JP2010064273A - Insert molding method and insert molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simplify the laminated structure of a backup material, a decorative plate and an adhesive film when manufacturing a natural wood decorative panel or the like. <P>SOLUTION: First, a spacer film 12 is mounted to a movable side mold 21, and a core film 10 using the natural wood or the like is stuck thereto. Next, the movable side mold 21 and a fixed side mold 22 are closed and a core component is manufactured by injecting a molten synthetic resin from an injection gate 23. The spacer film 12 is detached from the core component, and stuck to the fixed side mold 22 again. Next, a molten resin introduction component 24 is temporarily fixed to the core component stuck to the fixed side mold 22. The insert molded article having the synthetic resin layers 20a, 20b formed on the both surfaces of the front surface and the back surface of the core film 10 is manufactured by closing the movable side mold 21 and the fixed side mold 22, and injecting the molten synthetic resin from the injection gate 23. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an insert molding method for molding an insert molding product in which a synthetic resin layer is formed on the front and back surfaces of a core film such as natural wood, and an insert molding product molded using the insert molding method.

  For example, natural wood decorative panels are used for interiors of automobiles and the like (for example, Non-Patent Document 1). The natural wood decorative panel as described in Non-Patent Document 1 must be manufactured so as to satisfy the environment-resistant characteristics without any deviation in dimensional accuracy in order to satisfy the high requirement specification as an automobile part. Specifically, such natural wood decorative panels have environmental resistance (high temperature resistance, low temperature resistance, humidity resistance, weather resistance, etc.) and chemical resistance (water resistance, chemical resistance, sweat resistance, grease resistance, etc.). It is required to produce so as to satisfy.

Reichiro Fukuno, “Car is made in this way”, separate volume CG, Nigensha, July 20, 2007

  In order to satisfy environmental resistance characteristics, a natural wood decorative panel is generally manufactured in a multilayer laminated structure, and its manufacturing process is also complicated. FIG. 17 is an explanatory view showing an example of a manufacturing process of a natural wood decorative panel for automobile interior. When manufacturing a natural wood decorative panel, first, the core material 93 is produced by laminating about 10 layers of panels obtained by slicing wood to about 0.5 to 0.8 mm while orthogonally crossing each grain. Next, as shown in FIG. 17, a sandwich structure is formed by stacking a backer (phenol resin impregnated reinforced wood) 91 of about 5 to 6 mm impregnated with a phenol resin on both surfaces of a core material 93. The backer means a backup material. Further, in this case, as shown in FIG. 17, between the core material 93 and the backer 91 (as shown in FIG. 17, when a plurality of core materials 93 are overlapped, between the core materials 93). Sandwiches the phenolic dry adhesive film 92. Then, the sandwich structure is heated and heat-treated and bonded at once, and then polished to finish the plywood.

  Next, a decorative material backing sheet 95 and a two-component wet adhesive 94 are sandwiched between the produced plywood and a decorative board (walnut 0.2 mm plate) 96, and laminated by pressure bonding and heat treatment. Next, the polyester resin 97 is undercoated / intercoated using a spray, dried, and then polished. Then, a UV (ultraviolet) curable acrylic paint (acrylic UV dry paint) 98 is applied by top coating, then forcedly dried using UV, polished, and mirror polished.

  As mentioned above, when manufacturing a natural wood decorative panel, the process of pressing and bonding each layer which comprises a natural wood decorative panel while heating is repeated. Therefore, there are many manufacturing processes, and it takes time for manufacturing.

  Then, an object of this invention is to provide the insert molding method and insert molded product which can simplify the laminated structure of the backup material at the time of manufacturing a natural wood decorative panel etc., a decorative board, and an adhesive film.

  The insert molding method according to the present invention is an insert molding method in which a film is insert-molded to produce an insert-molded product, and a spacer component (for example, spacer film 12) is provided on a first mold (for example, movable-side mold 21). ) And a predetermined core film (for example, a natural wooden core film 10, which may be a synthetic resin film) is closely attached to the surface of the spacer component facing the first mold. Then, the first mold and the second mold (for example, the fixed-side mold 22) having a resin injection portion (for example, the injection gate 23) for injecting the molten synthetic resin are closed. Then, by injecting the molten synthetic resin from the resin injection part, the core part is manufactured, the spacer part is removed from the core part, and the core part is again sealed in the second mold. Molten resin introduction part (for example, introduction of molten resin) for preventing the core part from coming off from the second mold and peeling off the core film and guiding the synthetic resin injected from the resin injection part into the mold The component 24) is temporarily fixed to a portion of the core component that is in close contact with the second mold and located at the resin injection portion, and the first mold and the second mold are closed and melted. By injecting the synthetic resin from the resin injection part, an insert molded product in which a synthetic resin layer is formed on both the front surface and the back surface of the core film is produced.

  Further, the insert molding method temporarily fixes the molten resin-introduced component to a portion located in the resin injection portion of the core component that is in close contact with the second mold, and the predetermined mold for the first mold. A film (for example, skin film 11) is brought into close contact, the first mold and the second mold are closed, and a molten synthetic resin is injected from the resin injection portion, whereby the surface of the core film and A synthetic resin layer may be formed on both surfaces of the back surface, and an insert molded product covered with a skin film may be produced.

  The insert molding method may use a natural wood film as the core film.

  The insert-molded article according to the present invention is an insert-molded article produced by an insert molding method for insert-molding a film, and is a predetermined core film (for example, a natural wooden core film 10; a synthetic resin film). And a first synthetic resin layer (for example, synthetic resin layer 20a) is provided on the surface of the core film, and a second synthetic resin layer (for example, synthetic resin layer 20b) is provided on the back surface of the core film. Is provided.

  According to the present invention, an insert molded product in which a synthetic resin layer is formed on both front and back surfaces of a predetermined core film can be obtained by using the insert molding method. Therefore, it is not necessary to press or heat each layer of the molded product many times, and the laminated structure of the backup material, the decorative plate, and the adhesive film when manufacturing the molded product can be simplified.

Embodiment 1. FIG.
A first embodiment of the present invention will be described below with reference to the drawings. First, a specific example of an insert molded product molded by using the insert molding method according to the present invention will be described. FIG. 1 is a cross-sectional view showing a specific example of the structure of an insert molded product molded using the insert molding method according to the present invention. As shown in FIG. 1, in an insert molded product molded using the insert molding method according to the present invention, synthetic resin layers 20 a and 20 b are formed on both the front and back surfaces of a core film 10.

  Specifically, the core film 10 is a film manufactured using natural wood or the like. The synthetic resin layers 20a and 20b are specifically molded using a synthetic resin such as ABS (acrylonitrile, bradiene, styrene resin), AS (acrylonitrile styrene), PC (polycarbonate), or PMMA (acrylic resin). Is done.

  The insert-molded product shown in FIG. 1 has high environmental resistance (high temperature resistance, low temperature resistance, humidity resistance, weather resistance, etc.) and chemical resistance (water resistance, chemical resistance, sweat resistance, grease resistance, etc.). It is applied to applications that produce panels that require environmental resistance. For example, the insert-molded article shown in FIG. 1 is used for producing a natural wood panel used for automobile interiors.

  Next, the procedure of the insert molding method according to the present invention will be described. In the insert molding method according to the present invention, for example, as shown in FIG. 2, an existing movable mold 21 and a fixed mold 22 provided with an injection gate 23 are used.

  When performing insert molding, first, as shown in FIG. 3, the spacer film 12 is placed on the movable side mold 21 in a state where the molds of the existing movable side mold 21 and the fixed side mold 22 are opened. Set in close contact. Next, as shown in FIG. 3, the core film 10 is further set in close contact with the spacer film 12 set on the movable mold 21. The spacer film 12 and the core film 10 can be brought into close contact with the movable mold 21 by, for example, evacuation.

  Specifically, the spacer film 12 is produced using a material different from that of the core film 10 so as not to adhere to the core film 10 during injection molding. For example, the spacer film 12 is produced as a metal film. The spacer film 12 may be made of PET (polyethylene terephthalate), PC, or ABS as long as it is a synthetic resin made of a material different from that of the core film 10.

  Next, as shown in FIG. 4, the movable side mold 21 is moved to close the movable side mold 21 and the fixed side mold 22. Then, as shown in FIG. 5, from the injection gate 23 of the injection side fixed mold 22, the molten synthetic resin is injected and injected into the mold.

  Thereafter, when the injection of the melted synthetic resin is completed, the movable side mold 21 and the fixed side mold 22 are opened, and the insert molded product with the spacer film 12 attached thereto as shown in FIG. At this stage, it is not yet a finished product.

  As described above, since the spacer film 12 is made of a material different from that of the core film 10, the spacer film 12 can be easily detached from the core component. When the spacer film 12 is removed, as shown in FIG. 7, a core component in which the synthetic resin layer 20b is formed only on one side (in this example, the back side) of the core film 10 is obtained. Moreover, by using the spacer film 12, as shown in FIG. 7, a core part smaller than the dimension inside a metal mold | die is obtained.

  Next, an opening for a molten resin path for injecting the molten synthetic resin is provided in the obtained core part, and the core part is again brought into close contact with the fixed mold 22 as shown in FIG. set. In this case, as shown in FIG. 8, the core part is made to pass the synthetic resin injected and injected from the injection gate 23 into the portion located in the injection gate 23 in a state of being in close contact with the fixed mold 22. An opening shall be provided.

  Further, as shown in FIG. 8, a predetermined molten resin introduction component 24 is temporarily fixed to a core component that is brought into close contact with the fixed mold 22 side. The molten resin introduction component 24 prevents the core component that is in close contact with the fixed mold 22 that is the mold on the injection side from coming off the fixed mold 22 or peeling the core film 10, and the injection gate. 23 is a part for introducing the synthetic resin (molten synthetic resin) injected from the mold 23 into the mold. In addition, it is desirable that the molten resin-introduced component 24 is manufactured using a synthetic resin made of the same material as the synthetic resin layers 20a and 20b forming the insert molded product.

  As shown in FIG. 8, the molten resin introduction component 24 is temporarily fixed to a portion of the core film 10 of the core component located at the injection gate 23 of the fixed mold 22 using a predetermined adhesive. In this case, for example, an instantaneous adhesive using cyanoacrylate may be used as the predetermined adhesive. Moreover, you may use the adhesive agent (for example, adhesive agent using silylated urethane resin, an acrylic resin, and urethane resin) of the component suitable for adhesion | attachment of resin as predetermined | prescribed adhesive agent. Further, without using such an adhesive, for example, the molten resin introduction component 24 may be temporarily fixed to the core film 10 of the core component by ultrasonic welding.

  The shape of the molten resin introduction component 24 will be described. FIG. 9 is a perspective view showing a specific shape of the molten resin introduction component 24. FIG. 10 is an explanatory view showing a front surface, an upper surface, a lower surface, and each side surface of the molten resin introduction component 24 shown in FIG. 9 and 10, of the surfaces of the molten resin introduction component 24, the surface on which the groove portions 241 a to 241 d are provided is the front surface.

  9 and 10, the back surface 244 side of the molten resin introduction component 24 is temporarily fixed so as to be in contact with the core film 10 of the core component that is in close contact with the fixed mold 22. In addition, the front side of the molten resin introduction component 24 is in contact with the movable mold 21 in a state where the movable mold 21 and the fixed mold 22 are closed. As shown in FIGS. 9 and 10, in the front surface of the molten resin introduction component 24, the surfaces 243 a to 243 d of the portions where the grooves 241 a to 241 d are not formed are in contact with the movable side mold 21. A surface is formed.

  As shown in FIGS. 9 and 10, an opening 242 for injecting molten synthetic resin is provided on the back surface 244 of the molten resin introduction component 24. Accordingly, in FIG. 8, the molten resin introduction component 24 is the core film 10 of the core component such that the opening 242 provided in the back surface 244 of the molten resin introduction component 24 is positioned at the injection gate 23 of the stationary mold 22. Temporarily fixed.

  As shown in FIGS. 9 and 10, grooves 241a to 241d for introducing the molten synthetic resin into the mold are formed on the front side of the molten resin introduction component 24 in four directions, up, down, left, and right. Yes.

  In this embodiment, as shown in FIGS. 9 and 10, a case where a rectangular parallelepiped molten resin introduction component 24 is used will be described. However, the molten resin introduction component 24 has a core component that is detached from the stationary mold 22. As long as it can prevent the core film 10 from being peeled off and can introduce a melted synthetic resin into the mold, it is not limited to the shape shown in the present embodiment. For example, the molten resin introduction component 24 may be configured as a cylindrical component, and may be formed with a plurality of groove portions into which molten synthetic resin can be introduced.

  Next, as shown in FIG. 11, the movable mold 21 is moved to close the movable mold 21 and the fixed mold 22. Then, as shown in FIG. 11, from the injection gate 23 of the injection side fixed mold 22, the molten synthetic resin is injected and injected into the mold. In this case, the synthetic resin injected from the injection gate 23 passes through the openings 242 provided on the back surface 244 of the molten resin introduction component 24 and the grooves 241a to 241d provided on the molten resin introduction component 24. (See FIG. 9 and FIG. 10), which is injected into the mold. In the present embodiment, as shown in FIG. 11, the spacer film 12 was melted in a space formed between the core component obtained smaller than the mold size and the movable side mold 21 by using the spacer film 12. Synthetic resin is injected.

  Thereafter, when injection of the molten synthetic resin is completed, the movable side mold 21 and the fixed side mold 22 are opened, and the synthetic resin is formed on both the front and back surfaces of the core film 10 as shown in FIG. An insert-molded product (finished product) having an aspect in which the layers 20a and 20b are formed is obtained.

  As described above, according to the present embodiment, by using the insert molding method, it is possible to obtain an insert molded product in which the synthetic resin layers 20a and 20b are formed on both the front and back surfaces of the core film 10 such as natural wood. it can. Therefore, it is possible to eliminate the need to press and heat each layer of the molded product many times, and to simplify the laminated structure of backup materials, decorative boards and adhesive films when manufacturing natural wood decorative panels, etc. Can do.

  Moreover, according to this embodiment, since the surface side and the back surface side of the core film 10 can be formed as the synthetic resin layers 20a and 20b, it is possible to eliminate the deviation in product dimensions and to reduce the weight of the molded product. it can. Moreover, according to this embodiment, the press bonding process by the heating for every layer can be reduced by performing insert molding integrally.

  Further, according to the present embodiment, the front and back surface layers of the molded product are formed as the synthetic resin layers 20a and 20b by injection molding, so that the smoothness of the molds 21 and 22 can be achieved without performing flat finishing after processing. Depending on the properties, the surface of the molded product can be finished in a flat state. Therefore, the mirror polishing finish process by polishing can be eliminated, and the labor for manufacturing a molded product can be reduced.

  Moreover, in this embodiment, insert molding is performed in a state in which the molten resin introduction component 24 is temporarily fixed to the core film 10 of the core component that is in close contact with the injection-side stationary mold 22. Therefore, when performing the insert molding, it is possible to prevent a situation where the core component brought into close contact with the injection-side fixed-side mold 22 comes off from the fixed-side mold 22 or the core film 10 is peeled off. Insert molding can be performed appropriately.

Embodiment 2. FIG.
Next, a second embodiment of the present invention will be described with reference to the drawings. FIG. 13: is sectional drawing which shows the specific example of the structure of the insert molded product shape | molded using the insert molding method in 2nd Embodiment. As shown in FIG. 13, in the insert molded product, the synthetic resin layers 20 a and 20 b are formed on both the front surface and the back surface of the core film 10, similarly to the one shown in the first embodiment. In this embodiment, the surface of the synthetic resin layer 20a on the surface side of the insert molded product is further covered with the skin film 11.

  The skin film 11 is a film for decorating an insert-molded product, performing functional treatment such as coating, and protecting the internal synthetic resin layers 20a and 20b. For example, the skin film 11 is manufactured using a synthetic resin such as PET, PC, or ABS. For example, as the skin film 11, a functional film such as an AR (Anti-Reflection) coating film or a hard coating film may be used. For example, as the skin film 11, a film using a natural material such as leather, cloth, wood, paper, or the like may be used.

  In general, when an inexpensive general-purpose resin (ABS resin or the like) is used for the synthetic resin layers 20 and 20b, the synthetic resin layers 20 and 20b are weak against chemicals. The resin layers 20a and 20b can be protected.

  Next, the procedure of the insert molding method in the second embodiment will be described. In addition, in this embodiment, the process until it produces a core component is the same as those processes shown in 1st Embodiment (refer FIGS. 2-7).

  Next, as in the first embodiment, the obtained core part is provided with an opening for a molten resin path for injecting the molten synthetic resin, and the core part is again mounted as shown in FIG. Set in close contact with the fixed mold 22. In this case, as shown in FIG. 14, the core part is made to pass the synthetic resin injected and injected from the injection gate 23 through the portion positioned in the injection gate 23 in a state of being in close contact with the fixed mold 22. An opening shall be provided.

  Moreover, as shown in FIG. 14, the skin film 11 is set in close contact with the movable mold 21 side. The skin film 11 can be brought into close contact with the movable mold 21 by, for example, evacuation.

  Further, as shown in FIG. 14, a predetermined molten resin introduction component 24 is temporarily fixed to a core component brought into close contact with the fixed mold 22 side. As shown in FIG. 14, the molten resin introduction component 24 is temporarily fixed to a portion of the core film 10 of the core component located at the injection gate 23 of the fixed-side mold 22 using a predetermined adhesive. Therefore, in this embodiment, as shown in FIG. 14, the molten resin introduction component 24 is sandwiched between the skin film 11 set on the movable mold 21 and the core film 10 of the core component. Will be set.

  Next, as shown in FIG. 15, the movable side mold 21 is moved to close the movable side mold 21 and the fixed side mold 22. Then, as shown in FIG. 15, the molten synthetic resin is injected and injected into the mold from the injection gate 23 of the injection-side fixed mold 22. In this case, the synthetic resin injected from the injection gate 23 passes through the openings 242 provided on the back surface 244 of the molten resin introduction component 24 and the grooves 241a to 241d provided on the molten resin introduction component 24. (See FIG. 9 and FIG. 10), which is injected into the mold. Further, in the present embodiment, as shown in FIG. 14, between the core part obtained by using the spacer film 12 smaller than the mold size and the skin film 11 in close contact with the movable side mold 21. The melted synthetic resin is injected into the space that can be formed.

  Thereafter, when injection of the molten synthetic resin is completed, the movable side mold 21 and the fixed side mold 22 are opened, and the synthetic resin is formed on both the front and back surfaces of the core film 10 as shown in FIG. The layers 20a and 20b are formed, and an insert-molded product (finished product) having a surface coated with the skin film 11 is obtained.

  As described above, according to the present embodiment, an insert molded article covered with the skin film 11 can be obtained. Therefore, in addition to the effects shown in the first embodiment, an insert molded product having decorativeness and functionality can be obtained. Further, by protecting with the skin film 11, an insert-molded product having excellent chemical resistance can be obtained.

  In each of the embodiments described above, the case where a film using natural wood is used as the core film 10 is shown, but other films can be used as the core film 10. For example, as the core film 10, a synthetic resin film such as a PET film, a PC film, a functional film, or a decorative film may be used. For example, as the core film 10, a film using a natural material such as genuine leather, cloth, paper, or the like may be used.

  The present invention can be applied to, for example, an application for producing a natural wood panel used for automobile interiors.

It is sectional drawing which shows the specific example of the structure of the insert molded product shape | molded using the insert molding method by this invention. It is explanatory drawing which shows the example of the existing movable side metal mold | die and the fixed side metal mold | die provided with the injection gate 23. FIG. It is explanatory drawing which shows the state by which the metal mold | die of the existing movable mold and fixed mold was opened. It is explanatory drawing which shows the state by which the metal mold | die of the existing movable side metal mold | die and a fixed side metal mold | die was closed. It is explanatory drawing which shows the state which inject | poured and inject | poured the melted synthetic resin in the metal mold | die from the injection gate of the injection | fixed side metal mold | die on the injection side. It is explanatory drawing which shows the insert molded product (non-finished product) in the state to which the spacer film was attached. It is explanatory drawing which shows the insert molded product (non-finished product) of the state which removed the spacer film. It is explanatory drawing which shows the state which set the core component again in contact | adhered to the stationary-side metal mold | die again. It is a perspective view which shows the specific shape of molten resin introduction components. It is explanatory drawing which showed the front surface, upper surface, lower surface, and each side surface of the molten resin introduction component shown in FIG. It is explanatory drawing which shows the state which closed the movable mold and the stationary mold again. It is explanatory drawing which shows the insert molded product (finished product) of the aspect by which the synthetic resin layer was formed in both surfaces of the surface of a core film, and a back surface. It is sectional drawing which shows the specific example of the structure of the insert molded product shape | molded using the insert molding method in 2nd Embodiment. It is explanatory drawing which shows the state which set the core component again in contact with the stationary-side metal mold | die again in 2nd Embodiment. It is explanatory drawing which shows the state which closed the movable side metal mold | die and fixed side metal mold | die in 2nd Embodiment again. It is explanatory drawing which shows the insert molded product (finished product) of the aspect by which the synthetic resin layer was formed in both surfaces of the surface of a core film, and a back surface, and the surface side was coat | covered with the skin film. It is explanatory drawing which shows the example of the manufacturing process of the natural wood decorative panel for motor vehicle interior.

Explanation of symbols

10 Core film 11 Skin film 12 Spacer film 13
20a, 20b Synthetic resin layer 21 Movable side mold 22 Fixed side mold 23 Injection gate 23
24 Molten resin introduction parts 241a to 241d Groove 242 Openings 243a to 243d Contact surface 244 Back

Claims (4)

An insert molding method for producing an insert molded product by insert molding a film,
Attaching a spacer part to the first mold, and sticking a predetermined core film to the surface of the spacer part facing the first mold,
Closing the first mold and the second mold having a resin injection part for injecting molten synthetic resin, and injecting the molten synthetic resin from the resin injection part To produce core parts,
The spacer part is removed from the core part, and the core part is brought into close contact with the second mold again.
A molten resin introduction part for preventing the core part from coming off from the second mold and peeling off the core film and for guiding the synthetic resin injected from the resin injection part into the mold; Temporarily fixed to the portion located in the resin injection portion of the core component closely attached to the mold of 2;
By closing the first mold and the second mold and injecting a molten synthetic resin from the resin injection portion, a synthetic resin layer is formed on both the front and back surfaces of the core film. An insert molding method comprising producing a formed insert molded product. The molten resin introduction component is temporarily fixed to a portion located in the resin injection portion of the core component in close contact with the second mold, and a predetermined skin film is adhered to the first mold,
By closing the first mold and the second mold and injecting a molten synthetic resin from the resin injection portion, a synthetic resin layer is formed on both the front and back surfaces of the core film. The insert molding method according to claim 1, wherein the insert molding product is formed and coated with the skin film.   The insert molding method according to claim 1 or 2, wherein a natural wood film is used as the core film. An insert molded product produced by using an insert molding method for insert molding a film,
Provided with a predetermined core film,
A first synthetic resin layer is provided on the surface of the core film;
An insert-molded article, wherein a second synthetic resin layer is provided on the back surface of the core film.