JPH06270199A - Apparatus and method for manufacturing insert folded form - Google Patents

Abstract

PURPOSE:To prevent adherence of scrap to a surface of an insert molded form by so preforming and trimming an insert material by heat molding as to coincide with a cavity molding surface shape of molds, conveying the material to the molds, and mounting it at the cavity molding surface. CONSTITUTION:An insert material 7 is so preformed by preforming means 10 as to coincide with a cavity forming molding surface 6 of a female mold 3 having no resin injection port 4 of injection molds 1. An unnecessary peripheral edge extended part of the material 7 is trimmed by trimming means 20. The trimmed material 7 is conveyed to and mounted at the cavity molding surface of the female mold by conveying and mounting means 30. The molds 1 are clamped, and molding resin is injected to form an insert molded form. Thus, since the form is not formed with an extended part of the material and scrape of the material in the molds does not occur, adherence of the scrap to the surface of the form is eliminated, and its nondefective rate is improved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for manufacturing insert-molded products used for front panels and buttons of AV equipment, instrument panels of automobiles and the like.

[0002]

2. Description of the Related Art Conventionally, as an insert molded article manufacturing apparatus and an insert molded article manufacturing method, (1) JP-A-57-1 is used.
There are those described in JP-A No. 02328 and JP-A-59-202834, or (2) those described in JP-A-63-25012. In (1), the insert material made of a preformed plastic film is mounted on the female die of the injection molding die for insert molding, but the insert material is unnecessary in the injection molding die. The part is cut off.

(2) A pair of molds that define a cavity in the shape of the product to be molded, and a cutting means that operates to cut a blank from a long insert film,
First, a long insert film was cut into an appropriate length by the cutting means by using a device comprising a blank means, which was supplied from a cutting means to a mold and placed in a cavity to prepare for a molding operation. After that, by further forming a notch, a blank having the shape of the developed view having the wing portion is formed,
Next, the blank is supplied and introduced by the transfer means to the mold ready for the molding operation, the mold is closed, and insert molding is performed, but the blank in the flat state without preform is injected. Introduced into the molding die.
Moreover, the blank introduced into the injection-molding die was preformed by bending the wing portion of the blank by once adhering it to the male mold, and after the mold was closed, by the pressure of the molding resin injected from the male mold. The blank is pressed from the male surface to the female surface.

[0004]

However, there have conventionally been the following problems. In (1), the unnecessary part of the insert material is cut off by utilizing the edge of the male die and the edge of the female die of the injection molding die. Therefore, the film residue generated during cutting of the insert material is accumulated around the edge of the mold to form a hard mass, which damages the surface around the edge of the mold, resulting in frequent replacement of the mold and cost. Takes. Further, the film residue adheres to the surface of the insert material or the mold and is mixed with the molding resin, so that the film residue adheres to the surface of the insert molded product, resulting in a high defect rate.

Further, since the injection mold has a structure in which the molding resin is injected from either the male mold or the female mold, the heating temperature differs between the male mold and the female mold and the expansion coefficient also differs.
Therefore, it is difficult to always keep the distance between the male edge and the female edge constant. Therefore, when the male edge and the female edge are too close to each other, a blade spill occurs, and when the male edge and the female edge are too far apart, cutting failure of the insert material occurs, and the die Costs film and film costs.

In (2), a notch is formed in the insert film and trimmed into the shape of the developed view having the wing portion so as to match the cavity forming concave shape of the female die of the injection molding die. . Therefore, for example, when obtaining an insert-molded product with a three-dimensionally smoothly curved surface shape such as a round bowl, the cutout shape should be accurate so that the molten molding resin does not leak from the seams of the blank blades. It has to be set to be time-consuming, time-consuming, and not practical. Further, since the blank has a seam of the wing portion, the seam appears on the surface of the molded product, which is not preferable in terms of design.

Further, in (2), a blank which is not preformed into the concave surface shape of the cavity of the female mold and is in a flat state is introduced into the injection molding die. Therefore, it is necessary to preform in the injection mold,
Therefore, in (2), the blank is once brought into close contact with the male cavity-forming convex surface, and then pressed against the female cavity-forming concave surface by the pressure of the molding resin. However, the pressure applied to the blank near the resin injection port and the pressure applied to the blank in the part away from the resin injection port are not uniform. For this reason, the blank is deformed or wrinkled while being pushed by the molten molding resin, and the position of the blank is displaced during the movement from the male die to the female die, resulting in the accuracy of the female die. It may not be installed in the correct position.

An object of the present invention is to solve the above-mentioned problems, and a film residue is not generated in the injection molding die, and the insert can be neatly inserted at a correct position on the cavity forming surface having an arbitrary three-dimensional shape. An object of the present invention is to provide an insert molded product manufacturing apparatus and an insert molded product manufacturing method for obtaining an insert molded product having a high yield rate at a low cost, in which a material can be adhered and a molding resin does not appear on the surface of the insert molded product. .

[0009]

In order to achieve the above object, the insert molded article manufacturing apparatus according to the present invention inserts an insert so as to substantially match the shape of the cavity forming surface of the male mold or the female mold of the injection molding die. Preforming means for preforming the material, trimming means for trimming unnecessary parts of the insert material so as not to protrude from the peripheral edge of the surface of the desired three-dimensional molded product, and molding the desired three-dimensional molded product by closing the mold. For injection molding comprising a male mold having a cavity forming convex surface for forming a cavity and a female mold having a cavity forming concave surface, and carrying the preform and trimmed insert material to the injection molding die for injection molding It is configured so as to include a conveying / mounting means to be mounted on a cavity forming surface of a male mold or a female mold.

Further, according to the method of manufacturing an insert-molded product of the present invention, the insert is formed so as to substantially match the shape of the cavity forming surface of the male mold or the female mold of the injection molding die on the side where the resin injection port is not provided. While preforming the material, trim unnecessary parts of the insert material so that it does not protrude from the peripheral edge of the surface of the desired three-dimensional molded product, then carry the preform and trimmed insert material to the injection molding die, It is mounted on the cavity forming surface of the male mold or the female mold of the injection molding die, and then the female mold and the male mold are closed to form a cavity, the molding resin is injected into the cavity, and the molding resin is cooled and solidified. After that, the insert-molded product was taken out from the injection-molding die.

[0011]

According to the present invention, the preform means preforms the insert material so as to substantially match the shape of the cavity forming surface of the injection mold, and the trimming means causes the insert material to protrude from the peripheral edge of the desired three-dimensional molded article. The unnecessary part of the insert material is cut off so that it will not be attached before it is mounted on the injection mold. Therefore, the film residue adheres to the surface of the injection mold,
It does not get mixed in with the molten resin. In addition, spillage of the injection molding die and defective cutting of the insert material do not occur.

Further, in the present invention, the insert material is preformed by the preforming means so as to substantially conform to the shape of the cavity forming surface of the injection mold. Therefore, even if the cavity forming surface of the male mold or the female mold of the injection molding die is a three-dimensional curved surface, it is not necessary to form a cutout in the insert material, and therefore the molding resin leaks from the cutout portion. There is no such thing. Further, the cutout portion does not appear on the surface of the three-dimensional molded product.

Further, according to the present invention, the preformed insert material is transferred to the cavity forming surface of the male mold or the female mold of the injection molding die on the side where the resin injection port is not provided by the conveying and mounting means. It can also be installed directly. Therefore, it is not necessary to press the insert material from one mold to the other mold by the pressure of the molding resin.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the drawings. First, the insert molded article manufacturing apparatus will be described. The preforming means 10 is a male mold 2 of the injection mold 1.
The insert material 7 is preformed by thermoforming so as to substantially match the shape of the cavity forming surface (see FIGS. 6 to 8). It should be noted that the male mold 2 having the resin injection port 4 is mounted on the cavity forming convex surface 5 (see FIG. 17).
(See (b)) When the insert material 7 is obtained, when the male mold 2 and the female mold 3 are closed to form the cavity 8, the bottom surface of the cavity forming concave surface 6 of the female mold 3 and the bottom surface of the insert material 7 Preforming means 1 capable of preforming the insert material 7 in a shape such that the contacting parts (see FIG. 17 (b))
It is good to use 0.

As the preforming means 10, there is a press molding means (see FIGS. 2 to 6) consisting of an upper core mold 11 and a lower cavity mold 12. In this case, the insert material 7 whose end is fixed by the clamp means 13 (see FIG.
(A)), the convex portion 110 of the upper core mold 11 and the concave portion 120 of the lower cavity mold 12 are sandwiched and preformed (FIG. 6B). When the convex surface shape of the convex portion 110 of the upper core mold 11 is completely or almost the same as the cavity forming convex surface 5 of the male mold 2 of the injection molding die 1,
The preformed insert material 7 is an injection molding die 1.
The male mold 2 is mounted on the convex surface 5 for forming the cavity and used (see FIGS. 15 to 17). In addition, when the concave surface shape of the concave portion 120 of the lower cavity mold 12 is completely or almost the same as the cavity forming concave surface 6 of the female mold 3 of the injection molding die 1, the preformed insert material 7 is , The cavity forming concave surface 6 of the female die 3 of the injection molding die 1 is used (see FIG. 4). The preformed insert material 7 can be left in the lower cavity mold 12 by attaching the vacuum suction means 14 to the lower cavity mold 12, or by providing the lower cavity mold 12 with a pneumatic means or an ejector means, or by using an upper core. Vacuum suction means 14 may be attached to the mold 11 so that it remains in the upper core mold 11.

As another preforming means 10, there is a vacuum forming means (see FIG. 7) comprising a lower cavity mold 12 and a vacuum suction means 14. In this case, the clamp means 13
Insert material 7 whose end is fixed by (Fig.
(A)), the concave portion 1 of the lower cavity mold 12 by vacuum suction
Preform by closely contacting the concave surface of 20 (Fig. 7).
(B)). The insert material 7 may be a preform so as to have a shape to be mounted on the cavity forming convex surface 5 of the male die 2 of the injection molding die 1 in this way, or the female die 3
The cavity forming concave surface 6 may be preformed into a shape to be mounted.

Further, as another preforming means 10, there is a vacuum forming means (see FIG. 8) comprising a lower core die 15, an upper cavity die 16 and a vacuum suction means 14. In this case, the insert member 7 whose end is fixed by the clamp means 13 (FIG. 8A) is formed by the protrusion 1 of the lower core mold 15.
Lower core mold 15 by pressing against 50 and by vacuum suction
This is preformed by closely contacting the convex surface of the convex portion 150 (FIG. 8B). The insert material 7 may be preformed so as to be mounted on the cavity forming convex surface 5 of the male mold 2 of the injection molding die 1, or preformed so as to be mounted on the cavity forming concave surface 6 of the female mold 3. Good.
The preformed insert material 7 can be left in the lower core mold 15 or can be left in the upper cavity mold 16. When the upper cavity mold 16 is left, the lower core mold 15 is provided with a pneumatic means or an ejector means (not shown), or the upper cavity mold 16 is provided with a vacuum suction means (not shown). It can remain in the mold 16.

In any of the above preforming means, in order to easily preform the insert material 7, heating means 17 such as a heating plate or a hot air blower (FIG. 7 (a),
8 (see FIG. 8) may be installed so that it can move in and out between the inside and the outside of the preforming means 10.

The trimming means 20 should not extend beyond the peripheral edge 61 of the surface of the desired three-dimensional molded article 60 (FIG. 25,
This is a means for trimming unnecessary parts of the insert material 7 (see FIGS. 6 to 8). As the trimming means, a press cutting machine having a cutting blade 21 (FIG. 6,
(See FIG. 7), or a heating cutter (not shown), a laser cutter (not shown), etc., which burns out only the necessary portion may be used. Also, using a core-type edge and a cavity-type edge, the spacing between the two edges is 0.
A cutting die (see FIG. 8) for cutting may be used by setting a gap of 005 to 0.03 mm so as to open.

Preforming means 10 and trimming means 2
0 may be prepared separately. Alternatively, a preform and trimming combined means including a core mold with a cutting blade 21 and a cavity mold having a vacuum suction means 14 are prepared so that the preform and trimming of the insert material 7 can be performed at the same time. It may be present (see FIGS. 6 to 8).

The preform means 10 or the trimming means 20 may be provided with an insert material supplying means 40 (see FIG. 9) consisting of an unwinding roll 41 and a winding roll 42. The insert material supplying means 40 is a means for intermittently supplying the insert material 7 into the apparatus including the preforming means 10 and the trimming means 20.
The insert material 7 supplied from the unwinding roll 41 forms a shell and is wound up by the winding roll 42.

Further, a laminating means 70 having a heating part, a pressing part, etc. is installed at a position between the time when the insert material 7 is unwound and the time when it is sent to the preforming means 10 or the trimming means 20. It may be stored (see FIG. 9). The laminating means 70 laminates the thick second light-transmissive base material 77 in order to make the insert material 7 strong so that the preformed insert material 7 does not lose its shape.

The injection molding die 1 has a cavity forming convex surface 5
And a female mold 3 having a cavity forming concave surface 6
And (see FIG. 1). The male mold 2 and the female mold 3 are closed to form a cavity 8 for molding a desired three-dimensional molded product 60. Cavity forming convex surface 5
The resin injection port 4 is provided on the cavity forming surface composed of the cavity forming concave surface 6 and the cavity forming concave surface 6.
Molding resin 9 is injected into the inside (see FIG. 5).

The resin injection port 4 may be formed on the cavity forming convex surface 5 of the male mold 2 (see FIG. 1), or the female mold 3 may be formed.
It may be formed on the cavity forming concave surface 6 of FIG.
5). In the former case, the preformed and trimmed insert material 7 is mounted on the cavity forming concave surface 6 of the female die 3, and the obtained insert molded article 100 has the insert material 7 on the convex surface 66 of the three-dimensional molded article 60. Are formed (see FIG. 25). Further, in the latter case, the preformed and trimmed insert material 7 is mounted on the cavity forming convex surface 5 of the male mold 2, and the obtained insert molded product 100 is inserted into the concave surface 67 of the three-dimensional molded product 60. The material 7 is formed (see FIG. 26).

The injection molding die 1 has a structure shown in FIGS.
As shown in FIGS. 14 and 15 to 17, there is a mold attached to a vertical injection molding machine configured so that the molding resin is vertically injected. Alternatively, FIGS.
As shown in (1), there is a mold attached to a horizontal injection molding machine configured so that the molding resin is horizontally injected.

The conveying / mounting means 30 conveys the preform and the trimmed insert material to the injection molding die 1, and the cavity forming convex surface 5 or the cavity forming concave surface of the male mold 2 or the female mold 3 of the injection molding mold 1. 6 is a means for mounting. The carrier / mounting means 30 includes a support base 31, a movable arm 32, a carrier head 33, and the like. The support base 31 is installed at a position fixed to the preforming means 10, the trimming means 20 and the injection molding die 1. The movable arm 32 is rotatable about the support base 31, is rotatable about the axis of the movable arm 32, and is provided so as to be vertically and horizontally movable with respect to the support body. . The transfer head 33 is movably provided so as to move away from or approach the movable arm 32. Transport and mounting means 30
May consist of an articulated robot. Therefore, the transfer head 33 fixed to the movable arm 32 can reciprocate between the position of the preforming means 10 or the trimming means 20 and the position of the cavity forming surface of the injection molding die 1. In addition, the transport head 33 can face any direction such as the core mold or the cavity mold in the preforming means 10 or the trimming means 20. Inside,
It can be oriented in any direction such as facing the male mold 2 or the female mold 3. Further, the transport head 33 is provided with vacuum suction means, compressed air means, suction cups (not shown), etc., and the preformed and trimmed insert material 7 is provided.
It is advisable to hold and release the above.

The conveying / mounting means 30 may be provided with an insert molded product removing means 50. A suction cup 51, a vacuum suction means, a compressed air means (not shown), etc. are provided on the back surface of the transfer head 33, and the insert molded product 10
It is preferable that 0 can be held and released arbitrarily (see FIG. 24).

Next, a method for manufacturing an insert molded product will be described. First, the insert material 7 is preformed so as to substantially match the shape of the cavity forming convex surface 5 or the shape of the cavity forming concave surface 6 of the male mold 2 or the female mold 3 of the injection molding die 1, and a desired three-dimensional molded product 60 is formed. The unnecessary portion of the insert material 7 is trimmed so as not to protrude from the peripheral edge 61 of the surface (see FIGS. 25 and 26) (FIGS. 2 and 6).
~ See Figure 8).

As the insert material 7, on the base material 71,
There is one in which a pattern layer 72, an adhesive layer 73 and the like are sequentially formed (see FIG. 18). The base material 71 is used as a base material film or base material sheet of an ordinary insert material, and includes a plastic film such as polyethylene terephthalate. The pattern layer 72 is formed by a normal forming method such as printing using translucent ink or light-shielding ink in order to form patterns, paintings, logos, characters, blank characters, symbols, etc. on the surface of the three-dimensional molded product 60. Is formed by. Pattern layer 72
May have a metal layer formed by vacuum vapor deposition. The adhesive layer 73 is for adhering the insert material 7 to the surface of the three-dimensional molded product 60 at the same time when the three-dimensional molded product 60 is molded, and using a resin of the same type as the resin forming the three-dimensional molded product 60, such as printing. It is formed by a normal forming method.

In addition, as the insert material 7, a first colored layer 75 having a cutout portion 78 representing a character or a symbol is formed on the first transparent base material 74, and at least the cutout portion 78 is transparent. The second colored layer 76 having a light property is formed,
Further, a thick second translucent base material 77 may be formed. The thick second light-transmissive base material 77 is a film-like or sheet-like base material formed to give the insert material 7 an appropriate strength as a whole so as not to lose its shape after being preformed. Yes (see FIG. 19). Any material can be used as the insert material 7 as long as it can be preformed and trimmed and can be in close contact with the molding resin 9.

Preforming of the insert material 7 is preferably performed by using the preforming means 10 described above. In order to facilitate preforming, the insert material 7 may be heated and softened by using the heating means 17 during press molding or vacuum molding (see FIGS. 7A and 8A and 8B).
The insert material 7 mounted on the cavity forming convex surface 5 of the male mold 2 having the resin injection port 4 (see FIG. 17B).
In order to obtain the above, when the male mold 2 and the female mold 3 are closed to form the cavity 8, the bottom surface of the cavity forming concave surface 6 of the female mold 3 and the bottom surface of the insert material 7 are in contact with each other (see FIG. 17 (b)), the insert material 7 may be preformed.

The trimming of the insert material 7 is preferably performed by using the trimming means 20 described above. The trimming shape of the insert material 7 is a shape that does not at least protrude from the peripheral edge 61 of the surface of a desired three-dimensional molded product 60 obtained by the injection molding die 1 described later. Specifically, when the three-dimensional molded article 60 is a button-shaped three-dimensional molded article having a horizontal plane portion 62 and a frustoconical skirt portion 63 (see FIG. 2).
5, see FIG. 26), the insert material 7 is a three-dimensional molded product 60.
The horizontal surface 62 and the skirt portion 63 are covered with the skirt portion 63, and the skirt portion 63 protrudes from the peripheral edge 61 of the skirt portion 63 and does not have a tongue shape (see FIGS. 25 and 26). As another example, the skirt portion 63 is provided downward from the peripheral edge of the horizontal surface portion 62.
Is further provided, and a flange portion 64 is provided around the skirt portion 63, and a second portion is provided downward from the peripheral end of the flange portion 64.
In the case of a three-dimensional molded product having a skirt portion 65, the three-dimensional molded product 60 is shaped so as to cover the translucent three-dimensional molded product 60 so as not to protrude from the flange portion 64 or the second skirt portion 65 (FIG. 27). reference).

The preforming and trimming of the insert material 7 may be performed separately. The insert material 7 may be preformed and trimmed at the same time by using both preforming and trimming (see FIGS. 6 to 8).

For preforming and trimming the insert material 7, the insert material 7 is intermittently fed to the preform means 10 or the trimming means 20 by using the insert material supply means 40 consisting of the unwinding roll 41 and the winding roll 42. May be supplied to the device (see FIG. 9).
However, in the case of the insert material 7 having the thick second translucent base material 77 described above, the second translucent base material 77 is hard,
It may not be possible to wind it into a roll. In this case, in a state where the second light-transmissive base material 77 is not provided, it is unrolled from the unwinding roll 41 to reach the preforming means 10 or the trimming means 20 by the laminating means 70 or the like. The translucent base material 77 may be laminated, then preformed, trimmed, and wound by the winding roll 42 (see FIG. 9).

Next, the preform and the trimmed insert material 7 are conveyed to the injection mold 1 and mounted on the cavity forming surface of the male mold 2 or the female mold 3 of the injection mold 1 (FIGS. 3 to 3). 5, FIGS. 10 to 14, and 15 to 1
7, FIG. 20 to FIG. 23). The cavity forming surface includes the cavity forming convex surface 5 of the male mold 2 and the cavity forming concave surface 6 of the female mold 3.

The carrying and mounting of the preformed and trimmed insert material 7 may be carried out by the carrying / mounting means 30 comprising the support base 31, the movable arm 32 and the carrying head 33. For example, when the insert material 7 remaining in the recess 120 of the lower cavity mold 12 of the preforming means 10 is conveyed and mounted on the cavity forming concave surface 6 of the injection mold 1 attached to the vertical injection molding machine ( In FIGS. 3 to 4), first, the transport head 33 is brought close to the concave portion of the lower cavity mold 12 of the preforming means 10, and the transport head 33 holds the insert material 7 (see FIG. 3). Next, the movable arm 3 with the support 31 as an axis.
2 is rotated 180 degrees, and the conveying head 33 is mounted so as to face the cavity forming concave surface 6 of the injection molding die 1 (see FIG. 4).
(See FIG. 24), if necessary, the insert molded product take-out means 50 provided on the back surface of the transport head 33 holds the insert molded product 100 remaining on the cavity forming convex surface 5 (see FIG. 24), and the transport head 33 carries out the next transport. In order to prepare for the above, it is retracted from the injection molding die 1 (see FIG. 5).

Alternatively, when the insert material remaining in the upper cavity mold 16 of the preforming means 10 is conveyed and mounted on the cavity forming concave surface 6 of the injection mold 1 attached to the vertical injection molding machine (see FIG. (See 10 to 14)
First, the conveying head 33 facing upward is brought close to the concave portion 160 of the upper cavity mold 16 of the preforming means 10 to hold the insert material 7 on the conveying head 33 (FIG. 10, FIG. 1).
1). Next, with the axis of the movable arm 32 as the center,
The conveyance head 33 is rotated downward by 80 degrees (see FIG. 1).
2). Next, the movable arm 3 with the support 31 as an axis.
2 is rotated 180 degrees (see FIG. 13), and the transport head 33
Is mounted so as to face the cavity forming concave surface 6 of the injection molding die 1 (see FIG. 14), and is retracted from the inside of the injection molding die 1 in preparation for the next conveyance.

Alternatively, the insert material 7 remaining on the convex portion 110 of the upper core mold 11 of the preforming means 10 is conveyed to the cavity forming concave surface 6 of the injection mold 1 attached to the vertical injection molding machine. When installing (Figs. 15-17)
First, the upward conveying head 33 is brought close to the convex portion 110 of the upper core mold 11 of the preforming means 10, and the insert material 7 is held by the suction cups 51 provided on the conveying head 33 (FIGS. 15 and 16). reference). Next, the movable arm 32 is rotated 180 degrees about the support body 31, the conveyance head 33 is attached so as to face the cavity forming convex surface 5 of the injection molding die 1 (see FIG. 17A), and conveyance is performed. The head 33 retracts from the injection molding die 1 in preparation for the next conveyance.

Alternatively, the insert material 7 remaining in the recess 120 of the lower cavity mold 12 of the preforming means 10 is conveyed and mounted on the cavity forming concave surface 6 of the injection mold 1 attached to the horizontal injection molding machine. Case (Fig. 20-
23), first, the transfer head 33 is brought close to the recess 120 of the lower cavity mold 12 of the preforming means 10,
The insert material 7 is held by the transport head 33 (FIG. 20,
See FIG. 21). Next, the movable head 32 is rotated 90 degrees about the axis of the movable arm 32, and the transport head 33 is turned sideways (see FIG. 22). Next, the movable arm 32 is rotated 180 degrees about the support body 31, and the transfer head 33 is attached so as to face the cavity forming concave surface 6 of the injection molding die 1 (see FIG. 23), and if necessary, transfer is performed. The insert-molded product take-out means 50 provided on the back surface of the head 33 holds the insert-molded product 100 remaining on the cavity forming convex surface 5 (see FIG. 24), and the transport head 33 prepares the injection-molded metal in preparation for the next transport. Withdraw from the mold 1.

Since the insert material 7 has already been preformed so as to substantially match the cavity forming concave surface 6 of the female mold 3 or the cavity forming convex surface 5 of the male mold 1,
By simply fitting the cavity forming concave surface 6 of the female mold 2 or the cavity forming convex surface 5 of the male mold 2, it can be mounted at a predetermined position.

Next, the male mold 2 and the female mold 3 are closed to form a cavity 8, and a molding resin 9 is injected into the cavity 8 (see FIG. 5), and waits for cooling and solidification of the three-dimensional molded product 60. Then, the insert molded product 100 having the insert material 7 formed on the surface of the three-dimensional molded product 60 is taken out from the injection molding die 1.
The take-out of the insert-molded product 100 is performed by the transport head 33.
It is preferable to use the insert molded product takeout means 50 or the like provided on the back surface of the.

The adhesive layer of the insert material 7 is melted by the heat of the resin when the molding resin 9 is injected, and the adhesive layer adheres to the surface of the three-dimensional molded article 60 as the molding resin 9 is cooled and solidified. Examples of the molding resin 9 include acrylonitrile styrene resin, polycarbonate resin, polystyrene resin, acrylic resin, polyester resin and the like.

[0043]

The present invention has the following effects due to the above-described structure and operation. (1) Since no film dust is generated in the injection molding die, there is no damage to the injection molding die due to the accumulation of film dust. In addition, the surface of the insert-molded product can be obtained with a high rate of non-defective products, in which no film residue adheres to the surface of the insert-molded product.
Also, when cutting the insert material, blade spillage may occur,
It does not cost much because the defective cutting of the insert material does not occur.

(2) Since the molding resin does not leak from the insert material, the molding resin does not adhere to the surface of the insert material even in the case of a three-dimensionally smoothly curved concave curved surface. Further, since the insert material has no seam, it is preferable in terms of design.

(3) The preformed and trimmed insert material can be mounted on the cavity forming surface of the male mold or the female mold of the injection molding die on the side where the resin injection port is not provided. Since it is not necessary to press from one mold to the other mold by the pressure of the molding resin, the insert material is not deformed or wrinkled, or the position is not displaced.

[Brief description of drawings]

FIG. 1 is an explanatory sectional view showing a step of an insert-molded product manufacturing apparatus and an insert-molded product manufacturing method according to the present invention.

FIG. 2 is an explanatory cross-sectional view showing a state where an insert material is preformed and trimmed in the insert-molded product manufacturing apparatus and the insert-molded product manufacturing method of the present invention.

FIG. 3 is an explanatory cross-sectional view showing a state where a carrying / mounting means holds a preformed and trimmed insert material.

FIG. 4 is an explanatory cross-sectional view showing a state where a preform and trimmed insert material is mounted on an injection molding die by a conveying and mounting means.

FIG. 5 is an explanatory cross-sectional view showing a state where a preformed and trimmed insert material is sandwiched in an injection molding die and injection molded.

FIG. 6 is an explanatory sectional view showing a preforming means and a trimming means in the insert molded article manufacturing apparatus of the present invention.

FIG. 7 is an explanatory cross-sectional view showing another preform means and trimming means in the insert-molded article manufacturing apparatus of the present invention.

FIG. 8 is an explanatory cross-sectional view showing another preform means and trimming means in the insert molded article manufacturing apparatus of the present invention.

FIG. 9 is an explanatory sectional view showing an example of an apparatus for supplying an insert material to the preform means and the trimming means in the insert molded article manufacturing apparatus of the present invention.

FIG. 10 is an explanatory cross-sectional view showing a conveying / mounting means in the insert-molded article manufacturing apparatus of the present invention.

FIG. 11 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG.

FIG. 12 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG.

13 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG.

FIG. 14 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG.

FIG. 15 is an explanatory sectional view showing another carrying / mounting means in the insert-molded article manufacturing apparatus of the present invention.

16 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG.

17 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG.

FIG. 18 is an explanatory sectional view showing an insert material used in the present invention.

FIG. 19 is an explanatory cross-sectional view showing another insert material used in the present invention.

FIG. 20 is an explanatory sectional view showing another carrying / mounting means in the insert-molded article manufacturing apparatus of the present invention.

FIG. 21 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG. 20.

22 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG. 20. FIG.

FIG. 23 is an explanatory cross-sectional view showing one operation of the carrying / mounting means of FIG. 20.

FIG. 24 is an explanatory cross-sectional view showing the insert-molded product removing device provided in the conveying / mounting device in the insert-molded product manufacturing apparatus of the present invention.

FIG. 25 is an explanatory sectional view showing an example of an insert-molded article obtained by the present invention.

FIG. 26 is an explanatory sectional view showing another example of the insert-molded article obtained by the present invention.

FIG. 27 is an explanatory sectional view showing another example of the insert-molded article obtained by the present invention.

[Explanation of symbols]

 1 Injection Mold 2 Male 3 Female 4 Resin Injection Port 5 Cavity Forming Convex 6 Cavity Forming Concave 7 Insert Material 8 Cavity 9 Molding Resin 100 Insert Molded Product 10 Preform Means 11 Upper Core Mold 110 Convex 12 Lower Cavity Mold 120 concave part 13 clamping means 14 vacuum suction means 15 lower core type 150 convex part 16 upper cavity type 160 concave part 17 heating means 20 trimming means 21 cutting blade 30 conveying and mounting means 31 support 32 movable arm 33 conveying head 40 insert material supplying means 41 Unwinding Roll 42 Winding Roll 50 Insert Molded Product Taking Out Means 60 Three-dimensional Molded Product 61 Peripheral Edge 62 Horizontal Plane Section 63 Skirt Part 64 Flange Part 65 Second Skirt Part 66 Convex Surface 67 Concave Surface 70 Laminating Means 71 Base Material 72 Pattern Layer 73 Contact Layer 74 first translucent substrate 75 first colored layer 76 second colored layer 77 second translucent substrate 78 cut-out portion 100 insert-molded article

Claims (5)

[Claims] 1. Preforming means for preforming an insert material by thermoforming so as to substantially match the shape of a cavity forming surface of a male mold or a female mold of an injection molding die,
Trimming means for trimming unnecessary parts of the insert material so as not to protrude from the peripheral edge of the surface of the desired three-dimensional molded product, and a male mold and a female mold which are closed to form a cavity for molding the desired three-dimensional molded product. From an injection molding die consisting of a mold and a conveying and mounting means for conveying the preform and trimmed insert material to the injection molding die and mounting it on the cavity forming surface of the male or female mold of the injection molding die. An insert-molded product manufacturing apparatus characterized by: 2. The insert-molded article manufacturing apparatus according to claim 1, wherein the preform means and the trimming means are integrated so that the insert material can be preformed and trimmed at the same time. 3. The insert molded article manufacturing apparatus according to claim 1, wherein the preform means or the trimming means is provided with an insert material supply means for intermittently unwinding and winding up the insert material. 4. The insert molded product manufacturing apparatus according to claim 1, wherein the insert molded product takeout means is provided in the conveying / mounting means. 5. The insert material is preformed so as to substantially match the shape of the cavity forming surface of the male mold or the female mold of the injection molding die, and the insert material does not protrude from the peripheral edge of the surface of the desired three-dimensional molded product. Trimming the unnecessary parts of, then transport the preform and trimmed insert material to the injection mold, and attach it to the cavity forming surface of the male mold or the female mold of the injection mold,
Next, the female mold and the male mold are closed to form a cavity, the molding resin is injected into the cavity, and the insert molded product is taken out from the injection molding die after cooling and solidifying the molding resin. Insert molding product manufacturing method.