JP3255177B2 - Manufacturing method of three-dimensional laminated molded products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel method of manufacturing a three-dimensional molded product used for an illuminated switch, a dial, a display panel, etc., in which characters and marks are raised by an internal lamp light during operation. Partial transmission of light to clarify the design,
Switches and display panels for clearly identifying display contents from others are widely used in various electric and electronic devices such as automobiles, audio equipment, and VTRs. In particular, recently, with emphasis on design, display panels and switches having a three-dimensional shape rather than a flat or gentle curved surface have been demanded.

[0002]

2. Description of the Related Art Print coating, in which only characters and panels are light-transmitting and others are light-shielding, is easily performed by multi-layer printing or masking coating on products having flat or gentle curved surfaces, and has a three-dimensional shape. Even in the case of a product, if the printed painted portion has a convex shape, it can be processed by a post-processing method such as tampo or pad printing.

However, in the case of a three-dimensional product having irregularities, it is difficult to perform a post-processing method. A painting molding method that is integrated with the resin that is inserted and injection molded,
A molding transfer method of transferring only a coating film to a product is used.

Although a relatively small shape can be formed simultaneously with injection molding by using a flat sheet or film, wrinkles are generated in the sheet or film when processing from a flat state when the shaping amount is large. It was difficult to break, break or cut.

[0005] As a means for solving the problem, there is also known a method in which a sheet or film is formed into a product shape in advance, or a sheet or film is thermoformed in a mold to conform to the shape, and then injection molded.
However, when thermoforming a sheet or film according to its shape, the sheet or film is heated to a temperature higher than the softening temperature of the base resin of the sheet or film. In order to be disturbed, collapsed or discolored, it is necessary to select a special ink or stamping foil, which has a drawback that the selection range is limited.

In order to make up for the drawbacks of thermoforming, there is an example of using a sheet or film which can be cold drawn.
There is a drawback that the processing range is narrow and processing marks (elongation marks) remain on the sheet or film surface when larger shaping is performed.

[0007]

Means for Solving the Problems The present inventors have intensively studied a method for solving the above-mentioned problems of the conventional method, and as a result, in a mold, a movable core and a molten resin to be injection molded have a three-dimensional shape. A method of shaping was found, and the present invention was completed.

That is, the present invention uses a mold having at least a mounting side jig (CT) and a core side and a cavity side, and has a thickness of 0.1 to 0.1
A 2.0 mm light-transmitting flat aromatic polycarbonate resin sheet (1) is sandwiched and mounted between the jig (CT) and the cavity side, and the sheet (1) is moved by closing the mold. After the primary molding, the molten thermoplastic resin molding material is injected to perform final shaping of the sheet (1) into the cavity shape, and the injected thermoplastic resin molding material is laminated and integrated. This is a method for producing a three-dimensional laminated molded product.

In the above, the mold further comprises a movable core.
Are those made by providing a (MC), the primary forming of the sheet (1), the movable core of the (MC) until the sheet (1) is in contact with the cavity <br/> tee over of the cavity side This is a method of manufacturing a three-dimensional laminated molded product by moving the movable core (MC) forward and then retracting the movable core (MC) to a position where the molded product of the cavity is formed .

The present invention also provides at least a mounting jig.
Using a mold consisting of a core side and a cavity side provided with (CT) and a movable core (MC), it is made of light-transmitting flat aromatic polycarbonate resin with a thickness of 0.1 to 2.0 mm, which has been pre-printed and painted. The sheet (1) is sandwiched and mounted between the jig (CT) and the cavity side, and the movable core is mounted.
(MC) to the position where the molding of the cavity is formed.
And have about the position, the sheet by the operation for closing the mold
(1) After the primary molding, at the same time or immediately after injection of the weighed molten thermoplastic resin molding material, the movable core (MC)
Wherein the sheet (1) is advanced to a position where a molded product of the cavity is formed, and the final shape of the sheet (1) is formed into the shape of the cavity , and the molded product is formed into a molded product.

Hereinafter, the present invention will be described. First, the mold of the present invention is provided with a jig (CT) for mounting the sheet (1), and, if desired, a movable core (MC) on the mold core side forming the mold cavity. 1) can be mounted on a mold by being sandwiched between the mounting jig (CT) and the cavity side. The movable core (MC) provided as required is operated independently of the opening / closing of the mold and the operation of taking out the molded product, and the degree of primary molding of the sheet (1) is adjusted, This has a function of enabling pre-molding with a molten resin. Since the cavity surface side of the movable core (MC) is for shaping the sheet (1), it is preferable that the corner-corresponding portion is constituted by a smooth curve.

The sheet (1) of the present invention, which is mounted on the mold, shaped, and used for laminating and integrating into a three-dimensional laminated molded article, has a thickness of 0.1 to 2.0 mm, which is pre-printed and painted, and has a light transmitting property. This is a sheet made of an aromatic polycarbonate resin having flat properties.

The sheet used for the aromatic polycarbonate resin sheet may be a light-transmitting ordinary aromatic polycarbonate resin sheet having a thickness of 0.1 to 2.0 mm.
There is no particular limitation. The surface of the sheet may be a glossy smooth surface or a matte surface having fine matte unevenness without gloss. The sheet may be colored to a desired color with a suitable dye or pigment as long as the sheet transmits light.

Further, the sheet (1) is a sheet in which an adhesive layer is appropriately formed on the sheet surface on the side to be integrated with the thermoplastic resin for injection molding from the viewpoint of adhesiveness with a molding material resin used for injection molding. It is preferred that As an example of the adhesive layer, the thermoplastic resin molding material is polycarbonate (PC), PC
/ Polyester resin (PES) composition, PC / ABS resin composition, PC / polyamide resin (PAD) composition, other PC
In the case of a resin composition containing PC as one of the main components (PC alloy), there is no adhesive layer; the thermoplastic resin molding material is an acrylic resin such as polymethyl methacrylate (PMMA), polystyrene (PS), methyl methacrylate. Styrene-based copolymer (MS), acrylonitrile-styrene copolymer (AB
In the case of (S) or the like, an acrylic resin layer is formed;
In the case of polyvinyl chloride or other general-purpose applications that do not require heat resistance, an example in which an EVA-based resin layer is formed is exemplified.

On the sheet (1), a light-shielding portion having a design such as light-transmitting characters and marks is formed substantially at the center of the light-shielding portion. This method is not particularly limited, such as conventionally known silk screen printing, hot stamping, coating, sputtering, and plating. The characters or marks are not particularly limited, such as various characters, marks, and designs. In addition, if the characters or marks are naturally light-transmissive, white, clear coloring, or other printed materials such as paints or inks are preferably used.

Here, the binder component of the ink or paint used for forming the light-shielding portion may be any of those known for conventional polycarbonate resins, and is not particularly limited. For example, as the binder component, acrylic, acrylic / alkyd, urethane, acrylic / urethane, epoxy, vinyl chloride / vinyl acetate copolymer,
Nitrocellulose and the like. Oxides such as titanium dioxide, red iron and cobalt blue, sulfides such as zinc sulfide, sulfates such as precipitated barium sulfate, hydrated silicates, silicates such as ultramarine blue, and ferrocyanines such as dark blue Powders, metal powders such as aluminum powder and zinc powder, and various hydroxides, chromates, carbonates, phosphates, etc., and brilliant carmine 6 as an organic pigment.
B, azo pigments such as disazo yellow, phthalocyanine pigments such as phthalocyanine blue, nitro pigments such as naphthol yellow, condensed polycyclic pigments such as quinacridone red, and various other organic pigments and dyes are appropriately used.

A printing ink or paint is prepared by mixing these binders, colorants, appropriate solvents, additives and the like.
Light-transmitting characters or marks are formed by coating and drying the sheet (1). When a metal-like appearance is required, a method such as hot stanping or masking a character or mark portion is used, and a method such as sputtering, vacuum deposition, or plating is used. If necessary, under and top are coated.

The sheet (1) on which the light-transmitting characters or marks and other designs and the light-shielding portions are formed as described above is usually placed in the shape or size (cross section) of the mold cavity for mounting the sheet (1). And used as a single piece of the size obtained by adding the width of the mounting portion to the periphery of the device, or cut into a shape that can be continuously supplied and sequentially collected. The width of the mounting part is determined by the rate of increase in the surface property of the sheet (1) by the first step of shaping (= the rate of increase in the surface area by shaping from a flat state to a three-dimensional shape) or simple elongation for each product shape. (E.g., the length of the end face in the diameter direction for a cylindrical shape) .If the shaping amount of the sheet (1) is large or cold, When the area is large, it is preferable to make the area larger.

The thermoplastic resin molding material of the present invention usually comprises
It has light transmissivity, and the required performance, shape,
It is appropriately selected depending on cost and the like. In addition, a known condition range of the resin material to be used is applied to the injection molding conditions and the like.
Specific molding materials include PC, PC / PBT, PC / PET, PC / PCT
A, PC / PES composition such as PC / PCTG, PC / ABS, PC / polyphenylene ether (PPE) / PES composition, PC / PA composition, PC / P
ES / PA compositions, other PC alloys; Acrylic resins such as PMMA; Styrene resins such as PS, MS, AS, ABS; PPE /
PES, PPE / PA, PPE / PES, other PPE alloys; polyacetal resins and their compositions; nylon-6 (PA6), nylon-66 (PA66), nylon-6,10 (PA610), nylon-12
(PA12), PA such as nylon-MXD6; PET, PBT, 1,4-
PES such as hexanediol / terephthalic acid / isophthalic acid copolymer (PCTA) and 1,4-hexanedimethanol / ethylene glycol / terephthalic acid copolymer (PCTG); PVC, etc .; especially engineering plastics and alloys Is preferred.

Next, in order to facilitate understanding of the present invention,
An example will be described with reference to the drawings. FIG. 1 is a cross-sectional view for explaining the manufacturing process of the illuminated switch with mark according to the present invention. The first sheet is formed in a metal mold by using a mold clamping operation. It is the figure which imitated the state where the shape of the 2nd stage was given (final shaping) by the pressure and heat of the injection molding material, and the three-dimensional laminated molded article manufactured by lamination was manufactured.

Reference numerals in FIG. 1 are respectively: a polycarbonate resin sheet which has been printed and painted in advance with a design having a light transmitting property and the other part having a light shielding property, 2: an injection resin,
10: cavity side, 11: cavity, 20: core side, CT: jig for seat mounting, MC: movable core, 21,
Runner, 22: Indicates a gate, and corresponding portions in b, b ', and c indicate the same one.

In FIG. 1A, a sheet (1) is mounted on a mold cavity side, and the sheet (1) is mounted by being sandwiched by a sheet mounting jig (CT) by a mold closing operation. Naturally, the jig (CT) having a function of adjusting the pressure for sandwiching the sheet (1) is more preferable because the applicable range becomes wider.

[0023] Then, as shown in b, subsequently the mold closing operation, to a position where the core is a molded article is formed cavity
The sheet (1) is advanced in the tee and the primary forming of the sheet (1) is performed.
Further, the b ', the core is movable core (MC), the
Movable core (MC) is, after shaping the sheet (1) sheet (1) is advanced to a state in contact with the cavity, said cavitation
It retracts to the position where the molded product of ィ is formed and performs primary shaping.

Next, in the step c, after the mold clamping pressure is increased to the normal pressure, the molten thermoplastic resin is injected to perform secondary molding (final molding) of the sheet (1), and to form the sheet (1) with the molded article main body. After the lamination integration and formation of the molded article main body and the injection resin is cooled, the molded article is taken out. Sheets are usually included in manufactured parts
(1) Since the portion sandwiching is overhanging, it is cut into a product.

Although not shown, the movable core (MC) is moved to a position where a molded product of the cavity is formed.
The position of the degree to (middle position), after forming the primary to the intermediate position of the seat (1) by the operation for closing the mold,
The movable core (MC) is formed at the same time as or immediately after the molten thermoplastic resin molding material measured at the normal mold clamping pressure is injected.
The sheet (1) can be advanced to a position where a shaped article is formed to perform final shaping into the cavity shape of the sheet (1) and to be formed into a shaped article shape.

In this method of primary molding with the core → injection of the required amount of molten resin into the molded article → final molding with the core, it is necessary for the injection molding machine to produce a product with good molten resin measurement accuracy. . Therefore, when the accuracy of the molten resin measurement by the injection molding machine is insufficient, a slightly excessive amount of the molten resin is injected, and a mold is formed so that the excess resin flows back to the gate and the runner during the final molding with the core. It is preferable to design the gates and runners.

The present invention has been described with reference to the drawings. In the method for producing a three-dimensional laminated molded product of the present invention, the movable core (M
The shaping amount of the first step according to C) is preferably selected from a range in which the area increase rate or elongation of the sheet (1) is 50% or less, particularly when the sheet (1) is preheated. ~ 50%
It is possible to do so within the range of about 20%, and in the case of cold, it is preferable to carry out in the range of about 20% or less. In the present invention,
The sheet (1) generated by the primary molding due to the introduction of the molten resin immediately after the primary shaping easily loses the surface elongation traces, etc., but when the shaping amount exceeds the upper limit, it occurs at the time of shaping. The resulting stretch marks remain after forming the molded article, which is not preferable. In addition, the mold shape, especially the movable core (M
The larger the corner angle of the corner portion (C), the larger the shape can be formed, and it is preferable to make the molded product design in this way.

[0028]

The present invention will be described below in detail with reference to examples. Example 1 A mold corresponding to FIG. 1 and having a cylindrical mounting portion for a lighting switch component having a sheet mounting portion of 38 mmφ, a cavity cross section of 20 mmφ, a height of 25 mm, and a wall thickness of 2 mm was used as a mold.

A polycarbonate resin sheet having a thickness of 0.5 mm was used. The sheet had a light-transmitting mark at the center, and light-shielding topcoat printing was applied to the other portions. This sheet was punched out into a 38 mmφ disk in accordance with the dimensions of the die mounting portion with a press machine to obtain a mounting sheet (1).

The sheet (1) is placed on the mounting portion on the cavity side, and then the mold is closed by closing the mounting jig (C).
T) sandwiched the sheet (1), subsequently, the mold was closed, and the core was advanced to a position where a molded product was formed, thereby forming the sheet (1). In this case, open the mold and open the sheet
As a result of observing (1), the sheet (1) was formed in a trapezoidal shape with a cross section of 6 mm in height, and the external dimensions of the mounting fixed part changed to 36 mmφ (= area increase rate 11%, simple elongation 17%), The sheet (1) had no wrinkles or breakage, and the printed film on the surface was stretched to follow the shape.

Next, the mold clamping pressure was increased to the normal pressure used for injection molding, and a transparent polycarbonate resin (Iupilon S-3000) was injection-molded at a temperature of 290 ° C. and a pressure of 1,600 kgf / cm ² , and a pressure of 8 mm was measured from the upper surface. A molded product in which the sheet (1) and the injection resin are laminated and integrated up to the point (= 15% area increase rate), and the overhanging portion of the PC sheet (the portion that remains between the molds) remaining in the molded product is The product was obtained by press cutting.
The obtained product had a light-transmitting design in the center of the upper surface, and the design pattern and other portions of the laminated and integrated sheet (1) were not disturbed by shaping.

Example 2 As a mold, a movable core (MC) corresponding to FIG. 1 b ′ was provided, the seat mounting portion was 38 mm, and the cavity cross section was 20 mm.
[psi, height 25 mm, using the one having a cylindrical illuminated switch component cavity thickness 2 mm, mounting the sheet
Between the tool (CT) and the cavity side
Mounting, and to advance the movable core (MC) until the sheet (1) is in contact with the cavity of the cavity side, followed
The movable core (MC) is formed into a molded article of the cavity.
A molded product was obtained in the same manner as in Example 1 except that the PC sheet was retracted to a certain position, and the protruding portion of the PC sheet remaining in the molded product (the portion remaining after being sandwiched by the mold) was press-cut to obtain a product. The obtained product had a light-transmitting design in the center of the upper surface, and the design pattern and other portions of the laminated and integrated sheet (1) were not disturbed by shaping.

[0033]

According to the present invention, a flat sheet is formed in a mold to produce a molded product laminated and integrated with an injection molding resin, so that the sheet is formed into a three-dimensional laminated molded product. The step of preforming together is omitted, and the mounting of the sheet in the mold is easy because it is a flat plate.
(1) Since molten resin is introduced immediately after primary molding,
Elongation traces due to molding of the sheet (1) are also unlikely to occur.

As a result, compared to the conventional method, it is possible to manufacture a three-dimensional laminated molded product having a design pattern with higher productivity, and it is possible to form a three-dimensional molded product which has been conventionally difficult. Yes, its industrial significance is great.

[0035]

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a manufacturing process of an illumination switch with a cross-sectional mark.

[Explanation of symbols]

The reference numerals in FIG. 1 are respectively: a polycarbonate resin sheet which has been printed and painted in advance, the design of which is light transmissive and the other portions are light shielding, 2: injection resin, 10: cavity side, 11: cavity , 20: core side, CT:
Jig for seat mounting, MC: movable core, 21: runner, 2
2: Indicates a gate, and corresponding parts in b, b ', and c indicate the same one.

──────────────────────────────────────────────────続 き Continuing on the front page (51) Int.Cl. ⁷ identification symbol FI B29L 31:34 B29L 31:34 (58) Investigated field (Int.Cl. ⁷ , DB name) B29C 45/14-45/63 B29C 51/08

Claims (4)

(57) [Claims] 1. A light-transparent flat fragrance having a thickness of 0.1 to 2.0 mm, which is pre-printed and coated using a mold having a core side and a cavity side provided with at least a mounting jig (CT) for mounting. A group 1 polycarbonate resin sheet (1) is sandwiched between the jig (CT) and the cavity side and mounted, and the sheet (1) is primarily molded by an operation of closing a mold. A method for producing a three-dimensional laminated molded product, comprising: injecting a resin molding material to perform final shaping of the sheet (1) into a cavity shape, and laminating and integrating the injected thermoplastic resin molding material. 2. The method for manufacturing a three-dimensional laminated molded product according to claim 1, wherein said mold further comprises a movable core (MC). 3. A primary forming of the sheet (1) to advance the movable core a (MC) until the sheet (1) is in contact with the cavity of the cavity side, then the movable core (MC)
3. The method for producing a three-dimensional laminated molded product according to claim 2, wherein the step of retracting the molded product is performed to a position where the molded product of the cavity is formed. 4. A pre-printed thickness of 0.1 to 0.1 mm using a mold having at least a mounting jig (CT) and a core side provided with a movable core (MC) and a cavity side.
A 2.0 mm light-transmitting flat aromatic polycarbonate resin sheet (1) is sandwiched and mounted between the jig (CT) and the cavity side, and the movable core (MC) is molded into a cavity. After the sheet (1) is primarily molded by closing the mold, and the measured molten thermoplastic resin molding material is injected at the same time or immediately after the mold is closed, Core (MC) into the cavity
The sheet is advanced to the position where the
(3) A method for producing a three-dimensional laminated molded product, wherein the final shape is formed into the cavity shape of (1) and the molded product is formed.