JP5818163B2 - Injection molding apparatus and film insert molding method for laminated molded product - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a film insert molding method in which a film is integrally formed on a resin molded product, and decorativeness and functionality are imparted to the surface, and more specifically, an injection for molding a multilayer molded product composed of a plurality of resins. The present invention relates to a molding apparatus and a film insert molding method for laminated molded products.

  As a method for enhancing the decorating properties and functionality of resin molded products, film insert molding is often used in which a film (functional film) having such decorating properties and functionality is integrally formed on the surface of the resin molded product. Yes. Specifically, a film with decoration and functionality that is difficult to express with resin, such as coloring, gloss, and soft feeling (also called decorative sheets, painting sheets, painting films, etc.) is inserted into the mold. Then, these films are fused and integrated with the design surface of the resin molded product by injection filling, and such a resin molded product may be called a film insert molded product or the like. Especially for exterior components such as automobile interior parts (instrument panels, interior panels such as doors), home appliances OA equipment, and building materials, for softness, leather-like, wood-grained decoration, and to prevent scratches There is a great demand for such a film insert molded product in the case of imparting functionality such as hard coating and antistatic for preventing adhesion of dust and dirt.

  Furthermore, in recent years, with the main purpose of reducing weight and reducing assembly man-hours, glass replacement parts for automobiles, glass replacement parts that use translucent resin, and mounting structures and reinforcing structures that use colored resin, etc. The movement to replace a glass substitute resin molded product obtained by laminating parts and the like is proceeding. Therefore, such as UV resistance (ultraviolet ray-cutting properties) required for glass members such as windows, and weather resistance and scratch resistance (scratch resistance), which are considered to be inferior to glass members. Such a film insert molding method is considered to be effective in order to provide various functions not only on one side but also on the front and back sides. Similarly, solar panels, LCD TVs and PC monitors, mobile phone and tablet display screens, etc., are also used for glass substitute resin molded products that are formed by laminating glass substitute parts and mounting structure parts and reinforcing structure parts. In many cases, different functions are imparted to both surfaces, and the adoption of such a film insert molding method has been studied.

  Conventionally, when a functional film is integrally formed on both the front and back surfaces of a resin molded product, a decorative sheet (functional film) is sandwiched between molding dies as in Patent Document 1, and the decorative sheet of this molding die is used. A film insert molding method in which a molten resin is injected and filled in between is common. In patent document 1, what stuck the decorating sheet required for every resin molded product on the base | substrate sheet | seat continuous through a peeling layer is used. However, from the roll portion around which the base sheet is wound, the decorative sheet is supplied together with the base sheet between the molding dies, and only the base sheet from which the decorative sheet is peeled off by integral molding with the resin molded product is separated into another roll. In the decorative sheet feeding device (film supply means) that winds up at the section, for example, when the decorative sheet is supplied from the upper side to the lower side of the mold, the feeding device is installed on both the fixed mold side and the movable mold side. Then, since the installation space (especially the roll part mentioned above) between apparatuses interferes, there exists a problem that a wider space will be needed. Patent document 1 solves this problem by the apparatus arrangement | positioning which makes the feed direction of the base sheet | seat of this decorating sheet | seat feeding apparatus orthogonal on the fixed mold side and a movable mold side.

  On the other hand, Patent Document 2 discloses a manufacturing method for manufacturing a windshield member for a vehicle by integrally forming a cured film layer-attached film (functional film / hard coat film) having scratch resistance (scratch resistance) with a resin. A manufacturing method is disclosed in which after the film is fixed only to the upper part of each molding surface (mold cavity surface) of the movable mold and the fixed mold, resin is supplied (injection filling) from above the upper end of the film. . This is because the film having a hardened coating layer with poor ductility is difficult to fit on the molding surface of the mold, and cracks and wrinkles of the coating layer, peeling between the coating layer and the film, and the like that occur in the film during molding. The stress (unreasonable force) generated in the resin flow direction due to resin diffusion / filling is released to the free end side of the film that is not fixed to the molding surface in the same direction as the resin flow direction. Is to prevent.

  Further, in Patent Document 3, a rotating plate that can arbitrarily rotate a plurality of molds mounted on the same plane around a rotation axis that coincides with the mold opening and closing direction and is orthogonal to the same plane is movable. Double-molding (lamination molding) that can be arbitrarily switched between the combination of multiple molds attached to the rotating plate and the same multiple molds attached to the fixed platen by rotating the rotating plate. A film insert molding method using an injection molding apparatus (so-called die rotary injection: DRI method) is disclosed. Specifically, two sets of painting film conveying means (film supply means) are arranged on the fixed plate side of this DRI type injection molding apparatus, and the surface of the secondary resin molded product (secondary molded body); A resin molded product (laminated molded product) is obtained by integrally molding different painting films (functional films) between the secondary resin molded product and the primary resin molded product (primary molded product).

  The parentheses in the descriptions relating to Patent Document 1 to Patent Document 3 describe the constituent members of the present invention that are considered to be equivalent to or similar to the constituent requirements immediately before the parentheses so that the understanding of the present invention is easy. There is no suggestion that the constituent requirements immediately before the parentheses coincide with the constituent members in the parentheses.

JP 2004-181885 A JP-A-10-024443 JP 2007-216622 A

  Here, when considering a film insert molding method in which a functional film is integrally formed on both front and back surfaces of a laminated molded product composed of at least two layers of a primary molded body and a secondary molded body, instead of a single layer, Patent Document 1 There is no description for such a laminated molded article. Therefore, when a decorative sheet feeding apparatus as in Patent Document 1 is arranged in a DRI type injection molding apparatus as in Patent Document 3, it is necessary to arrange the apparatus on a rotating disk that rotates. In that case, as described in Patent Document 3 (paragraphs 0005 to 0007), a weight like a painting sheet conveying device (decorative sheet feeding device / film feeding means) is provided on the movable mold side to be rotationally driven. When an object is arranged, a large rotational driving force is required. If a small painting sheet conveying device is used to reduce the rotational driving force, the degree of freedom of the painting sheet (decorative sheet) may be impaired. Furthermore, there is a possibility that the positions of the painting sheet and the mold cavity are shifted due to the rotating operation of the rotating disk.

  Further, Patent Document 2 does not describe such a multilayer molded product. Therefore, when the manufacturing method as in Patent Document 2 is applied to the DRI type injection molding apparatus as in Patent Document 3, it cures to the movable molding surface on the turntable side and the fixed molding surface on the stationary platen side. When fixing the film with a coating layer, even if the film is fixed to the upper part of the molding surface of one of the molds, the film is fixed to the molding surface of the other mold by rotating the rotating disk. As a premise, it is necessary to fix the lower part instead of the upper part. Further, in the mold on the turntable side, even if the film is fixed to the upper part of the molding surface of the mold at first, the fixing position is turned upside down by the rotation operation of the turntable. Therefore, the film cannot be fixed to the molding surface with high accuracy, and it is difficult to achieve the same effect as that of Patent Document 2, and the positions of the film and the molding surface to which the film is fixed are shifted due to the rotation operation of the turntable. There is a fear.

  Furthermore, in the case of a DRI type injection molding apparatus, a plurality of molds (at least two) are mounted on the same plane of the movable platen-side rotary plate so that the rotational axis is symmetrical. There is a problem that the size of the mold that can be used is small with respect to the size of a general-purpose injection molding apparatus to which only a mold is attached.

  The present invention has been made in view of the above-described problems. Specifically, the functional film is integrated on both the front and back surfaces of the laminated molded product, which has few restrictions on the method of supplying the functional film and the mold size. An object of the present invention is to provide a moldable injection molding apparatus and a film insert molding method for a laminated molded product.

The object of the present invention is to provide a common mold,
A fixed platen to which the common mold is attached;
A dummy plate,
A movable plate to which the dummy plate is attached;
Wherein disposed between the stationary platen and said movable platen, said common mold combined with to have at least two mold parting surface to form a mold cavity, one of the at least two of the mold division plane , together to form the mold cavity in combination with the common die, and at least two other of the mold division plane, rotating mold section Ru to form a closed space in combination with the dummy plate,
Rotating mold support means for supporting the rotating mold part rotatably around a rotation axis orthogonal to the mold opening / closing direction and moving the rotating mold part in the mold opening / closing direction;
At least two injection units arranged so that molten resin can be injected and filled in the mold cavity;
First film supply means for supplying a first film between the common mold and the rotating mold part;
Second film supply means for supplying a second film between the rotating mold part and the dummy plate;
This is achieved by an injection molding apparatus comprising:

  With the configuration of this injection molding apparatus, by rotating the rotating mold part combined with the common mold, at least two kinds of mold cavities are formed, and a laminated molded product is formed between the common mold and the rotating mold part. Can be molded. In addition, since the first film and the second film are not simultaneously supplied to one mold cavity, but are separately supplied between the common mold and the dummy plate respectively facing the rotating mold portion, There are few restrictions. Furthermore, by rotating a rotating mold part having at least two mold dividing surfaces instead of a mold attached to the same plane, each one mold dividing surface is combined with one common mold. Since at least two types of mold cavities are formed, the usable mold size is not reduced with respect to the size of the injection molding apparatus, and there are few restrictions on the mold size.

In addition, such an injection molding apparatus includes a first holding unit configured to hold the first film on the common mold side facing one mold dividing surface of the rotating mold part by suction,
Second holding means for holding the second film on the other mold dividing surface side of the rotating mold part facing the dummy plate by suction;
It is preferable to provide.

Further, such an injection molding apparatus includes a first heating means for heating the first film,
A second heating means for heating the second film;
With
A mold cavity of a mold that holds the first film and the second film heated by the first heating unit and the second heating unit by the first holding unit and the second holding unit, respectively. It may be an injection molding apparatus that vacuum-forms the shape of the surface.

Using such an injection molding apparatus, the first mold cavity is formed from one side of the injection unit to the first mold cavity formed between one mold dividing surface of the common mold and the rotary mold part by clamping. A primary molding step of molding a primary molded body obtained by injection-filling 1 molten resin and integrally molding the first molten resin and the first film held on the common mold side;
In a state where the primary molded body and the first film are held on the common mold side, the rotating mold part and the dummy plate are opened from the common mold, and then the rotating mold part is rotated. A primary rotation step of moving the second film held on the other mold dividing surface side of the rotating mold part to a position facing the common mold;
A second mold formed between the second film held on the other mold dividing surface side of the rotating mold part and the primary molded body held on the common mold by clamping. A secondary molding step of molding a secondary molded body in which the second film and the second molten resin are integrally formed by injecting and filling the second molten resin into the cavity from the other of the injection units;
It is preferable to carry out a film insert molding method of a laminated molded product for molding a double-sided film insert laminated molded product comprising the primary molded body and the secondary molded body .

Further, the film insert molding method of this laminated molded product is characterized in that one of the injection units is placed in a first mold cavity formed between one mold dividing surface of the common mold and the rotating mold part by clamping. A primary molding step of molding a primary molded body in which the first molten resin is injected and filled, and the first molten resin and the first film held on the common mold side are integrally molded;
In a state where the primary molded body and the first film are held on the common mold side, the rotating mold part and the dummy plate are opened from the common mold, and then the rotating mold part is rotated. A primary rotation step of moving the second film held on the other mold dividing surface side of the rotating mold part to a position facing the common mold;
A second mold formed between the second film held on the other mold dividing surface side of the rotating mold part and the primary molded body held on the common mold by clamping. A secondary molding step of molding a secondary molded body in which the second film and the second molten resin are integrally formed by injecting and filling the second molten resin into the cavity from the other of the injection units;
During the primary molding step, in the sealed space formed between the other mold dividing surface of the rotating mold part and the dummy plate, the second heating means and the second holding means allow the second film to be a secondary preshaping step of vacuum forming the mold cavity shape of the other mold split surface of the rotating mold member may have a.

  Furthermore, in the film insert molding method of the laminated molded product, in the primary molding step, the first film is vacuum-formed into a mold cavity shape of the common mold by the first heating means and the first holding means. A primary pre-shaping step may be included.

  Furthermore, the film insert molding method of this laminated molded product is characterized in that in the primary molding step or the secondary molding step, a mold cavity whose volume is expanded by minute mold opening is injected and filled, and then the mold is clamped. Thus, a mold cavity volume reduction operation for reducing the volume of the mold cavity may be performed.

An injection molding apparatus according to the present invention includes a common mold, a fixed plate to which the common mold is attached, a dummy plate, a movable plate to which the dummy plate is attached, and between the fixed plate and the movable plate. are arranged, said common mold combined with to have at least two mold parting surface to form a mold cavity, one of the at least two of the mold division plane, the gold in combination with the common die orthogonal with to form a mold cavity, at least two other of the mold division plane, and the dummy plate combined with rotating mold section Ru to form a sealed space, the rotary mold unit, the mold opening and closing direction A rotating mold supporting means for rotating around the rotating shaft and moving in the mold opening and closing direction, and at least two jets arranged so that molten resin can be injected and filled in the mold cavity. A first film supplying means for supplying a first film between the unit, the common mold and the rotating mold part; and a second film supplying means for supplying a second film between the rotating mold part and the dummy plate. Therefore, at least two types of mold cavities are formed by rotating the rotating mold part combined with the common mold, and a laminated molded product is formed between the common mold and the rotating mold part. be able to. In addition, since the first film and the second film are not simultaneously supplied to one mold cavity, but are separately supplied between the common mold and the dummy plate respectively facing the rotating mold portion, There are few restrictions. Furthermore, by rotating a rotating mold part having at least two mold dividing surfaces instead of a mold attached to the same plane, each one mold dividing surface is combined with one common mold. Since at least two types of mold cavities are formed, the usable mold size is not reduced with respect to the size of the injection molding apparatus, and there are few restrictions on the mold size.

Further, the film insert molding method for a laminated molded product according to the present invention is characterized in that the injection is performed on the first mold cavity formed between one mold dividing surface of the common mold and the rotating mold part by clamping. A primary molding step of molding a primary molded body in which the first molten resin is injected and filled from one of the units and the first molten resin and the first film held on the common mold side are integrally molded;
In a state where the primary molded body and the first film are held on the common mold side, the rotating mold part and the dummy plate are opened from the common mold, and then the rotating mold part is rotated. A primary rotation step of moving the second film held on the other mold dividing surface side of the rotating mold part to a position facing the common mold;
A second mold formed between the second film held on the other mold dividing surface side of the rotating mold part and the primary molded body held on the common mold by clamping. A secondary molding step of molding a secondary molded body in which the second film and the second molten resin are integrally formed by injecting and filling the second molten resin into the cavity from the other of the injection units;
Therefore, the injection molding apparatus according to the present invention can be used to form a double-sided film insert laminated molded product comprising a primary molded body and a secondary molded body .

It is a schematic side view of the main component requirements of the injection molding apparatus which concerns on Example 1 of this invention. It is a general | schematic fragmentary sectional view which shows the first half of the shaping | molding process of the film insert shaping | molding method of the laminated molded product which concerns on Example 1 of this invention. It is a general | schematic fragmentary sectional view which shows the second half of the shaping | molding process of the film insert shaping | molding method of the laminated molded product which concerns on Example 1 of this invention. It is a schematic sectional drawing of the double-sided film insert laminated molded product and functional film which concern on Example 1 of this invention. It is a general | schematic fragmentary sectional view which shows the shaping | molding process of the film insert shaping | molding method of the laminated molded product which concerns on Example 2 which is an application example of this invention.

  Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings.

  A first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a schematic side view of main components of an injection molding apparatus according to Embodiment 1 of the present invention. FIG. 2 is a schematic partial cross-sectional view showing the first half of the molding process of the film insert molding method for a laminated molded product according to Example 1 of the present invention. 2A shows a film insert process, FIG. 2B shows a secondary pre-shaped process, a primary pre-shaped process and a primary molding process, and FIG. 2C shows a mold opening state after the primary rotating process. FIG. 3 is a schematic partial cross-sectional view showing the latter half of the molding step of the film insert molding method for a laminated molded product according to Example 1 of the present invention. 3A is an injection filling state in the secondary molding process, FIG. 3B is a mold cavity volume reduction operation (mold cavity volume reduction operation) in the secondary molding process, and FIG. 3C is a mold opening. The subsequent product removal process is shown. FIG. 4 is a schematic cross-sectional view of a double-sided film insert laminated molded product and a functional film according to Example 1 of the present invention. 4 (a) is a schematic sectional view of a double-sided film insert laminated molded product which is also a schematic detailed view of the main part A of FIG. 3 (c), FIG. 4 (b) is a schematic configuration diagram of the first film, and FIG. ) Is a schematic configuration diagram of the second film.

  First, the basic configuration of the injection molding apparatus 1 according to the present invention will be described with reference to FIG. The injection molding apparatus 1 is in a mold open state in which the product removal process is completed and a film insertion process for supplying a new functional film is performed. A fixed plate 3 fixed to the bed 2, a movable plate 5 provided so as to be movable in the mold opening / closing direction with respect to the fixed plate 3, and a rotating metal disposed between and attached to the fixed plate 3 and the movable plate 5. The mold part 40 is rotatably supported around a rotation axis in the vertical direction perpendicular to the mold opening / closing direction, and the rotating mold support mechanism 4 for moving in the mold opening / closing direction and a part of the rotating mold part 40 are configured and fixed. Rotating mold mounting portion having two mold mounting surfaces facing the panel 3 and the movable panel 5 and supported by the rotating mold support mechanism 4 so as to be rotatable around a vertical rotation axis perpendicular to the mold opening / closing direction. 41 and a first injection unit 17 provided on the fixed platen 3 side.

  A common mold 19 is attached to the surface of the fixed platen 3 on the front side (the side facing the movable platen 5), and the first injection unit 17 is directed to the common mold 19 from the back side to the front side. Through holes 3a for advancing and retreating are formed. The first injection unit 17 is disposed so as to be connectable to the common mold 19 from the through hole 3a, and a resin (not shown) is formed in a mold cavity formed between the common mold 19 and the rotating mold part 40 by clamping. The molten resin can be injected and filled through the flow path. A tie bar (not shown) protrudes from the four corners of the fixed platen 3 and passes through the movable platen 5.

  In addition to the first injection unit 17, a second injection unit 18 is disposed on the stationary platen 3 so as to be connectable to the common mold 19, and is clamped between the common mold 19 and the rotating mold part 40. The mold cavity to be formed is configured to be able to inject and fill molten resin via a resin flow path (not shown). Here, the second injection unit 18 is illustrated as being connected to the upper surface of the common mold 19 in FIG. 1, but this means that the second injection unit 18 is connected to the common mold 19. The second injection unit 18 may be disposed so as to be connectable to the side surface of the common mold 19 or to the back surface of the common mold 19 side by side with the first injection unit 17.

  The second injection unit 18 is preferably connected to the common mold 19 that does not move, but is not limited thereto, and may be connected to the rotating mold part 40. Further, the second injection unit 18 is configured such that the resin having the larger injection filling amount of the laminated molded product to be molded is injected and filled by the first injection unit 17 and the resin having the smaller amount is injected and filled by the second injection unit 18. If the size of the second injection unit 18 can be reduced, restrictions on the arrangement are reduced, and various arrangements of the second injection unit 18 as described above can be selected in accordance with the installation state of the injection molding apparatus. Furthermore, when the film insert molding method according to the present invention is performed by adding a rotary mold support mechanism or the like to a general-purpose injection molding apparatus, the second injection unit 18 is commercially available with a relatively small injection filling amount. An additional small injection unit or the like can be employed.

  The common mold 19 is provided with a first holding means 50 and a first heating means 19a. For the sake of simplicity, the first holding means 50 shown outside the injection molding apparatus 1 in FIG. 1 includes a plurality of suction holes (not shown) arranged on the mold cavity surface 19c of the common mold 19 and the mold dividing surface. Then, the air in the mold cavity is sucked through the suction pipe 19b connected to the suction hole, so that the first film supply means 60, which will be described later, is used between the common mold 19 and the rotating mold part 40. The first film 60a to be supplied is held on the common mold 19 side. The first holding means 50 does not need to be disposed outside the injection molding apparatus 1, and may be disposed on the common mold 19 or the fixed platen 3, or a vacuum line (pipe) as factory equipment in the vicinity of the injection molding apparatus 1. If there is, the form which connects these vacuum lines and the suction line 19b directly via the valve unit etc. which can adjust suction power may be sufficient.

  Further, the first heating means 19a is for arbitrarily heating the mold cavity surface 19c of the common mold 19 separately from a general mold temperature control device, and the first film 60a to be supplied is scratch resistant. The first film 60a is softened by heating and the mold cavity surface 19c before injection filling by the suction force of the first holding means 50 is used. The shape is subjected to vacuum / suction molding (preliminary shaping). The first heating means 19a is preferably an electric heater that can easily control the heating temperature and the heating pattern. However, if a known heating means having a heating capability sufficient to soften the hard coat film or the like is appropriately adopted. good. On the other hand, when the first film 60a has a sufficient elongation and can be formed into the shape of the mold cavity surface only by the pressure and temperature of the molten resin to be injected and filled, the first heating means 19a is used as the common mold 19. There is no need to place them. In this way, the film-like object is heated and softened, and the air between the object and the mold cavity surface is sucked into vacuum or vacuum, and the object is shaped into the mold cavity surface shape. The molding to be performed is referred to as “vacuum / suction molding” or “decompression / suction molding”, but is generally simply referred to as “vacuum molding”. The designation “molding” shall be used.

  A dummy plate 6 is attached to the movable platen 5 on the surface facing the rotating mold portion 40, guided by a tie bar (not shown), and is provided so as to be movable forward and backward with respect to the fixed platen 3 by a mold clamping means (not shown). Yes. The dummy plate 6 protects the mold dividing surface of the opposing rotating mold part 40 during clamping, and the heating means 6a is disposed on the surface of the rotating mold part 40 facing the mold dividing surface. . The dummy plate 6 and the heating means 6a will be described after other configurations are described.

  The rotary mold support mechanism 4 is disposed between the fixed platen 3 and the movable platen 5 and is provided on the bed 2 so as to be movable in the mold opening / closing direction. The movement guide (guide) of the rotary mold support mechanism 4 in the mold opening / closing direction may be provided by guide means such as a linear motion guide provided on the bed 2, or the rotary mold of the rotary mold unit 40. The mold mounting part 41 is composed of a rotating part that has a mold mounting surface and rotates, and a frame part that rotatably supports the mold mounting part, and tie bars (not shown) are passed through the four corners of the non-rotating frame part. And a known guide means may be selected as appropriate. The rotating mold support mechanism 4 supports a rotating mold part 40 supported rotatably around a vertical rotation axis orthogonal to the mold opening / closing direction. The rotating mold support part 4 includes a rotating mold mounting part 41 having a surface, and a first rotating mold 20 and a second rotating mold 21 respectively mounted on the mold mounting surface of the rotating mold mounting part 41. Is detachably attached.

  The rotating mold mounting portion 41, the first rotating mold 20 and the second rotating mold 21 are one mold (rotating mold) having two mold dividing surfaces facing the fixed platen 3 and the movable platen 5. Mold part), and may be detachably attached to the rotating mold support mechanism 4 or the non-rotating frame part of the rotating mold attaching part 41 described above. Further, the rotating mold part 40 may be configured to be rotatably supported around a horizontal rotation axis orthogonal to the mold opening / closing direction.

  The first rotating mold 20 and the second rotating mold 21 have different mold cavity shapes. In a primary molding process described later, the first rotary mold 20 is combined with the common mold 19 by clamping to form a first mold cavity 30 for molding the primary molded body 9a integrally formed with the first film 60a. Let On the other hand, in the secondary molding step described later, the second rotating mold 21 is combined with the primary mold 9a integrally formed with the first film 60a and the common mold 19 holding the first film 60a by clamping. Thus, the second mold cavity 31 for forming the secondary molded body 9b integrally formed with the second film 61a is formed. Further, the second holding means 51 is disposed in the rotary mold part 40. For the sake of simplicity, the second holding means 51 shown outside the injection molding apparatus 1 in FIG. 1 has the same configuration as the first holding means 50, and the mold cavity surface 21c of the second rotating mold 21 and By sucking air in the mold cavity from a plurality of suction holes (not shown) arranged on the mold dividing surface via suction pipes 21b connected to the suction holes, second film supply means 61 described later is provided. Thus, the second film 61a supplied between the rotating mold part 40 and the dummy plate 6 is held on the second rotating mold 21 side. In the first embodiment, it is not necessary to arrange the holding means on the first rotating mold 20 side.

  The dummy plate 6 is combined with the second rotating mold 21 by mold clamping to form a sealed space 33, and protects the mold dividing surface of the opposing rotating mold part 40 during mold clamping. And the 2nd heating means 6a arrange | positioned at the surface which opposes the metal mold | die division | segmentation surface of the rotary mold part 40 of the dummy plate 6 has the 2nd film 61a supplied, scratch resistance, etc. In the case of a hard coat film or the like having a low elongation rate, the second holding mold 51 causes the second rotating mold in the sealed space 33 formed between the dummy plate 6 and the rotating mold portion 40 by clamping. The second film 61a held on the 21 side is softened by heating, and vacuum-formed (preliminarily shaped) into the shape of the mold cavity surface 21c by the suction force of the second holding means 51. The second heating means 6a has the same configuration as that of the first heating means 19a, and the second film 61a has a sufficient elongation rate, and the shape of the mold cavity surface is determined only by the pressure and temperature of the molten resin to be injected and filled. Needless to say, it is not necessary to dispose the rotating mold portion 40 when it can be molded.

  The first film supply means 60 for supplying the first film 60 a between the common mold 19 and the rotating mold part 40 supplies the second film 61 a between the rotating mold part 40 and the dummy plate 6. Supply means 61 is arranged. In the first embodiment, the first film supply unit 60 and the second film supply unit 61 are configured by a device having a movable arm unit such as an articulated robot and a grip unit provided at the tip of the arm unit. Each functional film is gripped and supplied to each designated position.

  Here, as another form of the 1st film supply means 60 and the 2nd film supply means 61, like patent document 1, a functional film (decoration sheet) required for every resin molded product is put through a peeling layer. A continuous film on a base film (base sheet) is used, and a functional film is supplied between the base film and the molding die from a roll portion around which the base film is wound. A form in which only the base film from which the functional film is peeled off by integral molding is wound by another roll portion is also possible.

  In the injection molding apparatus and the film insert molding method for a laminated molded product according to the present invention, the supply position of the first film 60a (between the common mold 19 and the rotary mold part 40) and the supply position of the second film 60b (rotary mold). Since the mold part 40 and the dummy plate 6) are constant, the positions of the first film supply means 60 and the second film supply means 61 can be fixed even if these films have different specifications. In other words, even in the former apparatus having a movable arm unit such as a multi-joint robot, it is not necessary that these two apparatuses intersect to supply films to different positions. Further, even in the latter type of apparatus using two roll portions, one device is placed on the fixed platen 3 and the other device is placed on the movable platen 5 with a distance between the rotary mold part 40. Therefore, it is not necessary to arrange these two apparatuses so that the film feeding directions are orthogonal to each other as in Patent Document 1. Further, since it is not necessary to arrange the first film supply means 60 and the second film supply means 61 in a part where the mold is rotated (for example, a rotating disk of Patent Document 3), a large amount of rotation is required when the mold rotates. There is no need for rotational driving force, and there is no risk of misalignment between the functional film and the mold cavity surface.

  Next, the premise of the first embodiment will be described. As shown in FIG. 4 (a) (detailed view of main part A in FIG. 3 (c)), the object to be molded is a glass substitute part in which a part (primary molded body 9a) for attachment or the like has translucency. It is a glass substitute resin window (double-sided film insert laminated molded product 9) of an automobile or the like laminated and formed on at least a part of the outer peripheral portion of (secondary molded body 9b). Since there is no distinction between the design surface and the non-design surface in the glass replacement part having translucency, in the description of the following examples, the design surface and the non-design surface for integrally forming the functional film are replaced with a glass replacement for an automobile or the like. They are called the outside and inside of the resin window. In the first primary molding process, the first film 60a is integrally formed on the vehicle interior side of the part (first molten resin / primary molded body 9a) for mounting and the like, and in the next secondary molding process, for the mounting and the like. The glass substitute portion (second molten resin / secondary molded body 9b) having translucency is injection-molded by an injection press molding method so that the portion (primary molded body 9a) becomes at least a part of the outer peripheral portion. At the same time, the second film 61a is integrally formed on the outer side of the vehicle, and finally the glass substitute resin window (first and second films 61a and 61a having different functions on the inner and outer surfaces (front and back surfaces) is integrally formed ( A double-sided film insert laminated molded product 9) shall be molded.

  FIG. 4B shows a schematic configuration diagram of the first film 60a that is integrally formed inside the vehicle in the primary molding step. The 1st film 60a consists of three layers of the contact bonding layer 91, the scratch-resistant process layer 93, and the peeling layer 94 from the primary molded object 9a side. The adhesive layer 91 is a layer for firmly fixing the first film 60a to the primary molded body 9a and the secondary molded body 9b, and is composed of known components that cause the adhesiveness to be generated by the heat of the molten resin to be injected and filled. It is preferable. As the name suggests, the scratch-resistant treatment layer 93 prevents damage to the resin portion having a relatively low hardness, and maintains the appearance (translucency) of the surface over a long period of time. Since the hardness is very high, pre-shaping by heating and softening is often required. For the storage and handling of the first film 60a, the release layer 94 is a layer for reliably peeling the first film 60a, which is usually attached to the base film, from the base film at the time of molding. Although the base film itself is not shown, when the first films 60a are supplied one by one as in the first embodiment, the base film is integrally formed with the first film 60a as a protective layer in a subsequent process. Often removed. In the case where the first film 60a is continuously supplied from a roll portion or the like, it is common to use a film in which the first film 60a is bonded to a continuous base film at an equal interval.

  FIG. 4C shows a schematic configuration diagram of the second film 61a that is integrally formed on the vehicle outer side in the secondary molding step. The 2nd film 61a consists of four layers of the contact bonding layer 91, the weather resistance processing layer 92, the scratch resistance processing layer 93, and the peeling layer 94 from the secondary molded object 9b side. The difference between the second film 61a and the first film 60a is that the second film 61a has a weather-resistant treatment layer 92 because the second film 61a is on the vehicle exterior side. The weather resistance treatment layer 92 mainly has a function of blocking the ultraviolet rays that deteriorate the resin portion so as not to reach the resin portion, and the outer scratch resistance treatment layer 93 avoids physical damage, and the resin portion caused by the ultraviolet rays. Deterioration of the product is prevented for a long time. The other layers are basically the same as those of the first film 60a and have the scratch-resistant treated layer 93. Therefore, the same is true in that preliminary shaping by heating and softening is often necessary. In addition, the structure of these 1st films 60a and the 2nd films 61a is an example, and is not restrict | limited to this structure.

  Subsequently, the molding process of the film insert molding method for a laminated molded product according to Example 1 of the present invention will be described with reference to FIGS. 2 and 3. 2 and 3 are schematic partial cross-sectional views illustrating the molding process in order with a focus on the mold part (side view) of FIG. 1 in order to facilitate understanding of the molding process, and are not directly related to the molding process. The components are not shown. In addition, the common mold 19, the first rotating mold 20, the second rotating mold 21, and the dummy plate 6 are hatched to show a cross section. However, in order to make the drawing easier to see, the first heating means 19a and the suction conduit 19b of the common mold 19 shown in FIG. 1 and the suction conduit 21b of the second rotary mold 21 are not shown.

  In the film insertion process in the mold open state shown in FIG. 1, the first film 60 a is supplied by the first film supply means 60, and is held on the common mold 19 side by the first holding means 50 (not shown). Similarly, the second film 61a is supplied by the second film supply means 61, and is held on the second rotating mold 21 side of the rotating mold part 40 by the second holding means 51 (not shown). The first film 60a is supplied with the peeling layer 94 (or base film not shown) facing the common mold 19 on the rotating mold part 40 side facing the adhesive layer 91, and the second film 61a faces the adhesive layer 91 facing. A release layer 94 (or a base film (not shown)) is supplied on the side of the rotating mold 40 to the dummy plate 6 side.

  At this time, as shown in FIG. 2A, the first film 60a held on the common mold 19 side is heated and softened by the first heating means 19a (not shown), and the suction force of the first holding means 50 is increased. The first film 60a is appropriately adjusted according to the softened state of the first film 60a, and the first film 60a is vacuum formed (preliminarily shaped) into the shape of the mold cavity surface 19c of the common mold 19 (primary preshaped step). Since both the first heating means 19a and the first holding means 50 are arranged on the common mold 19 side, the first film 60a can be heated and softened in a short time and pre-shaped. Moreover, it is preferable to operate the 2nd heating means 6a arrange | positioned at the dummy plate 6 in preparation for the secondary preliminary shaping process mentioned later. The wave mark in the figure indicates that the first heating means 19a and the second heating means 6a are operating.

  Next, as shown in FIG. 2 (b), after the rotary mold portion 40 and the dummy plate 6 are closed to the common mold 19 by a mold clamping means and the rotary mold support mechanism 4 (not shown), the mold clamping is performed. A force is applied to shift to the mold clamping state. The arrow indicates the movement of the mold and the injection filling state of the injection unit, and the white arrow indicates that the mold clamping force is applied. In this mold clamping state, the first mold cavity 30 is formed between the common mold 19 holding the pre-shaped first film 60a and the first rotating mold 20, and the first injection unit 18 makes the first The mold cavity 30 is injected and filled with the first molten resin (primary molding step). As explained above, the primary molding step is to injection-mold a part for attachment or the like (primary molded body 9a), and if a resin and molding conditions suitable for the specifications of the primary molded body 9a are selected. good. As the first molten resin, a thermoplastic resin is generally selected. Further, in the first film 60a that has already been pre-shaped by the primary pre-forming step, the contact portion of the adhesive layer 91 with the first molten resin is activated by the heat, and the surface of the primary molded body 9a (common mold) 19 side / inside of the vehicle). The portion of the first film 60a that does not come into contact with the first molten resin is integrally formed on the surface of the secondary molded body 9b (on the side of the common mold 19 / inside the vehicle) in the secondary molding step described later. The adhesive layer 91 is not activated, and there is no possibility that the first film 60a sticks to the mold cavity surface of the first rotating mold 20.

  Here, in FIG. 2 (b), the first injection unit 18 penetrates the first film 60a and the first mold resin 30 is injected and filled with the first molten resin. If an injection gate corresponding hole is formed in the first film 60a in advance so as to coincide with an injection gate portion (not shown) that fills the first mold cavity 30 with one molten resin from the resin flow path, such injection is performed. Filling becomes possible. The injection gate portion may be appropriately provided from one place to a plurality of places corresponding to the shape of the first mold cavity 30, and the position is preferably provided at a portion where there is no problem even if a gate mark is generated. In addition, as described above, it is not always necessary to inject and fill the first film 60a, and the common mold 19 and the first rotating mold 20 are formed by a notch or an opening provided in the first film 60a in advance. A part that directly contacts the mold or a part that can be injected and filled directly into the first mold cavity 30 is formed, and a resin flow path and an injection gate are arranged in such a part and directly injected into the first mold cavity 30. It may be filled. The same applies to the injection filling of the second molten resin in the secondary molding step described later.

  On the other hand, in the sealed space 33 formed between the second rotating mold 21 and the dummy plate 6 of the rotating mold part 40 during the primary molding process, the second film 61a is heated and softened by the second heating means 6a, and The suction force of the second holding means 51 is appropriately adjusted according to the softened state of the second film 61a, and the second film 61a is vacuum-formed into the shape of the mold cavity surface 21c of the second rotating mold 21 (preliminary shaping). (Secondary pre-shaping process). In the sealed space 33, since the second film 61a is heated while being substantially in contact with the second heating means 6a, the heating efficiency is high, and the second film 61a can be preshaped in a short time. Further, during the primary molding process in the first mold cavity 33, that is, from the start of injection filling of the first molten resin until the cooling and solidification of the primary molded body 9a is completed, the second cycle is not affected. The next pre-shaping step can be optionally continued to ensure sufficient time for heating / softening and vacuum forming. Therefore, there are more weathering process layers 92 than the 1st film 60a, and it is suitable for the preliminary shaping of the thicker 2nd film 61a. Further, since this secondary pre-shaping step is performed in the sealed space 33, if necessary, a configuration for injecting compressed air into the dummy plate 6 side is arranged, and the dummy plate 6 side is combined with vacuum forming at the time of pre-shaping. It is also possible to perform compressed air molding in which compressed air is injected from the inside.

  After completion of the primary molding process in the first mold cavity 30 and the secondary pre-shaping process in the sealed space 33, as shown in FIG. 2C, the primary molded body 9a in which the first film 60a is integrally molded and the first With the one film 60 a held by the common mold 19, the dummy plate 6 and the rotating mold part 40 are opened from the common mold 19 by a mold clamping unit and the rotating mold support mechanism 4 (not shown). After opening the mold, the rotating mold support mechanism 4 rotates the rotating mold portion 40 to move the second rotating mold 21 holding the pre-shaped second film 61 a to a position facing the common mold 19. (Primary rotation process). When the mold opening 40 is completed, that is, before the dummy plate 6 reaches the mold opening limit position by the mold clamping means (not shown), the rotating mold part 40 can be moved to a position where the rotation can be performed. The primary rotation process may be started during mold opening.

  After the primary rotation process, as shown in FIG. 3A, the rotating mold part 40 and the dummy plate 6 are again closed in the common mold 19 by a mold clamping means and the rotating mold support mechanism 4 (not shown). Thereafter, the mold clamping force is applied to shift to the mold clamping state. In this mold clamping state, the primary molded body 9a integrally formed with the first film 60a and the common mold 19 holding the first film 60a and the second rotation holding the pre-shaped second film 61a are held. A second mold cavity 31 is formed between the mold 21 and the second molten resin is injected and filled from the first injection unit 17 into the second mold cavity 31 (secondary molding process / injection filling).

  As described above, the secondary molding step includes a glass substitute portion (secondary molding) having translucency so that a portion for attachment or the like (primary molded body 9a) becomes at least a part of the outer peripheral portion. The body 9b) is injection-molded by an injection press molding method, and a resin and molding conditions suitable for the specifications of the secondary molded body 9b may be selected. As the second molten resin, a thermoplastic resin is generally selected. Further, in order to injection-mold the secondary molded body 9b by the injection press molding method, the primary molded body 9a integrally formed with the first film 60a, the common mold 19 holding the first film 60a, and pre-shaped The second rotating mold 21 holding the second film 61a held is held at a position that is slightly opened by a minute distance α (alpha) in the mold opening and closing direction so as to counter the injection filling pressure. Thus, the second molten resin is injected and filled into the second mold cavity 31 in a state where the mold cavity volume is expanded by a minute mold opening amount α with respect to the complete mold clamping state.

  As shown in FIG. 3B, after the injection filling is completed or at an appropriate timing before the completion, as shown in FIG. 3B, the rotating mold portion 40 and the dummy plate 6 are shared by the mold clamping means and the rotating mold support mechanism 4 (not shown). After the mold 19 is completely closed, a mold clamping force is applied again to shift to the mold clamping state (secondary molding process / mold cavity volume reduction operation). It is preferable that the resin injection pressure is applied to the second molten resin in the second mold cavity 31 by the first injection unit 17 even during the mold cavity volume reduction operation in the secondary molding step. In addition, in the second film 61a that has already been pre-shaped by the secondary pre-forming step, the contact portion of the adhesive layer 91 with the second molten resin is activated by the heat, and the surface of the secondary molded body 9b (first The two-turn mold 21 side / the vehicle outer side) is integrally molded firmly. At the same time, in the first film 60a held on the common mold 19 side, the contact portion of the adhesive layer 91 with the second molten resin is activated by the heat, and the surface of the secondary molded body 9b (the common mold 19 side). / Inner car) In this way, the primary molded body 9a in which the first film 60a (the vehicle inner side) and the second film 61a (the vehicle outer side) are integrally formed on both the front and back surfaces (both inside and outside the vehicle) by the primary molding step or the secondary molding step. A double-sided film insert laminated molded product 9 (glass substitute resin window) composed of (a part for attachment and the like) and a secondary molded body 9b (a glass substitute portion having translucency) can be molded.

  In the first embodiment, in the secondary molding step, the injection press molding method is performed to injection-mold the secondary molded body 9b. However, depending on the laminated molded product to be molded, it is not an injection press molding method. Injection molding may be performed, or the injection press molding method may be performed only in the primary molding process, or in both the primary molding process and the secondary molding process. By filling and filling the mold cavity volume in such a state, the filling resistance of the molten resin is reduced, and then the mold cavity volume is reduced to substantially uniform the molten resin in the mold cavity. The injection press molding method that can give the mold clamping force to the resin is the same as the injection compression molding method, reduces the internal stress after cooling and solidification of the resin molded product, and after molding the resin molded product due to the internal stress. It is suitable for injection molding of resin-molded products such as glass-replacement resin windows and optical recording media such as optical discs where it is necessary to suppress such distortion as much as possible. In the first embodiment, an embodiment in which the injection press molding method is performed has been described. Needless to say, an injection compression molding method in which the mold cavity is expanded by the injection filling pressure in a state where the mold clamping force is weakened can also be performed.

  On the other hand, in the DRI type injection molding apparatus as in Patent Document 3, when the injection press molding method is performed only in one of the primary molding process and the secondary molding process by micro mold opening, the other that does not perform the injection press molding method. Since the volume of the mold cavity is also expanded, the primary molding process and the secondary molding process must be performed separately. In addition, even when the injection press molding method is performed in both the primary molding process and the secondary molding process, the injection conditions such as the minute mold opening amount in each of the primary molding process and the secondary molding process cannot be the same. The molding process and the secondary molding process must be performed separately. Further, when the injection compression molding method is performed, a rotating plate which is a heavy object is arranged on the movable platen side, and one of a plurality of molds mounted on the same plane of the rotating plate is injected and filled. Since the mold cavity volume is expanded, it is difficult to evenly apply the mold opening force due to the injection filling force to the fixed platen and the movable platen, so that there is a problem that it is difficult to control the minute mold opening amount at that time. Thus, in the DRI type injection molding apparatus, when performing the injection press molding method or the injection compression molding method by at least one of the primary molding step and the secondary molding step by micro mold opening, the primary molding step and the secondary molding step. It is not possible to make use of the advantage that it can be performed simultaneously, and the glass substitute resin window (laminated molded product) such as the injection press molding method and the injection compression molding method as in Example 1 is often employed. When functional films are integrally formed on both front and back surfaces, there is a problem in adopting a DRI type injection molding apparatus.

  Here, when the injection press molding method is performed as in the first embodiment, the mold cavity is opened when the micro mold is opened, so that the molten resin filled by injection does not leak out of the mold. It is necessary to use a mold having a sealing mechanism. The shear edge structure is sometimes called a hollow structure or an inlay structure, etc., and is generally known as a structure of a fitting portion that forms a mold dividing surface, and the mold opening and closing direction. It is a structure that prevents the resin and coating agent from leaking out of the mold cavity by forming between the mold split surfaces a fitting portion that can be inserted and removed while sliding on each other. . However, since the shear edge structure is a known structure and various structures are disclosed for the sealing mechanism and the like for preventing leakage of the molten resin to the outside of the mold, the common mold 19 is used in the first embodiment. Further, it is assumed that a structure or mechanism (not shown) that prevents the molten resin from leaking out of the mold is employed in the rotating mold part 40, and illustration and description of these structure and mechanism are omitted.

  Returning to the description of the molding process. After the cooling and solidifying time of the secondary molded body 9b has elapsed, as shown in FIG. 3C, the double-sided film insert laminated molded product 9 is held in either the common mold 19 or the second rotating mold 21. The dummy plate 6 and the rotating mold part 40 are opened from the common mold 19 by the mold clamping means and the rotating mold support mechanism 4 (not shown), and the double-sided film insert laminated molded product 9 is injected by the product taking-out means (not shown). It is carried out of the molding apparatus 1 (product removal process). In the mold opening in this product removal process, the dummy plate 6 and the rotating mold part 40 may be opened to a position where the rotating mold part 40 can be rotated. The mold part 40 may be opened until the mold plate is aligned with the dummy plate 6 located at the mold opening limit position so that the distance (daylight) between the common mold 19 and the rotating mold part 40 is maximized. In that case, a mechanism for integrating the dummy plate 6 and the rotating mold part 40 may be provided, and these may be integrally opened. After the product removing step, the rotating mold part 40 is rotated at a position where the rotating mold part 40 can rotate, and the first rotating mold 20 is moved to a position facing the common mold 19. (Secondary rotation process).

  Thus, the molding process of FIG. 1 to FIG. 3C is one molding cycle of the molding process of the film insert molding method of the laminated molded product according to Example 1 of the present invention, and by repeating this molding cycle, A double-sided film insert laminated molded product 9 composed of a primary molded body 9a and a secondary molded body 9b, in which a first film 60a and a second film 61a having different functions on both front and back surfaces are integrally molded, is opened every two times. Can be continuously formed.

  The double-sided film insert laminated molded product 9 conveyed to the outside of the apparatus is handled as a final product or a part by trimming unnecessary portions of the first film 60a and the second film 61a in a subsequent process. Further, as described above, when the base film is left on the surface of the first film 60a and the second film 61a as a protective film of the molded product, it is removed after this trimming, or as a final product or a part. While being stored, it may be left as it is on the surface of the first film 60a and the second film 61a. In addition, unnecessary portions of the first film 60a and the second film 61a are arranged on the mold dividing surface of the common mold 19 or the second rotating mold 21 at the time of clamping before the secondary molding process, not in the subsequent process. Trimming with the trimming means applied, or trimming unnecessary parts by utilizing the product extrusion operation before the product removal process, and many methods for trimming such functional film in the mold clamping means are also disclosed. Has been. In addition, when the functional film is a photo-curing type that is cured by irradiation with UV (Ultraviolet) or Electron Beam (EB) light, the functional film may be cured by irradiation with these light rays in a subsequent step. .

  According to the injection molding apparatus and the film insert molding method according to the present invention described in the first embodiment, when the functional films are integrally formed on both the front and back surfaces of the laminated molded product, the first film and the second film are made of one gold. Since it is not supplied simultaneously to the mold cavity, but separately supplied between the common mold and the dummy plate respectively facing the rotating mold part, there are few restrictions on the method of supplying the functional film. In addition, by rotating the rotating mold portion combined with the common mold, at least two types of mold cavities are formed, so that the size of the usable mold can be reduced with respect to the size of the injection molding apparatus. There are few restrictions on the mold size. Furthermore, even when a hard coat film having a low elongation rate of the film itself is used and pre-shaping of these hard coat films is necessary, pre-shaping during the molding cycle is performed by heating means and holding means. Is possible.

  In Example 1, both the first film 60a and the second film 61a are functional films (hard coat films) having a scratch-resistant layer 93 that require preliminary shaping, but are not limited thereto. Only one of the first film 60a and the second film 61a may be a hard coat film. In this case, it is only necessary to provide heating means corresponding to only the functional film side that needs pre-shaping, and both the first film 60a and the second film 61a are functional films that do not require pre-shaping. The heating means is unnecessary.

  Here, the film insert molding method for a laminated molded product according to the present invention is another method for molding a laminated molded product by changing some of the constituent requirements and the molding process of the injection molding device according to the present invention. The present invention can also be implemented by an injection molding apparatus having the form. This will be described with reference to FIG. 5 as an application example (hereinafter referred to as Example 2) of the film insert molding method for laminated molded products according to the present invention. FIG. 5 is a schematic partial cross-sectional view illustrating a molding process of a film insert molding method for a laminated molded product according to Example 2. FIG. 5A shows the primary molding process, FIG. 5B shows the rotation process, and FIG. 5C shows the primary molding process and the secondary molding process. In addition, like FIG. 2 of Example 1, FIG. 5 is a general | schematic fragmentary sectional view which illustrated the molding process in order centering on a metal mold | die part (side view), in order to make an understanding of a molding process easy. Components that are not directly related to the molding process are not shown. Further, the common mold 19 ′, the dummy plate 6 ′, the first rotating mold 20 ′, and the second rotating mold 21 ′ are hatched to show a cross section.

  The difference in the basic configuration between the injection molding apparatus having another form according to the second embodiment and the injection molding apparatus 1 according to the first embodiment is that the dummy plate 6 ′ attached to the movable platen 5 is used for molding. The second injection unit 18 is placed on the same base as the movable plate 5 and can be moved together with the movable plate 5 in the mold opening / closing direction by a mold clamping means or the like. It is the point arrange | positioned so that it can connect to the back surface (attachment surface to the movable platen 5) of dummy plate 6 'through the movable platen 5 above (what is called opposing arrangement | positioning of an injection unit). On the other hand, the common mold 19 ′ and the fixed plate 3 to which the common mold 19 ′ is attached, the fixed plate 3 and the movable plate 5 are arranged between the fixed plate 3 and the movable plate 5. The rotary mold support mechanism 4 that is rotatably supported and moved in the mold opening / closing direction has the same basic configuration as that of the first embodiment, and is a known configuration as an injection molding apparatus for molding a laminated molded product.

  The next difference in basic configuration is that the first holding means 50 is arranged not on the common mold 19 ′ but on the dummy plate 6 ′ configured as a molding die, and on the second holding means. A point 51 is configured to selectively hold the functional film on the first rotating mold 20 ′ side and the second rotating mold 21 ′ side. Further, the difference between the film insert molding method in Example 2 and Example 1 is that the primary molding process or the secondary molding process in Example 1 excluding the secondary pre-shaping process are all common mold 19 and rotating mold. One molding cycle is performed between the molds 40, and is performed between the common mold 19 ', the rotating mold part 40, and the dummy plate 6'. In other words, it is performed in one mold opening and one rotation process of the rotating mold part 40. Since the individual forming steps of the primary forming step to the secondary forming step are basically the same as the individual forming steps described in the first embodiment, the description thereof is omitted, and the same constituent elements as those in the first embodiment are the same in FIG. Only the differences from the first embodiment will be described.

  First, although not shown, in the film insertion process in the mold open state shown in FIG. 1, the second film 61 a is provided between the common mold 19 ′ and the rotating mold part 40 by the second film supply means 61 (not shown). And is held on the first rotating mold 20 ′ side by a second holding means 51 (not shown). Then, as shown in FIG. 5 (a), after the rotary mold portion 40 and the dummy plate 6 ′ are closed to the common mold 19 ′ by the mold clamping means and the rotary mold support mechanism 4 (not shown), the mold is closed. A clamping force is applied to shift to a mold clamping state. Here, due to the difference in the molding process from the first embodiment, the first rotating mold 20 ′ and the second rotating mold 21 ′ of the rotating mold portion 40 have the same mold cavity shape, and this mold clamping is performed. In the state, the first mold cavity 30 ′ is formed between the common mold 19 ′ and the first rotating mold 20 ′ (or the second rotating mold 21 ′) holding the second film 61a, and the first mold cavity 30 ′ is formed. The second molten resin is injected and filled from the first injection unit 17 into the first mold cavity 30 ′ (primary molding step). Unlike Example 1, the primary molding process involves injection molding a glass substitute portion (second molten resin / secondary molded body 9b) having translucency. The primary molding step may be performed by an injection press molding method as in the first embodiment. In the second film 61a, the contact portion of the adhesive layer 91 with the second molten resin is activated by the heat, and is firmly integrated with the surface of the secondary molded body 9b (the first rotating mold 20 ′ side / the vehicle outer side). Molded.

  Here, in the case where the second film 61a is preshaped before injection filling in the primary molding step, the second film 61a held on the first rotating mold 20 ′ side is clamped, although not shown. Thus, the first heating means 19a (not shown) is substantially brought into contact with the common mold 19 'and rapidly heated and softened, and the second holding means 51 (not shown) is used to attach the second film 61a to the first rotating mold. What is necessary is just to carry out vacuum forming (preliminary shaping) to the shape of the mold cavity surface 20'c of the mold 20 '(secondary preliminary shaping step).

  On the other hand, a first film 60a is supplied between the second rotating mold 21 '(or the first rotating mold 20') and the dummy plate 6 'by a first film supply means 60 (not shown), and a first film (not shown) is provided. It is held on the dummy plate 6 ′ side by the holding means 50. Then, a secondary molding step and the like as described later are performed, but the description here is omitted for the sake of simplicity.

  After completion of the primary molding step in the first mold cavity 30 ′ and the secondary molding step in the second mold cavity 31 ′, which will be described later, as shown in FIG. 5B, the second film 61a was integrally molded. In a state where the secondary molded body 9b is held by the first rotating mold 20 ′, the dummy plate 6 ′ and the rotating mold portion 40 are connected to the common mold 19 ′ by a mold clamping means and the rotating mold support mechanism 4 (not shown). Open the mold. After opening the mold, the rotating mold support mechanism 4 rotates the rotating mold portion 40, and the first rotating mold 20 ′ holding the secondary molded body 9b integrally formed with the second film 61a is used as the dummy plate 6 ′. Is moved to a position opposite to (rotation process).

  In the mold open state before and after this rotation process, the double-sided film insert laminated molded product 9 formed in the previous molding cycle is removed from the injection molding apparatus by a product take-out means (not shown) between the rotary mold portion 40 and the dummy plate 6 ′. A product take-out process to be carried out and a film insert process to supply a new functional film for the next molding cycle are performed. Through these steps, the second rotating mold 21 ′ holding the second film 61a is moved to a position facing the common mold 19 ′ holding nothing, and the first film 60a is placed on the dummy plate 6 ′. Hold. If necessary, the first film 60a held on the dummy plate 6 ′ is heated and softened by a heating means 6a (not shown) disposed on the dummy plate 6 ′, and the first film is provided by a first holding means 50 (not shown). 60a may be vacuum-formed (preliminary shaping) into the shape of the mold cavity surface 6'c of the dummy plate 6 '(primary preliminary shaping step).

  After the primary rotation process, as shown in FIG. 5 (c), the rotating mold portion 40 and the dummy plate 6 ′ are again closed to the common mold 19 ′ by the mold clamping means and the rotating mold support mechanism 4 (not shown). Then, the mold clamping force is applied to shift to the mold clamping state. In this mold-clamped state, the first rotating mold 20 ′ holding the secondary molded body 9b integrally formed with the second film 61a and the dummy plate 6 ′ holding the first film 60a are connected between the first rotating mold 20 ′. A second mold cavity 31 ′ is formed, and the second molten resin is injected and filled from the second injection unit 18 into the second mold cavity 31 ′ (secondary molding step). Unlike Example 1, this secondary forming step is a part for mounting or the like (first melting) so as to be at least a part of the outer peripheral part of the translucent glass substitute part (secondary molded body 9b). The resin / primary molded body 9a) is injection-molded, and is a process in which the description is omitted in the description of the primary molding process in the first mold cavity 30 ′. It is performed overlapping with the molding process. In the first film 60a, both the contact portion with the first molten resin of the adhesive layer 91 and the contact portion with the secondary molded body 9b whose high temperature is still maintained are activated by the heat, and the primary film 60a It is firmly and integrally formed on the surface of the molded body 9a (dummy plate 6 ′ side / inner side) and the surface of the secondary molded body 9b (dummy plate 6 ′ side / inner side).

  Although not illustrated after the cooling and solidifying time of the primary molded body 9a has elapsed, the double-sided film insert laminated molded product 9 is illustrated in a state in which it is held in either the first rotating mold 20 ′ or the dummy plate 6 ′. The dummy plate 6 ′ and the rotating mold part 40 are opened from the common mold 19 ′ by the mold clamping means and the rotating mold support mechanism 4, and the double-sided film insert laminated molded product 9 is injection molded by the product unillustrated means. The product is taken out of the apparatus (product removal process). After the product removal step, the rotary mold part 40 is rotated at a position where the rotation is possible, and the second film 61a is integrally formed at a position where the first rotary mold 20 ′ faces the common mold 19 ′. If the second rotating mold 21 ′ holding the next molded body 9b is moved to a position opposite to the dummy plate 6 ′, the first mold of the rotating mold part 40 in the mold open state shown in FIG. The rotating mold 20 ′ and the second rotating mold 21 ′ are switched (rotating process).

  Thus, the molding process of FIG. 5 (b) to FIG. 5 (c) becomes one molding cycle of the film insert molding method of the laminated molded product according to Example 2, and by repeating this molding cycle, A double-sided film insert laminate molded product 9 composed of a primary molded body 9a and a secondary molded body 9b, in which a first film 60a and a second film 61a having different functions on the front and back surfaces are integrally formed, is opened once each time the mold is opened. Can be continuously formed.

  The present invention can be implemented in various forms without being limited to the above-described embodiment, including various forms described in the first embodiment. For example, in Example 1, the functional film is integrally formed on both the front and back surfaces of the laminated molded product, but it goes without saying that the functional film can be integrally formed on only one of the surfaces. In that case, the holding means, the heating means, and the film supply means according to the present invention may be provided only on the necessary side of the functional film. Further, a glass substitute resin window for an automobile or the like in which a portion for attachment or the like (primary molded body 9a) is laminated and formed on at least a part of the outer peripheral portion of the glass substitute portion (secondary molded body 9b) having translucency. (Double-sided film insert laminated molded product 9) Even if the primary molded body is a laminated molded product that is laminated over substantially the entire surface of the secondary molded body, the functional film is integrally formed on both front and back surfaces. be able to. Furthermore, it is possible to integrally form a functional film on both the front and back surfaces of a resin molded product (single-layer molded product) composed of a single resin layer, not a laminated molded product. In that case, the primary mold process as shown in FIG. 2B is not performed, and the second mold cavity 31 formed by combining the common mold 19 and the second rotary mold 21 has the shape of a single-layer molded product. In the secondary molding step as shown in FIG. 3 (a) or FIG. 3 (b), the first injection unit 17 and the second injection unit 18 are formed in the second mold cavity 31 formed. What is necessary is just to carry out injection filling from either one. That is, if only the mold is replaced with an appropriate one, there is no need to remove one of the injection units, and the functional film can be integrally formed on both the front and back surfaces of the single-layer molded product.

  As described above, the injection molding apparatus and the film insert molding method for a laminated molded product according to the present invention have the first film and the second film as one when the functional films are integrally formed on both the front and back surfaces of the laminated molded product. Since it is not supplied simultaneously to the mold cavity, but separately supplied between the common mold and the dummy plate respectively facing the rotating mold part, there are few restrictions on the method of supplying the functional film. In addition, by rotating the rotating mold portion combined with the common mold, at least two types of mold cavities are formed, so that the size of the usable mold can be reduced with respect to the size of the injection molding apparatus. There are few restrictions on the mold size. Furthermore, even when a hard coat film having a low elongation rate of the film itself is used and pre-shaping of these hard coat films is necessary, pre-shaping during the molding cycle is performed by heating means and holding means. Is possible. In addition, the injection molding apparatus according to the present invention and the film insert molding method for laminated molded products require a small number of molds, and the basic configuration of the injection molding apparatus according to the present invention is to add an injection unit and support a rotating mold. By adding the mechanism, a general-purpose injection molding apparatus can be easily modified and obtained. Also in these respects, the industrial applicability of the present invention is very high for a resin molded product manufacturer that meets the demand for various kinds of small-volume production.

DESCRIPTION OF SYMBOLS 1 Injection molding apparatus 3 Fixed board 4 Rotating mold support mechanism 5 Movable board 6 Dummy plate 6a Second heating means 9 Double-sided film insert laminated molded product 9a Primary molded body 9b Secondary molded body 17 First injection unit 18 Second injection unit 19 common mold 19a first heating means 20 first rotating mold 21 second rotating mold 30 first mold cavity 31 second mold cavity 33 sealed space 40 rotating mold part 41 rotating mold mounting part 50 first Holding means 51 Second holding means 60 First film supply means 60a First film 61 Second film supply means 61a Second film

Claims (7)

A common mold,
A fixed platen to which the common mold is attached;
A dummy plate,
A movable plate to which the dummy plate is attached;
Wherein disposed between the stationary platen and said movable platen, said common mold combined with to have at least two mold parting surface to form a mold cavity, one of the at least two of the mold division plane , together to form the mold cavity in combination with the common die, and at least two other of the mold division plane, rotating mold section Ru to form a closed space in combination with the dummy plate,
Rotating mold support means for supporting the rotating mold part rotatably around a rotation axis orthogonal to the mold opening / closing direction and moving the rotating mold part in the mold opening / closing direction;
At least two injection units arranged so that molten resin can be injected and filled in the mold cavity;
First film supply means for supplying a first film between the common mold and the rotating mold part;
A second film supply means for supplying a second film between the rotating mold part and the dummy plate;
An injection molding apparatus comprising: First holding means for holding the first film on the side of the common mold facing one mold dividing surface of the rotating mold part by suction;
Second holding means for holding the second film on the other mold dividing surface side of the rotating mold part facing the dummy plate by suction;
The injection molding apparatus according to claim 1, further comprising: First heating means for heating the first film;
A second heating means for heating the second film;
With
A mold cavity of a mold that holds the first film and the second film heated by the first heating unit and the second heating unit by the first holding unit and the second holding unit, respectively. The injection molding apparatus according to claim 2, wherein vacuum molding is performed to form a surface. By clamping the mold, the first molten resin is injected and filled from one of the injection units into a first mold cavity formed between one mold dividing surface of the common mold and the rotating mold part, and the first mold A primary molding step of molding a primary molded body integrally molded with one molten resin and the first film held on the common mold side;
In a state where the primary molded body and the first film are held on the common mold side, the rotating mold part and the dummy plate are opened from the common mold, and then the rotating mold part is rotated. A primary rotation step of moving the second film held on the other mold dividing surface side of the rotating mold part to a position facing the common mold;
A second mold formed between the second film held on the other mold dividing surface side of the rotating mold part and the primary molded body held on the common mold by clamping. A secondary molding step of molding a secondary molded body in which the second film and the second molten resin are integrally formed by injecting and filling the second molten resin into the cavity from the other of the injection units;
The a, the multilayer molded article using the injection molding apparatus according to claim 1 or claim 2, characterized in that for molding the double-sided film insert laminated molded article made from the primary molded body and the secondary molded body Film insert molding method. By clamping the mold, the first molten resin is injected and filled from one of the injection units into a first mold cavity formed between one mold dividing surface of the common mold and the rotating mold part, and the first mold A primary molding step of molding a primary molded body integrally molded with one molten resin and the first film held on the common mold side;
In a state where the primary molded body and the first film are held on the common mold side, the rotating mold part and the dummy plate are opened from the common mold, and then the rotating mold part is rotated. A primary rotation step of moving the second film held on the other mold dividing surface side of the rotating mold part to a position facing the common mold;
A second mold formed between the second film held on the other mold dividing surface side of the rotating mold part and the primary molded body held on the common mold by clamping. A secondary molding step of molding a secondary molded body in which the second film and the second molten resin are integrally formed by injecting and filling the second molten resin into the cavity from the other of the injection units;
Between the primary molding step, in the enclosed space to be formed on the other mold split surface of the rotating mold member and between the dummy plate, by the second heating means and the second holding means, said second film A secondary pre-shaping step of vacuum forming into a mold cavity shape on the other mold dividing surface side of the rotating mold part ;
It is that the product layer molded article of the film insert molding method using an injection molding apparatus according to claim 3, characterized in that it comprises a. Wherein the primary molding step, by the first heating means and the first holding means, characterized in that it comprises a primary preshaping step of vacuum forming the first film in the mold cavity shape of said common mold film insert molding method of a multilayer molded article according to 請 Motomeko 5.   In the primary molding step or the secondary molding step, the mold cavity volume is reduced by injection-filling the mold cavity whose volume has been expanded by opening a minute mold and then reducing the volume of the mold cavity by clamping. The film insert molding method for a laminated molded product according to any one of claims 4 to 6, wherein the operation is performed.

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