JP2011240679A - Method for manufacturing resin molding with mesh sheet including flexible cable - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a resin molding with mesh sheet including a flexible cable in which a metal mesh layer has no problem on moisture resistance, scratch resistance and dust preventability, and to easily mount the flexible cable on the resin molding with mesh sheet.SOLUTION: A mesh sheet with heat resistant tape is arranged in a molding die so that a supporting sheet faces a molding cavity face. A molding resin injected into the molding cavity is cooled. A part of the heat resistant tape exposed to the surface of the resin molding is peeled from the resin molding, thereafter, the heat resistant tape is pulled out to form a gap between the metal mesh layer and the resin molding. A flexible cable is inserted into the gap between the metal mesh layer and the resin molding.

Description

  The present invention provides a housing for various electronic devices in which a mesh sheet having functions such as an antenna for transmitting and receiving terrestrial and satellite radio waves and a capacitive touch panel is integrated with a resin molded product. The present invention relates to a resin molded product with a mesh sheet used.

  Conventionally, as a method of obtaining the resin molded product 121 with a mesh sheet, there are the following methods (see FIGS. 5A and 5B). First, the mesh sheet 101 in which the adhesive layer 103 and the metal mesh layer 104 are laminated on the front surface side of the support sheet 102 and the adhesive layer 105 is formed on the back surface side of the support sheet 102 is prepared. Then, the mesh sheet 101 is placed on the molding die 111 so that the metal mesh layer 104 faces the molding cavity surface. Next, the molding resin 112 is cooled after being injected into the molding cavity (see FIG. 6A). Finally, the molding die 111 is opened to obtain a resin molded product 121 with a mesh sheet in which the mesh sheet 101 is formed on the resin molded product 122 formed by cooling the molding resin 112 (FIG. 6 ( b)).

JP 2009-212545 A

  As for the resin molded product 121 with a mesh sheet formed by the above method, the metal mesh layer 104 is exposed on the surface (see FIG. 6B). Therefore, the metal mesh layer 104 has problems in moisture resistance, scratch resistance, and dust resistance. In order to cope with these problems, when the mesh sheet 101 is arranged so that the metal mesh layer 104 faces the inside of the molding cavity, the metal mesh layer 104 is sandwiched between the support sheet 102 and the resin molded product 122, and the metal It becomes difficult to attach a flexible cable to the mesh layer 104 (see FIG. 6C).

  The present invention provides a method for producing a resin-molded product with a mesh sheet in which a flexible cable is attached, and the metal mesh layer has no problem of moisture resistance, scratch resistance and dust resistance, and the flexible cable can be easily attached. With the goal.

  In order to achieve the above object, the present invention has the following features.

The method for producing a resin molded product with a mesh sheet to which the flexible cable of the present invention is attached,
For a mesh sheet formed by laminating a metal mesh layer on a support sheet, a mesh sheet with a heat-resistant tape is formed by overlapping a part of the heat-resistant tape on a part of the metal mesh layer,
After placing the mesh sheet with heat-resistant tape on the molding die so that the support sheet faces the molding cavity surface, the molding resin is injected into the molding cavity and then cooled, so that the space between the metal mesh layer and the resin molded product A part of the heat-resistant tape is formed, and the part of the heat-resistant tape that does not overlap with the metal mesh layer forms a resin molded product with a mesh sheet exposed on the surface of the resin molded product outside the mesh sheet,
A gap is formed between the metal mesh layer and the resin molded product by pulling out the heat-resistant tape after peeling the heat-resistant tape exposed on the surface of the resin molded product from the resin molded product,
A step of inserting a flexible cable into the gap between the metal mesh layer and the resin molded product.

  Moreover, in said invention, you may fix the position of the mesh sheet with a heat resistant tape in a shaping | molding cavity by the weak adhesive layer formed in the heat resistant tape of the part which does not overlap with a metal mesh layer.

  According to the method for producing a resin molded product with a mesh sheet to which the flexible cable of the present invention is attached, the mesh sheet with a heat-resistant tape is arranged in the molding die so that the support sheet faces the molding cavity surface. Therefore, the metal mesh layer of the resin molded product with a mesh sheet is protected by the support sheet without being exposed to the surface. As a result, it is possible to obtain a resin molded product with a mesh sheet in which a flexible cable having no problem of moisture resistance, scratch resistance and dust resistance is attached to the metal mesh layer. In addition, by superimposing a part of the heat-resistant tape on a part of the metal mesh layer, a part of the heat-resistant tape is formed between the metal mesh layer and the resin molded product, and the part that does not overlap the metal mesh layer A resin molded product with a mesh sheet is formed in which the heat-resistant tape is exposed to the surface of the resin molded product outside the mesh sheet. Therefore, by removing the heat-resistant tape exposed on the surface of the resin molded product from the resin molded product and then pulling out the heat-resistant tape, a gap is easily formed between the metal mesh layer and the resin molded product, and the flexible cable By inserting, a flexible cable can be easily attached to a resin molded product with a mesh sheet.

  Further, when the position of the mesh sheet with the heat-resistant tape in the molding cavity is fixed by the weak adhesive layer formed on the heat-resistant tape in a portion not overlapping with the metal mesh layer, the position of the mesh sheet can be set to an arbitrary position.

It is sectional drawing which shows the mesh sheet | seat used for the manufacturing method of the resin molded product with a mesh sheet | seat with which the flexible cable of this invention was mounted | worn. It is sectional drawing which shows the manufacturing method of the resin molded product with a mesh sheet | seat with which the flexible cable of this invention was mounted | worn. It is sectional drawing which shows the manufacturing method of the resin molded product with a mesh sheet | seat with which the flexible cable of this invention was mounted | worn. It is sectional drawing which shows the manufacturing method of the resin molded product with a mesh sheet | seat with which the flexible cable of this invention was mounted | worn. It is sectional drawing which shows the manufacturing method of the resin molded product with a mesh sheet | seat with which the flexible cable of this invention was mounted | worn. It is sectional drawing which shows the manufacturing method of the conventional resin molded product with a mesh sheet.

  Embodiments of the present invention will be described in detail with reference to the drawings.

  First, the mesh sheet 1 used for the manufacturing method of the resin molded product with a mesh sheet | seat with which the flexible cable of this invention was mounted | worn is demonstrated (refer FIG. 1).

  The mesh sheet 1 can be used as an antenna for a mobile phone terminal or the like, and can also be used as a capacitive touch panel in addition to the antenna.

  The mesh sheet 1 has a configuration in which a metal mesh layer 4 is laminated on an insulating support sheet 2 made of a resin sheet. For bonding between the support sheet 2 and the metal mesh layer 4, an adhesive 3 made of a thermoplastic resin as a main raw material is used.

  As the support sheet 2, a resin sheet such as a polypropylene resin, a polyethylene resin, a polyamide resin, a polyester resin, a polyacrylic resin, or a polyvinyl chloride resin can be used.

  The adhesive layer 3 is preferably made of a material that slightly increases plasticity due to heat applied during preforming or injection of molten resin. Specifically, since the mesh sheet 1 is heated to approximately 180 ° C. at the time of preforming or molten resin injection, materials such as acrylic materials that increase plasticity at these temperatures can be used. . Further, as will be described later, the adhesive layer 3 is preferably configured to be slightly thicker (usually about 20 μm) to about 30 to 50 μm so as to be easily deformed during extension. The adhesive layer 3 can be formed by silk printing or the like.

  The metal mesh layer 4 is made of a metal foil having a thickness of about 10 μm, and a metal thin film such as copper, nickel, aluminum, gold, or silver can be used. The metal mesh layer 4 is formed into a fine mesh pattern by, for example, photoetching or an etching method using a printing resist.

  When the mesh pattern is formed by photoetching, first, the adhesive layer 3 is released on the surface of the support sheet 2 and a metal foil is attached. Next, a photoresist film (not shown) is formed, exposed using a photomask, and developed with a developer to form a mesh pattern of the resist film. This is etched with an etching solution, and the resist film is peeled off to form the metal mesh layer 4 having a mesh pattern made of ultrafine metal wires.

  The band width of the narrow band constituting the mesh pattern is approximately 40 μm or less. If the width of the narrow band is increased, the mesh pattern becomes easy to visually recognize, which causes the design of the casing to be impaired. However, the band width can be made larger than the above range in the use where the designability is not required.

  An adhesive layer 5 is further formed on the metal mesh 4 to be attached to a resin molded product 22 described later. The adhesive layer 5 may be formed by the same material, thickness, and forming method as the adhesive layer 3 described above. However, since a part of the metal mesh 4 is overlapped with a part of the heat-resistant tape 6 as described below, the adhesive layer 5 is not formed on the entire surface of the metal mesh 4.

  The mesh sheet 1 with the heat-resistant tape 6 is formed on the mesh sheet 1 thus formed by superimposing a part of the heat-resistant tape 6 on a part of the metal mesh layer 4 where the flexible cable 32 described later is attached. (See FIG. 1). As the heat-resistant tape 6, a material that does not adhere to a resin molded product 22 formed by cooling a molding resin 12 to be described later is selected. The heat-resistant tape 6 can be made of a material such as polyimide, Teflon (registered trademark), glass, mica, and a heat-resistant sheet having a thickness of 20 to 500 μm.

Next, the mesh sheet 1 with the heat-resistant tape 6 is placed on the molding die 11 so that the support sheet 2 faces the molding cavity surface, and the mold is closed (see FIG. 2). At this time, when the position of the mesh sheet 1 with the heat-resistant tape 6 in the molding cavity is fixed by a weak adhesive layer (not shown) formed on the heat-resistant tape 6 in a portion not overlapping with the metal mesh layer 4, the mesh The position of the sheet 1 can be set to an arbitrary position, which is preferable (see FIG. 2). Further, the mesh sheet 1 may be provided on the surface of the curved surface portion. The weak adhesive layer is preferably formed on the heat-resistant tape 6 by using an acrylic material or the like on the order of 10 μm and silk printing.

  Here, the mesh sheet 1 with the heat-resistant tape 6 sandwiched in the molding die 11 may be preformed in advance along the surface of the molding cavity. The preform is performed by pressing the mesh sheet 1 while heating it using a press device for preform. The mesh sheet 1 is deformed by a pressing force by a pressing device or an injection pressure of the molding resin 12 described below.

  After the molding die 11 is closed, the molding resin 12 is injected into the molding cavity and then cooled (see FIG. 3). Then, when the molding die 11 is opened after the molding resin 12 is cooled, a resin molded product 21 with a mesh sheet is formed (see FIG. 4). As the material of the molding resin 12, polycarbonate, acrylic, polyethylene terephthalate, triacetyl cellulose, or the like can be used.

  The resin molded product 21 with a mesh sheet has a resin molded product 22 as a main component layer, and a pattern such as an antenna formed of the mesh sheet 1 is formed on the surface of the resin molded product 22. Here, the resin molded product 22 may be formed into a desired shape of a casing member having a transparent window portion, and may be configured to be a curved surface portion where the periphery of the edge portion is bent. The transparent window portion may be integrally formed by, for example, a method such as two-color molding, or a transparent member made of another resin molded body is fitted into the opening for the transparent window portion of the resin molded product 22. You may be comprised so that it may include.

  If the metal mesh layer 4 in the resin molded product 21 with a mesh sheet is opaque but is configured to be extremely thin, at first glance, the metal ultrathin band is recognized only as a slight gradation change, and the resin molded product 22 There is no harm to the design. In addition, a relatively large area can be used as an antenna, and reception sensitivity can be improved. The metal mesh layer 4 is protected by the support sheet 2 without being exposed on the surface. As a result, the metal mesh layer 4 does not have problems of moisture resistance, scratch resistance, and dust resistance. In addition, the mesh sheet | seat 1 may be provided even to the surface of the transparent window part for displays.

  Here, in the resin molded product 21 with a mesh sheet, a part of the heat-resistant tape 6 is formed between the metal mesh layer 4 and the resin molded product 22, and the portion of the heat-resistant tape 6 that does not overlap the metal mesh layer 4 is meshed. It is exposed to the surface of the resin molded product 22 outside the sheet 1 (see FIG. 4). When the portion of the heat-resistant tape 6 exposed on the surface of the resin molded product 22 is peeled from the resin molded product 22 (see FIG. 5A) and the heat-resistant tape 6 is subsequently pulled out, A gap is formed between the mesh layer 4 and the resin molded product 22 (see FIG. 5B). Then, by inserting the flexible cable 32 into the gap between the metal mesh layer 4 and the resin molded product 22, the flexible cable 32 can be easily attached to the resin molded product with the mesh sheet, and finally flexible. A resin molded product 31 with a mesh sheet to which a cable is attached is formed (see FIG. 5C). After insertion of the flexible cable 32, heat and pressure may be applied to the mesh sheet 1 to crimp the flexible cable 32.

  An opaque decorative portion (not shown) may be provided on the surface of the resin molded product 22. Specifically, a decorative layer is provided on the surface of the resin molded product. As a method for forming the decorative layer, a transfer method or a simultaneous molding transfer method can be used. The transfer method uses a transfer material in which a transfer layer composed of a release layer, a decorative layer, an adhesive layer, and the like is formed on a base sheet, and heat-presses the transfer layer so that the transfer layer adheres to the resin molded product 22 that is a transfer target. Thereafter, the base sheet is peeled off, and only the transfer layer is transferred to the transfer surface for decoration. The simultaneous molding transfer method is a method in which a transfer material is sandwiched in a molding die 11 and a molding resin 12 is injected and filled in a molding cavity and cooled to obtain a resin molded product 22, and at the same time, a transfer material on the surface thereof. After the substrate is adhered, the substrate sheet is peeled off, and the transfer layer is transferred to the surface of the transfer object to decorate. In the simultaneous molding transfer method, since the adhesive strength of the resin molded product 22 is high, the adhesive layer can be omitted. Moreover, a decoration layer can be provided on the surface of the mesh sheet 1 for decoration.

  As the base sheet of the transfer material, a resin sheet such as polypropylene resin, polyethylene resin, polyamide resin, polyester resin, polyacrylic resin, or polyvinyl chloride resin can be used.

  The material of the release layer includes polyacrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, etc., as well as vinyl chloride-vinyl acetate. Copolymers such as polymer resins and ethylene-vinyl acetate copolymer resins may be used. When hardness is required for the release layer, a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, a thermosetting resin, or the like can be selected and used.

  As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the transfer object is appropriately used. For example, when the material of the transfer object is a polyacrylic resin, a polyacrylic resin may be used. In addition, when the material of the transferred material is a polyphenylene oxide copolymer, a polystyrene business polymer resin, a polycarbonate resin, a styrene resin, or a polystyrene blend resin, a polyacrylic resin having an affinity for these resins, A polystyrene resin, a polyamide resin, or the like may be used.

DESCRIPTION OF SYMBOLS 1 Mesh sheet 2 Support sheet 3 Adhesive layer 4 Metal mesh layer 5 Adhesive layer 6 Heat-resistant tape 11 Mold for molding 12 Molded resin 21 Resin molded product with mesh sheet 22 Resin molded product 31 Resin molded with mesh sheet with flexible cable attached 32 Flexible cable 101 Mesh sheet 102 Support sheet 103 Adhesive layer 104 Metal mesh layer 105 Adhesive layer 112 Molded resin 121 Resin molded product with mesh sheet 122 Resin molded product

Claims (2)

For a mesh sheet formed by laminating a metal mesh layer on a support sheet, a mesh sheet with a heat-resistant tape is formed by overlapping a part of the heat-resistant tape on a part of the metal mesh layer,
After placing the mesh sheet with heat-resistant tape on the molding die so that the support sheet faces the molding cavity surface, the molding resin is injected into the molding cavity and then cooled, so that the space between the metal mesh layer and the resin molded product A part of the heat-resistant tape is formed, and the part of the heat-resistant tape that does not overlap with the metal mesh layer forms a resin molded product with a mesh sheet exposed on the surface of the resin molded product outside the mesh sheet,
A gap is formed between the metal mesh layer and the resin molded product by pulling out the heat-resistant tape after peeling the heat-resistant tape exposed on the surface of the resin molded product from the resin molded product,
A method for producing a resin molded product with a mesh sheet to which a flexible cable is attached, wherein the flexible cable is inserted into a gap between the metal mesh layer and the resin molded product.   The resin molding with a mesh sheet attached with the flexible cable according to claim 1, wherein the position of the mesh sheet with the heat-resistant tape in the molding cavity is fixed by a weak adhesive layer formed on the heat-resistant tape in a portion not overlapping the metal mesh layer. Product manufacturing method.

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