KR102477745B1 - Manufacturing method for injection molded product comprising heating material - Google Patents

Abstract

The present specification relates to a method for manufacturing a resin injection molding product including a heating element. Using the method for manufacturing the resin injection molding product including the heating element according to an embodiment of the present invention, processability can be improved and compatibility between the cover and the heating element can be improved. In addition, there is an advantage in that the manufacturing process is simple since connection terminals can be introduced into the cover without a complicated additional process.

Description

Method for manufacturing a resin injection molding product including a heating element {MANUFACTURING METHOD FOR INJECTION MOLDED PRODUCT COMPRISING HEATING MATERIAL}

The present specification relates to a method for manufacturing a resin injection molding product including a heating element.

Recently, vehicles to which a smart cruise control (SCC) device is applied are increasing. A smart cruise control device is a device that measures an inter-vehicle distance to a preceding vehicle using a radar and controls the vehicle to maintain the inter-vehicle distance. Cruise control refers to a constant speed driving function or an automatic speed control function that maintains a constant speed of a vehicle.

In order to realize smart cruise control, an SCC sensor is provided in front of the vehicle to detect the vehicle in front, and a vehicle radar cover (SCC cover) is provided on the radiator grill in front of the vehicle to transmit and receive radar of the SCC sensor.

Such a vehicle radar cover must have proper transmission performance of the radar, and as it is provided in front of the vehicle, the image on the exterior of the vehicle must also be considered.

The radar cover is known as a radome. As mentioned above, the radome must minimize the effect its presence has on the radar emitting and receiving waves. This is particularly important in adverse weather conditions, where driving becomes more hazardous due to loss of visibility, road surface conditions, and the like. Clearly, water, ice and snow are clear hazards to the functioning of the radar because they can block radar waves and build up on the radome surface.

Therefore, the vehicle radar cover should be able to easily melt accumulated ice or snow. To this end, a technology for introducing a heating element pattern into a vehicle radar cover has been developed, but since a process of additionally forming a heating element pattern after injection of the cover must be additionally introduced, the process is complicated and the compatibility between cover configurations is poor. .

On the other hand, as the trend of the automobile market is changing from internal combustion engine vehicles to electric vehicles, the demand for electric vehicles is greatly increasing. Maintenance is required when driving an electric vehicle. Existing internal combustion engine vehicles generate warm air with engine heat from heaters in winter, so fuel is not consumed when the heater is used, whereas electric vehicles that do not have an engine to generate warm air consume batteries to drive the heater.

In particular, in winter, the efficiency of electric vehicle batteries decreases due to low temperatures, and the battery discharges at a faster rate when using a heater. there is.

In addition, the heating wire has a greater warming effect than the heater because the warmth is directly transmitted to the skin. However, since the heating wire used in conventional electric vehicles is applied only to the seat and handle, it is difficult to expect a warming effect without a heater.

In order to reduce battery usage and maximize the thermal insulation effect without using a separate heater, a technology that additionally introduces heating wires to garnish, console box, gear knob, and armrest, which are interior materials for vehicles, is required.

The present invention can be used for the above-described vehicle radar cover and the like, and relates to a method for manufacturing a resin injection molding product including a heating element.

Korean published patent KR 10-2018-0068785

The present specification provides a method for manufacturing a resin injection molding product including a heating element capable of improving processability and improving compatibility between a cover and a heating element.

An exemplary embodiment of the present invention comprises the steps of preparing a heating film including a base film and a heating element;

inserting the heating film and the connection terminal into a mold;

bringing the heating film and the connection terminal into contact with each other;

manufacturing a lower cover in which the heating film, the connection terminal, and the injection resin are integrated with each other by injecting an injection resin into the mold; and

It provides a method for manufacturing a resin injection molding product including a heating element, which includes stacking an upper cover on top of the lower cover.

Using the method for manufacturing an injection-molded resin product including a heating element according to an exemplary embodiment of the present invention, processability can be improved and compatibility between the cover and the heating element can be improved.

In addition, there is an advantage in that the manufacturing process is simple because connection terminals can be introduced into the cover without a complicated additional process.

1 is a diagram showing a method for manufacturing a resin injection molding product according to an embodiment.
2 illustrates the width and spacing of the heating element pattern.
3 shows the shape of the heating element pattern.
4 is a diagram showing a step of forming a logo pattern by pressing a heating film when manufacturing a resin injection molding according to an embodiment.
Figure 5 shows the form of applying the adhesive to the lower cover when manufacturing the resin injection molding of the embodiment.
6 is a view illustrating providing an air vent in a lower cover;

Hereinafter, the present specification will be described in more detail.

An exemplary embodiment of the present invention comprises the steps of preparing a heating film including a base film and a heating element;

inserting the heating film and the connection terminal into a mold;

bringing the heating film and the connection terminal into contact with each other;

manufacturing a lower cover in which the heating film, the connection terminal, and the injection resin are integrated with each other by injecting an injection resin into the mold; and

It provides a method for manufacturing a resin injection molding product including a heating element, which includes stacking an upper cover on top of the lower cover.

The injection-molded resin product including the heating element is a product for which demand is increasing for use in radar covers for vehicles. For example, a vehicle radar cover should be able to transmit received radar, but in bad weather conditions such as heavy snow and heavy rain, there is a problem in that snow or ice material accumulates on the radar cover and deteriorates radar permeability. Conventionally, in order to solve this problem, a technology for melting snow and ice by introducing a heating element pattern capable of generating heat in a vehicle radar cover has been developed.

However, when a heating element pattern is introduced into a vehicle radar cover, an additional process for introducing the heating element pattern is required, and there is a problem in that matching between radar cover parts is poor due to the heating element pattern. In order to solve this problem, conventionally, after injection of the upper cover and the lower cover, a heating element pattern is introduced between the upper cover and the lower cover, and a technique of sealing them using an adhesive has been developed. There was a problem that the consistency of the heating element was poor and many processes were required to introduce the heating element pattern. In addition, a terminal is required to supply power to the heating element pattern, but a complicated structure is required to expose the terminal to the outside, and a manufacturing process required to introduce the terminal is excessively required.

In the present invention, when manufacturing the lower cover, the processability is improved by integrally injecting the heating film capable of generating heat, the connection terminal, and the injection resin, and the final resin injection molding product can be manufactured with only one process of bonding the upper cover and the lower cover. It has the effect of improving the matching between the upper cover and the lower cover.

In this specification, in order to explain the laminated structure, the concepts of 'upper' and 'lower' of each component may be introduced.

In the present specification, the 'upper cover' is provided on the outside of the injection-molded resin product, and is distinguished from the 'lower cover' in that it does not include a heating film and connection terminals.

In the present specification, a 'lower cover' is a structure in which a heating film, a connection terminal, and an injection resin are integrated with each other, and is a structure distinguished from an 'upper cover'.

A method of manufacturing an injection-molded resin product including a heating element according to an exemplary embodiment of the present invention includes manufacturing a base film and a heating film including a heating element. The above step is to configure the heating element in the form of a film, and in this case, there is an effect of improving processability. If the heating element is not in the form of a film that is easy to process or change in shape, but has a rigid structure such as a copper plate, it is difficult to form a curve to insert a logo such as an emblem. did

In one embodiment of the present invention, manufacturing the heating film including the base film and the heating element may include forming a heating element on the base film.

In one embodiment of the present invention, forming the heating element on the base film may include applying a heating element composition on the base film.

In one embodiment of the present invention, forming the heating element on the base film may further include curing or drying the heating element composition applied on the base film. The curing or drying step is a process of evaporating or volatilizing the solvent included in the heating element composition and fixing the heating element composition to the base film.

In one embodiment of the present invention, the step of curing or drying the heating element composition applied on the base film may be performed for 1 minute to 1 hour under a temperature condition of 20°C to 200°C.

In one embodiment of the present invention, the temperature condition of curing or drying the heating element composition applied on the base film may be 50 °C to 180 °C or 60 °C to 150 °C.

In one embodiment of the present invention, the step of curing or drying the heating element composition applied on the base film may be performed for 5 minutes to 50 minutes or 8 minutes to 40 minutes. When the temperature and time conditions are satisfied, there are advantages in that the heating element composition is easily dried or cured and the base film is less damaged.

In one embodiment of the present invention, the heating element composition may include conductive particles. The conductive particle is a component capable of easily transferring heat to the outside of the resin injection molding product, and is not particularly limited as long as it is a material that easily generates heat and conducts heat electrically, and may include carbon particles or metal powder having conductivity.

In one embodiment of the present invention, carbon nanotube particles or graphite particles may be used as the carbon particles. The carbon nanotube particles may be selected from single-walled carbon nanotubes, double-walled carbon nanotubes, multi-walled carbon nanotubes, or mixtures thereof. For example, the carbon nanotube particles may be multi wall carbon nanotubes. When the carbon nanotube particles are multi-walled carbon nanotubes, the diameter may be 1 nm to 20 nm, and the length may be 1 μm to 100 μm. The graphite particles may have a diameter of 1 μm to 25 μm and a thickness of 1 nm to 25 μm.

In one embodiment of the present invention, the metal powder includes a powder of silver, copper or nickel material. In the case of silver powder, it may have a flake, spherical shape, polygonal plate shape, rod shape, or the like. As the copper powder, silver-coated copper (Ag coated Cu) powder, nickel-coated copper (Ni coated Cu) powder, or the like may be used. Also, as the nickel powder, silver-coated nickel powder may be used.

In one embodiment of the present invention, the heating element composition may further include any one or more of a binder, ceramic particles, an organic solvent, and a dispersant in addition to the conductive particles.

In one embodiment of the present invention, the binder may have a mixed form of hexamethylene diisocyanate, polyvinyl acetal resin, and phenolic resin. A phenolic resin refers to a phenolic compound including phenol and phenol derivatives. For example, phenol derivatives include p-Cresol, o-Guaiacol, Creosol, Catechol, 3-methoxy-1,2-benzenediol (3- methoxy-1,2-Benzenediol, Homocatechol, Vinylguaiacol, Syringol, Iso-eugenol, Methoxyeugenol, o- Cresol (o-Cresol), 3-methyl-1,2-benzenediol (3-methyl-1,2-Benzenediol), (z) -2-methoxy-4- (1-propenyl) -phenol (( z) -2-methoxy-4- (1-propenyl) -Phenol), 2,6-diethoxy-4- (2-propenyl) -phenol (2,6-dimethoxy-4- (2-propenyl) - Phenol), 3,4-dimethoxy-phenol (3,4-dimethoxy-Phenol), 4-ethyl-1,3-benzenediol, resole phenol, 4-methyl-1,2-benzenediol, 1,2,4-benzenetriol, 2-methoxy-6-methylphenol (2-Methoxy-6-methylphenol), 2-Methoxy-4-vinylphenol or 4-ethyl-2-methoxy-Phenol and the like, but is not limited thereto.

In one embodiment of the present invention, the organic solvent is for dispersing the conductive particles, the ceramic particles, and the mixed binder, Carbitol acetate, Butyl carbotol acetate, DBE (dibasic ester) , ethyl carbitol, ethyl carbitol acetate, dipropylene glycol methyl ether, cellosolve acetate, butyl cellosolve acetate, butanol (Butanol), and may be a mixed solvent of two or more selected from octanol (Octanol).

In one embodiment of the present invention, the heating element may include a heating element pattern or a planar heating element. The shape of the heating element may be changed to easily transfer generated heat to the outside. In addition, the heating element pattern means a heating element in the form of a circuit and is distinguished from a planar heating element. The shape of the heating element pattern and the planar heating element can be changed by changing the application form of the above-described heating element composition. For example, the heating element pattern may be a heating element pattern formed in a circuit form, and the planar heating element means a heating element formed in a plane shape without a pattern.

In one embodiment of the present invention, the heating element pattern may be formed by applying the heating element composition in the form of a line one or more times. For example, the heating element composition may be applied in the form of a line two or more times in a parallel direction, may be applied in the form of a line two or more times in a non-parallel direction, or in the form of a grid so that the heating element patterns overlap each other. It can be applied, and it can be applied in an irregular shape. For example, two or more parallel lines (Fig. 3 (a)), wave patterns (Fig. 3 (b)), plaid patterns (Fig. 3 (c)) or honeycomb patterns (Fig. 3 (d) )) can be.

In one embodiment of the present invention, the heating element pattern may include two or more heating element patterns spaced apart from each other.

In one embodiment of the present invention, it is preferable that the interval between patterns of the heating element pattern is greater than or equal to the wavelength of the radar reaching the injection-molded resin product. Specifically, it may be 1 mm or more and 100 mm or less, 1 mm or more and 80 mm or less, or 1 mm or more and 50 mm or less. When the above range is satisfied, radar transmittance is improved, and heating stability is improved because the distance between the heating element patterns is not too far. The spacing between the patterns means the spacing S in FIG. 2 .

In one embodiment of the present invention, the width of the heating element pattern may be 0.1 mm or more and 100 mm or less, 0.1 mm or more and 50 mm or less, or 0.1 mm or more and 10 mm or less. More specifically, it may be 0.1 mm or more and 2 mm or less, 0.2 mm or more and 1.5 mm or less, and more preferably 0.3 mm or more and 1 mm or less. When the above range is satisfied, radar permeability is improved and heating stability is improved. The width between the patterns means the width W of FIG. 2 .

In one embodiment of the present invention, when the spacing and width between patterns of the heating element pattern are adjusted within the above range, there is an effect of enabling efficient heat generation with a small amount of energy. In addition, it is possible to prevent the product from being damaged by heat by allowing the heat generated in the product to be dispersed in all directions instead of being locally distributed.

In one embodiment of the present invention, the heating element pattern may have a thickness of 0.05 mm to 5 mm or 0.1 mm to 1 mm. When the thickness is within the above range, heat is easily generated, the radar transmission function may not deteriorate, and the heating element pattern is possible even with a small amount of ink when forming the heating element pattern, thereby reducing process cost. The thickness of the heating element pattern means a thickness in an upper direction of the heating element pattern, and is perpendicular to the direction of the width.

)의 1/4보다 크거나(1/4

), 상기 발열체 패턴 간격이 상기 파장(

) 보다 작은 경우, 레이더 투과성이 저하되는 문제가 있다. 즉, 발열체 패턴 배열 형태는 레이더 커버에 도입되는 레이더의 주파수와 파장을 고려하여 조절되어야 한다.The arrangement of the heating element pattern may be variously adjusted within a range in which heat is transferred over the entire radar cover and the radar transmission function is not hindered. The radar transmitted to the radar cover has a unique frequency and a corresponding wavelength band, and the width of the heating element pattern is the wavelength (

) greater than 1/4 of (1/4

), the heating element pattern interval is the wavelength (

), there is a problem that radar permeability is lowered. That is, the heating element pattern arrangement should be adjusted in consideration of the frequency and wavelength of the radar introduced into the radar cover.

In general, vehicle radar has a wavelength range of 30 to 300 GHz and 1 mm to 10 mm corresponding to Extremely High Frequency (EHF). For example, since 76.5 GHz has a wavelength range of 3.921 mm, it is preferable that the heating element pattern width is less than 0.98 mm and the heating element pattern interval exceeds 3.921 mm.

It is preferable that the width of the heating element pattern is smaller than 1/4 of the wavelength of the radar reaching the injection-molded resin product.

In one embodiment of the present invention, the base film is polyethylene-terephthalate (PET), polycarbonate (PC), polymethyl methacrylate (PMMA), thermoplastic-polyurethane from the group consisting of (Thermo-Plastic-Polyurethane:TPU), Thermo-Plastic-Elastomer:TPE), Acrylonitrile-Butadiene-Styren:ABS), Polypropylene:PP, and Polyethylene:PE One or more of the selected ones may be included. These materials have excellent heat resistance, strength, or toughness, and thus have the advantage of being easy to perform thermoforming, vacuum forming, or pressure forming. Among them, it is preferable to use a polycarbonate resin in order to improve mechanical stability and radio wave transmittance.

In one embodiment of the present invention, the base film may have a thickness of 10 um to 1,000 um, preferably 50 um to 500 um, and more preferably 100 um to 300 um. When the above range is satisfied, process stability is secured because the base film is not broken when forming a heating element on the base film, and it is easy to form a curve corresponding to the emblem because the shape is easily changed.

In one embodiment of the present invention, the step of manufacturing the heating film including the base film and the heating element may further include forming a protective layer or a primer layer on the heating element. The protective layer is for protecting the heating element, and the primer layer is for improving bonding strength between the heating element and the insert injection resin.

In one embodiment of the present invention, the step of manufacturing the heating film including the base film and the heating element may further include forming a protective layer and a primer layer on the heating element. At this time, the primer layer may be formed on the protective layer.

In one embodiment of the present invention, forming a protective layer on the heating element may include printing black ink in 2 to 4 or 3 layers.

In one embodiment of the present invention, the protective layer is LiF, BaF ₂ , TiO ₂ , ZnO, SiO ₂ , SiC, SnO ₂ , WO ₃ , ZrO ₂ , HfO ₂ , Ta ₂ O ₅ , BaTiO ₃ , BaZrO ₃ , Al ₂ O ₃ , Y ₂ O ₃ , ZrSiO ₄ , Si ₃ N ₄ , TiN, and combinations thereof.

In one embodiment of the present invention, the thickness of the protective layer may be 5 μm to 50 μm or 10 μm to 40 μm.

In one embodiment of the present invention, the protective layer may include an opening corresponding to the connection terminal. The opening is configured to electrically connect the connection terminal to the heating element of the heating film, and has a thickness smaller than the thickness of the protective layer of a region other than the opening of the protective layer.

In one embodiment of the present invention, the step of manufacturing the heating film including the base film and the heating element may further include forming a protective layer or a primer layer on the heating element.

In one embodiment of the present invention, a step of forming a three-dimensional shape such as a logo pattern by pressing the heating film may be included.

In one embodiment of the present invention, the forming of the three-dimensional shape may include: putting the heating film into forming equipment equipped with a logo pattern; heating to a high temperature; pressurizing with high pressure; taking out the exothermic film from forming equipment; cooling the heating film; and trimming the heating film.

In one embodiment of the present invention, the heating to a high temperature may be performed at a temperature of 150 °C or higher, 200 °C or higher, or 250 °C or higher.

In one embodiment of the present invention, the step of cooling the heating film may be performed at a temperature of 100 °C or less, 50 °C or less, or 30 °C or less for a time of 30 seconds or more, or 1 minute or more. At this time, the temperature of the cooling step may be 10° C. or more, and the cooling time may be within 1 hour or 30 minutes.

In one embodiment of the present invention, the forming of the three-dimensional shape may be performed in a mold equipped with a pattern corresponding to the three-dimensional shape.

In one embodiment of the present invention, the step of inserting the heating film and the connection terminal into the mold is a step of manufacturing a lower cover by integrating the heating film and the connection terminal.

In one embodiment of the present invention, the mold may include an upper mold and a lower mold, the heating film may be provided in the upper mold, and the connection terminal may be provided in the lower mold. The upper mold and the lower mold are not for distinguishing upper/lower positions, but a concept introduced to explain that the molds are separate molds.

In one embodiment of the present invention, the step of contacting the heating film and the connection terminals is a step of allowing the heating film and the connection terminals to be well coupled to each other.

In one embodiment of the present invention, the step of contacting the heating film and the connection terminals may include pressing an upper mold equipped with the heating film and a lower mold equipped with the connection terminals to each other.

In one embodiment of the present invention, the step of manufacturing a lower cover in which the heating film, the connection terminal, and the injection resin are integrated with each other by injecting the injection resin into the mold is to insert the injection resin between the contact heating film and the connection terminal. By introducing, these structures are steps for manufacturing a lower cover integrated with each other. Using the above steps, the lower cover in which the heating film, the connection terminal, and the injection resin are integrally formed can be manufactured with only one process.

In one embodiment of the present invention, the upper mold may include a curved shape to form a molding space.

In one embodiment of the present invention, in a state where the injection resin is provided between the upper mold and the lower mold, the lower mold may be pressed against the upper mold.

In one embodiment of the present invention, an injection resin injection hole may be introduced into the upper mold or the lower mold to inject the injection resin.

In one embodiment of the present invention, the connection terminal may be positioned to correspond to the opening of the protective layer included in the heating film.

In one embodiment of the present invention, the connection terminal may include a through portion. The penetration part is introduced to improve the matching between the connection terminal and the heating film by allowing the injection resin to flow into the through part of the connection terminal when the lower cover is manufactured by injecting the injection resin into the mold.

In one embodiment of the present invention, the shape of the penetrating portion is not limited to circular, elliptical, rectangular, triangular, or polygonal shapes. The through portion may be formed by perforating the connection terminal.

In one embodiment of the present invention, the step of injecting an injection resin into the mold to manufacture a lower cover in which the heating film, the connection terminal, and the injection resin are integrated with each other is to set the mold to a temperature of 30 ° C. or more, 50 ° C. or more, or 70 ° C. It may include preheating to a temperature higher than or equal to.

In one embodiment of the present invention, the step of laminating the upper cover on top of the lower cover includes manufacturing the upper cover using an injection resin; and bonding the lower cover and the upper cover.

In one embodiment of the present invention, the upper cover is provided on top of the resin injection molding and is configured to transmit radar reaching the radar cover.

In one embodiment of the present invention, the injection-molded product of the upper cover may include an upper cover substrate. The upper cover substrate is a support that supports the upper cover.

In one embodiment of the present invention, the upper cover substrate may be manufactured by a mold injection method.

In one embodiment of the present invention, the manufacturing of the upper cover using the injection resin may include manufacturing the injection molding of the upper cover using the injection resin. That is, the upper cover may be a separately manufactured upper cover injection molding.

In one embodiment of the present invention, the upper cover substrate is acrylate-styrene-acrylonitrile resin (Acrylonitrile-Styrene-Acrylate:ASA), AES (Acrylonitrile-EPDM-Styrene), ABS (Acrylonitrile-Butadiene-Styrene) And polycarbonate resin (Polycarbonate: PC) may include any one or more selected from the group consisting of.

The acrylate-styrene-acrylonitrile resin is a plastic that has excellent impact resistance and weather resistance, and exhibits excellent balance of physical properties under a wide range of environmental conditions. It has small change and balance of physical properties required for plastic and excellent formability. In addition, the polycarbonate resin has excellent heat resistance and weather resistance, and has a small effect on the attenuation rate of the radar rather than detection radio waves.

In one embodiment of the present invention, the upper cover may further include a protective layer or a deposition layer. Specifically, the upper cover substrate; A first protective layer provided on top of the upper cover substrate; A deposition layer provided under the upper cover substrate and a second protective layer provided under the deposition layer may be further included.

In one embodiment of the present invention, the protective layer is a layer that protects the upper cover substrate, the deposition layer may be a layer that expresses various colors by optical characteristics, and the primer layer improves adhesion with the lower cover. It may have been introduced to do so.

In one embodiment of the present invention, the deposition layer is indium (In), titanium (Ti), tin (Sn), silicon (Si), germanium (Ge), aluminum (Al), copper (Cu), nickel ( Ni), vanadium (V), tungsten (W), tantalum (Ta), molybdenum (Mo), neodymium (Nb), iron (Fe), chromium (Cr), cobalt (Co), gold (Au) and silver ( It may be a single layer or a multi-layer including one or more materials selected from Ag), oxides thereof, nitrides or oxynitrides thereof, and one or two or more materials selected from carbon and carbon composites.

In one embodiment of the present invention, the deposition layer may be coated by known deposition techniques, for example, PECVD (Plasma Enhanced Chemical Vapor Deposition) and E-beam deposition, but is not limited thereto.

In one embodiment of the present invention, in one embodiment of the present invention, the step of bonding the lower cover and the upper cover may be included. The lower cover and the upper cover may be bonded using a known adhesive, and may be pressed together to have excellent bonding strength.

Specifically, the step of bonding the lower cover and the upper cover is the lower surface of the lower cover; Alternatively, it may include applying the adhesive to the upper surface of the lower cover. Specifically, the edge of the upper surface of the lower cover; Alternatively, it may be applied on the heating element of the lower cover.

When the adhesive is applied on the heating element of the lower cover, the interval between the adhesives applied may be 5 mm to 50 mm, 7 mm to 30 mm, or 10 mm to 20 mm. When the above range is satisfied, excellent bonding strength can be exhibited even with a small amount of adhesion.

With the amount of the adhesive applied, the diameter of the adhesive body formed by being formed at the time of one application may be 1 mm or less. If the amount exceeds the above range, the amount of adhesive applied may increase and the laser transmittance may decrease, so it is preferable to adjust the above range.

Drying or curing at room temperature for a certain period of time so that the adhesive can be sufficiently cured may be included. The predetermined time may be 1 minute to 1 hour or 1 minute to 20 minutes.

In one embodiment of the present invention, the adhesive may be a polyurethane (PU)-based adhesive.

In one embodiment of the present invention, the step of stacking the upper cover on top of the lower cover may include a heating element that includes forming a print layer on the upper part of the lower cover.

In one embodiment of the present invention, forming the print layer on the upper part of the lower cover may include applying and drying a composition for forming a print layer on the upper part of the lower cover.

In one embodiment of the present invention, forming the printed layer on the top of the lower cover may include forming a pattern or design on the printed layer. In this case, the pattern may use an imprinting method.

In one embodiment of the present invention, the manufacturing method of the injection-molded resin product including the heating element further includes providing an air vent to a lower cover or an upper cover. By including the air vent, it is possible to minimize damage to the appearance of the final product by discharging gas or air generated during manufacturing to the outside (FIG. 6).

In one embodiment of the present invention, providing an air vent includes providing an air vent accessory to the lower cover or the upper cover; and heat-sealing.

In one embodiment of the present invention, the injection-molded resin product including the heating element may have radar transparency. Having the radar permeability means that there is permeability to a vehicle radio wave receiving radar. Specifically, it may mean that there is transparency to 75 to 79 GHz frequency signals.

In one embodiment of the present invention, the injection-molded resin product including the heating element may be a radar cover for a vehicle. When the resin injection molding including the heating element is applied to a radar cover for a vehicle, it is easily removed even in bad weather in which snow may accumulate, thereby preventing a decrease in radar permeability.

In one embodiment of the present invention, the injection-molded resin product including the heating element may be any one or more of a radar cover for a vehicle and an interior/exterior material for a vehicle. The interior and exterior materials for a vehicle include a handle, a gear knob, a headliner, a console box, and the like included in a vehicle.

In one embodiment of the present invention, the injection-molded resin product including the heating element may be used as interior and exterior materials for home appliances, parts of mobile devices, parts of electronic devices, and the like.

Hereinafter, the present invention will be described in more detail through examples. However, the scope of the present invention is not limited by the examples described later.

Example

Manufacturing a heating film

Apply Ag paste in the same shape as the circuit pattern on a 0.25um-thick polycarbonate (PC) film as a base film and dry it at 90 ° C to 130 ° C for 10 to 30 minutes to obtain a 0.1 mm thick and 0.5 mm to 0.8 A heating circuit having a width of mm was formed.

Thereafter, black ink was printed three times to form a protective layer, and an opening was formed by placing a printing mask on a portion corresponding to the terminal.

In addition, bonding strength between the lower cover and the substrate film including the heating circuit may be improved by printing a binder ink for the purpose of a separate primer twice.

Pressing the heating film to form a logo pattern

The prepared exothermic film was put into forming equipment equipped with a logo pattern, and the film was heated at a temperature of 300°C. After the heated film was placed on the forming mold, the forming mold was pressed, and then the formed film was taken out and cooled at room temperature for 1 minute. Thereafter, the formed heating film was trimmed to fit the insert injection shape (see FIG. 4).

Manufacturing the lower cover

The temperature of the mold was preheated to 80 degrees. A connection terminal was inserted into the lower mold and a heating film was inserted into the upper mold (Fig. 1(a)). The upper and lower molds were pressed together (Fig. 1(b)), and the dried AES was melted at a temperature of 230 degrees and injected through the gate on the mold side (Fig. 1(c)). After that, the mold was opened to manufacture a lower cover (Fig. 1 (d)).

Manufacturing the lower cover

The temperature of the mold was preheated to 80 degrees.

A connecting terminal was inserted into the movable mold and a heating film was inserted into the fixed mold.

The movable mold was moved to the fixed mold, and the dried AES resin (acrylonitrile butadiene styrene copolymer) was melted at a temperature of 230 degrees through the gate on the mold side, and the lower cover was manufactured.

Steps to prepare the top cover

An upper cover substrate was prepared by injecting a polycarbonate (PC) resin. UV hard coating was applied to the top of the upper cover substrate, UV base coating was applied to the lower portion of the upper cover substrate, a metal layer was deposited under the UV base coating, and a shielding coating was applied to the lower portion of the metal to prepare an upper cover.

Laminating an upper cover on top of a lower cover

PU adhesive was evenly applied to the inner edge of the rim of the lower cover using a dispenser, and an instant adhesive such as Loctite (trade name) was applied in a dot format of 1 mm or less at the same location as the heating pattern (Fig. 5).

The upper cover and the lower cover were bonded to each other, mounted on a dedicated JIG, pressed, and left at room temperature for 10 minutes.

Claims (13)

Preparing a heating film including a base film and a heating element;
inserting the heating film and the connection terminal into a mold;
bringing the heating film and the connection terminal into contact with each other;
manufacturing a lower cover in which the heating film, the connection terminal, and the injection resin are integrated with each other by injecting an injection resin into the mold; and
Stacking an upper cover on top of the lower cover,
The upper cover does not include the heating film and the connection terminal,
The connection terminal includes a through portion
A method of manufacturing a resin injection molding product including a heating element. The method of claim 1,
The method of manufacturing a resin injection molding product including a heating element, wherein the heating element includes a heating element pattern or a planar heating element. The method of claim 2,
Method for producing a resin injection molding product including a heating element in which the interval between the patterns of the heating element pattern is 1 mm or more and 100 mm or less. The method of claim 2,
Method for producing a resin injection molding product including a heating element in which the width of the heating element pattern is 0.1 mm or more and 100 mm or less. The method of claim 1,
The base film is polyethylene-terephthalate (PET), polycarbonate (PC), polymethyl methacrylate (PMMA), thermo-plastic-polyurethane (TPU) , Thermo-Plastic-Elastomer (TPE), Acrylonitrile-Butadiene-Styren: ABS), Polypropylene (PP), Polyethylene (Polyethlylene: PE) containing at least one selected from the group consisting of A method of manufacturing a resin injection molding product including a heating element. The method of claim 1,
The step of manufacturing a heating film including the base film and the heating element is
A method of manufacturing a resin injection molding product including a heating element, further comprising forming a protective layer or a primer layer on the heating element. The method of claim 6,
The method of manufacturing a resin injection molding product including a heating element, wherein the protective layer includes an opening corresponding to the connection terminal. The method of claim 1,
The step of manufacturing a heating film including the base film and the heating element is
A method of manufacturing a resin injection molding product including a heating element comprising the step of pressing the heating film to form a three-dimensional shape such as a logo pattern. delete The method of claim 1,
Stacking an upper cover on top of the lower cover
Manufacturing an upper cover using an injection resin; and
A method of manufacturing a resin injection molding product including a heating element comprising the step of bonding the lower cover and the upper cover. The method of claim 1,
Stacking an upper cover on top of the lower cover
A method of manufacturing a resin injection molding product including a heating element comprising the step of forming a printing layer on top of the lower cover. The method of claim 1,
Method for manufacturing a resin injection molding including a heating element, wherein the resin injection molding including the heating element has radar transmittance. The method of claim 1,
The method of manufacturing a resin injection molding including a heating element, wherein the injection molding material including the heating element is at least one of a radar cover for a vehicle and an interior/exterior material for a vehicle.

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