JP2001277286A - Method and mold for manufacturing film-applied molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To bond a film to the uneven part provided on the rear surface of a molded article in a perfect adhesion state. SOLUTION: In a method for manufacturing a film-applied molded article by using a film 5, which can cover the surface of the molded article and the uneven part 4 provided on the rear surface 2 of the molded article, and an injection mold not only to integrally bond a part of the film 5 to the surface of the molded article simultaneously with the molding of the molded article but also to bond the remaining part 8 of the film to the uneven part 4 provided on the rear surface 2 of the molted article taken out of the injection mold by an adhesive, the remaining part 8 of the film is molded into a three- dimensional shape coinciding with the uneven part 4 provided on the rear surface 2 of the molted article by a mold before bonded to the uneven part 4 provided on the rear surface 2 of the molded article by the adhesive.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to automobile interior and exterior parts such as console panels, armrests, coin trays, door trims, center pillars, meter panels, dashboards, switch bases, operation buttons, instrument panels, various bezels, and the like. The present invention relates to a method for manufacturing a molded product with a film such as a front panel and operation buttons of an AV device, or a panel and operation buttons of home appliances such as a washing machine, a rice cooker, and a water purifier.

[0002]

2. Description of the Related Art Conventionally, a molded product front surface 1 and a molded product back surface 2
Irregularities 4 on the molded product back surface 2 of the molded product divided at the boundary with
As a product in which a film 5 on which a picture layer or the like is formed is bonded to a certain molded product 6, there is a product in which the film 5 is bonded not only to the molded product front surface 1 but also to the molded product back surface 2 (see FIG. 1). In addition, the reason why the film 5 must be adhered to the molded product back surface 2 is that the molded product back surface 2 is sometimes observed in appearance, and when the molded product is fitted to another member,
This is because the molded product back surface 2 may be seen from the fitting gap. Conventionally, as a method of manufacturing a product in which the film 5 is bonded not only to the front surface 1 of the molded product but also to the back surface 2 of the molded product, a method of integrally bonding the film 5 to the molded product 6 simultaneously with the injection molding, There was a method combining the bonding method for bonding to No. 6. That is, a film 5 having a size that can cover the molded product front surface 1 and the molded product back surface 2 of the molded product 6 with one sheet is prepared, and the film 5 is divided into, for example, a part 7 of the film and a remaining part 8 of the film. I do. A part 7 of the film is integrally adhered to the molded product surface 1 simultaneously with molding. Since the remaining portion 8 of the film remains flat, the film 8 is turned around to the molded product back surface 2 of the molded product 6, and is pushed into the concave portion of the molded product back surface 2 by a human finger 6, pressed against the corner of the convex portion, or formed. The film 5 was folded or bent along the irregularities 4 on the product back surface 2 (hereinafter, referred to as a curl).
It is called "finger work." Then, the adhesive is attached to the uneven portion 4 on the rear surface 2 of the molded product (see FIGS. 3 and 4).

[0003]

However, since the film 5 has a shape retaining property, the remaining portion of the film 5 is changed from a flat state to a concave and convex part 4
It was extremely difficult to deform and maintain the shape completely conforming to (see FIGS. 3 and 4). (1) If the film 5 is forcibly deformed by a finger operation, the nail or finger may be damaged when the film 5 is pressed into the concave portion or pressed against the corner of the convex portion, or the film 5 may be damaged.
In some cases, it was possible to cause damage to unnecessary parts. (2) In finger work, since it is impossible to keep the force of the finger uniform at all times, it is necessary to add a perfect straight line or a curved curve with a constant curvature, or to fold with a uniform force over the entire line. It was not possible to add a curl, and it was impossible to completely transform it into a complicated three-dimensional shape such as fine irregularities. (3) If the deformation of the film 5 is insufficient or the curl is not perfect, the adhesive strength of the film 5 due to the shape retention of the film 5 after the adhesive is adhered to the uneven portion 4 on the back surface 2 of the molded product. The film 5 is warped against the surface of the molded product, so that the film 5 is completely peeled off at the uneven portion 4 on the back surface 2 of the molded product, or is partially peeled off and adhered in a floating state, so that defective products are easily generated. . Acrylic film, polycarbonate film, ABS film, or their laminated films are particularly strong in shape retention and high in hardness. It was close to

[0004]

Means for Solving the Problems A method and a mold for manufacturing a molded article with a film according to the present invention have the following constitutions in order to solve the above problems.

The method of manufacturing a molded article with a film according to the present invention comprises the steps of: using a film capable of covering the irregularities on the surface of the molded article and the back surface of the molded article with a single sheet; Production of a molded product with a film in which the surface of the molded product is integrally bonded with the molded product at the same time as the molded product and then the remaining part of the film is bonded with an adhesive to the irregularities on the back surface of the molded product removed from the injection mold. In the method, the remaining portion of the film is formed by a mold into a three-dimensional shape that matches the unevenness on the rear surface of the molded product before the adhesive is bonded to the unevenness on the rear surface of the molded product with an adhesive.

In the method of manufacturing a molded article with a film according to the present invention, after setting the film in an injection molding die, the remaining part of the film is formed into a three-dimensional shape that matches the irregularities on the back surface of the molded product. May be configured.

In the method of manufacturing a molded article with a film according to the present invention, before setting the film in the injection molding die, the remaining part of the film is matched with the concave and convex portions on the back surface of the molded article by using a different mold from the injection molding die. It may be configured to be formed into a three-dimensional shape.

In the method of manufacturing a molded article with a film according to the present invention, the parting surface sandwiching the rest of the film of the injection mold has a portion having a shape matching the concave and convex portion on the back surface of the molded article. May be.

The mold according to the present invention is a mold having a surface on which a film capable of covering the surface of the molded product and the uneven portion on the back surface of the molded product with a single sheet is provided. Constructed so that it has a surface that can be set to be integrally bonded and a surface that can maintain a three-dimensional shape that matches the irregularities on the back of the molded product without the remaining part of the film being integrally bonded to the back of the molded product I do.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a molded article with a film according to the present invention will be described below with reference to the drawings.

First, a description will be given of a film 5, an injection mold, and a mold different from the injection mold applicable to the production method of the present invention.

As the injection mold, a mold A having a cavity forming concave portion 10 corresponding to the molded product surface 1 of the molded product 6 and a mold uneven portion 1 corresponding to the molded product back surface 2 of the molded product 6.
3 and a mold B having a molten resin injection port 14 (see FIGS. 5 to 9). In the injection mold, after the film 5 is introduced between the mold A and the mold B, the molten resin 16 is injected into the cavity 15 after the mold is completely closed, and the heat and pressure of the molten resin 16 and cooling after the injection. Thus, the film 5 and the molded product 6 are integrated. When the injection mold includes a fixed mold and a movable mold, a combination in which the mold A is a fixed mold and the mold B is a movable mold may be used. Alternatively, the mold B may be a fixed mold and a mold. A combination in which the mold A is a movable mold may be used. In addition, the injection molding die is not only a die A and a die B, but also an intermediate die that forms a part of a surface forming the inner surface of the cavity 15 by being sandwiched between the die A and the die B. A mold may be used. The mold B may be provided with an ejector pin for taking out the molded product with a film 6 by protruding (not shown). The mold A may be provided with a vacuum suction hole 17 for sucking and fixing the film 5 so as not to be displaced on the surface of the mold A.

[0013] The injection mold is a mold having a surface on which a film capable of covering the uneven surface of the molded product surface and the back surface of the molded product with a single sheet, and a part of the film is formed on the molded product surface. It is preferable to have a surface that can be set so as to be integrally bonded and a surface that can maintain a three-dimensional shape that matches the irregularities on the back surface of the molded product without the remaining portion of the film being integrally bonded to the back surface of the molded product. . For example, as for the injection mold, the parting surface that sandwiches the rest of the film of the injection mold has a portion having a shape that matches the irregularities on the back surface of the molded product, and sandwiches the rest of the film of the injection mold. Some parts have a parting surface 19 for forming an uneven part, which is a part whose shape is such that the parting surface can be formed into a shape that matches the uneven part 4 on the back surface 2 of the molded product.
This is effective when, after setting the film 5 in the injection molding die, the remaining portion 8 of the film is formed into a three-dimensional shape that matches the uneven portion 4 on the back surface 2 of the molded product in the injection molding die.
The surface of the uneven part forming parting surface 19 may be a heat dissipation surface. This is effective when the remaining portion 8 of the film needs to be heated to the softening temperature of the film 5. As the heat radiation surface, there is a surface in which a hot air blowing means or a heat ray irradiation means is embedded. The hot air blowing means sends out heat generated from a heat radiation source by wind. As the heat radiation source, there are a cast heater, a far infrared heater, a heating wire heater and the like. As a heat ray source used as the heat ray irradiation means, there is a halogen lamp or the like. The halogen lamp is effective because the speed of raising the temperature of the film 5 is high, and it is also possible to heat only a predetermined portion of the film 5. A vacuum suction hole 17 may be formed on the surface of the parting surface 19 for forming the uneven portion. It is effective to easily bring the film 5 which has reached the softening temperature by heating along the parting surface 19 for forming the uneven portion. The vacuum suction on the parting surface 19 for forming the concave and convex portions is performed by vacuum suction holes 17 formed in the cavity forming concave portion 10.
It may be performed by suction from the Further, the mold A may be provided with a clamp means so as to surround the periphery of the parting surface 19 for forming the concavo-convex portion (not shown).

Before setting the film 5 in the injection molding die, if the remaining portion 8 of the film is to be molded into a three-dimensional shape that matches the uneven portion 4 on the back surface 2 of the molded product by another die, the mold A
The evacuation unit 20 is a space having such a size that the three-dimensional shape of the remaining portion 8 of the film is not crushed by closing the mold A and the mold B when the mold and the mold B are closed. It must be formed on the parting surface of the mold. The retracting portion 20 includes a space having the same shape as the three-dimensional shape of the remaining portion 8 of the film (see FIG. 6), a wide space in which the three-dimensional shape of the remaining portion 8 of the film is closed and does not collapse.

The film 5 is formed by sequentially laminating a picture layer, an adhesive layer, and the like on a base sheet. There is a so-called insert film which does not peel off the base sheet after the molten resin 16 adheres to the film 5. . The film 5 is formed by sequentially laminating a release layer, a pattern layer, an adhesive layer, and the like on a base sheet, and there is also a so-called transfer film that peels the base sheet after the molten resin 16 adheres to the film 5. . Examples of the material of the base sheet include polyethylene terephthalate, polypropylene, and acrylic. The picture layer is a layer that imparts decorativeness and functionality to the surface of the molded article. The picture layer includes a normal printed pattern and a conductive pattern formed of a conductive material. The picture layer can be formed with a resin binder and a pigment or a dye. The picture layer may use a resin binder and a metal pigment or an inorganic pigment having a masking property. The picture layer may be composed of a metal vapor-deposited layer to give a metallic luster. The adhesive layer is a film 5
And a layer for adhering the molded article. For the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molten resin is appropriately used. For example, when the molten resin 16 is an acrylic resin or a urethane resin, a vinyl chloride-vinyl acetate copolymer resin or an acrylic resin may be used as the adhesive layer. The picture layer and the adhesive layer are formed by various printing methods. A resin film 5 may be used for the adhesive layer.

A method for manufacturing a molded product with a film of the present invention using the above-described injection mold and film will be described with reference to the drawings.

(1) After setting the film 5 in an injection mold, the remaining portion 8 of the film is molded into a three-dimensional shape that matches the uneven portion 4 on the back surface 2 of the molded product in the mold of the injection mold. (FIGS. 5 and 7 to 12). An injection mold having an uneven part forming parting surface 19 having a shape that can be formed into a shape matching the uneven part 4 on the molded product back surface 2 is prepared.

First, the film 5 is introduced into an injection mold (see FIGS. 5 and 7). A part 7 of the film is made to correspond to the cavity forming recess 10 of the mold A, and a remaining part 8 of the film is formed.
Correspond to the parting surface 19 for forming the concave and convex portions of the mold. Before setting the part 7 of the film in the injection molding die, the cavity forming recess 10
May be formed into a three-dimensional shape that matches the inner surface shape of. If the part 7 of the film is not formed into a three-dimensional shape that matches the inner surface shape of the cavity forming recess 10 of the mold A by another mold, the cavity forming recess is formed in the mold A by heating or vacuum suction. It is good to shape it so that it may be in intimate contact with the inner surface of 10. The timing of forming the remaining portion 8 of the film into a three-dimensional shape that matches the concave-convex portions 4 on the back surface 2 of the molded product may be performed before closing the mold, or may be performed simultaneously with closing the mold. In the former case, while heating the remaining portion 8 of the film near the softening point of the film 5, vacuum suction may be applied to the parting surface 19 for forming the concave and convex portions of the injection mold (see FIG. 7). In the latter case, the mold B may be pressed after heating the remaining portion 8 of the film near the softening point of the film 5 (not shown).

Next, the mold A and the mold B are closed, the molten resin 16 is injected from the molten resin injection port 14 of the mold B, and the part 7 of the film and the surface 1 of the molded product are separated. At the same time as the molding of the molded article, it is integrally bonded (FIGS. 8 and 9). Since the remaining portion 8 of the film has already been formed into a shape that matches the uneven portion 4 on the back surface 2 of the molded product, the mold is closed so as not to crush the shape. As a material of the molten resin 16, a polystyrene resin, an ABS resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, or the like can be used.

Next, the remaining portion 8 of the film is bonded to the uneven portion 4 of the molded product back surface 2 of the molded product (see FIGS. 2 and 10) taken out of the injection molding die with an adhesive 18 (FIG. 10).
(FIG. 12). In the molded product 6 removed from the mold, a part 7 of the film is integrally adhered to the molded product surface 1, but the remaining portion 8 of the film has a three-dimensional shape but is not adhered anywhere. And is connected at the end 3 of the molded product (see FIGS. 2 and 10). Therefore, the film 5 is bent at the end 3 of the molded product, and the remaining portion 8 of the film is wrapped around the rear surface 2 of the molded product to be along the rear surface 2 of the molded product (see FIG. 11).
Since the remaining portion 8 of the film already has a shape that matches the uneven portion 4 of the back surface 2 of the molded product, when the remaining portion 8 of the film is turned, the convex portion of the back surface 2 of the molded product matches the concave portion of the remaining portion 8 of the film. The protrusion of the remaining portion 8 of the film fits into the recess of the molded product back surface 2 (see FIGS. 1 and 12). The adhesive 18 applied to the remaining portion 8 of the film includes an acrylic resin, an epoxy resin, a urethane resin, and a silicone resin. The adhesive 18 may be applied to the remaining portion 8 of the film, or may be applied to the surface of the uneven portion 4 on the back surface 2 of the molded product.

(2) Before setting the film 5 in the injection mold, the remaining portion 8 of the film 5 is molded into a three-dimensional shape that matches the concave and convex portion 4 on the back surface 2 of the molded product by another mold. A method for producing a molded article with a film will be described. in this case,
A mold different from the mold A and the mold B, that is, a mold for forming the remaining portion 8 of the film into a three-dimensional shape that matches the uneven portion 4 on the back surface 2 of the molded product is prepared. Another mold is composed of a mold C and a mold D, and the remaining portion 8 of the film is sandwiched while being heated, thereby forming the molded product back surface 2 of the molded product 6 obtained by the mold A and the mold B. Some are formed into a three-dimensional shape that matches the concave and convex portions 4. In addition, as an injection mold,
When mold A and mold B are closed, the remaining portion of the film 8
A retraction part 20 is formed on the parting surface so that the three-dimensional shape is not crushed by closing the mold.

First, the remaining portion 8 of the film is formed into a three-dimensional shape conforming to the uneven portion 4 on the back surface 2 of the molded product by using another mold. In addition,
Not only the remaining portion 8 of the film, but also a portion 7 of the film may be formed into a three-dimensional shape that matches the inner surface shape of the cavity forming recess 10 of the mold A with this mold.

Next, the film 5 is introduced between the mold A and the mold B of the injection mold (see FIG. 1). At this time, a part 7 of the film is made to correspond to the cavity forming recess 10 of the mold A, and a remaining part 8 of the film is made to correspond to the retreating part 20 formed on the parting surface of the mold. Note that the part 7 of the film may be formed into a three-dimensional shape that matches the inner surface shape of the cavity forming recess 10 of the mold A by another mold before being set in the injection mold. In that case, the part 7 of the film only needs to be fitted into the recess of the mold A. The part 7 of the film is a separate mold, and the cavity forming recess 1 of the mold A is used.
If it is not molded into a three-dimensional shape that matches the inner surface shape of 0, it may be molded in the mold A so as to be in close contact with the inner surface of the cavity forming recess 10 by vacuum suction or the like.

Next, the mold A and the mold B are closed, the molten resin 16 is injected from the molten resin injection port 14 of the mold B, and the part 7 of the film and the surface 1 of the molded product are separated. The molded article 6 is integrally bonded at the same time as the molding. The remaining portion 8 of the film is formed into a shape conforming to the uneven portion 4 on the back surface 2 of the molded product. Even if the mold A and the mold B are closed, the remaining portion 8 of the film having a three-dimensional shape is present in the retreat space of the parting surface, so that the three-dimensional shape is not crushed. Molten resin 16
Examples of the material include polystyrene resin, ABS resin,
Polycarbonate resins, polypropylene resins, polyethylene resins, and the like can be used.

Next, the molded product 6 taken out of the injection molding die
The remaining portion 8 of the film is adhered to the uneven portion 4 on the back surface 2 of the molded product by an adhesive 18 (FIGS. 10 to 12). The molded product 6 removed from the mold has a part 7 of the film on the molded product surface 1.
The remaining part 8 of the film is connected to the end 3 of the molded product without being adhered to anywhere. Examples of the molded product end 3 include a sharp corner of the molded product 6 (see FIG. 2) and a portion (see FIG. 10) when the film 5 is integrally bonded (see FIG. 10). Therefore,
The film 5 is bent at the end 3 of the molded product, and the remaining portion 8 of the film is wrapped around the rear surface 2 of the molded product to be along the rear surface 2 of the molded product. Since the remaining portion 8 of the film already has a shape that matches the uneven portion 4 of the back surface 2 of the molded product, when the remaining portion 8 of the film is turned, the convex portion of the back surface 2 of the molded product matches the concave portion of the remaining portion 8 of the film. The protrusion of the remaining portion 8 of the film fits into the recess of the molded product back surface 2. As the adhesive 18 applied to the remaining portion 8 of the film, there is an acrylic resin or the like. The adhesive 18 may be applied to the remaining portion 8 of the film, or may be applied to the surface of the uneven portion 4 on the back surface 2 of the molded product.

[0026]

According to the present invention, the remaining portion of the film is formed by an injection molding die before bonding to the back surface of the molded product, or is formed into a three-dimensional shape from a flat state by a die different from the injection molding die. Since it is already molded and the shape in that state can be kept constant,
No need for finger work. In addition, the remaining part of the film can be molded into a three-dimensional shape that matches the irregularities on the back of the molded product with strong force such as closing the mold and the pressure of the molten resin, so that the shape completely matches the irregularities on the back of the molded product. Become. In addition, since it is not a finger operation, it is possible to perform high-temperature heating to reach the softening point of the film. (1) For this reason, there is no damage to nails and fingers, and no damage to unnecessary portions of the film. (2) In addition, since the remaining part of the film is formed into a three-dimensional shape by closing the mold or applying the pressure of the molten resin, a perfect straight line, a smooth curve with a constant curvature, or a uniform curve over the entire line is provided. It is possible to fold or add a curl with a great force, or to completely transform it into a complicated three-dimensional shape such as a fine uneven portion. (3) In addition, since the film is formed into a three-dimensional shape by a strong force or heating to reach the softening point, the film is adhered to the uneven portion with an adhesive, and then resists the adhesive force of the adhesive due to the shape retention of the film. The film does not warp. For this reason, the film is completely adhered and adhered to the uneven portion on the back surface of the molded product, and a defective product is unlikely to occur. Acrylic film, polycarbonate film, ABS film or their laminated film, etc., especially those with strong shape retention and high hardness, can completely adhere the film to the irregularities on the back of the molded product Becomes

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a molded product with a film obtained by the method for producing a molded product with a film of the present invention.

FIG. 2 is a cross-sectional view showing one step of the method for producing a molded article with a film according to the present invention.

FIG. 3 is a cross-sectional view showing one step of a conventional method for producing a molded product with a film.

FIG. 4 is a cross-sectional view showing one step of a conventional method for producing a molded article with a film.

FIG. 5 is a cross-sectional view showing one step of the method for producing a molded article with a film according to the present invention.

FIG. 6 is a cross-sectional view showing one step of the method for manufacturing a molded article with a film according to the present invention.

FIG. 7 is a cross-sectional view showing one step of the method for manufacturing a molded article with a film according to the present invention.

FIG. 8 is a cross-sectional view showing one step of the method for manufacturing a molded article with a film according to the present invention.

FIG. 9 is a cross-sectional view showing one step of the method for manufacturing a molded article with a film according to the present invention.

FIG. 10 is a cross-sectional view showing one step of the method of manufacturing a molded article with a film according to the present invention.

FIG. 11 is a cross-sectional view showing one step of the method of manufacturing a molded article with a film according to the present invention.

FIG. 12 is a cross-sectional view showing one step of the method for manufacturing a molded article with a film according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Molded product surface 2 Molded product back surface 3 Molded product end 4 Irregular portion 5 Film 6 Molded product 7 Part of film 8 Remaining portion of film 9 Finger 10 Cavity forming recess A Mold B Mold 13 Mold irregularity 14 Molten resin injection port 15 Cavity 16 Molten resin 17 Vacuum suction hole 18 Adhesive 19 Parting surface for forming irregularities 20 Evacuation part

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Toshikazu Kobe 3, Mibuhanai-cho, Nakagyo-ku, Kyoto-shi, Kyoto Inside Nihon Photo Printing Co., Ltd. Address Nihon Photo Printing Co., Ltd. F term (reference) 4F202 AA04 AA11 AA13 AA28 AD08 AG03 AH23 AH25 AH26 AH27 CA11 CB01 CB13 CK11 4F206 AA04 AA11 AA13 AA28 AD08 AG03 AH23 AH25 AH26 AH27 J07 JB13 JL02 J07

Claims (5)

[Claims] 1. A part of a film and the surface of a molded article are formed by molding a molded article using a film capable of covering the uneven surface of the molded article surface and the rear face of the molded article with a single sheet, and an injection mold. At the same time, after integrating and bonding, in the method of manufacturing a molded product with a film, the remaining portion of the film is bonded to the uneven portion on the back surface of the molded product of the molded product taken out from the injection mold with an adhesive. A method for producing a molded article with a film, comprising: before adhering with an adhesive, molding the remaining part of the film into a three-dimensional shape that matches the irregularities on the back surface of the molded article with a mold. 2. The molding with a film according to claim 1, wherein after setting the film in an injection molding die, the remaining portion of the film is formed into a three-dimensional shape that matches the concave and convex portions on the back surface of the molded product by the injection molding die. Product manufacturing method. 3. The method according to claim 1, wherein before setting the film in the injection mold, the remaining part of the film is formed into a three-dimensional shape that matches the irregularities on the back surface of the molded product using a mold different from the injection mold.
3. The method for producing a molded article with a film according to item 1. 4. A parting surface for sandwiching a remaining portion of a film of an injection mold used in the production method according to claim 2,
The method for producing a molded article with a film according to claim 3, wherein the molded article with a film has a portion having a shape corresponding to the uneven portion on the back surface of the molded article. 5. A mold having a surface on which a film capable of covering a surface of a molded article and an uneven portion on the back of the molded article with a single sheet, wherein a part of the film is integrally adhered to the surface of the molded article. And a surface capable of maintaining a three-dimensional shape conforming to the concave and convex portions on the rear surface of the molded product without the remaining portion of the film being integrally bonded to the rear surface of the molded product.