TWI409155B - In-mold decoration method of making molding products - Google Patents

Abstract

A method for producing in-mold decoration molding products includes following steps: providing a film; transporting the film into a cavity of a mold and making the film attached to the cavity; closing the mold, and making the male die of the mold not touch to the female die of the mold; injecting molten resin into the cavity; closing the mold again and making the male die jointed to the female die; cutting the film attached on the molding product down from the film; stopping injecting molten resin; and parting the mold.

Description

In-mold decoration molding method

The invention relates to an in-mold decorative molding method.

The appearance surface coating methods of general articles, automobiles, home appliances, and consumer electronic products are divided into liquid coating, powder coating, electrostatic coating, and electrophoretic coating. The surface processing by coating method cannot completely process the pattern. And when coating a large substrate having a flat surface and a side edge, since the side dimension of the substrate is very different from the planar size, when the paint is applied to the side of the coated substrate, a considerable amount of paint is applied. Will accumulate on the side. Through time evolution, an improved spin coater is applied to the coating of a substrate. The spin coater uses centrifugal force to drip the liquid paint on the middle of the surface of the horizontal substrate to be coated, and then coats the substrate level through high-speed rotation. Coating of the coating. However, the problem is that the end portion of the substrate turning edge is liable to cause uneven thickness of the coating layer.

As the design advances and the consumer's requirements for the appearance are increased, the housing for various products also has a high-gloss surface and a variable color pattern. Conventionally, a high-gloss surface shell is formed. It is used to paint the surface of piano paint, but the process must be placed in a clean room for several painting procedures, and then left to stand for several days to dry, so as not only lengthen the manufacturing time, but also because of more Road After painting, the film thickness of the paint on the product is uneven or too thick to cause cracking. In addition, after multiple painting processes, the overall yield of the finished product is reduced, resulting in a substantial increase in cost. Another manufacturing method for achieving a high-gloss surface is to mirror-finish the inner surface of the formed mold so that the inner surface of the mold is highly bright, and then the raw material is injection molded. The surface hardness of the product produced by this method cannot meet the abrasion resistance standards of the general industry, and it is easy to cause scratches and surface brightness reduction.

In order to achieve the high gloss of the surface, the variable color pattern and the wear resistance of the surface, the prior art achieves the above requirements by in-mold decorative transfer printing with a high gloss color pattern, wherein a decorative film is used, which is mainly used. The carrier layer, the release layer, the hard protective layer (hardened layer), the ink layer, and the adhesive layer are included. Wherein the carrier layer is used for carrying ink and transferring a high-gloss color pattern for transferring the other layers to a shaped plastic part located in the forming mold. After the forming is completed, the carrier layer is separated by a release layer. The effect is peeled off from the molded part. After the carrier layer is peeled off, the hard protective layer and the ink layer having the color pattern are adhered to the surface of the plastic part by the adhesive layer. The hard protective layer usually needs to be hardened by hot baking or ultraviolet irradiation to become a transparent material, which causes a high gloss effect and protects the plastic part and the ink layer from being worn and scratched. For a prior art of such a technique, see Japanese Patent No. 3546034, No. 3895896, Taiwan Patent No. 350820, and U.S. Patent No. 5,993,588. The decorative film disclosed by the technology has a release layer and a hardened layer, and when the mold is opened, the carrier layer and the release layer are peeled off from the hard protective layer adhered to the surface of the plastic part, and the molded parts and the transfer are formed. The hardened layer on the back decorative film cannot be aligned with the ink layer, and the thickness of the hardened layer is within 5 micrometers (5 μm), and generally cannot withstand severe external force scratches. After a long period of use, the hardened layer will be worn, resulting in reduced gloss, even color patterns. It will also be subject to wear and tear. Moreover, the release layer and the carrier layer can not be reused after being peeled off, and the production cost is high.

In another conventional technique, a film 7 is placed in a cutting die 10 by a transfer device 30, as disclosed in U.S. Patent No. 5,800,759, the disclosure of which is incorporated herein by reference. The cutting die 10 is used to cut the film 7 into an appropriate shape or size. Next, the conveying device 30 takes out the cut film 7 from the cutting die 10 and places it in the shooting die 1. Since the film 7 located in the injection mold 1 is not positioned, when the glue is applied, the flow of the glue and the resulting pressure tend to cause the film 7 to be displaced or wrinkled, and the film 7 cannot be It is completely covered in the plastic part, and since the film 7 needs to be cut into an appropriate shape or size, it must have a certain thickness to maintain the shape after cutting, which leads to an increase in cost. Referring to Figure 11, there is shown a schematic cross-sectional view of a product made in the U.S. Patent No. 5,800,759, wherein the edge 710 of the plastic member 700 is not completely covered by the decorative film 800, and the processing steps of the molding method are disclosed. Complex, finished products are unstable and unattractive.

In view of the above, it is necessary to provide an in-mold decorative molding method in which the processing steps are simple and the quality of the finished product is stable.

An in-mold decorative molding method comprising the steps of: providing an attached film; feeding the attached film into an in-mold decorative molding die, the in-mold decorative molding die comprising a master mold and a male mold, and the male mold is divided into molds a cutting portion is arranged on the surface, the mother mold is opened with a cavity, and a selected area of the attached film is placed in the cavity; the first clamping is performed, and the parting surface of the male mold and the parting surface of the female mold are Not in contact; apply glue to the cavity to fill it 90%-99.5% of the filling amount; the second clamping is performed, so that the parting surface of the male mold is in contact with the parting surface of the female mold, and the remaining filling amount is filled with the injection molding at the same time as the second clamping. At the same time, under the extrusion of the parting surface of the male mold, the cutting portion of the male mold cuts the selected area of the attached film from the attached film; when the filling is completed, the injection of the glue is stopped; and the molded article is taken out by the mold opening.

15‧‧‧film delivery device

30‧‧‧Male model

24, 24' ‧ ‧ grooves

100, 500, 120‧‧ ‧ attached film

200, 300‧‧‧ substrate

202, 302‧‧‧ side edge

102, 122‧‧‧ base layer

106, 126‧‧ ‧ adhesive layer

303‧‧‧First circumferential end face

128‧‧‧Second decorative layer

1041, 1042, 1043‧‧‧ ink layer

25‧‧‧Female model

22‧‧‧Move

26, 26'‧‧‧ Cutting Department

201, 301‧‧‧ top

10, 20‧‧‧ molded products

104‧‧‧Decorative layer

501‧‧‧second peripheral end face

124‧‧‧First decorative layer

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic cross-sectional view showing a mold used in the in-mold decorative molding method of the present invention.

2 is a schematic cross-sectional view showing another mold used in the in-mold decoration molding method of the present invention.

Figure 3 shows the mold clamping of Figure 1 for the first time. There is no contact between the male mold and the female mold, and the adhesive is ready for injection.

4 is a second clamping of the mold of FIG. 3 to complete the injection molding, and the cutting portion of the male mold cuts the attached film.

Fig. 5 is a flow chart showing a first embodiment of the in-mold decoration molding method of the present invention.

Fig. 6 is a flow chart showing a second embodiment of the in-mold decoration molding method of the present invention.

Fig. 7A is a perspective view showing a molded article produced by the in-mold decoration molding method of the present invention.

Fig. 7B is a cross-sectional view taken along line 7B-7B of Fig. 7A.

Fig. 8A is a perspective view showing another molded article produced by the in-mold decoration molding method of the present invention.

Fig. 8B is a cross-sectional view taken along line 8B-8B of Fig. 8A.

Figure 9A is a cross-sectional view taken along line 9-9 of Figure 7B, showing the in-mold decoration of the present invention. The structure of the attached film.

Fig. 9B is a cross-sectional view taken along line 9-9 of Fig. 7B, showing the decorative layer of the in-mold decorative molding film of the present invention formed of a plurality of ink layers.

Figure 10 is a cross-sectional view showing the structure of another embodiment of the attached film of the present invention.

Figure 11 is a schematic cross-sectional view of a product made in accordance with U.S. Patent No. 508,059,760.

Referring to FIG. 1, the present invention performs in-mold decoration molding using an in-mold decorative molding die, which includes a film feeding device 15, a master mold 25, and a male mold 30.

The film feeding device 15 includes a pair of film transfer wheels and a pair of guide wheels. The pair of film transfer wheels are disposed upstream and downstream of the mold for pulling the film. The guide wheel is used to guide the conveying direction of the film.

The master mold 25 opens the cavity 22 on one side. The master mold 25 has a plurality of exhaust grooves extending from one side of the cavity 22 to the other side for connection with the vacuuming device to adsorb the film fed by the film feeding device 15 to the inner wall of the cavity 22.

A groove 24 is formed on the parting surface of the male mold 30, and a cutting portion 26 is provided on the parting surface of the male mold 30. The male mold 30 includes a fitting portion corresponding to the cavity 22 of the female mold 25. The fitting portion is provided with a rubber injection port penetrating the male mold 30 at a central portion thereof for injecting molten plastic into the cavity 22 of the female mold 25. Referring to Fig. 2, it can be understood that a groove 24' may be formed around the cavity 22 on the parting surface of the master mold 25, and a cutting portion 26' may be formed around the cavity 22.

Referring to FIG. 5, the first embodiment of the in-mold decoration molding method of the present invention comprises the following steps:

Step S102, providing an attached film 100;

In step S104, the film-attaching device 15 is used to pull the attached film 100 and the attached film 100 is sent along the parting surface of the master mold 25 between the master mold 25 and the male mold 30, and is pressed into the branch of the master mold 25. Die surface. A selected area of the attached film 100 is placed against the inner wall of the cavity 22 of the master mold 25, as shown in FIG. In a preferred embodiment, the attaching film 100 is adsorbed to the cavity 22 of the master mold 25 by vacuuming the cavity 22 of the master mold 25.

In step S106, the first clamping is performed, but at this time, the parting surface of the male mold 30 and the parting surface of the master mold 25 are not in contact with each other.

In step S108, the injection is performed, and the glue is applied from the side of the male mold 30 to 90%-99.5% of the total amount of the molding resin filling, and the preferred embodiment is 99.5%, forming a molded article substrate; and attaching to the cavity 22 The film 100 is adhered to the surface of the molded article substrate as shown in FIG.

In step S110, the second clamping is performed to make contact between the parting surface of the male mold 30 and the parting surface of the female mold 25, and the remaining filling amount is filled with the adhesive at the same time as the second clamping, and at the same time, Under the extrusion of the parting surface of the male mold 30, the cutting portion 26 of the male mold 30 cuts the selected area of the attached film 100 adhered to the surface of the molded substrate from the attached film 100, and causes it to be sent. The attached film 100 on the film device 15 is detached.

In step S112, the filling is completed, and the glue is stopped.

Step S114, cooling.

Step S116, opening the mold, ejecting the molded product, and obtaining the attached film on the surface At the same time, the film feeding device 15 removes the portion of the attaching film 100 located in the molding cycle from between the male and female molds 30, 20, and starts the next molding cycle.

Referring to FIG. 6, a second embodiment of the in-mold decoration molding method of the present invention comprises the following steps:

Step S202, providing a continuous attached film 100;

In step S204, the continuous attaching film 100 is pulled by the film feeding device 15 and the attached film 100 is sent along the parting surface of the master mold 25 between the master mold 25 and the male mold 30 and pressed into the master mold 25 On the parting surface. A selected area of the attached film 100 is placed against the cavity 22 of the master mold 25, as shown in FIG. The mold is provided with a cutting portion 26 or 26'.

In step S206, the mold clamping is performed.

In step S208, a shot is applied to form a molded article substrate on the attaching film 100 in the cavity 22, as shown in FIG.

In step S210, the selected area of the attached film 100 adhered to the surface of the molded article substrate is cut from the continuous attached film 100 by the cutting portion 26 or 26' of the mold to be bonded to the continuous attached film 100. Get rid of.

In step S212, the filling is completed, and the glue is stopped.

Step S214, cooling.

In step S216, the mold is opened and the molded article substrate is ejected to obtain a molded article having the attached film 100 adhered to the surface.

In the above-mentioned in-mold decoration molding method, the attached film is automatically fed by a film feeding device, and the continuous film feeding of the attached film is realized, and the film is directly cut in the mold, thereby not only obtaining a plastic member which is firmly colored and is not easily worn. Moreover, continuous automatic production can be realized, the production efficiency is improved, the quality of the finished product is improved, and the aesthetic effect is increased.

Referring to FIGS. 7A and 7B, a molded article 10 is formed by the above-described in-mold decoration molding method. The molded article 10 includes a substrate 200 and an attached film 100 having a top surface 201 and a side edge. Around the top surface 201, the attachment film 100 is attached to the substrate 200 and completely covers the top surface 201.

Referring to FIGS. 8A and 8B, another molded article 20 is formed by the above-described in-mold decoration molding method. The molded article 20 includes a substrate 300 and an attached film 500 having a top surface 301 and one side. The edge 302 surrounds the top surface 301, and the attachment film 500 is attached to the substrate 300 and completely covers the top surface 301 and the side edge 302.

In this embodiment, the attaching film 500 has a second peripheral end surface 501 having a first peripheral end surface 303, a second peripheral end surface 501 of the attaching film 500 and the first peripheral end surface. The 303 is engaged, and the second peripheral end surface 501 of the attached film 500 is substantially flush with the first peripheral end surface 303 of the substrate 300.

9A is a cross-sectional view taken along line 9-9 of FIG. 7B. The attached film 100 includes a base layer 102, a decorative layer 104, and an adhesive layer 106.

The base layer 102 is attached to the film feeding device and attached to the surface of the substrate 200 after molding, and protects the decorative layer 104 therein to protect the decorative layer 104 and the substrate 200 from abrasion and scratching. The base layer 102 is generally composed of polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), oriented polypropylene. a single layer film made of one or two or more kinds of polymer materials such as (OPP), polyvinyl chloride (PVC), or a laminated film or copolymer made of two or more kinds selected from the foregoing materials. membrane. Since the in-mold decoration molding method of the present invention does not need to first cut the attached film 100, 500 into an appropriate shape or size, the film feeding device 15 performs automatic film feeding, and the attached film 100, 500 is sent. The support of the membrane device 15 allows the thickness of the base layer of the attached films 100, 500 to be relatively thin, preferably between 0.01 mm and 0.125 mm, to save cost.

A decorative layer 104 that can display a pattern, a color, or the like is formed on the inner surface of the base layer 102. Referring to FIG. 9B, the decorative layer 104 is formed by screen printing a plurality of ink layers 1041, 1042, and 1043 on the base layer 102, each ink layer having a thickness of between 0.005 mm and 0.02 mm. In addition, a metal film layer made of one or more of aluminum, chromium, copper, nickel, indium, and tin may be provided as the decorative layer 104 by a vacuum evaporation method, a vacuum sputtering method, or the like. 104 allows the surface of the molded article to exhibit a metallic color.

The adhesive layer 106 has the effect of bonding the attached film 100 to the molded article substrate 200, and preferably uses acrylic resin, nitrocellulose resin, polyurethane resin, chlorinated rubber resin, vinyl chloride- Vinyl acetate copolymer resin, polyamide resin, polyester resin, epoxy resin, polycarbonate resin, olefin resin, acrylonitrile-butene-styrene resin, etc. as the material of the adhesive layer 106 . The adhesive layer 106 achieves a better overall effect in terms of adhesion and drying after printing. The method of forming the adhesive layer 106 may be any general printing method such as gravure printing, screen printing, and offset printing, or a method such as spraying, brushing, or the like.

In the embodiment, the base layer 102 of the attached film 100 is transparent or translucent. Used to visualize the pattern and color of the decorative layer 104.

The attaching film 100 in the present invention may include only the base layer 102 and the adhesive layer 106. The adhesive layer 106 is adhered to the substrate 200. The base layer 102 is located on the other side of the adhesive layer 106 with respect to the substrate 200, and the original color of the substrate 200 is visualized by the transparent base layer 102. It will be apparent that the base layer 102 can also be made of a material having a color which, after being attached to the surface of the substrate 200, causes the molded article to exhibit the color of the base layer 102.

Referring to FIG. 10, the molded article 10 formed by the above-described in-mold decoration molding method may include another aspect of the attachment film 120 attached to the substrate 200. The adhesive film 120 includes a base layer 122, a first decorative layer 124, a second decorative layer 128, and an adhesive layer 126. The adhesive layer 126 is adhered to the substrate 200. The first decorative layer 124 is located on the base layer. Between 122 and the adhesive layer 126, the base layer 122 is located on the other side of the first decorative layer 124 with respect to the adhesive layer 126, and the second decorative layer 128 is located on the upper surface of the base layer 122. The first decorative layer 124 and the second decorative layer 128 are formed by screen printing a plurality of ink layers on the base layer 122, each ink layer having a thickness of between 0.005 mm and 0.02 mm.

In summary, the present invention complies with the requirements of the invention patent and submits a patent application according to law. The above description is only the preferred embodiment of the present invention, and equivalent modifications or variations made by those skilled in the art will be included in the following claims.

Claims (4)

An in-mold decorative molding method comprising the steps of: providing an attached film; feeding the attached film into an in-mold decorative molding die, the in-mold decorative molding die comprising a master mold and a male mold, and the male mold is divided into molds a cutting portion is arranged on the surface, the mother mold is opened with a cavity, and a selected area of the attached film is placed in the cavity; the first clamping is performed, and the parting surface of the male mold and the parting surface of the female mold are No contact; the glue is applied to the cavity to fill 90%-99.5% of the required filling amount; the second clamping is performed so that the parting surface of the male mold is in contact with the parting surface of the female mold, in the second joint At the same time, the remaining filling amount is filled by the injection molding, and at the same time, under the extrusion of the split surface of the male mold, the cutting portion of the male mold cuts the selected region of the attached film from the attached film; the filling is completed. , stop the injection of glue; open the mold to take out the molded part. The in-mold decoration molding method according to claim 1, wherein the attachment film comprises a base layer and an adhesive layer. The in-mold decoration molding method according to claim 2, wherein the attachment film further comprises a decorative layer between the base layer and the adhesive layer. The in-mold decorative molding method according to claim 2, wherein the base layer is made of polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA). ), one or two or more kinds of polymer materials of oriented polypropylene (OPP) and polyvinyl chloride (PVC).