WO2012105664A1 - Housing having layered textile/resin structure and manufacturing method therefor - Google Patents

Abstract

Provided is a housing having a layered textile/resin structure wherein a textile layer adheres well to a base resin layer, the surface of the textile layer is highly resistant to impact and abrasion, and the textile layer does not wrinkle or exhibit pattern distortion. Said housing (1) has an opening (6) in the bottom of an upside-down-boat-shaped structure and is provided with: a transparent acrylic-sheet layer (2); a textile layer (4) bonded to said transparent acrylic-sheet layer (2) by means of an adhesive (3); and a base resin layer (5) that penetrates into gaps between the fibers of the textile layer (4) and adheres thereto.

Description

Textile / resin laminated structure housing and manufacturing apparatus thereof

The present invention relates to a textile / resin laminated housing and a manufacturing apparatus thereof, and more particularly, to a textile / resin laminated housing in which a textile layer is laminated on a base resin layer and a manufacturing apparatus thereof.

In the technical field of housings for electronic devices, home appliances, etc. and housings for automobile interior parts, the housings are often made by resin molding in which a decorative material is laminated on the outer surface. Recently, various types of housings are applied to resin molded housings. Decorative material is an indispensable element for differentiating from other products. In such a situation, some companies can freely select a decorative design of a product by applying various decorative materials to the resin molded housing even for the same product.

As a method for decorating a resin molded housing, there is a technique for painting, transferring, and gravure printing on a resin sheet (see, for example, Patent Document 1), and a decorative material containing fibers (textiles) with excellent decorative properties is used. A resin molded body formed on the surface of a resin container by molding is proposed (for example, see Patent Document 2). In this resin molded body, a base material film and a decorative material made of a textile material bonded to each other are fused to the surface of the object to be decorated. For example, the decorative material is made of a textile material covered with a base film, and the base film is made of polyester resin, polyamide resin such as nylon, polyolefin resin, polystyrene resin, or the like.

In addition, as a technique for bonding textile materials as decorating materials to the body to be decorated, the textile materials are stretched over the mold cavity surface, and then molten resin is injected into the cavities to melt into the decorating materials. There is a technique in which a resin is infiltrated and both are laminated and pressure-bonded in a throwing state (see, for example, Patent Document 3).

JP 2000-25168 A JP 2010-36366 A JP-A-2005-471161

However, in the technology of Patent Document 1, the decoration by painting is not only a flat decoration part, but also the volatile organic compound (VOC) used in the painting process causes health damage, In many cases, the paint is easily peeled off from the plastic molded casing, and the decoration by gravure printing is not suitable for individual small-scale production because of the need to prepare a mold roll for each pattern.

In addition, in the technique of Patent Document 2, the base material film covering the textile material is inferior in impact resistance and easily damaged, and the textile material for the object to be decorated is low in resistance at high temperatures during in-mold molding. In order to form a product housing, it is necessary to subject the object to be decorated to which the decorative material has been fused to a further housing processing step.

In the technology of Patent Document 3, the adhesion of the textile material to the material to be decorated is not sufficient, and the low-volume productivity for diversification of products and the versatility of each product are not always taken into consideration. Further, in the technique of Patent Document 3, the textile material is liable to wrinkle or the pattern is distorted when the molten resin is injected under pressure, and the yield during mass production is poor.

The object of the present invention is to provide a textile / resin laminated structure housing which is excellent in adhesion of the textile layer to the base resin layer, impact resistance and scratch resistance of the surface of the textile layer, and in addition, there is no generation of wrinkles in the textile layer or distortion of the pattern. Textile / resin that can improve the adhesion of the textile layer to the base resin layer and the impact resistance and scratch resistance of the surface of the textile layer, as well as eliminate the occurrence of wrinkles in the textile layer and distortion of the pattern An object of the present invention is to provide an apparatus for manufacturing a laminated structure housing.

In order to achieve the above object, a textile / resin laminated structure housing according to claim 1, comprising: a transparent acrylic sheet layer; a textile layer bonded to the transparent acrylic sheet layer with an adhesive; and the textile layer. And a base resin layer fixed to the textile layer while infiltrating the gaps between the fibers.

An apparatus for manufacturing a textile / resin laminated structure housing according to claim 10, wherein a fixed mold for receiving a laminate of a transparent acrylic sheet layer and a textile layer bonded to each other via an adhesive with the textile layer as a front surface. A movable mold that is moved toward the stationary mold so as to push the received laminated body into the stationary mold in order to form the laminated body; and Other fixed molds that are received with the layers facing up, an injection mold that is moved toward the laminated body that is received in the other fixed mold, and a laminated body that is received in the other fixed mold And an injection means for injecting the raw material of the base resin layer into a space defined by the injection mold.

The textile / resin laminated housing manufacturing apparatus according to claim 11, comprising: a stationary mold for receiving a laminate of a transparent acrylic sheet layer and a textile layer bonded to each other via an adhesive with the textile layer as a front surface; A movable mold moved toward the fixed mold so as to push the received laminated body into the fixed mold in order to form the laminate, and a laminate pushed into the fixed mold An injection mold that is moved toward the body, and an injection unit that injects the raw material of the base resin layer into a space defined by the laminate received by the fixed mold and the injection mold. It is characterized by.

The textile / resin laminated housing according to claim 1 has improved adhesion of the textile layer to the base resin layer and excellent impact resistance and scratch resistance on the surface of the textile layer. There is no occurrence or distortion of the pattern.

According to the apparatus for manufacturing a textile / resin laminated structure housing according to claim 10 or 11, the adhesiveness of the textile layer to the base resin layer is improved, and the impact resistance and abrasion of the surface of the textile layer are improved by the transparent acrylic layer. In addition, the generation of wrinkles in the textile layer and distortion of the pattern can be eliminated during the injection molding of the base resin layer.

1 is an external perspective view of a textile / resin laminated structure housing according to an embodiment of the present invention. It is sectional drawing of the textile / resin laminated structure housing which follows the line II-II of FIG. It is a figure used for demonstrating the manufacturing apparatus of the textile / resin laminated structure housing which concerns on embodiment of this invention. It is an external appearance perspective view of the textile / resin laminated structure housing which concerns on other embodiment of this invention. FIG. 5 is a cross-sectional view of the textile / resin laminate housing taken along line VV in FIG. 4. FIG. 5 is a cross-sectional view of the textile / resin laminate housing taken along line VI-VI in FIG. 4.

Hereinafter, the present invention will be described in detail with reference to the drawings.

FIG. 1 is an external perspective view of a textile / resin laminated structure housing according to an embodiment of the present invention.

In FIG. 1, a textile / resin laminated structure housing 1 (hereinafter sometimes simply referred to as “housing 1”) is an upper casing for a remote control device having a reverse boat structure, and two openings 6 are formed at the bottom of the reverse boat structure. Have.

FIG. 2 is a cross-sectional view of the textile / resin laminate housing taken along line II-II in FIG.

The housing 1 is fixed to the textile layer 4 while infiltrating the gap between the fibers of the transparent acrylic sheet layer 2, the textile layer 4 adhered to the transparent acrylic sheet layer 2 via the adhesive 3, and the textile layer 4. And a base resin layer 5.

The transparent acrylic sheet layer 2 is made of a soft acrylic sheet having a thickness of 0.1 to 0.4 mm containing an elastomer, and has a function of coating the textile layer 4 and resistance to mechanical damage (impact resistance, scratch resistance). . The transparent acrylic sheet layer 2 is preferably, for example, a soft acrylic sheet (trade name: Clarity) manufactured and sold by Kuraray Co., Ltd. or a soft acrylic sheet (trade name: Technoloy) manufactured and sold by Sumitomo Chemical Co., Ltd. These soft acrylic sheets are excellent in impact resistance and scratch resistance. The above-mentioned elastomer has a kneading rate of 10 to 60 parts by weight with respect to 100 parts by weight of soft acrylic. The elastomer contained in the soft acrylic sheet (trade name: clarity) consists of a synthetic rubber containing one material selected from the group of acrylic rubber, nitrile rubber, and isoprene rubber. The soft acrylic sheet (trade name: Technoloy) ) Consists of PMMA (polymethacrylate) containing a rubber component in the molecule.

The textile layer 4 is made of textile including fiber products such as woven fabric and knitted fabric. Examples of the textile include polyester fabric, knitted fabric, lace, and carbon fiber.

This textile allows various designs to be easily obtained, and the three-dimensional feeling of the fiber fabric appears as it is. Further, the use of the textile has the effect of increasing the strength of the housing 1 in addition to increasing the degree of freedom of design of the housing 1.

It is preferable that the adhesive 3 has a characteristic that it can easily adhere both the transparent acrylic sheet layer 2 and the textile layer 4 to each other, and has a low viscosity and a curing speed that is slow enough to allow bubbles to escape. The adhesive is made of one material selected from the group of polyurethane adhesives, acrylic adhesives, epoxy resin adhesives, and vinyl chloride adhesives.

The base resin layer 5 is made of a thermoplastic synthetic resin, preferably a synthetic resin for injection molding. Specifically, the base resin layer 5 is made of ABS (acrylbutyl styrene) resin, PC (polycarbonate) resin, ABS + PC resin, PMMA resin (acrylic resin). It consists of one raw material selected from the group, preferably ABS resin, and the thickness is arbitrarily set according to the product, and in this embodiment is about 2 mm. The raw material of the base resin layer 5 is heated and melted by an injection molding machine 20 shown in FIG. 3 to be described later, and a laminate of the transparent acrylic sheet layer 2 and the textile layer 4 bonded to each other by the adhesive 3 has the textile layer 4 as a table. It is injected into a die die 22 shown in FIG. 3 that will be described later, and is fixed to the textile layer 4 while infiltrating the gaps between the fibers of the textile layer 4 (FIG. 3). The base resin layer 5 is more firmly fixed to the textile layer 4 due to shrinkage of the textile layer 4 and the base resin layer 5 during cooling and solidification.

According to the housing 1 of FIG. 1, since the base resin layer 5 is fixed to the textile layer 4 while infiltrating the gaps between the fibers of the textile layer 4, the textile layer 4 adheres to the base resin layer 5 by an anchor effect. The fibers of the textile layer 4 can improve the strength of the housing 1 and the transparent acrylic sheet layer 2 improves the impact resistance and scratch resistance of the upper casing for the remote control device. Generation of wrinkles in the textile layer 4 and distortion of the pattern can be eliminated during the injection molding of the base resin layer 5. Further, according to the housing of FIG. 1, the pattern on the surface of the housing 1 can be variously selected by changing the textile layer 4.

In the housing 1 of FIG. 1, a top coating having chemical resistance may be coated on the surface of the transparent acrylic sheet layer 2.

Although the housing 1 in FIG. 1 has an inverted boat structure with the transparent acrylic sheet layer 2 as the front, the housing 1 may have an inverted boat structure with the base resin layer 5 as the front. The use of the housing 1 is not limited to the upper casing of the remote control structure.

FIG. 3 is a diagram used for explaining a textile / resin laminated housing manufacturing apparatus according to an embodiment of the present invention.

In FIG. 3, steps I and II are performed by a press machine, and steps III and IV are performed by an injection molding machine.

First, a laminate of the transparent acrylic sheet layer 2 and the textile layer 2 bonded to each other via the adhesive 3 is prepared. In Step I of FIG. 3, the laminate of the transparent acrylic sheet layer 2 and the textile layer 4 is a textile layer. Table 4 is placed on a female die 10 (fixed die) of the press machine. This laminated body may be cut into a predetermined shape in advance. The adhesive 3 is made of one material selected from the group of polyurethane adhesives, acrylic adhesives, epoxy resin adhesives, and vinyl chloride adhesives.

Next, in step II, the male die 11 (movable die) of the press machine is moved to the female die so that the laminate of the transparent acrylic sheet 2 and the textile layer 4 placed in step I is pushed into the female die 10. Move toward the mold 10. Thereby, after shape | molding the laminated body of the transparent acrylic sheet layer 2 and the textile layer 4 in the shape prescribed | regulated with the female metal mold | die 10 and the male metal mold | die 11, this molded laminated body is taken out from a press machine. At this time, the periphery of the formed laminated body may be deburred by cutting with a laser cutter or a cutting die (cutting unit).

Subsequently, in Step III of FIG. 3, the laminate of the transparent acrylic sheet layer 2 and the textile layer 4 formed by a press machine is mounted in the female mold 22 (other fixed mold) with the textile layer 4 as a table. Then, the injection molding male mold 12 (injection molding mold) is moved toward the laminated body received in the mold die 22, and the injection hole 20 a of the injection machine 20 is moved through the injection molding male mold 12. After pressing against the injection molding hole 12a, the injection screw 21 is rotated clockwise to feed the raw material 31 of the base resin layer 5 in the tank 30 into the space defined by the laminate and the injection molding male mold 12. Eject. At this time, the raw material 31 of the base resin layer 5 is infiltrated into the gaps between the fibers of the textile layer 4, and the textile layer 4 and the base resin layer 5 are more firmly fixed to each other due to the shrinkage of the textile layer 4 and the base resin layer 5 when the raw material 31 is cooled and solidified. become.

Finally, in step IV, after the injection-molded base resin layer 5 is cooled and solidified, the injection machine 20 and the injection-molded male mold 12 are separated from the female mold 10 and the housing 1 is taken out.

The female mold 10 and the male mold 11 constitute a press machine, and the female mold 22, the injection molding male mold 12 and the injection machine 20 constitute an injection molding machine. The press machine and the injection molding machine are the housing 1. The manufacturing apparatus is configured. As a modification, the press machine and the injection molding machine may be integrated, and the female die 10 may be used as the female die 22. In this case, the injection molding male mold 12 is moved toward the laminated body of the transparent acrylic sheet layer 2 and the textile layer 4 molded in the female mold 10.

According to the textile / resin laminated housing manufacturing apparatus of FIG. 3, in step III, the raw material 31 of the base resin layer 5 infiltrates into the gaps between the fibers of the textile layer 4, and the textile layer 4 when the raw material 31 is cooled. Further, the shrinkage of the base resin layer 5 makes the fixing to the textile layer 4 stronger, and in addition, the manufacturing process of the housing 1 can be simplified and the surface coating process can be omitted. Furthermore, polycarbonate that can be molded only at high temperatures can be used as the material of the base resin layer 5.

In addition, according to the textile / resin laminated housing manufacturing apparatus of FIG. 3, the adhesiveness of the textile layer 4 to the base resin layer 5 is improved, and the impact resistance of the surface of the textile layer 4 is improved by the transparent acrylic layer 2. Scratch can be improved, and in addition, generation of wrinkles in the textile layer 4 and distortion of the pattern can be eliminated when the base resin layer 5 is injection molded.

In the textile / resin laminated housing manufacturing apparatus of FIG. 3, the housing 1 has an inverted boat structure with the transparent acrylic sheet layer 2 as the front. The housing 1 has an inverted boat structure with the base resin layer 5 as the surface. It is good. The use of these housings 1 is not limited to the remote control structure upper casing.

FIG. 4 is an external perspective view of a textile / resin laminated structure housing according to another embodiment of the present invention.

In FIG. 4, a textile / resin laminated structure housing 40 (hereinafter sometimes simply referred to as “housing 40”) is a casing having an inverted basin structure, and has one protrusion 41 and one opening at the bottom of the inverted basin structure. 42.

The structure of the housing 40 in FIG. 4 and the manufacturing apparatus thereof are the same as the structure of the housing 1 in FIG. 1 and the manufacturing apparatus thereof, and the same components are denoted by the same reference numerals.

The cross section of the protrusion 41 is shown in FIG. 5 as a cross-sectional view along line VV in FIG. 4, and the cross section of the opening 42 is shown in FIG. 6 as a cross sectional view along line VI-VI in FIG. .

In the embodiment of the present invention and the other embodiments, the textile / resin structure housings 1 and 40 are described as the upper casing for the remote control device. However, as another application technical field of the embodiment of the present invention, Is intended for decorative products by in-mold molding with a surface coating layer. Specifically, miscellaneous goods including containers and stationery, housings for electronic devices and home appliances including mobile phones and laptop computers, buildings, Examples include housings for interior and exterior products of automobiles and interior housings for aircraft.

DESCRIPTION OF SYMBOLS 1 Textile / resin laminated structure housing 2 Transparent acrylic sheet layer 3 Adhesive 4 Textile layer 5 Base resin layer 6 Opening part 10 Female mold 11 Male mold 12 Injection molding male mold 20 Injection machine 21 Injection screw 22 Female mold 30 Tank 31 Raw material 40 Textile / resin laminated housing 41 Projection 42 Opening

Claims (20)

A transparent acrylic sheet layer; a textile layer bonded to the transparent acrylic sheet layer with an adhesive; and a base resin layer fixed to the textile layer while infiltrating a gap between the fibers of the textile layer. Textile / resin laminated housing characterized by 2. The textile / resin laminated housing according to claim 1, wherein the base resin layer is made of a thermoplastic synthetic resin. 3. The textile / resin laminated housing according to claim 2, wherein the thermoplastic synthetic resin is made of a synthetic resin for injection molding. 4. The textile / resin laminated structure housing according to claim 3, wherein the synthetic resin for injection molding is made of one material selected from the group of ABS, PC, PMMA, and PC + ABS. The textile / resin laminated structure housing according to claim 4, wherein the synthetic resin for injection molding is made of ABS or PMMA. The textile / resin laminated housing according to any one of claims 1 to 5, wherein the transparent acrylic sheet layer contains an elastomer. The textile / resin laminated structure housing according to claim 6, wherein the elastomer is made of synthetic rubber or PMMA containing a rubber component in a molecule. The textile / resin laminated housing according to claim 7, wherein the synthetic rubber is made of one material selected from the group of acrylic rubber, nitrile rubber, and isoprene rubber. 9. The adhesive according to claim 1, wherein the adhesive is made of one material selected from the group consisting of a polyurethane adhesive, an acrylic adhesive, an epoxy resin adhesive, and a vinyl chloride adhesive. The textile / resin laminated housing according to claim 1. A fixed mold for receiving a laminate of a transparent acrylic sheet layer and a textile layer bonded to each other via an adhesive with the textile layer as a surface, and the received laminate for molding the laminate. A movable mold that is moved toward the fixed mold so as to be pushed into the fixed mold; another fixed mold that receives the molded laminate with the textile layer as a surface; and the other mold The base resin layer is placed in a space defined by the injection mold that is moved toward the laminate received in the fixed mold, the laminate received in the other fixed mold, and the injection mold. An apparatus for manufacturing a textile / resin laminated structure housing, comprising: an injection means for injecting a raw material. A fixed mold for receiving a laminate of a transparent acrylic sheet layer and a textile layer bonded to each other via an adhesive with the textile layer as a surface, and the received laminate for molding the laminate. A movable mold that is moved toward the fixed mold so as to be pushed into the fixed mold, an injection mold that is moved toward the laminate pressed into the fixed mold, and the fixed mold An apparatus for producing a textile / resin laminated structure housing, comprising: an injection means for injecting a raw material of the base resin layer into a space defined by the laminate received in the injection molding die. The apparatus for manufacturing a textile / resin laminated structure housing according to claim 10 or 11, further comprising a cutting unit for cutting a peripheral edge of the molded laminate. The textile / resin laminated housing manufacturing apparatus according to any one of claims 10 to 12, wherein the base resin layer is made of a thermoplastic synthetic resin. 14. The textile / resin laminated structure manufacturing apparatus according to claim 13, wherein the thermoplastic synthetic resin is made of a synthetic resin for injection molding. 15. The textile / resin laminated housing manufacturing apparatus according to claim 14, wherein the synthetic resin for injection molding is made of one material selected from the group of ABS, PC, PMMA, and PC + ABS. 16. The textile / resin laminated housing manufacturing apparatus according to claim 15, wherein the synthetic resin for injection molding is made of ABS. The textile / resin laminated structure manufacturing apparatus according to any one of claims 10 to 16, wherein the transparent acrylic sheet layer contains an elastomer. 18. The textile / resin laminated housing manufacturing apparatus according to claim 17, wherein the elastomer is made of synthetic rubber or PMMA containing a rubber component in a molecule. The apparatus for manufacturing a textile / resin laminated structure housing according to claim 18, wherein the synthetic rubber is made of one material selected from the group of acrylic rubber, nitrile rubber, and isoprene rubber. 20. The adhesive according to claim 10, wherein the adhesive is made of one material selected from the group consisting of a polyurethane adhesive, an acrylic adhesive, an epoxy resin adhesive, and a vinyl chloride adhesive. The manufacturing apparatus of the textile / resin laminated structure housing of Claim 1.

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