Manufacturing method for film insert molding

Abstract

To provide a manufacturing method of a film insert molded body with reduced quality variations and improved yield in the manufacturing process.SOLUTION: A manufacturing method of a film insert molded body includes steps of: preparing a laminate film with at least a part of a first surface which is one of a surface of a substrate film laminated with a printed layer; forming a decorative film having an ornamental design region by irradiating a laser beam to the printed layer of the laminate film, followed by removing a part of the printed layer; and forming a film insert molded body by arranging the decorative film in a molding die and injecting a fused thermoplastic resin to the printed layer side of the decorative film.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a method for producing a film insert molding. [Background technology]

[0002] Conventionally, plastic molded products have been widely used in automobile interior parts such as instrument panels, center clusters, center consoles, and switch bases, as well as various electrical appliances equipped with display panels such as rice cookers, washing machines, and temperature monitors. Meanwhile, film insert molded products are known as plastic molded products with decorated surfaces.

[0003] A known method for manufacturing such film insert molded products is to first form a decorative film by screen printing on a synthetic resin sheet, then process (hereinafter also referred to as "shaping") it into a shape that can be inserted into an injection molding die, and then insert the shaped decorative film into the die and inject molten resin into the die (see, for example, Patent Document 1).

[0004] In order to reduce the shape reproducibility and design deviation of the synthetic resin sheet (corresponding to the "decorative film" in this specification) during the shaping process, a shaping processing method has been adopted in which a fixed mold is provided with a gate and a recessed mold is formed in a local portion of the movable mold, and a local gap is created around the gate opening between the fixed mold and the synthetic resin sheet, so that the local portion of the synthetic resin sheet that swells due to the molten resin injected into the gap from the gate opening is shaped according to the internal shape of the recessed mold (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 1-299016 [Patent Document 2] Japanese Patent Application Laid-Open No. 2005-074743 Summary of the Invention [Problem to be solved by the invention]

[0006] In recent years, there has been an increasing demand for positional accuracy, sophistication, and sharpness in the designs of film insert moldings. Therefore, film insert moldings that do not meet these requirements have the problem of reduced yields in the manufacturing process of such moldings due to quality variations, etc.

[0007] This specification discloses a technique that can solve the above-mentioned problems. [Means for solving the problem]

[0008] The technology disclosed in this specification can be realized, for example, in the following forms.

[0009] (1) The method for manufacturing a film insert molded product disclosed in this specification includes a laminate film preparation step of preparing a laminate film having a printed layer laminated on at least a portion of a first surface (one surface of a base film); a decorative film formation step of irradiating the printed layer of the laminate film with laser light and removing a portion of the printed layer to form a decorative film having a design area; and a film insert molding step of placing the decorative film in a molding die and injecting molten thermoplastic resin into the printed layer side of the decorative film to form a film insert molded product. According to this method for manufacturing a film insert molded product, the decorative film having a design area is formed by laser processing. Therefore, compared to decorative films produced by screen printing a design on a synthetic resin sheet, the positional accuracy of the design on the decorative film is higher, and the design can be reproduced precisely and sharply. This reduces quality variation in film insert molded products equipped with the decorative film thus formed, thereby improving yield in the manufacturing process of such molded products.

[0010] (2) In the method for producing a film insert molding, the thickness of the base film may be greater than the thickness of the printed layer. By configuring the laminate film in this manner in the method for producing a film insert molding, the strength of the laminate film is improved, and damage to the laminate film during laser processing can be suppressed.

[0011] (3) In the method for producing a film insert molding product, the base film may be configured to transmit all or part of the visible light range. By configuring the laminated film in this manner, the laser light during laser processing can pass through the base film and remove only the printed layer without damaging the base film.

[0012] (4) In the method for producing a film insert molded product, the laminate film preparation step may include preparing a laminate film having a three-dimensional shape that corresponds to the surface shape of at least a portion of the molding die. Generally, in methods for producing film insert molded products, when a laminate film having a printed layer on which a design is formed is shaped, misalignment of the design in the printed layer may occur. In this method for producing a film insert molded product, the design is formed by laser processing using a film obtained by shaping the laminate film into a three-dimensional shape, thereby reducing misalignment of the design in the film insert molded product.

[0013] (5) In the method for manufacturing a film insert molded product described above, in the decorative film forming step, the laminate film may be irradiated with laser light while being vacuum-adsorbed to a jig that holds the laminate film. The jig may be made of a porous metal material. According to this method for manufacturing a film insert molded product, the decorative film forming step uses such a jig, which can prevent the laminate film from shifting during laser processing, thereby improving the positional accuracy of the design area in the film insert molded product.

[0014] (6) In the method for manufacturing a film insert molded product described above, in the decorative film forming step, the laminate film may be irradiated with laser light while being vacuum-adsorbed to a jig that holds the laminate film. The jig may be a white or milky white jig made of a resin material and configured with a vacuum suction hole. According to this method for manufacturing a film insert molded product, using such a jig in the decorative film forming step can suppress positional deviation of the laminate film during laser processing, thereby improving the positional accuracy of the design area in the film insert molded product. Furthermore, because the color of the jig is white or milky white, the laser light can be diffused during laser processing. This reduces damage to the jig caused by the laser light.

[0015] (7) In the method for producing a film insert molding product, the color of the printed layer may be black. In this way, the color of the printed layer is black, which absorbs all colors of light, and therefore the laser light absorption rate is high, making it easy to determine the laser processing conditions.

[0016] (8) In the method for producing a film insert molding, the printed layer may be laminated over the entire first surface of the laminate film. By using a laminate film having a printed layer laminated over the entire surface in this method for producing a film insert molding, all designs to be applied to the decorative film can be formed by laser processing.

[0017] (9) In the manufacturing method of the film insert molding product, the light transmittance may be adjusted by printing the design area of ​​the decorative film after the decorative film forming step. This makes the boundary between the design area and its surroundings more seamless, visually integrating the two and ultimately improving the design and decorativeness of the film insert molding product.

[0018] (10) In the manufacturing method of the above-mentioned film insert molding product, a predetermined color may be imparted by printing the design area of ​​the decorative film after the decorative film formation step. This manufacturing method of the film insert molding product can improve the design and design freedom of the decorative film. Furthermore, a person viewing the film insert molding product from the outside (hereinafter also referred to as "viewer") can visually recognize the color in the design area, thereby improving the design and decorativeness of the film insert molding product as a whole.

[0019] The technology disclosed in this specification can be realized in various forms, for example, in the form of a film insert molding or the like. [Brief explanation of the drawings]

[0020] [Figure 1] 1 is an explanatory diagram schematically illustrating an instrument panel 11 portion provided on a vehicle 1 in a first embodiment, viewed from the rear of the vehicle toward the front of the vehicle. [Figure 2] 1 is an explanatory diagram schematically showing the configuration of a decorative panel 111 in a first embodiment. [Figure 3] 2 is an explanatory diagram schematically showing a YZ cross-sectional configuration of the decorative panel 111 in the first embodiment. FIG. [Figure 4] 10 is a flowchart showing a manufacturing method of the decorative panel 111 in the first embodiment. [Figure 5] 3A to 3C are explanatory diagrams showing an outline of a manufacturing method for the decorative panel 111 in the first embodiment. [Figure 6] 3A to 3C are explanatory diagrams showing an outline of a manufacturing method for the decorative panel 111 in the first embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0021] A. First embodiment: A-1. Composition of decorative panel 111: FIG. 1 is an explanatory diagram schematically illustrating the instrument panel 11 in the first embodiment as viewed from the rear toward the front of the vehicle. FIG. 2 is an explanatory diagram schematically illustrating the configuration of the decorative panel 111 in the first embodiment. FIG. 3 is an explanatory diagram schematically illustrating the YZ cross-sectional configuration of the decorative panel 111 in the first embodiment. FIG. 3 illustrates the YZ cross-sectional configuration of portion A in FIG. 2, among the YZ cross-sectional configurations of the decorative panel 111 at position II-II in FIG. 2. FIGS. 2 and 3 illustrate mutually orthogonal X, Y, and Z axes for identifying directions. For convenience, the positive Z-axis direction is referred to as the upward direction and the negative Z-axis direction is referred to as the downward direction in this specification. However, the decorative panel 111 may actually be installed in an orientation different from these orientations. These points also apply to subsequent figures.

[0022] 1, in the first embodiment, the decorative panel 111 is a center cluster panel that covers a center cluster 110 provided on an instrument panel 11 arranged at the front of a vehicle 1. The center cluster 110 includes a navigation panel, a sensor sheet equipped with pressure-sensitive sensors, a light source such as an LED, and the like, on the side opposite to a surface S1 (hereinafter also referred to as an "operation surface S1") of the decorative panel 111.

[0023] The center cluster 110 includes a display 105 and a switch 107. The display 105 is a portion capable of displaying various images such as navigation images. In this embodiment, the switch 107 is a touch panel switch that can be used to operate the in-vehicle environment, comfort, etc. The decorative panel 111 corresponds to a film insert molding product in the claims.

[0024] The configuration of the decorative panel 111 of this embodiment will be described with reference to Figure 2. The decorative panel 111 has a three-dimensional shape and includes a decorative area 113, a display area 115, and a symbol mark area 117. When viewed in the Z-axis direction, the display area 115 and the symbol mark area 117 of the decorative panel 111 overlap the positions of the display 105 and the switch 107 of the center cluster 110, respectively. The display area 115 and the symbol mark area 117 both correspond to design areas in the claims.

[0025] The decorative region 113 is an area overlapped by a printing layer L2 (described later) when viewed in the Z-axis direction, and is a black portion in this embodiment. The display region 115 is a rectangular region having translucency. In other words, in this embodiment, the display region 115 is a transparent region that transmits light in almost the entire visible light range. In addition, in the symbol mark region 117, various symbol marks corresponding to the switches 107 are applied as translucent cutout characters or cutout shapes, similar to the display region 115. Figure 2(a) shows an enlarged view of a symbol mark region 117a representing a windshield defroster within the symbol mark region 117. Note that the decorative region 113 is not shown in Figure 2(a).

[0026] The cross-sectional structure of the decorative panel 111 will be described with reference to FIG. 3. In this embodiment, the decorative region 113 of the decorative panel 111 has a three-layer structure in the YZ cross section. More specifically, the decorative region 113 of the decorative panel 111 is composed of a base material layer L1, a printed layer L2, and a molded resin layer L3, in this order from the surface S1 of the decorative panel 111. The base material layer L1, the printed layer L2, and the molded resin layer L3 are bonded to one another. Meanwhile, the display region 115 and the symbol mark region 117 (portions P1, P2, and P3) of the decorative panel 111 have a two-layer structure composed of the base material layer L1 and the molded resin layer L3 in the YZ cross section. The base material layer L1 corresponds to the base material film in the claims, and the layer composed of the base material layer L1 and the printed layer L2 corresponds to the decorative film in the claims.

[0027] The base layer L1 of this embodiment constitutes the surface S1 of the decorative panel 111 and is made of a transparent material that transmits almost all light in the visible light spectrum. In other words, the area where the printed layer L2 does not overlap is transparent when viewed in the Z-axis direction. Here, "transparent" means that the total light transmittance measured according to JIS K7136 is, for example, approximately 60% or more, preferably approximately 80% or more. The material constituting the base layer L1 is not particularly limited, but examples include resins such as polycarbonate (PC), ABS, polyester-based polyethylene terephthalate (PET), polyethylene naphthalate, acrylic, polyimide-based, olefin-based, and triacetyl cellulose, as well as elastomers such as silicone rubber. From the viewpoints of weather resistance, chemical resistance, and impact resistance, polycarbonate (PC) resin is preferred. The base layer L1 may be made of one material or two or more materials. The thickness of the base layer L1 in the Z-axis direction is, for example, about 25 μm to 1000 μm, and preferably about 100 μm to 400 μm.

[0028] The printed layer L2 of this embodiment is a layer that provides decorativeness to the decorative panel 111. For example, symbol marks such as letters, figures, symbols, and pictures, window frames corresponding to navigation panels, other decorations, and any combination of these designs are applied as hollow letters, hollow shapes, or hollow areas. Such designs can be formed, for example, to correspond to the function of a pressure sensor provided on the center cluster 110 on the side opposite the operation surface S1 of the decorative panel 111. In the decorative panel 111 of this embodiment, various symbol mark areas 117 are formed corresponding to the positions of pressure sensors that can operate the in-vehicle environment, comfort, etc. The thickness of the printed layer L2 in the Z-axis direction is thinner than the thickness of the base layer L1. In other words, the thickness of the base layer L1 is thicker than the thickness of the printed layer L2. The thickness of the printed layer L2 is, for example, approximately 1 μm to 100 μm, preferably approximately 2 μm to 30 μm.

[0029] In this embodiment, the printing layer L2 is composed of a black colorant, but is not limited to this and may be composed of any colorant that can be removed by laser processing in the decorative film forming step described below. The colorant may be a pigment or a dye, but from the viewpoint of durability, a pigment is preferable. The pigment may be an inorganic pigment or an organic pigment.

[0030] Examples of inorganic pigments include white pigments such as titanium dioxide, zinc oxide, lithopone, precipitated calcium carbonate, white carbon, aluminum oxide, aluminum hydroxide, and barium sulfate; black pigments such as carbon black, titanium black, titanium carbon, iron oxide, and graphite; iron oxide, barium yellow, cadmium red, and chrome yellow.

[0031] Examples of organic pigments include phthalocyanine pigments such as phthalocyanine blue and phthalocyanine green; azo pigments such as azo red, azo yellow, and azo orange; quinacridone pigments such as quinacridone red, cinquasha red, and cinquasha magenta; perylene pigments such as perylene red and perylene maroon; carbazole violet, anthrapyridine, flavanthrone yellow, isoindoline yellow, industhrone blue, dibromoanzathrone red, anthraquinone red, and diketopyrrolopyrrole. The above colorants can be used alone or in combination of two or more. When two or more colorants are used, two or more inorganic or organic pigments can be combined, or an inorganic pigment and an organic pigment can be combined.

[0032] The molded resin layer L3 is a layer that constitutes the back surface S2 of the decorative panel 111 and is a resin layer that supports the base material layer L1 and the printed layer L2. The molded resin layer L3 is made of a thermoplastic resin. The material that constitutes the molded resin layer L3 is not particularly limited, but examples that can be used include polyolefin resin, polycarbonate resin, polymer alloy of polycarbonate resin and ABS resin, and acrylic resin. The thermoplastic resin can be used alone or in combination of two or more types. It is preferable that the deflection temperature under load of the material that constitutes the base material layer L1 is equal to or higher than the deflection temperature under load of the material that constitutes the molded resin layer L3.

[0033] During use, light is projected from a light source such as an LED arranged on the back surface S2 side of the display area 115 or the symbol mark area 117 onto the decorative panel 111 incorporated into the center cluster 110. The projected light passes through the hollowed-out portion of the display area 115 or the symbol mark area 117 of the decorative panel 111, and the transmitted light that passes through the hollowed-out portion makes the decorative printing layer L2 stand out to those viewing from the front surface S1 side of the center cluster 110.

[0034] A-2. Manufacturing method of decorative panel 111: FIG. 4 is a flowchart showing a method for manufacturing the decorative panel 111 in the first embodiment, and FIGS. 5 and 6 are explanatory diagrams showing an outline of the method for manufacturing the decorative panel 111 in the first embodiment.

[0035] First, a laminated film is prepared (laminate film preparation step S10). As shown in Figures 5(A) and (B), in the laminated film preparation step S10 of this embodiment, a laminated film 111S (hereinafter also referred to as "shaped film 111S") that has been shaped in advance to a shape corresponding to the surface shape of the molding die IM used in the film insert molding step S40 described below is prepared as the laminated film. In other words, in the laminated film preparation step S10 of this embodiment, a shaped film 111S having a three-dimensional shape is prepared. Note that the shaped film 111S corresponds to the laminated film in the claims.

[0036] First, as shown in FIG. 5(A), a laminate film 111P having a base layer L1 and a printed layer L2 is prepared. More specifically, in the laminate film 111P of this embodiment, a printed layer L2 is laminated over the entire surface S3 (the surface opposite to surface S1) of the base layer L1. The material and thickness of the base layer L1 are as described above. The printed layer L2 is made of a black colorant, and the type and thickness of the colorant are as described above. Such a laminate film 111P can be formed by a general printing method using, for example, a colored ink containing a black pigment as a colorant. Examples of such printing methods include offset printing, gravure printing, and screen printing. Surface S3 corresponds to the first surface in the claims.

[0037] 5(A)(B), while the laminated film 111P is fixed with a fixture F, the surface S1 of the laminated film 111P is heated with heat h from a heater H and shaped to match the surface shape of a shaping mold SM to form a shaped film 111S. Here, the surface shape of the shaping mold SM corresponds to the surface shape of the molding mold IM used in the film insert molding step S40. The shaping method is not particularly limited, and can be performed by, for example, vacuum forming, pressure forming, vacuum pressure forming, press molding, plug assist molding, etc.

[0038] Next, trimming is performed (trim processing step S20). As shown in FIG. 5(C), the shaped film 111S is cut at the peripheral edge T so that the shape of the shaped film 111S formed in the laminated film preparation step S10 matches the shape of the molding die IM used in the film insert molding step S40 described later. In other words, the outer peripheral portion OP of the shaped film 111S is trimmed. The trimming is not particularly limited, and can be performed by laser processing, ultrasonic cutting, press cutting, etc.

[0039] Next, a decorative film is formed (decorative film forming step S30). As shown in FIGS. 5(D) and 6(A), in the decorative film forming step S30 of this embodiment, the printed layer L2 of the trimmed shaped film 111S is laser processed to form the decorative film 111L. More specifically, laser light L is irradiated onto the areas of the printed layer L2 of the shaped film 111S corresponding to the display area 115 (part P1 in FIG. 6(A)) and the symbol mark area 117, and the printed layer L2 in these areas is removed to form the decorative film 111L in which the display area 115 and the symbol mark area 117 are formed. The type of laser used can be a solid-state laser, a semiconductor laser, a CO2 laser, or the like. The laser processing conditions (laser output, processing time, etc.) can be adjusted so as to remove the entire printed layer L2 in the display area 115 and the symbol mark area 117 of the shaped film 111S, exposing the base layer L1, without damaging the base layer L1. In this embodiment, a YVO4 laser is used, and the laser processing output can be set to 0.1 to 15 W. Note that in Figures 6(A) and 6(C), portions P2 and P3 corresponding to the symbol mark area 117 are not shown.

[0040] Next, film insert molding is performed (film insert molding step S40). As shown in FIGS. 6(B) and (C), film insert molding is performed using a decorative film 111L to manufacture a decorative panel 111 having a decorative region 113, a display region 115, and a symbol mark region 117. More specifically, the decorative film 111L is placed in a molding die IM, and molten thermoplastic resin MR is injected into the molding die IM through an injection port E of the molding die IM. After a predetermined cooling time, the molding die IM is opened and demolded to manufacture the decorative panel 111. When viewed in the X direction, the decorative panel 111 has the printed layer L2 removed from the portion where the display region 115 is located (portion P1 in FIGS. 3 and 6(A) and (C)). The decorative panel 111 has a two-layer structure consisting of a base layer L1 and a molded resin layer L3 made of thermoplastic resin MR. Similarly, the decorative panel 111 has a two-layer structure of a base material layer L1 and a molded resin layer L3 in the portion where the symbol mark area 117 is located (portions P2 and P3 in FIG. 3). Therefore, the decorative panel 111 of this embodiment has a transparent display area 115 and a symbol mark area 117 when viewed from above.

[0041] A-3. Advantages of the first embodiment: As described above, the manufacturing method of the decorative panel 111 of the first embodiment includes a laminated film preparation process S10 in which a laminated film 111P having a printed layer L2 laminated on the entire surface S3 of a base material layer L1 is prepared into a shaped film 111S, a decorative film formation process in which laser light is irradiated onto the printed layer L2 of the shaped film 111S to remove part of the printed layer L2 and form a decorative film 111L having a display area 115 and a symbol mark area 117, and a film insert molding process in which the decorative film 111L is placed in a molding die IM and molten thermoplastic resin is injected from the side of the printed layer L2 of the decorative film 111L to form the decorative panel 111.

[0042] According to the manufacturing method of the decorative panel 111 of this embodiment, a decorative film 111L having a display area 115 and a symbol mark area 117 as design areas is formed by laser processing. Therefore, compared to a decorative film manufactured by printing a design on a synthetic resin sheet using a screen printing method, the positional accuracy of the design on the decorative film 111L is high, and the design can be reproduced precisely and sharply. This reduces the variation in quality of the decorative panel 111 including the decorative film 111L formed in this way, and ultimately improves the yield in the manufacturing process of the decorative panel 111.

[0043] In the laminated film preparation step (S10) of this embodiment, a shaped film 111S having a three-dimensional shape shaped to correspond to the surface shape of the molding die IM is prepared. Generally, in a manufacturing method for a decorative panel, when a laminated film having a printed layer on which a design is printed is shaped, displacement of the design in the printed layer may occur. In the manufacturing method of this embodiment, the design is formed by laser processing using the shaped film 111S obtained by shaping the laminated film 111P into a three-dimensional shape, so displacement of the design in the decorative panel 111 can be reduced, improving yield and ensuring design precision that was previously unachievable.

[0044] When shaping a laminate film having a printed layer on which a design is printed, misalignment of the design on the printed layer tends to occur more easily the larger the decorative panel. The manufacturing method of this embodiment applies the design by laser processing after shaping, making it suitable for use in manufacturing relatively large decorative panels, where misalignment of the design is more likely to occur. On the other hand, when manufacturing multiple decorative panels using a single laminate film, the manufacturing method of this embodiment, in which the design is applied after shaping, minimizes the margin required to account for misalignment of the design during shaping, making it more economical. Furthermore, the manufacturing method of this embodiment makes it possible to apply designs to the bent portions of decorative panels with three-dimensional shapes, which was previously difficult due to the above-mentioned problem of misalignment of the design during shaping.

[0045] In the manufacturing method of this embodiment, the thickness of the base layer L1 is thicker than the thickness of the printed layer L2. This improves the strength of the shaped film 111S, thereby suppressing damage to the shaped film 111S during laser processing. In addition, in this embodiment, the base layer L1 is a transparent layer that transmits light in the entire visible light range. Therefore, during laser processing, the laser light passes through the base layer L1 and can remove only the printed layer L2 without damaging the base layer L1. In addition, in this embodiment, the color of the printed layer L2 is black. This makes it easy to determine the laser processing conditions. In addition, in this embodiment, the printed layer L2 is laminated on the entire surface S3 of the base layer L1. Therefore, all designs to be applied to the decorative film 111L (the display area 115 and the symbol mark area 117) can be formed by laser processing.

[0046] B. Second embodiment: In the manufacturing method for the decorative panel 111 of the second embodiment, the decorative film forming step S30 of the manufacturing method for the decorative panel 111 of the first embodiment is replaced by the following method. Specifically, the decorative film forming step of the second embodiment is performed in a vacuum environment. More specifically, in the vacuum environment, the surface S1 of the trimmed shaped film 111S is held in contact with a jig and vacuum-adsorbed to the jig, and laser light L is irradiated onto the areas of the printing layer L2 corresponding to the display area 115 and the symbol mark area 117. The jig is made of a porous metal material. Examples of the porous metal material that can be used include porous aluminum and porous stainless steel.

[0047] As described above, in the manufacturing method of the decorative panel 111 of the second embodiment, in the decorative film forming step, laser processing is performed in a state in which the shaped film 111S is vacuum-adsorbed to a jig made of a porous metal material. Therefore, it is possible to suppress positional deviation of the shaped film 111S during laser processing, and it is also possible to improve the positional accuracy of the display area 115 and the symbol mark area 117 in the decorative panel 111.

[0048] C. Third embodiment: In the manufacturing method of the decorative panel 111 of the third embodiment, the jig formed of porous metal material is replaced with the jig described below in the decorative film forming step S30 of the manufacturing method of the decorative panel 111 of the second embodiment. Specifically, in the decorative film forming step of the third embodiment, a jig formed of resin material and having vacuum suction holes is used. The color of the jig is white or milky white so that the jig diffuses the laser light.

[0049] The resin material is not particularly limited, but examples thereof include polyacetal resin, nylon resin, polyether ether ketone (PEEK) resin, acrylic resin, silicone resin, ABS resin, and phenolic resin. From the viewpoints of strength and cost, nylon resin, polyacetal resin, and the like are preferably used as the resin material. Furthermore, a pigment is blended into the resin material to adjust the color of the jig to white or milky white. The pigment is not particularly limited, but examples thereof include organic dyes and inorganic pigments.

[0050] The jig has a plurality of vacuum suction holes to more reliably vacuum-suck the shaped-transfer film 111S during laser processing. The positions of the vacuum suction holes in the jig are not particularly limited as long as they can reliably vacuum-suck the shaped-transfer film 111S. From the viewpoint of suppressing misalignment of the shaped-transfer film 111S during laser light irradiation, it is preferable to provide vacuum suction holes around the display area 115 and the symbol mark area 117, for example. The diameter of the vacuum suction holes is, for example, about 0.5 mm to 2 mm. The pitch of the vacuum suction holes (the distance between the vacuum suction holes) is, for example, about 5 mm to 30 mm.

[0051] As described above, in the manufacturing method of the decorative panel 111 of the third embodiment, in the decorative film forming step, the laser processing is performed in a state where the surface S1 of the shaped film 111S is vacuum-adsorbed so that it is in contact with a jig made of a resin material and has vacuum suction holes. This makes it possible to suppress misalignment of the shaped film 111S during laser processing, thereby improving the positional accuracy of the display area 115 and the symbol mark area 117 in the decorative panel 111. Furthermore, since the color of the jig in this embodiment is white or milky white, it is possible to diffuse the laser light during laser processing. This reduces damage to the jig.

[0052] D. Variations: The technology disclosed in this specification is not limited to the above-described embodiments, and can be modified into various forms without departing from the spirit thereof, for example, the following modifications are also possible.

[0053] In the above embodiment, the manufacturing method of the decorative panel 111 has been described by taking the center cluster panel as an example, but is not limited to this. The manufacturing method of the above embodiment can also be applied to the manufacturing of panels used in vehicle interior parts such as instrument panels, center consoles, and switch bases, as well as display panels of various electrical appliances such as rice cookers, washing machines, and temperature monitors.

[0054] In the decorative panel 111 of the above embodiment, the display area 115 and / or the symbol mark area 117 may be a translucent area that transmits a part of visible light. The transparency of the display area 115 and the symbol mark area 117 can be adjusted by adding a light diffusing agent or the like to the material constituting the base layer L1 of the laminate film 111P.

[0055] In the above embodiment, it is preferable that the deflection temperature under load of the material constituting the base layer L1 is equal to or higher than the deflection temperature under load of the material constituting the molded resin layer L3, but this is not limiting. That is, the deflection temperature under load of the material constituting the base layer L1 can be set lower than the deflection temperature under load of the material constituting the molded resin layer L3.

[0056] In the manufacturing method of the decorative panel 111 of the above embodiment, the printed layer L2 may be laminated only on a part of the surface S3 of the base layer L1. For example, in a laminate film, the printed layer may be laminated on an area excluding a large area such as the display area 115. The color of the printed layer L2 may be a color other than black. For example, it may be brown, wood grain, or the like.

[0057] The laminate film 111P in the above embodiment is a laminate film with a two-layer structure having a base layer L1 and a print layer L2, but is not limited to this. That is, the laminate film may have another layer, such as a coating layer, on the surface S1 of the base layer L1. Examples of the other layer include layers having weather resistance, chemical resistance, impact resistance, etc. Examples of materials that can be used to form the other layer include resins such as acrylic resins.

[0058] In the manufacturing method of the decorative panel 111 of the above embodiment, the light transmittance of the symbol mark area 117 of the decorative film 111L may be adjusted in the decorative film formation step. This makes the boundary between the design area and its surroundings more seamless, visually integrating the two and ultimately improving the design and decorativeness of the decorative film 111L. For example, the light transmittance of the symbol mark area 117 can be set to approximately 20% or less. Such adjustment of the light transmittance is not particularly limited, but can be achieved by applying a predetermined smoke ink to the back side of the shaping film 111S (the surface opposite to the surface S1) by a printing method such as pad printing, transfer printing, or screen printing.

[0059] In the decorative film 111L of the above embodiment, for example, a predetermined color may be imparted to the symbol mark area 117. This can improve the design and design freedom of the decorative film. Furthermore, a viewer can visually recognize the color in a design area such as the symbol mark area 117, thereby improving the design and decorativeness of the entire decorative panel. There is no particular limitation on the method for imparting a predetermined color to the symbol mark area 117 in this way. However, the predetermined color can be imparted to the back side of the shaping film 111S (the surface opposite to the surface S1) by a printing method such as pad printing, transfer printing, or screen printing.

[0060] The manufacturing method of the decorative panel 111 of the above embodiment is not limited to the three-dimensional decorative panel 111, but can also be applied to the manufacture of, for example, a two-dimensional decorative panel. In this case, the decorative film forming process is performed without shaping the laminated film 111P. Examples of two-dimensional decorative panels include display panels such as temperature monitors.

[0061] In the above embodiment, the trimming step S20 is performed, but the present invention is not limited to this, and if trimming is not required, it is not necessary to perform trimming.

[0062] The dimensions, materials, and colors of the components in the above embodiment are merely examples and may be modified in various ways.

[0063] Various additives may be blended as needed into the materials constituting the other layers, such as the substrate layer L1, the printed layer L2, the molded resin layer L3, and the coating layer, as long as the effects of the present invention are not impaired. For example, additives such as dyes for adjusting light transmittance and color tone, plasticizers, reinforcing agents, photosensitizers, light stabilizers, chain transfer agents, UV absorbers, antioxidants, viscosity modifiers, tackifiers, foam stabilizers, antifoaming agents, antifungal agents, and preservatives may be blended. [Explanation of symbols]

[0064] 1: Vehicle 11: Instrument panel 105: Display 107: Switch 110: Center cluster 111: Decorative panel 111L: Decorative film 111P: Laminated film 111S: Forming film 113: Decorative area 115: Display area 117: Symbol mark area 117a: Symbol mark area E: Injection port F: Fixture H: Heater IM: Molding mold L1: Base material layer L2: Printing layer L3: Molded resin layer MR: Thermoplastic resin OP: Outer periphery P1: Part P2, P3: Part S10: Laminated film preparation process S1: Surface (operating surface) S20: Trim processing process S2: Back surface S30: Decorative film forming process S3: Surface S40: Film insert molding process SM: Forming mold h: Heat

Claims

1. In a manufacturing method of a film insert molding product, a laminate film preparation step of preparing a laminate film in which a printed layer is laminated on at least a portion of a first surface, which is one surface of a base film, and the laminate film has a three-dimensional shape formed to correspond to the surface shape of at least a portion of a molding die; a decorative film forming step of forming a decorative film having a design area by irradiating the printed layer of the laminated film prepared in the laminated film preparing step with laser light and removing a portion of the printed layer; and a film insert molding process in which the decorative film formed in the decorative film forming process is placed in a molding die, and a molten thermoplastic resin is injected into the portion of the decorative film on the printing layer side from which the printing layer has been removed to form a film insert molding product. A method for producing a film insert molding product.

2. The method for producing a film insert molding according to claim 1, In the decorative film forming step, the laminated film prepared in the laminated film preparing step is irradiated with laser light while being vacuum-adsorbed to a jig that holds the laminated film, The jig is formed of a porous metal material. A method for producing a film insert molding product.

3. The method for producing a film insert molding according to claim 2, The porous metal material is porous aluminum or porous stainless steel. A method for producing a film insert molding product.

4. The method for producing a film insert molding according to claim 1, In the decorative film forming step, the laminated film prepared in the laminated film preparing step is irradiated with laser light while being vacuum-adsorbed to a jig that holds the laminated film, The jig is a white or milky white jig made of a resin material and has a vacuum suction hole. A method for producing a film insert molding product.

5. The method for producing a film insert molding according to claim 1, The thickness of the base film is greater than the thickness of the printing layer. A method for producing a film insert molding product.

6. The method for producing a film insert molding according to claim 1, The substrate film transmits all or part of the visible light range. A method for producing a film insert molding product.

7. The method for producing a film insert molding according to any one of claims 1 to 6, The color of the printing layer is black. A method for producing a film insert molding product.

8. The method for producing a film insert molding according to any one of claims 1 to 6, The printed layer is laminated over the entire first surface of the laminate film. A method for producing a film insert molding product.

9. The method for producing a film insert molding according to any one of claims 1 to 6, After the decorative film forming step, the light transmittance is adjusted by printing the design area of ​​the decorative film. A method for producing a film insert molding product.

10. The method for producing a film insert molding according to any one of claims 1 to 6, After the decorative film forming step, a predetermined color is imparted to the design area of ​​the decorative film by printing. A method for producing a film insert molding product.

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