JP2011126121A - Injection molding method and panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a panel improved in external design by improving the appearance of side end faces in particular, and an injection molding method for molding the panel. <P>SOLUTION: The injection molding method for molding the panel 1 including a rear face layer 3 having structure parts 2 with unevenness, and an outer layer 4 integrally provided on the rear face layer 3 to form an outer surface, includes processes for forming the rear face layer 3 by injection molding, and forming the outer layer 4 on the rear face layer 3 by injection molding. In the process for forming the outer layer 4, the outer layer 4 is formed covering the ends of the rear face layer 3. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an injection molding method and a panel.

  As a resin panel manufactured by injection molding, there is provided a panel having a smooth appearance surface on the front surface side and a structure portion formed of irregularities such as protrusions on the back surface side. As such a panel, in particular, a panel molded by a synthetic resin containing a glittering material is known in order to make the appearance as a decorative surface more beautiful.

  When such a panel is to be injected and molded by injecting molten resin into the mold at a time, the molten resin that flows preceding the structure part side and the molten resin that flows behind the other part are merged. A flow mark or a weld line may occur on the surface side of the panel, resulting in poor appearance. In particular, when a synthetic resin containing a glittering material is used, the flow of the resin in the mold is relatively slow, so that flow marks and weld lines are likely to occur on the surface side of the panel.

  Therefore, as a technique for preventing the occurrence of such a flow mark or weld line, a back surface side having a protrusion is formed, and then smoothed on one surface side (the side opposite to the protrusion) of the back surface side. An injection molding method has been proposed in which a panel (molded product) is formed by forming a front surface side and integrating the back surface side and the front surface side (see, for example, Patent Document 1). In this injection molding method, a first semi-molded product (back side) integrally having a thin plate portion and a protrusion is injection molded, and then a plate-like second half forming a plate portion together with the thin plate portion. The molded product (surface side) is integrally joined to the surface side of the thin plate portion.

JP 2001-225354 A

  However, in the injection molding method of Patent Document 1, a mold that forms a monotonous box-shaped space with a core back is used, and after the first semi-molded product is formed, the core is backed to form a space. By forming the second semi-molded product in the space, a molded product (panel) is obtained. Therefore, a molding line corresponding to the interface between the first semi-molded product by primary molding and the second semi-molded product by secondary molding appears on the side end surface. Therefore, when this molded product is used as, for example, a single plate (panel) as an external part, the side end face where the interface can be seen is exposed, so that the appearance is poor and the appearance design is greatly reduced. There is a problem such as.

  In addition, since the resin is directly filled from the side that becomes the surface of the second semi-molded product, that is, the side that becomes the appearance surface, the appearance surface of the second semi-molded product is formed. Otherwise, the appearance will deteriorate and the appearance design will be greatly reduced as described above.

  The present invention has been made to solve the above-mentioned problems, and the object of the present invention is, in particular, a panel with improved appearance of the side end face and improved appearance design, and an injection molding method for molding the panel. Is to provide.

In order to achieve the above object, an injection molding method of the present invention forms a panel including a back surface layer having an uneven structure portion, and an external layer that is integrally provided on the back surface layer to form an external surface. An injection molding method for
Forming the back layer by injection molding;
Forming the appearance layer on the back layer by injection molding,
In the step of forming the appearance layer, the appearance layer is formed so as to cover an end portion of the back surface layer.

  According to this injection molding method, the outer layer is formed on the rear surface layer having the uneven structure portion so as to cover the end portion of the rear surface layer, so that these interfaces are formed between the rear surface layer and the outer surface layer. Even if the corresponding molding line is formed, the molding line is hidden in the appearance layer by covering the end portion of the back surface layer with the appearance layer. Therefore, the appearance of the side end surface of the panel to be formed can be improved, and the appearance design can be improved.

Moreover, in the said injection molding method, you may make it inject | pour resin from the back surface side of the said back surface layer in the process of forming the said back surface layer, and the process of forming the said external appearance layer.
In this way, even if a gate mark is left when the resin is injected, the gate mark is formed not on the outer layer but on the back side of the back layer, so that the appearance design of the panel is deteriorated. There is nothing.

In the injection molding method, in the step of forming the back layer, the back layer is formed with a resin containing a glitter material, and in the step of forming the appearance layer, the appearance is formed with a resin containing a glitter material. A layer may be formed.
In this way, since the whole is formed of the resin containing the glittering material, it is possible to form a panel with better appearance and excellent appearance design.

Further, in the injection molding method, in the step of forming the appearance layer, the resin is injected from the back side of the back layer, and in the step of forming the appearance layer, the resin is injected from the side surface of the appearance layer. You may do it.
In this way, the resin is injected from the side surface of the outer layer to form the outer layer, so that the injected molten resin collides with the cavity surface, resulting in a disturbance in the flow, which causes the flow to the outer layer. Marks and the like are prevented from occurring.

In this injection molding method, in the step of forming the appearance layer, the appearance layer may be formed of a resin containing a glittering material.
In this way, since the appearance layer is formed of the resin containing the glittering material, it is possible to form a panel having a good appearance and excellent appearance design.

In the panel of the present invention, a panel comprising a back layer provided with a structure having irregularities, and an exterior layer that is integrally provided on the back layer and forms an exterior surface,
The appearance layer is formed so as to cover an end portion of the back surface layer.

  According to this panel, since the appearance layer is formed so as to cover the end portion of the back surface layer having the uneven structure portion, a molding line corresponding to these interfaces is formed between the back surface layer and the appearance layer. Even if it is done, the said shaping | molding line can be hidden with this external appearance layer by covering the edge part of a back surface layer with an external appearance layer. Therefore, this panel has a good appearance at the side end face and an improved appearance design.

In the panel, the appearance layer may be formed of a resin containing a glittering material.
If it does in this way, the appearance about the appearance layer will be good, and therefore the panel will have excellent appearance design.

Moreover, in the said panel, both the said back surface layer and the said external appearance layer may be formed with resin containing the luster material.
If it does in this way, it will become the panel which was good in appearance as a whole, and was excellent in appearance design nature.

(A)-(c) is a schematic block diagram of the panel of this invention. It is principal part side sectional drawing which shows schematic structure of an example of the injection mold which concerns on this invention. It is principal part side sectional drawing of the injection mold for demonstrating the injection molding method of this invention. It is principal part side sectional drawing of the injection mold for demonstrating the injection molding method of this invention. It is principal part side sectional drawing of the injection mold for demonstrating the injection molding method of this invention. It is principal part side sectional drawing which shows schematic structure of an example of the injection mold which concerns on this invention. It is principal part side sectional drawing of the injection mold for demonstrating the injection molding method of this invention. It is principal part side sectional drawing of the injection mold for demonstrating the injection molding method of this invention. It is principal part side sectional drawing of the injection mold for demonstrating the injection molding method of this invention.

Hereinafter, the present invention will be described in detail with reference to the drawings. In the following drawings, the scale of each member is appropriately changed in order to make each member a recognizable size.
1A to 1C are views showing an embodiment of the panel of the present invention, where FIG. 1A is a side sectional view of the panel, FIG. 1B is a rear view of the panel, and FIG. It is a front view.

In FIGS. 1A to 1C, reference numeral 1 denotes a panel. The panel 1 includes a back surface layer 3 having a structure 2 having irregularities as shown in FIG. And an external appearance layer 4 that forms an external appearance surface.
The back surface layer 3 is made of a synthetic resin formed in a rectangular shape, and the structure portion 2 is formed on the surface opposite to the appearance layer 4, that is, the surface to be the back surface of the panel 1. In this embodiment, the structure 2 is formed of cylindrical protrusions (screw bosses) serving as screw bosses, and corresponds to four corners of the rectangular back surface layer 3 as shown in FIG. Is formed. In addition to the screw boss, the structure 2 can be formed in various shapes and functions, such as a thin plate-like rib.

  The appearance layer 4 is made of a synthetic resin formed in a rectangular shape that is slightly larger than the back surface layer 3, and the end portion (side end portion) of the back surface layer 3 is formed on the back surface side (back surface layer 3 side) of the outer peripheral portion. ) Is integrally formed. The outer frame portion 5 is a rectangular frame formed to protrude toward the back surface layer 3 on the outer periphery of the outer appearance layer 4 formed larger than the back surface layer 3, that is, on the back surface side of the outer periphery located outside the back surface layer 3. This covers the end portion (side end portion) of the back layer 3.

  In the present embodiment, the panel 1 composed of the back layer 3 and the appearance layer 4 is all formed of a synthetic resin containing a glittering material. As the synthetic resin, ABS (acrylonitrile / butadiene / styrene) resin, AAS (acrylonitrile / acrylic rubber / styrene) resin, AES (acrylonitrile / chlorinated polyethylene / styrene), or the like is used. Further, as the glitter material, aluminum foil, glass beads, pearl mica, or the like is used.

  The blending ratio of the glittering material to the synthetic resin is, for example, about 0.1 to 7% by weight. In addition to the glittering material, an appropriate additive or compounding agent is added to the synthetic resin as necessary as in the conventional case.

Next, a first embodiment of the injection molding method of the present invention will be described based on the method for molding the panel 1 having such a structure.
FIG. 2 is a view showing an example of an injection mold suitably used in the first embodiment of the injection molding method of the present invention, and reference numeral 10 in FIG. 1 denotes a mold. First, the molding die 10 will be described. The molding die 10 includes a fixed die 11 and a movable die 12.

  The fixed mold 11 is formed with a recess 13, and the movable mold 12 is formed with a protrusion 14 that serves as a core that fits into the recess 13. The movable mold 12 is provided so as to be movable back and forth with respect to the fixed mold 11 by an operating portion (not shown). Based on such a configuration, the convex portion 14 can slide in the concave portion 13. And the fixed mold | type 11 and the movable mold | type 12 form a cavity between the recessed part 13 and the convex part 14, and the said panel 1 is shape | molded here.

  That is, in the concave portion 13, a concave back surface layer forming portion 15 corresponding to the back surface layer 3 is formed on the inner surface on the side opposite to the convex portion 14, and further, outside the back surface layer forming portion 15, A concave (rectangular groove-shaped) outer frame forming portion 16 corresponding to the outer frame portion 5 is formed. In addition, a concave structure forming portion 17 corresponding to the structure portion 2 is formed on the inner surface of the back surface layer forming portion 15. Note that the outer surface of the apparently projecting portion of the concave portion 13 located between the back surface layer molding portion 15 and the outer frame molding portion 16 abuts on the convex portion 14 of the movable mold 12 as will be described later. A contact surface 18 is formed.

  The fixed mold 11 has two gates for injecting molten resin (melted synthetic resin) into the cavity between the concave portion 13 and the convex portion 14, that is, a first gate 19 and a second gate 20. Is provided. These gates 19 and 20 are valve gates, and the first gate 19 has an inlet 19a opened at a position corresponding to the inner surface of the back surface layer forming portion 15, that is, the back surface of the back surface layer 3 in the panel 1. ing. The second gate 20 has an inlet 20a opened at a position corresponding to the opening surface of the back surface layer forming portion 15, that is, the interface between the back surface layer 3 and the appearance layer 4 in the panel 1.

  The fixed mold 11 includes a pin (not shown) for opening and closing the inlet 19a (20a) of the gates 19 and 20, and a cylinder (not shown) for moving the pin forward and backward in the axial direction. Provided.

  As described above, the movable mold 12 is provided so as to be movable back and forth with respect to the fixed mold 11. Specifically, the front surface 14a of the convex portion 14 for forming a cavity together with the concave portion 13 of the fixed mold 11 is in contact with the contact surface 18 in the concave portion 13 as shown by the solid line in FIG. It moves forward and backward between the position and a second position indicated by a two-dot chain line in FIG. Further, when the molded panel 1 is taken out from the molding die 10, the panel 1 is moved to a third position (not shown) further retracted from the second position. Here, the second position is a position where the distance between the front surface 14 a of the convex portion 14 and the contact surface 18 matches the thickness of the appearance layer 4 of the panel 1. The thickness of the appearance layer 4 referred to here is the thickness at a position excluding the outer frame portion 5.

  In order to injection-mold the panel 1 using the molding die 10 having such a configuration, first, the movable mold 12 is fixed to the first position with respect to the fixed mold 11 as shown in FIG. In this state, molten resin containing a glittering material is injected and injected from the first gate 19. Then, when the movable mold 12 is in the first position, the front surface 14 a of the convex portion 14 is in contact with the contact surface 18 in the concave portion 13, so that the molten resin does not flow into the outer frame molding portion 16. The back layer forming part 15 is filled. At this time, since there is a structural molding portion 17 in the back surface layer molding portion 15, the position corresponding to the structural molding portion 17, that is, the surface on the front surface 14 a side of the convex portion 14 opposite to the structural molding portion 17. In addition, a flow mark (not shown) may be formed. In this state, the second gate 20 is in a state where the injection port 20a is covered by the front surface 14a of the convex portion 14.

  In this way, the molten resin is injected into the back surface layer forming portion 15 and then cooled for a predetermined time to solidify the molten resin. After the back surface layer 3 in the panel 1 is formed, the movable mold 12 is retracted (core back). As shown in FIG. 4, the convex portion 14 is moved to the second position and fixed there. Then, a new space, that is, a cavity corresponding to the appearance layer 4 is formed between the front surface 14 a of the convex portion 14 and the back surface layer 3 in the concave portion 13 of the fixed mold 11. When the convex portion 14 is retracted in this manner, the front surface 14a and the contact surface 18 are separated from each other, so that a new cavity communicates with the outer frame forming portion 16 and becomes a space including the same. Further, the second gate 20 opens its injection port 20a on the front surface side of the back surface layer 3, and thus opens in a new cavity.

  Next, under this state, as shown in FIG. 5, molten resin containing a bright material is injected and injected from the second gate 20. Then, the molten resin fills a new cavity including the outer frame molding portion 16. At that time, since the outer frame molding portion 16 is located far from the second gate 20 and communicates with the entire outer peripheral portion of the new cavity, the molten resin precedes the outer frame molding portion 16. Therefore, the formation of flow marks and weld lines hardly occurs.

In this way, when the molten resin is injected into the new cavity and then cooled for a predetermined time to solidify the molten resin, the appearance layer 4 in the panel 1 is formed integrally with the back surface layer 3, thereby the panel 1 Is formed.
Thereafter, the convex portion 14 of the movable mold 12 is further retracted to the third position, and the convex portion 14 is detached from the concave portion 13 of the fixed mold 11. And the panel 1 shape | molded from the recessed part 14 in that state is released.

In such an injection molding method for the panel 1, the outer layer 4 is formed on the back layer 3 having the uneven structure portion 2 so as to cover the end of the back layer 3. Even if a molding line corresponding to these interfaces is formed between the outer layer 4 and the outer layer 4, the outer layer 5 of the outer layer 4 covers the side end surface (end) of the back surface layer 3, thereby forming the outer layer 4. The above molding line can be hidden. Therefore, the appearance of the side end face of the panel 1 to be formed can be improved, and the appearance design can be improved.
In addition, a flow mark may be formed on the surface of the back surface layer 3 on the appearance layer 4 side. However, since the flow mark is covered with the appearance layer 4 and is not exposed, the appearance design of the panel 1 is impaired. There is nothing.

  In addition, since both the first gate 19 and the second gate 20 are arranged on the back surface layer forming part 15 side and the molten resin is injected / injected from the back surface side of the back surface layer 3, the gate trace when the resin is injected is Even if it remains, the gate mark is formed not on the outer layer 4 but on the back side of the back layer 3, so that the appearance design of the panel 1 is not deteriorated. The second gate 20 has an inlet 20a opened at a position corresponding to the interface between the back surface layer 3 and the appearance layer 4, so that the back surface layer 3 has a recess (gate) at a position corresponding to the second gate 20. A mark) is formed. However, since the gate mark is formed on the back surface side of the back surface layer 3 as described above, the appearance design of the panel 1 is not impaired. However, as a matter of course, this concave portion may be backfilled or covered with a cap material as needed.

Moreover, since both the back surface layer 3 and the external appearance layer 4 are formed with the resin containing the same glittering material, the panel 1 excellent in the external appearance design property with a good appearance as a whole can be formed.
Moreover, in the panel 1 molded in this way, even if a molding line corresponding to these interfaces is formed between the back surface layer 3 and the appearance layer 4, the outer frame portion 5 of the appearance layer 4. By covering the side end surface (end portion) of the back surface layer 3 with this, the molding line can be hidden by the appearance layer 4. Therefore, the appearance of the side end face is good, and the appearance design is improved.
Further, since the back layer 3 and the external layer 4 are both formed of a resin containing a glittering material, the overall appearance is good, and thus the panel has an excellent external appearance design.

Next, a second embodiment of the injection molding method of the present invention as a method for molding the panel 1 will be described.
FIG. 6 is a view showing an example of an injection mold suitably used in the second embodiment of the injection molding method of the present invention, and reference numeral 30 in FIG. 1 denotes a molding mold. The molding die 30 differs from the molding die 10 shown in FIG. 2 in that the first gate 19 and the second gate 20 in the molding die 10 shown in FIG. 6, in the molding die 30 shown in FIG. 6, the position corresponding to the side surface of the new cavity described above, that is, the position corresponding to the side surface of the appearance layer 4, outside the back surface layer molding portion 15. Further, the second gate 31 is disposed.

  That is, in the molding die 30 shown in FIG. 6, the first gate 19 is arranged at the same position as the molding die 10 shown in FIG. 13 is a side gate that is open to the inner side surface of 13. Even in the molding die 30, the position of the movable die 12 relative to the fixed die 11 can be moved between the first position, the second position, and the third position, like the molding die 10. It has become.

  In order to injection-mold the panel 1 using the molding die 30 having such a configuration, first, the movable mold 12 is fixed to the first position with respect to the fixed mold 11 as shown in FIG. In this state, molten resin is injected and injected from the first gate 19. However, in the present embodiment, unlike the first embodiment, a synthetic resin that does not contain a bright material is used as the synthetic resin injected from the first gate 19. Then, the back surface layer 3 is formed in the back surface layer forming part 15 as in the first embodiment.

  When the back surface layer 3 is thus formed, the movable die 12 is retracted (core back), and the convex portion 14 is moved to the second position and fixed thereto as shown in FIG. Then, a new cavity corresponding to the appearance layer 4 is formed between the front surface 14 a of the convex portion 14 and the back surface layer 3 in the concave portion 13 of the fixed mold 11. And the convex part 14 recedes in this way and a new cavity is formed, so that the inlet 31a of the second gate 31 opens in this cavity.

  Next, under this state, as shown in FIG. 9, molten resin containing a bright material is injected and injected from the second gate 31. Then, the molten resin fills a new cavity including the outer frame molding portion 16. At that time, since the injection port 31a of the second gate 31 is opened at a position corresponding to the side surface of the external layer 4, the injected and injected molten resin directly collides with the cavity surface, for example, the front surface 14a of the convex portion 14. Therefore, the flow is prevented from being disturbed by directly colliding with the front surface 14a.

In this way, when the molten resin is injected into the new cavity and then cooled for a predetermined time to solidify the molten resin, the appearance layer 4 in the panel 1 is formed integrally with the back surface layer 3, thereby the panel 1 Is formed.
Thereafter, the convex portion 14 of the movable mold 12 is further retracted to the third position, and the convex portion 14 is detached from the concave portion 13 of the fixed mold 11. And the panel 1 shape | molded from the recessed part 14 in that state is released.

  Even in such an injection molding method of the panel 1, the outer layer 4 is formed on the back layer 3 having the uneven structure portion 2 so as to cover the end of the back layer 3. Even if a molding line corresponding to these interfaces is formed between the outer layer 4 and the outer layer 4, the outer layer 5 of the outer layer 4 covers the side end surface (end) of the back surface layer 3, thereby forming the outer layer 4. The above molding line can be hidden. Therefore, the appearance of the side end face of the panel 1 to be formed can be improved, and the appearance design can be improved.

  In addition, the injection port 31a of the second gate 31 is opened at a position corresponding to the side surface of the appearance layer 4, thereby preventing the flow of molten resin injected and injected from being disturbed. It is possible to prevent a flow mark or the like from being generated in the appearance layer 21 due to the disturbance of the appearance.

Moreover, since the appearance layer 4 is formed of a resin containing a glittering material, it is possible to mold the panel 1 with good appearance and excellent appearance design.
Moreover, in the panel 1 molded in this way, even if a molding line corresponding to these interfaces is formed between the back surface layer 3 and the appearance layer 4, the outer frame portion 5 of the appearance layer 4. By covering the side end surface (end portion) of the back surface layer 3 with this, the molding line can be hidden by the appearance layer 4. Therefore, the appearance of the side end face is good, and the appearance design is improved.
Further, since the outer appearance layer 4 is formed of a resin containing a glittering material, the appearance is good, and thus the panel has an excellent appearance design.

The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the gist of the present invention.
For example, in the second embodiment, the injection molding is performed using the molding die 30 provided with the first gate 19 and the second gate 31. For example, the first gate 19 and the second gate are used as the molding die. You may use the metal mold | die with three gates which added the 2nd gate 20 of the shaping die 10 in 1st Embodiment to the gate 31. FIG. In that case, when the appearance layer 4 is molded, molten resin is injected and injected from both the second gate 31 and the second gate 19.

By doing so, it is possible to better prevent the flow of the injected molten resin from being disturbed in the new cavity, and thus more reliably prevent the appearance layer 21 from having a flow mark or the like. can do.
In this case, the back layer 3 can also be formed of a synthetic resin containing a glittering material, as with the appearance layer 4.

  DESCRIPTION OF SYMBOLS 1 ... Panel, 2 ... Structure part, 3 ... Back surface layer, 4 ... Appearance layer, 5 ... Outer frame part, 10 ... Molding die, 11 ... Fixed mold, 12 ... Movable type, 13 ... Concave part, 14 ... Convex part, DESCRIPTION OF SYMBOLS 15 ... Back surface molding part, 16 ... Outer frame molding part, 17 ... Structure part molding part, 18 ... Contact surface, 19 ... 1st gate, 19a ... Injection port, 20 ... 2nd gate, 20a ... Injection port, 21 ... Flow mark, 30 ... Mold, 31 ... Second gate, 31a ... Inlet

Claims (8)

An injection molding method for molding a panel including a back surface layer having a structure having irregularities, and an external layer provided integrally on the back surface layer to form an external surface,
Forming the back layer by injection molding;
Forming the appearance layer on the back layer by injection molding,
In the step of forming the appearance layer, the appearance layer is formed so as to cover an end portion of the back surface layer.   2. The injection molding method according to claim 1, wherein in each of the step of forming the back layer and the step of forming the appearance layer, a resin is injected from the back side of the back layer. In the step of forming the back layer, the back layer is formed with a resin containing a glittering material,
The injection molding method according to claim 1 or 2, wherein in the step of forming the appearance layer, the appearance layer is formed of a resin containing a glittering material. In the step of forming the appearance layer, a resin is injected from the back side of the back layer,
The injection molding method according to claim 1, wherein in the step of forming the appearance layer, a resin is injected from a side surface side of the appearance layer.   5. The injection molding method according to claim 4, wherein in the step of forming the appearance layer, the appearance layer is formed of a resin containing a glittering material. A panel including a back surface layer having a structure having irregularities, and an external layer integrally formed on the back surface layer to form an external surface,
The outer appearance layer is formed so as to cover an end of the back surface layer.   The panel according to claim 6, wherein the outer appearance layer is formed of a resin containing a glittering material.   The panel according to claim 6, wherein the back layer and the external layer are both formed of a resin containing a glittering material.

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