JPH02215511A - Manufacturing method of illuminated switch parts - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention provides an illuminated switch - that is, a light source that allows only the characters and marks to pass through and is blocked from light, so that the characters and marks can be displayed even in the dark. This is a new method for manufacturing switches that appear floating. Illuminated switches are widely used as buttons, switches, etc. in various electrical and electronic devices such as automobiles, audio equipment, and VTRs.

[Conventional technology and its problems]

Currently, the manufacturing methods of illuminated switches are as follows.
There are methods like ~■.

(2) A method in which buttons are injection molded using a light-transmitting resin, the surface of which is undercoated if necessary, then metal is sputtered, predetermined characters and marks are laser engraved, and a top coat is applied.

(2) A method in which buttons are injection molded using a light-transmitting resin, predetermined characters and marks are masked on the surface of the buttons, and after plating, the mask is peeled off.

■A method of forming a button with a hole and pasting a printed sheet with a light-shielding layer on it, leaving letters and marks so as to cover the hole.

In addition, there are two methods (1) and (2) below that have been used to add characters to the buttons of telephones, keyboards, calculators, etc., and are used for illuminated switches.

■A method in which the 0 character to mark part is molded with transparent resin, and the surrounding area is double molded with light-shielding resin.

(2) A method in which a light-shielding part and a light-transmitting part having characters or marks are separately molded, and the light-transmitting part is fitted into the light-shielding part to integrate them.

The above methods ■ and ■ can produce beautiful and good-quality molded products, but the buttons to be inserted are made on three-dimensional surfaces by sputtering and plating, which makes it difficult to produce good-quality buttons. However, it has the disadvantage of being prone to defects. In addition, the above method (■) has the advantage that the light-shielding part can be created by plane printing or painting, but it requires a process of gluing it to each molded product, which is likely to cause poor appearance. . Also, method ■ is
There are constraints such as the mold being extremely complex and expensive, and in some cases it may not be possible to provide a lighting section.
Method (2) requires multiple molds and molding, making it extremely expensive, and also requires an assembly process, which poses a problem in terms of cost.

[Means to solve the problem]

As a result of studying a method for manufacturing a lighted switch that is superior in productivity and beautiful compared to conventional methods for manufacturing illuminated switches, the present invention forms a predetermined light-shielding portion with a light-transmitting character or mark. We discovered the possibility of solving this problem by using a sheet made of aromatic polycarbonate as an insert component, and after intensive study, we completed the process.

That is, in the present invention, a predetermined light-shielding portion having light-transparent characters or marks is formed on a light-transparent aromatic polycarbonate sheet having a thickness of 0.1 to 2.0 mm, and the sheet is This is a method for manufacturing an illuminated switch component in which a cut piece cut into a shape is inserted into a mold cavity, and then a thermoplastic resin is injection molded to integrate the cut piece and the injected resin. be preformed;
The cut piece is a punched piece obtained by preforming and punching, the cut piece has a plurality of light-shielding parts connected by one or more connecting parts, and the illumination This is a method for manufacturing an illuminated switch component, in which the illuminated switch component has a functional part.

The present invention will be explained below.

The aromatic polycarbonate sheet having a thickness of 0.1 to 2.0 mm in the present invention may be any ordinary polycarbonate and is not particularly limited. Further, the sheet surface may be a smooth surface with gloss or a matte surface with unevenness and matte without gloss. Further, since the sheet resin is used to form light-transparent characters or marks, it may be colored with a suitable dye or pigment in a desired color as long as the light for that purpose is transmitted. Furthermore, from the viewpoint of adhesiveness with the resin used for injection molding, it is preferable that an adhesive layer is appropriately formed on the sheet surface on the side that is to be integrated with the thermoplastic resin for injection molding. Examples of adhesive layers include polycarbonate (PC), polycarbonate-polyester resin compositions, polycarbonate-ABS resin compositions, polycarbonate-bonate polyamide compositions, and other polycarbonate resins. In the case of a composition (PC alloy), a polycarbonate sheet without an adhesive layer; the injection resin is an acrylic resin such as polymethyl methacrylate (PMMA), polystyrene (PS), methyl methacrylate-styrene copolymer (MS), acrylonitrile-styrene In the case of copolymer (AS), acrylonitrile-butadiene-styrene copolymer (ABS), etc., polycarbonate sheet with an acrylic resin layer formed: polyvinyl chloride, and other general-purpose materials that do not require heat resistance. In case of use,
A polycarbonate sheet on which an EVA resin layer is formed is exemplified.

A light-shielding portion having a light-transmissive character or mark portion approximately in the center of the light-shielding portion is formed on the above-mentioned polycarbonate sheet. This method is not particularly limited, and may include conventionally known silk screen printing, hot stamping, painting, sputtering, and plating. The characters and marks are also not particularly limited, such as various characters, marks, and designs. Furthermore, as long as the letters and marks are transparent layers, white, milky white, clear colored, or printed with other paints or inks are preferably used.

The binder component of the ink or paint used to form the light-shielding portion is not particularly limited, and may be any binder component known for use with conventional polycarbonate resins. For example, the binder component is acrylic,
Examples include acrylic/alkyd type, amino/alkyd type, urethane type, acrylic/urethane type, epoxy type, vinyl chloride/vinyl acetate copolymer, and nitrocellulose. In addition to carbon black, light-shielding components include
Inorganic pigments include oxides such as titanium dioxide, red iron oxide, and cobalt blue, sulfides such as zinc sulfide, sulfates such as precipitated barium sulfate, hydrated silicates, silicates such as ultramarine, ferrocyanides such as navy blue, Metal powders such as aluminum powder and zinc powder, various hydroxides, chromates,
There are carbonates and phosphates, and organic pigments include azo pigments such as brilliant carmine 6B and disazo yellow.
It is made by appropriately using phthalocyanine pigments such as phthalocyanine blue, nitro pigments such as naphthol yellow S, condensed polycyclic pigments such as quinacridone red, and various other organic pigments and dyes. These binders,
Printing inks and paints are prepared by mixing colorants, appropriate solvents, additives, etc., and are applied to polycarbonate sheets and dried to form light-transparent characters and marks. If a metal-like appearance is desired, methods such as hot stamping, sputtering, vacuum deposition, and plating are used after masking the characters and marks, and if necessary, coating is applied to the underside and top.

The polycarbonate sheet on which the light-shielding part with the light-transmitting characters and marks has been formed as described above can be cut as is by punching or other means into cut pieces, or it can be preformed and used as cut pieces for mold inserts. Use it as a cut piece.

The preforming method is selected mainly depending on the desired product shape and required appearance, and examples include simple bending, cold or hot compression molding, and vacuum forming. Especially for those that require deep drawing shape, Drape form
It is convenient and preferable to employ a method that causes little change in the shape of the light-transmitting characters to marks using vacuum forming such as g or plug assist forming.

After preforming, a desired punching process is usually performed, but it is preferable to devise a preforming die and perform a punching process together with the preforming process.

After inserting the cut piece produced above into a mold, a transparent to light-transmitting or opaque to light-shielding thermoplastic resin is injected to obtain the illuminated switch of the present invention.

The type of thermoplastic resin used for injection molding is selected appropriately depending on the required performance of the light switch, its shape, etc., and the injection molding conditions are within the known range of the thermoplastic resin molding material used. It is something. A specific thermoplastic resin molding material is polycarbonate) (
PC), polycarbonate-polyester resin compositions (PC/PBT, PC/PT, PC/PCTA,
PC/PE such as PC/PCTO! S composition), polycarbonate-ABS resin composition (PC/ABS),
Polycarbonate-polyphenylene ether-polyester resin composition (PC/PPB/PE5), polycarbonate-polyamide resin composition (PC/PA), polycarbonate-polyester-polyamide resin composition (
PC/PBS/FA), other polycarbonate resin compositions (PC alloy): Acrylic resins such as polymethyl methacrylate (PMMA); polystyrene (PMMA);
S), methyl methacrylate-styrene copolymer MS
), acrylonitrile-styrene copolymer (AS),
Acrylonitrile-butadiene-styrene copolymer (A
Styrenic resins such as BS); polyphenylene ether-polystyrene resin compositions (PPB/PS), polyphenylene ether-polyamide resin compositions (PPB/PS);
P^), polyphenylene ether-polyester resin composition (PPB/PBS), other polyphenylene ether resin compositions (PPBT Roy); polyacecool resin and its composition; nylon-6 (PA6), nylon-66 ( PA66), nylon-6, 10 (P
A610), nylon-12 (PA12), nylon-MXD6 tonophoramide resin (PA); polyethylene terephthalate (PBT), polybutylene terephthalate (PBT), 1゜4-hexane dimetatool/terephthalic acid/isophthalic acid combination Polymer (PCT^L1
．． Examples include polyester resins such as 4-hexane dimetatool/ethylene glycol/terephthalic acid copolymer (PCTG); polyvinyl chloride (PVC), and engineering plastics and alloys thereof are particularly suitable.

Next, an example of the present invention will be explained based on the drawings.

1 is a perspective view of an illuminated switch with a mark according to the present invention, FIG. 2 is a sectional view of the illuminated switch with a mark shown in FIG. This figure shows the state in which a polycarbonate sheet with stamped marks is attached. 4a to 4h show examples of the arrangement of a marked polycarbonate sheet integrated with injection molded resin in an illumination switcher.

In Figure 2, the illuminated switch with the mark in Figure 1 is
A polycarbonate sheet with markings is deep-drawn and vacuum formed, and a punched piece [1] is injected into the polycarbonate resin containing carbon black [2] and a light transmitting part [2].
All but 3] have been glued together. Further, another functional part [4] is simultaneously formed on the lower left side of the light transmitting part using polycarbonate resin. FIG. 3 shows a state in which a punched piece 1 is attached to a predetermined part of a mold cavity in order to mold this illuminated switch.

In this example, the injection resin is not introduced into the mark part (light transmitting part 3), and since the injection resin is a light-shielding composition, the side of the sheet where the light-shielding part is formed is the injection resin side. Also, good products can be manufactured on the opposite side without any particular problems.

Next, Fig. 4 shows an example of the method of inserting the cut piece into the mold cavity (or the placement position as an illumination switch), and corresponds to the case of a: Fig. 3, respectively. It is.

b: Normally, a preformed cut piece is attached to the inner surface portion of the illuminated switch.

C: Manufactured by attaching a cut piece to a portion corresponding to the outer surface of the illuminated switch.

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

e: Manufactured by attaching a cut piece to the intermediate surface position of the illuminated switch.

f: Manufactured by simply attaching a cut piece to the inner surface portion of the illuminated switch.

g: A lighted switch is manufactured by attaching a preformed cut piece to a portion corresponding to the outer surface of the switch.

h: This is usually manufactured by attaching a preformed cut piece to the inner surface portion of the illuminated switch.

For a-f, it is preferable to use a light-shielding resin composition as the resin for injection molding, and in the case of gSh, it is essential to use a light-transmitting resin composition. Also, gS
In the case of h, since the injection resin is also introduced into the characters and marks, it is easy to form a design pattern such as a lens pattern or a matte pattern on the mold surface and transfer it to the molded product. In addition, in the case of g, it is also possible to extend the light-transparent resin part to the side of the molded product and illuminate that part for indirect illumination using the light-transparent composition part as a path for the illumination light. A single light source can illuminate multiple switches and buttons, and it is also extremely easy to form functional parts below the characters and marks. In addition, in the case of h, since the characters and marks are covered with a light-transparent resin, it is possible to create a sense of depth, and by changing the thickness of the light-transparent resin, it is possible to add a lens effect. It is possible.

Although the example of the method for manufacturing an illuminated switch of the present invention has been explained above with reference to the drawings, the present invention is not limited to the drawings.
Various other embodiments can be implemented as long as a cut piece of a polycarbonate sheet in which a light-shielding part with a light-transmitting character or mark part is formed in the center part of the flap is used.

For example, an example of the process for manufacturing a four-piece lighted switch using the deep-drawn cut piece of the present invention and a light-shielding injection molding resin is as follows: ■: Thickness 0.5- 2.
A predetermined light-shielding portion is formed on a polycarbonate sheet of 0IIfl+ at a predetermined position in a square shape by multilayer printing or the like.

(2) Preforming is performed by suppressing the mark portion with a plug using a vacuum forming method such as P1ug assembly forming. (Preventing each mark from shifting its position and minimizing mark deformation).

(2): Manufacture punched pieces in which each punched piece is connected at about two thin connecting parts.

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

■: Cut the gate and connection to obtain individual lighted switches.

It is. In addition, as another example, when forming light-transparent characters or marks on a polycarbonate sheet,
By inserting different characters and marks, we can manufacture illuminated switches with the same shape and the desired characters and marks, and manufacture according to the production plan and significantly reduce costs; To further streamline the assembly process by manufacturing a light switch with approximately the same layout as the assembled shape; in the case of multiple molds, insert the cut piece with the connecting part into the mold, and as soon as the mold closes. For example, molding is performed using a mold equipped with a cutting blade so that the connecting portions of the cut pieces can be cut, and the mold is opened to produce a molded product with the connecting portions separated.

Furthermore, the method for manufacturing the illuminated switch of the present invention as described above includes:
Since the illumination part is extremely easy to form, it is possible to form functional parts other than the switch function, such as spring parts, cam parts, lever parts, snap-fits, press-fits, metal inserts, and their low-molded parts. The assembly has the advantage that it is easy to add the necessary parts and the like at the same time using injection resin.

〔Example〕

Hereinafter, the present invention will be explained in detail with reference to Examples.

Example 1 A 40×5 polycarbonate sheet with a thickness of 0.5 mm and a light-transmitting mark portion of 7 u×10 mm in the center.
A 0 mm light-shielding portion was formed by multilayer printing.

This sheet was formed by vacuum forming and punched to have an outer diameter of 15 mm x 25 mm and a depth of 5 mm.
Die-cut pieces with a collar of mm were produced. Substantially no displacement of the light transmitting portion of this punched piece was observed, no deformation of the mark was observed, and there were no wrinkles at the corners.

External size 15mm x 25mm, depth 7III11, wall thickness 2
A mold having a shape of 2111ff1 corner on the outer periphery of the upper surface and having a shape similar to that shown in the attached FIG. 3 was used.

The punched piece obtained above is attached to the fixed side of the mold so that the light-shielding part becomes the outer surface of the molded product, and a light-shielding polycarbonate resin containing carbon black is injection molded to have the punched piece on the outer surface. A predetermined light-blocking switch component integrated with light-blocking polycarbonate was obtained.

Example 2 A polycarbonate sheet having an acrylic resin layer formed on one side with a thickness of 1.0 mm was used, and four light-shielding parts each having a light-transmitting part were formed on the polycarbonate surface. The light-shielding parts are arranged in a square shape with a distance between centers of 70 mm, and the size is 30 mm x 30 m111 with a diameter of about 6 mm in the center.
It has a light transmitting part of am x 6 mm.

Using a vacuum forming mold with four holes arranged in a square shape with an outer diameter of 20 mm x 20 mm and a depth of 4 mm with a distance between the centers of the holes of 70 mm, this sheet was made into a plug assembly.
Vacuum forming was performed using the tforming method so that printing appeared on the surface.

The preformed sheet was then cut into 30 mm x 30
3 mm width between the four light-shielding parts of am and the center of the side of the adjacent light-shielding part as a connecting part
.

A punched piece was manufactured leaving a section with a length of 50 mm.

This punched piece is arranged in the order of 70 centers and has a depth of 4 mm.
A tunnel is created by setting four holes of 0 m + o x 20 mm in the insert part of a mold arranged in a square shape, and by overlapping two of the four connecting parts facing each other with a part of the molten resin flow path (runner) part. A black colored ABS resin was injection molded from the inner surface of the sheet using a gate to obtain a molded product in which four predetermined light switches were connected. In addition, the movable side of the mold has a width of 3 cm and a depth of 1.1 cm, which corresponds to the seat connection part.
A groove of mm is formed.

After cutting the connecting portion and gate portion of this molded product to obtain individual light switch components, the adhesion between the ABS resin and the polycarbonate sheet was examined, and it was found that they were extremely strongly integrated.

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

Length, width, height each 20mm x 20mm x 10
A box-shaped molded product with an average wall thickness of 3 mm made of m+n% injection resin.
A trapezoidal part with a height of 1 tnrn and a width of 3 cm protrudes from the inside of the outer peripheral part of the bottom part, and a 6 mm x 6 mm part of the inner central part of the bottom part is recessed by 3 mm from the outer peripheral part, and the inner and outer recessed parts A mold having an upside-down shape as shown in the attached Fig. 4(d) was used, in which the thickness of the mold was 1.5 mm, and a punching piece was attached to the recessed part to be integrated with the injected resin.

After inserting the punched piece produced above into the inner and outer recesses described above with the light-shielding printed surface facing the outer bottom side of the mold, a black polycarbonate-ABS resin composition was injection molded to cover the outer periphery of the punched piece. A luminescent molded product which was shaped and integrated with the injection resin was obtained.

Example 4 The same procedure was used as in Example 3, except that a punched piece in which a light-shielding part having a light-transmitting part in the center was formed by hot stamping aluminum foil was used.

As a result, a luminescent molded product having a glittering surface was obtained.

Example 5 A 40X polycarbonate sheet with a 7 mm x 10 mm light transmitting mark in the center on a 0.5 mm thick polycarbonate sheet.
A 50 mm light-shielding portion was formed by multilayer printing.

This sheet was formed by vacuum forming and punched to produce a punched piece with an outer diameter of 12 mm x 22 mm and a depth of 3 cm.

In addition, the mold has an outer diameter of 15 mm x 25 mm and a depth of 5 mm.
It has a corner edge of 2111ff1 on the outer periphery of its upper surface, and has a wall thickness of 2
A box-shaped molded product with a diameter of mm was used.

The punched piece was attached to the core (inner surface) of the mold so that its printed surface became the inner surface of the molded product, and a transparent polycarbonate resin was injection molded to obtain a predetermined illuminated switch component.

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

[Operation and effect of the invention]

As is clear from the detailed description of the invention, examples, etc.,
The method for manufacturing illuminated switch parts of the present invention uses materials on which desired light-transmissive characters, marks, designs, etc. are formed by flat printing, etc., so molded products such as three-dimensional shaped buttons are manufactured and Manufacturing is extremely easy compared to a method in which desired light-transmissive characters, marks, designs, etc. are individually formed on the substrate. For this reason, it has the characteristic that it can easily be provided with other functions as a switch component.

Furthermore, since a polycarbonate sheet is used, good shaping with excellent productivity can be easily carried out by vacuum forming or the like.

Furthermore, since the illuminated switch parts are integrated with a polycarbonate sheet that has excellent impact resistance, even if materials with poor impact resistance such as polystyrene, polymethyl methacrylate, or other resins are used, the impact resistance will be reduced. It also has superior mechanical properties, and is of great industrial significance as it combines beauty, performance, and productivity.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of an illuminated switch with a mark according to the present invention, Fig. 2 is a sectional view thereof, and Fig. 3 is a schematic diagram showing a state in which a polycarbonate sheet with a mark is attached to a mold. be. FIGS. 4a to 4h show examples of the arrangement of a marked polycarbonate sheet integrated with injection molded resin in an illuminated switch. The numbers in the figure are 1: punching piece, 2: injection resin, 3: light transmitting part, 4
: Functional part, 5: Fixed side mold, 6: Movable side mold, 7: Mold cavity, 8: Product ejection pin. Patent applicant Mitsubishi Gas Chemical Co., Ltd. Agent Patent attorney (9070) Sadafumi Kobori Figure 1 Figure 3 Figure 2 Figure 4

Claims (1)

[Claims] 1. A predetermined light-shielding portion having light-transparent characters or marks is formed on a light-transparent aromatic polycarbonate sheet having a thickness of 0.1 to 2.0 mm, and the sheet is A method of manufacturing an illuminated switch component, which comprises inserting a cut piece cut into a predetermined shape into a mold cavity, injection molding a thermoplastic resin, and integrating the cut piece and the injection resin. 2. The method for manufacturing an illuminated switch component according to claim 1, wherein the cut piece is preformed. 3. The method of manufacturing an illuminated switch component according to claim 1, wherein the cut piece is a punched piece that is preformed and punched. 4. The method of manufacturing an illuminated switch component according to claim 1, wherein the cut piece has a plurality of the light-shielding parts connected by one or more connecting parts. 5. The method of manufacturing a light-emitting switch component according to claim 1, wherein the light-emitting switch component has a functional section.