JP2012179773A - Multi-layer molding apparatus, and multi-layer molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a multi-layer molding apparatus that prevents displacement of a skin material caused by a draw-down phenomenon by a premolding process for enhancing the heating/softening efficiency of the skin material, and shortens molding cycle time, and to provide a multi-layer molding method.SOLUTION: The multi-layer molding apparatus includes: a common mold attached to a fixed plate; a rotary mold part which is combined with the common mold to form a mold cavity and has at least one set of parallel mold dividing surfaces; a dummy plate attached to a movable plate and having heating means arranged on the surfaces opposed to the mold dividing surfaces of the rotary mold part thereof; a rotary mold support means arranged between the fixed plate and the movable mold and rotatably supporting the rotary mold part around the rotation axis orthogonal to molding opening and closing directions to move the same; and a vacuum molding means enabling vacuum molding in the mold cavity of the rotary mold part.

Description

  The present invention relates to a multilayer molding apparatus and a multilayer molding method for molding a multilayer molded article having a skin layer made of a skin material and a base material layer made of a thermoplastic resin.

  In recent years, in order to improve the decorative properties and functionality of resin molded products, films or sheet-like skin materials that have been added with decorative properties and functionality that are difficult to express with resin, such as coloring, gloss, softness, etc. There is an increasing demand for multilayer molded products in which these films and skin materials are fused and integrated with the design surface of a resin molded product by injection filling after being inserted into a mold. Especially for exterior components such as automobile interior parts (instrument panels, interior panels such as doors), home appliances OA equipment, and building materials, for softness, leather-like, wood-grained decoration, and to prevent scratches There is a great demand for such a multilayer molded product in the case of imparting functionality such as hard coating and antistatic for preventing adhesion of dust and dirt.

  In Patent Document 1, a product take-out jig and a pressing core for pre-stretching a decorative sheet (skin material) are attached to a common arm, and the decorative sheet is abbreviated regardless of the mold shape. A decorative molded product that adheres closely to the cavity surface under a uniform thickness (preliminary shaping) and shortens the time required for the sheet stretching process (preliminary shaping process) and the molded product removal process in the mold opening state. A manufacturing apparatus is disclosed.

  Patent Document 2 discloses a method for producing an in-mold molded product (multilayer molded product) using a decorative film (skin material) having a base film, a release layer, a photocurable hard coat layer, a colored layer, and an adhesive layer. The colored film side is arranged between the fixed mold and the movable mold of the mold so that the colored layer side faces the injection port of the fixed mold, and the decorative film is matched to the mold surface shape of the movable mold Forming step (A) (preliminary shaping step), irradiating the movable mold with a light beam for curing the photocurable material from the fixed side, and combining the fixed mold and the movable mold. And the manufacturing method of the in-mold molded article including the process (C) (injection process) which injects molten resin is disclosed.

  In Patent Document 3, the skin (skin material) is gripped by a vacuum mold core mold (dummy plate) and a female mold (rotary mold), and this is vacuum molded and shaped (pre-shaped), The female mold with the shaped skin remaining in the cavity is opposed to the core mold for injection molding (common mold) by rotating the female mold (rotating mold rotating process). Then, the thermoplastic resin is injected between the skin that remains in the female mold that holds the skin with both molds and the mold surface of the core mold for injection molding, and the skin and the thermoplastic resin are integrated ( Injection process). In addition, a method of resin integration into the skin is disclosed, in which vacuum molding (preliminary shaping process) held by a mold and resin integration by injection molding (injection process) are started simultaneously or with a predetermined time difference. Has been.

  The parentheses in the descriptions relating to Patent Document 1 to Patent Document 3 describe the constituent elements of the present invention that are considered to be equivalent or similar to the constituent elements immediately before the parentheses so that the understanding of the present invention is easy. There is no suggestion that the constituent requirements immediately before the parentheses coincide with the constituent members in the parentheses.

JP-A-10-230531 JP 2010-247498 A Japanese Patent Laid-Open No. 05-253939

  In the device for manufacturing a decorative molded product of Patent Document 1, a product take-out jig and a pressing core are attached to a common arm, and a sheet stretching process (preliminary shaping process) and a molded product take-out process in a mold open state are performed. Although the time required for these steps can be shortened by continuously performing these steps, these steps are not simultaneously performed. In addition, it is difficult in terms of configuration to significantly reduce the molding cycle time in which a plurality of processes among these processes, injection processes, cooling solidification processes, and the like are performed simultaneously.

  In addition, the decorative sheet (skin material) inserted into the mold is heated and softened by a heating plate or the like (heating means) previously entered into the mold in the mold open state, and the heating plate or the like is molded into the mold. After retreating outside, the common arm is moved into the mold, pressed by the pressing core and pre-stretched, and then a sheet stretching step by vacuuming (vacuum forming) is performed. Therefore, the heating and softening efficiency is poor, and in general, in a decorative sheet having a small heat capacity and a large surface area, the heating means such as a heating plate is retracted out of the mold and the common arm is inserted into the mold. In the meantime, since the temperature is lowered and re-cured, there is a problem that the decorative sheet cannot be sufficiently adhered to the mold cavity surface by vacuum drawing. Furthermore, if the heating temperature of the decorative sheet is increased in consideration of the temperature decrease, a draw-down phenomenon in which the shape retaining property of the decorative sheet itself decreases due to softening more than expected, and the decorative sheet is misaligned. Another problem arises. Moreover, it is not preferable also from a viewpoint of energy saving.

  In the method for producing an in-mold molded product of Patent Document 2, after the decorative film is shaped according to the shape of the movable mold surface by vacuum molding, the photocuring material is cured on the shaped decorative film. Since the hard coat layer is cured by irradiating the working light, it is not necessary to irradiate the curing light after completion of the molded product, and the finished molded product is not deteriorated. That is, in the subsequent process, a process of curing the hard coat layer by irradiating a curing light beam becomes unnecessary, and the manufacturing process can be simplified.

  However, in order to heat, soften and harden the decorative film by the heating means inserted between the molds and the irradiation means of the curing light beam, the insertion time from the standby position of these means to the molds, until softening Heating time, irradiation time until curing, retreat time from between molds to a standby position, and the like are necessary, and it is difficult to shorten the molding cycle time. Further, as in Patent Document 1, the heating means is retracted outside the mold, that is, the re-curing of the decorative film due to poor heating and softening efficiency, and the drawdown phenomenon due to the heating temperature rise to avoid this. The problem remains.

  In the resin integration method in the skin of Patent Document 3, after mold clamping, the skin is vacuum-formed (preliminary shaping process), and the skin vacuum-formed in the previous cycle and the thermoplastic resin are integrated (injection process). Therefore, the molding cycle time can be greatly shortened as compared with Patent Document 1 and Patent Document 2. However, since the heating material is heated and softened by a heating unit arranged outside the mold before the skin material is inserted into the mold, the heating and softening efficiency is poor, and the vacuum molding (preliminary application) of the skin material of Patent Document 1 is poor. The problem of the re-curing of the skin material accompanying the temperature drop at the time of shape) and the drawdown phenomenon due to the heating temperature rise to avoid this is left. In addition, since the heated skin is formed in contact with the core mold for vacuum forming by clamping before being vacuum formed, the amount of heat is rapidly lost from the contact portion, and the hardening of the skin proceeds. There is a problem that the cavity shape of the female mold for vacuum forming is not sufficiently transferred to the skin.

  The present invention has been made in view of the above-described problems. Specifically, the pre-shaped step for improving the heating and softening efficiency of the skin material prevents the skin material from being displaced due to the draw-down phenomenon. In addition, an object of the present invention is to provide a multilayer molding apparatus and a multilayer molding method that can shorten the molding cycle time.

The object of the present invention is to provide a common type attached to a fixed platen as shown in claim 1,
A rotating mold part having at least two mold dividing surfaces combined with the common mold to form a mold cavity;
A dummy plate that is attached to a movable platen, and in which a heating means is disposed on a surface of the rotating mold portion that faces the mold dividing surface;
A rotating mold support means disposed between the fixed platen and the movable platen, rotatably supporting the rotating mold part around a rotation axis perpendicular to the mold opening and closing direction, and moving in the mold opening and closing direction;
Vacuum forming means capable of vacuum forming in the mold cavity of the rotating mold part;
It is achieved by a multilayer molding apparatus characterized by comprising:

  That is, the skin material inserted between the dummy plate and the rotating mold part is securely gripped by substantially clamping the entire periphery of these mold dividing surfaces by clamping, and the skin material and the mold cavity of the rotating mold part are The space formed by is sealed and is in a state suitable for vacuum forming. In this sealed mold cavity, the skin material in a substantially contact state is directly heated to the heating surface of the heating means disposed on the side facing the mold dividing surface of the rotating mold portion of the dummy plate. Compared to the case where heating is performed by bringing the heating means closer in the open space, the heat retention and heating properties are superior, and the heating efficiency is improved. Moreover, since the vacuum forming of the skin material can be started while the heating is continued, the softening efficiency is improved. Furthermore, the skin material can be started in vacuum forming of the skin material while being heated in a state where the skin material is securely gripped on almost the entire circumference, so that the positioning accuracy of the skin material is high and the softening efficiency is high. It is not necessary to raise the heating temperature more than necessary in consideration of the temperature drop of the skin material. Therefore, compared with the form in which the heating means is inserted between the molds in which the skin material is held by one mold, or the form in which the skin material is inserted into the mold after being heated and softened outside the mold. Further, it is possible to prevent the positional deviation of the skin material due to the drawdown phenomenon.

  Further, as shown in claim 2, the multilayer molding apparatus according to claim 1, wherein the dummy plate is provided with means for irradiating light for curing the photocurable material.

  When the skin material includes a hard coat layer made of a photo-curing material in a semi-cured state that is cured by irradiation with curing light such as ultraviolet rays or electron beams, after the skin material is vacuum-formed, ultraviolet rays are applied by the irradiation means. If the hard coat layer of the skin material is completely cured by irradiating a curing light beam such as an electron beam or the like, it is not necessary to irradiate the curing light after the multilayer molded product is completed, and the finished molded product is not deteriorated. . That is, in the subsequent process, a process of curing the hard coat layer by irradiating a curing light beam becomes unnecessary, and the manufacturing process can be simplified.

In such a multilayer molding machine, as shown in claim 3, a skin material is inserted between the dummy plate and one of the mold dividing surfaces of the rotating mold part, and the mold is divided by clamping. The skin material is heated and softened by the heating means in a state where the skin material is gripped on substantially the entire circumference of the surface, and the softened skin material is mold cavity of the rotating mold part by the vacuum forming means. A pre-shaping step of vacuum forming into a shape;
The pre-shaped skin material is opened in a state where it is held on one mold cavity surface of the mold dividing surface of the rotating mold part, and then the rotating mold part is rotated, A rotating mold rotating step of moving the shaped skin material to a position facing the common mold;
By mold clamping, the molten resin is injected and filled into a cavity formed between the skin material and the common mold held on one mold cavity surface of the mold dividing surface of the rotating mold part, An injection process for forming a molded body, and molding a multilayer molded product obtained by fusing and integrating the skin material and the molded body,
The multilayer molding method using the multilayer molding apparatus according to any one of claims 1 to 2, wherein the preliminary shaping step and the injection step are performed substantially simultaneously.

  By such a multilayer molding method, the pre-molding step and the injection step, which can improve the heating / softening efficiency of the skin material and prevent the positional displacement of the skin material due to the drawdown phenomenon, are performed substantially simultaneously, and the multilayer molding is performed. The molding cycle time of the product can be greatly shortened. Furthermore, all the time until the injection process performed between the other mold parting surface of the rotating mold part and the common mold and the subsequent cooling and solidifying process of the molded body are completed is the mold of the rotating mold part. Since it can be spent on the pre-shaped process performed between one of the divided surfaces and the dummy plate, the heating temperature, heating pattern, suction pressure, suction pattern of the heating means during heating or vacuum forming for each skin material Alternatively, the settable range of various setting conditions related to pre-shaping such as the start / change / completion timing of each can be expanded, and various troubles related to pre-shaping of the skin material including the drawdown phenomenon can be reduced. .

Further, as a multilayer molding method, as shown in claim 4, it is performed substantially simultaneously with the preliminary shaping step, and is formed by combining the common mold and the other of the mold dividing surfaces of the rotating mold part. A primary injection step of forming a primary molded body by injection filling the first cavity,
The primary molded body was held in the common mold, and the pre-shaped skin material was opened in a state of being held on one mold cavity surface of the mold dividing surface of the rotating mold part. Then, a first rotating mold rotating step of rotating the rotating mold portion and moving the pre-shaped skin material to a position facing the common mold,
By clamping the mold, between the skin material held on one mold cavity surface of the mold dividing surface of the rotating mold part, the common mold, and the primary molded body held on the common mold. A secondary molded body is formed by injecting and filling molten resin into the formed second cavity, and a multilayer molded product is formed by fusing and integrating the skin material, the secondary molded body, and the primary molded body. A second injection step to perform,
After the multilayer molded product is taken out, the rotating mold part is rotated so that one of the mold dividing surfaces of the rotating mold part is opposed to the dummy plate. A second rotating mold rotating step of moving the other of the mold dividing surfaces to a position facing the common mold;
The multilayer molding method according to claim 3 can be performed.

  With this multilayer molding method, although the molding process is increased, the base layer made of resin can be composed of two layers, and the multilayer molded product can be formed by a three-layer multilayer molded product including a skin layer made of a skin material. The decorativeness and functionality of can be further enhanced.

  Further, as another multilayer forming method, as shown in claim 5, in the preliminary shaping step, a hard coat layer of a vacuum-formed skin material is cured by the irradiation means. The multilayer molding method according to any one of claims 4 can be performed.

  With this multilayer molding method, even if the skin material includes a hard coat layer that is cured by a curing light beam, the decorative film is shaped and cured into the design surface shape of the multilayer molded product in the preliminary shaping process. Therefore, the molding cycle time is not affected by the hardening process of the hard coat layer. In addition, the hard coat layer curing step in the subsequent step after the molding of the multilayer molded product is not required, the manufacturing process can be simplified, and the resin molded body portion is irradiated with a curing beam such as UV and EB light. It is possible to prevent the resin molded body portion from being deteriorated in a subsequent process.

A multilayer molding apparatus according to the present invention includes a common mold attached to a fixed platen,
A rotating mold part having at least two mold dividing surfaces combined with the common mold to form a mold cavity;
A dummy plate that is attached to a movable platen, and in which a heating means is disposed on a surface of the rotating mold portion that faces the mold dividing surface;
A rotating mold support means disposed between the fixed platen and the movable platen, rotatably supporting the rotating mold part around a rotation axis perpendicular to the mold opening and closing direction, and moving in the mold opening and closing direction;
Vacuum forming means capable of vacuum forming in the mold cavity of the rotating mold part;
Therefore, a pre-shaping step for improving the heating / softening efficiency of the skin material can be performed, and the positional deviation of the skin material due to the drawdown phenomenon can be prevented.

Further, in the multilayer molding method using the multilayer molding die according to the present invention, a skin material is inserted between the dummy plate and one of the mold dividing surfaces of the rotating mold part, and the mold is clamped to The skin material is heated and softened by the heating means in a state where the skin material is gripped on substantially the entire circumference of the mold dividing surface, and the softened skin material is removed from the rotating mold part by the vacuum forming means. A pre-shaping process for vacuum forming into a mold cavity shape;
The pre-shaped skin material is opened in a state where it is held on one mold cavity surface of the mold dividing surface of the rotating mold part, and then the rotating mold part is rotated, A rotating mold rotating step of moving the shaped skin material to a position facing the common mold;
By mold clamping, the molten resin is injected and filled into a cavity formed between the skin material and the common mold held on one mold cavity surface of the mold dividing surface of the rotating mold part, An injection process for forming a molded body and molding a multilayer molded product in which the skin material and the molded body are fused and integrated, and the preliminary shaping process and the injection process are performed substantially simultaneously, The molding cycle time of the multilayer molded product can be greatly shortened. Furthermore, all the time required for completing the injection process performed between the other mold parting surface of the rotating mold part and the common mold and the subsequent cooling and solidifying process of the resin molded body is completed. Since it can be spent on the pre-shaping process performed between one of the mold dividing surfaces and the dummy plate, the heating temperature, heating pattern, suction pressure, and suction for each skin material during heating and vacuum forming The settable range of various setting conditions related to the preliminary shaping such as the pattern or the start / change / completion timing of each pattern is expanded, and troubles related to the preliminary shaping of the skin material including the drawdown phenomenon can be reduced.

1 is a schematic side view of a multilayer molding apparatus according to Embodiment 1 of the present invention. It is a general | schematic fragmentary sectional view which shows the multilayer molding process which concerns on Example 1 of this invention. It is a general | schematic fragmentary sectional view which shows the first half of the multilayer shaping | molding process which concerns on Example 2 of this invention. It is a general | schematic fragmentary sectional view which shows the second half of the multilayer shaping | molding process which concerns on Example 2 of this invention. It is a schematic side view of the multilayer molding apparatus which concerns on Example 3 of this invention. It is a general | schematic fragmentary sectional view which shows the pre-shaped process based on Example 3 of this invention.

  Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings.

  A first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a schematic side view of a multilayer molding apparatus according to Embodiment 1 of the present invention. FIG. 2 is a schematic partial cross-sectional view showing a multilayer molding process according to Example 1 of the present invention. 2A is the mold closing state immediately before the pre-shaped process and the injection process, FIG. 2B is the starting state of the pre-shaped process and the injection process, and FIG. 2C is the pre-shaped process and the injection process. The completed state, FIG. 2 (d) shows the product removal process after mold opening.

  First, the basic configuration of the multilayer molding apparatus 1 according to the present invention will be described with reference to FIG. The multilayer molding apparatus 1 is in a mold open state after the product take-out process is completed, and a fixed platen 3 fixed to the bed 2, a movable platen 5 movably provided in the mold opening / closing direction with respect to the fixed platen 3, and a fixed Rotating mold support means 4 which is disposed between the panel 3 and the movable board 5 and supports the attached rotating mold part 40 so as to be rotatable around a rotation axis perpendicular to the mold opening / closing direction and to move in the mold opening / closing direction. Rotating in the vertical direction that constitutes a part of the rotating mold part 40, has two mold mounting surfaces facing the fixed platen 3 and the movable platen 5, and is perpendicular to the mold opening / closing direction of the rotating die support means 4. A rotating mold mounting portion 41 that is rotatably supported around an axis, and a first injection unit 17 provided on the fixed platen 3 side are provided.

  A common mold 19 is attached to the surface of the fixed platen 3 on the front side (the side facing the movable platen 5), and the first injection unit 17 is advanced and retracted from the back side to the front side toward the common die 19. For this purpose, a through hole 3a is formed. A tie bar (not shown) protrudes from the four corners of the fixed platen 3 and passes through the movable platen 5.

  A dummy plate 6 is attached to the movable plate 5 on the surface facing the fixed plate 3. Further, the movable platen 5 is guided by a tie bar (not shown) and is provided so as to be movable forward and backward with respect to the fixed platen 3 by mold clamping means (not shown). The dummy plate 6 protects the mold dividing surface of the opposed rotating mold part 40 during mold clamping, and the heating means 6a is disposed on the surface of the rotating mold part 40 facing the mold mounting surface. . The heating means 6a is preferably an electric heater that can easily control the heating temperature and the heating pattern. Further, the heating means 6a is not disposed in a portion that contacts the mold dividing surface of the opposed rotating mold portion 40 in order to prevent breakage at the time of clamping, and the rotating mold portion 40 directly facing the heating surface. It is preferably arranged so as to be exposed on the mold dividing surface side. If it is inevitable to dispose the rotating mold part 40 facing the mold dividing surface when the mold is clamped, the heating means 6a is heated from the mold clamping force while preventing a reduction in heating efficiency. Measures to protect the surface should be considered. In addition, in order to prevent the loss of thermal energy from surfaces other than the mold dividing surface side of the opposed rotating mold part 40, heat insulation / heat insulation means such as a heat insulating material or a heat insulating structure is adopted for these parts. Needless to say.

  The rotary mold support means 4 is disposed between the fixed platen 3 and the movable platen 5 and is provided on the bed 2 so as to be movable forward and backward in the mold opening / closing direction. The rotary mold part 40 supported by the rotary mold support means 4 so as to be rotatable about a vertical rotation axis orthogonal to the mold opening / closing direction is provided with two mold mounting surfaces facing the fixed platen 3 and the movable platen 5. Rotating mold mounting part 41, and a first rotating mold 20 and a second rotating mold 21 respectively mounted on the mold mounting surface of the rotating mold mounting part 41, and the rotating mold support means 4. Is detachably attached. The rotating mold mounting portion 41, the first rotating mold 20 and the second rotating mold 21 are one mold (rotating mold) having two mold dividing surfaces facing the fixed platen 3 and the movable platen 5. Mold part) and may be detachably attached to the rotating mold support means 4. Further, the rotating mold part 40 may have two or more mold dividing surfaces facing the fixed platen 3 and the movable platen 5, and a pre-shaping step that is performed substantially simultaneously during mold clamping, which will be described later, During the injection process, a product take-out process for taking out the finished multilayer molded product from the mold dividing surface which is not clamped and opened, a skin material held on the opened mold dividing surface, or described later Another process such as a process of inserting an insert part into the primary molded body may be performed. Further, the rotating mold part 40 may be configured to be supported so as to be rotatable about a horizontal rotation axis orthogonal to the mold opening / closing direction.

  The first rotating mold 20 and the second rotating mold 21 have the same mold cavity shape, and the mold cavity surface becomes the design surface of the multilayer molded product. A plurality of suction holes 42 for sucking air in the mold cavities are provided on the mold cavity surfaces of these rotary molds, and communicated with one end of a suction pipe 43 arranged in these rotary molds. . The other end of the suction pipe 43 is connected to a vacuum forming means 44 disposed in the rotary mold mounting portion 41, and air on any mold cavity side is sucked by a switching valve (not shown) provided in the suction pipe 43. Then vacuum forming is performed. The vacuum forming means 44 may be disposed on the rotating mold support means 4.

  One of the two mold dividing surfaces of the rotating mold part 40, in this case, the mold dividing surface of the first rotating mold 20 is placed on the mold cavity surface with the dummy plate 6 and the first rotation in the pre-molding cycle. The position facing the common mold 19 in preparation for a molding cycle to be started by the rotation of the rotating mold part 40 in a state where the mold material 20 is clamped and the pre-shaped skin material 12a is held. Has been moved to.

  Further, between the dummy plate 6 attached to the movable platen 5 and the other of the two mold dividing surfaces of the opposed rotating mold part 40, in this case, the mold dividing surface of the second rotating mold 21, A skin material supply means 45 is arranged so that the skin material 12 can be supplied. The skin material supply means 45 is composed of a device having a movable arm part such as an articulated robot and a gripping means provided at the tip of the arm part, and a dummy plate 6 and an opposing rotating mold part. The skin material is gripped and supplied one by one between the 40 mold dividing surfaces.

  As another form of the skin material supply means 45, between the molds in which pre-shaping is performed from a supply roll obtained by laminating a transfer material to be a skin material or a skin material on a transport film, and winding this into a roll Also known is a form of continuous supply. In that case, only the skin material (transfer film) or the skin material (transfer film) at the time of clamping by the dummy plate 6 or the trimming means provided on the mold dividing surface of the rotary mold portion 40 and The necessary range of the transport film is trimmed (removed), and the remaining transport film is wound around a collecting roll disposed on the opposite side of the supply roll through a mold in which pre-shaping is performed. In addition, the entire skin material supply means including the supply roll and the recovery roll, or only the portion between the molds on which preliminary shaping is performed, is arranged to be movable in conjunction with the mold opening / closing operation.

  Next, a multilayer molding process according to Example 1 of the present invention will be described with reference to FIG. FIG. 2 is a schematic partial cross-sectional view illustrating the molding process in order with respect to the mold part (side view) of FIG. 1 in order to facilitate understanding of the molding process, and the components that are not directly related to the molding process are illustrated. Absent. Further, in order to make the drawing easy to see, hatching indicating a cross section is omitted from the rotating mold part 40 (the rotating mold attaching part 41, the first rotating mold 20, and the second rotating mold 21).

  From the mold open state shown in FIG. 1, the rotating mold part 40 and the dummy plate 6 are closed to the common mold 19 by a mold clamping means (not shown) to obtain the mold closed state shown in FIG. The pre-shaping process and the injection process have not yet started. At this time, the skin material supply means 45 (not shown) is placed between the other of the mold dividing surfaces of the rotating mold part 40, in this case, between the mold dividing surface of the second rotating mold 21 and the dummy plate 6. After it is confirmed by a sensor or the like that the skin material 12 has been gripped by closing, the gripping state between itself and the skin material 12 is released, and the skin material 12 is retracted to a position that does not hinder mold opening and closing.

  The skin material 12 inserted between the dummy plate 6 and the second rotating mold 21 is securely gripped on substantially the entire circumference of these mold dividing surfaces by closing the mold. Compared to the form in which the mold is held in the open state, the skin material 12 can be easily and reliably gripped, and it is needless to say that the positioning accuracy of the skin material 12 is high. Just do it. The space formed by the skin material 12 and the mold cavity of the second rotating mold 21 is sealed and is in a state suitable for vacuum forming, and is excellent in heat retention as compared with the heating mode in the mold open state. Further, the skin material 12 is in direct contact with the heating means 6a disposed on the surface of the dummy plate 6 facing the mold dividing surface of the second rotating mold 21 or facing the heating means 6a at a very short distance. When the heating means 6a is operated, the skin 12 is heated almost directly by the heating surface of the heating means 6a that is in contact with the heating means 6a. In comparison, the heating efficiency is greatly improved, which is advantageous from the viewpoint of energy saving such as heating temperature and heating time. Moreover, since the vacuum forming of the skin material can be started while the heating is continued, the softening efficiency is greatly improved. Furthermore, the skin material 12 can start vacuum forming of the skin material while continuing to be heated in a state where the skin material 12 is securely gripped on almost the entire circumference, so that the positioning accuracy of the skin material is high and softened. It is excellent in efficiency and it is not necessary to raise the heating temperature more than necessary in consideration of the temperature drop of the skin material. Therefore, compared with the form in which the heating means is inserted between the molds in which the skin material is held by one mold, or the form in which the skin material is inserted into the mold after being heated and softened outside the mold. Further, it is possible to prevent the positional deviation of the skin material due to the drawdown phenomenon or the like.

  Thus, the skin material can be heated with high heating efficiency in a sealed space, and vacuum forming of the skin material can be started while heating is continued, so that the material is thick or the material is Even if it is thin, it has a low elongation rate and poor formability, so-called low-skin skin material does not require a core mold, and only forms a base layer by vacuum forming a female mold (rotating mold part). Prior to the injection filling of the resin, it is possible to perform preliminary shaping in which the skin material is formed into a female mold cavity shape, that is, a design surface shape. Furthermore, since this heating is performed from the back surface of the design surface of the skin material 12, the possibility of damaging the design surface of the skin material 12 is very small, and the quality of the design surface of the multilayer molded product can be improved.

  On the other hand, between the common mold 19 and the first rotating mold 20, the skin material 12 a preliminarily shaped in the pre-molding cycle is a plurality of suctions provided on the mold cavity surface of the first rotating mold 20. The hole 42 is sucked at a predetermined pressure by the vacuum forming means 44 through the suction pipe 43 and is held in a state in which the pre-shaped shape is maintained on the mold cavity surface.

  After a mold clamping force is applied by a mold clamping means (not shown) from the mold closed state shown in FIG. 2A, as shown in FIG. 2B, the injection process and the pre-shaped process are started substantially simultaneously. The Between the common mold 19 and the first rotating mold 20, a cavity formed by the back surface of the pre-shaped skin material 12 a held on the mold cavity surface of the first rotating mold 20 and the common mold 19. 30, an injection process is performed in which molten resin is injected and filled from the first injection unit 17 through the injection gate 19 a of the common mold 19. At this time, in order to prevent displacement due to collision / contact of the molten resin with the skin material, it is preferable to continue sucking and holding the pre-shaped skin material 12a by the vacuum forming means 44. On the other hand, between the dummy plate 6 and the second rotating mold 21, the skin material 12 gripped on substantially the entire circumference is heated and softened by the heating means 6 a and the second rotating mold 21 is formed by the vacuum forming means 44. A pre-shaping step is performed in which the softened skin material 12 is sucked at a predetermined pressure from a plurality of suction holes 42 provided on the mold cavity surface of the mold cavity surface through a suction pipe 43 and vacuum-formed into a mold cavity shape. Is called.

  The suction pressure of the first rotating mold 20 for holding the preshaped skin material 12a is different from the suction pressure of the second rotating mold 21 for vacuum forming the heated and softened skin material 12. In this case, a pressure adjusting valve is provided in each suction line 43 to adjust each suction pressure. As another form, each of the vacuum forming means is provided independently, or in addition to the vacuum forming means 44 for performing suction for vacuum forming, the suction hole 42 and the suction conduit 43 are shared and pre-shaped. Further, a suction means for holding the skin material 12a may be provided.

  Each process proceeds from the starting state of the injection process and the pre-shaped process shown in FIG. 2 (b), and the injection process and the pre-shaped process are completed as shown in FIG. 2 (c). Between the common mold 19 and the first rotating mold 20, the common mold 19 is formed between the back surface of the pre-shaped skin material 12 a held on the mold cavity surface of the first rotating mold 20 and the common mold 19. The molten resin injected and filled in the cavity 30 in the injection process is cooled and solidified to form a molded body 9a as a base material layer, and melted in the process of cooling and solidifying the back surface of the pre-shaped skin material 12a. The multilayer molded article 9 is molded, which is integrally formed and includes a skin layer made of the skin material 12a and a single base material layer made of a molded body 9a (thermoplastic resin). On the other hand, between the dummy plate 6 and the second rotating mold 21, the skin material 12 is completely vacuum-formed into the shape of the mold cavity of the second rotating mold 21, and a newly pre-shaped skin material 12 a is obtained. It is held on the mold cavity surface of the second rotary mold 21. Since the second rotating mold 21 is in an injection process of the next molding cycle, the mold temperature is increased or is in a rising state, but the newly pre-shaped skin material 12a is a second rotating mold. Since the heat amount is lost to the mold side by contacting the mold cavity surface of 21 and the curing starts, the heating of the heating means 6a is continued in order to prevent the pre-shaped skin material 12a from being cured and to maintain the softened state. It is preferred that

  After completion of the injection process and the pre-shaping process shown in FIG. 2 (c), the dummy plate 6 and the rotating mold part 40 are opened from the common mold 19 by a mold clamping means (not shown), and shown in FIG. 2 (d). The mold is open. The multilayer molded product 9 is preferably opened with the molded body 9a, which is a non-design surface, held by the common mold 19 and extruded by a product extrusion means (not shown) disposed on the common mold 19. The extruded multilayer molded product 9 is conveyed outside the apparatus by a product take-out means (not shown). Thereafter, the rotating mold support unit 4 (not shown) rotates the rotating mold part 40, and the newly pre-shaped skin material 12 a held on the mold cavity surface of the second rotating mold 21 is used as the common mold 19. When the rotating mold rotating process of moving to the opposing position is performed, the mold opening state in which the positions of the first rotating mold 20 and the second rotating mold 21 are changed from the state shown in FIG.

  Thus, by repeating the steps from FIG. 1 to FIG. 2 (d), a multilayer molded article provided with a skin layer made of a pre-shaped skin material 12a and a single base material layer made of a molded body 9a. 9 is continuously formed. The multilayer molded product 9 transported out of the apparatus is handled as a final product by trimming unnecessary portions of the skin material 12a in a subsequent process. Further, when the necessary range of the skin material and the transport film is trimmed in another form of the skin material supply means 45 described above, the transport film attached to the surface of the skin material 12a is peeled off in the subsequent process. And handled as the final product. In this case, when trimming the unnecessary portion of the skin material 12a, the unnecessary portion of the transport film is also trimmed together so that the transport film is attached only to the range of the design surface of the skin material 12a. You may utilize as a protective film of 9 design surfaces (skin material 12a). In addition, an unnecessary portion of the skin material 12a may be trimmed by a known trimming means arranged on a die dividing surface of the common die 19 at the time of clamping, not in a post process.

  Here, the injection process and the pre-shaping process described above are few in the same case, although the time required for each process may differ depending on the resin and skin material used. That is, the molding cycle time required from the mold closed state shown in FIG. 2A to the mold open state shown in FIG. 2D is limited to the longer time required for each process. When the time required for the injection process and the pre-shaping process is compared, generally the time of the injection process is longer. The reason for this is that the resin molded body is thicker than the skin material and has a larger heat capacity, and then the resin molded body must be softened to the extent that it can be vacuum molded. It is necessary to cool and solidify to the extent that it can be taken out. Finally, since the skin material is fused and integrated between the design surface and the mold cavity surface, the skin material Functions as an unintended heat insulating and heat insulating material that prevents the cooling action by the mold cavity surface of the resin molded body, the cooling efficiency from the mold side on the design surface side decreases, and the mold side on the non-design surface side The point etc. where cooling from the main becomes the main are mentioned.

  Therefore, even if all the time required for this injection process including the cooling and solidifying time of the resin molded body is spent on the preliminary shaping process, there is no influence on the molding cycle time. Therefore, by allocating all of these times effectively to the pre-shaping process, the skin material is adapted to each stage in the injection process, such as molten resin injection start, molten resin filling, molten resin filling completion, molten resin cooling solidification, etc. The settable range of various setting conditions related to pre-shaping such as the heating temperature, heating pattern, suction pressure, suction pattern, or start / change / completion timing of each heating means at the time of heating or vacuum forming is expanded. It is possible to reduce troubles related to pre-shaping of the skin material including the draw-down phenomenon and improve the quality of the multilayer molded product. In the description of FIG. 2B, “substantially” simultaneous, such as “the injection process and the pre-shaping process are started almost simultaneously”, part of each process always proceeds in an overlapping manner. However, this suggests that they do not necessarily have to be started at the same time.

  Also, even if the time required for the pre-shaping process is longer, the injection cycle time is affected by the injection process including the cooling and solidifying time of the resin molded body from the time required for the pre-shaping process. Compared with Patent Document 1 in which these steps are separately performed and Patent Document 2 in which heating and softening of the skin material needs to be finished before insertion, it is only a time obtained by subtracting the time required for the molding. From the viewpoint of shortening the cycle time and improving the quality, the effects of the present invention are not reduced.

  Embodiment 2 of the present invention will be described with reference to FIGS. FIG. 3 is a schematic partial cross-sectional view showing the first half of the multilayer molding process according to Embodiment 2 of the present invention. FIG. 3A shows the mold closing state immediately before the preliminary shaping process and the first injection process, FIG. 3B shows the preliminary shaping process and the first injection process, and FIG. 3C shows the mold opening state. FIG. 4 is a schematic partial cross-sectional view showing the latter half of the multilayer molding process according to Example 2 of the present invention. 4A is a completed state of the first rotating mold rotating process, FIG. 4B is a starting state of the second injection process, FIG. 4C is a completed state of the second injection process, and FIG. 4D. Shows the product removal process after re-opening.

  The difference in the basic configuration of the second embodiment from the first embodiment is that the first rotating mold and the second rotating mold have different mold cavity shapes, and the second injection in addition to the first injection unit. This is where the unit is used. Although the molding process increases due to these differences, the base material layer made of the thermosetting resin can be changed from one layer to two layers in Example 1. Since the other basic configuration and multilayer molding method of the multilayer molding apparatus are basically the same as those of the first embodiment, only differences from the first embodiment will be described. 3 and 4, as in FIG. 2 of the first embodiment, components that are not directly related to the molding process are not shown, and a part of the rotating mold portion is a cross section. I omitted the hatch that represents.

  From the mold open state shown in FIG. 1, the rotary mold part 40 and the dummy plate 6 are closed by the common mold 19 ′ to obtain the mold closed state shown in FIG. A first cavity 31 is formed between the common mold 19 ′ and the first rotating mold 20 ′, and can be moved forward and backward with respect to the common mold 19 ′ via an injection gate 19b provided in the common mold 19 ′. It is comprised so that molten resin may be injection-filled from the 2nd injection unit 18 arrange | positioned in this. Although the second injection unit 18 is illustrated as being disposed perpendicular to the upper surface of the common mold 19 ′, in practice, if the second injection unit 18 is disposed so as to be movable back and forth with respect to the injection gate 19b provided in the common mold 19 ′, the second injection unit 18 is common. Even if it is arranged on either side of the side surface of the mold 19 ′, it may be arranged side by side with the first injection unit 17 on the back side of the common mold 19 ′ in the same manner as the first injection unit 17. It is only necessary that an optimal arrangement is appropriately selected in accordance with the situation and the arrangement restrictions of the injection unit. On the other hand, the skin material 12 is inserted between the dummy plate 6 and the second rotating mold 21 ′ by a skin material supply means 45 (not shown), and is gripped by the mold closing. The insertion and gripping method is the same as in the first embodiment.

  After a mold clamping force is applied by a mold clamping means (not shown) from the mold closed state shown in FIG. 3A, as shown in FIG. 3B, the primary injection process and the pre-shaped process are almost simultaneously performed. Done. The primary injection process, which is performed almost simultaneously with the pre-shaping process, forms a molded body to be a base material layer as in the injection process of Example 1, and melts the molded body and the pre-shaped skin material. The first base material is formed by injecting and filling molten resin from the second injection unit 18 into the first cavity 31 formed between the common mold 19 ′ and the first rotating mold 20 ′, instead of being integrally bonded. The primary molded body 9b to be a layer is molded. On the other hand, the preliminary shaping process performed between the dummy plate 6 and the second rotating mold 21 ′ substantially simultaneously with the primary injection process is the same as in the first embodiment.

  After completion of the first injection process and the pre-shaping process shown in FIG. 3B, the dummy plate 6 and the rotating mold part 40 are opened from the common mold 19 ′ by a mold clamping means (not shown), and FIG. ) Open the mold as shown in Similar to the first embodiment, the pre-shaped skin material 12 a is held on the mold cavity surface of the second rotating mold 21 ′ by suction of the vacuum forming means 44. Further, unlike the first embodiment, the primary molded body 9b is held in the common mold 19 '.

  From the mold open state shown in FIG. 3 (c), the rotary mold part 40 is rotated by the rotary mold support device 4 (not shown), and as shown in FIG. 4 (a), the mold of the second rotary mold 21 ′ is obtained. A first rotating mold rotating step is performed in which the preshaped skin material 12a held on the mold cavity surface is moved to a position facing the common mold 19 ′.

  After the first rotating mold rotating step shown in FIG. 4A is completed, the rotating mold portion 40 and the dummy plate 6 are closed to the common mold 19 ′ by a mold clamping means (not shown), and then the mold clamping force is applied. Is granted. Subsequently, as shown in FIG. 4 (b), pre-shaping was performed between the common mold 19 ′ and the second rotating mold 21 ′ and held on the mold cavity surface of the second rotating mold 21 ′. The second cavity 32 formed between the back surface of the skin material 12a and the common mold 19 ′ and the primary molded body 9b held by the common mold 19 ′ is provided with the first through the injection gate 19a of the common mold 19 ′. A second injection process for injecting and filling molten resin from the injection unit 17 to form the secondary molded body 9c serving as the second base material layer is started. On the other hand, the dummy plate 6 and the first rotating mold 20 'are only clamped, and no process is performed between them.

  From the start state of the second injection process shown in FIG. 4B, the second injection process is completed as shown in FIG. 4C. Between the common mold 19 ′ and the second rotating mold 21 ′, the secondary molded body in which the molten resin injected and filled in the second cavity 32 in the second injection step is cooled and solidified to become the second base material layer. 9c is formed, and the back surface of the pre-shaped skin material 12a and the primary molded body 9b molded in the first injection process are fused and integrated in the course of cooling and solidifying, and the skin made of the skin material 12a A multilayer molded product 9 ′ having a layer and a two-layer base material layer made of a primary molded body 9b and a secondary molded body 9c (thermoplastic resin) is molded.

  After completion of the second injection step shown in FIG. 4C, the dummy plate 6 and the rotating mold part 40 are opened from the common mold 19 ′ by a mold clamping means (not shown), and the mold opening shown in FIG. State. The multilayer molded product 9 ′ is a product extruding means (not shown) disposed in the common mold 19 ′ by opening the mold in a state where the primary molded body 9b and the secondary molded body 9c, which are non-design surfaces, are held by the common mold 19 ′. It is preferable to extrude by such as. The extruded multilayer molded product 9 'is transported outside the apparatus by a product take-out means (not shown). Thereafter, the rotary mold portion 40 is rotated by the rotary mold support device 4 (not shown), so that the mold dividing surface of the second rotary mold 21 ′ faces the dummy plate 6 and the first rotary mold 20 ′. When the second rotating mold rotating step for moving the mold dividing surface to the position facing the common mold 19 ′ is performed, the mold closed state shown in FIG. Again, the skin material supply means 45 causes the skin material 12 to be supplied between the dummy plate 6 and the second rotating mold 21 ', and the rotating mold portion 40 and the dummy plate 6 are closed to the common mold 19'. Then, the mold closed state shown in FIG.

  Thus, by repeating the steps from FIG. 3A to FIG. 4D, the skin layer made of the pre-shaped skin material 12a and the two layers made of the primary molded body 9b and the secondary molded body 9c. A multilayer molded product 9 ′ having a base material layer is continuously molded. With this multilayer molding method, although the molding process is increased, a base material layer made of a thermoplastic resin can be composed of two layers, and a multi-layer molded product including a skin layer made of a skin material adds a multilayer The decorativeness and functionality of the molded product can be further enhanced. It goes without saying that the entire time required for completing the first injection step and the subsequent cooling and solidification step of the primary molded body can be spent in the pre-shaping step.

  Embodiment 3 of the present invention will be described with reference to FIGS. FIG. 5 is a schematic side view of a multilayer molding apparatus according to Embodiment 3 of the present invention. FIG. 5A is a schematic side view around the dummy plate, and FIG. 5B is a detailed cross-sectional view of the main part A (skin material) of FIG. FIG. 6 is a schematic partial cross-sectional view showing a pre-shaping step according to Embodiment 3 of the present invention. FIG. 6A shows the mold closed state immediately before the pre-shaped step, FIG. 6B shows the start state of the pre-shaped step, and FIG. 6C shows irradiation of the curing light for the hard coat layer in the pre-shaped step. FIG. 6D shows the completed state of the start state of the pre-shaping process.

  The difference between Example 1 and Example 2 in Example 3 is that the hard coat layer is included in the decorative film that is the skin material, and the hard coat layer is cured in the dummy plate in the preliminary shaping step. The irradiation means of the curing light beam is arranged. That is, these are differences in the pre-shaping step, and the basic configuration and the multilayer molding method of the other multilayer molding apparatus are basically the same as those in the first and second embodiments. Only explained. Therefore, in the schematic side view of FIG. 5A, only the components around the dummy plate where the pre-shaping step is performed are illustrated.

  As shown in FIG. 5 (a), heating means 6 a and curing light irradiation means 6 b are arranged on a dummy plate 6 attached to the movable platen 5. The irradiating means 6b is not disposed in a portion that contacts the mold dividing surface of the opposed rotating mold part 40 during mold clamping, and the mold on the mold dividing surface side of the opposed rotating mold part 40 during mold clamping. It arrange | positions so that the light beam for hardening can be irradiated to the whole mold cavity surface. The second rotating mold 21 ″ is attached to the mold attaching surface of the rotating mold attaching portion 41 so as to face the dummy plate 6.

  As in the other embodiments, the decorative film 13 that is a skin material is formed by the skin material supply means 45 by the dummy plate 6 and the mold dividing surface of the rotating mold part 40, in this case, the second rotating mold 21 ″. As shown in Fig. 5 (b), the decorative film 13 is composed of six layers, and from the second rotating mold 21 "side, the base film 13a, A release layer 13b, a hard coat layer 13c, an anchor layer 13d, a colored layer 13e, and an adhesive layer 13f are included, and the hard coat layer 13c is included. Here, the configuration of the decorative film 13 including the hard coat layer 13c is an example, and the addition or deletion of layers or the order of each layer may be changed as necessary.

  The hard coat layer prevents the surface of the resin product having a relatively low hardness from being scratched and maintains the appearance of the design surface of the resin molded product over a long period of time. The hard coat layer may be composed of a thermosetting material that is cured by irradiation with heat rays such as far infrared rays or heating, or a curing accelerator-coated material that is cured by applying a curing reaction accelerator. Since the base film such as a decorative film is often softened by heat ray irradiation or heating at the time of forming, UV (Ultraviolet) or Electron Beam (EB) light (hereinafter referred to as “UV”) is used so as not to hinder the softening. In many cases, a hard coat layer made of a photo-curable material that is cured by irradiation with UV, EB light, etc.) is employed. The hard coat layer 13c of Example 3 is a hard coat layer made of this photocurable material.

  In order to form a hard coat layer on the design surface of a multilayer molded product, a decorative film or the like containing the hard coat layer is inserted into a mold in a state where the hard coat layer is cured, and the substrate is formed by injection filling. A method of fusing and integrating with a resin molding to be a layer, a hard film layer is not cured, or a decorative film in a semi-cured state is pre-shaped in a mold, and then injected and filled. In the post-process after the resin molded body that is the material layer is fused and integrated and taken out of the mold as a semi-finished multilayer molded product, the design surface of the multilayer molded product is cured with UV, EB light, etc. For example, there is a method of irradiating a light beam for curing and curing a hard coat layer that is not cured or semi-cured.

  In the former case, the hard coat layer that has been hardened has a very low moldability and ductility as a material. Therefore, depending on the shape of the mold cavity (design surface shape) having deep drawing and unevenness, it is necessary to follow the shape. There is a problem that defects such as cracks and cloudiness occur due to molding (deformation). In the latter case, the problem as in the former does not occur, but since the curing light beam that is irradiated onto the design surface of the multilayer molded product in the subsequent process is also irradiated onto the resin molded body that is the base material layer, the resin molded body is There is a problem of deterioration.

  The function of each layer will be briefly described. The base film 13a on the second rotating mold 21 "side is coated with or attached a photocuring material that is not hardened or is semi-cured to become the hard coat layer 13c. Until it is cured, it is a layer that maintains the film shape as the decorative film 13. The base film 13a is a photo-curing type that is applied and adhered to the hard coat layer 13c before the hard coat layer 13c is cured. In order to prevent the monomer component of the material from adhering to and contaminating the mold cavity surface of the rotating mold part 40, or after the hard coat layer 13c is cured, the hard coat layer 13c is protected. Furthermore, in the case of a form in which the decorative film 13 is continuously supplied from the supply roll, as a transport film During the molding, the next release layer 13b protects the hard coat layer 13c with the base film 13a attached to the hard coat layer 13c, and is cured in a subsequent process after the molding. The protective film 13a is easily peeled off from the hard coat layer 13c. While having these functions, the peeling component does not remain on the hard coat layer 13c at the time of peeling. The substrate film 13a and the release layer 13b are finally removed from the design surface, and in the case where the decorative film 13 is continuously supplied from the supply roll, the transport film is preferable. Is also referred to as a carrier portion.

  The hard coat layer 13c continuous to the carrier portion is used for curing UV, EB light, etc., in which the photocurable material that is cured by irradiation with UV, EB light, etc. is not cured or semi-cured. It is hardened by irradiation with light and forms a very hard layer. The next anchor layer 13d ensures that the colored layer 13e adheres to the hard coat layer 13c when a solvent-based coloring material (ink) is used for the colored layer 13e. This is not necessary when the same photocurable colorant as that of the layer 13c is used. The next colored layer 13e expresses on the design surface a color that is difficult to express with only the resin material, or gloss that improves the appearance of the design surface through a normally transparent or translucent hard coat layer 13c. As described above, there is a photocurable colorant similar to the hard coat layer 13c. The last adhesive layer 13f on the dummy plate 6 side securely fixes the four layers after the carrier part to the molded body as the base material layer. These four layers after the carrier portion are referred to as a transfer portion or the like with respect to the designation of the carrier portion or the like.

  Next, the pre-shaping process according to the third embodiment of the present invention will be described with reference to FIG. Like FIG. 2 of Example 1 and FIG. 3 of Example 2, in FIG. 6, the component part which is not directly related to a shaping | molding process is not shown in figure, and a part of rotary mold part must be a cross section. The hatching that represents is omitted.

  From the mold open state shown in FIG. 5 (a), the rotating mold part 40 and the dummy plate 6 are closed by a mold clamping means (not shown) to obtain the mold closed state shown in FIG. 6 (a). The preliminary shaping process of the decorative film 13 has not yet started.

  An injection process performed between the common mold and the first rotating mold after a mold clamping force is applied by a mold clamping unit (not shown) from the mold closed state shown in FIG. 6A, or a first injection process. At substantially the same time, as shown in FIG. 6 (b), the pre-shaped process is started between the dummy plate 6 and the second rotating mold 21 ″. It comprises two steps where the parts overlap.

  As in the other embodiments, first, the decorative film 13 gripped on the entire circumference is heated and softened by the heating means 6a, and the mold of the second rotating mold 21 "is formed by the vacuum forming means 44 (not shown). A vacuum forming step is performed in which the softened decorative film 13 is sucked at a predetermined pressure from a plurality of suction holes 42 provided on the cavity surface through the suction pipe 43 and vacuum-formed into a mold cavity shape.

  Next, after the decorative film 13 is vacuum-formed into a mold cavity shape, as shown in FIG. 6C, the curing light beam irradiation means 6b disposed on the dummy plate 6 is cured at a predetermined timing. Curing process in which the decorative film 13 held on the mold cavity surface of the second rotating mold 21 ″ is cured in the vacuum cavity shape of the second rotating mold 21 ″ while being irradiated with a working light beam. Is done. This curing takes a very short time to complete the curing because of the photopolymerization reaction caused by the irradiation of the curing light beam. For this reason, even during this curing step, suction by the vacuum forming means 44 (not shown) is continued so as not to cause a positional shift or the like in the vacuum-formed decorative film 13 on the mold cavity surface of the second rotating mold 21 ″. In addition, the transition timing from the vacuum forming step to the curing step is the change in the suction pressure of the mold cavity surface of the second rotating mold 21 ″ and the distance between the mold cavity surface and the decorative film 13. Alternatively, the proximity of the decorative film 13 to the mold cavity surface or the like may be detected by a pressure, distance, proximity sensor, or the like, and an appropriate transition timing may be determined from the detected value.

  A curing light beam such as UV or EB light that cures a photocurable material generally has a short wavelength, and thus is considered to have low permeability to the material. However, the adhesive layer of the decorative film 13 described above is used. The three layers 13f, the colored layer 13e, and the anchor layer 13d are often formed in a relatively thin film shape, and even through these three layers, the curing light beam can reach the hard coat layer 13c. It can be cured. Here, like these three layers, there are materials and components that greatly reduce the transmittance of the curing light beam or hardly transmit the light to the layer that is interposed between the hard coat layer and the curing light irradiation means. Needless to say, it cannot be used, but if the transparency of the light beam for curing these three layers is maintained, there is a problem in curing the hard coat layer in the pre-shaping process even if the thickness of the three layers is somewhat increased. There is no. Further, the heating means 6a also generates far infrared rays which are a kind of light rays when heated, but the wavelength of the far infrared rays is much longer than the wavelength of these curing light rays, so that the hard coat layer 13c is cured when the heating means 6a is operated. There is no fear.

  When the curing is completed in a state where the decorative film 13 is vacuum-formed into the mold cavity shape of the second rotating mold 21 ″ from the start state of the pre-shaping step shown in FIG. 6C, FIG. When the dummy plate 6 and the rotating mold part 40 are opened, the subsequent molding process is the same as that shown in FIG. To the product take-out step after the mold opening shown (second rotating mold 21 ″ = second rotating mold 21), in Example 2, the mold opening state (second rotating mold shown in FIG. 3C) 21 ″ = second rotating mold 21 ′), and the multilayer molded product 9 having a hard coat layer formed on the design surface or the multilayer molded product 9 ′ is continuously molded. Even in the preliminary shaping process of a decorative film including a layer, the injection process (first injection process) and the It is the same as in Example 1 and Example 2 that it can spend all the time until the cooling and solidifying step of the subsequent molded body 9a (primary molded body 9b) is completed. Since the curing of the layer is a photopolymerization reaction by irradiation with a curing light beam, the time required to complete the curing is very short, and the time ratio of the curing process in the pre-shaping process is very small.

  Thus, even when the hard coat layer that is cured by the curing light beam is included in the decorative film that is the skin material, the decorative film is shaped into the design surface shape of the multilayer molded product in the preliminary shaping step. Since it can be cured, the molding cycle time is not affected by the curing process of the hard coat layer. In addition, the hard coat layer curing step in the subsequent step after the molding of the multilayer molded product is not required, the manufacturing process can be simplified, and the resin molded body portion is irradiated with a curing beam such as UV and EB light. It is possible to prevent the resin molded body portion from being deteriorated in a subsequent process.

  Furthermore, before the hard coat layer is fused and integrated with the thermosetting resin as the base material, the molten resin is applied to the decorative film pre-shaped to the same shape as the design surface shape of the multilayer molded product. Because of fusion integration, almost no molding (deformation) is required for following the design surface shape of the hardened hard coat layer due to fusion integration by injection filling of molten resin, and it has deep drawing and unevenness. Even in the case of a design surface shape, it is possible to prevent the occurrence of defects such as cracks or cloudiness in the hard coat layer. Here, if the hard coat layer of the decorative film is configured to be pre-shaped on the mold cavity surface via a base film or a protective film, it is not cured or is photocured in a semi-cured state Even in the case of a hard coat layer using a mold material, there is no possibility that the mold cavity surface is contaminated by the monomer component or the like.

  In this Example 3, a photocurable material is used for the hard coat layer included in the decorative film as the skin material, and in order to cure this, irradiation with a curing light beam having a short wavelength such as UV or EB light is performed. Even if it is a hard coat layer whose curing is accelerated by light irradiation in the visible light region having a longer wavelength than these, the decorative film can be preshaped by selecting a suitable irradiation means. . Further, even if a thermosetting material is used for the hard coat layer, if the curing temperature is higher than the temperature at which the base film is brought into a softened state necessary for vacuum forming, the dummy plate Preliminary shaping of the decorative film can be performed by appropriately changing the heating temperature of the heating means between softening and curing of the decorative film.

  The present invention is not limited to the above embodiment and can be implemented in various forms. For example, in Example 1 to Example 3, the pre-shaped step of the skin material (decorative film) is performed by vacuum forming by the vacuum forming means 44, but at the same time as vacuum forming, compressed air is supplied from the dummy plate side. It is also possible to adopt a form in which pressure forming is performed by injecting and pre-shaped by vacuum pressure forming as a whole. This form is useful for pre-shaping when the design surface is wide and uneven.

  Further, in Example 2, the first injection step for forming the primary molded body 9b is performed by the second injection unit 18, the secondary molded body 9c is molded, and the pre-shaped skin material 12 and the primary molding are performed. Although the second injection process for integrally fusing with the body 9b is performed by the first injection unit 17, the injection gates 19a and 19b of the common mold 19 'are arranged so that each injection process is performed by the reverse injection unit. It may be arranged. That is, it is defined as a first injection unit that molds the primary molded body 9b and a second injection unit that molds the secondary molded body according to the arrangement of each of the two injection units to be arranged or the injection filling capacity. It ’s fine.

  Further, in the injection process of the first embodiment or the first injection process and the second injection process of the second embodiment, the rotary mold portion and the movable plate on which the dummy plate is attached are used as the mold of the rotary mold support means. If the mold is opened and closed as a whole by using a moving function in the opening / closing direction or another integration means, the molded body 9a, the primary molded body 9b, and the secondary molded body 9c are expanded and molded by expanded foam molding or injection. It is also possible to form a compression molded body by compression molding or injection press molding. Thus, if the molded body to be the base material layer is composed of a foam molded body, a compression molded body, or an ordinary resin molded body, and a combination thereof, the function of the design surface of the multilayer molded product with the skin material is improved. In addition to weight reduction with foamed molded products, heat insulation, heat insulation, sound insulation functions, flat surface smoothness and optical improvement by compression molded products, etc., it can be added to multilayer molded products, or to the non-design surface side substrate layer By adopting recycled resin, environmental protection and cost reduction can be achieved.

  The laminate molding apparatus and laminate molding method of the present invention can be applied to a wide variety of skin materials in the fusion integration of the skin material and the resin molded body, and the effect of shortening the molding cycle and improving the quality of the multilayer molded product. Therefore, the industrial utility value is extremely high for the manufacturer of the resin molded product.

DESCRIPTION OF SYMBOLS 1 Multilayer shaping | molding apparatus 3 Fixed platen 4 Rotating mold support means 5 Movable board 6 Dummy plate 6a Heating means 6b Curing light irradiation means 9 Multilayer molded product 9 'Multilayer molded product 9a Molded body 9b Primary molded body 9c Secondary molding Body 12 Skin material 12a Pre-shaped skin material 13 Decorative film 19 Common mold 19 'Common mold 20 First rotating mold 20' First rotating mold 21 Second rotating mold 21 'Second rotating mold 21 ”Second rotating mold 30 Cavity 31 First cavity 32 Second cavity 40 Rotating mold part 44 Vacuum forming means

Claims (5)

With a common type that can be attached to the fixed platen,
A rotating mold part having at least two mold dividing surfaces combined with the common mold to form a mold cavity;
A dummy plate that is attached to a movable platen, and in which a heating means is disposed on a surface of the rotating mold portion that faces the mold dividing surface;
A rotating mold support means disposed between the fixed platen and the movable platen, rotatably supporting the rotating mold part around a rotation axis perpendicular to the mold opening and closing direction, and moving in the mold opening and closing direction;
Vacuum forming means capable of vacuum forming in the mold cavity of the rotating mold part;
A multilayer molding apparatus comprising:   2. The multilayer molding apparatus according to claim 1, wherein means for irradiating a light beam for curing the photocurable material is disposed on the dummy plate. In a state where the skin material is inserted between the dummy plate and one of the mold dividing surfaces of the rotating mold part, and the skin material is gripped on substantially the entire circumference of the mold dividing surface by clamping, A pre-shaping step of heating and softening the skin material by the heating means, and vacuum forming the softened skin material into a mold cavity shape of the rotating mold portion by the vacuum forming means;
The pre-shaped skin material is opened in a state where it is held on one mold cavity surface of the mold dividing surface of the rotating mold part, and then the rotating mold part is rotated, A rotating mold rotating step of moving the shaped skin material to a position facing the common mold;
By mold clamping, the molten resin is injected and filled into a cavity formed between the skin material and the common mold held on one mold cavity surface of the mold dividing surface of the rotating mold part, An injection process for forming a molded body, and molding a multilayer molded product obtained by fusing and integrating the skin material and the molded body,
The multilayer molding method using the multilayer molding apparatus according to claim 1, wherein the preliminary shaping step and the injection step are performed substantially simultaneously. A primary molded body is formed by injection filling a first cavity formed by combining the common mold and the other of the mold dividing surfaces of the rotating mold part, substantially simultaneously with the preliminary shaping step. A primary injection process to
The primary molded body was held in the common mold, and the pre-shaped skin material was opened in a state of being held on one mold cavity surface of the mold dividing surface of the rotating mold part. Then, a first rotating mold rotating step of rotating the rotating mold portion and moving the pre-shaped skin material to a position facing the common mold,
By clamping the mold, between the skin material held on one mold cavity surface of the mold dividing surface of the rotating mold part, the common mold, and the primary molded body held on the common mold. A secondary molded body is formed by injecting and filling molten resin into the formed second cavity, and a multilayer molded product is formed by fusing and integrating the skin material, the secondary molded body, and the primary molded body. A second injection step to perform,
After the multilayer molded product is taken out, the rotating mold part is rotated so that one of the mold dividing surfaces of the rotating mold part is opposed to the dummy plate. A second rotating mold rotating step of moving the other of the mold dividing surfaces to a position facing the common mold;
The multilayer molding method according to claim 3, comprising:   5. The multilayer molding method according to claim 3, wherein, in the preliminary shaping step, a hard coat layer of a vacuum-formed skin material is cured by the irradiation unit.

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