JPH08267505A - Manufacture of insert-molded article and insert film - Google Patents

Abstract

PURPOSE: To realize the coincidence of the design of an insert-molded article with the shape of the modled article without positional slippage by a method wherein molten resin is injected under the condition that insert film is fixed so as to paste the insert film onto the surface of the molded article simultaneously with the molding of the molded article. CONSTITUTION: A female mold 1, which has a notched part 4 at the upper part of the side wall of a cavity 3 and pins 5 protruded from the bottom wall of the notched part 4, and a male mold 2, which has a projecting part 6 to be fitted to the notched part 4 under the state being adjacent to a core and having holes 7 to be fitted to the pins 5, are equipped. The holes 10 of the mounting pieces extending from an insert film 8 are inserted onto the pins of the female mold 1 so as to arrange the insert film 8 in the female mold 1. Next, after the insert film 8 is fixed through mold clamping, molten resin is injected in a space part made by the female mold 1 and the male mold 2 so as to mold an insert-molded article and simultaneously the insert film 8 is pasted onto the surface of the molded article.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an insert-molded product in which a resin is injection-molded and an insert film is attached to the molded product at the same time, and an insert film.

[0002]

2. Description of the Related Art In switch panels for office automation equipment such as facsimiles and copiers and FA equipment, and switch panels for home appliances such as microwave ovens, washing machines, rice cookers, etc., a painted film is attached to a molded product. The one attached is used. By covering the surface of the switch panel with a painted film, the switch panel can be decorated and surface protection functions such as chemical resistance, scratch resistance, and water resistance can be imparted to the switch panel.

As a method for obtaining a molded product obtained by laminating painted films, an insert film preliminarily cut into a desired shape is supplied into a mold for injection molding, and the insert film is molded into a molded product at the same time when the molded product is molded. There is an insert molding method that sticks together. In the insert molding method, since the insert film can be attached at the same time as molding in the mold, the manufacturing process can be greatly simplified. Further, when the painted film is attached to the molded product with an adhesive, air bubbles may be trapped, but such adhesion failure does not occur. Further, since the insert film is stretched by the injection pressure of the molten resin and follows the mold, there is an advantage that a three-dimensional switch panel can be easily obtained.

[0004]

However, the conventional method for producing an insert-molded article and the insert film have the following problems.

That is, in order to fix the insert film in the mold, the back surface of the insert film is charged with static electricity and is inserted into the bottom surface of the concave cavity, and the film is attached to the bottom surface of the cavity by the action of static electricity. I used to make fine holes in the bottom of the cavity and vacuum suction to attach the insert film to the bottom of the cavity.
In both cases, the adhesive force to the cavity bottom surface of the insert film is weak, so the insert film may fall off during the process of closing the mold, or the position of the insert film may not be stable due to the vibration of the molding machine and the desired design may not be obtained. there were.

Therefore, it is an object of the present invention to provide a method for manufacturing an insert-molded article and an insert film, which solve the above-mentioned drawbacks.

[0007]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a method for manufacturing an insert-molded article, comprising a pin having a cutout portion on the upper side wall of a cavity and protruding from a bottom wall of the cutout portion. A mold having a concave mold having a hole and a convex mold having a protruding part that is fitted to the cutout part adjacent to the core and having a hole to be fitted with a pin in the protruding part, and a mounting piece having a hole. Using the insert film provided, insert the hole of the mounting piece of the insert film into the concave pin to arrange the insert film in the concave type, then clamp the insert film to fix the insert film, and then the concave type and convex type. A molten resin was injected into the space of the above to form an insert-molded product, and at the same time, an insert film was attached to the surface of the molded product.

Further, according to the present invention, in order to achieve the above object, the insert film is constructed such that a mounting piece having a hole is extended.

Further, in the present invention, in the above-mentioned insert film, "a plurality of mounting pieces may be provided.

The present invention will be described in more detail with reference to the drawings.

FIG. 1 is a perspective view showing an embodiment of a method of manufacturing an insert-molded product and an insert film according to the present invention. 2 to 4 are cross-sectional views taken along the line AA in FIG. 1 showing one step of the method for manufacturing the insert-molded product of the present invention. Figure 5
It is a top view which shows one Example of the insert film of this invention. FIG. 6 is a plan view showing another embodiment of the insert film of the present invention. 7 to 8 are plan views showing other embodiments of the insert piece of the insert film of the present invention. FIG. 9 is a plan view showing another embodiment of the hole of the insert film of the present invention.

1 is a concave type, 2 is a convex type, 3 is a cavity, 4
Is a notch, 5 is a pin, 6 is a protrusion, 7 is a hole, 8 is an insert film, 9 is a mounting piece, 10 is a hole, and 11 is a molten resin.

According to the present invention, a pin 5 projecting from the bottom wall of the notch 4 has a notch 4 in the upper part of the side wall of the cavity 3.
And a convex mold 2 having a projecting portion 6 adjacent to the core and fitted with the notch 4 and having a hole 7 into which the pin 5 is fitted. Using the insert film 8 in which the mounting piece 9 having the hole 10 is extended, the hole 10 of the mounting piece 9 of the insert film 8 is inserted into the pin 5 of the concave die 1.
To insert the insert film 8 in the concave mold 1, then clamp the mold to fix the insert film 8, and then inject the molten resin 11 into the space between the concave mold 1 and the convex mold 2 to insert molded product. The insert film 8 is attached to the surface of the molded product at the same time when the above is formed.

The mold comprises a concave mold 1 and a convex mold 2.
The concave mold 1 is provided with a notch 4 on the upper side wall of the cavity 3 and a pin 5 protruding from the bottom wall of the notch 4.
The cross section of the pin 5 may have any shape, and may be circular or square. If the cross-sectional area of the pin 5 is the same as that of the hole 10 of the mounting piece 9 or is made slightly smaller, the positional deviation is less likely to occur. It is preferable that the pin 5 has a tapered shape with a thin tip and a thick root because the mounting piece 9 can be easily inserted into the hole 10. In this case, the diameter of the root of the pin 5 should be the same as the diameter of the hole 10 of the mounting piece 9. The convex mold 2 is provided with a protrusion 6 that is fitted to the cutout portion 4 adjacent to the core, and the protrusion 7 has a hole 7 that is fitted to the pin 5.
To provide. The mold has a parting line with a cavity 3
Take deep from the bottom. That is, the concave mold 1 having the cavity 3 with the side wall formed on the outer periphery is formed. Although the mold may be configured such that the back surface of the mounting piece 9 has the molding resin, or the mold may be configured so that the molding resin does not go around the back surface of the mounting piece 9, the mounting piece 9 is removed after the molding. Therefore, if there is no molding resin on the back surface of the mounting piece 9, the processing after molding is easier.

The insert film 8 is formed by extending a mounting piece 9 having a hole 10 and forming a pattern layer, an adhesive layer and the like on a base sheet (see FIG. 5).

As the material of the base sheet, a resin sheet of polypropylene resin, polyethylene resin, polyamide resin, polyester resin, acrylic resin, polyvinyl chloride resin or the like, metal foil such as aluminum foil or copper foil, It is preferable to use a glass sheet such as glassine paper, coated paper, cellophane or the like, or a laminate of the above-mentioned sheets, which is used as a base sheet of a normal transfer material. Alternatively, a base sheet having both surfaces coated may be used.

Next, a pattern layer is formed. The pattern layer is usually composed of either a colored layer or a metal thin film layer, or both. The place where the colored layer and the metal thin film layer are formed is not limited, and may be the entire surface or a partial area.

The colored layer is formed on the base sheet. As the material of the colored layer, polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, resin such as alkyd resin is used as a binder. It is preferable to use a colored ink containing a pigment or dye of an appropriate color as a colorant. As a method for forming the colored layer, an offset printing method,
Printing methods such as gravure printing and screen printing,
There are coating methods such as a gravure coating method, a roll coating method and a spray coating method. In particular, offset printing and gravure printing are suitable for multicolor printing and gradation expression.

The metal thin film layer is formed on the base sheet.
If there is a colored layer, it is formed on the colored layer. The metal thin film layer is provided to express a metallic luster itself or a hairline pattern having metallic luster. The metal thin film layer is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method or the like. Depending on the metallic luster color you want to express, the metal thin film layer can be made of aluminum, nickel, gold, platinum,
Chrome, iron, copper, tin, indium, silver, titanium,
Metals such as lead and zinc, alloys or compounds thereof are used. The metal thin film layer can be formed entirely or partially. As a method of partially forming a metal thin film layer, after forming a solvent-soluble resin layer in a portion that does not require a metal thin film layer, a metal thin film is formed on the entire surface thereof,
There is a method of cleaning with a solvent to remove an unnecessary metal thin film together with the solvent-soluble resin layer. Often used as a solvent is water or an aqueous solution. Further, as another method of partially forming the metal thin film layer, a metal thin film is formed on the entire surface, then a resist layer is formed on a portion where the metal thin film is to be left, and etching is performed with an acid or an alkali, There is a method of removing the layer.

A pre-anchor layer may be formed to improve the adhesion between the base sheet or the colored layer and the metal thin film layer. Further, a rear anchor layer may be formed in order to improve the adhesion between the metal thin film layer and the adhesive layer. As the material of the front anchor layer and the rear anchor layer, two-component curable urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin,
It is preferable to use a chlorine-containing vinyl resin, an acrylic resin, an epoxy resin, a vinyl copolymer resin, or the like. As a method of forming the front anchor layer and the rear anchor layer, there are a printing method such as a gravure printing method and a screen printing method, and a coating method such as a gravure coating method, a roll coating method and a spray coating method.

The adhesive layer adheres the above layers to the surface of the molded product. The adhesive layer is entirely formed on the metal thin film layer or the rear anchor layer. The adhesive layer is required to firmly adhere to the molded product. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molded product is appropriately used. For example, when the material of the molded product is acrylic resin, acrylic resin may be used. Also,
When the material of the molded product is polyphenylene oxide / polystyrene resin, polycarbonate resin, styrene copolymer resin, polystyrene blend resin, acrylic resin, polystyrene resin, polyamide resin, which has affinity with these resins, Alternatively, a copolymer resin of these or the like may be used. When the material of the molded product is polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, coumarone indene resin, or a resin composition in which these resins are appropriately mixed, etc. Should be used. As a method for forming the adhesive layer, there are a printing method such as a gravure printing method and a screen printing method, and a coating method such as a gravure coating method, a roll coating method and a spray coating method.

A mounting piece 9 having a hole 10 is extended on the insert film 8. The mounting pieces 9 may be provided at two upper and lower locations around the insert film 8 (see FIG. 1) or at only one location (FIG. 5) as long as they can be arranged in the mold without displacement. Alternatively, a large number may be provided (see FIG. 6). The shape of the hole 10 can be any shape such as a circle or a quadrangle.
Further, the hole 10 is not limited to a shape in which the periphery is all closed,
The shape may be partially open (see FIG. 9). Since the mounting piece 9 is an unnecessary portion after the insert-molded product is molded, perforations, large cutting lines (see FIG. 7), or cutouts may be provided for easy removal. . The attachment piece 9 can be provided by punching with Thomson or a die, or cutting with a router or the like.

In this way, the insert film 8 can be obtained.

Hole 10 in mounting piece 9 of insert film 8
Is inserted into the pin 5 of the concave mold 1 to arrange the insert film 8 in the concave mold 1 (see FIG. 3).

Here, the insert film 8 may be heated so that the insert film 8 can easily follow the mold. For heating, an infrared heater, a nichrome heater, or the like may be placed near the insert film 8.

Then, the mold is clamped and the insert film 8
And then the molten resin 11 is injected into the space between the concave mold 1 and the convex mold 2 to form an insert molded product, and at the same time, the insert film 8 is attached to the surface of the molded product (see FIG. 4).

As the molten resin 11, a general-purpose resin such as polystyrene resin, polyolefin resin, ABS resin, AS resin, acrylic resin can be used. In addition, general-purpose engineering resins such as polyphenylene oxide / polystyrene resin, polycarbonate resin, polyacetal resin, polycarbonate-modified polyphenylene ether resin, polybutylene terephthalate resin, polybutylene terephthalate resin, and ultrahigh molecular weight polyethylene resin can be used. Further, super engineering resins such as polysulfone resin, polyphenylene sulfide resin, polyphenylene oxide resin, polyarylate resin, polyetherimide resin, polyimide resin, liquid crystal polyester resin, and polyallyl heat resistant resin can be used. Further, a composite resin to which a reinforcing material such as glass fiber or an inorganic filler is added can be used.

In this way, an insert molded product can be obtained.

[0029]

The present invention having the above construction has the following operation.

In the method for manufacturing an insert-molded product according to the present invention, a concave mold having a cutout portion on the upper side wall of the cavity and a pin protruding from the bottom wall of the cutout portion, and the cutout portion adjacent to the core are fitted together. Using a mold consisting of a convex mold having a projection part having a hole fitted to the projection part and an insert film in which a mounting piece having a hole is extended, a hole of the mounting piece of the insert film is formed. When inserting the insert film into the concave pin and arranging the insert film in the concave mold, then clamping the insert film to fix the mold, and then injecting molten resin into the space between the concave mold and the convex mold to form the insert molded product. At the same time, since the insert film is attached to the surface of the molded product, the insert film is fixed by the pins and the positional displacement does not occur in the cavity.

Further, the insert film of the present invention is
Since the attachment piece having the hole is extended, the attachment piece is fitted and fixed to the concave pin.

[0032]

EXAMPLE A polyethylene terephthalate film having a thickness of 125 μm was used as a base sheet, and a pattern layer and an adhesive layer were formed thereon by a printing method. Then, the outer periphery was cut into a shape of a molded product with a Thomson blade to obtain an insert film having a mounting piece with a circular hole having a diameter of 5 mm.

Next, the mold was clamped, but the insert film did not drop even though the cavity surface was vertical. After injecting the ABS resin, when the mold was opened, the hole of the mounting piece was easily pulled out from the pin, and at the same time when the molded product was molded, an insert molded product integrated with the insert film could be obtained.

The insert-molded article thus obtained is
The shape of the molded product and the design of the insert film matched without any displacement.

[0035]

The method of manufacturing an insert-molded product according to the present invention has the following effects because it has the above-described operation and configuration.

In the method of manufacturing the insert-molded product of the present invention, the insert film is fixed by the pins and does not cause a positional shift in the cavity, so that the design of the insert-molded product does not have a positional shift that matches the shape of the molded product. Can be easily obtained. It is also easy to insert the insert film into the mold and position it. Moreover,
The insert film does not fall off when closing the mold.

Further, the insert film of the present invention is
Since the insert-molded product is fixed in conformity with the concave pin, the design of the insert-molded product can be matched with the shape of the molded product without misalignment. It is also easy to insert and position in the mold. Moreover, it does not fall out of the cavity when the mold is closed.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a method for manufacturing an insert-molded product and an insert film of the present invention.

FIG. 2 is a cross-sectional view taken along the line AA in FIG. 1 showing one step of the method for manufacturing the insert-molded product of the present invention.

FIG. 3 is a cross-sectional view taken along the line AA in FIG. 1, showing one step of the method for manufacturing the insert-molded product of the present invention.

FIG. 4 is a cross-sectional view taken along the line AA in FIG. 1 showing a step of the method for manufacturing the insert-molded article of the present invention.

FIG. 5 is a plan view showing an embodiment of the insert film of the present invention.

FIG. 6 is a plan view showing another embodiment of the insert film of the present invention.

FIG. 7 is a plan view showing another embodiment of the attachment piece of the insert film of the present invention.

FIG. 8 is a plan view showing another embodiment of the insert piece of the insert film of the present invention.

FIG. 9 is a plan view showing another embodiment of the holes of the insert film of the present invention.

[Explanation of symbols]

 1 Concave type 2 Convex type 3 Cavity 4 Notch part 5 Pin 6 Projection part 7 Hole 8 Insert film 9 Mounting piece 10 Hole 11 Molten resin

Claims (3)

[Claims] 1. A concave mold having a cutout portion on an upper portion of a side wall of a cavity and having a pin projecting from a bottom wall of the cutout portion, and a projection portion having a projection portion adjacent to the core and fitted with the cutout portion. Using a mold consisting of a convex mold having a hole to be fitted with a pin, and an insert film in which a mounting piece having a hole is extended, the hole of the mounting piece of the insert film is inserted into a concave pin to insert film Is placed in a concave mold, and then the mold is clamped to fix the insert film, and then the molten resin is injected into the space between the concave mold and the convex mold to form an insert molded product, and at the same time, the insert film is formed on the surface of the molded product. A method for manufacturing an insert-molded product, which comprises laminating them together. 2. An insert film, wherein a mounting piece having a hole is extended. 3. The insert film according to claim 2, which has a plurality of attachment pieces.