JP7117634B2 - Decorating molding method and decorating molding apparatus - Google Patents

Description

The present invention relates to a decorative molding method and a decorative molding apparatus for molding a resin molded body and transferring a pattern provided on a film to the resin molded body.

Conventionally, as this type of decorative molding method, for example, the method described in Patent Document 1 (Japanese Patent No. 5518599) is known. In Patent Document 1, positional information of two marks provided on a film is obtained, positional information of the two marks is compared with two registered positional information stored in advance, and a positional deviation is calculated. A method is described for moving the film so that the positional deviation is less than or equal to a predetermined value. According to this method, positional deviation between the resin molding and the pattern provided on the film can be corrected, and the pattern can be transferred to the resin molding with high accuracy.

Patent No. 5518599

However, in the conventional decorative molding method, there is still room for improvement in terms of transferring a pattern to a resin molding with higher accuracy.

That is, in the conventional decorative molding method, the positional information of two marks provided on the film is obtained, and the positional deviation is corrected based on the positional information of the two marks. The two marks are provided so as to correspond to different patterns adjacent to each other.

For example, when patterns and marks are provided on a long film by screen printing or the like, it is common to provide by screen printing or the like using a plurality of printing plates. For this reason, the patterns and marks may be displaced from desired positions on the film (hereinafter referred to as printing misalignment) for each printing plate. If one of the two marks is out of print, and the positional information of the two marks is acquired and the positional out-of-position is corrected, the tilt of the film in the film feed direction can be precisely determined because the out-of-print is not taken into account. cannot be corrected.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above problems and to provide a decorative molding method and a decorative molding apparatus capable of transferring a pattern to a resin molding with higher accuracy.

In order to achieve the above object, a decorative molding method according to one aspect of the present invention comprises:
A film provided with a pattern and a film-side alignment mark at a position corresponding to the pattern is conveyed in the film feed direction to arrange the pattern between a first mold and a second mold, and the first mold. The mold and the second mold are closed, and a molten resin is injected between the first mold and the second mold to mold a resin molded body, and the pattern is applied to the resin molded body. A decorative molding method for transferring,
detecting a first deviation amount between the film-side alignment mark and a preset upstream-side reference mark at a position on the upstream side in the film feeding direction;
further conveying the film in the film feeding direction, and detecting a second misalignment amount between the film side alignment mark and a preset downstream side reference mark at a position downstream in the film feeding direction;
moving the film based on the first shift amount and the second shift amount to align the film-side alignment mark and the downstream reference mark;
Including.

A decorative molding device according to one aspect of the present invention includes:
a film transport mechanism for transporting a film provided with a pattern and a film-side alignment mark at a position corresponding to the pattern in a film transport direction;
a first mold and a second mold that are configured to close or open with the transport path of the film sandwiched therebetween;
an injection machine for injecting molten resin between the closed first mold and the second mold;
an upstream detection unit that detects a first deviation amount between the film-side alignment mark and a preset upstream reference mark;
a downstream detection unit that detects a second deviation amount between the film-side alignment mark and a preset downstream reference mark;
After moving the film based on the first shift amount and the second shift amount to align the film side alignment mark and the downstream reference mark, the first mold and the second mold are moved. is closed, and the molten resin is injected between the closed first mold and the second mold to mold a resin molded body and to transfer the pattern to the resin molded body. a control unit that controls the film feed mechanism, the first mold, the second mold, and the injection machine;
Prepare.

ADVANTAGE OF THE INVENTION According to this invention, the decorating molding method and decorating molding apparatus which can transcribe|transfer a design to a resin molded body with high precision can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a decorating molding device that realizes a decorating molding method according to an embodiment of the present invention, viewed obliquely from above; FIG. 2 is a side view showing a schematic configuration of the decorative molding device of FIG. 1; FIG. 4 is a schematic configuration diagram showing how a camera detects an alignment mark; FIG. 10 is a plan view showing an example of the field of view of the upstream camera when detecting the first deviation amount between the film-side alignment mark and the upstream-side reference mark; FIG. 10 is a plan view showing an example of a field of view of a downstream camera when detecting a second deviation amount between the film side alignment mark and the downstream reference mark; FIG. 2 is a perspective view showing various dimensions of the decorative molding apparatus of FIG. 1; FIG. 3 is a schematic configuration diagram showing how a camera detects a film-side alignment mark of transparent color;

According to the first aspect of the present invention, the film provided with the pattern and the film-side alignment mark at the position corresponding to the pattern is transported in the film feed direction between the first mold and the second mold. The pattern is arranged, the first mold and the second mold are closed, and the molten resin is injected between the first mold and the second mold to form a resin molded body. A decorative molding method for transferring the pattern to the resin molded body,
detecting a first deviation amount between the film-side alignment mark and a preset upstream-side reference mark at a position on the upstream side in the film feeding direction;
further conveying the film in the film feeding direction, and detecting a second misalignment amount between the film side alignment mark and a preset downstream side reference mark at a position downstream in the film feeding direction;
moving the film based on the first shift amount and the second shift amount to align the film-side alignment mark and the downstream reference mark;
To provide a decorative molding method comprising:

According to a second aspect of the present invention, the decoration according to the first aspect, wherein at least one of the upstream reference mark and the downstream reference mark has a fixed relative position with respect to the first mold. A molding method is provided.

According to a third aspect of the present invention, at least one of the upstream reference mark and the downstream reference mark is a mold-side alignment mark provided on the first mold. A decorative molding method is provided.

According to the fourth aspect of the present invention, the film is provided with a plurality of patterns at predetermined intervals in the film feed direction, and the predetermined intervals are provided at positions corresponding to the plurality of patterns. A plurality of film-side alignment marks are provided in
The decorative molding method according to any one of the first to third aspects, wherein the distance between the upstream reference mark and the downstream reference mark in the film feeding direction is smaller than the predetermined interval. do.

According to the fifth aspect of the present invention, the decorative molding method according to any one of the first to fourth aspects, wherein the detection of the first deviation amount is performed while conveying the film in the film feeding direction. offer.

According to the sixth aspect of the present invention, after detecting the first deviation amount, the film is transported by a predetermined distance in the film feeding direction and stopped, and then the second deviation amount is detected. A decorative molding method according to any one of the first to fifth aspects is provided.

According to the seventh aspect of the present invention, after the first deviation amount is detected, the film-side alignment mark of the film is placed within the field of view of the camera arranged downstream in the film-feeding direction of the upstream-side reference mark. and the downstream reference mark are positioned, the film is conveyed by a predetermined distance in the film feeding direction and stopped, and then the second deviation amount is detected. A decorative molding method according to any one is provided.

According to an eighth aspect of the present invention, the film-side alignment mark, the upstream reference mark, and the downstream reference mark are transparent colors,
detecting the film-side alignment mark based on the parallel light that has passed through the film-side alignment mark;
detecting the upstream reference mark based on the parallel light that has passed through the upstream reference mark;
detecting the downstream reference mark based on parallel light that has passed through the downstream reference mark;
A decorative molding method according to any one of the first to seventh aspects is provided.

According to the ninth aspect of the present invention, a film transport mechanism for transporting a film provided with a pattern and a film-side alignment mark at a position corresponding to the pattern in a film transport direction;
a first mold and a second mold that are configured to close or open with the transport path of the film sandwiched therebetween;
an injection machine for injecting molten resin between the closed first mold and the second mold;
an upstream detection unit that detects a first deviation amount between the film-side alignment mark and a preset upstream reference mark;
a downstream detection unit that detects a second deviation amount between the film-side alignment mark and a preset downstream reference mark;
After moving the film based on the first shift amount and the second shift amount to align the film side alignment mark and the downstream reference mark, the first mold and the second mold are moved. is closed, and the molten resin is injected between the closed first mold and the second mold to mold a resin molded body and to transfer the pattern to the resin molded body. a control unit that controls the film feed mechanism, the first mold, the second mold, and the injection machine;
to provide a decorative molding device.

According to a tenth aspect of the present invention, the film-side alignment mark, the upstream reference mark, and the downstream reference mark are transparent colors,
an upstream illumination device that irradiates parallel light onto the film-side alignment mark and the upstream reference mark;
an upstream illumination device that irradiates parallel light onto the film-side alignment mark and the downstream reference mark;
further comprising
The upstream detection section detects the film-side alignment mark and the upstream-side reference mark based on the parallel light that has passed through the film-side alignment mark and the parallel light that has passed through the upstream-side reference mark. Detect the amount of deviation,
The downstream detection section detects the film-side alignment mark and the downstream-side reference mark based on the parallel light that has passed through the film-side alignment mark and the parallel light that has passed through the downstream-side reference mark. 2 Detecting the amount of deviation,
A decorative molding apparatus according to the ninth aspect is provided.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. It should be noted that the present invention is not limited by this embodiment. In the drawings, substantially the same members are denoted by the same reference numerals.

(embodiment)
FIG. 1 is a perspective view of a decorative molding apparatus for realizing a decorative molding method according to an embodiment of the present invention, viewed obliquely from above. FIG. 2 is a side view showing a schematic configuration of the decorative molding apparatus of FIG. 1. FIG.

A decorative molding apparatus according to the present embodiment is an apparatus that molds a resin molded body and transfers a pattern (for example, a decorative film) provided on a film to the resin molded body. The decoration molding apparatus according to this embodiment includes a film feeding mechanism 1, a first mold 2, a second mold 3, and an injection machine 4, as shown in FIG.

As shown in FIG. 1, the film transport mechanism 1 is a device that transports the film 5 in the film transport direction FD. The film 5 is provided with a pattern (not shown) and a film-side alignment mark 51 at a position corresponding to the pattern. In this embodiment, a plurality of patterns and a plurality of film-side alignment marks 51 are printed or laminated on the film 5 . A plurality of patterns are provided at predetermined intervals in the film feeding direction FD. The plurality of film-side alignment marks 51 are provided at predetermined intervals at positions corresponding to the plurality of patterns in the film feeding direction FD. In addition, the film-side alignment mark 51 has a color that does not transmit light and suppresses reflection of external light in order to provide a contrast difference with the background. That is, the film-side alignment mark 51 is a mark colored so as to have light shielding properties.

In this embodiment, the film feeding mechanism 1 includes an unwinding section 11 that conveys the film 5 between the first mold 2 and the second mold 3, A winding section 12 for winding the film 5 that has passed through is provided.

The unwinding section 11 includes an unwinding motor shaft 13 , a delivery motor shaft 14 and pinch rollers 15 . A roll of film 5 is wound around the unwinding motor shaft 13 . The feed motor shaft 14 unwinds the film 5 from the feed motor shaft 13 and feeds it between the first mold 2 and the second mold 3 . The feeding motor shaft 14 has its rotation amount controlled by the control unit 6, and the feeding amount of the film 5 is determined according to the rotation amount. The pinch roller 15 is configured to press the film 5 against the delivery motor shaft 14 so that the film 5 can be delivered following the delivery motor shaft 14 .

In this embodiment, the feed motor shaft 14 and the pinch roller 15 are configured to be movable in the film width direction WD which intersects (for example, is perpendicular to) the film feed direction FD. By moving the feed motor shaft 14 and the pinch roller 15 in the film width direction WD, the position of the film 5 in the film width direction WD can be adjusted.

The winding section 12 includes a winding motor shaft 16 , a drawing motor shaft 17 and pinch rollers 18 . A winding motor shaft 16 winds the film 5 into a roll. The pull-in motor shaft 17 winds up the film 5 that has passed between the first mold 2 and the second mold 3 with a constant torque. The pull-in motor shaft 17 has its rotation amount controlled by the control unit 6, pulls the film 5 so that a constant tension is applied to the film 5 so as not to cause wrinkles, etc., and causes the take-up motor shaft 16 to wind the film. The pinch roller 18 is configured to press the film 5 against the pull-in motor shaft 17 so that the film 5 can be fed out following the pull-in motor shaft 17 .

Further, in this embodiment, the pull-in motor shaft 17 and the pinch roller 18 are configured to be movable in the film width direction WD. By moving the pull-in motor shaft 17 and the pinch roller 18 in the film width direction WD, the position of the film 5 in the film width direction WD can be adjusted.

As shown in FIG. 2, the first mold 2 and the second mold 3 are configured to close or open with the transport path of the film 5 interposed therebetween. More specifically, the first mold 2 and the second mold 3 are closed by approaching each other across the transport path of the film 5, and are separated from each other across the transport path of the film 5. configured to open. The film 5 is conveyed with a gap (for example, 1 mm or more and 5 mm or less) that does not come into contact with the surface of the first mold 2 . The mold closing and mold opening operations of the first mold 2 and the second mold 3 are controlled by the controller 6 .

In this embodiment, the first mold 2 is provided with an adsorption mechanism (not shown) that adsorbs the film 5 and a clamp jig 21 that fixes the film 5 to the surface of the first mold 2. ing.

As shown in FIG. 2, the injection machine 4 is configured to inject molten resin between the closed first mold 2 and second mold 3 . In this embodiment, the first mold 2 and the second mold 3 are provided with cavities 2a and 3a, respectively. The injection machine 4 injects molten resin into the space formed by the cavities 2a and 3a between the closed first mold 2 and the second mold 3 through the gate 3b provided in the second mold 3. configured to eject. A resin molding is formed by cooling and solidifying the molten resin in the space. At this time, the film 5 is fixed to the surface of the first mold 2 by the adsorption mechanism and the clamping jig 21, and the pattern of the film 5 is arranged in the space formed by the cavities 2a and 3a, so that resin molding is performed. As the body is molded, the pattern is transferred to the resin molded body.

Further, the first mold 2 is provided with a preset upstream side reference mark 22 on the upstream side in the film feeding direction FD. In this embodiment, the upstream reference mark 22 is a mold-side alignment mark provided on the first mold 2 . Further, the first mold 2 is provided with a preset downstream reference mark 23 downstream of the upstream reference mark 22 in the film feed direction FD. In this embodiment, the upstream reference mark 22 and the downstream reference mark 23 are mold-side alignment marks provided on the first mold 2 . The downstream reference mark 23 is provided at a position away from the cavity 2a in the film width direction WD. The upstream reference mark 22 and the downstream reference mark 23 are printed, stamped, or fixed on the first die 2 so as to be positioned on the same straight line extending in the film feeding direction FD.

In this embodiment, the upstream reference mark 22 and the downstream reference mark 23 are larger than the film-side alignment mark 51 and have different shapes to distinguish them from the film-side alignment mark 51 . The film-side alignment mark 51 is formed in, for example, a square shape. The upstream reference mark 22 and the downstream reference mark 23 are formed, for example, in a rectangular frame shape. Further, the upstream reference mark 22 and the downstream reference mark 23 do not transmit light and have a color that suppresses reflection of external light. By using a different color for the film-side alignment mark 51 than the upstream-side reference mark 22 and the downstream-side reference mark 23, the difference in shape can be easily distinguished.

Further, in this embodiment, the distance between the upstream side reference mark 22 and the downstream side reference mark 23 in the film feeding direction FD is designed to be smaller than the predetermined interval at which the plurality of film side alignment marks 51 are provided. It is

At a position away from the upstream reference mark 22 in the film width direction WD, as shown in FIG. 1, an upstream camera 71, which is an example of an upstream detector, is arranged. The upstream camera 71 detects a first deviation amount between the film side alignment mark 51 and the upstream side reference mark 22 . In this embodiment, as shown in FIG. 3, the upstream camera 71 captures the light emitted from the upstream lighting device 81 and reflected by the mirror unit 91 and the film side alignment marks 51 to perform film side alignment. The position of mark 51 is detected. Similarly, the upstream camera 71 detects the position of the upstream reference mark 22 by capturing the light emitted from the upstream illumination device 81 and reflected by the mirror unit 91 and the upstream reference mark 22 . The film side alignment mark 51 and the upstream side reference mark 22 detected by the upstream side camera 71 are displayed on, for example, a monitor section (not shown).

In addition, as shown in FIG. 1, a downstream camera 72, which is an example of a downstream detector, is arranged at a position away from the downstream reference mark 23 in the film width direction WD. The downstream camera 72 detects the second deviation amount between the film side alignment mark 51 and the downstream side reference mark 23 . In this embodiment, as shown in FIG. 3, the downstream camera 72 captures the light emitted from the downstream illumination device 82 and reflected by the mirror unit 92 and the film side alignment marks 51 to perform film side alignment. The position of mark 51 is detected. Similarly, the downstream camera 72 detects the position of the downstream reference mark 23 by capturing the light emitted from the downstream illumination device 82 and reflected by the mirror unit 92 and the downstream reference mark 23 . The film-side alignment mark 51 and the downstream-side reference mark 23 detected by the downstream-side camera 72 are displayed, for example, on a monitor (not shown).

The film feeding mechanism 1 , the first mold 2 , the second mold 3 and the injection machine 4 are controlled by the controller 6 . The control unit 6 moves the film 5 based on the first shift amount detected by the upstream camera 71 and the second shift amount detected by the downstream camera 72, and aligns the film side alignment mark 51 with the downstream side reference mark 23. The film feeding mechanism 1 is controlled so as to align. After that, the control unit 6 closes the first mold 2 and the second mold 3, injects the molten resin between the closed first mold 2 and the second mold 3, The first mold 2, the second mold 3, and the injection machine 4 are controlled so as to form a resin molded body and transfer a pattern to the resin molded body. Based on the detection information of the upstream camera 71 and the downstream camera 72, the control unit 6 performs arithmetic processing such as position correction calculation, film feeding amount, and movement amount in the film width direction WD.

Next, a decorative molding method according to this embodiment will be described. The decoration molding method described below is performed under the control of the control unit 6 .

First, the film transport mechanism 1 transports the film 5 in the film transport direction FD.

Next, the upstream camera 71 detects the first deviation amount between the film side alignment mark 51 and the upstream side reference mark 22 . In this embodiment, the detection of the first deviation amount by the upstream camera 71 is performed while transporting the film 5 in the film feed direction FD.

FIG. 4 is a plan view showing an example of the field of view of the upstream camera 71 when detecting the first deviation amount between the film side alignment mark 51 and the upstream side reference mark 22. FIG. In this embodiment, it is assumed that the center of the film side alignment mark 51 and the center of the upstream side reference mark 22 are displaced by a distance X1 in the film width direction WD. That is, the first deviation amount is the distance X1.

Next, the film transport mechanism 1 further transports the film 5 in the film transport direction FD, transports the film 5 in the film transport direction FD by a predetermined distance, and then stops. Here, the “predetermined distance” is set to a distance at which the film side alignment mark 51 and the downstream side reference mark 23 are within the field of view of the downstream side camera 72 . As a result, the film-side alignment mark 51 and the downstream-side reference mark 23 are roughly positioned within the field of view of the downstream-side camera 72 .

The feeding amount of the film 5 by the film feeding mechanism 1 is determined according to the rotation amount of the feeding motor shaft 14 . However, the film 5 may slip on the delivery motor shaft 14 depending on the surface condition of the film 5 and the tension applied to the film 5 . In particular, when the film 5 moves several hundred millimeters or more at once, a large difference may occur between the feed amount by the feed motor shaft 14 and the actual movement amount of the film 5 . On the other hand, in this embodiment, since the film-side alignment mark 51 is detected by the upstream-side camera 71, the movement amount of the film 5 to be managed is only the distance between the upstream-side camera 71 and the downstream-side camera 72. good. Therefore, the accuracy of stopping the film 5 can also be improved.

By detecting the film-side alignment mark 51 by the upstream camera 71, the film-side alignment mark 51 can be roughly positioned within the field of view of the downstream camera 72, and the deviation amount can be calculated while the film 5 is transported. be possible. Therefore, if the upstream camera 71 has both a fast scan cycle and a fast shutter speed, the arithmetic processing speed of the device for detecting the first deviation amount and the second deviation amount may be slow.

After the rough positioning, the downstream camera 72 detects the second deviation amount between the film side alignment mark 51 and the downstream side reference mark 23 .

FIG. 5 is a plan view showing an example of the field of view of the upstream camera 71 when detecting the second deviation amount between the film side alignment mark 51 and the downstream side reference mark 23. FIG. In this embodiment, the center of the film-side alignment mark 51 and the center of the downstream-side reference mark 23 are displaced by a distance X2 in the film width direction WD and by a distance Y2 in the film feeding direction FD. shall be That is, the second deviation amounts are the distance X1 and the distance Y2.

Next, the film 5 is moved based on the first shift amount detected by the upstream camera 71 and the second shift amount detected by the downstream camera 72, and the film side alignment mark 51 and the downstream side reference mark 23 are aligned. . That is, the positional deviation between the film-side alignment mark 51 and the downstream-side reference mark 23 is corrected so as to fall within a predetermined allowable range. Thereby, the pattern provided on the film 5 is arranged at a desired position between the first mold 2 and the second mold 3 .

Next, the film 5 is fixed to the surface of the first mold 2 by at least one of the adsorption mechanism and the clamp jig 21 .

Next, the second mold 3 is moved closer to the first mold 2 to close the first mold 2 and the second mold 3 .

Next, the molten resin is injected into the space formed by the cavities 2a and 3a between the closed first mold 2 and the second mold 3 through the gate 3b provided in the second mold 3 by the injection machine 4. to inject. Thereafter, the molten resin is cooled and solidified to form a resin molded body, and the pattern is transferred to the resin molded body.

Next, the operation of aligning the film-side alignment mark 51 and the downstream-side reference mark 23 based on the first shift amount and the second shift amount will be described in more detail.

Alignment between the film side alignment mark 51 and the downstream side reference mark 23 can be performed by moving the unwinding section 11 and the winding section 12 in the film width direction WD. More specifically, the alignment can be performed by moving the feed motor shaft 14 and the pinch roller 15, and the pull-in motor shaft 17 and the pinch roller 18, in the film width direction WD.

The movement amount Δ1 of the unwinding portion 11 and the movement amount Δ2 of the winding portion 12 in the film width direction WD are calculated by the following formulas (1) and (2) based on the first shift amount and the second shift amount. can be done.

Δ1=X2+(X1-X2)×D2/D1/2 (1)
Δ2=X2-Δ1 (2)

Here, as shown in FIG. 6, the distance between the upstream camera 71 and the downstream camera 72 is D1. Also, let D2 be the distance between the unwinding portion 11 and the winding portion 12 . Also, let X1 be the distance by which the center of the film-side alignment mark 51 and the center of the upstream-side reference mark 22 are displaced in the film width direction WD. Also, let X2 be the distance by which the center of the film-side alignment mark 51 and the center of the downstream-side reference mark 23 are displaced in the film width direction WD.

By moving the unwinding portion 11 and the winding portion 12 based on the movement amounts Δ1 and Δ2, the tilt directions of the film side alignment mark 51 and the downstream side reference mark 23 with respect to the film width direction WD and the film feeding direction FD are adjusted. Alignment can be performed. Further, by moving the film 5 in the film feeding direction FD based on the distance Y2 of the second shift amount described with reference to FIG. can be aligned.

In addition, when the depth of the cavity 2a of the first mold 2 or the cavity 3a of the second mold 3 is, for example, 1 mm or more, the film 5 is deformed along the cavity 2a or the cavity 3a, so that the pattern and the resin It may occur that the molded body is misaligned. Therefore, assuming the amount of positional deviation, the amount of movement Δ3 of the unwinding portion 11 and the amount of movement Δ4 of the winding portion 12 are calculated, and the film-side alignment mark 51 and the downstream-side reference mark 23 are aligned. good too.

In this case, the movement amount Δ3 of the unwinding portion 11 and the movement amount Δ4 of the winding portion 12 in the film width direction WD are calculated by the following formulas (3) and (4) based on the first shift amount and the second shift amount. can be calculated.

Δ1=X2+Δx2+(X1+Δx1-X2)×D2/D1/2 (3)
Δ2=X2+Δx2−Δx1 (4)

Here, the positional fine adjustment amount of the upstream camera 71 in the film width direction WD is assumed to be Δx1. Also, let Δx2 be the position fine adjustment amount in the film width direction WD of the downstream camera 72 .

By moving the unwinding portion 11 and the winding portion 12 based on the movement amounts Δ3 and Δ4, the film width direction WD and Alignment in the tilt direction can be performed.

According to this embodiment, the first deviation amount between the film side alignment mark 51 and the upstream side reference mark 22 is detected at the position on the upstream side in the film feeding direction FD. After that, the film 5 is further conveyed in the film feeding direction FD, and the second deviation amount between the film side alignment mark 51 and the downstream side reference mark 23 is detected at a position on the downstream side in the film feeding direction FD. The film 5 is moved based on the first and second deviation amounts thus detected, and the film side alignment mark 51 and the downstream side reference mark 23 are aligned. In other words, the same film-side alignment mark 51 is used as a target for detecting the deviation amount with respect to the upstream-side reference mark 22 and the downstream-side reference mark 23 . As a result, it is possible to accurately correct the inclination of the film 5 with respect to the film feeding direction FD, and to transfer the pattern to the resin molded body with higher accuracy without the need to consider printing misalignment.

Further, according to the present embodiment, the upstream reference mark 22 and the downstream reference mark 23 are mold-side alignment marks provided on the first mold 2 . That is, the relative positions of the upstream reference mark 22 and the downstream reference mark 23 are fixed with respect to the first mold 2 without being displaced. Thereby, the first deviation amount and the second deviation amount can be detected with high accuracy. As a result, the pattern can be transferred to the resin molding with higher accuracy.

Further, according to this embodiment, the distance between the upstream side reference mark 22 and the downstream side reference mark 23 in the film feeding direction FD is smaller than the interval between the plurality of film side alignment marks 51 . As a result, even if there is a difference between the feed amount by the feed motor shaft 14 and the actual movement amount of the film 5, the small distance between the upstream side reference mark 22 and the downstream side reference mark 23 prevents the influence of the difference from occurring. can be suppressed. As a result, the stopping accuracy of the film 5 can be improved.

Further, according to this embodiment, the detection of the first shift amount is performed while the film 5 is conveyed in the film feeding direction FD. As a result, the time required to detect the first deviation amount can be shortened compared to the case where the transport of the film 5 is stopped. can be suppressed.

Further, according to this embodiment, after detecting the first amount of displacement, the film 5 is transported by a predetermined distance in the film feed direction FD and stopped, and then the second amount of displacement is detected. As a result, the film-side alignment mark 51 and the downstream-side reference mark 23 can be roughly positioned, and the amount of movement of the film 5 for alignment between the film-side alignment mark 51 and the downstream-side reference mark 23 can be suppressed. .

Further, according to this embodiment, after detecting the first shift amount, the film 5 is moved in the film feeding direction FD so that the film side alignment mark 51 and the downstream side reference mark 23 are positioned within the field of view of the downstream side camera 72 . is conveyed and stopped, and then the second deviation amount is detected. As a result, the film-side alignment mark 51 and the downstream-side reference mark 23 are roughly positioned with higher accuracy, and the film 5 is moved for alignment between the film-side alignment mark 51 and the downstream-side reference mark 23. The amount can be further reduced.

In the above description, the upstream reference mark 22 and the downstream reference mark 23 are mold-side alignment marks provided on the first mold 2, but the present invention is not limited to this. For example, only one of the upstream reference mark 22 and the downstream reference mark 23 may be a mold-side alignment mark provided on the first mold 2 .

Also, the upstream reference mark 22 and the downstream reference mark 23 may be provided outside the first mold 2, such as above or below the first mold 2, for example. However, in this case, at least one of the upstream reference mark 22 and the downstream reference mark 23 is preferably fixed relative to the first mold 2 . As a result, the first deviation amount or the second deviation amount can be detected with high accuracy, and the pattern can be transferred to the resin molding with higher accuracy.

Alternatively, the field of view of the upstream camera 71 may be fixed by precisely fixing the position of the upstream camera 71 , and a predetermined position within the field of view may be used as the upstream reference mark 22 . Similarly, the field of view of the downstream camera 72 may be fixed by precisely fixing the position of the downstream camera 72 , and a predetermined position within that field of view may be used as the downstream reference mark 23 . Even in this case, the first deviation amount or the second deviation amount can be detected with high accuracy, and the pattern can be transferred to the resin molding with higher accuracy.

As the depth of the cavities 2a and 3a increases, the film 5 is greatly deformed along the cavities 2a and 3a. It is possible that you will not be able to enter. Therefore, there may be provided a mechanism for individually focusing so that the film-side alignment mark 51 and the downstream-side reference mark 23 are within the field of view of the downstream-side camera 72 .

In the above description, the film-side alignment mark 51 does not transmit light and has a color that suppresses reflection of external light, but the present invention is not limited to this. For example, as the pattern provided on the film 5, a transmissive film such as an antireflection film or an anti-fingerprint film may be used for the purpose of improving functionality. In this case, if the film side alignment mark 51 is a mark colored so as to have a light shielding property, the pattern and the film side alignment mark 51 need to be provided on the film 5 in separate processes, leading to an increase in cost. Therefore, the film-side alignment mark 51 may be transparent. Here, the term "transmission color" refers to the color of transmitted light when the light is transmitted through a substance. It does not matter whether the film-side alignment mark 51 itself is colored or transparent.

When the film-side alignment mark 51 is transparent, the upstream camera 71 can detect the film-side alignment mark 51 with an optical system as shown in FIG. 7, for example. That is, parallel light is emitted from the upstream illumination device 83 toward the mirror unit 93 provided inside the first mold 2 . The parallel light is reflected by the mirror unit 93 and passes through the film 5 and the film-side alignment mark 51 . At this time, the parallel light is irregularly reflected at the edge of the film-side alignment mark 51 and cannot travel straight. As a result, the upstream camera 71 can recognize the shape of the film-side alignment mark 51 and detect the film-side alignment mark 51 based on the parallel light that passes through the film-side alignment mark 51 and is reflected by the mirror unit 94 . be able to.

Similarly, the downstream camera 72 can detect the film side alignment mark 51 with an optical system as shown in FIG. 7, for example. That is, parallel light is emitted from the downstream illumination device 84 toward the mirror unit 95 provided inside the first mold 2 . The parallel light is reflected by the mirror unit 95 and passes through the film 5 and the film-side alignment mark 51 . At this time, the collimated light is irregularly reflected at the edge of the film-side alignment mark 51 and cannot travel straight. As a result, the downstream camera 72 can recognize the shape of the film-side alignment mark 51 and detect the film-side alignment mark 51 based on the parallel light that passes through the film-side alignment mark 51 and is reflected by the mirror unit 96 . be able to.

Further, when the film-side alignment mark 51 is transparent, the upstream reference mark 22 and the downstream reference mark 23 may also be transparent. For example, the upstream reference mark 22 and the downstream reference mark 23 may be drawn on a transparent plate such as glass.

In this case, the upstream camera 71 detects the upstream reference mark 22 using the optical system shown in FIG. can be detected. In addition, since the film-side alignment mark 51 and the upstream-side reference mark 22 are of a transparent color, erroneous detection of both can be suppressed even when they overlap, and positioning accuracy can be improved. Also, the upstream camera 71 detects the film-side alignment mark 51 and the upstream-side reference mark 22 based on the parallel light that has passed through the film-side alignment mark 51 and the parallel light that has passed through the upstream-side reference mark 22, and performs the first detection. A deviation amount can be detected.

Similarly, the downstream camera 72 detects the downstream reference mark 23 using the optical system shown in FIG. can be detected. In addition, since the film-side alignment mark 51 and the downstream-side reference mark 23 are transparent colors, even if they overlap each other, erroneous detection of both can be suppressed, and positioning accuracy can be improved. Further, the downstream camera 72 detects the film-side alignment mark 51 and the downstream-side reference mark 23 based on the parallel light that has passed through the film-side alignment mark 51 and the parallel light that has passed through the downstream-side reference mark 23, and performs the second detection. A deviation amount can be detected.

In the description above, in FIG. 2, the mold shown below is the first mold and the mold shown above is the second mold, but the present invention is not limited to this. In FIG. 2, the mold shown below may be the second mold, and the mold shown above may be the first mold.

Also, in the above description, the upstream camera 71 and the downstream camera 72 detect light reflected by the mirror units 91 to 94, but the present invention is not limited to this. For example, the upstream camera 71 and the downstream camera 72 may directly detect light passing through or reflected by the film alignment mark 51, the upstream reference mark 22, or the downstream reference mark .

By appropriately combining any of the various embodiments described above, the respective effects can be obtained.

Although the present invention has been fully described in connection with preferred embodiments and with reference to the accompanying drawings, various variations and modifications will become apparent to those skilled in the art. Such variations and modifications are to be included therein insofar as they do not depart from the scope of the invention as set forth in the appended claims.

1 film feeding mechanism 2 first mold 2a cavity 3 second mold 3a cavity 3 gate 4 injection machine 5 film 6 control unit 11 unwinding unit 12 winding unit 13 unwinding motor shaft 14 unwinding motor shaft 15 pinch roller 16 winding Take-up motor shaft 17 Pull-in motor shaft 18 Pinch roller 21 Clamp jig 22 Upstream reference mark 23 Downstream reference mark 51 Film-side alignment mark 71 Upstream camera 72 Downstream camera 81, 83 Upstream illumination device 82, 84 Downstream illumination Equipment 91, 92, 93, 94, 95, 96 Mirror unit FD Film feed direction WD Film width direction

Claims (10)

A film provided with a pattern and a film-side alignment mark at a position corresponding to the pattern is conveyed in the film feed direction to arrange the pattern between a first mold and a second mold, and the first mold. The mold and the second mold are closed, and a molten resin is injected between the first mold and the second mold to mold a resin molded body, and the pattern is applied to the resin molded body. A decorative molding method for transferring,
detecting a first deviation amount between the film-side alignment mark and a preset upstream-side reference mark at a position on the upstream side in the film feeding direction;
further conveying the film in the film feeding direction, and detecting a second misalignment amount between the film side alignment mark and a preset downstream side reference mark at a position downstream in the film feeding direction;
moving the film based on the first shift amount and the second shift amount to align the film-side alignment mark and the downstream reference mark;
A decorative molding method, comprising: 2. The decorative molding method according to claim 1, wherein at least one of said upstream reference mark and said downstream reference mark has a fixed relative position with respect to said first mold. 3. The decorative molding method according to claim 2, wherein at least one of said upstream reference mark and said downstream reference mark is a mold-side alignment mark provided on said first mold. The film is provided with a plurality of patterns at predetermined intervals in the film feed direction, and a plurality of film-side alignment marks are provided at positions corresponding to the plurality of patterns at the predetermined intervals. ,
The decorative molding method according to any one of claims 1 to 3, wherein a distance between said upstream reference mark and said downstream reference mark in said film feeding direction is smaller than said predetermined interval. The decorative molding method according to any one of claims 1 to 4, wherein the detection of the first shift amount is performed while conveying the film in the film feeding direction. 6. The method according to any one of claims 1 to 5, wherein after detecting the first amount of displacement, the film is transported by a predetermined distance in the film feeding direction and stopped, and then the second amount of displacement is detected. The decorative molding method described in . After the detection of the first deviation amount, the film side alignment mark and the downstream side reference mark of the film are positioned within the field of view of a camera arranged downstream in the film feeding direction from the upstream side reference mark. The decorative molding according to any one of claims 1 to 5, wherein the film is conveyed by a predetermined distance in the film feeding direction and then stopped, and then the second deviation amount is detected. Method. the film-side alignment mark, the upstream reference mark, and the downstream reference mark are transparent colors;
detecting the film-side alignment mark based on the parallel light that has passed through the film-side alignment mark;
detecting the upstream reference mark based on the parallel light that has passed through the upstream reference mark, and detecting the downstream reference mark based on the parallel light that has passed through the downstream reference mark;
The decorative molding method according to any one of claims 1 to 7. a film transport mechanism for transporting a film provided with a pattern and a film-side alignment mark at a position corresponding to the pattern in a film transport direction;
a first mold and a second mold that are configured to close or open with the transport path of the film sandwiched therebetween;
an injection machine for injecting molten resin between the closed first mold and the second mold;
an upstream detection unit that detects a first deviation amount between the film-side alignment mark and a preset upstream reference mark;
a downstream detection unit that detects a second deviation amount between the film-side alignment mark and a preset downstream reference mark;
After moving the film based on the first shift amount and the second shift amount to align the film side alignment mark and the downstream reference mark, the first mold and the second mold are moved. is closed, and the molten resin is injected between the closed first mold and the second mold to mold a resin molded body and to transfer the pattern to the resin molded body. a control unit that controls the film feed mechanism, the first mold, the second mold, and the injection machine;
A decorative molding device. the film-side alignment mark, the upstream reference mark, and the downstream reference mark are transparent colors;
an upstream illumination device that irradiates parallel light onto the film-side alignment mark and the upstream reference mark;
a downstream illumination device that irradiates parallel light onto the film-side alignment mark and the downstream reference mark;
further comprising
The upstream detection section detects the film-side alignment mark and the upstream-side reference mark based on the parallel light that has passed through the film-side alignment mark and the parallel light that has passed through the upstream-side reference mark. Detect the amount of deviation,
The downstream detection section detects the film-side alignment mark and the downstream-side reference mark based on the parallel light that has passed through the film-side alignment mark and the parallel light that has passed through the downstream-side reference mark. 2 Detecting the amount of deviation,
The decorative molding device according to claim 9.

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