Manufacturing method for insert molding

Abstract

To improve the durability of insert-molded products by more reliably suppressing peeling of sheet material at the end part of sheet material in insert-molded products with a simple structure.SOLUTION: A method for manufacturing an insert molded product 100 comprises a sheet material 110 and a base resin layer 130. The method includes an end part processing process for continuously forming a concave-convex notch 112 at an end part 111 of the sheet material 110 along an edge 111A of the end part 111, a placement process S2 for placing the sheet material 110 in a molding die 200, and an injection process S4. The molding die 200 has, at a position opposite to the notch 112, a concave step 207 toward the sheet material 110, the step 207 forms a gap 208 between a portion of the end part 111 of the sheet material 110 and the molding die 200, and in the injection process S4, the base resin 131 is made to flow around the gap 208 through the notch 112.SELECTED DRAWING: Figure 8

Description

[Technical Field]

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

[0002] Conventionally, insert-molded products including a sheet material and a base resin layer formed on the back surface of the sheet material have been used, for example, as decorative parts. Deterioration of insert-molded products can be problematic, such as peeling of the sheet material from the base resin layer or, if the sheet material has a laminated structure, peeling at the interface between layers. Peeling often starts from the edge of the sheet material. For example, Patent Document 1 discloses a technology for suppressing edge peeling by forming a fixing portion made of a molded resin to cover the edge of the insert film. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-94813 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the technology of Patent Document 1, the shape of the cavity for forming the fixing portion is not simple, and there are problems in terms of the number of steps and costs involved in manufacturing.

[0005] Therefore, the present disclosure provides a simple configuration to more reliably suppress peeling of the sheet material at the end of the sheet material in an insert molded product, thereby improving the durability of the insert molded product. [Means for solving the problem]

[0006] In order to solve the above problems, one embodiment of a manufacturing method of an insert molded product disclosed herein includes: A method for manufacturing an insert-molded product including a sheet material and a base resin layer formed on a back surface of the sheet material, an end processing step of continuously forming at least one of a concave-convex cutout portion and a plurality of openings in the end portion of the sheet material along the edge of the end portion; a placement step of placing the sheet material in a mold; an injection step of injecting a base resin, which is a raw material for the base resin layer, onto the back surface side of the sheet material, the forming die has a step portion that is convex or concave toward the sheet material at a position facing at least one of the notch portion and the opening portion at an end of the sheet material when the sheet material is placed in the forming die, a gap is formed between a part of an edge of the sheet material and the molding die by the step portion when the sheet material is placed in the molding die, In the injection step, the base resin is injected into the gap through at least one of the notch and the opening. 、 The above-mentioned mold is a cavity mold in which the sheet material is placed; a core mold that is closed with the cavity mold at their mating surfaces to form a cavity into which the base resin is injected, the step portion is formed by an end portion of the mating surface of the core mold on the cavity side protruding toward the cavity side or receding in a direction away from the cavity side relative to an end portion of the mating surface of the cavity mold on the cavity side when the cavity mold and the core mold are closed together, In the placing step, the sheet material is placed in the cavity mold so that the surface of the sheet material contacts the surface of the cavity mold and a part of the edge side of at least one of the notch portion and the opening portion protrudes from the end portion of the cavity mold toward the core mold. It is characterized by:

[0007] In an insert-molded product including a sheet material and a base resin layer formed on the back surface of the sheet material, peeling of the sheet material is likely to occur at the edge of the sheet material. According to this configuration, by wrapping the base resin around the gap, the portion of the edge of the sheet material corresponding to the gap is covered by the base resin layer on both the front and back surfaces. This makes it possible to suppress peeling or progression of peeling of the sheet material at the edge of the sheet material, thereby improving the durability of the insert-molded product. In this specification, "peeling of the sheet material" refers to peeling of the sheet material from the base resin layer and, if the sheet material has a laminated structure, peeling at the interface between the layers constituting the sheet material.

[0008] This configuration So, the above mold is, a cavity mold in which the sheet material is placed; a core mold that is closed with the cavity mold at their mating surfaces to form a cavity into which the base resin is injected, the step portion is formed by an end portion of the mating surface of the core mold on the cavity side protruding toward the cavity side or receding in a direction away from the cavity side relative to an end portion of the mating surface of the cavity mold on the cavity side when the cavity mold and the core mold are closed together, In the placement process, the sheet material is placed in the cavity mold so that the surface of the sheet material contacts the surface of the cavity mold and a portion of the edge side of at least one of the notch and opening protrudes from the end of the cavity mold toward the core mold.

[0009] According to this configuration, a step can be provided by adjusting the relative positions of the sheet-side edges on the mating surfaces of the cavity mold and the core mold, which allows the base resin to flow around the edges of the sheet with a simple configuration, thereby preventing peeling or the progression of peeling at the edges of the sheet material with a simple configuration.

[0010] Another aspect of the method for producing an insert molding product disclosed herein is A method for manufacturing an insert-molded product including a sheet material and a base resin layer formed on a back surface of the sheet material, an end processing step of continuously forming at least one of a concave-convex cutout portion and a plurality of openings in the end portion of the sheet material along the edge of the end portion; a placement step of placing the sheet material in a mold; an injection step of injecting a base resin, which is a raw material for the base resin layer, onto the back surface side of the sheet material, the forming die has a step portion that is convex or concave toward the sheet material at a position facing at least one of the notch portion and the opening portion at an end of the sheet material when the sheet material is placed in the forming die, a gap is formed between a part of an edge of the sheet material and the molding die by the step portion when the sheet material is placed in the molding die, In the injection step, the base resin is injected into the gap through at least one of the notch and the opening, In the end processing step, the concave-convex notch is formed. It is characterized by: In an insert-molded product having a sheet material and a base resin layer formed on the back surface of the sheet material, peeling of the sheet material is likely to occur at the edge of the sheet material. According to this configuration, by wrapping the base resin around the gap, the portion of the edge of the sheet material corresponding to the gap is covered by the base resin layer on both the front and back surfaces. This makes it possible to suppress peeling or the progression of peeling of the sheet material at the edge of the sheet material, and improve the durability of the insert-molded product. Furthermore, the concave-convex cutouts are formed in the edge processing step. According to this configuration, the processing of the edge of the sheet material only requires the formation of the concave-convex cutouts, so that the wraparound of the base resin can be achieved with a simple configuration. the above other one In an embodiment, the mold comprises: a cavity mold in which the sheet material is placed; a core mold that is closed with the cavity mold at their mating surfaces to form a cavity into which the base resin is injected, The step portion is formed on at least one of the cavity mold and the core mold. It is preferable .

[0011] According to this configuration, the wraparound flow of the base resin can be achieved with a simple configuration in which a step portion is provided in at least one of the cavity mold and the core mold, and peeling or the progression of peeling at the edge of the sheet material can be suppressed with this simple configuration.

[0012] Also, In the above aspect, It is preferable that the uneven notch portion is formed in the end processing step.

[0013] According to this configuration, the processing of the edge of the sheet material only requires the formation of concave and convex cutouts, so that the wraparound of the base resin can be achieved with a simple configuration.

[0014] Furthermore, it is preferable that the gap is formed continuously in correspondence with at least one of the notch and the opening.

[0015] Since the gaps are continuously formed corresponding to at least one of the notches and the openings, the base resin can be continuously introduced around the edge of the sheet material where at least one of the notches and the openings is provided, thereby effectively preventing peeling or the progression of peeling of the sheet material at the edge of the sheet material.

[0016] It is also preferable that the end portion where at least one of the notch portion and the opening portion is provided extends from the center portion of the sheet material so as to bend toward the back surface of the sheet material.

[0017] Since the end portion of the sheet material is bent toward the rear surface side of the sheet material, the visibility of the portion covered by the base resin layer is reduced, and the deterioration of the design of the insert molded product can be suppressed.

[0018] One aspect of the insert-molded product disclosed herein is an insert-molded product including a sheet material and a base resin layer formed on a back surface of the sheet material, the end of the sheet material has at least one of a concave-convex cutout portion and a plurality of openings continuously formed along the edge of the end, At least a part of the portion in the end portion where at least one of the notch portion and the opening portion is provided is covered with the base resin layer on both the front and back surfaces of the sheet material. It is characterized by:

[0019] At least a portion of the edge of the sheet material has the front and back surfaces covered with the base resin layer, so that peeling or the progression of peeling of the sheet material at the edge of the sheet material can be effectively suppressed. [Effects of the Invention]

[0020] As described above, according to the present disclosure, a portion of the edge of the sheet material is covered on both the front and back surfaces with the base resin layer, thereby suppressing peeling or the progression of peeling at the edge of the sheet material and improving the durability of the insert-molded product. [Brief explanation of the drawings]

[0021] [Figure 1] 1A and 1B are views showing an insert-molded product according to a first embodiment. [Figure 2] 10A to 10C are diagrams showing modified shapes of the end portions of the sheet material. [Figure 3] FIG. 2 is a flow diagram illustrating a method for manufacturing an insert-molded product according to the first embodiment. [Figure 4] FIG. 10 is a diagram for explaining the procedure of a preparation process. [Figure 5] 4A to 4C are diagrams for explaining a placement step, a mold closing step, and an injection step. [Figure 6] FIG. 4 is a diagram for explaining the arrangement of the end portion of the sheet material. [Figure 7] 7A and 7B are cross-sectional views taken along lines B1-B1 and B2-B2 in FIG. 6. [Figure 8]8 is a diagram for explaining the state after the base resin is injected and the flow of the base resin in FIG. 7. FIG. [Figure 9] 7A and 7B are views illustrating a method for manufacturing an insert-molded product according to a second embodiment. [Figure 10] 8 for explaining the state after the base resin is injected and the flow of the base resin in FIG. 9. FIG. [Figure 11] FIG. 1 is a view corresponding to FIG. 1 showing an insert-molded product according to a second embodiment. [Figure 12] 1 is a cross-sectional view showing a specific example of an insert molded product according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0022] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The following description of the preferred embodiments is merely exemplary in nature and is not intended to limit the present disclosure, its applications, or its uses.

[0023] (Embodiment 1) <Insert molding> As shown in Fig. 1, an insert-molded product 100 according to this embodiment includes a sheet material 110 and a base resin layer 130 formed on the back surface of the sheet material 110. Fig. 1(a) is a perspective view of the insert-molded product 100, and Figs. 1(b) and 1(c) are cross-sectional views taken along lines A1-A1 and A2-A2 in Fig. 1(a), respectively.

[0024] The uses of the insert molded product 100 are not limited, but examples include interior and exterior parts for vehicles, housings and decorative parts for electronic devices, home appliances, building materials, furniture, etc., and particularly parts that require high design quality.

[0025] <Sheet material> There are no limitations on the material of the sheet material 110 as long as it is a sheet-shaped member. Specifically, for example, the sheet material 110 may be a resin film, a woven fabric layer, a nonwoven fabric layer, a thin plate sheet, veneer, genuine leather, a thin metal sheet, etc. Furthermore, the sheet material 110 may have a layered structure in which multiple sheets of a single type or multiple types of material are stacked on top of each other.

[0026] For example, the sheet material 110 may have a laminated structure including a resin layer having excellent weather resistance, light resistance, durability, etc., which is placed on the front side of the insert molded product 100, a decorative layer laminated on the back side of the resin layer, and a fiber layer laminated on the back side of the decorative layer.

[0027] ≪Base material resin layer≫ The base resin layer 130 can be made of a known base resin used in insert molding of sheet materials. While not intended to be limiting, specific examples of the base resin that can be used include acrylonitrile butadiene styrene copolymer (ABS), polycarbonate (PC), polycarbonate ABS (PC / ABS), glass fiber reinforced polycarbonate ABS (PC-ABS-GF), polycarbonate PBT (PC / PBT), polyamide (PA), and polypropylene (PP).

[0028] <Edge of sheet material> As shown in FIG. 1, an end 111 of a sheet material 110 has an uneven cutout portion 112 formed continuously along an edge 111A of the end 111.

[0029] In at least a portion of the portion of the end portion 111 where the cutout portion 112 is provided, both the front surface 110A and the back surface 110B of the sheet material 110 are covered with the base resin layer 130. More specifically, in this embodiment, at the tip portion 112A of the cutout portion 112, both of the above are covered with the base resin layer 130. Note that although both of the above may be covered with the base resin layer 130 over the entire cutout portion 112, in this embodiment, the front surface 110A of the base portion 112B of the cutout portion 112 is not covered with the base resin layer 130. In this way, it is sufficient that both of the above in at least a portion of the cutout portion 112 are covered with the base resin layer 130.

[0030] In this way, at the end 111 of the sheet material 110, at least a portion of the surface 110A of the sheet material 110 is covered by the base resin layer 130, so peeling of the sheet material 110 at the end 111 of the sheet material 110 can be effectively suppressed.

[0031] Although not intended to be limiting, the cutout portions 112 are preferably zigzag with a predetermined pitch P1, for example. This facilitates processing of the end portions 111 in the preparation step S1 (end portion processing step) of the sheet material 110, which will be described later. Although not intended to be limiting, the pitch P1 can be set to, for example, 1 mm or more and 10 mm or less in order to effectively prevent peeling of the sheet material 110 at the end portions 111. Furthermore, although not particularly limited, the width W1 of the cutout portions 112 can be set to, for example, 1 mm or more and 10 mm or less, similar to the pitch P1.

[0032] The shape of the notch 112 is not limited to the above configuration. For example, as shown in Fig. 2, the notch 112 may have a shape with a flat portion 112C at the tip end 112A and / or the base end 112B, or may have a curved shape such as a wave shape, although not shown.

[0033] Furthermore, the shape of the end portion 111 is not limited to the notch portion 112. Instead of or in combination with the notch portion 112, for example, a plurality of openings 114 may be formed continuously along the edge 111A. The shape of the openings 114 is not limited, and may be a circle as shown in FIG. 2, or a polygonal shape, etc. The pitch P2 of the openings 114 can be set to the same as the pitch P1 of the notch portions 112, although this is not intended to be limiting. The diameter R1 of the openings 114 is not particularly limited, and can be set appropriately depending on the pitch P2. The width W2 from the base end portion 114B of the openings 114 to the edge 111A can be set to the same as the width W1 of the notch portions 112, although this is not intended to be limiting.

[0034] 1, the end portion 111 provided with the cutout portion 112 preferably extends from the central portion 113 of the sheet material 110 so as to bend toward the back surface 110B of the sheet material 110. That is, the end portion 111 and the central portion 113 are preferably connected by a bent portion 115. This reduces the visibility of the portion of the end portion 111 where both the front surface 110A and the back surface 110B are covered with the base resin layer 130, thereby preventing a decrease in the design of the insert-molded product 100.

[0035] <Manufacturing method for insert molding products> An example of a method for manufacturing the insert molded product 100 according to this embodiment will be described.

[0036] As shown in FIG. 3, the method for manufacturing the insert molded product 100 includes a preparation step S1, a placement step S2, a mold closing step S3, an injection step S4, a cooling step S5, and a mold opening step S6.

[0037] ≪Preparation process≫ The preparation step S1 is a step of preparing a sheet material 110.

[0038] FIG. 4 shows an example of the procedure of the preparation step S1. First, a first precursor 105, which is a raw material for the sheet material 110, is prepared. When the first precursor 105 has a laminated structure, layers that serve as raw materials are prepared and laminated to form the first precursor 105 for the sheet material 110 (lamination step). Note that the lamination step is an optional step and may be provided as needed. Furthermore, the lamination method is not limited, and a known method can be used.

[0039] As an example of the lamination process, when the sheet material 110 has a three-layer structure of a resin layer, a decorative layer, and a fiber layer, for example, a resin film 101, which is the raw material for the resin layer, a decorative sheet 102, which is the raw material for the decorative layer, and a fiber sheet 103, which is the raw material for the fiber layer, can be laminated to obtain a first precursor 105.

[0040] In particular, when the insert-molded product 100 is an interior or exterior part for a vehicle, conventionally, a decorative layer is provided on a molded base resin layer 130 by adhesive or other means, and then a primer coat, intermediate coat, top coat, etc. are applied to improve the weather resistance, light resistance, durability, etc. of the part to obtain the part. On the other hand, in this method, the surface of the decorative layer is painted with a resin film 101 instead, and a sheet material 110 having a three-layer structure of a resin layer, a decorative layer, and a fiber layer is prepared in advance, and the base resin layer 130 is formed on the sheet material 110 by insert molding. Since this method does not require a painting step, it is advantageous because it simplifies the part manufacturing process and reduces manufacturing costs compared to conventional methods.

[0041] Resin film 101 is, for example, a single-layer or multi-layer film made of a transparent or translucent resin having a uniform thickness, and is excellent in weather resistance, durability, etc., although it is not intended to be limiting. The resin material of resin film 101 is, for example, an acrylic resin containing fluorine, although it is not intended to be limiting. The thickness of resin film 101 is, for example, 0.05 mm to 3.0 mm, although it is not limited.

[0042] The decorative sheet 102 is, for example, a sheet having a uniform thickness, and may be selected from, for example, veneer, genuine leather, thin-film metal sheet, polyvinyl chloride sheet, polyolefin sheet, urethane-coated paper, cork sheet, carbon sheet, etc. The thickness of the decorative sheet 102 is, for example, 0.15 mm or more and 3.0 mm or less, but is not limited thereto. The decorative sheet 102 may have a pattern such as a grain pattern.

[0043] The fiber sheet 103 is, for example, a cotton cloth, a resin cloth, or the like, but is not limited thereto. The fiber sheet 103 may be a woven fabric or a nonwoven fabric. The thickness of the fiber sheet 103 is, for example, 0.15 mm or more and 3.0 mm or less, but is not limited thereto.

[0044] Next, uneven notches 112 and / or openings 114 are continuously formed along the edge of the end of the first precursor 105 to obtain a second precursor 107 (end processing step). The method for forming the notches 112 and / or openings 114 is not limited, and known means such as trimming and punching can be used.

[0045] It is preferable to form cutouts 112, which are easy to process, in end portion 111, particularly zigzag cutouts 112 at a predetermined pitch P1. This makes it possible to prevent peeling of end portion 111 of sheet material 110 with a simple configuration.

[0046] Then, the second precursor 107 is shaped to obtain a sheet material 110 having a shape required for the insert-molded product 100 (shaping step). If the sheet material 110 has a bent portion 115, it is formed in the shaping step.

[0047] 4, an example is described in which the shaping step is performed after the end processing step, but the end processing step may be performed after the shaping step, or the shaping step and the end processing step may be performed simultaneously. Also, depending on the shape of the insert-molded product 100, the shaping step may not be necessary. In this case, after the end processing step, the process can proceed to the next arrangement step S2 without performing the shaping step.

[0048] ≪Placement process, mold closing process and injection process≫ Next, the arrangement step S2, mold closing step S3, and injection step S4 will be described with reference to FIGS.

[0049] FIG. 5(a) is a diagram showing an example of the arrangement step S2, and FIG. 5(b) is a diagram showing an example of the mold closing step S3 and the injection step S4.

[0050] As shown in FIG. 5(a), in the placement step S2, the sheet material 110 is placed in the forming die 200.

[0051] Here, the molding die 200 includes a cavity die 201 and a core die 203 .

[0052] The sheet material 110 is placed in the cavity mold 201 so that a surface 110A of the sheet material 110 contacts a surface 201A of the cavity mold 201. The sheet material 110 placed in the cavity mold 201 is sucked by a suction device 231 through a suction passage 233 as needed. In this way, the sheet material 110 is restrained by the surface 201A of the cavity mold 201 (placement step S2). Note that if suction of the sheet material 110 by the suction device 231 is not necessary due to the shape of the insert-molded product 100 or the like, suction does not have to be performed.

[0053] 6(a) and 7, the sheet material 110 is arranged so that a tip portion 112A (part of the edge side) of a notch portion 112 formed in the end portion 111 protrudes from an end portion 201C of the cavity mold 201 toward the core mold 203. This allows the base resin 131, which is the raw material of the base resin layer 130, to flow around to the surface 110A of the sheet material 110 at the notch portion 112, as will be described later.

[0054] 5(b), the cavity mold 201 and the core mold 203 are brought close to each other, and their mating surfaces, i.e., the mating surface 201B of the cavity mold 201 and the mating surface 203B of the core mold 203 are brought into contact with each other, and the molds are closed (mold closing step S3). Then, as shown in FIGS. 5, 7, and 8, a cavity 205 into which the base resin 131 is injected is formed by the rear surface of the sheet material 110, the surface 201A of the cavity mold 201, and the surface 203A of the core mold 203.

[0055] 7, the core mold 203 is configured so that an end 203C of its mating surface 203B on the cavity 205 side is positioned at a position receding in a direction away from the cavity 205 side from an end 201C of the mating surface 201B of the cavity mold 201 on the cavity 205 side. As a result, when the mold is closed, a step portion 207 is formed in the cavity 205 by the mating surface 201B of the cavity mold 201 and the mating surface 203B of the core mold 203.

[0056] As described above, the notch portion 112 of the sheet material 110 is positioned so that its tip portion 112A protrudes from the end portion 201C of the cavity mold 201 toward the core mold 203, and therefore the step portion 207 is a step portion that is recessed toward the sheet material 110 at a position opposite the notch portion 112.

[0057] As shown in the B1-B1 cross section of FIG. 7, the step 207 forms a gap 208 between the notch 112 of the sheet material 110 and the core mold 203.

[0058] 5(b), the base resin 131 in a molten state is injected into the cavity 205 through the introduction gate 204 (injection step). In this way, the base resin layer 130 is formed on the rear surface 110B of the sheet material 110.

[0059] Here, the manufacturing method of the insert molded product 100 according to this embodiment is characterized in that when the base resin 131 is injected, the base resin 131 is allowed to flow into the gap 208 formed by the cutout portion 112 and the step portion 207.

[0060] As shown in the B1-B1 and B2-B2 cross-sectional views of FIG. 8, when the base resin 131 is injected, the pressure of the base resin 131, as indicated by the arrows in the figure, presses most of the sheet material 110 against the surface 201A of the cavity mold 201. Meanwhile, because of the presence of the gap 208, it takes some time for the tip 112A of the cutout 112 to be pressed against the surface of the step 207. Then, as indicated by the arrows in the lower view of FIG. 8, the base resin 131 flows into the gap 208 through the inlet 112D formed between the base end 112B of the cutout 112 and the end 201C of the cavity mold 201. As a result, as shown in the B1-B1 cross-sectional view of FIG. 8, the base resin can be introduced around the surface 110A side of the tip 112A of the cutout 112.

[0061] According to this configuration, by letting the base resin 131 wrap around the gap 208, both the front surface 110A and the back surface 110B of the tip 112A of the cutout 112 are covered with the base resin layer 130. This makes it possible to suppress peeling or the progression of peeling of the sheet material 110 at the end 111 of the sheet material 110, and improve the durability of the insert-molded product 100.

[0062] As shown in FIG. 6( b), when the cutout 112 is closer to the cavity mold 201 than the end 201C of the cavity mold 201, i.e., when the entire surface 110A of the cutout 112 is in contact with the surface 201A of the cavity mold 201, the base resin 131 does not flow around. This is because the base resin 131 presses the entire surface 110A of the cutout 112 against the surface 201A of the cavity mold 201. Also, as shown in FIG. 6( c), when the cutout 112 protrudes toward the core mold 203 than the end 201C of the cavity mold 201, i.e., when the entire surface 110A of the cutout 112 forms a gap 208, the base resin 131 does not flow around. This is because the base resin 131 presses the entire surface 110A of the cutout 112 against the surface of the step 207 because the inlet 112D is not formed. Therefore, it is important to arrange the sheet material 110 in the cavity mold 201 so that the tip portion 112A, which is a part of the notch portion 112, protrudes from the end portion 201C of the cavity mold 201 toward the core mold 203 side.

[0063] Also, as shown in Figure 2, even if the shape of the cutout portion 112 is changed and / or an opening portion 114 is provided, the position of the end portion 201C of the cavity mold 201 must be positioned at a position corresponding to the cutout portion 112 and / or the opening portion 114.

[0064] In this configuration, step portion 207 is formed by adjusting the relative positions of end portion 201C of cavity mold 201 and end portion 203C of core mold 203. This does not require a major change in the design of molding die 200, and makes it possible to achieve wrapping of base resin 131 around notch portion 112 with a simple configuration.

[0065] Furthermore, it is preferable that the step portion 207 is continuously formed at a position corresponding to the notch portion 112 and / or the opening portion 114 of the sheet material 110. As a result, the gap portion 208 is continuously formed corresponding to the notch portion 112 and / or the opening portion 114, so that the base resin 131 can be caused to flow around continuously corresponding to the notch portion 112 and / or the opening portion 114. In this way, peeling or the progression of peeling of the sheet material 110 at the edge portion 111 of the sheet material 110 can be effectively suppressed.

[0066] ≪Cooling process and mold opening process≫ Once the injection of the base resin 131 is complete, for example, the base resin 131 is cooled from the injection temperature to the mold temperature at a constant cooling rate. The base resin 131 is then solidified to form the base resin layer 130 (cooling step S5). After the base resin 131 has solidified, the cavity mold 201 and core mold 203 are opened, and the insert-molded product 100 is released (mold-opening step S6).

[0067] (Embodiment 2) Other embodiments of the present disclosure will be described in detail below. In the description of these embodiments, the same parts as those in the first embodiment will be denoted by the same reference numerals, and detailed description thereof will be omitted.

[0068] In the first embodiment, the end 203C of the core mold 203 is configured to be positioned at a position that is set back from the end 201C of the cavity mold 201 in a direction away from the cavity 205, but this configuration is not limited thereto. The end 203C of the core mold 203 may be configured to protrude toward the cavity 205 more than the end 201C of the cavity mold 201, as shown in Fig. 9 .

[0069] As a result, the step portion 207 is provided in a position opposite the notch portion 112 so as to project toward the sheet material 110 side.

[0070] 9, the step portion 207 forms a gap 208 between the base end portion 112B of the notch portion 112 of the sheet material 110 and the cavity mold 201. As shown in the cross section B1-B1 of FIG.

[0071] In this configuration, when the base resin 131 is injected, the base resin 131 flows through the inlet 112D into the gap 208 formed between the base end 112B of the cutout 112 and the cavity mold 201, as shown in FIG. 10.

[0072] Thus, as shown in FIGS. 11(a) to 11(c), an insert-molded product 100 is obtained in which the surface 110A at the base end 112B of the cutout portion 112 is covered with the base resin layer .

[0073] In either of the configurations of Embodiments 1 and 2, if the spreading speed of base resin 131 is sufficiently fast, base resin 131 may spread over a wider area or the entire surface 110A of cutout portion 112. In this case, the wider area or the entire surface 110A of cutout portion 112 is covered with base resin layer 130.

[0074] (Other embodiments) In the configurations of the first and second embodiments, the step portion 207 is formed by adjusting the relative positions of the end portion 201C of the cavity mold 201 and the end portion 203C of the core mold 203, but this is not limited to this configuration. The step portion 207 may be formed on at least one of the cavity mold 201 and the core mold 203, preferably on the cavity mold 201 or the core mold 203. Specifically, for example, the step portion 207 may be provided around the end portion 201C of the cavity mold 201 or around the end portion 203C of the core mold 203. In this case, although not shown, the sheet material 110 may be arranged so that when the mold is closed, the tip 112A (part of the edge side) of the notch 112 formed in the end 111 of the sheet material 110 and / or a part of the edge 111A side of the opening 114 protrudes from the end of the stepped portion 207 that contacts the sheet material 110 (this end corresponds to the end 201C in embodiment 1 and the end 203C in embodiment 2) toward the core mold 203. From the viewpoint of simplifying the configuration of the molding mold 200, the configurations of embodiments 1 and 2 are desirable.

[0075] Furthermore, the notch 112 and / or the opening 114 do not have to be provided over the entire edge 111 of the sheet material 110 .

[0076] Specifically, Fig. 12 shows an automobile interior part as an example of an insert-molded product 100. A cutout 112 is provided in an end 111 of the part, which is located on the upper side of Fig. 12, and a portion of a surface 110A of the cutout 112 is covered with a base resin layer 130. Meanwhile, a plated-decorative part 401 abuts against the surface 110A of the end 111, which is located on the lower side of Fig. 12. Because the end 111 is pressed by the plated-decorative part 401, there is little possibility of peeling. Therefore, in such a portion where peeling is suppressed by the presence of other parts, etc., the cutout 112 and / or the opening 114 do not need to be provided. [Industrial Applicability]

[0077] INDUSTRIAL APPLICABILITY The present disclosure is extremely useful in insert-molded articles because it can more reliably suppress peeling of the sheet material at the ends of the sheet material with a simple configuration and improve the durability of the insert-molded article. [Explanation of symbols]

[0078] 100 Insert molding 110 Sheet material 110A surface 110B back side 111 End 111A Edge 112 Notch 112A Tip 112B Base end 112D Inlet 113 Central part 114 Opening 115 Bend 130 Base resin layer 131 Base resin 200 mold 201 Cavity type 201A Surface 201B mating surface 201C End 203-core type 203A surface 203B mating surface 203C end 205 cavity 207 step portion 208 gap portion S1 Preparation process (end machining process) S2 Arrangement process S4 Injection process

Claims

1. A method for manufacturing an insert-molded product including a sheet material and a base resin layer formed on a back surface of the sheet material, an end processing step of continuously forming at least one of a concave-convex cutout portion and a plurality of openings in the end portion of the sheet material along the edge of the end portion; a placement step of placing the sheet material in a mold; an injection step of injecting a base resin, which is a raw material for the base resin layer, onto the back surface side of the sheet material, the forming die has a step portion that is convex or concave toward the sheet material at a position facing at least one of the notch portion and the opening portion at an end of the sheet material when the sheet material is placed in the forming die, a gap is formed between a part of an edge of the sheet material and the molding die by the step portion when the sheet material is placed in the molding die, In the injection step, the base resin is injected into the gap through at least one of the notch and the opening, The above-mentioned mold is a cavity mold in which the sheet material is placed; a core mold that is closed with the cavity mold at their mating surfaces to form a cavity into which the base resin is injected, the step portion is formed by an end portion of the mating surface of the core mold on the cavity side protruding toward the cavity side or receding in a direction away from the cavity side relative to an end portion of the mating surface of the cavity mold on the cavity side when the cavity mold and the core mold are closed together, In the placing step, the sheet material is placed in the cavity mold so that the surface of the sheet material contacts the surface of the cavity mold and a part of the edge side of at least one of the notch portion and the opening portion protrudes from the end portion of the cavity mold toward the core mold. A method for manufacturing an insert molded product characterized by the above-mentioned.

2. A method for manufacturing an insert-molded product comprising a sheet material and a base resin layer formed on the back surface of the sheet material, an end processing step of continuously forming at least one of a concave-convex cutout portion and a plurality of openings in the end portion of the sheet material along the edge of the end portion; a placement step of placing the sheet material in a mold; an injection step of injecting a base resin, which is a raw material for the base resin layer, onto the back surface side of the sheet material, the forming die has a step portion that is convex or concave toward the sheet material at a position facing at least one of the notch portion and the opening portion at an end of the sheet material when the sheet material is placed in the forming die, a gap is formed between a part of an edge of the sheet material and the molding die by the step portion when the sheet material is placed in the molding die, In the injection step, the base resin is injected into the gap through at least one of the notch and the opening, In the end processing step, the concave-convex notch is formed. A method for manufacturing an insert molded product characterized by the above-mentioned.

3. In claim 2, The above-mentioned mold is a cavity mold in which the sheet material is placed; a core mold that is closed with the cavity mold at their mating surfaces to form a cavity into which the base resin is injected, The step portion is formed on at least one of the cavity mold and the core mold. A method for manufacturing an insert molded product characterized by the above-mentioned.

4. In claim 1, In the end processing step, the concave-convex notch is formed. A method for manufacturing an insert molded product characterized by the above-mentioned.

5. In any one of claims 1 to 4, The gap is formed continuously in correspondence with at least one of the notch and the opening. A method for manufacturing an insert molded product characterized by the above-mentioned.

6. In any one of claims 1 to 5, The end portion where at least one of the notch portion and the opening portion is provided is extended from the center portion of the sheet material so as to bend toward the rear surface side of the sheet material. A method for manufacturing an insert molded product characterized by the above-mentioned.

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