WO2002078937A9 - Preliminary forming device, preliminary forming method using the device, and main forming method - Google Patents

Abstract

A preliminary forming device capable of efficiently applying a pattern even on a deep-drawn or a complicatedly shaped formed product without applying any special working on an existing metal mold of a main forming device, a preliminary forming method using the preliminary forming device, and a main forming method; the preliminary forming device, comprising a film feeder (25) feeding a film with pattern (4) to a preliminary forming part (F) for performing a preliminary forming, a heater (30) movable closely to and away from the preliminary forming part and heating the film with pattern before the preliminary forming so as to be plasticized at the preliminary forming part (F), a preliminary forming mold (22) for preliminarily forming the film with pattern, and a film feeder (50) to feed a forming film for releasing the film from the mold after the preliminary forming of the film with pattern and inserting the film into a main forming mold, wherein, after the forming film is inserted into the main forming mold, resin is fed to provide a formed product with pattern, the preliminary forming being performed by vacuum forming or compressed air forming.

Description

 PREFORMING APPARATUS, PREFORMING METHOD USING THE SAME, AND MAIN FORMING METHOD

 In the present invention, a pre-forming apparatus for forming a molded film to obtain a molded article with a picture by mounting a painted film on the main mold of the main molding apparatus and supplying a resin to the main mold and a film forming method The present invention relates to a preforming method and a main molding method using That is, the present invention relates to main molding such as so-called insert molding in which the picture sheet itself adheres to the surface of the product or in-mold molding method in which the picture of the picture sheet is transferred to the surface of the product And it is used for preforming using this.

Background art

 Heretofore, as an in-mold molding method for attempting to rationalize transfer film waste etc., for example, the method described in JP-A-8-25414 is known. According to the technique described in the same publication, a part of a mold used for injection molding is cut by the thickness of a transfer film to enable partial transfer to a molded product.

 In addition, as a method which can be used for both in-mold and insert molding, and as a method of improving the positional accuracy of the painted film with respect to the mold, the method disclosed in JP-A-59-220232 is known. There is. According to the same publication, a film with a picture is placed on the mold of the molding machine, and the film with a radiation heater is softened on the mold with a radiation heater to perform preforming by vacuum forming. Also, the position accuracy of molded products is good. Then, after preforming, the male die is lowered to carry out injection molding.

However, in the molding method according to the first publication, there is a problem that the cost is increased because a part of the mold needs to be scraped instead of using the usual mold as it is. Also, with this method, it is impossible to cope with deep drawing or moldings with complicated shapes. It was

 On the other hand, in the molding method according to the second publication, since this preforming is performed with the same mold as injection molding, it is necessary to open the cooled mold after the injection molding, heat the film, and perform vacuum molding etc. is there. Since injection molding can not be performed during preforming, overall production efficiency is reduced. Also, in order to perform vacuum forming, it is necessary to form an air vent hole in the mold for injection molding, and the pressure in the mold is lowered depending on the thickness of the film, which causes problems in the quality of the molded product. There is also a disadvantage.

 As a method of manufacturing a parabolic antenna reflecting mirror in which a multilayer film having a metal foil reflecting layer is preformed separately from the main mold and then the main molding is performed, Japanese Patent Laid-Open No. 6-61 2 7 is known. It is done. However, this publication does not use a picture film and is not related to the present invention, but is listed for reference.

 In view of such a conventional actual condition, the object of the present invention is to make the design efficient even for deep-drawing or complex-shaped molded products without subjecting the existing mold in the main molding apparatus to special processing. It is an object of the present invention to provide a pre-forming apparatus which makes it possible to apply, and a pre-forming method and a main forming method using the same.

Disclosure of the invention

 In order to achieve the above object, the feature of the preforming apparatus according to the present invention is to attach a painted film to the main mold of the main molding apparatus and to obtain a molded article with a picture by supplying a resin to the main mold. A film supply device for supplying the painted film to a preforming section for performing preforming, proximity to the preforming section, and separation movement, and also before the preforming. A heating device for heating the coated film so as to plasticize it in the preforming section, a preforming mold for preforming the painted film, and a die for removing the film after preforming the painted film. And a film die-cutting device for producing a molded film to be inserted into the main mold.

On the other hand, the features of the preforming method using the preforming apparatus of the present invention are: The pictured film is supplied to the preforming part by the film feeding device, and a heating device is brought close to the preforming part to plasticize the pictured film, and then the pictured film plasticized by the preformed mold is used. An object of the present invention is to make a formed film for punching into a main forming die by preforming and further die-forming a formed film. According to the features of the preforming apparatus according to the present invention and the features of the preforming method according to the present invention, preforming is performed using a preforming mold prior to a forming step for producing a formed product. Since the painted film is preformed using a preforming mold and then cut out to form a molded film, when the molded film is attached to the main mold, the positional deviation of the pattern is very small. Since pre-forming and die-cutting are performed in parallel with main forming, combined with the ability to quickly attach the forming film to the main forming die, there is almost no loss of forming time, and production efficiency is improved.

 Further, according to the present invention, since the existing mold and molding machine can be used, there is no possibility that the quality of the molded product will be deteriorated due to a pressure drop or the like. And since it is sufficient to use a pre-molding apparatus in combination with the existing molding machine, the implementation is extremely easy.

 After the pictured film is plasticized by bringing the heating device close to the preformed part, the pictured film plasticized with the preformed mold is preformed, so that it is possible to cope with deep drawing with high positional accuracy. In addition, it is sufficient for the preforming mold to withstand the heat in the preforming, and it is sufficient if at least a part of the main mold and the main part are substantially the same. Therefore, the preforming mold, which is a preforming mold, can be made very inexpensively using a wood mold, a resin or the like.

By the way, in the invention described in the third publication, since the multilayer film is heated only at the same time as pressurization without being softened by heating in advance, its shape is gentle and simple. That is, since the object is a reflecting mirror and has a metal reflecting layer, it is possible to pre-form a film having a pattern by means of plasticizing the film by a heating device in order to make it compatible with deep drawing and the like. It is clear that the idea is different. In the above-mentioned preforming apparatus, the film die-cutting apparatus is provided with a saw-like blade And is desirable. The pressing force is concentrated on the peaks of the respective chevrons constituting the saw shape, so that the painted film can be punched out more efficiently and reliably. Then, the film die-extracting device comprises: a die-extractable unit capable of causing the blade to move close to the preforming portion; and an elastic body attached to an opposing surface of the preforming die opposed to the blade. By configuring more, it is possible to prevent damage to the cutting blade having a peak.

 In an embodiment of the present invention, the preforming mold and the film die-cutting device are selectively movable close to and away from the preforming portion. By making the molding operation and the die-cutting operation independent, each operation can be performed reliably, and furthermore, the maintainability can be improved.

 By forming the preforming mold with a pair of molds adjacent to each other with the preforming portion interposed therebetween, unnecessary stress and unnecessary displacement of the film can be prevented, and the positional accuracy between the pattern and the three-dimensional shape can be improved. It is possible to perform preforming while maintaining it. In particular, by providing a clamp member for sandwiching the picture film in the preforming part, the film holding and film forming become independent, and a more uniform drawing across the entire circumference of the film. Processing becomes possible.

 It is desirable that the painted film be oriented substantially horizontally in the preforming section. Even if the drooping occurs due to the plasticization of the painted film due to heating, the drooping of the film does not deviate in the plane direction of the film as in the vertical state of the film. It is because it can be kept good. In this case, in particular, it is desirable that the lower preforming mold forming the preforming mold be a male mold and be brought close to the preforming portion in the upward direction. It is possible to perform preforming with high accuracy by stabilizing the horizontal position by supporting the hanging part, which has become unstable in position, from the bottom first and then raising the male mold while maintaining the supporting state.

In the embodiment of the present invention, after the pictured film is disposed between the preforming mold and the heating device, and the pictured film is plasticized by the heat generation of the heating device to perform the preforming, the film die removal is performed. The preforming die is preformed with a cutting blade provided in the apparatus The molded film is made by pressing the pictured film supported by the. That is, since the picture-embedded film is sandwiched between the preforming mold and the cutter, the preforming mold is effectively used.

 The preforming is performed by, for example, vacuum forming or pressure forming. The painted film may have a substrate, a pattern and a protective layer of the pattern. When the painted film has a regular pattern, the film supply device delivers the painted film one step at a time. If the control device of the preforming device is subordinate to the timing of the control device of the forming device, control of the preforming device can be performed more reliably.

 The characteristics of the forming method using the pre-forming apparatus described in the above feature are as follows: after pre-forming the painted film by a pre-forming mold at least a part of which is substantially the same as the main forming mold of the main forming apparatus; Then, a molded film is produced by the preforming apparatus, and the molded film is inserted into the main mold of the main molding apparatus to supply the resin. Here, recycling is further promoted by making the resin of the painted film the same material as the supplied resin. Further, the present invention can be suitably carried out when the molding is a method for molding a thermoplastic resin.

 As described above, according to the above-described respective features of the above-described preforming apparatus and the preforming method and the main forming method using the same according to the present invention, it is possible to achieve deep processing without subjecting the existing mold in the main forming apparatus It has become possible to apply patterns efficiently even to squeezed and complex shaped molded products. Other objects, constitutions, and effects of the present invention will be clarified in the section "Best Mode for Carrying Out the Invention" described below.

Brief description of the drawings

 FIG. 1 is a side view of a molding system according to the present invention.

 FIG. 2 is a cross-sectional view taken along line A-A of FIG.

 FIG. 3 is a block diagram of a molding system according to the present invention.

Fig. 4 (a) is a perspective view of a molded product with the pattern on the inside, and (b) is a pattern with the pattern on the outside It is a perspective view of the molded article.

 FIG. 5 is an enlarged cross-sectional view of a molded product molded using a painted film.

 Figure 6 is a cross-sectional view near the preforming mold showing the procedure of preforming by vacuum forming. (A) shows the start of heating, (b) shows the film formed by suction, and (c) shows the formed It is a figure which each shows the time of cutting | disconnection of a film.

 FIG. 7 is an enlarged cross-sectional view in the vicinity of the blade of FIG. 6, where (a) shows a state before cutting and (b) shows a state at the time of cutting.

 Fig. 8 is a cross-sectional view showing conveyance and molding of the formed film, where (a) is the removal of the formed film from the preforming mold, (b) is the mounting of the formed film to the main mold, and (c) is the It is a figure which shows injection | pouring of resin, respectively.

 FIG. 9 is a view corresponding to FIG. 2 showing a molding system according to a second embodiment of the present invention. FIG. 10 is a cross-sectional view showing the procedure of preforming by pressure forming according to the third embodiment of the present invention, wherein (a) is at the start of heating, (b) is to pressure and suction. (C) shows the cutting of the formed film.

 Fig. 11 (a) shows a state in which the formed film is further cut after Fig. 10, and (b) shows a state in which the formed film is taken out.

 FIG. 12 is a front view of a preforming apparatus according to a fourth embodiment of the present invention.

 FIG. 13 is a cross-sectional view taken along line B-B of FIG.

 FIG. 14 is a plan view of FIG.

 FIG. 15 is a plan view showing the relationship between a preforming apparatus, a formed film conveying apparatus, and a main forming apparatus according to a fourth embodiment.

 FIG. 16 is a front view of an essential part of a preforming apparatus according to a fourth embodiment.

 FIG. 17 is a front view of an essential part showing a preforming procedure according to a fourth embodiment.

 FIG. 18 is a front view of an essential part showing a preforming procedure according to a fourth embodiment.

Fig. 19 (a) is a longitudinal sectional view in the circle indicated by the symbol c in Fig. 18 (a), and (b) is (a) is a figure which shows the cutting | disconnection state of (a), (c) is a front view of (a).

 FIG. 20 is a side view of the vicinity of the tip of the extraction blade.

 FIG. 21 is a side view showing the inclined state of the extraction blade.

 FIG. 22 is a cross-sectional view showing another embodiment of a mold.

BEST MODE FOR CARRYING OUT THE INVENTION

 The invention will now be described in more detail with reference to the accompanying drawings. First, the first embodiment of the present invention will be described with reference to FIGS.

 As shown in FIGS. 1 to 3, a molding system 1 according to the present invention includes a main molding device 2 and a preliminary molding device 3. The preforming apparatus 3 forms the formed film 5 to be inserted into the main forming apparatus 2 by forming and punching the roll-shaped picture film 4.

 The main molding device 2 includes a clamping device 11 and an injection device 16. Further, the mold clamping device 11 is provided with a movable platen 11 a that can slide via four rods 11 c and a stationary platen 11 b that faces the movable platen 11 a. A movable mold 12 and a fixed mold 13 which are main molds are attached to the movable board 11 a and the fixed board lib, respectively, and injection is performed between the movable mold 12 and the fixed mold 13. Main molding is performed as molding. Actuator 1 4 and the movable plate 1 1 a Thermoplasticized from the injection device 16 through the hole formed in the movable unit 1 4 between the movable type 1 2 and the fixed type 1 3 which are opened and closed via 1 a Resin is supplied.

The preforming apparatus 3 generally includes a frame 21, a preforming mold 22, a film supply apparatus 25, a heating and forming means 30, a film die removing apparatus 35, and a formed film conveying apparatus 50. Also, the preforming device 3 is straddled through the lower part of the frame 21 and above the movable plate 11a of the main molding device 2 which is configured as a separate ready-made product via the legs 21c. I'm sorry. The preform 1 of FIG. 6 and the movable die 12 of FIG. 8 in this embodiment are molded articles having a painted film 1 0 1 inside the curve of the resin 1 0 5 as shown in FIG. 4 (a). 0 is to be molded. However, the present invention is as shown in FIG. 4 (b). Alternatively, a molded article 100 having the painted film 101 on the curved outer side of the resin 105 may be molded. Further, the sheet is not limited to these, and the sheet may be formed into a more complicated shape or a planar shape.

 The film with picture 4 is formed by printing on a substrate made of various resin films or the like. A design is a picture, a figure, a character, a symbol, etc., or any combination thereof. Also, if the picture is damaged by the injected resin at the time of molding, as shown in FIG. 5, using the picture film 101 provided with the protective layer 104 for the picture 103 on the picture 103 side of the substrate 102. Also good. In this case, the resin 105 is injected to the protective layer 104 side so that the substrate 102 side is the surface, but the protective layer 104 side may be the surface. In the latter case, a hard coat processed layer of a thermosetting resin such as urethane may be used as the protective layer 104.

 As the resin 105 supplied from the injection device 16 in the main molding device 2, AB S, PP, PE, P S, PET, acrylic, PVC or the like can be used. On the other hand, these materials can also be used as the base material 102. And, by using the resin 105, the base material 102, the pattern 103 and the protective layer 104 as the same or the same family of resins, it is possible to promote the recycling of plastic products more easily. The same case refers to, for example, the case where the resin 105 of ABS is used for the base material 102, the pattern 103, and the protective layer 104 of ABS. Further, the case of the same family means, for example, the case of using resin 105 of ABS for base 102 of acrylic or styrene, pattern 103 and protective layer 104, and the like.

The preforming mold 22 and the film feeding device 25 are attached to the center of the frame 21. The film feeding device 25 comprises: a feeding bobbin 26 on which the picture film 4 is wound; a plurality of small rollers 28 having the picture film 4 straddling the opening side of the preforming mold 22; and one pitch of the picture film 4 It has a phototube 29 for feeding out the process, and a take-up povin 27 for drawing a molded film 4 after punching. Winding bobbin 27 has a winding side clutch 27a through a winding side motor 27b It is driven by the Also, the supply povin 26 is back-tensioned by the supply type motor 26 b via the supply side clutch 26 a.

 As shown in FIG. 6, the preforming die 22 is a portion for forming the formed film 5, and a mold portion 22 a, and an air passing the air in the preforming die 22 by the first pump 31. Edge 2 which sandwiches the picture film 4 by the cooperation of the passage 2 2 b and the elastic layer 3 9

2 c and is equipped. The preforming mold 22 can be easily made of a thermosetting resin or the like using the wood mold at the time of making the movable mold 1 2. That is, it is sufficient for the preforming mold 22 to have the property and the strength not to be deformed at the time of heating by the heating part 38 of the heat forming means 30 and there is an advantage that it can be manufactured very simply. Further, the movable mold 12 and the preforming mold 22 do not need to be identical to each other, and it is sufficient if the mold 22a and the mold 12a corresponding to the molded film 5 are common or substantially identical. .

 As shown in FIGS. 1 and 2, in the heat forming means 30 for preforming and punching the picture film 4 to form the formed film 5, the four bearings supported by the overhang 2 lb 3 3 3 The head 33 is slidably inserted into a, the heating head 32 is attached to the rod 33, and the heating head 32, which is a heating device for the film, is preformed by the horizontal actuator 34. Move in perspective with respect to type 2. The film die-cut-out device 35 in the heating head 32 comprises a head base 36 and an extruded portion 37 which penetrates the head base 36 in an arc or square shape according to the molding. The head base 36 and the push-out portion 37 are provided with heating portions 38 and elastic layers 39 that are attached independently to each other on the surface of the push-out portion 37. And an annular extraction blade 40. The push-out unit 37 is pushed toward the picture film 4 by the rotation of the cam 41. As shown in Figures 6 and 7, the cutting blade 40 is usually an elastic layer

Although it is protected not to protrude from the surface by the numeral 9, it is possible to push the picture film 4 by deforming the inertia layer 39 so that it becomes thinner by pushing the extruded part 3 7 to the molded picture film 4 side. Cut into The blade is used for Thomson processing or sealing processing. As shown in FIGS. 3 and 6, the cam 41 is driven and rotated by the motor 42, and functions as a push-out mechanism that pushes out the push-out portion 37. Note that the push-out mechanism can also be configured by hydraulic and pneumatic actuators. The heating unit 38 is a heater or the like made of a nichrome wire or carbon, and generates heat when power is supplied from the heating power supply 43 to thermoplasticize the painted film 4. The elastic layer 39 may be made of heat resistant silicone rubber or the like.

 As shown in FIGS. 1 to 3 and 8, the formed film transfer device 50 for taking out the formed film 5 formed by the heat forming means 30 from the preforming mold 22 and moving it to the movable die 12 The suction head 55 is moved up and down via a rod 51 supported freely on slide 21 via two bearings 51 supported on the part 2 1 a and a vertical actuator 52. . Repeater at the end of the rod 5 1, vertical actuator 5 2,

5 3 is attached, and the adsorption head 5 5 can be moved in the perspective direction with respect to the preforming mold 22 through the cross-over heater 54.

 A large number of fine holes are formed on the surface of the adsorption head 55, and the molded film 5 is adsorbed by suction by the adsorption pump 56. Further, the suction head 55 is charged by the charging device 57, and when the molded film 5 is suctioned and conveyed, the entire molded film 5 is charged to electrostatically adsorb the molded film 5 to the movable die 12. The adsorption head 55 may be formed three-dimensionally according to the three-dimensional shape of the molded film 5, or a suction disk made of rubber or resin may be provided on the surface and adsorbed at a plurality of places.

 The movable mold 12, which is a molding mold, and the actuator 14, which opens and closes the fixed mold 13, are driven by switching the hydraulic direction of the first solenoid valve 46a. Also, this first solenoid valve 4

The sequence control of 6 a and the whole of the injection device 16 is performed by the first control device 4 7 a. On the other hand, the horizontal actuator 34 has a second solenoid valve 46b, the horizontal actuator 54 has a third solenoid valve 46c, the vertical actuator 52 has a fourth solenoid valve 46d. The motors, pumps, etc. of the second solenoid valve 4 6 b, the third solenoid valve 4 6 c, the fourth solenoid valve 4 6 d and the preforming device 3 are controlled by the second controller 4 7 b, respectively. Control. And control of the 2nd control device 47 b is performed subordinate to control timing of the 1st control device 4 7 a, and operation of the preforming device 3 cooperates with operation of the main forming device 2 surely. It will be.

 Next, the operation of the above-described molding system 1 will be described. First, the picture film 4 is removed by the take-off motor 27 b and the winding povin 27, and when the pitch mark of the picture film 4 is detected by the phototube 2 9, the removal bobbin 27 stands still. . At this time, injection molding in the main molding device 2 is performed in parallel. Next, as shown in FIG. 6 (a), the heating head 32 is close to the preforming mold 22, and the picture film 4 is sandwiched between the edge 22 c and the elastic layer 39, The painted film 4 is plasticized (softened) by the heating unit 38, which is heated by energization. When the plasticization is completed in + minutes, the suction by the first pump 31 is performed, and the picture film 4 is vacuum formed as shown in FIG. 6 (b). After that, the cam 41 is rotated to push the extrusion part 3 7 to the preforming mold 2 2 side, and as shown in FIG. 6 (c) and FIG. Form By performing the punching process with the blade after molding, it is possible to prevent the displacement of the cutting position, and as a result, it is possible to prevent the displacement of the pattern relative to the molded product.

 After that, the horizontal actuator 34 in FIG. 1 is driven to separate the heating head 32 from the preforming mold 22, and as shown in FIG. 8 (a), the adsorption head 55 is preformed. 2 2, Lower the heating head 32. Then, the horizontal actuator 54 is extended to bring the molded film 5 into contact with the adsorption head 55 and operate the suction pump 56 to adsorb the molded film 5 onto the surface of the adsorption head 55. Reduce the factor 5 4

The molding is completed between the main mold 2 and the movable mold 12 by extending the vertical actuator 52 to the timing when the movable mold 12 and the fixed mold 13 are released. Irum 5 is transported by suction head 55. During this conveyance, the forming film 5 is charged by the charging device 5 7, and the transverse actuator 5 4 is extended to form the movable mold 12. When the film 5 is brought close, as shown in FIG. 8 (b), the formed film 5 is attracted to the mold 12a of the movable die 12 by static electricity.

 Next, the vertical actuator 52 is shrunk to retract the suction head 55 from the vicinity of the movable mold 12, and the actuator 14 in FIG. 3 is extended, as shown in FIG. 8 (c). Close movable type 1 2 and fixed type 1 3. Then, by injecting and supplying a plasticized resin in a state in which the injection device 16 is in contact with the fixed mold 13, the resin is filled in the space between the movable mold 12 and the molded film 5 and the fixed mold 13. The product is filled and a molded product with a picture is completed. The present invention can be carried out as insert molding in which the base of the film is not removed after molding, or as in-mold molding in which the base of the film configured as a transfer foil is removed.

 Next, still another embodiment of the present invention will be described below. The same members as those in the above-described embodiment are denoted by the same reference numerals.

 In the second embodiment shown in FIG. 9, the preforming device 3 is placed laterally to the main molding device 2. In this embodiment, the preforming mold 22, the feeding povin 26, the take-up bobbin 27 and the actuator 59 are attached to the frame 58 movable by a caster or the like. The preforming mold 22 is disposed at the same height as the movable mold 12 and moves the molded film 5 formed by the preforming mold 22 to the movable mold 12 by the expansion and contraction of the actuator 59. . If the molding system 1 is configured using the preforming apparatus 3 according to the present embodiment, the overall height is almost the same as before, so that there is an advantage that it is difficult to be constrained by the layout in a factory. There is also an advantage that installation and removal of the preforming device 3 can be performed with respect to the existing main forming device 2.

The second embodiment shown in FIGS. 10 and 11 is different in that a preforming mold 22 is used as a mold for pressure forming, and a second extraction blade 44 is provided in addition to the extraction blade 40. As shown in Fig. 10 (a), while the air passage 36a is formed in the head base 36, the heating unit 38, and the elastic layer 39, the second pump 45 for suction and compression is used. It is connected. First, the picture film 4 is sandwiched between the preforming mold 22 and the elastic layer 39, and compressed air is fed in by the first pump 31. The pictured film 4 is brought into close contact with the elastic layer 39 by suction with a second pump 45, and the pictured film 4 is plasticized by the heat generated by the heating unit 38.

 When plastic film 4 is sufficiently plasticized, as shown in Fig. 10 (b), picture film 4 is formed by suction by first pump 31 and feeding compressed air by second pump 45. Do. Further, as shown in FIG. 10 (c), the cam 41 is driven to cut the pictorial film 4 with the blade 40 to form the molded film 5.

 After that, as shown in Fig. 1 1 (a) and Fig. 1, the picture film 4 is further extended by further extending the horizontal actuator 34 and pressing the second extraction blade 44 to the edge 22 c. Cut to form a second formed film 6. Thereafter, the heating head 32 is opened and the molded film 5 and the second molded film 6 are removed from the preforming mold 22. By removing the second molded film 6 as well, it is also easy to take up and remove the painted film 4 by the unrolling povin 27. Removal of the second molded film 6 can be performed by an apparatus similar to the above-mentioned molded film conveying apparatus 50. The punching of the second formed film 6 according to the present embodiment can also be applied when preparing a sheet for forming a painted film shown in FIG. In addition, the present embodiment can be applied to the vacuum forming described in the first embodiment.

 Next, a fourth embodiment of the present invention will be described with reference to FIGS. The present embodiment is the same as the second embodiment in that the preforming apparatus 3 is placed on the side of the main forming apparatus 2, but the painted film 4 is oriented substantially horizontally in the preforming section and The difference is that the preforming mold and the blade are separate. In the present embodiment, the molded product is a basin, and the deep-drawn molded film 5 is formed, and a picture is provided on the inner surface of the basin by insert molding.

As shown in FIGS. 12 to 16, the preforming device 3 generally supplies a film 4 with a picture to the frame 61 and winds the film feeder 62 that winds up the film, and clamps the picture 4 with a film at the preforming portion. Clamp member 68, a heating device 70 for heating the picture film 4, a lower preforming unit 7 6 for preforming each other, and an upper spare It has a molding die 82 and a die removal die 91 for punching. Frame 61 passes two cross members 61c, 61c between a pair of lower frames 61b, 61b raised on frame base 61a, and an opening A pair of upper frames 61 e and 61 e are provided on the horizontal partition plate 61 d having the opening of 6 I f.

 In the film supply device 62, the picture film 4 is supplied to the air clamp shafts 62a and 62b disposed on the left and right of the lower part of the frame 61 as the supply side film roll 4a and the film side 4b. Each is attached and arranged. Also, a back tension and a back tension are applied to the air lamp shaft 62a by the drive mechanism 63, and a winding tension is applied to the air clamp shaft 62b by the drive mechanism 63. Ru. The picture film 4 supplied from the supply side film roll 4a passes through the rocking roller 66a, the photoelectric tube 29 and the plurality of rollers to reach the supply port 64 and crosses the preforming part F horizontally. The paper passes between the vertical rollers 6 5 and 6 5, passes through the swinging roller 6 7 a and a plurality of rollers, and is taken off to the take-up side film roll 4 b. The swinging roller 66a is at the end of the arm swinging around the swinging shaft 66b, and the swinging roller 67a is at the end of the arm swinging around the swinging shaft 67b. , Are arranged respectively.

 The clamp member 68 is made of a steel plate or a heat-resistant material, and has a through hole 68a for passing the lower preforming mold 80, the upper preforming mold 89, or the extraction blade 99. Further, each clamp member 68 is supported by an actuator 69 in the form of a square from the upper or lower side, and it is driven to lower and rise to clamp the picture film 4 between the two clamp members 68 and 68. From the relationship of alignment with the phototube 2 9, the position of the coated film 4 at the time of clamping becomes the formed horizontal center plane H, the formed horizontal center plane H is stretched between the supply roller 6 4 and the nip roller 65 It is desirable to match the position of the picture film 4.

The heating device 70 is for heating and softening the painted film 4 of the preforming portion F, and has a plurality of heater tubes 71, and is supported by the heating device support plate 70a. It slides from the left to the right in FIG. 12 via the guide rails 7 4 a and the slider 7 4 b supported between the pair of upper frames 61 1 e and 6 1 e. The slider 7 3 b is slidably fitted on the guide tube 7 3 a, and the slider 7 3 b moves interlockedly with the slider (not shown) in the guide tube 7 3 a which moves laterally with compressed air. . The guide tube 8 3 a, the slider 8 3 b, the guide tube 9 3 a, and the slider 9 3 b also have the same structure as the guide tube 7 3 a and the slider 7 3 b, and respectively have left and right standby positions and a formed vertical center line The heating device 70, the upper preforming mold 8 9, and the extraction blade 9 9 are reciprocated at the operation position where the center is aligned with M.

 A lower preforming mold unit 76 for moving the lower preforming mold 80 up and down is supported by a pair of support plates 7 6 a and 7 6 a fixed to the frame 61. Four ball guides 7 7 a are attached to the plate fixed on the support plate 7 6 a, and the movable plate 7 is mounted on the tip of each guide shaft 7 7 b which slides out and retracts to the pole guide 7 7 a. 9 a is fixed. Then, the movable plate 7 9 a is fixed to the drive port 7 8 b of the actuator 7 8 a fixed to the frame 6 1 side together with the ball guide 7 7 a, and the movable plate 7 8 a The lower preforming mold 80 moves up and down with the movable plate 7 9 a and the spacer 7 9 b by driving.

An upper preforming mold 82 2 for moving the upper preforming mold 89 up and down is supported by a slide plate 85 extending between a pair of upper frames 61 e and 61 e. A guide rail 84a is attached to the upper end of each upper frame 61e, and a slide plate 85 is attached via a slider 84b which slidably moves on the guide rail 84a. The above-mentioned guide tube 83a is fixed to the upper frame 61e near the main molding device 2, and a slider 83b for slidably moving the guide tube 83a is a slide plate via a connecting piece 83c. Fixed to 85, slide the slide plate 85 to the position of the forming vertical center line M and the standby position. A movable plate 8 8 a is supported via four pole guides 8 6 a fixed to the slide plate 85 and guide shafts 86 b slidably inserted in the four pole guides 8 6 a. The drive port 8 7 b of the actuator 8 7 a fixed to the slide plate 85 is attached to the movable plate 8 8 a, The preforming mold 89 is moved up and down together with the movable plate 8 8 a and the spacer 8 8 b. Similarly to the slide plate 85, the die removal unit 9 1 for moving the removal blade 9 up and down is supported by the slide plate 95 that spans between the pair of upper frames 61 1 e and 6 1 e. The slide plate 95 is attached via the slider 94 b which slidably moves the guide rail 84 a. The upper guide tube 9 3 a is fixed to the upper frame 6 1 e on the side far from the main forming device 2, and the slider 9 3 b for slidably moving this is fixed to the slide plate 9 5. Slide 5 to the position of the forming vertical center line M and the standby position. A movable plate 9 8 a is supported via four pole guides 9 6 a fixed to the slide plate 9 5 and a guide shaft 9 6 b slidably inserted in the pole guides 9 6 a. The drive rod 9 7 b of the actuator 9 7 a fixed to the slide plate 9 5 is attached to the movable plate 9 8 a, and the blade 9 is moved up and down with the movable plate 9 8 a and the spacer 9 8 b. Move it. In the present embodiment, the lower preforming mold 80 is a male mold and the upper preforming mold 89 is a female mold. Compressed air is supplied from the lower preforming mold 80 through fine holes (not shown), and suction is performed from the upper preforming mold 89 through fine holes (not shown). The lower and upper pre-forming molds 80 and 89 can be either male or female and can be suctioned or supplied with compressed air either at the top or bottom.

Fig. 1 9 (a) is an enlarged view of the portion c in Fig. 18. The blade support plate 9 8 c of the die-cutting unit 9 1 is an upper elastic body 9 8 d made of hard rubber or the like on the lower surface. 9 9 is supported. The blade 9 is a thin and sharp tip of a ribbon steel or the like, and as shown in FIG. 1 9 (c) and FIG. 2 0, a chevron 9 9 a having a peak 9 9 b in a side view It has a saw-like shape provided continuously. Each yamagata 9 9 a has its peak 9 9 b advantageously formed in a side view as shown in FIG. 2 0 (a) (c), and the peak 9 9 b has a side view as shown in FIG. 2 0 (b). You may form so that a gentle curve may be drawn. As an example, a film having a thickness of about 0.30 mm can be punched out by using a blade 9 that has a sharp peak with a pitch P of about 3 mm between peaks. However, the shape of each peak and the pitch between the peaks can be appropriately changed according to the thickness, material, etc. of the film 4 with pictures. It is not limited to numerical values. For example, each chevron 9 9 a is formed symmetrically as shown in FIG. 2 0 (a) (b) with respect to a perpendicular line passing through peak 9 9 b.

 It may be formed asymmetrically as shown in (c). The extraction blade of this shape can also be used for the extraction blade 40 and the second extraction blade 44 in the previous embodiment.

 The lower elastic body 80c similar to the upper elastic body 98d is attached to the upper surface of the spit portion 80b supporting the projecting portion 80a in the lower preforming mold 80, and the lower elastic body The pictorial film 4 is supported by the lower mold upper surface S 2 which is the upper surface of 80 c, and the tip of the blade 9 is received in the lower recess 80 d and the pictorial film 4 is cut at the position of X. That is, the die-cutting unit is composed of the die-cutting unit 91 and the flange portion 80 b of the lower preforming die 80. However, as shown in FIG. 21, even if the cutting edge 999 is serrated or straight relative to the lower mold upper surface S2 described above, it is also possible to apply a gentle slope to its cutting edge 9 9c. It is possible to improve the cutting ability.

 When the previous cutting position cutting portion X hangs on the three-dimensionally shaped portion of the painted film 4, a protrusion is produced on the remaining painted film 4 that has been cut, and the film is removed to the take-up side film roll 4b. Is difficult. Accordingly, the lower surface 89a of the upper preforming mold 89 and the upper end of the spit portion 80b of the lower preforming mold 80 are at least brought into contact with the forming horizontal center plane H at the cutting position X at the cutting position X. It is required to Therefore, as shown in FIGS. 17 and 19, the upper surface of the lower preform 80 of the lower preform 80 (the upper surface of the lower elastic body 80 c (upper surface S 2 of the lower mold)) and the upper preform 8 It is necessary to align the lower surface 9 of 9 9 (upper die lower surface SI) and the lower surface of the upper elastic body 9 8 d (lower blade support lower surface S 3) with the forming horizontal center plane H, The alignment according to the blade is adjusted by the thickness of spacer 7 9 b, spacer 1 8 8 b, and spacer 9 8 b.

Here, first, the feeding operation of the picture film 4 by the film supply device 62 will be described with reference to FIGS. 12 and 16. -When sending out the picture film 4 to the right by the press roller 65, the swing roller 6 6 with both the feed side film opening 4a and the take-up side film opening 4b stationary. One swing port to raise a Move down one 7a. The amount of film delivered by the EP roller 65 is determined by detecting a film mark of one pitch by a photoelectric tube 29. After that, the picture film 4 is clamped by the clamp members 6 8 and 6 8, and the picture film 4 is sent out from the supply side film roll 4 a while lowering the rocking roller 6 6 a, and the rocking roller 6 7 a is raised. While doing this, take out the picture film 4 with the film removal side film roll 4 b.

 Next, the forming procedure of the painted film 4 will be described with reference to FIGS. First, the printed picture film 4 is sent to the right by the pick roller 65 or the like according to the above-mentioned procedure by one pitch until the film mark is detected. Then, as shown in FIG. 17 (a), clamp members 6 8 and 6 8 are brought close to each other, and the picture film 4 is sandwiched between them. At this time, it is desirable that the central surface of the picture film 4 stretched between the feed rollers 6 4 and the nip rollers 6 5 coincide with the formed horizontal central surface H from the viewpoint of the positioning accuracy by the film mark. By sandwiching the picture film 4 with the clamp members 6 8 and 6 8, it is possible to improve the molding processing accuracy described later. In particular, the clamp member 68 can block the back tension of the supply side film roll 4a, and can heat the painted film 4 without stress.

 Subsequently, the heating device 70 is moved onto the clamp member 68 to heat the picture film 4 clamped through the through hole 6 8a. By heating, the picture film 4 once hangs down as indicated by a dot-and-dash line indicated by reference numeral 4 D, and returns to its original position by further heating. When picture film 4 is sufficiently heated, lower preformed mold 80 is pressed until the upper surface of the integral part with spit 80 b is made to coincide with the formed horizontal center plane H as shown in FIG. 17 (b). Raise it. Since the lower part 4 D of the picture film 4 clamped by the clamp member 6 8 is pushed up by the projection 80 0 a. Of the lower preforming mold 80 almost uniformly, the pattern of the picture film 4 is formed without distortion. It can be carried out.

Also, lower the upper preforming mold 89 as shown in Fig. 1 7 (c) to form the picture film 4. When molding is complete, the unshown micro holes in the lower preforming mold 80 Cooling air is supplied to cure the formed film 5. Then, as shown in Fig. 18 (a), lower the die-cut sheet 9 1 and perform the punching process of the picture film 4 with the blade 9 9. In the punching process, as shown in Fig. 1 9 (a) (b), the blade 9 is lowered to form a picture film between it and ^one upper surface of the lower elastic body 80 c (lower mold upper surface S 2). Disconnect.

 When the cutting is completed, the die-cut sheet 91 is returned to the original standby position, and as shown in FIG. 18 (b), the film formed by the suction head 55 of the above-described formed film transfer device 50 is formed. Take 5 In the example shown in FIG. 15, a general-purpose formed film transfer device 50 is used, and the rail 50a is attached to the main forming device 2 and the previous formed film 5 is transferred to the movable mold (mold) 1 2 Make it fit. When moving the formed film 5 from the clamp member 68, the formed film 5 is brought into contact with the charging device 5 7 to charge the film, thereby facilitating adsorption to the movable mold 12. Then lower the lower preforming mold 80 and move the clamp members 68 and 68 away from each other as shown in FIG. 18 (c). Take up film 4 to the right by one pitch and repeat the above operation.

 Finally, still another embodiment of the present invention will be described.

 In the fourth embodiment, the lower surface 8 9 a of the upper preforming mold 8 9 is located above the forming horizontal center plane H in all parts. However, as shown in FIG. 22, if the portion outside the cut portion of the painted film 4 substantially coincides with the formed horizontal center plane H, a part of the formed film 5 shown by the reference numeral 4 w There is no need to be located in the plane of the forming horizontal center plane H.

 In the above embodiment, injection molding is performed by the main molding device 2. However, as the main molding device 2 to which the preforming device 3 of the present invention is to be applied, any molding method using a thermoplastic resin molding machine may be used. For example, a blow molding method may be used.

In the above embodiment, a roll-shaped film is used as the painted film 4. However, as the painted film 4, a sheet-like film cut into a desired shape is used. You may use. In this case, the film supply device 25 can be substituted by a formed film transfer device 50 or a similar device.

 In the above embodiment, the film mark is detected by the photoelectric tube 29 to determine the film feed amount for one step. In the case of patterns such as wood grain patterns and ink flow patterns, the film feed amount for one process is determined by controlling the operation time of the film removal device and the removal amount. It is also good.

 In the above embodiment, the upper elastic body 98 d and the lower elastic body 80 c are made of hard rubber. The material of these elastic members may be any material as long as it does not damage the cutting blade 99. For example, various materials such as a heat resistant synthetic resin such as silicon can be appropriately used. The reference numerals in the claims are merely for the purpose of making the contrast with the drawings more convenient, and the present invention is not limited to the configuration of the attached drawings.

Industrial applicability

 The present invention is used for both main molding such as so-called insert molding in which the picture sheet itself adheres to the surface of the product and so-called in-mold molding method in which the picture of the picture sheet is transferred to the surface of the product. The molded product can be applied to a picture pattern on both the inner and outer surfaces of a molded product having a deep drawing portion as well as one having a flat shape in all fields.

Claims

The scope of the claims 1. A pre-forming apparatus for producing a molded film for obtaining a molded article with a picture by mounting a painted film on the main mold of the main molding apparatus and supplying a resin to the main mold, the preliminary molding apparatus comprising The film feeding device (25, 62) for feeding the above-mentioned painted film (4) to the preforming portion (F) for molding, and the above-mentioned preforming portion (F) can be moved close to and separated from before being preformed A heating device (32, 70) for heating the coated film to be plasticized in the preforming part, and a preforming mold (22, 80, 89) for preforming the coated film (4) And the film with picture (5) A film forming apparatus (35, 91) for forming a formed film (5) for forming the formed film (5) by die cutting of this film after the preforming of (4).  2. Preforming device according to claim 1, characterized in that the film die-cutting device (35, 91) is provided with a saw-like blade (40, 44, 99).  3. A die-cutting unit (91) capable of causing the film die-cutting device to move the blade (99) close to the preforming portion, and a preformed die facing the blade (99). The preforming apparatus according to claim 2, comprising an elastic body (80 c) attached to the opposite surface of (80).  4. The preform according to claim 1, wherein the preforming mold (89) and the film die-cutting device (91) are selectively movable close to and away from the preforming part (F). Forming device.  5. The preforming apparatus according to claim 1, wherein the preforming mold comprises a pair of preforming molds (80, 89) adjacent to each other with the preforming portion interposed therebetween. 6. The preforming apparatus according to claim 5, further comprising a clamp member (68, 68) for sandwiching the picture film (4) in the preforming part (F) around the part to be formed. . 7. A preforming apparatus according to claim 5, wherein the picture film (4) is oriented substantially horizontally in the preforming section (F).  8. The preforming apparatus according to claim 7, wherein the lower preforming mold (80) forming the preforming mold is a male mold and is adjacent to the preforming part (F) in the upward direction. 9. The pictorial film (4) is disposed between the preform mold (22, 80) and the heating device (32, 70), and the pictorial film (4) is generated by the heat generation of the heating device (32, 70). ) Is plasticized and preformed, and then the extraction blade (40, 44, 99) provided in the film die-cutting device (35, 91) is preformed and supported by the preforming mold (80). The molded film is pressed by pressing the painted film (4) The preforming apparatus according to claim 1, wherein (5) is created.  10. The preforming apparatus according to any one of claims 1 to 9, wherein the preforming is performed by vacuum forming or pressure forming.  The preformed film according to any one of claims 1 to 9, wherein the picture film (4) has a substrate (102), a picture (103) and a protective layer (104) of the picture. apparatus.  1 2. The scope of claim 1 wherein the pictured film (4) has a regular picture color, and the film supply device (25, 62) delivers the pictured film (4) one by one. The preforming apparatus in any one of -9.  1 3. The control device (47 b) of the preforming device (3) and the timing control device (47 a) of the main forming device (2). The pre-forming apparatus as described in any one. 14. A preforming method using the preforming apparatus according to any one of claims 1 to 9, wherein the film feeding apparatus (25, 62) is provided to a preforming section (F) for performing preforming. ) After supplying the painted film (4) and bringing the heating device (32, 70) close to the preformed part (F) to plasticize the painted film, the preformed mold (22, (80, 89), and the preformed film is And forming a molded film (5) for inserting the molded film into the main mold.  1 5. A molding method using the preforming apparatus according to any one of claims 1 to 9, which comprises a main mold (12) and at least a part of the main molding apparatus (2) (22 a ) The preformed film (4) is preformed using the substantially identical preforming mold (22) and then die-cut to form a molded film (5) by the preforming apparatus, and the molded film (5) is A main molding method of supplying the resin after being inserted into a main mold (12) of a molding apparatus.  16. The main molding method according to claim 15, wherein the resin of the painted film (4) is the same material as the supplied resin.  17. The main molding method according to claim 15, wherein the main molding is a molding method of a thermoplastic resin.