Method for manufacturing decorative molding and mold for the method

Patent metadata

Field	Value
Publication number	US-2018370100-A1
Application number	US-201816120980-A
Country	US
Kind code	A1
Filing date	Sep 4, 2018
Priority date	Jun 29, 2016
Publication date	Dec 27, 2018
Grant date	—

Abstract

A method for manufacturing a decorative molding in which a transfer layer is transferred onto an injection molded product from a transfer sheet simultaneously with performing of injection molding in which at least one knockout pin in a second half-mold is caused to retreat to clamp a first half-mold and the second half-mold together; and the at least one knockout pin is made to advance so that the first half-mold and the second half-mold are released from each other until the second half-mold and the first half-mold open to a predetermined interval, while the transfer layer in a non-transfer area that is to remain on the transfer sheet is pushed against the first half-mold.

First claim

What is claimed is:

1 . A method for manufacturing a decorative molding, comprising:
placing a transfer sheet onto a first half-mold, the sheet including a transfer layer that has a transfer area to be transferred onto an injection molded product and a non-transfer area that is not to be transferred onto the injection molded product; transferring the transfer layer onto the injection molded product from the transfer sheet simultaneously with performing of injection molding in which at least one knockout pin located in a second half-mold is caused to retreat so as to clamp the first half-mold and the second half-mold together; and releasing the first half-mold and the second half-mold from each other while the at least one knockout pin is caused to advance until the second half-mold and the first half-mold open to a predetermined interval and the transfer layer in the non-transfer area remaining on the transfer sheet is pressed against the first half-mold using the at least one knockout pin.

2 . The method according to claim 1 , wherein transferring the layer simultaneously with performing of injection molding includes forming at least one opening in the injection molded product through performing the injection molding when the first half-mold and the second half-mold are clamped, by causing a first area in a first half-molded surface of the first half-mold that is used to form one primary surface of the injection molded product to make close contact with a second area in a second half-molded surface of the second half-mold that is used to form another primary surface of the injection molded product with the transfer sheet sandwiched between the areas; and
releasing the first half-mold and the second half-mold from each other includes causing the at least one knockout pin to advance from the second area when the first half-mold and the second half-mold are released from each other, and pushing the non-transfer area of the transfer sheet that corresponds to the at least one opening against the first half-mold using the at least one knockout pin.

3 . The method according to claim 2 , wherein
the at least one knockout pin includes a plurality of first knockout pins; the at least one opening is formed in the injection molded product through performing of the injection molding by clamping the first half-mold and the second half-mold together with the transfer sheet sandwiched between the molds, causing the first area of the first half-mold and the second area of the second half-mold to make close contact with each other, pushing the transfer sheet against the first area with the at least one knockout pin, and retreating the at least one knockout pin; and when the first half-mold and the second half-mold are released from each other, the plurality of first knockout pins is caused to advance from the second area, and the non-transfer area of the transfer sheet is pushed against the first area using the plurality of first knockout pins.

4 . A mold, comprising:
a first half-mold on which a transfer sheet is to be placed, the sheet including a transfer layer that has a transfer area to be transferred onto an injection molded product at the same time of the injection molding of the product and a non-transfer area that is not to be transferred onto the injection molded product; and a second half-mold that is to be clamped to the first half-mold, the second half-mold including at least one knockout pin configured to freely advance and retreat in order to push the transfer layer in the non-transfer area that is to remain on the transfer sheet against the first half-mold until the second half-mold and the first half-mold open to a predetermined interval when the molds are released from each other.

5 . The mold according to claim 4 , wherein
the first half-mold includes, in a first half-molding surface used for forming one primary surface of the injection molded product, a first area corresponding to at least one opening in the injection molded product, the second half-mold includes, in a second half-molding surface used for forming another primary surface of the injection molded product, a second area to be making close contact with the first area, with the transfer sheet sandwiched between the areas, when the molds are clamped together, and the second area further includes the at least one knockout pin arranged therein, and the at least one knockout pin protrudes from the at least one opening to push the non-transfer area against the first area of the first half-mold when the first half-mold and the second half-mold are released from each other.

6 . The mold according to claim 5 , wherein
the at least one knockout pin includes a plurality of first knockout pins, and the plurality of first knockout pins are arranged for one of the at least one opening in the second half-mold.

7 . The mold according to claim 6 , wherein
the at least one knockout pin includes a second knockout pin having a tip surface area and a third knockout pin that has a tip surface area smaller than that of the second knockout pin, the tip surfaces configured to abut against the transfer sheet.

8 . The mold according to claim 7 , wherein the at least one knockout pin includes a fourth knockout pin that has a tip surface to abut against the transfer sheet and a base portion extending inward toward the second half-mold and having a cross-sectional area that is orthogonal to a release direction and smaller than an area of the tip surface.

9 . The mold according to claim 8 , wherein
the first half-mold includes a third area and a fourth area; the second half-mold includes a fifth area that corresponds to the third area and a sixth area that corresponds to the fourth area, and a position of contact between the third area and the fifth area via the transfer sheet when the molds are clamped together is located closer toward a rear surface of the first half-mold than a position of contact between the fourth area and the sixth area; the at least one knockout pin includes a fifth knockout pin arranged in the fifth area and a sixth knockout pin arranged in the sixth area, and the first half-mold and the second half-mold are configured such that, at substantially the same time as when the fifth knockout pin pushes the transfer sheet against the third area, the sixth knockout pin pushes the transfer sheet against the fourth area.

10 . The mold according to claim 5 , wherein
the first half-mold includes a seventh area that has a non-flat shape in the first half-molding surface, and the at least one knockout pin includes a seventh knockout pin that is arranged in the seventh area and that has a tip surface, the tip surface having a non-flat shape that is substantially the same as that of the seventh area.

11 . The mold according to claim 6 , wherein
the first half-mold includes a seventh area that has a non-flat shape in the first half-molded surface, and the at least one knockout pin includes a seventh knockout pin that is arranged in the seventh area and that has a tip surface, the tip surface having a non-flat shape that is substantially the same as that of the seventh area.

12 . The mold according to claim 4 , wherein
the at least one knockout pin includes a second knockout pin having a tip surface area and a third knockout pin that has a tip surface area smaller than that of the second knockout pin, the tip surfaces configured to abut against the transfer sheet.

13 . The mold according to claim 4 , wherein the at least one knockout pin includes a fourth knockout pin that has a tip surface to abut against the transfer sheet and a base portion extending inward to

Assignees

• Nissha Co Ltd

Inventors

• Taniguchi Takafumi
• Nakanishi Tatsuya
• Matsui Takafumi

Classifications

• B29C33/14

  against the mould wall · CPC title

• B29C45/26

  Moulds · CPC title

• B29C45/1679 Primary

  applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC] (applying suface layers after ejection B29C45/0053) · CPC title

• B29C45/14827 Primary

  using a transfer foil detachable from the insert · CPC title

• B29C45/401

  Ejector pin constructions or mountings · CPC title