WO2018074248A1 - 加飾ハウジング及びその製造装置 - Google Patents

加飾ハウジング及びその製造装置 Download PDF

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Publication number
WO2018074248A1
WO2018074248A1 PCT/JP2017/036316 JP2017036316W WO2018074248A1 WO 2018074248 A1 WO2018074248 A1 WO 2018074248A1 JP 2017036316 W JP2017036316 W JP 2017036316W WO 2018074248 A1 WO2018074248 A1 WO 2018074248A1
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WO
WIPO (PCT)
Prior art keywords
layer
decorative
mold
nonwoven fabric
laminate
Prior art date
Application number
PCT/JP2017/036316
Other languages
English (en)
French (fr)
Inventor
渡邊　泰
秀治 城野
深田　泰秀
Original Assignee
Ｎｉｓｓｈａ株式会社
Art&Tech株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ｎｉｓｓｈａ株式会社, Art&Tech株式会社 filed Critical Ｎｉｓｓｈａ株式会社
Priority to US16/342,955 priority Critical patent/US11712876B2/en
Priority to DE112017004689.0T priority patent/DE112017004689B4/de
Priority to CN201780064664.6A priority patent/CN109843583A/zh
Publication of WO2018074248A1 publication Critical patent/WO2018074248A1/ja

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    • 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
    • B29C45/1418—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 the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C45/14221—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 the inserts being deformed or preformed, e.g. by the injection pressure by tools, e.g. cutting means
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    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
    • 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
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/1418—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 the inserts being deformed or preformed, e.g. by the injection pressure
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C2045/14237—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 the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
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Definitions

  • the present invention relates to a decorative housing and a manufacturing apparatus thereof, and more particularly to a decorative housing in which a decorative layer is laminated on a base resin layer and a manufacturing apparatus thereof.
  • the housings are cut out of letters, symbols, and patterns, for example, a black resin layer and bonded to both sides of this resin layer
  • a symbol and a pattern portion are formed as an operation portion such as a switch pressed by the user.
  • FIG. 4 is a perspective view illustrating a housing of a conventional home appliance operation unit
  • FIG. 5 is a cross-sectional view taken along line VV in FIG.
  • the housing 50 of the home appliance operation unit is formed in an inverted tray shape, and has a structure of a window 54 as a pattern, a character 55 such as “AT”, for example, “ ⁇ ”, “ A black resin layer 51 in which a symbol 56 such as “ ⁇ ” is cut out, and two transparent plastic layers 52 and 53 bonded to both surfaces of the resin layer 51.
  • the housing 50 incorporates appropriate wiring in a portion of a symbol 56 such as “ ⁇ ” or “ ⁇ ” so as to constitute a switch portion to be pressed by the user.
  • a symbol 56 such as “ ⁇ ” or “ ⁇ ” so as to constitute a switch portion to be pressed by the user.
  • the symbol 56 part of “ ⁇ ” constitutes a power on / off switch
  • the symbol 56 part of “ ⁇ ” constitutes a stop switch.
  • the housing shown in FIG. 4 is based on the premise that the front surface layer is transparent, and it is impossible to use a decorative layer made of non-transparent main body and textile.
  • the object of the present invention is to provide a resin molded article that can transmit characters, symbols, and patterns even if a decorative layer made of non-transparent main body and textile is used for the front (front) surface layer. It is providing the decoration housing and its manufacturing apparatus.
  • the decorative housing according to claim 1 includes a decorative layer, a nonwoven fabric layer bonded to the decorative layer via an adhesive resin layer, and a gap between the fibers of the nonwoven fabric layer.
  • a colored resin film having a notch pattern is formed on either the back surface of the decorative layer and one or both surfaces of the nonwoven fabric layer. Has been.
  • the decorative housing according to claim 2 wherein the decorative housing, the colored nonwoven fabric layer bonded to the decorative layer via an adhesive resin layer, and the decorative housing while infiltrating a gap between the fibers of the nonwoven fabric layer.
  • a base resin layer fixed to the decorative layer, and a cutout pattern is formed in the nonwoven fabric layer.
  • An apparatus for manufacturing the decorative housing according to claim 1 or 2 is as described in any one of claims 9 to 12.
  • a decorative layer made of a non-transparent main wall and textile is used as a front (front) surface layer in a resin molded product, it is possible to transmit characters, symbols, and patterns.
  • FIG. 2 is a cross-sectional view of the decorative housing along the line II-II in FIG. 1. It is a figure used for demonstrating the manufacturing apparatus of the decorating housing which concerns on embodiment of this invention. It is an external appearance perspective view of the housing of the conventional household appliance operation part.
  • FIG. 5 is a cross-sectional view of the housing along the line VV in FIG. 4.
  • FIG. 1 is an external perspective view of a decorative housing which is a decorative layer / resin laminated structure housing according to an embodiment of the present invention
  • FIG. 2 is a cross-sectional view of the decorative housing along line II-II in FIG. FIG.
  • the housing 40 of the home appliance operation unit as a decorative housing according to the embodiment of the present invention is formed in an inverted basin shape, and a main wall as a decorative layer.
  • a predetermined notch pattern is formed on the colored coating film (in this embodiment, a black ink film) 44 applied to the front surface of the nonwoven fabric layer 43.
  • this colored coating film may be formed only on the surface of the nonwoven fabric layer 43 as in the present embodiment, it may be formed on both surfaces. Further, this colored coating film may be formed on the back surface of the main layer 41.
  • characters 47 such as “AT”, for example, symbols 48 such as “ ⁇ ” and “ ⁇ ” constitute the notch pattern.
  • the housing shown in FIG. 1 incorporates appropriate wiring in a portion of a symbol 48 such as “ ⁇ ” or “ ⁇ ” so as to constitute a switch portion to be pressed by the user.
  • a symbol 48 such as “ ⁇ ” or “ ⁇ ”
  • the symbol 48 part of “ ⁇ ” constitutes a power on / off switch
  • the symbol 48 part of “ ⁇ ” constitutes a stop switch.
  • the adhesive resin layer 42 is made of a polyvinyl acetal resin that has thermoplasticity and has a viscosity that allows the bubbles in the adhesive resin layer 42 to escape by softening when the housing 40 is molded.
  • This polyvinyl acetal resin is a polyvinyl alcohol (PVA) resin acetalized with an aldehyde, and is particularly preferably a polyvinyl butyral (PVB) resin acetalized with butyraldehyde.
  • PVA polyvinyl alcohol
  • PVB polyvinyl butyral
  • the adhesive resin layer 42 is formed by applying (spraying) an adhesive resin solution heated and melted to the nonwoven fabric layer 43.
  • the adhesive resin layer 42 may be formed by applying (spraying) an adhesive resin solution heated and melted to the main layer 41.
  • the adhesive resin layer 42 may be formed by sandwiching a PVB film between the main bag layer 41 and the adhesive resin layer 42.
  • the PVB resin may contain a plasticizer for the purpose of imparting flexibility to the adhesive resin layer 42, and the type of the plasticizer is not particularly limited.
  • a plasticizer for the purpose of imparting flexibility to the adhesive resin layer 42, and the type of the plasticizer is not particularly limited.
  • triethylene glycol di-2-ethylhexylate triethylene Monobasic organic acid esters such as glycol di-2-ethylbutyric acid ester, triethylene glycol di n-octylic acid ester, polybasic organic acid esters such as dibutyl sebacic acid ester, dioctyl azelaic acid ester, polyoxypropylene polyglyceryl ether And polyglycerin derivatives such as polyethylene glycol polyglyceryl ether.
  • the adhesive resin layer 42 is made of polyvinyl acetal resin, ethylene / vinyl acetate copolymer resin, ethylene / acrylic copolymer resin, propylene resin, propylene / 1-butene copolymer resin, propylene / isobutene copolymer.
  • the nonwoven fabric layer 43 is made of a spunbonded nonwoven fabric or a papermaking nonwoven fabric containing polyester (specifically, PY-120 manufactured by Awa Paper Co., Ltd.).
  • the thickness of the nonwoven fabric layer 43 is 50 to 1000 ⁇ m.
  • each fiber of the nonwoven fabric layer 43 has a thickness of 1 to 50 ⁇ m and a length of 1 to 50 mm, preferably 2 to 15 mm.
  • Each fiber of the nonwoven fabric layer 43 is made of at least one selected from the group consisting of polyester, polyamide, polypropylene, polyethylene, acrylic, polyacetal, and polycarbonate, and preferably made of polyester.
  • the base resin layer 45 is a resin that transmits light, and is made of a light-transmitting thermoplastic resin, preferably a synthetic resin for injection molding. Specifically, PMMA (polymethyl methacrylate), transparent ABS (acrylonitrile) / Butadiene / styrene copolymer), PC (polycarbonate), and one material selected from the group of ABS + PC, preferably PMMA, and the thickness is arbitrarily set according to the product. , About 1.2 mm. The molten resin of the base resin layer 45 is heated and melted by an injection molding machine 20 shown in FIG.
  • the main layer 41 and the nonwoven fabric layer 43 adhered to each other by the adhesive resin layer 42 are mounted with the nonwoven fabric layer 43 as the front. Further, it is injected into a female mold 22 in FIG. 3 to be described later, and is infiltrated and fixed in the gaps between the fibers of the main punch layer 41 (FIG. 3). When the molten resin of the base resin layer 45 is cooled and solidified, the non-woven fabric layer 42 is contracted, so that the base resin layer 45 is more firmly fixed.
  • the housing 40 of FIG. 1 even if a decorative layer made of a non-transparent main body and textile is used for the front (front) surface layer in the resin molded product, the characters, symbols, and patterns are translucent. Can do.
  • a transparent acrylic layer may be adhered to the surface of the main layer 41.
  • the main layer 41 may be a textile layer made of a textile including a textile product such as a woven fabric, a non-woven fabric, and a knitted fabric instead of the main frame.
  • a textile product such as a woven fabric, a non-woven fabric, and a knitted fabric instead of the main frame.
  • the textile include polyester woven fabric, non-woven fabric, knitted fabric, and lace.
  • FIG. 3 is a diagram used for explaining the decorative housing manufacturing apparatus according to the embodiment of the present invention.
  • steps I and II are performed by a press machine, and steps III and IV are performed by an injection molding machine. Finally, step V described later is performed by an appropriate method.
  • the adhesive resin layer 42 is formed by applying (spraying) a heated adhesive resin melt to the nonwoven fabric layer 43.
  • the adhesive resin layer 42 may be formed by applying (spraying) the adhesive resin melt liquid heated and melted to the textile layer 41.
  • the adhesive resin layer 42 may be formed by sandwiching a PVB film between the main bag layer 41 and the adhesive resin layer 42.
  • the adhesive resin constituting the adhesive resin layer 42 is obtained by heating and melting PVB at 150 to 250 ° C., preferably about 200 ° C., to fix the main layer 41 and the nonwoven fabric layer 43.
  • step I of FIG. 4 the laminate of the main layer 41, the adhesive resin layer 42, and the nonwoven fabric layer 43 is placed on the female die 10 (fixed die) of the press so that the nonwoven fabric layer 43 is the front. Place.
  • This laminated body may be cut into a predetermined shape in advance.
  • step II the male die 11 (movable) of the press machine is pressed so as to push the laminate of the main layer 41, the adhesive resin layer 42, and the nonwoven fabric layer 43 placed in step I into the female die 10.
  • the mold) is moved toward the female mold 10.
  • die 11 this molded laminated body is taken out from a press machine.
  • the periphery of the formed laminated body may be deburred by cutting with a laser cutter or a cutting die (cutting unit).
  • Step III of FIG. 4 the laminate formed by the press machine is mounted in the female mold 22 (other fixed mold) with the nonwoven fabric layer 6 as a table, and then in the female mold 22.
  • the injection molding male mold 12 injection molding mold
  • injection molding mold injection molding mold
  • the injection screw 21 is rotated clockwise to inject the molten resin 31 of the base resin layer 45 in the tank 30 into a space (cavity) defined by the laminate and the injection molding male mold 12.
  • the molten resin 31 of the base resin layer 45 infiltrates and adheres to the gaps between the fibers of the nonwoven fabric layer 43, and the adhesiveness between the nonwoven fabric layer 43 and the base resin layer 45 and the mechanical strength of the housing 40 are improved.
  • step IV after the injection-molded base resin layer 45 is cooled and solidified, the injection machine 20 and the injection-molded male mold 12 are separated from the female mold 22 and the molded product is taken out.
  • the female die 10 and the male die 11 constitute a press machine
  • the female die 22, the injection molding male die 12 and the injection machine 20 constitute an injection molding machine.
  • the press machine and the injection molding machine are a housing 40.
  • the manufacturing apparatus is configured.
  • the press machine and the injection molding machine may be integrated, and the female die 10 may be used as the female die 22.
  • the injection-molded male mold 12 is moved toward the laminate of the main bag layer 41 and the nonwoven fabric layer 43 molded in the female mold 10.
  • the decorative housing 40 As a modified example of the decorative housing 40 according to the embodiment of the present invention, instead of the colored coating film 44 formed on the front surface or both surfaces of the nonwoven fabric layer 43 or the back surface of the main layer 41, it is bonded to the main layer 41.
  • a colored nonwoven fabric layer bonded through the resin layer 42 and having a notch pattern may be used.
  • the structure and operation, and the manufacturing apparatus thereof are the same as described above.
  • the decorative housing 40 is merely described as a general housing. However, as an applied technical field of the embodiment of the present invention, the decorative housing 40 is applied by in-mold molding having a surface coating layer. Applicable to ornaments, specifically, miscellaneous goods including containers and stationary, housings for electronic devices and home appliances including mobile phones and laptops, housings for interior and exterior products of buildings and automobiles, aircraft, railway vehicles And ship interior housing.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Textile Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

【課題】　樹脂成形品において、表（おもて）面層に透明でない本杢及びテキスタイルからなる加飾層を用いたとしても、文字、記号、模様を透光することができる加飾ハウジング及びその製造装置を提供する。 【解決手段】　加飾ハウジングとしての家電製品のハウジング４０は、逆盆形に成形されており、本杢層４１と、本杢層４１に接着樹脂塗布層４２を介して接着された不織布層４３と、不織布層４３の各繊維の隙間の樹脂に浸潤して本杢層４１に固着された基盤樹脂層４５とを備える。不織布層４３の表（おもて）面に塗布された有色塗膜４４に所定の切り欠きパターンが形成されている。

Description

加飾ハウジング及びその製造装置
　本発明は、加飾ハウジング及びその製造装置に関し、特に、基盤樹脂層の上に加飾層が積層された加飾ハウジング及びその製造装置に関する。
　電子機器や家電製品等のハウジング及び自動車内装品のハウジングの技術分野において、そのハウジングは、文字、記号、模様が切り欠かれた、例えば黒色の樹脂層と、この樹脂層の両面に接着された２つの透明プラスチック層とから構成され、例えば記号、模様部が、ユーザが押下するスイッチのような操作部として形成される場合がある。
　図４は、従来の家電製品操作部のハウジングを説明する斜視図であり、図５は、図４のＶ－Ｖ線に沿う断面図である。
　図４及び図５において、家電製品操作部のハウジング５０は、逆盆形に成形されており、構造としては、模様としての窓５４、「ＡＴ」のような文字５５、例えば「○」、「□」のような記号５６が切り欠かれた黒色の樹脂層５１と、この樹脂層５１の両面に接着された二つの透明プラスチック層５２，５３とからなる。
　ハウジング５０は、例えば「○」、「□」のような記号５６の部分には、ユーザが押下するスイッチ部を構成するように適宜な配線を内蔵している。例えば、「○」の記号５６部分は、電源オン／オフスイッチを構成し、「□」の記号５６部分は、停止スイッチを構成している。
　しかしながら、図４のハウジングは、表（おもて）面層が透明であることを前提としており、透明でない本杢（ほんもく）及びテキスタイルからなる加飾層を用いることができなかった。
　本発明の目的は、樹脂成形品において、表（おもて）面層に透明でない本杢及びテキスタイルからなる加飾層を用いたとしても、文字、記号、模様を透光することができる加飾ハウジング及びその製造装置を提供することにある。
　上記目的を達成するために、請求項１に記載の加飾ハウジングは、加飾層と、前記加飾層に接着樹脂層を介して接着された不織布層と、当該不織布層の各繊維の隙間に浸潤しつつ前記加飾層に固着された基盤樹脂層とを備え、前記加飾層の裏面と前記不織布層の片面又は両面とのいずれか一方に、切り欠きパターンを有する有色塗膜が形成されている。
　請求項２に記載の加飾ハウジングは、加飾層と、前記加飾層に接着樹脂層を介して接着された有色の不織布層と、当該不織布層の各繊維の隙間に浸潤しつつ前記加飾層に固着された基盤樹脂層とを備え、前記不織布層に切り欠きパターンが形成されている。
　請求項１又は請求項２に記載の加飾ハウジングを製造する装置は、請求項９から請求項１２のいずれかに記載の通りである。
　本発明によれば、樹脂成形品において、表（おもて）面層に透明でない本杢及びテキスタイルからなる加飾層を用いたとしても、文字、記号、模様を透光することができる。
本発明の実施の形態に係る加飾ハウジングの外観斜視図である。 図１の線ＩＩ－ＩＩに沿う加飾ハウジングの断面図である。 本発明の実施の形態に係る加飾ハウジングの製造装置を説明するのに用いられる図である。 従来の家電製品操作部のハウジングの外観斜視図である。 図４の線Ｖ－Ｖに沿うハウジングの断面図である。
　以下、本発明を図面を参照しながら詳述する。
　図１は、本発明の実施の形態に係る加飾層／樹脂積層構造ハウジングである加飾ハウジングの外観斜視図であり、図２は、図１の線II－IIに沿う加飾ハウジングの断面図である。
　図１及び図２において、本発明の実施の形態に係る加飾ハウジングとしての家電製品操作部のハウジング４０は、逆盆形に成形されており、加飾層としての本杢（ほんもく）層４１と、本杢層４１に接着樹脂層４２を介して接着された不織布層４３と、不織布層４３の各繊維の隙間の樹脂に溶融しつつ本杢層４１に固着された基盤樹脂層４５とを備える。
　不織布層４３の表（おもて）面に塗布された有色塗膜（本実施の形態では、黒色インク膜）４４に所定の切り欠きパターンが形成されている。この有色塗膜は、本実施の形態のように不織布層４３の表面のみに形成されていてもよいが、両面に形成されていてもよい。また、この有色塗膜は、本杢層４１の裏面に形成されていてもよい。
　図１において、「ＡＴ」のような文字４７、例えば「○」、「□」のような記号４８は、上記切り欠きパターンを構成する。
　図１のハウジングは、例えば「○」、「□」のような記号４８の部分には、ユーザが押下するスイッチ部を構成するように適宜な配線を内蔵している。例えば、「○」の記号４８部分は、電源オン／オフスイッチを構成し、「□」の記号４８部分は、停止スイッチを構成している。
　接着樹脂層４２は、熱可塑性を有すると共に、ハウジング４０の成形時において、軟化により接着樹脂層４２内の気泡を逃すことができる程度の粘度を有するポリビニルアセタール系樹脂からなる。
　このポリビニルアセタール系樹脂は、ポリビニルアルコール（ＰＶＡ）樹脂をアルデヒドによりアセタール化したものであり、特に、ブチルアルデヒドによりアセタール化したポリビニルブチラール（ＰＶＢ）樹脂であるのが好ましい。
　接着樹脂層４２は、不織布層４３に加熱溶融した接着樹脂溶液を塗布（スプレー）することにより形成される。この接着樹脂層４２は、本杢層４１に加熱溶融した接着樹脂溶液を塗布（スプレー）することにより形成されてもよい。接着樹脂層４２は、本杢層４１と接着樹脂層４２の間にＰＶＢフィルムを挟むことにより形成してもよい。
　上記ＰＶＢ樹脂は、接着樹脂層４２に柔軟性を付与する目的で可塑剤を含んでもよく、可塑剤の種類については特に制限はないが、例えば、トリエチレングリコールジ２－エチルヘキシル酸エステル、トリエチレングリコールジ２－エチル酪酸エステル、トリエチレングリコールジｎ－オクチル酸エステル等の一塩基性有機酸エステル、ジブチルセバシン酸エステル、ジオクチルアゼライン酸エステル等の多塩基性有機酸エステル、ポリオキシプロピレンポリグリセルエーテル、ポリエチレングリコールポリグリセリルエーテル等のポリグリセリン誘導体が挙げられる。
　また、接着樹脂層４２は、ポリビニルアセタール系樹脂、エチレン／酢酸ビニル共重合体系樹脂、エチレン／アクリル系共重合体系樹脂、プロピレン系樹脂、プロピレン／１－ブテン共重合体系樹脂、プロピレン／イソブテン共重合体系樹脂、スチレン／プロピレン／イソブテン共重合体系樹脂、スチレン／イソプレン共重合体系樹脂、スチレン／イソプレン／イソブテン共重合体系樹脂、スチレン／イソプレン／ブテン共重合体系樹脂の群から選択された樹脂からなってもよい。
　不織布層４３は、スパンボンド系不織布、又はポリエステルを含む抄紙系不織布（具体的には、阿波製紙株式会社製のＰＹ－１２０）からなる。不織布層４３の厚さは、５０～１０００μｍである。
　具体的には、不織布層４３の各繊維は、太さが１～５０μｍ、長さが１～５０ｍｍ、好ましくは２～１５ｍｍである。
　不織布層４３の各繊維は、ポリエステル、ポリアミド、ポリプロピレン、ポリエチレン、アクリル、ポリアセタール、及びポリカーボネートからなる群から選択された少なくとも１つからなり、好ましくは、ポリエステルからなるのがよい。
　基盤樹脂層４５は、光を透過する樹脂であって、光透過性熱可塑性樹脂、好ましくは射出成形用合成樹脂からなり、具体的には、ＰＭＭＡ（ポリメチルメタアクリレート）、透明ＡＢＳ（アクリルニトリル／ブタジエン／スチレン共重合体）、ＰＣ（ポリカーボネート）、及びＡＢＳ＋ＰＣの群から選択された１つの素材、好ましくはＰＭＭＡからなり、厚さは、製品に応じて任意に設定され、本実施の形態では、約１．２ｍｍである。基盤樹脂層４５の溶融樹脂は、後述する図３の射出成形機２０で加熱溶融され、接着樹脂層４２により互いに接着された本杢層４１と不織布層４３が不織布層４３を表にして装着された後述する図３におけるメス金型２２の中に射出されて、本杢層４１の各繊維の隙間に浸潤して固着されている（図３）。基盤樹脂層４５の溶融樹脂の冷却固化時には、不織布層４２が収縮することにより基盤樹脂層４５との固着がより強固になっている。
　図１のハウジング４０によれば、樹脂成形品において、表（おもて）面層に透明でない本杢及びテキスタイルからなる加飾層を用いたとしても、文字、記号、模様を透光することができる。
　本杢層４１の表面に透明アクリル層を接着してもよい。
　本杢層４１は、本杢に代えて、織物、不織布、編物等の繊維製品を含むテキスタイルからなるテキスタイル層であってもよい。このテキスタイルとしては、ポリエステル織物、不織布、編物、レースが挙げられる。
　図３は、本発明の実施の形態に係る加飾ハウジングの製造装置を説明するのに用いられる図である。
　図３では、プレス機により工程Ｉ及びＩＩが実施されると共に、射出成形機により工程ＩＩＩ及びＩＶが実施される。最後に、適宜な方法により後述する工程Ｖが実施される。
　本杢層４１、及び本杢層４１に接着樹脂層４２を介して接着された不織布層４３の積層体であって、本杢層４１の裏面と不織布層４３の表（おもて）面又は両面とのいずれか一方に有色塗膜で切り欠きパターンが形成されている積層体を準備する。
　接着樹脂層４２は、不織布層４３に加熱した接着樹脂溶融液を塗布（スプレー）することにより形成される。この接着樹脂層４２は、テキスタイル層４１に加熱溶融した接着樹脂溶融液を塗布（スプレー）することにより形成されてもよい。接着樹脂層４２は、本杢層４１と接着樹脂層４２の間にＰＶＢフィルムを挟むことにより形成してもよい。
　接着樹脂層４２を構成する接着樹脂は、ＰＶＢを１５０～２５０℃、好ましくは約２００℃に加熱溶融されて、本杢層４１と不織布層４３を固着する。
図４の工程Ｉにおいて、本杢層４１、接着樹脂層４２、及び不織布層４３の積層体を、不織布層４３が表になるようにプレス機のメス金型１０（固定金型）の上に載置する。この積層体は、予め所定の形状に切断されていてもよい。
　次いで、工程ＩＩにおいて、工程Ｉで載置された本杢層４１、接着樹脂層４２、及び不織布層４３の積層体をメス金型１０の中に押し込むようにプレス機のオス金型１１（可動金型）をメス金型１０に向かって移動する。これにより、当該積層体をメス金型１０及びオス金型１１により規定される形状に成形した後、この成形された積層体はプレス機から取り出される。このとき、成形された積層体の周囲をレーザカッタや切断用金型（切断ユニット）で切断してバリ取りを行ってもよい。
　続いて、図４の工程ＩＩＩにおいて、プレス機で成形された積層体を不織布層６を表にしてメス金型２２（他の固定金型）内に装着した上で、メス金型２２内に配置された積層体に向けて射出成形オス金型１２（射出成形金型）を移動すると共に、射出機２０の射出孔２０ａを射出成形オス金型１２の射出成形孔１２ａに押し当てた上で、射出スクリュー２１を時計回りに回転させてタンク３０内の基盤樹脂層４５の溶融樹脂３１を当該積層体と射出成形オス金型１２とで規定される空間（キャビティ）に射出する。このとき、基盤樹脂層４５の溶融樹脂３１は不織布層４３の各繊維の隙間に浸潤して固着し、不織布層４３と基盤樹脂層４５との接着性及びハウジング４０の機械的強度が向上する。
　次いで、工程ＩＶにおいて、射出成形された基盤樹脂層４５が冷却して固化した後、射出機２０及び射出成形オス金型１２がメス金型２２から離間されて、成形品が取り出される。
　メス金型１０及びオス金型１１はプレス機を構成すると共に、メス金型２２、射出成形オス金型１２、及び射出機２０は射出成形機を構成し、プレス機及び射出成形機はハウジング４０の製造装置を構成する。変形例として、プレス機と射出成形機とが一体となっていて、メス金型１０がメス金型２２として使用されてもよい。この場合は、メス金型１０の中で成形された本杢層４１及び不織布層４３の積層体に向けて射出成形オス金型１２が移動される。
　本発明の実施の形態に係る加飾ハウジング４０の変形例として、不織布層４３の表面若しくは両面、又は本杢層４１の裏面に形成された有色塗膜４４に代えて、本杢層４１に接着樹脂層４２を介して接着された有色の不織布層であって、切り欠きパターンが形成されている不織布層を用いてもよい。構成及び作用、並びにその製造装置は、上記に準ずる。
　本発明の実施の形態においては、加飾ハウジング４０は、単に一般的なハウジングとして記載されているが、本発明の実施の形態の適用技術分野としては、表面コーティング層を有するインモールド成形による加飾品が対象であり、具体的には、容器やステーショナリを含む雑貨品、携帯電話やノートパソコンを含む電子機器や家電製品等のハウジング、建築物や自動車の内外装品のハウジング、航空機、鉄道車両、船舶の内装ハウジングが挙げられる。
４０　加飾ハウジング
４１　加飾層
４２　接着樹脂層
４３　不織布層
４４　有色塗膜
４５　基盤樹脂層
４６　窓
４７　文字
４８　記号

Claims (12)

  1. 　加飾層と、前記加飾層に接着樹脂塗布層を介して接着された不織布層と、当該不織布層の各繊維の隙間に浸潤しつつ前記加飾層に固着された基盤樹脂層とを備え、前記加飾層の裏面と前記不織布層の表面又は両面とのいずれか一方に、切り欠きパターンを有する有色塗膜が形成された、加飾ハウジング。
  2. 　加飾層と、前記加飾層に接着樹脂層を介して接着された有色の不織布層と、当該不織布層の各繊維の隙間に浸潤しつつ前記加飾層に固着された基盤樹脂層とを備え、前記不織布層は切り欠きパターンが形成された、加飾ハウジング。
  3. 　前記加飾層は、本杢層又はテキスタイル層の少なくとも一方を含む、請求項１又は請求項２に記載の加飾ハウジング。
  4. 　前記切り欠きパターンは、文字、記号、又は模様を含む、請求項１から請求項３のいずれかに記載の加飾ハウジング。
  5. 　前記切り欠きパターンの部分がスイッチを構成するように適宜な配線を更に備えた、請求項１から請求項４のいずれかに記載の加飾ハウジング。
  6. 　前記基盤樹脂層は、光透過性熱可塑性樹脂である、請求項１から５のいずれかに記載の加飾ハウジング。
  7. 　前記光透過性熱可塑性樹脂は、射出成形用合成樹脂である、請求項６に記載の加飾ハウジング。
  8. 　前記射出成形用合成樹脂は、ＰＭＭＡ、透明ＡＢＳ、ＰＣ、及びＰＣ＋ＡＢＳの群から選択された１つの素材からなる、請求項７に記載の加飾ハウジング。
  9. 　加飾層、及び前記加飾層に接着樹脂塗布層を介して接着された不織布層の積層体であって、前記加飾層の裏面と前記不織布層の表面又は両面とのいずれか一方に、切り欠きパターン有色塗膜を有する有色塗膜が形成されている積層体を、前記不織布層を表にして配置する固定金型と、前記積層体を成形するために当該配置された積層体を前記固定金型の中に押し込むように前記固定金型に向けて移動される可動金型と、前記成形された積層体を前記加飾層を表にして配置する他の固定金型と、前記他の固定金型に配置された積層体に向けて移動される射出成形金型と、前記他の固定金型に配置された積層体と前記射出成形金型とで規定される空間に基盤樹脂層の溶融樹脂を射出する射出手段とを備えた、加飾ハウジングの製造装置。
  10. 　加飾層、及び前記加飾層に接着樹脂塗布層を介して接着された不織布層の積層体であって、前記加飾層の裏面と前記不織布層の表面又は両面とのいずれか一方に、切り欠きパターン有色塗膜を有する有色塗膜が形成されている積層体を、前記不織布層を表にして配置する固定金型と、前記積層体を成形するために当該配置された積層体を前記固定金型の中に押し込むように前記固定金型に向けて移動される可動金型と、前記固定金型に押し込まれた積層体に向けて移動される射出成形金型と、前記固定金型に配置された積層体と前記射出成形金型とで規定される空間に基盤樹脂層の溶融樹脂を射出する射出手段とを備えた、加飾ハウジングの製造装置。
  11. 　加飾層、及び前記加飾層に接着樹脂塗布層を介して接着された有色の不織布層の積層体であって、前記不織布層に切り欠きパターンが形成されている有色の積層体を、前記不織布層を表にして配置する固定金型と、前記積層体を成形するために当該配置された積層体を前記固定金型の中に押し込むように前記固定金型に向けて移動される可動金型と、前記成形された積層体を前記加飾層を表にして配置する他の固定金型と、前記他の固定金型に配置された積層体に向けて移動される射出成形金型と、前記他の固定金型に配置された積層体と前記射出成形金型とで規定される空間に基盤樹脂層の溶融樹脂を射出する射出手段とを備えた、加飾ハウジングの製造装置。
  12. 　加飾層、及び前記加飾層に接着樹脂塗布層を介して接着された有色の不織布層の積層体であって、前記有色の不織布層に切り欠きパターンが形成されている積層体を、前記不織布層を表にして配置する固定金型と、前記積層体を成形するために当該配置された積層体を前記固定金型の中に押し込むように前記固定金型に向けて移動される可動金型と、前記固定金型に押し込まれた積層体に向けて移動される射出成形金型と、前記固定金型に配置された積層体と前記射出成形金型とで規定される空間に基盤樹脂層の溶融樹脂を射出する射出手段とを備えた、加飾ハウジングの製造装置。
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