KR101174650B1 - Film for insert molding using projection plate, method of manufacturing same, and method of manufacturing product by insert molding using projection plate - Google Patents

Abstract

Provided are a film for a stone plate insert, a method for producing the stone plate insert, and a method for producing a stone plate insert molded article, in which the position of the stone plate is not staggered or buried when the insert is formed, and no suction traces remain on the surface of the stone plate.
A film for stone insert having a stone plate cut into one surface of a base film in a predetermined external shape by a pressure-sensitive adhesive layer and having a wood grain region and other non-wood grain regions formed according to the shape appearing on the surface of the stone plate. And a film formed by integrating the molding resin into the cavity by closing the mold and then filling the molding resin in the cavity after the mold is placed in the injection molding mold so that the opposite surface to the base film is along the cavity forming surface. Obtain insert moldings.

Description

FILM FOR INSERT MOLDING USING PROJECTION PLATE, METHOD OF MANUFACTURING SAME, AND METHOD OF MANUFACTURING PRODUCT BY INSERT MOLDING USING PROJECTION PLATE}

Industrial Applicability The present invention is used to decorate parts of automobile interiors, decorative parts for home appliances, display panels, operation panels, operation parts for amusement equipment, and molded parts such as casings, operation parts for communication devices, and casings. In particular, in the case of insert molding, a film for inserting a stone plate in which the position of the stone plate is not staggered or the stone plate is not buried, and suction marks do not remain on the surface of the stone plate. ), And a method for producing the same, and a method for producing a stone insert insert molded article.

Background Art [0002] Conventionally, a stone plate insert molded article insert-molded using a stone plate (also referred to as a stab plate) has been used for interior decoration of automobiles. The process of manufacturing such a slab insert molded article is disclosed by patent document 1, for example. First, prepare a Motoki stone plate 92 of about 200 to 500 µm. Subsequently, the vinyl acetate adhesive 93 is impregnated into a nonwoven fabric, and then this is hot pressed against the stone plate 92.

Subsequently, as shown in Fig. 10A, a reinforcing plate 94 made of polycarbonate or veneer is formed on the back surface of the stone plate 92 via the adhesive 93. ) Is obtained to obtain a decorative sheet 90. Subsequently, the cosmetic sheet 90 is inserted into an injection molding mold, and a molding resin 99 is insert-molded on the back side thereof to form the cosmetic sheet 90 with a resin base material. A stone plate insert molded article 97 formed by bonding to the surface of the 99 is obtained (see Fig. 10 (b)).

Japanese Patent Laid-Open No. 11-000983

However, the insert molding using the stone plate of the said patent document 1 had the following problems.

First, in the case of using a plate insert molded product in which the stone plate is bonded to only a part of the surface of the resin base material (see FIG. 11), the cosmetic sheet is removed from the injection molding die at a predetermined position on the cavity forming surface of the injection molding die. In the state supported by the vacuum suction of the mold, the molding resin is filled into the cavity. However, even if the makeup sheet is supported by vacuum suction, the flow of the molding resin is directed to the end face of the makeup sheet (that is, the end face of the stone plate and the reinforcing plate laminated with the same dimensions). When it hits, the whole toilet seat was moved by the impact, and position aberration was generated in some cases. In particular, the more complicated the outer pattern of the stone plate is, the more the chance of hitting the end face of the decorative sheet in front is likely to occur.

In addition, the flow of the molding resin may penetrate between the cavity forming surface and the stone plate, so that the obtained stone insert molded article is partially buried in the molding resin, so that the surface of the stone plate is only incompletely exposed. There was also a problem. In particular, the more complicated the outer pattern of the stone plate is, the more complicated the flow of the molding resin becomes, and the easier it is to dig between the cavity forming surface and the stone plate.

In addition, since the toilet sheet is supported by vacuum suction from the vacuum suction hole provided on the cavity forming surface, the trace of the vacuum suction hole remains on the surface of the stone plate in close contact with the vacuum suction hole. There was. In particular, the more complicated the outer pattern of the stone plate is, the more difficult it is to select the place for forming the vacuum suction hole, and the more the vacuum suction force for the support needs to be strengthened, so the traces tend to remain.

Therefore, the technical problem to be solved by the present invention is to solve the above problems, the position of the stone plate when the insert molding, or the stone plate is not buried, and the suction film on the surface of the stone plate and the manufacturing method of the stone plate insert, It is to provide a method for producing a stone plate insert molded article.

MEANS TO SOLVE THE PROBLEM This invention provides the film for slab inserts which have the following structures, its manufacturing method, and the manufacturing method of a slab insert molded article in order to solve the said technical subject.

According to the first aspect of the present invention, a stone plate cut into a predetermined external pattern on one surface of a base film is adhered by a pressure-sensitive adhesive layer. A film for stone inserts, comprising a wood grain area and other non-wood grain areas formed according to the shape appearing on the surface of the stone plate. ).

According to the 2nd aspect of this invention, the said base film in 1st aspect provides the film for stone plate inserts characterized by the decoration being added.

According to the third aspect of the present invention, the base film and the stone plate in the first or second embodiment are continuously coated with a transparent resin film so as to sandwich the stone plate therebetween. It provides a film for a stone plate insert characterized in that.

According to the fourth aspect of the present invention, a step of temporarily fixing a stone plate on one surface of a pedestal film,

After using a double-sided adhesive film provided with a separator on both sides of the pressure-sensitive adhesive layer, and peeling one separator, the surface of the pedestal film was temporarily fixed. Adhering by pressure-sensitive adhesive layer,

After positioning the said laminated body in a half-cut shape and arrange | positioning, the said half cut type makes only the said slab, the said pressure-sensitive adhesive layer, and the said separator the predetermined | prescribed shape in the said laminated body. Process to do half cut processing to cut into pattern,

After removing the unnecessary part of the said slab, the said pressure-sensitive adhesive bond layer, and the said separator from the said half cut process laminated body, and peeling off the said separator which covers the said pressure-sensitive adhesive bond layer, this is made into the said pressure-sensitive adhesive bond layer on one side of a base film. Cohesive process,

Peeling the pedestal film from the stone plate adhered to the base film

It provides a method for producing a film for stone plate insert characterized in that it comprises a.

According to the 5th aspect of this invention, after peeling the said pedestal film in a 4th aspect, the process of covering the said base film and the said slabs continuously with a transparent resin film so that the said slabs may be sandwiched.

It provides a method for producing a film for stone plate insert characterized in that it comprises a.

According to the sixth aspect of the present invention, a step of temporarily fixing a stone plate on one surface of a pedestal film,

Using a double-sided adhesive film comprising a pressure-sensitive adhesive layer on one side of the separator, Adhering to the surface of the pedestal film by temporarily fixing the stone plate by the pressure-sensitive adhesive layer,

Positioning and placing the laminate in a half cut shape, and then performing half cut processing in which the slab, the pressure-sensitive adhesive layer, and the separator are cut into a predetermined outline pattern in the laminate by the half cut shape. ,

Peeling the said separator which covers the said pressure sensitive adhesive layer with respect to the part which needs to be transferred, without leaving the said slab, the said pressure sensitive adhesive layer, and the said separator of the part which does not need a transfer from the said half cut process laminated body. After that, the step of adhering this by the pressure-sensitive adhesive layer exposed on one side of the base film,

And a step of peeling the pedestal film from the stone plate adhered to the base film together with the stone plate, the pressure-sensitive adhesive layer, and the separator in a portion where transfer is unnecessary. to provide.

According to the seventh aspect of the present invention, a step of temporarily fixing a stone plate on one side of the pedestal film in the sixth aspect, and a double-sided adhesive film comprising a pressure-sensitive adhesive layer on one side of the separator are used. The manufacturing method of the film for stone plate inserts which changed the order of a process with respect to the process of sticking by the said pressure-sensitive adhesive layer on the surface which temporarily fixed the said stone plate of a film is provided.

According to the 8th aspect of this invention, after peeling the said pedestal film and unnecessary part in any one of a 6th form or a 7th form, the said base film and the said slab are interposed between the said slabs, a transparent resin film Coating process by

It provides a method for producing a film for stone plate insert characterized in that it comprises a.

According to the ninth aspect of the present invention, the base film according to any one of the fourth to eighth aspects is provided with a method for producing a film for stone plate inserts, wherein decoration is applied.

According to the 10th aspect of this invention, the film for stone plate inserts in any one of the 1st-3rd forms is used, and this surface is formed in the injection molding metal mold | die on the opposite surface to the said base film in the cavity forming surface ( arranging to conform to the cavity shape,

After the mold is closed, the molding resin is filled into the cavity to obtain a stone insert molded article in which the film for stone insert and the molding resin are integrated.

It provides a method for producing a stone plate insert molded article characterized in that it comprises a.

According to the eleventh aspect of the present invention, the step of fixing the film for stone plate insert in the tenth aspect on the outside of the cavity,

Removing the unnecessary part of the film for the plate insert after removing the plate insert molded product from the injection mold;

It provides a method for producing a stone plate insert molded article characterized in that it further comprises.

According to the first aspect of the present invention, a stone plate cut into one surface of a base film in a predetermined outline pattern is adhered by a pressure-sensitive adhesive layer, and a grained region and other ratios formed in accordance with the shape appearing on the surface of the stone plate Since it is a film for stone plate inserts having an intact area, if it is placed in the injection molding die so that the surface opposite to the base film is along the cavity forming surface, the position of the stone plate does not move even if the molding resin is filled in the cavity. This is because the molding resin flows along the base film without hitting the end face of the slab in front of the cavity by covering the slab and its surroundings with the base film in the cavity.

In addition, by covering the slab and its surroundings with the base film in the cavity, the molded resin insert molded article is obtained without the flow of the molding resin penetrating between the cavity-forming surface of the injection molding die and the slab. The surface of the slab is completely exposed from the molding resin (see Fig. 3). Moreover, when the thing which decoration was added as said base film can be used, it can decorate also in the said non-bare region.

In the first aspect, the base film and the stone plate may be continuously covered with a transparent resin film so as to sandwich the stone plate therebetween. In this case, in addition to the surface protection, it is possible to prevent the stone plate from being pushed forward by molding shrinkage after insert molding.

According to the 4th aspect and 6th aspect of this invention, a half plate process of a slab and a pressure-sensitive adhesive layer on a pedestal film to a predetermined | prescribed external pattern is carried out, and it transfers to a base film, without directly contacting the stone plate cut by the said external pattern. Since the film for stone plate inserts is obtained by this, even if it is a stone board cut | disconnected in a complicated external pattern, it can stick easily to the said base film. When the stone plate is directly adhered to the base film without using the manufacturing method, after the pressure-sensitive adhesive layer is formed on one side of the stone plate, the cross section is held up to the base film while not touching the adhesive surface. Will be moved. However, because of the complicated appearance pattern and the thin thickness of the stone plate, it is difficult to hold the pressure and the direction of pressurization of the force to the cross-section, so that the stone plate is destroyed or sticks out of a predetermined place. do. According to the manufacturing methods of the fourth aspect and the sixth aspect, such a problem does not occur.

According to the sixth aspect of the present invention, the transfer plate is not removed from the laminate, and the pressure-sensitive adhesive layer 3 and the separator 19 are not removed from the laminate until the transfer is completed. Since it is left behind, even if there is a part made of a small piece of stone, for example, it is peeled off due to something contacting from the side of the small piece part during work, or the position is staggered. I never do that. Moreover, when transferring to the base film, there is no difference in the thickness and strength of the lamination between the part with and without the stone plate, so that the pressure of the transfer roller is evenly applied, and the base film is wrinkled. This does not occur and becomes a clean finish.

Moreover, in 4th aspect and 6th aspect, after peeling the said base film, you may coat | cover continuously the said base film and the said slab with a transparent resin film so that the said slabs may be interposed. In this case, in addition to the surface protection as described above, it is possible to prevent the stone plate from being pushed forward by the molding shrinkage after the insert molding.

According to the 10th aspect of this invention, since insert molding is performed using the said film for slab inserts, the said slab insert molded article which the position of a slab does not stagger and a stone slab does not bury as mentioned above can be obtained.

Further, in the tenth aspect, if the stone plate insert film is fixed outside the cavity, the stone plate in the cavity can be easily fixed, so that a vacuum suction hole is provided in a portion in contact with the stone plate of the cavity forming surface. You may not install it. That is, the traces of the vacuum suction holes may not be left in the wood grain region as well as the non-grain grain region.

BRIEF DESCRIPTION OF THE DRAWINGS It is sectional drawing which shows one Example of the film for stone plate inserts which concerns on this invention.
Figure 2 is a perspective view showing one embodiment of a stone plate insert molded article according to the present invention.
3 is a view showing a cut stone insert insert according to the present invention.
4 is a cross-sectional view showing another embodiment of the film for stone plate insert according to the present invention.
5 is a cross-sectional view showing an embodiment of a manufacturing process of a film for stone plate insert according to the present invention.
6 is a cross-sectional view showing another embodiment of the manufacturing process of the film for stone plate insert according to the present invention.
7 is a cross-sectional view showing another embodiment of the manufacturing process of the film for stone plate insert according to the present invention.
8 is a cross-sectional view showing an embodiment of a step of manufacturing a slab insert molded article using the slab insert film according to the present invention.
Fig. 9 is a cross-sectional view showing another embodiment of a step of manufacturing a slab insert molded article using the slab insert film according to the present invention.
10 is a cross-sectional view showing a step of manufacturing a stone insert insert formed by insert molding a stone plate according to the prior art.
11 is a cross-sectional view showing a stone plate insert molded article according to the prior art.
It is sectional drawing which shows one Example of the film for stone plate inserts obtained by the manufacturing method which concerns on this invention.
It is sectional drawing which shows another Example of the film for stone plate inserts obtained by the manufacturing method which concerns on this invention.
It is sectional drawing which shows another Example of the manufacturing process of the film for stone plate inserts which concerns on this invention.
FIG. 15 is a diagram for explaining why the process of FIG. 14E is preferable.
Fig. 16 is a view for explaining why the process of Fig. 14F is preferable.
It is sectional drawing which shows another Example of the manufacturing process of the film for stone plate inserts which concerns on this invention.
It is sectional drawing which shows another Example of the manufacturing process of the film for stone plate inserts which concerns on this invention.

EMBODIMENT OF THE INVENTION Hereinafter, the film for slab inserts, its manufacturing method, and the manufacturing method of a slab insert molded article which concern on one Embodiment of this invention are demonstrated, referring drawings.

1 and 12 are cross-sectional views showing one embodiment of the film for stone insert according to the present invention. The film 1 for stone plate inserts of FIGS. 1 and 12 is a stone plate 4 cut into a predetermined external pattern on one surface of a base film 2. ) Is adhered by a pressure-sensitive adhesive layer (3), and the wood grain area 1a and other non-wood grain areas formed according to the shape appearing on the surface of the stone plate 4. (1b) is provided. The stone plate 4 is a single plate which is chopped wood, and is generally used as a surface cosmetic material in interior materials or furniture. In this invention, the thickness of the said slab 4 is 150 micrometers-500 micrometers. If the thickness is less than 150μm, the inside is visible, and if the thickness is over 500μm, the installation along the curved surface becomes difficult. More preferably, they are 150 micrometers-300 micrometers. As said stone plate 4, walnut, cherry, maple, cypress, birch, paulownia, camphor, cedar, zelkova, ebony are beautiful , Sapelli, sina, spruce, quince, zebra, castor aralia, wild wood, teak, prunus, elm, white oak Oak, mahogany, etc. can be used. Shapes that appear on the surface of the stone plate 4 include straight grains, flat grains, grained grains, and the like. Moreover, the protective layer may be previously provided in the side used as the surface of the stone plate insert molded article of the stone plate 4. As the protective layer, for example, a hard coating ink may be applied or formed by bonding a resin film such as polymethyl methacrylate (polymethyl methacrylate).

In the present invention, the stone plate 4 is cut into a predetermined external pattern and partially exists on one surface of the base film 2. For example, the contour pattern may have a complicated shape as shown in FIG. 2, and thus a stone insert insert may be obtained.

As a material of the base film 2, for example, acrylic resin, polyester resin, polypropylene resin, vinyl chloride resin, polyethylene resin, polyethylene terephthalate resin, polycarbonate resin, nylon resin, vinylon resin, acetate resin Resins such as polyethylene resins, polyamide resins, polyacrylic resins, and polyvinyl chloride resins can be used. Especially preferably, it is acrylic resin. As a film thickness of the said base film 2, the thing of 75 micrometers-200 micrometers can be used. If the resin used for the injection molding and the base film are in close contact with each other by melting by heat, the step of applying an adhesive ink coating on the back surface becomes unnecessary.

If the substrate film 2 is decorated with an ornament, it can also be decorated in the non-bare region 1b. For example, the base film 2 may be monochromatic printed on the whole surface, or the base film 2 may contain a coloring material. Further, the surface of the base film 2 may be provided with a fine uneven shape such as a hair line or a gloss. Moreover, you may combine these.

As the pressure-sensitive adhesive layer 3, an acrylic pressure-sensitive adhesive (PSA) or the like can be used. For example, it is formed using "high-transparent adhesive transfer tape: 8142" (PET on both sides, PET) manufactured by 3M, etc. The pressure-sensitive adhesive layer 3 is formed of the stone plate ( 4) Since it is disposed below, even if the transmittance is low, there is no problem.

Next, the manufacturing method of the said film for slab insert concerning this invention is demonstrated.

That is, for example, as shown in FIG. 5, the stone plate 4 is temporarily fixed to one surface of the pedestal film 17, and the separator 18 is formed on both surfaces of the pressure-sensitive adhesive layer 3. 19) using a double-sided adhesive film made of one, peeling off one separator 18, and then on the surface on which the stone plate 4 of the pedestal film 17 is temporarily fixed. It adheres by the said pressure-sensitive adhesive layer 3 (FIG. 5 (A), (B), (C)). Subsequently, after positioning the said laminated body in the half-cut type 20, and arrange | positioning, the said slab 4 and the said laminated body in the said laminated body by the said half-cut type 20. Half cut processing is performed in which only the pressure-sensitive adhesive layer 3 and the separator 19 are cut into a predetermined outline pattern (Fig. 5 (D)).

The separator which removes the unnecessary part 21 of the said slab 4, the said pressure-sensitive adhesive bond layer 3, and the said separator 19 from the said half cut process laminated body, and covers the said pressure-sensitive adhesive bond layer 3 ( 19), the adhesive film was attached to one side of the base film 2 by the pressure-sensitive adhesive layer 3 (FIG. 5 (E), (F), (G)), and finally the pedestal film ( 17) is peeled from the stone plate 4 adhered to the base film 2 to obtain the film 1 for stone plate insert.

The pedestal film 17 may use a dicing tape or the like used for fixing a workpiece (processing object) in a dicing process in the manufacture of semiconductors, optical components, and electronic components. have. For example, "SL216F" manufactured by Sun A. Kaken Co., Ltd. (As a polyethylene, the adhesive material is acrylic, film thickness 0.016mm), or "R410" manufactured by Nitto Denko. Etc. As the half cut type 20, a Thompson type, a Pinnacle type, or the like can be used.

Next, another manufacturing method of the film for stone plate inserts which concerns on this invention is demonstrated.

That is, for example, as shown in FIG. 14, the stone plate 4 is temporarily fixed to one surface of the pedestal film 17, and separators 18 and 19 are provided on both sides of the pressure-sensitive adhesive layer 3. After peeling one separator 18 using the said double-sided adhesive film which consists of, it adhere | attaches this by the said pressure-sensitive-adhesive layer 3 to the surface which temporarily fixed the said slab 4 of the said pedestal film 17 [ 14 (A), (B), (C)]. Subsequently, after positioning and arrange | positioning the said laminated body to the half cut mold 20, the said slab 4, the said pressure-sensitive adhesive bond layer 3, and the said separator in the said laminated body by the said half cut die 20 ( 19) only half-cut processing is performed in which a predetermined outline pattern is cut (Fig. 14 (D)). In addition, in FIG. 5, although the separator 18 is peeled and adhere | attached using the double-sided adhesive film which consists of separators 18 and 19 on both surfaces of the pressure-sensitive adhesive bond layer 3, it manufactured by 3M company " An adhesive transfer tape: F9460 " may use a double-sided adhesive film that only includes the pressure-sensitive adhesive layer 3 on one side of the separator 19 from the beginning.

From the half-cut laminated body, the stone plate 4, the pressure-sensitive adhesive layer 3, and the separator 19 of the portion where transfer is unnecessary are left without being removed. After peeling the said separator 19 which covers the pressure sensitive adhesive layer 3, these were adhered by the said pressure sensitive adhesive layer 3 which exposed one side of the base film 2 (FIG. 14 (E), (F). ), (G)], and finally the pedestal film 17 is adhered to the base film 2 together with the stone plate 4, the pressure-sensitive adhesive layer, and the separator 19 in a portion where transfer is unnecessary. It peels from the stone plate 4 and the said film for stone plate inserts is obtained. In addition, when the separator 19 is made of paper (one side is a release process) instead of transparent PET, the separator 19 of the portion where transfer is unnecessary is made with the pedestal film 17. It is easy to see if it can peel together without missing.

By the way, it is also possible to adopt a step different from the steps shown in Figs. This is because, as shown in Fig. 15A, the unnecessary portions of the slab 4, the pressure-sensitive adhesive layer 3, and the separator 19 may be removed from the laminate cut half-cut. If there is a part that is made of small pieces in the interior of the work, there is a risk of peeling off or being staggered due to something coming into contact from the side of the small piece part during the work (Fig. 15 (B)). . In this regard, as shown in Fig. 14E, the stone plate 4, the pressure-sensitive adhesive layer 3, and the separator 19 of the portion where transfer is unnecessary from the half-cut laminated body are not removed. If left as it is, something can be prevented from coming into contact from the side of the small piece portion.

Immediately after the half cut process, unnecessary portions of the stone plate 4, the pressure-sensitive adhesive layer 3, and the separator 19 are removed from the laminated body that has been half-cut, and the pressure-sensitive adhesive layer 3 is further removed. After peeling the said separator 19 which covers the surface (refer FIG. 16 (A)), it is also possible to stick this to one surface of the base film 2 by the said pressure-sensitive adhesive layer 3, but it demonstrated in the previous paragraph. More preferably. In order to adhere the slab 4 to the base film 2, it is necessary to pass pressure between the rollers (not shown) in the state shown in Fig. 16B, but in this case, the slab 4 The part with and without) has a large difference in the thickness and strength of the lamination (the stone plate 4 is a support and solid), so that the pressure of the transfer roller is not evenly applied and the wrinkles in the base film 2 I) There is a risk of occurrence. In this regard, as shown in Fig. 14F, the stone plate 4, the pressure-sensitive adhesive layer 3, and the separator 19 of the portion where transfer is unnecessary from the half-cut laminated body are not removed. If the separator 19 is peeled off only for the portion that needs to be transferred while leaving, the pressure of the transfer roller may be evenly applied, resulting in a clean finish without wrinkles.

The steps of Figs. 14 (A) and (B) are reversed, using a double-sided adhesive film including separators on both sides of the pressure-sensitive adhesive layer, and after peeling one separator, this is one surface of the stone plate. It may be adhered by the pressure-sensitive adhesive layer (see Fig. 18 (A)), and then the base film is temporarily fixed to the other surface of the stone plate (see Fig. 18 (B)).

In addition, the base film 2 and the stone plate 4 are made of a transparent resin film so as to sandwich the stone plate 4 after obtaining the film for stone insert by the above-described manufacturing method shown in FIG. 5 or FIG. 14. You may make it coat | cover continuously by the film 5 (refer FIG. 4, FIG. 13). As the transparent resin film 5, for example, acrylic resin, polyester resin, polypropylene resin, vinyl chloride resin, polyethylene resin, polyethylene terephthalate resin, polycarbonate resin, nylon resin, vinylon resin, acetate resin, Resin, such as polyethylene resin, polyamide resin, polyacrylic resin, and polyvinyl chloride resin, can be used. As a coating method of the said transparent resin film 5, there exist a lamination method using an adhesive, such as a dry laminate and a hot-melt laminate, an extrusion lamination method, etc.

In addition, as shown in FIG. 6, the positioning holes 22 penetrating the laminate formed from the pedestal film 17, the stone plate 4, the pressure-sensitive adhesive layer 3, and the separator 19 are formed. A step may be provided, and the positioning to the half cut die 20 may be performed using the positioning hole 22. In addition, injection molding is performed on the base film 2 according to the positioning holes 22 (see FIGS. 7 and 17) or after the pedestal film 17 is peeled off before the pedestal film 17 is peeled off. Positioning holes 23 for positioning in the dies 7 and 8 and the punching hole dies 13 and 14 may be provided.

Finally, the manufacturing method of the slab insert molded article using the said slab insert film which concerns on this invention is demonstrated.

That is, for example, as shown in the cross-sectional view illustrating the schematic step of FIG. 8, the film 1 for the stone plate insert obtained as described above is heated to an appropriate temperature, and the base film of the film 1 for the stone plate insert is heated. Pressing (2) to the inner side, the mold is pressed down to the preform mold 12, and preformed into a shape corresponding to the shape and dimensions of the stone insert molded article 11 (Fig. A), (B)]. Subsequently, after demolding the shape | molded said film for stone plate inserts, this was set in the punching metal mold | die 13 and 14, and the unevenness | corrugation for cut provided in these metal mold | die 13 and 14 was made. The unnecessary portion 15 is cut off by (13a, 14a) (Figs. 8 (C), (D) and (E)). 8 (A) and (B), although the convex preform mold 12 is used, the base film 2 of the film 1 for the plate insert is turned outward to form a concave shape. You may press down to the preform metal mold | die 12 side of a square. In this case, since it is possible in advance that the stone plate 4 will be pushed into the base film 2, the finish of the boundary of the stone plate 4 will be clean.

The stone insert insert film 1 of which unnecessary parts are removed is then inserted into an injection molding die having a split mold structure consisting of a cavity type 7 and a core type 8, and the cavity type. The cavity forming surface of (7) is set so that the surface opposite to the base film 2 follows, and the vacuum suction is carried out by the vacuum suction hole 7a provided on the cavity forming surface so as to face the base film 2. By supporting the stone insert film 1, closing the mold, and then injection molding by injecting the molding resin 9 into the cavity 16 from the gate 8a provided in the core mold 8 [ 8 (F), (G)]. Thereafter, after the molding resin 9 is cooled and solidified, the mold is demolded, and the insert 1 into which the film 1 for stone plate insert is bonded to the surface of the resin molded product 10 is integrated. The molded article 11 is obtained (Fig. 8 (H)).

For example, as shown in sectional drawing explaining the outline process of FIG. 9, the said film for stone plate inserts 1 is heated to moderate temperature, and the base film 2 of the said film for stone plate inserts 1 is turned inside. As a result, the mold is pressed down toward the preforming mold 12 and molded into a shape corresponding to the shape and dimensions of the stone insert molded article 11 (Figs. 9 (A) and (B)). Subsequently, after demolding the film 1 for the stone plate insert formed after cooling and solidifying (Fig. 9 (C)), this is opposite to the base film 2 on the cavity forming surface of the cavity type 7. It is set so that a surface may follow, and it is set to fix outside the cavity 16, and injection molding is carried out by inject | pouring the molding resin 9 into the cavity 16 from the gate 8a provided in the core mold 8 (FIG. 9). (D), (E)]. Thereafter, after the molding resin 9 is cooled and solidified, the molded resin 9 is demolded, and the stone insert insert film 1 is bonded to the surface of the resin molded article 10 to obtain an integrated stone insert insert 11 (Fig. 9 (F)). ].

Next, this is set in the punching die 13, and the unnecessary part 15 is cut out by the cutting blade 13a provided in the die 13 (FIG. 9 (G), (H), (I)). . In addition, when the vacuum suction hole 7a is provided outside the cavity 16, even if a suction trace remains on the base film 2 of the film for stone insert 1, it can be removed.

Examples of the molding resin 9 include polystyrene resins, polyolefin resins, ABS resins, AS resins, and AN resins. Furthermore, polyphenylene oxide polystyrene resin, polycarbonate resin, polyacetal resin, acrylic resin, polycarbonate modified polyphenylene ether resin, polybutylene terephthalate resin, polybutylene terephthalate resin, ultra high molecular weight polyethylene General purpose engineering resins, such as resin, polysulfone resin, polyphenylene sulfide type resin, polyphenylene oxide type resin, polyarylate resin, polyetherimide resin, polyimide resin, liquid crystal polyester resin, polyallyl (polyallyl) Super engineering resins, such as a) heat-resistant resin, can also be used. Moreover, composite resin which added reinforcing materials, such as glass fiber and an inorganic filler, can also be used. In addition, the molding resin 9 may be colored.

As a method of cutting out the flange-shaped unnecessary portion 15 of the above-mentioned stone plate insert film 1, in addition to the punching method using a Thompson type, a pinnacle type, or the like, a press method using a mold or a sand blast ( sand blast) and the like can also be employed. In particular, in the case where the base film 2 of the film for insert insert 1 is made of acrylic resin, the unnecessary portion 15 is soft compared to the PET film, so that the ablation can be easily performed by sand blasting or the like. .

In addition, in the example shown in FIG. 9, the above-mentioned slab insert film 1 is preliminarily formed outside the molds of the injection molding dies 7 and 8, but the preforming is carried out in the injection molding molds 7 and 8. You may also

In addition, when the stone plate insert film 1 is not covered by the transparent resin film and the stone plate is exposed, the injection plate molds 7 and 8 may be inserted into the injection molding dies 7 and 8 or may be separated from the preliminary mold 12. Before molding, if the moisture in the slab 4 is reduced by drying, mold contamination does not occur. It is presumed that the water contained in the stone plate 4 was causing mold contamination. As a drying method, normal temperature drying, heat drying, etc. are mentioned. In addition, when the obtained slab insert molded article 11 is not covered with the transparent resin film and is exposed to the slab, coating may be performed for surface protection of the insert molded article 11 after insert molding.

[Example 1]

A commercially available dicing tape was used as the base film, and a stone plate of a walnut joint having a length of 300 mm, a width of 400 mm, and a thickness of 0.3 mm was temporarily fixed to the temporary fixing surface. Subsequently, using "high-transparency adhesive transfer tape made by 3M company: 8142", one separator (PET) was peeled off, and then, the acrylic pressure-sensitive adhesive layer was formed on the surface of the pedestal film. Stick. Subsequently, after positioning the said laminated body in the half cut type | mold (pinnacle type), only the said slab, the said pressure-sensitive adhesive layer, and the remaining separator PET in the said laminated body by the said half cut type | mold are shown in FIG. Half cut processing was carried out to cut into a complex outline pattern as shown.

After removing the unnecessary part of the said slab, the said pressure-sensitive adhesive bond layer, and the said separator from the said half cut process laminated body, and peeling the said separator which covers the said pressure-sensitive adhesive bond layer, it is made of 350 mm long, 450 mm wide, and 0.125 mm thick. It adhere | attached on the one side of the base film which consists of PMMA by the said pressure-sensitive adhesive layer. Finally, the pedestal film was peeled from the stone plate adhered to the base film to obtain the film for stone plate insert.

The said slab insert film was heated to a suitable temperature, and the base film of the slab insert film was pressed down to the preforming mold side inside, and molded into a shape according to the shape and dimensions of the slab insert molded article. Subsequently, after cooling and solidifying, the molded film for stone insert is demolded, and then it is placed in an injection molding mold so that the opposite side to the base film follows the cavity-forming cavity forming surface and is fixed outside of the cavity. Then, injection molding was performed by injecting PC / ABS resin into the cavity from the gate provided in the core mold as the molding resin. Thereafter, the molded resin was cooled and solidified, and then demolded to obtain a stone insert molded article in which the film for plate insert was bonded to the surface of the top plate-shaped resin molded article of a notebook PC. After removing the slab insert molded product from the injection molding die, the unnecessary portion was excised by the sand blast method.

[Example 2]

Example 1 Except that the base film and the slab were continuously coated by a dry laminating method with a transparent resin film made of PMMA having a thickness of 0.075 mm so as to sandwich the slab between the slab insert films. Likewise.

[Example 3]

A commercially available dicing tape was used as the base film, and a stone plate of a walnut joint having a length of 300 mm, a width of 400 mm, and a thickness of 0.3 mm was temporarily fixed to the temporary fixing surface. Subsequently, using "high-transparency adhesive transfer tape made by 3M company: 8142", one separator (PET) was peeled off, and then, the acrylic pressure-sensitive adhesive layer was formed on the surface of the pedestal film. Stick. Subsequently, after positioning the said laminated body in the half cut type | mold (pinnacle type), only the said slab, the said pressure-sensitive adhesive layer, and the remaining separator PET in the said laminated body by the said half cut type | mold are shown in FIG. Half cut processing was carried out to cut into a complex outline pattern as shown.

After peeling the separator covering the pressure-sensitive adhesive layer to the portion that needs to be transferred, leaving the stone plate, the pressure-sensitive adhesive layer, and the separator of the portion where transfer is unnecessary from the half-cut laminate, It adhere | attached by the said pressure-sensitive adhesive layer exposed on one side of the base film which consists of PMMA of 350 mm long, 450 mm wide, and 0.125 mm thick. Finally, the pedestal film was peeled from the stone plate adhered to the base film together with the stone plate, the pressure-sensitive adhesive layer, and the separator in a portion where transfer is unnecessary, to obtain the film for the stone plate insert.

The said slab insert film was heated to a suitable temperature, and the base film of the slab insert film was pressed down to the preforming mold side inside, and molded into a shape according to the shape and dimensions of the slab insert molded article. Subsequently, after cooling and solidifying, the molded film for stone insert is demolded, and then it is placed in an injection molding mold so that the opposite side to the base film follows the cavity-forming cavity forming surface and is fixed outside of the cavity. Then, injection molding was performed by injecting PC / ABS resin into the cavity from the gate provided in the core mold as the molding resin. Thereafter, the molded resin was cooled and solidified and demolded to obtain a stone insert molded article in which the film for plate insert was bonded to the surface of a resin molded article of a notebook PC. After removing the slab insert molded product from the injection molding die, the unnecessary portion was excised by the sand blast method.

Example 4

Example 3 Except that the base film and the stone plate were continuously coated by a dry lamination method with a transparent resin film made of PMMA having a thickness of 0.075 mm so as to sandwich the stone plate between the film for the stone plate insert. Likewise.

While the present invention has been described fully in connection with the preferred embodiments with reference to the accompanying drawings, various modifications and variations are apparent to those skilled in the art. Such modifications and variations are to be understood as included therein without departing from the scope of the invention as set forth in the appended claims.

INDUSTRIAL APPLICABILITY The present invention can be used for decorative applications on the surface of molded parts such as automobile interior parts, home appliance decoration parts, display panels, operation panels, operation parts and casings for amusement machines, operation parts and casings for communication devices, and the like. will be.

1: Film for stone insert
1a: wood grain area
1b: non-wood grain area
2: base film
3: pressure-sensitive adhesive layer
4: stone plate
5: transparent resin film
7: cavity type
7a: vacuum suction hole (眞 空 吸引 孔)
8 core type
8a: gate part
9: molding resin
10: resin molded articles
11: stone plate insert molded product
12: preforming mold
13: punching die
14: punching die
15: unnecessary part
16: cavity
17: base film
18: separator
19: separator
20: half-cut type
21: unnecessary part
22: positioning hole
23: positioning hole
90: decorative sheet
92: stone plate
93: vinyl acetate adhesive
94: reinforcement plate
97: slab insert moldings
99: molding resin

Claims (14)

A stone plate cut into a predetermined external pattern on one surface of a base film is adhered by a pressure-sensitive adhesive layer, and the surface of the stone plate A film for inserting a stone plate comprising a wood grain region and other non-wood grain regions formed in accordance with the shape shown in FIG.
The method of claim 1,
The base film is a stone insert film, characterized in that the decoration was applied.
The method according to claim 1 or 2,
The said base film and the said slab are coat | covered continuously by a transparent resin film so that the said slab may be sandwiched between the said base film and a transparent resin film.
Temporarily fixing the stone plate on one side of the pedestal film,
After using a double-sided adhesive film formed with separators on both sides of the pressure-sensitive adhesive layer, and peeling one separator off, the surface of the pedestal film was temporarily fixed. Adhering by pressure-sensitive adhesive layer,
After positioning and placing the said laminated body in a half-cut shape, only the said slab, the said pressure-sensitive adhesive layer, and the said separator are predetermined | prescribed in the said laminated body by the said half cut type | mold. Process to do half cut processing to cut into pattern,
After removing the unnecessary part of the said slab, the said pressure-sensitive adhesive bond layer, and the said separator from the said half cut process laminated body, and peeling off the said separator which covers the said pressure-sensitive adhesive bond layer, this is made into the said pressure-sensitive adhesive bond layer on one side of a base film. Cohesive process,
Peeling the pedestal film from the stone plate adhered to the base film
Method for producing a film for stone plate insert, characterized in that it comprises a.
The method of claim 4, wherein
And after the peeling of the pedestal film, further comprising a step of continuously coating the base film and the stone plate with a transparent resin film so that the stone plate is sandwiched therebetween.
A film for stone insert having a stone plate cut into one surface of a base film in a predetermined external shape by a pressure-sensitive adhesive layer and having a wood grain region and other non-wood grain regions formed according to the shape appearing on the surface of the stone plate. As a way to get
Temporarily fixing the stone plate on one side of the pedestal film,
Using a double-sided adhesive film comprising a pressure-sensitive adhesive layer on one side of the separator and adhering it to the surface on which the stone plate of the pedestal film is temporarily fixed by the pressure-sensitive adhesive layer;
After positioning and arrange | positioning the said laminated body to a half cut type | mold, the half cut which cuts only the said slab, the said pressure-sensitive adhesive layer, and the said separator in a predetermined outline pattern by the said half cut type | mold in a said laminated body. Processing process,
Peeling the said separator which covers the said pressure sensitive adhesive layer with respect to the part which needs to be transferred, without leaving the said slab, the said pressure sensitive adhesive layer, and the said separator of the part which does not need a transfer from the said half cut process laminated body. After that, the step of adhering this by the pressure-sensitive adhesive layer exposed on one side of the base film,
Peeling the pedestal film from the stone plate adhered to the base film together with the stone plate, the pressure-sensitive adhesive layer, and the separator in a portion where transfer is unnecessary.
Method for producing a film for stone plate insert, characterized in that it comprises a.
The method of claim 6,
Temporarily fixing the stone plate on one side of the pedestal film,
The pressure sensitive adhesive layer is provided on one side of the separator The manufacturing method of the film for stone inserts which changed the order of the process about the process of using the double-sided adhesive film which consists of this and sticking this by the said pressure-sensitive adhesive bond layer to the surface which temporarily fixed the said slab of the said pedestal film.
The method according to claim 6 or 7,
After peeling the said pedestal film and an unnecessary part, the said base film and the said slab are further equipped with the process of continuously covering by the transparent resin film so that the said slabs may be interposed, The manufacture of the film for slab inserts characterized by the above-mentioned. Way.
The method according to claim 6 or 7,
The base film is a method of manufacturing a film for stone insert, characterized in that the decoration is applied.
delete A process for using the stone insert of claim 1 or 2, wherein the film is placed in an injection molding die such that a surface opposite to the base film conforms to the cavity forming surface;
After the mold is closed, the molding resin is filled into the cavity to obtain a stone insert molded article in which the film for stone insert and the molding resin are integrated.
Method for producing a stone plate insert molded article characterized in that it comprises a.
The method of claim 11,
Fixing the stone plate insert film outside the cavity;
Removing the unnecessary part of the film for the plate insert after removing the plate insert molded product from the injection mold;
Method for producing a molded stone insert, characterized in that it further comprises.
Using a film for inserting a stone plate according to claim 3, wherein the film is placed in an injection molding die so that a surface opposite to the base film conforms to the cavity forming surface;
After the mold is closed, the molding resin is filled into the cavity to obtain a stone insert molded article in which the film for stone insert and the molding resin are integrated.
Method for producing a stone plate insert molded article characterized in that it comprises a.
The method of claim 13,
Fixing the stone plate insert film outside the cavity;
Removing the unnecessary part of the film for the plate insert after removing the plate insert molded product from the injection mold;
Method for producing a molded stone insert, characterized in that it further comprises.

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