WO2011030861A1

WO2011030861A1 - Metallic decorative resin molded article, and process for production of metallic decorative resin molded article

Info

Publication number: WO2011030861A1
Application number: PCT/JP2010/065642
Authority: WO
Inventors: 西村剛
Original assignee: 日本写真印刷株式会社
Priority date: 2009-09-14
Filing date: 2010-09-10
Publication date: 2011-03-17
Also published as: JP2011056917A; TW201116396A

Abstract

A metallic decorative resin molded article comprising: a sheet layer (3) comprising a base sheet (2) and a metallic member (1) embedded in one surface of the base sheet (2); a first resin layer (25) formed on the other surface of the base sheet (2); and a transparent second resin layer (26) formed so as to be superposed on the base sheet (2) and the metallic member (1) in the sheet layer (3).

Description

Metallic decorative resin molded product and method for producing metallic decorative resin molded product

The present invention relates to a metal-decorated resin molded product that is composite-molded with a plurality of resins across a metal-decorated sheet and a method for producing the metal-decorated resin molded product.

A multilayer molded product in which an insert sheet (hereinafter, abbreviated as a decorative sheet) including a decorative layer between a plurality of resin layers is embedded is manufactured, for example, by the following process. The first mold (cavity mold) and the second mold (first core mold) on which the decorative sheet is arranged are clamped to form a first cavity formed between the first mold and the decorative sheet. A first resin is injected to form a first resin layer on one side of the decorative sheet. Next, the third mold (second core mold) and the first mold (cavity mold) are clamped while holding the first resin layer and the decorative sheet in the first mold (first cavity mold). Then, the second resin is injected into the second cavity formed between the decorative sheet and the third mold (second core mold) to form the second resin layer on the other side of the decorative sheet. In this way, a resin molded product in which a decorative sheet is embedded between a plurality of resin layers is obtained (see Patent Document 1).

According to the said structure, since a 1st resin layer and a 2nd resin layer can be laminated | stacked on both surfaces of a decorating sheet, among the 1st resin layer and 2nd resin layer of the manufactured multilayer molded article, it is the surface side. When a transparent resin is used for the resin layer, the pattern formed on the decorative sheet can be seen through.

JP 2005-66834 A

As shown in FIG. 31, the decorative sheet 5 disposed between the first resin layer 8 and the second resin layer 9 of the multilayer molded product is configured by, for example, laminating a vapor deposition layer 6 and a base sheet 7. Has been. In this case, the vapor deposition layer 6 becomes a layer which gives a design to a multilayer molded product. However, since the vapor deposition layer 6 is originally very thin, it has been difficult to impart a three-dimensional design to the multilayer molded article using only the vapor deposition layer 6.

Further, when the shape of the multilayer molded product is complicated, the decorative sheet 5 is also shaped to match the shape of the multilayer molded product. Here, since the vapor deposition layer 6 was very thin, the vapor deposition layer 6 sometimes cracked without being able to withstand the shape change of the multilayer molded product. Furthermore, when the design, characters, and the like applied to the vapor deposition layer 6 are partially formed on the base sheet 7, if the shape of the multilayer molded product is complicated, the vapor deposition layer 6 is stretched and the multilayer molded product is It was difficult to align the pattern and the like of the vapor deposition layer 6.

The present invention is to provide a metal-decorated resin molded product in which a metal-like sheet layer is arranged as an intermediate layer to improve design, and a method for producing the metal-decorated resin molded product.

The first characteristic configuration of the metallic decorative resin molded product according to the present invention includes a sheet layer having a base sheet and a metallic member embedded in one surface of the base sheet, and the other surface of the base sheet. And a transparent second resin layer formed on the base sheet and the metallic member of the sheet layer.

Thus, since the metallic member is arranged in a state of being embedded in the base sheet, for example, the thickness of the metallic member can be increased to about the thickness of the base sheet. As a result, it has become possible to impart a three-dimensional metallic member design to the resin molded product. Further, since the metallic member is disposed between the first resin layer and the second resin layer and the second resin layer is transparent, the surface pattern or three-dimensional shape of the metallic member is changed to the surface side of the resin molded product. Can be visually recognized.

The second characteristic configuration of the metallic decorative resin molded product according to the present invention is such that at least a part of the peripheral surface portion of the metallic member is convex on the surface side, and the thickness decreases toward the peripheral side. It is in the point formed.

With this configuration, light from the outside is reflected to a portion that is convex on the surface side of the peripheral surface portion of the metal-like member and is thinner toward the peripheral side. As a result, the three-dimensional effect of the metal-like member when the resin molded product is visually recognized from the outside is further increased.

A third characteristic configuration of the metallic decorative resin molded product according to the present invention is that the sheet layer has a coating layer that holds the metallic member in cooperation with the base sheet.

With this configuration, the metal tone member is securely held by the base sheet and the coating layer, and the metal tone member is less likely to be displaced in the resin molding process. Therefore, the design by the three-dimensional metallic member is stably given to the resin molded product.

The first characteristic means of the method for producing a metallic decorative resin molded product according to the present invention includes a step of attaching a metallic member to one surface of the base sheet, and the metallic member being in contact with the second mold. A step of disposing the base sheet in the second mold, and clamping the first mold to the second mold, so that the base sheet disposed in the second mold is between the first mold and the first mold. Forming a first cavity for injecting the first resin into the first cavity, injecting the first resin into the first cavity, and pressing the base sheet against the second mold by the pressure of the injected first resin, Forming the first resin layer on the side of the base sheet on which the metal-like member is not attached, and embedding the metal-like member in the base sheet; and The first mold is separated from the second mold while holding the layer and the base sheet. And clamping the first mold with respect to another third mold to form a second cavity between the base sheet and the third mold, and a second transparent to the second cavity. And a step of forming a second resin layer by injecting resin.

By this feature means, when the second resin is injected and the second resin layer is formed, the metal tone member is embedded in the base sheet, so that the second resin passes over the metal tone member. However, the metallic member is not peeled off by the second resin. In addition, since the metallic member is disposed in a state where it is embedded in the base sheet, for example, the thickness of the metallic member can be increased to the thickness of the base sheet. It is now possible to manufacture resin molded products with a design. Further, since the metallic member is disposed between the first resin layer and the second resin layer and the second resin layer is transparent, the surface pattern or three-dimensional shape of the metallic member is visually recognized from the surface side. A resin molded product that can be produced can be manufactured.
Further, since the metallic member is disposed after the base sheet is formed, the metallic member is not stretched as in the case of the vapor deposition layer by forming the base sheet, and there is a risk that cracks may occur in the metallic member and the base sheet. Nor. As a result, the metallic member can be easily arranged at a desired position of the resin molded product.

The second characteristic means of the method for producing a metal-decorated resin molded product according to the present invention is such that the outer peripheral portion of the base sheet or the first resin layer protrudes outside the metal-decorated resin molded product, and In the step of forming a projecting piece that contacts the first mold and molding the second resin layer, the second resin is injected into the second cavity through a channel facing the projecting piece. It is in.

By this feature means, the injected second resin comes into contact with the base sheet through a space sandwiched between the protruding piece and the third mold. At this time, even if the high temperature second resin comes into contact with the base sheet and the heat of the second resin is transferred to the base sheet, the heat of the base sheet is easily transferred to the first mold through the protruding piece. Hard to get hot. In particular, when the protruding piece is provided on the base sheet, the heat transferred from the second resin to the protruding piece of the base sheet first spreads along the width direction of the protruding piece and then the base sheet other than the protruding piece. Therefore, the local portion of the base sheet is unlikely to become hot as compared with the case where there is no protruding piece and the heat from the second resin is directly transmitted to the main body of the base sheet. For this reason, melting of the base sheet and deformation (gate jumping) of the metallic member can be prevented. In particular, the portion in the vicinity of the projecting piece in the base sheet is likely to become high temperature and the base sheet is likely to melt. By transferring the heat in the vicinity of the projecting piece to the first mold by the projecting piece, Sheet melting can be prevented appropriately. As a result, the phenomenon that the position of the metallic member embedded in the base sheet is displaced can be suppressed.

Further, according to this feature means, the heat of the second resin is transferred to the first mold through the protruding piece only by providing the base sheet in which the metallic member is embedded between the first resin layer and the second resin layer. Heat transfer. As a result, the amount of heat transferred to the first resin layer is reduced, the phenomenon that the first resin layer is remelted is sufficiently prevented, and the thickness of the resin molded product can be made sufficiently small.

According to a third feature of the method for producing a metal-decorated resin molded product according to the present invention, in the step of molding the second resin layer, the second resin is injected in a state where the edge of the protruding piece is fixed. Is in the point where is performed.

This characteristic means can prevent the position of the base sheet from shifting when the second resin is injected and causing the base sheet to be lifted or turned up. Thereby, since a contact with a protrusion piece and a 1st type | mold can be maintained favorably, the heat | fever of a base sheet can be reliably transmitted to a 1st type | mold through a protrusion piece. For this reason, melting of the base sheet can be reliably prevented. As a result, the phenomenon that the position of the metallic member embedded in the base sheet is displaced can be suppressed.

According to a fourth feature of the method for producing a metallic decorative resin molded product according to the present invention, in the step of molding the second resin layer, the flow path facing the protruding piece extends along the second cavity. In a connected state, the resin is injected along the extending direction of the protruding piece.

By this feature means, the injected second resin enters the second cavity while smoothly flowing along these portions of the base sheet without making a frontal collision contact with the protruding piece of the base sheet and the main body portion. Will do. Therefore, the resin is less likely to stagnate in the vicinity of the base sheet as compared with the structure in which the injected resin enters the cavity while making a frontal collision with the base sheet. Is more difficult than the base sheet. As a result, the phenomenon that the position of the metallic member embedded in the base sheet is displaced can be suppressed.

According to a fifth feature of the method for producing a metallic decorative resin molded product according to the present invention, in the step of molding the second resin layer, the base sheet supported by the first mold and the inner surface of the third mold Resin in a state in which the second cavity is formed between the decorative film and the clamp for fixing the decorative film to the third mold is provided at a position in contact with the base end of the protruding piece. Is at the point where it is injected.

By this characteristic means, the decorative film is pressed against the third mold by the clamp up to the position immediately before the part of the decorative film to be incorporated into the main body part of the final molded product. The phenomenon of rising from the inner surface of the recess is also suppressed, and a molded product with good quality is obtained.

According to a sixth feature of the method for producing a metallic decorative resin molded product according to the present invention, in the step of molding the second resin layer, the tip of the protruding piece formed on the base sheet is the first mold. The point is that the resin is injected in a state of being retracted in the step-shaped recess provided in the.

By this characteristic means, the tip of the protruding piece of the base sheet is protected by this step-shaped concave portion, so that the base sheet is not lifted or “turned” by the flow of the resin, and a molded product with good quality can be obtained. can get.

7th characteristic means of the manufacturing method of the metallic decoration resin molded product which concerns on this invention is at least one part of a peripheral surface part convex on the surface side with respect to the said metallic tone member, and the peripheral side A member formed so as to have a smaller thickness is used, and when the second resin is injected, the second resin flows from the side having the peripheral portion having the small thickness toward the metallic member. The point is to inject the resin.

By this characteristic means, the second resin is injected so as to flow toward the metal tone member from the side having the small peripheral portion of the metal tone member, so that the contact between the surface portion of the metal tone member and the second resin It is possible to suppress a phenomenon in which the frictional force due to is reduced and the position of the metallic member embedded in the base sheet is shifted.
Moreover, the manufactured resin molded product is convex on the surface side of the peripheral surface portion of the metal-like member, and light from the outside is reflected on a portion having a smaller thickness on the peripheral side. As a result, the three-dimensional effect of the metal-like member when the resin molded product is visually recognized from the outside is further increased.

The 8th characteristic means of the manufacturing method of the metallic decoration resin molded product which concerns on this invention attaches the said metallic tone member to one side of the said base sheet, Then, with respect to the said metallic base member so that the said metallic tone member may be covered And coating other resins.

When the surface portion of the metallic member is exposed from the base sheet when the second resin is injected into the second cavity, the injected second resin flows through the surface portion of the metallic member. In this case, the frictional force acts between the second resin and the surface portion of the metallic member, and the position of the metallic member may change. However, the surface of the metallic member is protected by the coating layer by this characteristic means. That is, when the second resin is injected into the second cavity, the second resin contacts the coating layer, but does not contact the metallic member. As a result, since it does not directly receive the action of the second resin into which the metal-like member is injected, it is possible to suppress the displacement of the metal-like member in the resin molded product, and to produce a resin molded product with excellent design. Can do.

These are figures which show the base sheet which affixed the metallic member of 1st Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 1st Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 1st Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 1st Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 1st Embodiment. FIG. 6 is a sectional view taken along line VI-VI in FIG. These are the expanded sectional views of the metal mold | die at the time of the primary shaping | molding of 1st Embodiment. These are the expanded sectional views of the metal mold | die at the time of the primary shaping | molding of 1st Embodiment. These are the expanded sectional views of the metal mold | die at the time of the secondary shaping | molding of 1st Embodiment. These are the whole perspective views of the metal decoration resin molded product of 1st Embodiment. These are plane sectional views when the movable mold and the first fixed mold in the second embodiment are clamped. FIG. 12 is a cross-sectional view taken along arrow XII-XII in FIG. FIG. 13 is a sectional view taken along arrow XIII-XIII in FIG. These are plane sectional views when the movable mold and the second fixed mold in the second embodiment are clamped. FIG. 15 is a cross-sectional view taken along arrow XV-XV in FIG. 14. FIG. 15 is a cross-sectional view taken along arrow XVI-XVI in FIG. 14. These are the whole perspective views of the metal tone decoration resin molded product in 2nd Embodiment. These are sectional side views when the movable mold | type and 1st fixed mold | type in another embodiment are clamped. These are sectional side views when the movable mold | type and 2nd fixed mold | type in another embodiment are clamped. These are figures which show the manufacturing process of the metallic decoration resin molded product of 3rd Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 3rd Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 3rd Embodiment. These are figures which show the manufacturing process of the metallic decoration resin molded product of 3rd Embodiment. FIG. 22 is a partially enlarged view of the vicinity of the first gate in FIG. 21. FIG. 22 is a partially enlarged view of the vicinity of the second gate in FIG. 21. These are the expanded sectional views of the metal mold | die at the time of the primary shaping | molding of 4th Embodiment. These are the expanded sectional views of the metal mold | die at the time of the secondary shaping | molding of 4th Embodiment. These are the expanded sectional views of the metal mold | die at the time of the primary shaping | molding of 5th Embodiment. These are the expanded sectional views of the metal mold | die at the time of the secondary shaping | molding of 5th Embodiment. These are the expanded sectional views of the metal mold | die at the time of the secondary shaping | molding of another embodiment. These are figures which show the conventional decorative resin molded product.

[First Embodiment]
Hereinafter, the metallic decorative resin molded product F2 and the manufacturing method thereof according to the present invention will be described.

[Step of sticking metallic member to base sheet]
The base sheet 2 is a resin molded body that is pre-shaped into a predetermined shape, and the metallic member 1 is adhered to the base sheet 2. The metallic member 1 is a transferable electroformed sealing material, metal beads, or the like. Specifically, when the metal tone member 1 is an electroformed sealing material, the release paper on the back surface of the electroformed seal is peeled off, and the whole film is attached to the portion of the base sheet 2 to be transferred. The electroformed part is lightly rubbed from the top of the film to fix it to the base sheet 2, and then the film is peeled off. Thus, as shown in FIG. 1, the metallic member 1 is adhered to the base sheet 2.

Since the step of attaching the metallic member 1 to the base sheet 2 is performed after the base sheet 2 is formed into a predetermined shape, cracks are generated in the metallic member 1 as the shape of the base sheet 2 changes. Nor. Moreover, since the position of the metal tone member 1 in the resin molded product is naturally determined by sticking the metal tone member 1 after the base sheet 2 is molded, it is easy to align the metal tone member 1 in the resin molded product. It becomes.

Various patterns can be formed on the base sheet 2, but a plain color sheet without a pattern may be used. The base sheet 2 can be composed of various resins such as an acrylic resin and a polyolefin resin. If the base sheet 2 is composed of a resin having high heat resistance such as a polycarbonate resin and PET, the base sheet 2 is a resin for secondary molding. This is more effective against the phenomenon of remelting under the influence of the heat of the resin during the injection, so-called “gate jump”. “Gate jump” means that when a resin for secondary molding at a high temperature (250 ° C to 280 ° C) comes into contact with the insert sheet, the heat of this resin is transferred to the insert sheet, while that heat is transferred to the primary molded product. It is difficult to transfer heat to the mold due to the heat insulating effect, so the insert sheet melts at a high temperature without being cooled by the mold, and as a result, the pattern applied to the decorative layer flows and deforms . The thickness of the base sheet 2 is suitably in the range of 75-200 μm, and 125-150 μm is most easy to use.

Next, the two-color molding die used when manufacturing the metallic decorative resin molded product F2 will be described.
The two-color molding die is provided in a two-color molding machine whose parts are shown in the drawing, and as shown in FIGS. 2 to 5, the

movable molds

11A and 11B (both are examples of the first mold). ), A first fixed mold 12 (an example of the second mold) and a second fixed mold 13 (an example of the third mold).

The two-color molding machine includes a fixed platen 14 and a rotary platen 15 that can rotate with respect to the fixed platen 14 and that can be moved back and forth. The fixed platen 14 includes a first fixed die 12 and a second fixed die 13, and the rotary plate 15 includes

movable molds

11A and 11B. The

movable molds

11A and 11B are disposed so that the first fixed mold 12 and the second fixed mold 13 face each other. Therefore, as shown in FIG. 3, when the turntable 15 is pressed against the fixed platen 14, the

movable molds

11A and 11B, the first fixed mold 12 and the second fixed mold 13 are simultaneously clamped, and the first resin is injected. And the second resin can be injected at the same time.

As shown in FIG. 2, in the state before clamping, the movable mold 11B facing the second fixed mold 13 has the primary molded product F1 (first resin layer 25 and sheet layer 3) molded in the preceding process. Is retained. On the other hand, the base sheet 2 used in the subsequent primary molding is held on the first fixed mold 12. The two-color molding machine includes a robot device 16 for installing the base sheet 2 on the first fixed mold 12.

The second fixed mold 13 includes a film delivery device 31 for delivering a decorative film (transfer foil) 30, a film take-up device 32 for winding up the decorative film 30, and the decorative film 30 on the side of the movable molds 11 A and 11 B. And a rectangular frame-shaped clamp 33 that is pressed down.

In the decorative film 30, the decorative portion 30 a fused to the second resin layer 26 and the base sheet 30 b for handling are integrated, and the decorative portion 30 a is transferred to the second resin layer 26. The base sheet 30b is peeled off in any of the steps. The decorative portion 30a generally has a peeling protective layer that is the outermost layer of the final multilayer molded article and an adhesive layer that is fused to the resin layer, and generally between the peeling protective layer and the adhesive layer. A pattern layer is provided.

Examples of the material of the base sheet include resin sheets such as polypropylene resin, polystyrene resin, polyamide resin, polyester resin, acrylic resin, and polyvinyl chloride resin, metal foil such as aluminum foil and copper foil, glassine Cellulose-based sheets such as paper, coated paper, and cellophane, or a composite sheet of these can be used. Moreover, in order to improve the peelability of the base sheet 30b, a release layer made of an aminoalkyd resin or the like may be formed between the base sheet 30b and the decorative portion 30a. The thickness of the base sheet 30b is preferably 5 to 500 μm.

Examples of the material for the release protective layer include acrylic resins, polyester resins, polyvinyl chloride resins, cellulose resins, rubber resins, polyurethane resins, polyvinyl acetate resins, and vinyl chloride-vinyl acetate. Copolymers such as copolymer resins and ethylene-vinyl acetate copolymer resins can be used. When the peel protection layer requires hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used.

The material for the adhesive layer should have a high affinity with the resin to be fused. For example, when the material of the transfer object is an acrylic resin, an acrylic resin may be used. In addition, when the material of the transferred material is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, A polyamide resin or the like may be used. When the resin molded material is a polypropylene resin, a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, or a coumarone indene resin may be used. The thickness of the adhesive layer is preferably 0.5 to 50 μm.

Note that the two-color molding die only needs to have a configuration for embedding the metallic member 1 in the base sheet 2. Temporarily, the decorative film 30, the film feeding device 31, the film winding device 32, and the clamp 33 are provided. There is no particular problem even if the configuration is not provided.

The first resin and the second resin may be different color resins, or may be different types of resins having different hardness and other characteristics. For example, the first resin may be polycarbonate resin, ABS resin, or an alloy of polycarbonate resin and ABS resin, and the second resin may be PMMA (polymethyl methacrylate resin). In particular, when the first resin is an ABS resin and the second resin is PMMA, the ABS resin has a high moldability, so that multilayer molding such as two-color molding can be performed satisfactorily. Moreover, even if the softening temperature of the ABS resin is lower than the softening temperature of PMMA, the presence of the base sheet 2 suppresses deformation of the molded ABS resin due to the heat of PMMA when PMMA is injected.

The

movable molds

11A and 11B are provided with a slide piece 17 (an example of a fixing means) that fixes a part of the base sheet 2 and a generally rectangular groove 18 that accommodates the clamp 33 during mold clamping. . Details of these configurations are shown in FIGS. As shown in FIG. 10 showing the secondary molded product F2 removed from the

movable molds

11A and 11B after solidification, an edge 2b of a trapezoidal protruding piece 2a is formed on one side of the base sheet 2, and this edge The portion 2b is fixed by the slide piece 17 described above. The movable mold 11B is formed with an auxiliary cavity 22A that can accommodate the protruding piece 2a when the second fixed mold 13 and the movable mold 11B are clamped. Further, the second gate 24 for injecting the second resin is provided at a position where the second resin is necessarily injected into the second cavity 22 through the auxiliary cavity 22A.

More specifically, when the movable mold 11B and the second fixed mold 13 are clamped, a communication flow path 40 that allows the second gate 24 and the second cavity 22 to communicate with each other is formed therebetween. The second resin injected from the second gate 24 is injected into the second cavity 22 through the communication channel 40. The communication flow path 40 includes a linear first communication portion 41 that extends from the second gate 24 to the clamp 33 on the near side, a substantially U-shaped second communication portion 42 that detours around the clamp 33, The auxiliary cavity 22 A is emitted from the two communicating portions 42 toward the farther clamp 33. As shown in FIG. 6, the auxiliary cavity 22A that can accommodate the protruding piece 2a has a divergent shape that becomes wider as it approaches the primary molded product F1.

As a result of the configuration of the communication flow path 40, when the second resin is injected, the second resin always starts to contact the base sheet 2 through the space surrounded by the protruding piece 2a and the second fixed mold 13. . Therefore, even if the high-temperature second resin comes into contact with the base sheet 2 and the heat of the second resin is transferred to the base sheet 2, the heat received by the base sheet 2 passes through the projecting piece 2a having a large area. Since heat is effectively dissipated to (11A), the base sheet 2 does not become too high, and the base sheet 2 is prevented from melting. In addition, when the mold is clamped, the clamp 33 slides and moves the slide piece 17 toward the protruding piece 2a, so that the edge 2b of the protruding piece 2a is sandwiched and fixed between the slide piece 17 and the movable die 11B. The phenomenon that the position of the base sheet 2 is shifted when the second resin is injected can also be prevented. As a result, the contact between the projecting piece 2a and the movable mold 11B is also maintained well, so that the heat of the base sheet 2 is reliably transferred to the movable mold 11B through the projecting piece 2a and the edge 2b of the projecting piece 2a. Heat can be efficiently and efficiently radiated to the movable mold 11B and the slide piece 17. Thus, the melting of the base sheet 2 can be reliably prevented, and the phenomenon that the position of the metallic member 1 embedded in the base sheet 2 is shifted can be suppressed. In addition, the multilayer sheet can be satisfactorily manufactured by preventing the base sheet 2 from floating and turning up.

Hereinafter, a method for producing a metal-decorated resin molded product using the two-color molding machine, in which the base sheet 2 having the metal-like member 1 bonded thereto is sandwiched between a plurality of resin layers, will be described.

[Process of arranging the base sheet]
As shown in FIG. 2, the base sheet 2 to which the metallic member 1 is attached using the robot device 16 is installed in the first fixed mold 12 with the movable mold 11 A and the first fixed mold 12 being opened. To do. Here, the base sheet 2 is arranged so that the metallic member 1 adhered to the base sheet 2 is in contact with the first fixed mold 12, and the base sheet 2 is provided on the first fixed mold 12 and is not shown. It is held by the device.

[Process for forming the first cavity]
As shown in FIG. 3, the rotating plate 15 is moved to the fixed platen 14 side to clamp the movable die 11 A with respect to the first fixed die 12, and the base sheet 2 supported by the first fixed die 12. A first cavity 21 is formed between the movable mold 11A.

[Process of forming the first resin layer]
As shown in FIG. 7, the first resin is injected from the first gate 23 toward the first cavity 21. When the first resin is injected into the first cavity 21, the base sheet 2 is pressed against the first fixed mold 12 by the pressure of the injected first resin. At this time, in the vicinity of the metal tone member 1, the base sheet 2 is stretched according to the shape of the metal tone member 1, and the metal tone member 1 is embedded in the base sheet 2, and the surface of the metal tone member 1 and the base sheet A sheet layer 3 is formed in which the two are flush with each other. Thus, as shown in FIGS. 4 and 8, the first resin layer 25 is formed on the back surface of the base sheet 2 while the metallic member 1 is embedded in the base sheet 2 by the injection of the first resin. A primary molded product F1 including the layer 3 and the first resin layer 25 is molded.

[Step of forming second cavity]
As shown in FIG. 5, while holding the first resin layer 25 and the sheet layer 3 on the movable mold 11A, the movable mold 11A is separated from the first fixed mold 12, and the turntable 15 is rotated 180 degrees to move the movable mold 11A. 11A is set to a position facing the second fixed mold 13. Thereafter, the rotary plate 15 is moved to the fixed platen 14 side, and the movable mold 11A and the first fixed mold 13 are clamped, and primary molding supported by the movable mold 11A (11B) as shown in FIG. A second cavity 22 is formed between the sheet layer 3 of the product F1 and the second fixed mold 13. At this time, the slide piece 17 pushed by the clamp 33 during mold clamping slides and moves toward the protruding portion 2a, so that the slide piece 17 and a part of the movable die 11A sandwich and fix the edge 2b of the protruding piece 2a. To do.

[Process of forming the second resin layer]
As shown in FIGS. 4 and 9, the second resin is injected from the second gate 24 toward the second cavity 22. That is, the second resin is injected toward the side of the sheet layer 3 where the metallic member 1 is embedded, and the second resin layer 26 is formed. At this time, the sheet layer 3 is in a state in which the metallic member 1 is embedded in the base sheet 2, and the surface of the base sheet 2 and the surface of the metallic member 1 are flush. Therefore, even if the second resin passes through the boundary surface between the metal tone member 1 and the base sheet 2, it is possible to suppress a problem that the metal tone member 1 is peeled from the base sheet 2 and the position of the metal tone member 1 is shifted. .

Thereafter, as shown in FIG. 5, the turntable 15 is separated from the fixed platen 14, and the movable mold 11 A (11 B) and the second fixed mold 13 are opened. By this mold opening, the base sheet 30b of the decorative film 30 is naturally peeled from the decorative portion 30a, and only the decorative portion 30a is transferred to the surface of the second resin (secondary molded resin-molded resin molding) Product) F2 is obtained. Thereafter, the solidified secondary molded product (metallic decorative resin molded product) F2 is removed from the movable mold 11A (11B).

Next, the turntable 15 is rotated 180 degrees so that the movable mold 11B and the second fixed mold 13 are opposed to each other, and secondary molding is performed by injection of the second gate 24 of the second fixed mold 13 and the movable mold 11A. And the first fixed mold 12 are opposed to each other, and primary molding is performed by injection of the first gate 23 of the first fixed mold 12. By repeating the above operation, a secondary molded product (metal-tone decorative resin molded product) in which the first resin layer 25, the sheet layer 3, the second resin layer 26, and the decorative portion 30a of the decorative film 30 are sequentially laminated. ) Manufacture F2. In addition, as a finishing process, the protrusion piece 2a which protrudes outside the secondary molded product (metallic decoration resin molded product) F2 is cut | disconnected (refer FIG. 10).

Thus, when manufacturing the multilayer molded product in which the metallic member 1 is disposed in the middle of the two resin layers, the metallic member 1 is first attached to the base sheet 2 and then subjected to the primary molding. The metallic member 1 was embedded in the base sheet 2 to form a sheet layer 3, and the resin layers on both sides of the sheet layer 3 were molded. By carrying out like this, compared with the case where a decoration layer is formed using a vapor deposition layer etc., it becomes possible to use the metal-like member 1 with large thickness for decoration, and the design which has a three-dimensional effect in a resin molded product Can be added. In addition, since the sheet member 3 is formed so that the metallic member 1 is embedded in the base sheet 2, the resin is injected even when the resin is injected into the side of the sheet layer 3 where the metallic member 1 is embedded. Since the resin to be passed passes through the upper part of the metal tone member 1, it is also suppressed that the metal tone member 1 of the sheet layer 3 is pushed by the injected resin and the positional deviation is generated.

Further, as a result of constituting the auxiliary cavity 22A, when the second resin is injected, the second resin starts to contact the base sheet 2 through the first communication portion 41, the second communication portion 42, and the auxiliary cavity 22A. Therefore, even if the high-temperature second resin comes into contact with the sheet layer 3 and the heat of the second resin is transferred to the sheet layer 3, the heat received by the sheet layer 3 is movable 11A (11B) via the protruding piece 2a. The heat is effectively dissipated. As a result, the sheet layer 3 does not reach a very high temperature, the sheet layer 3 is prevented from melting, and the metal tone member 1 is prevented from melting or misaligned.

[Second Embodiment]
As shown in FIGS. 11 to 16, the molding die used in the second embodiment includes

movable molds

51A and 51B (an example of a first mold), and a first fixed mold 52 (an example of a second mold). A second fixed mold 53 (an example of a third mold) is provided. 11 to 16 show a state after the first resin and the second resin are injected. 2nd Embodiment shows the example which uses only the base sheet 2 with which the metallic member 1 was embedded, and does not use the decorating film 30. FIG. Although not shown, the movable molds 51 A and 51 B are supported by the rotating plate 15, and the first fixed mold 52 and the second fixed mold 53 are supported by the fixed plate 14, as in the above embodiment.

When the first fixed mold 52 holding the base sheet 2 and the movable mold 51A are clamped, the first cavity 21 is formed between the base sheet 2 and the movable mold 51A. 12 and 13 show a state in which the first resin is injected into the first cavity 21 and the primary molded product F1 is obtained. On the other hand, when the movable mold 51B holding the primary molded product F1 injected / molded in the previous step is clamped with respect to the second fixed mold 53, the space between the base sheet 2 of the primary molded product F1 and the second fixed mold 53 is fixed. A second cavity 22 is formed. 15 and 16 show a state where the second resin is injected into the second cavity 22 and the secondary molded product F2 is obtained. As shown in FIG. 16, an auxiliary cavity 71 capable of accommodating the protruding piece 2a of the base sheet 2 is formed between the movable mold 51 and the second fixed mold 53, and the second gate 66 for injecting the second resin is The second resin is always provided at a position where the second resin is injected into the second cavity 22 through the auxiliary cavity 71.

As shown in FIG. 11, the protruding piece 2 a of the base sheet 2 has a rectangular shape protruding from almost the entire width of one long side of the base sheet 2. As shown in FIG. 12, which is an XII-XII cross section in FIG. 11, the cross section along one long side of the convex portion 51 is V-shaped between the parting surface 51a and the convex portion 51b of the movable mold 51A. A groove 63 is formed. On the other hand, between the parting surface 52a of the first fixed mold 52 and the recess 52b, a protrusion 62 having a V-shaped cross section that enters the groove 63 is formed. Therefore, when the movable mold 51A and the first fixed mold 52 are clamped, one side surface 62a of the protrusion 62 and one side surface 63a of the groove 63 come into contact with each other, and at the same time, the other side surface 62b of the protrusion 62 (the pressing portion of the pressing portion). The protruding piece 2a of the base sheet 2 is sandwiched between the example) and the other side surface 63b of the groove 63 (an example of a pressing portion).

As shown in FIG. 11, FIG. 12, and FIG. 13 which is an XIII-XIII cross section in FIG. 11, when the movable mold 51A and the first fixed mold 52 are clamped, the movable mold 51A and the first fixed mold 52 are separated. A first communication channel 61 that communicates the first gate 57 and the first cavity 21 is formed therebetween. The first resin injected from the first gate 57 is injected into the first cavity 21 through the first communication channel 61. The first communication channel 61 includes a linear first communication portion 58 formed between the parting surface 51 a of the first movable mold 51 A and the parting surface 52 a of the first fixed mold 52, and the protrusion 62. A linear second communication portion 59 formed between the one side surface 62a and the one side surface 63a of the groove 63, and the other side surface 62b of the protrusion 62 and the other side surface 63b of the groove 63 are formed. And a third communication part 60. The third communication part 60 has a divergent shape that becomes wider from the second communication part 59 toward the primary molded product F1. The second communication part 59 is connected to the first communication part 58, and the third communication part 60 is connected to the second communication part 59 in a bent shape.

On the other hand, as shown in FIG. 15, which is an XV-XV cross section in FIG. 14, a V-shaped protrusion 72 entering the groove 63 is formed between the parting surface 53a of the second fixed mold 53 and the recess 53b. Is formed. When the movable mold 51B and the second fixed mold 53 are clamped, one side surface 72a of the ridge 72 and one side surface 63a of the groove 63 come into contact with each other, and at the same time, the other side surface 72b of the ridge 72 (an example of a pressing portion). And the projecting piece 2a of the base sheet 2 is sandwiched between the other side surface 63b of the groove 63 (an example of a pressing portion).

As shown in FIGS. 14, 15, and FIG. 16, which is a cross section taken along XVI-XVI in FIG. 14, when the movable mold 51B and the second fixed mold 53 are clamped, the movable mold 51B and the second fixed mold 53 In the meantime, a second communication flow path 70 is formed to allow the second gate 66 and the second cavity 22 to communicate with each other. The second resin injected from the second gate 66 is injected into the second cavity 22 through the second communication channel 70. The second communication flow path 70 includes a linear first communication portion 67 formed between the parting surface 51a of the second movable mold 51B and the parting surface 53a of the second fixed mold 53, and the protrusions 72. The linear second communication portion 68 formed between the one side surface 72a and the one side surface 63a of the groove 63, and the other side surface 72b of the protrusion 72 and the other side surface 63b of the groove 63 are formed. And a third communication part 69. The third communication portion 69 has a divergent shape that becomes wider from the second communication portion 68 toward the primary molded product F1. The second communication portion 68 is connected to the first communication portion 67 in a bent manner, and the third communication portion 69 is connected to the second communication portion 68 in a bent shape. Between the other side surface 72b of the ridge 72 and the other side surface 63b of the groove 63, an auxiliary cavity 71 capable of accommodating a part of the protruding piece 2a of the base sheet 2 is formed. Here, the third flow path portion 69 in which a part of the protruding piece 2 a formed on the base sheet 2 is exposed constitutes the auxiliary cavity 71.

As a result of the configuration of the communication flow path 70, when the second resin is injected, the second resin always passes through the space surrounded by the protruding piece 56a near the auxiliary cavity 71 and the second fixed mold 53, and the base sheet. 2 is contacted. Therefore, even if the high-temperature second resin comes into contact with the base sheet 2 and the heat of the second resin is transferred to the base sheet 2, the heat received by the base sheet 2 is movable through the projecting piece 2a having a large area. Since heat is effectively dissipated to (51A), the base sheet 2 does not become too high, and the base sheet 2 is prevented from melting. As a result, the phenomenon that the position of the metallic member 1 embedded in the base sheet 2 is shifted can be suppressed.
In addition, at the time of mold clamping, as shown in FIGS. 11 and 12, both side portions 2c and 2d that do not overlap the third communication portion 60 in the protruding piece 2a are located between the movable mold 51A and the first fixed mold 52. It is pinched and fixed. Therefore, when the first resin is injected from the first gate 57 into the first cavity 21 and the first resin layer 25 is formed on the lower surface of the base sheet 2, the first resin is between the side surface 62 b on the other side. There is no risk of getting into the gap.

As for the second fixed mold 53 and the movable mold 51B, as shown in FIGS. 14 and 15, both

side portions

2f and 2g that do not overlap the third communicating portion 69 of the protruding piece 2a are formed by the movable mold 51B (51A ) And the second fixed mold 53. Therefore, when the second resin injected from the second gate 66 is injected into the second cavity 22 and the second resin layer 26 is formed on the side of the base sheet 2 where the metallic member 1 is embedded, the second resin layer 26 is formed. There is no possibility that the resin enters the gap between the side surface 63b on the other side.

Thereafter, the movable mold 51B and the second fixed mold 53 are opened, and the secondary molded product F2 is removed from the movable mold 51B. For finishing, the projecting pieces 26a projecting to the outside of the secondary molded product F2 removed from the movable mold 51B (51A), the projecting portions of the first resin layer 25 and the second resin layer 26 are cut (see FIG. 17). ). At this time, since the protruding portions 2a, the first resin layer 25, and the protruding portions of the second resin layer 26 protrude from the long side on one side of the secondary molded product F2, the process can be performed only once. Reduction and improvement of productivity are achieved. Further, since the protruding piece 2a is sandwiched between the movable mold 51A and the first fixed mold 52, and the movable mold 51B and the second fixed mold 53, it is not necessary to provide a separate structure for sandwiching the protruding piece 2a. Can be realized. Further, it is possible to provide a plurality of gates and perform a plurality of taking.

[Third Embodiment]
In the following third embodiment shown in FIGS. 20 to 27, only the configuration different from the configuration of the first embodiment will be mainly described, and the description of the same configuration will be omitted. As shown in FIG. 20, the molding die used in the third embodiment includes a first fixed mold 182 (an example of the second mold) and a second fixed mold 183 (an example of the third mold) supported by the fixed platen 14. ) And

movable molds

181A and 181B (an example of the first mold) supported by the turntable 15. The turntable 15 is configured to be rotatable with respect to the fixed platen 14 and to be able to leave and exit. Here, the fixed

molds

182 and 183 are concave female types, and the pair of

movable molds

181A and 181B are convex male types. In FIG. 20, the base sheet 2 to which the metallic member 1 is adhered is locked in the recess of the first fixed mold 182, and the decorative film 30 is disposed in the recess of the second fixed mold 183. Thus, the clamp 33 can be fixed. On the other hand, the primary molded product F1 obtained in the previous step is locked to the convex portion of the second movable mold 181B. This primary molded product F1 has the same shape as the primary molded product F1 shown in FIG.

Next, as shown in FIG. 21, when the turntable 15 is pressed toward the fixed platen 14, the first fixed mold 182 and the movable mold 181A are clamped, and at the same time, the second fixed mold 183 and the movable mold 181B. And are clamped.
In the mold clamping of the first fixed mold 182 and the movable mold 181A, as shown in the upper part of FIG. 21, the first fixed mold 182 is locked between the first movable mold 181A and the first movable mold 181A. A first cavity 21 for receiving resin is formed. If the first resin is injected into the first cavity 21, the first resin is fused to the inner surface of the base sheet 2, and the base sheet 2 (sheet layer 3) in which the metallic member 1 is embedded, the first resin layer 25, The primary molded product F1 consisting of is obtained. FIG. 21 shows a state where the first resin has already been injected.

On the other hand, as shown in the lower part of FIG. 21, in the clamping of the second fixed mold 183 and the movable mold 181B, the primary molded product F1 locked to the movable mold 181B and the second fixed mold 183 are locked. A second cavity 22 is formed between the decorative film 30 and the second resin is injected therein. Actually, before injecting the second resin, the decorative film 30 is adsorbed on the inner surface of the concave portion of the second fixed mold 183. In order to realize this adsorption, the concave portion of the second fixed mold 183 has a large number of fine suction holes (not shown) and reduced pressure for generating a negative pressure on the inner surface of the concave portion of the second fixed mold 183 through the suction holes. A pump (not shown) is provided. Such an adsorption mechanism is also provided in the first fixed mold 182.

As shown in FIGS. 24 and 25 which are enlarged views of the main part of FIG. 21, the base sheet 2 has two protruding pieces. One of them is a first protruding piece 2A that extends linearly from a part of the edge of the four sides of the base sheet 2, and the other is a second protruding piece that is bent outward from a part of the opposite side. 2B. During the molding process shown in FIGS. 20 and 21, both the first protruding piece 2 A and the second protruding piece 2 B are pressed against the inner surface of the first fixed mold 182. In the final secondary molded product F2, the protruding

pieces

2A and 2B are cut off.

As shown in FIG. 25, the first protruding piece 2A is accommodated in a first auxiliary cavity 136a formed in the movable mold 181B when the second fixed mold 183 and the movable mold 181B are clamped. The second gate 139 for injecting the second resin is positioned so that the second resin is always injected into the second cavity 22 through the region of the first auxiliary cavity 136a where the first protruding piece 2A is provided. It is provided. As shown in FIG. 24, the second projecting piece 2B is accommodated in a part of the second auxiliary cavity 132a formed in the movable mold 181A when the first fixed mold 182 and the movable mold 181A are clamped. The

When the solidification of the first resin and the second resin injected in the step shown in FIG. 21 is completed, the

movable molds

181A and 181B are respectively separated from the fixed platen 14 as shown in FIG. The mold is opened from the fixed mold 182 and the second fixed mold 183. In this state, the molded primary molded product F1 is supported on the convex portion of the movable mold 181A, and the molded secondary molded product F2 is supported on the convex portion of the second movable die 181B. The secondary molded product F2 is taken out from the second fixed mold 183, and as shown in FIG. 23, by rotating the turntable 15 by 180 °, the steps from FIG. 20 can be repeated. Processing such as excision operation of the protruding

pieces

2A and 2B is performed on the taken-out secondary molded product F2.

Here, the steps of FIGS. 20 and 21 will be described again in detail.
First, as shown in FIGS. 21 and 24, the first gate 138 and the first cavity 21 are communicated with each other between the

molds

182 and 181A by clamping the first fixed mold 182 and the movable mold 181A. A communication channel 140 is formed. The communication flow path 140 includes a linear first communication portion 140A that directly communicates with the outlet of the first gate 138, and a linear second communication portion 140B that communicates directly with the first cavity 21. The second communication portion 140B and the first communication portion 140A extend substantially parallel to each other, but are connected to each other in a crank shape. On the inner surface of the first fixed mold 182 corresponding to the boundary of the connection, a retracting portion 182X is formed, which is retracted stepwise toward the fixed platen 14 along the first resin entry direction. The tip of the second projecting piece 2B of the base sheet 2 is disposed so as to be pressed against the retreating part 182X, thereby preventing the base sheet 2 from being lifted or turned over by the flow of the first resin. Has been. The retraction part 182X has a depth exceeding the thickness of the base sheet 2.

Next, as shown in FIGS. 21 and 25, the second gate 139 and the second cavity 22 communicate with each other between the

molds

183 and 181B by clamping the second fixed mold 183 and the movable mold 181B. A communication flow path 142 is formed. The communication channel 142 is formed by the second auxiliary cavity 136a, and extends along the first linear communication portion 142A that extends from the second gate 139 to the clamp 33 on the near side, and the side surface 33b below the clamp 33. The second communication portion 142B that enters so as to approach the turntable 15, the third communication portion 142C that extends upward in the drawing along the upper surface 33c of the clamp 33, and the second communication portion that extends along the side surface 33d above the clamp 33. It consists of the 4th communication part 142D which approaches the fixed type | mold 183. FIG.

The fourth communication portion 142D, which is the final portion of the communication flow path 142, extends substantially horizontally in the drawing toward the second fixed mold 183. Therefore, at the boundary surface between the second fixed mold 183 and the movable mold 181B, The terminal end portion of the four communicating portions 142D (an example of the location of the channel facing the protruding piece) and the inlet portion of the second cavity 22 are connected in a substantially straight line without forming an angle with each other. Specifically, the base end portion of the upper side surface 33d in the drawing of the clamp 33 shown in FIG. 25 coincides with the position of the end surface of the final secondary molded product F2 at the point S attached to the drawing. Yes.
In the fourth communication portion 142D, a retracting portion 142X (an example of a step-shaped concave portion) that is recessed in a stepped manner near the center line of the movable mold 181B is formed along the direction in which the second resin enters. Then, the tip of the first protruding piece 2A of the base sheet 2 is disposed so as to be pressed against the retracting portion 142X, thereby preventing the base sheet 2 from being lifted or “turned up” by the flow of the second resin. Has been. The retraction part 142 X has a depth that exceeds the thickness of the base sheet 2.

As a result of configuring the communication flow path 142 in this way, when the second resin is injected, the second resin always passes through the space sandwiched between the first protruding piece 2A and the clamp 33 and enters the second cavity 22. Contact the base sheet 2. Therefore, even if the high-temperature second resin contacts the base sheet 2 and the heat of the second resin is transferred to the base sheet 2, the heat received by the base sheet 2 is laterally along the entering direction of the second resin. Since the heat is effectively radiated to the movable mold 181B through the projecting piece 2A having a widening and diverging shape, the base sheet 2 in the second cavity 22 does not become so hot, and the final secondary molded product F2 is obtained. Melting of the main body portion of the base sheet 2 to be incorporated and deformation of the metallic member 1 are prevented. Further, since the first projecting piece 2A has a divergent shape, the heat transferred from the second resin to the first projecting piece 2A of the base sheet 2 first spreads along the width direction of the first projecting piece 2A. Therefore, the phenomenon that the local part of the base sheet 2 becomes hot is prevented from being transmitted to the main body of the base sheet 2 other than the first protruding piece 2A. As a result, the phenomenon that the position of the metallic member 1 embedded in the base sheet 2 is shifted can be suppressed.

Further, as described above, since the end portion of the fourth communication portion 142D and the inlet of the second cavity 22 are connected in a substantially straight line without forming an angle with each other, in the step of forming the second resin layer The second resin injected from the second gate 139 is in the extending direction of the first protruding piece 2A in a state where the fourth communication portion 142D facing the first protruding piece 2A is connected along the second cavity 22. Injected along. That is, at this time, the second resin does not make a frontal collision contact with the main body portion incorporated in the first projecting piece 2A of the base sheet 2 and the final secondary molded product F2, and thus the same as that of the base sheet 2. The air enters the second cavity 22 while flowing smoothly along the main body portion. Therefore, as compared with the configuration in which the second resin injected from the second gate 139 enters the second cavity 22 while making a front collision with the base sheet 2, the second resin is closer to the base sheet 2. Since there is less possibility of causing stagnation, the influence of the heat of the second resin is more difficult on the base sheet 2.

Furthermore, as described above, the base end portion of the upper side surface 33d in the drawing of the clamp 33 shown in FIG. 25 coincides with the position of the end surface of the final secondary molded product F2. That is, the decorative film 30 is pressed against the second fixed mold 183 by the clamp 33 up to the position immediately before the part of the decorative film 30 incorporated in the main body portion of the final secondary molded product F2. The phenomenon that 30 is lifted from the inner surface of the concave portion of the second fixed mold 183 is also suppressed.

[Fourth embodiment]
As shown in FIG. 26, the metallic member 1 adhered to the base sheet 2 is formed such that a part of the peripheral surface portion 1A is convex on the surface side and the thickness decreases toward the peripheral side. The member currently used is used. Then, as shown in FIG. 27, the second resin is injected so as to flow from the side having the small peripheral edge portion of the metal tone member 1 toward the metal tone member 1 during the secondary molding. If it carries out like this, the frictional force by the contact of the surface part of the metallic member 1 and 2nd resin will reduce, and the phenomenon that the position of the metallic member 1 of the sheet | seat layer 3 will shift | deviate can be suppressed. Moreover, compared with the case where the side part of the metal tone member 1 is perpendicular | vertical planar shape, the surface area of a side part becomes large and the three-dimensional effect of the metal tone member 1 visually recognized from the outside of a resin molded product further increases. It became.

[Fifth Embodiment]
As shown in FIG. 28, after the metallic member 1 is attached to one side of the base sheet 2, the base sheet 2 is coated with another resin so as to cover the metallic member 1. Thus, by providing the coating layer 4 on the surface of the metallic member 1, as shown in FIG. 29, the metallic member 1 of the sheet layer 3 is protected by the coating layer 4 when the second resin is injected, and the sheet layer The positional deviation of the metallic member 1 can be further prevented. Various resins can be used for the coating layer 4, but it is preferable to use the same resin as the second resin. In this way, the coating layer 4 and the second resin layer 26 molded with the second resin are integrated so that the coating layer 4 is visible from the outside of the resin molded product (metallic decorative resin molded product) F2. The influence on the beauty of 1 can be reduced.

[Another embodiment]
(1) In each of the above embodiments, the protruding piece formed on the base sheet 2 is brought into contact with the movable mold (an example of the first mold) that holds the first resin layer 25 and the base sheet 2. The configuration in which the second resin is injected through a space sandwiched between the protruding piece and the second fixed mold (an example of the third mold) combined with the movable mold (an example of the first mold) is illustrated. However, instead of these configurations, a projecting piece that protrudes to the outside of the secondary molded product F2 is formed on the first resin layer 25, and a movable mold that holds the first resin layer 25 and the base sheet ( An example of the first mold is brought into contact with the projecting piece of the first resin layer 25 and sandwiched between the projecting piece and the second fixed type (an example of the third type) combined with the movable type (an example of the first type). The second resin may be injected through the space.

(2) As shown in FIG. 31, the width of the second cavity 22 corresponding to the thickness of the second resin layer 26 of the metallic decorative resin molded product is configured to be larger than the thickness of the first resin layer 25. May be. For example, when the thickness of the base sheet 2 is 75 to 200 μm as described above and the thickness 3 of the first resin layer 25 is 0.6 mm to 1.2 mm, the width of the second cavity 22 (second (Corresponding to the thickness of the resin layer 26) is made larger than the thickness of the first resin layer 25. If it carries out like this, when the 2nd resin passes on the metallic member 1 embedded in the base sheet 2, the shear stress which generate | occur | produces in the metallic member 1 will become small. As a result, the force in the flow direction of the second resin acting on the metal tone member 1 is reduced, making it difficult for the metal tone member 1 to flow from the position where the base sheet 2 is embedded.

(3) In the above embodiment, the configuration in which the decorative portion 30a is transferred to the surface of the second resin layer 26 using the decorative film 30 (transfer foil) has been described. Instead, a plain base sheet or base The insert sheet with a pattern or the like on the sheet may be integrated as it is, or the decorative film 30 and the insert sheet may not be used. The decorative film 30 may be in the form of a sheet, and the insert sheet may be in the form of a film.

(4) In the first embodiment, the configuration in which the fixing means is the slide piece 17 that sandwiches the edge 2b of the base sheet 2 is illustrated. However, the configuration is not limited to such a configuration. A suction means for sucking the part 2b may be used.

(5) In the above-described embodiment, there are two movable molds (an example of the first mold), the turntable 15 that can be moved in and out in the horizontal direction and rotatable about the axis along the horizontal direction, and the first fixed. A multilayer molding machine including a mold (an example of a second mold) and a stationary platen 14 having a second fixed mold (an example of a third mold) is illustrated. However, the present invention is not limited to such a multilayer molding machine. For example, primary molding is performed by clamping the first mold and the second mold, and secondary molding is performed in the first mold and the second mold. A slide mold (an example of a third mold) provided so as to be capable of moving forward and backward may be moved backward to form a second cavity, and the second resin may be injected into the second cavity. In addition, a first movable plate that includes a movable type (an example of the first type) and can be moved in and out in the vertical direction, and a first fixed type (an example of the second type) and a second fixed type (an example of the third type). A multi-layer molding machine equipped with a second movable plate that can be slid in the horizontal direction, or a movable plate that can move in and out in the horizontal direction with a movable die (an example of the first type), and a first fixed die ( An example of a second mold) and a second fixed mold (an example of a third mold) may be implemented in a form using a multi-layer molding machine including a turntable that is attached back to back and is rotatable about a vertical axis. Good.

(6) As a modification of the second embodiment, for example, as shown in FIGS. 18 and 19, an inclined portion on the movable mold 51 side is provided between the parting surface 51 a and the convex portion 51 b of the movable mold 51. 73 is formed, and an inclined portion 74 on the side of the first fixed mold 52 facing the inclined portion 73 is formed between the parting surface 52a of the first fixed mold 52 and the recess 52b, and the second fixed mold 53 is formed. An inclined portion 75 on the side of the second fixed mold 53 facing the inclined portion 73 is formed between the parting surface 53a and the recessed portion 53b, and between the movable mold 51 and the first fixed mold 52, A first communication channel 76 for injecting the first resin injected from the first gate 57 into the first cavity 21 is formed, and the second gate 66 is provided between the movable mold 51 and the second fixed mold 53. The second communication flow for injecting the second resin injected from the second cavity 22 77 may be configured to have been formed.

The metal-decorated resin molded product and the method for producing a metal-decorated resin molded product according to the present invention can be widely used for the production of various interior products and exterior products.

Claims

A sheet layer having a base sheet and a metallic member embedded in one surface of the base sheet;
A first resin layer molded on the other surface of the base sheet;
A metal-decorated resin molded article comprising: the base sheet of the sheet layer; and a transparent second resin layer molded over the metal-like member.
2. The metallic decorative resin molded product according to claim 1, wherein at least a part of the peripheral surface portion of the metallic member is convex on the surface side, and the thickness is reduced toward the peripheral side.
The metal-decorated resin molded product according to claim 1 or 2, wherein the sheet layer has a coating layer that wraps the metal-like member in cooperation with the base sheet.
A step of adhering a metallic member to one surface of the base sheet;
Disposing the base sheet on the second mold so that the metallic member contacts the second mold;
Forming a first cavity for injecting a first resin between a base sheet disposed in the second mold and the first mold by clamping the first mold with respect to the second mold;
Injecting the first resin into the first cavity, pressing the base sheet against the second mold by the pressure of the injected first resin, the metal tone member is embedded in the base sheet, and Forming a first resin layer on the non-sticking side of the metallic member of the base sheet;
While holding the first resin layer and the base sheet in the first mold, the first mold is separated from the second mold, the first mold is clamped with respect to another third mold, Forming a second cavity between the base sheet and the third mold;
A step of injecting a transparent second resin into the second cavity to form a second resin layer, and a method for producing a metallic decorative resin molded product.
On the outer periphery of the base sheet or the first resin layer, a protruding piece that protrudes outside the metallic decorative resin molded product and contacts the first mold is formed.
5. The method for producing a metallic decorative resin molded product according to claim 4, wherein in the step of forming the second resin layer, the second resin is injected into the second cavity through a flow path facing the protruding piece. .
The method for producing a metallic decorative resin molded product according to claim 5, wherein, in the step of molding the second resin layer, the second resin is injected in a state where an edge of the protruding piece is fixed.
In the step of forming the second resin layer, the resin is injected along the extending direction of the protruding piece in a state where the flow path facing the protruding piece is connected along the second cavity. Item 6. A method for producing a metallic decorative resin molded article according to Item 5.
In the step of molding the second resin layer, the second cavity is formed between the base sheet supported by the first mold and the decorative film disposed on the inner surface of the third mold, and the decoration The method for producing a metallic decorative resin molded product according to claim 7, wherein the resin is injected in a state where a clamp for fixing the film to the third mold is provided at a position in contact with a base end portion of the protruding piece.
The resin is injected in the step of forming the second resin layer in a state in which a tip of the protruding piece formed on the base sheet is retracted into a stepped recess provided in the first mold. A method for producing a metallic decorative resin molded product according to any one of 1 to 8.
As the metallic member, at least a part of the peripheral surface portion is convex on the surface side, and a member formed so that the thickness becomes smaller toward the peripheral side, the injection of the second resin, The metal-decorated resin molded product according to any one of claims 4 to 9, wherein the second resin is injected so that the second resin flows from the side having the peripheral portion having the small thickness toward the metal-like member. Manufacturing method.
The metal finish according to any one of claims 4 to 10, wherein after the metal tone member is attached to one of the base sheets, another resin is coated on the base sheet so as to cover the metal tone member. A method for producing a decorative resin molded product.