an irregular gasket forming apparatus 160, an operator can easily apply a bead or a foam bead to a desired application site. And after application | coating completion | finish, a to-be-coated part is turned upside down using the hand robot etc. which are shown in FIG. 2, and a bead is hardened.
[0073]
Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described examples, and can be arbitrarily and suitably changed within the scope not departing from the gist of the present invention.
For example, in each of the above embodiments, the thermosetting composition is used as the high-viscosity material. However, the present invention is not limited to this, and other materials that are cured by applying conditions other than normal other than the temperature may be used. Any composition can be used. For example, a moisture curable composition that cures when moisture is applied is also a preferred material. In this case, the heating furnace 90 shown in FIGS. 1 and 2 is replaced with moisture means for supplying moisture and moisture to the application beads. Further, the temperature sensor 94 in FIG. 2 may be changed to a humidity sensor, and control may be performed so as to maintain the humidity necessary for curing the used moisture curable composition. As described above, in the present invention, it is preferable to use a material that is cured by applying a condition different from the normal after the application is completed, in order to promote the extension of the material downward when it is turned upside down. A solid hot melt composition may be used. In this case, the entire system can be simplified by omitting the heating furnace 90 and the moisture means. Of course, the cover plate 23 may be disposed in a temperature-retaining room or the like during the curing process in order to maintain a constant room temperature.
[0074]
1 is not limited to the example shown in FIG. 2, and any other means can be used. For example, means for holding the cover plate 23 in the system of FIG. 1 is provided on the work table 67 itself, and the work plate 67 is turned upside down together with the work table when the work table 67 is folded back from the end roller of the conveying device. You may make it do. In addition, in the method for forming an irregular gasket according to the present invention, the operator may flip up and down by human power. For example, a method may be considered in which a table for holding the lid plate upside down in a microwave oven or the like is provided, and an operator places the lid plate after bead coating on the table and heats it.
[0075]
In the second embodiment, a mixture of a gas and a high-viscosity material is used as the foaming material. However, the present invention is not limited to this, and for example, a heat-foaming type high-viscosity material or two types You may use the foamable material etc. which are produced | generated by mixing the above composition.
[0076]
Further, in the present embodiment, the mechanical foaming system 17 shown in FIG. 2 is used as the mixing means for the gas and the high-viscosity material, but the present invention does not limit the mixing means to a specific one. There are mixers, gear pumps and so on.
[0077]
Moreover, in the said embodiment, although the lid | cover of the control panel was made into the object of shaping | molding application | coating, this invention is not limited to this, The opening-and-closing body (window glass, resin glass, a plastic plate, and a cover for covering arbitrary openings) All metal doors etc. are included), or it can be applied to parts that require waterproofness, confidentiality, and buffering properties such as fitting parts and gaps.
[0078]
Moreover, in the said embodiment, although the example which apply | coats a bead over the outer peripheral part perimeter of an opening / closing body was shown, this invention is not limited to this, The opening / closing by which the contact | adherence part with an opening part is limited to a part of circumference | surroundings In the case of the body, bead is applied only to that part. That is, the application site can be arbitrarily changed according to the opening / closing body.
[0079]
Furthermore, the present invention is not necessarily limited to the method of applying and bonding to a predetermined application target. For example, the present invention can also be applied to molding a bead or foam bead using a non-adhesive high viscosity material. For example, the beads formed on the coated surface are turned upside down so as not to fall, and after curing, they are separated from the coated surface and cut to a desired length, so that the beads are not attached to any member. It is also possible to make only products.
[0080]
【The invention's effect】
As described above in detail, according to the inventions of claims 1 to 25, the applied high-viscosity material is cured with the top portion thereof facing substantially vertically downward. Without using it, an excellent effect is obtained that a gasket having a better aspect ratio and excellent sealing properties and buffering properties can be easily and quickly formed corresponding to various applications, shapes and dimensions.
[0081]
According to the invention of claim 3, claim 15 and claim 26, since the nozzle having the gradually reduced diameter and the gradually enlarged diameter is provided, an effect that a bead having a large diameter can be easily formed is obtained. .
[Brief description of the drawings]
FIG. 1 is a diagram showing a schematic configuration of an automatic coating system for forming an irregular gasket according to first and second embodiments of the present invention.
FIG. 2 is a view showing one specific example of a reversing device used in the automatic coating system of FIG. 1;
3A and 3B are diagrams relating to a discharge nozzle according to an embodiment of the present invention, in which FIG. 3A is an internal cross-sectional view of the discharge nozzle, and FIG. 3B is a state in which material is discharged from the discharge nozzle toward an application surface. FIG.
4 is a diagram showing a detailed configuration of a high-viscosity material supply unit used in the automatic coating system of FIG. 1 according to the first embodiment.
FIGS. 5A and 5B are top views of a cover plate that is an application target for forming an irregular gasket in the automatic application system of FIG. 1, wherein FIG. 5A shows a state before application, and FIG. 5B shows a state after application and after curing.
6 is a diagram showing a detailed configuration of a mechanical foaming system used in the automatic coating system of FIG. 1 according to a second embodiment.
7 is a timing chart showing operation timings of a suction process and a discharge process of the piston pump of FIG. 6. FIG.
8 is a configuration diagram of a premixer used in the mechanical foaming system of FIG. 6, in which (a) is a cross-sectional side view of the premixer, (b) is a top view of the premixer showing rod-like protruding blades, and (c) is a diagram of the premixer. It is a top view of a cross-shaped stirring blade.
FIG. 9 is a diagram showing a schematic configuration of an irregular gasket forming apparatus according to a third embodiment of the present invention.
FIG. 10 is a diagram for explaining a problem of the prior art.
[Explanation of symbols]
1 Automatic coating system for forming irregular gaskets
10 Sending device
12 Discharge nozzle
16 High viscosity material supply section
17 Mechanical foaming system
22 Controller
23 Lid
37A Gas supply unit
37B Material supply section
37C mixing section
37D dispersion unit
41A, 41B Constant flow piston pump
43 Dispersion pipeline
45A, 45B Piston pump
56 Application site
57 Beads after coating or curing
60 Manipulator
65 Conveyor
70 reversing device
90 Heating furnace
100 Nozzle tip
102 Region of progressively reduced diameter of discharge nozzle
104 Area of gradual expansion of discharge nozzle
120 premixer
130 Housing
132 shaft
133 Cross shaped stirring blade
135 Wings
160 Non-standard gasket forming equipment

Claims (25)

A method of forming an irregular gasket,
A supply process for supplying a high viscosity material;
A discharge step of discharging the high-viscosity material supplied in the supply step onto the surface to be coated;
A curing step of curing the high-viscosity material that has been ejected in the ejection step and applied to the surface to be coated, with the top portion thereof facing substantially vertically downward;
A method for forming an amorphous gasket. In the discharge step, the high-viscosity material supplied in the supply step is discharged downward onto the application surface,
2. The indefinite shape according to claim 1, further comprising an inversion step of inverting the coated surface up and down so that a top portion of the high-viscosity material applied to the coated surface is directed substantially vertically downward after the discharging step. Gasket formation method. In the discharging step, the high-viscosity material is discharged onto the application surface through a nozzle,
The nozzle is formed such that an inner diameter of a material passage provided in the nozzle is gradually reduced to a predetermined position in a direction toward the nozzle tip and gradually increased from the position to the nozzle tip. The method for forming an irregular gasket according to claim 1 or claim 2.   The high-viscosity material supplied in the supplying step is a normal temperature solid hot melt composition, and in the curing step, the applied normal temperature solid hot melt composition is in a state where the top portion is directed substantially vertically downward. The method for forming an amorphous gasket according to any one of claims 1 to 3, wherein the composition is cured by holding at room temperature.   The high-viscosity material supplied in the supplying step is a thermosetting composition, and in the curing step, the applied thermosetting composition is heated in a state where the top portion is directed substantially vertically downward. The method for forming an amorphous gasket according to any one of claims 1 to 3, wherein the composition is cured.   The high-viscosity material supplied in the supplying step is a moisture curable composition, and in the curing step, moisture is applied to the applied moisture curable composition in a state where the top portion is directed substantially vertically downward. The method for forming an amorphous gasket according to any one of claims 1 to 3, wherein the composition is cured by the method.   4. The amorphous gasket according to claim 1, wherein the high-viscosity material supplied in the supplying step is a foamed material in which fine bubbles of gas are dispersed and mixed in the material. 5. Forming method. The supply step includes
Provided is a piston pump in which a suction process and a discharge process are executed by reciprocating a piston in a cylinder, and a gas having a predetermined pressure is supplied into the piston pump when the cylinder has a negative pressure in the suction process. Introduced
After the suction step is completed, the high-viscosity material in a fluid state is pumped and filled at a pressure higher than the pressure of the gas into the piston pump containing the gas,
By performing the discharge step, the gas mixed in the cylinder and the high-viscosity material are discharged from the discharge port of the cylinder.
Supplying the foamed material produced by performing each step of passing the pumped mixture through an elongated dispersion line to further shear and finely disperse the gas bubbles into the high viscosity material The method for forming an amorphous gasket according to claim 7.   9. The gas and high viscosity material mixture pumped from the piston pump is passed through a premixer to finely cut the gas bubbles and disperse the gas bubbles in the high viscosity material. A method for forming the amorphous gasket as described.   The high-viscosity material that is pumped and filled into the piston pump is a room-temperature solid hot melt composition, and in the curing step, the coated room-temperature solid hot melt composition is in a state in which the top portion is directed substantially vertically downward. The method for forming an amorphous gasket according to claim 8 or 9, wherein the composition is cured by holding at room temperature.   The high-viscosity material that is pumped and filled into the piston pump is a thermosetting composition, and in the curing step, the applied thermosetting composition is heated with its top portion facing substantially vertically downward. The method for forming an amorphous gasket according to claim 8 or 9, wherein the composition is cured by:   The high-viscosity material that is pumped and filled into the piston pump is a moisture-curable composition, and in the curing step, moisture is applied to the applied moisture-curable composition in a state where the top portion is directed substantially vertically downward. The method for forming an amorphous gasket according to claim 8 or 9, wherein the composition is cured by heating. An apparatus for forming an irregular gasket,
Supply means for supplying a high viscosity material;
A discharge nozzle for discharging the high-viscosity material supplied by the supply means onto the application surface;
Curing means for curing the high viscosity material discharged from the discharge nozzle and applied to the surface to be coated, with the top portion facing substantially vertically downward;
A device for forming an amorphous gasket.   The irregular-shaped gasket forming apparatus according to claim 13, further comprising a reversing unit capable of changing a direction of the coated surface so that a top portion of the high-viscosity material coated on the coated surface is directed substantially vertically downward.     The discharge nozzle is formed such that the inner diameter of a material passage provided in the nozzle gradually decreases to a predetermined position in a direction toward the nozzle tip, and gradually increases from the position to the nozzle tip. The apparatus for forming an irregular gasket according to claim 13 or 14.   The supply means supplies a room-temperature solid hot melt composition as the high-viscosity material, and the curing means applies the room-temperature solid hot melt composition in a state where the top portion is directed substantially vertically downward. The apparatus for forming an amorphous gasket according to any one of claims 13 to 15, wherein the composition is cured by being held at room temperature.   The supply means supplies a thermosetting composition as the high-viscosity material, and the curing means heats the applied thermosetting composition in a state where the top portion is directed substantially vertically downward. The apparatus for forming an amorphous gasket according to any one of claims 13 to 15, wherein the composition is cured.   The supply means supplies a moisture curable composition as the high-viscosity material, and the curing means gives moisture to the applied moisture curable composition in a state where its top portion is directed substantially vertically downward. The apparatus for forming an amorphous gasket according to any one of claims 13 to 15, wherein the composition is cured by:   The amorphous gasket according to any one of claims 13 to 15, wherein the supply means supplies, as the high-viscosity material, a foam material in which fine bubbles of gas are dispersed and mixed in the material. Forming equipment. The supply means includes
A plurality of piston pumps in which a suction process and a discharge process are alternately performed by reciprocating a piston in a cylinder;
A gas introduction means for introducing a gas having a predetermined pressure into the piston pump when the inside of the cylinder is under a negative pressure condition in the suction step;
Material pumping means for pumping and filling a high-viscosity material in a fluid state into the piston pump containing the gas at a pressure higher than the pressure of the gas after the suction step is completed;
A plurality of constant flow cylinder pumps that pressurize and pump a mixture of gas and high viscosity material discharged from the plurality of piston pumps at a constant flow rate;
In order to further finely disperse the gas bubbles in the pressure-pressure fed mixture, an elongated dispersion pipe interposed between the discharge end of the constant flow cylinder pump and the discharge nozzle;
An apparatus for forming an irregular gasket according to claim 19. The supply means further includes a premixer between discharge ends of the plurality of piston pumps and a suction end of the constant flow cylinder pump,
The premixer includes a housing having an inlet and an outlet, and a rotationally driven shaft extending along a central axis in the housing, and the blade has a wing tip near the inner wall of the housing. A plurality of cross-shaped stirring blades extending to the shaft are attached at predetermined intervals along the length direction of the shaft, and the housing protrudes so as to enter between adjacent stirring blades from a plurality of locations on the inner wall of the housing. 21. The apparatus for forming an irregular gasket according to claim 20, wherein rod-like projection wings are formed.   The material pumping means pumps and fills the piston pump with a normal temperature solid hot melt composition as the high-viscosity material, and the curing means has the top part of the applied normal temperature solid hot melt composition substantially vertical. The apparatus for forming an amorphous gasket according to claim 20 or 21, wherein the composition is cured by being held at room temperature while facing downward.   The material pumping unit pumps and fills the piston pump with a thermosetting composition as the high-viscosity material, and the curing unit has the top portion of the applied thermosetting composition facing substantially vertically downward. The apparatus for forming an amorphous gasket according to claim 20 or 21, wherein the composition is cured by heating in a state.   The material pumping means pumps and fills the piston pump with a moisture curable composition as the high-viscosity material, and the curing means has a top portion directed substantially vertically downward to the applied moisture curable composition. The apparatus for forming an amorphous gasket according to claim 20 or 21, wherein the composition is cured by applying moisture in a state. A manipulator capable of moving the discharge nozzle to an arbitrary position within a predetermined range;
Control means for automatically controlling the discharge of the irregular gasket from the discharge nozzle, and for automatically controlling the manipulator so that the discharge nozzle moves along the application site of the article;
The apparatus for forming an irregular gasket according to any one of claims 13 to 24, further comprising:

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