JP2011148264A - Method for manufacturing resin molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a resin molded article capable of obtaining the resin molded article while properly processing an overflowing excessive photocurable resin. <P>SOLUTION: The distances between an exposed face 36 of a translucent resin part and a decorative sheet 21 have original values in each of individual sites in the resin molded article, and the method for manufacturing the resin molded article includes the step for obtaining a base material 23 having an overhanging part 24 of the decorative sheet 21 in at least a part of a peripheral part 31, the resin mounting step for mounting a photocurable resin on the base material 23, the mold mounting step for mounting the mold 43 from above the base material 23, for filling a gap 44 with the photocurable resin, and for holding the overflowing excessive photocurable resin by the overhanging part 24, and a photocuring step for irradiating the photocurable resin with light. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a resin molded product in which a decorative portion that allows a pattern to be visually recognized through the light transmissive resin portion is provided on the back surface of the light transmissive resin portion.

  In order to obtain a deep visual effect, a concave portion such as a step or a wrinkle is formed on the back surface of the translucent resin portion, and the pattern can be visually recognized through the translucent resin portion on the back surface of the translucent resin portion. A resin molded product in which a decorative portion such as a decorative film or a decorative sheet is bonded is known.

  However, if a concave portion is formed on the back surface of the resin molded product, for example, when the resin molded product is bonded to another member with a double-sided tape, a sufficient adhesion state between the resin molded product and the double-sided tape is obtained. I can't. In addition, a gap is generated between the resin molded product and the other member, which causes a decrease in waterproofness and mechanical strength.

  For this reason, in order to make the resin molded product have sufficient surface contact with other members and eliminate the gap between the resin molded product and the other members, for example, in the concave portion on the back surface of the resin molded product. It is conceivable to inject a resin and form the back surface of the resin molded product in a flat surface.

  Various methods have been proposed in the past for forming a flat surface by injecting a resin into a concave portion of a member. For example, in Patent Document 1, a photocurable resin is injected into a concave portion of a resin film as a member arranged on a placement mold, and a translucent material is formed from above the concave portion of the resin film and the photocurable resin. Place a flat mold composed of the above, fill the photocurable resin between the concave portion of the resin film and the flat mold, overflow the excess photocurable resin, and light is transmitted through the flat mold It is disclosed that the upper surface of the photocurable resin portion is formed into a flat surface by being irradiated and cured.

  Here, by applying the technique disclosed in Patent Document 1 to the above-described resin molded product, it is possible to inject resin into the concave portion on the back surface of the resin molded product and form the back surface of the resin molded product in a flat surface. Conceivable.

JP 2008-246874 A

  However, in the above configuration, the excess photo-curing resin that overflows may flow from the peripheral edge of the resin molded product to the back side, adhere to the support of the resin molded product, or impair the appearance of the resin molded product. It was.

  The objective of this invention is providing the manufacturing method of the resin molded product which can obtain a resin molded product, processing appropriately the excess photocurable resin which overflowed.

  The first characteristic means of the method for producing a resin molded product of the present invention is that a cavity formed between the decorative sheet and the first mold is sandwiched between the first mold and the second mold. By injecting the translucent resin and then curing, the distance between the exposed surface of the translucent resin portion and the decorative sheet has an expected value for each part, and at least a part of the peripheral portion The base material formation process which obtains the base material provided with the overhang | projection part of the said decorating sheet; The resin mounting process which mounts photocurable resin on the exposed surface of the decorating sheet of the said base material; The said base material and the said A mold composed of a translucent material is placed on the photocurable resin, the gap formed by the contact between the mold and the base material is filled with the photocurable resin, and the periphery of the mold A mold placing step of holding the excess photocurable resin overflowing in the projecting portion; the mold or the translucent tree In that it has a; through one of the parts, the light photocuring step for irradiating the photocurable resin.

  A photocurable resin is placed on the exposed surface of the decorative sheet of the substrate, and a mold is placed on the substrate and the photocurable resin. At this time, the placed photocurable resin is filled in a gap formed by the contact between the mold and the substrate. Excess photocurable resin overflowing from the gap to the peripheral edge of the substrate is held by an overhang provided at least in part of the peripheral edge of the substrate. Thereby, it can prevent that the excess photocurable resin which overflowed flows down from the peripheral part of a base material. Therefore, by using this method, the excess photo-curing resin overflowing can be prevented from adhering to the support base of the base material or wrapping around the front surface of the base material, and has a sound appearance. A molded product can be obtained efficiently.

  The 2nd characteristic means of this invention exists in the point which forms the surface facing the said base material in the plane among the surfaces of the said type | mold.

  A photocurable resin is placed on the exposed surface of the decorating sheet of the base material, and a mold having a flat surface facing the base material is placed on the base material and the photocurable resin. At this time, the upper surface of the photocurable resin is leveled to a flat surface by the surface of the mold that faces the substrate. The photocurable resin is irradiated with light through either the mold or the translucent resin portion to be cured. For this reason, the upper surface of a photocurable resin part, ie, the back surface of a resin molded product, can be formed in a plane.

  Thereby, when connecting the resin molded product to another member, the resin molded product and the other member are sufficiently in surface contact. For this reason, the operation | work which bonds a resin molded product to another member with a double-sided tape becomes easy, for example. Moreover, the clearance gap between a resin molded product and another member can be eliminated, and waterproofness and mechanical strength can be maintained.

  The 3rd characteristic means of this invention exists in the point which provides the peeling sheet | seat which the said photocurable resin does not adhere to the surface which opposes the said base material among the surfaces of the said mold in the said mold mounting process.

  A photocurable resin is placed on the exposed surface of the decorative sheet of the substrate, and a mold provided with a release sheet is placed on the surface of the substrate and the photocurable resin facing the substrate. At this time, since the release sheet is interposed between the photocurable resin and the mold, the photocurable resin does not adhere to the mold. Therefore, it is easy to remove the mold from the photocurable resin portion, and the trouble of cleaning the mold can be saved.

In addition, by providing a release sheet on the surface of the mold that faces the substrate, it is possible to control the spread of the excess photocurable resin that has overflowed.
That is, when there is no release sheet, surplus photocurable resin passes between the mold and the base material and overflows to the peripheral edge of the base material. At this time, the photocurable resin may adhere not only to the surface of the mold facing the substrate but also to the side surface. For this reason, it is necessary to increase the thickness of the mold in order to prevent the photo-curing resin from wrapping around the surface of the mold opposite to the surface facing the substrate.

  On the other hand, when there is a release sheet, surplus photocurable resin passes between the release sheet and the base material and overflows to the peripheral edge of the base material. At this time, since the photocurable resin does not adhere to the mold, the photocurable resin does not wrap around from the side surface to the surface opposite to the surface facing the substrate. Therefore, the thickness of the mold can be reduced.

  The 4th characteristic means of the manufacturing method of the resin molded product of this invention is the cavity formed between the said decorating sheet and the said 1st type | mold, clamping the decorating sheet with the 1st type | mold and the 2nd type | mold. By injecting the translucent resin and then curing, the distance between the exposed surface of the translucent resin portion and the decorative sheet has an expected value for each part, and at least a part of the peripheral portion A base material forming step of obtaining a base material provided with a protruding portion of the decorative sheet; a resin placing step of placing a delayed photocurable resin on the exposed surface of the decorative sheet of the base material; A photocuring step of irradiating the delayed photocurable resin; a mold is disposed above the substrate and the delayed photocurable resin, and the mold and the exposed surface of the decorative sheet of the substrate are opposed to each other; A transfer sheet disposing step of disposing a transfer sheet including a design layer on a surface of the mold facing the substrate; The mold is placed from above the delay type photocurable resin, the gap formed between the transfer sheet and the base material is filled with the delay type photocurable resin, and the periphery of the mold A mold mounting step for holding the excess of the delayed photocurable resin overflowing in the projecting portion; removing the mold from the base material and the delayed photocurable resin portion, and removing the mold from the transfer sheet Is peeled off, and the pattern layer is transferred to the upper surface of at least one of the base material and the delayed photocurable resin portion.

  The delayed photocurable resin is placed on the exposed surface of the decorative sheet of the substrate, light is irradiated to the delayed photocurable resin, and the substrate is opposed to the substrate from above the delayed photocurable resin. A mold provided with a transfer sheet including a pattern layer on the surface is placed, and a delay type photocurable resin is filled in a gap formed between the transfer sheet and the substrate. At this time, the gap formed between the transfer sheet and the base material is filled with a delay type photocurable resin that has been irradiated with light in advance, so that the light is delayed through the transfer sheet and the mold. It is not necessary to irradiate the functional resin. Therefore, even transfer sheets and molds that do not have translucency can be used.

  Further, since the transfer sheet is interposed between the delay type photocurable resin and the mold, the delay type photocurable resin does not adhere to the mold. Therefore, it is easy to remove the mold from the base material and the delay type photocurable resin portion, and the trouble of cleaning the mold can be saved. Moreover, since the design layer is peeled off from the transfer sheet and the design layer is transferred to the upper surface of the base material and the delay type photocurable resin portion, the design layer is placed on the upper surface of the base material and the delay type photocurable resin portion. It can be transferred to give a predetermined decoration.

Furthermore, by providing a transfer sheet on the surface of the mold that faces the substrate, it is possible to control the spread of the excess delayed photocurable resin that has overflowed.
That is, when there is no transfer sheet, surplus delayed type photocurable resin overflows between the mold and the base material and overflows to the periphery of the base material. At this time, the delayed photocurable resin may adhere not only to the surface facing the substrate but also to the side surface of the mold surface. For this reason, it is necessary to increase the thickness of the mold in order to prevent the delayed photocurable resin from wrapping around the surface of the mold opposite to the surface facing the substrate.
On the other hand, when there is a transfer sheet, the excessive delay type photocurable resin overflows between the transfer sheet and the base material and overflows to the peripheral edge of the base material. At this time, since the delayed photocurable resin does not adhere to the mold, the delayed photocurable resin does not wrap around from the side surface to the surface opposite to the surface facing the substrate. Therefore, the thickness of the mold can be reduced.

It is a longitudinal cross-sectional view which shows the state which clamps a decorating sheet between 1st type | mold and 2nd type | mold by mold clamping. A state in which a substrate formed with a translucent resin in a peripheral portion and a protruding portion of a decorative sheet formed on a peripheral portion is shown by filling a cavity formed by contacting the first mold and the second mold with each other. It is a longitudinal cross-sectional view. It is a longitudinal cross-sectional view which shows the state which takes out a base material from between a 1st type | mold and a 2nd type | mold by mold opening. It is a longitudinal cross-sectional view which shows the state which mounts photocurable resin in the exposed surface of the decorating sheet of a base material in 1st Embodiment. In the first embodiment, a mold made of a translucent material is placed on the base material and the photocurable resin, and the gap formed by the contact between the mold and the base material is filled with the photocurable resin. It is a longitudinal cross-sectional view which shows the state which hold | maintains the excess photocurable resin which overflowed around the mold | type by the overhang | projection part. It is a longitudinal cross-sectional view which shows the state which removes a type | mold from a base material and a photocurable resin part in 1st Embodiment. It is a perspective view which shows the base material provided with the overhang | projection part of the decorating sheet in the peripheral part. It is a longitudinal cross-sectional view of the decorating sheet in 1st Embodiment. It is a longitudinal cross-sectional view which shows the state which mounts photocurable resin in the exposed surface of the decorating sheet of a base material in 2nd Embodiment. In the second embodiment, a mold made of a translucent material is placed on the substrate and the photocurable resin, and the photocurable resin is filled in the gap formed by the contact between the mold and the substrate. It is a longitudinal cross-sectional view which shows the state which hold | maintains the excess photocurable resin which overflowed around the mold | type by the overhang | projection part. It is a longitudinal cross-sectional view which shows the state which removes a type | mold from a base material and a photocurable resin part in 2nd Embodiment. It is a longitudinal cross-sectional view which shows the state which mounts photocurable resin in the exposed surface of the decorating sheet of a base material in 3rd Embodiment. In the third embodiment, a mold composed of a translucent material is placed on the base material and the photocurable resin, and the gap formed by the contact between the mold and the base material is filled with the photocurable resin. It is a longitudinal cross-sectional view which shows the state which hold | maintains the excess photocurable resin which overflowed around the mold | type by the overhang | projection part. It is a longitudinal cross-sectional view which shows the state which removes a type | mold from a base material and a photocurable resin part in 3rd Embodiment. It is a longitudinal cross-sectional view of the transfer sheet containing a pattern layer in 4th Embodiment. It is a longitudinal cross-sectional view which shows the state which mounts photocurable resin in the exposed surface of the decorating sheet of a base material in 4th Embodiment. It is a longitudinal cross-sectional view which shows the state which arrange | positions a transfer sheet in the surface which opposes a base material among the surfaces of the type | mold in 4th Embodiment. In the fourth embodiment, a mold composed of a translucent material is placed on the base material and the delay type photocurable resin, and the delay type photocuring property is formed in the gap formed by the contact between the mold and the base material. It is a longitudinal cross-sectional view which shows the state which fills resin and hold | maintains the excessive delay type photocurable resin which overflowed around the mold | type by the overhang | projection part. It is a longitudinal cross-sectional view which shows the state which removes a type | mold from a base material and a delay type photocurable resin part in 4th Embodiment. It is a longitudinal cross-sectional view which shows the state which mounts photocurable resin in the exposed surface of the decorating sheet of a base material in 5th Embodiment. It is a longitudinal cross-sectional view which shows the state which mounts the type | mold comprised with the translucent material from the base material and photocurable resin in 5th Embodiment. In the fifth embodiment, the gap formed by the contact between the mold and the base material is filled with the photocurable resin, and the excess photocurable resin overflowing around the mold is held by the overhanging portion. It is a longitudinal cross-sectional view shown.

[First Embodiment]
Hereinafter, the resin molded product and the manufacturing method thereof according to the present invention will be described.

(First type and second type)
As shown in FIG. 1, a first recess 4 for forming a cavity 3 and a first party surrounding the first recess 4 are formed on the upper surface of the first mold 1 (the surface facing the second mold 2). A ring surface 5 is formed. The first concave portion 4 includes a side surface portion 6 and a bottom surface portion 7. Ribs 8 are formed on the bottom surface portion 7. The side surface 6 is provided with a gate 9 for injecting a translucent resin.

  A second recess 10 for forming the cavity 3 and a second parting surface 11 surrounding the second recess 10 are formed on the lower surface of the second mold 2 (the surface facing the first mold 1). Yes. The second concave portion 10 includes a side surface portion 12 and a bottom surface portion 13. The bottom surface portion 13 includes a flat surface portion 14, an inclined portion 15 surrounding the flat surface portion 14, and left and right staircase portions 16 formed on the flat surface portion 14.

(Base material forming process)
With reference to FIGS. 1-3, the process of forming the base material 23 using the said 1st type | mold 1 and the 2nd type | mold 2 is demonstrated.

  As shown in FIG. 1, the decorative sheet 21 is attached to the second mold 2. At this time, the decorative sheet 21 is fitted into the second recess 10. The decorative sheet 21 is adsorbed and fixed to the second mold by an air suction device (not shown).

  As shown in FIG. 8, the decorative sheet 21 is configured by forming a decorative layer 84 on the base sheet 81 to decorate a translucent resin portion 22 described later at the same time as injection molding. The decorative layer 84 includes a design layer 82 on which a design, a feed direction mark, and a width direction mark are expressed, and an adhesive layer 83 that improves the adhesion between the translucent resin portion 22 and the design layer 82. Furthermore, an anchor layer or the like may be added to the decorative layer 84 in order to protect the design layer 82 or improve interlayer adhesion.

  For the base sheet 81, polyethylene terephthalate (PET), acrylic (PMMA), polycarbonate (PC), acrylonitrile / butadiene / styrene (ABS) or the like is used.

  The design layer 82 is made of a colored ink containing a resin and a coloring material such as a pigment or a dye. Resins used as binders include polyvinyl resins, polyamide (PA) resins, polyester resins, PMMA resins, polyurethane resins, polyvinyl acetal resins, polyester urethane resins, cellulose ester resins, alkyd resins, etc. There is. The pattern layer 82 is formed on the base sheet 81 by a gravure printing method, a screen printing method, an offset printing method, or the like. When it is desired to express metallic luster as a pattern, the pattern layer 82 is constituted by a metal thin film layer formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method or the like.

  For the adhesive layer 83, a heat-sensitive or pressure-sensitive resin suitable for the type of the translucent resin portion 22 is used. If the translucent resin portion 22 is a PMMA resin, for example, the adhesive layer 83 may be a PMMA resin. If the translucent resin portion 22 is a PC or polystyrene (PS) resin, for example, the adhesive layer 83 may be made of PMMA, PS, or PA resin that has an affinity for these resins. A thermosetting urethane resin or the like is used for the anchor layer. The adhesive layer 83 and the anchor layer are formed on the resin sheet by a gravure coating method, a roll coating method, a comma coating method, a gravure printing method, a screen printing method, an offset printing method, or the like.

  As shown in FIG. 2, the second mold 2 and the first mold 1 are moved close to each other by a driving mechanism (not shown) to perform mold clamping. At this time, the parting surfaces 5 and 11 of the first mold 1 and the second mold 2 are in contact with each other with the decorative sheet 21 interposed therebetween, and the cavity 3 is formed between the decorative sheet 21 and the first mold 1. . The peripheral edge of the decorative sheet 21 protrudes outward from the first mold 1 and the second mold 2. A translucent resin is injected from the gate 9 into the cavity 3 and filled.

  The adhesive layer 83 of the decorative sheet 21 faces the first mold 1 side (lower side). Thereby, the decorative sheet 21 and the translucent resin portion 22 are firmly bonded by the adhesive layer 83.

  As shown in FIG. 3, the mold is opened by moving the second mold 2 and the first mold 1 apart by a drive mechanism. Air suction by the air suction device is stopped, and an ejector pin (not shown) provided in the first mold 1 is projected and moved to the base 23 side. Thereby, the base material 23 is removed from the first mold 1. In this way, the base material 23 having the decorative sheet 21 adhered to the upper surface of the translucent resin portion 22 is formed.

  The translucent resin portion 22 is made of a material suitable for a product in which a resin molded product 47 described later is used. Examples thereof include ABS, PMMA, PS, styrene acrylonitrile (AS), PC, polyvinyl chloride (PVC), PP, and PET resin. Moreover, the pattern layer 82 formed on the decorative sheet 21 can be visually recognized from the outside of the resin molded product 47 by using a transparent or translucent resin for the translucent resin portion 22. A protective sheet may be provided on the base sheet 81 in order to prevent the base sheet 81 from being worn out and exposing the design layer 82. At this time, if the base sheet 81 and the protective sheet are made of the same kind of resin, the adhesion between the base sheet 81 and the protective sheet can be improved.

(Base material)
FIG. 7 shows a rectangular plate-like base material 23 obtained by the base material forming step. On the peripheral end surface 31 (an example of the peripheral portion) of the base material 23, the overhanging portion 24 of the decorative sheet 21 extends from the center in the vertical direction of the peripheral end surface 31 over the entire circumference of the peripheral end surface 31.

  The overhang portion 24 includes a front part 24a, a rear part 24b, a left part 24c, and a right part 24d.

  The upper surface 32 of the substrate 23 includes a flat portion 33, an inclined portion 34 that surrounds the flat portion 33, and left and right staircase portions 35 (an example of a concave portion) formed on the flat portion 33. The flat portion 33 corresponds to the flat portion 14 of the first mold 1, the inclined portion 34 corresponds to the inclined portion 15 of the first mold 1, and the staircase portion 35 corresponds to the staircase portion 16 of the first mold 1. It corresponds.

  The inclined portion 34 includes a front side portion 34 a, a rear side portion 34 b, a left side portion 34 c, and a right side portion 34 d, and is configured in a slope shape that becomes higher toward the peripheral end surface 31.

  The flat portion 33 includes a central side portion 33a formed between the staircase portions 35, a front side portion 33b formed between the staircase portions 35 and the front side portion 34a of the inclined portion 34, and the staircase portions 35. And a rear portion 33b formed between the rear portion 34b of the inclined portion 34, a left portion 33d formed between the left step portion 35 and the left portion 34c of the inclined portion 34, and a right step. A right portion 33e formed between the portion 35 and the right portion 34d of the inclined portion 34.

  Each of the staircase portions 35 is formed in a stepped shape such that three step portions 35a, 35b, and 35c along the long side direction are arranged in the short side direction and become higher toward the central side portion 33a of the flat surface portion 33.

  As shown in FIG. 3, a groove 37 for cutting the base material 23 into a desired shape is formed on the lower surface 36 of the base material 23. As described above, the distance between the lower surface 36 of the base material 23 (exposed surface of the translucent resin portion 22) and the decorative sheet 21 corresponds to each of the flat portion 33, the inclined portion 34, and the staircase portion 35. Will have the expected value.

(Resin placement process)
As shown in FIG. 4, the base material 23 is arrange | positioned on the support stand 41, and the photocurable resin 46 is put on the step part 35 of the upper surface 32 (surface which the decorating sheet 21 exposes) of the base material 23 with the dispenser 42. As shown in FIG. inject. An error may occur in the amount of the photocurable resin 46 injected by the dispenser 42. For this reason, the gap 44 surrounded by the amount of the photocurable resin 46 to be injected into the stepped portion 35 is surrounded by the stepped portion 35 and the lower surface 43a (surface facing the base material 23) of the transparent mold 43 made of quartz glass described later. Set the amount slightly larger than the volume. Thereby, when the transparent mold | type 43 is mounted in the base material 23, mixing of the air to the clearance gap 44 is prevented. In addition, it is preferable that the viscosity of the photocurable resin 46 is slightly high, and the photocurable resin 46 is raised in a convex upward state due to surface tension.

  The usable photo-curable resin 46 is a radical in which a photo radical polymerization initiator is blended with an acrylic monomer (monofunctional, bifunctional, polyfunctional, etc.) or an acrylic oligomer (epoxy acrylate, urethane acrylate, polyester acrylate, etc.). Examples thereof include a curable resin, or a cationic curable resin obtained by blending an epoxy resin or an oxetane resin with a cationic photopolymerization initiator. These photocurable resins 46 can be appropriately selected in consideration of the strength of the cured photocurable resin 46, the adhesion between the cured photocurable resin 46 and the molding substrate, and the like.

(Mold placement process)
As shown in FIG. 5, a transparent support 48 having translucency is fixed to the upper surface 43 d of the transparent mold 43. The transparent mold support portion 48 is moved downward by an actuator (not shown), and the transparent mold 43 is placed from above the stepped portion 35 of the base material 23 and the photocurable resin 46 while maintaining a horizontal state. As described above, the amount of the photocurable resin 46 injected into the stepped portion 35 is slightly larger than the volume of the gap 44 surrounded by the stepped portion 35 and the lower surface 43 a of the transparent mold 43. Therefore, the injected photocurable resin 46 overflows between the transparent mold 43 and the base material 23 from the gap 44 while being filled in the gap 44. A part of the excess photocurable resin 46 that overflows is blocked by the inclined portion 34 of the base material 23, and the remaining photocurable resin 46 passes over the inclined portion 34 of the base material 23 and surrounds the periphery of the base material 23. The end face 31 is suspended. The suspended photocurable resin 46 is held by the overhang portion 24 provided at the center of the peripheral end surface 31 of the base material 23.

  Thereby, the overflowing excess photocurable resin 46 can be prevented from flowing downward from the peripheral end surface 31 of the base material 23. Therefore, it is possible to prevent the excess photo-curing resin 46 that has overflowed from adhering to the support base 41 of the base material 23 or from adhering to the front surface of the base material 23. It should be noted that when the transparent mold 43 is placed from above the stepped portion 35 of the base material 23 and the photocurable resin 46, the base material 23 is covered with the lower surface 43a and the side surface 43b so as not to be damaged. A curved surface portion 43c having an R-shaped cross section is formed.

  A transparent mold 43 is placed on the stepped portion 35 of the base material 23 and the photocurable resin 46. At this time, the lower surface 43 a of the transparent mold 43 comes into contact with the central portion 33 a in the flat surface portion 33. Accordingly, even if the base material 23 is warped, the base material 23 can be solidified in a corrected state. Therefore, the flatness of the base material 23 is improved, for example, the warpage of the base material 23 is reduced when the transparent mold 43 is removed from the base material 23.

(Photocuring process)
As shown in FIG. 5, for example, light is irradiated obliquely downward by a UV lamp 45 (an example of irradiation means). The light passes through the transparent mold 43 and the transparent mold support portion 48 and is applied to the photocurable resin 46 to cure the photocurable resin 46.

(Substrate removal process)
As shown in FIG. 6, the transparent mold support 48 is moved upward by the actuator, and the transparent mold 43 is removed from the base material 23 and the photocurable resin 46. In addition, a release agent is applied to the transparent mold 43 in advance so that the transparent mold 43 can be easily detached from the photocurable resin portion 46. Cut along the groove 37 of the substrate 23 to obtain a resin molded product 47.

[Second Embodiment]
9 to 11 show a second embodiment according to the present invention. In this embodiment, the shape of the base material 23 is the same as that of the first embodiment. However, it differs from the first embodiment in that a release sheet 51 is provided on the transparent mold 43 side. Therefore, only the configuration different from the configuration of the first embodiment will be described, and the description of the same configuration will be omitted.

(Resin placement process)
As shown in FIG. 9, the base material 23 is placed on the support base 41, and the photocurable resin 46 is injected into the stepped portion 35 of the base material 23 by the dispenser 42. At this time, a release sheet 51 made of a fluororesin on which the photocurable resin 46 does not adhere is provided on the transparent mold 43 side. The release sheet 51 is in contact with the lower surface 43a of the transparent mold 43 and a part of the curved surface portion 43c. A feeding mechanism (not shown) for feeding the release sheet 51 and a winding mechanism (not shown) for winding the release sheet 51 are provided. Thus, when the contact portion of the transparent mold 43 of the release sheet 51 is damaged, the contact portion of the transparent mold 43 of the release sheet 51 is replaced with a new sheet by simultaneously operating the feeding mechanism and the winding mechanism. Can do.

(Mold placement process)
As shown in FIG. 10, the transparent mold support 48 is moved downward by the actuator, and the transparent mold 43 is placed from above the stepped portion 35 of the substrate 23 and the photocurable resin 46 while maintaining the horizontal state. The injected photocurable resin 46 overflows between the release sheet 51 and the base material 23 from the gap 44 while being filled in the gap 44. At this time, since the release sheet 51 is interposed between the photocurable resin 46 and the transparent mold 43, the photocurable resin 46 does not adhere to the transparent mold 43. Therefore, the trouble of cleaning the transparent mold 43 can be saved. Further, the photocurable resin 46 does not go around from the side surface 43 b of the transparent mold 43 to the upper surface 43 or the transparent mold support portion 48. Therefore, the thickness of the mold can be reduced.

  A part of the excess photocurable resin 46 that overflows is blocked by the inclined portion 34 of the base material 23, and the remaining photocurable resin 46 passes over the inclined portion 34 of the base material 23 and surrounds the periphery of the base material 23. The end face 31 is suspended. The suspended photocurable resin 46 is held by the overhang portion 24 provided at the center of the peripheral end surface 31 of the base material 23.

(Photocuring process)
As shown in FIG. 10, the UV lamp 45 irradiates light obliquely downward. The light passes through the transparent mold 43 and the transparent mold support portion 48 and is applied to the photocurable resin 46 to cure the photocurable resin 46.

(Substrate removal process)
As shown in FIG. 11, the transparent mold support portion 48 is moved upward by the actuator, and the transparent mold 43 is detached from the base material 23 and the photocurable resin portion 46. At this time, since the release sheet 51 has a characteristic that the photocurable resin 46 does not adhere, it is easy to remove the transparent mold 43 provided with the release sheet 51 from the photocurable resin portion 46. Cut along the groove 37 of the substrate 23 to obtain a resin molded product 47.

[Third Embodiment]
12 to 14 show a third embodiment according to the present invention. In the second embodiment, the release sheet 51 is provided on the transparent mold 43 side, whereas in this embodiment, the release sheet 51 is provided on the support base 41 side as shown in FIGS. It is. In other respects, it is almost the same as the second embodiment. Thereby, there exists an advantage which can attain compactization, such as accommodating a feeding mechanism and a winding mechanism in the support stand 41. FIG.

[Fourth Embodiment]
15 to 19 show a fourth embodiment according to the present invention. In the second and third embodiments, the release sheet 51 is made of a fluororesin, whereas in this embodiment, the release sheet 51 is composed of a transfer sheet 51. The transfer sheet 51 may or may not include a design layer.

  In the case of using the transfer sheet 51 that does not include the design layer, the manufacturing process of the resin molded product 47 is the same as in the first to third embodiments. However, in the case of using the transfer sheet 51 including the design layer, when the resin molded product 47 is manufactured in the same process as in the first to third embodiments, the light irradiated from the transparent mold 43 side in the photocuring process is generated. Further, it is shielded or captured by the design layer of the transfer sheet 51 interposed between the transparent mold 43 and the photocurable resin 46, and it is difficult to reach the photocurable resin 46. For this reason, the inconvenience which cannot harden the photocurable resin 46 favorably arises. In order to avoid such inconvenience, a delayed photocurable resin 75 is used in place of the photocurable resin 46. Moreover, the manufacturing process of the resin molded product 47 is significantly different from that of the first to third embodiments.

  As shown in FIG. 15, the transfer sheet 51 is configured by forming a transfer layer 77, which is transferred to the translucent resin portion 22 at the same time as injection molding, on a base sheet 71. The transfer layer 77 is a hard coat layer 73 that constitutes the outer surface of the resin molded product 47 and protects the inner layer, the pattern layer 74 on which a pattern, a feed direction mark, and a width direction mark are expressed, and the translucent resin portion 22. And an adhesive layer 76 for improving the adhesion between the transfer layer 77 and the transfer layer 77. Furthermore, an anchor layer or the like may be added to the transfer layer 77 in order to protect the pattern layer 74 or improve interlayer adhesion. In order to improve the peelability of the transfer layer 77 from the base sheet 71, it is preferable to form a release layer 72 between the base sheet 71 and the transfer layer 77. The release layer 72 is a layer that remains on the base sheet 71 even after the transfer layer 77 is transferred. The essential layers of the transfer layer 77 are the design layer 74 and the adhesive layer 76, and other layers may be omitted.

  The base sheet 71 is made of a material such as a resin sheet such as polyethylene terephthalate (PET), polypropylene (PP), or acrylic, a metal foil, a glassine paper, a coated paper, or a cellulosic sheet such as cellophane.

  For the hard coat layer 73, a copolymer such as an acrylic (PMMA) resin, a polyester resin, or a vinyl chloride-vinyl acetate copolymer resin is used. In order to increase the hardness of the hard coat layer 73 and improve the scratch resistance of the resin molded product 47, an ultraviolet curable resin, an electron beam curable resin, or the like is used. The hard coat layer 73 is formed on the base sheet 71 by a gravure printing method, a screen printing method, an offset printing method, or the like.

  The design layer 74 is formed of a colored ink containing a resin and a coloring material such as a pigment or a dye. Resins used as binders include polyvinyl resins, polyamide (PA) resins, polyester resins, PMMA resins, polyurethane resins, polyvinyl acetal resins, polyester urethane resins, cellulose ester resins, alkyd resins, etc. is there. The pattern layer 74 is formed on the hard coat layer 73 by a gravure printing method, a screen printing method, an offset printing method, or the like. When it is desired to express metallic luster as a pattern, the pattern layer 74 is constituted by a metal thin film layer formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method or the like. The symbol layer 74 is set entirely or partially depending on the symbol to be expressed. “Sheet” includes “film”. A melamine resin or the like is used for the release layer 72. For the adhesive layer 76, a heat-sensitive or pressure-sensitive resin suitable for the material of the translucent resin portion 22, for example, a PMMA resin is used if the translucent resin portion 22 is a PMMA resin. A thermosetting urethane resin or the like is used for the anchor layer. The release layer 72, the adhesive layer 76, and the anchor layer are printed by a gravure printing method, a screen printing method, or the like.

(Resin mounting process)
As shown in FIG. 16, the base material 23 is disposed on the support base 41, and the delay type photocurable resin 75 is injected into the stepped portion 35 on the upper surface 32 of the base material 23 by the dispenser 42.

  Ordinary photo-curable resins are cured immediately upon irradiation with light. In contrast, when the delayed photocurable resin 75 is irradiated with light, it does not cure until a certain time (reaction delay time) has elapsed. After a certain period of time, the curing of the delayed photocurable resin 75 proceeds.

  As an example of the delayed photocurable resin 75, a cationic curable resin in which a photocationic polymerization initiator is blended with an epoxy resin or an oxetane resin, and a Si-O such as an alkoxysilane, a siloxane, or a silanol as a reaction retarder. The thing which mix | blended the compound which has (sigma) bond is mentioned. The compound having a σ bond of Si—O reacts preferentially with the cation-growing species generated when the photocationic polymerization initiator is irradiated with light. For this reason, hardening of the epoxy resin and the oxetane resin by the cation-growing species can be delayed for a certain time.

(Photocuring process)
As shown in FIG. 16, the UV lamp 45 irradiates light obliquely downward. The light passes through the transparent mold 43 and the transparent mold support portion 48 and is applied to the delayed photocurable resin 75. At this time, the curing of the delayed photocurable resin 75 has not progressed.

(Transfer sheet placement process)
As shown in FIG. 17, the transfer sheet 51 is arranged so that the base sheet 71 is in contact with the lower surface 43a of the transparent mold 43 and a part of the curved surface portion 43c.

(Mold placement process)
As shown in FIG. 18, the transparent mold support 48 is moved downward by the actuator, and the transparent mold 43 is placed on the stepped portion 35 of the base material 23 and the delay type photocurable resin 75 while maintaining the horizontal state. To do. The injected delay type photocurable resin 75 overflows between the transfer sheet 51 and the base material 23 from the gap 44 while being filled in the gap 44.

  A part of the excess delay type photocurable resin 75 that overflows is blocked by the inclined portion 34 of the base material 23, and the remaining delay type photocurable resin 75 passes over the inclined portion 34 of the base material 23 and is based on it. The peripheral end surface 31 of the material 23 is suspended. The delayed type photocurable resin 75 that is suspended is held by the overhang portion 24 provided at the center of the peripheral end surface 31 of the substrate 23.

  In addition, it is preferable to mount the transparent mold | type 43 after a fixed time passes after irradiating light. Even if the transparent mold 43 is to be placed after a certain period of time, since the curing of the delayed photocurable resin 75 has already progressed, it becomes difficult to mold the delayed photocurable resin 75 into a desired shape. Because.

  When a predetermined time elapses after the light irradiation, the delayed photocurable resin 75 is completely cured and the adhesive layer 76 is bonded to the delayed photocurable resin portion 75.

  The adhesive layer 76 of the transfer sheet 51 faces the base material 23 side (lower side). As a result, the transfer layer 77 and the delayed photocurable resin portion 75 are firmly bonded by the adhesive layer 76.

(Transfer process)
As shown in FIG. 19, after a predetermined time has elapsed, the transparent mold support portion 48 is moved upward by the actuator, and the transparent mold 43 is removed from the base material 23 and the delay type photocurable resin portion 75. At this time, the transfer layer 77 is peeled off from the transfer sheet 51 and transferred to the upper surfaces of the base material 23 and the delayed photocurable resin portion 75.

  Therefore, it is easy to remove the transparent mold 43 from the delay type photocurable resin portion 75, and the trouble of cleaning the transparent mold 43 can be saved. In addition, the design layer 74 can be transferred to the upper surface of the base material 23 and the delay type photocurable resin portion 75 to give a predetermined decoration. In addition, it is possible to prevent the surface from being scratched by forming the hard coat layer 73 on the upper surface of the base material 23 and the delay type photocurable resin portion 75.

[Fifth Embodiment]
20 to 22 show a fifth embodiment according to the present invention. This embodiment is different from the first to third embodiments in the configuration of the base material 23, the posture of the transparent mold 43 when the transparent mold 43 is placed, and the like. Therefore, only a configuration different from the configurations of the first to third embodiments will be described, and the description of the same configuration will be omitted.

(Base material)
In the first to third embodiments, left and right step portions 35 are formed on the flat surface portion 33 of the base material 23. On the other hand, in this embodiment, as shown in FIGS. 20 to 22, one step portion 62 is formed on the flat portion 61 of the base material 23.

  The planar portion 61 of the base member 23 includes a front portion (not shown) formed between the staircase portion 62 and the front portion (not shown) of the inclined portion 34, and a rear portion of the staircase portion 62 and the inclined portion 34. A rear side portion (not shown) formed between (not shown), a left side portion 61a formed between the staircase portion 62 and the left side portion 34c of the inclined portion 34, and the staircase portion 62 and the inclined portion 34. Right side portion 61b formed between the right side portion 34d and the right side portion 34d.

  The stepped portion 62 is configured in a stepped shape such that two stepped portions 62 a and 62 b along the long side direction are arranged in the short side direction and become higher toward the right side portion 61 b of the flat surface portion 61.

(Transparent and transparent support parts)
In the first to third embodiments, a transparent support 48 having translucency is fixed to the upper surface 43 d of the transparent mold 43. On the other hand, in this embodiment, as shown in FIGS. 20 to 22, rods 58 are erected on the left and right sides of the upper surface 43 d of the transparent mold 43, respectively. The rods 58 are inserted through the through holes 48a of the transparent support portions 48, respectively. A compression spring 59 is provided between the upper surface 43 d of the transparent mold 43 and the lower surface 48 b of the transparent mold support 48 so as to wind the outside of the rod 59. A locking member 60 that protrudes radially outward from the rod 59 and locks the upper surface 48 c of the transparent support 48 is provided. As a result, when the transparent mold 43 is not in contact with the base material 23, the inclined state is maintained in the lower left direction. When the transparent mold 43 is in contact with the base material 23, the posture is changed from the inclined state to the horizontal state. It is configured.

(Resin placement process)
As shown in FIG. 20, the base material 23 is placed on the support base 41, and a photocurable resin is injected into the stepped portion 62 of the base material 23 by the dispenser 42. At this time, the top of the photocurable resin in the upward convex state is positioned slightly to the left of the center of the staircase 62.

(Mold placement process)
As shown in FIG. 21, the transparent support 48 is moved downward by the actuator. At this time, the transparent mold 43 maintains a left-downward inclined state. The left end of the lower surface 43 a of the transparent mold 43 abuts on the left side portion 61 a of the flat portion 61. At this time, the injected photo-curing resin is first in the groove portion 63 (the deepest portion of the step portion 35) between the left portion 61a of the flat portion 61 of the base member 23 and the step portion 62b on the left side of the step portion 35. While being filled, a part of the fluid flows to the left side from the groove part 63 and overflows between the transparent mold 43 and the left side part 34 c of the inclined part 34 of the base material 23. A part of the excess photocurable resin overflowing to the left side is blocked by the left side portion 34c of the inclined portion 34 of the base material 23, and the remaining photocurable resin is left side portion 34c of the inclined portion 34 of the base material 23. The peripheral end surface 31 of the base material 23 is suspended over the distance. The suspended photocurable resin is held by the left side portion 24 c of the overhang portion 24 provided at the central portion of the peripheral end surface 31 of the base material 23.

  At the same time, the remaining photocurable resin flows to the right side from the groove 63 and overflows between the transparent mold 43 and the right side portion 34 d of the inclined portion 34 of the base material 23. A part of the excess photocurable resin overflowing to the right side is blocked by the right side portion 34d of the inclined portion 34 of the base material 23, and the remaining photocurable resin is left sided 34d of the inclined portion 34 of the base material 23. The peripheral end surface 31 of the base material 23 is suspended over the distance. The suspended photocurable resin is held by the right side portion 24 d of the overhang portion 24 provided at the central portion of the peripheral end surface 31 of the base material 23.

  As shown in FIG. 22, when the transparent mold support 48 is further moved downward by the actuator, the transparent mold 43 changes its posture from the lower left inclined state to the horizontal state, and the right end of the lower surface 43 a of the transparent mold 43 is flat. The right side part 61b of this is contacted. At this time, the groove 63 is already filled. Furthermore, since the left end of the lower surface 43a of the transparent mold 43 is in contact with the left portion 61a of the flat surface portion 61, the overflowing photocurable resin hardly flows from the groove portion 63 to the left side. In addition, the right side portion 34d of the inclined portion 34 of the base material 23 has little remaining capacity to dam up the overflowing photocurable resin. For this reason, almost all of the overflowing excess photocurable resin hangs down the peripheral end surface 31 of the substrate 23 beyond the right side portion 34 d of the inclined portion 34 of the substrate 23. The suspended photocurable resin is held by the right side portion 24 d of the overhang portion 24 provided at the central portion of the peripheral end surface 31 of the base material 23. In this way, the injected photocurable resin is filled in the gap 44 surrounded by the stepped portion 62 and the lower surface 43 a of the transparent mold 43.

  Thus, in the case of the staircase portion 62 whose depth becomes deeper toward the other side, a photocurable resin is injected into the other side of the staircase portion 62, and the transparent mold 43 with the other side inclined downward is mounted. Then, the photocurable resin is caused to flow from a deep hole to a shallow hole. Thereby, even if it is the step part 62 whose depth of a hole becomes deep as it goes to the other side, it can be filled favorably.

  The amount of the photocurable resin held by the left side portion 24c of the overhang portion 24 is smaller than the amount of the photocurable resin held by the right side portion 24d of the overhang portion 24. Therefore, the protrusion amount of the left side portion 24c of the overhang portion 24 can be reduced. Further, by adjusting the amount of the photocurable resin to be injected, the inclination angle of the transparent mold 43, and the like, the photocuring that hangs down the peripheral end surface 31 of the base material 23 beyond the left side portion 34c of the inclined portion 34 of the base material 23. The conductive resin can be eliminated, and the left side portion 24c of the overhang portion 24 can be eliminated.

(Photocuring process)
As shown in FIG. 22, the UV lamp 45 irradiates light obliquely downward. The light passes through the transparent mold 43 and the transparent mold support portion 48 and is applied to the photocurable resin to cure the photocurable resin.

(Substrate removal process)
The transparent mold support part 48 is moved upward by the actuator, and the transparent mold 43 is removed from the base material 23 and the photocurable resin part 46. Cut along the groove 37 of the substrate 23 to obtain a resin molded product 47.
[Another embodiment]

(1) In the second embodiment, the configuration in which the release sheet 51 is made of a fluororesin is exemplified. However, it is not restricted to this, The release sheet 51 should just be a material which has the characteristic that photocurable resin does not adhere.

(2) In each of the above-described embodiments, the configuration in which light passes through the transparent mold 43 and the transparent mold support portion 48 and is irradiated to the photocurable resin 46 to cure the photocurable resin 46 is exemplified. However, the light may pass through the base material 23 and irradiate the photocurable resin 46 to cure the photocurable resin 46. At this time, the base material 23 needs to be made of a material that transmits light.

  Further, in the fourth embodiment, light may be applied to the delay type photocurable resin 75 without passing through the transparent mold 43 and the transparent mold support portion 48. Specifically, the transparent mold 43 and the transparent mold support portion 48 are retracted from above the base material 23, and light is directly applied to the delayed photocurable resin 75, and then the transparent mold 43 and the transparent mold support section 48. May be moved above the substrate 23. At this time, instead of the transparent mold 43, a mold having no translucency, such as a metal mold, can be used.

(3) In each of the above embodiments, the configuration in which the translucent material is quartz glass is exemplified. However, it is not limited to this. For example, the translucent material may be ultraviolet transmissive glass, ultraviolet transmissive plastic, CaF ₂ single crystal, or the like.

(4) In each of the above embodiments, as the base material 23, the configuration in which the decorative sheet 21 is bonded to the upper surface of the translucent resin portion 22 is exemplified. A film may be adhered.

(5) In the above embodiments, the configuration in which the photocurable resin is a UV (ultraviolet) curable resin is exemplified. However, it is not limited to this. For example, the curable resin may be a VL (visible light) curable resin.

  The present invention can be applied to various resin molded products in which a decorative portion capable of visually recognizing a pattern is provided on the back surface of the translucent resin portion.

DESCRIPTION OF SYMBOLS 1 1st type 2 2nd type 3 Cavity 21 Decorating sheet, transfer sheet 22 Translucent resin, translucent resin part 32 Exposed surface 36 of decorated sheet Exposed surface 23 Base material 24 Overhang part 31 Peripheral part 43 Transparent Mold 44 composed of a light-sensitive material 51 Gap 51 Release sheet 73 Pattern layer 75 Delay type translucent resin, delay type translucent resin portion

Claims (4)

Translucent by injecting a translucent resin into a cavity formed between the decorative sheet and the first mold and holding the decorative sheet between the first mold and the second mold, and then curing. A distance between the exposed surface of the resin portion and the decorative sheet has a predetermined value for each part, and a base material provided with a protruding portion of the decorative sheet on at least a part of the peripheral portion is obtained. Substrate forming step;
A resin placing step of placing a photocurable resin on the exposed surface of the decorative sheet of the substrate;
A mold composed of a translucent material is placed on the base material and the photocurable resin, and the photocurable resin is filled in a gap formed by contact between the mold and the base material. A mold placing step for holding the excess photocurable resin overflowing around the mold by the overhanging portion;
A photocuring step of irradiating the photocurable resin with light through either the mold or the translucent resin portion;
A method for producing a resin molded product having   The manufacturing method of the resin molded product of Claim 1 which forms the surface which opposes the said base material among the surfaces of the said mold | die in a plane.   The method for producing a resin molded product according to claim 1 or 2, wherein, in the mold placing step, a release sheet to which the photocurable resin does not adhere is provided on a surface of the mold that faces the substrate. Translucent by injecting a translucent resin into a cavity formed between the decorative sheet and the first mold and holding the decorative sheet between the first mold and the second mold, and then curing. A distance between the exposed surface of the resin portion and the decorative sheet has a predetermined value for each part, and a base material provided with a protruding portion of the decorative sheet on at least a part of the peripheral portion is obtained. Substrate forming step;
A resin placing step of placing a delayed photocurable resin on the exposed surface of the decorative sheet of the substrate;
A photocuring step of irradiating the delayed photocurable resin with light;
The surface which faces the said base material among the surfaces of the said mold, arrange | positions a type | mold above the said delay type photocurable resin, makes this type | mold and the exposed surface of the decorating sheet | seat of the said base material oppose A transfer sheet disposing step of disposing a transfer sheet including a pattern layer on the sheet;
The mold is placed over the base material and the delay type photocurable resin, and the delay type photocurable resin is filled in a gap formed between the transfer sheet and the base material, and A mold placing step for holding the excess of the delayed type photocurable resin overflowing around the mold by the overhanging portion;
The mold is removed from the base material and the delay type photocurable resin portion, and the design layer is peeled from the transfer sheet, and the design layer is at least one of the base material and the delay type photocurable resin portion. A transfer process to be transferred to one upper surface;
A method for producing a resin molded product having

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