JP2017189974A - Hard material/resin laminate structure housing and manufacturing device therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hard material/resin laminate structure housing capable of preventing generation of warpage on a housing due to difference in thermal expansion coefficient between a hard material layer and a base resin layer.SOLUTION: A housing 40 has a surface layer 1 with a reverse tray shape, a nonwoven fabric layer 3 sandwiching a soft layer 2 in cooperation with the surface layer 1 and a base resin layer 5 fixed on the nonwoven fabric layer 3 while permeating gaps between each fiber of nonwoven fabric of the nonwoven fabric layer 3. The surface layer 1 and the nonwoven fabric layer 3 accommodate the soft layer 2 therebetween and are bonded via an additive on the outer periphery.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a hard material / resin laminated housing and a manufacturing apparatus thereof, and more particularly to a hard material / resin laminated housing structure in which a hard material layer is laminated on a base resin layer and a manufacturing apparatus thereof.

  In the technical field of housings for electronic devices, home appliances, etc. and housings for automobile interior parts, the housings are often made by resin molding in which a decorative material is laminated on the outer surface. Recently, various types of housings are applied to resin molded housings. Decorative material is an indispensable element for differentiating from other products. In such a situation, some companies can freely select a decorative design of a product by applying various decorative materials to a resin molded housing even for the same product.

  As a method of decorating the resin molded housing, the transparent acrylic film layer, the textile layer bonded to the transparent acrylic film layer via an adhesive, and the textile layer are fixed to the textile layer while infiltrating the gaps between the fibers. A textile / resin laminated structure housing having a base resin layer formed has been proposed (for example, Patent Documents 1 and 2).

  According to the textile / resin laminated structure housing, the customer can freely determine the decorative design of the product by appropriately selecting the textile layer.

  On the other hand, in the technical field of housings for electronic devices and home appliances, and housings for automobile interior parts, the outer surface of the housing, such as a projecting plate or a metal mesh, is used to improve decoration, impact resistance, and scratch resistance. A hard material may be used.

International Publication No. 2012/105664 Pamphlet International Publication No. 2012/105665 Pamphlet

  However, when a hard material is used for the outer surface of the housing as described above, the housing tends to be warped or twisted due to the difference in thermal expansion coefficient between the hard material and the base resin layer.

  An object of the present invention is to provide a hard material / resin laminated structure housing capable of preventing the housing from being warped or twisted due to a difference in thermal expansion coefficient between the hard material layer and the base resin layer, and an apparatus for manufacturing the same. is there.

  In order to achieve the above object, the hard material / resin laminated structure housing according to claim 1 includes a hard material layer, a non-woven fabric or a papermaking layer sandwiching the soft material layer in cooperation with the hard material layer, and And a base resin layer fixed to the nonwoven fabric or papermaking layer while infiltrating the gaps between the fibers of the nonwoven fabric or papermaking layer.

  6. The manufacturing apparatus for a hard material / resin laminated structure housing according to claim 5, wherein a fixed mold for receiving a hard material layer and the received hard material layer for forming the hard material layer are used as the fixed mold. A movable mold that is moved toward the fixed mold so as to be pushed into the mold, the molded hard material layer, and a nonwoven fabric or a papermaking layer that sandwiches the soft material layer in cooperation with the hard material layer. Other fixed molds that receive the laminate with the nonwoven fabric or papermaking layer as a front surface, injection molds that are moved toward the laminate received in the other fixed molds, and the other fixed molds An injection means for injecting the resin liquid of the base resin layer into a space defined by the laminate received in the mold and the injection mold.

  According to the hard material / resin laminated housing according to claim 1, since the soft material layer is disposed between the hard material layer and the base resin layer, the difference in thermal expansion coefficient between the hard material layer and the base resin layer. Thus, it is possible to provide a hard material / resin laminated housing capable of preventing the housing from being warped or twisted.

  According to the manufacturing apparatus for a hard material / resin laminated structure housing according to claim 5, the hard material capable of preventing the housing from being warped or twisted due to a difference in thermal expansion coefficient between the hard material layer and the base resin layer. / Resin laminated structure The housing can be efficiently manufactured, and the non-woven fabric layer is bonded to the soft material layer, so that the heat transfer to the soft material layer is prevented during molding of the housing and the soft material layer is deteriorated. Can be prevented.

It is an external appearance perspective view of the hard material / resin laminated structure housing which concerns on embodiment of this invention. (A) is sectional drawing of the hard material / resin laminated structure housing which follows the line IIA-IIA of FIG. 1, (B) is sectional drawing of the hard material / resin laminated structure housing which follows the line IIB-IIB of FIG. FIG. It is a fragmentary sectional view of the surface layer in FIG. It is a fragmentary sectional view of the soft material layer in FIG. (A) is a partial sectional view of a nonwoven fabric layer, showing a case where the nonwoven fabric layer is composed of one layer, and (B) is a partial sectional view of the nonwoven fabric layer, showing a case where the nonwoven fabric layer is composed of three layers. It is a figure used for demonstrating the manufacturing apparatus of the hard material / resin laminated structure housing which concerns on embodiment of this invention.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is an external perspective view of a hard material / resin laminated housing according to an embodiment of the present invention.

  In FIG. 1, a hard material / resin laminated structure housing 40 (hereinafter may be simply referred to as “housing 40”) is a casing having an inverted basin structure, and one protrusion 41 and one opening at the bottom of the inverted basin structure. Part 42.

  The cross section of the protrusion 41 is shown in FIG. 2A as a cross-sectional view taken along line IIA-IIA in FIG. 1, and the cross section of the opening 42 is shown in FIG. 2 as a cross-sectional view taken along line IIB-IIB in FIG. It is indicated by (B).

  The housing 40 has an inverted bon-shaped surface layer 1 (described later with reference to FIG. 3) and a non-woven fabric layer 3 (FIG. 5) that sandwiches the soft material layer 2 (described later with reference to FIG. 4) in cooperation with the surface layer 1. And a base resin layer 5 fixed to the nonwoven fabric layer 3 while infiltrating the gaps between the fibers of the nonwoven fabric of the nonwoven fabric layer 3. The nonwoven fabric layer 3 consists of a nonwoven fabric.

  The surface layer 1 and the nonwoven fabric layer 3 are accommodated with the soft material layer 2 between them, and are bonded to each other at the outer edge via an adhesive (not shown).

  The surface layer 1 and the nonwoven fabric layer 3 may not be bonded to each other at the outer edge via an adhesive (not shown). In this case, the surface layer 1 and the soft material layer 2, and the soft material layer 2 and the nonwoven fabric layer 3 are Each is bonded through an adhesive (not shown).

  The nonwoven fabric layer 3 may be replaced with a papermaking layer containing papermaking.

  FIG. 3 is a partial cross-sectional view of the surface layer 1 in FIG.

  In FIG. 3, the surface layer 1 is a hard material layer 1-1 made of a metal mesh or a veneer lined with a thin nonwoven fabric 1-2 having a thickness of 10 to 100 μm, and a thermosetting polyurethane adhesive or thermoplastic. And an intermediate layer 1-3 having a thickness of 10 μm to 5 mm made of a nonwoven fabric bonded to the hard material layer 1-1 through an adhesive resin layer 1-2 having a thickness of about 10 μm made of PVB.

  The protruding plate 3 is made of a wood-grained plate having a thickness of 100 to 200 μm, and the metal mesh is made of an aluminum, copper, or stainless steel mesh having a thickness of 100 to 200 μm.

  4 is a partial cross-sectional view of the soft material layer 2 in FIG.

  In FIG. 4, the soft material layer 2 has a low resilience or high resilience cushion material 2-1 having a thickness of 1 to 5 mm, and a cushion material 2-1 made of a polyurethane thermosetting adhesive and having a thickness of about 10 μm. And a backing layer 2-3 made of a woven fabric and a non-woven fabric having a thickness of about 200 μm bonded via the adhesive resin layer 2-2. The backing layer 2-3 may adhere the cushion material 2-1 to the melted part caused by flame blowing without using the adhesive resin layer 2-2.

  FIG. 5A is a partial cross-sectional view of the heat insulation layer, showing a case where the non-woven fabric layer 3 is composed of one layer, and FIG. 5B is a partial cross-sectional view of the non-woven fabric layer 3, and the non-woven fabric layer 3 is 3 The case consisting of layers is shown.

  As shown in FIG. 5A, the nonwoven fabric layer 3 may be composed of one nonwoven fabric layer 3-1 having a thickness of 500 μm. The nonwoven fabric layer 3 may be replaced with a papermaking layer containing papermaking.

  As shown in FIG. 5 (B), the nonwoven fabric layer 3 includes a nonwoven fabric layer 3-1 having a thickness of 200 to 500 μm, and an adhesive resin layer 3-2 made of PVB and having a thickness of about 50 μm. The papermaking 3-3 having a thickness of 200 [mu] m bonded via the sheet may be used. The nonwoven fabric layer 3 is bonded to the backing layer 2-3 of the soft material layer 2 through an adhesive (not shown).

  3 to 5, the nonwoven fabric is made of a spunbonded nonwoven fabric, and the papermaking is made of a papermaking nonwoven fabric containing polyester (specifically, PY-120 manufactured by Awa Paper Co., Ltd.).

  The base resin layer 5 is made of a thermoplastic synthetic resin, preferably a synthetic resin for injection molding. Specifically, ABS (acrylonitrile / butadiene / styrene copolymer), PC (polycarbonate), PMMA (polymethyl methacrylate). ), Nylon, PP (polypropylene), and one material selected from the group of ABS + PC, preferably ABS or PMMA, more preferably ABS, and the thickness is arbitrarily set according to the product. In form, it is about 1.2 mm. The resin solution of the base resin layer 5 is heated and melted by an injection molding machine 20 shown in FIG. 6 to be described later, and the surface layer 1 and the nonwoven fabric layer 3 bonded to each other through the soft material layer 2 are mounted with the nonwoven fabric layer 3 as the front. Further, it is injected into a female mold 22 in FIG. 6 to be described later and fixed while infiltrating each fiber of the nonwoven fabric layer 3 (FIG. 6).

  According to the housing 40 of FIG. 1, since the soft material layer 2 is disposed between the surface layer 1 and the base resin layer 5, the housing 40 is warped due to the difference in thermal expansion coefficient between the surface layer 1 and the base resin layer 5. It is possible to prevent twisting.

  FIG. 5 is a diagram used for explaining a textile / resin laminated housing manufacturing apparatus according to an embodiment of the present invention.

  In FIG. 5, Steps I and II are performed by a press machine, and Step IV is performed by an injection molding machine through Step III described later. Finally, step V described later is performed by an appropriate method.

  First, a hard material layer 1-1 made of a metal mesh or a veneer lined with a thin nonwoven fabric 1-2 having a thickness of 10 to 100 μm, and an intermediate bonded to the hard material layer 1-1 through an adhesive resin layer 1-2. A laminate of layers 1-3 is prepared.

  In step I of FIG. 6, the surface layer 1 is placed on the female die 10 (fixed die) of the press with the intermediate layer 1-3 as the front. This laminated body may be cut into a predetermined shape in advance.

  Next, in step II, the male die 11 (movable die) of the press machine is moved toward the female die 10 so as to push the surface layer 1 placed in the step I into the female die 10. Thereby, after shape | molding the said surface layer 1 in the shape prescribed | regulated with the female metal mold | die 10 and the male metal mold | die 11, this shape | molded laminated body is taken out from a press machine. At this time, deburring may be performed by cutting the periphery of the formed surface layer 1 with a laser cutter or a cutting die (cutting unit).

  Next, in Step III, after the soft material layer 2 is pushed into the inverted basin-shaped surface layer 1, the non-woven fabric layer 3 sandwiching the soft material layer 2 in cooperation with the surface layer 1 is bonded to the surface layer 1 at its outer edge. Glue through the agent.

  Subsequently, in Step IV of FIG. 3, the laminate of the surface layer 1, the soft material layer 2, and the nonwoven fabric layer 3 is mounted in a female mold 22 (another fixed mold) with the nonwoven fabric layer 3 as a front. The injection molding male mold 12 (injection molding mold) is moved toward the laminate received in the mold die 22, and the injection hole 20a of the injection machine 20 is moved to the injection molding hole of the injection molding male mold 12. After being pressed against 12a, the injection screw 21 is rotated clockwise to inject the resin liquid 31 of the base resin layer 5 in the tank 30 into the space defined by the laminate and the injection molding male mold 12. . At this time, the resin liquid 31 of the base resin layer 5 infiltrates each fiber of the non-woven fabric layer 3-1 or the papermaking layer 3-3 of the non-woven fabric layer 3, and adheres to the base resin layer 5 and mechanical strength of the housing 40. Will improve.

  Next, in step V, after the injection-molded base resin layer 5 is cooled and solidified, the injection machine 20 and the injection-molded male mold 12 are separated from the female mold 10 and the molded product is taken out.

  The female die 10 and the male die 11 constitute a press machine, and the female die 22, the injection molding male die 12 and the injection machine 20 constitute an injection molding machine. The press machine and the injection molding machine are a housing 40. The manufacturing apparatus is configured.

  According to the manufacturing apparatus of the hard material / resin laminated structure housing of FIG. 5, since the soft material layer 2 is disposed between the surface layer 1 and the base resin layer 5, the difference in thermal expansion coefficient between the surface layer 1 and the base resin layer. Therefore, the housing 40 can be prevented from warping or twisting.

  Further, according to the manufacturing apparatus of the hard material / resin laminated structure housing of FIG. 6, since the nonwoven fabric layer 3 is bonded to the soft material layer 2, the heat to the soft material layer 2 is formed during the molding of the housing 40 in the process IV. Can be prevented and deterioration of the cushion material 2-1 can be prevented.

  In the description of the manufacturing apparatus of FIG. 5, the nonwoven fabric layer 3 may be replaced with a papermaking layer including papermaking.

  In the embodiment of the present invention, the hard material / resin laminated structure housing 40 is merely described as a general housing, but as an application technical field of the embodiment of the present invention, a decorative product by in-mold molding is used. Specifically, housings such as miscellaneous goods including containers and stationery, electronic devices and home appliances including mobile phones and laptop computers, housings for interior and exterior products of buildings and automobiles, aircraft, railway vehicles, An internal housing of a ship is mentioned.

1 Surface layer 1-1 Hard material layer 1-2 Adhesive resin layer 1-3 Intermediate layer 2 Soft material layer 2-1 Cushion material 2-2 Adhesive resin layer 2-3 Backing layer 3 Heat insulation layer 3-1 Nonwoven fabric layer 3-2 Adhesive resin layer 3-3 Papermaking layer 5 Base resin layer 10 Female mold 11 Male mold 12 Injection molded male mold 20 Injection machine 21 Injection screw 22 Female mold 30 Tank 31 Resin solution 40 Hard material / resin laminated structure housing 41 Projection 42 Opening

Claims (5)

  A hard material layer, a non-woven fabric or paper making layer sandwiching a soft material layer in cooperation with the hard material layer, and a base fixed to the non-woven fabric or paper making layer while infiltrating a gap between the fibers of the non-woven fabric or paper making layer A hard material / resin laminated structure housing comprising a resin layer.   The hard material / resin laminated structure housing according to claim 1, wherein the soft material layer is made of a soft material made of a cushion material, a low resilience rubber, or an impact resistant material.   The hard material / resin laminated structure housing according to claim 2, wherein the soft material layer includes the soft material and a backing layer bonded to the soft material via an adhesive resin layer.   4. The textile / resin laminated structure housing according to claim 3, wherein the backing layer is made of a woven fabric or a non-woven fabric.   A fixed mold for receiving the hard material layer, and a movable mold moved toward the fixed mold so as to push the received hard material layer into the fixed mold to form the hard material layer Other fixed metal that receives a laminate of a mold, the molded hard material layer, and a nonwoven fabric or papermaking layer sandwiching the soft material layer in cooperation with the hard material layer with the nonwoven fabric or papermaking layer as a front A mold, an injection mold that is moved toward the laminate received in the other fixed mold, and a laminate and the injection mold that are received in the other fixed mold. An apparatus for manufacturing a hard material / resin laminated structure housing, comprising: injection means for injecting a resin liquid of a base resin layer into a space.

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