JP5479169B2 - Film cutting device - Google Patents

Description

  The present invention relates to a film cutting apparatus for producing a sheet-like film from a roll-like film.

  Conventionally, a resin film having a design, for example, an acrylic film on which a design is printed, is integrally attached to the surface of the resin molded product to improve the design of the resin molded product. Such resin molded products (film integrated molded products) are used for interior parts such as automobile consoles, door trims, switch bases, cellular phones, and notebook computers, for example.

  Moreover, as described in Patent Document 1, a film integrated molded product in which a film in which an embedded body is at least partially embedded is attached to the surface is known. Such a film-integrated molded product looks like an inlay product. The embedded body is made of a material such as metal, paper, cloth, glass, veneer, and leather, and is designed in various shapes such as a manufacturer's logo and a one-point design shape.

  A film-integrated molded article having such a film on the surface is manufactured, for example, according to the following order.

  First, the peripheral part of the film (or the film to which the embedded body is affixed), the outer surface (the surface located outside when the film integrated molded product is completed) as the molding surface of the movable mold of the injection mold In this state, it is fixed to a movable parting surface (mating surface) by a clamping device.

  Next, the film is softened by heating the heater, and the softened film is sucked through suction grooves formed on the mating surface and suction holes formed in the molding surface so as to surround the molding surface of the movable mold. As a result, the film adheres to the movable molding surface. Further, when an embedded body is attached to the film, the embedded body is pressed around by the film.

  Subsequently, the movable mold is moved to the fixed mold, the mold is closed, and the molten resin is injected into the mold from the nozzle of the molding machine.

  Then, after cooling the injection resin, the mold is opened, the molded product is taken out, and a blank film at the periphery of the molded product is trimmed to provide a film (or a film in which an embedded body is embedded) on the surface. Is obtained.

Japanese Patent No. 4128930

  However, there are the following problems in the production of the above-mentioned film integrated molded product.

  If it demonstrates concretely, the film used for a film integrated molded product will be wound by the core and made into the roll shape from the reason on manufacture and conveyance. When manufacturing a film integrated molded product using a roll-shaped film, first, the film feeding device for feeding the roll-shaped film is used to send the leading end of the film to a position near the mold of the injection molding device, and at that position, the film The film hold unit holds the tip. The film hold unit moves along the mating surface of the injection mold, and conveys the film so that the film to be held covers the mating surface on the cavity side (including the cavity). At this time, the film holding unit conveys the film so that it passes between the main clamping device that presses the film around the cavity of the parting surface and the parting surface.

  Next, the leading end portion of the roll-shaped film that passes between the main clamp device and the mating surface on the cavity side by the movement of the film hold unit is pressed against the mating surface and fixed by the sub-clamp device. When the fixing of the leading end of the film is completed by the sub-clamp device, the film holding unit releases the film and retracts, and then the main clamping device fixes the film to the mating surface. Thereafter, the blade of the heat cutter device is brought into contact with the film portion located between the roll-shaped film main body and the main clamp device, and the blade is heated and melt-cut in the film width direction.

  According to such a manufacturing method, in the order of the film feeding device, the heat cutter device, the main clamp device, and the sub clamp device in the film transport direction, these devices are integrally installed on the injection molding device on a substantially straight line. .

  However, in this case, the film portion located between the heat cutter device and the main clamp device is wasted. In addition, if the shape of the integrated film molded product to be manufactured changes, a new mold will be manufactured, but this heat cutter device is built into the mold, so it matches the roll film width used each time. Usually, a heat cutter device is manufactured.

  Furthermore, since the film feeding apparatus is integrally installed in the injection molding apparatus, it is necessary to stop the operation of the injection molding apparatus when setting a new roll film in the film feeding apparatus. As a result, the operating rate of the injection molding apparatus is lowered, and the production efficiency of the film integrated molded product is lowered. Furthermore, setting a heavy roll-shaped film in a mold (film feeding device) places a heavy burden on the operator.

Therefore, the present invention reduces the loss of the roll-shaped film when manufacturing a roll-integrated molded product using the roll-shaped film, and does not require the incorporation of a heat cutter device in the mold, and is incorporated on the device side. It is an object of the present invention to cut roll-shaped films of all widths using the heat cutter device. Moreover, this invention makes it a subject to suppress the fall of the operation rate of the injection molding apparatus which produces a film integrated molded product, and to reduce the labor of the set at the time of film replacement | exchange.

In order to solve the above-described problem, according to the invention according to claim 1 of the present application,
A film cutting apparatus for producing a sheet film by cutting a roll film in its width direction,
A film roll support mechanism for rotatably and replaceably supporting a roll film;
A film chuck unit that pulls out the leading end by moving in a state of sucking and holding the leading end of the roll film supported by the roll support mechanism;
A cutter unit including a blade for producing a sheet-like film by cutting a portion of a roll-like film drawn out by the film chuck unit in the film width direction;
A sheet suction table having a suction surface for sucking a sheet-like film by suction;
The film chuck unit adsorbs and holds the leading end of the roll film and moves by a set amount. When the film is cut by the cutter unit, the adsorbed and held state is maintained. There is provided a film cutting apparatus configured to move to a sheet suction table in a state where the sheet-like film is sucked and held, and to stop suction when the sheet-like film is positioned on the sheet suction table.

Moreover, according to the invention which concerns on Claim 2,
Film chuck unit
A suction pad that sucks and holds the surface of the film on the side opposite to the sheet suction table;
An air cylinder that supports the suction pad and presses the sheet-like film against the suction surface of the sheet suction table via the suction pad;
Sheet adsorption table
After the film chuck unit presses the sheet film against the suction surface, the suction of the sheet film is started,
Film chuck unit
There is provided a film cutting device that stops suction of a suction pad after the sheet suction table starts suction of the sheet-like film and separates the suction pad from the sheet-like film via an air cylinder.

Further, according to the invention of claim 3,
A film cutting apparatus having a roller that rolls on the surface of a sheet-like film adsorbed on a sheet adsorbing table is provided.

Furthermore, according to the invention of claim 4,
A roller is provided in the film chuck unit,
By moving the film chuck unit, a film cutting device is provided in which the roller rolls on the surface of the sheet-like film adsorbed on the sheet adsorption table.

In addition, according to the invention of claim 5,
The film suction table is provided with a film cutting device configured to stop suction when another device handles the sheet-like film on the film suction table.

  According to this invention, a sheet-like film is produced from a roll-like film. Moreover, the sheet-like film of desired length can be produced by changing the moving amount | distance of the film chuck unit of the state which adsorbed and hold | maintained the front-end | tip part of a roll-shaped film. For example, a sheet-like film having a length necessary for producing a film-integrated molded product and a fixing margin (for example, clamping) necessary for fixing the film to a mold of an injection molding apparatus Can be produced. If such a sheet-like film is fixed to a mold of an injection molding apparatus to produce a film-integrated molded product, film loss can be reduced.

  In addition, the cutter unit can be used to produce roll-shaped films with different widths by installing a blade that can cut the maximum width of the roll-shaped film that may be used in the production of a film-integrated molded product in the width direction. Even if it changes, it is not necessary to produce a cutter unit according to it, and it can apply to a roll-shaped film of all widths.

  Furthermore, since it is not necessary to set the roll film in a film feeding device provided integrally with the mold of the injection molding apparatus, it is not necessary to stop the operation of the injection molding apparatus for the setting, and the injection molding is performed. It becomes possible to keep the operating rate of the apparatus constant.

  Furthermore, the sheet-like film produced by the film-cutting device is easier to set on the mold than the roll-like film. Also, the set can be easily automated.

It is sectional drawing of the film integrated molded product of an example. It is a figure which shows the flow of manufacture of the film integrated molded product shown in FIG. It is a top view of the film integrated molded product manufacturing system which concerns on one Embodiment of this invention. It is a top view of a film cutting apparatus. It is a side view of a film cutting apparatus. It is a side view of a sheet conveying apparatus. It is sectional drawing of the hand tool of a sheet conveying apparatus. It is a side view of an embedded object sticking apparatus. It is sectional drawing of the metal mold | die of an injection molding apparatus. It is a figure which shows the preparation methods of the film sheet by a film cutting apparatus. It is a figure which shows the preparation methods of the film sheet by the film cutting apparatus following FIG. It is a figure for demonstrating the method of delivering a film sheet from a film cut apparatus to a sheet conveyance apparatus. It is a figure for demonstrating the sticking method of the embedded body to the film sheet by an embedded body sticking apparatus. It is a figure for demonstrating position alignment to the metal mold | die of the film sheet by a sheet conveying apparatus.

  First, as an example of a film-integrated molded product, a film-integrated molded product that is integrally provided with a film in which an embedded body is embedded will be described. Then, the manufacturing system of a film integrated molded product is demonstrated.

  FIG. 1 shows a cross section of a film-integrated molded article that is integrally provided with a film in which an embedded body is embedded on the surface. Moreover, FIG. 2 has shown simply the manufacturing procedure of the film integrated molded product.

  As shown in FIG. 1, a film integrated molded product 10 according to the present invention is composed of a resin molded product (for example, a casing of a band phone) 12 and a film sheet 14 attached integrally to the surface thereof. Composed. An embedded body 16 is embedded in the film sheet 14. Moreover, this film integrated molded article 10 is produced with an injection molding apparatus.

  The film sheet 14 forms a printed layer 14b (pattern pattern layer) on one surface of a transparent, translucent, or partially transparent base film 14a (for example, an acrylic film sheet), and further on the surface of the printed layer 14b. The adhesive layer 14c (adhesive layer) is formed. The film sheet 14 and the resin molded product 12 are bonded by the adhesive layer 14c. The adhesive forming the adhesive layer 14c is an adhesive that melts by the heat of the injection resin and solidifies at room temperature. In addition, the film sheet 14 may be one in which only the adhesive layer is formed on the surface of a base film having a pattern without a print layer.

  The embedded body 16 is a thin body of a pattern or a pattern shape such as a character or a character, for example, as a design or touch feeling of natural or artificial material such as metal, paper, leather, rubber, cloth, veneer, glass, etc. Made of distinctive material.

  Next, the flow of manufacturing such a film integrated molded product 10 will be described. Here, the flow of manufacturing the embedded body 16 will also be described.

  First, as shown in FIG. 2A, a pressure sensitive adhesive (PSA: Pressure Sensitive Adhesives) or hot melt adhesive layer 22 is formed on the release sheet 20. Next, a layer 24 of a material (for example, metal) of the embedded body 16 is formed.

  Subsequently, as shown in FIG. 2B, the PSA layer 22 and the material layer 24 are punched into a desired shape of the embedded body 16 by a Thomson type or a pinnacle type. Then, as shown in FIG. 2C, a protective sheet 26 that protects the material layer 24 (that is, the embedded body 16) is attached. Thereby, the embedded seal 28 is completed.

  Next, as shown in FIG. 2D, the embedded body 16 of the embedded body seal 28 is attached to the film sheet 14 through the PSA layer 22. The embedded body 16 is attached to the surface S1 of the base film 14a on the side where the printed layer 14b and the adhesive layer 14c are not formed.

  Then, as shown in FIG. 2E, the peripheral edge of the film sheet 14 to which the embedded body 16 is attached is fixed to the mating surface 30c of one mold (movable mold) 30a of the mold 30 of the injection molding apparatus. To do. The film sheet 14 is softened by a heater (not shown), and the softened film sheet 14 by the suction hole 30a1 of the movable mold 30a is sucked toward the molding surface 30a2. Then, the film sheet 14 is brought into close contact with the molding surface 30a. At this time, the embedded body 16 is embedded in the film sheet 14.

  Next, the mold 30 is closed, and the resin 12 is injected into the mold 30 through the path of the sprue 30b1 of the fixed mold 30b. After the resin in the mold 30 has cooled, the mold 30 is opened, the molded product with the film sheet 14 in close contact with the surface is taken out, and the blank film at the periphery of the molded product is trimmed. The film integrated molded article 10 shown is obtained.

  From here, the manufacturing system based on the manufacturing method of the above-mentioned film integrated molded article 10 is demonstrated.

  The system for manufacturing the film integrated molded article 10 shown in the top view (layout diagram) of FIG. 3 is roughly composed of four apparatuses.

  The production system 50 of the film integrated molded article 10 includes a film cutting device 52 that cuts a roll-shaped film (roll film) to produce a sheet-shaped film (film sheet 14), and a sheet conveyance that conveys the film sheet 14. It has the apparatus 54, the embedded body sticking apparatus 56 which sticks the embedded body 16 to the film sheet 14, and the injection molding apparatus 58 which shape | molds the film integrated molded article 10. FIG.

  The film cutting device 52 is a device for producing a film sheet 14 used for the film integrated molded product 10 from a roll film 60 as shown in FIG. 4 which is a partially enlarged view of FIG. 3 and FIG. 5 which is a side view. is there. The film cutting device 52 cuts a roll support base 62 that supports the roll film 60, a film chuck unit 64 that pulls out the leading end of the roll film 60, and a portion 60 a of the drawn roll film 60 in the width direction to form a film. The cutter unit 66 for producing the sheet 14 and the suction table 70 for sucking the film sheet 14 are configured.

  The roll support base 62 of the film cutting device 52 is configured to support the roll film 60 so that the roll film 60 can be rotated and replaced, and can be pulled out with a predetermined tension. Further, the roll support base 62 has a surface S2 on which an adhesive layer (corresponding to the adhesive layer 14c of the film sheet 14) of the portion 60a drawn from the roll film 60 is directed upward (on the side of the anti-adsorption table 70). The roll film 60 is supported. The roll film 60 is wound around the core 72 with the adhesive layer facing outward. Furthermore, it is comprised so that the roll film 60 of the maximum width | variety which may be used in manufacturing a film integrated molded product can be supported. For example, the two support portions of the support base 62 that supports each end of the core 72 of the roll film 60 are configured to be movable in the width direction (Y-axis direction) of the roll film 60 in the approach direction or the separation direction.

  The film chuck unit 64 is configured to hold the tip of the roll film 60 and be movable in the drawing direction (X-axis direction) of the roll film 60, and is driven by a driving device including a ball screw 74 and a servo motor 76. Then, an arbitrary set amount is pulled out from the roll film 60 main body.

  For this purpose, the film chuck unit 64 has a plurality of suction pads 78 that suck and hold the surface S2 on the adhesive layer side of the tip portion when the tip portion of the roll film 60 is pulled out. These suction pads 78 are provided in the film chuck unit 64 side by side in the width direction (Y-axis direction) of the roll film 60. The plurality of suction pads 78 are connected to a vacuum pump (not shown) or a vacuum ejector (not shown) connected to a compressor, and the attachment / detachment of the film can be controlled by an air valve.

  The plurality of suction pads 78 are also supported by an air cylinder 79 and moved in the Z-axis direction by the air cylinder 79. Details of the movement of the suction pad 78 in the Z-axis direction by the air cylinder 79 will be described later.

  Further, the film chuck unit 64 has a roller 80 that freely rotates around a rotation center line extending in the Y-axis direction. As will be described in detail later, the roller 80 rolls on the surface S2 on the adhesive layer side of the film sheet 14 when the suction table 70 is sucking the film sheet 14, and makes the film sheet 14 adhere to the suction table 70. do. Each end of the roller 80 is supported by the tip of a piston rod that advances and retracts in the Z-axis direction of each of the two air cylinders 82 provided in the chuck unit 64. With these air cylinders 82, the roller 80 stands by at a retracted position (a position away from the film sheet 14) while the suction pad 78 is being sucked and held.

  The cutter unit 66 is configured so that the portion 60 a of the roll film 60 drawn by the film chuck unit 64 is sucked and held in the width direction (Y-axis direction) by the suction pad 78 of the film chuck unit 64 and the support base 62. A heat cutter 84 having a cutting blade and a linear motion mechanism 86 for moving the heat cutter 84 back and forth in the Z-axis direction are provided. Due to the linear motion mechanism 86, the heat cutter 84 moves back to the position where it does not interfere with the chuck unit 64 moving in the X-axis direction, and waits. The heat cutter 84 descends at the time of cutting and is pulled out by the chuck unit 64. The portion 60a is melted and cut by the blade. The chuck unit 64 pulls the tip of the roll film 60 by a predetermined length in the X-axis direction from the cutting position Cp of the cutter unit 66, and then cuts the portion 60a of the roll film 60 from which the cutter unit 66 has been pulled out. A film sheet 14 having a length of 1 mm is obtained.

  The length of the blade of the heat cutter 84 in the Y-axis direction is set to a length that can correspond to the maximum width roll film 60 that may be used in manufacturing a film integrated molded product. Thereby, the roll film 60 of all widths can be cut | disconnected in the width direction.

  The suction table 70 is a table that is brought into a flat state by sucking and sucking the film sheet 14, and includes a flat suction surface 70 a having a size capable of sucking the entire film sheet 14. Specifically, the suction surface 70a of the suction table 70 is sized so that the entire film sheet 14 produced from the roll film 60 having the maximum width that can be used in manufacturing a film integrated molded product can be sucked. ing. A plurality of suction holes 70b are formed in the suction surface 70a, and the film sheet 14 is sucked through the suction holes 70b by a vacuum pump (not shown) or a vacuum ejector (not shown) connected to a compressor. The As a result, the entire film sheet 14 is in close contact with the suction table 70 in a flat state. The suction by the suction pad 78 of the film chuck unit 64 and the suction by the suction table 70 are controlled separately by, for example, an electromagnetic valve.

  As shown in FIGS. 4 and 5, a suction hole seal tape 92 that partially covers the suction surface 70 a is attached to the suction surface 70 a of the suction table 70. This is a tape having a size corresponding to the size of the film sheet 14, and is used to close the suction hole 70 b not facing the film sheet 14 when the size of the film sheet 14 is smaller than that of the suction table 70. Is done. When the compressor connected to the vacuum pump or the vacuum ejector is operated without the suction hole seal tape 92, the suction hole 70b that does not face the film sheet 14 sucks outside air, and the suction table 70 has a predetermined suction force. This is because the film sheet 14 cannot be adsorbed.

  Details of the production of the film sheet 14 by the film cutting device 52 will be described later.

  Returning to FIG. 3, the sheet conveying device 54 conveys the film sheet 14 produced by the film cutting device 52 from the film cutting device 52 to the embedded body pasting device 56 and from the embedded body pasting device 56 to the injection molding device 58. Is configured to do.

  As shown in FIG. 6, the sheet conveying device 54 includes a hand tool 94 that holds the film sheet 14 in a flat state, a robot 96 that includes the hand tool 94 at the tip and changes the position and posture of the tool 94, and a robot And a linear motion mechanism 98 that moves 96 in the X-axis direction.

  As shown in FIG. 7, the hand tool 94 sucks and holds the film sheet 14 by suction, the plate base 102 that holds the suction plate 100, and the plate base that is fixed to the tip of the robot 96. Main base 104.

  The suction plate 100 includes a flat suction surface 100a, and a plurality of suction holes 100b are formed in the suction surface 100a. The plurality of suction holes 100b are connected to a vacuum pump (not shown) or a vacuum ejector (not shown) connected to a compressor. Note that the suction by the suction table 70 of the film cutting device 52 and the suction by the suction plate 100 of the sheet conveying device 54 are separately controlled by, for example, an electromagnetic valve (not shown).

  The plate base 102 is supported by the main base 104 so as to be movable in a direction orthogonal to the suction surface 100 a of the suction plate 100. Specifically, the main base 104 is provided with a plurality of guide bushes 108 that respectively support a plurality of guide rods 106 extending in the orthogonal direction of the suction surface 100a attached to the plate base 102 so as to be slidable in the orthogonal direction. It has been. A spring 110 is disposed between the main base 104 and the plate base 102 to urge them away from each other.

  Returning to FIG. 6, the robot 96 is, for example, a six-axis robot, and cooperates with the linear motion mechanism 98 that moves the robot 96 in the X-axis direction, and pastes the embedded body from the suction table 70 of the film cutting device 52. The film sheet 14 is transported to the device 56 and from the embedded body pasting device 56 to the mold 30 of the injection molding device 58 (the hand tool 94 is moved).

  Returning to FIG. 3, the embedded body attaching device 56 is configured to attach the embedded body 16 to the film sheet 14 held by the hand tool 94 of the sheet conveying device 54.

  Specifically, as shown in FIG. 8, the embedded body pasting device 56 includes a stage 112 including a placement surface 112 a on which the film sheet 14 held by the hand tool 94 of the sheet conveying device 54 is placed. An air cylinder 114 that presses the embedded body 16 against the film sheet 14 through a through-hole 112b formed in the stage 112, a support shaft 118 that supports a roll-shaped embedded body seal 28 (roll seal 116), and a protective sheet. 26, and a release sheet collection reel 122 that collects the release sheet 20 of the embedded seal 28. The embedded seal 28 is wound around the core 124 with the release sheet 20 facing outward.

  Further, the embedded body pasting device 56 guides the embedded body seal 28 from the support shaft 118 to the protective sheet collection reel 122 through the space between the through hole 112b of the stage 112 and the air cylinder 114. And a guide roller 130 for guiding the release sheet 20 to the release sheet collection reel 120.

  The stage 112 has a plate shape, and includes a flat placement surface 112a on which the film sheet 14 is placed by the sheet conveying device 54, and has a through hole 112b. The through hole 112b is formed in order to affix the embedded body 16 to the film sheet 14 on the placement surface 112a from the opposite side of the placement surface 112a. In addition, although the reason is mentioned later, the surface on the opposite side of the mounting surface 112a is subjected to non-adhesive treatment so that the PSA layer 22 of the embedded seal 28 does not adhere.

  The air cylinder 114 includes a pressing member 114a that moves forward and backward in the through hole 112b of the stage 112 at the tip of the piston rod. In the air cylinder 114, the release sheet 20 is disposed between the through hole 112b of the stage 112 and the pressing member 114a when the pressing member 114 is retracted as indicated by a two-dot chain line. The embedded body 16 of the embedded body seal 28 peeled off by 120 is pushed toward the inside of the through hole 112b through the protective sheet 26 by the pressing member 114a. Thereby, the embedded body 16 is affixed to the film sheet 14. At this time, the other embedded body 16 that has not been pushed toward the through hole 112b by the pressing member 114a comes into contact with the stage 112, but the PSA layer 22 of the embedded body 16 adheres to the stage 112 by non-adhesive treatment. There is no.

  The protective sheet collecting reel 120 is a reel that winds and collects the protective sheet 26 of the embedded seal 28 and is intermittently rotated by a servo motor (not shown). As the protective sheet collection reel 120 rotates intermittently, the embedded body 16 of the embedded body seal 28 is intermittently disposed from the support shaft 118 between the through hole 112b of the stage 112 and the air cylinder 114.

  The release sheet collection reel 122 is a reel that winds up and collects the release sheet 20 of the embedded seal 28 and is intermittently rotated by a servo motor (not shown). The release sheet collecting reel 122 rotates intermittently, and is released from the embedded seal 28 on the upstream side (with respect to the moving direction of the embedded seal 28) between the through hole 112 b of the stage 112 and the air cylinder 114. Remove 20 and collect.

  Returning to FIG. 3, the injection molding device 58 melts the solid resin material accommodated in the hopper 132 and injects the molten resin into the mold 30 with a predetermined injection pressure. The mold 30 includes a movable mold 30a that moves in the X-axis direction, and a fixed mold 30b in which runners and sprues that form a route for molten resin are formed. The mold 30 includes a flat mating surface 30c to which the film sheet 14 is fixed. The injection molding device 58 is configured so that the film sheet 14 in the state of being sucked and held by the suction plate 100 of the sheet conveying device 54 can be fixed to the mating surface 30c.

  Specifically, as shown in FIG. 9, the movable mold 30a of the mold 30 of the injection molding apparatus 58 has a clamp device 134 that fixes the peripheral edge of the film sheet 14 to the flat mating surface 30c of the movable mold 30a. . The suction plate 100 of the hand tool 94 of the sheet conveying device 54 holds the film sheet 14 by suction while leaving the peripheral edge so that the clamping device 134 can fix the peripheral edge of the film sheet 14 to the entire periphery of the cavity at the mating surface 30c. Designed to be the size you want. Although only two clamp devices 134 are shown in the figure, a plurality of clamp devices 134 are provided on the movable mold 30a so that the peripheral edge of the film sheet 14 can be fixed to the entire mating surface 30c of the movable mold 30a. ing.

  The clamp device 134 includes a clamp plate 136 whose one end contacts the peripheral edge of the film sheet 14, and a rotary actuator (not shown) that rotates a rod 138 that supports the other end of the clamp plate 136. As the rotary actuator rotates the rod 138, the clamp plate 136 fixes (clamps) or releases (unclamps) the film sheet 14 to the mating surface 30c of the movable mold 30a. Further, when the clamp device 134 is in an unclamped state, the clamp plate 136 is configured to be completely retracted from the mating surface 30c toward the movable mold 30a (the space 140 in which the clamp plate 136 can be completely retracted is movable). 30a). Thereby, the robot 96 of the sheet conveying apparatus 54 can align the film sheet 14 with the mating surface 30c of the movable mold 30a without contacting the crank plate 136 of the clamp apparatus 134.

  From here, the production flow of the integrated film molded article 10, particularly the film in which the film sheet 14 is produced from the roll film 60 and the embedded body 16 is attached to the movable mold 30 a of the mold 30 of the injection molding apparatus 58. A flow until the sheet 14 is fixed will be described.

  First, the flow in which the film sheet 14 is produced from the roll film 60 will be described with reference to FIGS.

  As shown in FIG. 10A, the film chuck unit 64 is positioned above the tip of the roll film 60 whose tip is located at the cutting position Cp of the bracket unit 66, and the air cylinder 79 holds the suction pad 78. The suction pad 78 is brought into contact with the tip of the roll film 60 by moving in the Z-axis direction. The suction pad 78 starts suction while being in contact with the leading end portion of the roll film 60, and sucks and holds the leading end portion of the roll film 60. Thereby, the suction pad 78 can easily and reliably hold the tip of the roll film 60 by suction.

  Next, the film chuck unit 64 moves toward the suction table 70, and the leading end of the drawn roll film 60 is separated from the cutting position Cp of the cutter unit 66 by a predetermined distance L as shown in FIG. Stop when the position is reached. Then, the heat cutter 84 of the cutter unit 66 is lowered to cut the portion 60 a of the roll film 60. Thereby, the film sheet 14 of length L is produced.

  After the cutting by the heat cutter 84 is completed, the film chuck unit 64 moves upward of the suction table 70 with the suction pad 78 holding the film sheet 14 by suction. As shown in FIG. 11A, when the film sheet 14 reaches a predetermined position on the suction table 14 (position on a portion where the suction hole seal tape 92 is not attached), the film chuck unit 64 stops. .

  When the film chuck unit 64 stops, the air cylinder 79 moves the suction pad 78 in a state where the film sheet 14 is sucked and held toward the suction table 70. Thereby, the film sheet 14 is pressed against the suction table 70 and fixed. If the stop position of the film chuck unit 64 is adjusted, the film sheet 14 can be pressed and fixed to an arbitrary position on the suction table 70.

  When the film sheet 14 is pressed and fixed to the suction table 70, the suction table 70 starts to suck the film sheet 14. At the same time, the suction pad 78 of the film chuck unit 64 stops sucking and is separated from the film sheet 14 by the air cylinder 79. At the same time or after that, as shown in FIG. 11B, the roller 80 is lowered by the air cylinder 82 and contacts the film sheet 14. Then, the film chuck unit 64 moves toward the cutter unit 66, and the roller 80 rolls on the surface of the film sheet 14. As a result, the film sheet 14 comes into close contact with the suction table 70.

  The film chuck unit 64 may reciprocate above the film sheet 14 so that the roller 80 rotates a plurality of times on the surface of the film sheet 14. As a result, the film sheet 14 is brought into close contact with the suction table 70.

  When the film chuck unit 64 moves and reaches a position near the cutter unit 66, the hand tool 94 of the sheet conveying device 54 moves, and the suction plate 100 sucks above the film sheet 14 sucked by the suction table 70. The surface 100a and the film sheet 1 are stopped in a parallel posture. Subsequently, the hand tool 94 is lowered, and the suction plate 100 of the hand tool 94 is pressed against the surface of the film sheet 14 as shown in FIG. Thereby, the film sheet 14 is clamped between the suction table 70 and the suction plate 100 in a flat state.

  When the film sheet 14 is sandwiched between the suction table 70 and the suction plate 100, the suction table 70 stops sucking the film sheet 14. Immediately thereafter, the suction plate 100 starts sucking the film sheet 14. Thereby, the film sheet 14 is delivered from the suction table 70 to the suction plate 100 in a flat state. Then, as illustrated in FIG. 12B, the sheet conveying device 54 raises the hand tool 94 and conveys the film sheet 14 toward the embedded body pasting device 56.

  When the film sheet 14 is received from the film cutting device 52, the sheet conveying device 54 puts the film sheet 14 held by the hand tool 94 on the stage 112 of the embedded body pasting device 56, as shown in FIG. Deploy. Specifically, the sheet conveying device 54 is in a state in which the portion of the film sheet 14 to which the embedded body 16 is attached is aligned with the through hole 112b of the stage 112 while continuing to suck and hold the film sheet 14 by the suction plate 100. Then, the film sheet 14 is pressed against the stage 112. Thereby, the film sheet 14 is clamped between the suction plate 100 and the stage 112 in a flat state.

  When the film sheet 14 is placed on the stage 112, as shown in FIG. 13B, the pusher 114a of the air cylinder 114 of the embedded body pasting device 56 rises, and the embedded body is interposed via the protective sheet 26. 16 is attached to the film sheet 14. At this time, the suction plate 100 of the hand tool 94 of the sheet conveying device 54 serves to support the film sheet 14. Thereby, the embedding body 16 can adhere | attach the film sheet 14 of a flat state strongly.

  When the attachment of the embedded body 16 to the film sheet 14 is completed, the sheet conveying device 54 moves the embedded body 16 from the embedded body attaching device 56 toward the mold 30 of the injection molding device 58. 14 is conveyed.

  As shown in FIG. 14A, the sheet conveying device 54 moves the hand tool 94 between the movable mold 30a and the fixed mold 30b in a state where the film sheet 14 is parallel to the mating surface 30c of the movable mold 30a. . Then, by moving the hand tool 94 toward the movable mold 30a, the film sheet 14 is aligned with the mating surface 30c of the movable mold 30a as shown in FIG. 14B. After completion of the alignment, as shown in FIG. 9, the film sheet 14 is fixed to the mating surface 30c of the movable mold 30a by the clamp device 134. Thereby, the film sheet 14 with the embedded body 16 attached thereto is fixed to the mating surface 30c of the movable mold 30a in a flat state.

  When the film sheet 14 is fixed to the mating surface 30c of the movable mold 30a, the suction of the film sheet 14 by the suction plate 100 of the hand tool 94 of the sheet conveying device 54 is stopped, and the hand tool 94 is fixed to the movable mold 30a and the fixed mold. Retreat from 30b. Then, the injection molding device 58 closes the mold 30 to produce the film integrated molded product 10 provided on the surface with the film sheet 14 in which the embedded body 16 is at least partially embedded.

  According to this embodiment, the film sheet 14 is produced from the roll film 60. Further, by changing the moving amount of the film chuck unit 64 in a state where the leading end portion of the roll film 60 is sucked and held, the sheet film 14 having a desired length can be produced. For example, a length necessary for manufacturing the film integrated molded product 10 and a clamp margin (a portion where the clamp device 134 clamps) necessary to fix the film to the mold 30 of the injection molding device 58 are provided. It becomes possible to produce the film sheet 14 of the length. If such a film sheet 14 is fixed to the mold 30 of the injection molding apparatus 58 to produce the film integrated molded product 10, the film loss can be reduced.

  In addition, the cutter unit is a roll film having different widths by installing a blade capable of cutting the maximum width roll film 60 that may be used in manufacturing the film integrated molded product 10 in the width direction. Even if it is changed to, it is not necessary to produce a cutter unit in accordance with it, and it can be applied to a roll film 60 of any width.

  Further, since it is not necessary to set the roll film in a film feeding device provided integrally with the mold of the injection molding apparatus, it is not necessary to stop the operation of the injection molding apparatus for the setting, and the injection molding apparatus It is possible to maintain a constant operating rate and increase production efficiency.

  Furthermore, the film sheet produced by the film cutting device 52 is easier to set on the mold 30 than the roll film 60. Also, the set can be easily automated. Therefore, as described above, the robot 96 can align the film sheet 14 with the mold.

  In addition, when the film chuck unit 64 pulls out the leading end portion by adsorbing and holding the leading end portion of the roll film 60 and moves, the leading end portion is cut when the cutter unit 66 cuts the portion 60 a of the drawn out roll film 60. It functions as a means to fix. Further, it functions as means for conveying the film sheet 14 produced by cutting the cutter unit 66 to the suction table 70. Thereby, it is not necessary to provide a film fixing means or a film conveying means at the time of cutting separately, and the configuration of the film cutting device 52 for producing the film sheet 14 from the roll film 60 becomes simple.

  In addition, since the film sheet 14 produced from the roll film 60 is sucked and fixed to the suction table 70, the film sheet 14 is transported to an injection molding device 58 for manufacturing a film integrated molded product. The device 54 can be handled easily.

  In addition, compared with the conventional method, it is not necessary to install a clamp device that fixes the tip of the roll-shaped film fed into the mold and a heat cutter that cuts the film, so the cost of the mold is reduced and maintenance is performed. Will also be easier.

  Although the present invention has been described with reference to the above embodiment, the present invention is not limited to the above embodiment.

  For example, in the above-described embodiment, the film integrated molded product is a film integrated molded product in which the embedded body is embedded in the film, but the present invention is not limited thereto. It may be a film-integrated molded article simply having a film integrally on its surface.

14 Sheet film (film sheet)
60 Roll film (roll film)
64 Film chuck unit 66 Cutter unit 70 Sheet suction table (suction table)
70a Adsorption surface

Claims (5)

A film cutting apparatus for producing a sheet film by cutting a roll film in its width direction,
A film roll support mechanism for rotatably and replaceably supporting a roll film;
A film chuck unit that pulls out the leading end by moving in a state of sucking and holding the leading end of the roll film supported by the roll support mechanism;
A cutter unit including a blade for producing a sheet-like film by cutting a portion of a roll-like film drawn out by the film chuck unit in the film width direction;
A sheet suction table having a suction surface for sucking a sheet-like film by suction;
The film chuck unit adsorbs and holds the leading end of the roll film and moves by a set amount. When the film is cut by the cutter unit, the adsorbed and held state is maintained. The film cutting device is configured to move to the sheet suction table in a state where the sheet-like film is sucked and held, and to stop the suction when the sheet-like film is positioned on the sheet suction table. Film chuck unit
A suction pad that sucks and holds the surface of the film on the side opposite to the sheet suction table;
An air cylinder that supports the suction pad and presses the sheet-like film against the suction surface of the sheet suction table via the suction pad;
Sheet adsorption table
After the film chuck unit presses the sheet film against the suction surface, the suction of the sheet film is started,
Film chuck unit
The film cutting device according to claim 1, wherein the suction of the suction pad is stopped after the sheet suction table starts suction of the sheet-like film, and the suction pad is separated from the sheet-like film via an air cylinder.   The film cutting apparatus according to claim 1, further comprising a roller that rolls on a surface of the sheet-like film adsorbed on the sheet adsorbing table. A roller is provided in the film chuck unit,
The film cutting apparatus according to claim 3, wherein the roller rolls on the surface of the sheet-like film adsorbed by the sheet adsorbing table as the film chuck unit moves.   5. The film cutting device according to claim 1, wherein the film suction table is configured to stop suction when another device handles the sheet-like film on the film suction table.

Images