JP2004001297A - Manufacturing method for resin molded article having film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a resin molded article having a film which reduces the cost of a mold and lessens a space for installation of the mold and which enables smooth and consecutive execution of a forming process, a molding process and a cutting process. <P>SOLUTION: The process of forming a film 11-1, the process of laying a film 11-2 on the formed film 11-1 and molding the resin molded article (key top) 31 between them and the process of cutting simultaneously a part of the resin molded article 31 and parts of the films 11-1 and 11-2 are executed on different stages A1, A2 and A3 of the same molds 200 and 300, so as to manufacture a key top board (the resin molded article having the film) 10. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a resin molded product having a film such as a key top plate for a push button switch.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a key top plate in which a key top for a plurality of push button switches is mounted on a film is used for an operation unit of an electronic device such as various portable devices. FIG. 10 is a perspective view showing an example of this type of key top plate 400, and FIG. 11 is a side sectional view of the key top plate 400 (a sectional view taken along line aa in FIG. 10). As shown in FIGS. 10 and 11, the key top plate 400 is configured by molding various key tops 410 into a film 430 made of synthetic resin.
[0003]
In order to manufacture the key top plate 400, first, the film 430 is formed (preformed) using a die, and the surface of the key top 410 is formed on a portion to be the key top 410 in a subsequent key top forming step. A curved portion 411 having the same shape as the shape is formed.
[0004]
The film 430 having the curved portion 411 formed therein is inserted into a molding die, and the recessed portion on the lower surface side of the curved portion 411 is filled and solidified with molten resin to form the key top body 413. The top 410 is formed.
[0005]
However, in the conventional method of manufacturing the key top plate 400, a mold for forming the film 430 and a mold for molding the key top body 413 on the film 430 are required, so that the mold cost is increased. Or, the installation space for installing both dies also becomes large.
[0006]
Also, since the forming process and the forming process are completely different processes, the progress speeds of both processes are different, so that the stock of the intermediate product is stagnant, or conversely, the intermediate product runs out and the continuous production is smooth. Had been inhibited.
[0007]
[Problems to be solved by the invention]
The present invention has been made in view of the above points, and its purpose is to reduce the cost of a mold when molding a molded product after forming a film to reduce the cost of the mold and to reduce the space for installing the mold. It is another object of the present invention to provide a method of manufacturing a resin molded product having a film capable of performing a forming step and a forming step smoothly and continuously.
[0008]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, a method for manufacturing a resin molded product having a film according to the present invention includes a forming step of forming a film and a forming step of forming the resin molded product on the formed film in the same mold. It is characterized by performing in.
[0009]
Further, the present invention is characterized in that a cutting step of cutting a part of the resin molded article and / or a part of the film is performed by the mold.
[0010]
Further, the present invention is characterized in that a resin molded article is formed in the forming step on a portion where the film is formed in the forming step.
[0011]
Also, in the present invention, the forming performed on the film in the forming step is forming of a portion to be a key top, the resin molded product formed in the forming step is a key top main body, and a resin molding having a film to be manufactured is provided. The product is a key top plate.
[0012]
Further, in the present invention, the forming performed on the film in the forming step is forming of a part to be an exterior part, and the resin molded part molded in the molding step is an exterior part main body, and the resin molding having the film to be manufactured is provided. The article is an exterior article.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a schematic configuration diagram (plan view) of a manufacturing facility using a key top plate manufacturing method according to an embodiment of the present invention. As shown in the figure, this manufacturing equipment includes a fixed mold 200 and a movable mold 300, and a film forming stage A1, a molding stage A2, and a cutting stage A3 are set in a pair of molds 200 and 300. Is provided. First, the structure of both dies 200 and 300 will be described.
[0014]
An uneven portion 201 for forming a film 11-1 described below into a desired shape is provided on the forming stage A1 of the fixed mold 200. Next, a hot runner gate 211 for injecting the molten mold resin is built in the molding stage A2 portion of the fixed mold 200, and a gate 213 is provided at the tip thereof. The molten mold resin is pressed into the hot runner gate 211 from the molten resin injection part 220. Next, a die 230 composed of a hole for cutting the key top plate 10 by inserting a punch 311 described below is provided at a portion of the cutting stage A3 of the fixed mold 200, and a cut piece discharging path is provided at a rear end side of the die 230. 231 are provided. The cut piece discharge path 231 is evacuated, and has a structure in which a cut piece inside the die 230 is sucked and drawn to the outside.
[0015]
On the other hand, on the forming stage A1 of the movable mold 300, there is provided an uneven portion 301 for forming a film 11-1 described below into a desired shape in cooperation with the uneven portion 201 of the fixed mold 200. Next, at the molding stage A2 of the movable mold 300, a cavity C1 for keytop molding is provided on the surface thereof. Next, in the portion of the cutting stage A3 of the movable die 300, a cavity C2 for inserting the portion of the keytop 31 and a predetermined portion of the keytop plate 10 are cut into the inside of the die 230 of the fixed die 200 by cutting. A punch 311 is provided. The tip of the punch 311 is protruded from the surface of the movable mold 300 by advancing its base 313. Here, pins 321, 323, and 325 that protrude so as to separate the keytop plate 10 from the surface of the movable mold 300 are provided at the stages A1, A2, and A3 of the movable mold 300. The tips of the pins 321, 323, and 325 are protruded from the surface of the movable mold 300 by advancing the base 327.
[0016]
Next, in order to manufacture the key top plate 10 using the molds 200 and 300, first, a flat film 11-1 cut to the external dimensions of the key top plate 10 is prepared, and this is cut by a robot hand (not shown). The film 11-1 is inserted into the forming stage A <b> 1, and the movable mold 300 is moved forward and joined to the fixed mold 200, so that the film 11-1 is formed into the same shape as the top surface of the key top plate 10 by the concave and convex portions 201 and 301. At the same time as the movable mold 300 is retracted, the pin 321 is projected to separate the formed film 11-1 from the surface of the movable mold 300, and the film 11-1 is transferred to the next forming stage A2 by a robot hand (not shown).
[0017]
In the forming stage A2, another film 11-2 is first stacked on the film 11-1 by a robot hand (not shown), and then the movable mold 300 is moved forward again and joined to the fixed mold 200 to form a hot runner gate. The mold resin melted from the gate 213 of the 211 is injected between the two films 11-1 and 11-2 to fill the cavity C1 with the melt mold resin, thereby forming the key top 31 formed with the key top 31. 10 is manufactured. At the same time as the movable die 300 is retracted, the pins 323 are projected to separate the key top plate 10 from the surface of the movable die 300, and then the key top plate 10 is transferred to the next cutting stage A3 by a robot hand (not shown).
[0018]
In the cutting stage A3, the movable mold 300 is advanced again and joined to the fixed mold 200, and then the punch 311 is inserted into the die 230, thereby removing a desired portion of the key top plate 10 to be cut. The removed cut pieces are sucked into the cut piece discharge path 231 and discharged to the outside. After retracting the movable mold 300 and simultaneously projecting the pin 325 to separate the key top plate 10 from the surface of the movable mold 300, the key top plate 10 is taken out by a robot hand (not shown) to manufacture a series of key top plates 10. Complete the process.
[0019]
As described above, if the production of the key top plate 10 is continuously performed at the same time in each of the stages A1, A2, and A3, it is possible to prevent the intermediate product from being kept in stock, and to perform efficient production. Further, since each process is performed by a pair of molds 200 and 300, the number of mold facilities can be reduced, and the space for manufacturing facilities can be reduced.
[0020]
Next, a method of manufacturing the key top plate 10 using the above manufacturing equipment will be described more specifically. FIG. 2 is a perspective view showing the key top plate 10 manufactured by using the manufacturing method according to the present invention. FIG. 3 is a side sectional view of the key top plate 10 (a sectional view taken along line AA in FIG. 2). As shown in both figures, the key top plate 10 is attached to the upper film 11-1 between two laminated synthetic resin films 11-1 and 11-2 (both of which constitute the film 11). Various key tops 31 (constituted by the bending portion 111 and the key top body (resin molded product) 32) are formed on the provided bending portion 111. A tongue-shaped resin injection portion 37 protrudes from the outer peripheral side surface of each key top 31, and a through hole 15 penetrating both films 11-1 and 11-2 is provided at the tip of these resin injection portions 37. I have. When this key top plate 10 is placed on a switch board (not shown) and each key top 31 is pressed, the switch contact on the switch board facing the key top is pressed and turned on.
[0021]
4 to 9 are views showing a method of manufacturing the key top plate 10 according to the present invention, FIGS. 4 and 5 show a forming step in the forming stage A1 shown in FIG. 1, and FIGS. 5 shows a molding step in the molding stage A2 shown in FIG.
[0022]
In order to manufacture the key top plate 10, first, a plate-shaped synthetic resin film 11-1 cut to the outer dimensions of the key top plate 10 is inserted between the forming stages A 1, and the movable mold 300 is turned into the fixed mold 200. By bonding, the film 11-1 is formed into the same shape as the top surface of the key top plate 10 by the two concavo-convex portions 201 and 301, and then both the dies 200 and 300 are opened to form the curved portion 111 as shown in FIG. , 113 is taken out. In this embodiment, the film 11-1 is made of a polyethylene terephthalate film, but may be made of another material.
[0023]
Next, as shown in FIG. 6, another synthetic resin film 11-2 is overlaid on one side of the formed film 11-1, and these are formed into two molds 200 and 300 as shown in FIG. It is clamped at the stage A2. In this embodiment, the film 11-2 is made of a polycarbonate film, but may be made of another material. The film 11-2 is provided with a resin injection port 115 penetrating therethrough at a position facing a portion serving as a resin reservoir 39 shown in FIG.
[0024]
Here, as shown in FIG. 6, the movable die 300 has a shape for accommodating the upper surface of the film 11-1, that is, a key-top molding having the same shape as the shape of each key top 31, the resin injection portion 37, and the resin reservoir 39. Is provided. On the other hand, gates 213 are provided at positions of the fixed mold 200 facing the resin injection port 115, respectively. The gate 213 is constituted by a hot runner gate 211, and a heater (for example, a solid heater) 217 is installed inside (at the center) of the runner 215 to remove the mold resin filled up to the end of the gate 213 in the runner 215. It is configured to always maintain its molten state by heating.
[0025]
Then, as shown in FIG. 7, when the film 11 is sandwiched between the two molds 200 and 300, the gate 213 faces each resin injection port 115.
[0026]
In this state, the molten resin is injected from each gate 213 to fill the cavity C1 for key top molding covered with the films 11-1 and 11-2 with the molten resin, and after the molten resin is solidified, the two molds are formed. When the space between 200 and 300 is opened, the key top plate 10 shown in FIGS. 8 and 9 is manufactured. As shown in both figures, since the resin reservoir 39 is provided at the tip of the resin injection portion 37 of each key top 31, the operation of each key top 31 may be deteriorated in this state. Therefore, in the case of this embodiment, in the cutting stage A3 shown in FIG. 1, the portion of the resin reservoir 39 is cut and removed together with the films 11-1 and 11-2, and the through holes 15 are provided. The key top plate 10 shown in FIG.
[0027]
In the above embodiment, since the hot runner gate 211 is used, the resin in the runner is always in a molten state and does not solidify by cooling. Therefore, the next keytop plate 10 can be manufactured immediately, and the molding cycle time is reduced. Can be shortened, and productivity is improved. In particular, it is preferable to continuously process each step as in the present invention.
[0028]
In addition, the concept of the key top plate of the present invention is a concept that includes a film in which the film around the key top is cut out to be a single key top as long as the key top has a film.
[0029]
Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications may be made within the scope of the claims and the technical idea described in the specification and the drawings. It is possible. Note that any shape, structure, or material not directly described in the specification and drawings is within the scope of the technical idea of the present invention as long as the effects and effects of the present invention are exhibited.
[0030]
For example, in the above-described embodiment, an example in which the present invention is applied to a method of manufacturing the key top plate 10 has been described. However, the present invention may be applied to various products other than the key top plate 10. In short, a resin is formed into a formed film. It can be applied to any resin molded product. That is, as shown in FIG. 12, for example, it can be used as an exterior component (display plate such as a nameplate) 50 that is attached to be exposed on the surface of a case or the like of various devices and performs various displays. The exterior component 50 according to this embodiment is, like the key top plate 10, between two laminated synthetic resin films 51-1 and 51-2 (both of which constitute the film 51). The exterior part 50 (constituted by the curved part 511 and the exterior part main body (resin molded article) 52) is formed on the curved part 511 provided on the upper film 51-1. By providing a desired printing layer (not shown) on the films 51-1 and 51-2, a desired display can be performed. This exterior component 50 can also be manufactured by the same method of the present invention as the key top plate 10.
[0031]
In the embodiment shown in FIG. 1, the pins 321, 323, and 325 are configured to be driven simultaneously, but may be configured to be driven independently. In the above embodiment, the stage for performing the cutting step is provided in the same mold, but this stage may be omitted as necessary. The cutting step may be one that cuts only the resin molded product, one that cuts only the film, or one that cuts both the resin molded product and the film. Further, in the above-described embodiment, the resin molded product is molded at the portion where the film is formed. However, the present invention can be applied to a case where the resin molded product is molded at a portion other than the formed portion.
[0032]
【The invention's effect】
As described in detail above, according to the present invention, the forming step of the film and the resin molding step of the formed film are performed in the same die, so that the cost of the die can be reduced, The installation space can be reduced, and the forming process and the forming process can be smoothly and continuously performed.
[0033]
Further, if the cutting step is performed using the same mold, the cost of the mold can be further reduced, the space for installing the mold can be reduced, and each step can be performed smoothly and continuously.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram (plan view) of a manufacturing facility using a key top plate manufacturing method according to an embodiment of the present invention.
FIG. 2 is a perspective view showing a key top plate 10 manufactured by using the manufacturing method according to the present invention.
FIG. 3 is a side sectional view of the key top plate 10 (a sectional view taken along the line AA in FIG. 2).
FIG. 4 is a view showing a method of manufacturing the key top plate 10 according to the present invention (part of the forming step in the forming stage A1 shown in FIG. 1).
FIG. 5 is a diagram showing a method of manufacturing the key top plate 10 according to the present invention (part of the forming step in the forming stage A1 shown in FIG. 1).
FIG. 6 is a view showing a method of manufacturing the key top plate 10 according to the present invention (part of the forming step in the forming stage A2 shown in FIG. 1).
FIG. 7 is a view showing a method of manufacturing the key top plate 10 according to the present invention (part of the forming step in the forming stage A2 shown in FIG. 1).
FIG. 8 is a view showing a method of manufacturing the key top plate 10 according to the present invention (part of the forming step in the forming stage A2 shown in FIG. 1).
FIG. 9 is a sectional view taken along line BB of FIG. 8;
FIG. 10 is a perspective view showing an example of a conventional key top plate 400.
11 is a side sectional view (aa sectional view of FIG. 10) of a conventional key top plate 400.
FIG. 12 is a side sectional view of the exterior component 50.
[Explanation of symbols]
200 fixed mold (mold)
201 Uneven portion 211 Hot runner gate 213 Gate 215 Runner 217 Heater 220 Molten resin injection section 230 Die 231 Cut piece discharge path 300 Movable mold (die)
301 Uneven portion 311 Punches 321, 323, 325 Pin C1 Cavity C2 Cavity A1 Forming stage A2 Forming stage A3 Cutting stage 10 Key top plate 11 (11-1, 11-2) Film 111, 113 Curved portion 15 Through hole 31 Key top 32 Key top body (resin molded product)
37 Resin Injection Portion 39 Resin Pool 115 Resin Injection Port 50 Outer Parts 51 (51-1 and 51-2) Film 511 Curved Part 52 Outer Parts Main Body (Resin Molded Article)

Claims (5)

A method for producing a resin molded article having a film, wherein a forming step of forming a film and a molding step of molding a resin molded article on the formed film are performed using the same mold. The method for producing a resin molded article having a film according to claim 1, wherein a cutting step of cutting a part of the resin molded article and / or a part of the film is performed by the mold. 3. The method for producing a resin molded article having a film according to claim 1, wherein a resin molded article is molded in the molding step at a portion where the film is formed in the forming step. The forming performed on the film in the forming step is forming of a portion to be a key top, the resin molded product formed in the forming step is a key top main body, and the resin molded product having the film to be manufactured is a key top plate. 4. A method for producing a resin molded article having a film according to claim 3, wherein: The forming performed on the film in the forming step is forming of a part to be an exterior part, the resin molded part molded in the molding step is an exterior part main body, and the resin molded part having the film to be produced is an exterior part. 4. A method for producing a resin molded article having a film according to claim 3, wherein:

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