JP6332387B2 - Film material insert molding method and apparatus - Google Patents

Description

  The present invention relates to a film material insert molding method and apparatus for forming a transparent resin layer on the surface of an intermediate body made of a film material having a design portion.

Conventionally, in order to improve decorativeness in synthetic resin molded products such as interior and exterior products of automobiles and home appliances, a film material provided with a design part is pasted and integrated with a transparent resin layer or a base resin layer by an insert molding method. What you do is in practical use.
As a method of attaching the film material to the synthetic resin layer or the like, after placing the film material in which the design part is decorated (preliminarily molded) with a pattern or an uneven shape in the cavity of the injection mold, the synthetic resin layer or the like A method of joining a film material and a synthetic resin layer or the like by thermal welding by injecting a molten resin material as a material into the cavity is employed.

  In the method of forming a transparent lid with a synthetic resin pattern in Patent Document 1, a convex mold portion having an upper surface for forming a lower surface and an outer peripheral surface for forming an inner peripheral surface of a peripheral wall is provided on a movable mold, and a side gate Stand up the flange from the outer edge of the convex mold part opposite to the film, place the film material on the upper surface of the convex mold part so as to contact the inner surface of the flange, and then inject the molten resin material into the cavity. Film material is insert molded. Thereby, the design part provided with the feeling of depth is formed.

From the viewpoint of merchantability, in order to prevent the occurrence of weld lines, the flow management of the molten resin material supplied into the cavity is performed by a temperature-controllable mold.
In the method of manufacturing a resin molded product of Patent Document 2, a temperature-adjustable mold is prepared, a film material is placed in the cavity, and then the cavity surface temperature is heated to a temperature equal to or higher than the heat deformation temperature of the transparent resin material. Inject the material. After filling the cavity with the transparent resin material, the mold is cooled and solidified in a state where the transparent resin material is integrated with the film material.

JP 2004-299340 A JP 2011-083961 A

Usually, in the film material insert molding method, the transparent resin material formed on the surface of the film material has transparency, and is an amorphous synthetic resin material having excellent coating, adhesion, printability and impact resistance (for example, PC, PPE, etc.).
Amorphous synthetic resin materials have high crystallinity, and have material characteristics such as a smaller molding shrinkage ratio than crystalline synthetic resin materials having a glass transition temperature and a melting point, thereby ensuring dimensional accuracy. It also has the property of being easy.

An insert molded product of a film material having a transparent resin layer made of an amorphous synthetic resin material is a transparent material composed of an intermediate made of a film material and an amorphous synthetic resin material after the transparent resin material is solidified. Based on the difference in molding shrinkage from the resin layer, there is a possibility that a cloudy portion that is cloudy in white is generated.
When the solidification of the transparent resin material is completed in the cavity, the transparent resin material and the intermediate are joined and integrated under a set mold temperature. After the mold is opened, when the transparent resin material and the intermediate product are cooled from the high temperature state to the normal temperature state, a peeling phenomenon due to the difference in molding shrinkage occurs at the joint portion between the two, and this peeling portion becomes white and cloudy it is conceivable that.
In particular, in the case of an intermediate in which an uneven design portion is formed, a cloudy portion is likely to occur around the ridge line portion formed at the uneven boundary portion, which causes a reduction in merchantability.

  An object of the present invention is to provide an insert molding method for a film material that can improve the appearance of the final product while increasing the bonding strength between the intermediate material composed of the film material and the transparent resin layer composed of the amorphous synthetic resin material. And an apparatus for the same.

The invention of claim 1 is a film material insert molding method for forming a transparent resin layer composed of a transparent resin material made of an amorphous synthetic resin material on the surface of a film material provided with a design portion. A mold preparing step of preparing an adjustable first mold and a second mold, an arranging step of arranging a first intermediate trimmed from the film material in a final shape on the first mold, An injection step of injecting the transparent resin material melted into a cavity formed by closing the molds of the first and second molds, and at the same time as the end of the injection step, the transparent resin material is raised above room temperature and transparent A first cooling step of cooling at a first cooling rate to a set temperature set lower than a glass transition temperature of the resin material, and the transparent resin layer is formed on the surface of the first intermediate after finishing the first cooling step the second intermediate to normal temperature that is It is characterized by having a second cooling step of cooling at a faster second cooling rate than serial first cooling rate.

According to this configuration, the disposing step of disposing the first intermediate trimmed from the film material in the final shape on the first mold, and the inside of the cavity formed by the mold closing of the first and second molds the until injection step and, the set set temperature lower than the glass transition temperature of the injection step is completed at the same time as the transparent resin material of higher than normal temperature and the transparent resin material for emitting the transparent resin material which is melted Since it has a 1st cooling process cooled at 1 cooling rate, a transparent resin material can be solidified as a transparent resin layer integrated with the film material. A second cooling step of cooling the second intermediate having the transparent resin layer formed on the surface of the first intermediate after completion of the first cooling to a normal temperature at a second cooling rate higher than the first cooling rate. Therefore, the shrinkage of the transparent resin layer having a smaller shrinkage rate than that of the first intermediate body is promoted, and the shrinkage amount of the transparent resin layer and the first intermediate body is synchronized so that the peeling phenomenon of the joint portion between them can be prevented. Suppresses and prevents generation of cloudy parts.

The invention of claim 2 is characterized in that, in the invention of claim 1, the method further comprises an intermediate forming step of forming an uneven shape in the design portion of the first intermediate before the arranging step.
According to this structure, in the insert-molded product of the film material provided with the concavo-convex design portion, the cloudy portion generated at the ridge line portion formed at the concavo-convex shape boundary portion can be eliminated.

The invention of claim 3 is the invention of claim 1 or 2, wherein the set temperature is Tg-40 ≦ T ≦ Tg-20, where T is the set temperature and Tg is the glass transition temperature of the transparent resin material. It is characterized by being set by the relational expression.
According to this structure, the solidification completion time which solidifies in the state which integrated the transparent resin material with the 1st intermediate body can be shortened.

A fourth aspect of the invention is characterized in that, in the invention of any one of the first to third aspects, the second cooling rate is 2 ° C./sec or more.
According to this configuration, the molding time of the second intermediate can be shortened.

The invention according to claim 5 is the invention according to any one of claims 1 to 4, wherein the second cooling step takes out the second intermediate body from the cavity after the mold opening of the first and second molds. It is characterized by that.
According to this configuration, the cooling mechanism can be omitted from the first and second molds, and the manufacturing cost can be reduced.

A sixth aspect of the invention is characterized in that, in the fifth aspect of the invention, the second cooling step is performed by any one of water immersion, water mist, and dry ice.
According to this structure, generation | occurrence | production of a cloudy part can be reliably prevented with a simple structure.

A seventh aspect of the present invention is the base resin according to any one of the first to sixth aspects, wherein a base resin layer is formed on the back surface of the second intermediate body by injection molding after the second cooling step. It has a layer forming step.
According to this configuration, it is possible to obtain an insert-molded product having a three-layer structure in which the occurrence of cloudy portions is prevented.

The invention of claim 8 is a film material insert molding method for forming a transparent resin layer composed of a transparent resin material made of an amorphous synthetic resin material on the surface of a film material provided with a design portion. A mold preparing step of preparing an adjustable first mold and a second mold, an arranging step of arranging a first intermediate trimmed from the film material in a final shape on the first mold, An injection step of injecting the transparent resin material melted into a cavity formed by closing the molds of the first and second molds, and the transparent resin material injected into the cavity is higher than room temperature and transparent A first cooling step of cooling at a first cooling rate to a set temperature set lower than the glass transition temperature of the resin material, and after separating the first and second molds, on the surface of the first intermediate Second intermediate in which the transparent resin layer is formed And a second cooling step of cooling the second intermediate to a normal temperature at a second cooling rate higher than the first cooling rate simultaneously with the end of the mold opening step. Yes.
According to this configuration, the appearance of the final product can be improved with a simple configuration.
The invention of claim 9, in the insert molding device of the film material forming the transparent resin layer made of a transparent resin material consisting of amorphous synthetic resin material on the surface of with a design portion film material, wherein the final shape The first intermediate body trimmed from the film material can be disposed and the temperature can be adjusted, and the cavity can be configured in cooperation with the first mold on which the first intermediate body is disposed, and the temperature can be adjusted. a second mold capable, the first, high and the transparent resin than the room temperature to the completion of injection at the same time as the molten transparent resin material of the transparent resin material into the formed cavity by mold closing of the second mold A first cooling means for cooling at a first cooling rate to a set temperature set lower than the glass transition temperature of the material, and the transparent resin layer on the surface of the first intermediate after cooling by the first cooling means second intermediate formed Is characterized by having a second cooling means for cooling at a faster second cooling rate than the first cooling rate to room temperature, the.
According to this configuration, simultaneously with the end of injection of the transparent resin material into the cavity formed by closing the molds of the first and second molds, the molten transparent resin material is raised above room temperature and the transparent resin material Since the first cooling means for cooling at a first cooling rate to a set temperature set lower than the glass transition temperature is provided, the transparent resin material can be solidified as a transparent resin layer integrated with the film material.
A second intermediate in which the cooling by the first cooling means is finished and the second intermediate having the transparent resin layer formed on the surface of the first intermediate is cooled to a normal temperature at a second cooling rate higher than the first cooling rate. Since it has a cooling means, it promotes the shrinkage of the transparent resin layer having a smaller shrinkage rate than the first intermediate, and synchronizes the shrinkage between the transparent resin layer and the first intermediate, thereby peeling the joint portion between them. This suppresses the phenomenon and prevents the occurrence of cloudy parts.

  According to the insert molding method and apparatus for a film material of the present invention, the bonding strength between an intermediate body made of a film material and a transparent resin layer made of an amorphous synthetic resin material is increased, and the final product The appearance can be improved.

It is a partial longitudinal cross-sectional perspective view of the emblem of the vehicle manufactured by the insert molding method of the film material which concerns on Example 1. FIG. FIG. 2 is an enlarged view of a main part of FIG. 1, where (a) is an a region and (b) is an enlarged view of a b region. It is a flowchart of the insert molding method of a film material. It is a flowchart of an intermediate body formation process. It is process drawing of a coloring process. It is process drawing which shows an unevenness | corrugation creation process in order. It is a front view of a 1st intermediate body. It is a flowchart of a transparent resin layer formation process. It is a disassembled perspective view of a 1st metal mold body and a telescopic mold. It is a longitudinal cross-sectional view of the 1st, 2nd metal mold | die in the 1st process of a transparent resin layer formation process. It is a longitudinal cross-sectional view of the 1st, 2nd metal mold | die in the 2nd process of a transparent resin layer formation process. It is a longitudinal cross-sectional view of the 1st, 2nd metal mold | die in the 3rd process of a transparent resin layer formation process. It is a longitudinal cross-sectional view of the 1st, 2nd metal mold | die in the 4th process of a transparent resin layer formation process. It is a longitudinal cross-sectional view around the side gate. It is a time chart of the resin temperature in a transparent resin layer formation process. It is the longitudinal cross-sectional view around the locate pin of the 1st metallic mold main part, (a) is before ejection and (b) is a figure at the time of ejection. It is a flowchart of a base-material resin layer formation process. It is a cross-sectional view of the 1st, 2nd metal mold | die in the 1st process of a base resin layer formation process. It is a cross-sectional view of the 1st, 2nd metal mold | die in the 2nd process of a base resin layer formation process. It is a cross-sectional view of the 1st, 2nd metal mold | die in the 3rd process of a base resin layer formation process. It is a cross-sectional view of the 1st, 2nd metal mold | die in the 4th process of a base resin layer formation process.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
The following description exemplifies the application of the present invention to a vehicle emblem molding method and apparatus, and does not limit the present invention, its application, or its use.

Embodiment 1 of the present invention will be described below with reference to FIGS.
First, a vehicle to which the emblem 1 (insert molded product) is mounted will be described.
This vehicle includes a millimeter wave radar (not shown) at a position on the back side of the front grill.
The millimeter wave radar uses a millimeter wave having a frequency of 30 GHz to 300 GHz and a wavelength of 1 to 10 mm, and a difference between a transmitted wave transmitted from the own vehicle and a received wave reflected from an object (for example, a preceding vehicle). The vehicle distance and relative speed between the object and the host vehicle can be measured based on this, and a driving support system such as an auto cruise system is executed using the detected value.
If the wall thickness that exists in front of the millimeter wave radar is not evenly formed, there will be a difference in the millimeter wave transmission speed between the thick and thin parts, and the control accuracy will be reduced due to variations in the detected values. Therefore, in the present embodiment, the installation position of the millimeter wave radar is defined so that the emblem 1 having a uniform thickness is included in the traveling path of the radar.

Next, the emblem 1 as the final product will be described.
As shown in FIG. 1, the emblem 1 includes a first intermediate body 2 on which a design portion is formed, a transparent resin layer 3 formed on the surface of the first intermediate body 2, and a back surface of the first intermediate body 2. The formed base resin layer 4 is provided. The thickness dimension of the emblem 1 is uniformly set to be an integral multiple of half the wavelength of the millimeter wave irradiated by the millimeter wave radar.

The first intermediate 2 has a wavelength selectivity capable of controlling the transmission and reflection of light for each wavelength, has a radar light reflectance of 90% or more, and does not contain heavy metal (for example, PICASUS manufactured by Toray Industries, Inc.) (Registered trademark)).
The first intermediate body 2 includes a design portion 5 including a shape portion 5a and a background portion 5b formed around the shape portion 5a. In the shape portion 5a, a predetermined mark shape having a metallic luster (for example, silver color) and an elliptical shape surrounding the mark shape are formed so as to protrude from the background portion 5b toward the surface, and the background portion 5b has a shape portion 5a. The design is expressed in black in the area excluding.

As shown in FIG. 1, the surface of the first intermediate 2 is uniformly covered with a transparent transparent resin layer 3. Thereby, a feeling of depth is given to the design part 5, and the design property of the emblem 1 is improved.
The transparent resin layer 3 is made of a transparent resin material 12 (for example, polycarbonate (PC)) made of an amorphous synthetic resin. Since this transparent resin material 12 has molecular chains and cannot take a regular molecular arrangement in the process of cooling and solidifying from a molten state, it has a characteristic that the mechanical strength rapidly decreases when the glass transition temperature Tg is exceeded. doing.
Further, since the transparent resin material 12 has a random arrangement even in the solidified state, the volume of the transparent resin material 12 is expanded or contracted by heating or cooling compared to a crystalline synthetic resin (for example, polyethylene (PE), polypropylene (PP), etc.). Has a gradual change trend.
Therefore, the transparent resin material 12 has a shrinkage rate smaller than that of the film material 11.
The surface exposed to the outside of the transparent resin layer 3 is uniformly coated with a hard coat layer having an ultraviolet cut effect.
Hereinafter, the intermediate structure in which the transparent resin layer 3 is formed on the surface of the first intermediate 2 will be described as the second intermediate 6 for convenience of description.

As shown in FIGS. 1, 2 (a), and 2 (b), the back surface of the first intermediate body 2 (second intermediate body 6) and the outer peripheral portion of the radially outer end of the first intermediate body 2 are It is uniformly covered by a colored (for example, black) base resin layer 4. Thus, the appearance of the emblem 1 is improved while ensuring the rigidity.
The base resin layer 4 is composed of a base resin material 13 made of an amorphous synthetic resin (for example, acrylonitrile butadiene styrene copolymer (ABS)). The base resin material 13 has a glass transition temperature lower than the glass transition temperature Tg (145 ° C.) of the transparent resin material 12.
Note that the base resin material 13 may be made of polycarbonate, polycarbonate ABS (PC / ABS), or polycarbonate PBT (PC / PBT) instead of ABS.

Next, a method for forming the emblem 1 will be described.
The following description includes a description of the insert molding apparatus.
As shown in FIG. 3, the insert molding processing procedure of the emblem 1 includes a first intermediate body 2 (see FIG. 7) provided with an edge 2 a extending radially outward in the vicinity of the outer peripheral end of the final shape of the film material 11. Intermediate forming step S1 to be formed, and a second intermediate 6 provided with a transparent resin layer 3 on the surface of the first intermediate 2 to which the edge 2a is fixed by the first and second molds 31 and 32 by injection molding. And forming an emblem 1 as an insert-molded product provided with a base resin layer 4 covering the radial outer end of the edge 2a on the back surface of the second intermediate body 6 by injection molding. And a base resin layer forming step S3.

First, the intermediate formation step S1 will be described in detail.
As shown in FIG. 4, the intermediate forming step S <b> 1 includes a coloring step S <b> 11 for performing screen printing on the design portion 5 continuously on the front and back surfaces of the long belt-like film material 11, and the shape of each design portion 5. A film corresponding to the emblem 1 by performing a concavo-convex creating step S12 for forming a concavo-convex shape (concavo-convex design) on the part 5a, and trimming to remove an unnecessary portion from the long strip-shaped film material 11 so as to obtain a final external shape The trimming process S13 which forms the final shape (1st intermediate body 2) of the material 11 is comprised.

As shown in FIG. 5, in the coloring step S <b> 11, continuous printing is performed by the coloring device 21 on both the front and back surfaces of the long belt-like film material 11 that moves in the arrow direction.
The coloring device 21 performs mask processing corresponding to the shape of the shape portion 5a on the surface of the film material 11, and in the first round, an unmasked region (background portion) on the surface of the film material 11 subjected to mask processing. The black paint is transferred to 5b), the mask is removed and dried, and then the gray paint is transferred to the back surface of the film material 11 and dried in the second round.
Thereby, the several design part 5 which consists of the shape part 5a in which the unevenness | corrugation is not formed, and the background part 5b is continuously printed on the elongate strip-shaped film material 11. FIG.

In the concavo-convex creating step S <b> 12, the concavo-convex shape is formed by the pressure forming dies 22 and 23 at a position corresponding to the shape portion 5 a of the long belt-like film material 11.
As shown in FIG. 6A and FIG. 6B, the film material 11 placed in a predetermined position and heated and softened is sandwiched by the mold closing operation of the pressure forming dies 22 and 23, and the mold 22 and the film material 11 are While the space is evacuated, the film material 11 is brought into close contact with the mold 22 by the pressure of the compressed air supplied from the mold 23 side to form an uneven shape.
As a result, an uneven design having a height difference of about 5 mm is formed at a position corresponding to the shape portion 5 a of the film material 11, a so-called central mark and an elliptical portion surrounding the mark.
The uneven shape may be formed by vacuum forming instead of pressure forming.

In the trimming step S13, the first intermediate body 2 is formed from the film material 11 by a trimming apparatus (not shown).
As shown in FIG. 7, the first intermediate body 2 includes a design part 5 including a shape part 5 a and a background part 5 b and is formed in a substantially elliptical shape in front view so as to correspond to the emblem 1, and near the outer peripheral end. The portion is provided with an edge 2a slightly extending radially outward.
The radial dimension of the edge 2a is a dimension that remains slightly due to melting or the like in the transparent resin layer forming step S2.

The edge 2a is uniformly formed over the entire circumference of the first intermediate body 2.
The edge portion 2a is provided with a pair of substantially rectangular recesses 2b recessed inward in the radial direction at both ends in the major axis direction, and a plurality of cut portions 2c extending in the radial direction over the entire circumference. .
An extension 2d extending radially outward from the radially outer end of the edge 2a is formed in a portion of the edge 2a that faces a runner 38b described later.
The extension portion 2d is set to a size such that the tip portion can partially enter the runner 38b (see FIG. 11).

Next, the transparent resin layer forming step S2 will be described in detail.
As shown in FIG. 8, the transparent resin layer forming step S <b> 2 includes a preparation step S <b> 21 for preparing the first and second molds 31 and 32, and an arrangement step S <b> 22 for arranging the first intermediate body 2 on the first mold 31. And the restraint process S23 which positions and supports the first intermediate body 2 with respect to the first mold 31, the mold closing process S24, and the transparent resin material 12 melted by the injection mechanism (not shown) is injected into the cavity C1. An injection step S25, a first cooling step S26 for cooling the transparent resin material 12 at a first cooling rate K1, a mold opening step S27, and a second cooling step S28 for cooling the second intermediate 6 at a second cooling rate K2. Etc. Here, the 1st, 2nd metal mold | dies 31 and 32 are transparent resin layer formation means, and are corresponded to the 1st cooling means.

In the preparation step S21, a first mold 31 that is a movable mold and a second mold 32 that is a stationary mold that forms the cavity C1 in cooperation with the first mold 31 are prepared.
The 1st metal mold | die 31 is provided so that the 1st intermediate body 2 can be supported in the state of a substantially orthogonal attitude | position with respect to a horizontal direction, and it is comprised so that mold temperature can be adjusted.
As shown in FIGS. 9 and 10a to 10d, the first mold 31 is provided in a vacuum pump 33 (suction mechanism) capable of vacuum suction of the first intermediate body 2, a main body 31a, and the main body 31a. A telescopic die 31b that can be inserted into the recess is provided.
The telescopic die 31b is formed in the same shape as the planar shape of the shape portion 5a in plan view, and a part of the main body 31a is preloaded in one half of the telescopic die 31b.
The main body 31a and the telescopic mold 31b form a first suction passage 34a that is a divided gap (interval of about 0.05 mm) at a portion corresponding to the boundary between the shape portion 5a and the background portion 5b.
Each of the first suction passages 34a communicates in an annular shape. Further, a second suction passage 34b is formed at a position in the vicinity of the downstream side of the convex portion 36 to be described later.

  The first mold 31 has a movable portion 31c, a plurality of grooves 34c that transmit the suction force of the vacuum pump 33 to the first and second suction passages 34a, 34b, and a uniform suction force distributed to the plurality of grooves 34c. And a convex portion 36 formed at a position corresponding to the upstream portion of the runner 38b of the main body 31a, a pair of locating pins 37 (positioning mechanism), and the like.

The movable portion 31c is provided at the outer peripheral portion on the second mold 32 side excluding the position corresponding to the runner 38b of the main body 31a, and slightly (for example, about 1) from the main body 31a while being urged toward the second mold 32. .3 mm) apart. The urging force and the separation distance are set to values that allow the air in the cavity C1 in the injection step S25 to be discharged to the outside when the movable portion 31c is in contact with the second mold 32 with this urging force.
During the injection step S25, when the transparent resin material 12 in the cavity C1 reaches a predetermined filling rate (for example, 80%), the first mold 31 moves forward so that the movable portion 31c is closest to the main body 31a. It has been adjusted.

As shown in FIGS. 10a to 10d, the plurality of groove portions 34c are formed corresponding to the end portions of the first and second suction passages 34a and 34b, respectively.
The distributor 35 communicates the first and second suction passages 34 a and 34 b with the vacuum pump 33. The distribution portion 35 is provided in a portion of the telescopic die 31b opposite to the second mold 32 (upstream portion of the first and second suction passages 34a and 34b), and is connected in parallel to the plurality of groove portions 34c. ing.

As shown in FIGS. 9 and 11, the cubic convex portion 36 protrudes in the direction of the second mold 32 orthogonally from the main body 31 a at a position in the vicinity of the upstream side of the extended portion 2 d of the first intermediate body 2. 38b is formed so as to cross from one end side to the other end side in the mold surface direction.
The wall portion facing the convex portion 36 of the second mold 32 constituting the convex portion 36 and the runner 38 b corresponds to the flow direction changing means of the transparent resin material 12.
The pair of locating pins 37 is configured to be fitted into a pair of recesses 2b formed at both ends of the first intermediate body 2 in the major axis direction. The pair of locating pins 37 are formed so as to be able to advance and retract from the main body 31a in the direction of the second mold 32, respectively, and engage the receiving surface portion 3a of the transparent resin layer 3 to thereby perform the eject function of the second intermediate body 6. I have.

As shown in FIGS. 10a to 10d, the second mold 32 is provided so that the second intermediate body 6 can be molded in a state of being substantially orthogonal to the horizontal direction, and the mold temperature can be adjusted. Yes.
The second mold 32 includes an injection mechanism, an introduction gate 38a that connects the injection mechanism and the side gate via a runner 38b, and a wall portion that constitutes a part of the runner 38b and faces the first mold 31. Etc. When the second mold 32 and the first mold 31 are closed, the first and second molds 31 and 32 cooperate to form the cavity C1 and the runner 38b, and the downstream end of the runner 38b. Forms a side gate.
As shown in FIG. 11, the introduction gate 38a is set so that the diameter dimension is increased toward the first mold 31. When the mold is closed, a volume chamber having a predetermined capacity is formed at the connecting portion with the runner 38b. It is configured as follows.

As shown in FIG. 10 a, the first intermediate body 2 is disposed at a specified position of the first mold 31 with the first and second molds 31 and 32 being separated from each other. In the placement step S22, the pair of recesses 2b formed in the first intermediate body 2 are respectively fitted to the pair of locating pins 37 and positioned.
As shown in FIG. 10b, in the restraint step S23, the first intermediate body 2 is sucked in the direction of the first mold 31 through the first suction passage 34a corresponding to the boundary portion between the shape portion 5a and the background portion 5b.
By sucking the boundary between the shape portion 5a and the background portion 5b, the supporting ability is improved while maintaining the merchantability. In particular, when the shape portion 5a has an uneven shape, the shape accuracy of the shape portion 5a can be increased by positively marking the boundary portion (ridge line portion).
Further, the first suction passage 34a is annularly communicated with the shape portion 5a, so that the first intermediate body 2 is sucked and fixed with a uniform suction force over the entire area.

As shown in FIG. 10c, in the mold closing step S24, when the first mold 31 moves closer, the mold surfaces of the first and second molds 31 and 32 come into contact with each other to form the cavity C1.
The first intermediate body 2 positioned with respect to the main body 31a has an edge portion over substantially the entire circumference except for the edge portion 2a corresponding to the extension portion 2d by the mold closing by the first and second molds 31 and 32. Since 2a is clamped between the first and second molds 31, 32, it is securely held at the specified position.
At this time, the movable part 31c is separated from the main body 31a by a predetermined urging force.

As shown in FIG. 10d, in the injection step S25, the molten transparent resin material 12 heated to the injection temperature T1 is injected into the cavity C1. The molten transparent resin material 12 is injected from the injection mechanism and supplied into the cavity C1 through the introduction gate 38a and the runner 38b.
As shown by the arrow F in FIG. 11, the convex portion 36 causes the transparent resin material 12 flowing in the runner 38 b to be on the wall portion of the second mold 32 constituting a part of the runner 38 b in the direction opposite to the convex portion 36. The transparent resin material is changed so that the wall portion of the second mold 32 constituting a part of the runner 38b presses the extension portion 2d of the first intermediate body 2 toward the first mold 31. 12 flow directions are changed. Thereby, the suction force from the second suction passage 34 b and the pressing force from the transparent resin material 12 act on the extension portion 2 d of the first intermediate body 2 in the direction of the first mold 31.
Further, during the period when the filling rate of the transparent resin material 12 in the cavity C1 is less than 80%, the contact pressure between the second mold 32 and the movable part 31c is adjusted to a predetermined value, so that the air in the cavity C1 The transparent resin material 12 is discharged outside without obstructing the inflow of the transparent resin material 12. Thereby, air can be smoothly discharged | emitted from the inside of the cavity C1 synchronizing with injection | pouring of the transparent resin material 12. FIG.

In the first cooling step S26, the transparent resin material 12 is cooled from the injection temperature T1 to the mold temperature T2 (T2 <T1) at the first cooling rate K1. As a result, the transparent resin material 12 is solidified to form the transparent resin layer 3, and an integrated body in which the first intermediate body 2 and the transparent resin layer 3 are joined is formed.
Since the transparent resin material 12 is an amorphous synthetic resin, the relationship between the glass transition temperature Tg and the mold temperature T2 in consideration of moldability can be expressed by the following formula (1).
Tg-40 ≦ T2 ≦ Tg-20 (1)
Therefore, when the transparent resin material 12 is polycarbonate, the temperature ranges are 250 ° C. ≦ T1 ≦ 320 ° C. and 105 ° C. ≦ T2 ≦ 125 ° C. In this embodiment, the injection temperature T1 is 300 ° C., and the mold temperature T2 is 120. Set to ° C.
The mold temperature T2 corresponds to the set temperature.

As shown in FIG. 12, during the period from t1 to t2 when the molten transparent resin material 12 is supplied into the cavity C1 (injection step S25), the temperature of the transparent resin material 12 is maintained at the injection temperature T1. Simultaneously with the end, cooling of the transparent resin material 12 is started.
The first cooling rate K1 is set as the following equation (2) according to the relationship between the injection temperature T1, the mold temperature T2, and the cooling period (t3-t2).
(T1−Tg + 40) / (t3−t2) ≦ K1 ≦ (T1−Tg + 20) / (t3−t2) (2)
The cooling period (t3-t2) is set in advance for each type of the transparent resin material 12 in consideration of molding efficiency and moldability.

Further, the pressure holding process is started simultaneously with the first cooling process S26.
In this pressure holding step, the first intermediate body 2 and the transparent resin layer 3 are held in the cavity C1 for a predetermined period in the period of the first cooling step S26.
The mold opening step S <b> 27 is performed during a period from t <b> 3 to t <b> 4, and after the first mold 31 is moved backward so as to be separated from the second mold 32, the second intermediate body 6 is taken out.

As shown in FIGS. 2 (b) and 13 (a), the transparent resin layer 3 of the second intermediate body 6 has a rectangular receiving surface 3a that is recessed radially inward at a position corresponding to the recess 2b. Are provided so that the radially inner end portions of the pair of locating pins 37 partially overlap the radially outer end portions of the second intermediate body 6 so as to be engageable with each other.
Therefore, as shown in FIG. 13B, after the mold is opened, the second intermediate body 6 is taken out from the first mold 31 by the advancing operation of the pair of locate pins 37.
The receiving surface portion 3a is not limited to a rectangular (rectangular) concave portion, but may be a concave concave portion. In the case of the recessed portion due to the inclination, there is no sudden luminance change of the reflected light, and the merchantability can be improved by improving the appearance.

In 2nd cooling process S28, the 2nd intermediate body 6 taken out out of the cavity C1 is cooled to normal temperature (for example, 20-30 degreeC) with the 2nd cooling rate K2 faster than the 1st cooling rate K1.
As shown in FIG. 12, the second intermediate body 6 taken out from the first mold 31 starts to be cooled simultaneously with the end of the mold opening step S28, and is cooled for a period of t4 to t5.
Thus, the first intermediate body 2 having a high heat shrinkage rate (high molding shrinkage rate) and the first intermediate body 2 are integrated with each other, and the heat shrinkage rate is slower than that of the first intermediate body 2 (of the mold shrinkage rate). (Small) The amount of shrinkage with the transparent resin layer 3 can be made uniform, and the occurrence of cloudy parts due to the peeling phenomenon occurring at the joint between the two is suppressed.

When the second cooling rate K2 of the second cooling step S28 is 2 ° C./sec or more, the effect of promoting shrinkage of the transparent resin layer 3 is exhibited, and a higher effect can be expected at 4 ° C./sec or more.
The second intermediate body 6 is immersed in room temperature water at the same time as being taken out from the first mold 31 (cavity C1). In addition, the water tank and the normal temperature water stored in this water tank are equivalent to the 2nd cooling means. The refrigerant of the second intermediate 6 only needs to manage a predetermined cooling rate, may be cooled by water mist, and may be cooled by dry ice.

Next, the base resin layer forming step S3 will be described in detail.
As shown in FIG. 14, the base resin layer forming step S <b> 3 includes a preparation step S <b> 31 for preparing the first and second molds 41 and 42, and an arrangement step for arranging the second intermediate body 6 in the first mold 41. S32, a restraining step S33 for positioning and supporting the second intermediate body 6 with respect to the first mold 41, a mold closing step S34, and a base resin material 13 melted by an injection mechanism (not shown) is injected into the cavity C2. An injection step S35, a cooling step S36 for cooling the base resin material 13, a mold opening step S37, and the like. Here, the 1st, 2nd metal mold | dies 41 and 42 are equivalent to the base-material resin layer formation means.

In the preparation step S31, a first mold 41 that is a fixed mold and a second mold 42 that is a movable mold that forms the cavity C2 in cooperation with the first mold 41 are prepared.
The 1st metal mold | die 41 is provided so that the 2nd intermediate body 6 can be supported in the state of a substantially orthogonal attitude | position with respect to a horizontal direction, and it is comprised so that mold temperature can be adjusted.
As shown in FIGS. 15a to 15d, the first mold 41 includes a pair of openings 41a, a vacuum pump 43 (a suction mechanism) that can vacuum-suck the second intermediate body 6, and a pair of openings 41a. Are provided with a pair of suction passages 44 for transmitting the suction force of the vacuum pump 43 to each other, a distribution portion 45 for uniformly distributing the suction force of the vacuum pump 43 for each passage, and the like.
For convenience of explanation, FIGS. 15a to 15d are cross-sectional views.

The pair of openings 41a is configured to suck the transparent resin layer 3 of the second intermediate body 6, and is formed in a substantially bowl shape. These openings 41 a are arranged at substantially symmetrical positions so as to correspond to regions where the thickness from the surface of the transparent resin layer 3 to the first intermediate body 2 is thicker than the average thickness of the second intermediate body 6. In the present embodiment, a pair of openings 41a is disposed at a position corresponding to the position P (see FIG. 7) of the background portion 5b on both sides in the major axis direction with respect to the center of the second intermediate body 6.
The pair of openings 41 a communicate with the vacuum pump 43 via a pair of suction passages 44 and a distributor 45. The distributor 45 has one end connected to the vacuum pump 43 and the other end connected in parallel to the upstream end of the pair of suction passages 44.

As shown in FIGS. 15a to 15d, the second mold 42 is provided so that the second intermediate body 6 can be molded in a substantially orthogonal posture with respect to the horizontal direction, and the mold temperature can be adjusted. Yes.
The second mold 42 includes an injection mechanism (not shown) and an introduction gate 48 that communicates the injection mechanism with the cavity C2. When the second mold 42 and the first mold 41 are closed, the first and second molds 41 and 42 cooperate to form a cavity C2.
The shape of the cavity C2 is such that the thickness of the final insert-molded product is substantially uniform and the base resin layer 4 that covers the surface of the edge 2a in the radial direction of the edge 2a of the first intermediate body 2 and the receiving surface 3a is formed. It is configured.
The introduction gate 48 is formed so as to correspond to the central portion of the cavity C2, and is configured such that the diameter dimension increases toward the first mold 41 side.

As shown in FIG. 15 a, the second intermediate body 6 is disposed at a specified position of the first mold 41 with the first and second molds 41 and 42 being separated from each other.
In the arrangement step S32, the transparent resin layer 3 is positioned so that the regions corresponding to the background portions 5b on both sides in the major axis direction (regions corresponding to the position P) are in contact with the pair of openings 41a.
As shown in FIG. 15b, in the restraining step S33, the second intermediate body 6 is sucked in the direction of the first mold 41 through the pair of openings 41a. Since the second intermediate body 6 is supported at a position substantially equally divided into three in the major axis direction, the support capability can be increased with an equal suction force.

As shown in FIG. 15c, in the mold closing step S34, when the second mold 42 moves closer, the first and second molds 41 and 42 come into contact with each other to form the cavity C2.
As shown in FIG. 15d, in the injection step S35, the molten base resin material 13 heated to the injection temperature T3 is injected into the cavity C2. The molten base resin material 13 is injected from the injection mechanism and supplied into the cavity C <b> 2 through the introduction gate 48.
When the base resin material 13 is ABS, the injection temperature (melting temperature) T3 is 180 to 270 ° C., which is higher than the glass transition temperature Tg of polycarbonate, so there is concern about suction marks due to softening of the transparent resin layer 3. However, the generation of suction marks is avoided by supporting the molten base resin material 13 at a portion (region corresponding to the position P) where heat is hardly transmitted. Further, since a plurality of cut portions 2c extending in the radial direction are formed in the edge portion 2a of the first intermediate body 2, in addition to measures against wrinkles, wraparound to the surface side of the edge portion 2a of the molten base resin material 13 is performed. Increases sex.

In the cooling step S36, the base resin material 13 is cooled at a constant cooling rate from the injection temperature T3 to the mold temperature T4 (T4 <T3). The base resin layer 4 is formed by solidifying the molten base resin material 13. When the base resin material 13 is ABS, the temperature range is 40 ° C. ≦ T4 ≦ 80 ° C.
The cooling rate of the cooling step S36 is set according to the relationship between the injection temperature T3, the mold temperature T4, and the cooling period. The cooling period is determined for each type of the base resin material 13 in consideration of the molding efficiency and moldability. Is set in advance.

Further, the pressure holding process is started simultaneously with the cooling process S36.
In this pressure holding step, the second intermediate body 6 and the base resin layer 4 are held in the cavity C2 for a predetermined period in the period of the cooling step S36.
In the mold opening step S37, after the second mold 42 is moved backward so as to be separated from the first mold 41, the final product emblem 1 is taken out by an eject mechanism (not shown), and the surface of the transparent resin layer 3 is removed. Hard coat treatment is applied to

Next, the operation and effect of the film material insert molding method and apparatus of this embodiment will be described.
According to this insert molding method, it is formed by placing the first intermediate body 2 trimmed to the final shape on the first mold 31 and closing the first and second molds 31 and 32. An injection step S25 for injecting the molten transparent resin material 12 into the cavity C1, and a gold that is set so that the transparent resin material 12 injected into the cavity C1 is higher than room temperature and lower than the glass transition temperature Tg of the transparent resin material 12. Therefore, the transparent resin material 12 can be solidified as the transparent resin layer 3 integrated with the film material 11. Since it has 2nd cooling process S29 which cools the 2nd intermediate body 6 which finished 1st cooling process S26 to normal temperature with the 2nd cooling speed K2 faster than the 1st cooling speed K1, it is contraction rate rather than the 1st intermediate body 2. By promoting the shrinkage of the transparent resin layer 3 having a small size and synchronizing the shrinkage amount between the transparent resin layer 3 and the first intermediate body 2, it is possible to suppress the peeling phenomenon at the joint portion between the two and 3, Occurrence is prevented.

In the insert molding product of the film material 11 having the concavo-convex design portion 5, since the intermediate formation step S <b> 1 for forming the concavo-convex shape is formed in the design portion 5 of the first intermediate body 2 before the arrangement step S <b> 22, It is possible to eliminate the cloudy portion generated in the ridge line portion formed at the boundary portion of the shape.
When the mold temperature is T2 and the glass transition temperature of the transparent resin material 12 is Tg, the mold temperature T2 is set by the relational expression of Tg−40 ≦ T2 ≦ Tg−20. The solidification completion time for solidification in a state of being integrated with the first intermediate 2 can be shortened.

Since the 2nd cooling rate K2 is 2 degrees C / sec or more, the shaping | molding time of a 2nd intermediate body can be shortened.
Since the second cooling step S29 is performed after the first and second molds 31 and 32 are opened and the second intermediate body 6 is taken out of the cavity C1, the cooling mechanism is removed from the first and second molds 31 and 32. The manufacturing cost can be reduced.

Since the second cooling step S29 is performed by any one of water immersion, water mist, and dry ice, the second intermediate body 6 can be reliably prevented from occurring with a simple configuration.
After the second cooling step S29, there is a base resin layer forming step S3 for forming the base resin layer 4 on the back surface of the second intermediate body 6 by injection molding. The emblem 1 which is a molded product can be obtained.

  In the insert molding apparatus for the film material 11 for forming the transparent resin layer 3 made of an amorphous synthetic resin material on the surface of the first intermediate body 2 composed of the film material 11 provided with the design portion 5, the film is trimmed to the final shape. The cavity C1 can be configured and the temperature can be adjusted in cooperation with the first mold 31 on which the first intermediate body 2 can be arranged and the temperature can be adjusted, and the first mold 31 on which the first intermediate body 2 is arranged. The glass transition of the transparent resin material 12 which is higher than the normal temperature and the molten transparent resin material 12 injected into the cavity C1 formed by closing the second mold 32 and the first and second molds 31 and 32 is performed. First cooling means (first and second molds 31 and 32) for cooling at a first cooling rate K1 to a mold temperature T2 set lower than the temperature Tg, and a second intermediate after finishing the first cooling step S26. The body 6 is cooled to room temperature faster than the first cooling rate K1. And a second cooling means for cooling the second cooling rate K2. As a result, the molten transparent resin material 12 injected into the cavity C1 formed by closing the molds of the first and second molds 31 and 32 is higher than room temperature and lower than the glass transition temperature Tg of the transparent resin material 12. Since the first cooling means for cooling to the set mold temperature T 2 at the first cooling rate K 1 is provided, the transparent resin material 12 can be solidified as the transparent resin layer 3 integrated with the film material 11. Moreover, since it has the 2nd cooling means which cools the 2nd intermediate body 6 which finished 1st cooling process S26 to normal temperature with the 2nd cooling speed K2 faster than the 1st cooling speed K1, it shrinks | contracts rather than the 1st intermediate body 2. By promoting the shrinkage of the transparent resin layer 3 having a low rate and synchronizing the shrinkage amount between the transparent resin layer 3 and the first intermediate body 2, the peeling phenomenon at the joint portion between them is suppressed, and the generation of cloudy parts is prevented. It is preventing.

Next, a modified example in which the embodiment is partially changed will be described.
1) In the above-described embodiment, an example of a design part in which the shape part is unevenly formed has been described, but at least the intermediate layer may be formed of a film material provided with the design part, and the design part is distinguished only by the color. It may be an insert-molded product formed by the formed shape portion and the background portion.
Moreover, although the example which provided the synthetic resin layer on the front and back both surfaces of the 1st intermediate body was demonstrated, what is necessary is just to provide a transparent resin layer on the surface among the front and back both surfaces of a 1st intermediate body at least.

2) In the above-described embodiment, the example in which the second cooling step is performed outside the cavity has been described. However, the second cooling step may be performed inside the cavity as in the first cooling step.
In this case, the transparent resin layer forming mold is provided with a cooling mechanism provided with a pipe capable of circulating a coolant (for example, cooling water, liquid nitrogen, etc.), and temperature control is performed so as to achieve a set cooling rate.

3] In the above-described embodiment, an example of an emblem with radio wave transmission that is an exterior product of a vehicle has been described. However, at least insert molding made of a transparent resin material and a film material having a molding shrinkage rate larger than that of the transparent resin material It may be a product, and can be applied to an interior product of a vehicle or a decorative product other than a vehicle.

4) In addition, those skilled in the art can implement the present invention in a form in which various modifications are added to the above-described embodiment or in a form in which each embodiment is combined without departing from the gist of the present invention. Various modifications are also included.

DESCRIPTION OF SYMBOLS 1 Emblem 2 1st intermediate body 3 Transparent resin layer 5 Design part 6 2nd intermediate body 11 Film material 12 Transparent resin material 31 1st metal mold | die 32 2nd metal mold C1 Cavity T2 Mold temperature K1 1st cooling rate K2 2nd Cooling rate

Claims (9)

In a film material insert molding method for forming a transparent resin layer composed of a transparent resin material made of an amorphous synthetic resin material on the surface of a film material provided with a design part,
A mold preparation step of preparing a first mold and a second mold capable of adjusting the mold temperature;
An arrangement step of arranging a first intermediate trimmed from the film material in a final shape in the first mold;
An injection step of injecting the melted transparent resin material into a cavity formed by closing the first and second molds;
A first step of cooling in the first cooling rate to set the set temperature lower than the glass transition temperature of the end of the injection step and higher than the room temperature the transparent resin material simultaneously and the transparent resin material,
A second cooling step of cooling the second intermediate having the transparent resin layer formed on the surface of the first intermediate after completion of the first cooling to a normal temperature at a second cooling rate higher than the first cooling rate. When,
An insert molding method for a film material, comprising:   2. The film material insert molding method according to claim 1, further comprising an intermediate forming step of forming an uneven shape in the design portion of the first intermediate before the arranging step.   2. The set temperature is set by a relational expression of Tg−40 ≦ T ≦ Tg−20, where T is the set temperature and Tg is the glass transition temperature of the transparent resin material. Or the insert molding method of the film material of 2.   The film material insert molding method according to any one of claims 1 to 3, wherein the second cooling rate is 2 ° C / sec or more.   5. The film according to claim 1, wherein the second cooling step is performed by removing the second intermediate body from the cavity after the first and second molds are opened. Material insert molding method.   6. The film material insert molding method according to claim 5, wherein the second cooling step is performed by water immersion, water mist, or dry ice for the second intermediate.   The base resin layer forming step of forming a base resin layer on the back surface of the second intermediate body by injection molding after the second cooling step. The film material insert molding method described. In a film material insert molding method for forming a transparent resin layer composed of a transparent resin material made of an amorphous synthetic resin material on the surface of a film material provided with a design part,
A mold preparation step of preparing a first mold and a second mold capable of adjusting the mold temperature;
An arrangement step of arranging a first intermediate trimmed from the film material in a final shape in the first mold;
An injection step of injecting the melted transparent resin material into a cavity formed by closing the first and second molds;
A first cooling step of cooling the transparent resin material injected into the cavity at a first cooling rate to a set temperature set higher than normal temperature and lower than the glass transition temperature of the transparent resin material;
After separating the first and second molds, a mold opening step of taking out the second intermediate having the transparent resin layer formed on the surface of the first intermediate;
A second cooling step of cooling the second intermediate to a normal temperature at a second cooling rate higher than the first cooling rate simultaneously with the end of the mold opening step;
An insert molding method for a film material, comprising: In a film material insert molding apparatus for forming a transparent resin layer composed of a transparent resin material made of an amorphous synthetic resin material on the surface of a film material provided with a design part,
A first mold capable of arranging a first intermediate trimmed from the film material in a final shape and capable of adjusting a temperature;
A second mold capable of forming a cavity and adjusting the temperature in cooperation with the first mold on which the first intermediate body is disposed;
Simultaneously with the end of injection of the transparent resin material into the cavity formed by closing the molds of the first and second molds, the transparent resin material is set to be higher than room temperature and lower than the glass transition temperature of the transparent resin material. A first cooling means for cooling at a first cooling rate to the set temperature,
A second intermediate in which the cooling by the first cooling means is finished and the second intermediate having the transparent resin layer formed on the surface of the first intermediate is cooled to a normal temperature at a second cooling rate higher than the first cooling rate. Cooling means;
A film material insert molding device characterized by comprising: