JP2013188903A - Synthetic resin molded article and method of molding the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of molding a synthetic molded article, by which the synthetic resin molded article to which an optional three-dimensional pattern is individually imparted in a single mold can be manufactured at a low cost and which is suitable for the molding of various kinds of and small quantity of the synthetic resin molded articles.SOLUTION: A method of molding a synthetic resin molded article includes: introducing a shape imparting sheet F to have a three-dimensional pattern and a protective sheet P laminated on the shape imparting sheet F on the resin injection side and protecting the shape imparting sheet F from the molten resin together into a mold 10 for molding a synthetic resin to impart the three-dimensional pattern to the surface of the synthetic resin molded article in the molding.

Description

  The present invention relates to a molding method for molding a synthetic resin molded article individually given an arbitrary three-dimensional pattern in a single mold, and a synthetic resin molded article to which a three-dimensional pattern is given by this molding method.

  The synthetic resin molded article is obtained by melting the synthetic resin in the heating section of the molding machine, injecting the molten resin into the cavity of the mold, and cooling and solidifying the molten resin in the cavity. Therefore, the shape of the mold cavity surface is reflected in the external shape of the synthetic resin molded product.

  That is, conventionally, as a means for imparting a pattern to the surface of a synthetic resin molded article, a pattern is directly applied to the mold cavity surface by engraving, etching, or the like, and the synthetic resin is molded in the mold cavity with the pattern. The method was general.

  The method of attaching a pattern to the mold cavity surface itself requires a new mold to be manufactured and replaced each time the pattern is changed. Since the mold is heavy and expensive, it has been devised that the entire mold is not replaced, but only a portion that needs to be changed is produced in a nested mold.

  However, even in the case of the nesting type, the exchange for each given pattern is complicated, and the mold production cost increases. Therefore, the method of attaching a pattern to the mold cavity surface itself is actually not suitable for molding a small amount of various types of synthetic resin molded products.

  Accordingly, the present inventors have developed a technique for transferring a fabric pattern or unevenness onto the surface of a molded product by stretching the fabric in a mold and injection molding a synthetic resin and peeling the fabric from the obtained molded product. (Refer to Patent Document 1).

  In addition, the present inventors polymerized a transfer film with a pattern and a fiber material in a mold and placed them, injection molded synthetic resin, and peeled off the carrier sheet and the fiber material of the transfer film from the obtained molded product. By doing so, the technique which transfers a pattern and a fiber pattern simultaneously on the surface of a molded article is proposed (refer patent document 2).

  Furthermore, a method of decorating the surface by subjecting a synthetic resin molded product to secondary processing such as printing or hot stamping has been implemented.

JP-A 63-306015 JP-A-4-261819

  By the way, the transfer molding technique described in Patent Document 1 and Patent Document 2 is a flat decoration direction, and a solid pattern with a strong unevenness cannot be imparted to a synthetic resin molded product.

  In addition, since the technology for post-processing a synthetic resin molded product has two steps, dust is mixed between the steps, and the manufacturing cost increases.

  In recent years, with the realization of a prosperous society, consumer needs have become individualized, and a variety of my goods have been demanded in order to differentiate them from others. However, the product supply side still employs a single mass production system due to manufacturing cost constraints, and thus there is a mismatch between consumers and product suppliers.

  Accordingly, an object of the present invention is to produce a synthetic resin molded product individually having an arbitrary three-dimensional pattern in a single mold at a low cost, and a molding method suitable for molding a small amount of various types of synthetic resin molded products, Another object of the present invention is to provide a synthetic resin molded article to which a three-dimensional pattern is imparted by this molding method.

  The configuration of the present invention made to achieve the above object is as follows.

  That is, the method for molding a synthetic resin molded article according to the present invention includes a shaping sheet having a three-dimensional pattern between the mold and the molten resin in a mold for molding the synthetic resin, and the above-mentioned shaping sheet. A protective sheet that is superimposed on the resin injection side and that protects the shaped sheet from the molten resin is introduced together, and the above three-dimensional pattern is imparted to the surface of the synthetic resin molded product during molding of the synthetic resin molded product. It is characterized by.

  As the shaped sheet, it is preferable to use a magnet sheet having the three-dimensional pattern and capable of adhering to the cavity surface of the mold by magnetic force.

  Alternatively, as the shaped sheet, a synthetic resin, synthetic rubber or cellulose sheet having the three-dimensional pattern is used, and the shaped sheet may be stretched on the mold parting surface.

  In addition, a transfer foil for providing a flat ground pattern on the surface of the synthetic resin molded product is introduced into the mold together with the shaping sheet and the protective sheet, or as a sheet also used as the protective sheet. May be.

  Further, it is preferable that the protective sheet or / and the transfer foil is introduced into the mold by a sheet supply device capable of supplying a plurality of sheets together between the mold and the molten resin.

  On the other hand, the method for molding a synthetic resin molded product according to the present invention is characterized in that the three-dimensional pattern is given by any one of the molding methods described above.

  According to the present invention, a shaped sheet having a three-dimensional pattern and a protective sheet are introduced between the mold and the molten resin in the mold. Due to the injection pressure of the molten resin into the mold, the three-dimensional pattern of the shaped sheet is transferred to the surface of the synthetic resin molded product molded in the mold via the protective sheet.

  Since the protective sheet is superimposed on the resin injection side of the shaped sheet, the shaped sheet is protected from the molten resin by the protective sheet. Therefore, the shaped sheet is easily peeled off from the synthetic resin molded product.

  Therefore, the present invention can produce a synthetic resin molded product individually having an arbitrary three-dimensional pattern in a single mold at low cost, and exhibits an excellent effect that it is suitable for molding a small amount of various types of synthetic resin molded products. To do.

It is sectional drawing which shows typically the metal mold | die used for the shaping | molding method of the synthetic resin molded product in 1st Embodiment. It is explanatory drawing which shows the lamination | stacking concept of the molding method of the synthetic resin molded product in 1st Embodiment. It is the schematic which shows typically the side surface external appearance of the sheet supply apparatus used for the shaping | molding method of the synthetic resin molded product in 2nd Embodiment. It is the schematic which expands and shows the feed side apparatus which comprises the sheet supply apparatus in 2nd Embodiment. It is the schematic which expands and shows the winding side apparatus which comprises the sheet | seat supply apparatus in 2nd Embodiment. It is a block diagram which shows the control system with which the feed side apparatus of the sheet supply apparatus in 2nd Embodiment was equipped. It is explanatory drawing which shows the lamination | stacking concept of the molding method of the synthetic resin molded product in 2nd Embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments. In addition, the well-known or well-known technique of the said technical field is applied regarding the part which is not illustrated or described in particular in this specification.

<First Embodiment>
First, with reference to FIG. 1, the metal mold | die used for the shaping | molding method of the synthetic resin molded product of 1st Embodiment is demonstrated. FIG. 1 is a cross-sectional view schematically showing a mold used in the method for molding a synthetic resin molded product according to the first embodiment.

  As shown in FIG. 1, the mold 10 in the first embodiment is a molding mold for injection molding a synthetic resin in a cavity 13. The mold 10 includes a movable mold 11 and a fixed mold 12. The fixed mold 12 is provided with an injection port 14 through which synthetic resin is injected into the cavity 13.

  The movable mold 11 and the fixed mold 12 may be provided in reverse. In this embodiment, one mold is a fixed mold, but both may be movable. Furthermore, the shape of the cavity 13 is an example for simplifying the illustration, and is different from the actual one.

  The mold 10 is preferably a relatively shallow diaphragm. The mold 10 of the present embodiment is not necessarily limited to an injection mold, and may be a mold that performs another molding method such as a thermoforming mold.

  Next, with reference to FIG.1 and FIG.2, the shaping | molding method of the synthetic resin molded product of 1st Embodiment implemented using the said metal mold | die 10 is demonstrated with an effect | action. FIG. 2 is an explanatory view showing a stacking concept of the molding method of the synthetic resin molded product in the first embodiment.

  First, the shaped sheet F and the protective sheet P for having the three-dimensional pattern L are introduced between the mold 10 and the molten resin in the mold 10. Specifically, the shaped sheet F and the protective sheet P are introduced to the parting surface of the movable mold 11 with the movable mold 11 and the fixed mold 12 being opened. The protective sheet P is superimposed on the resin injection side of the shaped sheet F.

  The shaped sheet F is a sheet for imparting a three-dimensional pattern L to the synthetic resin molded product 100. As the shaped sheet F, for example, a synthetic rubber magnet sheet manufactured by Magex Co., Ltd. is used, and the magnet sheet is processed to have a three-dimensional pattern L. The shaped sheet F is created, for example, by punching a solid pattern L such as an “AD” logo from a magnet sheet.

  The magnet sheet has ferromagnetism that can adhere to the iron mold 10. The shaped sheet F of this embodiment is directly attached to the cavity surface of the movable mold 11 by magnetic force. Since the shaped sheet F is only attached to the cavity surface of the movable mold 11 by magnetic force, positioning on the cavity surface can be easily performed. Further, when changing the three-dimensional pattern L to be applied to the synthetic resin molded product 100, the shaped sheet F can be easily detached from the mold 10, so that the shaped sheet F can be easily replaced.

  As shown in FIG. 2 (a), the protective sheet P is introduced while being superimposed on the resin injection side of the shaped sheet F along with the attachment of the shaped sheet F to the cavity surface. The protective sheet P is a sheet for protecting the shaped sheet F from the molten resin. Examples of the protective sheet P include synthetic resins such as PET (polyethylene terephthalate) film, cloth, and cellulose.

  Since the protective sheet P is superimposed on the resin injection side of the shaped sheet F, it is preferable that the protective sheet P is thin. This is because, as will be described later, the three-dimensional pattern of the shaped sheet F is reflected on the surface of the synthetic resin molded product 100 via the protective sheet P. The thickness of the protective sheet P is preferably 0.2 mm or less, for example.

  Any synthetic resin molded in the mold 10 can be used as long as it is a thermoplastic resin. Examples of the thermoplastic resin include PE (polyethylene), PP (polypropylene), PS (polystyrene), PVC (polyvinyl chloride), PC (polycarbonate), PMMA (polymethyl methacrylate), ABS (acrylonitrile / butadiene / styrene). ), PC / ABS, PA (polyamide), POM (polyoxymethylene) and the like.

  The synthetic resin is heated to, for example, 200 to 220 ° C. in a heating cylinder (not shown) and melted and fluidized.

  After the movable mold 11 is moved to the fixed mold 12 side and clamped, molten resin is injected from the injection port 14 of the fixed mold 12 into the cavity 13. As shown in FIG. 2B, when molten resin is injected into the mold 10, the resin pressure is applied to the shaped sheet F via the protective sheet P, and the shaped sheet is formed on the surface of the synthetic resin molded product 100. The solid pattern L of F is transferred.

  The synthetic resin molded product 100 in a molten state is solidified in the cavity 13 by cooling the mold 10 to, for example, 60 ° C. with warm water. Since the synthetic resin molded product 100 is cooled from the cavity 13 side, the three-dimensional pattern L remains on the surface of the synthetic resin molded product 100 as shown in FIG.

  After the synthetic resin is solidified, the mold is opened and the synthetic resin molded article 100 having the three-dimensional pattern L is taken out. Since the shaped sheet F is isolated from the heat of the molten resin at the time of molding by the protective sheet P, it can be used repeatedly.

  The combination of the shaped sheet F, the protective sheet P, and the synthetic resin for molding is determined by whether or not the protective sheet P and the synthetic resin molded product 100 need to be peeled after the synthetic resin molded product 100 is molded and cooled. When the protective sheet P is desired to be peeled off from the synthetic resin molded product 100 after molding, the shaped sheet F and a sheet that is incompatible with the molding synthetic resin are selected as the protective sheet P.

  On the other hand, when the protective sheet P is to be laminated on the surface of the synthetic resin molded article 100 by molding, the protective sheet P is a sheet that is incompatible with the shaped sheet F and is compatible with the molding synthetic resin. Select. The case where the protective sheet P is desired to be laminated on the surface of the synthetic resin molded article 100 by molding is, for example, a case where a transfer sheet on which a planar ground pattern such as wood grain is printed in advance is also used as the protective sheet P. Note that the transfer sheet provided with a planar ground pattern may be configured as a sheet different from the shaped sheet F and the protective sheet P.

  As described above, according to the method for molding a synthetic resin molded product in the first embodiment, the shaped sheet F having the three-dimensional pattern L and the protection between the mold 10 and the molten resin in the mold 10 are protected. The sheet P is introduced together. By injection of the molten resin into the mold 10, the resin pressure is applied to the shaped sheet F through the protective sheet P, and the three-dimensional pattern L of the shaped sheet F is transferred to the surface of the synthetic resin molded product 100.

  Since the protective sheet P is superimposed on the resin injection side of the shaped sheet F, the shaped sheet F is protected from the molten resin. Therefore, the shaped sheet F is easily peeled off from the synthetic resin molded product 100. When the transfer sheet is also used as the protective sheet P, the protective sheet P can remain on the surface of the synthetic resin molded product 100.

  Therefore, the molding method of the synthetic resin molded product in the first embodiment uses the single mold 10 for mass production of a single product, and the synthetic resin molded product 100 to which an arbitrary three-dimensional pattern L is individually given at low cost. It can be manufactured and is suitable for molding a small amount of various types of synthetic resin molded products 100.

  In the above embodiment, a magnet sheet is used as the shaping sheet. However, a synthetic resin, a synthetic rubber, or a cellulose sheet provided with a three-dimensional pattern may be used. In this case, a three-dimensional pattern is laminated on the surface of the shaped sheet by printing or the like. For example, a three-dimensional pattern such as a logo is laminated in a convex shape on the surface of a PET sheet by printing or the like.

  In the case of using a shaped sheet in which three-dimensional patterns are laminated in a convex shape on the surface of a synthetic resin, synthetic rubber or cellulose sheet, it is stretched on the parting surface of the movable mold 11 because it does not have magnetism.

Second Embodiment
Next, with reference to FIGS. 3 to 6, a method for molding a synthetic resin molded product in the second embodiment will be described.

  First, the sheet supply apparatus used for the synthetic resin molded product molding method according to the second embodiment will be described. FIG. 3 is a schematic view schematically showing a side appearance of a sheet feeding device used in the method for molding a synthetic resin molded product according to the second embodiment. FIG. 4 is an enlarged schematic view showing a feeding side device constituting the sheet feeding device in the second embodiment. FIG. 5 is an enlarged schematic view showing a winding side device constituting the sheet feeding device in the second embodiment. FIG. 6 is a block diagram illustrating a control system provided in the feeding side device of the sheet feeding device according to the second embodiment. In addition, about the member same as 1st Embodiment, the same code | symbol is attached | subjected and demonstrated.

  As shown in FIGS. 3 and 4, the sheet feeding apparatus 1 according to this embodiment is a molding capable of feeding a plurality of sheets together between the mold 10 and the synthetic resin, that is, to the parting surface of the movable mold 11. Device.

  A mold 10 according to the second embodiment includes a movable mold 11 and a fixed mold 12, and is the same resin mold as described in the first embodiment.

  As the shaped sheet F, a magnet sheet processed to have a three-dimensional pattern L as in the first embodiment is used. The shaped sheet F is directly attached to the cavity surface of the movable mold 11 by magnetic force.

  The protection sheet P is a sheet made of a material capable of protecting the shaped sheet F, as in the first embodiment. The protective sheet P is arranged on the resin injection side of the shaped sheet F, as in the first embodiment. As the protective sheet P of the present embodiment, a sheet wound in a roll shape is used.

  In the second embodiment, in addition to the shaped sheet F and the protective sheet P, a transfer sheet T is used. The transfer sheet T is a sheet for transferring a planar ground pattern onto the surface of a synthetic resin molded product. Here, as for the transfer sheet T, a transfer foil is laminated on a carrier sheet, and the transfer foil is transferred to a synthetic resin molded product by peeling off the carrier sheet, or a planar ground pattern such as a fabric pattern is formed as an uneven shape. What is transferred to a synthetic resin molded product is included. For example, a planar ground pattern such as wood grain is printed on the transfer sheet T in advance, and the planar ground pattern is transferred to the surface of the synthetic resin molded product at the time of molding. As the transfer sheet T of this embodiment, a roll wound is used.

  A plurality of sheet feeding devices 20 corresponding to the number of sheets to be transferred are provided on the upstream side of the mold 10 in the sheet transfer direction D. In the present embodiment, a transfer sheet T as an upper sheet and a protective sheet P as a lower sheet are simultaneously supplied between the molds 11 and 12. Accordingly, the sheet feeding device 20 includes two sets of a transfer sheet sheet feeding device 20A for feeding the transfer sheet T and a protective sheet feeding device 20B for feeding the protective sheet P. Specifically, a transfer sheet feeding device 20A and a protective sheet feeding device 20B are vertically arranged in a vertical direction on the apparatus base 21 arranged on the upper side of the movable mold 11.

  The mechanical configuration of the transfer sheet feeding device 20A and the protective sheet feeding device 20B is the same, and in order to avoid duplication, the structure of the transfer sheet feeding device 20A and the protection sheet feeding device 20B will be described below. It will be explained together.

  The sheet feeding devices 20A and 20B include feeding rollers 22A and 22B that rotatably support the sheet rolls TR and PR. The rotation shafts of the feeding rollers 22A and 22B are set laterally (horizontal) on the apparatus base 21, and the sheet T is rotated by rotating the feeding rollers 22A and 22B in the roll rewinding direction (sheet feeding direction). , P are fed out sequentially.

  Further, below the feeding rollers 22A and 22B in the roll unwinding direction (slightly downward to the right in FIG. 3), feeding rollers 23A and 23B that sequentially feed the belt-like sheets T and P from the feeding rollers 22A and 22B are rotatable. It is arranged. The rotation shafts of the feed rollers 23A and 23B are connected to the rotation shafts of the driving devices 24A and 24B that rotate the rollers. The drive devices 24A and 24B are constituted by a motor capable of controlling the rotation speed, such as a servo motor, and are fixed to the device base 21 with its rotation axis oriented sideways (horizontal).

  Thus, by providing the feed rollers 23A and 23B separately from the feed rollers 22A and 22B, the feed amount can be kept constant regardless of the winding diameter of the sheet rolls TR and PR. Therefore, it is not necessary to provide a position detection sensor for the sheet rolls TR and PR. The feeding rollers 22A and 22B may be shafts that do not rotate themselves. In this case, since the sheets T and P are fed from the sheet rolls TR and PR only by the feed rollers 23A and 23B, sagging of the sheets T and P before the feed rollers 23A and 23B can be prevented.

  The feed rollers 23A and 23B support the lower surfaces of the sheets T and P. Guide rollers 25A, 25B and 26A, 26B are disposed on both sides of the feed rollers 23A, 23B, and these guide rollers 25A, 25B and 26A, 26B support the upper surfaces of the sheets T, P. In this way, by using three rollers for guiding the feeding of the sheets T and P, it is not necessary to adjust the distance between the rollers even if the sheet thickness to be guided is different. Further, by arranging the guide rollers 25A, 25B and 26A, 26B on both sides of the feed rollers 23A, 23B, it is possible to increase the contact area of the sheets T, P and prevent the sheets T, P from slipping. Further, the guide rollers 25A, 25B or 26A, 26B may be movable, and an elastic member such as a spring may be provided to increase the pressing force on the sheets T, P.

  Further, on one side of the feed rollers 23A and 23B (on the right side in FIG. 3), direction changing rollers 27A and 27B that change the transport direction of the sheets T and P from the lateral direction (rightward in FIG. 3) to the downward direction are disposed. Has been. The direction changing rollers 27A and 27B protrude from the device base 21 to one side (right side in FIG. 3), and their respective tips substantially coincide with the parting surface of the movable die 11. As a result, the transfer sheet T and the protective sheet P are transported along the parting surface of the movable mold 11 in a state where they are superposed. Alternatively, the direction changing rollers 27A and 27B may be slidably disposed and slid and protruded so that the tip end substantially coincides with the parting surface of the movable die 11.

  The driving devices 24A and 24B of the feed rollers 23A and 23B are connected to a control system 30 that individually controls the sheet supply amounts of the sheets T and P, respectively. FIG. 6 illustrates a block configuration of the control system 30 of this embodiment. As shown in FIG. 6, the control system 30 according to the present embodiment includes a control device 31 such as a computer (PC), and the control device 31 supplies each sheet such as a transfer sheet T and a protection sheet P. An input device 32 such as a keyboard for setting the amount is connected. The control device 31 is connected with detection means 33A and 33B capable of detecting the rotational speeds of the drive devices 24A and 24B such as servo motors. Further, the output system of the control device 31 is connected to the power supplies 28A and 28B of the drive devices 24A and 24B, respectively. As a result, the control device 31 compares the detection data from the detection means 33A and 33B with the setting data from the input device 32, outputs the calculation result to the power supplies 28A and 28B, and controls the voltage. By adjusting the rotation speed of 24B, an appropriate sheet supply amount corresponding to the functions of the sheets T and P is ensured.

  As shown in FIG. 5, the sheet supply apparatus 1 of the present embodiment corresponds to the number of sheets T and P on the downstream side of the mold 10 in the sheet transfer direction D in addition to the plurality of sheet feeding apparatuses 20. A plurality of sheet take-up devices 40 are provided. Specifically, a protective sheet sheet winding device 40 </ b> B and a transfer sheet sheet winding device 40 </ b> A are vertically arranged in the vertical direction on the apparatus base 41 arranged at the lower part of the movable mold 11.

  In the sheet feeding device 20, the transfer sheet sheet feeding device 20 </ b> A is arranged on the upper side and the protective sheet feeding device 20 </ b> B is arranged on the lower side. On the other hand, in the sheet winding device 40, the protective sheet sheet winding device 40B is arranged in the vertical direction, and the transfer sheet sheet winding device 40A is arranged in the lower direction. This is because the transfer sheet T is arranged on the fixed mold 12 side having the synthetic resin injection port 14 and the protective sheet P is arranged on the movable mold 11 side.

  The mechanical configuration of the transfer sheet sheet winding device 40A and the protective sheet sheet winding device 40B is the same, and in order to avoid duplication, the transfer sheet sheet winding device 40A and the protective sheet sheet winding device will be described below. The structure of 40B will be described together.

  The sheet take-up devices 40A and 40B are arranged so that the transfer direction of the used sheets T and P after the in-mold molding with the mold 10 is directed from the downward direction to the lateral direction (leftward in FIG. 3). ) Direction change rollers (slide rollers) 42A and 42B. These slide rollers 42A and 42B are arranged on the winding-side apparatus base 41 so as to be slidable in the vertical direction. When the slide rollers 42A and 42B are lowered by their own weight, tension is applied to the sheet, and the sheets T and P are loosened. To prevent. These slide rollers 42A and 42B can adjust the tension by adjusting the weight, for example, and support the upper surface side of the used sheets T and P. Guide rollers 43A and 43B are disposed on one side of the slide rollers 42A and 42B (on the left side in FIG. 3), and these guide rollers 43A and 43B support the lower surfaces of the used sheets T and P. .

  Further, take-up rollers 44A and 44B are provided on one side of the guide rollers 43A and 43B (on the left side in FIG. 3) to wind up the used sheets T and P in a roll shape. The rotation shafts of the take-up rollers 44A and 44B are set sideways (horizontal) on the device base 41. The rotation shafts of the winding rollers 44A and 44B are belt-driven by the driving devices 45A and 45B. The drive devices 45A and 45B are constituted by, for example, constant speed drive motors or the like, and are fixed to the device base 41 with their rotation axes oriented sideways (horizontal).

  The apparatus base 21 of the sheet feeding apparatuses 20A and 20B and the apparatus base 41 of the sheet winding apparatuses 40A and 40B are connected and integrated by a connecting member 50. Further, the back surface of the movable mold 11 is fixed to the connecting member 50. Therefore, the apparatus bases 21 and 41 move toward the fixed mold 12 together with the movable mold 11. Thus, by integrating the feeding side device, the winding side device, and the movable mold 11, parallel adjustment (centering adjustment) of the device and the sheet becomes unnecessary. When at least one of the device bases 21 and 41 is disposed on the rear side (left side in FIG. 3) by, for example, directly fixing to the movable mounting plate (not shown) instead of the connecting member 50, the gold The movable mold 11 does not hit the apparatus base 21 or the apparatus base 41 at the time of mold replacement, and the mold can be easily replaced.

  Next, with reference to FIG. 3 to FIG. 7, a method for molding a synthetic resin molded product according to the second embodiment performed using the sheet feeding apparatus 1 will be described together with the operation. FIG. 7 is an explanatory view showing a lamination concept of a method for molding a synthetic resin molded product according to the second embodiment.

  As described above, in this embodiment, a plurality of sheets are simultaneously supplied between the movable mold 11 between the molds 11 and 12 in the mold opening state for molding the synthetic resin and the synthetic resin. Therefore, the molding method of the present embodiment performs in-mold molding in a molding method such as injection molding or thermoforming.

  First, the shaped sheet F is directly attached to the cavity surface of the movable mold 11 by a magnetic force.

  Then, the transfer sheet T is fed out from the sheet roll TR supported by the feed roller 22A by rotationally driving the feed roller 23A with the driving device 24A. The transferred transfer sheet T passes through the guide rollers 25A and 26A together with the feed roller 23A, and the transfer direction of the transfer sheet T is changed from the lateral direction (rightward in FIG. 3) to the downward direction by the direction changing roller 27A. Are transferred between the movable mold 11 between the molds 11 and 12 and the synthetic resin.

  At the same time, the protective roller P is fed out from the sheet roll PR supported by the feeding roller 22B by rotationally driving the feed roller 23B by the driving device 24B. The fed protection sheet P passes through the guide rollers 25B and 26B together with the feed roller 23B, and the direction changing roller 27B changes the transfer direction of the protection sheet P from the horizontal direction (right direction in FIG. 3) to the downward direction, so that the mold is open. Are transferred between the movable mold 11 between the molds 11 and 12 and the synthetic resin.

  The transfer sheet T and the protective sheet P are transported along the parting surface of the movable die 11 in a polymerized state so as to overlap the resin injection side of the shaped sheet F. That is, as shown in FIG. 7A, the shaped sheet F, the transfer sheet T, and the protective sheet P are simultaneously supplied between the movable mold 11 between the molds 11 and 12 in the mold open state and the synthetic resin. At that time, the transfer sheet T is arranged on the fixed mold 12 side having the injection port 14, and the protective sheet P is arranged on the movable mold 11 side.

  In this state, the transfer of the transfer sheet T and the protective sheet P is temporarily stopped, the movable mold 11 is moved to the fixed mold 12 side, and the mold is clamped. After completion of mold clamping, molten resin is injected from the injection port 14. As shown in FIG. 7B, when molten resin is injected into the mold 10, the resin pressure is applied to the shaped sheet F via the transfer sheet T and the protective sheet P, and the surface of the synthetic resin molded product 100. A three-dimensional pattern L of the shaped sheet F is transferred as well as a planar ground pattern such as wood grain is transferred.

  The synthetic resin molded product 100 in a molten state is solidified in the cavity 13 by cooling the mold 10 to, for example, 60 ° C. with warm water. Since the synthetic resin molded product 100 is cooled from the cavity 13 side, as shown in FIG. 7C, if the protective sheet P and the carrier sheet of the transfer sheet T are peeled from the obtained synthetic resin molded product 100, The transfer layer Ta is transferred to the surface of the synthetic resin molded product 100, and the three-dimensional pattern L of the shaped sheet F remains.

  As the resin that can be injection-molded in the cavity 13 of the mold 10, the same general-purpose resin as in the first embodiment is used.

  Further, the control device 31 of the control system 30 controls the rotation of the feed rollers 23A and 23B and individually controls the sheet supply amount of each of the sheets T and P. Therefore, an appropriate sheet supply can be performed and sheet loss can be prevented.

  The used transfer sheet T, which has been molded by the mold 10, is driven by the drive device 45A by driving the transfer sheet take-up roller 44A, and the take-up roller 44A via the slide roller 42A and the guide roller 43A. Rolled up.

  Similarly, the used protective sheet P that has been molded in the mold 10 is driven by the driving device 45B through the slide roller 42B and the guide roller 43B by driving the winding roller 44B for the concavo-convex pattern forming sheet. It is wound around the winding roller 44B.

  The method for molding a synthetic resin molded product in the second embodiment basically has the same effects as those in the first embodiment. In particular, in the molding method of the synthetic resin molded product in the second embodiment, the transfer sheet T is supplied together with the shaped sheet F and the protective sheet P between the movable mold 11 and the synthetic resin. A three-dimensional pattern L can be applied to the surface of the synthetic resin molded article 100 with a typical ground pattern.

  Moreover, since the protective sheet P and the transfer sheet T are continuously supplied batchwise in the method for molding the synthetic resin molded product in the second embodiment, only the shaped sheet F needs to be replaced with the change in the three-dimensional pattern L.

  Furthermore, since the molding method of the synthetic resin molded product in the second embodiment continuously supplies a plurality of sheets in batches, the productivity of the synthetic resin molded product 100 that is decorated and provided with the three-dimensional pattern L can be improved. There is a unique effect.

  Conventionally, synthetic resins have been widely used in various products because they have excellent properties such as easy moldability, toughness, lightness, waterproofness, non-corrosion and electrical insulation, and are relatively inexpensive. Yes. However, conventional molding methods for synthetic resin molded products are suitable for mass production of single products, and inevitably only the same appearance can be obtained due to restrictions on manufacturing costs.

  The synthetic resin molded product molding method in the first and second embodiments can produce a synthetic resin molded product having an arbitrary three-dimensional pattern individually with a single mold. Therefore, according to the molding method of the synthetic resin molded product in the first and second embodiments, it is possible to obtain a unique synthetic resin molded product extremely economically and easily while following the conventional molding apparatus for mass production. It becomes.

  Therefore, it is possible to manufacture a synthetic resin molded product that is differentiated from others such as My Goods without increasing the manufacturing cost. For example, an order for a synthetic resin molded product having an arbitrary three-dimensional pattern can be received from a customer via the Internet or the like. Examples of uses of the synthetic resin molded product in the first and second embodiments include a car key with a family crest, a costume case with a family name, and the like. Can be improved.

  The preferred embodiment of the present invention has been described above. However, this is merely an example for explaining the present invention, and various embodiments different from the above-described embodiment may be implemented without departing from the gist of the present invention. Can do.

  Next, the synthetic resin molding method and synthetic resin molded product according to the present invention will be described in more detail with reference to examples.

<Example 1>
The mold for molding the synthetic resin is attached to a 130t injection molding machine manufactured by Toyo Machine Metal Co., Ltd. In this mold, a container having an outer shape of 120 mm square and a thickness of 2 mm is injection-molded.

  As the shaped sheet for logo application, a sheet made by punching a logo “AD” from a synthetic rubber magnet sheet manufactured by Magex Co., Ltd. is used. As a protective sheet for protecting the shaped sheet, a PET film having a thickness of 0.1 mm is used.

  First, a shaping sheet for applying a logo is attached to a portion of the movable cavity surface where the container is formed by the magnetic force of a magnet. Next, a PET film as a protective sheet is stretched on the movable parting surface using an adhesive tape. The protective sheet covers the entire cavity of the movable mold.

  In the heating cylinder of the mold, PP resin (J707G manufactured by Prime Polymer Co., Ltd.) is heated to 200 to 220 ° C. and melted and fluidized.

  The movable mold and the fixed mold are clamped, and the softened and fluidized PP resin is injected into the cavity from the injection port of the fixed mold.

  The injected PP resin is solidified in the cavity by cooling the mold to 60 ° C. with warm water. After the synthetic resin is solidified, the mold is opened and the container as a synthetic resin molded product is taken out.

  The protective sheet adhered to the entire surface of the container as a synthetic resin molded product. The shaped sheet remained attached to the mold. When the protective sheet adhering to the synthetic resin molded product was peeled off by hand, it was very easily removed from the synthetic resin molded product. The “AD” logo was clearly transferred as a three-dimensional pattern on the surface of the synthetic resin molded product.

<Example 2>
As the shaped sheet, the same sheet as in Example 1 is used. In Example 2, a transfer sheet printed in advance with a grain is used as a sheet that also serves as a protective sheet. This transfer sheet is obtained by laminating a transfer foil of wood on a carrier sheet. The same molding machine and mold as those in Example 1 are used.

  First, a shaping sheet for applying a logo is attached to a portion of the movable cavity surface where the container is formed by the magnetic force of a magnet. Next, a transfer sheet serving as a protective sheet is stretched on the movable parting surface using an adhesive tape. The transfer sheet covers the entire cavity portion of the movable mold.

  The injection molding, cooling and solidification of the molten resin are performed in the same manner as in Example 1. After the synthetic resin is solidified, the mold is opened and the container as a synthetic resin molded product is taken out.

  In the container as the synthetic resin molded product, the transfer foil detached from the carrier sheet of the transfer sheet adhered to the entire surface. The shaped sheet remained attached to the mold. When the carrier sheet of the transfer sheet adhering to the synthetic resin molded product was peeled off by hand, it was peeled off from the synthetic resin molded product very easily. The entire surface of the synthetic resin molded product was grained, and the “AD” logo was clearly transferred as a three-dimensional pattern.

<Comparative example>
In the comparative example, a shaped sheet obtained by punching a logo “AD” from a synthetic rubber sheet is used. A protective sheet is not used. About a molding machine and a metal mold | die, the same thing as Example 1 is used.

  A synthetic rubber shaped sheet is stretched on the movable parting surface using an adhesive tape. Since the distance between the movable mold and the fixed mold is narrow, it is very difficult to position and attach the synthetic rubber shaped sheet.

  The injection molding, cooling and solidification of the molten resin are performed in the same manner as in Example 1. After the synthetic resin is solidified, the mold is opened and the container as a synthetic resin molded product is taken out.

  The synthetic rubber logo was deformed and fused on the surface of the container as a synthetic resin molded product. The synthetic rubber logo did not retain the shape of “AD” and could not be peeled off from the synthetic resin molded product. The cavity surface of the mold was soiled with the adhesive of the adhesive tape.

  As described above, according to the molding methods of Example 1 and Example 2, a synthetic resin molding in which a three-dimensional pattern of “AD” is clearly given by using a shaped sheet made of a magnetic sheet and using it together with a protective sheet. The product was confirmed to be obtained.

DESCRIPTION OF SYMBOLS 1 Sheet feeder 10 Mold 11 Movable mold 12 Fixed mold 13 Cavity F Shaped sheet T Transfer sheet P Protective sheet

Claims (6)

  Between the mold and the molten resin in the mold for molding the synthetic resin, a shaped sheet having a three-dimensional pattern is superimposed on the resin injection side of the shaped sheet, and the shaped sheet is made from the molten resin. A method for molding a synthetic resin molded product, comprising introducing a protective sheet for protection together and imparting the three-dimensional pattern to the surface of the synthetic resin molded product when molding the synthetic resin molded product.   The method for molding a synthetic resin molded product according to claim 1, wherein a magnet sheet having the three-dimensional pattern and capable of adhering to the cavity surface of the mold by a magnetic force is used as the shaped sheet.   The synthetic resin, synthetic rubber or cellulose sheet to which the three-dimensional pattern is imparted is used as the shaped sheet, and the shaped sheet is stretched on a mold parting surface. The molding method of the synthetic resin molded product as described in 2.   A transfer sheet for introducing a flat ground pattern on the surface of the synthetic resin molded product is introduced into the mold together with the shaping sheet and the protective sheet, or as a sheet also serving as the protective sheet. The method for molding a synthetic resin molded product according to any one of claims 1 to 3, wherein:   5. The protective sheet and / or the transfer sheet is introduced into the mold by a sheet supply device capable of supplying a plurality of sheets together between the mold and the molten resin. The molding method of the synthetic resin molded product as described in 2.   The synthetic resin molded product, wherein the three-dimensional pattern is imparted by the molding method according to any one of claims 1 to 5.

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