Abstract:
A composite ( 100 ) comprises: an integrally molded article of two or more function parts ( 111 ) made of a cured material of a liquid resin composition and two or more connection parts ( 112 ); and a retention part ( 120 ) made of a resin composition different from the liquid resin composition and having two or more through-holes ( 121 ) or concave parts. The function parts ( 111 ) are respectively arranged inside the through-holes ( 121 ) or the concave parts of the retention part ( 120 ). The connection parts ( 112 ) are joined to a surface of the retention part ( 120 ).

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a composite including at least one functional part composed of a cured product of a liquid resin composition, and a holding part composed of a resin composition which is different from the liquid resin composition and configured to hold the at least one functional part, and a method of manufacturing the composite. 
       BACKGROUND ART 
       [0002]    Currently, in the field of illuminating lamps, electrical products, automobiles and the like where heat resisting property is required, parts of a cured product of a thermosetting resin are used. In addition, injection molding is known as a method of molding a thermosetting resin. In general, however, a cured product of a thermosetting resin is brittle, fragile, and tends to adhere to the metal mold, and therefore, is difficult to release from the mold. In addition, when a thermosetting resin is charged to the cavity of the metal mold, a part of the resin covers the inner wall of the cavity before the resin is sufficiently charged into the cavity, and the resin is further heated and cured, and consequently, bubbles can possibly remain in the molded article in some situation. 
         [0003]    When the above-mentioned problems of damaging at the time of releasing and residual bubbles occur, the molded article is difficult to be used as an optical device. In view of this, a method for solving the above-mentioned problems has been proposed (see, for example, PTL 1). 
         [0004]    The molded article disclosed in PTL 1 is manufactured by injection molding using a liquid thermosetting resin having a low viscosity.  FIGS. 1A and 1B  illustrate a configuration of molded article  30  disclosed in PTL 1.  FIG. 1A  is a plan view, and  FIG. 1B  is a sectional view taken along line A-A of  FIG. 1A . As illustrated in  FIG. 1A , molded article  30  is formed in a sheet-like shape. In molded article  30 , a plurality of optical device parts  14  are arrayed. Optical device part  14  includes optical function part  11  having an optical function, and outer periphery part  12  disposed outside optical function part  11 . Optical function part  11  and outer periphery part  12  are integrally molded. In addition, cutting part  16  for separating optical device parts  14  is provided between optical device parts  14  adjacent to each other. 
         [0005]    In the molding of molded article  30 , a plurality of optical device parts  14  are integrally molded in one cavity. At this time, the side surfaces (except for the outer surface of optical device part  14  disposed on the outside) of optical device parts  14  make contact with the respective side surfaces of adjacent optical device parts  14 , without making contact with the inner wall of the cavity. Accordingly, in comparison with the case where optical device parts  14  are individually molded, the contact area between optical device part  14  and the inner wall of the cavity is small, and the force which is exerted on molded article  30  at the time of releasing is reduced. In addition, depending on the shape and the thickness of outer periphery part  12 , the strength of molded article  30  can be increased and concentration of the stress during the molding can be moderated. As a result, deformation and damaging of molded article  30  at the time of releasing can be reduced. Further, the smaller contact area between optical device part  14  and the inner wall of the cavity results in the smaller difference in flow rate between the surface of the resin and the inside of the resin. Thus, residual bubbles in molded article  30  can be reduced. Accordingly, molded article  30  disclosed in PTL 1 can be manufactured without causing damaging at the time of releasing or residual bubbles, and it is possible to efficiently manufacture two or more optical devices by separating optical device parts  14  from molded article  30 . 
       CITATION LIST 
     Patent Literature 
     PTL 1 
       [0000]    
       
         Japanese Patent Application Laid-Open No. 2011-206980 
       
     
       SUMMARY OF INVENTION 
     Technical Problem 
       [0007]    In the invention disclosed in PTL 1, a silicone resin is used as a thermosetting resin. A cured product of a silicone resin is, however, very flexible, and therefore, when sheet-like molded article  30  is manufactured with the silicone resin, molded article  30  is deflected, and cannot be easily handled in an appropriate manner. In view of this, optical device parts  14  cannot possibly be separated with high precision. To solve such a problem, it is conceivable to partially form a thick portion. Formation of a thick part is, however, not suitable for manufacturing of small-sized and thin molded articles. In addition, the material cost is unnecessarily increased when the thick part is formed. 
         [0008]    An object of the present invention is to provide a composite which includes an integral molded article of a cured product of a liquid resin composition including two or more functional parts, and is easy to handle after the releasing even when the cured product has a high flexibility. Another object of the present invention is to provide a method of manufacturing a composite including at least one functional part composed of a cured product of a liquid resin composition, and a holding part composed of a resin composition which is different from the liquid resin composition and configured to hold the at least one functional part. 
       Solution to Problem 
       [0009]    A composite according to an embodiment of the present invention includes: two or more functional parts, each of which is composed of a cured product of a liquid resin composition; a connecting part composed of the cured product of the liquid resin composition, the connecting part connecting the two or more functional parts together; and a holding part composed of a resin composition which is different from the liquid resin composition, the holding part including two or more through holes or recesses formed therein. The functional part and the connecting part are integrally molded, the two or more functional parts are respectively disposed in the two or more through holes or recesses, and the connecting part is joined to the holding part. 
         [0010]    A composite according to an embodiment of the present invention includes: a first layer composed of a cured product of a liquid resin composition; and a second layer composed of a resin composition which is different from the liquid resin composition. The first layer is formed over a region including: two or more single layer parts that are regions composed only of the first layer, and a multilayer part that is a region in which the first layer and the second layer are joined to each other, the single layer part includes a functional part, and the multilayer part includes: a connecting part composed of the cured product of the liquid resin composition and configured to seamlessly connect the regions of the two or more single layer parts, and a holding part composed of the resin composition and configured to hold the first layer. 
         [0011]    In a method of manufacturing a composite according to an embodiment of the present invention, the composite including at least one functional part composed of a cured product of a liquid resin composition, and a holding part composed of a resin composition which is different from the liquid resin composition and configured to hold the at least one functional part, the method comprising: preparing the holding part composed of the resin composition which is different from the liquid resin composition, the holding part including two or more through holes or recesses formed therein; disposing the holding part as an insert member in a metal mold such that the two or more through holes or recesses are communicated with a cavity of the metal mold; and integrally molding two or more functional parts respectively disposed in the two or more through holes or recesses, and a connecting part connecting the two or more functional parts and joined to the holding part by charging a liquid resin composition to the cavity and curing the liquid resin composition. 
       Advantageous Effects of Invention 
       [0012]    According to the present invention, an integral molded article of two or more resin molded articles (functional parts) which is easy to handle after the releasing can be highly efficiently manufactured at low cost. In addition, by cutting the integrally molded article, two or more resin molded articles (functional parts) can be easily manufactured with high precision. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0013]      FIGS. 1A and 1B  illustrate a configuration of a molded article disclosed in PTL 1; 
           [0014]      FIGS. 2A to 2C  illustrate a configuration of a composite according to an embodiment; 
           [0015]      FIG. 3  is a partially enlarged sectional view illustrating a configuration of the composite according to the embodiment; 
           [0016]      FIGS. 4A and 4B  illustrate a configuration of a holding part of the composite according to the embodiment; 
           [0017]      FIGS. 5A to 5C  are schematic views illustrating a configuration of a positioning structure in the holding part and a metal mold; 
           [0018]      FIG. 6  is a schematic cross-sectional view for illustrating a structure of a metal mold; 
           [0019]      FIG. 7  is a flowchart of an exemplary method of manufacturing the composite according to the embodiment; 
           [0020]      FIGS. 8A and 8B  are schematic cross-sectional views for describing a manufacturing process of the composite according to the embodiment; 
           [0021]      FIGS. 9A and 9B  are schematic cross-sectional views for describing a manufacturing process of the composite according to the embodiment; 
           [0022]      FIGS. 10A to 10C  illustrate a configuration of the composite immediately after releasing; 
           [0023]      FIGS. 11A to 11C  illustrates a configuration of an optical part; 
           [0024]      FIGS. 12A to 12C  are bottom views illustrating another exemplary shape of the holding part (groove part); and 
           [0025]      FIGS. 13A and 13B  illustrate another exemplary shape of the holding part (flow reducing part). 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0026]    An embodiment of the present invention is described in detail below with reference to the accompanying drawings. 
       (Configuration of Composite) 
       [0027]      FIGS. 2A to 2C  and  FIG. 3  illustrate a configuration of composite  100  according to the present embodiment.  FIG. 2A  is a plan view,  FIG. 2B  is a bottom view, and  FIG. 2C  is a sectional view taken along line C-C of  FIG. 2A . In addition,  FIG. 3  is a partially enlarged sectional view of a region surrounded with a broken line in  FIG. 2C . 
         [0028]    As illustrated in  FIGS. 2A to 2C  and  FIG. 3 , composite  100  according to the present embodiment includes integral molded article  110  including two or more functional parts  111  and connecting part  112 , and holding part  120  for holding two or more functional parts  111 . Functional part  111  and connecting part  112  are composed of cured products of a liquid resin composition, and holding part  120  is composed of a resin composition which is different from the resin composition of functional part  111  and connecting part  112 . In addition, as illustrated in  FIG. 2C  and  FIG. 3 , composite  100  includes a layer composed of a cured product of a liquid resin composition, and a layer composed of the above-mentioned resin composition. The layer composed of a cured product of a liquid resin composition is formed over two or more single layer parts and a multilayer part. Here, the single layer part is a region composed only of a layer composed of a cured product of a liquid resin composition. The multilayer part is a region in which a layer composed of a cured product of a liquid resin composition, and a layer composed of the above-mentioned resin composition are joined to each other. The single layer part includes functional part  111 , and the multilayer part includes connecting part  112  and holding part  120 . 
         [0029]    Functional part  111  is a resin member which can be used as various functional parts, and is molded integrally and seamlessly with connecting part  112 . In the present embodiment, functional part  111  and connecting part  112  are composed of a transparent cured resin, and functional part  111  can be used as an optical part (for example, a planoconvex lens). In addition, functional part  111  may be disposed only in the single layer part, or over a region including the entirety of the single layer part and a portion adjacent to the single layer part of the multilayer part. In the present embodiment, a plurality of functional parts  111  are disposed in respective through holes  121  of holding part  120  (which correspond to the single layer parts). It is to be noted that the use of functional part  111  is not limited, and functional part  111  may not be an optical part. Examples of the use of functional part  111  include optical parts, general industrial parts, mechanical parts, electronic parts and inner/outer parts of a vehicle. In addition, functional part  111  may have two or more functions. For example, functional part  111  may have an optical function as a main function, and a holder function as an auxiliary function. In this case, the multilayer part located in a region around the single layer part may have a holder function. 
         [0030]    The number of functional parts  111  is not limited as long as two or more functional parts  111  are provided. In the present embodiment, integral molded article  110  of a cured product of a liquid resin composition includes arrayed  16  functional parts  111 . 
         [0031]    Connecting part  112  connects two or more functional parts  111  together, and is joined to holding part  120 . In the present embodiment, connecting part  112  is joined to holding part  120  in groove part  122  formed on the rear surface of holding part  120 . 
         [0032]    The type of the resin composition for forming functional part  111  and connecting part  112  is not limited as long as the resin composition is a liquid curable resin composition which has a low viscosity at the temperature during the molding, and is appropriately selected in accordance with the performance required for functional part  111 . Examples of the resin included in the liquid resin composition include a thermosetting resin and a photosetting resin. In the present embodiment, functional part  111  and connecting part  112  are composed of a cured product of a transparent thermosetting resin. Examples of the thermosetting resin include a silicone resin, an epoxy resin and the like. 
         [0033]    Holding part  120  is a resin member for holding functional part  111  in which two or more through holes or recesses are formed. In the present embodiment, holding part  120  is a resin plate including arrayed  16  through holes  121 , and functions as a tray that holds a plurality of functional parts  111 . It is to be noted that holding part  120  may have other functions. For example, in the case where functional part  111  is an optical part, holding part  120  may function as a light shielding plate for blocking light incident on functional part  111  or light emitted from functional part  111 . As described later, holding part  120  is composed of a resin composition which is different from the resin composition for forming functional part  111  and connecting part  112 . In addition, through holes  121  may be disposed without being arrayed. For example, through holes  121  may be radially disposed around the position of the sprue at the time of injection molding of a liquid resin composition. In this case, composite  100  includes two or more radially disposed functional parts  111 . 
         [0034]      FIGS. 4A and 4B  illustrate a configuration of holding part  120 .  FIG. 4A  is a plan view, and  FIG. 4B  is a bottom view. As illustrated in  FIG. 4A  and  FIG. 4B , holding part  120  includes  16  through holes  121 , groove part  122  and flow reducing part  123  (see  FIG. 3  for the position of flow reducing part  123  and groove part  122 ). 
         [0035]    Through holes  121  are arrayed such that the opening on the rear surface side of holding part  120  is located in groove part  122 . As described above, functional parts  111  are disposed in respective through holes  121 . The number of through holes  121  is not limited, and is set in accordance with the number of functional parts  111 . In addition, the shape of through hole  121  is not limited, and is set in accordance with the shape of functional part  111 . In the present embodiment, through hole  121  has a quadrangular shape in plan view. 
         [0036]    Groove part  122  is formed to be communicated with through hole  121  on the surface of holding part  120  on which connecting part  112  is joined. In the present embodiment, as illustrated in  FIG. 4B , groove part  122  is formed on the rear surface of holding part  120  such that groove part  122  is communicated with all through holes  121 . 
         [0037]    The multilayer part is formed by joining connecting part  112  to groove part  122  formed in holding part  120 . In addition, as described in detail later, groove part  122  functions as a charging hole (a runner for guiding to through hole  121 ) for charging a liquid resin composition for forming functional part  111  to through hole  121  at the time of manufacturing composite  100 . The resin composition remaining in groove part  122  at this time is cured and becomes connecting part  112 . Accordingly, connecting part  112  is joined to groove part  122 . The depth of groove part  122  is not limited as long as the liquid resin composition can be appropriately charged to through hole  121 . For example, groove part  122  has a depth of about 0.1 to 1 mm. It is to be noted that, while groove part  122  is formed in holding part  120  in the present embodiment, the groove part may be formed in a metal mold described later. In this case, at the time of injection molding, the liquid resin composition is charged to through hole  121  of holding part  120  through a groove part formed in the metal mold. 
         [0038]    Flow reducing part  123  is a recess formed to surround each through hole  121  (which corresponds to single layer part) on one surface of holding part  120 . As illustrated in  FIG. 3 , in the present embodiment, flow reducing part  123  is a recess having a rectangular cross-sectional shape formed on the front surface (the surface on which groove part  122  is not formed) of holding part  120 . As described in detail later, at the time of manufacturing composite  100 , flow reducing part  123  reduces leakage of the liquid resin composition to unintended parts. The shape of flow reducing part  123  is not limited as long as the flow of the liquid resin can be suppressed. Examples of the cross-sectional shape of flow reducing part  123  include a triangular shape (see  FIG. 13 ), a semicircular shape, and a trapezoidal shape. 
         [0039]    Holding part  120  may further include a structure (hereinafter referred to as “positioning part”) for positioning holding part  120  with respect to the metal mold. The shape of the positioning part is not limited as long as holding part  120  can be positioned with respect to the metal mold. Examples of the shape of the positioning part formed in holding part  120  and the metal mold include a through hole, a recess and a protrusion. 
         [0040]      FIGS. 5A to 5C  are schematic views illustrating an exemplary configuration of the positioning structure in holding part  120  and the metal mold. In the example illustrated in  FIG. 5A , protrusions are formed in metal mold  200   a,  and through holes to which the protrusions can be fit are formed in holding part  120   a.  In the example illustrated in  FIG. 5B , protrusions are formed in holding part  120   b,  and recesses to which the protrusions can be fit are formed in metal mold  200   b.  In the example illustrated in  FIG. 5C , holding part  120   c  is fitted to a recess for positioning of holding part  120   c  which is formed in metal mold  200   c.    
         [0041]    As described above, holding part  120  is composed of a resin composition which is different from the resin composition for forming functional part  111  and connecting part  112 . The holding part is used as an insert member at the time when functional part  111  and connecting part  112  are molded by liquid injection molding (LIM), and therefore the resin composition of holding part  120  preferably has a heat resisting property enough to prevent deformation at the time when functional part  111  and connecting part  112  are molded by liquid injection molding. To be more specific, preferably, the deflection temperature under load of the resin composition of holding part  120  is higher than the molding temperature (for example, 150° C.) of functional part  111  and connecting part  112 . Examples of the resin of the resin composition of holding part  120  include a thermoplastic resin, a thermosetting resin and a photosetting resin. From a view point of productivity, the resin of the resin composition of holding part  120  is preferably a thermoplastic resin. Examples of the thermoplastic resin include polyetherimide (PEI), polyether sulfone (PES), polyphenylene sulfide (PPS), polyamide 6T (PA6T) and polybutylene terephthalate (PBT). 
       (Configuration of Metal Mold) 
       [0042]    Next, metal mold  200  that is used for manufacturing composite  100  by liquid injection molding (LIM) using an insert member is described. 
         [0043]      FIG. 6  is a schematic cross-sectional view illustrating a structure of metal mold  200 . In  FIG. 6 , holding part  120  as an insert member is disposed in a cavity of metal mold  200 . 
         [0044]    As illustrated in  FIG. 6 , metal mold  200  includes first metal mold  210  and second metal mold  220 . It is to be noted that, although not illustrated in the drawings, metal mold  200  is configured to be connectable to an injection device including a material supplying device, a material mixing device, a nozzle and the like. With this configuration, the injection device can charge the liquid resin composition into the cavity of mold-clamped metal mold  200  (first metal mold  210  and second metal mold  220 ). In addition, as described above, first metal mold  210  and second metal mold  220  may include a structure for positioning holding part  120  that is disposed in the cavity. 
         [0045]    First metal mold  210  is a metal mold piece for molding the front side (the convex surface side of a planoconvex lens) of functional part  111 . First metal mold  210  includes first metal mold main body  211  and  16  convex surface molding parts  212  ( FIG. 6  illustrates only four convex surface molding parts  212 ). 
         [0046]    First metal mold main body  211  is a metal mold piece for holding convex surface molding part  212 . Two recesses, first charging part  215  and second charging part  216 , where the liquid resin composition can be charged when first metal mold  210  and second metal mold  220  are mold-clamped are formed in first metal mold main body  211 . 
         [0047]    Convex surface molding part  212  is a metal mold piece for molding the front side of functional part  111  (the convex surface side of a planoconvex lens). Convex surface molding part  212  includes first plane  213  and convex surface transferring surface  214 . First plane  213  is a surface disposed to oppose second metal mold  220 . Convex surface transferring surface  214  is an internal surface of a recess formed at a center portion of first plane  213 . Convex surface transferring surface  214  is formed in a shape corresponding to the convex surface of functional part  111  (planoconvex lens). 
         [0048]    Second metal mold  220  is a metal mold piece for molding the rear side of functional part  111  (the plane side of a planoconvex lens). Second metal mold  220  includes second metal mold main body  221  and  16  plane molding parts  222  ( FIG. 6  illustrates only four plane molding parts  222 ). 
         [0049]    Second metal mold main body  221  is a metal mold piece for holding plane molding part  222 . Two recesses and a groove where the liquid resin composition can be charged when first metal mold  210  and second metal mold  220  are mold-clamped are formed in second metal mold main body  221 . Two recesses function as first charging hole  224  and fourth charging hole  227 , and the groove serves as second charging hole  225  and third charging hole  226 . It is to be noted that, while holding part  120  is disposed in the groove that serves as third charging hole  226 , through hole  121  and groove part  122  of holding part  120  where the liquid resin composition is charged are not closed with metal mold  200  (first metal mold  210  and second metal mold  220 ) when holding part  120  is disposed in the groove that serves as third charging hole  226 . 
         [0050]    Plane molding part  222  is a metal mold piece for molding the rear side of functional part  111  (the plane side of a planoconvex lens). Plane molding part  222  includes plane transferring surface  223 . In the present embodiment, plane transferring surface  223  is formed in a plane shape corresponding to the plane of functional part  111 . 
         [0051]    It is to be noted that, as described above, the groove part may be formed in second metal mold  220 . In this case, the groove part formed in second metal mold  220  functions as a runner for charging the liquid resin to through hole  121 . 
         [0052]    As illustrated in  FIG. 6 , when the above-described first metal mold  210  and second metal mold  220  are mold-clamped, the recess formed in first metal mold main body  211 , and the groove and the and recess formed in second metal mold main body  221  are covered with each other, and thus first charging hole  224 , second charging hole  225 , first charging part  215 , third charging hole  226 , fourth charging hole  227  and second charging part  216  are formed. First charging hole  224  is communicated with second charging hole  225 , second charging hole  225  is communicated with first charging part  215  and third charging hole  226 , third charging hole  226  is communicated with fourth charging hole  227 , and fourth charging hole  227  is communicated with second charging part  216 . 
         [0053]    When a liquid resin composition is introduced to metal mold  200  from an injection device not illustrated in the drawing, the liquid resin composition is charged to first charging hole  224 , second charging hole  225 , first charging part  215 , third charging hole  226 , fourth charging hole  227  and second charging part  216  in this order. 
       (Method of Manufacturing Composite) 
       [0054]    Next, a method of manufacturing composite  100  using the above-mentioned metal mold  200  is described.  FIG. 7  is a flowchart of an exemplary method of manufacturing composite  100  according to the present embodiment.  FIG. 8  and  FIG. 9  are schematic cross-sectional views for describing a manufacturing process of composite  100 . 
         [0055]    First, the above-described holding part  120  is prepared (step S 100 ). The method of manufacturing holding part  120  is not limited. For example, holding part  120  is manufactured by injection molding using a thermoplastic resin. 
         [0056]    Next, as illustrated in  FIG. 8A , metal mold  200  is opened. Then, prepared holding part  120  is disposed in the groove that serves as third charging hole  226  when first metal mold  210  and second metal mold  220  are mold-clamped (step S 110 ). At this time, holding part  120  is disposed such that through hole  121  of holding part  120  is located above plane molding part  222  of second metal mold  220 . 
         [0057]    Next, as illustrated in  FIG. 8B , second metal mold  220  in which holding part  120  is disposed, and first metal mold  210  are mold-clamped (step S 120 ). At this time, first metal mold  210  is disposed above second metal mold  220  such that convex surface molding part  212  is opposite to plane molding part  222  of second metal mold  220  through through hole  121  of holding part  120 . In this manner, holding part  120  is disposed in metal mold  200  such that through hole  121  is communicated with the cavity of metal mold  200 , or in other words, that through hole  121  opens to the cavity of metal mold  200 . 
         [0058]    Next, as illustrated in  FIG. 9A , the liquid resin composition is charged to the cavity and through hole  121  of holding part  120 , and cured (LIM; step S 130 ). To be more specific, by use of an injection device, the liquid resin composition is charged to the cavity of metal mold  200  that is heated to a predetermined temperature. At this time, the liquid resin composition injected from the injection device is charged to first charging hole  224 , second charging hole  225  and first charging part  215  in this order. The liquid resin having reached third charging hole  226  through second charging hole  225  is charged to the cavity and through hole  121  through groove part  122  formed in holding part  120  while being brought into contact with holding part  120 . Finally, the liquid resin is charged to fourth charging hole  227  and second charging part  216 . 
         [0059]    The liquid resin charged to the cavity is heated and thermally cured by metal mold  200 . The temperature (molding temperature) of first metal mold  210  and second metal mold  220  may be appropriately set in consideration of the deflection temperature under load of the resin of holding part  120 , the flow rate and the flow distance of the liquid resin composition and the like. For example, the temperature of first metal mold  210  and second metal mold  220  is about 130 to 200° C. In addition, the charging duration and the charging pressure of the liquid resin composition may be appropriately set. For example, the charging duration and the charging pressure of the liquid resin composition may be set to about 0.3 to 3 seconds and about 13 MPa, respectively. 
         [0060]    Finally, as illustrated in  FIG. 9B , metal mold  200  is opened (step S 140 ), and composite  100  composed of holding part  120  and integral molded article  110  (functional part  111  and connecting part  112 ) of a cured product of a liquid resin composition joined to each other is removed (step S 150 ).  FIGS. 10A to 10C  illustrate a configuration of composite  100  immediately after the releasing.  FIG. 10A  is a plan view,  FIG. 10B  is a bottom view, and  FIG. 10C  is a side view. Composite  100  can be used as a product even immediately after the releasing. 
         [0061]    Through the above-mentioned procedure, composite  100  including holding part  120  and integral molded article  110  (functional part  111  and connecting part  112 ) of a cured product of liquid resin can be manufactured. The molding of steps S 100  to S 150  can be carried out in about 30 seconds to 5 minutes. 
         [0062]    In the method of manufacturing composite  100  according to the present embodiment, a secondary processing may be further carried out as a step as appropriate. For example, it is possible to cut a cured product of a liquid resin composition protruding outward from the outer edge of holding part  120  in ejected composite  100  (gate cut; see and compare  FIGS. 2A to 2C  and  FIGS. 10A to 10C ). Composite  100  can be used as a product also after the gate cut. 
         [0063]    In addition, when functional part  111  (planoconvex lens) is separated from the obtained composite  100 , two or more functional parts  111  (planoconvex lens) can be efficiently obtained. The method of separating functional part  111  from composite  100  is not limited. For example, functional part  111  may be separated from holding part  120  by punching, or only connecting part  112  (cutting at the single layer part) or connecting part  112  and holding part  120  (cutting at the multilayer part) may be cut at positions between each functional part  111 . In the case where the separated body including one functional part  111  obtained in the above-mentioned manner is considered a composite as an end product, composite  100  prior to the separation including two or more functional parts  111  can be considered a composite as an intermediate (composite intermediate). 
         [0064]    While functional part  111  is a planoconvex lens in the above-mentioned example, the shape of functional part  111  is not limited. The shapes of holding part  120  and the metal mold pieces of the metal mold  200  are designed in accordance with the shape of functional part  111 .  FIGS. 11A to 11C  illustrate a configuration of optical part  300  as another exemplary functional part  111 .  FIG. 11A  is a plan view,  FIG. 11B  is a side view, and  FIG. 11C  is a sectional view taken along line C-C of  FIG. 11A . 
         [0065]    As illustrated in  FIGS. 11A to 11C , optical part  300  is a light flux controlling member that controls the distribution of light emitted from the light source. Optical part  300  includes rear surface  310 , incidence surface  320  and emission surface  330 . Optical part  300  has a nearly circular shape in plan view, and is essentially a body of revolution whose rotational axis is central axis CA 1 . Connection track  340  of the connecting part remains at a part of emission surface  330 . 
         [0066]    Rear surface  310  is the bottom side surface of optical part  300 . The shape of the rear surface  310  is not limited. Regarding the shape of rear surface  310 , a plurality of projected lines are formed in matrix in the present embodiment although not illustrated in the drawings. A recess whose internal surface serves as incidence surface  320  is formed at a center portion of rear surface  310 . 
         [0067]    Light emitted from the light source is incident on incidence surface  320 . Incidence surface  320  is an internal surface of a recess opening at rear surface  310 . Incidence surface  320  is a rotationally symmetrical surface, and central axis CA of incidence surface  320  and central axis CA 1  of optical part  300  coincide with each other. 
         [0068]    Emission surface  330  emits the light incident on incidence surface  320  to the outside of optical part  300 . Emission surface  330  includes first emission surface  331  located in a predetermined range around the central axis of emission surface  330 , second emission surface  332  continuously formed at the periphery of first emission surface  331 , and third emission surface  333  that connects second emission surface  332  and rear surface  310 . First emission surface  331  has a smooth curved surface projecting to the lower side (light source side). Second emission surface  332  has an annular protruding shape. Third emission surface  333  is a curved surface located at the periphery of second emission surface  332 . 
       (Effect) 
       [0069]    Composite  100  according to the present embodiment includes not only integral molded article  110  of a cured product of a liquid resin composition including functional part  111  but also holding part  120  that holds functional part  111 . Therefore, with the support of holding part  120 , composite  100  can be easily handled without causing deflection even when functional part  111  and connecting part  112  are formed with a flexible cured product of a silicone resin or the like. Accordingly, functional part  111  can be separated from composite  100  with high precision, and two or more resin molded articles (in the present embodiment, optical parts) can be easily manufactured with high precision. 
         [0070]    In addition, when the resin part has a small thickness in the case where a metal insert member is used in injection molding of a thermosetting resin by insert molding, it is considered that the flow state in the cavity is difficult to maintain since the thermosetting resin is quickly cured. As a result, it is difficult to obtain a resin molded article having a favorable external appearance. In contrast, holding part  120  according to the present embodiment is composed of a resin composition having a heat insulating property, and therefore the thermosetting rate of the liquid resin composition by the insert member (holding part  120 ) can be expected to be advantageously moderated. As a result, the flow state of the liquid resin composition in the cavity is maintained, and a cured product of a liquid resin composition can be appropriately molded even when integral molded article  110  of the cured product of the liquid resin composition has a small thickness. In addition, since the volume for charging the liquid resin composition can be set to a small value by disposing the insert member in the cavity, the amount of the gas ejected from the resin during the molding can be reduced, and the ease of the molding can be expected to be increased. 
         [0071]    In addition, with the method of manufacturing composite  100  according to the present embodiment, leakage of the liquid resin composition between first metal mold  210  and holding part  120  can be suppressed since holding part  120  is provided with flow reducing part  123 . In addition, even when the liquid resin composition reaches flow reducing part  123 , holding part  120  and integral molded article  110  of a cured product of a liquid resin composition can be further firmly joined to each other by anchor effect. Accordingly, it is possible to prevent holding part  120  and integral molded article  110  of a cured product of a liquid resin composition from being peeled off at the time of releasing. 
         [0072]    It is to be noted that the shape of the groove part of the holding part in the composite according to the embodiment of the present invention is not limited to the shape of groove part  122  of holding part  120  of the embodiment.  FIGS. 12A to 12C  are bottom views illustrating other examples of holding parts  120   d,    120   e  and  120   f.  As illustrated in  FIG. 12A , groove part  122   d  of holding part  120   d  may be extended only in a first direction (the vertical direction in the drawing). In addition, as illustrated in  FIG. 12B , groove part  122   e  of holding part  120   e  may be extended in both of a first direction (the vertical direction in the drawing) and a second direction (the lateral direction in the drawing). Further, as illustrated in  FIG. 12C , groove part  122   f  of holding part  120   f  may be composed of a first groove part that is extended in a first direction (the vertical direction in the drawing) and is not connected with through hole  121 , and a second groove part that is extended in a second direction (the lateral direction in the drawing) and connects the first groove part and through hole  121 . The composite including holding parts  120   d,    120   e  and  120   f  includes, in addition to the single layer part and the multilayer part, a second single layer part (a portion where connecting part  112  is not joined in holding parts  120   d,    120   e  and  120   f ) of a resin composition disposed between the single layer part and the multilayer part. The multilayer part is formed by joining connecting part  112  to groove parts  122   d,    122   e  and  122   f  formed in holding parts  120   d,    120   e  and  120   f.  A groove part that functions as a runner for charging the liquid resin composition to through hole  121  is formed to have a small width in a range enough for charging of resin as groove parts  122   d,    122   e  and  122   f  as mentioned above, and thus the amount of the liquid resin composition can be saved. 
         [0073]    In addition, the shape of the flow reducing part of the holding part in the composite according to the embodiment of the present invention is not limited to the shape of flow reducing part  123  of holding part  120  according to the embodiment.  FIGS. 13A and 13B  illustrate another exemplary holding part  120 .  FIG. 13A  is a plan view of holding part  120   g,  and  FIG. 13B  is a sectional view taken along line B-B of  FIG. 13A . As illustrated in  FIG. 13A  and  FIG. 13B , flow reducing part (cutout part)  123   g  may be a recess having a triangular cross-sectional shape formed to surround through hole  121 . By cutting holding part  120   g  at the valley part of cutout part  123   g  having a triangular cross-sectional shape, holding part  120   g  can function as a holder that holds functional part  111  formed in through hole  121  through connecting part  112 . 
         [0074]    While composite  100  includes holding part  120  in which two or more through holes  121  are formed in the present embodiment, two or more recesses may be formed in place of two or more through holes  121  in holding part  120  of composite  100  according to the embodiment of the present invention. In this case, functional part  111  is disposed in the recess, and groove part  122  is formed on the surface on the side same as that of the recess of holding part  120 . 
         [0075]    While holding part  120  includes groove part  122  in the present embodiment, holding part  120  according to the embodiment of present invention may not include groove part  122 . In this case, at the time of molding of composite  100 , holding part  120  is disposed with a gap such that a liquid resin composition can flow through a space between the inner wall of metal mold  200  and holding part  120 . 
         [0076]    While holding part  120  includes flow reducing part  123  in the present embodiment, holding part  120  according to the embodiment of the present invention may not include flow reducing part  123 . 
         [0077]    This application is entitled to and claims the benefit of Japanese Patent Application No. 2015-031702 filed on Feb. 20, 2015, the disclosure each of which including the specification, drawings and abstract is incorporated herein by reference in its entirety. 
       INDUSTRIAL APPLICABILITY 
       [0078]    The composite according to the embodiment of the present invention is applicable to, for example, a light flux controlling member and the like for controlling the light distribution of light emitted from the light source in a backlight of a liquid crystal display apparatus, a generally-used illumination apparatus and the like. 
       REFERENCE SIGNS LIST 
       [0000]    
       
           11  Optical function part 
           14  Optical device part 
           12  Outer periphery part 
           16  Cutting part 
           30  Molded article 
           100  Composite 
           110  Integral molded article of a cured product of a liquid resin composition 
           111  Functional part 
           112  Connecting part 
           120 ,  120   a  to  g  Holding part 
           121  Through hole 
           122 ,  122   d  to  f  Groove part 
           123 ,  123   g  Flow reducing part (Cutout part) 
           200 ,  200   a  to  c  Metal mold 
           210  First metal mold 
           211  First metal mold main body 
           212  Convex surface molding part 
           213  First plane 
           214  Convex surface transferring surface 
           215  First charging part 
           216  Second charging part 
           220  Second metal mold 
           221  Second metal mold main body 
           222  Plane molding part 
           223  Plane transferring surface 
           224  First charging hole 
           225  Second charging hole 
           226  Third charging hole 
           227  Fourth charging hole 
           300  Optical part 
           310  Rear surface 
           320  Incidence surface 
           330  Emission surface 
           331  First emission surface 
           332  Second emission surface 
           333  Third emission surface 
           340  Connection track 
         CA Central axis of incidence surface 
         CA 1  Central axis of optical part