JP6528198B2 - Injection molding method - Google Patents

Description

  The present invention relates to an injection molding method called in-mold molding / insert molding in injection molding.

  An in-mold molding method is known as a surface decoration technique for plastic molded articles. This is a molding method that injects a resin material by injection molding and at the same time decorates the surface of a molded article in a mold, and facilitates decoration on the surface of a molded article consisting of characters, figures, patterns, etc. without a painting process. It can be carried out. In recent years, the applicable product cases have been increasing.

  Among these in-mold molding methods, the so-called double in-mold molding method is a technology that can form a decorative layer on both sides of the resin, and a pattern or surface is previously formed on a substrate such as PET by various printing methods such as gravure, screen or inkjet. Printing such as a functional film is performed, and a decorative transfer film provided with an adhesive layer on the opposite side is set with the adhesive layers facing each other in the mold, and resin is injected between them to simultaneously mold and form the molded product. It is a method of transferring decorative and functional surfaces.

  The surface shape is almost flat in the case of a flat shape or a flat shape close to a flat surface, and a functional film such as an AR (Anti-Reflection anti-reflection) film or a functional film plus decoration layer is formed on one side, There are many examples where a decoration layer etc. are formed.

25-27 show the insert molding described in Patent Document 1. FIG.
The molded article 31 shown in FIGS. 25 (a), (b) and (c) is a transparent acrylic plate attached to the casing main body of a mobile phone, and a frame 31a is formed by a printing layer on the surface 31A side. The window portion 31b for viewing the liquid crystal screen on the side of the casing main body remains in the center portion as a portion where the print layer is not formed or a portion where the transparent print layer is formed. A button hole 31c is formed in a part of the molded product 31, and when the molded product 31 is attached to the casing main body, the pressing button on the side of the casing main body is peeked from the button hole 31c.

  On the back surface 31B of the molded product 31, as shown in FIGS. 25 (b) and 25 (c), a raised platform 31d is formed at a position facing the window 31b. While the film layer 37A is integrated with the front surface 31A, the sheet piece 34A is integrated with the back surface 31B only on the surface of the raised platform portion 31d.

Here, assuming that the width of the window portion 31b is A, the height is B, the width of the raised platform portion 31d is C, and the height D, then A <C, B <D.
As in this molded product 31, even if the window portion 31b and the button hole 31c are provided, the panel surface conventionally has the same texture, so the boundary between the display portion of the window portion 31b and the operation portion of the button hole 31c is There are a lot of design expressions which distinguish with the decoration layer etc. by coloring, and when expressing the different material feeling by design request etc., it is necessary to consider more complicated molding methods such as 2-color molding.

An injection molding apparatus 32 used to manufacture the molded article 31 is configured as shown in FIG.
The injection molding apparatus 32 is composed of a movable mold 51 consisting of a movable mold main body 41 and a punch 42 and a fixed mold 52. A cavity 41 a is formed on the top surface of the movable mold main body 41. A cavity 52 a is formed on the bottom surface of the fixed mold 52. By combining the movable mold main body 41 and the fixed mold 52, a space for injection molding the molded product 31 is formed.

  In the fixed mold 52, a resin injection gate 52b continuous to the cavity 52a is formed. A continuous film 53 passes between the movable mold 51 and the fixed mold 52. When the movable mold 51 and the fixed mold 52 are closed, the position of the injection hole 53A of the continuous film 53 coincides with the position of the resin injection gate 52b.

A through hole 41 b is formed in the movable mold main body 41. The push-up block 42B is inserted into and slide in the through hole 41b.
In FIG. 26, the upper surface of the die 42 is separated from the lower surface of the movable die body 41 by the distance L, and the die 42 is not completely pushed into the movable die body 41. When the punching die 42 is pushed up, the top surface 42a of the lifting block 42B is pushed up to the height T, and the top surface 42a forms a part of the cavity 41a at a position one step lower than the upper surface of the movable die 51.

Furthermore, a slit 41 c is formed in the movable mold main body 41 so as to cross the through hole 41 b. The continuous sheet 54 passes through the slit 41c.
When the lifting block 42B is lifted, the edge of the lifting block 42B cuts out the continuous sheet 54, and the lifting block 42B pushes the cut sheet piece up to the height T. The top surface 42a of the lifting block 42B pushed up to the height T is lowered by one step from the cavity 41a of the movable mold main body 41, and a step G is formed between the two.

  As shown in FIG. 27A, the continuous film 53 is formed by sequentially laminating a release layer 53b, a UV hard coat layer 53c, an anchor layer 53d, a print layer 53e, and an adhesive layer 53f on a PET base film 53a. There is. The printed layer 53 e is formed with a portion subjected to printing and a portion not subjected to printing, or a portion subjected to transparent printing, and the latter portion becomes the window portion 31 b of the molded article 31. The print layer 53e has a plurality of independent print patterns formed at predetermined intervals.

The continuous sheet 54 is formed by laminating the UV hard coat layer 54a, the base layer 54b, and the adhesive layer 54c from the bottom as shown in FIG. 27 (b).
The UV hard coat layer 53c of the continuous film 53 and the UV hard coat layer 54a of the continuous sheet 54 are used as a front surface AR base layer and a rear surface AR base layer, respectively, and AR treatment is performed thereon to form an AR layer (antireflection film) Form

  The continuous film 53 and the continuous sheet 54 thus configured are inserted into and set in a molding apparatus, and a resin is injected from the resin injection gate 52b to the injection molding apparatus 32 to produce a molded article 31.

Unexamined-Japanese-Patent No. 2002-225069

  In this conventional example, the display portion in the central portion and its peripheral portion are designed as the same surface layer by film in-mold or insert film and peripheral transparent resin, and the film surface shape (surface roughness) in the peripheral portion of the display portion It is difficult to realize a design that has a different material feeling).

  In addition, since the decorative film on the side of the insert film of the cut continuous sheet 54, ie, the central display unit side, is fixed by a step, the film is easily displaced due to the injection flow of the resin, or in the mold When the film is cut out of the film, the forming yield is deteriorated due to contamination of film waste and the like.

Moreover, AR (anti-reflection film) or a hard coat function and decoration (color) are simultaneously added to the surface, and only design expression where decoration (color) or the like is added to the back side can be supported.
The present invention solves the above-mentioned conventional problems, and realizes a design in which different materials are given to the central portion and its peripheral portion, and reduces the occurrence of pattern positional deviation defects and the like to obtain the yield of in-mold molded articles. it can be improved, and an object thereof is to provide an injection molding how.

In order to achieve the above object, according to an injection molding method of the present invention, a first mold and a second mold are clamped with an in-mold film and an insert film interposed therebetween, and the first mold and the second mold An injection molding method in which a molten resin is injected into a molding space formed by clamping a mold to transfer and mold an in-mold film and an insert film on the surface of a molded article, which is disposed on the first mold side An insert film temporary bonding step of bonding and fixing the insert film to the surface of the mold film on the second mold side, and clamping the in-mold film to which the insert film is bonded between the first mold and the second mold and, organic and molding step of transferring bonding the in-mold film and the insert film by injecting molten resin into the molding chamber space between the first mold second mold surface of the molded article, the The in-mold film in which the shape of the molded product is a panel shape, has a display portion of the window at the center, and is clamped between the first mold and the second mold is a base film with a release layer interposed therebetween. And a window frame-shaped first adhesive layer formed on the tactile layer so as to surround the window portion, and a functional surface is formed on one side of the insert film, and the other side is formed on the other side. (2) The base film, the peeling layer and the touch layer are peeled off by mold opening of the first mold and the second mold after forming the adhesive layer and injecting the molten resin, and the window frame shape of the molded article The functional surface may be exposed from the window portion inside the touch sensitive layer and the first adhesive layer .

  According to the present invention, after the insert film temporary bonding step of bonding and fixing the insert film to the in-mold film is performed, the in-mold film to which the insert film is bonded is divided into the first mold and the second mold. Since the molding process is performed in which the mold is clamped and the molten resin is injected and the in-mold film and the insert film are transferred and adhered to the surface of the molded product. It is possible to realize molded articles. In addition, even for in-vehicle molded products that require strict specifications in terms of strength, it is possible to provide seamless molded products that are advantageous in strength compared to two-color molded products and the like.

  More specifically, the functions of the insert film and the in-mold film can be added to one surface of the molded product, and the AR (anti-reflection film) or hard coat function on the molded product and the film surface shape (surface) Realization of a molded article simultaneously applied with different material feeling and decoration (color) different in roughness) can be realized only by molding without the need for a post process such as painting.

(A) Top view and (b) A-A sectional view of a molded article produced by the injection molding method according to Embodiment 1 of the present invention The block diagram of the injection molding apparatus in Embodiment 1 of this invention BB arrow view of FIG. 2 (A) A plan view of the transfer film as viewed from the side of the temporary adhesive layer in Embodiment 1 of the present invention, and (b) an enlarged cross section of the transfer film in the C-C cross section and an enlarged cross section of the insert film First step diagram in the first embodiment of the present invention Second step diagram in the first embodiment of the present invention Third step diagram according to Embodiment 1 of the present invention Fourth step diagram in the first embodiment of the present invention Explanatory drawing at the time of the mold clamp start of the 5th process in Embodiment 1 of this invention Explanatory drawing at the time of completion | finish of mold clamping of the 5th process in Embodiment 1 of this invention Explanatory drawing at the time of injection of the 5th process in Embodiment 1 of the present invention An enlarged cross-sectional view of the transfer film of the first step in the first embodiment of the present invention An enlarged cross-sectional view of the transfer film of the third step in the first embodiment of the present invention An enlarged cross-sectional view of the transfer film at the start of mold clamping in the fifth step according to Embodiment 1 of the present invention An enlarged cross-sectional view of the transfer film at the time of injection in the fifth step according to Embodiment 1 of the present invention An enlarged cross-sectional view of the transfer film at the time of mold opening in the fifth step according to Embodiment 1 of the present invention An enlarged cross-sectional view when the molded product in Embodiment 1 of the present invention is taken out from the male mold cavity The block diagram of the in-mold molding apparatus in Embodiment 2 of this invention Explanatory drawing of the 2nd process in Embodiment 2 of this invention Explanatory drawing of the 3rd process in Embodiment 2 of this invention Explanatory drawing at the time of the transfer film clamp of the 3rd process in Embodiment 2 of this invention Explanatory drawing of the 4th process in Embodiment 2 of this invention Explanatory drawing of the 5th process in Embodiment 2 of this invention The top view which looked at the transfer film of another Example of this invention from the temporary adhesive layer 22 side (A) perspective view and (b) transverse sectional view and (c) longitudinal sectional view of a conventional molded article Configuration diagram of a conventional injection molding apparatus (A) An enlarged sectional view of a conventional continuous film and (b) an enlarged sectional view of a continuous sheet

Embodiment 1
Hereinafter, the panel forming method and the panel forming apparatus according to the first embodiment of the present invention will be described based on FIGS. 1 (a) and (b) to FIG.

  FIGS. 1A and 1B show an example of a plate-like molded article 1 produced by the injection molding method of the present invention. The molded article 1 is a transparent panel with a window frame attached to a liquid crystal touch panel such as an on-vehicle display device, and is molded by a transparent polycarbonate 2.

  A window 3 as a display unit for displaying a liquid crystal touch panel screen is formed in a central portion on the surface side of the molded article 1. An insert film 4 having an anti-reflection function, an anti-fingerprint function, and the like is insert-molded in the portion of the window portion 3. A window frame 5 is formed on the surface side from the periphery of the window portion 3 to the side surface. The window frame 5 is disposed by overlapping a transfer film having a soft touch feeling with the insert film 4. The whole of the back side of the molded article 1 is covered with polycarbonate 2 and can be made of a single resin although it is a different material.

  The insert film 4 is based on a polyethylene terephthalate film 4a having a thickness of 100 to several hundreds μm, and in this case, AR (anti-reflection), AF (anti-fingerprint anti-fingerprint), AG (anti-glare anti-glare), HC It has a functional film 4b such as (hard-coat Hard-coat) on the surface side. An adhesive layer 4 c is provided on the back side of the insert film 4.

The level difference between the window frame 5 and the display portion is about several tens of μm, and a seamless design can be expressed while maintaining the different material feeling between the touch of the window 3 and the touch of the window frame 5.
Here, assuming that the area of the window portion 3 at the center of the molded product is S1 and the surface area of the window frame 5 is S2, it has a relationship of S12S2 and has a display portion having a functional surface in the central surface layer. It is a molded article of the design.

This molded article 1 can be manufactured by the injection molding apparatus shown in FIGS.
The injection molding apparatus shown in FIG. 2 includes a first mold female core 11 and a second mold male cavity 12, and a driving device for clamping and opening the female core 11 and the male cavity 12. A transfer device for controlling transfer-stop of the transfer film 13 having an in-mold film etc., and an injection device for injecting a molten resin into a molding chamber space formed by clamping the female core 11 and the male cavity 12 And a robot hand 15 as a handling device for taking out the molded product 1 which has been molded from the mold.

  A frame-like clamp 16 is attached to the female core 11 by a rod 17. A band-like transfer film 13 is inserted between the female core 11 and the male cavity 12 and between the female core 11 and the clamp 16.

FIG. 3 is a B-B arrow view of the female core 11 viewed from the side of the clamp 16. The width of the transfer film 13 is wider than the cavity 18 of the female core 11.
Further, in the female core 11, the vacuum pump 21 connected to the outside via the pressure valve 20 from the suction hole 19 is operated to evacuate the inside of the cavity 18 to extend the transfer film 13 to the surface of the cavity 18 to adhere thereto. be able to.

The structure of the transfer film 13 is shown in FIGS. 4 (a) and 4 (b).
As shown in FIG. 4B, the transfer film 13 is formed by laminating a release layer 13b, a touch sensitive layer 13c consisting of a soft touch touch decorative layer and a print layer, an adhesive layer 13d, etc. on a polyethylene terephthalate base film 13a. The base film 13 a is inserted between the female core 11 and the male cavity 12 with the base film 13 a facing the female core 11 and the adhesive layer 13 d facing the male cavity 12. The portion of the touch sensitive layer 13c and the adhesive layer 13d is an in-mold film.

  Here, only the adhesive layer 13d is printed in a window frame shape surrounding the periphery of the window portion 3 of the molded article 1 as shown in FIGS. 4 (a) and 4 (b). That is, since the adhesive layer 13 d can be gravure printed, it is printed in a window frame shape, and the adhesive layer 13 d is not provided on the central window portion.

  In the case of a transfer film called normal in-mold, gravure printing is generally used as a printing method, but in the case of forming the touch-sensitive layer 13c, securing of a film thickness (several tens of μm) giving soft touch feeling in gravure printing Printing is carried out using a gravure coater or the like. It is difficult to selectively print a window frame or the like as in this example due to the limitation of the printing method, and it is a general situation that the entire surface is uniformly printed.

  A temporary adhesive layer 22 for temporary fastening is provided in a window frame shape so as to overlap the insert film 4 on the surface on the adhesive layer 13 d side of the base film 13 a. The temporary adhesive layer 22 uses a thermosetting adhesive that can be cured at a temperature lower than that of the adhesive layer 13 d.

  In FIG. 2, the robot hand 15 not only carries out the removal of the molded product 1 whose molding is completed, but also operates in the process before the clamping of the female core 11 and the male cavity 12 to insert one piece of insert film 4. In a state in which the insert film 4 is inserted between the female core 11 and the male cavity 12 in a state in which the insert film 4 is held against the temporary adhesive layer 22 on the back surface of the transfer film 13 There is. A heater 23 is embedded in the insert film holding portion of the robot hand 15 so as to heat the insert film 4 being held.

  The temporary adhesive layer 22 is provided on the adhesive layer 13 d so as to overlap at a predetermined position of the insert film 4 which is later pressed against the transfer film 13 by the robot hand 15.

The curing temperature of the adhesive layer 4c is higher than the curing temperature of the temporary adhesive layer 22. For example, the curing temperature of the adhesive layer 4c is the same as that of the adhesive layer 13d.
Here, assuming that the cross-sectional thickness of the insert film 4 is T1 and the cross-sectional thickness of the transfer film 13 is T2, the relationship of T1 通常 T2 is established, the thickness of T1 is usually 100 to several hundreds μm, and the thickness of T2 is about 50 to 100 μm or less It has become.

The configuration of the injection molding apparatus will be described in detail based on the molding method.
5 to 11 show the molding process of the injection molding apparatus. 12 to 17 show enlarged views of the transfer film 13 and the like in the process of the main part.

  In the first step (transfer film transfer step) shown in FIG. 5, the transfer film 13 is transferred by the foil feeding device, and the window frame-like temporary adhesive layer 22 of the transfer film 13 arrives at the determined position of the cavity 18. The transfer film 13 is positioned and stopped with high accuracy based on an output signal of a means such as a positioning camera (not shown). The state of the transfer film 13 in this state is shown in FIG. 12, and is the same as the state described in FIG. 4 (b). The position of the cavity 18 at this stop position is shown by an imaginary line in FIG. 4 (a).

In the second step (transfer film clamping step) shown in FIG. 6, the transfer film 13 is pressed by the clamp 16 around the cavity 18 of the female core 11.
In the third step (transfer film adsorption step) shown in FIG. 7, the vacuum pump 21 is operated to vacuum-suction the inside of the cavity 18 to stretch the transfer film 13 to the inner surface of the cavity 18 as shown in FIG. In this process, the robot hand 15 holds the insert film 4 and stands by. Specifically, while the robot hand 15 holds the insert film 4 from the lower surface side with the functional surface 4b of the insert film 4 up, the robot hand 15 holds the held insert film 4 at or near the curing temperature of the temporary adhesive layer 22. Waiting while preheating to temperature.

  In the fourth step (insert film temporary bonding step) shown in FIG. 8, the robot hand 15 enters between the female core 11 and the male cavity 12, and the robot hand 15 ascends toward the cavity 18 and holds it. The outer peripheral portion of the functional surface 4 b of the insert film 4 is pressed against the window frame-shaped temporary adhesive layer 22 of the transfer film 13. As a result, the temporary adhesive layer 22 is cured by the heat from the side of the insert film 4 and the insert film 4 is temporarily fixed at a predetermined position of the transfer film 13 as shown in FIG.

The heating temperature by the robot hand 15 is set to a temperature not lower than a temperature at which the temporary adhesive layer 22 is softened and temporarily fixed, and not higher than a temperature at which the insert film 4 is not damaged.
In the fifth step (forming step) after the robot hand 15 with the temporary fixing of the insert film 4 to the transfer film 13 completed is retracted, the female core 11 is operated as shown in FIG. 9, FIG. 10, and FIG. The mold is clamped with the male mold cavity 12. Thereafter, the molten polycarbonate 2 is injected from the spool 24 through the hot runner 25 into the cavity 18 at the side gate via the hot runner 25 and the adhesive layer 13d of the transfer film 13 and the adhesive layer 4c of the insert film 4 are adhesively cured by the heat of the molten resin. Ru. This state is shown in FIG.

  When cooling of the female core 11 and the male cavity 12 is completed, the female core 11 ascends to perform mold opening. At the time of this mold opening, the molded article 1 is configured to be left in the male mold cavity 12 as shown in FIG. 16, and at the same time as the mold opening, the transfer film 13 is peeled from the peeling layer 13b. Since the transfer film 13 has a frame-like adhesive layer 13d formed on the touch sensitive layer 13c, when the transfer film 13 is peeled off from the release layer 13b at the same time as mold opening, the transfer film 13 is adhered to the molded article 1 by the adhesive layer 13d. The touch sensitive layer 13 c and the insert film 4 are transferred to the side of the molded product 1 and left. Since the central portion of the insert film 4 is an area of the transfer film 13 where the adhesive layer 13 d is not applied, the touch sensitive layer 13 c does not remain in the central portion of the insert film 4 and the functional surface 4 b of the insert film 4 is exposed. The touch sensitive layer 13c in the area of the transfer film 13 where the adhesive layer 13d is not applied remains on the side of the base film 13a.

  Thereafter, a hydraulic cylinder or the like is operated by an ejection mechanism (not shown) embedded in the male mold cavity 12 to take out the molded product 1 as shown in FIG. The molded article 1 is gripped by the robot hand 15 and carried out.

  As a means for preventing burrs from remaining on the interface between the insert film 4 and the touch sensitive layer 13c as the transfer layer at the time of mold opening, the heat insulation effect due to the difference in thickness between the transfer film 13 and the insert film 4 is used to make gold. By giving a difference between the temperature of the central display portion of the insert film 4 and the temperature of the portion of the window frame 5 by giving a local temperature adjustment function by embedding a heater in a mold or an independent cooling circuit, etc. It is also effective to adjust the foil breakage only by raising it.

  Moreover, since the thickness of the insert film 4 constituting the central display portion is larger than the transfer film 13, the heat insulating effect is large, and the printing state in the touch sensitive layer 13c of the transfer film 13 is transferred to the functional film 4b of the insert film 4 by the heat of the injection resin. Will not be degraded.

  Further, in the present embodiment, since the insert film 4 temporarily fixed on the side of the transfer film 13 is in contact with the female core 11 via the transfer film 13, the insert film 4 directly contacts the female core 11. The effect of reducing defects such as scratches on the functional surface 4b of the insert film 4 was also observed.

  In addition, the insert film 4 is disposed at the central portion of the molded article 1, that is, the insert film 4 is disposed at the central portion where the transfer film 13 is most easily stretched in the molded article 1, and the surface area is the surface area of the window frame 5. Since the structure is larger, it is possible to suppress the elongation of the most stretchable portion at the time of molding. As a result, the effect of preventing breakage and abnormal elongation of the transfer film 13 at the time of molding was also obtained.

  According to this configuration, after the transfer film 13 is positioned on the female core 11 and suctioned to the cavity 18 surface, the insert film 4 positioned and held by the robot hand 15 is set at a predetermined position of the transfer film 13 The layer 22 can be locally heated and fixed. In addition, since the positioning can be performed after suction of the transfer film 13, the fixing position of the insert film 4 is stabilized even if the elongation variation of the transfer film 13 occurs due to a film lot or an environmental change, etc. Occurrence can also be reduced.

  In the above embodiment, the case of temporarily fixing the insert film 4 using the thermosetting adhesive as the temporary adhesive layer 22 has been described as an example, but the UV curable adhesive as the temporary adhesive layer 22 It is also possible to temporarily fix them. In the case of temporary heating, there is a concern of positional displacement of the insert film 4 due to heat at the time of resin injection. On the other hand, it is more effective to temporarily fix the insert film 4 using a UV curing type adhesive as the temporary adhesive layer 22 because there is no positional displacement of the insert film 4 due to the heat at the time of resin injection. is there.

  In the above embodiment, when temporarily holding the insert film 4, the robot hand 15 holds the insert film 4 while preheating the insert film 4, and the robot hand 15 is inserted into the temporary adhesive layer 22 formed on the transfer film 13 side. 4 was pressed to temporarily bond, but when a UV curing type adhesive is used as the temporary adhesive layer 22, the robot hand 15 presses the insert film 4 against the temporary adhesive layer 22, and then the robot hand 15 temporarily adheres The layer 22 is irradiated with UV light to temporarily bond the insert film 4.

Second Embodiment
In the first embodiment, the insert film 4 is temporarily bonded to the transfer film 13 stretched and brought into close contact with the surface of the cavity 18 of the female core 11. In the second embodiment, the female core 11 and the male cavity are The second embodiment differs from the first embodiment only in that the insert film 4 is temporarily bonded to the transfer film 13 at a position on the upper side of the transfer direction of the transfer film 13 with respect to the molding position 12. The point that the temporary adhesive layer 22 is provided on the adhesive layer 13d of the transfer film 13 is also the same as that of the first embodiment.

FIG. 18 shows an injection molding apparatus for realizing the injection molding method of the second embodiment.
The same components as in the first embodiment will be described with the same reference numerals.
An insert film fixing portion 26 is provided on the side of the base film 13 a with the transfer film 13 interposed therebetween on the upper side of the transfer direction of the transfer film 13 than the female core 11 and the male cavity 12, and the adhesive layer 13 d The robot hand 15 is located on the side. A heater 27 is embedded in the insert film fixing portion 26. In the first step (transfer film transfer step) shown in FIG. 18, the transfer film 13 being transferred by the foil feeding device is highly accurate with respect to the mold based on the output of a positioning camera (not shown). Positioning and stop.

  In the second step (insert film temporary bonding step) shown in FIG. 19, the insert film 4 pressed by the robot hand 15 against the temporary bonding layer 22 of the transfer film 13 is heated by the heater 27 of the insert film fixing portion 26, The insert film 4 is temporarily adhered to the adhesive layer 13 d of the transfer film 13 via the temporary adhesive layer 22. At this time, before the robot hand 15 presses the insert film 4 against the transfer film 13, the heater 23 of the robot hand 15 preheats the insert film 4 and stands by.

  In the third step (clamping step) in which the robot hand 15 is retracted from the pressing position on the transfer film 13, the transfer film is reached until the insert film 4 temporarily bonded in the second step arrives at the cavity 18 of the female core 11. 13 is conveyed and stopped as shown in FIG. Then, as shown in FIG. 21, the transfer film 13 is pressed by the clamp 16 around the cavity 18 of the female core 11.

  In the fourth step (transfer film adsorption step) shown in FIG. 22, the vacuum pump 21 is operated to vacuum-suction the inside of the cavity 18 through the pressure valve 20 and the suction hole 19. By this, the transfer film 13 to which the insert film 22 is temporarily attached is stretched and brought into close contact with the inner surface of the cavity 18.

  Thereafter, in the fifth step (molding step), the female core 11 is operated and clamped with the male cavity 12 as in FIG. 10 described in the first embodiment. The molten polycarbonate 2 is injected from the spool 24 through the hot runner 25 into the cavity 18 by the side gate as shown in FIG. 23, and the adhesive film 4c of the transfer film 13 and the insert film 4 is adhered by the heat of the molten polycarbonate 2. Be cured. This state is shown in FIG.

  When cooling of the female core 11 and the male cavity 12 is completed, the female core 11 ascends to perform mold opening. At the time of this mold opening, the molded product 1 is left in the male mold cavity 12 as shown in FIG. 16, and at the same time as the mold opening, the transfer film 13 is peeled from the peeling layer 13d. Thereafter, a hydraulic cylinder or the like is operated by an ejection mechanism (not shown) embedded in the male mold cavity 12 to take out the molded product 1 as shown in FIG. The molded article 1 is gripped by the robot hand 15 and carried out.

According to this configuration, the same effect as that of the first embodiment can be realized.
In the second embodiment described above, although temporary bonding was performed by heating when temporarily holding the insert film 4, when a UV curing type adhesive material is used as the temporary bonding layer 22, the robot hand 15 is used as the transfer film 13. After pressing the insert film 4 against the temporary adhesive layer 22 formed on the side, UV light is irradiated to the temporary adhesive layer 22 from at least one of the robot hand 15 and the insert film fixing portion 26 to temporarily bond the insert film 4 You can also.

  The robot hand 15 in the second step shown in FIG. 21 does not hold the insert film 4 used in the next molding cycle, but the clamp 16 presses the transfer film 13 against the female core 11. The robot hand 15 holds the insert film 4 to be used in the next molding cycle as indicated by phantom lines until the female core 11 starts moving for clamping, as in FIG. By temporarily fixing the transfer film 13, an improvement in work efficiency can be expected.

  In each of the above embodiments, the case where the temporary adhesive layer 22 is applied or printed in advance on the side of the transfer film 13 has been described, but the same applies in the case where the temporary application layer 22 is applied or printed in advance. Can be implemented.

In each of the above-described embodiments, the material of the insert film 4 is polyethylene terephthalate, but it is also possible to use another material other than polycarbonate.
In each of the above-described embodiments, the molten resin is polycarbonate, but polymethyl methacrylate resin and other materials can also be used.

  As described above, according to the present invention, the insert film can be temporarily adhered on the transfer film, and the transfer layer such as the decorative touch sensitive layer of the transfer film can be adhered locally on the insert film. It becomes possible to realize a molded product having different material feeling and functions that are difficult to realize with a film alone.

  In addition, it becomes possible to determine the position between the two types of film in the process immediately before the injection, and it is possible to stabilize the position after film suction without being influenced by the film lot variation and the influence of the molding environment. The shape of a part of the elongation of 140% or more is required, and the transfer layer of the decorative film sheet has a design such as a pattern or characters by printing etc., and the alignment accuracy on the molded product is required At the time of in-mold molding, it is possible to reduce the appearance quality of the molded product and the occurrence of a defect such as misalignment of a pattern.

  In each of the above embodiments, the shape of the window portion 3 of the molded article 1 and the shape of the insert film 4 are rectangular, and the temporary adhesive layer 22 is formed on the adhesive layer 13 d of the transfer film 13. As shown in FIG. 4 (a) along the window frame-like side 13d, it is formed in a ring shape in which four sides are continuous in a window frame shape, but as shown in FIG. It is the same even if it does not have a window frame shape. Specifically, the temporary adhesive layer 22 is provided only at the four corners of the window frame-like adhesive layer 13 d in this example.

  The present invention is intended to improve the quality of various molded articles used in electrical appliances and in-vehicle molded articles that require stricter specifications in terms of strength, as well as panel-like molded articles attached to the casing body of a mobile phone. To contribute.

Reference Signs List 1 molded product 2 polycarbonate 3 window 4 insert film 4 a polyethylene terephthalate film 4 b functional film 4 c adhesive layer 5 window frame 11 female core (first mold)
12 Male cavity (2nd mold)
13 transfer film 13a base film 13b release layer 13c touch sensitive layer 13d adhesive layer 14 mold apparatus 15 robot hand (handling apparatus)
16 clamp 17 rod 18 cavity 19 suction hole 20 pressure valve 21 vacuum pump 22 temporary adhesive layer 23 heater 24 spool 25 hot runner portion 26 insert film fixing portion 27 heater

Claims (4)

Clamp the first mold and the second mold with the in-mold film and the insert film,
An injection molding method in which a molten resin is injected into a molding space formed by clamping a first mold and a second mold to transfer and mold an in-mold film and an insert film on the surface of a molded article,
An insert film temporary bonding step of bonding and fixing the insert film to the surface of the second mold side of the in-mold film disposed on the first mold side;
The in-mold film to which the insert film is adhered is clamped between the first mold and the second mold and clamped, and the molten resin is injected into the molding chamber space between the first mold and the second mold to have a, a molding step of transferring adhesive to the surface of the molded article of the in-mold film and the insert film,
The shape of the molded product is a panel shape, and has a display portion of a window portion at the center portion,
A window frame formed in the touch-sensitive layer so as to surround the window portion and the touch-sensitive layer formed on the base film with the release layer interposed between the first mold and the second mold. -Shaped first adhesive layer,
Forming a functional surface on one side of the insert film and forming a second adhesive layer on the other side;
The base film, the release layer and the touch sensitive layer are peeled off by mold opening of the first mold and the second mold after injecting the molten resin, and the touch frame layer and the first adhesive of the window frame shape of the molded product Exposing the functional surface from the window inside the layer,
Injection molding method. The insert fill-time temporary bonding process,
Positioning the insert film against the in-mold film sucked and held by the cavity surface of the first mold;
It has a bonding step of fixing the insert film to the in-mold film by heating or irradiating the contact portion of the in-mold film and the insert film with heat or light.
The injection molding method according to claim 1. The insert fill-time temporary bonding process,
Positioning the insert film against the in-mold film before being sucked and held by the cavity surface of the first mold;
It has a bonding step of fixing the insert film to the in-mold film by heating or irradiating the contact portion of the in-mold film and the insert film with heat or light.
The injection molding method according to claim 1. Making the thickness of the insert film which is responsible for the portion to be the display part greater than the thickness of the transfer film,
The injection molding method according to claim 1 .

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