JP2012206465A - Method for manufacturing surface panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a surface panel with a resin layer and a decorative film brought into close contact, that can position a decorative part with high accuracy without creasing the decorative film.SOLUTION: An unmolded decorative film 5 is interposed in a cavity C formed between a molding recess 12 of a first mold 10 and a molding protrusion 23 of a second mold 20, and molten resin 4a in the cavity C is injected from a gate 13. The decorative film 5 is brought into close contact with the surface of the molding protrusion 23 by the pressure of the molten resin 4a. The decorative film 5 is made easy to stretch without being restrained between the first mold 10 and the second mold 20. The decorative film 5 can thereby be brought into close contact with the molding protrusion 23 without being creased.

Description

  The present invention relates to a method for manufacturing a surface panel that can manufacture a surface panel having a decorative layer installed in a portable device or other electronic device with a minimum number of steps.

  A surface panel provided in a portable device or other electronic device has a transmissive region that transmits a display screen such as a liquid crystal display panel at the center, and a decorative portion colored like a frame around the transmissive region. Is provided.

  A conventional surface panel has a frame-like decorative part having a window at the center part made of synthetic resin, and a glass plate is fitted into the window, and this glass plate becomes a transmission region, or a translucent A panel is generally formed of the above synthetic resin, and a resin film having a frame-like decorative portion is generally pasted on the front or back surface of the panel.

  When the transparent area is formed of a glass plate, it is possible to make a high-quality surface panel with good transparency in the transparent area. However, it is necessary to assemble the glass plate into the decorative window. Work is complicated. In addition, when the resin film is bonded to the panel, the operation of applying the resin film is complicated, and it is difficult to maintain high positioning accuracy when the panel and the resin film are bonded.

JP 2009-130283 A Japanese Patent Publication No. 50-19132 JP-A-6-344377

Patent Documents 1 to 3 disclose a method for manufacturing a surface panel.
In the manufacturing method disclosed in Patent Document 1, the shape of the surface panel is obtained by injecting the molten resin into the cavity in a state where the resin film in which the transmission region and the decoration portion are formed is installed inside the cavity of the mold. Is decided. In this manufacturing method, it is necessary to form the resin film in a curved shape following the panel surface in advance and then install the resin film inside the mold, and the process is complicated. Moreover, although it is necessary to position the resin film inside the cavity, it is difficult to increase the positioning accuracy.

  In the manufacturing method described in Patent Document 2, a thermoplastic synthetic resin film having a printing layer is placed on a female mold, the film is heated to make the suction hole of the female mold in a vacuum state, and the film is formed on the female mold. Vacuum forming to follow the shape. Thereafter, the female mold and the male mold are combined to form a cavity, molten resin is supplied into the cavity to form a resin layer, and the vacuum-formed film and the resin layer are brought into close contact with each other. Since this manufacturing method requires two steps, that is, vacuum forming of a film using a female mold and injection molding for supplying molten resin to the cavity, the manufacturing process is complicated.

  In the manufacturing method described in Patent Document 3, a decorative sheet is installed on a female mold having a concave molding surface and a vent hole, and the decorative sheet is fixed to the surface of the female mold by sucking the vent hole. After that, the female mold and the male mold are combined to form a cavity in which the decorative sheet is located, and a molten resin is supplied into the cavity to form a resin layer, and the resin layer and the decorative sheet are in close contact with each other I am letting.

  In the manufacturing method described in Patent Document 3, the molten resin is injected into the cavity with the decorative sheet fixed to the female die by the suction force of the air holes formed in the female die. When pressure from the molten resin acts on a decorative sheet that is constrained with no degree of freedom, wrinkles are likely to occur on the decorative sheet, and the decorative sheet and the resin layer are in close contact with wrinkles Is likely to occur.

  Furthermore, the manufacturing methods described in Patent Documents 1, 2, and 3 all have a decorative film placed on the surface that is the protruding side of the resin layer, and are recessed like a surface panel of a portable device or the like. A decorative film cannot be installed on the back side, which is the shape side.

  Therefore, the decorative film may be damaged or broken by operating the surface of the front panel with a finger or the like.

  This invention solves the said conventional subject, and provides the manufacturing method of the surface panel which can install the film which has a decoration part in the back surface side which is the concave shape side of a resin layer by the minimum process. The purpose is that.

  Moreover, this invention aims at providing the manufacturing method of the surface panel which can be integrated with a resin layer in the state which a wrinkle etc. does not produce easily in the film which has a decoration part.

The present invention, in a method for producing a surface panel having a translucent resin layer protruding toward the front side, and a decorative portion provided on the back side of the resin layer,
Using a first mold having a molding concave part and a second mold having a molding convex part,
A step of installing an unformed film in which a decorative portion is formed between the first mold and the second mold;
Combining the first mold and the second mold to form a cavity in which the film is located between the molding concave portion and the molding convex portion;
The molten resin is injected into the cavity from the gate formed in the first mold, and the film is brought into close contact with the molding convex portion with the pressure, and the resin layer and the film molded in the cavity are bonded together. A process of adhering;
It is characterized by having.

  The manufacturing method of the surface panel of this invention can make a film adhere to a resin layer only by the process of installing an unshaped film in a type | mold and injecting molten resin. In the manufactured surface panel, the film having the decorating part is in close contact with the back side which is the concave shape side, and the film having the decorating part is not exposed on the panel surface. Therefore, even if a finger touches the panel surface, the decorative portion is not peeled off or damaged.

  In the present invention, the outer periphery of the film located between the first mold and the second mold outside the cavity can be stretched by pressure and heat when the molten resin is injected into the cavity. It is.

  In the present invention, the film is not completely restrained between the first mold and the second mold, and the film can be stretched between the two molds. Therefore, when the film is pressed against the formation convex portion of the second mold with the molten resin supplied into the cavity, wrinkles and the like are unlikely to occur on the film.

  In the present invention, a plurality of positioning pins for positioning the film are provided in an outer region outside the cavity, and a hole through which the positioning pin is inserted when the outer peripheral portion of the film is stretched. Can be configured as extended.

  By providing the positioning pin, it is possible to position the decorative portion of the film and the resin layer with high accuracy. In addition, since the film extends at the portion where the positioning pin is inserted, wrinkles or the like hardly occur on the film during molding.

  In the present invention, the cavity is installed such that a length direction orthogonal to a direction in which the first mold and the second mold face each other is directed to the direction of gravity. The gate is preferably provided below a midpoint in the longitudinal direction of the cavity, and the gate is located in a rising portion below the forming convex portion of the second mold. It is preferable to be provided at a position closer to the direction of the first mold than the point.

  In the present invention, the film has a decorative coating film that forms a frame-shaped decorative portion and a release coating film that includes a fine filler covering the decorative coating film on the back surface facing the molding convex portion. Can be configured.

  When the said release coating film is formed, when the surface panel after shaping | molding is separated from a 2nd type | mold, a decoration part will become easy to peel from a shaping | molding convex part. As a result, the surface panel can be easily peeled off from the second mold without applying a release agent to the surface of the molding convex portion. Since the release agent does not adhere to the transmission region of the film, the optical characteristics of the transmission region can be kept good.

In the present invention, the resin layer and the film are preferably the same resin material.
When the same resin material is used, the boundary portion between the resin layer and the film melts and becomes difficult to be integrated and separated.

  According to the present invention, a film having a decorative portion can be adhered to a resin layer mainly by two steps of a mold matching step and a molten resin injection step. Further, the film hardly generates wrinkles, and furthermore, the alignment between the decorative portion and the resin layer is easy.

  In the manufactured front panel, the film is located on the back side, which is concave, and the decorative part does not appear on the surface side where fingers are frequently touched, so the decorative part may be damaged or peeled off by the finger etc. Absent.

The perspective view of the surface panel manufactured with the manufacturing method of the present invention, Sectional drawing of the II-II line of the surface panel shown in FIG. Sectional drawing of the III-III line of the surface panel shown in FIG. Top view of decorative film, Expanded sectional view of the decorative film, The front view which looked at the 1st type from the molding side, FIG. 6 is a cross-sectional view of the first type VII-VII line shown in FIG. Sectional drawing which shows the state which put the unmolded decorative film in the cavity and matched the mold, A cross-sectional view of a state where the mold is matched and the molten resin is injected into the cavity, The front view which looked at the molding immediately after separating from the 2nd mold from the X arrow direction of Drawing 9, Explanatory drawing which expands and shows the state where molten resin is inject | emitted in the cavity from a gate in the manufacturing method of the Example of this invention, Explanatory drawing which expands and shows the state where molten resin is injected in a cavity from a gate in a manufacturing method of a comparative example,

  A front panel 1 shown in FIGS. 1 to 3 is used as a part of a case of a mobile device such as a mobile phone or a personal digital assistant.

  In the front panel 1, a protruding shape appears on the front side 2, and a concave shape appears on the back side 3. The front side 2 is directed to the outside of the case of the portable device, and the front side 2 is the operation side or the display side. The back side 3 is directed to the inside of the case of the portable device.

  The front side 2 of the surface panel 1 includes a front surface 2a having a large area, an upper surface 2b positioned at the upper end (Y1 side end) in the length direction, and a lower surface 2c positioned at the lower end (Y2 side end). And a right surface 2d positioned in the right lateral direction (X1 direction) and a left surface 2e positioned in the left lateral direction (X2 direction). The back side 3 of the front panel 1 has a front back surface 3a, an upper back surface 3b, a lower back surface 3c, a right back surface 3d, and a left back surface 3e.

  As shown in FIGS. 2 and 3, the front panel 1 is configured such that a resin layer 4 appearing on the front side 2 and a decorative film 5 appearing on the back side are in close contact with each other. The resin layer 4 is a light-transmitting acrylic synthetic resin material such as PMMA (polymethyl methacrylate). FIG. 5 shows an enlarged cross section of the decorative film 5. As shown in FIG. 5, the decorative film 5 has a translucent base film 5a and a decorative part 6 formed on the back surface thereof. The base film 5 a is a translucent synthetic resin film, and is formed of, for example, the same PMMA as that of the resin layer 4.

  In the present specification, the translucency is preferably so-called transparent having a total light transmittance of 90% or more, but it is sufficient that light can be transmitted inside even if the total light transmittance is lower than that. The total light transmittance should just be 60% or more.

  As shown in FIGS. 1 to 3, the decorative portion 6 is formed in a frame shape. A region surrounded by the frame-shaped decoration portion 6 is a transmission region 7.

  In the portable device using the front panel 1, a display device such as a liquid crystal display panel is provided inside the case, and the display screen is located inside the transmissive region 7. When a portable device is used, the display screen can be visually observed through the translucent resin layer 4 and the base film 5a in the transmissive region 7.

  By providing a sensor on the front side 2 or the back side 3 of the front panel 1, it is possible to detect the contact position of a finger or the like that has touched the front surface 2a. On the front side 2, it is possible to install a pressure sensing type resistance sensor having two opposing resistance layers. On the back side 3, an electrostatic sensor whose detection output changes when a finger touches the front surface 2a can be installed. In addition, it is also possible to form the translucent electrode layer which comprises an electrostatic sensor in the base film 5a of the decorating film 5, and to integrate the decorating film 5 and a sensor.

  As shown in FIG. 1 and FIG. 2, the front panel 1 includes a first opening 8 positioned on the lower end side (Y2 side) with respect to the midpoint in the length direction (Y direction), and an upper end with respect to the midpoint. It has the 2nd opening part 9 located in the side (Y1 side). The first opening 8 and the second opening 9 are formed through the resin layer 4 and the base film 5 a of the decorative film 5.

  Inside the case, a microphone and a speaker are installed at positions facing the first opening 8 and the second opening 9 to handle calls as a mobile phone and images displayed on the display screen. The sound to be output can be output.

Next, the manufacturing method of the said surface panel 1 is demonstrated.
FIG. 6 shows the first mold (mold) 10, and FIG. 7 shows both the first mold 10 and the second mold (mold) 20. The Y1-Y2 direction shown in FIGS. 6 and 7 and the X1-X2 direction shown in FIG. 6 correspond to the length direction (Y1-Y2 direction) and the width direction (X1-X2 direction) of the surface panel 1 to be molded. ing. Moreover, the 1st type | mold 10 and the 2nd type | mold 20 are installed longitudinally so that Y2 direction may face a gravitational direction (G direction).

  The first mold 10 has an opposing flat surface 11 extending in the Y1-Y2 direction, and a molding recess 12 is provided at the center thereof. As shown in FIGS. 6 and 7, the bottom of the molding recess 12 is a front surface molding portion 12 a for molding the front surface 2 a of the front panel 1. The Y1 side is an upper surface molding part 12b for molding the upper surface 2b, and the Y2 side is a lower surface molding part 12c for molding the lower surface 2c. The X1 side is a right surface molding portion 12d for molding the right surface 2d, and the X2 side is a left surface molding portion 12e for molding the left surface 2e.

  The front surface molding portion 12a has a rectangular first step portion 18 corresponding to the first opening 8 on the Y2 side, and a rectangular shape corresponding to the second opening 9 on the Y1 side. A second step portion 19 is formed.

  A gate (pouring gate) 13 is formed in the first mold 10, and an opening end 13 a is opened inside the molding recess 12 in the region of the first step portion 18. FIG. 7 shows the center O of the molding recess 12 in the Y1-Y2 direction. The center O is the midpoint between the upper surface molding portion 12b and the lower surface molding portion 12c. The gate 13 is located below the center O (Y2 side), and the gate 13 is located further on the Y2 side than the midpoint between the center O and the lower surface molding portion 12c.

  As shown in FIGS. 6 and 7, the first mold 10 has a relief recess 14 formed on the Y1 side of the molding recess 12, and the upper surface molding portion 12 b and the relief recess 14 of the molding recess 12 are formed. A plurality of exhaust passages 15 are formed therebetween. The exhaust passage 15 is a shallow groove that is slightly recessed from the opposing plane 11.

As shown in FIG. 6, relief holes 16 are formed at four locations outside the molding recess 12.
As shown in FIG. 7, the second mold 20 has an opposing flat surface 21 extending in the Y1-Y2 direction, and a molding convex part 23 projecting toward the first mold 10 is integrally formed at the center thereof. Is formed. The top portion of the forming convex portion 23 is a front back surface forming portion 23 a for forming the front back surface 3 a of the front panel 1. The Y1 side of the forming convex portion 23 is an upper back surface forming portion 23b for forming the upper back surface 3b, and the Y2 side is a lower back surface forming portion 23c for forming the lower back surface 3c. Although not shown in the drawing, the forming convex portion 23 is provided with a right back surface forming portion for forming the right back surface 3d and a left back surface forming portion for forming the left back surface 3e.

  As shown in FIG. 7, a first mold release pin 24 and a second mold release pin 25 are provided in the second mold 20 so as to freely advance and retract. The first release pin 24 is disposed at a position facing the first step portion 18 of the first mold 10, and the second release pin 25 is disposed at a position facing the second step portion 19. Has been.

  In the second mold 20, positioning pins 26 are fixed at four locations outside the molding convex portion 23. The positioning pin 26 protrudes vertically from the opposing plane 21. When the first mold 10 and the second mold 20 are matched, the positioning pins 26 are inserted into the escape holes 16 of the first mold 10 respectively.

  The arrangement position of the positioning pin 26 and the arrangement position of the relief hole 16 are the same. As shown in FIG. 6, the four positioning pins 26 are located at an equal distance from the center O of the molding recess 12. The center O is located at a point that bisects the molding recess 12 in the length direction (Y1-Y2 direction) and in the width direction (X1-X2 direction). Each positioning pin 26 is located at the same angle θ with respect to the center line O1 that passes through the center O and extends in the longitudinal direction, and is separated from the center O by the same distance.

  Depending on the shape of the surface panel 1 to be molded, that is, the shapes of the molding concave portion 12 and the molding convex portion 23, the positions of the positioning pins 26 and the relief holes 16 do not have to be all the same distance from the center O. For example, the positioning pin 26 on the Y1 side may be further away from the center O in the Y direction than the positioning pin 26 on the Y2 side. However, the distance in the X direction between the two positioning pins 26 on the Y1 side and the two positioning pins 26 on the Y2 side is preferably the same.

  As shown in FIG. 7, gap setting portions 27 protrude from a plurality of locations on the opposing plane 21 of the second mold 20. As shown in FIG. 8, when the first mold 10 and the second mold 20 are combined, the gap setting unit 27 hits the opposing plane 11 of the first mold, and the opposing plane 11 of the first mold 10 and A facing gap T with the facing plane 21 of the second mold 20 is determined. The facing gap T substantially matches the thickness dimension of the decorative film 5. Alternatively, it is set slightly larger than the thickness dimension of the decorative film 5. That is, the opposing gap T does not firmly sandwich the decorative film 5 but allows the decorative film 5 to be stretched in the opposing gap T when stress is applied to the decorative film 5 by pressure from the molten resin. Is set to

  The gap setting unit 27 may be provided on the opposing plane 11 of the first mold 10 or may be provided on both the opposing plane 11 and the opposing plane 21.

  FIG. 4 is a plan view of the unshaped decorative film 5 as viewed from the front. The decorative film 5 has a decorative portion 6 formed in a frame shape around the window portion 7 a for forming the transmission region 7 of the front panel 1. Further, the decorative film 5 has positioning holes 5b opened at four locations near the corners.

  FIG. 5 shows a cross-sectional view of the decorative film 5. For example, the base film 5a formed of PMMA resin has a thickness of about 0.05 to 0.3 mm. The decorative portion 6 is formed on the back surface of the base film 5a by painting. The decoration part 6 has the decorative coating film 6a closely_contact | adhered to the base film 5a. The decorative coating film 6a is a colored layer mainly composed of a polyester resin. As shown in FIG. 1, when the front panel 1 is viewed from the front, the decorative portion 6 is visually observed as the hue of the decorative coating film 6a. A backing coating 6b is formed on the back side of the decorative coating 6a. The backing film 6b is a colored layer mainly composed of a polyester resin, and is formed so that the interior of the case of the electronic device is not seen through in the decorative portion 6 and the hue of the decorative film 6a can be made clear. Has been. Therefore, the thickness of the decorative coating film 6a is about 3-15 micrometers, and the thickness of the backing coating film 6b is 20-50 micrometers larger than it.

  A release coating 6 c that faces the second mold 20 is formed on the decorating unit 6. The release coating film 6c is a so-called matte coating film that is a thermosetting resin such as a polyester resin and contains an inorganic filler therein. The inorganic filler is fine particles such as silica, titanium oxide, talc, mica, and glass, and is generally contained in the range of 1 to 3% by mass with respect to the release coating film 6c.

  The release coating film 6c has a high followability to the elongation force and easily follows the shape of the back side 3 of the surface panel 1 to be molded. On the other hand, the decorative coating 6a and the backing coating film 6b are formed of the base film 5a. It is adjusted by selecting the kind of the curing agent so that the adhesion of the coating film is good and the adhesion between the coating films is high.

  When the release coating film 6c containing the inorganic filler is applied and dried in the printing process, the resin layer contracts, and the surface of the release coating film 6c has a fine shape that traces the portion where the inorganic filler is present and the portion where the inorganic filler is not present. Unevenness is formed.

  By forming the release coating film 6c, the decorative portion 6 is easily separated from the second mold 20 after the surface panel 1 is molded. Therefore, it is not necessary to apply a release agent such as an oil agent to the surface of the molding convex portion 23 of the second mold 20. The surface panel 1 molded without using a release agent is not attached to the surface of the window portion 7a shown in FIG. 4 of the decorative film 5, so that the light transmittance of the transmission region 7 is improved. The display quality of the display screen viewed in the transmissive area 7 can be kept good.

  As shown in FIG. 7, the decorative film 5 is installed on the second mold 20 in a state where the first mold 10 and the second mold 20 are separated from each other. The decorative film 5 is positioned and installed with respect to the second mold 20 by inserting the positioning hole 5b shown in FIG. At this time, the first mold 10 and the second mold 20 are preheated. The temperature is higher than normal temperature and lower than the glass transition point of the base film 5a of the decorative film 5, for example, about 60 to 100 ° C.

  As shown in FIG. 8, when the first mold 10 and the second mold 20 are brought together, the positioning pin 26 protruding from the second mold 20 enters the inside of the relief hole 16 of the first mold 10. . The gap setting portion 27 of the second mold 20 abuts against the opposed plane 11 of the first mold 10, and an opposed gap T is formed between the opposed plane 11 of the first mold 10 and the opposed plane 21 of the second mold 20. Is set. Further, a cavity C is formed between the molding concave portion 12 of the first mold 10 and the molding convex portion 23 of the second mold 20.

  As shown in FIG. 8, when the molds are aligned, the decorative film 5 positioned by the positioning pins 26 is placed inside the cavity C in a state where the molding convex portion 23 is pushed and a little tension is applied. . Further, the outer peripheral portion of the decorative film 5 is installed inside the facing gap T between the first mold 10 and the second mold 20.

  Next, as shown in FIG. 9, molten resin 4 a such as PMMA is injected into the cavity C from the gate 13 of the first mold 10.

  The preheated decorative film 5 is heated to a temperature close to the glass transition point by being brought into contact with the molten resin 4a and softened, and is pressed against the surface of the molding convex portion 23 by the injection pressure of the molten resin 4a. The decorative film 5 pressed against the surface of the molding convex portion 23 tends to be stretched in the surface direction, but the decorative film 5 is not restrained inside the opposing gap T, and therefore can be stretched in the outer peripheral direction. it can. Therefore, the decorative film 5 pressed against the surface of the molding convex part 23 can be stretched relatively freely inside the cavity C, and wrinkles are less likely to occur.

  By injecting the molten resin 4 a into the cavity C, the shape of the front side 2 and the shape of the back side 3 of the front panel 1 are formed by the molten resin 4 a and the decorative film 5. Furthermore, as shown in FIG. 10, the outer peripheral part of the decorative film 5 protruding from the cavity C extends in the Y1 direction and the Y2 direction, as well as the X1 direction and the X2 direction. Moreover, since the base film 5a of the decorative film 5 is softened, the positioning hole 5b is expanded in the radial direction.

  As shown in FIG. 10, when the outer peripheral portion of the decorative film 5 extends in the Y1, Y2, X1, and X2 directions, the four positioning pins 26 are supported with equal force in each direction. The state where the window 7a formed in the film 5 is positioned at the center of the cavity C can be continued, and in the front panel 1 molded as shown in FIG. It becomes easy to form. In addition, it is preferable to set in advance the shape and size of the window portion 7a of the decorative film 5 in consideration of the stretching that occurs in the decorative film 5 when the molten resin is injected.

  The first mold 10 and the second mold 20 are installed in a vertical direction with respect to the gravitational direction (G direction), and the gate 13 is positioned sufficiently lower than the center O of the cavity C. It becomes easy to prevent wrinkles from occurring on the film 5.

  As shown in FIG. 11A, the decorative film 5 crosses the cavity C between the lower surface molding part 12c and the lower back molding part 23c at the stage where the molds are combined. As shown in FIG. 11B, when the molten resin 4a is injected from the gate 13 into the cavity C, the molten resin 4a flows between the lower surface molding portion 12c and the lower back molding portion 23c by gravity, The decorative film 5 is pressed along the surface of the lower back molding part 23c by the flow in the F1 direction. Since the gate 13 is at a low position, the flow of the molten resin in the F1 direction is not easily disturbed, and the decorative film 5 is in close contact with the lower back surface molding portion 23c without generating wrinkles.

  As shown in FIG. 11C, when the lower portion of the cavity C is filled with the molten resin and the decorative film 5 is brought into close contact with the lower back surface molding portion 23c, the molten resin gradually rises in the Y1 direction. At this time, the decorative film 5 is brought into close contact with the front and back molding part 23a of the molding convex part 23 by the force of the flow of the molten resin 4a in the F2 direction.

  While the molten resin 4a rises in the cavity C, the air in the cavity C is discharged into the escape recess 14 from the exhaust passage 15 provided at the upper end of the molding recess 12 of the first mold 10. The

  Due to the behavior of the decorative film 5 in the cavity C, wrinkles are unlikely to occur in the decorative film 5, and the decorative film 5 is easily adhered to the surface of the molding convex portion 23.

  FIG. 12 shows a molding operation when a gate 13A is provided at a position near the edge of the lower surface molding portion 12c of the first mold 10 as a comparative example. In this case, as shown in FIG. 12 (B), since a flow in the F3 direction obliquely upward occurs in the molten resin 4a injected into the cavity C from the gate 13A, wrinkles are likely to occur in the decorative film 5. . As shown in FIG. 12 (C), the wrinkles of the decorative film 5 are then pushed up by the molten resin 4a flowing in the F4 direction, and the probability that wrinkles are not eliminated increases.

  Therefore, it is preferable not to provide a gate in the range from the opposing flat surface 21 of the second mold 20 to half the height dimension H (H / 2) of the lower back surface molding portion 23c.

  After the molten resin is supplied to the cavity C and cooled, the first mold 10 and the second mold 20 are separated. By projecting the first mold release pin 24 and the second mold release pin 25 provided on the second mold 20, the molded product is separated from the molding convex part 23 of the second mold 20. As shown in FIG. 5, since the release coating 6 c in which an inorganic filler is mixed is formed on the outermost surface on the back side of the decorative portion 6, the coating is separated from the surface of the molding convex portion 23 of the second mold 20. It has become easier. Therefore, it is not necessary to apply a release agent to the molding convex portion 23, and the transmissive region 7 of the surface panel 1 after molding is less likely to be stained with an oil film or the like.

  As shown in FIG. 10, in the molded product, the gate trace 13b and the trace of the first release pin 24 remain in the thin portion 18a formed by the first step portion 18 of the first mold 10, and the second The trace of the 2nd mold release pin 25 remains in the thin part 19a formed of this level | step-difference part 19. FIG. The gate marks 13b and the like can be removed by punching the resin layer 4 and the decorative film 5 at the thin wall portions 18a and 19a to form the first opening 8 and the second opening 9. Moreover, the surface panel 1 is formed by cut | disconnecting the resin layer and the decoration film 5 which protruded from the cavity.

  As shown in FIG. 1, the front panel 1 completed by the above manufacturing method has a resin layer on the entire front side 2 and the decorative portion 6 is not exposed on the front side 2. The decorative part 6 is not damaged or peeled off when operating with.

  The surface panel of the present invention is not limited to the case used for the portable device case of the above embodiment, but can be used as a part of a case of a remote controller for operating various electric products or other electronic devices. It is.

DESCRIPTION OF SYMBOLS 1 Front panel 2 Front side 3 Back side 4 Resin layer 4a Molten resin 5 Decorating film 5a Base film 5b Positioning hole 6 Decorating part 6a Decorating coating 6b Backing coating 6c Release coating 7 Transmission area 10 1st type DESCRIPTION OF SYMBOLS 11 Opposite plane 12 Molding recessed part 13 Gate 15 Exhaust passage 20 2nd type | mold 21 Opposite plane 23 Molding convex part 24, 25 Mold release pin 26 Positioning pin 27 Gap setting part C Cavity

Claims (9)

In the method for producing a surface panel having a translucent resin layer protruding toward the front side and a decorative portion provided on the back side of the resin layer,
Using a first mold having a molding concave part and a second mold having a molding convex part,
A step of installing an unformed film in which a decorative portion is formed between the first mold and the second mold;
Combining the first mold and the second mold to form a cavity in which the film is located between the molding concave portion and the molding convex portion;
The molten resin is injected into the cavity from the gate formed in the first mold, and the film is brought into close contact with the molding convex portion with the pressure, and the resin layer and the film molded in the cavity are bonded together. A process of adhering;
The manufacturing method of the surface panel characterized by having.   The outer peripheral part of the film located between the first mold and the second mold outside the cavity is stretchable by pressure and heat when molten resin is injected into the cavity. The manufacturing method of the surface panel of 1 description.   A plurality of positioning pins for positioning the film are provided in an outer region away from the cavity, and a hole through which the positioning pin is inserted is expanded when an outer peripheral portion of the film is stretched. Item 3. A method for producing a surface panel according to Item 2.   The manufacturing of the surface panel according to any one of claims 1 to 3, wherein the cavity is installed such that a length direction orthogonal to a direction in which the first mold and the second mold face each other is directed to the direction of gravity. Method.   The method for manufacturing a surface panel according to claim 4, wherein the gate is provided below a midpoint in the longitudinal direction of the cavity.   The method for manufacturing a surface panel according to claim 5, wherein the gate is provided at a position closer to a first mold direction than a middle point of a rising portion below the forming convex portion of the second mold.   The film is provided with a release coating film including a decorative coating film that forms a frame-shaped decorative portion and a fine filler covering the decorative coating film on the back surface facing the molding convex portion. Item 7. A method for producing a surface panel according to any one of Items 1 to 6.   The manufacturing method of the surface panel of Claim 7 by which the mold release agent is not apply | coated to the surface of the said shaping | molding convex part.   The method for producing a surface panel according to claim 1, wherein the resin layer and the film are made of the same resin material.

Images