US20180178418A1 - Resin molding, printer, and method for manufacturing resin molding - Google Patents
Resin molding, printer, and method for manufacturing resin molding Download PDFInfo
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- US20180178418A1 US20180178418A1 US15/846,025 US201715846025A US2018178418A1 US 20180178418 A1 US20180178418 A1 US 20180178418A1 US 201715846025 A US201715846025 A US 201715846025A US 2018178418 A1 US2018178418 A1 US 2018178418A1
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- glossy portion
- resin molding
- glossy
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- metal mold
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0046—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
- B29C45/0055—Shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/263—Moulds with mould wall parts provided with fine grooves or impressions, e.g. for record discs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
- B29C45/372—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings provided with means for marking or patterning, e.g. numbering articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J29/00—Details of, or accessories for, typewriters or selective printing mechanisms not otherwise provided for
- B41J29/12—Guards, shields or dust excluders
- B41J29/13—Cases or covers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0046—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
- B29C2045/0049—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity the injected material flowing against a mould cavity protruding part
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
- B29C45/0055—Shaping
- B29C2045/0058—Shaping removing material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2793/00—Shaping techniques involving a cutting or machining operation
- B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/76153—Optical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/7616—Surface properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76451—Measurement means
- B29C2945/76461—Optical, e.g. laser
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76638—Optical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76645—Surface properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/0022—Bright, glossy or shiny surface
Definitions
- the present disclosure relates to a resin molding including a glossy portion and a non-glossy portion on an exterior surface of the resin molding. More specifically, the present disclosure relates to a plate-like resin molding having a front surface which is an exterior surface, and a back surface which is a non-exterior surface having recesses and protrusions.
- non-exterior surface On a non-exterior surface of a plate-like or box-like resin molding used for, for example, a printer, recesses and protrusions such as rib-like projections for reinforcement and positioning or a difference in level caused by an ejector pin may be present.
- the “non-exterior surface” refers to a surface on the back of an exterior surface, and the “exterior surface” refers to a surface of which the exterior requires a certain grade because the surface meets the eyes of a user.
- a resin used for the resin molding often mainly contains rubber such as acrylonitrile butadiene styrene (ABS) or high impact polystyrene (HIPS).
- ABS acrylonitrile butadiene styrene
- HIPS high impact polystyrene
- the shape of the rubber partially differs in the region of the recesses and protrusions on the non-exterior surface.
- a portion having reduced glossiness termed unevenness occurs around the exterior surface on the back of the recesses and protrusions.
- a glossy exterior such as a lustrous black exterior is needed. In such an exterior, the unevenness portion having reduced glossiness is more likely to be conspicuous.
- the “crimp pattern” refers to a minute pattern (recesses and protrusions) provided on the exterior surface, and this pattern is occasionally referred to simply as “crimps”).
- the crimps also reduce glossiness. Thus, the desired glossiness cannot be accomplished.
- there is also a method for adjusting the temperature of the metal mold or the temperature of the resin If the temperature of the resin becomes high, the rubber deformed to an ellipse when the injection molding is performed returns to a circle. Consequently, it is possible to eliminate partial differences in the shape of the rubber and therefore avoid the unevenness. If, however, the temperature of the metal mold or the temperature of the resin is high temperature, the molding cycle is lengthened, and productivity deteriorates.
- Japanese Patent Application Laid-Open No. 2014-000770 discusses a method for forming minute and regular recesses and protrusions on an undulating surface having high glossiness. This method can represent an excellent texture by the high-glossy surface, and has the effect of making a molding defect such as a sink mark, a weld line, or a flow mark less conspicuous by the regular recesses and protrusions.
- a resin molding includes a first surface, and a second surface, wherein the first surface includes a glossy portion and a non-glossy portion, and the second surface includes a rib.
- a method for manufacturing a resin molding by injecting a resin into a cavity in a metal mold including a first metal mold and a second metal mold includes forming, in the first cavity, a shape from which a glossy portion having a glossiness of equal to or greater than 80% is transferred and a shape from which a non-glossy portion having a kurtosis value of equal to or greater than 3.5 is transferred, and forming, in the second cavity, a shape from which a rib is transferred.
- FIG. 1 is a perspective view illustrating a printer including a document reader according to an exemplary embodiment of the subject disclosure.
- FIG. 2 is a perspective view illustrating a state where a document platen cover of the printer illustrated in FIG. 1 is opened, according to an exemplary embodiment of the subject disclosure.
- FIGS. 3A and 3B are diagrams illustrating unevenness, according to an exemplary embodiment of the subject disclosure.
- FIG. 4 is a diagram illustrating a grid pattern according to the exemplary embodiment of the subject disclosure.
- FIG. 5 is a diagram illustrating a document platen cover having the grid pattern according to the exemplary embodiment of the subject disclosure.
- FIG. 6 is an A-A cross-sectional view of the document platen cover illustrated in FIG. 5 , according to an exemplary embodiment of the subject disclosure.
- FIGS. 7A and 7B are diagrams illustrating a relationship between a kurtosis value and a shape according to the exemplary embodiment of the subject disclosure.
- FIGS. 8A, 8B, and 8C are diagrams illustrating resin moldings, according to exemplary embodiments of the subject disclosure.
- FIG. 9 is a diagram illustrating a machining center for processing a metal mold according to the exemplary embodiment of the subject disclosure.
- FIGS. 10A, 10B, and 10C are diagrams illustrating methods for manufacturing a metal mold for injection-molding a resin molding according to the exemplary embodiment.
- FIG. 11A illustrates a resin molding and metal molds, according to an exemplary embodiment of the subject disclosure.
- FIG. 11B illustrates a molding molded by the metal molds, according to an exemplary embodiment of the subject disclosure.
- the resin molding according to the present disclosure is a plate-like resin molding having a first surface and a second surface and is used for, for example, the exterior of a household electrical appliance product or an electronic device product, or an exterior part or an interior part of a vehicle such as an automobile, which requires a high-grade exterior.
- An example is illustrated where the resin molding is used for a printer including a document reader as the exemplary embodiment of the present disclosure.
- FIG. 1 is a perspective view of the printer including the document reader for which the resin molding according to the present disclosure is used as an example of the exemplary embodiment of the present disclosure.
- a multifunction printer 1 includes a document platen cover 12 and a housing 10 , which forms a main body.
- FIG. 2 is a perspective view of the state where the document platen cover of the printer including the document reader is opened.
- a second surface 13 (non-exterior surface) of the document platen cover 12 includes a rib 14 , which is a projection protruding from the second surface 13 .
- the first surface 11 will occasionally be referred to as an “exterior surface”
- the second surface 13 will occasionally be referred to as a “non-exterior surface”.
- plate-like may refer to either a case where either the first or the second surface is a planar surface, or a case where both the first and second surfaces are planar surfaces.
- either the first or second surface may be a curved surface, or both the first and second surfaces may be curved surfaces.
- the effects of the present disclosure are remarkably exerted in a resin molding in which the distance between the first and second surfaces is equal to or less than 3 mm.
- the effects of the present disclosure are remarkably exerted in a resin molding in which the cross section of the rib 14 when cut along a surface parallel to the second surface 13 is a rectangle or a shape obtained by chamfering corner portions of a rectangle.
- the effects of the present disclosure are remarkably exerted if the length of each short side of the rectangle is less than 2 mm, and the length of each long side of the rectangle is equal to or greater than 1 cm.
- the cross section is a shape obtained by chamfering corner portions of a rectangle
- the effects of the present disclosure are remarkably exerted if the length of each short side of the rectangle is less than 2 mm and the length of each long side of the rectangle is equal to or greater than 1 cm on the assumption that the corner portions are not chamfered.
- FIG. 3A is a diagram illustrating a partial enlarged view of a conventional document platen cover and illustrates unevenness occurring on the exterior surface 11 under the influence of a rib 14 of the non-exterior surface 13 .
- FIG. 3B illustrates a partial cross-sectional view of the conventional document platen cover.
- a document platen cover 12 is molded by injection molding. Although a manufacturing method will be described in detail below, the document platen cover 12 is manufactured by injection-molding a material in which rubber particles are included in a resin, such as acrylonitrile butadiene styrene (ABS) and high impact polystyrene (HIPS), into a cavity in a metal mold from a gate.
- ABS acrylonitrile butadiene styrene
- HIPS high impact polystyrene
- the shape of the rubber differs only in a portion of the exterior surface 11 on the back of the rib 14 of the non-exterior surface 13 of the molded molding. Then, as illustrated in FIGS. 3A and 3B , the glossiness of the portion is reduced, and the portion is visually recognized as unevenness 30 .
- the exterior surface 11 requires a high-grade surface.
- a glossy portion having high glossiness and a non-glossy portion having glossiness lower than that of the glossy portion are provided on the exterior surface 11 . It is more desirable that the non-glossy portion should be more raised than the glossy portion. However, even if the non-glossy portion is on the same plane as the glossy portion or is more recessed than the glossy portion, it is possible to make the unevenness 30 less conspicuous than a surface having only the glossy portion.
- FIG. 4 is a diagram illustrating an exterior surface 11 according to the present exemplary embodiment.
- the exterior surface 11 requires a high-grade surface.
- a resin molding 40 includes a glossy portion 41 , which is a flat surface, and a non-glossy portion 42 , which is raised from the glossy portion 41 .
- the exterior surface 11 includes the non-glossy portion 42 raised from the glossy portion 41 .
- the present disclosure is not limited to this.
- a glossy portion having high glossiness and a non-glossy portion having glossiness lower than that of the glossy portion may only need to be provided.
- the glossiness of the glossy portion 41 should be equal to or greater than 80% and equal to or less than 100%.
- the glossiness of the glossy portion 41 is equal to or greater than 80%, whereby it is possible to obtain an excellent texture (a high-grade surface).
- glossiness is a value measured using a gloss meter based on mirror surface glossiness at a reflection angle of 60° in JIS Z 8741.
- glossiness refers to a numerical value obtained by setting a handy gloss meter PG-1 manufactured by Nippon Denshoku Industries Co., Ltd. to a reflection angle of 60° and pressing a measurement switch with a photometric portion of the gloss meter placed on a glossy portion of a molding.
- the present disclosure is directed to, for example, making a non-glossy grid-like pattern (grid pattern) illustrated in FIG. 4 conspicuous to make the unevenness 30 inconspicuous, thereby reducing an exterior defect due to the unevenness 30 .
- grid pattern grid pattern
- the difference in glossiness between the glossy portion 41 and the non-glossy portion 42 is made great.
- the difference in glossiness being great means that there is a contrast.
- it is easy to visually recognize the grid pattern while it is difficult to visually recognize the unevenness 30 (the unevenness 30 is inconspicuous).
- the kurtosis value (Sku) of the non-glossy portion 42 should be equal to or greater than 3.5.
- the effects of the present disclosure are exerted if the kurtosis value is equal to or greater than 3.5. In manufacturing, however, it is difficult to produce a shape having a kurtosis value exceeding 50.0. Thus, it is more desirable that the kurtosis value should be equal to or greater than 3.5 and equal to or less than 50.0. Further, it is found that the non-glossy portion 42 has a grid pattern, whereby the effects are more remarkably exerted in a resin molding in which the cross section of a rib formed on a second surface when cut along a surface parallel to the second surface is a rectangle or a shape obtained by chamfering corner portions of a rectangle.
- the rib is likely to be hidden in the pattern of the non-glossy portion 42 .
- the cross section of the rib when cut along a surface parallel to the second surface is a rectangle, the effects are more exerted if the length of each short side of the rectangle is less than 2 mm, and the length of each long side of the rectangle is equal to or greater than 1 cm.
- the effects are more exerted if the length of each short side of the rectangle is less than 2 mm and the length of each long side of the rectangle is equal to or greater than 1 cm on the assumption that the corner portions are not chamfered.
- FIG. 5 illustrates a document platen cover 12 in which a grid pattern is drawn on an exterior surface 11 .
- FIG. 6 illustrates an A-A cross section of the document platen cover 12 in FIG. 5 .
- a non-glossy portion 50 at least a part of a surface 63 of the non-glossy portion 50 is a non-glossy surface.
- the surface 63 may be formed so that light incident on the surface 63 is scattered.
- kurtosis (Sku) is a surface property parameter defined in ISO25178 and is one of parameters indicating a height relative to a reference surface when a surface having the average height of a measured region is set as the reference surface.
- kurtosis (Sku) indicates the degree of pointedness of a roughness shape and is calculated by the following formula (1).
- Sq is obtained by extending two-dimensional Rq (root mean square (rms)) to three dimensions and represents a standard deviation calculated by formula (2).
- Sq is a root-mean-square deviation obtained by dividing by a measurement area A the volume of a portion obtained by squaring the distance between a surface shape and a reference surface and of a portion surrounded by the reference surface, and then obtaining the square root of the division result.
- Z represents the height of the measured surface shape
- x and y represent the axes of the reference surface.
- FIGS. 7A and 7B illustrate the relationship between the kurtosis value (Sku) and the surface property.
- FIG. 7A illustrates a surface 70 , of which the kurtosis value (Sku) is high
- FIG. 7B illustrates a surface 71 , of which the kurtosis value (Sku) is low.
- the kurtosis value (Sku) is high
- the height distribution of the surface 70 is pointed in a needle-like manner.
- the kurtosis value (Sku) is low
- the height distribution of the surface 71 is smooth.
- Light incident on the surface 70 of which the kurtosis value (Sku) is high, is scattered by the surface 70 , which is pointed in a needle-like manner.
- the glossiness of the surface 70 is low.
- the glossiness of the surface 71 is high.
- the kurtosis value (Sku) can be measured using a laser microscope manufactured by Keyence Corporation, for example.
- the kurtosis value is a numerical value measured using a shape analysis laser microscope VK-X100 manufactured by Keyence Corporation. More specifically, a non-glossy portion in a region of 0.5 mm ⁇ 0.7 mm in a molding is measured using a 10-power objective lens. Then, 10 regions in the non-glossy portion are measured. Then, kurtosis values are calculated from the measurement results of the respective regions using a multi-file analysis application, which is dedicated analysis software, and the average value of the calculated values is defined as the kurtosis value.
- the non-glossy portion 50 should be raised from the glossy portion 51 by equal to or greater than 40 ⁇ m and less than 500 ⁇ m. If the non-glossy portion 50 is raised by equal to or greater than 40 ⁇ m, a fingerprint is less likely to be attached to the molding, which is more desirable. If the non-glossy portion 50 is raised by equal to or greater than 500 ⁇ m, a region where the glossy portion 51 is visible is small depending on the angle, and the sense of luxuriousness is reduced. That is, it is desirable that the difference in height between the glossy portion 51 and the non-glossy portion 50 should be equal to or greater than 40 ⁇ m and less than 500 ⁇ m.
- the difference in height between the glossy portion 51 and the non-glossy portion 50 is obtained by measuring the height of the non-glossy portion 50 using a white interferometer such that the glossy portion 51 , which is a planar surface in the exterior surface 11 , is a reference.
- the difference in height between the glossy portion 51 and the non-glossy portion 50 is defined as the average value of values obtained by measuring 10 places in a region of 1.0 mm ⁇ 1.4 mm in a molding with a 10-power objective lens, using a three-dimensional optical profiler NewView 7000 manufactured by Zygo Corporation.
- the boundary portion of the non-glossy portion 50 and the glossy portion 51 will occasionally be referred to as a “base portion”.
- the radius of curvature of the base portion 64 is large, the ridge line 43 of the grid pattern seems blurry. Thus, it is desirable that the radius of curvature of the base portion 64 should be small, because the unevenness is less conspicuous. Particularly, if the radius of curvature of the base portion 64 is equal to or less than 20 ⁇ m, the ridge line 43 of the grid pattern is more clearly visible.
- the radius of curvature of the base portion 64 is calculated by measuring the profile of the base shape of the non-glossy portion 50 using a laser microscope manufactured by Keyence Corporation, for example, and then approximating the profile to a circular arc by the method of least squares.
- the radius of curvature of the base portion 64 is a numerical value measured using a shape analysis laser microscope VK-X100 manufactured by Keyence Corporation. More specifically, the radius of curvature of the base portion 64 is defined as a value obtained by measuring 10 places in a region of 0.5 mm ⁇ 0.7 mm in a molding with a 10-power objective lens, calculating the profile of a base portion in each measurement region and the radius of curvature of an approximate circular arc of the profile using a multi-file analysis application, which is dedicated analysis software, and averaging the calculated radii of curvature.
- a width P of the glossy portion 41 should be equal to or greater than 0.063 mm and equal to or less than 4.0 mm. It is known that when a person with normal eyesight views the resin molding 40 , the shortest width that enables the person to visually recognize the glossy portion 41 is about 0.063 mm. Based on this, if the width P of the glossy portion 41 is less than 0.063 mm, it is difficult to visually recognize the glossy portion 41 and distinguish the grid pattern. This also results in reducing the effect that the unevenness 30 is less conspicuous.
- the pitch of the grid of the grid pattern should be equal to or greater than 0.063 mm and equal to or less than 4.0 mm.
- FIGS. 8A, 8B, and 8C illustrate plan views of examples of the repetitive pattern.
- FIG. 8A illustrates an example of the grid pattern used in the present exemplary embodiment.
- FIG. 8B illustrates a polka-dot pattern, which is a set of circles
- FIG. 8C illustrates a snowflake pattern.
- the present disclosure is not limited to these patterns.
- a set of polygons such as triangles or rectangles may be used.
- concentric circles or character shapes may be used.
- the glossy portion 51 and the non-glossy portion 50 may only need to be alternately placed.
- any material including rubber particles, such as ABS or HIPS, can be used without limitation.
- a non-glossy portion raised from a glossy portion is formed, whereby light incident on the non-glossy portion is scattered, and a contrast occurs between the non-glossy portion and the glossy portion.
- the raised non-glossy portion can camouflage unevenness occurring on an exterior surface, thereby making it difficult to visually recognize the unevenness.
- FIG. 9 is a diagram illustrating a machining center 90 for processing the first metal mold and the second metal mold according to the exemplary embodiment.
- a machining center 90 includes a processing machine main body 91 and a controller 92 .
- the first metal mold and the second metal mold may be formed of a plurality of pieces (a piece will occasionally be referred to as a “cavity piece” in the specification). If the cavity is formed of pieces, even a molding having a complex shape can be processed by dividing a transfer surface. Thus, it is possible to reduce the manufacturing cost of the metal mold.
- the processing machine main body 91 performs cutting on a first metal mold (cavity piece) 931 (or a second metal mold 932 ), which is a processing target object, thereby manufacturing a metal mold.
- the processing machine main body 91 includes a spindle 95 , which is a main shaft for supporting a cutting tool 94 , an X-stage 96 , a Y-stage 97 , and a Z-stage 98 .
- the spindle 95 rotates the cutting tool 94 about a Z-axis.
- the Z-stage 98 supports the spindle 95 and moves the cutting tool 94 in a Z-direction relative to the first metal mold 931 (or the second metal mold 932 ).
- the X-stage 96 moves the cutting tool 94 in an X-direction relative to the first metal mold 931 (or the second metal mold 932 )
- the Y-stage 97 moves the cutting tool 94 in a Y-direction relative to the first metal mold 931 (or the second metal mold 932 ).
- the processing machine main body 91 can move the front end of the cutting tool 94 in the XYZ directions relative to the first metal mold 931 (or the second metal mold 932 ) while rotating the cutting tool 94 .
- the controller 92 includes a computer including a central processing unit (CPU) and a memory and controls the processing machine main body 91 according to numerical control (NC) data 99 .
- the NC data 99 includes various instructions for use in cutting, such as the amount of movement in the X-direction, the amount of movement in the Y-direction, the amount of movement in the Z-direction, the rotational speed of the main shaft, the feeding rate in the X-direction, the feeding rate in the Y-direction, and the moving speed in the Z-direction.
- the cutting tool 94 is moved relative to the first metal mold 931 (or the second metal mold 932 ) while being rotated, whereby it is possible to perform cutting on the first metal mold 931 (or the second metal mold 932 ), thereby obtaining a three-dimensional shape based on the NC data 99 .
- FIGS. 10A, 10B, and 10C illustrate the steps of manufacturing the first metal mold 931 .
- FIG. 10A illustrates a first processing step.
- FIG. 10B illustrates a second processing step.
- FIG. 10C illustrates a third processing step.
- a surface 101 of the first metal mold 931 is roughly processed.
- a radius end mill 102 is used as the cutting tool 94 in the machining center 90 illustrated in FIG. 9 .
- the radius end mill 102 is cut into the surface 101 while being rotated, and is scanned, thereby performing cutting.
- it is desirable that the flatness of the surface 101 should be made equal to or less than 10 ⁇ m in the first processing step.
- the surface 101 of the first metal mold 931 is subjected to mirror surface finishing using a rotary polishing tool 103 and diamond paste.
- a rotary polishing tool 103 and diamond paste it is desirable that the flatness of the surface 101 should be made equal to or less than 5 ⁇ m in the second processing step.
- the recessed portions 104 are processed on the surface 101 of the first metal mold 931 using a ball end mill 106 .
- the ball end mill 106 is cut into the surface 101 while being rotated, and is scanned, thereby performing cutting. Then, the shape of the ball end mill 106 is transferred to the first metal mold 931 , thereby forming the recessed portions 104 .
- the ball end mill 106 of which the material is cubic boron nitride (CBN) is used and rotated at 20000 revolutions per minute, thereby performing processing. Since CBN is the hardest next to diamond, the ball end mill 106 , which is made of CBN, has a sharp edge.
- a base portion 105 of each recessed portion 104 has an acute angle, and the radius of curvature of the base portion 105 is equal to or less than 20 ⁇ m. Further, when the recessed portion 104 is processed, it is desirable that the ball end mill 106 should be rotated at 20000 revolutions per minute and fed at 150 to 500 mm/min so that the kurtosis value (Sku) of the recessed portion 104 is equal to or greater than 3.5.
- the ball end mill 106 is rotated at 20000 revolutions per minute and fed at 150 to 500 mm/min, whereby a cyclic shape is formed in the scanning direction, and the kurtosis value becomes high. Further, it is desirable that the ball end mill 106 should be scanned twice or more. At this time, in each scan, the position of the tool may be shifted by about 50 ⁇ m in a direction perpendicular to the scanning direction. This is because lines to be scanned are shifted, whereby minute projection shapes are formed in the sub-scanning direction, the roughness of the surface becomes great, and the kurtosis value becomes high.
- Examples of the material of the first metal mold 931 and the second metal mold 932 to be subjected to the above processing include stainless steel. Alternatively, another material may be used in terms of processability and durability in injection molding.
- the second and third processing steps are performed in reverse order, whereby it is possible to manufacture a resin molding in which a glossy portion is raised from a non-glossy portion.
- FIG. 11A illustrates a resin molding and metal molds.
- An injection molding step is a known method. Injection molding is performed by injecting a resin 1061 into a cavity formed in the first metal mold 931 and the second metal mold 932 as illustrated in FIG. 11 using the first metal mold 931 and the second metal mold 932 manufactured as described above.
- the surface 101 of the first metal mold 931 illustrated in FIG. 11A has been subjected to mirror surface finishing.
- the kurtosis value (Sku) of the recessed portion 104 of the first metal mold 931 is equal to or greater than 3.5.
- the radius of curvature of the base portion 105 of the recessed portion 104 of the first metal mold 931 is equal to or less than 20 ⁇ m.
- a shape 107 from which a rib is transferred is formed.
- FIG. 11B illustrates a molding molded by the first metal mold 931 and the second metal mold 932 .
- a resin molding 110 includes a glossy portion 111 and a non-glossy portion 112 on a first surface of the resin molding 110 and includes a rib on a second surface of the resin molding 110 . Since the surface 101 of the first metal mold 931 has been subjected to mirror surface finishing, the glossiness of the glossy portion 111 of the resin molding 110 , which is a transfer surface, is equal to or greater than 80%.
- the resin molding 110 includes the glossy portion 111 , which is glossy, on its exterior surface, and thus can obtain a sense of luxuriousness.
- the kurtosis value (Sku) of the non-glossy portion 112 is equal to or greater than 3.5, light incident on the non-glossy portion 112 is scattered, and a contrast occurs between the glossiness of the non-glossy portion 112 and the glossiness of the glossy portion 111 . Thus, it is difficult to visually recognize unevenness occurring on the exterior surface.
- the radius of curvature of the base portion 105 of the recessed portion 104 of the first metal mold 931 is equal to or less than 20 ⁇ m
- the radius of curvature of a base portion 113 of the non-glossy portion 112 of the resin molding 110 which is a transfer surface, is also equal to or less than 20 ⁇ m.
- the radius of curvature of the base portion 113 of the non-glossy portion 112 is equal to or less than 20 ⁇ m, whereby a ridge line of the base portion 113 of the non-glossy portion 112 is clearly visually recognized, which is more desirable.
- FIG. 8A is a top view of an exterior of a resin molding according to a first example.
- a grid pattern was formed on a plate-like resin molding 80 having a thickness of 1.6 mm.
- a width P of a glossy portion 81 was 1.4 mm.
- a height of a non-glossy portion 82 was 50 ⁇ m.
- a rib having a width of 0.8 mm was provided on a non-exterior surface of the resin molding 80 .
- Stainless steel was used as the material of a metal mold.
- a radius end mill was attached to the machining center 90 illustrated in FIG. 9 , and the metal mold was roughly processed. Then the metal mold was subjected to mirror surface finishing using a rotary polishing tool and diamond paste. Then, a recessed portion having an inverted shape of the non-glossy portion 82 was processed in the metal mold using a ball end mill. The recessed portion was processed by two scans, and in each scan, the position of the tool was shifted by 50 ⁇ m in a direction perpendicular to the scanning direction. In addition, the kurtosis value was changed to fall in a range from 3.0 to 5.0 while changing the feeding rate and the number of revolutions. Further, the metal mold was processed so that the radius of curvature of the cross section of a base portion was 2.0 to 30.0 ⁇ m.
- the resin molding 80 As the resin material, black HIPS was used.
- the exterior surface of the obtained resin molding 80 was visually observed by a person with normal eyesight to evaluate the visibility of unevenness.
- Table 1 illustrates the visibility of unevenness with respect to each kurtosis value and each radius of curvature of cross section of base portion.
- the visibility of unevenness for a resin molding 80 in which the unevenness was inconspicuous if the resin molding was not carefully observed, i.e., the visibility of unevenness was low is indicated as “Low”.
- the visibility of unevenness for a resin molding 80 in which the conspicuousness of the unevenness was more reduced than in a resin molding 80 the visibility of unevenness for which is indicated as “Low”, i.e., the visibility of unevenness was further low is indicated as “Very low”.
- the kurtosis value (Sku) of the non-glossy portion 82 of the resin molding 80 according to the present example was equal to or greater than 3.5, the unevenness was hardly visually recognized. If the kurtosis value (Sku) was equal to or greater than 3.5 and further the radius of curvature of the cross section of the base portion was equal to or less than 20 ⁇ m, the conspicuousness of the unevenness was more remarkably reduced.
- condition A The condition that the kurtosis value (Sku) was 3.5, and the radius of curvature of the cross section of the base portion was 5.0 ⁇ m was set as condition A.
- condition B The condition that the kurtosis value (Sku) was 4.0, and the radius of curvature of the cross section of the base portion was 10.0 ⁇ m was set as condition B.
- condition C the condition that the kurtosis value (Sku) was 5.0, and the radius of curvature of the cross section of the base portion was 20.0 ⁇ m was set as condition C.
- the visibility of unevenness was evaluated when the width of the glossy portion was 0.05, 0.063, 1.4, 4.0, and 5.0 mm in each condition. Table 2 illustrates the results of the evaluations.
- the visibility of unevenness for a resin molding 80 in which the unevenness was inconspicuous if the resin molding was not carefully observed, i.e., the visibility of unevenness was low is indicated as “Low”.
- the visibility of unevenness for a resin molding 80 in which the conspicuousness of the unevenness was more reduced than in a resin molding 80 is indicated as “Very low”.
- the height of the non-glossy portion 82 was 50 ⁇ m. Also when the height was 40, 80, 100, and 500 ⁇ m, the results were the same. However, when the height was 40 ⁇ m, a fingerprint was easily left on the glossy portion 81 . When the height was 500 ⁇ m, a region where the glossy portion 81 was visible when the plate-like resin molding 80 was viewed from a 60° direction was small, namely less than 80%, and thus the sense of luxuriousness was slightly reduced.
- FIG. 8B is a top view of an exterior of a resin molding according to a second example.
- a polka-dot pattern was formed on a plate-like resin molding 83 having a thickness 1.6 mm.
- a width P between non-glossy portions 84 was 1.4 mm.
- a height of each non-glossy portion 84 was 50 ⁇ m.
- a rib having a width of 0.8 mm was provided on a non-exterior surface of the resin molding 83 .
- Stainless steel was used as the material of a metal mold.
- the metal mold was processed using the machining center 90 illustrated in FIG. 9 .
- the metal mold was roughly processed using a radius end mill having a diameter of 6 as the cutting tool 94 and subjected to mirror surface finishing using a rotary polishing tool and diamond paste.
- a recessed portion having an inverted shape of each non-glossy portion 84 was processed in the metal mold using a ball end mill having a diameter of 0.4.
- the recessed portion was processed by scanning the ball end mill in a concentric circle, and the pitch of each scan in the radial direction was 50 ⁇ m.
- the metal mold After the metal mold was manufactured, injection molding was performed, thereby obtaining the resin molding 83 .
- the resin material black HIPS was used.
- the kurtosis value (Sku) of the non-glossy portion 84 of the resin molding 83 according to the present example was equal to or greater than 3.5. Further, the radius of curvature of the cross section of a base portion of the non-glossy portion 84 was equal to or less than 20 m.
- the exterior surface of the obtained resin molding 83 was visually observed by a person with normal eyesight to evaluate the visibility of unevenness occurring on the back of the rib. As a result, the unevenness was inconspicuous.
- FIG. 8C is a top view of an exterior of a resin molding according to a third example.
- a snowflake pattern was formed on a plate-like resin molding 86 having a thickness 1.6 mm.
- the shortest distance P between non-glossy portions 87 was 3.3 mm.
- a width of the snowflake pattern was 0.5 mm, and a height of the snowflake pattern was 50 ⁇ m. Further, a rib having a width of 0.8 mm was provided on a non-exterior surface of the resin molding 86 .
- Stainless steel was used as the material of a metal mold.
- the metal mold was processed using the machining center 90 illustrated in FIG. 9 .
- the metal mold was roughly processed using a radius end mill having a diameter of 6 as the cutting tool 94 and subjected to mirror surface finishing using a rotary polishing tool and diamond paste.
- a recessed portion having an inverted shape of each non-glossy portion 87 was processed in the metal mold using a ball end mill having a diameter of 0.4.
- the recessed portion was processed by two scans, and in each scan, the position of the tool was shifted by 50 ⁇ m in a direction perpendicular to the scanning direction.
- the metal mold After the metal mold was manufactured, injection molding was performed, thereby obtaining the resin molding 86 .
- the resin material black HIPS was used.
- the kurtosis value (Sku) of the non-glossy portion 87 of the resin molding 86 according to the present example was equal to or greater than 3.5, and the radius of curvature of a base portion of the non-glossy portion 87 was equal to or less than 20 ⁇ m.
- the exterior surface of the obtained resin molding 86 was visually observed by a person with normal eyesight to evaluate the visibility of unevenness. As a result, the unevenness was inconspicuous.
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Abstract
Description
- The present disclosure relates to a resin molding including a glossy portion and a non-glossy portion on an exterior surface of the resin molding. More specifically, the present disclosure relates to a plate-like resin molding having a front surface which is an exterior surface, and a back surface which is a non-exterior surface having recesses and protrusions.
- On a non-exterior surface of a plate-like or box-like resin molding used for, for example, a printer, recesses and protrusions such as rib-like projections for reinforcement and positioning or a difference in level caused by an ejector pin may be present. The “non-exterior surface” refers to a surface on the back of an exterior surface, and the “exterior surface” refers to a surface of which the exterior requires a certain grade because the surface meets the eyes of a user.
- A resin used for the resin molding often mainly contains rubber such as acrylonitrile butadiene styrene (ABS) or high impact polystyrene (HIPS). When injection molding is performed using the resin, the shape of rubber in the resin injected into a cavity of a metal mold from an injection gate deforms from a circle to an ellipse due to flow pressure. However, in a case where recesses and protrusions are present on the non-exterior surface, the flow of the resin is disturbed in this recess/protrusion portion, and the pressure on the rubber weakens. Consequently, the rubber results in a shape close to a circle without deforming. Thus, the shape of the rubber partially differs in the region of the recesses and protrusions on the non-exterior surface. Thus, a portion having reduced glossiness termed unevenness occurs around the exterior surface on the back of the recesses and protrusions. In recent years, to improve design quality, a glossy exterior such as a lustrous black exterior is needed. In such an exterior, the unevenness portion having reduced glossiness is more likely to be conspicuous.
- As a method for avoiding the unevenness, there exist methods for forming a crimp pattern on the exterior surface (the “crimp pattern” refers to a minute pattern (recesses and protrusions) provided on the exterior surface, and this pattern is occasionally referred to simply as “crimps”). The crimps, however, also reduce glossiness. Thus, the desired glossiness cannot be accomplished. Further, there is also a method for adjusting the temperature of the metal mold or the temperature of the resin. If the temperature of the resin becomes high, the rubber deformed to an ellipse when the injection molding is performed returns to a circle. Consequently, it is possible to eliminate partial differences in the shape of the rubber and therefore avoid the unevenness. If, however, the temperature of the metal mold or the temperature of the resin is high temperature, the molding cycle is lengthened, and productivity deteriorates.
- Japanese Patent Application Laid-Open No. 2014-000770 discusses a method for forming minute and regular recesses and protrusions on an undulating surface having high glossiness. This method can represent an excellent texture by the high-glossy surface, and has the effect of making a molding defect such as a sink mark, a weld line, or a flow mark less conspicuous by the regular recesses and protrusions.
- In the method discussed in Japanese Patent Application Laid-Open No. 2014-000770, however, the roughness and the glossiness of the entirety of a resin molding are uniform. Thus, the unevenness still exists.
- According to an aspect of the present disclosure, a resin molding includes a first surface, and a second surface, wherein the first surface includes a glossy portion and a non-glossy portion, and the second surface includes a rib.
- According to another aspect of the present disclosure, a method for manufacturing a resin molding by injecting a resin into a cavity in a metal mold including a first metal mold and a second metal mold includes forming, in the first cavity, a shape from which a glossy portion having a glossiness of equal to or greater than 80% is transferred and a shape from which a non-glossy portion having a kurtosis value of equal to or greater than 3.5 is transferred, and forming, in the second cavity, a shape from which a rib is transferred.
- Further features of the present disclosure will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
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FIG. 1 is a perspective view illustrating a printer including a document reader according to an exemplary embodiment of the subject disclosure. -
FIG. 2 is a perspective view illustrating a state where a document platen cover of the printer illustrated inFIG. 1 is opened, according to an exemplary embodiment of the subject disclosure. -
FIGS. 3A and 3B are diagrams illustrating unevenness, according to an exemplary embodiment of the subject disclosure. -
FIG. 4 is a diagram illustrating a grid pattern according to the exemplary embodiment of the subject disclosure. -
FIG. 5 is a diagram illustrating a document platen cover having the grid pattern according to the exemplary embodiment of the subject disclosure. -
FIG. 6 is an A-A cross-sectional view of the document platen cover illustrated inFIG. 5 , according to an exemplary embodiment of the subject disclosure. -
FIGS. 7A and 7B are diagrams illustrating a relationship between a kurtosis value and a shape according to the exemplary embodiment of the subject disclosure. -
FIGS. 8A, 8B, and 8C are diagrams illustrating resin moldings, according to exemplary embodiments of the subject disclosure. -
FIG. 9 is a diagram illustrating a machining center for processing a metal mold according to the exemplary embodiment of the subject disclosure. -
FIGS. 10A, 10B, and 10C are diagrams illustrating methods for manufacturing a metal mold for injection-molding a resin molding according to the exemplary embodiment. -
FIG. 11A illustrates a resin molding and metal molds, according to an exemplary embodiment of the subject disclosure. -
FIG. 11B illustrates a molding molded by the metal molds, according to an exemplary embodiment of the subject disclosure. - A resin molding according to an exemplary embodiment of the present disclosure will be described with reference to the drawings.
- The resin molding according to the present disclosure is a plate-like resin molding having a first surface and a second surface and is used for, for example, the exterior of a household electrical appliance product or an electronic device product, or an exterior part or an interior part of a vehicle such as an automobile, which requires a high-grade exterior. An example is illustrated where the resin molding is used for a printer including a document reader as the exemplary embodiment of the present disclosure.
FIG. 1 is a perspective view of the printer including the document reader for which the resin molding according to the present disclosure is used as an example of the exemplary embodiment of the present disclosure. InFIG. 1 , a multifunction printer 1 includes adocument platen cover 12 and ahousing 10, which forms a main body. Thedocument platen cover 12 and thehousing 10 are molded with a black resin, for example. Further, a first surface (exterior surface) 11, which meets the eyes of a user, requires a high-grade exterior.FIG. 2 is a perspective view of the state where the document platen cover of the printer including the document reader is opened. A second surface 13 (non-exterior surface) of thedocument platen cover 12 includes arib 14, which is a projection protruding from thesecond surface 13. In the specification, thefirst surface 11 will occasionally be referred to as an “exterior surface”, and thesecond surface 13 will occasionally be referred to as a “non-exterior surface”. Further, in the specification, “plate-like” may refer to either a case where either the first or the second surface is a planar surface, or a case where both the first and second surfaces are planar surfaces. Alternatively, either the first or second surface may be a curved surface, or both the first and second surfaces may be curved surfaces. Further, the effects of the present disclosure are remarkably exerted in a resin molding in which the distance between the first and second surfaces is equal to or less than 3 mm. Further, the effects of the present disclosure are remarkably exerted in a resin molding in which the cross section of therib 14 when cut along a surface parallel to thesecond surface 13 is a rectangle or a shape obtained by chamfering corner portions of a rectangle. Further, in a case where the cross section is a rectangle, the effects of the present disclosure are remarkably exerted if the length of each short side of the rectangle is less than 2 mm, and the length of each long side of the rectangle is equal to or greater than 1 cm. Alternatively, in a case where the cross section is a shape obtained by chamfering corner portions of a rectangle, the effects of the present disclosure are remarkably exerted if the length of each short side of the rectangle is less than 2 mm and the length of each long side of the rectangle is equal to or greater than 1 cm on the assumption that the corner portions are not chamfered. -
FIG. 3A is a diagram illustrating a partial enlarged view of a conventional document platen cover and illustrates unevenness occurring on theexterior surface 11 under the influence of arib 14 of thenon-exterior surface 13.FIG. 3B illustrates a partial cross-sectional view of the conventional document platen cover. Adocument platen cover 12 is molded by injection molding. Although a manufacturing method will be described in detail below, thedocument platen cover 12 is manufactured by injection-molding a material in which rubber particles are included in a resin, such as acrylonitrile butadiene styrene (ABS) and high impact polystyrene (HIPS), into a cavity in a metal mold from a gate. When the material is injection-molded, rubber included in the resin injected into the cavity from the gate deforms from a circle to an ellipse along the flow direction of the resin. Meanwhile, if the resin reaches a shape (a groove shape) formed in the cavity to form therib 14 of thenon-exterior surface 13, the resin flows also into the groove, and the flow of the resin is disturbed in the groove. When the resin flows into the groove formed in the cavity to form therib 14, the pressure of the resin is temporarily released. Thus, the elliptical shape of the deformed rubber results in a shape close to the original circle. Consequently, the shape of the rubber differs only in a portion of theexterior surface 11 on the back of therib 14 of thenon-exterior surface 13 of the molded molding. Then, as illustrated inFIGS. 3A and 3B , the glossiness of the portion is reduced, and the portion is visually recognized asunevenness 30. - The
exterior surface 11 requires a high-grade surface. Thus, in the present exemplary embodiment, to make theunevenness 30 inconspicuous, a glossy portion having high glossiness and a non-glossy portion having glossiness lower than that of the glossy portion are provided on theexterior surface 11. It is more desirable that the non-glossy portion should be more raised than the glossy portion. However, even if the non-glossy portion is on the same plane as the glossy portion or is more recessed than the glossy portion, it is possible to make theunevenness 30 less conspicuous than a surface having only the glossy portion. -
FIG. 4 is a diagram illustrating anexterior surface 11 according to the present exemplary embodiment. Theexterior surface 11 requires a high-grade surface. Thus, to makeunevenness 30 inconspicuous, aresin molding 40 includes aglossy portion 41, which is a flat surface, and anon-glossy portion 42, which is raised from theglossy portion 41. In the present exemplary embodiment, an example is described where theexterior surface 11 includes thenon-glossy portion 42 raised from theglossy portion 41. The present disclosure, however, is not limited to this. A glossy portion having high glossiness and a non-glossy portion having glossiness lower than that of the glossy portion may only need to be provided. That is, even if the non-glossy portion is on the same plane as the glossy portion or is more recessed than the glossy portion, it is possible to make theunevenness 30 less conspicuous than a surface having only the glossy portion. It is desirable that the glossiness of theglossy portion 41 should be equal to or greater than 80% and equal to or less than 100%. The glossiness of theglossy portion 41 is equal to or greater than 80%, whereby it is possible to obtain an excellent texture (a high-grade surface). In the specification, glossiness is a value measured using a gloss meter based on mirror surface glossiness at a reflection angle of 60° in JIS Z 8741. More specifically, “glossiness” refers to a numerical value obtained by setting a handy gloss meter PG-1 manufactured by Nippon Denshoku Industries Co., Ltd. to a reflection angle of 60° and pressing a measurement switch with a photometric portion of the gloss meter placed on a glossy portion of a molding. - The present disclosure is directed to, for example, making a non-glossy grid-like pattern (grid pattern) illustrated in
FIG. 4 conspicuous to make theunevenness 30 inconspicuous, thereby reducing an exterior defect due to theunevenness 30. To make the grid-like pattern conspicuous, the difference in glossiness between theglossy portion 41 and thenon-glossy portion 42 is made great. The difference in glossiness being great means that there is a contrast. Thus, it is easy to visually recognize the grid pattern, while it is difficult to visually recognize the unevenness 30 (theunevenness 30 is inconspicuous). It is desirable that the kurtosis value (Sku) of thenon-glossy portion 42 should be equal to or greater than 3.5. The effects of the present disclosure are exerted if the kurtosis value is equal to or greater than 3.5. In manufacturing, however, it is difficult to produce a shape having a kurtosis value exceeding 50.0. Thus, it is more desirable that the kurtosis value should be equal to or greater than 3.5 and equal to or less than 50.0. Further, it is found that thenon-glossy portion 42 has a grid pattern, whereby the effects are more remarkably exerted in a resin molding in which the cross section of a rib formed on a second surface when cut along a surface parallel to the second surface is a rectangle or a shape obtained by chamfering corner portions of a rectangle. It is considered that this is because a part of the shape of thenon-glossy portion 42 is similar to the shape of the rib, and therefore, the rib is likely to be hidden in the pattern of thenon-glossy portion 42. In a case where the cross section of the rib when cut along a surface parallel to the second surface is a rectangle, the effects are more exerted if the length of each short side of the rectangle is less than 2 mm, and the length of each long side of the rectangle is equal to or greater than 1 cm. Alternatively, in a case where the cross section of the rib when cut along a surface parallel to the second surface is a shape obtained by chamfering corner portions of a rectangle, the effects are more exerted if the length of each short side of the rectangle is less than 2 mm and the length of each long side of the rectangle is equal to or greater than 1 cm on the assumption that the corner portions are not chamfered. -
FIG. 5 illustrates adocument platen cover 12 in which a grid pattern is drawn on anexterior surface 11.FIG. 6 illustrates an A-A cross section of thedocument platen cover 12 inFIG. 5 . To provide a contrast between anon-glossy portion 50 and aglossy portion 51, at least a part of asurface 63 of thenon-glossy portion 50 is a non-glossy surface. To form thesurface 63 of thenon-glossy portion 50 as a non-glossy surface, thesurface 63 may be formed so that light incident on thesurface 63 is scattered. If the kurtosis value (Sku) of thesurface 63 of thenon-glossy portion 50 is equal to or greater than 3.5, it is possible to achieve such a surface. “Kurtosis (Sku)” is a surface property parameter defined in ISO25178 and is one of parameters indicating a height relative to a reference surface when a surface having the average height of a measured region is set as the reference surface. Particularly, kurtosis (Sku) indicates the degree of pointedness of a roughness shape and is calculated by the following formula (1). -
- In formula (1), Sq is obtained by extending two-dimensional Rq (root mean square (rms)) to three dimensions and represents a standard deviation calculated by formula (2). Sq is a root-mean-square deviation obtained by dividing by a measurement area A the volume of a portion obtained by squaring the distance between a surface shape and a reference surface and of a portion surrounded by the reference surface, and then obtaining the square root of the division result. Z represents the height of the measured surface shape, and x and y represent the axes of the reference surface.
FIGS. 7A and 7B illustrate the relationship between the kurtosis value (Sku) and the surface property.FIG. 7A illustrates asurface 70, of which the kurtosis value (Sku) is high, andFIG. 7B illustrates asurface 71, of which the kurtosis value (Sku) is low. As illustrated inFIGS. 7A and 7B , if the kurtosis value (Sku) is high, the height distribution of thesurface 70 is pointed in a needle-like manner. If the kurtosis value (Sku) is low, the height distribution of thesurface 71 is smooth. Light incident on thesurface 70, of which the kurtosis value (Sku) is high, is scattered by thesurface 70, which is pointed in a needle-like manner. Thus, the glossiness of thesurface 70 is low. On the other hand, light incident on thesurface 71, of which the kurtosis value (Sku) is low, is regularly reflected. Thus, the glossiness of thesurface 71 is high. Thus, it is desirable that the kurtosis value of thenon-glossy portion 50 should be high. Then, when the glossiness of theglossy portion 51 is equal to or greater than 80%, and if the kurtosis value of thenon-glossy portion 50 is equal to or greater than 3.5, a contrast occurs, and the unevenness is less conspicuous. The kurtosis value (Sku) can be measured using a laser microscope manufactured by Keyence Corporation, for example. In the specification, the kurtosis value (Sku) is a numerical value measured using a shape analysis laser microscope VK-X100 manufactured by Keyence Corporation. More specifically, a non-glossy portion in a region of 0.5 mm×0.7 mm in a molding is measured using a 10-power objective lens. Then, 10 regions in the non-glossy portion are measured. Then, kurtosis values are calculated from the measurement results of the respective regions using a multi-file analysis application, which is dedicated analysis software, and the average value of the calculated values is defined as the kurtosis value. - Further, it is desirable that the
non-glossy portion 50 should be raised from theglossy portion 51 by equal to or greater than 40 μm and less than 500 μm. If thenon-glossy portion 50 is raised by equal to or greater than 40 μm, a fingerprint is less likely to be attached to the molding, which is more desirable. If thenon-glossy portion 50 is raised by equal to or greater than 500 μm, a region where theglossy portion 51 is visible is small depending on the angle, and the sense of luxuriousness is reduced. That is, it is desirable that the difference in height between theglossy portion 51 and thenon-glossy portion 50 should be equal to or greater than 40 μm and less than 500 μm. The difference in height between theglossy portion 51 and thenon-glossy portion 50 is obtained by measuring the height of thenon-glossy portion 50 using a white interferometer such that theglossy portion 51, which is a planar surface in theexterior surface 11, is a reference. In the specification, the difference in height between theglossy portion 51 and thenon-glossy portion 50 is defined as the average value of values obtained by measuring 10 places in a region of 1.0 mm×1.4 mm in a molding with a 10-power objective lens, using a three-dimensional optical profiler NewView 7000 manufactured by Zygo Corporation. - Further, the more clearly visible the grid pattern, i.e., the clearer a
ridge line 43 of thenon-glossy portion 42, the more excellent effects are exerted. More specifically, the smaller the numerical value of the radius of curvature of the cross section of a boundary portion of thenon-glossy portion 50 and theglossy portion 51, i.e., abase portion 64 of thenon-glossy portion 50 adjacent to theglossy portion 51, the more clearly theridge line 43 of the grid pattern is visually recognized. In the specification, the boundary portion of thenon-glossy portion 50 and theglossy portion 51 will occasionally be referred to as a “base portion”. Conversely, if the radius of curvature of thebase portion 64 is large, theridge line 43 of the grid pattern seems blurry. Thus, it is desirable that the radius of curvature of thebase portion 64 should be small, because the unevenness is less conspicuous. Particularly, if the radius of curvature of thebase portion 64 is equal to or less than 20 μm, theridge line 43 of the grid pattern is more clearly visible. The radius of curvature of thebase portion 64 is calculated by measuring the profile of the base shape of thenon-glossy portion 50 using a laser microscope manufactured by Keyence Corporation, for example, and then approximating the profile to a circular arc by the method of least squares. In the specification, the radius of curvature of thebase portion 64 is a numerical value measured using a shape analysis laser microscope VK-X100 manufactured by Keyence Corporation. More specifically, the radius of curvature of thebase portion 64 is defined as a value obtained by measuring 10 places in a region of 0.5 mm×0.7 mm in a molding with a 10-power objective lens, calculating the profile of a base portion in each measurement region and the radius of curvature of an approximate circular arc of the profile using a multi-file analysis application, which is dedicated analysis software, and averaging the calculated radii of curvature. - In the case of the grid pattern illustrated in
FIG. 4 , it is desirable that a width P of theglossy portion 41 should be equal to or greater than 0.063 mm and equal to or less than 4.0 mm. It is known that when a person with normal eyesight views theresin molding 40, the shortest width that enables the person to visually recognize theglossy portion 41 is about 0.063 mm. Based on this, if the width P of theglossy portion 41 is less than 0.063 mm, it is difficult to visually recognize theglossy portion 41 and distinguish the grid pattern. This also results in reducing the effect that theunevenness 30 is less conspicuous. Further, if the width P of theglossy portion 41 is greater than 4.0 mm, the glossy surface of theglossy portion 41 is emphasized, and it is more difficult to visually recognize the grid pattern. This, therefore, also reduces the effect that theunevenness 30 is less conspicuous. Thus, it is desirable that the pitch of the grid of the grid pattern should be equal to or greater than 0.063 mm and equal to or less than 4.0 mm. - In the present exemplary embodiment, an example is illustrated where a person is caused to visually recognize the grid pattern on the
exterior surface 11 using theglossy portion 41 and thenon-glossy portion 42. The present disclosure, however, is not limited to the grid pattern. That is, any pattern may be used so long as a person can be caused to visually recognize the pattern based on thenon-glossy portion 42 on theexterior surface 11 by the placement of theglossy portion 41 and thenon-glossy portion 42. If, however, thenon-glossy portion 42 has a repetitive pattern, it is easy to process the glossy surface when manufacturing theresin molding 40, which is suitable.FIGS. 8A, 8B, and 8C illustrate plan views of examples of the repetitive pattern.FIG. 8A illustrates an example of the grid pattern used in the present exemplary embodiment.FIG. 8B illustrates a polka-dot pattern, which is a set of circles, andFIG. 8C illustrates a snowflake pattern. The present disclosure, however, is not limited to these patterns. Alternatively, for example, a set of polygons such as triangles or rectangles may be used. Yet alternatively, concentric circles or character shapes may be used. Theglossy portion 51 and thenon-glossy portion 50 may only need to be alternately placed. - As the material to be used for the resin molding, any material including rubber particles, such as ABS or HIPS, can be used without limitation.
- According to the present exemplary embodiment, a non-glossy portion raised from a glossy portion is formed, whereby light incident on the non-glossy portion is scattered, and a contrast occurs between the non-glossy portion and the glossy portion. Thus, the raised non-glossy portion can camouflage unevenness occurring on an exterior surface, thereby making it difficult to visually recognize the unevenness.
- Next, a method for manufacturing the resin molding according to the present exemplary embodiment is described.
- The resin molding according to the present exemplary embodiment is molded by injection-filling a cavity formed in a first metal mold and a second metal mold with a resin from a gate.
FIG. 9 is a diagram illustrating amachining center 90 for processing the first metal mold and the second metal mold according to the exemplary embodiment. Amachining center 90 includes a processing machinemain body 91 and acontroller 92. The first metal mold and the second metal mold may be formed of a plurality of pieces (a piece will occasionally be referred to as a “cavity piece” in the specification). If the cavity is formed of pieces, even a molding having a complex shape can be processed by dividing a transfer surface. Thus, it is possible to reduce the manufacturing cost of the metal mold. - The processing machine
main body 91 performs cutting on a first metal mold (cavity piece) 931 (or a second metal mold 932), which is a processing target object, thereby manufacturing a metal mold. The processing machinemain body 91 includes aspindle 95, which is a main shaft for supporting acutting tool 94, an X-stage 96, a Y-stage 97, and a Z-stage 98. - It is desirable that an end mill should be used as the cutting
tool 94. Thespindle 95 rotates thecutting tool 94 about a Z-axis. The Z-stage 98 supports thespindle 95 and moves thecutting tool 94 in a Z-direction relative to the first metal mold 931 (or the second metal mold 932). Similarly, the X-stage 96 moves thecutting tool 94 in an X-direction relative to the first metal mold 931 (or the second metal mold 932), and the Y-stage 97 moves thecutting tool 94 in a Y-direction relative to the first metal mold 931 (or the second metal mold 932). Thus, the processing machinemain body 91 can move the front end of thecutting tool 94 in the XYZ directions relative to the first metal mold 931 (or the second metal mold 932) while rotating thecutting tool 94. - The
controller 92 includes a computer including a central processing unit (CPU) and a memory and controls the processing machinemain body 91 according to numerical control (NC)data 99. TheNC data 99 includes various instructions for use in cutting, such as the amount of movement in the X-direction, the amount of movement in the Y-direction, the amount of movement in the Z-direction, the rotational speed of the main shaft, the feeding rate in the X-direction, the feeding rate in the Y-direction, and the moving speed in the Z-direction. Under control of thecontroller 92, the cuttingtool 94 is moved relative to the first metal mold 931 (or the second metal mold 932) while being rotated, whereby it is possible to perform cutting on the first metal mold 931 (or the second metal mold 932), thereby obtaining a three-dimensional shape based on theNC data 99. -
FIGS. 10A, 10B, and 10C illustrate the steps of manufacturing thefirst metal mold 931.FIG. 10A illustrates a first processing step.FIG. 10B illustrates a second processing step.FIG. 10C illustrates a third processing step. First, in the first processing step illustrated inFIG. 10A , asurface 101 of thefirst metal mold 931 is roughly processed. Aradius end mill 102 is used as the cuttingtool 94 in themachining center 90 illustrated inFIG. 9 . Theradius end mill 102 is cut into thesurface 101 while being rotated, and is scanned, thereby performing cutting. At this time, to save the trouble when smoothing thesurface 101 in the second processing step, it is desirable that the flatness of thesurface 101 should be made equal to or less than 10 μm in the first processing step. - In the second processing step in
FIG. 10B , thesurface 101 of thefirst metal mold 931 is subjected to mirror surface finishing using arotary polishing tool 103 and diamond paste. At this time, to prevent differences between the depths of recessedportions 104 when the recessedportions 104 are processed in the third processing step, it is desirable that the flatness of thesurface 101 should be made equal to or less than 5 μm in the second processing step. - In the third processing step in
FIG. 10C , the recessedportions 104 are processed on thesurface 101 of thefirst metal mold 931 using aball end mill 106. Similarly to the first processing step, theball end mill 106 is cut into thesurface 101 while being rotated, and is scanned, thereby performing cutting. Then, the shape of theball end mill 106 is transferred to thefirst metal mold 931, thereby forming the recessedportions 104. At this time, theball end mill 106 of which the material is cubic boron nitride (CBN) is used and rotated at 20000 revolutions per minute, thereby performing processing. Since CBN is the hardest next to diamond, theball end mill 106, which is made of CBN, has a sharp edge. Thus, if theball end mill 106 is used and rotated at high speed, it is possible to perform processing with excellent cutting quality and perform removal processing without plastically deforming thesurface 101 of thefirst metal mold 931 when performing processing. Thus, abase portion 105 of each recessedportion 104 has an acute angle, and the radius of curvature of thebase portion 105 is equal to or less than 20 μm. Further, when the recessedportion 104 is processed, it is desirable that theball end mill 106 should be rotated at 20000 revolutions per minute and fed at 150 to 500 mm/min so that the kurtosis value (Sku) of the recessedportion 104 is equal to or greater than 3.5. This is because theball end mill 106 is rotated at 20000 revolutions per minute and fed at 150 to 500 mm/min, whereby a cyclic shape is formed in the scanning direction, and the kurtosis value becomes high. Further, it is desirable that theball end mill 106 should be scanned twice or more. At this time, in each scan, the position of the tool may be shifted by about 50 μm in a direction perpendicular to the scanning direction. This is because lines to be scanned are shifted, whereby minute projection shapes are formed in the sub-scanning direction, the roughness of the surface becomes great, and the kurtosis value becomes high. - Examples of the material of the
first metal mold 931 and thesecond metal mold 932 to be subjected to the above processing include stainless steel. Alternatively, another material may be used in terms of processability and durability in injection molding. - Further, the second and third processing steps are performed in reverse order, whereby it is possible to manufacture a resin molding in which a glossy portion is raised from a non-glossy portion.
-
FIG. 11A illustrates a resin molding and metal molds. An injection molding step is a known method. Injection molding is performed by injecting aresin 1061 into a cavity formed in thefirst metal mold 931 and thesecond metal mold 932 as illustrated inFIG. 11 using thefirst metal mold 931 and thesecond metal mold 932 manufactured as described above. Thesurface 101 of thefirst metal mold 931 illustrated inFIG. 11A has been subjected to mirror surface finishing. The kurtosis value (Sku) of the recessedportion 104 of thefirst metal mold 931 is equal to or greater than 3.5. The radius of curvature of thebase portion 105 of the recessedportion 104 of thefirst metal mold 931 is equal to or less than 20 μm. Further, in thesecond metal mold 932, ashape 107 from which a rib is transferred is formed. -
FIG. 11B illustrates a molding molded by thefirst metal mold 931 and thesecond metal mold 932. Aresin molding 110 includes aglossy portion 111 and anon-glossy portion 112 on a first surface of theresin molding 110 and includes a rib on a second surface of theresin molding 110. Since thesurface 101 of thefirst metal mold 931 has been subjected to mirror surface finishing, the glossiness of theglossy portion 111 of theresin molding 110, which is a transfer surface, is equal to or greater than 80%. Further, since the kurtosis value (Sku) of the recessedportion 104 of thefirst metal mold 931 is equal to or greater than 3.5, the kurtosis value (Sku) of thenon-glossy portion 112 of theresin molding 110, which is a transfer surface, is also equal to or greater than 3.5. Consequently, theresin molding 110 includes theglossy portion 111, which is glossy, on its exterior surface, and thus can obtain a sense of luxuriousness. - Further, since the kurtosis value (Sku) of the
non-glossy portion 112 is equal to or greater than 3.5, light incident on thenon-glossy portion 112 is scattered, and a contrast occurs between the glossiness of thenon-glossy portion 112 and the glossiness of theglossy portion 111. Thus, it is difficult to visually recognize unevenness occurring on the exterior surface. - Further, since the radius of curvature of the
base portion 105 of the recessedportion 104 of thefirst metal mold 931 is equal to or less than 20 μm, the radius of curvature of abase portion 113 of thenon-glossy portion 112 of theresin molding 110, which is a transfer surface, is also equal to or less than 20 μm. The radius of curvature of thebase portion 113 of thenon-glossy portion 112 is equal to or less than 20 μm, whereby a ridge line of thebase portion 113 of thenon-glossy portion 112 is clearly visually recognized, which is more desirable. - While the manufacturing method has been described, the manufacturing method is not limited to the above description.
- Specific examples will be described below.
-
FIG. 8A is a top view of an exterior of a resin molding according to a first example. A grid pattern was formed on a plate-like resin molding 80 having a thickness of 1.6 mm. A width P of aglossy portion 81 was 1.4 mm. A height of anon-glossy portion 82 was 50 μm. Further, a rib having a width of 0.8 mm was provided on a non-exterior surface of theresin molding 80. - Stainless steel was used as the material of a metal mold. A radius end mill was attached to the
machining center 90 illustrated inFIG. 9 , and the metal mold was roughly processed. Then the metal mold was subjected to mirror surface finishing using a rotary polishing tool and diamond paste. Then, a recessed portion having an inverted shape of thenon-glossy portion 82 was processed in the metal mold using a ball end mill. The recessed portion was processed by two scans, and in each scan, the position of the tool was shifted by 50 μm in a direction perpendicular to the scanning direction. In addition, the kurtosis value was changed to fall in a range from 3.0 to 5.0 while changing the feeding rate and the number of revolutions. Further, the metal mold was processed so that the radius of curvature of the cross section of a base portion was 2.0 to 30.0 μm. - Then, after the metal mold was manufactured, injection molding was performed, thereby obtaining the
resin molding 80. As the resin material, black HIPS was used. - The exterior surface of the obtained
resin molding 80 was visually observed by a person with normal eyesight to evaluate the visibility of unevenness. Table 1 illustrates the visibility of unevenness with respect to each kurtosis value and each radius of curvature of cross section of base portion. In table 1, the visibility of unevenness for aresin molding 80 in which the unevenness was inconspicuous if the resin molding was not carefully observed, i.e., the visibility of unevenness was low is indicated as “Low”. Further, the visibility of unevenness for aresin molding 80 in which the conspicuousness of the unevenness was more reduced than in aresin molding 80, the visibility of unevenness for which is indicated as “Low”, i.e., the visibility of unevenness was further low is indicated as “Very low”. As illustrated in table 1, if the kurtosis value (Sku) of thenon-glossy portion 82 of theresin molding 80 according to the present example was equal to or greater than 3.5, the unevenness was hardly visually recognized. If the kurtosis value (Sku) was equal to or greater than 3.5 and further the radius of curvature of the cross section of the base portion was equal to or less than 20 μm, the conspicuousness of the unevenness was more remarkably reduced. - Next, the condition that the kurtosis value (Sku) was 3.5, and the radius of curvature of the cross section of the base portion was 5.0 μm was set as condition A. The condition that the kurtosis value (Sku) was 4.0, and the radius of curvature of the cross section of the base portion was 10.0 μm was set as condition B. Further, the condition that the kurtosis value (Sku) was 5.0, and the radius of curvature of the cross section of the base portion was 20.0 μm was set as condition C. Then, the visibility of unevenness was evaluated when the width of the glossy portion was 0.05, 0.063, 1.4, 4.0, and 5.0 mm in each condition. Table 2 illustrates the results of the evaluations. Also in table 2, the visibility of unevenness for a
resin molding 80 in which the unevenness was inconspicuous if the resin molding was not carefully observed, i.e., the visibility of unevenness was low is indicated as “Low”. Further, the visibility of unevenness for aresin molding 80 in which the conspicuousness of the unevenness was more reduced than in aresin molding 80, the visibility of unevenness for which is indicated as “Low”, i.e., the visibility of unevenness was further low is indicated as “Very low”. - From table 2, it was found out that when the width of the glossy portion was equal to or greater than 0.063 mm and equal to or less than 4.0 mm, the conspicuousness of the unevenness was more remarkably reduced.
- In the present example, the height of the
non-glossy portion 82 was 50 μm. Also when the height was 40, 80, 100, and 500 μm, the results were the same. However, when the height was 40 μm, a fingerprint was easily left on theglossy portion 81. When the height was 500 μm, a region where theglossy portion 81 was visible when the plate-like resin molding 80 was viewed from a 60° direction was small, namely less than 80%, and thus the sense of luxuriousness was slightly reduced. -
FIG. 8B is a top view of an exterior of a resin molding according to a second example. A polka-dot pattern was formed on a plate-like resin molding 83 having a thickness 1.6 mm. A width P betweennon-glossy portions 84 was 1.4 mm. A height of eachnon-glossy portion 84 was 50 μm. Further, a rib having a width of 0.8 mm was provided on a non-exterior surface of theresin molding 83. - Stainless steel was used as the material of a metal mold. The metal mold was processed using the
machining center 90 illustrated inFIG. 9 . The metal mold was roughly processed using a radius end mill having a diameter of 6 as the cuttingtool 94 and subjected to mirror surface finishing using a rotary polishing tool and diamond paste. Then, a recessed portion having an inverted shape of eachnon-glossy portion 84 was processed in the metal mold using a ball end mill having a diameter of 0.4. The recessed portion was processed by scanning the ball end mill in a concentric circle, and the pitch of each scan in the radial direction was 50 μm. - After the metal mold was manufactured, injection molding was performed, thereby obtaining the
resin molding 83. As the resin material, black HIPS was used. - As a result, the kurtosis value (Sku) of the
non-glossy portion 84 of theresin molding 83 according to the present example was equal to or greater than 3.5. Further, the radius of curvature of the cross section of a base portion of thenon-glossy portion 84 was equal to or less than 20 m. - The exterior surface of the obtained
resin molding 83 was visually observed by a person with normal eyesight to evaluate the visibility of unevenness occurring on the back of the rib. As a result, the unevenness was inconspicuous. -
FIG. 8C is a top view of an exterior of a resin molding according to a third example. A snowflake pattern was formed on a plate-like resin molding 86 having a thickness 1.6 mm. The shortest distance P betweennon-glossy portions 87 was 3.3 mm. A width of the snowflake pattern was 0.5 mm, and a height of the snowflake pattern was 50 μm. Further, a rib having a width of 0.8 mm was provided on a non-exterior surface of theresin molding 86. - Stainless steel was used as the material of a metal mold. The metal mold was processed using the
machining center 90 illustrated inFIG. 9 . In the present example, the metal mold was roughly processed using a radius end mill having a diameter of 6 as the cuttingtool 94 and subjected to mirror surface finishing using a rotary polishing tool and diamond paste. Then, a recessed portion having an inverted shape of eachnon-glossy portion 87 was processed in the metal mold using a ball end mill having a diameter of 0.4. The recessed portion was processed by two scans, and in each scan, the position of the tool was shifted by 50 μm in a direction perpendicular to the scanning direction. - After the metal mold was manufactured, injection molding was performed, thereby obtaining the
resin molding 86. As the resin material, black HIPS was used. - As a result, the kurtosis value (Sku) of the
non-glossy portion 87 of theresin molding 86 according to the present example was equal to or greater than 3.5, and the radius of curvature of a base portion of thenon-glossy portion 87 was equal to or less than 20 μm. - The exterior surface of the obtained
resin molding 86 was visually observed by a person with normal eyesight to evaluate the visibility of unevenness. As a result, the unevenness was inconspicuous. -
TABLE 1 Kurtosis value (Sku) 3 3.5 4 5 Radius of curvature [μm] 2 Low Very Very Very of base portion low low low 5 Low Very Very Very low low low 10 Low Very Very Very low low low 20 Low Very Very Very low low low 30 Low Low Low Low -
TABLE 2 Width [mm] of flat portion 0.05 0.063 1.4 4 5 A Low Very low Very low Very low Low B Low Very low Very low Very low Low C Low Very low Very low Very low Low - While the present disclosure has been described with reference to exemplary embodiments, it is to be understood that the disclosure is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
- This application claims the benefit of Japanese Patent Application No. 2016-249457, filed Dec. 22, 2016, which is hereby incorporated by reference herein in its entirety.
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US20210308917A1 (en) * | 2020-04-07 | 2021-10-07 | Canon Kabushiki Kaisha | Molded resin product, method for manufacturing molded resin product, mold, and apparatus for manufacturing molded resin product |
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CN108215070B (en) | 2021-01-12 |
CN108215070A (en) | 2018-06-29 |
EP3338982A1 (en) | 2018-06-27 |
JP2018103621A (en) | 2018-07-05 |
JP7071110B2 (en) | 2022-05-18 |
US20220274294A1 (en) | 2022-09-01 |
EP3338982B1 (en) | 2020-04-22 |
US11833721B2 (en) | 2023-12-05 |
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