JP2002225069A - Method for producing protective panel for electronic device display window - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a resin molding which can prevent an injected resin from dislocating cut pieces and sheet pieces which are arranged in a mold and from entering the back side of film pieces and sheet pieces. SOLUTION: The mutual adhesive layers of a continuous film 7 and a continuous film 14 are made to face each other, the continuous film 7 is passed between a fixed mold 3 and a movable mold 4 and positioned, and the continuous sheet 14 is passed through the movable mold 3 and positioned. A trimming die 32 is pushed up, the sheet piece 14A is cut from the continuous sheet 14 to be larger than a window 12a on the continuous film 7 and pushed up to a state which is lower by one step than the upper surface of the movable mold 3, and the fixed mold 4 and the movable mold 3 are closed. A transparent resin is injected between the continuous film 7 and the sheet piece 14, the movable mold 3 and the fixed mold 4 are opened, and the molding is taken out to separate the peeling layer and base film of the continuous film 7.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a protective panel for an electronic device display window which prevents reflection and enhances visibility.

[0002]

2. Description of the Related Art At present, protection panels used for mobile phones and the like are made of PMMA in consideration of surface scratch prevention and transparency.
In many cases, (acrylic) materials are used. But,
In recent years, there has been a rapid increase in the tendency to take color images into mobile phones, and the visibility of such a protective panel is reduced. Therefore, a protective panel capable of coping with a color image has been manufactured by performing an AR process (operation of forming an optical multilayer film that suppresses reflection from external light) on the surface of the protective panel.

[0003]

At present, such a protective panel as a resin molded product has a continuous film on one side, and after the resin is injected, the base sheet is peeled off. Are manufactured by an insert molding method of cutting out and integrating this as a part of a molded article, and an insert molding method of replacing at least one continuous film with a sheet and integrating it as a part of a molded article.

However, in the above-described ordinary in-mold molding and insert molding, since the film piece or the sheet piece is difficult to be positioned in the cavity, when the resin is injected, the film piece or the sheet piece is displaced by the force. In particular, in the case of a resin molded product in which a molded product is composed of a transparent window and a window frame, such as a protective panel for an electronic device display window as described above, the defective product rate due to displacement is a major problem. Become.

In the case where the AR treatment is performed as described above, a hard coat layer or a print layer serving as an AR base layer of a cut piece or a sheet piece must be exposed on the surface of a molded product. The fact that the resin is thin and covers the surface is also a factor for increasing the defective product rate.

Accordingly, the present invention provides a resin molding method which can prevent the injected resin from displacing a cut piece or a sheet piece disposed in a mold and from flowing around the back side of a film piece or a sheet piece. An object of the present invention is to provide a method for manufacturing a product.

[0007]

In order to solve the above problems, in a method of manufacturing a protective panel for an electronic device display window using an insert molding method, a continuous film and a continuous sheet are made to face each other with an adhesive layer facing each other. The step of positioning the continuous film between the movable mold and the fixed mold by passing the continuous sheet into the movable mold, and pressing the punching die up from the continuous sheet to a window larger than the window on the continuous film. Cutting out a piece, pushing up to a state one step lower than the upper surface of the movable mold, closing the movable mold and the fixed mold, injecting a transparent acrylic resin between the continuous film and the sheet piece, Opening the movable mold and the fixed mold, and taking out a molded product so as to separate the release layer and the base film of the continuous film. We propose a method.

Further, in the method of manufacturing a protective panel for an electronic device display window using an in-mold molding method, the first continuous film and the second continuous film are made to face each other with their adhesive layers facing each other, and the first continuous film is movable. Between the mold and the fixed mold,
Positioning the second continuous film by passing it through a movable mold, and cutting out a film piece larger than a window portion on the first continuous film from the second continuous film by pushing up a die to form an upper surface of the movable mold. Pushing up to a state where it is further lowered, closing the movable mold and the fixed mold, injecting a transparent acrylic resin between the first continuous film and the film piece, and opening the movable mold and the fixed mold Removing the molded product so as to separate the first continuous film, the release layer of the film piece, and the base film from each other.

Further, the molded article may be configured to be subjected to an AR treatment on at least one surface of the hard coat layer or the printed layer, and the AR of the first continuous film or the second continuous film may be subjected to AR treatment. AR on the underlayer
A configuration in which a layer is formed in advance may be employed.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [First Embodiment] A first embodiment of a method for manufacturing a protection panel for an electronic device display window according to the present invention will be described with reference to the drawings. This embodiment relates to insert molding. 1 is an explanatory view of a protection panel manufactured by the method of the present embodiment, FIG. 2 is a side sectional view of a mold device used in the present embodiment, and FIG. 3 is a side section of a first continuous film and a second continuous film. FIG. 4 and FIG. 4 are explanatory diagrams of a method of manufacturing the protection panel.

FIG. 1 shows an example of a protection panel P manufactured according to the present embodiment. The protection panel P is a transparent panel with a frame attached to an electronic device display window such as a mobile phone. FIG. 1A shows a perspective view of the protective panel P. The protective panel P is a transparent acrylic plate 1, and a frame 1a is formed by a printing layer on the surface 1A side thereof. The window 1b for displaying the liquid crystal screen remains in the center as a portion where the print layer is not formed (or a portion where the transparent print layer is formed).

Further, a button hole 1c is formed in a part, and when the protection panel P is mounted on a casing body (not shown) of the portable telephone, the button is pressed into the button hole 1c.
Configuration.

FIG. 1B is a front sectional view taken along line XX of FIG. 1A, and FIG. 1C is a side sectional view taken along line YY of FIG. 1A. , The front surface 1 on the back surface 1B of the protection panel P.
A raised base 1d is formed at a position facing the window 1b of A. On the front surface 1A of the protection panel P, a film layer 7A composed of a predetermined layer of a first continuous film 7, which will be described later, is integrated, while on the back surface 1B of the protection panel P,
A continuous sheet to be described later is formed only on the surface of the ridge 1d.
A sheet piece 14A composed of a part of 14 is integrated.

Assuming that the width of the window 1b of the continuous sheet 14 is A and the height is B, the width C and the height D of the ridge 1d are A <C and B <D. That is, the sheet piece 14A integrated with the same portion also has the same dimensions C and D.

Hereinafter, a method of manufacturing the protection panel P for the display window of the electronic device according to the present embodiment will be described with reference to FIGS.

FIG. 2 is a side sectional view of a mold used in the present embodiment. The mold 2 includes a movable mold 3 including a movable mold body 31 and a punching mold 32, and a fixed mold 4. Movable body 31
The cavity 31 and the bottom of the fixed mold 4 respectively have a cavity 31
a and 4a are formed. By combining the movable mold body 31 and the fixed mold 4, a space for injection-molding the plate 1 of the protection panel P is formed.

The fixed mold 4 is formed with a resin injection gate 4b continuous with the cavity 4a. Movable type 3
A continuous film 7, which is stretched between a continuous film feeding device and a winding device (not shown), is passed between the fixed film 4 and the fixed die 4. In FIG. The movable mold 3 and the fixed mold 4 are closed with the hole 7a and the resin injection gate 4b aligned.

The movable die body 31 has a through hole 31b. The through hole 31b has a base 32A and a lifting block.
The push-up block 32B is inserted into the die 32 consisting of 32B and is configured to slide inside. FIG. 2 shows a state in which the punching die 32 is not completely pushed into the movable die body 31 at a distance L, but when the punching die 32 is pushed up, the top surface 32a of the push-up block 32B has a height T (see FIG. It is pushed up to the movable type 3
A part of the cavity 31a is formed at a position one step lower than the upper surface of the cavity 31a.

Further, a slit 31c is formed in the movable body 31 so as to traverse the through hole 31b. As will be described later, the slit 31c has a continuous sheet.
14 has passed. As described above, when the push-up block 32B is raised, the push-up block 32B cuts the continuous sheet 14 at its edge, and pushes up the cut sheet piece to the height T. Push-up block 32 pushed up to height T
The top surface 32a of B is one step lower than the cavity 31a of the movable mold body 31, and a step G is formed between them.

Next, the structure of the continuous film 7 and the continuous sheet 14 will be described with reference to FIG. As shown in FIG. 3 (a), a continuous film 7 is formed on a base film 8 made of PET in this order by a release layer 9 made of a material having no adhesive property, a UV hard layer 10 for improving the surface hardness, An anchor layer 11, a printing layer 12, and an adhesive layer 13 for improving fixing of printing are laminated. Further, as shown in FIG. 3B, the continuous sheet 14 includes a UV hard layer 15, a base layer 16, and an adhesive layer 17 from below.
Are laminated.

The UV hard layers 10 and 15 each have a surface AR
It is used as an underlayer and a backside AR underlayer, on which an AR process described later is performed to form an AR layer. This allows
An AR layer, which is difficult to form on the transparent acrylic resin, can be formed stably.

The printed layer 12 is formed with a printed portion and a non-printed portion (or a transparent printed portion), and the latter portion becomes the window 1b of the protection panel P. The print layer 12 forms a plurality of independent print patterns at predetermined intervals.

Referring to FIG. 4, the protection panel P of this embodiment will be described.
Will be described. First, as shown in FIG. 4A, the continuous film 7 passes between the fixed mold 4 and the movable mold body 31 with the movable mold body 31 and the punching mold 32 of the fixed mold 4 and the movable mold 3 opened. And the movable body 31 has a slit 31
The continuous sheet 14 is passed through c. Both are suspended between a feeding device (not shown) and a winding device, and are intermittently fed at a predetermined width. The continuous film 7 and the continuous sheet 14 are extruded and wound in directions orthogonal to each other.

Next, as shown in FIG. 4B, the injection hole 7a of the continuous film 7 is aligned with the resin injection gate 4b.
After the transparent portion 12a forming the window portion 1b of the printing layer 12 on the continuous film 7 is positioned so as to coincide with the push-up block 32B of the die 32, the fixed die 4 and the movable die body 31 are clamped. .

As shown in FIG. 4C, the die 32 is further raised to cut the continuous sheet 14 passing through the through-hole 31b, and the top surface 32a of the push-up block 32B is removed from the cavity 31a.
The sheet piece 14A that has been cut is pushed up to a position one step lower and placed at the same position. Then, the transparent acrylic resin is injected from the resin injection gate 4b so as to pass through the injection hole 7a of the continuous film 7 and go around the back side of the continuous film 7, and fill the cavities 4a and 31a.

The injected transparent acrylic resin is integrated with the continuous films 7 in the cavities 4a and 31a and the respective adhesive layers 13 and 17 on the surface of the sheet piece 14A. At this time, since the sheet piece 14A is surrounded by the step G, the position does not shift due to the pressure of the injected transparent acrylic resin, and the transparent acrylic resin goes around the back surface. Can also be prevented.

Finally, as shown in FIG. 4 (d), each mold is opened and the molded plate 1 is taken out. When the mold is opened, the plate 1 is engaged with the continuous film 7. When the plate 1 is peeled off from the base film 8 of the continuous film 7 by a vacuum device or the like, the base film 8 and the release layer 9 are separated. A portion 7A of the continuous film 7 including the UV hard layer 10, the anchor layer 11, and the printing layer 12 remains on the plate 1 side. On the back surface, a sheet piece 14A is integrated with the resin.

After the end of the insert molding process, an AR process is performed as shown in FIG. The formation of the AR layer can be performed by sputtering in a chamber having a predetermined atmosphere after removing unnecessary portions such as sprue S. In this case, as shown in FIG. 5A, a method of performing processing only on the back surface of the plate 1 may be used.
May be performed on both sides as shown in FIG. In any case, the AR layer is formed on the UV hard layers 10 and 15 which become the AR base layer exposed on the surface.

[Second Embodiment] Next, a second embodiment of a method for manufacturing a protective panel for an electronic device display window according to the present invention will be described with reference to the drawings. This embodiment relates to in-mold molding. FIG. 6A is a cross-sectional view of the second continuous film used in the method of the present embodiment.
FIG. 6B is a cross-sectional view of the plate after injection molding.
(c) is an explanatory view of an operation of peeling a base film from the plate body.

As shown in FIG. 6A, in the present embodiment, a second continuous film 11 is used instead of the continuous sheet of the first embodiment.
Use 4. The second continuous film 114 is formed on a base film 115 made of PET, in order, by a release layer 116 made of a material having no adhesive property, and a UV for improving the surface hardness.
Hard layer 117, anchor layer to improve fixing of print
118, a printing layer 119, and an adhesive layer 120 are laminated.

Thereafter, the second continuous film 114 is passed through the slit 31c of the movable mold 3 using the mold 2, and the mold is removed.
32 cuts the second continuous film 114 into a predetermined size to form a film piece 114A, and then injects a transparent acrylic resin between the film piece 114A and the (first) continuous film 7, and FIG. ) Is formed.

Then, as shown in FIG. 6C, the plate 1 is held in a state where a portion 7A is left from the first continuous film 7.
Is peeled off, and the base film 115 and the peeling layer 116 are peeled off from the film piece 114A integrated with the back surface of the plate body 1 to form the protective panel P. Thereafter, by the operation shown in FIG. 5, the AR layer can be formed on the surface of the plate 1 where the UV hard layer 10 serving as the AR underlayer is exposed.

In the first and second embodiments, the AR
Although the layer was formed on the front and back of the plate 1 as a molded product taken out of the mold by the last step, of course, if the AR layer is formed in advance on the first continuous film, the second continuous film, or the continuous sheet, The protection panel P can be manufactured by a simpler manufacturing method without separately providing an AR layer forming step.

[0034]

As described above, in the method of manufacturing a protective panel for an electronic device display window, in a mold, a die is cut from a continuous sheet or a second continuous film, and a film piece cut from a second continuous film, or a sheet piece is lowered one step. It is characterized in that it is held in a mold. For this reason, the film piece and the sheet piece will be surrounded by a step, and the injected resin does not shift the film piece and the sheet piece arranged in the mold, and also, on the back side of the film piece and the sheet piece. It is possible to prevent sneaking around, without shifting the position where the AR layer is molded,
Also, the molding can be performed reliably.

The cut film pieces and sheet pieces have a larger size than the window formed on the front side.
For this reason, the back surface portion corresponding to the window portion should be a sufficiently large A
It can be covered with an R layer.

[Brief description of the drawings]

FIG. 1A is a perspective view of a protection panel according to a first embodiment,
(b) is a front sectional view of the protection panel, and (c) is a side sectional view of the protection panel.

FIG. 2 is a sectional view of a mold used in the manufacturing method of the embodiment.

FIG. 3A is a cross-sectional view of a continuous film used in the manufacturing method of the present embodiment, and FIG. 3B is a cross-sectional view of the continuous sheet.

FIG. 4 is an explanatory diagram of a resin injection molding operation for manufacturing the protection panel.

FIG. 5 is an explanatory diagram of an AR layer forming operation for manufacturing the protection panel.

FIG. 6A is a side view of a second continuous film used in a method for manufacturing a protection panel according to the second embodiment, and FIG. 6B is a cross-sectional view of the plate after injection-molding the protection panel. (C) is explanatory drawing of the operation | work which peels a base film from the same plate.

[Explanation of symbols]

 P ... Protection panel 1 ... Plate 1a ... Frame 1b ... Window 1d ... Rolling stand 2 ... Mold 3 ... Movable mold 31 ... Movable mold body 32 ... Die mold 4 ... Fixed mold 7 ... Continuous film (first continuous film) 8 base film 9 release layer 10 UV hard layer 11 anchor layer 12 print layer 13 adhesive layer 14 continuous sheet 14A sheet piece 15 UV hard layer 16 base layer 17 adhesive layer 114 second Continuous film 114A… Film piece 115… Base film 116… Release layer 117… UV hard layer 118… Anchor layer 119… Printing layer 120… Adhesive layer

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F202 AD08 AD20 AG03 CA11 CB01 CB13 CK54 CL02 CQ01 CQ03 CQ07 4F206 AD08 AD20 AG03 JA07 JB13 JF01 JF05 JL02 JM02 JM04 JM06 JN11 JN33 JQ81

Claims (4)

[Claims] 1. A continuity in which at least a base film, an AR base layer as a printing layer on which a window and a window frame are formed, and an adhesive layer are laminated using a mold comprising a movable mold incorporating a die and a fixed mold. A method of manufacturing a protective panel for an electronic device display window using an insert molding method of injecting a transparent resin between a film and a sheet piece of a continuous sheet on which at least an AR base layer, a base layer, and an adhesive layer are laminated; Positioning the film and the continuous sheet with the adhesive layers facing each other, passing the continuous film between the movable mold and the fixed mold, and passing the continuous sheet into the movable mold, Cutting a sheet larger than the window on the continuous film from the continuous sheet by pushing up, and pushing up to a state one step lower than the upper surface of the movable mold, Closing the movable mold and the fixed mold and injecting a transparent resin between the continuous film and the sheet piece; and opening the movable mold and the fixed mold to separate the release layer and the base film of the continuous film. And removing the molded product as described above. 2. A mold comprising a movable die incorporating a punching die and a fixed die, wherein at least a base film, an AR base layer which is a printing layer having a window and a window frame formed thereon, and an adhesive layer are laminated. Protection of electronic device display windows using an in-mold molding method of injecting a transparent resin between a continuous film and a film piece of a second continuous film in which at least a base film, a release layer, an AR underlayer, and an adhesive layer are laminated. In the method of manufacturing a panel, the first continuous film and the second continuous film face each other with an adhesive layer therebetween, and the first continuous film is placed between the movable mold and the fixed mold, and the second continuous film is formed. Passing through the movable mold and positioning the film, and pushing up the die to form a film piece having a size larger than the window on the first continuous film from the second continuous film. Cutting and pushing up to a state one step lower than the upper surface of the movable mold; closing the movable mold and the fixed mold to inject a transparent resin between the first continuous film and the film piece; Opening the mold and the fixed mold, and taking out a molded product so as to separate the first continuous film and the release layer of the film piece and the base film, comprising the steps of: . 3. The method for manufacturing an electronic device display window according to claim 1, wherein said molded article is further subjected to an AR treatment on at least one surface of a hard coat layer or a print layer. A method for manufacturing an electronic device display window. 4. The method for manufacturing an electronic device display window according to claim 1, wherein an AR layer is previously formed on an AR base layer of the first continuous film or the second continuous film. A method for manufacturing an electronic device display window.