JP2009264801A - Manufacturing method of appearance inspecting apparatus and resin-molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of an appearance inspecting apparatus and a resin molding article capable of improving accuracy in detecting a trace amount and of performing an appearance inspection and a UV irradiation in the same step, for improving the productivity of the resin molding article. <P>SOLUTION: An appearance inspecting apparatus 10 includes: an illuminator 11 for irradiating the surface of a resin-molded article 20 with UV light; a line camera 12 for receiving the light reflected by the UV from the surface of the resin-molded article 20 to perform imaging, an imaging processing apparatus 14 for performing imaging processing on the inspection image acquired with imaging by the line camera 12; and a conveyor 13 for conveying the resin-molded article 20 so as to pass through the region, wherein the illuminator 11 illuminates UV. In a manufacturing method of the resin-molded article 20 using the appearance inspecting apparatus 10, since a UV curing of a hard coat layer 21 and an appearance inspection using UV light are performed simultaneously, the productivity of the resin-molded article 20 can be improved. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an appearance inspection apparatus and a method of manufacturing a resin molded product, and more particularly, to an appearance inspection apparatus for detecting irregularities in appearance of an inspection object having a hard coat layer formed on the surface and a resin having a hard coat layer formed on the surface. The present invention relates to a method for manufacturing a molded product.

  There is a resin molded product in which a hard coat layer is formed on the surface in order to ensure scratch resistance, and a design layer is formed on the back side of the hard coat layer in order to express the design. For example, a casing of a mobile phone. This resin molded product is transferred to the mold at the same time as injection molding by an injection molding machine having a transfer sheet feeding device that transfers a transfer sheet having a hard coat layer and a design layer formed as a transfer layer into the mold. The transfer layer is transferred from the sheet and molded. The hard coat layer is a layer made of a resin that is cured when irradiated with ultraviolet rays. Next, the molded resin molded product is conveyed from the injection molding machine to the appearance inspection device, and the appearance inspection device is inspected for the presence or absence of appearance defects. Next, the inspected resin molded product is conveyed from the appearance inspection device to the ultraviolet irradiation device, and is irradiated with ultraviolet rays by the ultraviolet irradiation device, and cured so that the hard coat layer has a desired hardness. Thus, the resin molded product which ensured abrasion resistance is manufactured (for example, refer patent document 1).

The injection molding machine includes a fixed mold, a movable mold in which a parting surface of the fixed mold is formed, and a transfer sheet feeding device that feeds a transfer sheet in parallel to the parting surface. The transfer sheet is configured to be in close contact with the cavity surface of the movable mold during injection molding. Therefore, the cavity surface of the movable mold and the resin molded product are not in direct contact. The appearance inspection device is a resin molded product that performs image processing on a light source that irradiates a resin molded product with visible light, an imaging device that receives reflected light from the visible light and performs imaging, and an inspection image acquired by imaging. And an image processing apparatus for detecting pass / fail defects, particularly dents on the surface. The dent is the mold on the side where the transfer sheet is in close contact, and in the above, foreign matter adheres to the cavity surface of the movable mold, and injection molding is performed with the foreign matter adhered between the cavity surface and the transfer sheet. It is a dent that occurs in the case. The ultraviolet irradiation device includes a light source that irradiates ultraviolet rays and a conveyor that conveys a resin molded product so that the ultraviolet rays are irradiated. The irradiation time of ultraviolet rays is adjusted by the conveying speed by the conveyor. A resin molded product having a hard coat layer formed on the surface is manufactured through an injection molding process by the injection molding machine, an appearance inspection process by the appearance inspection apparatus, and an ultraviolet curing process by the ultraviolet irradiation apparatus.
JP-A-8-108447

  In the conventional appearance inspection apparatus and the method for producing a resin molded product as described above, the step of curing the hard coat layer by irradiating ultraviolet rays and the inspection of appearance defects such as dents using reflected light by visible light. Since the process to perform is performed separately, the productivity of the resin molded product is reduced. Also, with visible light, depending on the pattern to be decorated, there is no difference in the amount of reflected light between the dent portion and other portions, and the dent can not be detected by the visual inspection device using visible light. There is. The foreign matter adhering to the cavity surface that is the cause of the dent is not directly in contact with the resin molded product by the transfer sheet, and therefore does not adhere to the resin molded product and is removed from the cavity surface. Therefore, once the dent is generated, the same dent is generated continuously. If the detection of the dent is missed, a defective product having the same dent is produced in large quantities.

  This invention has been made to solve the above-described problems, and can improve the detection accuracy of dents, perform visual inspection and ultraviolet irradiation in the same process, and improve the productivity of resin molded products. An object of the present invention is to provide a visual inspection apparatus and a method for manufacturing a resin molded product.

  In order to achieve the above object, the invention described in claim 1 is an appearance inspection apparatus for detecting irregularities in appearance of an inspection object having a hard coat layer formed on the surface, and irradiates the surface with ultraviolet rays. A light source, an imaging device that receives reflected light from the surface due to ultraviolet rays, and performs image processing on the inspection image acquired by imaging, and detects uneven defects on the inspection object corresponding to the inspection image An image processing apparatus that performs pass / fail determination and a transport apparatus that transports the inspection object so that the hard coat layer is cured to a desired hardness by ultraviolet rays.

  If comprised in this way, the ultraviolet curing and appearance inspection of a hard-coat layer will be performed simultaneously. Further, at the concave and convex defect portion, the irradiated ultraviolet rays are irregularly reflected, and the amount of reflected ultraviolet rays changes locally as compared with other portions.

  According to a second aspect of the present invention, in the configuration of the first aspect of the present invention, the inspection object has a design layer further formed on the back side of the hard coat layer.

  If comprised in this way, the reflection amount of an ultraviolet-ray will be hard to be influenced by the pattern formed in the test object by the pattern layer.

  According to a third aspect of the present invention, in the configuration of the first or second aspect of the present invention, the imaging device includes a filter that transmits near-ultraviolet rays in the reflected light.

  If comprised in this way, the range of the wavelength of the ultraviolet-ray for ultraviolet curing is not limited, The range of the wavelength of the ultraviolet-ray in an external appearance test is limited.

  According to a fourth aspect of the present invention, in the configuration of the first or second aspect of the present invention, the ultraviolet rays are near ultraviolet rays.

  If comprised in this way, a light source and an imaging device will respond | correspond in a common wavelength range.

  According to a fifth aspect of the present invention, there is provided the transfer sheet feeding device according to any one of the first to fourth aspects, wherein the transfer sheet having a hard coat layer formed as a transfer layer is fed into a mold. The inspection object is a resin molded product that is molded by the transfer layer being transferred by the transfer sheet sent into the mold simultaneously with the injection molding by the injection molding machine. The apparatus further includes stop means for stopping the injection molding machine when the apparatus detects the same uneven defect continuously a predetermined number of times.

  If comprised in this way, when the inferior goods which consist of the same uneven | corrugated defect of desired continuous frequency generate | occur | produce, shaping | molding of a resin molded product will stop.

  The invention according to claim 6 is a method for producing a resin molded product having a hard coat layer formed on a surface thereof, and a transfer sheet feeding device for feeding a transfer sheet having a hard coat layer formed as a transfer layer into a mold. The process of forming a resin molded product by transferring the transfer layer simultaneously with the injection molding by the injection molding machine, and the surface of the molded resin molded product is irradiated with ultraviolet rays so that the hard coat layer is cured to a desired hardness. At the same time of irradiation, the reflected light from the surface due to ultraviolet rays is received and imaged, image processing is performed on the inspection image obtained by the imaging, and the irregularity defect of the resin molded product corresponding to the inspection image is detected. And the step of performing the determination, and the injection molding machine is stopped when the same uneven defect is continuously detected a predetermined number of times.

  If comprised in this way, the ultraviolet curing and appearance inspection of a hard-coat layer will be performed simultaneously. The molding of the resin molded product is stopped when a defective product having the same irregularity defect of the desired number of continuous occurrences occurs.

  As described above, the invention according to claim 1 can improve the productivity of the inspection object because the ultraviolet curing of the hard coat layer and the appearance inspection are performed at the same time. Moreover, since the irradiated ultraviolet rays are irregularly reflected at the concave and convex defect portion, and the amount of reflected ultraviolet light changes locally as compared with other portions, the concave and convex defect can be detected with high accuracy.

  In addition to the effect of the invention described in claim 1, the invention described in claim 2 has a pattern on the surface because the reflection amount of ultraviolet rays is hardly affected by the pattern formed on the test object by the pattern layer. Even so, it is possible to accurately detect the concavo-convex defect.

  In the invention described in claim 3, in addition to the effect of the invention described in claim 1 or 2, the range of the wavelength of ultraviolet rays for ultraviolet curing is not limited, and the range of the wavelength of ultraviolet rays for visual inspection is limited. The For this reason, it is possible to detect an irregularity defect in appearance after effectively performing ultraviolet curing.

  In addition to the effects of the invention of claim 1 or 2, the invention of claim 4 can simplify the configuration of the apparatus because the light source and the imaging device are handled in a common wavelength region. .

  In addition to the effects of the invention according to any one of claims 1 to 4, the invention according to claim 5 is characterized in that a resin molded product is produced when a defective product having the same irregularity defect of a desired number of continuous occurrences occurs. Since the molding is stopped, it is possible to prevent the continuous generation of defective products in consideration of productivity.

  According to the sixth aspect of the present invention, the UV curing of the hard coat layer and the appearance inspection are performed at the same time, and the molding of the resin molded product is stopped when a defective product having the same irregularity defect of a desired number of continuous occurrences occurs. . Therefore, productivity can be improved and continuous occurrence of the same defective product can be prevented.

  Next, embodiments of the invention will be described with reference to the drawings.

  It is the block diagram which showed schematic structure of the external appearance inspection apparatus by 1st Embodiment of this invention.

  Referring to FIG. 1, an appearance inspection apparatus 10 includes an illuminator 11 that irradiates the surface of a resin molded product 20 with ultraviolet rays, and a line that receives the reflected light from the ultraviolet rays from the surface of the resin molded product 20 and performs imaging. A camera 12, an image processing device 14 that performs image processing on an inspection image acquired by imaging of the line camera 12, and a conveyor 13 that conveys the resin molded product 20 so as to pass through a region where the illuminator 11 irradiates ultraviolet rays. And. The illuminator 11, the image processing device 14, and the conveyor 13 are each electrically connected to the control unit 15. The control unit 15 controls the operation of the illuminator 11 and the conveyor 13. The control unit 15 is also electrically connected to an injection molding machine 30 that molds the resin molded product 20.

  The illuminator 11 is a light source using an ultraviolet lamp, and is, for example, a coaxial epi-illumination type light source having a built-in half mirror. Ultraviolet rays are emitted from the ultraviolet lamp toward the half mirror in the horizontal direction and reflected downward in the vertical direction by the half mirror. The reflected ultraviolet light is reflected vertically upward from the surface of the resin molded product 20, passes through the half mirror, and enters the line camera 12. In this way, the optical axes of the illuminator 11 and the line camera 12 are matched. If such coaxial epi-illumination is adopted, ultraviolet rays are irradiated and reflected in the vertical direction, so that it is easy to detect uneven defects on the surface of the resin molded product 20 spreading in a plane. The distance between the illuminator 11 and the resin molded product 20 is determined according to the irradiation amount of ultraviolet rays necessary for the resin molded product 20. As the ultraviolet lamp, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, an ultraviolet LED, or the like is used. When the ultraviolet rays irradiated to the resin molded product 20 are near ultraviolet rays, for example, black light is used as the ultraviolet lamp.

  The line camera 12 is an imaging device that images the resin molded product 20 from above. The line camera 12 is a camera corresponding to the ultraviolet region, and includes a photosensor such as a CCD in which light receiving elements are arranged one-dimensionally, a drive circuit, an imaging optical system, and the like. If a filter that transmits near-ultraviolet rays is attached to the lens, the near-ultraviolet rays can be incident on the line camera 12 at the center. The filter may not be directly attached to the line camera 12 as long as near ultraviolet light can be incident on the line camera 12 as a center.

  The image processing apparatus 14 performs image processing on the inspection image of the resin molded product 20 acquired by imaging with the line camera 12, detects an uneven defect on the appearance of the resin molded product 20 corresponding to the inspection image, and performs resin processing. The quality of the molded product is judged. The detection of the concavo-convex defect is performed because the reflection amount of ultraviolet rays is locally different in the concavo-convex defect portion as compared with other portions. Whether the resin molded product is good or bad is determined based on a difference in the amount of reflected ultraviolet light set in advance between the uneven defect portion and the other portion, or a predetermined amount of reflected ultraviolet light in a predetermined range. Further, the image processing unit 16 stores the inspection image in which the concavo-convex defect is detected, and compares the inspection image with the next imaged inspection image to determine whether the same concavo-convex defect has occurred continuously. to decide. If it is determined that the same uneven defect is continuously generated, the image processing unit 16 further detects the number of continuous occurrences of the same uneven defect. The image processing apparatus 14 includes a computer, a program that causes the computer to operate as the image processing apparatus 14, a display unit such as an LCD, an operation unit such as a keyboard, a mouse, a trackball, and a touch panel.

  The conveyor 13 is a conveying device that conveys the resin molded product 20 so that a hard coat layer 21 (to be described later) of the resin molded product 20 is cured to a desired hardness by ultraviolet rays from the illuminator 11. The conveyor 13 is, for example, a belt conveyor that rotates a wide belt in a ring shape and places the resin molded product 20 on the belt for conveyance. In order to adjust the irradiation amount of the ultraviolet rays to the resin molded product 20, the conveyance speed of the resin molded product 20 is adjusted by adjusting the rotation speed of the belt conveyor. In addition, since ultraviolet rays can be harmful to the human body, it is preferable to cover the ultraviolet irradiation regions of the illuminator 11, the line camera 12, and the conveyor 13 with a dark box (not shown).

  The control unit 15 controls the irradiation amount of the ultraviolet rays of the illuminator 11 and the conveyance speed of the conveyor 13. When the image processing apparatus 14 continuously detects the same uneven defect a predetermined number of times, the signal is received from the image processing apparatus 14 and the injection molding machine 30 is stopped. At this time, the operations of the illuminator 11, the line camera 12, and the conveyor 13 are also stopped. The injection molding machine 20 includes a fixed mold (not shown), a movable mold on which a parting surface of the fixed mold is formed, and a transfer sheet feeding device that feeds the transfer sheet in parallel to the parting surface. It has. The transfer sheet is configured to be in close contact with the cavity surface of the movable mold during injection molding. When the control unit 15 stops the injection molding machine 30 as described above, specifically, the control unit 30 sends a signal to the transfer sheet feeding device, and the transfer sheet feeding device sends a signal to the injection molding machine 30. , And the transfer sheet feeding device and the injection molding machine 30 are stopped. That is, the control unit 15 stops the injection molding machine 30 via the transfer sheet feeding device. The control unit 15 may send a signal directly to the injection molding machine to stop the transfer sheet feeding device and the injection molding machine 30.

  Next, the resin molded product 20 will be described.

  FIG. 2 is a plan view of the resin molded product (1) shown in FIG. 1, and (2) is a sectional view taken along line II-II shown in (1).

  Referring to FIG. 2, the resin molded product 20 is configured to have a rectangular shape in plan view with rounded corners, a surface having a flat surface, and a peripheral edge slightly rising on the back surface side while being smoothly bent. Yes. The resin molded product 20 is used, for example, in a mobile phone casing. The cross section includes a resin portion 23, a design layer 22 formed so as to cover the resin portion 23, and a hard coat layer 21 formed so as to cover the design layer 22. In other words, the hard coat layer 21 is formed on the surface of the resin molded product 20, and the design layer 22 is formed on the back side of the hard coat layer 21. The hard coat layer 21 is a resin layer that cures when irradiated with ultraviolet rays from the illuminator 11, and plays a role of improving the scratch resistance of the surface of the resin molded product 20. Since the hard coat layer 21 is transparent, the checkered pattern 25 formed by the pattern layer 22 is viewed from the outside in a range of about half of the plan view. The resin molded product 20 is molded by transferring a transfer layer by a transfer sheet sent into a mold simultaneously with injection molding. The transfer sheet fed into the mold by the transfer sheet feeding device is one in which the hard coat layer 21 and the design layer 22, which are transfer layers, are formed on one surface of the base sheet 24. The resin molded product 20 is molded by separating the hard coat layer 21 and the design layer 22 from the base sheet 24 and transferring them to the resin portion 23. The transfer sheet may be further provided with a functional layer such as a release layer for improving the peelability between the base sheet 24 and the transfer layer and an adhesive layer for improving the adhesiveness between the resin portion 23 and the transfer layer. Good.

  The base sheet 24 is made of a material such as a resin sheet such as polyethylene terephthalate (PET), polypropylene (PP), or acrylic, a metal foil, glassine paper, coated paper, a cellulosic sheet such as cellophane, or the like.

  For the hard coat layer 21, an ultraviolet curable resin is used, and examples thereof include an acrylic (PMMA) resin and an epoxy (EP) resin. The material of the hard coat layer 21 may be determined from the type of ultraviolet rays irradiated from the illuminator 11. The hard coat layer 21 is printed on the base sheet 24 by a gravure printing method, a screen printing method, an offset printing method, or the like.

  The pattern layer 22 is formed of a colored ink containing a resin and a coloring material such as a pigment or a dye. Resins used as binders include polyvinyl resins, polyamide (PA) resins, polyester resins, PMMA resins, polyurethane resins, polyvinyl acetal resins, polyester urethane resins, cellulose ester resins, alkyd resins, etc. is there. The pattern layer 22 is printed on the hard coat layer 21 by a gravure printing method, a screen printing method, an offset printing method, or the like. When it is desired to express metallic luster as a pattern, the pattern layer 22 is constituted by a metal thin film layer formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method or the like. The symbol layer 22 is set entirely or partially depending on the symbol 25 to be expressed.

  The resin part 23 is made of a material that matches the purpose of the molded product. For example, polymer alloys such as acrylonitrile, butadiene, styrene (ABS), PMMA, polystyrene (PS), styrene acrylonitrile (AS), polycarbonate (PC), polyvinyl chloride (PVC), PP, PET resin, PC / ABS alloy, etc. It is.

  For the release layer, a melamine resin or the like is used, and for the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the resin portion 23, for example, if the resin portion 23 is a PMMA resin, a PMMA resin is used. used. The release layer and the adhesive layer are printed by a gravure printing method, a screen printing method, or the like.

  Next, an inspection image subjected to image processing by the image processing apparatus will be described.

  FIG. 3 is an imaging schematic diagram of the resin molded product shown in FIG. 1, in which (1) is taken by the appearance inspection apparatus shown in FIG. 1, and (2) is a conventional appearance inspection apparatus. It was taken by. Note that these imaging schematic diagrams are image-processed by the line camera 12 taking an area indicated by a two-dot chain line in (1) of FIG. 2 as an imaging area.

  Referring to (1) of FIG. 3, an imaging schematic diagram 27 is a diagram schematically showing an inspection image that has been subjected to image processing by the image processing device 14 by receiving reflected light from ultraviolet rays. In the imaging schematic diagram 27, the pattern 25 disappears and the dent 26 is clearly recognized. The dent 26 is a dent generated on the surface of the resin molded product 20 at the time of injection molding, that is, an irregularity defect in the appearance of the resin molded product 20. Depending on the type of ultraviolet lamp used, the pattern 25 may be recognized somewhat. In the appearance inspection apparatus 10 using ultraviolet rays, the reflection amount of ultraviolet rays is hardly affected by the pattern 25. In the dent 26 portion, the irradiated ultraviolet rays are irregularly reflected, and the reflection amount of the ultraviolet rays changes locally as compared with other portions. For this reason, it is possible to accurately detect uneven defects such as the dent 26.

  On the other hand, with reference to (2) of FIG. 3, in the imaging schematic diagram 30 which image-processed what was imaged with the conventional external appearance inspection apparatus using visible light, both the pattern 25 and the dent 26 are recognized, It is difficult to distinguish the pattern 25 from the dent 26. In the conventional visual inspection apparatus using visible light, there is not much difference in the amount of reflected visible light between the pattern 25 portion and the dent 26 portion, and therefore the dent 26 may not be detected as an uneven defect.

  Next, a method for manufacturing the resin molded product 20 using the appearance inspection apparatus 10 will be described.

  FIG. 4 is a flowchart showing the control contents of the appearance inspection apparatus shown in FIG.

  Before being conveyed to the appearance inspection apparatus 10, the hard coat layer 21 and the design layer 23 are transferred simultaneously with the injection molding by the injection molding machine 30 to mold the resin molded product 20. The molded resin molded product 20 is conveyed by a robot (not shown) while being held by holding means such as vacuum suction, and is placed at a predetermined position on the conveyor 13 of the appearance inspection apparatus 10. The placed resin molded product is conveyed by the conveyor 13 so as to pass below the illuminator 11. At this time, the hard coat layer 21 is conveyed by the ultraviolet rays from the illuminator 11 so as to be cured to a desired hardness. Specifically, the irradiation area and the conveyance speed are adjusted.

  Next, referring to FIG. 4, the line camera 12 receives the reflected light from the surface of the resin molded product 20 (S100, n = 0) irradiated with ultraviolet rays while being transported as described above, and resin molded. The product is imaged (S101). Next, the image processing apparatus 14 performs image processing of the inspection image captured in step 101 (S102), detects the irregularity defect of the resin molded product 20 corresponding to the inspection image, and determines whether the resin molded product is good or bad. A determination is made (S103). Next, if a concavo-convex defect is detected in step 103 (Yes in S103), the image processing apparatus 14 stores the inspection image. Next, the line camera 12 captures an image of the second resin molded product 20 (No in S105, n = 1 in S110), and the image processing device 14 performs image processing and defect detection (S101 to S103). If an uneven defect is detected again (Yes in S103), the first and second inspection images are compared (Yes in S105, S106). If the two inspection images match (Yes in S107), the image processing apparatus 14 confirms the number of times of matching, and if the predetermined number P has not been reached (No in S108), the third and subsequent resins. The process from imaging to image comparison of the molded product 20 (n = 3, 4, 5,... In S110) is repeated (S101 to S106). In the image comparison in step S106, even if the second and subsequent inspection images are compared with the first inspection image as a reference, the first inspection image, the second inspection image, the second inspection image, and the third inspection are compared. Either the image or the like may be compared based on the immediately preceding inspection image.

  Next, when the number of consecutive matches reaches the predetermined number P (Yes in S107, Yes in S108), the image processing apparatus 14 transmits a signal to the control unit 15, and the control unit 15 sets the injection molding machine 30. Stop (S109). For example, if the predetermined number of times P = 5 is set, the transfer sheet feeding device and the injection molding machine 30 are stopped based on a command from the control unit 15 when the same uneven defect is detected five times in succession. Then, the molding of the resin molded product 20 is stopped. On the other hand, if the number of consecutive matches does not reach the predetermined number P (No in S108), the next resin molded product 20 is imaged (S110, S101).

  If the concave / convex defect is not detected in step S103 (No in S103), or if the inspection images do not match in Step S107 (No in S107), the resin molded product is the first resin molded product 20 (S100, n = 0). 20 images are captured (S101).

  In this way, the hard-coating layer is cured and the appearance inspection is performed in the same process, and the resin molded product 20 is manufactured while controlling so that the same defect that occurs continuously stops at a predetermined number of times P.

  In the appearance inspection apparatus 10 configured as described above, the ultraviolet rays irradiated from the illuminator 11 are irregularly reflected at the concave and convex portions such as the dents 26 generated on the surface of the resin molded product 20, and the amount of reflected ultraviolet rays is large. Changes locally compared to other parts. Therefore, it is possible to detect uneven defects with high accuracy. Even if the pattern 25 is formed on the resin molded product 20 by the design layer 22, the reflection amount of ultraviolet rays is not easily affected by the design 25, so that even the resin molded product 20 having the pattern 25 on the surface can accurately detect irregularities. Can be detected well.

  If the illuminator 11 uses an ultraviolet lamp having a width in the wavelength region and a filter that transmits mainly near-ultraviolet rays is attached to the line camera 12, the wavelength range of ultraviolet rays for ultraviolet curing on the hard coat layer 21 is limited. However, the range of the wavelength of ultraviolet rays for visual inspection is limited. For this reason, the hard coat layer 21 can be effectively cured with ultraviolet rays, and the irregularities of the appearance of the resin molded product can be detected. If the line camera 12 and the illuminator 11 for the near ultraviolet region are used, the configuration of the visual inspection apparatus 10 can be simplified because the light source and the imaging device are compatible with a common wavelength region.

  In the manufacturing method of the resin molded product 20 using the appearance inspection apparatus 10 described above, since the ultraviolet curing of the hard coat layer 21 and the appearance inspection are performed at the same time, the two steps become one step. Productivity can be improved. Moreover, since the molding of the resin molded product 20 is stopped when a defective product having the same number of continuous irregularities is generated, it is possible to prevent the continuous generation of defective products in consideration of productivity. Specifically, in the injection molding machine 30, when foreign matter adheres to the cavity surface of the movable mold, that is, the cavity surface on the side where the transfer sheet fed into the mold adheres during molding, a defective product due to the dent is found. appear. Since the foreign matter is not in direct contact with the resin molded product due to the presence of the transfer sheet, it remains attached to the cavity surface without adhering to and removing the resin molded product to be molded next. Therefore, defective products due to the same dent are continuously generated. However, according to the manufacturing method described above, the number of consecutive occurrences of defective products due to the same dent can be suppressed to a predetermined number.

  In the above embodiment, the inspection object is made of resin, but if a hard coat layer is formed on the surface, other materials such as rubber, metal, wood, glass, ceramics, etc. It may consist of.

  Further, in the above-described embodiment, the surface of the resin molded product is configured to be a flat surface, but the surface of the resin molded product may be a curved surface as long as the amount of reflected ultraviolet light does not change locally.

  Furthermore, in the above embodiment, the hard coat layer is formed on the resin molded product by transfer performed simultaneously with the injection molding. However, if the hard coat layer is formed on the outermost surface of the resin molded product, other methods such as lamination are used. It may be formed.

  Furthermore, in the above-described embodiment, the hard coat layer is formed on the entire outermost surface of the resin molded product, but may be partially formed as necessary.

  Furthermore, in the above embodiment, the coaxial epi-illumination is used as the illuminator. However, if the ultraviolet rays can be reflected from the surface of the resin molded product, other illuminators such as ring illumination and line illumination can be used. Also good. A plurality of illuminators may be used.

  Further, in the above embodiment, a line camera is used as the imaging device, but an area camera may be used as long as it can receive ultraviolet rays. A plurality of imaging devices may be used.

  Furthermore, in the above embodiment, a belt conveyor is used as the conveying device. However, as long as the hard coat layer can be conveyed so as to be cured by ultraviolet rays, reciprocal movement, placement and holding by an articulated robot, and the like. You may comprise with the conveying apparatus by a moving method.

It is the block diagram which showed schematic structure of the external appearance inspection apparatus by 1st Embodiment of this invention. (1) is a plan view of the resin molded product shown in FIG. 1, and (2) is a sectional view taken along the line II-II shown in (1). FIG. 2 is an imaging schematic diagram of the resin molded product shown in FIG. 1, wherein (1) is taken by the appearance inspection apparatus shown in FIG. 1, and (2) is taken by a conventional appearance inspection apparatus. It is a thing. It is the flowchart which showed the control content of the external appearance inspection apparatus shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Appearance inspection apparatus 11 Illuminator 12 Line camera 13 Conveyor 14 Image processing apparatus 20 Resin molded product 21 Hard coat layer 22 Design layer 26 Scar 30 Injection molding machine

Claims (6)

An appearance inspection apparatus for detecting irregularities in the appearance of an inspection object having a hard coat layer formed on the surface,
A light source for irradiating the surface with ultraviolet light;
An imaging device that receives the reflected light from the surface by the ultraviolet rays and performs imaging;
An image processing apparatus that performs image processing on the inspection image acquired by the imaging, detects the irregularity defect of the inspection object corresponding to the inspection image, and determines pass / fail;
An appearance inspection apparatus comprising: a conveyance device that conveys the inspection object so that the hard coat layer is cured to a desired hardness by the ultraviolet rays.   The appearance inspection apparatus according to claim 1, wherein a pattern layer is further formed on the back side of the hard coat layer.   The visual inspection apparatus according to claim 1, wherein the imaging device includes a filter that transmits near ultraviolet rays in the reflected light.   The appearance inspection apparatus according to claim 1, wherein the ultraviolet rays are near ultraviolet rays. Electrically connected to an injection molding machine having a transfer sheet feeding device for feeding the transfer sheet formed with the hard coat layer as a transfer layer into the mold,
The inspection object is a resin molded product in which the transfer layer is transferred and molded by a transfer sheet sent into the mold simultaneously with injection molding by the injection molding machine,
The appearance inspection according to any one of claims 1 to 4, further comprising a stopping unit that stops the injection molding machine when the image processing apparatus continuously detects the same uneven defect a predetermined number of times. apparatus. A method for producing a resin molded product having a hard coat layer formed on a surface,
A step of forming the resin molded product by transferring the transfer layer simultaneously with injection molding by an injection molding machine having a transfer sheet feeding device for feeding the transfer sheet having the hard coat layer formed as a transfer layer into the mold; ,
The surface of the molded resin molded product is irradiated with the ultraviolet rays so that the hard coat layer is cured to a desired hardness, and at the same time, the reflected light from the surface by the ultraviolet rays is received and imaged. The image processing is performed on the inspection image acquired by the imaging, and the step of detecting the unevenness defect of the resin molded product corresponding to the inspection image and determining the quality,
A method for manufacturing a resin molded product, wherein the injection molding machine is stopped when the same uneven defect is detected a predetermined number of times in succession.

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