JP2000043082A - Manufacture of simultaneous molding and decorating sheet and metallic gloss molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To give a beautiful metallic gloss decoration by forming a flexible transparent resin anchor layer and a metal thin film layer of an indium on a base sheet having flexibility, and drawing them at a specified draw ratio, thereby performing deep drawing. SOLUTION: The simultaneous molding and decorating sheet 1 is obtained by forming a flexible and transparent resin anchor layer 3 oriented by 130% or more of an original area at a molding temperature for improving adhesive properties of a metal thin film layer 4 and a thin film layer of an indium are formed on a base sheet 2 similarly oriented with flexibility. An insert material 1 having a design layer or the like provided on the sheet 2 is inserted into a mold 6, mold clamped, melt molding resin is injected in a sealed space between the material 1 and a core mold 6, thereby obtaining a molding integral with the molding of the material 1. Thus, even if the sheet 1 is oriented, no microcrack occurs in the layer 4 and the layer 3, and the metallic gloss molding without impairing a metallic color developing is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a simultaneously molded sheet and a method for producing a metallic luster molded article, which can give a beautiful metallic luster decoration to a molded article having large undulations.

[0002]

2. Description of the Related Art As a method of decorating the surface of a resin molded article to express metallic luster, there are a simultaneous molding transfer method and an insert method using a picture sheet.

[0003] The painting sheet is formed by forming at least a metal thin film layer of aluminum having a thickness of 200 to 800 ° formed on a base sheet by a vacuum deposition method or the like.
Examples of the sheet with a picture include a transfer material and an insert material.

In the simultaneous molding transfer method, a transfer material in which a transfer layer including a release layer, a metal thin film layer, an adhesive layer, etc. is formed on a base sheet is sandwiched in a molding die, and a resin is injected and filled in the molding die. Then, after cooling to obtain a resin molded product, a transfer material is adhered to the surface of the molded product, and then the base sheet is peeled off, and the transfer layer is transferred to the surface of the object to be transferred, thereby performing decoration.

In the insert method, an insert material in which a metal thin film layer or the like is formed on a base sheet is inserted into a mold and integrated with the surface of a molded article simultaneously with injection molding.

The simultaneous molding transfer method and the insert method can easily decorate a molded product having a three-dimensional surface, and cover many processes such as a printing process, a plating process, and an assembly process which are conventional methods. Since the manufacturing process can be reduced and the cost can be reduced, it is often used for indicator panels of home appliances such as video and audio products, and meter panels of automobile parts. In addition, aluminum is used as the material of the metal thin film layer of the painted sheet because aluminum is inexpensive, and vacuum evaporation is more convenient for processing aluminum into a metal thin film than sputtering or ion plating. This is because the method can be used.

[0007]

However, there is a demand for giving a metallic luster to a deep drawn product such as an automobile side molding or a bumper in which a picture sheet is stretched 130% or more of its original area. Nevertheless, it was not possible with the above method.

That is, when a transfer material including a metal thin film layer made of aluminum is molded by using a mold having a cavity shape for extending the painting sheet to 130% or more of the original area, fine cracks are formed on the surface of the metal thin film layer. However, there is a problem that microcracks are generated and whitened, and the metallic luster decreases. This is a phenomenon that occurs because aluminum itself has poor stretchability.

Further, since the anchor layer formed for firmly adhering the metal thin film layer to other layers of the painted sheet is hard and brittle, the anchor layer is easily broken, and the metal thin film layer laminated on the anchor layer causes microcracks. There is a problem of getting up.

[0010] Accordingly, the present invention is to solve the above-mentioned problems and to provide a method for producing a simultaneously painted sheet and a molded metallic gloss product which can be deep drawn and provide beautiful metallic gloss decoration. With the goal.

[0011]

Means for Solving the Problems In order to achieve the above objects, the method for producing a simultaneously-painted sheet and a glossy metal molded article of the present invention is constituted as follows.

[0012] That is, in the simultaneous-painting sheet of the present invention, at least a flexible transparent resin anchor layer and a metal thin film layer made of indium are formed on a flexible base sheet, and the original area is reduced at the molding temperature. For 130
% Or more.

Further, in the above invention, the metal thin film layer may be configured to have a thickness of 50 to 800 °.

Further, in the above invention, the simultaneously-molded sheet may be configured to be a transfer material.

Further, in the above invention, the sheet with simultaneous painting may be constituted by an insert material.

Further, the method for producing a metallic luster molded product according to the present invention is characterized in that a mold having a cavity shape for extending a simultaneously painted sheet to an area of 130% or more of the original area at the time of molding is provided. The molded simultaneous-painted sheet described in any one of No. 4 was inserted, and a resin melted by an injection molding method was injected to integrate the molded simultaneous-painted sheet with the resin to obtain a metallic gloss molded product.

[0017]

Embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view showing one step of the method for producing a metallic luster molded product of the present invention. FIG. 2 is a perspective view showing one embodiment of the metallic luster molded product of the present invention. In the figure,
1 is a sheet with simultaneous painting, 2 is a base sheet, 3 is a transparent resin anchor layer, 4 is a metal thin film layer, 5 is an adhesive layer, 6 is a mold, 7 is a suction hole, 8 is a clamp member, and 9 is metal luster molding. Goods.

In the sheet for simultaneous painting with molding 1 of the present invention, at least a flexible transparent resin anchor layer 3 and a metal thin film layer 4 made of indium are formed on a flexible base sheet 2, and the area is smaller than the original area. It can be stretched to an area of 130% or more (see FIG. 1).

A transfer material or an insert material can be used as the sheet for simultaneous painting.

The transfer material is such that a transfer layer including a release layer, a design layer, an adhesive layer 5 and the like is provided on a base sheet 2.

As the base sheet 2, a sheet having flexibility and capable of being stretched to 130% or more of the original area at the molding temperature is used. Or whitening or coloring due to a phase change inside the base sheet 2 can be prevented. Examples of the material of the base sheet 2 include polyethylene terephthalate (copolymer type / homo type),
A single or composite film such as acrylic, vinyl chloride, nylon, urethane, polypropylene, polyethylene, and TPE (a film containing a thermoplastic elastomer) can be used. Further, when the surface of the base sheet 2 has fine irregularities, the irregularities are transferred to the transfer layer, so that the surface shape such as matting and hair lines can be expressed.

The molding temperature mentioned here is a temperature at which the sheet 1 is simultaneously deformed into a three-dimensional shape. For example, when the molded simultaneous painting sheet 1 is deformed into a three-dimensional shape by the pressure of the molten resin injected during injection molding, the temperature of the molten resin is the molding temperature, and the molded simultaneous painting sheet 1 is fixed to the mold 6. In the case of performing vacuum forming, the temperature of a hot plate that heats the simultaneously formed sheet 1 during vacuum forming is the forming temperature.

Further, the elongation of 130% means that when the area of the simultaneously-painted sheet 1 before molding is assumed to be 100, the elongation percentage in the longitudinal direction and the elongation in the transverse direction becomes 130.
%. For example, 114% vertical x 114% horizontal divided by 130
%, 130% vertical × 100% horizontal = 130%, 90% vertical × 144% horizontal ≒ 130%, etc. Such growth rate is
It can be obtained by molding using the molded simultaneous painting sheet 1 having a grid pattern, measuring the longitudinal and lateral elongation percentages of the grid, and integrating them.

In order to enhance the releasability of the transfer layer from the base sheet 2, a release layer may be formed over the entire surface before providing the transfer layer on the base sheet 2. The release layer is composed of the base sheet 2
Is peeled off from the transfer layer together with the base sheet 2. As the material of the release layer, a melamine resin-based release agent,
Silicone resin release agent, fluororesin release agent, cellulose derivative release agent, urea resin release agent, polyolefin resin release agent, paraffin release agent, and composite release agents of these Can be used. Examples of the method for forming the release layer include a coating method such as a roll coating method and a spray coating method, and a printing method such as a gravure printing method and a screen printing method.

The release layer is formed entirely on the base sheet 2 or the release layer. The release layer is a layer which is peeled off from the base sheet 2 or the release layer when the base sheet 2 is peeled off after the simultaneous transfer of the molding to become the outermost surface of the transfer object. As the material of the release layer, acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin,
In addition to polyurethane resins and polyvinyl acetate resins, copolymers such as vinyl chloride-vinyl acetate copolymer resins and ethylene-vinyl acetate copolymer resins may be used. When the release layer requires hardness, a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. The release layer may be colored or uncolored. Examples of the method for forming the release layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

The transparent resin anchor layer 3 is provided to improve the adhesion of the metal thin film layer 4. The transparent resin anchor layer 3 has flexibility and can be stretched to an area of 130% or more of the original area at a molding temperature. Further, whitening and coloring due to an internal phase change can be prevented. As a material of such a transparent resin anchor layer 3, an acrylic resin, a urethane resin, an acrylic urethane resin, a polyester resin, or an epoxy resin may be used alone or in combination. Also,
These can be mixed with a compound containing an isocyanate group and used as a two-part curable resin. In consideration of flexibility and breaking strength, it is preferable to use a two-component curable resin. Examples of the method for forming the transparent resin anchor layer 3 include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

The metal thin film layer 4 is for expressing a metallic luster as a design layer, and is formed using indium by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. The thickness of the metal thin film layer 4 is 50 to 80
It is preferably 0 °. If the angle is less than 50 °, the color becomes light black (gray) without metallic luster. On the other hand, if it exceeds 800 °, the stretchability is deteriorated, microcracks are generated, whitening occurs, and the metallic luster decreases.

The metal thin film layer 4 may be partially formed. As an example of the case where the metal thin film layer 4 is partially formed, after forming a solvent-soluble resin layer in a portion where the metal thin film layer 4 is not required, a metal thin film is entirely formed thereon, and solvent cleaning is performed. There is a method of removing the unnecessary metal thin film together with the solvent-soluble resin layer. The solvent often used in this case is water or an aqueous solution. As another example, there is a method in which a metal thin film is formed on the entire surface, a resist layer is formed on a portion where the metal thin film is to be left, and the resist layer is removed by etching with an acid or an alkali. .

Further, in order to perform decoration other than metallic luster,
A design layer may be provided. As the material of the design layer, polyvinyl resin, polyamide resin, polyester resin,
When a resin such as an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, or an alkyd resin is used as a binder, and a coloring ink containing a pigment or dye of an appropriate color as a coloring agent is used. Good. As a method of forming the pattern layer, a normal printing method such as a gravure printing method, a screen printing method, and an offset printing method may be used.

The adhesive layer 5 is for bonding each of the above-mentioned layers on the transfer object. As the adhesive layer 5, a heat-sensitive or pressure-sensitive resin suitable for the material of the material to be transferred is appropriately used.
For example, when the material of the transfer object is an acrylic resin, an acrylic resin may be used. When the material to be transferred is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, or a polyamide having an affinity for these resins. A system resin or the like may be used. Further, when the material of the transfer object is a polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. Examples of the method for forming the adhesive layer 5 include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

As described above, the transfer material can be obtained. Next, a method for manufacturing the metallic luster molded article 9 using the transfer material will be described.

First, a transfer material is fed into a molding die 6 composed of a cavity die and a core die. As the mold 6, a mold having a cavity shape for extending the transfer material to an area of 130% or more of the area before molding without breaking the transfer material is used.

When the transfer material is fed into the molding die 6, sheet-like transfer materials may be fed one by one, or a necessary portion of a long transfer material may be fed intermittently. In order to feed the transfer material, when a long transfer material is used, it is preferable to use a feeder having a positioning mechanism so that the register of the design layer of the transfer material and the molding die 6 coincide.

When the drawing rate of the molding die 6 is high and the elongation rate of the transfer material is large, if the transfer material is instantaneously stretched by the hot pressure of the molten resin during injection molding, the breakage and elongation of the transfer material will occur. The transfer material may be preformed (see FIG. 1). As the preforming, a molding die 6 having a suction mechanism is used. After fixing the transfer material, the transfer material is heated, and the pressure of the transfer material is reduced through the suction mechanism so that the transfer material follows the cavity surface. Therefore,
At the time of preforming, the transfer material is stretched by 130% or more.

After the molding die 6 is closed, the molten resin is injected and filled into the die 6 from the gate, and the transfer material is adhered to the surface of the transfer material simultaneously with the formation of the transfer object.

As the injection resin, a polystyrene resin,
General-purpose resins such as polyolefin resins, ABS resins, AS resins, and AN resins can be given. In addition, polyphenylene oxide polystyrene resin, polycarbonate resin, polyacetal resin, acrylic resin,
General-purpose engineering resins such as polycarbonate-modified polyphenylene ether resin, polybutylene terephthalate resin, polybutylene terephthalate resin, ultrahigh molecular weight polyethylene resin, polysulfone resin, polyphenylene sulfide resin, polyphenylene oxide resin, polyarylate resin, polyetherimide resin, A super engineering resin such as a polyimide resin, a liquid crystal polyester resin, or a polyallyl heat-resistant resin can also be used. Further, a composite resin to which a reinforcing material such as glass fiber or inorganic filler is added can be used.

After cooling the resin molded product as the transfer object,
The molding die 6 is opened to take out the resin molded product. Finally,
The transfer material base sheet 2 is peeled off. In this way, only the transfer layer is transferred to the surface of the resin molded product, and the metallic luster molded product 9 can be obtained (see FIG. 2).

In order to obtain an insert material, the following method may be used.

The insert material has a pattern layer or the like provided on the base sheet 2. As the base sheet 2,
The same material as that for the transfer material may be used. Also, a transparent resin anchor layer 3, a metal thin film layer 4, a design layer, an adhesive layer 5
It is preferable to use the same material as that of the transfer material. Therefore, the insert material differs from the transfer material in that it does not have a release layer.

As a structure of the insert material, all layers such as the metal thin film layer 4 may be formed on one surface of the base sheet 2. Further, the metal thin film layer 4 and the like may be formed on one surface of the base sheet 2 and the adhesive layer 5 and the like may be formed on the other surface. Further, the metal thin film layer 4 and the like may be formed between two base sheets 2. When the metal thin film layer 4 is located on the outer surface of the molded product, the protective layer may be formed by painting after the molding process.

In manufacturing the insert material, the base sheet 2 can be laminated by dry lamination.
Further, the base sheet 2 can be formed into a thick film by an extrusion lamination method or a hot melt coating method. Further, the adhesive layer 5 can be formed into a thick film by an extrusion lamination method or a hot melt coating method.

As described above, the insert material can be obtained. Next, a method for manufacturing the metallic luster molded product 9 using the insert material will be described.

First, an insert material is fed into a molding die 6 composed of a cavity die and a core die. As the mold 6, a mold having a cavity shape for extending the insert material without breaking it to 130% or more of the area before molding is used. The insert material is fixed in or around the cavity mold by means such as the clamp member 8. When the molding shape is deep drawing, the insert material may be heated and softened by a heat source, and may be closely attached to the surface of the cavity mold by vacuum suction from the cavity mold side. The cavity mold and the core mold are clamped to form a closed space between the insert material and the core mold. The molten molding resin is injected into this space.
As the molding resin, the same resin as that used in molding the transfer material may be used. If you open the cavity mold and the core mold,
The metallic luster molded article 9 in which the insert material and the molding resin are integrated can be obtained.

Further, insert molding can be performed as follows. First, the insert material is fixed to a preforming mold having a concave portion for deep drawing by means of a clamp member 8 or the like, and then the insert material is heated and softened by a heat source and vacuum-sucked from the preforming mold side to prepare the preform. Adhere to the surface of the mold. Next, the vacuum suction is released, and the insert material is taken out of the preforming mold. In this way, a deep drawn insert material can be obtained. Next, the preformed insert material is placed in a molding die 6 including a cavity die and a core die, and a clamp member 8 is formed.
Fix inside or around the cavity mold by such means. Next, the cavity mold and the core mold are clamped, and the molten molding resin is injected to obtain the metallic luster molded article 9 in which the insert material and the molding resin are integrated.

[0046]

Example 1 A base sheet was prepared by subjecting an olefin film composed of 100 μm thick polypropylene and an olefin-based thermoplastic elastomer to a corona treatment, and using 100 parts by weight of an acrylic urethane-based resin with an isocyanate (manufactured by Nippon Polyurethane Co., Ltd.). After a transparent resin anchor layer having a thickness of 2 μm was formed using an ink containing 5 parts by weight of (Coronate HL), the transparent resin anchor layer was made flexible and tough by heat treatment at 50 ° C. for 24 hours. Next, the degree of vacuum 10
Indium vapor deposition was performed under the conditions of ⁻³ Pascal and 100 m / min to form a metal thin film layer having a thickness of 400 to 420 °. Next, a chlorinated polypropylene resin having a thickness of 0.5 μ
After gravure coating with m, an adhesive layer having a thickness of 30 μm was provided on the polypropylene resin by extrusion lamination to obtain an insert material.

The insert is placed in a mold having a cavity shape in which the insert is stretched to an area of 120% as a whole with respect to the original area of the opening of the cavity and 130% locally, and polypropylene resin is injected. Thus, a metallic luster molded product in which the adhesive layer of the insert material was melt-bonded to the resin molded product was obtained.

The metallic luster molded article thus obtained has a metallic luster due to the metallic luster of the metal thin film layer,
It was an alternative to plated products.

Example 2 A 100 μm-thick low-stretch polyethylene terephthalate film (A-PET manufactured by Teijin Limited) was used as a base sheet, a release layer was formed using an acrylic urethane resin ink, and a pattern was formed thereon. Forming a transparent resin anchor layer having a thickness of 1 μm comprising an ink obtained by mixing polyester urethane and isocyanate in a ratio of 10: 1,
The transparent resin anchor layer was made flexible and tough by heat treatment at 0 ° C. for 50 seconds. Next, indium vapor deposition was performed to form a metal thin film layer having a thickness of 300 to 330 °. Next, an adhesive layer was provided using an ink composed of vinyl chloride / vinyl acetate / maleic acid resin (VMCA manufactured by Union Carbide) to obtain a transfer material.

Next, the transfer material was placed in the same mold as in Example 1, the ABS resin was injected, the base sheet was peeled off, and the metallic gloss molded product in which the adhesive layer was melt-bonded to the surface of the resin molded product was obtained. Obtained.

The metallic luster molded article thus obtained has a metallic luster with a sufficient metallic luster due to the metal thin film layer,
It was an alternative to plated products.

Example 3 A long acrylic film (HBS-006 manufactured by Mitsubishi Rayon Co., Ltd.) having a thickness of 125 μm was used as a base sheet, and a design layer was provided with five vinyl-colored inks in the same manner as in Example 1. A transparent resin anchor layer and a metal thin film layer were formed. Next, an adhesive layer having a thickness of 2 μm was provided using an ink in which a polyester resin (Vylon 200 manufactured by Toyobo Co., Ltd.) and a vinyl chloride vinyl acetate copolymer resin (VYHH manufactured by Union Carbide) were mixed at a ratio of 5:10. Wood was obtained.

Next, the insert material is fixed to a cavity mold having a suction mechanism of a simultaneous injection molding apparatus by a clamp member, and a heating plate at an indicated temperature of 280 ° C. is opposed to the insert material at a distance of 10 cm from the insert material to soften the insert material. At the same time as starting, suction was performed from the cavity mold, and the insert material was molded so as to be along the cavity surface. In the center of the insert material, it was stretched to 150%.
Next, ABS resin was injected to obtain a metallic luster molded product in which the adhesive layer of the insert material was melt-bonded to the resin molded product.

The metallic luster molded product obtained in this way had a metallic feeling of the metal thin film layer even in a portion stretched to 150% of the insert material.

Example 4 In place of the adhesive layer of the insert material obtained in Example 3, a thickness of 3
An insert material was obtained by dry laminating a 00 μm ABS film.

When the insert material was preformed and stretched by using an insert material preforming mold having a portion to be stretched up to 160%, the metallic feeling of the metal thin film layer was not lost.

Next, the insert material was inserted into an injection mold having substantially the same shape, and ABS resin was injected to obtain a metallic luster molded product in which the adhesive layer of the insert material was melt-bonded to the resin molded product.

The metallic luster molded article thus obtained has a metallic luster with a sufficient metallic luster due to the metal thin film layer.
It was an alternative to plated products.

[0059]

Since the present invention has the above-described structure, it has the following effects.

The sheet with simultaneous painting according to the present invention has at least a flexible transparent resin anchor layer and a metal thin film layer made of indium formed on a flexible base sheet. %, The micro-cracks do not occur in the metal thin film layer and the transparent resin anchor layer even if the simultaneously-painted sheet is stretched to 130% or more, and the metallic coloring is impaired. Not something.

Further, the method for producing a metallic luster molded product of the present invention is characterized in that the above-mentioned simultaneous molding process is carried out in a mold having a cavity shape for extending the concurrently-painted sheet to an area of 130% or more of the original area during the molding process. The painted sheet is inserted, and the resin melted by the injection molding method is injected to integrate the molded simultaneous painting sheet and the resin to obtain a metallic gloss molded product. It is possible to obtain a metallic luster molded product in which microcracks do not occur in the thin film layer and the transparent resin anchor layer and the metallic coloring is not impaired.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one step of a method for producing a metallic luster molded product of the present invention.

FIG. 2 is a perspective view showing one embodiment of the metallic luster molded product of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Simultaneous painting sheet 2 Substrate sheet 3 Transparent resin anchor layer 4 Metal thin film layer 5 Adhesive layer 6 Die 7 Suction hole 8 Clamp member 9 Metal luster molded product

Claims (5)

[Claims] At least a flexible transparent resin anchor layer and a metal thin film layer made of indium are formed on a flexible base sheet, and can be stretched to 130% or more of the original area at a molding temperature. A sheet with simultaneous simultaneous painting, characterized in that: 2. The sheet according to claim 1, wherein the thickness of the metal thin film layer is 50 to 800 °. 3. The sheet according to claim 1, wherein the sheet is a transfer material. 4. The sheet according to claim 1, wherein the sheet is a sheet. 5. The molded simultaneous painting sheet according to any one of claims 1 to 4, wherein the molded simultaneous painting sheet according to any one of claims 1 to 4 is placed in a mold having a cavity shape for extending the molded simultaneous painting sheet to an area of 130% or more of the original area during molding. A method for producing a metallic glossy molded product, which comprises inserting a resin melted by an injection molding method, and integrating the molded simultaneous painting sheet and the resin to obtain a metallic glossy molded product.