JP2011056797A - Method of forming prepreg thin film by joining in-mold injection - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of forming a prepreg thin film by joining in-mold injection. <P>SOLUTION: In the method of forming the prepreg thin film by joining in-mold injection, an injection product having an appearance of a pattern or color of the natural or chemical fiber is formed by selecting natural or chemical fiber, applying the solvent-type or hot-melt-type prepreg treatment thereto by using a first thermoplastic resin to form the prepreg thin film, covering the upper surface and the lower surface of the prepreg thin film with a mold releasing film, cutting them to form a resin film, further applying the heating/pressing curing treatment thereto to form a cured resin film, successively applying the heating/pressing treatment thereto in a mold for molding the resin to form a resin film foamed case, placing the resin film foamed case in the mold for injection molding, applying the in-mold injection treatment thereto by utilizing a second thermoplastic resin to form an injection component in the mold for the injection molding by the second thermoplastic resin, and simultaneously completely joining the injection component with the resin film foamed case. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a prepreg thin film combined with a kind of in-mold injection, and in particular, a prepreg treatment is performed on any natural or chemical fiber with a first thermoplastic resin using a solvent type or hot melt type prepreg treatment. A thin film is formed, followed by heat and pressure treatment to form an exquisite resin film with plasticity, natural or chemical fiber patterns and colors, and then heat and pressure molding in a mold, and injection. The present invention relates to a method for injection molding a second thermoplastic resin by placing in a mold and obtaining an injection molded product having a natural or chemical fiber pattern and color coated appearance and having a necessary structure.

  Home appliances, information technology products or traffic tools all have a plastic outer shell, and a high demand for the plastic outer shell is common. In response to the growing market demand for diversified and customized plastic shells, outer shell patterning technologies such as in-mold decoration (IMD) and in-mold transfer (IMR) have been developed.

  In contrast to the market demand for further changes in the appearance and texture of the outer shell, the current ink printing on the film cannot satisfy the market demand. The present invention provides a manufacturing method that can provide a kind of pattern different from many kinds of texture changes and that can combine different plastic parts, and solves the problems of the currently known technology.

  The present invention provides a method of manufacturing a prepreg thin film combined with a kind of in-mold injection, which includes selecting a natural or chemical fiber material and performing a solvent type or hot melt type prepreg treatment using a first thermoplastic resin. And forming a prepreg thin film, covering each of the upper and lower surfaces of the prepreg thin film with a release film, cutting to form a resin film, and further heat and pressure aging to form an aged resin film, Then, heat and pressure treatment is performed in a resin molding die to form a resin film foam case. The resin film foam case is placed in an injection mold, an in-mold injection treatment is performed using a second thermoplastic resin, an injection member is formed in the injection mold using the second thermoplastic resin, and Fully bonded with resin film foam case to form injection product.

  According to the present invention, an injection product having a natural, chemical fiber pattern, pattern or color appearance can be formed.

It is a flowchart of the manufacturing method of the prepreg thin film which combined in-mold injection of the present invention. It is a display figure of the injection product of this invention.

  Please refer to the flowchart of the manufacturing method of the prepreg thin film combined with the in-mold injection of the present invention in FIG. The manufacturing method of the present invention starts at step S100 and then proceeds to step S200 to select a material to be subjected to prepreg processing. The material is a natural or chemical fiber, for example, a natural or chemical fiber having various continuity such as a non-woven fabric, an unwoven fabric, a non-woven fabric, a thin bark, a thin bamboo skin or leather having various colors and patterns.

  Then, it progresses to step S300, performs a solvent type or hot-melt type prepreg process with respect to the material selected by step S200 using a 1st thermoplastic resin, and forms a prepreg thin film, ie, 1st thermoplasticity Resin is uniformly coated on the material, and the material is coated with the first thermoplastic resin. After the surface is heated and dried, the upper surface and the lower surface of the prepreg thin film are coated with a release film, and further cut to a constant area size. A resin film having natural flakes or chemical fibers is formed.

  The first thermoplastic resin is polymethyl methacrylate (PMMA), polyethylimide (PEI), polyurethane (PU), thermoplastic polyurethane (TPU), polyethylsulfone (PES), polyphenylene ether (PPE), polystyrene (PS). Or polyetheretherketone (PEEK).

  Subsequently, the process proceeds to step S400, the resin film is heat-pressed and aged to form an aged resin film, the resin distribution contained in the aged resin film is uniform, the thickness is equal, the surface is smooth, and the resin is smoothed. It is covered and transparent with high gloss and has a pattern or pattern or color of natural or chemical fiber. The temperature of the heat and pressure aging treatment is set to 50 to 180 degrees Celsius, the pressure is set to 2 to 20 kg per square centimeter, maintained for 10 to 40 minutes, and then the process proceeds to Step S500.

  In step S500, the aged resin film is placed in a mold and heated and pressurized, heated to 120 to 200 degrees Celsius, and the pressure in the mold is changed from 2 kg to 20 kg per square centimeter. The degree of vacuum is 50% to 85%, and a resin film foam case is formed.

  Subsequently, the process proceeds to step S600, where the resin film foam case is placed in an injection mold, an in-mold injection process is performed using the second thermoplastic resin, and an injection member is injected into the second thermoplastic resin in the injection mold. The injection member has the necessary protrusions, grooves, ribs and the necessary thickness, and the injection member and the resin film foam case are completely joined to form an injection product. The flow of the manufacturing method of the invention is terminated.

  The second thermoplastic resin is acrylonitrile / butadiene styrene copolymer (ABS), polycarbonate / acrylonitrile / butadiene styrene copolymer (PC / ABS), polycarbonate (PC), polymethyl methacrylate (PMMA), polystyrene (PS), polypropylene. (PP), polyethylene terephthalate (PET), polyoxymethylene (POM), or polyamide (PA).

  In step S200, the selected material may be subjected to a standard process, for example, a calendar process is performed, the material is standardized, and the material is not easily deformed. Increase speed.

  In addition, in step S500, before the heat and pressure treatment in the molding die, the aged resin film is cut to a size slightly larger than the injection molding die and preheated, for example, the molding die. Heat to a temperature 10 to 30 degrees Celsius lower than the temperature of.

  In step S600, before the in-mold injection process, at least one of trimming and punch hole processing may be performed on the resin film foam case first. Among them, water knife, CNC or punch press can be used as processing equipment, thereby improving the appearance quality of subsequent injection products and eliminating the occurrence of fluff or burrs.

  For further understanding of the features of the present invention, please refer to the injection product display diagram of the present invention in FIG. As shown in FIG. 2, the injection product 10 forms a resin film foam case 20 and an injection member 30. Among them, the resin film foam case 20 has an outer casing shape, the injection member 30 has a lining shape, and the resin film foam case 20 and the injection member 30 are completely joined to form the injection product 10. It should be noted that the above-described embodiments are merely illustrated to facilitate the explanation of the features of the present invention, and the resin film foam case 20 and the injection member 30 having different shapes and combinations are both included in the present invention. It belongs to the range.

  The above description is for the purpose of illustrating a preferred embodiment of the invention and is not intended to be limiting in any form to the invention, and is therefore directed to the invention in the spirit of the same invention. Any modification and change belong to the category intended to protect the present invention.

10 Injection product 20 Resin film foam case 30 Injection member

Claims (9)

In the method of manufacturing a prepreg thin film combined with in-mold injection,
In step S100, start
In step S200, a material for prepreg processing is selected, and the material is natural or chemical fiber.
In step S300, the first thermoplastic resin is used to prepreg the selected material, the first thermoplastic resin is impregnated in the solvent type or hot melt type, and the first thermoplastic resin is impregnated. The resin is coated with the material, a prepreg thin film is formed, and the upper surface and the lower surface of the prepreg thin film are respectively coated with a release film, and further cut into a piece of natural or chemical fiber-containing resin. Without film,
In step S400, the resin film is subjected to heat and pressure aging treatment to form an aging resin film,
In step S500, the aged resin film is heated and pressurized in a molding die to form a resin film foam case,
In step S600, the resin film foam case is placed in an injection mold, an in-mold injection process is performed using the second thermoplastic resin, and the second thermoplastic resin is injected into the injection mold in the injection mold. The injection member has the necessary shape, and is completely joined to the resin film foam case to form an injection product,
In step S700, the process ends,
The manufacturing method of the prepreg thin film which combined the injection in the type | mold characterized by including the above step.   The method for manufacturing a prepreg thin film combined with in-mold injection according to claim 1, further comprising performing a standard processing on the selected material in step S200 to form the material and have a property of being difficult to deform. A method for producing a prepreg thin film combined with in-mold injection, wherein the production speed is increased in favor of subsequent prepreg processing.   3. The method for manufacturing a prepreg thin film combined with in-mold injection, according to claim 2, wherein the standard processing is a calendar process.   The method for producing a prepreg thin film combined with in-mold injection according to claim 1, wherein the first thermoplastic resin in step S300 is polymethyl methacrylate (PMMA), polyethylimide (PEI), polyurethane (PU), heat Prepreg combined with in-mold injection, characterized in that it is one of plastic polyurethane (TPU), polyethylsulfone (PES), polyphenylene ether (PPE), polystyrene (PS), or polyetheretherketone (PEEK) Thin film manufacturing method.   The method for producing a prepreg thin film combined with in-mold injection according to claim 1, wherein the heat and pressure aging treatment in step S400 is performed at a temperature of 50 to 180 degrees Celsius and a pressure of 2 to 20 kg per square centimeter, A method for producing a prepreg thin film combined with in-mold injection, wherein the method is performed for 10 to 40 minutes.   2. The method for producing a prepreg thin film combined with in-mold injection according to claim 1, wherein in the heating and pressurizing treatment in step S500, heating is performed from 120 degrees Celsius to 200 degrees Celsius, and the molding mold internal pressure is increased from 2 kg per square centimeter. A method for producing a prepreg thin film combined with in-mold injection, characterized in that the amount of vacuum in the mold is increased from 20% to 85%.   2. The method for producing a prepreg thin film combined with in-mold injection according to claim 1, wherein the aged resin film is cut before heating and pressurizing in the molding mold in step S500, and the injection molding mold is used. A method for producing a prepreg thin film combined with in-mold injection, characterized in that it has a slightly larger size and is preheated to a temperature of 10 to 30 degrees Celsius lower than the temperature of the mold.   2. The method for producing a prepreg thin film combined with in-mold injection according to claim 1, wherein the second thermoplastic resin in step S600 is an acrylonitrile / butadiene styrene copolymer (ABS) or a polycarbonate / acrylonitrile / butadiene styrene copolymer. (PC / ABS), polycarbonate (PC), polymethyl methacrylate (PMMA), polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyoxymethylene (POM), polyamide (PA) A method for producing a prepreg thin film combined with in-mold injection.   2. The method for producing a prepreg thin film combined with in-mold injection according to claim 1, wherein at least one of trimming and punch hole processing is performed on the resin film foam case before injection processing in the injection mold in step S600. A method for producing a prepreg thin film combined with in-mold injection, wherein fuzz or burrs are not generated in the subsequent injection product by performing

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