JP2011093243A - Resin molding with insert material and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin molding with a resin part around an insert material and improved in strength and beautiful appearance, and a method for producing the resin molding. <P>SOLUTION: The resin molding includes a sheet material 4 having a recess, the plate-shaped insert material 3 arranged in the recess and whose back is adhered to the surface of the sheet material 4, and a resin part 7 formed annularly on the back of the sheet material 4 and around the insert material 3 by injection molding to make the surface of the sheet material 4 closely contact to the side face of the insert material 3. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a resin molded product in which a resin portion is formed so as to surround the outer periphery of a transparent insert material, and a method for manufacturing the same.

  Conventionally, there is a resin molded product in which a resin portion is formed so as to surround the outer periphery of a transparent insert material such as glass. However, since the joint between the insert material and the resin part formed on the outer periphery of the insert material is generally not so strong, when an external force such as a bending force acts on the resin molded product, the joint between the two is loose. Thus, the insert material may come off the resin part. In view of the above, as shown in FIG. 14, there is one in which a receiving portion of the insert material 3 is formed in the resin portion 7 to strengthen the lower support of the insert material 3 (see Patent Document 1). Further, as a resin molded product that has been decorated, as shown in FIG. 15, there is a resin molded product in which a decorative layer 12 a is transferred to the surface of the resin portion 7 around the insert material 3 (see Patent Document 2). ).

JP 2009-154479 A JP 2005-144986 A

  In the resin molded product shown in FIG. 14, since the receiving part of the insert material 3 is formed in the resin part 7, the thickness of the whole resin molded product becomes thick correspondingly. Moreover, when using the insert material 3 as a display part, if opaque resin is used for the resin part 7, the part on which the insert material 3 and the resin part 7 are laminated cannot be used as the display part. The area as the display unit is reduced. In the resin molded product shown in FIG. 15, the decorative transfer layer 12a formed on the resin portion 7 on the surface of the resin molded product generates burrs on the exposed surface of the insert material 3 such as glass, which impairs the appearance of the resin molded product. There was a thing.

  An object of the present invention is to provide a resin molded product having a resin portion around an insert material and having improved strength and aesthetics, and a method for manufacturing the same.

The first characteristic configuration of the resin molded product according to the present invention is a sheet material having a recess,
A plate-like insert material disposed in the recess and having a back surface adhered to the surface of the sheet material;
A resin portion formed in an annular shape by injection molding around the back surface of the sheet material and around the insert material so that the surface of the sheet material is in close contact with the side surface of the insert material.

  With this configuration, the insert material of the resin molded product is disposed in the concave portion of the sheet material with its back surface adhered to the surface of the sheet material. And since the resin part is annularly formed by injection molding so that the surface of the sheet material is in close contact with the side surface of the insert material, the side surface of the insert material is caused by the shrinkage force of the resin that acts during the injection molding of the resin part. The sheet material positioned at the position is pressed toward the insert material, and the degree of adhesion between the side surface of the insert material and the sheet material increases. As a result, the insert material is stably held in the concave portion of the sheet material by adhesion between the back surface of the insert material and the surface of the sheet material and adhesion between the side surface of the insert material and the surface of the sheet material. Moreover, both the bottom surface and the side surface of the insert material are held by the concave portion of the sheet material, and the rigidity of the resin molded product is increased. Furthermore, on the surface side of the resin molded product, the boundary between the insert material and the sheet material becomes clear. For example, the resin does not cover the surface of the insert material, and the appearance is excellent.

  The 2nd characteristic structure of the resin molded product which concerns on this invention exists in the point in which the said sheet | seat material contains the fitting part fitted with the peripheral part of the said insert material.

  By this structure, since the peripheral part of the insert material of a resin molded product and the fitting part of a sheet material fit, the movement to the at least one of the thickness direction of an insert material is suppressed. Therefore, the insert material is more stably held in the recess of the sheet material.

  The 3rd characteristic structure of the resin molded product which concerns on this invention exists in the point by which the back surface of the said insert material and the back surface of the said resin part were set to the same shape.

  With this configuration, the back surface of the resin molded product becomes almost flat, and bonding of a capacitance sensor or the like becomes easy. Also, when the resin molded product is mounted on a housing of an electronic device or the like, it can be easily performed because the back surface of the resin molded product is almost flat. Furthermore, the thickness of the resin molded product can be reduced to the thickness of the insert material, and the application range of the resin molded product is expanded.

  The 4th characteristic structure of the resin molded product which concerns on this invention exists in the point which further provided the decorating layer by which the said resin part was transparent and was shape-transferred simultaneously on the back surface of the said resin part.

  With this configuration, the resin part of the resin molded product is decorated, and the decorative layer visually recognized from the surface side of the resin part becomes a deep design with a transparent resin part interposed therebetween. The appearance of the molded product has been improved. In addition, the decorative layer can also conceal the lower part of the resin portion around the insert material when the resin molded product is mounted on a housing such as an electronic device.

  The 5th characteristic structure of the resin molded product which concerns on this invention exists in the point in which the said sheet | seat material contains a decoration layer in the part corresponding to the surface of the said resin part.

  With this configuration, the periphery of the insert material of the resin molded product could be easily decorated. In addition, since the sheet material includes a decorative layer in a portion corresponding to the surface of the resin portion, the decorative layer is provided from the surface side of the resin molded product over the sheet material even if the resin portion does not have transparency. It can be visually recognized. Furthermore, since the decorative layer of the resin molded product is protected by the sheet material, the decorative layer is not worn.

The first characteristic means of the method for producing a resin molded product according to the present invention is a step of producing a composite insert material by bonding a resin sheet material to a flat insert material,
Arranging the composite insert material so that the insert material contacts the first mold;
Sucking the sheet material of the composite insert material arranged in the first mold and causing the sheet material to follow the first mold;
Clamping the first mold and the second mold to form a resin injection cavity between the second mold and the sheet material;
And a step of injecting a resin into the cavity and molding a resin portion around the insert material so that the sheet material is in close contact with the side surface of the insert material.

  By this characteristic means, a resin molded product in which the resin portion was formed in an annular shape by injection molding on the back surface of the sheet material and around the insert material so that the surface of the sheet material was in close contact with the side surface of the insert material could be manufactured. As a result, as described in the characteristic configuration of the resin molded product according to the present invention, the insert material is bonded by the adhesion between the back surface of the insert material and the surface of the sheet material, and the side surface of the insert material and the surface of the sheet material. Thus, a resin molded product stably retained in the concave portion of the sheet material was obtained.

  In addition, since the composite insert material in which the flat plate-like insert material is bonded to the sheet material is prepared first, and the prepared composite insert material is arranged in the first mold, the insert material according to the composite insert material in the mold is used. And positional deviation between the sheet material and the sheet material are suppressed. Thus, a good resin molded product in which the positions of the insert material and the sheet material in the composite insert material were maintained could be easily manufactured. The sheet material also serves to prevent the insert material from scattering when the insert material is a material that is scattered by receiving an external force such as glass.

  The 2nd characteristic means of the manufacturing method of the resin molded product which concerns on this invention has the process of arrange | positioning a decorating sheet | seat to the said 2nd type | mold before the said 1st type | mold and the said 2nd type | mold clamping. It is in.

  By this characteristic means, the back surface of the resin part is decorated simultaneously with the molding of the resin part. Here, when the resin part has transparency, the decorated part of the resin part becomes a deep design because it is visually recognized through the resin part from the surface side of the resin molded product. Furthermore, the manufactured resin molded product can also conceal the lower part of the resin part by decorating the resin part.

  The third characteristic means of the method for producing a resin molded product according to the present invention is that the sheet material is added to a surface around the portion to which the insert material adheres and opposite to the side to which the insert material adheres. It is in the point which uses the sheet material in which the decoration layer was formed.

  By this characteristic means, since the decorative layer is formed in advance on the sheet material, the periphery of the insert material of the resin molded product can be decorated without separately providing a decorative sheet feeding device on the mold. It was. In this way, the resin molded product can be easily decorated around the insert material, and the injection molding apparatus used for manufacturing the resin molded product can be simplified. Furthermore, since the decorative layer of the manufactured resin molded product is protected by the sheet material, the decorative layer is not worn.

It is a figure which shows the composite insert material which concerns on 1st Embodiment. It is a figure which shows the formation process of the resin molded product which concerns on 1st Embodiment. It is a figure which shows the formation process of the resin molded product which concerns on 1st Embodiment. It is a figure which shows the formation process of the resin molded product which concerns on 1st Embodiment. It is a figure which shows the shaping | molding process of the resin molded product which concerns on 1st Embodiment. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a resin molded product according to the first embodiment, (a) is the surface of the resin molded product (surface on which the insert material is exposed), and (b) is the back surface of the resin molded product. It is a figure which shows the shaping | molding process of the resin molded product which concerns on 2nd Embodiment. It is a figure which shows the shaping | molding process of the resin molded product which concerns on 2nd Embodiment. It is a figure which shows the shaping | molding process of the resin molded product which concerns on 2nd Embodiment. It is a figure which shows the shaping | molding process of the resin molded product which concerns on 2nd Embodiment. It is a figure which shows the resin molded product which concerns on another embodiment. It is a figure which shows the resin molded product which concerns on another embodiment. It is a figure which shows the resin molded product which concerns on another embodiment. It is sectional drawing which shows the resin molded product provided with the conventional transparent insert material. It is sectional drawing which shows the resin molded product provided with the conventional transparent insert material.

Hereinafter, the resin molded product according to the present invention and the manufacturing process of the resin molded product will be described with reference to FIGS.
The resin molded product according to the present invention includes a sheet material 4 having a recess, a flat insert material 3 that is disposed in the recess of the sheet material 4, and has a back surface bonded to the surface of the sheet material 4, and the surface of the sheet material 4. It is composed of a resin part 7 formed in an annular shape by injection molding around the back surface of the sheet material 4 and around the insert material 3 so as to be in close contact with the side surface of the insert material 3. It is manufactured after.

[First Embodiment]
[Process for forming composite inserts]
The insert material 3 is adhered to a predetermined position of the sheet material 4 (around the center of the sheet material 4) with an adhesive layer 5 (pressure-sensitive adhesive such as a double-sided tape) to produce a composite insert material 6. The insert material 3 is, for example, transparent glass, the peripheral portions of both surfaces are chamfered, and the thickness is, for example, 0.7 mm to 1.5 mm. As the insert material 3, a synthetic resin such as acrylic may be used, and it may not be transparent. In the present invention, the “transparent” of the insert material 3 only needs to be able to visually recognize the other side of the transparent object, and includes translucent. The same applies to “transparent” of the sheet material 4 and the resin portion 7, and includes translucent.

  The sheet material 4 is, for example, a resin such as transparent acrylic, polycarbonate, polychlorinated terephthalate (PET), and the thickness of the sheet material 4 is, for example, 100 μm to 200 μm. Note that the sheet material 4 may not be transparent. The sheet material 4 also serves to prevent the insert material 3 from scattering when the insert material 3 is a material that is scattered by receiving an external force such as glass.

Next, the metal mold | die used for manufacture of the resin molded product which concerns on this invention is demonstrated.
[First type]
The first mold 1 is formed with a recess for inserting the composite insert material 6. An end portion of the first mold 1 is provided with a position fixing portion 1 b for fixing the position of the composite insert material 6. The position fixing portion 1b is, for example, a protrusion that can be inserted into the hole 4a of the sheet material 4 of the composite insert material 6. Such protrusions are formed at a plurality of locations.

  A suction part 8 is provided in the first mold 1, and the sheet material 4 of the composite insert material 6 disposed in the first mold 1 is sucked by the suction part 8, and the sheet material 4 of the first mold 1 is sucked. Along the recess. In addition, the suction portion 8 is used as a portion for inserting a non-illustrated push member or supplying high-pressure air in order to take out the formed resin molded product P from the first mold 1. Prior to the suction of the sheet material 4, the periphery of the sheet material 4 is held in close contact with the first mold 1 by a clamp (not shown).

[Type 2]
The second mold 2 is clamped with the first mold 1 to form the cavity 9. For example, the second mold 2 and the first mold 1 are formed so as to be relatively movable in a direction perpendicular to the approaching / separating direction of both. Thus, when the composite insert material 6 is mounted on the first mold 1, the second mold 2 is kept waiting at another position, and the second mold 2 can be clamped after the composite insert material 6 is mounted. It is good to move to.

[Resin molding process]
As shown in FIG. 2, the composite insert material 6 is disposed at a predetermined position of the first mold 1 so that the insert material 3 is in contact with the first mold 1 using a manipulator or the like not shown. The position fixing portion 1 b of the first mold 1 is engaged with the hole 4 a of the sheet material 4 of the composite insert material 6. Thereafter, the periphery of the sheet material 4 is held in close contact with the first mold 1 by a clamp (not shown).

  Next, as shown in FIG. 3, after the sheet material 4 is heated by the heater 11 attached to the manipulator, the sheet material 4 is vacuum-sucked by the suction part 8 of the first mold 1, and the surface of the sheet material 4 is inserted. While being along the side surface of the material 3, it is also along the first mold 1.

  Next, as shown in FIG. 4, the first mold 1 is brought close to the second mold 2 and the mold is clamped. At this time, the second mold 2 and the sheet material 4 on the back surface side of the insert material 3 come into contact with each other, and a cavity 9 is formed between the sheet material 4 and the second mold 2.

  Next, resin is injected into the cavity 9 from the gate 10 formed in the second mold 2, and the resin portion 7 is molded so that the sheet material 4 is in close contact with the side surface of the insert material 3. After the resin is cured to some extent, the first mold 1 is separated to release the mold clamping, and the molded product is removed from the first mold 1. Thereafter, the sheet material 4 on the outer periphery of the molded product is cut to obtain a resin molded product P (FIG. 5).

  6A and 6B are perspective views of the resin molded product P. FIG. 6A shows the front surface of the resin molded product (surface on which the insert material is exposed), and FIG. 6B shows the back surface of the resin molded product. As shown in FIG. 6, the resin molded product P is a resin portion that is injection-molded on the back surface of the sheet material 4 and around the insert material 3 so that the surface of the sheet material 4 is in close contact with the side surface of the insert material 3. 7 is provided. Thus, a resin molded product P in which the insert material 3 was stably held in the concave portion of the sheet material 4 could be obtained.

  Although the thickness of the resin part 7 of the resin molded product P can be freely set, for example, as shown in FIG. 6, when the back surface of the insert material 3 and the back surface of the resin part 7 are set to be flush with each other, The back surface of the resin molded product P has a flat plate shape, which makes it easy to attach a capacitance sensor or the like. Further, when the resin molded product P is mounted on a housing of an electronic device or the like, it can be easily performed because the back surface of the resin molded product P is flat. Furthermore, the thickness of the resin molded product P can be reduced to the thickness of the insert material 3, and the application range of the resin molded product P is expanded.

  Note that when the insert material 3 is a synthetic resin, the rigidity is usually low. Therefore, if the insert material 3 having a small thickness is used, the insert material 3 may be deformed due to the shrinkage force of the resin that acts during injection molding. There is. However, when the insert material 3 is made of glass, the hardness is sufficient. Therefore, even if the insert material 3 having a small thickness is used, the possibility that the insert material 3 is deformed by the shrinkage force of the resin that acts during injection molding is low. . Therefore, it is easier to reduce the thickness of the resin molded product P when glass is used as the insert material 3.

[Second Embodiment]
A second embodiment of the present invention is shown in FIGS. In the embodiment, a decorative film (transfer foil) 12 is disposed on the second mold 2 as an example of a decorative sheet (FIG. 7). Although illustration is omitted, the second mold 2 may be provided with a suction portion that sucks the decorative film 12 toward the cavity surface of the second mold 2.

  As shown in FIG. 7, the composite insert material 6 is arranged at a predetermined position of the first mold 1 so that the insert material 3 contacts the first mold 1 using a manipulator or the like not shown. The position fixing portion 1 b of the first mold 1 is engaged with the hole 4 a of the sheet material 4 of the composite insert material 6. Thereafter, the periphery of the sheet material 4 is held in close contact with the first mold 1 by a clamp (not shown).

  Next, as shown in FIG. 8, after the sheet material 4 is heated by the heater 11 attached to the manipulator, the sheet material 4 is vacuum-sucked by the suction part 8 of the first mold 1 and the surface of the sheet material 4 is inserted. The first mold 1 and the second mold 2 are clamped after the decorative film 12 is arranged at a predetermined position of the second mold 2 along the first mold 1 along the side of the material 3. Resin is injected from the gate 10 (FIG. 9). At this time, the decorative layer 12 a of the decorative film 12 is transferred to the back surface of the resin portion 7 simultaneously with the molding of the resin portion 7, and the decorative layer 12 a is formed on the back surface of the resin portion 7 of the resin molded product P. In this case, the resin part 7 of the resin molded product P is preferably transparent.

  Thereafter, the molded product is taken out in the same manner as in the first embodiment, and unnecessary sheet material 4 is cut to obtain a resin molded product P (FIG. 10). The resin molded product P includes a resin part 7 that is injection-molded around the back surface of the sheet material 4 and around the insert material 3 so that the surface of the sheet material 4 is in close contact with the side surface of the insert material 3. 7 is provided with a decorative layer 12a simultaneously formed and transferred to the back surface. If the resin part 7 is transparent, the decorative layer 12a is visually recognized from the surface side of the resin part 7, and the transparent resin part 7 is interposed to provide a deep design, improving the aesthetics of the resin molded product P. Let

  The decorative film 12 disposed in the second mold 2 has a decorative layer 12 a fused to the resin portion 7 and a handling base sheet 12 b integrated with each other, and the decorative layer 12 a is integrated with the resin portion 7. The base sheet 12b is peeled off at an arbitrary step after the transfer. The decorative layer 12a generally has a peeling protective layer that is the outermost layer of the final resin molded product P, and an adhesive layer that is fused to the resin layer, and generally between the peeling protective layer and the adhesive layer. Is provided with a pattern layer.

  Examples of the material of the base sheet 12b include a resin sheet such as a polypropylene resin, a polystyrene resin, a polyamide resin, a polyester resin, an acrylic resin, and a polyvinyl chloride resin, a metal foil such as an aluminum foil and a copper foil, Cellulose-based sheets such as glassine paper, coated paper, and cellophane, or a composite sheet of these can be used. Moreover, in order to improve the peelability of the base sheet 12b, a release layer made of an aminoalkyd resin or the like may be formed between the base sheet 12b and the decorative portion 12a. The thickness of the base sheet 12b is preferably 5 to 500 μm.

  Examples of the material for the release protective layer include acrylic resins, polyester resins, polyvinyl chloride resins, cellulose resins, rubber resins, polyurethane resins, polyvinyl acetate resins, and vinyl chloride-vinyl acetate. Copolymers such as ethylene-based copolymer resins and ethylene-vinyl acetate copolymer resins can be used. When the peel protection layer requires hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used.

  For the adhesive layer, a material having a high affinity with the resin to be fused should be selected. For example, when the material of the transfer object is an acrylic resin, an acrylic resin may be used. In addition, when the material of the transferred material is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, A polyamide resin or the like may be used. Further, when the material of the resin molded product is a polypropylene resin, a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, or a coumarone indene resin may be used. The thickness of the adhesive layer is preferably 0.5 to 50 μm.

[Another embodiment]
(1) In the above embodiment, the sheet material 4 is in close contact with the side surface of the insert material 3, but as shown in FIG. 11, the sheet material 4 is fitted to the peripheral portion of the insert material 3. Alternatively, the fitting portion 4A may be included. In this way, even if an external force is applied to the resin molded product and the insert material 3 is about to come out to the exposed side, the fitting portion 4A of the sheet material 4 prevents movement of the insert material 3 to the exposed side. The position of 3 is maintained.

(2) In said 2nd Embodiment, although the structure which transfers the decorating layer 12a to the back surface of the resin part 7 using the decorating film 12 (transfer foil) was shown, it replaces with this and shows in FIG. As described above, the sheet material 4 may include the decoration layer 13 in a portion corresponding to the surface of the resin portion 7. The decorative layer 13 includes a design layer, an adhesive layer, and the like, and is formed on the sheet material 4 using various configurations such as printing and adhesion. If it carries out like this, it will become unnecessary to provide a decoration sheet feeding apparatus in a metal mold | die, and the decoration layer 13 can be easily formed around the insert material 3 of the surface side of a resin molded product. Since the decorative layer 13 is formed on the portion corresponding to the surface of the resin portion 7 of the sheet material 4, even if the resin portion 7 does not have transparency, the sheet material 4 passes from the surface side of the resin molded product. The decorative layer 13 can be visually recognized. Furthermore, since the decorative layer 13 of the resin molded product is protected by the sheet material 4, the decorative layer 13 is not worn.

(3) In the above-described embodiment, only one flat insert material 3 is arranged in the resin molded product, but a plurality of insert materials 3 may be arranged as shown in FIG. Moreover, you may make it improve the designability using various metals, stones, etc. as insert material 3 other than glass and an acrylic resin.

  The resin molded product according to the present invention can be widely used for housings of various devices having a display unit of electronic devices, various interior products, exterior products, and the like.

DESCRIPTION OF SYMBOLS 1 1st type | mold 1b Position fixing | fixed part 2 2nd type | mold 3 Insert material 4 Sheet material 4A Fitting part 4a Hole part 5 Adhesive layer 6 Composite insert material 7 Resin part 8 Suction part 9 Cavity 10 Gate 12 Decorating sheets 12a, 13 Decorative layer P Resin molded product

Claims (8)

A sheet material having a recess;
A plate-like insert material disposed in the recess and having a back surface adhered to the surface of the sheet material;
A resin molded product comprising: a resin portion formed in an annular shape by injection molding around the back surface of the sheet material and around the insert material so that the surface of the sheet material is in close contact with the side surface of the insert material.   The resin molded product according to claim 1, wherein the sheet material includes a fitting portion that fits with a peripheral edge portion of the insert material.   The resin molded product according to claim 1 or 2, wherein a back surface of the insert material and a back surface of the resin portion are set to be flush with each other. The resin part is transparent,
The resin molded product according to any one of claims 1 to 3, further comprising a decorative layer that is simultaneously transferred to the back surface of the resin portion.   The said sheet | seat material is a resin molded product in any one of Claims 1-3 containing a decoration layer in the part corresponding to the surface of the said resin part. A process of producing a composite insert material by adhering a sheet material to a flat insert material;
Arranging the composite insert material so that the insert material contacts the first mold;
Sucking the sheet material of the composite insert material arranged in the first mold and causing the sheet material to follow the first mold;
Clamping the first mold and the second mold to form a resin injection cavity between the second mold and the sheet material;
And a step of injecting a resin into the cavity and forming a resin portion around the insert material so that the sheet material is in close contact with a side surface of the insert material.   The manufacturing method of the resin molded product of Claim 6 provided with the process of arrange | positioning a decorating sheet to the said 2nd type | mold before the mold clamping of the said 1st type | mold and the said 2nd type | mold.   The resin molding according to claim 6, wherein the sheet material is a sheet material in which a decorative layer is formed on a surface around a portion to which the insert material adheres and opposite to a side to which the insert material adheres. Product manufacturing method.

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