JP2003103996A - Irregular transfer sheet, irregular sheet with transparent window part, manufacturing method therefor, and method for manufacturing decorative molded product with irregular face - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an irregular transfer sheet and an irregular sheet with a transparent window part which not only have irregularities formed with a feeling of a mechanically formed hairline but also a transparent window part of a flat face formed at an optional spot by softening a thermoplastic resin and a method for manufacturing the described sheets and a method for manufacturing a decorative molded product having an irregular face. SOLUTION: A translucent thermoplastic resin layer 4 is formed so that at least the irregularities 3 of a part 2 scheduled for forming a transparent window part among the other irregularities 3 of a base sheet 1 with irregularities 3 formed entirely on one of the sides, are levelled off by plugging with the layer 4. Further, a curable resin layer 5 is formed so that the irregularities 3 of a part other than the part 2 scheduled for forming a transparent window part are levelled off by plugging with the layer 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a concavo-convex transfer sheet which is a material for decorating the surface of mobile phone parts, electric appliance parts, automobile interior parts, etc., a concavo-convex sheet having a transparent window and a method for manufacturing the same. The present invention relates to a method for manufacturing a decorative molded product having an uneven surface.

[0002]

2. Description of the Related Art An adhesive layer of an uneven transfer sheet in which unevenness is formed on one entire surface of a base sheet, a thermoplastic resin layer is formed on the entire surface so as to fill the unevenness, and an adhesive layer is formed on the thermoplastic resin layer. Is attached to a translucent sheet that can be deformed into a three-dimensional shape, the base sheet of the uneven transfer sheet is peeled off, and there is an uneven sheet in which unevenness such as a hairline pattern is formed on the surface of the thermoplastic resin layer. . The unevenness is
There are (1) those in which a hairline pattern or the like is mechanically formed, and (2) those in which an uneven pattern is formed by a printed layer.

[0003]

However, the uneven sheet has the following problems.

In (1), since the unevenness of the hairline pattern is mechanically scratched and formed by a nail such as a metal, the unevenness of the hairline pattern is formed even in an unnecessary portion of the unevenness. It is not possible to control the part where is formed.

In (2), since the unevenness of the hairline pattern is formed by the printing layer, it is not possible to reproduce the texture that is mechanically scratched by the nail.

Further, in any of the above-mentioned concavo-convex sheets, since the concavities and convexities copied from the base sheet are all formed by the thermoplastic resin layer, the concavo-convex sheet is heated by the heating when deforming the concavo-convex sheet into a three-dimensional shape. The thermoplastic resin layer is softened, the sharpness of the hairline pattern is halved, and all surface irregularities disappear.

[0007]

A concavo-convex transfer sheet of the present invention is a translucent thermoplastic resin so as to fill at least concavo-convex portions of a base sheet having concavities and convexities on one side thereof at least in a portion where a transparent window is to be formed. The layer is formed, and the curable resin layer is formed so as to fill the irregularities other than the portion where the transparent window is to be formed.

Further, according to the method of manufacturing a concavo-convex sheet having a transparent window portion of the present invention, the surface of the concavo-convex transfer sheet opposite to the base sheet is adhered to a translucent sheet which can be deformed into a three-dimensional shape. The base sheet is peeled off, and the uneven sheet having unevenness formed on the surfaces of the thermoplastic resin layer and the curable resin layer is deformed into a three-dimensional shape by heating, and the unevenness of the thermoplastic resin layer of the uneven sheet is eliminated. It is characterized in that a transparent window portion having a flat surface is formed.

The method of deforming the concavo-convex sheet into the three-dimensional shape in the above manufacturing method is vacuum forming or pressure forming, the surface temperature of the concavo-convex sheet before deformation is T ° C., and the Tg of the resin forming the thermoplastic resin layer is Tg. (Glass transition point) Tg
When 1, the relational expression of Tg1 ≦ T ≦ 200 ° C. may be satisfied.

In the above manufacturing method, the translucent sheet that can be deformed into a three-dimensional shape is a thermoplastic resin sheet that is compatible with the injection molding resin, and the method of adhering the uneven transfer sheet is the thermal laminating method. May be.

The concavo-convex sheet having the transparent window portion of the present invention is formed by arranging the concavo-convex surface of the curable resin layer and the flat surface of the thermoplastic resin layer side by side on the translucent sheet transformed into a three-dimensional shape. It is characterized by

The method for producing a decorative molded article having an uneven surface according to the present invention is characterized in that the uneven sheet having the transparent window portion is put into a mold for injection molding and integrally bonded with a molding resin.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION First, the uneven transfer sheet of the present invention will be described (see FIG. 1).

The concavo-convex transfer sheet of the present invention has a translucent thermoplastic resin layer so as to fill at least the concavo-convex 3 of the transparent window portion formation planned portion 2 among the concavo-convex 3 of the base sheet 1 having the concavo-convex 3 on one entire surface. 4 is formed, and the curable resin layer 5 is formed so as to fill up the irregularities 3 other than the portion where the transparent window is to be formed.
Are formed.

As the pattern of the unevenness 3, there are embossed patterns such as a hairline pattern, a pear-skin pattern, a stone pattern, and a grain pattern. The pattern of the unevenness 3 may be partially formed on the base sheet 1.
For example, there are patterns such as partial hairlines and partial mats. The depth of the unevenness 3 can be 2 to 10 μm. In order to balance the ease of disappearance of the irregularities formed in the translucent thermoplastic resin layer 4 and the ease of recognizing the hairline pattern or the like due to the irregularities formed in the curable resin layer 5. , The depth of the unevenness 3 is 3 to
It is preferably set to 5 μm.

As the method for forming the unevenness 3, a hairline method of mechanically rubbing sandpaper, a metal brush, a non-woven fabric or the like on the surface of the base sheet 1, or an embossing roll and an impression cylinder having unevenness formed on the plate cylinder surface. There is an emboss roll method in which the base sheet 1 is sandwiched between the roll and the like.

When it is difficult for the base sheet 1 and the thermoplastic resin layer 4 and the curable resin layer 5 to separate from each other, a release layer may be formed on the surface of the unevenness 3. The release layer can be formed by using an aminoalkyd resin or a melamine resin by offset printing, gravure printing, or the like so as to have a thickness of 1 to 5 μm.

The thermoplastic resin layer 4 is formed so as to fill up the irregularities of the transparent window portion formation planned portion 2. Thermoplastic resin layer 4
May be formed in register with the curable resin layer 5, but may be formed so as to cover the curable resin layer 5 as shown in FIG. (Not shown). The thermoplastic resin layer 4 has translucency. This is because it is formed in the portion 2 where the transparent window portion is to be formed. Translucency includes translucency and transparency colored with a dye. Translucency is the total light transmittance (JIS-K
7105 (1981), item 5.5, "Light ray transmittance and total ray reflectance"), may be 50% or more. The material of the thermoplastic resin layer 4 includes acrylic resin, vinyl resin,
Examples include ethylene vinyl acetate resins. Among them, acrylic resin having transparency, surface strength, and release layer is preferable. The thickness of the thermoplastic resin layer 4 can be 1 to 5 μm. The reason is that the film thickness is the minimum necessary for peeling from the base sheet 1 and transferring the irregularities 3. Tg of resin that constitutes the translucent thermoplastic resin layer 4
The (glass transition point) is from 20 to 110 ° C. The reason is that it is sufficiently softened by heating when it is transformed into a three-dimensional shape. This is because if it is lower than 20 ° C., problems such as blocking are likely to occur, and if it exceeds 110 ° C., it becomes difficult to sufficiently eliminate the unevenness 3 by heating when deforming into a three-dimensional shape. As the method for forming the thermoplastic resin layer 4, an offset printing method, a gravure printing method,
Besides the screen printing method and the flexographic printing method, there are a coating method such as a lip coating method, a reverse coating method and a direct coating method, and a casting method.

The portion 2 for forming the transparent window portion is located in a part of one surface of the base sheet 1. Transparent window part formation planned part 2
Specifically, it is a window portion for a liquid crystal display of a mobile phone, a window portion for a liquid crystal display of a home electric appliance, or a window portion of a heater control panel of an interior part for an automobile.

The curable resin layer 5 is formed so as to fill up the irregularities other than the portion where the transparent window is to be formed. The curable resin layer 5 is
It may be formed so as to be covered with the thermoplastic resin layer 4 as shown in FIG. 1, or may be formed so as to cover the thermoplastic resin layer 4 (not shown). Examples of the material of the curable resin layer 5 include a thermosetting resin and an ionizing radiation curable resin layer. As the thermosetting resin, acrylic polyol resin, urethane resin, vinyl resin, epoxy resin,
Examples include phenoxy resin, amino resin, and melamine resin. Among these, acrylic polyol resins are particularly preferable. The reason is that it has both flexibility due to acrylic resin and shape retention due to three-dimensional crosslinking. Examples of the ionizing radiation curable resin include an ultraviolet curable resin and an electron beam curable resin. Examples of the ultraviolet curable resin include cyanoacrylate resin and vinyl ester resin. Examples of electron beam curable resins include acrylic urethane resins. The curable resin layer 5 may be transparent, translucent or opaque. Examples of the method for forming the curable resin layer 5 include an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method, a coating method such as a lip coating method, a reverse coating method, a direct coating method, and a casting method. is there.

The adhesive layer 7 is formed if necessary. The adhesive layer 7 can be formed on the thermoplastic resin layer 4 and / or the curable resin layer 5. The adhesive layer 7 has translucency. This is because it is also formed on the transparent window portion 9. Translucency includes translucency and colored transparency. Examples of the material of the adhesive layer 7 include acrylic resin, vinyl resin, urethane resin, chlorinated polypropylene resin, ethylene vinyl acetate resin. The film thickness can be set to 2 to 5 μm.

The pattern layer 6 is formed if necessary. The picture layer 6 is a layer for expressing characters, figures, symbols, patterns, colors and the like. The pattern layer 6 can be formed by an offset printing method, a gravure printing method, a screen printing method, a flexo printing method, a lip coating method, a reverse coating method,
There are coating methods such as direct coating method and casting method. When the pattern layer 6 is formed in a portion overlapping the thermoplastic resin layer 4, characters or the like will be formed in the transparent window portion 9.
1 to 4, the end portion of the pattern layer 6 and the curable resin layer 5
The edges of the transparent window portion are aligned with each other to form the outline of the transparent window portion. When the curable resin layer 5 is translucent,
The characters and the like on the picture layer 6 can be seen under the unevenness 3 such as the hairline.

Next, a method of manufacturing an uneven sheet having a transparent window portion using the uneven transfer sheet will be described.

In the method for manufacturing an uneven transfer sheet having a transparent window portion according to the present invention, the surface of the uneven transfer sheet opposite to the base sheet is adhered to the translucent sheet 8 which can be deformed into a three-dimensional shape, and the uneven transfer sheet is formed. The base sheet 1 is peeled off (see FIG. 2), and the uneven sheet having unevenness formed on the surfaces of the thermoplastic resin layer 4 and the curable resin layer 5 is deformed into a three-dimensional shape by heating. The unevenness of the resin layer 4 is eliminated to form the transparent window portion 9 having a flat surface.

First, the translucent sheet 8 capable of deforming the surface of the uneven transfer sheet opposite to the base sheet 1 into a three-dimensional shape.
And the base sheet 1 of the uneven transfer sheet is peeled off,
An uneven sheet having unevenness formed on the surfaces of the thermoplastic resin layer 4 and the curable resin layer 5 is obtained (see FIGS. 2 and 3).

Specifically, the so-called transfer method can be used. The transfer method is a base sheet 1 of an uneven transfer sheet.
The base sheet of the concavo-convex transfer sheet is placed so that the opposite surface of the sheet is placed in contact with the translucent sheet 8 which can be deformed into a three-dimensional shape, and the sheet is pressed with a flexible article such as a silicon roll heated from above. 1 is peeled off, and the thermoplastic resin layer 4 and the curable resin layer 5 are transferred to the translucent sheet 8 which can be deformed into a three-dimensional shape. Thermoplastic resin layer 4 and curable resin layer 5
The irregularities 3 formed on the base sheet 1 are copied on the surface of the. The heating temperature of the silicon roll is, for example,
It is 180 to 250 ° C., and the pressure can be 10 to 300 KPa. In the transfer method, as a method of adhering the opposite surface of the base sheet 1 of the uneven transfer sheet to the translucent sheet 8 which can be deformed into a three-dimensional shape, a method other than the method using a silicon roll or the like can be used. There is also a laminating method. The thermal laminating method is a method in which two or more sheets are overlapped and passed between two heated rolls to bond the sheets by thermocompression bonding. According to the heat laminating method, it is possible to adhere more firmly than the above-mentioned transfer method, and it is difficult to peel it off.

As the material of the translucent sheet 8 which can be deformed into a three-dimensional shape, acrylic resin, polycarbonate resin, polyester resin, acrylonitrile-butadiene-styrene resin, polyacrylonitrile resin, polypropylene resin, etc. Good to use. When the uneven sheet having the transparent window portion 9 of the present invention is put into an injection molding die and integrally bonded with a molding resin to produce a decorative molded article having an uneven surface, the translucent sheet 8 is: A material compatible with the molding resin used for injection molding can be used. This is because the adhesive strength between the uneven sheet having the transparent window portion 9 and the molding resin is improved.

Next, the uneven sheet is deformed into a three-dimensional shape by heating (see FIG. 4).

Specific examples of the "three-dimensional shape" include a dish-like shape having a large radius of curvature rising like a mobile phone part, and a gently curved shape like an automobile interior part.

Specific examples of the deformation method include a vacuum forming method, a pressure forming method, and an injection molding simultaneous painting method.

The following method is one example of the vacuum forming method. First, the periphery of a sheet that can be deformed into a three-dimensional shape is fixed to a vacuum forming mold by a clamp material, and the space between the vacuum forming mold and the sheet is sealed so that air does not enter. Heat source such as heater 1
0 heats the sheet for a certain time to soften it. Air between the vacuum forming mold and the sheet is sucked, and the sheet is brought into close contact with the cavity of the vacuum forming mold to be deformed into a desired three-dimensional shape. The heating temperature in this case is 140 to 200 ° C. Considering the material of the thermoplastic resin layer 4 and the depth of the unevenness, 155 to 170 ° C. is particularly preferable.

The following method is an example of the pressure molding method. First, the periphery of a sheet that can be deformed into a three-dimensional shape is fixed with a clamp material. The sheet is heated for a certain period of time by a heat source 10 such as a heater to soften it. Cover the sheet with the air-pressure molding die, push air into the space between the air-pressure molding die and the sheet, apply pressure to the sheet, and bring it into close contact with the cavity surface of the air-pressure molding die to obtain the desired three-dimensional shape. Transform it into a shape. The heating temperature in this case is 80 to 140 ° C. The reason why the heating temperature is lower than that in the vacuum forming method is that atmospheric pressure can be used, so that the required pressure can be obtained without raising the temperature. Considering the material of the thermoplastic resin layer 4 and the depth of the unevenness, 8 is particularly preferable.
It is 0 to 100 ° C.

The following method is an example of the simultaneous injection molding painting method. A sheet that can be deformed into a three-dimensional shape is placed in an injection molding die, the sheet is heated by a heat source 10 such as a heater, and after the mold is closed, a molding resin is injected into a cavity of the injection molding die, It refers to a method of integrally bonding a molded product and an uneven sheet. The uneven sheet is heated before the molding resin is injected. The heating temperature in this case depends on the material of the molding resin, but is 200 to 240 ° C. for an acrylic resin. If it is a polycarbonate resin, the temperature is 250 to 290 ° C.

According to the above-mentioned various methods, in the vacuum forming die, the pressure forming die and the injection forming die, the cavity surface to which the sheet is adhered can be made smooth. The smoothness is a mirror surface with a surface gloss Gs (60 °) = 150 or more. Even if the cavity surface of each mold is smoothed, the required unevenness 3 on the surface of the uneven sheet does not disappear. That is, since the curable resin layer 5 does not plastically deform even when heated, the unevenness 3 is retained. The surface of the translucent thermoplastic resin layer 4 becomes smoother in addition to the disappearance of the unevenness 3 due to heating.

As a result of the above, the uneven surface of the curable resin layer 5 and the flat surface of the transparent thermoplastic resin layer 4 are lined up on the transparent sheet 8 deformed into a three-dimensional shape. Is formed by.

When an ionizing radiation curable resin is used as the material for the curable resin layer 5, the curable resin layer 5 is cured by irradiation with ionizing radiation before the uneven sheet is deformed into a three-dimensional shape. Alternatively, the curable resin layer 5 may be cured by irradiating with ionizing radiation after deforming the uneven sheet into a three-dimensional shape.

The method of deforming the uneven sheet into a three-dimensional shape is vacuum forming or pressure forming, the surface temperature of the uneven sheet before deformation is T ° C., and the resin forming the translucent thermoplastic resin layer 4 is formed. When the Tg (glass transition point) of is Tg1, the relational expression of Tg1 ≦ T ≦ 200 ° C. may be satisfied.

When this condition is satisfied, it is effective in the following points. By setting Tg1 ≦ T, the unevenness 3 formed in the thermoplastic resin layer can be surely softened and the unevenness 3 can be eliminated, and by setting T ≦ 200 ° C., the drawdown becomes intense and the curing becomes difficult. It is possible to prevent the unevenness 3 of the functional resin layer 5 from being deformed, the characters and figures of the pattern layer 6 to be distorted, and the uneven sheet having the transparent window portion 9 to be broken.

The concavo-convex sheet having the transparent window portion 9 of FIG.
On the translucent sheet 8 transformed into a three-dimensional shape, the uneven surface of the curable resin layer 5 and the flat surface of the translucent thermoplastic resin layer 4 (transparent window) with the adhesive layer 7 and the pattern layer 6 interposed therebetween. The part 9) is formed side by side.

[0040]

Example A half vapor deposition plate for an automobile interior having a light transmitting character portion and a hairline was prepared as follows.

A base sheet made of biaxially stretched polyethylene terephthalate having a depth of 3 to 5 μm and hairline-shaped irregularities on one side and a thickness of 25 μm was prepared. A thermoplastic resin layer having a thickness of 2 μm was formed by a gravure printing method using an acrylic resin having a light-transmitting property on a portion where the transparent window portion was to be formed on this base sheet. Tg of thermoplastic resin layer is 93 ° C
Met. A thermosetting resin layer having a thickness of 2 μm was formed by a gravure printing method using a urethane resin so as to cover a portion where the thermoplastic resin layer does not exist. Next, an anchor layer before vapor deposition was printed with a thickness of 3 μm by gravure printing using a urethane resin. Next, an aluminum vapor deposition film having a total light transmittance of 30% is formed by a vacuum vapor deposition method, and vinyl chloride-
A translucent adhesive layer made of a vinyl acetate copolymer resin was formed to a thickness of 5 μm by gravure printing to obtain an uneven transfer sheet.

The uneven transfer sheet having the above-mentioned structure is laminated on a translucent sheet made of a polycarbonate resin having a thickness of 0.3 mm by a thermal laminating method so that the adhesive layer side is adhered, and the base sheet is peeled off to form an uneven surface. It was a sheet. The sheet made of polycarbonate resin is a translucent sheet that can be deformed into a three-dimensional shape.

Next, the surface temperature of this uneven sheet is set to 130.
Pressure molding was performed at 2026 KPa at 0 ° C. and three-dimensional deformation was performed to obtain an uneven sheet having a transparent window portion. At this time, the unevenness on the surface of the translucent thermoplastic resin layer of the uneven sheet disappears due to the heating when the uneven sheet is deformed into a three-dimensional shape, and the transparent window portion having a flat surface is formed, and the curable resin is formed. The surface irregularities of the layer did not disappear.

Next, this uneven sheet having a transparent window portion is punched into a desired shape with a Thomson blade, put into a mold for injection molding, and integrally bonded with a molding resin made of a polycarbonate resin melted at 283 ° C. A molded product was obtained.

The obtained molded article was a molded article having a transparent window portion that emits light due to a backlight and hairlines in other portions, and was excellent in design.

[0046]

Since the present invention is constructed as described above, it has the following operational effects.

The concavo-convex sheet having a transparent window portion of the present invention uses a thermoplastic resin layer and a curable resin layer, and therefore the curable resin layer has a concavo-convex pattern having a mechanically formed hairline texture. Not only is it formed, but also a transparent window portion having a flat surface can be formed at an arbitrary position by softening the thermoplastic resin.

Further, since the unevenness is made of a curable resin, the sharpness of the hairline is halved or all the unevenness on the surface disappears due to heating when the unevenness sheet is deformed into a three-dimensional shape. Since there is no such an unevenness, it is possible to form unevenness with excellent design.

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of an uneven transfer sheet of the present invention.

FIG. 2 is a cross-sectional view showing one step of a method for manufacturing an uneven sheet having a transparent window portion according to the present invention.

FIG. 3 is a cross-sectional view showing one step of a method for manufacturing an uneven sheet having a transparent window portion according to the present invention.

FIG. 4 is a cross-sectional view showing one step of a method for manufacturing a concavo-convex sheet having a transparent window portion according to the present invention.

[Explanation of symbols]

1 Base sheet 2 Plan to form transparent window 3 unevenness 4 Thermoplastic resin layer 5 Curable resin layer 6 picture layers 7 Adhesive layer 8 Translucent sheet 9 Transparent window 10 heat sources

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B29L 9:00 B29L 9:00 F term (reference) 3B005 EA06 EA09 EB01 EB03 EB05 FA04 FA17 FB21 FB39 FD05Z GA06 GB01 GC01 4F206 AD10 AD20 AD26 AG03 AG05 AH26 AR06 JA07 JB13 JB19 JB28 JF05 4F208 AD10 AD20 AD26 AG03 AG05 AH26 AR06 MA01 MA02 MB01 MG04 MG11 MG21 MH06 MK08

Claims (6)

[Claims] 1. A translucent thermoplastic resin layer is formed so as to fill at least the irregularities of a portion to be formed with a transparent window among the irregularities of the base sheet having irregularities on one entire surface, and the transparent window portion is to be formed. A concavo-convex transfer sheet, wherein a curable resin layer is formed so as to fill the concavities and convexities other than the portion. 2. The uneven transfer sheet according to claim 1, the surface opposite to the base sheet is adhered to a translucent sheet that can be deformed into a three-dimensional shape, and the base sheet of the uneven transfer sheet is peeled off to form a thermoplastic resin layer. And deforming the uneven sheet having unevenness formed on the surface of the curable resin layer into a three-dimensional shape by heating, and eliminating unevenness of the thermoplastic resin layer in the uneven sheet to form a transparent window portion having a flat surface. A method for manufacturing an uneven sheet having a transparent window portion, characterized by: 3. A method of deforming a concavo-convex sheet into a three-dimensional shape is vacuum forming or pressure forming, wherein the surface temperature of the concavo-convex sheet before deformation is T ° C., and Tg (glass of a resin forming the thermoplastic resin layer is used. Tg1 when the transition point) is Tg1
The method for producing a concavo-convex sheet having a transparent window portion according to claim 2, wherein the relational expression 1 ≦ T ≦ 200 ° C. is satisfied. 4. The three-dimensionally translucent translucent sheet is a thermoplastic resin sheet that is compatible with the injection molding resin, and the method of adhering the uneven transfer sheet is the thermal laminating method. Alternatively, the method for producing an uneven sheet having a transparent window part according to the item 3. 5. A transparent window portion characterized in that an uneven surface of a curable resin layer and a flat surface of a thermoplastic resin layer are formed side by side on a translucent sheet deformed into a three-dimensional shape. An uneven sheet having. 6. A decoration having an uneven surface having a transparent window portion, characterized in that the uneven sheet having the transparent window portion according to claim 5 is put into an injection molding die and integrally bonded with a molding resin. Molded article manufacturing method.