JP3762923B2 - Manufacturing method of insert molded product - Google Patents
Manufacturing method of insert molded product Download PDFInfo
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本発明は、表面にフィルムのシワを生じないインサート成形品の製造方法に関するものである。 The present invention relates to a method for manufacturing an insert-molded product that does not cause film wrinkles on the surface.
従来より、AV機器のフロントパネルやボタン、自動車の計器パネルなどに用いられるインサート成形品の製造方法としては、雄型と雌型とで構成される成形空間部が形成された射出成形金型を用い、雌型に予備成形および打抜き加工されたインサートフィルムを装着し、型閉めした後、成形空間部内に溶融樹脂を射出し、冷却固化後、成形品の外表面にインサートフィルムが形成されたインサート成形品を取り出すことが行なわれている（特許文献１参照）。 Conventionally, as an insert molding product used for front panels and buttons of AV equipment, instrument panels of automobiles, etc., an injection mold in which a molding space composed of a male mold and a female mold is formed is used. Used, insert insert film that has been preformed and punched into a female mold, close the mold, inject molten resin into the molding space, cool and solidify, and insert film is formed on the outer surface of the molded product A molded product is taken out (see Patent Document 1).
また、上記射出成形金型の成形空間部には、周縁において雄型に向かって立ち上がる、いわゆる立ち上がり部を有する成形品（図９〜１１参照）を成形し得るもの、とくに成形品の周縁全体に立ち上がり部を備えて箱状に成形し得るものが多い。
しかし、上記したように射出成形金型として成形空間部が立ち上がり部を有する成形品を成形し得るものを用いる場合、インサートフィルム４の荷重たわみ温度よりも高い温度で溶融樹脂７が射出されると、次のような問題を生ずる。 However, as described above, when using an injection mold that can form a molded product having a rising portion of the molding space, the molten resin 7 is injected at a temperature higher than the deflection temperature under load of the insert film 4. The following problems occur.
インサートフィルム４は、上記したようにその荷重たわみ温度よりも高い温度で溶融樹脂７が射出されると、溶融樹脂７の熱によって軟化し、さらに射出充填される溶融樹脂７の流動によって延伸されることがある。ところが、一般に予備成形および打抜き加工されたインサートフィルム４は成形品５の外表面と同じ寸法であり（図１２〜図１５参照）、雄型１と雌型２とが型閉めされたときに、インサートフィルム４の端面４ａが成形品５の立ち上がり部頂面５ａ（図１５参照）に相当する箇所で金型に接触している（図１３参照）。その結果、インサートフィルム４の先端位置は既に金型に突き当たって固定されているため、延伸したインサートフィルム４は行き場がなく、成形品の立ち上がり部外面５ｂを覆う端部（図１６参照）又はその周辺にシワを生じてしまう。
When the molten resin 7 is injected at a temperature higher than the deflection temperature under load as described above, the insert film 4 is softened by the heat of the molten resin 7 and further stretched by the flow of the molten resin 7 that is injected and filled. Sometimes. However, in general, the preformed and punched insert film 4 has the same dimensions as the outer surface of the molded product 5 (see FIGS. 12 to 15), and when the male mold 1 and the female mold 2 are closed, The end surface 4a of the insert film 4 is in contact with the mold at a location corresponding to the rising portion
これを回避するため、射出成形条件の調整によってインサートフィルム４の伸びを抑える方法も考えられる。例えば、溶融樹脂の射出速度をより低速にしたり、より低温で成形することなどが挙げられる。ところが、こういった方法は成形条件選択の幅を狭めることになり、溶融樹脂の充填不良などの新たな問題が誘発される。 In order to avoid this, a method of suppressing the elongation of the insert film 4 by adjusting the injection molding conditions is also conceivable. For example, the injection speed of the molten resin can be made lower, or molding can be performed at a lower temperature. However, this method narrows the range of selection of molding conditions, and induces new problems such as poor filling of molten resin.
また、予備成形および打抜き加工されたインサートフィルム４の寸法を、成形品５の外表面より延伸分を想定して予め小さく設計しておく方法も考えられるが、延伸の調整は難しく、成形品５の外表面を完全に覆いきれず、端部において成形品が不要に露出することが生ずる。 Further, a method of designing the dimensions of the insert film 4 that has been preformed and punched into a smaller size in advance than the outer surface of the molded product 5 is possible. As a result, the outer surface of the molded product cannot be completely covered, and the molded product is unnecessarily exposed at the end.
そこで、本発明の目的は、上記の問題点を解決し、表面にフィルムのシワを生じないインサート成形品の製造方法を提供することである。 Then, the objective of this invention is providing the manufacturing method of the insert molded product which solves said problem and does not produce the wrinkle of a film on the surface.
上記目的を達成するために、本発明は、立ち上がり部を有する成形品を成形し得る雄型と雌型とで構成される成形空間部を有する射出成形金型を用い、雌型に予備成形および打抜き加工されたインサートフィルムを装着し、型閉めし、成形空間部内にインサートフィルムの荷重たわみ温度よりも高い温度の溶融樹脂を射出し、冷却固化することによって、成形品の外表面にインサートフィルムが一体的に形成されたインサート成形品を得るインサート成形品の製造方法において、前記インサートフィルムが、前記成形品の立ち上がり部頂面と立ち上がり部外面とがなす角部に相当する箇所で金型に接触せずに湾曲し且つ端面が前記成形品の立ち上がり部内面の端縁に相当する箇所で金型に接触するように予備成形および打抜き加工が施されたものであるように構成した。 In order to achieve the above object, the present invention uses an injection mold having a molding space composed of a male mold and a female mold capable of molding a molded product having a rising portion, and preforms the female mold. The insert film that has been punched is mounted, the mold is closed, molten resin at a temperature higher than the deflection temperature under load of the insert film is injected into the molding space, and the insert film is placed on the outer surface of the molded product by cooling and solidifying. In the method of manufacturing an insert-molded product to obtain an integrally formed insert-molded product, the insert film contacts the mold at a location corresponding to a corner formed by the top surface of the molded product and the outer surface of the raised portion. And preforming and punching were performed so that the end face would be in contact with the mold at a location corresponding to the edge of the inner surface of the rising portion of the molded product. It was configured such that than.
本発明のインサート成形品の製造方法は、以上のような構成からなるので、次のような効果を奏する。 Since the manufacturing method of the insert molded product of the present invention is configured as described above, the following effects can be obtained.
すなわち、本発明は、型閉め状態でインサートフィルムが成形品の立ち上がり部頂面と立ち上がり部外面とがなす角部に相当する箇所で金型と接触せずに湾曲するように、インサートフィルムに対して予備成形を施している。したがって、溶融樹脂が射出されたときにインサートフィルムが延伸しても、インサートフィルムの端面が成形品の立ち上がり部頂面に相当する箇所で金型に接触することがなく、さらにインサートフィルムの先端位置が金型に突き当たったまま固定されることもないので、その結果、延伸したインサートフィルムは成形品の立ち上がり部外面を覆う端部又はその周辺にシワを生じにくい。 That is, the present invention relates to the insert film so that the insert film is curved without contacting the mold at the corner corresponding to the corner formed by the top surface of the molded part and the outer surface of the rising part when the mold is closed. Pre-molding. Therefore, even if the insert film is stretched when the molten resin is injected, the end surface of the insert film does not contact the mold at the position corresponding to the top surface of the molded product, and the tip position of the insert film As a result, the stretched insert film is less likely to be wrinkled at the end covering the outer surface of the rising portion of the molded product or in the vicinity thereof.
また、本発明は、型閉め状態で湾曲したインサートフィルムの端面が成形品の立ち上がり部内面の端縁に相当する箇所で金型に接触するように、予備成形および打抜き加工を施している。したがって、インサートフィルムは金型内で固定され、位置ずれを起こすことがない。 Further, in the present invention, pre-molding and punching are performed so that the end surface of the insert film curved in a closed state is in contact with the mold at a position corresponding to the edge of the inner surface of the rising portion of the molded product. Therefore, the insert film is fixed in the mold and does not cause a positional shift.
以下に、図を参照しながら本発明に係るインサート成形法の実施の形態を詳細に説明する。 Hereinafter, embodiments of the insert molding method according to the present invention will be described in detail with reference to the drawings.
本発明は、まず、雄型１と雌型２とからなる射出成形金型を用い、雌型２に予備成形および打抜き加工されたインサートフィルム４を装着する（図１参照）。 In the present invention, first, an injection mold comprising a male mold 1 and a female mold 2 is used, and a pre-molded and stamped insert film 4 is mounted on the female mold 2 (see FIG. 1).
雄型１と雌型２とは、型閉めされることによって、立ち上がり部を有する成形品５を成形し得る成形空間部３が形成されるようになっている。この立ち上がりは、雄型１に対して垂直であってもよいし（図２参照）、雄型１に対して垂直でなくてもよい（図６参照）。なお、上記立ち上がり部は、成形品５の周縁全体に設けられて箱を形成していてもよいし（図９参照）、成形品５の周縁のうち一部には設けないようにしてもよい（図１０，図１１参照）。なお、図面では雄型１の凸部にゲート６が設けられているが、ゲート方式はこれに限定されない。また、図示していないが、一般に雄型１は成型品の裏側になるため突き出し機構を備えている。 The male mold 1 and the female mold 2 are closed to form a molding space 3 in which a molded product 5 having a rising portion can be molded. This rising may be perpendicular to the male mold 1 (see FIG. 2) or may not be perpendicular to the male mold 1 (see FIG. 6). The rising portion may be provided on the entire periphery of the molded product 5 to form a box (see FIG. 9), or may not be provided on a part of the periphery of the molded product 5. (See FIGS. 10 and 11). In the drawing, the gate 6 is provided on the convex portion of the male mold 1, but the gate system is not limited to this. Although not shown, the male mold 1 is generally provided with a protruding mechanism because it is on the back side of the molded product.
インサートフィルム４としては、例えば、透明な基体フィルムの裏面に、図柄層、接着層などが順次形成されたものがある。基体フィルムには、通常のインサートフィルム４の基体フィルムとして使用されるものであり、ポリエチレンテレフタレート、ポリカーボネート、アクリル、スチレンなどのプラスチックフィルムなどがある。図柄層は、成形品外表面に、模様、絵画、ロゴ、文字、記号などを形成するために、オフセット印刷法、グラビア印刷法、スクリーン印刷法などの通常の印刷法などを用いるとよい。特に、多色刷りや階調表現を行うには、オフセット印刷法やグラビア印刷法が適している。また、単色の場合には、グラビアコート法、ロールコート法、コンマコート法などのコート法を採用することもできる。図柄層は、真空蒸着法、スパッターリング法、イオンプレーティング法、鍍金法などによって形成された金属層を有していてもよい。接着層は、成形品５の成形と同時に成形品５の外表面にインサートフィルム４を接着させるためのものであり、成形品５の素材に適した感熱性あるいは感圧性の樹脂を用いて、グラビアコート法、ロールコート法、コンマコート法などのコート法、グラビアコート法、スクリーン印刷法などの印刷法で形成される。 As the insert film 4, for example, there is a film in which a pattern layer, an adhesive layer, and the like are sequentially formed on the back surface of a transparent base film. The base film is used as a base film of a normal insert film 4, and includes plastic films such as polyethylene terephthalate, polycarbonate, acrylic, and styrene. The pattern layer may use a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method in order to form a pattern, a painting, a logo, a character, a symbol, or the like on the outer surface of the molded product. In particular, the offset printing method and the gravure printing method are suitable for performing multicolor printing and gradation expression. In the case of a single color, a coating method such as a gravure coating method, a roll coating method, or a comma coating method may be employed. The pattern layer may have a metal layer formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. The adhesive layer is for adhering the insert film 4 to the outer surface of the molded product 5 simultaneously with the molding of the molded product 5. The adhesive layer is a gravure using a heat-sensitive or pressure-sensitive resin suitable for the material of the molded product 5. It is formed by a coating method such as a coating method, a roll coating method or a comma coating method, a printing method such as a gravure coating method or a screen printing method.
なお、インサートフィルム４の構成は、上記した態様に限定されるものではなく、たとえば、図柄層の材質として成形品５との接着性に優れたものを使用する場合には、接着層を省略することができる。また、図柄層は基体フィルムの表面側に形成しても良いが、実際に使用する際に図柄層に対する傷付きや磨耗の危険性が増すため、この場合はさらに表面に透明なフィルムを貼り合わせるか、ハードコート処理などを行うことが望ましい。
また、インサートフィルム４としては、フィルム材質に顔料を練り込んだものを用いても良い。
In addition, the structure of the insert film 4 is not limited to the above-described embodiment. For example, the adhesive layer is omitted when a material having excellent adhesion to the molded product 5 is used as the material of the design layer. be able to. Also, the design layer may be formed on the surface side of the base film, but in actual use, the risk of scratches and wear on the design layer increases. In this case, a transparent film is further bonded to the surface. Alternatively, it is desirable to perform a hard coat treatment or the like.
Further, as the insert film 4, a film material in which a pigment is kneaded may be used.
予備成形および打抜き加工されたインサートフィルム４は、型閉め状態で成形品の立ち上がり部頂面５ａと立ち上がり部外面５ｂとがなす角部に相当する箇所で金型と接触せずに湾曲しているものである。そのため、後の射出工程においてインサートフィルム４が延伸しても、インサートフィルム４の外表面が成形品の立ち上がり部頂面５ａと立ち上がり部外面５ｂとがなす角部に相当する箇所で金型に沿うだけであり（図３参照）、インサートフィルム４に行き場がある限りにおいてはシワを生じない。
The insert film 4 that has been preformed and punched is curved without contacting the mold at a corner corresponding to the corner formed by the rising portion
ところで、一般的にインサート成形において、インサートフィルム４の予備成形形状を雌型２と異なった形状に変更することは、金型内でインサートフィルム４が位置ずれを起こす要素となり、インサートフィルム４に付与された絵柄等の成形品５に対する位置精度を損なうことにつながる（図７参照）。しかし、本発明においては、図２に示すように、湾曲したインサートフィルム４の端面４ａが成形品５の立ち上がり部内面５ｃの端縁に相当する箇所で金型に接触するように予備成形および打抜き加工が施されたものである。したがって、型閉め後、インサートフィルム４は金型内で固定され、位置ずれを起こすことがない。 By the way, in general, in insert molding, changing the preformed shape of the insert film 4 to a shape different from that of the female mold 2 becomes an element that causes the positional displacement of the insert film 4 in the mold and is applied to the insert film 4. This leads to a loss of positional accuracy with respect to the molded product 5 such as a pattern (see FIG. 7). However, in the present invention, as shown in FIG. 2, pre-molding and punching are performed so that the end surface 4a of the curved insert film 4 comes into contact with the mold at a position corresponding to the edge of the rising portion inner surface 5c of the molded product 5. It has been processed. Therefore, after the mold is closed, the insert film 4 is fixed in the mold and does not cause a positional shift.
なお、予備成形は、真空成形や型押し成形などによって行われる。また、インサートフィルム４の雌型２への装着は、真空吸引孔２ａなどによって行なうとよい（図１参照）。 Note that the preliminary molding is performed by vacuum molding, stamping molding, or the like. The insert film 4 may be attached to the female mold 2 through the vacuum suction hole 2a (see FIG. 1).
次に、雄型１と雌型２とを型閉した後（図２参照）、射出成形金型の成形空間部３内にゲート６より溶融樹脂７を射出する（図４参照）。 Next, after the male mold 1 and the female mold 2 are closed (see FIG. 2), the molten resin 7 is injected from the gate 6 into the molding space 3 of the injection mold (see FIG. 4).
溶融樹脂７としては、アクリロニトリルスチレン樹脂や、ポリカーボネート樹脂、ポリスチレン樹脂、アクリル樹脂、ポリエステル樹脂、ＡＢＳ樹脂などがあるが、携帯情報端末の匡体等の用途には、ポリカーボネート樹脂とＡＢＳ樹脂のアロイを選択するのがより好ましい。なぜなら、ポリカーボネート樹脂とＡＢＳ樹脂のアロイは、成形時の樹脂流動性が良好なため複雑な形状を成形するのに向いており、また耐熱性や耐衝撃性も兼ね備えるためである。 Examples of the molten resin 7 include acrylonitrile styrene resin, polycarbonate resin, polystyrene resin, acrylic resin, polyester resin, and ABS resin. For applications such as housings for portable information terminals, an alloy of polycarbonate resin and ABS resin is used. More preferably, it is selected. This is because an alloy of polycarbonate resin and ABS resin is suitable for molding a complicated shape because of good resin fluidity at the time of molding, and also has heat resistance and impact resistance.
本発明では、インサートフィルム４の荷重たわみ温度より射出される溶融樹脂の温度が高いため、射出成形時にインサートフィルム４は金型内で溶融樹脂の温度により軟化する。このあと射出成形樹脂の流れとその摩擦に応じてインサートフィルム４が延伸されるが、本発明の構成によれば、前述したように表面にフィルムのシワを生じないインサート成形品を得ることができる。 In the present invention, since the temperature of the molten resin injected is higher than the deflection temperature under load of the insert film 4, the insert film 4 is softened in the mold by the temperature of the molten resin during injection molding. Thereafter, the insert film 4 is stretched in accordance with the flow of the injection molding resin and its friction. According to the configuration of the present invention, an insert molded product that does not cause wrinkles on the surface as described above can be obtained. .
最後に、溶融樹脂６の冷却固化を待って、金型の型開きを行い、成形品５の外表面にインサートフィルム４が形成されたインサート成形品を取り出す。得られたインサート成形品は、インサートフィルム４の延伸程度に応じて、インサートフィルム４が成形品５の立ち上がり部頂面５ａを全面的に覆ったり（図５参照）、部分的に覆ったりする（図８参照）。
Finally, after the molten resin 6 is cooled and solidified, the mold is opened, and the insert molded product having the insert film 4 formed on the outer surface of the molded product 5 is taken out. In the obtained insert molded product, the insert film 4 covers the entire
２００μｍ厚のアクリルフィルムに８％加硫ゴム成分を添加したものを基体フィルムとし、その裏面に、アクリルビニル樹脂インキを用いて図柄層をグラビア印刷法にて形成し、最後にビニル樹脂インキを用いて接着層をグラビア印刷法にて形成してインサートフィルムとした。このインサートフィルム４の荷重たわみ温度（曲げ荷重４．６ｋｇｆ／ｃｍ２）を測定したところ、８７℃であった。 A 200 μm thick acrylic film with an 8% vulcanized rubber component is used as the base film, and on the back side, a pattern layer is formed by gravure printing using acrylic vinyl resin ink, and finally vinyl resin ink is used. Then, an adhesive layer was formed by a gravure printing method to obtain an insert film. The deflection temperature under load (bending load 4.6 kgf / cm 2 ) of this insert film 4 was measured and found to be 87 ° C.
雄型と雌型とで構成され、縦８０ｍｍ、横４９ｍｍ、立ち上がり部の高さ６．５ｍｍ、肉厚１．３ｍｍの箱状をした携帯電話の筐体を成形可能な成形空間部を有する射出成形金型を用い、雌型に所定の形状および寸法に予備成形および打抜き加工された前記インサートフィルムを装着した。 Injection having a molding space part that is composed of a male mold and a female mold and is capable of molding a box-shaped mobile phone casing having a length of 80 mm, a width of 49 mm, a rising height of 6.5 mm, and a wall thickness of 1.3 mm. Using the molding die, the insert film preliminarily molded and punched into a predetermined shape and size was mounted on a female mold.
次いで、型閉めしたところ、上記予備成形および打抜き加工されたインサートフィルムが成形品の立ち上がり部頂面と立ち上がり部外面とがなす角部に相当する箇所で金型と接触せずに湾曲し且つインサートフィルムの端面が成形品の立ち上がり部内面の端縁に相当する箇所で金型に接触した。 Next, when the mold was closed, the pre-molded and punched insert film was bent without contacting the mold at the corner corresponding to the corner formed by the top surface of the molded part and the outer surface of the raised part, and the insert film was inserted. The end surface of the film was in contact with the mold at a position corresponding to the edge of the inner surface of the rising portion of the molded product.
最後に、溶融状態のポリカーボネート樹脂とＡＢＳ樹脂のアロイを２６０℃で成形空間部内に射出し、冷却固化後、成形品の外表面および立ち上がり部頂面にインサートフィルムが形成された携帯電話の筐体を取り出した。 Finally, a molten polycarbonate resin and ABS resin alloy is injected into the molding space at 260 ° C., and after cooling and solidification, a cellular phone case in which an insert film is formed on the outer surface of the molded product and the top surface of the rising part. Was taken out.
このようにして得られた携帯電話の筐体は、成形品の立ち上がり部外面を覆うインサートフィルムの端部にシワを生じておらず、またインサートフィルムの位置精度に優れたものであった。 The cellular phone casing thus obtained had no wrinkles at the end of the insert film covering the outer surface of the rising portion of the molded product, and was excellent in the positional accuracy of the insert film.
１ 雄型
２ 雌型
２ａ 真空吸引孔
３ 成形空間部
４ インサートフィルム
４ａ 端面
５ 成形品
５ａ 立ち上がり部頂面
５ｂ 立ち上がり部外面
５ｃ 立ち上がり部内面
６ ゲート
７ 溶融樹脂
DESCRIPTION OF SYMBOLS 1 Male type 2 Female type 2a Vacuum suction hole 3 Molding space part 4 Insert film 4a End surface 5 Molded
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2007136841A (en) * | 2005-11-18 | 2007-06-07 | Shin Etsu Polymer Co Ltd | Resin molding with film, method for producing the molding, and injection molding mold |
| JP4992485B2 (en) * | 2007-03-13 | 2012-08-08 | ヤマハ株式会社 | Manufacturing method of decorative molded products |
| CN101850591A (en) * | 2009-04-06 | 2010-10-06 | 康准电子科技（昆山）有限公司 | In-mould decoration forming method and molded product |
| CN101856858A (en) * | 2009-04-08 | 2010-10-13 | 康准电子科技（昆山）有限公司 | Method for forming in-mold decoration mold product with microstructure and mold product thereof |
| CN115489075A (en) * | 2019-08-27 | 2022-12-20 | 深圳硅基仿生科技有限公司 | Injection molding method |
| CN210651668U (en) * | 2019-08-27 | 2020-06-02 | 深圳硅基仿生科技有限公司 | Mold for injection molding |
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