Ube Machinery Corporation, Ltd.

Dai Nippon Toryo Co., Ltd.

Ube Industries, Inc.

Kumi Kasei Co., Ltd.

Prime Polymer Co., Ltd.

Etsuo Okahara

Toshio Arai

Kazuaki Kobayashi

Kenji Yonemochi

Kenji Oota

Akio Okamoto

Yoshiaki Yamamoto

Takashi Okusako

Takeshi Minoda

Yoshikazu Fujita

Kaoru Yorita

Yuichi Matsuda

Koichi Ashima

Yoshiaki Imai

An object of the present invention is to provide a structure body, which allows the obtaining of superior impact performance while suppressing increases in thickness and weight of a plastic plate and reducing cost, and a method for manufacturing that structure body. Provided is a structure body () provided with a structure () made of a metal or a thermosetting resin, a plastic plate () attached to a surface () of the structure () with double-sided tape (), and a non-foamed plastic sheet (A) having a glass transition temperature of &#x2212;20&#xb0; C. or lower arranged between the structure () and the plastic plate (). Also provided is a method for manufacturing the structure body () that includes arranging the plastic sheet (A) between the structure () and the plastic plate () when attaching the plastic plate () to the surface () of the structure () with the double-side tape ().

Structure body and the manufacturing method

A resin injection molding method of molding a resin by injection-filling an inside of a mold cavity formed by mold-clamping a pair of a design surface mold and a non-design surface mold, with a melted thermoplastic polypropylene resin composition, the method including: setting a temperature of each cavity-forming surface of the design surface mold and the non-design surface mold prior to the injection filling to 60&#xb0; C. to 120&#xb0; C., with the temperature of the cavity-forming surface of the design surface mold being 5&#xb0; C. to 50&#xb0; C. higher than the temperature of the cavity-forming surface of the non-design surface mold; and causing the resin pressure to reach a negative pressure within 7 seconds after injection filling is complete, wherein the thermoplastic polypropylene resin composition contains a crystalline polypropylene resin and a rubber component and a content of the rubber component is 1 mass % to 40 mass %.

Resin injection molding method and resin injection molded product

The mold for in-mold coating formation is one including a mold main bodyhaving, provided thereinside, a mold cavitypermitting injection molding of a resin molding with coated surface and a coating material injecting unitcapable of injecting a coating material to an area corresponding to the coated surface of the resin molding, within the mold cavity, in which a groove portionof 0.3 to 1 mm width (W) is provided on the peripheral edgeof the mold, and in which the angle (&#x3b8;) made by the inner circumferential surfaceof the mold and the mold-opening-side internal wall surfaceof the groove portionis in the range of 30&#xb0; to 70&#xb0;.

Mold for in-mold coating formation

An in-mold coating method for molding a molded product with an excellent external appearance. A resin molded product is kept pressed against a mold cavity surface until immediately before coating. Mold-clamping force in a second step in which the shape of the resin molded product is fixed and that in a fourth step are selected so that the deformation of the mold cavity by the mold-clamping forces is substantially the same in the second and fourth steps. Even if the mold cavity deforms by the mold-clamping force in the second step, the mold cavity deforms similarly in the fourth step to provide a uniform coating thickness. Alternatively, a mold-clamping force smaller than that in the first step is selected for the second step to reduce the degree of deformation of the mold cavity and to achieve a uniform coating thickness.

In-mold coat-forming method

An in-mold coating method providing a mold having a specifically formed auxiliary cavity and an in-mold coating formation method which employs said mold, so that it is possible to prevent a coating material from leaking out of the mold, thereby shortening the molding formation cycle, and making it possible to manufacture a molded product having a stabilized quality. In addition, by using a mold having a specifically shaped sub-cavity, there is provided a still further in-mold coating formation method which can keep mold temperature at a relatively low value, cause the coating material to cure at a predetermined temperature and within a predetermined time period thereby shortening the molding formation cycle, improving the productivity, improving the physical properties of a coating layer, thus obtaining a good molded product.

Method of forming a coating layer on the surface of a molded product within a mold

An in-mold coating apparatus providing a mold having a specifically formed auxiliary cavity and an in-mold coating formation method which employs said mold, so that it is possible to prevent a coating material from leaking out of the mold, thereby shortening the molding formation cycle, and making it possible to manufacture a molded product having a stabilized quality. In addition, by using a mold having a specifically shaped sub-cavity, there is provided a still further in-mold coating formation method which can keep mold temperature at a relatively low value, cause the coating material to cure at a predetermined temperature and within a predetermined time period thereby shortening the molding formation cycle, improving the productivity, improving the physical properties of a coating layer, thus obtaining a good molded product.

An in-mold coating molded article is obtained by coating the surface of a resin molded product comprising a hydroxyl group-containing polypropylene resin composition (A) with a paint composition for in-mold coating, wherein the composition (A) comprises a polypropylene resin (i), an additive rubber (ii) and optionally a polymer compound (iii) other than the polypropylene resin (i) and the additive rubber (ii), the total hydroxyl value of the polypropylene resin (i), the additive rubber (ii) and the optional polymer compound (iii) is from 1 to 40, the composition (A) has a rubber component content (total of the amount of the additive rubber (ii) and the amount of components soluble in n-decane at 23&#xb0; C. of the polypropylene resin (i) and the optional polymer compound (iii)) of from 15 to 80% by mass based on 100% by mass of the total amount of the rubber component and the resin component other than the rubber component, the paint composition comprises a vehicle component comprising 10 to 70% by mass of an oligomer having at least two (meth)acrylate groups and 90 to 30% by mass of an ethylenically unsaturated monomer copolymerizable with the oligomer, a (meth)acryl modified chlorinated polyolefin having a chlorine content of from 2 to 40% by mass, an organic peroxide polymerization initiator, and a polyisocyanate compound.

Molded object obtained by in-mold coating and process for producing the same

An in-mold coat-forming mold and an in-mold coat-forming method are provided, wherein the mold prevents leakage of a coating material for the long term, which is likely to occur when the in-mold coat-forming method is carried out. By disposing a grove, a pressure piece, or both of them so as to serve as coating-material leakage-preventing means, in the vicinity of the edge of a mold cavity adjacent to a shear-structured engaging portion disposed along the circumference of the mold cavity, a coating material is prevented from leaking out of the mold from the engaging portion, and problems such as an adverse affect on a formed product caused by the leaked coating-material and a damage on the mold are prevented, whereby in-mold coat-forming is stably performed for the long term.

Internally coated mold, and internal mold coating forming method

A resin multilayer molding method in which a skin material having a resin decorating layer on a surface and a core-material resin are integrally molded in a mold, comprising the steps of: presetting a relationship of a glass transition point (Tgs) of the resin decorating layer of the skin material and a supply temperature (Tc) of a molten resin forming a core material to satisfy Tgs&#x3c;Tc, and performing molding on a condition that a maximum temperature (Tsm) of the resin decorating layer of the skin material during clamping satisfies Tsm&#x3e;Tgs. When a temperature of the resin decorating layer of the skin material reaches a previously estimated and set value (Tsd) so that a temperature Tsc, which temperature of the resin decorating layer reaches by rising again after an air insulating layer is formed, satisfies Tsc&#x2267;Tgs on the basis of a correlation between a temperature of the core-material resin during clamping and forming and retaining the air insulating layer and a temperature of the skin material decorating layer, the gap is made between the resin decorating layer of the skin material and the mold cavity surface opposed to the resin decorating layer to form and retain the air insulating layer. By this, remarkably high-quality resin multilayer molded products can be stably supplied at low cost without impairing surface decorating performance.

Resin multilayer molding method and multilayer molding device

A resin multilayer molding method in which a skin material having a resin decorating layer on a surface and a core-material resin are integrally molded in a mold, comprising the steps of: presetting a relationship of a glass transition point (Tgs) of the resin decorating layer of the skin material and a supply temperature (Tc) of a molten resin forming a core material to satisfy Tgs<Tc, and performing molding on a condition that a maximum temperature (Tsm) of the resin decorating layer of the skin material during clamping satisfies Tsm>Tgs. When a temperature of the resin decorating layer of the skin material reaches a previously estimated and set value (Tsd) so that a temperature Tsc, which temperature of the resin decorating layer reaches by rising again after an air insulating layer is formed, satisfies Tsc&gE;Tgs on the basis of a correlation between a temperature of the core-material resin during clamping and forming and retaining the air insulating layer and a temperature of the skin material decorating layer, the gap is made between the resin decorating layer of the skin material and the mold cavity surface opposed to the resin decorating layer to form and retain the air insulating layer. By this, remarkably high-quality resin multilayer molded products can be stably supplied at low cost without impairing surface decorating performance.

Growing community of inventors

Ube, Japan

Etsuo Okahara