JP2005096087A - Film inserted resin molded product and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a film inserted resin molded product having visibility, unnecassry to limit a film to a transparent film, to provide an adhesive layer, a heat-resistant layer or the like on a pattern at the time of production and to limit the position or size of the gate of a mold and capable of simplifying a manufacturing method to reduce a manufacturing cost, and its manufacturing method. <P>SOLUTION: In the film inserted resin molded product 10 wherein the film 12, the pattern 11 and a resin 13 are integrated, the film 12 has the pattern 11 formed on one side thereof and the resin 13 is formed on the other surface of the film 12. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention decorates components such as display panels, decorative panels, switch plates, console panels, exterior parts, cases, display protection panels, authentication ID cards, etc. used in home appliances, in-vehicle products, mobile phones, computers, etc. The present invention relates to a film insert resin molded product used for the purpose and a manufacturing method thereof.

  A conventional film insert resin molded product is formed by mounting an insert sheet in which a pattern and an adhesive layer are sequentially formed on a base film on an injection mold and injecting the resin into the adhesive layer (special feature). (See Kaihei 6-106562 and JP-A-10-329169).

  In these conventional film insert resin molded products, since the picture will be seen through the film, the film is limited to the transparent one, and the visibility becomes poor due to the low transparency of the film and the reflected light. There was a problem.

  Further, in the conventional method for producing a film insert resin molded product, a film is brought into contact with a mold, and a high-temperature molten resin is injected on the pattern side at a high pressure. Therefore, it is necessary to use special ink with high heat resistance and adhesion for the pattern, so that the ink that can be used is limited, and it is necessary to provide an adhesive layer and a heat-resistant layer on the pattern. Even if such a special ink is used for the pattern, and an adhesive layer or heat-resistant layer is provided, the pattern melts and breaks due to the heat and pressure of the molten resin during injection, depending on the product shape and molding conditions. In many cases, many defective products are generated.

As a method to prevent such pattern destruction, the position and size of the gate of the mold is limited, and an adhesive layer or heat-resistant layer is laminated on the pattern to increase the heat and pressure during injection molding. There is also a method of bonding and integrating while protecting the pattern from fluid shearing force, but there is a problem that the manufacturing difficulty is high and the cost is high (see Japanese Patent Application Laid-Open No. 2001-179772).
JP-A-6-106562 Japanese Patent Laid-Open No. 10-329169 JP 2001-179772 A

  Therefore, the present invention has good visibility and it is not necessary to limit the film to a transparent one, and it is not necessary to limit the ink used for the pattern to one having high heat resistance and high adhesion, and at the time of injection molding. There is no need to provide an adhesive layer or heat-resistant layer on the design, it is not necessary to limit the position and size of the gate of the mold, the manufacturing method is simple, and the manufacturing cost can be kept low. It is an object to provide a manufacturing method.

  In order to solve the problems as described above, the invention according to claim 1 is a film insert resin molded product in which a film, a picture, and a resin are integrated, and the film forms the picture on one side and the other The resin is formed on the surface.

  According to a second aspect of the present invention, in addition to the structure of the first aspect, the film is thermoplastic, and at least a part of the pattern bites into the film, and at least a surface of the pattern is the film. It is characterized by being located at the same height as the surface or protruding from the film surface.

  According to a third aspect of the present invention, in the manufacturing method according to the first or second aspect, the pattern is formed on one surface of the flat film to form an insert sheet composed of the film and the pattern. Then, the insert sheet is placed in an injection mold so that the pattern is in contact with the bottom of the cavity, the mold is closed, and the molten resin is injected onto the surface of the film where the pattern is not formed. A film insert resin molded product comprising the film and the resin is formed.

  The invention according to claim 4 is the manufacturing method according to claim 1 or 2, wherein the pattern is formed on one surface of the flat film to form an insert sheet composed of the film and the pattern. Then, the insert sheet is pre-processed so as to correspond to the shape of the cavity bottom of the injection mold with the design of the insert sheet as the surface side, and the insert member having a three-dimensional shape is formed, and the design is in contact with the bottom of the cavity. A film insert resin comprising the pattern, the film, and the resin by placing an insert member in the injection mold and closing the mold, and injecting a molten resin onto the surface of the film where the pattern is not formed. It is characterized by molding a molded product.

  According to the first aspect of the present invention, since the pattern is on the surface, it is not necessary to limit the film to one having transparency, and the visibility is good.

  According to the invention described in claim 2, in addition to the effect of the invention described in claim 1, since the pattern bites into the film, the pattern is hard to wear and the surface is gentle.

  According to invention of Claim 3, the insert sheet which consists of a pattern and a film is formed, an insert sheet is arrange | positioned so that a pattern may contact | connect a cavity bottom part, and it is high temperature on the surface in which the pattern of a film is not formed. Since the molten resin is injected under high pressure, there is no risk of the pattern being damaged by heat or pressure due to injection, ink used for the pattern is not limited, and it is not necessary to provide a heat resistant film or an adhesive layer on the pattern. Moreover, since the film is moderately softened by heat and pressure due to injection and the pattern is eroded, it is possible to obtain a film insert resin molded product having a gentle surface and a gentle surface.

  According to the invention described in claim 4, an insert sheet composed of a pattern and a film is used as an insert member by pre-processing it into a three-dimensional shape so as to correspond to the shape of the cavity bottom of the injection mold, with the pattern as the surface. This insert member is placed in the injection mold so that the pattern comes into contact with the bottom of the cavity, and the molten resin is injected under high temperature and high pressure onto the surface of the film where the pattern is not formed. Even if it has, there is no risk of distortion of the pattern due to pressure at the time of injection, and there is no risk of damage to the pattern due to heat or pressure due to injection, ink used for the pattern is not limited, heat resistant film or adhesion to the pattern There is no need to provide a layer. Moreover, since the film is moderately softened by heat and pressure due to injection and the pattern is eroded, it is possible to obtain a film insert resin molded product having a gentle surface and a gentle surface.

[Embodiment 1]
FIG. 1 is a cross-sectional view of the film insert resin molded product of the first embodiment. The film insert resin molded product 10 includes a pattern 11, a film 12, and a resin 13. The pattern 11, the film 12, and the resin 13 are laminated and integrated in this order. The pattern 11 bites into the film 12 except for a part.

  FIG. 2 is a cross-sectional view of an intermediate member obtained in the manufacturing process of the film insert resin molded product of the first embodiment. The intermediate member 14 has a pattern 11 formed on the surface of the film 12.

  FIG. 3 is a cross-sectional view of a mold used in the film insert resin molded product manufacturing process of the first embodiment. The mold 20 includes a female mold 21 having a cavity 25 and a male mold 22. The male mold 22 is provided with a gate 23, and the gate 23 is provided with a cylinder 24.

  Next, a method for producing the film insert resin molded product 10 will be described with reference to the drawings.

  First, an arbitrary pattern 11 is formed on the flat film 2 to obtain an insert sheet 14. At this point, the pattern 11 has not digged into the film 12. The insert sheet 14 is placed so that the pattern 11 is in contact with the bottom 27 of the cavity 25 of the female mold 21 and the mold is closed by the male mold 22 (see FIG. 3). Under high temperature and high pressure, the molten resin is injected from the gate 23 onto the surface on which the pattern of the film 12 is not formed, and the pattern 11, the film 12 and the resin are integrally molded, taken out from the mold 20, and the pattern 11 and the film 12 A film insert resin molded product 10 made of the resin 13 is obtained.

  In the film insert resin molded product 10 obtained in this way, most of the pattern 11 is biting into the film 12 except for its surface. Since the surface of the pattern 11 is on the film, the visibility is excellent and it is not necessary to limit the film 12 to a transparent one. In addition, since most of the pattern 11 is buried in the film 12 and only a part protruding from the film 12 is present, the pattern 11 is not easily worn and the touch feeling is not uncomfortable.

  In order to impart wear resistance and good feel to the pattern 11, at least 10% or more of the thickness of the pattern 11 bites into the film 12, and the thickness of the portion protruding from the film 12 is 40 μm or less. Is preferred. As injection conditions for obtaining such a finished product, it is preferable that the temperature of the mold 20 is 40 to 100 ° C., the temperature of the cylinder 24 (resin temperature) is 190 to 320 ° C., and the injection pressure is 50 to 180 MPa. If the temperature of the mold 20 is 120 ° C. or higher, the contacted pattern 11 may be destroyed, so care should be taken not to exceed that temperature.

  The film 12 is made of a resin, and examples of the material include acrylic, polyester, polyurethane, polyolefin, ABS, polycarbonate, polystyrene, and derivatives, alloy films, and laminated films. Of these, ABS, acrylic, polyester, and polycarbonate are preferably used from the standpoint of decoration suitability and ease of handling.

  As the ink for forming the pattern 11, acrylic, polyester, polyurethane, or the like is used. Since the resin melted under high temperature and high pressure is not directly injected into the pattern 11, high heat resistance is not required, and it is not necessary to form a special heat resistant layer or adhesive layer. In order to provide the pattern 11 using the above-described ink on the film 12, a conventionally known method such as printing, painting, coating, hot stamping, or the like may be performed. Also, as the pattern 11, in addition to the above-described ink alone, a metal thin film is formed using techniques such as vapor deposition, sputtering, plating, etching, etc., and the pattern made of ink and the metal thin film are combined. It may be a thing. Further, before the pattern 11 is formed, the film 12 may optionally be subjected to a ground treatment.

  In addition, the pattern 11 of the film insert resin molded product 10 has sufficient durability to withstand long-term use, but further, wear resistance, scratch resistance, contamination prevention, anti-light reflection, In order to impart performance such as antistatic properties, a hard coat layer, a fluorine-based coating layer, a silicone-based coating layer, a vapor deposition coating layer, a conductive material, or the like may be optionally formed on the pattern 11.

  Here, the pattern 11 refers to, for example, a character, numeral, partial coloring or the like applied to a part of the film 12, a full coloring or the like applied to the entire surface of the film, or a combination of both.

As the resin 13, an injection molding resin such as ABS, acrylic, polycarbonate, polyolefin, or polyester is used.
[Embodiment 2]

  FIG. 4 is a front view showing the film insert resin molded product of Embodiment 2, and FIG. 5 is a cross-sectional view taken along the line AA. It consists of a picture 41, a film 42, and a resin 43. The film 42 consists of a convex part 44 and an outer peripheral part 45 surrounding the convex part 44. The picture 41 is formed on the surface of the film 42 having the convex part 44, and a part of The resin 43 is provided on the inner side of the film convex portion 44 and the back surface of the outer peripheral portion 45.

  FIG. 6 is a cross-sectional view of the insert member obtained in the manufacturing process of the second embodiment. The intermediate member 46 includes a pattern 41 and a film 42. The film 42 includes a convex portion 44 and an outer peripheral portion 45 surrounding the convex portion 44. The pattern 41 is formed on the surface of the film 42.

  FIG. 7 is a sectional view of a mold used in the manufacturing process of the second embodiment. The mold 30 includes a female mold 31 having a recess 36 in a cavity 35 and a male mold 32 having a gate 33, and a cylinder 34 is provided at the tip of the gate 33.

  A pattern 41 is provided at a predetermined position of the flat film 42 to form an insert sheet composed of the film 42 and the pattern 41. This insert sheet is pre-processed so as to form the convex portion 44 on the pattern 41 side by a vacuum forming method so as to match the shape of the concave portion 36 of the cavity 35 of the female die 31 to obtain the insert member 46. Next, the insert member 46 is disposed in the mold so that the convex portion 44 of the pattern 41 is substantially joined to the concave portion 36 of the female cavity 35, and the male mold 32 is closed (see FIG. 7). Next, under a high temperature and high pressure, the molten resin is injection-molded from the gate 33 toward the film 42 and taken out from the mold 30 to obtain a film insert resin molded product 40 having a convex portion 44.

  The pattern 41 thus obtained is integrated into the film 42 by high temperature and high pressure at the time of injection molding, so that the surface of the pattern 41 is finished with a high quality appearance without fine irregularities due to printing, The touch feeling was gentle, and the pattern 41 and the film 42 were firmly adhered, and high durability was obtained.

  Other configurations and the manufacturing method are the same as those of the first embodiment, and the same components are denoted by the same reference numerals and the description thereof is omitted.

  Next, an example of the manufacturing method of the film insert resin molded product of Embodiment 1 is shown.

  On one side of a 75 μm thick acrylic resin film (Technoloy S001: manufactured by Sumitomo Science Co., Ltd.), 2500 series ink (manufactured by Seiko Advance Co., Ltd.) was screen-printed. The pattern 11 is formed by performing hot stamp printing repeatedly using Katani Sangyo Co., Ltd., and the insert sheet 14 composed of the film 12 and the pattern 11 having a thickness of 10 μm is obtained. Next, an injection mold 20 having a cavity portion 25 having a thickness of 2 mm and a length and width of 50 mm × 100 mm was prepared, and an insert sheet 14 was inserted into the mold 20 so that the pattern 11 was in close contact with the cavity bottom portion 27.

  Next, Parapet HR-F (manufactured by Kuraray Co., Ltd.), which is an acrylic resin, is injected from the gate 23 toward the surface on which the pattern of the film 12 is not formed, and from the pattern 11, the film 12, and the resin 13 A film insert resin molded product 10 was obtained. The injection molding conditions at this time were a mold temperature of 60 ° C., a cylinder temperature of 245 ° C., and an injection pressure of 80 MPa.

  The film insert injection molded product 10 obtained in this way had the pattern 11 neatly formed on the surface of the molded product, and there was no deterioration due to heat and pressure of the molten resin 13 at the time of injection. In addition, the heat and pressure of the molten resin 13 at the time of injection softens the entire film 12, and the adjacent pattern 11 bites in and is integrated. Therefore, the thickness of the pattern 11 protruding from the film 12 is 5 μm at the maximum. there were.

  When the surface of the film insert resin molded product 10 was visually observed, irregularities could not be confirmed, and since the pattern 11 was on the surface, the visibility was good and the appearance was high quality. Moreover, when the surface was touched, it was very smooth and did not feel unevenness.

When the surface of the pattern 11 was rubbed with a sand eraser (502: manufactured by Lion Office Co., Ltd.) under a load of 500 g, the pattern remained without being erased even after being rubbed 500 times.
[Comparative Example 1]

The same insert sheet 14 as in Example 1 is placed so that the pattern 11 faces the gate 23 side, injection molding is performed under the same conditions as in Example 1, and the pattern 11 is sandwiched between the film 12 and the resin 13 An injection molded product was obtained. The pattern melted and flowed out due to the heat and pressure of the resin at the time of injection, and could not withstand practicality.
[Comparative Example 2]

  Parapet HR-F (manufactured by Kuraray Co., Ltd.), which is an acrylic resin, was injection molded using the same mold 20 as in Example 1 to form a flat resin 13. Next, the same printing process as that applied to the film 12 in Example 1 was performed on one surface of the resin 13 to form a pattern 11 having a maximum thickness of 10 μm.

  When the surface of the pattern 11 was rubbed with a sand eraser (502: manufactured by Lion Corporation) under a load of 500 g, part of the pattern 11 disappeared after 200 round trips.

  Next, an example of the manufacturing method of the film insert resin molded product described in Embodiment 2 is shown.

  As a film, an Iupilon film (manufactured by Mitsubishi Engineering Plastics Co., Ltd.), which is a polycarbonate resin film, and a thickness of 200 μm were prepared. Transfer printing was performed on one side of this film using L type (manufactured by Tampo Print Co., Ltd.) as an ink to form a predetermined pattern 41 and an insert sheet composed of the pattern 41 and the film 42 was formed. At this time, the maximum thickness of the pattern 41 was about 3 μm.

  Next, this insert sheet was preformed by vacuum forming to obtain an insert member 46 having a convex portion 44 on the pattern 41 side.

Next, the projecting portion 44 of the insert member 46 is disposed so as to be substantially joined to the recessed portion 36 in the cavity 35 of the female die 31 and is closed with the male die 32, and Panlite L-1225, which is a polycarbonate resin for injection molding. (Teijin Kasei Co., Ltd.) was injected from the gate 33 toward the film and molded. Here, the injection molding conditions were a mold temperature of 100 ° C., a cylinder temperature of 290 ° C., and an injection pressure of 100 Mpa. The film insert injection-molded product thus obtained had the pattern 41 neatly formed on the film 42 without distortion of the film 42 or damage to the pattern 41.
[Comparative Example 3]

  An insert sheet similar to that of the second embodiment is formed, and the pattern 41 is placed in contact with the surface having the recess 36 in the cavity 35 without preforming, and the molten resin is formed into a film 42 under the same conditions as in the second embodiment. Were injected to obtain a fill insert resin molded product. Since the part located on the recess 36 of the insert sheet was not in close contact with the female die 31, it was broken by the temperature and pressure at the time of injection, and the pattern 41 melted and flowed.

It is sectional drawing of the film insert resin molded product of Embodiment 1 of this invention. It is sectional drawing of the insert sheet obtained at the manufacturing process of the same Embodiment 1. FIG. 6 is a cross-sectional view of a mold used in the manufacturing process of Embodiment 1. It is a front view of the film insert resin molded product of the same Embodiment 2. It is AA sectional drawing of FIG. It is sectional drawing of the insert member obtained at the manufacturing process of the same Embodiment 2. It is sectional drawing of the metal mold | die used at the manufacturing process of the same Embodiment 2.

Explanation of symbols

10 40 Film insert resin molded product
11, 41, pattern
12, 42 films
13, 43, resin
14, Insert sheet
20, 30, mold
21, 31 Female
22, 32 Male
25, 35 cavity
27 Bottom of cavity 25
36 Recessed cavity 35
46 Insert material

Claims (4)

In film insert resin molded products in which film, picture and resin are integrated,
A film insert resin molded product, wherein the film has the pattern formed on one surface and the resin formed on the other surface.   The film is thermoplastic, and at least a part of the pattern bites into the film, and at least a surface of the pattern is located at the same height as the film surface or protrudes from the film surface. The film insert resin molded product according to claim 1. A method for producing a film insert resin molded product according to claim 1 or 2,
The pattern is formed on one surface of the flat film to form an insert sheet composed of the film and the pattern, and the insert sheet is disposed in the injection mold so that the pattern is in contact with the bottom of the cavity. A mold insert film molding comprising the picture, the film and the resin is formed by injecting a molten resin onto the surface of the film where the picture is not formed. . A method for producing a film insert resin molded product according to claim 1 or 2,
Forming the pattern on one surface of the flat film to form an insert sheet composed of the film and the pattern, and corresponding to the shape of the cavity bottom of the injection mold with the pattern of the insert sheet as the surface side Pre-processed to form a three-dimensional insert member, and the insert member is placed in the injection mold so that the pattern is in contact with the cavity bottom, and the mold is closed. A method for producing a film insert resin molded product comprising the picture, the film and the resin by injecting a molten resin onto a surface which is not formed.

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