JP2008110501A - Insert molding mold and method for producing mold product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the following problem, wherein a conventional insert molding mold, so as to prevent the positional deviation of circuit patterns on a film which occurs during the injection of a resin, needs to perform molding after the film is held between the mold mating faces of a pair of molds and the molds are clamped, so that a mold product having the circuit patterns on both surfaces can not be obtained by one molding. <P>SOLUTION: A mold surface contacting the cavity of an insert molding mold is made a permeable porous substrate to control the mold surface to be a negative pressure. By sucking/fixing a plurality of films with patterns etc., formed along the mold surface, a cavity is formed between the films. An injection gate for injecting a fluid resin into the cavity is formed. Thus, the mold product having the circuit patterns on both surfaces is obtained by one molding. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an insert molding die for forming, for example, a pattern imparted to a film on a molded resin substrate and a molded product molded using the die.

  In the conventional insert molding die, it is necessary to prevent misalignment between the circuit pattern or the like applied to the film accompanying the injection of the resin and the insert molding die. Therefore, a predetermined portion of the film provided with a circuit pattern or the like is placed on the mold mating surfaces of a pair of molds constituting the insert mold, and the film is positioned by clamping the film, and the film is cavityd. -It was held in place. Then, the fluid resin melted from the pattern forming surface side is filled and molded in the cavity, and only the film is peeled off from the molded resin substrate obtained by curing the molded resin, and the pattern is formed on the molded resin substrate. The product was obtained from the transfer (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. Hei 6-275939 (paragraph 0919, paragraph 0020, FIG. 1)

  In conventional insert molding dies, it is necessary to place a predetermined part of the film on the mold mating surfaces of a pair of molds for pattern positioning, and then clamp the mold on one side of the molded resin substrate. However, the pattern could not be transferred. Therefore, it is difficult to position each pattern applied to a plurality of films by a single molding process, and to provide a cavity between the plurality of films to fill and mold the molten fluid resin. As a result, the pattern on the film could not be transferred and formed on a plurality of surfaces of the molded resin substrate which is the base material of the product.

  The present invention solves the above-mentioned problems and provides an insert molding die for transferring and forming a pattern applied to a film on a plurality of surfaces of a molded resin substrate by high-precision positioning while performing a single molding process. With the goal.

  The insert molding die of the present invention is “a gas-permeable porous base material that has a mold surface on which a film-like member can be sucked and adsorbed on the air-permeable porous base material by exhaust and is engaged with each other. The first and second molds are provided with an injection gate for injecting a resin into a cavity formed by the above-described mold surfaces ”.

  Since the inner wall surface in contact with the cavity, which is the mold surface of the insert mold, is sucked, each film-like member to which a plurality of patterns and the like are applied is placed on the inner wall surface (mold surface) of the mold. ), It can be easily positioned and fixed including its pattern. Therefore, a space along the mold surface can be secured between the plurality of films, and as a result, the molten fluid resin can be filled and molded into the space formed along the mold surface. A molded product having a pattern transferred onto a plurality of surfaces can be obtained.

Embodiment 1 FIG.
Hereinafter, Embodiment 1 of the present invention will be described in detail with reference to the drawings. FIG. 1 is a schematic diagram of a clamped state of an insert molding die of the present invention (FIG. 1a is a schematic diagram of a side section, FIG. 1b is a schematic diagram of a front surface), and FIG. 2 is used for Embodiment 1 of the present invention. A schematic diagram of a film provided with a circuit pattern such as an antenna made of a copper thin film (FIG. 1a is a schematic diagram of a side section, FIGS. 1b and c are schematic diagrams of an upper surface), and FIG. 3 is an insert molding of the present invention. FIG. 4 is a schematic diagram of the mold opening state when the first film and the second film provided with a pattern or the like are respectively positioned and arranged on the mold, and FIG. 4 is a mold clamped and melted of the insert mold of the present invention It is a schematic diagram of the mold clamping state filled and molded with fluid resin. 1 to 4, the same reference numerals are given to the same or corresponding parts.

  As shown in FIG. 1, an insert mold 100 according to the present invention includes a first mold 10 having a first mold surface 30a and a second mold having a second mold surface 30b. It is composed of 20 pairs of molds. The mold fitting surface 10A of the first mold 10 and the mold fitting surface 20A of the second mold 20 are in contact with each other so as to be in a mold-clamping state, whereby a molding resin is formed inside the insert mold 100. A cavity 30 for forming the first and second mold surfaces 30a and 30b, and an injection gate 31 for injecting molten fluid resin into the cavity 30 at the same time. The transverse groove 31a and the transverse groove 31b are provided to overlap each other. In the first embodiment, one injection gate 31 may be provided in advance in at least one position of the first mold 10 or the second mold 20. A plurality of fine vent holes 11 and vent holes 21 are provided in the negative pressure portion 10a and the negative pressure portion 20a in contact with the cavities 30 inside the first mold 10 and the second mold 20 (breathable porous Substrate) and an exhaust pump 200 which is an exhaust device provided outside the insert molding die 100 can be sucked through the vent pipes 201 and 202, respectively. As will be described in detail later, a film provided with a pattern or the like is disposed on the vent holes 11 and 21 provided in the negative pressure portion 10a and the negative pressure portion 20a.

  As shown in FIG. 2, a PET (polyethylene terephthalate) film 310 as a base material is provided in the first film 301 or the second film 302 to which the pattern used in the first embodiment of the present invention is applied. A first antenna pattern 312 or a second antenna pattern 322 made of copper foil is formed on one side of the substrate by a vacuum deposition method, a plating method, a printing method, or the like. The planar shape of the PET film of the base material used in the first embodiment is a planar shape that matches the bottom surface shape of the first or second mold surface 30a, 30b for positioning. Note that the PET film 310, the copper foil antenna pattern 312, the antenna pattern 322, etc., which are the base material in FIG. 2, are examples, and there is no particular need for each material to be PET or copper. What is necessary is just to select suitably according to. Moreover, the base material shape and pattern shape should just be designed according to convenience.

  Hereinafter, a molded product obtained by transferring the first antenna pattern 312 and the second antenna pattern 322 to the front and back surfaces of the molded resin substrate, respectively, using the insert molding die 100 of the present invention. A method for manufacturing the antenna 400 (not shown) will be described in detail.

  As shown in FIG. 3, with the insert molding die 100 of the present invention in the mold open state, the exhaust pump 200 is operated to exhaust the air in the ventilation pipes 201 and 202 in the A or B direction. As a result, the negative pressure portion 10a and the plurality of vent holes 11 and the vent holes 21 provided in the negative pressure portion 20a made of the breathable porous base material of the first mold 10 and the second mold 20 are both negative pressure. And the surrounding air is exhausted in the C or D direction. Along the first mold surface 30a of the first mold 10, the pattern surface of the first film 301 is inserted outward to be positioned at a predetermined position, and on the mold surface 30a. (Since the planar shape of the first film 301 matches the bottom shape of the first mold surface 30a). Further, the pattern is positioned at a predetermined position by inserting the pattern surface of the second film 302 outward along the inner surface of the second mold surface 30b of the second mold 20. It is fixed by suction along the mold surface 30b (because the planar shape of the second film 302 matches the bottom surface shape of the second mold surface 30b).

  Next, as shown in FIG. 4, the insert molding die 100 of the present invention is clamped to provide the cavity 30 and the injection gate 31. The fluid resin 400a melted from the injection gate 31 into the cavity 30 is injected, filled, and molded, and the molded resin substrate 401 is obtained after the molded resin is cured. Note that the molten fluid resin does not need to be a molten organic material such as plastic, and may be an inorganic fluid material using thixotropy such as a magnesium alloy, or a reactive fluid material such as cement, In short, any fluid can be inserted from the injection gate 31 into the cavity 30 as long as it is solidified thereafter. The operation of the exhaust pump 200 is stopped, the insert molding die 100 of the present invention is opened, the first film 301 is disposed on one surface of the molded resin substrate 401, and the second film 302 is disposed integrally on the opposite surface. The molded antenna 400 is taken out. Each of the PET films 310 as the base material of the first film 301 and the second film 302 has an effect of protecting the antenna pattern 312 or the antenna pattern 322 which is a copper foil. You may store without removing until just before installation. In addition, when incorporating into a wireless device, not all the PET film may be removed, but only a portion that establishes electrical continuity with a transmission circuit or an oscillation circuit may be removed by peeling or dissolving. Of course, it is possible to mechanically and manually remove all PET film by turning it over, and after that, it can be stored as an antenna 400 or incorporated into a device. Also good.

  As described above, in the first embodiment of the present invention, by using the insert molding die 100 of the present invention, the molded resin substrate is molded integrally with a film provided with a pattern or the like on both surfaces. An antenna that is a molded product is obtained, and an antenna that is a molded product in which a pattern is transferred and formed on both surfaces of a molded resin substrate is obtained by removing each PET film that is a base material.

Embodiment 2. FIG.
Hereinafter, a second embodiment of the present invention will be described in detail with reference to the drawings. FIG. 5 is a schematic diagram of a film provided with a pattern or the like used in Embodiment 2 of the present invention (FIG. 1a is a schematic diagram of a side section, FIGS. 1b and c are schematic diagrams of an upper surface), and FIG. After the first film and the second film obtained by applying a pattern or the like to the PET film 310 which is a tape-shaped base material are positioned and arranged at predetermined positions, the mold is clamped. In the first embodiment, the shape of the film substrate is changed from an independent shape to a continuous tape shape, and the others are as follows. Exactly the same. In FIG. 5 or FIG. 6, the same reference numerals are given to the same or corresponding parts as those in FIG. 1 to FIG.

  The antenna molded in the second embodiment of the present invention uses the same insert molding die as in the first embodiment of the present invention, and the first antenna pattern 312 and the second antenna pattern having the same shape. Since this is a molded product obtained by transferring the film 322, the same product is molded. The only difference is that the shape of the base material of the first film 303 and the second film 304 used for molding is changed to a tape shape, and the positioning procedure of the antenna pattern and the injection route of the fluid resin in which the resin is melted are slightly changed. is there.

  Since the exhaust mold 200 is operated with the insert mold 100 of the present invention in the mold open state, the negative pressure portion 10a and the negative pressure portion of the first mold 10 and the second mold 20 are operated. Air is exhausted from 20a. The first film 303 and the second film pattern 322 are arranged so that the antenna pattern 312 and the second antenna pattern 322 are respectively arranged at predetermined positions on the mating surface 20A of the first mold 10 and the second mold 20. Two films 304 are arranged. The first mold surface 30a and the second mold surface 30b of the first mold 10 and the second mold 20 gradually become negative pressure, and a tape-shaped first film is formed along the mold surface. The 303 and the second film 304 are inserted, and the first antenna pattern 312 and the second antenna pattern 322 are also positioned at predetermined mold surfaces on the negative pressure portion 10a and the negative pressure portion 20a. It is fixed by suction. The first mold 10 and the second mold 20 are provided with a transverse groove 31a and a transverse groove 31b for forming an injection gate, respectively. Therefore, the first film 303 and the second film 304 are transverse grooves. The first mold surface 30a and the second mold surface 30b opposite to each other where 31a and the transverse groove 31b are provided are inserted inward from the inside, and further, the first mold surface near the transverse groove 31a and the transverse groove 31b. Inserted from the inside to the outside of the first mold surface 30a and the second mold surface 30b, and finally sucked along the mating surfaces 10A and 20A including the shapes of the transverse grooves 31a and 31b. Fixed.

  Next, as shown in FIG. 6, the insert molding die 100 of the present invention is clamped to provide the cavity 30 and the injection gate 31 via the first film 303 and the second film 304. From the injection gate 31 (gap formed in the film) formed by the tape-shaped first film 303 and the second film 304 inserted into the transverse groove 31a and the transverse groove 31b toward the cavity 30 Then, the molten resin 400a is poured, filled, and molded, and the molded resin substrate 401 is obtained after the molded resin (molded fluid resin) is cured. The operation of the exhaust pump 200 is stopped, the insert molding die 100 of the present invention is opened, the first film 303 is arranged on one side of the molded resin substrate 401, and the second film 304 is arranged on the opposite side. Take out the integrally molded product. The antenna 400 can be obtained by mechanically turning and removing all PET films mechanically or manually.

  As described above, in the second embodiment of the present invention, the mold fitting surfaces 10A and 20A on the first mold 10 and the second mold 20 of the insert mold 100 of the present invention are used. Since the transverse groove 31a and the transverse groove 31b are provided in the liquid resin 400a melted from between the first film and the second film, it is possible to inject, fill, and mold the resin. An antenna which is a molded product molded integrally with the formed film is obtained, and an antenna which is a molded product in which a pattern is transferred and formed on both surfaces of a molded resin substrate by removing each PET film which is a base material. The special effect of being obtained is obtained. Further, by using the insert molding die 100 of the present invention, an arbitrary pattern is arranged so as to face every part inside the first mold surface 30a and the second mold surface 30b. (If a slit is inserted in a part of the film, the film can easily follow the mold surface). A molded product formed by transfer can be easily obtained. Further, since the film provided with a pattern or the like is used as a tape-like film, the tape-like film is continuously inserted on the mold surface of the insert molding die, In this way, it is possible to take in a molded product that is integrally molded, which has the effect of greatly improving productivity and workability. Also, since the molten fluid resin 400a is injected into the cavity from the injection gate (gap formed in the film) formed by the first film and the second film, the mold of the insert molding die body The effect is obtained that the transverse groove (injection gate) of the mating surfaces is not soiled. In addition, since the first and second film bases in the facing state attached to the molded product are separated from each other, it is possible to easily separate the molded resin substrate to which the pattern is transferred from the film. It is done.

Embodiment 3 FIG.
Hereinafter, the third embodiment of the present invention will be described in detail with reference to the drawings. The insert molding die 101 of the third embodiment of the present invention shown in FIG. 7 is the first mold 10 and the second mold of the insert molding die 100 described in the first embodiment of the present invention. Instead of the plurality of fine ventilation holes 11 and ventilation holes 21 forming the negative pressure part 10a and the negative pressure part 20a (the surfaces of the mold surfaces 30a and 30b), a porous, air-permeable solid material (ventilation) Porous porous substrate), and the others are exactly the same. In FIG. 7, the same reference numerals are given to the same or corresponding parts as in FIGS. 1 to 6.

  The porous air-permeable solid material may be pumice or ceramics, or may be a sintered powder of PTFE (tetrafluoroethylene resin) or an organic material such as plastic. Alternatively, it may be a porous metal or the like. In short, it may be a solid material having a ventilation hole therein. As can be seen from FIG. 7, the porous portion 12 and the porous portion 22 made of a solid material are formed on the mold-matching surfaces 10 </ b> A and 20 </ b> A of the first mold 10 and the second mold 20. The first mold surface 30a and the second mold surface 30b are provided on the inside of each flush surface (the mold matching surface of the porous portion). When the exhaust pump 200 is operated, air is exhausted from the surfaces of the porous portion 12 and the porous portion 22 composed of the air-permeable porous base material, so that the surface and the periphery thereof become negative pressure, and easily The first film and the second film can be sucked and fixed.

  The insert molding die 101 according to the third embodiment having the above-described configuration is obtained in the first or second embodiment by the same operation as that in the first or second embodiment. It is possible to obtain an antenna which is a molded product molded integrally with a film provided with a pattern or the like on both surfaces of such a molded resin substrate. Further, by forming the porous portion 12 and the porous portion 22 with a sintered body of PTFE powder, the surface energy of the porous portion is at least −50 ° C. while maintaining the porous property. The temperature can be remarkably lowered in the range from low temperature to 460 ° C., and in particular, the effect that the first film and the second film can be easily removed from the first mold and the second mold is obtained.

Embodiment 4 FIG.
Hereinafter, the fourth embodiment of the present invention will be described in detail with reference to the drawings. In the insert molding die 102 according to the fourth embodiment of the present invention shown in FIG. 8, the porous portion described in the third embodiment of the present invention is nested in a porous material made of air. The rest is exactly the same. In FIG. 8, the same or corresponding parts as those in FIGS. 1 to 7 are given the same reference numerals.

  The insert molding die 102 of the fourth embodiment having the above-described configuration is obtained in the first or second embodiment by the same operation as that of the first or second embodiment. It is possible to obtain an antenna which is a molded product molded integrally with a film provided with a pattern or the like on both surfaces of such a molded resin substrate. In addition, since the porous portion is the nesting 13 and the nesting 23 made of a porous material, the molding surface as a mold can be easily removed from the first mold and the second mold. Therefore, an effect that the maintenance of the mold becomes easy can be obtained.

Embodiment 5. FIG.
Hereinafter, the fifth embodiment of the present invention will be described in detail with reference to the drawings. The insert molding die 103 according to the fifth embodiment of the present invention shown in FIG. 9 has PTFE, FEP on the molding surface of the nesting made of the breathable porous material described in the fourth embodiment of the present invention. The negative pressure portions 41 and 42 formed by coating a fluororesin such as PFA are formed, except that protruding fixing pins 41a and 42a are respectively provided in the portions. It is the same configuration. In FIG. 9, the same reference numerals are given to the same or corresponding parts as those in FIGS. 1 to 8.

  The insert molding die 103 according to the fifth embodiment having the above-described configuration is patterned on both surfaces of the molded resin substrate as obtained in the fourth embodiment by the same operation as the fourth embodiment. It is possible to obtain an antenna which is a molded product molded integrally with a film or pattern to which the above is applied. In addition, since the fluororesin coating negative pressure portions 41 and 42 are provided on the molding surfaces of the insert 13 and the insert 23 made of a porous material, the first film and the first film can be easily removed from the insert 13 and the insert 23. Since the two films can be easily removed, the workability can be improved. In particular, PTFE coated so as to be sintered on a porous material can ensure sufficient air permeability in the range from a low temperature of -50 ° C to a high temperature of 460 ° C. The special effect that durability is particularly good is obtained. Further, since projection-like fixing pins 41a and 42a are respectively provided in a part of the negative pressure portion formed on the molding surface of each nesting, the first film 303 and the second film 304 are fixed to the predetermined positions in advance. Since holes corresponding to the pins 41a and 42b are provided and the holes are inserted into the fixing pins 41a and 42a, the pattern on the film can be positioned at a predetermined position on the shaping surface with high accuracy. In addition, it is possible to obtain a special effect that film displacement due to resin flow hardly occurs. In other embodiments and the prior art, such an effect can be obtained by providing a similar fixing pin on the molding surface of the mold or the insert.

It is a schematic diagram of the insert molding die of Embodiment 1 of this invention. It is a schematic diagram of the film used for Embodiment 1 of the present invention. It is a schematic diagram when a film is arrange | positioned to the insert molding die of this invention. It is a schematic diagram when filling and molding resin in the insert molding die of the present invention. It is a schematic diagram of the film used for Embodiment 1 of the present invention. It is a schematic diagram when filling and molding resin in the insert molding die of the present invention. It is a schematic diagram of the insert molding die of Embodiment 3 of this invention. It is a schematic diagram of the insert molding die of Embodiment 4 of this invention. It is a schematic diagram of the insert molding die of Embodiment 5 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 1st metal mold | die 10A type | mold joint surface 10a Negative pressure part (breathable porous base material) 12 Porous part (breathable porous base material)
20 Second mold 20A Mold mating surface 20a Negative pressure portion (breathable porous substrate) 22 Porous portion (breathable porous substrate)
30 cavity 30a first mold surface 30b second mold surface 31 injection gate 31a transverse groove 31b transverse groove 100 insert molding die 200 exhaust pump (exhaust device)
301 First film 302 Second film 321 First antenna pattern (circuit pattern)
322 Second antenna pattern (circuit pattern)
400a Fluid resin 401 Molded resin substrate

Claims (6)

The above-mentioned first and second molds, which are made of a breathable porous substrate and have a mold surface on which a film-like member can be sucked and adsorbed onto the substantially breathable porous substrate by exhaust, are arranged to be opposed to each other. An insert mold having an injection gate for injecting a fluid resin into a cavity formed by the mold surface. 2. The insert molding die according to claim 1, wherein the injection gate comprises a transverse groove provided so as to traverse at least one of the first and second mold mating surfaces. Insert molding mold characterized by The insert molding die according to claim 1 or 2, wherein the breathable porous base material constituting the die surface is a sintered body of tetrafluoroethylene resin powder. The above-mentioned first and second molds, which are made of a breathable porous substrate and have a mold surface on which a film-like member can be sucked and adsorbed onto the substantially breathable porous substrate by exhaust, are arranged to be opposed to each other. Using an insert mold having an injection gate for injecting a fluid resin into a cavity formed by the mold surface, the first film is placed on the first mold surface by operating the exhaust device. The second film is sucked and fixed along the second mold surface, the first mold and the second mold are clamped, and A step of injecting and molding a fluid resin from the injection gate into the cavity; and a step of curing the fluid resin to form a molded resin substrate, wherein the first film and the second film are molded resin substrates. Molded product manufacturing method characterized by integration on the surface . The above-mentioned first and second molds, which are made of a breathable porous substrate and have a mold surface on which a film-like member can be sucked and adsorbed onto the substantially breathable porous substrate by exhaust, are arranged to be opposed to each other. An injection gate for injecting a fluid resin into a cavity formed by the mold surface is provided, and the injection gate traverses at least one of the mold mating surfaces of the first and second molds. The first film is sucked along the first mold surface and the mold-matching surface by the operation of the exhaust device using an insert molding die characterized by comprising a transverse groove provided as described above. Fixing and fixing the second film by suction along the second mold surface and the mold mating surface; and clamping the first mold and the second mold; A first film and a second film along the transverse groove of the mold matching surface A step of injecting a fluid resin into a cavity from a gap formed between and molding the fluid resin; and curing the fluid resin to form a molded resin substrate, wherein the first film and the second film are formed. A method for producing a molded product, characterized by being integrated with the surface of a molded resin substrate. 6. The method for producing a molded product according to claim 4, wherein a circuit pattern is imparted to the first film and the second film.

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