JP2010214601A - Film insert molding, method for manufacturing the same, and liquid crystal display device including the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a film insert molding which can make the film deflected to some extent and in a flat state. <P>SOLUTION: The method for manufacturing the film insert molding includes a printing process S1 in which printing is applied to form an opening region in a prescribed region on one side of a transparent or translucent film to form a printing layer, a binder layer forming process S2 for forming a binder layer on the surface side of the printing layer, a forming process S4 for forming a film with the printing layer and the binder layer formed in a prescribed shape, a makeup extraction process S5 for forming an intermediate film article by applying extraction processing to the film after the forming process, and an insert molding process S6 in which the intermediate article is set in a concave mold after the makeup extraction process S5 the concave mold and the convex mold are combined after a frame member corresponding to an opening region is set in the convex part of a convex mold, and a molten resin is poured in a cavity to carry out insert molding. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a film insert molded product formed by inserting a film and a method for producing the same. Moreover, this invention relates to the liquid crystal display device provided with the film insert molded product shape | molded in this way.

  For example, a touch panel type liquid crystal display device includes liquid crystal display means and touch panel means disposed on the surface side of the liquid crystal display means. The touch panel means includes an upper resistance film provided on the inner surface of the transparent film substrate. An upper resistance film provided on the inner surface of the glass substrate is provided, and a number of dot spacers are disposed between the upper resistance film and the lower resistance film (see, for example, Patent Document 1).

  In such a liquid crystal display device, when the film substrate is pressed with a touch pen or the like, the touch position of the film substrate is bent and deformed, and the upper resistive film is bent by the bending of the film substrate and locally contacts the lower resistive film. At this time, when a predetermined voltage is applied between both ends of the upper resistance film in a predetermined direction, a voltage at one end of the lower resistance film in a direction perpendicular to the predetermined direction is detected, and the predetermined voltage of the lower resistance film is detected. The voltage at one end in the predetermined direction of the upper resistive film when a predetermined voltage is applied between both ends in the direction perpendicular to the direction is detected, and the contact between the upper resistive film and the lower resistive film is based on these detected voltages The coordinates of the position can be detected.

JP 2001-249766 A

  In such a liquid crystal display device, the surface of the film substrate is exposed to the outside, and the surface of the film substrate is directly pressed with a touch pen or the like. There's a problem.

  In order to solve such problems, it is possible to arrange a protective film on the surface side of the film substrate. However, such a protective film must be configured to bend to some extent when pressed with a touch pen or the like. In addition, in order to clean the appearance, it must be constructed in a flat state without undulations (the film itself bends like a wave), which satisfies these requirements. The realization of a liquid crystal display device provided with a protective film has been desired.

  An object of the present invention is to provide a film insert molded article that can be bent to a certain extent and can be made flat, and a method for manufacturing the same.

  Another object of the present invention is to provide a liquid crystal display device capable of protecting the surface of the touch panel means with a film.

  The method for producing a film insert molded article according to claim 1 of the present invention includes a printing step in which printing is performed to form an opening region in a predetermined region on one side of a transparent or translucent film to form a printing layer, A binder layer forming step for forming a binder layer on the surface side of the printed layer, a forming step for forming the printed layer and the film on which the binder layer is formed into a predetermined shape, and a punching process are performed on the film after the forming step. A makeup removal step for forming an intermediate film product, and mounting the intermediate film product in the concave mold after the makeup removal step, and corresponding to the opening peripheral area of the opening region in the convex portion of the convex mold After mounting the frame member having the shape to be melted, the molten resin is put into the cavity defined between the concave mold and the convex mold together. Characterized in that it comprises an insert molding step for resin molding, the poured.

  Moreover, in the manufacturing method of the film insert molded article of Claim 2 of this invention, the thermal contraction rate of the said frame member is smaller than the thermal contraction rate of the said film, It is characterized by the above-mentioned.

  Moreover, in the manufacturing method of the film insert molded article of Claim 3 of this invention, the said film is substantially rectangular shape, The heat shrinkage rate of the longitudinal direction of the said film is the heat | fever of the direction perpendicular | vertical with respect to the longitudinal direction. It is characterized by being larger than the shrinkage rate.

  In the method for manufacturing a film insert molded article according to claim 4 of the present invention, the opening region is rectangular, and the outer shape of the frame member is rectangular corresponding to the opening peripheral region of the opening region. It is a shape.

  In the method for manufacturing a film insert molded article according to claim 5 of the present invention, an annular mounting recess is provided at the tip of the convex portion of the convex mold, and the frame member is the annular mounting recess. It is attached to.

  In the method of manufacturing a film insert molded product according to claim 6 of the present invention, the depth of the concave cavity portion of the concave mold is somewhat larger than the height of the intermediate film product, and the cavity is formed from the inlet. The molten resin that has flowed in flows toward the convex mold on the outer peripheral side of the intermediate film product, and the outer peripheral portion of the intermediate film product is pulled toward the convex mold by this flow. .

  Moreover, in the manufacturing method of the film insert molded article of Claim 7 of this invention, glass fiber is contained in the ratio of 10 to 25 weight% in resin used for resin molding.

  In the method for producing a film insert molded article according to claim 8 of the present invention, the film is formed before the printing step, between the printing step and the binder layer forming step, or after the binder layer forming step. A functional layer forming step of forming a functional layer for imparting a function to the other surface is performed.

  Moreover, the film insert molded product according to claim 9 of the present invention is a film insert molded product manufactured by the manufacturing method according to any one of claims 1 to 8, and is a single side of a transparent or translucent film. The opening region formed in the predetermined region is formed flat.

  Furthermore, the touch-panel-type liquid crystal display device of Claim 10 of this invention is a film insert molded article manufactured by the manufacturing method in any one of Claims 1-8, and the said opening area | region of the said film insert molded article. Corresponding to the touch panel means, and a liquid crystal display means arranged on the lower side of the touch panel means.

  According to the method for producing a film insert molded product according to claim 1 of the present invention, a printing layer and a binder layer are formed on the film, and after forming the film into a predetermined shape, an intermediate film product is formed by performing a punching process. To do. And since this intermediate | middle film product is mounted in a concave mold and insert molding is performed, the insert molded product which inserted the film of the predetermined shape can be manufactured. Further, in insert molding, a frame member having a shape corresponding to the opening peripheral region of the opening region is attached to the convex portion of the convex mold, so that the frame member is placed in the opening peripheral region of the opening region of the film. By fixing to the molten resin and fixing the frame member in this way, the inner part of the film, that is, the part surrounded by the frame member can be flattened, and the heat shrinkage of the inner part can be effectively performed. It is possible to suppress the occurrence of undulation or the like that is likely to occur in the film during insert molding. Further, in the insert-molded product as described above, the inner part surrounded by the film frame member can function as an opening area, and when the film is pressed with a touch pen or the like, the opening area of the film has an appropriate deflection. Can be made. Such a film insert molded product can be conveniently used as, for example, a touch panel cover of a liquid crystal display device. The frame member is preferably formed of a material having high rigidity, for example, a metal material, in order to suppress thermal shrinkage of the film.

  Further, according to the method for manufacturing a film insert molded article according to claim 2 of the present invention, the thermal contraction rate of the frame member is smaller than the thermal contraction rate of the film. The inner part surrounded by the frame member is pulled by the frame member, and as a result, the inner part of the film can be kept in a more flat and clean state. The frame member can be formed from a metal material such as aluminum, aluminum alloy, stainless steel, or the like.

  According to the method for manufacturing a film insert molded article according to claim 3 of the present invention, since the thermal contraction rate in the longitudinal direction of the film is larger than the thermal contraction rate in the direction perpendicular to the longitudinal direction, During the heat shrinkage of the molding, a larger tensile force can be applied in the longitudinal direction of the film, and the entire area of this inner portion of the film can be kept flat and clean.

  In addition, according to the method for manufacturing a film insert molded article according to claim 4 of the present invention, since the outer shape of the frame member is a rectangular shape, the film can be advantageously applied to a rectangular opening region. it can.

  According to the method for manufacturing a film insert molded article according to claim 5 of the present invention, an annular mounting recess is provided at the tip of the convex portion of the convex mold, and a frame member is provided in the annular mounting recess. Since the frame member is mounted, this frame member defines a part of the cavity, prevents the molten resin from flowing out to the outside of the frame member, that is, the opening region side of the film, and clean insert molding can be performed.

  Further, according to the method for manufacturing a film insert molded product according to claim 6 of the present invention, the depth of the concave cavity portion of the concave mold is somewhat larger than the height of the intermediate film product. Since the molten resin that has flowed into the cavity from the injection port is configured to flow toward the convex mold on the outer peripheral side of the intermediate film product, the outer peripheral portion of the intermediate film product is formed into a convex mold by this flow. The intermediate film product can be cleanly insert-molded and the outer peripheral edge portion of the intermediate film product is prevented from protruding from the resin frame portion.

  According to the method for manufacturing a film insert molded article according to claim 7 of the present invention, the resin used for resin molding contains glass fibers at a ratio of 10 to 25% by weight. The rigidity, strength, and heat resistance of the frame portion can be increased, and shrinkage is reduced. If the glass fiber content is less than 10% by weight, the effect of improving rigidity, strength and heat resistance is small, and if the content exceeds 25% by weight, the flow of the molten resin during insert molding becomes poor. At the same time, the wear of the screws and cylinders of the molding machine and the mold becomes severe.

  Moreover, according to the manufacturing method of the film insert molded article according to claim 8 of the present invention, the other surface of the film before the printing step, between the printing step and the binder layer forming step, or after the binder layer forming step. Since the functional layer is formed on the film, the film can have various functions. For example, by providing a bird coat layer, the film can have an anti-scratch function, and by providing an anti-reflection layer, the film can have an anti-reflection function. As described above, since the functional layer is provided before insert molding, these are usually performed by post-processing as secondary processing, but various functions can be provided relatively easily and easily in the molding process.

  Moreover, the film insert molded product according to claim 9 of the present invention is a film insert molded product manufactured by the manufacturing method according to any one of claims 1 to 8, and is a single side of a transparent or translucent film. Since the opening area formed in the predetermined area is formed flat, it can be conveniently used for a touch panel cover of a liquid crystal display device.

  Furthermore, according to the touch panel type liquid crystal display device according to the tenth aspect of the present invention, it corresponds to the opening region of the film insert molded product produced by the production method according to any one of the first to eighth aspects. Since the touch panel means is provided on the side, the touch panel liquid crystal display device provided with the film as a protective cover can be provided by appropriately touching the touch panel means when the film is pressed with a touch pen or the like.

Sectional drawing which shows simply one Embodiment of a touch-panel-type liquid crystal display device. The perspective view which looked at the cover member of the liquid crystal display device of FIG. 1 from the plane side. The perspective view which looked at the cover member of FIG. 2 from the bottom face side. Sectional drawing by the IV-IV line in FIG. The manufacturing process figure which shows the flow of manufacture of the cover member of FIG. The figure for demonstrating the printing process in the manufacturing process of FIG. The figure for demonstrating the film extraction process in the manufacturing process of FIG. The figure for demonstrating the forming process in the manufacturing process of FIG. The figure for demonstrating the makeup | decoration removal process in the manufacturing process of FIG. The figure for demonstrating a state when an intermediate film product is mounted | worn with the concave mold in the insert molding process in the manufacturing process of FIG. The elements on larger scale which show the edge part of the intermediate film goods in FIG. The figure for demonstrating the state which attached the frame member to the convex-shaped shaping | molding die in the insert molding process. The figure for demonstrating the state which match | combined the concave mold and the convex mold in the insert molding process.

  Hereinafter, a film insert molded product according to the present invention, a manufacturing method thereof, and a touch panel type liquid crystal display device including the same will be described with reference to the accompanying drawings. FIG. 1 is a cross-sectional view schematically showing an embodiment of a touch panel type liquid crystal display device, and FIG. 2 is a plan view of a cover member (that is, a film insert molded product of the present invention) of the liquid crystal display device of FIG. 3 is a perspective view of the cover member of FIG. 2 viewed from the bottom side, FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 2, and FIG. 6 is a manufacturing process diagram showing a flow of manufacturing the cover member of FIG. 2, FIG. 6 is a diagram for explaining a printing process in the manufacturing process of FIG. 5, and FIG. 7 is a film removing process in the manufacturing process of FIG. 8 is a diagram for explaining the forming process in the manufacturing process of FIG. 5, and FIG. 9 is a diagram for explaining the makeup removal process in the manufacturing process of FIG. FIG. 10 shows an inserter in the manufacturing process of FIG. It is a figure for demonstrating a state when an intermediate film product is mounted | worn with a concave mold in a shaping | molding process, FIG. 11 is the elements on larger scale which expand and show the edge part of the intermediate film product in FIG. 10, and its vicinity. FIG. 12 is a diagram for explaining a state in which the frame member is attached to the convex mold in the insert molding process, and FIG. 13 is a combination of the concave mold and the convex mold in the insert molding process. It is a figure for demonstrating a state.

  In FIG. 1, the illustrated liquid crystal display device 2 is a touch panel type that can be input using a touch pen (not shown) or the like, and can be applied to, for example, a mobile terminal, a mobile phone, or the like. The liquid crystal display device 2 includes a box-shaped device housing 4 having an open upper surface. The liquid crystal display means 6 and the touch panel means 8 are built in the device housing 4 so as to cover the upper surface opening of the device housing 4. A cover member 10 is attached. The liquid crystal display means 6 is known per se for displaying various types of information, and a touch panel means 8 is disposed above the liquid crystal display means 6. The touch panel means 8 may also be a well-known one. For example, a glass substrate 12 disposed on the upper side of the liquid crystal display means 6 and a film substrate 14 disposed on the upper side facing the glass substrate 12 are provided. A lower electrode film 16 is provided on the inner surface (upper surface in FIG. 1) of the glass substrate 12, and an upper electrode film 18 is provided on the inner surface (lower surface in FIG. 1) of the film substrate 14. 16 and the upper electrode film 18 are disposed at a predetermined interval, for example, via a plurality of dot spacers (not shown). The film substrate 14 is flexible, and is bent downward when pressed with a touch pen or the like, and the upper electrode film 18 is brought into contact with the lower electrode film 16 at the pressed portion by this bending. The coordinates can be detected in the same manner as in the past. The glass substrate 12 and the surface of the liquid crystal display device 6 are in close contact via a transparent sheet member 17 (or resin layer).

  The cover member 10 includes a resin frame portion 22 formed of a synthetic resin, and a transparent or translucent film 24 provided on the surface of the resin frame portion 22, and the film 24 is formed by insert molding which will be described later. 22 is integrally provided over the entire surface. In this embodiment, an annular protrusion 26 that protrudes upward is provided at the upper end portion that defines the opening of the device housing 4, and the cover member 10 (specifically, resin resin) is provided so as to fit the annular protrusion 26. The outer peripheral part of the frame part 22) is mounted. When the cover member 10 is mounted in this manner, as shown in FIG. 1, the film 24 covers the touch panel means 8 and can prevent entry of dust, moisture, etc. into the apparatus housing 4, and a Dutch pen or the like can be used. Direct contact with the touch panel means 8 can be prevented.

  2 and 4 together with FIG. 1, the device housing 4 has a rectangular shape. The cover member 10 (specifically, the resin frame portion 22) corresponds to the outer shape of the device housing 4. The outer shape is also formed in a rectangular shape. In this embodiment, the resin frame portion 22 has a rectangular upper wall 26 and four side walls 28 extending downward from four side portions of the upper wall 26, and the four side walls 28 are annular projections 26 of the apparatus housing 4. It is attached to. The upper wall 26 is provided with an opening 30 in almost the entire region except for the peripheral edge thereof, and a frame member 32 is provided on the inner peripheral portion of the opening 30. The opening 30 of the upper wall 26 has a rectangular shape. In this connection, the outer shape of the frame member 32 is also rectangular, and the rectangular opening 30 of the resin frame portion 22 is formed by the inner peripheral surface of the frame member 32. Is stipulated. In this embodiment, the opening 30 is rectangular. However, the opening 30 may have an appropriate shape such as a square shape, a circular shape, or an oval shape. In this case, the frame member has a square shape corresponding to the shape of the opening. It is desirable to use a circular shape or an elliptical shape.

  In this embodiment, a print layer 36 is provided in a predetermined region (specifically, the peripheral edge portion) of the inner surface of the film 24 in order to form the opening region 34, and the print layer 36 allows the cover member 10 to be formed. The resin frame portion 22 and the frame member 32 are covered. Accordingly, an opening area 34 defined by the printing layer 36 is exposed from the outside of the cover member 10, and the opening area 34 functions as a display window of the liquid crystal display device 2. Thus, the touch panel means 8 is input.

  Next, with reference to FIG. 5, the manufacturing method of the cover member 10 mentioned above is demonstrated. In the following description, the cover member 10 will be described as a film insert molded product. However, in order to facilitate understanding, the same members as those in FIGS.

  In FIG. 5, in order to manufacture the film insert molded article 10 (cover member), printing is performed on one side of the transparent film 42 to form a printing layer 44 (printing step S1). PET (film, PC (polycarbonate) film, acrylic film, etc.) can be used as the transparent film 42. In this printing step, as shown in FIG. For example, black, white, red, or the like is printed on the region 46, and printing is performed in this manner to form a rectangular opening region 34 at the center of the predetermined region 46. This opening region 34 is the film insert molded article 10. In this embodiment, the printing layers 44 of a predetermined area are formed at eight positions at intervals on one transparent film 42, but an appropriate number corresponding to the size of the transparent film 42 is used. The printing layer 44 can be printed at a time by printing by screen printing, offset printing, or the like. It can be.

  Next, a binder layer (not shown) is formed on the surface side of the printing layer 44 of the transparent film 42 (binder layer forming step S2). This binder layer is preferably formed so as to overlap the printing layer 44. The binder layer functions as an adhesive for the molding resin (resin frame portion 22) and the frame member 32. During the insert molding, the binder layer dissolves by the heat of the molten resin to become an adhesive, and the printing layer 44, the molding resin, and the frame member. Adhesion with 32 is performed.

  Next, the transparent film 42 is subjected to a film punching process to form a film piece 48 including a predetermined region 46 (film punching step S3). In this film punching step S3, for example, it can be performed by punching using a press die (not shown) or the like, and by performing punching as shown by a one-dot chain line 50 in FIG. The film piece 48 shown can be formed.

  Thereafter, the film piece 48 shown in FIG. 7 is subjected to forming to form an intermediate film piece 50 shown in FIG. 8 (forming step S4). In this forming process, the film piece 50 is preheated to, for example, 150 to 190 ° C., the heated film piece 50 is set in a press die (not shown), and the forming process is performed by the press die. The intermediate film piece 48 having the shape shown in FIG. 8 can be formed. In the intermediate film piece 48, the predetermined region 46 provided with the printing layer 44 has a rising portion 51 (a portion corresponding to the side wall 28 of the film insert molded product 10) and a flat portion 52 (film insert molded product) following the rising portion 51. 10 to the peripheral edge of the upper wall 26), and can be formed into a shape that is substantially close to the outer shape of the film insert molded article 10. For this forming, for example, a manufacturing method disclosed in Japanese Patent No. 4073470 can be used.

  Next, the intermediate film piece 48 shown in FIG. 8 is punched to remove unnecessary portions to form an intermediate film product 54 as shown in FIG. 9 (decoration removing step S5). Also in this makeup removal step S5, as in the film removal step S3, for example, the intermediate film piece 48 is subjected to die cutting using a press die (not shown) or the like, and the flange 56 that spreads outside is removed. 9 can form the intermediate film product 54 shown in FIG. 9, and the intermediate film product 54 thus formed is formed in substantially the same shape as the film insert molded product 10, and is formed on the side wall 28 of the film insert molded product 10. A corresponding rising portion 51 and a flat portion 52 corresponding to the upper wall 26 are provided.

  Thereafter, the intermediate film product 54 is insert-molded by using the concave mold 56 and the convex mold 58 to form the above-described film insert molded product 10 (insert molding step S6). As shown in FIG. 10, the concave mold 56 is provided with a concave cavity portion 60 corresponding to the outer shape of the intermediate film product 54 on the die joining surface 59, and the intermediate film product 54 is formed on the concave cavity portion 60. It is installed so as to fit.

  The depth D of the concave cavity portion 60 of the concave mold 56 is preferably formed so as to be somewhat larger than the height H of the intermediate film product 54 (D> H). In the state where the intermediate film product 54 is mounted, as shown in FIG. 11, the outer peripheral edge of the intermediate film product 54 is somewhat lower than the die joining surface 59 of the concave mold 56, and the intermediate film product 54 has a concave shape. It is accommodated in the cavity part 60.

  Further, as shown in FIG. 12, the convex mold 62 is provided with a first convex portion 66 on the joint surface 64, and an annular mounting concave portion 65 is provided at the tip of the first convex portion 66, The frame member 32 is attached to the annular attachment recess 65, and in this attached state, the frame member 32 is accommodated in the annular attachment recess 65 and does not protrude in the distal direction or the radial direction. As shown in FIG. 13, the first convex portion 66 and the frame member 32 are intermediate in the state in which the concave mold 56 and the convex mold 58 are combined and their mold joining surfaces 59 and 64 are joined. There is no cavity into which the molten resin flows between the first projecting portion 66 and the front end surface of the frame member 32 and the intermediate film product 54 attached to the concave mold 62 while being pressed against the inner surface of the film product 54. However, this part is not resin-molded.

  In the state where the annular second convex portion 68 is provided around the first convex portion 66 of the convex mold 58 and the mold joining surfaces 59 and 64 of both the molds 56 and 58 are joined, A cavity 70 into which molten resin flows is defined between the second convex portion 68 of the convex mold 58 and the concave cavity portion 60 of the concave mold 56 (the intermediate film product 54 attached thereto). The cavity 70 corresponds to the shape of the resin frame portion 22 of the film insert molded product 10. The second convex portion 68 is provided with a plurality of injection ports 72 (one of which is shown in FIG. 13) at intervals in the circumferential direction, and the molten resin is injected into the cavity 70 through these injection ports 72. Is done.

  In the insert molding step S <b> 6, when the molten resin is injected through the injection port 72 by combining the concave mold 56 with the intermediate film product 54 and the convex mold 58 with the frame member 32, the molten resin enters the cavity 70. The molten resin is flow-filled and insert-molded, and this molten resin is cooled and solidified to form the film insert molded product shown in FIGS. 1 to 4, that is, the cover member 10 as required.

  As shown in FIG. 13, the injection port 72 of the convex mold 58 opens to the tip surface of the second convex portion 68 (specifically, the portion facing the flat portion 52 of the intermediate film product 54). By arranging the injection port 72 in this way, the molten resin injected through the injection port 72 is formed in the outer peripheral portion of the intermediate film product 54, that is, in a convex shape as shown by the arrow in FIG. The outer peripheral portion of the intermediate film product 54 is pulled outwardly toward the convex mold 58 by the flow of the resin, and as a result, the intermediate film product 54 is stretched. Insert molding can be done cleanly. Further, the intermediate film product 54 is stretched somewhat by the flow of the molten resin, and the depth D of the concave cavity portion 60 of the concave mold 56 is larger than the height H of the intermediate film product 54. Since the outer peripheral portion of the intermediate film product 54 does not protrude outward even if it extends somewhat in this way, the intermediate film product 54 (film 24) becomes a resin frame after molding. The surface of the portion 22 is covered cleanly.

  When the molten resin is injected and injection-molded in this way, the binder layer (not shown) is dissolved by the heat of the molten resin to become an adhesive, and this adhesive causes the printing surface of the intermediate film product 54 and the resin (resin frame). Part 22) and the printing surface of the intermediate film product 54 and the frame member 32 are bonded, and the intermediate film product 54 and the frame member 32 are integrally formed with resin (resin frame part 22). Is done.

  Since the frame member 32 is bonded to the intermediate film product 54 via the binder layer at the time of insert molding, it has the following characteristics. Although the molding resin (resin frame portion 22) and the intermediate film product 54 are thermally contracted during cooling after molding, the frame member 32 is fixed to the intermediate film product 54, so that the central portion of the intermediate film product 54 (that is, the frame member). The thermal contraction of the portion surrounded by 32 is effectively suppressed, whereby the central portion can be kept neat and the area of the central portion can be increased. As a result, when the molded product (cover member 12) is completed, the opening region 34 surrounded by the frame member 32 can be maintained in a flat state free of undulations, etc., and moderately when pressed with a touch pen or the like. Can be bent.

  In order to effectively suppress the heat shrinkage of the intermediate film product 54, it is desirable that the heat shrinkage rate of the frame member 32 is smaller than the heat shrinkage rate of the intermediate film product 54 (that is, the transparent film 42). The frame member 32 can be formed from a metal material such as aluminum, an aluminum alloy, stainless steel, or the like.

  Moreover, when insert-molding using the intermediate film product 54 of such a form, it is preferable that the thermal contraction rate in the longitudinal direction is larger than the thermal contraction rate in the direction perpendicular to the longitudinal direction. In general, in a film manufacturing process, a film is pulled in the longitudinal direction and stretched, and then pulled in a lateral direction (a direction perpendicular to the longitudinal direction) to form a film having a predetermined width in a roll shape. When such a roll-shaped film is used, the heat shrinkage rate in the longitudinal direction that is long in the roll shape is larger than the heat shrinkage rate in the width direction. Considering such characteristics, when a lobed film is cut as shown in FIG. 7 and used as a film piece 48, the longitudinal direction of the film piece 48 (film) (up and down in FIGS. 7 to 9). Direction) is made larger than the heat shrinkage rate in the lateral direction (left and right direction in FIGS. 7 to 9), in other words, the vertical direction in FIGS. It is desirable to form the predetermined printing layer 44 on the transparent film 42 so that the horizontal direction in FIGS. With this configuration, a large tensile force acts in the longitudinal direction by the frame member 32 at the central portion of the intermediate film product 54 (that is, the portion surrounded by the frame member 32) during cooling after molding. As a result, it is possible to more effectively suppress the occurrence of undulations and achieve a beautiful state.

  In order to cause such a tensile force to act on the central portion of the intermediate film product 54 by the frame member 32, it is preferable to use a transparent film 42 (intermediate film product 54) having a large thermal shrinkage, and JIS C2318. It is desirable to use one having a heat shrinkage ratio of 1% or more.

  As described above, the film insert molded product 10 (cover member) as shown in FIGS. 1 to 4 can be formed by injection molding. Such a cover member can be conveniently used as the cover member 10 of the touch panel means 8 of the liquid crystal display device 2. In this case, the opening area of the cover member and the touch panel means 8 may be fixed using a sheet-like or liquid adhesive. Further, the present invention is not limited to such applications, and can be widely applied to a cover member of a normal liquid crystal display device, a cover member of a mobile phone, a cover member of various operation switches, and the like.

  In order to give various functions to the film 24 of the cover member 10 (film insert molded product), for example, it can be configured as follows. For example, in order to give the film 24 an anti-scratch function, a hard coat layer may be provided as a functional layer on the other surface of the film 24 (the surface opposite to the surface on which the printing layer 44 is formed). In order to provide an antireflection function, an antireflection layer may be provided on the other surface of the film 24 as a functional layer. In order to provide a plurality of these functions, a plurality of functional layers may be provided. May be.

Such a functional layer (hard coat layer or antireflection layer) is formed before the printing step S1, between the printing step S1 and the binder layer forming step S2, or after the binder layer forming step S3. It can be provided easily and easily by providing a functional layer at the stage of such a film.
Further, in order to increase the heat resistance of the molding resin (resin frame portion 22), it is preferable to contain glass fibers in a proportion of 10 to 25% by weight in the molding resin (molten resin at the time of insert molding).

  The embodiments of the film insert molded article according to the present invention, the manufacturing method thereof, and the liquid crystal display device including the same have been described above, but the present invention is not limited to these embodiments and departs from the scope of the present invention. Various changes or modifications can be made without any problem.

  For example, in the above-described insert molding process, an annular mounting recess is provided at the tip of the first convex portion of the convex mold, and a frame member is attached to the annular mounting recess. Alternatively, the annular mounting concave portion may be omitted, and the frame member may be mounted so as to protrude radially outward at the tip portion of the first convex portion.

  Further, for example, in the above-described embodiment, the description has been made by applying to the resistive film type touch panel as the touch panel means. However, the present invention is not limited to this, and the same applies to a capacitance type touch panel known per se. can do. In that case, it is good to give the functionality of a gas barrier to a film.

2 Liquid crystal display device 4 Device housing 6 Liquid crystal display means 8 Touch panel means 10 Cover member (film insert molded product)
22 resin frame part 24 film 32 frame member 34 opening area 36 printing layer 54 intermediate film product 56 concave mold 58 convex mold 66 first convex 68 annular mounting concave 70 cavity

Claims (10)

  A printing step of forming a printing layer by performing printing to form an opening region in a predetermined region on one side of the transparent or translucent film; a binder layer forming step of forming a binder layer on the surface side of the printing layer; A forming process for forming the film on which the printed layer and the binder layer are formed into a predetermined shape, a makeup removing process for forming an intermediate film product by performing a punching process on the film after the forming process, and after the makeup removing process The intermediate film product is mounted in the concave mold, and a frame member having a shape corresponding to the opening peripheral area of the opening region is mounted on the convex portion of the convex mold, and then the concave mold and the convex And an insert molding process in which a molten resin is poured into a cavity defined between the mold and the mold and the resin molding is performed. Method of producing a film insert molding to.   The method of manufacturing a film insert molded article according to claim 1, wherein the thermal contraction rate of the frame member is smaller than the thermal contraction rate of the film.   The film insert according to claim 1 or 2, wherein the film has a substantially rectangular shape, and a thermal shrinkage rate in a longitudinal direction of the film is larger than a thermal shrinkage rate in a direction perpendicular to the longitudinal direction. Manufacturing method of molded products.   The said opening area | region is rectangular shape, The outer shape of the said frame member is a rectangular shape corresponding to the said opening peripheral region of the said opening area | region, The manufacture of the film insert molded article of Claim 3 characterized by the above-mentioned. Method.   5. The annular mounting recess is provided at a tip portion of the convex portion of the convex mold, and the frame member is attached to the annular mounting recess. Manufacturing method of film insert molded product.   The depth of the concave cavity portion of the concave mold is somewhat larger than the height of the intermediate film product, and the molten resin that has flowed into the cavity from the injection port is the convex mold on the outer peripheral side of the intermediate film product. The method for producing a film insert molded article according to any one of claims 1 to 5, wherein the outer peripheral portion of the intermediate film article is pulled toward the convex mold by this flow.   The method for producing a film insert molded article according to any one of claims 1 to 6, wherein the resin used for resin molding contains glass fibers at a ratio of 10 to 25% by weight.   A functional layer forming step of forming a functional layer for imparting a function to the other surface of the film before the printing step, between the printing step and the binder layer forming step, or after the binder layer forming step. The method for producing a film insert molded product according to claim 1, wherein the method is performed.   It is a film insert molded product manufactured by the manufacturing method according to any one of claims 1 to 8, wherein an opening region formed in a predetermined region on one side of a transparent or translucent film is formed flat. Characteristic film insert molded product.   A film insert molded product manufactured by the manufacturing method according to claim 1, touch panel means disposed below the film insert molded product corresponding to the opening region of the film insert molded product, and the touch panel And a liquid crystal display means disposed on the lower side of the means.

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