阅读说明：本技术 树脂成型品 (Resin molded article ) 是由 李圣勋 乡原谅 玄永进 高畑武三 今井弘树 清宫朝臣 于 2020-03-30 设计创作，主要内容包括：本发明提供一种树脂成型品。树脂成型品(10)具有设计层(30),所述设计层(30)包括：呈现出第1颜色的装饰层(44)、呈现出颜色与所述第1颜色不同的第2颜色的遮蔽层(46)和树脂基材层(40)。在该设计层(30)的一端侧设置有由高分子膜构成的外壳层(32)。装饰层(44)的一部分为从遮蔽层(46)显露出的显露部位(44a),由该显露部位(44a)和遮蔽层(46)的一部分形成图案部(36),在通过外壳层(32)俯视观察时,所述图案部(36)呈规定的图形或者文字形状。另一方面,遮蔽层(46)的剩余部形成基体部(34)。在该结构中,设定基体部(34)的层厚小于图案部(36)中的形成有遮蔽层(46)的部位的层厚。据此,能使美观性优异。(The invention provides a resin molded product. A resin molded article (10) has a design layer (30), and the design layer (30) includes: a decorative layer (44) exhibiting a1 st color, a masking layer (46) exhibiting a 2 nd color different from the 1 st color, and a resin base material layer (40). An outer shell layer (32) made of a polymer film is provided on one end side of the design layer (30). A part of the decoration layer (44) is an exposed part (44a) exposed from the shielding layer (46), a pattern part (36) is formed by the exposed part (44a) and a part of the shielding layer (46), and the pattern part (36) has a predetermined figure or character shape when viewed from above through the shell layer (32). On the other hand, the remaining portion of the shielding layer (46) forms a base portion (34). In this structure, the thickness of the base portion (34) is set to be smaller than the thickness of the portion of the pattern portion (36) where the shielding layer (46) is formed. This enables the appearance to be excellent.)

1. A resin molded article (10) having a skin layer (32) formed of a polymer film and a design layer (30) provided on one end surface side of the skin layer and being observable through the skin layer,

the design layer includes a decorative layer (44), a masking layer (46), and a resin substrate layer (40), wherein,

the decorative layer (44) exhibits a1 st color;

the masking layer (46) covers a masked portion (44b) that is part of the decorative layer when viewed from above through the outer shell layer, and exhibits a 2 nd color that is different in color from the 1 st color;

the resin base material layer (40) covers an exposed portion (44a) of the shielding layer and the decorative layer exposed from the shielding layer, the resin base material layer (40) is adjacent to the outer shell layer,

a pattern part (36) is formed by the exposed part and a part of the shielding layer, and the pattern part (36) is in a predetermined figure or character shape when viewed from the plane through the outer shell layer and the resin base material layer,

a base portion (34) formed of the remaining portion of the shielding layer other than the part thereof and having no pattern when viewed in a plan view through the outer shell layer and the resin base material layer,

the thickness of the base portion is set to be smaller than the portion of the pattern portion where the shielding layer is formed.

2. The resin molded article according to claim 1,

the thickness of the resin base material layer at the portion where the base portion is formed is set to be smaller than the thickness of the portion where the pattern portion is formed.

3. The resin molded article according to claim 1,

the resin molded article further includes a member to be joined (12) joined to the base portion by a joining body (20).

4. The resin molded article according to claim 3,

the member to be engaged has a convex portion (16) protruding toward the design layer and a concave portion (18) relatively recessed with respect to the convex portion,

the recessed portion is joined to the base portion by the joining body, and the resin molded article has a guide body (22) provided on the base portion and abutting against the raised portion.

5. The resin molded article according to claim 4,

the engaging body has a thickness larger than that of the guide body.

6. The resin molded article according to claim 4,

the engaging body and the guide body are separated from each other.

7. The resin molded article according to claim 4,

the joint body is a double-sided adhesive tape, and the guide body is a single-sided adhesive tape.

Technical Field

The present invention relates to a resin molded article in which a pattern such as a figure or a character formed inside can be observed.

Background

A resin molded article having a design layer and a shell layer provided on one end surface of the design layer and protecting the design layer is widely used as a component for obtaining a so-called smart key, for example (see japanese patent laid-open publication No. 2013-166248). Decorative patterns such as figures and characters are formed inside the design layer, and a user can observe the decorative patterns through the outer shell layer. Thus, the decorative pattern becomes an element of beauty that can be observed by the user.

When the resin molded article includes the member to be joined, a joint body such as a joint tape is attached to the other end surface of the design layer. As described in japanese patent laid-open publication No. 2005-113085, the bonded member is bonded to the design layer via the bonding body.

Disclosure of Invention

Assume a case where a design layer is bonded to a member to be bonded whose bonded surface is a curved surface. In this case, the design layer needs to have flexibility to the extent that it can be bent along the curved surface. Further, since the smart key is an article carried by a user, a resin molded article having a weight as light as possible is required.

The main object of the present invention is to provide a resin molded article exhibiting sufficient flexibility.

Another object of the present invention is to provide a lightweight resin molded article.

According to one aspect of the present invention, there is provided a resin molded article having a skin layer made of a polymer film and a design layer provided on one end surface side of the skin layer and being observable through the skin layer,

the design layer comprises a decorative layer, a shielding layer and a resin substrate layer, wherein,

the decorative layer presents a1 st color;

the shielding layer covers a shielded part which is a part of the decoration layer when viewed from above through the outer shell layer, and presents a 2 nd color different from the 1 st color;

the resin base material layer covers an exposed portion of the shielding layer and the decorative layer exposed from the shielding layer, the resin base material layer being adjacent to the outer shell layer,

a pattern portion formed by the exposed portion and a part of the shielding layer, the pattern portion having a predetermined pattern or character shape when viewed in a plan view through the outer shell layer and the resin base material layer,

forming an unpatterned base portion from a remaining portion of the shielding layer other than the portion, in a plan view through the outer shell layer and the resin base material layer,

the thickness of the base portion is set to be smaller than the portion of the pattern portion where the shielding layer is formed.

According to the present invention, since the layer thickness of the base portion is set to be smaller than that of the pattern portion, the base portion exhibits sufficient flexibility, and the design layer exhibits sufficient flexibility. Therefore, in the case where the resin molded article includes the member to be joined, even in the case where the surface to be joined of the member to be joined is curved, the design layer can be easily joined. Therefore, a resin molded article having excellent appearance can be obtained.

Further, the resin molded product can be reduced in weight in accordance with the small layer thickness. Therefore, when a portable article such as a smart key is formed of a resin molded article, the portable article is lightweight, and therefore, it is easy for a user to carry the portable article.

The above objects, features and advantages will be readily understood from the following description of the embodiments to be described with reference to the accompanying drawings.

Drawings

Fig. 1 is a schematic perspective view of the entire resin molded article according to the embodiment of the present invention.

Fig. 2 is an exploded perspective view of the resin molded article of fig. 1.

Fig. 3 is a cross-sectional view of the resin molded article of fig. 1 in the stacking direction (thickness direction).

Fig. 4 is a schematic sectional view of a main portion showing a state in which a laminate constituting the resin molded article of fig. 1 is bent to be joined to a member to be joined.

Detailed Description

Hereinafter, a resin molded article according to the present invention will be described in detail with reference to the accompanying drawings by referring to preferred embodiments.

Fig. 1 to 3 are a schematic perspective view, an exploded perspective view, and a cross-sectional view in the stacking direction (thickness direction) of the resin molded article 10 according to the present embodiment. The resin molded article 10 includes a member to be joined 12 and a laminated body 14 joined to the member to be joined 12.

In the upper surface 18 of the engaged member 12, the width direction end portions are gently curved so as to bulge out from the edge portion toward the width direction center. In other words, the engaged member 12 carries a slight curvature.

In this case, the bonded member 12 is a case in which electronic components (not shown) such as a circuit board are housed. As shown in fig. 2 and 3, a plurality of (5 in fig. 2) hollow projections 16 for avoiding interference with electronic components housed inside protrude from the flat upper surface 18 of the engaged member 12. Therefore, the flat upper surface 18 of the member to be joined 12 becomes a concave portion recessed relatively to the hollow convex portion 16.

The member to be joined 12 is joined to the laminated body 14 by a joining tape 20 shown in fig. 3. Further, a guide tape 22 is interposed between the joined member 12 and the stacked body 14. These splicing tape 20 and guide tape 22 will be described later.

The laminated body 14 has a design layer 30 and an outer shell layer 32, and a base portion 34 and a pattern portion 36 are formed on the design layer 30. In this case, the pattern portion 36 includes the decorative letter "H". The user can observe the decorative character "H" appearing three-dimensionally on the base portion 34.

As shown in fig. 3, the design layer 30 has a resin base material layer 40. Next, when the resin base material layer 40 is denoted as a lower end in fig. 3 and an upper end in fig. 3, 2 groove-shaped concave portions 42a and 42b extending from the front side toward the depth side of the paper surface in fig. 3 are formed at the lower end. These recessed portions 42a, 42b correspond to 2 longitudinal leg portions of the decorative letter "H", respectively.

The recesses 42a, 42b are recessed toward the upper end side (the shell layer 32 side). Further, the depth of the concave portions 42a, 42b becomes deeper as they approach each other. That is, the depth of the concave portions 42a and 42b is deepest at positions facing each other and shallowest at positions farthest from each other. The depth of the recessed portion (not shown) constituting the horizontal bar portion of the decorative letter "H" is substantially the same as the deepest portion of the recessed portions 42a and 42 b.

A metal layer 44 (decorative layer) constituting the pattern portion 36 is provided on the entire lower end surface of the resin base layer 40 including the recesses 42a and 42 b. When a user views the resin molded product 10 and further views the laminate 14 from the side of the outer shell layer 32 in a plan view, the user can view the exposed portion 44a of the metal layer 44 exposed without being covered with the printing layer 46 as a shielding layer. The metal layer 44 further improves the appearance by showing gloss. The exposed portion 44a is formed in an "H" shape as a whole, and allows the user to see the "H" as a decorative character.

The metal layer 44 except the exposed portions 44a is shielded portions 44b covered (shielded) by the printed layer 46. In other words, the printed layer 46 is interposed between the shielded portions 44b of the metal layer 44 and the resin base material layer 40. Therefore, the shielded region 44b is hidden behind the printed layer 46 from the perspective of a user using the resin molded article 10, and is thus in an invisible state.

The printed layer 46 exhibits a different color than the metal layer 44. The print layer 46 is preferably black. This is because, in this case, the difference in the contrast with the gloss of the metal layer 44 becomes large, and the appearance of the exposed portion 44a, in other words, the appearance of the decorative character "H" is improved.

Preferable materials of the metal layer 44 include indium, tin, and alloys thereof. Since these metals exhibit electromagnetic wave permeability, when the resin molded article 10 is used as a smart key, it is possible to avoid interference with communication between the smart key and a vehicle body. On the other hand, preferable materials of the printing layer 46 include polyurethane resin, vinyl chloride resin, and the like.

In the present embodiment, the resin base layer 40 is made of an ultraviolet curable resin. Since the ultraviolet curable resin is relatively flexible, the laminate 14 is easily bent when an external force is applied to bend the laminate 14. In this way, the resin base material layer 40 made of an ultraviolet curable resin is a layer that imparts flexibility to the laminated body 14.

Further, the print layer 46 is softer than the resin base material layer 40. That is, the printed layer 46 has a larger elongation than the resin base material layer 40 and a smaller shore D hardness than the resin base material layer 40. Therefore, the printed layer 46 and the metal layer 44 are easily deflected (bent) in accordance with the deflection of the resin base material layer 40. Accordingly, peeling of the printing layer 46 and the metal layer 44 from the resin base material layer 40 due to the difference in softness can be avoided.

The elongation is measured by the so-called B method defined in JIS K7161 (according to ASTM D638). The resin base layer 40 and the print layer 46 have respective elongations of, for example, about 1 to 100% and about 1 to 200%. The shore D hardness of the resin base layer 40 and the print layer 46 is, for example, about 60 ° to 90 ° and about 70 ° to 90 °.

The upper end of the resin substrate layer 40 located near the center in the width direction is a flat portion. The outer shell layer 32 is provided on the upper surface of the resin base material layer 40. The outer shell layer 32 is formed of a polymer film, and a preferable example of the polymer film is polyethylene terephthalate (PET).

The resin substrate layer 40 and the outer shell layer 32 are thin and transparent in wall and are of a degree that they are light permeable. Therefore, when the user views (overlooks) the resin molded article 10 from the outside of the outer shell layer 32, the exposed portion 44a of the metal layer 44 and the decorative character "H" can be easily observed.

On the lower surface of the metal layer 44, a holding layer 48 for preventing the printed layer 46 and the metal layer 44 from falling off from the resin base material layer 40 is provided. The holding layer 48 is formed of, for example, a polyurethane resin, a vinyl chloride resin, or the like, and has a shape conforming to the shape of the metal layer 44.

The pattern portion 36 is a portion in an imaginary area a1 (see fig. 1 and 2) surrounding the outermost edges of the decorative letter "H". Thus, the pattern part 36 includes: the exposed portion 44a of "H" as a decorative letter, the shielded portion 44b in the virtual region a1, the printed layer 46 covering the shielded portion 44b in the virtual region a1, and the resin base material layer 40 and the holding layer 48 in the virtual region a1 are observed. In contrast, the base portion 34 is a portion other than the virtual region a 1. That is, the base body portion 34 includes the shielded portion 44b outside the virtual region a1, the printing layer 46 covering the shielded portion 44b outside the virtual region a1, the resin base material layer 40 outside the virtual region a1, and the holding layer 48.

As can be seen from fig. 3, the thickness T1 of the resin base material layer 40 in the base body portion 34 (outside the virtual region a 1) is set smaller than the thickness T2 of the resin base material layer 40 in the pattern portion 36 (inside the virtual region a 1) where the print layer 46 is formed. Therefore, the layer thickness of the base portion 34 is smaller than that of the pattern portion 36 where the print layer 46 is present. The thicknesses of the recesses 42a and 42b in the pattern portion 36, that is, the sum of the thicknesses of the holding layer 48, the metal layer 44 (exposed portion 44a), and the resin base material layer 40 is less than the 2 layers.

The base portion 34 is attached with a bonding tape 20 (a bonded body) for bonding the stacked body 14 and the bonded member 12, and a guide tape 22 (a guide body) which comes into contact with the hollow convex portion 16 at this time. The splicing tape 20 is formed of a double-sided tape, and the guide tape 22 is formed of a single-sided tape. In addition, the thickness of the joint tape 20 is larger than that of the guide tape 22.

The splicing tape 20 is provided at a position corresponding to the flat upper surface 18 of the member to be spliced 12. On the other hand, the guide tape 22 is provided at a position corresponding to the hollow convex portion 16. Thus, the splicing tape 20 and the guide tape 22 are separated from each other. Further, neither the joint tape 20 nor the guide tape 22 is provided to the pattern portion 36. The adhesive surface of the guide tape 22 faces the lower end surface of the laminate 14.

The resin molded article 10 according to the present embodiment is configured substantially as described above, and its operational effects will be described next.

The laminated body 14 is adhered to the member to be engaged 12 (for example, a housing of a smart key) by the joint tape 20. At this time, when the stacked body 14 is stacked on the joined member 12, the posture, position, and the like of the stacked body 14 may be set so that the guide tape 22 is disposed and abuts on the hollow convex portion 16. Accordingly, the relative position of the laminated body 14 and the member to be joined 12 is determined, and therefore, the laminated body 14 is easily stuck to the member to be joined 12, in other words, joining is easily performed.

Since the guide tape 22 is a single-sided tape, it only abuts the hollow convex portion 16 and does not participate in joining the design layer 30 of the laminated body 14 and the joined member 12. In other words, the joining tape 20 composed of only the double-sided adhesive tape participates in joining the design layer 30 (laminated body 14) to the joined member 12. Therefore, it is easy to correct the position of the laminated body 14 before the laminated body 14 is pressed against the member to be joined 12 in a process in which a sufficient adhesive force is not yet exhibited immediately after the joint tape 20 is temporarily attached to the member to be joined 12.

As shown in fig. 4, in the case where there is a curved surface on the width direction end portion of the members to be joined 12, the stacked body 14 is bent so as to follow the curved surface of the members to be joined 12. Here, the resin base material layer 40 is made of a relatively soft ultraviolet curable resin. In the present embodiment, the thickness T1 of the resin base material layer 40 in the base portion 34 (outside the virtual region a 1) is smaller than the thickness T2 of the resin base material layer 40 on the print layer 46 in the pattern portion 36 (inside the virtual region a 1). Therefore, the resin base layer 40 has sufficient flexibility.

In addition, the print layer 46 is softer than the resin base material layer 40. Therefore, the print layer 46 is easily bent (curved) with the deflection of the resin base material layer 40. As described above, the laminate 14 is excellent in flexibility and is easily bent. Therefore, the resin molded article 10 can be easily attached to the member to be joined 12 with rounded corners.

In addition, since the thickness T1 of the resin base material layer 40 in the base body portion 34 is sufficiently small, the thickness of the layer as the laminated body 14 can be reduced, and the weight of the resin molded article 10 can be reduced.

When the laminate 14 is joined to the joining member 12 with sufficient adhesion by the joining tape 20, the operator presses the laminate 14 against the joining member 12 with a finger. Here, when the bonding tape 20 or the guide tape 22 is stuck to the pattern portion 36, the bonding tape 20 or the guide tape 22 is crushed and spread to a range wider than the metal layer 44 when the laminated body 14 is bonded to the member to be bonded 12. In this case, when viewed from the outer shell layer 32 side, the presence of the splicing tape 20 or the guide tape 22 may be recognized, thereby affecting the aesthetic appearance.

However, in the present embodiment, the bonding tape 20 and the guide tape 22 are only bonded to the base portion 34, and are not bonded to the pattern portion 36. Therefore, the above-described influence can be eliminated. That is, the appearance of the laminate 14 is maintained, and the appearance of the resin molded article 10 is maintained.

Further, the guide tape 22 having a small thickness is provided at a position corresponding to the hollow convex portion 16, and the joint tape 20 having a large thickness is provided at a position corresponding to the flat upper surface 18, wherein the flat upper surface 18 is a concave portion relatively recessed with respect to the hollow convex portion 16. Therefore, even if the laminated body 14 having a small thickness of the design layer 30 and the envelope layer 32 is joined to the joined member 12, it is possible to avoid forming convex portions or concave portions corresponding to the hollow convex portions 16 or the upper surface 18 on the design layer 30 and the envelope layer 32. That is, the outer shell layer 32 is made substantially flat regardless of the uneven shape of the surface to be joined of the joined member 12.

In addition, the amount of recess of the laminated body 14 when the operator presses the laminated body 14 with a finger is reduced. For the above reasons, the design portion 36, and particularly the decorative character "H", has good appearance.

Also, the joint tape 20 and the guide tape 22 are separated from each other (refer to fig. 3 in particular). Therefore, a flow path 60 is formed between the bonding tape 20 and the guide tape 22. When the stacked body 14 and the joined member 12 are joined, in other words, when they are brought into close contact with each other, the air interposed therebetween is discharged to the outside through the flow passage 60. Therefore, it is possible to avoid air remaining between the two and the formation of bubbles caused thereby.

The resin molded article 10 can be obtained by joining the laminated body 14 to the joined member 12. When the user visually observes the resin molded article 10 from the outer shell layer 32 side, only the portion of the metal layer 44 not covered by the printed layer 46, that is, only the exposed portion 44a provided in the concave portions 42a and 42b can be observed. Since the concave portions 42a and 42b have a three-dimensional shape recessed toward the outer shell layer 32 side, the user recognizes the decorative character "H" in the pattern portion 36 as a three-dimensional decoration. As described above, according to the present embodiment, the pattern portion 36 including the decorative character "H" having a rich three-dimensional effect can be easily provided.

The present invention is not particularly limited to the above-described embodiments, and various modifications can be made without departing from the scope of the present invention.

For example, the holding layer 48 may be formed as needed, and may be omitted depending on the bonding strength between the metal layer 44 and the resin base material layer 40.

In this embodiment, the case where the laminated body 14 is attached to the curved surface of the member to be joined 12 is exemplified, but it is needless to say that the laminated body 14 may be attached to a flat surface which is not curved.