JP2711629B2 - Insert molded product and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an insert molded product used for a front panel of an AV device, various switch buttons, an instrument panel of an automobile, and the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Molded articles such as front panels of AV equipment, various switch buttons, and instrument panels of automobiles are structured so that letters and symbols on the outer surface side can be seen illuminated by illumination from behind, Alternatively, there is also a configuration in which characters or symbols on the outer surface side can be seen from the front surface regardless of illumination from the back side.

[0003] Hereinafter, an example will be described in which characters and symbols on the outer surface side are illuminated by illumination from the back side. Further, as typical examples of this type of product, a top surface portion, an upper apron portion extending substantially downward from a peripheral end of the top surface portion, a flange portion extending around a lower end of the upper apron portion, and a flange. Switch button having a lower apron portion extending substantially downward from a peripheral end of the switch portion (FIG. 1).
The related art will be described below with reference to an example.

(1) A light-transmitting resin molded product having a top surface portion, an upper apron portion, a flange portion, and a lower apron portion is injection-molded, and then a light-shielding paint is applied to the outer surface of the light-transmitting resin molded product. Is applied, and then the light-shielding paint is removed by laser etching in order to form a blank character.

(2) A light-transmissive resin molding portion in which only characters and symbols protrude is injection-molded, and then a light-shielding resin molding is formed so as to cover all but the protruding portion of the translucent resin molding portion. The part is injection molded, and the translucent resin molded part and the light shielding resin molded part are overlapped.

(3) A light-shielding insert sheet 10 having a blank character, a preform mold 20 having a cavity 23 having the same shape as a female recess of an injection mold, and an end of the light-shielding insert sheet 10 The clamped light-shielding insert sheet 10 is heated by heating means 50 (see FIG. 14) using the clamping means 30 (see FIG. 13) for clamping the light-shielding insert sheet 10 (see FIG. 14). The mold 23 is pulled down to the bottom 25 of the cavity 23 (see FIG. 15).
After preforming so that it conforms to the inner surface shape of, the unnecessary part is trimmed, this preformed insert sheet is mounted on the injection mold, and after closing the mold, light is transmitted through the cavity of the injection mold. Method for producing a so-called insert molded product, in which a transparent resin molded product is formed by injecting a transparent molding resin, and at the same time, an insert sheet is formed so as to cover the outer surface of the transparent resin molded product. What you got by.

[0007]

However, in (1),
Because of the function of the laser irradiation device used in the laser etching step, it is difficult to etch a three-dimensional surface such as a fine uneven surface or a curved surface, so that a place where a blank character can be formed is limited. Further, since the light-shielding paint is applied to the outer surface of the light-transmitting resin molded product, a uniform coating film cannot be obtained, and the illumination light leaks from a thin portion of the coating film to the outside. Therefore, the switch button obtained by this method is limited to a specific shape, the distinction between a blank character portion and other portions is unclear, or the design is poor.

In (2), two types of dies must be prepared, one for injection-molding the light-transmitting resin molded part and the other for injection-molding the light-shielding resin molded part. .
Therefore, the insert molded product obtained by this method had to be expensive.

In (3), the light-shielding insert sheet 10
Since the distance drawn into the bottom 25 of the cavity 23 for the preform becomes longer, the vicinity of the center of the light-shielding insert sheet 10 is stretched best. As a result, the thickness of the light-shielding ink layer at the top surface of the stretched light-shielding insert sheet 10 becomes thinner, and the light-shielding property is reduced. In addition, the formed cutout characters are also stretched to cause deformation or breakage. Therefore, in the switch button obtained by this method, the discrimination between the portion of the cutout character and the other portions is unclear, the cutout character is distorted, and the cutout character is registered at the exact position of the switch button. It may not be possible to place it accurately.

[0010] In order to shorten the distance that the light-shielding insert sheet 10 is drawn, it is conceivable to lower the position where the light-shielding insert sheet 10 is clamped. For this purpose, the preform mold 20 must be divided into upper and lower parts usually with the extension line 26 of the flange as a boundary, and the light-shielding insert sheet 10 must be mounted between the divided molds. Since the light-shielding insert sheet 10 does not follow the upper cavity 23 of the divided mold, the lower apron portion of the obtained switch button is not covered with the light-shielding insert sheet 10. When a large number of such switch buttons are incorporated into a switch button mounting panel of an automobile or the like, light leaks from each switch button, and thus light leaks from the lower apron portion of the entire panel. Therefore, it was not preferable in design.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems. Particularly, the present invention is applied to a structure in which characters or symbols on the outer surface side are illuminated by illumination from the back side. Clear inserts with no distinction between character parts and other parts, with no deformation or breakage, are formed with high registration accuracy, while providing insert molded products that do not leak light from the lower apron, and resin molding An object of the present invention is to provide a method of manufacturing an insert molded product in which a pattern formed on a top surface of the product is not deformed or damaged.

[0012]

In order to achieve the above object, an insert molded product of the present invention comprises a top surface, an upper apron extending substantially downward from a peripheral end of the top surface, and The surface of a resin molded product having a flange portion extending around the lower end of the apron portion and a lower apron portion extending substantially downward from a peripheral end of the flange portion extends from the top surface portion to the lower apron portion. Up to the insert sheet,
The insert sheet was configured such that a pattern was formed on the top surface.

In the insert molded product of the present invention, the resin molded product may be a translucent resin molded product, the insert sheet may be a light-shielding insert sheet, and the picture may be a blank character.

The method of manufacturing an insert molded product according to the present invention is characterized in that the end of the insert sheet is clamped by ramp means, the insert sheet is heated and softened by heating means, and the insert sheet is formed into a female recess of an injection molding die. The top surface of the convex portion of the preform mold provided with the convex portion to be brought into contact with the insert sheet having the pattern, the insert sheet is preformed so as to conform to the convex shape of the preform mold, and the insert sheet is formed. Attach the preformed insert sheet to the injection mold consisting of a female mold and a male mold to trim unnecessary parts and mold the insert molded product, close the injection mold, and use it for injection molding. The molding resin was injected into the cavity of the mold, the mold for injection molding was opened, and the insert molded product was taken out.

According to the method of manufacturing an insert molded product of the present invention, an end of an insert sheet is clamped by a clamping means, and a preform mold provided with a convex portion corresponding to a female concave portion of an injection mold. The top surface of the convex portion is brought into contact with the insert sheet having a pattern, the insert sheet is heated and softened by heating means, and the insert sheet is preformed so as to conform to the convex shape of the preform mold. Attach the preformed insert sheet to the injection mold consisting of a female mold and a male mold to trim unnecessary parts and mold the insert molded product, close the injection mold, and use it for injection molding. The molding resin was injected into the cavity of the mold, the mold for injection molding was opened, and the insert molded product was taken out.

The method of manufacturing an insert molded article according to the present invention is characterized in that the end of the insert sheet is clamped by the clamp means, and the insert sheet is heated and softened by the heating means while the concave portion of the female mold of the injection molding die is formed. The top surface of the convex part of the preform mold provided with the corresponding convex part is brought into contact with the insert sheet having a picture, and the insert sheet is preformed so as to conform to the convex part shape of the preform mold. Trim the unnecessary part of, insert the preformed insert sheet into the injection molding mold consisting of the female mold and the male mold to mold the insert molded product, close the injection molding mold, and injection molding The molding resin was injected into the cavity of the mold, the mold for injection molding was opened, and the insert molded product was taken out.

In the method of manufacturing an insert molded product according to the present invention, when preforming the insert sheet, the clamping means is brought closer to the preform mold side, and the top surface of the projection of the preform mold is brought into contact with the insert sheet. You may make it do.

In the method of manufacturing an insert molded product according to the present invention, an unnecessary portion of the insert sheet may be trimmed using a laser cutting machine.

In the method for manufacturing an insert-molded article of the present invention, the insert sheet may be a light-shielding insert sheet, the pattern may be a blank character, and the molding resin may be a translucent resin.

[0020]

The insert-molded article of the present invention is an insert-molded article in which an accurate pattern without deformation or breakage is formed at an accurate position of the switch button with high register accuracy. In particular, when the characters or symbols on the outer surface side are illuminated by illumination from the back side, they are formed from the top surface of the transparent resin molded product to the lower apron. Blocks light from going out of the apron. On the other hand, in the portion where the cut characters are formed, the illumination light from the back side leaks outside through the cut characters of the translucent resin molded product and the insert sheet (see FIG. 1).

In the method of manufacturing an insert molded product employed in the present invention, since the insert sheet is preformed by the convex portion provided on the preform mold, the insert sheet is brought into contact with the top surface of the convex portion of the preform mold. Is a portion located on the top surface of the molded product of the insert sheet, and the stretched distance of this portion can be extremely short. In addition, the insert sheet is softened by heating, but when comparing the part that is in contact with the top surface of the convex part of the preform mold with the part that is not, the former is cooled by the preform mold or the temperature is lower. Since the rise is small, the degree of softening of the insert sheet is reduced or stopped. Therefore,
If the latter part is further stretched by vacuum suction, the former part will not be stretched.

In particular, when manufacturing a structure in which the characters and symbols on the outer surface side are illuminated and illuminated by the illumination from the back side, the light-shielding insert sheet is provided by a convex portion provided on the preform mold. Since the preforming is performed (see FIGS. 3 to 8 and FIGS. 16 to 21), the first contact with the top surface of the convex portion of the preform mold is located on the top surface of the molded product of the light-shielding insert sheet. Part, and the stretched distance of this part can be extremely short (see FIGS. 5, 6, 18, and 19). In addition, the light-shielding insert sheet is softened by heating, but when comparing the part in contact with the top surface of the convex part of the preform mold and the part that is not, the former is different depending on the preform mold. Since the cooling sheet is cooled, the degree of softening of the light-shielding insert sheet is reduced or stopped. Therefore,
Even if the latter part is further stretched by vacuum suction, the former part is not stretched (see FIGS. 5 to 8).

[0023]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to the drawings. Hereinafter, particularly, an insert molded product configured such that characters and symbols on the outer surface side are illuminated by illumination from the back side will be described. The insert molded product of the present invention comprises a light-transmitting resin molded product 6 and a light-shielding insert sheet 10 covering the surface thereof. The shape of the translucent resin molded product 6 includes a top surface portion 1, an upper apron portion 2, a flange portion 3, and a lower apron portion 4. The light-shielding insert sheet 10 covers the surface of the translucent resin molded product 6 from the top surface 1 to the lower apron 4, and a cutout character 11 is formed on the top surface of the light-shielding insert sheet 10. (See FIG. 1).

In the case of an insert molded product in which the characters and symbols on the outer surface side can be seen from the front surface regardless of the illumination from the back side, the resin molded product 6 may be a light-shielding resin molded product.

The top surface portion 1 is a portion having a horizontal surface or a gently curved surface shape. When the insert molded product of the present invention is used as a switch button, it becomes a portion to be touched by a human finger at the time of operation. The top surface portion 1 is covered with the light-shielding ink layer 13 of the light-shielding insert sheet 10, and the light-shielding insert sheet 10 on the top surface portion 1 is covered.
Is formed with a blank character 11 representing a character or a symbol.

The upper apron portion 2 is a portion extending substantially downward from the peripheral end of the top surface portion 1. The upper apron portion 2 is also covered by the light-shielding ink layer 13 of the light-shielding insert sheet 10, and the light-shielding insert sheet 10 on the upper apron portion 2 has a blank character 11 that expresses a character or a symbol.
May or may not be formed.

The flange portion 3 is a portion extending around the lower end of the upper apron portion 2. The flange portion 3 is also covered with the light-shielding ink layer 13 of the light-shielding insert sheet 10, and the light-shielding insert sheet 10 on the upper apron portion 2 is formed with a blank character 11 representing a character or a symbol. Or may not be formed. When the insert molded product of the present invention is used as a switch button, the upper surface of the flange portion 3 is positioned at the same height as the surface of the switch button mounting panel by being incorporated into the switch button mounting panel. become. The flange portion 3 has an upper surface shape that can be seen externally as a part of the surface shape of the switch button mounting panel. For example, if the surface shape of the switch button mounting panel is wavy, the top surface shape of the switch button flange 3 is also wavy.

The lower apron portion 4 is a portion extending substantially downward from the peripheral end of the flange portion 3. At least, it is necessary that the light-shielding ink layer 13 of the light-shielding insert sheet 10 be covered with the light-shielding ink layer 13 to the lower side from the boundary between the flange portion 3 and the lower apron portion 4.

As the light-shielding insert sheet 10 covering the surface of the light-transmitting resin molded product 6, for example, the base sheet 1
2, a light-shielding ink layer 13 is formed thereon, and an adhesive layer 15 is formed thereon.
After the formation of No. 3, a translucent colored ink layer 14 is formed thereon so as to cover at least the blank character 11, and an adhesive layer 15 is formed thereon (see FIG. 2).
In the former case, the cutout characters 11 appear in the color of the illumination light, and in the latter case, they appear in the color of the translucent colored ink layer 14. The blank characters 11 correspond to the light-shielding ink layer 13.
It is good to provide on the base material sheet 12 so that a blank character may be formed (a portion to which the light-shielding ink is not attached becomes a character). The blank character 11 can be an arbitrary pattern such as a character, a symbol, a pattern, a picture, or a logo.

In the case of an insert molded product configured so that the characters and symbols on the outer surface side can be seen from the front surface irrespective of the illumination from the back side, the insert sheet may include characters, symbols, and the like on the base sheet 12. An arbitrary pattern such as a pattern, a picture, a logo, or the like is formed by a normal ink layer , and an adhesive layer 15 is formed thereon.

Next, a method of manufacturing an insert molded product according to the present invention will be described. In particular, a description will be given of a method of manufacturing an insert molded product in which characters and symbols on the outer surface side are illuminated by illumination from the back side. In FIGS. 1, 3 to 12, and 16 to 21, as the translucent resin molded product 6, a top surface portion, an upper apron portion extending substantially downward from a peripheral end of the top surface portion, and an upper apron The figure shows a shape having a flange portion extending around the lower end of the portion and a lower apron portion extending substantially downward from the peripheral end of the flange portion. However, the method for manufacturing an insert molded product according to the present invention is applied to a translucent resin molded product 6 having at least two portions, a top surface portion and an apron portion extending substantially downward from the periphery of the top surface portion. (See FIG. 23).

A convex part 21 corresponding to a concave part 41 of a female mold 42 of an injection mold 40 to be described later was preformed with a preform mold 20 (see FIGS. 3 to 8) provided in a cavity 23. A trimming means for cutting off unnecessary portions of the light-shielding insert sheet 10, a clamp means 30 for clamping the light-shielding insert sheet 10 (see FIGS. 3 to 8), and a female mold 42 having a concave portion 41 for molding a molded product. An injection mold 40 including a male mold 43 and a heating means 50 (see FIGS. 10 to 12) are prepared.

Light-shielding insert sheet 10 (see FIG. 2)
Is a film or sheet used as a base sheet of a normal insert sheet, for example, acrylic resin, polycarbonate resin, polybutylene terephthalate resin, polyethylene terephthalate resin, chloride There are resin films such as vinyl resin and resin sheets. The light-shielding ink layer 13 is formed using an opaque material such as carbon black having a concealing property and an ink made of a resin binder so as to form the blank characters 11 representing characters and symbols.
It is formed on the base sheet 1. Translucent colored ink layer 14
Is formed on the cut characters 11 of the light-shielding ink layer 13 using an ink composed of a dye and a resin binder, or an ink composed of a color pigment or a fluorescent pigment having a small particle size and a transparent resin binder. Translucent colored ink layer 14
May be formed in different colors such as green and orange for each of the cut characters 11 of the light-shielding ink layer 13. The adhesive layer 15 is made of an acrylic resin, a polycarbonate resin,
It is formed on the translucent ink layer 13 or the translucent colored ink layer 14 using a transparent resin similar to the molding resin 60, such as polybutylene terephthalate resin, polyethylene terephthalate resin, and vinyl chloride resin.

When manufacturing an insert molded product in which characters and symbols on the outer surface side can be seen from the surface regardless of illumination from the back side, the base sheet 12 is
An arbitrary pattern such as a character, a symbol, a pattern, a picture, and a logo may be formed with a normal ink layer , and an adhesive layer 15 may be formed thereon.

Preform mold 20 (see FIGS. 3 to 8)
Is a mold provided with a convex portion 21 and is made of metal, wood, plastic, or the like. The convex portion 21 has a cavity 23
It may be provided inside (see FIGS. 3 to 8) or may be provided without a cavity (see FIGS. 16 to 21). The convex portion 21 has a surface shape corresponding to the concave portion 41 of the female mold 42 of the injection molding die 40 (see FIGS. 10 to 12) for molding a molded product.

In the method of manufacturing an insert molded product according to the present invention, the corresponding surface shape is a shape that substantially matches the shape of the concave portion 41 of the female mold 42, a shape that almost completely matches, and a shape that completely matches. Is included. Further, even if the shape does not completely match, the shape may substantially correspond to the shape of the cavity, and after preforming, the shape may be such that it completely matches the surface of the cavity by using the pressure at the time of injection of the molding resin.

Using the preform mold 20, the light-shielding insert sheet 10 is preformed by vacuum and / or compressed air. FIGS. 3 to 8 and FIGS. 16 to 21 show aspects in which preform is performed by vacuum suction.
A vacuum suction port 24 is formed.

The clamping means 30 (see FIGS. 3 to 8)
The light-shielding insert sheet 10 is
Light-shielding insert sheet 10 when vacuum-formed with
Of the light-shielding insert sheet 10 so that an extra portion of the end of the sheet is not dragged into the surface of the preform mold 20.
This is a means for sandwiching the end of the frame and securely fixing it. The preform mold 20 and the clamp means 30 are configured to operate relatively close to or apart from each other. That is, only the clamp means 30 may move, only the preform mold 20 may move, or both may move.

The injection molding die 40 (see FIGS. 10 to 12) includes a top surface portion, an upper apron portion extending substantially downward from the periphery of the top surface portion, and a periphery of a lower end of the upper apron portion. A mold including a female mold 42 and a male mold 43 having a concave portion 41 for molding a molded product having a provided flange portion and a lower apron portion extending substantially downward from a peripheral end of the flange portion. It is. The inner shape of the concave portion 41 of the female mold 42 is a shape corresponding to the surface shape of the convex portion 21 of the preform mold 20. That is, the protrusion 21 of the preform mold 20
The light-shielding insert sheet vacuum-formed and preformed is designed to fit into the concave portion 41 of the injection mold 40. The male mold 43 is provided with a resin injection port 44.

The light-shielding insert sheet 10 described above
The light-shielding insert sheet 10 is preformed using the preform mold 20, the clamping means 30, and the injection mold 40, and then the light-shielding insert sheet 10 is preformed.
Manufactures an insert molded product covered on the translucent resin molded product 6. First, the end of the light-shielding insert sheet 10 is clamped by the clamping means 30 (see FIGS. 4 and 17).

Next, the light shielding insert sheet 10 is heated and softened from above by the heating means 50 (see FIGS. 5 and 18). The heating means 50 includes a heating plate and a hot air device.

At this time, the temperature of the heat radiated by the heating means 50 is about 240 ° C., and the heat causes the light-shielding insert sheet 10 to be heated to about 150 to 160 ° C.
It becomes a softened state. The softening temperature T1 of the light-shielding insert sheet 10 depends on the material of the light-shielding insert sheet,
The temperature is such that when vacuum suction is applied, it becomes easy to adhere closely along the surface shape of the preform mold 20.
The softening temperature T1 depends on the material of the base sheet 12 of the light-shielding insert sheet 10. For example, if the base sheet 12 is a polycarbonate resin, the softening temperature T1 is 14
The temperature is 0 to 150 ° C., and in the case of an acrylic resin, the softening temperature T1 is about 120 ° C.

Next, the projection 21 of the preform mold 20
Character 1 of the top surface 22 and the light-shielding insert sheet 10
1 (see FIGS. 6 and 19). This contact
The contact may be made by vacuum suction, by moving the clamp means 30, or by the softened light-shielding insert sheet 10 hanging down by its own weight.

Top surface 2 of convex portion 21 of preform mold 20
2 is apart from the heating means 50, so that a temperature T2 lower than that of the light-shielding insert sheet 10 is maintained. Therefore, since the top surface 22 of the convex portion 21 removes the heat of the light-shielding insert sheet 10, the degree of softening of the light-shielding insert sheet decreases. The temperature T2 of the top surface 22 of the projection 21 depends on the softening temperature T1 of the base sheet 12 of the light-shielding insert sheet 10. For example, when a polycarbonate resin is used as the base sheet 12 of the light-shielding insert sheet 10, the top surface 22 of the projection 21
Temperature T2 is suitably maintained at 90 ° C. or lower.
In the case of an acrylic resin, it is appropriate that the temperature T2 of the top surface 22 of the projection 21 is maintained at 60 ° C. or less.

The softening by heating may be performed after the top surface 22 of the projection 21 of the preform mold 20 and the cutout 11 of the light-shielding insert sheet 10 are brought into contact with each other.

Alternatively, the softening by heating may be performed and completed before the top surface 22 of the convex portion 21 of the preform mold 20 and the cutout character 11 of the light-shielding insert sheet 10 are brought into contact with each other.

Alternatively, the top surface 22 of the projection 21 of the preform mold 20 may be brought into contact with the cutout character 11 of the light-shielding insert sheet 10 while softening by heating.

Next, the gap between the light-shielding insert sheet 10 and the preform mold 20 is evacuated (FIGS. 7 and 2).
0), and the light-shielding insert sheet 10 is adhered to the preform mold 20 so as to follow the shape of the convex portion 21 (see FIGS. 8 and 21). By doing so, the softened light-shielding insert film is preformed into a shape according to the surface shape of the projection 21. The surface shape of the convex portion 21 of the preform mold 20 depends on the shape of the injection mold 40.
Since the shape corresponds to the inner shape of the concave portion 41 of the female mold 42, the light-shielding insert sheet 10 thus preformed has a shape that fits into the concave portion 41 of the female mold 42 of the injection molding die 40. Become.

Next, unnecessary portions of the preformed light-shielding insert sheet 10 are trimmed by trimming means (see FIGS. 9 and 23). The light-shielding insert sheet 10 may be trimmed so as to cover the entire surface from the top surface portion 1 to the lower apron portion 4, or may be trimmed to cover the top surface portion 1, the flange portion 3 and the middle of the lower apron portion 4. May be trimmed. The light-shielding insert sheet 10 is trimmed by a press cutting device having a knife or a cutting blade, a sliding cutting die for cutting the periphery of the first mold and the periphery of the second mold, a heating cutting device, and a laser cutting device. For example, an ordinary resin sheet cutting means may be used.

In the laser cutting device, as shown in FIG. 22, a laser irradiation head 70 is mounted on an XYZ stage 71 so that the laser irradiation head 70 can be moved arbitrarily in a three-dimensional direction, that is, in the XYZ directions. .
This laser cutting device can be arranged above the preform mold 20.

Next, the injection molding die 40 is
The preformed light-shielding insert sheet 10 is mounted (see FIG. 10). Since the light-shielding insert sheet 10 has already been preformed so as to match the concave portion 41 of the female mold 42, the light-shielding insert sheet 10 is inserted into the concave portion 41 of the female mold 42 by a suitable conveying device (not shown), a robot, or manually. Just fit it.

Next, after the mold is closed, the translucent molding resin 60 is injected between the molds (see FIG. 11) to form the translucent resin molded product 6 and at the same time, the surface thereof is made of a light-shielding insert sheet. 12 (see FIG. 12).
See). The adhesive layer 15 of the light-shielding insert sheet 10 is melted by the heat of the resin at the time of injecting the molding resin 60, and the molding resin 60 is cooled and solidified.
5 adheres to the surface of the molded article. Examples of the molding resin 60 include acrylonitrile styrene resin, polycarbonate resin, polystyrene resin, acrylic resin, transparent ABS resin, and polyester resin.

When manufacturing an insert molded product in which the characters and symbols on the outer surface side can be seen from the front surface regardless of the illumination from the back side, a light-shielding resin may be used as the molding resin 60.

Next, the molding resin 60 is cooled and solidified, the mold 40 for injection molding is opened, and the light-shielding insert sheet 10 is formed on the surface of the light-transmitting resin molded article 6. From the injection mold 40.

[0055]

The insert-molded article of the present invention is an insert-molded article in which an accurate pattern without deformation or breakage is formed at an accurate position of the switch button with high register accuracy.

In particular, in the case where the characters and symbols on the outer surface side are made to look shining by the illumination from the back side, the illuminating light going to the outside from the lower apron portion is completely blocked, and Since only the illuminating light leaks outside, the part of the blank character and the other part are clearly distinguished. For example, when a large number of switch buttons are mounted on a switch button mounting panel of an automobile, the illumination light from the rear of the panel leaks only from the part of the cutout, and the other parts are completely blocked and the outer surface is completely blocked. Since it does not leak to the side, it is a preferable product in design.

Further, the method of manufacturing an insert molded product and the insert molded product of the present invention not only exhibit the effects of the conventional technique for manufacturing an insert molded product, but also exhibit the following special effects. In other words, the pattern portion of the insert sheet needs to be drawn only a short distance during preform, and is softened at the top of the projection so that it is not stretched while the other portions of the insert sheet are being vacuumed. Since the degree is reduced or stopped, the thickness of the ink layer on the top surface of the insert sheet is not reduced. Therefore, it is possible to obtain an insert molded product in which an accurate pattern without deformation or breakage is formed at an accurate position of the switch button with high registration accuracy.

In particular, when manufacturing a structure in which the characters and symbols on the outer surface side are illuminated and illuminated by the illumination from the back side, the cutout portion of the light-shielding insert sheet is used in the preform. As the retracted distance is short, the degree of softening is reduced or stopped at the top surface of the projection so that the other part of the light-shielding insert sheet is not stretched while the other part of the light-shielding insert sheet is being vacuumed. The thickness of the light-shielding ink layer on the top surface does not become thin, and the light-shielding property of this portion hardly decreases. Therefore, the distinction between the part of the blank character and the other part is clear, and the accurate blank character without deformation or damage,
It is formed with accurate registration at the exact position of the switch button,
Moreover, it is possible to obtain an insert molded product without light leakage from the lower apron portion.

[Brief description of the drawings]

FIG. 1 is an explanatory sectional view showing an insert molded product of the present invention.

FIG. 2 is an explanatory sectional view showing an insert sheet used in the method of manufacturing an insert molded product according to the present invention.

FIG. 3 is an explanatory sectional view showing one step of the method for manufacturing an insert molded product according to the present invention.

FIG. 4 is an explanatory cross-sectional view showing a state where an end portion of a light-shielding insert sheet is clamped in the method of manufacturing an insert molded product according to the present invention.

FIG. 5 is an explanatory cross-sectional view showing a state in which the light-shielding insert sheet is being heated in the method of manufacturing an insert molded product according to the present invention.

FIG. 6 is a cross-sectional explanatory view showing a state in which the cutout portion of the light-shielding insert sheet and the top surface of the projection of the preform mold are in contact with each other in the method of manufacturing an insert molded product according to the present invention.

FIG. 7 is an explanatory cross-sectional view showing a state in which the light-shielding insert sheet is vacuum-sucked in the method of manufacturing an insert molded product according to the present invention.

FIG. 8 is an explanatory cross-sectional view showing a state in which the light-shielding insert sheet is in close contact with the surface of the preform mold in the method for producing an insert molded product according to the present invention.

FIG. 9 is an explanatory sectional view showing a state in which an unnecessary portion of the light-shielding insert sheet preformed by the method for manufacturing an insert molded product according to the present invention is trimmed.

FIG. 10 is an explanatory sectional view showing a state in which a preformed insert sheet is to be placed in an injection molding die in the method for manufacturing an insert molded product according to the present invention.

FIG. 11 is an explanatory sectional view showing a state in which a molding resin is injected into a cavity of an injection molding die in the method of manufacturing an insert molded product according to the present invention.

FIG. 12 is an explanatory cross-sectional view showing a state in which the insert molded product is taken out from the injection molding die in the method of manufacturing an insert molded product according to the present invention.

FIG. 13 is an explanatory sectional view showing one step of a conventional method for producing an insert molded product.

FIG. 14 is an explanatory sectional view showing one step of a conventional method for manufacturing an insert molded product.

FIG. 15 is an explanatory sectional view showing one step of a conventional method for manufacturing an insert molded product.

FIG. 16 is an explanatory sectional view showing one step of a method of manufacturing another insert molded product according to the present invention.

FIG. 17 is an explanatory cross-sectional view showing a state where an end portion of a light-shielding insert sheet is clamped in another method of manufacturing an insert molded product according to the present invention.

FIG. 18 is an explanatory cross-sectional view showing a state in which a light-shielding insert sheet is being heated in another method of manufacturing an insert molded product according to the present invention.

FIG. 19 is a cross-sectional explanatory view showing a state in which the cutout portion of the light-shielding insert sheet and the top surface of the projection of the preform mold are in contact with each other in the method of manufacturing an insert molded product according to the present invention. is there.

FIG. 20 is an explanatory cross-sectional view showing a state where a light-shielding insert sheet is vacuum-sucked in another method of manufacturing an insert molded product according to the present invention.

FIG. 21 is an explanatory cross-sectional view showing a state in which the light-shielding insert sheet is in close contact with the surface of the preform die in another method of manufacturing an insert molded product according to the present invention.

FIG. 22 is an explanatory cross-sectional view showing a state in which a preformed light-shielding insert sheet is being trimmed by a laser cutting device in another method of manufacturing an insert molded product according to the present invention.

FIG. 23 is an explanatory sectional view showing a state in which an unnecessary portion of the light-shielding insert sheet preformed by the method for manufacturing an insert molded product according to the present invention is trimmed.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Top surface part 2 Upper apron part 3 Flange part 4 Lower apron part 6 Translucent resin molding 10 Light-shielding insert sheet 11 Cutout character 12 Base material sheet 13 Light-shielding ink layer 14 Light-transmissive coloring ink layer 15 Adhesive layer 20 Pre Forming die 21 Convex part 22 Top surface 23 Cavity 24 Vacuum suction port 25 Bottom part 26 Extension line of flange part 30 Clamping means 40 Injection molding die 41 Depression 42 Female mold 43 Male mold 44 Resin injection opening 50 Heating means 60 Molding resin 70 Laser irradiation head 71 XYZ stage

Claims (8)

(57) [Claims] A top surface portion, an upper apron portion extending substantially downward from a peripheral end of the top surface portion, a flange portion extending around a lower end of the upper apron portion, and a peripheral end of the flange portion. The surface of the resin molded product having a lower apron portion extending substantially downward is covered with an insert sheet from the top surface to the lower apron portion, and a pattern is formed on the top surface of the insert sheet. Insert molded product characterized by the following. 2. The resin molded article is a translucent resin molded article,
The insert molded product according to claim 1, wherein the insert sheet is a light-shielding insert sheet, and the pattern is a blank character. 3. A preform in which an end of an insert sheet is clamped by a clamp means, the insert sheet is heated and softened by a heating means, and a convex part corresponding to a concave part of a female mold of an injection mold is provided. The top surface of the convex part of the mold is brought into contact with the insert sheet having a picture, the insert sheet is preformed so as to conform to the shape of the convex part of the preform mold, and unnecessary parts of the insert sheet are trimmed to obtain an insert molded product. Attach the preformed insert sheet to the injection mold consisting of a female mold and a male mold to mold the mold, close the mold for injection molding, and inject molding resin into the cavity of the mold for injection molding. A method for manufacturing an insert molded product, comprising opening a mold for injection molding and removing an insert molded product. 4. An end portion of an insert sheet is clamped by a clamping means, and a top surface and a picture of a convex portion of a preform mold provided with a convex portion corresponding to a female concave portion of an injection mold are provided. The insert sheet is brought into contact with the insert sheet and heated by the heating means to soften the insert sheet. Attach the preformed insert sheet to the injection mold consisting of a female mold and a male mold to mold the mold, close the mold for injection molding, and inject molding resin into the cavity of the mold for injection molding. A method for manufacturing an insert molded product, comprising opening a mold for injection molding and removing an insert molded product. 5. A pre-pressurizer having a protrusion corresponding to a recess of a female mold of an injection mold while clamping an end of an insert sheet by a clamp means and heating and softening the insert sheet by a heating means. The top surface of the convex part of the form mold is brought into contact with the insert sheet having a picture, the insert sheet is preformed so as to conform to the shape of the convex part of the preform mold, trimming unnecessary parts of the insert sheet, and insert molding. Attach the preformed insert sheet to the injection mold consisting of a female mold and a male mold to mold the product, close the injection mold, and add the molding resin to the cavity of the injection mold. A method for producing an insert molded product, comprising injecting, opening a mold for injection molding, and taking out an insert molded product. 6. When preforming an insert sheet, the clamping means is moved closer to the preform mold side,
The method for producing an insert molded product according to any one of claims 3 to 5, wherein a top surface of the convex portion of the preform mold is brought into contact with the insert sheet. 7. The method for producing an insert molded product according to claim 3, wherein unnecessary portions of the insert sheet are trimmed using a laser cutting machine. 8. The method for manufacturing an insert molded product according to claim 3, wherein the insert sheet is a light-shielding insert sheet, the pattern is a blank character, and the molding resin is a translucent resin. .