JP5413167B2 - Panel forming method - Google Patents

Description

  The present invention relates to a method of forming a panel in which a frame-like portion is integrally provided on the entire periphery of the rear surface of the panel body, and more particularly to a panel suitable for use as a transparent panel-like member of a roof or window of a vehicle such as an automobile. The present invention relates to a molding method.

  JP-A-2005-103907 and JP-A-2008-94087 describe resin window plates for automobiles, which are made of a two-color molded product in which a transparent resin panel has a border formed with an opaque resin.

  Japanese Patent Application Laid-Open No. 2005-103907 includes a transparent portion (panel body) formed in a rectangular flat plate shape, and a frame-shaped portion integrally formed at the outer peripheral end of one surface of the front and back surfaces of the transparent portion. An automotive window is described. In the outer peripheral part of the transparent part, the transparent part and the frame-like part are laminated in the thickness direction, and the central part of the transparent part has a single-layer structure in which the frame-like part is not laminated. This two-color molded product is manufactured by two-color injection molding in which the frame-shaped part is molded with an opaque material and then the transparent part is molded with a transparent material.

  Japanese Patent Application Laid-Open No. 2008-94087 discloses a method of molding a panel made of a two-color molded product having a frame-like portion at the peripheral edge of the panel main body, by injection-molding a plate-like panel main body (primary molded product), and then the panel A method is described in which a frame-like portion (secondary molded product) is injection-molded at the peripheral edge of one surface of the main body. In paragraph 0103 of the publication, after a primary material is injected into a mold to form a primary molded product (panel body), the mold is opened so that the primary molded product remains attached to the core side, and then It is described that a mold for forming a secondary molded product is closed, a secondary material is injected to form a secondary molded product (frame-shaped portion), and then removed to take out a panel-shaped molded body. Yes. The temperature of the primary molded product when this secondary material is injected is not described.

  In JP-A-2001-225349, as a method of manufacturing a molded product having a gradation color, a B layer is formed by injecting a resin B between a layer A made of a resin molded product in a mold and the mold cavity surface. In this method, the temperature of the cavity surface is described as being 1 to 50 ° C. higher than the glass transition temperature of the resin B, but the surface temperature of the A layer at the time of injection of the resin B is not described.

JP-A-2005-103907 JP2008-94087 JP 2001-225349 A

  In a panel molding method in which a second synthetic resin material is injected into a part of the surface of a panel body made of the first synthetic resin material in a mold to form a frame-shaped portion and integrated with the panel body, When the surface temperature of the panel main body when the synthetic resin material 2 is injected is excessively high and the rigidity and strength of the panel main body are low, the second synthetic resin material is injected to form the frame-shaped portion The panel body is distorted with the shrinkage when the temperature of the frame-shaped portion is lowered.

  The present invention forms a frame-shaped portion by injecting a second synthetic resin material onto a part of the surface of a panel body made of the first synthetic resin material in a mold, and molding the panel to be integrated with the panel body. In the method, an object is to prevent (including suppression, the same applies hereinafter) that the panel main body is distorted due to molding shrinkage of the second molded body.

In the panel molding method of the present invention, a frame-shaped portion made of the second synthetic resin material is integrally formed by injection molding at the peripheral portion of the panel body made of the first synthetic resin material having a glass transition temperature Tg (° C.). In the panel molding method, the first synthetic resin material is an aromatic polycarbonate resin, the main components of the first synthetic resin material and the second synthetic resin material are the same, and the panel main body is made of a mold. The second synthetic resin material is injected to form a frame-like portion in a state where the surface temperature of the panel body is 40 ° C. or higher (Tg−60 ° C.) while being held on the core side. To do.

  In the panel molding method of the present invention, the second synthetic resin material is injected into a part of the surface of the panel body made of the first synthetic resin material in the mold to mold the frame-shaped portion, and the panel In the method of molding the panel integrated with the main body, the surface temperature of the panel main body when injecting the frame-shaped portion is (Tg-60 ° C.) or less, and the rigidity of the panel main body at the time of injection of the second synthetic resin material, The strength is high. Therefore, even if the contraction force when the temperature of the frame-like part is lowered acts on the panel body, the panel body is prevented from being distorted.

It is sectional drawing of the panel shape | molded by the shaping | molding method which concerns on embodiment. It is a top view of the panel of FIG. It is sectional drawing explaining the shaping | molding method which concerns on embodiment. It is sectional drawing explaining the shaping | molding method which concerns on embodiment. It is sectional drawing explaining the shaping | molding method which concerns on embodiment. It is sectional drawing explaining the shaping | molding method which concerns on embodiment. It is sectional drawing of another panel shape | molded by the shaping | molding method which concerns on embodiment. It is sectional drawing of a part of panel explaining distortion. It is a partial cross-sectional view of a panel for explaining a strain evaluation method.

  Hereinafter, embodiments will be described with reference to the drawings.

<Panel structure>
First, the structure of the panel formed by the method of the present invention will be described with reference to FIG. 1 and FIG.
FIG. 1 is an overall cross-sectional view of a panel formed by the forming method according to the embodiment, and FIG. 2 is a plan view of this panel. 1 is a cross-sectional view taken along the line II of FIG.

  The panel 4 is a resin window glass of a vehicle, and includes a plate-like panel main body 1 and a frame-like portion 2 provided so as to go around the entire periphery of the rear surface of the panel main body 1. In addition, the inner peripheral side of the frame-shaped portion 2, that is, the panel plate central portion where the frame-shaped portion 2 does not overlap is a transparent region 3.

The panel body 1 is transparent with a thickness t ₁ of about ₂ to 10 mm, and the frame-like portion 2 is opaque with a thickness t ₂ of about 0.5 to 5 mm. _{t 1} / t ₂ is preferably about 0.75 to 5.0, especially 1.5 to 4.0.

  The panel 4 is curved so that the front surface (upper surface in FIG. 1) side of the panel body 1 is convex.

The panel 4 has a substantially rectangular shape, and there is no particular limitation on the size thereof. The panel 4 may be appropriately selected and determined according to the application. Usually, as window materials for automobiles, the area of the transparent window layer portion is about 400 cm ^{2 to 2} m ² , and the width of the window frame layer portion is about 30 to 200 mm. Of these, 800 cm ² to 1 m ² as the area of the transparent window layer portion, the width of the window frame layer portion is preferably 30 to 150 mm. Similarly, the curved height (interval with the outermost peripheral edge on the rear surface side of the frame-like part 2) c, the length a of the long side, and the length b of the short side of the front surface of the panel body 1 are also used. It may be determined as appropriate according to the situation. Usually, since the front surface (upper surface in FIG. 1) side of the panel body 1 is curved so as to be convex, a and b are the long side length a when the area of the transparent window layer portion is in the above range. It is preferable that the curvature radius R [m] in the direction is 5000R to 20000R, particularly about 10000R to 20000R, and the R in the short side length b direction is 1000R to 15000R, particularly about 5000R to 10,000R.

<Method for forming panel 1>
Next, a method for forming the panel 4 will be described with reference to FIGS.
The panel molding die has a pair of side molds 11 and 12 and a central mold 13 disposed between the side molds 11 and 12. The central mold 13 is supported so as to be rotatable around a vertical axis, and can be rotated by a driving device. The side molds 11 and 12 can be moved toward and away from the central mold 13, and are closed and opened by a mold closing mold opening cylinder (not shown).

  A panel body forming cavity 14 is provided on one surface of the central mold 13, and a panel body forming cavity 15 is provided on the other surface. The first side mold 11 is provided with a cavity 16 for forming a frame-like part on the surface facing the central mold 13. The side mold 11 is provided with a runner 17 for guiding the synthetic resin material from the injection device 23 to the cavity 16. The second side mold 12 is provided with a runner 18 for guiding the synthetic resin material from the injection device 20 to the cavity 15.

  In order to mold the panel 4 using the mold 10, the first synthetic resin material 21 in the first injection device 20 is injected into the cavity 15 through the runner 18 as shown in FIG. The panel body 1 is molded as shown in FIG. In the other cavity 14, the first synthetic resin material 21 has already been injected and the panel body 1 is present. As shown in FIG. 3, the second synthetic resin material 22 is injected into the cavity 16 from the second injection device 23, and the frame-like portion 2 is molded as shown in FIG. The timing of injecting the second synthetic resin material 22 into the cavity 16 is a timing when the surface temperature of the panel body 1 in the cavity 14 facing the cavity 16 is equal to or lower than (Tg-60 ° C.). Tg is the glass transition temperature of the first synthetic resin material. This surface temperature can be measured by an infrared thermography, a contact thermometer (for example, a thermocouple) or the like.

  After injection of the first and second synthetic resin materials 21 and 22, the panel body 1 is molded in the cavity 15 as shown in FIG. 4, and the panel 4 is molded in the cavities 14 and 16, and then, as shown in FIG. The side molds 11 and 12 are separated from the central mold 13 and opened. The panel body 1 and the panel 4 are attached and held on the central mold 13. The central mold 13 is rotated about 90 ° around its axis, and after the panel 4 is removed from the cavity 14, the central mold 13 is further rotated 90 °. As a result, the central die 13 is turned 180 ° from the state shown in FIG. 3 as indicated by the arrow θ in FIG. 6, the cavity 14 faces the second side die 12, and the panel body 1 in the cavity 15 is The first side mold 11 faces the first side mold 11.

  Therefore, the side molds 11 and 12 are moved toward the central mold 13 and the molds are closed as shown in FIG. Thereafter, although not shown, the first synthetic resin material 21 is injected from the first injection device 20 into the cavity 14, and the panel body 1 is molded in the cavity 14. Further, the second synthetic resin material 22 is injected from the second injection device 23 into the cavity 16, and the frame-like portion 2 is molded so as to be integrated with the panel body 1 in the cavity 15. The timing of injection of the second synthetic resin material 22 at this time is a timing when the surface temperature of the panel main body 1 in the cavity 15 is (Tg-60 ° C.) or less.

  Thereafter, the side molds 11 and 12 are separated from the central mold 13 and opened, the panel body 4 is removed from the cavity 15, the central mold 13 is inverted by 180 °, and then the side molds 11 and 12 are moved to the central mold 13. Close the mold. 3 returns to the state shown in FIG. 3, so that the first synthetic resin material 21 is injected from the first injection device 20 into the empty cavity 15 and from the second injection device 23 to the cavity 16. The second synthetic resin material 22 is injected.

As described above, the time when the second synthetic resin material 22 is injected into the cavity 16 is set as the time when the surface temperature of the panel body 1 facing the cavity 16 is equal to or lower than (Tg-60 ° C.). When the second synthetic resin material 22 is injected, the panel body 1 has a required strength. Therefore, in the removed panel 4, even if the contraction force of the frame-like portion 2 is applied to the panel body 1, the panel body 1 is prevented from being distorted. The timing of injecting the second synthetic resin material into the cavity 16 is preferably when the surface temperature of the panel body 1 is (Tg−70 ° C.) or less, particularly (Tg−80 ° C.) or less. There is no restriction | limiting in particular in the minimum of the surface temperature of the panel main body at the time of inject | pouring the 2nd synthetic resin material, Room temperature (room temperature. For example, 20 degreeC) may be sufficient.
Further, the surface temperature of the panel body can be arbitrarily adjusted by the mold temperature, the cooling time, and the cooling time when the central mold 13 is reversed.
In addition, Tg of the 1st synthetic resin material is about 150-160 degreeC in the case of PC mentioned later, for example.

  3 to 6, the panel body 1 is injection-molded. However, the present invention can also be applied to a case where a previously molded panel body is set in a mold and subjected to insert molding. it can.

<Strain removal treatment and hard film formation treatment>
The panel 4 removed from the mold 10 as described above is preferably subjected to an annealing treatment for holding the molded product at 100 to 130 ° C., particularly 120 to 130 ° C. for 1 to 5 hours, particularly 1 to 2 hours, to remove the distortion. It is preferable.

  Further, after applying the hard coat stock solution to the entire front surface of the panel body 1 of this panel 4 and the transparent region 3 in the rear surface of the panel body 1, it is cured by UV irradiation or heating to form a hard film (hard coat layer). ) May be formed. A suitable composition of this hard film will be described later.

  When this hard film is formed, the annealing process may be combined with the thermosetting process of forming the thermosetting hard film due to the temperature rise of the panel body during the formation of the hard film.

  In the panel molded by the method of the present invention, when the frame-shaped portion 2 is molded, the inner peripheral portion of the frame-shaped portion 2 is made closer to the center of the panel in order to reduce the shrinkage force particularly near the inner periphery of the frame-shaped portion 2. It is good also as a structure provided with the thickness reduction | decrease area | region where thickness becomes thin continuously or in steps. In the panel main body that overlaps with the gradually decreasing region, the stress generated as the frame-shaped portion contracts is dispersed. Therefore, when the inner peripheral end surface of the frame-like portion 2 is perpendicular to the rear surface of the panel body, it is possible to prevent a minute distortion 8 from occurring on the front surface of the panel body as shown in FIG.

  Examples of the shape of the inner peripheral portion in the frame-like portion 2 include shapes as shown in FIGS. 7 (a) to (c). The frame-like portion 2A shown in FIG. 7 (a) has a shape in which the thickness continuously decreases toward the center side of the panel 4A, that is, has a gradually decreasing shape, and the length direction of the inner peripheral portion. When viewed in a cross-section perpendicular to the plane, it has a flat inclined surface.

  Further, the inner peripheral portion of the frame-like portion 2B shown in FIG. 7 (b) has a shape in which the wall thickness gradually decreases toward the center side of the panel 4B as in the case of FIG. 7 (a), and The curved surface immerses in the interface side with the panel body 1 when viewed in a cross-section perpendicular to the length direction of the inner peripheral portion.

  The inner peripheral part of the frame-like part 2C shown in FIG. 7 (c) has a shape in which the thickness is gradually reduced toward the center side of the panel 4C, that is, the inner peripheral part is gradually reduced in thickness. When viewed in a cross-section perpendicular to the length direction, a step-like surface that gradually approaches the interface side with the panel body 1 is formed.

When frame portion 2A, and 2B or 2C the thickness _{t 2,} the width is _{L 1,} the frame-shaped portion 2A, and 2B or 2C the width of the thickness changing region and _{L 2,} and L ₂ / _t 2,, L ₂ / L ₁ is (L ₂ / t ₂ ) ≧ 1.75
1> (L ₂ / L ₁ ) ≧ 0.25
It is preferable that

The ratio _L 2 / _{t 2} and the ratio _L 2 / _{L 1} described above, the ratio that are complementary to each other influences. Therefore, it is preferable that L ₂ / t ₂ and L ₂ / L ₁ satisfy the relationship of the following formula.
(L ₂ / t ₂ ) · (L ₂ / L ₁ ) ≧ 0.4

<Constituent materials for panels>
Next, materials suitable for molding automobile window glass and the like by the method of the present invention will be described.

  If the constituent material of the panel main body 1 is a transparent resin, it can be suitably selected from conventionally well-known arbitrary things. Here, the term “transparent” is generally 10% or more, preferably 15% or more, more preferably 20%, as a total light transmittance in a plate-shaped molded article having a smooth surface thickness of 3 mm measured according to JIS K7105. This means that the Haze value is usually 10% or less, preferably 5% or less, and more preferably 3% or less. In a transparent resin containing a dye or pigment, the proportion of the dye or pigment used is usually 0.001 to 2 parts by weight, preferably 0.005 to 1 part by weight, based on 100 parts by weight of the transparent resin. Preferably it is 0.005-0.5 weight part.

  Examples of the transparent resin include polystyrene resin, high impact polystyrene resin, hydrogenated polystyrene resin, polyacryl styrene resin, ABS resin, AS resin, AES resin, ASA resin, SMA resin, polyalkyl methacrylate resin, poly Methacryl methacrylate resin, polyphenyl ether resin, polycarbonate resin, amorphous polyalkylene terephthalate resin, polyester resin, amorphous polyamide resin, poly-4-methylpentene-1, cyclic polyolefin resin, amorphous polyarylate resin, poly Heat of ether sulfone, styrene thermoplastic elastomer, olefin thermoplastic elastomer, polyamide thermoplastic elastomer, polyester thermoplastic elastomer, polyurethane thermoplastic elastomer, etc. Plastic elastomers Kyora. Among these, from the viewpoint of impact resistance and heat resistance, a polycarbonate resin (PC), particularly, an aromatic polycarbonate resin as a main constituent resin is preferable. The main constituent resin means that the ratio of the aromatic polycarbonate resin in all resin components is usually 50% by weight or more, preferably 60% by weight or more, and more preferably 70% by weight or more.

  Examples of resins used in combination with PC as the main constituent resin include polystyrene resin, ABS resin, AS resin, AES resin, ASA resin, polyphenylene ether resin, polymethacryl methacrylate resin, and polyester resin. An alloy or a copolymer may be used as long as the properties are maintained.

  The PC used in the present invention is, for example, a linear or branched thermoplastic polymer obtained by reacting an aromatic dihydroxy compound and a carbonate precursor, or a small amount of a polyhydroxy compound in combination therewith. Or a copolymer. PC can be produced by a known method, and examples of the production method include an interfacial polymerization method, a melt transesterification method, a pyridine method, a ring-opening polymerization method of a cyclic carbonate compound, and a solid phase transesterification method of a prepolymer. .

  Examples of aromatic dihydroxy compounds used as raw materials include 2,2-bis (4-hydroxyphenyl) propane (also known as bisphenol A), 2,2-bis (3,5-dibromo-4-hydroxyphenyl) propane ( Also known as: tetrabromobisphenol A), bis (4-hydroxyphenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4 -Hydroxyphenyl) octane, 2,2-bis (4-hydroxy-3-methylphenyl) propane, 1,1-bis (3-tert-butyl-4-hydroxyphenyl) propane, 2,2-bis (4- Hydroxy-3,5-dimethylphenyl) propane, 2,2-bis (3-bromo-4-hydroxyphenyl) propane, , 2-bis (3,5-dichloro-4-hydroxyphenyl) propane, 2,2-bis (3-phenyl-4-hydroxyphenyl) propane, 2,2-bis (3-cyclohexyl-4-hydroxyphenyl) Propane, 1,1-bis (4-hydroxyphenyl) -1-phenylethane, bis (4-hydroxyphenyl) diphenylmethane, 2,2-bis (4-hydroxyphenyl) -1,1,1-trichloropropane, 2 , 2-bis (4-hydroxyphenyl) -1,1,1,3,3,3-hexachloropropane, 2,2-bis (4-hydroxyphenyl) -1,1,1,3,3,3- Bis (hydroxyaryl) alkanes such as hexafluoropropane; 1,1-bis (4-hydroxyphenyl) cyclopentane, 1,1-bis (4-hydride) Bis (hydroxyaryl) cycloalkanes such as xylphenyl) cyclohexane and 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane; 9,9-bis (4-hydroxyphenyl) fluorene; Cardiostructure-containing bisphenols such as 9,9-bis (4-hydroxy-3-methylphenyl) fluorene; dihydroxy diphenyls such as 4,4′-dihydroxydiphenyl ether and 4,4′-dihydroxy-3,3′-dimethyldiphenyl ether Aryl ethers; dihydroxydiaryl sulfides such as 4,4′-dihydroxydiphenyl sulfide, 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfide; 4,4′-dihydroxydiphenyl sulfoxide, 4,4 '-Dihydroxy-3,3'- Dihydroxydiaryl sulfoxides such as dimethyldiphenyl sulfoxide; dihydroxydiaryl sulfones such as 4,4′-dihydroxydiphenylsulfone and 4,4′-dihydroxy-3,3′-dimethyldiphenylsulfone; hydroquinone, resorcin, 4,4′-dihydroxydiphenyl and the like.

  Among the above, bis (4-hydroxyphenyl) alkanes are preferable, and 2,2-bis (4-hydroxyphenyl) propane (also known as bisphenol A) is particularly preferable from the viewpoint of impact resistance. Two or more kinds of these aromatic dihydroxy compounds may be used in combination.

  As the carbonate precursor to be reacted with the aromatic dihydroxy compound, carbonyl halide, carbonate ester, haloformate and the like are used. Specifically, phosgene; diaryl carbonates such as diphenyl carbonate and ditolyl carbonate; dimethyl carbonate And dialkyl carbonates such as diethyl carbonate; and dihaloformates of dihydric phenols. Two or more of these carbonate precursors may be used in combination.

  In the present invention, the PC may be a branched aromatic polycarbonate resin obtained by copolymerization of a trifunctional or higher polyfunctional aromatic compound. Examples of the trifunctional or higher polyfunctional aromatic compound include phloroglucin, 4,6-dimethyl-2,4,6-tri (4-hydroxyphenyl) heptene-2, 4,6-dimethyl-2,4,6- Tri (4-hydroxyphenyl) heptane, 2,6-dimethyl-2,4,6-tri (4-hydroxyphenyl) heptene-3, 1,3,5-tri (4-hydroxyphenyl) benzene, 1, In addition to polyhydroxy compounds such as 1,1-tri (4-hydroxyphenyl) ethane, 3,3-bis (4-hydroxyaryl) oxyindole (also known as isatin bisphenol), 5-chloroisatin, Examples include 5,7-dichloroisatin and 5-bromoisatin. Among these, 1,1,1-tri (4-hydroxyphenyl) ethane is preferable. The polyfunctional aromatic compound is used by substituting a part of the aromatic dihydroxy compound, and the amount used is usually 0.01 to 10 mol%, preferably 0.1%, based on the aromatic dihydroxy compound. ~ 2 mol%.

  Although the molecular weight of PC used for this invention is arbitrary, it is 10,000-35,000 normally as viscosity average molecular weight [Mv] converted from solution viscosity. By setting the viscosity average molecular weight to 10,000 or more, the mechanical strength is improved and it is suitable for applications requiring high mechanical strength. On the other hand, when the viscosity average molecular weight is 35,000 or less, the fluidity is lowered and the molding process becomes easy. In addition, when forming hard films, such as a hard coat, in a post process, a viscosity average molecular weight becomes like this. Preferably it is 18,000-35,000, More preferably, it is 20,000-30,000. By setting the viscosity average molecular weight to 18,000 or more, it is possible to suppress a decrease in impact strength when a cured film is formed on the surface. Two or more types of PCs having different viscosity average molecular weights may be mixed.

Here, the viscosity average molecular weight [Mv] means that the intrinsic viscosity [η] (unit dl / g) at a temperature of 20 ° C. is obtained with an Ubbelohde viscometer using methylene chloride as a solvent, and the Schnell viscosity formula (η = It means a value calculated from 1.23 × 10 ⁻⁴ M ^0.83 ).

  The terminal hydroxyl group concentration of the PC used in the present invention is usually 2,000 ppm or less, preferably 1,500 ppm or less, more preferably 1,000 ppm or less. In addition, the lower limit is usually 10 ppm, preferably 30 ppm, more preferably 40 ppm, especially for PC produced by the transesterification method.

  By setting the terminal hydroxyl group concentration to 10 ppm or more, a decrease in molecular weight can be suppressed, and the mechanical properties of the resin composition tend to be further improved. Moreover, it exists in the tendency which the residence heat stability and color tone of a resin composition improve more by making terminal group hydroxyl group density | concentration into 2,000 ppm or less. When forming a cured film such as a hard coat, by applying a terminal hydroxyl group concentration of 100 to 2,000 ppm, preferably 200 to 1,000 ppm, and more preferably 300 to 1,000 ppm, with a high terminal hydroxyl group concentration, Its adhesion and durability are improved. The unit of the terminal hydroxyl group concentration is the weight of the terminal hydroxyl group expressed in ppm with respect to the weight of PC, and the measurement method is a colorimetric determination by the tetrachloride / acetic acid method (Macromol. Chem. 88 215 (1965)). Method).

  Further, in order to improve the appearance of the molded product and the fluidity, the PC used in the present invention may contain an aromatic polycarbonate oligomer. The aromatic polycarbonate oligomer has a viscosity average molecular weight [Mv] of usually 1,500 to 9,500, preferably 2,000 to 9,000. The usage-amount of an aromatic polycarbonate oligomer is 30 weight% or less normally with respect to PC.

  Furthermore, the PC used in the present invention may contain not only virgin PC but also PC regenerated from used products, so-called material recycled PC. Used products include optical recording media such as optical discs, light guide plates, vehicle transparent parts such as automobile window glass, automobile headlamp lenses, and windshields, containers such as water bottles, eyeglass lenses, soundproof walls, glass windows, and waves. Examples include building members such as plates. Also, non-conforming products, pulverized products obtained from sprues, runners, etc., or pellets obtained by melting them can be used. The use ratio of the regenerated PC is usually 80% by weight or less, preferably 50% by weight or less based on virgin PC.

  In addition to the above-mentioned dyes or pigments, any conventionally known auxiliary agent can be added to the constituent material of the panel body. Examples thereof include mold release agents, heat stabilizers, antioxidants, and weather resistance improvements. Agents, alkali soaps, metal soaps, plasticizers, fluidity improvers, nucleating agents, flame retardants, anti-dripping agents and the like. The usage-amount of these adjuvants is suitably selected from a well-known range.

  The constituent material of the frame-shaped portion is not particularly limited, and various known arbitrary thermoplastic resins can be used. Specifically, for example, polycarbonate resin; thermoplastic polyester resin such as polyethylene terephthalate resin, polytrimethylene terephthalate, polybutylene terephthalate resin; polystyrene resin, high impact polystyrene resin (HIPS), acrylonitrile-styrene copolymer (AS resin) ), Styrene-based resins such as acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene-acrylic rubber copolymer (ASA resin), acrylonitrile-ethylenepropylene rubber-styrene copolymer (AES resin); Polyolefin resins such as polyethylene resins and polypropylene resins; Polyamide resins; Polyimide resins; Polyether resins; Polyurethane resins; Polyphenylene ether resins; Id resins; polysulfone resins; and polymethacrylate resins and the like, which may be used in combination of two or more. Among these, PC and thermoplastic polyester resin are preferable from the viewpoint of thermal stability, rigidity, and adhesion to the panel body. Among them, PC is the main material, especially combined use of PC and thermoplastic polyester resin. Is preferred.

  Of the constituent resin materials of the panel main body 1 and the frame-like portions 2 and 2A to 2C, it is desirable that the main components blended in an amount of 10% by weight or more are the same in order to enhance the bonding property between them.

  When a polymer alloy composed of PC and a thermoplastic polyester resin is used as the constituent material of the frame-like portion 2, the ratio of PC to the total amount of both components is usually 50 to 95% by weight.

  The thermoplastic polyester resin is a polymer or copolymer obtained by condensation reaction of a dicarboxylic acid component composed of a dicarboxylic acid or a reactive derivative thereof and a diol component composed of a diol or an ester derivative thereof.

  In general, the thermoplastic polyester resin is produced by reacting a dicarboxylic acid component with a diol component in the presence of a polycondensation catalyst containing titanium, germanium, antimony, etc. This is done by discharging out of the system. The condensation reaction may be either a batch type or a continuous type, and the degree of polymerization may be increased by solid phase polymerization.

  The dicarboxylic acids may be either aromatic dicarboxylic acids or aliphatic dicarboxylic acids, but aromatic dicarboxylic acids are preferred from the viewpoints of heat resistance and dimensional stability. Aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, orthophthalic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 4,4′-biphenyldicarboxylic acid, 4,4′-biphenylether dicarboxylic acid 4,4′-biphenylmethanedicarboxylic acid, 4,4′-biphenylsulfonedicarboxylic acid, 4,4′-biphenylisopropylidenedicarboxylic acid, 1,2-bis (phenoxy) ethane-4,4′-dicarboxylic acid, 2,5-anthracene dicarboxylic acid, 2,6-anthracene dicarboxylic acid, 4,4′-p-ter-phenylenedicarboxylic acid, 2,5-pyridinedicarboxylic acid and the like can be mentioned. In addition, alkyl group-substituted products such as 5-methylisophthalic acid; reactive derivatives such as alkyl ester derivatives such as dimethyl terephthalate and diethyl terephthalate can also be used.

  Among the above, terephthalic acid, 2,6-naphthalenedicarboxylic acid and their alkyl ester derivatives are preferable, and terephthalic acid and its alkyl ester derivatives are more preferable. Two or more of these aromatic dicarboxylic acids may be used in combination, and together with the aromatic dicarboxylic acid, an aliphatic dicarboxylic acid such as adipic acid, azelaic acid, sebacic acid, dodecanedioic acid, or a fatty acid such as cyclohexanedicarboxylic acid. It is also possible to use a cyclic dicarboxylic acid in combination.

  The diols include ethylene glycol, 1,2-propylene glycol, 1,3-propanediol, 1,4-butanediol, neopentyl glycol, 1,5-pentanediol, 1,6-hexanediol, deca Aliphatic diols such as methylene glycol and 2,2-dimethyl-1,3-propanediol; 1,4-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, cyclohexanediol, trans- or cis-2,2, Alicyclic diols such as 4,4-tetramethyl-1,3-cyclobutanediol; aromas such as p-xylenediol, bisphenol A, tetrabromobisphenol A, tetrabromobisphenol A-bis (2-hydroxyethyl ether) Group diols. These substitution products can also be used.

  Among the above, ethylene glycol, 1,3-propanediol, 1,4-butanediol, and 1,4-cyclohexanedimethanol are preferable from the viewpoint of thermal stability, impact resistance, rigidity, and the like. 1,3-propanediol and 1,4-butanediol are more preferable, and ethylene glycol is particularly preferable. Two or more of these may be used in combination. Further, as the diol component, a long chain diol having a molecular weight of 400 to 6,000, that is, one or more of polyethylene glycol, poly-1,3-propylene glycol, polytetramethylene glycol and the like are used in combination with the above diols. It may be copolymerized.

  Further, the thermoplastic polyester resin used in the present invention can be branched by introducing a small amount of a branching agent. Examples of the branching agent include trimesic acid, trimellitic acid, trimethylolethane, trimethylolpropane, pentaerythritol and the like.

  Preferable specific examples of the thermoplastic polyester resin used in the frame portion include polyethylene terephthalate resin (PET), polypropylene terephthalate resin (PPT), polybutylene terephthalate resin (PBT), polyhexylene terephthalate resin, and polyethylene-naphthalate resin. (PEN), polybutylene naphthalate resin (PBN), poly (1,4-cyclohexanedimethylene terephthalate) resin (PCT), polycyclohexylcyclohexylate (PCC), and the like. Among these, polyethylene terephthalate resin (PET), polypropylene terephthalate resin (PPT), and polybutylene terephthalate resin (PBT) are preferable in terms of fluidity and impact resistance.

  The polyethylene terephthalate resin is a saturated polyester polymer or copolymer obtained by a condensation reaction of terephthalic acid as a main component as a dicarboxylic acid component and ethylene glycol as a diol component as a main component. The proportion of the ethylene terephthalate unit as the repeating unit is usually 70 mol% or more, preferably 80 mol% or more. In addition, in the polyethylene terephthalate resin, diethylene glycol, which is a side reaction product during polymerization, may be included as a copolymerization component. The amount of diethylene glycol is usually based on the total amount of the diol component used in the polymerization reaction. 0.5 to 6 mol%, preferably 0.5 to 5 mol%.

Specific examples of other thermoplastic polyester resins include, for example, polypivalolactone resins obtained by ring-opening polymerization of lactone, poly (ε-caprolactone) resins, and liquid crystal polymers that form liquid crystals in the molten state (Thermotropic).
Liquid Crystal Polymer (TLCP). Specifically, commercially available liquid crystal polyester resins include “X7G” manufactured by Eastman Kodak Co., “Xyday” manufactured by Dartco Co., “Econol” manufactured by Sumitomo Chemical Co., Ltd., “ Vector "and the like.

  The intrinsic viscosity of the thermoplastic polyester resin used in the present invention is usually 0.4 to 1.5 dl / g, preferably 0.5 to 1.3 dl / g. Here, the intrinsic viscosity means a value measured at 30 ° C. in a solvent of phenol / tetrachloroethane = 50/50 (weight ratio). When the intrinsic viscosity is less than 0.4, the impact resistance tends to decrease, and when it exceeds 1.5, the fluidity tends to decrease. The amount of terminal carboxyl groups of the thermoplastic polyester resin is usually 5 to 50 μeq / g, preferably 10 to 30 μeq / g. When the terminal carboxyl group amount is less than 5 μeq / g, the impact resistance tends to decrease, and when it exceeds 50 μeq / g, the moist heat resistance and the thermal stability tend to be insufficient.

  Furthermore, as the thermoplastic polyester resin used in the present invention, not only virgin raw materials but also thermoplastic polyester resins regenerated from used products, so-called material recycled thermoplastic polyester resins can be used. . As used products, containers, films, sheets, fibers, and the like are mainly exemplified, and containers such as PET bottles are preferable. In addition, as the recycled thermoplastic polyester resin, non-conforming products, pulverized products obtained from sprues, runners, etc., or pellets obtained by melting them can be used.

  Moreover, it is preferable to mix | blend a filler with the structural material of a frame-shaped part in order to improve rigidity, dimensional stability, and heat resistance. Examples of such fillers include titanium oxide, zinc oxide, barium sulfate, silica, calcium carbonate, iron oxide, alumina, calcium titanate, aluminum hydroxide, magnesium hydroxide, calcium hydroxide, magnesium carbonate, calcium sulfate, sulfuric acid. Sodium, calcium sulfite, magnesium silicate (talc), aluminum silicate (mica), calcium silicate (wollastonite), clay, glass beads, glass powder, glass fiber, carbon fiber, aramid fiber, biodegradable fiber, silica sand, silica Examples include stone, quartz powder, shirasu, diatomaceous earth, white carbon, iron powder, and aluminum powder. Among these, glass fiber, carbon fiber, aramid fiber, biodegradable fiber, magnesium silicate (talc), aluminum silicate (mica), and calcium silicate (wollastonite) are preferable. Two or more kinds of fillers can be used in combination.

  The shape of the filler may be any of spherical, cubic, granular, needle-like, plate-like, and fiber-like, but improves the dimensional stability of the finally obtained thermoplastic resin composition. From the viewpoint of high rigidity and good appearance, a plate shape or a needle shape is preferable, and a filler having a laser diffraction particle size (D50) of 10 μm or less is preferable.

  The usage-amount of a filler is 2-50 weight part normally with respect to 100 weight part of all the structural materials of a frame-shaped part, Preferably it is 5-40 weight part. When the amount of the filler is less than 2 parts by weight, the effect of improving rigidity, dimensional stability and heat resistance is small, and when it exceeds 50 parts by weight, the impact resistance is lowered.

  The above fillers may be left untreated, but for the purpose of increasing the affinity with the resin component or the interfacial binding force, surface treatment agents, higher fatty acids or their derivatives, derivatives such as salts, coupling agents, etc. It is preferable to treat with. When the surface treatment is performed in combination with various surfactants such as nonionic, cationic, and anionic types and dispersants such as various resins, the mechanical strength and kneadability are preferably improved. .

  Conductive carbon black and / or hollow nanocarbon fibers can be blended with the constituent material of the frame-like portion for the purpose of imparting antistatic properties and conductivity capable of electrostatic coating. Examples of the conductive carbon black include acetylene black obtained by thermally decomposing acetylene gas, and Ketjen black produced by crude incomplete combustion using crude oil as a raw material. Hollow nanocarbon fibers have an outer region consisting of an essentially continuous multi-layer of regularly arranged carbon atoms and an inner hollow region, with each layer and the hollow region being arranged substantially concentrically. There are essentially cylindrical fibrils. Furthermore, the regularly arranged carbon atoms in the outer region are graphite-like. The diameter of the hollow region is usually 2 to 20 nm. Such hollow nanocarbon fibers are sold by Hyperion Catharsis under the trade name “graphite fibrils” and are readily available.

  The panel body is preferably made of a non-reinforced synthetic resin, while the frame-like portion is preferably made of a composite reinforced synthetic resin. That is, it is preferable to add reinforcing fibers to the resin material of the frame-shaped part. As the reinforcing fiber, for example, at least one selected from the group consisting of glass fiber, carbon fiber, aromatic polyamide fiber (aramid fiber), biodegradable fiber, talc, mica, and wollastonite can be used. The weight average fiber length of the reinforcing fibers is usually 1.5 to 10 mm, preferably 1.8 to 5 mm, from the viewpoint of strength and dispersibility. Moreover, in order to improve mechanical strength, dimensional accuracy, and heat resistance, the weight average fiber length of the fibers in the finished molded product is 0.1 to 5 mm, preferably 0.2 to 5 mm, more preferably 1 to 5 mm. Is preferred. In order to keep the weight average fiber length of the finished molded product high, the configuration of the injection cylinder of the injection molding machine is essential. Especially, the compression ratio of the screw is loosely compressed, the clearance is wide, and the clearance of the check ring is wide. It is effective. Moreover, as conditions at the time of injection molding, it is effective to mold the resin temperature at a high setting, the back pressure at the time of measurement is low, and the injection speed is low.

  Although not shown, in the present invention, a hard coat (hard coating) as a protective film may be provided in order to mainly prevent the panel body 1 from being damaged or deteriorated. Such a hard film may be provided only on the front surface opposite to the frame-like portion 2. The thickness of the hard coating is preferably 1/100 or less of the thickness of the panel body 1, and usually 1 to 50 μm, particularly 5 to 20 μm.

  The hard coating may be a single layer, but may have a multilayer structure of two or more layers in order to improve the protection function and weather resistance. In the multilayer structure, it is preferable to set the hardness of the outermost layer to the maximum. As the hard coating having a multilayer structure, for example, it has at least one function among a functional layer of each of heat ray shielding, ultraviolet absorption, thermochromic, photochromic, electrochromic, primer layer, colored decoration layer, etc. It is preferable.

  A transparent resin is suitable for the constituent material of the hard coating. As such a transparent resin, a known material known as a hard coat agent can be used as appropriate. For example, various hard coat agents such as silicone, acrylic, silazane, and urethane can be used. I can do it. In these, in order to improve adhesiveness and a weather resistance, the 2-coat type hard coat which provides a primer layer before apply | coating a hard-coat agent is preferable. Examples of the coating method include spray coating, dip coating, flow coating, spin coating, and bar coating. Moreover, the method by a film insert, the method of apply | coating and transferring the chemical | medical agent suitable for a transfer film, etc. can also be employ | adopted.

  Thin films having various functions (heat ray shielding, ultraviolet absorption, thermochromic, photochromic, and electrochromic functions) may be formed on the outermost layer of the hard coating.

  A transparent resin layer may be provided between the surface of the panel body 1 and the hard coating.

  The present invention is suitable for application to windows of vehicles, particularly automobiles, and is particularly suitable for application to sunroofs, but is also applicable to quarter windows, rear windows, and the like.

  In the present invention, an uneven portion is formed at the boundary between the rear surface of the panel body 1 and the frame-like portions 2 and 2A to 2C, and the bonding strength between the panel body 1 and the frame-like portions 2 and 2A to 2C is increased. Good. In the present invention, an attachment piece for attaching other components may be provided on the frame-like portion.

<Description of preferred physical property values of panel body and frame-shaped part>
In the present invention, the volume of the panel body 1 is V ₁ , the volume of the frame-like portion 2 is V ₂ , and a 3 mm-thick 100 mm × 100 mm flat plate molded from the material constituting the panel body is maintained at 130 ° C. for 2 hours. The shrinkage rate (%) when held is S ₁ , and the shrinkage rate (%) when a 3 mm-thick 100 mm × 100 mm flat plate molded with the material constituting the frame-like portion is held at 130 ° C. for 2 hours is S _2. 0.01 <V ₂ / V ₁ <1.0, preferably 0.05 ≦ V ₂ / V ₁ ≦ 1.0, particularly preferably 0.1 ≦ V ₂ / V ₁ ≦ 0.75, 1.0 <S ₂ / S ₁ <3.0, preferably 1.1 ≦ S ₂ / S ₁ ≦ 3.0, particularly preferably 1.1 ≦ S ₂ / S ₁ ≦ 2.5.

Further, preferably 0.35 <(S ₂ · V ₂ ) / (S ₁ · V ₁ ) <1.1, particularly preferably 0.35 <(S ₂ · V ₂ ) / (S ₁ · V. ₁ ) ≦ 1.0.

When the bending elastic modulus of the panel body 1 is F ₁ and the bending elastic modulus of the frame-like portion is F ₂ , preferably 0.35 <(S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · F ₁ ) <1.5, particularly preferably 0.35 <(S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · F ₁ ) ≦ 1.4.

When the molding shrinkage rate at the time of injection molding of the frame-shaped portion is I ₂ and the linear expansion coefficient of the panel body is α ₁ , preferably 0.8 × 10 ⁻² <α ₁ / I ₂ <2.3 × 10. ⁻² and particularly preferably 0.8 × 10 ⁻² <α ₁ / I ₂ ≦ 2.0 × 10 ⁻² .

When the physical properties of the panel main body and the frame-shaped part are in the above range, the contraction behavior of the peripheral part of the panel main body during annealing is prevented from being constrained by the contraction behavior of the frame-shaped part or conversely assisted. Good product panel shape accuracy. That is, as represented by 0.01 <V ₂ / V ₁ <1.0, when the volume of the frame-shaped portion is smaller than the volume of the panel main body, the shrinkage rates S ₂ , S ₁ of the frame-shaped portion and the panel main body. Is 1.0 <S ₂ / S ₁ <3.0, the degree of contraction of the convex curved panel body and the degree of contraction of the frame-like portion are substantially equal, and the curvature radius of the convex curvature of the panel is annealed. The shape is almost the same at the front and back, and the shape accuracy of the product panel is improved.

In this case, if S ₂ / S ₁ is less than 1.0, the contraction of the panel body is constrained by the frame portion. That is, the deformation behavior of the panel main body to be contracted may be hindered by the frame-shaped portion. As a result, the radius of curvature of the convex curve of the panel becomes larger than the allowable range, and the panel becomes concave from a flat (flat plate) shape. On the other hand, when S ₂ / S ₁ exceeds 3.0, the frame-like portion tends to shrink and deform beyond the shrink deformation of the panel body, and the convex warpage of the panel body becomes strong. That is, the radius of curvature of the panel may be smaller than the allowable range.

Note that the deformation behavior of the panel during the annealing treatment is the ratio of the product of the volume of the panel main body and the frame-like portion and the shrinkage during the annealing treatment, such as S ₂ · V ₂ / S ₁ · V _1, and the flexural modulus F ₁ , F ₂ is also affected. In addition, since the panel body is injection-molded first and the frame body is cooled to a certain degree to an allowable hardness, the frame-shaped part is injection-molded on the rear surface of the panel body. _2. The linear expansion coefficient α ₁ of the panel body also affects the deformation behavior of the panel. Therefore, the values of (S ₂ · V ₂ ) / (S ₁ · V ₁ ), (S ₂ · V ₂ · F ₂ ) / (S ₁ · V ₁ · F ₁ ), α ₁ / I ₂ are By setting the range, the shape accuracy of the product panel can be increased.

The shrinkage rates S ₁ and S ₂ are average values of the shrinkage rate in the flow direction during injection molding and the shrinkage rate in the direction orthogonal to the flow direction. The linear expansion coefficient is also an average value in the flow direction and the direction orthogonal thereto.

  Hereinafter, examples and comparative examples will be described.

[Examples 1-4, Comparative Examples 1-3]
A panel having the shape shown in FIG. 7 (a) was formed. The molding method is the method shown in FIG. 3 to FIG. 6, when the panel body 1 is first injection molded (injection temperature 320 ° C.), and then the surface temperature of the panel body 1 is lowered to the temperature shown in Table 2. The frame portion 2A was injection molded (injection temperature 270 ° C.). After demolding, an annealing treatment of 130 ° C. × 3 Hr was performed.

  The panel dimensions are as follows.

Long side a 750mm
Short side b 465mm
Curved height c As shown in Table 2 Width of the frame-like portion 2 (location along the long side, section HH in FIG. 2) 90 mm
The width of the frame-shaped part 2 (location along the short side, section II in FIG. 2) 97 mm
Panel body thickness 5mm
Frame thickness 3.5mm

Therefore, the volume V ₁ , V ₂ and V ₂ / V ₁ ratio of the panel main body and the frame-shaped portion are as follows.

V ₁ 1743.8 cm ³
V ₂ 666.0 cm ³
_{V 2} / V 1 0.38

A polycarbonate resin (manufactured by Mitsubishi Engineering Plastics; trade name “Iupilon (registered trademark) S2000UR”) was used as a molding material for the panel body. The glass transition temperature Tg was 153 ° C., the viscosity average molecular weight (Mv) was 24,500, and the linear expansion coefficient was 6.5 × 10 ⁻⁵ [/ ° C.]. The 3 mm thick 100 mm × 100 mm flat plate has a 130 ° C. × 2 Hr shrinkage S ₁ of 0.08%, a flexural modulus F ₁ of 2300 MPa, a total light transmittance of 90%, and a Haze of 0%.

  As the molding material (second synthetic resin material) of the frame-like portion 2A, the one described in Table 1 was used. In Table 1, PC is the above polycarbonate resin (Mitsubishi Engineering Plastics: Iupilon (registered trademark) S-3000FN, viscosity average molecular weight Mv = 21,000), PET is polyethylene terephthalate resin (Mitsubishi Chemical Corporation: Novapex (registered trademark)) ) GG500), PE is a polyethylene resin (ethylene-propylene copolymer “HF310 (trade name)” manufactured by Nippon Polyethylene Co., Ltd.). GF is a glass fiber (manufactured by Nippon Electric Glass Co., Ltd .: ECS03T-571, average fiber diameter 13 μm, average fiber length 3 mm). Table 1 also shows the physical properties of the injection-molded product with the blending.

Table 2 shows V ₂ / V ₁ , S ₂ / S _{1 of} each panel, the panel body surface temperature at the time of injection of the second synthetic resin material, the appearance evaluation of the product panel, and the bending height c before and after the annealing treatment. The panel body surface temperature at the time of injection of the second synthetic resin material was adjusted by the mold temperature and cooling time at the time of molding the panel body and the cooling time at the time of reversal. The surface temperature was measured by bringing a thermocouple into contact with the surface of the panel body.

[Example 5]
A product panel was obtained in the same manner as in Example 2 except that the molding material for the panel body was a coloring material having a total light transmittance of 23% and a haze of 1%.

[Example 6]
As the molding material for the panel body, melt-polymerized polycarbonate resin (manufactured by Mitsubishi Engineering Plastics Co., Ltd .; trade name “Novalex (registered trademark) 7027U”) was used, except that the resin temperature during molding was 320 ° C. A product panel was obtained as in Example 2. The glass transition temperature Tg was 150 ° C., the viscosity average molecular weight (Mv) was 27,000, the terminal hydroxyl group concentration was 350 ppm, and the linear expansion coefficient was 6.5 × 10 ⁻⁵ [/ ° C.]. The 3 mm thick 100 mm × 100 mm flat plate has a 130 ° C. × 2 Hr shrinkage S ₁ of 0.08%, a flexural modulus F ₁ of 2300 MPa, a total light transmittance of 90%, and a Haze of 0%.

Evaluation methods in Examples and Comparative Examples are as follows.
(1) Secondary shrinkage rate Each resin is injected and filled into a 100 mm x 100 mm x 3 mm thick injection mold, with marks set at intervals of 90 mm in the flow direction and 90 mm in the direction perpendicular to the flow direction. A test piece on a flat plate was used after holding the holding pressure of 50% of the peak pressure for 10 seconds and cooling for 20 seconds.
Mold shrinkage: The molded test piece was kept in a state of 23 ° C. and 50% Rh for a whole day and night, and the interval between the marks was measured. The measured value was divided by the interval on the mold to calculate the molding shrinkage.
Secondary shrinkage: After measuring the molding shrinkage, the test piece was heat-treated at 130 ° C. for 2 hours. Then, the heat-treated test piece was kept for a whole day and night in an atmosphere of 23 ° C. and 50% Rh, and the interval between the marks was measured. The secondary shrinkage was calculated by dividing the measured value from the interval after molding used to calculate the molding shrinkage.

(2) Flexural modulus ISO 178 Measurement was performed based on a plastic bending test method.

(3) Total light transmittance, Haze
A test piece having a size of 50 mm × 50 mm was cut out from the transparent part of the obtained panel-shaped molded article, and the total light transmittance and Haze were measured based on ISO 13468-1 and ISO 14782.

(4) Curvature height The obtained panel-shaped molded object was set | placed on the surface plate, the height from a surface plate surface to the highest point was measured, and it was set as the curve height.

(5) Appearance Evaluation of Product As shown in FIG. 9, a grid 9 having a pitch of 20 mm is prepared, and the projection angle (elevation angle) is 45 degrees with respect to the front surface of the sample panel. A grid 9 is arranged, and the shadow of the grid is projected on the front surface of the panel body 1 together with the light passing through the grid 9. Then, the shadow of the grid 9 is observed from a position symmetrical to the grid 9 with respect to the virtual perpendicular of the projection point of the panel body 1. When the surface of the panel body 1 is flat, no distortion is seen in the shadow of the lattice 9, and when there is a minute distortion on the surface of the panel body 1, the shadow of the lattice 9 is also distorted. The evaluation was made with the case where there was no distortion at all, the case where there was very little distortion being good, and the case where distortion was normally visually recognized as being impossible.

  In Examples 1-5 and Comparative Examples 1-3, Tg-60 ° C is 93 ° C, and in Example 6, Tg-60 ° C is 90 ° C. As is apparent from Table 2, Examples 1-4 have no or little distortion, while Comparative Examples 1-3 have a large distortion.

DESCRIPTION OF SYMBOLS 1 Panel main body 2,2A, 2B, 2C Frame-shaped part 3 Transparent area | region 4,4A, 4B, 4C Panel 8 Distortion 9 Lattice 10 Mold 11,12 Side type | mold 13 Central type | mold 14,15,16 Cavity 17,18Runner 20 , 23 Injection device 21 First synthetic resin material 22 Second synthetic resin material

Claims (3)

In the panel molding method, the frame-shaped portion made of the second synthetic resin material is integrally formed by injection molding on the peripheral portion of the panel body made of the first synthetic resin material having the glass transition temperature Tg (° C.). The synthetic resin material is an aromatic polycarbonate resin, the main components of the first synthetic resin material and the second synthetic resin material are the same, and the panel body is held on the core side of the mold, A method for forming a panel, comprising: injecting a second synthetic resin material to form a frame-like portion in a state where the surface temperature of the panel body is 40 ° C. or higher (Tg−60 ° C.).   2. The method for forming a panel according to claim 1, wherein the second synthetic resin material contains an aromatic polycarbonate resin and a thermoplastic polyester resin. 3. The structure according to claim 1, wherein when the volume of the panel body is V ₁ and the volume of the frame-like portion is V ₂ , 0.1 ≦ V ₂ / V ₁ ≦ 1.0 is satisfied. Panel forming method.

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