JP4707150B2 - Method and apparatus for manufacturing hollow film-formed molded product - Google Patents

Description

The present invention relates to the technical field of a method for manufacturing a hollow film-formed molded article , which is a molded body on which a film such as a front lamp, tail lamp, or emblem mounted on a vehicle or the like is formed , and a device for manufacturing a film-formed molded article. It belongs to.

Generally, among these types of film-forming molded products, there are those whose design properties are improved by covering the surface of the member with a material having an effect such as a coloring effect or a reflection effect, such as parts 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. 6-147069 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, but also the removal process, the setting process, and the transport process from the equipment to the equipment. 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 has been created in view of the above circumstances and has been created for the purpose of solving these problems. The invention of claim 1 is capable of moving with respect to a fixed mold and the fixed mold. A first injection step of injecting a pair of molded products so as to have an injection allowance on its end surface using the configured movable mold, and the first and second molded by the first injection step A film forming step in which a mold is opened with one molded product remaining on the fixed mold and the other molded product remaining on the movable mold, and a film is formed on the inner surface of at least one molded product. And the end surfaces of the first and second molded products after the film formation process are finished in a state of remaining in the mold, and then the resin is injected to the injection allowance to bond the first and second molded products. a manufacturing method comprising a second injection step of obtaining the deposition molded article, the deposited after the first injection step, the mold Open, the moldings in the state remaining in the mold, is freely displaceable by the articulated arm, and abuts the casing film forming apparatus is provided therein, and Turkey be performed in the mold This is a method for producing a hollow film-formed molded product.
According to a second aspect of the present invention, molding is performed using a fixed mold and a movable mold provided to be movable to a molding position where the first and second injection steps are performed on the fixed mold . The method for producing a hollow film-formed molded article according to claim 1.
According to a third aspect of the present invention, there is provided a mold comprising a fixed mold and a movable mold provided so as to be movable to a molding position for performing the first and second injection steps on the fixed mold, and film formation a combination of the device, wherein the fixed mold, for injection was a forming surface for injection in which the convex shape for molding the first molded article, a concave shape to form a second molded article A molding surface having a concave shape for molding the first molded product and a convex shape for forming the second molded product. At the position where the first injection step of the movable mold is performed, the fixed molding surface of the fixed mold and the concave molding surface of the movable mold, and the fixed A first and second molded product forming a pair is formed by the concave molding surface of the mold and the convex molding surface of the movable mold, In the position to perform Dokin type of the second injection step, the first remaining respectively to the fixed mold concave-shaped molding surface of the concave-shaped molding surface of the movable mold, the second molded product The film forming apparatus includes a casing that is displaced so as to be abutted against a molding surface of at least one mold by an articulated arm when the mold is opened. be empty shaped deposition molded article manufacturing apparatus in you, wherein the inside film forming apparatus is provided.
The invention according to claim 4, the movable mold is first with respect to the fixed mold, are moved to the position to perform the second injection step is provided as a rotational movement around the axis Turkey The manufacturing apparatus for a hollow film-formed molded article according to claim 3 .

By setting it as invention of Claim 1, 2, the film-forming molded article can be easily manufactured using the existing injection molding apparatus.
According to the third and fourth aspects of the invention, a film-formed molded product can be easily manufactured using an existing injection molding apparatus.

  Next, a first embodiment of the present invention 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, the movable mold 1 is configured to move in the direction along the mold surface (parallel movement with respect to the mold surface) with respect to the fixed mold 2 while being separated from the fixed mold 2. Details of the above are omitted because they can be executed by using a conventionally known technique of mold movement. 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 mold surface, but may be a rotational movement around the axis.

The movable mold 1 has a concave injection molding surface 1a for injection molding the first molded body 3 and a convex injection molding for forming the second molded body 4. A surface 1b is formed, while a fixed mold 2 is formed with a convex molding surface 2a for injection molding of the first molded body 3 and a second molded body 4. A concave molding surface 2b for injection and a molding surface 2c for forming an injection allowance 3c for bonding the first and second molded bodies 3 and 4 to each other are formed.

On the other hand, 5 is a robot hand (manipulator, magic hand), and the robot hand 5 is configured by using the molds 1 and 2 and various member devices such as an injection molding machine and a mold moving means (not shown). The joint arm 5a is arranged in the vicinity of the injection molding apparatus, and is configured to freely swing and rotate. A vacuum deposition apparatus (film formation means, film formation apparatus) is provided at the tip of the joint arm 5a. For example, a rectangular casing 5b is provided so as to be rotatable around the axis. The robot hand 5 is configured such that the vacuum vapor deposition apparatus 6 can be freely displaced three-dimensionally by swinging and rotating the joint arm 5a and rotating the casing 5b. Since the conventionally known one is adopted, the details thereof are omitted. In the drawings, the description will be made assuming that only the casing 5b and the vacuum vapor deposition apparatus 6 are drawn from FIG.

  The vacuum vapor deposition device 6 is provided with a publicly known device, and as a general outline thereof, an intake passage 7 connected to the vacuum pump P through a hose 7a drawn out of the casing 5b, a metal to be vapor deposited (for example, aluminum or Chrome), and a heater 9 connected to a power source via an electrical wiring 9a drawn out of the casing 5b for heating the boat 8. The hose 7a and the electrical wiring 9a can also be implemented as those provided directly on the robot hand, particularly the casing 5a. The present invention is not limited to the above-described embodiment, and the film forming means is not limited to the vacuum vapor deposition apparatus 6, and a normally known film forming apparatus such as film formation by cathode sputtering is necessary. Can be adopted.

Next, the process of creating the film- formed molded article 10 using the first and second molded bodies 3 and 4 will be described. In the present embodiment, the hollow emblem is used. A description will be given assuming that the molded bodies 3 and 4 are each formed with a film formed on the inner surface thereof. First, FIG. 2 shows an outline of a process for manufacturing the first and second molded bodies 3 and 4 in the first injection process, but FIG. 2A shows a movable mold 1 and a fixed mold 2. Comrades are in a state in which the corresponding molding surfaces 1a and 2a, 1b and 2b of the first and second molded bodies 3 and 4 face each other. From this state, the movable mold 1 is moved to the movable mold 2. It moves to abut, and it will be in a mold matching state (refer to Drawing 2 (B)). In this state, the first injection step is executed, and the first and second molded bodies 3 and 4 in the unformed state are formed.

Next, although the movable mold 1 is separated from the fixed mold 2, the first molded body 3 remains on the movable mold 1 side and the second molded body 4 remains on the fixed mold 2 side (FIG. 3A). ) Refer to) The surface design is in the state. Then, the movable mold 1 moves in parallel with the mold surface, and moves in a state where the facing distance is separated to a position where the first and second molded bodies 3 and 4 face each other (see FIG. 3B). .

In such a separated state, the casing 5b is abutted against the molding surface 1a of the movable mold 1 by the operation of the robot hand 5 (see FIG. 4A), and then the first is performed by the vacuum vapor deposition apparatus 6. Film formation 3a is performed on the inner surface of the molded body 3 (see FIG. 4B). In this case, the end surface 5b of the first molded body 3 is masked by abutting the end surface 5c of the casing 5b. When the film formation on the first molded body 3 is completed, the robot hand 5 moves the casing 5b toward the second molded body 4 and reverses the casing 5b against the molding surface 2b of the fixed mold ( 5A), the film formation 4a is applied to the inner surface of the second molded body 4 (see FIG. 5B). In this case as well, the end surface 4b of the second molded body 4 is masked by the casing end surface 5c. Needless to say, the film formation step can be performed even in the state of FIG.

As described above, when the film formations 3a and 4a are applied to the inner surfaces of the first and second molded bodies 3 and 4, the casing 5b moves to the outside of the injection molding apparatus by the operation of the robot hand 5 (FIG. 6 ( After that, the movable mold 1 moves so as to abut against the fixed mold 2 (see FIG. 6B). As a result, the end surfaces of the first and second molded bodies 3 and 4 are abutted in a state where the injection allowance 3c is a space, and a second injection process is performed on the injection allowance 3c. After the molded bodies 3 and 4 were bonded together by the injected resin material 11 (see FIG. 6C), the movable mold 1 was separated from the fixed mold 2 and completed. A series of film forming products 10 is manufactured by taking out the film forming products 10 from the fixed mold 2 (see FIGS. 7A and 7B). Thereafter, the movable mold is moved to the position of FIG. As 1 moves, it is possible to manufacture the film- formed molded article 10 repeatedly.

In the embodiment of the present invention configured as described above, the first and second molded bodies 3 and 4 which are the constituent parts of the manufactured film- formed molded article 10 were injection molded in the first injection step. Then, after film formation from the outside of the injection molding apparatus, the film deposition 3a and 4a are performed by the vacuum vapor deposition apparatus 6 that moves outside the apparatus. As a result, a series of operations of injection molding and film formation are performed. Can be done continuously. Moreover, since the vacuum vapor deposition apparatus 6 is not provided in the mold 1 or 2, the existing injection molding apparatus can be used as it is, and can be employed as a retrofit facility, and a reduction in equipment investment can be achieved.

In addition, in the above-described embodiment, the first and second molded bodies 3 and 4 are formed while the film is still warm immediately after injection. Therefore, the film-forming material is excellent in the adhesion performance to the resin material, and the appearance is excellent. It will be a thing. In addition, since the film formation on the first and second molded bodies 3 and 4 can be continuously performed using one vacuum deposition apparatus, for example, if the plurality of molded bodies 3 and 4 are all made the same shape, This makes it possible to efficiently produce a film- formed molded product having the same shape.

In addition, the first and second molded bodies 3 and 4 on which the films 3a and 4a have been applied are brought into contact with each other by moving the mold, and bonded together by the second injection process. It is possible to improve the workability.

Of course, the present invention is not limited to the above-described embodiment. In the above-described embodiment, both molded bodies are formed , but the selected one is formed. may also sequentially changed to a plurality of shaped bodies (first molded body → made different molded body formed to a second molded body → first molded body.) and to film formation It may be.

Further, as in the second embodiment shown in FIG. 8, when a plurality of molded bodies 11 and 12 are formed, simultaneous film formation 11a and 12a using a plurality of film formation means 13 and 14 is performed. You can also. In this case, the film forming materials of the film forming units 13 and 14 may be the same or different. In this case, the film forming bodies 13 and 14 provided on the robot hands 15 and 16 can be implemented (see FIG. 8A), but a plurality of film forming means 13 and 14 are provided on one robot hand 17. The film formations 11a and 12a may be performed simultaneously with the molded bodies 13 and 14 facing each other (see FIG. 8B), or a plurality of film formations 11a and 12a are sequentially performed. You may make it like that (refer FIG.8 (C)). In this case, the film forming means 13 and 14 may have the same or different film formation. In the case of different film formation, there are different film forming materials, different film formation times, and the like.

Further, as in the third embodiment shown in FIG. 9, the film forming means 19 is provided at the tip 18a of the robot hand 18, and the mounting material (interior product) 20 (or masking material) is detachably supported. The mounting material 20 can be configured to be mounted on the molded body 21 before film formation (in the case of a masking material, it is removed after film formation). Various film forming products can be manufactured.

Furthermore, as in the fourth embodiment shown in FIG. 10, in addition to mounting the film forming device 23 on the tip 22a of the robot hand 22, the masking material 24 and the mounted product 25 are detachably supported. The molded body 26 is masked with the masking material 24, and then the film is formed by the film forming apparatus 23. Thereafter, the masking material 24 is removed, and the attachment 25 can be attached. In FIG. 10, the counterpart mold is omitted.

Next, as a reference example of the present invention, a description will be given of a case where a molded body is moved out of an injection molding apparatus by a moving means and set in a film forming apparatus provided outside the apparatus to form a film.
A first reference example will be described with reference to FIGS. 11 to 14. The first reference example includes a movable mold 27 and a fixed mold 28, and the movable mold 27 has a concave mold surface for forming a first molded body 29. 27a, a convex surface 27b for forming the second molded body 30 is formed, and a convex surface 27c for forming the connection allowance 31 in the second injection step is formed on the convex surface 27b side. Yes. The fixed mold 28 is provided with a convex surface 28a for forming the first molded body 29 and a concave mold surface 28b for forming the second molded body 30. Further, in the second injection step, the connection allowance is formed. A concave surface 28c for forming 31 is formed as a convex surface 28b.

Further, the robot hand 32 has a configuration in which the tip 32a can freely move three-dimensionally as in the first embodiment, and the first molded body 29 is supported and fixed to the tip 32a. A moving member 33 is provided for moving out of the mold 28 (demolding). Various members such as a gripping tool and a locking tool can be adopted as the moving member 33. In this reference example , an attachment tool 32b is attached to and connected to the first molded body 29 from the demolding exposure side. A vacuum type is employed in which the vacuum pump P is brought into a vacuum state between the first molded body 29 and brought into close contact with the first molded body 29 to remove the mold. Further, as the film forming apparatus 34, a vacuum vapor deposition apparatus similar to that used in the first embodiment is provided on the base 34a. In this device, the moving member 33 and the film forming apparatus 34 are connected to the vacuum pump P through dedicated flow paths 33a and 34b, respectively, and each flow is provided by the open / close valves 33b and 34c provided in the flow paths 33a and 34b. The passages 33a and 34b are individually opened and closed so that the moving member 33 and the film forming apparatus 34 can be evacuated.

Next, the manufacturing process of the film- formed molded product 35 formed by integrally bonding the first and second molded bodies 29 and 30 will be described. The first injection process shown in FIGS. The process up to this point is the same as that of the first embodiment, and the description thereof is omitted. In the demolding process after the first injection process is completed, the first molded body 29 remains on the stationary mold 28 side (see FIG. 12D).

Next, in this film forming process, the adherend 32a is attached to the first molded body 29, and the vacuum pump P is operated to bring it into a vacuum state so that the first molded body 29 is in close contact with the adherend 32a. In this state, the adherend 32a is moved and removed from the fixed mold 28, and set in the film forming apparatus 34. In this case, the tip 34b of the casing 34a in the film forming apparatus 34 is masked by coming into contact with the tip 29b of the first molded body 29 (see FIG. 13B). In this state, when the film forming apparatus 34 is operated and the molds 27 and 28 of the first molded body 29 are separated from each other, the first molded body 29 is not the surface exposed by being removed from the movable mold 27. The film 29a can be formed on the surface that is exposed when the mold is removed from the fixed mold 28 (see FIG. 13C).

The first molded body 29 on which the film formation 29a is formed in this manner is abutted against the second molded body 30 held by the fixed mold 27 by moving the robot hand 32 (see FIG. 14A). After that, air is introduced into the adherend 32a to separate the first molded body 29 from the adherend 32a (see FIG. 14B), and then the movable mold 27 is moved to the concave mold surface 27a. The detached first molded body 29 is inserted and set, and in this state, a second injection step of injecting the resin material 31a to the bonding margin 31 is performed (see FIG. 14C), whereby the first molded body 29 is formed. A film-formed molded product 35 to which the film 29a has been applied is formed, and then the mold is removed by moving the movable mold 27 away, and the film- formed molded product 35 is taken out, and a series of manufacturing steps of the film- formed molded product 35 is executed. By repeating this, the film- formed molded product 35 is continuously manufactured.

In the present reference example configured as described, the first molded body 29 that is one of the first and second molded bodies 29 and 30 that are components of the manufactured film- formed molded product 35 is the first After the injection molding in the injection process, the film is moved from the inside of the injection molding apparatus to the outside of the apparatus and set in the film forming apparatus 34, where the film forming 29a is performed. As a result, the injection molding and the film forming are performed. Can be done continuously by a series of operations. Moreover, since the film forming apparatus 34 is not provided in the mold 1 or 2, the existing injection molding apparatus can be used as it is, and can be employed as a retrofit facility, thereby reducing the equipment investment.

In addition, in this reference example , since the injected molded body is moved out of the injection molding apparatus to form a film, the surface exposed when the movable mold 27 is separated from the fixed mold 28 and removed. At this time, it is possible to form a film on the surface hidden behind the mold, thereby ensuring the diversity of film formation.

In addition, in the reference example , the first and second molded bodies 29 and 30 are formed while the film is still warm immediately after injection, so that the film-forming material is excellent in adhesion to the resin material and has an excellent appearance. It becomes. In addition, since film formation on the first and second molded bodies 29 and 30 can be continuously performed using a single vacuum deposition apparatus, for example, if the plurality of molded bodies 29 and 30 are all made the same shape, This makes it possible to efficiently produce a film- formed molded body having the same shape.

In addition, as described above, when the molded body is moved out of the injection molding apparatus to form a film, both molded bodies 29 and 30 can be taken out and moved to form a film. Needless to say, a film can be formed by using a material or providing a mounting material. And as the film formation in this case, by providing a plurality of film deposition apparatus, or deposition, respectively, can also be applied a plurality of deposition on one of the molding, further, the second as shown in FIG. 15 a plurality of the provided film forming apparatus 36 and 37, these masking unit 36a provided in the device, 37a or different deposition 38a in the molded body 38 by masking by a masking material prepared for each separate, as in reference example, 38b can be applied.

Moreover, this can also be made into the 3rd reference example shown in FIG. This compound, when moving from the injection mold 28 is taken out molded body 40 to the outside of the injection molding apparatus, the molded body 40 that has moved extracted in mobile 39a provided at the tip portion of the robot hand 39, separately provided The mold 41 is set (see FIG. 16B), and the film forming apparatus 42 is set in this state to form a film. In this way, the movable mold is separated from the fixed mold. The film formation 40a can be applied to the exposed surface.

Furthermore, as in the fourth reference example shown in FIG. 17, the exposed surface is released from the mold 43 by mold release, and the exposed surface is separated from the mold 43 by movement of the molded body 42. Film formation 42a and 42b can also be given to both surfaces. First, the step of applying the film formation 42a by the first film formation apparatus 45 on the surface separated and exposed from the mold 43 by the movement of the formed body 42 by the moving body 44a provided in the magic hand 44 is the first step . The process of one reference example can be employed, and the moving tool 45a is moved from the molded body 42 in a state where the molded body 42 on which the film formation 42a is applied is set on the mold 46 so that the film formation 42a is on the inside. By separating the fixed mold from the movable mold, the exposed surface is removed, and the exposed surface is exposed to the second film forming apparatus 47 (the same as the first film forming apparatus). may be subjected to film formation 42b to the surface that issued the exposed a good) be different even to set the mold material 46, ing in amenable both sides of the film by such.

(A), (B) is the schematic of a film- forming apparatus, and the longitudinal cross-sectional view of a film-forming molded product. (A), (B), (C) is a process schematic diagram until the first injection is performed. (A) and (B) are process schematic diagrams of a movable mold detachment process and a movable mold parallel movement process. (A), (B) is the process schematic of the butting process with respect to the 1st molded object of the film-forming apparatus, and the film-forming process to a 1st molded object. (A), (B) is the process schematic of the butting process with respect to the 2nd molded object of the film-forming apparatus, and the film-forming process to a 2nd molded object. (A), (B), (C) is process schematic of the movement process of the film- forming apparatus out of the injection molding apparatus, the second butting process, and the second injection process. (A), (B) is process schematic of a 2nd demolding process and a product taking-out process. (A) is the schematic of the film-forming process which shows 2nd embodiment, (B) is the schematic of the film-forming process which shows the deformation | transformation form, (C) is the film-forming process which shows the further deformation | transformation form. FIG. (A), (B), (C) is the schematic of the demolding process in the third embodiment, a mounting tool attachment process, and a film-forming process, respectively. (A), (B), (C), (D) is a schematic diagram showing a film forming apparatus moving process, a masking material setting process, a film forming process, and a mounting material setting process in the fourth embodiment, respectively. It is. (A), (B) is the schematic of the film- forming apparatus which shows a 1st reference example , respectively, and the longitudinal cross-sectional view of a film-forming molded product. (A), (B), (C), (D) are schematic views of a mold release process, a first mold matching process, a first injection process, and a first mold release process in the first reference example, respectively. is there. (A), (B), and (C) are schematic views showing a moving device setting process, a setting process to a film forming apparatus, and a film forming process of the first reference example , respectively. (A), (B), (C) is a schematic diagram of a setting process of the first molded body of the first reference example to the second molded body, a moving process of the moving device outside the apparatus, and a second mold matching process, respectively. is there. It is the schematic which shows the film-forming process of the 2nd reference example . (A), (B), (C) is a schematic diagram showing a demolding process of a molded body from a mold showing a third reference example , a setting process of a molded body on a film forming mold, and a film forming process. is there. (A), (B), (C), and (D) are a molding demolding step, a first film forming step, a molding step for setting the molded body on a film forming mold, and a fourth reference example . It is the schematic which shows the 2nd film-forming process.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Movable metal mold 2 Fixed mold 3 1st molded object 3a Film-forming 4 Second molded object 4a Film-forming 5 Robot hand 5b Casing 6 Film-forming apparatus

Claims (4)

A first injection step of using a fixed mold and a movable mold configured to be movable with respect to the fixed mold to inject a pair of molded products so as to have an injection allowance on its end surface;
Open the mold with one of the first and second molded products molded by the first injection step remaining on the fixed mold and the other molded product remaining on the movable mold. A film forming step of forming a film on the inner surface of at least one molded product;
After the end surfaces of the first and second molded products after the film forming process are finished in a state of remaining in the mold, a resin is injected for the injection allowance to bond the first and second molded products. A production method comprising a second injection step for obtaining a film-formed molded article,
The film formation, after the first injection step, the mold is opened, the molded product in the state remaining in the mold, is freely displaceable by the articulated arm, and in the film forming apparatus is provided therein butted against're casing, hollow manufacturing method of deposition molded article, wherein the benzalkonium be performed in the mold. Claim that the fixed mold, first with respect to the stationary mold, characterized in that the molded using a movable mold the secondary to the forming position to perform an injection step of are provided translatable A method for producing a hollow film-formed molded article according to 1. A combination of a mold including a fixed mold and a movable mold provided to be movable to a molding position for performing the first and second injection steps on the fixed mold, and a film forming apparatus ,
The fixed mold is provided with a convex injection molding surface for molding the first molded product and a concave injection molding surface for forming the second molded product. The movable mold is provided with a concave molding surface for molding the first molded product and a convex molding surface for forming the second molded product,
At the position where the first injection step of the movable mold is performed, the convex mold surface of the fixed mold and the concave mold surface of the movable mold and the concave mold surface of the fixed mold are used. A first and second molded product forming a pair is formed by the molding surface and the convex molding surface of the movable mold,
At the position where the second injection step of the movable mold is performed, the first and second molded articles remaining on the concave molding surface of the movable mold and the concave molding surface of the fixed mold, respectively. Is to be glued,
The film forming apparatus includes a casing that is displaced so as to be abutted against a molding surface of at least one mold by an articulated arm when the mold is opened, and the film forming apparatus is provided inside the casing. sky-like deposition molded article manufacturing apparatus in you, characterized in that there. Claim movable mold is first with respect to the fixed die, moving to a position for performing a second injection step is characterized by the Turkey provided as a rotational movement about an axis 3. An apparatus for producing a hollow film-formed molded article according to 3 .

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