Molding mold for insert molded products and method for manufacturing insert molded products
The molding die with a stepped groove design addresses the issue of resin exposure and film stretching in insert molded products by guiding the film end into a groove, maintaining the product's appearance by covering the resin end with the film.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TOYODA GOSEI CO LTD
- Filing Date
- 2024-11-29
- Publication Date
- 2026-06-10
AI Technical Summary
Existing insert molded product manufacturing methods result in gaps between the outer surface of the insert film edges and the molded surface, leading to exposure of injection-molded resin on the decorative side, which impairs the appearance of the product and can cause the edges of the insert film to be stretched by molten resin, further compromising the appearance.
A molding die configuration with a stepped portion and groove design that allows the insert film end to be inserted into a groove while restricting resin flow, ensuring the film end protrudes beyond the resin end and is not pinched during clamping, using a molding die with inclined or curved corners to guide the film end into the groove.
The solution prevents direct exposure of the insert film edges to molten resin, maintaining the appearance of the insert molded product by ensuring the film end covers the resin end, thus preventing resin exposure on the design surface.
Smart Images
Figure 2026094558000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a molding die for insert molded products and a method for manufacturing insert molded products.
Background Art
[0002] Patent Document 1 describes a method for manufacturing an insert molded product used as a plastic decorative molded member such as an automotive interior member. This manufacturing method includes a preform process for a decorative film and an injection molding process for an injection molding resin.
[0003] In the preform process, after heating the decorative film, it is shaped using a preform die to obtain an insert film with a shape in which the ends are folded inward. In the injection molding process, an injection molding die having a pair of male and female dies that operate in the horizontal direction is used. The male die has a groove for forming the ends of the injection molding resin. In the injection molding process, after inserting the insert film between the male and female dies so that the ends of the insert film are positioned within the grooves, injection molding is performed.
[0004] With such a manufacturing method, it becomes possible to shape the insert film with a design in which the ends are longer than the contact surface position of the male and female dies. Also, even when using such an insert film, when the male and female dies are clamped, the ends of the insert film are less likely to be sandwiched between the male and female dies outside the cavity. Then, by performing injection molding in a state where the male and female dies are clamped, an insert molded product is obtained in which the ends of the insert film wrap around to the ends of the injection molding resin.
[0005] Also, in the insert molded product thus obtained, since the ends of the injection molding resin are covered by the decorative film, it is possible to suppress the appearance of the insert molded product from being impaired by the ends of the injection molding resin being exposed on the design surface side of the insert molded product.
Prior Art Documents
Patent Documents
[0006] [Patent Document 1] Japanese Patent Publication No. 2013-184445 [Overview of the project] [Problems that the invention aims to solve]
[0007] However, the following problems arise with this manufacturing method. Specifically, because the edges of the insert film are folded inward, a gap is created between the outer surface of the edges and the molded surface of the groove when the male and female molds are clamped together. As a result, during the injection molding process, molten resin may flow into this gap, potentially forming an insert molded product in which some of the injection-molded resin has wrapped around to the decorative side of the decorative film. In such insert molded products, the appearance of the insert molded product is impaired because the injection-molded resin is exposed to the decorative side. Furthermore, during the injection molding process, the edges of the insert film may be rapidly stretched by being directly exposed to the molten resin in the cavity. In this case as well, the appearance of the insert molded product is impaired.
[0008] Based on the above, the injection molding die and the method for manufacturing insert molded products described in Patent Document 1 have room for improvement in terms of improving the appearance of the insert molded products. [Means for solving the problem]
[0009] This document describes various embodiments of a mold for insert molded products and a method for manufacturing insert molded products to solve the above problems. [Aspect 1] A molding die divided into a first type and a second type, in which a film member is inserted into a cavity formed between the first type and the second type, and molten resin is injected into the cavity to form an insert molded product in which the film member is laminated on the surface of a resin substrate, wherein the first type comprises a dividing surface that constitutes the parting line of the molding die and a molding surface that forms the back surface of the substrate, and the second type comprises the molding surface and the cavity, and also comprises a molding recess that contacts the film member, and when the dividing direction of the first type and the second type is the dividing direction, the molding surface is the same as the dividing surface A molding die for a film insert molded product, comprising: a general surface on a flat plane; a molded projection that protrudes toward the second mold from the general surface in the dividing direction; a stepped portion formed on the molded projection that creates a step between the general surface and the tip surface of the molded projection in the dividing direction; a groove portion that opens toward the second mold in the dividing direction, formed by the stepped portion, the general surface, and the molded recess; and the stepped portion being configured to allow the end of the film member to be inserted into the groove portion, while restricting the flow of the molten resin into the groove portion when the end is inserted into the groove portion.
[0010] According to the above configuration, the stepped portion is configured to allow the end of the film member to be inserted into the groove. Also, the general surface is on the same plane as the dividing surface of the first mold. Therefore, if the film member is designed so that its end is spaced apart from the general surface in the dividing direction, the end will not be pinched in the parting line of the molding die when the first and second molds are clamped together. Furthermore, it becomes possible to inject molten resin into the cavity with the end of the film member inserted into the groove. Here, according to the above configuration, the stepped portion is configured to restrict the flow of molten resin into the groove when the end of the film member is inserted into the groove. Therefore, it is possible to suppress the direct exposure of the end of the film member to molten resin in the cavity during the injection molding process. In addition, an insert molded product is obtained in which the end of the film member protrudes more than the end of the base material in the dividing direction. In such an insert molded product, since the end of the base material is covered by the film member, it is possible to suppress the exposure of the end of the base material to the design surface side of the insert molded product.
[0011] Based on the above, it is possible to suppress any deterioration in the appearance of the insert molded product. [Aspect 2] The stepped portion has a corner portion that constitutes the opening edge of the groove portion, and when the direction intersecting the dividing direction is defined as the intersecting direction, the corner portion is inclined or curved so that it approaches the general surface in the dividing direction as it approaches the molded recess in the intersecting direction, the further it approaches the general surface in the dividing direction, the molding die for an insert molded product as described in [Aspect 1].
[0012] For example, when the corner of the step portion is formed at a right angle, when the first mold and the second mold are clamped, the corner interferes with the end of the film member, making it difficult for the end to be inserted into the groove portion. In this regard, according to the above configuration, the corner is inclined or curved so as to approach the general surface in the dividing direction as it approaches the molding recess in the intersecting direction. Therefore, even when the corner interferes with the end of the film member when the first mold and the second mold are clamped, the end is guided into the groove portion by the corner. Therefore, when the first mold and the second mold are clamped, the end of the film member can be easily inserted into the groove portion.
[0013] [Aspect 3] A method for manufacturing an insert molded product using the mold for an insert molded product according to [Aspect 1] or [Aspect 2], comprising an insertion step of inserting the film member into the cavity of the mold so that the end of the film member is located within the groove, and an injection molding step of molding the base material by injecting the molten resin into the cavity with the film member inserted into the cavity.
[0014] According to the above method, an insert molded product in which the end of the film member protrudes more than the end of the base material in the above dividing direction can be obtained by the insertion step and the injection molding step. [Aspect 4] When the direction intersecting the dividing direction is defined as the intersecting direction, the minimum value of the width of the groove in the intersecting direction is W, and the thickness of the end in the intersecting direction is D, the step portion is set such that the width of the groove satisfies 0 mm < W - D ≤ 0.06 mm. The method for manufacturing an insert molded product according to [Aspect 3].
[0015] According to the above method, it is possible to more preferably suppress the inflow of the molten resin into the groove when the end of the film member is inserted into the groove during the injection molding step. [Aspect 5] The method for manufacturing an insert molded product according to [Aspect 3] or [Aspect 4], wherein the film member is set such that, in a state where the end portion of the film member is inserted into the groove portion, the end portion and the general surface are separated in the dividing direction.
[0016] According to the above method, after the insertion step, the end portion of the film member and the general surface are in a state of being separated in the above dividing direction. Here, the general surface is on the same plane as the dividing surface. Therefore, when the first mold and the second mold are clamped, the end portion of the film member is not sandwiched by the parting line of the molding die. Accordingly, it is possible to further suppress a decrease in the appearance of the insert molded product.
Effect of the Invention
[0017] According to the present invention, it is possible to suppress the appearance of the insert molded product from being impaired.
Brief Description of the Drawings
[0018] [Figure 1] FIG. 1 is a front view showing an exterior component for a vehicle including an insert molded product manufactured by a molding die and a manufacturing method according to an embodiment. [Figure 2] FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1. [Figure 3] FIG. 3 is a cross-sectional view showing a state where a film member is inserted into a molding die for an insert molded product. [Figure 4] FIG. 4 is an enlarged cross-sectional view showing a main part of FIG. 3. [Figure 5] FIG. 5 is a cross-sectional view showing a state where molten resin is injected into the cavity of the molding die of FIG. 3. [Figure 6] FIG. 6 is an enlarged cross-sectional view showing a main part of FIG. 5.
Mode for Carrying Out the Invention
[0019] Hereinafter, with reference to FIGS. 1 to 6, an embodiment of a molding die for an insert molded product and a manufacturing apparatus for an insert molded product will be described. First, an emblem 10 including a cover 40 as an insert molded product manufactured by the present invention will be described.
[0020] <Emblem> As shown in FIG. 1, at the front part of the vehicle, an emblem 10 as an exterior part of the vehicle that forms a part of the outer shell of the vehicle is provided. The emblem 10 has an elliptical shape as a whole when viewed from the front. On the design surface 10a of the emblem 10, a character part 11 displaying a mark or the like and an annular frame part 12 surrounding the character part 11 are provided. In the present embodiment, the character part 11 displays the English letter "A".
[0021] As shown in FIG. 2, the emblem 10 has a substrate 21 on which a light source 20 is mounted, a housing 30 that holds the substrate 21, and a cover 40 that covers the light source 20 and the housing 30. In the emblem 10 of the present embodiment, visible light emitted from the light source 20 is irradiated toward the cover 40 and transmitted through the cover 40, so that the character part 11 and the frame part 12 of the design surface 10a emit light. Hereinafter, each component will be described.
[0022] A plurality of light sources 20 are arranged on the substrate 21 at intervals from each other. Each of the plurality of light sources 20 is constituted by a light emitting element such as a light emitting diode (LED: Light Emitting Diode), for example.
[0023] The housing 30 constitutes the back surface 10b on the side opposite to the design surface 10a in the thickness direction of the emblem 10 (the vertical direction in FIG. ②). The housing 30 is formed in a flat plate shape from a resin material. Examples of the resin material forming the housing 30 include acrylonitrile - butadiene - styrene copolymer (ABS) resin and the like.
[0024] The cover 40 covers the light source 20 and the housing 30 from the design surface 10a side in the thickness direction of the emblem 10. The cover 40 as a whole is transparent to visible light. The cover 40 has a base material 41 and a film member 44. The base material 41 is formed of a transparent material that is transparent to visible light. As the transparent material, for example, an acrylic resin such as polymethyl methacrylate resin (PMMA) or a transparent resin such as polycarbonate resin (PC) can be used. In this embodiment, "transparent" includes not only colorless transparency but also colored transparency (colored transparency).
[0025] The base material 41 has a flat base material body 42 and a base material side portion 43 that bends from the periphery of the base material body 42 and extends to the back surface 10b side in the thickness direction of the emblem 10. The base material side portion 43 is joined to the periphery 30a of the housing 30 via an adhesive layer 50 made of a well-known adhesive. As a result, a space S is formed inside the emblem 10 that is surrounded by the base material body 42, the base material side portion 43, and the housing 30, and is sealed from the outside. The substrate 21 on which the light source 20 is mounted is housed in space S.
[0026] The film member 44 is a decorative film that decorates the cover 40. The film member 44 is laminated and bonded to the surface 41a of the base material 41. The film member 44 is, for example, a metal vapor-deposited film in which a metal such as aluminum or indium is vapor-deposited onto a resin film base material. The film member 44 has a film body 45 that covers the surface of the base material body 42 and a film side portion 46 that bends from the periphery of the film body 45 and covers the surface of the base material side portion 43. The end portion 46a of the film side portion 46 protrudes further toward the back surface 10b side than the end portion 43a of the base material side portion 43 in the thickness direction of the emblem 10. The end portion 46a is bonded to the periphery portion 30a of the housing 30 via an adhesive layer 50.
[0027] The cover 40 is formed by injection molding the base material 41 with the film member 44 as an insert member. <How to manufacture the cover> The manufacturing method of the cover 40 will be described below with reference to Figures 3 to 6.
[0028] The method for manufacturing the cover 40 comprises the steps of inserting a film member 44 into a molding die 60 and injection molding the base material 41 using the molding die 60. First, let's explain the molding die 60.
[0029] As shown in Figures 3 and 4, the molding die 60 comprises a first die 61 and a second die 67 that is provided to be movable forward and backward relative to the first die 61. In this embodiment, the direction in which the second die 67 moves forward and backward, that is, the direction in which the first die 61 and the second die 67 are separated, coincides with the thickness direction of the emblem 10 and corresponds to the vertical direction in Figures 3 and 4.
[0030] On the surface of the first mold 61 facing the second mold 67 in the splitting direction, a first splitting surface 62 and a molding surface 63 are provided. The first splitting surface 62 is the part that constitutes the parting line PL of the molding die 60 when the first mold 61 and the second mold 67 are clamped together. The molding surface 63 is provided with a general surface 64 that is connected to the first splitting surface 62 and a molding protrusion 65. The general surface 64 is located on the same plane as the first splitting surface 62. The molding protrusion 65 protrudes toward the second mold 67 from the general surface 64 in the splitting direction. The molding protrusion 65 has a stepped portion 66 that forms a step between the general surface 64 and the tip surface 65a of the molding protrusion 65 in the splitting direction. The stepped portion 66 has a first surface 66a, a second surface 66b, and a corner portion 66c. The first surface 66a is a portion that extends along the tip surface 65a, and is located further from the second mold 67 than the tip surface 65a in the dividing direction, and closer to the second mold 67 than the general surface 64. The second surface 66b extends from the general surface 64 in the dividing direction. The second surface 66b is slightly inclined with respect to the dividing direction in order to facilitate the removal of the molded cover 40 from the first mold 61. Specifically, when the direction intersecting the dividing direction is defined as the intersection direction (left-right direction in Figures 3 and 4), the second surface 66b is inclined so that it moves away from the side surface 69b of the molded recess 69, which will be described later, as it approaches the general surface 64 in the dividing direction. The corner 66c is located between the first surface 66a and the second surface 66b. The corner 66c is inclined or curved so that it moves closer to the general surface 64 in the dividing direction as it approaches the molded recess 69 in the intersection direction. In this embodiment, the corner 66c is curved.
[0031] On the surface of the second mold 67 facing the first mold 61 in the dividing direction, a second dividing surface 68 and a molding recess 69 are provided. The second dividing surface 68, together with the first dividing surface 62, forms a parting line PL when the molding die 60 is clamped. The molding recess 69, together with the molding surface 63 of the first mold 61, forms a cavity 70, which is a space filled with molten resin (hereinafter, resin R) when the molding die 60 is clamped.
[0032] As shown in Figure 3, the cavity 70 is provided with a main body molding section 71 that mainly molds the main body 42 of the base material, a side molding section 72 that mainly molds the side portion 43 of the base material, and a groove section 73. The main body molding section 71 is the portion enclosed by the tip surface 65a of the molded protrusion 65, the bottom surface 69a of the molded recess 69, and a part of the side surface 69b of the molded recess 69. The side molding section 72 is the portion enclosed by the side surface 65b of the molded protrusion 65 that connects the tip surface 65a and the first surface 66a, the first surface 66a of the stepped portion 66, and a part of the side surface 69b of the molded recess 69. The groove section 73 is the portion enclosed by the corner portion 66c and the second surface 66b of the stepped portion 66, the general surface 64, and a part of the side surface 69b of the molded recess 69.
[0033] As shown in Figure 4, the groove 73 opens toward the second type 67 in the dividing direction. The depth of the groove 73 in the dividing direction, that is, the protrusion height H of the stepped portion 66 from the general surface 64 in the dividing direction, is preferably 0.5 mm or more and 2.0 mm or less.
[0034] The stepped portion 66 is configured to allow the end portion 46a of the film member 44 to be inserted into the groove portion 73 during the insertion process described later, while restricting the flow of resin R into the groove portion 73 during the injection molding process described later.
[0035] Next, a method for manufacturing the cover 40 using the molding die 60 will be described. First, as shown in Figures 3 and 4, the film member 44, which has been pre-shaped to conform to the shape of the molded recess 69 and whose end portion of the film side portion 46 has been trimmed, is inserted into the cavity 70, and the first mold 61 and the second mold 67 are clamped together (this is the insertion process).
[0036] When the first mold 61 and the second mold 67 are clamped together, the end portion 46a of the film side portion 46 is inserted into the groove portion 73. As a result, the end portion 46a is positioned within the groove portion 73. In this case, it is preferable that the following conditions are met.
[0037] Condition 1: The end portion 46a of the film side portion 46 and the general surface 64 are spaced apart in the dividing direction. Condition 2: When the minimum width of the groove 73 in the intersecting direction is W, and the thickness of the end portion 46a in the intersecting direction is D, then 0 (mm) <W-D≦0.06(mm)。
[0038] In this embodiment, both condition 1 and condition 2 are satisfied. If condition 1 is met, the general surface 64 is on the same plane as the first dividing surface 62, so when the first mold 61 and the second mold 67 are clamped together, the end portion 46a of the film member 44 will not be caught in the parting line PL of the molding die 60.
[0039] Next, as shown in Figures 5 and 6, resin R is injected and filled into the cavity 70 (this completes the injection molding process). Here, if condition 2 is met, the resin R fills the main body molding section 71 and the side molding section 72 (see Figure 3), while its flow into the groove section 73 is suitably suppressed, so that the groove section 73 is not filled with resin R. This suppresses the direct exposure of the end portion 46a of the film member 44 to the resin R within the cavity 70 during the injection molding process. It also suppresses the flow of resin R between the end portion 46a and the side surface 69b of the molded recess 69.
[0040] Next, after the resin R has cooled and solidified, the cover 40 is removed from the molding die 60. This results in a cover 40 in which the end portion 46a of the film member 44 protrudes towards the first mold 61 side more than the end portion 43a of the base material 41 in the dividing direction. In this case, a minute protrusion 43b is formed on the end portion 43a of the base material 41 by the resin R that has slightly flowed between the corner portion 66c of the groove portion 73 and the end portion 46a.
[0041] <Effects of this embodiment> (1) The molding die 60 is divided into a first die 61 and a second die 67. The first die 61 has a first dividing surface 62 that constitutes the parting line PL of the molding die 60 and a molding surface 63 that molds the back surface 41b of the base material 41. The second die 67 has a molding surface 63 that constitutes a cavity 70 and also has a molding recess 69 that contacts the film member 44.
[0042] The molding surface 63 is provided with a general surface 64 that lies on the same plane as the first dividing surface 62, and a molding projection 65 that protrudes toward the second mold 67 from the general surface 64 in the dividing direction. The molded protrusion 65 has a stepped portion 66 formed on it, which creates a step between the general surface 64 and the tip surface 65a of the molded protrusion 65 in the dividing direction.
[0043] The stepped portion 66, the general surface 64, and the molded recess 69 form a groove 73 that opens towards the second mold 67 in the dividing direction. The stepped portion 66 is configured to allow the end portion 46a of the film member 44 to be inserted into the groove portion 73, while restricting the flow of resin R into the groove portion 73 when the end portion 46a is inserted into the groove portion 73.
[0044] With this configuration, the stepped portion 66 is configured to allow the end portion 46a of the film member 44 to be inserted into the groove portion 73. Also, the general surface 64 is on the same plane as the first dividing surface 62 of the first mold 61. Therefore, by designing the film member 44 so that its end portion 46a is spaced apart from the general surface 64 in the dividing direction, the end portion 46a will not be pinched by the parting line PL of the molding die 60 when the first mold 61 and the second mold 67 are clamped together. Furthermore, with the end portion 46a of the film member 44 inserted into the groove portion 73, it becomes possible to inject the resin R into the cavity 70. Here, with the above configuration, the stepped portion 66 is configured to restrict the flow of resin R into the groove portion 73 when the end portion 46a of the film member 44 is inserted into the groove portion 73. Therefore, it is possible to suppress the direct exposure of the end portion 46a of the film member 44 to the resin R in the cavity 70 during the injection molding process. Furthermore, in the dividing direction, a cover 40 is obtained in which the end portion 46a of the film member 44 protrudes more than the end portion 43a of the base material 41. With such a cover 40, since the end portion 43a of the base material 41 is covered by the film member 44, it is possible to suppress the exposure of the end portion 43a of the base material 41 to the design surface 10a side of the emblem 10.
[0045] Based on the above, it is possible to prevent the appearance of cover 40 from being compromised. (2) The stepped portion 66 has a corner portion 66c that forms the opening edge of the groove portion 73. The corner portion 66c is curved such that it approaches the molded recess 69 in the intersecting direction and approaches the general surface 64 in the dividing direction.
[0046] For example, when the corner 66c of the step portion 66 is formed at a right angle, when the first mold 61 and the second mold 67 are clamped, the corner 66c interferes with the end portion 46a of the film member 44, making it difficult for the end portion 46a to be inserted into the groove portion 73. In this regard, according to the above configuration, the corner 66c is curved so as to approach the general surface 64 in the dividing direction as it approaches the molding recess 69 in the intersecting direction. Therefore, even when the corner 66c interferes with the end portion 46a of the film member 44 when the first mold 61 and the second mold 67 are clamped, the end portion 46a is guided into the groove portion 73 by the corner 66c. Thus, when the first mold 61 and the second mold 67 are clamped, the end portion 46a of the film member 44 can be easily inserted into the groove portion 73.
[0047] (3) The manufacturing method of the cover 40 includes an insertion step of inserting the film member 44 into the cavity 70 of the molding die 60 so that the end portion 46a of the film member 44 is located within the groove portion 73. The manufacturing method also includes an injection molding step of molding the base material 41 by injecting the resin R into the cavity 70 with the film member 44 inserted into the cavity 70.
[0048] According to such a method, by the insertion step and the injection molding step, a cover 40 in which the end portion 46a of the film member 44 protrudes more than the end portion 43a of the base material 41 in the dividing direction can be obtained. <00,00196>
[0049] (4) The step portion 66 is set such that the width of the groove portion 73 satisfies 0 (mm) < W - D ≤ 0.06 (mm). According to such a method, it is possible to more preferably suppress the resin R from flowing into the groove portion 73 in a state where the end portion 46a of the film member 44 is inserted into the groove portion 73 during the injection molding step.
[0050] (5) The film member 44 is set such that the end portion 46a and the general surface 64 are separated from each other in the dividing direction in a state where the end portion 46a of the film member 44 is inserted into the groove portion 73. According to such a method, since the general surface 64 is on the same plane as the first dividing surface 62, when the first mold 61 and the second mold 67 are clamped, the end portion 46a of the film member 44 is not sandwiched between the parting lines PL of the molding die 60. Therefore, it is possible to further suppress the deterioration of the appearance of the cover 40.
[0051] <Modified Example> This embodiment can be implemented with the following modifications. This embodiment and the following modified examples can be implemented in combination with each other within a technically non - conflicting range.
[0052] · The emblem 10 is not limited to being joined between the cover 40 and the housing 30 via the adhesive layer 50. For example, the cover 40 and the housing 30 may be joined by welding the end portion 43a of the base material 41 and the peripheral edge portion 30a.
[0053] · The emblem 10 is not limited to having the end portion 46a of the film member 44 protruding from the end portion 43a in the dividing direction as exemplified in this embodiment. For example, after the injection molding process, the film member 44 may be trimmed so that the end portion 46a is flush with the end portion 43a.
[0054] · The film member 44 does not have to be set such that the end portion 46a and the general surface 64 are separated in the dividing direction when the end portion 46a is inserted into the groove portion 73. That is, the film member 44 may be in contact with the general surface 64 during the insertion process. In this case, the end portion 46a of the film member 44 may be trimmed after the injection molding process.
[0055] · The step portion 66 does not have to be set such that the width of the groove portion 73 satisfies 0(mm) < W - D ≦ 0.06(mm) as exemplified in this embodiment. The step portion 66 only needs to be configured to allow the end portion 46a of the film member 44 to be inserted into the groove portion 73 during the insertion process and to restrict the resin R from flowing into the groove portion 73 during the injection molding process.
[0056] In this embodiment, the second mold 67 is provided to be able to move back and forth along the dividing direction relative to the first mold 61, but the molding die 60 may also be provided in which the first mold 61 is able to move back and forth along the dividing direction relative to the second mold 67. [Explanation of symbols]
[0057] D...thickness H...height PL...Parting line R…Resin S…Space W…width 10… Emblem 10a…Design surface 10b…Back side 11...Character part 12...frame section 20...Light source 21… Circuit board 30… Housing 30a... Peripheral area 40...cover 41...Base material 41a…Surface 41b…Back side 42…Main body 43... Side of the base material 43a...end 43b... protruding part 44…Film component 45... Film body 46... Film side 46a...end 50...adhesive layer 60…Molding mold 61…Type 1 62...1st dividing plane 63…molding surface 64…General side 65…Molded protrusions 65a…Tip surface 65b…side 66... Step section 66a…Side 1 66b…Second side 66c…corner 67…2nd type 68…Second dividing plane 69…Molded recess 69a...Bottom 69b... Side view 70... Cavity 71...Main body molding section 72... Side molding section 73… Groove
Claims
1. A molding die is divided into a first type and a second type, and a film member is inserted into a cavity formed between the first type and the second type, and molten resin is injected into the cavity to form an insert molded product in which the film member is laminated on the surface of a resin substrate, The first type comprises a dividing surface that constitutes the parting line of the molding die and a molding surface that molds the back surface of the substrate, The second type comprises the molded surface and the cavity, and also includes a molded recess that contacts the film member. When the division direction of the first type and the second type is defined as the division direction, The molding surface is provided with a general surface that lies on the same plane as the dividing surface, and a molding projection that protrudes toward the second mold from the general surface in the dividing direction. The molded protrusion has a stepped portion formed therein, which creates a step between the general surface and the tip surface of the molded protrusion in the dividing direction. The stepped portion, the general surface, and the molded recess form a groove that opens towards the second mold in the dividing direction. The stepped portion is configured to allow the end of the film member to be inserted into the groove, while restricting the flow of the molten resin into the groove when the end is inserted into the groove. A mold for insert-molded products.
2. The stepped portion has corners that form the opening edge of the groove, When the direction intersecting the aforementioned division direction is defined as the intersection direction, The aforementioned corner is inclined or curved such that it approaches the general surface in the dividing direction as it approaches the molded recess in the intersecting direction. A mold for an insert molded product as described in claim 1.
3. A method for manufacturing an insert molded product using an insert molded die according to claim 1 or claim 2, Insertion step of inserting the film member into the cavity of the molding die such that the end of the film member is located within the groove; The process includes an injection molding step of molding the substrate by injecting the molten resin into the cavity while the film member is inserted into the cavity. A method for manufacturing insert molded products.
4. When the direction intersecting the division direction is defined as the intersecting direction, the minimum width of the groove in the intersecting direction is W, and the thickness of the end in the intersecting direction is D, The stepped portion is set such that the width of the groove portion satisfies 0 mm < W - D ≤ 0.06 mm. A method for manufacturing an insert molded article according to claim 3.
5. The film member is configured such that, with its end portion inserted into the groove, the end portion and the general surface are spaced apart in the dividing direction. A method for manufacturing an insert molded article according to claim 3.