JP2020185745A - Manufacturing method for resin molded products - Google Patents
Manufacturing method for resin molded products Download PDFInfo
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- JP2020185745A JP2020185745A JP2019092616A JP2019092616A JP2020185745A JP 2020185745 A JP2020185745 A JP 2020185745A JP 2019092616 A JP2019092616 A JP 2019092616A JP 2019092616 A JP2019092616 A JP 2019092616A JP 2020185745 A JP2020185745 A JP 2020185745A
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- decorative
- resin molded
- molded product
- decorative sheet
- mold
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- 239000011347 resin Substances 0.000 title claims abstract description 207
- 229920005989 resin Polymers 0.000 title claims abstract description 207
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 57
- 238000000465 moulding Methods 0.000 claims abstract description 71
- 230000001681 protective effect Effects 0.000 claims abstract description 44
- 238000000034 method Methods 0.000 claims abstract description 24
- 238000005034 decoration Methods 0.000 abstract description 17
- 230000000694 effects Effects 0.000 description 7
- 238000001746 injection moulding Methods 0.000 description 7
- 230000037303 wrinkles Effects 0.000 description 6
- 239000000428 dust Substances 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 239000011888 foil Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Landscapes
- Moulds For Moulding Plastics Or The Like (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
Description
本発明は、加飾シートを用いてインサート成形することによって、樹脂成形品の一面を加飾する樹脂成形品の製造方法に関する。 The present invention relates to a method for producing a resin molded product that decorates one surface of the resin molded product by insert molding using a decorative sheet.
加飾フィルムを用いて、樹脂成形品の成形と同時に加飾を行う方法として、主にインモールド成形とインサート成形の２種類の成形方法が用いられている。インモールド成形は、金型でロール状の加飾フィルムを挟み込んだ状態で、樹脂を射出し射出成形を行うことにより、樹脂成形品の表面に転写する（特許文献１参照）。インモールド成形は、樹脂成形品からはみ出した加飾フィルムは箔バリとなるので箔バリを除去する工程が必要であり、また、ロール状の加飾フィルムを金型で挟み込むことから位置ずれが生じるという問題がある。 Two types of molding methods, in-mold molding and insert molding, are mainly used as a method of decorating a resin molded product at the same time by using a decorative film. In in-mold molding, a roll-shaped decorative film is sandwiched between molds, and resin is injected and injection-molded to transfer the resin to the surface of the molded product (see Patent Document 1). In in-mold molding, the decorative film protruding from the resin molded product becomes foil burrs, so a step of removing the foil burrs is required, and the roll-shaped decorative film is sandwiched between the molds, resulting in misalignment. There is a problem.
インサート成形は、所定の形状にカット加工した加飾シートを金型内に入れ、金型内に樹脂を射出して成形することによって、樹脂成形品の表面に加飾シートを一体化させる方法である（特許文献２参照）。インサート成形は、インモールド成形と比べて、箔バリの問題が無く、位置ずれが生じ難くはなるが、加飾シートをカット加工する際に発生する切り粉や加飾シート表面へのごみなどの付着、加飾シートの形状が円形の場合だと位置決めが難しいという問題があり、加飾シートと金型との間に樹脂が流れ込む、あるいは、加飾シートがずれるという問題もあり、特に曲面への加飾が困難であった。 Insert molding is a method in which a decorative sheet cut into a predetermined shape is placed in a mold, and resin is injected into the mold to form the decorative sheet, thereby integrating the decorative sheet on the surface of the resin molded product. Yes (see Patent Document 2). Compared to in-mold molding, insert molding does not have the problem of foil burrs and is less likely to cause misalignment, but chips and dust generated when cutting the decorative sheet are generated. Adhesion, there is a problem that positioning is difficult if the shape of the decorative sheet is circular, there is also a problem that resin flows between the decorative sheet and the mold, or the decorative sheet shifts, especially on curved surfaces It was difficult to decorate.
本発明は、加飾シートを用いてインサート成形する際に、加飾シートの位置決めが簡単かつ正確であり、製造時の加飾シート表面へのごみなどの付着および破損を防止し、さらに、樹脂を射出した際の加飾シートの位置ずれなどを防止し、樹脂成形品の曲面への加飾が可能な樹脂成形品の製造方法を提供することを目的とする。 The present invention makes it easy and accurate to position the decorative sheet when insert molding using the decorative sheet, prevents adhesion and damage of dust and the like to the surface of the decorative sheet during manufacturing, and further, resin. It is an object of the present invention to provide a method for manufacturing a resin molded product capable of decorating a curved surface of the resin molded product by preventing misalignment of the decorative sheet when the resin is injected.
本発明の樹脂成形品の製造方法は、加飾シートを用いてインサート成形することによって、樹脂成形品の一面を加飾する樹脂成形品の製造方法であって、加飾部と前記加飾部の周囲に位置する挟持部とを有し、加飾部と挟持部を分離する切り込みが形成されている加飾フィルムと、前記加飾フィルムの加飾面に付着された保護フィルムを有する加飾シートを用意する工程と、前記加飾シートをキャビティおよびコアを有する金型に配置し、前記キャビティには凹部が設けられており、前記凹部内に前記加飾シートを保持する保持部が設けられており、前記加飾シートを、前記保護フィルムが内側となるように、前記保持部に配置する工程と、前記コアには前記凹部内に挿入される凸部が設けられており、前記凸部には樹脂成形品を成形する成形部が設けられており、前記凹部内に前記凸部を挿入し、前記キャビティの保持部と前記コアの凸部とで前記加飾シートの前記挟持部を挟んで固定する工程と、前記金型内に樹脂を射出して樹脂成形品をインサート成形する工程と、前記金型から前記樹脂成形品を取り出す工程とを含み、前記保護フィルムをはがすことにより、前記加飾部によって前記樹脂成形品の表面の加飾が行われることを特徴とする。 The method for producing a resin molded product of the present invention is a method for producing a resin molded product that decorates one surface of a resin molded product by insert molding using a decorative sheet, and is a method for producing a decorative portion and the decorative portion. A decoration having a holding portion located around the above, and a notch forming a notch for separating the decoration portion and the holding portion, and a protective film attached to the decorative surface of the decoration film. The step of preparing the sheet, the decorative sheet is arranged in a mold having a cavity and a core, the cavity is provided with a recess, and a holding portion for holding the decorative sheet is provided in the recess. The decorative sheet is arranged in the holding portion so that the protective film is on the inside, and the core is provided with a convex portion to be inserted into the concave portion, and the convex portion is provided. Is provided with a molding portion for molding a resin molded product, the convex portion is inserted into the concave portion, and the holding portion of the decorative sheet is sandwiched between the holding portion of the cavity and the convex portion of the core. A step of injecting resin into the mold to insert-mold the resin molded product, and a step of taking out the resin molded product from the mold are included, and the protective film is peeled off to obtain the above-mentioned. It is characterized in that the surface of the resin molded product is decorated by the decoration portion.
前記キャビティの保持部には前記加飾部に対応する部分に、凹状の曲面を設け、前記樹脂成形品の表面を凸状の曲面に形成し、前記樹脂成形品の曲面の表面を前記加飾部によって加飾することも可能である。 The holding portion of the cavity is provided with a concave curved surface in a portion corresponding to the decorative portion, the surface of the resin molded product is formed into a convex curved surface, and the surface of the curved surface of the resin molded product is decorated. It is also possible to decorate by the part.
前記加飾シートの加飾部の平面形状を、円形または楕円形とすることができる。 The planar shape of the decorative portion of the decorative sheet can be circular or oval.
本発明の樹脂成形品の別の形態の製造方法は、加飾シートを用いてインサート成形することによって、樹脂成形品の一面を加飾する樹脂成形品の製造方法であって、加飾部と前記加飾部の周囲に位置する挟持部とを有し、加飾部と挟持部を分離する切り込みが形成されている加飾フィルムと、前記加飾フィルムの加飾面に付着された保護フィルムを有する加飾シートを用意する工程と、前記加飾シートをコアおよびキャビティを有する金型に配置し、前記コアには凹部が設けられ、前記凹部内に前記樹脂成形品を成形する成形部および前記加飾シートを保持する保持部が設けられており、前記加飾シートを、前記保護フィルムが外側となるように、前記保持部に配置する工程と、前記キャビティには前記凹部内に挿入される凸部が設けられており、前記凹部内に前記凸部を挿入し、前記コアの保持部と前記キャビティの凸部とで前記加飾シートの前記挟持部を挟んで固定する工程と、前記金型内に樹脂を射出して樹脂成形品をインサート成形する工程と、前記金型から前記樹脂成形品を取り出す工程とを含み、前記保護フィルムをはがすことにより、前記加飾部によって前記樹脂成形品の表面の加飾が行われることを特徴とする。 Another method of manufacturing the resin molded product of the present invention is a method of manufacturing a resin molded product that decorates one surface of the resin molded product by insert molding using a decorative sheet, and the decorative portion and the decorative portion. A decorative film having a sandwiching portion located around the decorative portion and having a notch for separating the decorative portion and the sandwiching portion, and a protective film attached to the decorative surface of the decorative film. A step of preparing a decorative sheet having the above, a molding portion for arranging the decorative sheet in a mold having a core and a cavity, a recess is provided in the core, and a molding portion for molding the resin molded product in the recess. A holding portion for holding the decorative sheet is provided, and the step of arranging the decorative sheet in the holding portion so that the protective film is on the outside and the cavity being inserted into the recess. The convex portion is provided, and the convex portion is inserted into the concave portion, and the holding portion of the core and the convex portion of the cavity sandwich and fix the holding portion of the decorative sheet. A step of injecting resin into a mold to insert-mold a resin molded product and a step of taking out the resin molded product from the mold are included. By peeling off the protective film, the resin molding is performed by the decorative portion. The feature is that the surface of the product is decorated.
前記コアの保持部には前記加飾部に対応する部分に凹状の曲面を設け、前記樹脂成形品の表面を凸状の曲面を形成し、前記樹脂成形品の曲面の表面を前記加飾部によって加飾することも可能である。 The core holding portion is provided with a concave curved surface at a portion corresponding to the decorative portion, the surface of the resin molded product is formed with a convex curved surface, and the surface of the curved surface of the resin molded product is the decorative portion. It is also possible to decorate with.
前記加飾シートの加飾部の平面形状を、円形または楕円形とすることができる。 The planar shape of the decorative portion of the decorative sheet can be circular or oval.
本発明の樹脂成形品の製造方法は、加飾シートを用いてインサート成形することによって、樹脂成形品の一面を加飾する樹脂成形品の製造方法であって、加飾部と前記加飾部の周囲に位置する挟持部とを有し、加飾部と挟持部を分離する切り込みが形成されている加飾フィルムと、前記加飾フィルムの加飾面に付着された保護フィルムを有する加飾シートを用意する工程と、前記加飾シートをキャビティおよびコアを有する金型に配置し、前記キャビティには凹部が設けられており、前記凹部内に前記加飾シートを保持する保持部が設けられており、前記加飾シートを、前記保護フィルムが内側となるように、前記保持部に配置する工程と、前記コアには前記凹部内に挿入される凸部が設けられており、前記凸部には樹脂成形品を成形する成形部が設けられており、前記凹部内に前記凸部を挿入し、前記キャビティの保持部と前記コアの凸部とで前記加飾シートの前記挟持部を挟んで固定する工程と、前記金型内に樹脂を射出して樹脂成形品をインサート成形する工程と、前記金型から前記樹脂成形品を取り出す工程とを含み、前記保護フィルムをはがすことにより、前記加飾部によって前記樹脂成形品の表面の加飾が行われた状態となるので、前記加飾シートの位置決めが簡単に、かつ、正確に行うことができるようになり、前記樹脂成形品の表面に、位置ずれ、または、皺などを生じることなく綺麗に加飾することが可能となり、さらに、加飾シートをカット加工する際に発生する切り粉や加飾シート表面へのごみなどの付着および損傷が少なくなって歩留まりが向上することで、加飾された樹脂成形品の製造コストを低減することができるようになる。 The method for producing a resin molded product of the present invention is a method for producing a resin molded product that decorates one surface of a resin molded product by insert molding using a decorative sheet, and is a method for producing a decorative portion and the decorative portion. A decoration having a holding portion located around the above, and a notch forming a notch for separating the decoration portion and the holding portion, and a protective film attached to the decorative surface of the decoration film. The step of preparing the sheet, the decorative sheet is arranged in a mold having a cavity and a core, the cavity is provided with a recess, and a holding portion for holding the decorative sheet is provided in the recess. The decorative sheet is arranged in the holding portion so that the protective film is on the inside, and the core is provided with a convex portion to be inserted into the concave portion, and the convex portion is provided. Is provided with a molding portion for molding a resin molded product, the convex portion is inserted into the concave portion, and the holding portion of the decorative sheet is sandwiched between the holding portion of the cavity and the convex portion of the core. A step of injecting resin into the mold to insert-mold the resin molded product, and a step of taking out the resin molded product from the mold are included, and the protective film is peeled off to obtain the above-mentioned. Since the surface of the resin molded product is decorated by the decorative portion, the decorative sheet can be easily and accurately positioned, and the surface of the resin molded product can be easily and accurately positioned. In addition, it is possible to decorate the decorative sheet neatly without causing misalignment or wrinkles, and further, adhesion of chips and dust generated when the decorative sheet is cut to the surface of the decorative sheet and By reducing the damage and improving the yield, it becomes possible to reduce the manufacturing cost of the decorated resin molded product.
前記キャビティの保持部には前記加飾部に対応する部分に、凹状の曲面を設け、前記樹脂成形品の表面を凸状の曲面に形成し、前記樹脂成形品の曲面の表面を前記加飾部によって加飾することにより、前記樹脂成形品の表面に、位置ずれ、または、皺などを生じることなく加飾することが可能となる。 The holding portion of the cavity is provided with a concave curved surface in a portion corresponding to the decorative portion, the surface of the resin molded product is formed into a convex curved surface, and the surface of the curved surface of the resin molded product is decorated. By decorating the resin molded product by the portion, it is possible to decorate the surface of the resin molded product without causing misalignment or wrinkles.
本発明の樹脂成形品の別の形態の製造方法は、加飾シートを用いてインサート成形することによって、樹脂成形品の一面を加飾する樹脂成形品の製造方法であって、加飾部と前記加飾部の周囲に位置する挟持部とを有し、加飾部と挟持部を分離する切り込みが形成されている加飾フィルムと、前記加飾フィルムの加飾面に付着された保護フィルムを有する加飾シートを用意する工程と、前記加飾シートをコアおよびキャビティを有する金型に配置し、前記コアには凹部が設けられ、前記凹部内に前記樹脂成形品を成形する成形部および前記加飾シートを保持する保持部が設けられており、前記加飾シートを、前記保護フィルムが外側となるように、前記保持部に配置する工程と、前記キャビティには前記凹部内に挿入される凸部が設けられており、前記凹部内に前記凸部を挿入し、前記コアの保持部と前記キャビティの凸部とで前記加飾シートの前記挟持部を挟んで固定する工程と、前記金型内に樹脂を射出して樹脂成形品をインサート成形する工程と、前記金型から前記樹脂成形品を取り出す工程とを含み、前記保護フィルムをはがすことにより、前記加飾部によって前記樹脂成形品の表面の加飾が行われた状態となるので、前記加飾シートの位置決めが簡単に、かつ、正確に行うことができるようになり、前記樹脂成形品の表面に、位置ずれ、または、皺などを生じることなく綺麗に加飾することが可能となり、さらに、加飾シートをカット加工する際に発生する切り粉や加飾シート表面へのごみなどの付着および損傷が少なくなって歩留まりが向上することで、加飾された樹脂成形品の製造コストを低減することができるようになる。 Another form of manufacturing method of the resin molded product of the present invention is a method for manufacturing a resin molded product that decorates one surface of the resin molded product by insert molding using a decorative sheet, and is a method of manufacturing the resin molded product together with the decorative portion. A decorative film having a sandwiching portion located around the decorative portion and having a notch for separating the decorative portion and the sandwiching portion, and a protective film attached to the decorative surface of the decorative film. The step of preparing a decorative sheet having the above, the decorative sheet is placed in a mold having a core and a cavity, a recess is provided in the core, and a molding portion for molding the resin molded product in the recess and a molding portion. A holding portion for holding the decorative sheet is provided, and the step of arranging the decorative sheet in the holding portion so that the protective film is on the outside and the cavity being inserted into the recess. The convex portion is provided, and the convex portion is inserted into the concave portion, and the holding portion of the core and the convex portion of the cavity sandwich and fix the holding portion of the decorative sheet. A step of injecting resin into a mold to insert-mold a resin molded product and a step of taking out the resin molded product from the mold are included, and by peeling off the protective film, the resin molding is performed by the decorative portion. Since the surface of the product is decorated, the decorative sheet can be easily and accurately positioned, and the surface of the resin molded product is misaligned or misaligned. It is possible to decorate beautifully without causing wrinkles, and the yield is reduced by reducing the adhesion and damage of chips and dust generated when cutting the decorative sheet to the surface of the decorative sheet. By improving, it becomes possible to reduce the manufacturing cost of the decorated resin molded product.
前記コアの保持部には前記加飾部に対応する部分に、凹状の曲面を設け、前記樹脂成形品の表面を凸状の曲面に形成し、前記樹脂成形品の曲面の表面を前記加飾部によって加飾することにより、前記樹脂成形品の表面に、位置ずれ、または、皺などを生じることなく加飾することが可能となる。 The core holding portion is provided with a concave curved surface in a portion corresponding to the decorative portion, the surface of the resin molded product is formed into a convex curved surface, and the surface of the curved surface of the resin molded product is decorated. By decorating the resin molded product by the portion, it is possible to decorate the surface of the resin molded product without causing misalignment or wrinkles.
前記加飾シートの加飾部の平面形状を、円形または楕円形とすることにより、前記加飾シートのずれを防止し、さらに、前記加飾シートの位置決めを容易にすることができる。 By making the plane shape of the decorative portion of the decorative sheet circular or elliptical, it is possible to prevent the decorative sheet from shifting and further facilitate the positioning of the decorative sheet.
本発明の樹脂成形品の製造方法について、図面を参照しながら以下に詳細に説明する。最初に、本発明の第１の実施形態の樹脂成形品の製造方法について説明するが、第１の実施形態で使用する加飾シート１から説明する。図１に示すのが、本発明の第１の実施形態の樹脂成形品の製造方法に使用する加飾シート１の斜視図であり、図２が断面図である。第１の実施形態の樹脂成形品の製造方法の説明は、樹脂成形品１０として円形の蓋を用いて説明し、前記蓋の表面に加飾を施す場合について説明する。樹脂成形品の用途、形状、加飾する場所については、特に限定するものではなく、本発明は、様々な用途、形状の樹脂成形品に適用することが可能であり、加飾する面については、樹脂成形品の一面であれば表面に限定するものではない。 The method for producing the resin molded product of the present invention will be described in detail below with reference to the drawings. First, the method for producing the resin molded product according to the first embodiment of the present invention will be described, but the decorative sheet 1 used in the first embodiment will be described first. FIG. 1 is a perspective view of a decorative sheet 1 used in the method for producing a resin molded product according to the first embodiment of the present invention, and FIG. 2 is a sectional view. The method of manufacturing the resin molded product of the first embodiment will be described using a circular lid as the resin molded product 10, and a case where the surface of the lid is decorated will be described. The use, shape, and place to decorate the resin molded product are not particularly limited, and the present invention can be applied to resin molded products of various uses and shapes, and the surface to be decorated can be used. , If it is one side of a resin molded product, it is not limited to the surface.
第１の実施形態の樹脂成形品の製造方法に使用する加飾シート１は、樹脂成形品１０である蓋の表面を加飾するためのシートであって、図１に示すように、加飾フィルム２および保護フィルム３から構成されている。前記加飾フィルム２は、図１に示すように、樹脂成形品１０の加飾部分に合わせた円形の加飾部２１、前記加飾部２１の周囲に位置し、矩形の輪郭を有する挟持部２２から構成されており、前記加飾部２１と前記挟持部２２とは環状の切り込み２３によって分離されている。 The decorative sheet 1 used in the method for producing the resin molded product of the first embodiment is a sheet for decorating the surface of the lid, which is the resin molded product 10, and is decorated as shown in FIG. It is composed of a film 2 and a protective film 3. As shown in FIG. 1, the decorative film 2 is a circular decorative portion 21 that matches the decorative portion of the resin molded product 10, and a holding portion that is located around the decorative portion 21 and has a rectangular outline. It is composed of 22, and the decorative portion 21 and the sandwiching portion 22 are separated by an annular notch 23.
前記加飾フィルム２は、一面に印刷などによって加飾が施された加飾面を有するフィルムであって、少なくとも前記加飾部２１だけに加飾が施されていればよく、場合によっては前記挟持部２２にも加飾が施されていてもよい。前記加飾部２１の形状は円形に限定するものではなく、樹脂成形品１０の加飾部分に合わせた形状であればよく、楕円形とすることも可能であり、その他にも様々な形状とすることができる。また、前記加飾部２１の加飾方法についても限定するものではなく、従来の様々な手段を用いることができる。 The decorative film 2 is a film having a decorative surface which is decorated by printing or the like on one surface, and it is sufficient that at least only the decorative portion 21 is decorated, and in some cases, the decorative film 2. The sandwiching portion 22 may also be decorated. The shape of the decorative portion 21 is not limited to a circular shape, and may be any shape that matches the decorative portion of the resin molded product 10, and may be an elliptical shape. can do. Further, the decoration method of the decoration portion 21 is not limited, and various conventional means can be used.
前記切り込み２３は、前記樹脂成形品１０の加飾部分の形状に合わせて、前記加飾フィルム２をカットしたラインであり、前記切り込み２３を前記加飾フィルム２に設けておくことにより、前記樹脂成形品１０を成形した後、前記加飾部２１を前記樹脂成形品１０の表面に残した状態で、簡単に前記加飾シート１を前記樹脂成形品１０から取り外すことができる。 The notch 23 is a line obtained by cutting the decorative film 2 in accordance with the shape of the decorative portion of the resin molded product 10, and by providing the notch 23 in the decorative film 2, the resin is formed. After molding the molded product 10, the decorative sheet 1 can be easily removed from the resin molded product 10 with the decorative portion 21 left on the surface of the resin molded product 10.
前記保護フィルム３は一面が粘着面となっており、前記粘着面に前記加飾フィルム２が付着されている。前記保護フィルム３の粘着力は、前記加飾フィルム２を保持し、樹脂成形品１０を成形後、前記加飾部２１を残した状態で前記加飾シート１を取り外すことができる粘着力があればよく、前記保護フィルム３として、一般的な粘着フィルムを用いることができる。前記保護フィルム３は、例えば、ポリエチレン系のフィルムの一面に粘着面を設けたものを用いることができるが、特に材質を限定するものではなく、様々なフィルムを用いることができ、透明、半透明、または、不透明でもよい。樹脂成形品の表面が平坦ではない場合は、射出成形の際に前記保護フィルム３が変形する必要があることから、この場合、変形しやすい材質を用いることが好ましい。 One side of the protective film 3 is an adhesive surface, and the decorative film 2 is attached to the adhesive surface. The adhesive strength of the protective film 3 is such that the decorative film 2 can be held, the resin molded product 10 is molded, and then the decorative sheet 1 can be removed while the decorative portion 21 remains. As the protective film 3, a general adhesive film can be used. As the protective film 3, for example, a polyethylene-based film having an adhesive surface provided on one surface can be used, but the material is not particularly limited, and various films can be used, and transparent or translucent. , Or it may be opaque. If the surface of the resin molded product is not flat, the protective film 3 needs to be deformed during injection molding. In this case, it is preferable to use a material that is easily deformed.
前記加飾シート１は、前記加飾フィルム２の加飾面に前記保護フィルム３を付着させていることにより、前記樹脂成形品１０の成形が完了するまで、加飾面を保護することができ、前記加飾フィルム２の表面にごみなどが付着することや、表面を損傷することといった不具合を防ぐことができる。従来のような製造過程において生じる加飾フィルムの不具合による歩留まりを向上させることができ、製造コストの低減が可能となる。 By adhering the protective film 3 to the decorative surface of the decorative film 2, the decorative sheet 1 can protect the decorative surface until the molding of the resin molded product 10 is completed. It is possible to prevent problems such as dust adhering to the surface of the decorative film 2 and damage to the surface. It is possible to improve the yield due to defects in the decorative film that occur in the conventional manufacturing process, and it is possible to reduce the manufacturing cost.
次に、第１の実施形態の樹脂成形品の製造方法に使用する金型について説明する。前記金型は、キャビティ５およびコア６から構成されている。前記キャビティ５は、図３に示すように、前記加飾シート１を挿入し配置するための凹部５１が設けられている。前記凹部５１は、前記加飾シート１を挿入し、前記キャビティ５に対して所定の位置に配置するために設けられていることから、前記加飾シート１と同じ平面形状を有している。前記凹部５１に前記加飾シート１を保持する保持部５２、および、前記樹脂成形品１０の加飾部分を成形する加飾面成形部５３が設けられている。前記加飾面成形部５３は円形の平面形状を有し、さらに、前記樹脂成形品１０の加飾部分を凸状の曲面とするために、凹状の曲面に形成されている。前記加飾面成形部５３の周囲の平坦な面が前記保持部５２となっている。 Next, the mold used in the method for producing the resin molded product of the first embodiment will be described. The mold is composed of a cavity 5 and a core 6. As shown in FIG. 3, the cavity 5 is provided with a recess 51 for inserting and arranging the decorative sheet 1. Since the recess 51 is provided for inserting the decorative sheet 1 and arranging it at a predetermined position with respect to the cavity 5, it has the same planar shape as the decorative sheet 1. The recess 51 is provided with a holding portion 52 for holding the decorative sheet 1 and a decorative surface molding portion 53 for molding the decorative portion of the resin molded product 10. The decorative surface molding portion 53 has a circular planar shape, and is further formed on a concave curved surface in order to make the decorative portion of the resin molded product 10 a convex curved surface. The flat surface around the decorative surface forming portion 53 is the holding portion 52.
前記凹部５１内に前記加飾シート１を挿入した時に確実に保持するために、前記保持部５２の部分に吸引溝を設けることも可能である。前記吸引溝は、例えば、前記加飾面成形部５３を囲むように環状に配置することができ、前記吸引溝によって前記加飾シート１を吸引することにより、前記キャビティ５と前記コア６とを組み合わせるまでの間、確実に前記保護シート１を保持することが可能となる。 It is also possible to provide a suction groove in the portion of the holding portion 52 in order to securely hold the decorative sheet 1 when the decorative sheet 1 is inserted into the recess 51. The suction groove can be arranged in an annular shape so as to surround the decorative surface molding portion 53, for example, and the cavity 5 and the core 6 are sucked by the suction groove to suck the decorative sheet 1. It is possible to reliably hold the protective sheet 1 until it is combined.
前記コア６は、図４に示すように、前記コア６を前記キャビティ５と組み合わせる際に、前記キャビティ５の凹部５１内に挿入される凸部６１を有している。前記凸部６１は前記凹部５１に嵌合される形状を有しており、図４に示すように、前記凸部６１の先端の表面には、前記樹脂成形品１０を成形するための成形部６２が設けられており、前記成形部６２の開口の周囲に平坦な保持部６３が設けられている。前記成形部６２の開口の形状は、前記樹脂成形品１０の加飾部分の平面形状（本実施形態では円形）となっている。 As shown in FIG. 4, the core 6 has a convex portion 61 that is inserted into the concave portion 51 of the cavity 5 when the core 6 is combined with the cavity 5. The convex portion 61 has a shape of being fitted into the concave portion 51, and as shown in FIG. 4, a molding portion for molding the resin molded product 10 is formed on the surface of the tip of the convex portion 61. 62 is provided, and a flat holding portion 63 is provided around the opening of the molded portion 62. The shape of the opening of the molded portion 62 is a planar shape (circular in this embodiment) of the decorative portion of the resin molded product 10.
前記コア６を前記キャビティ５と組み合わせるために、前記コア６の凸部６１を前記キャビティ５の凹部５１に挿入すると、前記コア６の保持部６３は前記キャビティ５の保持部５２と当接し、この時、図６（ｂ）に示すように、前記保持部６３と前記保持部５２とによって、前記加飾シート１の挟持部２２の部分を挟み込むことにより、前記加飾シート１を所定の位置で固定することができる。 When the convex portion 61 of the core 6 is inserted into the concave portion 51 of the cavity 5 in order to combine the core 6 with the cavity 5, the holding portion 63 of the core 6 comes into contact with the holding portion 52 of the cavity 5. At that time, as shown in FIG. 6B, the decorative sheet 1 is placed at a predetermined position by sandwiching the portion of the holding portion 22 of the decorative sheet 1 between the holding portion 63 and the holding portion 52. Can be fixed.
前記金型には、シートインサート成形に必要な樹脂を射出するゲートなどが設けられているが、このような射出成形に必要な従来の構造については、従来の金型の様々な構造を用いることができることから、図示しておらず、詳細な説明は省略している。前記金型については、前記樹脂成形品１０の形状に合わせて様々な形状および構造に変更することや、彫刻などの加工を施すことにより、様々な模様を形成することができる。 The mold is provided with a gate for injecting a resin required for sheet insert molding, and various structures of the conventional mold are used for the conventional structure required for such injection molding. Therefore, it is not shown and detailed explanation is omitted. Various patterns can be formed on the mold by changing it to various shapes and structures according to the shape of the resin molded product 10 or by performing processing such as engraving.
前記キャビティ５の凹部５１および前記コア６の凸部６１の平面形状に関しては、本実施形態では矩形としているが、特に限定するものではなく、樹脂成形品の形状に合わせて変更することが可能である。ただし、前記加飾シート１を前記凹部５１に挿入することにより位置決めが行われる必要があることから、前記加飾シート１の位置決めが可能な形状であればよく、円形とすることは好ましくない。 The planar shape of the concave portion 51 of the cavity 5 and the convex portion 61 of the core 6 is rectangular in the present embodiment, but is not particularly limited and can be changed according to the shape of the resin molded product. is there. However, since positioning needs to be performed by inserting the decorative sheet 1 into the recess 51, the shape may be any shape as long as the decorative sheet 1 can be positioned, and it is not preferable to make it circular.
前記凹部５１の先端の前記加飾面成形部５３の形状は、前記樹脂成形品１０の加飾部分の表面の形状に合わせて変更することができ、本実施形態のような凹状の曲面だけでなく、凸状の曲面なども可能であり、射出成形の際に、前記加飾シート１が追従して変形可能な形状であればよい。 The shape of the decorative surface molding portion 53 at the tip of the concave portion 51 can be changed according to the shape of the surface of the decorative portion of the resin molded product 10, and only the concave curved surface as in the present embodiment is used. However, a convex curved surface or the like is also possible, and any shape may be used as long as the decorative sheet 1 can follow and deform during injection molding.
本発明の第１の実施形態の樹脂成形品の製造方法について説明する。第１の実施形態の樹脂成形品の製造方法は、前記加飾シート１および前記金型を用いて、蓋である樹脂成形品１０をインサート成形し、前記樹脂成形品１０の表面を加飾する製造方法である。図１に示すような、所定のデザインで加飾した前記加飾シート１を用意し、図５（ａ），（ｂ）に示すように、前記金型のキャビティ５の凹部５１内に前記加飾シート１を挿入し、前記凹部５１内の前記保持部５２の表面に前記加飾シート１を配置する。 A method for producing a resin molded product according to the first embodiment of the present invention will be described. In the method for producing a resin molded product of the first embodiment, the resin molded product 10 which is a lid is insert-molded using the decorative sheet 1 and the mold, and the surface of the resin molded product 10 is decorated. It is a manufacturing method. The decorative sheet 1 decorated with a predetermined design as shown in FIG. 1 is prepared, and as shown in FIGS. 5A and 5B, the decoration sheet 1 is inserted into the recess 51 of the cavity 5 of the mold. The decorative sheet 1 is inserted, and the decorative sheet 1 is arranged on the surface of the holding portion 52 in the recess 51.
前記加飾シート１は、前記保護フィルム３が内側となり、前記キャビティ５の保持部５２と当接する状態で前記凹部５１内に挿入する。前記加飾シート１を前記凹部５１に挿入し前記保持部５２と当接するように配置すると、図５（ｂ）に示すように、前記加飾シート１の加飾フィルム２の加飾部２１は、前記キャビティ５の加飾面成形部５３と重なるように配置される。この時、前記金型の凹部５１の平面形状と、前記加飾シート１の平面形状が同じであることから、前記加飾シート１の向きを確認し前記凹部５１内に挿入するだけで、前記加飾シート１を正確に所定の位置に正確に配置することができ、前記加飾部２１は前記加飾面成形部５３と正確に重なった状態となる。この時、前記保持部５２に前記吸引溝が設けられていれば、前記加飾シート１をより確実に保持した状態を維持することができるようになる。 The decorative sheet 1 is inserted into the recess 51 with the protective film 3 on the inside and in contact with the holding portion 52 of the cavity 5. When the decorative sheet 1 is inserted into the recess 51 and arranged so as to come into contact with the holding portion 52, as shown in FIG. 5B, the decorative portion 21 of the decorative film 2 of the decorative sheet 1 becomes , Is arranged so as to overlap the decorative surface forming portion 53 of the cavity 5. At this time, since the planar shape of the concave portion 51 of the mold is the same as the planar shape of the decorative sheet 1, the orientation of the decorative sheet 1 is confirmed and the decorative sheet 1 is simply inserted into the concave portion 51. The decorative sheet 1 can be accurately arranged at a predetermined position, and the decorative portion 21 is in a state of accurately overlapping the decorative surface forming portion 53. At this time, if the suction groove is provided in the holding portion 52, it is possible to maintain the state in which the decorative sheet 1 is held more reliably.
前記加飾シート１を前記凹部５１に挿入した後、前記コア６を前記キャビティ５と組み合わせて前記金型を組み立てるために、図５（ｃ），図６（ａ）に示すように、前記コア６の凸部６１を前記キャビティ５の凹部５１内に挿入する。前記凸部６１を凹部５１内に挿入すると、図６（ａ）に示すように、前記凸部６１の先端は前記加飾シート１の加飾フィルム２と当接して、前記加飾シート１の挟持部２２の部分が、前記キャビティ５の保持部５２と前記コア６の保持部６３とによって挟まれて、前記加飾シート１が固定された状態となる。 After inserting the decorative sheet 1 into the recess 51, the core 6 is combined with the cavity 5 to assemble the mold, as shown in FIGS. 5 (c) and 6 (a). The convex portion 61 of 6 is inserted into the concave portion 51 of the cavity 5. When the convex portion 61 is inserted into the concave portion 51, as shown in FIG. 6A, the tip of the convex portion 61 comes into contact with the decorative film 2 of the decorative sheet 1 and the decorative sheet 1 The portion of the sandwiching portion 22 is sandwiched between the holding portion 52 of the cavity 5 and the holding portion 63 of the core 6, and the decorative sheet 1 is fixed.
この時、前記キャビティ５の凹部５１内に設けられた加飾面成形部５３は、前記加飾シート１の前記保護フィルム３と前記加飾部２１とを介して、前記コア６の成形部６２の開口と重なるように位置しているが、前記加飾面成形部５３は凹状の曲面を有していることにより、図６（ａ）の断面図に示すように、前記加飾シート１とは当接しておらず、前記加飾面成形部５３と前記加飾シート１の保護フィルム３との間には隙間が生じた状態となっている。前記加飾面成形部５３が平坦な場合にはこのような隙間は生じない。 At this time, the decorative surface forming portion 53 provided in the concave portion 51 of the cavity 5 passes through the protective film 3 of the decorative sheet 1 and the decorative portion 21 to form the forming portion 62 of the core 6. Although it is located so as to overlap the opening of the above, the decorative surface forming portion 53 has a concave curved surface, so that the decorative surface forming portion 53 and the decorative sheet 1 are as shown in the cross-sectional view of FIG. 6A. Are not in contact with each other, and a gap is formed between the decorative surface forming portion 53 and the protective film 3 of the decorative sheet 1. When the decorative surface forming portion 53 is flat, such a gap does not occur.
このようにして、前記キャビティ５と前記コア６を組み合わせて前記金型を組み立てて、前記キャビティ５の保持部５２と前記コア６の保持部６３とによって前記加飾シート１の挟持部２２を挟み込んだ状態で、前記キャビティ５と前記コア６とを互いに固定すると、前記加飾シート１は、前記金型内において所定の位置に正確に位置決めされた状態で強固に固定される。 In this way, the cavity 5 and the core 6 are combined to assemble the mold, and the holding portion 22 of the decorative sheet 1 is sandwiched between the holding portion 52 of the cavity 5 and the holding portion 63 of the core 6. When the cavity 5 and the core 6 are fixed to each other in this state, the decorative sheet 1 is firmly fixed in a state of being accurately positioned at a predetermined position in the mold.
このようにして前記加飾シート１を前記金型内に固定した後、前記金型の前記成形部６２内にゲートを通じて樹脂を射出し、前記樹脂成形品１０を射出成形する。前記金型内にゲートから射出された樹脂は、前記成形部６２内に射出されて、前記加飾シート１の加飾フィルム２の加飾部２１を前記キャビティ５の前記加飾面成形部５３へと押圧し、図６（ｂ）に示すように、前記樹脂成形品１０の加飾部分が成形される。 After fixing the decorative sheet 1 in the mold in this way, resin is injected into the molding portion 62 of the mold through a gate, and the resin molded product 10 is injection-molded. The resin injected from the gate into the mold is injected into the molding portion 62, and the decorative portion 21 of the decorative film 2 of the decorative sheet 1 is molded into the decorative surface molding portion 53 of the cavity 5. As shown in FIG. 6B, the decorative portion of the resin molded product 10 is molded.
この時、前記加飾部２１は、前記切り込み２３によって前記挟持部２２とは分離されていることから、前記加飾フィルム２は、前記加飾部２１だけが前記樹脂成形品１０の加飾部分に合わせて変形し、前記加飾部２１が付着されている前記保護フィルム３については、前記加飾部２１が付着された部分が弾性変形する。このように、本発明の樹脂成形品の製造方法は、前記加飾フィルム２の加飾部２１が、前記切り込み２３によって前記挟持部２２と分離されていることから、前記挟持部２２は固定された状態で、前記加飾部２１だけが変形できることから、曲面を加飾した場合に、前記加飾フィルム２に皺などが生じにくいという効果を奏する。 At this time, since the decorative portion 21 is separated from the sandwiching portion 22 by the notch 23, only the decorative portion 21 of the decorative film 2 is the decorative portion of the resin molded product 10. With respect to the protective film 3 to which the decorative portion 21 is attached, the portion to which the decorative portion 21 is attached is elastically deformed. As described above, in the method for producing the resin molded product of the present invention, since the decorative portion 21 of the decorative film 2 is separated from the sandwiching portion 22 by the notch 23, the sandwiching portion 22 is fixed. Since only the decorative portion 21 can be deformed in this state, there is an effect that wrinkles and the like are less likely to occur on the decorative film 2 when the curved surface is decorated.
さらに、本実施形態の樹脂成形品の製造方法は、前記加飾フィルム２の加飾部２１の表面が前記保護フィルム３によって保護されていることによって、射出成形の際に前記加飾部２１の表面に樹脂が回り込むことを防止することができ、前記樹脂成形品１０の加飾面を綺麗に仕上げることができるという効果を奏する。また、前記加飾部２１が前記保護フィルム３と付着されていることにより、前記加飾部２１が樹脂によって押され、動いて位置ずれが生じることを防止することができるという効果を奏する。 Further, in the method for producing a resin molded product of the present embodiment, the surface of the decorative portion 21 of the decorative film 2 is protected by the protective film 3, so that the decorative portion 21 can be formed during injection molding. It is possible to prevent the resin from wrapping around the surface, and it is possible to achieve the effect that the decorative surface of the resin molded product 10 can be beautifully finished. Further, since the decorative portion 21 is attached to the protective film 3, it is possible to prevent the decorative portion 21 from being pushed by the resin and moving to cause misalignment.
前記金型内への樹脂の射出が終わり、前記樹脂成形品１０の成形が完了したら、図７（ａ）に示すように、前記コア６を前記キャビティ５から取り外して前記金型の面を開放し、その後、図７（ｂ）に示すように、前記樹脂成形品１０を前記キャビティ５内から取り出す。前記樹脂成形品１０を取り出すと、図８に示すように、前記樹脂成形品１０に前記加飾シート１が付着した状態となっている。 When the injection of the resin into the mold is completed and the molding of the resin molded product 10 is completed, the core 6 is removed from the cavity 5 to open the surface of the mold as shown in FIG. 7A. Then, as shown in FIG. 7B, the resin molded product 10 is taken out from the cavity 5. When the resin molded product 10 is taken out, as shown in FIG. 8, the decorative sheet 1 is in a state of being attached to the resin molded product 10.
このような状態の前記樹脂成形品１０から、前記加飾シート１を取り外すと、図９に示すように、前記樹脂成形品１０の表面には、前記加飾部２１が一体に成形されて加飾された状態の前記樹脂成形品１０が完成する。前記樹脂成形品１０から取り外した前記加飾シート１は、図９に示すように、前記加飾部２１が除去された状態となる。 When the decorative sheet 1 is removed from the resin molded product 10 in such a state, as shown in FIG. 9, the decorative portion 21 is integrally molded and added to the surface of the resin molded product 10. The resin molded product 10 in the decorated state is completed. As shown in FIG. 9, the decorative sheet 1 removed from the resin molded product 10 is in a state in which the decorative portion 21 has been removed.
前記加飾シート１を取り外す際、前記加飾部２１は前記切り込み２３によって分離されていることから、前記加飾シート１を引っ張る、あるいは、前記樹脂成形品１０を引っ張るだけで、前記加飾部２１を前記樹脂成形品１０の表面に残した状態で、簡単に前記樹脂成形品１０から取り外すことができる。そして、前記樹脂成形品１０の表面の前記加飾部２１の縁は綺麗にカットされた状態であることから、従来のように、樹脂成形後に加飾フィルムをカットする従来技術と比べると、前記樹脂成形品１０の加飾部分の精度および美観は向上し、そして、樹脂成形後の加飾フィルムをカットする工程が不要となることから、製造コストの低減につながる。 When the decorative sheet 1 is removed, the decorative portion 21 is separated by the notch 23. Therefore, simply by pulling the decorative sheet 1 or pulling the resin molded product 10, the decorative portion 21 is pulled. The 21 can be easily removed from the resin molded product 10 while leaving the 21 on the surface of the resin molded product 10. Since the edge of the decorative portion 21 on the surface of the resin molded product 10 is in a state of being neatly cut, as compared with the conventional technique of cutting the decorative film after resin molding, the above The accuracy and aesthetics of the decorative portion of the resin molded product 10 are improved, and the step of cutting the decorative film after resin molding becomes unnecessary, which leads to a reduction in manufacturing cost.
前記加飾シート１を前記樹脂成形品１０から取り外すタイミングは、前記樹脂成形品１０を前記金型から取り外した直後とする必要はなく、前記加飾シート１が不要となる工程まで、前記樹脂成形品１０から前記加飾シート１を取り外さないで、前記樹脂成形品１０の加飾部分を保護する保護シートとして使用することも可能である。 The timing of removing the decorative sheet 1 from the resin molded product 10 does not have to be immediately after the resin molded product 10 is removed from the mold, and the resin molding is performed until the step of eliminating the decorative sheet 1. It is also possible to use the decorative sheet 1 as a protective sheet for protecting the decorative portion of the resin molded product 10 without removing the decorative sheet 1 from the product 10.
本発明の樹脂成形品の製造方法は、前記加飾シート１および前記金型を用いることにより、従来よりも簡単にかつ正確に加飾を行うことができるという優れた効果を奏し、さらに、前記樹脂成形品１０を成形後の工程は、前記加飾シート１を取り外すだけであることから、従来のような加飾シートの切断工程が不要となり、また、前記保護フィルム３によって樹脂成形前および樹脂成形中に前記加飾部２１を保護することで歩留まりが向上することにより、製造コストを低減することができるという優れた効果を奏する。 The method for producing a resin molded product of the present invention has an excellent effect that decoration can be performed more easily and accurately than before by using the decoration sheet 1 and the mold. Since the process after molding the resin molded product 10 is only to remove the decorative sheet 1, the conventional process of cutting the decorative sheet becomes unnecessary, and the protective film 3 makes it possible to perform before resin molding and the resin. By protecting the decorative portion 21 during molding, the yield is improved, which is an excellent effect that the manufacturing cost can be reduced.
次に、第２の実施形態の樹脂成形品の製造方法について説明する。第２の実施形態で使用する加飾シート１は、第１の実施形態と同じものを使用することから、加飾シート１に関する説明は省略し、第２の実施形態の樹脂成形品の製造方法に使用する金型について説明する。前記金型は、コア７およびキャビティ８から構成されている。前記コア７は、図１０に示すように、前記加飾シート１を挿入し配置するための凹部７１が設けられており、前記凹部７１内に前記樹脂成形品１０を成形するための成形部７２、および、保持部７３が設けられている。 Next, a method for producing the resin molded product of the second embodiment will be described. Since the decorative sheet 1 used in the second embodiment is the same as that in the first embodiment, the description of the decorative sheet 1 is omitted, and the method for manufacturing the resin molded product of the second embodiment is omitted. The mold used for is described. The mold is composed of a core 7 and a cavity 8. As shown in FIG. 10, the core 7 is provided with a recess 71 for inserting and arranging the decorative sheet 1, and a molding portion 72 for molding the resin molded product 10 in the recess 71. , And a holding portion 73 is provided.
前記凹部７１は、前記加飾シート１を挿入し、前記コア７に対して所定の位置に配置するために設けられていることから、前記加飾シート１と同じ平面形状を有している。前記凹部７１内に前記成形部７２の開口が位置しており、前記開口の形状は、前記樹脂成形品１０の加飾部分の平面形状（本実施形態では円形）となっている。前記凹部７１内には、前記開口の周囲に前記保持部７３が設けられている。前記凹部７１内に挿入した前記加飾シート１を確実に保持するために、前記保持部７３の部分に吸引溝を設けることも可能である。例えば、前記成形部７２の開口を囲むように環状に配置した前記吸引溝によって前記加飾シート１を吸引することにより、前記コア７と前記キャビティ８とを組み合わせるまでの間、確実に前記保護シート１を保持することが可能となる。 Since the recess 71 is provided for inserting the decorative sheet 1 and arranging it at a predetermined position with respect to the core 7, it has the same planar shape as the decorative sheet 1. The opening of the molded portion 72 is located in the recess 71, and the shape of the opening is a planar shape (circular in the present embodiment) of the decorative portion of the resin molded product 10. In the recess 71, the holding portion 73 is provided around the opening. In order to reliably hold the decorative sheet 1 inserted into the recess 71, it is also possible to provide a suction groove in the portion of the holding portion 73. For example, by sucking the decorative sheet 1 by the suction grooves arranged in an annular shape so as to surround the opening of the molding portion 72, the protective sheet is surely used until the core 7 and the cavity 8 are combined. It becomes possible to hold 1.
前記キャビティ８は、図１１に示すように、前記キャビティ８を前記コア７と組み合わせる際に、前記コア７の凹部７１内に挿入される凸部８１を有している。前記凸部８１は前記凹部７１に嵌合される形状を有しており、図１１に示すように、前記凸部８１の先端の表面には、前記コア７の保持部７３と当接する保持部８２、および、前記成形部７２の開口を塞ぎ、前記樹脂成形品１０の加飾部分を成形する加飾面成形部８３が形成されている。前記加飾面成形部８３は円形の平面形状を有し、さらに、前記樹脂成形品１０の加飾部分を凸状の曲面とするために、凹状の曲面に形成されている。 As shown in FIG. 11, the cavity 8 has a convex portion 81 that is inserted into the concave portion 71 of the core 7 when the cavity 8 is combined with the core 7. The convex portion 81 has a shape of being fitted into the concave portion 71, and as shown in FIG. 11, a holding portion that abuts the holding portion 73 of the core 7 on the surface of the tip of the convex portion 81. A decorative surface molding portion 83 is formed which closes the openings of the molding portion 72 and the molding portion 72 and forms the decorative portion of the resin molded product 10. The decorative surface molding portion 83 has a circular planar shape, and is further formed on a concave curved surface in order to make the decorative portion of the resin molded product 10 a convex curved surface.
前記キャビティ８を前記コア７と組み合わせるために、前記キャビティ８の凸部８１を前記コア７の凹部７１に挿入すると、前記キャビティ８の保持部８２は前記コア７の保持部７３と当接し、この時、図１３（ｂ）に示すように、前記保持部８２と前記保持部７３とによって、前記加飾シート１の挟持部２２の部分を挟み込むことにより、前記加飾シート１を所定の位置で固定することができる。 When the convex portion 81 of the cavity 8 is inserted into the concave portion 71 of the core 7 in order to combine the cavity 8 with the core 7, the holding portion 82 of the cavity 8 comes into contact with the holding portion 73 of the core 7. At that time, as shown in FIG. 13B, the decorative sheet 1 is held at a predetermined position by sandwiching the portion of the holding portion 22 of the decorative sheet 1 between the holding portion 82 and the holding portion 73. Can be fixed.
前記金型には、シートインサート成形に必要な樹脂を射出するゲートなどが設けられているが、このような射出成形に必要な従来の構造については、従来の金型の様々な構造を用いることができることから、図示しておらず、また、詳細な説明は省略している。前記金型については、前記樹脂成形品１０の形状に合わせて様々な形状および構造に変更することができる。 The mold is provided with a gate for injecting a resin required for sheet insert molding, and various structures of the conventional mold are used for the conventional structure required for such injection molding. Therefore, it is not shown and detailed description is omitted. The mold can be changed to various shapes and structures according to the shape of the resin molded product 10.
前記コア７の凹部７１および前記キャビティ８の凸部８１の平面形状に関しては、本実施形態では矩形としているが、特に限定するものではなく、樹脂成形品の形状に合わせて変更することも可能である。ただし、前記加飾シート１を前記凹部７１に挿入することにより位置決めが行われる必要があることから、前記加飾シート１の位置決めが可能な形状であればよく、円形とすることは好ましくない。 The planar shape of the concave portion 71 of the core 7 and the convex portion 81 of the cavity 8 is rectangular in the present embodiment, but is not particularly limited and can be changed according to the shape of the resin molded product. is there. However, since positioning needs to be performed by inserting the decorative sheet 1 into the recess 71, the shape may be any shape as long as the decorative sheet 1 can be positioned, and it is not preferable to make it circular.
前記凸部８１の先端の前記加飾面成形部８３の形状は、前記樹脂成形品１０の加飾部分の表面の形状に合わせて変更することができ、本実施形態のような凹状の曲面だけでなく、凸状の曲面なども可能であり、射出成形の際に、前記加飾シート１が追従して変形可能な範囲での湾曲形状、または、その他の形状とすることができる。 The shape of the decorative surface molding portion 83 at the tip of the convex portion 81 can be changed according to the shape of the surface of the decorative portion of the resin molded product 10, and only the concave curved surface as in the present embodiment can be changed. However, a convex curved surface or the like is also possible, and it can be a curved shape within a range in which the decorative sheet 1 can follow and deform during injection molding, or another shape.
本発明の第２の実施形態の樹脂成形品の製造方法について説明する。第２の実施形態の樹脂成形品の製造方法は、第１の実施形態と同様に、前記加飾シート１および前記金型を用いて、蓋である樹脂成形品１０をインサート成形し、前記樹脂成形品１０の表面を加飾する製造方法である。図１に示すような、所定のデザインで加飾した前記加飾シート１を用意し、図１２（ａ），（ｂ）に示すように、前記金型のコア７の凹部７１内に前記加飾シート１を挿入し、前記凹部７１の保持部７３の表面に前記加飾シート１を配置する。 A method for producing a resin molded product according to a second embodiment of the present invention will be described. In the method for producing a resin molded product of the second embodiment, similarly to the first embodiment, the resin molded product 10 as a lid is insert-molded using the decorative sheet 1 and the mold, and the resin is formed. This is a manufacturing method for decorating the surface of the molded product 10. The decorative sheet 1 decorated with a predetermined design as shown in FIG. 1 is prepared, and as shown in FIGS. 12 (a) and 12 (b), the decorative sheet 1 is inserted into the recess 71 of the core 7 of the mold. The decorative sheet 1 is inserted, and the decorative sheet 1 is arranged on the surface of the holding portion 73 of the recess 71.
前記加飾シート１は、前記保護フィルム３が外側となり、前記加飾フィルム２が前記コア７の保持部７３と当接するように前記凹部７１内に挿入する。前記加飾シート１を前記凹部７１に挿入し配置すると、図１２（ｂ）に示すように、前記加飾シート１の加飾フィルム２の加飾部２１は、前記コア７の成形部７２の開口と重なるように配置される。この時、前記金型の凹部７１の平面形状と、前記加飾シート１の平面形状が同じであることから、前記加飾シート１の向きを確認し前記凹部７１内に挿入するだけで、前記加飾シート１を正確に所定の位置に配置することができ、前記加飾部２１は成形部７２の開口と正確に重なった状態となる。 The decorative sheet 1 is inserted into the recess 71 so that the protective film 3 is on the outside and the decorative film 2 is in contact with the holding portion 73 of the core 7. When the decorative sheet 1 is inserted into the recess 71 and arranged, as shown in FIG. 12B, the decorative portion 21 of the decorative film 2 of the decorative sheet 1 is formed on the molded portion 72 of the core 7. Arranged so as to overlap the opening. At this time, since the planar shape of the concave portion 71 of the mold and the planar shape of the decorative sheet 1 are the same, it is only necessary to confirm the orientation of the decorative sheet 1 and insert it into the concave portion 71. The decorative sheet 1 can be accurately arranged at a predetermined position, and the decorative portion 21 is in a state of accurately overlapping the opening of the molded portion 72.
前記加飾シート１を前記凹部７１に挿入した後、前記キャビティ８を前記コア７と組み合わせて前記金型を組み立てるために、図１２（ｃ），図１３（ａ）に示すように、前記キャビティ８の凸部８１を前記コア７の凹部７１内に挿入する。前記凸部８１を凹部７１内に挿入すると、図１３（ａ）に示すように、前記凸部８１の先端は前記加飾シート１の保護フィルム３と当接して、前記加飾シート１の挟持部２２の部分が、前記コア７の保持部７３と前記キャビティ８の保持部８２とによって挟まれて、前記加飾シート１が固定された状態となる。 After inserting the decorative sheet 1 into the recess 71, the cavity 8 is combined with the core 7 to assemble the mold, as shown in FIGS. 12 (c) and 13 (a). The convex portion 81 of 8 is inserted into the concave portion 71 of the core 7. When the convex portion 81 is inserted into the concave portion 71, as shown in FIG. 13A, the tip of the convex portion 81 comes into contact with the protective film 3 of the decorative sheet 1 and sandwiches the decorative sheet 1. The portion of the portion 22 is sandwiched between the holding portion 73 of the core 7 and the holding portion 82 of the cavity 8, and the decorative sheet 1 is fixed.
この時、前記凸部８１の先端に設けられた前記加飾面成形部８３は、前記加飾シート１の加飾部２１と前記保護フィルム３を介して、前記コア７の成形部７２の開口と重なるように位置しているが、前記加飾面成形部８３は凹状の曲面を有していることにより、図１３（ａ）の断面図に示すように、前記加飾シート１とは当接しておらず、前記加飾面成形部８３と前記加飾シート１の保護フィルム３との間には隙間が生じた状態となっている。前記加飾面成形部８３が平坦な場合にはこのような隙間は生じない。 At this time, the decorative surface molding portion 83 provided at the tip of the convex portion 81 opens the molding portion 72 of the core 7 via the decoration portion 21 of the decoration sheet 1 and the protective film 3. However, since the decorative surface forming portion 83 has a concave curved surface, as shown in the cross-sectional view of FIG. 13A, the decorative surface forming portion 83 is in contact with the decorative sheet 1. It is not in contact with each other, and a gap is formed between the decorative surface forming portion 83 and the protective film 3 of the decorative sheet 1. When the decorative surface forming portion 83 is flat, such a gap does not occur.
このようにして、前記コア７と前記キャビティ８を組み合わせて前記金型を組み立てて、前記コア７の保持部７３と前記キャビティ８の保持部８２とによって前記加飾シート１の挟持部２２を挟み込んだ状態で、前記コア７と前記キャビティ８とを互いに固定すると、前記加飾シート１は、前記金型内において所定の位置に正確に位置決めされた状態で強固に固定される。 In this way, the core 7 and the cavity 8 are combined to assemble the mold, and the holding portion 22 of the decorative sheet 1 is sandwiched between the holding portion 73 of the core 7 and the holding portion 82 of the cavity 8. When the core 7 and the cavity 8 are fixed to each other in this state, the decorative sheet 1 is firmly fixed in a state of being accurately positioned at a predetermined position in the mold.
このようにして前記加飾シート１を前記金型内に固定した後、前記金型の前記成形部７２内にゲートを通じて樹脂を射出し、前記樹脂成形品１０を射出成形する。前記金型内にゲートから射出された樹脂は、前記成形部７２内に射出されて、前記加飾シート１の加飾フィルム２の加飾部２１を前記キャビティ８の前記加飾面成形部８３へと押圧し、図１３（ｂ）に示すように、前記樹脂成形品１０の加飾部分が成形される。 After fixing the decorative sheet 1 in the mold in this way, resin is injected into the molding portion 72 of the mold through a gate, and the resin molded product 10 is injection-molded. The resin injected from the gate into the mold is injected into the molding portion 72, and the decorative portion 21 of the decorative film 2 of the decorative sheet 1 is molded into the decorative surface molding portion 83 of the cavity 8. As shown in FIG. 13B, the decorative portion of the resin molded product 10 is molded.
この時、前記加飾部２１は、前記切り込み２３によって前記挟持部２２とは分離されていることによって、本発明の樹脂成形品の製造方法は、曲面を加飾した場合に、前記加飾フィルム２に皺などが生じにくいという効果を奏する。また、本発明の樹脂成形品の製造方法は、前記加飾シート１の加飾フィルム２が保護フィルム３で保護されていることによって、射出成形の際に前記加飾部２１の表面に樹脂が回り込むことを防止し、前記樹脂成形品１０の加飾面を綺麗に仕上げることができるという効果を奏し、さらに、前記加飾部２１が樹脂によって押され、動いて位置ずれが生じることを防止することができるという効果を奏する。 At this time, the decorative portion 21 is separated from the sandwiching portion 22 by the notch 23, so that the method for producing a resin molded product of the present invention is the decorative film when a curved surface is decorated. It has the effect of preventing wrinkles from occurring in 2. Further, in the method for producing a resin molded product of the present invention, the decorative film 2 of the decorative sheet 1 is protected by the protective film 3, so that the resin is applied to the surface of the decorative portion 21 during injection molding. It has the effect of preventing the resin molded product 10 from wrapping around and finishing the decorative surface of the resin molded product 10 neatly, and further prevents the decorative portion 21 from being pushed by the resin and moving to cause misalignment. It has the effect of being able to do it.
前記金型内への樹脂の射出が終わり、前記樹脂成形品１０の成形が完了したら、図１４（ａ）に示すように、前記キャビティ８を前記コア７から取り外して前記金型の面を開放し、その後、図１４（ｂ）に示すように、前記樹脂成形品１０を前記コア７の凹部７１内から取り出す。前記樹脂成形品１０を取り出すと、図８に示すように、前記樹脂成形品１０に前記加飾シート１が付着した状態となっている。 When the injection of the resin into the mold is completed and the molding of the resin molded product 10 is completed, the cavity 8 is removed from the core 7 to open the surface of the mold as shown in FIG. 14A. Then, as shown in FIG. 14B, the resin molded product 10 is taken out from the recess 71 of the core 7. When the resin molded product 10 is taken out, as shown in FIG. 8, the decorative sheet 1 is in a state of being attached to the resin molded product 10.
この後は、第１の実施形態と同様に、前記樹脂成形品１０から、前記加飾シート１を取り外すと、図９に示すように、表面に前記加飾部２１が一体に成形されて加飾された状態の前記樹脂成形品１０が完成する。前記樹脂成形品１０から取り外した前記加飾シート１は、図９に示すように、前記加飾部２１が除去された状態となる。 After that, as in the first embodiment, when the decorative sheet 1 is removed from the resin molded product 10, the decorative portion 21 is integrally molded on the surface as shown in FIG. The resin molded product 10 in the decorated state is completed. As shown in FIG. 9, the decorative sheet 1 removed from the resin molded product 10 is in a state in which the decorative portion 21 has been removed.
前記加飾シート１を取り外す際、前記切り込み２３を設けていることによって、前記加飾シート１を引っ張る、あるいは、前記樹脂成形品１０を引っ張るだけで、前記保護フィルム３および前記加飾フィルム２の挟持部２２を簡単に、そして、綺麗に前記樹脂成形品１０から取り外すことができる。 When the decorative sheet 1 is removed, the protective film 3 and the decorative film 2 can be obtained by simply pulling the decorative sheet 1 or the resin molded product 10 by providing the notch 23. The sandwiching portion 22 can be easily and neatly removed from the resin molded product 10.
前記加飾シート１を前記樹脂成形品１０から取り外すタイミングは、前記樹脂成形品１０を前記金型から取り外した直後、あるいは、前記加飾シート１が不要となる工程など様々なタイミングとすることができる。 The timing for removing the decorative sheet 1 from the resin molded product 10 may be various timings such as immediately after the resin molded product 10 is removed from the mold, or a step in which the decorative sheet 1 becomes unnecessary. it can.
１ 加飾シート
２ 加飾フィルム
２１ 加飾部
２２ 挟持部
２３ 切り込み
３ 保護フィルム
５，８ キャビティ
５１，７１ 凹部
５２，７３ 保持部
５３，８３ 加飾面成形部
６，７ コア
６１，８１ 凸部
６２，７２ 成形部
６３，８２ 保持部
１０，１０’ 樹脂成形品
1 Decorative sheet 2 Decorative film 21 Decorative part 22 Holding part 23 Notch 3 Protective film 5,8 Cavity 51,71 Recessed part 52,73 Holding part 53,83 Decorative surface molded part 6,7 Core 61,81 Convex part 62,72 Molded part 63,82 Holding part 10,10'Resin molded product
Claims (6)
加飾部と前記加飾部の周囲に位置する挟持部とを有し、加飾部と挟持部を分離する切り込みが形成されている加飾フィルムと、前記加飾フィルムの加飾面に付着された保護フィルムを有する加飾シートを用意する工程と、
前記加飾シートをキャビティおよびコアを有する金型に配置し、前記キャビティには凹部が設けられており、前記凹部内に前記加飾シートを保持する保持部が設けられており、前記加飾シートを、前記保護フィルムが内側となるように、前記保持部に配置する工程と、
前記コアには前記凹部内に挿入される凸部が設けられており、前記凸部には樹脂成形品を成形する成形部が設けられており、前記凹部内に前記凸部を挿入し、前記キャビティの保持部と前記コアの凸部とで前記加飾シートの前記挟持部を挟んで固定する工程と、
前記金型内に樹脂を射出して樹脂成形品をインサート成形する工程と、
前記金型から前記樹脂成形品を取り出す工程とを含み、
前記保護フィルムをはがすことにより、前記加飾部によって前記樹脂成形品の表面の加飾が行われることを特徴とする樹脂成形品の製造方法。 It is a method for manufacturing a resin molded product that decorates one surface of the resin molded product by insert molding using a decorative sheet.
A decorative film having a decorative portion and a holding portion located around the decorative portion and having a notch for separating the decorative portion and the sandwiching portion, and adhering to the decorative surface of the decorative film. The process of preparing a decorative sheet with a protective film
The decorative sheet is arranged in a mold having a cavity and a core, the cavity is provided with a recess, and a holding portion for holding the decorative sheet is provided in the recess, and the decorative sheet is provided. In the step of arranging the protective film on the holding portion so as to be inside.
The core is provided with a convex portion to be inserted into the concave portion, and the convex portion is provided with a molding portion for molding a resin molded product. The convex portion is inserted into the concave portion, and the convex portion is inserted. A step of sandwiching and fixing the holding portion of the decorative sheet between the holding portion of the cavity and the convex portion of the core, and
The process of injecting resin into the mold and insert molding the resin molded product,
Including the step of taking out the resin molded product from the mold.
A method for producing a resin molded product, characterized in that the surface of the resin molded product is decorated by the decorative portion by peeling off the protective film.
加飾部と前記加飾部の周囲に位置する挟持部とを有し、加飾部と挟持部を分離する切り込みが形成されている加飾フィルムと、前記加飾フィルムの加飾面に付着された保護フィルムを有する加飾シートを用意する工程と、
前記加飾シートをコアおよびキャビティを有する金型に配置し、前記コアには凹部が設けられ、前記凹部内に前記樹脂成形品を成形する成形部および前記加飾シートを保持する保持部が設けられており、前記加飾シートを、前記保護フィルムが外側となるように、前記保持部に配置する工程と、
前記キャビティには前記凹部内に挿入される凸部が設けられており、前記凹部内に前記凸部を挿入し、前記コアの保持部と前記キャビティの凸部とで前記加飾シートの前記挟持部を挟んで固定する工程と、
前記金型内に樹脂を射出して樹脂成形品をインサート成形する工程と、
前記金型から前記樹脂成形品を取り出す工程とを含み、
前記保護フィルムをはがすことにより、前記加飾部によって前記樹脂成形品の表面の加飾が行われることを特徴とする樹脂成形品の製造方法。 It is a method for manufacturing a resin molded product that decorates one surface of the resin molded product by insert molding using a decorative sheet.
A decorative film having a decorative portion and a holding portion located around the decorative portion and having a notch for separating the decorative portion and the sandwiching portion, and adhering to the decorative surface of the decorative film. The process of preparing a decorative sheet with a protective film
The decorative sheet is arranged in a mold having a core and a cavity, the core is provided with a recess, and a molding portion for molding the resin molded product and a holding portion for holding the decorative sheet are provided in the recess. The step of arranging the decorative sheet on the holding portion so that the protective film is on the outside.
The cavity is provided with a convex portion to be inserted into the concave portion, the convex portion is inserted into the concave portion, and the decorative sheet is sandwiched between the holding portion of the core and the convex portion of the cavity. The process of sandwiching and fixing the part and
The process of injecting resin into the mold and insert molding the resin molded product,
Including the step of taking out the resin molded product from the mold.
A method for producing a resin molded product, characterized in that the surface of the resin molded product is decorated by the decorative portion by peeling off the protective film.
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08267505A (en) * | 1995-03-31 | 1996-10-15 | Nissha Printing Co Ltd | Manufacture of insert-molded article and insert film |
| JP2002360809A (en) * | 2001-06-13 | 2002-12-17 | Aiwa Raito:Kk | Game machine component and production method therefor |
| JP2007290315A (en) * | 2006-04-27 | 2007-11-08 | Dainippon Ink & Chem Inc | Insert molding sheet and method for manufacturing insert molding article |
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- 2019-05-16 JP JP2019092616A patent/JP2020185745A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08267505A (en) * | 1995-03-31 | 1996-10-15 | Nissha Printing Co Ltd | Manufacture of insert-molded article and insert film |
| JP2002360809A (en) * | 2001-06-13 | 2002-12-17 | Aiwa Raito:Kk | Game machine component and production method therefor |
| JP2007290315A (en) * | 2006-04-27 | 2007-11-08 | Dainippon Ink & Chem Inc | Insert molding sheet and method for manufacturing insert molding article |
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