Manufacturing method of film insert molded article

• US 20080277823A1
• Filed: 04/15/2008
• Published: 11/13/2008
• Est. Priority Date: 05/09/2007
• Status: Active Grant

• Current Assignee: Sanwa Screen Co., Ltd.
• Original Assignee: Sanwa Screen Co., Ltd.
• Inventors: Goto, Yoshihide, Hayashi, Seiji, Matsuoka, Kiyomi, Goto, Eiichiro
• Granted Patent: US 7,655,163 B2
• Time in Patent Office: Days
• US Class Current: 264/241
• CPC Class Codes: B29C 2045/14704 ink decorations
• CPC Class Codes: B29C 45/14688 Coating articles provided with a decoration
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29K 2715/006 Glues or adhesives, e.g. hot melts or thermofusible adhesives

Abstract

A manufacturing method of a film insert molded article in which no resin layer is seen in the front and no wrinkle is generated in a film is provided. A thermoformed film (11) for coating is arranged within a cavity (15), and molten resin is injected so that a film insert molded article (50) molded integrally with the film (11) for coating and having a coating plane coated with the film (11) for coating is obtained. A printing ink layer (20) and a binder layer (30) are formed in a raw material film (10). The raw material film (10) is cut out and the film (11) for coating is formed so as to have a size for coating the coating plane and being able to form an outer circumferential bending portion (12) arranged in an outer circumferential side portion (41) by adding a width exceeding a heat shrinking amount of the film. After the film (11) for coating is preheated, the film (11) for coating is thermoformed so that a predetermined three-dimensional shape (13) and the outer circumferential bending portion (12) are formed. The film (11) for coating in which the three-dimensional shape (13) and the outer circumferential bending portion (12) are formed, is arranged within the cavity (15) such that the binder layer (30) comes into contact with molten resin. The molten resin is then injected.

Claims

1. A manufacturing method of a film insert molded article in which a film for coating thermoformed in a predetermined shape in advance is arranged within a cavity of an injection molding die, and molten resin is injected into the cavity and is molded integrally with the film for coating, and the film insert molded article having a coating plane coated with the film for coating is obtained;

the manufacturing method comprising;

a process for performing printing on a raw material film and forming a printing ink layer;

a process for forming a binder layer on the printing ink layer;

a process for forming the film for coating by cutting out the raw material film into a size for coating the coating plane and being able to form an outer circumferential bending portion arranged in an outer circumferential side portion of the coating plane of the film insert molded article by adding a width exceeding a heat shrinking amount of the film due to the thermoforming;

a process for forming a predetermined three-dimensional shape and the outer circumferential bending portion, by preheating the film for coating and thermoforming the film for coating thereafter; and

a process for injecting molten resin into a cavity within which the film for coating forming the three-dimensional shape and the outer circumferential bending portion therein is arranged so as to make the binder layer come into contact with molten resin.

2. The manufacturing method of the film insert molded article according to claim 1, wherein the raw material film is a film made from polyethylene terephthalate resin.

3. The manufacturing method of the film insert molded article according to claim 2, wherein the film for coating is preheated at a temperature in a range of 150°

C. to 190°

C.

4. The manufacturing method of the film insert molded article according to claim 1, wherein the outer circumferential bending portion of the film for coating has a width (a) of 1.1% or more of a maximum width (L) of the coating plane.

5. The manufacturing method of the film insert molded article according to claim 1, wherein the three-dimensional shape of the film for coating includes an emboss portion.

6. The manufacturing method of the film insert molded article according to claim 5, wherein the injection molding die has a shape in which a portion corresponding to the emboss portion of the film insert molded article becomes a through hole.