JP4359374B2 - Method for producing molded product with film, mold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention includes console panels, armrests, coin trays, door rims, center pillars, instrument panels, dashboards, switch bases, operation buttons, instrument panel ornaments, various interior bezels, exterior parts for automobiles, front panels and operations for AV equipment. The present invention relates to a method of manufacturing a molded article with a film such as a button or a panel of a home appliance such as a washing machine, a rice cooker, a water purifier, or an operation button.
[0002]
[Prior art]
Conventionally, as a product obtained by adhering a film 5 having a pattern layer or the like formed on a molded product 6 having a concavo-convex portion 4 on the molded product back 2 of the molded product divided at the boundary between the molded product surface 1 and the molded product back 2, There is a product in which the film 5 is adhered not only on the surface 1 of the molded product but also on the back surface 2 of the molded product (see FIG. 1).
The reason why the film 5 must be adhered also to the molded product back surface 2 is that the molded product back surface 2 may also be observed in appearance, and when the molded product is fitted to another member, This is because the molded product back surface 2 may be visible from the gap.
Conventionally, as a method of manufacturing a product in which the film 5 is adhered not only to the molded product front surface 1 but also to the molded product back surface 2, a method of integrally bonding the film 5 to the molded product 6 simultaneously with injection molding, and a molded product using an adhesive. 6 was combined with an adhesive method for adhering to 6.
That is, a film 5 having a size capable of covering the molded product surface 1 and the molded product back surface 2 of the molded product 6 with one sheet is prepared, and the film 5 is divided into, for example, a part 7 of the film and a remaining part 8 of the film. To do. A part 7 of the film is integrally bonded to the surface 1 of the molded product at the same time as molding. Since the remaining part 8 of the film remains flat, it is turned around to the rear surface 2 of the molded product 6 and pushed into the concave portion of the rear surface 2 of the molded product, or pressed against the corner of the convex portion by a human finger 6. Since the film 5 is folded or bent (hereinafter referred to as “finger work”) along the uneven portion 4 on the back surface 2 of the product, it is attached to the uneven portion 4 on the back surface 2 of the molded product with an adhesive. (See FIGS. 3 to 4).
[0003]
[Problems to be solved by the invention]
However, since the film 5 has shape-retaining properties, the remaining portion of the film 5 is deformed from a flat state to a shape that completely matches the concavo-convex portion 4 of the molded product back surface 2 by finger operation with a weak force, and the shape is maintained. It was extremely difficult to do so (see FIGS. 3 and 4).
(1) If the film 5 is forcibly deformed by finger work, the nail or finger may be damaged when the film 5 is pushed into the concave portion or pressed against the corner of the convex portion. In some cases, damage was caused.
(2) In finger work, it is impossible to keep the finger force uniform all the time, so a straight curve or a curved curve with a constant curvature can be applied, or the finger can be folded with a uniform force over the entire line. It was impossible to add a curve, and it was impossible to completely transform into a complicated three-dimensional shape such as a fine uneven portion.
(3) If the deformation of the film 5 is insufficient or the bending is not complete, the adhesive strength of the adhesive is maintained by the shape retention of the film 5 after being adhered to the concavo-convex portion 4 of the back surface 2 of the molded product with an adhesive. Since the film 5 is warped against this, the film 5 is peeled off completely at the concavo-convex portion 4 on the back surface 2 of the molded product, or is adhered in a state of being lifted off by being half peeled. .
Acrylic film, polycarbonate film, ABS film, or their laminated film has particularly strong shape retention and high hardness, so it is impossible to attach them in perfect conformity with the concavo-convex part 4 of the molded product back 2 after integral molding. It was close to.
[0004]
[Means for Solving the Problems]
In order to solve the above problems, the manufacturing method of the molded article with film and the mold of the present invention have the following configuration.
[0005]
The method for producing a molded article with a film according to the present invention comprises using a film that can cover the concave and convex portions of the molded article surface and the molded article back surface with a single sheet, and an injection mold, and a part of the film and the molded article surface. In the method for producing a molded article with a film, wherein the rest of the film is adhered to the concavo-convex part of the molded article back surface of the molded article taken out from the injection molding die with an adhesive. Before adhering to the concavo-convex portion on the back of the molded product with an adhesive, the rest of the film was formed with a mold into a three-dimensional shape that matched the concavo-convex portion on the back of the molded product.
[0006]
In the method for producing a molded article with a film according to the present invention, after the film is set in an injection mold, the remaining part of the film is molded into a three-dimensional shape that matches the irregularities on the back of the molded article with the injection mold. It may be configured.
[0007]
The method for producing a molded article with a film according to the present invention is a three-dimensional shape in which the rest of the film is matched with the concavo-convex portion on the back surface of the molded article in a mold different from the injection mold before the film is set in the injection mold. You may comprise so that it may shape | mold.
[0008]
The method for producing a molded article with a film according to the present invention may be configured such that the parting surface sandwiching the remaining part of the film of the injection mold has a portion having a shape that matches the uneven portion on the back surface of the molded article. Good.
[0009]
The mold of the present invention is a mold having a surface for setting a film that can cover the uneven surface of the molded product surface and the molded product back surface with a single sheet, and a part of the film is integrally bonded to the molded product surface. And a surface that can maintain a three-dimensional shape that matches the concavo-convex portion on the back surface of the molded product without being integrally bonded to the back surface of the molded product.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereafter, the manufacturing method of the molded article with a film of this invention is demonstrated, referring drawings.
[0011]
First, a film 5 that is applicable to the manufacturing method of the present invention, an injection mold, and a mold other than the injection mold will be described.
[0012]
The injection mold has a mold A having a cavity forming recess 10 corresponding to the molded product surface 1 of the molded product 6 and a mold uneven portion 13 corresponding to the molded product back surface 2 of the molded product 6 and is melted. There exists what consists of the metal mold | die B which has the resin injection port 14 (refer FIGS. 5-9).
In the injection mold, after the film 5 is introduced between the mold A and the mold B, the molten resin 16 is injected into the cavity 15 after the mold closing is completed, and the heat and pressure of the molten resin 16 and the cooling after the injection are injected. Thus, the film 5 and the molded product 6 are integrated. When the injection mold consists of a fixed mold and a movable mold, a combination in which the mold A is a fixed mold and the mold B is a movable mold, or the mold B is a fixed mold, A combination in which the mold A is a movable mold may be used. In addition to the mold A and the mold B, the injection mold is an intermediate mold that forms part of the surface that forms the inner surface of the cavity 15 by being sandwiched between the mold A and the mold B. A mold may be used. The mold B may be provided with an ejector pin (not shown) for taking out the molded article 6 with film by protrusion. The mold A may be provided with a vacuum suction hole 17 for sucking and fixing the film 5 so as not to be displaced on the surface of the mold A.
[0013]
An injection mold is a mold that has a surface for setting a film that can cover the uneven surface of the molded product surface and the molded product back with a single sheet, and a part of the film is integrated and bonded to the molded product surface. It is preferable to have a surface that can be set as described above, and a surface that can maintain a three-dimensional shape that matches the concavo-convex portion on the back of the molded product without the remaining part of the film being integrally bonded to the back of the molded product.
For example, an injection mold is such that the parting surface that sandwiches the rest of the film of the injection mold has a shape that matches the irregularities on the back of the molded product, and sandwiches the rest of the film of the injection mold. Some have a parting surface 19 for forming an uneven part, which is a part having a shape that allows the parting surface to be formed into a shape that matches the uneven part 4 on the back surface 2 of the molded product. This is effective when the film 5 is set in an injection mold and then the remaining portion 8 of the film is molded into a three-dimensional shape that matches the concavo-convex portion 4 on the back surface 2 of the molded product in the mold of the injection mold.
The surface of the uneven part forming parting surface 19 may be a heat radiating surface. This is effective when it is necessary to heat the remaining part 8 of the film to the softening temperature of the film 5. As a heat radiating surface, there is one in which a hot air blowing means part or a heat ray irradiating means part is embedded. The hot air blowing means sends out heat generated from the heat radiation source by the wind. Examples of the heat radiation source include a cast-in heater, a far-infrared heater, and a heating wire heater. As a heat ray source used as the heat ray irradiation means, there is a halogen lamp or the like. The halogen lamp is effective because the speed of raising the temperature of the film 5 is high and only a predetermined portion of the film 5 can be heated.
A vacuum suction hole 17 may be formed on the surface of the uneven part forming parting surface 19. This is effective for easily aligning the film 5 that has reached the softening temperature by heating with the parting surface 19 for forming the uneven portion. Note that the vacuum suction on the uneven part forming parting surface 19 may be performed by suction from the vacuum suction hole 17 formed in the cavity forming recess 10.
Moreover, you may have a clamp means so that the circumference | surroundings of the parting surface 19 for uneven | corrugated | grooved part shaping | molding of the metal mold | die A may be surrounded (not shown).
[0014]
Before the film 5 is set in the injection mold, the remaining part 8 of the film is molded into a three-dimensional shape that matches the concavo-convex part 4 on the back surface 2 of the molded product with another mold. When the mold B is closed, the retraction part 20 is a space of a size such that the three-dimensional shape of the remaining part 8 of the film is not crushed by the mold closing of the mold A and the mold B. It is necessary to form it on the surface. The retreat unit 20 includes a space having the same shape as the three-dimensional shape of the remaining portion 8 of the film (see FIG. 6), a wide space that does not collapse even when the three-dimensional shape of the remaining portion 8 of the film is closed.
[0015]
The film 5 is a film in which a picture layer, an adhesive layer and the like are sequentially laminated on a base sheet, and there is a so-called insert film in which the base sheet is not peeled after the molten resin 16 is bonded to the film 5. The film 5 is obtained by sequentially laminating a release layer, a pattern layer, an adhesive layer, and the like on a base sheet, and there is also a so-called transfer film in which the base sheet is peeled after the molten resin 16 adheres to the film 5. . Examples of the material for the base sheet include polyethylene terephthalate, polypropylene, and acrylic. The pattern layer is a layer that imparts decorativeness and functionality to the surface of the molded product. The pattern layer includes a normal printed pattern, a conductive pattern formed of a conductive material, and the like. The pattern layer can be formed of a resin binder and a pigment or dye. The pattern layer may use a resin binder and a concealing metal pigment or inorganic pigment. The pattern layer may be a metal vapor deposition layer in order to give a metallic luster. The adhesive layer is a layer for adhering the film 5 and the molded product. For the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molten resin is appropriately used. For example, when the molten resin 16 is an acrylic resin or a urethane resin, a vinyl chloride vinyl acetate copolymer resin or an acrylic resin may be used as the adhesive layer. The pattern layer and the adhesive layer are formed by various printing methods. A resin film 5 may be used for the adhesive layer.
[0016]
A method for producing a molded article with a film according to the present invention using the injection mold and film described above will be described with reference to the drawings.
[0017]
(1) After film 5 is set in an injection mold, the remaining part 8 of the film is molded into a three-dimensional shape that matches the concavo-convex part 4 of the molded product back surface 2 in the mold of the injection mold. A method for producing a molded product will be described (FIGS. 5 and 7 to 12).
As an injection mold, a mold having an uneven portion forming parting surface 19 having a shape that can be formed into a shape that matches the uneven portion 4 of the back surface 2 of the molded product is prepared.
[0018]
First, the film 5 is introduced into an injection mold (see FIGS. 5 and 7).
A part 7 of the film is made to correspond to the cavity forming recess 10 of the mold A, and the remaining part 8 of the film is made to correspond to the parting surface 19 for forming the uneven part of the mold. The part 7 of the film may be molded into a three-dimensional shape that matches the inner surface shape of the cavity forming recess 10 of the mold A with another mold before being set in the injection mold. When a part 7 of the film is not formed into a three-dimensional shape that matches the shape of the inner surface of the cavity forming recess 10 of the mold A by another mold, the cavity forming recess is formed in the mold A by heating, vacuum suction, or the like. It is good to shape | mold so that it may adhere to the inner surface of 10. FIG.
The timing of forming the remaining portion 8 of the film into a three-dimensional shape that matches the concavo-convex portion 4 on the back surface 2 of the molded product may be performed before the mold closing or simultaneously with the mold closing.
In the former case, vacuum suction may be performed on the uneven part forming parting surface 19 of the injection mold while heating the remaining part 8 of the film near the softening point of the film 5 (see FIG. 7).
In the latter case, the mold B may be pressed after heating the remaining portion 8 of the film near the softening point of the film 5 (not shown).
[0019]
Next, the mold A and the mold B are closed, the molten resin 16 is injected from the molten resin injection port 14 of the mold B, and the part 7 of the film and the surface 1 of the molded product are bonded to the molded product. At the same time as molding, it is integrally bonded (FIGS. 8 and 9).
Since the remaining part 8 of the film has already been formed into a shape that matches the concavo-convex part 4 on the back surface 2 of the molded product, the mold is closed so as not to crush the shape. As a material of the molten resin 16, polystyrene resin, ABS resin, polycarbonate resin, polypropylene resin, polyethylene resin, or the like can be used.
[0020]
Next, the remaining portion 8 of the film is adhered to the concavo-convex portion 4 of the molded product back surface 2 of the molded product (see FIGS. 2 and 10) taken out from the injection mold (FIGS. 10 to 12).
In the molded product 6 taken out from the mold, a part 7 of the film is integrally bonded to the molded product surface 1, but the remaining part 8 of the film is in a three-dimensional shape but is not bonded anywhere. In this state, the end portions 3 are connected to each other (see FIGS. 2 and 10). Therefore, the film 5 is bent at the molded product end 3, and the remaining portion 8 of the film is turned around the molded product back surface 2 so as to follow the molded product back surface 2 (see FIG. 11). Since the remaining portion 8 of the film is already in a shape that matches the uneven portion 4 of the back surface 2 of the molded product, when the remaining portion 8 of the film is turned, the convex portion of the back surface 2 of the molded product matches the concave portion of the remaining portion 8 of the film. The projection of the remaining portion 8 of the film fits into the recess of the back surface 2 of the molded product (see FIGS. 1 and 12). Examples of the adhesive 18 applied to the remaining portion 8 of the film include those made of acrylic resin, epoxy resin, urethane resin, and silicone resin. The adhesive 18 may be applied to the remaining portion 8 of the film, or may be applied to the surface of the concavo-convex portion 4 on the back surface 2 of the molded product.
[0021]
(2) Molding with a film in the case where the remaining part 8 of the film 5 is molded into a three-dimensional shape that matches the concavo-convex part 4 of the molded product back surface 2 with another mold before the film 5 is set in the injection mold. A method for manufacturing the product will be described.
In this case, a mold different from the mold A and the mold B, that is, a mold for making the remaining portion 8 of the film into a three-dimensional shape that matches the concavo-convex portion 4 of the molded product back surface 2 is prepared. Another mold includes a mold C and a mold D, and the molded product back surface 2 of the molded product 6 obtained by the mold A and the mold B is obtained by sandwiching the remaining portion 8 of the film while heating. Some of them are molded into a three-dimensional shape that matches the uneven portion 4. In addition, as an injection mold, a retraction part 20 is formed on the parting surface so that when the mold A and the mold B are closed, the three-dimensional shape of the remaining portion 8 of the film is not crushed by the mold closing. prepare.
[0022]
First, the remaining part 8 of the film is made into a three-dimensional shape that matches the concavo-convex part 4 on the back surface 2 of the molded product with another mold. Note that not only the remaining portion 8 of the film but also the portion 7 of the film may be formed into a three-dimensional shape that matches the inner shape of the cavity forming recess 10 of the mold A with this mold.
[0023]
Next, the film 5 is introduced between the mold A and the mold B of the injection mold (see FIG. 1).
At this time, a part 7 of the film is made to correspond to the cavity forming recess 10 of the mold A, and the remaining part 8 of the film is made to correspond to the retracting part 20 formed on the parting surface of the mold. The part 7 of the film may be molded into a three-dimensional shape that matches the shape of the inner surface of the cavity forming recess 10 of the mold A with another mold before being set in the injection mold. In that case, the part 7 of the film need only be fitted into the recess of the mold A. When a part 7 of the film is not formed into a three-dimensional shape that matches the shape of the inner surface of the cavity forming recess 10 of the mold A by another mold, the cavity forming recess 10 is formed in the mold A by vacuum suction or the like. It is good to shape | mold so that it may adhere to an inner surface.
[0024]
Next, the mold A and the mold B are closed, the molten resin 16 is injected from the molten resin injection port 14 of the mold B, and the part 7 of the film and the surface 1 of the molded product are bonded to the molded product 6. At the same time as molding, it is integrally bonded. The remaining part 8 of the film is formed into a shape that matches the concavo-convex part 4 of the back surface 2 of the molded product.
Even when the mold A and the mold B are closed, the three-dimensional film remaining portion 8 exists in the retreat space of the parting surface, so that the three-dimensional shape is not crushed.
As a material of the molten resin 16, polystyrene resin, ABS resin, polycarbonate resin, polypropylene resin, polyethylene resin, or the like can be used.
[0025]
Next, the remaining part 8 of the film is adhered to the concavo-convex portion 4 of the molded product back surface 2 of the molded product 6 taken out from the injection mold with an adhesive 18 (FIGS. 10 to 12).
The molded product 6 taken out from the mold is connected to the molded product end 1 in a state where a part of the film 7 is integrally bonded to the molded product surface 1 but the remaining part 8 of the film is not adhered anywhere. It is in a state. Examples of the molded product end 3 include an acute corner (see FIG. 2) of the molded product 6 and a portion (see FIG. 10) when the film 5 is integrally bonded (see FIG. 10). Therefore, the film 5 is bent at the end portion 3 of the molded product, and the remaining portion 8 of the film is turned around the back surface 2 of the molded product so as to follow the back surface 2 of the molded product. Since the remaining portion 8 of the film is already in a shape that matches the uneven portion 4 of the back surface 2 of the molded product, when the remaining portion 8 of the film is turned, the convex portion of the back surface 2 of the molded product matches the concave portion of the remaining portion 8 of the film. The projection of the remaining portion 8 of the film fits into the recess of the back surface 2 of the molded product. Note that the adhesive 18 applied to the remaining portion 8 of the film includes an acrylic resin. The adhesive 18 may be applied to the remaining portion 8 of the film, or may be applied to the surface of the concavo-convex portion 4 on the back surface 2 of the molded product.
[0026]
【The invention's effect】
In this invention, the remaining part of the film is molded with an injection mold before being bonded to the back of the molded product, or has already been molded from a flat state into a three-dimensional shape with a mold different from the injection mold. Since the shape of the state can be kept constant, there is no need for finger work. In addition, the remaining part of the film can be molded into a solid shape that matches the irregularities on the back of the molded product with a strong force such as closing the mold and the pressure of the molten resin. Become. Further, since it is not a finger operation, it is possible to perform high-temperature heating that reaches the softening point of the film.
(1) For this reason, a nail | claw and a finger | toe are not damaged and an extra part of a film is not damaged.
(2) In addition, because the rest of the film is molded into a three-dimensional shape by closing the mold or pressure of the molten resin, it can be a straight line or a curved curve with a constant curvature, or even across the entire line. It can be folded or bent with a sufficient force, and can be completely transformed into a complicated three-dimensional shape such as a fine uneven part.
(3) In addition, since the film is formed into a three-dimensional shape by heating to reach a strong force or softening point, it is resistant to the adhesive force of the adhesive to maintain the shape of the film after it is adhered to the concavo-convex portion with an adhesive. The film does not warp. For this reason, a film will adhere | attach and adhere | attach completely on the uneven | corrugated | grooved part of a molded article back surface, and it is hard to generate | occur | produce a defective product.
Acrylic film, polycarbonate film, ABS film or their laminated film, such as those with strong shape retention and high hardness, can be adhered and adhered to the uneven part on the back of the molded product. It becomes.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a molded article with a film obtained by the method for producing a molded article with a film according to the present invention.
FIG. 2 is a cross-sectional view showing one step of a method for producing a molded article with a film according to the present invention.
FIG. 3 is a cross-sectional view showing one step of a conventional method for producing a molded article with a film.
FIG. 4 is a cross-sectional view showing one step of a conventional method for producing a molded article with a film.
FIG. 5 is a cross-sectional view showing a step of the method for producing a molded article with a film according to the present invention.
FIG. 6 is a cross-sectional view showing one step of the method for producing a molded article with a film according to the present invention.
FIG. 7 is a cross-sectional view showing one step of the method for producing a molded article with a film of the present invention.
FIG. 8 is a cross-sectional view showing one step in the method for producing a molded article with a film of the present invention.
FIG. 9 is a cross-sectional view showing one step in the method for producing a molded article with a film of the present invention.
FIG. 10 is a cross-sectional view showing a step of the method for producing a molded article with a film according to the present invention.
FIG. 11 is a cross-sectional view showing a step of the method for producing a molded article with a film of the present invention.
FIG. 12 is a cross-sectional view showing one step of a method for producing a molded article with a film of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Molded product surface 2 Molded product back surface 3 Molded product edge part 4 Uneven part 5 Film 6 Molded article 7 Part of film 8 Remaining part of film 9 Human finger 10 Cavity formation recessed part A Mold B Mold 13 Mold uneven part 14 Molten resin injection port 15 Cavity 16 Molten resin 17 Vacuum suction hole 18 Adhesive 19 Parting surface 20 for forming concave and convex portions Retracting portion

Claims (5)

Using a film that can cover the uneven surface of the molded product surface and the molded product back with a single sheet and an injection mold, a part of the film and the molded product surface are bonded together at the same time as the molded product is molded. After that, in the method of manufacturing a molded product with a film in which the remaining part of the film is adhered to the concavo-convex part on the back surface of the molded product taken out from the injection mold with an adhesive, the parting that sandwiches the remaining part of the film of the injection mold The surface has a part that matches the uneven part on the back of the molded product, and before bonding the adhesive to the uneven part on the back of the molded article with an adhesive, the rest of the film has a three-dimensional shape that matches the uneven part on the back of the molded product A method for producing a molded article with a film, characterized by molding with a mold.   The method for producing a molded article with a film according to claim 1, wherein after the film is set in an injection mold, the remaining part of the film is molded into a three-dimensional shape that matches the irregularities on the back surface of the molded article.   2. The molded article with a film according to claim 1, wherein the remaining part of the film is molded into a three-dimensional shape that matches the concavo-convex part on the back of the molded article with a mold different from the injection molding mold before the film is set in the injection molding mold. Manufacturing method. A mold having a surface for setting a film capable of covering the surface of the molded product and the concavo-convex portion on the back of the molded product with a single sheet, and a surface that can be set so that a part of the film is integrally bonded to the surface of the molded product; A mold having a surface capable of maintaining a three-dimensional shape that matches the concavo-convex portion on the back of the molded product without the remaining part of the film being integrally bonded to the back of the molded product. The surface capable of maintaining the three-dimensional shape is a heat dissipating surface that heats the remainder of the film, and the surface of the film that has been heated by the heat dissipating surface to reach the softening temperature is capable of maintaining the three-dimensional shape. The mold according to claim 4, wherein a vacuum suction hole to be along is formed in the heat radiation surface.

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