JP2000210973A - Method and apparatus for producing film integrated resin window - Google Patents

Abstract

PROBLEM TO BE SOLVED: To perform good injection molding by effectively applying a film even to a curved cavity. SOLUTION: This apparatus is constituted of a locking means 27 and a suction means 28 for positioning a transparent film 26 having a hard coat along a cavity 3 and a gate 19 communicating with the cavity 3. In this case, the gate 19 is allowed to communicate with the intermediate position of the longest side 3-1 of the outer shape of the cavity 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a film-integrated resin window used for a vehicle or the like.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a film-integrated resin window for a vehicle or the like, for example, a transparent film having a hard coat layer on its surface is placed in advance in a cavity of an injection molding die, and is placed in the cavity. In some cases, a resin-integrated window made of a resin and a film is obtained by injecting a resin.

FIG. 8 and FIG. 9 are side sectional views of a mold showing an example of a conventional method of manufacturing a resin-integrated resin window. As shown in FIG. 8, a cavity 3 is formed by a front mold 1 and a back mold 2, and a transparent film 4 having a hard coat layer 4 a on the front surface is formed on the inner surface of the hard mold layer 4 a. , And are positioned by positioning pins 5 provided on the surface forming die 1. Positioning holes 5 for inserting positioning pins 5 in film 4
a is formed in advance. Reference numeral 6 denotes a step formed so as to dispose the film 4 on the inner surface of the surface molding die 1, and reference numeral 7 denotes a gate for injecting the resin 8 into the cavity 3.

[0004] The surface forming die 1 in which the positioning hole 5 a is fitted to the positioning pin 5 and the film 4 is arranged, and the back surface forming die 2 are drawn down, and the resin 8 is injected into the cavity 3 from the gate 7. A resin plate in which the film 4 and the resin 8 are integrated is formed. Subsequently, the molds 1 and 2 are opened, and the resin plate is pushed out with the ejection pins 9 to take out the resin plate.

In the above, when the film 4 and the resin 8 to be injected are different resins, it is necessary to prevent the film 4 from peeling off. Further, a hole is formed on the surface of the resin plate by the positioning pin 5 and the positioning hole 5a, and there is a case where it is required that the hole is hidden so as not to be seen. In addition, on the outer periphery of the resin plate described above, FIG.
The hole can be concealed by integrally forming the frame member 10 having a U-shaped cross section by the method shown in FIG.

That is, as shown in FIG. 9, the resin plate formed according to FIG. 8 is fitted into a back mold 2 ′ having the same shape as the back mold 2, and then a frame material for forming a frame material is formed. The molding dies 11a and 11b are squeezed into the back molding dies 2 ',
By injecting the resin 13 from the gate 12, a resin window 14 to which the frame member 10 is fixed is formed integrally with the outer periphery of the resin plate. Next, the back mold 2 ′ and the frame material molds 11a, 1
The film-integrated resin window 14 is taken out by opening 1b and pushing it out by the ejection pin 9.

According to the above, a resin plate having the hard coat layer 4a formed on the surface of the resin 8 by injection molding is manufactured.
Further, the frame material 10 is integrally fixed to the outer periphery of the resin plate by injection molding, so that the holes formed on the surface by the positioning pins 5 and the positioning holes 5a are hidden and the strength of the film-integrated resin window 14 is increased. Manufactured.

The resins 8 and 13 used for the injection include:
A transparent resin such as a polycarbonate resin or a polymethyl methacrylate resin is used. The film 4 includes a base made of a resin compatible with the resin 8, and a hard coat layer 4a formed on the surface of the base. Are integrally laminated. As the hard coat layer 4a, a SiOx film formed by a PVD method or a CVD method,
A siloxane-based or UV-curable hard coat, or a laminate of these materials is used.

The film 4 generally has a thickness of about 0.5 mm (about the thickness of a commonly used stationery underlay) for the purpose of forming a uniform hard coat layer 4a on the surface. It has a strength that is relatively hard to bend.

[0010]

In the conventional method of manufacturing a resin-integrated resin window, holes formed by positioning pins 5 and positioning holes 5a for positioning the film 4 remain on the surface when manufacturing the resin plate. In order to hide this hole, the frame material 10 is formed integrally with the outer periphery of the resin plate. For this reason, the conventional method requires two injection operations, and has a problem that the manufacturing operation is inefficient.

Also, resin windows of automobiles and the like are often curved. Therefore, as shown in FIG. 10, which is a cut-away plan view of FIG. Often equipped.

When arranging the film 4 in such a curved cavity 3, as described above, the film 4 usually has a thickness of about 0.5 mm and is difficult to bend. 10 is inserted into the positioning pin 5 and the position is determined by the difference in length between the straight line and the curved surface.
The case where the film 4 is not inserted into the step portion 6 as shown by a virtual line in FIG. When the film 4 cannot be inserted into the step 6, the inner surface of the curved surface molding die 1 and the film 4 are not inserted.
And the resin 8 enters the space S between the two, and the resin 8 protrudes outside the hard coat layer 4a.
Defective products will result. Also, the film 4 is connected to the
, The resin 8 may enter the space S formed between the inner surface of the curved surface molding die 1 and the straight film 4.

Further, the film 4 is simply a positioning pin 5
The film 4 is easily dropped from the positioning pin 5 when the mold is squeezed,
If the film 4 comes off, the film 4 will be displaced from the proper position, resulting in a defective product.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems. The present invention has been made in view of the above circumstances. An object of the present invention is to provide a method and an apparatus for manufacturing a resin window.

[0015]

According to the present invention, a transparent film having a hard coat layer is positioned and arranged along a front side cavity and a back side cavity, and resin is injected into the cavity from a gate. This is a method for manufacturing a resin-integrated window in which a film is integrally fixed on the front and back sides by injecting the resin toward the cavity from the middle position of the longest side in the outer shape of the cavity. And a method for manufacturing a film-integrated resin window.

According to the present invention, there is provided a resin mold having a front mold and a back mold, wherein a front cavity of the front mold and a back cavity of the back mold form a cavity, and a front cavity and a back cavity. Locking means and suction means for positioning and keeping the transparent film having the hard coat layer, and a gate for injecting resin into a cavity in which the film is arranged are provided, and the film is provided on both sides. A film integrated resin window manufacturing apparatus for manufacturing a resin window integrally fixed, comprising a gate communicating with an intermediate position of the longest side in the outer shape of the cavity. A manufacturing apparatus for a resin window.

A locking means and a suction means may be provided in the vicinity of the long side of the cavity, and a front mold and a back mold are arranged so that the surface of the cavity is vertical. A gate communicating with the long side of the cavity may be formed on the upper side such that the longest side of the external shape is positioned on the upper side.

In this case, since the film is made to follow the inner surface of the cavity by the suction means at a position close to the gate, it is possible to prevent the problem that the film falls off the positioning pins when the mold is narrowed, and the cavity is curved. Even when the resin is injected, the resin does not protrude outside the hard coat layer of the film when the resin is injected, so that the occurrence of defective products can be reduced as much as possible.

In the present invention, the gate is communicated with the longest side of the outer shape of the cavity to inject the resin, so that the distance of the resin injected from the gate to flow in the cavity can be shortened. Therefore, the entire cavity can be filled with the resin in a short time, and stable injection molding can be realized.

Since the film is positioned near the long side of the cavity by the locking means, a position near the gate of the film can be accurately positioned.

Since the film is sucked by the suction means in the vicinity of the long side of the cavity and the film is made to follow the curved surface of the cavity, the film is easily bent. It is possible to prevent the resin from entering between them, thereby preventing the occurrence of defective products.

The front mold and the back mold are arranged so that the surface of the cavity is vertical, and the longest side of the external shape of the cavity is located on the upper side, and the gate communicating with the long side of the cavity is formed. When formed on the upper side, the effect of filling the entire cavity with the resin from the gate can be further enhanced.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings.

FIGS. 1 to 5 show an example of an apparatus for manufacturing a film-integrated resin window for carrying out the present invention. FIG. 1 is a schematic side view showing an example of a mold used in the present invention. 1 is a view taken in the direction of arrows II-II in FIG. 1, and FIG.
FIG. 4 is an arrow view in the direction of arrow I, FIG. 4 is a view in the direction of arrow IV-IV in FIG. 1, and FIG.

In FIG. 1, reference numeral 1 denotes a front mold, and 2 denotes a back mold. By combining the front mold 1 and the back mold 2, a curved flat cavity 3 formed by a front cavity 3a and a back cavity 3b is formed. Is formed. The front mold 1 and the back mold 2 are supported by an outer frame 15, respectively, so that the front mold 1 and the back mold 2 are narrowed and opened. In addition, when performing injection molding by combining the molds, it is necessary to provide an ejection pin as shown in FIGS. 8 to 10, but is not shown in FIG. 1.

FIG. 3 shows the back cavity 3b of the back mold 2.
In the back side cavity 3b, a step 16 for forming a resin window and a groove 17 for forming a rib along the step 16 are formed. Further, a resin supply port 18 is formed substantially at the center of the upper side of the back side cavity 3b in the width direction (left-right direction), and the flow path extends in the width direction of the cavity 3 from the resin supply port 18 toward the back side cavity 3b. The gate 19 is formed by expanding the gate 19.

It is important that the gate 19 is formed so as to communicate with the longest side 3-1 of the sides 3-1, 3-2, 3-3 and 3-4 forming the outer shape of the cavity 3. It is. At this time, in the examples shown in FIGS. 2 and 3, the case where the substantially rectangular cavity 3 is formed is exemplified, but the same applies to the case of manufacturing a resin window having a polygonal shape of a triangle or a pentagon or more. be able to.

FIG. 2 shows the front side cavity 3a of the surface molding die 1.
In the front side cavity 3a of the surface molding die 1, a step portion 20 is formed so as to correspond to the back side cavity 3b. At a position corresponding to the gate 19 in the surface molding die 1, a gate portion 21 having a curved surface of the front side cavity 3a is formed as shown in FIG.

The front side cavity 3a of the surface molding die 1 shown in FIG.
The front side film 22 disposed in the front side cavity 3a
And a hard coat layer 22a (see FIG. 5) on the side facing the front side cavity 3a and extending into the gate portion 21.
have.

The gate 21 near the long side 3-1 of the cavity 3 of the surface molding die 1 has a positioning fitting portion 24a formed in the extension 23 of the front film 22 as shown in FIG. The pin 24 (locking means) is fixed. As shown in FIG. 2, a plurality of (two in FIG. 2) positioning pins 24 are provided in the longitudinal direction of the long side 3-1 in the gate portion 21. Except for one of the positioning holes 24a, It is elongated in the horizontal direction so that the difference between the length of the curve and the length of the straight line can be absorbed.

Further, the gate portion 21 of the surface molding die 1 of FIG. 2 is provided with a suction means 25 for sucking the extension 23 of the front film 22 into the surface molding die 1 as shown in FIG. I have. As shown in FIG. 2, a plurality of suction units 25 (two in FIG. 2) are provided in the width direction of the front side cavity 3a.

The back cavity 3b of the back mold 2 shown in FIG.
The rear film 26 disposed in the rear cavity 3b
Hard coat layer 26a (see FIG. 5) having a shape that fits inside groove 17 and facing the backside cavity 3b.
It has.

At a position inside the groove 17 near the long side 3-1 in the cavity 3 of the back mold 2, positioning pins 27 fitted into positioning holes 27a formed in the back film 26 as shown in FIG. (Locking means) is fixed. This positioning pin 27 is, as shown in FIG.
-1 are provided in the longitudinal direction (two in FIG. 3), except for one of the positioning holes 27a, which is a long hole in the horizontal direction, and can absorb the difference between the curved length and the straight line length. It has become.

Further, the long side 3-1 of the back mold 2
As shown in FIG. 5, a backside film 26 is provided in the backside cavity 3b inside the groove 17 in the vicinity of
There is provided a suction means 28 for sucking the water.

As shown in FIGS. 1 and 5, the suction means 25 and 28 are provided with a suction port 29 formed on the outer frame 15 and the front and back molding dies 1 and 2 and connected to a suction device (not shown). The suction block 31 includes a plurality of slits 30 and is fitted and fixed to the suction port 29.

Suction block 31 of suction means 25, 28
Has a cylindrical main body 32 that can be fitted into the suction port 29 as shown in FIGS. 6 and 7, and has a radial width at a required width from a central portion 33 of a required diameter at one end of the main body 32 toward the outer surface. A plurality of slits 30 extending in the width direction are formed, and a cutout portion 34 having a required depth and a width similar to that of the slit 30 is formed in the outer peripheral portion at one end. A cylindrical space 35 communicating with the slit 30 is formed at a position corresponding to the center 33 at the other end of the main body 32. As shown in FIG. 6, the suction block 31 is provided in the suction port 29 such that one end where the notch 34 is formed faces the cavity 3. Thus, as shown in FIG. 7, the films 22, 26 can be sucked in a required range by the slits 30 and the cutouts 34.

Hereinafter, a method for manufacturing a film-integrated resin window using the apparatus shown in FIGS. 1 to 7 will be described.

In a state where the front mold 1 and the back mold 2 are separated from each other, the front film 22 is placed in the front cavity 3a of the front mold 1 as shown in FIG. At this time, as shown in FIG. 5, the hard coat layer 22a of the front side film 22 is directed to the front side cavity 3a side, and the positioning holes 24a formed in the extension portions 23 are aligned with the positioning pins 24 (locking holes) provided in the gate portions 21. Means).

Further, as shown in FIG. 3, a back film 26 is disposed in the back cavity 3b of the back mold 2. At this time, as shown in FIG. 5, the hard coat layer 26a of the back film 26 faces the back cavity 3b, and the positioning holes 27a formed in the back film 26 are positioned by the positioning pins 27 (locking holes) provided in the back cavity 3b. means)
Insert

In this state, suction is performed by a suction device (not shown) through the suction port 29. Then, the suction means 25,
The films 22 and 26 are sucked by the slits 30 and the notches 34 formed in the 28 suction blocks 31.

The extension 23 of the front film 22 is sucked by the gate 21 of the surface molding die 1, and at this time, a plurality of suction means 25 are provided in the width direction of the cavity 3 (two in FIG. 2).
By being provided, the extension portion 23 and the upper portion of the front film 22 are sucked along the curved surface of the front cavity 3a.

The back film 26 is sucked into the back cavity 3b of the back mold 2, and the suction means 28
Are provided in the width direction of the cavity 3 (four in FIG. 3), so that the upper portion of the back film 26 is sucked along the curved surface of the back cavity 3b.

As described above, the long side 3 of the cavity 3
1, films 22 and 26 by suction means provided in the vicinity of
Is sucked, so that the films 22 and 26 are easy to bend, so that the films 22 and 26 can favorably follow the curved cavity 3.

In this state, the front molding die 1 and the back molding die 2 are squeezed, and the resin is injected from the resin supply port 18 through the gate 19, whereby the resin is supplied between the films 22 and 26 of the cavity 3. A resin-integrated resin window 37 in which the resin and the films 22 and 26 are integrated and in which the ribs 36 are formed on the outer peripheral rear surface by the grooves 17 can be manufactured by a single injection.

At this time, as described above, since the gate 19 is provided so as to communicate with the longest side 3-1 of the outer shape of the cavity 3, the distance that the resin injected from the gate 19 flows through the cavity 3 is provided. Therefore, since the entire cavity 3 can be filled with the resin in a short time, stable injection molding can be realized.

Since the films 22, 26 are positioned near the long side 3-1 of the cavity 3 by the positioning pins 24, 27 (locking means), the films 22, 2 are positioned.
The position close to the gate 19 can be accurately positioned.

Further, the film 2 near the long side 3-1
Since the suction means 2 and 26 are sucked by the suction means 25 and 28 so as to follow the curved surface of the cavity 3, the gate 1
The films 22 and 26 in the vicinity of 9 can favorably follow the front side cavity 3a and the back side cavity 3b.

Therefore, it is difficult to form a gap between the films 22, 26 and the front-side cavity 3a and the back-side cavity 3b at a position close to the gate 19, so that there is no space between the films 22, 26 and the front-side cavity 3a and the back-side cavity 3b. The problem that resin enters can be prevented. Also,
The resin injected from the gate 19 is applied to the films 22, 26.
Move in the cavity 3 so as to spread the cavity, the cavity 3 is curved in the vertical direction,
Even if the 26 and the front-side cavity 3a and the back-side cavity 3b are separated from each other at the upper and lower middle or lower part, the films 22 and 26 are reliably formed along the cavity 3 by the resin to be pressed, so that good molding is performed.

When the injection is completed, the front mold 1 and the back mold 2 are opened, and the film-integrated resin window 37 is taken out by extruding the mold with an ejection pin (not shown). The film-integrated resin window 37 taken out is cut at the position indicated by the broken line in FIGS.
The part corresponding to is removed to form a product.

In the film-integrated resin window 37 obtained as described above, the front side film 22 is positioned and supported by the positioning pins 24 provided on the gate portion 21 and the suction means 25. There is no trace of suction by the suction means 25.

On the other hand, on the back side of the film-integrated resin window 37, since the back side film 26 is positioned and supported by the positioning pins 27 provided in the back side cavity 3b and the suction means 28, the traces of the positioning pins 24 are kept. A suction mark by the suction means 25 is generated. Such traces remain on the rear surface and are slight, so there is no particular problem. However, since the traces are formed on one side of the film-integrated resin window 37, they are hidden when assembled into a vehicle or the like. In some cases, if necessary, a process for closing the trace may be performed.

It should be noted that the present invention is not limited only to the above-described embodiment, and it goes without saying that various changes can be made without departing from the spirit of the present invention.

[0053]

According to the present invention, since the resin is injected by connecting the gate to the longest side of the outer shape of the cavity, the distance that the resin injected from the gate flows through the cavity is reduced. So that the entire cavity can be filled with resin in a short time,
There is an effect that stable injection molding can be realized.

Further, since the film is positioned by the locking means in the vicinity of the long side of the cavity, there is an effect that a position near the gate of the film can be accurately positioned.

The front mold and the back mold are arranged so that the surface of the cavity is vertical, and the longest side of the external shape of the cavity is positioned on the upper side, and the gate communicating with the long side of the cavity is connected. When formed on the upper side, there is an effect that the effect of filling the entire cavity with the resin from the gate can be further enhanced.

Further, since the film is made to follow the inner surface of the cavity by the suction means at a position close to the gate, it is possible to prevent the problem that the film falls off the positioning pins when the mold is narrowed, and the cavity is curved. Even when the resin is injected, however, the resin does not protrude outside the hard coat layer of the film, so that the occurrence of defective products can be reduced as much as possible.

[Brief description of the drawings]

FIG. 1 is a schematic side view showing an example of an apparatus for manufacturing a film-integrated resin window of the present invention.

FIG. 2 is a view taken in the direction of arrows II-II in FIG.

FIG. 3 is a view taken in the direction of arrows III-III in FIG. 1;

FIG. 4 is a view in the direction of arrows IV-IV in FIG. 1;

FIG. 5 is an enlarged sectional view showing a main part of the present invention.

FIG. 6 is a side view showing an example of a suction unit in the present invention.

7 is a view in the direction of arrows VII-VII in FIG. 6;

FIG. 8 is a side sectional view of a mold showing an example of injection molding a conventional resin plate.

9 is a side sectional view of a mold showing an example in which a frame material is injection-molded on the outer periphery of the resin plate molded in FIG.

FIG. 10 is a view as viewed in the direction of arrows XX in FIG. 8;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 front mold 2 back mold 3 cavity 3a front cavity 3b back cavity 3-1 long side 19 gate 22 front film 22a hard coat layer 24 positioning pin (locking means) 25 suction means 26 back film 26a hard coat layer 27 positioning Pin (locking means) 28 Suction means 37 Resin window integrated with film (resin window)

 ──────────────────────────────────────────────────続 き Continued on front page F term (reference) 4F202 AA21 AA28 AD08 AD24 AD27 AG03 AG28 AH17 CA11 CB01 CB13 CB20 CK06 CK11 CQ01 CQ05 CQ06 4F206 AA21 AA28 AD08 AD24 AD27 AG03 AG28 AH17 JA07 JB13 JB20 JF05 JQ

Claims (5)

[Claims] 1. A transparent film having a hard coat layer is positioned and arranged along a front side cavity and a back side cavity, and a resin is integrally fixed on the front and back sides by injecting a resin into a cavity from a gate. A method for manufacturing a film-integrated resin window for manufacturing a molded resin window, characterized by injecting a resin toward the cavity from an intermediate position of the longest side in the outer shape of the cavity. Manufacturing method. 2. The method for manufacturing a film-integrated resin window according to claim 1, wherein the film is sucked along the inner surface of the cavity near the gate and resin is injected. 3. A resin mold having a front mold and a back mold, and forming a cavity with a front cavity of the front mold and a back cavity of the back mold, and hard coating the front cavity and the back cavity. Locking means and suction means for positioning and keeping the transparent film having a layer along, and a gate for injecting resin into the cavity in which the film is arranged are provided, and the film is integrated on the front and back. A film integrated resin window manufacturing apparatus for manufacturing a resin window fixed to a resin integrated film, comprising a gate communicating with an intermediate position of the longest side in the outer shape of the cavity, wherein Window manufacturing equipment. 4. An apparatus according to claim 3, further comprising a locking means and a suction means near the long side of the cavity. 5. A front mold and a back mold are arranged so that the surface of the cavity is vertical, and the longest side of the external shape of the cavity is positioned on the upper side, and communicates with the long side of the cavity. The apparatus according to claim 3 or 4, wherein the gate is formed on an upper side.