JP2013256130A - Laminate manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate manufacturing method.SOLUTION: A laminate manufacturing method includes: a step of placing a film 15 having a size corresponding to a surface shape of a resin mold on a surface of a first mold formed with an uneven shape corresponding to a shape of the film 15, in accordance with the uneven shape; a step of forming a cavity between the first mold and a second mold by making the second mold facing the first mold abut on the first mold; a step of forming the resin mold corresponding to the shape of the cavity by injecting a resin solvent to the cavity; and a step of pasting the film 15 on the surface of the resin mold by heat of an injected resin solvent.

Description

  The present invention relates to a method for manufacturing a laminate, and more particularly to a technique for improving the design of the surface of the laminate.

  In a portable electronic device such as a mobile phone, in order to increase the added value, it is important to enhance the performance of the device itself and the design of the casing. A casing of a portable electronic device is generally made of a resin molded product formed by an injection molding technique, and the surface thereof is painted.

  In a portable electronic device, for example, there is a case where it is desired to decorate a surface of a housing with a three-dimensional pattern such as a cloth for the purpose of giving a soft texture to a user. In the manufacture of such a case, conventionally, a method of sticking the fabric directly on the surface of the resin molded product using an adhesive or the like, or the fabric is sandwiched in advance inside the cavity that is an injection molding space, the resin The method (insert molding) was integrally formed. However, in the methods using these actual fabrics, there is a problem that wrinkles occur in the fabric at the corners of the housing, and the uniformity of the appearance is impaired.

  On the other hand, Patent Document 1 proposes to perform insert molding using a film on which a fabric pattern is printed instead of an actual fabric.

JP 2002-293097 A

  In the method described in Patent Document 1, the fabric can be visually expressed by sticking a film on which the pattern of the fabric is printed on the surface of the resin molded body. Further, by using a flexible soft material for the film, generation of wrinkles at the corner portion of the housing can be suppressed. However, in order to further improve the design of the portable electronic device, it is desired to express the texture of the fabric more realistically by expressing the fabric not only in a plane but also in a three-dimensional manner.

  An object of this invention is to provide the manufacturing method of the laminated body which expressed the texture of the raw material more realistically, without using an actual raw material in view of the above.

In order to achieve the above object, a method for manufacturing a laminate according to the present invention is a method for manufacturing a laminate in which insert molding is performed using a film having a dimension corresponding to the surface shape of a resin molded product,
Placing a film having a dimension corresponding to the surface shape of the resin molded body on the surface of the first mold on which the uneven shape corresponding to the shape of the film is formed, according to the uneven shape;
Forming a cavity between the first mold and the second mold by bringing a second mold opposed to the first mold into contact with the first mold;
Injecting a resin solvent into the cavity to form a resin molded body corresponding to the shape of the cavity;
The step of sticking the film on the surface of the resin molded body by the heat of the injected resin solvent,
It is characterized by providing.

  According to the method for producing a laminate of the present invention, the surface of the resin molded body is formed with a concavo-convex shape in accordance with the pattern, thereby expressing the decoration three-dimensionally and improving the design of the resin molded body or the casing. Can be raised. The term “pattern” used in the present invention may include a color.

  In a preferred aspect of the laminate of the present invention, the decoration is a decoration that represents an actual material. The texture of the material can be expressed realistically. As the material, for example, soft materials such as fabrics and animal body surfaces are suitable, and the soft texture can be effectively expressed. In a preferred embodiment of the resin molded body of the present invention, a coating film having elasticity corresponding to the decoration is further formed on the surface. When touching the surface, it is possible to give a feel corresponding to decoration, and to suppress the generation of scratches and dirt on the surface of the resin molded body.

  According to the manufacturing method of the laminated body which concerns on this invention, the film on which the pattern was printed is affixed on the surface in which the uneven | corrugated shape of a resin molding is formed.

It is a perspective view which shows the structure of the housing | casing which concerns on one Embodiment of this invention. It is sectional drawing which shows the cross section along the II-II line | wire of FIG. It is a side view which shows the structure of the injection molding apparatus used for in-mold shaping | molding. It is a flowchart which shows the procedure which forms a resin molding using the injection molding apparatus of FIG. It is a side view which shows the state which performs in-mold shaping | molding using the injection molding apparatus of FIG. It is sectional drawing which shows the cross section of the housing | casing which concerns on the modification of embodiment.

  Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a perspective view showing a configuration of a front side portion of a cellular phone casing according to an embodiment of the present invention. A three-dimensional decoration of a fabric knitted with warp yarns and weft yarns is provided on the surface of the resin molded body constituting the housing 10. A window 13 for exposing the liquid crystal display panel is formed in the center of the housing 10.

  2 is a cross-sectional view showing a cross section taken along the line II-II in FIG. The housing 10 includes a resin molded body 11 and a coating film 12 applied to the surface of the resin molded body 11. The surface of the resin molded body 11 is formed with an uneven shape imitating the uneven shape of the fabric, and the color and pattern of the fabric are drawn by printing according to the uneven shape. The coating film 12 is made of an ultraviolet curable resin having low elasticity corresponding to the fabric, and has a thickness of about 10 to 15 μm. The coating film 12 softens the surface of the housing 10 and suppresses the generation of scratches and dirt on the surface of the resin molded body 11.

  According to the housing 10 of the present embodiment, an uneven shape imitating the uneven shape of the fabric is formed on the surface of the resin molded body 11, and the color and pattern of the fabric are drawn by print printing according to the uneven shape. Therefore, the fabric can be expressed in three dimensions without using an actual fabric. Therefore, the three-dimensional vision obtained by the uneven shape and pattern on the surface of the housing 10 and the tactile sensation obtained by the uneven shape on the surface of the housing 10 and the soft coating film 12 are combined to express the soft texture of the fabric more realistically. it can.

  When manufacturing the housing 10, first, a resin molded body 11 having an uneven shape imitating a fabric and a colored pattern on the surface is formed by in-mold molding. Next, coating is performed on the surface of the resin molded body 11 to form the coating film 12.

  FIG. 3 is a side view showing a configuration of an injection molding apparatus used for in-mold molding. The injection molding apparatus 20 includes a pair of molds 21 and 22 that face each other, a fixed mold (first mold) 21 is fixed by a fixed portion 23, and a movable mold (second mold) 22 is movable. The parts 24 are held respectively. The movable part 24 can move the second mold 22 in the direction of the arrow 25 to bring the surface of the second mold 22 into contact with the surface of the first mold 21.

  With the surface of the second mold 22 in contact with the surface of the first mold 21, an injection molding space (cavity) 26 having a shape corresponding to the shape of the resin molded body 11 is formed between them. The An uneven shape corresponding to the uneven shape of the fabric is formed on the surface of the cavity 26 on the first mold 21 side, and the second mold 22 is not shown for injecting a resin solvent into the cavity 26. An injection hole is formed.

  The injection molding apparatus 20 includes a pair of a film delivery unit 27 and a film take-up unit 28, and the film delivery unit 27 and the film take-up unit 28 are configured such that the belt-like film 29 is positioned between the pair of molds 21 and 22. Hold on. The belt-like film 29 is wound inside the film delivery unit 27 and the film winding unit 28, and the film winding unit 28 winds the belt-like film 29 so that the belt-like film 29 is moved in the direction of the arrow 30. It can be moved little by little to the film take-up portion 28 side.

  On the surface of the band-shaped film 29 on the second mold 22 side, the color and pattern of the fabric are printed by print printing except for the side edge portion. The belt-like film 29 is made of a material that easily stretches and is made of, for example, polyester. Moreover, it has a thickness of about 100 μm. In addition to print printing, various printing techniques may be used.

  On the surface of the second mold 22, a columnar guide 31 protrudes at the peripheral edge. A guide receiving hole (not shown) corresponding to the guide 31 is formed at the peripheral edge of the first mold 21 and the fixed portion 23, and the guide 31 is formed when the second mold 22 approaches the first mold 21. And is accommodated in the guide accommodation hole.

  FIG. 4 is a flowchart showing a procedure for forming the resin molded body 11 using the injection molding apparatus of FIG. Prior to the in-mold molding, the film delivery unit 27 and the film take-up unit 28 move the belt-like film 29 in the direction of the arrow 30 to make the pattern printed on the belt-like film 29 the cavity 26 on the first mold 21 side. Alignment is performed to match the uneven shape formed on the surface (step S11).

  At the time of in-mold molding, the movable part 24 moves the second mold 22 to the first mold 21 side as shown in FIG. 5, and the surface of the second mold 22 is moved to the first mold 21 via the belt-like film 29. 1 Abut on the surface of the mold 21. With the cavity 26 formed between the first mold 21 and the second mold 22, the movable part 24 injects the resin solvent into the cavity 26 through the injection hole. Thus, the resin molded body 11 corresponding to the shape of the cavity 26 is formed, and the color and pattern printed on the surface of the belt-like film 29 are transferred to the surface of the resin molded body 11 by the heat of the injected resin solvent ( Step S12).

  The corner portion of the cavity 26 has a roundness corresponding to the corner portion of the resin molded body 11, and the band-shaped film 29 is made of a material that easily expands and contracts. There is no habit. After the in-mold molding is finished, the movable part 24 pulls the second mold 22 away from the first mold 21 with the resin molded body 11 attached to the surface of the first mold 21. Subsequently, a device (not shown) of the movable portion 24 removes the resin molded body 11 from the surface of the first mold 21 (step S13).

  At the time of coating, an ultraviolet curable resin is applied to the surface of the resin molded body 11, and then the applied ultraviolet curable resin is cured by ultraviolet irradiation. Thereby, the coating film 12 is formed, and the housing 10 shown in FIGS. As the ultraviolet curable resin, a colorless transparent or colored transparent resin is used.

  According to the manufacturing method of the housing according to the present embodiment, an uneven shape imitating the uneven shape of the fabric is formed on the surface of the cavity 26 on the first mold 21 side, and the cavity 26 on the first mold 21 side. By performing in-mold molding by combining the uneven shape and the pattern of the belt-like film 29, it is possible to form the resin molded body 11 that combines the uneven shape and pattern of the surface.

  At the time of in-mold molding, the band-shaped film 29 that easily expands and contracts is used, and the corner portion of the cavity 26 is rounded, so that the generation of wrinkles in the band-shaped film 29 can be suppressed. Thereby, the uniformity of the appearance of the housing 10 can be maintained. Further, in-mold molding can reduce the thickness of the film compared to insert molding, and thus can be used for decoration having a smaller uneven shape.

  FIG. 6 is a cross-sectional view showing a configuration of a housing according to a modified example of the embodiment in a cross section corresponding to FIG. The casing 14 is except that the film 15 is formed between the resin molded body 11 and the coating film 12 and that the color and pattern of the fabric are drawn on the outer surface of the film 15. 1 and 2 has the same configuration as that of the housing 10 shown in FIGS.

  In manufacturing the housing 14, insert molding is performed using the film 15 having a dimension corresponding to the surface shape of the resin molded body 11 instead of in-mold molding using the belt-shaped film 29. On the film 15, the color and pattern of the fabric are printed in advance, and an uneven shape corresponding to the uneven shape of the first mold 21 is formed. The uneven shape is formed according to the pattern. Prior to the insert molding in step S12 of FIG. 4, the film 15 is placed on the surface of the first mold 21 according to the uneven shape using a predetermined apparatus. The film 15 is made of a material that easily expands and contracts, for example, polycarbonate. The thickness of the film 15 is set to be thicker than that at the time of in-mold molding in order to improve workability when being placed on the surface of the first mold 21 and suppress deformation at the time of insert molding. The thickness is about 300 μm.

  At the time of insert molding in step S12, the resin molded body 11 corresponding to the shape of the cavity 26 is formed, and the film 15 is attached to the surface of the resin molded body 11 by the heat of the injected resin solvent. According to the case 14 of this modification, the surface of the case 14 can be made softer by interposing the easily stretchable film 15 between the resin molded body 11 and the coating film 12.

  In the above-described embodiments and modifications, the casing is decorated with a fabric, but the decoration is not limited to the fabric. For example, even if the animal body surface is decorated, the soft texture of the animal body surface can be expressed realistically. The coating film 12 is formed of an ultraviolet curable resin, but is not limited to an ultraviolet curable resin, and a two-component curable resin may be used. By adopting a resin having elasticity corresponding to the material according to the type of the material, when touching the surface of the housing, a tactile sensation corresponding to the material can be effectively given.

  In the above-described embodiments and modifications, the case constitutes the case of the mobile phone. However, the case is not limited to the mobile phone, and various portable electronic devices such as a digital camera, a portable game machine, or a music player can be used. Applicable to equipment casings.

  As mentioned above, although this invention was demonstrated based on the suitable embodiment, the resin molding which concerns on this invention, its manufacturing method, and a housing | casing are not limited only to the structure of the said embodiment, The said implementation A resin molded body, a manufacturing method thereof, and a housing that have been variously modified and changed from the configuration of the form are also included in the scope of the present invention.

  Some or all of the above reference examples and embodiments may be described as in the following supplementary notes, but are not limited thereto.

[Appendix 1]
A resin molded body with a predetermined decoration on the surface,
The resin molded body is characterized in that an uneven shape corresponding to the decoration is formed on a surface of the resin molded body, and a pattern corresponding to the decoration is formed in accordance with the uneven shape.

[Appendix 2]
The resin molding according to appendix 1, wherein the decoration is a decoration that represents an actual material.

[Appendix 3]
3. The resin molded article according to appendix 1 or 2, wherein a coating film having elasticity corresponding to the decoration is further formed on the surface.

[Appendix 4]
The said pattern is a resin molding as described in any one of Additional remarks 1-3 currently formed by printing.

[Appendix 5]
The said pattern is a resin molding as described in any one of the additional remarks 1-3 currently formed in the film affixed on the surface of the resin molding.

[Appendix 6]
A housing formed of the resin molded body according to any one of appendices 1 to 5.

[Appendix 7]
A method for producing the resin molded body according to any one of appendices 1 to 4,
When forming the resin molding using the first mold having the uneven shape and the second mold facing the first mold, the film on which the pattern is printed is A method for producing a resin molded body, comprising: arranging the pattern on the first mold side, and transferring the pattern from the film to a surface on which the uneven shape of the resin molded body is formed.

  The present invention is useful as a casing of a mobile device such as a mobile phone and a PDA.

10: Housing 11: Resin molded body 12: Paint film 13: Window 14: Housing 15: Film 20: Injection molding device 21: Fixed mold (first mold)
22: Movable mold (second mold)
23: Fixed part 24: Movable part 25: Movement direction of second mold 26: Cavity 27: Film delivery part 28: Film winding part 29: Strip film 30: Movement direction of strip film 31: Guide

Claims (3)

A method for producing a laminate in which insert molding is performed using a film having dimensions corresponding to the surface shape of a resin molded body,
Placing a film having a dimension corresponding to the surface shape of the resin molded body on the surface of the first mold on which the uneven shape corresponding to the shape of the film is formed, according to the uneven shape;
Forming a cavity between the first mold and the second mold by bringing a second mold opposed to the first mold into contact with the first mold;
Injecting a resin solvent into the cavity to form a resin molded body corresponding to the shape of the cavity;
The step of sticking the film on the surface of the resin molded body by the heat of the injected resin solvent,
The manufacturing method of the laminated body characterized by comprising.   The thickness of the film is set to be thicker than in-mold molding in order to enhance workability when placing on the surface of the first mold and to suppress deformation during insert molding. The manufacturing method of the laminated body of Claim 1.   The thickness of the said film is 200-300 micrometers, The manufacturing method of the laminated body of Claim 2 characterized by the above-mentioned.

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