JP2734055B2 - Manufacturing method of illuminated switch parts - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial application] The present invention relates to an illuminated switch-that is, a character-mark is provided even in darkness having a light source inside where only the character-mark portion passes light and the other portions are light-shielded. This is a novel method of manufacturing floating switches. Illuminated switches are widely used as buttons and switches for various electric and electronic devices such as automobiles, audio and VTRs.

[Conventional technology and its problems]

At present, there are the following methods as a method of manufacturing an illuminated switch.

. A method in which buttons are injection-molded with a light-transmitting resin, the surface is undercoated if necessary, then metal is sputtered, predetermined characters to marks are laser-engraved, and top-coated.

. A method in which buttons and the like are injection-molded with a light-transmitting resin, a predetermined character or mark is masked on the surface thereof, plated, and then the mask is removed.

. A method in which a perforated button is formed, and a printed sheet on which a light-shielding layer is formed while leaving letters to marks so as to cover the perforated portion is attached.

Further, the following methods have been used for inserting characters in buttons of telephones, keyboards, calculators, and the like, which are used in illumination switches.

. A method in which characters to marks are molded with a transparent resin, and the surroundings are double molded with a light-shielding resin.

. A method in which a light-shielding part and a light-transmitting part having a character to a mark part are separately formed, and the light-transmitting part is fitted into the light-shielding part and integrated.

Although the method described above can produce a beautiful and good target molded product, the production of buttons to be inserted is performed on a three-dimensional surface by sputtering and plating, and it is difficult to produce good buttons. However, there is a drawback that defects are likely to occur. Further, the above method has an advantage that the light-shielding portion can be formed by flat printing or painting. However, since a step of bonding the light-shielding portion to each molded article is required, poor appearance is likely to occur. In addition, the method is extremely complicated because the mold is extremely complicated, and is expensive, and there is a restriction that the illuminating section cannot be provided. For example, the method requires a plurality of molds and molding, which is extremely expensive. Then, an assembling process was added, and the process was problematic in terms of cost.

[Means for solving the problem]

The present invention is superior in productivity as compared with the conventional method of manufacturing an illuminated switch, and as a result of examining a beautiful manufacturing method, a predetermined light-shielding portion having light-transmitting characters to marks was formed. The present inventors have found that there is a possibility that this problem can be solved by a method of using an aromatic polycarbonate sheet as an insert part, and have intensively studied and completed the present invention.

That is, the present invention forms a predetermined light-shielding portion having light-transmitting characters and marks on a light-transmitting aromatic polycarbonate sheet having a thickness of 0.1 to 2.0 mm, and cuts the sheet into a predetermined shape. After inserting the cut piece into the mold cavity, a method of manufacturing an illuminated switch component by injection molding a thermoplastic resin and integrating the cut piece and the injection resin, wherein the cut piece is preformed. The cut piece is a punched piece formed by preforming and punching, and the cut piece has a plurality of the light-shielding portions connected by one or more connecting portions. And a method for manufacturing an illuminable switch component comprising the illuminable switch component having a functional part.

 Hereinafter, the present invention will be described.

The aromatic polycarbonate sheet of the present invention having a thickness of 0.1 to 2.0 mm may be a normal polycarbonate, and is not particularly limited. Further, the sheet surface may be a smooth surface having gloss or a mat surface having matte unevenness having no gloss. In addition, since the sheet resin forms light-transmitting characters to marks, if light for that purpose is transmitted,
It may be colored to a desired color with an appropriate dye or pigment. Further, from the viewpoint of adhesiveness with the resin used for injection molding, it is preferable that the sheet surface on the side integrated with the thermoplastic resin for injection molding has an adhesive layer formed appropriately. Examples of the adhesive layer include polycarbonate (PC), a polycarbonate-polyester resin composition, a polycarbonate-ABS resin composition, a polycarbonate-polyamide composition, and other polycarbonate resin compositions (PC alloy). )), A polycarbonate sheet without an adhesive layer; the injection resin is an acrylic resin such as polymethyl methacrylate (PMMA), polystyrene (PS), methyl methacrylate-styrene copolymer (M
S), acrylonitrile-styrene copolymer (AS), acrylonitrile-butadiene-styrene copolymer (AB
In the case of S) and the like, a polycarbonate sheet having an acrylic resin layer formed thereon; polyvinyl chloride, and for other general-purpose applications not requiring heat resistance, a polycarbonate sheet having an EVA resin layer formed thereon are exemplified.

The above polycarbonate sheet has light-transmitting characters
A light-shielding portion having a mark portion substantially at the center of the light-shielding portion is formed. This method is conventionally known silk screen printing,
There is no particular limitation on the hot stamping method, the coating method, the sputtering method, the plating method, and the like. Characters ~ marks are also various characters,
There is no particular limitation on marks, designs, and the like. Also,
Characters to marks etc. are naturally white if they are light-transmitting layers,
Milky white, clear coloring and those printed with other paints or inks are also preferably used.

Here, the binder component of the ink or paint used for forming the light-shielding portion is not particularly limited, and may be any known one for a conventional polycarbonate resin. For example, as a binder component, acrylic, acrylic alkyd, amino alkyd,
Examples include urethane-based, acrylic / urethane-based, epoxy-based, vinyl chloride / vinyl acetate copolymers, and nitrocellulose. In addition to carbon black as a light-shielding component, inorganic pigments such as titanium dioxide, red iron oxide, oxides such as cobalt blue, sulfides such as zinc sulfide, sulfates such as precipitated barium sulfate, hydrated silicates, ultramarine blue, etc. There are silicates, ferrocyanides such as navy blue, metal powders such as aluminum powder and zinc powder, and various hydroxides, chromates, carbonates, and phosphates.As organic pigments, brilliant carmine 6B, disazo yellow Azo pigments, such as phthalocyanine blue, phthalocyanine pigments, such as
Nitro pigments such as naphthol yellow S, condensed polycyclic pigments such as quinacridone red, and other various organic pigments and dyes are appropriately used. Printing inks and paints are prepared by mixing these binders, colorants, suitable solvents, additives, and the like, and applied to a polycarbonate sheet and dried to form light-transmitting characters or marks. When a metal-like appearance is required, a method such as sputtering, vacuum deposition, or plating is used by hot stamping or masking a character to a mark portion, and the under and top are coated if necessary.

The polycarbonate sheet on which the light-shielding portion having the light-transmitting characters to marks is formed as described above is cut into a cut piece by punching or other means as it is, or is preformed, and is used as a cut piece for a mold insert. Cut into pieces.

The method of preforming is selected mainly depending on the desired product shape and required appearance, and examples include simple bending, cold or hot compression molding, and vacuum molding. In particular, those that require deep drawing shapes include Drape forming and Plug as
It is convenient and preferable to adopt a method of using a vacuum forming method such as sist forming to reduce the change in the shape of the light transmitting character to the mark portion. After preforming, usually the desired punching process,
It is preferable to devise a preforming die and perform punching together with preforming.

After inserting the cut piece produced above into a mold, a transparent to light transmitting or opaque to light shielding thermoplastic resin is injected to obtain an illuminated switch of the present invention. The type of thermoplastic resin used for injection molding is appropriately selected depending on the required performance of the illuminated switch, its shape, and the like, and the injection molding conditions and the like are within the known condition range of the thermoplastic resin molding material to be used. Things. Specific thermoplastic resin molding materials include polycarbonate (PC), polycarbonate-polyester resin compositions (PC / PBT, PC / PET, PC / P
PC / PES composition such as CTA, PC / PCTG), polycarbonate-ABS resin composition (PC / ABS), polycarbonate-polyphenylene ether-polyester resin composition (PC
/ PPE / PES), polycarbonate-polyamide resin composition (PC / PA), polycarbonate-polyester-polyamide resin composition (PC / PES / PA), other polycarbonate resin compositions (PC alloy); polymethyl methacrylate Acrylic resin such as (PMMA); polystyrene (P
S), methyl methacrylate-styrene copolymer (M
S), acrylonitrile-styrene copolymer (AS), acrylonitrile-butadiene-styrene copolymer (AB
S) and other styrene resins; polyphenylene ether-
Polystyrene resin composition (PPE / PS), polyphenylene ether-polyamide resin composition (PPE / PA), polyphenylene ether-polyester resin composition (PPE / PE)
S) and other polyphenylene ether-based resin compositions (P
PE alloy); polyacetal resin and its composition; nylon-6 (PA6), nylon-66 (PA66), nylon-
6,10 (PA610), nylon-12 (PA12), nylon-MXD
Polyamide resin (PA) such as 6; polyethylene terephthalate (PET), polybutylene terephthalate (PBT),
1,4-hexanedimethanol / terephthalic acid / isophthalic acid copolymer (PCTA), 1,4-hexanedimethanol
Examples thereof include polyester resins such as ethylene glycol / terephthalic acid copolymer (PCTG); polyvinyl chloride (PVC); and the like. Particularly, engineering plastics and alloys thereof are suitable.

Next, an example of the present invention will be described with reference to the drawings.

FIG. 1 is a perspective view of a marked lighting switch according to the present invention, FIG. 2 is a cross-sectional view of the marked lighting switch of FIG. 1, and FIG. 3 is a metal for manufacturing the marked lighting switch of FIG. It shows a state in which a polycarbonate sheet with a mark punched into a mold is mounted. The fourth
FIGS. A to h are examples of the arrangement of the marked polycarbonate sheet integrated with the injection molding resin in the illuminating switch.

In FIG. 2, the marked illuminated switch shown in FIG. 1 is formed by deep drawing vacuum forming of a marked polycarbonate sheet and punching a punched piece [1] and a carbon black-containing polycarbonate resin [2]. It is bonded and integrated except for the part [3]. Another functional part [4] is simultaneously formed on the lower left side of the light transmitting part by the polycarbonate resin. FIG. 3 shows a state in which a punching piece 1 is attached to a predetermined portion of a mold cavity in order to form the illumination switch. In the case of this example, no injection resin is introduced into the mark portion (light transmission portion 3), and since the injection resin is a light-shielding composition, the light-shielding portion forming surface side of the sheet is set as the injection resin side. However, even on the opposite side, a good product can be manufactured without any particular problem.

Next, FIG. 4 shows an example of a method of inserting a cut piece into a mold cavity (or an arrangement position as an illumination switch). It is.

b: Usually manufactured by mounting a preformed cut piece on a portion corresponding to the inner surface of the illumination switch.

c: It is manufactured by attaching a cut piece to a portion corresponding to the outer surface of the illumination switch.

d: It is manufactured by mounting a cut piece so as to cover the entire surface of the illumination switch and shaping the cut piece at the same time as injection.

e: It is manufactured by mounting a cut piece at the intermediate position of the illumination switch.

f: It is manufactured by simply attaching a cut piece to a portion corresponding to the inner surface of the illumination switch.

g: Usually manufactured by mounting a preformed cut piece on a portion corresponding to the outer surface of the illumination switch.

h: Usually manufactured by mounting a preformed cut piece on a portion corresponding to the inner surface of the illumination switch.

For a to f, it is preferable to use a light-shielding resin composition for the resin for injection molding, and in the case of g and h, it is essential to use a light-transmitting resin composition. Also, g,
In the case of h, since the injection resin is also introduced into the characters to the mark portions, it is easy to form a design pattern such as a lens pattern or a mat pattern on the surface of the mold and transfer it to a molded product. In the case of g, it is also possible to extend the light-transmitting resin portion to the side surface of the molded product, illuminate the portion, and perform indirect illumination using the light-transmitting composition portion as a passage of illumination light. In addition, a plurality of switches and buttons can be illuminated by one light source, and it is also extremely easy to form a functional section or the like below the character to mark section. In the case of h, since the characters to the mark portions are covered with a light-transmitting resin, a sense of depth can be obtained, and a lens effect can be provided by changing the thickness of the light-transmitting resin. It is possible.

As mentioned above, although the example of the manufacturing method of the illuminated switch of the present invention has been described with reference to the drawings, the present invention is not limited to the drawings. Various other embodiments can be implemented as long as the cut pieces of the formed polycarbonate sheet are used.

For example, using the deep-drawing cut piece of the present invention, and using a light-shielding resin for injection molding, an example of a process for manufacturing four illuminated switches is shown below. A predetermined light-shielding portion is formed on a polycarbonate sheet at a predetermined position in a square shape by multilayer printing or the like.

: Pre-forming by using a vacuum forming method such as Plug assiset forming while suppressing the mark portion with a plug. (Each mark position deviation is prevented and the deformation of the mark is minimized).

: A punched piece is produced in which each punched piece is connected in such a manner as to be connected at about two thin connecting portions.

: A punched piece is attached to a predetermined portion of the mold cavity, and a light-shielding resin composition is injection-molded.

: Cut the gate and the connecting part to obtain individual illuminated switches.

It is. Further, as another example, when forming light-transmitting characters to marks on a polycarbonate sheet,
By providing different characters to marks, an illuminated switch having desired characters to marks in the same shape is manufactured, and manufacturing according to the production plan and significant cost reduction are performed; To manufacture an illuminated switch having substantially the same arrangement as that of the assembled shape by using the same, and to streamline the assembling process; in the case of multi-cavity, insert a cut piece having a connecting portion into the mold, and at the same time when the mold is closed, Molding is performed using a mold provided with a cutting blade so as to be able to cut the connection portion of the cut piece, and the mold is opened to produce a molded product in which the connection portion is cut off.

In the method of manufacturing an illuminated switch of the present invention as described above, since the illuminated portion is extremely easy to form, a functional portion other than a functional portion as a switch-for example, a spring portion, a cam portion, a lever portion, This has the advantage that it is easy to simultaneously add parts such as snap fits, press fits, metal inserts, and other molding parts such as molding parts by using an injection resin.

〔Example〕

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

Example 1 A polycarbonate sheet having a thickness of 0.5 mm and a central portion of 7 mm
A 40 × 50 mm light-shielding portion having a × 10 mm light-transmitting mark portion was formed by multilayer printing.

This sheet was formed by vacuum forming and punched to produce a punched piece having an outer diameter of 15 mm × 25 mm, a depth of 5 mm and a 2 mm collar on the outer periphery of the upper surface. Substantially no misalignment of the light transmitting portion of the punched piece was observed, no deformation of the mark was observed, and no wrinkles were found at the corners.

External dimensions 15mm x 25mm, depth 7mm, wall thickness 2mm
A mold similar to the shape in FIG. 3 having a 2 mm square edge was used.

The punched piece obtained above is mounted on the fixed side of the mold so that the light-shielding portion is the outer surface of the molded product, the light-shielding polycarbonate resin containing carbon black is injection molded, and the punched piece is provided on the outer surface, A predetermined illumination switch component integrated with the light-shielding polycarbonate was obtained.

Example 2 Using a polycarbonate sheet on which a single-sided acrylic resin layer having a thickness of 1.0 mm was formed, four light-shielding portions having a light transmitting portion were formed on the polycarbonate surface. The light-shielding portion is arranged in a square shape with a center distance of 70 mm, and the size is 30
It has a light transmissive part of about 6 mm x 6 mm at the center with a size of mm x 30 mm.

Use a vacuum forming mold with four holes of 20 mm x 20 mm and a depth of 4 mm arranged in a square shape with a center-to-center distance of 70 mm, and print this sheet on the surface by Plug assist forming method. Was vacuum molded.

Next, the preformed sheet is formed of four light-shielding portions of 30 mm × 30 mm and a connecting portion having a width of 3 mm and a length of 50 mm between the center of the side of the light-shielding portion and the center of the side of the adjacent light-shielding portion. A punched piece was manufactured except for the part.

20mm with a depth of 4mm with this punched piece as center distance 70mm
A set of four m × 20 mm holes was set in the insert part of a mold in which four squares were arranged.
In a form where one part is overlapped with a part of the molten resin flow path (runner) part, ABS resin colored black is injected from the inner surface of the sheet by the tunnel gate, and a molded product with four predetermined illumination switches connected Obtained. Note that a groove having a width of 3 mm and a depth of 1.1 mm corresponding to the sheet connecting portion is formed on the movable side of the mold.

After cutting the connecting portion and the gate portion of the molded product to obtain individual illuminated switch components, the adhesion between the ABS resin and the polycarbonate sheet was examined. As a result, it was found that the molded product was very strongly integrated.

Example 3 A punched piece of a light-shielded printed polycarbonate sheet having an outer diameter of 20 mm x 20 mm and a thickness of 1.5 mm and having a light transmitting portion in the center was manufactured.

A box-shaped molded product with a length, width and height of 20 mm × 20 mm × 10 mm and an average thickness of injection resin of 3 mm, and a trapezoidal part with a height of 1 mm and a width of 3 mm on the outer periphery of the bottom part. Protruding from the inside, the central part on the bottom of the bottom part is 6 mm × 6 mm part is recessed 3 mm from the outer part, the thickness of the inner and outer concave parts is 1.5 mm, and a punching piece is attached to this concave part and injection A mold having an upside down shape in FIG. 4d attached so as to be integrated with the resin was used.

After inserting the punched piece manufactured above with the light-shielding printing surface as the outer bottom surface side of the mold, in the inner and outer recesses,
The black polycarbonate-ABS resin composition was injection-molded to form an outer peripheral portion of the punched piece and obtain an illuminated molded product integrated with the injection resin.

Example 4 Example 3 was the same as Example 3, except that a light-shielding portion having a light-transmitting portion at the center was formed by hot stamping of aluminum foil as a punched piece.

As a result, an illuminated molded product having a glittering surface on the surface was obtained.

Example 5 A polycarbonate sheet having a thickness of 0.5 mm and a central portion having a thickness of 7 mm
A 40 × 50 mm light-shielding portion having a × 10 mm light-transmitting mark portion was formed by multilayer printing.

This sheet was formed by vacuum forming and punched to produce a punched piece having an outer shape of 12 mm × 22 mm and a depth of 3 mm.

The mold used was a box-shaped molded product having an outer diameter of 15 mm × 25 mm, a depth of 5 mm, a 2 mm square edge on the outer periphery of the upper surface, and a wall thickness of 2 mm.

The punched piece was mounted on the core (inner surface) of the mold so that the printed surface was the inner surface of the molded product, and a transparent polycarbonate resin was injection-molded to obtain a predetermined illumination switch component.

This part had a transparent resin on the surface and had a sense of depth.

[Functions and Effects of the Invention]

As is apparent from the detailed description of the invention and the embodiments, the method for manufacturing the illuminated switch component of the present invention uses a desired light-transmitting character, mark, pattern, etc. formed by flat printing or the like. Therefore, molded products such as three-dimensional buttons are manufactured, and the desired light-transmitting characters,
The production is extremely easy as compared with the method of forming marks, designs and the like. For this reason, it has a characteristic that it is easy to provide other functions as a switch component.

In addition, since a polycarbonate sheet is used,
Good shaping excellent in productivity can be easily performed by vacuum forming or the like.

Furthermore, since it is an illuminated switch component with an integrated polycarbonate sheet having excellent impact resistance, it has poor impact resistance, such as polystyrene, polymethyl methacrylate, and other resins. It will also be better in mechanical properties,
It is of great industrial significance that combines beauty, performance, and productivity.

[Brief description of the drawings]

FIG. 1 is a perspective view of an illuminated switch with a mark according to the present invention, FIG. 2 is a cross-sectional view thereof, and FIG. 3 is a schematic view showing a state in which a polycarbonate sheet with a mark is mounted on a mold. is there. FIGS. 4a to 4h show examples of the arrangement of the marked polycarbonate sheet integrated with the injection molding resin in the illumination switch. The numbers in the figure are respectively 1: stamped piece, 2: injection resin, 3: light transmitting part, 4: functional part,
5: Fixed mold, 6: Movable mold, 7: Mold cavity, 8:
3 shows a product ejection pin.

Claims (5)

(57) [Claims] 1. A light-shielding portion having a light-transmitting character or mark is formed on a light-transmitting aromatic polycarbonate sheet having a thickness of 0.1 to 2.0 mm, and the sheet is cut into a predetermined shape. A method for producing an illuminated switch component comprising: inserting a cut piece into a mold cavity; and injection molding a thermoplastic resin to integrate the cut piece with the injection resin. 2. The method according to claim 1, wherein the cut pieces are preformed. 3. The method according to claim 1, wherein the cut pieces are preformed and punched pieces. 4. The method for manufacturing an illuminable switch component according to claim 1, wherein said cut piece has a plurality of said light shielding portions connected by one or more connecting portions. 5. The method for manufacturing an illuminable switch component according to claim 1, wherein said illuminable switch component has a functional portion.