JP2009154402A - Film-formed molding and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To form a film-formed surface 3 to be applied on the surface of a substrate 2, a convex mirror 1 having good transfer properties with distortion corrected. <P>SOLUTION: After the substrate 2 is injection-molded by first and second die-matched molds 5 and 6, after the film-formed surface 3 is applied on the surface of the substrate 2 by a film forming device 7, a child mold 6b set in the second mold 6 is protruded while the substrate 2 is blocked on a mold surface 5a for injection, and the back of the substrate 2 is pressurized to make density high, so that the film forming surface 2 to be a reflecting surface, the convex mirror 1 having good transfer properties with distortion corrected is produced. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention belongs to the technical field of a film-formed molded article having a high degree of distortion correction that can be used for a mirror or the like and a manufacturing method thereof.

Conventionally, when a film is formed on the surface of an injection-molded injection-molded body, a plurality of injection-molded bodies taken out from a mold for injection molding are carried to the film-forming chamber and injected onto the surface. However, in this case, when dust adheres to the film formation surface or a finger touches in the process of carrying the injection-molded product, there is a problem that film formation at that part becomes poor.
Therefore, the film forming apparatus is incorporated into an injection mold, and injection molding and film forming are performed in a series of processing steps of forming a film on the surface of the molded injection molded body. A proposal has been proposed in which the defective rate can be significantly reduced by preventing dust from being attached or touched by a finger so that significant cost reduction can be achieved (for example, Patent Documents 1 and 2).
International Publication WO2004-101253 International Publication WO2004-101254

  By the way, in the case of performing the molding film formation in a series of steps, as in the case of normal injection molding, there is contraction due to heat of the injection molded body, and as a result, distortion is inevitably generated on the film formation surface, There is a problem that the larger the size is, the larger the size becomes, and there is a problem that it is difficult to adopt it for a product such as a mirror that does not like the generation of distortion, and there is a problem to be solved by the present invention. .

The present invention was created in view of the above-described circumstances in order to solve these problems, and the invention of claim 1 uses the first and second molds that are matched with each other. In a method for manufacturing a film-formed product comprising an injection process for injection-molding a resin material and a film-forming process for forming a film on the surface of the molded resin material, pressure is applied to the resin material after the film-forming process. And a pressurizing step for pressurizing the film-formed product.
The invention according to claim 2 is the method for producing a film-formed molded article according to claim 1, wherein the pressurizing step is performed by protruding a mold provided on at least one mold side. .
The invention according to claim 3 is the method for producing a film-formed molded article according to claim 2, characterized in that the mold projects part or all of the mold surface for forming the injection material.
The invention according to claim 4 is the method for producing a film-formed molded article according to claim 1, wherein the pressurizing step performs secondary injection of the resin material.
The invention of claim 5 is a film-formed molded article manufactured by injection-molding a resin material using first and second molds that are matched to each other and then forming a film on the resin material. Thus, the film-formed molded article is a film-formed molded article that is pressurized after film formation.

According to the invention of claim 1 or 5, it is possible to efficiently produce a film-formed molded article that is corrected in distortion and has a good transfer positiveness.
According to any one of claims 2 to 4, pressurization can be easily performed.

  Next, embodiments of the present invention will be described with reference to the drawings. In the figure, reference numeral 1 denotes a concave mirror. The concave mirror 1 has a partially spherical shape formed by injecting a resin material, and a base material 2 made of a transparent material such as trill on acrylic, and the base. When formed on the back surface of the material 2 in a layered manner by the film-forming surface 3 constituting the reflective surface and the opaque protective film 4 applied on the back surface of the film-forming surface 3, as viewed from the surface of the substrate 2 The concave surface 1 is formed as a concave surface, and the concave mirror 1 is formed. The concave mirror 1 is formed as follows.

  FIGS. 2 and 3 show an embodiment of the present invention. In this embodiment, 5 and 6 are configured to move relative to each other in a direction perpendicular to and parallel to a die surface facing each other. In the present embodiment, the first mold 5 is a fixed mold and the second mold 6 is a movable mold. May be reversed, or both may be moved.

  In the present embodiment, the first mold 5 has a concave injection mold surface 5a for forming the back surface side of the concave mirror 1, and a film forming apparatus (vacuum evaporation) for forming a film on the back surface of the concave mirror 1. And a film forming mold surface 5b incorporating (internally) 7 is formed, and the surface of the concave mirror 1 is formed on the second mold 6. A concave injection mold surface 6a is formed for forming the injection mold surface 6a, and the entire surface of the base material 2 (surface fitted to the injection mold surface 6a) is formed on the injection mold surface 6a. A mold that can move in and out with respect to the injection mold surface 6a for pressurization (hereinafter referred to as a "child mold" to distinguish it from the first and second molds 5 and 6. This is referred to as a "pressurization mold". 6b is provided.

  In this case, first, as shown in FIG. 2 (A), the die 6b does not protrude or dip into the mold surface 6a, that is, in a state of being flush with the injection mold. From the posture in which the surfaces 5a and 6a face each other, the first and second molds 5 and 6 are matched to each other, the injection mold surfaces 5a and 6a are attached to each other, and a resin material is injected here to form a base material. 2 is formed (see FIG. 2B). Next, the first and second molds 5 and 6 are separated from each other. At this time, the substrate 2 is designed so as to remain in the second mold 6. In this state, the mold surface 6a of the second mold 6 is moved so that the mold surface 5b of the first mold 5 and the film mold surface 5b of the first mold 5 are aligned, and then the back surface of the substrate 2 is formed by the film forming apparatus 7. A metal material to be a reflective surface such as aluminum, copper, silver, or gold is formed on the (demolded surface from the mold surface 5a) to form the film formation surface 3 (see FIG. 2C).

  Thereafter, the base material 2 on which the film-forming surface 3 has been applied is placed on the injection mold surface 5a of the first mold 5 by relative movement of the first and second molds 5 and 6, and the second The child mold 6b on the mold 6 side is protruded from the injection mold surface 6a (see FIG. 2D). As a result, the base material 2 is pressed (pressed) from the surface side to be in a high density state, whereby the film-forming surface 3 is corrected by the injection mold surface 6a, and is a reflective surface with good transferability. Thus, the concave mirror 1 is formed. Incidentally, in the step of applying pressure by the child mold 6b, it is necessary that the temperature of the injected resin material is still high and the resin material can still flow by the pressure by the child mold 6b, that is, maintained in a gel state. . The protective film 4 is applied when necessary, but the protective film 4 is preferably applied after the pressing step.

  By forming the film forming surface 3 on the surface of the base material 2 according to the embodiment of the present invention configured as described above, the base material 2 is densified by pressurization with the sub die 6b. The film surface 3 can be corrected in distortion, and as a result, the concave mirror 1 having the film forming surface 3 excellent in transferability can be obtained. Incidentally, not only a concave mirror but also a plane mirror and a convex mirror can be formed in the same manner.

  Of course, the present invention is not limited to the above-described embodiment, but is not limited to the manufacture of mirrors, and is applicable to various products such as lamps and other reflective surfaces and emblems. In addition, as the pressurizing step, a mold surface exclusively for pressurization used for pressurizing the molded resin material may be formed on the first mold 5 side. Further, as shown in FIG. 3A, it is possible to use a child mold 6c that presses a part of the resin material 2, and the film-forming surface 3 of the resin material 2 is formed as shown in FIG. It is also possible to use a die 5c that pressurizes the formed surface. Further, as shown in FIG. 3C, a mold surface 5d for secondary injection is formed, and a resin material is used as a secondary material. You may make it pressurize by injecting, and in this case, if the resin material to be secondarily injected is on the film forming surface side, the pressure-injecting resin material to be secondarily injected may be used also as the protective film 4. it can.

It is sectional drawing of a film-forming molded object. (A)-(D) are schematic process drawings which show the manufacturing process of a film-forming molded article. (A)-(C) are schematic process drawings which respectively show the pressurization process of other embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Concave mirror 2 Resin material 2a Pressurization part 3 Film-forming surface 4 Protective film 5 1st metal mold 6 2nd metal mold 6b Child mold

Claims (5)

  Production of a film-molded article comprising: an injection process in which a resin material is injection-molded using first and second molds that are mold-matched to each other; and a film-forming process in which a film is formed on the surface of the molded resin material In the method, a method for producing a film-formed molded article is characterized in that after the film-forming step, a pressurizing step of applying pressure to the resin material to pressurize is provided.   The method for producing a film-formed molded article according to claim 1, wherein the pressurizing step is performed by projecting a mold provided on at least one mold side.   3. The method for producing a film-formed molded article according to claim 2, wherein the mold projects part or all of the mold surface for forming the injection material.   The method for producing a film-formed molded article according to claim 1, wherein the pressurizing step performs secondary injection of a resin material.   A film-formed molded article manufactured by injection-molding a resin material using first and second molds that are matched to each other and then forming a film on the resin material, the film-formed molded article Is a film-formed molded article characterized by being pressurized after film formation.

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