JP2000108158A - Manufacture of in-mold molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To allow a shape of a recess of a die to be free and to effectively mold an in-mold film by bringing the film into close contact with a cavity forming surface, then injecting a molten molding resin, and integrating the resin with the molding. SOLUTION: An in-mold film is pressed to a periphery of a recess of a die A with a clamping member to form a sealed space A. Then, the film is pressed from above the member by a protrusion 4b and a heater 4 to form a sealed space B. The spaces A, B are vacuum evacuated from a suction port 2 to reduce their pressures. The film is heated and softened by the heater 4. Then, an atmosphere or a compressed air is injected to bring the film into close contact with the cavity forming surface of the die A in the state that the space A is pressure reduced and the film is sufficiently softened. After the molding is complete, the die is closed, molten molding resin is injected to integrate the film with the molding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to automobile interior parts such as console panels, center clusters and switch bases, automobile exterior parts such as wheel caps and malls, building materials such as walls and pillars, rice cookers and washing machines, and the like. The present invention relates to a method for producing an in-mold molded product applied to the production of home electric appliance parts such as display panels.

[0002]

2. Description of the Related Art Conventionally, an in-mold molded article has been manufactured by simultaneously performing injection molding and painting the surface of the molded article with a pattern or a character.

In order to perform painting simultaneously with injection molding, an apparatus as shown in FIG. 23 is used. First, a mold A of an injection mold is used.
The in-mold film 5 is sent between the mold and the mold B, and then the in-mold film 5 is pressed around the concave portion including the cavity forming surface 1a of the mold A by the frame-shaped clamp member 7 to thereby form the in-mold film. Mold film 5 into mold A
And a closed space A is formed between the in-mold film 5 and the concave portion 1 of the mold A. Then, the protruding portion 4b surrounding the periphery of the surface facing the mold A and the heating portion 4a are formed. By pressing the in-mold film 5 around the concave portion 1 of the mold A from above the clamp member 7 with the heating device 4 having the same, the space B sealed between the in-mold film 5 and the heating device 4 And then
The in-mold film 5 is softened by heating the in-mold film 5 with the heating device 4. At this time,
Vacuum suction is performed from the suction port 2 provided in the concave portion 1 of the mold A, and compressed air is injected from the injection port 6 provided in the heating device 4 (see FIG. 24). By doing so, the in-mold film 5 is formed on the cavity surface forming surface 1 of the mold A.
It is deformed so as to conform to a and adheres closely. This step is generally called preforming.

Subsequently, the heating device 4 is retracted from between the two molds A and B, and the mold A having the injection port 3 is advanced by moving the mold A in which the in-mold film 5 is moved along the cavity forming surface 1a. B, and after closing the mold, the molten molding resin is injected into the cavity from the injection port 3 provided in the mold B.

As a result, the in-mold film 5 along the cavity forming surface 1a is integrated with and adhered to the molded product. When the mold is opened after the completion of the injection molding, the in-mold film 5 is applied from the inside of the mold to the outer surface. The adhered molded product is taken out.

Here, when the in-mold film 5 is an overlay in-mold film, it means that the painting is performed as it is, and all the layers of the in-mold film 5 are adhered and integrated on the outer surface of the molded product 7 to decorate. Layer. On the other hand, when the in-mold film 5 is a transfer in-mold film, only the base film of the in-mold film 5 integrated with the outer surface of the molded product 7 after opening the mold or simultaneously with opening the mold is peeled off. Painting is completed by leaving a transfer layer such as a layer on the molded article side to form a decorative layer.

In the method of manufacturing an in-mold molded article, the suction port 2 is connected to the cavity forming surface 1a in order to prevent the appearance of the suction port 2 from being deteriorated due to the trace of the suction port 2 on the surface of the completed in-mold molded article. It is often provided on the outer parting surface.

[0008]

However, the conventional method for manufacturing an in-mold molded product is the same as that shown in FIGS.
When the suction port 2 is provided on the parting surface outside the cavity forming surface 1a as described above, or when the shape of the cavity forming surface 1a is complicated, before the in-mold film 5 comes into close contact with the entire surface of the cavity forming surface 1a. Suction port 2
May be closed by the in-mold film 5, and the in-mold film 5 cannot be formed any more (see FIG. 25). That is, the formable shape of the in-mold film 5 is restricted by the position, the number, the size, and the like of the suction ports 2.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-mentioned problem, and the shape of the concave portion including the cavity forming surface of the mold A is free, so that the in-mold film can be reliably moved along the cavity forming surface. An object of the present invention is to provide a method for producing an in-mold molded article that can be molded.

[0010]

In order to achieve the above object, a method for producing an in-mold molded product according to the present invention has the following constitutions (1) to (8).

(1) A step of inserting the in-mold film between the mold A and the mold B of the injection mold, and the step of inserting the in-mold film into the cavity forming surface of the mold A by a frame-shaped clamp member. A step of clamping the in-mold film to the mold A by forming a sealed space A between the in-mold film and the recess of the mold A by pressing the mold A around the recess including the mold A; By pressing the in-mold film around the concave portion of the mold A directly or from above the frame-shaped clamp member with a heating device having a protrusion surrounding the periphery of the surface to be formed and a heating portion, Forming a closed space B between the heating device and the heating device, and performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, A step of depressurizing both the spaces A and B across the mold film, a step of softening the in-mold film by heating the in-mold film with a heating device, and a step of depressurizing the space A and softening the in-mold film. After the in-mold film is completely in contact with the cavity forming surface of the mold A by injecting outside air or compressed air into the space B in a state where the Closing the mold A and the mold B, and injecting the molten molding resin into the cavity from an injection port provided in the mold B, thereby integrating the in-mold film with the molded product. .

(2) A step of inserting the in-mold film between the mold A and the mold B of the mold for injection molding, and a step of clamping the in-mold film to the concave portion including the cavity forming surface of the mold A by the clamp member. A step of clamping the in-mold film to the mold A by pressing it around, and a step of heating the in-mold film with a heating device having a protrusion surrounding the periphery of the surface facing the mold A and a heating unit. The space A sealed between the in-mold film and the recess of the mold A is formed as a sealed space B between the in-mold film and the heating device by pressing the mold A around the recess. By performing vacuum suction from both the process and the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, the spaces A and B opposed to each other with the in-mold film interposed therebetween are depressurized. A step of the state, by heating the in-mold film in a heating device, a step of softening the in-mold film in a state in which the softening has been sufficiently reduced pressure and in-mold film space A, the space B
By injecting outside air or compressed air into the inside, the step of bringing the in-mold film into close contact with the cavity forming surface of the mold A, and after the formation of the in-mold film is completed,
Closing the mold A and the mold B, and injecting the molten molding resin into the cavity from an injection port provided in the mold B, thereby integrating the in-mold film with the molded product. I have.

(3) a step of inserting an in-mold film between the mold A and the mold B of the mold for injection molding;
By pressing the in-mold film around the concave portion including the cavity forming surface of the mold A with a heating device having a protrusion and a heating portion surrounding the periphery of the surface facing the
A step of clamping the in-mold film to the mold A and forming a closed space A between the in-mold film and the recess of the mold A and a closed space B between the in-mold film and the heating device; By performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, both the spaces A and B opposed to each other with the in-mold film interposed therebetween are reduced in pressure. Heating the in-mold film with a heating device to soften the in-mold film; and, in a state where the pressure in the space A and the softening of the in-mold film have been sufficiently increased, open air or compressed air in the space B. The step of bringing the in-mold film into close contact with the cavity forming surface of the mold A by injecting the The mold A and the mold B and mold closing, mold B
A step of injecting the molded resin melted into the cavity from the injection port provided in the mold to integrate the in-mold film into the molded product.

(4) The step of inserting the in-mold film between the mold A and the mold B of the injection mold, and the step of inserting the in-mold film into the cavity forming surface of the mold A by a frame-shaped clamp member. A step of clamping the in-mold film to the mold A by forming a closed space A between the in-mold film and the recess of the mold A by pressing the mold around the recess including the heating section; A closed space B is formed between the in-mold film and the heating device by pressing the in-mold film around the concave portion of the mold A from above the frame-shaped clamp member with the plate-like heating device. By performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, so that the spaces A and B opposed to each other with the in-mold film interposed therebetween. Both the steps of in a reduced pressure state, by heating the in-mold film in a heating device,
By injecting outside air or compressed air into the space B in a state where the in-mold film is softened and the space A is sufficiently depressurized and the in-mold film softened, the in-mold film is removed from the cavity of the mold A. After the step of bringing the mold into close contact with the forming surface and the molding of the in-mold film are completed, the mold A and the mold B are closed, and the molten molding resin is injected into the cavity from an injection port provided in the mold B. Thereby integrating the in-mold film into the molded product.

(5) A step of inserting the in-mold film between the mold A and the mold B of the injection mold, and the step of inserting the in-mold film into the cavity forming surface of the mold A by a frame-shaped clamp member. A step of clamping the in-mold film to the mold A by forming a closed space A between the in-mold film and the recess of the mold A by pressing the mold around the recess including the heating section; Pressing the in-mold film around the concave portion of the mold A with the plate-shaped heating device, and vacuum suction through both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device. Is performed, and the space A is depressurized while the in-mold film is held on the side of the heating device, and the in-mold film is heated by the heating device. By injecting outside air or compressed air between the in-mold film and the heating device in a state where the step of softening and the decompression of the space A and the softening of the in-mold film are sufficiently performed, the in-mold film After the step of bringing the mold into close contact with the cavity forming surface and the completion of the molding of the in-mold film, the mold A and the mold B are closed, and the molding resin melted into the cavity from the injection port provided in the mold B. Integrating the in-mold film into the molded product by injection.

(6) The step of inserting the in-mold film between the mold A and the mold B of the injection mold, and the step of inserting the in-mold film into the concave portion including the cavity forming surface of the mold A by the clamp member. By pressing around the periphery, the step of clamping the in-mold film to the mold A, and pressing the in-mold film around the concave portion of the mold A by a plate-shaped heating device having a heating unit, Forming a sealed space A between the in-mold film and the concave portion of the mold A; and performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device. By performing the step, the space A is depressurized while the in-mold film is held on the heating device side, and the in-mold film is heated by heating the in-mold film with the heating device. A step of reduction, in the state in which the softening has been sufficiently reduced pressure and in-mold film space A,
Injecting outside air or compressed air between the in-mold film and the heating device to bring the in-mold film into close contact with the cavity forming surface of the mold A; And closing the mold B and injecting the molten molding resin into the cavity from an injection port provided in the mold B to integrate the in-mold film with the molded product.

(7) A step of inserting the in-mold film between the mold A and the mold B of the injection mold, and a step of heating the in-mold film by a plate-shaped heating device having a heating unit. A step of clamping the in-mold film to the mold A by pressing the mold A around the concave portion including the cavity forming surface and forming a closed space A between the in-mold film and the concave portion of the mold A. By performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, the space A is depressurized while the in-mold film is held on the heating device side. A step of softening the in-mold film by heating the in-mold film with a heating device, and a state in which the decompression of the space A and the softening of the in-mold film are sufficient. Injecting outside air or compressed air between the in-mold film and the heating device to bring the in-mold film into close contact with the cavity forming surface of the mold A; A and a mold B are closed, and a molten resin is injected into a cavity from an injection port provided in the mold B to integrate the in-mold film into a molded product.

(8) The in-mold film is held in the heating device by performing vacuum suction from a suction port provided in a plate-shaped heating device having a heating section, and the injection molding die is used. A step of inserting the in-mold film between A and the mold B, and pressing the in-mold film around the concave portion including the cavity forming surface of the mold A by a heating device that suction-holds the in-mold film, A step of clamping the in-mold film to the mold A and forming a closed space A between the in-mold film and the recess of the mold A, and applying vacuum suction from a suction port provided in the recess of the mold A. By performing the step, the space A is depressurized while the in-mold film is held on the side of the heating device, and the in-mold film is heated by the heating device. A step of softening the field film,
By injecting outside air or compressed air between the in-mold film and the heating device in a state where the pressure in the space A and the softening of the in-mold film have been sufficiently increased, the in-mold film is transferred to the cavity forming surface of the mold A. After the process of making it close and the molding of the in-mold film are completed,
Closing the mold A and the mold B, and injecting the molten molding resin into the cavity from an injection port provided in the mold B, thereby integrating the in-mold film with the molded product. I have.

In the above configuration (8), the in-mold film was clamped to the mold A after the heating of the in-mold film by the heating device was started.

Further, in the above arrangements (1) to (8), after the heating of the in-mold film by the heating device was started, the pressure in the closed space was reduced.

Further, in the above arrangements (1) to (8), the heating of the in-mold film was started by the heating device, and at the same time, the pressure in the closed space was reduced.

Further, in the above arrangements (1) to (8), after the pressure in the closed space was started, the in-mold film was heated by the heating device.

Further, in the step of injecting the outside air or the compressed air having the above-mentioned respective structures, the outside air or the compressed air is injected after or simultaneously with the stop of the vacuum suction from the suction port provided in the heating device.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing an in-mold molded product according to the present invention will be described in detail with reference to the drawings.

FIGS. 1 to 22 are views showing an embodiment of a process for producing an in-mold molded product according to the present invention. In the figure, 1 is a concave portion, 1a is a cavity forming surface, 2 is a suction port, 3 is an injection port, 4 is a heating device, 4a is a heating section, 4b is a protruding section, 5 is an in-mold film, 6 is an injection port, 7 Indicates a clamp member.

First, the in-mold film 5 is inserted between the mold A and the mold B of the injection mold (see FIG. 1).

The injection mold used for manufacturing the in-mold molded article of the present invention is a pair of molds A, which can be closely attached to and separated from each other.
Mold B. The mold A has a concave portion 1 including a cavity forming surface 1a, and the mold B is closed by closing the mold.
A molding cavity conforming to the shape of the in-mold molded product is formed therebetween. At this time, the entire concave portion 1 of the mold A may be the cavity forming surface 1a, or a part of the concave portion 1 of the mold A may be the cavity forming surface 1a. Further, a suction port 2 is provided in the concave portion 1 of the mold A. On the other hand, the mold B is provided with an injection port 3 for injecting a molding resin in a molten state into the cavity when the mold A and the mold A are closed. The mold B is shown in FIG.
As shown in the figure, the mold A may have a concave portion in which the clamp member 7 is stored when the mold is closed.

The in-mold film 5 is formed by forming a picture layer, an adhesive layer, and the like on a base film. As the material of the base film, a resin film such as a polyethylene-based resin, a polycarbonate-based resin, a polyester-based resin, an acrylic-based resin, a polyvinyl chloride-based resin, or a composite of the above-described films, or a general in-mold film What is used as a base film can be used. The picture layer is usually formed as a printing layer on the base film. As a material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. Colored inks containing a pigment or dye of an appropriate color as a coloring agent may be used, and may be colored translucent, colorless or translucent. The printing layer may be provided entirely or partially depending on the picture to be expressed. Also, the picture layer is made of a metal thin film layer,
Alternatively, a combination of a printing layer and a metal thin film layer may be used. The metal thin film layer is for expressing metallic luster as a picture layer, and is formed by a vacuum evaporation method, a sputtering method, an ion plating method, a plating method, or the like. In this case, aluminum, nickel, gold, platinum, chromium, iron, copper, tin,
Metals such as indium, silver, titanium, lead, and zinc, and alloys or compounds thereof are used. The adhesive layer is for bonding each of the above layers to the surface of the molded article. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for a molding resin material described later is appropriately used. For example, when the material of the molding resin is an acrylic resin, an acrylic resin may be used. Also, if the material of the molding resin is polyphenylene oxide
In the case of a polystyrene-based resin, a polycarbonate-based resin, a styrene-copolymer-based resin, or a polystyrene-based blended resin, an acrylic resin, a polystyrene-based resin, a polyamide-based resin, or the like that has an affinity for these resins may be used. When a material having excellent adhesion to a molded product is used as the material of the picture layer, the adhesive layer can be omitted.

When the in-mold film 5 is a transfer in-mold film that peels off the base film after molding, a release layer or a release layer may be provided on the base film. The release layer releases the mold release from the transfer layer together with the base film when the base film is peeled off. As the release layer, a melamine resin-based release agent, a silicone resin-based release agent, a fluororesin-based release agent, a cellulose derivative-based release agent, a urea resin-based release agent, a polyolefin resin-based release agent,
Paraffin-based release agents, composite release agents thereof, and the like can be used. The release layer is a layer which is formed entirely or partially on the base film or the release layer, and which is peeled off from the base film or the release layer to become the outermost surface of the transferred material when the base film is released. . The release layer may be a polyacrylic resin, a polyester resin, a polyvinyl chloride resin, a cellulose resin, a rubber resin, a polyurethane resin, a polyvinyl acetate resin, or a vinyl chloride-vinyl acetate copolymer resin. And a copolymer such as ethylene-vinyl acetate copolymer resin. When the release layer requires hardness, a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used.

As a specific example of feeding the in-mold film 5 into the injection mold, the long in-mold film 5 is once wound around a roll shaft upstream of the injection molds A and B. The in-mold film 5 is taken out from the roll-shaped roll, and is passed through the mold while being unwound from the roll-shaped roll. It is preferable to wind up the mold film 5. Further, the in-mold film 5 may be cut into single sheets.

Next, the in-mold film 5 is clamped to the mold A by pressing the in-mold film 5 around the concave portion 1 including the cavity forming surface 1a of the mold A with the frame-shaped clamp member 7. A space A sealed between the in-mold film 5 and the concave portion 1 of the mold A
Is formed (see FIG. 2).

The clamp member 7 is not provided directly on the injection molding die, but enters the injection molding die from outside the injection molding die by a robot arm or the like, and presses the arm and the electromagnetic force of the electromagnet. The in-mold film 5 may be clamped around the concave portion 1 including the cavity forming surface 1a by force or the like. Note that a shield member such as rubber may be formed at a portion where the clamp member 7 contacts.

Next, the in-mold film 5 is cut from above the frame-shaped clamp member 7 by the heating device 4 having a protruding portion 4b surrounding the periphery of the surface facing the mold A and a heating portion 4a. A sealed space B is formed between the in-mold film 5 and the heating device 4 by pressing it around the concave portion 1 of A (see FIG. 3).

As the heating section 4a, a heater, a halogen lamp, or the like may be used. The heating device 4 is provided with a suction port 2 and an injection port 3. Note that, since the shape of the clamp member 7 is frame-shaped, a closed space B can be formed even when the in-mold film 5 is pressed by the heating device 4 from above as shown in FIG. The device 4 may directly press the in-mold film 5 outside (see FIG. 4) or inside (see FIG. 5) the clamp member 7.

Next, vacuum suction is performed through both the suction port 2 provided in the concave portion 1 of the mold A and the suction port 2 provided in the heating device 4, so that the space facing the in-mold film 5 is interposed. Both A and B are brought into a reduced pressure state. Further, the in-mold film 5 is softened by heating the in-mold film 5 with the heating device 4. Either the decompression of the spaces A and B and the heating of the in-mold film 5 may be started first or may be performed simultaneously.

In the state where both the spaces A and B are decompressed, there is no change in the air pressure balance between the spaces A and B. Therefore, even if the in-mold film 5 is softened, its shape is maintained. is there.

Next, in a state where the pressure in the space A is sufficiently reduced and the in-mold film 5 is sufficiently softened (see FIG. 6), outside air or compressed air is injected into the space B from the inlet 6 (FIG. 7). ), The in-mold film 5 is brought into close contact with the cavity forming surface 1a of the mold A.

That is, by injecting the outside air or the compressed air into the space B, the pressure in the space B rises at once, and the pressure balance tends to be lost. However, since the in-mold film 5 is sufficiently softened, the volume of the space A is reduced and the space A and the space B are deformed so as to maintain the pressure balance. That is, since the in-mold film 5 approaches the surface of the concave portion 1 of the mold A, and there is no air left only,
Finally adhere. In-mold film 5 at this time
Contributes to the molding of the mold 1 by the sufficiently reduced pressure in the entire space A sealed between the in-mold film 5 and the recess 1 of the mold A.
The degree of contribution of the position, the number, the size of the suction ports 2 provided in the nozzle, and the suction force of the vacuum suction performed therefrom is extremely low. Whatever the position, number, size or suction power of the suction ports 2, the space B
It is sufficient that the space A can be sufficiently depressurized before the outside air or the compressed air is injected into the inside.

Finally, after the molding of the in-mold film 5 is completed (see FIG. 8), the mold A and the mold B are closed,
By injecting the molten molding resin into the cavity through the injection port 3 provided in the mold B, the in-mold film 5 is integrated with the molded product.

Examples of the material of the molding resin include polypropylene resin, acrylonitrile butadiene styrene resin, polystyrene resin, ethylene vinyl acetate resin, polycarbonate resin, nylon resin and the like.

The method of manufacturing an in-mold molded article of the present invention is not limited to the above-described embodiment. For example, the closed space A and the closed space B may be formed at the same time. Law 1).

That is, the in-mold film 5 is clamped to the mold A by pressing the in-mold film 5 around the concave portion 1 including the cavity forming surface 1a of the mold A with the clamp member 7 (see FIG. 9). Then, the protruding portion 4b surrounding the periphery of the surface facing the mold A and the heating portion 4a
By pressing the in-mold film 5 around the concave portion 1 of the mold A by the heating device 4 having the following, the space A sealed between the in-mold film 5 and the concave portion of the mold A is formed. A sealed space B is formed between the in-mold film 5 and the heating device 4 (see FIG. 10).

In this case, since the role of forming the closed space A is not expected in the clamp member 7, FIGS.
It is not necessary to use a frame-shaped clamp member as shown in FIG. 8, and a planar "one" type clamp member, a planar substantially "U" type clamp member, or the like can be used.

The method of manufacturing an in-mold molded product of the present invention not only forms the closed space A and the space B at the same time, but also adds a clamp member 7 to the heating device 4.
(Alternative method 2).

That is, the in-mold film 5 is formed on the cavity forming surface 1 of the mold A by the heating device 4 having the protruding portion 4b surrounding the periphery of the surface facing the mold A and the heating portion 4a.
a, the space A sealed between the in-mold film 5 and the recess 1 of the mold A is clamped to the mold A by pressing the in-mold film 5 around the recess 1 including A sealed space B is formed between the heating device 4 and the heating device 4 (see FIG. 11).

Further, in the method of manufacturing an in-mold molded product of the present invention, a plate-like device having no projection 4b may be used as the heating device 4 (Alternative Method 3).

That is, the in-mold film 5 is pressed around the concave portion 1 of the mold A from above the frame-shaped clamp member 7 by the plate-shaped heating device 4 having the heating portion 4a (see FIG. 12). Thereby, a closed space B is formed between the in-mold film 5 and the heating device 4 (see FIG. 13). In this case, the suction port 2 and the injection port 6 can be provided in the clamp member 7 instead of the heating device 4 (not shown).

Further, the method for producing an in-mold molded article of the present invention can be carried out without forming the closed space B (alternative method 4).

For example, first, an in-mold film is inserted between a mold A and a mold B of an injection mold (FIG. 14).
Then, the in-mold film 5 is removed from the concave portion 1 including the cavity forming surface 1a of the mold A by the frame-shaped clamp member 7.
To clamp the in-mold film 5 to the mold A and form a closed space A between the in-mold film 5 and the concave portion 1 of the mold A (see FIG. 15).

Next, the in-mold film 5 is pressed around the concave portion of the mold A by the plate-shaped heating device 4 having the heating portion 4a (see FIG. 16). Therefore, no space B is formed between the in-mold film 5 and the heating device 4, and the in-mold film 5 comes into contact with the surface of the heating device 4.

Next, vacuum suction is performed from both the suction port 2 provided in the concave portion 1 of the mold A and the suction port 2 provided in the heating device 4 to move the in-mold film 5 to the heating device 4 side. The space A is depressurized while being held. Also,
The in-mold film 5 is softened by heating the in-mold film 5 with the heating device 4. In the case where the space B is not formed, either of the decompression of the space A and the heating of the in-mold film 5 may be started first or may be performed simultaneously. Note that a metal plate or the like that is easily heated by heat transfer may be used as the heating unit 4a.

In the state where the space A is depressurized while holding the in-mold film 5 on the heating device 4 side,
Since there is no change in the pressure balance between the space between the in-mold film 5 and the heating device 4, more specifically, the space inside the suction port 2 provided in the heating device 4 and the space A, the in-mold film 5 is softened. Even if it does, its shape is maintained.

Next, in a state where the pressure in the space A and the softening of the in-mold film 5 have been sufficiently increased (see FIG. 17),
By injecting outside air or compressed air between the in-mold film 5 and the heating device 4 from the injection port 6 (FIG. 18).
), The in-mold film 5 is brought into close contact with the cavity forming surface 1a of the mold A.

That is, by injecting outside air or compressed air between the in-mold film 5 and the heating device 4, the pressure in the space between the in-mold film 5 and the heating device 4 rises at once, and the pressure balance is broken. To try. However, since the in-mold film 5 is sufficiently softened, the volume of the space A is reduced and the space A and the in-mold film 5 are reduced.
And the space between the heating device 4 and the heating device 4 are deformed so as to maintain the pressure equilibrium. In other words, the in-mold film 5 approaches the surface of the concave portion 1 of the mold A, and since there is no air that is left behind, the in-mold film 5 finally adheres. What contributes to the molding of the in-mold film 5 at this time is a sufficiently sufficiently reduced pressure state in the entire space A sealed between the in-mold film 5 and the concave portion 1 of the mold A,
The contribution of the position, number and size of the suction ports 2 provided in the concave portion 1 of the mold A and the suction force of vacuum suction performed therefrom is extremely low. Whatever the position, number, size and suction force of the suction ports 2, it is only necessary to sufficiently reduce the pressure in the space A before injecting outside air or compressed air between the in-mold film 5 and the heating device 4.

Finally, after the molding of the in-mold film 5 was completed (see FIG. 19), the mold A and the mold B were closed and melted into the cavity through the injection port 3 provided in the mold B. By injecting the molding resin, the in-mold film 5 is integrated with the molded product.

Further, in the method of manufacturing an in-mold molded article performed without forming the closed space B, the closed space A may be formed by the heating device 4 (Alternative Method 5).

That is, the in-mold film 5 is clamped on the mold A by pressing the in-mold film 5 around the concave portion 1 including the cavity forming surface 1a of the mold A with the clamp member 7, and then the heating unit is heated. By pressing the in-mold film 5 around the concave portion 1 of the mold A with the plate-shaped heating device 4 having 4a, the space between the in-mold film 5 and the concave portion 1 of the mold A was sealed. A space A is formed (see FIG. 20).

In this case, since the role of forming the closed space A is not expected in the clamp member 7, FIG.
It is not necessary to use a frame-shaped clamp member as shown in FIGS.

Further, in the method of manufacturing an in-mold molded product performed without forming the closed space B, the closed space A is formed not only by the heating device 4 but also by the clamp member 7. (Alternative method 6).

That is, the in-mold film 5 is pressed around the recess 1 including the cavity forming surface 1a of the mold A by the plate-shaped heating device 4 having the heating section 4a. While being clamped to the mold A, a closed space A is formed between the in-mold film 5 and the concave portion 1 of the mold A (see FIG. 21).

When the heating device 4 is also used as the clamp member 7 in the method of manufacturing an in-mold molded product without forming the closed space B, the in-mold film 5 is transferred to the heating device 4 before the mold is inserted. It may be held by suction (alternative method 7).

That is, by performing vacuum suction from the suction port 2 provided in the plate-shaped heating device 4 having the heating portion 4a, the in-mold film 5 is held by the heating device 4, and the injection molding metal The in-mold film 5 is inserted between the molds A and B (see FIG. 22). In this case, when the pressure in the space A is reduced, the pressure in the space A is higher than the space between the in-mold film 5 and the heating device 4, more specifically, the space inside the suction port 2 provided in the heating device 4. It may be slightly higher than the atmospheric pressure. This is because the in-mold film 5 is only pressed against the heating device 4 and there is no room for further deformation.

In the alternative method 7, after the heating of the in-mold film 5 by the heating device 4 is started, the in-mold film 5 can be clamped to the mold A.

In each of the above methods, after the heating of the in-mold film 5 by the heating device 4 is started, or when the pressure in the closed space is reduced at the same time, the heating device 4 is started after the pressure in the closed space is started. May be used to heat the in-mold film 5.

In the step of injecting outside air or compressed air, the outside air or compressed air is injected after or at the same time as the vacuum suction from the suction port 2 provided in the heating device 4 is stopped. The film 5 can be pressed against the cavity forming surface 1a.

[0066]

The method of manufacturing an in-mold molded article according to the present invention has the following configuration and operation, and therefore has the following effects.

That is, what contributes to the formation of the in-mold film in the present invention is that the entire space A sealed between the in-mold film and the concave portion of the mold A is in a sufficiently reduced pressure state in advance. In addition, the contribution of the position, the number, the size of the suction ports provided in the concave portion of the mold A and the suction force of the vacuum suction performed therefrom is extremely low.

Therefore, the shape of the concave portion including the cavity forming surface of the mold A is free, and even if the suction port is blocked by the in-mold film after the deformation of the in-mold film starts, the in-mold film can be formed. It is possible to continue the in-mold film along the cavity forming surface without fail.

[Brief description of the drawings]

FIG. 1 is a view showing one embodiment of a manufacturing process of an in-mold molded product according to the present invention.

FIG. 2 is a view showing one embodiment of a manufacturing process of an in-mold molded product according to the present invention.

FIG. 3 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 4 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 5 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 6 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 7 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 8 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 9 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 10 is a view showing one embodiment of a process of manufacturing an in-mold molded product according to the present invention.

FIG. 11 is a view showing one embodiment of a process of manufacturing an in-mold molded product according to the present invention.

FIG. 12 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 13 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 14 is a view showing one embodiment of the manufacturing process of the in-mold molded product according to the present invention.

FIG. 15 is a view showing one embodiment of the manufacturing process of the in-mold molded product according to the present invention.

FIG. 16 is a view showing one embodiment of a process of manufacturing an in-mold molded product according to the present invention.

FIG. 17 is a view showing one embodiment of the manufacturing process of the in-mold molded product according to the present invention.

FIG. 18 is a view showing one embodiment of a manufacturing process of the in-mold molded article according to the present invention.

FIG. 19 is a view showing one embodiment of the manufacturing process of the in-mold molded product according to the present invention.

FIG. 20 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 21 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 22 is a view showing one embodiment of a manufacturing process of the in-mold molded product according to the present invention.

FIG. 23 is a diagram showing an example of a manufacturing process of an in-mold molded product according to the related art.

FIG. 24 is a diagram showing an example of a manufacturing process of an in-mold molded product according to a conventional technique.

FIG. 25 is a view showing one embodiment of a manufacturing process of an in-mold molded product according to the prior art.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Concavity 1a Cavity formation surface 2 Suction port 3 Injection port 4 Heating device 4a Heating part 4b Projection 5 In-mold film 6 Injection port 7 Clamp member

Continuing on the front page (72) Inventor Tetsuo Miyatani 3 in Mibuhanai-cho, Nakagyo-ku, Kyoto-shi, Kyoto Japan Photo Printing Co., Ltd. F-term (reference) in Photo Printing Co., Ltd. 4F202 AD08 AG03 CA11 CB19 CN01 CN24 CP01 CP06 CQ01 CQ05 4F206 AD08 AG03 JA07 JB19 JF05 JF35 JM02 JM04 JQ06 JQ07 JQ82

Claims (13)

[Claims] 1. A step of inserting an in-mold film between a mold A and a mold B of an injection molding mold, and the step of inserting the in-mold film into a cavity forming surface of the mold A by a frame-shaped clamp member. Pressing the in-mold film to the mold A by pressing the mold around the recess, and forming a sealed space A between the in-mold film and the recess of the mold A; By pressing the in-mold film around the concave portion of the mold A directly or from above the frame-shaped clamp member with a heating device having a protrusion and a heating portion surrounding the periphery of the surface, the in-mold film and The step of forming a closed space B between the heating device and the vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, Depressurizing both the spaces A and B across the shielded film, heating the in-mold film with a heating device to soften the in-mold film, and depressurizing the space A and reducing the pressure of the in-mold film. Injecting outside air or compressed air into the space B in a state where the softening is sufficiently performed, thereby bringing the in-mold film into close contact with the cavity forming surface of the mold A, and after completing the formation of the in-mold film, Closing the mold A and the mold B, and injecting the molten molding resin into the cavity from an injection port provided in the mold B to integrate the in-mold film into the molded product. A method for producing an in-mold molded product. 2. A step of inserting an in-mold film between a mold A and a mold B of an injection mold, and a step of clamping the in-mold film around a concave portion including a cavity forming surface of the mold A by a clamp member. A step of clamping the in-mold film to the mold A by pressing the in-mold film onto the mold A, and heating the in-mold film with the heating unit having a protrusion surrounding the periphery of the surface facing the mold A and a heating unit. By pressing around the concave portion of the mold A, the space A sealed between the in-mold film and the concave portion of the mold A becomes the space B sealed between the in-mold film and the heating device.
And forming vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, so that the spaces A and B opposed to each other with the in-mold film interposed therebetween. A step of reducing the pressure, a step of softening the in-mold film by heating the in-mold film with a heating device, and a step of reducing the pressure in the space A and the softening of the in-mold film into the space B. A step of injecting the in-mold film into the cavity forming surface of the mold A by injecting outside air or compressed air; and, after the formation of the in-mold film, the mold A and the mold B are closed, and the mold is closed. Integrating the in-mold film with the molded product by injecting the molten molding resin into the cavity from the injection port provided in the mold B. A method for producing an in-mold molded product. 3. A step of inserting an in-mold film between a mold A and a mold B of an injection mold, a projecting portion surrounding a periphery of a surface facing the mold A, and a heating portion. The in-mold film is clamped to the mold A by pressing the in-mold film around the concave portion including the cavity forming surface of the mold A by the heating device, and the in-mold film and the concave portion of the mold A A step of forming a closed space B between the in-mold film and the heating device with the space A sealed therebetween; and a suction port provided in the concave portion of the mold A and a suction port provided in the heating device. A step of reducing the pressure in both of the spaces A and B across the in-mold film by performing vacuum suction from both; and a step of heating the in-mold film by a heating device. A step of softening the film; and a step of injecting outside air or compressed air into the space B in a state where the pressure in the space A and the softening of the in-mold film are sufficiently increased. After the molding of the in-mold film is completed, the mold A and the mold B are closed, and the molten molding resin is injected into the cavity through an injection port provided in the mold B. And a step of integrating the in-mold film with the molded product. 4. A step of inserting an in-mold film between a mold A and a mold B of an injection mold, and the step of inserting the in-mold film into a cavity A of the mold A by a frame-shaped clamp member. A step of clamping the in-mold film to the mold A by pressing the periphery of the recess to form a sealed space A between the in-mold film and the recess of the mold A; A closed space B is formed between the in-mold film and the heating device by pressing the in-mold film around the concave portion of the mold A from above the frame-shaped clamp member with a plate-like heating device. By performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, spaces A and B opposed to each other with the in-mold film interposed therebetween are formed. The step of reducing the pressure in the space A, the step of heating the in-mold film with a heating device to soften the in-mold film, and the step of reducing the pressure in the space A and the softening of the in-mold film to the space B A step of injecting the in-mold film into the cavity forming surface of the mold A by injecting outside air or compressed air into the mold, and closing the mold A and the mold B after the molding of the in-mold film is completed. Integrating the in-mold film into the molded product by injecting a molten molding resin into the cavity from an injection port provided in the mold B. Production method. 5. A step of inserting an in-mold film between a mold A and a mold B of an injection mold, and the step of inserting the in-mold film with a cavity-forming surface of the mold A by a frame-shaped clamp member. A step of clamping the in-mold film to the mold A by pressing the periphery of the recess to form a sealed space A between the in-mold film and the recess of the mold A; Pressing the in-mold film around the concave portion of the mold A with a plate-shaped heating device, and applying vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device. By performing the step, the space A is depressurized while the in-mold film is held on the heating device side, and the in-mold film is heated by heating the in-mold film. And injecting outside air or compressed air between the in-mold film and the heating device in a state where the pressure in the space A and the softening of the in-mold film are sufficiently increased, so that the in-mold film is After the in-mold film is completely formed and the step of forming the in-mold film, the mold A and the mold B are closed, and the molding resin melted into the cavity from the injection port provided in the mold B. A process of injecting the in-mold film into a molded product by injecting the molded product. 6. A step of inserting an in-mold film between a mold A and a mold B of an injection mold, and a step of clamping the in-mold film around a concave portion including a cavity forming surface of the mold A by a clamp member. By clamping the in-mold film to the mold A by pressing the in-mold film around the concave portion of the mold A with a plate-shaped heating device having a heating unit.
Forming a closed space A between the in-mold film and the concave portion of the mold A; and performing vacuum suction through both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device. Performing a step of depressurizing the space A while holding the in-mold film on the heating device side; a step of softening the in-mold film by heating the in-mold film with the heating device; And injecting outside air or compressed air between the in-mold film and the heating device in a state where the in-mold film is sufficiently softened, thereby bringing the in-mold film into close contact with the cavity forming surface of the mold A. After the formation of the in-mold film was completed, the mold A and the mold B were closed, and the mold was melted into the cavity from an injection port provided in the mold B. Injecting a molding resin to integrate the in-mold film into the molded product. 7. A step of inserting an in-mold film between a mold A and a mold B of an injection mold, and the step of inserting the in-mold film by a plate-shaped heating device having a heating unit. A by pressing the in-mold film around the concave portion including the cavity forming surface of the mold A.
In-mold film and mold A
Forming a hermetically sealed space A between the mold and the concave portion of the mold A, and performing vacuum suction from both the suction port provided in the concave portion of the mold A and the suction port provided in the heating device, thereby forming an in-mold film. And the step of heating the in-mold film with the heating device to soften the in-mold film, and the step of reducing the pressure in the space A and the softening of the in-mold film. In a state in which the in-mold film is sufficiently in contact with the cavity forming surface of the mold A by injecting outside air or compressed air between the in-mold film and the heating device, the molding of the in-mold film is performed. After completion, the mold A and the mold B are closed, and the molten molding resin is injected into the cavity from an injection port provided in the mold B. And a step of integrating the in-mold film with the molded product. 8. An in-mold film is held in a heating device by performing vacuum suction from a suction port provided in a plate-shaped heating device having a heating portion, and a mold A for an injection molding die is formed. By inserting the in-mold film between the mold and the mold B, and pressing the in-mold film around the concave portion including the cavity forming surface of the mold A by a heating device that sucks and holds the in-mold film. A step of clamping the mold film to the mold A and forming a closed space A between the in-mold film and the recess of the mold A; and performing vacuum suction through a suction port provided in the recess of the mold A. Thus, the step of depressurizing the space A while holding the in-mold film on the heating device side, and the step of heating the in-mold film by the heating device, Injecting outside air or compressed air between the in-mold film and the heating device in a state where the pressure in the space A and the softening of the in-mold film are sufficiently increased, After the step of bringing the mold A into close contact with the cavity-forming surface and the completion of the molding of the in-mold film, the mold A and the mold B were closed and melted into the cavity from the injection port provided in the mold B. A method of integrating an in-mold film into a molded product by injecting a molding resin. 9. The method of manufacturing an in-mold molded article according to claim 8, wherein the in-mold film is clamped to the mold A after heating of the in-mold film by the heating device. 10. The method for producing an in-mold molded article according to claim 1, wherein the pressure in the closed space is reduced after the heating of the in-mold film by the heating device is started. 11. The method for producing an in-mold molded product according to claim 1, wherein the heating of the in-mold film is started by the heating device, and simultaneously the pressure in the closed space is reduced. 12. The method for producing an in-mold molded product according to claim 1, wherein the in-mold film is heated by a heating device after the pressure in the closed space is started. 13. The outside air or compressed air is injected in the step of injecting outside air or compressed air after or simultaneously with stopping the vacuum suction from the suction port provided in the heating device. The method for producing an in-mold molded product according to the above.