JP6950940B2 - Manufacturing method of resin molded products - Google Patents

Description

The present invention relates to a method for producing a resin molded product and a decorative film used in the method for producing a resin molded product.

Two types of molding methods, in-mold molding and insert molding, are mainly used as a method of performing decoration at the same time as molding a resin molded product using a decorative film. In in-mold molding, a roll-shaped decorative film is sandwiched between molds, filled with resin, and injection-molded to decorate the surface of the resin-molded product (see Patent Document 1). In in-mold molding, the decorative film protruding from the resin molded product becomes burrs, so a step of cutting is required, and there is a problem that the roll-shaped decorative film is sandwiched between the molds, resulting in misalignment. ..

Insert molding is a method of decorating the surface of a resin molded product by putting a decorative film processed into a predetermined shape into a mold, filling the mold with resin, and injection molding (Patent Document 2). reference). Compared with in-mold molding, insert molding has the advantage that there is no problem of foil burrs and misalignment is unlikely to occur. However, in order to decorate not only the upper surface but also the side surface of the resin molded product at the same time, it is necessary to use a preform film, which causes a problem that the process becomes complicated and the manufacturing cost increases. Therefore, when decorating a resin molded product at low cost by using insert molding, there is a problem that only the upper surface of the resin molded product can be decorated.

In order to solve such a problem of insert molding, a method is used in which a fold line is provided on the decorative film to make it easier to fold the decorative film, whereby an expensive preform film is used. The side surface of the resin molded product is decorated (see Patent Document 3).

Japanese Unexamined Patent Publication No. 2014-184726 Japanese Unexamined Patent Publication No. 2013-184294 Japanese Unexamined Patent Publication No. 2016-55622

However, when the decorative film is provided with a fold line, there is a problem that the external dimensions of the decorative film vary and the positioning accuracy deteriorates. Further, since the decorative film is cut as a fold line, there is a problem that the bent portion of the decorative film is stretched and easily torn, and the stretched portion is thinned so that the base can be seen through. Further, when the corner portion of the resin molded product is chamfered with a curved surface, there is a problem that if the R of the corner portion becomes large, a portion that cannot be decorated with one decorative film occurs.

Therefore, the present invention is used in a method for manufacturing a resin molded product and a method for manufacturing a resin molded product, which can improve positioning accuracy and simultaneously decorate the upper surface and the side surface of the resin molded product at low cost. It is an object of the present invention to provide a decorative film.

The method for producing a resin molded product of the present invention is a method for producing a resin molded product that decorates the upper surface and side surfaces of the resin molded product by insert molding using one flat decorative film. The step of arranging and positioning the decorative film having the upper surface decorating portion for decorating the upper surface of the resin molded product and the side surface decorating portion for decorating the side surface of the resin molded product in the positioning jig. The upper surface decoration portion of the decorative film arranged in the positioning jig is pressed from above by the bending guide, and the side surface decoration portion protruding in the horizontal direction from the bending guide is decorated on the upper surface by the folding means. A step of bending the portion, a step of holding the bent decorative film by a holding means, taking it out from the positioning jig, moving it into the mold, and arranging it in the mold, and bending. It is characterized by including a step of filling the mold in which the decorative film is arranged with a resin and performing insert molding to form a resin molded product.

This includes a step of bending the side decoration portion of the decorative film at a predetermined angle and then further bending the side decoration portion.

When the side surface decoration portion is bent by the folding means, the top surface decoration portion is pressed by the bending guide, the decoration film is moved downward, and the bending means arranged below the side surface decoration portion. The side decoration portion is bent upward by the method.

The resin molded product has a shape in which the corners of the side surface are chamfered with a curved surface, and the decorative film has the corners of the upper surface decorative portion molded with the resin in accordance with the resin molded product. Cut with a curved surface that matches the curved surface of the corners of the side surface of the product, and make the edges of the adjacent side decorations abutting and contacting each other on the curved surface of the corners of the side surface of the resin molded product. One corner portion formed and formed of a curved surface on the side surface of the resin molded product is decorated by the two side surface decoration portions.

The end portion of the adjacent side surface decoration portion is formed at a corner portion formed by a curved surface of the side surface of the resin molded product so that a part thereof overlaps with each other.

The decorative film of the present invention is a decorative film for simultaneously decorating the upper surface, the side surface, and the corners chamfered by the curved surface of the side surface when the resin molded product is insert-molded. The upper surface decoration portion for decorating the upper surface of the resin molded product and the side decoration portion for decorating the side surface of the resin molded product are provided, and the upper surface decoration portion and the side surface decoration portion are provided. It is integrally formed flat, and the corners of the upper surface decoration portion are cut with a curve that matches the curved surface of the corner portion of the side surface of the resin molded product, and the end portion of the adjacent side surface decoration portion is cut. Is formed so as to be abutted against each other and in contact with each other on the curved surface of the corner portion of the side surface of the resin molded product.

The end portions of the adjacent side surface decoration portions are formed so as to partially overlap each other on the curved surface of the corner portion of the side surface of the resin molded product.

The method for producing a resin molded product of the present invention is a method for producing a resin molded product that decorates the upper surface and side surfaces of the resin molded product by insert molding using one flat decorative film. The step of arranging and positioning the decorative film having the upper surface decorating portion for decorating the upper surface of the resin molded product and the side surface decorating portion for decorating the side surface of the resin molded product in the positioning jig. The upper surface decoration portion of the decorative film arranged in the positioning jig is pressed from above by the bending guide, and the side surface decoration portion protruding in the horizontal direction from the bending guide is decorated on the upper surface by the folding means. A step of bending the portion, a step of holding the bent decorative film by a holding means, taking it out from the positioning jig, moving it into the mold, and arranging it in the mold, and bending. By including the step of filling the mold in which the decorative film is arranged with resin and performing insert molding to form a resin molded product, the positioning accuracy of the decorative film in the mold is improved. The upper surface and the side surface of the resin molded product can be beautifully decorated at the same time by the decorative film, the yield can be improved, and the cost of decorating the resin molded product can be reduced.

The resin molded product has a shape in which the corners of the side surface are chamfered with a curved surface, and the decorative film has the corners of the upper surface decorative portion molded with the resin in accordance with the resin molded product. Cut with a curve that matches the curved surface of the corner of the side surface of the product, and make the edges of the adjacent side decorations abutting and contacting each other on the curved surface of the corner of the side surface of the resin molded product. By forming and decorating one corner portion formed of the curved surface of the side surface of the resin molded product with the two side decoration portions, it is possible to form a shape in which the corner portion of the resin molded product is chamfered with a large curved surface of R. Therefore, the design of the resin molded product can be improved.

By forming the end portions of the adjacent side surface decoration portions at the corner portions formed by the curved surfaces of the side surfaces of the resin molded product so that some of them overlap each other, the decorative film at the corner portions of the resin molded product can be formed. It is possible to prevent a gap from being formed in the butt portion.

The decorative film of the present invention is a decorative film for simultaneously decorating the upper surface, the side surface, and the corners chamfered by the curved surface of the side surface when the resin molded product is insert-molded. The upper surface decoration portion for decorating the upper surface of the resin molded product and the side decoration portion for decorating the side surface of the resin molded product are provided, and the upper surface decoration portion and the side surface decoration portion are provided. It is integrally formed flat, and the corners of the upper surface decoration portion are cut with a curve that matches the curved surface of the corner portion of the side surface of the resin molded product, and the end portion of the adjacent side surface decoration portion is cut. Is formed so as to be abutted against each other and come into contact with each other on the curved surface of the corner portion of the side surface of the resin molded product, so that the upper surface, side surface and curved surface of the resin molded product are chamfered by one decorative film. The corners can be beautifully decorated at the same time, the yield can be improved, and the radius of the corners of the resin molded product can be increased, making it possible to make resin molded products of various shapes. You will be able to use it.

The end portion of the adjacent side surface decoration portion is formed so as to partially overlap each other on the curved surface of the corner portion of the side surface of the resin molded product, so that the corner portion of the resin molded product is decorated. It is possible to prevent a gap from being formed at the butted portion of the film.

It is a top view of the decorative film used in the manufacturing method of the resin molded article of this invention. It is a perspective view of the resin molded article decorated with a decorative film. It is a perspective view of the apparatus provided with a positioning jig. It is a perspective view of the state where the decorative film is arranged on the positioning jig. It is a perspective view of the state where the decorative film is pressed by a folding guide. It is sectional drawing which shows the process from positioning of a decorative film to pressing by a bending guide, and is a partially enlarged sectional view. It is sectional drawing which shows the bending process of a decorative film, and is the partially enlarged sectional view. It is sectional drawing which shows the process of taking out a bent decorative film from a positioning jig, and is the partially enlarged sectional view. It is a top view and a partially enlarged plan view of the decorative film of this invention. It is a perspective view of the corner part of the decorative film of this invention in a folded state. It is a perspective view of the corner part of the resin molded article decorated by the decorative film of this invention. It is a top view of the corner part of the decorative film of another form of this invention. It is a perspective view of the corner part of the resin molded article decorated by the decorative film of another form of this invention.

The method for producing the resin molded product of the present invention and the decorative film will be described in detail below with reference to the drawings. First, the method for producing the resin molded product of the present invention will be described. FIG. 1 shows a plan view of the decorative film 10 used in the method for producing a resin molded product of the present invention, and FIG. 2 shows a perspective view of the resin molded product 20 decorated with the decorative film 1. It is a figure, and FIG. 3-8 is a figure which shows the process of the manufacturing method of the resin molded article of this invention.

In the method for producing a resin molded product of the present invention, the upper surface and the side surface of the resin molded product 20 are simultaneously formed as shown in FIG. 2 by insert molding using one decorative film 10 as shown in FIG. This is a method of manufacturing a resin molded product by decorating it. First, the decorative film 10 used in the method for producing a resin molded product of the present invention will be described.

As shown in FIG. 1, the decorative film 10 is a film having one upper surface decorating portion 11 and four side surface decorating portions 12, and the upper surface decorating portion 11 is rectangular and has four sides thereof. The side decoration portions 12 are arranged respectively. The boundary between the upper surface decoration portion 11 and the side decoration portion 12 is drawn with a line in the drawing to make the boundary easy to understand, but the notch of the fold line or the like is not provided, and the decoration The film 10 is composed of a single flat film. Although not shown, the decorative film 10 can be decorated with various patterns, characters, and the like by printing or the like. The material and decoration method of the decorative film 10 are not particularly limited, and conventionally used materials and decoration methods can be applied.

The decorative film 10 is arranged in the positioning jig 3 of the device 2 as shown in FIGS. 4 and 6 (a). As shown in FIG. 3, a table 4 on which the decorative film 10 is placed is arranged in the positioning jig 3, and as shown in FIGS. 4 and 6 (a), the table 4 is arranged in the positioning jig 3. When the decorative film 10 is arranged, the decorative film 10 is positioned by the four side surfaces of the positioning jig 3, and the upper surface decorative portion 11 of the decorative film 10 is placed on the table 4. As shown in FIG. 6A, the side decoration portion 12 is in a state of protruding horizontally from the table 4. The means for arranging the decorative film 10 in the positioning jig 3 is not particularly limited, and the decorative film 10 is arranged from the position where the decorative film 10 is placed by using moving means, or the decorative film 10 is manually arranged. It is also possible to arrange the 10 in the positioning jig 3.

After arranging the decorative film 10 in the positioning jig 3, as shown in FIGS. 6 (b) and 6 (c), the upper surface decorative portion 11 of the decorative film 10 is bent from above by the bending guide 5. Press. The bending guide 5 has a size that covers the entire upper surface decoration portion 11, and as shown in FIGS. 6 (b) and 6 (c), the peripheral edge portion has a thin thickness, and further. It has a built-in vacuum suction means 6. As shown in FIG. 5, when the decorative film 10 is pressed by the bending guide 5, the upper surface decorative portion 11 of the decorative film 10 has the bending guide 5 and the bending guide 5 and the decorative film 10 as shown in FIG. 6 (c). It is sandwiched up and down by the table 4, and the side decoration portion 12 is in a state of projecting horizontally from the periphery of the bending guide 5 and the table 4.

As shown in FIG. 6C, four rollers 7, which are bending means, are arranged below the side decoration portion 12, and the side decoration portion 12 is bent by the rollers 7. .. When the upper surface decoration portion 11 is pressed from above by the bending guide 5, the base 4 held by elastic means such as a spring moves downward, so that the decoration film 10 is the positioning jig. Move downward in 3.

As shown in FIG. 7A, when the decorative film 10 is moved downward, the bending guide 5 and the side decorative portion 12 projecting horizontally from the base 4 are located downward. It comes into contact with the roller 7 and is bent upward, and as shown in FIG. 7B, the side surface decoration portion 12 is bent at a right angle to the top surface decoration portion 11.

In this way, the decorative film 10 is bent by the roller 7, which is a folding means, so that the decorative film 10 has four side decorative portions with respect to the upper surface decorative portion 11. The 12 is bent at a right angle, and the shape can be formed along the surface of the resin molded product 20.

In this way, the decorative film 10 is bent, but depending on the material, thickness, configuration, etc. of the decorative film 10, the bent state of the side decorative film 12 is slightly original after the bending process. May return to. Therefore, it is possible to use the step of further bending the side surface decoration portion 12 from a right angle by using the roller 7.

In order to further bend the side surface decoration portion 12 from a right angle, the pressing by the bending guide 5 is continued so that the upper surface of the peripheral edge portion of the bending guide 5 is below the roller 7. Then, when the upper surface of the peripheral edge portion of the bending guide 5 moves below the roller 7, the pressing of the bending guide 5 is stopped, and the two opposing rollers 7 are moved horizontally so as to approach each other. As shown in FIG. 7C, the side decoration portion 12 is further bent toward the upper surface of the peripheral edge portion of the bending guide 5. At this time, instead of moving the four rollers 7 at the same time, as shown in FIG. 7 (c), the two side decoration portions 12 are bent by the two opposing rollers 7, and the two said ones. After returning the roller 7 to its original position, the remaining two rollers 7 further bend the remaining two side decoration portions 12. After that, when the remaining two rollers 7 are returned to their original positions, the bending process of the decorative film 10 is completed. Even if the side decoration portion 12 is bent to the folded state as shown in FIG. 7C, the side decoration portion 12 tries to return to its original position, but as shown in FIG. 8A, it is omitted. The bending strength and angle, the material of the decorative film 10, and the like are appropriately set so that the film fits in the state of being bent at a right angle.

When the bending process of the decorative film 10 is completed in this way, the decorative film 10 is held by the suction means 6 which is a holding means, and as shown in FIG. 8B, the decorative film 10 is held. 10 is taken out from the positioning jig 3 and moved into a mold (not shown). At this time, as shown in FIG. 8B, the decorative film 10 is moved while being bent while being inserted into a predetermined position in the mold, but the decorative film 10 is inserted. Since the shape is bent to fit the mold, it can be easily and accurately placed at a predetermined position in the mold.

After arranging the decorative film 10 in the mold, although not shown, the resin molded product 20 is formed by filling the mold with resin and performing insert molding in the same manner as in the conventional insert molding. To form. As a result, as shown in FIG. 2, the resin molded product 20 whose upper surface and side surface are decorated with one decorative film 10 is completed.

The method for producing a resin molded product of the present invention improves the positioning accuracy of the decorative film 10, the bent portion of the decorative film 10 does not become thin, and the upper surface and the side surface of the resin molded product 20 are simultaneously formed by one sheet. It becomes possible to decorate beautifully, and the yield can be improved.

The shape of the decorative film 10 is described on the assumption that the upper surface and four side surfaces of the resin molded product 20 such as a compact lid will be decorated, and a form having four side surface decoration portions 12 is used. However, for example, it is possible to decorate only the upper surface and a part of the side surface of the resin molded product 20, and in that case, it can be easily dealt with by changing the number of the side decoration portions 12. can do.

Further, although it is assumed that the side surface of the tree molded product 20 is perpendicular to the upper surface, the side surface is not limited to a right angle, but may be an inclined side surface. In this case, it can be easily dealt with by changing the bending angle of the side decoration portion 12 of the decoration film 10.

In the bending step of the decorative film 10, the decorative film 10 is pressed by the bending guide 5 and moved downward, but the decorative film 10 is pressed from above by the bending guide 5. By moving the folding means upward in the fixed state, it is also possible to bend the side surface decoration portion 12 protruding from the bending guide 5. The bending means is not limited to the roller 7, and various bending means can be used as long as the side decoration portion 12 can be bent at a right angle without being damaged.

Then, in the step of further bending from a right angle by the roller 7, as shown in FIG. 7C, not only the bending is made to 180 °, but also the upper surface of the peripheral edge of the bending guide 5 is used as an inclined surface. It is also possible to bend it to a predetermined angle in the range of about 180 °, and it can be changed according to the thickness, material and the like of the decorative film 1. Further, the bending angle can be appropriately changed according to the angle of the side surface of the resin molded product 20.

Next, the decorative film 1 of the present invention will be described. The decorative film 1 of the present invention is used for decorating a resin molded product 21 having a curved surface whose side corners are chamfered, and as shown in FIG. 9, the upper surface of the resin molded product 21 is decorated. It has one upper surface decorating portion 13 and four side surface decorating portions 14 for decorating the four side surfaces of the resin molded product 21. Although the decorative film 1 is not shown, various decorations can be applied, and the decoration method and material are not particularly limited, and various decorations used in the conventional decoration film are not particularly limited. Various materials and decoration methods can be applied. Further, the number of the side decoration portions 14 is not limited to four.

As shown in FIG. 9, the upper surface decorative portion 13 of the decorative film 1 is formed by cutting four corners with curves in accordance with the curved surface of the corners of the resin molded product 21. The size and shape of the side surface decorating portion 14 are determined so that the end portions of the adjacent side surface decorating portions 14 are abutted against each other and come into contact with each other on the curved surface of the corner portion of the resin molded product 20.

The decorative film 1 of the present invention uses the method for producing a resin molded product of the present invention to form a corner portion composed of the upper surface, the side surface, and the curved surface of the resin molded product 21 in which the corner portion of the side surface is chamfered by a curved surface. At the same time, it can be beautifully decorated. The step of decorating the resin molded product 21 with the decorative film 1 is not significantly different from that of the case of using the decorative film 10, and therefore detailed description thereof will be omitted. The process will be described below.

When the decorative film 1 is positioned by the method for producing a resin molded product of the present invention and then bent, the decorative film 1 is in a bent state as shown in FIG. The side decoration portion 14 of the decorative film 1 is in a flat state because the portion that decorates the curved surface of the corner portion of the resin molded product 21 is not a curved surface. However, when the decorative film 1 is arranged in the mold in such a state, the end portion of the side decoration portion 14 becomes a curved surface along the curved surface of the corner portion of the mold (the side decoration). A step of pushing the end of the portion 14 into the mold may be required).

After that, the mold is filled with resin and insert molding is performed to complete the resin molded product 21 decorated with the decorative film 1. As shown in FIG. 11, in the resin molded product 21 decorated with the decorative film 1, not only the upper surface and the side surface but also the curved surfaces of the corners of the side surfaces are all added by the side decorative portion 14 of the decorative film 1. In addition, the edges of the four corners on the upper surface of the resin molded product 21 are also neatly decorated by the upper surface decorating portion 13 of the decorative film 1.

As described above, by using the decorative film 1 of the present invention, even if the resin molded product 21 has a shape in which the corners of the side surfaces are chamfered with a curved surface, all the corners are cleaned by one decorative film 1. Will be able to decorate.

When forming the decorative film 1, it is necessary to cut with a curved line, but if a laser is used, the vicinity of the curved line at the corner of the upper surface decorative portion 13 may not be finished cleanly and a gap may be generated. Therefore, it is preferable to perform cutting with a cutting tool.

When the decorative film 1 is used to decorate the resin molded product 21 whose side corners are curved, as shown in FIG. 11, the resin molded product 21 is adjacent on the curved surface of the side corners of the resin molded product 21. Since the seam of the side decoration portion 14 is formed, a gap is generated and conspicuous due to a dimensional error of the side decoration portion 14 or a slight deviation at the time of positioning. In order to prevent this, the decorative film 1 can be in the form of overlapping a part of the side decorative portion 14.

FIG. 12 is a plan view of the corner portion of the decorative film 1 in the form in which the portion 15 overlapping the side decorative portion 14 is provided. The decorative film 1 has a shape in which the width below the side decorative portion 14 is widened, and is a portion 15 in which the triangular regions described by shading in FIG. 12 overlap each other. Since the overlapping portion 15 may not be sufficiently adhered when the area becomes large, the overlapping portion 15 is not provided on the entire end portion of the side decoration portion 14, but is a part of the end portion (in the case of FIG. 12, the upper end portion). (Triangles with zero overlap) are set to overlap.

In the decorative film 1 of the present invention, when the resin molded product 21 is decorated by providing the overlapping portion 15, as shown in FIG. 13, the side decorative portion 14 is formed on the curved surface of the corner portion of the side surface. Even if an error, a deviation, or the like occurs, the overlapping portion 15 of the resin molded product 21 may have a gap on the curved surface of the corner portion of the resin molded product 21 only by changing the area of the overlapping portion 15. It can be significantly reduced.

The decorative film 1 of the present invention is assumed to be used in the method for producing a resin molded product of the present invention, but it can also be used in a method for producing another resin molded product. It is also possible to provide a notch as a fold line in order to make the decorative portion 14 easy to bend.

1,10 Decorative film 2 Equipment 3 Positioning jig 4 units 5 Bending guide 6 Suction means 7 Roller 11,13 Top decoration part 12,14 Side decoration part 20,21 Resin molded product

Claims (4)

It is a method for manufacturing a resin molded product that decorates the upper surface and the side surface of the resin molded product by insert molding using one flat decorative film.
A step of arranging and positioning the decorative film having a top surface decorating portion for decorating the upper surface of the resin molded product and a side surface decorating portion for decorating the side surface of the resin molded product in a positioning jig.
The upper surface decorative portion of the decorative film arranged in the positioning jig is pressed from above by a bending guide, and the side surface decorative portion protruding in the horizontal direction from the bending guide is added to the upper surface by a bending means. The process of bending the decorative part,
A step of holding the bent decorative film by a holding means, taking it out from the positioning jig, moving it into the mold, and arranging it in the mold, and
The decorative film is bent is filled with a resin to arranged the mold perform insert molding, it viewed including the steps of forming a resin molded product,
When the side surface decoration portion is bent by the folding means, the top surface decoration portion is pressed by the bending guide to move the decoration film downward, and below the side surface decoration portion and the positioning jig. A method for producing a resin molded product, which comprises bending the side surface decorative portion upward by a plurality of rollers which are the bending means arranged inside. The production of the resin molded product according to claim 1, further comprising a step of bending the side decoration portion of the decoration film at a predetermined angle and then further bending the side decoration portion by the plurality of rollers. Method. The resin molded product has a shape in which the corners of the side surfaces are chamfered with a curved surface.
In accordance with the resin molded product, the decorative film cuts the corner portion of the upper surface decoration portion with a curved surface matching the curved surface of the side surface portion of the resin molded product, and the adjacent side surface decoration portion is formed. The ends of the resin molded product are formed so as to be abutted against each other and in contact with each other on the curved surface of the corner portion of the side surface of the resin molded product.
The method for producing a resin molded product according to claim 1 or 2 , wherein one corner portion formed of a curved surface on a side surface of the resin molded product is decorated by the two side decoration portions. The resin molded product according to claim 3 , wherein the end portions of the adjacent side surface decoration portions are formed at corner portions formed by curved surfaces on the side surfaces of the resin molded product so that some of them overlap each other. Production method.

Images