JPH11188755A - Insert molded article having window part and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an insert molded article having a window part covered with a sheet free from waviness or the like and a manufacturing method of the insert molded article having the window part which enables attainment of the article with an excellent yield. SOLUTION: An insert sheet 1 having at least a pattern layer formed on a base sheet and an injection mold composed of a mold (A) and a mold (B) having a projecting part for forming a through hole and a molding resin injection port being used, first the insert sheet 1 is positioned between the mold (A) and the mold (B) and the fore end of the projecting part of the mold (B) for forming the through hole is struck on a part of the surface of the mold (A), by closing the mold, so that a cavity be formed. Simultaneously with injection molding of an injection-molded article 12 having the through hole, the insert sheet is so fusion-bonded and integrated as to cover the through hole 11 at least, by the execution of the injection molding. After an insert molded article having the window part is taken out of the injection mold, the part of the insert sheet 1 covering the through hole 11 of the injection molded article 12 is heated to be flattened.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an operation panel attached to OA equipment and FA equipment such as facsimile machines and copiers, a membrane switch attached to electric appliances such as a microwave oven, a washing machine and a rice cooker, and a print of AV equipment. The present invention relates to a method for manufacturing an insert molded product having a window used for a panel, an instrument panel of an automobile, and the like.

[0002]

2. Description of the Related Art There are the following methods for producing an insert molded product used as a conventional membrane switch. That is, an insert sheet having a pattern layer and an adhesive layer formed on a base sheet, and a mold A having a concave portion.
B having a protrusion for forming a through hole and a molding resin injection port
First, the insert sheet is positioned in the recess of the mold A, and the mold A and the mold B are used.
By closing the mold, the tip of the projection for forming a through-hole of the mold B is brought into contact with the inner surface of the recess of the mold A to form a cavity, and injection molding is performed. Simultaneously with the injection molding, the insert sheet is fused and integrated so as to cover at least the through hole, and the insert molded product having the window portion is taken out from the injection mold.

[0003]

The insert molded product taken out of the injection mold is cooled, so that the resin shrinks and the area of the through hole is reduced.
On the other hand, the portion of the insert sheet that covers the through hole of the injection molded product does not shrink as much as the injection molded product. For this reason, in the portion of the insert sheet that covers the through-hole of the injection-molded product, a so-called “wavy” or “sag” in which the sheet exhibits a distorted dent or distorted swelling occurs (see FIG. 8). Therefore, the design of the insert molded product is impaired, and the liquid crystal display and the LED coloring arranged in the window of the insert molded product are easily distorted and appear, and the yield is poor.

The present invention solves the above-mentioned drawbacks, and provides an insert-molded article having a window covered with a sheet having no wavy or the like and a method of manufacturing the insert-molded article having a window capable of obtaining the same at a high yield. The purpose is to do.

[0005]

Means for Solving the Problems In order to achieve the above object, the present invention is as follows. The method of manufacturing an insert molded product having a window according to the present invention described in claim 1 is
Using an insert sheet having at least a pattern layer formed on a base sheet, a mold A, and an injection mold including a mold B having a through hole forming projection and a molding resin injection port, First, the insert sheet is positioned between the mold A and the mold B, and the mold is closed so that the tip of the protrusion for forming a through hole of the mold B abuts against a part of the surface of the mold A to form a cavity. Is formed, and at the same time as the injection molding of the injection molded article having the through hole, the insert sheet is fused and integrated so as to cover at least the through hole, and the insert molded article having the window portion is injection molded. A method for manufacturing an insert molded product having a window portion, wherein a portion of the insert sheet covering the through hole of the injection molded product is flattened by heating after removing the insert molded product from the mold.

According to a fifth aspect of the present invention, there is provided a method of manufacturing an insert molded product having a window portion, comprising the steps of: forming an insert sheet having at least a pattern layer formed on a base sheet;
B having a protrusion for forming a through hole and a molding resin injection port
First, the insert sheet is positioned between the mold A and the mold B by using an injection molding mold consisting of: Is pressed against a part of the surface of the mold A to form a cavity, and injection molding is performed. At the same time as injection molding of an injection molded product having a through hole, an insert sheet is integrally fused so as to cover at least the through hole. After taking out the insert molded product having the window from the injection molding die, the sheet portion of the insert sheet covering the through hole of the injection molded product is heated and pressed by the shaping plate having the convex curved surface portion. A method for producing an insert molded product having a window portion characterized by having a convex curved surface.

According to the method for manufacturing an insert-molded product having a window according to the present invention, an insert sheet having at least a pattern layer formed on a base sheet, a mold A having a concave curved surface portion, First, an insert sheet is positioned between the mold A and the mold B by using an injection molding mold including a through hole forming projection and a mold B having a molding resin injection port, and the mold is closed. Then, the tip of the projection for forming a through hole of the mold B is abutted against a part of the concave curved surface portion of the mold A to form a cavity, and injection molding is performed. Simultaneously with the injection molding, the insert sheet is fused and integrated so as to cover at least the through hole, and the insert molded product having the window portion is taken out from the injection molding die, and then the through hole of the injection molded product in the insert sheet is formed. Covering While heating the portion, the shaping plate having a convex curved surface portion corresponding to the curvature of the concave curved surface portion of the mold A is pressed against the portion, and the portion corresponding to the curvature of the surface of the injection molded article is pressed. A method for producing an insert molded product having a window portion, wherein the insert molded product has a convex curved surface.

According to a tenth aspect of the present invention, there is provided an insert-molded product having a window, wherein a portion of the insert sheet covering the through-hole of the injection-molded product has no wavy or slack. It is a state.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in more detail. The insert sheet 1 used in the method of manufacturing an insert molded product having a window according to the present invention will be described.
The insert sheet 1 has at least a pattern layer formed on a base sheet.

[0010] As the base sheet, a thickness of 100 to 250
μm polyethylene terephthalate film, thickness 80
~ 300 μm polycarbonate film, thickness 50 ~
250 μm unstretched polyester film, thickness 30 to
250 μm acrylic film, 12 to 25 μm thick fluorine film, 10 to 50 μm thick ethylene vinyl alcohol film, 12 to 100 μm thick unstretched polypropylene film, 20 to 100 μm thick unstretched polybutylene terephthalate film, thickness 10 to 10
0 μm cellulose acetate film, thickness 10-1
00 µm polystyrene film, thickness 10-100 µ
m polyvinyl chloride film. In order to make LEDs and the like placed inside the insert molded product visible from the outside through the window of the insert molded product,
Transparent substrate sheets are preferred. In addition, thickness 100-25
0 μm polyethylene terephthalate film, thickness 8
0-300 μm polycarbonate film, thickness 50
An unstretched polyester film of 100 μm to 100 μm is particularly preferable when a membrane switch having a window is manufactured.

The pattern layer is formed on the entire surface or a part of the surface of the base sheet. The picture layer is a layer for decorating the whole or a part of the surface of the injection molded article with characters, figures, symbols, and the like. The picture layer includes not only a pigment ink layer but also a metal vapor-deposited layer composed of a vapor-deposited film, a glitter pigment layer composed of a pearl pigment and a resin binder, and a dye ink layer composed of a dye and a resin binder. Further, the picture layer may have a light-shielding property for completely blocking light, or may have a light-transmitting property for slightly transmitting light. The picture layer may be formed using a material having adhesiveness to a molding resin. The picture layer may be formed by a normal printing method such as an offset printing method, a gravure printing method or a screen printing method, or a coating method such as a roll coating method or a spray coating method.

[0012] The transparent portion of the insert sheet may be formed by a portion where the pattern layer is not formed (also referred to as a "cut portion"). The transparent portion of the insert sheet is effective when LEDs and the like disposed inside the insert molded product can be seen from the outside through the window of the insert molded product.

If necessary, an adhesive layer may be formed on the picture layer. The adhesive layer is a layer for improving adhesiveness with a molding resin described later, that is, an injection molded product. As the material of the adhesive layer, polyvinyl chloride-vinyl acetate copolymer resin,
An acrylic resin, a urethane resin, a polypropylene resin, and the like can be given. The adhesive layer may be formed by a normal printing method such as an offset printing method, a gravure printing method, a screen printing method, a roll coating method, a spray coating method, or the like. The adhesive layer may be an adhesive sheet. For example, there is a laminate obtained by laminating an acrylonitrile butadiene styrene resin sheet of 250 μm at 160 ° C. In addition, when the adhesiveness with the molding resin can be obtained only by the pattern layer without the adhesive layer, the adhesive layer can be omitted. An adhesive layer formed using a transparent resin is preferable in order to allow the LEDs and the like arranged inside the insert molded product to be easily seen from the outside through the window of the insert molded product.

The method for manufacturing an insert molded product having a window according to the present invention described in claim 1 may be performed in the following order (see FIGS. 5 to 10).

First, the insert sheet 1 is positioned between the mold A2 and the mold B3 (see FIG. 5). In positioning, the insert sheet 1 having a transparent portion is used, and the insert sheet 1 is positioned between the mold A2 and the mold B3 such that the transparent portion covers the through hole 11 of the injection molded product 12. You may make it. The mold A2, which is an element of the injection mold, may have the concave portion 4.
The mold B3 has a projection 5 for forming a through-hole and a molding resin injection port 6. As a specific example, the insert sheet 1 is unwound from an insert sheet supply roll means (not shown) in which the long insert sheet 1 is wound into a roll, and a predetermined distance between the mold A2 and the mold B3 is obtained. When the predetermined position of the insert sheet 1 reaches the position, the unwinding operation is stopped, and the insert sheet 1 may be pressed against the parting surface of the mold A2 by a clamp member (not shown). After pressing the insert sheet 1 against the parting surface of the mold A, the insert sheet 1 may be heated and softened, and the insert sheet 1 may be brought into close contact with the inner surface of the concave portion 4 of the mold A2 by, for example, vacuum suction. The insert sheet 1 that has passed through a predetermined position between the mold A2 and the mold B3 may be wound by insert sheet winding roll means (not shown) or the like. Alternatively, the sheet-like insert sheet 1 from which an unnecessary portion has been cut out may be put into the mold A2 manually or by a robot arm and positioned. Alternatively, insert sheet 1 is inserted into mold A2.
Before positioning between the mold A3 and the mold B3, the insert sheet 1 may be formed into a shape so as to be in close contact with, for example, the inner surface of the recess 4 of the mold A2. The surface of the mold A2 may have a concave curved surface around the portion where the tip of the through-hole forming projection 5 of the mold B3 abuts when the mold is closed.

Next, by closing the mold A2 and the mold B3, the tip 8 of the through hole forming projection 5 of the mold B3 is closed.
Is pressed against a part of the surface of the mold A2 to form the cavity 9 (see FIG. 6), and the molding resin 10 is ejected from the molding resin injection port 6 to be injection-molded, whereby an injection-molded article having a through hole 11 is formed. Simultaneously with the injection molding of No. 12, the insert sheet 1 is fused and integrated so as to cover at least the through hole 11 (see FIG. 7), and the insert molded product having the window portion is taken out from the injection molding die (see FIG. 8). ). The protrusion 5 for forming a through hole of the mold B3 is for forming the through hole 11 in the injection molded product 12. In addition, using the mold A2 having the concave curved surface portion 13, the tip 8 of the through-hole forming convex portion 5 of the mold B3 may be abutted against a part of the concave curved surface portion 13 to form the cavity 9 (FIG. 13). Even if the molding resin 10 is injected into the cavity 9, the molding resin 10 does not flow into a portion of the surface of the mold A <b> 2 where the tip 8 of the projection 5 for forming a through hole abuts. Molding resin for injection molding 10
Examples thereof include polypropylene resin, acrylonitrile butadiene styrene resin, polystyrene resin, acrylic resin, acrylic styrene resin, vinyl resin, polycarbonate resin, and nylon resin. Note that a colored resin may be used as the molding resin.

Next, a portion of the insert sheet that covers the through hole 11 of the injection molded article 12 is heated and flattened. When the insert molded product having the window portion is removed from the mold, the area of the through hole 11 is reduced due to the resin shrinkage of the injection molded product. "Waviness" occurs (see FIG. 8). However, it is softened once by heating (see FIG. 9), and is flattened without “sag” or “undulation” (see FIG. 10). Therefore, a portion of the insert sheet 1 that covers the through hole 11 of the injection molded product 12 becomes flat (see FIG. 10). The reason why the portion of the insert sheet 1 that covers the through hole 11 of the injection molded article 12 becomes flat by heating is considered to be due to the shape memory property of the film used as the base sheet that shrinks when heated. The shrinkage of the film is 2
Larger ones are stretched in the axis or uniaxially.

As one specific example, the heating is performed by the heater 1
4 can be performed without contacting the insert sheet 1 (see FIG. 9). For example, the size of the through hole 11 of the injection molded product 12 is a rectangle of 30 mm × 16 mm, and the thickness of the insert sheet 1 is 188 μm to 190 μm.
In the case of m, the temperature of the heater 14 may be set to 250 ° C., the heating time may be set to about 30 seconds to 60 seconds, and the distance to the insert sheet 1 may be set to about 5 mm to 7 mm. In this case, the thickness of the insert sheet 1 in the flattened portion is 190 μm.
m to 193 μm, which is thicker on average than the insert sheet 1 in the portion fused to the injection molded product 12.

As another specific example, the heating can be performed by bringing the heater 14 into contact with the insert sheet 1 (see FIG. 21). For example, a portion of the insert sheet 1 covering the through hole 11 of the injection molded product 12 is
1 and hot pressing. The hot press mold 21 has a size such that a tip of the insert sheet 1 comes into contact with a portion of the insert sheet 1 that covers the through hole 11 of the injection molded product 12 and passes through the through hole 11 of the injection molded product 12, and It is a plane (not shown). The hot press mold 21 is made of aluminum, iron, or the like as a material. For example, when the size of the through hole 11 of the injection molded product 12 is a rectangle of 30 mm × 16 mm and the thickness of the insert sheet 1 is 188 μm to 190 μm, the set temperature is 250 ° C. The pinching pressure is about 0.5 kg to 1.0 kg per square centimeter. In this case, the thickness of the insert sheet 1 in the flattened portion is 188 μm to 193 μm, and there is not much difference in the thickness. However, since the slack portion is pushed in, it is fused to the injection molded product 12. The density is higher than that of the insert sheet 1 at the portion where the insertion is performed.

At the time of the heating, the through hole 1 of the injection molded product 12
Parts other than 1 may be covered with a heat insulating material 15 that blocks heat rays (see FIGS. 9 and 10). The heat insulating material 15 is provided in the through hole 1.
It may have a hole 7 approximately the same size as 1. Insulation material 15
Examples of the material include aluminum and iron. Insulation material 15
Has a thickness of 5 mm to 10 mm. Injection molding 1
By covering the portion other than the through hole 11 with the heat insulating material 15, further resin shrinkage of the injection-molded product 12 can be prevented, so that the flat state of the insert sheet 1 in the window can be easily maintained, which is effective. It is.

After the heating, cooling may be performed forcibly. For cooling, the insert sheet 1 may be heated and softened, then placed in a low-temperature room, or rapidly cooled by applying cool air. Cooling may be performed on the entire insert molded product so that the insert sheet 1 flattened by the heating does not recur, or the like. In order to prevent the flat state from being deformed, a flat plate is brought into close contact with a portion of the insert sheet 1 which covers the through hole 11 of the injection molded product 12, or the portion is sandwiched between two flat press dies to cool the insert sheet. May go.

The insert molded product obtained by the method for manufacturing an insert molded product having a window according to the present invention is the injection molded product 1 of the insert sheet 1.
The portion covering the second through-hole 11 is in a state without waving or sagging. For example, the curved portion 16 and the flat portion 17
The through hole 11 is formed in a part of the flat portion 17 of the injection molded article 12 having the following. The insert sheet 1 covers the curved surface portion 16 and the flat portion 17, and the portion covering the through hole 11 is flat. (See FIG. 1). Alternatively, a through-hole 11 is formed in the curved surface portion 16 of the injection molded product 12, and the insert sheet 1 covers the curved surface portion 16 and only the portion covering the through-hole 11 is flat. (See FIG. 2). Further, as another example of the obtained insert molded product, a flat portion fused to the injection molded product 12 and a flat portion of the insert sheet 1 covering the through hole 11 have a step. is there.

The method of manufacturing an insert molded product having a window according to the present invention as described in claim 5 (FIGS. 3, 4 and 12)
This is almost the same as the order in the method of manufacturing an insert molded article having a window according to the present invention described in claim 1. However, in the method for manufacturing an insert molded product having a window according to the first aspect of the present invention, after removing the insert molded product having a window from an injection molding die,
The portion of the insert sheet covering the through hole of the injection molded product is heated to be flat, but in the method of manufacturing an insert molded product having a window portion according to the present invention, the insert molded product having a window portion is provided. Is removed from the injection molding die, the portion of the insert sheet 1 that covers the through hole 11 of the injection molded product 12 is heated and the convex surface 20 is formed.

In order to form the convex surface 20, the shaping plate 19 having the convex surface portion 18 is pressed against the insert sheet 1 simultaneously with or after the heating. Generally, the insert sheet 1 at the portion covering the through hole 11 of the injection molded product 12 contracted by heating is cooled by pressing the shaping plate 19, and is maintained in the shape of the convex curved surface portion 18. The shaping plate 19 may have a cooling function after the insert sheet 1 is heated. The shaping plate 19 may be capable of heating and cooling the insert sheet 1. The shaping plate 19 has such a size that a tip of the shaping plate 19 contacts a portion of the insert sheet 1 that covers the through hole 11 of the injection molded product 12, and passes through the through hole 11 of the injection molded product 12. Some have a convex curved surface (see FIG. 12). The shape of the convex curved surface is arbitrary, for example, a curved surface that rises to have a steep slope, a curved surface that rises smoothly to have a gentle slope,
There are curved surfaces that are raised in a trapezoidal shape. Examples of the material of the shaping plate include aluminum and iron. As an example of use of the shaping plate 19, when the thickness of the insert sheet 1 made of a polyethylene terephthalate film is 188 μm,
The temperature of the shaping plate 19 may be set to 20 ° C., the cooling time may be set to 30 seconds to 1 minute, and the pressing pressure of the shaping plate 19 may be set to about 3 kg per square centimeter. The shaping plate 19 may be used so as to sandwich the insert sheet 1 from above and below. The other steps may be performed in the same manner as in the first aspect.

In the insert molded product obtained by the method for manufacturing an insert molded product having a window according to the fifth aspect of the present invention, a portion of the insert sheet 1 covering the through hole 11 of the injection molded product 12 has a wavy shape. It is a state without slack. For example, the through hole 11 is formed in the flat portion 17 of the injection-molded product 12 having the curved portion 16 and the flat portion 17, and the insert sheet 1 covers the curved portion 16 and the flat portion 17, and the through hole 11 is formed. There is a case where the covered portion has a convex curved surface 20 (see FIG. 3). The shape of the convex curved surface 20 is arbitrary, and includes, for example, a curved surface that rises to have a steep slope, a curved surface that rises smoothly to have a gentle slope, and a curved surface that rises to a trapezoidal shape.

In the method of manufacturing an insert molded product having a window according to the present invention described in claim 6 (see FIGS. 4, 13, and 14), the insert having a window according to the present invention described in claim 5 is provided. It is almost the same as the order in the method of manufacturing a molded article. However, in the method of manufacturing an insert-molded product having a window according to the present invention described in claim 5, the shape of the mold A2 to be used and the projection for forming a through hole of the mold B3 when the mold is closed on the surface of the mold A2. Although the surface shape of the portion where the tip 8 of the portion 5 abuts is not limited, in the method of manufacturing an insert-molded product having a window according to the present invention described in claim 6, the mold A2 having the concave curved surface portion 13 is provided. And the point at which the tip 8 of the projection 5 for forming a through hole of the mold B abuts against the concave curved surface portion 13 of the mold A2. After being removed from the insert sheet 1, the portion of the insert sheet 1 covering the through hole 11 of the injection molded product 12 is heated, and the portion corresponding to the curvature of the concave curved surface portion 13 of the mold A2 is added to the portion.
Pressing the shaping plate 19 having the shape 8, the said portion is formed into a convex curved surface 20 having a surface matching the curvature of the surface of the injection molded article.
Is different.

The curvature of the concave curved surface portion 13 of the mold A2 matches the curvature of the surface of the injection molded product 12 of the insert molded product having the window to be obtained. As the curvature, for example, 150R, 300R, 1000R
and so on. For example, 150R refers to how a circumference or a sphere having a radius of 150 mm bends. For example, the curvature of the concave curved surface portion 13 of the mold A2 may be a combination of a width of 300R and a height of 150R. In this case, the curvature of the surface of a portion of the insert sheet 1 that covers the through hole 11 of the injection molded product 12 is provided. Is a combination of 300R horizontally and 150R vertically. In order to form the convex curved surface 20, the shaping plate 19 having the convex curved surface portion 18 may be pressed against the insert sheet 1 simultaneously with or after the heating. Generally, the insert sheet 1 at the portion covering the through hole 11 of the injection molded product 12 contracted by heating is cooled by pressing the shaping plate 19, and is maintained in the shape of the convex curved surface portion 18. The shaping plate 19 may have a cooling function after the insert sheet 1 is heated. The shaping plate 19 may be capable of heating and cooling the insert sheet 1. The shaping plate 19 has a size such that a tip of the shaping plate 19 contacts a portion of the insert sheet that covers the through hole 11 of the injection molded product 12, and passes through the through hole 12 of the injection molded product 12. It is a convex curved surface having a surface that matches the curvature of the concave curved surface portion 13 of the mold A2 (see FIG. 14). As the curvature, for example, 150
R, 300R, and 1000R. For example, the convex curved surface includes a convex curved surface obtained by combining horizontal 300R and vertical 150R. Examples of the material of the shaping plate 19 include aluminum and iron. As an example of use of the shaping plate 19, when the thickness of the insert sheet 1 made of a polyethylene terephthalate film is 188 μm, the temperature of the shaping plate 19 is set to 20 ° C., the cooling time is 30 seconds to 1 minute, and the pressing pressure is May be set to about 3 kg per square centimeter. It may be sandwiched from above and below as shown in FIG. The pressing of the shaping plate 19 may be performed immediately after the insert sheet 1 is heated and softened. Others may be performed in the same manner as in the fifth aspect of the invention.

In the insert molded product obtained by the method for producing an insert molded product having a window according to the present invention, the portion of the insert sheet 1 covering the through hole 11 of the injection molded product 12 is corrugated. It is a state without slack. For example, there is a case where a through-hole is formed in the curved surface portion 16 of the injection-molded product 12, and a portion of the insert sheet 1 that covers the through-hole 11 has a convex curved surface matching the curvature of the surface of the injection-molded product. (See FIG. 4).

Conventionally, when the window portion of the insert molded product is a portion for viewing a liquid crystal display or the like, the insert is shielded from light except for the portion where the window portion is formed, in order to prevent the occurrence of the "wavy" or the like. There has been a method of manufacturing an insert molded product in which a sheet is used and a molding resin is fused to a window of an insert sheet using a transparent resin as a molding resin. In this conventional method, for example, it is impossible to use a molding resin colored in black having concealing properties, and the design width and use of insert molded products are limited. In addition, in this conventional method, in order to prevent light leakage at the end of the molded product, it is necessary to perform a bending process so that the end of the insert sheet 1 covers the side surface of the injection molded product. However, in the insert molded product having a window portion of the present invention, the injection molded product 12
Since there is no distorted waving or slack in the portion covering the through hole 11, there is no need to adopt a configuration according to the conventional method.
For this reason, it is not always necessary to make portions other than the window of the injection molded product 12 transparent. Therefore, for example, it is also possible to use the molding resin 10 that is colored black having concealing properties, and the design width and application of the insert molded product are expanded,
Also, there is an effect that bending of the insert sheet is unnecessary.

[0030]

Example 1 A woodgrain panel for an automobile interior was manufactured under the following conditions.
On a 188 μm-thick polyethylene terephthalate film, a pipe pattern pattern layer is formed by gravure printing using a vinyl chloride resin black ink containing 10% carbon black and a vinyl chloride resin brown ink containing 2% iron oxide. An adhesive layer having a thickness of 10 μm was formed by screen printing using a vinyl resin having a thickness of 188 μm to obtain an insert sheet having a membrane switch surface pattern. After processing this insert sheet into a three-dimensional shape, it is positioned and fitted into the concave portion of the mold A, and the mold A is brought close to the mold B having the convex portion for forming a through-hole and the molding resin injection port to close the mold. By doing so, the tip of the protrusion for forming a through hole of the mold B (the tip face is 17 m
(a rectangle of mx 30 mm) is abutted against the inner surface of the concave portion of the mold A to form a cavity, and a white colored molding resin made of an acrylonitrile-butadiene-styrene copolymer resin is injected into the cavity to have a through hole. Simultaneously with the injection molding of the injection molded product, the insert sheet was fused and integrated so as to cover at least the through hole, and the insert molded product having the window was taken out of the injection molding die. A portion of the insert sheet covering the window of the injection molded product was distorted due to resin shrinkage of the injection molded product. This wavy portion was heated at 250 ° C. for 7 seconds with a heater to flatten it. Thereafter, while the flattened portion of the insert sheet was sandwiched and cooled by a cold flat press mold, the entire insert molded product was also rapidly cooled by applying cold air.

[0031]

The method for manufacturing an insert-molded article having a window according to the present invention is as described above, and has the following effects. In other words, resin shrinkage occurs in the insert molded product taken out of the injection molding die and the area of the through hole is reduced, and so-called "undulation" or the like occurs in a portion of the insert sheet covering the through hole of the injection molded product. Even by heating the sheet after injection molding,
The above-mentioned “undulation” and the like can be eliminated. Therefore, the design of the insert molded product is improved, and the liquid crystal display and the LED coloring arranged in the window of the insert molded product do not look distorted, so that the yield is improved.

[Brief description of the drawings]

FIG. 1 is a plan view and a sectional view showing one embodiment of a product obtained by a method of manufacturing an insert molded product having a window according to the present invention.

FIG. 2 is a cross-sectional view showing one embodiment of a product obtained by the method of manufacturing an insert molded product having a window according to the present invention.

FIG. 3 is a cross-sectional view showing one embodiment of a product obtained by the method of manufacturing an insert molded product having a window according to the present invention.

FIG. 4 is a cross-sectional view showing one embodiment of a product obtained by the method of manufacturing an insert molded product having a window according to the present invention.

FIG. 5 is a cross-sectional view showing one step of an embodiment of the method for manufacturing an insert molded article having a window according to the present invention.

FIG. 6 is a cross-sectional view showing one step of an embodiment of the method for manufacturing an insert molded article having a window according to the present invention.

FIG. 7 is a cross-sectional view showing one step of an embodiment of the method for manufacturing an insert molded article having a window according to the present invention.

FIG. 8 is a cross-sectional view showing one step of an embodiment of the method for manufacturing an insert molded article having a window according to the present invention.

FIG. 9 is a cross-sectional view showing a step of one embodiment of a method for manufacturing an insert molded article having a window according to the present invention.

FIG. 10 is a cross-sectional view showing one step of an embodiment of the method for manufacturing an insert molded article having a window according to the present invention.

FIG. 11 is a cross-sectional view showing a step of one embodiment of a method for manufacturing an insert molded article having a window according to the present invention.

FIG. 12 is a cross-sectional view showing one step of an embodiment of the method of manufacturing an insert molded article having a window according to the present invention.

FIG. 13 is a cross-sectional view showing one step of an embodiment of the method of manufacturing an insert molded article having a window according to the present invention.

FIG. 14 is a cross-sectional view showing one step of an embodiment of the method for manufacturing an insert molded article having a window according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 insert sheet 2 mold A 3 mold B 4 concave portion 5 convex portion for forming through hole 6 molding resin injection port 7 hole 8 tip 9 cavity 10 molding resin 11 through hole 12 injection molded product 13 concave curved surface portion 14 heater 15 heat insulating material Reference Signs List 16 curved surface portion 17 flat surface portion 18 convex curved surface portion 19 shaping plate 20 convex curved surface 21 hot press type

Claims (10)

[Claims] 1. An injection mold comprising an insert sheet having at least a picture layer formed on a base sheet, a mold A, and a mold B having a projection for forming a through hole and a molding resin injection port. First, by positioning the insert sheet between the mold A and the mold B and closing the mold,
The tip of the projection for forming a through hole of the mold B is abutted against a part of the surface of the mold A to form a cavity, and injection molding is performed, thereby simultaneously performing injection molding of an injection molded product having a through hole.
After the insert sheet is fused and integrated so as to cover at least the through hole, and the insert molded product having the window portion is taken out of the injection mold, the portion of the insert sheet covering the through hole of the injection molded product is heated. A method for producing an insert molded product having a window portion, wherein the product is flattened. 2. An insert sheet having a transparent portion, wherein the insert sheet is positioned between the mold A and the mold B such that the transparent portion covers the through hole of the injection molded product. 5. A method for producing an insert molded product having a window according to item 5. 3. The method according to claim 1, wherein the mold A has a concave curved surface portion. 4. The insert having a window according to claim 1, wherein the heating is performed by sandwiching a portion of the insert sheet covering the through hole of the injection molded product with a hot press mold and hot pressing. Manufacturing method of molded article. 5. An injection mold comprising an insert sheet having at least a picture layer formed on a base sheet, a mold A, and a mold B having a convex portion for forming a through-hole and a molding resin injection port. First, by positioning the insert sheet between the mold A and the mold B and closing the mold,
The tip of the projection for forming a through hole of the mold B is abutted against a part of the surface of the mold A to form a cavity, and injection molding is performed, thereby simultaneously performing injection molding of an injection molded product having a through hole.
After the insert sheet is fused and integrated so as to cover at least the through hole, and the insert molded product having the window portion is taken out of the injection mold, the portion of the insert sheet covering the through hole of the injection molded product is heated. A method for producing an insert-molded article having a window portion, wherein the shaped plate having a convex curved surface portion is pressed to form a convex curved surface. 6. An insert sheet having at least a picture layer formed on a base sheet, and a mold A having a concave curved surface portion.
B having a protrusion for forming a through hole and a molding resin injection port
First, the insert sheet is positioned between the mold A and the mold B by using an injection molding mold consisting of: Is pressed against a part of the concave curved surface portion of the mold A to form a cavity, and injection molding is performed. At the same time as the injection molding of an injection molded product having a through hole, the insert sheet is covered so as to cover at least the through hole. After fusing and integrating, and taking out the insert molded product having the window from the injection mold,
While heating the portion of the insert sheet that covers the through-hole of the injection molded product, pressing a shaping plate having a convex curved surface portion that matches the curvature of the concave curved surface portion of the mold A against the portion, A method for producing an insert-molded article having a window, wherein the convex-curved surface has a surface matching the curvature of the surface of the injection-molded article. 7. An insert sheet having a transparent portion, wherein the insert sheet is positioned between the mold A and the mold B such that the transparent portion covers the through hole of the injection molded product. 7. A method for producing an insert molded article having the window portion according to 5 or 6. 8. After removing the insert molded product having the window portion from the injection molding die, a portion other than the through hole of the injection molded product is covered with a heat insulating material, and the through hole of the injection molded product in the insert sheet is covered. A method for producing an insert molded article having a window according to any one of claims 1 to 7, wherein the portion is heated. 9. The molding resin according to claim 1, wherein the molding resin is a colored resin.
A method for producing an insert molded article having a window portion according to any one of the above. 10. An insert-molded product having a window, wherein a portion of the insert sheet covering the through-hole of the injection-molded product is free from waving or slack.