JP2023105467A - Resin molding, and method for manufacturing resin molding - Google Patents

Abstract

To provide a resin molding for a vehicle capable of enhancing the appearance.SOLUTION: A resin molding 10 comprises: a resin-made base material 20 having a surface 21 provided with a rugged pattern 23; and a resin-made surface layer material 30 having a visible light transmissivity, and laminated on the base material 20 to cover the surface 21. The resin molding 10 is formed by two-color molding using the base material 20 as a primary molding material and the surface layer material 30 as a secondary molding material. The base material 20 has a through hole 26 that opens in the surface 21. The base material 20 and the surface layer material 30 separate from each other in a lamination direction X.SELECTED DRAWING: Figure 2

Description

TECHNICAL FIELD The present invention relates to a resin molded product and a method for manufacturing a resin molded product.

Patent Literature 1 discloses a decorative film. This decorative film has a first synthetic resin film and a transparent second synthetic resin film laminated on the upper surface of the first synthetic resin film.

On the upper surface of the first synthetic resin film, a texture having an uneven shape is formed. The cross-sectional shape of the crimp is a shape in which a plurality of crests are arranged, that is, a so-called sawtooth shape.
In such a decorative film, since the transparent second synthetic resin film is laminated on the grain of the first synthetic resin film, the grain is less likely to be stained or damaged. In addition, since the uneven shape of the grain is clearly visible through the second synthetic resin film, a three-dimensional effect can be obtained in the decorative film.

JP 2005-14374 A

By the way, in such a resin molded product, there is room for improvement in improving the three-dimensional effect of the resin molded product and, in turn, improving the appearance.

A resin molded product for solving the above problems includes a resin substrate having a surface provided with an uneven pattern, and a resin that has visible light transparency and is laminated on the substrate to cover the surface. A resin molded product formed by two-color molding using the base material as a primary molding material and the surface layer material as a secondary molding material, wherein the base material has an opening on the surface The base material and the surface layer material are separated from each other in the lamination direction of the base material and the surface layer material.

According to this configuration, it is possible to form the intermediate layer by injecting air, a coloring material, or the like through the through holes between the base material and the surface layer material. By making the refractive index of the intermediate layer different from the refractive index of the surface layer material, the shadows of the uneven pattern on the base material become clearer, and the three-dimensional effect of the uneven pattern increases. Therefore, the appearance of the resin molded product can be improved.

In the resin molded product, the surface layer material is made of a resin material having a melting point lower than that of the base material.
In the case of manufacturing a resin molded product by forming a surface layer material having visible light transmittance on the surface of a base material on which an uneven pattern is formed, if injection molding is used to form the surface layer material, the uneven pattern on the surface of the base material will be formed. There is a risk of collapse due to the injected molten resin.

In this respect, according to the above configuration, the uneven pattern of the substrate is less likely to collapse due to the heat of the molten resin during the secondary molding. That is, it becomes easy to maintain the three-dimensional effect of the uneven pattern of the substrate. As a result, the shading of the uneven pattern on the base material becomes clearer, and the three-dimensional effect of the uneven pattern is further enhanced. Therefore, the appearance of the resin molded product can be further improved.

In the resin molded product, the surface layer material is made of a resin material having a higher mold shrinkage than the base material.
According to this configuration, after the secondary molding, the surface layer material is subjected to mold shrinkage, so that the surface layer material is pressed against the side surface of the convex portion forming the uneven pattern of the base material. This improves the adhesion between the substrate and the surface layer material. Therefore, it is possible to suppress a decrease in adhesion between the base material and the surface layer material while separating the base material and the surface layer material in the stacking direction.

In the resin molded product described above, the through hole is provided with a sealing material that seals the through hole.
According to this structure, the sealing material prevents the air, the coloring material, and the like, which form the intermediate layer, from leaking out through the through holes. Therefore, deterioration of the appearance of the resin molded product can be suppressed.

In the resin molded product described above, a coloring material is filled between the base material and the surface layer material in the lamination direction.
According to this configuration, by appropriately setting the refractive index of the coloring material, it is possible to adjust the clarity of the shadows of the uneven pattern of the base material and, in turn, the three-dimensional effect of the uneven pattern.

In the above resin molded product, the surface layer material has a body portion covering the front surface, and an anchor portion continuing from the body portion and covering the back surface of the base material.
According to this configuration, the anchor portion of the surface layer material facilitates maintaining the state in which the substrate and the surface layer material are in close contact with each other. Therefore, it is possible to suppress a decrease in adhesion between the base material and the surface layer material while separating the base material and the surface layer material in the stacking direction.

A method for manufacturing a resin molded product for solving the above problems includes a primary molding step of molding the base material, and a state where the opening of the through hole opening to the surface is closed, and the surface and the mold are closed. A secondary molding step of molding the surface layer material by filling a molten resin into a cavity formed between them, and applying pressure between the base material and the surface layer material through the through holes to form the laminate. and a separating step of separating the base material and the surface layer material in a direction.

According to this method, the base material is molded in the primary molding process. Next, in the secondary molding process, the surface layer material is formed by filling the cavity formed between the surface of the base material and the molding die with molten resin while the openings of the through holes in the base material are closed. be done. Next, in the separating step, the base material and the surface layer material are separated in the stacking direction by applying pressure between the base material and the surface layer material through the through holes of the base material. In this manner, the resin molded product can be manufactured.

ADVANTAGE OF THE INVENTION According to this invention, the appearance of the resin molding for vehicles can be improved.

FIG. 1 is a cross-sectional view showing one embodiment of a resin molded product. FIG. 2 is an enlarged cross-sectional view of the resin molded product of FIG. 1, centering on the concave-convex pattern. FIG. 3 is a cross-sectional view showing the concave-convex pattern of FIG. 2 by enlarging the side surface of the convex portion. FIG. 4 is an enlarged cross-sectional view of the resin molded product of FIG. 1 centering on the anchor portion. FIG. 5 is a cross-sectional view showing a primary molding step for molding a base material in the method of manufacturing the resin molded product of FIG. FIG. 6 is a cross-sectional view showing a secondary molding step for molding a surface layer material in the method for manufacturing the resin molded product of FIG. 7 is a cross-sectional view showing a separation step of separating the base material and the surface layer material in the method of manufacturing the resin molded product of FIG. 1. FIG. 8 is a cross-sectional view showing a trimming process in the method of manufacturing the resin molded product of FIG. 1. FIG.

Hereinafter, one embodiment of a resin molded product and a method for manufacturing a resin molded product will be described with reference to FIGS. 1 to 8. FIG. In each drawing, for convenience of explanation, a part of the configuration is exaggerated or simplified, so the dimensional ratio of each configuration may differ from the actual one. Further, the term "perpendicular" in the following description includes not only the strictly orthogonal case, but also the generally orthogonal case within the range in which the effects of each embodiment can be achieved.

<Resin molded product 10>
As shown in FIGS. 1 and 2, the resin molded product 10 includes a base material 20 made of resin, and a surface layer material 30 made of resin which is laminated on the base material 20 and covers the surface 21 of the base material 20. have.

Further, the resin molded product 10 has an intermediate layer 40 provided between the base material 20 and the surface layer material 30 and a sealing material 50 provided on the base material 20 .
The resin molded product 10 is formed by trimming an end portion 111 of an intermediate body 110 molded by two-color molding (see FIGS. 7 and 8). The resin molded product 10 is applied, for example, to an interior material of a vehicle such as an instrument panel.

In the following description, the lamination direction of the base material 20 and the surface layer material 30 is simply referred to as the lamination direction X.
<Base material 20>
As shown in FIGS. 1 and 2, the substrate 20 includes an uneven pattern 23 provided on the front surface 21 and a plurality of (two in this embodiment) penetrating the substrate 20 from the front surface 21 toward the back surface 22. and a through hole 26 of .

The concave-convex pattern 23 is provided on the central portion 21 a in the width direction Y on the surface 21 of the base material 20 .
The uneven pattern 23 is composed of a plurality of protrusions 24 arranged side by side on the surface 21 and a plurality of recesses 25 positioned between the protrusions 24 . The plurality of protrusions 24 protrude in the stacking direction X. As shown in FIG. In this embodiment, the shapes of the plurality of protrusions 24 are individually set. That is, as shown in FIG. 2, the width and protrusion height of each protrusion 24 are set separately. In addition, in FIG. 1, the rough shape of the uneven pattern 23 is shown in a simplified manner.

Hereinafter, the direction corresponding to the width direction of the convex portion 24 among the directions orthogonal to the stacking direction X will be simply referred to as the width direction Y.
As shown in FIGS. 2 and 3, each convex portion 24 has a tip surface 24a and a pair of side surfaces 24b extending in a bent manner from both sides of the tip surface 24a in the width direction Y. As shown in FIGS.

As shown in FIG. 3, the side surface 24b is inclined with respect to an imaginary straight line V1 extending in the stacking direction X. As shown in FIG. An angle θ between the side surface 24b and the virtual straight line V1 is preferably 0.5 degrees or more and less than 20 degrees. In this embodiment, the inclination angle θ of the side surface 24b with respect to the virtual straight line V1 is set at 0.5 degrees.

As shown in FIGS. 1 and 2, the through holes 26 are provided at positions adjacent to the uneven pattern 23 in the width direction Y. As shown in FIGS. The through holes 26 are arranged on both sides of the uneven pattern 23 in the width direction Y one by one. Each through-hole 26 extends linearly in the stacking direction X. As shown in FIG.

As the resin material of the base material 20, for example, PP (polypropylene), ABS resin, PC-ABS (polymer alloy of polycarbonate and ABS resin), or the like can be used. In this embodiment, PC-ABS (melting point: about 250° C., molding shrinkage: about 0.7%) is used as the resin material of the base material 20 .

<Surface layer material 30>
As shown in FIGS. 1 and 4 , the surface layer material 30 includes a body portion 31 covering the front surface 21 of the base material 20 and an anchor portion 32 continuing from the body portion 31 and covering a portion of the back surface 22 of the base material 20 . have.

The body portion 31 covers the entire surface 21 in the width direction Y. As shown in FIG.
As shown in FIGS. 2 and 3, the main body portion 31 and the central portion 21a of the substrate 20 are separated from each other in the stacking direction X. As shown in FIGS. In the concave-convex pattern 23, the tip end surface 24a of the convex portion 24, the bottom surface 25a of the concave portion 25, and the main body portion 31 are separated from each other in the stacking direction X. As shown in FIG. An intermediate layer 40 is interposed between the body portion 31 and the central portion 21a.

The body portion 31 and the uneven pattern 23 of the base material 20 are in close contact with each other in the width direction Y. As shown in FIG. Specifically, the body portion 31 and the side surface 24b of the convex portion 24 are in close contact with each other in the width direction Y. As shown in FIG.

As shown in FIGS. 1 and 4, the anchor portions 32 are provided on both sides of the body portion 31 in the width direction Y. As shown in FIGS. The anchor portion 32 includes a base end portion 33 extending along the end surface 27 of the base material 20 from both edges of the main body portion 31 in the width direction Y, and a tip end extending from the tip of the base end portion 33 to the back surface 22 of the base material 20 . and a portion 34 .

The surface layer material 30 is made of a resin material having visible light transmittance. Specifically, the surface layer material 30 is made of a resin material having a visible light transmittance such that the uneven pattern 23 of the base material 20 can be seen through the surface layer material 30 . Here, the resin material includes not only a colorless and transparent resin material but also a resin material containing a coloring material that transmits only a part of visible light.

The surface layer material 30 is made of a resin material having a melting point lower than that of the base material 20 . Specifically, the melting point M2 of the resin material of the surface layer material 30 is preferably 50° C. or more lower than the melting point M1 of the resin material of the base material 20 (M1−M2≧50). Further, the melting point M2 is more preferably lower than the melting point M1 by 70° C. or more (M1−M2≧70). Further, the melting point M2 is more preferably lower than the melting point M1 by 100° C. or more (M1−M2≧100).

The surface layer material 30 is made of a resin material having a larger mold shrinkage rate than the base material 20 .
As the resin material of the surface layer material 30, for example, hard PU (polyurethane) or polyurea can be used. In this embodiment, hard PU (melting point: about 150° C., molding shrinkage: about 1.5%) is used as the resin material of the surface layer material 30 .

<Intermediate layer 40, sealing material 50>
As shown in FIG. 2 , the intermediate layer 40 is a layer formed of a material having a different refractive index from that of the surface layer material 30 . In this embodiment, the intermediate layer 40 is a layer made of air A. As shown in FIG.

As shown in FIGS. 1 and 2 , the sealing material 50 seals the through holes 26 of the base material 20 and is provided in each of the two through holes 26 .
As a material of the sealing material 50, for example, a UV (ultraviolet) curable resin or the like can be used.

<Intermediate 110 of Resin Molded Product 10>
As shown in FIG. 7 , the intermediate 110 has a base material 120 and a surface layer material 130 .
Substrate 120 is an intermediate of substrate 20 prior to trimming edge 111 from intermediate 110 . Therefore, hereinafter, the same reference numerals are given to the components of the base material 120 that are common to the base material 20, and the description thereof is omitted.

The substrate 120 has a plurality of (two in this embodiment) through-holes 128 that pass through the substrate 120 from the front surface 121 toward the back surface 122 , apart from the through-holes 26 . A part of the inner peripheral surface 128 a of the through hole 128 is configured by the end surface 27 of the base material 20 .

The surface layer material 130 is an intermediate body of the surface layer material 30 before trimming the end portion 111 from the intermediate body 110 .
The surface layer material 130 has a body portion 131 that covers the front surface 121 of the base material 120 and an anchor portion 132 that continues to the body portion 131 and covers the back surface 122 of the base material 120 . A portion of the anchor portion 132 is inserted through the through hole 128 of the base material 120 .

<Manufacturing device 60>
Next, the manufacturing apparatus 60 for molding the intermediate 110 of the resin molded product 10 will be described.
As shown in FIGS. 5 and 6 , the manufacturing apparatus 60 includes a primary mold 70 for molding the base material 120 and a secondary mold 80 for molding the surface layer material 130 .

As shown in FIG. 5, the primary molding die 70 includes a first die 71A and a slide die 71B, and a second die 72 provided so as to be close to or separate from the first die 71A and the slide die 71B in the stacking direction X. and

A molding surface 73 for molding the back surface 122 of the base material 120 is formed on the surfaces of the first mold 71A and the slide mold 71B that face the second mold 72 .
The first die 71A is formed with an insertion hole 75 through which a pin 91 for forming the through hole 26 is inserted. One end 91a of the pin 91 in the extending direction is in contact with the second mold 72 when the primary mold 70 is clamped. The pin 91 is configured to be relatively movable in the stacking direction X with respect to the first die 71A.

The first mold 71A is configured to be separable in the stacking direction X from the slide mold 71B and the molded base material 120 when the primary mold 70 is opened.
The slide mold 71B has a molding projection 71b for forming the through hole 128. As shown in FIG. The tip of the molding projection 71b abuts on the second mold 72 when the primary mold 70 is clamped.

The slide mold 71B is configured to be slidable in the width direction Y with respect to the base material 120 while the first mold 71A is separated from the base material 120 when the primary mold 70 is opened.

A molding surface 74 for molding the surface 121 of the substrate 120 is formed on the surface of the second mold 72 facing the first mold 71A and the slide mold 71B.
The molding surface 74 is formed with molding uneven portions 74 a for forming the uneven pattern 23 .

The molding surface 73 , the molding surface 74 , the molding projections 71 b , and the pins 91 form a cavity 76 that is a space filled with molten resin for molding the base material 120 .
As shown in FIG. 6 , the secondary molding die 80 includes a first die 81 and a second die 82 provided so as to be close to or separated from the first die 81 in the stacking direction X. As shown in FIG.

A support surface 83 that supports the base material 120 is formed on the surface of the first die 81 that faces the base material 120 .
A through hole 85 communicating with the through hole 26 of the base material 120 is formed in the first mold 81 . A pin 92 is inserted through the through hole 26 and the through hole 85 . One end 92a of the pin 92 in the extending direction is separated from the second mold 82 when the secondary mold 80 is clamped. The pin 92 is configured to be relatively movable in the stacking direction X with respect to the first die 81 .

The first mold 81 is configured to be separable from the substrate 120 in the stacking direction X when the secondary mold 80 is opened.
A molding surface 84 for molding the surface 131 a (see FIG. 7) of the body portion 131 of the surface layer material 130 is formed on the surface of the second mold 82 facing the first mold 81 .

A cavity 86, which is a space filled with molten resin for molding the anchor portion 132, is formed by part of the support surface 83 of the first mold 81, the back surface 122 of the base material 120, and the inner peripheral surface 128a of the through hole 128. formed.

The molding surface 84 and the surface 121 of the base material 120 form a cavity 87 which is a space filled with molten resin for molding the main body portion 131 of the surface layer material 130 .
<Manufacturing Method of Resin Molded Product 10>
Next, a method for manufacturing the resin molded product 10 using the manufacturing apparatus 60 will be described with reference to FIGS. 5 to 8. FIG.

First, as shown in FIG. 5, the pins 91 are inserted through the insertion holes 75 of the first mold 71A in a state where the first mold 71A and the slide mold 71B and the second mold 72 are clamped. Then, the cavity 76 formed by the molding surface 73, the molding surface 74, the molding projections 71b, and the pins 91 is filled with molten resin. Thereby, the base material 120 is molded (the above is the primary molding step). At this time, the concave-convex pattern 23 is formed on the surface 121 of the substrate 120 by the molded concave-convex portion 74a. Also, the through hole 26 is formed by the pin 91 . Further, a through hole 128 is formed by the molded convex portion 71b.

Next, as shown in FIG. 6, the pin 92 is inserted through the through hole 85 and the through hole 26 in a state in which the substrate 120 removed from the primary mold 70 is supported on the supporting surface 83 of the first mold 81. . At this time, the pin 92 blocks the opening 26 a of the through hole 26 that opens to the surface 121 . Then, while the first mold 81 and the second mold 82 are clamped together, the cavity 87 formed between the molding surface 84 and the surface 121 of the substrate 120 is filled with molten resin. At this time, the molten resin also fills a cavity 86 formed by a portion of the support surface 83 of the first mold 81, the back surface 122 of the base material 120, and the inner peripheral surface 128a of the through hole 128. FIG. Thereby, the body portion 131 and the anchor portion 132 of the surface layer material 130 covering the surface 121 of the base material 120 are formed. That is, the intermediate 110 is molded (the above is the secondary molding step).

Next, as shown in FIGS. 7 and 8, by injecting air A through the through-holes 26 of the intermediate 110 removed from the secondary mold 80, the pressure between the base material 120 and the surface layer material 130 is increased. is applied. As a result, the base material 120 and the surface layer material 130 are separated from each other in the stacking direction X (the above is the separation step). At this time, an intermediate layer 40 made of air A is formed between the central portion 21 a of the base material 120 and the surface layer material 130 . 7 and 8, the intermediate layer 40 is omitted because the intermediate 110 is shown in a simplified manner. Subsequently, after injecting the UV curable resin into the through holes 26, the UV curable resin is rapidly cured by UV irradiation. Thereby, a sealing material 50 for sealing the through hole 26 is formed (see FIG. 8).

Next, the intermediate body 110 is trimmed along an imaginary plane V2 passing through the axis L of the through hole 128 and perpendicular to the stacking direction X, thereby cutting off the end portion 111 from the intermediate body 110 . Thereby, the resin molded product 10 including the base material 20 and the surface layer material 30 is manufactured (above, the trimming process).

Next, the effects of this embodiment will be described.
(1) The resin molded product 10 includes a resin base material 20 having a surface 21 provided with an uneven pattern 23 and a resin surface layer material 30 covering the surface 21 . Base material 20 has through holes 26 that open to surface 21 . The base material 20 and the surface layer material 30 are separated from each other in the lamination direction X. As shown in FIG.

According to such a configuration, it is possible to form the intermediate layer 40 by injecting the air A through the through holes 26 between the base material 20 and the surface layer material 30 . By making the refractive index of the intermediate layer 40 different from the refractive index of the surface layer material 30, the shadow of the uneven pattern 23 of the base material 20 becomes clear, and the three-dimensional effect of the uneven pattern 23 increases. Therefore, the appearance of the resin molded product 10 can be improved.

(2) The surface layer material 30 is made of a resin material having a melting point lower than that of the base material 20 .
When manufacturing the resin molded product 10 by forming the surface layer material 30 having visible light transmittance on the surface 21 of the base material 20 on which the uneven pattern 23 is formed, if injection molding is employed to form the surface layer material 30, the base material There is a risk that the uneven pattern 23 on the surface 21 of 20 may collapse due to the injected molten resin.

In this respect, according to the above configuration, the uneven pattern 23 of the base material 20 is less likely to collapse due to the heat of the molten resin during the secondary molding. That is, the three-dimensional effect of the uneven pattern 23 of the base material 20 is easily maintained. As a result, shadows of the uneven pattern 23 on the substrate 20 become clearer, and the three-dimensional effect of the uneven pattern 23 further increases. Therefore, the appearance of the resin molded product 10 can be further improved.

(3) The surface layer material 30 is made of a resin material having a higher mold shrinkage rate than the base material 20 .
According to such a configuration, the surface layer material 30 undergoes mold shrinkage after the secondary molding, so that the surface layer material 30 is pressed against the side surfaces 24b of the protrusions 24 forming the uneven pattern 23 of the base material 20 . This improves the adhesion between the base material 20 and the surface layer material 30 . Therefore, even though the base material 20 and the surface layer material 30 are spaced apart in the stacking direction X, it is possible to suppress a decrease in adhesion between the base material 20 and the surface layer material 30 .

(4) The through hole 26 is provided with the sealing material 50 for sealing the through hole 26 .
According to such a configuration, the sealing material 50 prevents the air A forming the intermediate layer 40 from leaking out through the through holes 26 . Therefore, deterioration of the appearance of the resin molded product 10 can be suppressed.

(5) The surface layer material 30 has a body portion 31 that covers the front surface 21 and anchor portions 32 that continue to the body portion 31 and cover the back surface 22 of the base material 20 .
According to such a configuration, the anchor portions 32 of the surface layer material 30 facilitate maintaining the state in which the base material 20 and the surface layer material 30 are in close contact with each other. Therefore, even though the base material 20 and the surface layer material 30 are spaced apart in the stacking direction X, it is possible to suppress a decrease in adhesion between the base material 20 and the surface layer material 30 .

(6) The method for manufacturing the resin molded product 10 includes a primary molding process for molding the base material 120 and a secondary molding process for molding the surface layer material 130 . Further, the method of manufacturing the resin molded product 10 includes a separating step of separating the base material 120 and the surface layer material 130 in the stacking direction X by applying pressure between the base material 120 and the surface layer material 130 through the through holes 26. Prepare.

According to such a method, the base material 120 is molded in the primary molding process. Next, in the secondary molding step, a cavity 86 is formed between the surface 121 of the substrate 120 and the molding surface 84 of the second mold 82 with the opening 26a of the through hole 26 of the substrate 120 closed. The surface layer material 130 is molded by filling the molten resin into the . Next, in the separating step, the base material 120 and the surface layer material 130 are separated in the stacking direction X by applying pressure between the base material 120 and the surface layer material 130 through the through holes 26 of the base material 120 . Thus, the intermediate 110 of the resin molded product 10 can be manufactured.

<Change example>
This embodiment can be implemented with the following modifications. This embodiment and the following modified examples can be implemented in combination with each other within a technically consistent range.

- The method for manufacturing a resin molded product according to the present invention is not limited to having a trimming process as in the present embodiment, and the trimming process can be omitted. In this case, the intermediate 110 corresponds to the resin molded product according to the present invention, and the base material 120 and surface layer material 130 correspond to the base material and surface layer material according to the present invention.

- The anchor portions 32 and 132 may be omitted. In this case, the through hole 128 can also be omitted. In addition, along with this, the slide mold 71B having the molding projections 71b can be omitted from the primary mold 70. As shown in FIG.

According to such a configuration, complication of the configuration of the primary molding die 70 is suppressed.
The arrangement of the uneven pattern 23 is not limited to being provided in the central portion 21a of the surface 21 as exemplified in this embodiment, and the arrangement can be appropriately changed according to the specifications of the resin molded product 10.

- The arrangement of the through-holes 26 is not limited to being provided at positions adjacent to the uneven pattern 23 in the width direction Y as exemplified in the present embodiment. As long as pressure can be applied between the base material 120 and the surface layer material 130 by injecting the air A through the through holes 26, the arrangement thereof can be appropriately changed. For example, the through holes 26 may be provided at positions overlapping the uneven pattern 23 in the stacking direction X. As shown in FIG.

- The number of through-holes 26 is not limited to two as exemplified in the present embodiment, and may be one or three or more.
- The through-hole 26 is not limited to extending linearly in the stacking direction X as exemplified in the present embodiment. For example, the through-holes 26 may extend obliquely with respect to the stacking direction X as long as they are open to the surface 21 .

The intermediate layer 40 is not limited to the one composed of the air A as exemplified in the present embodiment, and an appropriate material may be used as long as the refractive index of the intermediate layer 40 is made different from the refractive index of the surface layer material 30. You can change it. For example, by filling a coloring material between the base material 20 and the surface layer material 30, an intermediate layer made of the coloring material can be formed.

According to such a configuration, by appropriately setting the refractive index of the coloring material, it is possible to adjust the clarity of the shadows of the uneven pattern 23 of the substrate 20 and, in turn, the three-dimensional effect of the uneven pattern 23 .
- The sealing material 50 may be omitted. In this case, a viscous coloring material or the like may be used as the material forming the intermediate layer.

- The surface layer material 30 is not limited to a material formed of a resin material having a larger mold shrinkage rate than the base material 20 . For example, the molding shrinkage rate S2 of the resin material of the surface layer material 30 may be the same as the molding shrinkage rate S1 of the resin material of the base material 20 (S2=S1). (S2<S1). Even in such a case, the melting point M2 of the resin material of the surface layer material 30 should be higher than the melting point M1 of the resin material of the base material 20 .

- The resin molded product according to the present invention is not limited to those applied to vehicle interior materials such as instrument panels, but can also be applied to vehicle exterior materials, for example.

θ... Angle A... Air L... Axis M1, M2... Melting point S1, S2... Mold shrinkage rate V1... Imaginary straight line V2... Imaginary plane X... Lamination direction Y... Width direction 10... Resin molded product 20, 120... Base material 21, DESCRIPTION OF SYMBOLS 121... Surface 21a... Center part 22, 122... Back surface 23... Concavo-convex pattern 24... Convex part 24a... Tip surface 24b... Side surface 25... Recessed part 25a... Bottom surface 26... Through-hole 26a... Opening part 27... End surface 30, 130... Surface layer material DESCRIPTION OF SYMBOLS 31, 131... Main-body part 32, 132... Anchor part 33... Base end part 34... Tip part 40... Intermediate layer 50... Sealing material 60... Manufacturing apparatus 70... Primary mold 71A... First mold 71B... Slide mold 71b... Convex mold 72 Second mold 73 Molding surface 74 Molding surface 74a Molding uneven part 75 Insertion hole 76 Cavity 80 Secondary mold 81 First mold 82 Second mold 83 Support surface 84 Molding Surface 85 Through hole 86 Cavity 87 Cavity 91 Pin 91a One end 92 Pin 92a One end 110 Intermediate body 111 End 128 Through hole 128a Inner peripheral surface 131a Surface

Claims (7)

a resin substrate having a surface provided with an uneven pattern;
a resin surface layer material having visible light transmittance and being laminated on the base material to cover the surface, wherein the base material is used as a primary molding material, and the surface layer material is used as a secondary molding material. A resin molded product formed by color molding,
The base material has a through-hole opening to the surface,
The base material and the surface layer material are separated from each other in the lamination direction of the base material and the surface layer material,
Resin molded product. The surface layer material is formed of a resin material having a lower melting point than the base material,
The resin molded product according to claim 1. The surface layer material is formed of a resin material having a higher mold shrinkage rate than the base material,
The resin molded article according to claim 1 or 2. The through hole is provided with a sealing material that seals the through hole,
The resin molded product according to any one of claims 1 to 3. A coloring material is filled between the base material and the surface layer material in the lamination direction,
The resin molded product according to any one of claims 1 to 4. The surface layer material has a body portion that covers the surface, and an anchor portion that is continuous with the body portion and covers the back surface of the base material.
The resin molded product according to any one of claims 1 to 5. A method for manufacturing a resin molded product according to any one of claims 1 to 6,
A primary molding step of molding the base material;
a secondary molding step of molding the surface layer material by filling a molten resin into a cavity formed between the surface and the molding die in a state where the openings of the through-holes that open to the surface are closed;
a separating step of separating the base material and the surface layer material in the stacking direction by applying pressure between the base material and the surface layer material through the through holes;
A method for manufacturing a resin molded article.

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