JP2017213758A - Manufacturing method of resin molded article and mold - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a resin molded article capable of adhering a hard coat treated protective film at same time with injection molding along a base of the resin molded article and a standing wall which stands from the base and a mold suitable for the manufacturing method.SOLUTION: A flat protective film 15 having surface hardness of 3H or more as a pencil hardness by a hart coat treatment is arranged in a first mold 51 having a base formation face 58 corresponding to an outer face of the base of a resin molded article and a standing molding face corresponding to an outer face of a standing wall. A protective film 15 is pressed at both sides on an extended line of a Y direction of the standing wall formation face by a first one projection 61 and a second one projection 62 of a second mold 52 corresponding to the first mold 51, the base formation face 58 and the standing wall formation face are extended along the protective film 15 and the first mold 51 and the second mold 52 are closed.SELECTED DRAWING: Figure 18

Description

  The present invention relates to a method for producing a resin molded product molded by injection molding and a mold.

Conventionally, for example, as described in Patent Document 1 (Japanese Patent Application Laid-Open No. 2003-211487), a decorative film is disposed in a mold before injection molding, and the decorative film is simultaneously formed with injection molding. There is known a simultaneous molding decoration method in which the front and back surfaces of a molded product are adhered.
The decorative film used in such a simultaneous molding method is relatively soft and easily softened by heating, so it is relatively easy to conform to the shape of the mold cavity. Yes.
However, a hard coat layer can be formed on the surface of the molded product simultaneously with molding using the same production method as the molding simultaneous decoration method described above, but because a protective film with a hard coat layer is used, The place which can adhere a protective film will be restricted to the surface and back surface of a comparatively flat resin molded product.

JP 2003-211487 A

By the way, if the place where the protective film on which the hard coat layer is formed can be bonded is limited to the flat surface or the flat back surface of the resin molded product, the use of the resin molded product is limited, and a method for producing such a resin molded product The number of products that can be applied decreases. Therefore, for example, even if a protective film including a hard coat layer is adsorbed with air and is to be applied from the surface to the side surface, a gap is formed between the mold and the protective film due to the high rigidity of the protective film. If injection molding is performed with a gap left, resin enters the gap and becomes a defective product, or cracks in the hard coat layer result in a defective product.
In order to prevent such a problem, it may be possible to preform the protective film in advance according to the shape of the cavity of the mold. However, it takes time to preform the protective film, and the manufacturing cost of the resin molded product increases by increasing the number of manufacturing steps.

  The subject of this invention is providing the manufacturing method of the resin molded product which can adhere | attach the protective film by which the hard coat process was carried out along injection molding along the standing wall rising from the base and the base of a resin molded product. is there. Moreover, it is providing the metal mold | die suitable for such a manufacturing method.

Hereinafter, a plurality of modes will be described as means for solving the problems. These aspects can be arbitrarily combined as necessary.
A method of manufacturing a resin molded product according to an aspect of the present invention is a method of manufacturing a resin molded product having a standing wall that rises from a base having a two-dimensional extension and extends in a predetermined direction. A flat protective film having a surface hardness of 3H or more in terms of pencil hardness by hard coating treatment on a first mold having a base forming surface corresponding to the outer surface of the base and a standing wall molding surface corresponding to the outer surface of the standing wall to form The base film forming surface and the standing wall formation by pressing the protective film on both sides of the extending line in the predetermined direction of the standing wall molding surface by the first protrusion and the second protrusion of the second mold corresponding to the first mold. A step of closing the first mold and the second mold along the protective film on the surface, injecting a molten resin between the protective film and the second mold, and forming the standing wall and the base portion of the protective film with the molten resin Stand against the forming surface And a step of injection molding the protective film is pasted resin molded article from the outer surface of the wall toward the outer surface of the base.
According to such a method for producing a resin molded product, it is possible to apply a bending force to the protective film by the first protrusion and the second protrusion of the second mold from both sides on the extended line of the standing wall forming surface. The protective film can be bent by transmitting the force for bending the protective film generated by the protrusion and the second protrusion to the first protrusion and the second protrusion. As a result, it is difficult for stress concentration to occur on the protective film on the surface where the standing wall is formed, and it is difficult to generate cracks on the protective film that has been hard-coated, and at the same time, the molten resin does not wrap around the protective film The gap between the protective film and the standing wall forming surface can be reduced.

In the above method for producing a resin molded article, the standing wall has a depth of 1 mm or more and 4 mm or less, and an angle formed with a straight line perpendicular to the plane when the base is placed on the plane is 0 degree or more and 45 degrees or less. Yes, the radius of curvature of the round shape at the boundary between the standing wall and the base may be not less than 0.5 mm and not more than 4 mm. When the shape of the standing wall is such a shape, the protective film can be adhered with good yield along the standing wall.
The protective film used in the method for producing a resin molded product described above has a resin base layer and a hard coat layer, and the resin base layer has a heat deformation temperature of 120 ° C. or higher by the ASTM-D648 method (1.82 MPa). It may include a thermoplastic resin layer. By using such a protective film, a protective layer excellent in heat resistance and durability can be formed from the base of the resin molded product to the standing wall.
As for the protective film used for the manufacturing method of the above-mentioned resin molded product, a resin base material layer may contain a polycarbonate-type resin base material layer and an acrylic resin base material layer. When the resin base material layer includes a polycarbonate resin base material layer and an acrylic resin base material layer, a protective layer excellent in thermoformability, transparency, and impact resistance can be formed.
In the above-described method for producing a resin molded product, the standing wall forming surface includes one standing wall forming surface and the other standing wall forming surface facing each other, and the first protrusion is disposed on the one standing wall forming surface. A first protrusion and a first other protrusion disposed with respect to the other standing wall forming surface, and a second protrusion with respect to the second one protrusion and the other standing wall forming surface disposed with respect to the one standing wall forming surface; In the step of forming the resin molded product including the second other protrusions arranged in a manner, the molten resin is formed between the protective film and the second mold from the gate formed between the first one protrusion and the first other protrusion. May be configured to inject.

A mold according to an aspect of the present invention has a standing wall that rises from a base having a two-dimensional extension and extends in a predetermined direction, and has a pencil hardness of 3H or more by hard coat treatment from the outer surface of the base to the outer surface of the standing wall. A mold for producing a resin molded product in which a flat protective film having a surface hardness of is bonded together with injection molding, and a base corresponding to the outer surface of the base to form the outer surface of the resin molded product A first mold having a standing wall molding surface corresponding to the outer surface of the forming surface and the standing wall, and a standing film for placing the protective film on the base forming surface and the standing wall forming surface when clamped to the first mold. A first projection and a second die having a second projection are provided so that the protective film can be pressed on both sides of an extension line in a predetermined direction of the wall molding surface.
According to such a mold, when the first mold and the second mold are clamped, the bending force is applied to the protective film by the second mold first protrusion and the second protrusion from both sides on the extension line of the standing wall forming surface. Accordingly, the protective film generated by the first protrusion and the second protrusion can be transmitted between the first protrusion and the second protrusion to bend the protective film. As a result, it is difficult for stress concentration to occur on the protective film on the surface where the standing wall is formed, and it is difficult to generate cracks on the protective film that has been hard-coated, and at the same time, the molten resin does not wrap around the protective film. The gap between the protective film and the standing wall forming surface can be reduced.
In the above-described mold, the second mold may be configured such that at least one of the first protrusion and the second protrusion is disposed at a position straddling the edge of the protective film. By straddling the edge of the protective film with the first protrusion or the second protrusion, the edge of the protective film is pressed, and the molten resin can be prevented from flowing from the periphery of the edge to the back side of the protective film.
In the above-described mold, the first mold may have the holes for sucking the protective film arranged side by side only along a predetermined direction in which the standing wall forming surface extends around the base forming surface. By being arranged in this way, when the protective film is pressed by the first protrusion and the second protrusion, it becomes difficult for wrinkles to enter, and the molten resin does not easily flow around the back side of the protective film.

  According to the method for producing a resin molded product of the present invention, the hard coat-treated protective film can be well bonded simultaneously with the injection molding along the base portion of the resin molded product and the standing wall rising from the base portion. Moreover, according to the metal mold | die of this invention, the above-mentioned resin molded product can be manufactured favorably.

The fragmentary sectional view which shows the part of the standing wall of the resin molded product which concerns on embodiment. The perspective view which shows the external appearance of gate resin and a resin molding. The partial expansion perspective view which notched and expanded some resin moldings of FIG. The partial front view which shows the external appearance of a part of gate resin and a resin molding. The partial side view which shows the external appearance of a part of gate resin and a resin molding. The perspective view which shows the protective film and resin molding on a metal mold | die. The top view which shows the protective film and resin molding on a metal mold | die. The top view which shows the structure of the principal part of a 1st type | mold. The top view which shows the structure of the principal part of a 2nd type | mold. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold along the II line | wire shown by FIG.8 and FIG.9 in the state which mounted the protective film. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold along the II line | wire shown by FIG.8 and FIG.9 in the state which attracted | sucked the protective film. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold which were clamped along the II line | wire shown by FIG.8 and FIG.9. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold along the II-II line shown by FIG.8 and FIG.9 in the state which mounted the protective film. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold along the II-II line shown by FIG.8 and FIG.9 in the state which attracted | sucked the protective film. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold which were clamped along the II-II line | wire shown by FIG.8 and FIG.9. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold along the III-III line | wire shown by FIG.8 and FIG.9 in the state which mounted the protective film. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold along the III-III line | wire shown by FIG.8 and FIG.9 in the state which attracted | sucked the protective film. Sectional drawing which cut | disconnected the 1st type | mold and 2nd type | mold which were clamped along the III-III line | wire shown by FIG.8 and FIG.9. The fragmentary sectional view of the 1st type and the 2nd type concerning a modification. The fragmentary sectional view which shows the part of the standing wall of the resin molded product which concerns on a modification.

The manufacturing method of the resin molded product which concerns on one Embodiment of this invention is demonstrated using drawing. First, the resin molded product manufactured by the manufacturing method of this invention is demonstrated.
(1) Outline of Resin Molded Product FIG. 1 shows a part of the cross-sectional shape of the resin molded product 10. A resin molded product 10 shown in FIG. 1 is, for example, an upper lid of a case. For example, a touch screen is accommodated in a case configured using the resin molded product 10. As described above, when the touch screen is accommodated inside the case, the resin molded product 10 is mainly formed of a transparent resin or a translucent resin.
As shown in FIG. 1, the resin molded product 10 includes a resin molded body 11 and a protective film 15. The protective film 15 is formed on the outer surface of the resin molded product 10 and plays a role of preventing the outer surface of the resin molded product 10 from being damaged. In the resin molded product 10, the side where the protective film 15 is not attached is the inner surface.
The inner surface 22 and the protective film 15 of the resin molded product 10 may be decorated.
The protective film 15 is a film subjected to a hard coat process. A hard coat layer 17 is formed on the outer surface of the protective film 15, and a resin base material layer 16 is formed on the inner surface of the protective film 15.

The resin molded product 10 includes a base portion 20 and a standing wall 30. In FIG. 1, the directions indicated by the arrows are the X direction and the Z-axis direction, and the direction perpendicular to the paper surface of FIG. 1 is the Y direction. The base 20 extends two-dimensionally along the XY plane. The standing wall 30 extends in the Y direction. When such a base 20 is placed on the XY plane, the angle α formed by the vertical wall (here, the Z axis) of the standing wall 30 is, for example, 20 degrees. The angle of the standing wall 30 can be measured by using a substantially straight portion 26 up to the round shape 25 and the Z axis. Further, the depth D of the standing wall 30 is a distance from the end portion 31 of the standing wall 30 to the outer surface 21 of the base portion 20. The depth D of the standing wall 30 is, for example, 2.0 mm. A round shape 25 is formed at the boundary between the standing wall 30 and the base 20. The radius of curvature of the round shape 25 in the XZ plane is 2.0 mm.
In the manufacturing method of the resin molded product 10 to be described later, in order to adhere the protective film 15 to the standing wall 30 cleanly and adhere with good yield, the angle α formed by the standing wall 30 and the Z axis is −20 degrees or more and 45 degrees. It is preferable to be within the following range. That the formed angle α is smaller than 0 degrees means that it has an undercut shape. Moreover, it is preferable that the depth D exists in the range of 1 mm or more and 4 mm or less. Further, the radius of curvature of the round shape 25 in the XZ plane is preferably set within a range of 0.5 mm or more and 4 mm or less.

(2) Resin molding 11, gate resin 91, and tab resin 92
2 to 5 show the resin molded body 11, the gate resin 91, and the tab resin 92. FIG. 2 shows a state in which the resin molded body 11, the gate resin 91, and the tab resin 92 are viewed from an oblique direction. FIG. 3 shows an enlarged view of the partially molded resin molded body 11, the gate resin 91, and the tab resin 92 as viewed from an oblique direction. FIG. 4 shows a state in which the periphery of the rising portion 13a of the resin molded body 11 is enlarged and viewed from the front. FIG. 5 shows a state in which the resin molded body 11, the gate resin 91, and the tab resin 92 partially broken are viewed from the side.
The resin molded body 11 is a portion obtained by removing the protective film 15 from the resin molded product 10. That is, the resin molded body 11 is a molded body formed by solidifying the molten resin at the time of injection molding. The resin molded body 11 includes a flat portion 12 and a rising portion 13. The rising portion 13 is a portion corresponding to the rising wall 30 and includes two one rising portions 13a and the other rising portion 13b facing each other.
At the time of injection molding, the molten resin is injected from the end 11a of the resin molded body 11 in the Y direction toward the end 11b of the resin molded body 11. A gate resin 91 is formed on the gate for injecting the molten resin. A tab resin 92 is formed to protrude the molded product. Therefore, the shape of the gate can be understood from the shapes of the gate resin 91 and the tab resin 92. The gate resin 91 and the tab resin 92 are cut to obtain the resin molded product 10 after the injection molding.

(3) Protective film 15
As illustrated in FIG. 1, the protective film 15 includes a hard coat layer 17 and a resin base material layer 16. The thickness of the protective film 15 is an appropriate thickness in the range of 50 μm to 500 μm, for example, according to the resin molded product 10. The hard coat layer 17 can be formed, for example, by treating the resin base material layer 16 with an active energy ray-curable resin composition. The hard coat layer 17 is formed of, for example, a urethane acrylate resin or a cyanoacrylate resin. The thickness of the hard coat layer 17 is adjusted to an appropriate thickness in the range of 0.5 μm to 30 μm, for example.
The resin base material layer 16 has a first thermoplastic resin layer having a heat deformation temperature of 120 ° C. or higher by the ASTM-D648 method (1.82 MPa), and a light transmittance higher than that of the first thermoplastic resin layer. A second thermoplastic resin layer that is high and has high adhesive strength with the resin molded body 11 is laminated and formed. Moreover, it is preferable that the heat deformation temperature of the first thermoplastic resin layer is higher than the heat deformation temperature of the second thermoplastic resin layer. In this case, the first thermoplastic resin layer is disposed under the hard coat layer 17, and the surface opposite to the hard coat layer 17 and bonded to the resin molded body 11 is the second thermoplastic resin. Formed in layers. The first thermoplastic resin layer is made of, for example, a polycarbonate resin, and the second thermoplastic resin layer is made of, for example, an acrylic resin.

(4) Positional relationship between the protective film 15 and the resin molded body 11 on the mold FIG. 6 shows a part of the second mold 52 of the mold, the protective film 15, the resin molded product 10, the gate resin 91, and the tab resin. A state in which 92 is viewed from an oblique direction is shown. FIG. 7 shows a state in which a part of the second mold 52, the protective film 15, the resin molded product 10, the gate resin 91, and the tab resin 92 are viewed in plan. The state in plan view here is a state in which the second mold 52 is viewed from the Z direction.
The state shown in FIGS. 6 and 7 is, for example, from the second mold 52 when the mold opening is performed after the injection molding is finished, the protective film 15, the resin molded product 10, the gate resin 91, and the tab resin. In this state, 92 has not been taken out yet. The excess protective film 15, the gate resin 91, and the tab resin 92 are cut from the state shown in FIGS. 6 and 7 to obtain the resin molded product 10 as a finished product.
The protective film 15 is arranged so as to protrude largely to the outside of the resin molded product 10 on both sides in the X direction, and is arranged to a little outside of the resin molded product 10 on both sides in the Y direction.
The first one protrusion 61 and the second one protrusion 62 shown in FIGS. 6 and 7 are provided corresponding to the one standing wall 30a, and the first other protrusion 63 and the second other protrusion 64 are the other standing wall. 30b is provided. The first one protrusion 61, the second one protrusion 62, the first other protrusion 63, and the second other protrusion 64 are disposed directly under the protective film 15, as shown in FIGS.

Further, it can be seen from FIGS. 6 and 7 that the first first protrusion 61 and the first other protrusion 63 are arranged at both ends in the X direction of the gate resin 91. In other words, the first one protrusion 61 and the first other protrusion 63 are disposed at both ends in the X direction of the gate 53 (see FIGS. 8 and 9). Note that the gate 53 includes a gate forming surface 53a (see FIG. 8) of the first mold 51 and the second mold 51 when the first mold 51 (see FIG. 8) and the second mold 52 (see FIG. 9) are clamped. It is formed between the gate forming surface 53b of the mold 52 (see FIG. 9). More specifically, the first one protrusion 61 and the first other protrusion 63 are formed at both ends in the X direction of the gate forming surface 53 b of the second mold 52. The first one protrusion 61 and the first other protrusion 63 are arranged so as to straddle the end side 15 a of the protective film 15. Thus, by disposing the first one protrusion 61 and the first other protrusion 63 at both ends of the gate forming surface 53b, the molten resin is prevented from flowing around the back side of the protective film 15 through the gap of the protective film 15. be able to.
Further, it can be seen from FIGS. 6 and 7 that the second first protrusion 62 and the second other protrusion 64 are disposed at both ends of the tab resin 92 in the X direction. In other words, the second first protrusion 62 and the second other protrusion 64 are disposed at both ends in the X direction of the tab 54 (see FIGS. 8 and 9). The tab 54 has a tab forming surface 54a (see FIG. 8) of the first mold 51 and the second mold 51 when the first mold 51 (see FIG. 8) and the second mold 52 (see FIG. 9) are clamped. It is formed between the tab forming surface 54b (see FIG. 9) of the mold 52. More specifically, the second one protrusion 62 and the second other protrusion 64 are formed at both ends in the X direction of the tab forming surface 54 b of the second mold 52. The second one protrusion 62 and the second other protrusion 64 are arranged so as to straddle the end side 15 b of the protective film 15. Thus, by disposing the second first protrusion 62 and the second other protrusion 64 at both ends of the tab forming surface 54b, the molten resin is prevented from flowing around the back side of the protective film 15 through the gap of the protective film 15. be able to.
Further, as can be seen from the gate resin 91 in FIG. 5, the molten resin flow 93 has a Z-direction component that presses the protective film 15, so that it is difficult for the molten resin to rotate around the back side of the protective film 15. .

(5) Configuration of the first mold and the second mold FIG. 8 shows a part of the first mold 51 viewed from the Z direction, and FIG. 9 shows the Z direction (the direction opposite to FIG. 8). A portion of the viewed second mold 52 is shown.
The first mold 51 is provided with a recess 55 for forming the resin molded product 10 between the gate forming surface 53a and the tab forming surface 54a already described. One standing wall forming surface 56 and the other standing wall forming surface 57 extending in the Y direction are formed at both ends in the X direction of the recess 55. In the recess 55, a base forming surface 58 is two-dimensionally spread between the one standing wall forming surface 56 and the other standing wall forming surface 57.
Further, in order to suck the protective film 15 with air, the first mold 51 has five holes 66 arranged in the Y direction outside the recess 55 with the recess 55 interposed therebetween.
The second mold 52 is provided with a convex portion 59 for forming the resin molded product 10 between the gate forming surface 53b and the tab forming surface 54b. The first one protrusion 61, the second one protrusion 62, the first other protrusion 63, and the second other protrusion 64 which have already been described are arranged at the four corners of the convex portion 59.
When the first mold 51 and the second mold 52 are clamped, the first one protrusion 61 and the second one protrusion 62 are arranged on the extension line in the Y direction of the one standing wall forming surface 56, and the first other protrusion 63 and the second mold 52 are (2) The other projection 64 is disposed on an extension line in the Y direction of the other standing wall forming surface 57.
A decorative film 80 (see FIGS. 10 to 18) for simultaneously decorating the inside of the resin molded product 10 may be placed on the second mold 52. Therefore, the second mold 52 is provided with a hole 67 for sucking the decorative film 80 with air so as to surround the convex portion 59. The decorative film 80 is, for example, a transfer film that transfers the decorative layer to the resin molded body 11.

(6) Manufacture of Resin Molded Product 10 FIGS. 10 to 12 show the first mold 51 and the second mold 52 set in a molding machine (not shown) as shown in FIG. 8 and FIG. A cross section cut along the line I is schematically shown. 13 to 15 schematically show a cross section of the first mold 51 and the second mold 52 set in the molding machine, taken along the line II-II shown in FIGS. 8 and 9. ing. 16 to 18 schematically show cross sections of the first mold 51 and the second mold 52 set in the molding machine taken along the line III-III shown in FIGS. 8 and 9. It is shown. In FIGS. 10 to 18, the respective members are described in a deformed manner so that the respective members can be easily seen on the drawings.

(6-1) Arrangement of Protective Film 15 and Decorating Film 80 The steps of arranging the protective film 15 and the decorating film 80 are shown in FIGS. In this step, in order to form the outer surface of the resin molded product 10, as shown in FIGS. 10, 13, and 16, the base forming surface 58 with respect to the outer surface of the base 20 and the outer surface of the standing wall 30 are supported. The protective film 15 is disposed on the standing wall forming surface 56 and the other standing wall forming surface 57. In addition, the decorative film 80 is disposed so as to cover the convex portion 59 of the second mold 52.
11, 14, and 17 show a process of sucking the protective film 15 and the decorative film 80. Air is sucked from the holes 66 shown in FIG. 8, and the protective film 15 is adsorbed to the first mold 51. In addition, air is sucked from the holes 67 shown in FIG. 9, and the decorative film 80 is adsorbed to the second mold 52. Since the decorative film 80 is thin and has low rigidity, the decorative film 80 adheres along the convex portion 59 of the second mold 52 by being sucked. However, since the protective film 15 has high rigidity, it does not come into close contact with the one standing wall forming surface 56 and the other standing wall forming surface 57 of the first mold 51 even when sucked. However, the protective film 15 is positioned so as not to be sucked and moved to the surface of the first mold 51.

(6-2) Clamping of the first mold 51 and the second mold 52 FIGS. 12, 15 and 18 show a process in which the first mold 51 and the second mold 52 are closed and clamped. ing. When the first mold 51 and the second mold 52 are closed, the first one protrusion 61 and the second one protrusion 62 press the protective film 15 on both sides of the one standing wall forming surface 56 on the extension line in the Y direction. As shown in FIG. 15, the protective film 15 pressed by the first one protrusion 61 and the second one protrusion 62 is in close contact with the one standing wall forming surface 56 that does not face the protrusion.
Similarly, when the first mold 51 and the second mold 52 are closed, the first other protrusion 63 and the second other protrusion 64 are disposed on both sides of the other standing wall forming surface 57 on the extension line in the Y direction. suppress. As shown in FIG. 15, the protective film 15 pressed by the first other protrusion 63 and the second other protrusion 64 is in close contact with the other standing wall forming surface 57 that does not face the protrusion.
At this time, the first one protrusion 61 and the first other protrusion 63 are pressed so as to straddle the end side 15a of the protective film 15 (see FIG. 6). Moreover, the 2nd 1 processus | protrusion 62 and the 2nd other processus | protrusion 64 are pressing so that the edge 15b (refer FIG. 6) of the protective film 15 may be straddled.

(6-3) Injection Molding of Resin Molded Product 10 In the injection process, molten resin is injected between the protective film 15 and the second mold 52, more specifically, between the protective film 15 and the decorative film 80. . The molten resin enters the gate 53 and the cavity 70 shown in FIG. As the molten resin injected into the gate 53 and the cavity 70 is solidified, the resin molded body 11 shown in FIGS. 2 to 5 is formed.
(6-4) Removal of Resin Molded Product 10 After the injection molding, the first mold 51 and the second mold 52 are opened, and the resin molding with the gate resin 91, the tab resin 92, and the extra protective film 15 attached thereto. Product 10 is removed. The resin molded product 10 is obtained by cutting the gate resin 91, the tab resin 92 and the extra protective film 15 from the resin molded product 10 taken out.

(7) Modification (7-1)
In the above-described embodiment, the case where the angle α formed by the standing wall 30 and the straight line (here, the Z axis) is greater than 0 degrees has been described. However, as shown in FIGS. 19 and 20, even when the angle α formed is negative, that is, when the standing wall 30 and the first mold 51 and the second mold 52 are formed in the undercut shapes 35 and 75, Simultaneously with the injection molding, the protective film 15 can be bonded to the outer surface side of the resin molded body 11. FIG. 19 and FIG. 20 show an example where the angle α formed is −20 degrees and the length L entering inside due to the undercut shape is 0.3 mm. Even in the case of such an undercut shape, the protective film 15 can be formed using the first protrusion and the second protrusion, as in the above embodiment. In the case of an undercut shape, the length L is preferably greater than 0 and 1 mm or less.
(7-2)
In the above embodiment, the case where the one standing wall 30a and the other standing wall 30b extend in parallel has been described. However, the one standing wall 30a and the other standing wall 30b do not necessarily have to extend in parallel. For example, the one standing wall 30a may extend so as to be inclined with respect to the Y direction, and the other standing wall 30b may extend so as to be inclined at a different angle in the opposite direction. Moreover, although the said embodiment demonstrated the case where the standing wall 30 was extended linearly in the Y direction, it is not restricted to the case where it extends linearly.

(8) Features (8-1)
According to the method for manufacturing the resin molded product 10 described above, the first standing wall forming surface 56 (by the first one protrusion 61 and the second one protrusion 62 of the second mold 52 (example of the first protrusion and the second protrusion)) ( On the extension line of the example of the standing wall forming surface, a force for bending the protective film 15 from both sides of the one standing wall forming surface 56 can be applied. Similarly, on the extension line of the other standing wall forming surface 57 (an example of the standing wall forming surface) by the first other projection 63 and the second other projection 64 (an example of the first projection and the second projection) of the second mold 52. Moreover, the force which bends the protective film 15 from both sides of the other standing wall forming surface 57 can be applied.
Then, a bending force can be transmitted to the protective film 15 existing between the first one protrusion 61 and the second one protrusion 62, and as shown in FIG. 15, the first one protrusion 61 and the second one The protective film can be bent along the standing wall forming surface 56 where the protrusion 62 does not exist. Similarly, the bending force can be transmitted to the protective film 15 existing between the first other projection 63 and the second other projection 64, and as shown in FIG. The protective film can be bent along the other standing wall forming surface 57 where the other protrusion 64 does not exist.
As a result, it is possible to avoid stress concentration on the protective film 15 on the one standing wall forming surface 56, and it is possible to prevent occurrence of cracks in the hard-coated protective film 15. At the same time, the gap between the protective film 15 and the one standing wall forming surface 56 can be reduced to such an extent that the molten resin does not wrap around the back of the protective film 15 as shown in FIG. Similarly, stress concentration on the protective film 15 at the other standing wall forming surface 57 can be avoided, and cracks can be prevented from occurring in the hard-coated protective film 15. At the same time, the gap between the protective film 15 and the other standing wall forming surface 57 can be reduced to the extent that the molten resin does not wrap around the back of the protective film 15 as shown in FIG.

As described above, when the resin mold product 10 can be injection-molded using the first mold 51 having the one standing wall forming surface 56 and the other standing wall forming surface 57, the two one standing wall 30a and the other standing wall 30 are opposed to each other. Since the resin molded product 10 can be provided with the wall 30b, the resin molded product 10 can be commercialized as, for example, a lid such as a case, and the application is expanded.
The standing wall 30 has a depth of 1 mm or more and 4 mm or less as a shape, and an angle formed by a straight line perpendicular to the plane when the base is placed on the plane is 0 degree or more and 45 degrees or less, The radius of curvature of the round shape at the boundary between the standing wall and the base is limited to a range of 0.5 mm to 4 mm. When the shape of the standing wall 30 is such a shape, the protective film 15 can be adhered beautifully along the standing wall 30 with a good yield.

(8-2)
The protective film 15 has a polycarbonate resin layer having a heat distortion temperature of 120 ° C. or more on the resin base material layer 16 below the hard coat layer 17. Due to the presence of this polycarbonate resin layer, high heat resistance and durability can be imparted to the protective film 15 and thus to the outer surface of the standing wall 30. Further, since there is an acrylic resin layer at the interface with the resin molded body 11, the protective film 15 can be easily adhered to the resin molded body 11 by the acrylic resin layer having high transparency, and thermoformability, transparency, and resistance. Impact properties can be increased. Moreover, a protective film is good also as 2 types and 3 layers in order of an acrylic resin layer, a polycarbonate-type resin layer, and an acrylic resin layer from under a hard-coat layer. Surface hardness can be obtained more by the acrylic resin layer under the hard coat layer. A separation film may be bonded onto the hard coat layer.

DESCRIPTION OF SYMBOLS 10 Resin molded product 15 Protective film 17 Hard coat layer 16 Resin base material layer 20 Base 30 Standing wall 51 1st type | mold 52 2nd type | mold 56 One standing wall formation surface 57 The other standing wall formation surface 58 Base formation surface 61 1st one protrusion 62 Second one protrusion 63 First other protrusion 64 Second other protrusion

Claims (8)

A method for producing a resin molded article having a standing wall that rises from a base having a two-dimensional extension and extends in a predetermined direction,
In order to form the outer surface of the resin molded article, a first mold having a base forming surface corresponding to the outer surface of the base and a standing wall molding surface corresponding to the outer surface of the standing wall is 3H or more in pencil hardness by hard coat processing. Placing a flat protective film having a surface hardness of
Forming the base portion forming surface and the standing wall by pressing the protective film on both sides of the standing wall forming surface on the extension line in the predetermined direction by the first protrusion and the second protrusion of the second mold corresponding to the first mold A step of closing the first mold and the second mold along the surface with the protective film;
The molten resin is injected between the protective film and the second mold, and the protective film is pressed against the standing wall forming surface and the base forming surface by the molten resin, from the outer surface of the standing wall to the outer surface of the base. And a step of injection molding the resin molded product to which the protective film is attached. The standing wall has a depth of 1 mm or more and 4 mm or less, and an angle formed by a straight line perpendicular to the plane when the base is placed on a plane is -20 degrees or more and 45 degrees or less, The radius of curvature of the round shape at the boundary with the base is 0.5 mm or more and 4 mm or less,
The manufacturing method of the resin molded product of Claim 1. The protective film includes a resin base material layer and a hard coat layer, and the resin base material layer includes a thermoplastic resin layer having a heat deformation temperature of 120 ° C. or higher according to ASTM-D648 method (1.82 MPa).
The manufacturing method of the resin molded product of Claim 1 or 2. In the protective film, the resin base layer includes a polycarbonate resin base layer and an acrylic resin base layer.
The manufacturing method of the resin molded product as described in any one of Claim 1 to 3. The standing wall forming surface includes one standing wall forming surface and the other standing wall forming surface facing each other,
The first protrusion includes a first one protrusion disposed with respect to the one standing wall forming surface and a first other protrusion disposed with respect to the other standing wall forming surface,
The second protrusion includes a second one protrusion disposed with respect to the one standing wall forming surface and a second other protrusion disposed with respect to the other standing wall forming surface,
In the step of forming the resin molded product, molten resin is injected between the protective film and the second mold from the gate formed between the first one protrusion and the first other protrusion.
The manufacturing method of the resin molded product as described in any one of Claim 1 to 4. A flat protective film having a standing wall that rises from a base having a two-dimensional extension and extends in a predetermined direction, and has a surface hardness of 3H or more in pencil hardness by a hard coat process from the outer surface of the base to the outer surface of the standing wall Is a mold for producing a resin molded product that is attached at the same time as injection molding,
A first mold having a base forming surface corresponding to the outer surface of the base and a standing wall molding surface corresponding to the outer surface of the standing wall to form the outer surface of the resin molded product;
When the mold is clamped to the first mold, the protective film is formed on both sides of the standing wall forming surface on the extension line in the predetermined direction so that the protective film is aligned with the base forming surface and the standing wall forming surface. A mold comprising: a first projection provided so as to hold the second projection and a second mold having a second projection. The second mold is disposed at a position where at least one of the first protrusion and the second protrusion straddles the edge of the protective film.
The mold according to claim 6. In the first mold, the holes for sucking the protective film are arranged side by side only along a predetermined direction in which the standing wall forming surface extends around the base forming surface.
The mold according to claim 6 or 7.

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