Insert-molded article and manufacturing method thereof

Abstract

To provide an insert-molded article with suppressed crack initiation of a film on resin injection and a manufacturing method thereof.SOLUTION: An insert-molded article is assembled with a transparent resin member having a cave-in recess on an outer edge part and a film integrally adhered to an inner surface of the recess of the transparent resin member and a surface continuing from the inner surface of the recess. A manufacturing method of an insert-molded article includes: preparing a film assembled with a recess part on an outer edge part; arranging the film on the first mold inner surface in a manner that the recess part is engaged with a protrusion provided in a first mold; and combining the first mold and a second mold corresponding to the first mold and injecting a resin material between the film and the second mold.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to an insert molded article and a method for manufacturing the same. [Background technology]

[0002] In recent years, there has been an increasing demand for insert molding, also for vehicle lighting parts, in which a decorative film made by applying printing to a transparent plastic film is preformed by vacuum forming, and the preformed product is inserted into an injection molding die for integral molding. On the other hand, when integral molding is performed by filling the preformed film inserted into the die with injection resin, the film may become misaligned due to shear stress caused by the flow of the injected resin. To solve this problem, a method has been adopted in which a through hole is formed in the film, and a protrusion provided on the die is inserted into the through hole and fixed to prevent misalignment (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-199743 A Summary of the Invention [Problem to be solved by the invention]

[0004] On the other hand, when through holes are formed in a film as in Patent Document 1, if resin is injected into the areas where the through holes are formed, cracks may occur in the film during resin injection due to shear stress caused by the flow of the injected resin.

[0005] The present disclosure has been made in consideration of the above, and has an object to provide an insert molded product in which the occurrence of cracks in a film during resin injection is suppressed, and a manufacturing method thereof. [Means for solving the problem]

[0006] The present disclosure has the following aspects. [1] An insert molded product comprising: a transparent resin member having a recessed portion on its outer edge; and a film integrally attached to an inner surface of the recessed portion of the transparent resin member and to a surface continuing from the inner surface of the recessed portion. [2] Preparing a film having a concave portion on an outer edge thereof; placing the film on an inner surface of the first mold so that the concave portion fits into a convex portion provided on the first mold; A method for manufacturing an insert molded product, comprising: combining the first mold with a second mold corresponding to the first mold, and injecting a resin material between the film and the second mold. Effect of the Invention

[0007] According to the present disclosure, it is possible to provide an insert molded product in which the occurrence of cracks in a film during resin injection is suppressed, and a manufacturing method thereof. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a plan view showing an insert molding product according to an embodiment of the present disclosure. [Diagram 2] 2 is a cross-sectional view showing a configuration taken along the cross section AA in FIG. [Diagram 3] 2 is a cross-sectional view showing a configuration along the cross section BB in FIG. 1. [Figure 4] FIG. 2 is a cross-sectional view of an insert molding according to an embodiment of the present disclosure. [Diagram 5] FIG. 2 illustrates a manufacturing method according to an embodiment of the present disclosure. [Figure 6] FIG. 2 is a cross-sectional view of a manufacturing apparatus according to an embodiment of the present disclosure. [Figure 7] FIG. 4 is a cross-sectional view of a manufacturing apparatus according to another embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of an insert molded product and a manufacturing method thereof according to the present disclosure will be described with reference to the drawings. However, the scope of the present disclosure is not limited to one embodiment described here, and various modifications can be made within the scope of the present disclosure. Each aspect disclosed in this specification can be combined with any other feature disclosed in this specification. In addition, when multiple upper and lower limit values ​​are described for a specific parameter, any upper and lower limit values ​​among these upper and lower limit values ​​can be combined to form a suitable numerical range. In addition, the lower and / or upper limit values ​​of the numerical range described in this disclosure are numerical values ​​within the numerical range and may be replaced with numerical values ​​shown in the examples. The expression "X to Y" indicating a numerical range means "X or more and Y or less". When a specific description described for one embodiment is also applicable to other embodiments, the description may be omitted in other embodiments.

[0010] [Insert molding] 1, 2, and 3 are diagrams showing an insert molded product 1 shown as an embodiment of this disclosure. FIG. 1 shows an overall image of the insert molded product 1, FIG. 2 is a schematic diagram of the AA cross section of the insert molded product 1 shown in FIG. 1, and FIG. 3 is a schematic diagram of the BB cross section of the insert molded product 1 shown in FIG. The insert molded product 1 includes a transparent resin member 10 having a recessed recess 11 at an outer edge portion 12, and a film 20 integrally attached to the inner surface of the recess 11 of the transparent resin member 10 and a surface continuing from the inner surface of the recess 11. FIG. 1 is a plan view seen from the side facing the film 20. The insert molded product 1 of this embodiment can be used as an outer lens of a vehicle lamp such as a headlamp, a fog lamp, a daytime running lamp, or a clearance lamp. As shown in FIG. 1, the insert molded product 1 may include a welding foot 40.

[0011] (Transparent resin material) 1, transparent resin member 10 has a sunken recess 11 at its outer edge portion 12. When used as an outer lens, transparent resin member 10 has incident surface 10A on the side where light enters and exit surface 10B on the side where light exits, and recess 11 is provided on the surface of incident surface 10A. The shape of the recess 11 of the outer edge portion 12 is not particularly limited, and can be selected from a rectangular column, a rectangular cone, a rectangular frustum, a cylinder, a cone, a cone frustum, and a combination thereof. In one embodiment, the recess 11 is recessed from the incident surface 10A of the transparent resin member 10 formed substantially flat toward the inside of the incident surface 10A, and the recess 11 is composed of a first side surface 11A extending toward the inside and a first bottom surface 11B formed at the tip of the side surface 11A. In FIG. 2, the recess 11 has a shape that combines a truncated cone and a cylinder. The diameter of the recess 11 is preferably 0.3 to 8.0 mm, more preferably 0.3 to 5.0 mm, and even more preferably 0.4 to 2.0 mm, and the depth of the recess 11 is preferably 0.2 to 5.0 mm, more preferably 0.3 to 2.0 mm, and even more preferably 0.4 to 1.0 mm. In addition, in FIG. 2, a convex shape is formed on the exit surface 10B side of the recess 11, but this convex shape is not an essential configuration and may not be formed.

[0012] In one embodiment, the transparent resin member 10 has an outer edge portion 12 and a three-dimensional shape portion 14 having a three-dimensional shape. The shape of the three-dimensional shape portion 14 is not particularly limited, but may be, for example, the shape of an outer lens of a vehicle headlamp or combination lamp. More specifically, the three-dimensional shape portion 14 is composed of an upper wall portion 15 and a side wall portion 16 that surrounds the upper wall portion 15 and connects the upper wall portion 15 and the outer edge portion 12. The outer edge portion 12 is a portion that extends in the circumferential direction from the outer peripheral end of the three-dimensional shape portion 14. When used as an outer lens, the outer edge portion 12 forms a portion other than the design surface. The material of the transparent resin member 10 is preferably, for example, an acrylic resin, a polycarbonate resin, a polystyrene resin, an acrylonitrile-styrene resin, a silicone resin, etc. "Transparent" includes various types of transparency such as completely transparent, semi-transparent, colorless transparent, and colored transparent (including milky white, etc.). The average thickness of the transparent resin member 10 is preferably from 1 to 10 mm, more preferably from 1 to 7 mm, and further preferably from 2 to 4 mm.

[0013] (film) The film 20 is a thin film member integrally attached to the inner surface of the recess 11 of the transparent resin member 10 and a surface continuous from the inner surface of the recess 11. The film 20 also forms a continuous surface on the inner surface of the recess 11 of the transparent resin member 10, and does not have a hole. The film 20 has a concave portion 27 along the recess 11 of the transparent resin member 10, and the concave portion 27 is composed of a second side surface 27A extending from a substantially flat first surface along the incident surface 10A of the transparent resin member 10 along the side surface 11A of the recess 11, and a second bottom surface 27B continuous with the second side surface 27A and along the first bottom surface 11B. That is, the film 20 also forms a continuous surface on the first side surface 11A and the first bottom surface 11B of the recess 11 in the transparent resin member 10. In addition, it is preferable that the film 20 does not have a hole. In one embodiment, the film 20 is attached to the entire surface of the transparent resin member 10 corresponding to the three-dimensional shape portion 14, but is not attached to the surface corresponding to the outer edge portion 12 or is attached only to a portion of the surface. The film 20 may be decorated with a color and / or pattern different from that of the transparent resin member 10. Therefore, a color or pattern different from that of the transparent resin member 10 is recognized. The material of the film 20 is preferably, for example, an acrylic resin, a polycarbonate resin, a polystyrene resin, an acrylonitrile styrene resin, a silicone resin, or the like. The average thickness of the film 20 is preferably from 0.1 to 2.0 mm, more preferably from 0.2 to 1.5 mm, and even more preferably from 0.3 to 1.0 mm.

[0014] In one embodiment, the film 20 has suction marks 25. These suction marks 25 are marks that are formed when the film 20 is sucked by a suction groove provided in a mold during insert molding. Therefore, the suction marks 25 are convex portions that protrude in a band shape from the surface of the film 20 opposite to the surface attached to the transparent resin member 10. The length of the suction marks 25 is preferably 50 to 1000 mm, more preferably 100 to 800 mm, and even more preferably 200 to 500 mm. The width of the suction marks 25 is preferably 1 to 15 mm, more preferably 2 to 10 mm, and even more preferably 3 to 5 mm. The height of the suction marks 25 is preferably 0.1 to 2.0 mm, more preferably 0.2 to 1.5 mm, and even more preferably 0.3 to 1.0 mm.

[0015] In one embodiment, an opaque resin member 30 is molded on the surface of the transparent resin member 10 opposite to the side to which the film 20 is attached, from the side wall portion 16 to the outer edge portion 12. Generally, if the end of a film in an insert molding product is not sufficiently treated, the design may be impaired. However, in this embodiment, as shown in FIG. 4, the opaque resin member 30 is molded on the surface of the transparent resin member 10 so as to hide the end of the film 20, and the design may not be impaired due to the end of the film 20.

[0016] [Manufacturing method for insert molding] A manufacturing method of an insert molded product 1 in one embodiment of the present disclosure includes preparing a film 20 having a concave portion 27 on its outer edge, arranging the film 20 on the inner surface of a first mold 50 so that the concave portion 27 fits into a convex portion 55 provided on the first mold 50, combining the first mold 50 with a second mold 60 corresponding to the first mold 50, and injecting a resin material between the film 20 and the second mold 60. 5 is a diagram showing the manufacturing process of the insert molded product according to this embodiment. FIG. 5a shows a preparation process of the film 20 having the concave portion 27 on the outer edge. FIG. 5b shows a process of arranging the film 20 on the inner surface of the first mold 50 so that the concave portion 27 on the outer edge of the film 20 fits into the convex portion 55 on the first mold 50. FIG. 5c shows a process of combining the first mold 50 and the second mold 60. FIG. 5d shows a process of injecting a resin material between the film 20 and the second mold 60.

[0017] Each step in the manufacturing method of the present disclosure will be briefly described below. (Step 1: Film preparation process) In the film preparation step, a film 20 having a recessed portion 27 on its outer edge is prepared. 5a, the concave portion 27 is provided on the outer edge of the film 20, but the method of providing the concave portion 27 on the film 20 is not particularly limited, and a method of forming a resin material into a sheet and then thermoforming (vacuum forming or pressure forming), a compression molding method, an injection molding method, etc. can be used. The diameter and height of the concave portion 27 can be appropriately selected so as to fit into the protrusion 55 provided on the first mold 50, taking into consideration thermal shrinkage.

[0018] (Step 2: Film placement step) In the film placement step, the film 20 is placed on the inner surface of the first mold 50 so that the concave portions 27 fit into the convex portions 55 provided on the first mold 50. The first mold 50 has a plurality of protrusions 55 on the periphery of the portion that forms the transparent resin member 10. The protrusions 55 protrude outward from the substantially flat surface of the first mold 50, and are composed of a third side surface 55A extending in the protruding direction and a tip surface 55B located at the end of the third side surface 55A. 5b, the concave portions 27 are shaped to fit into the convex portions 55, and in the film arrangement step, the film 20 is arranged on the inner surface of the first mold 50 so that the concave portions 27 fit into the convex portions 55. At this time, the film 20 is arranged so that substantially all points on one side of the film 20 are in contact with the inner surface of the first mold 50. By arranging the concave portions 27 to fit into the convex portions 55, misalignment of the film 20 is suppressed in the subsequent resin material injection step. In one embodiment, the placed film 20 may be fixed by suction using suction grooves provided on the inner surface of the first mold 50. By fixing the film 20 by suction, the positional deviation of the film 20 is further suppressed.

[0019] (Step 3: Resin material injection step) In the resin material injection step, the first mold 50 and the second mold 60 corresponding to the first mold 50 are combined, and the resin material is injected between the film 20 and the second mold 60 . 5c and 5d, the first mold 50 and the second mold 60 have corresponding shapes. By injecting a resin material from a gate into the gap between the arranged film 20 and the second mold 60, an insert molded product 1 in which the film 20 is attached to a molded product of the resin material is obtained.

[0020] In the manufacturing method of the present disclosure, film 20 forms a continuous surface even in concave portion 27 that fits into convex portion 55, and is not a hole, thereby suppressing the occurrence of cracks in the film due to shear stress caused by the flow of injected resin.

[0021] In one embodiment, after the injection step, the opaque resin material is injected using a third mold instead of the second mold 60. By this step, the opaque resin member 30 is molded on the surface of the insert molded product 1 on the resin material molded product side, and the end of the film 20 can be hidden from the design surface, thereby suppressing deterioration of the design.

[0022] [Manufacturing equipment] Hereinafter, a manufacturing apparatus 100 for manufacturing the insert molded product 1 as described above will be described with reference to FIG. 6. FIG. 6 is a diagram showing a main part of the manufacturing apparatus 100 in one embodiment of the present disclosure. The manufacturing apparatus 100 of this embodiment is an apparatus 100 for manufacturing the insert molded product 1 of the film 20, and includes a first mold 50 having a shape corresponding to the film 20, a second mold 60 combined with the first mold 50, and a gate for injecting a resin material between the film 20 and the second mold 60, which are disposed on a surface of the first mold 50 facing the second mold 60, and is configured such that a convex portion 55 for fitting with the concave portion 27 of the film 20 is provided on the outer edge portion 53 of the first mold 50.

[0023] The shape of the first mold 50 is not particularly limited as long as the first mold outer edge 53 is provided with a convex portion 55 for fitting with the concave portion 27 of the film 20, but it is preferable that the shape is suitable for molding, for example, an outer lens of a vehicle headlamp, combination lamp, etc. The shape of the second mold 60 is also not particularly limited, and it is preferable that the shape is suitable for molding an outer lens of a vehicle headlamp, combination lamp, etc. in combination with the first mold 50.

[0024] In one embodiment, the first mold 50 has a three-dimensional shape molding portion 52 and a first mold outer edge portion 53, and the three-dimensional shape molding portion 52 has a shape corresponding to the outer lens of, for example, a vehicle headlamp or combination lamp.

[0025] The shape of the protrusions 55 corresponds to the shape of the recessed portions 27 of the film 20, so that when the film 20 is placed on the inner surface of the first mold 50, the protrusions 55 fit into the recessed portions 27. The shape of the protrusions 55 is not particularly limited, and can be selected from a rectangular column, a rectangular cone, a rectangular frustum, a cylinder, a cone, a frustum of a cone, and combinations thereof. As shown in Fig. 6, in one embodiment, the shape is a combination of a frustum of a cone and a cylinder. As shown in Figure 6, the first mold outer edge portion 53 has a convex portion 55 for fitting into the concave portion 27 of the film 20. Therefore, during the film placement process, the concave portion 27 of the film 20 is fitted into the convex portion 55, thereby suppressing misalignment of the film 20 during the subsequent resin material injection process. Furthermore, by making the convex portion 55 shaped so that it can fit into the concave portion 27, the concave portion 27 of the film 20 can also be made to have a continuous surface without holes, thereby suppressing the occurrence of cracks in the film due to shear stress caused by the flow of the injected resin.

[0026] 7, suction grooves 57 are provided on the inner surface of the first mold 50. By suction-fixing the arranged film 20 by the suction grooves 57, the positional deviation of the film 20 during the resin material injection process is further suppressed.

[0027] The configuration of the present disclosure can be summarized as follows. [1] An insert molded product comprising: a transparent resin member having a recessed portion on its outer edge; and a film integrally attached to an inner surface of the recessed portion of the transparent resin member and to a surface continuing from the inner surface of the recessed portion. [2] The insert molding product described in [1], having band-shaped suction marks on a surface of the film. [3] The insert molding product according to [1] or [2], wherein an opaque resin member is molded on the surface of the transparent resin member opposite to the side to which the film is attached. [4] Preparing a film having a concave portion on an outer edge thereof; placing the film on an inner surface of the first mold so that the concave portion fits into a convex portion provided on the first mold; A method for manufacturing an insert molded product, comprising: combining the first mold with a second mold corresponding to the first mold, and injecting a resin material between the film and the second mold. [5] The manufacturing method described in [4], which includes placing the film on the inner surface of the first mold and then suction-fixing the film using suction grooves provided on the inner surface of the first mold. [Explanation of symbols]

[0028] 1 Insert molding 10 Transparent resin parts 10A entrance surface 10B Output surface 11 Recess 11A First Aspect 11B 1st bottom surface 12 Outer edge 14 Three-dimensional shape part 15 Upper wall 16 Side wall 20 Film 25 Suction marks 27 Concave portion 27A Second Aspect 27B Second bottom 30 Opaque resin parts 40 Welded feet 50 First Mold 52 Three-dimensional shape molding section 53 First mold outer edge 55 Convex 55A Third Aspect 55B Tip surface 57 Suction groove 60 2nd Mold 100 Manufacturing equipment

Claims

1. An insert molded product comprising a transparent resin member having a sunken recess on its outer edge, and a film integrally attached to the inner surface of the recess of the transparent resin member and to a surface continuing from the inner surface of the recess.

2. The insert molding according to claim 1 , wherein a surface of the film has band-shaped suction marks.

3. 3. The insert molding according to claim 1, wherein an opaque resin member is molded on a surface of said transparent resin member opposite to the surface to which said film is attached.

4. Providing a film having a recessed portion on an outer edge thereof; disposing the film on an inner surface of the first mold so that the concave portion fits into a convex portion provided on the first mold; A method for manufacturing an insert molded product, comprising: combining the first mold with a second mold corresponding to the first mold, and injecting a resin material between the film and the second mold.

5. The method according to claim 4 , further comprising, after placing the film on the inner surface of the first mold, suction-fixing the film by suction grooves provided on the inner surface of the first mold.

Images