JP2009166287A - Decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet for a simultaneous molding/decoration apparatus which prevents the execution of simultaneous molding and decoration by using a pattern having a defect so as to improve the yield of a decorative molding. <P>SOLUTION: The decorative sheet 71 is used in the simultaneous molding/decoration apparatus 1 in which molds 34 and 40 are closed while a decorative sheet 71 is aligned with the molds, a molten resin is injected to transfer a transfer layer to the surface of a molding with the molten resin solidified. The transfer layer 23 including a plurality of conforming patterns 91 and a defective pattern 91N is set on the surface of a substrate sheet 20, and a defect mark 86a set in accordance with the defective pattern 91N, a width direction mark 84, and a longitudinal direction mark 85 are given. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  TECHNICAL FIELD The present invention relates to a positioning and defect management technology for a decorative sheet used in a simultaneous molding decorative device that performs decoration on a resin molded product using a decorative sheet.

  Conventionally, as a method of decorating the surface of a resin molded product, there is a simultaneous molding decoration method using a decorative sheet in which a transfer material or the like is formed on the surface of a base sheet.

  The simultaneous molding method is a method in which a decorative sheet with a transfer layer formed on a base sheet is sandwiched in a molding die, molten resin is injected into the die, and cooled to obtain a resin molded product. In this method, the decorative sheet is bonded to the surface of the molded product, and then the base sheet is peeled off, and the transfer layer is transferred to the surface of the object to be transferred for decoration. The simultaneous molding and decorating method has a feature that a pattern can be formed even for a molded product having a shape in which it is difficult to directly form the pattern by a printing method.

  By the way, the decorative sheet used for molding simultaneous decoration is usually a long sheet in which a transfer layer including a release layer, a pattern layer, an adhesive layer and the like is printed by gravure printing on the surface of a substrate sheet such as polycarbonate. Consists of roles.

  However, in the transfer layer provided on the roll-shaped decorative sheet, fine defects such as streaks and pinholes may occur during gravure printing or winding. Since simultaneous decoration using a transfer layer having defects leads to generation of a molded product having defects, the decorative sheet used in the simultaneous molding decoration device is inspected in advance to remove the defective transfer layer (pattern). Things have been done.

The inspection of the decorative sheet is usually performed by visually confirming the transfer layer while unwrapping the decorative sheet wound up in a roll shape after finishing the printing process. And in order to remove the part of the transfer layer which has a defect, after cutting a part of decorating sheet containing a defective part, the cutting and sticking which connects two sheets cut | disconnected with the tape etc. is performed.
International Publication No. WO2005 / 008155

  However, visually checking the decorative sheet requires a lot of confirmation work, and the decorative sheet connected with tape or the like is difficult to align during molding, resulting in the molding process. It becomes the cause of the secondary defect that causes the defective product.

  Also, in the decorative sheet manufacturing process, instead of checking every single pattern of the transfer layer, the entire roll of decorative sheet is divided into blocks of several meters, and the entire block having a defective pattern is removed. Will be. Therefore, the pattern which does not have a defect may be included in the block, and the decorative sheet has been discarded.

  Therefore, the technical problem to be solved by the present invention is to prevent simultaneous molding using a pattern having defects contained in the decorative sheet, and as a result, improve the yield of the decorative molded product. It is providing the decorating sheet | seat for shaping | molding simultaneous decorating apparatuses which can be made.

  In order to solve the above technical problem, the present invention provides a decorative sheet for a simultaneous molding decorative device having the following configuration.

According to the first aspect of the present invention, the molding simultaneous decorating device that closes the mold in a state of being aligned with the mold, injects the molten resin, and transfers the transfer layer onto the surface of the molded product solidified by the molten resin. A decorative sheet used for
A transfer layer including a plurality of non-defective patterns and defect patterns is attached to the surface of the base sheet, and a defect mark, a width direction mark, and a longitudinal direction mark provided corresponding to the defect pattern are provided. Provide a decorative sheet.

  According to the 2nd aspect of this invention, the said width direction mark is extended and provided in strip | belt shape in the longitudinal direction in the width direction end vicinity of the decorating sheet, The said longitudinal direction mark is the said width direction mark. It is provided corresponding to the pattern in the vicinity of the end on the side where it is not provided, and the defect mark is configured to be in the same row as the longitudinal direction mark with respect to the longitudinal direction of the decorative sheet, A decorative sheet according to the first aspect is provided.

  According to the 3rd aspect of this invention, the said defect mark is comprised continuously by the said supply direction downstream of the said longitudinal direction mark corresponding to a defect pattern, The decorating sheet of the 2nd aspect characterized by the above-mentioned. I will provide a.

  According to the fourth aspect of the present invention, the defect mark is configured to be provided between the longitudinal mark corresponding to the defective pattern and the longitudinal mark corresponding to the previous pattern. A decorative sheet according to a second aspect is provided.

  According to the 5th aspect of this invention, the said width direction mark is extended and provided in the strip | belt shape in the longitudinal direction in the width direction end vicinity of the decorating sheet, The said longitudinal direction mark is the said width direction mark. Provided in the vicinity of the end portion on the side not provided, in an intermittent band shape so that a gap corresponding to the pattern is opened, and the defect mark is provided so as to fill the gap corresponding to the defective pattern. The decorative sheet according to the first aspect is provided.

  According to the present invention, it is possible to skip and align the defect mark with the molding simultaneous decorating apparatus as a reference, so that the molded product is not molded based on the defect pattern. Therefore, it is possible to save labor for removing the defective pattern on the decorative sheet, and to eliminate the problem of defects caused by cutting and pasting the decorative sheet generated in the previous removing operation. In addition, since the molded product is created excluding the defective pattern, it is possible to improve the manufacturing yield of non-defective molded products.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The simultaneous molding decoration system according to the present embodiment includes a simultaneous molding decoration device that performs simultaneous molding decoration and an inspection device that inspects a decorative sheet used in the simultaneous molding decoration device.

  In FIG.1 and FIG.2, the structure of the shaping | molding simultaneous decorating apparatus concerning embodiment of this invention is shown. The simultaneous molding and decorating apparatus 1 is a state in which a roll-shaped decorating sheet 71 is continuously fed between molds (fixed mold and movable mold) according to control by the control unit 100, and the decorating sheet is sandwiched between the molds. In this apparatus, the molten resin is injected to decorate the resin molded product by transferring the pattern attached to the surface of the decorative sheet 71 to the surface of the resin molded product. Note that the decorative sheet 71 used in the simultaneous molding decorative device according to the present embodiment is inspected for scratches, pinholes, and the like by the inspection device 10 (see FIG. 4), as will be described later. The one with a defect mark corresponding to is used.

  In the simultaneous molding and decorating apparatus 1, a movable platen 34 is guided by a tie bar 33 attached to a fixed platen 32 fixed on a frame 31. The movable platen 34 is supported by a roller (not shown) so as to be movable.

  A fixed mold 36 is attached to the fixed platen 32. The fixed die 36 has a convex portion 36a on its parting surface side. A molten resin can be injected into the fixed mold 36 from an injection nozzle 39.

  A movable mold 40 is attached to the movable platen 34. The movable mold 40 has a concave portion 40 a corresponding to the convex portion 36 a of the fixed mold 36. The movable mold 40 is provided with film clamps 80 and 81 for bringing the decorative sheet 71 into close contact with the mold. In order not to interfere with the film clamps 80 and 81 provided on the movable mold 61, the fixed mold 40 is provided with a recess (not shown), and the clamp is avoided by the recess when the mold is closed.

  An upstream frame 60a and a downstream frame 60b are attached to the movable platen 34 so as to be movable in the horizontal direction. The upstream frame 60a and the downstream frame 60b feed the decorative sheet by an arbitrary feed amount, align the decorative sheet in the longitudinal direction, and move in the horizontal direction, thereby moving the decorative sheet in the width direction. Alignment can be performed. That is, the upstream frame 60a and the downstream frame 60b function as a decorative sheet supply unit. The upstream frame 60a and the downstream frame 60b are guided by guides 62a and 62b with respect to guide rails 61a and 61b attached to the movable platen 34. As the guides 62a and 62b, direct acting slide bearings are used.

  The upstream frame 60a and the downstream frame 60b can be independently moved in the horizontal direction by a width direction moving device (not shown) provided correspondingly. Each width direction moving device is configured such that a ball screw can be rotated at a predetermined rotational speed by, for example, a motor, a pulley, a belt, etc., and this ball screw meshes with a nut attached to the upstream frame 60a and the downstream frame 60b. ing. Therefore, by rotating the motor, the ball screw rotates and thereby the frame 60 moves in the horizontal direction.

  The upstream frame 60a is provided with a sheet supply roller 69. The upstream sheet guide rollers 72 and 78 are driven by the upstream motor 76a to unwind the decorative sheet 71. The decorative sheet 71 unwound from the roller 69 is guided and supplied in the vertical direction so as to be positioned on the surface of the movable mold 40. The upstream sheet guide rollers 72 and 78 provided in the upstream frame 60a are not limited to two, and an arbitrary number can be provided. In order to apply an appropriate tension to the supplied decorative sheet 71, a powder clutch (not shown) may be provided on the reel shaft around which the decorative sheet is wound.

  The downstream frame 60b is provided with a sheet take-up roller 70, which takes up the decorative sheet 71 located on the mold surface. In order to apply an appropriate tension to the supplied decorative sheet 71, a motor 76b composed of a DC servo motor is provided for driving the reel. In order to guide the decorative sheet 71 that has passed through the cavity surface of the mold to the sheet take-up roller 70, the downstream frame 60b is provided with an arbitrary number of downstream sheet guide rollers 77, 78, and 75.

  On the upper and lower sides of the movable mold 40, width direction sensors 82a and 82b are arranged in the feeding direction of the decorative sheet, respectively. Further, the movable mold 40 is provided with a longitudinal sensor 83 embedded in the mold. By placing the longitudinal sensor 83 in the mold, the positions of the pattern and the sensor are close to each other, and the alignment accuracy can be improved.

  The decorative sheet 71 is supplied vertically downward from the sheet supply roller 69, passes through the upstream side sheet guide rollers 72, 78, passes through the cavity surface of the mold, and passes through the downstream side sheet guide rollers 77, 78, 75. The sheet is wound around the sheet winding roller 70.

  The supply of the decorative sheet 71 is driven and controlled to stop during positioning so that the pattern 91 formed on the decorative sheet 71 is arranged at a predetermined position with respect to the cavity shape 40a of the mold. The The control and control of the sheet feeding roller 69, the sheet take-up roller 70, the upstream frame width direction moving device, and the downstream frame width direction moving device are controlled by the control unit 100 to supply and position the decorative sheet 71.

  The molding simultaneous decorating apparatus 1 performs the positioning operation of the decorating sheet as described later by the detection of the width direction sensors 82a and 82b and the longitudinal direction sensor 83, and thereafter the operation of injecting the molten resin.

  In the state where the positioning of the decorative sheet is completed, the pattern of the decorative sheet is arranged at a position corresponding to the cavity of the fixed mold 36 and the movable mold 40. When positioning of the decorative sheet is completed, the movable platen 34 is moved to perform a mold closing operation, and the pattern 91 on the decorative sheet 71 is transferred simultaneously with molding. After cooling the molded product, the mold is opened and the molded product is taken out. This completes one cycle of operation.

  In FIG. 3, the structure of the decorating sheet | seat used for this embodiment is shown. The decorative sheet shown in FIG. 3 is in a state where the inspection process described later is not finished, and the mark for detecting the position is in a state attached at the time of printing. The decorative sheet 71 has a configuration in which a transfer layer 23 (see FIG. 5B) including the release layer 21, the design layers 84, 85, 91, the adhesive layer 22, and the like is provided on the surface of the transparent base sheet 20. As the pattern layer, a feed direction mark 85 (also referred to as an eye mark) formed in a dotted shape for each pattern 91 from each pattern 91 at a certain interval, and near one end in the width direction of the decorative sheet at a certain interval from each pattern 91. A width direction mark 84 (also referred to as a flow line) formed in a band shape is provided.

  The width direction sensors 82a and 82b and the length direction sensor 83 are a width direction mark 84 and a length direction mark 85 provided on the decorative sheet 71 and defect marks 86a, 86b and 86c attached in an inspection process described later (FIG. 5A, 6A, 7A) for detecting the position of the film in the transport direction and the width direction. In addition, the defect mark is read for the pattern on the defective decorative sheet so as not to be used for molding injection, and the defective pattern is detected. In addition, the width direction sensors 82a and 82b and the longitudinal direction sensor 83 are configured so that the attachment positions can be finely adjusted.

  FIG. 4 is a diagram illustrating a schematic configuration of an inspection apparatus that performs an inspection process of a decorative sheet. The inspection apparatus 10 is an apparatus that inspects a roll-shaped decorative sheet on which a transfer layer is printed by a gravure printing apparatus (not shown). The inspection apparatus shown in FIG. 4 can inspect the decorative sheet with an effective width of the decorative sheet of 600 mm, a defect detection size of 30 μm, and a film feed speed of 10 to 40 m / min.

  The decoration sheet 71 to be inspected is attached to the delivery roller 11. The feed roller 11 is driven and controlled by a torque motor 11a, and is controlled so as to send a decorative sheet 71 wound up by driving a winding roller 12 described later with a predetermined tension. The winding roller 12 is controlled with respect to its driving amount and driving torque, and the inspection device 10 is configured to be able to detect the conveyance amount of the decorative sheet.

  The decorative sheet 71 fed from the feed roller is sent to the guide roller 19 through the film pressing rollers 16a and 17a through the dancer roller 13a. The film pressing roller 17a is connected to an air cylinder that can move up and down, and is configured to be capable of adjusting the clamping force of the decorative sheet 71 between the film pressing roller 16a and the film pressing roller 16a as a pair, to ensure film feeding. Can do.

  The guide roller 19 is provided with three rollers arranged almost horizontally, and guides the film in the horizontal direction. The film conveyed through the area of the guide roller 19 is inspected by the line sensor unit 15 provided above the guide roller 19. The line sensor unit 15 includes two sensors for measuring transmitted light and reflected light. Further, a transmitted light source 14a and a reflected light source 14b are provided as inspection light sources by the line sensor unit. A defect in the transfer layer is optically discriminated by inspecting the image captured by each line sensor unit 15 and inspecting the captured image by a control calculation unit (not shown).

  Further, a defect mark imparting portion 18 is provided on the downstream side of the line sensor unit 15. The defect mark imparting unit can take various configurations depending on what kind of mark is added as a defect mark to be described later. As a specific example, an inkjet unit or a laser marker for printing on the surface of the film, a removal unit for removing a part of the transfer layer provided on the film, or the like can be used.

  The decorative sheet 71 guided by the guide roller 19 is guided by the film pressing rollers 16b and 17b. The film pressing roller 17b is connected to an air cylinder that can move up and down, and is configured to be capable of adjusting the clamping force of the decorative sheet 71 between the film pressing roller 16b and the film pressing roller 16b as a pair, to ensure film feeding. Can do. A dancer roller 13 b is provided on the downstream side of the film pressing rollers 16 b and 17 b, and the decorative sheet 71 guided by the dancer roller 13 b is taken up by the take-up roller 12. The take-up roller is provided with a torque motor 12a, and can take up the decorative sheet 71 while maintaining a predetermined tension.

  The defect mark imparting unit 18 processes the decorative sheet so that the longitudinal mark 85N corresponding to the pattern of the transfer layer having the defect determined by the line sensor unit 15 is different from the non-defective longitudinal mark 85. Do. Although a detailed configuration will be described later, a longitudinal mark is added to or deleted from a specific portion of the decorative sheet 71 in accordance with the timing of conveyance of the decorative sheet 71. The control of the mark application timing is controlled by a control unit of an inspection apparatus (not shown).

  A decorative sheet that has been subjected to defect inspection by an inspection device and to which a defect mark has been assigned will be described. FIG. 5A is a plan view showing a first example of a decorative sheet provided with a defect mark by an inspection apparatus. 5B is a cross-sectional view taken along line BB in FIG. 5A. Note that FIG. 5B shows a reduced scale in the longitudinal direction of the film.

  As shown in FIG. 5A, the decorative sheet 71a is provided with a width direction mark 84, a longitudinal direction mark 85, and patterns 91 and 91N. These are attached to a transfer layer 23 provided on the surface of the base sheet 20, as shown in FIG. 5B. The transfer layer 23 includes a release layer 21 provided on the surface of the base sheet 20 and an adhesive layer 22 provided on the upper surfaces of the design layers 84, 85, and 91. In addition, the arrow F has shown the conveyance direction in which the decorating sheet | seat 71a is conveyed in a shaping | molding simultaneous decorating apparatus.

  In order to improve the peelability of the transfer layer 23 from the base sheet 20, a release layer (not shown) may be formed on the entire surface before the transfer layer 23 is provided on the base sheet 20. The design layers 84, 85, and 91 are layers for expressing the design 91, the longitudinal direction mark 85, the width direction mark 84, and the like, and are provided on the surface of the release layer 21. The pattern layers 84, 85, 91 are formed of a metal thin film layer or the like applied on the release layer 72 by printing using ink, sputtering, or the like. In addition, when providing a metal thin film layer, in order to improve the adhesiveness of another transfer layer and a metal thin film layer, you may provide an anchor layer (not shown). The adhesive layer 22 is a layer for adhering each layer to the surface of the resin molded product.

  The defect mark 86a is a mark given by the defect mark applying unit 18 of the inspection apparatus 10 shown in FIG. 4, and in this embodiment, the longitudinal mark 85N corresponding to the defect pattern 91N is located downstream in the transport direction F. It is continuously printed on the longitudinal mark 85N. The surface to be printed is the surface of the transfer layer 23. As the defect mark applying unit 18 of the inspection apparatus 10 according to the present embodiment, an ink jet unit or the like can be suitably used.

  FIG. 6A is a plan view showing a second example of the decorative sheet to which the defect mark is given by the inspection apparatus. 6B is a cross-sectional view taken along line BB in FIG. 6A. Note that FIG. 6B shows a reduced scale in the longitudinal direction of the film.

  As shown to FIG. 6A, the width direction mark 84, the longitudinal direction mark 85, and the designs 91 and 91N are attached | subjected to the decorating sheet 71b. These are attached to the transfer layer 23 provided on the surface of the base sheet 20, as shown in FIG. 6B. In addition, since the layer structure of the decorating sheet 71b is the same as that of the decorating sheet 71a of 1st Example, it abbreviate | omits for details.

  The defect mark 86b is a mark attached by the defect mark applying unit 18 of the inspection apparatus 10 shown in FIG. 4, and in this embodiment, the upstream side of the conveyance direction F of the longitudinal direction mark 85N corresponding to the defect pattern 91N, That is, the image is printed at an intermediate position between the longitudinal mark 85F corresponding to the pattern 91F located one upstream of the defective pattern 91N and the longitudinal mark 85N corresponding to the defective pattern 91N. The surface to be printed is the surface of the transfer layer 23. As the defect mark applying unit 18 of the inspection apparatus 10 according to the present embodiment, an ink jet unit or the like can be suitably used.

  FIG. 7A is a plan view showing a third example of the decorative sheet to which the defect mark is given by the inspection apparatus. 7B is a cross-sectional view taken along line BB in FIG. 7A. Note that FIG. 7B shows a reduced scale in the longitudinal direction of the film.

  As shown to FIG. 7A, the width direction mark 84, the longitudinal direction mark 85c, and the designs 91 and 91N are attached | subjected to the decorating sheet 71c. These are attached to a transfer layer 23 provided on the surface of the base sheet 20, as shown in FIG. 7B. In addition, since the layer structure of the decorating sheet 71c is the same as that of the decorating sheet 71a of 1st Example, it abbreviate | omits for details.

  In the decorative sheet 71c of the present embodiment, the longitudinal direction mark 85 is intermittently formed in a band shape, and positions 87 and 87N at which the band-shaped mark is interrupted (hereinafter referred to as intermittent positions) correspond to the patterns 91 and 91N. Is provided. That is, in the decorating sheet 71c of the present embodiment, the simultaneous molding and decorating apparatus 1 performs longitudinal alignment by detecting the intermittent position of the longitudinal mark using the longitudinal sensor 83.

  The defect mark 86c is a mark given by the defect mark applying unit 18 of the inspection apparatus 10 shown in FIG. 4, and is printed at the intermittent position 87N of the longitudinal mark 85 corresponding to the defect pattern 91N in this embodiment. . As a result, the gap at the intermittent position 87N is filled and a continuous longitudinal mark 85 is connected. The surface to be printed is the surface of the transfer layer 23. As the defect mark applying unit 18 of the inspection apparatus 10 according to the present embodiment, an ink jet unit or the like can be suitably used.

  FIG. 8A is a plan view showing a fourth example of the decorative sheet to which the defect mark is given by the inspection apparatus. 8B is a cross-sectional view taken along line BB in FIG. 8A. FIG. 8B shows the film in a reduced scale in the longitudinal direction.

  As shown to FIG. 8A, the width direction mark 84, the longitudinal direction mark 85, and the designs 91 and 91N are attached | subjected to the decorating sheet 71d. These are attached to the transfer layer 23 provided on the surface of the base sheet 20, as shown in FIG. 8B. In addition, since the layer structure of the decorating sheet 71d is the same as that of the decorating sheet 71a of 1st Example, it abbreviate | omits for details.

  The defect mark 86d is a mark given by the defect mark giving unit 18 of the inspection apparatus 10 shown in FIG. 4, and is given by removing the longitudinal direction mark 85N corresponding to the defect pattern 91N in this embodiment. That is, by removing the region of the transfer layer 23 including the longitudinal direction mark 85N corresponding to the defective pattern 91N, the longitudinal direction mark 85N corresponding to the defective pattern 91N is eliminated, and the longitudinal direction in the molding simultaneous decorating apparatus as will be described later. Disable detection during alignment. As the defect mark applying unit 18 of the inspection apparatus 10 according to the present embodiment, for example, an adhesive unit for removing the transfer layer 23 is preferably used, and the transfer unit 23 is brought into contact with the transfer layer from which the head 18d is removed. The layer is transferred to the head 18d side, and the transfer layer is removed from the decorative sheet.

  Next, the positioning operation | movement of the decorating sheet in the simultaneous shaping | molding decorating apparatus shown in FIG. 1 is demonstrated. First, the case where the defect mark is not attached and the pattern used for the simultaneous molding decoration is aligned in the longitudinal direction and the width direction will be described, and then the simultaneous decoration decoration is performed by attaching the defect mark. An operation for skipping defective patterns that are not used in the above will be described.

(Pattern alignment operation)
First, when a cycle start signal is input, the upstream frame 60a and the downstream frame 60b return to the machine origin, and vertical feeding is started. By operating the motors 76a and 76b, the sheet supply roller 69 and the sheet take-up roller 70 are rotated to unwind the decorative sheet 71 from the roll of the decorative sheet. At this time, since the motors 76a and 76b are rotated at a high speed, the feeding speed of the decorative sheet 71 is high. The high-speed rotation of the motors 76a and 76b is held until the longitudinal direction mark 85 of the decorative sheet 71 is detected by the longitudinal direction sensor 83, as will be described later.

  When the decorative sheet 71 is fed a predetermined length and the longitudinal sensor 83 detects the longitudinal mark 85 of the decorative sheet 71 (intermittent position 87 in the embodiment shown in FIG. 7A), the motors 76a and 76b The rotation speed is switched to a low speed, and the feeding speed of the decorative sheet is reduced. The feeding speed of the decorative sheet at low speed can be set to about 1/20 of that at high speed, for example.

  Further, as control for taking the timing of switching from high-speed feed to low-speed feed, the control may be performed not by the detection timing of the longitudinal sensor 83 but by the feeding amount of the decorative sheet. That is, since the decorating sheet 71 according to the present embodiment is not cut and pasted to remove the defective pattern, the interval between the longitudinal marks adjacent to each other is not changed from that at the time of producing the decorating sheet. Therefore, the intervals between the longitudinal marks are all constant, and even if the control is performed based on the feed amount, the accuracy does not decrease.

  When the decorative sheet 71 is driven at a low speed, the motors 76a and 76b are stopped in a state in which the longitudinal sensor 83 has released the detection of the longitudinal mark 85, that is, when transmission or non-transmission of the longitudinal sensor 83 is switched. The feeding of the decorative sheet 71 is stopped. In addition, as the motor 76a provided in the upstream frame, in order to stabilize the rotation speed, it is preferable to use a servo motor and control the rotation speed by feedback control using a tachometer or an encoder.

  After positioning in the longitudinal direction as described above, positioning in the film width direction is performed. By moving the upstream frame 60a and the downstream frame 60b in the horizontal direction, the decorating sheet 71 arranged on the cavity surface of the mold is moved in the horizontal direction, and one end of the width direction mark 84 is at the width direction sensor 82a. , 82b, the moving speed of the decorating sheet 71 is decreased, and the decorating sheet 71 is moved by the timing when the other end of the width direction mark 84 is detected or by a predetermined length, and then stopped. Further, since the moving distance in the horizontal direction is small, the movement of the decorating sheet 71 may be stopped immediately when one end of the width direction mark 84 is detected by the width direction sensors 82a and 82b. In the horizontal alignment, the two sensors of the width direction sensors 82a and 82b are used to adjust the inclination of the decorative sheet 67 with respect to the vertical direction.

(Defect pattern skipping operation)
As shown in FIGS. 5A to 8A, the defect pattern skipping operation is performed differently depending on the form of the defect mark attached to the decorative sheet. Hereinafter, the defect pattern skipping operation will be described for each decorative sheet shown in the examples. In the following description, the skip operation refers to an operation from the end of the molding operation for one cycle before the defective pattern until the end of the next good pattern alignment in the longitudinal direction.

  FIG. 9 is a flowchart showing the skip operation when the decorative sheet shown in FIG. 5A is used. In the skip operation to be set in the simultaneous molding and decorating apparatus when this decorative sheet is used, first, the feeding operation of the decorative sheet 71a is started (# 10). The feeding speed of the decorative sheet 71a at this time is high-speed feeding as described above. When the decorative sheet 71a is sent in the longitudinal direction, the longitudinal sensor 83 detects the longitudinal mark 85 and switches to the non-transmissive state (yes in # 11). At this timing, the motor 76 switches to a low speed as described above (# 12), and a timer (not shown) starts time counting (# 13).

  If the longitudinal sensor is switched from non-transmission to transmission state before the predetermined time elapses during low-speed feeding (yes in # 15), that is, the time during which the longitudinal sensor is shielded is predetermined. If it is shorter than the time, the motor 76 is stopped and the longitudinal alignment is completed.

  On the other hand, when a predetermined time elapses while the longitudinal sensor 83 is not transmissive, it is determined that the defect mark 86a is continuously attached to the longitudinal mark 85. In this case, the motor 76 is switched to high speed driving to advance the decorative sheet. Note that the defect sensor 86a passes through the longitudinal sensor 83 on the way, and the longitudinal sensor 83 becomes non-transmissive, but this detection signal is ignored (# 18).

  Subsequently, the decorative sheet at high speed is fed until the longitudinal sensor becomes non-transmissive, and the above process is repeated to complete the alignment in the longitudinal direction.

  In the case of using the decorative sheet of FIG. 5A, the skip operation of the simultaneous molding and decorating apparatus can start the timer count at the timing when the motor switches from high speed to low speed, thereby reducing the trigger of processing, and easy processing. Skip operation can be performed.

  As a modification of the skip operation, the presence or absence of a defect mark may be determined based on the feeding amount of the decorative sheet instead of performing time counting. That is, it is possible to count the decorative sheet feed amount after the longitudinal sensor is in a non-transparent state in # 11, and determine the presence or absence of a defect mark based on whether or not a predetermined distance has been moved in the non-transparent state. it can.

  FIG. 10 is a flowchart showing a skip operation when the decorative sheet shown in FIG. 6A is used. In the skip operation to be set in the simultaneous molding device when this decorative sheet is used, first, the feeding operation of the decorative sheet 71b is started (# 20). The feeding speed of the decorative sheet 71a at this time is high-speed feeding as described above. At the same time as sheet feeding is started, a timer (not shown) starts time counting (# 21).

  When the decorative sheet 71b is sent in the longitudinal direction, the longitudinal sensor 83 detects the longitudinal mark 85 and switches to the non-transmissive state (yes in # 22). It is determined whether the predetermined time of the timer has elapsed, and if the predetermined time has elapsed (Yes in # 23), the motor 76 is switched to a low speed as described above (# 24).

  Next, when the longitudinal sensor is switched from the non-transmissive state to the transmissive state (Yes in # 25), the motor 76 is stopped and the alignment in the longitudinal direction is completed.

  On the other hand, if the longitudinal sensor is switched from the transmission state to the non-transmission state before the predetermined time elapses during high-speed feeding (no in # 23), a defect provided between the longitudinal direction sensors 85 It is determined that the mark 86b is detected by the longitudinal sensor 83. In this case, the high speed movement is continued. Note that the defect sensor 86a passes through the longitudinal sensor 83 on the way, and the longitudinal sensor 83 becomes non-transmissive, but this detection signal is ignored (# 28).

  When the decorative sheet of FIG. 6A is used, the skip operation of the simultaneous molding and decorating apparatus starts a timer count at the timing when the motor is driven, and thus the processing trigger increases. However, in order to ensure continuity with the longitudinal sensor 83 in the process of printing the defect mark 86b in the inspection apparatus, alignment is not performed with high accuracy. Can be simple.

  FIG. 11 is a flowchart showing the skip operation when the decorative sheet shown in FIG. 7A is used. In the skip operation to be set in the simultaneous molding device when this decorative sheet is used, first, the feeding operation of the decorative sheet 71c is started (# 30). The feeding speed of the decorative sheet 71c at this time is high-speed feeding as described above. Since the longitudinal direction mark of the decorating sheet 71c is configured in a band shape provided intermittently, the longitudinal direction sensor 83 is in a non-transmissive state at a timing when no pattern is detected. When the decorative sheet 71c is sent in the longitudinal direction, the longitudinal sensor 83 detects the intermittent region 87 of the longitudinal mark 85 and switches from the non-transmissive state to the transmissive state (yes in # 31). In addition, since the defect mark 86c is given to the intermittent position 87N corresponding to the pattern 91N having a defect, the longitudinal sensor 83 does not detect the defect pattern 91N, and the longitudinal sensor 83 When the transmission state is detected, it means that the pattern corresponding to the intermittent position has not been determined as a defective pattern by the inspection apparatus 10. At the timing when the longitudinal sensor 83 is switched from the non-transmissive state to the transmissive state, the motor 76 is switched to the low speed as described above (# 32).

  The decorative sheet is fed at a low speed, and the motor 76 is stopped (# 34) at the timing when the longitudinal sensor 83 is switched from the transmission state to the non-transmission state, thereby completing the alignment in the longitudinal direction.

  When the decorative sheet of FIG. 7A is used, the skip operation of the simultaneous molding decorative device is devised by the shape of the longitudinal direction mark, and the simultaneous simultaneous decorative device 1 can be operated with easy control operation without performing timer counting. Since it is possible to easily distinguish a defective pattern from a good pattern, a skip operation can be performed with easy processing. Also, the application of defect marks in the inspection apparatus 10 can be realized with a simple configuration such as an inkjet unit.

  FIG. 12 is a flowchart showing a skip operation when the decorative sheet shown in FIG. 8A is used. In the skip operation to be set in the simultaneous molding device when this decorative sheet is used, first, the feeding operation of the decorative sheet 71d is started (# 40). The feeding speed of the decorating sheet 71d at this time is high-speed feeding as described above. The longitudinal direction mark of the decorating sheet 71d is attached only to the good pattern 91, and the longitudinal direction mark attached to the defective pattern before the inspection by the inspection apparatus is removed. Therefore, the longitudinal direction mark 85 is not given at the position corresponding to the defective pattern 91N, and the longitudinal direction sensor 83 does not detect the defective pattern 91N. Therefore, when the longitudinal direction sensor 83 detects the non-transmission state, it means that the pattern corresponding to the intermittent position has not been determined to be a defective pattern by the inspection apparatus 10.

  When the decorating sheet 71d is sent in the longitudinal direction, the longitudinal sensor 83 detects the longitudinal mark 85 and switches from transmitting to non-transmitting (yes in # 41). At the timing when the longitudinal sensor 83 is switched from the transmission state to the non-transmission state, the motor 76 is switched to the low speed as described above (# 42).

  The decorative sheet is fed at a low speed, and the motor 76 is stopped (# 44) at the timing when the longitudinal sensor 83 is switched from the non-transmissive state to the transmissive state, thereby completing the longitudinal alignment.

  In the case where the decorative sheet of FIG. 8A is used, the skip operation of the simultaneous molding and decorating device particularly removes the longitudinal direction mark corresponding to the defective pattern, thereby controlling the skip operation in the simultaneous molding and decorating device 1 in particular. The processing for the alignment operation can be used as it is without being required.

  As explained above, according to the shaping simultaneous decorating system including the simultaneous molding decorative device 1 and the inspection device 10 according to the present embodiment, the longitudinal direction mark corresponding to the defect pattern detected in the inspection stage of the decorative sheet. By giving a defect mark to the surface, it is possible to form a molded product by skipping the defective pattern in the simultaneous decoration. Therefore, it is not necessary to cut and connect the sheets at the inspection stage of the decorative sheet, and a good pattern is not wasted. Therefore, it is possible to prevent the sheet and the defective molded product from being formed, and to improve the production yield of a good molded product.

  In addition, this invention is not limited to the said embodiment, It can implement in another various aspect.

  For example, in the said embodiment, although the longitudinal direction sensor was used as a sensor which detects a defect mark in a shaping | molding simultaneous decorating apparatus, you may be comprised so that the independent sensor which detects a defect mark may be further provided. In this case, it is preferable that the positional relationship between the longitudinal direction sensor and the defect mark detection sensor be different in the film width direction as shown in FIG.

  In this case, it is determined whether or not to skip the pattern depending on whether or not the sensor for inspecting the defect mark is in a shielding state at any timing until the decorative sheet is stopped after the longitudinal mark is detected. do it.

  Further, in the inspection apparatus, when the line sensor 15 determines that the pattern is defective, only the defect mark is added. For example, a visually identifiable defect display is added to the defect pattern. You may do it. Examples of the defect display include “NG characters” and cross marks. In addition, the defect indication is attached to any surface of the decorative sheet 71, but when it is attached to the side where the transfer layer is provided, there is a malfunction in the skip operation in the simultaneous decorative device. In such a case, the defect indication is directly transferred to the molded product at the time of the simultaneous molding in the molding simultaneous decorating apparatus. Therefore, there is an effect that visual judgment can be easily made in the defect inspection of the molded product after molding.

  Moreover, in the said embodiment, although the shaping | molding simultaneous decoration apparatus and the test | inspection apparatus were comprised as an independent apparatus as an apparatus which comprises a shaping | molding simultaneous decoration system, this can also be comprised integrally. That is, you may make it perform a test | inspection and provision of a defect mark at the timing which feeds a decorating sheet for shaping | molding simultaneous decorating. In this case, a defect mark providing unit such as a line sensor unit and an ink jet unit may be provided on the upstream frame.

It is a figure which shows the structure of the shaping | molding simultaneous decoration apparatus used for the shaping | molding simultaneous decoration system concerning embodiment of this invention. It is sectional drawing which follows II-II of FIG. It is a top view which shows one Example of the decorating sheet which shows the state before the test | inspection used for the shaping | molding simultaneous decorating apparatus shown in FIG. It is a figure which shows the structure of the test | inspection apparatus used for the shaping | molding simultaneous decoration system concerning embodiment of this invention. It is a top view which shows 1st Example of the decorating sheet to which the defect mark was provided by the inspection apparatus. It is sectional drawing in the BB line of FIG. 5A. It is a top view which shows 2nd Example of the decorating sheet | seat with which the defect mark was provided by the inspection apparatus. It is sectional drawing in the BB line of FIG. 6A. It is a top view which shows 3rd Example of the decorating sheet | seat with which the defect mark was provided by the inspection apparatus. It is sectional drawing in the BB line of FIG. 7A. It is a top view which shows the 4th Example of the decorating sheet | seat with which the defect mark was provided by the inspection apparatus. It is sectional drawing in the BB line of FIG. 8A. It is a flowchart which shows the skip operation | movement at the time of using the decorating sheet shown to FIG. 5A. It is a flowchart which shows the skip operation | movement at the time of using the decorating sheet shown to FIG. 6A. It is a flowchart which shows the skip operation | movement at the time of using the decorating sheet shown to FIG. 7A. It is a flowchart which shows the skip operation | movement at the time of using the decorating sheet shown to FIG. 8A. It is a top view which shows the modification of the decorating sheet shown to FIG. 5A.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molding simultaneous decorating apparatus 10 Inspection apparatus 11 Sending roller 11a Torque motor 12 Winding roller 13a, 13b Dancer roller 15 Line sensor unit 16a, 16b, 17a, 17b Film pressing roller 18 Defect mark giving part 19 Guide roller 20 Base sheet 21 Peeling Layer 22 Adhesive layer 23 Transfer layer 31 Frame 32 Fixed platen 34 Movable platen 39 Injection nozzle 40 Movable mold 60a Upstream frame 60b Downstream frame 61a, 61b Guide rails 62a, 62b Guide 69 Sheet supply roller 70 Sheet winding rollers 71, 71a , 71b, 71d, 71d, 71e Decorating sheets 72, 78 Upstream sheet guide rollers 76a, 76b Motors 80, 81 Film clamps 82a, 82b Width direction sensor 83 Long direction sensor 84 Width direction marks 85, 85 Longitudinal mark 86,86a defect mark 87 intermittently position 91 picture 91N defect picture

Claims (5)

A decorative sheet used in a simultaneous molding decoration device for closing a mold in a state of being aligned with a mold, injecting a molten resin, and transferring a transfer layer to the surface of the molded product solidified by the molten resin,
A transfer layer including a plurality of non-defective patterns and defect patterns is attached to the surface of the base sheet, and a defect mark, a width direction mark, and a longitudinal direction mark provided corresponding to the defect pattern are provided. Decorative sheet.   The width direction mark is provided extending in the longitudinal direction in the vicinity of one end in the width direction of the decorative sheet, the longitudinal direction mark is provided corresponding to each of the patterns, and the defect mark is It is comprised so that it may become the same row as the said longitudinal direction mark with respect to the longitudinal direction of a decorating sheet, The decorating sheet of Claim 1 characterized by the above-mentioned.   The decorative sheet according to claim 2, wherein the defect mark is continuously formed on the downstream side in the supply direction of the longitudinal mark corresponding to a defective pattern.   The said defect mark is comprised so that it may be provided between the said longitudinal direction mark corresponding to the previous pattern and the said longitudinal direction mark corresponding to a defective pattern, The Claim 2 characterized by the above-mentioned. Decorative sheet.   The width direction mark is provided in the vicinity of one end in the width direction of the decorative sheet so as to extend in a strip shape in the longitudinal direction, and the longitudinal direction mark is an intermittent strip shape so that a gap is formed corresponding to the pattern The decorative sheet according to claim 1, wherein the defect mark is provided so as to fill the gap corresponding to the defect pattern.

Images