CN101284413B - 模内转印方法 - Google Patents

模内转印方法 Download PDF

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CN101284413B
CN101284413B CN200710200451XA CN200710200451A CN101284413B CN 101284413 B CN101284413 B CN 101284413B CN 200710200451X A CN200710200451X A CN 200710200451XA CN 200710200451 A CN200710200451 A CN 200710200451A CN 101284413 B CN101284413 B CN 101284413B
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mould
paper tinsel
transfer printing
tinsel film
medium channel
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CN101284413A (zh
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张浚元
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Kang Zhun Electronical Technology Kunshan Co ltd
Hon Hai Precision Industry Co Ltd
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Kangzhun Electronic Technology Kunshan Co Ltd
Hon Hai Precision Industry Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B29C2037/0042—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied in solid sheet form, e.g. as meltable sheet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14213—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure deforming by gas or fluid pressure in the mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14286—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure means for heating the insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C2045/1486—Details, accessories and auxiliary operations
    • B29C2045/14868—Pretreatment of the insert, e.g. etching, cleaning
    • B29C2045/14877—Pretreatment of the insert, e.g. etching, cleaning preheating or precooling the insert for non-deforming purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
    • B29C35/045—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using gas or flames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14008—Inserting articles into the mould
    • B29C45/14016—Intermittently feeding endless articles, e.g. transfer films, to the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14688—Coating articles provided with a decoration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

一种模内转印方法，包括以下步骤：将箔膜送入第一与第二模具之间，其中第一模具具有一模穴，第二模具包括一设有泄压阀的排气槽及一进气口；将箔膜压制于第一模具，箔膜与第一模具间形成一气密空间；将所述气密空间抽真空，以将箔膜向第一模具的模穴内吸附；将第一与第二模具合模；利用介质向箔膜加压，使箔膜完全贴合于第一模具的模穴内；向模穴内射胶；及冷却开模。本方法可通过第一模具吹气加压及与第二模具抽真空的双重作用下，极大延伸该两模具间的箔膜本身的拉伸长度，且可达到使得箔膜即便是在小角度情况下也可与第二模具模穴完美贴合的效果。

Description

模内转印方法
技术领域
本发明涉及一种模内转印方法。
背景技术
在模内成型制程中，现有技术中仅依靠母模侧在常温状态抽真空将箔膜吸附定位于母模模穴内，因此箔膜拉深深度受限于箔膜基体层本身在常温状态时的拉伸极限，例如当箔膜本身被拉伸超过其自然状态20％时可能会破损或被拉断；再者当母模模穴设计有小角度(特别是锐角角度时)结构时，由于抽真空产生的负压的大小及箔膜基体层材料的常温变形的限制，箔膜亦不易完全的与模穴的形状相契合。
基于以上现有技术的缺失，业界已出现对箔膜预先加热的制程，如现有技术中揭示了一种在合模前对箔膜进行加热的独立加热装置，该加热装置是独立于模具外部，当需要加热时需另外的传送装置将该加热装置送至公母模之间对箔膜加热，加热后，再由该传送装置将该加热装置从公母模之间移出。因此，现有技术不仅需要设计加热装置及配合其使用的传送装置，致使整个设备结构庞大，成本较高；并且导致整个制程时间增长，效率较低。且该项技术中亦存在箔膜拉深深度及小角度结构有所限制的缺失。
发明内容
基于以上，有必要提供一种可增加箔膜拉深深度及角度范围的模内转印方法。
一种模内转印方法，包括以下步骤：将箔膜送入第一与第二模具之间，其中第一模具具有一模穴，第二模具包括一设有泄压阀的排气槽及一进气口；将箔膜压制于第一模具，箔膜与第一模具间形成一气密空间；将所述气密空间抽真空，以将箔膜向第一模具的模穴内吸附；将第一与第二模具合模；利用介质向箔膜加压，使箔膜完全贴合于第一模具的模穴内；向模穴内射胶；及冷却开模。
本方法可通过第一模具吹气加压及与第二模具抽真空的双重作用下，极大延伸该两模具间的箔膜本身的拉伸长度，且可达到使得箔膜即便是在小角度及大拉深深度的情况下也可与第二模具模穴完美贴合的效果。
附图说明
图1是运用本发明模内转印方法的较佳实施方式的模具的剖视图。
图2是图1中所示的第二模具的剖视图。
图3与图4是图1中所示的的第一模具的介质通道部分的剖视图，分别表示其两个不同的状态。
图5是图1中所示的第二模具与箔膜相贴合的剖视图。
图6是本发明模内转印方法的较佳实施方式合模后并向模穴内充气状态的剖视图。
图7是运用本发明模内转印方法的较佳实施方式的模具合模后射胶成型状态的剖视图。
图8是本发明模内转印方法的较佳实施方式的流程框图。
具体实施方式
请参阅图1，一种模内转印方法用来在注射成型的同时将箔膜100上的图案转印于工件上，运用该模内转印方法的较佳实施方式的模内转印设备包括送膜装置10、第二模具20、第一模具30、压合框40及热介质源90。
请一并参阅图2，该第一模具30开设一模穴31，模穴31包括一第一表面A1，一第二表面A2及一第三表面A3，模穴31开口位置第一表面A1与第二表面A2间的连线长度为L，母模30于模穴31内及其周围开设有若干排气槽32，排气槽32一端与抽真空装置相连。第一模具30周缘与排气槽32间设置有密封圈33。
请继续参阅图1，第二模具20包括一与第一模具30的模穴31相对应的配合部21，邻近第二模具20的配合部21开设若干排气槽23，每一排气槽23连接一可调泄压阀80，泄压阀80的泄压阀值可根据成型条件所需的压力变化作调节。该第二模具20周缘与排气槽23之间开设有收容对应压合框40的收容槽25，收容槽25内装设有密封圈27。
请一并参阅图3与图4，该第二模具20穿过该配合部21开设若干介质通道29，介质通道29包括一开设于配合部21的喇叭口状的开口291及自开口291的较细端向第二模具20内延伸的通道本体295。介质通道29的通道本体295远离开口291处开设一流道296并通过一管路91与热介质源90相连。介质通道29的通道本体295远离开口291的一端为一固定体298，固定体298开设一通孔。可以理解，该介质通道29的数量应视产品实际需求而定。介质通道29内装设一开关装置，本实施方式中该开关装置为柱塞70，柱塞70包括与介质通道29的形状相配合的圆台状柱塞头71、一与柱塞头71相连的杆部73及一可固定于该杆部73另一端的固定件75，该柱塞头71用于封闭该介质通道29的开口291，柱塞70的杆部73远离柱塞头71的一端穿过该固定体298的通孔并穿设于一弹性元件内，该弹性元件在本实施方式中为一弹簧79，该固定件75固定于该杆部73的末端将该弹簧79限制于该固定体298与该固定件75之间。
该热介质源90可为气体，气体可通过一电阻丝或者红外线加热器(IR Heater)加热后通过一调压阀与该管路91连通，其中电阻丝可以为可变电阻，因而可以根据成型条件对气体温度作调节。另外，气体也可以利用模具水道产生的热量加温。调压阀可根据成型压力需要调节输出气体的气压。
送膜装置10包括分设于模具上下游的两箔膜传送轮13及对箔膜传送方向导向的两导向轮15。
箔膜100包括一基体层与印刷于基体层的转印层，基体层一般为PC/PBT等高分子材料制成，转印层一般为用油墨或涂料印刷至基体层上的图案或文字。
请一并参阅图8，合模前，送膜装置10通过传送轮13的传送及导向轮15的导向，将箔膜100沿竖直方向自上而下地送入第一、第二模具之间并定位，箔膜100覆盖于第一模具30表面，之后压合框40将箔膜100压制于第一模具30表面，同时配合密封圈33，使箔膜100与模穴31之间形成一第一气密空间。抽真空装置通过排气槽32将该第一气密空间的部分空气抽出，将箔膜100向模穴31内吸入一部分，如图5所示。
合模时，压合框40收容于第二模具20的收容槽25内并压抵第二模具20的密封圈27，使箔膜100与第二模具20之间形成一第二气密空间。此时排气槽23与该第二气密空间相通。关闭泄压阀80，并对泄压阀80设定一泄压阀值。热介质源90通过管路91向介质通道29内通一定压力的热介质(本实施方式中为热空气)，热空气推动柱塞70向第一模具30侧运动，露出介质通道29的开口291，热空气通过介质通道29向箔膜100吹气并加压(如图4所示)，箔膜100的基体层软化，且在第一模具30侧通过排气槽32抽真空及通过第二模具20介质通道29的注入的热空气加温与加压的共同作用下箔膜100完全贴附于第一模具30的模穴31内壁，如图6所示。热介质源90停止供气，柱塞70在弹簧79的回复力作用下反向运动，将介质通道29封闭。
向第一模具30模穴31内射胶，当第一模具30模穴31内气压大于泄压阀阀值时，泄压阀80自动打开，将第一模具30模穴31内的气体泄出，继续射胶，直到充满第一模具30的模穴31，如图7所示。保压冷却，最后开模，取出成型品，箔膜100的转印层将附着于成型品表面，其基体层由于压合框40的压制将同转印层剥离。之后松开压合框40，继续开动送膜装置10，箔膜100位于前一成型周期内的基体层自第一、第二模具间移出，并开始下一成型周期。
本发明的技术方案中通过合模后对箔膜加热及在第一模具30侧抽真空与第二模具20侧吹气加压的双重作用，可极大延伸箔膜本身的拉伸长度，且可达到使得箔膜100即便是在小角度及大深度情况下也可与第一模具30的模穴31完美贴合的效果。例如纵使当第一模具30的模穴31的第一表面A1、第二表面A2及第三表面A3的尺寸关系符合关系式a1+a2+a3＞＝(1+20％)*L(其中第一表面A1的长度为a1，第二表面A2的长度为a2，第三表面A3的长度为a3)的大深度情况下，本发明也可达到箔膜100与第一模具30的模穴31完美贴合的效果。
可以理解，作为本发明的另一较佳实施方式，将该第一气密空间抽真空的步骤可以在第3一、第二模具合模后进行。

Claims (11)

1.一种模内转印方法，包括以下步骤：
将箔膜送入第一与第二模具之间，其中第一模具具有一模穴，第二模具开设一介质通道，介质通道包括一朝向第一模具的开口，介质通道内设置一开关装置以封闭或打开所述介质通道开口，所述开关装置为一柱塞，所述介质通道的开口呈喇叭口状，所述柱塞包括一柱塞头，所述柱塞头的形状与所述介质通道的开口相适配；
将箔膜压制于第一模具，箔膜与第一模具间形成一气密空间；
将所述气密空间抽真空，以将箔膜向第一模具的模穴内吸附；
将第一与第二模具合模；
利用气体通过第二模具开设的介质通道向箔膜加压，使箔膜完全贴合于第一模具的模穴内；
向模穴内射胶；及
冷却开模。
2.如权利要求1所述的模内转印方法，其特征在于：所述介质通道与一介质源连通以提供所述气体。
3.如权利要求2所述的模内转印方法，其特征在于：所述第二模具还开设有至少一排气槽，所述排气槽连通一泄压阀，当第一与第二模具间气压达到设定值时，泄压阀自动打开泄压。
4.如权利要求1所述的模内转印方法，其特征在于：所述柱塞还包括一与柱塞头相连的杆部，所述杆部远离柱塞头的一端连接一弹性元件，所述弹性元件用于使所述柱塞移动复位。
5.如权利要求2所述的模内转印方法，其特征在于：所述气体经过加热后通过所述第二模具对所述箔膜加热。
6.如权利要求5所述的模内转印方法，其特征在于：所述气体是经过一电阻丝加热。
7.如权利要求6所述的模内转印方法，其特征在于：所述电阻丝之阻值可调，以便根据成型条件调节所需的气体温度。
8.如权利要求1至7所述的模内转印方法，其特征在于：所述模穴包括相对设置的第一表面与第三表面及连接第一与第三表面的第二表面，所述三者尺寸关系符合关系式a1+a2+a3＞＝(1+20％)*L，其中第一表面的长度为a1，第二表面的长度为a2，第三表面的长度为a3，模穴开口位置第一表面与第二表面间的连线长度为L。
9.如权利要求1所述的模内转印方法，其特征在于：开模步骤中，箔膜的基体层与转印层相剥离，箔膜的转印层贴合于成品表面。
10.一种模内转印方法，包括以下步骤：
将箔膜送入第一与第二模具之间，其中第一模具具有一模穴，第二模具开设一介质通道，介质通道包括一朝向第一模具的开口，介质通道内设置一开关装置以封闭或打开所述介质通道开口，所述开关装置为一柱塞，所述介质通道的开口呈喇叭口状，所述柱塞包括一柱塞头，所述柱塞头的形状与所述介质通道的开口相适配；
将箔膜压制于第一模具，箔膜与第一模具间形成一气密空间；
将第一与第二模具合模；
将所述气密空间抽真空，将箔膜向第一模具的模穴内吸附，利用气体通过第二模具向箔膜加压，使箔膜完全贴合于第一模具的模穴内；
向模穴内射胶；及
开模。
11.如权利要求10所述的模内转印方法，其特征在于：开模步骤中，箔膜的基体层与转印层相剥离，箔膜的转印层贴合于成品表面。
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