JP4474029B2

JP4474029B2 - Injection molding simultaneous painting method and apparatus

Info

Publication number: JP4474029B2
Application number: JP2000232350A
Authority: JP
Inventors: 浩之阿竹
Original assignee: Dai Nippon Printing Co Ltd
Current assignee: Dai Nippon Printing Co Ltd
Priority date: 2000-07-31
Filing date: 2000-07-31
Publication date: 2010-06-02
Anticipated expiration: 2020-07-31
Also published as: JP2002046142A

Description

【０００１】
【発明の属する技術分野】
本発明は、射出成形と同時に型内で図柄や文字等が施された絵付シートを射出樹脂成形体の表面に一体的に接着積層して加飾積層品（積層製品）を得るようにした射出成形同時絵付装置に関する。
【０００２】
【従来の技術】
射出成形と同時に射出樹脂成形体の表面に絵付シートを一体的に接着する射出成形同時絵付方法としては、従来より幾つもの態様が提案されているが、それらの大半は、次の（ａ）〜（ｉ）の工程の全部又は幾つかを記述順に又はその順番を入れ換えて、順次、又は複数の工程を同時に重複してもしくは並列的に行うようにされている（特公昭５０−１９１３２号、実公平３−５６３４４号、特公平７−４１６３７号公報等を参照）。
【０００３】
（ａ）絵付シートを射出成形に用いられる雌型のパーティング面上に供給するシート供給工程。
（ｂ）絵付シートを雌型のパーティング面に押圧固定するクランプ工程。
（ｃ）絵付シートを熱盤等により加熱軟化させる加熱軟化工程。
（ｄ）絵付シートを真空吸引及び／又は圧空供給等により雌型のキャビティに沿わせるように延伸させる延伸工程（予備成形工程）。
（ｅ）雌型と雄型の一方（通常は雌型）を他方（通常は雄型）側へ移動させて型締めを行う型締め工程。
（ｆ）雌型と雄型との間に形成されるキャビティ内に雄型側から流動状態の樹脂（熔融樹脂）を注入充填して射出成形を行う射出成形工程。
（ｇ）雌型と雄型とを離間させる型開き工程。
（ｈ）絵付シートのうちの射出樹脂成形体に接着付随させるべき部分を他の部分（余剰部分）から切り離すシートトリミング工程。
（ｉ）絵付シートが接着積層された積層品を雄雌両成形型から取り出す取出工程。
【０００４】
なお、複数の工程を同時に重複して行うとは、複数の工程が一工程に含まれることをいい、例えば、前記（ｅ）の型締め工程において絵付シートを雌型と雄型との間に挟んで固定保持するようになせば、該型締め工程と同時に重複して前記（ｂ）のクランプ工程が行われたことになり、また、前記（ｆ）の射出成形工程において絵付シートを射出された熔融樹脂の熱と圧力により延伸させるようになせば、該射出成形工程と同時に重複して前記（ｄ）の延伸工程が行われたことになる場合をいう。
【０００５】
また、絵付シートとしては、製品種別に応じて貼合わせ積層シート（ラミネートシート）と転写シートのいずれかが用いられ、ラミネートシートである場合には、射出成形によりそのままで絵付けが行われたことになり、射出樹脂成形体の表面にシート全層が接着一体化して化粧層となる。それに対し、絵付シートが転写シートである場合には、射出樹脂成形体の表面に一体化した絵付シートのうちの支持体シートを剥離し、装飾層等の転写層のみを射出樹脂成形体側に残留させて化粧層となすことにより絵付けが完了する。
【０００６】
【発明が解決しようとする課題】
ところで、射出成形同時絵付により得るべき積層製品には、その特定部位に、視認性等を向上させるべく裏面側からの光（照明）を目盛・パターン状に透過させる透明の光透過部を有する、計器類用目盛文字板等の透光部品（透光部）を設けることが要求される場合がある。このように、積層製品の特定部位に目盛文字板等の透光部品（透光部）を設けるには、従来、下記の二つの方法が採られていた。
【０００７】
第１の方法は、図１１（Ａ）、（Ｂ）に示される如くの透光部品６付きの積層製品４を得るべく、前記した（ａ）〜（ｉ）の如くの射出成形同時絵付方法により、図９に示される如くに、射出樹脂成形体４Ｐの表面に木目模様が施された絵付シート５を接着積層するとともに、計器パネル類を後付けするための矩形の窓開口４Ａ、及び、目盛文字部が光透過部とされた円形の透光部品（目盛文字板）６を取り付けるための段差部４ｂ付きの装着穴４Ｂを設ける。この場合、絵付シート５は射出樹脂成形体４Ｐの表面全体を覆うように接着積層されるので、射出成形工程後に雄雌両成形型から積層品４’（未完成品）を取り出した後、絵付シート５のうち、射出樹脂成形体４Ｐに接着積層されていない外周余剰部分５Ｃや前記窓開口４Ａ及び装着穴４Ｂ（の段差部４ｂ）を塞いでいる閉塞部分５Ａ、５Ｂを切除し、しかる後、前記透光部品（目盛文字板）６の裏面側外周に接着剤等を塗工して前記装着穴４Ｂ（の段差部４ｂ）に押し込んで取付固定する（図１０、図１１参照）。
かかる第１の方法では、射出成形同時絵付終了後に、透光部品６を積層品４’に取り付け固定する必要があるので、工数が増えて手間がかかり、製造コストが高くなるという問題があった。
【０００８】
第２の方法は、図１２に示される如くに、絵付シート８として、そのその装飾層８Ｂの特定部位に、木目模様に代えて透光部（目盛文字部）９を予め形成しておき、この絵付シート８を使用して、前記した（ａ）〜（ｉ）の如くの射出成形同時絵付方法により、図１３に示される如くに、射出樹脂成形体７Ｐの表面に前記絵付シート８を接着積層するとともに、計器パネル類を後付けするための矩形の窓開口７Ａを設ける。この場合、射出成形工程において成形キャビティ内に射出充填する樹脂（射出樹脂成形体７Ｐ）として、透明のものを使用する。これにより、絵付シート８は、透明の射出樹脂成形体７Ｐの表面全体を覆い、かつ、前記透光部（目盛文字部）９が特定の部位に位置するように、接着積層される。その後は、絵付シート８のうち、射出樹脂成形体７Ｐに接着積層されていない外周余剰部分８Ｃや前記窓開口７Ａを塞いでいる閉塞部分８Ａを切除すれば、図１４に示される如くに、透光部９付きの積層製品７が得られる。なお、この方法では、絵付シート８に予め縦方向位置決めマークＭａ、Ｍａ、…や横方向位置決めマークＭｂを形成しておいて（図１２参照）、絵付シート供給工程において、それらのマークＭａ、Ｍｂをセンサで読み取って、雌型キャビティ１３に対する絵付シート８の位置決めを行うようにされる。
かかる第２の方法では、透光部品を別途に必要とせず、射出成形同時絵付と同時に透光部（目盛文字部）９を設けることができるので、第１の方法に比して、手間がかからず、製造コストを低く抑えることができる。
【０００９】
しかしながら、該方法では、絵付シート８が延伸工程で延伸せしめられることに起因して、絵付シート８に形成された透光部９に、図１４（Ａ）において仮想線Ｆで示される適正位置、形状に対して、実際の透光部９に歪み、傾斜、位置ずれ等の不具合が生じるという問題があった。つまり、絵付シート８の延伸方向、延伸量は、射出成形及びそれに先立つ予備成形の際の温度等の環境条件や製品形状如何等によって一義的には定まらず、それらを精密に制御することは極めて難しく、例えば、積層製品７の縦横寸法が２０〜３０ｃｍである場合、直径が３０〜５０ｍｍの透光部（目盛文字部）９に１〜２ｍｍ程度の歪み、傾斜、位置ずれ等が生じることは避けられないが、透光部（目盛文字部）９に１〜２ｍｍ程度の歪み、傾斜、位置ずれが生じると、その裏面の照明光源との位置、角度とのずれによって、美観、視認性が損なわれて不良品となり、歩留りが悪くなる。
【００１０】
本発明は、上述の如くの問題を解消すべくなされたもので、その目的とするところは、積層製品の表面の特定部位に、視認性等を向上させるべく裏面側からの光（照明）を透過させる文字乃至目盛上の透明の光透過部を有し、該光透過部の周囲に遮光部を有する、計器類用目盛文字板等の透光部品を、射出成形同時絵付と同時に取付固定でき、しかも、目盛文字部等の透光部に歪み、傾斜、位置ずれ等を生じさせず、美観、視認性を低下させることがなく、歩留りを向上できるとともに、製造コストを可及的に抑えることのできる射出成形同時絵付方法及び装置を提供することにある。
【００１１】
【課題を解決するための手段】
上述の目的を達成すべく、本発明に係る射出成形同時絵付方法は、射出樹脂成形体の表面に、絵付シートを接着積層するとともに、遮光層が透明な目盛文字等からなる光透過部を有するように形成されてなる透光部品を接着積層するためのもので、前記射出樹脂成形体における前記透光部品の裏面側に窓開口を形成するための窓形成用凸部が設けられた雄型を用意するとともに、雌型のキャビティにおける前記雄型の窓形成用凸部と対向する特定部位に、前記透光部品を積層製品取出方向に沿って着脱可能な状態で配置し、雌型のパーティング面上に絵付シートを供給し、クランプ手段により前記絵付シートを前記雌型のパーティング面上に固定保持した後、前記絵付シートを前記雌型のキャビティに沿わせて密着させるように延伸させ、前記雌型と雄型の一方を他方側へ移動させて型締めを行い、前記雌型と雄型との間に形成される成形キャビティ内に前記雄型側から流動状態の樹脂を射出充填するとともに、その樹脂からなる射出樹脂成形体と前記絵付シートとを積層して一体化させ、その後、前記雌型と雄型とを離間させる型開きを行って、前記絵付シート及び透光部品が接着積層された積層製品を前記雌型から取り出すことを特徴としている。
【００１２】
本発明方法では、前記流動状態の樹脂（射出樹脂）として、遮光性を有しているもの使用することが好ましい。
さらに好ましい態様では、前記透光部品として、その裏面側外周縁部に、前記絵付シートと一体化するための、接着剤、粘着剤、あるいは、両面テープ等の一体化手段が施されているものを用い、前記積層一体化の工程の際に、該透光部品と絵付シートとを前記裏面側外周縁部のみにおいて接着一体化せしめ、しかる後、前記射出樹脂成形体の表面を覆っている前記絵付シートのうちの前記窓開口を塞いでいる部分を切除して、前記透光部品の光透過部を露出させるようになされる。
【００１３】
また、本発明に係る射出成形同時絵付装置は、前記方法を実施するためのもので、前記射出樹脂成形体における前記透光部品の裏面側に窓開口を形成するための窓形成用凸部が設けられた雄型と、前記雌型のキャビティにおける前記雄型の窓形成用凸部に対向する特定部位に、前記透光部品を前記積層製品取出方向に沿って脱着可能に位置決め固定するための部品位置決め手段が設けられた雌型と、備えていることを特徴としている。
【００１４】
前記部品位置決め手段は、好ましくは、前記透光部品に設けられた嵌合穴又は嵌合凸部が前記積層製品取出方向に沿って着脱可能に嵌め込まれる嵌合凸部又は嵌合穴を備える。なお、部品位置決め手段としては、前記嵌合法を用いたものの他、真空吸着法、磁気吸着法等が挙げられる。
【００１５】
上述の如くの構成とされた本発明の射出成形同時絵付方法及び装置の好ましい態様においては、雌型のキャビティの特定部位に、例えば、前記透光部品に設けられた嵌合穴が前記積層製品取出方向に沿って着脱可能に嵌め込まれる嵌合凸部が設けられ、この嵌合凸部に、例えば、裏面側に遮光性インキが目盛文字等の光透過部を有するようにされて表示部とされた、透明樹脂成形品、ガラス等からなる透光部品が積層製品取出方向に沿って着脱可能に嵌め込まれて位置決め固定される。このようにして嵌合凹部に加飾部品が位置決め固定された後、雌型のパーティング面上に絵付シートを供給するとともに（シート供給工程）、供給された絵付シートをクランプ手段によって前記パーティング面上に固定保持し（クランプ工程）た後、該絵付シートを真空吸引手段等により前記雌型キャビティに沿って密着させるべく延伸させる（延伸工程乃至予備成形工程）。
【００１６】
このため、絵付シートが延伸工程で延伸せしめられることに起因して、適正位置、つまり、前記透光部品に対して、多少の歪み、傾斜、位置ずれ等が生じても、前記目盛文字等からなる光透過部には全く悪影響は与えない。そのため、絵付シートの位置決め、延伸方向、延伸量等を厳密に制御しなくても、美観、視認性を損なうことがなく、歩留りを向上させることができるとともに、製造コストを可及的に抑えることができる。即ち、図１５（Ａ）に示される如く、透光部品３の半径をＲ０＋ΔＲ、目盛文字部の外接円半径をＲ０とし、且つ、図１５（Ｂ）に示される如くに、前記絵付シート２における透光部品３に対向する部分に、半径Ｒ０＋ΔＲ／２の絵柄模様の無い光透過部（透明領域）２ｚを形成しておく。そして、位置決め目標を、前記絵付シート２の光透過部（透明領域）２ｚの輪郭線が、前記透光部品３の中心から半径Ｒ０＋ΔＲ／２の線上に位置するように設定することによって、位置決め許容誤差は、図１５（Ａ）からわかるように、Ｙ方向及びＺ方向にそれぞれ、ΔＹ＝±ΔＲ／２、ΔＺ＝±ΔＲ／２となる。これにより、絵付シートの位置決め、延伸方向、延伸量等を厳密に制御しなくても、美観、視認性を損なうことがなく、歩留りを向上させることができるとともに、製造コストを可及的に抑えることができる。
【００１７】
上記のようにして、透光部品、絵付シート、及び射出樹脂成形体の三者が一体化した積層製品は、その後、雄型に伴って、あるいは、取り出しロボットやイジェクターピン等により、雌型から型開き方向に取り出される。この場合、前記透光部品は、雌型のキャビティに積層製品取出方向（通常は型開き方向）に沿って着脱可能に嵌め込まれているので、絵付シート（積層製品表面）から離れることなくそれと一体に取り出される。
【００１８】
この場合、更に、透光部品の裏面側外周縁部（言い換えれば、射出樹脂成形体に形成される窓開口の周縁部に絵付シートを介して対接せしめられる部分）に接着剤等の一体化手段が施されておれば、前記延伸工程において、絵付シートの表面の特定部位に前記透光部品が接着一体化され、続いて行われる射出成形工程において絵付シートと射出樹脂成形体とが一体化され、前記透光部品がその特定部位に位置決め固定され、かつ、射出樹脂成形体における前記透光部品の裏面側に窓開口が形成されている積層製品が得られる。この場合は、射出成形工程及び型開き工程の後、前記射出樹脂成形体の表面を覆っている前記絵付シートのうちの前記窓開口（透光部品）を塞いでいる部分を裏面側から切除して、前記透光部品の光透過部を露出させる。
この形態の方法装置では、目盛文字部等を有する透光部品は、予め雌型キャビティに位置決め固定され、予備成形工程での変形を受け無いとともに、射出成形工程での熱や応力も絵付シートが緩和してくれるので、透光部品に不所望な歪み、傾斜、位置ずれ等が生じることはなく、また、絵付シートとして全面に通常の木目模様等が施され、全面が光を透過しないものを用い、絵付シートの雌型キャビティに対する位置決めを行わ無い場合でも、この絵付シートのうちの前記窓開口を塞いでいる部分は切除されるので、前記透光部品の光透過部は、最終的には露出せしめられる。
【００１９】
本発明において、雄雌両成形型は、鉄等の金属あるいはセラミックス等で作製され、それらに必要に応じて、真空吸引や圧空供給用に小孔（真空吸引孔等）を設ける。
また、雌型を複数の分割部分の集合体で構成（いわゆる入れ子構造に）し、隣合う分割部分間にスリット状の隙間を形成してこの隙間を真空吸引孔（及び圧空供給孔）として用いて真空吸引（及びエアーブロー）を行うようにしてもよい。
【００２０】
前記雄型には、流動状態の樹脂を射出するためのランナーと所要本のゲートを設ける。ゲートの本数、位置、形状等は、得るべき製品の形状等を勘案して自由に設定することができる。
また、絵付シートを雌型パーティング面に固定保持すべくクランプ手段を付設する。クランプ手段としては、枠状ないし井桁状のものを用いることができる。
【００２１】
また、クランプ手段を雌型パーティング面に対して進退動させるには、型締め動作等の成形用駆動力を用いたり、イジェクターピン駆動機構の動力を利用したりすることができる他、別途に流体圧アクチュエーター等の駆動手段を設けることによりなされる。
【００２２】
絵付シートの供給方法としては、巻き出し巻き取り方式（ロール／ロール方式）、あるいは、ロール状に巻き取られた長尺の連続帯状シートの先端を搬送チャック等で把持して雌型のパーティング面上に供給するとともに、１ショット分毎に切断して枚葉シートとなす方式、枚葉シートをロボット等で供給する方式等、いずれの供給方式も採用できる。
【００２３】
また、本発明装置では、好ましくは、予備成形（延伸工程）を行うべく、熱盤を備える。熱盤としては、伝導熱を用いる接触加熱方式、あるいは輻射熱や誘電加熱を用いる非接触加熱方式のいずれを採用してもよい。また、熱盤に絵付シートを幅方向に切断する切断手段を設けてもよい。切断手段としては、切断刃やニクロム線等の電熱線からなる加熱線条を用いることができる。
【００２４】
絵付シートは、基材シートとその上に積層された装飾層からなり、基材シートを射出樹脂成形体と密着一体化させたまま最終製品として使用する貼り合わせ積層シート（ラミネートシート）を使用することができる。
前記貼合わせ積層シートの場合、基材シートとしては、ポリエチレン、ポリプロピレン等のポリオレフィン樹脂、ポリ塩化ビニル、アクリル樹脂、ポリスチレン、ＡＢＳ樹脂、ポリカーボネート樹脂、ポリエステル樹脂等の熱可塑性樹脂を用いることができる。基材シートの厚さは、通常２０〜５００μｍ程度である。装飾層としては、印刷絵柄、着色又は透明塗装、金属薄膜、あるいは、硬質塗膜、防曇塗料、導電性層等の機能性層等を用いることができる。
【００２５】
射出成形用の樹脂としては、ＡＢＳ（アクリロニトリル・ブタジエン・スチレン共重合体）樹脂、ポリオレフィン樹脂、ポリスチレン、ポリ塩化ビニル、アクリル樹脂、ポリカーボネート樹脂等の熱可塑性樹脂を加熱熔融して液状ないし流動状態となったもの、あるいは、二液硬化型、触媒硬化型の樹脂、例えば、ウレタン樹脂、ポリエステル樹脂等の未硬化液等の射出成形同時絵付用として従来より知られている材料を使用でき、製品の要求物性やコスト等に応じて選定される。
【００２６】
本発明方法装置では、前記樹脂が遮光性を持つように、それに顔料（黒…カーボンブラック、鉄黒、褐色…弁柄、白…チタン白等）を添加することが好ましく、これにより、光漏れ対策（マスキングテープ貼り等）を不要とすることができる。
【００２７】
【発明の実施の形態】
以下、図面を参照して本発明の実施の形態を詳細に説明する。
【００２８】
図１は、本発明に係る射出成形同時絵付装置の一実施形態を示す全体概略縦断面図である。
本実施形態の射出成形同時絵付装置１０により得るべき積層製品１は、前記した従来例（図９〜図１１）のものと同様に、平面視では矩形状で断面がコ字状のパネルであり、その表面側中央上部に計器パネル類を後付けするための矩形の窓開口１Ａ（図７）が形成され、射出樹脂成形体１Ｐ（図７、図８）の表面に絵付シート２を接着積層し、表面側中央下部に目盛文字部が光透過部とされた円形の透光部品（計器類用目盛文字板）３が射出成形同時絵付と同時に取付積層されるようになっている。
【００２９】
前記透光部品３は、図２及び図８に拡大図示される如くに、厚さが０．５〜３ｍｍのポリカーボネートからなる透明な円板３Ａが使用されており、その裏面側に、シルク印刷等により、光透過部３ｅとしての透明（無色透明、或いは、白色、赤色、青色、黄色等の着色透明乃至は半透明）の目盛文字及び黒色等の遮光部３ｆからなる表示層３Ｂが形成され、その裏面側外周縁部には、絵付シート２と一体化するための感熱融着型の接着剤層３ｇが形成されている。前記遮光部３ｆは、黒色、白色等の遮光性インキ、アルミニウム、クロム等の金属薄膜等の遮光層を、光透過部３ｅの部分を除いて形成することきにより得られる。
【００３０】
また、この透光部品３の中央には、後述する雌型キャビティ１３の底面に突設された、位置決め固定（抜け落ち防止）手段としての嵌合凸部９０に着脱可能に外嵌される嵌合穴３ｃが形成されるとともに、その表面側の中央下部（外周部）には、雌型キャビティ１３に形成された位置決め凹部９１に嵌め込まれる位置決め突起３ｄが突設されている。
【００３１】
絵付シート２として、ここでは、アクリル樹脂製の基材シート（厚みは１２５μｍ）と、その上にグラビア印刷法により積層された装飾層（アクリル樹脂と塩化ビニル酢酸ビニル共重合体の１：１重量比混合物をバインダー樹脂とし、これに、チタン白、弁柄、黄鉛、フタロシアニンブルー、及びカーボンブラックからなる顔料を添加）と、接着剤層（塩化ビニル酢酸ビニル共重合体系）とからなり（装飾層兼接着剤層２ｓ）、基材シートを射出樹脂成形体１Ｐと密着一体化させたまま最終製品として使用する貼り合わせ積層シート（ラミネートシート）を用いている。前記装飾層（絵柄層）は、柄版を３色組み合わせた木目模様となっており、また、前記接着剤層は、スクリーン線数４０線／ｃｍのグラビアベタ印刷版（版深６０μｍ）を２度用いて（グラビア印刷２色刷りして）形成した厚みが２μｍの層である。
【００３２】
また、前記絵付シート２には、図３に示される如くに、シート供給方向（Ｚ方向）に沿って所定間隔をもって縦位置決めマークＭａ、Ｍａ、…が形成されるとともに、シート供給方向に沿って直線からなる横位置決めマークＭｂが形成されている。前記縦位置決めマークＭａ、Ｍａ、…は、後述する雌型１２上流側に配在されたセンサ５６により読み取られ、前記横位置決めマークＭｂは、雌型１２上流側及び下流側に配在されたセンサ５７、５８により読み取られるようにされ、それらのセンサ５６、５７、５８からの検出信号に基づいて、絵付シート２の送り量の調節や位置決めを行うようになっている。
【００３３】
本実施形態の射出成形同時絵付装置１０は、前記した得るべき積層製品に対応した凹凸形状の雌型１２と雄型３０とを備え、雌型１２は、図示はされていないが、その底部が可動盤に固定されていて、流体圧シリンダのラム等により水平方向（図１のＸ方向）、言い換えれば、雄型３０に対して接近−離隔する方向に進退動するようされている。
【００３４】
なお、本実施形態では、上記のように雌型１２が可動型とされていて水平方向に移動するようにされているが、これに限定される訳ではなく、例えば、雄型、雌型を上下に対向配置してそれらの一方を鉛直方向に移動させる等の形態を採用することもできる。
【００３５】
前記雌型１２の上方（シート供給方向上流側）には、雌型１２のパーティング面１４上に絵付シート（ラミネートシート）２を供給すべく、上流側送り出し装置１０１が配置され、また、前記雌型１２の下部付近（シート供給方向下流側）には下流側シート固定装置１０２が配置されている。
【００３６】
前記上流側送り出し装置１０１は、巻き取られた長尺帯状の絵付シート（シートロール）が装填された巻出機１０３と、一対のニップロールからなるシート送りロール１０４と、案内ロール１０５と、に加えて、前記巻出機１０３から巻き出された絵付シート２の下流側端部２ｅより若干上流側部分を把持して前記下流側シート固定装置１０２まで搬送する開閉挟持式の搬送チャック５０を有している。該搬送チャック５０は、図示されていないエアーシリンダのピストンロッド５２の先端部に取り付けられており、図１に示される初期位置からＺ方向（鉛直方向＝シート供給方向）に沿って真っ直ぐに前進及び後退せしめられる。また、前記巻出機１０３、シート送りロール１０４、案内ロール１０５、及び搬送チャック５０は、絵付シート２を挟持した状態で互いに同期して絵付シート２の幅方向、すなわち、Ｘ方向及びＺ方向に直行するＹ方向（図４）に横移動できるようになっている。
【００３７】
前記下流側シート固定装置１０２は、前記搬送チャック５０により搬送されて来た絵付シート２の下流側端部２ｅを受け取って把持固定する開閉挟持式の受取固定チャック６０と、該受取固定チャック６０を絵付シート２の幅方向及びシート供給方向に移動させる支持駆動機構６５と、を有し、前記絵付シート２（の下流側端部２ｅ）を幅方向及びシート供給方向に移動させ得るようになっている。
【００３８】
また、前記雌型１２には、得るべき積層製品に対応したキャビティ１３が形成され、このキャビティ１３には、絵付シート２を該キャビティ１３に沿わせるように延伸させるべく真空吸引するための多数の真空吸引孔１５、１５、…が開口せしめられ、この真空吸引孔１５、１５、…は、真空吸引通路１８及び導管１９を介して外部の真空ポンプ等からなる真空源（図示せず）に接続されている。
【００３９】
また、キャビティ１３の底面には、得るべき積層製品１の窓開口１Ａを形成するための角形凸部８９が突設されるとともに、前記透光部品３の中央に形成された嵌合穴３ｃが着脱可能に外嵌される、位置決め固定（抜け落ち防止）手段としての嵌合凸部９０が突設され、さらに、前記透光部品３に設けられている位置決め突起３ｄが嵌め込まれる位置決め凹部９１が形成されている。
【００４０】
さらに、前記雌型１２のパーティング面１４の外周側には、Ｏリング２２が装着された環状の装着溝２３が設けられている。前記Ｏリング２２は、後述するＸ方向から見た形状が矩形枠状ないし井桁状のクランパー２０が、間に絵付シート２を挟んで雌型１２のパーティング面１４に押し付けられた際、前記キャビティ１２と外部とを気密的に遮断する役目を果たす。
【００４１】
一方、前記雄型３０は、図示はされていないが、射出成形機のノズルが装着される固定盤に固定されており、この雄型３０には、前記積層製品形状に対応した凸状コア部３１が設けられるとともに、その内部には、熔融樹脂射出用のランナー３２及びそれに連なるゲート３３が設けられている。
【００４２】
前記凸状コア部３１には、図７を参照すればよくわかるように、角形凸部８９及び透光部品３に対向するように凹部３１ａ、３１ｂが形成されるとともに、射出樹脂成形体１Ｐにおける前記透光部品３の裏面側に窓開口１Ｂを形成するための窓形成用凸部３１ｃが設けられている。
【００４３】
また、前記雌型１２には、供給された１ショット分の絵付シート２を前記パーティング面１４上に押圧固定すべく、図４に２点鎖線の仮想線で示される如くの矩形枠状ないし井桁状のクランパー２０が設けられている。このクランパー２０は、その四隅に連結された４本の摺動ロッド２４を介して図示されていない駆動手段により前記パーティング面１４に対して垂直方向（図のＸ方向）に進退動できるようになっている。
【００４４】
さらに、予備成形を行うべく、図５に示される如くの熱盤８０を備える。熱盤８０は、エアーシリンダ等の熱盤移送手段８１により、雄雌両成形型外の待機位置から雌型１２のパーティング面１４上の絵付シート加熱位置まで移動せしめられて、絵付シート２を加熱軟化させるようになっている。熱盤８０は、図５の例では赤外線輻射による非接触加熱方式であるが、勿論、絵付シートと接触させて熱伝導を利用する接触加熱方式であってもよい。また、この熱盤８０の上端部には、前記絵付シート加熱位置まで移動せしめられたとき、絵付シート２を幅方向に切断するための切断刃８５が設けられている。なお、前記雌型１２の上端部付近には、前記切断刃８５を受け入れる受入れ溝８６が穿設されている。
【００４５】
上記のような構成とされた本実施形態の射出成形同時絵付装置１０においては、以下のようにして射出成形同時絵付が行われる。
まず最初に、図２に示される如くに、透光部品３の嵌合穴３ｃ及び位置決め突起３ｄを雌型キャビティ１３底面に形成されている嵌合凸部９０及び位置決め凹部９１に嵌め込んで位置決め固定する。
【００４６】
このようにして透光部品３を位置決め固定した後、前記搬送チャック５０を下降させて絵付シート２の１ショット分を雌型のパーティング面１４とクランパー２０との間に供給するシート供給工程を行い（図３、図４）、次に、図５に示される如くに、絵付シート２を前記クランパー２０により前記雌型１２のパーティング面１４に保持固定するクランプ工程を行う。
【００４７】
続いて、熱盤８０を、クランパー２０により押圧固定されている絵付シート２上に移動させるとともに、雌型パーティング面１４に接近させて、それに設けられている切断刃８５により絵付シート２を雌型１２の上流側端部付近で切断し、かつ、シート加熱位置（図示位置）にて絵付シート２を加熱軟化させるとともに、雌型キャビティ１３に開口する真空吸引孔１５等で構成される真空吸引手段による真空吸引を行って、前記絵付シート２を雌型キャビティに沿って密着させるべく延伸させる。
【００４８】
なお、この真空吸引による延伸工程以後は、前記真空吸引孔１５を通じて、前記透光部品３も吸引されるので、該透光部品３がしっかりと固定されるとともに、該透光部品３に被さるように絵付シート２が密着せしめられる。
その後、図６に示される如くに、雌型１２を雄型３０側に移動させて、雄型３０と雌型１２との型締めを行って、射出成形機からの流動状態の透明樹脂１Ｐを雌型１２と雄型３０との間に形成される成形キャビティへ射出充填し、この透明樹脂が固化した後、前記雄雌両成形型１２、３０の型開きを行う。これにより、射出樹脂成形体１Ｐ表面に絵付シート２が接着積層され、かつ、絵付シート２の表面に透光部品３が接着固定され、透光部品３、絵付シート２、及び射出樹脂成形体１Ｐの三者が一体化した積層製品１は、その後、雄型３０に伴って、あるいは、取り出しロボットやイジェクターピン等により、雌型１２から型開き方向に取り出される。この場合、前記透光部品３は、雌型１２のキャビティ１３に積層製品取出方向（通常は型開き方向）に沿って着脱可能に嵌め込まれているので、絵付シート（積層製品表面）２から離れることなくそれと一体に取り出される（図７参照）。
【００４９】
しかる後、図８（Ｂ）に示される如くに、前記射出樹脂成形体１Ｐの表面を覆っている前記絵付シート２のうちの前記窓開口１Ｂを塞いでいる部分２Ｂを裏面側から切除して、前記透光部品９の目盛文字からなる光透過部（中央部）３ｅを露出させる。絵付シート２のうちの前記窓開口１Ｂを塞いでいる部分２Ｂは、射出樹脂成形体１Ｐ及び透光部品３のいずれにも接着されていないので、容易に取り除くことができる。
【００５０】
ここで、本実施形態では、目盛文字部等を有する透光部品３は、予め雌型キャビティ１３に位置決め固定されるので、それに不所望な歪み、傾斜、位置ずれ等が生じることはなく、また、絵付シート２として通常の木目模様等が施されたもの、つまり、光を透過しないものが用いられるが、この絵付シート２のうちの前記窓開口１Ｂを塞いでいる部分２Ｂは切除されるので、前記透光部品３の目盛文字からなる光透過部３ｅは、最終的には露出せしめられる。
【００５１】
このため、絵付シート２が延伸工程で延伸せしめられることに起因して、適正位置、つまり、前記透光部品３に対して、多少の歪み、傾斜、位置ずれ等が生じても、前記目盛文字等からなる光透過部３ｅには全く悪影響は与えない。そのため、絵付シート２の位置決め、延伸方向、延伸量等を厳密に制御しなくても、美観、視認性を損なうことがなく、歩留りを向上させることができるとともに、製造コストを可及的に抑えることができる。
【００５２】
【発明の効果】
以上の説明から理解されるように、本発明に係る射出成形同時絵付方法及び装置によれば、積層製品の表面の特定部位に、視認性等を向上させるべく裏面側からの光（照明）を透過させる透明の光透過部を有する、計器類用目盛文字板等の透光部品を、射出成形同時絵付と同時に取付固定でき、しかも、目盛文字部等の透光部に歪み、傾斜、位置ずれ等を生じさせず、美観、視認性を低下させることがなく、歩留りを向上できるとともに、製造コストを可及的に抑えることができる。
【図面の簡単な説明】
【図１】本発明に係る射出成形同時絵付装置の一実施形態を示す全体概略縦断面図。
【図２】透光部品を示し、（Ａ）は平面図、（Ｂ）は雌型キャビティに装着前の断面図である。
【図３】図１に示される装置のシート供給工程の説明に供される概略縦断面図。
【図４】図１に示される装置のシート供給工程の説明に供される雌型周辺部の平面図。
【図５】図１に示される装置のクランプ工程、加熱軟化工程、延伸工程の説明に供される概略縦断面図。
【図６】図１に示される装置の射出成形工程の説明に供される概略縦断面図。
【図７】図１に示される装置の射出成形工程完了状態を示す概略拡大縦断面図。
【図８】図１に示される装置から得られた積層製品の要部を拡大して示し、（Ａ）要部平面図、（Ｂ）は要部縦断面図。
【図９】積層製品の特定部位に目盛文字板等の透光部品（透光部）を設ける場合の従来の第１方法の説明に供される図。
【図１０】従来の第１方法の透光部品取付段階の説明に供される図。
【図１１】従来の第１方法で得られた透光部品付き積層製品を示す図。
【図１２】積層製品の特定部位に目盛文字板等の透光部品（透光部）を設ける場合の従来の第２方法で用いる絵付シートを示す図。
【図１３】従来の第２方法で得られた積層製品を示す概略縦断面図。
【図１４】従来の第２方法で得られた透光部付き積層製品の要部を示す拡大図。
【図１５】図１〜図８に示される本発明の方法及び装置による透光部品と絵付シート（の光透過部分）との位置決め精度の説明に供される図。
【符号の説明】
１積層製品
１Ｐ射出樹脂成形体
２絵付シート
１Ｂ窓開口
３透光部品
３ｅ光透過部
１０射出成形同時絵付装置
１２雌型
１３キャビティ
１４パーティング面
１５真空吸引孔
２０クランパー
３０雄型
３１ｃ窓開口形成用凸部[0001]
BACKGROUND OF THE INVENTION
The present invention is an injection in which a decorative sheet (laminated product) is obtained by integrally bonding and laminating a picture sheet with a pattern, characters, etc. in a mold on the surface of an injection resin molding simultaneously with injection molding. The present invention relates to a molding simultaneous painting apparatus.
[0002]
[Prior art]
As an injection molding simultaneous painting method in which a painting sheet is integrally bonded to the surface of an injection resin molded body at the same time as injection molding, several modes have been proposed in the past, most of which have the following (a) to (a) to All or some of the steps (i) are performed in the order of description or by changing the order thereof, so that a plurality of steps are performed simultaneously or in duplicate or in parallel (Japanese Patent Publication No. 50-19132, actual No. 3-56344, Japanese Patent Publication No. 7-41637, etc.).
[0003]
(A) A sheet supplying step of supplying a picture-attached sheet onto a female parting surface used for injection molding.
(B) A clamping step of pressing and fixing the picture sheet to the female parting surface.
(C) A heating and softening process in which the picture sheet is softened by heating with a hot platen or the like.
(D) A stretching process (preliminary molding process) in which the picture sheet is stretched along the female cavity by vacuum suction and / or compressed air supply.
(E) A mold clamping step in which one of the female mold and the male mold (usually female mold) is moved to the other (usually male mold) side to perform mold clamping.
(F) An injection molding process in which injection molding is performed by injecting and filling a resin (melted resin) in a fluid state from the male mold side into a cavity formed between the female mold and the male mold.
(G) A mold opening step for separating the female mold and the male mold.
(H) A sheet trimming step in which a portion to be attached to the injection resin molded body of the picture-attached sheet is separated from other portions (excess portions).
(I) A step of taking out a laminated product in which a sheet with a picture is bonded and laminated from both male and female molds.
[0004]
In addition, performing a plurality of processes simultaneously and overlapping means that a plurality of processes are included in one process. For example, in the mold clamping process of (e), a picture sheet is placed between a female mold and a male mold. If sandwiched and held, the clamping step (b) was performed at the same time as the mold clamping step, and the picture sheet was injected in the injection molding step (f). If the resin is stretched by the heat and pressure of the molten resin, it refers to the case where the stretching step (d) is performed simultaneously with the injection molding step.
[0005]
In addition, as a sheet with a picture, either a laminated sheet (laminate sheet) or a transfer sheet is used depending on the product type. In the case of a laminate sheet, the picture was painted as it was by injection molding. Thus, the entire layer of the sheet is bonded and integrated on the surface of the injection resin molded body to form a decorative layer. On the other hand, when the picture sheet is a transfer sheet, the support sheet of the picture sheet integrated on the surface of the injection resin molded body is peeled off, and only the transfer layer such as a decoration layer remains on the injection resin molded body side. The painting is completed by making it a makeup layer.
[0006]
[Problems to be solved by the invention]
By the way, the laminated product to be obtained by injection molding simultaneous painting has a transparent light transmitting part that transmits light (illumination) from the back side in a scale / pattern to improve visibility and the like at the specific part. In some cases, it is required to provide a light-transmitting component (light-transmitting portion) such as a scale dial for instruments. Thus, in order to provide a translucent component (translucent part) such as a scale dial at a specific part of a laminated product, the following two methods have been conventionally employed.
[0007]
The first method is a method of simultaneous injection-molding painting as described above (a) to (i) in order to obtain a laminated product 4 with a translucent component 6 as shown in FIGS. 11 (A) and 11 (B). 9, as shown in FIG. 9, the picture sheet 5 having a wood grain pattern is adhered and laminated on the surface of the injection resin molded body 4 P, and a rectangular window opening 4 A for retrofitting an instrument panel and the scale A mounting hole 4B with a stepped portion 4b for attaching a circular translucent component (scale dial plate) 6 having a character portion as a light transmitting portion is provided. In this case, since the picture sheet 5 is bonded and laminated so as to cover the entire surface of the injection resin molded body 4P, after the injection molding process, the laminated product 4 ′ (unfinished product) is taken out from the male and female molds, and then the picture is attached. Out of the sheet 5, the outer peripheral surplus portion 5C that is not adhesively laminated to the injection resin molded body 4P and the closed portions 5A and 5B that close the window opening 4A and the mounting hole 4B (the stepped portion 4b thereof) are cut off, and thereafter Then, an adhesive or the like is applied to the outer periphery of the back surface of the translucent component (scale dial) 6 and is pressed into the mounting hole 4B (the stepped portion 4b thereof) to be fixed (see FIGS. 10 and 11).
In the first method, it is necessary to attach and fix the translucent component 6 to the laminated product 4 ′ after the completion of the simultaneous injection molding, which increases the number of steps and labor and increases the manufacturing cost. .
[0008]
In the second method, as shown in FIG. 12, a translucent part (scale character part) 9 is formed in advance on a specific part of the decorative layer 8B of the decorative sheet 8B as shown in FIG. Using this picture sheet 8, the picture sheet 8 is adhered to the surface of the injection resin molded body 7P by the injection molding simultaneous painting method as described in (a) to (i) as shown in FIG. While being laminated, a rectangular window opening 7A for retrofitting instrument panels is provided. In this case, a transparent resin is used as the resin (injection resin molding 7P) to be injected and filled into the molding cavity in the injection molding process. Thereby, the sheet | seat 8 with a picture covers the whole surface of the transparent injection resin molding 7P, and is bonded and laminated | stacked so that the said translucent part (scale character part) 9 may be located in a specific site | part. After that, if the outer peripheral surplus portion 8C that is not bonded and laminated to the injection resin molded body 7P or the closed portion 8A that closes the window opening 7A is cut out of the picture sheet 8, as shown in FIG. The laminated product 7 with the light part 9 is obtained. In this method, longitudinal positioning marks Ma, Ma,... And lateral positioning marks Mb are formed in advance on the picture sheet 8 (see FIG. 12), and these marks Ma, Mb are provided in the picture sheet supply process. Is read by the sensor to position the picture sheet 8 with respect to the female cavity 13.
In the second method, a translucent component is not required separately, and the translucent part (scale character part) 9 can be provided simultaneously with the simultaneous injection molding picture, so that it is less labor-intensive than the first method. However, the manufacturing cost can be kept low.
[0009]
However, in this method, due to the fact that the picture sheet 8 is stretched in the stretching process, the translucent part 9 formed on the picture sheet 8 has an appropriate position indicated by a virtual line F in FIG. There is a problem that the actual translucent portion 9 has problems such as distortion, inclination, and positional deviation with respect to the shape. That is, the drawing direction and the drawing amount of the picture sheet 8 are not uniquely determined by the environmental conditions such as the temperature and the product shape during the injection molding and the preliminary molding prior to the injection molding, and it is extremely difficult to precisely control them. Difficult, for example, when the vertical and horizontal dimensions of the laminated product 7 are 20 to 30 cm, the light transmission part (scale character part) 9 having a diameter of 30 to 50 mm may be distorted, inclined, misaligned, or the like by about 1 to 2 mm. Although unavoidable, when distortion, inclination, or positional deviation of about 1 to 2 mm occurs in the translucent part (scale character part) 9, the aesthetics and visibility are affected by the deviation from the position and angle of the illumination light source on the back side. It is damaged and becomes a defective product, resulting in poor yield.
[0010]
The present invention has been made to solve the above-described problems, and the object of the present invention is to provide light (illumination) from the back side to improve the visibility and the like on a specific part of the surface of the laminated product. A translucent part such as a scale dial for instruments, which has a transparent light transmitting part on the character or scale on the scale, and a light shielding part around the light transmitting part, can be mounted and fixed simultaneously with the injection molding simultaneous painting. In addition, distortion, inclination, misalignment, etc. are not caused in the translucent part such as the scale character part, the appearance and visibility are not lowered, the yield can be improved, and the manufacturing cost can be suppressed as much as possible. An object of the present invention is to provide an injection molding simultaneous painting method and apparatus capable of performing the same.
[0011]
[Means for Solving the Problems]
In order to achieve the above-mentioned object, the injection molding simultaneous painting method according to the present invention has a light-transmitting portion made of a transparent scale character and the like, and a light-shielding layer is bonded and laminated on the surface of an injection resin molded body. A male mold provided with a window-forming convex part for forming a window opening on the back side of the translucent part in the injection-molded resin body. And the translucent component is arranged in a detachable manner along the direction in which the laminated product is taken out at a specific portion of the female cavity facing the male window forming convex portion. A picture sheet is supplied onto the drawing surface, and the picture sheet is fixed and held on the parting surface of the female mold by the clamping means, and then the picture sheet is stretched so as to be in close contact with the cavity of the female mold. ,in front The mold is clamped by moving one of the female mold and the male mold to the other side, and the resin in a fluid state is injected and filled from the male mold side into a molding cavity formed between the female mold and the male mold. The injection resin molded body made of the resin and the picture sheet are laminated and integrated, and then the mold is opened to separate the female mold and the male mold, and the picture sheet and the translucent component are bonded and laminated. The laminated product thus obtained is taken out from the female mold.
[0012]
In the method of the present invention, it is preferable to use a resin having light shielding properties as the fluidized resin (injection resin).
In a more preferred embodiment, the translucent component is provided with an integration means such as an adhesive, a pressure-sensitive adhesive, or a double-sided tape for integrating with the picture sheet on the outer peripheral edge of the back surface. In the step of laminating and integrating, the translucent component and the picture sheet are bonded and integrated only at the outer peripheral edge of the back surface, and then the surface of the injection resin molded body is covered. A portion of the sheet with a picture covering the window opening is cut out to expose a light transmitting portion of the light transmitting component.
[0013]
An injection molding simultaneous painting apparatus according to the present invention is for carrying out the above method, and has a window forming convex part for forming a window opening on the back side of the translucent part in the injection resin molded body. For positioning and fixing the translucent component detachably along the laminated product take-out direction at a specific portion facing the male window forming convex portion in the male mold provided and the male mold in the female mold cavity And a female die provided with component positioning means.
[0014]
Preferably, the component positioning means includes a fitting convex portion or a fitting hole into which a fitting hole or a fitting convex portion provided in the light transmitting component is detachably fitted along the laminated product take-out direction. Examples of the component positioning means include those using the fitting method, vacuum adsorption method, magnetic adsorption method, and the like.
[0015]
In a preferable aspect of the injection molding simultaneous painting method and apparatus of the present invention configured as described above, a fitting hole provided, for example, in the translucent part is provided at a specific portion of the female cavity. There is provided a fitting convex portion that is detachably fitted along the take-out direction, and the fitting convex portion has, for example, a light-shielding ink on the back surface side to have a light transmitting portion such as scale characters, and a display portion. The translucent component made of transparent resin molded product, glass or the like is detachably fitted along the direction of taking out the laminated product and positioned and fixed. After the decorative part is positioned and fixed in the fitting recess in this way, the picture sheet is supplied onto the female parting surface (sheet supply process), and the supplied picture sheet is clamped by the clamping means. After being fixedly held on the surface (clamping process), the picture sheet is stretched so as to be brought into close contact with the female mold cavity by a vacuum suction means or the like (stretching process or preliminary molding process).
[0016]
For this reason, due to the fact that the picture sheet is stretched in the stretching process, even if some distortion, inclination, misalignment, etc. occur with respect to the appropriate position, that is, the translucent component, There is no adverse effect on the light transmission part. Therefore, it is possible to improve the yield without impairing the aesthetics and visibility without strictly controlling the positioning, stretching direction, stretching amount, etc. of the picture sheet, and to suppress the manufacturing cost as much as possible. Can do. That is, as shown in FIG. 15A, the radius of the translucent component 3 is R0 + ΔR, the circumscribed circle radius of the scale character portion is R0, and as shown in FIG. A light transmitting portion (transparent region) 2z having no pattern of radius R0 + ΔR / 2 is formed in a portion facing the light transmitting component 3 in FIG. Then, the positioning target is set by setting the contour line of the light transmitting portion (transparent region) 2z of the painted sheet 2 to be located on the line of radius R0 + ΔR / 2 from the center of the light transmitting component 3. As can be seen from FIG. 15A, the allowable errors are ΔY = ± ΔR / 2 and ΔZ = ± ΔR / 2 in the Y direction and the Z direction, respectively. This makes it possible to improve the yield without impairing the aesthetics and visibility without strictly controlling the positioning, stretching direction, stretching amount, etc. of the painting sheet, and to suppress the manufacturing cost as much as possible. be able to.
[0017]
As described above, the laminated product in which the three parts of the translucent part, the sheet with a picture, and the injection resin molded body are integrated is then removed from the female mold along with the male mold or by a take-out robot or an ejector pin. It is taken out in the mold opening direction. In this case, since the translucent component is detachably fitted in the female product cavity along the direction of taking out the laminated product (usually the mold opening direction), it is integrated with the picture sheet (the surface of the laminated product) without leaving it. To be taken out.
[0018]
In this case, further, an adhesive or the like is integrated with the outer peripheral portion on the back surface side of the translucent component (in other words, the portion that is brought into contact with the peripheral portion of the window opening formed in the injection resin molded body via the sheet with a picture). If the means is applied, in the drawing step, the translucent component is bonded and integrated to a specific part of the surface of the picture sheet, and in the subsequent injection molding process, the picture sheet and the injection resin molded body are integrated. Then, a laminated product is obtained in which the translucent component is positioned and fixed at the specific part, and a window opening is formed on the back surface side of the translucent component in the injection resin molded body. In this case, after the injection molding step and the mold opening step, a part of the picture sheet covering the surface of the injection resin molded body covering the window opening (translucent part) is cut off from the back side. Then, the light transmitting portion of the light transmitting component is exposed.
In the method apparatus of this embodiment, the translucent component having a scale character portion or the like is positioned and fixed in advance in the female mold cavity and is not subjected to deformation in the pre-molding process, and the picture sheet also has heat and stress in the injection molding process. Because it relaxes, there is no undesired distortion, tilt, misalignment, etc. in the translucent parts, and the regular wood grain pattern etc. is applied to the entire surface as a picture sheet, and the entire surface does not transmit light Even if the positioning of the picture sheet is not performed with respect to the female mold cavity, the part of the picture sheet that closes the window opening is cut off, so that the light transmission part of the light transmitting component is finally Exposed.
[0019]
In the present invention, the male and female molds are made of metal such as iron, ceramics, or the like, and provided with small holes (vacuum suction holes or the like) for vacuum suction or pressurized air supply as necessary.
Further, the female mold is composed of an assembly of a plurality of divided portions (so-called nested structure), a slit-like gap is formed between adjacent divided portions, and this gap is used as a vacuum suction hole (and a pressure air supply hole). Then, vacuum suction (and air blow) may be performed.
[0020]
The male mold is provided with a runner and a required book gate for injecting resin in a fluid state. The number, position, shape, and the like of the gate can be freely set in consideration of the shape of the product to be obtained.
In addition, a clamp means is provided to fix and hold the picture sheet on the female parting surface. As the clamping means, a frame-shaped or cross-girder-shaped one can be used.
[0021]
In addition, in order to move the clamping means forward and backward with respect to the female parting surface, it is possible to use a driving force for molding such as a clamping operation or use the power of the ejector pin driving mechanism. This is done by providing driving means such as a fluid pressure actuator.
[0022]
As a method for supplying a picture sheet, the unwinding / rolling method (roll / roll method) or the part of a long continuous belt wound in a roll shape is held by a conveying chuck or the like, and the female parting is performed. Any of the supply methods such as a method of cutting on a surface and cutting each shot for a single sheet and a method of supplying a single sheet with a robot or the like can be adopted.
[0023]
Moreover, in this invention apparatus, Preferably, a hot platen is provided in order to perform a preforming (drawing process). As the hot platen, either a contact heating method using conduction heat or a non-contact heating method using radiant heat or dielectric heating may be employed. Moreover, you may provide the cutting means which cut | disconnects a sheet | seat with a picture in a width direction in a heating platen. As a cutting | disconnection means, the heating filament which consists of heating wires, such as a cutting blade and a nichrome wire, can be used.
[0024]
The sheet with a picture is composed of a base sheet and a decorative layer laminated on the base sheet, and uses a laminated sheet (laminate sheet) that is used as a final product while the base sheet is closely integrated with the injection resin molding. be able to.
In the case of the laminated sheet, a thermoplastic resin such as polyolefin resin such as polyethylene or polypropylene, polyvinyl chloride, acrylic resin, polystyrene, ABS resin, polycarbonate resin or polyester resin can be used as the base sheet. The thickness of a base material sheet is about 20-500 micrometers normally. As the decorative layer, a printed pattern, coloring or transparent coating, a metal thin film, or a functional layer such as a hard coating film, an antifogging paint, or a conductive layer can be used.
[0025]
As the resin for injection molding, a thermoplastic resin such as ABS (acrylonitrile / butadiene / styrene copolymer) resin, polyolefin resin, polystyrene, polyvinyl chloride, acrylic resin, polycarbonate resin is heated and melted to form a liquid or fluid state. It is possible to use materials that have been previously known for simultaneous injection molding of unmolded liquids such as uncured liquids such as two-part curable resins and catalyst curable resins such as urethane resins and polyester resins. It is selected according to the required physical properties and cost.
[0026]
In the method apparatus of the present invention, it is preferable to add a pigment (black: carbon black, iron black, brown: petal, white: titanium white, etc.) to the resin so that the resin has light shielding properties. Measures (such as masking tape) can be eliminated.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0028]
FIG. 1 is an overall schematic longitudinal sectional view showing an embodiment of an injection molding simultaneous painting apparatus according to the present invention.
The laminated product 1 to be obtained by the injection molding simultaneous painting apparatus 10 of the present embodiment is a panel having a rectangular shape and a U-shaped cross section in plan view, like the conventional example (FIGS. 9 to 11). A rectangular window opening 1A (FIG. 7) for retrofitting instrument panels and the like is formed in the center upper portion of the surface side, and the picture sheet 2 is adhered and laminated on the surface of the injection resin molded body 1P (FIGS. 7 and 8). A circular translucent component (instrument scale dial plate) 3 having a scale character portion as a light transmissive portion is attached and laminated at the same time as injection molding at the same time at the lower center of the surface side.
[0029]
As shown in FIGS. 2 and 8, the translucent component 3 uses a transparent disc 3A made of polycarbonate having a thickness of 0.5 to 3 mm, and silk printing is performed on the back side thereof. As a result, a transparent (colorless transparent or colored transparent or translucent color such as white, red, blue, yellow, etc.) scale characters and a light shielding part 3f such as black are formed as the light transmission part 3e. A heat-sensitive adhesive layer 3g for integration with the picture sheet 2 is formed on the outer peripheral edge of the back surface. The light-shielding part 3f is obtained by forming a light-shielding layer such as a light-shielding ink such as black or white, or a metal thin film such as aluminum or chrome, excluding the light transmission part 3e.
[0030]
Further, at the center of the translucent component 3, a fitting that is detachably fitted to a fitting convex portion 90 that projects from the bottom of a female cavity 13 to be described later and serves as a positioning and fixing (prevention of falling out) means. The hole 3c is formed, and a positioning projection 3d that is fitted into the positioning recess 91 formed in the female cavity 13 is provided projectingly at the center lower part (outer peripheral part) on the surface side.
[0031]
Here, as a sheet 2 with a picture, a base sheet made of an acrylic resin (thickness is 125 μm) and a decorative layer laminated thereon by a gravure printing method (1: 1 weight of an acrylic resin and a vinyl chloride vinyl acetate copolymer) A specific mixture is used as a binder resin, and this consists of a titanium white, petal, yellow lead, phthalocyanine blue, and carbon black pigment added) and an adhesive layer (vinyl chloride vinyl acetate copolymer system) (decoration) A layered and adhesive layer 2s) and a laminated laminate sheet (laminate sheet) that is used as a final product while the base sheet is closely integrated with the injection resin molded body 1P are used. The decorative layer (pattern layer) has a wood grain pattern combining three colors of pattern plates, and the adhesive layer is a gravure solid printing plate having a screen line number of 40 lines / cm (plate depth 60 μm). This is a layer having a thickness of 2 μm formed using two times (by gravure printing two colors).
[0032]
Further, as shown in FIG. 3, longitudinal positioning marks Ma, Ma,... Are formed on the picture sheet 2 at predetermined intervals along the sheet supply direction (Z direction) and along the sheet supply direction. A horizontal positioning mark Mb made of a straight line is formed. The vertical positioning marks Ma, Ma,... Are read by a sensor 56 disposed on the upstream side of the female mold 12 which will be described later, and the lateral positioning marks Mb are sensors disposed on the upstream and downstream sides of the female mold 12. The feeding amount of the picture sheet 2 is adjusted and positioned based on detection signals from the sensors 56, 57, and 58.
[0033]
The injection molding simultaneous painting apparatus 10 according to the present embodiment includes an uneven female die 12 and a male die 30 corresponding to the laminated product to be obtained, and the bottom of the female die 12 is not shown. It is fixed to the movable platen and is moved forward and backward in the horizontal direction (X direction in FIG. 1) by the ram of the fluid pressure cylinder, in other words, in a direction approaching and separating from the male mold 30.
[0034]
In this embodiment, the female mold 12 is movable as described above and moves in the horizontal direction. However, the present invention is not limited to this. For example, a male mold and a female mold are used. It is also possible to adopt a form such as arranging them vertically opposite to each other and moving them in the vertical direction.
[0035]
Above the female mold 12 (upstream side in the sheet supply direction), an upstream delivery device 101 is disposed to supply the picture sheet (laminate sheet) 2 onto the parting surface 14 of the female mold 12, A downstream sheet fixing device 102 is disposed near the lower part of the female die 12 (downstream side in the sheet supply direction).
[0036]
The upstream delivery device 101 includes an unwinder 103 loaded with a wound long belt-like picture sheet (sheet roll), a sheet feed roll 104 including a pair of nip rolls, and a guide roll 105. And an open / close clamping transport chuck 50 that grips a portion slightly upstream from the downstream end 2e of the picture sheet 2 unwound from the unwinder 103 and transports it to the downstream sheet fixing device 102. ing. The conveying chuck 50 is attached to the tip of a piston rod 52 of an air cylinder (not shown), and advances straight from the initial position shown in FIG. 1 along the Z direction (vertical direction = sheet feeding direction). It is made to retreat. Further, the unwinding machine 103, the sheet feeding roll 104, the guide roll 105, and the conveying chuck 50 are synchronized with each other in a state where the picture sheet 2 is sandwiched in the width direction of the picture sheet 2, that is, the X direction and the Z direction. It can be moved laterally in the perpendicular Y direction (FIG. 4).
[0037]
The downstream side sheet fixing device 102 receives and holds the downstream end 2e of the picture sheet 2 conveyed by the conveying chuck 50 and holds and fixes the receiving and fixing chuck 60. A support drive mechanism 65 for moving the picture sheet 2 in the width direction and the sheet supply direction, and the picture sheet 2 (downstream end 2e) can be moved in the width direction and the sheet supply direction. Yes.
[0038]
The female mold 12 is formed with a cavity 13 corresponding to the laminated product to be obtained, and the cavity 13 is provided with a number of vacuum suctions for extending the painting sheet 2 along the cavity 13. The vacuum suction holes 15, 15,... Are opened, and the vacuum suction holes 15, 15,... Are connected via a vacuum suction passage 18 and a conduit 19 to a vacuum source (not shown) including an external vacuum pump. Has been.
[0039]
Further, on the bottom surface of the cavity 13, a square convex portion 89 for forming the window opening 1 A of the laminated product 1 to be obtained is projected, and a fitting hole 3 c formed at the center of the translucent component 3 is formed. A fitting convex portion 90 is provided as a positioning fixing (preventing dropout) means that is detachably fitted, and a positioning concave portion 91 into which the positioning projection 3d provided on the translucent component 3 is fitted is formed. Has been.
[0040]
Further, an annular mounting groove 23 in which an O-ring 22 is mounted is provided on the outer peripheral side of the parting surface 14 of the female mold 12. When the O-ring 22 is pressed against the parting surface 14 of the female die 12 with a picture frame 2 sandwiched between a clamper 20 having a rectangular frame shape or a cross beam shape as viewed from the X direction, which will be described later, 12 and the outside are sealed off from the outside.
[0041]
On the other hand, although not shown, the male mold 30 is fixed to a fixed platen on which a nozzle of an injection molding machine is mounted. The male mold 30 has a convex core portion corresponding to the laminated product shape. 31 is provided, and a runner 32 for injecting molten resin and a gate 33 connected to the runner 32 are provided therein.
[0042]
As can be understood with reference to FIG. 7, the convex core portion 31 is formed with concave portions 31 a and 31 b so as to face the square convex portion 89 and the translucent component 3, and in the injection resin molded body 1 P. A window forming convex portion 31 c for forming the window opening 1 B is provided on the back surface side of the translucent component 3.
[0043]
Further, the female mold 12 has a rectangular frame shape as shown by a two-dot chain phantom line in FIG. 4 in order to press and fix the supplied sheet 2 with a picture on the parting surface 14. A cross-girder-shaped clamper 20 is provided. The clamper 20 can be moved back and forth in the vertical direction (X direction in the figure) with respect to the parting surface 14 by driving means (not shown) via four sliding rods 24 connected to the four corners. It has become.
[0044]
Further, a hot platen 80 as shown in FIG. 5 is provided to perform preforming. The hot platen 80 is moved by the hot platen transfer means 81 such as an air cylinder from the standby position outside the male and female molds to the heated sheet heating position on the parting surface 14 of the female mold 12, and the painted sheet 2 is moved. It is designed to soften by heating. The heating platen 80 is a non-contact heating method using infrared radiation in the example of FIG. 5, but may of course be a contact heating method that makes use of heat conduction by contacting with a picture sheet. Further, a cutting blade 85 for cutting the picture sheet 2 in the width direction when it is moved to the picture sheet heating position is provided at the upper end of the heating plate 80. In the vicinity of the upper end of the female die 12, a receiving groove 86 for receiving the cutting blade 85 is formed.
[0045]
In the injection molding simultaneous painting apparatus 10 of the present embodiment configured as described above, injection molding simultaneous painting is performed as follows.
First, as shown in FIG. 2, the fitting hole 3 c and the positioning protrusion 3 d of the translucent component 3 are fitted into the fitting convex portion 90 and the positioning concave portion 91 formed on the bottom surface of the female cavity 13 for positioning. Fix it.
[0046]
After the translucent component 3 is positioned and fixed in this way, a sheet supply step is performed in which the conveying chuck 50 is lowered to supply one shot of the picture sheet 2 between the female parting surface 14 and the clamper 20. Next, as shown in FIG. 5, a clamping step of holding and fixing the picture sheet 2 to the parting surface 14 of the female mold 12 by the clamper 20 is performed.
[0047]
Subsequently, the hot platen 80 is moved onto the picture sheet 2 pressed and fixed by the clamper 20, brought close to the female parting surface 14, and the picture sheet 2 is made female by the cutting blade 85 provided thereon. Vacuum suction composed of a vacuum suction hole 15 or the like which is cut near the upstream end of the mold 12 and softens the picture sheet 2 at the sheet heating position (illustrated position) and opens to the female mold cavity 13. By means of vacuum suction by means, the picture sheet 2 is stretched to adhere along the female cavity.
[0048]
After the stretching step by vacuum suction, the translucent component 3 is also sucked through the vacuum suction hole 15, so that the translucent component 3 is firmly fixed and covered with the translucent component 3. The picture sheet 2 is brought into close contact.
Thereafter, as shown in FIG. 6, the female mold 12 is moved to the male mold 30 side, the male mold 30 and the female mold 12 are clamped, and the transparent resin 1P in a fluid state from the injection molding machine is obtained. The mold cavity formed between the female mold 12 and the male mold 30 is injected and filled, and after the transparent resin is solidified, the male and female molds 12 and 30 are opened. As a result, the picture sheet 2 is bonded and laminated on the surface of the injection resin molded body 1P, and the translucent component 3 is bonded and fixed to the surface of the pictorial sheet 2 so that the translucent part 3, the pictorial sheet 2 and the injection resin molded body 1P are bonded. Then, the laminated product 1 in which the three members are integrated is taken out from the female die 12 in the mold opening direction along with the male die 30 or by a take-out robot or an ejector pin. In this case, since the translucent component 3 is detachably fitted in the cavity 13 of the female mold 12 along the direction of taking out the laminated product (usually the mold opening direction), it is separated from the picture sheet (laminated product surface) 2. It is taken out integrally with it (refer FIG. 7).
[0049]
Thereafter, as shown in FIG. 8B, a portion 2B of the picture sheet 2 covering the surface of the injection resin molded body 1P covering the window opening 1B is cut off from the back surface side. The light transmission part (center part) 3e which consists of the scale character of the said translucent component 9 is exposed. The portion 2B of the picture sheet 2 that covers the window opening 1B is not adhered to either the injection-molded resin 1P or the translucent component 3, and can be easily removed.
[0050]
Here, in the present embodiment, the translucent component 3 having a scale character portion or the like is preliminarily positioned and fixed in the female cavity 13, so that undesired distortion, inclination, misalignment or the like does not occur on the translucent component 3. A sheet with a normal wood grain pattern or the like, that is, a sheet that does not transmit light is used as the picture sheet 2, but the part 2B of the picture sheet 2 that covers the window opening 1B is cut off. The light transmitting part 3e composed of the scale characters of the light transmitting part 3 is finally exposed.
[0051]
For this reason, even if some distortion, inclination, position shift, etc. occur with respect to the appropriate position, that is, the translucent component 3 due to the fact that the picture sheet 2 is stretched in the stretching process, the scale characters There is no adverse effect on the light transmission part 3e made of, for example. Therefore, without strictly controlling the positioning, stretching direction, stretching amount, etc. of the picture sheet 2, it is possible to improve the yield without impairing aesthetics and visibility, and to suppress the manufacturing cost as much as possible. be able to.
[0052]
【The invention's effect】
As can be understood from the above description, according to the injection molding simultaneous painting method and apparatus according to the present invention, light (illumination) from the back side is applied to a specific part of the surface of the laminated product so as to improve visibility and the like. Translucent parts, such as scale dials for instruments, that have a transparent light transmitting part to be transmitted can be mounted and fixed simultaneously with the injection molding simultaneous painting, and the translucent parts such as scale letters are distorted, tilted and misaligned. Etc., aesthetics and visibility are not lowered, yield can be improved, and manufacturing cost can be suppressed as much as possible.
[Brief description of the drawings]
FIG. 1 is an overall schematic longitudinal sectional view showing an embodiment of an injection molding simultaneous painting apparatus according to the present invention.
2A is a plan view, and FIG. 2B is a cross-sectional view before mounting on a female cavity. FIG.
3 is a schematic longitudinal sectional view for explaining a sheet supply process of the apparatus shown in FIG.
4 is a plan view of a peripheral part of a female mold used for explaining a sheet supply process of the apparatus shown in FIG. 1. FIG.
FIG. 5 is a schematic longitudinal sectional view for explaining a clamping process, a heat softening process, and a stretching process of the apparatus shown in FIG. 1;
6 is a schematic longitudinal sectional view for explaining an injection molding process of the apparatus shown in FIG.
7 is a schematic enlarged longitudinal sectional view showing a completed state of an injection molding process of the apparatus shown in FIG.
8 is an enlarged view of a main part of a laminated product obtained from the apparatus shown in FIG. 1, (A) a plan view of the main part, and (B) a longitudinal sectional view of the main part.
FIG. 9 is a diagram used for explaining a first conventional method in the case where a translucent part (translucent part) such as a scale dial is provided at a specific part of a laminated product.
FIG. 10 is a diagram which is used for explaining a translucent component mounting stage of a conventional first method.
FIG. 11 is a view showing a laminated product with a translucent part obtained by the first conventional method.
FIG. 12 is a view showing a picture sheet used in the second conventional method when a translucent part (translucent part) such as a scale dial is provided at a specific part of a laminated product.
FIG. 13 is a schematic longitudinal sectional view showing a laminated product obtained by a second conventional method.
FIG. 14 is an enlarged view showing a main part of a laminated product with a light transmitting part obtained by a second conventional method.
15 is a diagram which is used for explaining the positioning accuracy between a light transmitting component and a picture sheet (light transmitting portion thereof) by the method and apparatus of the present invention shown in FIGS. 1 to 8; FIG.
[Explanation of symbols]
1 Laminated products
1P injection molded resin
2 Picture sheet
1B Window opening
3 Translucent parts
3e Light transmission part
10 Injection molding simultaneous painting equipment
12 Female
13 cavity
14 Parting surface
15 Vacuum suction hole
20 Clamper
30 male
31c convex part for window opening formation

Claims

Simultaneously with injection molding for bonding and laminating translucent parts formed by adhering and laminating a sheet with a light-shielding layer on the surface of an injection resin molded body and having a light-transmitting portion made of a transparent scale character, etc. A male mold provided with a window-forming convex part for forming a window opening on the back side of the translucent component in the injection resin molded body, and the male mold in a female cavity The translucent component is arranged in a detachable state along the direction of taking out the laminated product at a specific portion facing the window forming convex portion, and a picture sheet is supplied onto the female parting surface, and the clamping means After the picture sheet is fixedly held on the female parting surface, the picture sheet is stretched so as to be in close contact with the cavity of the female mold, and one of the female mold and the male mold is moved to the other side. Move Tightening and injecting and filling resin in a fluid state from the male mold side into a molding cavity formed between the female mold and the male mold, and the injection resin molded body made of the resin and the picture sheet Stacking and integrating, then performing mold opening to separate the female mold and the male mold, and taking out the laminated product in which the picture sheet and the translucent component are bonded and laminated from the female mold Injection molding simultaneous painting method.

The injection molding simultaneous painting method according to claim 1, wherein the resin in a fluid state has a light shielding property.

As the translucent component, an adhesive, a pressure-sensitive adhesive, or a double-sided tape or the like that is integrated with the picture sheet is provided on the outer peripheral edge on the back surface side, and the laminate is used. In the integration step, the translucent component and the painted sheet are bonded and integrated only at the outer peripheral edge of the rear surface side, and then the painted sheet covering the surface of the injection resin molded body 3. The method of simultaneous injection molding and painting according to claim 1 or 2, wherein a portion that closes the window opening is cut out to expose a light transmitting portion of the light transmitting component.

In the injection molding simultaneous painting device that glues and laminates a sheet with a picture on the surface of an injection resin molded article, and glues and laminates a translucent part formed so that the light shielding layer has a light transmitting part composed of transparent scale characters, etc. There,
A male mold provided with a window-forming convex part for forming a window opening on the back surface side of the translucent component in the injection resin molded body;
A cavity, in particular a position facing the window-forming convex part of the male in the cavity, wherein the component positioning means for the light-transmitting part along the stacking product outlet direction detachably positioned and fixed is provided Female type,
A picture sheet supply means for supplying a picture sheet on the female parting surface;
Clamping means for fixing and holding the picture sheet supplied by the picture sheet supply means on the female parting surface;
A sheet extending means for extending a picture sheet fixedly held by the clamp means so as to be closely adhered along the cavity of the female mold;
Mold clamping means for clamping one by moving one of the female mold and the male mold to the other side;
Injection obtained by injecting and filling a resin in a fluid state from the male mold side into a molding cavity formed between the female mold and the male mold by clamping with the mold clamping means and solidifying the resin Injection molding means for laminating and integrating the resin molded body and the picture sheet;
Mold opening means for separating the female mold and the male mold;
A take-out means for taking out the laminated product on which the picture sheet is bonded and laminated from the female mold,
An apparatus for simultaneous painting with injection molding, characterized by comprising:

The component positioning means includes a fitting convex portion or a fitting hole in which a fitting hole or a fitting convex portion provided in the light transmitting component is detachably fitted along the laminated product take-out direction. The injection molding simultaneous painting apparatus according to claim 4.