JP6691649B2 - Electromagnetic induction heating type resin molding die and method of manufacturing resin molding using the die - Google Patents
Electromagnetic induction heating type resin molding die and method of manufacturing resin molding using the die Download PDFInfo
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- 238000010438 heat treatment Methods 0.000 title claims description 202
- 239000011347 resin Substances 0.000 title claims description 76
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- 230000005674 electromagnetic induction Effects 0.000 title claims description 49
- 238000004519 manufacturing process Methods 0.000 title claims description 11
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- 229910052751 metal Inorganic materials 0.000 claims description 34
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 9
- 239000002826 coolant Substances 0.000 claims description 9
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- 238000001721 transfer moulding Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 229910001289 Manganese-zinc ferrite Inorganic materials 0.000 description 1
- 229910001053 Nickel-zinc ferrite Inorganic materials 0.000 description 1
- 229910001308 Zinc ferrite Inorganic materials 0.000 description 1
- JIYIUPFAJUGHNL-UHFFFAOYSA-N [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Mn++].[Mn++].[Mn++].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Zn++].[Zn++] Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Mn++].[Mn++].[Mn++].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Zn++].[Zn++] JIYIUPFAJUGHNL-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000000071 blow moulding Methods 0.000 description 1
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- Moulds For Moulding Plastics Or The Like (AREA)
Description
本発明は、電磁誘導加熱式樹脂成形金型及び該金型を用いた樹脂成形体の製造方法に関する。更に詳しくは、脱着容易なカセットタイプのコイルによる電磁誘導局所加熱により樹脂成形体に対する局所加熱により温度傾斜加熱、および局所冷却により温度傾斜冷却を可能とする電磁誘導加熱式樹脂成形金型と、この金型を用いて局所加熱、局所冷却を行うことでハイサイクル成形を可能とする樹脂成形体の製造方法に関する。 The present invention relates to an electromagnetic induction heating type resin molding die and a method for manufacturing a resin molding using the metal mold. More specifically, an electromagnetic induction heating type resin molding die that enables temperature gradient heating by local heating of a resin molded body by electromagnetic induction local heating by a cassette type coil that can be easily attached and detached, and temperature gradient cooling by local cooling, and this metal mold. The present invention relates to a method for producing a resin molded product that enables high cycle molding by locally heating and locally cooling a mold.
金型を用いて賦型する樹脂成形法としては、射出成形法、圧縮成形法、ブロー成形法等が挙げられる。これらは、金型に溶融した原料樹脂を投入した後、熱の授受を行って、樹脂を賦型し、固化させる方法である。そして、金型の加熱方法としては、電熱ヒーターを用いる方法、蒸気またはオイル等の熱媒を用いる方法の他、高周波電磁誘導加熱による方法が知られている。この高周波電磁誘導を加熱手段として用いた樹脂成形用金型は、熱媒を必要としないことから、設備費や運転費の面で優れており、近年注目を集めている。こうした金型の加熱は、ウェルドレス成形と高転写成形には必須の技術である。 Examples of the resin molding method in which a mold is used for molding include an injection molding method, a compression molding method, and a blow molding method. In these methods, a molten raw material resin is charged into a mold, and then heat is transferred to shape and solidify the resin. As a method for heating the mold, a method using an electric heater, a method using a heat medium such as steam or oil, and a method using high-frequency electromagnetic induction heating are known. A resin molding die that uses this high-frequency electromagnetic induction as a heating means does not require a heat medium, and therefore is excellent in terms of equipment costs and operating costs, and has recently attracted attention. Such heating of the mold is an essential technique for weldless molding and high transfer molding.
このようなウェルドレス成形と高転写成形のための従来技術として、例えば特許第4052600号には、金型の入れ子を、キャビティ表面を有する入れ子表部材と、キャビティ表面を有しない入れ子裏部材に分割して、この入れ子表部材に、キャビティ表面の近傍部位を通過する溝を設け、この溝に電熱ヒーターを収容した金型が開示されている。しかしながらこの構成では、金型毎にウェルドライン発生個所が異なるために、電熱ヒーターを収納する溝を設計する必要があり、多種多様の成型品に対応するのが困難であるという欠点を有していた。 As a conventional technique for such weldless molding and high transfer molding, for example, in Japanese Patent No. 4052600, a mold nest is divided into a nest front member having a cavity surface and a nest back member having no cavity surface. Then, there is disclosed a mold in which a groove passing through a portion in the vicinity of the surface of the cavity is provided in this nesting surface member, and an electric heater is housed in this groove. However, in this configuration, since the weld line generation point is different for each mold, it is necessary to design a groove for accommodating the electric heater, and it is difficult to handle a wide variety of molded products. It was
更に同一出願人に係る特許5261283号においても同様な構成により、電熱ヒーターを収納する溝を有し、かつ電熱ヒーターを複数系統に分けて設置し制御ゾーンごとに異なる温度制御を行ない、樹脂成形体のウェルドラインの発生を防ぐ構成が開示されている。しかしながらこの構成も上記引例と同様に、多種多様の成型品に対応するのが困難であるという欠点を有していた。 Further, in the patent No. 5261283 of the same applicant, with the same configuration, it has a groove for accommodating the electric heater, and the electric heater is installed in a plurality of systems separately, and different temperature control is performed for each control zone. There is disclosed a structure for preventing the occurrence of a weld line. However, this structure also has a drawback that it is difficult to deal with a wide variety of molded products, like the above-mentioned reference.
更に特開2007-8035号には、相対的に開閉する一対の型板と、この一対の型板に各々埋め込まれるキャビティ側金型およびコア側金型と、このキャビティ側金型の内部に設置され、キャビティ側金型を樹脂の熱変形温度以上の高温に加熱する熱源体を収納してウェルドライン発生を防止する成型金型装置が開示されている。しかしながらこの構成でも依然として金型内部に熱源体を収納する基本的な構成は上記引例と変わらず、したがって多種多様の成型品に対応するのが困難であるという欠点を有していた。 Further, in Japanese Patent Laid-Open No. 2007-8035, a pair of relatively openable mold plates, a cavity side mold and a core side mold which are respectively embedded in the pair of mold plates, and a cavity side mold are installed inside the mold plate. There is disclosed a molding die device which houses a heat source body for heating the cavity side die to a temperature higher than the thermal deformation temperature of the resin to prevent the occurrence of weld lines. However, even with this structure, the basic structure for accommodating the heat source body in the mold is still the same as the above-mentioned reference, and thus there is a drawback that it is difficult to deal with a wide variety of molded products.
同様な構成は同一出願人に係る特開2007-8036号、特開2007-223168号、特開2009-226778号にも開示されているが、いずれの構成も金型内部に熱源体を収納する基本的な構成は上記引例と変わらず、したがってこの構成でも多種多様の成型品に対応するのが困難であるという欠点を有していた。 Similar configurations are disclosed in Japanese Patent Application Laid-Open Nos. 2007-8036, 2007-223168, and 2009-226778, all of which are filed by the same applicant, but in any configuration, the heat source is housed inside the mold. The basic structure is the same as the above-mentioned reference, and thus this structure has a drawback that it is difficult to deal with a wide variety of molded products.
次に高周波電磁誘導を加熱手段として用いた樹脂成形用金型として、特表2007-535786号には電磁場を、インダクタと加熱される材料との間に配置された中間要素に印加する手段を備えた金型が開示されている。しかしながらこの構成では、金型全体を加熱するもので、金型の形状に応じて必要最小限度の範囲のみを加熱するという構成ではないため加熱エネルギーの無駄となる欠点を有している。 Next, as a resin molding die using high-frequency electromagnetic induction as a heating means, Japanese Patent Publication No. 2007-535786 has means for applying an electromagnetic field to an intermediate element arranged between an inductor and a material to be heated. A mold is disclosed. However, this configuration has a drawback that heating energy is wasted because the entire die is heated and not only the minimum necessary range is heated according to the shape of the die.
更に同出願人による特表2006-546570号においても複数のキャビティが界磁巻線を囲む金型が開示されている。しかしながらこの構成では成形または変形させるべき部品の形状に応じて界磁巻線の大きさを簡便に変更させることはできず、上記引例と同様に加熱エネルギーの無駄となる欠点を有している。 Further, Japanese Patent Publication No. 2006-546570 by the same applicant also discloses a mold in which a plurality of cavities surround the field winding. However, with this configuration, the size of the field winding cannot be easily changed according to the shape of the part to be molded or deformed, and there is a drawback that the heating energy is wasted as in the above-mentioned reference.
更にまた同出願人による特表2009-507674号には、上記引例とは異なり高周波電磁誘導により局所加熱を可能とする構成が開示されている。すなわち電流発生器に電気的に接続された誘導器のネットワークが金型ケーシングの周囲に配置され、各金型ケーシングの外面の一部分に遮蔽層を設けて、2つの金型ケーシングの相互に対面する面の一部分を被覆して、局所加熱を可能としている。この遮蔽層に使用される非磁気材料は、エネルギー損失を制限するように低い抵抗率を有する例えば銅またはアルミニウムが用いられる。しかしながらこの構成でも樹脂成形体形状に合わせてまでも局所加熱するということはできず、依然として上記引例と同様に加熱エネルギーの無駄となる欠点を有している。 Further, Japanese Patent Publication No. 2009-507674 by the same applicant discloses a configuration that enables local heating by high-frequency electromagnetic induction unlike the above-mentioned reference. That is, a network of inductors electrically connected to the current generator is arranged around the mold casings, a shielding layer is provided on a part of the outer surface of each mold casing, and the two mold casings face each other. A part of the surface is covered to enable local heating. The non-magnetic material used for this shielding layer is, for example, copper or aluminum, which has a low resistivity to limit energy loss. However, even with this configuration, it is not possible to locally heat even the shape of the resin molded body, and there is a drawback that the heating energy is wasted as in the case of the above-mentioned reference.
次に高周波電磁誘導を加熱手段として用いた樹脂成形用金型として特開2012-214040号には、金型を構成する2つの型にキャビティ面を成形し、それぞれキャビティ面を有する部位に磁性金属部を配置し、その磁性金属部の外面に複数の誘導コイルをキャビティ外周縁から所定の範囲内に配するように構成された樹脂成形用電磁誘導加熱式金型装置が開示されている。しかしながらこの構成でも、金型毎に誘導コイルを設けなければならずカセットタイプのコイルによる電磁誘導局所加熱ではなく電磁誘導全面加熱、および局所冷却ではなく全面冷却という構成に留まっている。このような構成では加熱・冷却エネルギーの無駄となり易い。更に誘導コイルはキャビティ外周縁から固定されたギャップを置いて配置されるので、金型キャビティ表面の各部毎に温度傾斜を付与することも困難であるという欠点を有している。 Next, as a resin molding die that uses high-frequency electromagnetic induction as a heating means, Japanese Patent Laid-Open No. 2012-214040 discloses that a cavity surface is formed in two molds, and a magnetic metal is formed in each portion having a cavity surface. There is disclosed an electromagnetic induction heating type mold device for resin molding, which is configured so that a plurality of induction coils are arranged on the outer surface of the magnetic metal portion within a predetermined range from the outer peripheral edge of the cavity. However, even in this structure, an induction coil must be provided for each mold, and the structure is limited to electromagnetic induction whole surface heating instead of electromagnetic induction local heating by a cassette type coil and whole surface cooling instead of local cooling. With such a configuration, heating / cooling energy is likely to be wasted. Further, since the induction coil is arranged with a fixed gap from the outer peripheral edge of the cavity, it is difficult to give a temperature gradient to each part of the mold cavity surface.
最後に特開2013-226810号には、上記引例と類似構成の電磁誘導加熱式金型を用いた連続的な樹脂成形体の製造サイクルにおいて、必要とする時間を安定的に短縮する樹脂成形体の製造方法が開示されている。しかしながらここで用いられる電磁誘導加熱式金型も上述のように局所加熱、加熱コイルのカセット化という技術思想には至っておらず、結局は効率よい樹脂成形体の製造方法とはなっていない欠点を有している。 Finally, in JP-A-2013-226810, in a continuous resin-molded product manufacturing cycle using an electromagnetic induction heating mold having a configuration similar to that of the above-mentioned reference, a resin-molded product that stably reduces the time required Is disclosed. However, the electromagnetic induction heating mold used here has not yet reached the technical idea of forming a cassette of local heating and heating coils as described above, and has the drawback of not being an efficient method for producing a resin molded body. Have
解決しようとする問題点は、従来の電磁誘導加熱式金型においては全面加熱、全面冷却の構造であり、各樹脂成形体の形状により異なるウェルドライン発生個所や転写性不完全個所に対応して、効率よく局所加熱、局所冷却することが出来ないという欠点を有していた。換言すれば無駄に全面加熱、全面冷却する構造であり、効率的にエネルギーの使用が出来ないという欠点を有していた。更に電磁誘導加熱のための誘導加熱コイルが金型と一体的に構成され、各樹脂成形体の形状毎に電磁誘導コイルを簡便に取替えることが出来ないという欠点を有していた。また更に金型・金型キャビティ表面と誘導加熱コイル間のギャップが固定された構造上、金型キャビティ面に微妙な温度傾斜付与が出来ないという欠点を有している。 The problem to be solved is the structure of whole surface heating and whole surface cooling in the conventional electromagnetic induction heating type mold, and it corresponds to the weld line generation part and the transfer imperfect part which are different depending on the shape of each resin molding. However, it has a drawback that it cannot efficiently perform local heating and local cooling. In other words, it has a structure in which the entire surface is unnecessarily heated and the entire surface is unnecessarily cooled, and there is a drawback that energy cannot be used efficiently. Further, the induction heating coil for electromagnetic induction heating is integrally formed with the mold, and there is a drawback that the electromagnetic induction coil cannot be easily replaced for each shape of each resin molding. Further, due to the structure in which the gap between the die / die cavity surface and the induction heating coil is fixed, there is a drawback that a slight temperature gradient cannot be applied to the die cavity surface.
本願発明に係る電磁誘導加熱式樹脂成形金型は、成形する樹脂成形体の形状に応じて、脱着容易な誘導加熱用のコイル・カセットで、局所加熱により温度傾斜加熱する構成とする。このコイル・カセットはコイル保持板と、このコイル保持板に取付けられた誘導加熱コイルにより構成する。誘導加熱コイルは、成形する樹脂成形体の形状に応じて任意の個数だけ取付可能とし、更に個々の誘導加熱コイルとコイル保持板のギャップも個々に調整可能である。そしてこのコイル・カセットを、金型本体の加熱面から任意のギャップを設けて取付け調整可能としている。また金型冷却についても、この局所加熱の個所に対応して局所冷却により温度傾斜冷却を行う構成としている。更に上記コイル・カセットを金型キャビティ面に対して平行ではなく適度な傾斜を付けることで金型キャビティ面に微妙な温度傾斜を付与するように構成する。この温度傾斜付与は、誘導加熱コイル毎に付加的な磁性材(ソフトフェライト)等を接近配置させる構成としてもよい。 The electromagnetic induction heating type resin molding die according to the present invention is a coil cassette for induction heating which can be easily attached and detached according to the shape of the resin molded body to be molded, and is configured to perform temperature gradient heating by local heating. The coil cassette is composed of a coil holding plate and an induction heating coil attached to the coil holding plate. Any number of induction heating coils can be attached according to the shape of the resin molded body to be molded, and the gap between each induction heating coil and the coil holding plate can be adjusted individually. The coil cassette can be attached and adjusted by providing an arbitrary gap from the heating surface of the die body. Regarding mold cooling as well, temperature gradient cooling is performed by local cooling corresponding to the location of local heating. Further, the coil cassette is not parallel to the cavity surface of the mold, but is appropriately inclined, so that a slight temperature gradient is imparted to the cavity surface of the mold. The temperature gradient may be imparted by arranging an additional magnetic material (soft ferrite) or the like close to each induction heating coil.
本願発明は誘導加熱コイルをカセット化して局所加熱による熱容量の最小化を図り、また同時に局所加熱の個所に対応して局所冷却を行うことで、樹脂成形体表面のウェルドライン等の不良部を効率良く解消することが出来る。またこのような局所加熱、局所冷却によって、ハイサイクル成形を図ると共に、金型コストの削減及び作業性向上が可能となるという利点を有する。また更に誘導加熱コイル・カセットを金型キャビティ面に対して適度の傾斜を付与することで、自在に温度傾斜を付与して金型キャビティ面の温度を微調整できるという利点を有する。特に従来の全面加熱の構成とは異なり、誘導加熱コイルが取付けられた近傍のみを局所的に加熱でき、またこの個所を局所的に冷却することにより、効率的な金型の加熱・冷却工程を構成することが可能となる。更に本願発明のコイル・カセットはコイル保持板と金型本体の加熱面とのギャップ調整、そして個々の誘導加熱コイルとコイル保持板のギャップも調整可能であるので、成形する樹脂成形体の形状に応じてフレクシブルに加熱、冷却することでエネルギーの効率的な利用が可能となる。 In the present invention, the induction heating coil is formed into a cassette to minimize the heat capacity by local heating, and at the same time, local cooling is performed corresponding to the location of local heating, so that defective parts such as weld lines on the surface of the resin molding can be efficiently treated. It can be resolved well. Further, by such local heating and local cooling, there are advantages that high cycle molding can be achieved, and die cost can be reduced and workability can be improved. Further, by providing the induction heating coil cassette with an appropriate inclination with respect to the mold cavity surface, there is an advantage that the temperature of the mold cavity surface can be finely adjusted by freely giving a temperature inclination. Especially, unlike the conventional whole surface heating configuration, only the vicinity where the induction heating coil is attached can be locally heated, and by cooling this part locally, an efficient mold heating / cooling process can be performed. It becomes possible to configure. Further, in the coil cassette of the present invention, the gap between the coil holding plate and the heating surface of the mold body can be adjusted, and the gap between each induction heating coil and the coil holding plate can be adjusted, so that the shape of the resin molded body to be molded can be adjusted. Accordingly, by flexibly heating and cooling, energy can be efficiently used.
図1は、樹脂成形機200内に本願発明に係る電磁誘導加熱式樹脂成形金型100を収納設置した電磁誘導加熱式樹脂成形装置1の概略接続図である。電磁誘導加熱式樹脂成形金型100を収納した樹脂成形機200には、電磁誘導加熱装置300と冷却機構400が各々加熱電力供給のため、冷却水および空気供給のために接続されている。この構成自体は従来の電磁誘導加熱式樹脂成形装置と同一であるので詳細は割愛する。なお誘導加熱に必要な最も原理的な構成は、高周波発信部(インバータ)と加熱コイル(インダクター)と被加熱物質であるが、本願発明ではさらに図示しない整合部と呼ばれる変圧トランスおよびコンデンサーを具備することにより広範囲の加熱コイル形状に最適化が可能となり、複数の加熱コイルとソフトフェライトによる局所加熱と温度傾斜コントロールが実現できるように構成されている。 FIG. 1 is a schematic connection diagram of an electromagnetic induction heating type resin molding apparatus 1 in which an electromagnetic induction heating type resin molding die 100 according to the present invention is housed and installed in a resin molding machine 200. An electromagnetic induction heating device 300 and a cooling mechanism 400 are connected to a resin molding machine 200 accommodating the electromagnetic induction heating type resin molding die 100 for supplying heating power and cooling water and air, respectively. The structure itself is the same as that of the conventional electromagnetic induction heating type resin molding device, and therefore its details are omitted. The most basic configuration required for induction heating is a high-frequency transmitting unit (inverter), a heating coil (inductor), and a substance to be heated. However, the present invention further includes a transformer and a capacitor called a matching unit, which are not shown. This makes it possible to optimize the shape of the heating coil in a wide range, and it is configured to realize local heating and temperature gradient control by a plurality of heating coils and soft ferrite.
図2は本願発明の電磁誘導加熱式樹脂成形金型100の断面図であり、図3は意匠面金型100bにコイル・カセット30を設置した平面図である。すなわち金型100は、図2中の左側の非意匠面側金型100aと、右側の意匠面側金型100bで構成されている。非意匠面側金型100aと意匠面側金型100bの間には、樹脂成形体が成形される任意形状の金型キャビティ100cが設けられている。前者の非意匠面側金型100aは従来技術に係る金型と同様に取付板10に一体的に取り付けられ、内部には冷却用に複数個の冷却孔50およびエジェクタ11が設けられている。そして金型100の右側には成形用の金型キャビティ100cを挟んで意匠面側金型100bが設けられている。この意匠面側金型100bには、電磁誘導加熱のためのコイル・カセット30が所定の深さのコイル・カセット収納部20内に取付けられている。また冷却機構からの冷却媒体を流す複数個の冷却孔50が、コイル・カセット30に対して金型キャビティ100c側にある被加熱金属部40内にも複数個が設けられている。 2 is a cross-sectional view of the electromagnetic induction heating type resin molding die 100 of the present invention, and FIG. 3 is a plan view in which the coil cassette 30 is installed on the design surface die 100b. That is, the mold 100 is composed of a non-design surface side mold 100a on the left side in FIG. 2 and a design surface side mold 100b on the right side. Between the non-design surface side mold 100a and the design surface side mold 100b, a mold cavity 100c having an arbitrary shape for molding a resin molded body is provided. The former non-design surface side die 100a is integrally attached to the attachment plate 10 like the die according to the related art, and a plurality of cooling holes 50 and the ejector 11 are provided inside for cooling. A design surface side mold 100b is provided on the right side of the mold 100 with a molding mold cavity 100c interposed therebetween. A coil cassette 30 for electromagnetic induction heating is attached to the design surface side mold 100b in the coil cassette housing portion 20 having a predetermined depth. Further, a plurality of cooling holes 50 through which the cooling medium from the cooling mechanism flows are also provided in the heated metal portion 40 on the mold cavity 100c side with respect to the coil cassette 30.
ここでコイル・カセット30は、例えば耐熱温度が100℃以上で、絶縁性、耐熱性の理由により厚さ1〜30mm程度のコイル保持板31と、図示しない例えば非磁性体の取付板を介してコイル保持板31に誘導加熱コイル取付ネジ34で取付けられた誘導加熱コイル33とで構成される。ただし取付方法は、コイルを外側から挟持する等、その取付方法は特に限定しない。厚さを1〜30mm程度に限定するのは、絶縁性、耐熱性を考慮し、かつ機械的強度の点より最適と考えられるからである。なお30mmを超えると、被加熱金属部40に渦電流が生じ難くなり、誘導加熱され難くなるからである。 Here, the coil cassette 30 has a heat-resistant temperature of 100 ° C. or higher, a coil holding plate 31 having a thickness of about 1 to 30 mm due to insulation and heat resistance, and a non-magnetic mounting plate (not shown). An induction heating coil 33 is attached to the coil holding plate 31 with an induction heating coil mounting screw 34. However, the mounting method is not particularly limited, such as sandwiching the coil from the outside. The reason for limiting the thickness to about 1 to 30 mm is that it is considered to be optimum from the viewpoint of mechanical strength while considering the insulating property and heat resistance. If it exceeds 30 mm, eddy current is less likely to be generated in the heated metal portion 40, and induction heating is less likely to occur.
誘導加熱コイル33は、例えば内寸半径Rが50mm以下である。このような内寸半径Rとするのは、内寸半径Rを50mm以下とすることで被加熱金属のコイル内径部分も均等に加熱され、被加熱金属部40の局所加熱により温度傾斜加熱が可能となる。すなわち内寸半径Rをこの程度の小径にして誘導磁束が被加熱金属部40に垂直となるように構成すれば、温度を高くしたい部位にエネルギーを均等に集中させることが可能となり、内径寸法を50mm以上にすると、コイル内径部分に磁束密度が疎の部分ができ、コイル内径部分の加熱面への投影面の温度が低くなってしまうからである。この内寸半径Rは、金型キャビティ内の樹脂成形体の形状やサイズに応じて適宜決定してもよい。また誘導加熱コイル33の取付位置は、樹脂成形体のウェルドラインが発生し易い個所や、転写性が不完全な個所等の成形不良が発生する蓋然性が高い個所の近傍となるように、前記コイル保持板31上で誘導加熱コイル33を自在に配置変更できるように構成してもよい。例えば図3に示すように樹脂成形体の凸部90の近傍であり、凸部90に対し溶融樹脂の下流側となる個所である。このような個所では分流した溶融樹脂が合流し流速が低下して、十分に融合せずウェルドラインが発生し易い。したがってこの様な個所を、局所的に加熱することにより、全面加熱と異なり効果的にウェルドライン発生を防止することが可能となる。誘導加熱コイル33の大きさ(外径)も、この凸部90のサイズと成形体のサイズ・形状に対応して必要最小限のサイズとし、また誘導加熱コイル33の個数もウェルドライン等の不良発生箇所の数に合わせることにより、加熱電力の最少化を図ることが可能である。またコイル保持板31の厚さも、誘導加熱コイル33の個数等により、適宜変更してもよい。 The induction heating coil 33 has an inner dimension radius R of 50 mm or less, for example. The inner radius R is set to be 50 mm or less so that the inner diameter of the coil of the metal to be heated is evenly heated, and the temperature gradient heating can be performed by locally heating the metal to be heated 40. Becomes That is, if the inner radius R is set to such a small diameter that the induced magnetic flux is perpendicular to the heated metal portion 40, the energy can be evenly concentrated at the portion where the temperature is to be raised, and the inner diameter is This is because if the thickness is 50 mm or more, a portion having a sparse magnetic flux density is formed in the coil inner diameter portion, and the temperature of the projection surface onto the heating surface of the coil inner diameter portion becomes low. The inner radius R may be appropriately determined according to the shape and size of the resin molded body in the mold cavity. In addition, the induction heating coil 33 is installed at a position near the place where the weld line of the resin molded body is likely to occur and the place where the defective molding such as incomplete transferability is likely to occur. The induction heating coil 33 may be freely arranged on the holding plate 31. For example, as shown in FIG. 3, it is in the vicinity of the convex portion 90 of the resin molded body, and is a portion on the downstream side of the molten resin with respect to the convex portion 90. In such a place, the divided molten resins join together to reduce the flow velocity, and they are not sufficiently fused to easily cause a weld line. Therefore, by locally heating such a part, unlike the whole surface heating, it is possible to effectively prevent the generation of a weld line. The size (outer diameter) of the induction heating coil 33 is also set to the minimum necessary size corresponding to the size of the convex portion 90 and the size / shape of the molded body, and the number of induction heating coils 33 is also defective such as a weld line. It is possible to minimize the heating power by adjusting the number of occurrence points. Further, the thickness of the coil holding plate 31 may be appropriately changed depending on the number of induction heating coils 33 and the like.
コイル・カセット30は、図3に示すコイル・カセット取付ネジ32により、図2に示すように被加熱金属部40に対し平面的に取付られている。なお被加熱金属部40との取付ギャップはコイル・カセット取付ネジ32で調整可能とし、この調整された取付ギャップにより加熱調整してもよい。更にコイル・カセット30は、例えば四隅に設けた各コイル・カセット取付ネジ32を調整して、被加熱金属部40に対し(同時に金型キャビティ100cに対し)適度の傾斜角を持たせて自在に温度傾斜を付与してもよい。これにより加熱の微調整が可能となる。このような温度傾斜付与は従来例に係る金型と異なり、本願発明のように意匠面金型100b本体とは別筐体となるコイル・カセット30で構成することにより初めて可能となる。 The coil cassette 30 is planarly attached to the heated metal portion 40 as shown in FIG. 2 by the coil cassette attachment screw 32 shown in FIG. The mounting gap with the metal part 40 to be heated may be adjusted by the coil / cassette mounting screw 32, and the adjusted mounting gap may be used for heating adjustment. Further, the coil cassette 30 can be freely adjusted, for example, by adjusting the coil cassette mounting screws 32 provided at the four corners so as to have an appropriate inclination angle with respect to the heated metal portion 40 (simultaneously with the mold cavity 100c). A temperature gradient may be applied. This allows fine adjustment of heating. Unlike the mold according to the conventional example, such a temperature gradient can be provided only by using the coil cassette 30 which is a case different from the main body of the design surface mold 100b as in the present invention.
更にコイル・カセット30について詳述すれば、誘導加熱コイル33はコイル保持板31に誘導加熱コイル取付ネジ34で取付けられているが、複数個取付けられた誘導加熱コイル33の個々は、各々の誘導加熱コイル取付ネジ34にスペーサ等を挟み込む等の調整を行い被加熱金属部40とのギャップを微調整出来るように構成してもよい。なおこの誘導加熱コイル33のコイル保持板31への取付け方は、上述のようなコイル中央で誘導加熱コイル取付ネジ34で取付ける構成に限らず、コイルを外側から挟持する等、その取付方法は特に限定しない。また誘導加熱コイル33は、成形する樹脂成形体の形状に応じて任意の個数だけ取付可能とし、更に個々の誘導加熱コイル33とコイル保持板31のギャップも誘導加熱コイル取付ネジ34を調整することにより個々に調整可能である。この様にコイル・カセット30を構成することで、成形する樹脂成形体の形状に応じてフレクシブルに加熱、冷却することでエネルギーの効率的な利用が可能となる。従ってコイルをカセット化することにより、従来のようにコイルが金型本体に固定設置される構成に比較して自在に温度傾斜を付与することが可能となる。 More specifically, the coil cassette 30 will be described in detail. The induction heating coils 33 are attached to the coil holding plate 31 with the induction heating coil attachment screws 34. The heating coil mounting screw 34 may be adjusted by sandwiching a spacer or the like so that the gap with the heated metal portion 40 can be finely adjusted. The method of attaching the induction heating coil 33 to the coil holding plate 31 is not limited to the configuration of attaching the induction heating coil attachment screw 34 at the center of the coil as described above, and the attachment method such as sandwiching the coil from the outside is particularly preferable. Not limited. Further, the induction heating coil 33 can be attached in an arbitrary number according to the shape of the resin molded body to be molded, and the gap between the individual induction heating coil 33 and the coil holding plate 31 can be adjusted by the induction heating coil mounting screw 34. Can be adjusted individually. By constructing the coil cassette 30 in this way, it is possible to efficiently use energy by flexibly heating and cooling according to the shape of the resin molded body to be molded. Therefore, by forming the coil into a cassette, it becomes possible to give a temperature gradient more freely than the conventional configuration in which the coil is fixedly installed on the mold body.
更に図2に示す被加熱金属部40は、キュリー温度の異なる合金或いはその複合材とし、温度コントロールを行ってもよい。特に加熱温度の上限をコントロールする場合に有効な構成である。 Further, the heated metal portion 40 shown in FIG. 2 may be an alloy having a different Curie temperature or a composite material thereof to control the temperature. In particular, this configuration is effective when controlling the upper limit of the heating temperature.
次に本願発明に係る電磁誘導加熱式樹脂成形金型100では、図2に示すように図中左側の非意匠面側金型100aと右側の意匠面側金型100bに複数個の冷却孔50(a,b,c,d)が各々配置されている。特に右側の意匠面側金型100bに設けられた複数個の冷却孔50は、コイル・カセット30の金型キャビティ100c側にある被加熱金属部40内に複数個が設けられている。これに対して従来の電熱ヒーターで加熱するタイプの金型では、冷却孔が電熱ヒーターを挟んでキャビティより離れて設けられていたため冷却効率が低いという欠点を有していた。しかしながら本願発明では、金型キャビティ100cにより近い位置に冷却孔50が設けられているので冷却効率が良いという利点を有する。これはコイル・カセット30が被加熱金属部40とは別筐体で構成されていることで可能となる構成である。各冷却孔50は、図示しない制御部で各々冷却媒体の注入・排出がコントロールできる構成となっている。この実施例では意匠面金型100bには局所加熱による温度傾斜加熱のために2つの誘導加熱コイル33が冷却孔50aと50cの近傍に取付けられている。したがって誘導加熱コイル33で局所加熱により温度傾斜加熱され、溶融樹脂が注入された後、この誘導加熱コイル33の近傍に配置された冷却孔50aと50cのみに冷却媒体を注入し冷却する。換言すれば局所加熱されなかった近傍に配置された冷却孔50b、50dには冷却媒体を注入しない、または50aと50cに比べ冷却媒体の量を少なくする。この様にして本願発明では加熱、冷却とも全面加熱、全面冷却ではなく、局所加熱、局所冷却することで消費エネルギーの最少化を図るのみでなく、成形工程の短縮化を図ることでハイサイクル成形が可能となるように構成されている。また、図1中の冷却機構400のエアーパージは冷却後、加熱工程前に冷却孔内部を空気置換することで冷却媒体を加熱するというエネルギーロスを防ぐものである。 Next, in the electromagnetic induction heating type resin molding die 100 according to the present invention, as shown in FIG. 2, a plurality of cooling holes 50 are provided in the non-design surface side die 100a on the left side and the design surface side die 100b on the right side in the figure. (A, b, c, d) are arranged respectively. In particular, a plurality of cooling holes 50 provided in the design surface side mold 100b on the right side are provided in the heated metal portion 40 on the mold cavity 100c side of the coil cassette 30. On the other hand, the conventional mold of the type heated by the electric heater has a drawback that the cooling efficiency is low because the cooling hole is provided apart from the cavity with the electric heater interposed therebetween. However, the present invention has an advantage that the cooling efficiency is good because the cooling hole 50 is provided at a position closer to the mold cavity 100c. This is possible because the coil cassette 30 is configured in a housing separate from the heated metal portion 40. Each cooling hole 50 is configured such that the control unit (not shown) can control the injection and discharge of the cooling medium. In this embodiment, two induction heating coils 33 are attached to the design surface mold 100b in the vicinity of the cooling holes 50a and 50c for temperature gradient heating by local heating. Therefore, the induction heating coil 33 performs local temperature gradient heating and injects the molten resin, and then injects the cooling medium only into the cooling holes 50a and 50c arranged in the vicinity of the induction heating coil 33 for cooling. In other words, the cooling medium is not injected into the cooling holes 50b and 50d arranged in the vicinity where local heating is not performed, or the amount of the cooling medium is reduced as compared with 50a and 50c. In this way, according to the present invention, not only the heating and cooling of the entire surface but also the entire surface cooling is not performed, but local heating and local cooling are performed, so that not only the energy consumption can be minimized but also the molding process can be shortened to achieve high cycle molding. Is configured to be possible. Further, the air purging of the cooling mechanism 400 in FIG. 1 prevents energy loss of heating the cooling medium by replacing air inside the cooling holes after cooling and before the heating step.
図4は、誘導加熱コイル33の近傍に複数個のソフトフェライトを配置した別の実施例を示す平面図である。このソフトフェライトは、マンガン亜鉛フェライト、ニッケル亜鉛フェライト、銅亜鉛フェライト等が代表的なものである。 透磁率が高く、また電気抵抗が高いことから高周波数領域での渦電流損失が小さいため、“フェライトコア”と言われる高周波用のインダクタやトランスの磁芯材料として用いられる。このようなソフトフェライトを配置することで磁束をコントロールして磁束密度を高め、その結果、渦電流の電流密度も高くなるので図2に示す金型の被加熱金属部40の加熱効率を高くすることが可能である。また必要に応じて、電気抵抗が低く比較的誘導加熱され難い銅板等の金属を誘導加熱コイル周辺に配置してもよい。すなわち銅板上のうず電流による表皮効果を利用して、被加熱金属部40に対して電磁シールドを行い、これにより誘導コイルによる加熱の必要性が低い部分の温度を微調整することが可能となる。換言すれば誘導加熱コイル33の近傍に、電気抵抗が十分に低く厚みが表皮深さ以上ある非磁性導電材である銅板等を配置し、それにより磁束密度を低下させて加熱の必要性が低い部分を実質的に磁気遮蔽することで被加熱金属部40の加熱温度を微調整することが可能となる。いずれの場合にも、誘導加熱コイル33の近傍にフェライトや銅板等を配置することで、更に効率の良い局所加熱により温度傾斜加熱が可能となる利点を有する。(a)は誘導加熱コイル33内部にソフトフェライトを配置したものであり、(b)は誘導加熱コイル33の外部に、(c)は上部に配置したものであり、それぞれ異なる特性の局所加熱により温度傾斜加熱が計測されているので、樹脂成形体の形状等に応じて各々の配置を決定するのがよい。 FIG. 4 is a plan view showing another embodiment in which a plurality of soft ferrites are arranged near the induction heating coil 33. Typical examples of this soft ferrite are manganese zinc ferrite, nickel zinc ferrite, and copper zinc ferrite. Since it has a high magnetic permeability and a high electric resistance, it causes little eddy current loss in the high frequency region, and is therefore used as a magnetic core material for high frequency inductors and transformers called "ferrite cores". By arranging such soft ferrite, the magnetic flux is controlled to increase the magnetic flux density, and as a result, the current density of the eddy current is also increased, so that the heating efficiency of the heated metal portion 40 of the mold shown in FIG. 2 is increased. It is possible. If necessary, a metal such as a copper plate having a low electric resistance and relatively hard to be induction-heated may be arranged around the induction heating coil. That is, the skin effect of the eddy current on the copper plate is used to electromagnetically shield the metal part 40 to be heated, which makes it possible to finely adjust the temperature of the part where heating by the induction coil is low. .. In other words, a copper plate or the like, which is a non-magnetic conductive material having a sufficiently low electric resistance and a thickness equal to or greater than the skin depth, is arranged near the induction heating coil 33, thereby lowering the magnetic flux density and reducing the need for heating. By substantially magnetically shielding the portion, the heating temperature of the heated metal portion 40 can be finely adjusted. In any case, by arranging ferrite or a copper plate in the vicinity of the induction heating coil 33, there is an advantage that temperature gradient heating can be performed by more efficient local heating. (A) is the one in which the soft ferrite is arranged inside the induction heating coil 33, (b) is the one outside the induction heating coil 33, and (c) is the one above it. Since the temperature gradient heating is measured, it is preferable to determine each arrangement according to the shape of the resin molded body and the like.
なお誘導加熱コイル33の大きさ(外径)を変更して、加熱部位に対する加熱エネルギーの集中度を変更し、局所加熱の温度コントロールを行うように構成してもよい。当然、コイルの大きさを小径にすれば加熱エネルギーの集中度は向上し、高温での局所加熱が可能となる。 Note that the size (outer diameter) of the induction heating coil 33 may be changed to change the degree of concentration of heating energy with respect to the heating portion, and the temperature of local heating may be controlled. Naturally, if the size of the coil is made small, the degree of concentration of heating energy is improved, and local heating at high temperature becomes possible.
なお本願発明では、上記電磁誘導加熱式樹脂成形装置1を用いた樹脂成形体の製造方法も併せて開示する。すなわちまず金型100を開いた状態で、誘導加熱コイル33に通電することにより金型キャビティ100cを局所加熱により温度傾斜加熱を行い、傾斜温度を付与して所定温度に昇温する。次に金型100を閉じて金型キャビティ100c内に樹脂を充填すると共に、圧力を保持し、所定時間経過後、金型100に接続した冷却機構400によって局所加熱した部位近傍のみを局所冷却し、降温完了後に樹脂成形体を取り出すようにしてもよい。この場合、誘導加熱コイル33の内部または外部あるいは上部にソフトフェライトを配し、前記金型キャビティ100cの表面温度を10℃〜200℃の傾斜を設けて所定温度に昇温する工程を含むようにしてもよい。 Note that the present invention also discloses a method for manufacturing a resin molded body using the electromagnetic induction heating type resin molding apparatus 1. That is, first, with the mold 100 open, the induction heating coil 33 is energized to locally heat the mold cavity 100c to perform temperature gradient heating, and a gradient temperature is applied to raise the temperature to a predetermined temperature. Next, the mold 100 is closed to fill the resin into the mold cavity 100c, the pressure is maintained, and after a lapse of a predetermined time, the cooling mechanism 400 connected to the mold 100 locally cools only the vicinity of the locally heated portion. Alternatively, the resin molded body may be taken out after the completion of the temperature reduction. In this case, a soft ferrite may be arranged inside or outside the induction heating coil 33 or on the upper side thereof, and the surface temperature of the mold cavity 100c may be inclined at 10 ° C. to 200 ° C. to raise the temperature to a predetermined temperature. Good.
上述のように本願発明に係る電磁誘導加熱式樹脂成形金型100では、誘導加熱用のコイル・カセット30を用いたため、樹脂成形体の形状等に応じて容易に局所加熱する個所を変更することが可能となる。またこの局所加熱に対応した個所のみを局所冷却する構成であるので冷却エネルギーの最少化を図ることが可能となる。また同一のコイル・カセット30を、樹脂成形体の形状に合わせて誘導加熱コイル33の位置設定を変えることにより、各種の金型に流用することが可能となり、金型製造が容易となる利点を有する。更に被加熱金属部40と誘導加熱用のコイル・カセット30のギャップ、或いはコイル保持板31と個々の誘導加熱コイル33のギャップを微調整することで、金型キャビティ100c表面への局所加熱により温度傾斜付与が可能となる利点も有する。さらに誘導加熱コイル近傍に、磁束集中させる目的で磁性材であるフェライトを配置することによっても局所加熱の温度コントロールが可能となる利点を有する。 As described above, in the electromagnetic induction heating type resin molding die 100 according to the present invention, since the induction heating coil cassette 30 is used, it is possible to easily change the location of local heating according to the shape of the resin molded body and the like. Is possible. Further, since the structure is such that only the portion corresponding to the local heating is locally cooled, it is possible to minimize the cooling energy. Further, by changing the position setting of the induction heating coil 33 according to the shape of the resin molded body, it is possible to use the same coil cassette 30 for various molds, which is advantageous in that the mold manufacturing becomes easy. Have. Further, by finely adjusting the gap between the heated metal part 40 and the induction heating coil cassette 30 or the gap between the coil holding plate 31 and the individual induction heating coils 33, the temperature can be locally heated on the surface of the mold cavity 100c. There is also an advantage that inclination can be imparted. Further, by arranging ferrite, which is a magnetic material, for the purpose of concentrating the magnetic flux in the vicinity of the induction heating coil, there is an advantage that the temperature of local heating can be controlled.
100 電磁誘導加熱式樹脂成形金型
20 コイル・カセット収納部
30 コイル・カセット
31 コイル保持板
32 コイル・カセット取付ネジ
33 誘導加熱コイル
34 誘導加熱コイル取付ネジ
40 被加熱金属部
50 冷却孔
100 Electromagnetic Induction Heating Resin Mold 20 Coil / Cassette Storage Section 30 Coil / Cassette 31 Coil Holding Plate 32 Coil / Cassette Mounting Screw 33 Induction Heating Coil 34 Induction Heating Coil Mounting Screw 40 Heated Metal Part 50 Cooling Hole
Claims (15)
コイル保持板(31)と該コイル保持板に取付けられた1または複数個の誘導加熱コイル(33)により構成された局所誘導加熱用のコイル・カセット(30)を有し、該コイル・カセットは、コイル・カセット収納部(20)内で被加熱金属部(40)に脱着容易に取付けられ、前記電磁誘導加熱装置により制御された所定の高周波電力により被加熱金属部を局所加熱により温度傾斜加熱するように構成され;
更に前記冷却機構からの冷却媒体を流す複数個の冷却孔(50)が、前記コイル・カセットと金型キャビティ面の間の被加熱金属部(40)内に設けられ、前記誘導加熱コイルにより局所加熱された被加熱金属部の近傍に設けられた冷却孔のみに、冷却媒体を流して局所冷却により温度傾斜冷却するように構成されたことを特徴とする電磁誘導加熱式樹脂成形金型。 An electromagnetic induction heating type resin molding die used in the resin molding machine of the electromagnetic induction heating type resin molding apparatus (1) including the resin molding machine (200), the electromagnetic induction heating device (300) and the cooling mechanism (400) ( 100);
A coil cassette (30) for local induction heating constituted by a coil holding plate (31) and one or a plurality of induction heating coils (33) attached to the coil holding plate, the coil cassette comprising: , The coil / cassette housing (20) is easily attached to the metal part (40) to be heated and detached, and the metal part to be heated is subjected to temperature gradient heating by local heating by a predetermined high frequency power controlled by the electromagnetic induction heating device. Configured to do;
Further, a plurality of cooling holes (50) through which a cooling medium from the cooling mechanism flows are provided in the heated metal part (40) between the coil cassette and the mold cavity surface, and the induction heating coil locally serves. An electromagnetic induction heating type resin molding die characterized in that a cooling medium is caused to flow only through a cooling hole provided in the vicinity of a heated metal part to be locally cooled to perform temperature gradient cooling.
ルギーの集中度を変更し、局所加熱の温度コントロールを行うように構成されたことを特徴とする請求項1記載の電磁誘導加熱式樹脂成形金型。 The size (outer diameter) of the induction heating coil (33) is changed to change the degree of concentration of heating energy with respect to a heating portion, and the temperature of local heating is controlled. 1. The electromagnetic induction heating type resin molding die described in 1.
金型キャビティ内に樹脂を充填すると共に圧力を保持し、
所定時間経過後、金型に接続した冷却機構(400)から供給される冷却媒体を流す複数個の冷却孔(50)の内、前記局所加熱した個所の近傍に設けられた冷却孔のみに冷却媒体を流すように制御することで局所冷却により温度傾斜冷却し、降温完了後に樹脂成形体を取り出す樹脂成形体の製造方法。 The mold cavity (100c) is heated by energizing the induction heating coil (33) with high frequency from the electromagnetic induction heating device (300) with the electromagnetic induction heating type resin molding mold (100) according to claim 1 being opened. Then, temperature gradient heating by local heating to a predetermined temperature,
Fill the mold cavity with resin and hold the pressure,
After a lapse of a predetermined time, of the plurality of cooling holes (50) through which the cooling medium supplied from the cooling mechanism (400) connected to the mold flows, only the cooling holes provided near the locally heated portion are cooled. A method for producing a resin molded body, in which temperature gradient cooling is performed by local cooling by controlling the medium to flow, and the resin molded body is taken out after completion of cooling.
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