WO2013084550A1 - ガラス一体型成形品の製造方法、ガラス一体型成形品 - Google Patents
ガラス一体型成形品の製造方法、ガラス一体型成形品 Download PDFInfo
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- WO2013084550A1 WO2013084550A1 PCT/JP2012/071984 JP2012071984W WO2013084550A1 WO 2013084550 A1 WO2013084550 A1 WO 2013084550A1 JP 2012071984 W JP2012071984 W JP 2012071984W WO 2013084550 A1 WO2013084550 A1 WO 2013084550A1
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- Prior art keywords
- glass
- layer
- resin
- frame
- plate
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 67
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- 238000013461 design Methods 0.000 description 15
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Images
Classifications
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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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
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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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
- B29C45/14434—Coating brittle material, e.g. glass
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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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14688—Coating articles provided with a decoration
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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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
- G06F1/16—Constructional details or arrangements
- G06F1/1613—Constructional details or arrangements for portable computers
- G06F1/1626—Constructional details or arrangements for portable computers with a single-body enclosure integrating a flat display, e.g. Personal Digital Assistants [PDAs]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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- G06F1/16—Constructional details or arrangements
- G06F1/1613—Constructional details or arrangements for portable computers
- G06F1/1633—Constructional details or arrangements of portable computers not specific to the type of enclosures covered by groups G06F1/1615 - G06F1/1626
- G06F1/1637—Details related to the display arrangement, including those related to the mounting of the display in the housing
- G06F1/1643—Details related to the display arrangement, including those related to the mounting of the display in the housing the display being associated to a digitizer, e.g. laptops that can be used as penpads
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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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
- B29C2045/14844—Layers protecting the insert from injected 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
-
- 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
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1671—Making multilayered or multicoloured articles with an insert
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3475—Displays, monitors, TV-sets, computer screens
Definitions
- This invention relates to a method for producing a glass integrated molded product. Specifically, the present invention relates to a method for producing a glass integrated molded product in which a plate-like glass is fixed to the inside of a frame integrally molded with a resin by glass insert molding. It also relates to a glass integrated molded product.
- Patent Document 1 describes a method for manufacturing a glass insert mold product in which a window frame is integrally formed using a window glass plate glass as an insert member. Specifically, it describes a manufacturing method for plate glass fittings such as sashes. And in the manufacturing method, while fitting a tight material with a U-shaped cross section into the edge of the glass and attaching an elastic member to the back of the tight material, while placing the glass in the mold in this state, It is molded by injecting resin that forms a frame such as a sash. At this time, a reactive injection resin is used to prevent the glass from being broken or the tight material being deformed by the heat of the resin in a molten state. Further, the elastic member absorbs the stress applied to the glass as the frame after molding cools.
- FIG. 1A is a perspective view of the front cover 1
- FIG. 1B is a cross-sectional view taken along the line aa in FIG.
- FIG. 2 is a perspective view in which the front cover 1 is disassembled for each component.
- the front cover 1 is a substantially rectangular dish-shaped part with a shallow bottom that constitutes the front side of the exterior case for housing the internal circuit of the smartphone. Such a front cover 1 corresponds to the bottom of the dish.
- the frame 10 is formed of a resin integrally molded product having a large opening, and a plate-like glass (hereinafter, glass plate) 20 disposed on the inner periphery of the frame 10. As illustrated, in the front cover 1, when the direction in which the glass plate 20 faces outward is upward, the glass plate 20 transmits the display on the display panel arranged on the lower surface 22 side to the upper surface 11 side. However, it has a function of protecting the display panel.
- the front cover 1 forms a surface in which the upper surface 11 of the frame body 10 and the upper surface 21 of the glass plate 20 are continuous, and in many cases is flush.
- an edge 13 is formed on the inner periphery of the frame body 10 by cutting away from the upper side to the lower side with the thickness of the glass plate 20 to make it thinner.
- the upper surface 14 of the part 13 supports the periphery of the lower surface 22 of the glass plate 20 from below.
- This front cover 1 is normally assembled by manufacturing only the frame body 10 by injection molding and fitting the glass plate 20 into the inner periphery of the frame body 10. That is, the glass plate 20 is dropped into the frame 10 from above with the edge 13 of the frame 10 as a support. And the upper surface 14 of the edge part 13 and the lower surface 22 of the glass plate 20 which touches it are adhere
- Recent portable electronic devices with thin display devices such as smartphones, portable music playback devices, portable LCD TVs, digital cameras, etc. are assumed to be used in kitchens, bathrooms, or rainy weather, High waterproofness is required.
- Many of these electronic devices have a plate-like glass disposed on the inner periphery of a resin frame, as well as the front cover of a smartphone, and the front surface of the frame and the glass plate.
- the front surface includes a part that forms a continuous surface (hereinafter referred to as a glass integrated molded product).
- a conventional glass integrated molded product has been manufactured by fitting a glass plate into a molded frame. Therefore, in order to improve the waterproof performance between the frame and the glass plate, an O-ring is interposed between the peripheral edge of the lower surface of the glass plate and the upper surface of the edge portion, or the portion where the glass plate and the frame are in contact with each other. It was filled with waterproof resin. Therefore, parts and materials for improving waterproofness and additional processes are required. Therefore, cost reduction was difficult.
- the present inventor has considered simplifying the manufacturing process while improving the waterproof performance of the glass integrated molded product such as the front cover described above.
- the front cover, etc. is composed of a continuous surface of the glass surface and the frame, so unlike the sash, the edge of the glass plate that contacts the high-temperature, high-pressure molten resin that becomes the frame during injection molding. Cannot be sandwiched with any cushioning material. For this reason, if the glass plate is molded as an insert as it is, the edge of the glass is likely to be damaged by heat and pressure during molding.
- the resin and glass forming the frame do not have adhesiveness in both materials themselves, and in fact, the waterproof performance as expected cannot be obtained.
- an object of the present invention is to provide a method for producing a glass integrated molded product having high reliability and waterproof performance by glass insert molding without causing an increase in cost.
- the present invention for achieving the above object is a method for producing a glass integrated molded product in which a glass sheet is fixed inside a frame integrally molded with a resin by glass insert molding, With the one surface side of the plate glass as the upper side, the frame body is provided with an edge that supports the lower surface periphery of the plate glass while the upper surface is continuous with the upper surface of the plate glass,
- the method A resin layer that is compatible with the resin constituting the frame body and functions as a cushioning material for reducing the stress applied to the plate glass during molding of the frame body on the lower surface periphery of the plate glass.
- the method includes a transfer film erection step that spans a transfer film for in-mold molding, in which a decorative film is laminated on a base film, over the mold,
- the transfer film erection step the base film of the transfer film and the inner surface of the mold face each other
- the plate glass placement step when the plate glass is placed in the mold, the transfer film is interposed between the inner surface of the mold and the upper surface of the plate glass
- the molten resin is injected while the transfer film is sandwiched between the closed molds, thereby forming the frame body and the decorative film on the surface of the frame body. It can also be set as the manufacturing method of the glass integral-type molded article made to transcribe
- a resin that functions as a decoration is printed when the upper surface side is visually recognized through the upper surface of the sheet glass, and in the injection molding step, the printed layer is visually recognized through the upper surface of the sheet glass. It is good also as a manufacturing method of the glass integral-type molded product which shape
- An intermediate layer is formed between the decorative layer and the adhesive layer using a resin that is more easily elastically deformed than the resin that forms the decorative layer and the adhesive layer. It can also be.
- the plate-like glass has a slope in which the region of the upper surface is included in the region of the lower surface as viewed from above, and the side surface is inclined outward from the upper surface to the lower surface, and in the resin layer printing step, While aligning the outer edges of the decorative layer and the layer laminated below the decorative layer constituting the frame-shaped resin layer, the width of the decorative layer is larger than the layer laminated below the decorative layer. It is good also as a manufacturing method of the glass integral-type molded product which forms each layer so that it may become wide.
- the pressure buffer that circulates the side surface of the sheet glass while contacting a part of the lower surface and the side surface of the resin layer between the resin layer printing step and the sheet glass arranging step.
- a step of forming a portion, and in this step, the pressure buffer portion may be formed of a resin that is more elastically deformed than a resin that forms the frame and the resin layer.
- the present invention also extends to a glass integrated molded product in which a sheet glass is fixed to the inside of a frame integrally molded with a resin.
- the frame body With one surface side of the plate glass as the upper side, the frame body includes an edge portion that supports an upper surface of the plate glass and supports a lower surface periphery of the plate glass, A resin layer serving as a cushioning material between the upper surface of the edge portion and the peripheral edge of the lower surface of the glass is formed on the plate-like glass at the periphery of the lower surface supported by the edge portion while being fixed to the upper surface of the edge portion. Being It is characterized by that.
- the glass integrated molded article may be characterized in that the upper surface of the resin layer is decorated through the upper surface of the plate glass.
- the resin layer may be a glass integrated molded article having a structure in which an adhesive layer that adheres to the upper surface of the edge portion is laminated below the decoration layer that functions as the decoration.
- An intermediate layer is interposed between the decorative layer and the adhesive layer, and the intermediate layer is formed of a resin that is more easily elastically deformed than the resin that forms the decorative layer and the adhesive layer. It can also be a molded product.
- the plate-like glass has an inclined surface that is inclined from the upper surface to the lower surface on the side surface, with the upper surface region included in the lower surface region when viewed from above,
- the resin layer has the decorative layer constituting the frame-shaped resin layer and the outer edge of each layer laminated below the decorative layer, and the width of the decorative layer is laminated below the decorative layer. It is good also as a glass integral type molded article wider than the layer to be formed.
- any one of the glass integrated molded articles includes a pressure buffering portion that circulates around the side surface of the plate glass while contacting a part of the lower surface and the side surface of the resin layer, and the pressure buffering portion includes the resin layer. It may be formed of a resin that is more easily elastically deformed than the resin that forms the film.
- a glass integrated molded product having high reliability and waterproof performance can be manufactured by glass insert molding.
- FIG. 1 shows the structure of the front cover of the smart phone manufactured by the conventional method. It is a disassembled perspective view of the conventional front cover manufactured with the said conventional method. It is an external view of the front cover manufactured with the manufacturing method which concerns on the 1st Example of this invention. It is sectional drawing which shows the structure of the said front cover manufactured with the manufacturing method which concerns on the said 1st Example. It is a figure which shows the flow of the manufacturing method which concerns on the said 1st Example. It is a figure which shows the modification of the said front cover. It is a figure which shows the other example of the said modification shown in FIG. It is an external view of the front cover manufactured by the method according to the second embodiment of the present invention.
- a front cover of a smartphone is given.
- a specific manufacturing method corresponding to the structure of the front cover will be described as an embodiment of the present invention.
- FIG. 3 is a schematic view of the front cover 1a formed by the manufacturing method according to the first embodiment. Again, the vertical relationship of the front cover 1a is defined as shown in FIGS.
- FIG. 3A is a perspective view when the front cover 1a is viewed from above
- FIG. 3B is a perspective view when viewed from below.
- 4 is a cross-sectional view taken along the line bb in FIG. 3A
- FIG. 4A is an overall view of the cross section
- FIG. 4B is an enlarged view of the circle in FIG. FIG.
- the front cover 1a has a substantially rectangular dish shape with a shallow bottom, and a glass plate 20 is disposed in a portion corresponding to the bottom surface of the dish. Is going.
- the height of the step from the upper surface 14 of the edge 13 of the frame body 10a to the upper surface 11 of the frame body 10a itself substantially matches the thickness of the glass plate 20, and the upper surface 21 of the glass plate 20
- the outer periphery and the inner periphery of the frame 10a there is no step between the outer periphery and the inner periphery of the frame 10a, and both form a continuous surface.
- the outer periphery of the upper surface of the frame 10a is substantially flat, and the upper surface 21 of the glass plate 20 and the upper surface 11 of the frame 10a are substantially flush.
- the front cover 1a molded by the manufacturing method according to the first embodiment has the same appearance as the conventional front cover 1 shown in the figure. Further, as shown in FIG. 4A, the upper surface 14 of the edge 13 of the frame body 10a supports the lower surface 22 of the glass plate 20. The structure so far is the same as that of the conventional front cover 1. However, the front cover 1a molded by the manufacturing method according to the first embodiment is provided between the periphery of the lower surface 22 of the glass plate 20 and the upper surface 14 of the edge portion 13 as shown in FIG. The point that the resin layer 30 is interposed is different from the structure of the conventional front cover 1. In this example, the resin layer 30 is formed over the same width W1 as the upper surface 14 of the edge portion 13. The lower surface 31 of the resin layer 30 and the upper surface 14 of the edge portion 13 are fixed in a compatible state, and sufficient reliability and waterproofness are ensured.
- the present invention is a method that enables a glass integrated molded product, such as a front cover, that has heretofore been difficult to manufacture by glass insert molding to be manufactured by glass insert molding.
- a method for manufacturing the front cover 1a shown in FIGS. FIGS. 5A to 5F show the flow of the manufacturing method.
- the resin layer 30 is formed by printing around the lower surface 22 of the glass plate 20 (A) (B).
- 5A is a perspective view when the glass plate 20 on which the resin layer 30 is formed is viewed from below
- FIG. 5B is a cross-sectional view taken along the line cc in FIG. .
- the resin layer 30 is compatible with the molten resin 110 forming the frame 10, and in this embodiment, an acrylic resin is formed to a thickness of about 4 to 8 ⁇ m by a known silk printing method. Yes.
- the resin layer 30 is not limited to an acrylic resin, and may be formed of a resin compatible with the molten resin 110.
- an appropriate resin such as urethane, epoxy, polyester, or vinyl may be used. Can be adopted.
- the thickness of the resin layer 30 is not limited to the above numerical value.
- the glass plate 20 on which the resin layer 30 is printed is placed in the mold (41, 42) (C).
- the mold 42 on which the glass plate 20 is disposed is formed with an adsorption portion 45 that communicates the surface in contact with the lower surface 22 of the glass plate 20 and the outside of the mold 42.
- the glass plate 20 is held in a state of being attracted to the inner surface of the mold 42 by leading the air of the portion 45 to the outside.
- the molds (41, 42) are closed and clamped. Thereby, the cavity 44 filled with the molten resin 110 which finally becomes the frame body 10 is formed (D).
- the molten resin 110 is injected into the molds (41, 42) (E)
- the resin layer 30 printed on the periphery of the lower surface 22 of the glass plate 20 is melted by the heat of the molten resin 110.
- the molten resin 110 is cooled, the lower surface 31 of the resin layer 30 and the upper surface 14 of the edge 13 of the frame 10a are fixed in a compatible state.
- the front cover 1a which is a molded article is taken out from a metal mold
- the pressure applied to the portion of the glass plate 20 that is in contact with the molten resin 110 during mold clamping or injection molding. It is relaxed by the resin layer 30 formed at the contact portion. That is, the resin layer 30 functions as a buffer material during injection molding. Therefore, the glass plate 20 is not damaged at the time of injection molding, and the glass of a glass integrated molded product in which the upper surface 21 of the glass plate 20 such as the front cover 1a and the upper surface 11 of the frame 10a form a continuous surface. Insert molding is now practical.
- the glass plate 20 and the frame body 10a are firmly bonded and extremely high. Reliability can be obtained and sufficient waterproof performance can be achieved with respect to the periphery of the glass plate 20.
- the manufacturing cost of the front cover 1a can also be reduced by glass insert molding.
- FIG. 6 is a sectional view showing a front cover 1b in which an overhanging portion (hereinafter referred to as a bowl-shaped portion) 16 is formed on a frame 10b as a modification of the front cover (1, 1a). Note that the cross-sectional view shown in this figure corresponds to the circle in FIG.
- the frame body 10b having the hook-like portion 16 and the edge portion 13 is integrally formed as a single component.
- the groove surrounding the inner periphery of the frame body 10 b is simultaneously formed by the hook-shaped portion 16 and the edge portion 13. Therefore, an undercut processing mechanism is required for a mold for forming the frame body 10b alone. Therefore, the configuration of the mold is complicated, and it is difficult to reduce the manufacturing cost.
- the glass plate 20 is fitted into the groove portion between the bowl-shaped portion 16 and the edge portion 13, and excessive stress is applied to the glass plate 20 and the frame body 10 b, so that the glass plate 20 and the frame body 10 b are There was a possibility of damage.
- the front cover 1b can be manufactured by glass insert molding, so that the molten resin 110 is filled so as to level the chamfered slope 23 at the time of injection molding.
- the front cover 1b in which the glass plate 20 and the frame 10b are integrated is in a completed state. This eliminates the need for an undercut processing mechanism for forming the bowl-shaped portion 16, and does not cause an increase in cost for the molds (41, 42).
- the glass plate 20 having the same shape and the same upper surface 21 and lower surface 22 was used. For this reason, when the width W1 of the resin layer 30 is increased, the display area of the display panel disposed below the glass plate becomes narrow, and thus the width of the resin layer 30 cannot be increased too much. On the other hand, if the width W1 of the resin layer 30 is reduced, the adhesive strength between the resin layer 30 and the frame 10a at the edge 13 may be reduced.
- the upper surface 21 of the glass plate 20b is chamfered like the front cover 1b shown in FIG. 6, that is, the upper surface is formed inside the region formed by the periphery of the lower surface 22 of the glass plate 20b.
- the portion (the portion having the width W2 in the drawing) hidden behind the bowl-shaped portion 16 around the lower surface 22 of the glass plate 20b does not contribute to the display.
- the resin layer 30 can be provided, and the width W1 of the resin layer 30 can be substantially increased. Therefore, sufficient adhesive strength can be ensured without sacrificing the display area of the display panel.
- the shape of the side surface from the upper surface 21 to the lower surface 22 is a polygonal line shape. It may be.
- the side surface of the glass plate 20b is generally formed so as to be an inclined surface 23 that inclines inward toward the frame of the frame body 10c.
- a wall surface 23b perpendicular to the part is formed.
- the side surface of the glass plate 20b is formed to have a polygonal cross-sectional shape in which the two inclined surfaces 23a are continuous via the wall surface 23b.
- the lower surface 22 of the glass plate (20b, 20c) may have a shape including the region of the upper surface 21, and the slope 23 may be formed on the side surface of the glass plate (20b, 20c).
- the shape is a polygonal line in which a plurality of inclined surfaces 23a are formed on the side surface of the glass plate 20c
- the hook-shaped portion 16 and the side surface of the glass plate 20c are complicatedly combined.
- the effect that it can prevent reliably that the glass plate 20c falls below is also expectable.
- a glass integrated part that is a part of an exterior case of an electronic device such as a front cover of a smartphone
- a surface exposed to the outside as an exterior case (hereinafter referred to as an outer surface), such as the upper surface 11 of the frame body or the outer surface of the side wall 15 )
- decoration it may be applied to a part of the outer surface of the frame body, such as a product logo, or it may be applied to the entire outer surface by imitating other materials (metal, etc.). It can be a pattern.
- a molded product manufacturing method for applying low-cost and highly reliable decoration to the frame of the front cover by assuming the first embodiment. I will give you.
- FIG. 8 shows an external view of the front cover 1d manufactured according to the second embodiment.
- 9A and 9B are sectional views taken along the line cc in FIG. Note that FIG. 9B is an enlarged view of the circle in FIG.
- the frame 10d of the front cover 1d shown here is made of a film in which a decorative design is formed on the entire outer surface of the frame body 111 having the same structure as the frame 10a in the front cover 1a of the first embodiment.
- the decorative film layer 50 is bonded.
- the surface layer of the decorative film layer 50 forms a continuous surface with the upper surface 21 of the glass plate 20.
- the thickness of the decorative film layer 50 is exaggerated so that the detailed structure of the frame 10d can be easily understood.
- a method of manufacturing the front cover 1d will be described as a second embodiment.
- the second embodiment is characterized in that an in-mold molding technique is used to decorate the outer surface of the frame main body 111 while being based on the first embodiment.
- the in-mold molding technique is such that decorative films and characters or patterns imitating other materials (hereinafter referred to as decorative patterns) have been formed on the film serving as the base material (hereinafter referred to as the base film).
- a molten resin is injected in a state in which a transfer film on which a film (decorative film) is laminated is sandwiched in a mold of an injection molding machine, and the decorative film is transferred to the resin by the heat of the molten resin.
- FIG. 10 shows a partially broken perspective view of a general transfer film 60.
- the transfer film 60 basically has a structure in which a decorating film 62 is laminated on a base film 61.
- the base film 61 includes only a base body 63 made of a film material such as a PET film and a decorating film 62. It has a structure in which a release layer 64 for correctly peeling from the base film 61 is laminated.
- the decorative film 62 includes a decorative design layer 66 on which a decorative design is formed by printing, vapor deposition, or the like, a protective layer 65 disposed on the base film 61 side, and a molten resin facing outward. This is a structure sandwiched between adhesive layers 67 having compatibility. In in-mold molding, peeling is performed at the boundary between the release layer 64 and the protective layer 65.
- FIGS. 11A to 11E show the flow of the molded product manufacturing method according to the second embodiment.
- the resin layer 30 is printed and formed in advance on the periphery of the lower surface 22 of the glass plate 20 in the same manner as in FIGS.
- the transfer film 60 is stretched over the mold 41 on the side where the glass plate 20 is not disposed (A). At this time, the transfer film 60 is stretched over so that the base film 61 side faces the inner surface 43 of the mold 41. In other words, the decorative film 62 side faces the mold 42.
- the glass plate 20 is arrange
- the structure of the molds (41, 42) is slightly different from that shown in FIG.
- the molten resin 110 is injected into the molds (41, 42) (D).
- the decorative film 62 side of the transfer film 60 comes into contact with the molten resin 110 and the contact surface is in a compatible state.
- the decorating film 62 is peeled off from the base film 61, the decorating film 62 is adhered to the outer surface of the frame body 111, and the decorative design is transferred.
- the transfer film 60 the region in contact with the glass plate 20 is not in contact with the molten resin 110, and the decorative film 62 does not peel from the base film 61. That is, the decorative design is not transferred to the upper surface 21 of the glass plate 20, and the decorative design is selectively transferred only to the outer surface of the frame body 111 (E).
- the glass integrated molded product is manufactured by glass insert molding so that the upper surface 21 of the glass plate 20 and the frame 10c form a continuous surface. That is, the manufacturing method of the second embodiment is possible by assuming the molded product manufacturing method according to the first embodiment.
- decoration can be performed simultaneously with the molding of the frame body 111 using an in-mold molding technique on a substantially flat surface. Therefore, high-quality decoration can be applied at low cost.
- the glass plate is decorated by printing or sticking a film.
- the upper surface of the glass plate is constantly rubbed with a finger operating the device. Even if it is not a cover glass for a touch panel, if the object of protection by the cover glass is a display panel, some display is visible through this glass plate. . That is, the glass plate is placed in an environment where friction due to fingers, cloth, etc. is constantly applied, and there is a concern that the decoration will deteriorate over time.
- the decoration on the glass plate 20 is likely to deteriorate over time as compared with the decoration formed on the surface of the resin by in-mold molding as in the second embodiment.
- a coating for improving various optical properties and strength is applied on the upper surface side of a glass plate, and the adhesiveness with other substances (such as an adhesive) is low. That is, it is difficult to decorate the film by bonding a film or the like. Therefore, as a third embodiment, a molded product manufacturing method for applying a highly durable decoration to a glass plate at a low cost will be given.
- the third embodiment is realized by developing the molded article manufacturing method of the first embodiment. Specifically, in the first embodiment, by forming the resin layer 30 on the periphery of the lower surface 22 of the glass plate 20 by printing, the glass plate 20 is protected during the injection molding of the frame 10a, and the frame 10a. The resin and the glass plate 20 are firmly bonded to enhance waterproofness. In the third embodiment, the resin layer 30 is also used as a decoration.
- FIG. 12 shows an example of the front cover 1e using the resin layer 30 for decoration as a perspective view from above.
- FIG. 13 shows the glass plate 20 in a state where the resin layer 30 that also functions as a decoration is formed by printing.
- FIG. 13A is a perspective view when the glass plate 20 is viewed from above
- FIG. 13B is a perspective view when viewed from below.
- a decorative region (rough halftone dot region in the figure) 70 is formed so as to border the periphery of the glass plate 20.
- the decoration region 70 is formed by making the resin layer 30 printed on the lower surface 22 side of the glass plate 20 visible from the upper surface 21 side of the glass plate 20.
- the resin layer 30 function as a decoration, it can be realized, for example, by using a resin material that colors the resin layer 30 in a predetermined color or using a resin in which a pigment is dispersed. Moreover, since the resin layer 30 is formed by printing, not only the shape which borders the glass plate 20, but a design and a character can also be formed. And since the decoration is formed in the lower surface 22 of the glass plate 20, degradation with time by friction etc. does not occur in principle. Deterioration over time due to the surrounding environment (humidity, ultraviolet rays, etc.) is greatly reduced as compared to the decoration exposed to the outside. In particular, since glass absorbs ultraviolet rays, it can be expected to greatly improve light resistance.
- the third embodiment is characterized in that the resin layer 30 on the lower surface 22 of the glass plate 20 is used as a decoration.
- the original purpose of the resin layer 30 is to enable glass insert molding of a glass integrated molded product. Therefore, if the original function of the resin layer 30 is impaired in order to improve the function as a decoration, it falls to the end. Ideally, it is desirable to make the original function and the function as a decoration compatible at a high level. Therefore, the resin layer 30 may have a two-layer structure including a layer (decorative layer) that functions as a decoration and a resin layer (buffer layer) that functions as a buffer material during injection molding.
- the decorative layer may also serve as a buffer layer
- the layer formed in the lower layer of the decorative layer may be a binder layer (adhesive layer) that mediates adhesion between the decorative layer and the frame. Both layers may function as a buffer layer.
- the decorative layer may also serve as a buffer layer
- the layer formed in the lower layer of the decorative layer may be a binder layer (adhesive layer) that mediates adhesion between the decorative layer and the frame. Both layers may function as a buffer layer.
- not only two layers but two or more layers by resin may be laminated
- FIG. 14 is an enlarged view of the main part of the front cover (1f, 1g).
- (A) and (B) in the same figure are different only in the cross-sectional shape of the glass plate (20f, 20c).
- the structure of the resin layer 30 in each front cover (1f, 1g) is the same.
- the glass plate 20f in the front cover 1f shown in (A) is chamfered on both the upper surface 21 and the lower surface 22.
- the front cover 1g shown in (B) the front cover shown in FIG.
- a glass plate 20c is used in which the region of the upper surface 21 is included in the region of the lower surface 22 and the side surface is a polygonal line.
- the resin layer 30 of the front cover (1f, 1g) shown in (A) and (B) has a two-layer structure including an upper decorative layer 33 and a lower adhesive layer 34.
- the width W3 of the decorative layer 33 is wider than the width W4 of the adhesive layer 34, and the width W4 of the adhesive layer 34 is narrower than the upper surface 14 of the edge 13 of the frame (10f, 10g).
- An example is shown. That is, the edge portion 13 of the frame (10f, 10g) extends to the side surface of the adhesive layer 34, and the edge portion 14 contacts the lower surface of the decorative layer 33 while covering the adhesive layer 34.
- the contact area between the adhesive layer 34 and the frame (10f, 10g) is widened, and the glass plate (20f, 10c) can be more reliably prevented from falling off or rattling.
- both the outer edges of the decorative layer 33 and the adhesive layer 34 are aligned, and the adhesive layer 34 is located above the edge 13 in the front cover (1f, 1g).
- Only the decoration layer 33 is formed to the inside of the glass plate (20f, 20c).
- the front cover 1g shown in (B) when viewed from above, the region of the upper surface 21 of the glass plate 20c is included in the region of the lower surface 22, and the side surface is outward from the upper surface to the lower surface. It has an inclined surface. Therefore, compared with the front cover 1f shown in (A), the width of the adhesive layer 34 can be provided wider while making the region functioning as a decoration the same, and the resin layer 30 has a function of decoration and adhesion. Are compatible at a high level.
- FIGS. 15A to 15E show the flow of the molded product manufacturing method according to the third embodiment.
- a resin layer 30 is printed in advance on the periphery of the lower surface 22 of the glass plate 20f.
- FIG. 15A corresponds to a cross-sectional view taken along the line dd in FIG.
- the resin layer 30 to be printed is a two-layer structure in which a second layer 34 is printed below the first layer 33 on the side in contact with the lower surface 22 of the glass plate 20f. It has become.
- the first layer is the decorative layer 33 that also serves as a buffer layer
- the second layer is the adhesive layer 34.
- the resin forming the decoration layer 33 is visually recognized through the upper surface 21 of the glass plate 20f and functions as a decoration.
- the decorative layer 33 functions as a cushioning material at the time of injection molding and it is necessary to consider the adhesiveness with the glass plate 20f, in this example, a pigment is dispersed in an acrylic urethane resin.
- the used resin ink is used.
- the resin forming the adhesive layer 34 functions as a binder for firmly bonding the decorative layer 33 and the resin constituting the frame 10f. Therefore, the adhesiveness with resin which forms the decoration layer 33 is excellent, and compatibility with resin which forms the frame 10f is calculated
- a transparent acrylic resin is used in consideration of the function of not inhibiting the decorating function of the decorating layer 33.
- the thicknesses of the decorative layer 33 and the adhesive layer 34 are both 4 ⁇ m.
- the thickness of each layer (33, 34) can be set appropriately.
- various design properties can be realized by appropriately increasing or decreasing the thickness of the decoration layer 33 for decoration use.
- the shade of the color of the decorated portion can be controlled by the thickness of the decorated layer 33. If the thickness of the decorative layer 33 is reduced, if the color of the resin constituting the frame 10f or the adhesive layer 34 is not transparent, the color of the adhesive layer 34 is transmitted upward, and the frame 10f. Or the color of the resin constituting the decorative layer 33 can be mixed.
- the glass plate 20f provided with the resin layer 30 having the two-layer structure is placed in the mold (41, 42) (B).
- the frame body 10f having the decorative layer 50 provided on the outer surface of the frame body 111 is formed, and the glass plate 20f and the gold on the side where the glass plate 20f is not disposed are formed.
- the transfer film 60 is interposed between the inner surface 43 of the mold 41, and the molds (41, 42) are closed in this state, and the transfer film 60 is sandwiched between the molds (41, 42) (C).
- the molten resin 110 is injected into the mold (41, 42) (D).
- the decorative design is transferred to the outer surface of the frame body 111, and the molten resin 110 is fixed to the adhesive layer 34 of the resin layer 30 of the glass plate 20f.
- the molds (41, 42) are opened, and the molded front cover 1f is taken out (E).
- the glass integrated molded product such as the front cover 1f molded by the molded product manufacturing method according to the third embodiment is decorated on the lower surface 22 of the glass plate 20f and has excellent durability. Become. Further, the decoration on the glass plate 20f is formed by a process of merely printing the resin layer 30 on the glass plate 20f. If the frame body 10f is formed by glass insert molding using the glass plate 20f, the glass plate 20f is made of glass. An integral molded product is completed. That is, a glass integrated molded product in which the glass plate 20f is decorated can be manufactured at low cost.
- the resin layer 30 printed on the lower surface 22 of the glass plate 20f has a two-layer structure of a decoration layer 33 for decoration use and an adhesive layer 34 that functions as a binder between the decoration layer 33 and the frame 10f.
- the original function of the resin layer 30 enabling the glass insert mold formation of the glass integrated molded product and the function as decoration can be made compatible at a high level.
- the resin layer 30 may not be a two-layer structure of the decoration layer 33 and the adhesive layer 34 for decoration use, but may have a structure of three or more layers. And, for example, if the resin is printed on a partial region of the upper surface of the decorative layer 33, it becomes possible to visually recognize a logo or the like with the decorative layer 33 in the background through the upper surface 21 of the glass plate 20. Furthermore, it becomes possible to improve the designability.
- the resin layer 30 may have a single-layer structure in consideration of the manufacturing cost and the design as a product. In any case, the upper surface side of the resin layer 30 visible through the upper surface 21 of the glass plate 20 may be used for decoration, and the lower surface side may be used for bonding with the frame 10f.
- FIG. 16 shows an example of a front cover 10h provided with a resin layer 30 having a three-layer structure.
- the glass plate 20c whose side surface is a polygonal line is used, and the resin layer 30 including three layers is formed around the lower surface 22 of the glass plate 20c. Yes.
- the resin layer 30 is a resin (for example, urethane resin) in which the intermediate layer 35 is more easily elastically deformed than the resin (for example, acrylic resin) constituting the uppermost decorative layer 33 and the lowermost adhesive layer 34. , Elastomer, rubber, etc.).
- the intermediate layer 35 may be formed by printing or may be formed by sticking a frame-shaped resin sheet. In any case, since the resins constituting each layer are welded to each other at the time of injection molding, there is a low possibility that each layer will be peeled off between the layers.
- the resin layer 30 is formed around the lower surface 22 of the glass plate (20, 20b, 20c, 20f), so that the glass plate (20, 20b, 20c, 20f) is added during glass insert molding. The pressure was relieved to prevent the glass plates (20, 20b, 20c, 20f) from being damaged. Further, this technical idea is further developed, and it is more easily elastically deformed and relatively softer than the resin (for example, acrylic resin) that forms the resin layer 30 on the periphery of the glass plate (20, 20b, 20c, 20f). You may form so that resin (for example, urethane type resin) may be wound.
- resin for example, urethane type resin
- FIG. 17 shows an example of the front cover 1i in which the pressure buffering portion 80 made of the highly elastic resin is formed on the periphery of the glass plate 20c.
- the front cover 1i includes a glass plate 20c and a resin layer 30 similar to the front cover 1g shown in FIG. 14B, and a pressure buffering portion 80 is provided around the side surface of the glass plate 20c on which the resin layer 30 is formed. It is wound.
- the pressure buffer 80 is formed so as to cover from the lower side of the side surface of the glass plate 20 c to a part of the lower surface of the resin layer 30.
- a ring-shaped pressure buffering portion 80 may be wound around the glass plate 20c in advance, and injection molding may be performed in this state, or the pressure buffering portion 80 may be formed by glass in-mold molding. After forming the periphery of the plate 20c, glass in-molding is performed again using another mold and the glass plate 20c in a state where the pressure buffering portion 80 is formed. Finally, FIG. The illustrated front cover 1i may be completed. That is, since the resin layer 30 that functions as a buffer material is formed on the glass plate 20c, the pressure buffering portion 80 can also be formed in glass.
- FIG. 18 shows a schematic view of a mold (46 to 49) for manufacturing the front cover 1i with the pressure buffering portion 80 built therein.
- FIG. 18A is a cross-sectional view of a mold (46, 47) for forming the pressure buffering portion 80
- FIG. 18 (B) shows a mold (48, 48) for finally forming the front cover 1i. 49).
- the glass plate 20c in which the resin layer 30 was formed is arrange
- the present invention is not limited to smartphones, but covers a wide variety of objects such as mobile phone devices, portable music terminals, flat panel displays provided in in-vehicle navigation systems, and finders and displays of digital cameras.
- the shape of the upper surface of the glass plate is not limited to a substantially rectangular shape, but may be an appropriate shape such as a polygon or a circle. And even if the upper surface of the glass plate has a complicated shape, if the manufacturing method of the glass integrated molded product of the present invention is applied, the inner peripheral shape along the shape of the glass without using a complicated mold It is possible to mold a frame having
- the present invention is suitable for a method for manufacturing a front cover for protecting a display panel such as a touch panel of a smartphone.
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Abstract
Description
前記板状ガラスの一方の面側を上方として、前記枠体は、上面が当該板状ガラスの上面に連続するとともに、前記板状ガラスの下面周縁を下支えする縁部を備えてなり、
前記方法は、
前記板状ガラスの下面周縁に、前記枠体を構成する樹脂と相容性を有するともに、前記枠体の成形時に当該板状ガラスに加わる応力を軽減させるための緩衝材として機能する樹脂層を、前記板状ガラスの下面周縁を周回する枠状に形成する樹脂層形成ステップと、
前記板状ガラスを前記枠体を成形するための金型内に配置する板状ガラス配置ステップと、
閉じた状態の前記金型内に溶融した前記樹脂を射出して前記枠体を成形する射出成形ステップと、
を実行することで、
前記板状ガラスの下面周縁と前記縁部の上面とを固着させる、
ことを特徴とするガラス一体型成形品の製造方法としている。
当該転写フィルム架設ステップでは、前記転写フィルムの基材フィルムと前記金型の内面とを対面させ、
前記板状ガラス配置ステップでは、前記板状ガラスを前記金型内に配置する際、前記金型の内面と前記板状ガラスの上面との間に前記転写フィルムを介在させ、
前記射出成形ステップでは、前記転写フィルムを前記閉じた状態の金型によって挟持させつつ前記溶融樹脂を射出することで、前記枠体を成形するとともに、当該枠体の表面に前記加飾用フィルムを転写させる、ガラス一体型成形品の製造方法とすることもできる。
前記板状ガラスの一方の面側を上方として、前記枠体は、上面が当該板状ガラスの上面に連続するとともに、前記板状ガラスの下面周縁を下支えする縁部を備え、
前記板状ガラスには、前記縁部によって下支えされる下面周縁に、当該縁部の上面と固着しつつ、当該縁部上面と前記ガラス下面の周縁との間の緩衝材となる樹脂層が形成されている、
ことを特徴としている。
前記樹脂層は、前記枠状の樹脂層を構成する前記加飾層と当該加飾層の下方に積層される層のそれぞれの外側縁辺が揃いつつ、前記加飾層の幅が前記下方に積層される層よりも広いガラス一体型成形品としてもよい。
<ガラス一体型成形品の外観と構造>
図3は、第1の実施例に係る製造方法により成形された前面カバー1aの概略図である。ここでも、前面カバー1aの上下関係を図1、図2に示したように規定する。図3(A)は、前面カバー1aを上方から見たときの斜視図であり、(B)は、下方から見たときの斜視図である。図4は、図3(A)のb-b矢視断面図であり、図4(A)は、当該断面の全体図であり、図4(B)は、(A)の円内を拡大した図である。当該前面カバー1aは、従来の前面カバー1と同様に、底が浅い略矩形皿状で、その皿の底面に相当する部分にガラス板20が配置され、そのガラス板20の周囲を枠体10aが囲繞している。そして、当該前面カバー1aは、枠体10aの縁部13の上面14から枠体10a自体の上面11までの段差の高さがガラス板20の厚さとほぼ一致し、ガラス板20の上面21の外周と枠体10aの内周との間に段差がなく、双方が連続面を形成している。なお、この例では、枠体10aの上面外周がほぼ平坦で、ガラス板20の上面21と枠体10aの上面11とがほぼ面一となっている。
本発明は、前面カバーなど、従来ではガラスインサートモールド成形によって製造することが困難だったガラス一体型成形品をガラスインサートモールド成形によって製造可能とする方法である。本発明の第1の実施例として、図3、図4に示した前面カバー1aの製造方法を挙げる。図5(A)~(F)に当該製造方法の流れを示した。まず、ガラス板20の下面22の周囲に印刷により樹脂層30を形成する(A)(B)。なお、図5(A)は、この樹脂層30が形成されたガラス板20を下方から見たときの斜視図であり、(B)は、(A)におけるc-c矢視断面図である。樹脂層30は、枠体10を形成する溶融樹脂110と相溶性があり、この実施例では、アクリル系の樹脂を周知のシルク印刷方法によって、約4~8μmの厚さとなるように形成している。もちろん、樹脂層30は、アクリル系の樹脂に限らず、溶融樹脂110と相溶性がある樹脂で形成されていればよく、例えば、ウレタン系、エポキシ系、ポリエステル系、ビニル系など適宜な樹脂を採用することができる。そして、樹脂層30の厚さについても上記数値に限定されない。
ところで、従来の前面カバー1などのガラス板一体型部品では、ガラス板20の上面21の周縁と枠体10の上面11との連続性をより向上させるとともに、ガラス板20と枠体10との間に上方からの水滴などが侵入しにくくなるように、ガラス板20上面21の周縁を面取りし、その面取りした部分を上方から覆うようにオーバーハングさせた部位を枠体10の上面11の内側周縁に形成することがある。図6に、前面カバー(1,1a)の変形例として、枠体10bに、オーバーハングした部位(以下、庇状部)16が形成された前面カバー1bを断面図にして示した。なお、この図に示した断面図は、図4(A)における円内に相当する。
<枠体への加飾について>
スマートフォンの前面カバーなど、電子機器の外装ケースの一部となるガラス一体型部品では、枠体の上面11や側壁15の外側の面など、外装ケースとして外方に露出する面(以下、外表面)に加飾が施される場合が多い。加飾としては、製品のロゴなど、枠体の外表面の一部に限定的に施される場合もあるし、他の材質(金属など)を模倣して外表面の全領域に施される模様である場合もある。以下では、本発明の第2の実施例として、第1の実施例を前提とすることで、前面カバーの枠体に、低コストで信頼性の高い加飾を施すための成形品製造方法を挙げる。
図8に第2の実施例によって製造された前面カバー1dの外観図を示した。また、図9(A)(B)に図8におけるc-c矢視断面図を示した。なお、図9(B)は、図8(A)における円内を拡大した図である。ここに示した前面カバー1dの枠体10dは、第1の実施例の前面カバー1aにおける枠体10aと同様の構造を有する枠本体111の外表面全域に加飾図案が形成されたフィルムからなる加飾フィルム層50が接着された構造となっている。そして、枠体10dの上面11では、その加飾フィルム層50の表層がガラス板20の上面21と連続面を形成している。なお、図8では、枠体10dの細部の構造が分かり易いように、加飾フィルム層50の厚さ誇張している。以下、この前面カバー1dの製造方法を第2の実施例として説明する。
第2の実施例は、第1の実施例を基本としつつ、枠本体111の外表面に加飾を施すために、インモールド成形技術を利用していることに特徴がある。周知のごとく、インモールド成形技術は、基材となるフィルム(以下、基材フィルム)に加飾となる図案や文字、あるいは他の材質を模した模様など(以下、装飾図案)が形成されたフィルム(加飾用フィルム)を積層した転写フィルムを射出成形機の金型内に挟み込んだ状態で溶融樹脂を射出し、その溶融樹脂の熱により加飾用フィルムを樹脂に転写するものである。
図11(A)~(E)に第2の実施例に係る成形品製造方法の流れを示した。まず、ガラス板20の下面22の周縁には、図5(A)(B)と同様に、あらかじめ樹脂層30を印刷形成しておく。また、転写フィルム60をガラス板20が配置されない側の金型41に架け渡しておく(A)。このとき、転写フィルム60において、基材フィルム61側を金型41の内面43と対面させるように架け渡しておく。すなわち、加飾用フィルム62側が金型42に対面するようにしておく。つぎに、ガラス板20を金型42内に配置し、転写フィルム60を金型41の内面43とガラス板20の上面21との間に介在させる(B)。そして、金型(41,42)を閉じ、転写フィルム60を金型(41,42)で挟み込む(C)。なお、この例では、枠本体111(図9参照)の外表面全域に加飾を施すために、金型(41,42)の構造が図5に示したものと若干異なっている。
図1に示したような、従来のガラス一体型成形品1では、枠体10のみを単体で射出成形しており、この枠体10にインモールド成形技術を適用して加飾を施そうとすると、枠体10の内周の上縁辺が鋭利なエッジとなって、転写フィルム60が破断したり、枠体10のガラス板20が嵌め込まれる矩形の開口のコーナー部分で皺が寄ったりして、加飾品質が劣化する。そのため、従来では、成形後の枠体10に、シルク印刷を施したり、装飾図案が印刷されたフィルムを貼着したりして、加飾を施していた。したがって、従来の成形品製造方法では、製造工程が多く、コストダウンが難しい。
<ガラス板に対する加飾について>
ガラス一体型成形品は、その上面の面積のほとんどがガラス板で占有されてしまう。そのため、意匠上の特徴を出し難い、という問題がある。例えば、スマートフォンの前面カバーなどは、製品の意匠上の特徴を大きく左右する部位に使用されているものの、この前面カバーに製品としての特徴を訴求するための加飾を施す領域が枠体の外表面の僅かな領域にしか存在しない。そのため、スマートフォンは、外形以外はどれも似通ったデザインとならざるを得なく、他社製品とのデザイン上の差別化が難しい。外形にしても、携帯性や操作性を考慮すれば、ほとんど同様の形状となってしまう。
第3の実施例は、第1の実施例の成形品製造方法を発展させることで実現している。具体的には、第1の実施例では、ガラス板20の下面22の周縁に樹脂層30を印刷により形成することで、枠体10aの射出成形時にガラス板20を保護し、かつ枠体10aを構成する樹脂とガラス板20とを強固に接着して防水性を高めていた。そして、第3の実施例では、その樹脂層30を加飾と兼用することとしている。
上述したように、第3の実施例は、ガラス板20下面22の樹脂層30を加飾として利用することに特徴がある。しかし、この樹脂層30の本来の目的は、ガラス一体型成形品のガラスインサートモールド成形を可能とすることにある。したがって、加飾としての機能を向上させるために樹脂層30の本来の機能が損なわれては本末転倒となる。理想的には、本来の機能と加飾としての機能を高い次元で両立させることが望ましい。そこで、樹脂層30を加飾として機能する層(加飾層)と射出成形時に緩衝材として機能する樹脂の層(緩衝層)からなる2層構造としてもよい。もちろん、加飾層に緩衝層を兼ねさせ、加飾層の下層に形成される層を加飾層と枠体との接着仲介するバインダーの層(接着層)としてもよい。二つの層がともに緩衝層として機能してもよい。また、2層に限らず、加飾層の下面に樹脂による層が2層以上積層されていてもよい。
以下に、第3の実施例として、図14(A)に示した前面カバー1fの製造方法を挙げる。図15(A)~(E)に、第3の実施例に係る成形品製造方法の流れを示した。まず、図15(A)に示したように、ガラス板20fの下面22の周縁に、あらかじめ樹脂層30を印刷形成しておく。この図15(A)は、図13(B)におけるd-d矢視断面図に相当する。ここで印刷形成する樹脂層30は、第1あるいは第2の実施例と異なり、ガラス板20fの下面22に接する側の第1層33の下方に第2層34が印刷形成された2層構造となっている。ここでは、第1層が緩衝層を兼ねた加飾層33であり、第2層が接着層34であることとする。
上記各実施例では、ガラス板(20,20b,20c,20f)の下面22の周囲に樹脂層30を形成することで、ガラスインサートモールド成形時にガラス板(20,20b,20c,20f)に加わる圧力を緩和し、ガラス板(20,20b,20c,20f)の破損などを防止していた。そして、この技術思想をより発展させて、ガラス板(20,20b,20c,20f)の周縁に樹脂層30を形成する樹脂(例えば、アクリル系樹脂)よりも弾性変形しやすく、相対的に柔らかい樹脂(例えば、ウレタン系樹脂)を巻回するように形成してもよい。
以上、本発明の実施例として、スマートフォンの前面カバーをガラスインサートモールド成形によって製造する方法を示した。もちろん、本発明は、スマートフォンに限らず、携帯電話器、携帯型音楽端末、あるいは車載型ナビゲーションシステムなどが備えるフラットパネルディスプレイ、デジタルカメラのファインダーやディスプレイなど、その対象は多岐に亘っている。
Claims (13)
- 樹脂で一体成形された枠体の内方に板状ガラスが固定されたガラス一体型成形品をガラスインサートモールド成形によって製造するための方法であって、
前記板状ガラスの一方の面側を上方として、前記枠体は、上面が当該板状ガラスの上面に連続するとともに、前記板状ガラスの下面周縁を下支えする縁部を備えてなり、
前記方法は、
前記板状ガラスの下面周縁に、前記枠体を構成する樹脂と相容性を有するともに、前記枠体の成形時に当該板状ガラスに加わる応力を軽減させるための緩衝材として機能する樹脂層を、前記板状ガラスの下面周縁を周回する枠状に形成する樹脂層形成ステップと、
前記板状ガラスを前記枠体を成形するための金型内に配置する板状ガラス配置ステップと、
閉じた状態の前記金型内に溶融した前記樹脂を射出して前記枠体を成形する射出成形ステップと、
を実行することで、
前記板状ガラスの下面周縁と前記縁部の上面とを固着させる、
ことを特徴とするガラス一体型成形品の製造方法。 - 請求項1において、
基材フィルムに加飾用フィルムが積層されたインモールド成形用の転写フィルムを前記金型に架け渡す転写フィルム架設ステップを含み、
当該転写フィルム架設ステップでは、前記転写フィルムの基材フィルムと前記金型の内面とを対面させ、
前記板状ガラス配置ステップでは、前記板状ガラスを前記金型内に配置する際、前記金型の内面と前記板状ガラスの上面との間に前記転写フィルムを介在させ、
前記射出成形ステップでは、前記転写フィルムを前記閉じた状態の金型によって挟持させつつ前記溶融樹脂を射出することで、前記枠体を成形するとともに、当該枠体の表面に前記加飾用フィルムを転写させる、
ことを特徴とするガラス一体型成形品の製造方法。 - 請求項1または2において、前記樹脂層形成ステップでは、上面側が前記板状ガラスの上面を通して視認された際に加飾として機能する樹脂を印刷し、前記射出成形ステップでは、当該印刷層が前記板状ガラスの上面を通して視認される形状の前記枠体を成形することを特徴とするガラス一体型成形品の製造方法。
- 請求項3において、前記樹脂層形成ステップでは、前記板状ガラスの下面に前記加飾として機能する樹脂を印刷して加飾層を形成するとともに、当該加飾層の下方に、前記枠体を構成する前記樹脂との相容性とを有する樹脂を印刷して接着層を形成することを特徴とするガラス一体型成形品の製造方法。
- 請求項4において、前記加飾層と前記接着層の間に、当該加飾層および当該接着層を形成する樹脂よりも弾性変形しやすい樹脂で中間層を形成することを特徴とするガラス一体型成形品の製造方法。
- 請求項4または5において、前記板状ガラスは、上方から見て、上面の領域が下面の領域内に包含されて、側面に上面から下面に向かって外側へ傾斜する斜面を有し、前記樹脂層印刷ステップでは、前記枠状の樹脂層を構成する前記加飾層と当該加飾層の下方に積層される層のそれぞれの外側縁辺を揃えつつ、前記加飾層の幅を前記下方に積層される層よりも広くするように各層を形成することを特徴とするガラス一体型成形品の製造方法。
- 請求項1~6のいずれかにおいて、前記樹脂層印刷ステップと前記板状ガラス配置ステップの間に、前記樹脂層の下面の一部と側面とに接触しつつ前記板状ガラスの側面を周回する圧力緩衝部を形成するステップを含み、当該ステップでは、前記枠体および前記樹脂層を形成する樹脂よりも弾性変形しやすい樹脂により前記圧力緩衝部を形成することを特徴とするガラス一体型成形品の製造方法。
- 樹脂で一体成形された枠体の内方に板状ガラスが固定されたガラス一体型成形品であって、
前記板状ガラスの一方の面側を上方として、前記枠体は、上面が当該板状ガラスの上面に連続するとともに、前記板状ガラスの下面周縁を下支えする縁部を備え、
前記板状ガラスには、前記縁部によって下支えされる下面周縁に、当該縁部の上面と固着しつつ、当該縁部上面と前記ガラス下面の周縁との間の緩衝材となる樹脂層が形成されている、
ことを特徴とするガラス一体型成形品。 - 請求項8において、前記樹脂層の上面は、前記板状ガラスの上面を通して視認される加飾であることを特徴とするガラス一体型成形品。
- 請求項9において、前記樹脂層は、前記加飾として機能する加飾層の下方に前記縁部の上面と固着する接着層が積層された構造であることを特徴とするガラス一体型成形品。
- 請求項10において、前記加飾層と前記接着層との間に中間層が介在し、当該中間層は、前記加飾層および前記接着層を形成する樹脂よりも弾性変形しやすい樹脂で形成されていることを特徴とするガラス一体型成形品。
- 請求項10または請求項11において、
前記板状ガラスは、上方から見て、上面の領域が下面の領域内に包含されて、側面に上面から下面に向かって外側へ傾斜する斜面を有し、
前記樹脂層は、前記枠状の樹脂層を構成する前記加飾層と当該加飾層の下方に積層される層のそれぞれの外側縁辺が揃いつつ、前記加飾層の幅が前記下方に積層される層よりも広いことを特徴とするガラス一体型成形品。 - 請求項8~12のいずれかにおいて、前記樹脂層の下面の一部と側面とに接触しつつ前記板状ガラスの側面を周回する圧力緩衝部を備え、当該圧力緩衝部は、前記樹脂層を形成する樹脂よりも弾性変形しやすい樹脂により形成されていることを特徴とするガラス一体型成形品。
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NL2025583B1 (en) * | 2020-05-14 | 2021-11-30 | Microsoft Technology Licensing Llc | Systems and methods for overmolding on electronic device surfaces |
WO2023013570A1 (ja) * | 2021-08-06 | 2023-02-09 | Mccアドバンスドモールディングス株式会社 | 車載用表示パネル及び表示装置 |
JP2024031465A (ja) | 2022-08-26 | 2024-03-07 | アルプスアルパイン株式会社 | 表示装置用筐体および表示装置用筐体の製造方法 |
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- 2012-08-30 KR KR1020147014283A patent/KR20140100482A/ko not_active Application Discontinuation
- 2012-08-30 US US14/363,233 patent/US20140308469A1/en not_active Abandoned
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- 2012-08-30 CN CN201280060405.3A patent/CN104080587A/zh active Pending
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WO2015098300A1 (ja) | 2013-12-27 | 2015-07-02 | 旭硝子株式会社 | ガラス樹脂一体成形品の製造方法及び装置 |
KR20160102975A (ko) | 2013-12-27 | 2016-08-31 | 아사히 가라스 가부시키가이샤 | 유리 수지 일체 성형품의 제조 방법 및 장치 |
CN105992684A (zh) * | 2013-12-27 | 2016-10-05 | 旭硝子株式会社 | 玻璃树脂一体成形品的制造方法及装置 |
JPWO2015098300A1 (ja) * | 2013-12-27 | 2017-03-23 | 旭硝子株式会社 | ガラス樹脂一体成形品の製造方法及び装置 |
EP3088154A4 (en) * | 2013-12-27 | 2017-08-02 | Asahi Glass Company, Limited | Method and device for producing integrally molded glass-resin article |
CN105992684B (zh) * | 2013-12-27 | 2018-05-15 | 旭硝子株式会社 | 玻璃树脂一体成形品的制造方法及装置 |
CN103853382B (zh) * | 2014-02-17 | 2017-04-19 | 东莞万德电子制品有限公司 | 防水抗震手机触摸屏的制作方法 |
JPWO2018194103A1 (ja) * | 2017-04-19 | 2020-02-27 | Agc株式会社 | カバー部材および表示装置 |
JP2020066162A (ja) * | 2018-10-24 | 2020-04-30 | 双葉電子工業株式会社 | ガラス成形品 |
JP2022530102A (ja) * | 2019-04-26 | 2022-06-27 | エージーシー グラス ユーロップ | 検知装置用保護ハウジング |
JP7486520B2 (ja) | 2019-04-26 | 2024-05-17 | エージーシー グラス ユーロップ | 検知装置用保護ハウジング |
Also Published As
Publication number | Publication date |
---|---|
US20140308469A1 (en) | 2014-10-16 |
KR20140100482A (ko) | 2014-08-14 |
JP6050962B2 (ja) | 2016-12-21 |
CN104080587A (zh) | 2014-10-01 |
JP2013139136A (ja) | 2013-07-18 |
EP2789446A1 (en) | 2014-10-15 |
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