JP2006168160A - Manufacturing method of film-forming molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To remove a molded substrate once from a mold in a conventional die slide type, and then reset the film formed by a film forming apparatus to the mold and inject it onto the film forming surface. It takes. In addition, in the film forming process, the film formation part of the base material is touched and becomes a defective product, so it is necessary to handle the base material carefully, so that workability is poor and the yield is low. There's a problem.
In manufacturing a solid film-molded article 9 in which the surface of a film 10 formed on a film-forming side surface 3a of the substrate 3 is coated with a coating material 4 to protect the film 10, the substrate 3 Between the first injection molding step for injection molding and the second injection step for integrating the base material 3 and the covering material 4, a film forming step for forming a film 10 is provided. The film forming product 9 can be formed by a series of die slide methods.
[Selection] Figure 3

Description

  The present invention belongs to the technical field of a method for manufacturing a film-forming molded product in which film-forming portions are laminated in a sandwich with a resin material.

In general, some of these types of film-formation molded products have an improved design by covering the surface of the member with a material having an effect such as a coloring effect or a reflection effect, such as a member such as an emblem for a vehicle. As this manufacturing method, for example, there is a method in which the surface of a member is formed by coating with a decorative chrome plating film (see, for example, Patent Document 1).
Nowadays, hexavalent chromium used for plating is a substance harmful to the human body, and since it causes pollution problems due to environmental pollution, it is subject to regulation and dechromation is required.
As an improvement measure, there is one in which a film is formed on a substrate surface by a film forming apparatus such as vacuum deposition or sputtering, and the surface of the film is covered with a resin material (for example, refer to Patent Document 2). .
Japanese Patent Laid-Open No. 6-147069 JP-A-6-169191

  However, in such a case, after the injection-molded base material is taken out from the injection molding apparatus, it is set in a vacuum vapor deposition apparatus to form a film, and then the film-formed base material is taken out from the vacuum vapor deposition apparatus and then injected. The number of processes is increased because it is set on the molding machine and injection molding of the resin material on the film forming surface is troublesome, and the work efficiency is not only poor, but also the removal process, the setting process, and the transport process from the equipment to the equipment. At this time, the film-forming surface, as well as the film-forming surface, may be scratched, dusty, or touched and the oil may adhere to it. There is a problem that non-defective products are produced and the yield is poor, and there are problems that the present invention does not solve.

The present invention was created in view of the above-described circumstances in order to solve these problems, and the invention of claim 1 is based on the separation movement in the opposing direction between the mold surfaces and the surface direction. A first mold and a second mold configured so that the parallel movement along the first and second molds are relatively performed. After the mold surfaces for molding the first molded product formed on both molds are matched, A first injection step for molding a molded product, a first demolding step in which the molded first molded product is demolded from a second mold while being supported by the first mold, and the first A film forming step of forming a film on the first molded article by facing the film forming means provided on the second mold so as to face the film forming means; A second demolding step of demolding the molded product from the second mold in a state supported by the first mold, and a second molding in which the film-formed first molded product is provided in the second mold. And a second injection step of forming a second molded product by injecting at least the film-forming surface of the film-formed first molded product against the mold surface for use. Manufacturing method.
According to a second aspect of the present invention, there is provided a method for producing a film-formed molded product according to the first aspect, wherein the film forming means is a vacuum evaporation apparatus.
A third aspect of the present invention is the method of manufacturing a film-formed molded product according to the first or second aspect, wherein the film formation is a part of a surface exposed by removing the second mold.
According to a fourth aspect of the present invention, there is provided a method for producing a film-molded article according to the third aspect, wherein a part of the film is formed by covering with a second mold and masking.
A fifth aspect of the present invention is the method of manufacturing a film-formed molded article according to the third aspect, wherein part of the film formation is performed by covering the exposed surface of the first molded article with a masking material.
According to a sixth aspect of the present invention, in any one of the third to fifth aspects, the film formation is not performed on an edge portion of the exposed surface.
A seventh aspect of the present invention is a method for manufacturing a film-formed molded article according to any one of the first to fifth aspects, wherein there are a plurality of film forming steps.
The invention of claim 8 is the method of manufacturing a film-formed molded product according to claim 7, wherein the plurality of film formations are different in film formation position.
A ninth aspect of the present invention is the method of manufacturing a film-forming molded product according to the seventh aspect, wherein the plurality of film formations are such that a part or all of the film formation positions coincide with each other.
A tenth aspect of the invention is a method for manufacturing a film-formed molded product according to any one of the first to ninth aspects, wherein the film forming step, the second demolding step, and the second injection step are repeated. .
The eleventh aspect of the present invention is the method according to the tenth aspect, wherein the second injection step is performed while leaving a part of the film formation surface formed in the previous film formation step. This is a method for producing a film-forming molded product, which is performed on the film-forming surface left in the second injection step and the molding surface injection-molded in the previous second injection step.
A twelfth aspect of the invention is a method for producing a film-formed molded article according to the eleventh aspect, wherein the film-formed molded article is an electric base material, and the film-forming surface is an electric wiring.

By using the invention of claim 1 or claim 2, it is possible to improve the workability and increase the yield as compared with the prior art.
By setting it as invention of Claim 3, the designability of the film-forming molded article can be improved.
According to the invention of claim 4, it is possible to form only a portion where film formation is desired.
By setting it as invention of Claim 5, it can form into a film, changing the shape of a non-film-forming part easily.
By setting it as invention of Claim 6, since the edge part of the exposed part of a 1st molded product is directly inject | emitted by a 2nd injection process, it can be set as a firm 2nd molded product.
According to the seventh aspect of the invention, a plurality of different film formations can be formed in a polymer form, so that different film formations can be formed in a polymer form.
By setting it as the invention of claim 8, it can be made rich in color and excellent in design.
According to the ninth aspect of the present invention, when the film-forming molded product is viewed from the outside, the first molded product side and the second molded product side can have different color schemes.
According to the invention of claim 10, the film formation and the second molded product can be alternately polymerized on the first molded product.
By setting it as invention of Claim 11, film-forming can be set as the structure connected on the series.
According to the twelfth aspect of the present invention, it is possible to easily form an electric base material with a small amount of metal used for wiring and without waste.

  Next, a first embodiment of the present invention will be described with reference to FIGS. In the drawings, 1 is a movable mold (first mold), 2 is a fixed mold (second mold), and the movable mold 1 can be moved away from and in contact with the fixed mold 2. At the same time, it is configured to move in the direction along the surface with respect to the fixed mold 2 while being separated from the fixed mold 2 (parallel movement with respect to the mold surface). Since it can be performed using the technique of the mold moving method known from No. 1, it will be omitted. Since the movement of the mold may be relative, the first mold may be fixed and the second mold may be moved, or of course, both may be moved. . Further, the movement is not limited to the parallel movement in the linear direction as long as the movement is in the direction along the surface, and may be a rotational movement around the axis.

  The movable mold 1 is formed with an injection molding surface 1a having a concave shape for injection molding of the base material 3 (first molded product), while the fixed mold 2 is provided with the base 3 A first injection molding surface 2a that is flat for injection molding the film formation side surface 3a (inner side surface) and a concave injection molding for forming the coating material 4 (second molded product) by injection molding Each of the molding surfaces 2b is formed, and a film forming surface 2c having a concave shape is formed to accommodate (internally) a vacuum vapor deposition apparatus (film forming means, film forming apparatus) 5. Incidentally, in the fixed mold 2 of the present embodiment, the film forming molding surface 2c is formed between the first injection molding surface 2a and the second injection molding surface 2b. It can be set arbitrarily if necessary. The vacuum vapor deposition apparatus 5 is provided with a publicly known apparatus. As an outline, an intake passage 6 connected to a vacuum pump P, a boat 7 for containing a metal to be deposited (for example, aluminum or chromium), and heating the boat 7 are provided. And a heater 8 for doing so.

  The film-formed molded product 9 is an emblem for a vehicle in the present embodiment, and is molded in a series of steps using the molds 1 and 2 as will be described later. The base material 3 formed by the above process, the covering material 4 formed by injection molding of a light-transmitting resin material, and the base material 3 and the covering material 4 are formed by vacuum deposition at positions sandwiched between the base material 3 and the covering material 4. The film 10 is difficult to be peeled off and has an excellent design.

  Next, the manufacturing method of the film forming product 9 will be described. FIG. 2A shows both molds 1 and 2 in which the molding surface 1a for forming the base material 3 and the molding surface 2a for first injection face each other in a state of being separated from each other. The movable mold 1 is moved from the state to the fixed mold 2 side, and the opposing mold surfaces are matched (first mold matching step: see FIG. 2B). In this mold matching state, the first injection is performed, and the base material 3 (first molded product) is injection-molded (first injection step: see FIG. 2C).

  Thereafter, as shown in FIG. 3A, the movable mold 1 moves in a direction away from the fixed mold 2. At this time, the base material 3 is separated (demolded) from the fixed mold 2. The mold is designed so as to be supported (remain) on the movable mold 1 side (first demolding step). Next, the movable mold 1 is translated (see FIG. 3B) so that the base material 3 faces the vacuum deposition apparatus 5, and then moves to the fixed mold 2 side to be in a mold-matching state (second state). Mold matching step: see FIG.

When the base material 3 and the vacuum vapor deposition apparatus 5 are in a mold-matching state, the air in the film forming surface 2c is drawn from the intake passage 6 to be in a vacuum state, and the heated heater 8 The film 7 is supplied to the boat 7 and the molten metal is vaporized, and the film formation side surface 3a (the lower surface of FIG. 4A) where the substrate 3 is exposed is vacuum-deposited to form the film formation 10 (synthetic film formation). Membrane process: see FIG. 4 (A)). Next, the movable mold 1 is separated from the fixed mold 2 while supporting the base material 3 (second mold release step: see FIG. 4B), and then the movable mold 1 is fixed to the fixed mold 2. The base material 3 and the second injection molding surface 2b are opposed to each other (see FIG. 4C).
Incidentally, since the film formation 10 is generally as thin as several micrometers to several tens of micrometers, for example, when trying to show it in a cross-sectional view, it is practically difficult to illustrate this. In order to make this easy to understand, in the drawings, it is described as having a certain thickness for the sake of convenience, but in actuality, it is almost the same surface as the film formation surface (hereinafter the same). For this reason, as will be described later, in the case where the film formation is partially laminated, even if the laminated portion is described in a stepped shape in the drawing (for example, the cross-sectional view in FIG. 11C), these Needless to say, when viewed with the naked eye, they are not stepped but can be seen only almost flush.
Needless to say, the film thickness can be arbitrarily adjusted by adjusting the deposition time.

  Thereafter, the movable mold 1 is moved to the fixed mold 2 side, and the opposing base material 3 and the second injection molding surface 2b are mold-matched (third mold-matching step: see FIG. 5A). After that, a resin material is injected onto the film formation side surface 3a on which the film formation 10 is formed (see the second injection step: FIG. 5B) to form the covering material 4 (second molded product), thereby forming the base material 3 The film formation 10 is formed by integrating the film 10 and the covering material 4. Then, after the movable mold 1 is separated from the fixed mold 2 and the film-forming molded product 9 is taken out (see FIG. 5C), the movable mold 1 is moved to the first position in FIG. By moving in parallel and thereafter repeating this process, the film-formed molded product 9 can be continuously formed.

  In the first embodiment of the present invention configured as described above, a solid film-forming molded product 9 in which the surface of the film-forming 10 formed on the film-forming side surface 3a of the substrate 3 is covered with the covering material 4 is manufactured. Then, in protecting the film 10, a first injection molding process for injection molding the base material 3 and a second injection process for integrating the base material 3 and the coating material 4 In the meantime, as a result of providing a film forming process for forming the film 10 and forming the film forming product 9 by a series of processes, the film forming 10 is once applied to the base material 3 taken out from the mold as in the prior art. After forming, the work efficiency is improved because the work of taking out and resetting the base material 3 becomes unnecessary as in the conventional case where it is necessary to set the mold again and cover with the covering material 4. Moreover, since the substrate 3 is not taken out and re-set, there is no touch of the film-forming surface, fingerprints, or damage to the object, and the entire process can be performed in a clean room. The occurrence of defective products can be greatly reduced.

  The present invention is not limited to the above-described embodiment, and the film forming means is not limited to the vacuum vapor deposition apparatus 5, and a generally known film forming apparatus such as a method by cathode sputtering is required. Can be employed.

In the first embodiment, the film forming side surface 3 a of the base material 3 is formed on the entire surface 10 a, and the film forming molded product 9 is formed by covering all the film forming surfaces 10 with the covering material 4. However, in the case where the film formation 10 has poor adhesion to the resin material, peeling is considered, so that the film forming molded body 11 is caused by the covering material 17 entering the periphery of the base material 14 as shown in FIG. The resin materials can be configured to be in direct contact and firmly bonded.
The second embodiment similarly includes a fixed mold 12 and a movable mold 13, but the fixed mold 12 is formed with a convex surface 12 a that enters the peripheral edge 13 a of the movable mold 13. Then, after molding the peripheral surface 14a of the base material 14 with the convex surface 12a (see FIG. 7A), the film deposition side surface 14b of the base material 14 is vacuum-deposited by the vacuum deposition device 15 (see FIG. 7B). ), And after that, a coating material 17 is injected onto the film-formed surface and the peripheral surface 14a to form a solid film-formed molded article 11 (see FIG. 7 (c)). The movement of the movable mold 13 is the same as in the first embodiment, and the details thereof are omitted (the same applies hereinafter).

In the first or second embodiment, the films 10 and 16 are formed on the entire film formation side surfaces 3a and 14b of the substrates 3 and 14, but as shown in FIG. The film-forming molded product 19 can be formed so as to have a part (non-film-forming part) 18b where a part of the film-forming side surface 18a is masked and partially not subjected to the film-forming 48. In this case, the masking can be performed at the peripheral edge 21b of the film forming surface 21a of the fixed mold 21 that accommodates the vacuum evaporation apparatus 20 as in the third embodiment shown in FIG. Further, the masking material 22 can be attached as in the fourth embodiment shown in FIG. 9B. And when using the masking material 22, it can carry out by coat | covering the masking material 22 on the film-forming side surface 18a of the base material 18 between the 1st demolding process and the 2nd mold matching process.
When masking is performed in this way, the base material 18 and the covering material 23 are directly brought into contact with each other at the non-film-forming portion 18b and are bonded to each other, so that an increase in strength can be achieved.

  Furthermore, in the first to fourth embodiments, the film forming process is performed once, but the present invention is not limited to this, and the film forming process can be performed two or more times. For example, as shown in FIG. 10 (A), two sets of vacuum vapor deposition devices 24 and 25 are mounted on film forming mold surfaces 26a and 26b formed on a fixed mold 26, respectively, and are molded in the first injection process. After the first film formation process is performed on the film formation side surface 27a of the material 27, the second film formation process is performed, and then the second injection process is performed. The film surface can be formed so as to be covered with the covering material 28.

In this case, as in the fifth embodiment, when the second film 30 is applied to the entire surface of the first film 29 (see FIG. 10B), The front and back sides are differently formed and visually observed (limited to the case where the base material and the covering material are translucent materials). Further, as in the sixth embodiment, the film formation positions of the first film formation 32 and the second film formation 33 are made different by performing the masking (FIG. 11A, In the case of (see (B)), two different film formations 32 and 33 are visually observed from the surface of the film formation molded product 34. Furthermore, as in the seventh embodiment, the first film formation 35 and the second film formation position 36 are applied so as to partially overlap each other by performing the masking (FIG. 11 (C), (D)), the second film 36 is thin and the first film 35 is visible through the surface of the film-formed molded article 37. The three different film formations of the first and second film formations 35 and 36 and the mixture of the film formations 35 and 36 are visually observed.
In this case, two or more vacuum vapor deposition apparatuses are built in one film forming mold surface, and a plurality of films can be continuously formed.
Incidentally, the portion where the first film formation 35 and the second film formation 36 overlap is in a polymerized state as shown in FIG. 11C, but the time for vacuum evaporation is controlled, By making the film thickness very thin, it can be formed substantially flush with the first and second film formations 36.

  Furthermore, as in the eighth embodiment, the film forming process according to the first embodiment, the second demolding process and the second injection process can be repeated, and in this case, The film formation 38 and the injection of the resin material are repeated so as to be simply polymerized in a state where the film formation positions are different by masking or the like as in the fourth embodiment (FIG. 12A, ( B), and in this case, the film formation 38 is a film formation molded product 39 that is visually observed in a three-dimensional state.

  Further, when the film forming process, the second demolding process, and the second injection process are repeated, the previous second injection process is performed by the first film formation 40 formed in the previous film forming process. The film formation process that is performed while leaving a part is repeated between the first film formation 40 left in the previous second injection process and the second base material 41 injection-molded in the previous second injection process. It can be performed on the molding side surface 41a. That is, as in the ninth embodiment shown in FIGS. 13, 14A, and 14B, the first substrate 42 formed in the first injection process is linear (or formed in the film formation process). A first film 40 having a strip shape (hereinafter the same) is vacuum-deposited, and a second film is formed on the film-forming surface side 42a of the first substrate 42 so that one end of the first film 40 is exposed (leaves). The base material 41 is formed by injection molding. Next, the film formation process is repeated again, and a linear second film formation 43 communicating from the film formation surface side 41 a of the second base material 41 to the first film formation 40 is formed. Further, in the subsequent third injection step, the third substrate 44 is formed by performing the third injection step on the film formation surface side 41a, leaving one end on the film formation surface side 41a of the second film formation 43. In the subsequent film forming step, the third film 45 exposed from the film forming surface 44a of the third base 44 to the second film 43 is formed and then exposed to the third film 45. The film formation 45, the second and third substrates 41, 44 are covered with a covering material 46 to form a film formation molded product 47. And by forming in this way, the three-dimensional film-forming molded product in a three-dimensional direction can be shape | molded.

  Incidentally, in this embodiment, it is hierarchical only in the vertical direction, but it can be configured in a hierarchical manner in any direction such as front and rear, left and right. The first, second, and third film formations 40, 43, and 45 are all linear, but have various branched shapes such as an L shape, a T shape, a Y shape, and a curved shape. (See FIG. 14C), and further, the film formation is made of a conductive metal such as gold, silver, copper, etc., so that electric wiring is formed, and the film-formed molded article 47 is used as the electric substrate. be able to. As a result, the films 40, 43, and 45 can be formed thinner than the conventional electric wiring, so that the cost can be reduced, and further, various shapes can be formed by masking or the like. The substrate can be easily formed.

(A), (B) is the perspective view and longitudinal cross-sectional view of a film-forming molded product, respectively. (A), (B), (C) is a process schematic diagram until the first injection is performed. (A), (B), (C) is process schematic until the second matching. (A), (B), (C) is process schematic until a base material and the concave surface of a fixed mold oppose. (A), (B), and (C) are process schematic diagrams until the film-forming molded product is taken out. It is a longitudinal cross-sectional view of the film-forming molded product of 2nd embodiment. (A), (B), (C) is the schematic of the 1st injection | emission process of a 2nd embodiment, a film-forming process, and a 2nd injection | emission process, respectively. (A) and (B) are a side view and a plan view of the third or fourth embodiment, respectively. (A), (B) is the schematic of the film-forming process in 3rd Embodiment, and the film-forming process in 4th Embodiment, respectively. (A), (B) is the schematic of the film-forming process in 5th Embodiment, respectively, and the longitudinal cross-sectional view of a film-forming molded product. (A) and (B) are respectively a cross-sectional view and a front view of the film-formed molded product of the sixth embodiment, and (C) and (D) are cross-sections of the film-formed molded product of the seventh embodiment. It is a surface view and a front view. (A), (B) is the schematic of the film-forming process in 8th Embodiment, respectively, and the side view of a film-forming molded product. (A), (B), (C) is the front view of the film-forming molded product of 9th Embodiment, a side view, respectively, and XX sectional drawing of FIG. 13 (A). (A), (B), (C) is the process schematic of the film-forming molded article in 9th Embodiment, respectively.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Movable metal mold 1a Injection molding surface 2 Fixed mold 2a First injection molding surface 2b Second injection molding surface 2c Film forming surface 3 Base material 3a Film forming side surface 4 Covering material 5 Vacuum deposition apparatus 9 Film-forming molded article 10 Film-forming 11 Film-forming molded body 12 Fixed mold 13 Movable mold 14 Base material 17 Covering material 18 Base material 48 Film-forming 18b Non-film-forming part 19 Film-forming molded article 20 Vacuum evaporation apparatus 21 Fixed mold 21b Periphery 22 Masking material 23 Coating material 24, 25 Vacuum deposition apparatus 26 Fixed mold 26a, 26b Film forming mold surface 27 Base material 27a Film forming side surface 28 Coating material 29, 30 Film forming 31 Film forming molded product 32, 33 Film 34 Film-formed molded product 35, 36 Film-formed 37 Film-formed molded product 38 Film-formed 39 Film-formed molded product 40, 43, 45 Film-formed 41a, 42a, 44a Molded side surfaces 41, 42, 44 Base material 46 Coating material 47 Composition Membrane molded product

Claims (12)

The first and second molds are configured so that the separation movement in the opposing direction between the mold surfaces and the parallel movement along the surface direction are relatively performed,
A first injection step for molding the first molded product after matching the mold surfaces for molding the first molded product formed on both molds;
A first demolding step of demolding from the second mold in a state where the molded first molded product is supported by the first mold;
A film forming step of forming the first molded product by forming a film on the first molded product by abutting the first molded product so as to face the film forming means provided in the second mold,
A second demolding step of demolding the film-formed first molded product from the second mold while being supported by the first mold;
A second molded product is formed by abutting the film-formed first molded product against a mold surface for a second molded product provided in a second mold and injecting at least the film-formed surface of the film-formed first molded product. A method for producing a film-forming molded product, comprising:   2. The method of manufacturing a film-forming molded product according to claim 1, wherein the film-forming unit is a vacuum vapor deposition apparatus.   3. The method for producing a film-formed molded product according to claim 1, wherein the film is formed on a part of a surface exposed by removing the second mold.   4. The method of manufacturing a film-formed molded article according to claim 3, wherein a part of the film is formed by covering with a second mold and masking.   4. The method of manufacturing a film-formed molded product according to claim 3, wherein a part of the film is formed by covering an exposed surface of the first molded product with a masking material.   6. The method for manufacturing a film-formed molded article according to claim 3, wherein the film is not formed on the edge of the exposed surface.   6. The method for manufacturing a film-forming molded product according to claim 1, wherein there are a plurality of film-forming steps.   8. The method of manufacturing a film-forming molded product according to claim 7, wherein the plurality of film formations have different film formation positions.   8. The method of manufacturing a film-forming molded product according to claim 7, wherein a part or all of the film forming positions coincide with each other in the plurality of film forming.   10. The method for manufacturing a film-forming molded product according to claim 1, wherein the film-forming step, the second demolding step, and the second injection step are repeated.   In claim 10, the second injection step is performed while leaving a part of the film formation surface formed in the previous film formation step, and the repeated film formation step is performed in the second injection step. A method for producing a film-forming molded product, which is performed on the remaining film-forming surface and a molding surface injection-molded in the previous second injection step.   12. The method for manufacturing a film-formed molded article according to claim 11, wherein the film-formed molded article is an electric base material, and the film-forming surface is an electric wiring.

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