JPH10651A - Method and apparatus for manufacturing molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and apparatus for manufacturing molded article by clamping the end peripheries of a thin film to be positively held in a split face between the mold having in a manner that a thin film is interposed between the two mold halves of a open injection molding machine and stability is obtained while the molds become close around the mold cavities prior to manufacturing a formed article. SOLUTION: This relates to a reprocessing method of a molded article 2 manufactured by a thermoplastic material covered with a thin film in a part of the surface and having peripheral part 8 of the thin film extending beyond the article 2. At least a part of peripheral parts of the thin film is laminated on the surface part of the article 2 because the peripheral parts become separated or shrunk as a result of cutting the peripheral parts of the end peripheries along the separation line. The peripheral parts 8 of the thin film are folded by guide rolls 26 and, next, if required, they are cut into a predetermined width by a cutting device 30 and then pressed against the surface area by means of pressing rolls 168 to subsequently be heated together with the surface area within the lamination device for welding the peripheral parts 8 of the thin film to the surface area, after that, the reprocessing is conducted by a reprocessing device in which the heating area of the formed article 2 is cooled again within the cooling device.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus for producing or reworking a partially thin-film molded article having a thin-film coating made of a thermoplastic material.

[0002]

2. Description of the Related Art Molded articles coated with thin films are used, for example, for the finishing of automobiles, plastic outer parts, door decoration and protection strips, other body parts, bang strips, outer mirrors, furniture, and even more. It is very widely used as a cooking device and a housing in the electronic communication field. In this case, thermoplastic materials such as polyurethane are most widely used. Basically, a molded part coated with a thin film is intended to give a part of its surface, especially a surface visible from the outside, a color different from the inherent color of the molded part, or a certain surface tone (molding). It can generally be used when it is not possible to apply the concave mold directly to the surface of the mold half of the tool, or when it is desired to apply a surface texture which would be very costly if possible. . Further uses for thin films on molded articles made of thermoplastic materials include, for example, poor coloration due to poor mounting, poor durability, or poor varnishing equipment from the manufacturer. May be possible.

[0003]

It is preferable to apply a thin film during the production of a molded article, since a thin film applied after production is generally insufficient in adhesive strength or extremely expensive to apply. . For this purpose, a thin film is placed between the two mold halves of an open injection molding machine before producing the molding. The edges of the membrane are clamped to ensure stability within the separation plane between the mold halves so that stability is obtained while the mold closes around the mold cavity. The thin film is oriented such that the colored surface, or surface-grained surface, faces in the opposite direction from the opening of the injection nozzle. Thereafter, plastic is injected into the mold cavity by injecting gas into the interior of the molded article. The plastic contacts the back surface of the film, presses the film against the opposite wall of the mold cavity, and when cured forms an integral bond with the film.

After curing, the mold is opened and the molded product is taken out. In this state, the molded product still has a gate, and the edge of the thin film (the edge that has been stretched in advance between the mold halves) protrudes beyond the molded product. And, after curing, the molded parts require rework before being delivered or before further processing steps are performed.

Conventionally, during rework, the edges of the thin film have been removed by hand or by an automatic cutting method or die along a line corresponding to the separation plane set by the mold halves. When designing the part, the above-mentioned lines coincide with the edges that make up the outer edge of the exposed surface of the part. However, in such a case, the edge of the film may separate slightly from the molded article, so that starting from the outer edge of the externally visible surface, most of the film may separate (in particular, If the outer parts for plastic cars are exposed to bad weather). Especially when cutting by hand, cut straight,
Also, there is no certainty of having a clean edge.

One object of the present invention is to obviate or mitigate the above-mentioned disadvantages.

[0007]

SUMMARY OF THE INVENTION Generally speaking, a feature of the method of the present invention is that at least a portion of the edge of the thin film is laminated to a still uncoated surface area of the molded article. . In this case, the surface area is located adjacent to the already coated surface area. Thus, in the preferred embodiment, the edge of the membrane extends from the outer edge of the externally visible surface of the molded article to a position that is not visible from the outside (a position protected by the molded article itself). If the separation line between the coated and uncoated surface areas extends along one edge (the edge that bounds the externally visible surface of the part) (a common case) This is particularly suitable.

According to a preferred embodiment of the invention, the edge of the membrane envelops this separating edge of the molded article and thereby surrounds the separating edge. Also, the edge of the thin film is laminated to the surface area of the molded article (at a position adjacent to the separation edge, preferably at a rear edge or a rear edge which is not visible from the outside). By this means, the peripheral edge of the thin film is displaced away from the separating edge which is particularly exposed at the edge of the surface visible from the outside of the molding. Thereby, especially, the adhesiveness and weather resistance of the plastic outer molded article made of plastic are improved. When machining a surface adjacent to a narrow surface portion of a molded article (such as a top or bottom surface of a C-shaped band strip), the edges of the thin film may correspond to the corresponding edges of the edge. It is advantageous that the part wrapping around and projecting beyond the end face extends substantially parallel to the membrane along the coated surface area adjacent to the end face. Laminating the edges of the membrane, i.e. forming an integral bond between the edge of the membrane and the molding, is in this case made over the entire width of the edge of the enveloped membrane. You.

A further preferred embodiment of the invention makes it possible to weld the edges of the membrane without pre-applying an adhesive or tackifier to the molded article. Basically, this is ensured by the use of a temperature-stable membrane that heats the thermoplastic material of the molded article and then presses its peripheral edge against the molded article. The preferred embodiment of the invention makes it possible, in particular, to use a thin film designed for the coating step, so that its edges can be subsequently welded. The film comprises at least one support layer with at least one thermally stable coating or varnish layer. The at least one support layer is oriented in the direction of the molded article and melts or softens when heat is applied. The support layer can be formed of a thermoplastic material, but it is preferable to use a thermally stable fluoropolymer for the cover layer.

[0010] Yet another advantageous embodiment of the invention is that the edge of the membrane projecting beyond the molded article is relatively wide so that it can be stably gripped between the mold halves during molding. According to the above, the protruding edge of the thin film is cut off before lamination. As a result of this cutting, an edge of the thin film having a predetermined width suitable for a specific molded product is formed. In the edge region, it is not desirable that the thin films are laminated so that the edges thereof overlap, but in this edge region, the thin film is cut or die-cut at an angle toward the edge direction of the molded article. It is also possible. In the case of a narrow and narrow molded article, it is also possible to completely cut the edge of the thin film at the narrow surface and to laminate only at the narrow side. According to a further advantageous embodiment of the invention, the edge of the membrane is placed on the uncoated surface, preferably at one-half the angle required to be able to be positioned relative to the area of the uncoated surface. If it bends or folds towards it, it will be easier to cut the edge of the thin film to a predetermined width.

[0011] To ensure uniform and repeatable positioning of the molded article during lamination and cutting of the edges of the membrane, the molded article is preferably first placed in a cavity in the support. The shape of the cavity conforms to the shape of the coating surface portion, so that at the edge of the part only the edges of the film extend beyond the cavity.

Finally, the edge portion of the thin film adjacent to the molded article is pressed against the molded article, and energy is applied to the edge to weld the edge to the molded article. Subsequent cooling steps performed under pressure until the thermoplastic material of the molded article, or the material of the backing layer of the thin film, is completely cured may result in loosening of the bond between the edge of the thin film and the molded article. It is surely prevented.

For example, in a narrow area facing forward,
If it is desired to stack around two edges, the stacking is preferably performed in two stages. First, the edge portion of the thin film adjacent to the coating surface area is bent around the first edge and laminated to the front surface. Thereafter, the remaining portion of the edge of the film is pressed against the uncoated surface adjacent to its front surface, after which it is energized and welded.

In general terms, an apparatus for reworking a molded article made of a thermoplastic material in which the edges of the thin film protrude and are partially coated with the thin film is known as an uncoated surface area of the molded article. And a device for stacking at least a part of the edge of the thin film protruding outward. According to one advantageous embodiment of the invention, the laminating device comprises at least one device for pressing and welding the edge of the thin film against the molding.

[0015] In front of the laminating device, it is advantageous to provide a further device, which advantageously has one or more blades, for cutting the edge of the thin film to a predetermined width.

In order to ensure uniform and repeatable positioning of the molding during both the cutting and lamination of the edge of the thin film, a further preferred embodiment of the invention comprises a cavity (in which the molding is formed). (Where the article can be placed). This support is movable with respect to the laminating device and the cutting device. Basically, the laminating device and the cutting device can be fixed in place, while the support of the molding is movable along the guide rail. However,
In the case of long moldings, space must be taken into account, and conversely, it is more advantageous to fix the support of the moldings and make the laminating and cutting devices movable.

The bending or folding of the edge of the thin film (the portion that protrudes outwardly around the molded article in approximately one plane after forming) is performed by using a guide device for the edge of the thin film in one or two steps. It is preferable to perform the above steps separately. This guiding device preferably has two or more guiding rolls arranged in sequence. Advantageously, a part of this guide roll mechanism is arranged at a position in front of the cutting device, and another part thereof is arranged between the cutting device and the laminating device.

[0018] In order to cool the edge of the deposited thin film quickly, it is advantageous to arrange a cooling device behind the laminating device. The cooling device can include a nozzle to which pressurized air is supplied. The opening of the nozzle is oriented towards the edge of the membrane. Advantageously, the cooling device further comprises one or more pressure rolls which press the edge of the membrane against the molding until the bond by welding is assured.

In order to enable the reworking of moldings of variable width or height, a further preferred embodiment of the invention is characterized in that the moldings or the membranes are positioned against the edges of the membranes or of the membranes. At least a part, preferably the whole, or an element of the reworking device, pressed against or gripping the edges of the membrane, has at least 1 ° of freedom, preferably 2 ° of freedom. It is adapted to be adjustable perpendicular to the direction of movement.

The reworking device, or a component of the device, positioned against or pressed against, or gripping, the edge of the molded article or thin film, moves in the direction of travel. To at least 1 °, or preferably 2 °, of freedom, and using a pressure device, one or two of the supports of the molding in which the device or its components are used. By ensuring that the molded product can be moved until it comes into contact with the contact surface described above, it becomes possible to rework a molded product having an edge surface curved in the movement direction. The pressure device can consist of a compression spring, a pneumatic drive or a hydraulic drive.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the accompanying drawings.

The apparatus shown in FIGS. 1 to 8 serves for reworking an injection-molded article 2 made of a thermoplastic material. The molded product is covered with a thin film 6 on a part 4 of the surface thereof by a molding device (not shown) (as shown in FIG. 8). Article 2
Is bent around two elongated edges of the molded article 2 at one of the edges 10 of the molded article forming the separating edge, and then cut to a suitable width. . Thereafter, the edge of the film is pressed into the uncoated surface area 12 of the molded part 2 during a further bending operation.
The region 12 is located adjacent to the edge 10, and
The edge 8 is thereby laminated or welded to the area 12. This molded article 2 is fixed in a fixed mounting support 14 for rework. Next, the mounting support 14
The part of the device displaceably mounted with respect to is moved over the mounting support 14 in the direction of arrow P (FIG. 1), so that the above-mentioned processing steps are performed one after the other. be able to.

The apparatus comprises a fixed base plate 1 having an upper surface 18 to which a mounting support 14 is removably mounted.
6 is provided. The base plate 16 is provided with two parallel cylindrical rails 20 arranged at equal intervals above the upper surface 18. Using a linear bearing 22, a carriage 24 is mounted on the rail 20 so that it can move back and forth in the longitudinal direction of the mounting support 14 (FIGS. 3 and 4). During the reworking of the molded part 2, in the direction opposite to the direction in which the carriage 24 moves (direction P in FIG. 1), the carriage 24 moves the two front guide rolls 26 (the thin film edge 8 into an upright position) ), A clamping roll 28 for securing the molded part in its mounting support 14, a cutting device 30 for cutting the edge 8 of the membrane, a further clamping roll 34, and adjoining the uncoated upper surface area 12. Two rear guide rolls 36 which bend the edge 8 of the membrane in position and two pressure rolls 3 which press the edge 8 of the membrane against the upper surface area 12
8, a laminating or welding device 40, and a cooling device 42 (FIGS. 1 and 2) in turn, one after the other.
Together, they constitute one reworking device.

The length of the rail 20 is set as follows.
That is, the carriage 24 may be positioned at both end faces 44, 44 of the molded article mounting support 14 in such a way that the complete reworking device provided on the carriage 24 can reach a position completely beyond both ends 44, 46. The length is such that it can be displaced in both directions over 46.

The mounting support 14 for a molded product, preferably made of aluminum, has a recess 48 which opens upward on the upper surface thereof. The shape of the recess is adapted to the molded article 2 such that the outer surface portion 4 covered with the thin film 6 lies flat inside the recess 48 during molding. This recess 48 is formed in the upper part 50 of the mounting support 14. Unlike the lower part 52 oriented towards the base 16, the upper part 50 does not have a uniform width and follows each of the side dimensions of the part 2. The upper edge of each of the vertical side surfaces 54 is continuously coincident with the lateral edge of the parting edge 10 of the part (located at the parting line of the mold half during molding). Thus, the edge 8 of the thin film adjacent to the separation edge 10 projects outward beyond the recess 48 and can be easily reworked (FIG. 8).

Upper part 5 of mounting support 14 for moldings
Both the zero and lower portions 52 have respective end faces 44, 46 that extend beyond the ends of the recess 48. In the case of a molded article 2 having a tapered rear end, the upper part 50
The rear end 44 is advantageously tapered to match the taper of the molding 2 so as to facilitate reworking of the upper surface of the recess 48. A plate 56 (attached to the lower part 52 by a screw) is provided as an extension of the upper part 50 of the mounting support 14 for the molded article (FIG. 7). This plate 56 has an end face that matches the taper of the part 2 and holds the rear end of the part 2 in the recess 48.

The mounting support 14 for the molded product is connected to the base plate 16.
Is performed using a plurality of fastening bolts (not shown). These fastening bolts are distributed along the mounting support 14 of the molded part and from below the base plate 1.
6 and extends upward. These fastening bolts are provided in screw holes 60 in the mounting support 14 (FIG. 8) of the molded product.
(Open downwardly) to further screwably engage.
Between the mounting support 14 of the molded article and the base plate 16,
A spacer plate 62 having a hole in the area of the fixing bolt is provided. The width of this spacer plate is
4 corresponds to the width of the lower part 52.

As best shown in FIG. 3, the components of the reworking device, namely the guide roll 26, the cutting device 30, the rear guide roll 36, the pressure roll 38, the fusing device 40 and the cooling roll 42, comprise a pair of vertical Plate 25 (a pair of rods 27
(A plate that is slidably supported above). A spring 29 biases the plates 25 toward each other over the support 14. The front guide rolls 26 are rotatably mounted about a vertical axis of rotation 64, each of which has a cylindrical lower portion 66 and an upwardly tapered frustoconical upper portion 68. have. The upper portion 68 meets and is integral with the lower portion 66 so that the diameter of the cylindrical lower portion 66 is equal to the largest diameter at the lower end of the frustoconical portion 68. These guide rolls 26 are provided with support bolts 7 having an expanded top and connected to a cylindrical shaft 74.
Mounted on 0. The shaft 74 protrudes upward into the stepped hole 72 of the guide roll 26.
One end portion 76 of the shaft having a male thread and a reduced diameter extends upwardly from each guide roll 26 and threadably engages a threaded hole 80 (opened downward) at the distal end of plate 25. .

The spring 29 urges the plate 25 and the guide roll 26 inward toward the mounting guide 14 for the molded product, and the guide roll 26 having its cylindrical lower portion 66.
Is in contact with one of the two vertical surfaces 54 (surfaces acting as abutment surfaces) of the upper part 50 of the mounting support of the molded article. The thickness of the spacer plate 62 is selected as follows. That is, the peripheral edge between the cylindrical lower portion 66 and the frusto-conical upper portion 68 is the separation edge 10 of the molded article 2.
So that it is located at a height exactly equal to. With this arrangement, the projecting thin film edge 8 is bent at an angle above the separation edge 10. The bending direction is a direction extending substantially perpendicularly to the non-coated upper surface region 12 adjacent to the separation edge 10 on the rear side of the molded product 2. Therefore, the edge 8 can be cut to a predetermined width by using the cutting device 30.

The cutting device 30 basically consists of two replaceable blades 98, each of which is a plate 25.
Are removably fixed to a blade holder 100 attached to each one of them. These two blade holders 100 arranged at adjacent positions have two clamping jaws 102, 104, respectively. A knife 98 is held between the jaws, the blade portion of which extends over the molded article mounting support 14 at the midpoint 106 of the device.
Is arranged substantially at the position of the mirror image. The blade portion extends obliquely forward toward the direction of the front guide roll 26 (FIG. 4), the blade portion of which is substantially parallel to the surface area 12, and thus the edge of the thinly bent upwardly curved film. 8 (FIG. 3). The two lower clamping jaws 104 are rigidly connected to the blade holder 100, while the two upper clamping jaws 102 are connected to the respective lower clamping jaws via mounting bolts 106 (bolts that are tightened to securely tighten the width 98). Tightening jaw 10
It is tightened to 4.

These two knife holders 100 are vertically displaceable with respect to the plate 25 so that the thin film strip 8 can be cut to a desired width. This blade holder 100
Is made using a vertically adjustable screw 112 having a knurled upper head 114. This adjusting screw is inserted into the hole 1 of the upper support member 118 of the plate 25.
At 16, it is supported so as to be rotatable but not displaceable in the axial direction. This adjustment screw, at its lower end,
It has an external thread 122 (which engages a corresponding internal thread in the lower end portion 120 of the vertical hole 124 of the blade holder 100). A compression spring 126 is provided around the adjusting screw 112, and the compression spring 126 is provided at its lower end with the blade holder 1.
00 at its upper end.
8 to eliminate play between the tool holder 100 and the adjusting screw 112.

In order to guide the blade holder 100, a plate 25
Have vertical slots 130 (each of which receives a correspondingly shaped guide projection 132 of the tool holder 100). The two knife holders 100 are positioned by a pair of clamping screws 134, each of which is threadably engaged from outside to inside through a vertical slot 130 formed in an adjacent plate 25.

In a similar manner to the front guide roll 26, the two rear guide rolls 36 are also rotatable about a vertical axis of rotation 146 on the plate 25, as shown in FIGS. Attached to. These guide rolls 36 are arranged such that their cylindrical lower part 152 rolls on vertical side surfaces 54.

Unlike the front guide roll 26, the upper portion 150 of the rear guide roll 36 has a cylindrical lower portion 152
From above, so that the thin film edge 8 on the opposing elongated edge of the mold part 2 is separated from the separating edge 10.
Is further bent towards the uncoated surface area 12 adjacent to the surface (FIGS. 1 and 2). A pressure roller 38 provided at a position behind the roll 36 is rotatably mounted on the plate 25, and its rotation axis 156 (FIG. 5) is arranged at an angle opposite to the gradient of the upper surface area 12, and , So that the edges 8 of the membrane are pressed against the two elongated edges of the molding 2
It is located at a distance from the surface region 12.

The laminating apparatus 40 is supported by the plate 25. The laminating apparatus basically consists of two solid heating elements 158 located along the elongated side edges of the molded part 2. These heating elements 158
It has a heating coil 160 (FIG. 6) arranged inward, but it may also be constituted by ultrasonic or laser welding elements.

The heating element 15 oriented in the direction of the cooling device 42
The rear part of 8 has a lower surface or inner surface 162 that matches the cross-sectional shape of the molded article 2 (FIG. 6). On the other hand, between its lower and inner surface 162 and the surface area 12 of the part or the side surface 54 of the mounting support 14, at the front end of the heating element 158 a tapered guideway 166 is provided, Of the heating element 158
It shrinks backward from 4. This tapered guideway 166 is such that the edge 8 of the membrane is slightly upward or sideways.
When protruding, the edge 8 is prevented from being obstructed.

The temperature in the heating element 158 is such that the edge 8 of the thin film is
(A region adjacent to the separation edge 10).

The cooling device 42 arranged downstream of the heating element 158 consists essentially of two further pressure rolls 168, similar to the pressure roll 38. The pressure roll 168 presses together, in the heated state, the thin film edge 8 and the surface area 12 adjacent to the separating edge 10. Thereafter, for cooling purposes, two air nozzles 170 located downstream of the pressure roll 168 blow air onto the edge 8 of the membrane traveling below the pressure roll 168.

The carrier 24 has a pair of vertical cross members. The pair of vertical cross members are provided with a tightening roll 28,
A pair of horizontal pivot bearings 140 opposed to the rotation shaft 142 are supported. These tightening rolls 28 and 34 are provided at front and rear positions of the blade 98, respectively. The plates 25 have notches 127, 129 that allow these plates to move independently laterally. The bearing 140 is disposed in the slot 131 and biased downward by the spring 133 to provide the rolls 28, 3
4 allows for limited vertical movement. A spring 133 acting on the rotary shaft 142 pushes the molded article 2 into the cavity 48 of the molded article mounting support 14.

For this reason, during operation, the molding 2 is placed in a support 14 attached to a base plate 16. The carriage 24 is driven across the part 2 such that the front roller 26 deflects the edge 8 upward into the path of the cutting tool 98. The bias of the plate 25 supporting the rollers 26 allows the rollers and the blade to follow the contour of the blade portion 10 and provides a smooth and arcuate fold.

The rollers 28, 34 engage the upwardly facing surface of the molding 2 and hold the molding in the support 14 as the cutting tool cuts the edge 8. The roller 36 then continues with the next step so that the edge 8 can be placed in a position substantially aligned with the pressure roller 38. The pressure roller keeps the edge 8 of the thin film in contact with the surface area 12 so that the laminator 40 can fuse the edge 8 to the surface area 12. As the weld cools, cooling roller 168 maintains pressure. After the carriage 24 has completely passed over the article 2, the carriage may be returned to remove the article 2, or the article 2 may be removed before the carriage 24 returns.

The carriage 24 can be advanced by any convenient means, such as, for example, a hydraulic or pneumatic cylinder, or a screw drive. It will also be appreciated that, if desired, the processing apparatus may be kept stationary while the support 14 is advanced. Similarly,
The plates 25 can be biased towards each other by hydraulic, pneumatic or other resilient devices so that the reworking device can follow the edges of the part 2.

To facilitate the welding of the thin film edge 8 to the thermoplastic molded article 2, it is also possible to coat the molded article 2 with a thin film 6 comprising a plurality of layers during injection molding. The thin film 6 includes at least one surface layer that is stable in temperature and a support layer (a layer that is melted when heat is applied and is applied to the surface of the surface layer toward the molded product). The characteristics of the surface layer and the support layer are selected as follows. That is, the temperature is selected so that the support layer is weak at a temperature near the melting point of the thermoplastic material, while the surface layer does not shrink or change in the form of the surface such as wrinkles at the same temperature. This may impair the properties of the material of the surface layer or reduce the heating element 158.
The edge 8 of the membrane can be adhered flat to the surface area 12 adjacent to the separating edge 10 without the risk of adhesion to the edge.

The surface layer may be made of one or more different fluoropolymers, one or more thin film pieces (eg an inner varnish layer as colored and an outer transparent varnish layer). While the support layer is advantageously made of a thermoplastic material, the thermoplastic material of the support layer and of the molded article being identical and therefore having an equal melting point.

FIGS. 9 to 13 show several cross-sectional views of a reworked part 2 made of a thermoplastic material used as a trim strip or protective strip for motor vehicles. The molded part 2 has a part of its surface 4 which acts as an externally visible surface during molding in the injection molding machine,
Covered. The protruding edge 8 is cut to a predetermined width in a subsequent reworking step, and before and / or after cutting, the uncoated surface area 1 at a position adjacent to the separating edge 10.
2 or are folded over and welded to the molded article 2 to be laminated on this surface.

The edge 8 of the membrane, in the exemplary embodiment shown in FIGS. 9 and 10, is bent only around the separation edge 10 and has a flat surface area at a position adjacent to the edge 10. 12 to provide a grip, as already described above for the device. The wrapping, pressing and laminating of the edge 8 of the thin film in the exemplary embodiment shown in FIGS. 11 to 13 are performed in two steps. After folding and cutting the edge 8 of the membrane, the first step is to press the portion of the edge 8 of the membrane adjacent to the surface 4 against and weld to the front 9 of the molded part 2, the front 9 being That is, it is adjacent to the separation edge 10.
After the weld has cooled, the other part of the edge of the membrane is folded over one edge 11 of the front surface 9 (the surface facing away from the separating edge 10). After applying pressure, the edge of the membrane is laminated to the uncoated surface area 13 at a position adjacent to the front face 9. Therefore, the portion of the thin film 6 adjacent to the front surface 9
They extend substantially parallel to each other. This means that, in this embodiment, the surface area 12 consists of two parts 9, 13 separated by an edge 11. Additional folding, pressing and laminating steps can be performed at a later stage on the carriage 24 to repeat the steps of the rollers 36, 38 and the operation of the laminating stage 40.
Of course, such additional rollers are configured to follow the edge 11 and to apply the requisite force and direction to the membrane 6.

As described above, in all the embodiments,
The edge of the edge 8 of the thin film is arranged on the rear side which is not visible from the outside of the molded article 2. Furthermore, the illustrated plastic outer parts of the motor vehicle are protected from inclement weather.

The molded product 2 shown in FIGS. 9, 10 and 11
Has an internal cavity 15 formed by injecting gas into the molded article 2 during the injection molding process, while the molded article shown in FIGS. 12 and 13 is manufactured without injecting gas. .

[Brief description of the drawings]

FIG. 1 is a simplified plan view of an apparatus for reworking a molded article made of a thermoplastic material and partially covered with a thin film having outwardly projecting thin film edges.

FIG. 2 is a side view of the reworking apparatus according to FIG. 1;

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1 shown on a large scale and in more detail;

FIG. 4 is a detailed side view of the cutting device of the reworking device of the present invention.

FIG. 5 is a cross-sectional view on a larger scale taken along line 5-5 of FIG. 1;

FIG. 6 is a cross-sectional view on a larger scale taken along line 6-6 of FIG. 1;

FIG. 7 is a perspective view of a fixed molded product support incorporated in the apparatus of the present invention.

8 is a sectional view taken along line 8-8 in FIG. 7 with the molded article located in the support.

FIG. 9 is a sectional view of a plastic outer part coated with a thin film for an automobile.

FIG. 10 is a sectional view of a plastic outer part similar to FIG. 9;

FIG. 11 is a sectional view of a plastic outer part similar to FIG. 9;

FIG. 12 is a sectional view of a plastic outer part similar to FIG. 9;

FIG. 13 is a sectional view of a plastic outer part similar to FIG. 9;

[Explanation of symbols]

2 Injection molding 6 Thin film 8 Thin film edge 10 Thin film edge 12 Thin film surface area 14 Mounting support 16 Base plate 18 Upper surface of base plate 20 Cylindrical rail 22 Linear bearing 24 Carriage 25 Vertical plate 26 Guide roll 27 Rod 28 Tightening Roll 29 Spring 30 Cutting Device 36 Rear Guide Roll 38 Working Roll 40 Welding Device 42 Cooling Device 44, 46 End of Support 48 Depression of Support 50 Upper Part of Support 52 Lower Part of Support 56 Plate 60 Screw Hole 62 Spacer plate 66 Lower part of guide roll 68 Upper part of guide roll 70 Support bolt 72 Stepped hole of guide roll 74 Cylindrical shaft 76 One end of shaft 80 Screw hole 98 Cutting tool 100 Blade holder 150 Upper part of guide roll 152 Lower part of guide roll 158 Heating element 1 4 the front end edge 166 guideway 168 pressure roll 170 air nozzle of the heating element

 ──────────────────────────────────────────────────の Continuation of the front page (71) Applicant 597033247 20 Queen Street West, Box 27, Suite 2700, Toronto, Ontario M5H 3 S1, Canada

Claims (37)

[Claims] 1. A method of manufacturing a molded article having a part of its surface coated with a thin film, comprising: a thin film that traverses a predetermined region of an outer surface of the molded article; Manufacturing the molded article that protrudes from a region and is not fixed to the area; thereafter, fitting the edge of the thin film to the outer surface of the molded article; and Securing the edge to the outer surface. 2. The method of claim 1, wherein the edge is edged before being fitted to the outer surface. 3. The method according to claim 1, wherein the thin film is fixed to the predetermined area while injecting a molding material into a mold cavity so as to form the molded article. The manufacturing method characterized by the above-mentioned. 4. A molded product in which a part of its surface is covered with a thin film integrally adhered during molding of the molded product, wherein the edge of the thin film protrudes beyond the molded product. Re-working, bonding at least a portion of the edge of the thin film to an uncoated surface area of the molded article, and laminating the thin film area to the uncoated surface area. A reworking method characterized by comprising: 5. The reworking method according to claim 4, wherein the edge of the thin film is cut before being laminated on the molded article. 6. The reworking method according to claim 5, wherein an edge of the thin film is cut to a predetermined width. 7. The reworking method according to claim 4, wherein the edge of the thin film is arranged at a position adjacent to an edge of the molded article located between the coated surface area and the uncoated surface area. ,
In such a manner that the edge of the thin film wraps around the edge,
A reworking method wherein the uncoated surface region adjacent to the edge is laminated. 8. The reworking method according to claim 4, wherein an edge of the thin film is folded around the edge, and the uncoated surface area is relative to a surface on which the molded article is mounted. A reworking method, wherein the edge is fixed and laminated to the rear side of the molded product which is not normally visible from the outside. 9. The method of claim 7, wherein the edge of the thin film is folded about a second edge adjacent to the edge of the molded article, the edge of the thin film. Are sequentially laminated on the adjacent uncoated surface region. 10. The reworking method according to claim 4, wherein
A method of reworking, wherein laminating the edges of the thin film comprises welding the edges to the molded article. 11. The method according to claim 5, wherein
A method of reworking, characterized in that the edges of the thin film are folded towards the uncoated surface area of the molding before being cut. 12. The method of claim 11, wherein the edge of the thin film is cut, and then pressed against the uncoated surface area of the molded article, heated and welded to the molded article. A reworking method characterized by being performed. 13. The reworking method according to claim 12, wherein the molded article is cooled under pressure at least in the region of the edge of the deposited thin film. 14. The reworking method according to claim 4, wherein
The molded article is elongate, and the edges of the thin film are laminated to edges of two opposite longer sides of the molded article, and the edges of the thin film are laminated to the longer side. A reworking method characterized in that the cutting is performed at a narrow surface blade portion extending between the edges of the portion. 15. The reworking method according to claim 4, wherein
A method of reworking, characterized in that the molding is placed in a recess formed in a mounting support, the recess conforming to a surface coated with the thin film. 16. The reworking method according to claim 15, wherein the support has a circumference corresponding to a circumference of the molded article, and the circumference attaches the edge to the molded article. A reworking method, characterized in that it provides a guiding means for a device used for contacting and fixing. 17. An apparatus for reworking a molded article having a thin film integrally bonded at a portion of its surface, the edge of the thin film protruding beyond the molded article, the apparatus comprising: A reworking device comprising a laminating device for laminating at least a part of an edge on an uncoated surface area of the molded article. 18. The reworking device according to claim 17, further comprising a cutting device provided in front of the laminating device so that an edge of the thin film can be cut into a predetermined width. Rework equipment. 19. The reworking apparatus according to claim 18, further comprising a guide device that engages an edge of the thin film and folds the edge of the thin film toward the uncoated surface area. A reworking device characterized by the above-mentioned. 20. The reworking device according to claim 19, further comprising a guide device provided in front of and behind said cutting device. 21. The reworking apparatus according to claim 17, wherein the laminating apparatus includes a heating device having at least one heating element. 22. The reworking apparatus according to claim 17, wherein the laminating apparatus includes an ultrasonic or laser welding element. 23. The reworking device according to claim 21, further comprising a cooling device disposed at a position behind the heating device. 24. The reworking apparatus according to claim 17, further comprising at least one pressure roll disposed in front of the laminating apparatus to keep the molded article in the support. apparatus. 25. An edge of the membrane is secured to the article such that the membrane is adhered integrally over a portion of the surface of the article and the edge protrudes beyond the article. A device that is movable via the guiding means, a guiding device that engages an edge of the thin film and folds the edge of the thin film in the direction of the uncoated surface area, and an edge of the thin film. A fixing device, comprising: a cutting device for performing edge processing to a predetermined width; and a laminating device for laminating the edge to the uncoated surface region. 26. The fixing device according to claim 25, wherein:
When the support and the reworking device move relative to each other, the reworking device moves in a direction perpendicular to the support, and the reworking device follows the circumference of the molded article. A fixing device characterized by permitting the following. 27. The fixing device according to claim 28,
The fixing device, wherein the molded product is held on the support by a tightening device disposed at a position in front of the cutting device. 28. The fixing device according to claim 27,
An anchoring device, wherein the clamping device is resiliently biased toward the support. 29. The fixing device according to claim 28,
A fastening device, wherein the fastening device comprises a roller engageable with the molded article. 30. The fixing device according to claim 29,
A fixing device, comprising a second roller driven by the cutting device and holding the molded product on the support. 31. The fixing device according to claim 26,
The fixing device, wherein the guiding device includes a pair of rollers disposed on both sides of the cutting device. 32. The fixing device according to claim 26,
An anchoring device, wherein the cutting device comprises a blade adjustable with respect to the molded article such that the predetermined width of the edge can be varied. 33. An injection-molded article made of a thermoplastic material, the surface of which, when molded, is coated with an injected thin film and the edge of the thin film extends over at least a portion of its length. An injection-molded article characterized in that the film extends around and wraps around the edge of the article, and the thin film is laminated to an uncoated surface area adjacent the edge. 34. The injection molded article according to claim 33, wherein an edge of the thin film is welded to the surface region. 35. The injection-molded article according to claim 34, wherein the outer peripheral edges of the two laminated portions of the edges on both sides of the molded article are located at positions substantially facing each other. Injection molded products. 36. The injection molded article of claim 34, wherein an edge of the membrane encloses two edges of a front face of the molded article, and portions of the membrane adjacent the front face are substantially parallel to one another. An injection-molded product characterized by being elongated. 37. The injection molded article of claim 34, wherein the thin film comprises at least one carrier layer oriented toward the molded article, wherein the corner layer melts when heat is applied. An injection-molded article characterized in that it becomes weak or weak and at least one surface film remains stable when heated.