Patent Description:
Conventionally, there has been known a technique of integrally molding a circuit sheet to a molded article, which is a part of a housing. For example, Patent Document <NUM> (<CIT>) discloses a display panel. The display panel described in Patent Document <NUM> is a molded article used as a part of a housing of an electronic device. In this display panel, a base substrate film on which a detection electrode layer is formed, an outer molded body, and an inner molded body are integrally formed. A circuit sheet of Patent Document <NUM> is the base substrate film on which the detection electrode layer is formed. The base substrate film of Patent Document <NUM> is sandwiched between the outer molded body and the inner molded body.

Patent Document <NUM> (<CIT>) and Patent Document <NUM> (<CIT>) relate to overmolding printed circuit films or boards as inserts and disclose positioning and fixation of the inserts in the mould using projections of the cavity wall.

In the display panel described in Patent Document <NUM>, the base substrate film is sandwiched between the outer molded body and the inner molded body, and the outer molded body, the base substrate film, and the entire inner molded body are covered with a surface protection layer. With such a structure, the display panel described in Patent Document <NUM> can effectively prevent entrance of moisture or corrosive gas along an outer surface or an inner surface of the base substrate film.

The display panel described in Patent Document <NUM> is molded using a primary molding mold for molding the inner molded body and a secondary molding mold for molding the outer molded body. Therefore, to obtain a molded article as described in Patent Document <NUM>, two sets of molding molds are required and injection molding needs to be performed twice, resulting in an increase in manufacturing cost.

An object of the present invention is to inexpensively provide a molded article in which a circuit sheet is inserted.

Some aspects will be described below as means to solve the problems. These aspects can be combined randomly as necessary.

A method for manufacturing a molded article according to an aspect of the present invention includes: setting a circuit sheet including a first main surface, a second main surface opposed to the first main surface, and a conductive pattern in a first mold such that a first region of the second main surface contacts a plateau portion of the first mold and a second region of the second main surface does not contact the first mold; clamping the second mold to the first mold such that the circuit sheet does not contact the second mold to form a cavity where the first main surface and the second region of the second main surface of the circuit sheet are exposed; introducing a molten material into the cavity to bring the molten material into contact with the first main surface and the second region of the second main surface of the circuit sheet; cooling and solidifying the molten material to form a molded body made of resin having an outer surface opposed to the first main surface and an inner surface opposed to the second region of the second main surface of the circuit sheet; and opening the first mold and the second mold to take out the molded article. In the setting, a first fixed portion of the circuit sheet is arranged in a first portion of the first mold, and a second fixed portion of the circuit sheet including the second region is arranged in a second portion of the first mold. The first portion is a portion along at least one of a first protruding portion and a second protruding portion that are higher than the plateau portion and are provided along the plateau portion of the first mold. The second portion is a portion in which neither the first protruding portion nor the second protruding portion is provided along the plateau portion.

In the method for manufacturing the molded article configured as described above, the molded article including the circuit sheet inserted into the resin can be manufactured with the pair of the first mold and the second mold. In addition, the molded article including the circuit sheet inserted into the resin can be manufactured by introducing the molten material in one shot from clamping the first mold and the second mold until opening the molds.

In the method for manufacturing the molded article described above, the second portion of the first mold is a portion where a width of the plateau portion is narrower than a width of the circuit sheet. In the method for manufacturing the molded article configured as described above, a configuration of the first mold is simplified and the configuration of the molded article is simplified, and therefore the molded article is easily manufactured.

In the method for manufacturing the molded article described above, the second portion of the first mold is a portion that divides the plateau portion. In the setting, the circuit sheet is laid across two divided portions of the divided plateau portions in the second portion. In the method for manufacturing the molded article configured as described above, a supporting portion resin portion that supports the circuit sheet in the second portion can be large, and the circuit sheet can be firmly fixed.

In the method for manufacturing the molded article described above, in the first portion of the first mold, groove portions may be formed between the first protruding portion and the plateau portion and between the second protruding portion and the plateau portion. In the method for manufacturing the molded article configured as described above, a thickness of the resin in contact with the second region on both sides of the plateau portion of the circuit sheet can be increased by the molten material entering the groove portions. The thickened resin allows improving strength of the resins for fixing the circuit sheet.

In the method for manufacturing the molded article described above, the first mold may be configured such that a gap is formed in at least one of between the first protruding portion and a first end side of the circuit sheet and between the second protruding portion and a second end side of the circuit sheet. In the method for manufacturing the molded article configured as described above, the molten material enters at least one of the gap between the first protruding portion and the first end side and the gap between the second protruding portion and the second end side. An amount of the resin on at least one of a periphery of the first end side and a periphery of the second end side of the circuit sheet is increased by the entered resin, and support by the resin on at least one of the peripheries of the first end side and the second end side of the circuit sheet is strengthened.

In the method for manufacturing the molded article described above, in the setting, a connecting portion of the circuit sheet may be inserted into a slit of the first mold. In the method for manufacturing the molded article configured as described above, the connecting portion can be drawn out to the inner surface side of the molded article.

In the method for manufacturing the molded article described above, the first mold includes a plurality of sets of the first protruding portions and the second protruding portions. In the setting, the circuit sheets may be arranged between all of the plurality of sets of the first protruding portions and the second protruding portions. In the method for manufacturing the molded article configured as described above, the plurality of sets of the first protruding portions and the second protruding portions make it difficult for the circuit sheets to be displaced with respect to the first molds when the molten resins are injected. By thus providing the plurality of sets of the first protruding portions and the second protruding portions, the circuit sheet is fitted between the first protruding portion and the second protruding portion of the first mold, and the circuit sheet is not displaced by flow of the molten resin and can be fixed at a predetermined position of the molded body with high accuracy.

In the method for manufacturing the molded article described above, the first protruding portion, the second protruding portion, and the plateau portion of the first mold may be formed on a sliding block. In the introducing, the sliding block may be moved to form the cavity in a place where the first protruding portion, the second protruding portion, and the plateau portion were present before the sliding block is moved to introduce the molten material. In the method for manufacturing the molded article configured as described above, in a state in which the sliding block is pressed against the second mold, displacement of the circuit sheet during molding can be suppressed with the first protruding portion, the second protruding portion, and the plateau portion. In addition, after the sliding block is moved backward, the cavity expands and the molten material enters the place where the first protruding portion, the second protruding portion, and the plateau portion were present before the sliding. The fixation of the circuit sheet in the molded article is strengthened with the resin that has entered in this manner.

A molded article according to an aspect of the present invention includes a circuit sheet and a molded body. The circuit sheet includes a first main surface, a second main surface opposed to the first main surface, and a conductive pattern. The molded body covers an entirety of the first main surface of the circuit sheet. The molded body includes a plurality of resin supporting portions extending from a periphery of the circuit sheet while being in contact with the second main surface over an entirety of the periphery of the circuit sheet. The molded body includes a plurality of recessed portions arranged in the periphery of the circuit sheet over the entirety of the periphery of the circuit sheet. The plurality of resin supporting portions and the plurality of recessed portions are alternately arranged so as to be arranged along the periphery.

In the molded article configured as described above, a force received from the molten material by the circuit sheet is relaxed in the protruding portions formed in the mold for forming the recessed portions during manufacturing. The circuit sheet receives the force of the molten material for forming the resin supporting portions by the entirety of the periphery of the circuit sheet. Therefore, the displacement of the circuit sheet in the molded body is reduced, and the molded article with high accuracy of an arrangement position of the circuit sheet can be provided.

According to the method for manufacturing the molded article of the present invention, the molded article in which the circuit sheet is inserted can be inexpensively provided.

<FIG> and <FIG> illustrate an example of a molded article <NUM>. <FIG> illustrates a cross-sectional shape of the molded article <NUM> cut at a plane PL1 indicated by one dot chain line in <FIG>. The plane PL1 is an XZ plane. <FIG> illustrates a cross-sectional shape of the molded article <NUM> cut along the line I-I in <FIG>, in other words, a cross-sectional shape of the molded article <NUM> cut at a plane (XY plane) perpendicular to a Z direction in <FIG> and <FIG>. <FIG> illustrates an enlarged part surrounded by one dot chain line in <FIG>. <FIG> illustrates a first mold <NUM> and a second mold <NUM> for manufacturing the molded article <NUM> illustrated in <FIG>. <FIG> illustrates a circuit sheet <NUM> before being folded.

The shape of the molded article <NUM> is a hollow, three-dimensional shape having a housing space HS therein. The molded article <NUM> includes a molded body <NUM> and the circuit sheet <NUM>. The molded article <NUM> illustrated in <FIG> and <FIG> is formed by integrating the molded body <NUM> and the circuit sheet <NUM> by one-shot insert molding. In <FIG>, <FIG>, hatching indicating the cross section of the molded body <NUM> is omitted to avoid the drawings being difficult to be seen.

The molded body <NUM> has an outer surface <NUM> and an inner surface <NUM>. The inner surface <NUM> is exposed to the housing space HS. Resin may be exposed on the outer surface <NUM> of the molded body <NUM>. A decorative layer may be formed on the outer surface <NUM> of the molded body <NUM> simultaneously with molding. The outer surface <NUM> of the molded body <NUM> may be coated after molding. The circuit sheet <NUM> has a first main surface <NUM> and a second main surface <NUM>. The molded body <NUM> is arranged in contact with the first main surface <NUM> of the circuit sheet <NUM> and is arranged in contact with the second main surface <NUM> of the circuit sheet <NUM>. In <FIG>, an outer peripheral portion <NUM> is a portion in contact with the first main surface <NUM> of the circuit sheet <NUM>, and an inner peripheral portion <NUM> is a portion in contact with the second main surface <NUM> of the circuit sheet <NUM>. In other words, the circuit sheet <NUM> is inserted into the molded body <NUM> so as to be sandwiched between the outer peripheral portion <NUM> and the inner peripheral portion <NUM>. The circuit sheet <NUM> inserted into the molded body <NUM> in this manner is sandwiched between and fixed from both sides of the first main surface <NUM> and the second main surface <NUM> with a constituent material constituting the molded body <NUM>. When the circuit sheet <NUM> is fixed by being sandwiched between both sides of the first main surface <NUM> and the second main surface <NUM> as described above, an adhesive for bonding the circuit sheet <NUM> and the molded body <NUM> together can be omitted. When the adhesive is omitted, an adhesive application step can be omitted. However, an adhesive for bonding the circuit sheet <NUM> and the molded body <NUM> together may be provided.

The molded article <NUM> is manufactured using the first mold <NUM> and the second mold <NUM> illustrated in <FIG>. An opening <NUM> is provided in the central portion of the circuit sheet <NUM>. The portion where the circuit sheet <NUM> is arranged is a plateau portion <NUM> of the first mold <NUM> located around the opening <NUM> of the circuit sheet <NUM>. The first mold <NUM> has air suction holes <NUM>. The circuit sheet <NUM> set in the first mold <NUM> is sucked and held by the air suction holes <NUM>. A gate <NUM> through which molten resin is injected is provided at the central portion of the first mold <NUM>. The resin is injected from the gate <NUM> through the opening <NUM>. Here, the gate <NUM> is provided in the opening <NUM> of the circuit sheet <NUM> at the central portion of the first mold <NUM>. However, the position where the gate <NUM> is provided is not limited to the above-described position. The gate <NUM> only needs to be provided at a position where the molten resin is not directly injected onto the second main surface <NUM> of the circuit sheet <NUM>.

The circuit sheet <NUM> is, for example, a metal sheet, a sheet in which a metal sheet and an insulating film are laminated, a printed circuit film, a flexible wiring board (hereinafter referred to as an FPC in some cases), or a combination thereof. The metal sheet is obtained by punching a copper foil into a predetermined shape, for example. The metal sheet may be processed to have a three-dimensional shape. For example, the punched copper foil may be bent by press working. The printed circuit film is formed by thick-film printing of a wiring pattern on an insulating film with conductive ink. In the printed circuit film, for example, a portion coated with conductive ink containing a conductive substance, such as silver particles, functions as the wiring pattern after drying. The insulating film used in the printed circuit film and the FPC is made of, for example, an organic material. An example of the organic material constituting the insulating film is resin. Examples of the resin constituting the insulating film include a polyimide resin, a polycarbonate resin, and a polyester resin. The printed circuit film and the FPC may be obtained by processing an insulating film on which a wiring pattern is formed into a three-dimensional shape, for example.

The circuit sheet <NUM> illustrated in <FIG> and <FIG> is the printed circuit film. The circuit sheet <NUM> illustrated in <FIG> includes wiring patterns <NUM> formed by printing, an antenna <NUM>, and a touch switch <NUM> on a film-like base substrate <NUM>. The base substrate <NUM> is, for example, an insulating resin film. The antenna <NUM> and the touch switch <NUM> are connected to, for example, a device outside the molded article <NUM> with the wiring patterns <NUM>. These wiring patterns <NUM> are conductive patterns provided on the circuit sheet <NUM>. The antenna <NUM> is a functional component for a device connected to the circuit sheet <NUM> to communicate. The touch switch <NUM> is a functional component for inputting information, such as ON/OFF, to the device connected to the circuit sheet <NUM>. The opening <NUM> having a rectangular shape in plan view is provided in a substantially central portion of the circuit sheet <NUM>.

The circuit sheet <NUM> is divided into a main portion 20a in which the antenna <NUM> and the touch switch <NUM> are formed and a lead portion 20b in which the wiring patterns <NUM> mainly led out to the outside of the molded article <NUM> are formed. A connecting portion 20c connected to a wiring line outside the circuit sheet <NUM> is provided at the distal end of the lead portion. The circuit sheet <NUM> is bent by a simple bending device before being integrally molded with the molded body <NUM> such that the main portion 20a and the lead portion 20b are orthogonal to one another. Although the case where the main portion 20a and the lead portion 20b are orthogonal to one another is described here as an example, the main portion 20a and the lead portion 20b need not be orthogonal to one another. A reinforcing plate <NUM> is attached to the back surface of the connecting portion 20c. The back surface of the connecting portion 20c is a surface opposite to the formation surface of the wiring line. The reinforcing plate <NUM> may be attached after molding the molded body <NUM>.

<FIG>, <FIG> illustrate the molded article <NUM> in which the circuit sheet <NUM> is a metal sheet. <FIG> illustrates a state in which the molded article <NUM> is viewed from above (a state of being seen in the Z-axis direction). <FIG> illustrates the cross-sectional shape of the molded article <NUM> cut along the line II-II in <FIG>. <FIG> illustrates the cross-sectional shape of the molded article <NUM> cut along the line III-III in <FIG>.

The circuit sheet <NUM> illustrated in <FIG> is an antenna <NUM> and a touch switch <NUM> formed by a metal sheet. The metal sheet is, for example, a sheet of copper or a copper alloy. For example, when a terminal portion connected to a device is provided, a phosphor bronze plate having excellent spring characteristics is used for the circuit sheet <NUM>. The circuit sheet <NUM> is shaped in a three-dimensional shape as necessary, punched into a predetermined shape, finished into a shape suitable for insertion, and then usually plated with nickel or gold to prevent corrosion. The thickness of the phosphor bronze plate is from <NUM> to <NUM>, and the thickness suitable for press working is from <NUM> to <NUM>. A portion extending along the outer surface <NUM> of the molded body <NUM> is the main portion 20a for the antenna <NUM> and the touch switch <NUM>. A portion of the phosphor bronze plate extending in the Z-axis direction is the lead portion 20b for the antenna <NUM> and the touch switch <NUM>. The connecting portion 20c is connected to a device accommodated on the inner surface <NUM> side of the molded body <NUM>. Also in the circuit sheet <NUM> illustrated in <FIG>, the outer peripheral portion <NUM> of the molded body <NUM> is in contact with the first main surface <NUM> of the circuit sheet <NUM>, and the inner peripheral portion <NUM> is in contact with the second main surface <NUM> of the circuit sheet <NUM>.

<FIG>, <FIG> illustrate the molded article <NUM> in which the circuit sheet <NUM> is the FPC. <FIG> illustrates a state in which the molded article <NUM> is viewed from the back surface (a state of being seen in the Z-axis direction). <FIG> illustrates the cross-sectional shape of the molded article <NUM> cut along the line IV-IV in <FIG>. <FIG> illustrates the cross-sectional shape of the molded article <NUM> cut along the line V-V in <FIG>. In <FIG>, a portion indicated by dot hatching is a portion where the circuit sheet <NUM> is covered with the molded body <NUM>.

The circuit sheet <NUM> illustrated in <FIG> includes wiring patterns <NUM> formed by etching or plating, LEDs <NUM>, and high-function electronic components <NUM>, such as integrated circuits. The wiring patterns <NUM> are covered with a cover film. The wiring patterns <NUM> are an example of conductive patterns. The LED described above is an abbreviation for a light emitting diode. The LED <NUM> and the high-function electronic component <NUM> are connected to, for example, a device outside the molded article <NUM> with the wiring patterns <NUM>. The LED <NUM> is a functional component for notifying information to the outside of the molded article <NUM> by light. The high-function electronic component <NUM> is a functional component that achieves a complicated function in response to an input from the device connected to the circuit sheet <NUM>, for example. The circuit sheet <NUM> is divided into the main portion 20a in which the LEDs <NUM> and the high-function electronic components <NUM> are formed and the lead portion 20b in which the wiring patterns <NUM> mainly led out to the outside of the molded article <NUM> are formed. The circuit sheet <NUM> is bent by a simple bending device before being integrally molded with the molded body <NUM> such that the main portion 20a and the lead portion 20b are orthogonal to one another. As illustrated in <FIG>, a reinforcing plate <NUM> is pasted to the connecting portion 20c of the circuit sheet <NUM>. The reinforcing plate <NUM> before being bent has a rectangular shape. A part of the reinforcing plate <NUM> extends up to a part of the main portion 20a. The reinforcing plate <NUM> is made of, for example, a thin plate of thermoplastic resin or stainless. The cross-sectional shape of the reinforcing plate <NUM> after bending is an L-shape.

The molded body <NUM> is formed by solidifying a molten material injected during insert molding. The thickness (a distance L1 between the outer surface <NUM> and the inner surface <NUM>) of the molded body <NUM> is, for example, <NUM> (see <FIG>, <FIG>, and <FIG>). The distance L1 between the outer surface <NUM> and the inner surface <NUM> is set within a range from <NUM> to <NUM>, for example. The molded body <NUM> may be colored or need not be colored. The molded body <NUM> is molded using at least one of transparent, translucent, or opaque thermoplastic resin and thermoplastic elastomer. The molten material here is, for example, a material obtained by melting at least one of thermoplastic resin and thermoplastic elastomer by heat. As the material of the molded body <NUM>, a general-purpose thermoplastic resin, such as a polystyrene resin, a polyolefin resin, an ABS resin, or an AS resin, is used. Besides, a polycarbonate resin, a polyacetal resin, an acrylic resin, a polybutylene terephthalate resin, an engineering resin (for example, a polysulfone resin, a polyphenylene sulfide resin, a polyphenylene oxide resin, and a polyacrylate resin), a polyamide resin, or a urethane, polyester, or styrene elastomer is used as the material of the molded body <NUM>. Furthermore, natural rubber or synthetic rubber is used as the material of the molded body <NUM>. The molded body <NUM> need not be constituted only by the solidified molten material. A resin reinforcing material, such as glass fiber, or an inorganic filler for increasing a dielectric constant, such as barium titanate, may be added to the molded body <NUM>. Further, it is also possible to use thermosetting resin that is in a fluid state by heating before introduction of, for example, a silicone resin, a phenol resin, or an epoxy resin, but cures by a chemical reaction in a mold, or a urethane resin obtained by mixing two liquids. The circuit sheet <NUM> can be physically fixed to the molded body <NUM> even when the molded body <NUM> is molded with, for example, a polyacetal resin and an engineering resin that are difficult to bond to the circuit sheet <NUM>, or a thermosetting resin that does not bond to a general-purpose adhesive. The molding method is not limited to injection molding, and only needs to be selected from, for example, transfer molding, foam molding, blow molding, and RIM molding, suitable for the material of each molded body.

The molded article <NUM> is manufactured using, for example, the first mold <NUM> and the second mold <NUM> illustrated in <FIG>. <FIG> depicts an outline of a manufacturing flow of the molded article <NUM>.

In a transfer sheet arranging step (Step S1) illustrated in <FIG>, as illustrated in <FIG>, a transfer sheet <NUM> is arranged between the opened molds (the first mold <NUM> and the second mold <NUM>).

The arranged transfer sheet <NUM> is fixed to the second mold <NUM> with, for example, a clamp (not illustrated). The transfer sheet <NUM> is obtained by forming a transfer layer and an adhesive layer on a base substrate film. In the method for manufacturing the molded article <NUM> illustrated in <FIG> and <FIG>, the transfer layer is bonded to the outer surface <NUM> of the molded body <NUM> with the adhesive layer. In most cases, the base substrate film constituting the transfer sheet <NUM> is formed of a polyolefin resin, a polycarbonate resin, or a polyethylene terephthalate resin.

Together with the arrangement of the transfer sheet <NUM>, or before or after the arrangement of the transfer sheet <NUM>, the circuit sheet <NUM> is set in the first mold <NUM> (Step S1).

After the circuit sheet <NUM> is set, the first mold <NUM> and the second mold <NUM> are clamped (Step S2). By clamping the first mold <NUM> and the second mold <NUM>, a cavity Cv (see <FIG>) surrounded by the first mold <NUM> and the second mold <NUM> is formed.

Molten resin is injected into the cavity Cv of the first mold <NUM> and the second mold <NUM> (Step S3). A predetermined pressure is continuously applied such that the resin injected into the cavity Cv has an appropriate density. In the first embodiment, molten resin will be described as an example of the molten material. However, the molten material may be other than the molten resin. For example, as the molten material instead of the molten resin, a molten thermoplastic elastomer may be used, and the molten material may be thermosetting resin that becomes a fluid state by heating and causes a chemical reaction to cure by heat in the mold or may be urethane resin produced by mixing two liquids of a main agent and a reactant to cause a chemical reaction in the mold.

Next, the molten resin in the cavity Cv is cooled (Step S4). The resin cooled and solidified in the cavity Cv becomes the molded body <NUM>.

Finally, the first mold <NUM> and the second mold <NUM> are opened to take out the molded article <NUM> (Step S5).

The setting of the circuit sheet <NUM> to the first mold <NUM> in the above-described Step S1 (first step) will be described in more detail. <FIG> and <FIG> illustrate a part of the enlarged first mold <NUM> illustrated in <FIG>. In <FIG>, a core surface CF of the first mold <NUM> and the circuit sheet <NUM> constituting the antenna <NUM> set on the core surface CF are enlarged. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut at a position along the line VI-VI in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line VII-VII in <FIG>. <FIG> illustrate an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut at a position along the line VIII-VIII in <FIG>. The difference between <FIG> is whether the connecting portion 20c of the lead portion 20b of the circuit sheet <NUM> is bent or not.

As illustrated in <FIG>, the first mold <NUM> has the plateau portion <NUM> on the core surface CF. In <FIG>, hatching indicating the cross section of the first mold <NUM> is omitted to avoid the drawings being difficult to be seen. The plateau portion <NUM> is a portion having a flat surface and that is raised from the surrounding core surface CF. A part of the second main surface <NUM> of the circuit sheet <NUM> is in contact with the plateau portion <NUM>. A part of the second main surface <NUM> in contact with the plateau portion <NUM> is a first region AR1. Further, a part of the second main surface <NUM> of the circuit sheet <NUM> is not in contact with the plateau portion <NUM>. A part of the second main surface <NUM> not in contact with the plateau portion <NUM> is a second region AR2. A plurality of the air suction holes <NUM> are provided in the plateau portion <NUM>.

A first protruding portion <NUM> and a second protruding portion <NUM> are provided along the plateau portion <NUM>. More specifically, the first protruding portion <NUM> and the second protruding portion <NUM> are provided along positions opposed to both side surface portions of the plateau portion <NUM>. For example, when the thickness of the molded article (the distance between the core surface CF and the inner surface of the second mold <NUM>) is <NUM>, the height of the plateau portion <NUM> from the core surface CF is greater than <NUM> and <NUM> or less. The heights of the first protruding portion <NUM> and the second protruding portion <NUM> only need to be the height of the first main surface equal to or greater than the half of the thickness of the circuit sheet <NUM> set on the plateau portion <NUM>. As described above, the first protruding portion <NUM> and the second protruding portion <NUM> are higher than the plateau portion <NUM> when viewed from the core surface CF. The heights of the first protruding portion <NUM> and the second protruding portion <NUM> are preferably equal to or higher than the end surface of the circuit sheet <NUM> set in the first mold <NUM>. The first protruding portion <NUM> and the second protruding portion <NUM> may have different heights from one another. A first portion Pa1 and a second portion Pa2 on which the circuit sheet <NUM> is arranged will be described using three sets of the first protruding portions <NUM> and the second protruding portions <NUM> in <FIG>. In the three sets of the first protruding portions <NUM> and the second protruding portions <NUM> in <FIG>, the portions hatched with oblique lines between the first protruding portions <NUM> and the second protruding portions <NUM> are the first portions Pa1. The second portions Pa2 are portions hatched with dots in <FIG>. To avoid the drawings being difficult to be seen, hatching is provided to only a part of the first portions Pa1 and the second portions Pa2 in <FIG>. Therefore, in <FIG>, even in a portion not hatched in the portion where the circuit sheet <NUM> is arranged, a portion between the first protruding portion <NUM> and the second protruding portion <NUM> is the first portion Pa1. In addition, in <FIG>, even in a portion not hatched in the portion where the circuit sheet <NUM> is arranged, a portion along the plateau portion <NUM> where neither the first protruding portion <NUM> nor the second protruding portion <NUM> is arranged is the second portion Pa2. A length L2 of the first portion Pa1 is, for example, from <NUM> to <NUM>, and a length L3 of the second portion Pa2 is, for example, from <NUM> to <NUM>.

As illustrated in <FIG> and <FIG>, the second portion Pa2 is a portion where the width of the plateau portion <NUM> is narrower than the width of the circuit sheet <NUM>. Therefore, the circuit sheet <NUM> protrudes from the plateau portion <NUM> by the difference in width between the plateau portion <NUM> and the circuit sheet <NUM>. The portion of the circuit sheet <NUM> protruding from the plateau portion <NUM> becomes the second region AR2 not in contact with the plateau portion <NUM>.

In the first portion Pa1, groove portions <NUM> and <NUM> are formed between the first protruding portion <NUM> and the plateau portion <NUM> and between the second protruding portion <NUM> and the plateau portion <NUM>.

A third protruding portion <NUM> is provided at one end portion of the plateau portion <NUM>. The third protruding portion <NUM> is higher than the plateau portion <NUM> when viewed from the core surface CF. By providing such the third protruding portion <NUM>, a force that the circuit sheet <NUM> receives from the molten resin when the molten resin is injected is weakened by the third protruding portion <NUM>. Due to the action of the third protruding portion <NUM>, displacement of one end portion of the circuit sheet <NUM> by the force applied from the molten resin to the circuit sheet <NUM> is suppressed.

As illustrated in <FIG>, in the state where the circuit sheet <NUM> is set in the first mold <NUM>, the lead portion 20b of the circuit sheet <NUM> is accommodated in an opening <NUM>, a slit <NUM>, and an accommodating portion <NUM>. The opening <NUM> is wider and thicker than the lead portion 20b. During molding, molten resin enters the opening <NUM>. The molten resin that has entered the opening <NUM> becomes a support portion <NUM> at the root of the bent portion of the lead portion 20b after molding. The width and the thicknesses of the slit <NUM> are only slightly larger than the width and the thicknesses of the lead portion 20b of the circuit sheet <NUM>. Since the lead portion 20b is inserted into the slit <NUM>, the molten resin cannot enter the slit <NUM> and the resin does not enter the accommodating portion <NUM>. Therefore, since the connecting portion 20c is exposed even after molding, electrical connection can be performed using the connecting portion 20c. The first mold <NUM> is provided with a tapered portion <NUM> extending from the opening <NUM> to the slit <NUM> to easily guide the lead portion 20b to the slit <NUM>. Further, the molten resin enters the opening <NUM> wider and thicker than the slit <NUM>, and the rising portion of the connecting portion 20c is reinforced.

In the above-described Step S2 (second step), as illustrated in <FIG>, the first mold <NUM> and the second mold <NUM> are clamped such that the circuit sheet <NUM> is not in contact with the second mold <NUM>. In the above-described Step S3 (third step), the molten resin is injected into the cavity Cv, and comes into contact with the first main surface <NUM> and the second regions AR2 of the second main surface <NUM> of the circuit sheet <NUM>. Further, in Step S4 (fourth step), the molten resin is cooled and solidified to form the molded article <NUM> made of resin having the outer surface <NUM> opposed to the first main surface <NUM> of the circuit sheet <NUM> and the inner surface <NUM> opposed to the second regions AR2 of the second main surface <NUM>. In Step S5 (fifth step), the first mold <NUM> and the second mold <NUM> are opened to take out the molded article <NUM>. A decorative layer <NUM> is transferred to the outer surface <NUM> of the molded body <NUM>.

As illustrated in <FIG>, the molded article <NUM> molded using the antenna <NUM> set in the first mold <NUM> and the second mold <NUM> is illustrated in <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line IX-IX in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line X-X in <FIG>. <FIG> illustrate the enlarged cross-sectional shape of the molded article <NUM> cut along the line XI-XI in <FIG>. Neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM> on the second portion Pa2 of the first mold <NUM>. As illustrated in <FIG>, resin supporting portions 10b of the molded body <NUM> are in contact with the second regions AR2 of the second main surface <NUM> of the circuit sheet <NUM> in the second portion Pa2 where neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM>. Since the circuit sheet <NUM> is sandwiched between the resin supporting portions 10b in contact with the second regions AR2 of the second main surface <NUM> and a resin 10a in contact with the first main surface <NUM> opposed to the second regions AR2, the circuit sheet <NUM> is firmly fixed by the resin 10a on the first main surface <NUM> side and the resin supporting portions 10b on the second main surface <NUM> side between which the circuit sheet <NUM> is sandwiched.

Recessed portions 15a and 15b illustrated in <FIG> are recesses formed when the first protruding portion <NUM> and the second protruding portion <NUM> illustrated in <FIG> come off. Ribs 16a and 16b adjacent to the recessed portions 15a and 15b are formed by the molten resin entering the groove portions <NUM> and <NUM> illustrated in <FIG>. The circuit sheet <NUM> is sandwiched between the ribs 16a and 16b and the resin 10a on the first main surface <NUM> side opposed to the ribs 16a and 16b. The resins (ribs 16a and 16b) entering the groove portions <NUM> and <NUM> in this manner reinforce the fixation of the circuit sheet <NUM> in the molded article <NUM>.

As illustrated in <FIG>, a gap In1 is provided between the circuit sheet <NUM> and the first protruding portion <NUM>. Similarly, a gap In2 is provided between the circuit sheet <NUM> and the second protruding portion <NUM>. The gaps In1 and In2 serve as margins when the circuit sheet <NUM> is set between the first protruding portion <NUM> and the second protruding portion <NUM>. Therefore, the narrower the gaps In1 and In2 become, the higher the positional accuracy of the circuit sheet <NUM> in the molded body <NUM> becomes, but the shape of the circuit sheet <NUM> is required to be highly accurate at all portions. To prevent the set circuit sheet <NUM> from falling off from the first mold <NUM>, one or more air suction holes may be provided at any portion of the plateau portion <NUM>. Regarding fixation of the circuit sheet <NUM>, the molten resin also enters the gaps In1 and In2 to form resin side walls 10c and 10d outside a first end side <NUM> and a second end side 20n of the circuit sheet <NUM>, and the fixation of the circuit sheet <NUM> is strengthened by the side walls 10c and 10d. The total size of the widths of the gaps In1 and In2 is, for example, from <NUM> to <NUM>.

As illustrated in <FIG>, the resin does not bond to the connecting portion 20c of the circuit sheet <NUM>. Therefore, the circuit sheet <NUM> can be satisfactorily electrically connected to a device outside the molded article <NUM> using the connecting portion 20c. The resin that has entered the opening <NUM> in <FIG> becomes the support portion <NUM> that reinforces the root of the bent portion of the lead portion 20b. The circuit sheet <NUM> in <FIG> is made of a thin plate of phosphor bronze and is a metal sheet having an excellent spring property. As illustrated in <FIG>, the connecting portion 20c may be used in a straight shape without being bent. However, as illustrated in <FIG>, before or after insert-molding of the molded article <NUM>, the connecting portion 20c made of the metal sheet may be deformed into a shape suitable for electrical connection by, for example, press working.

In the first embodiment, as illustrated in <FIG>, the case where the molded article <NUM> is manufactured using the first mold <NUM> in which the groove portions <NUM> and <NUM> are formed between the plateau portion <NUM> and the first protruding portion <NUM> and the second protruding portion <NUM> has been described. However, the molded article <NUM> may be manufactured using the first mold <NUM> in which the groove portion <NUM> or <NUM> is not formed.

In the second embodiment, a method for manufacturing the molded article <NUM> using the first mold <NUM> in which the groove portion <NUM> or <NUM> is not formed and a molded article manufactured by the method will be described.

The molded article <NUM> is manufactured using, for example, the first mold <NUM> illustrated in <FIG>. As a manufacturing flow of the molded article <NUM> of the second embodiment, a manufacturing flow depicted in <FIG> can be used similarly to the first embodiment. Since the manufacturing method of the second embodiment is the same as the manufacturing method of the first embodiment except that the first mold <NUM> illustrated in <FIG> is used, the description of the outline of the manufacturing flow according to the second embodiment will be omitted.

The setting of the circuit sheet <NUM> to the first mold <NUM> in the above-described Step S1 (first step) will be described in more detail. <FIG> and <FIG> illustrate a part of the enlarged first mold <NUM> illustrated in <FIG>. In <FIG>, the core surface CF of the first mold <NUM> and the circuit sheet <NUM> constituting the antenna <NUM> set on the core surface CF are enlarged. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut at a position along the line XII-XII in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XIII-XIII in <FIG>. In <FIG>, hatching indicating the cross section of the first mold <NUM> is omitted to avoid the drawings being difficult to be seen. Note that the components of the first mold <NUM> of the second embodiment same as those of the first mold <NUM> of the first embodiment are denoted by the same reference numerals, and description thereof is omitted.

In contrast to the second portion Pa2, the first portion Pa1 is a portion where the width of the plateau portion <NUM> is wider than the width of the circuit sheet <NUM>. Therefore, the plateau portion <NUM> protrudes from the circuit sheet <NUM> by the difference in width between the plateau portion <NUM> and the circuit sheet <NUM>.

In the second embodiment, as illustrated in <FIG> and <FIG>, in the first portion Pa1, a groove portion is not formed between the first protruding portion <NUM> and the plateau portion <NUM> or between the second protruding portion <NUM> and the plateau portion <NUM>. The third protruding portion <NUM> is provided at one end portion of the plateau portion <NUM>. A groove is not formed between the third protruding portion <NUM> and the plateau portion <NUM> as well.

In the above-described Step S2 (second step), as illustrated in <FIG>, the first mold <NUM> and the second mold <NUM> are clamped such that the circuit sheet <NUM> is not in contact with the second mold <NUM>. In the above-described Step S3 (third step), molten resin is injected into the cavity Cv. Further, in Step S4 (fourth step), the molten resin is cooled and solidified to form the molded article <NUM> made of resin having the outer surface <NUM> opposed to the first main surface <NUM> of the circuit sheet <NUM> and the inner surface <NUM> opposed to the second regions AR2 of the second main surface <NUM>. In Step S5 (fifth step), the first mold <NUM> and the second mold <NUM> are opened to take out the molded article <NUM>. The decorative layer <NUM> is transferred to the outer surface <NUM> of the molded body <NUM>.

As illustrated in <FIG>, the molded article <NUM> molded using the antenna <NUM> set in the first mold <NUM> and the second mold <NUM> is illustrated in <FIG> illustrates the enlarged cross-sectional shape of the molded article <NUM> corresponding to <FIG>. <FIG> illustrates the enlarged cross-sectional shape of the molded article <NUM> corresponding to <FIG>. Neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM> on the second portion Pa2 of the first mold <NUM>. In the second portion Pa2 where neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM>, the width of the plateau portion <NUM> is narrower than the width of the circuit sheet <NUM>. Therefore, as illustrated in <FIG>, resin supporting portions 10b of the molded body <NUM> are in contact with the second regions AR2 of the second main surface <NUM> of the circuit sheet <NUM> in the second portion Pa2. Since the circuit sheet <NUM> is sandwiched between the resin supporting portions 10b in contact with the second regions AR2 of the second main surface <NUM> and the resin 10a in contact with the first main surface <NUM> opposed to the second regions AR2, the circuit sheet <NUM> is firmly fixed by the resin 10a on the first main surface <NUM> side and the resin supporting portions 10b on the second main surface <NUM> side between which the circuit sheet <NUM> is sandwiched.

The recessed portions 15a and 15b illustrated in <FIG> are recesses formed when the first protruding portion <NUM> and the second protruding portion <NUM> illustrated in <FIG> come off. As illustrated in <FIG>, the gap In1 is provided between the circuit sheet <NUM> and the first protruding portion <NUM>. The gap In2 is provided between the circuit sheet <NUM> and the second protruding portion <NUM>. To prevent the set circuit sheet <NUM> from falling off from the first mold <NUM>, one or more air suction holes may be provided at any portion of the plateau portion <NUM>. When the molten resin also enters the gaps In1 and In2 to form the resin side walls 10c and 10d outside the first end side <NUM> and the second end side 20n of the circuit sheet <NUM>, the fixation of the circuit sheet <NUM> is strengthened by the side walls 10c and 10d.

As illustrated in <FIG>, the case in which the first protruding portion <NUM> and the second protruding portion <NUM> of the second embodiment are higher than the height of the end surface (the end surface including the first end side <NUM> and the second end side 20n) of the circuit sheet <NUM> has been described. However, when the air suction hole <NUM> is provided, it becomes possible to firmly suck and hold the circuit sheet <NUM>, the first protruding portion <NUM> and the second protruding portion <NUM> may be formed as illustrated in <FIG>. The heights of the first protruding portion <NUM> and the second protruding portion <NUM> illustrated in <FIG> are the same as the height of the end surface (the end surface including the first end side <NUM> and the second end side 20n) of the circuit sheet <NUM>. <FIG> illustrates the cross-sectional shape of the molded article <NUM> corresponding to the portion illustrated in <FIG>.

As illustrated in <FIG> of the first embodiment, in the second portion Pa2 in the first mold <NUM>, the first region AR1 of the second main surface <NUM> of the circuit sheet <NUM> is supported to the plateau portion <NUM> of the first mold <NUM>. However, in the second portion Pa2 of the first mold <NUM>, the first mold <NUM> configured such that the circuit sheet <NUM> is not supported by the plateau portion <NUM> may be used.

With reference to <FIG>, <FIG>, <FIG>, and <FIG>, the configuration of the first mold <NUM> configured such that the circuit sheet <NUM> is not supported by the plateau portion <NUM> will be described. The molded article <NUM> molded with the first mold <NUM> and the second mold <NUM> illustrated in <FIG> will be described with reference to <FIG>, <FIG>, and <FIG>.

The setting of the circuit sheet <NUM> to the first mold <NUM> in Step S1 (first step) of <FIG> will be described in more detail. <FIG> and <FIG> illustrate a part of the enlarged first mold <NUM> illustrated in <FIG>. In <FIG>, the core surface CF of the first mold <NUM> and the circuit sheet <NUM> constituting the antenna <NUM> set on the core surface CF are enlarged. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XIV-XIV in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XV-XV in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XVI-XVI in <FIG>.

As illustrated in <FIG>, the first mold <NUM> has the plateau portion <NUM> on the core surface CF. However, as illustrated in <FIG>, the first mold <NUM> does not include the plateau portion <NUM> in the second portion Pa2, and thus the circuit sheet <NUM> is not supported. The second portion Pa2 is a portion that divides the plateau portion <NUM>. In other words, the plateau portion <NUM> is divided by the second portion Pa2. Further, it can be reworded that the plateau portion <NUM> has the two divided portions of the plateau portions <NUM> on both sides of the second portion Pa.

In <FIG>, hatching indicating the cross section of the first mold <NUM> is omitted to avoid the drawings being difficult to be seen. In the first portion Pa1 of the first mold <NUM>, a part of the second main surface <NUM> of the circuit sheet <NUM> is in contact with the plateau portion <NUM>. A part of the second main surface <NUM> in contact with the plateau portion <NUM> is the first region AR1. In the second portion Pa2 of the first mold <NUM>, a part of the second main surface <NUM> of the circuit sheet <NUM> is not in contact with the plateau portion <NUM>. A part of the second main surface <NUM> not in contact with the plateau portion <NUM> is the second region AR2. As can be seen from <FIG>, the circuit sheet <NUM> is laid across the divided portions of the plateau portions <NUM> adjacent to one another so as not to contact the first mold <NUM> in the second portion Pa2. In other words, the circuit sheet <NUM> is in a state of floating in the second portion Pa2 in the cavity Cv.

The first protruding portion <NUM> and the second protruding portion <NUM> are provided along the plateau portion <NUM>. As illustrated in <FIG>, in the first portion Pa1, a groove portion is not formed between the first protruding portion <NUM> and the plateau portion <NUM> or between the second protruding portion <NUM> and the plateau portion <NUM>. As illustrated in <FIG>, the third protruding portion <NUM> is provided at one end portion of the plateau portion <NUM>. As illustrated in <FIG>, in the state where the circuit sheet <NUM> is set in the first mold <NUM>, the lead portion 20b of the circuit sheet <NUM> is inserted into the opening <NUM>, the slit <NUM>, and the accommodating portion <NUM>. The tapered portion <NUM> extending from the opening <NUM> to the slit <NUM> is provided to easily guide the lead portion 20b to the slit <NUM>.

In Step S2 (second step) of <FIG>, as illustrated in <FIG>, the first mold <NUM> and the second mold <NUM> are clamped such that the circuit sheet <NUM> is not in contact with the second mold <NUM>. In Step S3 (third step) of <FIG>, the molten resin is injected into the cavity Cv, and comes into contact with the first main surface <NUM> and the second regions AR2 of the second main surface <NUM> of the circuit sheet <NUM>. Further, in Step S4 (fourth step), the molten resin is cooled and solidified to form the molded article <NUM> made of resin having the outer surface <NUM> opposed to the first main surface <NUM> of the circuit sheet <NUM> and the inner surface <NUM> opposed to the second regions AR2 of the second main surface <NUM> (see <FIG>). In Step S5 (fifth step), the first mold <NUM> and the second mold <NUM> are opened to take out the molded article <NUM>.

As illustrated in <FIG>, the molded article <NUM> molded using the antenna <NUM> set in the first mold <NUM> and the second mold <NUM> is illustrated in <FIG>, <FIG>, and <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line XVII-XVII in <FIG>. <FIG> illustrate an enlarged cross-sectional shape of the molded articles <NUM> cut along the line XVIII-XVIII in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line XIX-XIX in <FIG>.

Neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM> on the second portion Pa2 of the first mold <NUM>. Further, the plateau portion <NUM> is not provided on the second portion Pa2. Therefore, as illustrated in <FIG>, in the second portion Pa2 where the plateau portion <NUM>, the first protruding portion <NUM>, or the second protruding portion <NUM> is not provided, the resin 10a and the resin supporting portion 10b of the molded body <NUM> are arranged so as to surround the first main surface <NUM> and the second main surface <NUM> of the circuit sheet <NUM>. <FIG> differ in the shape of the resin supporting portion 10b in contact with the second main surface <NUM> of the circuit sheet <NUM>. The difference in the state of the resin supporting portion 10b is caused by, for example, a difference in the timing and the flow rate at which the injection-molded molten resin enters from both sides of the second region AR2. When the molten resin flowing from one side of the circuit sheet <NUM> and the molten resin flowing from the other side are joined together, the resin supporting portion 10b connected from one side to the other side of the circuit sheet <NUM> on the second main surface <NUM> side is formed (see <FIG>). Further, when the injection is finished before the molten resins flowing from both sides of the circuit sheet <NUM> are joined together, the resin remains to be not filled in the vicinity of the center as illustrated in <FIG>. Since the circuit sheet <NUM> is sandwiched between the resin supporting portions 10b in contact with the second regions AR2 of the second main surface <NUM> and the resin 10a in contact with the first main surface <NUM> opposed to the second regions AR2, the circuit sheet <NUM> is firmly fixed by the resin 10a on the first main surface <NUM> side and the resin supporting portions 10b on the second main surface <NUM> side between which the circuit sheet <NUM> is sandwiched.

The recessed portions 15a and 15b illustrated in <FIG> are recesses formed when the first protruding portion <NUM> and the second protruding portion <NUM> illustrated in <FIG> come off. As illustrated in <FIG>, the gap In1 is provided between the circuit sheet <NUM> and the first protruding portion <NUM>. Similarly, the gap In2 is provided between the circuit sheet <NUM> and the second protruding portion <NUM>. The molten resin also enters the gaps In1 and In2 to arrange the resin side walls 10c and 10d outside the first end side <NUM> and the second end side 20n of the circuit sheet <NUM>. The side walls 10c and 10d arranged on both sides of the circuit sheet <NUM> strengthen the fixation of the circuit sheet <NUM>. As illustrated in <FIG>, the resin does not bond to the connecting portion 20c of the circuit sheet <NUM>. The portions denoted by the same reference numerals as the reference numerals illustrated in <FIG> have the same configurations as the portions with the same reference numerals in <FIG>, and thus description thereof will be omitted. After molding the molded article <NUM>, the connecting portion 20c made of a metal sheet may be deformed into a shape suitable for electrical connection by, for example, press working.

In the first portion Pa1 of the first mold <NUM> illustrated in <FIG> of the embodiment and <FIG> of Modification Example A, the first protruding portion <NUM> and the second protruding portion <NUM> are provided along the plateau portion <NUM>. However, the first protruding portion <NUM> or the second protruding portion <NUM> may be provided on one side of the plateau portion <NUM> in the first portion Pa1 of the first mold <NUM>. It is only necessary that the first protruding portion <NUM> or the second protruding portion <NUM> is provided at any position, and the first protruding portion <NUM> and the second protruding portion <NUM> need not be provided regularly.

<FIG>, <FIG> illustrate the configuration of the first mold <NUM> in which the first protruding portion <NUM> or the second protruding portion <NUM> is provided on one side of the plateau portion <NUM>. <FIG>, <FIG> illustrate the molded article <NUM> molded with the first mold <NUM> and the second mold <NUM> illustrated in <FIG>.

In <FIG>, the core surface CF of the first mold <NUM> and the circuit sheet <NUM> constituting the antenna <NUM> set on the core surface CF are enlarged. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XX-XX in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XXI-XXI in <FIG>.

Among the configurations illustrated in <FIG>, the same configurations as those illustrated in <FIG> are denoted by the same reference numerals, and description thereof is omitted. As illustrated in <FIG>, the first protruding portions <NUM> and the second protruding portions <NUM> are alternately arranged so as not to be opposed to one another. As can be seen from the comparison between <FIG> and <FIG>, in the first portion Pa1, the first protruding portion <NUM> is arranged on one side of the plateau portion <NUM> of Modification Example B, and the second protruding portion <NUM> is not arranged on the opposite side. In the second portion Pa2, the configuration of <FIG> is the same as the configuration of <FIG>. <FIG>, <FIG> illustrate the molded article <NUM> molded using the antenna <NUM> set in the first mold <NUM> and the second mold <NUM> is illustrated in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line XXII-XXII in <FIG>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line XXIII-XXIII in <FIG>.

Among the configurations illustrated in <FIG>, the same configurations as those illustrated in <FIG> are denoted by the same reference numerals, and description thereof is omitted. As illustrated in <FIG>, the recessed portions 15a and the recessed portions 15b are alternately arranged so as not to be opposed to one another. In Modification Example B, the ribs 16a and the ribs 16b are also alternately arranged so as not to be opposed to one another. As can be seen from the comparison between <FIG> and <FIG>, in the first portion Pa1, the rib 16a is arranged on one side of the circuit sheet <NUM> of Modification Example B, and the rib 16b is not arranged on the portion corresponding to the rib 16a on the opposite side of the circuit sheet <NUM>. In the second portion Pa2, the configuration of <FIG> is the same as the configuration of <FIG>.

In Modification Example B, the case in which the groove portions <NUM> and <NUM> are provided has been described. However, in the first mold <NUM> of Modification Example B, it may be configured such that the groove portion <NUM> or <NUM> is not formed.

In the embodiment, Modification Example A, and Modification Example B, the case in which the lead portion 20b of the circuit sheet <NUM> is bent toward the inner surface <NUM> side of the molded body <NUM> and the connecting portion 20c is drawn out of the molded body <NUM> has been described. However, the connecting portion 20c of the circuit sheet <NUM> may be arranged in the molded body <NUM>. <FIG> illustrates the cross section of the first mold <NUM> and the second mold <NUM> when the connecting portion 20c is arranged in the molded body <NUM>. In Modification Example C, the connecting portion 20c is arranged in contact with the plateau portion <NUM>. By injecting the molten resin into the cavity Cv of the first mold <NUM> and the second mold <NUM> as in <FIG>, as illustrated in <FIG>, an inner surface exposed portion <NUM> can be formed at any portion of the connecting portion 20c arranged on the inner surface <NUM> side of the molded body <NUM>. For electrical connection with the circuit sheet <NUM> having the inner surface exposed portion <NUM>, electrical connection can be performed by, for example, bringing a pogo pin or a leaf spring terminal installed on a mating substrate into contact with the inner surface exposed portion <NUM>, or a flexible terminal member may be connected with a conductive adhesive or solder as necessary.

In the embodiment and Modification Examples A to C, a movable portion is not provided in the first mold <NUM> or the second mold <NUM>, but the movable portion may be provided in at least one of the first mold <NUM> and the second mold <NUM>. For example, a sliding block connected to a hydraulic or pneumatic cylinder and can be driven at any timing even during clamping may be provided at a position where the high-function electronic component <NUM> illustrated in <FIG> is arranged.

<FIG> illustrate an enlarged cross-sectional shape of the first mold <NUM> and the second mold <NUM> in the clamped state and the circuit sheet <NUM> cut along the line XXIV-XXIV in <FIG>. <FIG> illustrates a state in which a sliding block <NUM> is pressed against the second mold <NUM>. <FIG>illustrates a state in which the sliding block <NUM> is separated from the second mold <NUM>. <FIG> illustrates an enlarged cross-sectional shape of the molded article <NUM> cut along the line XXIV-XXIV in <FIG>.

As illustrated in <FIG>, the first protruding portion <NUM> and the second protruding portion <NUM> of the first mold <NUM> and the plateau portion <NUM> are formed on the sliding block <NUM>. In Step S3 (third step) of <FIG> after the clamping, as illustrated in <FIG>, molten resin MR is injected before the sliding block <NUM> is moved backward. At this time, the second main surface <NUM> of the circuit sheet <NUM> is in contact with the plateau portion <NUM> of the first mold <NUM>. In the first portion Pa1 of the first mold <NUM>, since the circuit sheet <NUM> is located between the first protruding portion <NUM> and the second protruding portion <NUM> during injection in <FIG>, the circuit sheet <NUM> is less likely to be displaced even when receiving a force from the molten resins MR.

When the molten resin MR injected when the sliding block <NUM> is in the state illustrated in <FIG> becomes solidified, the sliding block <NUM> moves. When the sliding block <NUM> is moved to the position illustrated in <FIG>, the cavity Cv is formed in the place where the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM> were present before the movement of the sliding block <NUM>. <FIG> illustrates a state in which the molten resin has been injected into the cavity Cv formed by the movement of the sliding block <NUM>.

Before the sliding block <NUM> is slid, displacement of the circuit sheet <NUM> during injection molding is suppressed with the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM>. After the sliding block <NUM> is slid, the molten resin enters the place where the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM> were present before the sliding. As a result, the high-function electronic component <NUM> is enclosed and embedded in the molded body <NUM>.

Although <FIG> illustrate only one set of the first protruding portion <NUM> and the second protruding portion <NUM>, a plurality of the first protruding portions <NUM> and a plurality of the second protruding portions <NUM> may be formed on the sliding block <NUM>. In addition, the plateau portion <NUM> formed on the sliding block <NUM> is not limited to the plateau portion <NUM> between a pair of the first protruding portion <NUM> and the second protruding portion <NUM>. For example, the plateau portion <NUM> may be formed between a plurality of pairs of the first protruding portions <NUM> and the second protruding portions <NUM> on the sliding block <NUM>. In addition, the plateau portion <NUM> of the second portion Pa2 of the first mold <NUM> may be formed on the sliding block <NUM>.

As illustrated in <FIG>, the circuit sheet <NUM> may be inserted into a position lower than the core surface CF. <FIG> illustrate the molded article <NUM> molded by inserting the circuit sheet <NUM> into the position lower than the core surface CF. Note that portions of respective components of Modification Example E corresponding to the respective components of the embodiment are denoted by the same reference numerals, and description thereof is omitted. The heights of the first protruding portion <NUM> and the second protruding portion <NUM> illustrated in <FIG> are the same as the height of the core surface CF. As illustrated in <FIG>, only the ribs 16a and 16b (resin supporting portions 10b) support the circuit sheet <NUM>.

In the embodiment, the case where the decorative layer <NUM> is provided by transfer has been described, but the decorative layer may be provided by insert molding of a decorative film. Further, the decorative layer <NUM> need not be formed in the molded article <NUM>.

(<NUM>-<NUM>)
In the methods for manufacturing the molded articles <NUM> according to the embodiment and the modification examples, in Step S1 (first step) depicted in <FIG>, for example, as illustrated in <FIG>, a first fixed portion of the circuit sheet <NUM> is arranged in the first portion Pa1 of the first mold <NUM>. Further, in Step S1 of <FIG>, for example, as illustrated in <FIG>, a second fixed portion of the circuit sheet <NUM> including the second region AR2 of the circuit sheet <NUM> is arranged in the second portion Pa2 of the first mold <NUM>. The first fixed portion of the circuit sheet <NUM> is mainly a portion where the first main surface <NUM> is fixed, and is, for example, a portion along at least one of the recessed portions 15a and 15b as illustrated in <FIG>. On the other hand, the second fixed portion of the circuit sheet <NUM> is a portion where the first main surface <NUM> and the second main surface <NUM> are sandwiched and fixed by resins, and is a portion not along the recessed portion 15a or 15b as illustrated in <FIG>, for example. The first fixed portion of the circuit sheet <NUM> is the portion illustrated in <FIG>, <FIG>, or <FIG>, and the second fixed portion of the circuit sheet <NUM> is the portion illustrated in <FIG>, <FIG>, or <FIG>. At least a part of the first fixed portion of the circuit sheet <NUM> is arranged to be in contact with the plateau portion <NUM>.

As described above, the molded article <NUM> including the circuit sheet <NUM> inserted into the resin can be manufactured by injecting the molten resin from the clamping of the first mold <NUM> and the second mold <NUM> until opening the molds. The molded article <NUM> including the circuit sheet <NUM> can be manufactured with one set of the first mold <NUM> and the second mold <NUM>, and it is not necessary to use a plurality of assembled molds as in the conventional one, and thus it is possible to reduce the cost required for the molds. In addition, since it is not necessary to replace the mold and perform injection of molten resin by a plurality of times as in the conventional one, it is possible to reduce the time required for manufacturing one molded article <NUM> and to reduce the manufacturing cost.

In other words, the molded article <NUM> in which the circuit sheet <NUM> is fixed to the inside of the molded body <NUM> can be manufactured by one-time molding instead of two color molding, and the cost advantage is large. In addition, even when the molded body <NUM> has a curved shape, the circuit sheet <NUM> can be fixed to the inside of the molded body <NUM> by one molding.

Even when an adhesive layer having adhesiveness with molded resin is not provided in the circuit sheet <NUM>, by the first main surface <NUM> and the second main surface <NUM> of the circuit sheet <NUM> being partially sandwiched between the molded resins, the circuit sheet <NUM> inserted into the molded body <NUM> can be fixed. Therefore, a material having extremely poor adhesiveness can be used for the base substrate <NUM> of the circuit sheet <NUM> and the molding resin.

In a case where the injection-molded resin shrinks in volume in the cooling process and the circuit sheet <NUM> hardly changes, when the circuit sheet <NUM> is firmly bonded by using an adhesive, deformation, such as warping or twisting of the molded body <NUM>, occurs. At this time, since an internal stress against the contraction of the molding resin is generated in the circuit sheet <NUM>, there is a case where the circuit sheet <NUM> is peeled off due to a change in environment, such as temperature and humidity, or an impact from the outside. However, in a case where an adhesive is not used, such a problem can be suppressed.

In the first mold <NUM>, the first protruding portions <NUM>, the second protruding portions <NUM>, and the third protruding portion <NUM> are dividedly provided according to the planar shape of the circuit sheet <NUM> such that the circuit sheet <NUM> can be set at a predetermined position. Therefore, the circuit sheet <NUM> can be inserted and fixed at the predetermined position of the molded body <NUM> with high accuracy. When the air suction holes are further provided, the circuit sheet <NUM> can be fixed at the predetermined position of the molded body <NUM> after molding with further high accuracy by the effect of air suction. Although the case where the circuit sheet <NUM> has the planar shape is described here, the circuit sheet <NUM> may have a three-dimensional shape other than the planar shape. For example, the circuit sheet <NUM> may be curved. Even in such a case, in the first mold <NUM>, the first protruding portions <NUM>, the second protruding portions <NUM>, and the third protruding portion <NUM> only need to be dividedly provided in accordance with the surface shape of the circuit sheet <NUM> such that the circuit sheet <NUM> can be set at the predetermined position.

For example, as illustrated in <FIG>, <FIG>, the molded article <NUM> has a plurality of the resin supporting portions 10b extending from the periphery of the circuit sheet <NUM> while being in contact with the second main surface <NUM> over an entirety of the periphery of the circuit sheet <NUM>. The molded article <NUM> has a plurality of the recessed portions 15a, 15b, and 15c arranged around the circuit sheet <NUM> over the entirety of the periphery of the circuit sheet <NUM>. The plurality of resin supporting portions 10b and the plurality of recessed portions 15a, 15b, and 15c are arranged such that the resin supporting portions and the recessed portions are alternately arranged along the periphery of the circuit sheet <NUM>. In the molded article <NUM>, the first protruding portion <NUM>, the second protruding portion <NUM>, and the third protruding portion <NUM> formed in the first mold <NUM> for forming the recessed portions 15a, 15b, and 15c serve as breakwaters for preventing the molten resin from directly contacting the end surface of the circuit sheet <NUM> during manufacturing, and the molten resin flows into the groove portions <NUM> and <NUM> in a state of a pressure is dispersed and relaxed to form the resin supporting portions 10b. This reduces the displacement of the circuit sheet <NUM> in the molded body <NUM>, and therefore the molded article with high accuracy of the arrangement position of the circuit sheet <NUM> can be provided.

(<NUM>-<NUM>)
For example, the second portion Pa2 of the first mold <NUM> described with reference to <FIG> and <FIG> is a portion in which the width of the plateau portion <NUM> is narrower than the width of the circuit sheet <NUM>. As can be seen from <FIG>, in the configuration of the plateau portion <NUM> in this case, since the central portion of the plateau portion <NUM> is not divided, there is no portion that is deformed toward the second main surface <NUM> side by the pressure of the molten resin applied to the first main surface <NUM> of the circuit sheet <NUM>. Therefore, in the manufacturing method using the first mold <NUM>, the structure of the molded article <NUM> is simplified, and the molded article <NUM> is easily manufactured.

(<NUM>-<NUM>)
For example, the second portion Pa2 of the first mold <NUM> described with reference to <FIG> is a portion that divides the plateau portion <NUM>. In Step S1 of <FIG>, the circuit sheet <NUM> is laid across the divided portions of the plateau portions <NUM> adjacent to one another so as not to contact the first mold <NUM> in the second portion Pa2. In other words, the circuit sheet <NUM> is in a state of floating in the second portion Pa2. Therefore, in the second portion Pa2 of the first mold <NUM>, the molten resin enters between the first mold <NUM> and the circuit sheet <NUM>. As a result, as illustrated in <FIG>, the resin supporting portions 10b becomes large, and the circuit sheet <NUM> is firmly fixed in the molded article <NUM> by the large resin supporting portions 10b.

(<NUM>-<NUM>)
For example, in the first portion Pa1 of the first mold <NUM> described with reference to <FIG>, the groove portions <NUM> and <NUM> are formed between the first protruding portion <NUM> and the second protruding portion <NUM> and the plateau portion <NUM>. The molten resin enters the groove portions <NUM> and <NUM> to the first mold <NUM>. Accordingly, as described with reference to <FIG>, the ribs 16a and 16b are formed, and it is possible to increase the thicknesses of the resin supporting portions 10b in contact with the second regions AR2 of the circuit sheet <NUM> on both sides of the plateau portion <NUM>. The thickened resins (for example, the ribs 16a and 16b) can improve the strength of the resins for fixing the circuit sheet <NUM>.

(<NUM>-<NUM>)
For example, in the first mold <NUM> described with reference to <FIG>, the gaps In1 and In2 are formed between the first protruding portion <NUM> and the first end side <NUM> of the circuit sheet <NUM> and between the second protruding portion <NUM> and the second end side 20n of the circuit sheet <NUM>. Therefore, the molten resins possibly enter between the gaps In1 and In2, and in this case, the support by the resins is strengthened at the end sides of the circuit sheet <NUM>.

(<NUM>-<NUM>)
For example, in the first mold <NUM> described with reference to <FIG>, the accommodating portion <NUM> into which the lead portion 20b of the circuit sheet <NUM> is inserted is formed. In Step S1 (first step) of <FIG>, the lead portion 20b of the circuit sheet <NUM> is accommodated in the accommodating portion <NUM> of the first mold <NUM>. In the molded article <NUM> manufactured in this way, as illustrated in <FIG>, the lead portion 20b of the circuit sheet <NUM> is drawn out to the inner surface <NUM> side of the molded article <NUM>. As a result, it is possible to obtain the molded article <NUM> in which while the circuit sheet <NUM> is inserted into the molded body <NUM>, the electrical connection between the circuit sheet <NUM> and a device outside the molded body <NUM> is easy.

(<NUM>-<NUM>)
For example, in the first mold <NUM> illustrated in <FIG>, a plurality of sets of the first protruding portions <NUM> and the second protruding portions <NUM> are provided. In Step S1 (first step) of <FIG>, the circuit sheets <NUM> are arranged between all of the plurality of pairs of the FIRST protruding portions <NUM> and the second protruding portions <NUM>. The plurality of sets of the first protruding portions <NUM> and the second protruding portions <NUM> make it difficult for the circuit sheets <NUM> to be displaced with respect to the first mold <NUM> when the molten resin is injected. By providing a plurality of sets of the first protruding portions <NUM> and the second protruding portions <NUM> in this manner, it is possible to suppress the circuit sheet <NUM> becoming largely displaced with respect to the first mold <NUM> and the molded article <NUM> becoming a defective product.

In particular, when the circuit sheet <NUM> is sucked and held by air suction, it is possible to reliably prevent the inserted circuit sheet <NUM> from being peeled off and fallen from the first mold <NUM>, to further reduce sheet displacement of the sheet of the circuit sheet <NUM>, and to fix the circuit sheet <NUM> at a predetermined position of the molded body <NUM> with high accuracy.

Further, when the injection molding resin shrinks in volume in the cooling process and the circuit sheet <NUM> hardly changes, the circuit sheet <NUM> is warped by an amount corresponding to the amount of resin shrinkage. In the above-described method for manufacturing the molded article <NUM>, the circuit sheet <NUM> is fixed at the large number of portions and the fixed portions are configured to be small areas as much as possible, and thus deformation of the circuit sheet <NUM> due to the warp can be uniformly dispersed.

(<NUM>-<NUM>)
In the first mold <NUM> described with reference to <FIG>, the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM> are formed on the sliding block <NUM>. By using the first mold <NUM> configured as described above, before the sliding block <NUM> is slid, the displacement of the circuit sheet <NUM> during injection molding can be suppressed with the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM>. In addition, after the sliding block <NUM> is slid, the cavity Cv spreads and the molten resin enters the place where the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM> were present before the sliding. For example, as illustrated in <FIG>, the fixation of the circuit sheet <NUM> in the molded article <NUM> is strengthened with the resin entering the place where the first protruding portion <NUM>, the second protruding portion <NUM>, and the plateau portion <NUM> were present.

(<NUM>-<NUM>)
For example, the second portion Pa2 of the first mold <NUM> described with reference to <FIG> has the configuration in which neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM>. When the manufacturing is performed using the first mold <NUM> in which neither the first protruding portion <NUM> nor the second protruding portion <NUM> is provided along the plateau portion <NUM>, in the second portion Pa2, the recessed portion caused by the first protruding portion <NUM> or the second protruding portion <NUM> is not formed outside the second region AR2 of the circuit sheet <NUM>. Therefore, the strength of the portion where the circuit sheet <NUM> is sandwiched between the resin supporting portions 10b in contact with the second regions AR2 and the resin 10a in contact with the first main surface <NUM> opposed to the second region AR2 is higher than that of the portion where the recessed portions are formed. As a result, the circuit sheet <NUM> is firmly fixed with the resins 10a on the first main surface <NUM> side and the resin supporting portion 10b on the second main surface <NUM> side between which the circuit sheet <NUM> is sandwiched.

Claim 1:
A method for manufacturing a molded article (<NUM>), comprising:
setting a circuit sheet (<NUM>) including a first main surface (<NUM>), a second main surface (<NUM>) opposed to the first main surface (<NUM>), and a conductive pattern in a first mold (<NUM>) such that a first region (AR1) of the second main surface (<NUM>) contacts a plateau portion (<NUM>) of the first mold (<NUM>) and a second region (AR2) of the second main surface (<NUM>) does not contact the first mold (<NUM>);
clamping a second mold (<NUM>) to the first mold (<NUM>) such that the circuit sheet (<NUM>) does not contact the second mold (<NUM>) to form a cavity (Cv) where the first main surface (<NUM>) and the second region (AR2) of the second main surface (<NUM>) of the circuit sheet (<NUM>) are exposed;
introducing a molten material into the cavity (Cv) to bring the molten material into contact with the first main surface (<NUM>) and the second region (AR2) of the second main surface (<NUM>) of the circuit sheet (<NUM>);
cooling and solidifying the molten material to form a molded body (<NUM>) made of resin having an outer surface (<NUM>) opposed to the first main surface (<NUM>) and an inner surface (<NUM>) opposed to the second region (AR2) of the second main surface (<NUM>) of the circuit sheet (<NUM>); and
opening the first mold (<NUM>) and the second mold (<NUM>) to take out the molded article (<NUM>), wherein
in the setting, a first fixed portion of the circuit sheet (<NUM>) is arranged in a first portion (Pa1) of the first mold (<NUM>), and a second fixed portion of the circuit sheet (<NUM>) including the second region (AR2) is arranged in a second portion (Pa2) of the first mold (<NUM>),
the first portion (Pa1) is a portion along at least one of a first protruding portion (<NUM>) and a second protruding portion (<NUM>) that are higher than the plateau portion (<NUM>) and are provided along the plateau portion (<NUM>) of the first mold (<NUM>), and
the second portion (Pa2) is a portion in which neither the first protruding portion (<NUM>) nor the second protruding portion (<NUM>) is provided along the plateau portion (<NUM>).