JP2825725B2 - Method for manufacturing plastic mirror, apparatus for manufacturing the same, and method for manufacturing plastic molded product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a plastic mirror, an apparatus for manufacturing the same, and a method for manufacturing a plastic molded product. The present invention relates to a method for producing a molded article.

[0002]

2. Description of the Related Art Conventionally, plastic mirrors and fθ mirrors used for optical scanning of laser printers and copiers are frequently used because of their small quantity and variety. Higher precision is required for the mirror surface in accordance with the development.

As a method of manufacturing a plastic mirror of this type, first, a high-precision mirror surface of a mold is transferred by injection molding or injection compression molding, and then a predetermined metal is directly deposited on the mirror surface portion of the molded product. To form a metal reflective film to form a mirror surface. Further, in order to improve the adhesion between the metal reflection film and the molded product, MgF
_In order to improve the strength of the metal reflection film, a protective film such as SiO ₂ is formed on the surface of the metal reflection film in order to improve the strength of the metal reflection film. Such a plastic mirror manufacturing method is described in, for example, Japanese Patent Publication No. 61-25131 and Japanese Utility Model Application Laid-open No. Sho 59-116905.

Further, a metal reflection film is formed on a plastic film, and the metal reflection film side of the plastic film is sucked to a mirror surface of a mold by suction or the like, and then resin is injected from the back side of the metal reflection film of the plastic film. Molded,
A plastic mirror manufacturing method for laminating a mirror surface has been put to practical use. Such a plastic mirror manufacturing method is described in, for example, Japanese Patent Publication No. Hei 4-9647 and Japanese Patent Application Laid-Open No. 62-224533.

[0005]

However, in the method of manufacturing a plastic mirror by vapor deposition, a predetermined surface is formed by directly vapor-depositing a predetermined metal on a mirror surface portion by batch processing, so that the cost is high. Since the shape differs depending on the application, there is a problem that the deposition conditions must be changed for each molded product and the operation becomes complicated. Further, when the mirror surface has irregularities, there is a problem that a uniform metal reflection film cannot be formed.

A method of manufacturing a plastic mirror by laminating has an advantage that a plastic mirror manufacturing apparatus can be manufactured by adding equipment with a small investment to an existing injection molding apparatus, but a plastic film is adsorbed. Since the molten resin is injected into the cavity, the plastic film is deformed by wrinkles and the like due to the high temperature and the flow pressure during the injection molding, and there is a problem that a highly accurate mirror surface cannot be obtained.

On the other hand, a specific method of forming a metal reflection film on a plastic base material constituting a plastic molded product such as a plastic mirror or the like before depositing or laminating a metal reflection film is described in JP-A-4-163119. There is a manufacturing method. This has a step of injecting a molten resin into a cavity of an injection mold to previously mold a plastic base material having a substantially final shape, and has a volume equivalent to the cavity of the mold, and has at least one or more After inserting the plastic base material into an aging mold having one or more cavities having a mirror surface, the mirror surface is transferred to the base material by the internal pressure of the plastic base material by heating above the glass transition point temperature, An aging step of opening and removing the aging mold when the mold is cooled and the internal pressure of the base material becomes equal to the atmospheric pressure below the heat deformation temperature of the resin.

FIG. 2 shows a specific configuration of the aging mold.
As shown in FIG. 1 (a), the aging mold is composed of an upper mold 203 and a lower mold 204 on which mirror surface pieces 201 and 202 having mirror surfaces 201a and 202a are slidably provided. By inserting and aging a plastic base material formed into a substantially final shape by injection molding into a cavity 205 formed in a space defined by the molds 203 and 204,
The mirror surface is transferred to the base material.

After the aging, the mirror pieces 201 and 202 are respectively moved in the vertical direction to prevent the transferred mirror surface from being damaged, thereby forming the convex lens 206 shown in FIG. 21B. Also, when forming a borgon mirror, a plastic base material is inserted into the cavity 212 of the molds 210 and 211 as shown in FIG.
The mirror surface is transferred to the base material by inserting the motor shaft 215 into the inner periphery of the base material and performing aging. Then, after the aging, the mirror pieces 213 and 214 having the mirror surfaces 213a and 213b are moved in the left and right directions,
Take out the motor shaft 215 from the inner periphery, and mold 210, 21
Open the mold 1 and use the polygon mirror 2 as shown in FIG.
Mold 16

However, in such a method for manufacturing a plastic molded product, the weight of the plastic base material at the time of removal in the aging step is limited to a pressure at which the internal pressure of the resin becomes the atmospheric pressure at a temperature lower than the heat deformation temperature. The problem has occurred. For this reason, if the weight is small, the molded product will sink and the mirror surface cannot be sufficiently transferred, and if the weight is large, the molded product will be correspondingly large. And the molding cycle was lengthened. In addition to this, if the molding cycle is long, many cavities are provided in the aging mold to improve productivity,
It is required to remove a large number of molded products from the cavity. However, in consideration of the variation occurring in the plastic base material, it is presently not allowed to cause variation in each cavity space of the aging mold.

As described above, in the conventional method for producing a molded plastic article, it is necessary to strictly control the weight of the plastic base material. This weight variation must be at least about ± 0, 2%, preferably about ± 0, 1%.
For this reason, a large-sized molded product weighing 5 g falls within this range by ordinary precision injection molding, but falls below 5 g when falling below 5 g.

Therefore, in the conventional manufacturing method, in order to strictly inspect the weight of all the molded products taken out from the aging mold and remove those out of the range, a 100% inspection process is required, There has been a problem that the yield of molded articles is reduced and productivity is deteriorated. In addition, the conventional aging mold has a mirror surface piece 20 to prevent the mirror surface from being damaged.
Since 1, 202, 213, and 214 were provided, the mold became large and complicated, and it was difficult to achieve multi-cavity.

Therefore, the invention according to claims 1 to 15 is a plastic mother having a mirror-finished portion formed into a substantially final shape.
Insert the material and the film with the reflective film into the cavity.
Put the plastic base material and film into uniform temperature,
It is an object of the present invention to provide a low-cost plastic mirror manufacturing method and a manufacturing apparatus for manufacturing a high-precision mirror surface by transferring a mirror surface of a mold with high accuracy by heating and joining with uniform pressure. .

Further, according to the invention of claims 16 to 23, even if there is a slight variation in the weight of the plastic base material, the weight is strictly controlled by compensating for this variation with each base material. Can be unnecessary, and 1
Provided is a method of manufacturing a plastic molded product that can take out a large number of molded products from one cavity of one aging mold, can improve productivity, and can be molded with high precision. The purpose is.

[0015]

In order to achieve the above object, an invention according to claim 1 includes a pair of dies having at least one mirror surface which are arranged to face each other and define at least one cavity. A thermoplastic base material pre-processed to a substantially final shape in advance and a film having a reflective film having the same area or less as the mirror surface of the mold are prepared, and the film and the plastic base material are formed on the reflective film side of the film. The mirror is brought into contact with the mirror surface, and the plastic base material is inserted into the cavity so that the plastic base material is located on the back side of the reflective film of the film. depending on whether either, or pressurized <br/> pressure before and after the glass transition point heating to transfer the mirror surface reflection film of the film by generating a predetermined resin pressure in the cavity, then gradually cooled mold hand Plastic base material is characterized in that the taking out from the cavity when it is below the thermal deformation temperature.

According to a second aspect of the present invention, the film is
The projection film is formed by electroless plating, vapor deposition or sputtering. Claim 3
The described invention is characterized in that an amorphous resin is used for the plastic base material.

According to a fourth aspect of the present invention, the same material is used for the plastic base material and the film . According to a fifth aspect of the invention, in advance, the plug
Stick the base material to the film or the film
A thermosetting or hot-melt adhesive layer is provided on at least one of the back sides of the film , and the adhesive layer is formed of plastic.
In the cavity so that it is between the base material and the film
Inserting and joining the plastic base material and the film .

The invention according to claim 6 is characterized in that an amorphous plastic composite material containing a reinforcing filler such as fiber is used as the plastic base material. The invention according to claim 7 is that the film has a thickness of 50 μm to 800 μm.
It is characterized in that it has a thickness of μm. The invention according to claim 8 is characterized in that the plastic base material or
Is characterized in that at least one of the films is heated to a deformable temperature in advance and then inserted into the cavity.

According to a ninth aspect of the present invention, the film is heated to a deformable temperature in advance, deformed into a shape substantially equal to the mirror surface shape, and then inserted into the cavity. is there. According to a tenth aspect of the present invention, at least one of the surfaces of the plastic base material and the film that are in contact with each other is roughened to a predetermined surface roughness by a chemical or physical treatment. is there.

[0020] The invention according to claim 11 is the invention of the film,
A protective film is formed on the surface of the reflective film . According to a twelfth aspect of the present invention, there is provided an insertion portion to be inserted into the mirror surface of the mold, and a positioning portion provided near the insertion portion and formed on the mold when the insertion portion is positioned on the mirror surface. A film having a reflective film provided continuously with an engaging portion to be inserted and a support portion for supporting the insertion portion in the feed direction is prepared.
And feeds and inserts the film by the film feeder.
While inserting the reflective film at the entrance into the mold so that the reflective film is in contact with the mirror surface, the plastic base material is inserted by the base material supply device.
After inserting into the mold so as to be located on the back side of the reflection film at the entrance, the mold is clamped, and before or after the plastic base material is melted, the operation of cutting the insertion portion from the support portion is performed by filling.
This is characterized in that it is performed continuously in accordance with the feed amount of the program .

According to a thirteenth aspect of the present invention, after inserting the plastic base material and the film into the cavity and clamping the mold, a predetermined resin internal pressure is generated in the cavity while the interior of the cavity is evacuated. It is characterized by the following. Invention, the plug according to claim 14, wherein
The surface in contact with the film of the stick base material has a radius of curvature smaller than the radius of curvature of the mirror surface when the mirror surface of the mold is formed in a convex shape, and the curvature of the mirror surface when the mirror surface shape is formed in a concave shape. It is characterized by being formed with a radius of curvature larger than the radius.

According to a fifteenth aspect of the present invention, there is provided a pair of dies having one or more mirror surfaces which are arranged to face each other and which form at least one or more cavities, and which have a positioning portion for aligning each other. Forming a plastic base material having a substantially final shape and a reflection film to which the mirror surface is transferred
The inserted film is inserted into the cavity and
Bonding the stick base material and film a plastic mirror manufacturing apparatus for forming a plastic mirror, wherein
An insertion portion in which the film is inserted into the mirror surface of the mold, and an engagement portion provided near the insertion portion and engaged with a positioning portion formed on the mold when the insertion portion is positioned on the mirror surface. , And a supporting portion for supporting the insertion portion, in the feed direction, and before the film is inserted into the cavity of the mold , the insertion portion of the film is heated to a deformable temperature and the mirror surface of the substantially final shape is formed. Forming means for forming, base material supply means for supplying a plastic base material into the cavity, film supply means for transporting a film insertion portion to a mirror position of the mold, and mold clamping for opening and closing the mold. Opening means, pressurizing means for applying a predetermined pressure to the mold, heating / cooling means for heating the mold and cooling the mold at a predetermined temperature gradient, and cutting the insertion portion from the plastic film support portion Cutting means for cutting and the plastic And retrieval means for retrieving a disconnected molded article from click film, is characterized in that it comprises a.

Here, the amorphous resin is an alkali resin, a polycarbonate resin, an amorphous polyolefin or the like. In addition, the reinforcing material is glass fiber,
Carbon fiber, mica, and the like improve strength and Young's modulus. The invention according to claim 16 is substantially equivalent to
Aging gold with a constant weight of plastic base material in the final shape
Inserted into the cavity of the mold, then heated above the glass transition temperature of the resin to transfer the mirror surface to the base material by the internal pressure of the resin, and then gradually cooled for a predetermined time, and then the internal pressure of the resin was large below the thermal deformation temperature of the resin. In the method of manufacturing a plastic molded article, in which the plastic molded article is taken out of the aging mold when the pressure becomes substantially equal to the atmospheric pressure, at least
One or more cavities with one or more mirrors
An aging mold to be prepared is prepared, and aging is performed by simultaneously inserting a plurality of plastic base materials and a plurality of separating members for separating the base materials into cavities of the aging mold. .

The invention according to claim 17 is characterized in that a material having a higher heat deformation temperature than a plastic base material is used as the isolation member. The invention according to claim 18 is
The thickness of the isolation member is 0, 1 to 100 μm. The invention according to claim 19 is characterized in that a metal member having a thickness of 0.5 mm or more is used as the separating member, and both ends in the longitudinal direction of the separating member can be slid on an aging mold. And

The invention according to claim 20 is characterized in that members having high releasability are used as the separating members, and two separating members are provided between the respective plastic base materials. In the invention according to claim 21, a plastic base material and an isolating member are alternately inserted into the aging mold so as to be adjacent to each other, and a model having the same shape as the base material is used for the plastic members at both ends in the adjacent direction. It is characterized by:

According to a twenty-second aspect of the present invention, the thermal conductivity and the thickness of the walls of the aging mold at both ends in the adjacent direction of the plastic base material and the separating member are the same as those of the separating member. In addition, the thermal conductivity and the thickness of the portion adjacent to the wall portion are made to be the same as the thermal conductivity and the thickness of the plastic base material, and the plastic base material and the isolation member are adjacent to each other in the aging mold. Aging is performed by alternately inserting.

According to a twenty-third aspect of the present invention, a reflective film is provided on the surface.
Providing a coated film, the film and a plus
The tic preform is inserted into the cavity of the aging mold such that the reflective film side of the film contacts a plurality of mirror surfaces, and the plastic preform is located on the back surface of the film.

[0028]

According to the first aspect of the present invention, the reflection film is formed on one side.
After the formed film and the plastic base material formed into a substantially final shape are inserted into the cavity of the mold to melt the plastic base material, a resin internal pressure is generated in the cavity and a predetermined pressure is reached. Gradually cool to below the heat distortion temperature and apply plastic and plastic without strain and stress .
To the base metal. At this time, it is reflected by the resin internal pressure.
Since the film is pressed against the mirror surface of the mold, a highly accurate mirror surface can be obtained even if the thickness of the reflection film is not uniform.

According to the second aspect of the present invention, the reflective film is deposited by vapor deposition or sputtering in order to make the film thickness uniform. since it is possible, use a low-cost electroless plating
Thus, a reflective film can be formed on one side of the film . According to the third aspect of the present invention, since an amorphous resin having good transferability is used for the plastic base material, a mirror surface with higher precision is obtained.

In the present invention, since the same material is used for the plastic base material and the film , the plastic material is used.
The adhesion and bonding between the base material and the film are improved.
Further, since the film and the plastic base material are integrated, the influence of stress, temperature, humidity and the like is reduced.
In the invention according to claim 5, a film of a plastic base material
At least on the bonding side or the back side of the film's reflective film
Also, an adhesive layer is provided on one of the
Since the film is joined , the adhesion and the joining property between the film and the plastic base material are further improved.

In the sixth aspect of the present invention, since the amorphous plastic composite material containing the reinforcing filler such as fiber is used for the plastic base material, the deformation of the mirror surface due to stress, temperature change and the like is prevented. In the invention according to claim 7, the fill
Since the thickness of the film is 50 μm to 800 μm,
Due to the mechanical stress at the time of insertion into the mold and the thermal stress at the time of heating that occur when using a film of less than 50 μm
Deformation such as wrinkling of the reflective film, or the material of the plastic base material
To prevent the reflection film from being affected by the
Transfer mirror surface of mold that occurs when using film
This prevents the reflective film from wrinkling or cracking due to the shape deformation at the time of the transfer, and prevents transfer accuracy from deteriorating due to distortion due to the difference in heat shrinkage rate from the plastic base material.

[0032] In the invention according to claim 8 , at least one of the plastic base material and the film is preliminarily changed.
Since heating is performed to a temperature at which the mold can be formed, distortion generated when the mirror surface of the mold is transferred to the film is prevented, and transfer accuracy is prevented from being reduced. Furthermore, the molding cycle is shortened. According to the ninth aspect, the film can be deformed in advance.
After heating to a suitable temperature and forming approximately the same as the mirror surface of the mold,
Since the film is inserted into the cavity, the film is easily inserted into the mold, and the transfer accuracy of the mirror surface of the mold is further improved.

According to the tenth aspect of the present invention, at least one of the surfaces of the plastic base material or the film which are in contact with each other.
Since one of the surfaces is roughened to a predetermined surface roughness,
Adhesion and bonding between the film and the plastic base material are further improved. In the invention according to claim 11, the film is
Since the protective film is formed on the surface of the reflective film, the mechanical and temporal deterioration of the metal reflective film is prevented.

In the twelfth aspect of the present invention, the position of the insertion portion is determined by engaging the engagement portion with the positioning portion of the mold, and the insertion portion and the plastic base material are inserted into the mold to clamp the mold. The supporting part is cut before or after the plastic base material is melted, so the film insertion part is automatically fed into the mold.
And the molded product can be automatically ejected from the mold.
You. Also, the reflective film is not formed on the entire surface of the film.
Can be formed only on the
A spray film can be formed.

[0035] In the present invention of claim 13, wherein, in the cavity to melt the plastic matrix while evacuating the resin pressure is generated within the cavity, Oyo plastic matrix
Since the film and the film are joined, it is possible to prevent air or the like from entering between the film and the plastic base material, thereby preventing the transfer accuracy of transferring the mirror surface of the mold from being lowered.

In the invention according to claim 14, the plastic is
The surface in contact with the film of the base material has a radius of curvature smaller than the radius of curvature of the mirror surface when the mirror surface shape of the mold is convex, and the surface of the mirror surface when the mirror surface shape is concave. Inserts plastic base material and film into the mold because it is formed with a radius of curvature larger than the radius of curvature
When the mold is closed, the plastic base metal
The surface in contact with the lum is in close contact with the mirror surface via the film, and the transfer accuracy of the mirror surface of the mold is further improved.

According to the fifteenth aspect of the present invention, the insertion portion of the film is heated to a deformable temperature by the molding means and is formed substantially in the same shape as the mirror surface of the mold, so that the insertion portion can be easily inserted into the cavity. Then, the plastic base material is inserted into the cavity by the base material supply means. Then, a predetermined pressure is applied by the pressurizing unit, the predetermined temperature is applied by the heating and cooling means the resin in the pressure is generated in the cavity, with the mold specular surface is transferred to the insertion portion plus
The tic base material and the film are joined and gradually cooled at a predetermined temperature gradient. Therefore, the mirror surface of the mold is transferred with high accuracy without applying stress to the insertion portion.

After the joining of the plastic base material and the film , the supporting portion is cut by the cutting means, and the molded product is taken out by the taking out means. Therefore, since the film and the plastic base material are automatically and continuously inserted into the mold and the molded product is taken out, the productivity is improved and the quality is stabilized. In the invention according to claim 16,
One or more cavities having at least one mirror surface
An aging mold having an aging mold is prepared, and a plurality of plastic base materials and a plurality of separating members for separating the base materials are simultaneously inserted into a cavity of the aging mold to perform aging.

Accordingly, when the aging mold is heated and the internal pressure of the resin is generated and melted in the plastic base material, each base material partitioned by each separating member has a divided cavity volume corresponding to its weight, and the separated base material has a divided cavity volume. The internal pressure of each base material defined by the member is constant throughout the cavity. For this reason, even if variations occur in the respective base materials, the respective base materials cancel each other and approach the average value. Therefore, when the plastic base material is gradually cooled and taken out of the mold at a temperature equal to or lower than the thermal deformation temperature of the resin, pressure variation does not occur, so that a mirror-like transfer failure such as sink marks does not occur in the molded product. . As a result, it is not necessary to strictly control the weight of the plastic base material, and a large number of molded products are taken out from one aging mold, and a high-precision plastic molded product is obtained. Is improved. Further, since a large number of base materials can be inserted into one cavity for aging, the size of the aging mold can be reduced.

In the seventeenth aspect of the present invention, the isolation member having a higher heat deformation temperature than the plastic base material is used. Therefore, when the aging mold is heated and the plastic base material is melted, the base material is not welded to the separating member, and the plastic base material is not bonded via the separating member. Therefore, after aging, a large number of molded products are reliably separated from the mold and taken out, so that the yield of plastic molded products does not decrease. In the invention according to claim 18, the separating member has a thickness of 0, 1 to 100.
μm is used. This is because it is only necessary that the plastic base material can be separated and taken out of the mold without being joined. Therefore, if the thin isolation member is inserted into the mold by bonding the thin isolation member to the plastic base material in advance, the volume occupied by the isolation member in the cavity is reduced, and even if the isolation member has some thickness variation. The required resin internal pressure is generated stably. Therefore, a high-precision molded product can be obtained while reducing the size of the mold or taking out a large number of molded products in the same cavity.

According to the nineteenth aspect of the present invention, the separating member is made of metal having a thickness of 0.5 mm or more, and both ends of the separating member in the longitudinal direction come into sliding contact with the aging mold. ing. Therefore, the isolating member is slid in the cavity, and a uniform internal resin pressure is stably generated throughout the cavity, so that a highly accurate molded product can be obtained. Further, since the isolating member is made of metal like the metal mold, the temperature distribution in the cavity defined by the isolating member is made uniform by utilizing the thermal conductivity of the isolating member, and a uniform molded product is obtained. Can be

According to the twentieth aspect of the present invention, members having high releasability are used as the separating members, and two separating members are provided between the respective plastic base materials. Therefore,
The separating member and the plastic base material are integrally inserted into the cavity, so that the inserting operation is easily performed and the productivity is improved. Then, the plastic members are easily separated from each other by separating the separating members after aging.

According to the twenty-first aspect of the present invention, a plastic base material and an isolating member are alternately inserted adjacently into an aging mold, and the plastic members at both ends in the adjacent direction have the same shape as the base material. Is used. This is done in order to prevent a situation in which each plastic base material in the cavity is not manufactured uniformly due to the shape of the plastic base material, the slow cooling rate, and the like. It becomes remarkable at both ends and the center of the base material in the adjacent direction. Therefore, by inserting the models at both ends in the adjacent direction and aging the plastic base material, it is possible to prevent the base materials from being varied, thereby obtaining a uniform molded product.

In the invention according to claim 22, the thermal conductivity and the thickness of the walls of the aging mold at both ends in the adjacent direction of the plastic base material and the separating member are made of the same material as the thermal conductivity and the thickness of the separating member. And the thermal conductivity and thickness of the portion adjacent to the wall portion are made of the same material as the thermal conductivity and thickness of the plastic base material, and the plastic base material is placed in the aging mold. Aging is performed by alternately inserting the and the isolation member adjacent to each other. Therefore, the work of inserting the model into the cavity every time aging is not required, and the productivity of the molded product is improved.

According to a twenty-third aspect of the present invention, a reflective film is provided on the surface.
A coated film is prepared and the reflective side of the film is
The film is brought into contact with a plurality of mirror surfaces and the plastic base material is
The film and plastic preform are inserted into the cavity of the aging mold so as to lie on the back of the mold. Therefore, a large number of plastic mirrors can be easily manufactured at one time, and high-precision plastic mirrors can be manufactured at low cost and in large quantities.

[0046]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. FIGS. 1 to 6 are views showing one embodiment of a plastic mirror manufacturing apparatus for carrying out a first embodiment of a plastic mirror manufacturing method according to the present invention. First, the configuration will be described.

1 to 6, reference numeral 10 denotes a pressing device, and the pressing device 10 includes a pair of an upper die 11 and a lower die 12.
And a predetermined pressure is applied between the upper and lower dies 11, 12. Reference numeral 20 denotes a mold. The mold 20 includes a pair of an upper mold 21 and a lower mold 22 provided with positioning portions 25 and 26 (shown in FIGS. 2 and 3) for aligning each other.
1, 22 are fixed to the opposing surfaces of the upper and lower dies 11, 12, and the mold 20 defines a plurality of cavities 24 in which a mirror surface 23 is formed by matching the opposing surfaces of the upper and lower dies 21, 22. . The cavity 24 of the mold 20 communicates with a vacuum device (not shown) via a passage (not shown), and the air in the cavity 24 is evacuated by the vacuum device. Also, this mold 20 is
As a result, a predetermined pressure is applied to the cavity 24, for example, by vibration pressure, and the cavity 24 is opened. That is, the press device 10 constitutes a mold clamping / opening unit and a pressing unit of the mold 20. Further, the press device 10 includes, for example, a heating medium such as a bar heater or a heating wire, and a refrigerant such as water and oil, and a heating / cooling unit 13 for heating and cooling the mold 20 at a predetermined temperature gradient. The mold 20 is heated under predetermined temperature conditions and gradually cooled.

Reference numeral 31 denotes a plastic base material. The plastic base material (hereinafter simply referred to as base material) 31 is made of, for example, an amorphous resin such as an acrylic resin, a polycarbonate resin, and an amorphous polyolefin. It is formed in a substantially final shape equivalent to the space to be formed. The base material 31 is inserted into the cavity 24 of the mold 20 by the base material supply device 40 shown in FIG.

The substantially final shape of the base material 31 is preferably formed by injection molding in terms of productivity.
Although the base material 31 may be formed using the same, since the mirror surface 23 of the mold 20 is formed in a concave shape, the surface corresponding to the mirror surface 23 of the base material 31 has a curvature larger than the radius of curvature of the mirror surface 23. Separately, a base metal mold having a radius of curvature larger than the radius of curvature of the mirror surface 23 is prepared so as to form a convex shape with a radius, and a molten amorphous resin is injected into the cavity of the base metal mold and heated. It is preferable to form the base material 31 by cooling to a temperature lower than the deformation temperature. Since the base material 31 is again melted and gradually cooled in the mold 20, it is not necessary to gradually cool the base material 31 so as not to cause distortion in forming the base material 31, and the base material 31 can be formed quickly. In addition,
Needless to say, by keeping the temperature of the base material molding die at the time of injection molding of the base material 31 at or below the thermal deformation temperature of the amorphous resin to be injected, the operation time is further shortened. Also,
It goes without saying that the base material 31 may be formed by mechanical processing using a lathe or the like.

Reference numeral 32 denotes a plastic film. The plastic film (hereinafter, also simply referred to as a film) 32 is made of an amorphous resin having an excellent bonding property with the base material 31, and aluminum is formed on one side by, for example, electroless plating. The metal reflection film 33 is formed by coating. This film 32 includes
As shown in FIG. 2, the number of mirrors 23 of the mold 20 corresponds to the number of mirrors 23, the insertion part 37 that transfers the mirror surface 23, the support part 38 that supports the insertion part 37, and the positioning part 25 of the mold 20. the engaging portion 39 align with the combined and the insertion portion 37 and the mirror 23, but is provided with a plurality, the insertion portion 37 of the film 32 continuously for a predetermined feeding amount to be inserted into cavity 24 ing.

The film 32 and the base material 31 are made of a film
The metal reflection film 33 of the insertion portion 37 of the mold 32 is inserted so as to be in contact with the mirror surface 23 of the mold 20, and the metal reflection film 33 of the insertion portion 37 is inserted so that the back side of the metal reflection film 33 becomes the base material 31. The mold clamping / opening means of the press device 10 clamps the mold. As shown in FIG. Vibration pressure is applied to generate an internal resin pressure inside the cavity 24, and the mirror surface 23 of the mold 20 is transferred to the metal reflection film 33 of the insertion portion 37 to form the molded product 30 shown in FIG.
Further, the insertion portion 37 of the film 32 is heated to a deformable temperature by a molding device 50 shown in FIG. The reflecting film 33 side is formed in advance to be approximately equivalent to the mirror surface 23 shape of the mold 20.

The heat deformation temperature of this film 32 is
It is preferable that the base material 31 is made of an amorphous resin of the same material as the base material 31 as shown in FIG.
Needless to say, it can be integrated with 31 and is more preferable. The metal reflection film 33 may be deposited on the film 32 by sputtering or vapor deposition, but it is more advantageous to cover the metal reflection film 33 by electroless plating from the viewpoint of manufacturing cost and mass productivity. In addition, the metal reflection film 33 needs to have the same area or less as the mirror surface 23 of the mold 20. It is possible to use a means of punching and using the same area or less.

In FIG. 3, the base material supply device 40 is a mold.
The base material supply means for supplying the 20 base materials 31 is provided, and an engagement hole 41 is provided for engaging with the positioning portion 25 provided in the lower mold 22 of the mold 20. The base material supply device 40 has an engagement hole 41.
Engages with the positioning portion 25 to align the position with the mold 20, and places the base material 31 held by a suction means (not shown) or the like on the insertion portion 37. .
Further, a heating means for heating the base material 31 held in the base material supply device 40 may be provided.

The molding device 50 constitutes a molding means for molding the insertion portion 37 of the film 32 in advance.
It consists of 52. Opposite surfaces of the upper and lower dies 51 and 52 are formed in a mirror surface 23 shape of the mold 20, and the upper die 51 side is formed in a convex shape and the lower die 52 side is formed in a concave shape. The molding device 50 includes a heating unit that holds the upper and lower dies 51 and 52 at a predetermined temperature.
Without inserting the insertion portion 37 between the opposing surfaces of the upper and lower dies 51, 52, and by applying a predetermined pressure so as to match the surfaces by heating to a deformable temperature without distorting The insertion section 37 is formed by press molding.

Reference numeral 60 denotes a cutting device. The cutting device 60 has a pair of blades 61, and constitutes cutting means for descending to cut the support portion 38 of the film 32 and cut off the insertion portion 37 from the film 32. I have. Reference numeral 70 denotes a molded product take-out device. 72 and constitutes a molded product taking-out means.

Reference numeral 75 denotes a film supply device. The film supply device 75 takes up a predetermined amount of the film 32 from which the transfer unit 37 has been cut off based on a signal from the controller.
This constitutes a film supply means for transporting the insertion portion 37 to the mirror position of the mold 20. The controller includes a CPU, a memory, an I / O circuit, and the like, and according to a control program stored in advance in its internal memory, information on temperature and pressure in the cavity 24 of the mold 20 detected by a sensor group (not shown), Based on information on the position of the insertion portion 37 of the film 32, the driving of the press device 10, the base material supply device 40, the molding device 50, the cutting device 60, the molded product removal device 70, and the film supply device 75 is controlled. It has become.

Next, the operation will be described. First, the film supply device 75 winds the film 32 by a predetermined amount and transports the insertion portion 37 to a predetermined position between the upper and lower dies 51, 52 of the molding device 50, and the molding device 50 heats the insertion portion 37 to a deformable temperature. Then, press-molding is performed in substantially the same shape as the mirror surface 23 of the mold 20. Then
The mold 20 is heated by the heating / cooling means 13 so as to be equal to or lower than the heat deformation temperature of the base material 31, and the engaging portion 39 of the film 32 is engaged with the positioning portion 25 of the mold 20, and the insertion portion 37 The insertion portion 37 is inserted into the mold 20 so that the metal reflection film 33 of the mold 20 contacts the mirror surface 23 of the mold 20.
Insert inside. Next, the position assembly portion of the mold 20 is
The base material supply device 40 moves so that the engagement of the base material 25 is performed, the held base material 31 is transferred and placed on the insertion portion 37, and the insertion portion 37 of the film 32 and the base material 31 are Insert into cavity 24. Thereafter, the base material supply device 40 inserts the base material 31 into the cavity 64 and then returns to the origin position.

Next, the upper and lower dies 11, 12 of the press device 10
Is driven to close the mold 20. The mold clamping pressure at this time is a pressure that withstands the internal pressure of the resin when the base material 31 is melted, and is a pressure that does not deform the mold 20 or the mirror surface 23 of the mold 20. Then, while the inside of the cavity 24 is evacuated by the vacuum device, the heating / cooling means 13 heats and melts the mold 20 at a temperature higher than the glass transition point of the base material 31, or heats the mold 20 to a temperature near the glass transition point, and presses the pressing device 10 on whether the vibration pressure by
Therefore, as shown in FIG. 4, a resin internal pressure is generated. The mirror surface 23 of the mold 20 is transferred to the metal reflection film 33 of the insertion portion 37 by the internal pressure of the resin inside the cavity 24 of the mold 20, and the base material 31 and the insertion portion are transferred.
Join 37. After the base material 31 is melted and the inside of the cavity 64 reaches a predetermined pressure, the vacuum device is stopped, and the heating / cooling means 13 is gradually cooled so that the temperature and the pressure do not become uneven inside the cavity 24, and is formed. The product 30 is formed. When the pressure inside the cavity 24 becomes substantially atmospheric pressure and reaches a temperature equal to or lower than the heat deformation temperature of the base material 31, the press device 10 drives the upper and lower dies 11, 12 up and down to open the mold 20. The cooling rate depends on the size of the mold 20, the shape of the cavity 24, the material of the base material 31, and the like. Here, when polycarbonate is used for the base material 31, the glass transition point is about 145 ° C. and the heat deformation temperature is about 135 ° C., so that the heating temperature of the mold 20 is 1 °.
About 45 ° C to 180 ° C is appropriate.

Next, the molded product 30 in which the insertion portion 37 in which the mirror surface 23 of the mold 20 has been transferred to the metal reflection film 33 and the base material 31 are conveyed to a predetermined position below the cutting device 60, and the molded product removal device The cutting device 60 descends and cuts the support portion 38 of the film 32 while the holding portion 71 of the 70 holds the metal reflection film 33 of the molded product 30 without damaging it. Device for taking out the molded product 30
70 is discharged to a predetermined position, and the film supply device 75 is inserted into the insertion portion 37.
Winds the cut film 32.

As described above, in the present embodiment, the base material 31 and the film 32 whose surfaces corresponding to the mirror surface 23 of the mold 20 are processed into a substantially final shape having a radius of curvature larger than the radius of curvature of the mirror surface 23.
Is inserted into the mold 20, the base material 31 is brought into close contact with the mirror surface 23 via the film 32, and the base material 31 is melted.
Since the resin internal pressure is generated in the inside 24 and the mirror surface 23 of the mold 20 is transferred to the metal reflection film 33 of the insertion portion 37 by the resin internal pressure, even if the film thickness of the metal reflection film 33 is uneven, the mold 20 mirror surfaces
23 can be transferred with high precision. Further, since the base material 31 and the film 32 are made of an amorphous resin having good transferability, the mirror surface 23 of the mold 20 can be transferred with high precision, and the adhesion and bonding properties between the film 32 and the base material 31 can be improved. Can be improved. If the base material 31 and the film 32 are made of the same material, the base material 31 and the film 32 can be integrated to reduce the influence of stress, temperature, humidity, and the like.

After the resin internal pressure reaches a predetermined pressure,
Since the temperature and pressure in the cavity 24 are gradually cooled so as not to be uneven until the temperature is equal to or lower than the heat deformation temperature, the base material 31 and the film 32 can be joined without generating distortion and stress, and the deformation of the film 32 Can be prevented. Further, the insertion part 37 of the base material 31 and the film 32 is
Prior to insertion into the mold, the insertion part 37 is heated to a deformable temperature in advance, and the metal reflection film 33 is processed so as to be substantially similar to the mirror surface 23 of the mold 20, and the base material 31 and the insertion part 37 are molded. Insertion into the mold 20 is facilitated by inserting the insertion portion 37 into the mold 20.
The transfer accuracy of transferring the mirror surface 23 to the metal reflection film 33 can be further improved.

Further, since the base material 31 is melted while the interior of the cavity 24 is evacuated to generate a resin internal pressure in the cavity 24, air or the like enters between the film 32 and the base material 31, and The transfer accuracy for transferring the mirror surface 23 is prevented from being reduced. Further, in order to make the film thickness uniform, the metal reflective film 33 is usually deposited by vapor deposition or sputtering, but even if the film thickness is not uniform, the mirror surface 23 of the mold 20 can be transferred with high accuracy. Therefore, the metal reflection film 33 can be formed using low-cost electroless plating.

The film supply device 75 inserts the insertion portion 37 of the film 32, and the base material supply device 40 inserts the base material 31 into the cavity 24, and joins the base material 31 and the insertion portion 37 to form the molded product 30. After that, the cutting device 60 cuts the support portion 38 of the film 32, and the molded product removal device 70 discharges the metal reflective film 33 of the molded product 30 to a predetermined position so as not to damage it. Therefore, it is possible to continuously mold the molded article 30 having a high-precision mirror surface without human intervention, and it is possible to improve productivity with stable quality.

Further, the metal reflection film 33 may be formed only on the insertion portion 37 without being formed on the entire surface of the film 32, so that the metal reflection film 33 can be formed corresponding to the mirror shape. Next, FIG.
FIG. 7 is a view showing a second embodiment of the method for manufacturing a plastic mirror according to the present invention. In this embodiment, the same components as those in the above-described embodiment are denoted by the same reference numerals, and description thereof will be omitted.
This embodiment corresponds to the invention described in claim 5.

In FIG. 7, reference numeral 34 denotes an adhesive layer.
34 is applied to the back side of the metal reflection film 33 of the film 32 and joins the base material 31 and the film 32.
34 is inserted into the mold 20 while being sandwiched between the base material 31 and the film 32, and is heated to near the glass transition point of the base material 31 to join the base material 31 and the film 32. The bonding layer 34 is heated to a temperature close to the glass transition point of the base material 31, and is thermoset to bond the base material 31 and the film 32. Alternatively, the base layer 31 is melted and cooled by heating. This is a hot-melt type adhesive for bonding the material 31 and the film 32.

In this embodiment, in addition to the effects of the above embodiment,
Since the base material 31 and the film 32 are joined by the adhesive layer 34,
Different materials can be used as the material of the film 32 and the base material 31, and the adhesion and the bondability between the film 32 and the base material 31 can be further improved. It is needless to say that the same effect can be obtained by applying the adhesive layer 34 to the side of the base material 31 where the film 32 is bonded.

FIG. 8 is a view showing a third embodiment of the method for manufacturing a plastic mirror according to the present invention.
The same components as those in the above-described embodiment are denoted by the same reference numerals, and description thereof will be omitted. This embodiment corresponds to the sixth and seventh aspects of the invention. In FIG. 8, 81 is a base material,
The base material 81 is an amorphous plastic composite material made of a reinforcing filler 85 such as glass fiber, carbon fiber, or mica, and has improved strength and Young's modulus. The base material 81 is formed in a substantially final shape.

Reference numeral 82 denotes a film, and the film 82 is a base material 81.
Composed of an amorphous resin serving as a base, and having a thickness of 50 μm.
m to 800 μm. This film
A metal reflective film 83 is coated on one side of the
The shape of the mirror surface 23 is transferred. The base material 81 and the film 82 are inserted into the mold 20 and transfer the mirror surface 23,
As shown in FIG. 1A, a molded product 80 having a high-precision mirror surface with improved strength and Young's modulus is formed.

In this embodiment, in addition to the effects of the above embodiment,
Since an amorphous plastic composite material made of the reinforcing filler material 85 is used for the base material 81, it is possible to prevent the base material 81 from being stressed and deformed due to a difference in expansion coefficient from the attached housing or the like. As a result, it is possible to prevent the mirror shape of the metal reflection film 83 from being deformed. Also film
Since a thickness of 50 μm to 800 μm is used for 82,
As shown in FIG. 3C , the film 82b having a thickness of less than 50 μm is formed.
The metal reflective film 83 is deformed such as wrinkles due to mechanical stress at the time of insertion into the mold 20 and thermal stress at the time of heating, which occurs when the metal material is inserted into the mold 20, and the reinforcing filler 85 of the base material 81 reflects the metal. Membrane83
It is possible to prevent the vicinity from being exposed and affecting the mirror surface shape of the metal reflection film 83. Further, as shown in FIG. (B), the film 82a exceeding 800μm
When the mirror surface 23 of the mold 20 is transferred, the metal reflective film 83 is wrinkled or cracked, and the difference in the heat shrinkage rate from the base material 81 is difficult because the shape deformation that occurs when using the mirror is difficult. As a result, it is possible to prevent the transfer accuracy from being reduced due to the occurrence of stress distortion.

FIG. 9 is a view showing a fourth embodiment of the method for manufacturing a plastic mirror according to the present invention.
The same components as those in the above-described embodiment are denoted by the same reference numerals, and description thereof will be omitted. This embodiment corresponds to the tenth and eleventh aspects of the present invention. In FIG. 9, 91 is a base material, 92
Is a film, the base material 91 is made of an amorphous resin, and the film 92 is made of an amorphous resin having good bonding properties with the base material 91. Physical treatment or chemical treatment is performed so as to obtain a rough surface having a predetermined surface roughness. Further, on one surface side of the film 92, a metal reflection film 93 protected by a protection film 96 made of, for example, SiO ₂ is formed. The base material 91 and the film 92 are joined to form a molded product 90.

In this embodiment, in addition to the effects of the above embodiment,
Since the surfaces of the surfaces of the base material 91 and the film 92 that are in contact with each other are roughened to a predetermined surface roughness, the adhesiveness and bondability between the film 92 and the base material 91 can be further improved. Further, since the protective film 96 is formed on the surface of the metal reflection film 93, mechanical and temporal deterioration of the metal reflection film 93 can be prevented. In the present embodiment, the surfaces of the surfaces of the base material 91 and the film 92 that are in contact with each other are rough surfaces having a predetermined surface roughness, but it goes without saying that either one of them may be used.

FIGS. 10 and 11 are views showing a first embodiment of a method for producing a plastic molded product according to the present invention. First, the configuration will be described. In FIG. 10, reference numeral 101 denotes an upper mold on a fixed side, and 102 denotes a side mold on a movable side. Mirror surface pieces 106 to 108 on which 106a to 108a are formed are slidably provided.

The intermediate member 109 is provided between the dies 101 and 102.
a, 109b are provided, and the intermediate members 109a, 109b are provided.
b is movable with the lower mold 102 on the movable side. The intermediate members 109a and 109b and the mold 10
Reference numerals 1 and 102 constitute an aging mold. Also mold 10
A cavity 110 is defined in the space defined by 1, 102 and the intermediate members 109a, 109b, and the cavity 110 is formed to have a larger volume than the cavity of an injection mold (not shown). As shown in FIG. 11, a plurality of plastic base materials (three in this embodiment) 111a to 111c and the base materials 111a to 111c are provided in the cavity 110.
A plurality of separating members (two in this embodiment) for separating c from each other
112a and 112b are inserted at the same time.

As the plastic base materials 111a and 111b, those belonging to an amorphous resin as a thermoplastic resin, for example, PM
MA is used. Also, as the isolation members 112a and 112b, iron-based NAK55, which is frequently used as a mold material, has a coefficient of thermal expansion equivalent to that of the mold material, and has a higher thermal deformation temperature than the base materials 111a to 111c, is used. The separating members 112a and 112b are formed to have a thickness of 0.5 mm or more, and both ends in the longitudinal direction are in sliding contact with the dies 101 and 102.

Next, a method for producing a plastic molded product will be described. First, a molten resin is injected into a cavity of an injection molding die maintained at a temperature equal to or lower than the thermal deformation temperature of the resin to produce plastic base materials 111a to 111c having a constant weight.
Next, as shown in FIG.
After sandwiching the separating members 112a and 112b between 11c and making them adjacent to each other, the molds 101 and 102 are inserted into the cavity 110 to close and close the molds. At this time, the distance between the mold 101 and the mold 102 at both ends in the longitudinal direction of the isolation members 112a and 112b is several μm.
And slides in the direction adjacent to the base materials 111a to 111c.

Next, the molds 101 and 102 are heated to 140 ° C., which is higher than the glass transition temperature of PMMA. For this reason, the base materials 111a to 111c melt and expand to generate respective internal pressures. At this time, if the separating members 112a and 112b do not slide in the adjacent direction, the generated internal pressure is increased by the base materials 111a to 111b.
Although determined by the weight of the cavity 110 and the volume of the cavity 110, in the present embodiment, the isolation members 112a and 112b are slidable in the direction adjacent to the base materials 111a to 111c.
The internal pressure generated as a whole becomes constant, and the divided cavity volume is determined according to the weight of each of the members 111a to 111c.

For this reason, the pressure becomes uniform throughout the cavity 110, and even if the base materials 111a to 111c vary, they cancel each other and approach the average value. Also, at this time, since the separating members 112a and 112b are in sliding contact with the dies 101 and 102, no burrs or the like are generated on the dies 101 and 102 during the sliding contact, and the base materials 111a to 111c are mirror-finished. The mirror surfaces 103a to 108a of the pieces 103 to 108 are transferred.

Next, after gradually cooling for a predetermined time, when the temperature reaches 110 ° C., which is lower than the heat deformation temperature of PMMA, and becomes substantially equal to the atmospheric pressure, the mirror pieces 103 to 108 are moved to the molds 101 and 102. Move up or down. At this time, it is possible to prevent the mirror surface transferred to the molded product from being damaged. Next, the molds 101 and 102 are opened and the cavity 110 is opened.
Take out the molded products from the inside, and separate each molded product
Separate from 12b.

As described above, in this embodiment, a plurality of mirror surfaces 103
An engine having a cavity 110 in which a to 108a are formed
A mold is prepared, and a plurality of plastic base materials 111a to 111c and the base material 11 are placed in the aging mold cavity 110.
A plurality of separating members 112a, 112 for separating 1a to 111c from each other.
b and aging at the same time,
Aging mold is heated and plastic base material 111a-1
When 11c is melted, the base materials 111a to 111c partitioned by the respective isolation members 112a and 112b can be divided into divided cavity volumes according to their respective weights.
Even if variations occur in 11c, each base material 111a
~ 111c can cancel each other and approach the average value. As a result, it is not necessary to strictly control the weights of the base materials 111a to 111c, and a large number of molded products can be taken out from one aging mold, and a highly accurate plastic molded product can be obtained. And the productivity of the mirror can be improved.
Also, a large number of base materials 111a to 111
Since aging can be performed by inserting c, the size of the aging mold can be reduced.

The thickness of the isolation members 112a and 112b is
Since the separation members 112a and 112 are made of a metal having a diameter of 0.5 mm or more and the both ends in the longitudinal direction of the separation members 112a and 112 are in sliding contact with the molds 101 and 102, the separation members 112a and 112b are moved in the cavity 110. By sliding, a uniform internal resin pressure can be stably generated in the entire cavity 110, and a highly accurate molded product can be obtained. Also, the isolation members 112a and 112b are
Since it is made of metal similarly to 101 and 102, the separating member 11
2a, 112b using the thermal conductivity of the isolation members 112a, 112b
The temperature distribution in the cavity defined by the above can be made uniform, and a uniform molded product can be obtained.

Further, since a metal having a higher heat deformation temperature than the plastic base materials 111a to 111c is used as the isolation members 112a and 112b, when the aging mold is heated to melt the plastic base materials 111a to 111c. Isolation member 112
The base materials 111a to 111c can be prevented from being welded to the base materials 111a to 111c.
a to 111c can be prevented from binding. Therefore, after aging, a large number of molded products can be reliably separated from the mold and taken out, and the yield of plastic molded products can be prevented from lowering.

In this embodiment, PMMA is used for the base materials 111a to 111c. However, the present invention is not limited to this, and any thermoplastic resin which is amorphous may be used. Such materials include polystyrene, polycarbonate, amorphous polyolefin, polyethersulfone, polysulfone, polyphenylene oxide and the like. Further, the isolation member may be a metal such as aluminum and its alloy, iron and its alloy, copper and its alloy.
The use of such a metal is effective in that it can be easily processed and reused, and can be easily formed into a film.

In addition to metals, SiC, Si, Al
Ceramics such as ₂ O ₃ and Zr ₂ O ₃ may be used. Further, the invention is not limited to such metals, and paper, coated paper, oil paper, and the like may be used. Resin may be used. Examples of the resin include polyolefins such as polyethylene and polypropylene, polyamides such as 12 nylon and 6 nylon, polyesters such as PET and PBT, fluororesins such as tetrafluoroethylene, polyimide resins, PPS, polyurethane, liquid crystal polymers, polystyrene, polycarbonate, and the like. May be an amorphous resin.

Further, a thermosetting resin such as an epoxy resin, an allyl resin, a urea resin, or a phenol resin, or a reinforcing material such as glass fiber or carbon fiber, talc, mica, It may be a mixture of a filler such as calcium carbonate or a photo-curable resin. 12 and 13 are views showing a second embodiment of the method for producing a plastic molded product according to the present invention, and correspond to claim 16. This embodiment is an example in which the present invention is applied to a device for manufacturing a polygon mirror.

In FIG. 12, reference numeral 121 denotes an upper mold on the fixed side, 122 denotes a lower mold on the movable side, and the lower mold 122 is provided with mirror surface pieces 123 and 124 having mirror surfaces 123a and 124a on the surface. It is provided movably. The dies 121 and 122 form an aging die, and a cavity 125 is formed in a space defined by the dies 121 and 122 and the mirror pieces 123 and 124. Also, the lower mold 122 has a cavity 125
A pin 126 protruding inward is provided slidably, and the inner peripheral portions of a plurality of plastic base materials 127 and isolation members 128 are fitted into the pins 126 as shown in FIG. Has become.

In this embodiment, the plastic base material 127 is made of polycarbonate, and the separating member 128 is formed by punching the inner peripheral portion of a Teflon plate. In this embodiment, the plastic base material molded into a substantially final shape in the injection molding process
After separating 127 by the isolation member 128, after inserting the pin 126 into each inner peripheral part and inserting it into the cavity 125,
The molds 121 and 122 are closed, and the molds are closed. Then mold 12
1, 122 are heated to 160 ° C., which is a temperature not lower than the glass transition temperature of polycarbonate. For this reason, the base material 127 melts,
They expand and generate internal pressure. At this time, the isolation member
128 slides in the direction adjacent to the base material 127, the internal pressure generated in the entire cavity 125 becomes constant, and the divided cavity volume according to the weight of each base material 127 is obtained.

For this reason, the pressure is made uniform throughout the cavity 125, and even if the base materials 127 vary, they cancel each other and approach the average value, and the mirror surfaces of the mirror-face pieces 123, 124.
123a and 124a are transferred. Then, when cooled to a temperature of 110 ° C., which is equal to or lower than the thermal deformation temperature of the polycarbonate, for a predetermined time, and when the pressure becomes substantially equal to the atmospheric pressure, the motor shaft 126 is pulled out from each base material 127 and transferred to the molded product. Mirror pieces 123, 1 to prevent the damaged mirror surface from being damaged
24 is moved in the left-right direction with respect to the dies 121 and 122. Next, the molds 121 and 122 are opened to take out molded products from the cavity 125, and each molded product is separated from the isolation member 128 and divided into a plurality of molded products. Therefore, a polygon mirror 129 as shown in FIG. 13B can be obtained, and the same effect as in the first embodiment can be obtained.

In the present embodiment, the inner peripheral portion of the base material 127 is inserted into the pin 126 and the inner peripheral surface inserted into the pin 126 is used as a reference. The positional relationship may be such that the parallelism of the pin 126 with respect to the central axis of each mirror surface 123a, 124a and the angle with respect to each mirror surface 123a, 124a are constant. At this time, since a flexible Teflon plate is used for the isolation member 128, even if the inner peripheral surface of the molded product after aging slightly undulates, the molded product can be sufficiently used as a polygon mirror as long as there is no problem in rotational balance. .

Although the present embodiment is based on the inner peripheral surface of the base material 127 to be inserted into the pin 126, the present invention is not limited to such an example, and the structure shown in FIG. Is also good. That is, the one shown in FIG. 14 has a plurality of mirror surfaces 131a and 132a on the inner peripheral surface and substantially rectangular grooves 131b and 132b having the mirror surfaces 131a and 132a on the bottom. , 132b and cavity 13 on the opposite surface
Provide an upper mold 131 and a lower mold 132 where 3 is defined,
A pin 134 is inserted into the cavity 133.

Then, after the plastic base material (not shown) molded into the substantially final shape after the injection molding is partitioned by the separating member 135 and inserted into the pin 134, the pin 134, the base material and the separating member 135 are inserted. Is inserted into the cavity 133. Then, after performing aging in the same manner as in the above embodiment,
The pin 134 is pulled out from the plastic base material to obtain a polygon mirror 136 as shown in FIG.

In this embodiment, at this time, the reference can be made not only to the inner peripheral portion of the base material inserted into the pin 134, but also to the side portions (shown by a and b) of the groove. For,
Accuracy can be obtained sufficiently. Also, the grooves 131b, 132
b are provided with mirror surfaces 131a, 132a at the bottom thereof, and the grooves 131b, 1
Since 32b is also configured as a cavity, the area where the plastic base material contacts via the separating member 135 can be reduced. Therefore, the size of the isolation member 135 can be reduced, and its cost can be reduced. Other effects are the same as those of the above embodiments.

FIG. 15 is a view showing a third embodiment of the method for producing a plastic molded product according to the present invention.
18 is supported. This embodiment is an example in which the present invention is applied to a device for manufacturing a convex lens. In FIG. 15A, 14
Reference numeral 1 denotes an upper mold, and a plurality of mirror surfaces 141 are provided on the surface of the mold 141.
a is formed. Reference numeral 142 denotes a lower mold, and a plurality of mirror surfaces 142a are formed on the surface of the mold 142.
When the molds 141 and 142 are brought into contact with each other, a cavity 143 is formed in the joint surface, and a plurality of plastic base materials as shown in FIG. 144 and a plurality of isolation members 145 are inserted alternately adjacently.

In this embodiment, a base material 144 is made of Zeonex 280 (manufactured by Zeon Corporation), which is a kind of amorphous polyolefin, and a separating member 145 is made of a 50 μm-thick polyimide film. In the present embodiment, the base material 144 and the isolation member 145 formed into a substantially final shape by the injection molding process
Are alternately inserted into the cavity 144 adjacent to each other. Then
The base material 144 is heated to 160 ° C. which is equal to or higher than the glass transition temperature of the base material 144. At this time, the base material 144 melts and expands to generate internal pressure. At this time, the internal pressure generated in the entire cavity 143 due to the deformation of the isolation member 145 is constant, and the divided cavity volume is in accordance with the weight of each base material 144.

Therefore, the pressure is equalized in the entire cavity 143, and even if the base materials 144 vary, they cancel each other and approach the average value, and the mirror surfaces 141a and 142a are transferred to the base material 144. Next, after cooling the base material 144 to 120 ° C., which is lower than the heat deformation temperature of the base material 144, when the resin internal pressure becomes substantially equal to the atmospheric pressure, the mold 14
The molds 1 and 142 are opened to take out molded products from the cavity 143, and each molded product is separated from the isolation member 145 and divided into a plurality of molded products.

According to the present embodiment, the same effects as those of the first embodiment can be obtained, and the volume of the cavity 143 can be reduced because the film having a thickness of 50 μm is used for the isolation member 145. Thus, the dies 141 and 142 can be reduced in size. That is, the separating member 145 basically needs to be such that the base materials 144 are not joined to each other.
Since it is only necessary to be able to separate easily after taking out from 42, it may be thinned. Therefore, if the thickness of the isolation member 145 can be reduced, the volume of the cavity 143 can be reduced.

The reason why the thickness of the isolation member 145 is reduced is as follows. When the isolation member is made of metal, the internal pressure generated in the cavity 143 is [cavity volume] − [isolation member volume] = [divided cavity volume]. ] And the weight of the whole base material 144. When the isolation member has a large thermal expansion coefficient such as resin, the cavity volume,
It is determined by the balance between the weight of the base material and the weight of the isolation member. Therefore, in the case of resin, it is necessary to control the weight balance of the isolation member unless the isolation member is made as thin as possible.
It is preferably set to 1 μm to 100 μm.

[0097] When a resin is used as the isolating member as described above, it cannot be used in a thick wall because the Young's modulus is lower than that of metal or ceramics, but it is most easily formed into a film. A member having poor adhesion as represented is most preferable as the separating member. Also,
Since the coefficient of thermal expansion is almost equal to that of the base material, it is possible to prevent the base materials from welding together during melting, even though the insertion into the cavity is easy, and the expansion after cooling and after taking out from the mold. It is possible to prevent a high-precision molded product from being distorted due to the difference, and it is particularly preferable to form the isolation member 145 into a film as in the present embodiment in order to more effectively prevent distortion.

FIG. 16 is a view showing a fourth embodiment of the method of manufacturing a plastic molded product according to the present invention. This embodiment is an example in which the present invention is applied to a method for manufacturing a convex lens, and the same components as those in the third embodiment are denoted by the same reference numerals and description thereof is omitted. In this embodiment, FIG.
As shown in (1), polycarbonate is used for the plastic base material 147, and the outer periphery of the base material 147 is coated with an isolation member 148 made of a photo-curable resin. The plate thickness of the isolation member 148 is set to about 0, 1 to 50 μm.
This is because a problem occurs in that 147 are bonded to each other, and if the thickness is larger than that, a uniform film cannot be formed.

In this embodiment, a plurality of such base materials 147
Is inserted adjacent to the cavity 143 and heated at 170 ° C., which is equal to or higher than the glass transition temperature of polycarbonate, and then cooled to 130 ° C., which is equal to or lower than its thermal deformation temperature, and the base material 147 is aged and the mirror surfaces 141 a, 142 a Is transcribed. For this reason, unless the separating members 148 are closely integrated by the temperature and pressure at the time of melting the base material 147, the separating members
Even if the molded product 148 is tightly integrated with the base material 147, the molded product can be easily taken out of the dies 141 and 142 and separated. Further, although the isolation member 148 cannot be reused, it can be inserted into the cavity 143 integrally with the base material 147, so that the insertion operation can be easily performed. In this embodiment, the entire surface of the isolation member 148 is light-cured. However, the same effect can be obtained by light-curing only the portion where the base materials 147 are joined. Further, in the present embodiment, since the base material 147 is coated with the thin film separating member 148, the base material 147 and the base material 147 at both ends in the longitudinal direction and the dies 141 and 142 can be reliably isolated. .
On the other hand, in the case of a thick isolation member, since the base material and the isolation member are inserted alternately, the number of isolation members becomes one less than the number of base materials as shown in FIG. . In the present embodiment, such a phenomenon does not occur because the entire surface is coated.

FIG. 17 is a view showing a fifth embodiment of the method for producing a plastic molded product according to the present invention, and corresponds to claim 20. This embodiment is an example in which the present invention is applied to a method for manufacturing a convex lens, and the same components as those in the third embodiment are denoted by the same reference numerals and description thereof is omitted. In the present embodiment, the base material 15
1 is made of polystyrene, and paper having high releasability is used as the separating member 152. Then, an adhesive layer is provided on the surface of the separating member 152, and the separating member 152 is bonded to both side surfaces of the base material 151.

In this embodiment, a plurality of such base materials 151
Is bonded adjacent to the cavity 143, and heated at 125 ° C., which is higher than the glass transition temperature of polystyrene, and is then heated to a temperature lower than its thermal deformation temperature.
After cooling to 5 ° C, the base material 151 is aged and the mirror surface 141a, 1
42a is transcribed. As described above, in the present embodiment, since two release members 152 having high releasability are provided between the base materials 151, the separation member 152 and the plastic base material 151 can be integrally inserted into the cavity 143. Thus, the insertion operation can be easily performed, and the productivity can be improved.
Then, the plastic molded products can be easily separated from each other by separating the separating members 152 after aging.

FIG. 18 is a view showing a sixth embodiment of the method for producing a plastic molded product according to the present invention, and corresponds to claim 21. In FIG. 18, reference numeral 171 denotes an upper mold, 172 denotes a lower mold, and the lower mold 172 has a groove 172b having a mirror surface 172a formed on the bottom surface. This mold 171 and 172
When the mold is closed, a cavity 173 is defined between the opposed molds 171 and 172, and a plastic base material and an isolation member (not shown) are inserted alternately adjacent to each other in the cavity 173. It has become so.

In this embodiment, at the time of inserting the separating member and the plastic base material, the base material 174 of the model having the same shape as the base material is added to the plastic members at both ends in the adjacent direction of the plastic base material.
To perform aging. There is no problem in aging by inserting the model base material 174 when the thickness of the plastic base material is thin in a direction perpendicular to the adjacent direction of the base material, but the thickness in the direction is not great. This is because, in some cases, when the base material is cooled, the temperature distribution at both ends in the adjacent direction differs from that at the center in the adjacent direction. To solve this problem, it is sufficient to increase the cooling rate. However, doing so would greatly reduce the production efficiency. For this reason, the model base material 174
And aging is performed, it is possible to prevent unevenness due to the temperature distribution during cooling, to obtain a uniform molded product, and to obtain a highly accurate molded product.

FIG. 19 is a view showing a seventh embodiment of the method for producing a plastic molded product according to the present invention, and corresponds to claim 22. In FIG. 19, reference numeral 181 denotes an upper mold, and 182, a lower mold. The lower mold 182 has a groove 182b having a mirror surface 182a formed on the bottom surface. This mold 181 and 182
When the mold is closed, a cavity 183 is defined between the opposed molds 181 and 182, and a plastic base material 184 and an isolation member 185 are inserted alternately adjacent to the cavity 183. It has become so.

Further, a model separating material portion 182c is formed on the wall of the lower mold 182 at both ends of the plastic base material 184 and the separating member 185 in the adjacent direction.
Is made of a material having the same thermal conductivity and thickness as that of the isolation member 185. In addition, a portion adjacent to the model separating material portion 182c has a model base material portion 182d.
The thermal conductivity and the thickness of the model base material 182d are made of the same material as the thermal conductivity and the thickness of the plastic base material 184.

In the present embodiment, because of this configuration, it is possible to prevent the occurrence of variations due to the temperature distribution during cooling and obtain a uniform molded product as in the sixth embodiment. An accurate molded product can be obtained. In addition, since the model separating member portion 182c and the model base material portion 182d are formed directly on the lower mold 182, it is not necessary to insert a model into the cavity 183 every time aging is performed. And a uniform molded product can be easily obtained. Therefore, the productivity of the molded product can be improved.

FIG. 20 is a view showing an eighth embodiment of the method of manufacturing a plastic mirror according to the present invention, and corresponds to claim 23. In FIG. 20A, reference numeral 191 denotes an upper mold, 1
92 is a lower mold, and the lower mold 192 has a mirror surface 192a on the bottom surface.
The groove 192b in which is formed is formed. This mold 191,
When the mold is closed, a cavity 193 is defined between the opposed molds 191 and 192. The cavity 193 has a plastic base material made of polycarbonate as shown in FIG. 194 and a separating member 195 made of a polyimide film are adjacently inserted alternately.

In this embodiment, as shown in FIG. 20C, a plastic film made of polycarbonate having aluminum 196 as a metal reflection film deposited on the surface in advance.
197 is prepared, the film 197 is brought into contact with a plurality of mirror surfaces 192a by the base material 194, and the aluminum 196 of the film 197 is brought into contact with the plurality of mirror surfaces 192a.
Is positioned on the back of the film 197 and cavity 1
Insert into 93 and perform aging. In addition, this film
197 is preferably deformed by heating in advance so as to be in close contact with the mirror surface 192a.

Then, after the aging is completed, the molds 191, 192
The mold is opened to take out the molded product from the cavity 193, the film 197 is cut off, and a plurality of molded products are separated to form a plastic mirror as shown in FIG.
198 can be obtained. Note that the film 197 may be provided with a cutout in advance so as to be easily cut off, or may be in a punched state.

In the present embodiment, with such a configuration, a large number of plastic mirrors can be easily manufactured at once, and a high-precision plastic mirror can be manufactured at low cost and in large quantities. In this embodiment, aluminum is used as the metal reflection film.
However, the present invention is not limited thereto, and may be made of nickel, copper, silver, or the like. The invention is not limited thereto, and a protection film formed of SiO ₂ or the like to prevent oxidation may be used.

[0111]

According to the first aspect of the present invention, the reflection film is
After the film formed on one side and the plastic base material formed in the final shape are inserted into the mold and the plastic base material is melted, the internal pressure of the resin is generated in the cavity and a predetermined pressure is reached. Slowly cools to below the heat distortion temperature, allowing plastic and film
To prevent deformation of the film.
Can be stopped. In addition, the reflective film
Is pressed against the mirror surface of the mold, so the thickness of the reflective film is uneven.
Can transfer the mirror surface of the mold with high accuracy
it can. Also, the reflective film is formed on the film in advance
Fills highly accurate reflective film despite low cost
Can be formed on the system.

According to the second aspect of the present invention, the reflection film is a film.
The film is deposited by vapor deposition or sputtering to make the thickness uniform, but even if the film thickness is not uniform, the mirror surface of the mold can be transferred with high precision, so low-cost electroless plating
Can be used to form a reflective film . According to the third aspect of the present invention, since an amorphous resin having good transferability is used for the plastic base material, the transfer can be performed with higher precision than the mirror surface of the mold.

According to the fourth aspect of the present invention , the same material is used for the plastic base material and the film.
To improve adhesion and bonding between the base material and the plastic base material.
Can be Further, the film and the plastic base material can be integrated, and the effects of stress, temperature, humidity, and the like can be reduced.

According to the fifth aspect of the present invention, the plastic is
Of the base material or the reflective film of the film
Provide an adhesive layer on at least one of the back side
Since the stick base material and the film are bonded, the adhesiveness and bondability between the film and the plastic base material can be further improved.

According to the sixth aspect of the present invention, the plastic
Since an amorphous plastic composite material containing a reinforcing filler such as fiber is used for the base material, deformation of the mirror surface shape due to stress, temperature change, and the like can be prevented. According to the seventh aspect of the present invention, since a film having a thickness of 50 μm to 800 μm is used, mechanical stress and heating when the film is inserted into a mold, which is generated when a film having a thickness of less than 50 μm is used. It is possible to prevent deformation such as wrinkling of the metal reflection film due to thermal stress at the time and to prevent the influence of the plastic base material on the metal reflection film, which is generated when a film exceeding 800 μm is used. When the mirror surface of the mold is transferred, the metal reflective film becomes wrinkled or cracked due to deformation, and the difference in heat shrinkage from the plastic base material causes distortion, which lowers the transfer accuracy. This can be prevented from being performed.

[0116] According to the invention of claim 8, since the pre-heating the at least one of the plastic matrix or film to a predetermined temperature, the distortion occurs in transferring the mirror surface of the mold to the film To prevent the transfer accuracy from being reduced. Further, the molding cycle can be shortened.

According to the ninth aspect of the present invention, the film is heated to a deformable temperature in advance, is formed into a shape substantially equal to the mirror surface of the mold, and is then inserted into the mold. Insertion becomes easy, and the transfer accuracy of the mirror surface of the mold can be further improved. According to the invention as set forth in claim 10, at least one of the surfaces of the plastic base material and the film that are in contact with each other is formed into a rough surface having a predetermined surface roughness.
Therefore, the adhesiveness and the bondability between the film and the plastic base material can be further improved.

According to the eleventh aspect, the film
Since the protective film is formed on the surface of the reflective film , mechanical and temporal deterioration of the reflective film can be prevented. Claim 1
According to the second aspect of the invention, the position of the insertion portion is determined by engaging the engagement portion with the positioning portion of the mold, the insertion portion and the plastic base material are inserted into the mold, and the mold is clamped. Before or after the base material is melted, the support is cut ,
The film insertion part can be automatically supplied into the mold, and the molded product can be automatically ejected from the mold. Also, reflective film
It is not necessary to form the reflective film on the entire surface of the film .
Can be. Therefore, since the film and the plastic base material are automatically and continuously inserted into the mold and the molded product is taken out, the productivity can be improved and the quality can be stabilized.

According to the thirteenth aspect of the present invention, the plastic base material is melted while the interior of the cavity is evacuated to generate a resin internal pressure in the cavity.
Further, since the film and the film are joined, it is possible to prevent air or the like from entering between the film and the plastic base material, thereby preventing the transfer accuracy of transferring the mirror surface of the mold from being lowered.

According to the fourteenth aspect, the plastic
The surface in contact with the film of the stick base material has a radius of curvature smaller than the radius of curvature of the mirror surface when the mold has a convex mirror surface, and the curvature of the mirror surface when the mirror surface has a concave shape. Since it is formed with a radius of curvature larger than the radius, the plastic base material and film are inserted into the mold, and when the mold is closed, the plastic base material
The surface in contact with the film can be in close contact with the mirror surface via the film, and the transfer accuracy of the mirror surface of the mold can be further improved.

According to the fifteenth aspect of the present invention, the insertion portion of the film is heated to a temperature at which the forming means can be deformed and formed substantially in the same shape as the mirror surface of the mold so that the insertion portion can be easily formed. The base material supply means inserts the plastic base material into the cavity. Next, the pressing means applies a predetermined pressure to the mold, and the heating / cooling means applies a predetermined temperature to generate a resin internal pressure in the cavity,
Plastic matrix with transferring the mirror surface of the mold insert portion
The material and the film are joined and gradually cooled at a predetermined temperature gradient. Therefore, the mirror surface of the mold can be transferred with high accuracy without applying stress to the insertion portion.

After the joining of the plastic base material and the film , the support portion is cut by the cutting means, and the molded product is taken out by the taking out means. Therefore, since the film and the plastic base material are automatically and continuously inserted into the mold and the molded product is taken out, the productivity can be improved and the quality can be stabilized.

According to the sixteenth aspect of the present invention, even if variations occur in each of the base materials, the base materials can cancel each other and approach the average value. When the mold is taken out of the mold at a temperature not higher than the heat deformation temperature, it is possible to prevent the pressure from fluctuating, thereby preventing the molded product from having a mirror transfer failure such as sink marks. As a result, it is not necessary to strictly control the weight of the plastic base material, and it is possible to take out a large number of molded products from one aging mold, thereby obtaining a highly accurate plastic molded product. In addition, the productivity of the molded article can be improved.
In addition, since a large number of base materials can be inserted into one cavity for aging, the size of the aging mold can be reduced.

According to the seventeenth aspect of the invention, when the aging mold is heated to melt the plastic base material, the base material can be prevented from being welded to the separating member. Bonding of the plastic base material can be prevented. For this reason, after aging, a large number of molded products can be reliably separated from the mold and taken out, and the yield of plastic molded products can be prevented from lowering.

According to the eighteenth aspect of the present invention, the occupied volume of the isolation member in the cavity can be reduced, and the required resin internal pressure can be stably maintained even if the isolation member has some thickness variation. Can be generated. For this reason, it is possible to obtain a high-precision formed product while making it possible to reduce the size of the mold or take out a large number of molded products in the same cavity.

According to the nineteenth aspect of the present invention, a uniform internal resin pressure can be stably generated in the entire cavity by sliding the isolation member in the cavity, and a highly accurate molded product can be obtained. . Further, since the isolating member is made of metal like the mold, the temperature distribution in the cavity defined by the isolating member can be made uniform by utilizing the thermal conductivity of the isolating member. A molded article can be obtained.

According to the twentieth aspect, the separating member and the plastic base material are integrally inserted into the cavity, so that the inserting operation can be easily performed, and the productivity can be improved. Then, the plastic molded products can be easily separated from each other by separating the separating members after aging. According to the twenty-first aspect of the present invention, it is possible to prevent a temperature variation from occurring at both ends and the center of the plastic base material in the adjacent direction, and to obtain a uniform molded product.

According to the twenty-second aspect of the present invention, the work of inserting a model into the cavity every time aging is performed can be eliminated, and the productivity of a molded product can be improved. According to the twenty-third aspect, a large number of plastic mirrors can be easily manufactured at once, and a high-precision plastic mirror can be manufactured at low cost and in large quantities.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing a main part of a first embodiment of a plastic mirror manufacturing apparatus for performing a plastic mirror manufacturing method according to the present invention.

FIG. 2 is a perspective view showing the first embodiment.

FIG. 3 is a side view showing the entire configuration of the first embodiment.

FIG. 4 is an explanatory diagram showing a temperature and a pressure inside a cavity when the first embodiment is performed.

FIG. 5 is a side view showing a molded article formed according to the first embodiment.

FIG. 6 is a side view showing another molded article molded according to the first embodiment.

FIG. 7 is a side view showing a molded product formed by a second embodiment of the method for manufacturing a plastic mirror according to the present invention.

FIG. 8 is a side view showing a molded article formed by a third embodiment of the method of manufacturing a plastic mirror according to the present invention.

FIG. 9 is a side view showing a molded product formed by a fourth embodiment of the method of manufacturing a plastic mirror according to the present invention.

FIG. 10 is a cross-sectional view of a mold for showing the first embodiment of the method for producing a plastic molded product according to the present invention, and for achieving the production method.

FIG. 11 is a configuration diagram of a plastic base material and an isolation member according to the first embodiment.

FIG. 12 is a cross-sectional view of a mold for illustrating a second embodiment of the method for manufacturing a plastic molded product according to the present invention, and for achieving the manufacturing method.

FIG. 13A is a view showing a state in which a plastic base material and an isolating member are inserted into a mold according to a second embodiment, and FIG. 13B is a view showing a configuration of a molded product.

FIG. 14 is a view showing another aspect of the second embodiment, and FIG.
FIG. 2 is a cross-sectional view of a mold for achieving the manufacturing method, and FIG.

15A and 15B show a third embodiment of the method for producing a plastic molded article according to the present invention, wherein FIG. 15A is a cross-sectional view of a mold for achieving the production method, and FIG. It is a block diagram of a member.

16A and 16B show a fourth embodiment of the method for producing a plastic molded product according to the present invention, wherein FIG. 16A is a sectional view of a mold for achieving the production method, and FIG. It is a block diagram of a member.

17 (a) and 17 (b) show a fifth embodiment of the method for producing a plastic molded product according to the present invention, wherein FIG. 17 (a) is a sectional view of a mold for achieving the production method, and FIG. It is a block diagram of a member.

FIG. 18 is a cross-sectional view of a mold for achieving the method of manufacturing a plastic molded product according to a sixth embodiment of the present invention.

FIG. 19 is a sectional view showing a seventh embodiment of the method of manufacturing a plastic molded product according to the present invention, showing a state in which a plastic base material and an isolating member are inserted into a mold for achieving the manufacturing method.

20A and 20B show an eighth embodiment of the method for producing a plastic molded product according to the present invention, wherein FIG. 20A is a cross-sectional view of a mold for achieving the production method, and FIG. FIG. 3C is a configuration diagram of the plastic film, and FIG. 4D is a configuration diagram of the plastic mirror.

21A is a cross-sectional view of an aging mold for a conventional plastic molded product, and FIG. 21B is a configuration diagram of the molded product.

FIG. 22A is a cross-sectional view of an aging mold of a conventional plastic molded product, and FIG. 22B is a configuration diagram of the molded product.

[Explanation of symbols]

10 Press device (sealing / opening means and pressurizing means) 13 Heating / cooling means 20 Mold 23 Mirror surface 24 Cavity 25, 26 Positioning part 30, 80, 90 Molded product 31, 81, 91 Plastic base material 32, 82, 92 Plastic films 33, 83, 93 Metal reflective film 34 Adhesive layer 37 Insert section 38 Support section 39 Engaging section 40 Base material supply device (base material supply device) 50 Molding device (molding device) 60 Cutting device (cutting device) 70 Molding Product take-out device (molded product take-out means) 75 Film feeder device (film supply means) 85 Reinforcing filler 96 Protective film 101, 121, 131, 141, 171, 181, 191 Upper die 102, 122, 132, 142 , 172, 182, 192 Lower molds 103a to 108a, 123a, 124a, 131a, 132a, 141a, 1
42a, 172a, 182a, 192a Mirror surfaces 110, 125, 133, 143, 173, 183, 193 Cavities 111a to 111c, 127, 147, 151, 184, 194 Plastic base materials 112, 128, 135, 145, 152, 185, 195 Separation member 174 Model base material 196 Aluminum (metal reflective film) 197 Plastic film

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29C 65/52 B29C 65/52 G02B 5/08 G02B 5/08 C // B29L 11:00

Claims (23)

(57) [Claims] 1. A pair of dies having at least one mirror surface which are arranged to face each other and define at least one or more cavities, a thermoplastic base material pre-processed to a substantially final shape in advance, and said metal mold. A film having a reflective film having the same area or less as the mirror surface of the mold; and a film and a plastic base material, wherein the reflective film side of the film is in contact with the mirror surface, and the plastic base material is located on the back side of the reflective film of the film. and inserted into the cavity so that, then, depending on whether the mold is clamping, or heating above the glass transition point plastic matrix by heating the mold, or pressure before and after the glass transition point, the cavity A predetermined resin internal pressure is generated inside to transfer the mirror surface to the reflective film of the film. Then, the mold is gradually cooled, and the plastic base material is cooled from the heat deformation temperature to below the cavity. Method for producing a plastic mirror, characterized in that issue Ri. 2. The method according to claim 1, wherein the reflective film of the film is formed by electroless plating.
The method according to claim 1, wherein the plastic mirror is formed by vapor deposition or sputtering. 3. The method according to claim 1, wherein an amorphous resin is used as the plastic base material. 4. The method according to claim 1, wherein the same material is used for the plastic base material and the film . 5. The method according to claim 1, wherein a film contact of said plastic base material is made in advance.
A thermosetting or hot-melt type adhesive layer is provided on at least one side of the mating side or the back side of the film reflective film , and the adhesive layer is formed between the plastic base material and the film.
Insert into the cavity so that the plastic matrix
2. The method for manufacturing a plastic mirror according to claim 1, wherein the film and the film are joined. 6. The method according to claim 1, wherein an amorphous plastic composite material containing a reinforcing filler such as fiber is used as the plastic base material. 7. The method according to claim 1, wherein the film has a thickness of 50 μm to 800 μm. 8. The method of manufacturing a plastic mirror according to claim 1, wherein at least one of the plastic base material and the film is heated to a deformable temperature before being inserted into the cavity. 9. The plastic according to claim 1, wherein the film is heated to a deformable temperature in advance, then deformed into a shape substantially equal to the mirror surface shape, and then inserted into the cavity. Mirror manufacturing method. 10. A method according to claim 1, wherein at least one of the surfaces of said plastic base material and said film which are in contact with each other is roughened to a predetermined surface roughness by a chemical or physical treatment. Item 7. A method for producing a plastic mirror according to Item 1. 11. The method according to claim 1, wherein a protective film is formed on a surface of the reflective film of the film. 12. An insertion part inserted into a mirror surface of the mold,
An engaging portion, which is provided near the insertion portion and is engaged with a positioning portion formed on the mold when the insertion portion is positioned on the mirror surface, and a support portion for supporting the insertion portion, are continuously formed in the feed direction. do it
Prepare a film having a reflective film provided , and feed the film by a film supply device to insert the film.
And the plastic base material is inserted by the base material supply device into the insertion portion so that the reflection film of the base material is in contact with the mirror surface.
After inserting into the mold so as to be located on the back side of the reflective film, the mold is closed, and before or after the plastic base material is melted, the operation of cutting the inserted portion from the supporting portion is performed by a film feeding amount. 2. The method for manufacturing a plastic mirror according to claim 1, wherein the method is performed continuously according to the following conditions. 13. A method according to claim 1, wherein said plastic base material and said film are inserted into said cavity, a mold is clamped, and then a predetermined resin internal pressure is generated in said cavity while evacuating the cavity. A method for manufacturing a plastic mirror according to claim 1. 14. The surface of the plastic base material that is in contact with the film has a radius of curvature smaller than the radius of curvature of the mirror surface when the mirror shape of the mold is convex, and conversely, the surface of the mold has a concave shape. 2. The method according to claim 1, wherein when the mirror is in a state of curvature, the radius of curvature is larger than the radius of curvature of the mirror surface.
A method for producing the plastic mirror according to the above. 15. A pair of molds having at least one mirror surface which is disposed to face each other and forms at least one or more cavities, and has a pair of molds each having a positioning portion for aligning each other, and formed into a substantially final shape. And a film on which a reflection film to which the mirror surface is transferred is formed.
What is claimed is: 1. A plastic mirror manufacturing apparatus for forming a plastic mirror by joining a plastic base material and a film by inserting the film into a cavity , wherein the film is provided near an insertion portion inserted into a mirror surface of a mold. An engagement portion engaged with a positioning portion formed on the mold when the insertion portion is positioned on the mirror surface,
A support part for supporting the insertion part is provided continuously in the feeding direction, and before being inserted into the mold cavity, the insertion part of the film is heated to a deformable temperature and formed into a mirror surface having a substantially final shape. preform supply hand supplies the forming means, the plastic matrix into the cavity to
Step, film supply means for transporting the film insertion portion to the mirror surface position of the mold, mold clamping and releasing means for clamping and releasing the mold, pressurizing means for applying a predetermined pressure to the mold, and the mold. Heating and cooling means for heating the mold and cooling the mold at a predetermined temperature gradient, cutting means for cutting the insertion portion from the support portion of the plastic film, and removing means for taking out the molded product cut off from the plastic film And a manufacturing apparatus for a plastic mirror. 16. A plastic mother having a substantially final shape and a constant weight.
The material is inserted into the cavity in the aging mold, and then heated to a temperature higher than the glass transition temperature of the resin to transfer the mirror surface to the base material by the internal pressure of the resin. In a method of manufacturing a plastic molded product in which the plastic molded product is removed from an aging mold when the internal pressure of the resin becomes substantially equal to the atmospheric pressure, at least one mirror having at least one mirror surface is formed.
An aging mold having a viability is prepared, and aging is performed by simultaneously inserting a plurality of plastic base materials and a plurality of separating members for separating the base materials into a cavity of the aging mold. Method of manufacturing plastic molded products. 17. A method for manufacturing a plastic molded product according to claim 16, wherein a material having a higher heat deformation temperature than a plastic base material is used as said separating member. 18. The separation member has a thickness of 0, 1 to 100 μm.
18. The method according to claim 16, wherein:
A method for producing the plastic molded article according to the above. 19. The separating member is made of metal having a thickness of 0.5 mm or more, and both ends of the separating member in the longitudinal direction are slidably contacted with an aging mold. Item 17. A method for producing a plastic molded product according to Item 16. 20. The method of manufacturing a plastic molded product according to claim 16, wherein members having high releasability are used as said separating members, and two peeling members are provided between said plastic base materials. 21. A plastic base material and a separating member are alternately inserted into the aging mold so as to be adjacent to each other.
17. The method according to claim 16, wherein a model having the same shape as the base material is used for the plastic members at both ends in the adjacent direction. 22. The thermal conductivity and the thickness of the walls of the aging mold at both ends in the adjacent direction of the plastic base material and the separating member are made of the same material as the thermal conductivity and the thickness of the separating member. The heat conductivity and thickness of the part adjacent to the part are made of the same material as the heat conductivity and thickness of the plastic base material, and the plastic base material and the isolation member are alternately inserted into the aging mold adjacent to each other. The method for producing a plastic molded product according to any one of claims 16 to 20, wherein aging is performed. 23. A film having a reflective film coated on the surface.
The film and the plastic base material are
23. The aging mold according to claim 16, wherein a reflective film side of said metal film contacts a plurality of mirror surfaces, and said plastic base material is inserted into a cavity of an aging mold so as to be located on a back surface of said film.
A method for producing a plastic molded product according to any one of the above.