JP2000084973A - Insert film and production of insert molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an insert film high in the adhesion to a molding resin because gas generated from the molding resin does not remain in the molding resin and a method for producing an insert molded product. SOLUTION: In the insert film 1 integrally bonded to the surface arranged in a mold, the insert film is a laminate of at least two kinds of sheets and the sheet of the surface bonded to the molding resin of the insert film 1 is a gas permeable sheet 2 and the other sheet is a thermoplastic resin sheet 3. The test piece with a width 20 mm of the insert film 1 is fixed by a pair of chucks at an environmental temp. of 110 deg.C so that the distance between the opposed end edges of the chuck is set to 100 mm and, when one end of the test piece is loaded at a constant speed of 3 mm/sec to perform a tensile test, the tensile breaking elongation of the test piece is set to 90% or more.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an insert film used for decorating the surface of a resin molded product such as an injection molded product or a blow molded product used for automobile exterior parts and the like, and a method for producing the insert molded product. .

[0002]

2. Description of the Related Art Large-sized resin molded products such as injection molded products and blow molded products are used for automobile exterior parts such as automobile body panels, spoilers, and bumper guards. To decorate the resin molded products, an insert film is used. Used. That is, by placing an insert film provided with a design in a molding die and simultaneously forming and bonding the insert film to the surface of the resin molded product, the resin molded product can be decorated. . The insert film used for such automobile exterior parts is required to have light resistance, surface strength and other resistance, and suitability for three-dimensional processing.

[0003] Materials suitable for a base sheet of an insert film having durability and suitability for three-dimensional processing include acrylic resin, vinyl chloride resin, light-resistant olefin resin, nylon resin, fluorine resin and the like. There is a thermoplastic resin sheet.

[0004]

However, when insert molding these films, when the size of the molded product is large and the thickness of the molded product is thin, gas generated from the molded resin remains in the molded resin. There was a problem. In addition, since air in the mold easily intervenes between the molding resin and the insert film, there is a problem that the adhesion of the insert film to the molding resin is not good.

Accordingly, an object of the present invention is to provide an insert film and a method of manufacturing an insert molded product in which gas generated from the molding resin does not remain in the molding resin and the insert film has high adhesion to the molding resin. I do.

[0006]

Means for Solving the Problems The present invention has the following configuration to achieve the above object.

That is, the insert film of the present invention is a laminate of at least two types of sheets, wherein the insert film is disposed in a molding die and integrally bonded to the surface of a molding resin.
The sheet on the surface of the insert film adhered to the molding resin was a gas permeable sheet, and the other sheet was a thermoplastic resin sheet.

In the above invention, a test piece having a width of 20 mm is fixed at a distance between a pair of chuck opposing edges of 100 mm at an environmental temperature of 110 ° C., and one end of the test piece is loaded at a constant speed of 3 mm / sec. , The tensile elongation at break when a tensile test is performed may be 90% or more.

In the above invention, the difference in load between the elongation values of the sheets constituting the insert film is at most 5.0 kg within a range until the insert film reaches the upper limit of tensile elongation at break. It may be configured as follows.

In the above invention, the gas permeable sheet may be constituted by a nonwoven fabric.

In the above invention, the nonwoven fabric may be made of any of spandex, acrylic fiber, polyethylene fiber, and polyamide fiber.

Further, in the above invention, the thermoplastic resin sheet or the gas permeable sheet may have a design layer.

Further, according to the present invention, there is provided a method for producing an insert molded product, comprising: placing the insert film according to any one of claims 1 to 6 in a molding die; Was formed and an insert film was integrally bonded to the surface at the same time.

Further, according to a method of manufacturing an insert molded product of the present invention, the insert film according to any one of claims 1 to 6 is arranged in a molding die, and after three-dimensional processing in the die,
At the same time that the mold was closed to form a resin molded product, an insert film was integrally bonded to the surface of the resin molded product.

In the above invention, the molding die may be any one of an injection molding die and a blow molding die.

[0016]

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

FIG. 1 is a sectional view showing one embodiment of the insert film of the present invention. 2 to 4 are cross-sectional views illustrating one of the steps of the method for manufacturing an insert molded product according to the present invention. FIG. 5 is a cross-sectional view showing an insert molded product obtained by the method for producing an insert molded product of the present invention. FIG.
FIG. 2 is a cross-sectional view showing a three-dimensionally processed insert film used in the method for producing an insert molded product of the present invention. 7 to 10 are cross-sectional views illustrating one of the steps of the method for manufacturing an insert molded product according to the present invention. FIG. 11 is a sectional view showing a deep drawing mold used for examining the characteristics of the insert film. FIG. 12 is a perspective view showing an apparatus for measuring the tensile elongation at break of the sheet for simultaneous painting with molding. FIG.
FIG. 3 is a plan view showing a portion for fixing a test piece of an apparatus for measuring tensile elongation at break. FIG. 14 is a cross-sectional view showing a portion for fixing a test piece of an apparatus for measuring tensile elongation at break. In the drawing, 1 is an insert film, 2 is a gas permeable sheet, 3 is a thermoplastic resin sheet, 4 is a design layer, 5 is a movable mold, 6 is a fixed mold, 7 is a cavity forming surface, 8 is a clamp member, and 9 is a clamp member. Gate part, 10 is a molded resin, 11 is a resin molded product, 12 is a vacuum suction hole, 13 is a cavity, 14 is a blow mold, 15 is a hot plate, 16 is a parison, 20 is a test piece, 21 is a screw, 22 is a chuck, 23 is a chuck,
Reference numeral 24 denotes a movable member.

The insert film 1 of the present invention is a laminate of at least two types of sheets, wherein the insert film 1 is arranged in a molding die and integrally bonded to the surface of a molding resin 10. The sheet on the surface of the insert film 1 which is bonded to the molding resin 10 is the gas permeable sheet 2 and the other sheet is the thermoplastic resin sheet 3 (see FIG. 1).

The gas permeable sheet 2 is used to allow gas generated from the molding resin 10 during insert molding to be released to the outside without accumulating due to the presence of the insert film 1. , Non-woven fabric, flocking fiber sheet, foam sheet, ordinary woven fabric and the like. In particular, a nonwoven fabric is suitable in consideration of the uniformity of tensile strength and elongation and the defoaming effect during insert processing.

The gas permeable sheet 2 also has a function of physically increasing the adhesiveness by finally entering the molding resin 10 into the gas permeable sheet 2.

Examples of the thermoplastic resin sheet 3 include acrylic resin, vinyl chloride resin, light-resistant olefin resin, nylon resin, fluorine resin, polyethylene terephthalate resin, and polyurethane resin having resistance and suitability for three-dimensional processing. A thermoplastic resin sheet 3 made of a resin, a polycarbonate resin, an ethylene vinyl alcohol resin, a polystyrene resin, a polybutylene terephthalate resin, or the like can be used.

[0022] Insert molded articles are required to have durability in accordance with their uses. In particular, in automotive exterior parts,
Performances with strict resistance such as heat resistance, moisture resistance, light resistance, and water resistance are required. Therefore, in such an application, an acrylic resin,
It is preferable to use a polyvinyl chloride resin, a light-resistant olefin resin, a fluorine resin, a polycarbonate resin, or the like.

The lamination of the gas permeable sheet 2 and the thermoplastic resin sheet 3 to form the insert film 1 includes a method of thermal lamination and a method of dry lamination with an adhesive. That is, in the method using thermal lamination, a thermoplastic resin sheet 3 is preferably coated with a thermoplastic resin having good adhesiveness to the gas permeable sheet 2, and the gas permeable sheet 2 is laminated and thermally laminated. Further, when the thermoplastic resin sheet 3 itself has an adhesive property to the gas permeable sheet 2, the coating of the thermoplastic resin is unnecessary. In the method using dry lamination, the thermoplastic resin sheet 3 may be coated with an adhesive for dry lamination with a thick film of at least 10 μm or more, and the gas permeable sheet 2 may be overlaid and pressed for lamination. The surface of the gas permeable sheet 2 has irregularities, and when the adhesive for dry lamination is a thin film, the contact area is small and the adhesion is insufficient, so that the thickness is preferably 10 μm or more. As the adhesive for dry lamination, a urethane-based adhesive or a polyester-based adhesive can be applied to a wide range of gas-permeable sheets 2 and is suitable because it has excellent resistance.

When the insert film 1 has a locally elongated portion in the shape of the molded product at the time of molding or when a process such as vacuum forming is required in advance, the thermoplastic film and the gas permeable material are used. It is easy to peel between the sheets 2, to peel inside the gas permeable sheet 2, and to break the gas permeable sheet 2. In order to prevent such a problem from occurring, it is preferable to select a gas permeable sheet 2 and a thermoplastic resin sheet 3 which have the same elongation during molding. In particular, at a processing temperature equal to or higher than the softening temperature of the thermoplastic resin sheet 3, the thermoplastic resin sheet 3 shows considerable elongation. Therefore, the gas permeable sheet 2 is also selected to be sufficiently elongated according to the thermoplastic resin sheet 3. Good to do.

For this reason, in the present invention, the mechanical properties of the gas permeable sheet 2 were selected so as to be as similar as possible to the thermoplastic resin sheet 3. The temperature suitable for three-dimensionally processing the thermoplastic resin sheet 3 is about 110 to 150 ° C. As a result of examining a tensile test at the lowest processing temperature of 110 ° C., it was found that at least the mechanical properties at which the elongation becomes 90% or more are obtained. It has been found that the insert film 1 can be processed into a very deep three-dimensional shape even in a single film state. Therefore, even if it is an insert film 1 in which two sheets are laminated, a material which can be easily three-dimensionally processed can be obtained by selecting a material so as to satisfy this property.

That is, the insert film 1 is
At an environmental temperature of ° C., a test piece 20 having a width of 20 mm is sandwiched between a pair of chucks 22 and 23 and fixed at a distance between chuck-facing edges of 100 mm (see FIGS. 13 and 14).
It is preferable that the tensile elongation at break is 90% or more when a tensile test is carried out by applying a load to one end of 0 at a constant speed of 3 mm / sec (see FIGS. 12 to 14). With this configuration, when the shape is changed while heating, peeling does not occur between the laminated films or only one of the sheets is not broken, and the shape can be easily changed to a three-dimensional shape. Insert film 1
Can be obtained.

Here, the environmental temperature is the temperature of the atmosphere in which the test piece 20 is actually tested. The test piece 20 is obtained by cutting the insert film 1 into a size that can be subjected to a tensile test with a width of 20 mm and a distance between a pair of chuck-facing edges of 100 mm. The dimensions of the insert film 1 actually manufactured to obtain an insert molded product are 300 mm × 1 in the case of a body panel which is an automobile exterior part.
300mm, 250mm × 1200 for spoiler
mm, 350mm x 1800m for bumper guard
m, the ratio between the width and the length of the insert film 1 was almost 2:10. Based on this ratio, the test piece 20 was set to have a width of 20 mm and a distance between a pair of chuck-facing edges of 100 mm. .

In the present invention, a material having good extensibility such that the mechanical properties of the gas permeable sheet 2 are as similar as possible to the thermoplastic resin sheet 3 is selected, and a measuring method for confirming that the mechanical properties are similar. As a result, a tensile test method based on Japanese Industrial Standards (JIS) C5318 was selected, and how to set the environmental temperature and an appropriate range was examined.

Although it is necessary to take into consideration both the case of the resin temperature during molding and the case of the processing temperature during vacuum molding, the former is measured at a constant temperature because the former is heated and cooled instantaneously. Not suitable for the tensile test method.
Therefore, the environmental temperature for confirming that the mechanical properties are similar was set based on the latter processing temperature during vacuum forming.

The reason why the environmental temperature is set to 110 ° C. is a temperature suitable for three-dimensionally processing the thermoplastic resin sheet 3.
110 ° C., which is the lower value of 0 to 150 ° C., is adopted. Forming at a processing temperature as low as possible can prevent thermal deterioration of the ink of the symbol layer 4 and the insert film 1. The speed at which the test piece 20 is pulled is 3 mm.
The value of / sec is the value of the lowest speed at which the insert film 1 is stretched when performing three-dimensional processing.

Specifically, when the thermoplastic resin sheet 3 is vacuum formed, the temperature applied to various films is 110 ° C. for a vinyl chloride film, 120 ° C. for an acrylic film, and 12 ° C. for a polystyrene film.
0 ° C, 140 ° C for fluorine film, 150 ° C for polycarbonate film, 150 ° C for light-resistant polypropylene film, 140 ° C for polybutylene terephthalate film, 11 for polyurethane film
Since the temperature was 0 ° C., in the present invention, 110 ° C. which is the minimum value of these temperatures was selected as the environmental temperature.

The tensile elongation at break referred to in the present invention is 110 ° C.
The test piece 20 of the insert film 1 having a width of 20 mm is placed at a distance of 10
The elongation at break obtained when performing a tensile test in which one end of the test piece 20 is fixed at 0 mm and a load is applied at a constant speed of 3 mm / sec, that is, the elongation when the test piece 20 breaks. When the maximum elongation of the insert film 1 was measured for some insert molded products,
120-300% for body panel, 90-180% for spoiler, 100 for bumper guard
In the present invention, at least 90%, which is the minimum of these values, is set as the tensile elongation at break.

As the gas permeable sheet 2 used in the present invention, a non-woven fabric made of any of spandex, acrylic fiber, polyethylene fiber and polyamide fiber is preferable. These nonwoven fabrics can be used alone or
When a test piece 20 having a width of 20 mm is fixed at an environment temperature of 0 ° C. at a distance between a pair of chuck-facing edges of 100 mm, and a load is applied to one end of the test piece 20 at a constant speed of 3 mm / sec to perform a tensile test. Has a tensile elongation at break of 90% or more and exhibits a large elongation behavior under a low load.

In selecting the gas permeable sheet 2,
It is ideal to select a thermoplastic resin sheet 3 that has a tensile elongation load curve that is substantially the same as that of the thermoplastic resin sheet 3. However, even if the tensile elongation load curves do not match, the difference in load between the elongation values of the sheets constituting the insert film 1 is at most 5.
A preferable result can be obtained by selecting one within 0 kg.

The tensile elongation load curve refers to a test piece 20 of a material.
(In the present invention, a load is applied to a width of 20 mm and a distance between a pair of chuck-facing edges of 100 mm) to give a constant speed (3 in the present invention).
(mm / sec) was obtained by examining the mechanical properties of the material when pulled at a vertical axis.
A curve depicting the relationship until the test piece 20 breaks by taking the increase length in the tensile direction of 0 as a percentage of the original length of the test piece 20 in the tensile direction (100 mm in the present invention). Means

In the present invention, the characteristics such as the moldability of the insert film 1 composed of various gas-permeable sheets 2 and thermoplastic resin sheets 3 are determined by using a deep drawing mold having a shape as shown in FIG. As a result of conducting a tensile test on the gas permeable sheet 2 and the thermoplastic resin sheet 3 constituting the insert film 1, each of the constituents of the insert film 1 was obtained within the range up to the tensile elongation at break. In the case of the laminated insert films 1 in which the difference in the load in the elongation value of the sheet was within a maximum of 5.0 kg, the range was such that no trouble occurred, so this value was used.

The insert film 1 may be provided with a design layer 4. The design layer 4 may be provided on either the thermoplastic resin sheet 3 or the gas permeable sheet 2. The design layer 4 is for displaying characters, figures, symbols, and the like on the surface of the resin molded product 11, and for representing a colored surface. Further, the design layer 4 may be a single color having no pattern, such as black or silver metallic color, or a single color or a multi-color having a pattern such as a grain pattern or a stone pattern. There may be.
Alternatively, the design layer 4 may be formed by stacking a transparent yellow solid or pattern layer and a silver metallic color solid or pattern layer to express a gold solid or pattern layer. The design layer 4 includes at least one layer selected from the group consisting of a pigment ink layer composed of a pigment and a resin binder, a glitter pigment layer composed of a pearl pigment and a resin binder, and a dye ink layer composed of a dye and a resin binder. Be composed. Such a pattern layer 4 may be formed by 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 roll coating method or a spray coating method. The thickness of the design layer 4 is 0.1 to 2
0 μm is preferred. According to a normal printing method, this range is set.

The design layer 4 may be composed of a metal thin film layer or a combination of a metal thin film layer and a printing layer. The metal thin film layer is formed by a vacuum evaporation method, a sputtering method, an ion plating method, a plating method, or the like. Aluminum, nickel, gold, platinum, chromium, iron,
A metal such as copper, tin, indium, silver, titanium, lead, or zinc, or an alloy or compound thereof is used.

Also, the insert film 1 which is not provided with the design layer 4 and which is decorated with the color of the thermoplastic resin sheet 3 or the gas permeable sheet 2 itself may be used.

The thickness of the insert film 1 is 5
0 to 3000 μm is preferred. If the thickness is less than 50 μm, when the molding resin 10 is injected, the insert film 1 is wrinkled due to the heat and pressure of the molding resin 10. If it exceeds 3000 μm, the moldability of the insert film 1 is inferior.
It is difficult to process the insert film 1 into a three-dimensional shape. In particular, 50 to 1500 μm is preferable. The insert film 1 in this range has good workability such as punching, cutting, and inserting the insert film 1 into an arbitrary shape. Further, since the insert film 1 is excellent in moldability, it is possible to process the insert film 1 into a three-dimensional shape in a short time. If it exceeds 1500 μm, it is difficult to form the insert film 1 in a wound state, and the productivity becomes poor. Further, when processing into a three-dimensional shape is performed on the movable mold 5 of an injection molding die, an unnecessary portion of the insert film 1 is trimmed after molding, so that a slightly thinner 50 to 300 μm is preferable. In addition, when processing into a three-dimensional shape is performed using a mold different from the injection molding die, a step of inserting the three-dimensional shape into the three-dimensional shape processing molding die is required.
Rigidity is required, and it is slightly thicker 300 ~ 1500μm
Is preferred.

The thickness of the thermoplastic resin sheet 3 is preferably 5 to 700 μm. If less than 5 μm,
The thermoplastic resin sheet 3 is likely to be wrinkled, and printing for forming the design layer 4 becomes difficult. If it exceeds 700 μm, it is difficult to form the wound thermoplastic resin sheet 3, and the productivity becomes poor. More preferably, the thickness is 5 to 200 μm. When the thickness of the thermoplastic resin sheet 3 is small as in this range, the length of the thermoplastic resin sheet 3 that can be wound on one roll becomes longer, and thus the production efficiency increases.

The thickness of the gas permeable sheet 2 is preferably 10 to 2500 μm. If it is less than 10 μm, the effect of outgassing decreases. In particular, when laminating by the dry laminating method, the dry laminating adhesive fills the gap in the gas permeable sheet 2. If the thickness exceeds 700 μm, the cohesive force (strength) of the gas permeable sheet 2 itself decreases, so that cohesive failure occurs in the gas permeable sheet 2 after being integrated with the molding resin 10.

Next, a method of manufacturing an insert molded product will be described.

First, the insert film 1 is arranged on the surface of the movable mold 5 which is a molding die, and is fixed by the clamp member 8 or the like (see FIG. 2). As a molding die, an injection molding die, a blow molding die 14, and the like can be used.

As a specific example of the method of disposing the insert film 1, in the case of an injection molding die, the long insert film 1 is once wound around a roll shaft to form a roll-shaped roll, and this roll-shaped roll is injection-molded. The movable mold 5 is placed on the upper part of the movable mold 5 so as to be movable integrally therewith, and while the insert film 1 is unwound from the roll-shaped material, the insert film 1 is passed between the retracted movable mold 5 and the fixed mold 6, Movable mold 5 for molding
The insert film 1 is rotated by a roll shaft of a film winding means which is installed so as to be movable integrally with the movable mold 5 at a lower portion of the insert film 1.
Should be taken up. Further, as another example in the case of the injection molding die, the insert film 1 may be set on the surface of the movable die 5 by a robot or manually using a single-sheet insert film 1. When setting the insert film 1 on the surface of the movable mold 5, the insert film 1 is
After the arrangement, the position of the insert film 1 with respect to the surface of the movable mold 5 is determined by a positioning sensor or the like, and the insert film 1 may be pressed against the surface of the movable mold 5 for injection molding by the clamp member 8.

In the case of the blow molding die 14, the insert film 1 is disposed on one or both of the blow molding die 14 (see FIG. 9). The arrangement of the insert film 1 may be the same as in the case of the injection mold.

Next, after fixing the insert film 1 to a molding die, it is processed into a three-dimensional shape (see FIG. 3).

As a specific example of a method of processing into a three-dimensional shape, in the case of an injection molding die, it is fixed to the surface of the movable die 5 by a heating plate 15 inserted between the movable die 5 and the fixed die 6. The insert film 1 is heated to a temperature higher than its softening point to be softened, the space between the concave portion of the movable mold 5 for injection molding and the insert film 1 is closed, and the space is evacuated from the vacuum suction hole 12 to perform vacuum suction. There is a method of bringing the insert film 1 into close contact with the inner surface of the concave portion (cavity forming surface 7) of the movable mold 5 for molding. When processing into a three-dimensional shape or when pressing and fixing the insert film 1 with the clamp member 8, an unnecessary portion of the insert film 1 may be punched.

In the case of the blow molding die 14, the insert film 1 may be three-dimensionally processed before the insert film 1 is arranged in the blow molding die 14. When the insert film 1 is three-dimensionally formed in the blow molding die 14, a suction hole is provided in the blow molding die 14, and the insert film 1 is brought into close contact with the inner surface of the concave portion of the blow molding die 14 (FIG. 10).

Instead of the above method, insert film 1
Before placing the insert film 1 in a molding die, the insert film 1 is previously three-dimensionally processed into a desired shape using a three-dimensional processing molding die different from the movable mold 5 and the fixed die 6 for injection molding (FIG. 6).
(See FIG. 7). Alternatively, after punching into a desired shape, it may be arranged in a molding die (see FIG. 7). Examples of a method of processing the insert film 1 into a three-dimensional shape in advance include a vacuum forming method, a pressure forming method, a press forming method of pressing heated rubber, and a press forming method.
Here, the vacuum forming method means that the insert film 1 is heated to a temperature higher than its softening point to be softened, the space between the concave portion of the vacuum forming die and the insert film 1 is sealed, and vacuum suction is performed. In this method, the insert film 1 is brought into close contact with the inner surface of the concave portion of the mold, and the insert film 1 is molded into a three-dimensional shape that matches the cavity forming surface 7 of the molding die. As a method of punching into a desired shape, there are a Thomson punching method, a pressing method using a die, and the like. Examples of the punched shape include a line along the outer periphery of a predetermined shape and a hole of a predetermined shape. It should be noted that punching may be performed at the same time as processing into a three-dimensional shape.

Next, the mold is closed to form the resin molded article 11, and at the same time, the insert film 1 is integrally bonded to the surface thereof.

Specifically, when an injection mold is used, the molding resin 10 is injected into the mold, the molding resin 10 is filled in the mold, and the molding resin 10 is molded into a desired shape. At the same time that the molding resin 10 is solidified to form the resin molded article 11, the gas permeable sheet 2 side of the insert film 1 is integrated and adhered (see FIG. 4). In the case of the blow molding die 14, compressed air is blown into the parison 16 to form the molding resin 10 three-dimensionally and filled in the mold to form the molding resin 10 into a desired shape and solidify the molding resin 10. At the same time as forming the resin molded product 11, the gas permeable sheet 2 side of the insert film 1 is integrated and adhered.

After removing the resin molded product 11 from the molding die, unnecessary portions of the insert film 1 adhered to the resin molded product 11 are removed (see FIG. 5).
In the case where punching into a desired shape has been performed in advance as described above, it is unnecessary to remove unnecessary portions of the insert film 1.

The molding resin 10 is not particularly limited. Representative molding resins 10 used for exterior parts of automobiles include polypropylene resin containing talc,
Modified polypropylene resin and the like can be mentioned.

Although the present invention has been described based on the use of exterior parts for automobiles, the present invention is not limited to this use. For example, building material panels such as unit bath panels, containers such as bottles and cases, and the like. It is also applicable to toys, miscellaneous goods, etc.

[0056]

Example 1 Under the following conditions, an injection molded article for a seat, which is an interior part for a vehicle, was manufactured.

100 μm thick as a thermoplastic resin sheet
A light-resistant polypropylene film was used, and a pattern layer having a lattice pattern was formed thereon by a gravure printing method using a white vinyl resin-based ink.

Next, a 2 mm thick nonwoven fabric made of polyamide fiber as a gas permeable sheet was laminated on a thermoplastic resin sheet with a urethane resin-based dry laminating adhesive to obtain an insert film.

Next, the insert film was placed and fixed in a mold for injection molding, and an insert molded product was obtained using a gray polypropylene resin as a molding resin.

The injection molded product for seats, which is an insert molded product thus obtained, had no gas accumulation of the molding resin, and the insert film and the molding resin were firmly adhered to each other.

Example 2 A blow molded article for a spoiler, which is an exterior part for an automobile, was manufactured under the following conditions.

125 μm thick as a thermoplastic resin sheet
, And a black solid pattern layer was formed thereon by a gravure printing method using a black acrylic resin-based ink.

Next, a 1 mm thick flocked fiber sheet made of acrylic fiber / polyethylene fiber = 2/1 (weight ratio) as a gas permeable sheet is laminated on a thermoplastic resin sheet with a urethane resin-based dry laminating adhesive. An insert film was obtained.

Next, the insert film was placed and fixed in a mold for blow molding, and an insert molded product was obtained using a black polypropylene resin as a molding resin.

The insert molded product thus obtained, which is a blow molded product for a spoiler, had no gas accumulation of the molding resin, and the insert film and the molding resin were firmly adhered to each other.

[0066]

The present invention adopts the above-described configuration, and has the following effects.

That is, the insert film of the present invention
Since the insert film is a laminate of at least two types of sheets, and the sheet on the surface of the insert film adhered to the molding resin is a gas permeable sheet, the gas generated from the molding resin is a fine gap between the gas permeable sheets. Is discharged to the outside and does not remain in the molding resin, and the adhesiveness of the insert film to the molding resin is high. Further, since the molding resin enters the minute gaps on the surface of the gas-permeable sheet, the adhesiveness of the insert film to the molding resin is high.

The method for producing an insert-molded article according to the present invention is characterized in that the above-mentioned insert film which has been three-dimensionally processed is placed in an injection-molding mold or the above-mentioned insert film is placed in an injection-molding mold. Since the insert film and the molding resin are integrated by injection molding after three-dimensional processing, the gas generated from the molding resin does not remain in the molding resin and the adhesion of the insert film to the molding resin does not decrease. An insert molded product can be obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of an insert film of the present invention.

FIG. 2 is a cross-sectional view showing one of the steps of the method for producing an insert molded product according to the present invention.

FIG. 3 is a cross-sectional view showing one of the steps of the method for producing an insert molded product according to the present invention.

FIG. 4 is a cross-sectional view showing one of the steps of the method for manufacturing an insert molded product according to the present invention.

FIG. 5 is a cross-sectional view showing an insert molded product obtained by the method for producing an insert molded product of the present invention.

FIG. 6 is a cross-sectional view showing a three-dimensionally processed insert film used in the method of manufacturing an insert molded product according to the present invention.

FIG. 7 is a cross-sectional view showing one of the steps of the method for manufacturing an insert molded product according to the present invention.

FIG. 8 is a cross-sectional view showing one of the steps of the method for manufacturing an insert molded product according to the present invention.

FIG. 9 is a cross-sectional view showing one of the steps of the method for manufacturing an insert molded product according to the present invention.

FIG. 10 is a cross-sectional view showing one of the steps of the method for producing an insert molded product according to the present invention.

FIG. 11 is a cross-sectional view showing a deep drawing mold used for examining characteristics of an insert film.

FIG. 12 is a perspective view showing an apparatus for measuring the tensile elongation at break of a sheet for simultaneous painting with molding.

FIG. 13 is a plan view showing a portion for fixing a test piece of an apparatus for measuring tensile elongation at break.

FIG. 14 is a cross-sectional view showing a portion for fixing a test piece of an apparatus for measuring tensile elongation at break.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Insert film 2 Gas permeable sheet 3 Thermoplastic resin sheet 4 Symbol layer 5 Movable type 6 Fixed type 7 Cavity forming surface 8 Clamp member 9 Gate part 10 Molded resin 11 Resin molded product 12 Vacuum suction hole 13 Cavity 14 Gold for blow molding Mold 15 Hot plate 16 Parison 20 Test piece 21 Screw 22 Chuck 23 Chuck 24 Movable member

Claims (9)

[Claims] 1. An insert film disposed in a molding die and integrally bonded to a surface of a molding resin,
The insert, wherein the insert film is a laminate of at least two types of sheets, the sheet on the surface of the insert film adhered to the molding resin is a gas-permeable sheet, and the other sheet is a thermoplastic resin sheet. the film. 2. At an environmental temperature of 110 ° C., a width of 20
mm test piece, distance between a pair of chuck opposing edges is 100 m
m, and one end of the test piece was subjected to a tensile test with a load applied at a constant speed of 3 mm / sec.
The insert film according to claim 1, which is 0% or more. 3. The load difference in elongation value of each sheet constituting the insert film is within a maximum of 5.0 kg within a range until the insert film reaches the upper limit of tensile elongation at break. Insert film. 4. The insert film according to claim 1, wherein the gas permeable sheet is a nonwoven fabric. 5. The insert film according to claim 4, wherein the nonwoven fabric is made of any one of spandex, acrylic fiber, polyethylene fiber, and polyamide fiber. 6. The insert film according to claim 1, wherein the thermoplastic resin sheet or the gas permeable sheet has a design layer. 7. The three-dimensionally processed insert film according to claim 1 is arranged in a molding die,
A method of manufacturing an insert molded product in which a mold is closed to form a resin molded product, and at the same time, an insert film is integrally adhered to the surface thereof. 8. The insert film according to claim 1, which is arranged in a molding die, three-dimensionally processed in the die, and then closed to form a resin molded product. A method of manufacturing an insert molded product in which an insert film is integrally bonded to the surface. 9. The method for producing an insert molded product according to claim 7, wherein the molding die is one of an injection molding die and a blow molding die.