WO2022044754A1

WO2022044754A1 - Decorative molded body and method for manufacturing same

Info

Publication number: WO2022044754A1
Application number: PCT/JP2021/029090
Authority: WO
Inventors: 健二木村; 將博大西; 卓宏篠▲崎▼; 恭之三輪
Original assignee: 住友理工株式会社
Priority date: 2020-08-24
Filing date: 2021-08-05
Publication date: 2022-03-03
Also published as: JP2022036602A; CN115835944A

Abstract

A decorative molded body (1) comprises: a transparent layer (10) having a front surface (13) which is visible from the outside, and a back surface (14) which has an uneven shape; a decorative film layer (20) which is disposed on the back side of the transparent layer (10) so as to conform to the uneven shape; a molded layer (30) which is disposed on the back side of the decorative film layer (20) and which is made of a thermosetting material; and a base material layer (40) which is disposed on the back side of the molded layer (30). The transparent layer (10), the decorative film layer (20) and the base material layer (40) are integrated via the molded layer (30). In the method for manufacturing the decorative molded body (1), when the molded layer (30) is formed of a thermosetting material, the decorative film layer (20) is formed and the base material layer (40) is integrated, while a decorative film body (200), which is flat, is placed on the back surface (14) of the transparent layer (10) so as to conform with the uneven shape of the back surface.

Description

Decorative molded body and its manufacturing method

The present invention relates to a decorative molded body mounted on a vehicle, particularly a decorative molded body arranged in a path of radio waves emitted from a radio wave radar device, and a method for manufacturing the same.

Emblems with metallic luster are often placed on the front grill of automobiles. In addition, when ACC (adaptive cruise control, constant speed driving / inter-vehicle distance control device) is installed, a radio wave radar device for measuring the inter-vehicle distance and the distance to obstacles is installed on the back side of the front grill. Be placed. In this case, the radio wave radar device is arranged on the back side of the emblem and transmits / receives radio waves via the emblem. For this reason, the emblem is required to have radio wave transmission as well as design.

For example,

Patent Documents

1 and 2 describe a decorative molded body having radio wave transmission as a radio wave transmitting cover. As described in FIGS. 1 and 2 of Patent Document 1, this type of decorative molded body has a laminated structure in which a transparent layer, a decorative layer, and a base material layer are laminated from the front side (front side of the vehicle). have. The front surface of the transparent layer has a planar shape, and the back surface has an uneven shape. The decorative layer is arranged so as to follow the uneven shape of the transparent layer. The decorative layer is visible from the outside through the transparent layer. Since the decorative layer has an uneven shape, the design is displayed three-dimensionally in the decorative molded body. The base material layer is arranged so as to sandwich the decorative layer from the back side. The substrate layer is arranged so as to fill the recesses of the transparent layer and the decorative layer. As a result, the thickness of the laminated body composed of the transparent layer, the decorative layer, and the base material layer is kept constant.

Japanese Unexamined Patent Publication No. 2004-251868 Japanese Unexamined Patent Publication No. 2016-141355 Japanese Unexamined Patent Publication No. 2019-85083

In the decorative molded body described in Patent Document 1, a film to be a decorative layer is first shaped by vacuum forming, and then the shaped film is arranged in a molding mold to form a transparent layer on one surface of the film. Is manufactured, and finally, a base material layer is formed on the other surface of the film (paragraphs [0067]-[0072] of Patent Document 1). Further, in the decorative molded body described in Patent Document 2, a transparent layer is first injection-molded, then a decorative layer is formed on the back surface of the transparent layer by a method such as printing or vapor deposition, and finally the decorative layer is formed. It is manufactured by a process of injection molding a base material layer using the transparent layer on which the above-mentioned material is formed as an insert material (paragraph [0023] of Patent Document 2).

It is important from the viewpoint of design and radio wave transmission to arrange the decorative layer in close contact with the back surface of the transparent layer so as to follow the uneven shape of the transparent layer. However, when the unevenness is sharp, it is difficult to accurately form the decorative layer by a method such as thin film deposition or spraying. There is also a method of making a flat film follow the uneven shape by vacuum forming, but it is difficult to make the film follow the uneven shape (particularly the concave shape) even with this method. Further, as described in Patent Document 1, there is a method of shaping a film into an uneven shape in advance, but if preformation is performed, the manufacturing man-hours increase and the cost increases.

In order to achieve good radio wave transmission in a decorative molded product, it is important to keep the thickness of the part through which radio waves pass through constant. For example, when the transparent layer, the decorative layer, and the base material layer are individually manufactured and integrated by adhesion or fitting, the thickness of the manufactured layers varies (molding error), so that the layers are laminated. The total thickness is difficult to be constant. Further, if air, moisture, or the like is present between the layers, the radio wave permeability may decrease due to the change in the dielectric constant of the portion. Therefore, in order to achieve good radio wave transmission, it is also important that there is no air, moisture, etc. between the layers. For this purpose, it is necessary to eliminate the mixing of air and moisture in the process of laminating each layer, and it is necessary to perform work such as evacuation in each process.

Furthermore, it is also important to increase the yield of the decorative molded product as a product. Defective products can occur at each manufacturing process. Therefore, when a series of processes are performed in series, the yield of the product may be low. In order to avoid this, it is desirable to perform at least some steps in parallel.

The present invention has been made in view of such an actual situation, and an object of the present invention is to provide a decorative molded body having good radio wave transmission. Another object of the present invention is to provide a method for manufacturing the decorative molded product at low cost.

(1) In order to solve the above problems, the decorative molded article of the present invention has a transparent layer having a front surface visible from the outside and a back surface having an uneven shape, with the stacking direction as the front and back directions, and the uneven shape. A decorative film layer arranged on the back side of the transparent layer, a molded layer made of a thermosetting material arranged on the back side of the decorative film layer, and a base material layer arranged on the back side of the molded layer. , The transparent layer, the decorative film layer, and the base material layer are integrated by the molding layer.

(2) In the first manufacturing method, which is one of the preferred manufacturing methods for the decorative molded article of the present invention, the transparent layer is arranged on the molding die with the surface facing the mold surface, and the transparent layer side. In order from the beginning, the member arranging step of arranging the decorative film body having a flat shape and the base material layer, and the cavity formed between the decorative film body and the base material layer after molding. The heat-curable material for molding the molded layer is injected, and the decorative film layer and the molded layer are molded while the decorative film body is formed along the uneven shape of the back surface of the transparent layer. It is characterized by having a molding step of integrating the base material layer into the transparent layer and the decorative film layer via the molding layer.

(3) The second manufacturing method of the decorative molded article of the present invention is the first manufacturing method among the preferred manufacturing methods in which the decorative molded article of the present invention has a frame member, and is molded. The transparent layer is arranged on the mold with the surface facing the mold surface, and the decorative film body having a flat surface and the base material layer are arranged in order from the transparent layer side, and further, the base material layer is arranged. The member arranging step of arranging the frame member on the peripheral edge of the frame, and the thermosetting for forming the molded layer in the cavity formed between the decorative film body and the base material layer after molding. The material is injected to form the decorative film layer and the molded layer while the decorative film body is formed along the uneven shape of the back surface of the transparent layer, and the transparent layer and the addition are formed through the molded layer. It is characterized by having a molding step of integrating the base material layer and the frame member into the decorative film layer.

(4) The third manufacturing method of the decorative molded article of the present invention is the second manufacturing method among the preferred manufacturing methods in which the decorative molded article of the present invention has a frame member. A bonding step of attaching a decorative film body having a flat surface to a frame member to manufacture a decorative film unit, and placing the transparent layer on a molding die with the surface facing the mold surface, and the decorative film. A member arranging step of arranging the decorative film unit with the body on the transparent layer side and arranging the base material layer inside the frame member, and after molding, the decorative film body and the base material layer The thermosetting material for molding the molding layer is injected into the cavity formed between the two, and the decorative film layer and the decorative film layer are formed along the uneven shape of the back surface of the transparent layer. It is characterized by having a molding step of molding the molded layer and integrating the transparent layer, the decorative film layer, and the base material layer into the frame member via the molded layer.

(1) The decorative molded product of the present invention has a molded layer between the decorative film layer and the base material layer. The molding layer is molded from a thermosetting material. The heat and pressure applied during molding of the molding layer form a decorative film layer in close contact with the transparent layer so as to follow the uneven shape of the back surface of the transparent layer, and the base material layer is integrated with the decorative film layer. To.

In the decorative molded body of the present invention, the decorative film layer is brought into close contact with the back surface of the transparent layer having an uneven shape by using the molding of the molded layer, and the layers including the base material layer are fixed to each other. .. Since heat and pressure are applied during molding, a decorative film layer that follows the uneven shape of the back surface of the transparent layer can be obtained even when the unevenness is sharp. This improves the design of the decorative molded product. Further, by enhancing the shape followability of the decorative film layer and bringing it into close contact with the transparent layer, the gap between the transparent layer and the decorative film layer can be eliminated as much as possible, so that the radio wave transmission property is improved. Further, the preform for shaping the decorative film layer into the uneven shape of the transparent layer in advance is not required, and the layers can be fixed to each other in one molding, so that the manufacturing man-hours can be reduced. The cost can be reduced. Further, as compared with the case where each layer is laminated in order, the steps of removing air and moisture can be reduced, and air and moisture are less likely to enter between the layers. Therefore, the radio wave transmission of the decorative molded product is improved.

The decorative molded product of the present invention has a base material layer. Therefore, even if the uneven shape due to the transparent layer and the decorative film layer appears on the back surface of the molded layer, by arranging the base material layer so as to fill the recesses, the transparent layer, the decorative film layer, the molded layer, And the thickness (total thickness) of the laminate composed of the base material layer can be made constant. As a result, the thickness of the portion through which the radio wave emitted from the radio wave radar device is transmitted becomes constant, so that good radio wave transmission is realized in the decorative molded body of the present invention.

Incidentally, Patent Document 3 describes a radio wave transmitting component for a vehicle having a surface layer portion, a middle layer portion made of the same material as the surface layer portion, and a back layer portion. In the radio wave transmitting component (decorative molded body) described in Patent Document 3, the surface layer portion is first injection-molded, and then the concave portion on the back surface is decorated by coloring, and then the surface layer portion and the same material as the surface layer portion are applied. It is manufactured by a process of arranging a sheet material made of the above material in a molding die and finally injection molding the back layer portion from the sheet material side (paragraphs [0026]-[0028] of Patent Document 3). According to the manufacturing method described in Patent Document 3, the sheet material is molded along the uneven shape of the surface layer portion by the pressure when the back layer portion is injection-molded to become the middle layer portion. However, the back layer portion is made of AES resin (acrylonitrile-EPDM-styrene copolymer) or ABS resin (acrylonitrile-butadiene-styrene copolymer) (paragraph [0025]), and no thermosetting material is used. Further, in Patent Document 3, in order to solve the problem of reducing the thickness of the back layer portion having poor radio wave transmission, the middle layer portion of the same material as the surface layer portion is merely arranged (paragraph [0007]. ], [0031]). That is, the sheet material (middle layer portion) is made of the same material as the surface layer portion, and is not a decorative film layer. The decorative molded product described in Patent Document 3 is completely different in composition and manufacturing method from the decorative molded product of the present invention having a transparent layer, a decorative film layer, a molded layer, and a base material layer.

(2) The first manufacturing method of the decorative molded body of the present invention includes a member arranging step and a molding step. In the member arranging step, the decorative film body having a flat surface is arranged in a molding mold together with the transparent layer and the base material layer. Here, the "decorative film body" is a member before becoming a decorative film layer that exhibits an uneven shape along the back surface shape of the transparent layer. Then, in the molding step, the thermosetting material is injected into the cavity formed between the decorative film body and the base material layer to mold the molded layer. As a result, the flat decorative film body is deformed along the uneven shape of the transparent layer and adheres to the back surface of the transparent layer to become the decorative film layer. At the same time, the base material layer is integrated via the molding layer.

According to the first manufacturing method of the present invention, by utilizing the molding of the molding layer, the decorative film layer which is in close contact with the back surface of the transparent layer having an uneven shape is formed by using the decorative film body which exhibits a flat shape. At the same time, the base material layer can be fixed by sandwiching the molded layer between the molded decorative film layers. Since heat and pressure are applied during molding, the decorative film body can accurately follow the uneven shape of the back surface of the transparent layer even when the unevenness is sharp. As a result, the gap between the transparent layer and the decorative film layer can be eliminated as much as possible, and a decorative molded product having excellent design and radio wave transmission can be manufactured. Further, since the preform of the decorative film layer is not required and the layers can be fixed by one molding, the manufacturing man-hours can be reduced and the cost can be reduced. Further, as compared with the case where each layer is laminated in order, the steps of removing air and moisture can be reduced, and air and moisture are less likely to enter between the layers. This makes it possible to manufacture a decorative molded body having excellent radio wave transmission.

According to the first manufacturing method of the present invention, the thermosetting material is injected and integrally molded with the transparent layer, the decorative film body, and the base material layer arranged in the molding die. In this case, the total thickness of the decorative molded product can be adjusted depending on the state after molding. Further, even if there is a variation in thickness (molding error) in the decorative film body, the base material layer, etc., it can be absorbed by the cavity, so that the total thickness of the decorative molded body should be constant. Can be done. As a result, it is possible to manufacture a decorative molded product having excellent radio wave transmission.

According to the first manufacturing method of the present invention, the transparent layer, the decorative film body, and the base material layer are manufactured in advance. Here, the steps of manufacturing each do not need to be performed in series by a series of lines, but can be performed in parallel by separate lines. Therefore, the yield of the decorative molded product as a product can be increased as compared with the case where each process is performed in series.

(3) The second manufacturing method of the decorative molded body of the present invention is one form of the first manufacturing method described above, and is a method of manufacturing a decorative molded body having a frame member. That is, in the member arranging step, the decorative film body having a flat surface is arranged in a molding mold together with the transparent layer and the base material layer, and the frame member is arranged on the peripheral edge of the base material layer. Then, in the molding step, the thermosetting material is injected into the cavity formed between the decorative film body and the base material layer to mold the molded layer. As a result, the flat decorative film body is deformed along the uneven shape of the transparent layer and adheres to the back surface of the transparent layer to become the decorative film layer. At the same time, the base material layer and the frame member are integrated via the molding layer.

The frame member has a function of supporting a constituent member such as a transparent layer and also has a function of a member for attaching the decorative molded body to the mating member. According to the second manufacturing method of the present invention, a decorative molded body having a frame member and excellent in design and radio wave transmission can be manufactured at low cost by a simplified manufacturing process as in the first manufacturing method. can do.

(4) The third manufacturing method of the decorative molded product of the present invention is the same as the second manufacturing method described above, which is a manufacturing method of the decorative molded product having a frame member. The third manufacturing method of the present invention is the same as the second manufacturing method of the present invention in that the decorative film body is attached to the frame member and the decorative film unit is manufactured in advance before the member arranging step. different. That is, first, in the pasting process, a decorative film unit is manufactured. Next, in the member arranging step, the decorative film unit is arranged in the mold together with the transparent layer and the base material layer. Then, in the molding step, the thermosetting material is injected into the cavity formed between the decorative film body and the base material layer to mold the molded layer. As a result, the flat decorative film body is deformed along the uneven shape of the transparent layer and adheres to the back surface of the transparent layer to become the decorative film layer. At the same time, the base material layer is integrated via the molding layer.

According to the third manufacturing method of the present invention, a decorative molded body having a frame member and excellent in design and radio wave transmission can be manufactured at low cost by a simplified manufacturing process as in the second manufacturing method. can do. Further, according to the third manufacturing method of the present invention, by attaching the decorative film body to the frame member in advance, the displacement of the decorative film body is suppressed and the placement in the molding die becomes easy. Further, in consideration of appearance, it is necessary to prevent the decorative film layer from protruding from the outer periphery of the decorative molded product. Normally, the protruding portion of the decorative film layer is cut after the decorative molded product is manufactured, but the cost is high because three-dimensional processing is required. According to the third manufacturing method of the present invention, the decorative film body may be cut into a desired shape and then attached to the frame member. Therefore, it can be cut by relatively inexpensive processing, and the amount of waste of the decorative film body can be reduced, which leads to cost reduction.

It is a perspective view of the decorative molded article of 1st Embodiment. It is a front view of the decorative molded body. It is a rear view of the decorative molded body. FIG. 2 is a sectional view taken along line IV-IV of FIG. It is a partially enlarged view of the decorative film layer constituting the decorative molded body. It is a flowchart which shows the manufacturing process of the decorative molded article. It is a vertical sectional view of the molding die in a member arrangement process. It is a vertical sectional view of the molding die in the vacuum drawing process after a member arrangement process. It is a vertical sectional view of the mold compaction state of a molding die. It is a vertical sectional view of the molding die in a molding process. It is a stacking direction sectional view of the decorative molded body obtained after opening a mold (corresponding to FIG. 4). It is sectional drawing in the stacking direction of the decorative molded article of 2nd Embodiment. It is a vertical sectional view of the molding die in the member arrangement process of the manufacturing process of the decorative molded body. It is a vertical sectional view of the mold compaction state of a molding die. It is a vertical sectional view of the molding die in a molding process.

An embodiment of the decorative molded body of the present invention and a method for manufacturing the same will be described. In the embodiment, the decorative molded body is embodied as an emblem placed in front of a radio wave radar device mounted on an automobile. In the following figure, the front-rear direction corresponds to the stacking direction and the front-back direction of the members.

<First Embodiment>
[Structure of decorative molded product]
First, the configuration of the decorative molded body of the present embodiment will be described. FIG. 1 shows a perspective view of the decorative molded product of the present embodiment. FIG. 2 shows a front view (front view) of the decorative molded body. FIG. 3 shows a rear view (rear view) of the decorative molded product. FIG. 4 shows a sectional view taken along line IV-IV of FIG. FIG. 5 shows a partially enlarged view of the decorative film layer constituting the decorative molded body. For convenience of explanation, in FIG. 2, dotted line hatching is applied to the portion other than the characters in the portion corresponding to the coating film portion.

As shown in FIGS. 1 to 4, the decorative molded body 1 has a circular shape when viewed from the front. The decorative molded body 1 includes a transparent layer 10, a decorative film layer 20, a molding layer 30, a base material layer 40, a frame member 50, and a sealing member 60.

The transparent layer 10 has a main body portion 11 and coating film portions 12a and 12b. The main body 11 is made of a polycarbonate resin and has a disk shape. The main body 11 has a front surface 13 that is visible from the front of the vehicle and a rear surface 14 that is arranged on the opposite side of the front surface 13 in the front-rear direction. The front surface 13 is included in the concept of a surface in the present invention. The rear surface 14 is included in the concept of the back surface in the present invention. The front surface 13 has a curved surface shape that is slightly curved forward. A hard coat layer (not shown) is formed on the front surface 13 to prevent scratches. The rear surface 14 has a concave portion 140, a convex portion 141, and a notch portion 142. The recess 140 has a groove shape extending in the left-right direction. The notch 142 is formed in a concave shape on the entire peripheral edge of the rear surface 14. The convex portion 141 is a portion other than the concave portion 140 and the notch portion 142. The rear surface 14 has an uneven shape due to the concave portion 140 and the convex portion 141.

Of the coating film portions 12a and 12b, the coating film portion 12a is arranged on the entire convex portion 141 of the rear surface 14. The coating film portion 12a corresponds to the dotted line hatched portion in FIG. The coating film portion 12b is arranged in a part of the recess 140 of the rear surface 14. The coating film portion 12b corresponds to the character portion of "ABCD" when viewed from the front. The coating film portions 12a and 12b are made of a black acrylic evaporative drying type paint. The coating film portions 12a and 12b pass through the transparent layer 10 and are visually recognized as black from the front.

The decorative film layer 20 is arranged behind the transparent layer 10. The decorative film layer 20 is arranged so as to follow the uneven shape of the rear surface 14 of the transparent layer 10. The decorative film layer 20 is sandwiched between the transparent layer 10 and the molding layer 30 described later, and is in close contact with the transparent layer 10. As shown in FIG. 5, the decorative film layer 20 has a resin film 21 and a decorative layer 22. The resin film 21 is made of acrylic resin. The decorative layer 22 is an indium film and is formed on the front surface of the resin film 21. The decorative film layer 20 passes through the transparent layer 10 and is visually recognized from the front in the portion where the coating film portions 12a and 12b are not arranged. That is, the metallic luster of the decorative layer 22 is visually recognized from the front.

The molded layer 30 is arranged behind the decorative film layer 20. The molded layer 30 is arranged so as to follow the uneven shape of the decorative film layer 20, and is arranged so as to surround the outer periphery of the base material layer 40 described later. The molded layer 30 is in close contact with the decorative film layer 20 and the base material layer 40. The molded layer 30 has a bottomed tubular shape when viewed from the rear, and the uneven shape of the rear surface 14 of the transparent layer 10 appears on the bottom (central portion). The molded layer 30 is made of a thermosetting material having silicone rubber. The thermosetting material can be molded at a temperature lower than the whitening temperature of indium.

The base material layer 40 is arranged on the back side of the molded layer 30. The base material layer 40 is housed in the bottom of the bottomed cylindrical molded layer 30. The base material layer 40 is made of a polycarbonate resin and has a disk shape. The front surface of the base material layer 40 has a convex portion corresponding to the concave portion 140 of the rear surface 14 of the transparent layer 10, and the rear surface is a smooth surface without unevenness. The rear surface has a curved surface having the same curvature as the front surface 13 of the transparent layer 10, in other words, the front surface 13 is offset rearward. The base material layer 40 and the decorative film layer 20 are fixed and integrated by the molding layer 30. As shown in FIGS. 3 and 4, an injection hole 41 penetrating in the front-rear direction is formed in the lower center of the base material layer 40. The injection hole 41 is included in the concept of the injection portion in the present invention. The injection hole 41 is filled with a thermosetting material which is a molding material of the molding layer 30. A millimeter-wave radar 9 is installed behind the decorative molded body 1. The injection hole 41 is arranged outside the irradiation range of the radio wave emitted from the millimeter wave radar 9. The millimeter wave radar 9 is included in the concept of the radio wave radar device in the present invention.

The frame member 50 is arranged so as to surround the outer periphery of the base material layer 40 via the molding layer 30. The frame member 50 is made of PBT (polybutylene terephthalate) resin. The frame member 50 has a frame main body 51 and a mounting portion 52. The frame body 51 has a ring shape. The frame body 51 is attached to the peripheral edge of the decorative film layer 20. That is, the peripheral edge portion of the decorative film layer 20 is sandwiched between the frame main body 51 and the transparent layer 10. The mounting portion 52 has a flat plate shape and protrudes from the rear surface of the frame main body 51. Four mounting portions 52 are arranged at equal intervals in the circumferential direction of the frame main body 51. The mounting portion 52 serves as a portion for mounting the decorative molded body 1 to a mating member such as a front grill.

The sealing member 60 is arranged in a ring shape on the outer peripheral side of the frame member 50. The sealing member 60 is arranged in the notch 142 of the rear surface 14 of the transparent layer 10. The sealing member 60 covers the outer peripheral end surface of the decorative film layer 20. The sealing member 60 is made of a thermosetting material having the same silicone rubber as the molded layer 30.

[Manufacturing method of decorative molded product]
Next, a method for manufacturing the decorative molded product of the present embodiment will be described. The manufacturing method of the present embodiment corresponds to the third manufacturing method of the present invention. FIG. 6 shows a flowchart of the manufacturing process of the decorative molded product. As shown in FIG. 6, the method for manufacturing the decorative molded body of the present embodiment includes a member preparation step (S1 to S4), a pasting step (S5), a member placement step (S6), and a molding step (S7). ) And.

First, the transparent layer 10 is manufactured (S1). Specifically, after the main body 11 is manufactured by injection molding and a hard coat layer is formed on the front surface 13 by painting (S1a), the coating film portions 12a and 12b are screened at predetermined positions on the rear surface 14 of the main body 11. It is formed by printing (S1b). At the same time, a flat decorative film body 200 is manufactured (S2). Specifically, as the material of the decorative film body 200, a strip-shaped sheet in which the resin film 21 and the decorative layer 22 are laminated is manufactured (S2a), and the strip-shaped sheet is cut out into a predetermined shape (S2b). In parallel, the frame member 50 is manufactured by injection molding (S3). In parallel, the base material layer 40 is manufactured by injection molding (S4).

Next, the decorative film body 200 is attached to the frame member 50 to manufacture the decorative film unit 53 (S5). Then, the manufactured transparent layer 10, the decorative film unit 53, and the base material layer 40 are arranged in a molding die (S6). Then, the molding layer 30 is molded from the thermosetting material, and the decorative film layer 20, the base material layer 40, and the frame member 50 are integrated (S7).

Hereinafter, the member arrangement process (S6) and the molding process (S7) will be described with reference to the drawings. First, the member arrangement process will be described. FIG. 7 shows a vertical sectional view of the molding die in the member arranging process. FIG. 8 shows a vertical sectional view of the molding die in the evacuation step after the member arranging step. As shown in FIG. 7, as the molding die, the lower die 80, the middle die 81, and the upper die 82 are used. The lower mold 80, the middle mold 81, and the upper mold 82 are preheated to 80 to 120 ° C., which is equal to or lower than the indium whitening temperature. The transparent layer 10 is arranged on the lower mold 80 with the front surface 13 facing the mold surface side (lower side). The decorative film unit 53 and the base material layer 40 are arranged on the medium-sized 81. The decorative film unit 53 is arranged with the decorative film body 200 on the transparent layer 10 side (lower side). The decorative film body 200 is arranged while maintaining a flat surface. The base material layer 40 is arranged with the front surface having the convex portion facing the decorative film body 200 side (lower side). When the decorative film unit 53 is manufactured (the frame member 50 is manufactured and the decorative film body 200 is attached) using the medium-sized 81, the decorative film unit previously arranged in the medium-sized 81 is used. The base material layer 40 may be arranged inside the 53. Then, as shown by the white arrows in FIG. 8, the medium mold 81 and the upper mold 82 are moved downward, and the upper mold 82 is brought into contact with the upper surface of the base material layer 40 of the medium mold 81. At this stage, the decorative film body 200 remains flat. In this state, a vacuum is drawn between the transparent layer 10 arranged on the lower mold 80 and the decorative film body 200, and between the decorative film body 200 and the base material layer 40. As a result, the upper and lower regions of the decorative film body 200 are in a vacuum state.

Next, the molding process will be described. FIG. 9 shows a vertical sectional view of the molded mold in a molded state. FIG. 10 shows a vertical sectional view of the molding die in the molding step. FIG. 11 shows a cross-sectional view in the stacking direction of the decorative molded product obtained after the mold is opened. FIG. 11 corresponds to FIG. 4 described above. First, as shown in FIG. 9, the lower mold 80, the middle mold 81, and the upper mold 82 are molded. Then, the decorative film body 200 comes into contact with the convex portion on the lower surface (front surface) of the base material layer 40. As a result, the contacted portion is deformed downward in a convex shape. In the mold-clamped state, the upper cavity A is formed by the medium-sized mold 81, the decorative film unit 53, and the base material layer 40. The lower cavity B is formed by the transparent layer 10 and the decorative film body 200. The outer peripheral cavity C is formed by the medium size 81, the notch 142 of the transparent layer 10, and the decorative film unit 53.

Next, as shown by the white arrow in FIG. 10, the silicone rubber material R is injected through the sprue 820 of the upper mold 82. The silicone rubber material R is a material that is liquid at room temperature, and is injected in a liquid state. The injected silicone rubber material R is filled in the upper cavity A through the injection hole 41 of the base material layer 40. Here, the lower cavity B is in a vacuum state. Therefore, when the upper cavity A is filled with the silicone rubber material R, the decorative film body 200 is deformed downward due to the pressure thereof, and the decorative film layer adheres closely along the uneven shape of the rear surface 14 of the transparent layer 10. It becomes 20. As a result, the lower cavity B disappears. Further, the silicone rubber material R filled in the upper cavity A is cured by being heated and pressed by the molding dies 80, 81, 82 to become the molding layer 30. The molded layer 30 is in close contact with the decorative film layer 20, the base material layer 40, and the frame body 51. As a result, the decorative film layer 20, the base material layer 40, and the frame member 50 are integrated.

At the same time, the silicone rubber material R is injected through the sprue 821 of the upper mold 82. The injected silicone rubber material R is filled in the outer peripheral cavity C through the medium mold 81. The silicone rubber material R filled in the outer peripheral cavity C is cured by being heated and pressed by the molding dies 80, 81, 82 to become a sealing member 60. Finally, the mold is opened to manufacture the decorative molded body 1 as shown in FIG.

[Action effect]
Next, the operation and effect of the decorative molded product of the present embodiment and the method for producing the same will be described. The decorative molded body 1 of the present embodiment has a molded layer 30 between the decorative film layer 20 and the base material layer 40. In the decorative molded body 1, the decorative film layer 20 is brought into close contact with the rear surface 14 of the transparent layer 10 having an uneven shape by utilizing the molding of the molded layer 30, and the base material layer 40 is integrated. Since heat and pressure are applied when the molding layer 30 is molded, the decorative film layer 20 follows the uneven shape and adheres even when the unevenness of the rear surface 14 of the transparent layer 10 is sharp. Therefore, there is no gap between the transparent layer 10 and the decorative film layer 20 that affects the radio wave transmission, and the decorative molded body 1 is excellent in design and radio wave transmission. Further, since the preform of the decorative film layer 20 is unnecessary and the layers can be fixed by one molding, the manufacturing man-hours can be reduced and the manufacturing cost can be suppressed. Further, as compared with the case where each layer is laminated in order, the steps of removing air and moisture can be reduced, and air and moisture are less likely to enter between the layers. In this respect as well, the decorative molded body 1 is excellent in radio wave transmission.

The front surface of the base material layer 40 has a convex portion corresponding to the concave portion 140 of the rear surface 14 of the transparent layer 10, and the rear surface has a shape in which the front surface 13 of the transparent layer 10 is offset rearward. In this case, even if the rear surface of the molded layer 30 has an uneven shape, the base material layer 40 is arranged so as to fill the recesses, so that the transparent layer 10, the decorative film layer 20, the molded layer 30, and the molded layer 30 are arranged. The thickness (total thickness) of the laminate composed of the base material layer 40 is constant. In other words, the thickness of the portion through which the radio wave emitted from the millimeter wave radar 9 is transmitted becomes constant. Therefore, the decorative molded body 1 is excellent in radio wave transmission.

The decorative molded body 1 has a frame member 50. As a result, the constituent members such as the transparent layer 10 are stably supported, and the decorative molded body 1 can be easily attached to the mating member. Further, by making the molded layer 30 and the frame member 50 separate members, it is possible to select an appropriate material according to the function required for each member. The molded layer 30 is molded from a thermosetting material having silicone rubber and has viscoelasticity. The viscoelastic force of the molded layer 30 can firmly hold the base material layer 40 and the frame member 50. Further, since the impact resistance is enhanced by the presence of the molded layer 30, the transparent layer 10 is not easily cracked. On the other hand, since the frame member 50 is made of PBT resin, it is possible to secure predetermined strength, heat resistance, wear resistance and the like.

The decorative molded body 1 has a sealing member 60. As a result, the space between the transparent layer 10, the decorative film layer 20, and the frame body 51 is sealed, and the intrusion of air and moisture is effectively suppressed. Further, since the sealing member 60 covers the outer peripheral end surface of the decorative film layer 20, the designability is improved.

In the manufacturing method of the present embodiment, the decorative film layer 200 which exhibits a flat shape by utilizing the molding of the molded layer 30 is used, and the decorative film layer which is in close contact with the rear surface 14 of the transparent layer 10 having an uneven shape. 20 is molded, and the base layer 40 is fixed by sandwiching the molded layer 30 between the molded decorative film layers 20. By applying heat and pressure during molding of the molding layer 30, even when the unevenness of the rear surface 14 of the transparent layer 10 is sharp, the decorative film body 200 can accurately follow the uneven shape of the rear surface 14 of the transparent layer 10. can. Therefore, according to the manufacturing method of the present embodiment, it is possible to manufacture the decorative molded body 1 having excellent design and radio wave transmission. Further, as described above, the preform of the decorative film layer 20 is unnecessary, and the layers can be fixed by one molding, so that the manufacturing man-hours can be reduced and the cost can be reduced. can. Further, as compared with the case where each layer is laminated in order, the steps of removing air and moisture can be reduced, and air and moisture are less likely to enter between the layers. Therefore, according to the manufacturing method of the present embodiment, it is possible to manufacture the decorative molded body 1 having excellent radio wave transmission.

In the manufacturing method of the present embodiment, the transparent layer 10, the decorative film unit 53, and the base material layer 40 are arranged in the molding dies 80, 81, 82, and the thermosetting material R is injected to perform integral molding. conduct. In this case, the total thickness of the decorative molded product 1 to be manufactured can be adjusted according to the state after molding. Further, even if there is a variation in thickness (molding error) in the decorative film body 200, the base material layer 40, etc., it can be absorbed by the cavities A and B, so that the total thickness of the decorative molded body 1 can be absorbed. The error can be constant. Further, the thermosetting material R has silicone rubber and can be molded at an indium whitening temperature (about 120 to 150 ° C. or higher) or lower. Therefore, the decorative layer 22 (indium film) of the decorative film layer 20 is difficult to whiten.

According to the manufacturing method of the present embodiment, the transparent layer 10, the decorative film unit 53, and the base material layer 40 are manufactured separately. Here, the process of manufacturing each is not performed in series by a series of lines, but is performed in parallel by separate lines. Therefore, the yield of the decorative molded body 1 can be increased as compared with the case where each step is performed in series. As described above, according to the manufacturing method of the present embodiment, the decorative molded body 1 having the frame member 50 and having excellent design and radio wave transmission can be manufactured at low cost and with good yield by a simplified manufacturing process. can.

Further, according to the manufacturing method of the present embodiment, by attaching the decorative film body 200 to the frame member 50 in advance, the displacement of the decorative film body 200 is suppressed and the placement on the medium size 81 becomes easy. Further, in consideration of appearance, it is necessary to prevent the decorative film layer 20 from protruding from the outer periphery of the decorative molded body 1. Normally, the protruding portion of the decorative film layer 20 is cut after the decorative molded body 1 is manufactured, but the cost is high because three-dimensional processing is required. According to the manufacturing method of the present embodiment, when the decorative film unit 53 is manufactured, the decorative film body 200 can be cut into a desired shape and then attached to the frame member 50. Therefore, it can be cut by relatively inexpensive processing, and the amount of waste of the decorative film body 200 can be reduced, which leads to cost reduction.

When manufacturing the decorative film unit 53, in order to securely fix the decorative film body 200, the decorative film body 200 is cut out to be larger than the outer diameter of the frame body 51 and slightly protrudes from the frame body 51. Attach it in a state of being. However, by arranging the sealing member 60, it is possible to avoid deterioration of the design. That is, since the protruding portion of the decorative film body 200 is embedded when the sealing member 60 is molded, a good design can be realized.

<Second embodiment>
The difference between the decorative molded body of the present embodiment and the decorative molded body of the first embodiment is that the base material layer and the frame member are integrally made of the same material. Here, the differences will be mainly described.

[Structure of decorative molded product]
FIG. 12 shows a cross-sectional view in the stacking direction of the decorative molded product of the present embodiment. FIG. 12 corresponds to FIG. 4 above. In FIG. 12, the same members as those in FIG. 4 are indicated by the same reference numerals. As shown in FIG. 12, the decorative molded body 2 includes a transparent layer 10, a decorative film layer 20, a molding layer 30, a back surface member 42, and a sealing member 60. The transparent layer 10, the decorative film layer 20, and the molded layer 30 are laminated in order from the front to the rear, as in the first embodiment. The molded layer 30 is made of a thermosetting material having silicone rubber, and is in close contact with the decorative film layer 20 and the back surface member 42. Similar to the first embodiment, the sealing member 60 is made of a thermosetting material having the same silicone rubber as the molded layer 30, and is arranged in the notch 142 of the rear surface 14 of the transparent layer 10. The sealing member 60 is arranged in a ring shape on the outer peripheral side of the back surface member 42.

The back member 42 is arranged on the back side of the molded layer 30. The back member 42 is fixed and integrated by the molding layer 30. The back member 42 is an integral body made of a polycarbonate resin. The back surface member 42 has a base material layer 43 and a frame member 44. The base material layer 43 and the frame member 44 correspond to the base material layer 40 and the frame member 50 in the decorative molded body 1 of the first embodiment, respectively.

The base material layer 43 has a disk shape. The front surface of the base material layer 43 has a convex portion corresponding to the concave portion 140 of the rear surface 14 of the transparent layer 10, and the rear surface is a smooth surface without unevenness. The rear surface has a curved surface having the same curvature as the front surface 13 of the transparent layer 10, in other words, the front surface 13 is offset rearward. An injection hole 45 penetrating in the front-rear direction is formed in the lower center of the base material layer 43. The injection hole 45 is included in the concept of the injection portion in the present invention. The injection hole 45 is filled with a thermosetting material which is a molding material of the molding layer 30. Similar to the first embodiment, the injection hole 45 is arranged outside the irradiation range of the radio wave emitted from the millimeter wave radar arranged behind the decorative molded body 2.

The frame member 44 is arranged so as to surround the outer periphery of the base material layer 43. The frame member 44 has a frame main body 46 and a mounting portion 47. The frame body 46 has a ring shape. The mounting portion 47 has a flat plate shape and protrudes from the rear surface of the frame main body 46. Four mounting portions 47 are arranged at equal intervals in the circumferential direction of the frame main body 46.

[Manufacturing method of decorative molded product]
Next, a method for manufacturing the decorative molded product of the present embodiment will be described. The manufacturing method of the present embodiment corresponds to a mode in which the base material layer and the frame member are an integral body (back surface member) in the second manufacturing method of the present invention. That is, in the method for manufacturing a decorative molded body of the present embodiment, a transparent layer is placed on a molding die with the surface facing the mold surface, and the decorative film body and the back surface member exhibit a flat shape in order from the transparent layer side. A heat-curable material for forming a molding layer is injected into a cavity formed between the decorative film body and the back surface member after the member arranging step of arranging the decorative film body and the back surface member, and the decorative film body is formed. It has a molding step of forming a decorative film layer and a molding layer along the uneven shape of the back surface of the transparent layer, and integrating the decorative film layer and the back surface member.

Also in the manufacturing method of the present embodiment, the transparent layer 10 and the flat decorative film body 200 are prepared in the same manner as in the manufacturing method of the first embodiment. Further, the back surface member 42 is manufactured by injection molding (these correspond to the member preparation steps of the first embodiment).

Hereinafter, the member arranging process and the molding process will be described focusing on the differences from the first embodiment with reference to the drawings. First, the member arrangement process will be described. FIG. 13 shows a vertical sectional view of the molding die in the member arranging process. As shown in FIG. 13, as the molding die, a lower die 80, a middle die 81, and an upper die 82 are used, and these are preheated to 80 to 120 ° C. The transparent layer 10 is arranged on the lower mold 80 with the front surface 13 facing the mold surface side (lower side). Then, the decorative film body 200 is arranged on the upper side of the transparent layer 10 while maintaining the flatness. A back member 42 is arranged on the medium-sized 81. The back surface member 42 is arranged with the front surface of the base material layer 43 facing the decorative film body 200 side (lower side). After that, as in the first embodiment, the middle mold 81 and the upper mold 82 are moved downward, and the upper mold 82 is brought into contact with the upper surface of the back member 42 (base material layer 43) of the middle mold 81. In this state, a vacuum is drawn between the transparent layer 10 arranged on the lower mold 80 and the decorative film body 200, and between the decorative film body 200 and the back surface member 42. As a result, the upper and lower regions of the decorative film body 200 are in a vacuum state.

Next, the molding process will be described. FIG. 14 shows a vertical sectional view of the molded mold in a molded state. FIG. 15 shows a vertical sectional view of the molding die in the molding step. First, as shown in FIG. 14, the lower mold 80, the middle mold 81, and the upper mold 82 are molded. Then, the decorative film body 200 comes into contact with the convex portion on the lower surface (front surface) of the back surface member 42. In the decorative film body 200, the portion pressed by the convex portion of the base material layer 43 is deformed downward in a convex shape. In the mold-clamped state, the upper cavity A is formed by the back surface member 42 and the decorative film body 200. The lower cavity B is formed by the transparent layer 10 and the decorative film body 200. The outer peripheral cavity C is formed by the medium size 81, the notch 142 of the transparent layer 10, the decorative film body 200, and the back surface member 42.

Next, as shown in FIG. 15, the silicone rubber material R is injected through the sprue 820 of the upper mold 82. The injected silicone rubber material R is filled in the upper cavity A through the injection hole 45 of the back member 42. Here, the lower cavity B is in a vacuum state. Therefore, when the upper cavity A is filled with the silicone rubber material R, the decorative film body 200 is deformed downward due to the pressure thereof, and the decorative film layer adheres closely along the uneven shape of the rear surface 14 of the transparent layer 10. It becomes 20. As a result, the lower cavity B disappears. Further, the silicone rubber material R filled in the upper cavity A is cured by being heated and pressed by the molding dies 80, 81, 82 to become the molding layer 30. The molded layer 30 is in close contact with the decorative film layer 20 and the back surface member 42. As a result, the decorative film layer 20 and the back surface member 42 are integrated.

At the same time, the silicone rubber material R is injected through the sprue 821 of the upper mold 82. The injected silicone rubber material R is filled in the outer peripheral cavity C through the medium mold 81. The silicone rubber material R filled in the outer peripheral cavity C is cured by being heated and pressed by the molding dies 80, 81, 82 to become a sealing member 60. Finally, the mold is opened to manufacture the decorative molded body 2 shown in FIG. 12 above.

[Action effect]
Next, the operation and effect of the decorative molded product of the present embodiment and the method for producing the same will be described. The decorative molded article of the present embodiment and the method for producing the same have the same effect and effect with respect to the portion having a common configuration. The decorative molded body 2 of the present embodiment has a back surface member 42. The back surface member 42 is an integral body integrally molded from one material, and has a base material layer 43 and a frame member 44. Since the base material layer and the frame member are integrated, it is more difficult for moisture to enter as compared with the form in which each is a separate body. Further, by combining the base material layer and the frame member into one component, the number of components can be reduced and the cost can be reduced. In addition, it is necessary to attach the decorative film body to the frame member as in the first embodiment. Nor. Therefore, in the present embodiment, the manufacturing process can be further simplified. Further, since one back member 42 may be arranged on the medium mold 81, the arrangement on the molding die (member arrangement step) becomes easy.

<Other forms>
The embodiment of the decorative molded article of the present invention and the method for producing the same has been described above. However, the embodiment is not particularly limited to the above embodiment. It is also possible to carry out in various modified forms and improved forms that can be performed by those skilled in the art.

[Transparent layer]
The material of the transparent layer (main body) is not particularly limited as long as the transparency can be maintained, and may be a transparent resin material such as an acrylic resin, a polyethylene terephthalate (PET) resin, a transparent glass material, or the like, in addition to the polycarbonate resin in the above embodiment. .. In the above embodiment, the hard coat layer is formed on the surface of the main body, but the hard coat layer may not be present. Depending on the material of the main body, another layer may be formed separately from the hard coat layer or in addition to the hard coat layer.

The shape of the transparent layer is not particularly limited, and any shape such as an elliptical plate or a polygonal plate may be adopted in addition to the disk shape in the above embodiment. In the above embodiment, the surface of the transparent layer is curved to be convexly curved to the front side (front), but the surface shape may be a curved surface or flat surface to be concavely curved to the back side (rear). The uneven shape of the back surface of the transparent layer may be appropriately determined according to the design to be displayed. In the above embodiment, the concave portion is made to correspond to the glossy decorative portion (the portion where the decorative film layer is visible), and the convex portion is made to correspond to the black coating film portion, but the concave portion and the convex portion are opposite to each other. You may do it.

The transparent layer does not necessarily have to have a coating film portion. In the above embodiment, the coating film portion is arranged on the entire convex portion and a part of the concave portion on the back surface, but may be arranged on only one of the convex portion and the concave portion, for example. The material and color of the coating film portion are not particularly limited. The method for manufacturing the coating film portion is also not particularly limited. In the transparent layer, the decorative film layer may be visible from the entire region, or may be partially masked by a coating film portion or the like and visible from only a partial region. By combining the back surface shape of the transparent layer and the visible area of the decorative film layer, various designs can be displayed on the decorative molded product.

[Decorative film layer]
The structure of the decorative film layer is not particularly limited, and may be a multi-layer structure composed of the resin film and the decorative layer shown in the above embodiment, or a single-layer structure composed of a single substance such as a resin film or a metal film. When the decorative film layer is composed of a resin film and a decorative layer, a non-stretchable PET resin or the like can be adopted as the resin film in addition to the acrylic resin. The resin film may be transparent or colored. The decorative layer may be formed on one side of the resin film or may be formed on both sides. In addition to indium, a glossy metal material such as tin or gold or a resin material may be applied as the decorative layer. The decorative layer does not necessarily have to have gloss, and may be imparted with decorativeness by coloring or the like. The shape of the decorative film layer may be appropriately determined according to the shape of the transparent layer.

[Molding layer]
The molding layer is molded from a thermosetting material. As the thermosetting material, in addition to the silicone rubber in the above embodiment, an epoxy resin, a phenol resin, or the like may be used. From the viewpoint of enhancing the holding power of the base material layer, a material having viscoelasticity such as silicone rubber is suitable as the thermosetting material. The thermosetting material may have an adhesive component, a coloring component, and the like in addition to the elastomer and resin components.

For thermosetting materials, it is desirable to consider the molding temperature so that heating during molding does not adversely affect other members. For example, when the decorative film layer contains indium, it is desirable to use a material that can be molded at a temperature lower than the whitening temperature of indium. Silicone rubber is also preferable in this respect as well. Considering moldability, the thermosetting material is preferably a material that is liquid at room temperature or a material that is semi-solid. Further, when a translucent material is adopted as the thermosetting material, for example, a backlight is arranged on the back side of the decorative molded body, and the light is emitted to the base material layer, the molding layer, the decorative film layer, and the transparent. It is also possible to display the layer transparently. The surface of the molded layer exhibits an uneven shape along the uneven shape of the decorative film layer. On the other hand, the back surface may have the same uneven shape as the front surface, or may have a different shape such as a flat surface or a curved surface.

[Base layer]
In the decorative molded body of the present invention, the thickness (total thickness) of the laminated body composed of the transparent layer, the decorative film layer, the molded layer, and the base material layer corresponding to the portion through which the radio wave emitted from the radio wave radar device is transmitted. It is desirable that the) is constant. Therefore, the base material layer may be arranged so that the total thickness is constant. The front surface of the base material layer may have a shape that follows the shape of the back surface of the molded layer, and the back surface has the same shape as the front surface of the transparent layer (a shape in which the front surface of the transparent layer is offset in the stacking direction). The material of the base material is not particularly limited as long as it can maintain predetermined strength, heat resistance, environmental resistance, chemical resistance, etc., and is not easily deformed during molding of the molded layer in addition to the polycarbonate (PC) resin in the above embodiment. From this point of view, examples thereof include high heat resistant AES resin having relatively high heat resistance among AES resins, high heat resistant ABS resin having relatively high heat resistance among ABS resins, and PC / ABS resin. Further, when the decorative molded body has a frame member, the base material layer and the frame member may be integrally molded from the same material as in the second embodiment.

Since the base material layer is arranged on the back side of the molded layer, it has an injection portion into which a thermosetting material is injected when the molded layer is molded. The shape, size, number, etc. of the injection portion are not particularly limited. For example, a hole having an arbitrary shape such as the cylindrical hole shown in the above embodiment may be used, or a notch portion having an arbitrary shape may be used. Two or more injection portions may be formed. When the radio wave radar device is arranged on the back side of the decorative molded body of the present invention, the injection portion may be arranged outside the irradiation range of the radio wave emitted from the radio wave radar device so as not to affect the transmission and reception of the radio wave. desirable. Examples of the radio wave radar device include millimeter wave radar and microwave radar.

[Frame member]
In the above embodiment, the decorative molded body has a frame member, but the frame member is not an essential member in the decorative molded body of the present invention. When the frame member is provided, the material thereof is not particularly limited as long as it can maintain predetermined strength, heat resistance, environmental resistance, chemical resistance, etc., and examples thereof include high-strength PET resin in addition to the PBT resin in the above embodiment. .. The frame member may be transparent or colored. Further, as described above, the frame member and the base material layer may be integrally molded from the same material.

The frame member may be configured to have a frame body and a mounting portion in consideration of mountability to the mating member. The shape of the frame body may be a shape corresponding to the outer peripheral shape of the transparent layer, but may be a different shape. Examples of the shape of the frame body include a circular frame shape (ring shape), an elliptical frame shape, and a polygonal frame shape. The mounting portion may be arranged so as to protrude from the back surface of the frame body, for example. The shape and number of the mounting portions are not particularly limited, and for example, a configuration having a locking claw, a locking hole, or the like may be used.

In the function of the frame member to support the constituent member, it is desirable that the peripheral edge portion of the decorative film layer is sandwiched between the transparent layer and the frame member. In this case, as shown in the first embodiment, the frame body may be attached over the entire peripheral edge of the decorative film layer.

[Sealing member]
In the above embodiment, the decorative molded body has a sealing member, but the sealing member is not an essential member in the decorative molded body of the present invention. When the sealing member is provided, the material thereof is not particularly limited as long as it has a sealing property. For example, it may be manufactured from the same thermosetting material as the molded layer, such as silicone rubber, epoxy resin, and phenol resin. Alternatively, it may be manufactured from a thermoplastic material.

The sealing member is arranged in a frame shape so as to cover the outer peripheral end surface of the decorative film layer. The color of the sealing member is not particularly limited, but in the above embodiment, since the sealing member is arranged in the notch on the back surface of the transparent layer, the sealing member is visually recognized through the transparent layer. In this case, by making the sealing member the same color as the coating film portion, the boundary between the sealing member and the coating film portion becomes difficult to see, and the designability is improved.

[Production method]
The method for manufacturing a decorative molded body of the present invention includes a member placement step of arranging constituent members in a molding die, and a molding step of molding a decorative film layer into an uneven shape while molding a molding layer to integrate the constituent members. And have. The structure of the molding die is not limited to the above embodiment. The heating of the molding die may be appropriately adjusted according to the molding temperature of the thermosetting material which is the material of the molding layer. As shown in the above embodiment, when the decorative film layer contains indium, it is desirable to keep the molding die below the indium whitening temperature.

In the first embodiment, the decorative film body is attached to the frame member in advance to manufacture the decorative film unit (attachment step), but the decorative film body is not attached to the frame member (decorative film). It may be placed in the mold as it is (without manufacturing the unit). The decorative film body when placed in the molding die may have a shape different from the shape in close contact with the back surface of the transparent layer (final shape as the decorative film layer). In the above embodiment, a flat decorative film body is used, but the shape of the decorative film body is not necessarily limited to a flat shape, and may be a curved shape or a shape having a slightly uneven shape. Further, when the decorative film unit is manufactured, the decorative film body may be attached before or after the frame member is arranged in the medium size. The size of the decorative film body should be the same as or slightly larger than the outer shape of the frame body.

In the above embodiment, in the member preparation process, constituent members such as a transparent layer are manufactured by injection molding. In addition, a liquid silicone rubber material was injection-molded to form a molded layer. However, the method for manufacturing the constituent members is not particularly limited. For example, as for the molded layer, a semi-solid thermosetting material may be placed on the upper side of the decorative film body (base material layer side, upper cavity A in the above embodiment) and compression molded.

[Use]
The decorative molded body of the present invention can be used not only for emblems for vehicles such as automobiles, but also for emblems, key chains, straps, and the like attached to products. When used as a vehicle emblem, it may be placed on the front grill of the vehicle.

1: Decorative molded body 2: Decorative molded body, 9: Millimeter wave radar, 10: Transparent layer, 11: Main body part, 12a, 12b: Coating film part, 13: Front surface (front surface), 14: Rear surface (back surface) ), 20: Decorative film layer, 21: Resin film, 22: Decorative layer, 30: Molding layer, 40: Base material layer, 41: Injection hole, 42: Back member, 43: Base material layer, 44: Frame Member, 45: Injection hole, 46: Frame body, 47: Mounting part, 50: Frame member, 51: Frame body, 52: Mounting part, 53: Decorative film unit, 60: Sealing member, 80: Lower mold, 81: Medium size, 82: Upper type, 140: Concave part, 141: Convex part, 142: Notch part, 200: Decorative film body, 820, 821: Sprue, A: Upper cavity, B: Lower cavity, C: Outer circumference cavity.

Claims

With the stacking direction as the front and back directions
A transparent layer having a front surface visible from the outside and a back surface having an uneven shape,
A decorative film layer arranged on the back side of the transparent layer so as to follow the uneven shape, and
A molding layer made of a thermosetting material arranged on the back side of the decorative film layer,
A base material layer arranged on the back side of the molded layer and
Equipped with
A decorative molded product, wherein the transparent layer, the decorative film layer, and the base material layer are integrated by the molded layer.
The decorative molded body according to claim 1, wherein the base material layer has an injection portion into which the thermosetting material is injected when the molded layer is molded.
When the radio wave radar device is arranged on the back side of the base material layer,
The decorative molded body according to claim 2, wherein the injection portion is arranged outside the irradiation range of the radio wave emitted from the radio wave radar device.
The decorative molded body according to any one of claims 1 to 3, wherein the thermosetting material has a silicone rubber, an epoxy resin, or a phenol resin.
The decorative molded product according to any one of claims 1 to 4, wherein the decorative film layer has a resin film and a decorative layer formed on the resin film.
The decorative layer is an indium film and is
The decorative molded product according to claim 5, wherein the thermosetting material is a material that can be molded at a temperature lower than the whitening temperature of indium.
The decorative molded product according to any one of claims 1 to 6, further comprising a frame member arranged on the peripheral edge of the base material layer.
The decorative molded body according to claim 7, wherein the peripheral edge portion of the decorative film layer is sandwiched between the transparent layer and the frame member.
The decorative molded body according to claim 7 or 8, wherein the frame member has a frame body and a mounting portion protruding from the back surface of the frame body.
The decorative molded body according to any one of claims 7 to 9, wherein the frame member is made of the same material as the base material layer and is integrally molded with the base material layer.
The decorative molded product according to any one of claims 1 to 10, further comprising a sealing member arranged in a frame shape so as to cover the outer peripheral end surface of the decorative film layer.
The decorative molded body according to claim 11, wherein the sealing member is made of the same material as the molded layer.
The decorative molded body according to any one of claims 1 to 12, which is an emblem for a vehicle that transmits radio waves emitted from a radio wave radar device.
The method for manufacturing a decorative molded article according to claim 1.
A member arranging step of arranging the transparent layer on the molding die with the surface facing the mold surface, and arranging the decorative film body having a flat surface and the base material layer in order from the transparent layer side.
After molding, the thermosetting material for molding the molded layer is injected into the cavity formed between the decorative film body and the base material layer, and the decorative film body is made of the transparent layer. A molding step of molding the decorative film layer and the molded layer while following the uneven shape of the back surface, and integrating the transparent layer and the base material layer into the transparent layer and the decorative film layer via the molded layer. ,
A method for manufacturing a decorative molded product, which comprises.
The method for manufacturing a decorative molded article according to claim 7.
The transparent layer is arranged on the molding die with the surface facing the mold surface, and the decorative film body having a flat surface and the base material layer are arranged in order from the transparent layer side, and further, the base material is arranged. A member arranging step of arranging the frame member on the peripheral edge of the layer, and
After molding, the thermosetting material for molding the molded layer is injected into the cavity formed between the decorative film body and the base material layer, and the decorative film body is made of the transparent layer. The decorative film layer and the molded layer are molded along the uneven shape of the back surface, and the transparent layer and the decorative film layer are integrated with the base material layer and the frame member via the molded layer. Molding process and
A method for manufacturing a decorative molded product, which comprises.
The method for manufacturing a decorative molded article according to claim 7.
A pasting process in which a decorative film body having a flat surface is attached to the frame member to manufacture a decorative film unit, and
The transparent layer is placed on the molding die with the surface facing the mold surface, the decorative film unit is placed with the decorative film body on the transparent layer side, and the base material layer is placed inside the frame member. And the member placement process to place
After molding, the thermosetting material for molding the molded layer is injected into the cavity formed between the decorative film body and the base material layer, and the decorative film body is made of the transparent layer. The decorative film layer and the molded layer are molded along the uneven shape of the back surface, and the transparent layer, the decorative film layer, and the base material layer are integrated with the frame member via the molded layer. Molding process and
A method for manufacturing a decorative molded product, which comprises.
The base material layer has an injection portion into which the thermosetting material is injected.
The decorative molded product according to any one of claims 14 to 16, wherein in the molding step, the thermosetting material is injected into the cavity through the injection portion formed in the base material layer. Production method.