Molded article, display device including the molded article and method for manufacturing a molded article

Abstract

Molded article (10; 10A to 10D) with a display section (41) through which light (Li) can pass, wherein the molded article (10; 10A to 10D) comprises: a molded article body (11) including a first molded section (11a, 11d) and a second molded section (11b, 11c), wherein the second molded section (11b, 11c) is made of a translucent resin which transmits light (Li) which is directed to the display section (41), and wherein the first molded section (11a, 11d) is made of an opaque resin which has a lower translucency than the second molded section (11b, 11c); a decorative foil (40; 40A) which is formed in one piece with the molded article body (11) and includes a decorative section (42) which decorates the display section (41); and a translucent touch sensor film (50; 50A) which is formed in one piece with the molded article body (11) and which allows light (Li) to pass through the display section (41), wherein the molded article body (11) further includes a shielding structure (12) which is arranged at least partially around an outer circumferential edge (40e) of the decorative foil (40; 40A) and suppresses the light (Li) passing through the translucent resin.

Description

FIELD OF TECHNOLOGY

[0001] The present disclosure relates to a molded article formed by integrally molding a decorative sheet and a touch sensor sheet, a display device including the molded article, and a method for manufacturing the molded article. STATE OF THE ART

[0002] In the prior art, a display device including a molded article having a display portion through which light can pass is known. For example, JP 2008-210528 A discloses a housing with an illuminated switch, the housing including a housing made of a light-transmitting material, a decorative layer displaying a light-transmitting pattern and a light-shielding pattern, and an electrically conductive thin film.

[0003] Further prior art is provided by JP H06-134 805 A, US 2017 / 0 062 756 A1 and US 2016 / 0 366 779 A1. In detail, JP H06-134 805 A, which is considered to be the closest, discloses a molded article having a display portion through which light can pass, the molded article comprising: a molded article body including a first molded portion and a second molded portion, wherein the second molded portion is made of a light-transmitting resin that transmits light guided to the display portion, and wherein the first molded portion is made of an opaque resin that has a lower light transmittance than the second molded portion, and a film that is molded integrally with the molded article body and encloses a light-transmitting portion.US 2017 / 0 062 756 A1 teaches a window part as a molded article having a display portion through which light can pass, the display portion comprising: a molded article body including a first molded portion and a second molded portion, the second molded portion being made of a translucent resin that transmits light guided to the display portion, and the first molded portion being made of a translucent resin that has a lower thickness, hardness, and expansion than the second molded portion. Finally, US 2016 / 0 366 779 A1 shows a molded article in which a device is partially embedded in plastic and has a connection to the outside. A holder holds the outwardly projecting connection and is embedded in the plastic.During the overmolding of the device, a recess is provided in the injection mold for the connection. SUMMARY OF THE INVENTIONTechnical Problem

[0004] When a molded article is formed by integrally molding a decorative sheet and a touch sensor sheet based on, for example, injection molding, light may leak from near an end portion of the decorative sheet to the outside of the molded article due to, for example, misalignment of the decorative sheet placed in a mold.

[0005] An object of the present disclosure is to suppress light leakage from a molded article formed by integrally molding a decorative sheet and a touch sensor sheet. Solution to the problem

[0006] Some aspects are described below as means of solving the problems. These aspects can be combined as needed.

[0007] A molded article according to one aspect of this disclosure is a molded article having a display portion through which light can pass, the molded article including: a molded article body including a first molded portion and a second molded portion, the second molded portion being made of a light-transmitting resin that transmits light guided to the display portion, and the first molded portion being made of an opaque resin having lower light transmittance than the second molded portion; a decorative sheet molded integrally with the molded article body and including a decorative portion that decorates the display portion;and a light-transmitting touch sensor sheet molded integrally with the molded article body and transmitting light passing through the display portion, the molded article body further including a shielding structure disposed at least partially around a periphery of an outer peripheral edge of the decorative sheet and suppressing light passing through the light-transmitting resin;

[0008] In the molded article, the shielding structure may be provided in or around a gap between a parting line of the second molded portion and the outer peripheral edge of the decorative film.

[0009] In the molded article, the molded article body may include a partial region in which the second molded portion is sandwiched between the decorative sheet and the touch sensor sheet and filled with a translucent resin, and at least one of the decorative sheet and the touch sensor sheet may include a resin introduction hole continuous with the partial region due to the translucent resin.

[0010] In the molded article, the shielding structure may be a rib erected at a peripheral edge portion of the first molded portion to a higher position than the outer peripheral edge of the decorative sheet.

[0011] In the molded article, the rib may be inclined toward a direction in which the gap is present and may be in contact with the decorative film at a peripheral edge of the gap.

[0012] In the molded article, the shielding structure may be formed by mixing ink with the translucent resin in or around the gap.

[0013] In the molded article, the shielding structure may be the first molded portion formed in a band shape and embedded in the gap, and the first molded portion may be made of an opaque resin having lower light transmittance than the second molded portion.

[0014] A display device according to one aspect of this disclosure includes the molded article described above; a control device connected to the touch sensor sheet; and a light-emitting element that emits light toward the molded article.

[0015] A method for producing a molded article according to one aspect of this disclosure is a method for producing a molded article formed by integrally molding: a molded article body including a first molded portion and a second molded portion, wherein the second molded portion is made of a translucent resin that transmits light guided to the display portion, and wherein the first molded portion is made of an opaque resin that has lower light transmittance than the second molded portion; a decorative sheet including a decorative portion that decorates the display portion;and a light-transmitting touch sensor film that transmits the light passing through the display portion, the method including forming a shielding structure during insert molding of the molded article body and the decorative film to suppress the light passing through the light-transmitting resin at least partially around an outer peripheral edge of the decorative film in the molded article body. Advantageous effects of the invention

[0016] According to the molded article, the display device, or the method for manufacturing a molded article according to this disclosure, it is possible to suppress light leakage from a molded article formed by integrally molding a decorative sheet and a touch sensor sheet. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a block diagram illustrating an example of a display device according to the present disclosure. Fig. 2 is a cross-sectional view illustrating an example of a molded article and an LED according to a first embodiment. Fig. 3 is a perspective view illustrating an example of the molded article according to the first embodiment. Fig. 4A is an enlarged partial cross-sectional view of the molded article in Fig. 3. Fig. 4B is a partially enlarged cross-sectional view showing a mold and a first molded portion in a manufacturing process for the Fig. 4A illustrated molded article. Fig. 5A is a cross-sectional view illustrating an injection method for the first molded portion according to the first embodiment. Fig. 5B is a cross-sectional view illustrating a clamping method for manufacturing a second molded portion according to the first embodiment. Fig. 5C is a cross-sectional view illustrating an injection method for the second molded portion according to the first embodiment. Fig. 5D is a cross-sectional view illustrating an example of the molded article according to the first embodiment. Fig. 6A is an enlarged partial cross-sectional view illustrating a mold and a first molded portion in a molding method for a molded article according to Modification Example 1A. Fig. 6B is an enlarged partial cross-sectional view of the molded article according to Modification Example 1A. Fig. 7A is a plan view of a molded article according to Modification Example 1B. Fig. 7B is a plan view of a touch sensor sheet in the molded article according to Modification Example 1B. Fig. 7C is a plan view of a first molded portion according to Modification Example 1B. Fig. 7D is a cross-sectional view illustrating the molded article according to Modification Example 1B. Fig. 7E is a plan view of the first molded portion when the entire periphery of the first molded portion is surrounded by a rib. Fig. 7F is a plan view of the first molded portion when ribs are disposed along two long sides of the first molded portion. Fig. 8A is a cross-sectional view illustrating an example of a molded article according to a second embodiment. Fig. 8B is a cross-sectional view illustrating an injection method for a first molded portion according to the second embodiment. Fig. 8C is a cross-sectional view illustrating a clamping method for manufacturing a second molded portion according to the second embodiment. Fig. 8D is a cross-sectional view illustrating an injection method for the second molded portion according to the second embodiment. Fig. 9A is a perspective view of a molded article according to Modification Example 2A. Fig. 9B is a partially cutaway perspective view of the molded article according to Modification Example 2A. Fig. 9C is a partially enlarged cross-sectional view of the molded article according to Modification Example 2A. Fig. 9D is a cross-sectional view illustrating a clamping method for manufacturing the second molded portion according to Modification Example 2A. Fig. 9E is a cross-sectional view illustrating an injection molding process for the second molded portion according to Modification Example 2A. Fig. 9F is a cross-sectional view illustrating an injection molding process for a first molded portion according to Modification Example 2A. Fig. 10A is a cross-sectional view of a molded article according to a third embodiment. Fig. 10B is a rear view of a decorative film used to manufacture the molded article in Fig. 10A is used. Fig. 10C is a cross-sectional view illustrating an injection method for a first molded portion according to a third embodiment. Fig. 10D is a cross-sectional view illustrating a clamping method for manufacturing a second molded portion according to the third embodiment. Fig. 10E is a cross-sectional view illustrating an injection method for the second molded portion according to the third embodiment. DESCRIPTION OF EMBODIMENTSFirst Embodiment(1) Overall Configuration

[0017] A display device according to a first embodiment of this disclosure will be described below with reference to the drawings. Fig. 1, each component constituting a display device 1 is illustrated as a block. The display device 1 includes a molded article 10, a light-emitting diode (LED) 80, a drive circuit 81, and a controller 90. The molded article 10 includes a molded article body 11, a decorative sheet 40, a touch sensor sheet 50, and a flexible printed circuit board (FPC) 51. The drive circuit 81 is an electrical circuit that causes the LED 80 to emit light. The drive circuit 81 is controlled by the controller 90. Therefore, the controller 90 controls the emission of light by the LED 80.

[0018] The decorative film 40, the touch sensor film 50, and the FPC 51 are molded integrally with the molded article body 11. As described later, the decorative film 40, the touch sensor film 50, and the FPC 51 are attached to the molded article 10 using insert molding (also referred to as "in-molding"), in which the decorative film 40, the touch sensor film 50, and the FPC 51 are inserted into a mold before molten resin is injected into the mold. The touch sensor film 50 is electrically connected to an external device through the FPC 51. Fig. In the display device 1 illustrated in FIG. 1, the touch sensor sheet 50 is connected to the controller 90 through the FPC 51. Therefore, a contact portion of the FPC 51 connected to the external device is exposed to the outside of the molded article 10. (1-1) Relationship between molded article 10 and LED 80

[0019] The LED 80 and a cross-sectional structure of the molded article 10 are in Fig. 2. The LED 80 is mounted on a rigid circuit board 89. The driver circuit 81, which controls the LED 80, is mounted as an integrated circuit on the circuit board 89. A connector 91, which is electrically connected to the FPC 51 extending from the touch sensor film 50, is also mounted on the circuit board 89. Although in Fig. 2 not shown, the connector 91 is connected to the controller 90.

[0020] The decorative sheet 40 is disposed on an upper surface of the molded article body 11. The decorative sheet 40 is formed with a display portion 41 capable of transmitting light. The touch sensor sheet 50 is disposed on a lower surface of the molded article body 11. A transparent electrode is disposed in the touch sensor sheet 50 at a position where, for example, at least light emitted from the LED 80 is transmitted. With this structure, the touch sensor sheet 50 can transmit light and input information according to a change in capacitance due to the approach of a finger or the like to the touch sensor sheet 50.

[0021] The molded article body 11 includes a second molded portion 11b made of a translucent resin and a first molded portion 11a made of an opaque resin. Here, the phrase "translucent resin" refers to a concept that includes a transparent resin and a translucent resin. The phrase "opaque resin" refers to a concept that includes both a resin that is opaque by inherently having a color and a resin that is opaque by being colored with a pigment or the like. Furthermore, the phrase "opaque resin" refers to a concept that includes a resin with a lower transmittance to light Li emitted from the LED 80 than a translucent resin, and also a resin that does not have the function of completely blocking light.The second molded portion 11b and the first molded portion 11a have, in addition to functions for forming the shape of the molded article body 11, functions related to the light emitted from the LED 80. In . Fig. 2, the area surrounded by a dotted line indicates the light Li emitted from the LED 80.

[0022] The second molded portion 11b is arranged such that the light Li emitted from the LED 80 can pass through the second molded portion 11b and be guided to the display portion 41 in the decorative sheet 40. Specifically, the light-transmitting resin forming the second molded portion 11b fills a gap between the display portion 41 and the transparent electrode in the touch sensor sheet 50 above the LED 80. In other words, a region in the molded article body 11 below the display portion 41 is a region where the second molded portion 11b is sandwiched between the decorative sheet 40 and the touch sensor sheet 50 and filled with the light-transmitting resin.

[0023] The first molded portion 11a is arranged to suppress the leakage of excess light to improve the display effect of the light Li emitted from the LED 80. For this purpose, the opaque resin constituting the first molded portion 11a preferably has light-blocking properties. For example, the opaque resin is colored black. However, if, for example, light with a lower luminous intensity than that of the second molded portion 11b is to be emitted in order to improve the decorative effect of the molded article, the first molded portion 11a may not completely block light and may be partially colored to be translucent. In other words, the first molded portion 11a only needs to have a lower light transmittance than the second molded portion.

[0024] The light Li emitted from the LED 80 passes through the touch sensor sheet 50 and the second molded portion 11b in this order. Then, the light Li is transmitted through the display portion 41 of the decorative sheet 40 and emitted toward the top of the molded article body 11. The periphery of the display portion 41 is shielded from light by a decorative portion 42, such as a graphic layer on the decorative sheet 40. The molded article 10 is configured such that excess light does not leak from portions other than the display portion 41. (1-2) Measures against light leakage

[0025] A portion of the light Li incident on the second shaped portion 11b may, for example, travel in a direction other than toward the display portion 41 due to reflection within the second shaped portion 11b. To prevent this, side surfaces of the second shaped portion 11b are also covered with the decorative portion 42 of the decorative film 40. Furthermore, the front surface of the second shaped portion 11b is covered with the decorative film 40, except for a portion not in contact with the first shaped portion 11a and a portion where the light Li from the LED 80 enters. Fig. 3 illustrates a state in which the molded article 10 is viewed obliquely from above.

[0026] Herein, an example will be described in which portions of the second molded portion 11b that are not in contact with the first molded portion 11a are covered by the decorative film 40, but not all portions of the second molded portion 11b that are not in contact with the first molded portion 11a need be covered by the decorative film 40. For example, when the molded article 10 is joined to another component and shielded from light by that component, the second molded portion 11b may not be covered by the decorative film 40 up to the portion shielded from light by the other component, and the light-transmitting resin constituting the second molded portion 11b may be exposed at a location where the molded article 10 comes into contact with the other component.

[0027] As described below, the second molded portion 11b and the first molded portion 11a are injection-molded, for example, by multi-color molding (or multi-material injection molding) using a plurality of mold sets. The decorative sheet 40 is inserted into a mold (for example, a second fixed plate 120 formed in Fig. 5C) for forming the second molded portion 11b to be molded later. Due to the adoption of such a manufacturing method, a gap In may be formed between a parting line PL of the second molded portion 11b and an outer peripheral edge 40e of the decorative sheet 40. If this gap In is not provided, the outer peripheral edge 40e of the decorative sheet 40 comes into contact with the first molded portion 11a or the parting surface of the mold and may not be properly installed on the decorative sheet 40 due to misalignment during manufacturing. As a result, the decorative sheet 40 incorporated into the molded article 10 becomes wrinkled or other defects occur. The gap In between the parting line PL and the outer peripheral edge 40e of the decorative sheet 40 is, for example, from 0.05 mm to 0.7 mm.

[0028] The gap In, which is provided to achieve satisfactory manufacturing, is likely to be located at a position where the light Li leaks from the molded article 10. Therefore, to suppress light leakage from the gap In, a shielding structure 12 is arranged in or around the gap In within the molded article body 11. In other words, the shielding structure 12 is provided within the molded article body 11 at least partially around the outer peripheral edge 40e of the decorative sheet 40. The light Li that has passed through the second molded portion 11b is attenuated or completely blocked by the shielding structure 12. Therefore, by providing the shielding structure 12, light Li that is stronger than necessary can be prevented from leaking from the molded article 10 via the gap In.Since the shielding structure 12 is part of the structure in the molded article body 11, the light suppression function is less likely to be adversely affected due to damage or breakage. (1-3) Shielding structure 12

[0029] As in Fig. As illustrated in FIG. 4A, the shielding structure 12 according to the first embodiment is a rib 14 arranged at a peripheral edge portion 13 of the first molded portion 11a so as to be erected. In this embodiment, the rib 14 is provided along the entire outer peripheral edge 40e of the decorative sheet 40. The rib 14 is made of the opaque resin constituting the first molded portion 11a and covers the gap In between the parting line PL of the second molded portion 11b and the decorative sheet 40. Further, the rib 14 blocks the light Li traveling from the second molded portion 11b to the outside of the molded article 10.

[0030] Fig. 4B illustrates a step in the manufacturing process for forming the shielding structure 12. The Fig. The state shown in Fig. 4B is a state before clamping a movable plate 100 into a second stationary plate 120 and injecting molten resin into a cavity in the second stationary plate 120. The first molded portion 11a is already formed in the movable plate 100. The touch sensor sheet 50 is integrated into the first molded portion 11a during the molding of the first molded portion 11a. The rib 14 formed on the peripheral edge portion 13 of the first molded portion 11a is erected to a higher position than the outer peripheral edge 40e of the decorative sheet 40. In the state shown in Fig. 4B, the rib 14 does not yet cover the gap In between the second molded portion 11b and the outer peripheral edge 40e of the decorative film 40. The rib 14 is deformed by heat and pressure of the molten resin injected to mold the second molded portion 11b, resulting in a shielding structure like the one shown in Fig. 4A, which can block the light Li passing through the second molded portion 11b made of a light-transmitting resin. (2) Configuration of components (2-1) First molded section 11a and second molded section 11b

[0031] The resin constituting the first molded portion 11a and the second molded portion 11b may be, for example, a polycarbonate resin, an ABS resin, an acrylic resin, a polyamide resin, a polyethylene terephthalate (PET) resin, a polybutylene terephthalate (PBT) resin, a polypropylene resin, a polyester resin, a polyester elastomer, or a polyurethane elastomer, or combinations of various resins using these materials.

[0032] The first molded portion 11a is manufactured so that it does not melt to the point where the shape of the first molded portion 11a cannot be fully maintained during molding of the second molded portion 11b. Therefore, the resin forming the first molded portion 11a preferably has a softening temperature equal to or higher than that of the resin forming the second molded portion 11b. Furthermore, the first molded portion 11a may contain a filler to adjust the flowability of the first molded portion 11a. Examples of fillers compounded in the first molded portion 11a include glass fiber and carbon.In order to cover the gap In to prevent light leakage due to deformation of the rib 14 during injection of the light-transmitting resin forming the second molded portion 11b, the second molded portion 11b preferably has a softening temperature equivalent to or close to that of the opaque resin forming the first molded portion 11a. In typical two-color molding, the resin forming the first molded portion 11a has a softening temperature equivalent to or slightly higher than that of the resin forming the second molded portion 11b to prevent the resin forming the first molded portion 11a from flowing out due to the resin forming the second molded portion 11b. However, the resin forming the first molded portion 11a softens easily if this resin is flaky, similar to the rib 14 according to this disclosure.

[0033] The opaque resin used for the first molded portion 11a may, for example, be a resin that is inherently colored or may be colored with a pigment. The first molded portion 11a is preferably colored black if light is to be blocked by the shielding structure 12. (2-2) Decorative film 40

[0034] The decorative film 40 includes a carrier film and a graphic layer. A transparent resin is used for the carrier film. The carrier film can be made of, for example, a resin film consisting of a polyester resin, a polyethylene terephthalate (PET) resin, an acrylic resin, a polycarbonate resin, a polybutylene terephthalate (PBT) resin, a triacetylcellulose resin, a styrene resin, or an ABS resin; a multilayer film consisting of an acrylic resin and an ABS resin; or a multilayer film consisting of an acrylic resin and a polycarbonate resin. The thickness of the carrier film is generally selected from a range of, for example, 30 µm to 500 µm.

[0035] The graphic layer is a layer used to express a design, such as an image. The graphic layer is formed on the carrier film, for example, by gravure printing or screen printing. The materials constituting the graphic layer can be, for example, an acrylic resin, a vinyl chloride-vinyl acetate copolymer resin, a thermoplastic urethane resin, or a polyester resin, and a pigment or dye added to the resin. The graphic layer can also have a metallic design formed, for example, using an insulated aluminum paste or a mirror ink.

[0036] A hard coating layer for improving surface strength and imparting scratch resistance may be formed on the decorative film 40. Furthermore, an adhesive layer may be formed on the decorative film 40 to improve the adhesion between the decorative film 40 and the molded article body 11.

[0037] The graphic layer is transparent at a portion of the decorative film 40 provided with the display portion 41. Therefore, in the display portion 41 of the decorative film 40, the light Li emitted from the LED 80 is emitted outward after passing through the carrier film and the graphic layer. (2-3) Touch sensor film 50

[0038] The touch sensor sheet 50 is a sheet formed with an electrical circuit for configuring, for example, an electrostatic capacitance-type touch sensor. The touch sensor sheet 50 includes an electrode for detecting information input by a human body (fingertip) as a change in electrostatic capacitance. A transparent electrode is used for an electrode disposed at a position through which the light Li emitted from the LED 80 passes. The transparent electrode of the touch sensor sheet 50 is formed of, for example, a metal oxide, a transparent conductive polymer, or a transparent conductive ink. Examples of metal oxides include indium tin oxide (ITO) and indium zinc oxide (IZO). An example of a transparent conductive polymer is poly-3,4-ethylenedioxythiophene / polysulfonic acid (PEDOT / PSS).Examples of transparent conductive inks include carbon nanotubes or silver nanofibers compounded in a binder. Instead of a transparent electrode, a touch sensor function can also be easily realized by printing a non-transparent conductive ink (e.g., silver paste or conductive carbon ink) around a non-electrically conductive, translucent part. (2-4) FPC 51

[0039] The FPC 51 includes a film substrate and a conductor circuit formed on the film substrate. The conductor circuit is exposed at one end portion of the film substrate. Examples of film substrates that can be used include flexible insulating films made of, for example, polyimide (PI), polyethylene terephthalate (PET), and polyethylene naphthalate (PEN). The film substrate is, for example, 25 μm to 75 μm thick. The conductor circuit is formed by photoetching copper foil laminated on a film substrate and then laminating a film substrate of the same quality to protect the circuit layer. The FPC 51 can be formed by using a silver paste, copper paste, carbon paste, or the like to form a circuit layer by means such as screen printing, and then printing a coating layer for protection. Note that a cover film can be applied to the FPC 51 with an adhesive.The FPC 51 and the touch sensor sheet 50 are electrically connected to each other by an anisotropic conductive film. Furthermore, the first molded portion 11a covers a portion of the FPC 51 of the touch sensor sheet 50, where the FPC 51 is connected to the controller 90, which is a device external to the molded article. The FPC 51 can be considered a lead-out wiring unit in which only the plurality of lead-out wires extend outward in the touch sensor sheet 50. (3) Method for producing the molded article 10

[0040] A method of manufacturing the molded article 10 will now be described with reference to Fig. 5A to 5D. Fig. 5A illustrates a state in which the movable plate 100 is clamped into a first fixed plate 110 to form the first molded portion 11a. Before the movable plate 100 is clamped into the first fixed plate 110, the touch sensor sheet 50 attached to the FPC 51 is inserted into the movable plate 100. A molten resin is injected through a runner 111 into a cavity between the movable plate 100 and the first fixed plate 110. Then, the molten resin cools and solidifies in the cavity between the movable plate 100 and the first fixed plate 110, thereby forming the first molded portion 11a. The movable plate 100 is provided with ejector pins 101, a slide core 102, and a slide core 103 for receiving the FPC.

[0041] When the forming of the first formed portion 11a is completed, the opening of the mold is removed from the Fig. 5A, with the first molded portion 11a remaining fixed to the movable plate 100. Thereafter, the movable plate 100 rotates, for example, and moves to be located in front of a second fixed plate 120.

[0042] Fig. 5B illustrates a state in which the movable plate 100 is clamped into the second fixed plate 120. The decorative sheet 40 is inserted into the second fixed plate 120. The decorative sheet 40 is sucked by air, for example, through a suction hole 123, and adsorbed onto the inner surface of the second fixed plate 120. In the first embodiment, a case in which the decorative sheet 40 is not preformed is described, but the decorative sheet 40 may be preformed to conform to the inner surface of the cavity in the second fixed plate 120.

[0043] Before forming the second shaped section 11b, a height d1 (see Fig. 4B) of the rib 14 from the dividing line PL must be higher than a height d5 (see Fig. 4B) of the gap In between the outer peripheral edge 40e of the decorative film 40 and the parting line PL of the first molded portion 11a. For example, it is sufficient that d5 + 0.3 mm < d1 < d2. For example, when d5 is 0.2 mm and d2 is 2.0 mm, approximately 0.5 mm < d1 < 1.5 mm is satisfactory. When d5 is 1 mm and d2 is 2.0 mm, approximately 1.3 mm < d1 < 1.8 mm is satisfactory.

[0044] A thickness d3 (see Fig. 4B) of the rib 14 is preferably thin so that the rib 14 can deform more easily. However, in order to maintain the shape of the rib 14, the thickness d3 preferably remains thick until the molten resin for forming the second molded portion 11b is injected. The thickness d3 of the rib 14 is preferably from 0.2 mm to 1.0 mm at a base thereof, preferably from 0.02 mm to 0.7 mm at a tip 14a thereof, preferably from 0.3 mm to 0.7 mm at the base, and preferably from 0.1 mm to 0.4 mm at the tip 14a. A distance d4 from the outer surface of the rib 14 to the inner surface of the decorative sheet 40 is preferably set to be from 0.2 mm to 0.5 mm at the base of the rib 14 and from 0.5 mm to 1.0 mm at the tip 14a.

[0045] Fig. 5C illustrates a state in which a molten resin 220 has been injected to form the second molded portion 11b. The molten resin 220 is injected through a runner 121 and a manifold 122 into a cavity between the movable platen 100 and the second fixed platen 120. The rib 14 is softened by the heat of the molten resin 220 and deformed by the pressure of the molten resin 220 to fill the gap In between the decorative sheet 40 and the first molded portion 11a.

[0046] When the molten resin 220 cools and solidifies and then forms the second molded portion 11b, the slide cores 102 and 103 slide out of the first molded portion 11a and the second fixed plate 120 and the movable plate 100 are opened. Fig. 5D illustrates the molded article 10 removed from the movable platen 100 by the ejector pins 101. As in Fig. 5D, a resin injection hole 52 described above for injecting the molten resin 220 is formed in the touch sensor sheet 50. The outer surface of the decorative sheet 40 and the outer surface of the first molded portion 11a are formed flush with each other without a gap therebetween due to the heat and pressure of the molten resin 220. The deformed rib 14 serves as the shielding structure 12. By providing the shielding structure 12, the light Li emitted from the LED 80 (see Fig. 2) and passes through the second molded portion 11b made of light-transmitting resin, exits from near the outer peripheral edge 40e of the decorative film 40, in particular from the gap In between the outer peripheral edge 40e and the parting line PL of the first molded portion 11a, for example due to refraction or reflection thereof. (4) Modification Examples (4-1) Modification Example 1A

[0047] In the first embodiment described above, a case is described in which the rib 14 of the shielding structure 12 is erected and extended beyond the outer peripheral edge 40e of the decorative film 40. However, the rib 14 may be folded, as shown in Fig. 6B. As in Fig. As illustrated in FIG. 6A, in the gap In, a distance d5 from the parting line PL to the outer peripheral edge 40e of the decorative film 40 is, for example, from 0.05 mm to 0.7 mm. Therefore, when the height h1 of the rib 14 is small and the distance d4 between the rib 14 and the decorative film 40 is large, the gap In can be covered even if the rib 14 is folded. Therefore, a folded rib 14 can be used as the shielding structure 12. (4-2) Modification Example 1B

[0048] In the first embodiment described above, a case is described in which the shielding structure 12 covers the entire circumference of the molded article 10. The molded article may be configured such that the shielding structure does not cover the entire circumference of the molded article. Fig. The molded article 10 illustrated in Figure 3 has a complex shape. Therefore, a configuration in which the shielding structure does not cover the entire circumference of the molded article will be described with reference to the Fig. 7A to 7D. As shown in Fig. As illustrated in Figure 7A, the molded article 10A has a substantially rectangular shape when viewed from above. The upper surface of the molded article 10A is covered with the decorative film 40. The decorative film 40 encloses the display portion 41, in which arrows and the letters A, B, and C are illustrated. Light passes through the display portion 41. The FPC 51 is in Fig. 7A marked by dashed lines.

[0049] Fig. 7B illustrates a touch sensor sheet 50A viewed from above. Three transparent electrodes 53, each having a circular shape, and three transparent electrodes 53, each having a square shape, are formed on the touch sensor sheet 50A. The circular transparent electrodes 53 overlap the arrows on the display portion 41, and the square transparent electrodes 53 overlap the letters A, B, and C on the display portion 41. A lead-out wiring 54 electrically connects the transparent electrodes 53 and the FPC 51. From the entire surface of the touch sensor sheet 50A, light can be blocked in a region formed with the lead-out wiring 54 because light does not need to be transmitted in this region.The touch sensor sheet 50A is further formed with the resin injection hole 52 through which a molten resin is injected to form the second molded portion 11b.

[0050] Fig. Figure 7C illustrates the first formed portion 11a as viewed from above. Fig. 7D illustrates the cross-sectional shape of the molded article 10A. Three rectangular openings 15 and three circular openings 15 are formed in the first molded portion 11a. The rectangular openings 15 overlap the arrows on the display portion 41, and the circular openings 15 overlap the letters A, B, and C on the display portion 41. The first molded portion 11a is further formed with a resin injection hole 16 through which a molten resin is injected to form the second molded portion 11b. The first molded portion 11a is also formed with an opening 17 in which the FPC 51 is disposed. Fig. 7C, the touch sensor sheet 50A is arranged in an area surrounded by a two-dot line L1.

[0051] When viewed from above, the rib 14A is formed along two long sides and one short side of the substantially rectangular-shaped molded article 10A, but is not formed along the other short side of the molded article 10A. The rib 14A does not surround the entire peripheral edge portion 11aa of the first molded portion 11a. For example, when the side on which the FPC 51 is arranged is a back side, the Fig. 7A illustrated molded article 10A on the right side of the front and rear and the left and right sides not surrounded by the rib 14A.

[0052] When the entire circumference of the molded article 10A is surrounded by the rib 14A, the first molded portion 11a has the Fig. 7E. Furthermore, as shown in Fig. 7F, the ribs 14A may be configured to block light only on two sides along the long sides of the molded article 10A. (4-3) Modification Example 1C

[0053] In the first embodiment described above, a case where the display portion 41 is formed with the transparent graphic layer of the decorative film 40 is described. However, the graphic layer may be formed to be translucent, and the display portion 41 may be formed by providing an opening in the decorative film 40. Note that the same applies to the second and third embodiments described below. (4-4) Modification Example 1D

[0054] In the first embodiment described above, a case where the light-emitting element included in the display device 1 is the LED 80 is described, however, the light-emitting element may be an element other than an LED. The light-emitting element included in the display device 1 may be, for example, a fluorescent lamp, an incandescent lamp, or an electroluminescent element. Note that the same applies to the second and third embodiments described below. (4-5) Modification Example 1E

[0055] In the first embodiment described above, a case is described where the FPC 51 is used to connect the touch sensor sheet 50 to a device external to the molded article 10 (for example, the controller 90). However, the touch sensor sheet 50 itself may include a connection circuit extending to the outside of the molded article 10. In other words, the touch sensor sheet may be configured such that the touch sensor sheet 50 and the FPC 51 are integrated according to the first embodiment. Note that the same applies to the second and third embodiments described below. (4-6) Modification Example 1F

[0056] In the first embodiment described above, a case where the first molded portion 11a and the second molded portion 11b are formed using two-color molding is described. However, the molded article body 11 may further include another molded portion, and the technology of the present disclosure can also be applied to polychromatic molding (or multi-material injection molding) in which three or more different colored resins or three or more different materials are used. Note that the same applies to the second and third embodiments described below. Second embodiment(5) Overall configuration

[0057] In the first embodiment described above, a case is described in which the ribs 14 are arranged inward from the outer peripheral edge 40e of the decorative sheet 40. However, in a molded article 10B according to a Fig. In the second embodiment illustrated in FIG. 8A, a rib 14B is arranged outwardly from the outer peripheral edge 40e of the decorative sheet 40. The molded article 10B according to the second embodiment differs from the molded article 10 according to the first embodiment in the shielding structure 12. Besides this structure, components of identical structures are assigned the same reference numerals, and descriptions of these components are omitted.

[0058] As in Fig. As illustrated in FIG. 8A, the shielding structure 12 according to the second embodiment is the rib 14B arranged and erected on the peripheral edge portion 13 of the first molded portion 11a. In this embodiment, the rib 14B is provided around the entire outer peripheral edge 40e of the decorative sheet 40. The rib 14B is made of the opaque resin constituting the first molded portion 11a and covers the gap In between the parting line PL of the second molded portion 11b and the decorative sheet 40. Further, the rib 14B blocks the light Li traveling from the second molded portion 11b to the outside of the molded article 10B. (6) Method for producing the molded article 10B

[0059] A method for producing the molded article 10B will be described with reference to Fig. 8B to 8D. Fig. 8B illustrates a state in which the movable plate 100 is clamped into a first fixed plate 110B, thereby forming the first molded portion 11a. The first fixed plate 110 according to the first embodiment differs from the first fixed plate 110B according to the second embodiment in the structures for forming the ribs 14 and 14B. Before the movable plate 100 is clamped into the first fixed plate 110B, the touch sensor sheet 50 attached to the FPC 51 is inserted into the movable plate 100. A molten resin is injected through the runner 111 into a cavity between the movable plate 100 and the first fixed plate 110B. Then, the molten resin cools and solidifies in the cavity between the movable plate 100 and the first fixed plate 110B, thereby forming the first molded portion 11a.

[0060] When the forming of the first shaped portion 11a is completed, the mold is removed from the Fig. 8B, with the first molded portion 11a remaining fixed to the movable plate 100. Then, the movable plate 100 rotates, for example, and moves toward the front of the second fixed plate 120.

[0061] Fig. 8C illustrates a state in which the movable plate 100 is clamped into the second fixed plate 120. The decorative sheet 40 is inserted into the second fixed plate 120. The decorative sheet 40 is pre-shaped to fit the inner surface of the cavity in the second fixed plate 120. The outer peripheral edge 40e of the decorative sheet 40 is pre-shaped to be located on the inner side of the rib 14B. The formed decorative sheet 40 is sucked by air through, for example, the suction hole 123 and adsorbed on the inner surface of the second fixed plate 120.

[0062] A height d1 of the rib 14B from the parting line PL must be greater than a height d6 of the gap In between the parting line PL and the outer peripheral edge 40e of the decorative film 40. It is sufficient that d6 + 0.3 mm < d1 < d2 is satisfied. For example, if d6 is 0.2 mm and d2 is 2.0 mm, approximately 0.7 mm < d1 < 1.5 mm is satisfactory. If d6 is 1 mm and d2 is 2.0 mm, approximately 1.3 mm < d1 < 1.8 mm is satisfactory.

[0063] Fig. 8D illustrates a state in which the molten resin 220 has been injected to form the second molded portion 11b. The molten resin 220 is injected through the runner 121 and the manifold 122 into the cavity between the movable platen 100 and the second fixed platen 120. The decorative sheet 40 is softened by the heat of the molten resin 220 and deformed by the pressure of the molten resin 220, and is brought into contact with the inner side of the rib 14A without a gap therebetween. An adhesive may be applied to the outer peripheral surface near the outer peripheral edge 40e of the decorative sheet 40 to firmly adhere the inner peripheral surface of the molded rib 14A to the outer peripheral surface near the outer peripheral edge 40e of the decorative sheet 40.The adhesive applied to the outer peripheral surface near the outer peripheral edge 40e is, for example, a pressure-sensitive and / or heat-sensitive adhesive, so that bonding can be performed by the molten resin 220.

[0064] When the molten resin 220 cools and solidifies, thereby forming the second molded portion 11b, the slide cores 102 and 103 slide out of the first molded portion 11a, and the second fixed plate 120 and the movable plate 1100 open. Fig. Figure 8A illustrates the molded article 10B removed from the movable platen 100 by the ejector pins 101. As shown in Fig. 8A, the above-described resin injection hole 52 for injecting the molten resin 220 is formed in the touch sensor sheet 50. The outer surface of the decorative sheet 40 and the outer surface of the first molded portion 11a are formed flush with each other without a gap therebetween due to the heat and pressure of the molten resin 220. This deformed rib 14 serves as the shielding structure 12. With this shielding structure 12, the light Li emitted from the LED 80 (see Fig. 2) and passes through the second molded portion 11b made of light-transmitting resin, from around the outer peripheral edge 40e of the decorative film 40, in particular from the gap In between the outer peripheral edge 40e and the parting line PL of the first molded portion 11a, for example due to its refraction or reflection. (7) Modification Example 2A

[0065] In the second embodiment, a case is described in which the rib 14B forms the shielding structure 12 on the outer peripheral portion around the outer peripheral edge 40e of the decorative film 40. However, the shielding structure 12 may be formed on the outer periphery of the outer peripheral edge 40e by a method other than using the

[0066] Rib 14B according to the second embodiment. Another manufacturing method for forming the shielding structure 12 on the outer periphery of the outer peripheral edge 40e will be described with reference to Fig. 9A to 9F. Fig. 9A illustrates a molded article 10C viewed obliquely from above. Fig. 9B illustrates a state in which a portion of the molded article 10C is cut out and this portion is viewed obliquely from above, and a cross section of the molded article 10C. Further, Fig. 9C shows a section of the cross section of the molded article 10C according to Modification Example 2A.

[0067] In the molded article 10C, a main shape of the molded article 10C is formed from a second molded portion 11c. A first molded portion 11d mainly forms the shielding structure 12. Therefore, the first molded portion 11d is formed in a band shape so as to surround the outer periphery of the outer peripheral edge 40e of the decorative sheet 40. The first molded portion 11d is also integrally formed with the second molded portion 11c and the decorative sheet 40. An adhesive may be applied to an outer peripheral surface near the outer peripheral edge 40e of the decorative sheet 40 to firmly adhere the inner peripheral surface of the molded first molded portion 11d to the outer peripheral surface near the outer peripheral edge 40e of the decorative sheet 40.The adhesive applied to the outer peripheral surface near the outer peripheral edge 40e is, for example, a pressure-sensitive and / or heat-sensitive adhesive, so that bonding is performed by the molten resin for forming the second molded portion 11c.

[0068] Fig. 9D illustrates a state in which a first fixed plate 140 is clamped into a movable plate 130. The decorative film 40 is inserted into the first fixed plate 140. The decorative film 40 is sucked by air, for example, through a suction hole 142, and adsorbed on the inner surface of the first fixed plate 140. The first fixed plate 140 is provided with a sliding core 141, which presses the outer peripheral edge 40e of the decorative film 40 toward the interior of the cavity. The portion of the

[0069] The slide core 141 will serve as an area where the first molded portion 11d is formed. The touch sensor sheet 50 and the FPC 51 are also inserted into the clamped movable plate 130. The movable plate 130 is provided with an ejector pin 131, a slide core 132, and a slide core 133 for receiving the FPC.

[0070] Fig. 9E illustrates a state in which a molten resin 230 has been injected to form the second molded portion 11c. The molten resin 230 is injected through a runner 143 and a manifold 144 into a cavity between the movable platen 130 and the first fixed platen 140. The decorative sheet 40 is softened by the heat of the molten resin 230 and deformed by the pressure of the molten resin 230 to conform to the shape of the slide core 132.

[0071] When the molten resin 230 cools and solidifies, thereby forming the second molded portion 11c, the slide cores 132 and 141 slide out of the movable plate 130 and the first fixed plate 140, and the movable plate 130 and the first fixed plate 140 are opened. Then, the movable plate 130 rotates and moves toward a second fixed plate 150, and the movable plate 130 and the second fixed plate 150 are clamped together.

[0072] Fig. 9F illustrates a state in which a molten resin 240 is injected into a cavity between the movable plate 130 and the second fixed plate 150, which are clamped together. The molten resin 240 is injected through a runner 151 and a manifold 152 into the cavity between the movable plate 130 and the second fixed plate 150. The molten resin 240 cools and solidifies, thereby forming the shield structure 12 (see Fig. 9C) is formed by the first molded portion 11d. This shielding structure 12 can prevent light from leaking from around the outer peripheral edge 40e of the decorative sheet 40. Note that the second molded portion 11c is exposed on the side surfaces of the molded article 10C below the shielding structure 12. Therefore, light leaks from the exposed second molded portion 11c. However, this molded article 10C has a structure in which a part of the shielding structure 12 and the exposed second molded portion 11c are housed within the device, and light leaking from the exposed portion of the second molded portion 11c does not leak to the outside of the device. Therefore, if light does not leak to reach the location of the shielding structure 12, the problem of light leakage is eliminated. Fig. 9A to 9F illustrate only a case where the first molded portion 11d forms the shielding structure 12, however, the first molded portion 11d may form a structure of the molded article body 11 other than the shielding structure 12, and may also form another molded portion by using another fixed plate. Third embodiment(8) Overall configuration

[0073] In the above-described first and second embodiments, a case is described in which the rib 14, 14B is arranged around the outer peripheral edge 40e of the decorative film 40. However, in a molded article 10D according to a third embodiment shown in Fig. 10A, instead of the rib 14, 14B, a colored region 20 in which the light-transmitting resin is colored with ink is arranged around the outer peripheral edge 40e of a decorative sheet 40A. The molded article 10D according to the third embodiment and the molded articles 10 and 10B according to the first and second embodiments differ from each other mainly in the shielding structure 12, therefore, components of identical structures other than this structure are assigned the same reference numerals, and descriptions of these components are omitted.

[0074] As in Fig. As illustrated in FIG. 10A, the shielding structure 12 according to the third embodiment is the colored region 20 located between the parting line PL of the first molded portion 11a and the outer peripheral edge 40e of the decorative sheet 40A. Here, the colored region 20 is provided along the entire circumference of the outer peripheral edge 40e of the decorative sheet 40A. Fig. 10B illustrates the decorative film 40A as viewed from the back. Ink 43 is printed along the entire outer peripheral edge 40e to form the colored region 20. This ink 43 is different from ink used in an image layer, which does not melt by injection molding, and is easily melted by a molten resin used in injection molding. The ink 43 can be obtained, for example, by using a resin having a lower melting point than the ink used in the image layer as a binder resin for ink. The ink 43 is preferably printed thickly, for example, by screen printing performed a plurality of times. The thickness of the ink 43 is, for example, from 5 μm to 30 μm, preferably from 7 μm to 20 μm. The colored region 20 is a region where the molten ink 43 mixes with the translucent resin that forms the second molded portion 11b.The colored area 20 is located in the gap In (see . Fig. 10D) between the parting line PL of the second molded portion 11b and the decorative film 40A and / or covers the gap In, thereby blocking the light Li traveling from the second molded portion 11b to the outside of the molded article 10D. (9) Method for producing the molded article 10D

[0075] A method for producing the molded article 10D will be described with reference to Fig. 10C to 10E described. Fig. 10C illustrates a state in which the movable plate 100 is clamped into a first fixed plate 110D, thereby forming the first molded portion 11a. The first fixed plate 110D according to the third embodiment differs from the first fixed plates 110 and 110D according to the first and second embodiments in the presence or absence of the structure for forming the rib 14, 14B. In other words, in the first fixed plate 110 according to the third embodiment, there is no structure for forming a rib. The manufacturing steps are the same as those in the first embodiment except for using a different mold, and the molten resin cools and solidifies in the cavity between the movable plate 100 and the first fixed plate 110D, thereby forming the first molded portion 11a.

[0076] When the forming of the first shaped portion 11a is completed, the mold is removed from the Fig. 10C, with the first molded portion 11a remaining fixed to the movable plate 100. Then, the movable plate 100 rotates, for example, and moves toward the front of the second fixed plate 120.

[0077] Fig. 10D illustrates a state in which the movable plate 100 is clamped into the second fixed plate 120. The decorative sheet 40A is inserted into the second fixed plate 120. The formed decorative sheet 40A is sucked by air, for example, through the suction hole 123, and adsorbed onto the inner surface of the second fixed plate 120.

[0078] Fig. 10E illustrates a state in which the molten resin 220 for molding the second molded portion 11b has been injected. The molten resin 220 is injected through the runner 121 and the manifold 122 into the cavity between the movable plate 100 and the second fixed plate 120. The ink 43 for the decorative film 40A is melted by the heat of the molten resin 220 and mixes with the molten resin due to the flow of the molten resin 220, thereby forming the colored region 20. This colored region 20 serves as the shielding structure 12. By providing the shielding structure 12, the light Li emitted from the LED 80 (see Fig. 2) and passes through the second molded portion 11b made of a light-transmitting resin, exits near the outer peripheral edge 40e of the decorative film 40A, in particular from the gap between the outer peripheral edge 40e and the parting line PL of the first molded portion 11a, for example due to refraction or reflection.

[0079] When the molten resin 220 cools and solidifies to form the second molded portion 11b, the slide cores 102 and 103 slide out of the first molded portion 11a, and the second fixed plate 120 and the movable plate 1100 open. Fig. 10A illustrates the molded article 10D after removal from the movable platen 100 by the ejector pins 101. As in Fig. 10A, the above-described resin injection hole 52 for injecting the molten resin 220 is formed in the touch sensor sheet 50. (10) Properties(10-1)

[0080] In the molded articles 10 and 10A to 10D according to the first to third embodiments described above, the decorative film 40, 40A and the

[0081] Touch sensor film 50, 50A is formed integrally with the molded article body 11 by insert molding. Around the outer peripheral edge 40e of the decorative film 40, 40A, at which the Fig. 2, the light Li passing through the second molded portion 11b, 11c made of a light-transmitting resin is suppressed by the shielding structure 12, and leakage of the light Li is suppressed. As a result, the display of an image on the decorative film 40, 40A can be remarkably accentuated by the light Li emitted from the display portion 41. (10-2)

[0082] When the shielding structure 12 is provided in or around the gap In between the parting line PL of the second molded portion 11b, 11c and the outer peripheral edge 40e of the decorative sheet 40, 40A, this gap can prevent the occurrence of defects such as wrinkling of the decorative sheet 40, 40A caused by contact of the outer peripheral edge 40e of the decorative sheet 40A with the parting surface of the mold, thereby giving the decorative sheet 40, 40A an aesthetically pleasing finish. (10-3)

[0083] In the molded article body 11, the second molded portion 11b, 11c below the display portion 41 is sandwiched between the decorative sheet 40, 40A and the touch sensor sheet 50, 50A and filled with a translucent resin. In other words, the second molded portion 11b, 11c below the display portion 41 is a portion filled with a translucent resin. The resin injection hole 52 in the touch sensor sheet 50, 50A is continuous with this portion. By providing such a structure, an optical path of the light Li emitted from the LED 80 can be seamlessly connected to the display portion 41 using the touch sensor sheet 50, 50A and the translucent resin. As a result, light can be efficiently emitted from the display portion 41.

[0084] It should be noted that in the first to third embodiments, a case is described where the resin introduction hole 52 is provided in the touch sensor sheet 50, 50A, however, the resin introduction hole may be provided in the decorative sheet 40, 40A, and a similar effect is achieved when such a configuration is adopted. (10-4)

[0085] With respect to the shielding structure 12 according to the first and second embodiments, the rib 14, 14A, 14B is described which is formed on the peripheral edge portion 13 of the first molded portion 11a to a higher position than the

[0086] Outer peripheral edge 40e of the decorative film 40, 40A is erected. When the shielding structure 12 is provided, these ribs 14, 14A, 14B can suppress the light Li passing through the second shaped portion 11b. Furthermore, if the ribs 14, 14A, 14B have light-blocking properties, the shielding structure 12 can be imparted with light-blocking properties. (10-5)

[0087] In the first embodiment, the rib 14, 14A is described, wherein the rib 14, 14A is inclined toward a specific direction in which the gap In exists and is in contact with the decorative film 40, 40A around the peripheral edge of the gap In. In the shielding structure 12, the light Li is less likely to leak from a position where the decorative film 40, 40A and the rib 14, 14A are in contact, and therefore, due to the contact between the decorative film 40, 40A and the rib 14, it is possible to achieve a sufficient light leakage suppression effect with the shielding structure 12. (10-6)

[0088] In the third embodiment, the shielding structure 12 is a colored region 20 formed by mixing ink with the light-transmitting resin in or around the gap In. As shown in Fig.As illustrated in Fig. 10B, this colored region 20 is formed by the ink 43 printed on the outer peripheral edge 40e of the decorative film 40. An insert molding method can be performed as in the prior art. In some cases, this colored region 20 cannot completely block light. However, since the light Li leaking from the outer peripheral edge 40e far from the LED 80 is weak, the method of using the colored region 20 as the shielding structure 12 is a cost-effective and convenient method, which is effective in a case where it suffices as long as light leakage needs to be suppressed. (10-7)

[0089] The shielding structure 12 may be the band-shaped first molded portion 11d described in Modification Example 2A of the second embodiment. The band-shaped first molded portion 11d is made of an opaque resin having lower light transmittance than the second molded portion 11c made of a light-transmitting resin, and is embedded in the gap between the parting line PL and the outer peripheral edge 40e of the decorative sheet 40. Therefore, the light Li emitted from the LED 80 and transmitted through the second molded portion 11c made of a light-transmitting resin is attenuated by the band-shaped first molded portion 11d made of an opaque resin with low light transmittance. When the first molded portion 11d is provided with light-blocking properties, the shielding structure 12 can block the light Li. (11) Other embodiments

[0090] The first to third embodiments of the present invention have been described above, but the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the invention. In particular, the various embodiments and modified examples described in this specification can be freely combined with each other. (11-1)

[0091] For example, the decorative sheet is molded by insert molding through primary molding, forming an intermediate molded article in which the outer peripheral edge of the decorative sheet protrudes from the primary molded article. Then, during secondary molding, opaque resin is injected to cover the resin-molded portion of the intermediate molded article formed during primary molding and the outer peripheral edge portion of the decorative sheet. Note that during secondary molding, a touch switch is molded by insert molding. A method for producing this type of molded article is also conceivable. (12) Notes(12-1)

[0092] In the embodiments described above, a method for producing a molded article such as a method below has been described.

[0093] That is, there is provided a method for producing a molded article formed by integrally molding a molded article body including a first molded portion and a second molded portion, the second molded portion being made of a translucent resin that transmits light guided to the display portion, and the first molded portion being made of an opaque resin having lower light transmittance than the second molded portion; a decorative sheet including a decorative portion that decorates the display portion;and a light-transmitting touch sensor film that transmits light passing through the display portion, the method including forming a shielding structure during insert molding of the molded article body and the decorative film to suppress the light passing through the light-transmitting resin at least partially around an outer peripheral edge of the decorative film in the molded article body. (12-2)

[0094] More specifically, a method for producing a molded article such as a method below has been described.

[0095] That is, in the method for producing a molded article according to (12-1) described above, a rib erected at a peripheral edge portion of the first molded portion to a higher position than the outer peripheral edge of the decorative sheet is formed before insert molding, and during insert molding, molten resin causes the rib to come into contact with the decorative sheet, thereby forming the shielding structure. (12-3)

[0096] Also, a method for producing a molded article, in which, in the method for producing a molded article according to (12-1) described above, a decorative sheet on which ink is printed near the outer peripheral edge of the decorative sheet is prepared before insert molding, and during insert molding, a colored region formed by mixing the ink with the light-transmitting resin constituting the second molded portion is formed as the shielding structure. (12-4)

[0097] Also, a method for producing a molded article, in which, in the method for producing a molded article according to (12-1) described above, a band-shaped cavity is formed by sliding cores near the outer peripheral edge of the decorative sheet during insert molding, and after insert molding, the band-shaped first molded portion is formed by injecting an opaque resin into the cavity. List of reference symbols 1 display device 10, 10A to 10D molded articles 11 Molded article body 11a, 11d First formed section 11b, 11c Second shaped section 12 Shielding structure 14, 14A, 14B rib 20 Colored area 40, 40A decorative film 40e outer peripheral edge 41 Display section 42 decorative section 43 Ink 50, 50A touch sensor film 51 FPC 52 Resin injection hole Li Light In Spalt PL dividing line

Claims

[1] A molded article (10; 10A to 10D) having a display portion (41) through which light (Li) can pass, the molded article (10; 10A to 10D) comprising: a molded article body (11) including a first molded portion (11a, 11d) and a second molded portion (11b, 11c), wherein the second molded portion (11b, 11c) is made of a translucent resin that transmits light (Li) guided to the display portion (41), and wherein the first molded portion (11a, 11d) is made of an opaque resin that has a lower light transmittance than the second molded portion (11b, 11c); a decorative film (40; 40A) molded integrally with the molded article body (11) and including a decorative portion (42) decorating the display portion (41); and a light-transmitting touch sensor film (50; 50A) molded integrally with the molded article body (11) and transmitting light (Li) passing through the display portion (41), wherein the molded article body (11) further includes a shielding structure (12) which is arranged at least partially around an outer peripheral edge (40e) of the decorative film (40; 40A) and suppresses the light (Li) passing through the light-transmitting resin. [2] The molded article (10; 10A to 10D) according to claim 1, wherein the shielding structure (12) is provided in or around a gap (In) between a parting line (PL) of the second molded portion (11b, 11c) and the outer peripheral edge (40e) of the decorative film (40, 40A). [3] Molded article (10; 10A to 10D) according to claim 1 or 2, wherein the molded article body (11) includes a partial region in which the second molded portion (11b, 11c) is sandwiched between the decorative film (40, 40A) and the touch sensor film (50, 50A) and filled with a light-transmitting resin; and at least one of the decorative film (40, 40A) and the touch sensor film (50, 50A) includes a resin introduction hole (52) which is continuous with the partial area due to the light-transmitting resin. [4] The molded article (10; 10A to 10D) according to any one of claims 1 to 3, wherein the shielding structure (12) is a rib (14, 14A, 14B) erected at a peripheral edge portion of the first molded portion (11a, 11d) to a higher position than the outer peripheral edge (40e) of the decorative sheet (40, 40A). [5] The molded article (10; 10A to 10D) according to claim 4, wherein the rib (14, 14A, 14B) is inclined toward a direction in which the gap (In) is present and is in contact with the decorative film (40, 40A) at a peripheral edge of the gap (In). [6] The molded article (10; 10A to 10D) according to any one of claims 1 to 5, wherein the shielding structure (12) is formed by mixing ink (43) with the light-transmitting resin in or around the gap (In). [7] The molded article (10; 10A to 10D) according to any one of claims 1 to 6, wherein the shielding structure (12) is the first molded portion (11a, 11d) formed in a band shape and embedded in the gap (In), the first molded portion (11a, 11d) being made of an opaque resin having a lower light transmittance than the second molded portion (11b, 11c). [8] Display device (1) comprising: the molded article (10; 10A to 10D) described in any one of claims 1 to 7; a control device connected to the touch sensor film (50, 50A); and a light-emitting element (80) controlled by the control device to emit light (Li) to the molded article (10; 10A to 10D). [9] A method for producing a molded article (10; 10A to 10D) formed by integrally molding: a molded article body (11) including a first molded portion (11a, 11d) and a second molded portion (11b, 11c), wherein the second molded portion (11b, 11c) is made of a light-transmitting resin that transmits light (Li) guided to the display portion (41), and wherein the first molded portion (11a, 11d) is made of an opaque resin that has a lower light transmittance than the second molded portion (11b, 11c); a decorative sheet (40, 40A) including a decorative portion (42) decorating the display portion (41);and a light-transmitting touch sensor film (50, 50A) that transmits light (Li) passing through the display portion (41), the method comprising forming a shielding structure (12) during insert-molding of the molded article body (11) and the decorative film (40, 40A) to suppress the light (Li) passing through the light-transmitting resin at least partially around an outer peripheral edge (40e) of the decorative film (40, 40A) in the molded article body (11);

Images