JP5482498B2 - Panel forming method - Google Patents

Description

  The present invention relates to a method of forming a panel in which a frame-like portion is integrally provided on the peripheral edge of one surface of a panel body, and particularly suitable for use as a transparent panel-like member for a roof or window of a vehicle such as an automobile. It relates to a molding method.

  Japanese Patent Application Laid-Open No. 2008-51184 discloses a method of molding a resin resin window plate made of a two-color molded product in which a transparent resin panel is bordered with an opaque resin at the periphery.

  In Japanese Patent Application Laid-Open No. 2008-51184, a panel-shaped first molded body (panel main body) is injection-molded using a fixed mold and a first movable mold, and then the first movable mold is opened and the first movable mold is opened. The second movable mold is replaced with a fixed mold, and the frame-shaped second molded body (frame-shaped portion) is injection-molded.

JP2008-511184A

  As described above, after the panel body is injection-molded with the fixed mold and the first movable mold, when the first movable mold is opened, the entire panel body remains attached to the cavity surface of the fixed mold. If it exists, the shrinkage | contraction of the panel main body during replacement | exchange of the 1st movable mold | type with the 2nd movable mold | type will be restrained by a fixed mold | type, and a big residual stress will arise in a panel main body. Further, the product panel may be warped or distorted in appearance due to the residual stress.

  An object of the present invention is to provide a method of injection-molding a panel in which a panel main body and a frame-shaped portion are integrated so as to prevent warping (including suppression).

  The panel molding method according to claim 1 is a panel body made of a synthetic resin material curved so that one surface side is convex, and a synthetic resin integrally provided with the panel body on the periphery of the other surface of the panel body. A panel body molding method for injection molding of a panel having a frame portion made of material, wherein the panel body is injection molded using a fixed mold and a first movable mold closed by the fixed mold. And a step of opening the first movable mold, closing the second movable mold having a frame-shaped part forming cavity with respect to the fixed mold, and injection-molding the frame-shaped part. In the panel molding method, the peripheral portion of the one surface of the panel body is separated from the cavity surface of the fixed mold when the first movable mold is opened. is there.

  The panel forming method according to claim 2 is the method according to claim 1, wherein when the first movable mold is opened, the peripheral portion extends from the cavity surface of the fixed mold over an area of 15% or more of one surface of the panel body. It is characterized by separating.

  The panel forming method according to claim 3 is the panel forming method according to claim 1 or 2, wherein the panel main body contracts in the cavity when the first movable mold is open, and the end surface of the panel main body is the fixed mold. It separates from the side surface of the cavity surface.

  The panel forming method according to claim 4 is the panel main body according to any one of claims 1 to 3, wherein when the second movable mold is closed, the peripheral portion of the panel main body is pushed by the second movable mold. Is pressed against the cavity surface of the fixed mold.

  In the panel molding method of the present invention, after the panel main body is injection-molded with the fixed mold and the first movable mold, the first movable mold is opened. In the present invention, when the first movable mold is in the opened state, the peripheral edge of the molded panel body is separated from the cavity surface of the fixed mold. For this reason, while the mold is opened, the panel main body contracts without being restrained so much from the fixed mold, and the residual stress of the panel main body becomes small. At this time, the peripheral stress of the panel body is separated from the fixed cavity surface over an area of 15% or more of the surface of the panel body, so that the residual stress of the panel body becomes extremely small. Thereafter, the second movable mold is closed with respect to the fixed mold holding the panel body, and the frame-shaped portion is injection-molded so as to be integrally connected to the other surface side of the panel body.

  In addition, when the panel main body contracts when the first movable mold is opened as described above, the end surface of the panel main body is preferably separated from the side surface of the cavity surface of the fixed mold. When the second movable mold is closed and the frame-shaped part is injection-molded with respect to the panel body in which the end surface is separated from the side surface of the cavity surface in this way, the second movable mold is molded after the frame-shaped part is molded. When the panel is opened and removed from the cavity, the end face of the panel is not constrained from the side surface of the fixed mold cavity surface, so that the panel can be removed smoothly.

  In the present invention, when the second movable mold is closed, the peripheral edge of the panel body may be pushed by the second movable mold and brought into contact with the fixed cavity surface. By doing in this way, the curvature of a panel main body can be corrected.

It is sectional drawing of the panel which concerns on embodiment. It is a front view of the panel which concerns on embodiment. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention. It is sectional drawing explaining the method of this invention.

  Hereinafter, embodiments will be described with reference to the drawings. FIG. 1 is a sectional view in the thickness direction of a panel formed by the forming method according to the embodiment, and FIGS. 3 to 13 are sectional views of a mold showing the forming method of this panel.

  The panel 20 is a resin window glass of a vehicle, and includes a plate-shaped panel main body 21 and a frame-shaped portion 22 provided so as to go around the entire peripheral edge of the rear surface of the panel main body 21. The panel 20 is curved so as to be convex toward the front side. The curvature radius of this curve is preferably 1000 to 50000 mm, particularly about 5000 to 20000 mm. Also, a three-dimensional R shape having different radii of curvature on the long side and the short side may be used. In this case, it is preferable that the radius of curvature on the long side is larger than that on the short side. As the value thereof, the radius of curvature on the long side is 5000 to 20000 mm, particularly about 10,000 to 20000 mm, and the radius of curvature on the short side is 1000. It is preferably about 10000 mm, particularly about 5000 to 10000 mm.

  The panel body 21 is transparent with a thickness of about 2 to 10 mm, and the frame-like portion is opaque with a thickness of about 0.5 to 5 mm.

  The frame-shaped portion 22 has a trapezoidal cross-sectional shape, and a side surface facing the center side of the panel plate, that is, the center of the plate surface of the panel body 21 is an inclined surface. The shape of the slope is arbitrary according to other product specifications, design, and appearance as long as the thickness gradually decreases toward the center of the plate, such as a straight line, a staircase, or an R shape. Can take the shape of However, the side surface of the frame-shaped portion on the center side of the panel plate may be substantially perpendicular to the plate surface of the panel body 21 as in the embodiments of FIGS.

The frame-like part 22 is separated from the outer edge part of the panel body 21 by a predetermined distance. This predetermined distance is preferably 0.1 to 10 mm, in particular 0.5 to 7 mm, in particular 1 to 5 mm. If this distance is too long, when a load is applied to the panel main body 21 at the outer edge of the frame-shaped part 22, there is a tendency that problems such as breakage of the panel main body 21 and occurrence of cracks tend to occur. Further, it is necessary to be careful when assembling the panel 20 to the vehicle main body or the like, and the productivity of the vehicle or the like may be reduced.
If this distance is too short, the second movable mold 12 will not sufficiently abut the cavity surface 3a of the panel body 21 in the injection molding of the panel 20, which will be described later. In some cases, the material flows into the outer edge of the panel main body 21 to cause defective products.

  Next, the panel forming method will be described in detail with reference to FIGS.

  First, as shown in FIGS. 3 and 4, a transparent resin material is injected into the cavity 3 formed between the fixed mold 2 of the mold 1 and the first movable mold 11, and the panel body 21 is molded. . Next, the first movable mold 11 is opened. In the method of the present invention, the panel body 21 is curved so that the front side thereof is convex, and the rear side is contracted more than the front side by opening the movable mold 11 and cooling the rear side. Then, the panel body 21 comes to warp, and the peripheral edge of the panel body 21 is separated from the cavity surface 3a of the fixed mold 2 as shown in FIG. At this time, the peripheral edge of the panel body 21 may be separated from the cavity surface 3a over a range of 15% or more, for example, 15 to 50%, particularly 15 to 40% of the area of the front surface (upper surface in FIG. 5) of the panel body 21. preferable. If the separation area is too large, the panel main body 21 may move within the cavity surface 3a of the fixed mold 2 and may be displaced or fall off. On the other hand, if the separation area is too small, the panel main body 21 is restrained by the fixed mold 2 and the effect of reducing the residual stress, which is the object of the present invention, becomes insufficient. It becomes difficult to secure.

In the present invention, in order to move the panel body 21 away from the cavity surface 3a of the fixed mold 2, specifically, for example, a space generated after the first movable mold 11 is opened, that is, a space where the rear surface side of the panel body 21 contacts. It is preferable that the ambient temperature is at least equal to or lower than the temperature of the fixed mold 2 so as to produce a temperature difference.
Specifically, for example, there is a method of closing the movable mold 12 after a certain period of time without shortening the time until the second movable mold 12 is closed after the first movable mold 11 is opened. Can be mentioned. Specifically, for example, this time is preferably 5 to 180 seconds, more preferably 10 to 120 seconds, and particularly preferably 10 to 60 seconds.

Furthermore, the rear surface side of the panel body 21 is actively cooled by air blow or the like, or in a narrow space sandwiched between the side surface portion of the panel body 21 or the peripheral edge portion of the front surface side surface of the panel body 21 and the fixed mold 2. Cooling air may be injected.
As described above, the blow time when the rear surface of the panel body 21 is positively cooled is specifically 60 seconds or less, preferably 30 seconds or less, and particularly preferably 10 seconds or less. If this blow time is too long, the cooling of the panel body 21 proceeds too much, the separation proceeds not only to the peripheral part but also to the vicinity of the center part, and the panel body 21 moves within the cavity surface 3a of the fixed mold 2, Misalignment may occur or it may fall off.

In the present invention, the air cooling as described above encloses the injection molding region including the mold and a closed system, and creates an air flow in the closed system by generating a pressure difference inside and outside the system. The rear side of the panel body 21 may be cooled.
In particular, in the present invention, it is possible to shorten the time until the first movable mold 11 is opened and the second movable mold 12 is closed, and to actively perform air cooling by air blow or the like as described above. This is preferable because the desired separation of the main body 21 occurs and the production efficiency is improved.

  In this embodiment, as the panel body 21 contracts, the side end surface of the panel body 21 moves away from the side surface 3b of the cavity 3 (the surface rising from the cavity surface 3a).

  Thereafter, as shown in FIG. 6, the second movable mold 12 is matched, and the panel body 21 is brought into contact with the cavity surface 3a by the movable mold 12. The edge portion 12c on the outer edge side of the cavity 13 of the second movable mold 12 presses the panel body 21 and presses against the cavity surface 3a.

  The central portion of the front surface of the second movable mold 12 is a recessed recess 12d, and when the second movable mold is clamped, the portion of the recess 12d does not contact the panel body 21. It has become. The recess 12d may not be provided.

Further, in the second movable mold 12, when the fixed mold 2 and the second movable 12 are matched with each other at the portion between the recess 12d and the cavity 13 that contacts the panel main body 21, the panel main body 21 and the second movable mold 12 are aligned. You may design so that a clearance (clearance) may arise between two movable molds 12. Providing this clearance is preferable because it prevents excessive pressing on the panel body 21 that occurs when the fixed mold 2 and the second movable mold 12 are matched.
Since this clearance needs to prevent the filled resin material from protruding to the center of the panel body 21 when the cavity 13 is filled with the resin material and the frame-shaped portion 22 is injection-molded, the clearance, That is, the distance between the panel body 21 and the second movable mold 12 is usually 0.01 to 0.1 mm, preferably 0.01 to 0.08 mm, particularly preferably 0.03 to 0.08 mm. If this clearance is too large, the injection molding resin tends to protrude from the center side of the panel body 21. On the other hand, if the clearance is too small, the effect of providing the clearance cannot be obtained.

  Next, as shown in FIGS. 6 and 7, the resin material is injected into the cavity 13 formed by the second movable mold 12 to form the frame-shaped portion 22. Thereafter, the second movable mold 12 is opened, and the molded panel is removed.

  According to the molding method of the panel 20 using the mold 1, as shown in FIG. 5, when the first movable mold 12 is opened, the peripheral edge of the panel body 21 is separated from the cavity surface 3a. Shrinkage contracts without being restrained from the fixed mold 2. Thereby, the residual stress of the panel main body 21 becomes small, and curvature is prevented. Further, since the peripheral edge of the panel body 21 contracts relatively freely, a gap is generated between the end surface of the panel body 21 and the cavity side surface 3b. Thereby, when the molded panel 20 is removed from the fixed mold 2, the end surface of the panel body 21 does not interfere with the cavity side surface 3b, and the panel 20 can be removed smoothly.

  Further, in this embodiment, the second movable mold 12 is prevented from warping and deforming during the molding because the edge 12c presses the panel body 21 against the cavity surface 3a. In addition, the resin material for molding the frame-like portion 22 is prevented from spreading from the cavity 13 to the outer edge side of the panel body 21 and further entering the cavity 3a side (so-called reverse side).

  Furthermore, in this embodiment, the recess 12 d is provided in the second movable mold 12, and the center portion of the panel body 21 does not contact the second movable mold 12. Therefore, the panel main body 21 is prevented from being damaged due to contact with the second movable mold 12.

  Next, a panel forming method according to another embodiment of the present invention will be described with reference to FIGS.

  First, as shown in FIGS. 8 and 9, a transparent resin material is injected into the cavity 3 formed between the fixed mold 2 of the mold 1N, the opposed mold 4 and the first movable mold 11N, and the panel body. 21N is molded. The first movable mold 11N has a rectangular frame shape facing the peripheral edge of the cavity surface of the fixed mold 2 and surrounds the opposed mold 4. The facing mold 4 is of a shape and size that fits inside the first movable mold 11N. The first movable mold 11N and the opposed mold 4 are in slidable contact with each other in the vertical direction of FIG. As shown in FIG. 8, the opposed mold 4 and the first movable mold 11N are closed with respect to the fixed mold 2 so that their cavity surfaces are flush with each other.

  After the panel body 21N is molded, the first movable mold 11N is opened as shown in FIG. The opposed mold 4 does not open and remains in contact with the panel body 21N. When the first movable mold 11N is opened, as shown in FIG. 10, the rear surface side of the panel body 21N is allowed to cool and contracts more than the front surface side, and the peripheral edge of the panel body 21 is separated from the cavity surface 3a. Further, due to this contraction, the end surface of the panel body 21N is separated from the cavity side surface 3b.

  Next, as shown in FIGS. 11 and 12, the second movable mold 12N is closed. The second movable mold 12N is provided with an advancing / retreating portion 14 that can advance / retreat so as to press the entire peripheral edge of the panel main body 21N. The advance / retreat part 14 is adjacent to the outer edge side of the cavity 13N. The advancing / retreating portion 14 is slidably fitted in a storage portion 15 that is recessed in the second movable mold 12N. A hydraulic cylinder (not shown) is connected to the advance / retreat portion 14 via a rod 16. Thereby, the advance / retreat portion 14 can take a state in which the cavity 13 is formed by projecting from the front surface of the second movable mold 12N (FIGS. 12 and 13) and a state in which the cavity 13 is retracted (FIG. 11). It has become.

  The second movable mold 12N has a rectangular frame shape like the first movable mold 11N, and is slidably fitted in the up-down direction of FIGS. A cavity 13N is formed on the front surface of the second movable mold 12N, that is, the surface facing the panel main body 21N, when the fixed mold 2 and the opposed mold 4 are combined.

  The cavity 13N faces the inner peripheral edge of the rectangular frame-shaped second movable mold 12N. The cavity 13N is separated from the outer peripheral edge portion of the second movable mold 12N by the width of the advance / retreat portion 14.

  As shown in FIG. 11, the second movable die 12N is closed with the advancing / retreating portion 14 retracted, and then the advancing / retreating portion 14 is advanced to press the panel body 21N with the advancing / retreating portion 14 and press against the cavity surface 3a. . Further, when the advance / retreat portion 14 is advanced, a cavity 13N is formed. Therefore, as shown in FIG. 13, a resin material is injected into the cavity 13N to form a frame-like portion 22N. The cavity 13N has a shape that matches the frame-shaped portion 22N. Thereafter, the opposing mold 4 and the second movable mold 12N are opened and removed to obtain the panel 20N.

  Also by the molding method of the panel 20N using the mold 1N, when the first movable mold 11N is opened, the fixed mold of the panel main body 21N is separated from the cavity surface 3a, so that the residual stress of the panel main body 21N is reduced. A panel in which warpage is prevented is obtained. Further, since the end surface of the panel main body 21N is separated from the cavity side surface 3b, the panel can be removed from the fixed mold 2 smoothly.

  In particular, in this embodiment, the panel main body 21N can be pressed against the cavity surface 3a by the advancing / retreating portion 14, and the panel main body 21N is prevented from being warped and deformed during the molding. Further, the resin material for molding the frame-like portion 22N is prevented from spreading from the cavity 13N to the outer edge side of the panel body 21N and further entering the cavity 3a (so-called reverse).

  Further, although not shown, as shown in FIGS. 3 to 5, after the panel body 21 is formed by a combination of the fixed mold 2 and the first movable mold 11, and the mold is opened, as shown in FIG. The frame-shaped portion 22N may be formed by a process shown in FIGS. 11 to 13 using a movable mold constituted by two blocks of the opposed mold 4 and the movable mold 12N. In this case, in order to adjust the force for pressing the panel body 21 against the cavity 3a, a hydraulic cylinder, an air cylinder, a damper, a spring or the like may be attached to the opposed mold 4 and used. Further, a clearance may be provided between the facing mold 4 and the panel body 21 when the frame portion 22 is formed by filling the cavity 13N with a resin material, and this clearance is provided by the second movable mold 12 described above. It is preferable to be the same as that in FIG.

  In the present invention, the panel 20 which is a molded article molded in this way is preferably annealed for holding 0.5 to 3 hours, particularly 1 to 2 hours, preferably at 80 to 130 ° C, particularly preferably at 100 to 120 ° C. It is preferable to remove the distortion.

  In addition, after apply | coating a hard-coat stock solution to the front surface and rear surface of this panel main body, you may harden by UV irradiation or a heating, and may form a hard film (hard-coat layer).

  When forming this hard film, heat treatment for forming a hard film using a thermosetting resin, and heat treatment for solvent dispersion and annealing treatment when using a UV curable resin are combined. May be.

  Next, a material suitable when the panel obtained by the present invention is applied to an automobile window glass or the like will be described.

  If the constituent material of a panel main body is transparent resin, it can be suitably selected from conventionally well-known arbitrary things. Here, the term “transparent” is generally 10% or more, preferably 20% or more, more preferably 30%, as the total light transmittance in a plate-shaped molded product having a smooth surface thickness of 3 mm measured according to JIS K7105. This means that the Haze value is usually 10% or less, preferably 5% or less, and more preferably 3% or less. In a transparent resin containing a dye or pigment, the proportion of the dye or pigment used is usually 0.001 to 2 parts by weight, preferably 0.005 to 1.2 parts by weight with respect to 100 parts by weight of the thermoplastic resin. Parts, more preferably 0.005 to 0.5 parts by weight.

  Examples of the transparent resin include polystyrene resin, high impact polystyrene resin, hydrogenated polystyrene resin, polyacryl styrene resin, ABS resin, AS resin, AES resin, ASA resin, SMA resin, polyalkyl methacrylate resin, poly Methacryl methacrylate resin, polyphenyl ether resin, polycarbonate resin, amorphous polyalkylene terephthalate resin, polyester resin, amorphous polyamide resin, poly-4-methylpentene-1, cyclic polyolefin resin, amorphous polyarylate resin, poly Heat of ether sulfone, styrene thermoplastic elastomer, olefin thermoplastic elastomer, polyamide thermoplastic elastomer, polyester thermoplastic elastomer, polyurethane thermoplastic elastomer, etc. Plastic elastomers Kyora. Among these, from the viewpoint of impact resistance and heat resistance, a polycarbonate resin (PC), particularly, an aromatic polycarbonate resin as a main constituent resin is preferable. The main constituent resin means that the ratio of the aromatic polycarbonate resin in all resin components is usually 50% by weight or more, preferably 60% by weight or more, and more preferably 70% by weight or more.

  Examples of resins used in combination with PC as the main constituent resin include polystyrene resin, ABS resin, AS resin, AES resin, ASA resin, polyphenylene ether resin, polymethacryl methacrylate resin, and polyester resin. An alloy or a copolymer may be used as long as the properties are maintained.

  The PC used in the present invention is, for example, a linear or branched thermoplastic polymer obtained by reacting an aromatic dihydroxy compound and a carbonate precursor, or a small amount of a polyhydroxy compound in combination therewith. Or a copolymer. PC can be produced by a known method, and examples of the production method include an interfacial polymerization method, a melt transesterification method, a pyridine method, a ring-opening polymerization method of a cyclic carbonate compound, and a solid phase transesterification method of a prepolymer. .

  Examples of aromatic dihydroxy compounds used as raw materials include 2,2-bis (4-hydroxyphenyl) propane (also known as bisphenol A), 2,2-bis (3,5-dibromo-4-hydroxyphenyl) propane ( Also known as: tetrabromobisphenol A), bis (4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4 -Hydroxyphenyl) octane, 2,2-bis (4-hydroxy-3-methylphenyl) propane, 1,1-bis (3-tert-butyl-4-hydroxyphenyl) propane, 2,2-bis (4- Hydroxy-3,5-dimethylphenyl) propane, 2,2-bis (3-bromo-4-hydroxyphenyl) propane, , 2-bis (3,5-dichloro-4-hydroxyphenyl) propane, 2,2-bis (3-phenyl-4-hydroxyphenyl) propane, 2,2-bis (3-cyclohexyl-4-hydroxyphenyl) Propane, 1,1-bis (4-hydroxyphenyl) -1-phenylethane, bis (4-hydroxyphenyl) diphenylmethane, 2,2-bis (4-hydroxyphenyl) -1,1,1-trichloropropane, 2 , 2-bis (4-hydroxyphenyl) -1,1,1,3,3,3-hexachloropropane, 2,2-bis (4-hydroxyphenyl) -1,1,1,3,3,3- Bis (hydroxyaryl) alkanes such as hexafluoropropane; 1,1-bis (4-hydroxyphenyl) cyclopentane, 1,1-bis (4-hydride) Bis (hydroxyaryl) cycloalkanes such as xylphenyl) cyclohexane and 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane; 9,9-bis (4-hydroxyphenyl) fluorene; Cardiostructure-containing bisphenols such as 9,9-bis (4-hydroxy-3-methylphenyl) fluorene; dihydroxy diphenyls such as 4,4′-dihydroxydiphenyl ether and 4,4′-dihydroxy-3,3′-dimethyldiphenyl ether Aryl ethers; dihydroxydiaryl sulfides such as 4,4′-dihydroxydiphenyl sulfide, 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfide; 4,4′-dihydroxydiphenyl sulfoxide, 4,4 '-Dihydroxy-3,3'- Dihydroxydiaryl sulfoxides such as dimethyldiphenyl sulfoxide; dihydroxydiaryl sulfones such as 4,4′-dihydroxydiphenylsulfone and 4,4′-dihydroxy-3,3′-dimethyldiphenylsulfone; hydroquinone, resorcin, 4,4′-dihydroxydiphenyl and the like.

  Among the above, bis (4-hydroxyphenyl) alkanes are preferable, and 2,2-bis (4-hydroxyphenyl) propane (also known as bisphenol A) is particularly preferable from the viewpoint of impact resistance. Two or more kinds of these aromatic dihydroxy compounds may be used in combination.

  As the carbonate precursor to be reacted with the aromatic dihydroxy compound, carbonyl halide, carbonate ester, haloformate and the like are used. Specifically, phosgene; diaryl carbonates such as diphenyl carbonate and ditolyl carbonate; dimethyl carbonate And dialkyl carbonates such as diethyl carbonate; and dihaloformates of dihydric phenols. Two or more of these carbonate precursors may be used in combination.

  In the present invention, the PC may be a branched aromatic polycarbonate resin obtained by copolymerization of a trifunctional or higher polyfunctional aromatic compound. Examples of the trifunctional or higher polyfunctional aromatic compound include phloroglucin, 4,6-dimethyl-2,4,6-tri (4-hydroxyphenyl) heptene-2, 4,6-dimethyl-2,4,6- Tri (4-hydroxyphenyl) heptane, 2,6-dimethyl-2,4,6-tri (4-hydroxyphenyl) heptene-3, 1,3,5-tri (4-hydroxyphenyl) benzene, 1, In addition to polyhydroxy compounds such as 1,1-tri (4-hydroxyphenyl) ethane, 3,3-bis (4-hydroxyaryl) oxyindole (also known as isatin bisphenol), 5-chloroisatin, Examples include 5,7-dichloroisatin and 5-bromoisatin. Among these, 1,1,1-tri (4-hydroxyphenyl) ethane is preferable. The polyfunctional aromatic compound is used by substituting a part of the aromatic dihydroxy compound, and the amount used is usually 0.01 to 10 mol%, preferably 0.1%, based on the aromatic dihydroxy compound. ~ 2 mol%.

  Although the molecular weight of PC used for this invention is arbitrary, it is 10,000-35,000 normally as viscosity average molecular weight [Mv] converted from solution viscosity. By setting the viscosity average molecular weight to 10,000 or more, the mechanical strength is improved and it is suitable for applications requiring high mechanical strength. On the other hand, when the viscosity average molecular weight is 35,000 or less, the fluidity is lowered and the molding process becomes easy. The viscosity average molecular weight is preferably 18,000 to 35,000, more preferably 20,000 to 30,000. By setting the viscosity average molecular weight to 18,000 or more, it is possible to suppress a decrease in impact strength when a cured film is formed on the surface. Two or more types of PCs having different viscosity average molecular weights may be mixed.

Here, the viscosity average molecular weight [Mv] means that the intrinsic viscosity [η] (unit dl / g) at a temperature of 20 ° C. is obtained with an Ubbelohde viscometer using methylene chloride as a solvent, and the Schnell viscosity formula (η = It means a value calculated from 1.23 × 10 ⁻⁴ M ^0.83 ).

  The terminal hydroxyl group concentration of the PC used in the present invention is usually 2,000 ppm or less, preferably 1,500 ppm or less, more preferably 1,000 ppm or less. In addition, the lower limit is usually 10 ppm, preferably 30 ppm, more preferably 40 ppm, especially for PC produced by the transesterification method.

  By setting the terminal hydroxyl group concentration to 10 ppm or more, a decrease in molecular weight can be suppressed, and the mechanical properties of the resin composition tend to be further improved. Moreover, it exists in the tendency which the residence heat stability and color tone of a resin composition improve more by making terminal group hydroxyl group density | concentration into 2,000 ppm or less. When forming a hard coating such as a hard coat, the terminal hydroxyl group concentration is relatively high. Specifically, when the terminal hydroxyl group concentration is 100 to 2,000 ppm, preferably 200 to 1,000 ppm, and more preferably 300 to 1,000 ppm, the adhesion and durability are improved. The unit of the terminal hydroxyl group concentration is the weight of the terminal hydroxyl group expressed in ppm with respect to the PC weight, and the measuring method is a colorimetric determination by the tetrachlorotitanium / acetic acid method (Macromol. Chem. 88 215 (1965). Method).

  Further, in order to improve the appearance of the molded product and the fluidity, the PC used in the present invention may contain an aromatic polycarbonate oligomer. The aromatic polycarbonate oligomer has a viscosity average molecular weight [Mv] of usually 1,500 to 9,500, preferably 2,000 to 9,000. The usage-amount of an aromatic polycarbonate oligomer is 30 weight% or less normally with respect to PC.

  Furthermore, the PC used in the present invention may contain not only virgin PC but also PC regenerated from used products, so-called material recycled PC. Used products include optical recording media such as optical discs, light guide plates, vehicle transparent parts such as automobile window glass, automobile headlamp lenses, and windshields, containers such as water bottles, eyeglass lenses, soundproof walls, glass windows, and waves. Examples include building members such as plates. Also, non-conforming products, pulverized products obtained from sprues, runners, etc., or pellets obtained by melting them can be used. The use ratio of the regenerated PC is usually 80% by weight or less, preferably 50% by weight or less based on virgin PC.

  In addition to the above-mentioned dyes or pigments, any conventionally known auxiliary agent can be added to the constituent material of the panel body. Examples thereof include mold release agents, heat stabilizers, antioxidants, and weather resistance improvements. Agents, alkali soaps, metal soaps, plasticizers, fluidity improvers, nucleating agents, flame retardants, anti-dripping agents and the like. The usage-amount of these adjuvants is suitably selected from a well-known range.

  The constituent material of the frame-shaped portion is not particularly limited, and various known arbitrary thermoplastic resins can be used. Specifically, for example, polycarbonate resin; thermoplastic polyester resin such as polyethylene terephthalate resin, polytrimethylene terephthalate, polybutylene terephthalate resin; polystyrene resin, high impact polystyrene resin (HIPS), acrylonitrile-styrene copolymer (AS resin) ), Styrene-based resins such as acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene-acrylic rubber copolymer (ASA resin), acrylonitrile-ethylenepropylene rubber-styrene copolymer (AES resin); Polyolefin resins such as polyethylene resins and polypropylene resins; Polyamide resins; Polyimide resins; Polyether resins; Polyurethane resins; Polyphenylene ether resins; Id resins; polysulfone resins; and polymethacrylate resins and the like, which may be used in combination of two or more. Among these, from the viewpoint of thermal stability, rigidity, and adhesion to the panel main body, PC and thermoplastic polyester resin are preferable, and among them, those using PC as the main material, especially combined use with thermoplastic polyester resin are preferable. .

  Of the constituent resin materials for the panel main body and the frame-like portion, it is desirable that the main components blended in an amount of 10% by weight or more are the same in order to enhance the bonding property between them.

  When a polymer alloy composed of PC and a thermoplastic polyester resin is used as a constituent material of the frame-like portion, the ratio of PC to the total amount of both components is usually 10 to 90% by weight.

  The thermoplastic polyester resin is a polymer or copolymer obtained by condensation reaction of a dicarboxylic acid component composed of a dicarboxylic acid or a reactive derivative thereof and a diol component composed of a diol or an ester derivative thereof.

  In general, the thermoplastic polyester resin is produced by reacting a dicarboxylic acid component with a diol component in the presence of a polycondensation catalyst containing titanium, germanium, antimony, etc. This is done by discharging out of the system. The condensation reaction may be either a batch type or a continuous type, and the degree of polymerization may be increased by solid phase polymerization.

  The dicarboxylic acids may be either aromatic dicarboxylic acids or aliphatic dicarboxylic acids, but aromatic dicarboxylic acids are preferred from the viewpoints of heat resistance and dimensional stability. Aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, orthophthalic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 4,4′-biphenyldicarboxylic acid, 4,4′-biphenylether dicarboxylic acid 4,4′-biphenylmethanedicarboxylic acid, 4,4′-biphenylsulfonedicarboxylic acid, 4,4′-biphenylisopropylidenedicarboxylic acid, 1,2-bis (phenoxy) ethane-4,4′-dicarboxylic acid, 2,5-anthracene dicarboxylic acid, 2,6-anthracene dicarboxylic acid, 4,4′-p-ter-phenylenedicarboxylic acid, 2,5-pyridinedicarboxylic acid and the like can be mentioned. In addition, alkyl group-substituted products such as 5-methylisophthalic acid; reactive derivatives such as alkyl ester derivatives such as dimethyl terephthalate and diethyl terephthalate can also be used.

  Among the above, terephthalic acid, 2,6-naphthalenedicarboxylic acid and their alkyl ester derivatives are preferable, and terephthalic acid and its alkyl ester derivatives are more preferable. Two or more of these aromatic dicarboxylic acids may be used in combination, and together with the aromatic dicarboxylic acid, an aliphatic dicarboxylic acid such as adipic acid, azelaic acid, sebacic acid, dodecanedioic acid, or a fatty acid such as cyclohexanedicarboxylic acid. It is also possible to use a cyclic dicarboxylic acid in combination.

  The diols include ethylene glycol, 1,2-propylene glycol, 1,3-propanediol, 1,4-butanediol, neopentyl glycol, 1,5-pentanediol, 1,6-hexanediol, deca Aliphatic diols such as methylene glycol and 2,2-dimethyl-1,3-propanediol; 1,4-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, cyclohexanediol, trans- or cis-2,2, Alicyclic diols such as 4,4-tetramethyl-1,3-cyclobutanediol; aromas such as p-xylenediol, bisphenol A, tetrabromobisphenol A, tetrabromobisphenol A-bis (2-hydroxyethyl ether) Group diols. These substitution products can also be used.

  Among the above, ethylene glycol, 1,3-propanediol, 1,4-butanediol, and 1,4-cyclohexanedimethanol are preferable from the viewpoint of thermal stability, impact resistance, rigidity, and the like. 1,3-propanediol and 1,4-butanediol are more preferable, and ethylene glycol is particularly preferable. Two or more of these may be used in combination. Further, as the diol component, a long chain diol having a molecular weight of 400 to 6,000, that is, one or more of polyethylene glycol, poly-1,3-propylene glycol, polytetramethylene glycol and the like are used in combination with the above diols. It may be copolymerized.

  Further, the thermoplastic polyester resin used in the present invention can be branched by introducing a small amount of a branching agent. Examples of the branching agent include trimesic acid, trimellitic acid, trimethylolethane, trimethylolpropane, pentaerythritol and the like.

  Preferable specific examples of the thermoplastic polyester resin used in the frame portion 22 include polyethylene terephthalate resin (PET), polypropylene terephthalate resin (PPT), polybutylene terephthalate resin (PBT), polyhexylene terephthalate resin, polyethylene naphthalate. Examples include resin (PEN), polybutylene naphthalate resin (PBN), poly (1,4-cyclohexanedimethylene terephthalate) resin (PCT), polycyclohexylcyclohexylate (PCC), and the like. Among these, polyethylene terephthalate resin (PET), polypropylene terephthalate resin (PPT), and polybutylene terephthalate resin (PBT) are preferable in terms of fluidity and impact resistance.

  The polyethylene terephthalate resin is a saturated polyester polymer or copolymer obtained by a condensation reaction of terephthalic acid as a main component as a dicarboxylic acid component and ethylene glycol as a diol component as a main component. The proportion of the ethylene terephthalate unit as the repeating unit is usually 70 mol% or more, preferably 80 mol% or more. In addition, in the polyethylene terephthalate resin, diethylene glycol, which is a side reaction product during polymerization, may be included as a copolymerization component. The amount of diethylene glycol is usually based on the total amount of the diol component used in the polymerization reaction. 0.5 to 6 mol%, preferably 0.5 to 5 mol%.

Specific examples of other thermoplastic polyester resins include, for example, polypivalolactone resins obtained by ring-opening polymerization of lactone, poly (ε-caprolactone) resins, and liquid crystal polymers that form liquid crystals in the molten state (Thermotropic).
Liquid Crystal Polymer (TLCP). Specifically, commercially available liquid crystal polyester resins include “X7G” manufactured by Eastman Kodak Co., “Xyday” manufactured by Dartco Co., “Econol” manufactured by Sumitomo Chemical Co., Ltd., “ Vector "and the like.

  The intrinsic viscosity of the thermoplastic polyester resin used in the present invention is usually 0.4 to 1.5 dl / g, preferably 0.5 to 1.3 dl / g. Here, the intrinsic viscosity means a value measured at 30 ° C. in a solvent of phenol / tetrachloroethane = 50/50 (weight ratio). When the intrinsic viscosity is less than 0.4, the impact resistance tends to decrease, and when it exceeds 1.5, the fluidity tends to decrease. The amount of terminal carboxyl groups of the thermoplastic polyester resin is usually 5 to 50 μeq / g, preferably 10 to 30 μeq / g. When the terminal carboxyl group amount is less than 5 μeq / g, the impact resistance tends to decrease, and when it exceeds 50 μeq / g, the moist heat resistance and the thermal stability tend to be insufficient.

  Furthermore, as the thermoplastic polyester resin used in the present invention, not only virgin raw materials but also thermoplastic polyester resins regenerated from used products, so-called material recycled thermoplastic polyester resins can be used. . As used products, containers, films, sheets, fibers, and the like are mainly exemplified, and containers such as PET bottles are preferable. In addition, as the recycled thermoplastic polyester resin, non-conforming products, pulverized products obtained from sprues, runners, etc., or pellets obtained by melting them can be used.

  Moreover, it is preferable to mix | blend a filler with the structural material of the frame-shaped part 22 in order to improve rigidity, dimensional stability, and heat resistance. Examples of such fillers include titanium oxide, zinc oxide, barium sulfate, silica, calcium carbonate, iron oxide, alumina, calcium titanate, aluminum hydroxide, magnesium hydroxide, calcium hydroxide, magnesium carbonate, calcium sulfate, sulfuric acid. Sodium, calcium sulfite, magnesium silicate (talc), aluminum silicate (mica), calcium silicate (wollastonite), clay, glass beads, glass powder, glass fiber, carbon fiber, aramid fiber, biodegradable fiber, silica sand, silica Stone, quartz powder, shirasu, diatomaceous earth, white carbon, iron powder, aluminum powder and the like. Among these, glass fiber, carbon fiber, aramid fiber, biodegradable fiber, magnesium silicate (talc), aluminum silicate (mica), and calcium silicate (wollastonite) are preferable. Two or more kinds of fillers can be used in combination.

  The shape of the filler may be any of spherical, cubic, granular, needle-like, plate-like, and fiber-like, but improves the dimensional stability of the finally obtained thermoplastic resin composition. From the viewpoint of high rigidity and good appearance, a plate shape or a needle shape is preferable, and a filler having a laser diffraction particle size (D50) of 10 μm or less is preferable.

  The usage-amount of a filler is 2-50 weight part normally with respect to 100 weight part of constituent materials of a frame-shaped part, Preferably it is 5-40 weight part. When the amount of the filler is less than 2 parts by weight, the effect of improving rigidity, dimensional stability and heat resistance is small, and when it exceeds 50 parts by weight, the impact resistance is lowered.

  The above fillers may be left untreated, but for the purpose of increasing the affinity with the resin component or the interfacial binding force, surface treatment agents, higher fatty acids or their derivatives, derivatives such as salts, coupling agents, etc. It is preferable to treat with. When the surface treatment is performed in combination with various surfactants such as nonionic, cationic, and anionic types and dispersants such as various resins, the mechanical strength and kneadability are preferably improved. .

  Conductive carbon black and / or hollow nanocarbon fibers can be blended with the constituent material of the frame-like portion for the purpose of imparting antistatic properties and conductivity capable of electrostatic coating. Examples of the conductive carbon black include acetylene black obtained by thermally decomposing acetylene gas, and Ketjen black produced by crude incomplete combustion using crude oil as a raw material. Hollow nanocarbon fibers have an outer region consisting of an essentially continuous multi-layer of regularly arranged carbon atoms and an inner hollow region, with each layer and the hollow region being arranged substantially concentrically. There are essentially cylindrical fibrils. Furthermore, the regularly arranged carbon atoms in the outer region are graphite-like. The diameter of the hollow region is usually 2 to 20 nm. Such hollow nanocarbon fibers are sold by Hyperion Catharsis under the trade name “graphite fibrils” and are readily available.

  The panel body is preferably made of a non-reinforced synthetic resin, while the frame-like portion is preferably made of a composite reinforced synthetic resin. That is, it is preferable to add reinforcing fibers to the resin material of the frame-shaped part. As the reinforcing fiber, for example, at least one selected from the group consisting of glass fiber, carbon fiber, aromatic polyamide fiber (aramid fiber), biodegradable fiber, talc, mica, and wollastonite can be used. The weight average fiber length of the fiber blended in the resin material is usually 0.05 to 10 mm, preferably 0.2 to 5 mm, from the viewpoint of strength and dispersibility. Moreover, in order to improve mechanical strength, dimensional accuracy, and heat resistance, the weight average fiber length of the fibers in the finished molded product is relatively long, specifically 0.1 to 5 mm, particularly 0.2 to 5 mm, especially 1. It is preferable to be set to ˜5 mm. In this way, in order to increase the weight average fiber length of the fiber in the finished molded product, specifically, for example, in the configuration of the injection cylinder of the injection molding machine, the screw compression ratio is set to loose compression, and the screw and cylinder It is effective to take a wide clearance and check ring clearance. Further, as the conditions at the time of injection molding, it is effective to increase the setting of the resin temperature, to lower the back pressure at the time of measurement, and to reduce the injection speed for molding. In particular, the effect of the back pressure is great. Specifically, it is preferably 1 to 20 MPa, more preferably 1 to 15 MPa, and particularly preferably 5 to 10 MPa.

  Although not shown, in the present invention, a hard coat (hard coating) may be provided as a protective film in order to mainly prevent damage and deterioration of the panel body. Such a hard coating may be provided only on the front surface of the panel body 21 on the side opposite to the frame-shaped portion 22 formation side. The thickness of the hard coating is preferably 1/100 or less of the thickness of the panel body 21, usually 1 to 50 μm, particularly preferably 5 to 20 μm.

  The hard coating may be a single layer, but may have a multilayer structure of at least two layers in order to enhance the protective function and weather resistance. In the multilayer structure, it is preferable to set the hardness of the outermost layer to the maximum. As the hard coating having a multilayer structure, for example, it has at least one function among a functional layer of each of heat ray shielding, ultraviolet absorption, thermochromic, photochromic, electrochromic, primer layer, colored decoration layer, etc. It is preferable.

  A transparent resin is suitable for the constituent material of the hard coating. As such a transparent resin, a known material known as a hard coat agent can be used as appropriate. For example, various hard coat agents such as silicone, acrylic, silazane, and urethane can be used. I can do it. In these, in order to improve adhesiveness and a weather resistance, the 2-coat type hard coat which provides a primer layer before apply | coating a hard-coat agent is preferable. Examples of the coating method for the hard coating agent include spray coating, dip coating, flow coating, spin coating, and bar coating. Moreover, the method by a film insert, the method of apply | coating and transferring the chemical | medical agent suitable for a transfer film, etc. can also be employ | adopted.

  Thin films having various functions (heat ray shielding, ultraviolet absorption, thermochromic, photochromic, and electrochromic functions) may be formed on the outermost layer of the hard coating.

  A transparent resin layer may be provided between the surface of the panel body 21 and the hard coating.

  The panel formed by the method of the present invention is suitable for application to windows of vehicles, particularly automobiles, and particularly suitable for application to sunroofs, but is also applicable to quarter windows, rear windows, and the like. is there.

  In the present invention, an uneven portion may be formed at a boundary portion between the rear surface of the panel main body and the frame-shaped portion to increase the bonding strength between the panel main body and the frame-shaped portion. In the present invention, an attachment piece for attaching other components may be provided on the frame-like portion.

<Description of physical properties of panel main body and frame-shaped part>
In the present invention, when the volume of the panel body is V ₁ , the volume of the frame-like part is V ₂ , and a 3 mm thick 100 mm × 100 mm flat plate molded from the material constituting the panel body is held at 130 ° C. for 2 hours The shrinkage rate (%) is S ₁ , and the shrinkage rate (%) when a 3 mm-thick 100 mm × 100 mm flat plate molded from the material constituting the frame-like part is held at 130 ° C. for 2 hours is S _2. In addition, 0.01 <V ₂ / V ₁ <1.0 is preferable, and in particular, 0.05 ≦ V ₂ / V ₁ ≦ 1.0, and further 0.1 ≦ V ₂ / V ₁ ≦ 0. 75, in particular 0.1 ≦ V ₂ / V ₁ ≦ 0.5. Moreover, it is preferable that 1.0 <S ₂ / S ₁ <3.0, among which 1.1 ≦ S ₂ / S ₁ ≦ 3.0, and further 1.1 ≦ S ₂ / S ₁ ≦ 2.5. In particular, it is preferable that 1.5 ≦ S ₂ / S ₁ ≦ 2.3.

Preferably, 0.35 <(S ₂ · V ₂ ) / (S ₁ · V ₁ ) <1.1, and further 0.5 ≦ (S ₂ · V ₂ ) / (S ₁ · V ₁ ) <1.0, in particular 0.6 ≦ (S ₂ · V ₂ ) / (S ₁ · V ₁ ) <0.8.

The bending elastic modulus of a 3 mm thick 100 mm × 100 mm flat plate molded from the material constituting the panel body is F _1, and the bending elastic modulus of a 3 mm thick 100 mm × 100 mm flat plate molded from the material constituting the frame portion is F ₂ is preferably 0.35 <(S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · F ₁ ) <1.5, particularly preferably 0.7 ≦ (S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · F ₁ ) ≦ 1.2.

When the molding shrinkage rate (%) at the time of injection molding of the frame-like portion is I ₂ and the linear expansion coefficient of the panel body is α ₁ (/ ° C.), preferably 0.8 × 10 ⁻² <α ₁ / I ₂ <2.3 × 10 ⁻² , further 0.8 × 10 ⁻² <α ₁ / I ₂ ≦ 2.0 × 10 ⁻² , particularly 0.8 × 10 ⁻² <α ₁ / I _2. ≦ 1.5 × 10 ⁻² is preferable.

When the physical properties of the panel main body and the frame-shaped part are in the above range, the contraction behavior of the peripheral part of the panel main body during annealing is prevented from being constrained by the contraction behavior of the frame-shaped part or conversely assisted. Good product panel shape accuracy. That is, as represented by 0.01 <V ₂ / V ₁ <1.0, when the volume of the frame-shaped portion is smaller than the volume of the panel main body, the shrinkage rates S ₂ and S ₁ between the frame-shaped portion and the panel main body. Is 1.0 <S ₂ / S ₁ <3.0, the degree of contraction of the convex curved panel body and the degree of contraction of the frame-like portion are substantially equal, and the curvature radius of the convex curvature of the panel is annealed. The shape is almost the same at the front and back, and the shape accuracy of the product panel is improved.

In this case, if S ₂ / S ₁ is 1 or less, the contraction of the panel body is constrained by the frame-shaped portion. That is, the deformation behavior of the panel main body to be contracted is hindered by the frame-shaped portion. As a result, the radius of curvature of the convex curve of the panel becomes larger than the allowable range, and the panel becomes concave from a flat (flat plate) shape. On the other hand, when S ₂ / S ₁ is 3 or more, the frame-like portion tends to shrink and deform beyond the shrink deformation of the panel body, and the convex warpage of the panel body becomes strong. That is, the curvature radius of the panel is smaller than the allowable range.

Note that the deformation behavior of the panel during the annealing treatment is the ratio (S ₂ · V ₂ ) / (S ₁ · V ₁ ) of the product of the volume of the panel body and the frame-like portion and the shrinkage rate during the annealing treatment, and the flexural modulus. It is also affected by F ₁ and F ₂ . In addition, since the panel body is injection-molded first and the frame body is cooled to a certain degree to an allowable hardness, the frame-shaped part is injection-molded on the rear surface of the panel body. _2. The linear expansion coefficient α ₁ of the panel body also affects the deformation behavior of the panel. Therefore, the values of (S ₂ · V ₂ ) / (S ₁ · V ₁ ), (S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · F ₁ ), α ₁ / I ₂ are By setting the range, the shape accuracy of the product panel can be increased.

The shrinkage rates S ₁ and S ₂ are average values of the shrinkage rate in the flow direction during injection molding and the shrinkage rate in the direction orthogonal to the flow direction. The linear expansion coefficient is also an average value in the flow direction and the direction orthogonal thereto.

  In the present invention, when the first movable mold is opened, the peripheral edge of the panel main body may be pressed by a pressing member to prevent the panel main body from falling off. If it does in this way, the production efficiency of a panel can be improved.

  Hereinafter, examples and comparative examples will be described.

[Examples 1 to 4, Comparative Example 1]
Except that the inner peripheral edge of the frame-like portion 22 is perpendicular to the rear surface of the panel main body 21, a rectangular laminated panel having the cross-sectional shape shown in FIG. 1 was formed according to the method shown in FIGS. . In Comparative Example 1, the mold of the panel body 21 before the secondary material was injection-molded was a flat flat plate mold without a convex curve. However, the design value of the curved height C of the panel formed by injection molding the secondary material on the panel main body 21 was set in consideration of deformation due to thermal shrinkage after the secondary material was injection molded. First, the panel body 21 was injection-molded (resin temperature at the time of injection 300 ° C.).

  In Examples 1 to 4 and Comparative Example 1, the fixed mold 2 and the first movable mold 11 are filled at a single mold temperature of 90 ° C. and an injection speed of 50 mm / sec, and the injection time is 12 seconds. Injection holding pressure switching position is 2mm, molding is done with a valve gate type hot runner, there is no holding pressure, injection compression molding is performed, the mold is opened 2mm before injection, and re-clamping 700 ton at the injection holding pressure switching position The cooling time was 15 seconds and the cooling time was 60 seconds.

  In any of the examples and comparative examples, the clamping force 700 ton is applied to the panel molded body during the cooling time.

Next, the first movable mold 11 was replaced with the second movable mold 12, and the frame portion 22 was injection-molded (resin temperature at the time of injection 270 ° C.) using the materials shown in Table 1. The time from the opening of the first movable mold 11 to the closing of the second movable mold 12 and the injection molding of the frame 22 is 30 seconds in the first and second embodiments, and 60 in the third embodiment. Seconds. In Example 4, after the first movable mold 11 was opened, instrumentation air (room temperature) having a pressure of 0.5 MPa was used, and air blowing was performed on the rear surface side of the panel body 21 for 10 seconds. At this time, the time from the opening of the first movable mold 11 to the closing of the second movable mold 12 and the injection molding of the frame portion 22 was 40 seconds.
Both the fixed mold 2 and the second movable mold 12 are filled with a mold temperature of 90 ° C. and an injection speed of 40 mm / sec. The injection time is 4 seconds, the holding pressure is 25 MPa, the cooling time is 5 seconds, and the cooling time is 60 seconds. It is.

  The panel dimensions are as follows. Below, the dimension of each part is a dimension of the site | part shown in FIG. 1 and FIG.

Long side a: 750 mm
Short side b: 465mm
Curvature height C: As shown in Table 1 Width of the frame-shaped part 2 (location along the long side, section HH): 90 mm
The width of the frame-shaped part 2 (location along the short side, cross-section II): 97 mm
Panel body thickness: 5mm
Frame part thickness: 3.5mm

Accordingly, the volume V ₁ , V ₂ and V ₂ / V ₁ ratio of the panel main body 21 and the frame-like portion 22 are as follows.

V ₁ : 1312.5 cm ³
V _2: 459.4cm ³
_{V 2} / V 1: 0.35

A polycarbonate resin (manufactured by Mitsubishi Engineer Plastics; trade name “Iupilon (registered trademark) S2000UR”) was used as a molding material for the panel body. The viscosity average molecular weight (Mv) was 24,500, and the linear expansion coefficient was 6.5 × 10 ⁻⁵ [/ ° C.]. The 3 mm thick 100 mm × 100 mm flat plate has a 130 ° C. × 2 Hr shrinkage S ₁ of 0.08% and a flexural modulus F ₁ of 2300 MPa.

  The molding material for the frame-like portion 22 was formulated as shown in Table 1. In Table 1, PC is the polycarbonate resin (Mitsubishi Engineering Plastics Co., Ltd .: Iupilon (registered trademark) S-3000FN, viscosity average molecular weight Mv = 21,000), PET is polyethylene terephthalate resin (Mitsubishi Chemical Corporation: Novapex ( Registered trademark) GG500). GF is a glass fiber (manufactured by Nippon Electric Glass Co., Ltd .: ECS03T-571, average fiber diameter 13 μm, average fiber length 3 mm).

  After mixing the polycarbonate resin and the second component PET uniformly with a tumbler mixer at the blending ratio shown in Table 1, a twin-screw extruder (manufactured by Nippon Steel Works, TEX30XCT, L / D = 42, barrel) 12), at a cylinder temperature of 280 ° C. and a screw rotation speed of 250 rpm, feed from the barrel 1 (the uppermost barrel) to the extruder and melt knead, and further, barrel 7 (the seventh barrel from the upstream side) The glass fiber was fed to the extruder at a ratio shown in Table 1 and melt kneaded to produce pellets of the resin composition as molding materials. Table 1 also shows the physical properties of the injection-molded product with the blending. The curved height C is the height of the most convex part of the panel body 21 from the outermost peripheral part of the panel body 21. In the flat comparative example 1, when the first movable mold 11 is opened, the panel body 21 remains in close contact with the cavity surface 3a, and C = 0.

[Comparative Examples 2 to 5]
In Comparative Example 2, a laminated panel was obtained in the same manner as in Example 1 except that the injection compression molding was stopped when the panel body 21 was molded and a holding pressure of 20 MPa was applied for 120 seconds. At this time, when the first movable mold 11 was opened, the panel body 21 remained in close contact with the cavity surface 3a and did not separate from the cavity surface 3a (the separation area ratio was 0%). Further, the side surface portion of the panel main body 21 is separated from the cavity surface side surface portion 3b.

  In Comparative Example 3, a laminated panel was molded in the same manner as in Example 1 except that the injection compression re-clamping time when forming the panel body 21 was 90 seconds. At this time, when the first movable mold 11 was opened, the panel main body 21 remained in close contact with the cavity surface 3a and the side surface portion 3b.

  In Comparative Example 4, a panel was molded in the same manner as in Example 4 except that air blowing was performed for 60 seconds on the rear side of the panel body 21. At this time, during the air blow, the separation from the cavity surface 3a of the panel main body 21 proceeds too much and is greatly displaced from the cavity surface, and when the second movable mold 12 is closed, there is a gap between the movable mold 12 and the fixed mold 2. The frame-shaped part 22 could not be formed.

  In Comparative Example 5, a laminated panel was molded in the same manner as in Example 1 except that the time from the opening of the first movable mold 11 to the injection molding of the frame portion 22 was set to 300 seconds. At this time, when the second movable mold 12 is closed when the second movable mold 12 is closed because the separation from the cavity surface 3a of the panel body 21 proceeds too much during the mold opening, and the second movable mold 12 is closed. The window frame part could not be formed due to being sandwiched between them.

V ₂ / V ₁ , S ₂ / S ₁ , (S ₂ · V ₂ ) / (S ₁ · V ₁ ), (S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · Tables 2 and 3 show the number of F ₁ ) and the like, and the measurement results of warpage and warpage variation (shape stability). Where "warp" is percentage difference between the measured value _{C n} of the bending height as the designed value _{C o} a _(C n -C _o) divided by _{C o (C n -C o)} / C o × 100 ( %), Which is the average of 10 samples. In addition, since the panel bending height varies depending on the material used for injection molding the window frame portion, the thermal contraction analysis when the frame-shaped portion used in the example and the comparative example is molded with respect to the mold shape of the panel body 21 is performed. The analysis results were used as design values.
The “warp variation” is a percentage obtained by dividing the difference between the maximum value and the minimum value (B _max −B _min ) by the average value B _ave of 10 samples among the warp values (%) of 10 samples. a _{(B max -B min) / B} ave × 100%.

  As shown in Table 3, according to the present invention, it is possible to form a panel having a small appearance deviation and a good appearance accuracy from the design value.

2 Fixed mold 3 Cavity 3a Cavity surface 3b Cavity side 4 Opposed mold 11, 11N First movable mold 12, 12N Second movable mold 13, 13N Cavity 21 Panel body 22 Frame-shaped part

Claims (4)

A panel having a synthetic resin material panel main body curved so that one surface side is convex, and a synthetic resin material frame-shaped portion integrally provided with the panel main body at the periphery of the other surface of the panel main body A method of injection molding,
A panel body molding step of injection molding the panel body using a fixed mold and a first movable mold closed by the fixed mold;
A frame-shaped part forming step of opening the first movable mold, closing the second movable mold having a frame-shaped part forming cavity with respect to the fixed mold, and injection-molding the frame-shaped part; In a method for forming a panel having:
A panel molding method, wherein when the first movable mold is opened, a peripheral portion of the one surface of the panel body is separated from a cavity surface of the fixed mold.   2. The panel molding according to claim 1, wherein when the first movable mold is opened, a peripheral portion is separated from a cavity surface of the fixed mold over an area of 15% or more of one surface of the panel body. Method.   3. The method according to claim 1, wherein when the first movable mold is in a state of being opened, the panel main body contracts in the cavity, and the end surface of the panel main body separates from the side surface of the cavity surface of the fixed mold. A panel forming method characterized.   4. The method according to claim 1, wherein when the second movable mold is closed, the panel body is pressed against the cavity surface of the fixed mold by pressing the peripheral edge of the panel body with the second movable mold. A panel forming method characterized.

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