Film insert molded article and method for manufacturing film insert molded article

Abstract

To prevent an insert film of a film insert molded article from being easily peeled off from the inside of a step part of a resin material.SOLUTION: An insert film 15 of an emblem which is a film insert molded article and a plastic material 14 are integrated such that the insert film 15 is joined to the plastic material 14 and a 15a portion of a front face of the insert film 15 is exposed from the plastic material 14. On the outer surface of the resin material 14, a step portion 16 recessed to accommodate the insert film 15 is formed. A space expansion part 17 for expanding the opening area of the step part 16 as it goes away from the 16a part of the bottom surface of the step part 16 is formed in the opening part of the step part 16. The insert film 15 is accommodated in the step portion 16 such that the 15a of the front face of the insert film 15 is located closer to the 16a of the bottom face of the step portion 16 than the space enlargement portion 17. Thus, the side surface of the insert film 15 is not exposed in the space enlargement section 17.SELECTED DRAWING: Figure 3

Description

[Technical Field]

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

[0002] Patent Document 1 describes a film insert molded product in which an insert film is bonded to a resin material and the two are integrated so that the surface of the insert film is exposed from the resin material. Such an insert molded product is formed by placing an insert film in a cavity between molds that are repeatedly closed and opened, and then injecting molten resin into the cavity.

[0003] 7 and 8 show an example of a film insert molding formed by the above-mentioned manufacturing method. The film insert molding shown in Fig. 7 comprises an insert film 71 and a resin material 72. A recessed step 73 is formed on the outer surface of the resin material 72 to accommodate the insert film 71. The surface of the insert film 71 is exposed from the resin material 72.

[0004] The resin material 72 of the film insert molded product is formed by injecting molten resin into a cavity between clamped molds, with an insert film 71 placed in the cavity. The resin injected into the cavity in this manner melts with the insert film 71 at the boundary with the insert film 71. As a result, a film insert molded product is formed in which the insert film 71 is integrated with the inner wall of the step portion 73 in the resin material 72.

[0005] When a film insert molding product is formed in this manner, an expanded space portion 74 shown in Fig. 8 is formed at the opening of the stepped portion 73 in the resin material 72, i.e., an expanded space portion 74 that increases the opening area of ​​the stepped portion 73 the further away from the bottom surface of the stepped portion 73. This is because it is difficult for the resin injected into the cavity to fill the expanded space portion 74 due to the relationship between the temperature of the mold, voids, etc. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2018-94813 Summary of the Invention [Problem to be solved by the invention]

[0007] In the film insert molding product formed as described above, the surface of the insert film 71 is located corresponding to the expanded space portion 74 of the stepped portion 73 in the resin material 72. As a result, the side surface of the insert film 71 is exposed at the expanded space portion 74, and therefore the side surface of the insert film 71 is not fused to the inner wall of the stepped portion 73. As a result, there is a risk that a chemical agent used in manufacturing or the like will seep into the boundary between the insert film 71 and the stepped portion 73 from the expanded space portion 74. Then, when the chemical agent seeps into the boundary between the insert film 71 and the stepped portion 73, the insert film 71 will be easily peeled off from within the stepped portion 73. [Means for solving the problem]

[0008] Next, various aspects of a film insert molded article and a method for manufacturing a film insert molded article that solves the above problems will be described. (Aspect 1) In a film insert molding product in which an insert film is bonded to a resin material and the two are integrated so that the surface of the insert film is exposed from the resin material, a step portion is formed on the outer surface of the resin material that is recessed to accommodate the insert film, and a space expansion portion is formed at the opening of the step portion that expands the opening area of ​​the step portion the further it moves away from the bottom of the step portion, and the insert film is accommodated in the step portion so that its surface is positioned closer to the bottom of the step portion than the space expansion portion.

[0009] According to the above configuration, the surface of the insert film is located closer to the bottom of the step portion than the expanded space portion, so the side surface of the insert film is not exposed in the expanded space portion. This prevents the drug from easily penetrating the boundary between the insert film and the stepped portion, and therefore prevents the insert film from easily peeling off from within the stepped portion.

[0010] (Aspect 2) The film insert molding according to (Aspect 1), wherein the insert film has a structure having multiple layers overlapping in the thickness direction.

[0011] According to the above configuration, if a drug infiltrates into the boundary between the insert film and the step portion, the drug may infiltrate between the multiple layers of the insert film, causing the layers to peel off from each other. However, since the drug can be prevented from easily infiltrating into the boundary between the insert film and the step portion, the multiple layers can be prevented from peeling off from each other as described above.

[0012] (Aspect 3) The film insert molding according to (Aspect 2), wherein at least one of the layers in the insert film is an adhesive layer that bonds the layers together.

[0013] According to the above configuration, if a drug infiltrates into the boundary between the insert film and the step portion, the drug will infiltrate between the adhesive layer and the adjacent layer in the insert film, thereby reducing the adhesive function of the adhesive layer. As a result, there is a risk of the adjacent layers bonded by the adhesive layer peeling off. However, since the drug can be prevented from easily infiltrating into the boundary between the insert film and the step portion, peeling off of the adjacent layers bonded by the adhesive layer can be prevented as described above.

[0014] (Aspect 4) The film insert molding according to (Aspect 2) or (Aspect 3), wherein the multiple layers of the insert film include adjacent printed layers.

[0015] According to the above configuration, if a drug infiltrates into the boundary between the insert film and the step portion, the drug will easily infiltrate between adjacent printed layers of the insert film. This is because the adhesion between adjacent printed layers is likely to decrease. If the drug infiltrates between adjacent printed layers, there is a risk that the printed layers will peel off. However, since the drug can be prevented from easily infiltrating into the boundary between the insert film and the step portion, peeling of the printed layers can be prevented as described above.

[0016] (Aspect 5) a protective film attached to one of the two surfaces of the insert film in the thickness direction that faces the outer surface of the film insert molded product; a space enlargement portion is formed at an opening of the step portion during formation of the resin material, the space enlargement portion increasing in opening area as the opening moves away from the bottom surface of the step portion; and the thickness of the protective film is set so that the surface of the protective film facing the insert film is closer to the bottom surface of the step portion than the space enlargement portion; and the protective film is peeled off the insert film after formation of the resin material.

[0017] According to the above method, when a resin material having a stepped portion that recesses to accommodate an insert film is formed, an expanded space portion is formed at the opening of the stepped portion. At this time, a protective film is positioned corresponding to the expanded space portion. Furthermore, the surface of the insert film to which the protective film is attached is located closer to the bottom of the stepped portion than the expanded space portion. Then, by peeling the protective film from the insert film, a film insert molded product is formed in which the surface of the insert film is exposed from the outer surface of the resin material. Because the surface of the insert film in this film insert molded product is located closer to the bottom of the stepped portion than the expanded space portion, the side surface of the insert film is not exposed at the expanded space portion. This prevents chemicals used in the manufacture of film insert molded products from easily penetrating the boundary between the insert film and the stepped portion. Furthermore, this prevents the insert film from easily peeling from within the stepped portion due to chemicals penetrating the boundary between the insert film and the stepped portion. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 2 is a front view showing an emblem attached to the exterior surface of a vehicle. [Figure 2] 2 is a cross-sectional view showing the emblem of FIG. 1 as viewed in the direction of arrows II-II. [Figure 3] 3 is an enlarged cross-sectional view showing a portion of the emblem in FIG. 2 surrounded by a dashed line. FIG. [Figure 4] 3 is a cross-sectional view showing the integrated resin material and insert film in the emblem of FIG. 2, and a mold used to form the integrated resin material and insert film. FIG. [Figure 5] 5 is an enlarged cross-sectional view showing a portion surrounded by a dashed line in the resin material and the insert film in FIG. 4. [Figure 6] FIG. 10 is an enlarged cross-sectional view showing another example of an emblem. [Figure 7] FIG. 10 is a cross-sectional view showing a conventional example of an insert molding product. [Figure 8]8 is an enlarged cross-sectional view showing a portion surrounded by a dashed line in the insert-molded product of FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, one embodiment of a film insert molded product and a method for producing the same will be described with reference to FIGS. <Configuration of film insert molding product> An example of a film insert molded product is a vehicle emblem 11 shown in Fig. 1. This emblem 11 can be attached to the outer surface of a vehicle 12. As shown in Fig. 2, the emblem 11 includes a base 13 that is attached to the outer surface of the vehicle 12, a resin material 14 that is attached to the base 13, and an insert film 15 that is bonded to the resin material 14 to form an integrated body.

[0020] When attached to the outer surface of the vehicle 12, the base 13 protrudes from the outer surface. The resin material 14 is attached to the tip of the base 13 in the protruding direction relative to the outer surface of the vehicle 12. When attached to the base 13, the resin material 14 protrudes from the tip of the base 13 in a direction away from the outer surface of the vehicle 12. A step portion 16 that is recessed to accommodate the insert film 15 is formed on the outer surface of the resin material 14. The step portion 16 is recessed into the outer surface of the resin material 14, forming a depression. The insert film 15 is accommodated in the step portion 16 of the resin material 14. A surface 15a of the insert film 15 is exposed from the resin material 14.

[0021] <Details of the step portion 16 and the insert film 15> 3, a space enlarging portion 17 is formed at the opening of the step portion 16 in the resin material 14, increasing the area of ​​the opening of the step portion 16 the further away from the bottom surface 16a of the step portion 16. The insert film 15 is housed in the step portion 16 so that its surface 15a is located closer to the bottom surface 16a of the step portion 16 than the space enlarging portion 17. In this case, the surface 15a is located on the inner wall 16b of the step portion 16, corresponding to a location closer to the bottom surface 16a of the step portion 16 than the space enlarging portion 17.

[0022] The insert film 15 has a structure having multiple layers overlapping in its thickness direction. Specifically, the insert film 15 is formed by laminating a backer layer 19, an adhesive layer 20, and a top layer 21 in this order in the thickness direction from the bottom surface 16a of the stepped portion 16 toward the opening. The backer layer 19 and the top layer 21 in the insert film 15 are bonded to each other by the adhesive layer 20. The surface of the top layer 21, i.e., the surface of the top layer 21 opposite to the surface on the adhesive layer 20 side, forms the surface 15a of the insert film 15.

[0023] The backer layer 19 is formed of the same material as the resin material 14. The resin material 14 may be formed of, for example, ABS resin or polycarbonate. The material of the backer layer 19 does not necessarily have to be the same material as the resin material 14; for example, a material with a lower melting point than the material of the resin material 14 may be used. The adhesive layer 20 is formed of, for example, an acrylic adhesive. The top layer 21 is formed of, for example, an acrylic resin (PMMA).

[0024] <Manufacturing method for film insert molding> Next, a method for manufacturing the emblem 11, more specifically, a method for manufacturing the integrated resin material 14 and insert film 15, will be described.

[0025] As shown in Fig. 4, the integrated resin material 14 and insert film 15 of the emblem 11 are formed using molds 22, 23 that are repeatedly closed and opened. More specifically, the insert film 15 is placed in a position of the opened molds 22, 23 that corresponds to the cavity 24 in the mold 23. As shown in Fig. 5, a protective film 25 is attached to one of the two surfaces of the insert film 15 in the thickness direction that faces the outer surface of the film insert molding product, in other words, to the surface 15a of the insert film 15.

[0026] The insert film 15 is arranged so that the protective film 25 comes into contact with the portion corresponding to the cavity 24. Thereafter, molten resin is injected into the cavity 24 between the clamped molds 22, 23, thereby forming the integrated resin material 14 and insert film 15 of the emblem 11. The resin material 14 thus formed has a stepped portion 16 that is recessed to accommodate the insert film 15. In addition, a space enlargement portion 17 is formed at the opening of the stepped portion 16 in the resin material 14, which increases the opening area of ​​the stepped portion 16 the further away from the bottom surface 16a of the stepped portion 16.

[0027] The thickness of the protective film 25 attached to the surface 15a of the insert film 15 is set so that the surface on the insert film 15 side is closer to the bottom surface 16a of the stepped portion 16 than the spatial enlargement portion 17. By peeling this protective film 25 from the surface 15a of the insert film 15, the integrated resin material 14 and insert film 15 of the emblem 11 are formed. At this time, the insert film 15 is exposed from the resin material 14. Furthermore, the surface 15a of the insert film 15 is closer to the bottom surface 16a of the stepped portion 16 than the spatial enlargement portion 17.

[0028] <Effects of film insert molding and its manufacturing method> According to the present embodiment described above in detail, the following advantageous effects can be obtained. (1) The integrated resin material 14 and insert film 15 in the emblem 11 are formed with a protective film 25 attached to the surface 15a of the insert film 15. When the resin material 14 is formed with a stepped portion 16 that is recessed to accommodate the insert film 15, an expanded space portion 17 is formed at the opening of the stepped portion 16. At this time, the protective film 25 is positioned in correspondence with the expanded space portion 17. The surface 15a of the insert film 15 to which the protective film 25 is attached is located in correspondence with the inner wall 16b of the stepped portion 16, closer to the bottom surface 16a of the stepped portion 16 than the expanded space portion 17. When the protective film 25 is peeled off the insert film 15, the surface 15a of the insert film 15 is exposed from the outer surface of the resin material 14.

[0029] In the integrated resin material 14 and insert film 15 of the emblem 11, the surface 15a of the insert film 15 is located closer to the bottom surface 16a of the stepped portion 16 than the spatial expansion portion 17, so the side surface of the insert film 15 is not exposed in the spatial expansion portion 17. This prevents chemicals used in manufacturing, etc. from seeping into the boundary between the side surface of the insert film 15 and the inner wall 16b of the stepped portion 16. As a result, the insert film 15 is prevented from being easily peeled off from within the stepped portion 16 by the seeped chemicals.

[0030] (2) If a drug infiltrates into the boundary between the side surface of the insert film 15 and the inner wall 16b of the stepped portion 16, the drug may infiltrate between the multiple layers of the insert film 15, causing those layers to peel off from one another. In particular, the drug may infiltrate between the adhesive layer 20 and an adjacent layer in the insert film 15, thereby reducing the adhesive function of the adhesive layer 20. As a result, there is a risk of peeling between the adjacent layers bonded by the adhesive layer 20, i.e., the backer layer 19 and the top layer 21. However, because it is possible to prevent the drug from easily infiltrating into the boundary between the side surface of the insert film 15 and the inner wall 16b of the stepped portion 16, it is possible to prevent peeling between the multiple layers, as described above, more specifically, peeling between the backer layer 19 and the top layer 21 bonded by the adhesive layer 20.

[0031] The above embodiment can be modified as follows, for example: The above embodiment and the following modifications can be combined and implemented within the scope of technical compatibility. The insert film 15 has a layered structure including a backer layer 19, an adhesive layer 20, and a top layer 21. Alternatively, as shown in FIG. 6, a layered structure including a backer layer 19, a printed layer 26, and a printed layer 27 may be used. The printed layer 26 and the printed layer 27 in the insert film 15 are adjacent to each other. The surface of the printed layer 27 opposite to the surface facing the printed layer 26 constitutes the surface 15a of the insert film 15. The printed layers 26 and 27 may be printed with, for example, a hard coat, piano black, the body color of the vehicle 12, or a vapor-deposited metal on at least one of the front and back surfaces in the thickness direction.

[0032] In this case, if a drug used in manufacturing or the like permeates the boundary between the side surface of the insert film 15 and the inner wall 16b of the stepped portion 16, the drug will likely permeate between the adjacent printed layers 26, 27 of the insert film 15. This is because the adhesion between the adjacent printed layers 26, 27 is likely to decrease. If the drug permeates between the adjacent printed layers 26, 27, there is a risk that the printed layers 26, 27 will peel off from each other. However, because the drug can be prevented from permeating the boundary between the side surface of the insert film 15 and the inner wall 16b of the stepped portion 16, peeling off between the printed layers 26, 27 can be prevented, as described above.

[0033] 6 may be disposed between the backer layer 19, adhesive layer 20, and top layer 21 of the insert film 15 of Fig. 3. Alternatively, the printing layer 26 or one of the printing layer 27 may be disposed on the surface of the top layer 21 opposite to the surface on the adhesive layer 20 side, or on the surface of the backer layer 19 opposite to the surface on the adhesive layer 20 side.

[0034] Although the emblem 11 has been given as an example of a film insert molded product, the present invention may be applied to film insert molded products such as exterior parts for vehicles other than the emblem 11, or film insert molded products for purposes other than vehicles.

[0035] The insert film 15 does not necessarily have to have a multi-layer structure, but may have a single-layer structure. [Explanation of symbols]

[0036] 11...Emblem 12...Vehicle 13...Foundation 14...Resin material 15...Insert film 15a…Surface 16...Step 16a…Bottom surface 16b…Inner wall 17...Spatial expansion section 19...Backer layer 20...adhesive layer 21...Top tier 22...Mold 23...Mold 24...cavity 25...Protection film 26...printing layer 27...printing layer

Claims

1. In a film insert molding product in which an insert film is bonded to a resin material and the surface of the insert film is exposed from the resin material, the two are integrated together, A recessed step portion is formed on the outer surface of the resin material to accommodate the insert film, a space enlarging portion is formed at the opening of the step portion, which enlarges the opening area of ​​the step portion as it moves away from the bottom surface of the step portion; The insert film is housed in the step portion so that its surface is positioned closer to the bottom surface of the step portion than the expanded space portion.

2. 2. The film insert molding according to claim 1, wherein the insert film has a structure having a plurality of layers overlapping in the thickness direction.

3. 3. The film insert molding according to claim 2, wherein at least one of the layers in the insert film is an adhesive layer that bonds the layers together.

4. 4. The film insert molding according to claim 2, wherein the plurality of layers of the insert film include adjacent printed layers.

5. In a method for manufacturing a film insert molded product, an insert film is placed in a cavity between molds that are repeatedly closed and opened, and molten resin is injected into the cavity to bond the insert film to the resin material and form a film insert molded product in which the resin material and the insert film are integrated so that the surface of the insert film is exposed from the resin material, A protective film is attached to the surface of the insert film on the outer surface side of the film insert molding product, among the surfaces on both sides in the thickness direction of the insert film, forming the resin material having a stepped portion that is recessed to accommodate the insert film by injecting molten resin into the cavity in which the insert film is placed; When the resin material is formed, a space enlarging portion is formed in the opening of the step portion, which enlarges the opening area of ​​the step portion as it moves away from the bottom surface of the step portion, the thickness of the protective film is such that the surface of the protective film on the insert film side is closer to the bottom surface of the step portion than the spatial enlargement portion, After the resin material is formed, the protective film is peeled off from the insert film to form the film insert molding product.

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