Patent Publication Number: US-2009230588-A1

Title: Transfer molding apparatus and transfer molding method

Description:
TECHNICAL FIELD 
     The present invention relates to a transfer molding apparatus and a transfer molding method in which a transfer film is held between molds, and decoration portions on the transfer film are transferred to molded products in synchronization with molding. 
     BACKGROUND ART 
     As a transfer film positioning method in a conventional transfer molding apparatus, a method disclosed in Japanese Patent Publication No. 3-56650 is available, for example. This transfer film positioning method for this conventional transfer molding apparatus is a film positioning method for a transfer molding apparatus comprising a longitudinal direction movement device for feeding a transfer film in the longitudinal direction and a longitudinal direction sensor for detecting longitudinal direction positioning marks on the transfer film, the method being characterized in that the longitudinal direction movement device is driven in a feeding direction to feed the transfer film, the driving of the longitudinal direction movement device is stopped so that the transfer film stops at a position beyond the longitudinal direction stop position of the transfer film, the stop position being preset according to the relative positional relationship of the longitudinal direction positioning mark with respect to the longitudinal direction sensor, and that the longitudinal direction movement device is driven in the returning direction so that the transfer film is fed reversely to the longitudinal direction stop position. 
     In this transfer film positioning method, first, the transfer film is fed in the longitudinal direction to an overrun state beyond the longitudinal direction stop position, and then a step of driving the device in the returning direction so that the transfer film is returned to the longitudinal direction stop position is carried out. At this time, the step of feeding the transfer film to the overrun state is carried out while the relative position to the transfer film is detected by the longitudinal direction sensor. 
     More specifically, as disclosed in FIG. 3 in Japanese Patent Publication No. 3-56650, the step of feeding the transfer film to the overrun state is carried out as described below. First, after the transfer film is fed and one end of the longitudinal direction positioning mark is detected, the transfer film is driven at high speed until a predetermined time passes. When the one end of the longitudinal direction positioning mark has been detected and the predetermined time has passed, the transfer film is fed at low speed, whereby the feeding speed of the transfer film becomes low. Then, when the longitudinal direction sensor detects that the other end of the longitudinal direction positioning mark is reached, the motor stops, and the feeding of the transfer film is stopped. At this time, because deceleration cannot be done sufficiently owing to inertia, the transfer film stops such that the longitudinal direction sensor is located beyond the other end of the longitudinal direction positioning mark. 
     The dimension of the overrun at this time is measured by a rotary encoder, and the transfer film is returned in a direction opposite to the feeding direction, whereby the transfer film stops at the position where the other end of the longitudinal direction positioning mark has passed the longitudinal direction sensor. 
     DISCLOSURE OF THE INVENTION 
     However, in the method disclosed in the above-mentioned patent document, at the step of feeding the transfer film to the overrun state, the width of the feeding is controlled by detecting the longitudinal direction positioning mark by the longitudinal direction sensor; hence, when the transfer film is fed at high speed, there is a issue that the dimension of the overrun increases. If the dimension of the overrun is too large, the time required for returning the film becomes long, and there is a issue that the running time increases. Hence, in the above-mentioned patent document, the transfer film is fed at high speed until the one end of the longitudinal direction positioning mark is detected, and then the transfer film is fed at low speed until the other end of the longitudinal direction positioning mark is detected, whereby the dimension of the overrun is decreased. 
     However, the longitudinal direction positioning mark provided on the transfer film is usually a small mark having a size of several millimeters in the longitudinal direction of the transfer film. For the purpose of controlling the stop position and the feeding speed of the transfer film by detecting both ends of the longitudinal direction positioning mark having this small size by the longitudinal direction sensor while the transfer film is fed, if the difference between the high film feeding speed and the low film feeding speed is too large, efficient control cannot be carried out. In other words, owing to inertia, a predetermined time is necessary between the detection of the one end of the longitudinal direction positioning mark and the switching of the film feeding speed from high speed to low speed. For this reason, if the film is fed at excessively high speed, the other end of the longitudinal direction positioning mark passes the longitudinal direction sensor before the film feeding speed is switched from high speed to low speed, and the step of stopping the transfer film cannot be carried out. Therefore, in the above-mentioned steps, the maximum speed of feeding the transfer film is limited to approximately 200 mm/sec, for example. 
     The feeding speed of the transfer film has influence on the time of injection molding that is carried out continuously. In other words, if the transfer film can be fed at high speed, the positioning of the transfer film can be carried out in a short time, and the time for the injection molding that is carried out continuously can be reduced; as a result, the number of products produced per unit time can be increased, and the efficiency of production can be improved. 
     Hence, the present invention is intended to solve the above-mentioned issues and to provide a transfer molding apparatus and a transfer molding method capable of feeding the transfer film at higher speed and capable of increasing the number of products produced per unit time and capable of improving the efficiency of production. 
     For the purpose of attaining the above-mentioned objects, the present invention is configured as described below. The present invention has a basic configuration in which a transfer molding apparatus a transfer molding apparatus comprising: 
     a transfer molding section equipped with a stationary mold and a movable mold disposed so as to have a closed state and an open state, and an injection nozzle for injecting molten resin into a cavity formed between the stationary mold and the movable mold mutually closed while a transfer film having decoration portions to be transferred to molded products and also having longitudinal direction positioning marks intermittently disposed in a longitudinal direction thereof is positioned at a transfer position of one of the molds and while the transfer film is held between the stationary mold and the movable mold, for transferring the decoration portion to a molded product in synchronization with molding; 
     a film moving section for moving the transfer film in parallel with parting surfaces of the molds in the longitudinal direction; 
     a longitudinal direction positioning mark detection section for detecting the positions of the longitudinal direction positioning marks on the transfer film that is moved by the film moving section, 
     a film feeding control section for controlling the film moving section to move the transfer film in a feeding direction thereof by a feeding length being set larger than an interval between adjacent longitudinal direction positioning marks and to stop the transfer film before transfer molding is carried out by the transfer molding section while detecting a feeding amount of the transfer film that is moved by the film moving section; and 
     a film returning control section for controlling the moving section to move the transfer film which has been moved in the feeding direction by the film feeding control section, in a returning direction, and then stopping the transfer film after the longitudinal direction positioning mark detection section has detected the longitudinal direction positioning mark. 
     A first aspect of the present invention provides a transfer molding apparatus comprising: 
     a transfer molding section equipped with a stationary mold and a movable mold disposed so as to have a closed state and an open state, and an injection nozzle for injecting a molten resin into a cavity formed between the stationary mold and the movable mold mutually closed while a transfer film having decoration portions to be transferred to molded products and also having longitudinal direction positioning marks intermittently disposed in a longitudinal direction thereof is positioned at a longitudinal direction transfer position of one of the molds and while the transfer film is held between the stationary mold and the movable mold, for transferring the decoration portion to the molded product in synchronization with transfer molding; 
     a film moving section equipped with a film feeding roller for moving the transfer film in parallel with parting surfaces of the molds in the longitudinal direction, and a film take-up roller for taking up the transfer film having been fed by the film feeding roller; 
     a longitudinal direction positioning mark detection section for detecting positions of the longitudinal direction positioning marks on the transfer film that is moved by the film moving section; 
     a film feeding control section for controlling a revolution angle of the film feeding roller so that the transfer film is moved in a feeding direction thereof by a feeding length being set larger than an interval between adjacent longitudinal direction positioning marks and then stopped before the transfer molding is carried out by the transfer molding section; and 
     a film returning control section for driving the film feeding roller to move the transfer film which has been moved in the feeding direction by the film feeding control section, in a returning direction, and then stopping the transfer film at the longitudinal direction transfer position by controlling the revolution angle of the film feeding roller after the longitudinal direction positioning mark detection section has detected the longitudinal direction positioning mark. 
     A second aspect of the present invention provides the transfer molding apparatus of the first aspect, wherein the film returning control section is adapted to control revolution of the film feeding roller at a speed lower than that at which the film feeding control section drives the film feeding roller. 
     A third aspect of the present invention provides the transfer molding apparatus of the first aspect, wherein the film moving section is equipped with a servomotor for driving the film feeding roller, the revolution angle of which is controlled by a pulse-shaped drive signal, and 
     the film feeding control section is adapted to control the revolution angle of the film feeding roller by applying the drive signal, having a number of pulses required to move the transfer film in the feeding direction by the feeding length being set larger than the interval between the adjacent longitudinal direction positioning marks, to the servomotor. 
     A fourth aspect of the present invention provides the transfer molding apparatus of the third aspect, wherein the film feeding control section is adapted to change a revolution speed of the film feeding roller depending on a transition in number of pulses of the drive signal applied to the servomotor in the control of the revolution angle of the film feeding roller. 
     A fifth aspect of the present invention provides the transfer molding apparatus of the third aspect, wherein the film returning control section is adapted to control the revolution angle of the film feeding roller by applying the drive signal having the number of pulses required to stop the transfer film at the longitudinal direction transfer position, to the servomotor. 
     A sixth aspect of the present invention provides the transfer molding apparatus of the third aspect, wherein the film feeding control section and the film returning control section are adapted to change the number of pulses of the drive signal applied to the servomotor depending on a take-up diameter of the transfer film disposed at the film feeding roller to make a feeding amount of the transfer film constant. 
     A seventh aspect of the present invention provides the transfer molding apparatus of the first aspect, wherein the film take-up roller of the film moving section is driven by a torque adjustment motor, whose torque for taking up the transfer film is adjustable, so that a tension applied to the transfer film disposed between the film feeding roller is adjustable, and 
     the film feeding control section and the film returning control section are adapted to control the driving of the torque adjustment motor so that the tension applied to the transfer film is constant. 
     A eighth aspect of the present invention provides the transfer molding apparatus of the first aspect, wherein the film returning control section carries out control so that the film feeding roller is stopped at a timing when the longitudinal direction positioning mark detection section detects the longitudinal direction positioning mark. 
     A ninth aspect of the present invention provides the transfer molding apparatus of the first aspect, wherein the transfer molding section is configured so that the decoration portion is transferred to the molded product while the transfer film having a width direction positioning mark being provided in succession in the longitudinal direction is positioned at the longitudinal direction transfer position and a width direction transfer position thereof, 
     the film moving section is further equipped with a width direction drive section for moving the transfer film in the width direction before transfer molding is carried out by the transfer molding section, 
     the transfer molding section further comprises: 
     a width direction positioning mark detection section for detecting a position of the width direction positioning mark on the transfer film that is moved by the film moving section; and 
     a width direction control section for driving the width direction drive section to move the transfer film which has been moved in the feeding direction by the film feeding control section, in the width direction at a timing when the film returning control section drives the film feeding roller and stopping the transfer film at the width direction transfer position when the width direction positioning mark detection section detects the width direction positioning mark. 
     A tenth aspect of the present invention provides the transfer molding apparatus of the ninth aspect, wherein the width direction positioning mark detection section is equipped with a laser line sensor provided so as to be extended in the width direction of the transfer film and detects the width direction position of the transfer film by an output signal regarding a ratio at which the width direction positioning mark on the transfer film blocks the laser line sensor, and 
     the width direction control section controls the driving of the width direction drive section so that a ratio value of the output signal from the laser line sensor coincides with a transfer position ratio serving as the ratio at which the width direction positioning mark on the transfer film located at the width direction transfer position blocks the laser line sensor. 
     A eleventh aspect of the present invention provides the transfer molding apparatus of the tenth aspect, wherein the width direction drive section is adapted to change a driving speed of the width direction drive section depending on a difference between the ratio value of the output signal from the laser line sensor and the value of the transfer position ratio. 
     A twelfth aspect of the present invention provides a transfer molding method for transferring a decoration to molded product in synchronization with molding by a transfer molding apparatus comprising:
         a transfer molding section equipped with a stationary mold and a movable mold disposed so as to have a closed state and an open state, and an injection nozzle for injecting molten resin into a cavity formed between the stationary mold and the movable mold mutually closed while a transfer film having decoration portions to be transferred to a molded product and also having longitudinal direction positioning marks intermittently disposed in a longitudinal direction is positioned at a longitudinal direction transfer position thereof and while the transfer film is held between the stationary mold and the movable mold;   a film moving section equipped with a film feeding roller for moving the transfer film in parallel with parting surfaces of the molds in the longitudinal direction, and a film take-up roller for taking up the transfer film having been fed by the film feeding roller, before transfer molding is carried out by the transfer molding section; and   a longitudinal direction positioning mark detection section for detecting positions of the longitudinal direction positioning marks on the transfer film that is moved by the film moving section,       

     the method comprising: 
     controlling the revolution angle of the film feeding roller so that the transfer film is moved in the feeding direction thereof by a feeding length being set larger than an interval between adjacent longitudinal direction positioning marks and then stopped before transfer molding is carried out by the transfer molding section; 
     driving the film feeding roller to move the transfer film, having been moved in the feeding direction, in a returning direction, and then stopping the transfer film at the longitudinal direction transfer position by controlling the revolution angle of the film feeding roller after the longitudinal direction positioning mark detection section has detected the longitudinal direction positioning mark; and 
     closing the stationary mold and the movable mold, injecting the molten resin into the cavity from the injection nozzle, and transferring the decoration to molded product in synchronization with molding. 
     According to the first to twelfth aspects of the present invention, for the purpose of the decoration portions of moving the transfer film to the longitudinal direction transfer position, after the transfer film is fed to a slightly overrun state from the longitudinal direction transfer position by the film feeding control section, the transfer film is rewound reversely by the film returning control section, and the transfer film is stopped at the longitudinal direction transfer position after the longitudinal direction positioning mark is detected; hence, slack and vibration occurring in the transfer film owing to inertia when the transfer film is fed and then stopped can be eliminated. For this reason, even if large slack and vibration occur in the film when the film is fed at high speed by the film feeding control section, the slack and vibration can be eliminated; hence, even if the film feeding speed controlled by the film feeding control section is raised to high speed, the positioning accuracy and the time required for the positioning are not adversely affected, whereby the film feeding speed can be increased. 
     In addition, at the time of positioning at the longitudinal direction transfer position, the position of the film is adjusted by the film feeding roller on the side of film feeding, and the positioning is carried out by a portion of the film not deformed by the preceding transfer molding, whereby film vibration is eliminated and the accuracy of the positioning can be improved. 
     Furthermore, because the film feeding control section and the film returning control section control the feeding amount of the transfer film depending on the revolution angle of the film feeding roller, the control sections can carry out film feeding control while always considering information regarding whether film feeding is stopped after how long the film is fed. In other words, because the film feeding control is carried out on the basis of the feeding amount instead of the position of the transfer film, the amount of the overrun that occurs when the transfer film is stopped can be controlled by the film feeding control section, and the amount can be made small. Hence, as the amount of the overrun is made small, the amount of the film rewinding is also made small by the film returning control section, whereby the time required for the positioning of the transfer film at the longitudinal direction transfer position can be shortened. 
     According to the second aspect of the present invention, the time required for the positioning can be shortened by raising the revolution speed of the film feeding roller by the film feeding control section. Furthermore, because the rewinding of the transfer film by the film returning control section is used for the positioning at the longitudinal direction transfer position, the accuracy of the positioning at the longitudinal direction transfer position can be improved by lowering the speed. 
     According to the third to fifth aspects of the present invention, the feeding amount of the transfer film is controlled depending on the number of pulses applied to the servomotor; hence, the configurations of the film feeding control section and the film returning control section can be simplified. And the revolution angle can be controlled accurately depending on the number of pulses. 
     According to the fourth aspect of the present invention, the revolution speed of the film feeding roller is changed depending on the transition in the number of pulses supplied to the servomotor; hence, the amount of overrun after the film feeding by the film returning control section is finished can be controlled easily. For example, in the case that the number of pulses applied to the servomotor from the film feeding means is 10000, control is carried out depending on the transition in the number of pulses such that the film feeding roller rotates at the maximum speed until the number of pulses reaches 8000 and such that the revolution speed of the film feeding roller is lowered gradually when the number of pulses is more than 8000. Hence, the control of the revolution speed near the end of the film feeding amount can be made easy, and the amount of the overrun that occurs at the stopping time of the film feeding roller can be controlled. Furthermore, slack and vibration occurring in the transfer film owing to inertia when the film feeding roller is stopped can be reduced by lowering the revolution speed near the end of the film feeding amount. 
     According to the sixth aspect of the present invention, in the transfer film being supplied in the shape of a roll, the feeding amount per unit revolution number differs depending on the take-up diameter. Hence, the number of pulses applied to the servomotor is changed depending on the take-up diameter, whereby the transfer film can be fed at a constant amount of feeding without being affected by the take-up diameter. 
     According to the seventh aspect of the present invention, the film feeding control section and the film returning control section control the torque adjustment motor that drives the film take-up roller so that the tension applied to the transfer film is constant; hence, slack and vibration that occur when the transfer film is fed can be eliminated. Furthermore, when the film is wound by the film returning control section, the torque applied to the film take-up roller serves as a brake, and the tension of the transfer film can be stabilized regardless of the take-up diameter of the transfer film. 
     According to the eighth aspect of the present invention, the film returning control section can stop the transfer film at the position of the longitudinal direction positioning mark by stopping the revolution of the film take-up roller at the timing when the longitudinal direction positioning mark is detected. Hence, the transfer film can be positioned easily by setting the relative positional relationship between the longitudinal direction positioning mark and the longitudinal direction positioning mark detection section as the longitudinal direction transfer position of the transfer film. 
     According to the ninth aspect of the present invention, because the positioning in the width direction of the transfer film and the positioning in the longitudinal direction thereof can be carried out simultaneously, the transfer film is not moved after the positioning in either of the directions is carried out, and the positioning operations are not affected mutually. Therefore, the time required for the positioning in the width direction of the transfer film and the positioning in the longitudinal direction thereof can be shortened, and the accuracy of the positioning can be improved. 
     According to the tenth aspect of the present invention, because the positioning at the width direction transfer position is carried out by a laser line sensor, the amount of correction and the direction of correction can be detected by one sensor, whereby the configuration can be simplified. 
     According to the eleventh aspect of the present invention, for example, when the transfer film detected by the laser line sensor is away from the width direction transfer position, the transfer film can be moved at high speed. Therefore, the positioning at the width direction transfer position can be carried out in a short time. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other aspects and features of the present invention will become clear from the following description taken in conjunction with the preferred embodiments thereof with reference to the accompanying drawings In these drawings: 
         FIG. 1  is a side view of a transfer molding apparatus according to a first embodiment of the present invention; 
         FIG. 2  is a sectional view taken on line A-A of  FIG. 1 ; 
         FIG. 3A  is a sectional view showing the configuration of a transfer film being used for the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 3B  is a view showing the external configuration of the transfer film being used for the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 4A  is a view explaining the detection of the longitudinal direction position, carried out by the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 4B  is a view explaining the detection of the longitudinal direction position, carried out by the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 4C  is a view explaining the detection of the longitudinal direction position, carried out by the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 5A  is a view explaining the detection of the width direction position, carried out by the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 5B  is a view explaining the detection of the width direction position, carried out by the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 5C  is a view explaining the detection of the width direction position, carried out by the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 6  is a sectional view taken on line B-B of  FIG. 1 ; 
         FIG. 7  is a detailed sectional view taken on line C-C of  FIG. 6 ; 
         FIG. 8  is a perspective view showing the film take-up mechanism of the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 9  is a magnified view showing the sensor installation section of the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 10  is a perspective view showing the first width direction sensor installation section of the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 11  is a control circuit diagram of the transfer molding apparatus shown in  FIG. 1 ; 
         FIG. 12  is a view showing a processing flow in the case that the transfer film is positioned at the longitudinal direction transfer position and the width direction transfer position; 
         FIG. 13A  is a graph showing the feeding speed and direction of the transfer film in the case that the transfer film is positioned at the longitudinal direction transfer position; 
         FIG. 13B  is a view showing the relationship among the positions of the longitudinal direction positioning marks on the transfer film, the position of the longitudinal direction sensor and the time shown in  FIG. 13A  in the case that the transfer film is positioned at the longitudinal direction transfer position; 
         FIG. 14  is a view showing a configuration example of a pulse count table; and 
         FIG. 15  is a graph showing the feeding speed of the transfer film in the case that the transfer film is positioned at the width direction transfer position. 
     
    
    
     BEST MODES FOR CARRYING OUT THE INVENTION 
     Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout the accompanying drawings. A first embodiment according to the present invention will be described below in detail referring to the drawings. 
     As shown in  FIGS. 1 and 2 , a transfer molding apparatus is provided with a transfer molding section  100  comprising a stationary mold  2  installed on a stationary base  1 , a movable mold  4  installed on a movable base  3 , and an injection nozzle  5  for injecting molten resin into a cavity formed between the two molds  2 ,  4 . 
     In the transfer molding apparatus according to this embodiment, the stationary base  1  is secured to a pedestal  6 , and the movable base  3  is guided with four tie bars  7  secured to the stationary base  1  and moves so as to be able to come close to and be away from the stationary base  1 . 
     By virtue of the movement of the movable base  3 , switching is possible between a closed state in which the parting surface  2   a  of the stationary mold  2  makes pressure contact with the parting surface  4   a  of the movable mold  4  and a cavity is formed in the molding sections (the molding section  2   b  of the stationary mold  2  and the molding section  4   b  of the stationary mold  4 ) of the molds  2 ,  4  and an open state in which the parting surfaces  2   a  and  4   a  are separated. 
     In addition, in the transfer molding section  100 , the stationary mold  2  and the movable mold  4  are used basically, and the two molds  2 ,  4  form the cavity; however, other molds, such as intermediate plates, may also be used. 
     A film feeding device  10  and a film take-up device  11  are provided on the movable base  3 . The film feeding device  10  and the film take-up device  11  constitute a film moving section for moving a transfer film  20  in parallel with the parting surface  4   a  of the movable mold  4  (in the longitudinal direction of the transfer film  20 ). 
     The transfer film  20  is moved in the longitudinal direction thereof by film feeding device  10  and the film take-up device  11  so as to be separated from and in parallel with the parting surface  4   a  of the movable mold  4 . 
     Furthermore, the film feeding device  10  and the film take-up device  11  are disposed so that they can be moved by a first movement mechanism  12  and a second movement mechanism  13 , respectively, in a direction perpendicular to the movement direction of the movable mold  4  (the width direction of the transfer film  20 ). In other words, the film feeding device  10  and the film take-up device  11  are moved in the width direction of the film by the first movement mechanism  12  and the second movement mechanism  13 , thereby constituting a width direction driving section for moving the transfer film  20  in the width direction thereof, together with the first movement mechanism  12  and the second movement mechanism  13 . 
     In this embodiment, the film feeding device  10  is installed above the movable base  3 , and the transfer film  20  is moved in the width direction by the first movement mechanism  12 . 
     The film take-up device  11  comprises a film tension mechanism  14  installed below the movable base  3  and a film take-up mechanism  15  installed on the pedestal  6 , and the film tension mechanism  14  is moved in the width direction of the transfer film  20  by the second movement mechanism  13 . 
     The installation positions of the film feeding device  10  and the film take-up device  11  are not limited to these positions; it may be possible that the film feeding device  10  is installed below or on the left/right side of the movable base  3  and that the film take-up device  11  is installed above or on the other left/right side of the movable base  3 , and it may also be possible that the film feeding device  10  and the film take-up device  11  are installed on the pedestal  6  or the stationary base  1 . 
     In other words, the film moving section is only configured so that the transfer film  20  can be moved in the longitudinal direction of the transfer film  20  and preferably also in the width direction of the transfer film  20  with respect to the parting surface of a mold (the parting surface  2   a  of the stationary mold  2  or the parting surface  4   a  of the movable mold  4 ) before transfer molding is carried out, and so that the transfer film  20  can be moved in the longitudinal direction and preferably in both the longitudinal and width directions when the transfer film  20  is positioned at the longitudinal direction transfer position and the width direction transfer position thereof as described later. 
     Next, the transfer film will be described. As shown in  FIGS. 3A and 3B , on the surface of the base film  20   a  of the transfer film  20 , decoration portions  21  are provided at intervals in the longitudinal direction. The decoration portions  21  are peeled from the base film  20   a  and transferred to molded products when molding is carried out in the transfer molding section  100 . In the transfer film  20 , a peeling protective layer  20   b  is provided on the base film  20   a , and decoration ink layers  20   c  constituting the decoration portions  21  are provided thereon. Furthermore, on the decoration ink layers  20   c , an adhesive layer  20   d  is provided, and the adhesive layer makes contact with molten resin during injection molding and is bonded thereto, and the decoration ink layers  20   c  are peeled from the base film together with the peeling protective layer  20   b  and transferred to molded products. 
     The transfer film  20  that is used in the present invention will be described. The transfer film  20  that is used in the present invention is formed of a substrate sheet  20   a  and a decorative layer. The decorative layer comprises a peeling protective layer  20   b , a decoration layer  20   c  and an adhesive layer  20   d.    
     As the substrate sheet  20   a , a single-layer film made of a material selected from among polycarbonate resin, polyamide resin, polyimide resin, polyester resin, acrylic resin, olefin resin, urethane resin, acrylonitrile-butadiene-styrene resin, vinyl chloride resin, etc. or a laminated film or a copolymer film made of two or more kinds of resins selected from among those described above is available. 
     The thickness of the substrate sheet  20   a  is preferably 5 to 500 μm. If the thickness of the sheet is less than 5 μm, the handling thereof during the setting in the molds  2 ,  4  is defective, and the molding processing becomes unstable; if the thickness of the sheet  20   a  is more than 500 μm, its rigidity is too high. 
     The peeling protective layer  20   b  is formed on the substrate sheet  20   a  so that the decorative layer can be peeled easily from the substrate sheet  20   a . As the material of the peeling protective layer, polyester resin, acrylic resin, olefin resin, urethane resin, or the like are available. As a method for providing the peeling protective layer  20   b , any of general-purpose printing methods, such as gravure printing, screen printing and offset printing, or any of various kinds of coating methods may be used. 
     On the peeling protective layer  20   b , the decoration layers  20   c  indicating letters, geometric patterns, solids, etc. are formed. As the material of the decoration layers  20   c , acrylic resin, nitrocellulose resin, polyurethane resin, chlorinated rubber resin, vinyl chloride-vinyl acetate copolymer resin, polyamide resin, polyester resin, epoxy resin, or the like are available, but the material is not particularly limited to these. 
     In addition, a metal film layer made of aluminum, chromium, copper, nickel, indium, tin, silicon oxide, or the like may also be provided as the decoration layer  20   c  by the vacuum deposition method, plating method, or the like In this case, the metal film layer may be provided on the entire face of the decoration portions or may be provided partially on part of the resin layer or the like. 
     The thickness of the decoration layer  20   c  is preferably 0.5 to 50 μm. If the thickness is less than 0.5 μm, there is a problem of being incapable of obtaining sufficient design property, and if the thickness is more than 50 μm, there is a problem of being difficult to dry after printing. However, in the case of a metal film layer, its thickness is preferably 50 to 1200 Å. If the thickness of the metal film layer is less than 50 Å, there is a problem of being incapable of obtaining sufficient metallic luster feeling, and if the thickness is more than 1200 Å, there is a problem of being apt to cause cracks. 
     As a method for providing the decoration layers  20   c  entirely or partially, general-purpose printing methods, such as gravure printing, screen printing and offset printing, and metallic film forming methods, such as tampo printing, painting, various kinds of coating methods, evaporation, ion plating, sputtering and the like are available. 
     The adhesive layer  20   d  has an effect of bonding the transfer film  20  to molded resin. It is preferable that acrylic resin, nitrocellulose resin, polyurethane resin, chlorinated rubber resin, vinyl chloride-vinyl acetate copolymer resin, polyamide resin, polyester resin, epoxy resin, polycarbonate resin, olefin resin, acrylonitrile-butadiene-styrene resin, or the like is used as the material of the adhesive layer  20   d.    
     The thickness of the adhesive layer  20   d  is preferably 0.5 to 50 μm. If the thickness is less than 0.5 μm, there is a problem of being incapable of obtaining sufficient adhesiveness; if the thickness is more than 50 μm, there is a problem of being difficult to dry after printing. As a method for forming the adhesive layer  20   d , any of general-purpose printing methods, such as gravure printing, screen printing and offset printing, or any of various methods, such as painting, dipping and reverse coater, may be used. 
     A mold release layer may also be provided on the substrate sheet  20   a  to form a substrate sheet having mold releasability. 
     It is preferable that acrylic resin, nitrocellulose resin, polyurethane resin, chlorinated rubber resin, vinyl chloride-vinyl acetate copolymer resin, polyamide resin, polyester resin, epoxy resin, polycarbonate resin, olefin resin, acrylonitrile-butadiene-styrene resin, or the like is used as the material of the peeling protective layer  20   b.    
     The thickness of the peeling protective layer  20   b  is preferably 0.5 to 50 μm. If the thickness is less than 0.5 μm, there is a problem of being incapable of obtaining sufficient adhesiveness; if the thickness is more than 50 μm, there is a problem of being difficult to dry after printing. As a method for forming the peeling protective layer, any of general-purpose printing methods, such as gravure printing, offset printing and screen printing, or any of various methods, such as painting, dipping and reverse coater, may be used. 
     Furthermore, as shown in  FIG. 3B , the transfer film  20  is equipped with longitudinal direction positioning marks  22  and a width direction positioning mark  23  for the purpose of detecting the position of the transfer film  20  at the time when the decoration portions  21  are transferred to molded products in synchronization with molding, that is, the transfer position of the transfer film  20 . 
     As shown in  FIG. 3B , for example, the longitudinal direction positioning marks  22  (having a longitudinal direction dimension of 3 mm, for example) on the transfer film are provided intermittently at intervals in the longitudinal direction of the transfer film on one width direction side of the transfer film  20 , and the width direction positioning mark  23  (having a width direction dimension of 3 mm, for example) is provided in succession in the longitudinal direction of the transfer film on the other width direction side of the transfer film. Both the longitudinal direction positioning marks  22  and the width direction positioning mark  23  can be configured so as to be nearly equal to or smaller in size than marks placed on a conventional transfer film. More specifically, although both ends of the longitudinal direction positioning mark are detected conventionally, only one end is detected in this embodiment, whereby the mark can be made smaller that that used on the conventional transfer film. 
     In this embodiment, the transfer film  20  is transparent, and the respective positioning marks  22  and  23  are not transparent; however, the respective positioning marks  22  and  23  may be configured so as to be translucent. Alternatively, it may also be possible that the transfer film  20  is configured so as to be not transparent or translucent and that the respective positioning marks  22  and  23  are configured so as to be transparent. 
     This transfer film position detection device comprises a longitudinal direction sensor  30  and first and second width direction sensors  31 ,  32  provided on the transfer molding apparatus as shown in  FIGS. 1 and 2 , and detects the positioning marks  22 ,  23  on the transfer film, thereby detecting the relative positions from the positioning marks  22 ,  23  on the transfer film as shown in  FIG. 3B . 
     Next, a transfer molding method according to this embodiment will be described. The transfer molding method is carried out continuously by continuously feeding the transfer film, on which the decoration portions  21  are disposed at intervals, between the stationary mold  2  and the movable mold  4  as being carried out conventionally. 
     The transfer molding method includes, for example, a first step in which while the stationary mold  2  and the movable mold  4  are open, the transfer film  20  is moved in the longitudinal direction and the width direction so as to be positioned at the longitudinal direction transfer position and the width direction transfer position in both the longitudinal direction and the width direction, respectively, and a decoration portion  21  is opposed to the molding section of the mold, such as the molding section  2   b  of the stationary mold  2 ; a second step in which after this first step, the movable mold  4  is moved, and the molds are closed to hold the transfer film  20  therebetween, molten resin is injected into the cavity  110  formed in the molds  2 ,  4 , and the decoration portion  21  is transferred to a molded product in synchronization with molding; and a third step in which the molds are opened, and the molded product to which the decoration  21  has been transferred is obtained. 
     Although the step of positioning the transfer film  20  at the longitudinal direction transfer position and the width direction transfer position will be described in detail later, for example, the feeding amount of the transfer film  20  by the film moving section is set in advance, and the film  20  is moved intermittently at high speed in the longitudinal direction by the feeding amount, and then both the positions in the longitudinal direction and the width direction are fine-adjusted and determined. This fine adjustment positioning is carried out by detecting the positions of the positioning marks  22 ,  23  provided on the transfer film  20  by the sensors  30 ,  31 ,  32  as described later. 
     For the purpose of correcting the position of the transfer film  20  in the width direction, a mechanism configured so as to be capable of moving the transfer film  20  in the width direction is necessary on the film entrance and the film exit side of the molds  2 ,  4 . The specific configuration of the mechanism is provided on the film feeding device  10  and the film take-up device  11  as described later. 
     Next, the specific configuration of the film feeding device  10  will be described. As shown in  FIGS. 1 and 2 , the film feeding device  10  comprises a bracket  40  provided on the movable base  3 , a moving member  41  that is provided on this bracket  40  so as to be movable in the movement direction of the movable base  3 , and a third movement mechanism  42  for moving the moving member  41  in the movement direction of the movable base  3  along the bracket  40 . 
     The third movement mechanism  42  is configured, for example, so that a screw rod  42   a  that is threadedly engaged with the moving member  41  via a lock nut  42   b  is rotatably connected to the bracket  40 , and so that the moving member  41  is moved in the movement direction of the movable base  3  by tightening or loosening the screw rod  42   a.    
     The third movement mechanism  42  may also be configured so that the screw rod  42   a  is rotated by a cylinder or a motor and so that the screw rod  42   a  is threadedly engaged with a nut. 
     Because the moving member  41  is configured so as to be moved in the movement direction of the movable base  3  by the third movement mechanism  42 , a feeding roller  45  is moved in the movement direction of the movable base  3  together with a housing  43 ; hence, the space between the parting surface  4   a  of the movable base  4  and the transfer film  20  can be adjusted by adjusting the feeding position of the transfer film  20 . 
     The housing  43  is provided on the moving member  41  so as to be movable in the width direction of the transfer film  20 , and the first movement mechanism  12  is provided to move the housing  43  with respect to the moving member  41  in the width direction. 
     As shown in  FIG. 2 , in the first movement mechanism  12 , a motor  12   b  is installed on a guide frame  12   a , a nut  12   d  is threadedly engaged with a screw rod  12   c  that is rotated by this motor  12   b  so that the nut  12   d  is movable along the guide frame  12   a ; the guide frame  12   a  is secured to the moving member  41 , and the nut  12   d  is secured to the housing  43 . 
     A guide frame  47  is provided on the moving member  41 , and sliders  48  that are moved along this guide frame  47  are secured to the housing  43 , whereby the housing  43  is configured so as to be movable with respect to the moving member  41  in the width direction of the transfer film  20 . 
     Because the transfer film  20  wound on a feeding reel  44  is moved in the width direction by moving the housing  43  with respect to the moving member  41  by the first movement mechanism  12 , the transfer film  20  can be moved in the width direction. 
     Both the feeding reel  44  and the feeding roller  45 , serving as film feeding roller, are rotatably supported in the housing  43 , and the transfer film  20  is wound on the feeding reel  44 . The feeding reel  44  is driven so as to be rotated forward and backward by a first motor  46 . The feeding reel  44  comprising a shaft  44   a  and a pair of flanges  44   b  installed thereon is removably installed on the housing  43 . 
     The first motor  46  is formed of a servomotor, and its driving revolution angle can be controlled by the number of drive pulses supplied from a control section (see  FIG. 11 ). 
     With the above-mentioned configuration, by the forward revolution of the feeding reel  44 , the transfer film  20  is drawn out and fed out from the feeding roller  45  in the longitudinal direction of the transfer film  20 ; by the backward revolution of the feeding reel  44 , the a to be molded portion of the transfer film  20  having been fed out can be rewound on the feeding reel  44 . 
     The transfer film  20  fed out from the film feeding device  10  passes through the space between both the molds  2 ,  4  and is fed further by the film tension mechanism  14 . The specific configuration of the film tension mechanism  14  will be described. 
     The film tension mechanism  14  comprises a drive roll  50  and a driven roll  51 , and the drive roll  50  is configured so as to be driven and rotated by a second motor  52 . The driven roll  51  is provided so that the driven roll  51  can make pressure contact with and be separated from the drive roll  50 ; in the separated state, the transfer film  20  is inserted between the drive roll  5   b  and the driven roll  51 ; in the pressure contact state, the drive roll  50  is driven to convey the transfer film  20  having been fed from the film feeding device  10 , whereby a tension is applied. As described later, the second motor  52  is formed of a torque adjustment motor, and the tension of the transfer film located between the film feeding device  10  and the drive roll  50  and the driven roll  51  is controlled by the control section (see  FIG. 11 ) so as to be nearly constant. 
     In this embodiment, the drive roll  50  and the second motor  52  are provided in a first housing  53 , and the driven roll  51  is provided in a second housing  54 . 
     The first housing  53  and the second housing  54  are rockably connected to each other, and energizing members, such as springs  55 , are installed between the first housing  53  and the second housing  54  to energize the first housing  53  and the second housing  54  so that the first housing  53  and the second housing  54  are pushed mutually. 
     When the springs  55  are removed, and when the second housing  54  is rocked in the direction (for example downward) of being moved away from the first housing  53 , the drive roll  50  is separated from the driven roll  51 . When the springs  55  are installed, the second housing  54  is energized so at to be rocked in the direction of coming close to the first housing  53 , and the drive roll  50  makes pressure contact with the driven roll  51 . 
     The film tension mechanism  14  (for example, the first housing  53 ) is installed on the movable base  3  via the second movement mechanism  13 . 
     In this embodiment, the second movement mechanism  13  comprises a bracket  56  provided on the movable base  3 , and a moving member  57  provided so as to be movable in the movement direction of the movable base  3  with respect to this bracket  56 . For the purpose of securing the moving member  57  and the bracket  56 , a fourth movement mechanism  58  that is used to install the moving member  57  so as to be movable in the movement direction of the movable base  3  is provided. 
     The fourth movement mechanism  58  is configured so that the screw rod  58   a  threadedly engaged with the moving member  57  is rotatably connected to the bracket  56  and that the moving member  57  is moved by tightening or loosening the screw rod  58   a . The moving member  57  is threadedly engaged with the screw rod  58   a  via a lock nut  58   b . The fourth movement mechanism  58  may also be configured so that the screw rod  58   a  is rotated by a cylinder or a motor and so that the screw rod  58   a  is threadedly engaged with the nut. 
     In the moving member  57 , the film tension mechanism  14  is provided so as to be movable in the width direction of the transfer film  20 , and the second movement mechanism  13  is provided to move the film tension mechanism  14  in the width direction with respect to the moving member  57 . 
     As shown in  FIGS. 1 and 2 , as in the case of the first movement mechanism  12 , in the second movement mechanism  13 ′, a motor  13   b  is installed on a guide frame  13   a , a nut  13   d  is threadedly engaged with a screw rod  13   c  that is rotated by this motor  13   b  so that the nut  13   d  is movable along the guide frame  13   a ; the guide frame  13   a  is secured to the moving member  57 , and the nut  13   d  is secured to the film tension mechanism  14  (the first housing  53 ). 
     The second movement mechanism  13  and the first movement mechanism  12  are not limited to the above-mentioned configurations but they may be configured using a cylinder, a motor, a combination of a screw rod and a nut, or the like. 
     With the above-mentioned configuration, the transfer film  20  can be moved in the thickness direction thereof by moving the film tension mechanism  14  in the movement direction of the movable base  3 , and the transfer film  20  can be moved in the width direction thereof by moving the film tension mechanism  14  in the width direction of the transfer film  20 . 
     The transfer film  20  is fed to the film take-up mechanism  15  by the film tension mechanism  14  and then taken up. The specific configuration of the film take-up mechanism  15  will be described. 
     As shown in  FIG. 1  and  FIGS. 6 to 8 , the film take-up mechanism  15  is movable between a film removing position protruding outward from the end  8   a  of an apparatus body  8  (the end  8   a  in the movement direction of the movable base  3 ) and a film take-up position inside the apparatus body  8 . 
     With the use of the above-mentioned configuration, the film take-up mechanism  15  is positioned inside the apparatus body  8  during molding operation, whereby it is possible not to block the passage outside the apparatus body  8 . 
     On the other hand, after the transfer film  20  is taken up and transfer is finished, that is, when the transfer film  20  having been used up is removed, the film take-up mechanism  15  can be moved outside the apparatus body  8 ; hence, film removing work can be carried out easily. 
     In this embodiment, the film take-up mechanism  15  is installed on the apparatus body  8  (the pedestal  6 ) so that two upper and lower guide rails  60  being in parallel with each other extend in the movement direction of the film  20 , and the ends of the guide rails  60  protrude outside the end  8   a  of the apparatus body  8 . The guide rails  60  are provided so as to be connected to the apparatus body  8  (the pedestal  6 ) by a connecting member  66 . 
     The guide rails  60  have a hexagonal cross-section as shown in  FIG. 7  and are connected to each other by a plate  68 . The guide rails  60  are adjustable in length and can take a retracted posture in which the guide rails are retracted inside the apparatus body  8  and a protruded posture in which the guide rails are protruded from the end  8   a  of the apparatus body  8 . 
     In this embodiment, as shown in  FIGS. 6 and 8 , the guide rails  60  comprise base-side guide rails  60   a  connected to the apparatus body  8  (the pedestal  6 ) by the connecting member  66 , and tip-side guide rails  60   b ; both are foldably connected by a hinge  60   c . In the hinge  60   c , a one-side piece  81  is rotatably connected to the other-side piece  82  by a pin  83 ; the tip-side guide rails  60   b  are secured to the one-side piece  81 , and the base-side guide rails  60   a  are secured to the other-side piece  82 . 
     More specifically, as shown in  FIG. 8 , the one-side piece  81  has a pair of pin supporting portions  81   a , the other-side piece  82  is configured so that the installation portion  82   a  thereof is movably provided with a plate  82   c  having a pin supporting portion  82   b , and the pin supporting portions  81   a ,  82   b  are connected mutually by the pin  83 . With the above-mentioned configuration, the one-side piece  81  is rotated together with the tip-side guide rails  60   b  with respect to the other-side piece  82  with the pin  83  being used as a fulcrum. 
     When the base-side guide rails  60   a  and the tip-side guide rails  60   b  are set in a straight line, the tip-side guide rails  60   b  protrude from the end  8   a  of the apparatus body  8  and take the protruded posture. When the tip-side guide rails  60   b  are folded, the tip-side guide rails  60   b  are retracted into the apparatus body  8  and take the retracted posture. In the retracted posture, the tip-side guide rails  60   b  may also be configured so as to be folded in the direction opposite to the arrow shown in  FIG. 6  (that is, the upward direction in  FIG. 6 ). With this configuration, the tip-side guide rails  60   b  are folded in the same direction as that of a take-up reel  61  described later, and the portion protruded from the apparatus body  8  can be decreased. 
     The tip-side guide rails  60   b  can be folded at the hinge  60   c  and can take the retracted posture by installing the hinge  60   c  configured as described above between the tip-side guide rails  60   b  and the base-side guide rails  60   a.    
     In the embodiment shown in  FIG. 8 , the pin supporting portions  81   a ,  82   b  are secured to the guide rails  60  so as to face the side on which a moving member  64  is not provided, whereby the tip-side guide rails  60  are configured so as to be foldable in the direction indicated by the arrow shown in  FIG. 6 ; hence, the moving member  64  is prevented from interfering with the hinge  60   c.    
     The guide rails  60  may have a telescopic configuration so as to take the retracted posture in which they are retracted inside the apparatus body  8  and the protruded posture in which they are protruded from the end  8   a  of the apparatus body  8 . 
     Furthermore, a bracket  67  is provided at the ends of the base-side guide rails  60   a , that is, on the side where the hinge  60   c  is not installed, and a third motor  62  is secured thereto. The third motor  62  has a rotating member  63  that is driven and rotated when the third motor  62  is driven. 
     The guide rails  60  are provided with the moving member  64  that is movable between the film removing position and the film take-up position. The moving member  64  is provided with wheels  69  making contact with the lower side of an upper rail  601  and also provided with wheels  69  making contact with the upper side of a lower rail  602 , and can move smoothly along the guide rails  60  while being held between the guide rails  60  at the upper and lower positions. 
     The wheels  69  provided on the moving member  64  are provided with a dovetail groove. The dovetail grooves are fitted on the guide rails  60  having a hexagonal cross-section; hence, the wheels  69  are prevented from derailing from the guide rails  60 , and the guide rails  60  are prevented from deviating in the width direction of the guide rails  60 . 
     The take-up reel  61  is rotatably supported in a cantilever manner on the moving member  64  for moving, and at the end of the take-up reel  61 , a rotation disc  65  is secured to the rotation shaft of the take-up reel  61  in a direction perpendicular thereto. 
     When the moving member  64  is located at the film take-up position indicated by the dashed lines shown in  FIG. 6 , the take-up reel  61  is driven and rotated by the third motor  62  at the film take-up position as shown in  FIG. 7 . 
     When the moving member  64  is located at the film take-up position indicated by the dashed lines shown in  FIG. 6 , the take-up reel  61  is driven by the third motor  62  at the film take-up position as shown in  FIG. 7 . 
     More specifically, when the moving member is located at the film take-up position, the rotation disc  65  and the rotating member  63  of the third motor make contact with each other, preferably make pressure contact with each other. When the third motor  62  is driven and the rotation disc  63  is rotated, the rotation force is transmitted to the rotation disc  65  by friction exerted between the two members  63 ,  65 , whereby the take-up reel  61  is rotated. In this embodiment, a rubber ring  63   b  is installed on the outer circumferential face of the rotation disc  63   a  of the rotating member  63  to increase frictional resistance. 
     Next, the specific configurations of the sensors being used for the transfer molding apparatus according to this embodiment will be described. As shown in  FIGS. 1 and 2 , near the molds, for example, near the movable mold  4 , the longitudinal direction sensor  30  and the width direction sensors, such as the first and second width direction sensors  31 ,  32 , are provided. It is not always necessary to provide two width direction sensors, but the number thereof may be one or may be three or more. 
     The longitudinal direction sensor  30  is installed on the upper portion of the movable mold  4  on one side in the width direction, and the first width direction sensor  31  is installed on the upper portion of the movable mold  4  on the other side in the width direction, and the second width direction sensor  32  is installed on the lower portion of the movable mold  4  on the other side in the width direction. 
     The longitudinal direction sensor  30  detects the longitudinal direction positioning marks  22  on the transfer film  20 , and the first and second width direction sensors  31  and  32  detect the width direction positioning mark  23  on the transfer film  20 ; they also detect the amounts of deviation from the respective positioning marks  22 . 
     Each sensor is formed of a laser line sensor (having a light receiving width of 3 mm), for example, and comprises a light emitter  33  and a light receiver  34 . The transfer film  20  is positioned between the light emitter  33  and the light receiver  34 , the light from the light emitter  33  passes through the transfer film  20  and is received by the light receiver  34  as shown in  FIG. 3B . 
     The longitudinal direction sensor  30  is configured so that its extension direction is in the longitudinal direction of the transfer film  20 . In addition, the width of the light from the light emitter  33  (the width in the longitudinal direction of the film) is nearly equal to the width of the longitudinal direction positioning mark  22  (the width in the longitudinal direction of the film  20 ). Furthermore, the first and second width direction sensors  31  and  32  are configured so that their extension directions are aligned with the width direction of the transfer film, and the width of the light from the light emitter  33  is nearly equal to the width of the width direction positioning mark  23  (the width in the width direction of the film). 
     With the sensors being configured as described above, for example, when the transfer film  20  is at the longitudinal direction transfer position, and in the case that the longitudinal direction positioning marks  22  is aligned with the longitudinal direction sensor  30 , the light  33   a  from the light emitter  33  is completely blocked by the longitudinal direction positioning mark  22  as shown in  FIG. 4A , and the light receiving amount of the light receiver  34  becomes zero. 
     Furthermore, in the case that the longitudinal direction positioning mark  22  goes beyond the longitudinal direction sensor  30 , the light  33   a  from the light emitter  33  deviates upward with respect to the longitudinal direction positioning mark  22  as shown in  FIG. 4B , and the light receiver  34  receives the light receiving amount corresponding to the deviation amount S 1 ; hence, the ratio at which the positioning mark  22  blocks the light receiver  34  can be detected by the light receiving amount. 
     On the other hand, in the case that the longitudinal direction positioning mark  22  is just before the longitudinal direction sensor  30 , the light  33   a  from the light emitter  33  deviates downward with respect to the longitudinal direction positioning mark  22  as shown in  FIG. 4C , and the light receiver  34  receives the light receiving amount corresponding to the deviation amount S 2 ; hence, the ratio at which the positioning mark  22  blocks the light receiver  34  can be detected by the light receiving amount. 
     In the states shown in  FIGS. 4B and 4C , the longitudinal direction position of the transfer film  20  can be detected according to the ratio at which the positioning mark  22  blocks the light receiver  34 . Furthermore, the direction of the deviation of the transfer film  20  can be detected by tracing the history of the ratio of blocking the light receiver  34  when the transfer film is moved in the longitudinal direction. 
     More specifically, in the transfer molding apparatus shown in  FIG. 1 , the transfer film  20  is fed downward from above; hence, the size of S 2  shown in  FIG. 4C  decreases gradually, and the ratio of blocking the light receiver  34  increases gradually; in the state shown in  FIG. 4A , the blocking ratio becomes maximum; when the longitudinal direction positioning mark  22  is moved further downward and is in the state shown in  FIG. 4B , the size of S 1  increases gradually as the positioning mark is moved, and the ratio of blocking the light receiver  34  decreases gradually. 
     In this way, the deviation amount and the deviation direction of the transfer film in the longitudinal direction thereof can be detected by detecting the longitudinal direction positional relationship between the longitudinal direction sensor  30  equipped with a laser line sensor and the positioning mark  22 . Hence, the longitudinal direction sensor  30  constitutes a positioning mark detector that detects the transfer position (the deviation amount) of the transfer film  20  in the longitudinal direction as digital values. 
     On the other hand, regarding the width direction positioning mark  23 , when the transfer film  20  is at the transfer position, in the case that the width direction positioning mark  23  is aligned with the first width direction sensor  31 , the light  33   a  from the light emitter  33  is completely blocked by the width direction positioning mark  23  as shown in  FIG. 5A , and the light receiving amount of the light receiver  34  becomes zero. 
     Furthermore, in the case that the width direction positioning mark  23  deviates to one side in the width direction from the first width direction sensor  31 , the light  33   a  from the light emitter  33  deviates to the other side in the width direction of the width direction positioning mark  23  as shown in  FIG. 5B , and the light receiver  34  receives the light receiving amount corresponding to the deviation amount S 3 ; hence, the ratio at which the positioning mark  23  blocks the light receiver  34  can be detected by the light receiving amount. 
     On the other hand, in the case that the width direction positioning mark  23  deviates to the other side in the width direction from the first width direction sensor  31  when the transfer film  20  is at the transfer position, the light  33   a  from the light emitter  33  deviates to one side in the width direction of the width direction positioning mark  23  as shown in  FIG. 5C , and the light receiver  34  receives the light receiving amount corresponding to the deviation amount S 4 ; hence, the ratio at which the positioning mark  23  blocks the light receiver  34  can be detected by the light receiving amount. 
     In the states shown in  FIGS. 5B and 5C , the width direction position of the transfer film  20  can be detected according to the ratio at which the positioning mark  23  blocks the light receiver  34 . Furthermore, the direction of the deviation of the transfer film  20  can be detected by tracing the history of the ratio of blocking the light receiver  34  when the transfer film  20  is moved in the width direction. 
     The positional relationship between the second width direction sensor  32  and the width direction positioning mark  23  is similar to the positional relationship between the first width direction sensor  31  and the width direction positioning mark  23 , and the position of the width direction positioning mark  23  can be measured by the second width direction sensor  32 . 
     Hence, the deviation amount and the deviation direction of the transfer film  20  in the width direction can be detected by detecting the width direction positional relationship between the first and second width direction sensors  31 ,  32  equipped with a laser line sensor and the positioning mark. Hence, the width direction sensors  31 ,  32  function as a positioning mark detector that detects the transfer position (the deviation amount) of the transfer film  20  in the width direction. 
     The longitudinal direction sensor  30  and the first and second width direction sensors  31  and  32  can move in the movement direction of the movable base  3  (the thickness direction of the transfer film  20 ), in the movement direction of the transfer film  20  (the longitudinal direction) and in the width direction of the transfer film  20 ; positions of the sensors can be adjusted in the longitudinal direction depending on the size of the decoration  21  on the transfer film  20  and the size of the mold, and positions of the sensors can also be adjusted in the movement direction of the movable base depending on the size of the mold (the size in the movement direction of the movable base); the sensors are installed in the transfer molding apparatus so that positions the sensors can be adjusted in the width direction depending on the width of the transfer film  20 . 
     For example, as shown in  FIGS. 1 and 2 , first moving members  71  are respectively installed so as to be movable in the movement direction of the movable base  3  along the horizontal guides  70  that are respectively installed on the brackets  40 ,  56 , vertical rods  72  are respectively supported on the first moving members  71  so as to be slidably movable in the movement direction (the vertical direction) of the transfer film  20 , and a second moving member  73  is installed on each vertical rod  72  so that the second moving member  73  is movable in the vertical direction. 
     Brackets  74  are respectively installed on the second moving members  73  so as to be movable in the width direction of the transfer film  20 . 
     The light emitters  33  and the light receivers  34  are installed on the brackets  74  so that they serve as the longitudinal direction sensor  30  and the first and second width direction sensors  31  and  32 . 
     More specifically, as shown in  FIG. 9 , the first moving member  71  is secured by tightening first screws  75 , and when the screws  75  are loosened, the first moving member  71  moves along the horizontal guides  70 . 
     The vertical rods  72  are secured by tightening second screws  76 , and when the screws  76  are loosened, the vertical rods  72  move in the vertical direction with respect to the first moving member  71 . 
     The bracket  74  has an installation piece  74   a  and a sensor installation piece  74   b  as shown in  FIG. 10 , the sensor installation piece  74   a  is secured by a bolt  77  that is supported so as to be movable along the dovetail groove  73   a  of the second moving member  73 ; when the bolt  77  is loosened, the bracket  74  moves along the dovetail groove  73   a  with respect to the second moving member  73  in the width direction of the transfer film  20 . 
     The light emitter  33 , and the light receiver  34  are installed on the sensor installation piece  74   b  of the bracket  74 , and a pair of guides  78  is provided between the light emitter  33  and the light receiver  34  so that the transfer film  20  can easily enter the space therebetween. 
     Because the installation positions of the longitudinal direction sensor  30  and the first and second width direction sensors  31  and  32  in the sensor installation structure shown in  FIGS. 9 and 10  are different individually, the sensor installation structure has two configurations being bilaterally symmetric to each other; for example, the configuration shown in  FIG. 10  is a structure for installing the first width direction sensor  31 , and the structure for installing the longitudinal direction sensor  30  and the second width direction sensor  32  has a configuration being bilaterally symmetric with the configuration shown in  FIG. 10 . 
     Next, in the transfer molding apparatus having the above-mentioned configuration, control in the case that the transfer film  20  is positioned at the longitudinal direction transfer position and the width direction transfer position will be described. The transfer molding apparatus shown in  FIG. 1  is driven under the control of the control mechanism thereof. 
     As shown in  FIG. 11 , the transfer molding apparatus is provided with a control section  90  serving as the control mechanism. The control section  90  conceptually comprises a film feeding control section  90   a , a film returning control section  90   b  and a width direction control section  90   c . Output signals including information regarding the amounts of light received from the respective light receivers  34  of the longitudinal direction sensor  30  and the first and second width direction sensors  31  and  32  are input to the control section  90 . In addition, the control section generates drive pulses for driving and rotating the first motor  46  formed of a servomotor forward and backward, and also generates drive signals for driving the second motor  52 , the third motor  62 , the first movement mechanism motor  12   b  and the second movement mechanism motor  13   b . Furthermore, in a data storage section  91 , programs and data for positioning the transfer film  20  at the longitudinal direction transfer position and the width direction transfer position are stored. A pulse count table described later and including pulses that are used to allow the first motor to overrun and stop is taken as an example of the data. Still further, the data storage section  91  also functions as a temporary memory that is used when control described later is carried out and stores information, such as history information described later regarding the ratio at which light to the light receiver  34  of the laser line sensor is blocked. 
     The first motor  46 , a servomotor, receives drive pulses from the control section  90  and is rotated by a predetermined revolution angle per pulse. In addition, when the first motor  46  is rotated by receiving the drive pulses, it transmits feedback pulses to the control section  90 . The control section  90  can detect the revolution angle of the first motor  46  in real time by the feedback pulses transmitted from the first motor  46 . 
     The second motor  52 , a torque adjustment motor, receives drive signals from the control section  90  and feeds back the information of the current torque value to the control section  90 . The control section  90  controls the driving of the second motor  52  on the basis of the information of the torque value having been fed back, whereby the tension applied to the transfer film  20  is controlled so as to be constant. 
     The first movement mechanism motor  12   b  and the second movement mechanism motor  13   b  are motors that are used to move the transfer film  20  in the width direction as described above. When these motors are driven, the positional relationship among the film, width direction positioning mark  23 , the first width direction sensor  31  and the second width direction sensor  32  is changed. The control section  90  controls the first movement mechanism motor  12   b  and the second movement mechanism motor  13   b  on the basis of the output values from the first width direction sensor  31  and the second width direction sensor  32 , thereby carrying out positioning at the width direction transfer position. 
       FIG. 12  shows a processing flow in the case that the transfer film  20  is positioned at the longitudinal direction transfer position and the width direction transfer position. The transfer molding apparatus according to the present embodiment positions the transfer film  20  at the longitudinal direction transfer position and the width direction transfer position according to the following procedure after the transfer molding for the preceding frame is finished. 
     First, the film feeding device  10  and the film take-up device  11  are operated to feed the transfer film by almost one frame. At this time, the transfer film  20  is stopped in a state of being allowed to slightly overrun from the longitudinal direction stop position (at step # 2 ). Then, the transfer film  20  is rewound by the amount of the overrun and is positioned at the longitudinal direction transfer position, and in synchronization with this positioning, the first movement mechanism  12  and the second movement mechanism  13  are operated to carry out positioning at the width direction transfer position (at step # 3 ). After the positioning at the longitudinal direction transfer position and the positioning at the width direction transfer position are both finished, the transfer molding for the current frame starts (at step # 4 ). 
     These steps will be described below specifically.  FIG. 13A  is a graph showing the feeding speed and direction of the transfer film  20  in the case that the transfer film  20  is positioned at the longitudinal direction transfer position. In addition,  FIG. 13B  is a view showing the relationship among the positions of the longitudinal direction positioning marks on the transfer film  20 , the position of the longitudinal direction sensor and the time shown in  FIG. 13A  in the case that the transfer film  20  is positioned at the longitudinal direction transfer position. In  FIG. 13A , the upper side of the time axis of the graph indicates the speed at the time when the transfer film  20  is moved in the feeding direction (downward in  FIG. 1 ), and the lower side of the time axis of the graph indicates the speed at the time when the transfer film  20  is moved in the rewinding direction (upward in  FIG. 1 ). 
     First, after the transfer molding for the preceding frame is finished, the control section  90  supplies drive pulses to the first motor  46  and transmits drive signals to the second and third motors  52  and  62 , thereby feeding the transfer film  20  in the longitudinal direction. Because the first motor is formed of a servomotor as described above, its revolution angle is determined to have a unique value depending on the number of drive pulses applied. At this time, the feeding position of the transfer film is set so that the longitudinal direction positioning mark for the preceding frame is positioned at the stop position, and the transfer film  20  is moved downward by the driving of the first motor. 
     At this time, the control section  90  control for rotating the first motor  46  at high speed. The control section  90  starts the driving of the first motor  46 , and the longitudinal direction feeding speed of the transfer film  20  rises and reaches the high feeding speed being preset at timing T 1 . 
     Furthermore, after driving the first motor  46  according to the pulse count preset at timing T 2 , the control section  90  gradually lowers the feeding speed of the transfer film  20  and completely stops the first motor  46  when a predetermined pulse count is reached (at timing T 3 ). 
     The pulse count that is used at this time is obtained by referring to a pulse count table stored in the data storage section  91 .  FIG. 14  shows an example of the pulse count table. The pulse count table is a table that stores a pulse count for certainly feeding the transfer film  20  by a feeding amount slightly exceeding the amount of one frame when the first motor  46  is driven to feed the transfer film  20  and when the transfer film  20  is stopped at timing T 3 . The pulse count table stores the pulse counts of the drive pulses for all the frames from the first frame to the last frame (for example, 5000 frames in  FIG. 14 ) of the transfer film  20  having the shape of a roll, the drive pulses being supplied to the first motor  46 . 
     The take-up diameter of the transfer film  20  is proportional to the amount of film feeding per unit revolution number; hence, for the purpose of making the amount of film feeding per unit revolution number nearly constant, the pulse count is configured so that the pulse count of the first frame is smallest and so that the pulse count of the last frame is largest. In other words, in the case of the first frame, the take-up diameter of the transfer film  20  is large, and the amount of the transfer film  20  being fed by the angle of revolution of the first motor  46  per pulse is large; however, as the transfer film  20  is consumed, the take-up diameter of the transfer film  20  becomes smaller, and the amount of the transfer film  20  being fed by the angle of revolution per pulse also becomes smaller. For this reason, the amount of feeding the transfer film  20  that is fed by the driving of the first motor  46  can be made nearly constant without being affected by the take-up diameter. 
     The pulse count of drive pulses is set so that the transfer film  20  is fed by an amount slightly larger than the interval between the longitudinal direction positioning marks, that is, slightly larger than the amount of one frame, as shown in  FIG. 13A  when the first motor  46  rotates depending on the number of drive pulses determined according to the pulse count table. The feeding length of the transfer film  20  is set by the setting of the pulse count, and the feeding length of the transfer film  20  is certainly set to a length slightly larger than the length of one frame. In other words, as shown in  FIG. 13B , the transfer film  20 , being in the state in which the longitudinal direction positioning mark  22 - 1  on the preceding frame is aligned with the longitudinal direction sensor  30  at timing T 0 , is fed by the feeding length P slightly larger than the length of one frame. At this time, the longitudinal direction positioning mark  22 - 2  on this frame moves beyond the longitudinal direction sensor  30  by the amount of overrun Q and stops while having the positional relationship shown in  FIG. 4C . 
     In this embodiment, the state in which the longitudinal direction positioning mark  22  is aligned with the longitudinal direction sensor  30  is defined as a state in which the light  33   a  of the light  33  is completely blocked by the longitudinal direction positioning mark  22  and the light receiving amount of the light receiver  34  is zero. The light receiving amount of the light receiver  34  in this state of alignment is not limited to zero but can be set to any desired value as a matter of course. 
     In the transfer molding apparatus according to this embodiment, the feeding length P of the transfer film  20  is determined by the number of drive pulses supplied to the first motor  46 , and the position where the transfer film  20  is located can be detected in real time while the transfer film  20  is fed. Furthermore, it is not necessary to detect the longitudinal direction positioning marks  22  on the transfer film  20  during the control operation. Hence, even when the feeding speed of the transfer film  20  is made high, the occurrence of vibration and slack in the transfer film  20  owing to inertia at the time of stopping the feeding of the transfer film  20  can be reduced. 
     Next, the control section  90  drives the first motor  46  in a direction opposite to that of the preceding operation to rewind the transfer film having overrun. More specifically, the transfer film  20  having overrun and stopped is moved upward at timing T 4  so as to be rewound. At this time, the control section  90  controls for rotating the first motor  46  so that it runs at low speed; the speed is preferably approximately several m/sec, for example. 
     Furthermore, while driving the first motor  46  at the low speed, the control section  90  detects the output from the longitudinal direction sensor  30 . When the longitudinal direction positioning mark  22 - 2  on this frame reaches the end of the longitudinal direction sensor  30  and when a state in which the light blocking ratio corresponding to the target stop position (for example, the positional relationship shown in  FIG. 4A ) is obtained, the supply of the drive pulses to the first motor  46  is stopped, or a predetermined count number of drive pulses are applied and the positioning at the longitudinal direction transfer position is finished. 
     The light blocking ratio corresponding to the stop position at which the longitudinal direction positioning mark on this frame is stopped may be the value obtained in the above-mentioned corresponding state or can have a unique value. Furthermore, the value of the light blocking ratio at the stop position is not required to be constant at all times but may be changeable while transfer molding is carried out continuously. More specifically, for example, it is possible to change the alignment position so that the position of the decoration is measured by subjecting a transfer molded product molded by injection molding to image recognition, so that the deviation amount between the target position and the actually measured position of the decoration is detected and so that the stop position of the decoration is adjusted depending on the deviation amount. 
     The configuration of the drive pulse count for feeding the transfer film  20  by the first motor  46  is not limited to the configuration that uses the pulse count table described above. More specifically, only the number of drive pulses for feeding the first frame of the transfer film  20  may be stored in the table, or the number of drive pulses for the first frame can be obtained by calculation. For example, by virtue of providing information regarding the number of decoration in one roll of the transfer film  20 , the diameter of the roll in the initial state of the transfer film  20 , the pitch between the decoration, the thickness of the transfer film  20  and the like, the feeding amount slightly larger than the pitch between the adjacent decoration is determined for the first frame by multiplying the information regarding the pitch between the decoration by a constant (the constant can be in the range of 1.00 to 1.05, for example) indicating an excess amount. Next, it may be possible that the revolution angle of the motor corresponding to the feeding amount is calculated on the basis of the information regarding the diameter of the roll, and that the pulse count corresponding to the revolution angle is obtained. 
     Then, for the purpose of compensating for the decrease in the roll diameter corresponding to the feeding amount of the transfer film  20  on the basis of the information regarding the thickness of the transfer film  20  and other information, the value obtained by cumulatively adding a predetermined number to the number of pulses applied at the time of the longitudinal direction positioning of the preceding frame may also be used as the pulse count for the second and following frames. For example, when the number of pulses applied for the purpose of positioning a given frame is 10000, processing is made possible so that the pulse count is increased each time by five, that is, 10005 at the next time and then 10010. This kind of pulse count calculation is carried out by the control section  90 , for example. 
     In the case that the target light blocking position is not reached even after a predetermined time has passed in the step of taking up the transfer film  20 , for example, in the case that the longitudinal direction sensor cannot detect the longitudinal direction positioning mark within the predetermined time, it may be judged that a transfer film  20  feeding error has occurred by the control section, and it may be possible that processing for generating an alarm regarding the error is carried out. 
     In the transfer molding apparatus according to this embodiment, for the purpose of moving the transfer film  20  to the longitudinal direction transfer position, after the transfer film  20  is fed to a state slightly overrun from one frame amount position serving as the longitudinal direction transfer position, the transfer film  20  is rewound reversely and stopped at the longitudinal direction transfer position as described above; hence, slack and vibration occurring in the transfer film  20  owing to inertia when the transfer film is fed and then stopped can be eliminated. In other words, even if slack and vibration occur in the transfer film  20  when the transfer film  20  is fed at high speed, the slack and vibration can be eliminated by rewinding; hence, the feeding speed of the film can be set at high speed (for example, 300 mm/sec) without adversely affecting the accuracy of the positioning. 
     In addition, at the time of positioning at the longitudinal direction transfer position, the position of the film is adjusted by the film feeding roller on the side of film feeding, and the positioning is carried out while a driving force is transmitted to a film portion not deformed by the preceding transfer molding, whereby the positioning can be carried out without being affected by the film vibration. 
     Furthermore, because the control section  90  carries out film feeding on the basis of the transfer film feeding amount determined by the pulse count of the drive pulses supplied to the first motor  46 , the control section  90  can carry out film feeding control while always detecting information regarding whether film feeding is stopped after how long the film is fed. 
     Next, the positioning at the width direction transfer position will be described. As described above, the positioning at the width direction transfer position is carried out in synchronization with the taking up of the transfer film that have overrun and stopped. By the simultaneous positioning at the transfer positions in both the directions, the time required for the positioning at the transfer positions can be shortened, and highly accurate positioning can be carried out at one time while the two positioning operations are prevented from being affected mutually, whereby the time for the positioning of the transfer film  20  can be reduced. 
     In the transfer molding apparatus according to this embodiment, because laser line sensors are used for the width direction sensors  31 ,  32 , the positioning at the longitudinal direction transfer position and the positioning at the width direction transfer position can be carried out simultaneously. More specifically, because the laser line sensors can detect the positional relationship between the transfer film and the width direction sensors  31 ,  32  according to the blocking ratios, the movement width of the width direction transfer position can be reduced. In other words, in the case of a photosensor, such as a photo interrupter, that detects only the transmission and blocking of light, when the positioning at the width direction transfer position is carried out, it is necessary to carry out positioning by moving the transfer film  20  once to a position at which the sensor is not blocked at all by the width direction positioning mark and then by moving the film to a position at which the sensor is blocked by the width direction positioning mark. At this time, the width of the movement to the width direction of the transfer film  20  increases, and there is a problem that the longitudinal direction positioning mark becomes away from the longitudinal direction sensor and that the longitudinal direction positioning cannot be carried out. For the purpose of preventing this problem that the longitudinal direction positioning mark becomes away from the longitudinal direction sensor, the width of the longitudinal direction positioning mark should be made larger; however, in this case, the width of the transfer film  20  is required to be made larger, and this causes a problem in cost. 
     On the other hand, by the use of laser line sensors for the width direction sensors, the movement width of the transfer film in the width direction can be reduced at the time of the positioning at the width direction transfer position, and the longitudinal direction positioning mark can be prevented from being away from the longitudinal direction sensor. Hence, the positioning in the longitudinal direction and the positioning in the width direction can be carried out simultaneously without increasing the width of the transfer film  20 . 
     The positioning at the width direction transfer position is carried out by driving the first movement mechanism motor  12   b  and the second movement mechanism motor  13   b  so that the output values from the first width direction sensor  31  and the second width direction sensor  32  are aligned with the target value obtained when a predetermined transfer film  20  is located at the width direction transfer position. 
     In synchronization with the movement of the transfer film  20 , the first and second width direction sensors  31 ,  32  monitor the width direction position of the transfer film  20  in a way similar to that described above on the basis of the change in the light receiving amounts of the first and second width direction sensors  31 ,  32 . When the control section  90  detects that the signals regarding the ratios at which the first and second width direction sensors  31 ,  32  are blocked, that is, the output values from the first and second width direction sensors  31 ,  32 , are aligned with the target ratio (transfer position ratio) obtained when the transfer film  20  is located at the width direction transfer position, the motors  12   b ,  13   b  are stopped. 
     When the output values from the first and second width direction sensors  31 ,  32  deviate greatly from the target value as shown in  FIG. 15 , the control section  90  controls both the motors  12   b ,  13   b  so that the driving speeds of the first movement mechanism motor  12   b  and the second movement mechanism motor  13   b  increase. By virtue of the control on the basis of the target value as described above, overrun can be reduced at the time of the positioning at the width direction transfer position, and the positioning can be carried out in a short time. 
     After the positioning at the longitudinal direction transfer position and the positioning at the width direction transfer position of the transfer film  20  are finished as described above, the processing advances to the transfer molding operation. 
     The present invention is not limited to the above-mentioned embodiment but can be embodied in other various embodiments. 
     For example, in the film take-up device  11 , the film take-up mechanism  15  may be disposed so as to be movable in the width direction of the transfer film  20  by the second movement mechanism without providing a film tension mechanism. 
     INDUSTRIAL APPLICABILITY 
     By an appropriate combination of any embodiments of the above-mentioned various embodiments, it is possible to obtain their respective effects. 
     In the transfer molding apparatus and the transfer molding method according to the present invention, a transfer film is held between molds, and decoration portions on the transfer film are transferred to molded products in synchronization with molding; hence, the present invention is useful when decoration portions are attached to molded products, such as the display panel of a mobile telephone, in synchronization with the molding of the molded products being formed by injection molding. 
     Although the present invention has been fully described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications are apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart therefrom.