Molded article and method for manufacturing molded article

Patent metadata

Field	Value
Publication number	US-11747526-B2
Application number	US-201916754418-A
Country	US
Kind code	B2
Filing date	Jan 17, 2019
Priority date	Jan 29, 2018
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

A molded article includes a light transmission portion disposed in superposition with a display portion of a display device, the light transmission portion transmitting light from the display portion. Recesses and protrusions are formed on a surface of the light transmission portion opposite to the display portion, and thus the surface has anti-glare properties.

First claim

The invention claimed is:

1. A resin molded article comprising:
a light transmission portion, in which recesses and protrusions are formed directly on one surface and thus the surface has anti-glare properties; and
a frame-shaped portion disposed adjacent to the light transmission portion to surround the surface of the light transmission portion and colored; wherein
the surface of the light transmission portion and the surface of the frame-shaped portion are smoothly continuous.

2. The resin molded article according to claim 1 , wherein a center line average surface roughness on the surface of the light transmission portion is set to a value in a range of 0.01 μm or greater and 2.0 μm or less.

3. The resin molded article according to claim 1 , wherein an average peak-valley interval on the surface of the light transmission portion is set to a value in a range of 1 μm or greater and 500 μm or less.

4. The resin molded article according to claim 1 , wherein an average inclination angle on the surface of the light transmission portion is set to a value in a range of 0.001° or greater and 10° or less.

5. The resin molded article according to claim 1 , wherein a haze value on the surface of the light transmission portion is set to a value in a range of 0.5% or greater and 95% or less.

6. The resin molded article according to claim 1 , wherein a maximum thickness dimension of the light transmission portion is set to a value in a range of 0.2 mm or greater and 50 mm or less.

7. The resin molded article according to claim 1 , wherein an absolute value of skewness on the surface of the light transmission portion is set to a value of 3 or less, and the kurtosis on the surface of the light transmission portion is set to a value of 10 or less.

8. The resin molded article according to claim 1 , comprising:
a laminated member comprising an anti-glare layer, the anti-glare layer comprising a surface having anti-glare properties; and a base layer disposed opposite to the surface of the anti-glare layer; and
a base member disposed in superposition on the base layer side of the laminated member; wherein
the surface of the anti-glare layer is the surface of the light transmission portion, and at least the light transmission portion is a film insert molded portion, the film insert molded portion being an integrally molded portion of the base member and the laminated member.

9. A disposed structure comprising the resin molded article described in claim 1 and a display device comprising a display portion, wherein
the display portion is disposed in superposition with the light transmission portion to transmit light from the display portion of the display device.

10. The disposed structure according to claim 9 , wherein
the display device comprises a plurality of pixels located side by side along the surface of the display portion, and
a standard deviation of a luminance distribution of the light transmission portion is set to a value in a range of 3 or greater and 25 or less.

11. A method for manufacturing a resin molded article, the method comprising:
casting a surface of an original mold to form a master mold, recesses and protrusions being formed on the surface of the original mold and thus the surface having anti-glare properties;
adhering to mold a thermoplastic resin integrally with an uncured material in a state of disposing a base layer and the uncured material superposed with one surface of the base layer to be adhered to the surface of the master mold; and
curing the uncured material and the thermoplastic resin to form a light transmission portion, in which the recesses and protrusions of the master mold are transferred to one surface and thus the surface has anti-glare properties, and a frame-shaped portion disposed adjacent to the light transmission portion to surround the surface of the light transmission portion and colored, and thus the surface of the light transmission portion and the surface of the frame-shaped portion are smoothly continuous.

12. The method for manufacturing a resin molded article according to claim 11 , wherein, in the adhering, the master mold is disposed inside a mold, and the thermoplastic resin is injected into the inside of the mold to mold the thermoplastic resin integrally with the uncured material.

13. The method for manufacturing a resin molded article according to claim 11 , wherein, in the adhering, the thermoplastic resin is injected into the inside of the mold from an opposite side to the master mold side of the laminated member to mold the thermoplastic resin.

14. A method for manufacturing a resin molded article, the method comprising:
casting a surface of an original mold to form a master mold, recesses and protrusions being formed on the surface of the original mold and thus the surface having anti-glare properties;
adhering an uncured material to a surface of the master mold; and
curing the uncured material adhered to the surface of the master mold to form a resin molded article comprising a light transmission portion having a surface to which a shape of the surface of the master mold is transferred; wherein
in the adhering, in a state of disposing the master mold inside a mold and disposing a laminated member comprising a base layer and a coating layer disposed in superposition with one surface of the base layer, the coating layer containing the uncured material, the laminated member being a separate body from the master mold, to adhere the coating layer to the surface of the master mold, and thus the uncured material being adhered to the surface of the master mold, a thermoplastic resin is injected into the inside of the mold from an opposite side to the master mold side of the laminated member to mold the thermoplastic resin integrally with the laminated member, and
in the curing, the light transmission portion is formed by the laminated member and the thermoplastic resin.

15. The method for manufacturing a resin molded article according to claim 11 , a film member having an anti-glare property on one surface is used as the original mold.

16. The method for manufacturing a resin molded article according to claim 15 , the film member containing a plurality of resin components and comprising a co-continuous phase structure formed by phase separation of the plurality of resin components is used.

17. The method for manufacturing a resin molded article according to claim 14 , the film member containing a matrix resin and a plurality of fine particles dispersed in the matrix resin is used.

18. The method for manufacturing a resin molded article according to claim 11 , wherein the uncured material contains a thermosetting resin material.

19. The method for manufacturing a resin molded article according to claim 11 , wherein the uncured material contains a photocurable resin material.

Assignees

• Daicel Corp

Inventors

• Usa Daisuke
• Hayashi Masaki

Classifications

• B60K2360/33

  Illumination features · CPC title

• G02B5/0221 Primary

  the surface having an irregular structure (G02B5/0226 takes precedence) · CPC title

• B29C33/3842

  Manufacturing moulds, e.g. shaping the mould surface by machining · CPC title

• B29D11/0073

  Optical laminates · CPC title

• B60Q3/14

  lighting through the surface to be illuminated · CPC title