METHOD FOR PRODUCING RESIN MEMBER INCLUDING CONDUCTIVE PASTE LAYER AND FEED PORTION, AND METHOD FOR CONNECTING RESIN MEMBER INCLUDING CONDUCTIVE PASTE LAYER AND FEED PORTION TO EXTERNAL FEED MEMBER

Abstract

A method for producing a resin member including a conductive paste layer and a feed portion that can suitably fix an insert member in place relative to a mold without leaving a part having no relationship with the structural members of the final product within the insert member, and a method for connecting the resin member produced with such a method to an external feed member. The method includes storing an insert member including an exterior resin film with a conductive paste layer, and a first magnetic attractor to become a feed portion into a cavity of a mold including a second magnetic attractor; positioning and fixing the insert member in the cavity using magnetic attractive force of the first and the second magnetic attractors; and injecting resin into the cavity to form a resin panel, thereby integrating the insert member with the resin panel to produce a resin member.

Claims

1. A method for producing a resin member including a conductive paste layer and a feed portion, comprising: storing in a cavity of a mold an insert member including an exterior resin film with a conductive paste layer, and a first magnetic attractor to become a feed portion, the mold being a second magnetic attractor; positioning and fixing the insert member in place within the cavity using magnetic attractive force of the first magnetic attractor and the second magnetic attractor; and injecting resin into the cavity to form a resin panel, thereby integrating the insert member, the first magnetic attractor, and the resin panel with one another to produce a resin member.

2. The method for producing a resin member including a conductive paste layer and a feed portion according to claim 1, wherein: each of the first magnetic attractor and the second magnetic attractor is a magnet, or the first magnetic attractor is a magnet and the second magnetic attractor is magnetically attracting metal, or the first magnetic attractor is magnetically attracting metal and the second magnetic attractor is a magnet.

3. The method for producing a resin member including a conductive paste layer and a feed portion according to claim 1, wherein when the second magnetic attractor is a magnet, the magnet is buried in the mold.

4. A method for connecting a resin member including a conductive paste layer and a feed portion to an external feed member, comprising: after producing a resin member with the method according to claim 1, screwing a screw portion of an external feed member into a threaded hole provided in the feed portion, thereby connecting the resin member and the external feed member.

5. The method for connecting a resin member including a conductive paste layer and a feed portion to an external feed member according to claim 4, further comprising: storing a two-solution-mixture paste containing a conductive paste and a curing accelerator in the threaded hole in advance so that when the screw portion of the external feed member is screwed into the threaded hole, the two-solution-mixture paste is mixed and a curing reaction occurs, and the resin member and the external feed member are thus connected.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 is a schematic diagram illustrating a method for producing a resin member including a conductive paste layer and a feed portion of the present disclosure;

[0035] FIG. 2 is a schematic diagram illustrating the method for producing a resin member continued from FIG. 1;

[0036] FIG. 3 is a schematic diagram illustrating the method for producing a resin member continued from FIG. 2;

[0037] FIG. 4 is a schematic diagram illustrating Embodiment 1 of a method for connecting a resin member including a conductive paste layer and a feed portion to an external feed member of the present disclosure;

[0038] FIG. 5 is a schematic diagram illustrating Embodiment 2 of a method for connecting a resin member including a conductive paste layer and a feed portion to an external feed member of the present disclosure; and

[0039] FIG. 6 is a schematic diagram illustrating Embodiment 2 of the connection method continued from FIG. 5.

DETAILED DESCRIPTION

[0040] Hereinafter, an embodiment of a method for producing a resin member including a conductive paste layer and a feed portion of the present disclosure, and an embodiment of a method for connecting a resin member including a conductive paste layer and a feed portion to an external feed member will be described with reference to the accompanying drawings. Although an example shown in the drawings illustrates a configuration in which a second magnetic attractor made of a magnet is buried in a mold, and a first magnetic attractor is also made of a magnet, it is also possible to use a configuration in which one of the first magnetic attractor or the second magnetic attractor is a magnet and the other is magnetically attracting metal, such as iron, cobalt, or nickel, or alloys thereof, for example. Further, although the example shown in the drawings illustrates a method of, with a threaded hole facing a wide surface of an insert member, screwing a screw portion of an external feed member into the threaded hole from the wide surface side of the insert member, it is also possible to use a method of, with the threaded hole facing the thickness side of a resin member (i.e., side surface of the resin member perpendicular to the wide surface thereof), inserting the screw portion of the external feed member into the threaded hole from the thickness side of the insert member.

[0041] (Embodiment of Method for Producing Resin Member Including Conductive Paste Layer and Feed Portion)

[0042] FIGS. 1 to 3 are schematic diagrams sequentially illustrating a method for producing a resin member including a conductive paste layer and a feed portion of the present disclosure. Although a resin member including a conductive paste layer and a feed portion, which is the target to be produced in the example shown in the drawings, is window glass for vehicles, the targets of the production method and the connection method of the present disclosure are not limited thereto.

[0043] In the method for producing a resin member shown in the drawings, an insert member 4 made of an exterior resin film with a conductive paste layer 3b is prepared first. More specifically, the insert member 4 made of an exterior resin film has a stack of a resin film 3a, the conductive paste layer 3b, and a black resin paste layer 3c. The conductive paste layer 3b is printed in a stria heating wire pattern, while the black resin paste layer 3c is printed at a position corresponding to a window frame, and the two layers are printed on the same plane of the resin film 3a.

[0044] Herein, a method of producing the insert member 4 will be briefly described. First, a silver paste containing silver powder, additive, and the like is printed in a predetermined pattern (predetermined stria heating wire pattern) on the resin film 3a and is dried so that the conductive paste layer 3b made of the silver paste is produced on the resin film 3a. Examples of the printing method herein include screen printing and gravure printing.

[0045] Next, a black resin paste is printed and dried so that the black resin paste layer 3c with a frame shape that conforms to the contour of the rear glass or the like is produced. Examples of the printing method herein include screen printing and gravure printing.

[0046] Although the example herein illustrates a method of sequentially printing a silver paste and a black resin paste, the printing order may be reversed. In addition, drying may be performed either after termination of each printing step or all of the printing steps. Further, other conductive pastes such as a copper paste may be applied instead of a silver paste.

[0047] A mold 1 used to produce the resin member includes a stationary mold 1A and a movable mold 1B. The stationary mold 1A has buried therein a second magnetic attractor 2 made of a magnet. In addition, the insert member 4 is stored into a cavity 1a of the mold 1 (in the X direction of FIG. 1), and further, a first magnetic attractor 5 is disposed so that the insert member 4 is fixed in place by the attraction between the first magnetic attractor 5 and the second magnetic attractor 2. Then, the mold is closed.

[0048] Herein, each of the first magnetic attractor 5 for fixing the insert member 4 in place within the cavity 1a of the mold 1, and the second magnetic attractor 2 buried in the stationary mold 1A is formed of a neodymium magnet, a samarium cobalt magnet, or the like.

[0049] As shown in FIG. 2, the first magnetic attractor 5 and the second magnetic attractor 2 are mutually magnetically attracted to each other (with magnetic attractive force Q), whereby the insert member 4 can be suitably positioned within the mold 1.

[0050] Once the insert member 4 is positioned within the mold 1, resin 6 for a resin panel is injected into the mold 1 as shown in FIG. 2. Examples of the method for injecting the resin 6 herein include injection molding, blow molding, and compression molding. In addition, examples of the resin material injected herein include polycarbonate, acrylic, polyester, polyethylene, PBT, and ABS.

[0051] After the resin 6 has cured, it is removed from the mold, whereby the insert member 4 and a resin panel 6 are integrated with each other while being stacked as shown in FIG. 3. Therefore, a resin member 10, which includes the resin panel 6 having buried therein a part of the first magnetic attractor 5 to become a feed portion, is produced.

[0052] According to the method for producing a resin member shown in the drawings, the first magnetic attractor 5 that is buried becomes a feed portion. Therefore, there is no possibility that a member having no relationship with the final product will remain in the product, and thus, it is possible to produce the resin member 10 including a conductive paste layer and a feed portion while suitably fixing the insert member 4 in place relative to the mold 1.

[0053] (Embodiment of Method for Connecting Resin Member Including Conductive Paste Layer and Feed Portion to External Feed Member)

[0054] Next, a method for connecting the resin member produced with the production method shown in FIGS. 1 to 3 to an external feed member will be described. FIG. 4 is a schematic diagram illustrating Embodiment 1 of the connection method, and FIGS. 5 and 6 are schematic diagrams sequentially illustrating Embodiment 2 of the connection method.

[0055] In the connection method shown in FIG. 4, a connector 7a (screw portion) of an external feed member 7, which includes a lead wire 7b and the connector 7a, is screwed into a wide surface of the insert member 4 of the resin member 10 at a position corresponding to the feed portion 5, and is further screwed into a threaded hole 5a provided in the feed portion 5 so that the external feed member 7 is connected to the feed portion 5.

[0056] Although not shown in the drawing, a threaded hole may be opened in advance in the insert member 4 before the external feed member 7 is screwed thereinto.

[0057] When the screw portion 7a of the external feed member 7 is screwed into the threaded hole 5a of the feed portion 5 so as to connect the resin member 10 and the external feed member 7, the feed portion 5 is allowed to bite into the conductive paste layer 3b (printed layer) of the insert member 4 by the screwing and thus, the mutual contact resistance between the two can be lowered. Such screwing also allows the screw portion 7a of the external feed member 7 to engage with the feed portion 5, thus lowering the mutual contact resistance between the two.

[0058] Further, since the external feed member 7 is attached to the feed portion 5 later, that is, since the external feed member 7 is not connected to the resin member 10 yet until the external feed member 7 is connected to the feed portion 5, the portability and handling property of the insert member 4 that is the intermediate product as well as the resin member 10 that is the final product become excellent, and excellent workability can thus be achieved.

[0059] Furthermore, in the production of the resin member 10, only the insert member 4 is stored in the cavity 1a of the mold 1, and the external feed member 7 is not present therein. Therefore, there is no possibility that the external feed member 7 may damage the surface of the cavity.

[0060] Meanwhile, a connection method shown in FIGS. 5 and 6 is a method of first storing a two-solution-mixture paste 8, which contains a conductive paste 8a and a curing accelerator 8b, in the threaded hole 5a of the feed portion 5 as shown in FIG. 5, and then screwing the screw portion 7a of the external feed member 7 into the threaded hole 5a as shown in FIG. 6, thereby causing mixing and a curing reaction of the two-solution-mixture paste 8 to connect the resin member 10 and the external feed member 7.

[0061] As the screw portion 7a of the external feed member 7 is screwed into the threaded hole 5a, the two-solution-mixture paste 8 containing the conductive paste 8a and the curing accelerator 8b stored in the threaded hole 5a is mixed, and the mixed two-solution-mixture paste 8 is extruded such that it flows out of the threaded hole 5a, and also, a curing reaction of the mixed two-solution-mixture paste 8 starts, so that the screw portion 7a, the conductive paste layer 3b of the insert member 4, and the threaded hole 5a are brought into contact with one another physically. Additionally, the gaps between such members are also filled with the mixed two-solution-mixture paste 8, and the mixed two-solution-mixture paste 8 is then cured.

[0062] Accordingly, the contact between the external feed member 7, the conductive paste layer 3b, and the feed portion 5 is further improved and even higher conductivity can thus be realized, and also, the connection strength between the external feed member 7 and the feed portion 5 can be increased.

[0063] Although the embodiments of the present disclosure have been described in detail with reference to the drawings, specific configurations are not limited thereto, and any design changes and the like that may occur within the spirit and scope of the present disclosure are all included in the present disclosure.

DESCRIPTION OF SYMBOLS

[0064] 1 Mold [0065] 1A Stationary mold [0066] 1B Movable mold [0067] 2 Second magnetic attractor (magnet) [0068] 3a Resin film [0069] 3b Conductive paste layer [0070] 3c Black resin paste layer [0071] 4 Insert member (exterior resin film) [0072] 5 First magnetic attractor (feed portion, magnet) [0073] 5a Threaded hole [0074] 6 Resin panel [0075] 6 Resin [0076] 7 External feed member [0077] 7a Connector (screw portion) [0078] 7b Lead wire [0079] 8 Two-solution-mixture paste [0080] 8a Conductive paste [0081] 8b Curing accelerator [0082] 8 Two-solution-mixture paste that has been mixed [0083] 10 Resin member (resin member including conductive paste layer and feed portion)