JP5873383B2 - Method for manufacturing molded article and cutting apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing a molded product obtained by cutting an excess portion with a cutting blade, and a cutting device used therefor.

  A resin molded material molded into a predetermined shape by injection molding or the like may be made into a product (resin molded product) through a cutting process in which excess portions are cut off. Here, as a method of cutting the resin molding material, generally, the resin molding material is melted by a cutting blade (so-called hot blade) heated by a heating means such as a heater (for example, see Patent Document 1). ). In such a cutting method using the hot blade 110, the hot blade 110 heated from the surface 100a side which becomes the design surface of the resin molding material 100 is brought closer to the resin molding material 100 supported by a support (not shown) ( 6 (a)), the hot blade 110 is advanced in the thickness direction of the resin molding material 100, so that the resin molding material 100 is softened by the heat applied from the hot blade 110 while the hot blade 110 softens the resin molding material 100. (See FIG. 6B). Then, the hot blade 110 is moved away from the resin molding material 100 (see FIG. 6C), and the resin molded product 102 obtained by cutting off the excess portion 101 is removed from the support.

JP-A 64-5799

  In the above-described cutting with the hot blade 110, since the hot blade 110 is pushed into the resin molding material 100 while the resin molding material 100 is softened by heat, the resin pushed away by the hot blade 110 rises so as to protrude toward the surface 100a. (See FIG. 6B). That is, there is a difficulty that a burr 103 called “burr” is generated at the cut end of the obtained resin molded product 102. If such a burr 103 is present in the resin molded product 102, the appearance of the burr 103 is poor, and the burr 103 may be caught. Therefore, a process for removing the burr 103 by polishing or the like is required, which is troublesome.

  That is, the present invention has been proposed in view of the above-described problems related to the prior art, and provides a manufacturing method capable of obtaining a molded article with a clean cut end and an apparatus used therefor. For the purpose.

In order to overcome the above-mentioned problems and achieve the intended purpose, a method for producing a molded article according to claim 1 of the present application is as follows.
A manufacturing method for obtaining a molded product by cutting a surplus portion from a resin-molded molding material,
By cutting a heated cutting blade from the surface side of the molding material to a portion adjacent to the cutting planned portion of the surplus part, a cut is formed along the cutting planned portion,
The gist is that cutting is performed from the surface side of the molding material at the planned cutting site with a heated cutting blade.
According to the first aspect of the present invention, it is possible to suppress the occurrence of defects such as burrs caused by cutting with a heated cutting blade by previously forming a cut adjacent to the planned cutting site and then cutting with the cutting blade. it can. That is, the cut end of the obtained molded product can be finely finished without performing post-processing such as polishing.

The gist of the invention according to claim 2 is that the forming material is cut with a cutting blade having a blade edge facing the surplus portion side, using the cutting blade having a single blade.
According to the invention which concerns on Claim 2, generation | occurrence | production of defects, such as a crack, can be suppressed more by using the single blade which orient | assigned the inclined blade surface to the surplus part side at the time of a cutting | disconnection.

In order to overcome the above-mentioned problems and achieve the intended purpose, the cutting device according to the third aspect of the present invention provides:
A cutting device for cutting an excess portion from a resin-molded molding material,
Supporting means for supporting the molding material;
Cutting means having a cutting blade capable of moving back and forth in the thickness direction of the molding material supported by the support means;
The support means displaces the molding material between a first position where a portion adjacent to the cutting scheduled portion of the surplus portion faces the cutting blade and a second position where the cutting planned portion faces the cutting blade. Configured and
The cutting means forms a cut from the surface side in the surplus portion of the molding material at the first position by the cutting blade heated by the heating means, and at the second position by the cutting blade heated by the heating means. The gist of the present invention is that the part to be cut of a certain molding is cut from the surface side.
According to the invention which concerns on Claim 3, since it cuts with a cutting blade after forming incision previously adjacent to a cutting | disconnection plan site | part, generation | occurrence | production of defects, such as a crack accompanying the cutting | disconnection with a heated cutting blade, can be suppressed. . That is, the cut end of the obtained molded product can be finely finished without performing post-processing such as polishing.

In the invention according to claim 4, the cutting edge of the cutting edge is a single edge,
The gist of the invention is that the cutting blade is disposed so as to process the molding material with the inclined blade surface of the blade edge directed toward the surplus portion.
According to the invention which concerns on Claim 4, generation | occurrence | production of defects, such as a crack, can be suppressed more by processing an inclined blade surface toward the surplus part side at the time of a cutting edge with the cutting edge of a single blade.

  According to the method for manufacturing a molded product according to the present invention, a molded product with a clean cut end can be obtained. Moreover, according to the cutting device which concerns on this invention, a molding material can be cut | disconnected neatly.

(a) is a schematic perspective view which shows a basic console main body, (b) is a schematic perspective view which shows the change console main body obtained from the basic console main body. It is the schematic which shows the cutting device which concerns on an Example. It is explanatory drawing of the manufacturing method of an Example, (a) shows the state which set the basic console main body to the support means, and aligned with the 1st position, (b) shows the state which has formed the notch | incision. . It is explanatory drawing of the manufacturing method of an Example, (a) shows the state which formed the notch | incision, (b) shows the state which aligned the basic console main body from the 1st position to the 2nd position. It is explanatory drawing of the manufacturing method of an Example, (a) shows the cutting | disconnection process of an excessive part, (b) shows the state which the cutting blade penetrated the side wall part, (c) is the state which cut off the excessive part Indicates. It is explanatory drawing of the conventional cutting method, (a) is the state before cutting | disconnection, (b) is the state in cutting | disconnection, (c) shows the state after cutting | disconnection.

  Next, a method for manufacturing a molded article and a cutting apparatus according to the present invention will be described below with reference to the accompanying drawings by giving preferred examples.

  In the vehicle compartment of the vehicle, a floor console provided with a storage unit that can store small items is disposed between the front seats. As shown in FIG. 1, the console body 10 constituting the floor console is formed so as to connect a pair of side wall portions 12, 12 opposed to each other with a gap in the left-right direction, and both side wall portions 12, 12. And a box-shaped storage portion 14 opening upward. The console body 10 is installed such that both side wall portions 12 and 12 formed in a plate shape rise from the floor surface of the vehicle compartment, and one plate surface (surface) 12a of each side wall portion 12 is exposed to the vehicle compartment side. It becomes a design surface, and the other plate surface (back surface) 12b is invisible from the passenger compartment side. In the embodiment, the console main body 10 is formed by molding such as injection molding using a thermoplastic resin such as polypropylene, and the height of the side wall portions 12 and 12 is adjusted to match the vehicle for two-wheel drive. Is set. Since the four-wheel drive vehicle has a higher floor surface than the two-wheel drive vehicle, four-wheel drive is achieved by cutting off the lower portions of both side walls 12 and 12 of the console body 10 for two-wheel drive. The console main body 11 is formed. Thus, in the embodiment, the console main body (referred to as the basic console main body) 10 as the molding material is cut by using the cutting device 20 according to the embodiment, so that the console main body (change) (Called console body) 11 is manufactured. Accordingly, it is possible to deal with the console main bodies 10 and 11 having two specifications of two-wheel drive and four-wheel drive with one mold facility.

  As shown in FIG. 2, the cutting device 20 according to the embodiment includes a support means 22 for supporting the basic console body 10, a cutting means 28 having a cutting blade 30 for processing the basic console body 10, and the basic console body 10. Receiving means 36 for holding the periphery of the cutting site. The support means 22 has a support base 24 for receiving the storage part 14 installed between the side wall parts 12 and 12 from below, and the support base 24 can be moved up and down by a lift drive means 26 such as an air cylinder. ing. And the support means 22 raises / lowers the support stand 24, and the 1st position (the solid line of FIG. 2) which makes the part adjacent to the cutting | disconnection plan part S in the surplus part 13 of the side wall part 12 face the cutting blade 30 is shown. 3) and the second position (see the two-dot chain line in FIG. 2, see FIGS. 4 and 5) where the scheduled cutting site S of the side wall 12 faces the cutting blade 30. It is comprised so that it can be displaced. Further, the support means 22 can stop and hold the support base 24 by the elevating drive means 26 at each of the height at which the basic console body 10 is at the first position and the height at which the basic console body 10 is at the second position. It has become. In the embodiment, in the surplus portion 13 extending below the planned cutting site S of the side wall portion 12, a site adjacent to the lower side of the planned cutting site S faces the cutting blade 30 at the first position, and the support base 24 is moved. The main console body 10 is moved down to the second position.

  As shown in FIG. 2, corresponding to the left and right side wall portions 12 and 12 of the basic console body 10, cutting means 28 are disposed on both the left and right sides sandwiching the support base 24, and each side wall portion 12 is on the corresponding side. It is processed by the cutting means 28. Both the cutting means 28, 28 have the same configuration, and the both cutting means 28, 28 are also arranged in a symmetrical relationship corresponding to the both side wall portions 12, 12 formed symmetrically. The cutting means 28 is a so-called hot blade provided with a cutting blade 30, a heating means 32 such as a heater for heating the cutting blade 30, and an advancing / retreating drive means 34 for moving the cutting blade 30 back and forth. The cutting blade 30 is disposed on the surface 12 a side of the side wall portion 12 of the basic console body 10 supported by the support means 22, and is advanced and retracted in the plate thickness direction of the side wall portion 12 by the advance / retreat driving means 34. That is, the direction in which the basic console main body 10 is displaced by the support means 22 and the direction in which the cutting blade 30 is advanced and retracted by the advance / retreat drive means 34 are substantially orthogonal to each other. Then, the cutting means 28 advances the cutting blade 30 toward the side wall part 12 from the retracted position (see FIG. 3A) retracted to the outside of the side wall part 12, and heats from the surface 12a side of the side wall part 12. The cutting edge of the cutting blade 30 is cut. Here, the cutting means 28 is a cutting position for stopping the retracted position and the cutting edge of the cutting blade 30 within the range of the thickness of the side wall portion 12 with respect to the side wall portion 12 of the basic console body 10 in the first position (see FIG. 3 (see (b)). Further, the cutting means 28 is separated from the side wall portion 12 of the basic console main body 10 in the second position with the retracted position and the cutting position where the cutting edge of the cutting blade 30 penetrates the side wall portion 12 (see FIG. 5B). Configured to move forward and backward. That is, the cutting means 28 forms the notch 16 that does not penetrate the side wall portion 12 in the surplus portion 13 of the side wall portion 12 in the first position by the cutting blade 30 heated by the heating means 32, while in the second position. A certain side wall portion 12 is cut at a planned cutting site S.

  The cutting blade 30 is a flat blade whose cutting edge is continuous in the front-rear direction in accordance with the planned cutting site S (see FIG. 1) set in the front-rear direction of the side wall portion 12 that is long in the front-rear direction. Further, the cutting blade 30 is a single blade in which one surface of the blade edge (referred to as an inclined blade surface 30a) is inclined and another surface (referred to as a flat blade surface 30b) is cut flat. Then, when the side wall portion 12 is processed, the cutting blade 30 faces the surplus portion 13 side where the inclined blade surface 30a is cut off at the side wall portion 12 and the flat blade surface 30b faces the product portion side left at the side wall portion 12. (See FIGS. 2 to 5). That is, in the embodiment, the cutting blade 30 is disposed so that the inclined blade surface 30a faces downward and the flat blade surface 30b faces upward, and the displacement direction of the basic console body 10 by the support means 22 and the thickness of the cutting blade 30 are arranged. The flat blade surface 30b extends in the plate thickness direction of the side wall portion 12 while the directions are aligned.

  As shown in FIG. 2, the receiving means 36 is disposed on the back surface 12 b side that is opposite to the cutting edge 30 disposed on the front surface 12 a side of the side wall portion 12 with the side wall portion 12 interposed therebetween. . In the cutting apparatus 20 of the embodiment, a pair of receiving means 36, 36 are disposed on the lower side of the support base 24, and the both receiving means 36, 36 are both side wall portions of the basic console main body 10 supported by the support base 24. 12 and 12 are arranged inside. Note that the receiving means 36 and 36 have the same configuration, and the receiving means 36 and 36 are also arranged in a symmetrical relationship corresponding to the side wall portions 12 and 12 formed symmetrically. The receiving means 36 has a receiving surface 38 formed in conformity with the back surface 12b of the side wall portion 12, and the receiving surface 38 abuts on the back surface 12b of the side wall portion 12 so as to displace the side wall portion 12 toward the back surface 12b. It comes to regulate. In addition, the receiving surface 38 is formed so as to allow the upward and downward displacement of the side wall portion 12 as the support base 24 is raised and lowered, and the side wall portion 12 is moved up and down along the receiving surface 38. The receiving means 36 is provided with a recess 40 that can receive the cutting blade 30 at a position facing the cutting blade 30. The recess 40 is formed to be equal to or slightly larger than the thickness of the cutting blade 30 and to extend in the front-rear direction in accordance with the cutting edge of the cutting blade 30 so as to be aligned with the cutting blade 30 penetrating the side wall portion 12. It has become. The depth of the recess 40 is set so that the cutting edge of the cutting blade 30 penetrating the side wall portion 12 does not hit.

  As shown in FIG. 2, the cutting device 20 includes a pressing unit 42 that presses the basic console main body 10 supported by the supporting unit 22. The pressing means 42 includes a pressing piece 44 disposed above the support base 24 so as to face the support base 24, and a pressing drive means 46 such as an air cylinder that moves the pressing piece 44 forward and backward with respect to the support base 24. It consists of. The pressing piece 44 is spaced apart from the basic console main body 10 placed on the support base 24 (see a two-dot chain line in FIG. 2), and pressed against the basic console main body 10 from above (see FIG. 2). It is moved up and down by the pressing drive means 46 (see the solid line). The pressing means 42 can move the pressing piece 44 up and down in accordance with the up-and-down movement of the support base 24, and the basic console body 10 can be moved up and down at both the first position and the second position. It can be held between.

  Next, the manufacturing method according to the embodiment will be described in the case of using the cutting apparatus 20 of the embodiment described above. The basic console body 10 is set on the support base 24 in a state where both the cutting blades 30 and 30 are retracted to the retracted position and the pressing piece 44 is retracted above the support base 24. Then, the pressing console 44 is lowered by the pressing drive means 46, and the basic console body 10 is positioned by sandwiching the basic console body 10 between the pressing piece 44 and the support base 24. At this time, the support base 24 is in the raised position, the basic console main body 10 placed on the support base 24 is aligned with the first position, and the receiving surface 38 of the receiving means 36 is the back surface of the side wall portion 12. The side wall part 12 is hold | maintained from the back surface 12b side by contact | abutting to 12b. In this way, in the setting step, the excessive portion 13 of the side wall portion 12 that is unnecessary for reducing the height of the basic console body 10 is aligned so as to face the cutting blade 30 (see FIG. 3A). ). Here, the basic console main body 10 aligned with the first position has a portion to be cut at the surplus portion 13 extending below the portion to be cut S which is the lower end of the side wall portion 12 of the changed console main body 11. A part adjacent to S faces the cutting edge 30.

  The cutting blade 30 is heated to a temperature at which the resin constituting the basic console body 10 can be softened by the heating means 32, and the cutting blade 30 is advanced toward the surface 12 a of the side wall portion 12 by the advance / retreat driving means 34. Then, by cutting the heated cutting blade 30 from the surface 12a side of the side wall portion 12, a cut 16 is formed along the planned cutting site S at a site adjacent to the planned cutting site S (see FIG. 3B). ). The cutting blade 30 is retracted from the side wall portion 12 by being reversely driven by the advancing / retreating drive means 34 after having finished moving forward with the blade edge being within the thickness range of the side wall portion 12 (see FIG. 4A). ). Here, the cutting blade 30 is cut into the side wall portion 12 so that the inclined blade surface 30a faces the surplus portion 13 (downward) and the flat blade surface 30b remains. In addition, the cut 16 is formed in a groove shape that opens on the surface 12a of the side wall 12 without penetrating the side wall 12 in the thickness direction. In the notch forming step, the back surface 12b side of the side wall portion 12 is supported by the receiving surface 38 of the receiving means 36. Therefore, when the cutting is performed from the front surface 12a side of the cutting blade 30 to the side wall portion 12, the side wall portion 12 is not moved to the back surface 12b side. Instead, the cuts 16 can be formed in the side wall portion 12 with high accuracy.

  After the cut 16 is formed, the support 24 is lowered to the lowered position by the raising / lowering driving means 26, and the basic console body 10 is aligned with the second position where the planned cutting site S of the side wall 12 faces the cutting blade 30 ( (Refer FIG.4 (b)). The cutting blade 30 is heated to a temperature at which the resin constituting the basic console body 10 can be softened by the heating means 32, and the cutting blade 30 is advanced toward the surface 12 a of the side wall portion 12 by the advance / retreat driving means 34. Then, the heated cutting blade 30 is cut from the surface 12a side of the side wall portion 12 (see FIG. 5A), and the side wall portion 12 is cut at the planned cutting site S. The cutting blade 30 is retracted from the side wall portion 12 by being reversely driven by the advancing / retreating drive means 34 after the advancement is finished with the blade edge penetrating to the back surface 12b side of the side wall portion 12 (see FIG. 5B). (See FIG. 5C.) Here, the cutting blade 30 is cut into the side wall portion 12 with the inclined blade surface 30a facing the surplus portion 13 (downward) and the flat blade surface 30b remaining. In such a cutting process, the side wall portion 12 is cut at the planned cutting site S and the surplus portion 13 is cut off (see FIG. 5C), so that the height is lower than the basic console body 10. The adjusted change console main body 11 is obtained, although the operation timing of the two cutting means 28 and 28 is not particularly limited in the notch forming process and the cutting process, but in the embodiment, the two cutting means 28 and 28 are synchronized. Corresponding side wall 12 It is processed.

  The interval W (see FIG. 3B) between the planned cutting site S and the formation position of the cut 16 is several mm depending on the thickness of the cutting blade 30, the material of the console body 10, the heating temperature of the cutting blade 30, and the like. In the embodiment, the interval W is set to 1 mm. That is, the cut 16 needs to be formed away from the planned cutting site S to the extent that the resin pushed away by the cutting blade 30 toward the remaining portion side (upward) of the side wall portion 12 does not reach the planned cutting site S. is there. In addition, since the resin (referred to as the resin wall 18) between the cutting blade 30 and the cutting 16 must fall to the cutting 16 side as the cutting blade 30 is inserted in the cutting process, the cutting 16 is cut. It is better to approach the planned site S as close as possible. The depth F of the cut 16 is preferably at least half the plate thickness of the side wall 12. In the embodiment, the cutting blade 30 is cut in the cut forming process up to 2/3 of the plate thickness of the side wall 12. That is, as the depth F of the cut 16 increases, the resin between the cutting blade 30 and the cut 16 tends to fall to the cut 16 side in the cutting process.

  In the notch forming step, the resin softened by the heated cutting blade 30 may be pushed up by the cutting blade 30 and bulge so as to protrude to the surface 12a side of the side wall portion 12 (see FIG. 3B). However, in the incision forming process, the notch 16 is formed in a portion of the surplus portion 13 that is separated from the planned cutting site S. Therefore, even if burrs or the like are generated due to the formation of the notch 16, the cuts are not affected. Can be prevented. When the cutting blade 30 is cut into the planned cutting site S adjacent to the formation position of the cut 16 in the cutting step, the resin wall 18 between the cutting blade 30 and the cut 16 is softened by the heated cutting blade 30. Then, as the cutting blade 30 is pushed, the resin wall 18 falls to the notch 16 side using the space formed by the notch 16 (see FIGS. 5A and 5B). That is, in the cutting process, the force applied to the resin as the cutting blade 30 is pushed is released to the surplus portion 13 side due to the displacement of the resin wall 18, so that the pressing force of the cutting blade 30 is applied to the remaining portion side of the side wall portion 12. Can be suppressed. Thereby, it can prevent that resin swells to the residual part side of the side wall part 12 in a cutting process, and can suppress generation | occurrence | production of cutting edge defects, such as a crack accompanying the cutting | disconnection by the heated cutting blade 30. FIG. That is, the cut end of the obtained changed console main body 11 can be finished finely without performing post-processing such as polishing. Further, when the cutting edge 30 is processed with the single-edged cutting edge 30, the inclined blade surface 30a is directed toward the surplus portion 13 so that it is pushed toward the surplus portion 13 as compared with the remaining portion of the side wall portion 12 that contacts the flat blade surface 30b. The pressure can be released and the occurrence of cutting edge defects such as burrs can be further suppressed. And since the surplus part 13 in which the notch 16 was formed in the cutting process is cut off without completely cutting off the surplus part 13 in the notch forming process, it is possible to avoid the occurrence of fine cutting residue.

(Change example)
The present invention is not limited to the configuration of the embodiment described above, and can be modified as follows.
(1) In the embodiment, an example in which another console body is obtained by cutting a part of the basic console body, but vehicles such as instrument panels, door trims, pillar garnishes, floor consoles, console lids, etc. Applicable to interior members. Moreover, it is applicable also when obtaining a molded article from the molding material which consists of resin other than a vehicle interior member.
(2) In the embodiment, the molding material is cut from one end to the other end. However, the present invention can be applied to a case where a molded product is obtained by punching a part of the molding material. For example, when cutting the inside of a partial region of the molding material, an incision is formed in the inner peripheral edge of the planned cutting site that is annularly closed, and when cutting the outer periphery of the molding material, the cutting target site that is annularly closed is cut. A cut is formed in the outer periphery.
(3) The cut may partly penetrate the molding material unless the molding material is cut off.

10 Basic console body (molded material), 11 Change console body (molded product),
12a surface, 13 surplus parts, 16 cuts, 22 support means, 28 cutting means,
30 cutting blade, 30a inclined blade surface, 32 heating means, S scheduled cutting site

Claims (4)

A manufacturing method for obtaining a molded product by cutting a surplus portion from a resin-molded molding material,
By cutting a heated cutting blade from the surface side of the molding material to a portion adjacent to the cutting planned portion of the surplus part, a cut is formed along the cutting planned portion,
A method for producing a molded product, characterized in that the cutting is performed from the surface side of the molding material at the planned cutting site by a heated cutting blade.   The method for producing a molded product according to claim 1, wherein the cutting material is cut with a cutting blade having an inclined blade surface directed to the surplus portion side, using the cutting blade having a single blade. A cutting device for cutting an excess portion from a resin-molded molding material,
Supporting means for supporting the molding material;
Cutting means having a cutting blade capable of moving back and forth in the thickness direction of the molding material supported by the support means;
The support means displaces the molding material between a first position where a portion adjacent to the cutting scheduled portion of the surplus portion faces the cutting blade and a second position where the cutting planned portion faces the cutting blade. Configured and
The cutting means forms a cut from the surface side in the surplus portion of the molding material at the first position by the cutting blade heated by the heating means, and at the second position by the cutting blade heated by the heating means. A cutting apparatus configured to cut a predetermined cutting portion of a molding from the surface side. The cutting edge has a single-edged edge.
The said cutting blade is a cutting device of Claim 3 arrange | positioned so that the inclined blade surface of a blade edge | tip may be processed to the said excessive part side, and the said molded material is processed.

Images