Patent Application
20070029700
The invention relates to a film forming mold for various types of moldings including headlamps, direction indicators (including side blinkers), tail lamps, etc., which are incorporated in a vehicle, etc., a film forming method using the mold, and a film forming control system.
Generally, as such a type of moldings, there is a molding such as a lamp body of a headlamp for a vehicle, having a mirror-finished surface being a reflection surface film-formed on the injection-molded molding to increase the light amount and to secure a wider range of irradiation. However, conventionally, a lamp body is produced so that a lamp holder in which a bulb is incorporated and a lens portion formed of resin having transmittance are mold-matched, and the surfaces of the mold-matched portions are adhered together. As such a production method, a mold-slide injection system has been known (For example, refer to Japanese Patent Publication No. Hei-2-38377). According thereto, after a lamp holder and a lens portion, which are primary products, are respectively injection-molded in a state where its movable mold and its fixed mold are disposed so as to be opposed to each other, the movable mold is caused to slide, and the respective primary products are mold-matched to be matched to each other. And, a resin material is secondary injected to the mold-matched portions of the primary products, thereby integrally molding the lamp body.
However, such a type of molding cannot cope with a case where a reflection surface is formed on a lamp holder as described above. Therefore, in a case of film-forming the reflection surface, after the lamp holder injection-molded by a mold is removed from the mold, a multitude of corresponding removed lamp holders are set in a film-forming chamber, and a reflection surface is formed on the inner surfaces of the corresponding multitude of moldings by using forming means such as a vacuum deposition apparatus and a spattering apparatus. Thereafter, the lamp holder and lens portion are formed to be integral with each other.
However, since the film-forming chamber is provided to form films with a multitude of moldings set therein in order to increase efficiency, the area of the chamber is caused to be increased, wherein not only the time required for vacuuming the film-forming chamber is lengthened, but also it is necessary to make the vacuuming degree higher because the distance between a molded lamp holder and film-forming means is long. Therefore, there is a problem in that work efficiency is worse.
Furthermore, where it is necessary to vacuum the film-forming space for film formation, because opening/closing means is provided at the side of a vacuum pump, the cubic volume from the opening/closing means and the film-forming space is made large, and the time required for vacuuming the film-forming space is lengthened. Therefore, there is another problem in that work efficiency is worse.
Still further, where film-forming work is carried out by using a mold which is not available in the prior arts, where the film-forming space is made vacuum, and atmospheric air is caused to flow in the film-forming space when opening the mold, there remains a question as to quickness of work and improvement of work efficiency. However, in prior arts, there has been no case where such matters are taken into consideration. The present invention is brought about to solve these matters.
The invention was developed to solve such problems in view of the above-described situations. The invention is as follows:
A first aspect of the invention is featured in that a film-forming mold is composed of the first mold in which a work on which a film is formed is incorporated, and the second mold in which film-forming means to form a film on the work is incorporated.
A second aspect of the invention is a film-forming mold and is featured, in addition to the first aspect, in that the second mold is a mold for molding a work.
A third aspect of the invention is a film-forming mold and is featured, in addition to the first or the second aspect, in that the first mold is a movable type and the second mold is a fixed type.
A fourth aspect of the invention is a film-forming mold and is featured, in addition to any one of the first aspect through the third aspect, in that the film-forming means is a spattering apparatus or a vacuum deposition apparatus.
A fifth aspect of the invention is a film-forming mold and is featured, in addition to any one of the first aspect through the fourth aspect, in that the film-molding means is provided in a cylindrical recessed hole having a bottom, which is formed in the second mold, and a film-forming space is secured between the film-forming means and the work.
A sixth aspect of the invention is a film-forming mold and is featured, in addition to any one of the first aspect through the fourth aspect, in that the film-forming means is provided so as to airtightly seal a through-hole provided in the second mold, and a film-forming space is secured between the film-forming means and the work.
A seventh aspect of the invention is a film-forming mold and is featured, in addition to any one of the first aspect through the sixth aspect, in that the second mold is provided with a vacuuming flow channel to make the film-forming space vacuum, and first opening/closing means for opening and closing the vacuuming flow channel.
An eighth aspect of the invention is a film-forming mold and is featured, in addition to any one of the first aspect through the seventh aspect, in that the second mold includes a masking portion for masking a work attached to the first mold.
A ninth aspect of the invention is a film-forming mold and is featured, in addition to any one of the first aspect through the eighth aspect, in that the first mold or the second mold is provided with an atmospheric air inlet channel for permitting atmospheric air to flow into the film-forming space, and second opening/closing means for opening and closing the atmospheric air inlet channel.
A tenth aspect of the invention is a film-forming mold and is featured, in addition to the ninth aspect, in that the atmospheric air inlet channel and the second opening/closing means are provided with ejector means for removing a film-formed work from the first mold.
An eleventh aspect of the invention is a film-forming mold and is featured, in addition to the ninth aspect or the tenth aspect, in that the second mold is provided with third opening/closing means for opening and closing a film-forming space, which is positioned between the vacuuming flow channel and the atmospheric air inflow channel.
A twelfth aspect of the invention is a film-forming method using a mold, which comprises at least the sequential steps of: mold matching of a first mold in which a work on which a film is formed is incorporated and a second mold in which film-forming means to form a film on the work is incorporated; film-forming for forming a film on a work; and opening the first mold and the second mold.
A thirteenth aspect of the invention is featured, in addition to the twelfth aspect, in a film-forming method using a mold in which the first mold is a movable type and the second mold is a fixed type.
A fourteenth aspect of the invention is featured, in addition to the twelfth aspect or the thirteenth aspect, in a film-forming method using a mold, wherein the film-forming means is a spattering apparatus or a vacuum deposition apparatus.
A fifteenth aspect of the invention is featured, in addition to the twelfth aspect through the fourteenth aspect, in a film-forming method using a mold, wherein a vacuuming step to make vacuum a film-forming space between the film-forming means and a work is provided between the mold-matching step and the film-forming step.
A sixteenth aspect of the invention is featured, in addition to the fifteenth aspect, in a film-forming method using a mold, wherein the second mold is provided with a vacuuming flow channel communicating with a vacuum pump to make the film-forming space vacuum, and first opening/closing means for opening and closing the vacuuming flow channel, and the vacuuming step is carried out by opening the first opening/closing means.
A seventeenth aspect of the invention is featured, in addition to any one of the twelfth aspect through the sixteenth aspect, in a film-forming method using a mold, wherein the second mold is provided with a masking portion for masking a work attached to the first mold, and the work is masked in the mold-matching step.
An eighteenth aspect of the invention is featured, in addition to the sixteenth aspect or the seventeenth aspect, in a film-forming method using a mold, wherein the first mold or the second mold is provided with an atmospheric air inflow channel for causing atmospheric air to flow into the film-forming space, and second opening/closing means for opening and closing the atmospheric air inflow channel, and a first opening/closing means closing step for closing the first opening/closing means and a second opening/closing means opening step for opening the second opening/closing means are provided between the film-forming step and the mold-matching step.
A nineteenth aspect of the invention is featured, in addition to the eighteenth aspect, in a film-forming method using a mold, wherein the atmospheric air inflow channel and the second opening/closing means are provided in ejector means for removing a film-formed work from the first mold, and the second opening/closing means opening step is carried out in line with removal of the work by the ejector means.
A twentieth aspect of the invention is featured, in addition to the eighteenth aspect, in a film-forming method using a mold, wherein the atmospheric air inflow channel is a mold-matching surface between the first mold and the second mold, and the second opening/closing means closes up the atmospheric air inflow channel by mold matching in the mold-matching step, and opens the atmospheric air inflow channel in the mold-opening step.
A twenty-first aspect of the invention is featured, in addition to any one of the sixteenth aspect through the twentieth aspect, in a film-forming method using a mold, wherein the second mold is provided with third opening/closing means for opening and closing a film-forming space between the vacuuming flow channel and the second opening/closing means, and a third opening/closing means closing step for closing the third opening/closing means is provided between the film-forming step and the second opening and closing opening step.
A twenty-second aspect of the invention is featured in a film-forming method using a mold which comprises a first mold in which a work on which a film is formed is incorporated; a second mold in which film-forming means for molding a film on the work in a vacuum state; a vacuuming flow channel for making vacuum a film-forming space between the film-forming means and the work; first opening/closing means for opening and closing the vacuuming flow channel; and second opening/closing means for opening and closing the film-forming space for communication with the atmosphere; and the same method comprises the steps of; mold-matching the first mold in which the work is incorporated and the second mold; making vacuum the film-forming space in a state where the second opening/closing means is closed and the first opening/closing means is opened; film-forming by film-forming means in a state where the first opening/closing means is opened or closed, and the second opening/closing means is closed; causing atmospheric air to flow into the film-forming space in a state where the first opening/closing means is opened or closed, and the second opening/closing means is opened; and opening the mold-matched molds.
A twenty-third aspect of the invention is featured in a film-forming method using a mold which comprises a first mold in which a work on which a film is formed is incorporated; a second mold in which film-forming means for forming a film on the work in a vacuum state; a vacuuming flow channel for making vacuum a film-forming space between the film-forming means and the work; first opening/closing means for opening and closing the vacuuming flow channel; second opening/closing means for opening and closing the film-forming space for communication with the atmosphere; and third opening/closing means for opening and closing a film-forming space between the vacuum flow channel and the second opening/closing means; and the same method comprises the steps of mold-matching the first mold in which the work is incorporated and the second mold; making vacuum the film-forming space in a state where the second opening/closing means is closed and the first and the second opening/closing means are opened; film-forming by film-forming means in a state where the first opening/closing means is opened or closed, the second opening/closing means is closed, and the third opening/closing means is closed; causing atmospheric air to flow into a space of the film-forming space nearer at the work side than the third opening/closing means by opening the second opening/closing means in a state where the first opening/closing means is opened or closed; and opening the mold-matched molds.
A twenty-fourth aspect of the invention is featured in a film-formation controlling system using a mold, comprising: means for forming a film in a vacuum state; means for actuating a mold for mold matching of a first mold in which a work on which a film is formed is incorporated and a second mold in which the film-forming means is incorporated; and first opening/closing means for opening and closing a vacuuming flow channel to make vacuum a film-forming space between the film-forming means and the work; and simultaneously including a control portion the control of which is established to sequentially carry out; output of a mold-matching operation command to the mold-matching means; output of an opening operation command to the first opening/closing means; output of a film-forming operation command to the film-forming means; output of a film formation stopping command to the film-forming means; output of a closing operation command to the first opening/closing means; and output of a mold-opening operation command to the mold actuating means.
A twenty-fifth aspect of the invention is featured in a film-formation controlling system using a mold, comprising: means for forming a film in a vacuum state; means for actuating a mold for mold matching of a first mold in which a work on which a film is formed is incorporated and a second mold in which the film-forming means is incorporated, and for opening the molds; and first opening/closing means for opening and closing a vacuuming flow channel to make vacuum a film-forming space between the film-forming means and the work; and simultaneously including a control portion the control of which is established to sequentially carry out; output of a mold-actuating operation command to the mold-matching means; output of an opening operation command to the first opening/closing means; output of a closing operation command to the first opening/closing means; output of a film-forming operation command to the film-forming means; output of a film formation stopping command to the film-forming means; output of a mold opening operation command to the mold actuating means.
A twenty-sixth aspect of the invention is featured, in addition to any one of the twenty-third aspect through the twenty-fifth aspect, a film-formation controlling system using a mold, comprising: an atmospheric air flow channel for causing atmospheric air to flow into the film-forming space and second opening/closing means for opening and closing the atmospheric flow channel; wherein the control portion is established to control so that an opening operation command is outputted to the second opening/closing means simultaneously with or prior to output of the mold opening operation command.
A twenty-seventh aspect of the invention is featured, in addition to the twenty-sixth aspect, in a film-formation controlling system using a mold, wherein third opening/closing means for opening and closing a film-forming space between the vacuuming flow channel and the second opening/closing means is provided, and the control portion is established to control so that a closing operation command is outputted to the third opening/closing means simultaneously with or prior to output of an opening operation command to the first opening/closing means, and an opening operation command is outputted to the third opening/closing means simultaneously with or prior to output of a mold-opening operation command to the mold-actuating means.
According to the first aspect of the invention, it is possible to simply form a film on a work by using the first mold and the second mold.
According to the second aspect of the invention, because molds for molding a work can be effectively utilized to form a film on the work, and at the same time, a film is formed successively to molding of the work, film formation can be carried out in a state where no fingerprints are attached to the surface of the work or there is no case where the work is brought into contact with other members and is damaged.
According to the third aspect of the invention, because the second mold in which film-forming means is incorporated is a fixed mold, members derived from the film-forming means, such as lead wires and piping led from (connected to) the film-forming means can be made stationary (immovable) when molding by the mold. Therefore, such members can be freed from repeated strain based on repeated folding and bending.
According to the fourth aspect of the invention, spattering and vacuum deposition can be carried out.
According to the fifth aspect of the invention, incorporation of film-forming means in the second mold can be carried out from the mold-matching surface side.
According to the sixth aspect of the invention, incorporation of film-forming means in the second mold can be carried out from the side opposite the mold-matching surface side.
According to the seventh aspect of the invention, since the second mold is provided with a vacuuming flow channel and first opening/closing means for opening and closing the vacuuming flow channel, the second mold can be simplified, and at the same time, the cubic volume at the film-forming space side from the first opening/closing means can be made smaller than in a case where the first opening/closing means is provided at the vacuum pump side, wherein the time required for securing a vacuum state can be shortened, and work efficiency can be improved.
According to the eighth aspect of the invention, masking of a work can be carried out by effectively using the second mold in which film-forming means is provided.
According to the ninth aspect of the invention, because the molds can be opened in a state where atmospheric air is flown into the vacuumed film-forming space, the molds can be smoothly and gently opened.
According to the tenth aspect of the invention, inflow of atmospheric air can be carried out by effectively utilizing ejector means secured to remove a film-formed work from the first mold.
According to the eleventh aspect of the invention, it is possible that the film-forming means side of the film-forming space from the third opening/closing means between the vacuuming flow channel of the film-forming space and the atmospheric air flow channel can be maintained in a vacuum state.
According to the twelfth aspect of the invention, it becomes possible to form a film by using a mold for a work.
According to the thirteenth aspect of the invention, because the second mold in which the film-forming means is incorporated is a fixed mold, and members derived from (connected to) the film-forming means, such as lead wires and piping, etc., are not brought into contact with the molding molds and can be made stationary (immovable) , the members can be freed from any repeated strain generated due to repeated folding and bending.
According to the fourteenth aspect of the invention, spattering and vacuum deposition may be applicable.
According to the fifteenth aspect of the invention, vacuuming can be easily achieved in a film-forming space when spattering and vacuum deposition are carried out.
According to the sixteenth aspect of the invention, the vacuuming flow channel secured in the second mold can be opened and closed by the first opening/closing means, wherein the second mold can be simplified, and at the same time, the cubic volume at the film-forming space from the first opening/closing means can be made smaller than in the case where the first opening/closing means is provided at the vacuum pump side. And, the time required for vacuuming can be shortened, and work efficiency can be improved.
According to the seventeenth aspect of the invention, masking of a work can be carried out by effectively utilizing the second mold in which film-forming means is incorporated.
According to the eighteenth aspect of the invention, since the film-forming space which is vacuumed when forming a film is opened with atmospheric air is flown in, the mold can be smoothly and gently opened.
According to the nineteenth aspect of the invention, atmospheric air can be flown in by effectively utilizing the ejector means provided to remove a film-formed work from the first mold.
According to the twentieth aspect of the invention, it is possible to cause atmospheric air to flow in the film-forming space that is vacuumed, without forming an exclusive atmospheric air flow channel and any second opening/closing means.
According to the twenty-first aspect of the invention, it is possible that the film-forming means side of the film-forming space from the third opening/closing means between the vacuuming flow channel of the film-forming space and the atmospheric air flow channel can be maintained in a vacuum state.
According to the twenty-second aspect and the twenty-third aspect of the invention, a series of film-forming processes of a work, in which a film is formed with the film-forming space vacuumed, can be continuously carried out.
According to the twenty-fourth aspect and the twenty-fifth aspect of the invention, film formation on a work can be automatically carried out by using the control portion.
According to the twenty-sixth aspect of the invention, inflow of atmospheric air in the vacuumed film-forming space can be automatically controlled while opening the mold after a film is formed.
According to the twenty-seventh aspect of the invention, the space at the film-forming means side of the film-forming space from the third opening/closing means can be automatically controlled so that the space can be maintained in a vacuum state with the mold opened.
Next, a description is given of Embodiment 1 of the present invention with reference to the accompanying drawings
While, in the movable mold 1, a concave mold surface 1a for forming the outside face of a lamp holder 3 (corresponding to a “work” of the invention) and a convex mold surface 1b for forming the inside face of a lens portion 4 are formed, respectively, a convex mold surface 2a for forming the inside face of the lamp holder 3 and a concave mold surface 2b for forming the outside face of the lens portion 4 are formed in the fixed mold 2. Simultaneously, in the fixed mold 2, a concave mold surface 2c is formed, as film-forming means, to accommodate (internally include) a vacuum deposition apparatus 5 employed in the present embodiment. The concave mold surface 2c is formed between the convex mold surface 2a for forming the inside face of the lamp holder 3 and the concave mold surface 2b for forming the outside face of the lens portion 4. Although the vacuum deposition apparatus 5 that has been publicly known is employed, the vacuum deposition apparatus 5 is briefly structured so as to be provided with a vacuuming flow channel 6 connected to a vacuum pump P via the first opening/closing valve 6a, a boat (target) 7 in which metal (for example, aluminum and chromium) to be deposited is accommodated, and a heater 8 for heating the boat 7.
A lamp body 9 is a side blinker in the present embodiment. A terminal 10 and a bulb 11 are incorporated therein as necessary components. The lamp body 9 is composed of a lamp holder 3 molded with a non-translucent resin material and a lens portion 4 molded with a translucent resin material. As described later, after the lamp holder 3 and the lens portion 4 are molded by the primary injection molding process, the movable mold 1 is moved (mold-slid), wherein the lamp holder 3 and the lens portion 3 are mold-matched. And, a resin material 12 is secondarily injection-molded on the mold-matched face portions, and these components are integrated to mold the lamp body 9.
Next, a description is given of a method for producing the lamp body 9 with reference to the drawings.
Thereafter, as shown in
And, in a state where both the molds 1, 2 are apart from each other before or after making the parallel movement, a masking member (covering member) 1 for masking (covering) portions not to be vacuum-deposited, herein, the terminal 10 of the lamp holder 3 and an insertion portion 3a of the bulb 11 is built in (inserted) in the lamp holder 3 (Masking member incorporating process) . The masking member incorporating process is carried out. In the embodiment, the masking member 13 is incorporated at a stage before making parallel movement. Also, the molds are designed so that the peripheral portion 2d at the opening side of the concave mold surface 2c internally including the vacuum deposition apparatus 5 masks the mold-matching surface 3b between the lamp holder 3 and the lens portion 4, and the mold-matching surface 3b is not vacuum-deposited.
After a sealed film-forming space S is formed in a mold-matched state where the lamp holder 3 and the vacuum deposition apparatus 5 are opposed to each other, the first opening/closing valve 6a is opened, air in the film-forming space S is removed from the vacuum flow path 6 to cause the interior of the film-forming space S to be vacuumed. In this state, molten metal supplied to the boat 7 is evaporated by a heated heater 8, wherein the metal is vacuum-deposited on an exposed inner surface of the lamp holder 3, and a reflection surface 14 is film-molded (Film-forming (reflection surface forming) process:
After that, the movable mold 1 is moved to the fixed mold 2, and the lamp holder 3 and the lens portion 4 are mold-matched (Third mold-matching process:
In the embodiment according to the invention, which is structured as described above, when producing the lamp body 9, because a film-forming process for forming a reflection surface 14 on the inner surface of the lamp holder 3 is provided between the primary injection molding process for forming the lamp holder 3 and the lens portion 4 and the secondary injection molding process for integrating the lamp holder 3 and the lens portion 4, any work for removing the lamp holder 3 and resetting the same is no longer required as in the prior art in which it is necessary that, after a reflection surface is formed on the lamp holder 3 once removed from the mold, the lamp holder 3 is set in the mold again thereafter, and it is possible to produce the lamp holder 3 and to form a film for the reflection surface in a series of mold sliding processes, wherein work efficiency can be improved. Furthermore, because it is not necessary that the lamp holder 3 is removed and reset, there is no case where any fingerprints are adhered to the reflection surface 14 by touching the same or the reflection surface is damaged due to being brought into collision with any other materials, wherein generation of defects can be reduced to a large extent.
Still further, in the embodiment, in the film-forming process, the surface of the lamp holder 3 (that is, the surface covered by the first mold 1) is supported, as it is, in the movable mold 1 without being released therefrom, that is, is completely hidden from the outside, wherein the first mold 1 itself functions as a masking member with respect to the surface of the lamp holder 3 (the surface when the lamp holder is made into a final product) , and there is no case where any film is formed on the surface of the lamp holder 3. Furthermore, in this case, because the concave mold surface 2c in which the vacuum deposition apparatus 5 body is accommodated is formed on the second mold 2 that is a fixed mold, the vacuum deposition apparatus 5 is fixed, wherein, as in the case where the vacuum deposition apparatus 1 is installed in the movable mold 1 side, it is not necessary to employ such a structure for which movement of pump piping and wiring is taken into consideration. Therefore, the structure is simplified along with an attempt to improve the durability.
Still further, in the embodiment, because, if a reflection surface of metal film is formed on portions where the reflection surface is not desired to be formed, that is, on the portions where the terminal 10 and the bulb 11 are attached to, insulation is spoiled and circuits are shorted, the portions are clogged by the masking member 13, and the reflection surface 14 is formed. Therefore, the lamp body 9 free from any problem of short-circuiting can be brought about. Furthermore, in the embodiment, because the terminal 10 and the bulb 11 are incorporated after removing the masking member 13 after the reflection surface 14 is formed, all the production work including film formation in a series of mold-sliding processes can be smoothly carried out, and it is possible to efficiently produce the lamp body 9.
Still further, although the lamp body 9 is structured so that the mold-matching portion between the lamp holder 3 and the lens portion 4 is cemented together (adhered to each other) in the secondary injection molding process, when forming a film in the lamp holder 3, the cementing portion is masked by the peripheral portion at the opening side of the concave mold surface 2c in which the vacuum deposition apparatus 5 body is accommodated. Therefore, there is no case where a film is formed on the reflection surface. As a result, it is not necessary to use any exclusive masking member 13 with respect to masking of a portion exposed in releasing from the first mold 1, wherein the portion can be masked by using the second mold 2. There is no case where a film is formed on the portion molded in the secondary injection molding process, and the lamp holder 3 and the lens portion 4 can be securely adhered to each other, wherein work efficiency can be increased.
Also, because the concave mold surface 2c for accommodating the vacuum deposition apparatus 5 body, which is formed in the fixed mold 2, is disposed between the mold surfaces 2a, 2b on which the lamp holder 3 and the lens portion 4 are formed, the direction along which the movable mold 1 moves from the primary injection molding process to the reflection surface forming process becomes identical to the direction along which the movable mold 1 moves from the reflection surface forming process to the secondary injection molding process. Resultantly, there is an advantage in that the structure of the mold-sliding mechanism can be simplified.
In addition, the invention is not limited to the above-described embodiment, and the film formation is not limited to a reflection surface such as a mirror-like surface, but it may be film formation based on painting, etc. Furthermore, the film-forming means is not limited to an vacuum deposition apparatus, wherein normally known various types of film-forming apparatuses may be employed, in which a physical vapor deposition method (PVD) such as spattering deposition, etc., a chemical vapor deposition method (CVD) such as thermal deposition and plasma deposition, etc., are available. In addition, in a case of a molding such as a lamp holder, the molding may be made into such a type in which accessories such as a terminal and a bulb, etc., are installed after molding. Further, in the film-forming means, the color of a film formed may be varied based on a type of metal (for example, copper, aluminum, nickel, etc.) being a target, the degree of vacuum and the type of filling gas.
Also, although the invention is embodied by injection molding as a molding process, the invention is not limited to such molding process. It may be embodied to a commonly known molding such as, for example, press molding, blow molding, etc. Still further, if, for instance, a description is given of a case where a final product is a lamp body, the invention is applicable to a case where the lamp body is not continuously molded to the end as in the present embodiment, a semi-product in which a mirror-like surface 14 is formed on the lamp holder 3 is molded, and the molding is released from a mold and is used as a component. Also, the film-forming means may be not only provided in the same mold as the mold for forming a surface which becomes a mirror-like surface, but also provided in a different mold.
In addition, with respect to the mold, an example in which two molds of the first mold and the second mold are employed was described in the above-described embodiment. Where a molding having a complicated shape, which cannot be molded with only two molds, is molded, it is possible to increase the number of molds as necessary, for example, the third mold, the fourth mold, etc. In this case, it is a matter of course that the invention can be embodied if the invention is structured so that masking is carried out with at least one mold.
Furthermore, a description is given of Embodiment 2 according to the invention with reference to
While a mold surface 16a for incorporating and supporting a work 16 is formed in the first mold 15, a through-hole 17a for incorporating a spattering apparatus 18 employing an argon gas as an inactive gas is drilled in the second mold 17. The spattering apparatus 18 that is inserted from the outside of the through-hole 17a is sealably attached to the second mold 17 via tightening bolts 18a. In this case, the first mold 15 molds the work (lamp holder) 16 as in the first mold 1 according to Embodiment 1, and the mold surface 15a may be formed as in the mold surface 1a of Embodiment 1. And, the first mold 15 is set so as to be tightened and released, wherein an actuator such as a hydraulic cylinder may be used as an operation actuator 20.
On the other hand, a film-forming space X is formed between the spattering apparatus 18 and the work 16 in a state where the first mold 15 and the second mold 17 are matched to each other. A vacuuming flow channel 21 connected to a vacuum pump P, which is made cylindrical so as to communicate with and connect to the vacuum pump P, is drilled at the work 16 side nearer than the spattering apparatus 18 in the second mold 17. Further, in the second mold 17, the first opening/closing valve (corresponding to the first opening/closing means of the invention) 22 is provided to open and close the vacuuming flow channel 21. The first opening/closing valve 22 may be an electromagnetic valve type, a hydraulic pilot valve type, and any universal valve type in the present embodiment. Therefore, the detailed structure thereof is omitted. Herein, it is assumed, for the following description, that actuating means such as an electromagnetic solenoid or a hydraulic valve changing means, etc., is employed as the first actuator 23 for opening and closing the first opening/closing valve 22.
Further, an atmospheric air communicating channel 24 communicating with the atmospheric air, which is located at the first mold 15 side (at the work side) nearer than the vacuuming flow channel 20 is provided in the second mold 17, and at the same time, the second opening/closing valve 25 for opening and closing the atmospheric air communicating channel 24 is provided therein. Also, the third opening/closing valve 26 for opening and closing the film-forming space X is provided between the atmospheric air communicating channel 24 and the vacuuming flow channel 20. With respect to these second and third opening/closing valves 25, 26, it is assumed in the following description that, as in the first opening/closing valve 22, the second and third actuators 27, 28 are employed as operating means such as an electromagnetic solenoid or a pilot valve changing means to carry out opening and closing operations of the second and third opening and closing valves 25, 26. In addition, a masking portion 17b for masking the peripheral edge portion of the work 16 is formed, as shown in
Reference number 29 denotes a control portion composed by using various types of member devices such as a microcomputer, etc. The control portion 29 outputs control commands, which will be described later, to the respective actuators 20, 23, 27, 28. Various types of detection signals are inputted into the control portion 29, which are issued from a work incorporation detection sensor 30 for detecting whether or not a work 16 is incorporated in the first mold 15, a mold status detection sensor 31 for detecting whether the second mold 17 is located at a mold-matched position or at a mold-opened position with respect to the first mold 15, the first through the third opening/closing detection sensors 32, 33, 34 for respectively detecting opening and closing of the first through the third opening/closing valves 23, 27, 28, and a film-forming condition accomplishment detection sensor 35 for detecting whether or not the film-forming space X reaches the film-forming conditions (the film-forming situations).
Herein, for example, if a series of molding processes carry out molding and film formation with respect to the work 16 as in Embodiment 1, the work incorporation detection sensor 30 recognizes whether or not the molding process is carried out, and detects incorporation based on judgment that the molding process has been carried out. Further, where a separately film-formed work 16 is incorporated in the first mold 15, or a masking member is incorporated in a work 16 molded by molding, a sensor may be directly provided in the first mold 15 in order to directly detect the work 16 incorporated in the first mold 15. However, such a mode may also be available in which an apparatus for incorporating a work or a masking member is composed of, for example, a robot (not illustrated) including an incorporation arm, and a detection sensor for detecting presence or absence of a work 16 is provided in the corresponding incorporation arm, wherein it is detected whether or not the work 16 is incorporated in the first mold 15.
In addition, the mold status detection sensor 31 may be embodied as, for example, a detection sensor (two-point position detection sensor) for detecting whether the first mold 15 is located at a mold-matched position or a mold-opened position. However, respective exclusive sensors for separately detecting these positions may be used.
Further, the opening/closing detection sensors 32, 33, 34 may be embodied by using sensors for detecting whether the corresponding operation actuators 23, 27, 28 are turned on or off. Still further, the film-forming condition accomplishment detection sensor 35 judges whether or not the film-forming space X reaches a vacuum state necessary for film formation. For example, the sensor 35 may be embodied by using the vacuuming flow channel 21 (may be located either at the vacuum pump P side or at the film-forming space X side nearer than the first opening/closing valve 22) and a barometer (capable of detecting the vacuum degree) installed in, for example, a tubing channel 21a reaching the vacuum pump P from the vacuuming flow channel 21. Also, in the embodiment, it is assumed that the vacuum pump P always operates by means of a switch-on. However, it is a matter of course that the vacuum pump P may be controlled so as to be driven, for example, only in the film formation controlling process.
Next, with respect to the film formation controlling process by means of the control portion 29, a description is given of Embodiment 2 using a block circuit diagram shown in
And, in the film formation controlling process, first, the control portion 29 carries out judgment on whether or not a work 16 is incorporated in the first mold 15, based on a detection signal from the work incorporation detection sensor 30. And, where the control portion 29 judges that the work 16 is incorporated, the control portion 29 outputs a control command to the first mold operation actuator 20 for a mold-matching operation, and when the mold status detection sensor 31 detects that the first mold 15 is positioned at a mold-matched position, the control portion 29 outputs a closing control command to the second opening/closing valve actuator 27. Corresponding thereto, the second opening/closing valve opening/closing detection sensor 33 inputs a closing signal of the second opening/closing valve 25. Thereafter, the control portion 29 outputs an opening control command to the first and the third opening/closing valve operation actuators 23, 28, thereby causing the film-forming space X to communicate with the vacuum pump P and to make the entire film-forming space X vacuum. Then, the film-forming condition accomplishment detection sensor 35 detects whether or not the film-forming space X is made vacuum.
In addition, output of the closing control command to the second opening/closing valve actuator 27 may be issued prior to the mold-matching process. However, if the output is issued after the mold-matching process as in the present embodiment, the pressure in the film-forming space X sealed in the mold-matching process can be brought into an atmospheric state. Thus, there is an advantage in that it is possible to prevent the time required for vacuuming in the vacuuming process from being lengthened. That is, if the mold matching is further intensively carried out in an almost sealed state in the final state of mold matching, and the cubic volume of the film-forming space X is made smaller, the pressure in the film-forming space X is made higher than the atmospheric pressure as in the case where the valve is closed prior to the mold-matching process.
By employing such a mode thus controlled, it is possible to continuously form a film on the work 16 through a series of control processes by using the molds 15, 17. Further, the film-forming work can be simplified by achievement in which the process is repeatedly executed. And, because, in the embodiment, the first and the third opening/closing valves 22, 26 are closed in the process prior to the mold-opening process, and the second opening/closing valve 25 is opened, in the mold-opening process, atmospheric air is flown into the film-forming space X at the work side between the third opening/closing valve 26 and the work 16 for which the mold is opened, and the film-forming space X is brought into the atmospheric pressure while the film-forming space X at the film-forming apparatus 18 side between the film-forming apparatus 18 and the third opening/closing valve 26 is maintained in a vacuum state. Accordingly, when operating for mold opening, it is not necessary to carry out a forced mold opening operation in a vacuum state as in Embodiment 1, wherein the molds are smoothly and gently opened under the atmospheric pressure.
Further, because the film-forming space X at the film-forming apparatus side between the film-forming apparatus 18 and the third opening/closing valve 26 is maintained in a vacuum state when the molds are opened, it is sufficient that air equivalent for the film-forming space X at the work side between the third opening/closing valve 26 and the work 16 is absorbed to secure a vacuum state when carrying out the next film-forming operation. Therefore, there is an advantage in that the vacuuming process to bring the entire film-forming space X into the film-forming conditions can be carried out in a short time and work efficiency can be improved.
Where the invention is embodied as described above, because, in the present embodiment, the film-forming space X at the film-forming apparatus 18 side is closed by the third opening/closing valve 26 at least from the mold-opening process to the mold-matching process, the first opening/closing valve 22 can be made no longer necessary. However, at the stage of commencing the operation, if the vacuum pump P is actuated in advance in a state where the first opening/closing valve 22 is closed in the stage to the mold matching, the flow channel from the first opening/closing valve 22 to the vacuum pump P can be made vacuum in advance. Thus, because the vacuuming flow channel 21 located nearer at the film-forming space X side than the first opening/closing valve 22 and the corresponding film-forming space X are only made vacuum in the vacuuming process, the vacuuming process can be carried out in a shorter time. And, after the beginning film-forming process is completed, control can be carried out with the first opening/closing valve 22 opened.
Next, the embodiment shown in
In addition, the invention may be embodied without the third opening/closing valve 26 as in Embodiment 3 shown in FIG. 11 and
The above-described third embodiment is provided with the first mold 36 and the second mold 37 and differs from Embodiment 2 in that neither masking portion for masking the peripheral portion of the work 16 nor the third opening/closing valve 26 are provided in the second mold 37. And in the embodiment, the first mold 36 is provided with an ejector body (ejector means) 38 whose description is omitted in the first mold and the second mold, wherein prior to the mold opening or simultaneously therewith after the film-forming process, the ejector body 38 is caused to protrude from the mold surface and causes the work 16 to be removed from the first mold 36. However, an atmospheric air inflow channel 40 is formed in an insertion channel through which the ejector body 38 can be taken out and retracted. And, in this case, in a state where the ejector body 38 is retracted and the molds are not released, the atmospheric air inflow channel 40 is closed to stop atmospheric air flow into the film-forming space X. However, as soon as the ejector body 38 is taken out and is brought into a provisional removing posture of the work 16 from the molds, the atmospheric air inflow channel 40 is opened to permit atmospheric air to flow into the vacuumed film-forming space X. The embodiment can be thus embodied. Also, the ejector body 38 may completely remove the work 16 from the molds. However, in this case, because the work 16 is freed from the first mold 16, there causes a problem in that, when opening the molds, the work 16 is dropped from the first mold 36. Therefore, the work 16 is half removed from the first mold 36, that is, it is in a provisionally supported state where a part of the work 16 is left in the first mold 36 before it is completely removed from the mold, that is, in a half-removed state, whereby there is an advantage in that the work 16 can be prevented from dropping when opening the mold. In the mode according to the embodiment, it is possible to carry out the half-removing operation and a full-removing operation when taking the work 16 out of the mold.
In this connection, where the first mold 36 is provided with vertical mold surfaces 36a, 36b that support the work 16, it is common in the field of mold formation that a slightly tapered section (taper for removal) which is widened toward the open end of the mold so that the work 16 can be easily removed is formed on the vertical mold surfaces 36a, 36b (Refer to
And, in such a mode, it is not necessary that an exclusive atmospheric air inflow channel and the second opening/closing valve are provided as in Embodiment 2. Such an advantage is brought about, by which inflow of atmospheric air can be controlled by effectively utilizing the ejector body 38 and the through-hole 39 provided to bring in and retract the ejector body 38. This is convenient.
Herein,
Herein, the ejector posture detection sensor 41 may be composed of such a type that is capable of detecting movement by which the ejector 38 is taken but and retracted. However, the ejector posture detecting sensor 41 may be embodied as a type capable of judging the status by reading a control signal outputted to the operation actuator 42 of the ejector body 38.
In
Thus, after a film is formed on the work 16 and the first opening/closing valve 22 is entered into a closed state, a control command by which the ejector operation actuator 42 is caused to be entered into a half removing posture is outputted, and when a detection signal detected by the ejector posture detection sensor 41 is inputted to recognize that atmospheric air has been flown into the film-forming space X, a mold opening command is outputted to the first mold operation actuator 20 to execute the corresponding mold opening operation, wherein a series of film-forming processes are finished by the mold opening being detected by the mold status detection sensor 31. Further, the next process control such as a process for removing the work 16 from the first mold and taking it out by protruding the ejector body 38 is carried out. In this connection, where the next process operation is to take out the work 16, a taking-out robot is applied to the work 16 which has been half-removed, and the ejector body 38 is further protruded in this state to bring the work 16 in a fully removing posture thereof, wherein the taking-out robot catches the work 16 and removes it from the mold. Thus, it becomes possible to prevent the work 16 from dropping the first mold 36.
In Embodiment 3 thus embodied, because atmospheric air can be flown into the vacuumed film-forming space X by effectively utilizing the ejector body 38, which is provided to take out the film-formed work 16, and the insertion channel 39 thereof, such an advantage can be brought about, by which the mold structure can be simplified.
In such a mode, there is an advantage in that the ejector means can be effectively utilized for the atmospheric air inflow channel and the opening/closing means thereof. However, it is a matter or course that the atmospheric air inflow channel and the opening/closing means may be formed in the first mold.
The present invention is useful and effective as a film-forming mold for a various types of moldings (work) including headlamps, direction indicators (including side blinkers) , tail lamps, etc., which are incorporated in a vehicle, etc., a film-forming method using the corresponding mold, and a film formation controlling system.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003-140060 | May 2003 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP04/06981 | 5/17/2004 | WO | 11/18/2005 |
