CN114147914A - Method for manufacturing injection molding product - Google Patents
Method for manufacturing injection molding product Download PDFInfo
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- CN114147914A CN114147914A CN202111402590.7A CN202111402590A CN114147914A CN 114147914 A CN114147914 A CN 114147914A CN 202111402590 A CN202111402590 A CN 202111402590A CN 114147914 A CN114147914 A CN 114147914A
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- injection
- pattern
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 238000001746 injection moulding Methods 0.000 title claims abstract description 11
- 238000000034 method Methods 0.000 title claims description 21
- 229920001971 elastomer Polymers 0.000 claims abstract description 24
- 239000000806 elastomer Substances 0.000 claims abstract description 24
- 239000011347 resin Substances 0.000 claims abstract description 23
- 229920005989 resin Polymers 0.000 claims abstract description 23
- 238000002347 injection Methods 0.000 claims abstract description 15
- 239000007924 injection Substances 0.000 claims abstract description 15
- 238000002360 preparation method Methods 0.000 claims abstract description 10
- 238000000465 moulding Methods 0.000 claims abstract description 9
- 238000003825 pressing Methods 0.000 claims abstract description 3
- 238000007639 printing Methods 0.000 claims description 18
- 229910052751 metal Inorganic materials 0.000 claims description 15
- 239000002184 metal Substances 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 13
- 229920001296 polysiloxane Polymers 0.000 claims 1
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000013536 elastomeric material Substances 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 238000007650 screen-printing Methods 0.000 description 2
- 229920002379 silicone rubber Polymers 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical class ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001336 alkenes Chemical class 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
- 150000001408 amides Chemical class 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 239000003779 heat-resistant material Substances 0.000 description 1
- 238000007641 inkjet printing Methods 0.000 description 1
- 238000007644 letterpress printing Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 150000003440 styrenes Chemical class 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
Images
Classifications
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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
- 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
-
- 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
- B29C45/14221—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 by tools, e.g. cutting means
-
- 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
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
Abstract
A method of manufacturing an injection molded article, comprising: a sheet preparation step of preparing a die surface-forming sheet 30 composed of a flat plate-shaped elastomer sheet and having a 1 st surface 31 and a 2 nd surface 32, the 1 st surface 31 having a pattern formed by the irregularities of the elastomer itself; a sheet fixing step of fixing a mold surface forming sheet to an injection molding mold 40 having a recessed inner wall 42A, the 2 nd surface 32 facing the mold inner wall 42A, and the 1 st surface 31 facing the inside of the cavity; a mold closing step of clamping the mold 40; a molding step of injecting a molten resin MP into the cavity, changing the shape of the mold surface forming sheet 30 by the pressure of the molten resin MP, pressing the 2 nd surface 32 against the inner wall 42A of the mold 40, and transferring the pattern on the 1 st surface 31 to the product surface PS; and a taking-out step of taking out the injection-molded article 50 with the mold surface-forming sheet 30 remaining in the mold 40 after the molten resin MP is solidified.
Description
Technical Field
The present invention relates to a method for molding an injection-molded article having a pattern formed on the surface thereof.
Background
The following inventions are known in the past: a pattern consisting of fine lines with fine pitches is formed on the surface of a resin film by screen printing, and a sheet for forming a mold surface is produced by this method. The mold surface forming sheet is placed in a mold, and a pattern is transferred to the surface of an injection-molded article. Thus, an injection molded article having a pattern on the surface can be easily produced without directly producing the pattern on the surface of the mold.
However, since the pattern on the conventional die surface forming sheet is formed by printing, there is a problem that the pattern is easily damaged when injection molding is repeated. In addition, the conventional die surface forming sheet is deformed along the inner wall of the die by heat during injection molding, adheres to the inner wall of the die and remains in the die, and generates strong creases at the boundary between the cavity and the parting line where the shape changes. Further, since the resin film lacks flexibility, the strong fold is likely to cause a problem of breakage.
Accordingly, an object of the present invention is to provide a method for reducing the frequency of replacement of a die surface forming sheet and improving the production efficiency of an injection molded article.
Patent document
Patent document 1: japanese patent No. 5750747.
Disclosure of Invention
The method for producing an injection-molded article to achieve the above object comprises the steps of: a sheet preparation step of preparing a mold surface-forming sheet which is composed of a flat plate-shaped elastomer sheet, has a 1 st surface and a 2 nd surface opposite to the 1 st surface, and has a pattern of projections and recesses of an elastomer formed on the 1 st surface of the mold surface-forming sheet; a sheet fixing step of fixing the mold surface-forming sheet to an injection molding mold having a recessed inner wall such that the 2 nd surface faces the inner wall of the mold and the 1 st surface faces the inside of the cavity; a mold closing process, namely clamping the mold; a molding step of injecting a molten resin into the cavity, changing the shape of the mold surface-forming sheet by the pressure of the molten resin, pressing the 2 nd surface against the inner wall of the mold, and transferring the pattern on the 1 st surface to the surface of the molten resin product; and a taking-out step of taking out the injection-molded article in a state where the mold surface-forming sheet remains in the mold after the molten resin is solidified.
With this structure, the elastic body is formed into a flat plate shape, and thus the pattern can be easily formed by the unevenness of the elastic body. Further, since the die surface forming sheet is a flat elastic body, it is more flexible than conventional resin films and is less likely to be broken. Further, since the pattern on the 1 st surface of the mold surface forming sheet is formed of the unevenness of the elastomer itself, not the printing ink, it has higher durability in the repeated injection molding operation than the unevenness pattern formed by the printing, that is, the printing ink. Therefore, the frequency of replacement of the die surface forming sheet can be reduced, and the production efficiency of the injection molded article can be improved.
In the taking-out step, the die surface-forming sheet is elastically restored to a flat plate shape. That is, by using the die surface forming sheet of an elastic body having sufficient heat resistance, when the mold is opened in the taking-out step, the die surface forming sheet returns to a flat plate shape and the injection molded article is extruded, and thus the injection molded article can be taken out smoothly.
In the sheet preparation step, a master plate is first produced by printing a raised pattern on the surface of a flat-plate-shaped metal plate, an elastomer material is then adhered to the surface of the master plate on which the pattern is formed, and after the elastomer is cured, the cured elastomer is peeled off from the master plate, thereby producing a sheet for forming a mold surface.
In this method, the metal plate is simply patterned by printing, and the elastic body is transferred with the pattern, so that the elastic body can be easily patterned into the uneven pattern.
In the sheet preparation step, the surface of the flat elastic sheet is provided with irregularities by a laser direct writing method, and a sheet for forming a mold surface can be similarly prepared.
With this structure, the uneven pattern can be easily formed on the elastic body.
According to the present invention, the frequency of replacing the mold surface forming sheet can be reduced, and the production efficiency of the injection molded article can be improved.
Drawings
Fig. 1(a) is a front view of an injection-molded article according to the production method of the present invention, and fig. 1(b) is an enlarged view of a part of the pattern in (a).
Fig. 2(a) is a front view of a master plate with a pattern printed thereon, and fig. 2(b) is an enlarged view of a partial section of (a).
Fig. 3(a) is a diagram including a master plate set in a mold, and fig. 3(b) is a diagram when a mold surface forming sheet is produced.
Fig. 4 is an explanatory view of an injection molding process, in which fig. 4(a) shows a fixing process for fixing a mold surface forming sheet, fig. 4(b) shows a mold clamping process for fixing and clamping a mold surface forming sheet to a mold, fig. 4(c) shows a molding process for injecting a molten resin, and fig. 4(d) shows a taking-out process for taking out an injection molded article by opening the mold.
Description of the reference numerals
10 original edition
11 metal plate
13 ink
20 mould
30 die face forming sheet
31 item 1
32 nd 2 nd side
33 concave state
40 mould
42A inner wall
50 injection-molded article
Detailed Description
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
As shown in fig. 1(a), the injection molded article 50 manufactured by the manufacturing method of the present invention has a concave-convex pattern M formed on the surface thereof. The surface of the injection molded article 50 having the pattern M is convex and the back surface thereof is concave. The lines constituting the pattern M extend like ridges.
As shown in the enlarged view of a part of the pattern M in fig. 1(B), the pattern M has fine streaks 3A, 3B, and 3C in addition to the line 2 indicating the boundary of the region. The stripes 3A, 3B, and 3C are formed of parallel lines, and the direction in which the stripe 3A extends, the direction in which the stripe 3B extends, and the direction in which the stripe 3C extends are different from each other. Therefore, the stripes 3A, 3B, 3C are both strongly and weakly reflective depending on the direction in which a person views the pattern M. Therefore, the visually enhanced portions of the pattern M are different depending on the direction in which a person observes the pattern M, and a glittering feeling is given to the person.
In the manufacturing method according to the present embodiment, first, the mold surface-forming sheet 30, that is, the pattern M formed of the irregularities is formed on the surface of the elastic body (see fig. 3(c)) (sheet forming step).
As shown in fig. 2(a) and (b), in the sheet preparation step, a raised pattern M is formed on the surface of a flat metal plate 11 by printing, thereby forming a master plate 10. The printing method in this case may be screen printing or inkjet printing. The ink used in the printing process is ultraviolet curable, and the ink is printed on the surface of the metal plate 11 and then irradiated with ultraviolet light, so that the floating printing can be performed quickly. Alternatively, a general ink is used, and resin powder is spread over the undried ink to be melted and adhered, so-called letterpress printing.
The material of the metal plate 11 is not particularly limited as long as ink can be adhered thereto, and for example, aluminum or stainless steel can be used. The metal plate 11 is used as a material of the original plate 10, and the molded elastic body mold surface forming sheet 30 is easily peeled from the original plate 10.
As shown in fig. 3(a) to (c), an elastic body mold surface forming sheet 30 is produced from the master 10. As shown in fig. 3(a), the mold 20 has a recessed portion slightly deeper than the thickness of the original plate 10, and the original plate 10 is provided on the inner wall of the recessed portion. The mold 20 is divided into a fixed side 22 and a moving side 21, and the master 10 can be placed on the inner wall of either side thereof only by directing the pattern M toward the cavity (mold internal space). At this time, the pin P is disposed, and thus the hole 35 is formed in the molded die surface forming sheet 30.
Also, as shown in fig. 3(b), an elastomeric material EM is injected so that the elastomeric material EM is in close contact with the surface of the master 10 on which the pattern M is prepared. The material EM of the elastomer is not particularly limited, and any thermoplastic material or thermosetting material may be used. Examples of the thermoplastic elastomer material include styrenes, olefins, esters, hard vinyl chlorides, polyurethanes, amides, and the like; the thermosetting material may be a silicone elastomer other than butadiene, isoprene, and polyurethane. The silicone elastomer having excellent heat resistance and flexibility is particularly preferably used for the mold surface forming sheet 30. In any of the elastomer materials, a heat-resistant material having high heat resistance and capable of withstanding at least the melting point of the resin used in the molding step described below is preferably used.
As shown in fig. 3(c), after the elastomer is cured, the cured elastomer is peeled off from the master 10 to form a mold surface forming sheet 30. The mold surface-forming sheet 30 is a flat plate-shaped elastomer sheet and has a 1 st surface 31 and a 2 nd surface 32 opposite to the 1 st surface 31. On the 1 st surface 31 of the die surface forming sheet, the elastic body itself is formed into a pattern M of irregularities by being inversely embossed with the convex shape of the ink 13. In the present embodiment, the recesses 33 formed by the projection transfer of the ink 13 constitute the pattern M. When the pins P are provided in the mold 20, the holes 35 corresponding to the pins P are formed in the mold surface forming sheet 30.
After the preparation of the mold surface-forming sheet 30 is completed, the mold surface-forming sheet 30 is fixed to an injection mold 40 having a concave inner wall 42A (sheet fixing step) so that the 2 nd surface 32 faces the inner wall 42A of the mold 40 and the 1 st surface 31 faces the mold cavity, as shown in fig. 4 (a).
Specifically, as an example, the mold 40 is divided into a fixed side 41 and a moving side 42, and a concave-shaped inner wall 42A is provided on the moving side 42, and a convex-shaped inner wall 41A corresponding to the concave-shaped inner wall 42A is provided on the fixed side 41. The inner wall 42A of the concave shape may be provided on either the fixed side 41 or the moving side 42. The die surface forming sheet 30 can be fixed by providing a pin P2 on the moving side 42 and engaging the pin with the hole 35 of the die surface forming sheet 30. When the mold surface-forming sheet 30 is fixed to the mold 40, it may be fixed to the edge flat portion 44 of the concave inner wall 42A. In addition, when the mold surface forming sheet 30 is fixed to the mold 40, the sheet may be fixed using an adhesive or a double-sided tape. When the die surface forming sheet 30 is fixed to the die 40, the die surface forming sheet 30 is fixed only to the moving side 42 and does not come into contact with the inner wall 42A of the recessed shape because the die surface forming sheet 30 has a flat plate shape (see the two-dot chain line).
As shown in fig. 4(b), when the mold 40 is clamped (mold clamping step), the mold surface-forming sheet 30 is pressed and extended by the convex inner wall 41A, but does not come into contact with the concave inner wall 42A. In the mold 40, the cavity filled with the material is a space formed between the mold surface forming sheet 30 and the convex inner wall 41A (a space filled with the molten resin MP in the next molding step).
As shown in fig. 4 c, the molten resin MP is injected into the cavity, the pressure of the molten resin MP changes the shape of the mold surface-forming sheet 30, the 2 nd surface 32 is pressed against the inner wall 42A of the mold 40, and the pattern M on the 1 st surface 31 is transferred onto the product surface PS of the molten resin MP (molding step).
As shown in fig. 4 d, after the molten resin MP is solidified, the injection-molded article 50 is taken out while the mold surface-forming sheet 30 remains in the mold 40 (taking-out step). When the runner gate 59 remains in the injection-molded article 50, the runner gate 59 can be cut off. The uneven shape on the 1 st surface 31 of the mold surface forming sheet 30 is transferred to the surface of the injection molded article 50 to form a pattern M. In the present embodiment, the pattern M is a pattern formed of the convex shapes 53.
Since the die surface forming sheet 30 is made of a material having high heat resistance, the die surface forming sheet 30 is restored to its flat shape by its own elasticity in the taking-out step. Therefore, the force of the mold surface forming sheet 30 returning to the flat plate shape can be used to smoothly take out the injection molded article 50 by separating it from the mold surface forming sheet 30. In addition, as in the case of a general injection molding method, it is preferable to use an ejector pin suitable for taking out a finished product.
As described above, the method for producing an injection-molded article according to the present embodiment can produce the following operations and effects.
Since the elastic body constituting the die surface forming sheet 30 has a flat plate shape, the uneven pattern can be easily formed. In the present embodiment, when the elastic body is molded, the concave shape 33 of the elastic body itself can be easily formed on the surface of the elastic body by transferring the convex shape formed by printing. In addition, since the projection shape formed by the above printing is formed on the surface of the flat metal plate 11, the manufacturing is easy.
Further, since the die surface forming sheet is a flat elastic body, it is more flexible than conventional resin films, and is less likely to be creased or damaged. Further, since the pattern M on the 1 st surface 31 of the mold surface forming sheet 30 is formed by the unevenness of the elastomer itself, not by the printing ink, it has higher durability in the repeated injection molding operation than the case of the printing unevenness. Therefore, the frequency of replacing the die surface forming sheet 30 can be reduced, and the production efficiency of the injection molded article 50 can be improved.
In the taking-out step, when the mold 40 is opened, the mold surface-forming sheet 30 returns to the flat plate shape and the injection-molded article 50 is extruded, so that the injection-molded article 50 can be smoothly taken out.
In the present embodiment, the uneven pattern M can be easily formed on the mold surface forming sheet 30 by simply forming the pattern M on the metal plate by the printing method and then transferring the pattern M to the elastic body.
While one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and can be implemented by appropriate modification.
For example, in the above embodiment, the surface irregularities of the elastic body are produced by a method of transferring the irregularities printed on the metal plate 11 to the elastic body; however, in the sheet preparation step, the sheet for forming a mold surface may be produced by a method of forming irregularities on the surface of a flat plate-shaped elastomer sheet by laser direct writing.
In this way, the uneven pattern can be easily formed on the elastic body.
In the above embodiment, the original plate is produced by printing the unevenness on the metal plate, but the unevenness may be formed on the surface of the metal plate by laser direct writing, machining, or engraving. These non-printed asperities can also be transferred to the surface of the elastomer. The material of the original plate is not limited to a metal plate as long as it can satisfy the molding requirements of the elastic body, and for example, a material such as ceramic can be used.
Further, the sheet for forming a mold surface may not necessarily be processed by oneself, and may be manufactured by another person.
In the described embodiment, the pattern on the surface of the elastomer is constituted by concave lines, but it can also be depicted with convex lines or dots. For example, a convex pattern can be formed on the surface of the elastic body by forming a concave pattern on the surface of the metal plate by a laser direct writing method and transferring the pattern to the surface of the elastic body. In addition, both concave and convex lines can be made on the surface of the elastic body.
The pattern is an alternating pattern of fine lines as described in japanese patent No. 5594641. The alternating pattern includes: a 1 st line, which is a base pattern composed of a plurality of parallel dotted lines as a background; and the 2 nd line is at least one type of pattern which is arranged in the overlapping area of the 1 st line and is formed by a plurality of parallel broken lines with different directions from the broken lines of the 1 st line. In addition, each of the dotted lines is formed in the shape of a ridge, and thus the pattern to be seen also changes depending on the direction of observation. Since the production of such a line made of fine lines is suitable for a method of forming unevenness by printing, the present invention can be effectively utilized.
In addition, the elements described in the above embodiments and modified examples may be arbitrarily combined and implemented.
Claims (5)
1. A method of manufacturing an injection molded article, comprising:
a sheet preparation step of preparing a mold surface-forming sheet composed of a flat plate-shaped elastomer sheet and having a 1 st surface and a 2 nd surface opposite to the 1 st surface, the 1 st surface of the mold surface-forming sheet having a pattern formed by the projections and recesses of the elastomer itself;
a sheet fixing step of fixing the mold surface forming sheet to an injection molding mold having a recessed inner wall such that the 2 nd surface faces the inner wall of the mold and the 1 st surface faces the inside of a cavity;
a mold clamping step of clamping the mold;
a molding step of injecting a molten resin into the cavity, changing the shape of the mold surface forming sheet by the pressure of the molten resin, pressing the 2 nd surface against the inner wall of the mold, and transferring the pattern on the 1 st surface to the surface of the molten resin product;
and a taking-out step of taking out the injection-molded article in a state where the mold surface-forming sheet remains in the mold after the molten resin is solidified.
2. The method of manufacturing an injection-molded article according to claim 1,
in the taking-out step, the die surface-forming sheet is elastically restored to a flat plate shape.
3. The method of manufacturing an injection-molded article according to claim 1 or 2,
in the sheet preparation step, a master is produced by printing a raised pattern on the surface of a flat metal plate, an elastomer material is brought into close contact with the surface of the master on which the pattern is produced,
after the elastomer is cured, the cured elastomer is peeled off from the master to produce the die surface-forming sheet.
4. The method of producing an injection-molded article according to claim 1 or 2, wherein in the sheet preparation step, the sheet for forming the mold surface is produced by laser direct-write engraving of irregularities on a surface of a flat-plate-shaped elastomer sheet.
5. The method of producing an injection-molded article according to claim 1 or 2, wherein the elastomer is silicone.
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JP2021021440A JP6994277B1 (en) | 2021-02-15 | 2021-02-15 | Manufacturing method of injection molded products |
JP2021-021440 | 2021-02-15 |
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