JP2023094409A - Method of manufacturing insert molded products and insert molded products - Google Patents

Abstract

To improve the durability of insert-molded products by more reliably suppressing peeling of sheet material at the end part of sheet material in insert-molded products with a simple structure.SOLUTION: A method for manufacturing an insert molded product 100 comprises a sheet material 110 and a base resin layer 130. The method includes an end part processing process for continuously forming a concave-convex notch 112 at an end part 111 of the sheet material 110 along an edge 111A of the end part 111, a placement process S2 for placing the sheet material 110 in a molding die 200, and an injection process S4. The molding die 200 has, at a position opposite to the notch 112, a concave step 207 toward the sheet material 110, the step 207 forms a gap 208 between a portion of the end part 111 of the sheet material 110 and the molding die 200, and in the injection process S4, the base resin 131 is made to flow around the gap 208 through the notch 112.SELECTED DRAWING: Figure 8

Description

TECHNICAL FIELD The present disclosure relates to a method for manufacturing an insert-molded article and an insert-molded article.

2. Description of the Related Art Conventionally, an insert-molded product including a sheet material and a base resin layer formed on the back surface of the sheet material has been used as, for example, a decorative part. Deterioration of insert-molded products is caused by detachment of the sheet material from the base resin layer, and interfacial detachment between layers when the sheet material has a laminated structure. There are many things. For example, Patent Literature 1 discloses a technique for suppressing peeling of the edge of an insert film by forming a fixing portion made of molding resin to cover the edge of the insert film.

JP 2018-94813 A

However, in the technique of Patent Document 1, the shape of the cavity for forming the fixing portion is not simple, and there are problems in terms of man-hours and costs involved in manufacturing.

Therefore, in the present disclosure, in an insert-molded article, peeling of the sheet material at the end portion of the sheet material is more reliably suppressed with a simple configuration, and the durability of the insert-molded article is improved.

In order to solve the above problems, one aspect of the method for manufacturing an insert-molded product disclosed herein includes:
A method for manufacturing an insert-molded product comprising a sheet material and a base resin layer formed on the back surface of the sheet material,
an end portion processing step of continuously forming at least one of an uneven notch portion and a plurality of opening portions in an end portion of the sheet material along the edge of the end portion;
An arranging step of arranging the sheet material in a mold;
an injection step of injecting a base resin, which is a raw material of the base resin layer, onto the back side of the sheet material;
When the sheet material is placed in the mold, the molding die is provided at a position facing at least one of the notch and the opening at the end of the sheet toward the sheet material. having a convex or concave stepped portion,
In a state in which the sheet material is placed in the mold, a gap is formed between a part of the end of the sheet material and the mold by the stepped portion,
In the injection step, the base resin is allowed to flow into the gap through at least one of the notch and the opening.

In an insert-molded product including a sheet material and a base resin layer formed on the back surface of the sheet material, peeling of the sheet material is likely to occur at the edge of the sheet material. According to this configuration, by wrapping the base resin in the gap, both the front surface and the back surface of the portion corresponding to the gap at the end of the sheet material are covered with the base resin layer. Thus, it is possible to suppress the progress of peeling or peeling of the sheet material at the edge of the sheet material, and improve the durability of the insert-molded product. In this specification, "peeling of the sheet material" means peeling of the sheet material from the base resin layer, and interfacial peeling between layers constituting the sheet material when the sheet material has a laminated structure. do.

In a preferred embodiment, the mold is
a cavity mold in which the sheet material is arranged;
a core mold that forms a cavity into which the base resin is injected by being closed by the cavity mold and the mating surfaces of each other,
In the stepped portion, when the cavity mold and the core mold are closed, the cavity-side end of the mating surface of the core mold is aligned with the cavity-side end of the mating surface of the cavity mold. formed by protruding toward the cavity side or retreating in a direction away from the cavity side,
In the arranging step, the surface of the sheet material is in contact with the surface of the cavity, and a part of the edge side of at least one of the notch and the opening is the end of the cavity. is arranged in the cavity mold so as to protrude from the core mold side.

According to this configuration, the stepped portion can be provided by adjusting the relative position of the sheet-side end portion on the mating surfaces of the cavity mold and the core mold. A wraparound flow of the resin can be achieved. Thus, with a simple configuration, it is possible to suppress the peeling or progress of peeling of the sheet material at the edge of the sheet material.

In another preferred embodiment, the mold comprises
a cavity mold in which the sheet material is arranged;
a core mold that forms a cavity into which the base resin is injected by being closed by the cavity mold and the mating surfaces of each other,
The stepped portion is formed in at least one of the cavity mold and the core mold.

According to this configuration, the wraparound flow of the base resin can be achieved with a simple configuration in which the stepped portion is provided in at least one of the cavity mold and the core mold. Thus, with a simple configuration, it is possible to suppress the peeling or progress of the peeling of the end portion of the sheet material.

Moreover, it is preferable to form the uneven notch portion in the end processing step.

According to this configuration, since the processing of the end portion of the sheet material only needs to form the recessed and recessed notch portions, it is possible to achieve the wrapping of the base resin with a simple configuration.

Furthermore, it is preferable that the gap is formed continuously corresponding to at least one of the notch and the opening.

Since the gap is continuously formed corresponding to at least one of the notch and the opening, the part of the edge of the sheet material provided with at least one of the notch and the opening is provided with the base material. Wrapping of the resin can be caused continuously. Thus, it is possible to effectively suppress the peeling of the sheet material at the edge of the sheet material or the progress of the peeling.

Further, it is preferable that the end portion provided with at least one of the notch portion and the opening portion extends from the central portion of the sheet material so as to be bent toward the back side of the sheet material.

Since the end portion of the sheet material is bent toward the back side of the sheet material, the visibility of the portion covered with the base resin layer is reduced, and deterioration of the design of the insert-molded product can be suppressed.

One aspect of the insert-molded product disclosed herein is an insert-molded product comprising a sheet material and a base resin layer formed on the back surface of the sheet material,
The edge of the sheet material has at least one of an uneven notch and a plurality of openings continuously formed along the edge of the edge,
At least a portion of the end portion provided with at least one of the notch portion and the opening portion is characterized in that both the front surface and the back surface of the sheet material are covered with the base resin layer. do.

Since the surface and the back surface of the sheet material are covered with the base resin layer at least partly at the ends of the sheet material, it is possible to effectively suppress the progress of peeling or peeling of the sheet material at the ends of the sheet material. .

As described above, according to the present disclosure, both the front surface and the back surface of a part of the edge of the sheet material are covered with the base resin layer. Thus, it is possible to suppress the progress of peeling or peeling of the sheet material at the edge of the sheet material, and improve the durability of the insert-molded product.

FIG. 2 is a diagram showing an insert-molded product according to Embodiment 1; The figure which shows the modification of the shape of the edge part in a sheet|seat material. FIG. 2 is a flowchart for explaining a method for manufacturing an insert-molded product according to Embodiment 1; The figure for demonstrating the procedure of a preparation process. The figure for demonstrating the arrangement|positioning process, a mold closing process, and an injection process. FIG. 4 is a diagram for explaining the arrangement of the ends of the sheet material; FIG. 7 is a cross-sectional view taken along lines B1-B1 and B2-B2 of FIG. 6; FIG. 8 is a view for explaining the state after injection of the base resin and the flow of the base resin in FIG. 7 ; FIG. 7 is a view equivalent to FIG. 7 for explaining the method of manufacturing an insert-molded product according to Embodiment 2; FIG. 9 is a view equivalent to FIG. 8 for explaining the state after injection of the base resin and the flow of the base resin in FIG. 9 ; FIG. 1 is a view equivalent to FIG. 1 showing an insert-molded product according to Embodiment 2; FIG. 2 is a cross-sectional view showing a specific example of an insert-molded product according to the present disclosure;

Hereinafter, embodiments of the present disclosure will be described in detail based on the drawings. The following description of preferred embodiments is merely exemplary in nature and is in no way intended to limit the disclosure, its applicability or its uses.

(Embodiment 1)
<Insert molded product>
As shown in FIG. 1 , an insert-molded product 100 according to this embodiment includes a sheet material 110 and a base resin layer 130 formed on the back surface of the sheet material 110 . FIG. 1(a) is a perspective view of the insert-molded product 100, and (b) and (c) are sectional views taken along line A1-A1 and line A2-A2 of (a), respectively.

Applications of the insert-molded product 100 are not limited, but include, for example, interior and exterior parts for vehicles, housings and decorative parts for electronic devices, home appliances, building materials and furniture, etc. Examples include parts that require good design.

≪Sheet material≫
The material of the sheet material 110 is not limited as long as it is a sheet-like member. Specifically, the sheet material 110 is, for example, a resin film, a woven fabric layer, a nonwoven fabric layer, a thin sheet, veneer, genuine leather, a thin metal sheet, or the like. Moreover, the sheet material 110 may have a laminated structure in which a plurality of sheets made of a single type or a plurality of types of materials are laminated.

For example, the sheet material 110 includes a resin layer having excellent weather resistance, light resistance, durability, etc., disposed on the front side of the insert-molded product 100, a decorative layer laminated on the back side of the resin layer, and the and a fiber layer laminated on the back side of the decorative layer.

≪Base resin layer≫
The base resin layer 130 can be made of a known base resin used for insert molding of sheet materials. Specific examples of the base resin include, but are not limited to, acrylonitrile-butadiene-styrene copolymer (ABS), polycarbonate (PC), polycarbonate ABS (PC/ABS), glass fiber-filled polycarbonate ABS (PC- ABS-GF), polycarbonate PBT (PC/PBT), polyamide (PA), polypropylene (PP) and the like can be used.

<<End of sheet material>>
As shown in FIG. 1, the end portion 111 of the sheet material 110 has an uneven notch portion 112 continuously formed along the edge 111A of the end portion 111 .

Both the front surface 110A and the back surface 110B of the sheet material 110 are covered with the base resin layer 130 at least part of the portion of the end portion 111 where the notch portion 112 is provided. Specifically, in the present embodiment, both of the above are covered with the base resin layer 130 at the tip portion 112A of the notch portion 112 . Note that both of the above-described notches 112 as a whole may be covered with the base resin layer 130, but in the present embodiment, the surface 110A of the base end portion 112B of the notch 112 is covered with the base resin layer 130. not covered. In this manner, both of the above-mentioned parts in at least part of the notch 112 should be covered with the base resin layer 130 .

As described above, since at least part of the surface 110A of the sheet material 110 is covered with the base resin layer 130 at the end portion 111 of the sheet material 110, peeling of the sheet material 110 at the end portion 111 of the sheet material 110 is prevented. can be effectively suppressed.

The notch 112 preferably has a zigzag shape with a predetermined pitch P1, for example, although this is not intended to be limiting. This facilitates processing of the end portion 111 in the preparation step S1 (end portion processing step) of the sheet material 110, which will be described later. Although the pitch P1 is not intended to be limited, it can be, for example, 1 mm or more and 10 mm or less from the viewpoint of effectively suppressing peeling of the sheet material 110 at the end portion 111 . Also, the width W1 of the notch 112 is not particularly limited, but can be, for example, 1 mm or more and 10 mm or less, like the pitch P1.

Note that the shape of the notch portion 112 is not limited to the configuration described above. For example, as shown in FIG. 2, the notch 112 may have a flat portion 112C at the distal end portion 112A and/or the proximal end portion 112B, or may have a curved shape such as a waveform (not shown).

Also, the shape of the end portion 111 is not limited to the notch portion 112 . Instead of the notch 112 or in combination with the notch 112, for example, a plurality of openings 114 may be formed continuously along the edge 111A. The shape of the opening 114 is not limited, and may be circular as shown in FIG. 2, polygonal, or the like. The pitch P2 of the openings 114 can be set similarly to the pitch P1 of the cutouts 112, although this is not intended to be limiting. The diameter R1 of the openings 114 is not particularly limited, and can be appropriately set according to the pitch P2. A width W2 from the base end portion 114B of the opening 114 to the edge 111A can be set similarly to the width W1 of the notch portion 112, although it is not intended to be limited.

Note that, as shown in FIG. 1, the end portion 111 provided with the notch portion 112 extends from the central portion 113 of the sheet material 110 so as to bend toward the back surface 110B of the sheet material 110. preferable. That is, it is preferable that the end portion 111 and the central portion 113 are connected by the bent portion 115 . As a result, the visibility of the portion where both the front surface 110A and the back surface 110B of the end portion 111 are covered with the base resin layer 130 is reduced, so that deterioration in the design of the insert-molded product 100 can be suppressed.

<Manufacturing method of insert molded product>
An example of a method for manufacturing the insert-molded product 100 according to this embodiment will be described.

As shown in FIG. 3, the method for manufacturing the insert-molded product 100 includes a preparation step S1, an arrangement step S2, a mold closing step S3, an injection step S4, a cooling step S5, and a mold opening step S6. .

≪Preparation process≫
The preparation step S<b>1 is a step of preparing the sheet material 110 .

FIG. 4 shows an example of the procedure of the preparation step S1. First, the first precursor 105, which is the raw material of the sheet material 110, is prepared. When the first precursor 105 has a layered structure, layers as raw materials are prepared and layered to form the first precursor 105 of the sheet material 110 (layering step). Note that the lamination step is an optional step, and may be provided as necessary. Moreover, the lamination method is not limited, and a known method can be adopted.

As an example of the lamination process, when the sheet material 110 has a three-layer structure of a resin layer, a decorative layer, and a fiber layer, for example, the resin film 101 that is the raw material of the resin layer and the raw material of the decorative layer. The first precursor 105 can be obtained by laminating the decorative sheet 102 and the fibrous sheet 103 which is the raw material of the fibrous layer.

In particular, when the insert-molded product 100 is an interior/exterior component for a vehicle, conventionally, a decorative layer is provided on the molded base resin layer 130 by means of adhesion or the like to further improve the weather resistance and light resistance of the component. In addition, it is common to obtain parts by performing undercoating, intermediate coating, top coating, etc. for improving durability and the like. On the other hand, in this method, the coating of the surface of the decorative layer is replaced with the resin film 101, the sheet material 110 having a three-layer structure of the resin layer, the decorative layer and the fiber layer is prepared in advance, and the sheet material 110 is inserted. A base resin layer 130 is formed by molding. Since this method does not require a coating process, it is advantageous in that it simplifies the parts manufacturing process and reduces the manufacturing cost compared to conventional methods.

Although the resin film 101 is not intended to be limited, for example, it is a transparent or translucent resin single-layer or multilayer film having a uniform thickness, and is excellent in weather resistance, durability, and the like. The resin material of the resin film 101 is not intended to be limited, but is formed of, for example, an acrylic resin containing fluorine. Although the thickness of the resin film 101 is not limited, it is, for example, 0.05 mm to 3.0 mm.

The decorative sheet 102 is not intended to be limited, but is, for example, a sheet having a uniform thickness, such as veneer, genuine leather, thin film metal sheet, polyvinyl chloride sheet, polyolefin sheet, urethane coated paper, It may be selected from cork sheets, carbon sheets and the like. Although the thickness of the decorative sheet 102 is not limited, it is, for example, 0.15 mm or more and 3.0 mm or less. The decorative sheet 102 may have a pattern such as a heathered pattern.

The fiber sheet 103 is, but not limited to, cotton cloth, resin cloth, or the like. The fiber sheet 103 may be a woven fabric or a nonwoven fabric. Although the thickness of the fiber sheet 103 is not limited, it is, for example, 0.15 mm or more and 3.0 mm or less.

Next, an uneven notch 112 and/or an opening 114 are continuously formed along the edge of the end of the first precursor 105 to obtain a second precursor 107 ( edge processing). A method for forming the notch 112 and/or the opening 114 is not limited, and known means such as trimming and punching can be employed.

In addition, it is preferable to form notch portions 112 that are easy to process, particularly zigzag notch portions 112 with a predetermined pitch P1 in the end portion 111 . As a result, peeling of the end portion 111 of the sheet material 110 can be suppressed with a simple configuration.

Then, the second precursor 107 is shaped to obtain the sheet material 110 having the shape required for the insert-molded product 100 (shaping step). If the sheet material 110 has a bent portion 115, it is formed in the shaping process.

In addition, in the procedure of the preparation step S1 shown in FIG. 4, an example of performing the shaping step after the end processing step is described, but the end processing step may be performed after the shaping step, or the shaping step and the shaping step may be performed. You may perform an edge part processing process simultaneously. Further, depending on the shape of the insert-molded product 100, the forming process may not be necessary. In this case, it is possible to proceed to the next arranging step S2 without performing the shaping step after the end processing step.

≪Placement process, mold closing process and injection process≫
Next, the arrangement step S2, the mold closing step S3 and the injection step S4 will be described with reference to FIGS. 5 to 8. FIG.

(a) of FIG. 5 is a diagram showing an example of the placement step S2, and (b) is an example of each of the mold closing step S3 and the injection step S4.

As shown in (a) of FIG. 5, the sheet material 110 is placed in the mold 200 in the placement step S2.

Here, the mold 200 has a cavity mold 201 and a core mold 203 .

Sheet material 110 is placed in cavity 201 such that surface 110A of sheet material 110 contacts surface 201A of cavity 201 . The sheet material 110 arranged in the cavity mold 201 is sucked through the suction passage 233 by the suction device 231 as required. The sheet material 110 is then restrained by the surface 201A of the cavity mold 201 (placement step S2). Note that if the shape of the insert-molded product 100 does not require the suction of the sheet material 110 by the suction device 231, suction may not be performed.

As shown in FIGS. 6(a) and 7, the sheet material 110 has a notch 112 formed in the end 111, and a leading end 112A (part of the edge side) of the cutout 112 extends from the end 201C of the cavity mold 201 to the core. It is arranged so as to protrude toward the mold 203 side. Thereby, as will be described later, it becomes possible for the base resin 131, which is the raw material of the base resin layer 130, to wrap around the surface 110A of the sheet material 110 at the notch portion 112. FIG.

Next, as shown in FIG. 5B, the cavity mold 201 and the core mold 203 are brought closer to each other so that the mating surfaces, that is, the mating surfaces 201B of the cavity mold 201 and the mating surfaces 203B of the core mold 203, are aligned. They are brought into contact with each other and the mold is closed (mold closing step S3). Then, as shown in FIGS. 5, 7 and 8, the back surface of the sheet material 110, the surface 201A of the cavity mold 201 and the surface 203A of the core mold 203 form a cavity 205 into which the base resin 131 is injected. be done.

At this time, as shown in FIG. 7, the end 203C of the mating surface 203B of the core mold 203 on the cavity 205 side is closer to the cavity 205 than the end 201C of the mating surface 201B of the cavity mold 201 on the cavity 205 side. It is configured to be placed in a retracted position in a direction away from. As a result, when the molds are closed, a stepped portion 207 is formed in the cavity 205 by the mating surface 201B of the cavity mold 201 and the mating surface 203B of the core mold 203 .

As described above, the notch portion 112 of the sheet material 110 is arranged so that the tip portion 112A protrudes from the end portion 201C of the cavity mold 201 toward the core mold 203. A stepped portion provided in a concave shape toward the sheet material 110 side at a position facing the portion 112 .

Then, as shown in the B1-B1 cross section of FIG.

Next, as shown in FIG. 5B, the molten base resin 131 is injected into the cavity 205 through the introduction gate 204 (injection step). In this way, the base resin layer 130 is formed on the back surface 110B of the sheet material 110 .

Here, in the method for manufacturing the insert-molded product 100 according to the present embodiment, when the base resin 131 is injected, the base resin The feature is that 131 is wrapped around.

As shown in the B1-B1 and B2-B2 cross-sectional views of FIG. 8, when the base resin 131 is injected, most of the sheet material 110 is pushed into the cavity mold 201 by the pressure of the base resin 131 indicated by the arrows in the figure. It is pressed against the surface 201A. On the other hand, it takes some time for the tip portion 112A of the notch portion 112 to be pressed against the surface of the stepped portion 207 due to the presence of the gap portion 208 . Then, as indicated by an arrow in the lower part of FIG. 8, the base resin is introduced into the gap 208 through the introduction port 112D formed between the base end 112B of the notch 112 and the end 201C of the cavity mold 201. 131 flows in. Then, as shown in the B1-B1 cross-sectional view of FIG. 8, the base resin can be wrapped around the surface 110A of the tip portion 112A of the notch portion 112. As shown in FIG.

According to this configuration, by wrapping the base resin 131 in the gap portion 208 , both the front surface 110 A and the back surface 110 B of the front end portion 112 A of the notch portion 112 are covered with the base resin layer 130 . Thus, it is possible to suppress the progress of peeling or peeling of the sheet material 110 at the end portion 111 of the sheet material 110 and improve the durability of the insert-molded product 100 .

As shown in FIG. 6B, the notch 112 is closer to the cavity 201 than the end 201C of the cavity 201, that is, the entire surface 110A of the notch 112 is in contact with the surface 201A of the cavity 201. In this state, the wrapping of the base resin 131 is not achieved. This is because the base resin 131 presses the entire surface 110A of the notch 112 against the surface 201A of the mold cavity 201 . Moreover, as shown in FIG. 6(c), the notch 112 protrudes toward the core mold 203 from the end 201C of the cavity mold 201, that is, the entire surface 110A of the notch 112 is the gap portion 208. is formed, the wrapping of the base resin 131 is not achieved. This is because the entire surface 110A of the notch portion 112 is pressed against the surface of the stepped portion 207 by the base resin 131 because the introduction port 112D is not formed. Therefore, it is important to arrange the sheet material 110 in the cavity mold 201 so that the tip portion 112A, which is a part of the notch portion 112, protrudes from the end portion 201C of the cavity mold 201 toward the core mold 203 side.

Also, as shown in FIG. 2, when changing the shape of the notch 112 and/or when providing the opening 114, the position of the end portion 201C of the cavity mold 201 does not change with the notch 112 and/or the opening. 114 must be placed.

In this configuration, the stepped portion 207 is formed by adjusting the relative positions of the end portion 201C of the cavity mold 201 and the end portion 203C of the core mold 203 . As a result, it is possible to allow the base resin 131 to wrap around the notch 112 with a simple configuration without requiring a significant design change of the molding die 200 .

Moreover, the stepped portion 207 is preferably formed continuously at positions corresponding to the notch portion 112 and/or the opening portion 114 of the sheet material 110 . As a result, the gap 208 is continuously formed corresponding to the notch 112 and/or the opening 114 , so that the wraparound of the base resin 131 corresponds to the notch 112 and/or the opening 114 . can be generated continuously. Thus, peeling or progress of peeling of the sheet material 110 at the end portion 111 of the sheet material 110 can be effectively suppressed.

≪Cooling process and mold opening process≫
When the injection of the base resin 131 is completed, for example, it is cooled from the injection temperature to the mold temperature at a constant cooling rate. Then, the base resin 131 is solidified to form the base resin layer 130 (cooling step S5). After the base resin 131 is solidified, the cavity mold 201 and the core mold 203 are opened to release the insert-molded product 100 (mold opening step S6).

(Embodiment 2)
Other embodiments according to the present disclosure will be described in detail below. In the description of these embodiments, the same reference numerals are given to the same parts as in the first embodiment, and detailed description thereof will be omitted.

In Embodiment 1, the end portion 203C of the core mold 203 is arranged at a position that is receded from the end portion 201C of the cavity mold 201 in the direction away from the cavity 205 side. Not limited. The end portion 203C of the core mold 203 may be configured to protrude further toward the cavity 205 than the end portion 201C of the cavity mold 201, as shown in FIG.

As a result, the stepped portion 207 becomes a stepped portion that protrudes toward the sheet material 110 at a position facing the notch portion 112 .

Then, as shown in the B1-B1 cross section of FIG.

In this configuration, when the base resin 131 is injected, as shown in FIG. The material resin 131 wraps around.

Thus, as shown in FIGS. 11(a) to 11(c), the insert molded product 100 having the base resin layer 130 covering the surface 110A of the base end portion 112B of the notch portion 112 is obtained.

In any of the configurations of Embodiments 1 and 2, when the base resin 131 wraps around at a sufficiently high speed, the base resin 131 wraps over a wider range or the entire surface 110A of the notch 112. obtain. In this case, a wider range or the entire surface 110</b>A of the notch 112 is covered with the base resin layer 130 .

(Other embodiments)
In the configurations of Embodiments 1 and 2, the step portion 207 is formed by adjusting the relative positions of the end portion 201C of the cavity mold 201 and the end portion 203C of the core mold 203. is not limited to The stepped portion 207 may be formed in at least one of the cavity mold 201 and the core mold 203 , preferably the cavity mold 201 or the core mold 203 . Specifically, for example, the stepped portion 207 may be provided around the end portion 201C of the cavity mold 201 or around the end portion 203C of the core mold 203 . In this case, although not shown, when the mold is closed, the leading end portion 112A (part of the edge side) of the notch portion 112 formed in the end portion 111 of the sheet material 110 and/or the edge 111A side of the opening portion 114 so that a part protrudes toward the core mold 203 from the edge of the stepped portion 207 in contact with the sheet material 110 (the edge corresponds to the edge 201C of Embodiment 1 and the edge 203C of Embodiment 2), The sheet material 110 may be arranged. From the viewpoint of simplifying the configuration of the molding die 200, the configurations of the first and second embodiments are desirable.

Also, the notch 112 and/or the opening 114 may not be provided over the entire end 111 of the sheet material 110 .

Specifically, FIG. 12 shows an automobile interior part as an example of the insert-molded product 100 . A cutout portion 112 is provided in the end portion 111 positioned on the upper side in FIG. On the other hand, the plated decorative component 401 is in contact with the surface 110A of the end portion 111 located on the lower side of FIG. Since the end portion 111 is pressed by the plated decorative component 401, the possibility of peeling off is low. Therefore, it is not necessary to provide the notch 112 and/or the opening 114 in the portion where peeling is suppressed due to the presence of other components, for example.

INDUSTRIAL APPLICABILITY The present disclosure is extremely useful in an insert-molded product because it can more reliably suppress peeling of the sheet material at the ends of the sheet material with a simple configuration and improve the durability of the insert-molded product.

100 Insert molded product 110 Sheet material 110A Front surface 110B Back surface 111 End portion 111A Edge 112 Notch portion 112A Tip portion 112B Base end portion 112D Introduction port 113 Central portion 114 Opening 115 Bent portion 130 Base resin layer 131 Base resin 200 Molding Mold 201 Cavity mold 201A Surface 201B Mating surface 201C End 203 Core mold 203A Surface 203B Mating surface 203C End 205 Cavity 207 Stepped portion 208 Gap S1 Preparatory step (end processing step)
S2 Placement process S4 Injection process

Claims (7)

A method for manufacturing an insert-molded product comprising a sheet material and a base resin layer formed on the back surface of the sheet material,
an end portion processing step of continuously forming at least one of an uneven notch portion and a plurality of opening portions in an end portion of the sheet material along the edge of the end portion;
An arranging step of arranging the sheet material in a mold;
an injection step of injecting a base resin, which is a raw material of the base resin layer, onto the back side of the sheet material;
When the sheet material is placed in the mold, the molding die is provided at a position facing at least one of the notch and the opening at the end of the sheet toward the sheet material. having a convex or concave stepped portion,
In a state in which the sheet material is placed in the mold, a gap is formed between a part of the end of the sheet material and the mold by the stepped portion,
A method for producing an insert-molded product, wherein in the injection step, the base resin is caused to flow into the gap through at least one of the notch and the opening. In claim 1,
The above mold is
a cavity mold in which the sheet material is arranged;
a core mold that forms a cavity into which the base resin is injected by being closed by the cavity mold and the mating surfaces of each other,
In the stepped portion, when the cavity mold and the core mold are closed, the cavity-side end of the mating surface of the core mold is aligned with the cavity-side end of the mating surface of the cavity mold. formed by protruding toward the cavity side or retreating in a direction away from the cavity side,
In the arranging step, the surface of the sheet material is in contact with the surface of the cavity, and a part of the edge side of at least one of the notch and the opening is the end of the cavity. A method of manufacturing an insert-molded product, wherein the insert-molded product is arranged in the cavity mold so as to protrude from the core mold side. In claim 1,
The above mold is
a cavity mold in which the sheet material is arranged;
a core mold that forms a cavity into which the base resin is injected by being closed by the cavity mold and the mating surfaces of each other,
A method of manufacturing an insert-molded product, wherein the stepped portion is formed in at least one of the cavity mold and the core mold. In any one of claims 1 to 3,
A method of manufacturing an insert-molded product, wherein the uneven notch portion is formed in the end processing step. In any one of claims 1 to 4,
A method of manufacturing an insert-molded product, wherein the gap is formed continuously corresponding to at least one of the notch and the opening. In any one of claims 1 to 5,
The insert molding characterized in that the end portion provided with at least one of the notch portion and the opening portion extends from the central portion of the sheet material so as to bend toward the back surface side of the sheet material. method of manufacturing the product. An insert-molded product comprising a sheet material and a base resin layer formed on the back surface of the sheet material,
The edge of the sheet material has at least one of an uneven notch and a plurality of openings continuously formed along the edge of the edge,
At least a portion of the end portion provided with at least one of the notch portion and the opening portion is characterized in that both the front surface and the back surface of the sheet material are covered with the base resin layer. insert molding products.

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