JP2014223742A - In-mold molding method and in-mold molding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an in-mold molding method capable of correcting the position of a transfer film in a shorter time compared with the conventional case even if the displacement of a pattern is generated.SOLUTION: A movable mold 1 and a stationary mold 2 are closed to form a cavity space. A resin is injected into the cavity space to form a molded product and an unnecessary part incidental to the molded product. Simultaneously therewith, the pattern 22 of a transfer film 21 is transferred to the surface of the molded product, and further, a mark 25 for displacement detection in the transfer film 21 is transferred to the unnecessary part. Thereafter, the movable mold 1 and the stationary mold 2 are opened, the molded product incidental with the unnecessary part is taken out, and the amount of the displacement between the mark 25 for displacement detection transferred to the unnecessary part and a prescribed standard position is measured.

Description

  The present invention relates to an in-mold molding method and an in-mold molding apparatus for simultaneously molding a molded product and transferring a pattern onto the surface of the molded product.

  In in-mold molding, it may be required to transfer the pattern to the surface of the molded product with high positional accuracy. In this case, a positioning mark is printed on the decorative film of the transfer film, and a detector for detecting the positioning mark is provided in the in-mold molding apparatus (for example, Patent Document 1, Patent Document 2, Patent). See reference 3.)

  For example, as shown in FIG. 23, a plurality of positioning marks 232 for positioning the transfer film 231 in the transfer direction of the transfer film 231 and a line mark 233 for positioning the transfer film 231 in the width direction of the transfer film 231 It is printed on the decorative film of the transfer film 231 together with the plurality of patterns 234.

Japanese Patent No. 3990424 JP 2008-001047 A JP 2011-005834 A

  However, in-mold molding requires the transfer film to be stretched along the concave product surface formed in the movable mold, and the transfer film to adhere to the concave product surface. Generally, a transfer film is fixed to a movable parting surface around a concave product surface by a film pressing plate, and a sealed space is formed between the movable mold and the transfer film. Vacuum suction is performed from the suction hole that opens to the transfer product, and the transfer film is adsorbed to the concave product surface. For this reason, when the film pressing plate presses the transfer film, the transfer film moves and the pattern is displaced. In addition, when the transfer film is stretched by vacuum suction, the pattern is displaced. Furthermore, the positional displacement of the pattern also occurs due to the pressure received by the transfer film from the resin injected toward the concave product surface and the flow of the injected resin. Therefore, even if the transfer film is accurately positioned before the transfer film is restrained by the film pressing plate, a positional deviation occurs between the molded product and the pattern.

  Furthermore, when the molded product is deep-drawn, when the transfer film is completely fixed to the movable parting surface by the film pressing plate, tension exceeding the elastic limit of the transfer film acts on the transfer film during vacuum suction. The transfer film may be broken. Therefore, the film pressing plate is transferred so that the transfer film can slide between the movable parting surface and the film pressing plate before the tension becomes large enough to cause tearing of the transfer film. The force to hold the film against the parting surface is adjusted. For this reason, the transfer film is drawn from the outer side of the film pressing plate toward the concave product surface of the mold during vacuum suction, and the pattern is displaced. At this time, wrinkles are generated on the transfer film. Due to the occurrence of the wrinkles, the amount of pattern positional deviation increases.

  Further, depending on the shape or pattern of the molded product, it may be difficult to obtain a reference (reference position) for measuring the positional deviation between the molded product taken out of the mold and the pattern. In this case, it is difficult to automatically correct the position of the transfer film, and various molding conditions are manually adjusted. For this reason, it takes time to correct the position of the transfer film. Furthermore, it takes time to measure the positional deviation between the molded product and the pattern itself.

  An object of the present invention is to provide an in-mold molding method and an in-mold molding apparatus that can correct the position of a transfer film in a shorter time than the conventional case even if a pattern misalignment occurs. .

  One aspect of the first in-mold molding method of the present invention is that the film is fed from between the movable mold and the film pressing plate while the transfer film is fed between the movable mold and the film pressing plate from the film unwinding portion. A film feeding step for winding the transfer film at the film winding portion and positioning the transfer film; a step for constraining the transfer film to the movable mold by the film pressing plate; and a concave concave product surface. Forming a cavity space by closing the movable mold and the stationary mold, and injecting a resin into the cavity space to form a molded product and its molded product. At the same time as molding unnecessary parts attached to the surface, the pattern is transferred to the surface of the molded product and for detecting misalignment in unnecessary parts A step of transferring a mark, a step of opening the movable die and the fixed die, and taking out the molded product accompanied by the unnecessary portion, the position shift detection mark transferred to the unnecessary portion, and a predetermined reference position Measuring the amount of misalignment between the first position and the second position.

  Another aspect of the first in-mold molding method of the present invention is that the unnecessary portion is a runner.

  According to another aspect of the first in-mold molding method of the present invention, after the transfer film positioning operation is completed in the film feeding step, the amount of misalignment measured before the transfer film positioning operation is determined. Accordingly, the position of the transfer film is corrected.

  Also, one aspect of the second in-mold molding method of the present invention is that the transfer film is fed from the film unwinding portion between the movable mold and the film pressing plate, and sent out between the movable mold and the film pressing plate. A film feeding step of winding the transferred film at a film winding unit and positioning the transfer film, a step of constraining the transfer film to the movable mold by the film pressing plate, and a concave shape of the movable mold A step of vacuum-sucking the transfer film so that the transfer film is along the product surface, and a position between a misalignment detection mark printed on the transfer film adsorbed on the concave product surface and a predetermined reference position A step of measuring the amount of misalignment, a step of closing the movable mold and the fixed mold to form a cavity space, and a tree in the cavity space. It was injected at the same time a molded product, and transferring the pattern on the surface of the molded product, open the fixed mold and the movable mold is to anda step of taking out the molded product.

  In another aspect of the second in-mold molding method of the present invention, the amount of positional deviation measured before the transfer film positioning operation after the transfer film positioning operation in the film feeding step is completed. Accordingly, the position of the transfer film is corrected.

  Another aspect of the second in-mold molding method of the present invention is that the position shift detection mark is a grid scale mark.

One aspect of the first in-mold molding apparatus of the present invention is:
A transfer film printed with a pattern transferred to a molded product, and a misalignment detection mark transferred to an unnecessary portion accompanying the molded product;
A movable mold with a concave shaped product surface;
A film pressing plate that restrains the transfer film on the movable mold;
A fixed mold that forms a cavity space with the movable mold;
A foil feeding device for winding the transfer film fed from between the movable mold and the film pressing plate and positioning the transfer film while feeding the transfer film between the movable mold and the film pressing plate;
A suction mechanism for vacuum-sucking the transfer film so that the transfer film is along the concave product surface;
A measurement unit that measures the amount of positional deviation between the positional deviation detection mark transferred to the unnecessary part taken out between the fixed mold and the movable mold and a predetermined reference position;
The resin is injected into the cavity space, and the molded product and the unnecessary portion are molded. At the same time, the pattern is transferred to the surface of the molded product, and the displacement detection is performed on the unnecessary portion. The mark is transferred.

  Moreover, the other side surface of the 1st in-mold shaping | molding apparatus of this invention is that the said unnecessary part is a runner.

  Further, according to another aspect of the first in-mold molding apparatus of the present invention, after the positioning operation of the transfer film by the foil feeding device is completed, the amount of misalignment measured before the positioning operation of the transfer film is set. In response, the foil feeder corrects the position of the transfer film.

Also, one aspect of the second in-mold molding apparatus of the present invention is
A transfer film on which a misalignment detection mark is printed together with a pattern;
A movable mold with a concave shaped product surface;
A film pressing plate that restrains the transfer film on the movable mold;
A fixed mold that forms a cavity space with the movable mold;
A foil feeding device for winding the transfer film fed from between the movable mold and the film pressing plate and positioning the transfer film while feeding the transfer film between the movable mold and the film pressing plate;
A suction mechanism for vacuum-sucking the transfer film so that the transfer film is along the concave product surface;
A measuring unit that measures the amount of positional deviation between the positional deviation detection mark of the transfer film adsorbed on the concave product surface and a predetermined reference position;
The resin is injected into the cavity space to mold the molded product, and at the same time, the pattern is transferred to the surface of the molded product.

  Further, another aspect of the second in-mold molding apparatus of the present invention is the amount of positional deviation measured before the transfer film positioning operation after completion of the transfer film positioning operation by the foil feeding device. In response, the foil feeder corrects the position of the transfer film.

  In addition, another aspect of the second in-mold molding apparatus of the present invention is that the misalignment detection mark is a grid scale mark.

  According to the present invention, it is possible to correct the position of the transfer film in a shorter time than in the prior art even if the pattern is misaligned. Further, since the position of the transfer film can be corrected, the positioning accuracy of the transfer film is improved. Therefore, it is possible to transfer the pattern onto the surface of the molded product with high positional accuracy, and it is possible to improve the quality of the molded product.

The figure which shows the outline of a structure of the in-mold shaping | molding apparatus in Embodiment 1 of this invention. The top view of the transfer film in Embodiment 1 of this invention The figure which shows the outline of the molded article in Embodiment 1 of this invention The figure which shows an example of the position shift detection mark in Embodiment 1 of this invention. Diagram showing one step in a general in-mold molding method The figure which shows the other process in a general in-mold molding method The figure which shows the other process in a general in-mold molding method The figure which shows the other process in a general in-mold molding method The figure which shows the other process in a general in-mold molding method The top view for demonstrating a motion of a transfer film when a transfer film is restrained by a movable mold | type in a general in-mold molding method Plan view for explaining movement of transfer film when vacuum suction of transfer film is started in a general in-mold molding method Plan view for explaining movement of transfer film in vacuum suction process of general in-mold molding method The top view for demonstrating the movement of the transfer film when resin injection is performed in the general in-mold molding method Flow chart of in-mold molding method in Embodiment 1 of the present invention The figure which shows the other example of the mark for position shift detection in Embodiment 1 of this invention. The figure which shows the other example of the mark for position shift detection in Embodiment 1 of this invention. The figure which shows the other examples of the reference position for position shift detection in Embodiment 1 of this invention. Plan view of a transfer film in Embodiment 2 of the present invention The figure which shows schematically a part of structure of the in-mold shaping | molding apparatus in Embodiment 2 of this invention. The top view which shows the grid-like scale mark immediately after positioning of the transfer film in Embodiment 2 of this invention The top view which shows an example of the state of the grid-shaped scale mark at the time of completion of vacuum suction in Embodiment 2 of this invention The top view which shows the other example of the state of the grid-like scale mark at the time of completion of vacuum suction in Embodiment 2 of this invention Plan view of conventional transfer film

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the same components may be denoted by the same reference numerals, and redundant description may be omitted. In addition, the drawings schematically show each component as a main component for easy understanding. In addition, the thickness, length, and the like of each illustrated component are different from actual ones for the convenience of drawing. Embodiments 1 and 2 described in detail below are merely examples, and various modifications can be made without departing from the effects of the present invention. The matters detailed in the following first and second embodiments can be combined as appropriate.

(Embodiment 1)
FIG. 1A is a side view showing the outline of the configuration of the in-mold molding apparatus according to Embodiment 1 of the present invention, and FIG. 1B shows the outline of the configuration of the in-mold molding apparatus according to Embodiment 1 of the present invention. FIG. However, FIG. 1A shows a part of the movable mold 1 in cross section. Further, in FIG. 1B, the fixed mold 2 is omitted. FIG. 2 is a plan view of the transfer film in the first embodiment of the present invention. FIG. 3 (a) is a front view showing an outline of the molded product taken out from the mold in the first embodiment of the present invention, and FIG. 3 (b) is taken out from the mold in the first embodiment of the present invention. FIG. 3C is a front view showing the outline of the runner associated with the molded product taken out from the mold in Embodiment 1 of the present invention, and FIG. It is a side view which shows the outline of the runner and sprue accompanying the molded product taken out from the metal mold | die in Embodiment 1 of this invention.

  As shown in FIGS. 3A and 3B, the molded product 31a according to the first embodiment has a circular frame shape having an opening hole at the center. Therefore, the molded product 31a when viewed in plan has an annular shape. For this reason, as shown in FIG. 2, a large number of annular patterns 22 are printed along the feeding direction of the transfer film 21. Further, as positioning marks, a plurality of positioning marks 23 for positioning the transfer film 21 in the transfer direction of the transfer film 21 and a line mark 24 for positioning the transfer film 21 in the width direction of the transfer film 21, It is printed on the decorative film of the transfer film 21 together with a plurality of patterns 22. Specifically, each positioning mark 23 is printed for each pattern 22 on one end of the transfer film 21 in the width direction of the transfer film 21, and the other of the transfer films 21 on the side opposite to the plurality of positioning marks 23. At the end, a line mark 24 is continuously printed along the feeding direction of the transfer film 21. Further, in the first embodiment, a position deviation detection mark 25 is printed at the center of each picture 22. When the pattern 22 is transferred to the surface of the molded product, the position shift detection mark 25 is transferred to the bottom surface of the runner at the same time. That is, as shown in FIGS. 3A to 3D, the molded product 31 taken out from the mold includes a molded product 31a, and a runner 31b and a sprue 31c that are unnecessary portions associated with the molded product 31a. including. The pattern 22 is transferred to the surface of the molded product 31a, and the misalignment detection mark 25 is transferred to the bottom surface of the runner 31b. In addition, in FIG.3 (b), the pattern 22 is abbreviate | omitted.

  Here, the outline | summary of the in-mold shaping | molding apparatus in this Embodiment 1 is demonstrated with reference to Fig.1 (a) and FIG.1 (b).

  The mold of the in-mold molding apparatus in the first embodiment includes a movable mold 1 and a fixed mold 2 as molding molds for molding a resin product. Further, the mold of this in-mold molding apparatus includes a film pressing plate 3 between the movable mold 1 and the fixed mold 2. The film pressing plate 3 has a frame shape, and is housed in a recess (not shown) provided in the fixed mold 2 when the movable mold 1 and the fixed mold 2 are in close contact with each other. The film pressing plate 3 is not limited to a rectangular frame shape. For example, a circular frame-shaped film pressing plate 3 may be used. Furthermore, the film pressing plate 3 is not limited to a frame shape. For example, as the film pressing plate 3, two bars facing each other with the concave product surface 1 b of the movable mold 1 in the feeding direction of the transfer film 21, and the concave shape of the movable mold 1 in the width direction of the transfer film 21. Two bars facing each other across the product surface 1b may be used. Alternatively, only two bars facing each other across the concave product surface 1 b of the movable mold 1 in the feeding direction of the transfer film 21 may be used as the film pressing plate 3.

  The transfer film 21 is attached to the unwinding bobbin shaft 4 while being wound in a roll shape. The transfer film 21 includes a base film and a transfer layer formed on the base film. The transfer layer includes a decorative film. The transfer layer may contain a functional film in addition to the decorative film. The plurality of positioning marks 23, the line marks 24, and the plurality of misalignment detection marks 25 are printed on a decorative film formed on the base film together with the plurality of patterns 22. Alternatively, a decorative film on which a plurality of patterns 22, a plurality of positioning marks 23, a line mark 24, and a plurality of positional deviation detection marks 25 are printed may be transferred and laminated on the base film.

  The transfer film 21 attached to the unwinding bobbin shaft 4 is pulled out, passed between the unwinding roller 5 and the unwinding side pressing roller 6, and sent toward the mold. At this time, the line mark 24 is passed between the light projecting and receiving devices of the unwinding side line detection sensor 7. The unwinding bobbin shaft 4, the unwinding roller 5, the unwinding side pressing roller 6, and the unwinding side line detection sensor 7 are provided in the film unwinding portion. The transfer film 21 drawn out from the film unwinding section is sent between the movable mold 1 and the film pressing plate 3. At this time, the transfer film 21 is passed between the movable mold 1 and the film pressing plate 3 so that the positioning mark 23 is reflected on the reflection plate installed in the mold. The reflector is installed at the detection position of the feed direction mark detection sensor 8. The transfer film 21 sent out from the mold is passed through the tension roller of the film tension detector 9. At this time, the line mark 24 is passed between the light projecting and receiving devices of the winding side line detection sensor 10. Further, the transfer film 21 is passed between the take-up roller 11 and the take-up side pressing roller 12, and is finally wound around the take-up bobbin shaft 13. The film tension detection unit 9, the winding side line detection sensor 10, the winding roller 11, the winding side pressing roller 12, and the winding bobbin shaft 13 are provided in the film winding unit.

  The transfer film 21 is inserted into the mold so that a new pattern 22 is sent to a predetermined position in the mold every time resin injection molding is completed. Specifically, the transfer film 21 attached to the unwinding bobbin shaft 4 is unwound by rotation of the unwinding bobbin shaft 4 by the unwinding motor 14 of the film unwinding portion. And the unwound transfer film 21 is sent out toward a metal mold | die by rotation of the unwinding roller 5 by the sending-out motor 15 of a film unwinding part. The transfer film 21 is pressed against the unwinding roller 5 by the unwinding-side pressing roller 6 so that the transfer film 21 is fed following the rotation of the feeding motor 15. That is, the transfer film 21 is sandwiched between the unwinding roller 5 and the unwinding side pressing roller 6. Further, when the transfer film 21 is sent out from the film unwinding portion, the bobbin motor 16 of the film winding portion rotates the winding bobbin shaft 13 so that the transfer film 21 is wound around the winding bobbin shaft 13. At the same time, the film tension detector 9 measures the tension acting on the transfer film 21 in the transfer direction of the transfer film 21, and the take-up motor 17 of the film take-up part based on the measured tension, the take-up roller 11. Rotate. Thereby, the transfer film 21 is pulled to the film take-up portion side with a predetermined constant torque. Therefore, the film winding unit winds the transfer film 21 while maintaining a constant tension acting on the transfer film 21 in the feeding direction of the transfer film 21. Thus, the transfer film 21 is pressed against the take-up roller 11 by the take-up side pressing roller 12 so that the transfer film 21 is pulled following the rotation of the take-up motor 17. That is, the transfer film 21 is sandwiched between the winding roller 11 and the winding-side pressing roller 12. The feed motor 15 of the film unwinding section stops when the feed direction mark detection sensor 8 detects the positioning mark 23. At the same time, the unwinding motor 14 of the film unwinding section and the bobbin motor 16 of the film unwinding section are also stopped. Thereby, the transfer film 21 is positioned in the feeding direction of the transfer film 21.

  When the positioning of the transfer film 21 in the transfer direction of the transfer film 21 is completed, the detection process of the line mark 24 by the unwinding side line detection sensor 7 and the winding side line detection sensor 10 is executed. If the line mark 24 is not detected, the film winding portion width direction correction motor 18 and the film winding portion until the line mark 24 is detected by the winding side line detection sensor 7 and the winding side line detection sensor 10. The width direction correction motor 19 is driven. The width direction correction motors 18 and 19 move the film unwinding portion and the film winding portion in the width direction of the transfer film 21, respectively. The film unwinding portion width direction correction motor 18 stops when the unwinding side line detection sensor 7 detects the line mark 24. The film winding portion width direction correction motor 19 stops when the winding-side line detection sensor 10 detects the line mark 24. Thereby, the transfer film 21 is positioned in the width direction of the transfer film 21. Alternatively, the inclination of the line mark 24 with respect to the feeding direction of the transfer film 21 is corrected, and the line mark 24 can be aligned with the feeding direction of the transfer film 21. Note that the winding motor 17 continues to pull the transfer film 21 at a predetermined constant torque while the transfer film 21 is positioned in the width direction of the transfer film 21.

  When the feeding operation of the transfer film 21 is completed, the film pressing plate 3 moves toward the movable mold 1, and the positioned transfer film 21 is moved between the parting surface 1 a of the movable mold 1 and the film pressing plate 3. Sandwiched between them. As a result, the transfer film 21 comes into close contact with the parting surface 1 a of the movable mold 1, and a sealed space is formed between the movable mold 1 and the transfer film 21. Next, vacuum suction is performed from a suction hole (not shown) opened in the sealed space, and the transfer film 21 is adsorbed to the concave product surface 1 b formed in the movable mold 1. Thereby, the transfer film 21 is closely fixed to the concave product surface 1 b of the movable mold 1.

  After the vacuum suction is completed or during the vacuum suction, the movable platen 20 is moved in the mold clamping direction by the mold clamping operation of the molding machine, and the movable mold 1 comes into close contact with the fixed mold 2. After the clamping of the movable mold 1 and the fixed mold 2 is completed, the molten resin is injected from the fixed mold 2 side toward the transfer film 21 along the concave product surface 1b. When a predetermined amount of molten resin is injected into the cavity space formed between the clamped movable mold 1 and the fixed mold 2, the molten resin is held at a predetermined pressure for a predetermined time. That is, the molten resin is maintained at a pressure. At this time, the transfer film 21 adheres to the molten resin. Thereafter, the resin in the cavity space is solidified into a molded product through a cooling process for a certain time. Thereafter, the movable platen 20 is moved in the mold opening direction by the mold opening operation of the molding machine, and the movable mold 1 is separated from the fixed mold 2. Next, the molded product remaining on the fixed mold 2 is ejected by a projecting mechanism installed on the fixed mold 2 and then gripped by the chuck of the take-out machine. The gripped molded product is taken out from the mold. Alternatively, the extruded molded product may be sucked by the suction head. In this case, the adsorbed molded product is taken out from the mold.

  After the molded product is taken out from the mold, the transfer operation of the transfer film 21 described above is performed, and the transfer film 21 after the decorative film is transferred to the molded product is taken up on the take-up bobbin shaft 13. At the same time, the next pattern 22 is positioned in the mold.

  As described above, the transfer film 21 on which the positioning marks 23 and 24 are printed is inserted into the mold, and the positioning of the transfer film 21 using the positioning marks 23 and 24 is performed in the feeding direction of the transfer film 21. And in the width direction. Then, the molten resin is injected onto the positioned transfer film 21, and simultaneously with the molding of the molded product, the decorative film (picture 22) of the transfer film is transferred to the molded product of the molded product. When the transfer film 21 includes a functional film, the decorative film (pattern 22) and the functional film of the transfer film 21 are transferred to a molded product of the molded product. Further, in the first embodiment, as shown in FIGS. 3A and 3C, the pattern 22 is transferred to the molded product 31a, and at the same time, the runner 31b associated with the molded product 31a The misalignment detection mark 25 is transferred to the bottom surface of (example).

  As already mentioned, depending on the size and appearance (shape) of the molded product, the design of the pattern, etc., the positional deviation between the molded product taken out of the mold and the pattern must be measured mechanically and optically. There are many cases where this is difficult. For example, a standard for measuring a positional deviation between a molded product and a pattern when a pattern with a gradually changing color or a solid pattern is transferred to the molded product, or when the molded product has a three-dimensional shape. It may be difficult to obtain (reference position). Therefore, in the first embodiment, as shown in FIG. 2, the position deviation detection mark 25 is printed at a position corresponding to the bottom surface of the runner, and as shown in FIGS. 3 (a) and 3 (c), The positional deviation detection mark 25 is transferred to the bottom surface of the runner 31b, so that the positional deviation between the bottom surface of the runner 31b and the positional deviation detection mark 25 can be measured. Since it is considered that the amount of positional deviation between the bottom surface of the runner 31b and the position deviation detection mark 25 corresponds to the amount of positional deviation between the molded product 31a and the pattern 22, detection of the positional deviation from the bottom surface of the runner 31b. When the position of the transfer film 21 after the next positioning is corrected by using the amount of the positional deviation with respect to the mark 25 as a correction amount, a positional deviation occurs between the next molded product 31 a and the pattern 22. It becomes difficult.

  Since the bottom surface of the runner 31b is usually located at substantially the center of the molded product 31 and the diameter of the bottom surface of the runner 31b is relatively small, the measurement range of the position deviation detection mark 25 may be narrow. Accordingly, the position between the bottom surface of the runner 31b and the position shift detection mark 25 is not changed without changing the setting of an image recognition device such as a CCD camera each time shooting or imaging is performed, and without using a plurality of image recognition devices. It is possible to measure the deviation.

  FIG. 4A and FIG. 4B show an example of the misalignment detection mark 25. In the first embodiment, a + character is printed as the misalignment detection mark 25. 4A shows the position deviation detection mark 25 printed on the transfer film 21, and FIG. 4B shows the position deviation detection mark 25 transferred to the bottom of the runner 31b. In this case, the center of the bottom surface of the runner 31b transported to the measurement position by a transport unit such as a take-out machine (an example of a predetermined reference position) and the + of the misalignment detection mark 25 transferred to the bottom surface of the runner 31b. The amount of positional deviation between the intersections of the characters is measured by a positional deviation measuring device (an example of a measuring unit) provided with an image recognition device such as a CCD camera. The positional deviation measuring device quantifies the amount of positional deviation in the feeding direction of the transfer film 21 and the amount of positional deviation in the width direction of the transfer film 21. If necessary, the amount of positional deviation in the rotational direction around an axis perpendicular to the surface of the transfer film 21 is also digitized.

  Next, details of the in-mold molding apparatus according to the first embodiment will be described with reference to FIGS. 1 (a) and 1 (b).

  The feed motor 15 of the film unwinding unit is a motor that can designate a feed amount by a numerical value, represented by a servo motor or a pulse motor. Similarly, the width direction correction motor 18 of the film unwinding portion is also a motor that can specify the feed amount numerically. The feed direction mark detection sensor 8 installed on the mold is a CCD camera, and recognizes the positioning mark 23 copied on the reflection plate. Alternatively, the feed direction mark detection sensor 8 may be an image sensor or a fiber sensor. The unwinding side line detection sensor 7 of the film unwinding unit is a fiber sensor including a light projecting / receiving device, and detects the edge of the line mark 24 of the transfer film 21.

  The film winding portion width direction correction motor 19 is a motor that can specify the feed amount by a numerical value in the same manner as the film winding portion width direction correction motor 18. The take-up line detection sensor 10 of the film take-up unit is a fiber sensor including a light projecting / receiving device, and detects the edge of the line mark 24 on the transfer film 21.

  In the transfer operation of the transfer film 21, first, in order to remove the distortion of the transfer film 21, the pressing rollers 6 and 12 are opened and closed instantaneously (0.1 seconds to 0.5 seconds). Thereafter, the unwind motor 14 and the feed motor 15 rotate at high speed, and the transfer film 21 is sent out. The unwinding motor 14 and the feeding motor 15 decelerate, for example, when the transfer film 21 is fed 30 to 50 mm before a preset feeding amount. Thereafter, the unwinding motor 14 and the feeding motor 15 are stopped when the feed direction mark detection sensor 8 detects the positioning mark 23. During this time, the take-up motor 17 of the film take-up unit continues to draw the transfer film 21 with a predetermined constant torque. Further, the transfer film 21 is wound around the winding bobbin shaft 13 by driving the bobbin motor 16 of the film winding portion. When the positioning of the transfer film 21 in the transfer direction of the transfer film 21 is completed, the width direction correction motors 18 and 19 are driven so that the film unwinding portion and the film winding portion operate at a low speed in the width direction of the transfer film 21, respectively. When the line detection sensors 7 and 10 detect the edges of the line marks 24 on the transfer film 21, the width direction correction motors 18 and 19 are stopped. During this time, as described above, the winding motor 17 that rotates the winding roller 11 is driven.

  Subsequently, taking the in-mold molding apparatus shown in FIGS. 1 (a) and 1 (b) as an example, the behavior of the transfer film 21 when the pattern displacement occurs in the in-mold molding process will be described with reference to FIGS. This will be described in detail with reference to FIGS. 5B to 9A and 9B. FIG. 5A to FIG. 9A are plan views showing steps of a general in-mold molding method, and FIG. 5B to FIG. 9B are each of the general in-mold molding method. It is sectional drawing which shows a process. FIG. 5A and FIG. 5B to FIG. 9A and FIG. 9B schematically show the transfer film 21 inserted in the mold.

  FIG. 5A and FIG. 5B show the transfer film 21 when the transfer operation (positioning operation) of the transfer film 21 is completed. At this time, the transfer film 21 is held at the traveling position and is not in contact with the movable mold 1 and the film pressing plate 3.

  FIG. 6A and FIG. 6B show the transfer film 21 pressed against the parting surface of the movable mold 1 by the film pressing plate 3. When the film pressing plate 3 presses the transfer film 21, the transfer film 21 is pulled out of the film unwinding portion and the film winding portion from the one having a weak force for holding the transfer film 21. For this reason, the transfer film 21 is drawn into the mold non-uniformly, and the transfer film 21 (the pattern 22) is displaced in the feeding direction of the transfer film 21. The detailed movement of the transfer film 21 at this time will be described with reference to FIG.

  When the transfer film 21 is pressed against the movable mold 1 from the running position, a force for pulling out the transfer film 21 from each of the film unwinding part and the film winding part is generated. At this time, since the film take-up part has a weaker force for holding the transfer film 21 than the film take-out part, the transfer film 21 is pulled out from the film take-up part, and the transfer film 21 on the film take-up part side. Is drawn into the mold. As a result, as shown in FIG. 10, the transfer film 21 (picture 22) is displaced in the feeding direction of the transfer film 21. In FIG. 10, the ideal position of the pattern is indicated by a two-dot chain line. The amount of positional deviation at this time increases as the distance between the running position of the transfer film 21 and the parting surface of the movable mold 1 increases. For example, when the molded product has a deep drawing shape, the distance between the running position of the transfer film 21 and the parting surface of the movable mold 1 increases. This is because when the transfer film that is plastically deformed into the deep drawing shape along the deep drawing shape product surface is sent to the film winding portion, it is necessary to prevent the transfer film from coming into contact with the movable mold. .

  7A and 7B show the transfer film 21 at the start of vacuum suction. As already described, when the molded product has a deep drawing shape, tension exceeding the elastic limit of the transfer film 21 may act on the transfer film 21 during vacuum suction, and the transfer film 21 may be broken. In order to prevent the transfer film 21 from being broken, the force with which the film pressing plate 3 presses the transfer film is adjusted so that the transfer film 21 can slide between the parting surface of the movable mold 1 and the film pressing plate 3. The That is, before the transfer film 21 is torn, the transfer film 21 is drawn from the outside of the film pressing plate 3 toward the concave product surface. For this reason, as shown in FIG. 7A, wrinkles are generated on the outer side of the film pressing plate 3. In addition, the deep drawing here is a standard for a molded product having a depth of 5 mm or more.

  After the transfer film 21 is constrained by the film pressing plate 3, the transfer film 21 is sucked by a suction mechanism (not shown) installed in the movable mold 1 so that the transfer film 21 is along the concave product surface of the movable mold 1. It is stretched within the frame of the plate 3. At this time, as indicated by arrows in FIG. 11, the elongation of the transfer film 21 is relatively large particularly at the four corners of the film pressing plate. However, due to variations in suction force and suction speed, a bias occurs in the direction in which the transfer film 21 extends, and a bias occurs in the extension amount of the transfer film 21 within the mold range. As a result, the transfer film 21 (the pattern 22) is displaced in both the feeding direction and the width direction of the transfer film 21. In FIG. 11, the ideal position of the pattern is indicated by a two-dot chain line. The amount of positional shift at this time is a relatively small amount of the deviation of the extension amount of the transfer film 21.

  FIGS. 8A and 8B show the transfer film 21 at the end of vacuum suction. When the molded product has a deep drawing shape, the transfer film 21 is further drawn from the outside of the film pressing plate 3 toward the concave product surface. The detailed movement of the transfer film 21 during vacuum suction will be described with reference to FIG.

  As shown in FIG. 12, the transfer film 21 is drawn from the outside of the film pressing plate 3 toward the concave product surface by a vacuum suction with a force exceeding the gripping force of the film pressing plate 3. At this time, as indicated by the size of the arrow 121, a difference occurs in the drawing amount of the transfer film 21 between the end and the center on the same side. For this reason, the positional deviation of the pattern 22 occurs in the transfer direction and the width direction of the transfer film. Furthermore, due to the difference in the drawing amount of the transfer film 21, undulations and wrinkles are generated in the transfer film 21. Thereby, the position shift of the pattern 22 increases. At the same time, the transfer film 21 is further stretched toward the concave product surface. In particular, as indicated by arrows 122, the elongation of the transfer film 21 is further increased at the four corners of the film pressing plate 3. This also increases the positional deviation of the pattern 22. In FIG. 12, the ideal position of the pattern is indicated by a two-dot chain line.

  FIG. 9A and FIG. 9B show the transfer film 21 at the time of resin injection. As described above, the movable mold 1 and the fixed mold 2 are clamped, and the movable mold 1 is brought into close contact with the fixed mold 1 to form a cavity space in the mold. Molten resin 91 is injected into the cavity space. At this time, the transfer film 21 is transferred along the resin flow 131 as shown in FIG. 13 by the pressure received by the transfer film 21 from the resin 91 injected toward the concave product surface and the flow of the injected resin 91. The film 21 is stretched. At this time, as shown by an arrow 132, the force to stretch the transfer film 21 becomes non-uniform, and the amount of elongation of the transfer film 21 within the mold range is biased. As a result, the positional deviation of the pattern 22 is shifted. May occur. In FIG. 13, the ideal position of the pattern 22 is indicated by a two-dot chain line.

  As described above, even when the transfer film 21 is accurately positioned at the stage where the transfer film 21 is inserted into the mold, the pattern 22 is displaced in the operation of the film pressing plate 3, the vacuum suction process, and the injection process. However, the cause of the positional deviation of the pattern 22 is diverse. The amount of positional deviation of the pattern 22 varies depending on many factors such as the shape of the concave product surface formed on the mold, the suction force and suction speed during vacuum suction, and the tension acting on the transfer film 21. .

  With respect to such a quality defect due to the positional deviation between the molded product and the pattern, in the first embodiment, the amount of positional deviation between the positional deviation detection mark transferred to the molded product and the molded product. Is directly measured, and the measured amount of positional deviation is reflected in the positioning of the next transfer film 21. Thereby, the precision of the position of the pattern with respect to a molded product improves.

  FIG. 14 is a diagram showing an outline of the flow of the in-mold molding method according to Embodiment 1 of the present invention. Hereinafter, the in-mold molding method according to the first embodiment will be described with reference to FIGS. 1 and 14.

  First, when the positioning of the transfer film 21 is completed (step S1), position correction data is stored in a control unit (not shown) that controls the operation of the foil feeding device including the film unwinding unit and the film winding unit. In that case, the position of the transfer film 21 is corrected (step S2). This position correction will be described later.

  Next, after the transfer film 21 is restrained by the film pressing plate 3, suction of the transfer film 21 by vacuum suction is started (step S3). Next, after the movable mold 1 is in close contact with the fixed mold 2 and the mold is in a clamped state, a molding process is performed (step S4). In the molding process, resin injection, pressure holding, and cooling are performed. When the molding process is completed, the movable mold 1 and the fixed mold 2 are opened, and then the film pressing plate 3 is separated from the movable mold 1 (step S5).

  On the other hand, a take-out machine (not shown) provided with a chuck for gripping a molded product moves to a standby position after the mold clamping is started and until the molding process is completed (step S11). . Thereafter, the take-out machine takes the take-off position between the start of mold opening and the end of the movement of the film pressing plate 3 away from the movable mold 1 or after the movement of the film pressing plate 3 is completed. (Step S12). In place of the take-out machine, a take-out robot provided with a chuck for gripping the molded product may be used. Further, a suction head may be used instead of the chuck.

  When the movement of the film pressing plate 3 away from the movable mold 1 is completed and the movement of the take-out machine to the take-out position is completed, the molded product is pushed out by a push-out mechanism (not shown) installed in the fixed mold 2 (step) S6). As described above, the molded product includes a molded product and runners and sprues that are unnecessary portions attached to the molded product. In conjunction with the ejecting operation of the molded product, the take-out machine grips the extruded molded product (step S13). Thereafter, the take-out machine moves to the standby position (step S14). Next, the take-out machine conveys the molded product to the position deviation detection position (measurement position) (step S15). At this time, the take-out machine may convey the molded product to the position deviation detection position without moving to the standby position.

  At the misalignment detection position, the misalignment measuring device (an example of a measurement unit) 141 determines the amount of misalignment between the misalignment detection mark 25 and the bottom surface of the runner in the film feeding direction and the width direction of the transfer film 21. Measure in both directions. If necessary, the amount of positional deviation in the rotational direction around an axis perpendicular to the surface of the transfer film 21 is also measured. The positional deviation measuring device 141 includes an image recognition device 142 such as a CCD camera, and measures the amount of positional deviation by performing image processing on an image captured or photographed by the image recognition device 142. The amount of this positional deviation is transmitted to the control unit of the foil feeder as position correction data (correction amount data). Specifically, the difference between the center of the bottom surface of the runner and the intersection of the + characters of the position deviation detection mark 25 is transmitted. At this time, the positional deviation measuring device 141 further determines whether or not the measured positional deviation amount is within a preset allowable range, and sends a pass / fail judgment signal representing the determination result to the foil feeding device. Are transmitted to the control unit and the control unit (not shown) of the take-out machine. The setting of the allowable range includes the dimensions of the transfer film 21, the dimensions of the mold, the movable range of the film unwinding portion, the movable range of the film winding portion, and the like. The positional deviation measuring device 141 notifies the correction amount when the positional deviation amount is small or the positional deviation amount is substantially zero and it is determined that the correction of the position of the transfer film 21 is unnecessary. The specification may not be performed.

  Upon receiving the pass / fail judgment signal, the take-out machine moves to a product storage operation or a defective discharge operation. Specifically, the control unit of the take-out machine confirms the pass / fail determination result notified from the positional deviation measuring device 141 (step S16). If the measured amount of positional deviation is within the allowable range (OK in step S16), the take-out machine transports the molded product to the non-defective product storage position (step S17), and then moves to the standby position (step S17). S11). When the molded product is conveyed to the non-defective product storage position, the runner and the sprue are cut from the molded product, and the runner and the sprue are discharged. If the measured positional deviation amount is outside the allowable range (NG in step S16), the molded product is determined to be defective, and the take-out machine conveys the molded product to the defective discharge position (step S18), and thereafter Then, it moves to the standby position (step S11). An alarm signal indicating that the amount of positional deviation is outside the allowable range may be transmitted as the pass / fail determination signal. In this case, the take-out machine moves to the defective discharge operation only when the alarm signal is received.

  On the other hand, the molding machine returns the protruding rod to the original position while the take-out machine is moving to the standby position or after the movement (step S7). When the protruding rod returns to the original position, the control unit of the foil feeding device confirms the pass / fail judgment result notified from the positional deviation measuring device 141 (step S8). When the measured amount of positional deviation is within the allowable range (OK in step S8), the feeding operation of the transfer film 21 is started (step S9). When the measured positional deviation amount is outside the allowable range (NG in step S8), it is determined that the position of the transfer film 21 cannot be corrected, and the operation of the foil feeding device is stopped. At this time, the molding machine may sound an alarm. An alarm signal indicating that the amount of positional deviation is outside the allowable range may be transmitted as the pass / fail determination signal. In this case, the foil feeder stops operating only when an alarm signal is received. Further, the positional deviation measuring device 141 may be configured not to notify the correction amount when transmitting an alarm signal.

  After the operation of the foil feeding device stops, the operator investigates the factors that stopped the operation of the foil feeding device, for example, abnormalities of the transfer film, abnormal mounting state of the transfer film, abnormalities of the molding machine, etc. Make corrections to remove the factor. After completing the correction, the worker restarts the molding machine.

  When positioning of the transfer film 21 is completed (step S1), the foil feeding device corrects the position of the transfer film 21 by dividing the transfer film 21 into the feeding direction and the width direction based on the transmitted position correction data (step S1). S2). First, the transfer film 21 is sent out from the film unwinding portion toward the mold by a correction amount. Thereby, the position of the transfer film 21 in the feeding direction of the transfer film 21 is corrected. At this time, the feed direction mark detection sensor 8 is not used. Next, the width direction correction motors 18 and 19 move the film unwinding portion and the film winding portion by the correction amount in the width direction of the transfer film 21, respectively. The film unwinding unit and the film winding unit may move simultaneously or individually. The order in which the film unwinding unit and the film winding unit move may be any first. While the position of the transfer film 21 is being corrected, the take-up motor 17 continues to pull the transfer film 21 with a predetermined constant torque.

  As described above, in the first embodiment, the tension applied to the transfer film 21 in the transfer direction of the transfer film 21 is measured by the film tension detection unit 9 during the transfer operation of the transfer film 21 and when the position of the transfer film 21 is corrected. Thus, the tension acting on the transfer film 21 in the feeding direction of the transfer film 21 is kept constant. Therefore, it is possible to wind up the transfer film 21 while maintaining a constant tension acting on the transfer film 21 in the feeding direction of the transfer film 21. Further, the foil feeding device includes a lateral feeding mechanism that moves the film unwinding portion and the film winding portion in the width direction of the transfer film 21, and the film unwinding portion and the film winding portion are designated individually or collectively. The amount of movement made can be moved.

  A control unit (not shown) that controls the operation of the foil feeding device controls the operation of the foil feeding device using the stored correction amount data. The stored correction amount data is updated each time correction amount data is transmitted from the positional deviation measuring device 141. Specifically, the correction amount data is updated by adding the correction amount transmitted from the positional deviation measuring device 141 to the stored correction amount. This calculation of the correction amount has an advantage that it can be applied to various in-mold forming apparatuses without requiring a complicated calculation process. Further, the correction amount data is not transmitted to the molding machine for each molding shot, but an average correction amount for each molding 5 shot or molding 10 shot may be calculated and the average correction amount may be transmitted. .

  As described above, in the first embodiment, the case where the + -shaped misalignment detection mark is transferred to the bottom surface of the runner has been described. However, the positional deviation detection mark is not limited to the + character. For example, when the pattern displacement is expected to be larger, or when the shape of the molded product is complicated, the transfer film may be wrinkled and the intersection of + characters may not be read. Due to film elongation, ink discoloration caused by the molten resin coming into contact with the transfer film, ink flow caused by the molten resin flow, etc., it may be difficult to read the intersection of the + characters. In this case, as shown in FIGS. 15 (a) and 15 (b), a mark with a scale on each side of the + character, or as shown in FIGS. 16 (a) and 16 (b), Even if a misalignment detection mark is selected depending on the shape and size of the bottom surface of the runner 31b from among the marks with a plurality of concentric circles centered on the intersection of the + characters as the scale, etc. Good. 15 (a) and 16 (a) show another example of the misalignment detection mark 25 printed on the transfer film 21, and FIGS. 15 (b) and 16 (b) show the bottom of the runner 31b. Another example of the transferred position deviation detection mark 25 is shown.

  Moreover, in this Embodiment 1, the amount of position shift between the center of the bottom face of a runner and the intersection of + character was measured. However, when there is another reference (reference position) for measuring the amount of positional deviation, the center of the bottom surface of the runner may not be the reference (reference position). For example, when there is a protrusion or boundary in the molded product, the amount of misalignment between the protrusion or boundary and the intersection of the + character may be measured. In addition, for example, as shown in FIG. 17, when the pattern 22 includes a character and a frame 171 into which the character enters, the amount of positional deviation between the frame 171 and the intersection of the + character is measured. Also good.

  As described above, in the first embodiment, the case where the correction of the position of the transfer film 21 is automated has been described. However, the correction of the position of the transfer film 21 may be performed manually. That is, various molding conditions may be manually adjusted. In this case, the amount of positional deviation of the positional deviation detection mark 25 may be displayed on a monitor or the like. According to the first embodiment, even when various molding conditions are manually adjusted, the amount of position deviation of the position deviation detection mark 25 is automatically measured, so that the transfer can be performed in a shorter time than conventional. It becomes possible to correct the position of the film.

  The configuration of the in-mold molding apparatus is not limited to the configuration shown in FIGS. 1 (a) and 1 (b). Further, the in-mold forming method is not limited to the flow shown in FIG.

  Further, the unnecessary portion to which the positional deviation detection mark is transferred is not limited to the runner. The misregistration detection mark may be transferred to a member cut off from the molded product after resin injection molding. Therefore, the position where the position deviation detection mark is printed is not limited to the center of each pattern 22. For example, if a part of a molded product is cut off from the molded product after injection molding of the resin to shape the molded product into an undercut shape, it is used to detect misalignment in the part of the molded product that is cut off. The mark may be transferred.

(Embodiment 2)
Subsequently, regarding the second embodiment, matters different from the matters described in the first embodiment will be described. In the second embodiment, the amount of positional deviation of the position deviation detection mark when it is placed along the concave product surface by vacuum suction is measured, and the measured amount of positional deviation is the next transfer film 21. This is reflected in the positioning. Thereby, the precision of the position of the pattern with respect to a molded product improves.

  FIG. 18 is a plan view of a transfer film according to Embodiment 2 of the present invention. As shown in FIG. 18, in the second embodiment, the grid-like scale mark 26 is printed as a misalignment detection mark.

  FIG. 19 (a) is a side view schematically showing a part of the configuration of the in-mold molding apparatus according to the second embodiment of the present invention, and FIG. 19 (b) is a diagram of the in-mold molding apparatus according to the second embodiment of the present invention. It is a top view which shows a part of structure roughly. However, FIG. 19A shows a part of the movable mold 1 in cross section. Further, in FIG. 19B, the fixed mold 2 is omitted.

  As in the first embodiment, the transfer film 21 is restrained by the parting surface of the movable mold 1 by the film pressing plate 3 and then sucked toward the concave product surface of the movable mold 1. As shown in FIG. 19B, when the transfer film 21 is in close contact with the concave product surface, traces 191 such as an edge portion of the product surface and an edge portion of a suction hole opening on the product surface are attached to the transfer film 21. Hereinafter, the trace of the edge portion is referred to as an edge trace.

  In the second embodiment, as shown in FIG. 19A, an image recognition device 192 having a high position resolution such as a CCD camera is attached to the arm 193 or the suction portion 194 of the take-out machine. The image recognition device 192 moves to a measurement position set between the movable mold 1 and the fixed mold 2 while the movable mold 1 and the fixed mold 2 are opened, and the lattice after the vacuum suction is completed. The scale mark 26 is imaged or photographed. Data of the captured or captured image is sent to a misalignment measuring device (an example of a measuring unit) (not shown). The image recognition device 192 installed in the take-out machine needs to have a size that fits into the gap between the movable mold 1 and the fixed mold 2 that are opened. In addition, the bracket etc. which drive independently may be attached to the movable board of a molding machine. In this case, the bracket or the like that supports the image recognition device 192 moves to the measurement position only when the movable platen moves in the mold opening direction.

  Here, the deformation | transformation of the grid-like scale mark 26 by vacuum suction is demonstrated with reference to FIGS.

  FIG. 20 shows a grid scale mark 26 immediately after positioning of the transfer film. At this time, as described in the first embodiment, only the tension generated by the driving of the winding motor 17 acts on the transfer film. For this reason, the grid scale mark 26 is uniform, the shape of each frame of the grid scale mark 26 is square, and the grid scale mark 26 is not misaligned.

  FIG. 21 and FIG. 22 show the state of extension of the grid scale mark 26 when the vacuum suction is completed. Specifically, FIG. 21 shows the grid scale mark 26 when the positional shift of the grid scale mark 26 is small, and FIG. 22 shows the grid scale mark 26 when the positional shift of the grid scale mark 26 is large. .

  As shown in FIGS. 21 and 22, the grid scale mark 26 is entirely extended by vacuum suction, with the center of the concave product surface as the base point. Further, the elongation at the four corners of the grid-like scale mark 26 tends to be large, and the extension at the center of each side constituting the outer frame of the grid-like scale mark 26 tends to be small.

  As described above, the image recognition device 192 captures or captures an image of the grid scale mark 26 after completion of vacuum suction. A position deviation measuring device (not shown) performs image processing on the image transmitted from the image recognition device 192, and measures the deviation of the extension amount of the transfer film within the range of the mold. Specifically, as shown in FIG. 21, among a plurality of frames of the grid-like scale mark 26, a plurality of frames 211 that are stretched by vacuum suction and a plurality of frames that are stretched by vacuum suction are large. 212 is selected. As described above, the extension of the frame of the grid scale mark 26 located at the center of the concave product surface is relatively small, and the extension of the four corner frames of the grid scale mark 26 is relatively large. The selected shapes of the frames 211 and 212 after vacuum suction are compared with the shapes of the frames 211 and 212 stored in advance before vacuum suction. Thereby, the bias | inclination of the elongation amount of the transfer film 21 in the range of a metal mold | die can be measured. This deviation in elongation is monitored for each vacuum suction step. The deviation of the elongation amount may be used to determine whether each molded product molded after each vacuum suction step is a good product or a defective product. Since the shapes of the frames 211 and 212 before vacuum suction are square as described above, the dimensions of the squares are stored in advance.

  As described in the first embodiment, when the molded product has a deep drawing shape, the transfer film is drawn from the outside of the film pressing plate toward the concave product surface. Therefore, the deviation of the pull-in amount of the transfer film is measured by image processing by a position deviation measuring device (not shown). Specifically, the positions in the image of the frames 211 and 212 after the vacuum suction described above are compared with the positions in the image of the frames 211 and 212 before the vacuum suction stored in advance. Thereby, the bias | inclination of the drawing amount of a transfer film can be measured. The deviation of the transfer film pull-in amount is monitored for each vacuum suction step. The unevenness of the transfer film pull-in amount may be used to determine whether each molded product molded after each vacuum suction step is a good product or a defective product.

  Data on the deviation in elongation of the transfer film and data on the deviation in the pull-in amount of the transfer film are accumulated for each vacuum suction process. Thereby, it becomes possible to grasp the tendency of unevenness of the elongation amount of the transfer film and the tendency of unevenness of the pulling amount of the transfer film. Therefore, when the pattern is deviated from the molded product, it can be specified whether the cause is due to the uneven elongation of the transfer film or the uneven pulling amount of the transfer film.

  Further, the positional deviation measuring device (not shown) performs image processing on the image captured or photographed by the image recognition device 192 to obtain the center of the edge trace 191 as shown in FIG. A misalignment measuring apparatus (not shown) determines the amount of misalignment between the center of the edge mark 191 and the intersection of the center lines 26a and 26b of the grid-like scale mark 26, and the transfer film feed direction and the transfer film position. Digitize in both width directions. If necessary, the amount of positional deviation in the rotational direction around the axis perpendicular to the surface of the transfer film is also digitized. As described in the first embodiment, when the molded product has a deep-drawn shape, each of the deviations in the stretch amount and the pull-in amount of the transfer film that occurs during vacuum suction causes the maximum positional deviation between the molded product and the pattern. It becomes a factor of. Therefore, the position of the transfer film after the next positioning is corrected using the amount of pattern displacement at the time of vacuum suction completion as a correction amount, so that it is difficult for position displacement to occur between the next molded product and the pattern. Become. Therefore, in the second embodiment, the amount of misalignment between the center of the edge mark 191 and the center of the grid scale mark 26 is measured. This is because the amount of positional deviation at the center of the grid scale mark 26 when vacuum suction is completed is considered to correspond to the amount of pattern positional deviation when vacuum suction is completed.

  The amount of misalignment measured as described above is transmitted to the control unit of the foil feeder as position correction data (correction amount data) in the same manner as in the first embodiment described above to position the next transfer film. After completion, the foil feeding device corrects the position of the transfer film 21 based on the transmitted position correction data. Since the correction of the position of the transfer film is the same as that in the first embodiment, description thereof is omitted. As described in the first embodiment, when the amount of positional deviation is small or substantially zero and it is determined that the correction of the position of the transfer film is unnecessary, the correction amount is not notified. Also good.

  Similarly to the first embodiment described above, it is determined whether or not the measured amount of positional deviation is within a preset allowable range, and a pass / fail determination signal or an alarm signal is used to control the foil feeder. And the control unit (not shown) of the take-out machine. In the second embodiment, when the amount of positional deviation is outside the allowable range, the take-out machine and the foil feeding device are stopped before the molding process of the molded product. At this time, the molding machine may sound an alarm. The setting of the allowable range includes the dimensions of the transfer film, the dimensions of the mold, the movable range of the film unwinding portion, the movable range of the film winding portion, and the like. After the operation of the foil feeding device stops, the operator investigates the factors that stopped the operation of the foil feeding device, for example, abnormalities of the transfer film, abnormal mounting state of the transfer film, abnormalities of the molding machine, etc. Make corrections to remove the factor. After completing the correction, the worker restarts the molding machine.

  A control unit (not shown) that controls the operation of the foil feeding device controls the operation of the foil feeding device using the stored correction amount data. The stored correction amount data is updated every time the correction amount data is transmitted. Specifically, the correction amount data is updated by adding the transmitted correction amount to the stored correction amount. This calculation of the correction amount has an advantage that it can be applied to various in-mold forming apparatuses without requiring a complicated calculation process. Further, the correction amount data is not transmitted to the molding machine for each shot of molding, but an average correction amount for each molding 5 shot or molding 10 shot is calculated and the average correction amount is transmitted. Good.

  As described above, in the second embodiment, the case where the correction of the position of the transfer film is automated has been described. However, the correction of the position of the transfer film may be performed manually. That is, various molding conditions may be manually adjusted. In this case, the amount of misalignment of the center of the grid scale mark 26 may be displayed on a monitor or the like. According to the second embodiment, even when various molding conditions are manually adjusted, the amount of misalignment at the center of the grid-like scale mark 26 is automatically measured, so that it takes less time than in the past. It becomes possible to correct the position of the transfer film.

  Further, a position deviation measuring device (an example of a measuring unit) provided with the image recognition device 192 compares the shape of a predetermined frame in the grid-like scale mark 26 before and after vacuum suction, so that the transfer film 21 The bias in elongation is measured.

  Further, a position shift measuring device (an example of a measuring unit) provided with an image recognition device 192 compares the position of a predetermined frame in the grid-like scale mark 26 before and after vacuum suction, thereby drawing in the transfer film. The quantity bias is measured.

  Preferably, a frame 211 having a relatively small elongation amount and a frame 212 having a relatively large elongation amount by vacuum suction are selected from the frames of the grid-like scale marks 26 in order to measure the deviation of the elongation amount of the transfer film 21. The Similarly, a frame 211 and a frame 212 having a relatively small elongation amount due to vacuum suction are selected from the frames of the grid scale marks 26 in order to measure the deviation of the transfer film drawing amount.

  In the second embodiment, the grid-like scale mark 26 is used as a position shift detection mark. However, the misregistration detection mark is not limited to the grid scale mark 26. For example, in the case where only the measurement of the positional deviation amount of the positional deviation detection mark at the time of completion of vacuum suction is performed, a mark having an aspect in which the center is known may be used. For example, a + character mark may be used as in the first embodiment.

  Similarly to the first embodiment described above, the position where the misregistration detection mark such as the grid scale mark 26 is printed is not limited to the central portion of each pattern 22.

  Further, the first embodiment described above may be combined with the second embodiment. In this case, the image recognition device 192 of the second embodiment and the image recognition device 142 of the first embodiment may be the same, or the image recognition device 192 and the image recognition device 142 may be provided separately. Good.

  An in-mold molding method and an in-mold molding apparatus according to the present invention include a roll-shaped film with a picture or a roll-shaped transfer film, represented by film in-mold molding, simultaneously with molding of a molded product, and the surface of the molded product. It is useful for technology to transfer to

DESCRIPTION OF SYMBOLS 1 Movable type 1a Parting surface 1b Concave product surface 2 Fixed type 3 Film pressing plate 4 Unwinding bobbin shaft 5 Unwinding roller 6 Unwinding side pressing roller 7 Unwinding side line detection sensor 8 Feed direction mark detection sensor 9 Film Tension detection unit 10 Winding side line detection sensor 11 Winding roller 12 Winding side pressing roller 13 Winding bobbin shaft 14 Winding motor 15 Feeding motor 16 Bobbin motor 17 Winding motor 18, 19 Width direction correction motor 20 Movable platen 21 Transfer Film 22 Picture 23 Positioning mark 24 Line mark 25 Misalignment detection mark 26 Grid scale mark 26a, 26b Center line of grid scale mark 31 Molded product 31a Molded product 31b Runner 31c Sprue 91 Resin 1 1 resin flow 141 positional displacement measurement apparatus 142 the image recognition device 191 edge marks 192 image recognition apparatus 193 arm 194 chucks 211 and 212 grid-like scale marking frame 231 transfer film 232 positioning marks 233 line mark 234 picture

Claims (12)

While transferring the transfer film from the film unwinding section to the movable mold and the film pressing plate, the transfer film fed from between the movable mold and the film pressing plate is wound up by the film winding section, and the transfer film A film feeding process for positioning,
Constraining the transfer film to the movable mold by the film pressing plate;
A step of vacuum sucking the transfer film so that the transfer film is along the movable concave product surface;
Closing the movable mold and the stationary mold to form a cavity space;
Injecting resin into the cavity space to mold a molded product and an unnecessary part associated with the molded product, and at the same time, transferring a pattern to the surface of the molded product and transferring a displacement detection mark to the unnecessary part. When,
Opening the movable mold and the fixed mold, and taking out the molded product accompanied by the unnecessary portion;
Measuring the amount of misalignment between the misalignment detection mark transferred to the unnecessary portion and a predetermined reference position;
An in-mold molding method comprising:   The in-mold molding method according to claim 1, wherein the unnecessary portion is a runner.   The transfer film position is corrected according to the amount of positional deviation measured before the transfer film positioning operation after the transfer film positioning operation in the film feeding step is completed. 3. The in-mold molding method according to 1 or 2. While transferring the transfer film from the film unwinding section to the movable mold and the film pressing plate, the transfer film fed from between the movable mold and the film pressing plate is wound up by the film winding section, and the transfer film A film feeding process for positioning,
Constraining the transfer film to the movable mold by the film pressing plate;
A step of vacuum sucking the transfer film so that the transfer film is along the movable concave product surface;
Measuring the amount of misalignment between the misalignment detection mark printed on the transfer film adsorbed on the concave product surface and a predetermined reference position;
Closing the movable mold and the stationary mold to form a cavity space;
Injecting resin into the cavity space to mold a molded product, and simultaneously transferring a pattern to the surface of the molded product;
Opening the movable mold and the fixed mold, and taking out the molded product;
An in-mold molding method comprising:   The transfer film position is corrected according to the amount of positional deviation measured before the transfer film positioning operation after the transfer film positioning operation in the film feeding step is completed. 4. The in-mold molding method according to 4.   The in-mold molding method according to claim 4 or 5, wherein the misalignment detection mark is a grid scale mark. A transfer film printed with a pattern transferred to a molded product, and a misalignment detection mark transferred to an unnecessary portion accompanying the molded product;
A movable mold with a concave shaped product surface;
A film pressing plate that restrains the transfer film on the movable mold;
A fixed mold that forms a cavity space with the movable mold;
A foil feeding device for winding the transfer film fed from between the movable mold and the film pressing plate and positioning the transfer film while feeding the transfer film between the movable mold and the film pressing plate;
A suction mechanism for vacuum-sucking the transfer film so that the transfer film is along the concave product surface;
A measurement unit that measures the amount of positional deviation between the positional deviation detection mark transferred to the unnecessary part taken out between the fixed mold and the movable mold and a predetermined reference position;
The resin is injected into the cavity space, and the molded product and the unnecessary portion are molded. At the same time, the pattern is transferred to the surface of the molded product, and the displacement detection is performed on the unnecessary portion. An in-mold molding apparatus, wherein a mark is transferred.   The in-mold molding apparatus according to claim 7, wherein the unnecessary portion is a runner.   After completing the positioning operation of the transfer film by the foil feeding device, the foil feeding device corrects the position of the transfer film according to the amount of positional deviation measured before the positioning operation of the transfer film. The in-mold molding apparatus according to claim 7 or 8, characterized in that A transfer film on which a misalignment detection mark is printed together with a pattern;
A movable mold with a concave shaped product surface;
A film pressing plate that restrains the transfer film on the movable mold;
A fixed mold that forms a cavity space with the movable mold;
A foil feeding device for winding the transfer film fed from between the movable mold and the film pressing plate and positioning the transfer film while feeding the transfer film between the movable mold and the film pressing plate;
A suction mechanism for vacuum-sucking the transfer film so that the transfer film is along the concave product surface;
A measuring unit that measures the amount of positional deviation between the positional deviation detection mark of the transfer film adsorbed on the concave product surface and a predetermined reference position;
An in-mold molding apparatus, wherein a resin is injected into the cavity space to mold a molded product, and at the same time, the pattern is transferred to the surface of the molded product.   After completing the positioning operation of the transfer film by the foil feeding device, the foil feeding device corrects the position of the transfer film according to the amount of positional deviation measured before the positioning operation of the transfer film. The in-mold molding apparatus according to claim 10. The in-mold molding apparatus according to claim 10 or 11, wherein the misalignment detection mark is a grid scale mark.

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