Patent ID: 7879278
Filing Date: 2011-02-01
Classification: B29C,Y10T

Abstract:
1. A method for manufacturing a panel unit comprising: circumferentially chamfering a panel along a periphery thereof to form a chamfered portion having a peripheral edge and an end surface, applying a synthetic resin removable cover tape having a predetermined width to a first surface of the panel so as to substantially extend along a periphery of the panel, the removable cover tape being applied such that a lateral part of the removable cover tape projects over the peripheral edge of the chamfered portion, continuously cutting the removable cover tape along the peripheral edge of the chamfered portion of the panel, and trimming the removable cover tape along a cutting line which is positioned on an end surface side of the panel in a widthwise direction of the removable cover tape, then, forming an adhesive layer on the periphery of the panel, the adhesive layer being formed so as to overlap at least a lateral portion of the trimmed removable cover tape on the first surface, the chamfered portion, the end surface and a second surface of the panel, relatively moving an extrusion molding die with respect to the panel on which the adhesive layer has been formed so that the molding die selectively moves along the removable cover tape applied to the panel while contacting the removable cover tape but not directly contacting the surface of the panel, simultaneously extruding a molten molding material from the extrusion molding die, thereby integrally forming a molded article along the periphery of the panel, the formed molded article adhering to the periphery of the panel via the adhesive layer, such that a peripheral edge of the molded article corresponds to the cutting line of the removable cover tape, wherein the removable cover tape has heat resistance sufficient to be prevented from melting when the heated extrusion molding die contacts the cover tape, extending a part of the molten molding material onto the overlapped adhesive layer so as to extend in a widthwise direction when the molten molding material is extruded, thereby forming a flash that is adhered to the removable cover tape via the overlapped adhesive layer, wherein the molten molding material is extruded at least on the end surface, the chamfered portion and the second surface so that the molded article is bonded to the end surface, the chamfered portion and the second surface via the adhesive layer, and removing all of the cut and trimmed removable cover tape from the first surface of the panel by peeling, without cutting, the removable cover tape after the molded article is formed, and removing thereby the flash and the adhesive layer on the cover tape with the peeled removable cover tape, such that the removable cover tape is not interleaved between the molded article and the surface of the panel and the peripheral edge of the molded article is bonded to the periphery of the panel via the adhesive layer, and the peripheral edge of the molded article aligns with the peripheral edge of the chamfered portion and is substantially flush with the first surface of the panel.