JP2007283704A - Resin molded body and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance design properties by improving a feel of three dimensions with regard to a resin molded body which can be manufactured by film in molding and has a transparent decorative part of a high degree of design properties capable of attaining the feel of three dimensions although the surface is flat and no indentation exists, and a manufacturing method therefor. <P>SOLUTION: A first print layer 20 is formed on one surface of a transparent film body 2 and a second print layer 22 is formed on the opposite side by a specified pattern, the transparent decorative parts 21 comprising transparent protruding parts are formed in an island shape on the surface of the second print layer 22 to form a decorative film, the decorative film is arranged on the mold surface of the mold, and molten resin is poured on the surface of the side having the first print layer 20 to integrally form a base material 1. During a molding process, the transparent decorative part 21 is submerged into the film body 2 together with the second print layer 22 by heat and pressure and a part facing the transparent decorative part 21 in the first print layer 20 is submerged into the base material 1. The feel of three dimensions is improved by the cooperation of the first print layer 20 and the second print layer 22. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a resin molded body having a highly-designed transparent decorative part that can be produced by film-in-mold molding and has a three-dimensional effect despite having a flat surface and no irregularities, and a method for producing the same.

  In order to impart a high degree of design to a resin molded body, a film-in-mold molding method is known in which a decorative film is disposed on a mold surface and a resin base material is integrally molded. By performing printing or embossing on the decorative film in advance, it is possible to manufacture a resin molded article having excellent design properties.

  For example, Japanese Patent Application Laid-Open No. 2002-264289 proposes a method of manufacturing a resin molded body that can provide a three-dimensional feeling with a flat surface and no irregularities by a film-in-mold molding method. In this method, first, a printing layer is formed on the back surface of the film body, and a partially thick ultraviolet curable resin layer or thermosetting resin layer is formed on the surface of the film body.

  The decorative film thus obtained is heated to soften the film body, and vacuum molded to give a predetermined shape. This is placed in the mold so that the ultraviolet curable resin layer or the thermosetting resin layer faces the mold surface, and the molten resin is injected to the printed layer side to mold the substrate. Then, the ultraviolet curable resin layer or the thermosetting resin layer is immersed in the film body by the heat and pressure during molding, and a resin molded body having a smooth surface is obtained.

  The obtained resin molded product has a large distance from the surface to the printing layer in the region where the ultraviolet curable resin layer or the thermosetting resin layer is provided, and in the region where the ultraviolet curable resin layer or the thermosetting resin layer is not provided. The distance from the surface to the printed layer is small. Accordingly, a step is visually recognized in the printed layer, so that a three-dimensional effect can be obtained even though the surface is flat and has no irregularities.

Japanese Patent Application Laid-Open No. 2004-358919 also discloses that in a film-in-mold molding method, a decorative layer is formed on the surface of the sheet in advance and a convex layer is formed on the back surface, and the convex layer is immersed in the sheet during molding. Describes that the decorative layer is formed into a concavo-convex shape.
JP 2002-264289 A JP2004-358919

  However, even with the manufacturing method described in Patent Document 1 or Patent Document 2, a desired stereoscopic effect cannot be obtained yet, and further improvement in the stereoscopic effect is required.

  This invention is made | formed in view of the said situation, and makes it the subject which should be solved to further improve a three-dimensional effect.

The resin molded body of the present invention that solves the above problems is a resin molded body comprising a resin base material and a decorative film layer integrally bonded to the surface of the base material,
The decorative film layer is partially formed opposite to the transparent film body, the first printed layer formed on the substrate side surface of the film body, and the surface opposite to the substrate side surface of the film body. A thick and transparent transparent decorative part immersed in the film body from the surface on the side, and a second printed layer formed at the interface between the transparent decorative part and the film main body,
The first printed layer is that the surface facing the transparent decorative portion is recessed and is immersed in the substrate.

The feature of the method for producing a resin molded body of the present invention is that the first printed layer is formed on one surface of the transparent film body and the second printed layer is formed in a predetermined pattern on the other surface opposite to the one surface. A decorative film forming step of forming a decorative film by forming a transparent convex portion in an island shape on at least a part of the surface of the second printed layer;
A molding step of arranging a decorative film on the mold surface of the mold, injecting a molten resin into the surface having the first printed layer, and molding a resin base material integrally joined with the decorative film; and Become
In the molding step, the convex portion is immersed in the film main body together with the second printed layer by heat and pressure, and the portion facing the convex portion of the first printed layer is immersed in the resin base material.

  According to the resin molded body of the present invention, the first printed layer having a step is visually recognized through the film body, and the second printed layer is visually recognized inside the film body so as to overlap the concave portion of the first printed layer. . Therefore, since a double printed layer is visually recognized, a three-dimensional feeling improves and design nature improves markedly.

  Moreover, according to the manufacturing method of this invention, the resin molding of this invention can be manufactured easily and stably.

  The resin molding of this invention consists of a resin-made base material and the decorative film layer laminated | stacked integrally on the surface of the base material. The material of the substrate is not particularly limited as long as it can be molded by various molding methods. The color tone and shape can be variously selected according to the purpose.

  The decorative film layer is partially formed opposite to the transparent film body, the first printed layer formed on the substrate side surface of the film body, and the surface opposite to the substrate side surface of the film body. A thick and transparent transparent decorative part immersed in the film main body from the surface on the side, and a second printed layer formed at the interface between the transparent decorative part and the film main body.

  The film body is not particularly limited as long as it is transparent and can be printed, and various materials such as acrylic, PET, polyethylene naphthalate, polycarbonate, polypropylene, and polyethylene can be used.

  The first printed layer is formed on the surface of the film body that faces the substrate. The first print layer is, for example, a base color of a resin molded body, and can be formed by gravure printing, offset printing, screen printing, or the like. The first printed layer has a surface that is partially concave with a predetermined pattern and is immersed in the substrate.

  The transparent decorative portion is formed on the surface opposite to the surface on which the first printing layer of the film body is formed, that is, the surface that is visually recognized (hereinafter referred to as the viewing surface), and is immersed in the film body from the viewing surface. . This transparent decorative portion is thick and transparent, and is first formed in a convex shape on the viewing surface, and then immersed in the film body by heat and pressure during film in-mold molding. Therefore, the visual recognition surface of the film body is a smooth surface.

  The transparent decorative portion can be formed from a material that is not softened by heat during molding, and may be formed from, for example, a high-melting thermoplastic resin, or may be formed from an ultraviolet curable resin or a thermosetting resin. preferable. Moreover, in order to form a transparent decoration part with a predetermined pattern, it can form using screen printing, gravure printing, etc. It is particularly preferable to use screen printing, which allows thick printing.

  A second printed layer is formed at the interface between the transparent decorative part immersed in the film body and the film body. That is, the second print layer is formed inside the film body. The second printed layer is first printed with a predetermined pattern on the viewing surface, and a transparent decorative portion is printed with a predetermined pattern on the surface. And the heat and pressure at the time of film-in-mold shaping | molding immerse a transparent printing part in a film main body, and a 2nd printing layer also immerses in a film main body simultaneously. Therefore, the second printed layer is visually recognized through the transparent decorative portion from the viewing surface.

  The second print layer can be formed by gravure printing, offset printing, screen printing, and the like, like the first printing layer. Moreover, there is no restriction | limiting in particular as a predetermined pattern, A repeating pattern, a character, a picture, etc. can be selected freely. It is desirable that the pattern of the second printed layer and the pattern of the transparent decorative portion match.

  Depending on the material used, the bonding strength between the first printed layer and the substrate may be low. In such a case, it is desirable to form an adhesive layer having compatibility with the base resin on the surface of the first printed layer.

  Hereinafter, the present invention will be specifically described with reference to Examples and Comparative Examples.

Example 1
FIG. 1 shows a cross-sectional view of the resin molded body of this example. This resin molded body is a lid for small items placed in an automobile interior, and includes a base material 1 made of ABS, a first printed layer 20 laminated on the surface of the base material 1 via an adhesive layer (not shown), A film body 2 made of acrylic resin laminated on the surface of the first printing layer 20, a large number of transparent decoration portions 21 that have entered the inside from the surface of the film body 2, a transparent decoration portion 21, and the film body 2 And a second printed layer 22 formed at the interface.

  The first printed layer 20 has a light silver color tone with a glittering feeling using an aluminum pigment. Further, the transparent decorative portion 21 and the second printed layer 22 are formed in a predetermined pattern, and the second printed layer 22 has a slightly lighter color tone than the first printed layer 20.

  The first printed layer 20 has concave portions 23 that are respectively immersed in the base material 1 at portions facing the transparent decorative portion 21 and the second printed layer 22. The transparent decorative portion 21 has substantially the same refractive index as that of the film body 2. Therefore, when this resin molding is observed from the surface of the film body 2, the first printing layer 20 and the second printing layer 22 are visually recognized through the film body 2 and the transparent decoration portion 21, and the transparent decoration portion 21. The presence of is not visible.

  The second printed layer 22 is visually recognized in a predetermined pattern inside the silm main body 2, and the concave portion 23 of the first printed layer 20 is visually recognized in the same pattern as the second printed layer 22. Therefore, the first printed layer 20 and the second printed layer 22 are visually recognized with a difference in the thickness direction, and the surface of the film body 2 is smooth. A design with a three-dimensional effect is exhibited.

  The manufacturing method of the resin molding of a present Example is demonstrated below.

  First, the decorative film shown in FIG. 2 is formed. The decorative film includes a film body 2, a first printing layer 20 formed on the entire back surface of the film body 2, a second printing layer 22 formed in a predetermined pattern on the surface side of the film body 2, and a thickness. It consists of a transparent decorative portion 21 for meat.

  As shown in FIG. 3, first, a film main body 2 made of acrylic resin and having a thickness of 0.1 mm was prepared, and a first printing layer 20 having a thickness of 1 μm was formed on one surface thereof by gravure printing. After the first printed layer 20 was dried, a second printed layer 22 having a thickness of 1 μm was formed on the surface opposite to the first printed layer 20 by screen printing. The second printed layer 22 was formed into a predetermined pattern in which a large number of substantially circular single patterns were arranged.

  Next, an uncured UV curable resin is printed on the surface of the second printed layer 22 in the same pattern as the second printed layer 22 by screen printing to a thickness of 50 μm, and is cured to form island-shaped transparent decoration Part 21 was formed. Each transparent decorating part 21 was formed in a substantially hemispherical shape on the surface of each single pattern of the second printed layer 22.

  The decorative film thus obtained was shaped into a predetermined shape by vacuum forming and then placed on the mold surfaces of the pair of molds 3 as shown in FIG. At this time, the transparent decorative portion 21 was disposed so that the surface thereof was in contact with the mold surface. Then, molten ABS resin is injected into the cavity 30 formed between the first printed layer 20 and the other mold surface, and the substrate 1 is formed by injection molding.

  Then, the film main body 2 is softened by heat at the time of molding, and the transparent decorative portion 21 is pressed against the mold surface by the molding pressure, so that the transparent decorative portion 21 is immersed in the film main body 2 together with the second printed layer 22. . Along with this, the film body 2 is locally pressed, and the first printing layer 20 is locally immersed in the molten resin together with the film body 2. As a result, a recess 23 is formed in the first printed layer 20 at a portion facing the transparent decorative portion 21 and the second printed layer 22. In this state, the molten resin is cooled and solidified, whereby the base material 1 integrally joined with the film body 2 is formed, and the resin molded body of this embodiment is formed.

(Example 2)
In the above embodiment, the present invention is applied to the lid of the accessory case. However, the present invention is also effective when it is desired to visually recognize design characters such as a scuff plate or a nameplate. In this case, for example, a decorative film as shown in FIG. 6 is used.

  The decorative film includes a film body 2, a first printing layer 20 formed on the entire back surface of the film body 2, and a second printing layer 22 formed with a predetermined character pattern on the surface side of the film body 2. And a thick transparent decoration portion 21. The material may be the same as in the first embodiment.

  If this decorating film is used and the substrate 1 is molded in the same manner as in Example 1, the resin molded body shown in FIG. 7 can be produced. That is, the resin molded body includes a substrate 1, a first printed layer 20 laminated on the surface of the substrate 1 via an adhesive layer (not shown), and a film body 2 laminated on the surface of the first printed layer 20. The transparent decorative portion 21 having a predetermined character pattern that has been immersed from the surface of the film main body 2 and the second printed layer 22 formed at the interface between the transparent decorative portion 21 and the film main body 2. ing.

  The first printed layer 20 has a color tone like marble. The second printed layer 22 has a brilliant silver color tone using an aluminum pigment.

  The first printed layer 20 has concave portions 23 that are respectively immersed in the base material 1 at portions facing the transparent decorative portion 21 and the second printed layer 22. The transparent decorative portion 21 has substantially the same refractive index as that of the film body 2. Therefore, when this resin molding is observed from the surface of the film body 2, the first printing layer 20 and the second printing layer 22 are visually recognized through the film body 2 and the transparent decoration portion 21, and the transparent decoration portion 21. The presence of is not visible.

  The second printed layer 22 is visually recognized with a predetermined character pattern inside the film body 2, and the concave portion 23 of the first printed layer 20 is visually recognized with the same character pattern as the second printed layer 22. Therefore, the first printed layer 20 and the second printed layer 22 are visually recognized with a difference in the thickness direction, and the surface of the film body 2 is smooth. A design with a three-dimensional effect is exhibited.

  The resin molded body of the present invention can be used in various fields such as interior / exterior panels for automobiles, furniture, home appliances, various cards, nameplates, Buddhist accessories, and the like.

It is principal part sectional drawing of the resin molding which concerns on one Example of this invention. It is a principal part perspective view of the decorating film used for manufacture of the resin molding which concerns on one Example of this invention. It is explanatory drawing which shows the manufacturing method of the decorating film used for manufacture of the resin molding which concerns on one Example of this invention. In the manufacturing method of the resin molding which concerns on one Example of this invention, it is principal part sectional drawing which shows the state which has arrange | positioned the decoration film in the shaping | molding die. In the manufacturing method of the resin molding which concerns on one Example of this invention, it is principal part sectional drawing which shows the molded object immediately after injection molding with a shaping | molding die. It is a principal part perspective view of the decorating film used for manufacture of the resin molding which concerns on the 2nd Example of this invention. It is principal part sectional drawing of the resin molding which concerns on 2nd Example of this invention.

Explanation of symbols

1: Base material 2: Film body 3: Mold
20: 1st printing layer 21: Transparent decoration part 22: 2nd printing layer
23: Recess

Claims (2)

A resin molded body comprising a resin base material and a decorative film layer integrally bonded to the surface of the base material,
The decorative film layer includes a transparent film body, a first printed layer formed on the substrate-side surface of the film body, and a portion of the film body on the surface opposite to the substrate-side surface. A thick and transparent transparent decorative portion that is immersed in the film body from the opposite surface, and a second printed layer formed at the interface between the transparent decorative portion and the film body, With
The first printed layer has a concave surface on the surface facing the transparent decorative portion and is immersed in the substrate. A first printed layer is formed on one surface of the transparent film body, a second printed layer is formed in a predetermined pattern on the other surface opposite to the one surface, and transparent on at least a part of the surface of the second printed layer. A decorative film forming step of forming a convex film in an island shape to form a decorative film;
A molding step of arranging the decorative film on the mold surface of the molding die, injecting a molten resin into the surface having the first printed layer, and molding a resin base material integrally joined with the decorative film And more,
In the molding step, the convex portion is immersed in the film body together with the second printed layer by heat and pressure, and a portion of the first printed layer facing the convex portion is immersed in the resin base material. The manufacturing method of the resin molding characterized by these.

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