Patent ID: 12208589

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Specific embodiments of the present invention are described in detail below with reference to the accompanying drawings. The embodiments are described in detail in order for those skilled in the art to readily implement the present invention. It is to be understood that the various embodiments of the present invention are different from each other, but do not need to be exclusive. For example, a specific shape, structure and characteristic described in this specification in connection with an embodiment may be implemented as another embodiment without departing from the spirit and scope of the present invention. It is also to be understood that the position or arrangement of an individual element within each disclosed embodiment may be changed without departing from the spirit and scope of the present invention. Accordingly, the detailed description hereinafter is not intended to have a limited meaning, and the range of right of the present invention is restricted by only the attached claims along with the entire range equivalent to things claimed by the claims, if it is appropriately described. Similar reference numerals in the drawings denote the same or similar functions from several aspects.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings

FIG.1is a flowchart illustrating an insert injection method including a laminating process according to an embodiment of the present invention.

Referring toFIG.1, the insert injection method including a laminating process according to an embodiment of the present invention comprises:a step (S10) in which a material receiving part10receives a metal sheet S1made of SUS material;a step (S20) of adhering a film-type bond S2to one side of the metal sheet S1prepared in the material receiving step (S10) through a laminating process;a step (S30) in which a laminating system20performs a press molding on the metal sheet S1to which the film-type bond S2is adhered to manufacture a molded object;a first injection molding step (S40) in which a pressing part30injects plastic resin onto one side of the molded object to which the film-type bond S2is adhered to manufacture an injected product;a second injection molding step (S50) in which a first injection molding part40injects plastic resin to one side or both sides of the injected product to enhance the rigidity of the injected product; anda step (S60) in which a machining operation part60receives the injected product manufactured by the second injection molding step (S50) from a second injection molding part50to perform a post-injection process.

The insert injection method having the above-described steps and including a laminating process according to an embodiment of the present invention is carried out using the insert injection system1described below inFIG.2.

The insert injection method including the laminating process according to an embodiment of the present invention is performed by using an insert injection system1including the laminating process according to an embodiment of the present invention as illustrated inFIG.2.

Referring toFIG.2, the insert injection system1including the laminating process according to an embodiment of the present invention comprises a material receiving part10, a laminating system20, a pressing part30, a first injection molding part40, a second injection molding part50, and a machining operation part60.

The material receiving part10receives a metal sheet S1made of SUS430 (0.4 T) material.

The laminating system20adheres a film-type bond S2to one side of the metal sheet S1prepared in the material receiving part10through a laminating process.

The pressing part30performs a press molding on the metal sheet S1to which the film-type bond S2is adhered to manufacture a molded object.

The first injection molding part40performs a first injection molding by injecting plastic resin onto one side of the molded object, to which the film-type bond S2is adhered, to manufacture an injected product.

The second injection molding part50performs a second injection molding by injecting plastic resin to one side or both sides of the injected product to enhance the rigidity of the injected product.

The machining operation part60receives the injected product from the second injection molding part50, and performs a post-injection process (e.g., burr removal or defective product sorting).

It was found that the insert injection method including the laminating process according to an embodiment of the present invention, by using the laminating system20, obtained an average strength of 7.21 kgf, which was higher than the conventional method of manufacturing an injected product using solvent-based bond, and confirmed an approximately 1.8 times increase in adhesive strength.

Therefore, according to an aspect of the present invention, the insert injection method including the laminating process can enhance adhesive force between a metal sheet made of a SUS material and plastic resin through introduction of film-type adhesive and dedicated adhesive equipment, which are raw materials for injection-molded products, such as automobile window moldings, when the injection-molded products are manufactured, and can save labor costs generated due to manual work by workers and improve the workshop environment (e.g., the unique smell of solvent-type bond/contamination).

TABLE 1No. ofEffect AmountEffect AmountDiv.peoplePrice(Month)(Year)RemarkExistingSolvent-type45KR135,000,000KR128,000,000KR1,536,000,000ApplicableChangedFilm type2KR6,00,000to allMaintenance costKR1,000,000moldingitems

In addition, the insert injection method including the laminating process according to an embodiment of the present invention with the configuration as described above, can improve the ease of material management, minimize the odor of the bond, and enhance the uniformity of the quality of the injected product. Moreover, as indicated in Table 1, the insert injection method including the laminating process can offer various benefits in terms of manpower, cost, and the like.

FIG.4is a flowchart illustrating a laminating method according to an embodiment of the present invention.

Referring toFIG.4, in the laminating method according to an embodiment of the present invention, that is, in the laminating step (S20) ofFIG.1, a unwinding part100rotates and unwinds a metal sheet S1, which is wound in a roll type, to continuously supply the metal sheet S1(S100).

A first heating chamber part200heats the metal sheet S1continuously transmitted from a unwinding part100to a preset temperature (S200).

In an embodiment, in first heating step (S200), an inner space of the first heating chamber200in which the metal sheet S1is moved is heated to a temperature of 220 to 260° C. to heat the metal sheet S1.

The film bond adhesion part300continuously moves the metal sheet S1which has been heated by the first heating chamber part200and the film-type bond S2which is continuously supplied from a film supply device M1between a first adhesive roller R1and a second adhesive roller R2which are closely arranged in a vertical direction to be rotated, and continuously adheres the film-type bond S2on one side of the moving metal sheet S1(S300).

The second heating chamber part400heats the metal sheet S1, on which the film-type bond S2transferred from the film bond adhesion part300is adhered, to a predetermined temperature so as to strengthen the adhesion of the film-type bond S2and the metal sheet S1(S400).

In an embodiment, in the second heating step (S400), the second heating chamber part400can heat the inner space, in which the metal sheet S1is moved, to a temperature of 230° C. to 270° C. to heat the metal sheet S1to heat the metal sheet S1on which the film-type bond S2is adhered.

The protective tape adhesion part500adheres an SPV protective tape S3onto the other side of the metal sheet S1where the film-type bond S2is not adhered (S500).

The winding part600receives the metal sheet S1to which the film-type bond S2and the SPV protective tape S3are adhered, and winds the metal sheet S1in a roll form (S600).

As illustrated inFIG.6, the laminating method (S20) having the steps according to an embodiment of the present invention can further include a defect detection step (S700) in which a defect detection part900detects defect of the adhesive surfaces of the metal sheet S1and the film-type bond S2by using vision inspection.

The laminating method (S20) having the steps according to an embodiment of the present invention can further include a defective section notification step (S700) wherein when a defect is detected in the defect detection step (S700) (“Yes” in S700ofFIG.4) and the defect detection part900notifies an adhesion defect, as illustrated inFIG.6, the defective section notification part1000identifies the section where the adhesion defect occurred, and requests a worker to cut and discard the identified adhesion defective section or remove the identified adhesion defective section.

As described above, the laminating method (S20) according to an embodiment of the present invention may further include a cooling step (not shown) in which a cooling part700cools the metal sheet S1to which the film-type bond S2transferred from the second heating chamber part400is adhered, and then, transfers the cooled metal sheet S1to the protective tape adhesion part500.

The laminating method (S20) according to an embodiment of the present invention may further include a roller overheating prevention step (not shown) in which a roller overheating prevention part800which is installed at the front end of the film bond adhesion part300blows cool air in the direction of the metal sheet S1inserted into the film bond adhesion part300to prevent the film-type bond S2from being adhered to the first adhesive roller R1or the second adhesive roller R2as the first adhesive roller R1or the second adhesive roller R2is heated.

The laminating method (S20) comprising such steps as described above is carried out by using the laminating system20according to an embodiment of the present invention.

Referring toFIG.5, the laminating system20includes an unwinding part100, a first heating chamber part200, a film bond adhesion part300, a second heating chamber part400, a protective tape adhesion part500, and a winding part600.

The unwinding part100rotates and unwinds a metal sheet S1, which is wound in a roll type, to continuously supply the metal sheet S1.

In an embodiment, the unwinding part100supplies the metal sheet S1at the linear speed of 1.8 M/MIN, and can adjust the linear speed of the metal sheet S1with an acceleration time of 20 sec±5 sec, a deceleration time of 20 sec±5 sec, and a stop time of 5 sec±1 sec.

The first heating chamber part200heats the metal sheet S1continuously transmitted from the unwinding part100to a preset temperature.

In an embodiment, the first heating chamber part200heats an inner space, in which the metal sheet S1is moved, to a temperature of 220° C. to 260° C., preferably, 240° C., to heat the metal sheet S1.

The film bond adhesion part300continuously moves the metal sheet S1which has been heated by the first heating chamber part200and the film-type bond S2which is continuously supplied from the film supply device M1between a first adhesive roller R1and a second adhesive roller R2which are closely arranged in a vertical direction to be rotated, and continuously adheres the film-type bond S2on one side of the moving metal sheet S1.

In an embodiment, for efficient adhesion of the metal sheet S1and the film-type bond S2, it is preferable that the film bond adhesion part300sets the pressure between the first adhesive roller R1and the second adhesive roller R2to 8±1 kgf/cm2.

The second heating chamber part400heats the metal sheet S1, on which the film-type bond S2transferred from the film bond adhesion part300is adhered, to a predetermined temperature so as to strengthen the adhesion of the film-type bond S2and the metal sheet S1.

In an embodiment, the second heating chamber part400can heat the inner space, in which the metal sheet S1is moved, to a temperature of 230° C. to 270° C., preferably, 250° C., to heat the metal sheet S1to heat the metal sheet S1on which the film-type bond S2is adhered.

The protective tape adhesion part500adheres an SPV protective tape S3, which is continuously supplied from a protective tape supply device M2, onto the other side of the metal sheet S1where the film-type bond S2is not adhered.

In this case, the SPV protective tape S3acts as a protective film covering the outer surface based on the final injected product (for example, vehicle molding, etc.).

In an embodiment, for efficient adhesion of the metal sheet S1and the SPV protective tape S3, it is preferable that protective tape adhesion part500sets the pressure between a third adhesive roller R3and a fourth adhesive roller R4to 8±1 kgf/cm2.

The winding part600receives the metal sheet S1to which the film-type bond S2and SPV protective tape S3are adhered and winds the metal sheet S1in a roll form.

The laminating system20with the configuration can further include a cooling part700.

The cooling part700cools the metal sheet S1to which the film-type bond S2transferred from the second heating chamber part400is adhered, and then, transfers the cooled metal sheet S1to the protective tape adhesion part500.

In an embodiment, the cooling part700can cool the metal sheet S1, to which the film-type bond S2is adhered, to room temperature (for example, within the range of 20±5° C.) by natural cooling or forced cooling using a blower.

At this time, the film-type bond S2may be cooled to room temperature by the cooling part700to become non-adhesive.

The laminating system20having the configuration can further include a roller overheating prevention part800.

As illustrated inFIG.6, the roller overheating prevention part800is installed in an inner space of the film bond adhesion part300or at the front end of the film bond adhesion part300. That is, to prevent the film-type bond S2from being adhered to the first adhesive roller R1or the second adhesive roller R2as the first adhesive roller R1or the second adhesive roller R2is heated, the roller overheating prevention part800is installed at the front end of the film bond adhesion part300to blow cool air in the direction of the metal sheet S1inserted into the film bond adhesion part300.

In an embodiment, the film bond adhesion part300can include a first air blower A1which sprays heated compressed air onto the adhesive surface of the metal sheet S1to remove dust and other foreign substances from the adhesive surface of the metal sheet S1before the film-type bond S2is adhered.

Here, preferably, the first air blower A1blows air heated at about 200° C. to prevent the cooling of the metal sheet S1.

In an embodiment, the protective tape adhesion part500can include a second air blower A2which sprays heated compressed air onto the adhered surface of the metal sheet S1to remove dust and other foreign substances from the adhered surface of the metal sheet S1before the SPV protective tape S3is adhered.

The laminating system20with the configuration can further include a defect detection part900and a defective section notification part1000.

The defect detection part900detects defects on the adhesive surfaces of the metal sheet S1and the film-type bond S2using vision inspection, and then, transmits the occurrence of defects to the defective section notification part1000.

The defective section notification part1000divides the metal sheet S1supplied from the unwinding part100into a predetermined length unit (for example, 1 m), and when receiving a notification of adhesive defect from the defect detection part900, identifies the section where the adhesion defect occurred, and requests a personal terminal1100-1or a management terminal1100-2that a worker uses to cut and discard the identified adhesion defective section or remove the identified adhesion defective section.

Therefore, since the worker cuts and discards the adhesion defective section notified from the defective section notification part1000or performs removal of the adhesion defective section, the quality of the product is improved.

The above description is only exemplary, and it will be understood by those skilled in the art that the invention may be embodied in other concrete forms without changing the technological scope and essential features. Therefore, the above-described embodiments should be considered only as examples in all aspects and not for purposes of limitation. For example, each component described as a single type may be realized in a distributed manner, and similarly, components that are described as being distributed may be realized in a coupled manner.

The scope of the present invention is defined by the appended claims, and encompasses all modifications or alterations derived from meanings, the scope and equivalents of the appended claims.