KR20140143668A - Forming yarn, forming element using it, moulding product using it and manufacturing method of moulding product - Google Patents

Abstract

The present invention relates to a yarn, a planar element using the same, a molding product using the same, and a manufacturing method of a molding product. More specifically, the present invention relates to a yarn, a planar element using the same, a molding product using the same, and a manufacturing method of a molding product, wherein the yarn secures the sufficient strength and flexibility, can minimize the thickness of a resin molding product, has a simple structure so as to improve marketability, has simple manufacturing processes so as to reduce the manufacturing costs and improve productivity, and prevents the damage of the yarn while conveniently manufacturing a resin molding product having a complicated structure and shape so as to improve marketability and the strength. The yarn according to the present invention is characterized by comprising a support yarn arranged therein; and a resin layer for molding laminated on the outer surface of the support yarn. The planar element according to the present invention is characterized in that multiple yarns consisting of a support yarn arranged therein and a resin layer for molding laminated on the outer surface of the support yarn are woven to form a planar structure. The molding product according to the present invention is characterized in that the planar element is heated and molded. The manufacturing method of a molding product according to the present invention is characterized by comprising a planar element formation step of forming a planar element having a planar structure by weaving yarns; and a molding product formation step of forming a molding product by heating and molding the planar element formed at the planar element formation step.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded article, a molded article using the molded article, a molded article using the molded article,

The present invention relates to a molded article, a molded article using the molded article, a molded article using the molded article, and a method of manufacturing the same, and more particularly, to a method of manufacturing a molded article, The structure can be simple and simple, and the merchantability can be improved. The manufacturing process is simple and simple, the manufacturing cost can be reduced, the productivity can be improved, and the resin molded product having complicated structure and shape can be manufactured easily, A molded article using the molded article, a molded article using the molded article, and a method of manufacturing the same.

In general, various items such as cases of electronic and communication devices, cases of household appliances, storage boxes of articles, storage cabinets, and the like are produced by using metal plates or wood, but they are not only complicated and difficult to manufacture due to expensive raw materials, A method of injection molding using a thermosetting resin is widely used because it takes a long time to manufacture.

Such an injection molding method has advantages of low manufacturing cost and high productivity, but it has a disadvantage that rigidity is poor when manufactured thinly. Accordingly, a method of stiffening a reinforcement material for reinforcement is applied to the injection-molded product.

However, when the reinforcing material is additionally disposed in the molded product, the adhesion and bonding force between the molded product and the reinforcing material are lacking, and a separate reinforcing material preparation step is required. In addition, since the number of assembling holes is required and the manufacturing cost is increased, As shown in Fig.

For example, in Korean Patent Laid-Open Publication No. 10-1999-0082990, as shown in Fig. 1, a flexible mesh-like electromagnetic wave shielding fiber is disposed in a molding die, and soft electromagnetic wave shielding fibers To be deformed in accordance with the formation in the molding die (2).

According to the above-mentioned Unexamined Patent Publication No. 10-1999-0082990, there is no need to prepare a separate inside water, and the advantage that the adhesion between the electromagnetic wave shielding fiber and the resin layer is improved by injecting the injection resin into the electromagnetic wave shielding fiber on the mesh However, there are disadvantages that the following problems are caused.

First, since the conventional resin molded article has the additional shielding fiber attached to the resin layer, the thickness of the entire resin molded article increases, so that a thin and compact product can not be produced. In particular, there is a limit in that a small case such as a smart phone can not be manufactured commercially.

Secondly, since the above-mentioned conventional resin molded article requires a step of preparing the shielding fiber in advance in injection molding and a step of injecting the shielding fiber into the injection mold, the manufacturing process is complicated and the manufacturing time is increased, .

Thirdly, since the conventional resin molded product does not stretch the shielding fiber during injection molding, when the molded product having a sharp sectional change such as a bent portion or a concavo-convex portion or a molded product having a complicated shape is broken, the shielding fiber is broken, Resulting in deterioration of rigidity due to breakage of the shielding fiber.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described circumstances, and has as its object to provide a molded article which is simple in structure, simple in structure and improved in merchantability by minimizing the thickness of the resin molded article while ensuring sufficient rigidity and flexibility, It is an object of the present invention to provide a molded article using a molding yarn and a manufacturing method thereof.

Another object of the present invention is to provide a molding yarn, a molding body using a molding yarn, a molded article using the molding yarn, and a method of manufacturing the same, wherein the manufacturing process is simple and simple, so that the manufacturing cost is reduced and the productivity is improved.

It is still another object of the present invention to provide a molding machine, a molding body for molding using a molding machine, and a molding yarn, which can prevent damage to the molding yarn while easily manufacturing a resin molded product having a complicated structure and shape, And a method for producing the same.

In order to achieve the above object, a forming yarn according to the present invention is a forming yarn comprising: a supporting yarn disposed inside; And a molding resin layer laminated on the outer surface of the support yarn.

The forming resin layer may be formed by forming a resin for molding on the outer surface of the supporting yarn or a resin hollow yarn formed to have a hollow part by a molding resin and sandwiching the supporting yarn.

At this time, the support yarn may be composed of a stretchable polymer yarn which is expanded when an external force is applied and contracted when an external force is released.

The support yarn may be formed as a yarn formed in a winding structure or a zigzag structure so as to be stretched when an external force is applied.

Further, the support yarn may be composed of a conductive yarn having conductivity. Here, the conductive yarn may be selected from a carbon paper including carbon, a metal yarn formed of a conductive metal, and a conductive fiber yarn coated or contained with a conductive material on the fiber yarn.

On the other hand, the forming resin layer can be constituted by winding a resin yarn formed by a molding resin on the outer surface of the supporting yarn.

The resin yarn may have a check in its center. At this time, all or a part of the examination may be made of a conductive yarn having conductivity.

The conductive thin film layer may be formed on the outer surface of the molding resin layer.

On the other hand, the support yarns may be made of flat fibers whose thickness is thinner than the width thereof and whose surfaces are flat.

Here, the flat fibers are polyethylene fibers (PE yarns) having a thickness of 50 to 200 denier, and the number of filaments constituting one strand of the polyethylene fibers is 10 to 200 strands.

The support yarns may be formed of bristles having a plurality of bristles formed on the outer surface of the linear body.

The support yarns may be composed of a plurality of strands. At this time, some of the support yarns may be arranged with a resin yarn in which the resin forming the molding resin layer is formed in a preliminary form.

In order to achieve the above object, the molding sheet body according to the present invention is characterized in that the molding yarns of a plurality of strands each composed of a supporting yarn disposed inside and a molding resin layer laminated on the outer surface of the supporting yarn are woven together to form a planar structure .

Here, all or a part of the support yarns may be made of conductive yarn having conductivity.

Then, the molding body can be woven in a planar structure by supplying the molding yarn as a weft yarn and a warp yarn.

On the other hand, the molding surface body may be woven so as to have a planar structure, wherein the molding yarn has a molded surface layer of a two-layer structure or more.

Wherein the molding surface body comprises a molded surface layer that is woven in the form of a sheet by the molding yarn, a bottom molded surface layer that is spaced apart from the molded surface layer and is woven in a plane by the molding yarn, And a planar layer connection formed of a plurality of connecting yarns arranged in the spaced space so as to be connected between the lower molded surface layers.

Here, the connecting yarn may be formed of any one of inorganic fiber yarns, organic fiber yarns, and conductive conductive yarns, and may be formed as a hollow space between the upper and lower molded surface layers in a state of being molded into a molded product.

In addition, a filling layer formed of any one of a heat insulating material, an insulating material, a shock absorbing material, and a conductive material may be embedded in the spacing space.

On the other hand, the molding surface body may be formed of a molded surface layer woven in a planar shape by supplying the molding yarn as weft yarns and warp yarns; And a reinforcing layer that is woven to protrude from one or both sides of the molded surface layer.

In order to attain the above object, the molded article according to the present invention is characterized in that the above-mentioned molding sheet body is heated and molded.

In order to achieve the above object, the molded article according to the present invention is molded using a molding yarn.

In order to achieve the above object, a method of manufacturing a molded article according to the present invention is a method of manufacturing a molded article, comprising the steps of: forming a shaping yarn by weaving each other into a sheet- And a molded product forming step of producing a molded product by heating and molding the molding surface member formed by the above-mentioned surface member forming step.

According to the molded article, the molded article using the molded article using the molded article, the molded article using the molded article, and the method of manufacturing the same according to the present invention, the reinforcing layer or the shielding fiber is not separately poured or inserted into the mold, Since the molding is made using a molding yarn composed of a stratum or a molding body woven or woven using the molding yarn, the thickness of the molding can be minimized, and the molding can be made thin and compact.

According to the molded article, the molded article using the molded article, and the method for producing the same, the step of preparing the reinforcing layer or the shielding fiber in advance or injecting the shielding fiber into the injection mold is required The manufacturing process is simple and the manufacturing time is shortened, so that the manufacturing cost is reduced and the productivity is improved.

Further, according to the molded article, the molded article using the molded article, and the method of manufacturing the molded article using the molded article, the molded article using the molded article, and the molded article using the molded article having the stretchability, When the molded article is formed into a sudden molded product or a complicated shape, the support yarn is not broken or damaged, the surface of the molded article is uniform and cracks are prevented, and thus the molding quality is improved and the rigidity is increased.

1 is a view for explaining a conventional resin molded article,
FIG. 2A is an enlarged principal perspective view showing a molding yarn according to the first embodiment of the present invention, FIG.
FIG. 2B and FIG. 2C are enlarged perspective views of the main part showing a modified example of the molded yarn according to the first embodiment of the present invention,
Fig. 3 is an enlarged perspective view of a molded part according to a second embodiment of the present invention,
Fig. 4 is an enlarged perspective view of a molded part according to a third embodiment of the present invention, Fig.
FIGS. 5A and 5B are enlarged perspective views of a molded part according to a fourth embodiment of the present invention,
FIG. 6 is an enlarged perspective view of a molded part according to a fifth embodiment of the present invention,
FIG. 7 is an enlarged perspective view of the main part showing a modified example of the molded yarn according to the fifth embodiment of the present invention,
FIG. 8 is an enlarged perspective view of a molded part according to a sixth embodiment of the present invention,
Fig. 9 is an enlarged perspective view of a main portion of a molding body using a molding yarn according to the first embodiment of the present invention, Fig.
10 is a plan view showing a modified example of a molding surface body using a molding yarn according to the first embodiment of the present invention,
Fig. 11A is a schematic cross-sectional view showing a main part of a molding body using a molding yarn according to a second embodiment of the present invention, Fig. 11B is a schematic sectional view of a molded body formed using the molding body shown in Fig. Fig.
12 is an enlarged cross-sectional view of a main portion of a molding body using a molding yarn according to a third embodiment of the present invention,
13 is an enlarged cross-sectional view of a main part showing a modified example of a molding surface body using a molding yarn according to a third embodiment of the present invention,
Fig. 14 is a view for explaining a method for producing a molded product using the molding yarn according to the present invention.

Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to FIGS. 2A to 14, and the same reference numerals are given to the same constituent elements in FIGS. 2A to 14B. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

FIG. 2A is an enlarged perspective view showing a molding yarn according to the first embodiment of the present invention, in which a part of the molding resin layer of the molding yarn is removed so that the inner supporting yarn is partially exposed.

Referring to FIG. 2A, a forming yarn 1 according to an embodiment of the present invention can be used as a material for forming a plurality of strands by weaving or weaving them together. The forming yarn 1 includes a supporting yarn 11 disposed therein, And a molding resin layer (12) laminated on the outer surface of the supporting yarn (11).

The supporting yarn 11 is a preliminary yarn disposed along the longitudinal direction at the center of the inside of the forming yarn 1, and can be applied to various types of preforms formed of various materials depending on the form, type, purpose of use, application and the like.

The supporting yarn 11 can be applied without any particular limitation as long as it is an elongated thin linear member (hereinafter referred to as a preliminary yarn), but a variety of fiber yarns such as inorganic fibers and organic fibers having higher melting points than molding resins can be typically applied.

The fiber yarn is selected and applied to a fiber yarn having inherent characteristics according to the characteristics of the molding to be molded. For example, when used for forming a molded article having a high tensile strength, aramid yarn (trade name) or Kevlar yarn (trade name) may be applied as the aramid yarn having a large tensile strength.

When the supporting yarn 11 is applied to a molded article requiring heat insulation, a ship having excellent heat insulating properties such as glass fiber yarn can be applied.

In addition, when the molded product itself formed by the molding yarn is an article requiring conductivity (current conduction), the supporting yarn 11 can be selected and applied to the conductive yarn.

Typically, a metal yarn formed of a conductive metal can be applied to a conductive yarn, but a carbon yarn (including a carbon nanotube) containing carbon, which is also referred to as a carbon fiber yarn, a conductive yarn coated or contained with a conductive material, Etc. may be applied. At this time, the conductive material may be applied as a conductive polymer (conductive ink), metal oxide particles, metal nanoparticles, graphene particles, and the like.

The metal wire may be selectively coated with a conductive metal such as copper or stainless steel with a coating having a diameter in the range of 10 to 500 micrometers (占 퐉), followed by coating with an insulating coating layer.

The support yarn 11 may be selected and applied to a carrier having an electromagnetic wave shielding function when the molded product itself is an article requiring application of electromagnetic wave shielding (in the case of appliances or communication devices). At this time, since the ship having the electromagnetic wave shielding function can be made conductive like the conductive yarn, it can be selected and applied from among the suppliers that can be applied as the above-mentioned conductive yarn.

On the other hand, the molding resin layer 12 is formed by applying a molding resin to the outer surface of the supporting yarn 11 or by forming a resin hollow yarn (not shown, And a preheating yarn in which a through hole is formed) is sandwiched by the supporting yarn 11. [

The molding resin constituting the molding resin layer 12 may be selected and applied according to the kind of the product to be molded, the purpose of use, among the thermosetting resin or the thermoplastic resin. For example, it is preferable that the molding resin layer 12 be selected and applied to a thermoplastic resin having excellent moldability and impact strength when a molded product is manufactured by press molding or injection molding.

The thermosetting resin may be applied by applying epoxy, phenol (resol type), urea, melamine, polyimide, unsaturated polyester, vinyl ester, or a copolymer of the above-mentioned ones, modified bodies and two or more kinds of resins, A resin to which an elastomer or a rubber component is added may be applied

The thermoplastic resin may be at least two kinds of thermoplastic resins selected from a styrene type resin, a polycarbonate resin, a polyphenylene ether resin, a polyester resin, a polyamide resin, a polyphenylene sulfide resin, a polyolefin resin, Resins can be selected and applied.

Figs. 2B and 2C are enlarged perspective views showing a modified example of the molded yarn according to the first embodiment of the present invention.

The supporting yarn 11 may be composed of a plurality of strands as shown in Fig. 2B. At this time, the supporting yarn 11 is formed by arranging a ship with a small denier.

As shown in FIG. 2B, if the support yarns 11 are formed of a plurality of strands, the support yarns are arranged more densely in the molded product, so that the rigidity of the molded product can be further improved.

2C, a part of the supporting yarn 11 may be applied to the fiber yarn 11a and the other part of the supporting yarn 11b may be disposed. At this time, the resin yarn 11b is obtained by forming the resin forming the molding resin layer 12 in a preliminary form.

2C, when the fiber yarn 11a and the resin yarn 11b are mixed together while the supporting yarn 11 is composed of a plurality of strands, the supporting yarn composed of the resin yarn 11b is melted and formed adjacent It is possible to prevent the cracks and deformation of the molded product as well as the rigidity of the molded product by increasing the binding force of the molded product.

Hereinafter, the second to sixth embodiments and modifications according to the present invention will be described. However, detailed description of components similar to those shown in the first embodiment and its modifications will be omitted, . In the following second and sixth embodiments, the present invention can be selectively applied to any of the constituent elements shown in the first embodiment and modifications thereof. In addition, components shown in the second to sixth embodiments and modifications thereof may be selectively applied to each other within a practicable range, and a detailed description thereof will be omitted.

Fig. 3 is an enlarged perspective view of a molded part according to a second embodiment of the present invention.

3, the forming yarn 2 according to the second embodiment of the present invention comprises a supporting yarn 21 disposed inside and a forming resin layer 22 (see FIG. 3) laminated on the outer surface of the supporting yarn 21 The main feature of the present invention is that the longitudinal shape of the preform is made of a flat type yarn having a flat surface with a thin thickness compared with the width so as to minimize the thickness of the molded article during molding of the molded article.

If the supporting yarn 21 is made of flat fibers, the flatness of the supporting yarn 21 is stabilized in a molded state, so that a thin and precise and light molded product can be obtained.

In addition, when the molded fiber 2 is to be used for production of a more precise molded product, flat fibers having a thickness of 50 to 500 deniers are applied, and a filament yarn constituting one strand of the flat fiber (a) The number is from 10 to 200 strands.

In addition, the flat fiber is preferably composed of polyethylene fibers (PE yarns) when it is desired to produce a molded article having excellent heat resistance, abrasion resistance, impact resistance, low friction coefficient and chemical resistance and being resistant to thermal deformation and impact.

On the other hand, a flat fiber (not shown) having a large number of bristles formed on the outer surface of the linear body may be applied to the flat fiber composed of the supporting yarn 21 so that the rigidity of the molded product is further improved. When such a bristle yarn is applied as the supporting yarn 21, a large number of bristles are hardened together with the resin forming the molding resin layer 22, so that the adhesive force and the connecting force are increased mutually, so that deformation and cracks of the molded product are reduced .

Fig. 4 is an enlarged perspective view of a molded part according to a third embodiment of the present invention.

4, the forming yarn 3 according to the third embodiment of the present invention includes a supporting yarn 31 disposed inside and a forming resin layer 32 (see FIG. 4) laminated on the outer surface of the supporting yarn 31 And the support yarn 31 is formed in a structure that is expanded when an external force is applied and can be contracted when an external force is released.

When the support yarn 31 is formed in such a manner that the support yarn 31 can be stretched and shrunk, the support yarn 31 is stretched when the molded product having an abrupt change in cross section, such as concavo-convex portion, bent portion or the like, is formed through injection molding or press molding, It is possible to prevent the support yarn from being damaged or broken, and thus the moldability, strength, molding quality, and the like of the molded article can be remarkably improved.

For this purpose, the supporting yarn 31 is composed of a stretchable polymer yarn, which is stretched or contracted depending on the action of a tensile force, and is called spun yarn or polyurethane yarn. Here, the polymer resin used in the production of the stretchable polymer yarns may be formed of a stretchable thermally conductive silicone resin, or may be composed of a polyester, a polyethylene terephthalate, or a copolymer thereof.

FIGS. 5A and 5B are enlarged perspective views illustrating a molded yarn according to a fourth embodiment of the present invention.

5A, the forming yarn 4 according to the fourth embodiment of the present invention includes a supporting yarn 41 disposed therein and a forming resin layer 42 The supporting yarn 41 constituting the forming yarn is formed so as to be able to expand and contract, and is formed of a yarn formed in a winding structure having a shape similar to that of a coil structure so as to be stretched when an external force is applied.

At this time, the supporting yarn 41 shown in Fig. 5A can be manufactured by winding the supporting yarn on the core line disposed at the center and removing the core line in a state of being formed.

Meanwhile, the supporting yarn 41 'may also be formed as a jigging structure in which a zigzag structure is formed so that the supporting yarn 41' can be extended when an external force is applied, as shown in FIG. 5B.

The support yarn 41 'formed in a zigzag structure may be selected and applied to a gear crimp yarn which is bent in a zigzag shape and has protrusions of a serrated structure. The gear crimp wire is a thread made of metal or monosilicate yarn (also referred to as monofilament yarn, which means a yarn made of one strand of filament fibers, which is used as a fishing line or the like) And then thermoformed.

5A and 5B, even when a molded article having a sharp sectional change is formed, when an external force is applied from a mold at the time of injection molding or press molding, a portion formed of a winding structure or a zigzag structure is unfolded, 41, 41 ') is increased, so that fracture is prevented, so that moldability, strength, molding quality, and the like of the molded article can be remarkably improved.

Fig. 6 is an enlarged perspective view of a molded part according to a fifth embodiment of the present invention.

6, the forming yarn 5 according to the fifth embodiment of the present invention includes a supporting yarn 51 disposed inside and a forming resin layer 52 Wherein the molding resin layer 52 is formed by winding the resin yarn 52a formed by the molding resin on the outer surface of the supporting yarn 51 or by laminating the same.

In the fifth embodiment, it is preferable that the supporting yarn 51 is selected and applied to a stretchable polymer yarn as described in the third embodiment. When the support yarn 51 is made of the stretchable polymer yarn, when the external force is applied from the mold at the time of injection molding or press molding, the resin yarn 52a may be arranged in a winding configuration to increase its length. At the same time, ) Can be formed of stretchable polymer yarns and can be stretched. Therefore, even if the sectional change of the molded article is abruptly changed, breakage is prevented, so that the moldability, strength and molding quality of the molded article can be remarkably improved.

The shaping yarn 5 according to the fifth embodiment can be produced by a winding machine (not shown in the figure, a machine for winding a wire or a thread), that is, the support yarn 51 is fed to the center of the winding machine, When the resin thread 52a is wrapped around the threaded portion 52a, the forming thread 5 of the type shown in FIG. 6 is obtained.

Fig. 7 is an enlarged perspective view showing a modified example of the molded yarn according to the fifth embodiment of the present invention. As shown in Fig. 7, the molded yarn 5 is wound on the outer surface of the supporting yarn 51 And the resin yarn 52a has a check yarn 52b embedded in its inner center. At this time, the examination 52b can be selected from among the inorganic fibers and organic fibers described above.

When the check yarn 52b is disposed inside the resin yarn 52a as described above, the fiber yarn (examination) performing the function of the reinforcement line in a state of being formed into a molded product is arranged more densely in the resin layer, So that cracks and deformation can be prevented.

In addition, the examination 52b may be constituted by a conductive yarn having conductivity so as to have conductivity or perform an electromagnetic wave shielding function.

FIG. 8 is an enlarged perspective view of a molded part according to a sixth embodiment of the present invention. FIG.

The molding yarn 6 according to the sixth embodiment of the present invention includes a support yarn 61 disposed inside as shown in Fig. 8, and a molding resin layer 62 , And a conductive thin film layer 63 is formed on the outer surface of the molding resin layer 62. [

The electroconductive thin film layer 63 is formed by winding a belt-shaped film having electroconductivity such as silver foil on a molded resin layer 62. When the electroconductive thin film layer 63 is formed as a molded product by injection molding or press molding, The electromagnetic wave shielding unit 63 can function to shut off the heat or shield the electromagnetic wave.

Fig. 9 is an enlarged cross-sectional view showing a main portion of a molding body using a molding yarn according to the first embodiment of the present invention. Fig.

The molding body 100 using the molding yarn according to the first embodiment of the present invention is different from the molding yarns 1, 2, 3, 4, 5, and 6 shown in the first to sixth embodiments and its modifications, 6, which are formed of a planar body irregularly interlaced or entangled with each other to form a nonuniform structure, or formed into a planar body having a uniform structure by weaving while weaving and supplying a forming yarn can do.

The planar body having a non-uniform structure can be used in the production of a molded article such as a case in which the thickness of the molded article is relatively large and precision is not required. For example, a plurality of strands of a molded yarn are wound in a coil form to form a planar structure .

As shown in FIG. 9, a planar body having a uniform structure is advantageous for the production of a molded article having relatively thin thickness and high precision, such as a cellular phone case. In this embodiment, the planar body having a uniform structure .

More specifically, as shown in Fig. 9, the molding surface member 100 has supporting yarns 11, 21, 31, 41, 51, and 61 disposed therein, Stranded forming yarn 1 composed of the resin layers 12, 22, 32, 42, 52, and 62 is supplied to the loom in a weft and warp manner to be woven in a planar structure.

At this time, the molding yarns (1, 2, 3, 4, 5, 6) are constituted by supplying a part or all of the support yarns in which conductive yarn having conductivity is embedded.

The molding member 100 using the above-described molding yarn is formed into a molded product through heating and molding by injection molding or press molding as will be described later in detail.

Fig. 10 is a plan view showing a modified example of a molding body using a molding yarn according to the first embodiment of the present invention. As shown in Fig. 10, the molding body 100 is provided with weft yarns and warp yarns 2, 3, 4, 5, 6 are densely arranged.

At this time, it is preferable that the molding yarn 2 is applied with the flat type yarn described in the second embodiment.

Since the molding body 100 using the molding yarn shown in Fig. 10 is woven by applying flat type yarn 2 as a molding yarn, the gap between the molding yarn and the molding yarn is minimized and the thickness is small A molded product having sufficient strength can be produced.

Fig. 11A is a schematic cross-sectional view showing a main part of a molding body using a molding yarn according to a second embodiment of the present invention, Fig. 11B is a schematic sectional view of a molded body formed using the molding body shown in Fig. Fig.

The molding body 200 using the molding yarn according to the second embodiment of the present invention is woven so as to have a planar structure, but the molding yarn has a molded surface layer of a two-layer structure or more.

More specifically, as shown in FIG. 11A, the molding surface member 200 includes a molded surface layer 210 which is woven in a plane by molding yarns 1, 2, 3, 4, 5 and 6, A lower molded surface layer 220 spaced from the upper molded surface layer 210 and spaced apart from the upper molded surface layer 210 and woven in a plane by the formed molded surface layer 210 and the upper and lower molded surface layers 210, And a planar layer connection part 230 formed of a plurality of connection yarns arranged in the spacing space to be connected between the connection parts.

At this time, the connection yarns constituting the planar layer connection portion 230 may be selected from among the above-mentioned formed yarns 1, 2, 3, 4, 5, and 6, but may be formed of inorganic fibers, Is selected and configured.

When any one of the inorganic fiber yarn, the organic fiber yarn, and the conductive conductive yarn is selected without using the molding yarn including the resin as the connecting yarn of the planar layer connection portion 230, The spacing space 240 between the molded surface layers 210 and 220 is formed with a hollow portion (formed as an empty space).

On the other hand, as described above, when the molding body 200 having the spacing space between the upper and lower molded surface layers 210 and 220 is formed into a molded product, the molded surface layer 210, as shown in FIG. 11B, Is formed as an upper layer 210 'of the molded product 200' together with the support yarn after the molding resin layer of the molded yarn is melted and the molding resin layer of the molded yarn constituting the lower molded surface layer 220 is melted Together with the backing yarn, is formed as a lower layer 220 'of the molding 200', and the spacing space 240 is formed as a hollow.

When a void space in which the fluid such as air is filled can be formed in the spacing space 240 formed in the molded product 200 ', a heat retaining function can be performed. When an external force such as an impact force is applied to the molded product, , So that the buffering function can be performed.

The molding surface member 200 shown in FIG. 11A may be formed of a heat insulating material such as an airgel or the like, an insulating material such as a ceramic, or the like, in a spacing space 240 between the upper and lower molded surface layers 210 and 220, (Not shown) including at least one of a shock absorbing material such as foamed foam, a conductive polymer (conductive ink), metal oxide particles, metal nanoparticles, graphene particles, and the like.

When the molded product 200 'is manufactured using the molding member 200 having conductive conductive yarns selected as the connecting yarns of the plane-shaped layer connecting portion 230, the upper layer 210' and the lower layer 220 ' ') To be electrically connected to each other, thereby realizing a molded product that performs a power application function. When the molding surface body having such electric conductivity is used as a case molding material for household appliances or communication devices, it is possible to simplify and simplify the input and output terminals of power and electric signals, and to provide convenience of design and convenience of use It will be possible.

Fig. 12 is an enlarged cross-sectional view of the main part showing a molding body using a molding yarn according to the third embodiment of the present invention. Fig.

The molding body 300 using the molding yarn according to the third embodiment of the present invention is a molding body formed by molding yarns 1, 2, 3, 4, 5, and 6 supplied as weft yarns and warp yarns, (310), and a reinforcing layer (320) woven on one surface of the molded surface layer (310) so as to protrude in the form of a ring or a short fiber.

The molding body 300 using the molding yarn according to the third embodiment of the present invention described above can be woven by a loom capable of weaving a plain weave or the like, When the formed reinforcing layer 320 is formed, the supporting yarns 11, 21, 31, 41, 51, and 61 included in the molding yarn in the form of an annular or monofilament constituting the reinforcing layer 320, When the thermally deforming force and the physical strain force are applied to the molded product, they are entangled with each other in a similar manner to the truss structures of various structures such as bridges and buildings, and the structural rigidity is increased. It is possible to provide rigidity against distortion.

Fig. 13 is an enlarged cross-sectional view of a main part showing a modified example of a molding surface body using a molding yarn according to a third embodiment of the present invention.

The molding surface body 300 'using the molding yarn shown in FIG. 13 is obtained by forming the reinforcing layers 320 and 320' which are woven to protrude from one side and the other side of the molded surface layer 310 woven in a planar structure, ).

Since the molding surface member 300 'of the shape shown in FIG. 13 is composed of the reinforcing layers 320 and 320' on both sides of the molded surface layer 310, the structural rigidity 300 'is higher than that of the molding surface member 300 shown in FIG. And thus has an increased characteristic.

Meanwhile, the molded product using the molding yarn according to the present invention is not specifically described with reference to the drawings, but may be formed in various shapes in addition to the area structure shown in FIGS. 10 to 13. For example, the molding yarns 1, 2, 3, 4, 5, and 6 may not be formed as an in-plane body, but the molding yarns of a plurality of strands may be woven together to form a rope shape.

Fig. 14 is a view for explaining a method for producing a molded product using the molding yarn according to the present invention.

The method for manufacturing a molded product using the molding yarn according to the present invention relates to the method for forming a molded product using the molding yarn shown in the first to sixth embodiments and its modified examples, , And a molded product forming step (s2).

As shown in Fig. 14 (A), the face-body forming step (s1) is a step of forming woven or knitted fabrics with each other to form a planar face body 100 having a planar structure, It can be constructed using looms. At this time, the molding surface member 100 shown in Fig. 14 (A) can be woven by a loom that can weave a plain weave or the like.

Although the manufacturing process is not specifically shown, the molding surface member 200 of the multi-layer structure shown in Fig. 11A can be woven by a loom called a warp knitting machine or a velvet weaving machine.

The molding forming step s2 is a step of manufacturing a molded article 100 'by heating and molding the molding surface member 100 formed by the above-mentioned in-plane forming step, and can be realized by press molding or injection molding. 14 (B), the molding resin layer 12 of the molding yarn 1 is heated and melted, and the portion of the supporting yarn 11 is pressed And then hardened to remain as an outer skin layer 12 'of the molded article 100'. The detailed process of press molding and injection molding is a general technique in the molding field, so a detailed description thereof will be omitted.

The molding method described above has been described on the basis of the manufacturing method using the molding surface member 100 shown in FIG. 9, and the molding surface member shown in FIGS. 11A, 12, Method, so a detailed description thereof will be omitted.

On the other hand, the method for producing a molded product using the molding yarn according to the present invention has various advantages as compared with the conventional method for producing a molded product as described above.

First, the method of manufacturing a molded article using the molding yarn according to the present invention is not a method of padding or inserting a reinforcing layer or a shielding fiber separately in the manufacture of a molded article, but a method in which the molded yarn 1, The thickness of the molded article can be minimized and the molded article can be made thin and compact. Particularly, there is an advantage that a small case such as a smart phone can be manufactured thinly and in a merchantable manner.

In addition, since a step of preparing the reinforcing layer or the shielding fiber in advance or injecting the reinforcing layer or the shielding fiber into the injection mold is not required at the time of molding, the manufacturing process is simple and the manufacturing time is shortened so that the manufacturing cost is reduced and the productivity is improved.

In addition, when a molding product having a stretchability is applied, a molded product having a sharp change in cross section such as a bent portion and a concavo-convex portion is molded or molded into a complicated molded product, such that the supporting yarn is not broken or damaged, The molding quality is improved and the rigidity is increased.

The present invention is not limited to the above-described embodiments, but may be applied to other types of moldings, such as a molding body using a molding yarn, a molding body using a molding yarn, a molding using a molding yarn, It will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. .

In addition, the terms used in the present application are used only to illustrate specific embodiments and are not intended to limit the invention. The singular expressions include plural expressions unless the context clearly dictates otherwise. In the present application, the terms "comprises" or "having" and the like are used to specify that there is a feature, a number, a step, an operation, an element, a component or a combination thereof described in the specification, But do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

1,2,3,4,5,6: Molding machine
11, 21, 31, 41, 41 ', 51, 61:
11a: fiber yarn
11b, 52a:
12, 22, 32, 42, 52 and 62:
52b: Screening
63: Conductive thin film layer
100, 200, 300, 300 ': forming surface body
100 ', 200': moldings
210: phase forming surface layer
220: Lower molded surface layer
230: plane layer connection
240: Spacing space
310: molded surface layer
320,320 ': Stiffening layer

Claims (27)

In the molding yarn,
A support yarn disposed inside;
And a molding resin layer laminated on the outer surface of the support yarn. The method according to claim 1,
Wherein the forming resin layer is formed by applying a molding resin to the outer surface of the supporting yarn or a resin hollow yarn formed to have a hollow portion by the molding resin is inserted into the supporting yarn. The method according to claim 1,
Wherein the supporting yarns are composed of a stretchable polymer yarn which is expanded when an external force is applied and contracted when an external force is released. The method according to claim 1,
Wherein the supporting yarns are formed of a yarn formed in a winding structure or a zigzag structure so as to be stretched when an external force is applied. The method according to claim 1,
Wherein the support yarn is a conductive yarn having conductivity. 6. The method of claim 5,
Wherein the conductive yarn is one of a carbon paper including carbon, a metal yarn formed of a conductive metal, and a conductive fiber yarn coated or contained with a conductive material in the fiber yarn. The method according to claim 1,
Wherein the forming resin layer is formed by winding a resin yarn formed by a molding resin on the outer surface of the supporting yarn or by laminating the same. 8. The method of claim 7,
Characterized in that the resin yarn has a check in the center thereof. 9. The method of claim 8,
Wherein all or part of the examination is a conductive yarn having conductivity. The method according to claim 1,
And a conductive thin film layer is formed on an outer surface of the molding resin layer. The method according to claim 1,
Wherein the support yarns are made of flat fibers whose thickness is thinner than the width and whose surfaces are flat. 12. The method of claim 11,
Wherein the flat fibers are polyethylene fibers (PE yarns) having a thickness of 50 to 200 denier, and the number of filaments constituting one strand of the polyethylene fibers is 10 to 200 strands. The method according to claim 1,
Wherein the supporting yarns are formed of bristles having a plurality of bristles formed on the outer surface of the linear body. The method according to claim 1,
Characterized in that said support yarns are composed of a plurality of strands. 15. The method of claim 14,
Wherein a part of the support yarns is provided with a resin yarn in which a resin forming the molding resin layer is formed in a preliminary form. In the molding surface body,
Wherein a plurality of strands of a forming yarn constituted by a supporting yarn disposed in the inside of the supporting yarn and a forming resin layer laminated on the outer surface of the supporting yarn are woven together to form a planar structure. In the molding surface body,
A molding surface body according to any one of claims 1 to 15, wherein the molding yarns are woven together to form a planar structure. 18. The method of claim 17,
Wherein all or a part of the support yarn is a conductive yarn having conductivity. 18. The method of claim 17,
Wherein the shaping yarn is supplied as weft yarns and warp yarns and is woven in a planar structure. 20. The method of claim 19,
Wherein the molding surface body is woven so as to have a planar structure, wherein the molding yarn is woven so as to have a molded surface layer having a multilayer structure of two or more layers. 21. The method of claim 20,
Wherein the molding surface body comprises a molded surface layer that is woven in the form of a sheet by the molding yarn, a bottom molded surface layer that is spaced apart from the molded surface layer and is woven in a plane by the molding yarn, And a planar layer connection formed by a plurality of connection yarns arranged in the spaced space so as to be connected between the lower molded surface layers. 22. The method of claim 21,
Wherein the connecting yarn is formed of any one of inorganic fiber yarns, organic fiber yarns, and conductive conductive yarns, and a space between the upper and lower molded surface layers is formed as a hollow portion in a state of being molded into a molded product. 23. The method of claim 22,
And a filling layer formed of any one of a heat insulating material, an insulating material, an impact absorbing material, and a conductive material is embedded in the spacing space. 18. The method of claim 17,
Wherein the molding surface member is formed of a resin-
A molded surface layer woven in a planar shape by the shaping yarn being fed at warp and weft; And
And a reinforcing layer which is woven to protrude from one or both surfaces of the molded surface layer. A molded article characterized by heating and molding the molding body of claim 17. A molded article obtained by molding using the molding yarn of any one of claims 1 to 15. In the method for producing a molded article,
15. A method for manufacturing a molded article, comprising: a step of forming a molding yarn of any one of claims 1 to 15 into a planar molding body having a planar structure; And
And a molded article forming step of forming a molded article by heating and molding the molding surface member formed by the step of forming the article on a surface.

Images