JP2000052375A - Preparation of in-mold decorating molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for preparing an in-mold decorating molded article wherein dimensional stability at an arbitrary position is improved and distortion of the picture pattern is not generated in an in-mold decorating sheet which forms a three-dimensional shape by means of vacuum molding or pressure forming after heating. SOLUTION: An in-mold decorating sheet 1 is arranged on a cavity mold 2 and then, a heat insulating plate 6 is partly arranged between a heating means 5 and the in-mold decorating sheet 1 to heat partly the in-mold decorating sheet 1 and then, the in-mold decorating sheet 1 is vacuum-molded or pressure- formed along the mold cavity and then, the mold is closed and a molding resin is injected into the mold to integrate the in-mold decorating sheet and the resin to obtain an in-mold decorating molded article.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a molded article with simultaneous molding and painting, which can be used for automobiles, electric appliance panels and the like.

[0002]

2. Description of the Related Art As a method of decorating the surface of an article, there are an insert molding method and a simultaneous molding transfer method using a simultaneously painted sheet. With the insert molding method, an insert material with a pattern layer etc. formed on a base sheet is supplied into an injection molding die, and a three-dimensional molded product is molded, and at the same time, the insert material is integrally bonded to the molded product It is a way to decorate.

In the simultaneous molding transfer method, a transfer material having a transfer layer comprising a release layer, a pattern layer, an adhesive layer, etc. formed on a base sheet is sandwiched in a molding die, and the resin is injected and filled in the die. At the same time as cooling to obtain a resin molded product, the transfer material is integrally bonded to the surface of the molded product, and then the base sheet is peeled off.
This is a method in which the transfer layer is transferred to the surface of the transfer object to perform decoration.

In the case of obtaining a molded article with a simultaneous drawing with deep drawing by using such a sheet with a simultaneous painting as an insert material or a transfer material, the heating means is brought close to the sheet with a simultaneous painting with the cavity fixed. After softening,
It is preformed into a three-dimensional shape so as to be in close contact with the cavity mold by vacuum or air pressure, but at this time the sheet with simultaneous painting is stretched uniformly, so depending on the shape of the molded product,
The design was sometimes greatly distorted (see FIG. 7).
In particular, in the case of a product having a complicated shape, it is necessary to sufficiently heat and elongate the sheet at the same time as vacuum forming or pressure forming of the simultaneously-painted sheet, so that the pattern is greatly deformed.

Therefore, in consideration of the elongation of the simultaneously-painted sheet, the amount of distortion is calculated, and the pattern layer is deformed in advance.

[0006]

However, in order to form a design layer which has been deformed in advance in consideration of the elongation of the simultaneously-painted sheet, the design layer is deformed and the shape of the formed product is increased in many respects. It is necessary to take a procedure of collecting the position data, repeating the plate making several times while analyzing the degree of the positional deviation, and properly matching the pattern to the shape of the molded product. In addition, since the amount of distortion varies depending on the molding conditions, the deformation pattern of the design layer is not always constant. The analysis of such a deformation pattern of the design layer has a problem that it is troublesome and expensive.

Therefore, the present invention solves the above-mentioned problems, and provides a dimensional stability of an arbitrary portion in a molded simultaneous painting sheet that forms a three-dimensional shape by heating and then vacuum forming or pressure forming. It is an object of the present invention to provide a method of manufacturing a molded article with simultaneous molding and picture which does not cause distortion of the design.

[0008]

Means for Solving the Problems A method for producing a molded article with simultaneous molding and painting according to the present invention is constituted as follows in order to achieve the above object.

That is, in the method of manufacturing a molded article with simultaneous painting according to the present invention, the sheet with simultaneous painting is arranged on a cavity mold, and then a heat shielding plate is partially arranged between the heating means and the sheet with simultaneous molding. Partially heat the sheet with simultaneous painting and then form the sheet with vacuum simultaneously or along the mold cavity along the mold cavity, then close the mold and inject molding resin into the mold to simultaneously mold The painting sheet and the resin were integrated to obtain a molded article with simultaneous painting.

In the above invention, the heat shield plate may be configured to cover the entire design partially formed on the simultaneously-painted sheet.

Further, in the above invention, the heat shield plate may be configured to cover the boundary of the symbol partially formed on the simultaneously-painted sheet.

Further, in the above-mentioned 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.

[0014]

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

FIGS. 1 and 2 are sectional views showing one embodiment of the steps of the method for producing a molded article with simultaneous molding according to the present invention. 3 and 4 are plan views showing the positional relationship between the simultaneously-painted sheet and the heat shielding plate used in the method for producing a simultaneously-painted molded article of the present invention. FIG. 5 is a plan view showing the positional relationship between the simultaneously-molded sheet and the cavity mold used in the method for producing a simultaneously-molded molded article of the present invention. FIG. 6 is a sectional view showing one embodiment of the steps of the method for producing a molded article with simultaneous painting according to the present invention. In the drawing, 1 is a sheet with simultaneous painting, 2 is a cavity type, 3 is a suction hole, 4 is a clamp member, 5 is a heating means, 6 is a heat shield plate, 7 is a design part such as characters and symbols, 8 is a pattern, etc. It is a design part.

First, the sheet 1 is simultaneously placed on the cavity mold 2 (see FIG. 5). Simultaneous painting sheet 1
It is preferable to use a clamp member 4 or the like in order to fix the predetermined position of the cavity mold 2.

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

The insert material has a pattern layer or the like formed on a base sheet.

Examples of the base sheet include polyethylene terephthalate film, acrylic film, polypropylene film, thermoplastic elastomer film, polycarbonate film, polyamide film, acrylonitrile-butadiene-styrene film, acrylonitrile-styrene film, polystyrene film, polyurethane film and the like. A sheet used as a base sheet of a normal insert material, such as a composite of the above sheets, can be used.

The design layer is a layer for decorating the surface of a molded article with simultaneous molding and picture, and specifically includes, for example, designs such as letters and symbols, solid designs, wood grain patterns and stone grain patterns. The design layer is usually formed as a printing layer. As a material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method, or a coating method such as a gravure coating method, a roll coating method, or a comma coating method can be used. The printing layer is
Depending on the purpose of the decoration, it may be provided entirely or partially.

The design layer may be composed of a metal thin film layer or a combination of a print layer and a metal thin film layer. The metal thin film layer is for expressing metallic luster as a design layer, and is formed by a vacuum evaporation method, a sputtering method, an ion plating method, a plating method, or the like. Metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, and zinc, and alloys or compounds thereof are used according to the metallic luster color to be expressed. When providing the metal thin film layer, a front anchor layer or a rear anchor layer may be provided in order to improve the adhesion between another transfer layer and the metal thin film layer.

Further, an adhesive layer may be formed on the insert material. The adhesive layer adheres the insert material to the molding resin, and may be formed as necessary. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin is appropriately used. For example, when the material of the molding resin is an acrylic resin, an acrylic resin may be used. Also, if the material of the molding resin is polyphenylene oxide
In the case of a polystyrene-based resin, a polycarbonate-based resin, a styrene-copolymer-based resin, or a polystyrene-based blended resin, an acrylic resin, a polystyrene-based resin, a polyamide-based resin, or the like that has an affinity for these resins may be used. Further, when the material of the molding resin is polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. Examples of a method for forming the adhesive 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 transfer material is such that a transfer layer comprising a release layer, a design layer, an adhesive layer and the like is provided on a base sheet.

As the base sheet, the same one as in the case of the insert material can be used. Further, when the surface of the base sheet has fine irregularities, the irregularities are transferred to the transfer layer, and the surface shape such as matting and hair lines can be expressed.

In order to improve the releasability of the transfer layer from the base sheet, a release layer may be formed over the entire surface before providing the transfer layer on the base sheet. The release layer is released from the transfer layer together with the base sheet when the base sheet is peeled off after the simultaneous molding transfer. As the material of the release layer, a melamine resin-based release agent, a silicone resin-based release agent, a fluororesin-based release agent, a cellulose derivative-based release agent, a urea resin-based release agent,
Polyolefin resin-based release agents, paraffin-based release agents, and composite release agents thereof 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 or partially on the base sheet or the release layer. The release layer is a layer that becomes the outermost surface of the transferred object by being separated from the base sheet or the release layer when the base sheet is separated after the transfer or the simultaneous transfer with the molding. Examples of the material of the release layer include acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, and the like, as well as vinyl chloride-vinyl acetate copolymer. It is preferable to use a resin or a copolymer such as an ethylene-vinyl acetate copolymer resin. 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 design layer is a layer for decorating the surface of the molded article with simultaneous molding and is preferably provided in the same manner as in the case of the insert material.

The adhesive layer is for bonding the above-mentioned layers to the surface of the object to be transferred. The adhesive layer is formed on a portion to be bonded. That is, if the portion to be bonded is the entire surface, the adhesive layer is entirely formed on the pattern layer. If the portion to be bonded is partial, an adhesive layer is partially formed on the design layer. The adhesive layer may be provided in the same manner as in the case of the insert material.

The structure of the transfer layer is not limited to the above-described embodiment. For example, when a material having excellent adhesiveness to an object to be transferred is used as a design layer material, the adhesive layer is omitted. be able to.

Next, the heat shielding plate 6 is partially disposed between the heating means 5 and the molded simultaneous painting sheet 1 to partially heat the molded simultaneous painting sheet 1 (see FIGS. 1 and 2).

As the heat shielding plate 6, a metal plate made of aluminum or stainless steel, a metal mesh, a mica plate, or the like can be used. Further, a metal plate and a mica plate laminated on each other, a mica plate having a reflective layer made of a metal vapor-deposited layer or the like laminated on the surface thereof, and the like can be used.

By forming the heat shielding plate 6 in an arbitrary shape, it is possible to heat only an arbitrary portion of the sheet 1 at the same time. In particular, if it is a shape that covers the entire design portion 7 such as characters and symbols partially formed in the insert form, the design portion 7 such as characters and symbols is not sufficiently heated, and the design portion 8 such as a pattern is not heated. Is sufficiently heated, the entire pattern portion 7 such as characters and symbols can be suppressed from being stretched, and three-dimensional processing can be performed without distorting the characters and symbols (see FIGS. 1 and 3). Further, the heat shield plate 6 is composed of a symbol portion 7 such as a character and a symbol and a symbol portion 8 such as a pattern, which are partially formed on the molded simultaneous painting sheet 1.
If it is a shape that covers the boundary between the pattern part 7 such as characters and symbols, the boundary between the design part 7 such as a pattern and the pattern part 8 such as a pattern can be aligned with the shape of the molded product. And the design part 8 such as a pattern is sufficiently heated, so that the three-dimensional processing in which the periphery of the design part 7 such as a character or a symbol is aligned with the shape of the molded product can be performed (FIG. 2, (See FIG. 4).

The heat shielding plate 6 may be attached to the heating means 5 or may be drivably attached to a mold. The heat shield plate 6 may be installed in parallel with the molded simultaneous painting sheet 1. At that time, the heat shielding plate 6 is made to be as close as possible to the molded simultaneous painting sheet 1. Further, the heat shielding plate 6 may come into contact with the molded simultaneous painting sheet 1. The heating from the heating means 5 is preferably performed by radiant heat. Therefore, by minimizing the distance between the heat shielding plate 6 and the molded simultaneous painting sheet 1, the radiant heat is generated between the heat shielding plate 6 and the molded simultaneous painting sheet 1. It is preferable to prevent wraparound.

The temperature of the heating means 5 may be adjusted together with the use of the heat shield plate 6. That is, the heating means 5
If the temperature of the heating means 5 can be partially changed, the temperature of the heating means 5 at the portion corresponding to the heat shielding plate 6 can be lowered, or the heating means 5 other than the portion corresponding to the heat shielding plate 6 can be reduced.
By increasing the temperature of the sheet, it is possible to more finely control the heating of the sheet 1 at the same time.

Then, the sheet 1 with simultaneous forming and painting is formed by vacuum forming or pressure forming along the mold cavity (FIG. 6).
reference). Simultaneous painting sheet 1 by means of clamp 4
Is pressed into the cavity mold 2 and the sheet 1
And the cavity mold 2 are sealed, and when the part not covered by the heat shielding portion is sufficiently heated and softened, vacuum suction is performed from the suction holes 3 provided in the cavity mold 2 so that the sheet with the simultaneous forming and painting is formed. Vacuum forming can be performed so that 1 is along the cavity mold 2. Further, the molded simultaneous painting sheet 1 is fixed to the cavity mold 2 by the clamp 4 means, the core mold is clamped, and the compressed air is sent out from the core mold so that the compressed simultaneous painting sheet 1 is compressed along the cavity mold 2. Can be molded.

The portion of the heat shield plate 6 where the degree of heating is low is lower than the other portions in the degree of softening. And the distortion of the design is reduced. In addition, the other portions of the sheet with simultaneous painting 1 are sufficiently heated and softened, so that even if the shape of the cavity mold 2 is complicated, vacuum forming or pressure forming can be performed along the cavity surface.

Next, the mold is closed and the molding resin is injected into the mold.

As the molding resin, an acrylic resin, a polystyrene resin, a polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin or the like may be used.

Next, the mold is opened, and the sheet with simultaneous painting 1 is formed.
Take out the resin molded product which is integrated and adhered. When the sheet 1 is a transfer material, the base sheet is peeled off. In this manner, a molded article with simultaneous molding and painting can be obtained.

[0040]

EXAMPLE A 125 μm-thick acrylic film was used as a base sheet, and a pattern layer composed of a grain pattern, a black pattern and a logo pattern and an adhesive layer were formed by gravure printing to obtain an insert material. .

Next, the insert material was fixed to a cavity mold of an injection mold using a frame-shaped clamp member. The insert material was positioned and fixed so that the wood pattern, the black pattern, and the logo mark pattern were at predetermined positions in the mold. In addition, a sealing material made of silicone was provided between the cavity mold and the insert material, and the space formed between the cavity mold and the insert material was sealed.

Next, the heat shield plate and the heating means were arranged in front of the insert material, and the surface of the insert material was heated by a heating means comprising an infrared heater. Here, the heat shield plate is
A total of 20mm width range and 10mm x 30mm logo pattern each with 10mm left and right around the border between the wood pattern and the black pattern
It was arranged so as to cover a range of 20 mm × 50 mm with respect to mm. The heat shield plate was made of an aluminum plate having a thickness of 2 mm, and was introduced into the cavity mold only when the heater was heated by driving the air cylinder, and moved out of the mold after heating. The heat shield plate is 10
mm and 20 mm away from the heating means and placed parallel to the insert material. The heating by the heating means was performed for 10 seconds in a state where the surface temperature of the insert material was 120 ° C. with respect to the heat deformation temperature of 110 ° C. of the insert material.

Thereafter, vacuum suction was performed through a parting surface on the outer periphery of the cavity-shaped molded product and a vacuum suction hole provided in the cavity surface. In the portion covered by the heat shield plate and not heated by the heating means, the surface temperature of the insert material is 50 ° C., does not reach the heat deformation temperature of 110 ° C., and the boundary between the wood grain pattern and the black pattern. The line and the logo pattern were not deformed, and the insert material was stretched in other parts, and three-dimensionally formed along the cavity surface.

After vacuum forming, the heating means and the heat shielding plate were moved out of the mold, clamped, and injection molded using polypropylene resin as a molding resin.

Finally, the mold was opened to obtain a molded article with a simultaneous molded picture having a pattern aligned with the surface of the resin molded article.

[0046]

According to the method for producing a molded article with simultaneous painting according to the present invention, the sheet with simultaneous painting is arranged on a cavity mold.
Next, a heat shield plate is partially disposed between the heating means and the molded simultaneous painted sheet to partially heat the molded simultaneous painted sheet, and then the formed simultaneous painted sheet is vacuum formed or compressed air along the mold cavity. Molding, then closing the mold, injecting the molding resin into the mold, and integrating the molding simultaneous painting sheet and the resin to obtain a molding simultaneous painting molded product, has the following effects. .

The portion of the simultaneous-painted sheet covered with the heat shield plate and having a low degree of heating has a lower degree of softening than the other portions. Therefore, the vacuum is applied so that the simultaneous-painted sheet adheres to the cavity mold. When formed and stretched, the elongation rate is low, and the design is not distorted.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a process of a method for producing a molded article with simultaneous molding and painting according to the present invention.

FIG. 2 is a cross-sectional view showing another embodiment of the steps of the method of manufacturing a molded article with simultaneous painting according to the present invention.

FIG. 3 is a plan view showing a positional relationship between a simultaneously-molded sheet and a heat shielding plate used in the method of manufacturing a simultaneously-molded article of the present invention.

FIG. 4 is a plan view showing a positional relationship between a simultaneously-molded sheet and a heat shielding plate used in the method for manufacturing a simultaneously-molded article of the present invention.

FIG. 5 is a plan view showing a positional relationship between a simultaneously-molded sheet and a cavity mold used in the method for manufacturing a simultaneously-molded molded article of the present invention.

FIG. 6 is a cross-sectional view showing one embodiment of the steps of the method for producing a molded article with simultaneous painting according to the present invention.

FIG. 7 is a plan view showing an insert molded product obtained by a conventional method for producing a molded product with a simultaneous painting with picture.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Simultaneous painting sheet 2 Cavity type 3 Suction hole 4 Clamp member 5 Heating means 6 Heat shielding plate 7 Design part such as characters and symbols 8 Design part such as pattern

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification FI FI Theme Court ゛ (Reference) // B29L 9:00 (72) Inventor Toshikazu Kobe 3 Mibuhanaicho, Nakagyo-ku, Kyoto, Kyoto Japan Photograph Within Printing Co., Ltd. (72) Terumasa Yamamoto Inventor: 3 Mibuhanai-cho, Nakagyo-ku, Kyoto, Kyoto, Japan F-term (reference) 4F202 AA11 AA13 AA21 AD05 AD09 AD10 AD20 AG02 AG03 AH25 AH51 AJ02 AJ13 AM03 AR06 CA11 CA17 CB12 CB13 CB16 CB19 CK86 CL01 CN01 CN17 CN25 CN30 CQ01 CQ06 4F206 AA11 AA13 AA21 AD05 AD09 AD10 AD20 AG02 AG03 AH25 AH51 AJ02 AJ13 AM03 AR06 JA07 JB12 JB14 JB15 JB19 AD08 JA08 AD08 AG03 AH25 AH51 AJ02 AJ13 AM03 AR06 MA01 MA02 MB01 MC01 MH07 MH10 MJ22 MK08 MK13 MW01

Claims (5)

[Claims] Claims 1. A molded simultaneous painting sheet is placed on a cavity mold, and then a heat shield plate is partially arranged between a heating means and the molded simultaneous painting sheet to partially heat the molded simultaneous painting sheet. Next, the simultaneous-painted sheet is vacuum-formed or compressed-air-formed along the mold cavity, then the mold is closed, the molding resin is injected into the mold, and the simultaneous-painted sheet and the resin are integrated to form the simultaneous-painting. A method for producing a molded article with simultaneous molding and picture, characterized by obtaining a molded article. 2. The method according to claim 1, wherein the heat shield plate has a shape that covers the entire design partially formed on the molded simultaneous painting sheet. 3. The method according to claim 1, wherein the heat shield plate has a shape covering a boundary portion of a pattern partially formed on the sheet with simultaneous painting. 4. The method for producing a molded article with simultaneous simultaneous painting according to claim 1, wherein the sheet with simultaneous simultaneous painting is a transfer material. 5. The method for producing a molded article with simultaneous simultaneous painting according to claim 1, wherein the sheet with simultaneous simultaneous painting is an insert material.