JP6070593B2 - Mold for resin injection molding and manufacturing method of resin molded product - Google Patents

Description

  The present invention relates to an injection mold for manufacturing a resin molded body having a design surface, and a method for manufacturing a resin molded product using the mold. A metal plating layer is formed on the design surface of the resin molded body molded using the injection mold of the present invention.

  Many members having a metal plating layer such as an ornament, a grill, a wheel cap, a register, and a bumper are used in an automobile. Such a member is manufactured by creating a resin base material by injection molding or the like and applying a metal plating such as chromium on the design surface. Although metal plating is performed by electrolytic plating, the resin base material is often an insulator, and electrolytic plating is often difficult.

  Therefore, electroless plating is performed on the resin base material to form a conductive metal layer such as nickel, and then electrolytic plating is performed. Alternatively, electroplating is performed by omitting the electroless plating process by a plating direct method.

  However, the adhesion of the plating film to the resin molded body often becomes a problem, and various methods have been proposed to improve the adhesion. For example, in Japanese Unexamined Patent Publication No. 2011-063855, a resin base material is treated with an ozone solution to form a surface modified layer, and after applying the energy such as plasma to remove the surface layer of the surface modified layer, electroless plating How to do is described.

  JP-A 2007-327131 discloses that the surface of a resin substrate is treated with a pretreatment solution containing an anionic surfactant and an organic solvent, and then contains a noble metal ion containing an anionic surfactant and a noble metal ion. A method is described in which treatment is performed with a treatment liquid, and then a material to be plated is heat-treated, followed by treatment with an alkaline aqueous solution, followed by electroless plating treatment.

  According to these methods, the adhesion of the plating film is improved without using harmful substances such as chromic acid.

JP 2011-063855 JP 2007-327131 A

  However, even a resin molded product with a plating film manufactured by the technique described in the above publication may swell or peel off in the plating film when a thermal history with a large temperature difference is applied. This is considered because the difference in thermal expansion coefficient between the metal plating film and the resin base material is large. In addition, the technique described in the above publication has a problem that the man-hour is large and the productivity is low as compared with the etching process using chromic acid or the like.

  The present invention has been made in view of the above-mentioned problems, and by devising a molding die, the formation of a brittle layer is suppressed, and a resin molded body in which the adhesion of a plating film is remarkably improved is stably produced. Making it possible is an issue to be solved.

The resin injection mold of the present invention that can solve the above problems is characterized in that the first mold surface for molding the design surface on which the metal plating of the resin molded body is applied and the back surface opposite to the design surface are molded. A second mold surface opposite to the one mold surface, and the second mold surface along the main flow direction of the molten resin flowing through the cavity formed by the first mold surface and the second mold surface during injection molding A plurality of stepped portions extending from the general mold surface portion with a step surface higher or lower and then continuing to the general mold surface portion;
The step surface intersects the main flow direction of the molten resin, the second mold surface is a mold surface extending in the mold drawing direction of the resin molded body, and the step portion is from the step surface to the opposite side of the mold cutting direction or from the mold. The taper step portion is continuous with the general mold surface portion in the direction.

  A plating film was formed on a resin molded body molded by a conventional resin injection mold, and the peeling state was investigated. Instead of peeling from the interface between the plating film and the resin substrate, the resin substrate It became clear that it peeled inside the surface layer in which the plating film was formed. That is, it was found that the peeling occurred not by interfacial peeling but by cohesive failure of the resin substrate.

  Accordingly, the surface of the resin molded body to be plated was removed to a predetermined depth by polishing, a plating film was formed on them, and a test was performed to measure the adhesion strength. The results are shown in FIG. As shown in FIG. 1, it became clear that the adhesion strength is greatly improved as the polishing amount is thicker, that is, as the polishing amount is deeper. That is, it was found that the resin molded body molded by the injection molding method has a different structure between the surface layer and the inside, and an embrittled layer is formed on the surface layer.

  Therefore, it is presumed that if the formation of the brittle layer on the surface is suppressed, the adhesion of the plating film is improved, and as a result of extensive research, the present invention has been completed.

  That is, according to the mold for resin injection molding of the present invention, the flow of the molten resin during molding is changed by the step portion of the second mold surface, and the influence is also applied to the surface layer of the design surface molded by the first mold surface. It is thought that it reaches. Therefore, formation of an embrittlement layer is suppressed and adhesion of a plating film formed on the design surface is improved.

  And the level | step-difference part is made into the taper step part which continues to a general mold surface part gradually from the level | step difference surface to the opposite side to a die-cutting direction, or a die-cutting direction. Therefore, the convex portion formed by the step portion is prevented from being undercut, and the resin molded body can be die-cut.

It is a graph which shows the relationship between the grinding | polishing amount with respect to the design surface of a resin molding, and the peeling strength of a plating film. It is typical explanatory drawing which shows the injection mold which concerns on one Example of this invention in a partial cross section. It is a perspective view which shows the principal part of the 2nd mold surface of the injection mold which concerns on one Example of this invention. It is a typical top view which shows the principal part of the 2nd mold surface of the injection mold which concerns on one Example of this invention. It is a typical top view which shows the principal part of the 2nd mold surface of the injection mold which concerns on one Example of this invention.

  The mold for resin injection molding of the present invention includes a first mold surface and a second mold surface. A 1st type | mold surface means the type | mold surface which shape | molds the design surface of a resin molding, ie, the surface where metal plating is given. The second mold surface is a mold surface that molds the back surface of the resin molded body that is opposite to the design surface, and refers to a mold surface that faces the first mold surface. One of the first mold surface and the second mold surface can be a fixed mold surface and the other can be a movable mold surface. Further, the second mold surface may be a mold surface of the slide core.

  In order to effectively express the action by the step portion, the distance between the first mold surface and the second mold surface is important. If the distance is too large, the action by the step portion is not achieved. Further, it is considered that the optimum range of the interval varies depending on the flow rate, viscosity, material, etc. of the molten resin flowing in the cavity. For example, in the case of the ABS resin used in the examples, when the flow rate of the molten resin is in the range of 2 cm to 150 cm / sec, the interval is preferably in the range of 2 mm to 6 mm, and most preferably in the range of 2.5 mm to 4 mm.

  The second mold surface is one step higher or lower with a step surface from the general mold surface along the main flow direction of the molten resin flowing through the cavity formed by the first mold surface and the second mold surface during injection molding. A plurality of step portions extending and then continuing to the general mold surface portion are formed. The step portion is a taper step portion that gradually continues from the step surface toward the opposite side of the die-cutting direction or toward the die-cutting direction and gradually continues to the general die surface portion. The step surface may be a wall surface that rises from the general mold surface portion of the second mold surface, or may be a wall surface of a recess carved from the general mold surface portion to the inside of the second mold surface. From the viewpoint of ease of mold processing, it is preferable that the wall surface of the recess carved into the second mold surface is a stepped surface.

  The step portion is formed on the second mold surface facing the first mold surface that molds at least a range where the metal plating is performed on the design surface of the resin molded body, but the step facing the range where the metal plating is not performed. It may be formed on the mold surface.

  The angle formed between the general mold surface portion and the step surface is desirably 90 ° or more. If the angle is acute, it may be undercut and it may be difficult to remove the molded resin. In addition, the general mold surface portion and the step surface may be continuous through a chamfered curved surface, but in the cross section obtained by cutting the step portion along a plane parallel to the main flow direction of the molten resin, the general mold surface portion and the step surface It is desirable to cross the edges. By doing in this way, the adhesiveness of a plating film may improve further.

  The depth or height of the stepped portion is preferably in the range of 0.1 mm to 0.3 mm. If the depth or height exceeds 0.3 mm, sink marks may occur on the design surface formed by the first mold surface. On the other hand, when the depth is less than 0.1 mm, it is difficult to achieve the effect of forming the stepped portion, and the adhesion of the plating film is lowered.

  A plurality of step portions are formed alternately with the general mold surface portions along the main flow direction of the molten resin flowing through the cavity. The pitch of the step portions in the direction along the main flow direction of the molten resin, that is, the distance between the step surfaces is preferably in the range of 2 mm to 20 mm. When this pitch exceeds 20 mm, the range of the general mold surface portion is widened, and the adhesion of the plating film is lowered. Even if the pitch is smaller than 2 mm, the adhesion of the plating film is lowered. Most preferred is about 3 to 10 mm.

  The step surface intersects the main flow direction of the molten resin in a straight line or a curved line. It is preferable that the step surface intersects with the main flow direction of the molten resin in a straight line rather than a curved line. Most preferably, the step surface is a plane that intersects at right angles to the main flow direction of the molten resin.

  A plurality of step portions are also formed at intervals from each other in the direction intersecting the main flow direction of the molten resin. That is, a plurality of step portions and general mold surface portions are alternately formed in a direction perpendicular to the main flow direction of the molten resin. By doing in this way, the dispersion | variation in the change of the flow of molten resin is suppressed and the adhesiveness of a plating film is stabilized.

  The length of the stepped portion in the cross section cut along a plane perpendicular to the main flow direction of the molten resin is preferably 2 mm or more. If the length is less than 2 mm, the adhesion of the plating film cannot be improved. The interval between the stepped portions in the cross section cut by a plane perpendicular to the main flow direction of the molten resin is not particularly limited, but the interval is approximately the same as the length of the stepped portion in the direction perpendicular to the main flow direction of the molten resin. It is preferably 2 mm or more, and more preferably in the range of 3 mm to 20 mm.

  The resin species that can be molded using the resin injection mold of the present invention may be not only a resin species that can form a metal plating film, but also a resin species that can be molded by an injection molding method. For example, polyester, ABS (acrylonitrile-butadiene-styrene), PC / ABS polymer alloy, polystyrene, polycarbonate, acrylic, liquid crystal polymer (LCP), polyolefin, cellulose modified resin, polysulfone, polyphenylene sulfide, polyethersulfone, polyetheretherketone, Polyimide, fluorine resin, or the like can be used.

  The resin molded body molded using the mold for resin injection molding of the present invention has a design surface molded on the first mold surface and a back surface molded on the second mold surface, and a stepped portion is formed on the back surface. A plurality of transferred convex portions or concave portions are formed. By setting the size and pitch of the stepped portion within the above range, the volume of the convex portion or the concave portion can be reduced to a predetermined range or less, and it is possible to prevent the design surface from sinking or reducing the strength of the resin molded body. The

  The resin molded body molded using the mold for resin injection molding of the present invention can form a metal plating film on the design surface molded on the first mold surface. Hereinafter, a method for forming a metal plating film will be described.

  The resin molded body is first subjected to a cleaning process such as cleaning and degreasing, and then generally an etching process is performed. The etching treatment may be performed using chromic acid, a mixed liquid of chromic acid and sulfuric acid, permanganate, or the like, or an ozone solution or an ozone gas may be used. For example, a mixed solution of chromic acid and sulfuric acid may be used, and at least the design surface of the resin molded body may be immersed in an appropriately heated solution. In the case of using a resin molded body formed from ABS, the butadiene rubber as a constituent component is eluted by the etching process due to the oxidation of chromic acid, and an anchor portion having a pore diameter of about 1 to 2 μm is formed on the resin surface. Is oxidatively decomposed to give a polar group such as a carbonyl group, so that the catalyst can be easily adsorbed in the subsequent step.

  After the etching process, an electroless plating process and an electrolytic plating process are performed. Alternatively, there may be a case where the electroless plating process is not performed as in the plating direct method. In the case of performing electroless plating, a catalyst adhesion process is performed prior to electroless plating. As the metal fine particles (catalyst) having catalytic activity for electroless plating, gold, silver, ruthenium, rhodium, palladium, tin, iridium, osmium, platinum or the like can be used alone or in combination. These catalysts are often used as colloidal solutions.

  After the catalyst adhesion treatment, a conductive plating layer made of nickel, copper or the like is formed by an electroless plating treatment by a known method, and thereafter a metal plating film made of chromium or the like is formed by a known electrolytic plating method.

  In the case of the direct plating method, as much palladium as possible is adsorbed on the resin surface by treatment with an activator solution such as tin / palladium / colloid solution surrounded by tin chloride. Thereafter, a conductive treatment such as removal of inert colloidal tin from the palladium film is performed, and then a metal plating film made of chromium or the like is formed by a known electrolytic plating method.

  In the case of the plating direct method, the convex portion of the resin molded body generally becomes an obstacle to plating growth. However, in the present invention, the convex portion or the concave portion formed by the step portion is present on the back surface on the opposite side to the design surface, so that it is difficult to cause a problem. Moreover, if the level | step-difference part of a 2nd type | mold surface is made into the above-mentioned dimension, it can be made to grow by plating also on a convex part in the plating direct construction method.

  Hereinafter, embodiments of the present invention will be described specifically by way of examples.

Example 1
FIG. 2 shows a resin injection mold according to the present embodiment. This mold has a fixed mold 1 and a movable mold 2, has a first mold surface 10 for molding a design surface of a resin molding on the mold surface of the fixed mold 1, and a design surface on the mold surface of the movable mold 2. The second mold surface 20 is formed on the back surface of the mold. As shown in FIG. 3, the surface of the second mold surface 20 is spaced from each other along the main flow direction of the molten resin flowing through the cavity 100 formed by the first mold surface 10 and the second mold surface 20. A plurality of stepped portions 21 spaced apart are formed. The step portion 21 extends long in a straight line in a direction orthogonal to the main flow direction. The distance between the first mold surface 10 and the second mold surface 20 (the thickness of the cavity 100) is 3 mm.

  The second mold surface 20 has a first vertical surface 201 and a second vertical surface 202 extending substantially in the mold opening direction, and is perpendicular to the mold opening direction between the first vertical surface 201 and the second vertical surface 202. There is a flat surface 203 extending in the direction. The molten resin injected from the gate 204 is first guided by the first vertical surface 201 to reach the flat surface 203 and proceeds from the flat surface 203 to the end of the second vertical surface 202. Accordingly, the flow directions of the molten resin flowing through the first vertical surface 201 and the second vertical surface 202 are opposite to each other.

  As shown in FIG. 4, the stepped portion 21 formed on the first vertical surface 201 and the flat mold surface 203 is deeply carved with the stepped surface 21b from the edge-shaped general mold surface portion 21a, and then the molten resin A tapered groove 21c whose depth gradually decreases toward the front side with respect to the main flow direction is formed, and the tapered groove 21c is continuous with the next general mold surface portion 21a. As for the dimensions of the tapered grooves 21c, the depth of the deepest portion is 0.2 mm, and the pitch between the tapered grooves 21c, that is, the pitch between the stepped surfaces 21b is 4 mm.

  On the other hand, as shown in FIG. 5, the stepped portion 21 formed on the second vertical surface 202 gradually increases in depth from the edge-shaped general mold surface portion 21a toward the front side with respect to the main flow direction of the molten resin. A tapered groove 21d is formed, and then continues to the next general mold surface portion 21a with a step surface 21e. The taper groove 21d has a depth of 0.2 mm at the deepest portion, and the pitch between the taper grooves 21d, that is, the pitch between the stepped surfaces 21e is 4 mm.

  4 and 5 also show the die-cutting direction of the resin molded body. On both the first vertical surface 201 and the second vertical surface 202, the resin molded body is die-cut in a direction away from the step surfaces 21b and 21e.

  Accordingly, the resin molded body has a plurality of tapered convex portions formed by the tapered grooves 21c and 21d on the surface formed by the first vertical surface 201 and the second vertical surface 202. There will be no undercutting. Further, the convex portion formed by the tapered groove 21c of the flat mold surface 203 does not interfere with the vertical wall of the mold opening. Therefore, the molded product can be easily punched.

(Comparative Example 1)
A mold similar to Example 1 was used as Comparative Example 1 except that the stepped portion 21 was not formed.

<Test example>
Using the molds of Example 1 and Comparative Example 1, resin molded bodies were molded from ABS resin. The molding conditions were a molten resin speed of 12 cm / second and a molten resin temperature of 230 ° C.

  The obtained resin molded body was subjected to a cleaning process, and then the resin molded body was immersed in a moderately heated mixed solution of chromic acid and sulfuric acid to etch the design surface. Next, a Pd catalyst was adhered to the design surface, and a nickel plating layer was formed by electroless plating. Further, a metal chromium plating layer was formed on the surface of the nickel plating layer by electrolytic plating.

  The obtained resin-molded product with metal plating was allowed to stand at 25 ° C. for 48 hours, and was then subjected to a film property measuring device (“Autograph AGS-500ND” manufactured by Shimadzu Corporation) at a tensile rate of 25 mm / min and 20 ° C. The peel strength of the plating film was measured. The results are shown in Table 1.

  From Table 1, it can be seen that according to the injection mold of Example 1, the peel strength of the plating film is remarkably improved as compared with Comparative Example 1, which is an effect obtained by forming the step portion 21. . The reason for the peel strength of the plating film on the design surface corresponding to the surface formed by the first vertical surface 201 and the second vertical surface 202 is unknown, but the first vertical surface 201 is the second vertical surface. It was higher than 202. Therefore, the groove shape of the flat surface 203 is preferably a tapered groove 21c whose depth gradually decreases toward the front side with respect to the main flow direction of the molten resin, like the first vertical surface 201.

1: Fixed type 2: Movable type
10: First mold surface 20: Second mold surface 21: Stepped part
21a: General mold surface 21b, 21e: Stepped surface 21c, 21d: Tapered groove
201: First vertical surface 202: Second vertical surface 203: Flat surface

Claims (6)

A first mold surface for molding a design surface on which metal plating of the resin molded body is performed, and a second mold surface that molds a back surface opposite to the design surface and faces the first mold surface. On the two mold surfaces, along the main flow direction of the molten resin flowing through the cavity formed by the first mold surface and the second mold surface at the time of injection molding, one step higher from the general mold surface portion with a step surface or A plurality of step portions extending low and then continuing to the general mold surface portion are formed,
The step surface intersects the main flow direction, the second mold surface is a mold surface extending in the mold drawing direction of the resin molded body, and the step portion is on the side opposite to the mold drawing direction from the step surface. A mold for resin injection molding, characterized by being a taper step portion that continues to the general mold surface portion gradually toward or toward the die cutting direction.   The mold for resin injection molding according to claim 1, wherein an interval between the step surfaces in a direction parallel to the main flow direction is in a range of 2 mm to 20 mm.   The mold for resin injection molding according to claim 1 or 2, wherein the stepped portion has a step (height of the stepped surface) with respect to the general mold surface portion in a range of 0.1 mm to 0.3 mm.   4. The resin injection molding according to claim 1, wherein the general mold surface portion and the step surface intersect in an edge shape in a cross section obtained by cutting the step portion along a plane parallel to the main flow direction. Mold.   A resin molded body is formed by injection molding a thermoplastic resin using the resin injection mold according to any one of claims 1 to 4, and a metal plating layer is formed on a design surface of the resin molded body. A method for producing a resin molded product.   The method for producing a resin molded product according to claim 5, wherein the thermoplastic resin includes butadiene rubber particles.

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