JP4699019B2 - Manufacturing method of film-forming molded product - Google Patents

Description

  The present invention belongs to the technical field of a method for manufacturing a film-forming molded product in which film-forming portions are laminated in a sandwich with a resin material.

In general, some of these types of film-formation molded products have an improved design by covering the surface of the member with a material having an effect such as a coloring effect or a reflection effect, such as a member such as an emblem for a vehicle. As this manufacturing method, for example, there is a method in which the surface of a member is formed by coating with a decorative chrome plating film (see, for example, Patent Document 1).
Nowadays, hexavalent chromium used for plating is a substance harmful to the human body, and since it causes pollution problems due to environmental pollution, it is subject to regulation and dechromation is required.
As an improvement measure, there is one in which a film is formed on a substrate surface by a film forming apparatus such as vacuum deposition or sputtering, and the surface of the film is covered with a resin material (for example, refer to Patent Document 2). .
Japanese Patent Laid-Open No. 6-146069 JP-A-6-169191

  However, in such a case, after the injection-molded base material is taken out from the injection molding apparatus, it is set in a vacuum vapor deposition apparatus to form a film, and then the film-formed base material is taken out from the vacuum vapor deposition apparatus and then injected. The number of processes is increased because it is set on the molding machine and injection molding of the resin material on the film forming surface is troublesome, and the work efficiency is not only poor. At this time, the film-forming surface, as well as the film-forming surface, may be scratched, dusty, or touched and the oil may adhere to it. There is a problem that non-defective products are produced and the yield is low, and there is a problem that the present invention does not solve.

The present invention was created in view of the above-described circumstances in order to solve these problems, and the invention of claim 1 is based on the separation movement in the opposing direction between the mold surfaces and the surface direction. A first mold and a second mold configured to be relatively moved in parallel with each other, the mold surfaces for forming the first molded product formed on both molds are matched, A first injection step for molding a molded product, a first demolding step of demolding from the second mold in a state where the molded first molded product is supported by the first mold, and the first first deposition for forming the first film molding to form a first film forming surface against so as to face the first deposition forming means provided one molding the second mold the first molded product a membrane process, a second demolding step of demolding from the second mold in a state that is supporting the first film molding a first mold, the first film molding a second A second injection step of forming a second molding by injecting leaving a portion of the first film molding of the Kazunari film surface against the mold surface for the second moldings provided on the mold, A third demolding step of demolding the second molded product from the second mold while being supported by the first mold, and a second film forming process in which the second molded product is provided in the second mold. A second film-formation product that forms a second film-formation product by forming a second film-formation surface so as to communicate with the second molded product and the remaining first film-formation surface. A process for producing a film-molded article characterized in that the steps are sequentially executed .
According to a second aspect of the present invention, in the first aspect , the second mold is removed from the first mold in a state where the second film-formed molded product is supported by the first mold after the second film-forming step. And a part of the second film-forming surface of the second film-formed molded product, leaving the second film-formed molded product butted against the mold surface for the third molded product provided in the second mold. A third injection step of injecting to form a third molded product, a fifth demolding step of releasing the third molded product from the second mold in a state supported by the first mold, and The third film formation surface is made to communicate with the third molded product and the remaining second film formation surface by abutting the third molded product against the third film formation means provided on the second mold. A third film forming step of forming a third film forming product by forming the film forming step is sequentially performed .
The invention of claim 3 is the method of manufacturing a film-formed molded article according to claim 1 or 2 , characterized in that the film-formed molded article is an electric base material, and the film-forming surface is an electric wiring.

According to the invention of claim 1 or 2, a three-dimensionally formed film-molded product can be improved in workability and high in yield compared to the prior art.
By setting it as invention of Claim 3 , the quantity of the metal used for wiring is small, and an electric base material without waste can be formed easily.

Next, a first reference example will be described with reference to FIGS. In the drawings, 1 is a movable mold (first mold), 2 is a fixed mold (second mold), and the movable mold 1 can be moved away from and in contact with the fixed mold 2. At the same time, it is configured to move in the direction along the surface with respect to the fixed mold 2 while being separated from the fixed mold 2 (parallel movement with respect to the mold surface). Since it can be performed using the technique of the mold moving method known from No. 1, it will be omitted. Since the movement of the mold may be relative, the first mold may be fixed and the second mold may be moved, or of course, both may be moved. . Further, the movement is not limited to the parallel movement in the linear direction as long as the movement is in the direction along the surface, and may be a rotational movement around the axis.

  The movable mold 1 is formed with an injection molding surface 1a having a concave shape for injection molding of the base material 3 (first molded product), while the fixed mold 2 is provided with the base 3 A first injection molding surface 2a that is flat for injection molding the film formation side surface 3a (inner side surface) and a concave injection molding for forming the coating material 4 (second molded product) by injection molding Each of the molding surfaces 2b is formed, and a film forming surface 2c having a concave shape is formed to accommodate (internally) a vacuum vapor deposition apparatus (film forming means, film forming apparatus) 5. Incidentally, in the fixed mold 2 of the present embodiment, the film forming molding surface 2c is formed between the first injection molding surface 2a and the second injection molding surface 2b. It can be set arbitrarily if necessary. The vacuum vapor deposition apparatus 5 is provided with a publicly known apparatus. As an outline, an intake passage 6 connected to a vacuum pump P, a boat 7 for containing a metal to be deposited (for example, aluminum or chromium), and heating the boat 7 are provided. And a heater 8 for doing so.

  The film-formed molded product 9 is an emblem for a vehicle in the present embodiment, and is molded in a series of steps using the molds 1 and 2 as will be described later. The base material 3 formed by the above process, the covering material 4 formed by injection molding of a light-transmitting resin material, and the base material 3 and the covering material 4 are formed by vacuum deposition at positions sandwiched between the base material 3 and the covering material 4. The film 10 is difficult to be peeled off and has an excellent design.

  Next, the manufacturing method of the film forming product 9 will be described. FIG. 2A shows both molds 1 and 2 in which the molding surface 1a for forming the base material 3 and the molding surface 2a for first injection face each other in a state of being separated from each other. The movable mold 1 is moved from the state to the fixed mold 2 side, and the opposing mold surfaces are matched (first mold matching step: see FIG. 2B). In this mold matching state, the first injection is performed, and the base material 3 (first molded product) is injection-molded (first injection step: see FIG. 2C).

  Thereafter, as shown in FIG. 3A, the movable mold 1 moves in a direction away from the fixed mold 2. At this time, the base material 3 is separated (demolded) from the fixed mold 2. The mold is designed so as to be supported (remain) on the movable mold 1 side (first demolding step). Next, the movable mold 1 is translated (see FIG. 3B) so that the base material 3 faces the vacuum deposition apparatus 5, and then moves to the fixed mold 2 side to be in a mold-matching state (second state). Mold matching step: see FIG.

When the base material 3 and the vacuum vapor deposition apparatus 5 are in a mold-matching state, the air in the film forming surface 2c is drawn from the intake passage 6 to be in a vacuum state, and the heated heater 8 The film 7 is supplied to the boat 7 and the molten metal is vaporized, and the film formation side surface 3a (the lower surface of FIG. 4A) where the substrate 3 is exposed is vacuum-deposited to form the film formation 10 (synthetic film formation). Membrane process: see FIG. Next, the movable mold 1 is separated from the fixed mold 2 while supporting the base material 3 (second mold release step: see FIG. 4B), and then the movable mold 1 is fixed to the fixed mold 2. The base material 3 and the second injection molding surface 2b are opposed to each other (see FIG. 4C).
Incidentally, since the film formation 10 is generally as thin as several micrometers to several tens of micrometers, for example, when trying to show it in a cross-sectional view, it is practically difficult to illustrate this. In order to make this easy to understand, in the drawings, it is described as having a certain thickness for the sake of convenience, but in actuality, it is almost the same surface as the film formation surface (hereinafter the same). For this reason, as will be described later, in the case where the film formation is partially laminated, even if the laminated portion is described in a stepped shape in the drawing (for example, the cross-sectional view in FIG. 11C), these Needless to say, when viewed with the naked eye, they are not stepped but can be seen only almost flush.
Needless to say, the film thickness can be arbitrarily adjusted by adjusting the deposition time.

  Thereafter, the movable mold 1 is moved to the fixed mold 2 side, and the opposing base material 3 and the second injection molding surface 2b are mold-matched (third mold-matching step: see FIG. 5A). After that, a resin material is injected onto the film formation side surface 3a on which the film formation 10 is formed (see the second injection step: FIG. 5B) to form the covering material 4 (second molded product), thereby forming the base material 3 The film formation 10 is formed by integrating the film 10 and the covering material 4. Then, after the movable mold 1 is separated from the fixed mold 2 and the film-forming molded product 9 is taken out (see FIG. 5C), the movable mold 1 is moved to the first position in FIG. By moving in parallel and thereafter repeating this process, the film-formed molded product 9 can be continuously formed.

In the first reference example configured as described above, a solid film-formation molded article 9 in which the surface of the film-formation 10 formed on the film-formation side surface 3a of the base material 3 is coated with the coating material 4 is manufactured to form a film. 10 is protected between a first injection molding process for injection molding of the base material 3 and a second injection process for integrating the base material 3 and the covering material 4. As a result of providing a film forming process for forming the film 10 and forming the film forming article 9 by a series of processes, the film forming 10 is once formed on the substrate 3 once taken out of the mold as in the prior art. Thereafter, as in the conventional case where it is necessary to set the mold again and cover with the covering material 4, the work of taking out and resetting the base material 3 becomes unnecessary, and the work efficiency is improved. Moreover, since the substrate 3 is not taken out and re-set, there is no touch of the film-forming surface, fingerprints, or damage to the object, and the entire process can be performed in a clean room. The occurrence of defective products can be greatly reduced.

As the film forming means is not limited to vacuum deposition apparatus 5, it is possible to employ for example, a method by cathode sputtering or the like, in the normal requires a known film deposition forming apparatus.

In the first reference example , the film formation 10 was formed on the entire surface of the film formation side surface 3 a of the substrate 3, and the entire film formation 10 surface was covered with the coating material 4. In the case where the film formation 10 has poor adhesion to the resin material, separation may be considered, and therefore the film formation molded body 11 is formed by the covering material 17 entering the periphery of the base material 14 as shown in FIG. It can be configured such that the materials are in direct contact and firmly bonded.
The second reference example similarly includes a fixed mold 12 and a movable mold 13, but the fixed mold 12 is formed with a convex surface 12 a that enters the peripheral portion 13 a of the movable mold 13. Then, after molding the peripheral surface 14a of the base material 14 with the convex surface 12a (see FIG. 7A), the film deposition side surface 14b of the base material 14 is vacuum-deposited by the vacuum deposition device 15 (see FIG. 7B). ), And after that, a coating material 17 is injected onto the film-formed surface and the peripheral surface 14a to form a solid film-formed molded article 11 (see FIG. 7 (c)). The movement of the movable mold 13 is the same as that of the first reference example , and the details thereof are omitted (the same applies hereinafter).

In the first or second reference example , the film formation surfaces 10 and 16 were applied to the entire film formation side surfaces 3a and 14b of the base materials 3 and 14, but as shown in FIG. The film-forming molded article 19 can be formed so as to have a portion (non-film-forming portion) 18b that is partially masked and not subjected to the film-forming 48, such as the peripheral portion of the film-forming side surface 18a. And in this case, masking can be performed at the peripheral edge 21b of the film forming surface 21a of the fixed mold 21 that accommodates the vacuum evaporation apparatus 20 as in the third reference example shown in FIG. Further, the masking material 22 can be attached as in the fourth reference example shown in FIG. And when using the masking material 22, it can carry out by coat | covering the masking material 22 on the film-forming side surface 18a of the base material 18 between the 1st demolding process and the 2nd mold matching process.
When masking is performed in this way, the base material 18 and the covering material 23 are directly brought into contact with each other at the non-film-forming portion 18b and are bonded to each other, so that an increase in strength can be achieved.

Furthermore, in the first to fourth reference examples , the film forming process is performed once, but it can be performed two or more times. For example, as shown in FIG. 10 (A), two sets of vacuum vapor deposition devices 24 and 25 are mounted on film forming mold surfaces 26a and 26b formed on a fixed mold 26, respectively, and are molded in the first injection process. After the first film formation process is performed on the film formation side surface 27a of the material 27, the second film formation process is performed, and then the second injection process is performed. The film surface can be formed so as to be covered with the covering material 28.

In this case, as in the fifth reference example , when the second film 30 is formed on the entire surface of the first film 29 (see FIG. 10B), the front and back of the film-formed molded article 31 Will be visually observed as a different film formation (limited to the case where the base material and the covering material are translucent materials). Further, as in the sixth reference example , the film formation positions of the first film formation 32 and the second film formation 33 are made different by performing the masking (FIGS. 11A and 11B). In the case of B), two different film formations 32 and 33 are visually observed from the surface of the film formation product 34. Furthermore, as in the seventh embodiment, the first film formation 35 and the second film formation position 36 are applied so as to partially overlap each other by performing the masking (FIG. 11 (C), (D)), the second film 36 is thin and the first film 35 is visible through the surface of the film-formed molded article 37. The three different film formations of the first and second film formations 35 and 36 and the mixture of the film formations 35 and 36 are visually observed.
In this case, two or more vacuum vapor deposition apparatuses are built in one film forming mold surface, and a plurality of films can be continuously formed.
Incidentally, the portion where the first film formation 35 and the second film formation 36 overlap is in a polymerized state as shown in FIG. 11C, but the time for vacuum evaporation is controlled, By making the film thickness very thin, it can be formed substantially flush with the first and second film formations 36.

Furthermore, as in the eighth reference example , the film forming process according to the first embodiment, the second demolding process, and the second injection process can be repeatedly performed. The film 38 and the injection of the resin material are repeated so as to be simply polymerized in a state where the film forming positions are different by masking or the like as in the fourth embodiment (FIGS. 12A and 12B). In this case, the film formation 38 is a film formation product 39 that is visually observed in a three-dimensional state.

Embodiments of the present invention will be described with reference to FIGS. 13 and 14, and as described in the respective reference examples, when the film forming process, the second demolding process, and the second injection process are repeated, The second injection step was performed leaving a part of the first film formation 40 formed in the previous film formation step, and the repeated film formation step was left in the previous second injection step. It can be performed on the molding side surface 41a of the second base material 41 injection-molded in the first film formation 40 and the second injection step. That is, after the first base material (first molded product) 42 is formed in the first injection step as in the embodiment of the present invention shown in FIGS. As described in the example, the first demolding step is performed, and the first film formation 40 that is linear (or strip-like, the same applies hereinafter) is formed on the first substrate 42 in the first film formation step. The first film-forming molded products 40 and 42 are manufactured by vacuum deposition. Thereafter, after the second demolding step, the second base material (second molded product) is placed on the first film-formed molded products 40 and 42 so that one end of the first film formed 40 is exposed (leaves). ) 41 is formed by injection (second injection step). Next, after passing through the third demolding step, the second film forming step is repeated, and the second linear formation component communicating from the film forming surface side 41 a of the second base material 41 to the first film forming 40 is performed. A film 43 is formed (second film-forming molded product).
Further, after passing through the fourth demolding step, in the subsequent third injection step, the third injection is performed on the second film-formed molded product, leaving one end of the second film-forming 43 on the film-forming surface side 41a side. After the process is performed and the third base material (third molded product) 44 is formed, and after the fifth demolding process, the film forming surface side of the third base material 44 is followed by the third film forming process. After the formation of the third film-formation product having the third film-formation 45 communicating from the second film-formation 44a to the second film-formation 43, the exposed third film-formation 45, second, and third The base materials 41 and 44 are covered with a covering material 46 to form a film-forming molded product 47. And by forming in this way, the three-dimensional film-forming molded product in a three-dimensional direction can be shape | molded.

Incidentally, in the embodiment of the present invention, it is hierarchical only in the vertical direction, but it can be configured to be hierarchical in any direction such as front and rear, left and right. The first, second, and third film formations 40, 43, and 45 are all linear, but have various branched shapes such as an L shape, a T shape, a Y shape, and a curved shape. (See FIG. 14C), and further, the film formation is made of a conductive metal such as gold, silver, copper, etc., so that electric wiring is formed, and the film-formed molded article 47 is used as the electric substrate. be able to. As a result, the films 40, 43, and 45 can be formed thinner than the conventional electric wiring, so that the cost can be reduced, and further, various shapes can be formed by masking or the like. The substrate can be easily formed.

(A), (B) is the perspective view and longitudinal cross-sectional view of the film-forming molded article of a 1st reference example , respectively. (A), (B), (C) is process schematic until it carries out the 1st injection of a 1st reference example . (A), (B), (C) is process schematic until the second butt | matching of a 1st reference example . (A), (B), (C) is process schematic until the base material of a 1st reference example and the concave surface of a fixed mold oppose. (A), (B), and (C) are process schematic diagrams until the film-forming molded product of the first reference example is taken out. It is a longitudinal cross-sectional view of the film-forming molded article of a 2nd reference example . (A), (B), (C) is the schematic of the 1st injection process of the 2nd reference example , a film-forming process, and a 2nd injection process, respectively. (A) and (B) are a side view and a plan view of a third or fourth reference example , respectively. (A), (B) is the schematic of the film-forming process in a 3rd reference example, and the film-forming process in a 4th reference example , respectively. (A), (B) is the schematic of the film-forming process in a 5th reference example, respectively, and the longitudinal cross-sectional view of a film-forming molded article. (A), (B) is a cross-sectional view and a front view of a film-formed molded product of the sixth reference example , respectively, and (C), (D) are cross-sectional views of a film-formed molded product of the seventh embodiment. FIG. (A), (B) is the schematic of the film-forming process in a 8th reference example, respectively, and the side view of a film-forming molded article. (A), (B), (C) is the front view of the film-forming molded article of embodiment of this invention , a side view, and XX sectional drawing of FIG. 13 (A), respectively. (A), (B), (C) is the process schematic of the film-forming molded article in embodiment of this invention, respectively.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Movable metal mold 1a Injection molding surface 2 Fixed mold 2a First injection molding surface 2b Second injection molding surface 2c Film forming surface 3 Base material 3a Film forming side surface 4 Covering material 5 Vacuum deposition apparatus 9 Film-forming molded article 10 Film-forming 11 Film-forming molded body 12 Fixed mold 13 Movable mold 14 Base material 17 Covering material 18 Base material 48 Film-forming 18b Non-film-forming part 19 Film-forming molded article 20 Vacuum evaporation apparatus 21 Fixed mold 21b Periphery 22 Masking material 23 Coating material 24, 25 Vacuum deposition apparatus 26 Fixed mold 26a, 26b Film forming mold surface 27 Base material 27a Film forming side surface 28 Coating material 29, 30 Film forming 31 Film forming molded product 32, 33 Film 34 Film-formed molded product 35, 36 Film-formed 37 Film-formed molded product 38 Film-formed 39 Film-formed molded product 40, 43, 45 Film-formed 41a, 42a, 44a Molded side surfaces 41, 42, 44 Base material 46 Coating material 47 Composition Membrane molded product

Claims (3)

The first and second molds are configured so that the separation movement in the opposing direction between the mold surfaces and the parallel movement along the surface direction are relatively performed,
A first injection step for molding the first molded product after matching the mold surfaces for molding the first molded product formed on both molds;
A first demolding step of demolding from the second mold in a state where the molded first molded product is supported by the first mold;
First forming a first film molding to form a first film-forming surface in the first molded product against so as to face the first deposition forming means provided with the first molding to the second mold A film forming process of
The a second demolding step of demolding from the second mold in a state that is supporting the first film molding a first mold, the first film molding is provided in the second mold A second injection process in which a second molded product is formed by injecting but leaving a part of the first film- formed surface of the first film- formed molded product by butting against the mold surface for the two molded products;
A third demolding step of demolding the second molded product from the second mold while being supported by the first mold;
The second film-formed surface is formed so as to face the second film-forming unit provided on the second mold so as to face the second molded product and the remaining first film-formed surface. And a second film forming step of forming a second film- forming molded product in order. 4. The fourth demolding step according to claim 1, wherein after the second film-forming step, the second mold is demolded in a state where the second film-formed molded product is supported by the first die,
The second film-forming molded product is abutted against the mold surface for the third molded product provided in the second mold, and a part of the second film-forming surface of the second film-forming molded product is left to be injected and third molded. A third injection process to form a product;
A fifth demolding step of demolding the third molded product from the second mold while being supported by the first mold;
The third film-forming surface is formed so as to face the third film-forming unit provided in the second mold so as to face the third molded product and the remaining second film-forming surface. And a third film forming step of forming a third film- forming molded product in order. 3. The method for producing a film-formed molded article according to claim 1, wherein the film-formed molded article is an electric base material, and the film-forming surface is an electric wiring.

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